1. 140T Crane Maintenance Issues,AMC, Spares Mgt,Trouble Shooting-Field (Open Line)

2. 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

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

4. 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

5. COMPONENTS REQUIRED REGULAR ATTENTION

6. Main Diesel Engine Photo

7. 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

8. 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.

9. Filter Photo Air FilterHydraulic Filter

10. 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.

11. Battery Check – Visually, – Clean & dry battery cover after 6 months – Clean cable conection terminals – Electrolyte level – Battery charging condition Change battery after Two years.

12. Hoses Visual & functional check – End fitting, – Wearing of flange – Rubber portion. Replace if any leakage found Must change item in every POH

13. Hydraulic Tank Check – Visually, – oil level, – breather filter – Filter element – Oil contamination in Lab after every six months Change Hyd. Oil after Two years

14. Hydraulic & Pneumatic Fittings Check – Visual & functional – End connections – Any crack/loose/leakage Replace if required

15. Slewing Ring Photo

16. 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.

17. 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.

18. Wire Rope Defects Broken Wires Waviness Bird cage

19. Wire Rope Defects Loop deformation Loose wires Nodes

20. Wire Rope Defects Thining of the rope Kinks Flat area

21. 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

22. 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

23. Lifting Tackles Photo

24. Nylon Items Nylon pulleys – Edge damage – Bearing damage – Groove worn out Roller,Gliding plate – Worn out Replace

25. SLI Items Main Hook Load Sensor Boom Angle Sensor Slew Angle Sensor Aux. Hook Load Sensor Display Board Micro Processor Chips(X1 Card)

26. SLI Items

27. 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

28. SLI-AMC

29. 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

30. 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.

31. POH & MLR ScheduleTime periodCumulative life EXISTING1 st POH8 yrs MLR6 yrs14 yrs 2 nd POH6 yrs20 yrs Condemn6 yrs26 yrs REVISED1 st POH8 yrs 2 nd POH6 yrs14 yrs MLR6 yrs20 yrs 3 rd POH8 yrs28 yrs Condemn8 yrs36 yrs

32. 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

33. Condition Basis During POH Solenoidvalves, Major pins,Pumps,Motors,Cylinders(Propping,Outrig ger,CWT,Axle blocking,DUV),Pressure Switch,Rotors,Hyd. Hoses,Wire Ropes,PTO,Lamina brakes,Bearings in gear boxes,Wheels & all other components.

34. 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

35. 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

36. 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

37. 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

38. 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