140t crane maintenance issues,amc, spares mgt,trouble shooting-field (open line)
TRANSCRIPT
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140T Crane Maintenance Issues,AMC, Spares Mgt,Trouble Shooting-Field (Open Line)
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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
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Introduction
• To avoid Break Down of Crane– Regular cleaning– Continual inspection– Maintain scheduled preventive maintenance.
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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
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COMPONENTS REQUIRED REGULAR ATTENTION
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Main Diesel Engine Photo
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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
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Engine-Mtc
• Check– Lube oil filter element– Fuel oil filter element– Check oil filter pollution indicator– V belts used in engine
• Found any fault,call OEM’s representative.• POH done after 8 years by Cummins India Ltd.
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Filter Photo
Air Filter Hydraulic Filter
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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.
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Battery
• Check– Visually,– Clean & dry battery cover after 6 months– Clean cable conection terminals– Electrolyte level– Battery charging condition
• Change battery after Two years.
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Hoses
• Visual & functional check– End fitting,– Wearing of flange– Rubber portion.
• Replace if any leakage found• Must change item in every POH
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Hydraulic Tank
• Check– Visually,– oil level,– breather filter– Filter element– Oil contamination in Lab after every six months
• Change Hyd. Oil after Two years
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Hydraulic & Pneumatic Fittings
• Check– Visual & functional– End connections– Any crack/loose/leakage
• Replace if required
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Slewing Ring Photo
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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.
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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.
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Wire Rope Defects
Broken Wires
Waviness
Bird cage
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Wire Rope Defects
Loop deformation
Loose wires
Nodes
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Wire Rope Defects
Thining of the rope
Kinks
Flat area
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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
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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
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Lifting Tackles Photo
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Nylon Items
• Nylon pulleys– Edge damage– Bearing damage– Groove worn out
• Roller,Gliding plate– Worn out
• Replace
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SLI Items
• Main Hook Load Sensor• Boom Angle Sensor• Slew Angle Sensor• Aux. Hook Load Sensor• Display Board• Micro Processor
Chips(X1 Card)
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SLI Items
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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
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SLI-AMC
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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
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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.
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POH & MLRSchedule 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
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Must Change Items during POH
• Pneu.Hoses of U/C,Nylon pad,Owa seal,O-ring,Brake shoes,Pins,Bushes,Hyd. Gauges,Indicating lamps,Electric wiring of SLI circuit & lighting,Coil & Disc springs,Engine control circuit,Sensors,Hyd. & Pneu. Filter elements,HP-90 gear oil,HLP-68 Hyd. Oil,15W40 Engine lub. Oil,Radiator coolant.
• POH of Engine by CIL,Pune
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Condition Basis During POH
• Solenoidvalves, Major pins,Pumps,Motors,Cylinders(Propping,Outrigger,CWT,Axle blocking,DUV),Pressure Switch,Rotors,Hyd. Hoses,Wire Ropes,PTO,Lamina brakes,Bearings in gear boxes,Wheels & all other components.
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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
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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
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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
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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
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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