140T Crane Maintenance Issues,AMC,

Spares Mgt,Trouble Shooting-Field

(Open Line)
 Objective
Name of components required
regular attention.
List instructions for maintenance of
these items.
Know about Annual Maintenance
Contract.
List the spares
Trouble shooting areas
 Introduction
To avoid Break Down of Crane
Regular cleaning
Continual inspection
Maintain scheduled preventive
maintenance.
 Maintenance schedule
Daily
Monthly or after 125 hours
Half-yearly or every 750 hours.
Yearly or every 1,500 hours.
Every Two years or every 3000 hours.
POH schedule after 8 years.
MLR after 6 years of Ist POH
COMPONENTS REQUIRED
REGULAR ATTENTION
Main Diesel Engine Photo
 Main Diesel Engine
Check
Lube oil pressure & temp. gauge,
Fuel indicator
Engine RPM
Battery charging ammeter
Water Temp. gauge
Abnormal noise during running
Air intake system
 Engine-Mtc
Check
Lube oil filter element
Fuel oil filter element
Check oil filter pollution indicator
V belts used in engine
Found any fault,call OEMs
representative.
POH done after 8 years by Cummins
India Ltd.
Filter Photo
Air Filter Hydraulic Filter
 Diesel Engine-AMC
Done by consignee with Cummins
India Ltd
Representative of OEM attended
quarterly
Check all datas as shown
Replace the item if required with its
cost.
 Battery
Check
Visually,
Clean & dry battery cover after 6
months
Clean cable conection terminals
Electrolyte level
Battery charging condition
Change battery after Two years.
 Hoses
Visual & functional check
End fitting,
Wearing of flange
Rubber portion.
Replace if any leakage found
Must change item in every POH
 Hydraulic Tank
Check
Visually,
oil level,
breather filter
Filter element
Oil contamination in Lab after every six
months
Change Hyd. Oil after Two years
 Hydraulic & Pneumatic
Fittings
Check
Visual & functional
End connections
Any crack/loose/leakage
Replace if required
Slewing Ring Photo
 Slewing Gear Box/Slewing
Ring
Slewing Gear Box
Running noise,
Oil level,
Bolt connections
Pinion & Gear wheel
Clean & grease
Roller Bearing slewing ring
Lubricate through grease gun.
Check stud connections.
 Air Pressure System
Air Pressure Tank
Visual check
Drain water after 6 months
Air Brake Cylinders
Functional Test
Clean & overwhaul if required
Air pr. Fine filter
Check filter element
Change if required.
 Wire Rope Defects

Broken Wires

Waviness

Bird cage
 Wire Rope Defects

Loop
deformation

Loose wires

Nodes
 Wire Rope Defects
Thining of the
rope

Kinks

Flat area
 Survey of Removal of Wire
Rope
Broken wires
5% of the total no. of wires in the rope in
10Xd
5 broken wires between two adjacent
strands within a length of 10Xd
15% reduction in diameter
Corrosion
Damaged due to heat
Rope deformation as shown
 Lifting Tackles-mtc
Mark strength wise for proper use
Check each & every link of the chain.
Check wire rope slings
String(any cut)
Rope deformations(bulging,twisting)
Corrosion
Check hook deformation & joint
fittings
Replace on condition basis
Lifting Tackles Photo
 Nylon Items
Nylon pulleys
Edge damage
Bearing damage
Groove worn out
Roller,Gliding plate
Worn out
Replace
 SLI Items
Main Hook Load
Sensor
Boom Angle Sensor
Slew Angle Sensor
Aux. Hook Load
Sensor
Display Board
Micro Processor
Chips(X1 Card)
SLI Items
 SLI System-mtc
Do not bypass SLI system during
operation.
Protect cards from dusts
Check functional test
If any error found,call OEM
representatives.
OEM-M/S PAT, Germany
M/S Mechanica, Pune.
M/S Hytec Micro Measurement,Delhi
SLI-AMC
 Suspension coil & disc
spring
Springs used in secondary
suspension
Coil
Disc
Change if required
Suppliers
M/S G.D. Spring,KKK for Coil Spring.
M/S Gala Precision Technology Ltd,Thane
for Disc
 Service Engineer Group
Function
Attend the crane at division & check
crane in running condition.
If any problem ocurrs, sort out it.
Check records for maintaining the crane
as per RDSO mannual
Staff-One engineer+ Four
technicians.
 POH & MLR
Schedule Time period Cumulative
life
EXISTING 1st POH 8 yrs 8 yrs
MLR 6 yrs 14 yrs
2nd POH 6 yrs 20 yrs
Condemn 6 yrs 26 yrs

REVISED 1st POH 8 yrs 8 yrs

2nd POH 6 yrs 14 yrs
MLR 6 yrs 20 yrs
3rd POH 8 yrs 28 yrs
Condemn 8 yrs 36 yrs
 Must Change Items during
POH
Pneu.Hoses of U/C,Nylon pad,Owa
seal,O-ring,Brake
shoes,Pins,Bushes,Hyd.
Gauges,Indicating lamps,Electric
wiring of SLI circuit & lighting,Coil &
Disc springs,Engine control
circuit,Sensors,Hyd. & Pneu. Filter
elements,HP-90 gear oil,HLP-68 Hyd.
Oil,15W40 Engine lub. Oil,Radiator
coolant.
Condition Basis During POH
Solenoidvalves, Major
pins,Pumps,Motors,Cylinders(Proppin
g,Outrigger,CWT,Axle
blocking,DUV),Pressure
Switch,Rotors,Hyd. Hoses,Wire
Ropes,PTO,Lamina brakes,Bearings in
gear boxes,Wheels & all other
components.
 Must Change Items During
MLR
All pneu. & hyd. Hoses
All wire ropes
All hyd. Pumps,motors,cylinders & valves
SLI Systems
Wheel disc,Major pins,Solenoid valves
Coil & Disc springs,Engine control units
Elec. Wiring,All filter elements,All hyd.
Oils
POH of Engine by CIL,Pune
 Spares-Category
Category A High value items
One crane set for each design
Category B Regular spares
20% of total population of each design
Category C Items for pneumatic
fittings
One crane set to be stored by Depot
 Spares Kept at Depot
Category C Pneumatic items(KNORR
make)
Oil filter,Filter element
VEBEO fittings
Hyd. & Pneu. Hoses
Bolster springs
Snubber springs
Seal kits
 Spares Kept at JMP
Workshop
Category A items
Hyd. Pumps(axial piston),Motors
Pump Distribution gear box,Control
Block
Valve plate,Oil air cooler
Wire Ropes-Main,Derrick,Aux.
Bearings,Hook Block Assly
Hoist & Gear Boxes,Hyd. Cylinders
SLI Items,Brake Cylinders,Wire Rope
Slings
 Category B Items
Pneumatic(valves,gauges,filters)
Hyd.(valves,gear pumps,gear
motors,filters)
Differential Cylinders,Seal Kits
Hydraulic & Pneumatic Hoses
Electrical Items
VEBEO fittings,Parker fittings
Rope Pulleys