Maintenance Schedule for 140 T Cowans Sheldon New Design Crane

Crane No :- IR 141001 Shed :- DAUND Railway :- CR

Form No :- F/C/01 Issue no :- 1 Rev.No.0 Issue Date :- 01.10.13
Hour Meter Reading
Date..........………… Daily Maintenance …………………….To…………………..
Schedule Crane start :-
Crane stop : -

S.No. Maintenance Point Type of Maintenance Action taken

Drive Belt Belt condition for cracking,
( Main Engine) fraying shiny surface & tension
1
(6.13)

Cracks, loose rivets, bent/loose

Fan (Main Engine)
2 blades and contact between fan
(6.14)
blade tips and fan shroud
Air cleaner Clean air cleaner, pre-cleaner
3
(6.15) and dust pan
Check coolant level in engine
Coolant level radiator. Use distilled water NOTE
4 (Main engine) :Don’t remove the radiator cap
(6.10) from a hot engine and don’t add
the coolant in hot engine.
Check Oil Condition.
Engine oil level
5 Up to ‘H’ level in stop condition. If
(6.01)
required filled 15W40 lube oil
Level of fuel (Maintained high
level of fuel for reduce the
Fuel level possibility of condensation)
6 (H.S. Diesel) Leakage in fuel tank, pipes (on
(6.05) tank and engine compartment)
Fuel level gauge in Cabin.
Main engine Water Drain the water and sediment
and sediment from the separator (Open the
7 filter drain valve fully, squeeze the
primer bulb to evacuate all
(6.07) contaminants)

Check hydraulic oil level in engine

Hydraulic oil level stopped and crane in the stowed
8 in train formation. If required to
(8.01) top up use Servo system 46
hydraulic oil.

Suspension Visually check all top and bottom

9 linkage linkage pins and link for signs of
(10.07) wear and physical damage.
10 Splitter gear box Check oil condition and oil level.
 Check loose and deficient parts
11 Air Brake System Check air leakage.

Release air from brake system

Air reservoir drains Open drain cock and drain all
12
(11.11) reservoir. Close the cock after
the drain.
Check the supply and level of
fuel
Auxiliary engine
13 Check the level and condition of
(7.07)
lube. Oil. Top up 15W40 as
required.
14 Pipe work Leakage and cracks in system
(11.04)
15 Warning Horns Function correctly
(11.05)
16 Safe load indicator Self diagnosticcheck .Check all
(11.09) lamps and alarm.
17 Unusual Engine By hearing
noise
18 Aux. fuel tank Availability of fuel
19 Cabin Visual check.
Clean.
Check all gauges
Visual check.
20 Control panels Clean
Check lightings.
21 Screen wiper and Functional test
wash system
22 Battery Clean &Check Battery
connection and condition.

Signature of Supervisor …………….

 Maintenance Schedule for 140 T Cowans Sheldon New Design Crane
Crane No :- IR 141001 Shed:-DAUND Railway:- CR
Form No :- F/C/02 Issue No :- 1 Rev.No 0 Issue Date :- 01.10.13
Hour Meter
Weekly Maintenance DATE……………………….
Reading..........……
Schedule DUE DATE…………………..

S. Maintenance Type of Maintenance Action taken

No Point
.
Lubricate the slewing ring by 2-3 strokes
Slewing ring and of grease gun to each 24 nipples around
1 gear teeth the slewing ring.
( 4.01/4.02) Lubricate the gear teeth of slewing ring
by brush.
Checked air intake piping for
cracked/punctured hoses, loose clamps.
Examine the intake system piping for
corrosion under the clamps and hoses.

Clean / replace the air filter

Main Engine - Air
element.NOTE : Clean the air filter
2 intake system
element with compressed air not
(6.09)
exceeding 2 bar or 30 psi. Never
operate the engine without air
cleaner.
Examine the air cleaner service
indicator. Clean/replace filter when signal
advices.
UIC Side bearers Examine depth of wear pad material (4 in
3 each bogie) .
(10.10)
Examine torque arm at each end of
carriage for damage, distortion and
welding failure.

Examine security of torque arm. Check

nut, washer and split pins are in
respective manner.
Travel gear boxes Examine security of travel drive motors
4
(10.09)
Examine security of gear box covers.
Check all hydraulic and lubrication pipe
for leaks.
Examine security of travel clutch limit
switch and hydraulic jack. Renew the
cable for damage.
 Check the tightness of all
electrical connections

Collector column Examine fixing bolts for security.

5
(11.06)
Check the housing panels are
properly closed and all gaskets
are in position.
Security of load pin on M/Hoist

Security of load pin on A/Hoist

Examine cable connection to load

pins for security.
Examine all wiring external to the
cabin for insulation,
damage/cracking. Renew if
necessary
Safe Load Indicator Examine tightness and bonding of
6
(11.10) cable glands.
Test accuracy of radius indicator
at 2-3 different position with load
and accurately measured the
hook radius. Check the radius
measured matches the display.

Test the accuracy of load

indicator by lifting a load of known
weight.

7 Air brake system Functional check.

8 Auxiliary Hoist gear Check oil level.
box Functional Check
9 Main hoist gear box Check oil level.
Functional Check
10 Derrick gear box Check oil level.
Functional Check
11 Slewing gear box Check oil level.
Functional Check
12 Traveling gear box Check oil level.
Functional Check
13 Hauling gear box Check oil level.
Functional Check
14 Counter weight jack Functional check

15 Outrigger jack Functional check

Signature of Supervisor …………….

 Maintenance Schedule for 140 T Cowans Sheldon New Design Crane
Crane No :- IR 141001 Shed :- DAUND Railway :- CR

Hour Meter
Quarterly Maintenance DATE……………………….
Reading..........……
Schedule DUE DATE…………………….

S.N Maintenance Point

Action taken
o. Type of Maintenance
Repeat daily and weeklyschedules

1 1.01, Rail clips, Outriggers sliding surface,

2 2.04,
Outrigger locking pins, Jib foot pin
3 2.05,
5.13, Lubrication: surface, Slew lock pin, Door hinges,
4
5.14, Use Servogem Hauling winch LS chain , counter
5 11.08 EP-2 Grease weight guides.
6 5.15
7 by Brush
5.17
8

10 1.02 Use Servogem Bogie suspension pivots-8

EP-2
10 2.01 Outrigger extend cylinder -4
by Grease gun
11 2.02 Outrigger swing cylinder-4
12 2.03 Outrigger pivots - 4
13 3.01 Jib guide pulley bearing-2
14 3.02 Jib M/H pulley bearing-6
15 3.03 Jib A/H pulley bearing -2
16 3.04 M/H block pulley bearing-2
17 3.05 M/H block thrust bearing -1
18 3.06 A/H block pulley bearing -2
19 3.07 A/H block thrust bearing-1
20 3.08 Derrick pulley bearing on jib-6
21 3.09 Derrick pulley bearing on ‘A’ Frame-
8
22 3.10 Derrick return pulley bearing on ‘A’
frame-1
23 3.11 ‘A’ frame raise cylinder-1
24 5.09 M/Hoist drum support bearing
25 5.10 A/Hoist drum support bearing
26 5.11 Derrick winch drum support bearing
27 5.12 Hauling winch drum support bearing
28 5.18 Counter weight cylinder
3.12,
3.13, Use Wire ropes of M/hoist, A/Hoist,
29 3.14, Servocoat-120 Derrick, Hauling winch limit switch
5.15, by brush drive chain & counter weight guides.
5.17
 S Maintenance
Type of Maintenance Action taken
No Point
Examine visually the limit switch
Hauling winch L.S
30 drive chain. Renew if worn or
chain (5.16) damage.
Examine all the cooling system
Main Engine
hoses for signs of deterioration.
31 Cooling system
Renew all hoses and clamps if signs
hoses (6.12) of cracks/damage

Check main engine visually for

32 Main Engine
air,oil,coolant leakage and damage

Clean dust from filter using low

pressure clean dry air. The filter
Auxiliary Engine: must be renewed about doubt its
33 Air intake filter condition. Also clean filter support
(7.01) and the inside of the cover. After re-
assemble secured with screw and
seal washer.
Examine security of all nuts, bolts
and unions paying particular
attention to the fuel system
Checks drive belt tension. Adjust if
necessary
Check lube. Oil level. Top up 15W40
if required.

Auxiliary Engine Observe exhaust at normal full

34
(7.05) load. The exhaust gases must be
free from soot. A black exhaust
gas means the engine is
overloaded or that the injector
equipment is out of order. NOTE
: Don’t run the engine with dirty
exhaust.

Clean air after cooler

Air compressor
35
after cooler (7.02) Disconnect pipe work outlet valve
and condensate drain from the after
cooler outlet .
Main,Aux,derrick
36 winch limit switch. Test that the limit switch on the
(11.02) winches are functioning correctly .

Test the over hoist limit switch on

Over hoist limit
37 the jib are functioning correctly and
switch (11.03) that the cables are running freely in
their guides .
 Check battery connection
Battery and
38
Alternator (11.07)

Check battery voltage and alternator

output .
Enclosure door Grease with grease gun.
39
hinges (11.08)
 S Maintenance
Type of Maintenance Action taken
No Point
Examine brake blocks for presence and
security.
Examine blocks and surrounding areas for
contamination especially oil. If the blocks
Brake blocks are contaminated, renew them and take
39
(9.01) appropriate action to prevent further
contamination.
Measure the brake block thickness
minimum allowable thickness of brake
block is 15 mm. Replace if necessary
Examine the bogie wheels thoroughly for
damage and tread wear Minimum 813mm,
NOTE : Re-profile if minimum or maximum
Bogie Wheel exceeded.
40 sets Examine the visible portion of all axles for
(10.02) evidence of corrosion, impact damage and
circumferential scoring
Gauge all wheel profiles for conformance
to IR profile
Examine all springs for damage or cracks.
Renew any damaged/cracked springs.
Examine axle box casting for damage and
cracks. If cracks are found, renew or repair
axle box casting
Springs Examine hydraulic dampers fitted to all
41
(10.06) axles of crane bogie. Check security of
mounting bolts on bogie dampers.
Examine damper rubber mounting bushes
if deteriorated, renew.
Check for leaking oil. Renew damper if
leaking.
Labels and Clean and examine the condition of
notices any labels and notice . Repair and
42 renew as necessary
(11.15)

Paint work Examine paint work .Repair any

43 (11.14) damaged paint work with correct color.

Signature of Supervisor …………….

 Maintenance Schedule for 140 T Cowans Sheldon New Design Crane
Crane No :- IR 141001 Shed :- DAUND Railway :- CR
Form No :-F/C/04 Issue No :- 1 Rev.No.0 Issue Date :- 01.10.13
Hour Meter
Half Yearly Maintenance DATE………………………….
Reading..........……
Schedule DUE DATE……………………...

S. Maintenance
Type of Maintenance Action taken
no Point
Drain via sump plug. The oil will drain
better if slightly warm. Remove oil filler
cap. Clean the drain plug threads and
tighten it.
Refill 15W40 grade lubricating oil in sump
to top dipstick mark. Refit filter cap. Do not
over fill.
Renew the oil filter. Use only approved oil
Auxiliary Engine filters only.
lube oil and filter Renew fuel filter.
1
change.
Lightly grease or oil the face of the rubber
(7.06)
joint on the new filter.
Screw the filter on a further quarter to half
a turn.
Start the engine and run it for a few
minutes to circulate the oil.
Stop the engine and allow time for the oil
to drain down and recheck the level. Top
up if necessary
Clean the air cleaner, if the engine is
operating in moderately dusty condition
2 Auxiliary Engine Examine engine for leaks. Check fuel,
(7.08) coolant and lube oil for leaks.
Check the batteries for electrolyte level.
Slew Ring Bolt / Slew ring gear inspection
3 Stud inspection
Examine the clutch position indicator
Clutch position cables for damage and wear . Renew
4 indicator cables. cables if necessary .
(1.06) Lubricate cables with grease by brush.
 Clean and examine the crankcase
breathers and breather tube.
The tube should be removed and
examined internally for obstructions or
Main Engine sludge builds up. If the tube is blocked it
5 Crankcase should be cleaned to prevent excess
Breather Tube crankcase pressure build up,
(6.06) Use solvent to clean the breather. Dry it
with compressed air.
Examine the breather tube; connector
hose and the rubber gasket for cracks or
other damage. Renew as necessary.
 Maintenance Schedule for 140 T Cowans Sheldon New Design Crane
Crane No :- IR 141001 Shed:- DAUND Railway:- CR
Form No :- F/C/05 Issue No :- 1 Rev.No.0 Issue Date :- 01.10.13
Hour Meter
Yearly Maintenance DATE………………………….
Reading..........……
Schedule DUE DATE……………………..
S Maintenance
Type of Maintenance Action taken
no Point
Drain oil from each gear box by
Travel Gear removing the drain plug at the base of
gear box.
1 Boxes
When completely drained refit the drain
(1.04) plug, and refill the 35 ltrs oil SP-220 in
each gear box through filler cap.
Drain the oil from the Slew gear box.
Slew Gear Box Refill 29ltrs. SP-220.
2
(4.04) The gearbox breather will be require to
be renew if damaged/block
Drain oil from M/H G/Box. Refill 14 ltr.
Main Hoist SP-220.
3 Gear Box The gearbox breather will be require to
(5.05) be renew if damaged/block
Drain oil from the A/H G/Box. Refill 04
Aux. Hoist ltr. SP-220
4 Gear Box The gearbox breather will be require to
(5.06) be renew if damaged/block
Drain oil from the Derrick G/box .Refill
Derrick Gear 30 ltrs. SP 220.
5 Box
The gearbox breather will be require to
(5.07) be renew if damaged/block
Drain the oil from the Hauling winch
Hauling Gear gear box. Refill 04 ltrs. SP-220.
6 Box
The gearbox breather will be require to
(5.08) be renew if damaged/block

Pump Distri. Drain the oil from Splitter Gear Box and
7 G/Box refill new 05 ltrs. 85W140 grade oil.
(6.04)
Drained the oil from hydraulic tank and
to be collected in oil drums and
Hydraulic Oil disposed of in statutory manner. Clean
8 the tank and refill new 900ltrs Servo
(8.02) system 46 or equivalent. NOTE :
Change all the hydraulic filter during oil
change.
Check suspension clearances on bogie
Bogie with Jib stowed and counter-weights on
Suspension match truck and standing on level flat
9
clearance track. Nominal clearance 28 mm
(10.04) Repair if necessary
S. Maintenance
Type of Maintenance Action taken
No Point
Examine all axles on the bogies and subject
to a UAT. Apply the crane parking brakes and
chock the crane wheels. The crane must not
be moved during the time that the axle
Bogie Axles bearing have end caps removed. Axle
10 (10.01) bearings shall be open for as short as period
of time as possible. Where covers are
removed suitable covers shall be placed over
the open bearings to prevent contamination of
the bearing. Refit the bearing retaining caps.
Torque screw to the correct value.
Change Return filters.(A105 & A110) 2 Nos
Location :-Top of hyd tank.
Change Suction filters.(A130 & A135) 2 Nos
Location :- Bottom of the hyd tank.
Change low pressure filter.(E040) 1 Nos
Hydraulic oil Location :- Near L010.
Change pressure filter cooling (E045) 1 Nos
11 filters
Location :- Near main diesel engine.
(8.03)
Change pressure filter.(E050) 1 Nos
Location :- Near hyd oil cooler.
Change pressure filter.(F030) 1 Nos
Location :- Near hyd oil cooler.
Change hyd oil filling filter.(A120) 1 Nos
Location :- Top of hyd tank.
During UAT examine the exposed grease at
Axle Bearings
12 axle end for any signs of metallic debris. If
(10.05) debris is found renew all affected bearings.
Examine all bogie frame members for
Bogie frames damage, defects and weld failures.
13
(10.08) Repair as necessary. For any weld defect
consult OEM before proceeding with repair.
Slew Ring Gear
14 Inspection Inspection slew ring inspection.
(11.12)
Slew Ring Bolt /
15 Stud inspection Slew ring bolt and stud inspection.
(11.13)
16 Main Engine Drain oil fully
Change engine oil Refill with new engine oil
(6.02)
17 Change filters:-
 Oil full flow
 Oil by pass
 Fuel filter
 Coolant filter
(6.08)
18 Clean/change
Crankcase breather
tube
(6.06)
19 Check Coolant
Additive
(DCA4)
Concentration
(All Application)

Signature of supervisor……………………………