Railway Crane User s Manual Operation (Part-II)

Transcription

1 User s Manual Operation (Part-II) 140 TONNE DIESEL HYDRAULIC B.D.CRANE WITH A FRAME

2 Table of Contents (Part-II) 1 Lifting Capacity Charts P-1/2 1.1 Load Chart without CWT 1.2 Load Chart with Standard CWT 1.3 Load Chart with Heavy duty CWT 2 General Operation Diagram including dimensions 3. Check Lists 3.1 Work Operation 3.2 Check Lists for Operation Propped Crane Operation Free-on-wheel Crane Operation 3.3 Check Lists for Rigging & Derigging In Train Formation Out Train Formation 4. Operating Instructions 4.1 Rigging Couple/Uncouple Match Truck Suspension Blocking Cylinder/ Engage/Disengage Travel Gear Transport Position Brake System Outriggers Re-railing Counterweight Pick up and Set Down Counterweight Raise/ Lower Boom 4.2 Start up Requirements Hydraulics Diesel Engine System Battery Main Switch Fuel Supply Undercarriage Hydraulics On /Off Ropes Hoist and Lowering Limit Switches Boom Angle Sensor Emergency Diesel Engine

3 Table of Contents (Part-II) P-2/2 4.3 Emergency Diesel Engine System Start/Stop Emergency Diesel Engine 4.4 Diesel Engine System Start / In-Operation/ Stop Diesel Engine Accelerator 4.5 Travel Operation Travel Forward / In Reverse Brake 4.6 Crane Operation Slew Right / Left Derrick In / Out Hoist / Lower Using Main Hoist/ Auxiliary Hoist Lifting Beams and Slings 4.7 General Operating Functions PAT System Lighting Signal Horns Screen/Wiper System Fans Parking Crane Safely Safe Load Indicator Emergency Operation Recovery Winch 5. DOs and DON Ts for Operation

4 Railway crane Lifting Capacity Charts 1 P-1/1 The lifting capacity charts for each propping base can be found on the next pages. The maximum crane lifting capacity charts are shown in Tonne as functions of the transverse swing -out angle and as a function of the radius beyond buffer in meters. The following outrigger bases as a function of the load are available for work with the crane. Caution: All the data in the lifting capacity as well as the data on the counterweights, working range and hoisting heights must always be observed - Danger of accidents and mortal danger! Lifting Capacity Charts 1.1 Load Chart without CWT - Free on wheel - Full Propping - Half Propping 1.2 Load Chart with Standard CWT - Free on wheel - Full Propping - Half Propping 1.3 Load Chart with Heavy duty CWT - Free on wheel - Full Propping - Half Propping

5 Load Chart without CWT 1.1 P-1/1 Radius Outreach Full Propping Half Propping (m) (m) 360 degree 360 degree (91.0) 25.0 (23.2) --- Free on Wheel 360 degree (75.0) 21.8 (20.3) (55.0) 17.1 (16.0) (43.0) 13.8 (13.0) (35.5) 11.4 (10.7) (29.0) 9.5 ( 9.0) (24.5) 8.0 ( 7.5) (21.5) 6.6 ( 6.2) (19.0) 5.5 ( 5.2) (17.0) 4.6 ( 4.4) (15.0) 3.8 ( 3.6) (13.5) 3.0 ( 2.8) --- NOTE:- FIGURES IN BRACKETS SHOW THE REDUCED CAPACITY DUE TO SHORTENING OF A FRAME (REF: RDSO S No. SL/CR/140T/BG/JMP. DT: ) COUNTER WEIGHT POSITION:- Without counter weight

6 Load Chart with Standard CWT 1.2 P-1/1 Radius Outreach Full Propping Half Propping Free on Wheel (m) (m) 360 degree ± 30 degree 360 degree ±30 degree 360 degree ±30 degree (130.0) 140 (130.0) 52 (48.0) 114 (106.0) (48.0) (126.5) 140 (130.0) 46 (42.5) 103 (96.0) (43.5) (93.5) 140 (130.0) 37 (34.5) 84 (78.5) (37.0) (74.0) 140 (130.0) 31 (29.0) 70 (65.5) 21.0 (19.7) 35(32.5) (61.0) 128 (120.5) 26 (24.5) 56 (52.5) 17.8 (16.7) 30(28.0) (52.0) 115 (108.5) 22 (20.5) 45 (42.5) 15.2 (14.3) 27(25.5) (44.5) 104 (98.5) 19 (18.0) 39 (37.0) 13.4 (12.7) 24(22.5) (40.0) 94 (89.0) 17 (16.0) 34 (32.0) 11.5 (10.9) 21(20.0) (35.0) 86 (82.0) 15 (14.0) 31 (29.5) 9.8 (9.3) 19(18.1) (31.5) 79 (75.5) 14 (13.0) 28 (26.5) 8.4 (8.0) 17(16.0) (29.0) 69 (66.0) 12 (11.5) 25 (24.0) 7.2 (6.9 ) 15(14.5) (26.0) 56 (54.0) 11 (10.5) 23 (22.0) 6.2 (6.0) 14(13.5) NOTE:- FIGURES IN BRACKETS SHOW THE REDUCED CAPACITY DUE TO SHORTENING OF A FRAME (REF: RDSO S No. SL/CR/140T/BG/JMP. DT: ) COUNTER WEIGHT POSITION:- Standard counter weight * For full and half propping t (5.2 t + 6 t + 18 t) * For free on rail - 24 t (6 t + 18 t) on gallows and 5.2 t on chassis.

7 Load Chart with Heavy duty CWT 1.3 P-1/1 Radius Outreach Full Propping Half Propping Free on Wheel (m) (m) 360 degree ±30 degree 360 degree ±30 degree ±13 degree (130.0) 140(130.0) 36 (33.5) 135.0(125.5) 85.0 (79.0) (130.0) 140(130.0) 36 (33.5) 114.0(106.0) 78.0 (72.5) (108.0) 140(130.0) 36 (33.5) 97.0 (90.5) 68.0 (63.5) (85.0) 140(130.0) 36 (33.5) 83.5 (78.0) 59.5 (55.5) (71.5) 140(130.0) 34 (32.0) 70.0 (65.5) 52.5 (49.0) (60.0) 132(124.5) 30 (28.0) 59.0 (55.5) 46.8 (44.0) (53.0) 119(114.5) 26 (25.0) 51.8 (50.0) 42.5 (41.0) (46.5) 109(103.5 ) 23 (21.5) 45.7 (43.0) 38.5 (36.5) (41.0) 100 (95.0) 21 (20.0 ) 40.7 (38.5) 35.0 (32.0) (36.0) 92 (88.0) 19 (18.0) 36.5 (34.5) 32.4 (31.0) (33.5) 86 (82.5) 17 (16.0) 33.5 (32.0) 30.0 (28.5) (29.5) 77 (74.0) 15 (14.0) 30.2 (29.0) 27.7 (26.5) NOTE:- FIGURES IN BRACKETS SHOW THE REDUCED CAPACITY DUE TO SHORTENING OF A FRAME (REF: RDSO S No. SL/CR/140T/BG/JMP. DT: ) COUNTER WEIGHT POSITION:- Heavy duty counter weight 43.2 t (29.2 t + 14 t)

8 General Operation Diagram including dimensions 2 P-1/1 Dimension in working position Dimension in train position

9 Check Lists 3 Note: The points in these check lists are not a replacement for the descriptions, instructions and safety instructions in the! The daily checks laid down in the Maintenance Manual are not included in the following checklists. 3.1 Work Operation 3.2 Check Lists for Operation Propped Crane Operation Free-On-Wheel Crane Operation 3.3 Check List for Rigging & Derigging In Train Formation Out Train Formation

10 Work Operation 3.1 P-1/2 PREPARATION Prior to every work operation establish the - size of the load to be lifted - required radius - required working cycle (hook height, slewing range, traveling the load) Moreover dependent on job site - site conditions for propping - ground conditions in outrigger pad area Subsequently with the aid of the lifting chart check the - admissibility of Job site and determine the required - counterweight combination and the - type of outrigger propping required. Finally the - max. outrigger loadings to be expected are to be established with the aid of the following chart the required size of the - ground distribution pads can be established. PERMISSIBLE GROUND FORCES Natural ground kn/ sq.m. Medium sand, firm clay, mud and gravel 400 kn/ sq.m. Fine sand, firm 150 kn/ sq.m. PERMISSABLE WHEEL LOADS The max. Permissible wheel load by propped operation, P = 350 kn/wheel

11 Work Operation 3.1 P-2/2 CHECK LIST Prior to every work operation resp. after 10 hours operation the following points are to he checked: Prior to starting the diesel engine: - Engine oil level - Pump transfer box oil level - Coolant level - Hydraulic oil supply - Check, if all stop slide valves on oil tank are opened. - Fuel supply - Air pressure oilier supply - Drain all air supply tanks - Check fuel supply and auxiliary unit oil level After starting the diesel engine: - Engine oil pressure - Air filter pollution indicator - Air pressure gauge - Hydraulic oil filter pollution indicator** - Generator charging current - Visible check for leaks in the oil - fuel and water circuits ** Due to low oil temperatures the possibility exists, that initially the gauge indicators a higher pressure than 3 bar and consequently a change of filter is required. In this case check the gauge once again after the operating temperature of the oil has been reached. The reading now shown is decisive for the grade of pollution

12 Check List for Operation Propped Crane Operation Free-On-Wheel Crane Operation

13 Propped Crane Operation P-1/2 Number Operation in the Instructions Diesel engine check in stationary condition Check recovery winch rope Check luffing gear rope Check main hoist & auxiliary hoist ropes Move all control levers to neutral position Switch main battery switch to ON Start diesel engine Safe load indicator switches on automatically Perform visual control of hydraulics check leakages in the system Check & Safety Instructions Pressure gauge in cab Check air pressure (min 6.2 bar) Pressure gauge in cab Engage travel gear and ensure axle blocking and brake application Pressure gauge in U/C Indicator If required, release parking brake and remove drag shoes Erect A frame Set hydraulics selector switch to undercarriage Extend outrigger beams to selected position Extend jack cylinders Select propping base Safe load indicator Raise boom Match truck is uncoupled Set hydraulics selector switch to counterweight hydraulics If required, pick up counterweight Select counterweight combination Safe load indicator Notes

14 Propped Crane Operation P-2/2 Number in the Instructions Operation Check & Safety Instructions Indicator Set hydraulics selector switch to crane operation Raise / lower hoist rope and check the movement of ropes Slew right/ left Safe load indicator Derrick in and out boom and check the movement of ropes Safe load indicator switches on automatically Move all control levers to neutral position On completion of work, observe section Parking Crane Safely Safe load indicator Notes

15 Free-On-Wheel Crane operation P-1/1 Number in Operation the Instructions Perform diesel engine check in stationary condition Check main hoist & auxiliary hoist ropes Check derricking rope Check recovery winch rope Move all control levers to neutral position Switch main battery switch to ON Start diesel engine Safe load indicator switches on automatically Perform visual control of hydraulics Check & Safety Instructions Pressure gauge in cab check for leakages Check air pressure (min 6.2 bar) Pressure gauge in cab Erect A frame Raise boom Engage travel gear and ensure axle blocking and brake application Pressure gauge in U/C Indicator If required, release parking brake and remove drag shoes Uncouple match truck Set hydraulics selector switch to counterweight If required, pick up counterweight Check counterweight combination Safe load indicator Raise / lower hoist rope and check for movement of ropes Slew right / left Safe load indicator Derrick in and out boom and check for movement of ropes Move all control to neutral position On completion of work, observe section Parking Crane Safely Safe load indicator Notes

16 Check List for Rigging & Derigging In Train Formation Out Train Formation

17 In Train Formation P-1/2 Number in the Instructions Operation Check & Safety Instructions Indicator These check points are applicable for attaching the crane in the train for haulage after completion of relief/recovery operation: If required, release parking brake Undercarriag e If required, retract outriggers Undercarriag e If, required, bring MT on line Approach match truck Couple match truck Move counterweight to match truck side Set hydraulics selector switch to counterweight hydraulics Lower entire counterweight onto undercarriage centering device Rotate superstructure 180 degree Derrick in further; bridge limit switch for rigging (4.1.9) Ramshorn is located above counterweight support Lower entire counterweight onto the undercarriage centering device Set down counterweights 1, 2 and 3 on to match truck separately Counterweight 4 remains on undercarriage ahead of the cab Lower boom until hook is vertical to the storage place on match truck Lower auxiliary hoist hook Boom is in straightahead position Boom in steepest working position Notes

18 In Train Formation P-2/2 Number in Operation the Instructions Set down auxiliary hoist hook on undercarriage and secure Lower main hoist hook Set down main hoist hook on undercarriage and secure Move the boom out of its fulcrum point Simultaneously slacking derricking rope (derrick out) Thus, boom head slips into boom support guide Check & Safety Instructions Watch ropes! Locked! Indicator Simultaneously slacken derricking rope (derrick out) Fold in A frame mechanism Set hydraulics selector switch to undercarriage Dismantle the outrigger pads and store on match truck as per regulations Retract outrigger beam and secure Switch Off parking brake Disengage travel gear undercarriage Shut down crane Close windows and doors Remove key. Crane is ready for transportation in train formation Notes

19 Out Train Formation P- 1/2 Number in the Instructions Operation Check & Safety Instructions Indicator Notes These check points are applicable for checking after the crane reaches site for relief/recovery operation: Perform diesel engine check in stationery condition Perform visual control of hydraulics Check main hoist & auxiliary ropes Check derricking gear & recovery winch ropes Switch battery main switch to ON Move all control levers to neutral position Start diesel engine Safe load indicator switches on automatically Check air pressure (min 6.2 bar) Pressure gauge in cab Set hydraulics selector switch to undercarriage Engage travel gear and ensure axle blocking and brake application If required, release the crane parking brake Set hydraulics selector switch to counterweight hydraulics Simultaneously tension the ropes Counterweight support locking device must latch in! Set hydraulics selector switch to crane operation Unlock boom head locking device Undercarriage

20 Out Train Formation P-2/2 Number Operation in the Instructions Derrick in ropes Thus, the boom slips into its fulcrum point Boom head is suspended freely above boom support If required, tension main & auxiliary hoist ropes Derrick in until boom in lowest Check & Safety Instructions Watch rope Indicator working position Caution slacken main or auxiliary hoist ropes (lower) 46.3 Raise main or auxiliary hoist Hook blocks are suspended freely Set hydraulics selector switch to counterweight hydraulics Pick up counterweight Select counterweight combination Safe load indicator Set hydraulics selector switch to crane operation Select main hoist block position Safe load indicator If required, uncouple match truck Crane is ready for operation Notes

21 Rigging Couple/ Uncouple Match Truck Suspension Blocking Cylinder/Engage/Disengage Travel Gear Transport Position Brake System Outriggers Re-railing Counterweight Pick up and Set Down Counterweight Raise/Lower Boom

22 Couple/Uncouple the Match Truck P-1/1 Description The match truck serves in the train formation to store and to protect the boom as the boom protrudes beyond the buffer. Should a match truck without a handbrake arrangement be used, the match truck must be underpinned with drag shoes when it is parked. SAFETY INSTRUCTIONS! Use caution in the area between the crane and the match truck. Standing between crane and match truck is prohibited during in and out! Danger of being crushed! Danger of accidents! Operating Instructions The following procedures are applicable for coupling the match truck to and uncoupling the match truck from the crane as well as coupling the crane or match truck to and uncoupling the crane or match truck from other wagons in the train formation. 1. To couple: Travel the crane to the match truck buffer. Note: Please maintain the following work sequence: Connect the hook Secure the crane and the match truck against rolling according to regulations Connect the brake air pressure or vacuum brake system coupling heads Air pressure brake system only: Open the stops for the brake air pressure If necessary, remove drag shoes Release the handbrake 2. To Uncouple: It is assumed that the match truck remains at the uncoupling site and the crane travels to job site. Note: Please maintain the following work sequence: Secure the crane against rolling according to regulations. Apply the match truck handbrake and, if necessary, underpin with drag shoes. Air pressure brake system only: Close the stops cocks for the brake air pressure. Release the brake air pressure or vacuum brake hose. Disconnect the train hook.

23 Suspension Blocking Cylinders / Engage /Disengage Travel Gear P-1/1 Description Item No. 2 Item No. 1 The spring deflection on the wheel set springs is blocked via hydraulic cylinders during crane and travel operations. When the crane is being hauled in train formation, the suspension spring block is released. The travel gear must be disengaged when the crane is being hauled in train formation. The change over for engage/disengage travel gear is coupled to the suspension spring blocking as the suspension spring blocking is released for hauling in train formation. SAFETY INSTRUCTIONS! Caution Change over may only be carried out when the crane is at a standstill! Secure the crane according to regulations against rolling. Caution! - The condition of the suspension blocking cylinders must be checked after changeover, i.e. it must be checked as to whether the suspension blocking cylinders have been engaged or disengaged. Operating Instructions The change- over for the suspension blocking cylinders is located on the undercarriage. It is coupled to the function engage/ disengages travel gear. 1. Crane and travel operations: To engage travel gear / switch on suspension blocking: * Suspension blocking ON Place lever (Item 1) in downward position. * The indicator (Item 2) is red. 2. Hauling operation in train formation: To disengage travel gear /switch off suspension blocking: * Suspension blocking OFF Place lever (Item 1) in upright position. * The indicator (item 2) is green.

24 Transport Position P-1/1 Description Transport position is to be understood as the position specified for the crane when it is being hauled in train formation. SAFETY INSTRUCTIONS! Conveying persons or loads in the customary fashion is prohibited! Operating Instructions After derigging the crane, when the boom has been properly locked in the trestle and gallows with A frame lowered in position, outrigger beam locked, the following operations should be done before hauling the crane. 1. The crane wagon is coupled to the match truck. 2. The 6T, 14T and 18T counterweights are stored on the match truck and 5.2 T counterweight on the undercarriage is placed on the cab side and secured. 3. The boom is stored on and locked to the match truck. 4. The ropes are slack. 5. The hook gear is stored properly on the match truck. 6. The travel gear are disengaged and suspension blocking is switched off. 7. The outrigger pads are stored in their mountings on the match truck. 8. The outrigger cylinders have been retracted to their retainers and the outrigger beams have been swung in and secured. 9. The parking brake has been released. 10. The braking system is set to the corresponding brake system (vacuum/air pressure). Conveyance in both travel directions is permissible.

25 Brake System P-1/3 Description The crane is fitted with a dual brake system. The crane can be operated with the air pressure brake system or the vacuum brake system. Switchover is carried out by means of two levers, which are located on both sides of the cranes. In addition, the crane has a parking brake with a quick-release device, which can be controlled independently of the train brake system by means of air pressure or the vacuum system. When leaving the crane and in every case when the diesel engine is not running, the parking brake must be applied. On track with more than a 3% gradient additional wedges should be used to protect the crane from rolling. The respective brake condition (opened, closed) is signaled by a sidemounted indicator device. The status of the brakes can be read off via the corresponding indicators (red and green). The spring loaded cylinders also have a mechanical emergency release device which can be actuated by means of Bowden cables on the axles. The crane has two types of parking brakes. a) Hyd. Parking Brake It is provided in Crane No to & to By turning the parking brake hand wheel the brake jaws will be closed by means of a piston pump and additional hydraulic cylinders on each brake cylinder per axle b) Pneumatic Parking Brake- It is provided in Crane No to Pneu. Parking brake actuates by means of a system comprises a separate air reservoir, valves & parking brake actuation lever fitted in undercarriage Caution! If the emergency release device is used, you must pressurize the brake system with air pressure before you can be begin a new braking procedure. SAFETY INSTRUCTIONS! Caution! Please note that the brake system must be pressurized before a new braking procedure can be carried out when the Bowden cables have been activated. Prior to releasing the parking brake, start up the crane and secure via the service brake. On exiting the crane, always apply (switch on) the parking brake. Caution! Only begin travel operation when the parking brake has been completely released!- It is prohibited to begin travel when the brake is still on. Operating Instructions 1. To apply parking brake: (Figure A ) * Place the parking brake lever (Item 1) to the On position. The parking brake indicator (Item 6) is red. To release parking brake: * Place the parking brake lever (Item 1) to the Off position. The braking brake indicator (Item 2) is green.

26 Brake System P-2/3 2. To release the brake quickly: The brake has a handle (Item 3) for quick-release. The quick-release acts directly on the brake valve during operation of the air pressure system or on the vacuum control valve during vacuum operation: To operate the quick-release for the air pressure system: Pull out the handle once until the brake has been completely released (opened). To operate the quick-release for the vacuum system: Pull out the handle once until the vacuum has been completely equalized. 3. To switch the brake system from air pressure to vacuum: Note: The switch over devices for the air pressure and vacuum systems are coupled to each other mechanically, i.e. when the air pressure brake system is switched on, the vacuum brake system is switched off automatically and vice versa. Generally, the following applies: Lever in horizontal position: Lever in vertical position Brake ON, Brake OFF. It is also possible to switch off both brake systems simultaneously. Caution: danger of the crane rolling secure the crane without fail using drag shoes. 1. To switch on the air pressure brake: * Set the air pressure brake (Item 4) to On. The service brake indicator (Item 6) is red. 2. To switch off air pressure brake: * Set the air pressure brake (Item 4) to Off. The service brake indicator (Item 2) is green. 3. To switch on the vacuum brake: Set the vacuum brake (Item 5) to On. The service brake indicator (Item 6) is red. 4. To switch off the vacuum brake: * Set the vacuum brake (Item 5) to Off. The service brake indicator (Item 2) is green. 5 To switch off the service brake: Both brake system can be switched off: * Set the levers (Item 4 and 5) to Off. The service brake indicator (Item 2) is green. 6 Mechanical emergency release device of the spring-loaded cylinders (not illustrated):

27 Brake System P-3/3 Caution! Once the Bowden cables have been actuated, the crane is without brakes until the brake have been re-pressurized. Danger of accidents! The mechanical emergency quick-release device is actuated via 6 Bowden cables on the bogies. The spring-loaded brake is not active until sufficient pressure is available. The pressure required can be generated via the compressor on the diesel engine or the air pressure compressors in the undercarriage. When the pressure required is to be generated during traveling in an air undercarriage to released position. Otherwise the parking brake closes automatically when the activating pressure has been reached. When the pressure is set in a vacuum brake operated train, the air supply for activating the spring-loaded and service must be checked prior to departure, as no braking function is possible until the pressure has been generated via the axle compressors. Filling only the main airline is not sufficient to activate the brake system (min.7.5 bar) but it is enough to make the service brake functional. Parking the crane rake is released is prohibited. Danger of the crane rolling! Secure the crane by means of drag shoes or the like. To actuate the emergency quick-release device: * Pull the Bowden cables on the bogies to release the spring loaded cylinders. Figure A Item 1 Item 3 Item 2 Item 6 Item 4 Item 5

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29 Outriggers P-1/3 Description The crane is fitted with four outriggers. Each of the outriggers can be swung in and out as well as secured independently of each other. The outrigger pads can be extended and retracted via the outrigger cylinders. Swing Cylinder Jack Cylinder SAFETY INSTRUCTIONS! Use caution near the outriggers Danger of being crushed! Ensure that no one is near moving parts- Danger of being crushed and being pulled in! When the crane is propped on supporting ground, the outrigger pads may have to be supported by a suitable means to distribute the weight over a greater area Caution Take account the crane weight and outrigger loadings on account of the suspended load Danger of accidents and mortal danger! When propping the crane, use leveling devices to level the crane! Caution Switch over the safe load indicator according to the set propping base - Lifting Capacity Chart! Operating Instructions The outriggers can be propped at two different propping bases. The propping base is directly related to the permissible lifting capacity for the outrigger base (see section on the lifting capacity charts).the outriggers can be operated via four control levers on the longitudinal sides of the undercarriage (Figure A Item No. 1 to 4)

30 Outriggers P-2/3 OUT RIGGER COMBINATION Condition - Propping Base Half Propping m x 11.8 m Full Propping m x 11.8 m PROPPING THE CRANE a) Switch on oil Transmission line (pre-selector in the crane cabin to undercarriage). b) Operate lever (fitted on the undercarriage) to swing out the outrigger beams as required. c) Operate lever (fitted on the undercarriage) to lower the propping cylinder on the stabilizer foot. Lock the stabilizer foot and the piston with pin. Note: It is advisable to use load distribution pads, except where space does not permit. d) Raise the crane until the wheel sets lift clear off the rails. e) Set oil transmission line pre-selector in the crane to neutral position. f) Level the crane with the help of side mounted spirit level on the undercarriage. There are two control levers on the longitudinal sides of the undercarriage for each outrigger. One control lever is for the function retracts /extends outrigger beams, the other is for the function extends/ retracts jack cylinders. The jack cylinders can be activated when the undercarriage hydraulics are switched on. The assignment of the extend /retract an outrigger beam control lever is as follows: To extend the outrigger beam: Secure the crane according to regulations against rolling. Unlock the outrigger safety pins. To do so, turn the locking levers on the outrigger cylinders on all the outrigger beams from their locking position by 180 degree and place them in upright position. Move the control lever (Items 1 and 2) in downward position (Figure A Item No. 1 to 4) To retract the outrigger beam Move the control lever (Items 1 and 2) into upright position. Lock the safety pins. To do so, turn the locking lever on the jack cylinders 180 degree from its unlocked position and move into downward position. The assignment of the extend / retract : jack cylinder control levers are as follows: Note: Operate the right-hand control lever for the right-hand outrigger and the left-hand control for the left-hand outrigger (Figure A ) If this has not yet occurred, secure the crane against rolling according to regulations. Move the control levers (Items 3 and 4) into downward position. To retract the jack cylinders: Move the control levers (Items 3 and 4) into upright position. Use the leveling devices located in the control panel to level the crane. When the crane is propped, it must be in horizontal position.

31 Outriggers P-3/3 Figure A Propping left, Item 3 Propping right, Item 4 Out rigger left, Item 1 Out rigger right, Item 2 Out rigger left, Item 1 Out rigger right, Item 2 Propping left, Item 3 Propping right, Item 4

32 Re-Railing P-1/1 Description In the event that the crane is de-railed, the crane can be re-railed by using the hydraulic outriggers. SAFETY INSTRUCTIONS! Use caution near the outriggers- Danger of being crushed! Ensure that no one is near moving parts- Danger of being crushed and being pulled in! When the crane is propped on supporting ground, the outrigger pads may have to be supported by a suitable means to distribute the weight over a greater area. Caution Remember to take the load attached when crane weight and outrigger loadings are calculated- Danger of accidents! Mortal danger! Caution an increase degree of attention is required for re-railing Danger of accidents! Mortal danger! Operating Instructions The individual bogies are re-railed, i.e. first the front and then the rear bogie. Let us assume that the crane has de-railed to the left of the track. The diesel engine is running and the outrigger beams are unlocked. 1. Set the hydraulics selector switch to undercarriage 2. Extend the outrigger beams, as described, to the middle propping base beams 3. Position the outrigger pads, extend the right and left outrigger and raise the crane evenly in this way. 4. Simultaneously retract the right-hand outrigger beam and extend the left-hand outrigger beam until the wheels of the bogie are located directly above the rails or have reached the maximum width of 50 mm. If the cylinders must be run shift the crane again, the right and left jack cylinders must be retracted and the crane must be lowered evenly. Run out the jack cylinders 50 mm at maximum in the direction in which the crane is to be shifted and raise the bogie again. Repeat step 4 as often as required until the wheel of the bogies is located directly above the rails. 5. Retract the right and left outrigger cylinders and lower the crane evenly in this way until the wheels are on the rails. 6. Retract the outrigger cylinders completely, retract the outrigger beams completely and secure. Then, repeat this procedure for the second bogie. If the swing-out angle of the outrigger beams is not sufficient to re-rail the crane in one cycle, the re-railing procedure must be repeated in several steps.

33 Counterweight P-1/1 Description Counterweight Gallows lever Counterweights are mounted on the superstructure as per requirement of load condition. Sensing of 29.2 T/43.2 T or no counterweight is done by pressure switch as provided with the counterweight gallows hydraulic cylinder and it is transmitted to the PAT and also indicated in the driver s cabin. The counterweight consists of 4 counterweight slabs. Counterweight t Counterweight 2 18 t Counterweight 3 6 t Counterweight 4 14 t The counterweight slabs are combined by means of a counterweight suspension and secured by means of inter locking system onto the crane counterweight support. SAFETY INSTRUCTIONS! As the rigging procedures present particularly dangerous situations, ensure that sight voice contact between the crane operator and assisting personnel runs smoothly. Ensure that no one is near moving parts-danger of being crushed or pulled into the equipment! Use caution when the counterweight is picked up and set down. In addition an increased degree of attention is required when the inter locking system and connecting mechanism are required. When work is carried out on the counterweight and the counterweight support, contact must be maintained continuously to the crane operator; it may be necessary to have additional banks men-danger of accidents! Mortal danger! Operation may only be carried out using the pertaining handles and levers- Danger of being crushed or sheared! Danger of accidents! Caution! Danger of being crushed or sheared when the locking claws need to be thrown over.

34 Pick Up and Set Down Counterweight P-1/2 Description The lowest counterweight slab 5.2 t is stored on the undercarriage for transport ahead of the cab. The other three counterweights are stored on the match truck. For crane operation with counterweight, the three counterweights must be picked up off the match truck and set down on the counterweight located on the undercarriage. Counterweight pick-up and set-down can be carried out by the crane with S-hook.! SAFETY INSTRUCTIONS As the rigging procedures present particularly dangerous situations, ensure that sight and voice contact between the crane operator and assisting personnel runs smoothly. Use caution when the counterweight is picked up and set down. In addition an increased degree of attention is required when the inter locking system and counterweight suspension are required. When work is carried out on the counterweight and the counterweight support, contact to the crane operator must be maintained continuously; it may be necessary to have additional banks men Danger of accidents! Mortal danger! The counterweights may only be combined as laid down in the lifting capacity charts! Ensure that no one is near moving parts Danger of being crushed, sheared or pulled into the equipment! Caution! Danger of being crushed and sheared when the locking claws are thrown. Caution: The hydraulic cylinders must be run into their respective end positions. When they have reached their respective end position, the hydraulic cylinders must be switched off immediately Danger of accidents! Caution Mortal danger of being crushed in the area between the superstructure and the counterweight support! Standing in this area is only permitted when the ignition key has been removed and battery main switch has been switched off!

35 Pick Up and Set Down Counterweight P-2/2 There are three counterweights of 6, 14 and 18 tonne respectively. All lie on the match truck and have to be picked up as per requirements, (a weight of 5.2 tonne lies on the chassis as base load). For using the counterweights, follow the instructions given below. a) Switch on boom bridging key, so that 5 meters limit switch is in circuit (by passing 5.5m limit switch). b) Switch on key switch which bridges safe load indicator. Now the crane should not be slewed. c) Pick up the counterweight from match wagon individually to form standard counterweight condition as below. STANDARD COUNTERWEIGHT:- Place 18 T on 5.2 T (5.2 T lying on the undercarriage in front of the cabin). Then place 6 T on 18 T counterweight. ONLY FOR FREE ON RAIL = 24 T on Gallows 5.2 T on chassis. HEAVY DUTY COUNTERWEIGHT:- Place 18 T, 6T and 14T counterweights on 5.2 T weight on the undercarriage in front of the cab. This gives 43.2 Tonne on gallows. Note: Half propped and full propped conditions: During half propped and full propped conditions the counterweight combination is 29.2 T ( ) on gallows and 43.2T ( ) counterweight on gallows. d) Switch OFF safe load indictor switch key to bring the computer safety system into the circuit. Check the correct mode of stability. e) Interlock the counterweight sections and boom out to 8m radius. Then slew the super structure to 180 degrees. f) Set oil Transmission line selector switch at Counterweight, lower counterweight gallows, mount the weights and raise the gallows to the limit position. (Indication lamp goes off). g) Switch off boom key switch, so that 5.5 m limit switch is in circuit. CAUTION a) Check if safe load indicator is in operation. b) Correct mode of stabilization is set on the selector switch. c) Axle blocking pressure is approximately 240 bar.

36 Raise / Lower Boom P-1/4 Lever forward Raise Boom Raise/Lower Boom Lever Left Slewing left Lever Right Slewing right Lever Back Description Lower Boom The boom can be lowered onto the boom support located on the match wagon coupled to the crane. In order to attain the necessary radius in curves, the boom fulcrum point must be extended forward from the superstructure. SAFETY INSTRUCTIONS! As the rigging procedures present particularly dangerous situations, ensure that sight and voice contact between the crane operator and assisting personnel runs smoothly. Ensure that no one is near moving parts- Danger of being crushed or pulled into the equipment!

37 Raise / Lower Boom P-2/4 Operating Instructions 1. Erection of Crane- Rigging 1.1 Before starting the Engine the following oil and coolant level should be checked once again. a) Hydraulic oil level. b) Fuel oil level (cab be checked by gauge in the operator s cab). c) Oil level in the gear boxes. d) Engine lubrication oil. e) Radiator water level. 1.2 All stop valves of Hydraulic oil lines should be in open position. 1.3 Start engine and check the following: a) Engine Lub. Oil pressure (40 to 60 psi) b) Battery charging current (Ammeter in the cab.) c) Pilot circuit pressure should be 30 bar. d) Air pressure should be about 6.5 bar plus. e) Visual check of the oil line, air line water line leakages. 1.4 Axle Blocking The bogie spring suspension is provided purely for hauling operations. When crane operation is required or self propulsion in the crane is necessary, axle blocking is a must, i.e. spring suspension is to be blocked. This means that the spring should make a solid block. For this an Axle blocking control lever is fitted on the side of the undercarriage. Two pressure gauges (0 to 600 bar) are also fitted near the control lever on the undercarriage to indicate axle blocking pressure which should be approximately 240 bar. When operating the crane one person should be nominated to observe the axle blocking pressure gauges. Any fall in the pressure caused due to leakage of oil of axle blocking cylinder should be made up by repressurising the control lever. Sequence of operation for axle blocking is explained below. Select oil transmission line pre-selector switch (in the operator s cab) for undercarriage. a) Operate Axle blocking lever (side mounted on the undercarriage) until all springs are compressed against the stop. The pressure should be 240 bar approx. when axle blocking is done, the following operations take place simultaneously: i) Traveling gear engages, ii) Brake apply, iii) All side mounted display devices indicate RED

38 Raise / Lower Boom P-3/4 Erection of Boom a) Pre-selector switch for oil line transmission to counterweight. b) By operating the valve (on the left panel) counterweight gallows should be raised to maximum position until the indicating lamp (in the cabin) is off. c) Derrick IN until boom heels sits on the pin. d) Continue derricking IN till A frame is at full position. e) Secure A Frame pin in position. f) Remove boom lock provided on the match truck trestle. g) Raise boom clear of head rest (trestle) approx. 40 cms bring hook blocks under the boom head vertically either by moving the Crane or Match Wagon. OR After raising the boom approx. 40 cms above the trestle continue derricking IN and simultaneously both hook blocks are to be lowered till the boom head is vertically above the hook blocks. The crane is ready for picking up the counterweight as per requirements, or freely for operation without counterweight. the crane is Note: 1. Repositioning of the match wagon: If necessary due to space requirements, the match wagon can be repositioned behind the crane undercarriage or on a side track. In any case, prior to uncoupling the match wagon, parking brake should be closed. 2. Folding the buffers:- To reduce the required radius crane buffers can be folded sideward. 1.7 Derigging of the Crane Sequence of derigging is given briefly below: * Check axle blocking pressure. * Unload counterweights on the match truck. * Leave base counterweight of 5.2 T on crane chassis in direction of match truck. This is mandatory. * Boom out to 16m radius. At this point derricking out will be cut off by 16m limit. * Switch and PAT. * Switch IN boom over bridge key. * Switch IN computer over bridge key. * Raise both hooks to limit position of derigging. * Boom down until both hooks lower into match truck well. * Continue to boom down causing hook blocks to incline forward. * Boom down so that boom head is approx. 40 cms higher than rest position. * Travel crane forward until boom rest pin matches with recess in boom rest. * Boom down until boom slides fully into the boom rest to the lock position.

39 Raise / Lower Boom P-4/4 IMPORTANT At this point lock the hook in the boom rest. Raise counterweight gallows to full height. Fasten the A frame hind bottom leg with counterweight gallows by link rope arrangements. Remove pins from A frame. Boom out to give small amount of slack in derrick ropes. Lower counterweight gallows which will result in A frame going over centre which will facilitate further collapse. Raise gallows fully. Remove link rope arrangement. Further derrick out till A frame front rests on the top of raised gallows. Now simultaneously derrick out and lower gallows till gallows sit on their desired position on super-structure. Continue to derrick OUT while simultaneously lowering A frame arms into locking rest position on crane chassis. Derrick out until the ropes is slack over the operator s cab. This derricking out should be restricted by minimum number of turns on drum limit switch (the setting should be for slackness just adequate to negotiate designed track curve). It is essential that while rigging and derigging one staff member is deputed to watch proper setting of the rope on drum and to ensure that rope does not get out of its path.

40 Start up Requirements Hydraulics Diesel Engine System Battery Main Switch Fuel Supply Undercarriage Hydraulics On/Off Ropes Hoist and Lowering Limit Switches Boom Angle Sensor Emergency Diesel Engine

41 Hydraulics P-1/1 Description The hydraulic system is driven by the diesel engine via a pump distributor gearbox. It must be ensured without fail that the hydraulics function properly in crane and in travel operation under own power. SAFETY INSTRUCTIONS! The respective specialist personnel may only remedy leakages or any other malfunctions on the hydraulic system. Operating Instructions * Check the hydraulic oil tanks and its connections for external damage and leakages. * Read off the oil level by the dip stick. The oil level should also be read off later when the crane at operating temperature. The maximum oil level has been reached when all the cylinders have been retracted. The oil must not fall below the minimum oil level when all the cylinders have been extended. * Check the hydraulic system for leakages. * The cock stops must be open.

42 Diesel Engine System P-1/1 Description The diesel engine system drives the hydraulic pumps for travel and crane operations via the pump distributor gearbox. The diesel engine also supplies the air pressure system with air pressure via its direct mounted air compressor, as well as power to the batteries. The diesel engine is an air- cooled 6 cylinders, 4- cycle diesel engine with direct injection and exhaust turbo charger. SAFETY INSTRUCTIONS! Prior to commencing check work on the crane, remove the ignition key from the cab and affix a respective check work sign. Operating Instructions Check the diesel engine for visible damage and extended leakages. Check the oil level on the oil dipstick. The exact oil level can first be read off after the engine has been at a stand still at least 10 minutes. The following points should be recorded by the crane operator and reported to the maintenance personnel: 1. Engine oil pressure too low 2. Low output 3. Excessive cylinder head and oil temperatures 4. Unusual noises 5. Heavy smoke 6. Above average consumption of coolant, fuel or lubricating oil. 7. Leakage in the fuel or lubricating systems. 8. Excessive Water Temperature.

43 Battery Main Switch P-1/1 Description By means of the battery main switch, the power supplied to the batteries can be cut off. This means that, for example, the diesel engine can only be started up when the main battery switch is switched on. The crane has two types of Battery Main Switch. a) Rotary Type- It is provided in Crane No to b) Knife Type- - It is provided in Crane No to & to SAFETY INSTRUCTIONS! The battery main switches can be secured by removing the key for safe keeping. Operating Instructions For Rotary Type To switch ON the battery main switch, insert the main switch key and turn 90 degree. To switch OFF the battery main switch,, turn the main switch key 90 degree and remove. For Knife Type To switch ON insert the knife in the female socket tightly. To switch OFF remove the knife switch from the female socket.

44 Fuel Supply P-1/1 Description The diesel fuel tank supplies the fuel required for the diesel engines. The tank is integrated in the steel construction of the superstructure. The fuel capacity is approx.1000 L. SAFETY INSTRUCTIONS! The fuel tank should not be completely run empty under any circumstances as re-commissioning the diesel engine as a result necessitates a great deal of time and effort. In addition, it should be ensured that the fuel supply is sufficient to carry out the scheduled job as a dangerous situation could be caused under certain circumstances if the diesel engine were to come to a standstill. Caution Fuel is inflammable! Naked light and smoking are prohibited when work is being performed near fuel- related parts. Operating Instructions: The fuel supply is displayed in the cab. There should always be sufficient fuel for the scheduled job for the day. The fuel consumption based on an average job operation is as follows: Fuel consumption (approx) at Full speed : 45 ltrs/ hr. Half speed : ltrs/ hr. Never run the tank until it is empty as this involves time- intensive cleaning and bleeding work before it can be re-used.

45 Undercarriage Hydraulics On/ Off P-1/1 Description Preselector Valve The hydraulic functions for the undercarriage, crane operation and the counterweights hydraulics are switched on and off via this under carriage hydraulic system. SAFETY INSTRUCTIONS! Caution When the undercarriage hydraulic is not switched on, no work can be carried out. Operating Instructions For safety reasons, when the lever is in one of the three positions, the other functions are disabled so that unauthorized personnel, for example, cannot activate the lever on the undercarriage exterior, when the crane is in operation. The lever for the under carriage hydraulics has been assigned the following two functions: 1. To switch the undercarriage hydraulics ON * Move the lever forward. 2. To switch the counterweight hydraulics ON * Move the lever back.

46 Ropes P-1/1 Description The rope must run properly and safely on the rope drums, the rope pulleys and the guides to provide safety crane operation. The ropes must be in defect-free condition. Damage ropes can cause accidents. SAFETY INSTRUCTIONS! Work on the ropes may only be carried out by Special maintenance personnel. Caution near the overhead lines! Do not climb up onto the crane superstructure. Mortal danger! Operating Instructions Check the ropes for external damage. In addition, ensure that the ropes coil properly on the drums and run through the rope pulleys and guides. Always carry out a functional test without load prior to crane operation.

47 Hoist and Lowering Limit Switches P-1/1 Description The hoist and lowering limit switches for the derrick, the main hoist and the auxiliary hoists are fitted on the rear end of the drum.! SAFETY INSTRUCTIONS Caution near the over headlines! Do not climb up onto the crane superstructure Mortal danger! In the event of a limit switch malfunction, crane operation must be started or crane operation must be stopped immediately. Operating Instructions Prior to commencing with a job, check the limit switches for proper functioning. To do so, approach the respective end position slowly and without load. Also check limit switches after bridging the boom end positions

48 Boom Angle Sensor P-1/1 Description The angle sensor to determine the boom angle when the boom is derricked in and out is located in the boom lower section. The angle sensor for the superstructure/undercarriage rotation angle is located near the rotary lead-through.! SAFETY INSTRUCTIONS Caution near the over headlines! - Do not climb up onto the crane superstructure! Mortal danger! In the event of a limit switch malfunction, crane operation must not be started or crane operation must be stopped immediately. Operating Instructions Prior to commencing work, check the angle sensor for proper functioning. To do so, move the boom to the smallest and greatest radius showing without load. At the same time, check whether the corresponding radius is indicated correctly on the display.

49 Emergency Diesel Engine System P-1/1 Description The emergency diesel engine drives a tandem gear pump during emergency operation. The diesel engine can be started up manually. SAFETY INSTRUCTIONS! In the event the emergency diesel engine is not in operation, crane operation must not be done. Caution- fuel is inflammable! When work is carried out near fuel-related parts, fire, naked light and smoking are prohibited! Operating Instructions Prior to commencing with the work, check the emergency diesel engine as to whether the diesel engine is operational. To do so, the following points should be checked: Check the emergency diesel engine and the mounted hydraulic auxiliary pump and their caps for external damage and firm seating. Also check the emergency diesel engine for leakages. The diesel fuel for the emergency diesel engine is taken from the emergency diesel engine capacity 10 L fuel tank. Check the engine oil lever on the oil dipstick. Check the control panel for external damage.

50 Emergency Diesel Engine Start/Stop Emergency Diesel Engine

51 Start/Stop Emergency Diesel Engine P-1/3 Description The emergency diesel engine drives a tandem gear pump during emergency operation. The diesel engine can be started up manually for Crane No to & to and rest of the crane can be started manually as well as through self starter. The 2- cylinder four-cycle vertical diesel engine has an output of 10.5 KW at 1,800 rpm. The fuel is supplied via the fuel tank of the emergency diesel engine for the operation of the emergency diesel engine. In the event the Main Diesel Engine fails, the crane can be brought into transport position by means of the emergency diesel engine. The following motions can be carried. Slewing of the superstructure Hoisting and lowering motions using hoists but without load Lowering motions using hoists under load Lowering of counterweights Retraction/ swing-in of the outriggers SAFETY INSTRUCTIONS! The emergency diesel engine may only be operated in emergency situation in the event of a Main diesel engine failure in order to allow the crane to be brought into transport position. The emergency diesel engine is not designed for regular crane operation and thus it is not permissible to use this engine for regular crane operation. Caution- danger of fire! The emergency diesel system must never be operated with it protective covering on. The engine must work in a well-ventilated area as otherwise there is danger of the engine overheating and catching fire! Keep all inflammable objects away from the engine! Only re-fuel the engine when the engine is stationary. Use caution when the engine is still hot and the tank is being refueled! Do not spill any fuel on the system danger of fire and explosion! In the event the emergency diesel engine is not in operation, crane operation must not be done. Caution fuel is inflammable! When work is carried out near fuel-related parts, fire, naked light and smoking are prohibited! Never operate the engine in an enclosed area!

52 Start/ Stop Emergency Diesel Engine P-2/3 Operating Instructions Observe the User s Manual. Caution! - Prior to starting up the emergency diesel engine, open the pertaining stopcocks on the hydraulic system- otherwise, there is a danger of damaging the engine! The following instruments controls are on the control panel for Crane No to Ignition 2. Battery charging Indicator 3. Ampere meter 4. Lub. oil pressure 5. Wiring Circuit Item No. 3 Item No. 2 Item No. 1 Item No. 5 Item No. 4

53 Start/ Stop Emergency Diesel Engine P-3/3 To start up engine: Move stop lever into in operation position. Set the accelerator to full speed. Pull out the choke on the engine when the engine is cold. Set both decompression levers in vertical position to START. Mount the crank on the shaft of the emergency diesel engine and turn in arrow direction (clockwise) until the engine starts. When the engine has been started, set the decompression levers in horizontal position one after the other. To stop the engine: Never stop the emergency diesel engine directly after full-speed operation. Allow the engine idle 2 to 3 minutes unloaded. Then set the stop lever to STOP position. Do not release the stop lever until the emergency diesel engine has come to a complete standstill. Move the stop lever to in-operation position.

54 Diesel Engine System Start/In- operation/ Stop Diesel Engine Accelerator

55 Start/ In operation/ Stop Diesel Engine P-1/4 Description The diesel engine drives the hydraulic pumps for travel and crane operations via the pump distributor gearbox. The diesel engine is an air-cooled 6 cylinders, four-cycle diesel engine with direct injection and turbo charged cooling. The control panel for the diesel engine is located in the cab on the front right hand side (See Figure A ) SAFETY INSTRUCTIONS! It must be ensured that the crane cannot be switched on unknowingly. Remove ignition key and battery main switch and store in safekeeping to prevent unauthorized re-starting. The diesel engine system and the emergency diesel engine must not be operated in an enclosed area- Danger of asphyxiation due to the exhaust fumes! Never leave the crane untended when the diesel engine is running. The crane must not be in the way of other vehicles. Prior to starting, ensure there is sufficient fuel, water in radiator, hyd. oil and lub. oil. Operating Instructions Observe the Cummins User s Manual The following instruments/ controls are on the control panel: (Figure A ) 1. Ignition Switch 2. Start Switch 3. Stop Switch 4. RPM cum Hour Meter 5. Hour meter 6. Battery Charger Meter( Ammeter) 7. MCB 4A 8. Engine Water Temperature Gauge 9. Lub. Oil Pressure Gauge 10. Lub. Oil Temperature Gauge 11. Fuel Indicator 12. PAT Bypass Key

56 Start/ In operation/ Stop Diesel Engine P-2/4 Figure A RPM cum Hour meter, Item 4 Figure B of Page No: 73 Railway Crane Battery Charger Meter (Ammeter), Item 6 MCB 4 A, Item7 Operating Ignition Switch, Item 1 Start Switch, Item 2 Stop Switch, Item 3 Engine Water Temp, Item 8 Lub. Oil Pressure, Item 9 Lub. Oil Temp, Item 10 Fuel Indicator, Item 11 Hour Meter, Item 5 PAT Bypass Key, Item 12 Diesel Engine

57 Start/ In-operation/ Stop Diesel Engine P-3/4 1. Start diesel engine: To carry out a cold start at temperatures above 0 degree Celsius: * Insert the ignition key in the ignition (Item-1, Figure A ) and turn to the right to RUN position- the ignition switches on. * Press the START push button and hold until the diesel engine starts. Please observe the following: Allow the engine to run 3 to 5 minutes at approx. 1,000 rpm before it is loaded. Do not activate the starter longer than 30 seconds- danger of damaging the starter. Wait 2 minutes before re-starting. The lub. oil pressure must be indicated within 15 seconds after starting. When the engine is cold on starting, increase the speed slowly until the bearings are properly lubricated and the oil pressure has stabilized. Do not allow the engine to idle too long (10 minutes) danger of engine damage. Caution: Never press START push button when the engine is running- danger of severely damaging the engine! 2. In- operation: Please observe the following: Do not allow the engine to run below the engine peak speed for a longer period of time (30 seconds). Allow the engine to run for 3 to 4 minutes after full-speed operation before switching off. Watch the oil pressure and coolant temperature indicators during operation and / or take into account the engine indication function; if required, switch off the engine and eliminate problem. Lengthy operation at low (below 60 degree C) or high (above 100 deg. C) coolant temperatures can cause damage to the engine. If the engine threatens to overheat, check the water level of the radiator. Watch for early warning signs and if required take required measures. Early warning signs include: - Misstarting. Misfiring, backfiring - Excessive smoke - Shocks - Loss in power - Unusual engine noises - Increase oil consumption - Fuel, oil or coolant leakages - Increase fuel consumption - Sudden operating temperature or pressure fluctuations

58 Start/ In-operation/ Stop Diesel Engine P-4/4 3. To stop the diesel engine: Press the STOP push button till engine stop and turn the ignition key and remove. (Item 1, Figure A ) Please observe the following: Allow the engine to run 3 to 5 minutes before switching off. Do not allow the engine to idle too long. Do not allow the ignition to remain switched on after the engine has been switched off- Danger of engine damage through fuel running in from the fuel tank after the engine has been switched off.

59 Accelerator P-1/1 Description Accelerator The diesel engine speed is regulated by means of the foot-operated pedal for the accelerator. Thus, the speed can be adjusted smoothly for all travel and crane motions. SAFETY INSTRUCTIONS! Caution! - Never store objects in the cab foot area. Any object in this area could slide below or on the foot-operated pedals and cause a dangerous situation! Caution! -Only start travel operation when the parking brake has been completely released! - Do not begin to travel when the crane brake is applied. Operating Instructions The end speeds for the working motions are not only depending on how the foot-operated pedal is activated, but also on what speed has been selected via the respective control lever. To increase speed : To decrease speed : Depress the foot-operated at the front Release the foot pedal.

60 Travel Operation Travel Forward / In Reverse Brake

61 Travel Forward/ In Reverse P-1/2 Description The crane has a traction gear switch to change travel direction. This means that the travel lever motion always corresponds to the current sitting position. Thus, if the superstructure is rotated on the undercarriage, the travel lever motion is reversed when the superstructure is at approx 90 degree to the undercarriage.! SAFETY INSTRUCTIONS Caution! - The crane may only be traveled when the superstructure is in longitudinal position. Rotating the superstructure during travel or travel with the superstructure in transverse position is prohibited! Reverse travel direction! On exiting the crane, always apply the parking brake. Caution! -Only start travel operation when the parking brake has been completely released! - Do not begin to travel when the crane brake is applied. Operating Instructions The crane may travel forwards or in reverse with or without load. The travel control lever is assigned the double function Travel forwards/ reverse. (See Figure A ) To travel forward: Move the travel lever forward to travel forward and to regulate the speed. Full travel speed can only be reached when the diesel engine output is at its fullest, i.e. when the accelerator pedal is pressed to the floor. To travel in reverse: Pull back the travel lever to travel in reverse and to regulate the speed. Full travel speed can only be reached when the diesel engine output is at its fullest, i.e., when the gas pedal is pressed to the floor.

62 Travel Forwards/ In Reverse P-2/2 Figure A Traveling Motion lever Railway Crane Brake P-1/1

63 Description Brake Pedal The crane is fitted with an air pressure brake system. As soon as the brake pedal is activated, the travel drive idles automatically.! SAFETY INSTRUCTIONS Caution! In particular when the crane is traveled with load, the braking motion must be carried out smoothly. Any sudden or abrupt braking causes the load to swing dangerously! Caution! When the parking brake has been activated, renewed braking action cannot be carried out until the brake system has been pressurized with air pressure. Prior to releasing the parking brake, start up the crane and secure via the service brake. On exiting the crane, always apply the parking brake. Caution! Only start travel operation when the parking brake has been completely released! - Do not begin to travel when the crane brake is applied. Operating Instructions To brake the crane, your foot must not be on the gas pedal so that the diesel engine idles. Then gently depress the brake pedal. At the same time, release the travel control lever. Always check the air pressure during brake operation. A respective pressure gauge is mounted on the left hand panel for this purpose. The air pressure must be a approx. 6 bar to 7 bar.

64 Crane Operation Slew Right/ Left Derrick in / out Hoist/ Lower using Main Hoist/ Auxiliary Hoist Lifting Beams and Slings

65 Slew Right/ Left P-1/2 Description By means of the slew gear, the superstructure can be infinitely variably rotated 360 degree on the undercarriage. The superstructure can be slewed when the crane is propped with or without load. Slewing during travel is prohibited Reverse travel direction The slewing gear is operated via the control lever in the cab. (See Figure B ) SAFETY INSTRUCTIONS! During crane operation, always ensure that no person or obstacles are in the working or danger zones. Caution! - Observe the load indicator! In the event the load indicator or safe load indicator fail, crane operation must not be started or must be stopped immediately! Use caution when crane work is being carried out on adjacent tracks! Increased danger of accidents! Operating Instructions When work is carried out on adjacent tracks or near other obstacles, use caution, as there is a danger of the crane colliding with passing trains or other obstacles. The slewing motion corresponds to lever motion. To slew left: * Move the control lever to the left. To slew to the right: * Move the control lever to the right. Note: When the control lever is released, the lever returns to center position. The slewing motion is limited and switched off by the safe load indicator in accordance with the lifting capacity charts. Only slewing in the opposite direction is then possible to reduce the load moment.

66 Slew Right/ Left P-2/2 Figure A Figure B Slewing Gauge Slewing Motion lever Lever forward Derrick Out Lever Left Slewing left Lever Right Slewing right Lever Back Derrick In

67 Derrick In / Out P-1/2 Description The boom position can be altered by means of the derricking gear. The winch, the rope drum, gearbox and drive assembly are located on the superstructure. When the boom is derricked out, the derricking gear uncoils the rope and moves the boom into its greatest radius. When the boom is derricked in, the derricking gear coils the rope and moves the boom into steepest position. Both end positions are monitored by means of the limit switches, which switch off operation automatically when the boom reaches the end positions. For the rigging purposes, switching on the boom bridging key must bridge the end switch-off position of the normal working range. The end positions (ultimate end positions) in rigging operation are also monitored by limit switches, which switch off operation automatically when the boom reaches the end positions. The boom position is sensed via the angle sensor. This data forms the basis for the lifting capacity charts. The derricking gear is operated by means of the control lever in the cab. ( See Figure A ) SAFETY INSTRUCTIONS! During crane operation, always ensure that no persons or obstacles are in the working or danger zones. Watch for train traffic on adjacent tracks- Danger of Accidents! Do not stand or move below suspended loads Mortal danger! Caution!- observe the load indicator! In the event the load indicator or safe load indicator failure, crane operation must not be started or must be stopped immediately! The crane may only be propped at the propping bases indicated in the Technical Data. The ground must withstand the propping pressures. Use caution near the overhead lines- Mortal danger! Keep out of slewing range! Loads must be lifted vertically. Diagonal pull is prohibited. The limit switches may only be bridged for rigging and not other purposes! During crane operation, bridging the boom position limit switches is prohibited! Rigging must also be carried out in connection with a competent banks man. Operating Instructions When work is carried out near bridges, masts and overhead lines, the working height is restricted as otherwise there is a danger of the boom colliding with the overhead lines Use a banks man! The control lever for the derricking motion is a combined function lever for the functions slew right/ left and derrick in /out. To derrick in: Pull back control lever. To derrick out: Move control lever forward. Note: When the control lever is released, it returns to center position.

68 Derrick In / Out P-2/2 Figure A Derricking lever Lever forward Derrick Out Lever Left Slewing left Lever Right Slewing right Lever Back Derrick In

69 Hoist / Lower Using Main Hoist/Aux. Hoist P-1/2 Description The crane is fitted with two hoists (Main Hoist & Aux. Hoist), which work independently of one another. The main hoist lifts and lowers the ramshorn hook. The auxiliary hoist lifts and lowers the single hook. You may select normal speed or high speed to hoist and lower small and medium-size loads in the range below full load.! SAFETY INSTRUCTIONS During crane operation, always ensure that no persons or obstacles are in the working or danger zones. Caution- observes the load indicator! In the event the load indicator or safe load indicator failure, crane operation must not be started or must be stopped immediately! Caution the high-speed gear may only be used to hoist and lower small and medium-sized loads in the range below full load-do not use this gear for any other purpose! During crane operation in high-speed gear, watch the rope drum of the Main hoist & Aux. hoist. If the rope is not properly coiled or the rope slackens during lowering, stop the hoist if required, re-coil ropes properly and proceed with work at normal speed as otherwise there is a danger of rope damage and accidents. Operating Instructions The hoist/lower control lever is a combined function lever for the functions hoist/lower using main hoist or hoist/lower using auxiliary hoist. (See Figure A ) The lever motion for the main hoist/aux. hoist corresponds to rope motion: To hoist using the main hoist/aux.hoist: * Pull back control lever. To lower using the main hoist/aux. hoist: * Move control lever forward. To switch to high-speed gear: * Press the knob/lever of rapid motion 3/2 way DC Valve located in the cab. (Foot operated) (See Figure B ) 1) DC Valve No. LS 1227 for Crane No to ) DC Valve No. 4 WMM6 for Crane No to ) DC Valve No. 4 WMU6 for Crane No to To switch off the high-speed gear: Release the knob/lever on the control lever. Note: - After release the knob in neutral position, the control lever returns to neutral position. To change over from neutral to high speed gear.

70 Hoist / Lower Using Main Hoist/ Aux. Hoist P-2/2 Figure A Figure B Valve Valve Valve LS L S WMM 6 4 WMU 6 Valve for Aux: Hoist lever Main Hoist lever Rapid Motion for Hoist

71 Lifting Beams and Slings P-1/1 Lifting Beam Description Two lifting beams (Max. lifting capacities being 70 T or 140 T) according to their two signs respectively as well as various slings and chains have been supplied.! SAFETY INSTRUCTIONS Prior to attaching the lifting beams and slings/chains, check them for external damage. The lifting beams and slings/chains may only be used when operating safety has been ensured. Use only original parts for lifting purposes. The lifting beams may only be operated as laid down by regulations. Lifting beam are secured with lever. Use caution when the lifting beams are mounted and operated- Danger of being crushed or drawn into the equipment. Ensure that the bolt connection is firmly seated. An improperly mounted lifting beam or a suspended load on an improperly mounted lifting beam can cause serious accidents- Danger of accidents!- Mortal danger! No persons may be conveyed on a lifting beams or on a load suspended from a lifting beam- Mortal danger! Stay out of the range of lifting beams or suspended loads. The maximum loading for the lifting beams and for the individual slings and chains must not be exceeded. Operating Instructions Lifting Beam: Both lifting beams are attached in the same manner: 1. Lower the hook to the lifting beam (1) so that the lifting beam can be attached to the hook by means of the pin-and bolt connections. 2. Insert the bolts until they reach the end stop through the opening in the lifting beams and hook (2) and then turn them behind the links to secure against loosening (3). Note: To set down the lifting beam, proceed in reverse sequence. Slings and chains (not shown): When loads are being attached, observe the instructions on safety and use posted on the signs mounted on the slings and chains.

72 General Operating Functions PAT system Lighting Signal Horns Screen/Wiper System Fans Parking Crane Safely Safe load Indicator Emergency Operation Recovery Winch

73 PAT System P-1/8 Figure A Figure B! Description The PAT DS 350 load moment indicator system consists of a central micro processor unit, display operator s console, and angle sensor and force transducer (Figure A ). The system operates on the principle of reference/real comparison. The real values resulting from the force measurement is compared with the reference data stored in the central processor memory and evaluated in the micro processor. When limits are exceeded, an overload warning signal is generated at the display and operator s console. The firm data regarding the crane, such as capacity charts, boom weights, centers of gravity and dimensions are stored in memory chips in the central processor unit. This firm data is the reference information used to calculate the overload conditions. System operation is controlled by the angle sensor functioning automatically or by manual devices such as switches in the operator console. The boom angle is registered by the angle sensor mounted on the boom. The crane operator s console has analog displays for reference value, real value and radius and a digital display for the error code. The crane load is measured by force transducers attached to the boom hoist unit, for main boom. In crane No to SLI of Amrita Lakshmi Electronics and in Crane No to SLI of Mechanica Systems Pvt Ltd. Pune, has been fitted (Figure B ). For this refer to the manual of these suppliers. SAFETY INSTRUCTIONS While the function of the load moment indicator is to alert the operator of approaching overload conditions, errors are possible in the functioning of this load moment indicator and it is impossible to warn of all possible dangers. The operator is solely responsible for the safe operation of the crane.

74 PAT System P-2/8 CONTROL IDENTIFICATION The figure illustrates the controls and displays of DS 350 load moment indicator. The numbers on the illustration correspond to the numbers in the following list, which describes the function of each control OVERLOAD LIGHT AND AUDIBLE ALARM SWITCH This red luminous key will light when the load on the crane is in excess of 100% of the crane rating. Pressing this key allows the audible alarm to be silenced. When leaving the overload condition, this silencing is effected automatically.! SAFETY INSTRUCTIONS The audible alarm must not be silenced during crane operation, as the operator may not be alerted by the red warning light alone, especially in bright sunlight.

75 PAT System P-3/8 2. PREWARNING LIGHT This yellow light will light when the load on the crane is between 90% of the crane rating, indicating that an overload condition is approaching. 3. REFERENCE VALUE DISPLAY This analog display shows the share of the greatest permissible moment of the operating mode adjusted in each case by which the crane may be loaded. This display varies with the changes of the boom position. 4. REAL VALUE DISPLAY This analog display shows the share of the greatest permissible moment of the operating mode adjusted in each case by which the crane is loaded. Display represents an increasing utilization of the crane rating. The crane rating has been fully utilized once the two needles are in the same position and the overload lamp (1) lights up. 5. RADIUS DISPLAY This analog display indicates the operating radius of the main hoist (left hand scale) and the auxiliary hoist (right hand scale.) 6. ERROR CODE DISPLAY In the event of a malfunction, this digital display shows an error code indicating the crane of the failure (see TROUBLESHOOTING). This display is blank in normal operation. 7. OPERATING MODE SWITCH This rotary switch serves for setting the safe load indicator to the operating configuration (Outrigger position) of the crane.! SAFETY INSTRUCTIONS Setting the operating mode switch must be done with utmost care since an incorrect setting of the operating configuration of the crane may result in dangerous overload conditions for the crane. 8. COUNTERWEIGHT DISPLAY These lamps automatically indicate the counterweight used. The meaning of the individual counterweight numbers is outlined in the manual of the crane. The load curves valid in each case are automatically selected by the safe load indicator.

76 PAT System P-4/8 PRE OPERATION INSPECTION 1. Check the cables, plugs and sockets connecting the various parts of the system for physical damage. Replace damage parts. 2. Check force transducer, angle sensors for boom and slewing for any physical damage. 3. Check that the display of the operating radius of the crane agrees with the actual radius. 4. Check that the display of the slewing angle agrees with the actual slewing angle. 5. The operator should select the correct mode of the OPERATION MODE SWITCH. After this setting, the operation of the Load Moment Indicator is fully automated. The operator must be thoroughly familiar with all controls of the Load Moment Indicator. 6. Check the COUNTERWEIGHT DISPLAY indicates correct counterweights used. If the indication is wrong the operator must get the fault rectified before starting crane operation. OPERATION After being properly set, the operation of the load moment indicator is fully automated. Therefore, the operator must be thoroughly familiar with all controls of the load moment indicator and he must properly set each switch before operating the crane. All setting must be checked by lifting a load of known weight and comparing the load to the information displayed on the load moment indicator. TROUBLESHOOTING Description With the mode selector switch in position 7 the machine status display will indicate a code which identifies the system malfunction. The error codes listed in the Malfunction Table will identify various errors which can occur with the load moment indicator.following the Malfunction Table are pages which explain each fault and describes the action which should be taken to correct the fault. Faults within the electronic microprocessor must be repaired by trained service personnel.

77 PAT System SYSTEM MESSAGES P-5/8 Code Letter O: Overload P: Prewarning H: Anti Two Block Switch activated MALFUNCTIONS TABLE Error Code Number: 01 : Fallen below the radius or angle range 02 : Radius range exceeded 03 : Error in the A/D converter 04 : Operating mode not existing 05 : Prohibited length range 06 : Prohibited angle range 07 : Error overload relay 08 : Error hoist end switch relay 09 : Error relay 2 11 : Error in the length registration 12 : Error in the pressure registration 13 and 23 : Error in the force registration Force Pickup 1 14 and 24 : Error in the force registration Force pickup 2 15 and 25 : Error in the angle registration main boom 16 and 26 : Error in the angle registration Jib 17 and 27 : Error in the no-load moment correction 18 and 28 : Error in the reference voltage 31 : Error in the system program PROM 1 32 : Error in the system program PROM 2 33 : Error in the system program PROM 3 34 : Error in the system program PROM 4 38 : Incorrect system program 41 : Error in the RAM memory 1 42 : Error in the RAM memory 2 51 : Error in the data memory PROM 1 52 : Error in the data memory PROM 2 53 : Error in the data memory PROM 3 54 : Error in the data memory PROM 4 55 : Error in the data memory PROM 5 56 : Error in the data memory PROM 6 57 : Error in the data memory PROM 7 58 : Error in the data memory PROM 8 59 : Error in the data memory PROM 9 80 : Fallen below minimum radius 84 : Error in the slewing angle registration 91 : No data transmission from the console 92 : Error in the data transmission from the console 93 : Error in the data transmission to the console 94 : No data transmission to the console

78 PAT System P-6/8 ERROR Display E 01 E 02 ERROR CAUSE ELIMINATION Fallen below radius or angle range Radius or angle range exceeded E 03 Error in the analog / digital conversion E 04 Operating mode not available E 06 Angle luffing jib exceeded E 07 E 08 E 09 No acknowledge signal from overload relay No acknowledge signal from hoist limit switch relay No acknowledge signal from relay 2 E 13 Fallen below lower limit value for measuring channel Force pickup 1 Fallen below the minimum radius or angle given in the load chart due to raising the boom too far The maximum radius or angle given in the load chart was exceeded due to lowering the boom too far Defect on the electronic basic board Operating modes switch in the console set incorrectly The maximum angle given in the corresponding load chart was exceeded due to lowering the luffing jib too much Overload relay is stuck, defective or not being selected Hoist limit switch relay is stuck, defective or not being selected Relay 2 is stuck, defective or not being selected Cable from central unit to the force pickups defective or water inside the plugs Force pickup defective Put boom back to a radius or angle given in the load chart Raise boom back to a radius or angle given in the load chart Contact OEM Set operating modes switch correctly to the code assigned to the operating mode of the machine Raise luffing jib to an angle given in the load chart Exchange relay if this is not successful, Contact OEM Exchange relay if this is not successful, Contact OEM Exchange relay if this is not successful, Contact OEM Verify cable as well as plugs replace, if need be Replace force pickup E 14 Fallen below lower limit value for measuring channel Force Pickup 2 Electronic module in measuring channel defective Cable from central unit to the force pickups defective or water inside the plugs Force pickup defective Electronic module in measuring channel defective Contact OEM Verify cable as well as plugs and replace, if need be Replace force pickup Contact OEM

79 PAT System P-7/8 E 15 Fallen below lower limiting value for the measuring channel angle main boom E 16 Fallen below lower limiting value for the measuring channel angle luffing jib E 17 Fallen below lower limiting value for the measuring channel no-load moment potentio meter E 18 Error in the reference voltage E 25 Upper limiting value for the measuring channel angle main boom exceeded Cable from central unit to length /angle sensor defective or loose or water in the plug Angle sensor defective Electronic component in the measuring channel defective Cable from central unit to angle sensor of luffing jib defective or loose or water in the plug ( watch cable drum and distribution boxes) Angle sensor defective Electronic component in the measuring channel defective Electronic component on basic board defective Electronic component on the basic Board defective Cable from central unit to length / angle sensor defective or loose or water in the plug Angle sensor defective Check cable as well as plug and exchange, if necessary Contact OEM Contact OEM Check cable plug cable drum distribution boxes and exchange, if necessary Contact OEM Contact OEM Contact OEM Contact OEM Check cable as well as plug and exchange, if necessary Contact OEM E 26 Upper limiting value for the measuring channel angle luffing jib exceeded Electronic component in the measuring channel defective Cable from central unit to length / angle sensor of luffing jib defective or loose or water in the plug (watch cable drum and distribution boxes) Contact OEM Check cable, plug, cable drum and distribution boxes and exchange, if necessary Angle senor defective Contact OEM Electronic component in the measuring channel defective Contact OEM

80 PAT System P-8/8 E 27 Upper limiting value for the measuring channel no load moment potentiometer exceeded E 28 Error in the reference voltage E Error in the system program E 38 Incorrect system program specific set of EPROMs Electronic component on basic board defective Electronic component on the basic board defective E PROMs with system program defective System EPROM (s) mounted is (are) not compatible with the crane. Contact OEM Contact OEM Contact OEM Replace system EPROM (s) with the one (s) provided for the crane. Contact OEM E Error in the RAM RAM range on the basic board defective E Error in data memory Data PROMs or board defective Contact OEM E 80 Fallen below minimum Fallen below the given minimum Increase radius radius radius by raising the boom too far. E 84 Error in the slewing angle registration. Cable from central unit to slewing angle potentiometer defective or loose Check cable and replace, if need be. Slewing angle potentiometer defective E No data transmission from console E Error in the data transmission to the console Electronic component in the measuring channels defective. Plug on console loose, cable defective Cable to the console not plugged in or interrupted Defect in the central electronics ( basic board) Contact OEM Check cable and plug Exchange console Check cable, plug in plug Contact OEM

81 Lighting P-1/2 Description The crane is fitted with sufficient lighting for crane and travel operations:! SAFETY INSTRUCTIONS Crane operation is only permitted when there is adequate lighting. If visibility is considerably reduced in the event of lighting failure, operation must be stopped immediately. Replace any faulty lighting equipment- Danger of accidents! Operating Instructions The following is applicable to all buttons. To switch on the lighting Activate the buttons once. To switch off the lighting: Re-activate the buttons. Assignment of buttons ( See Figure A ) - Jib light - Front cabin light - Cabin light - Engine cabin light - Dash board light - Back light To switch on the lighting Turn the rotary switch down wards To switch off the lighting. Turn the rotary switch upwards.

82 Lighting P-2/2 Figure A Jib light Front cabin light Cabin light Engine cabin light Dash board light Back light

83 Signal Horns P-1/2 Description The signal horns serve to provide an audible warning during crane and travel operation and generally in case of danger. The signal horns are installed at the front and rear on the superstructure. (Figure A ) Each signal horn can be activated separately. SAFETY INSTRUCTIONS! The signal horns serve to provide operating safety! Malfunctions must be reported immediately to the maintenance personnel. Operating Instructions To activate the signal horn at the front: Press button as long as you desire the sound. To activate the signal horn at the rear: Press button as long as you desire the sound. Note: As long as there are air pressure reserves, the signal horn function even when the ignition is switched off, i.e. when the crane is at standstill.

84 Signal Horns P-2/2 Figure A Horn Horn Button

85 Screen Wiper P-1/1 Front Wiper Description Front Wiper Button Roof Wiper Button The electrically operated screen wiper serves to clean the front and roof screens. The front screen and roof screen can be wiped.! SAFETY INSTRUCTIONS The signal horns serve to provide operating safety! Malfunctions must be reported immediately to the maintenance personnel. Operating Instructions: Front Screen: To switch on/ off the front screen wiper. * The front screen wiper is switched on and off by pressing the wiper switches Roof Screen * The roof screen wiper is switched on and off by pressing the wiper switches