140T Crane Maintenance Issues,AMC, Spares Mgt,Trouble Shooting-Field (Open Line)

Objective

• Name of components required regular attention.

• List instructions for maintenance of these items.

• Know about Annual Maintenance Contract.• List the spares • Trouble shooting areas

Introduction

• To avoid Break Down of Crane– Regular cleaning– Continual inspection– Maintain scheduled preventive maintenance.

Maintenance schedule

• Daily• Monthly or after 125 hours• Half-yearly or every 750 hours.• Yearly or every 1,500 hours.• Every Two years or every 3000 hours.• POH schedule after 8 years.• MLR after 6 years of Ist POH

COMPONENTS REQUIRED REGULAR ATTENTION

Main Diesel Engine Photo

Main Diesel Engine

• Check– Lube oil pressure & temp. gauge,– Fuel indicator– Engine RPM– Battery charging ammeter– Water Temp. gauge– Abnormal noise during running– Air intake system

Engine-Mtc

• Check– Lube oil filter element– Fuel oil filter element– Check oil filter pollution indicator– V belts used in engine

• Found any fault,call OEM’s representative.• POH done after 8 years by Cummins India Ltd.

Filter Photo

Air Filter Hydraulic Filter

Diesel Engine-AMC

• Done by consignee with Cummins India Ltd• Representative of OEM attended quarterly• Check all datas as shown• Replace the item if required with its cost.

Battery

• Check– Visually,– Clean & dry battery cover after 6 months– Clean cable conection terminals– Electrolyte level– Battery charging condition

• Change battery after Two years.

Hoses

• Visual & functional check– End fitting,– Wearing of flange– Rubber portion.

• Replace if any leakage found• Must change item in every POH

Hydraulic Tank

• Check– Visually,– oil level,– breather filter– Filter element– Oil contamination in Lab after every six months

• Change Hyd. Oil after Two years

Hydraulic & Pneumatic Fittings

• Check– Visual & functional– End connections– Any crack/loose/leakage

• Replace if required

Slewing Ring Photo

Slewing Gear Box/Slewing Ring

• Slewing Gear Box– Running noise,– Oil level,– Bolt connections

• Pinion & Gear wheel– Clean & grease

• Roller Bearing slewing ring– Lubricate through grease gun.– Check stud connections.

Air Pressure System

• Air Pressure Tank– Visual check– Drain water after 6 months

• Air Brake Cylinders– Functional Test– Clean & overwhaul if required

• Air pr. Fine filter– Check filter element– Change if required.

Wire Rope Defects

Broken Wires

Waviness

Bird cage

Wire Rope Defects

Loop deformation

Loose wires

Nodes

Wire Rope Defects

Thining of the rope

Kinks

Flat area

Survey of Removal of Wire Rope

• Broken wires– 5% of the total no. of wires in the rope in 10Xd– 5 broken wires between two adjacent strands

within a length of 10Xd• 15% reduction in diameter• Corrosion• Damaged due to heat• Rope deformation as shown

Lifting Tackles-mtc

• Mark strength wise for proper use• Check each & every link of the chain.• Check wire rope slings– String(any cut)– Rope deformations(bulging,twisting)– Corrosion

• Check hook deformation & joint fittings• Replace on condition basis

Lifting Tackles Photo

Nylon Items

• Nylon pulleys– Edge damage– Bearing damage– Groove worn out

• Roller,Gliding plate– Worn out

• Replace

SLI Items

• Main Hook Load Sensor• Boom Angle Sensor• Slew Angle Sensor• Aux. Hook Load Sensor• Display Board• Micro Processor

Chips(X1 Card)

SLI Items

SLI System-mtc

• Do not bypass SLI system during operation.• Protect cards from dusts• Check functional test• If any error found,call OEM representatives.• OEM-M/S PAT, Germany– M/S Mechanica, Pune.– M/S Hytec Micro Measurement,Delhi

SLI-AMC

Suspension coil & disc spring

• Springs used in secondary suspension– Coil– Disc

• Change if required• Suppliers– M/S G.D. Spring,KKK for Coil Spring.– M/S Gala Precision Technology Ltd,Thane for Disc

Service Engineer Group

• Function– Attend the crane at division & check crane in

running condition.– If any problem ocurrs, sort out it.– Check records for maintaining the crane as per

RDSO mannual• Staff-One engineer+ Four technicians.

POH & MLRSchedule Time period Cumulative life

EXISTING 1st POH 8 yrs 8 yrs

MLR 6 yrs 14 yrs

2nd POH 6 yrs 20 yrs

Condemn 6 yrs 26 yrs

REVISED 1st POH 8 yrs 8 yrs

2nd POH 6 yrs 14 yrs

MLR 6 yrs 20 yrs

3rd POH 8 yrs 28 yrs

Condemn 8 yrs 36 yrs

Must Change Items during POH

• Pneu.Hoses of U/C,Nylon pad,Owa seal,O-ring,Brake shoes,Pins,Bushes,Hyd. Gauges,Indicating lamps,Electric wiring of SLI circuit & lighting,Coil & Disc springs,Engine control circuit,Sensors,Hyd. & Pneu. Filter elements,HP-90 gear oil,HLP-68 Hyd. Oil,15W40 Engine lub. Oil,Radiator coolant.

• POH of Engine by CIL,Pune

Condition Basis During POH

• Solenoidvalves, Major pins,Pumps,Motors,Cylinders(Propping,Outrigger,CWT,Axle blocking,DUV),Pressure Switch,Rotors,Hyd. Hoses,Wire Ropes,PTO,Lamina brakes,Bearings in gear boxes,Wheels & all other components.

Must Change Items During MLR

• All pneu. & hyd. Hoses• All wire ropes• All hyd. Pumps,motors,cylinders & valves• SLI Systems• Wheel disc,Major pins,Solenoid valves• Coil & Disc springs,Engine control units• Elec. Wiring,All filter elements,All hyd. Oils• POH of Engine by CIL,Pune

Spares-Category

• Category ‘A’ High value items– One crane set for each design

• Category ‘B’ Regular spares– 20% of total population of each design

• Category ‘C’ Items for pneumatic fittings– One crane set to be stored by Depot

Spares Kept at Depot

• Category ‘C’ Pneumatic items(KNORR make)– Oil filter,Filter element– VEBEO fittings– Hyd. & Pneu. Hoses– Bolster springs– Snubber springs– Seal kits

Spares Kept at JMP Workshop

• Category ‘A’ items– Hyd. Pumps(axial piston),Motors– Pump Distribution gear box,Control Block– Valve plate,Oil air cooler– Wire Ropes-Main,Derrick,Aux.– Bearings,Hook Block Assly– Hoist & Gear Boxes,Hyd. Cylinders– SLI Items,Brake Cylinders,Wire Rope Slings

Category ‘B’ Items

• Pneumatic(valves,gauges,filters)• Hyd.(valves,gear pumps,gear motors,filters)• Differential Cylinders,Seal Kits• Hydraulic & Pneumatic Hoses• Electrical Items• VEBEO fittings,Parker fittings• Rope Pulleys