File - 140T Jamalpur Cranes
Contents
1. Datei Repeat all checks of Daily Monthly half yearly amp f yearly Schedules S Detail of work to be carried out Condition Sign Remarks No Action 1 Batteries a Remove and recharge the batteries b Clean the battery box and paint it Page 8 of 8 Part VI Schedule for Pneumatic amp Brake system Schedule for Maintenance of 140 t Gottwald Upgrade Crane Pneumatic amp Brake system Daily Schedule Crane No SNC A PW ics chaceea ran taans Hour Meter Reading Date 200 Sl Description of defects Action Signature Remarks No taken 1 Air pressure Reservoir Check visually any external damage of air pressure reservoirs amp its connections a 50 Itrs 3 Nos b 25 ltrs 2 Nos c 14 ltrs 3 Nos d 9 ltrs 2 Nos e 5ltrs 1 No 2 Disengaging device for travel gear unit a Check visually connection amp mounting for external damage amp firm seating b Check air pressure cylinder for connection mounting amp firm seating c Check visually spline shaft teeth for dirt if required clean amp grease d Check disengaging device for its proper functioning 3 Wheel set a Check wheel set mounting and its firm seating visually b Check visually any crack skidding or damage on wheel hub or tread 4 Wheel set bearing a Check wheel set bearing visually for any external crack or d2. Page of 6 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Auxiliary Engine KOEL HA 294 Monthly or 125 Hr Whichever is earlier Crane No Sh d srini RIV ene ione Hour Meter Reading 5 Date Repeat Daily check S No Details of work to be carried out Condition actio Sign Remarks n 1 Clean the engine externally by blowing compressed air 2 Fastening Check amp tight if necessary a Check amp tighten up the fasteners for following b Exhaust manifold c Exhaust piping Lube oil sump e Front cover f Hose clip for air cleaner g Lube oil filter mounting h Engine mountings i Fuel connections Page 2 of 6 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Auxiliary Engine KOEL HA 294 Half Yearly or 250 Hr Whichever is earlier Crane No Shed Hour Meter Reading 5 Repeat all checks of Daily amp 125 Hr Schedules S No Details of work to be carried out Condition action Remark S A CONDITION DIESEL ENGINE STOPPED Lube oil filter a Remove and replace paper element type filter b Clean filter housing c Check condition of sealing ring amp change if necessary Change engine lube oil Fuel filter insert a Remove the pre filter element b Flush the housing c Replace the filter insert Lube Oil level in fuel pump an
3. Periodically cleaning amp greasing of ropes should be done for proper and smooth running of ropes on drums amp sheaves Rope Change If rope change is necessary it must be ensured that a wire rope of the same type and breaking strength as the original wire rope in new condition is fitted When a new wire rope is being mounted ensure that it is not twisted Prior to operating with a newly fitted rope it must be ensured that the rope is properly placed and guided in the grooves of the rope drum rope pulleys and the compensation rollers It is advisable always to change both main hoist amp derricking ropes together to ensure the same quality and maintain the same inspection and maintenance intervals General Instruction for Gears Generally gears with considerable back lash will continue to function reasonably well but with excessive noise Abnormal back lash on gears affects the life of other components in gear box due to vibration Care should be taken while checking the back lash on primary side gears because of cyclic variation of torque and speed of diesel engine If premature gear wear or damage is noticed it would be found generally that the cause was due to bearing trouble misalignment presence of foreign matter or insufficient lubrication The first indication of a defective gearing would be an increase in the noise level which indicates rough operation The following indications of undue wear and tear may be looked for i
4. Yearly or 1500 Hr Whichever is earlier Crane No Shed Rly thai weaned Hour Meter Reading Date savastvanesuseyes Repeat all checks of Daily Monthly amp half yearly Schedules Page 6 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Hydraulic system including all Cylinders Valves pumps amp motors etc 2 Yearly or 3000 Hr Whichever is earlier Crane No NCOs cs caneseeledilcetdeud FW crchaceueawrentsaas Hour Meter Reading Daley necne Repeat all checks of Daily Monthly half yearly amp Yearly Schedules Detail of work to be carried out Condition Sign S Action Remarks 1 Hydraulic oil tank Change the hydraulic oil through an external mounted filter assembly with two stage filtration cart For detail refer clause 5 4 3 of General Description Page 7 of 7 Part IV Schedule for Slewing ring Gear boxes and Reduction gear units Schedule for Maintenance of 140 t Gottwald Upgrade Crane Schedule for Slewing ring Gear boxes and Reduction gear units Daily Schedule Crane No Shed eenia Rly Hour Meter Reading Date Detail of work to be carried out Condition Sign S Action Rema No rks Pump distribution gear box a Check the gear box at flange connections for external damage leakage and firm seating b Check for abnormal running noise
5. Hour Meter Reading Date S No Details of work to be carried out Condition action Sign Remarks A CONDITION DIESEL ENGINE STOPPED 1 Oil filling Check and top up if necessary a Lube oil b Fuel oil 2 Coolant filling Check coolant level and top up if necessary 3 Engine fuel system Drain sediments from a fuel water separator 4 Check and clean fuel tank level gauge for proper indication 5 V Belts Check the belts for i Correct tension ii Unwanted grease amp oil on it iii Any misalignment Page 1 of 12 6 Engine air intake system i Remove and clean dust pan and check air pollution indicator ii Check for complete red band on vacuum indicator Clean outer element only with dry compressed air from inside to outside iv Check piping Visually inspect hoses and pipes for damages cracks and clamps for looseness Rectify if required 7 Radiator Fan Visually inspect the fan for cracks loose rivets bent or loose blades and contact between the fan blade and fan shroud A CONDITION DIESEL ENGINE RUNNING 9 Mechanical General examination b General visual checking to be made to detect loose defective missing or leaky parts in the following systems i Cooling water ii Lube oil iil Fuel oil iv Air intake amp exhaust 10 Check and record Idle 1800 rpm Engine lube oil pressure Permissible valu
6. b Generator on auxiliary engine c 24 V battery charging alternators d Starters e Starter motor Check the limit switches and their mounting and connections for external damage and firm seating for following limits of motion a Main hoist limit switch b Auxiliary hoist limit switch c Derrick in out limit switch Safe load indicator a Check the limit switches near the rotary lead through for sensing superstructure position the load cells and angle sensor for damage and firm seating b Check proper function indication of SLI for different mode of display Batteries a Check the electrolyte level by opening out the filler plug Top up with distilled water to the marking if required Check following lighting elements of the crane their mountings and cable connection for damage firm seating and moisture damaged or Page of 8 moist lighting fixture must be replaced a Control panel lighting b Cab lighting c Machinery house lighting d Spotlight mounted on each to the left and right of the cab front side A spot light behind the cab for checking of motion drums f Out rigger lightings on each corner of superstructure g Two red travel lights at the front and at rear of the superstructure h Two adjustable spot light on jib xe n Ss wm e x i Check the screen wiper and wash system for proper functioning Page 2 o
7. c Check for any groove or scoring of disc maximum permissible size 1 0 mm i In case the above values are reached the friction surface of disc to be faced Permissible surface roughness after machining should be lt Rz 20 i e 20 microns ii Check the brake pads and if required replace them REF Manual for wheel mounting brake disc by SAB Wabco Page 6 of 8 Brake Pad Check a Check for wear i Thickness of new brake pad 724mm ii Permissible thickness of wear 6mm iii Minimum thickness of worn pad 18mm b Checking of Longitudinal clearance between Brake Pad and Pad Holder i When the brake is released the pads may move by a maximum of 2 mm in dovetail direction inside the pad holder If the freedom of movement exceeds this value remove the pads and check the dovetail guide on the pad and inside the pad holder ii The pads must be replaced if there is any damage on the backs of the pads iii The holder must be replaced if there is any damage to the pad holder and or locking piece iv Checking Brake Pad Brake Disc Clearance The two brake pads of the brake calliper must have a clearance of 2 mm each from the brake disc or 4 mm clearance for one brake pad when the other is in contact REF Manual BSI Brake Caliper by SAB Wabco Page 7 of 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Pneumatic amp Brake system 2 Yearl
8. 855 L 6 Monthly or After 250 Hr Whichever is earlier Crane No Shed Hour Meter Reading 5 Repeat all checks of Daily amp Weekly Schedule S No Details of work to be carried out Condition action Remark S A CONDITION DIESEL ENGINE STOPPED Change the following filters a Engine lube oil system i Full flow filter ii By pass filter b Engine fuel filter c Water filter Note Change gasket while changing the filter Engine Oil Drain engine oil Clean and check oil drain plug threads and seal surface Change engine oil Run the engine at idle for some time and shut down Again check level and add if required to ensure the oil level to H Fuel inlet connection screens Check and clean magnetic filter screens in fuel system Check throttle linkages with hand for freeness Clean and inspect Replace if damaged a Crank case breather b Fuel Tank breather Coolant Check SCA Supplement Coolant Additive concentration with test kit CC 2626 Add SCA at the rate of 1 5 units gallon Test procedure given in page V 23 in OEM s manual Page 4 of 12 Water used should have the following maximum levels Calcium Magnesium 170 PPM as CaCO3 MgCO3 Chloride 40 PPM as Cl Sulphur 100 PPM as SO4 B CONDITION DIESEL ENGINE RUNNING 1 Cooling water
9. For official use only DNY A aa IPNI Water g W01 TOERE ORGANISATION NV Certification B V THE NETHERLANDS GOVERNMENT OF INDIA MINISTRY OF RAILWAYS Maintenance Schedule of 140 t Diesel Hydraulic Gottwald Break down Crane upgraded Report No MP MI 19 Rev 00 September 2001 HAGAN bca Cd mad Ao CHIT 22E 099 RESEARCH DESIGNS amp STANDARDS ORGANISATION LUCKNOW 226011 General Description Introduction The schedule for examination and maintenance of 140t crane has been prepared taking into account the recommendation of original equipment manufacturers and suitably modified keeping in view the experience of the other Gottwald cranes operating in Indian Railways The service periods of cranes specified in this schedule for maintenance attention are the maximum allowable periods between successive examinations Variation in operating conditions in different regions may make it necessary to carry out examination more frequently or introduce examinations not scheduled herein In such cases the matter should be brought to the notice of the appropriate Sr DME DME AME who alone is authorized to introduce any change in the standard examination detailed herein The Sr DME DME AME in all such cases will bring to the notice of the Motive Power Directorate of RDSO for any modification to the schedules giving full details REFERENCES The following documents are also required to be referred for further
10. Reading Date Repeat all checks of Daily amp Monthly Schedule 1 Axle mounted compressor a Remove the fine filter element clean the filer elements by compressed air at pressure of 2kg cm and clean the housing check corrosion visually inspect the gasket if required to change 2 Clean the bogie suspension by compressed air 3 Check visually the erased painting areas amp to be painted Page 5 of 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Pneumatic amp Brake system Yearly or 1500 Hr Whichever is earlier Crane No SNCs E RIV eenn Hour Meter Reading Dateien Repeat all checks of Daily Monthly amp half yearly Schedules 1 Wheel set a check the difference in wheel dia i Dia of wheel in same axle Permissible 0 5mm Service limit 2 0 mm ii one axle to another axle Permissible limit 2 0 mm Service limit 8 0 mm iii one bogie to another bogie Permissible limit 15 mm Service limit 25 mm b Check the wheel profile by profile gauge 2 Wheel set bearing a Remove the cover amp check the bearings visually from out side b Change the grease of bearing but the inner bearing should not be opened 3 Brake disc a Check for hollow wear of disc i e area adjacent to center when wear is not uniform Hollow wear max 2 5 mm b Check for wear of disc max imum limit 7 0mm
11. carried out Condition Action Remarks Damaged paintwork on following item must be thoroughly de rusted and painted the following a Protective housing b Stairways footboards and holding straps c Counter weight d Outrigger beams e Superstructure locking device f Bogies g Jib and jib root point h Jib support i Cab j Match truck Lubricate the following rope drums with suitable grade of oil a Main Hoist rope drum b Auxiliary Hoist rope drum c Derricking gear rope drum d Recovery winch rope drum Match truck a Clean and lubricate screw coupling and buffers Page 5 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Basic Construction Super structure Undercarriage Bogie Cab Ropes Sheaves Drums Yearly or 1500 Hr Whichever is earlier Crane No SMO si dege PV accereueteete tates Hour Meter Reading Date Repeat all checks of Daily Monthly amp half yearly Schedules Page 6 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Basic Construction Super structure Undercarriage Bogie Cab Ropes Sheaves Drums 2 Yearly or 3000 Hr Whichever is earlier Crane No Shed naene Riyin norint Hour Meter Reading Date Repeat all checks of Daily Monthly half yearly amp f yearly Schedules Page 7 of 7
12. mm or 10 wire breakages on a length of 30 X rope diameter e g 30X 26 mm 780 mm e Auxiliary Hoist rope diameter 22 mm If the rope shows more than 5 wire breakages on length of 6 X rope diameter e g 6 X 22 mm 132 mm length or 13 on a length of 30 X rope diameter e g 30 X 22 mm 660 mm Check for Rope diameter If the rope diameter is reduced by 15 or more from the actual rope diameter in new condition over a length of 10x rope diameter i e 260m for main hoist derrick and 220 mm for auxiliary hoist rope The part of rope passing over sheaves and drum are more vulnerable Wear through friction If the rope diameter is reduced by 10 or more due to wear or friction with any member Rope deformations If deformations like waviness loop formations loose wires nodes rope thinning misplaced outer wires kinks and flat areas are noticed on the rope Page 7 of 11 6 2 2 Special observation on wire rope 6 3 6 4 6 5 The wire breakages generally occur after a certain number of operating hours and then the number increases more quickly It is recommended to keep watch on the condition of wire after any of wire breakage has started Action for the discarding should to be taken as indicated in Para 6 2 1 a above Functional Test After every rope change functional test without load must be carried out During the test it should be ensured that rope runs smoothly Cleaning amp Greasing
13. 1500 Hr Whichever is earlier Crane No Shed eiai RIY Hour Meter Reading Date Repeat all checks of Daily Monthly amp half yearly Schedules Detail of work to be carried out Condition Sign S Action Remarks 1 Change the oil of following gear boxes with prescribed grade of oil a Pump distribution gear box b Slewing reduction gear unit Main hoist reduction gear unit Auxiliary reduction hoist gear unit Derrick reduction gear unit Recovery winch reduction gear unit c d d e Page 6 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Schedule for Slewing ring Gear boxes and Reduction gear units 2 Yearly or 3000 Hr Whichever is earlier Crane No She ace ciies eemenene Riy nanen Hour Meter Reading Date 2000 Repeat all checks of Daily Monthly half yearly amp Yearly Schedules Page 7 of 7 Part V Schedule for Electrical and control System Schedule for Maintenance of 140 t Gottwald Upgrade Crane Electrical and control System Daily Schedule Crane No Shed Hour Meter Reading 4 S No Detail of work to be carried out Condition Action Remarks 1 i Check the generators and its connections for firm seating external damage unusual sound high temperature and dour a Generator on main engine
14. EL ENGINE STOPPED Use a suitable solvent like kerosene to clean engine Note Protect electrical components amp openings from spray nozzle Engine mounting Inspect flexible mounting rubber for deterioration amp age hardening Replace the damaged mounting Replace broken lost bolts and torque the mounting nuts and bolts Crank shaft end clearance Measure the crankshaft end clearance with dial indicator It should meet the following specification New Min 0 10 mm Max 0 45 mm Maximum permissible worn limit 0 56 mm Turbocharger Mounting Check the turbocharger mounting nuts Tighten the nuts with 48 Nm torque V band clamps Turbocharger Check the clamps amp tighten with 8 Nm torque on a Discharge elbow b Compressor housing c Turbine housing Page 6 of 12 Fuel injectors and valves a Adjust cross head b Adjust fuel injectors c Check and adjust valve clearance at coolant temperature of 60 C or below Inlet 0 28 mm Exhaust 0 58 mm Replace Rocker cover gasket amp tighten the cover cap screw to 45 Nm Cooling system Hoses Inspect the cooling system hoses and connections for leak deterioration Replace the damaged hose connecting part clamps CONDITION DIESEL ENGINE RUNNING Check for leakages in all the systems Page 7 of 12 Crane No Shed Schedule for M
15. a rod ii Strand An element of rope consisting of an assembly of appropriate shape and dimensions helically wound wires in one or more layer iii Core The center of a strand or the center of a wire rope which may be of steel or fiber 6 1 1 Wire Rope Specification Wire rope shall be of standard 6x37 18 12 6 1F C construction to IS specification No IS 2266 Breaking strength of the rope shall not be less than six times the maximum static load on the rope Explanation of 6x37 18 12 6 1 with fiber core It consists of 6 strands wounded helically over a fiber core Each strand contains 37 wires wounded helically in succession i e 6 wires on one steel wire core then 12 wires and then 18 wires respectively Page 6 of 11 6 2 6 2 1 Rope Inspection Criteria Wire ropes are consumable items with a limited life Therefore the complete length of wire ropes and rope fittings must be inspected daily In addition the wire rope must be examined by competent person at regular intervals An examination should be necessarily carried out if the rope is to be put back into service after a long period Condition for discarding wire rope Wire rope must be discarded immediately if following condition were observed a Breakage in wire of strand b c e Main Hoist and Derrick wire rope rope diameter 26 mm If the rope shows more than 5 wire breakages on a length of 6 X rope diameter e g 6 X 26 mm 156
16. aintenance of 140 t Gottwald Upgrade Crane Main Engine NTA 855 L Two Year or after 6000 Hr Whichever is earlier Hour Meter Reading 4 Repeat all checks of Daily Weekly 6 monthly amp yearly Schedule S No Details of work to be carried out Condition action Sign Remarks Air Intake amp Exhaust System 1 Turbocharger i Check oil leakages through intake amp exhaust seals ii Check turbocharger axial and radial clearances Radial Min mm Max mm Impeller 0 18 0 46 Turbine 0 25 0 53 Axial 0 03 0 10 iii Repair the turbo with repair kit 2 Check for leakage in air intake system if any rectify the same with necessary parts 3 Replace air cleaner inner amp outer filter elements 4 Check vacuum indicators for functioning amp external damages and replace if necessary 5 Check for leakage from exhaust system if any rectify the same with necessary parts 6 Check air intake and exhaust piping supports Take corrective action accordingly Fuel System 1 Clean water separator assembly Page 8 of 12 Check all fuel line hoses for damage and leakage and replace if required Inspect the spider coupling for damage Mount the spider coupling and pump Tighten the mounting screw with 45 Nm torque Check fuel lines amp connections for leakage Check fuel pump linkages Check actuator function
17. amage 5 Bogie Spring suspension a Check visually the component of spring assembly for crack or damage b Check visually spring assembly for its firm seating 6 Brake system a Check visually all component of brake Page 1 of 8 system for external damage any air leakage and if required rectify b Check visually changeover device Self or train brake amp its mountings for any damage firm seating c Check Bowden cable for any damage and proper fitment visually d Check visually brake cylinders for any air leakage firm seating and mountings e Check the brake disc for any crack or damage visually f Check visually the brake cylinder adjuster unit for any external damage and its firm seating T Functional tests a Check the function of emergency release device from the cab b Carry out the function of brake system c Check the working of parking brakes d Check the brake cylinder pressure from the gauge in the cab Max admissible cylinder pressure 6 bars Spring cylinder release Pressure 5 bars 8 Brake pipe amp couplings a Check visually brake pipe feed pipe vacuum hose pipe couplings amp their pertaining stop cock for any external damage b Observe air leakage from these and rectify if required 9 Axle mounted compressor a Check visually the compressor amp its coupling for mounting firm seating b Check visually leakage of oil 10 Test th
18. d its governor Loosen oil level control plug through 3 4 turns Remove the screw plug amp fill in fresh oil until it spills at oil level control plug Air breather a Remove and wash the breather thoroughly in petrol b Blow dry with compressed air c Assemble Exhaust silencer Remove soot from exhaust silencer and clean the exhaust piping V Belt for auxiliary generator and Blower fan drive i Check V belts over whole length for damage and cracks Renew if necessary ii Check for correct tension of the belt by pressing midway between the pulley If it deflects inward by more than 10 to 15 mm then re tension the V belts Page 3 of 6 Crane No Shed Schedule for Maintenance of 140 t Gottwald Upgrade Crane Auxiliary Engine KOEL HA 294 Yearly or 1000 Hr Whichever is earlier Hour Meter Reading 5 Repeat all checks of Daily 125 Hr amp 250 Hr Schedules S No Details of work to be carried out Condition action Remark S CONDITION DIESEL ENGINE STOPPED Cooling system a Remove air cowling b Clean with wire brush the fin of cylinder liner cylinder head amp lube oil cooler c Blow through engine with compressed air from the exhaust air side d Remove dirt from cooling air ducting Assemble cooling air cowling Micro fuel filter insert a Remove the micro filter element b Flus
19. e signal horns 11 Check the brake paddle in cab for its firm seating 12 Match Truck a Check visually all brake equipment air pipes their safety clamps for any damage and firm seating Page 2 of 8 b Check application and releasing of brakes c Check emergency release d Check air leakage Page 3 of 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Pneumatic amp Brake system Monthly or 125 Hr Whichever is earlier Crane No SOG naseer Fl ycorevus inania Hour Meter Reading Date Repeat all checks of Daily Schedule 1 Axle mounted compressor a Check axle mounted compressor connection for any damage firm seating and sealing b Lubricate the lubricating nipples on compressor shaft a Check visually filter element for dirt if required replace b Check the oil level by dip stick and top up if required 2 Pressure regulator a Check the pressure regulator visually for external damage Brake paddle to clean Lubricate the bogie hinge Check side bearer clearance O 01 amp GO Bogie a Check the bogie frame visually for any crack amp damage Page 4 of 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Pneumatic amp Brake system 6 Monthly or 750 Hr Whichever is earlier Crane No SHO seca ci ees PRU cress nn Hour Meter
20. ectly on electrical equipment should be avoided The fire extinguishers should be refilled and maintained as per the schedule Under no circumstances should crane be allowed to leave the shed without its required number of fire extinguishers in working order Periodic maintenance of the crane should be done after it is placed on level track and parking brakes of crane and match truck applied The staff while working under the crane or while standing over footboards super structure must not smoke or strike up fire nearby In case any structural part is damaged and is to be rectified ensure the following Direct flame should not damage cables hoses pipes must take all fire prevention measures for hoses cables etc from direct heat by shielding the flame For any structural repair ensure proper preheating use only recommended electrodes and argon shield welding If welding is carried out on the crane it is a wise precaution to disconnect SLI from both sides of the crane Disconnect main battery While welding earth the respective structure directly Whenever any schedule examination except the daily is carried out all the items of the lower schedules should also be attended to Page 11 of 11 Part Schedule for Main Engine Cummins NTA 855 L Schedule for Maintenance of 140 t Gottwald Upgrade Crane Main Engine NTA 855 L Daily Schedule Crane No Shedge dienei Rly a
21. ed above Tool Kit Tool kit is located behind the seat in the cab The following is the list of tools 1 Hammer 800 gm 2 Flat chisel 3 Oil spray can Page 9 of 11 4 Hand lever operated grease gun 5 17 Double ended open jawed spanners 8x10 55x60 6 6 Single ended open jawed spanners 8 41 65 70 75 80 mm 7 8 Hex socket head wrench SE 6 8 12 14 22 27 32 8 4 Tubular hex Box spanners 13X7 19X22 24X30 30X36 9 4 Tommy bars for spanners A 10 12 16 18 10 Standard ratchet 7 11 Extension piece 10 12 Articulated square drive socket adapter 70 mm 13 Socket for wrenches SW 17 19 14 3 screw drivers 15 Light tester 16 Pressure gauge 0 400 bar 17 Hose DN 6 222bX5000 18 Pressure gauge connection fitting 19 Union nuts 20 Cutting ring 21 Seeger circlip ring pliers A3 A4 22 Flat nosed and cutting nippers 23 Pipe wrench 24 Sickle spanner 25 Hose NW18X3 5000 General Instructions The high reliability of availability of cranes necessitates properly laid down maintenance schedules to be followed A well organized inspection is essential to ensure reliability and freedom from failure in service There are certain fundamental requirements that are important to any successful maintenance program These are 1 2 3 Adequate provision of well trained supervisors and skilled workmen Adequate provision of proper maintenance facilities and tools Provision of lubricating oil coolant etc req
22. er 5 The filters lubricants oil change etc provided in the various systems of engine are required to be changed as per the instructions of OEM These are summarized below for information 5 1 Filters of Main Engine NTA 855 amp Auxiliary Engine HA 294 Description Periodicity Full flow lube oil filter 250 hrs 6 month By pass filter do Fuel system Fuel filter 250 hrs 6 month Note whichever is earlier 5 2 Lube oil change of Main Engine NTA 855 amp Auxiliary Engine HA 294 Description Periodicity Lube oil 250 Hrs 6 monthly Note whichever is earlier 5 3 Recommended Lubricants for Main amp Auxiliary Engine S No Name of Manufacturer Brand name 1 Indian Oil Corporation SERVO PREMIUM CF4 15W40 2 Bharat Petroleum Corporation MAKCF4 15W40 3 Hindustan Petroleum Corporation Hylube Milcy Power 4 Valvoline Cummins Ltd Volvoline power Supreme 15 W 40 Page 3 of 11 5 4 Hydraulic oil for pumps and motors M s Gottwald had earlier recommended ATF Suffix A for use as hydraulic oil on the new crane It has been confirmed by them that either ATF Suffix A or HLP 68 can be used on the new Gottwald cranes While converting from ATF Suffix A to HLP 68 it must be ensured that the entire system is drained and flushed other wise it will not operate smoothly 5 4 1 Recommended brand
23. es 1 2 kg cm for idle 3 7 kg cm for 1800rpm Lube oil temp Should lie between 75 C 105 C Cooling water temp Not more than 95 C Page 2 of 12 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Main Engine NTA 855 L Monthly or 125 Hr Whichever is earlier Crane No DNS Ow ecstiin Poco an Ryo te Hour Meter Reading 5 Date c Repeat all Daily check S No Details of work to be carried out Condition action Sign Remarks A CONDITION DIESEL ENGINE STOPPED T General check Check tightness of foundation mounting bolts of the following a Engine b Radiators c Compressor d Radiator fan e Inlet amp Exhaust manifolds 2 Engine fuel system Drain sediments from a Fuel filter b Fuel tank 3 Clean the outer body of engine air intake filters Check following V belts for correct tension and serviceability a Cooling fan belts b Water pump drive belt c Compressor and fuel pump drive belt d Alternator drive belt CONDITION DIESEL ENGINE RUNNING Mechanical General examination General visual checking to be made to detect loose defective missing or leaky parts in the following systems a Cooling water b Lube oil c Fuel oil d Air intake amp exhaust Page 3 of 12 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Main Engine NTA
24. f 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Electrical and control System Monthly or 125 Hr Whichever is earlier Repeat Daily check S No Detail of work to be carried out Condition Action Remarks 1 Switch cabinets a Check the switch cabinets for any external damage b Check the door connection whether they are close properly Any faulty seals must be replaced immediately c Check cable connections for firm seating and damage Junction boxes and cableways a Check the junction boxes for external damage and ensure their cover for proper seating and tightness b Check the cables for external damage bent and for proper seating Batteries a Check the batteries and the cable connecting terminals for external damage Clean the batteries battery boxes tighten the terminal lugs and apply petroleum jelly on all terminals c Ensure the plugs are clean d Check the specific gravity and should be 1200 1240 e Check if any battery is having reverse polarity o x Page 3 of 8 f Check and record battery voltage Should be min 1 8 V max 2 2 V Check the functioning of following limit switches without load for all switching points slowly a Main hoist limit switch b Auxiliary hoist limit switch c Derrick in out limit switch Lighting control panels fan and sockets a Clean the
25. f gear damage is suspected Page 8 of 11 i Fractures a Tooth face fracture generally occurs due to shock loads or foreign matter such as broken pieces of metal forced through gear teeth in mesh b Fatigue fracture generally occurs from the root of the tooth c Tooth corner fracture or tooth splinter occurs generally due to misalignment of gear Misalignment of gears also results in a great load on tooth corners ii Tooth face damage a Pitting The working surface of the teeth is severely damaged by pitting or spalling over entire surface or at the base of the gear teeth b Deformation This is due to too little back lash which leads to frictional heating and softening of the case c Wear due to sliding This is due to inadequate lubrication especially on gear meshes of high gear ratio d Development of grooves roughing of the face or cavitation This is due to abrasive foreign matter coming between the meshing teeth e Cracking of the Case Hardened surface f Running hot This is indicated by the development of blue colorations due to heat concentration which may be caused by inadequate lubrication Pipelines may be choked or spray jet dislocated Lubrication is vital to gears and therefore nozzles must always be carefully checked on assembly and dismantling of the gears so as to always ensures a stream of oil to the gears Note It is generally advisable to replace gears subjected to the defects mention
26. g assembly runs smoothly by rotating superstructure slowly on the undercarriage Lubricate the slew ring via two lubrication nipples located in the left machinery house near the slewing reduction gear unit c Check the bolt connection for oO Page 2 of 7 looseness if required bolts must be tighten tightening force S60000N Pinion amp Gear wheels Travel gear a Check the gear wheel amp pinion for external damage like cracks broken teeth b Clean the gear wheel and pinion to remove waste grease and dirt and then re grease the same Travel reduction gear unit a Check the oil level via an overflow gauge screw out the oil filler plug If required add the oil until the oil level remains constant Main Hoist reduction gear unit a Check all connections lines for firm seating b Check the oil level via oil level inspection plug if required Top up oil c Check the bolt connection for firm seating tighten them if required Auxiliary Hoist reduction gear unit a Check all connections lines for firm seating b Check the oil level via oil level inspection plug if required top up oil c Check the bolt connection for firm seating Tighten if required Derricking gear reduction gear unit a Check all connections lines for firm seating b Check the oil level via oil level inspection plug if required top up oil c Check the bolt connection f
27. ger beams assembly 4 Nos c Out rigger pads 8Nos d Superstructure locking device e Bogies f Buffer and draw gear Arrangement Rope Check rope condition as per inspection criteria Check visually the entire crane steel construction for external damage such as cracks or deformation Jib and Jib route point a Check the jib for external damage amp cracks b Check the jib rope pulleys for external damage firm seating amp excessive wear Any damage or worn pulleys must be replaced immediately Check the jib support for external damage and firm seating d Check the moving latching unit and see whether it moves easily ie Check both the main hoist and auxiliary hoist hook blocks for external damage Page of 7 amp cracks Any damage parts must be replaced immediately Cab a Check the entire cab for external damage and deformation b Check the glass for damage any damaged panes must be replaced Match truck a Check the for external crack damage in match truck under frame and bogie frame Check for the loose broken mounting of counter weight holding brackets and trestle assembly strengthen the same if required c Check the draw gear and buffer assembly for any defect damage d Check the Cwts and its supporting arrangement for any crack damages oO Page 2 of 7 Schedule for Maintenance of 140 t Gottwa
28. h the housing c Replace the filter insert d Change the sealing range if the required Valve clearance Check and adjust valve clearance if necessary For both inlet and exhaust valves the permitted clearance is 0 15 mm Page 4 of 6 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Auxiliary Engine KOEL HA 294 2 Yearly or 2000 Hr Whichever is earlier Crane No Sheda e RIY Hour Meter Reading Dateien Repeat all checks of Daily 125 Hr 250 Hr amp 1000Hr Schedules Page 5 of 6 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Auxiliary Engine KOEL HA 294 3 Yearly or 3000 Hrs Whichever is earlier Crane No Sheda et Rly Hour Meter Reading Date iges Repeat all checks of Daily 125 Hr 250 Hr 1000Hr amp 2000Hr Schedules S No Details of work to be carried out Condition action Sign Remark s C CONDITION DIESEL ENGINE STOPPED 1 Injector a Remove injector clean and test for the correct opening pressure of 175 to 180 kg cm b If necessary replace the nozzle along with sealing washer 2 Calibrate the fuel pump 3 Calibrate the PT pump by replacing the necessary parts Page 6 of 6 Part Ill Schedule for Hydraulic system including all Cylinders Valves pumps amp motors etc Schedule for Maintenance of 140 t Got
29. he running noises of the following hydraulic motors a Main hoist motor b Auxiliary hoist motor c Slewing motor d Travel gear motors 2 Nos e Derricking motor f Recovery winch motor Clean the mounting bolts and lubricate the following a Counter weight cylinders b Jib root point cylinders Page 4 of 7 Crane No Shed Schedule for Maintenance of 140 t Gottwald Upgrade Crane Hydraulic system including all Cylinders Valves pumps amp motors etc 6 Monthly or 750 Hr Whichever is earlier Hour Meter Reading 4 Repeat all checks of Daily amp Monthly Schedule Detail of work to be carried out Condition Action Remarks Check operating pressures in pressure gauges mounted behind the cab Faulty pressure gauges must be changed The max operating pressure of following pumps are a Main variable displacement pumps 1 amp 2 400 bar b Slewing gear pump 250 bar c Gear pump for control Circuit 30 bar d secondary Gear pumps for main pressure circuit 200bar c Secondary gear pumps for control circuit 30 bar Hydraulic oil tank a Check the breather filter fitted on the top of the tank for clogging damage if required cartridges to be replaced Page 5 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Hydraulic system including all Cylinders Valves pumps amp motors etc
30. hedule for Pneumatic system amp Brake systems vii Part VII Schedule for Structural Items Super structure Undercarriage Bogie Cab Ropes Sheaves Drums 4 Periodicity of Maintenance of Major Sub assemblies and systems 4 1 Periodicity of maintenance of CIL Main Engine NTA 855 L i Daily schedule ii Monthly schedule or after 125 Hours ili Half Yearly schedule or after 250 Hours iv Yearly schedule or after 1500 Hours v 2 Yearly schedule or after 6000 Hours vi 3 Yearly schedule or after 6000 Hours vii Major Overhaul after 8 Years at the time of POH Note Whichever is earlier 4 2 Periodicity of maintenance of KOEL Auxiliary Engine HA 294 i Daily schedule ii Monthly schedule or after 125 Hours ili Half Yearly schedule or after 250 Hours iv Yearly schedule or after 1000 Hours v 2 Yearly schedule or after 2000 Hours vi 3 Yearly schedule or after 3000 Hours vii Major Overhaul after 8 Years at the time of POH Note whichever is earlier 4 3 Periodicity of maintenance of Hydraulic System Gear boxes and reduction gear unit Electric and control system Pneumatic amp brake system and Basic construction i Daily Schedule ii Monthly Schedule or after 125 Hours Page 2 of 11 iii Half Yearly Schedule or after 750 Hours iv Yearly Schedule or after 1500 Hours v 2 Yearly schedule or after 3000 Hours vi POH after 8 Years Note whichever is earli
31. information i Operating Maintenance amp Service Manuals No GS 140 08 H 1997 Issued by M s Gottwald ii Operating and Maintenance Manual NT NTA 855 Big Cam III Bulletin No 3666002 02 1994 Issued by Cummins Engine Company USA iii Operating Maintenance Manual HA 294 No 03 066 01 0 01 Feb 96 Issued by M s Kirloskar Oil Engine Limited iv Brake system a Manual BSI Brake Caliper No V H 97 065 01 1997 issued by SAB WABCO b Manual for wheel mounting brake disc R 780 G No V H 97 065 03 1998 issued by SAB WABCO c Maintenance manual for brake cylinder adjuster unit type PBACF 53 72GB 1992 issued by SAB WABCO v Safe Load Indicator SLI a User Manual IK350 1327 17 06 1997 issued by PAT b Trouble Shooting Manual 24 350 19 0688 Rev A 20 04 1998 issued by PAT vi Repair instruction manual for hydraulic motors RDE 91001 01 1996 issued by Rexroth vii Operating instruction for pump distribution gear box GFC 230 1048 Feb 1998 issued by Lohmann amp Stolterfohnt Page 1 of 11 3 Scope of Maintenance Schedule i Part l Schedule for Main Engine NTA 855 L ii Part Il Schedule for Auxiliary Engine KOEL HA 294 iii Part Ill Schedule for Hydraulic system including all pumps motors Cylinders amp Valves etc iv Part IV Schedule for Slewing Gear Gear boxes and Reduction gear units v Part V Schedule for Electrical amp Control system vi Part Vl Sc
32. ing Clean thoroughly fuel tank with steam and detergents and dry the tank with air blast Lubricating Oil System Check amp replace the damaged oil line hoses amp clamps Check external oil leakage from head gasket rocker housing gasket seals etc If necessary replace the same Cooling System Flush cooling water tank Replenish with SCA and water Check for concentration Check all hoses clamps amp coupling O Rings of cooling system pipe lines and radiator assembly and replace if necessary Remove radiator assembly from the mounting amp clean the radiator assembly Check all radiator Anti Vibration Mountings and replace if necessary Water Pump Idler pulley Check for a Freedom of rotation b Cracked chipped or broken pulley groove Water Pump Check water pump for water leakage If any continuous leak indication or drip is Page 9 of 12 indicated replace the pump with new or rebuilt one Replace following belts i Water pump drive belts ii Compressor and fuel pump drive belt iii Cooling fan hub belt drive iv Alternator drive belt Others Vibration Damper Viscous Check Vibration damper for a Evidence of fluid loss dents and wobble b Any deformation or raising of the damper from cover plate c Replace if necessary Do not repair or balance damper in field Check for the leakages in vari
33. ir connections for external damage and leakage Tighten the fittings if required 10 Counter weight cylinders 5 Nos amp Jib root point cylinder 2 Nos Check the cylinders and their connections for external damage and leakage Tighten the fittings if required Page 2 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Monthly or 125 Hr Whichever is earlier Hydraulic system including all Cylinders Valves pumps amp motors etc Check the oil filter visual clogging indicator mounted on the tank With the oil at operating temperature See the colour indication i If green Normal ii If Yellow Advisable to change the filter inserts iii Red MUST change the filter inserts Crane No Shediac RIV ene ione Hour Meter Reading 5 Date ce Repeat Daily check Detail of work to be carried out Condition Sign S Action Remarks No 1 Check the abnormal running noises of the following pumps i Pumps connected with main engine a Main variable displacement pump 1 b Main variable displacement Pump 2 c Slewing gear variable displacement pump d Gear pump for oil cooler circuit e Gear pump for control circuit ii Secondary pumps connected with auxiliary engine a Gear pumps for main pressure circuit b Gear pumps for control circuit 2 Hydraulic oil tank Page 3 of 7 Check t
34. l damage firm seating and proper sealing Replace any damaged components immediately Any loose or leaky connections must be Page of 7 tightened or if required replaced b Check the carrier for the rotary lead through for correct seating and damage Spring suspension blocking cylinders a Check the blocking cylinders and their connections for external damage firm seating and proper sealing b Retract amp extend the cylinders and check for proper working and carry out inspection of the piston rods for any scoring marks Control blocks in the Under carriage a Check the valve block and their connections for external damage and leakage Tighten the fittings if required b Check functions of suspension blocking cylinders and travel gear pinion disengagement engagement device by means of hand lever Outrigger beam cylinders a Check the cylinders and their connections for loose leaky external damage firm seating and proper sealing Tighten the fitting if required b Check automatic latching of the piston rod of jack cylinder in retracted position Check the following hydraulic motors and their connections for firm seating external damage and proper sealing a Main hoist motor b Auxiliary hoist motor c Slewing motor d Travel gear motors 2 Nos e Derricking motor f Recovery winch motor Control blocks on Superstructure a Check the valve block and the
35. ld Upgrade Crane Basic Construction Super structure Undercarriage Bogie Cab Ropes Sheaves Drums Monthly or 125 Hr Whichever is earlier Crane No SONEA eae rere eee PRI Vo seine Terrasa Hour Meter Reading Date 00 Repeat all checks of Daily Schedule Detail of work to be carried out Condition Sign S Action Remarks 1 Clean the following a Protective housing amp panelling b Stairways boards amp holding straps 2 Check and lubricate the following a Out rigger beams Remove the waste grease and lubricate until the bearing points are protected by means of a surrounding bead of grease b Out rigger pads Clean the knuckle joints and grease Superstructure locking device Clean the knuckle joints and then grease Bogies The side bearers between the under carriage and the bogie must be lubricated regularly Jib support Clean and grease the knuckle joints and sliding surfaces f Lubricate bogie pivots Screw coupling and buffers Cc d e 3 Check the functional tests of the following a Out rigger beams Check whether they extend amp retract properly amp whether they lock properly Jib Rope pulleys Jib Rope guides Jib supports 2o er NN NN Page 3 of 7 Ropes a Clean amp Grease b Functional Test for smooth running Signs amp labeling a Check visua
36. lighting fixture and control panel with suitable aid Clean fan vent grates with suitable aid Check the lighting elements and fan for proper function any faulty broken lamps or lighting elements must be replaced immediately d Check other cab equipments for their proper functioning and any external damage b Cc Page 4 of 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Electrical and control System 6 Monthly or 750 Hr Whichever is earlier Crane No Shed ecccagtaseecenecedeeet ah ee eee ere re Hour Meter Reading Date Repeat all checks of Daily amp Monthly Schedule Detail of work to be carried out Condition Sign S Action Remarks Clean the Switch cabinet interior with suitable cleaning aid Clean the limit switches with dry compressed air at 3 Kg cm and their mountings and check connections for firm seating Page 5 of 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Electrical and control System Yearly or 1500 Hr Whichever is earlier Crane No Shed Hour Meter Reading 5 Repeat all checks of Daily Monthly amp half yearly Schedules S No Detail of work to be carried out Condition Action Sign Remarks 1 Clean the junction box interior with the suitable aid preferably with vacuum cleaner Starters fo
37. lly amp re write any thing that has got erased Check the following rope drums and rope clamp for external damage and firm seating a Main Hoist rope drum b Auxiliary Hoist rope drum c Derricking gear rope drum d Recovery winch rope drum Derrick rope pulley and rope guides a Check for external damage wear amp tear any damaged item must be replaced b Check the functionally rope pulley and guides for smooth running Deflection rolls on recovery winch a Check for external damage wear amp tear any damaged item must be replaced b Check the functionally deflection rolls pulley for smooth running Cab a Clean grease and the door hinges and their lock for proper functioning 10 Seat a Check the entire seat and its controls and mountings for external damage and firm seating b Clean the slide tracks on which the movable seat is fixed and grease slightly 11 Match truck a Check the trestle assembly for crack damage and lubricate the liners b Cleans lubricate Bogie Pivot and bolster Page 4 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Drums 6 Monthly or 750 Hr Crane No Shed Hour Meter Reading 5 Repeat all checks of Daily amp Monthly Schedule Basic Construction Super structure Undercarriage Bogie Cab Ropes Sheaves Whichever is earlier Detail of work to be
38. or firm seating Tighten if required Recovery winch reduction gear unit a Check all connections lines for Page 3 of 7 firm seating b Check the oil level via oil level inspection plug if required top up oil c Check the bolt connection for firm seating Tighten if required Page 4 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Schedule for Slewing ring Gear boxes and Reduction gear units 6 Monthly or 750 Hr Whichever is earlier Crane No SHE nasrini Rly eeina en Hour Meter Reading Date Repeat all checks of Daily amp Monthly Schedule Detail of work to be carried out Condition Sign S Action Remarks 1 Pump distribution gear boxes a Check the vent filter on the housing upper side if required clean or replace 2 Lubricate the following gear boxes via lubricating nipple a Main hoist reduction gear unit b Auxiliary hoist reduction gear unit b Derrick reduction gear unit c Recovery winch reduction gear unit 3 Travel reduction gear unit a Clean the gear unit exterior b Check vent on the gear box unit If it is clogged screw out vent and wash in a suitable solution and dry with compressed air Page 5 of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Schedule for Slewing ring Gear boxes and Reduction gear units Yearly or
39. ous systems Page 10 of 12 Crane No Shed Schedule for Maintenance of 140 t Gottwald Upgrade Crane Main Engine NTA 855 L 3 Yearly or After 6000 Hr Whichever is earlier Hour Meter Reading 5 Repeat all checks of Daily Weekly 6 monthly yearly amp 2 yearly Schedules S No Details of work to be carried out Condition action Sign Remarks 1 Remove clean and Calibrate the injectors after replacing the cups and O rings 2 Adjust valve Check the conditions of push rods adjusting nut amp screws if necessary replace 3 Calibrate the PT pump by replacing the necessary parts e g magnetic filter gasket set etc Page 11 of 12 Part Il Schedule for Auxiliary Engine KOEL HA 294 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Auxiliary Engine KOEL HA 294 Daily Schedule Crane No SHO icc cecesceeccseceneccns Rly ern Hour Meter Reading DANS Fascia seiseceaeses S No Details of work to be carried out Condition actio Sign Remarks n A CONDITION DIESEL ENGINE STOPPED 1 Lube oil filling Check the lube oil level and top up if necessary Ensure that the oil is up to the upper max mark 2 Engine air intake system a Remove and clean dust pan 3 Run the Engine warm up amp check the leakages in the systems
40. r Main amp Auxiliary engine Remove and overhaul a Check the brushes If worn to approximately 10 mm then renew the brushes Must always be replaced in sets amp with correct grade Check the brush spring pressure It must be 0 965 to 1 080 kg Check the commutator surface Clean with fine emery if surface is dirty or badly discoloured Check the drive assembly for free movement over the shaft spline Smear grease over shaft spline Ensure that the mounting bolts are securely fastened f Ensure that all electrical connections are clean and tight o C Qa e x Alternator on Main amp Auxiliary engine a Check the brushes Renew the brush and spring assembly if overall length of the brushes is worn to less than 10 mm Otherwise clean the brushes with petrol moistened cloth b Ensure that the slip ring Page 6 of 8 surfaces are clean and smooth If required refinishing clean the surfaces with fine emery paper c Check bearing for play and wear renew if required d Externally clean the alternator and ensure that the ventilation slot air spaces are clear e Ensure proper belt tension Page 7 of 8 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Electrical and control System 2 Yearly or 3000 Hr Whichever is earlier Crane No Shed decccagtaseecenecedeeet RIY anssi Hour Meter Reading
41. s c Check the oil level in distribution gear box through the dipstick Top up if required Check the following reduction gear units for external damage leakages and abnormal running noises i Slewing gear reduction Unit ii Main Hoist reduction gear unit iii Auxiliary Hoist reduction gear unit iv Derricking gear reduction gear unit v Recovery winch reduction gear unit Travel reduction gear unit a Check visually reduction gear unit for any leakage and crack or damage b Check visually the sealing of drain plug Page of 7 Schedule for Maintenance of 140 t Gottwald Upgrade Crane Schedule for Slewing ring Gear boxes and Reduction gear units Monthly or 125 Hr Whichever is earlier Repeat Daily check Detail of work to be carried out Condition Sign S Action Remarks Check the bolt connection of Pump distribution gear box for firm seating tighten if required Slewing gear reduction Unit a Check for all connections lines amp connection for firm seating b Check the oil level with help of dipstick The oil level must be between the upper amp lowering marking on the dipstick Top up if required Check the bolt connection firm seating Tighten If required d Check the breather filter for cleanliness damage and if required clean or replace O Roller bearing of slewing ring a Check the running noises to ensure that the bearin
42. s of anti wear Hydraulic Oil HLP 68 to IS 11656 1992are as under S No Recommended equivalent brands 1 IOC Servosystem HLP N 68 2 HPC Enklo HLP 68 3 BPC Bharat Hydrol HLP 68 4 IBP IBPEXHD 68 5 4 2 Recommended brands of ATF suffix A S No Recommended equivalent brands 1 IOC Servo Transfluid A 2 HPC HP ATF 3 BPC ATF A 5 4 3 Topping up Replacement of Hydraulic oil a During oil change and also during top up oil is recommended to be added through two stage filtration cart as per following specifications Stage 25 micron absolute Stage II 10 micron absolute Pump flow rate 20 Ipm Note The details of the hydraulic oil filtration trolley is provided separately in RDSO instruction bulletin No MP IB HY 02 18 01 Rev 0 00 b In the absence of filtration trolley oil must be added through atleast an external oil filter with minimum retaining rate of 10 um so that cleanliness of oil is maintained 5 5 High speed Diesel The high speed diesel oil shall be to IS 1460 1995 read with Amendment 2 February 1999 Page 4 of 11 5 6 Oils and Lubricants for other items SN Fluid filling capacity Recommended oil and Grease Mobil Shell IOC BPC HPC 1 Lube oil for pump Mobil gear Shell Servo Amocam Parthan distribution gear box 629 Omala mesh 150 EP 150 capacity Mobil gear 150 Shell SP150 approx 5 5 li
43. system Check that vent pipes in the system are open General check For any leakages in the systems Safety Devices Ensure that oil pressure switch is in proper working order Setting of OPS Pick up at 1 0 kg cm Drop out 1 0 8kg cm To check stop the engine LED will glow when pressure drops below 0 8kg cm Now start the engine LED should shut off when pressure reaches above 1 kg cm b Ensure proper working of hot water temperature safety device LED indication should come and buzzer should sound Max temp 95 C To check remove the temperature safety switch and test with hot water at 95 C LED indication should come on panel with buzzer sound c Ensure proper working of low cooling water level safety device On pick up engine should shut down along with LED indication d Ensure proper working of engine over speed safety device Raise engine RPM by pressing governor plunger Engine should shutdown at 1800 RPM along with LED indication Page 5 of 12 Crane No Shed aiae anea Schedule for Maintenance of 140 t Gottwald Upgrade Crane Main Engine NTA 855 L One Year or After 1500 Hr Whichever is earlier Hour Meter Reading 6 8 Repeat all checks of Daily Weekly amp 6 monthly Schedule S No Details of work to be carried out Condition action Remarks A CONDITION DIES
44. tres XMP 150 HD 150 2 Chassis air Mobil Rimula X Servo Mak T40 HP Milcy compressor Devec Mono Pride 40 40 lubrication oil 1340 grade capacity 0 5 litre SAE 40 3 Lube oil for Mobil Shell Servo Amocam Parthan i Slewing gear unit Gear 629 Omela mesh 100 EP 100 Capacity approx Mobil 150 SP100 15 5 Itres Gear Shell XMP Omela ii Main hoist gear 150 HD 150 unit Capacity approx 6 5 Itres ili Auxiliary hoist gear unit Capacity approx 6 5 Itres iV Derricking gear unit Capacity approx 9 5 Itres V Recovery winch gear Capacity approx 3 4 Itres Vi Travel gear unit Capacity approx 12 Itres Page 5 of 11 4 Lube oil for bearing Mobil EP 2 Shell Servo MP Lithon I Main hoist gear Retinex gem Grease3 EP 2 unit EP 2 EP2 ii Auxiliary hoist gear unit iii Derricking gear unit 5 Lube grease for Mobiltac Shell Servo Lithon gear wheel pinion 375 NC Malleus gem EP 1 EP1 6 Lube grease for Mobilux EP Shell Servo Lithon slew ring 2 Retinex gem EP 2 Mobilgreas EP 2 EP2 e XHP 222 Shell Alvania EP LF 2 7 Lube grease for Mobilux Shell Servo Lithon axle gear unit EP 2 Retinex gem EP 2 Mobilgreas EP 2 EP2 e XHP 222 Shell Alvania EP LF 2 6 Wire Rope Details 6 1 Terminology used in rope details i Wire Round A single circular rope of continuous length of metal drawn cold drawn from
45. twald Upgrade Crane Hydraulic system including all Cylinders Valves pumps amp motors etc Daily Schedule Crane No Sac o EE RIY iets Hour Meter Reading Dale ia ai at Detail of work to be carried out Condition Sign S Action Rema No rks i Check connection for damage and leakage in following pumps connected with main engine a Main variable displacement pump 1 b Main variable displacement Pump 2 c Slewing gear variable displacement pump d Gear pump for oil cooler circuit e Gear pump for control circuit ii Secondary pumps connected with auxiliary engine a Gear pumps for main pressure circuit b Gear pumps for control circuit Hydraulic tank a Check connection for damage and leakage b Check the hydraulic oil level through oil level glass on the tank Top up with same brand of oil if necessary as per clause 5 4 3 of General Description Level to be checked when all the cylinders are in retracted position c Check the hydraulic oil temperature on the gauge mounted in the cab in working condition Max 70 C Slewing gear pump filter a Check the oil filters and its connections amp mountings for external damage leakage or firm seating b Check the pollution indicator for red indication on filter if red indication visible change the filter Rotary lead through a Check the hoses their connections and attachments for externa
46. uired to ensure satisfactory engine performance A well scheduled maintenance program including an adequate system of maintenance of records While carrying out the work of the schedule all missing nuts bolts set screws cotters split pins etc must be REPLACED as and when found defective Split pins and cotters once removed must not be used again but new ones must be fitted All loose nuts setscrews etc must be tightened Wherever cotters or split pins are fitted they must be of the correct size and so fitted that they bear against the nut or washer properly Examine and ensure that all locking devices wherever provided are properly secured Page 10 of 11 10 11 12 13 14 15 16 All measuring devices such as torque wrenches electric meters lubricant dispensers etc which require calibration should be checked quarterly or sooner if required for accuracy All tools and parts should be accounted for and removed from the crane after any maintenance work has been performed All work done including methods and tools used must be in accordance with the manufacturers instructions maintenance manual or any technical orders issued Do not mix different brands of greases Excessive lubrication is as harmful as inadequate lubrication Use of waste cotton on crane is PROHIBITED Use lintless rags or wiping towels The underframe and top surface of fuel tanks should be cleaned to remove dirt and oil Spraying of water dir
47. y or 3000 Hr Whichever is earlier Crane No Shed steers ees PR Waricenderan dure sand Hour Meter Reading Date Repeat all checks of Daily Monthly half yearly amp Yearly Schedules 1 Brake Disc a Check the tightness of brake disk by torque wrench up to 200Nm b Check visually for crack in cooling fins Maximum 2 nos cracked cooling fins are permissible 2 Air Compressor Engine mounted i Measure total carbon deposit thickness inside the air discharge line pipe If it exceeds 2 mm clean and inspect the cylinder head the valve assembly and discharge line Replace any pipes or connections if it exceed the specified limit and does not get clean ii Replace worn out parts iii Replace all O rings gaskets oil seals iv Assemble and run the compressor to evaluate its performance Page 8 of 8 Part VII Schedule for Basic Construction Super structure Undercarriage Bogie Cab Ropes Sheaves Drums Schedule for Maintenance of 140 t Gottwald Upgrade Crane Drums Daily Schedule Crane No Shed Hour Meter Reading 5 Basic Construction Super structure Undercarriage Bogie Cab Ropes Sheaves Detail of work to be carried out Condition Action Remarks Check visually for any crack damage of the following a Counter weight 22 t 8 t 6t and its mountings b Out rig
Download Pdf Manuals
Related Search