For official use only ISO 9001-2000 Certified Organisation A POCKET BOOK on and for Operation and Maintenance of Jamalpur/Gottwald 140T DH Crane (Old Design) CRANE ORGANISATION EASTERN RAILWAY, LOCOMOTIVE WORKS JAMALPUR 1 811214
1 TO BRING THE CRANE IN TRAIN ORDER BEFORE LEAVING THE SHED: a) Travel gear should be in dis engaged position. b) Parking brake to be ON position. Crane brake should be c) released with indication as GREEN. d) Brake change lever should be put according to AIR or VACUUM brake system available with the locomotive. e) Boom should be locked in trestle. f) Filling of the air reservoir either by starting the engine or from out side agencies. g) All side-mounted platforms should be lowered and outriggers should be folded and locked properly. Do not leave axle blocking in ON position. Do not pull the crane when indication is RED, in any case. Do not leave the air reservoir empty in any case. / are Travel gear will get damaged and suspension system will not work. Air brake system will get damaged. The barking of crane will not be possible. 2
h) Check for hyd. oil, fuel oil, engine lub oil, radiator water level & oil level in all the gearboxes. i) Check function of aux. engine. Release the parking j) brake. 3 / are 2 RIGGING OF THE CRANE AFTER REACHING AT THE SITE: a) Before starting rigging check (i) size of the load to be lifted, (ii) required radius and (iii) required working cycle eg. hook height, slewing range, space for travelling the load etc. These should be in conformation with the load chart and with reference to the site condition for propping. b) All stop valves for hyd. lines should be opened before starting the engine. c) Before starting the engine check for hyd. oil, fuel oil, engine lub oil, radiator water level, oil level in all the gearboxes and battery water level. Do not leave any of the stop valves closed. Do not allow the hyd. level to go below the baffle plate level. The pumps may get damaged or the hyd. system will burst. Hydraulic pump may be affected.
d) After starting the engine check engine lub oil pressure and battery charging current. e) Check for pilot pressure, it must be 30 bars. f) Check for air pressure, it should like between 6.5 7.5 bars. 3 AXLE BLOCKING: a) Check for axle blocking pressure after giving line to U/Carriages, through preselector switch. It should be 240 bars. b) Ensure engagement of the travelling gear. c) Ensure application of brake confirmed by the RED indication. 4 BOOM ERECTION: a) Check for gallows frame fully lifted by giving line to counter weight gallows through pre-selector switch. b) Depute 2 staffs to go up and watch the reeving and unreeving of the derrick wire rope. c) Derrick N until boom heels sit on the pins. Do not level any air leakage in the system. Do not allow even slight leakage in the pipe of axle blocking cylinder. / are Air braking will be difficult. This will disturb the stability of the crane. 4
d) Secure A frame pin while the A frame is fully lifted. e) Remove boom lock from the jib trestle. f) Raise boom cautiously as per usual practice. 5 Do not leave A legs unlocked. 5 PROPPING THE CRANE : a) Set the propping pads Do not prop the properly on ground by crane on loose strengthening the ground. ground in any case Depute one staff on each prop to watch its movement. Check the level of the b) crane by spirit level. 6 COUNTERWEIGHT: a) Select the total counterweight with proper assessment of load, in consultation with the load chart. b) Switch on boom bridging key. 5-meter limit switch should remain activated. c) Switch off key switch, which bridges safe load indicator. The crane should not be allowed to slew in this condition. d) Pick up the CWT. One by one to have desired formation. Do not slew the crane under these conditions. / are The A frame may fall down causing accident. The prop may sink causing major accident eg. toppling of crane.
e) For only free on rail condition 5.2 tonnes cwt to be kept on chassis and 24T on the gallows, if std. wt. formation is to be used. f) For half propped & full propped condition the cwt. combination for 29.2 tonnes is (5.2 +6 +18).For full cwt 43.3 tonne (5.2+6+14+18) on gallows frame. g) Switch on S.L.I. switch key to bring the computer safely system back in the circuit. Check the correct mode of stability. h) Inter lock the cwt sections and boom out to 8 m radius. Then slew the superstructure by 180 deg. i) The engage the cwt on the gallows frames. j) Switch on boom key switch, so that 5.5 mm limit switch is in circuit. k) Check if safe load indicator is in operation. Don t interlock the cwt without putting proper spacers in between the links. / are CWT lifting may cause problem. 6
l) Correct mode of stabilisation is set on the selector switch of SLI system. m) Axle blocking pressure should be checked by a nominated person. It should be recharged to 240 bar, if required. n) After fixing cwt. on the crane, the crane should not be slewed unless correct propping base is selected on the mode selector on the display unit of the PAT system. o) Load chart affixed inside the cabin should be followed in toto. p) After gallows operation or axle blocking operation preselector switch for oil transmission should be brought O position. Do not miss to consult load chart in any condition of working. / are Crane may get damaged if the crane is on Free on rail but selector switch is set to propped condition The current may be subjected to unsafe working. 7
q) Before starting work make sure that computer override key and boom override key are switched to working position. r) Ensure cwt indicating lamps indicating correct cwt on gallows, when in operation. s) Manually operated modes switch showing correct outrigger basis is operational. 7 OPERATION: a) Ensure proper signalling to the crane driver. Driver should also ensure crosschecking the signal by ground staff with condition of load. b) Ensure firm and proper use of wire ropes and chains. c) Avoid jerk during operation. Penulum motion of load not permitted. Avoid diagonal pull of the load. Don t put load on the rope / tackle. / are 8
d) Don t pull loads which are stuck in the ground unless it is ensured that it will not offer resistance beyond the capabilities of the crane. e) Take care of high wind forces on the boom as it is dangerous. f) Do watch for trend of sub oil caving by watching the prop level and spirit level of the under frame of the crane. Avoid subsoil cave-in g) Lifting of load through derricking N should be avoided to the possible extent. 8 DERIGGING THE CRANE: a) Check axle blocking pressure to 240 bar. b) Unload cwt on the match Truck c) Leave 5.2 cwt on the chassis in the direction of match truck. / are 9
d) Boom out to 16 mm radius. At this point derricking out will be cut off by 16 m limit switch and PAT. e) Switch ON boom over bridge key. f) Switch ON computer over bridge key. g) Raise both hooks to limit position of derigging. h) Boom down until both hooks lower into match truck well. i) Continue to boom down causing hook block incline forward. j) Boom down so that boom head is approx. 40 cms higher than the rest position. k) Travel crane until boom rest pin matches with the recess in boom rest. l) Boom down until boom slides fully into the boom rest to the lock position. m) At this point, lock the boom in the boom rest n) Raise cwt gallows to full height. / are 10
o) Fasten the A frame hind bottom leg with cwt gallows by link rope arrangement. p) Remove pins from A frame. q) Boom out to give small amount of slack in derrick ropes. r) Lower cwt gallows which will result in A frame going over the centre, which will facilitate further fold. s) Raise gallows fully. t) Remove link rope arrangement. u) Further derrick out till A frame front rests on the top of raised gallows. w simultaneously derrick out and lower gallows till gallows sit on their desired position on super structure. v) Continue to derrick OUT while lowering A frame arms into locking rest position on crane chassis. Do not fold crane without opening out the pin lock from A frame legs. Do not forget to book staff for watching the reeving /unreeving of ropes. / are Gallows frame may be damaged. Wire rope may be damaged if entrapped in between the drum and the frame. 11
w) Derrick out untill the ropes are slack over the operator s cab. This derricking out should be retrcted by minimum number of turns on drum limit switch ( the setting should be for slackness just adequate to negotiate designed track curve) 9 PREPAIRING CRANE FOR TRANSPORT: a) Parking brake ON b) Brake hoses should be connected as per the requirement. Brake change over lever of match truck and brake handle in the crane under carriage to be set as per requirement. c) Axle blocking released. d) Release parking brake in the last when the crane is going to be formed in train order. Do not forget releasing brake. 10 MAINTENANCE CHECKING OF ENGINE: a) Engine should be maintained as per manufacture s Maintenance Schedule. / are 12
11 MAINTENANCE OF HYDRAULIC SYSTEM: a) Clean hoses and area, around the equipment, to Do not open the hyd. system in a be opened. dirty Clean the tray in which the open parts are kept. b) Do not over tighten any leaking joints provided with O rings/ seals. c) Connected isolating valves must be closed before opening out any hoses. d) Ensure that no water is mixed with the hyd. oil in the tank. Oil should be tested in lab as per guideline given in the maintenance manual. 12 ATTENTION TO WIRE ROPE: a) Replace wire ropes when there is a diametrical reduction in its size by 5% or more with respect to its normal diameter. b) Replace wire rope if there is any bend, kink, abrasion, and uncoiling or heavy corrosion. / are 13
c) While reeving / unreeving the wire rope on the drum a person/ operator must be watchful so that there is no overlapping of wire ropes, which may cause damage to the wire rope. d) Proper greasing of wire rope around fitting clamps / sockets should be done. / are Corrosion of wire rope will take place. 13 MAINTENANCE PRECAUTION FOR SAFETY DEVICES: a) All limit switches; force and angle sensors must Don t disturb the switching point of be cabled. the limit switches. Damaged cables must immediately be replaced. They should always be kept operational. b) The crane axis must be vertically levelled. c) Check all limit switches Do not operate when rigging to ensure computer over their functioning. bridge key and boom over bridge key during crane working. These are slowly for use during rigging / de-rigging. 14
d) The safe load indicator does not relieve the crane user from his responsibility to thoroughly determine the weight of the load to be lifted and check the admissibility of the operation according to be lifting chart. e) Do not keep the electric solenoid valves for cut off function bridged. / are 15