ISO 9001-2000

Certified Organisation

For official use only

A POCKET BOOK on

DOs and DON’Ts for

Operation and Maintenance of

Jamalpur/Gottwald 140T DH Crane (New Design)

CRANE ORGANISATION EASTERN RAILWAY, LOCOMOTIVE WORKS

JAMALPUR – 811214

2

SL No:

DOs DONTs

Repercussion if DOs/DONTs

are not followed

1 TO BRING THE CRANE IN TRAIN ORDER BEFORE LEAVING THE SHED

a)

Travel gear should be in dis–engaged position

Do not leave Axle blocking in “ON” position

Travel gear will get damaged and suspension system will not Work

b)

Crane Brake should be released with indication as “GREEN”

Do not pull the crane when indication is “RED”, in any case.

Wheel will get skid due to brake binding.

c)

Boom should be locked in trestle. Do not leave the boom unlock in trestle.

Auxiliary boom head & pulley will get damage.

d)

All side-mounted platforms should be lowered and outriggers should be folded and locked properly.

Do not leave the side mounted platform & outriggers in unlocked position.

3

e)

Check for Hyd. Oil, Fuel Oil, Engine Lub oil, Radiator water level and Oil level in all the gearboxes.

f)

Check function of Aux. Engine.

g)

Release the parking Brake.

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.

4

b)

All stop valves for Hyd. Lines should be opened before starting the engine.

Do not leave any of the stop valves closed.

The pumps may get damaged or the Hyd. System will size.

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 allow the Hyd. Level to go below the lower level indicator.

Hyd. Pump may be affected.

d)

After starting the engine check Engine Lubricant oil pressure and battery charging current.

e)

Check for pilot pressure, it must be 30 bars.

5

f)

Check for AIR pressure, it should like between 6.5 –7.5 bars.

Do not leave any air leakage in the system.

Air braking will be difficult.

3 AXLE BLOCKING

a)

Ensure engagement of the travelling gear.

b)

Ensure application of brake confirmed by the “RED” indication.

4 BOOM ERECTION

a)

Secure rear section lock while rear section is fully lifted.

b)

Depute 2 staff to go up and watch the revving and unreeling of the derrick wire rope.

6

c) Derrick “IN” until boom heels sit on the PINs.

d)

Remove boom lock from the jib trestle.

e)

Raise boom cautiously as per usual practice.

5 PROPPING THE CRANE

a)

Set the propping pads properly on ground by strengthening the ground. Depute one staff on each prop to watch its movement.

Do not prop the crane on loose ground in any case

The prop may sink causing major accident eg. Toppling of crane.

b)

Check the level of the crane by spirit level.

7

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 ON key switch, which bridges safe load indicator. The crane should not be allowed to slew in this condition.

d)

Pick up the CWT as per load chart.

e)

Select the proper prop position by selector switch as per required of load chart.

Wrong selection causing major accident e.g. toppling of crane.

8

f)

Switch on S.L.I. switch key to bring the computer safety system back in the circuit. Check the correct mode of stability.

g) Switch on boom key switch, so that 5.5 mm limit switch is in circuit.

h)

Check if safe load indicator is in operation

i)

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 SLI system.

j) Load chart should be followed in Toto.

Do not miss to consult load chart in any condition of working.

The current may be subjected to unsafe working.

k)

After Rear operation or axle blocking operation pre-selector switch for oil transmission should be brought “Neutral” position.

Avoid parallel operation of U/C or gallows and derricking or hoisting.

9

l)

Before starting work make sure that computer override key and boom override key are switched to working position.

m)

Ensure the CWT switch is on proper position.

7 OPERATION

a)

Ensure proper selection of lifting tackle (Chain & Wire rope sling).

b)

Avoid jerk during operation. Pendulum motion of load not permitted. Avoid diagonal pull of the load.

Don’t pull the load diagonally.

c)

Pull the load which are stacked in the ground cautiously. It is ensure that it will not offer resistance beyond the capability of the Crane.

Don’t pull loads which are stuck in the ground without close supervision.

d) Take care of High wind forces on the boom as it is dangerous.

10

e) Do watch for trend of soil caving by watching the prop level and spirit level of the under frame of the crane.

f)

Ensure proper signalling to the crane driver. Driver should also ensure cross- checking the signal by ground staff with condition of load.

8 DERIGGING THE CRANE:

a)

Leave 8T cwt on the chassis in the direction of match truck.

b)

Unload CWT On the match Truck

c)

Boom out to 17M radius. At this point derricking out will be cut off by 17M limit switch and SLI system.

d)

Switch “ON” boom over bridge key.

e)

Switch “ON” computer over bridge key.

11

f)

Boom down until both hooks lower into match truck well.

g)

Travel crane until boom rest pin matches with the recess in trestle.

h)

Boom down until boom slides fully into the boom rest to the lock position. At this point, lock the boom in the trestle.

i)

Unlock rear section with the help of lever.

j) Lower rear section according to its

last position.

k)

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)

12

l)

OFF Axle blocking.

9 PREPAIRING CRANE FOR TRANSPORT

a)

Parking brake “ON”

b)

Brake hoses should be connected as per the requirement.

c) Release parking brake in the last when the crane is going to be formed in train order.

Do not forget releasing parking brake.

10 MAINTENANCE CHECKING OF ENGINE

a)

Engine should be maintained as per Manufacture’s Maintenance Schedule.

Do not allow fuel level less than half of tank capacity.

b) Clean fuel tank as per maintenance schedule.

11 MAINTENANCE OF HYDRAULIC SYSTEM

a)

Clean hoses and area, around the equipment, to be opened. Clean the tray in which the open parts are kept.

Do not open the Hyd. System in a dirty environment.

13

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.

14

c) While revving / unreving 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.

Corrosion of wire rope will take place.

13 MAINTENANCE PRECAUTION FOR SAFETY DEVICES

a)

All limit switches, force and angle sensors must be cabled. Damaged cables must immediately be replaced. They should always be kept operational.

Don’t disturb the switching point of the limit switches.

b)

Check all limit switches when rigging to ensure their functioning.

Do not operate computer over bridge key and boom over bridge key during crane working. These are only operated at time of rigging / de-rigging.

c)

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.