maintenance manual new part-i

1997 DESIGN 140T GOTTWALD/JAMALPUR CRANE ISSUE 1997

Railway Crane

User’s Manual

Maintenance


Railway Crane Maintenance Manual

Table of Contents (P-1/3)

1. General Notes 1.1 Preface 1.2 General Safety Instructions 1.3 Legend for Notices, Danger and Prohibiting Signs

2. Crane Specifications 2.1 Technical Data 2.2 Crane General Drawing

3. Instructions on How to Use this Maintenance Manual 3.1 Instructions on How to Use this Maintenance Manual 4. Check Lists for Maintenance 4.1 Daily Maintenance 4.2 Monthly Maintenance 4.3 Semi-Yearly Maintenance or every 750 hours 4.4 Yearly Maintenance or every 1,500 hours 4.5 Maintenance Every 2 years or 3,000 hours 5. Maintenance Instructions 5.1 Electrical System 5.1.1 Switch Cabinets 5.1.2 Junction Boxes and Cableways 5.1.3 Batteries 5.1.4 Three-Phase Generator 5.1.5 Three-Phase Generator on the Emergency Diesel Engine 5.1.6 Hoist and Lowering Limit Switches 5.1.7 Safe Load Indicator 5.1.8 Lighting and Socket 5.2 Hydraulic System 5.2.1 Main Pumps 5.2.2 Secondary Pumps 5.2.3 Hydraulic Oil Tank 5.2.4 Slewing Gear Pump Filter 5.2.5 Rotary Lead-Through 5.2.6 Suspension Blocking Cylinders 5.2.7 Undercarriage Control Blocks 5.2.8 Outrigger Cylinders 5.2.9 Hoist, Derricking Gear, Slewing Gear and Travel Gear Motors 5.2.10 Superstructure Control Blocks 5.2.11 Counterweight Cylinders 5.2.12 Boom Root Point Cylinder




5.3 Air Pressure System 5.3.1 Air Pressure Tank 5.3.2 Brake Cylinder 5.3.3 Brake Couplings 5.3.4 Air pressure Fine Filter 5.3.5 Brake Pedal 5.3.6 Signal Horns 5.3.7 Undercarriage Air Pressure Compressor 5.3.8 Pressure Regulator 5.4 Diesel Engine System 5.4.1 Diesel Engine 5.4.2 Exhaust System 5.4.3 Fuel System 5.4.4 Diesel Engine Accelerator 5.4.5 Pump Distributor Gear Box 5.5 Emergency Diesel Engine System 5.5.1 Emergency Diesel Engine

5.6 Travel and Running Gear 5.6.1 Travel Reduction Gear Unit 5.6.2 Pinion and Gear Wheel 5.6.3 Disengaging Devices 5.6.4 Wheel Sets 5.6.5 Wheel Set Bearings 5.6.6 Spring suspension 5.6.7 Expander-Operated Brake Disks 5.6.8 Brake Cylinder Adjuster Units 5.6.9 Brake System

5.7 Cab 5.7.1 Cab 5.7.2 Control Panels 5.7.3 Screen Wash/Wiper System 5.7.4 Fan 5.7.5 Seat 5.7.6 Additional equipment

5.8 Slewing Gear 5.8.1 Slew Reduction Gear Unit 5.8.2 Pinion and Gear Wheel 5.8.3 Roller Bearing Slew Ring 5.9 Main Hoist 5.9.1 Main Hoist Reduction Gear Unit including Brake 5.9.2 Rope Drum




5.10 Auxiliary Hoist 5.10.1 Auxiliary Hoist Reduction Gear Unit including Brake 5.10.2 Rope Drum 5.11 Derricking Gear 5.11.1 Derricking Reduction Gear Unit including Brake 5.11.2 Rope Drum 5.11.3 Rope Pulleys and Rope Guide on the Superstructure 5.12 Recovery Winch 5.12.1 Recovery Winch including Brake 5.12.2 Rope Drum 5.12.3 Deflection Rollers

5.13 Basic Construction 5.13.1 Steel Construction 5.13.2 Paintwork 5.13.3 Protective Housing and Panelling 5.13.4 Stairways, Footboards and Supporting Straps 5.13.5 Counterweights 5.13.6 Outrigger Beams 5.13.7 Outrigger Pads 5.13.8 Signs and Labelling 5.13.9 Tool Kit 5.13.10 Superstructure Locking Device 5.13.11 Bogies

5.14 Boom 5.14.1 Boom and Root Point 5.14.2 Rope Pulleys 5.14.3 Rope Guides 5.14.4 Boom Support Block

5.15 Ropes and Lifting Gear 5.15.1 Ropes 5.15.2 Hook Blocks

6. Fuel, Oil and Lubricant Chart

7. Torque Moments 8. Maintenance Diagrams 8.1 Undercarriage Maintenance Diagram 8.2 Superstructure Maintenance Diagram 8.3 Boom Maintenance Diagram

9 Subsupplier Documentation



General Notes 1 (P-1/1)

1.1 Preface

1.2 General Safety Instructions

1.3 Legend for Notices, Danger and Prohibiting Sings



Preface 1.1 (P-1/1)

Proper and regular maintenance work as laid down in the Maintenance Manual is essential for smooth crane operation. Maintenance work as well as additionally required materials are not warranty services.

For this reason, the maintenance instructions should always be available for the operating and maintenance personnel. This is especially important as otherwise incorrect or irregular maintenance can cause considerable damage which is not covered by the warranty. Consequently, read the Maintenance Manual before you begin maintenance work and act according to the information in the various sections.

However, not only for cost- effectiveness, but also for safety reasons, regular and proper maintenance of the crane is absolutely imperative. Only a crane, which is in proper technical order can ensure that persons will not be injured and property not damaged.

Observe without fail all the safety instructions provided during maintenance work. With caution and adherence to the relevant instructions, accidents can be prevented. As not all the same precautions apply for all work, special safety instructions are specified before each individual description.

The Safety Instructions are accentuated with a warning sign.

Observe the Lubricants Chart in the Maintenance Manual when you carry out maintenance work. Use only the fuel, oil and lubricants listed in the chart. The application of unsuitable lubricants and fuels can lead to considerable consequential damage, which is not covered under our warranty. Therefore, please read the Maintenance Manual before you carry out such work. Likewise observe and read the manuals which we have provided and to which reference are made in various sections of this Maintenance Manual.

We have endeavoured to produce clear and comprehensible Maintenance Instructions. When

you have read the “Instructions on how to use this Maintenance Manual” and adhere to the sequence of the Check Lists, you will easily find and be able to carry out the various Maintenance Points.

This Maintenance Manual was drawn up based on all the information available at hand at the

time of despatch. Should any changes, retrofits or modifications have occurred since then, which must be added, the owner must insure that documentation is provided or altered to accommodate these differences by the company provided subsequent services or additional equipment.



General Safety Instructions 1.2 (P-1/2)

Proper and Due Operation The GS 140.08 H has been designed exclusively for crane work. This means that, for

example, conveyance of loads or persons is not permissible. In crane operation, only one person per seat may be conveyed with the crane.

Only lifting gear and accessories, which have been supplied or approved expressly by the crane

manufacturer, may be used. It is prohibited to use the crane for any other purpose other than for what is was designed.

It is assumed that the ambient conditions for the working Zone of the crane meet the

requirements so that the data provided in “Technical Data” can be adhered to without any danger occurring.

Caution! - Please note the various lifting capacities for the individual mode of operation. These

lifting capacities can be found in the section “Technical Data” and in the Lifting Capacity Charts.

In addition, it should be noted that the information provided here applies, in particular, to your

crane, i.e. cranes of the same type can have different features. Limit switches must not be bridged. Mean figures for outside temperature; air humidity and

degree of dust have been used as a basis for these data. Should the figures be higher, the maintenance intervals must be stepped up accordingly.

Observe all the information provided by the respective lifting gear manufacturer.

In addition, ensure that all the pertaining statutory safety regulations are observed during all work! Observe all the information provided by the manufacturer when system requiring monitoring are operated or serviced. Use of Skilled Personnel Maintenance, service and repairs may only be carried out by specially trained or initiated personnel. It must be ensured that the skilled personnel engaged not only have the corresponding technical knowledge, but in addition are also informed regarding all relevant Safety and Prevention of Accident Directives and can apply same. Furthermore, the persons selected by the operating company must be qualified for the work they are to perform. Standing in the slewing range is prohibited. Likewise unauthorised persons must not be in or on the crane during operation, including travel operation. Loads must be lifted properly, i.e. diagonal pull and breaking loose of loads is prohibited.



General Safety Instructions 1.2 (P-2/2)

Special safety instructions have been indicated in advance of the specific instructions for

maintenance work in this Maintenance Manual. These instructions are to be interpreted as a supplement and do not exclude the general safety instructions mentioned!

Before any work is carried out on the electrical system, ensure that the system is not under power, i.e. the auxiliary power supply is not connected and the diesel engine are switched off. It must be ensured that all the above equipment is safeguarded against starting. Should the power supply have to be established again for functional checks, ensue that the complete power supply is switched off again before work is resumed.

Please note that when work is performed on the hydraulic system, the system is under pressure and the hydraulic oil is hot. Ensure the systems are not under pressure before work is carried out on the air pressure or hydraulic systems. When subjected to fire or naked light, hydraulic oil is inflammable. As the crane must be operational for pressure, temperature and leakage checks, there is a high degree of danger involved. During or after maintenance work in the crane, the pre-set hydraulic pressures must not be altered. Special qualified personnel and utmost care for this work are essential. Before maintenance work is started, ensure that the crane cannot be switched on by unauthorised persons and is secured against rolling.

Caution! Certain parts of the system are still under pressure even when the crane is at a standstill.

Please bear in mind when releasing connections that higher mounted components could drain dry. In these cases, ensure an adequately sized drip pan is available, so that no environmental damage can occur through un-controlled oil running out.

Ensure without fail that waste oil from the hydraulic system, diesel engine and the emergency diesel engine and the condensation containing oil from de-airing and cleaning work is disposed of according to regulations!

Special caution is required when maintenance work is carried out on the diesel engine or the

emergency diesel engine directly after operation. Engine oil, engine housing and exhaust system are still hot. As the crane must be operational for functional and sealing tests, there is an increased degree of danger as with the hydraulic system. As a rule, when work to the diesel engine system is carried out, ensure that the engine cannot be started by unauthorised persons. The diesel engine and the emergency diesel engine must not be operated in enclosed areas- Danger of asphyxiation through exhaust fumes!

No smoking, no naked flame or light, sparks or glowing ashes near the fuel or diesel engine system- Danger of explosion and fire!

It is forbidden to climb up onto the crane when the crane is in operation. In addition, ensure that all respective statutory safety regulations are observed during all work! This applies, in particular, to tests on the tank and pipe systems. The maintenance and overhaul work performed in relation to this manual do not exclude the currently applicable maintenance and servicing regulations set down by the railway administration and consequently these regulations must also always be observed.



Legend for Notices, Danger and Prohibiting Signs 1.3 (P-1/1)

Keep out of the slewing range

Keep out of the slewing

range



Crane Specifications 2 (P-1/1)

2.1 Technical Data

2.2 General Crane Drawing including Dimensions



Technical Data 2.1 (P-1/3)

Dimensions Track gauge 1.676mm Rim diameter in new condition 920mm Wear limit 840mm Wheel Set arrangement (2A)( A2) Distance between bogie pivots 7,500mm Distance between twin wheel set 3,000 (1,500) mm Length ahead of buffer 13,290mm Draw and buffing gear side buffers and screw couplings Minimum Travel able curve 175mm Maximum towing speed 100 km/h Maximum wheel set load 200 kN Total weight in train formation 120.0 t Height in transport position 3,900mm Width in transport position 3,100mm Elevated curves 140 mm Brake System Primary Dual –VD-P-12 x 10 m.Z. Secondary 12 wheel disk-operated brakes Ø 780 mm Parking brake spring-loaded brakes on 6 wheels sets Outriggers Base 11.6m x 6.0m Maximum support force 2,200 kN Outrigger cylinder stroke 500 mm Free on wheels base 7.5mm x 1.7mm Maximum wheel force 350 kN Travel Gear Driven wheel sets on each bogie 1 Speed 20 km/h Superstructure Cab 1 seat/and 1 emergency seat Over-rear radius 5.5m/6.5m Diesel Engine Type Cummins NTA 855 Model 6-cylinders in series Water-cooled Exhaust turbo charger Out put 205 kW at 1,800 rpm Torque 1,158 Nm at 1,400 rpm Cubic capacity 1,400 ccm Fuel supply 900 l Generator 28 V 55 A




Emergency Diesel Engine Type Kirloskar HA 294 Model 2- Cylinder in series Air cooled exhaust turbo charger Output 16.9 kW at 1.800 rpm Cubic capacity 1,884 ccm Main Hoist Type 3-stage planetary hoist with spring-loaded multi disk brake Rope diameter 26mm Rope speed max- 72m/min. Hoist speed max- 4m/min. Hook block 18 strand 140 t Hoist range above track 17.0 m below track 4.0 m Auxiliary Hoist Type 2- stage planetary hoist with spring-loaded multi disk brake Rope diameter 22 mm Rope speed max- 60m/min. Hoist speed max- 15m/min. Hook block 4 strand 25 t Hoist range above track 18.0 m below track 3.0 m Slewing Gear Type 3-stage planetary hoist with spring-loaded multi disk brake Roller slew ring with external teething Superstructure speed 0-1.0 rpm Derricking Gear Type 3- stage planetary hoist with spring-loaded multi disk brake Rope diameter 26 mm Rope speed max- 28m/min. Derricking Time approx – 165 s Rope tension 2 x 14 strand 2,200 kN Counterweight

3 Sections Slab 1 (transported on the Match Truck) 24.0 t Slab 2 (transported on the Match Truck) 15.0 t Slab 3 (transported on the undercarriage) 8.0 t Boom Length to the main hook 18.75 m Length to the auxiliary hook 19.5 m Main hook working range 5.5 m- 17.0 m Auxiliary hook working range 6.5m - 18.0 m




Match Truck Length beyond buffer 16.0 m

Distance between Wheel Set 2.0 m

Track gauge 1,676 mm

Distance between bogie pivots 11.30 m

Draw and buffing gear side buffers and screw couplings

Turing Radius 175 m

Maximum towing speed 100 km/h

Maximum wheel set load 200 kN

Total Weight loaded 80.0 t

1997 DESIGN 140T GOTTWALD/JAMALPUR CRANE

Railway CraneMaintenance Manual

Crane General Drawing

1997 DESIGN 140T GOTTWALD/JAMALPUR CRANE

Railway Crane Manual

Crane General Drawing

ISSUE 1997

2.2 (P-1/1)



Instructions on How to use this Maintenance Manual 3 (P-1/1)

3.1 Instructions on How to use this Maintenance Manual



Instructions on How to use this Maintenance Manual 3.1 (P-1/1)

This Maintenance Manual is compiled in such a way that by folding out the side wings you have the most important components in front of you without unnecessary skimming the pages to and fro. All sections drawn up in the manual have been numbered. This numbering is maintained throughout, which means that in the respective section number applies to the same components or function in the Table of contents, the Maintenance Check Lists, the Instructions and the Maintenance Diagrams. 4. Check Lists 5. Maintenance Instructions 8 Maintenance Diagram

Fold out the he checklist to the

Left. You will find all the maintenance points itemised according to catchwords here. In addition, the check and safety instructions can be found here.

In the skim-through middle section of the Maintenance Manual, all maintenance functions are explained in detail.

The text passages on the right hand side refer to the adjoining photos on the left-hand side (same section numbering).

In several text passages, additional position numbers are specified, e.g. Item .1; the 1 you will find on an arrow in the adjoining photo.

In addition the safety Instructions specified here, observe also without fail the General Safety Instructions indicated in section 1.2.

Fold out the Maintenance Diagram successively to the right. You will find the location of all the positions numbers listed in the check lists and the Maintenance instructions here. The colours used in the diagram represent the following assemblies: Diesel Engine system

Emergency diesel system

Electrical system

Hydraulic system

Air pressure system

Travel and running gears

Cab

Hoists

Derricking gears

Recovery winch

Boom basic construction

Ropes


Slewing gear/ Slew ring


Check Lists for Maintenance 4 (P-1/1)

0.1 Check List for Maintenance, daily

0.2 Check List for Maintenance, monthly order every 125 hours

0.3 Check List for Maintenance, semi –yearly or every 750 hours

0.4 Check List for Maintenance, Yearly or every 1,500 hours

0.5 Check List for Maintenance, every 2 years or every 3000 hours



(P-1/3) 4.1 Check List for Maintenance daily

Maintenance Point Type of Maintenance

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Electrical System 5.1.4 3-phase generator 5.1.5 3-phase generator on the

Emergency diesel engine 5.1.6 Hoist/ derrick-in limit

switches 5.1.6 Lowering/derrick-out

limit switches 5.1.7 Safe load indicator 5.1.7 Lighting and sockets Hydraulic System 5.2.1 Main pumps 5.2.2 Secondary pumps 5.2.3 Hydraulic oil tank 5.2.4 Slewing gear pump filter 5.2.5 Rotary lead- through 5.2.6 Spring suspension

blocking cylinders 5.2.7 Control blocks in the

undercarriage 5.2.8 Outrigger beam cylinders 5.2.9 Hoist, derricking, slewing

+ travel gear motors 5.2.10 Control blocks in the

superstructure 5.2.11 Counterweight cylinders 5.2.12 Boom root point cylinder

Air Pressure System

5.3.1 Air pressure tanks 5.3.2 Brake cylinders 5.3.3 Brake couplings 5.3.4 Air pressure fine filter 5.3.5 Brake pedal 5.3.7 Air pressure compressor

in the undercarriage

Visual check. Visual check. Visual check. Visual check. Visual check. Functional test. Visual check. Visual check. Visual check. Visual check. Check oil level. Visual check Check oil filter pollution indicator; If required, replace filter element. Visual check. Visual check Functional test. Visual check. Functional Test Visual check. Visual check. Visual check. Visual check Visual check Visual check Visual check Visual check Visual check Visual check Visual check Check oil level

O K



(P-2/3) 4.1 Check List for Maintenance daily


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Diesel Engine System 5.5.1 Diesel Engine 5.5.2 Exhaust system 5.5.3 Fuel system 5.4.4 Accelerator 5.4.5 Pump distributor gear boxes Emergency Diesel Engine 5.5.1 Emergency diesel engine Travel and Running Gear 5.6.1 Travel reduction gear units . 5.6.2 Pinions and gearwheels 5.6.3 Disengaging devices 5.6.4 Wheels sets 5.6.7 Brake disks 5.6.8 Brake expanders 5.6.9 Brake system Cab 5.7.1 Cab 5.7.2 Control panels 5.7.3 Screen wiper and wash

system

Visual Check Check oil level. Check coolant level + concentration Check fan belt condition and tension. Weekly checks: Check air filter pollution indicator Check air intake hoses, pipes and clamps Visual check Visual check Visual check Visual check Check running noises. Check oil level Visual check Check oil level Check fuel pump oil level Visual check Visual Check Visual check Visual check Visual check Functional test ( Inspection A ) Visual check Functional Test ( Inspection A) Visual check Functional Test Visual check Visual check Visual check Check wash water Functional test

A B E C C



(P-3/3) 4.1 Check List for Maintenance daily Maintenance Point Type of Maintenance

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Basic Construction 5.13.1 Steel construction 5.13.5 Counterweight 5.13.6 Outrigger beams 5.13.7 Outrigger pads 5.13.10 Superstructure locking .

device 5.13.11 Bogies Boom 5.14.1 Boom and boom root point 5.14.2 Rope pulleys 5.14.3 Rope guides

Ropes 5.15.1 Ropes 5.15.2 Hook block

Visual check Visual check Visual check Visual check Visual check Visual check Visual check Visual check Visual check Check rope condition as per inspection criteria Visual check



(P-1/6)

4.2 Check List for Maintenance monthly or after 125 hours


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Electrical System 5.1.1 Superstructure switch

cabinets 5.1.2 Junction boxes and cable

ways 5.1.3 Batteries 5.1.4 3-phase generator 5.1.5 3-phase generator on the

emergency diesel engine 5.1.6 Hoist/derrick-in-limit

switches 5.1.7 Lowering/derrick-out limit

switches 5.1.8 Safe load indicator 5.1.9 Lighting and sockets

Hydraulic System 5.2.1 Main Pumps 5.2.2 Secondary pumps 5.2.3 Hydraulic oil tank 5.2.4 Slewing gear pump filter 5.2.5 Rotary lead – through 5.2.6 Spring suspension blocking

cylinder 5.2.7 Control blocks in the

undercarriage 5.2.8 Outrigger beam cylinders 5.2.9 Hoist, derricking, slewing+

travel gear motors

Visual check. Visual check. Visual check. Visual check. Visual check. Visual check. Functional test. Visual check. Functional test. Visual check. Functional test Visual check. Clean. Functional test. Visual check. Check running noises. Visual check. Check running noises. Visual check. Check oil level. Check oil filter pollution indicator. If required, replace filter element. Visual check. Check oil level. Check oil filter pollution indicator. If required, replace filter element. Visual check. Visual check. Functional test. Visual check. Functional test. Visual check. Visual check. Check running noises.

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(P-2/6)



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5.2.10 Superstructure control blocks 5.2.11 Counterweight cylinders 5.2.12 Boom root point cylinder

Air Pressure System 5.3.1 Air pressure tanks 5.3.2 Brake cylinders 5.3.3 Brake couplings 5.3.4 Air pressure fine filter 5.3.5 Brake pedal 5.3.6 Signal horns 5.3.7 Air pressure compressor in

the undercarriage 5.3.8 Pressure regulator

Diesel Engine System 5.4.1 Diesel engine 5.4.2 Exhaust system 5.4.3 Fuel system

Visual check. Visual check. Cleanse and grease. Functional test Visual check. Cleanse and grease. Functional test Visual check Visual check. Functional test. Visual check Visual check Check fine filter element; If required, replace Visual Check Clean Visual Check Functional Test Visual check Check oil level Check air filter, if required, replace filter element. Lubricate lube nipple on compressor shaft. Visual check Functional Test Visual check. Check oil level. Check coolant level+ concentration Check fan belt condition and tension. Weekly checks: Check air filter pollution indicator Check air intake hoses, pipes and clamps. Change oil. Change oil filter elements. Change fuel filter elements. Clean or change crank house ventilation. Change DCA coolant filter. Visual check. Visual check. If required, replace any damaged fuel lines.

P P K O A B A



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5.4.4 Accelerator 5.4.5 Pump distributor gearboxes Emergency Diesel Engine 5.5.1 Emergency diesel engine Travel and Running Gear 5.6.1 Travel reduction gear units 5.6.2 Pinions and gear wheels 5.6.3 Disengaging devices 5.6.4 Wheels sets 5.6.5 Wheel set bearings 5.6.6 Spring suspension system 5.6.7 Brake disks 5.6.8 Brake expanders 5.6.9 Brake system

Visual check. Functional test Visual check. Check running noises. Check oil level. Check bolt connection. Visual check Check oil level Change oil Replace lube oil filter Clean fuel strainer Check fuel pump oil level Clean air filter. Check and clean exhaust system Check fan belt tension; if required, adjust. Replace fuel preliminary filter element Replace fine filter element Check mounting elements. Check starter and generator Check valve clearance; if required, adjust. Functional test. Visual check Check oil level Visual check Visual check Visual check Visual check Visual check Visual check Functional test (Inspection A). Visual check Functional test (Inspection A). Visual check Clean Check emergency release function Functional test

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Cab 5.7.1 Cab 5.7.2 Control panels 5.7.3 Screen wiper and wash

system 5.7.4 Fan 5.7.5 Seat 5.7.6 Additional equipment Slewing Gear 5.8.1 Slew reduction gear unit

incl. brake 5.8.2 Pinions and gearwheels 5.8.3 Roller bearing slew ring Main Hoist 5.9.1 Main hoist reduction gear

unit incl. Brake 5.9.2 Rope drum

Visual check Clean. Clean and grease door and Carry out functional test. Visual check Clean Visual check Check wash water Functional test Visual check Clean Functional test Visual check Check side tracks Visual check Functional test Visual check Check running noises Check oil level Check bolt connections Check breather filter, if required, replace Visual check Cleanse and grease Visual check Lubricate Check bolt connection Visual check Check running noises Check oil level Check bolt connections Visual check Check rope clamps.

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Auxiliary Hoist 5.10.1 Auxiliary hoist reduction

gear unit incl. Brake 5.10.2 Rope drum Derricking Gear 5.11.1 Derricking reduction gear

unit incl. Brake 5.11.2 Rope drum 5.11.3 Pulleys and rope guides

on the superstructure Recovery Winch 5.12.1 Recovery winch reduction

gear unit incl. Brake 5.12.2 Rope drum 5.12.3 Deflection rolls Basic Construction 5.13.1 Steel construction 5.13.2 Paintwork 5.13.3 Protective housing

+panelling 5.13.4 Stairways, footboards and

holding straps 5.13.5 Counterweight 5.13.6 Outrigger beams 5.13.7 Outrigger pads

Visual check. Check running noises. Check oil level. Check bolt connections. Visual check Check rope clamps. Visual check. Check running noises. Check oil level. Check bolt connections. Visual check Check rope clamps Visual check. Functional test. Visual check. Check running noises. Check oil level. Check bolt connections. Visual check Check rope clamps Visual check. Functional test. Visual check. Visual check. Clean. Visual check. Clean Visual check Visual check Visual check Lubricate Functional test Visual check Cleanse and grease

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5.13.8 Signs and labelling 5.13.9 Tool kit 5.13.10 Superstructure locking

device 5.13.11 Bogies Boom 5.14.1 Boom and boom root point 5.14.2 Rope pulleys 5.14.3 Rope guides 5.14.4 Boom support Ropes 5.15.1 Ropes 5.15.2 Hook Block

Visual check Check inventory Visual check Cleanse and grease Visual check Lubricate Check side bearing clearance Visual check Visual check Lubricate Functional test Visual check Clean Functional test Functional test Cleanse and grease Check rope condition as per inspection criteria Cleanse and grease Functional test Visual check

Q Q Q Q Q



P-1/8

4.3 Check List for Maintenance semi- yearly or every 750 hours


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cabinets 5.1.2 Junction boxes and

cableways 5.1.3 Batteries 5.1.4 3-phase generator 5.1.5 3-phase generator on the

emergency diesel engine 5.1.6 Hoist/derrick-in limit

switches 5.1.6 Lowering/derrick-out limit . switches 5.1.7 Safe load indicator 5.1.8 Lighting and sockets Hydraulic System 5.2.1 Main pumps 5.2.2 Secondary pumps 5.2.3 Hydraulic oil tank.

Visual check. Clean. Visual check. Visual check. Clean and dry battery cover. Clean cable connection terminals, grease with pole grease and check for firm seating. Visual check. Visual check. Visual check. Functional test Visual check Clean Functional test. Visual check. Functional test Visual check. Clean Functional test Visual check Check running noises Check pressure gauges Visual check Check running noises Check pressure gauges Visual check Check oil level Check breather filter Check oil filter pollution indicator If required, replace filter element

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(P-2/8)



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5.2.4 Slewing gear pump filter 5.2.5 Rotary lead-through 5.2.6 Spring suspension blocking . cylinders 5.2.7 Control blocks in the . . undercarriage 5.2.8 Outrigger beam cylinders 5.2.9 Hoist, derricking, slewing + . . travel gear motors 5.2.10 Control blocks in the

superstructure 5.2.11 Counterweight cylinders 5.2.12 Boom Root point cylinder Air Pressure System 5.3.1 Air pressure tanks 5.3.2 Brake cylinders 5.3.3 Brake couplings 5.3.4 Air pressure fine filter 5.3.5 Brake pedal 5.3.6 Signal horns 5.3.7 Air pressure compressor in the . . undercarriage 5.3.8 Pressure regulator

Visual check. Check oil filter pollution indicator; If required, replace filter element. Visual check. Visual check. Functional test. Visual check. Functional test. Visual check. Visual check. Check running noises. Visual check. Visual check. Cleanse and grease Functional test Visual Check Cleanse and grease. Functional Test Visual check Drain water Visual check Functional test Visual check Visual check Check fine filter element; if required, replace Visual check Clean Visual check Functional test Visual check Check oil level Change oil

Che Check air filter; if required, replace filter element Lubricate lube nipple on compressor shaft. Visual check Functional test

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Diesel Engine System 5.4.1 Diesel engine 5.4.2 Exhaust system 5.4.3 Fuel system 5.4.4 Accelerator 5.4.5 Pump distributor gearboxes

Visual check Check oil level Check coolant level+ concentration Check fan belt condition and tension Weekly checks: Check air filter, pollution indicator Check air intake hoses, pipes and clamps Change oil Change oil filter elements Change fuel filter elements Clean or change crank house ventilation Change DCA coolant filter Visual check Visual check If required, replace any damaged fuel lines Check tank cover Drain condensation water. Visual check Functional test Visual check Check running noises Check oil level Carry out oil analysis Clean vent filter Check bolt connections

A B A E



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Emergency Diesel Engine 5.5.1 Emergency diesel engine Travel and Running Gear 5.6.1 Travel reduction gear units 5.6.2 Pinions and gear wheels 5.6.3 Disengaging devices 5.6.4 Wheel sets 5.6.5 Wheels set bearings 5.6.6 Spring suspension system 5.6.7 Brake disks 5.6.8 Brake expanders

Visual check. Check oil level. Change oil. Replace lube oil filter. Clean fuel strainer. Clean air filter. Check and clean exhaust system. Check fan belt tension; if required, adjust. Replace fuel preliminary filter element. Replace fine filter element. Check mounting elements Check starter and generator. Check valve clearance, if required, adjust. Functional test Visual check Check oil level Clean gear unit exterior Check vent; if required, clean Visual check Clean Grease. Visual check Check air pressure cylinders Functional test Visual check Check mountings Visual check Visual check Clean Visual check Functional test ( Inspection A ) Visual check Functional test ( Inspection A )

C C C C E Q



(P-5/8)



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5.6.9 Brake system Cab 5.7.1 Cab 5.7.2 Control panels 5.7.3 Screen wiper and wash system 5.7.4 Fan 5.7.5 Seat 5.7.6 Additional equipment Slewing Gear 5.8.1 Slew reduction gear unit incl. . brake

5.8.2 Pinions and gearwheels 5.8.3 Roller bearing slew ring

Visual check Clean Check emergency release function Functional test Visual check Clean Clean and grease door and carry out functional test. Eliminate paintwork damage. Visual check Clean Visual check Check wash water Functional test Visual check Clean Functional test Visual check Check slide tracks Visual check Functional test Visual check Check running noises Check oil level Carry out oil analysis. Check bolt connections Check breather filter; if required, replace. Visual check Cleanse and grease Visual check Lubricate. Check bolt connections

L O P



(P-6/8)



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Main Hoist 5.9.1 Main Hoist reduction gear . unit incl. Brake

5.9.2 Rope drum Auxiliary Hoist 5.10.1 Auxiliary hoist reduction gear . unit incl. Brake 5.10.2 Rope drum Derricking Gear 5.11.1 Derricking reduction gear. . unit incl. Brake 5.11.2 Rope drum 5.11.3 Pulleys and rope guides on

the superstructure

Recovery Winch 5.12.1 Recovery winch reduction. . gear unit incl. Brake

Visual check Check running noises Check oil level Carry out oil analysis. Lubricate counter bearing lubrication nipple Check bolt connections Visual check Check Rope clamps Visual check Check running noises Check oil level Carry out oil analysis Lubricate counter bearing lubrication nipple Check bolt connections. Visual check Check rope clamps Visual check Check running noises Check oil level Carry out oil analysis. Lubricate counter bearing lubrication nipple Check bolt connections Visual check Check rope clamps Visual check Functional test Visual check Check running noises Check oil level Carry out oil analysis. Check bolt connections

L M L M L M L



(P-7/8) 4.3 Check List for Maintenance semi- yearly or every 750 hours


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5.12.2 Rope Drum 5.12.3 Deflection rolls Basic Constructions 5.13.1 Steel construction 5.13.2 Paint work 5.13.3 Protective housing +

panelling 5.13.4 Stairways, footboards and

holding straps 5.13.5 Counterweight 5.13.6 Outrigger beams 5.13.7 Out rigger pads 5.13.8 Signs and labelling 5.13.9 Tool kit 5.13.10 Superstructure locking

device 5.13.11 Bogies

Visual check Check rope clamps Visual check Functional test Visual check Visual check Eliminate paintwork damage Clean Visual check Eliminate paint work damage Check hinges, locks and storm hooks Clean Visual check Eliminate paintwork damage Visual check Eliminate paintwork damage Visual check Eliminate paintwork damage Lubricate Functional test Visual check Cleanse and grease Visual check Check inventory Visual check Cleanse and grease Eliminate paintwork damage Visual check Eliminate paint work damage Lubricate Check side bearing clearance

Q Q Q Q



(P-8/8)



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Boom 5.14.1 Boom and boom root point 5.14.2 Rope pulleys 5.14.3 Rope guides 5.14.4 Boom support Ropes 5.15.1 Ropes 5.15.2 Hook block

Visual check Cleanse root point when boom dislodged and grease Eliminate paintwork damage Visual check Lubricate Functional test Clean Visual check Visual check Cleanse and grease Eliminate paint work damage Check rope condition as per inspection criteria Cleanse and grease Functional test Visual check Lubricate

Q Q Q Q Q



(P-1/9)

4.4 Check List for Maintenance yearly or every 1,500 hours


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Electrical System 5.1.1 Superstructure switch cabinets 5.1.2 Junction boxes and cableways 5.1.3 Batteries 5.1.4 3-phase generator 5.1.5 3-phase generator on the


switches 5.1.6 Lowering/derrick-out limit . switches 5.1.7 Safe load indicator 5.1.8 Lighting and sockets Hydraulic System 5.2.1 Main pumps 5.2.2 Secondary pumps 5.2.3 Hydraulic oil tanks

Visual check Clean. Cleanse Functional test Visual check Clean Visual check Clean and dry battery cover Clean cable connection terminals, grease with pole grease and check for firm seating Visual check Visual check Visual check Functional test Visual check Clean Functional test Visual check Functional test Visual check Clean Functional test Visual check. Check running noises Check pressure gauges Visual check Check running noises Check pressure gauges Visual check Check oil level Check breather filter; if required, replace. filter element Check oil filter pollution indicator; if required, replace.filter element.

N O



(P-2/9)



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5.2.4 Slewing gear pump filter 5.2.5 Rotary lead-through 5.2.6 Spring suspension blocking

cylinders 5.2.7 Control blocks in the

undercarriage 5.2.8 Outrigger beam cylinders 5.2.9 Hoist, derricking, slewing +

travel gear motors 5.2.10 Control blocks in the

superstructure 5.2.11 Counterweight cylinders 5.2.12 Boom root point cylinder Air Pressure System 5.3.1 Air pressure tanks 5.3.2 Brake cylinders 5.3.3 Brake couplings 5.3.4 Air pressure fine filter 5.3.5 Brake pedal 5.3.6 Signal horns 5.3.7 Air pressure compressor in the

undercarriage 5.3.8 Pressure regulator

Visual check Check oil filter pollution indicator If required, replace filter element Visual check Visual check Functional test Visual check Functional test Visual check Visual check Check running noises Visual check Visual check Cleanse and grease Functional test Visual check Cleanse and grease Functional test Visual check Drain water Visual check Functional test Visual check Visual check Check fine filter element; if required, replace Visual check Clean Visual check Functional test Visual check Check oil level Change oil

Che Check air filter; if required, replace filter element. Lubricate lube nipple on compressor shaft. Visual check Functional test

P P K K O



(P-3/9)



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Diesel Engine System 5.4.1 Diesel engine 5.4.2 Exhaust system 5.4.3 Fuel system 5.4.4 Accelerator 5.4.5 Pump distributor gearboxes

Visual check. Check oil level. Check coolant level+ concentration. Check fan belt condition and tension. Weekly checks: Check air filter, pollution indicator. Check air intake hoses, pipes and clamps. Change oil. Change oil filter elements. Change fuel filter elements. Clean or change crank house ventilation. Change DCA coolant filter. Check clean and set infectors Adjust piston cross heads Adjust valves Check hoses and lines; if required, change. Check and tighten mounting elements Check crank shaft axial clearance Check turbo charger mounting elements Visual check Visual check If required, replace any damaged fuel lines Check tank cover Drain condensation water. Visual check Functional test Visual check Check running noises. Check oil level Carry out oil analysis Change oil. Clean vent filter. Check bolt connections.

A B A E E



(P-4/9)



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Emergency Diesel Engine 5.5.1 Emergency diesel engine Travel and Running Gear 5.6.1 Travel reduction gear units 5.6.2 Pinions and gear wheels 5.6.3 Disengaging devices 5.6.4 Wheel sets 5.6.5 Wheels set bearings 5.6.6 Spring suspension system

Visual check. Check oil level. Change oil. Replace lube oil filter. Clean fuel strainer. Check fuel pump oil level. Clean air filter Check and clean exhaust system. Check fan belt tension; if required, adjust. Replace fuel preliminary filter element. Replace fine filter element. Check mounting elements. Check starter and generator. Check valve clearance, if required, adjust. Functional test. Visual check Check oil level Change oil Clean gear unit exterior Check vent; if required, clean Visual check Clean Grease. Visual check Check air pressure cylinders Functional test Visual check Check mountings Check wheel back-to-back distance Check running circle diameter. Carry out wear test Visual check Replace grease filling Visual check Clean

C C C C E E Q R



(P-5/9)



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5.6.7 Brake disks 5.6.8 Brake expanders 5.6.9 Brake system Cab 5.7.1 Cab 5.7.2 Control panels 5.7.3 Screen wiper and wash system 5.7.4 Fan 5.7.5 Seat 5.7.6 Additional equipment

Visual check Functional test ( Inspection A ) Inspection B Visual check Functional test ( Inspection A ) Inspection B Visual check Clean Check emergency release function Functional test Visual check Clean Clean and grease door and Carry out functional test. Eliminate paintwork damage. Visual check Clean Visual check Check wash water Functional test Visual check Clean Functional test Visual check Check slide tracks Visual check Functional test

HI



(P-6/9)



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Slewing Gear 5.8.1 Slew reduction gear unit incl. . brake

5.8.2 Pinions and gearwheels 5.8.3 Roller bearing slew ring Main Hoist 5.9.1 Main Hoist reduction gear. . unit incl. Brake

5.9.2 Rope drum Auxiliary Hoist 5.10.1 Auxiliary hoist reduction

gear unit incl. Brake 5.10.2 Rope drum

Visual check Check running noises Check oil level Change oil Check bolt connections Check breather filter; if required, replace. Visual check Cleanse and grease Visual check Lubricate Check bolt connections Visual check Check running noises Check oil. Lubricate counter bearing lubrication nipple Check oil level Check bolt connections Visual check Lubricate Check Rope clamps Visual check Check running noises Change oil level. Lubricate counter bearing lubrication nipple Change oil Check bolt connections Visual check Lubricate Check rope clamps

L L O P L M L Q L M L Q



(P-7/9)



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Derricking Gear 5.11.1 Derricking reduction gear

unit incl. Brake 5.11.2 Rope drum 5.11.3 Pulleys and rope guides on

the superstructure

Recovery Winch

5.12.1 Recovery winch reduction gear unit incl. brake

5.12.2 Rope Drum 5.12.3 Deflection rolls Basic Constructions 5.13.1 Steel construction 5.13.2 Paint work 5.13.3 Protective housing +

panelling

Visual check Check running noises Check oil level Lubricate counter bearing lubrication nipple Change oil Check bolt connections Visual check Lubricate Check rope clamps Visual check Lubricate bearings Functional test Visual check Check running noises Check oil level Change oil Check bolt connections Visual check Lubricate Check rope clamps Visual check Lubricate Functional test Visual check Visual check Eliminate paintwork damage Clean Visual check Eliminate paint work damage Straighten deformations and paint Check hinges, locks and storm hooks

L M L Q Q L L Q

Q



(P-8/9)



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5.13.4 Stairways, footboard and holding straps

5.13.5 Counterweight 5.13.6 Outrigger beams 5.13.7 Outrigger pads 5.13.8 Signs and labelling 5.13.9 Tool kit 5.13.10 Bogies Boom 5.14.1 Boom and boom root point 5.14.2 Rope pulleys 5.14.3 Rope guides 5.14.4 Boom support

Clean Visual check Eliminate paintwork damage Straighten deformations and paint Visual check Eliminate paintwork damage Visual check Eliminate paintwork damage Lubricate Functional test Visual check Cleanse and grease Visual check Check inventory Visual check Eliminate paint work damage Lubricate Check side bearing clearance Visual check Cleanse root point when boom dislodged and grease Eliminate paintwork damage Visual check Lubricate Functional test Clean Visual check Visual check Cleanse and grease Eliminate paint work damage

Q Q Q Q Q Q



(P-9/9)



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Ropes 5.15.1 Ropes 5.15.2 Hook block

Check rope condition as per inspection criteria Cleanse and grease Functional test Visual check Lubricate

Q Q



(P-1/9) 4.5 Check List for Maintenance every 2 years or every 3,000 hours


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cabinets 5.1.2 Junction boxes and

cableways 5.1.3 Batteries 5.1.4 3-phase generator 5.1.5 3-phase generator on the


switches 5.1.6 Lowering/derrick-out limit

switches 5.1.7 Safe load Indicator 5.1.8 Lighting and sockets

Hydraulic System 5.2.1 Main pumps 5.2.2 Secondary pumps 5.2.3 Hydraulic oil tanks

Visual check Functional test Cleanse Functional test Visual check Clean Visual check Check electrolyte level Clean and dry battery cover Clean cable connection terminals, grease with pole Grease and check for firm seating. Visual check Visual check Visual check Functional test Visual check clean Functional test Visual check Functional test Visual check Clean Functional test Visual check Check running noises Check pressure gauges Visual check Check running noises Check pressure gauges Visual check Check oil level Change hydraulic oil Check breather filter

N O O



(P-2/9) 4.5 Check List for Maintenance every 2 years or every 3,000 hours


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5.2.4 Slewing gear pump filter 5.2.5 Rotary lead-through 5.2.6 Spring suspension blocking

cylinders 5.2.7 Control blocks in the

undercarriage 5.2.8 Outrigger beam cylinders 5.2.9 Hoist, derricking, slewing +

travel gear motors 5.2.10 Control blocks in the

superstructure 5.2.11 Counterweight cylinders 5.2.12 Boom root point cylinder Air Pressure System 5.3.1 Air pressure tanks 5.3.2 Brake cylinders 5.3.3 Brake couplings 5.3.4 Air pressure fine filter 5.3.5 Brake pedal 5.3.6 Signal horns 5.3.7 Air pressure compressor in

the undercarriage 5.3.8 Pressure regulator

Check oil filter pollution indicator; If required, replace filter element. Visual check. Check oil filter pollution indicator; If required, replace filter element. Visual check Visual check Functional test Visual check Functional test Visual check Visual check Check running noises Visual check Visual check Cleanse and grease Functional test Visual check Cleanse and grease Functional test Visual check Drain water Visual check Functional test Visual check Visual check Check fine filter element; if required, replace Visual check Clean Visual check Functional test Visual check Check oil level Change oil

Che Check air filter; if required, replace filter element. Lubricate lube nipple on compressor shaft. Visual check Functional test

P P K K O



(P-3/9)

4.5 Check List for Maintenance every 2 years or every 3,000 hours


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Diesel Engine System 5.4.1 Diesel engine 5.4.2 Exhaust system 5.4.3 Fuel system

Visual check Check oil level Check coolant level+ concentration Check fan belt condition and tension Weekly checks: Check air filter pollution indicator Check air intake hoses, pipes and clamps Change oil Change oil filter elements Change fuel filter elements Clean or change crank house ventilation Change DCA coolant filter Check clean and set infectors Adjust piston cross heads Adjust valves Check hoses and lines; if required, change. Clean engines Check and tighten mounting elements Check crank shaft axial clearance Check turbo charger mounting elements Clean and adjust fuel pumps Clean radiator and change coolant. Check fan hub. Check idler pulleys. Check water pump. Check turbo charger. Check air compressor. Check vibration damper. Visual check. Visual check. If required, replace any damaged fuel lines. Check tank cover. Drain condensation water.

A B A



(P-4/9)



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5.4.6 Accelerator 5.4.7 Pump distributor gearboxes Emergency Diesel Engine 5.5.1 Emergency diesel engine Travel and Running Gear 5.6.1 Travel reduction gear units 5.6.2 Pinions and gear wheels

Visual check. Functional test. Visual check. Check running noises. Check oil level. Carry out oil analysis. Change oil. Clean vent filter. Check bolt connections. Visual check. Check oil level. Change oil. Replace lube oil filter. Clean fuel strainer. Check fuel pump oil level. Clean air filter. Check and clean exhaust system. Check fan belt tension; if .required, adjust. Replace fuel preliminary filter element. Replace fine filter element. Check mounting elements Check valve clearance, if required , adjust Check injectors Functional test Visual check Check oil level Change oil Clean gear unit exterior Check vent; if required, clean Visual check Clean Grease.

E E C C C C E E Q



(P-5/9)



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5.6.3 Disengaging devices 5.6.4 Wheel sets 5.6.5 Wheels set bearings 5.6.6 Spring suspension system 5.6.7 Brake disks 5.6.8 Brake expanders 5.8.9 Brake system Cab 5.7.1 Cab 5.7.2 Control panels

Visual check. Check air pressure cylinders. Functional test. Visual check. Check mountings. Check wheel back-to-back distance. Check for rolling circle diameter differences Carry out wear test. Visual check. Replace grease filling. Visual check. Clean. Visual check Functional test ( Inspection A) Inspection B Inspection C Inspection D ( for the main overhaul) Visual check Functional test ( Inspection A) Inspection B Inspection C Inspection D ( for the main overhaul) Visual check Clean Check emergency release function Functional test Visual check Clean Clean and grease door and carry out Functional test. Eliminate paintwork damage. Visual check Clean

R HI HI GHIJ FGHIJS



(P-6/9)



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5.7.3 Screen wiper and wash system 5.7.4 Fan 5.7.5 Seat 5.7.6 Additional equipment Slewing Gear 5.8.1 Slew reduction gear unit

incl. brake

5.8.2 Pinions and gearwheels 5.8.3 Roller bearing slew ring Main Hoist 5.9.1 Main Hoist reduction gear

unit incl. Brake

5.9.2 Rope drum

Visual check Check wash water Functional test Visual check Clean Functional test Visual check Check slide tracks Visual check Functional test Visual check Check running noises Check oil level Change oil Check bolt connections Check breather filter; if required, replace. Visual check Cleanse and grease Visual check Lubricate Check bolt connections Visual check Check running noises Check oil level Lubricate counter bearing lubrication nipple Check oil Check bolt connections Visual check Lubricate Check Rope clamps

L

L O P L M L Q



(P-7/9)



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Auxiliary Hoist 5.10.1 Auxiliary hoist reduction

gear unit incl. brake 5.10.2 Rope drum Derricking Gear 5.11.1 Derricking reduction gear

unit incl. Brake 5.11.2 Rope drum 5.11.3 Pulleys and rope guides on

the superstructure

Recovery Winch 5.12.1 Recovery winch reduction

gear unit incl. brake 5.12.2 Rope Drum

Visual check Check running noises Check oil level Lubricate counter bearing lubrication nipple Change oil Check bolt connections Visual check Lubricate Check rope clamps Visual check Check running noises Check oil level Lubricate counter bearing lubrication nipple Change oil Check bolt connections Visual check Lubricate Check rope clamps Visual check Lubricate bearings Functional test Visual check Check running noises Check oil level Change oil Check bolt connections Visual check Lubricate Check rope clamps

L M L Q L M L Q Q L L Q



(P-8/9)



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5.12.3 Deflection rolls Basic Constructions 5.13.1 Steel construction 5.13.2 Paint work 5.13.3 Protective housing +

panelling 5.13.4 Stairways, footboards and

holding straps 5.13.5 Counterweight 5.13.6 Outrigger beams 5.13.7 Out rigger pads 5.13.8 Signs and labelling 5.13.9 Tool kit 5.13.10 Superstructure locking

device 5.13.11 Bogies

Visual check Lubricate Functional test Visual check Visual check Eliminate paintwork damage Clean Visual check Eliminate paintwork damage. Straighten deformations and paint Check hinges, locks and storm hooks Clean Visual check Eliminate paintwork damage Straighten deformations and paint Visual check Eliminate paintwork damage Visual check Eliminate paintwork damage Lubricate Functional test Visual check Cleanse and grease Visual check Check inventory Visual check Cleanse and grease Eliminate paintwork damage Visual check Eliminate paint work damage Lubricate Check side bearing clearance

Q Q Q Q Q



(P-9/9)



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Boom 5.14.1 Boom and boom root point 5.14.2 Rope pulleys 5.14.3 Rope guides 5.14.4 Boom support Ropes 5.15.1 Ropes 5.15.2 Hook block

Visual check Cleanse root point when boom dislodged and grease Eliminate paintwork damage Visual check Lubricate Functional test Clean Visual check Visual check Cleanse and grease Eliminate paint work damage Check rope condition as per inspection criteria Cleanse and grease Functional test Visual check Lubricate

Q Q Q Q Q

maintenance manual new part-i

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