Final Draft Maintenance Schedule 20T - Indian · PDF fileMaintenance schedule Of ... .3 Check gauge and indicators for engine speed, ammeter, lube oil temperature, lube oil pressure,

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

Maintenance schedule

Of

20T Diesel hydraulic Crane (1676 mm GAUGE)

Report No.-MP. MI-36 (Rev.-00)

September- 2017

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RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW – 226011

MAINTENANCE SCHEDULE OF 20T DIESEL HYDRAULIC CRANE (JAMALPUR MADE)

General GUIDE LINES The schedule for examination and maintenance of the various parts of 20T diesel hydraulic Crane (Jamalpur made) has been evolved taking into account the experience gained by allottee railways in the field of crane maintenance. The service of cranes specified on this schedule for maintenance attention are the maximum allowable between successive examination. Variation in operation conditions may make it necessary to carry out examinations more frequently, or to introduce examination of details not scheduled herein. In such cases the matter should be brought to the notice of the concerned officers Dy. CME/WM/AWM who alone are authorised to introduce any change in the standard examination detailed herein. The Dy. CME/WM/AWM must in all cases, bring to the notice of the Motive Power Directorate of RDSO, any modification to the schedule giving full details. Whilst carrying out the works of schedule, all missing nuts, bolts, set screws, cotters and split pins etc must be replaced and also the items when found defective must be renewed. There are certain fundamental requirements that are important to any successful maintenance programme. These are :-

1. Adequate provision of all well trained supervisors and quality workmen. 2. Adequate provision of proper maintenance facilities and tools. 3. Adequate time for schedule maintenance work to be completed properly before the crane is

released for it’s next assignment. 4. Provision of fuel, lubricating oil and water treatment equal to or better than that required to

ensure satisfactory crane performance. 5. All measuring devices such as torque wrenches, lubricant dispensers etc., which require

calibrating should be checked quarterly for accuracy or sooner, if required. 6. Only genuine spare parts should be used. Use only lintels rags or wiping towels. The fire

extinguishers are to be maintained by the appropriate authority upto the requisite standard. 7. The nature of any ball or roller bearing is such that very little lubrication is required. The grease

which may be packed in the bearing is sufficient for many hours of operation, and unless the grease is lost by leaking out through the seals, the amount of grease applied at any one greasing is small. More failure in ball and roller bearings are caused from dirt and over greasing than from lack of lubrication. The manufacturer’s recommendation for the maintenance and lubrication should, therefore be rigidly followed.

8. Whenever any schedule examination is carried out, all the items of the lower schedules should also be attended to. PERIODIC MAINTENANCE SCHUDLES

To ensure reliable operation and for the proper upkeep of 20T DH Cranes following periodic maintenance schedules have been prescribed:- 1. Daily schedule, 2. Schedule at the completion of 100 working hours (Monthly*) 3. Schedule at the completion of 250 working hours (3 Monthly*) 4. Schedule at the completion of 500 working hours (6 Monthly*) 5. Schedule at the completion of 1000 working hours (Yearly*) 6. Schedule at the completion of 2000 working hours (2Yearly*) * 7. Schedule at the completion of 3500 working hours (3½ Yearly*) 8. Schedule at the completion of 7000 working hours (7Yearly*)

*Whichever is earlier

Periodicity of Overhauling Items Periodicity Cumulative Life 1st POH 7yrs 7 yrs 2nd POH 7yrs 14 yrs Complete POH 6 yrs 20 yrs

Condemn 25 yrs Codal life 25 yrs

STANDARD EXAMINATION/REPAIR PERIODIC MAINTENANCE SCHEDULES

1. DAILY 1.1 BEFORE STARTING THE ENGINE

1.1.1 ENGINE: .1 Check engine oil level and top up if necessary (as per recommended oil only). Must be

maintaining looking glass. .2 Check for evidence of fuel, oil, water and exhaust leaks. .3 Fill/top-up radiator with ‘Distilled’ water which should be free from any suspended impurities

such as clay, sans etc. Radiator cap should be fitted back after necessary fill up since this will cause aeration and overheating of the water coolant.

.4 Battery acid level to be checked up and to be topped up if necessary with distilled water. The terminal should be adequately coated with petroleum jelly .

.5 Clean dust pan and pre-cleaner on dry type air cleaners. .6 Clean crank case breather

.7 Check belt tension and condition of belts for cuts, fretting, cracking etc.

.8 Fuel tank to be filled up with clean diesel oil to ‘Fuel’ capacity (Capacity 180 litres).

.9 Check for loose foundation bolts. Tighten them, if required.

1.1.2 SUPER STRUCTURE:

.1 Check for the Centamax coupling

.2 Check hydraulic oil level. Top up, if necessary (Oil: HLP 68 Grade). For this check, rising of gallows may be necessary. .3 Check if all the stop valves of the hydraulic tank are open; if not, open them fully. .4 Top up air oiler supply, if necessary (Oil: HLP 68 Grade). .5 Observe for any leakage or damages of hoses and pipes. Rectify if necessary. .6 Check the cablings connecting various parts of the electrical systems for physical damages. .7 Drain condensate from both air reservoirs. .8 Check fire- extinguishers and First Aid Box in position and keep them in working order.

Note: Even minor leakage of oil must be noted and eliminated.

1.1.3 UNDER CARRIAGE .1 Check for axle mounted air compressor system for damage and deficiencies; make good if

any. .2 Check spring suspension for any breakage or deficiency. .3 Check for damage and deficiency in the brake system including pipes and hoses .4 Floor plate to be cleaned. Ensure it is free from oil and greasy substances .5 Drain out condensate from all the two air reservoirs .6 Check leakage and functioning of parking brake. .7 Check for any leakage of oil.

Note: Even minor leakage of oil must be noted and eliminated.

1.1.4 MATCH TRUCK: .1 Check for breakage or deficiency in spring suspension system.

.2 Check for damage and deficiency in the brake system including pipes and hoses .3 Check leakage and functioning of parking brake.

1.2 AFTER STARTING THE ENGINE 1.2.1 ENGINE:

.1 Check leakages of oil, water and air supply and rectify wherever required.

.2 Check for any loose nut, bolt or fastener. Tighten them, if required.

.3 Check gauge and indicators for engine speed, ammeter, lube oil temperature, lube oil pressure, water temperature indicator and fuel indicator in driver’s cab. (For details refer engine maintenance manual.)

.4 Check lube oil pressure at both idling and maximum speeds (Operating pressure 8PSI and 40/70 PSI respectively).

.5 Clean the engine.

1.2.2 SUPER STRUCTURE:

.1 Check air pressure (Operating pressure to be 6.5 bar to 7.5 bar) ; rectify faults if any.

.2 Check pollution indicator of hydraulic oil filter. Replace the filter if the indicator is at red mark. .3 Check hydraulic oil pressure of slewing circuit (280 bar Maxm), power circuit I II (280 bar

Maxm ) and pilot circuit (35 bar) .4 Check functioning of fans, lights, screen wipers and horns in cab. .5 Check leakage of oil, water and air rectify wherever required. .6 Ensure that all limit switches are in working order. .7 Check that solenoid valves are not bridged (manually)

1.2.3 UNDER CARRIAGE:

.1 Check leakage of oil, water and air; rectify wherever required.

.2 Check functioning of Brake rigging arrangement.

2. Schedule at the completion of 100 working hours (Monthly)

2.1 ENGINE: 1. Clean the air intake filter. 2. Make sure that the vent hole in the fuel tank cap is clear.

2.2 SUPER STRUCTURE :

.1 Check proper working of the Radius indicator provided on the Jib

.2 Check all working parameters as per load charts.

2.3 UNDER CARRIAGE : .1 Check travel brake equipment, linkage, linings, etc and pneumatic systems. .2 Check functioning of out riggers and hydraulic cylinders. .3 Lubricate travel gears with grease. .4 Lubricate brake linkage, out riggers pins with oil and side bearer with grease.

2.4 MATCH TRUCK: .1 Lubricate trestle pad and trestle pivot with grease. .2 Lubricate brake linkage, with oil and side bearer with grease.

2.5 JIB : .1 Lubricate snatch block swivel and sheave bearings. .2 Lubricate derrick pulley blocks and sheave bearings. .3 Lubricate ropes with grease.

3. Schedule at the completion of 250 working hours (3 Monthly)

3.1 ENGINE: .1 Change/replace engine oil. Note: When lube oil is examined through lube oil analysis in a laboratory , oil change periodic it

may be extended, if oil condition is satisfactory.

.2 Fit new lube oil full flow, filter element and gasket.

.3 Remove, clean and inspect dry type air cleaner for holes and tears. Check gaskets/ ‘O’ rings for damage. Paper type elements should be cleaned by compressed air, in the direction flow opposite to the flow of air Discard element even if a pin-hole exists. .4 Change lubricating oil bypass filter element and gasket. .5 Change water filter element. .6 Change fuel filter element and gasket. .7 Check all air cleaner connections for cracks, chafing etc. Tighten all air in-take connections. .8 Drain water and sediments from fuel tank. .9 Clean crankcase breather.

3.2 UNDER CARRIAGE:

.1 Check wear on brake lining.

3.3 MATCH TRUCK: .1 Check wear on brake lining.

3.4 JIB: .1Lubricate rope, drum, sheaves and jib stopper pad with grease. .2 All structural components are to be visually examined for defects/ cracks.

4. Schedule at the completion of 500 working hours (6 Monthly)

4.1 SUPER STRUCTURE: .1 Check drive assemblies. .2 Check oil level and top up, if necessary(oil-HP-90): • Pump distribution gear box • Hoist reduction unit • Derrick reduction unit Recovery winch reduction unit slewing gear reduction unit .3 Clean and re-grease boom foot sliding surface (fork and pin) .4 Lubricate: • Rope drum bearings with grease, • Foot pedal in cab with oil .5 Check ropes for damages/breakages .6 Collect sample of hydraulic oil. Get it tested and replace, if required.

4.2 UNDER CARRIAGE:

.1Clean and lubricate with grease : • Sliding surfaces • Slewing gear teeth • Traction gear reduction unit • Splined shaft • Screw coupling and buffers. .2 Lubricate with grease (SERVO RR 606) Path way Gear wearing through grease nipples. .3 Lubricate bogie pivot with grease.

4.3 MATCH TRUCK: .1 Clean and lubricate SCREW COUPLING AND BUFFERS with grease : .2 Lubricate bogie pivot with grease. .3 Lubricate bogie BOLSTER PINS with grease.

5. Schedule at the completion of 1000 working hours (yearly)

5.1 ENGINE: .1 Check for turbocharger oil leakage. .2 Tighten turbocharger mounting nuts.

.3 Check engine blow-by, clean radiator, adjust injectors and valves.

.4 Check wobble and eccentricity/ alignment marks on rubber type. Discard damper, if misalignment is more than 1/16”

.5 Check belt tension and adjust as required.

.6 Remove and clean air compressor breather element.

5.2 SUPER STRUCTURE: .1 Drain sediment from hydraulic oil tank. .2 Check oil water and air hoses. Change them, if necessary. .3 Check for corrosion. Repair, if required and paint. .4 Clean water and air cooler fans with water jet. Inspect drive assembly. Carry out fuel oil tank

flushing. Change gear box oil. Check setting of limit switches .5 Check windows and doors for corrosion, proper fitting and locks.

5.3 UNDER CARRIAGE .1 Check oil level of the travel gear box.

5.4 MATCH TRUCK: .1 Check oil level in compensator tank of hydraulic brake control

6. Schedule at the completion of 2000 working hours (2 yearly)

6.1 SUPER STRUCTURE:

.1 Re-tighten all the bolts of the path way gear as per drawing. If one or more bolts are found to be slack while tightening with torque wrench , then loose bolts should be replaced. Simultaneously, two adjacent slack bolts/bolts also should be replaced. If 12 or more bolts are slack, all bolts should be replaced.

.2 Check brake equipment for functioning. 6.2 UNDER CARRIAGE: .1 Re-tighten all the bolts of the Path way Gear as per OEM’s manual. If one or more bolts are found to be slack while tightening with torque wrench, then loose bolts should be replaced. Simultaneously, two adjacent slack bolts/bolts also should be replaced. If 12 or more bolts are slack, all bolts should be replaced. .2 Check brake equipment for functioning. 6.3 MATCH TRUCK:

.1 Check brake equipment for functioning. 7. Schedule at the completion of 3500 working hours (3½yearly)

7.1 Engine:

.1 Check turbocharger end clearance.

.2 Check accessory drive end clearance.

.3 Check crankshaft end clearance.

.4 Clean injector inlet screens.

.5 Clean and calibrated all injectors

.6 Check fuel pump calibrations.

.7 Replace fuel pump filter screen and magnet

.8 Check fan hub drive.

.9 Clean and tighten all electrical connections. Note: Arrange for authorised dealer for engine manufacturer’s mechanic to check your engine

completely- refer engine maintenance manual for details.

7.2 SUPER STRUCTURE: .1 Carry out visual inspection of wire ropes by dis-assembling.

7.3 UNDER CARRIAGE: .1 Check wheel wear

.2 Inspect axle box roller bearings and refill with grease (LITHON- 3 HPC) 7.4 MATCH TRUCK:

.1 Check wheel wear .2 Inspect axle box roller bearings and refill with grease (LITHON- 3 HPC)

8. POH Schedule at the completion of 7000 working hours (7 Yearly or whichever is earlier) (To be carried out at E. Rly. Workshop, Jamalpur)

8.1 Start power pack and slew the crane under propped condition: .1 Check all motions .2 Check all safety devices. .3 Check all load chart parameters with respect to recommended Limit Switch cut-off. .4 Check engine radiator and repair/ replace if required. Hose connection for radiator cooling

circuit to be replaced. 8.2 Jointly check with crane in charge for all damages/ deficiencies/ working problems/ anything

abnormal. Verify Jointly with crane incharge consignee reports, when crane is received for POH.

8.3 Crane with M/T to be placed in POH bay, having E.O. T. Facility. 8.4 Remove all lifting tackles, wire rope (main), derrick wire ropes, snatch block assembly and C/W

from U/C. Send all lifting tackles and chains to chain testing house along with original certificates for examination and testing.

8.5 Remove Jib and Jib bridle, (Check jib bridle pulleys, jib pulleys, brass bearing of jib and structural check of jib bridle and jib).

8.6 Remove Match Truck for POH. 8.7 Disconnect all sensing devices of main power pack ( electrical). 8.8 Open power pack and lower for POH (Before opening, close all stop cocks ). Send the power

pack to authorised dealer/ manufacturer for POH and load testing. 8.9 Disconnect all hoses and pipes of U/C and rotary union. 8.10 Release wheel and send to wheel shops for inspection of bearings and re-greasing and

necessary repairs. 8.11 Open the bottom pivot nut, lift the S/S and keep on trestle /stand 8.12 Open the bogie lock nut, brake lever pins, axle guard, brake beam guard. Run out bogie and

U/C and keep on trestle /stand 8.13 Open the pivot nut of M/T , lift the M/T , run out bogie, keep on trestle. 8.14 Check structural damage of bogies( Crane and M/T ) and repair as required. 8.15 Disconnect all hoses and pipes of S/S and U/C 8.16 Drain out entire hydraulic oils (HLP-68) and diesel oil. Store in drum. Flush the tank before

refilling with fresh diesel oil and hyd. Oil (HLP-68). 8.17 Check hyd oil cooler and replace, if required. 8.18 Dismantle all motion’s m/c i.e.:

I. Main hoist drum assembly II. Derrick drum assembly.

iii. Inspect these assemblies and replace as required. 8.19 Fitment of Path way Gear :

I. Levelling of Path way Gear to be ensured II. Systematically replace all bolts and nuts of Path way Gear of S/S and U/C

III. Grease the Path way Gear . 8.20 Tighten the bolts with a tightening force as per drawing. Lift S/S and keep on trestle. 8.21 Check all gear boxes(replaced if required):

I. Hoist II. Derrick

III. Slewing gear box iv. Replace the oil (Oil HP-90)

8.22 Check all cylinders, valves of S/s and U/c (Replace, if required). 8.23 Check structural damage of S/s and U/c Repair, if required. 8.24 Lift S/s and keep on U/c on Path way Gear . Follow manufacturer’s instruction while assembly 8.25 Keep all motion’s machinery in position systematically:

I. Hoist drum assembly .

II. Derrick drum assembly. III. Recovery winch drum assembly IV. Slewing gear box

Inspect these assemblies and replace as required. 8.26 Connect the hoses and pipes of rotor with S/S. 8.27 Connect all hoses and pipes of all drum assembly of S/S. 8.28 Fill up hydraulic oil(HLP-68) into the tank (Capacity 210 Ltr) 8.29 Assemble the bogies (after receiving wheel sets from wheel shop) of Crane and Match truck. 8.30 Push the bogies inside the Crane and M/T. 8.31 Lift the crane and lower on bogies (Tighten the pivot nut). Lift the Match truck and lower on

bogies (Tighten the pivot nut). 8.32 Connect all hoses and pipes with U/c and Rotary union. 8.33 Attach match truck with crane. 8.34 Assemble power pack in position; connect all pipes. 8.35 Assemble jib and bridle block in position. 8.36 Reeve on derrick, hoist and wire ropes. 8.37 Check all electrical items and replace complete electrical Kit. Also repairer engine harnessing if

required. All batteries to be replaced by new ones. 8.38 Pneumatic brake system- all pneumatic valves to be replaced if defective. Distributer Valves to

be overhauled. All pipe lines fitting to be checked and to be replaced, if required. 8.39 U/C travelling gear arrangement- Check, replace bearing and defective material, if required. 8.40 Complete set of fasteners to be replaced. 8.41 Rotary union to be checked and replace , if required. 8.42 Test and trial at 25% over load 8.43 Spray paint

9. General Working Instructions:

.1 Periodic maintenance of crane should be done after it is placed on level track and parking brakes of crane and match truck applied.

.2 After completion of schedule maintenance work, check and ensure that no tools or replaced parts lie over the crane.

.3 The staff while working under the crane or while standing over footboards/ super structure must not smoke or strike fire nearby.

.4 In case, any structural part is damaged and it is to be rectified, ensure: .5 Direct flame doesn’t damage cables, hoses , pipes must take all fire prevention measures for

hoses, cables etc. from direct heat by shielding the flame. .6 For any structural repair, ensure proper pre-heating, use of recommended electrodes and

argoshield welding.

FURTHER READING: 1. L&T Ltd Crane manual for 20T DH crane. 2. Engine manufacturer’s manual.

SET OF SCHEDULE FORMS

Containing: • FORM A-DAILY • FORM B- MONTHLY • FORM C- 3 MONTHLY • FORM D-6 MONTHLY • FORM E - YEARLY • FORM F-2 YEARLY • FORM G - 3½ YEARLY

R.D.S.O Form - A

DAILY MAINTENANCE SCHEDULE FOR

20T DH HYDRAULIC CRANE

Crane No.________________ Date ____________ Shed _____________ Rly. ___________

Hours Meter Reading ______________ Time From ___________ To _______________

A. IMPORTANT REPAIRS (Observed by JE/SSE/ Driver):

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S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

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B. SCHEDULE REPAIRS :

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S. No. ITEAM OBSERVATION ACTION TAKEN /ANY PART RENEWAL SIGNATURE

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BEFORE STARING ENGINE 1. ENGINE .1 Check engine oil level and top up if necessary (as per recommended oil only). Must be

maintained looking glass. .2 Check for evidence of fuel, oil, water and exhaust leaks. .3 Fill/top-up radiator with clean/chromate treated water which should be free from any

suspended impurities such as clay, sans etc. Radiator cap should be fitted back after necessary fill up since this will cause aeration and overheating of the water coolant.

.4 Battery acid level to be checked and to be topped up, if necessary with distilled water. The terminal should be adequately coated with petroleum jelly .

.5 Clean dust pan and pre-cleaner on dry type air cleaners.

.6 Clean crank case breather.

.7Check belt tension and condition of belts for cuts, fretting, cracking etc.

.8 Fuel tank to be filled up with clean diesel oil to ‘Fuel’ capacity (Capacity 180 litres).

.9 Check for loose foundation bolts. Tighten them, if required.

2. SUPER STRUCTURE:

.1 Check for the Centamax coupling . Top up, if necessary (Oil: HP-90).

.2 Check hydraulic oil level. Top up, if necessary (Oil: HLP-68 grade). For this check, rising of gallows may be necessary.

.3 Check if all the stop valves of the hydraulic tank are open; if not, open them fully.

.4 Top up air oiler supply, if necessary(Oil: HLP 68 Grade).

.5 Observe for any leakage or damages of hoses and pipes. Rectify if necessary.

.6 Check the cablings connecting various parts of the electrical systems for physical damages.

.7 Drain condensate from both air reservoirs .

.8 Check fire‐ extinguishers and First Aid Box in position and keep them in working order. Note: Even minor leakage of oil must be noted and eliminated.

3. UNDER CARRIAGE .1 Check for axle mounted air compressor system for damage and deficiencies; repair if any. .2 Check spring suspension for any breakage or deficiency. .3 Check for damage and deficiency in the brake system including pipes and hoses .4 Floor plate to be cleaned. Ensure it is free from oil and greasy substances .5 Drain out condensate from all the two air reservoirs .6 Check leakage and functioning of parking brake. .7 Check for any leakage of oil.

Note: Even minor leakage of oil must be noted and eliminated. 4. MATCH TRUCK:

.1 Check for breakage or deficiency in spring suspension system. .2 Check for damage and deficiency in the brake system including pipes and hoses .3 Check leakage and functioning of parking brake.

AFTER STARTING THE ENGINE

1. ENGINE: .1Check leakage of oil, water and oil supply. .2Check for loose nut, bolt or any fastener and tighten them. .3Check working of all gauges and indicators in cab. .4Check and record lube oil pressure at: Idling speed – 8 PSI Max. speed – 40/70 PSI

2. SUPER STRUCTURE : .1 Check air pressure( 6.5 to 7.5 bar). .2Check pollution indicator for hydraulic oil filter.(Replace filter, if indicator is at red mark or above

3.0 bar) .3Check hydraulic oil pressure : • Power circuit & II (280 bar)- • Slew circuit (200 bar)- • Pilot circuit (30 bar)- .4Check working of cab equipments – fans/ lights / wipers/ horns etc. .5Check leakages of oil, water and air. .6Check working of limit switches. .7Check that solenoid valves are not bridged (manually).

3. UNDER CARRIAGE:

.1Check for any leakages.

.2Check functioning of brake rigging arrangement.

-------------------------------------------------------------------------------------------------------------------------------------- Certified that examination and repairs have been completed. If not, reasons as below:-

Checked by: - JE:- SSE:-

R.D.S.O Form ‐ B

MONTHLY MAINTENANCE SCHEDULE

[Schedule after the completion of 100 working hours (Monthly)]

20T DH HYDRAULIC CRANE

Crane No. _________________ Date ____________ Shed _____________ Rly. _________________

Hours Meter Reading ______________ Last schedule done (Type)-----------------------------------------------------

Date of last schedule done…………………………………………………………………………………………………………………….

Time From ___________ To _______________Time taken……………..Hrs……………..Minutes

A. IMPORTANT REPAIRS ( Observed by JE/SSE/ Driver):

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1. ENGINE:

.1Clean the air intake filter.

.2Make sure that the vent hole in the fuel tank cap is clear.

2. SUPER STRUCTURE : .1 Check the display of radius on the provided console of the crane matches with the actual

radius. .2 Check that all working parameters of load charts are in relation to provided console cut- off

3. UNDER CARRIAGE : .1 Check travel brake equipment, linkage, linings, etc and pneumatic systems. .2 Check functioning of out riggers and hydraulic cylinders. .3 Lubricate travel gears with grease. .4 Lubricate brake linkage, out riggers pins with oil and side bearer with grease. .5 Check lubricating oil level of axle driven compressor and top up if necessary ( recommended

oil should be complied)

4. MATCH TRUCK: .1 Lubricate trestle pad and trestle pivot with grease. .2 Lubricate brake linkage, with oil and side bearer with grease.

5. JIB : .1 Lubricate snatch block swivel and sheave bearings. .2 Lubricate derrick pulley blocks and sheaves bearings. .3 Lubricate ropes with grease.


Checked by:- JE:- SSE:-

R.D.S.O Form ‐ C MONTHLY MAINTENANCE SCHEDULE

[Schedule after the completion of 250 working hours (3 Monthly) ] 20T DH HYDRAULIC CRANE






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1. ENGINE: .1 Change/replace engine oil. Note: When lube oil is examined through lube oil analysis in a laboratory , oil change periodicity

may be extended, if oil condition is satisfactory. .2 Fit new lube oil full flow, filter element and gasket. .3 Remove, clean and inspect dry type air cleaner for hole and tears. Check gaskets/ ‘O’ rings for

damage. Paper type elements should be cleaned by compressed air, in the direction flow opposite to the

flow of air. Discard element even if a pin-hole exists. .4 Change lubricating oil by-pass filter element and gasket. .5 Change water filter element. .6 Change fuel filter element and gasket. .7 Check all air cleaner connections for cracks, chafing etc. Tighten all air in-take connections. .8 Drain water and sediments from fuel tank. .9 Clean crankcase breather.

2. UNDER CARRIAGE: .1 Check wear on brake lining.

3. MATCH TRUCK:

.1 Check wear on brake lining.

4. JIB: .1Lubricate rope, drum, sheaves and jib stopper pad with grease. .2 All structural components are to be visually examined for defects/ cracks.

-------------------------------------------------------------------------------------------------------------------------------------- Certified that examination and repairs have been completed. If not, reasons as below:


R.D.S.O Form ‐ D MONTHLY MAINTENANCE SCHEDULE

[Schedule after the completion of 500 working hours (6 Monthly)] 20T DH HYDRAULIC CRANE






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1. SUPER STRUCTURE: .1 Check drive assemblies. .2 Check oil level and top up, if necessary (Oil-HP-90): • Pump distribution gear box • Hoist reduction unit • Derrick reduction unit Recovery winch reduction unit slewing gear reduction unit • Traction gear box .3 Clean and re-grease boom foot sliding surface (fork and pin) .4 Lubricate: • Counter wt gallows with grease, • Rope drum bearings with grease, • Foot pedal in cab with oil .5Check ropes for damages/breakages .6 Collect sample of hydraulic oil. Get it tested and replace, if required.

2. UNDER CARRIAGE: .1Clean and lubricate with grease : • Sliding surfaces • Slewing gear teeth • Traction gear reduction unit • Splined shaft

• Screw coupling and buffers. .2 Lubricate with grease (Servo RR 606) slewing ring wearing through grease nipples. .3 Lubricate bogie pivot with grease.

3. MATCH TRUCK:

.1 Clean and lubricate Screw coupling and buffers with grease :

.2 Lubricate bogie pivot with grease.

.3 Lubricate bogie Bolster pins with grease.

-------------------------------------------------------------------------------------------------------------------------------------- Certified that examination and repairs have been completed. if not, reasons as below:-


R.D.S.O Form - E MONTHLY MAINTENANCE SCHEDULE

[Schedule after the completion of 1000 working hours (Yearly)] 20T DH HYDRAULIC CRANE






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B. SCHEDULE REPAIRS : ------------------------------------------------------------------------------------------------------------------------------------------------


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1. ENGINE: .1 Check for turbocharger oil leakage. .2 Tighten turbocharger mounting nuts. .3 Check engine blow-by, clean radiator, adjust injectors and valves. .4 Check wobble and eccentricity/ alignment marks on rubber type. Discard damper, if

misalignment is more than 1/16” .5 Check belt tension and adjust as required. .6 Remove and clean air compressor breather element.

2. SUPER STRUCTURE:

.1 Drain sediment from hydraulic oil tank.

.2 Check oil water and air hoses. Change them, if necessary.

.3 Check for corrosion. Repair , if required and paint.

.4 Clean water and air cooler fans with water jet. Inspect drive assembly. Carry out fuel oil tank flushing. Change gear box oil. Check setting of limit switches

.5 Check windows and doors for corrosion, proper fitting and locks.

3. UNDER CARRIAGE .1 Check oil level of the travel gear box.

4. MATCH TRUCK: .1 Check oil level in compensator tank of hydraulic brake control

--------------------------------------------------------------------------------------------------------------------------------------Certified that examination and repairs have been completed. If not, reasons as below:-


R.D.S.O Form - F MONTHLY MAINTENANCE SCHEDULE

[Schedule after the completion of 2000 working hours (2 Yearly) ] 20T DH HYDRAULIC CRANE






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1. SUPER STRUCTURE: .1 Check & re-tighten all the bolts of the slewing ring as per manual provided by firm. .2 Check brake equipment for functioning.

2. UNDER CARRIAGE:

.1 Check & re-tighten all the bolts of the slewing ring as per manual provided by firm.

.2 Check brake equipment for functioning.

3. MATCH TRUCK: .1 Check brake equipment for functioning. -------------------------------------------------------------------------------------------------------------------------------------- Certified that examination and repairs have been completed. If not, reasons as below:-


R.D.S.O Form - G MONTHLY MAINTENANCE SCHEDULE

[Schedule after the completion of 3500 working hours (3½ Yearly)] 20T DH HYDRAULIC CRANE






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1. Engine: .1 Check turbocharger end clearance. .2 Check accessory drive end clearance. .3 Check crankshaft end clearance. .4 Clean injector inlet screens. .5 Clean and calibrate all injectors .6 Check fuel pump calibrations. .7 Replace fuel pump filter screen and magnet .8 Check fan hub drive. .9 Clean and tighten all electrical connections.

Note: Arrange for authorised dealer or engine manufacturer’s mechanic to get your engine examined completely- Refer engine maintenance manual for details.

2. SUPER STRUCTURE:

.1 Carry out visual inspection of wire ropes by dis-assembling.

3. UNDER CARRIAGE: .1 Check wheel wear. Turn, if required .2 Inspect axle box roller bearings and refill with grease (LITHON- 3 HPC)

4. MATCH TRUCK: .1 Check wheel wear. Turn, if required .2 Inspect axle box roller bearings and refill with grease (LITHON- 3 HPC)



Final Draft Maintenance Schedule 20T - Indian · PDF fileMaintenance schedule Of ... .3 Check gauge and indicators for engine speed, ammeter, lube oil temperature, lube oil pressure,

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