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Railway Crane Maintenance Manual

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1. 2 Clean the oil tank and ceramic filter thoroughly 3 Clean fuel filter bowl 4 Change paper element of the fuel filter 5 Change the lub oil filter 5 3 SUPERSTRUCTURE 2 2 1 Drain sediment from hydraulic oil tank 2 Check oil water and air hoses Change them if necessary 3 Check for corrosion Repair if required and paint 4 Clean water and air cooler fans with water jet 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 1000 Working Hours Yearly 1 6 P 2 2 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 5 Inspect drive assembly 6 Carry out fuel oil tank flushing 7 Change gearbox oil 8 Check setting of limit switches 9 Check windows and doors for corrosion proper fitting and locks 5 4 UNDERCARRIAGE 2 6 1 Check oil level of the travel gear box 5 5 MATCH TRUCK 2 6 1 Check oil level in compensator tanks of hydraulic brake control 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 2000 Working Hours 2 Yearly 1 7 P 1 1 Schedule Item as per RDSO Maintenance Schedule Vide Report No MP 727 90 Ref No of Maintenance Manual 6 3 6 4 AT THE COMPLETION OF 2000 HOURS 2 YEARLY AUXILIARY ENGINE Change the paper element of air cle
2. Protective Housing and Panelling 2 13 2 1 2 Description The protective housing and panelling screen off hot and moving components and protect persons near the components See Figure A Simultaneously the components are protected against moisture and other external influences SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages When dressing with a flame use caution danger of explosion near fuel and oil related components Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment When electrical welding work is being performed the earthling terminal must be connected directly to the part to be welded In addition the battery pole terminals on the diesel engine system and the emergency diesel engine system must be disconnected Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Prior to commencing with inspection and maintenance work
3. Two position valve 2 ports normally open 2 directions of flow Two position valve 3 ports normally open 2 directions of flow 2 2 way directional valve 2 ports 2 spool positions 3 2 way directional valve 3 ports 2 spool positions 1 cross over point solenoid operation spring offset 5 2 way directional valve 5 ports 2 spool positions pressure operated in both dir ections 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 4 3 way directional valve detailed diagram electro hydraulically operated 4 ports 3 spool positions 1 spring centered mid position emergency stop operation external pilot oil return simplified diagram 4 3 way directional valve detailed diagram electro hydraulically operated 4 ports 3 spool positions pressure centered mid posi tion emergency stop operation external pilot oil return simplified diagram Continuously variable modulating valves Modulating valve negative overlap Modulating valve positive overlap 4 3 way servo valve typical example Check valves isolating valves Check valve without spring loading Check valve spring loaded Check valve pilot operated without spring pre load LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Symbols used in Hydraulic Circuits Name description examples Check valve p
4. Variable displacement pump motor manual adjustment 2 directions of flow 2 directions of rotation Case drain port Hydraulic rotary actuator Q gH pi P Am a 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 P 4 7 Name Symbol description examples Hydraulic compact drive Variable displacement pump with pressure compensator 1 direction of flow 1 direction of rotation Case drain port Variable displacement pump motor with pressure compensator 2 directions of flow 2 directions of rotation Case drain port Hydraulic cylinders Single acting hydraulic cylinder return stroke via pressurisation full bore connected to tank Double acting single rod hydraulic cylinder adjustable damping at both ends of stroke Telescopic hydraulic cylinder single acting Telescopic hydraulic cylinder double acting Accumulators Without initial pressure With initial gas pressure LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Symbols used in Hydraulic Circuits Name description examples Gas bottle in upright position only Open and closed loop control of energy Directional valves Two position valve with 1 cross over point Two position valve with stepless control of spool position Three position valve with stepless control of spool position Two position valve 2 ports normally closed 2 directions of flow
5. Air pressure System S S amp U C 2 3 2 2 1 Air pressure Tank 22 Brake Cylinder 243 3 Brake couplings 2 3 4 pressure Fine Filter 2 5 5 Brake Pedal 2 3 6 Signal Horns 2d Undercarriage Air Pressure Compressor 2 3 8 Pressure Regulator 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Air Pressure Tank 2 3 1 1 2 Description The Crane No 142032 t0 142043 amp 143001 to 143002 has three 50L one 25L amp three 14L air pressure tanks and Crane No 143003 to 143010 has three SOL two 25L amp two 14L air pressure tanks See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt crushed or drawn into the equipment Caution Observe air pressure tank regulations Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air pressure connections are being tightened Maintenance Instruction
6. LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Stairways Footboards and Holding Straps 2 13 3 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Counterweight 2 13 4 P 1 2 Description The Four section steel counterweight which can be detached for transport purposes is mounted on the counterweight support See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane can not be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages When dressing with a flame use caution danger of explosion near fuel and oil related components Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment When electrical welding work is being performed the earthling terminal must be connected directly to the part to be welded In addition the battery pole terminals on the diesel engine system and the emergency diesel engine system must be disconnected Ensure th
7. Pedal 2 3 6 Signal Horns 2 51 Undercarriage Air Pressure Compressor 2 3 8 Pressure Regulator 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Table of Contents Part III P 2 3 2 4 Diesel Engine System 24 1 Diesel Engine 2 4 1 1 Diesel Engine Different types 2 4 1 2 Diesel Engine Crane wise list 2 4 2 Exhaust System 2 4 3 Fuel System 2 4 4 Diesel Engine Accelerator 2 4 5 Pump Distributor Gear Box 2 5 Emergency Diesel Engine System 2 5 1 Emergency Diesel Engine 2 5 1 1 Emergency Diesel Engine Different types 25 12 Emergency Diesel Engine Crane wise list 2 6 Travel and Running Gear 2 6 1 Travel Reduction Gear Unit 2 6 2 Pinion and Gear Wheel 2 6 3 Disengaging Devices 2 6 4 Wheel Sets 2 6 5 Wheel Set Bearings 2 6 6 Spring Suspension 2 6 7 Expander Operated Brake Discs 2 6 8 Brake Cylinder Adjuster Units 2 6 9 Brake System 2 7 Cab 27 0 Cab 27 2 Control Panels 2 1 3 Screen Wiper 2 7 4 Fan KA ES Additional Equipment 2 8 Slewing Gear 2 8 1 Slew Reduction Gear Unit 2 8 2 Pinion and Gear Wheel 25 3 Roller Bearing Slew Ring 2 9 Main Hoist 2 9 1 Main Hoist Reduction Gear Unit including Brake 2 9 2 Rope Drum 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Table of Contents Part III P 3 3 2 10 Auxiliary Hoist 2
8. Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Please note that the manufacturer must be consulted before any burning welding or dressing work is carried out on the crane Maintenance Instructions Check both bogies for external damage cracks and deformations Clean the paintwork damage immediately and protect against corrosion using primer and the corresponding paint The pivot bearing assembly between the undercarriage and the bogies is maintenance free The side bearers between the undercarriage and the bogie must be lubricated regularly The clearance between the side bearers on the undercarriage and on the bogies must be checked 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Bogies 2 13 7 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Boom 2 14 1 2 14 2 2 14 3 2 14 4 Boom and Root Point Rope Pulleys Rope Guides Boom Support Block 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 2 14 LOCO
9. WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Main Pumps 2 2 1 P 2 2 Figure Main Pumps Figure B Item 4 Item 3 Item 2 Item 1 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Secondary pumps 2 202 P 1 2 Description The secondary pump for emergency operation is located on the emergency diesel engine See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one in near hot or moving parts danger of getting burnt crushed or drawn into the equipment Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections those higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sectio
10. be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment When working with paint and solvents ensure to observe without fail the respective safety instructions on the packages When dressing with a flame use caution danger of explosion near fuel and oil related components When work is being performed on the crane ensure that the switches and levers cannot be operated by accident or unknowingly Ensure that no one is in the danger Zone Maintenance instructions Check the control panels for external damage and firm seating Damaged components must be replaced immediately Clean the control panels with a suitable aid Ensure that water and other wet cleaning agents cannot damage the sensitive electrical components 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Control Panels 2 7 2 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Screen Wiper 2 7 3 P 1 1 Screen Wiper Description The crane has an electrically operated wiper system its front and roof wind screens SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be v
11. burnt or scalded Observe disposal regulations Maintenance Instructions Check the components of the spring assembly for external damage as well as for cracks and fractures Any damaged spring elements must be replaced immediately If required clean spring suspension with a suitable aid 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake Discs 2 6 7 P 1 1 Description Brake Disc The brake discs in connections the brake cylinder adjuster unit and the brake cylinder forms the wheel disc brakes These wheel brake discs are used as the service brakes The brake discs are mounted on the wheels of the wheel set axles SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Caution The brake discs must be cooled down Danger of injury through burns as a result of contact with the brake discs When the following work is performed on the brake discs observe the safety instructions in the BSI Verkehrstechnik User s Manual The brake discs may first be used again when all the criteria in the BSI Verkehrstechnik User s Manual have been m
12. clean the protective housing and panelling with a suitable aid This applies in particular to the stairway and walkway areas Oily and greasy components increase the danger of slipping Check the protective housing and panelling for external damage Clean the damaged areas Eliminate the damage with suitable knifing filler glass fibre mats and polyester or corresponding primer and paintwork and then touch up with paint Damage on minor components must be straighten and touched up with paint Oil the hinges and locks on the doors and check for proper functioning Check the storm hooks on the doors for external damage and proper functioning 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Protective Housing and Panelling 2 13 2 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Stairways Footboards and Holding Straps 2 13 3 P 1 2 Description The stairways footboards and holding straps provide an easy and safe hold when climbing into the cab and onto the crane See Figure A They have anti slip weather proof treads SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outs
13. manually 1 2 4 UNDERCARRIAGE 2 3 1 Check for leakages rectify wherever required 2 Check functioning of brake rigging arrangement 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 100 Working Hours Monthly 1 3 P 1 1 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 2 AFTER 100 WORKING HOURS MONTHLY 2 1 MAIN ENGINE 24 1 Clean the air intake filter 2 Make sure that the vent hole in the fuel tank cap is clear 2 1 6 2 2 SUPERSTRUCTURE dn 1 Check that display of radius on console of the crane agrees with the actual radius 2 Check that all working parameters of load charts are in relation to PAT cut off 2 3 UNDERCARRIAGE 22 amp 2 3 1 Check for travel brake equipment linkages linings etc and pneumatic systems 2 Check functioning of out riggers and hydraulic cylinders 3 Lubricate travel gears with grease 4 Lubricate brake linkage with oil 5 Lubricate out rigger pins with oil 6 Lubricate side bearer with grease 7 Check lubricating oil level and top up if necessary Recommended oil Castrol Densol Super 20 W 40 SAE 40 equivalent REF RDSO s SL CR 140UBG JMP dt 8 5 1992 8 Lubricate bogie pivot with grease 2 6 2 4 MATCH TRUCK 1 Lubricate trestle pad and trestle pivot with grease 2 Lubricate side bearer with grease 3 Lubricate brake link
14. oil analysis according to the intervals in the maintenance schedule Lubricate the lubrication nipple on the counter bearing To change the oil e The crane must be in horizontal position to change when the oil has reached operating temperature e Screw out the oil filler plug the oil level inspection plug and the oil drain plug and allow the oil to drain in a suitable and sufficient large enough tray oil Always check the drained oil for metallic pollution and excessive abrasion e Then screw in the oil drain plug and add oil through the opening using the brand as classified in the chart in Section 3 of this manual Monitor the oil level on the oil level inspection plug e Wait afew minutes e Ifthe oil level falls top up the oil until the oil level maintains constant e Then screw in the oil filler plug and the oil level inspection plug Check the screw connections taking into the account the torque moment in the installation drawing and check for firm seating 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Drum 2 10 2 P 1 1 Description The rope drum forms a rigid unit with the auxiliary hoist reduction unit The rope drum coils the hoist rope in several layers SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work wa
15. or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Rope pulley set Check the rope pulleys for external damage and wear Any damaged or worn pulleys must be replaced Check also the rope pulleys for firm seating and whether they move easily if required re tighten Carry out a functional test on the rope pulleys and checked as to whether they move easily and run properly Rope guide Check the rope guide for external damage firm seating and wear any damaged or loose rope guides must be replaced Check also the rope pulleys for firm seating and whether they move easily if required re tighten using the torque laid down in regulations Carry out a functional test on the rope guide whether it moves easily and runs properly 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Pulley Set and Rope Guide on the Superstructure 2 11 3 P 1 2 Figure A Figure B Rope Guide Pulleys 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Recovery Winch 2 12 1 Recovery Winch including Brake 2 12 2 Rope Drum 2 12 3 Deflection Rollers 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 2 12 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Recovery Winch including Brake 2 123 P 1 2 Moto
16. pumps and hydraulic motors via their respective leakages oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stop cocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rotary Lead Through 2 2 5 P 2 2 Figure A Rotary Lead Through 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Suspension Blocking Cylinders 2 2 6 P 1 2 Description The suspension blocking cylinders serve to lock the suspension spring deflection to the wheel set springs during crane operation See Figure A The suspension blocking cylinders are single acting plunger type cylinders spring return mechanism The undercarriage hydraulics must be switched on via the respective selector switch in the cab SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside t
17. radiator with clean chromate treated water which should be free from any suspended impurities such as clay sand etc Radiator cap should be fitted back after necessary fill up since this will cause aeration and over heating of the water coolant 4 Battery acid level to be checked up and to be topped up if necessary with distilled water The terminal should be adequately coated with petroleum jelly 5 Clean dust pan and pre cleaner on dry type Air Cleaners 6 Clean crank case breather 7 Check belt tension and condition of belts for cuts fretting cracking etc 8 Fuel tank to be filled up with clean diesel oil to FULL capacity Capacity 1000 litres 9 Check for loose foundation bolts Tighten then if required 2 5 11 2 AUXILIARY ENGINE 1 Check for engine sump oil level Top up if necessary 2 Fuel tank to be filled up with clean diesel oil to FULL capacity capacity 11 litres 2 2 1 1 3 SUPERSTRUCTURE 1 Check for the oil level in pump distribution box P T O Unit Top up if necessary oil HP 90 2 Check hydraulic oil level Top up if necessary oil HLP 68 For this check rising of gallows may be necessary 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Daily 1 2 P 2 3 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 3 Check if all the stop valv
18. required replace 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Air Pressure Fine filter 2 3 4 P 2 2 Figure A Air Pressure Fine Filter 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake Pedal 2 3 5 P 1 1 Description Brake Pedal The brake pedal in the cab serves to smoothly and directly brake the travel motion SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt crushed or drawn into the equipment Caution Some sections of the system are not pressure less until the accumulators have been emptied Before work is carried out on the air pressure system ensure the system is without pressure Caution Observe air pressure tank regulations Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air pressure connections are being tight
19. slewing gear drive The pinion and gear wheel must be checked regularly for damage and lubricated according to the maintenance check list SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment To check and clean the pinion and gear wheel the superstructure must be rotated several times on the undercarriage Prior to commencing with the actual work ensure using the above measures that the crane cannot be set into operation danger of being crushed of being crushed or drawn into the equipment Maintenance instructions Check the gear wheel and in particular the pinion for external damage such as cracks broken teeth dimples and steel pits Clean the gear wheel and pinion of waste grease and dirt Then grease with spray grease brand as classified in the chart in Section 3 of this manual 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Roller Bearing Slew Ring 2 8 3 P 1 1 Description The roller bearing slew ring is t
20. suitable aid e g vacuum cleaner Eliminate any water which may have penetrated into the boxes Establish the cause and eliminate 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Batteries 2 1 3 P 1 2 Description The batteries are fed by the 3 phase generator of the diesel engine system The batteries supply the electrical system of the crane with power The batteries for the diesel engine are located on a stand in machinery house See Figure A SAFETY INSTRUCTION Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Never place objects or tools on the batteries Keep the batteries clean and dry Danger of short circuiting Use caution when handling battery acid Observe the respective safety regulations Avoid contact with skin and do not drink Danger of causticisation Do not drink the purified water Danger of poisoning No smoking no naked flame or light sparks or glowing ashes near the batteries Danger of expl
21. system Danger of explosion and fire Use caution when dealing with oil danger of being burnt or scalded 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Diesel Engine 2 4 1 P 2 2 Caution Hydraulic system work may only be performed on the hydraulic system when there is no pressure and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections because higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Caution air pressure system Work may only be performed on the air pressure system when the diesel engine is not running and the entire air pressure system is without pressure This is also applicable for the tightening of the air pressure connections Caution sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Ensure that no one is in the danger zone Observe the safety instructions provided in the Cummins User s Manual Maintenance Instructions The following maintenance work on the diesel engine system is to be carried out according to the information in the Cummins User s Manual Please note All the maintenance work listed in the interval before hand must be carried out as well Check the oil level if required top up oil using the brand as classified in the chart i
22. time A well organised inspection is essential to ensure reliability and freedom from failure of various details in service Whilst carrying out the works of the schedule all missing nuts bolts set screws cotters and split pins etc must be replaced and also the items when found defective must be renewed There are certain fundamental requirements that are important to any successful maintenance programme These are 1 Adequate provision of well trained supervisors and quality workmen 2 Adequate provision of proper maintenance facilities and tools 3 Adequate time for scheduled maintenance work to be completed properly before the crane is released for its next assignment 4 Provision of fuel lubricating oil and water treatment equal to or better than that required ensuring satisfactory crane performance 5 A well scheduled maintenance programme including an effective system of maintaining records for this purpose various prescribed schedule forms recommended to be filled up during each schedule are given at the end of the report 6 measuring devices such as torque wrenches lubricant dispensers etc which require calibrating should be checked quarterly for accuracy or sooner if required 7 tools and parts should be accounted for and removed from the crane after any maintenance work has been performed 8 All work done including methods and tools used must be in accordance with manufactures instructions main
23. with the corresponding paint Caution The sliding tracks must be not be soiled by paint and should not be painted 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Boom and Root Point 2 14 1 P 2 2 Figure A Root Point 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Pulleys 2 14 2 P 1 2 Rope Pulleys Description The rope pulleys serve to guide the ropes precisely to the boom head They ensure that the rope runs properly in every boom position The crane is fitted with plastic rope pulleys which ensure minimum wear of the steel ropes SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Use caution near the overhead lines Do not climb up onto the crane superstructure Mortal danger 140 T GOT
24. 10 1 Auxiliary Hoist Reduction Gear Unit including Brake 2 10 2 Rope Drum 2 11 Derricking Gear 2 0 Derricking Reduction Gear Unit including Brake 2 11 2 Rope Drum 2 11 3 Rope Pulleys Rope Guide on the Superstructure 2 12 Recovery Winch 2121 Recovery Winch including Brake 2122 Rope Drum 2 123 Deflection Rollers 2 13 Basic Construction 2 13 1 Steel Construction 2 13 2 Protective Housing and Panelling 2 13 3 Stairways Footboards and Holding Straps 2 13 4 Counterweights 2 13 5 Outrigger Beams 2 13 6 Outrigger Pads 2 13 7 Bogies 2 14 Boom 2 14 1 Boom and Root Point 2 142 Rope Pulleys 2 14 3 Rope Guides 2 14 4 Boom Support Block 2 15 Ropes and Lifting Gear 2 15 1 Ropes 2 15 2 Hook Blocks 3 Fuel Oil and Lubricant Chart 4 Torque Moments 5 DOS and DON Ts for Maintenance 6 Symbols used in Hydraulic Circuits 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Periodic Maintenance Schedules 1 1 1 General Guidelines 1 2 Daily 1 3 After 100 Working Hours Monthly 1 4 After 250 Working Hours 3 Monthly 1 5 After 500 Working Hours 6 Monthly 1 6 After 1000 Working Hours Yearly 1 7 After 2000 Working Hours 2 Yearly 1 8 After 4000 Working Hours 4 Yearly 1 9 After 8000 Working Hours 8 Yearly POH Note The maintenance overhaul work performed in relation to this manual given in Part 1 is as per RDSO Maintenance Schedule of 140 T cr
25. 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 8000 Working Hours 8 Yearly 1 9 P 6 6 SI Schedule Item as per RDSO Maintenance Schedule No Vide Report No MP 727 90 9 GENERAL WORKING INSTRUCTIONS 1 Periodic maintenance of the crane should be done after it is placed on level track and parking brakes of crane and match truck applied 2 After completion of schedule maintenance work check and ensure that no tools or replaced parts lie over the crane 3 The staff while working under the crane or while standing over footboards super structure must not smoke or strike up fire nearby 4 In case any structural part is damaged and it is to be rectified ensure 4 1 Direct flame does not damage cables hoses pipes must take all fire prevention measures for hoses cables etc from direct heat by shielding the flame 4 2 For any structural repair ensure proper preheating use of recommended electrodes and argoshield welding FURTHER READING 1 Gottwald s manual 2 Engine manufacturer s manual 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Electrical System 2 1 2 1 1 Switch Cabinets 2 1 2 Junction Boxes and cableways 2 13 Batteries 2 1 4 Three Phase Generator Out put 24 V DC 2 13 Hoist and Lowering limit switches 2 1 6 PAT system 2 1 7 Lighting and sockets 140 T GOTTWALD C
26. 2 3 4 P 1 2 Description The air pressure system is fitted with an air pressure fine filter The fine filter has a drainage option and a filter element See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt crushed or drawn into the equipment Caution Some sections of the system are not pressure less until the accumulators have been emptied Before work is carried out on the air pressure system ensure the system is without pressure Caution Observe air pressure tank regulations Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air pressure connections are being tightened Maintenance Instructions Check the air pressure fine filter its mountings and connections for external damage firm seating and proper sealing In addition clean the cooling spiral Unscrew the air pressure fine filter and check the fine filter element for its degree of pollution or damage if
27. 277 D 00 6 2770 degree 06 nos The twelve brake cylinders are single acting air pressure cylinders with automatic brake expander cups and spring return mechanism Six brake cylinders are fitted with a spring loaded assembly which can be activated by means of a mechanical emergency release device connected to Bowden cables on the axles SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt crushed or drawn into the equipment Caution Some sections of the system are not pressure less until the accumulators have been emptied Before work is carried out on the air pressure system ensure the system is without pressure Caution Observe air pressure tank regulations Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air pressure connections are being tightened Caution In this case braking cannot be carried out until the brake system is re pressurised with air pressure Use caution when the brake c
28. 40 Nm 980 Nm 24 X 2 740 Nm 1 050 Nm 1 250 Nm M27 X2 1 100 Nm 1 550 Nm 1 800 Nm M 30 X 2 1 500 Nm 2 150 Nm 2 500 Nm 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual DOS and DON Ts for Maintenance 5 P 1 1 SI DOs DON Ts Repercussion No 1 MAINTENANCE CHECKING OF ENGINE Engine should be maintained as per Manufacture s Maintenance Schedule 2 MAINTENANCE OF HYDRAULIC SYSTEM a Clean hoses and area around the equipment Do not open the Hyd System in a to be opened dirty Clean the tray in which the open parts are kept c Do not over tighten any leaking joints provided with O rings seals d Connected isolating valves must be closed before opening out any hoses e Ensure that no water is mixed with the hyd Oil in the tank Oil should be tested in lab as per guideline given in the maintenance manual 3 ATTENTION TO WIRE ROPE a Replace wire ropes when there is a diametrical reduction in its size by 5 or more with respect to its normal diameter b Replace wire rope if there is any bend kink abrasion and uncoiling or heavy corrosion c While reeving unreeving the wire rope on the drum a person operator must be watchful so that there is no overlapping of wire ropes which may cause damage to the wire rope d Proper greasing of wire rope around fitting Corrosi
29. 40 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Guides 2 14 3 P 1 2 Description The rope guides permit the ropes to be guided cleanly and prevent in particular the ropes from being sheared by the boom See Figure SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages When working with paint and solvents ensure to observe without fail the related components When electrical welding work is being performed the earthen terminal must be connected directly to the part be welded In addition the battery pole terminals on the diesel engine system and the emergency diesel engine system must be disconnected Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Use caution near the overhead lines Do not climb up onto the crane superstructure Mortal danger Maintenance Instructions The good condition of the rope guide is important for a long ho
30. ALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Wheel Sets 2 6 4 P 1 2 Description The six wheel sets are specially manufactured sets which are suited to absorbing all the forces and stresses which occur during crane and travel operation See Figure A amp B SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Caution when dealing with hot oil Danger of being burnt or scalded Observe disposal regulations Maintenance Instruction The following maintenance work on the wheel sets must be carried out according to the information in the Gutehoffnungshutte Radsatz GmbH User s Manual Check the wheel sets for cracks fractures and damage Watch for the following features If required repair or replace Cracks in the hub or disk of the solid wheels Indicating groove on the solid wheels is no longer visible on the circumference Shape and location of the wheel contours Surface finish of wheel treads Broken or cracked wheel rims on the solid wheels Whee
31. Caution When dealing with hot oil Danger of being burnt or scalded Observe disposal regulations Maintenance Instructions Check the wheel set bearings and their guides for external damage The bearings have grease filling To replace the filling open the bearing and remove the bearing housing Then clean the entire anti friction bearing and the housing and filled with fresh grease Re assembly in reverse order Note The inner bearings should not be opened 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Spring Suspension 2 6 6 P 1 1 Description To provide optimal suspension the crane is fitted with a spring system The system consists of combinations of cup spring and the helical springs In crane operation the spring suspension clearance is blocked during crane operation by means of hydraulic cylinders SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on nd is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Caution When dealing with hot oil Danger of being
32. Daily 1 2 P 3 3 SI Schedule Item as per RDSO Maintenance Schedule Ref No of Vide Report No MP 727 90 Maintenance Manual 1 2 AFTER STARTING THE ENGINE 1 2 1 MAIN ENGINE 2 4 1 Check leakages of oil water and air supply and rectify wherever required 2 Check for any loose nut bolt or fastener Tighten them if required 3 Check gauges and indicators for engine speed ammeter lube oil temperature lube oil pressure water temperature indicator and fuel indicator in driver s cab For details refer engine maintenance manual 4 Check lube oil pressure at both idling and maximum speed Operating Pressure 8 PSI and 40 70 PSI respectively 5 Clean the engine 1 2 2 AUXILIARY ENGINE 2 5 1 Check for any leakage of oil Rectify wherever required 2 Check for loose foundation bolts Tighten them if required 3 Clean the engine 1 2 3 SUPERSTRUCTURE 2 2 2 3 2 7 amp 1 Check air pressure operating pressure to be 6 5 bar to 7 5 bar rectify faults 6 5 if any 2 Check pollution indicator of hydraulic oil filter Replace the filter if the indicator is at the red mark or above 3 bar 3 Check hydraulic oil pressure of slewing circuit 200 bar power circuits I and II 280 bar and pilot circuit 30 bar 4 Check functioning of fans lights screen wipers and horns in cab 5 Checks for leakages of oil water and air rectify wherever required 6 Ensure that all limit switches are in working order 7 Check that solenoid valves are not bridged
33. ED EDITION Dec 2002 Use caution when dealing with hot oil danger of being burnt or scalded 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Pump Distributor Gearbox 2 4 5 P 2 2 Maintenance Instructions The following maintenance work on the diesel engine system must be carried out according to the information in the Lohmann and Stolterfoht User s Manual Check the pump distributor gearbox in particular near the flange connection for external damage leakages and firm seating Note To check the oil level of the distributor box the railway crane must be in horizontal position Switch off the engine when it has reached operating temperature and wait approx 10 minutes to check the oil level e Pull out the oil dipstick of the pump distributor gearbox e The oil level must be between the upper and lower markings of the dipstick if required top up oil using the brand as classified in the chart in Section 3 of this manual Note Add or top up oil via the filler opening the plug of which is screwed out for this purpose The screw in the plug and tighten An oil analysis should be carried out every 750 operating hours to test the oil quality If required adjust the oil changing intervals e Flush the gearbox with flushing oil Note To change the oil of the distributor gearbox the crane must be in horizontal position Switch off the engine when it has re
34. ESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Slewing Gear Pump Filter 2 2 4 P 2 2 Figure A Slewing Gear Pump Filter Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stopcocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rotary Lead Through 2 2 5 P 1 2 Description The rotary lead through is a rotary hydraulic connection between the undercarriage and the superstructure See Figure In addition it houses the ducts for the air pressure supply SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remov
35. ION Dec 2002 Railway Crane Maintenance Manual 2 1 1 Switch Cabinet P 2 2 Figure A 2 lt t r 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Junction Boxes and Cableways 2 1 2 P 1 1 Description The cableways and junction boxes serve to protect distribute and fan in the cable looms To provide a better overview and to protect the individual cables the cables are concentrated in cableways SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The cane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the junction boxes for external damage Ensure in particular that the cover is sealed properly and tightly If a cover is not seal properly electrical equipment can be severely damaged through water and dirt penetrating Check the cables for external damage bends or sheering points and check whether the cables are firmly seated in the cable looms Clean the junction box interior with a
36. Lubricate with grease Servo Coat 140 slewing ring bearing through grease nipples 3 Lubricate bogie bolster pins with grease 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 500 Working Hours 6 Monthly 1 5 P 2 2 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 4 4 MATCH TRUCK 2 6 amp 2 13 7 1 Clean and lubricate screw coupling and buffers with grease 2 Lubricate bogie pivots with grease 3 Lubricate bogies bolster pins with grease 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 1000 Working Hours Yearly 1 6 P 1 2 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 5 AT THE COMPLETION OF 1000 HOURS YEARLY 5 1 MAIN ENGINE 2 4 1 Check for turbocharger oil leaks 2 Tighten turbocharger mounting nuts 3 Check engine blow by 4 Clean radiator 5 Adjust injector and valves 6 Check wobble and eccentricity alignment marks on rubber type Discard damper if misalignment is more than 1 16 7 Check belt tension and adjust as required 8 Remove and clean air compressor breather element 5 2 AUXILIARY ENGINE 2 5 1 Drain sumps Flush out with approved brand of flushing oil and refill with new oil
37. MOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Boom and Root Point 2 14 1 P 1 2 Description The boom is seated on an open type root point See Figure A In transport position the boom is lowered onto the match truck SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Please note that the manufacturer must be consulted before any burning welding or dressing is carried out on the crane Maintenance Instructions Check the boom for external damage and cracks Clean the bearing sleeves of the shafts on the boom root point when they are disengaged and then protect against corrosion by greasing If the crane is subject to extreme external conditions e g sea air a high degree of dust and sand maintenance must be carried out on the boom root in between the intervals indicated e Clean the paintwork damage immediately and prime and protect against corrosion
38. NE 1986 DESIGN REVISED EDITION Dec 2002 Operation by means of pressurisation or pressure relief Directly acts on positioning element By means of opposed control areas of different sizes Internal control channel External control channel Pneumatic hydraulic operation 2 stage hydraulic operation 2 stage electro hydraulic operation external pilot oil supply 2 stage pneumatic hydraulic operation external pilot oil return 2 stage electro hydraulic operation spring centering of mid position external pilot oil feed and return 2 stage electro hydraulic operation pressure centering of mid position external pilot oil feed and return External feedback of actual position of positioning element Internal feedback of actual position of positioning element LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Symbols used in Hydraulic Circuits Name description examples Energy sources Hydraulic Pneumatic Electrical motor Drive unit except for electrical motor Energy transfer and storage Hydraulic pumps and motors Fixed displacement pump ge neral Fixed displacement pump 1 direction of flow 1 direction of rotation Variable displacement pump 2 directions of flow 1 direction of rotation Case drain port Fixed displacement motor 2 directions of flow 2 directions of rotation Fixed displacement pump motor 1 direction of flow 1 direction of rotation
39. Output Torque Generator 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 Cummins USA Brazil NT 855 RA 6 cylinders in series Water cooled Exhaust turbo charger 224 kW at 1 800 rpm 1 158 Nm at 1 400 rpm 28 V 55 A CIL PUNE NTA 855 R FFC 6 cylinders in series Vertical Water cooled Exhaust turbo charger 224 kW at 1 800 rpm 1 158 Nm at 1 400 rpm 28V 55A LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Diesel Engine Crane wise list 2 4 1 2 P 1 1 Crane wise Engine fitted Crane Number Crane Type Type of Engine fitted 142032 Fully Imported A 142033 Fully Imported A 142034 Fully Imported A 142035 Fully Imported A 142036 Fully Imported A 142037 Fully Imported A 142038 Knock down A 142039 Knock down A 142040 Knock down A 142041 Kit Crane A 142042 Kit Crane A 142043 Kit Crane A 143001 Jamalpur Manufactured B 143002 Jamalpur Manufactured B 143003 Jamalpur Manufactured B 143004 Jamalpur Manufactured B 143005 Jamalpur Manufactured B 143006 Jamalpur Manufactured B 143007 Jamalpur Manufactured B 143008 Jamalpur Manufactured B 143009 Jamalpur Manufactured B 143010 Jamalpur Manufactured B 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Exhaust System 2 4 2 P 1 1 Description The exhaust system e
40. RANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Switch Cabinets 2 1 1 P 1 2 Description The superstructure switch cabinets serve to house the essential electrical and electric components which are required to control monitor and supply the crane with power They are located in the machinery house side panel See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot and moving parts Danger of getting burnt crushed and drawn into the equipment Maintenance Instructions Check the switch cabinets for any external damage In particular check the doors as to whether they close properly Any faulty seals must be replaced immediately Check cabin connections for firm seating and damage Clean the switch cabinet s interior with a suitable cleaning aid Remove any water which has penetrated into the cabinet Establish the cause and eliminate Clean the hinges and locks on the switch cabinet door and grease slightly 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDIT
41. Railway Crane User s Manual Maintenance Part II 140 TONNE DIESEL HYDRAULIC B D CRANE WITH A FRAME 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Table of Contents Part III P 1 3 1 Periodic Maintenance Schedules 1 1 General Guidelines 1 2 Daily 1 3 After 100 Working Hours Monthly 1 4 After 250 Working Hours 3 Monthly L3 After 500 Working Hours 6 Monthly 1 6 After 1000 Working Hours Yearly LT After 2000 Working Hours 2 Yearly 1 8 After 4000 Working Hours 4 Yearly 1 9 After 8000 Working Hours 8 Yearl POH 2 Maintenance Instructions 2 1 Electrical System 2 1 1 Switch Cabinets 2 12 Junction Boxes and Cableways 2 1 3 2 1 4 Three Phase Generator Output 24 V DC 2 1 3 Hoist and Lowering Limit Switches 2 1 6 PAT System 2 4 7 Lighting and Socket 2 Hydraulic System S S amp U C 22d Main Pumps 2 2 2 Secondary Pumps Lata Hydraulic Oil Tank 2 2 4 Slewing Gear Pump Filter CAR Rotary Lead Through 2 2 6 Suspension Blocking Cylinders NUN Undercarriage Control Blocks 2 2 8 Out rigger Cylinders 2 2 9 Hoist Derricking Gear Slewing Gear and Travel Gear Motors 2 2 10 Superstructure Control Blocks 22 11 Counterweight Cylinders 2 3 Air Pressure System S S amp U C 2 Air Pressure Tank 2 3 2 Brake Cylinders 243 9 Brake Couplings 2 3 4 Air pressure Fine Filter 2 Brake
42. SIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Ropes 2 15 1 P 2 3 Maintenance Instructions 1 a b c Inspection Wire ropes are consumable items with a limited life This is why the wire ropes and rope fittings must be inspected daily The complete length of the ropes must be inspected In additions the wire ropes must be examined for operating safety by a competent person in regular intervals The intervals should be scheduled so that any damage will be detected early This is what during the first few weeks after the installations of a new rope and after the first broken wire or other damage the intervals should be reduced accordingly If the rope has been overloaded or if non visible damage is suspected the intervals between examinations should be reduced accordingly if required every few hours Moreover an examination should be carried out when the rope is put back into service after long periods of standstill A wire rope must be removed in time to maintain crane operating safety The following criteria detaining a rope must be discarded Type and number of wire breakages Main hoist and derricking ropes rope diameter 26 mm If the rope shows more than 5 wire breakages on a length of 6 x diameter or 10 on a length of 30 x diameter the rope is unserviceable and must be discarded Auxiliary hoist ropes rope diameter 22 mm If the rope shows more than 5 wire
43. Secondary pumps 22 2 P 2 2 Figure Secondary Pump 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Hydraulic Oil Tank 2 2 3 P 1 2 Description The hydraulic oil tank serves to store the hydraulic oil for the hydraulic system The hydraulic oil is added topped and drained via the tank The tank capacity is approx 1400 Ltrs SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured the crane can not be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic System Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections that higher mounted components could drain dry In these cases ensure adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the hydraulic oil tank and its connections for external damage and leakages The oil le
44. Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the cylinders and their connections for external damage firm seating and proper sealing Tighten or replace loose or leaky connections when the system is not under pressure On completion of maintenance work carry out a sealing test under pressure The piston rods are lubricated on retraction automatically Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stop cocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Counterweight Cylinders 2 2 11 P 2 2 Figure Counterweight Cylinder 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual
45. TENANCE SCHEDULES To ensure reliable operation and for the proper upkeep of140T diesel hydraulic brake down cranes following periodic maintenance schedules have been prescribed Daily schedule Schedule at the completion of 100 working hours monthly Schedule at the completion of 250 working hours 3 monthly Scheduler at the completion of 500 working hours 6 monthly Schedule at the completion of 1000 working hours yearly Schedule at the completion of 2000 working hours 2 yearly Schedule at the completion of 4000 working hours 4 yearly Schedule at the completion of 8000 working hours 8 yearly i e this is to be carried out at Eastern Railway Workshop Jamalpur Qo NO Den Details in regards to various checks attentions to different components assemblies during mentioned prescribed time bound maintenance schedule are given in subsequent pages KKK 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Daily 1 2 P 1 3 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 1 DAILY 1 1 BEFORE STARTING THE ENGINE 1 1 4 MAIN ENGINE 2 4 1 Check engine oil level and top up if necessary recommended oil castrol Deusol Super 20 m W 40 SAE 40 or equivalent Must be maintained at H mark 2 Checks for evidence of fuel oil water and exhaust leaks 3 Fill top up
46. TWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Pulleys 2 14 2 P 2 2 Maintenance Instructions Check for the rope pulleys for external damage firm seating and excessive wear Any damaged or worn pulleys must be replaced immediately Once the pulleys have been re installed carry out a functional test The rope fatigue is measured on the diameter contraction of the rope and by a contraction of 5 compared to the original actual dimension the rope must be replaced The actual dimension must be measured by the crane user before initial operation The nominal dimension of the rope is not appropriate as a reference as the manufacturer s conditions could include a 446 tolerance Independent of the above the rope must be replaced when through faulty handling bends kinks flattenings abrasion or heavy corrosion appearance occur Rope end fittings rope pendent rope clamps are severely exposed to corrosion as moisture which has penetrated has difficulty in drying These connections are therefore to be checked more frequently and where necessary shorten the rope to eliminate the corroded section According to operating conditions and frequency of use the ropes should be treated from time to time with an acid free corrosion proofing When changing ropes ensure that ropes of the same type and diameter are used Determine the actual diameter of ropes for wear check 1
47. UR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Steel Construction 2 13 1 P 1 1 Description The steel construction supports all the components of the crane and provides it with the required strength and rigidity to carry out its duties for which it is designed The shape and dimensions of the steel construction have been calculated exactly and thus ensure that crane operation can be carried out safely The undercarriage has mainly been manufactured in material Fe 540 to IS 8500 the superstructure and boom in SAILMA 450 HI and ST 55 HTW to IS 961 SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fail the respective safety instructions on the packages Please note that the manufacturer must be consulted before any burning welding or dressing work is carried out on the crane Maintenance Instructions Check the entire crane steel construction for external damage such as cracks or deformations 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual
48. Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections that higher mounted component could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the cylinders and their connections for external damage firm seating and proper sealing Tighten or replace loose or leaky connections when the system is not under pressure On completion of maintenance work carry out a sealing test under pressure The piston rods of the propping latch into retracted position automatically Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed
49. ached operating temperature and wait approx 10 minutes to check the oil level e To drain the oil screw out the oil drain plug on the gearbox under side and collect the waste oilin a suitable and sufficiently large enough pan e Clean the magnet plug on the oil drain plug screw in and tighten according to regulations e To carry out an oil analysis if there is considerable metal abrasion in the oil or the drain plug this means that there is high degree of wear or considerable gearbox damage If required consider a gearbox inspection e Top up oil as per the classification in the chart until the upper marking on the dipstick is reached e To add or top up on observe the information in the section on the oil level check Check the vent filter on the housing upper side if required clean or replace Check the screw on connection for firm seating taking into account the torque on the installation drawing 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Emergency Diesel Engine System 2 5 Emergency Diesel Engine 2 5 1 1 Emergency Diesel Engine Different Types 2 5 1 2 Emergency Diesel Engine Crane wise list 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 2 5 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Emergency Diesel Engine 2 5 1 P 1 2 Description The emergency diesel engine drives a hydraulic pump i
50. against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections that higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the valve blocks and their connections for external damage and leakages Tighten the fittings if required but only when they are not under pressure Then carry out a sealing test under pressure Check each of the Propping and Outrigger cylinders directly by means of the hand levers The suspension blocking and travel gear pinion disengagement device are operated by means of one hand lever Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil co
51. age pins with oil 2 5 JIB 2 14 1 Lubricate main and auxiliary snatch block swivel and sheave bearings 2 Lubricate derrick pulley blocks and sheaves bearings 3 Lubricate ropes with grease 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 250 Working Hours 3 Monthly 1 4 P 1 1 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 3 AFTER 250 WORKING HOURS 3 MONTHLY 3 1 MAIN ENGINE 2 4 1 Change replace engine oil NOTE When lube oil is examined through lube oil analysis in a laboratory oil change period may be extended if oil condition satisfactory 2 Fit new lube oil full flow filter element and gasket 3 Remove clean and inspect dry type air cleaner for holes and tears Check gaskets rings for damage Paper type elements should be cleaned by compressed air in the direction opposite to the flow of air Discard element even if a pinhole exists 4 Change lubricating oil bypass filter element and gasket 5 Change water filter element 6 Change fuel filter element and gasket 7 Check all air cleaner connections for cracks chafing etc Tighten all air in connections 8 Drain water and sediments from fuel tank 9 Clean crankcase breathers 3 2 UNDERCARRIAGE 2 3 amp 2 13 7 1 Checks wear on brake lining 3 3 MATCH TRUCK 2 6 1 Checks wea
52. alibrate all injectors 6 Check fuel pump calibrations 7 Replace fuel pump filter screen and magnet 8 Check fan hub and drive 9 Clean and tighten all electrical connections NOTE Arrange for authorised dealer for engine manufacturer s mechanic to check your engine completely refer engine maintenance manual for details 7 2 AUXILIARY ENGINE 2 5 NOTE Arrange for authorised dealer for engine manufacturer s mechanic to check your engine completely refer engine maintenance manual for details 2 1 5 7 3 SUPERSTRUCTURE 15 1 Carry out visual inspection of wire ropes by disassembling 74 UNDERCARRIAGE 2 3 1 Check wheel wear 2 Inspect axle box roller bearings and refill with grease LITHON 3 HPC 2 6 75 MATCH TRUCK 1 Check wheel wear 2 Inspect axle box roller bearing and refill with grease LTTHON 3HPC 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 8000 Working Hours 8 Yearly 1 9 P 1 6 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 8 POH AT THE COMPLETION OF 8000 HOURS 8YEARLY TO BE CARRIED OUT AT E RLY WORKSHOP JAMALPUR 8 1 Run the main power pack 24 1 Check all motions 2 Check all safety devices 3 Check all load chart parameters in regard to PAT and Limit Switch cut off 8 2 Run the auxiliary power pack and check all motions of auxiliary Circui
53. and Travel Gear Motors 22 10 Superstructure Control Blocks 2 2 11 Counterweight Cylinders 140 TGOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Main Pumps 2 2 1 P 1 2 Description The Crane has a main pump assembly which is located directly downstream of the pump distributor gearbox on the diesel engine SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections that higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane i
54. and firm seating Check the moving latching unit for external damage and firm seating Check whether it moves easily Clean and grease the knuckle joints and sliding surfaces Clean the paintwork damage immediately and prime and protect against corrosion with the corresponding paint 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Ropes and Lifting Gear 2 15 2 15 1 Ropes 2 15 2 Hook Blocks 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Ropes 2 15 1 P 1 3 Description The ropes are of the following types Hoist ropes Rotation resistant flexible hoist rope with a compacted steel core Langs lay Derricking ropes 8 Strand rope made out of conventional strands Langs lay SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn the equipment Use caution near the overhead lines Do not climb up onto the crane superstructure 140 T GOTTWALD CRANE 1986 DE
55. ane vide Report No MP 727 90 and added by Jamalpur on feedback of users amp experience gained during SEG Visits Any change in the RDSO s Maintenance Schedule Report will be circulated by RDSO Corresponding correction should be made in this manual also 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual General Guide Line 1 1 P 1 2 This schedule for examination and maintenance of the various parts of 140 t Diesel Hydraulic Breakdown Crane GOTTWALD DESIGN has been evolved taking into account the experience gained by allot tee rail ways in the field of crane maintenance The service periods of cranes specified in this schedule for maintenance attention are the maximum allowable between successive examinations Variations in operating conditions between successive examinations Variations in operating conditions may make it necessary to carry out examinations more frequently or to introduce examination of details not scheduled herein In such cases the matter should be brought to the notice of the concerned Sr DME DME AME who alone is authorised to introduce any change in the standard examination detailed herein The Sr DME DME AME must in all cases bring to the notice of the Motive Power Directorate of RDSO any modifications to the schedules giving full details The intensive utilisation of the crane makes such a scheme necessary in order to reduce the ineffective
56. aner SUPERSTRUCTURE Re tightens all the bolts of the slewing ring with a tightening force of 783 7 KN 6 6 KN If one or more bolts are found to be slack while tightening with torque wrench then loose bolts should be replaced Simultaneously two adjacent bolts of the slack bolt bolts also should be replaced If 12 or more bolts are slack all bolts should be replaced Check brake equipment for functioning UNDERCARRIAGE Re tighten all the bolts of the slewing ring with a tightening force of 783 7 KN _6 KN If one or more bolts are found to be slack while tightening with torque wrench then loose bolts would be replaced Simultaneously two adjacent bolts of the slack bolt bolts also should be replaced If 12 or more bolts are slack all bolts should be replaced Check brake equipment for functioning MATCH TRUCK Check brake equipment for functioning 2 5 2 8 3 amp 2 6 2 8 3 amp 2 6 2 6 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 4000 Working Hours 4 Yearly 1 8 P 1 1 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 7 AT THE COMPLETION OF 4000 HOURS 4 YEARLY 7 1 MAIN ENGINE 2 4 1 Check turbocharger end clearance 2 Check accessory drive end clearance 3 Check crank shaft end clearance 4 Clean injector inlet screens 5 Clean and c
57. ange the oil Note The crane must be in horizontal position to change the oil e The oil must be changed when the oil has reached operating temperature e Screw out the oil filler plug and the oil level inspection plug Insert the unattached pipe supplied to the opening on the oil drain plug Screw out the drain plug and allow the oil to drain in suitable and sufficiently large enough tray oil e Always check the oil for metal pollution and excessive abrasion Then remove the pipe screw in the oil plug and add oil using the brand as classified in the chart in Section 3 of this manual Monitor the oil level on the level inspection plug e Wait a few minutes e the oil level falls top up the oil until the oil level maintains constant e Then screw in the oil filler plug and the oil level inspection plug Check the screw connections taking into the account the torque moment in the installation drawing 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Drum 2 11 2 y s MIT m oe Description The rope drum serves to coil the rope The rope drum is rigidly connected with the planetary gearboxes for the winch drive assembly SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affix
58. at no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the counterweight and the mountings for external damage and crack Clean the paintwork damage immediately and protect against corrosion using primer and the corresponding paint 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Counterweight 2 13 4 P 2 2 Figure 14 Tonne 6 Tonne 18 Tonne 5 2 Tonne 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Outrigger Beams 2 13 5 P 1 1 Description Outrigger Beam The outrigger beams are extended and retracted via a hydraulic cylinder The outrigger beams are latched in transport position by means of socket pins SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages When dressing with a flame use caution danger of explosion near fuel and oil rel
59. ated components Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the outrigger beams for external damage cracks fractures and deformations Clean the paintwork damage immediately and protect against corrosion using primer and the corresponding paint The bearings of the outrigger beams on the undercarriage are fitted with one lubrication nipple each on the upper and lower sides Remove the waste grease and lubricate until the bearing points are protected by means of a surrounding bead of grease Check the outrigger beams as to whether they extend and retract properly and whether they lock properly 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Outrigger Pads 2 13 6 P 1 1 Description The outrigger pads are hinged to transfer the support forces for the crane evenly into the ground SAFETY INSTRUCTIONS Before maintenance work performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instru
60. both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment To check and clean the pinion and gear wheel the superstructure must be rotated several times on the undercarriage Prior to commencing with the actual work ensure using the above measures that the crane cannot be set into operation danger of being crushed double or drawn into the equipment 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Auxiliary Hoist Reduction Gear Unit including Brake 2 10 1 P 2 2 Maintenance instructions The maintenance work on the planetary gearbox must be carried out according to the information in the Lohmann amp Stolterfoht GmbH User s Manual Check the planetary gearbox its attachments and all connections for external damage and leakages Check all connections lines and links for firm seating Carry out a running noise check Note The crane must be in horizontal position to check the oil level e The oil is checked via the overflow meter To do so screw out the oil filler plug and the oil level inspection plug if required top up oil using the brand as classified in the chart in Section 3 of this manual e Then screw in both plug Carry out an
61. both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Caution When dealing with hot oil Danger of being burnt or scalded Observe disposal regulations Maintenance Instructions Check the pinions and gear wheel for external damage Clean the pinion and gear wheels with a suitable aid Caution Grease using the lubrication brand as per the chart in the Section 3 of this manual 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Disengaging Devices 2 6 3 P 1 2 Description By means of the disengaging device the pinion and the gear wheel of the travel drive are disengaged prior to transport The disengaging device is attached via an air pressure cylinder The crane has a total of two travel drives and thus two disengaging devices See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure
62. breakages on a length of 6 x diameter or 13 on a length of 30 x diameters the rope is unserviceable and must be discarded Position of the wire breakages When wire basketing occurs or if a stand breaks the rope is immediately unserviceable Inevitable wire breakages As wire breakage occurs after a certain number of operating hours and then the number increases more quickly it is recommended to observe the times in which breakages occur so as to be able to judge the overall condition of the rope Rope diameter contraction during operating time If the rope diameter over a greater length is reduced by 15 or more from the actual measured rope diameter in new condition nominal damage the rope is no longer serviceable Corrosion To what degree the ropes are subject to corrosion will depend very much on the crane site e g Ocean atmosphere Should the rope show a high degree of corrosion the rope is no longer serviceable 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Ropes 2 15 1 P 3 3 4 Wear through friction If the rope diameter is reduced by 10 or more through wear by friction the rope is no longer serviceable 5 Rope deformations Deformations in the rope such as waviness birdcaging loop formations loose wires nodes rope thinning misplaced outer wires kinks and flat areas are visible changes in the rope structure A rope with such deformatio
63. c 2002 Railway Crane Maintenance Manual Deflection Rollers 2 12 3 P 1 1 Description The deflection rolls of the recovery winch ensure that the rope is guided properly and contribute to the safe operation and long service life of the ropes SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the deflection rolls for external damage wear and firm seating If required tighten the mounting elements Replace any damage or worn deflection rolls Check the rope clamp for firm seating and damage Lubricate the lubrication nipple on the deflection rolls 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Basic Construction 2 13 2 13 1 Steel Construction 132 Protective Housing and Panelling 2 13 3 Stairways Footboards and Supporting Straps 2 13 4 Counterweight 2 1353 Outrigger Beams 2 13 6 Outrigger Pads 2 13 7 Bogie 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALP
64. chedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 8 14 Open main power pack and lower for POH Before opening close all stop 2 4 cocks except auxiliary pumps Q8 and Q9 Send the main power pack to authorised dealer manufacturer for POH and load testing 8 15 Start auxiliary power pack slew back the crane and release the props 2 5 8 16 Open auxiliary power pack and lower for POH Before opening close stop cock 2 5 Send the auxiliary power pack to authorised dealer manufacture for POH and load testing 8 17 Disconnect all hoses and pipes of under carriage and rotor check replace if 2 2 required 8 18 Open the pivot nut lift the crane run out bogie keep on trestle 2 64 8 19 Release wheels and send to wheel shops for inspection of bearings and 2 65 regressing and necessary repairs Check wear of brake disc brake shoe and e working of the parking brakes Re adjust replace if required 8 20 Open the pivot nut of match truck lift the match truck run out bogie keep on trestle 2 6 4 8 21 Release wheels and send to wheel shop for necessary inspection and repair Check wear of brake disc brake shoe and working of the parking brakes Re 2 6 4 2 6 5 amp adjust replace if required 2 6 9 8 22 Check travelling gear box pneumatic cylinders and valves Replace as required 261 8 23 Check structural damage of bogie crane and match truck and repair as required 2 13 7 8 24 Disconnect all hoses and pipes of
65. cking motion is switched off in the lowest boom position for transport purposes or in the steepest position for raising lowering the counterweight Main and Auxiliary hoists Both hoists are fitted with a hoist and lowering limit switch which are located on their respective hoist drums The hoist limit switches switch off the hook in the highest hook position and thus prevent the hook gear from being pulled into the boom head The lowering limit switches switch off the hoist in the lowest hook position and thus prevent the rope from uncoiling beyond the required remaining safety windings SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane can not be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Caution near the overhead lines Do not climb up onto the crane superstructure Mortal danger Ensure that no one in near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the limit switches and their mountings and connections for external damage and firm seating Open the limit switches and their mountings and connections for external damage and firm seating The functional test must be carried out witho
66. ctions on the packages When dressing with a flame use caution danger of explosion near fuel and oil related components When electrical welding work is being performed the earthingl must be connected directly to the part to be welded In addition the battery pole terminals on the diesel engine system and the emergency diesel engine system must be disconnected Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the outrigger pads for external damage cracks fractures and deformations Likewise check the mounting bolts and the safety pins as to whether they are in good condition Clean the Knuckle joints and then protect against corrosion by greasing 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Bogies 2 13 7 P 1 2 Description The crane has 2 bogies which support 3 wheel sets each See Figure A In addition a travel gear reduction unit including the disengaging device a brake system and a suspension assembly are located in each of the bogies The undercarriage is seated on the bogies above bogie pivots SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane can not be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab
67. cture and under carriage 22 Replace if required 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 8000 Working Hours 8 Yearly 1 9 P 4 6 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 8 32 Check structural damage of super structure and under carriage Repair as 2 13 required 8 33 Lift super structure and keep on under carriage on slewing ring Follow 2 13 manufacturer s instructions while assembly 8 34 K ll motion hi 1 iti tematicall all motion s machinery in position systematically 2 922 102 1 Main hoist drum assembly 2 11 2 amp 2 12 7 2 Auxiliary hoist drum assembly 3 Derrick drum assembly 4 Slewing gear box 5 Recovery winch drum assembly 8 35 Keep auxiliary power pack in position and connect the hoses 8 36 Connect the hoses and pipes of rotor with super structure 2 5 8 37 Connect all hoses and pipes of all drum assembly of super structure 22 2 922 102 8 38 Fill up hydraulic oil HLP 68 into the tank Capacity 1400 litre 2 11 2 amp 2 12 2 2 2 9 8 39 Assemble the bogies after receiving wheel sets from wheel shop of 2 13 7 1 Crane 2 Match Truck 8 40 Push the bogies inside the crane match truck 2 13 7 8 41 Lift the crane remove trestle and lower on bogies Tighten the pivot nut 8 42 Lift the match truck remove trestle and lower on bo
68. ding surfaces K2K to DIN 51825 7 Fuel Tank 1000 Itrs Diesel Ref RDSO s 1 Report No 727 90 Jan 1990 ii Report No MP MI 19 Rev 00 Sep 2001 lii L No SL CR BG 140T Gott UP dt 22 11 2000 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Torque Moments 4 P 1 1 The bolt torque moments indicated here apply when no other values for the torque moments of the individual bolts are provided in the Maintenance Manual The bolt size is based on the metric system in accordance with DIN German Industrial Standards and the bolt quality is based on ISD 898 Section 1 Bolt Classification Bolt Size 8 8 10 9 12 9 M 4 2 8 Nm 4 Nn 4 8 Nn M 5 5 5Nm 8 1 Nm 9 5 Nm M 6 9 6 Nm 14 Nm 16 Nm M 8 23 Nm 34 Nm 40 Nm M 10 46 Nm 67 Nm 79 Nm M 12 79 Nm 115 Nm 135 Nm M 14 125 Nm 185 Nm 220 Nm M 16 195 Nm 290 Nm 340 Nm M 18 280 Nm 400 Nm 470 Nm M 20 395 Nm 560 Nm 660 Nm M 22 540 Nm 760 Nm 890 Nm M 24 680 Nm 970 Nm 1 150 Nm 27 1 000 Nm 1 450 Nm 1 700 Nm M 30 1 350 Nm 1 950 Nm 2 300 Nm M 8XI 25 Nm 37 Nm 43 Nm M 10 X 1 25 49 Nm 71 Nm 83 Nm M 12 X 1 25 87 Nm 130 Nm 150 Nm MI2X 1 5 83 Nm 120 Nm 145 Nm 14 1 5 135 Nm 200 Nm 235 Nm M16X 1 5 210 Nm 310 Nm 360 Nm 18 X 1 5 315 Nm 450 Nm 530 Nm 20 X 1 5 440 Nm 630 Nm 730 Nm 22 X 1 5 590 Nm 8
69. e superstructure must be rotated several times on the undercarriage Prior to commencing with the actual work ensure using the above measures that the crane cannot be set into operation danger of being crushed of being crushed or drawn into the equipment Maintenance instructions Check the rope drum for external damage and firm seating Check the rope clamp for firm seating and damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Auxiliary Hoist 2 10 2 10 1 Auxiliary Hoist Reduction Gear Unit including Brake 2 10 2 Rope Drum 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Auxiliary Hoist Reduction Gear Unit including Brake 2 10 1 P 1 2 Description The auxiliary hoist is a two stage planetary gearbox The equipment includes an integrated hydraulically lifted multi disc brake with free wheeling option and a counter bearing The wheels with external toothing have been hardened The entire gearbox is seated on an anti friction bearing and is fitted with an oil bath lubrication system Power tale off and drive motions have counter rotary directions SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane can not be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to
70. e the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections those higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the hoses their connections and attachments for external damage firm seating and proper sealing a Replace any damaged components immediately Any loose or leaky connections must be tightened or if required replaced b Check the carrier for the rotary lead through for correcting seating and damage Caution The rotary lead through must not be twisted as otherwise the built in seals will be damaged Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic
71. e wise list Exhaust System Fuel System Diesel Engine Accelerator Pump Distributor Gearbox 140 TGOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 2 4 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Diesel Engine 2 4 1 P 1 2 Description The diesel engine drives the hydraulic pumps for travel and crane operations via the pump distributor gearbox The diesel engine supply the air pressure via the attached air compressor to the air pressure system the batteries with power via the attached 3 phase generator Out put 24V DC and thus also the electrical equipment with power Two Types of diesel engine has been fitted in 1986 Design 140T Crane The types are given in Section 2 4 1 1 and Crane wise engine fitted is given in Section 2 4 1 2 SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or squashed Observe safety and disposal regulations for the respective product when dealing with oil and fuel No smoking no naked flame or light sparks or glowing ashes near the fuel or diesel engine
72. eck all connections lines and links for firm seating Carry out a running noise check To check the oil level Note The crane must be in horizontal position to check the oil level The oil level inspection oil filler and oil drain plugs are located on the gearbox side The counterweight support must be lowered to check the oil level or to carry out an oil change e The oil is checked via the overflow meter To do so screw out the oil filler plug and the oil level inspection plug if required top up oil using the brand as classified in the chart in Section 3 of this manual e Then screw in both plugs Carry out an oil analysis according to the intervals in the maintenance check list Lubricate the lubrication nipple on the counter bearing To change the oil Note The crane must be in horizontal position to change the oil The oil level inspection oil filler and oil drain plugs are located on the gearbox The oil must be changed when the oil has reached operating temperature Screw out the oil filler plug which is simultaneously the oil level inspection plug and the oil drain plug and allow the oil to drain in suitable and sufficiently large enough tray oil Always check the drained oil for metallic pollution and excessive abrasion Then screw in the oil drain plug and add oil through the opening using the brand as classified in the chart in Section 3 of this manual Monitor the oil level on the oil level inspection plu
73. ed or drawn into the equipment Use caution near the overhead lines Do not climb up onto the crane Superstructure Mortal danger Maintenance instructions Check the entire hook block for external damage and cracks Any damaged parts must be replaced immediately 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Fuel Oil and lubricant Chart 3 P 1 1 SI Lubricant Fuel Manu No Place of Use quantity Lubricants facturer Brand 2 Approx 1 Hydraulic Tank 1400 Itrs IOC Sevosystem Hydraulic Oil HLP N 68 HLP 68to HPC Enklo HLP 68 Compensation Tank on 10 ltrs IS 11656 BPC Bharat Hydrol Match Truck 1992 HLP 68 IBP IBPEXHD 68 2 Main Engine 36 ltrs IOC Servo Premium CF 4 15 W 40 HPC Hylub Milcy Power Auxiliary Engine 5 5 ltrs Enei BPC MACKF4 15W40 ngine Oil Valvo line Valvoline Power Cummins Supreme 15W40 Ltd 3 Main Hoist Gear Box 08 ltrs Auxiliary Hoist Gear 04 ltrs Box Derrick Gear Box 17 5 Itrs Recovery Winch Gear 1 8 ltrs Gear Box Oil HPC HP 90 Boxe Travel Gear Box 12 Itrs in each motor Slewing Gear Box 11 Itrs PTO Gear Box 07 ltrs 4 Compressor Oil 02 Itrs Compressor Cummins 15W40 Oil 5 Roller bearing slewing Qty not fix Adhesive Adhesive lubricant Ring and Traction gear Lubricant BB to DIN 51513 reduction unit 6 Lubricating nipples and Qty not fix Grease purpose grease sli
74. ed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance instructions Check the rope drum for external damage Check the rope clamps for firm seating if required re tighten The rope grooves in the drum for damage and excessive wear when the rope is coiled Check the rope clamp for firm seating and damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Pulley Set and Rope Guide on the Superstructure 2 11 3 P 1 2 Description The pulley set at the rear of the superstructure See Figure and the rope guide on the front of the crane superstructure See Figure B ensure that the ropes are properly guided in every boom position and thus contribute to safe operation and a long rope service life SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot
75. ened Maintenance Instructions Check the brake pedal and its mountings for external damage and firm seating Clean the brake pedal with a suitable aid Dirty or oily pedals can endanger safety 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Signal Horns 2 3 6 P 1 1 Signal Horn Actuating Valve Description The two signal horns serve as an audible warning during travel and crane operations They are located on the crane at the front SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt crushed or drawn into the equipment Caution Some sections of the system are not pressure less until the accumulators have been emptied Before work is carried out on the air pressure system ensure the system is without pressure Caution Observe air pressure tank regulations Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air
76. er s manual 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Diesel Engine Accelerator 2 4 4 P 1 1 Description Accelerator lever The accelerator controls the injection pump of the engine The accelerator is operated via a Bowden cable by means of a pedal in the cab SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or squashed Observe safety and disposal regulations for the respective product when dealing with oil and fuel No smoking no naked flame or light sparks or glowing ashes near the fuel or diesel engine system Danger of explosion and fire Use caution when releasing connections because higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Ensure that no one is in the danger zone Observe the safety instructions provided in the Cummins User s Manual Maintenance Instructions Check the accelerator and the pertaining linkage including Bowden cable for external damage and firm sea
77. ere is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections those higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the motors and their connections for firm seating external damage and proper sealing Note Motors are lubricated by means of leakage oil this is why no oil change is required Check the running noises of the motors if the level of the running noise has increased in connection with an increase in pressure the motors could be damaged The maximum permissible leakage oil quantity of the hydraulic motor is 15 min at operating pressure The leakage oil connection must not be closed under any circumstances as the hydraulic motors could be destroyed as a result Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Cau
78. erformed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt crushed or drawn into the equipment Caution Some sections of the system are not pressure less until the accumulators have been emptied Before work is carried out on the air pressure system ensure the system is without pressure Caution Observe air pressure tank regulations Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air pressure connections are being tightened Maintenance Instructions Check the brake couplings their connections and pertaining cock stops and dummy couplings for external damage proper sealing and firm seating 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake Couplings 2 3 3 2 2 Figure A Vacuum Hose Feed Pipe Brake Pipe 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Air Pressure Fine filter
79. es of the hydraulic tank are open if not open them fully 4 Top up air oilier supply if necessary Oil HP 90 5 Observe for any leakage or damages of hoses and pipes Rectify if necessary 6 Check the cablings connecting the various parts of the PAT electrical system for physical damages 7 Drain condensate from both air reservoirs 8 Check fire extinguishers and first Aid Box in position and keep them in working order NOTE Even minor leakage of oil must be noted and eliminated 11 4 UNDERCARRIAGE 23 1 Check for axle mounted air compressor system for damages and deficiencies make good if any 2 Checks spring suspension for any breakage or deficiency 3 Check for damage and deficiency in the brake system including pipes and hoses 4 Floor plate to be cleaned Ensure it is free from oil and greasy substances 5 Drain out condensate from all the six air reservoirs 3 small size ones of capacity 14 litres each and 3 large size ones of capacity 50 litres each 6 Check leakages and functioning of parking brake NOTE Even minor leakage of oil must be noted and eliminated 2 6 1 1 5 MATCH TRUCK 1 Check for breakage of deficiency in spring suspension system 2 Check for damage and deficiency in the brake system including pipes and hoses 3 Check leakages and functioning of parking brake 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual
80. et Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions The following maintenance work on the brake disc must be carried out in accordance with the instructions in the BSI Verkehrstechnik User s Manual Check the brake discs for external damage cracks great thermal shock cracks and fractures n addition when the wear markings on the discs have been reached check the pads and the clearance Wear markings Disk wear limit max 7 0 mm Hollow wear max 2 5 mm Grooves max 1 mm Carry out a functional test brake test 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake System 2 6 9 P 1 2 Description The crane can either be operated by means of an air pressure brake system or a vacuum brake system The brake system can be changed from the air pressure system to the vacuum system and vice versa by means of two levers which can be operated on both sides of the crane See Figure A The status of the brakes can be read off the respective indicators red and green If required the spring loaded cylinders of the brakes can be relieved of pressure by means of the Bowden cables Caution In this case braking cannot be carried out again until the brake system has been re pressurised with air pressure SAFETY INSTRUCTIONS Before maintenance work is perfor
81. g Wait a few minutes If the oil level falls top up the oil until the oil level maintains constant Then screw in the oil filler plug and the oil level inspection plug Check the screw connections taking into the account the torque moment in the installation drawing and check for firm seating 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Drum 2122 P 1 1 Description The rope drum serves to take up the rope The rope drum is rigidly connected to the planetary gearboxes for the drive assembly SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane can not be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the rope drum for external damage Check the rope clamps for firm seating if required re tighten Check the rope grooves in the drum for damage and excessive wear when the rope is uncoiled Check the rope clamp for firm seating and damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION De
82. ghtening with the prescribed torque moment 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Main Hoist 2 9 1 Main Hoist Reduction Gear Unit including Brake 2 9 2 Rope Drum 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 2 9 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Main Hoist Reduction Gear Unit Including Brake 2 9 1 P 1 2 Description The main hoist is a three stage planetary gearbox The equipment includes an integrated hydraulically lifted multi disk brake with free wheeling option and a counter bearing The wheels with external toothing have been hardened The entire gearbox is seated on anti friction bearing and is fitted with an oil bath lubrication system Power take off and drive motions have counter rotary directions SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Check and clean the pinion and gear wheel the superstructure must be rotated several times on t
83. gies Tighten the pivot nut 8 43 Connect all hoses and pipes with under carriage and rotor 8 44 Connect all hoses and pipes of match truck nn 2 2 amp 2 3 140 GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 8000 Working Hours 8 Yearly 1 9 P 5 6 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 8 44 Attach match truck with crane 8 45 Assemble main power pack in position connect all pipes after slewing the 2 4 crane and propping by auxiliary power pack 8 46 Assemble gallows in position and fit cylinders 2 2 11 8 47 Assemble A frame lower leg upper leg and front leg in position 2 14 8 48 Assemble boom in position 2 14 8 49 Assemble stopper in position 2 14 8 50 Assemble bridle block in position 2 14 8 51 Assemble gantry tension wire rope with equaliser load cell and bridle 2 15 block 8 52 Start main auxiliary power pack 2 4 amp 2 5 8 53 Reeve on derrick wire ropes 2 11 2 8 54 Reeve on main hoist wire rope 2 9 2 8 55 Reeve on auxiliary hoist wire rope 2 10 2 8 56 Reeve on recovery winch rope 2 12 2 8 57 Check all electrical items and connect 2 1 8 58 Check all load chart parameters in reference to PAT and set all limit 2 1 6 switches 8 59 Test and trial at 25 over load 8 60 Spray paint 140 T GOTTWALD CRANE
84. he 360 degree rotatable connection between the superstructure and the undercarriage SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn the equipment To check and clean the pinion and gear wheel the superstructure must be rotated several times on the undercarriage Prior to commencing with the actual work ensure using the above measures that the crane cannot be set into operation danger of being crushed of being crushed or drawn into the equipment Maintenance instructions To carry out the running noises check the superstructure must be rotated slowly on the undercarriage ensure that the bearing assembly runs smoothly and quietly Two lubrication nipples are located in the left machinery house near the slew reduction gear unit The entire slew ring must be lubricated via these nipples The grease is fed via a pipeline system to the 20 lubrication points These points must be lubricated until the slew ring is protected by means of a clean surrounding bead of grease To compensate for settling the bolts must be ti
85. he cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections that higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Use caution when opening the suspension blocking cylinders The pistons are spring loaded Danger of accidents Mortal danger Maintenance Instructions Check the suspension blocking cylinders and their connections for external damage proper sealing and firm seating Retract and extend the cylinders In particular check for proper retraction and at the same time carry out an inspection of the piston rods Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hyd
86. he undercarriage Prior to commencing with the actual work ensure using the above measures that the crane into operation danger of being crushed of being crushed or drawn into the equipment 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Main Hoist Reduction Gear Unit Including Brake 2 9 1 P 2 2 Maintenance Instructions The maintenance work on the planetary gearbox must be carried out according to the information in the Lohmann amp stolterfoht GmbH User s Manual Check the planetary gearbox its attachments and all connections for external damage and leakages Check all connections lines and links for firm seating Carry out a running noise check Note The crane must be in horizontal position to check the oil level e The oil is checked via the overflow meter To do so screw out the oil filter plug and the oil level inspection plug if required top up oil using the brand as classified in the chart in Section 3 of this manual e Then screw in both plugs Carry out an oil analysis according to the intervals in the maintenance schedule Lubricate the lubrication nipple on the counter bearing Note The crane must be in horizontal position to change the oil e The oil must be changed when the oil has reached operating temperature e Screw out the oil filler plug the oil level inspection plug and the oil drain plug and allow the oil to drain in suitab
87. horised start The crane must not be in the way of other vehicles Ensure that no one in near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check the limit switches the load cells and the angle sensor for damage and firm seating When the functional test is carried out all the limit switch switch off points must be approached with care Check as to whether the controls on the panel show the proper indication In addition check as to whether the limit switches switch off properly 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Lighting and Sockets 2 1 7 P 1 2 Description The crane lighting consists of e Cab lighting e Machinery house lighting One halogen spotlights for crane operation at the centre in front of cab See figure A e Ahalogen spotlight for crane operation located up behind the superstructure A spotlight located behind the cab for checking the hoist and derricking gears e Two adjustable spotlights on the boom head In addition the crane is fitted with four 24 V sockets of which one is located in the cab and one each is located at the front and rear of each crane side SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign
88. ide the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fall the respective safety instructions on the packages When dressing with a flame use caution danger of explosion near fuel and oil related components Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment When electrical welding work is being performed the earthling terminal must be connected directly to the part to be welded In addition the battery pole terminals on the diesel engine system and the emergency diesel engine system must be disconnected Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Clean the stairways footboards and the walking surfaces and their mountings thoroughly with a corresponding cleaning agent The oil and grease film on stairways increase the danger of slipping Check the stairways footboards and holding straps and their mountings for damage and firm seating Missing screws must be replaced and loose connection must be replaced Clean the paintwork damage immediately and protect against corrosion using primer and the corresponding paint Damage on minor components must be straighten and touched up with paint 140 T GOTTWALD CRANE 1986 DESIGN
89. ilot operated with spring pre load Shuttle valve Air bleed valve Pressure control valves Pressure relief valve direct operated internal pilot oil feed Pressure relief valve direct operated external pilot oil feed Pressure relief valve pilot operated internal pilot oil feed and return Pressure relief valve pilot operated electrically operated relief internal pilot oil feed external pilot oil return 2 way pressure reducing valve direct operated internal pilot oil feed 2 way pressure reducing valve pilot operated internal pilot oil feed external pilot oil return 3 way pressure reducing valve direct operated internal pilot oil feed 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 Name description examples Flow control valves Throttle valve adjustable Shut off valve Deceleration valve Throttle check valve 2 way flow control valve pressure compensated 2 way flow control valve pressure and temperature compensated 3 way flow control valve pressure and temperature compensated Flow divider 2 way cartridge valves logic elements Directional valve leakage free differing effective areas Flow control valve LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Symbols used in Hydraulic Circuits Directional valve leakage free in one direction identical effective areas Fluid
90. intenance work is performed it must be ensured that the crane can not be switched on and secured against rolling In addition a maintenance Work warning sign must be visibly affixed to both in and out side the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger getting burnt crushed or drawn into the equipment The crane must not be operated in enclosed areas without an exhaust fumes discharges When work is being performed on the crane ensure that the switches levers can not be operated by accident or unknowingly Ensure that no one is in the danger zone Maintenance Instructions Check the fans and their cover grates for external damage and firm seating Screw off the vent grates when the fans are switched off and clean with a suitable aid Activate the respective switch on the control panel and test whether both fans run properly Caution When the diesel engine is stationary the fans should run only shortly as otherwise the battery will run flat and the charging rate will not be sufficient to start the diesel engine 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Additional Equipment 2 7 9 P 1 1 Description There are various pieces of additional equipment on the crane in particular in the cab Never
91. ir pressure system ensure the system is without pressure Caution Observe air pressure tank regulations Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air pressure connections are being tightened Maintenance Instructions Check the air pressure compressors their attachments and all connections for external damage and leakage Check all connections and lines for firm seating Check the oil level via a dipstick if required top up the oil until it reaches the upper marking of the dipstick using the brand as classified in the chart in Section 3 of this manual Check the air filter if required clean or replace a filter element Lubricate the lubrication nipple on the compressor shaft See Figure 1 2 amp 3 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Undercarriage Air Pressure Compressor 2 37 P 2 2 Figure A 140 TGOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Pressure Regulator 2 3 8 P 1 1 Description The pressure regulator maintains the operating pressure of the air pressure system at a constant pressure It switches off at a pressure of 7 3 bar and switches on at 6 2 bar SAFETY INSTRUCTIONS Before commencing with
92. isibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment When working with paint and solvents ensure to observe without with out fail the respective safety instructions on the packages When dressing with a flame use caution danger of explosion near fuel and oil related components When work is being performed on the crane ensure that the switches and levers cannot be operated by accident or unknowingly Ensure that no one is in the danger Zone Maintenance instructions Check the entire system for external damage and firm seating In particular ensure the wiper blades are in good condition Any damaged or worn wiper blades must be replaced immediately Check the system for proper functioning Caution When the diesel engine is at a standstill the screen wipers should only be switched on momentarily as other the batteries will run flat and the charged status will not be sufficient to start the diesel engine 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Fan 2 7 4 P 1 1 Fan Description The fans built into the cab rear wall at the top serve to suction off and intake the cab air SAFETY INSTRUCTIONS Before ma
93. ist rope service life Check the rope guides for external damage and firm seating Any damaged or loose rope guides can damage the rope Clean rope guides with a suitable aid 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Guides 2 14 3 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Boom Support Block 2 14 4 P 1 1 Description The boom support not illustrated on the match truck supports the boom head when the boom is lowered during towing operation SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against unauthorised start Crane must not be in the way of other vehicles When working with paint and solvents ensure to observe without fail the respective safety instructions on the packages Ensure that no one is near hot or moving parts danger of getting burnt crushed or into the equipment Please note that the manufacturer must be consulted before any burning welding or dressing work is carried out on the crane Maintenance Instructions Check the boom support for external damage
94. l flats on the wheel tread Heat cracks in the disk wheels Clamping nicks on the solid wheels Spalling on the wheel treads Wheel shift Cracks in the wheel axle Deformed wheel axle Heavy rusting on axles and disk wheels Check the mountings of the brake discs for proper and firm seating Wheel Back to back distance The wheel back to back distance crane unloaded 1596 mm _2 mm Wear Test Operating limit size Diameter New 915 mm _1 mm Diameter Min 860 mm 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Wheel Sets 2 6 4 P 2 2 Figure Non driving Figure Driving 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Wheel Set bearings 2 6 5 P 1 1 Wheel set bearings Description The wheel set bearings are anti friction bearings with a grease filling SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment
95. le and sufficiently large enough tray oil Always check the drained oil for metallic pollution and excessive abrasion e Then screw in the oil drain plug and add oil through the opening using the brand as classified in the chart in Section 3 of this manual Monitor the oil level on the oil level inspection plug e Wait a few minutes e Ifthe oil level falls top up the oil until the oil level maintains constant e Then screw in the oil filler plug and the oil level inspection plug Check the screw connections taking into the account the torque moment in the installation drawing and check for firm seating 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Rope Drum 2 9 2 Description The rope drum forms a rigid unit with the main hoist reduction unit The rope drum coils the hoist rope in several layers automatically SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment To check and clean the pinion and gear wheel th
96. maintenance work remove the battery main switch In addition a Maintenance Work warning sign must be securely affixed here and in the cab If the diesel engine must be started for test purposes ensure that no one is near moving or hot components Danger of being crushed Danger of being burnt Caution ensure without fail that a Maintenance Work sign is posted in the cab during the test phase On completion of the test shut off the crane without fail and secure accordingly Use caution when dealing with the air pressure system Work may only be carried out on when the system is without pressure and the diesel engine is at a standstill This also applicable when air pressure connections are being tightened Caution some sections of the system are not pressure less until the accumulators have been emptied Maintenance Instructions Check the pressure regulators and its pipe connections for external damage firm seating and proper sealing The switch off pressure is attained when the pressure regulators can be heard to let off pressure the switch on pressure is attained when the indicator on the pressure gauge for the air reservoir begins to climb 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Diesel Engine System 2 4 1 2 4 1 1 2 4 1 2 2 4 2 2 4 3 2 4 4 2 4 5 Diesel Engine Diesel Engine Different Types Diesel Engine Cran
97. med it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Caution The brake discs must be cooled down Danger of injury through burns as a result of contact with the brake discs When the following work is performed on the brake discs observe the safety instructions in the BSI Verkehrstechnik User s Manual The brake discs may first be used again when all the criteria in the BSI Verkehrstechnik User s Manual have been met Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check all the components of the brake system in particular the change over devices and the Bowden cables as well as their pertaining mountings for external damage and firm seating Also check the indicators for firm seating Clean the change over devices and the Bowden cables Check the six pull cables of the emergency release device for proper functioning Carry out a functional test on the entire brake system The brake must be operated and then released Observe the indicators during this procedure 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Mainte
98. mits the exhaust fumes into air reduces the emission speed of the exhaust and silence the noise level of the diesel engine The system consists of manifold compensator and silencer SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or squashed Observe safety and disposal regulations for the respective product when dealing with oil and fuel No smoking no naked flame or light sparks or glowing ashes near the fuel or diesel engine system Danger of explosion and fire Ensure that no one is in the danger zone Maintenance Instructions Check the exhaust system its connections and mountings elements for external damage and firm seating 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Fuel System 2 4 3 P 1 1 Description The fuel system supply the fuel required to operate the diesel engine The fuel capacity is 1000 litres The system is fitted with an electric indicator for fuel level SAFETY INSTRUCTIONS Before maintenance work is perf
99. must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Caution near the overhead lines Do not climb up onto the crane superstructure Mortal Danger Ensure that no one in near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instructions Check all the lighting elements of the crane their mountings and cable connections for damage firm seating and moisture Damaged or moist lighting fixtures must be replaced Any damaged or faulty sockets must also be replaced Clean the lighting fixtures with a suitable aid Check the lighting elements for proper functioning Any faulty lamps or lighting element with broken glass must be replaced immediately 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Lighting and Sockets 2 1 7 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Hydraulic System S S amp U C 2 2 2 2 1 Main Pumps Secondary Pumps 2 2 3 Hydraulic Oil Tank 2 2 4 Slewing Gear Pump Filter 2 2 5 Rotary Lead Through 2 2 6 Suspension blocking cylinders 24 7 Undercarriage Control Blocks 2 2 8 Outrigger Cylinders 229 Hoist Derricking Gear Slewing Gear
100. n Section 3 of this manual Oil Changing Filter Changing Check the coolant level if required top up coolant using the brand as classified in the chart in Section 3 of this manual In this case the coolant concentration must be checked Check the fan belt condition and tension if required readjust tension Monthly or every 125 hours Change oil Note The interval for changing the oil must be determined based on the Cummins User s Manual and the operating data recorded i e Average fuel and oil consumption or after an oil analysis for oil drain plug e Change fuel filter elements e Clean or change crank house ventilation e Change DCA coolant filter Semi yearly or every 750 hours Change oil filter elements Note The interval for changing the oil must be determined based on the Cummins User s Manual and the operating data recorded i e average fuel and oil consumption or after an oil analysis for oil drain plug e Change air compressor filter elements 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Diesel Engine Different type 2 4 1 1 P 1 1 Following two types of Diesel Engine has been fitted in 1986 Design 140T Crane Type Diesel Engine For Crane No 142032 to 1422043 Make Type Model Output Torque Generator Type Diesel Engine For Crane No 143001 to 143010 Make Type Model
101. n emergency operation See Figure A Two types of emergency engine has been fitted in 1986 design cranes of Gottwald amp Jamalpur make The brief specification is given in Section 2 5 1 1 and Crane wise emergency engine fitted is given in Section 2 5 1 2 SAFETY INSTRUCTIONS Caution fuel is inflammable When working near fuel related parts fire naked light and smoking are prohibited Caution Lubrication oil etc are drained at operating temperature danger of scalding Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connection because higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution air pressure system Work may only be performed on the air pressure system when the diesel engine is not running and the entire air pressure system is without pressure This is also applicable for the tightening of the air pressure connections Caution sections of the air pressure systems are under pressure until the accumulators have been emptied Prior to commencing work remove the battery main switch In addition a Maintenance Work warning sign must be affixed here and in the cab When work is being performed in the cab ensure that the switches and levers are not ope
102. n is no longer serviceable Rope change If a 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 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 reeved and guided in the grooves of the rope drum rope pulleys and the compensation rollers In particular for the ropes on the derricking gear 2 ropes on drum it is advisable to always change both ropes at the same time to ensure the same rope quality and to maintain the same inspection and maintenance intervals Functional test In particular a functional test without load is to be conducted after a rope change During the test it should be ensured that the rope runs smoothly the rope coils properly and the limit switches function After a wire rope has been mounted and before it beings its actual works load tests with very light loads should be carried out for at least an hour Cleaning greasing Wire popes must undergo maintenance regularly However the kind of maintenance will depend on how much the rope is used Regular maintenance may considerably increase the service life of steel wire rope During production the rope receives intensive lubrication This in process treatment will provide the rope with ample protection against corrosion and is meant to reduce the friction betwee
103. n the elements which make up the rope as well as the friction between rope and sheaves or drums This lubrication however only lasts for a limited time and should be re applied periodically When choosing the relubricant it must be ensured that it is in accordance with the recommendations of the rope manufacturer It is important that relubrication of steel wire ropes is carried out regularly right from the beginning of the service life of the rope and not only after the first damage has been ascertained Clean the ropes with a suitable aid and then lubricate As dirt can reduce the service life of a rope considerably depending on crane site it may be necessary to clean and grease the rope in between the indicated intervals 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Hook Blocks 2 15 2 P 1 1 Description The crane has two hook blocks one for the main hoist and other for the auxiliary hoist SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting bunt crush
104. nance Manual Brake System 2 6 9 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Cab 2 7 1 Cab 2 1 2 Control Panels 2 7 3 Screen Wiper Wash System 2 7 4 Fan 2 1 3 Additional Equipment 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 2 7 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Cab 2 7 1 1 2 Description The cab protects the operating personnel and the sensitive controls against the influences of weather See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment When working with paint and solvents ensure to observe without with out fail the respective safety instructions on the packages When dressing with a flame use caution danger of explosion near fuel and oil related components When work is being performed on the crane ensure that the switches and levers cannot be operated by accident or unknowingly Ensure that no o
105. ne is in the danger Zone Maintenance instructions Check the entire cab for external damage and deformations Caution Check material before commencing with straightening work In some cases the cab has aluminium profile which must not be heated by flame Check the glass for damage Any damaged panels must be replaced immediately Clean the cab width a suitable aid This applies in particular to the walkways and stair areas oily and greasy components increase the danger of slipping Clean grease and check the hinges and door lock for proper functioning Clean the paintwork damage immediately and protect against corrosion with primer and paint 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Cab 2 7 1 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Control Panels 272 P 1 2 Description By means of the control panels all crane and travel motions can be affected and most functions can be monitored SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not
106. ned prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Superstructure Control Blocks MO 30 4F 2 2 10 P 2 2 Figure Control Block M 1 Control Block M 2 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Counterweight Cylinders 2 2 11 P 1 2 Description The counter weight is fitted with two hydraulic cylinders See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationery This also applies to the tightening of hydraulic connections Use caution when releasing connections that higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution
107. ning e Then screw in the oil dipstick Carry out an oil analysis according to the intervals laid down in the maintenance manual To change the oil Note The crane must be in horizontal position to change the oil level e The oil must be changed when the oil has reached operating temperature e Direct the hose for the oil drain below the slew reduction gear unit into an external outlet e Screw out the oil dipstick and the oil drain plug on the hose end Drain the oil into a suitable and sufficiently large enough tray Always check the drained oil for metal pollution and excessive abrasion e Screw out the oil drain plug on the hose end and direct the hose back into the opening e Add oil using the brand as classified in the chart in Section of this manual Monitor the oil level via the oil dipstick e Wait a few minutes e the oil level falls top up the oil until the oil level maintains constant e Then screw in the oil dipstick Check the screw connections taking into the account the torque moment in the installation drawing and check for firm seating Unscrew the breather filter adjacent to the pipe whenever oil is topped up and check for pollution if required clean or replace the filter 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Pinion and Gear wheel 2 8 2 P 1 1 Description The pinion and gear wheel forms the last stage of the
108. nnections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stopcocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Undercarriage Control Blocks 2 27 P 2 2 Figure A Control block lever 140 TGOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Outrigger Cylinders 2 2 8 P 1 2 Description The crane is fitted with four outrigger beams Each outrigger beam has a swing out cylinder See Figure A and a propping cylinder See Figure B SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near to or moving parts danger of getting burnt crushed or drawn into the equipment
109. ns of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions As the secondary pumps on the emergency diesel engine do not run in normal operation it is necessary to carry out a trial run The trial run must last at least 5 minutes against a minimum pressure 5 bar to a maximum pressure of 200 bar Check the pumps and their connections for external damage and leakages The running noises of the pumps must be checked An increase in the running noises coupled with an increase in pressure indicates pump damage In this case the crane must not be operated and the pump must be replaced Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a maximum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stop cocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual
110. nuously with grease SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Slew Reduction Gear Unit 2 8 1 P 2 2 Maintenance instructions Carry out the maintenance work on the planetary gearbox according to documentation supplied by Lohmann amp amp Stolterfoht GmbH Check the planetary gearbox its attachments and connections for damage and leakages Check for all connections lines and connections for firm seating Carry out a running noises check To check the oil level Note The crane must be in horizontal position to check the oil level e Screw out the oil dipstick and wipe off with a clean lint free cloth Then screw in the oil dipstick and then screw out again The oil level must be between the upper and lowering markings on the dipstick if required top up the oil using the brand as classified in the chart in Section 3 of this manual via the oil dipstick ope
111. ny unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Caution When dealing with hot oil Danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections because higher mounted components could drain dry In these Observe disposal regulations Caution Some sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the travel gear reduction units for external damage leakages and firm seating Note To check the oil level bring the railway crane into horizontal position and switch off the engine at operating temperature e The oil level is checked via an overflow gauge e do so clean the exterior of the oil filler plug See Figure A on the bottom left and screw out e f required add oil until the oil level remains constant e Screw in the oil filler plug and tighten To change the oil the railway crane must be in a horizontal position and switch off the engine at operating temperature e The oil must be changed at operating temperature e Screw out the oil filler plug and the oil drain plugs See Fig
112. o applies to the tightening of hydraulic connections Use caution when releasing connections that higher mounted component could drain dry In these cases ensue an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the filter and its connections and mountings for external damage leakages or firm seating The filter is fitted with a visual pollution indicator See Figure A When the oil is at operating temperature the red indicator on the filter must not be visible To change the filter tis not possible to clean the filter insert It must be replaced when clogged Prior to changing the filter insert first release the pressure via the pressure drain plug on the under side of the filter body Then unscrew the filter body remove the filter insert empty the filter body and clean thoroughly Check the thread and the seals as to whether they are in good condition and then wet with hydraulic oil Prior to inserting the new filter element screw the pressure drain plug tightly on Screw in the filter body by hand until the mechanical stop Then it must be loosed by 1 4 rotations The sealing effect is not better as a result of increased tightening Oncompletion of maintenance check filter for proper sealing 140 T GOTTWALD CRANE 1986 D
113. on of wire clamps sockets should be done rope will take place 4 MAINTENANCE PRECAUTION FOR SAFETY DEVICES a limit switches force and angle sensors Don t disturb the switching point must be cabled Damaged cables must of the limit switches immediately be replaced They should always be kept operational b The crane axis must be vertically levelled c Check all limit switches when rigging to Do not operate computer over ensure their functioning bridge key and boom over bridge key during crane working These are slowly for use during rigging de rigging d The safe load indicator does not relieve the crane user from his responsibility to thoroughly determine the weight of the load to be lifted and check the admissibility of the operation according to be lifting chart e Do not keep the electric solenoid valves for cut off function bridged 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Symbols used in Hydraulic Circuits Symbols to DIN ISO 1219 Symbols for hydraulic systems are for functional interpre tation and comprise one or more basic symbols and in geneneral one or more function symbols Symbols are neither dimensioned nor specified for any particular posi tion The following listis incomplete It is designed as an aid for creating symbols Name description examples Basic symbols Symbol Line
114. on the hydraulic system check as to whether the stop cocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Outrigger Cylinders 2 2 8 Figure A Swing out Cylinder Propping Cylinder 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Hoist Derricking Slew and Travel Gear Motors 229 P 1 3 Description Both hoists See figure A item 1 and 2 the derricking gear item 3 the slewing gear item 4 the two travel gears item 5 and the recovery winch not illustrated are driven by the axial piston constant motor The motors are lubricated by means of the hydraulic oil system and are thus more or less maintenance free SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when th
115. ormed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or squashed Observe safety and disposal regulations for the respective product when dealing with oil and fuel No smoking no naked flame or light sparks or glowing ashes near the fuel or diesel engine system Danger of explosion and fire Use caution when releasing connections because higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Ensure that no one is in the danger zone Maintenance Instructions Check the fuel system its pipe and hoses connections for external damage firm seating and Any damaged fuel lines must be replaced immediately Also check the connections on the electric indicator for firm seating The tank has a filler neck on the superstructure Check the tank cover for proper functioning A faulty tank cover must be replaced To avoid corrosion damage drain the condensation via the drain plug on the tank under side To do so open the plug until clean diesel fuel emerges When re closing ensure the seal is seated properly For details use Cummins us
116. osion and fire Caution near the overhead lines Do not climb up on to crane superstructure Mortal danger Maintenance Instructions Check the batteries and the cable connecting terminal for external damage Check whether the batteries are firmly seated on the battery carrier if required tighten the mounting bolts on the retainer bar Screw out the filler plugs and check the electrolyte level if required top up the distilled water to the marking Clean battery covers with a suitable aid according to regulations and then dry to avoid leakage current If moisture has penetrated in to the batteries find the cause and eliminate it Clean the cable connecting terminals grease with pole grease and check for firm seating Then close the battery drawer 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Batteries 2 1 3 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Three Phase Generator 2 1 4 P 1 1 3 phase generator Description The generator converts the mechanical power into electric power SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Wo
117. performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Derricking Reduction Gear Unit including Brake 2 11 1 P 2 2 Maintenance instructions The maintenance work on the planetary gearbox must be carried out according to the information in the Lohmann amp stolterfoht GmbH User s Manual Check the planetary gearbox its attachments and all connections for external damage and leakages Check all connections lines and links for firm seating Carry out a running noise check To check the oil level Note The crane must be in horizontal position to check the oil level e The oil is checked via the overflow meter To do so screw out the oil filler plug and the oil level inspection plug if required top up oil using the brand as classified in the chart in Section 3 of this manual Carry out an oil analysis according to the intervals in the maintenance check list Lubricate the lubrication nipple on the counter bearing To ch
118. pressure connections are being tightened Maintenance Instructions Check the signal horns and their connections for external damage firm seating and proper sealing Clean the horn elements and test the signal horns 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Undercarriage Air Pressure Compressor 2 3 7 P 1 2 Description The two air pressure compressors in the undercarriage supply the required air pressure during the operation in train formation to the air pressure brake system See Figure A The compressors are driven via a coupling When the required air pressure has been reached the line is opened and the air pressure compressors continue to run but without pressure The compressors are fitted with an air cooling system SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt crushed or drawn into the equipment Caution Some sections of the system are not pressure less until the accumulators have been emptied Before work is carried out on the a
119. r Brake Drum Description The recovery winch is a three stage planetary gearbox The equipment consists of an integrated hydraulically lifted multi disc holding brake with free wheeling option The wheels with external toothing have been hardened The entire gearbox is seated on an anti friction bearing and is fitted with an oil bath lubrication system The bearing of the drive pinion in the stay pipe is lubricated continuously with grease Power take off and drive motions have counter rotary directions SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Recovery Winch including Brake 2 12 1 2 2 Maintenance Instructions The maintenance work on the planetary gearbox must be carried out according to the information in the Lohmann amp Stolterfoht GMBH User s Manual Check the planetary gearbox its attachments and all connections for external damage and leakages Ch
120. r on brake lining 3 4 JIB 2 14 1 Lubricate rope drum sheaves and jib stopper pad with grease 2 structural components are to be visually examined for defects cracks 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 500 Working Hours 6 Monthly 1 5 P 1 2 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 4 AT THE COMPLETION OF 500 HRS 6 MONTHLY 4 1 AUXILIARY ENGINE 2 5 1 Knock out soot from the exhaust silencer 2 Clean the cooling air duct and space between cooling fins on cylinders 4 2 SUPERSTRUCTURE 2 2 1 Checks drive assemblies 2 Check oil level and top up if necessary Oil HP 90 Pump distribution gear box Main hoist reduction unit Auxiliary hoist reduction unit Derrick reduction unit Recovery winch reduction unit Slewing gear reduction unit Traction gearbox 3 Clean and re grease boom foot sliding surface fork and pin 4 Lubricate Counter weight gallows with grease Rope drum bearings with grease Foot pedal in cab with oil 5 Check ropes for damages breakages 6 Collect sample of hydraulic oil Get it tested and replace if required 4 3 UNDERCARRIAGE 2 3 amp 2 13 7 1 Clean and lubricate with grease Sliding surfaces Slewing gear teeth Traction gear reduction unit Splined shaft Screw coupling and buffers 2
121. rane A 142043 Kit Crane A 143001 Jamalpur Manufactured B 143002 Jamalpur Manufactured B 143003 Jamalpur Manufactured B 143004 Jamalpur Manufactured B 143005 Jamalpur Manufactured B 143006 Jamalpur Manufactured B 143007 Jamalpur Manufactured B 143008 Jamalpur Manufactured B 143009 Jamalpur Manufactured B 143010 Jamalpur Manufactured B 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Travel and Running Gear 2 6 2 6 1 Travel Reduction Gear Unit 2 6 2 Pinion and Gear wheel 2 6 3 Disengaging Devices 2 6 4 Wheel Sets 2 6 5 Wheel Set Bearings 2 6 6 Spring Suspension 26 7 Expander operated Brake Discs 2 6 8 Brake Cylinder Adjuster Units 2 6 9 Brake System 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Travel Reduction Gear Unit 2 6 1 P 1 2 Description The travel gear reduction unit reduces the drive speed of the hydraulic motor to the required pinion speed The crane has a total of two travel drives and thus two travel gear reduction units SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against a
122. rated by accident or unknowingly Ensure that no one is in the danger zone Observe the safety regulations in the SCHULE Kirloskar User s Manual Maintenance Instructions The following maintenance work on the diesel engine must be carried out according to the information provided in the Kirloskar User s Manual Check the emergency diesel engine its attachments and connections for external damage and leakages Check all connections and lines for firm seating Note To check the oil level the crane must be in horizontal position The oil should be changed when the oil is at operating temperature e Switch off the engine when it has reached operating temperature and wait until the oil has run back into the oil tray e To check the oil level pull out the oil dipstick and wipe off with a clean lint free rag Then insert the oil dipstick and pull out again The oil level must be between upper and lower markings of the dipstick If required top up with oil using the brand as classified in the chart in section 6 of this manual e Switch off engine and Screw out the oil drain plug on the bath and drain the waste oil into a sufficiently large enough collection tray approx 4 5 Itrs Then screw in the drain plug with a new seal tightly Then top up oil via oil filler neck using the brand as classified in the chart in Section 3 of this manual until the oil level is between upper and lower markings on the dipstick e Clean the different type
123. raulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stop cocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Suspension Blocking Cylinders 2 2 6 P 2 2 Figure A Suspension Blocking Cylinder 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Undercarriage Control Blocks 2 21 P 1 2 Description The control blocks in the undercarriage serve to retract and extend raise and lower the outriggers operate the suspension blocking and to disengage the travel gear pinion See Figure A The undercarriage hydraulic must be switched on via the selector switch in the cab SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure
124. rk warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one in near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance Instruction Check the generator and its connections for firm seating and external damage The fan belt and its tensioning are dealt with in the section on maintenance work for the diesel engine Note When the engine is running do not switch off the battery main switch do not release battery terminals pole terminals or lines in the mains do not allow the generator to run without being connected to the battery It is not permissible to short circuit or tap the connections on the generator and the controller among one other or by earthing 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Hoist and Lowering Limit Switches 2 1 5 1 2 Description The crane has limit switches for the main and auxiliary hoists as well as for the derricking gear See Figure A Derricking gear The limit switches for the derricking gear are mounted directly on the rope drum In working range the limit switches switch off in the steepest or lowest boom working positions In addition when the bridging switch activated the derri
125. rning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Maintenance instructions Check the rope drum for external damage and firm seating Check the rope clamp for firm seating and damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Derricking Gear 2 11 2 11 1 Derricking Reduction Gear Unit including Brake 2 11 2 Rope Drum 2 11 3 Rope Pulley and Rope guide on the Superstructure 140 TGOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Derricking Reduction Gear Unit including Brake 2 11 1 P 1 2 Description The derricking gear permits the boom to derricked in and out The derricking gear is a three stage planetary gearbox The equipment includes an integrated hydraulically lifted multilink disc brake with free wheeling option and a counter bearing The wheels with external toothing have been hardened The entire gearbox is seated on an anti friction bearing and is fitted width an oil bath lubrication system Power take off and drive motions have counter rotary directions SAFETY INSTRUCTIONS Before maintenance work is
126. s Continuous Main line electrical line Dashed Control line drain line transition position Chain dotted To group two or more com ponents in a sub assembly Double Mechanical connection shaft lever piston rod Circle Energy transfer unit Measuring device Check valves rotary connection mechanical pivots Rollers always with centre point 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 Name description examples Semi circle Motor or pump with limited angle of rotation Rotary actuator Square Connections perpendicular to sides Control elements Drive unit except for E motor Connections to corners of preparation devices filters separators lubricating devices heat exchangers Damping in positioning ele ments accumulator weight Rectangle Cylinders valves Piston in cylinder Adjustment element Offsets for connecting lines 1 41 T 1 21 1 21 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Symbols used in Hydraulic Circuits Name description examples Open rectangle Tank Oval Pressure tank Accumulator Gas bottle Function symbols Triangle Shows direction of flow and operating medium Filled hydraulic Open pneumatic Arrows Straight Linear movement path and direction of flow through a valve direction of heat flow Curved Rotational movement direction of ro
127. s Check the air pressure tanks and their components for external damage firm seating and proper sealing Tighten fittings if required when the system is not under pressure Loosen the drainage plugs until no more moisture emerges A high degree of moisture can damage the air pressure system In this case the air pressure fine filter must also be checked if required the filter element must be changed in between normal intervals and or the air pressure filter must be drained more frequently 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Air pressure Tank 2 3 1 P 2 2 Figure A 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake Cylinders 2 32 P 1 3 Description In Crane No 142032 to 142043 amp 143001 to 143002 3 types of brake cylinders have been used for service brake and parking brake Hyd These are the three types of brake cylinders Figure B i PB 254 140 D 67370 D 02 4 K 270 degree 06 nos ii PB 254 140 D 60699 D 01 4K 90 degree 05 nos and iii PB 254 140 D 60702 D 01 4K 270 degree 01 no In Crane No 143003 to 143010 2 types of brake cylinders have been used for service brake and parking brake Pneu These are the two types of brake cylinders Figure A i PBAF 254 160 200278 D 01 6 PF 13 90 degree 06 nos and ii PBA 254 160 200
128. s at standstill Maintenance Instructions Check the pumps See Figure A and their connections for external damage and leakages The running noises of the pumps must be checked An increase in the running noises coupled with an increase in pressure indicate pump damage In this case the crane must not be operated and the pump must be replaced During operation the operating pressure can be checked by means of pressure gauges mounted on right side panel in the cab See Figure B Faulty pressure gauges must be replaced Item No 1 Control Oil Operating Pressure Max 30 bar Item No 2 Slewing Gear Operating Pressure Max 200 bar Item No 3 Pump 1 Operating Pressure Max 280 bar Item No 4 Pump 2 Operating Pressure Max 280 bar Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stop cocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE
129. s of filter as per SCHULE Kirloskar maintenance manual 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Emergency Diesel Engine 2 5 1 P 2 2 Figure 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Emergency Diesel Engine Different Types 2 5 1 1 P 1 1 Following two types of Emergency Diesel Engine has been fitted in 1986 Design 140T Crane Type Emergency Diesel Engine For Crane No 142032 to 1422043 Type SCHULE TAF 2 Model 2 Cylinder in series Vertical Air cooled Output 10 5 KW at 1800 rpm Type Emergency Diesel Engine For Crane No 143001 to 143010 Type KIRLOSKAR TA 2 Model 2 Cylinder in series Vertical Air cooled Output 10 5 KW at 1800rpm 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Emergency Diesel Engine Crane wise list 2 5 1 2 P 1 1 Crane wise Emergency Engine fitted Crane Number Crane Type Type of Engine fitted 142032 Fully Imported A 142033 Fully Imported A 142034 Fully Imported A 142035 Fully Imported A 142036 Fully Imported A 142037 Fully Imported A 142038 Knock down A 142039 Knock down A 142040 Knock down A 142041 Kit Crane A 142042 Kit C
130. storage and preparation Ventilated tank M V oo 8009066 B Pressure tank Filter Filter with clogging indicator Separator Filter with separator Preparation unit comprising filter separator pressure reducing valve pressure gauge and lubricator Cooler Temperature control 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 Name description examples P 7 7 Name description examples Measuring devices and indicators Pressure indicator generat Pressure gauge Differential pressure gauge Fluid level measuring device Flow indicator Flowmeter Tachometer Torque meter Hydro electric pressure switch Limit switch LOCOMOTIVE WORKS JAMALPUR
131. superstructure and rotor 8 25 Drain out entire hydraulic oil HLP 68 and store in drum Flush the tank before refilling with fresh hydraulic oil 2 2 3 8 26 Drain out entire diesel oil and store in drum Flush the tank before refilling with fresh diesel oil 243 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 8000 Working Hours 8 Yearly 1 9 P 3 6 SI Schedule Item as per RDSO Maintenance Schedule Ref No of No Vide Report No MP 727 90 Maintenance Manual 8 27 Dismantled all motion s machineries i e 2 9 2 2 10 2 2 11 2 amp 1 Main hoist drum assembly 2 12 2 2 Auxiliary hoist drum assembly 3 Derrick drum assembly 4 Recovery winch drum assembly Inspect these assemblies and replace as required 8 28 Fitment of slewing ring 2 8 1 Levelling of slewing ring to be ensured 2 Systematically replace all bolts and nuts of slewing ring of super structure and under carriage 3 Grease the slewing ring 4 Tighten the bolts with a tightening force of 783 7 KN 6 6 KN Follow the sequence strictly as recommended by manufacture 8 29 Lift super structure and keep on trestle 8 30 Check all gear boxes replace if required 24 2 2 8 2 9 1 2 10 1 1 Hoist I Main 2 11 1 amp 2 Hoist II Auxiliary 3 Derrick 4 Slewing gear box 5 Recovery winch Replace the oil Oil HP 90 8 31 Check all cylinders valves of super stru
132. t 2 5 8 3 Jointly check with crane Incharge for all damages deficiencies working 22 problems anything abnormal Verify jointly with crane Incharge consignee reports while crane received for POH 8 4 Crane with match truck to be placed in POH bay having E O T facility ae p a 2 13 4 amp 2 15 8 5 Remove all lifting tackles lifting beams and counter weights from match truck Send lifting tackles and beams to chain house along with original certificates for examination and testing 2 15 8 6 Open hoist I wire rope hoist wire rope derrick wire ropes and winch rope Send them Chain House along with original certificate for examination and testing 2 15 8 7 Open gantry rope load cell equaliser sensor cable and stopper 2 14 8 8 Remove bridle stopper and boom Check bridle pulleys structural damage and nylon items 2 14 8 9 Open A frame front leg upper leg Check pulleys structural damage and nylon items 2 14 8 10 Open gallows Check structural damage and nylon items 8 11 Remove match truck for POH 2 5 8 12 Start auxiliary power pack and slew the crane for take out main power pack under propped condition 24 8 13 Disconnect all sensing devices of main power pack electrical 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual After 8000 Working Hours 8 Yearly 1 9 P 2 6 SI Schedule Item as per RDSO Maintenance S
133. t not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This also applies to the tightening of hydraulic connections Use caution when releasing connections those higher mounted components could drain dry In these cases ensure an adequately sized drip pan is available Observe disposal regulations Caution Sections of the hydraulic and air pressure systems are still under pressure even when the crane is at a standstill Maintenance Instructions Check the control blocks and their connections for external damage and leakages Tighten the fittings if required but when the system is not under pressure Then carry out a sealing test under pressure Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydraulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stop cocks have been re ope
134. tation viewed on shaft end Diagonal arrow Adjustability in pumps motors springs solenoids Electrical Closed path or connection Linear electrical positioning elements acting in opposition 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 Name description examples Temperature display or control Drive unit Seat of check valve Flow lines Connection Cross over Flexible line Connections Breather connection continuous Limited with respect to time Open closed Quick release coupling without mechanically opening check valves With mechanically opening check valves Rotary coupling with 1 through channel Rod linear movement Shaft rotational movement Detent maintains specified position LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Symbols used in Hydraulic Circuits Name Symbol Name description examples description examples Operational modes General symbol Push button Pull out knob Push button pull out knob Lever Pedal 1 direction of operation Pedal 2 directions of operation Push rod Push rod with stroke limitation Spring Roller shaft Roller lever Electrical 1 winding Electrical 2 windings which act in opposition to each other Electrical 2 windings which act in opposition to each other and which may be steplessly adjusted 2 parallel acting operators AAA 140 T GOTTWALD CRA
135. tenance manual or any technical orders issued 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual General Guide Line 1 1 P 2 2 9 Only genuine spare parts should be used 10 Use of waste cotton on diesel hydraulic crane is PROHIBITED Use only lint less rags or wiping towels The appearance of exterior and interior of the crane must be maintained properly 11 The crane must be maintained in first class tip top condition so that it can be despatched to the site of accident without any delay 12 The Fire Extinguishers are to be maintained by the appropriate authority up to the requisite standard Under no circumstance should any diesel hydraulic crane be allowed to leave the shed without Fire Extinguishers 13 The nature of any ball or roller bearing is such that very little lubrication is required The grease which may be packed in the bearing is sufficient for many hours of operation and unless the grease is lost by leaking out through the seals the amount of grease applied at any one greasing is small More failure in ball and roller bearings are caused from dirt and over greasing than from lack of lubrication The manufactures recommendations for the maintenance and lubrication should therefore be rigidly followed 14 Whenever any schedule examination is carried out all the items of the lower schedules should also be attended to PERIODIC MAIN
136. that no one is near hot or moving parts danger of getting burnt crushed or drawn into the equipment Caution When dealing with hot oil Danger of being burnt or scalded Observe disposal regulations Caution Some sections of the system are under pressure until the accumulators have been emptied Prior to commencing work on the air pressure system ensure the system is completely without pressure Use caution when dealing with air pressure system Work may only be performed on the air pressure system is without pressure This is also applicable for the tightening of the air pressure connections Maintenance Instructions Check the disengaging devices their connections and mountings for external damage and firm seating e Check the air pressure cylinders their connections and mountings for external damage firm seating and proper sealing e Tighten and replace loose and leaky connections when the system is not under pressure e On completion of the maintenance work a sealing test under pressure must be carried out The spline shaft teething for dirt if required clean then grease Check the disengaging devices for proper functioning 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Disengaging Devices 2 6 3 P 2 2 Figure A Engagement Pinion Axle Split Gear Engagement Cylinder 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAM
137. theless they do not serve to affect any crane functions directly but are required for smooth running and proper operation SAFETY INSTRUCTIONS When work is being performed on the crane ensure that the switches and levers cannot be operated by accident on unknowingly Ensure that no one is in the danger zone Maintenance instructions Check the entire cab equipment for proper functioning Any damaged parts must be repaired or replaced Caution Remember that fire extinguishers and first aid kits etc have expiry dates Then they must be serviced or replaced accordingly 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Slewing Gear 2 8 1 Slew Reduction Gear Unit 2 8 2 Pinion and Gearwheel 2 8 3 Roller Bearing Slew Ring 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 2 8 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Slew Reduction Gear Unit 2 8 1 P 1 2 y z z Description The slewing gear reduction unit is a three stage planetary gearbox The equipment consists of an integrated hydraulically lifted multi disk holding brake with free wheeling option The wheels with external toothing have been hardened The entire gearbox is seated on a anti friction bearing and is fitted with an oil bath lubrication system The bearing of the drive pinion in the stay pipe is lubricated conti
138. ting Start the diesel engine for the functional test and operate the gas pedal in the cab Check whether the diesel engine runs evenly in the various speed ranges 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Pump Distributor Gearbox 2 4 5 P 1 2 Pump distributor gearbox Description The pump distributor gearbox PTO is mounted on the diesel engine through centa max coupling and transfers the drive output of the diesel engine to the pumps flanged mounted on the gearbox The pump distributor gearbox is a spur gear seated on a roller bearing and fitted with an oil bath lubrication system SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to both in and outside the cab Remove ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near hot or moving parts danger of getting burnt crushed or squashed Observe safety and disposal regulations for the respective product when dealing with oil and fuel No smoking no naked flame or light sparks or glowing ashes near the fuel or diesel engine system Danger of explosion and fire 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVIS
139. tion If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stopcocks have been re opened prior to re starting as otherwise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Hoist Derricking Slew and Travel Gear Motors 2 2 9 Figure 2 3 Main Hoist Motor Item 1 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Hoist Derricking Slew and Travel Gear Motors Figure A Slewing Motor Item 4 2 2 9 P 3 3 140 T GOTTWALD CRANE 1986 DESIGN REVISED EDITION Dec 2002 LOCOMOTIVE WORKS JAMALPUR Railway Crane Maintenance Manual Superstructure Control Blocks MO 30 4F 2 2 10 P 1 2 Description The superstructure control blocks control the crane s all motions except slewing The individual control levers gate valves are operated via pilot control valves from within the cab See Figure A SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and out side the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane mus
140. ulic motors via their respective leakage oil connections Otherwise the hydraulic system could suffer severe damage To replace or top up oil an external oil filter with a minimum retaining rate of 10 um must be used Caution If the oil stop cocks below the hydraulic oil tank are closed for work being performed on the hydraulic system check as to whether the stopcocks have been re opened prior to re starting as other wise the hydraulic system could suffer severe damage 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Slewing Gear Pump Filter 2 2 4 P 1 2 Description The hydraulic oil flow of the slewing gear pump is cleaned via line filter SAFETY INSTRUCTIONS Before maintenance work is performed it must be insured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unauthorised start The crane must not be in the way of other vehicles Ensure that no one is near to or moving parts danger of getting burnt crushed or drawn into the equipment Use caution when dealing with oil danger of being burnt or scalded Caution Hydraulic system Work may only be performed on the hydraulic system when there is no pressure in the system and the diesel engine is stationary This als
141. ure B at the top item 1 and drain the oil completely Check drained oil for metallic pollution and excessive abrasion In the event of considerable oil pollution the gear unit must be filled with preheated oil Then tighten the oil drain plug using a new sealing ring Add oil until the oil level remains constant e Screw in the oil filter plug and tighten To check the vent 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 e the vent is seriously closed screw out the vent See Figure on the bottom right item 2 from the gear unit wash in a suitable solution and dry with compressed air 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Travel Reduction Gear Unit 2 6 1 P 2 2 Figure A Item 1 Figure B amp C 1 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Pinion and Gear Wheel 2 6 2 P 1 1 Description The pinion and gear wheel on the wheel shafts forms the last stage of the disengaging travel gear drive The crane has a total of two travel drives and thus two pinion and gear wheels SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly affixed to
142. ut load Approach all the switching points slowly 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual PAT System 2 1 6 P 1 1 Figure A Figure B Description The PAT System Figure A ensures that crane elements are not subject to overload in all working positions and to ensure that the crane does not tip over because the load lifted exceeds the lifting capacity in the particular configuration The PAT system functions based on e selected outrigger base e The load cells on the load sensor located with gantry wire rope left side e The angle sensor on the boom and slewing sensor The respective data is shown on the control and display panel in the cab Figure A In Crane No 143001 to 143004 SLI of Amrita Lakshmi Electronics Figure and in Crane No 143005 to 143010 SLI of Mechanica Systems Pvt Ltd Pune has been fitted Figure B For this refer to the manual of these suppliers SAFETY INSTRUCTIONS Before maintenance work is performed it must be ensured that the crane cannot be switched on and is secured against rolling In addition a Maintenance Work warning sign must be visibly posted both in and outside the cab Remove the ignition key and battery main switch and secure against any unaut
143. vel can be read off by means of the dipstick See Figure A on the tank side The oil level must be checked at operating temperature The maximum oil level has been reached when all the cylinders are retracted The oil must not fall below a minimum level when all the cylinders are completely extended When oil is added it must be poured through an external mounted filter assly with a filter absolute fineness of 10 um Caution only use oil of the same brand for topping up The oil is drained via the oil drain plug below the hydraulic tank See Figure B Caution oil quantity approx 1400 Itrs The breather filters are installed on the tank upper side See Figure A whenever hydraulic oil is topped up the filter cartridges of the breather filter must be checked and if required replaced To do so unscrew the filter cover change the cartridges and screw on the cover again tightly There are two gauges 0 16 bar or 0 10 bar If the impact pressure in running condition is 3 4 bar Filters must be replaced by new 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Oil Tank 2 2 3 P 2 2 Figure A Figure Hyd Tank Oil dipstick Drainage Cock Note After work has been completed on the hydraulic system during which oil has been lost out of the hydraulic circuit top up the hydraulic oil in the housings of the hydraulic pumps and hydra
144. ylinders are opened The brake cylinders are under spring loaded tension Danger of accidents Mortal Danger Maintenance Instructions Carry out the maintenance work on brake cylinder according to the documentation supplied by SAB WABCO Check the air pressure tanks and their components for external damage firm seating and proper sealing Tighten fittings if required when the system is not under pressure Carry out a brake test and inspection when the crane is at a standstill Check whether all cylinders are extended properly 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake Cylinders 2 3 2 Figure A Figure A Item ii 140 TGOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake Cylinders 2 52 P 3 3 Figure B Item ii 140 T GOTTWALD CRANE 1986 DESIGN LOCOMOTIVE WORKS JAMALPUR REVISED EDITION Dec 2002 Railway Crane Maintenance Manual Brake Couplings 2 3 3 P 1 2 Description The three brake couplings Brake pipe Feed pipe and Vacuum hose on each face side together with the stop cocks serve in train formation to couple the crane to the customary train air pressure brake system See Figure A The air pressure brake system consists of a main air line the main air tank line and the vacuum line SAFETY INSTRUCTIONS Before maintenance work is p

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