qKfr {fFbR - td qildq Government of India-Ministry of Railways wguun ofi6w sik qrfi dTr{ Research Designs & Standards Organisation qIGFI\F - 226011 Lucknow -226011 EPBX (0522)2451200 otD (0522)2450115 Fax (0522) 2458500 DrD (0522) 2465310

No. SD.CRMG Date: 04.07.2018 The Chief Motive Power Engineer/Dsl, 1. Central Railway, CST Mumbai - 400 001. 2. Eastern Railway, Fairlie place, Kolkata - 700 OO1. g44101 3. East Central Railway, Hajipu r - . 4. East coast Railway, Rail Vihar, B-2, Bhubaneshwar - Ts1 017 5. Northern Railway, Baroda House, New Delhi - 110 001. 6. North Central Railway, Allahabad - 211 OO1. 7. North Eastern Railway, Gorakhpur - 273 OO1. 8. Northeast Frontier Railway, Maligaon, Guwahat -791 011. 9. North Western Railway, Jaipur - 302 006. 10. southern Railway Park rown, chennai - 600 003. 11. south central Railway, Rail Nilayam, secunderabad - 500 or1 . 12. south Eastern Railway, Garden Reach, Kolkata - Too 043. 13. South East Central Railway, Bilaspur - 495 004. 14. South Western Railway, Hubli - 580 023. 15. Western Railway, Churchgate, Mumbai - 400 001. 16. West Central Railway, Jabalpur - 492 OO1 17.Dy. CME/JMP (Crane), Locomotive Ws Eastern Railway, Jamalpur - 811 214. 18. Dy. CME/PR (Diesel), Locomotive Ws Parel Central naituay, Mumbai - 40OOO1.

Sub: Common Maintenance Schedule for 14OT diesel hydraulic breakdown cranes (Gottwald & Cowans Sheldon design). Ref: Railway Board's letter no.2011lM (M&P)t17it3inn dated 04.0g.2017.

With reference to above, as per directives of Railway Board, a common Maintenance Schedule no. MP.MI-37 (Rev.-00) June'2018 for 14Ot diesel hydraulic breakdown cranes (Gottwald & Cowans Sheldon design) has been finaliied by incorporating the recommendations of SAG & JAG committe"s, suggestions-tie & inputs from Jamalpur Wshop, Parel Wshop & user Railways. A copy of same is enclosed herewith for your klnd information & necessary action please.

This Maintenance Schedule supersedes the earlier schedule nos. Mp-721lg1 (Jan.'1990), MP-731/91 (Mar.'1991) & MP.MI- 19 (Sep.'2001) retated to l4OtGottwatd & Cowans Sheldon cranes issued by RDSO. n \-# YtiF,'26r\t, DA: As above (VUay Kumar Goel) Jt. Director I Motive Power for Director General (MP) Copy to:

DME lP-ll, Railway Board, Rail Bhawan, New Delhi - 110 001. (Fax no.: 011-2g38 9696) R.D.S.O (For official use only)

, GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes

No. MP. MI-37 (Revision 00) June’2018 ______

RESEARCH DESIGNS & STANDARDS ORGANISATION LUCKNOW - 226011

Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

CONTENTS

S. No. DESCRIPTION Page Nos. 1 General Description 3-16 2 Daily Schedule 17-19 3 Weekly Schedule or 20-22 at the completion of 25 working hours 4 Monthly Schedule or 23-24 at the completion of 100 working hours 5 Quarterly Schedule or 25-26 at the completion of 250 working hours 6 Half-yearly Schedule or 27-28 at the completion of 500 working hours 7 Yearly Schedule or 29-31 at the completion of 1000 working hours 8 2-Yearly Schedule or 32-33 at the completion of 2000 working hours 9 4-Yearly Schedule or 34-35 at the completion of 4000 working hours 10 8-Yearly Schedule (POH) or at the completion of 8000 working hours of: a) Main & Auxiliary Engine 36-38 b) Hydraulic System including all Cylinders, Valves, Pumps & 39-41 Motors, A-Frame & Drum/Barrel/Winch Assemblies, Wire Ropes & Pulleys, Nylon Items etc. c) Slewing Ring, Gear Boxes and Reduction Gear units 42-43 d) Electrical & Control System 44-45 e) Pneumatic, Brake system & Hand Brake 46-48 f) Basic Steel Construction, Superstructure, Cab, Jib & 49-53 Equipments, Undercarriage & Bogie, Assembly & Testing

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 1 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______SCHEDULE OF STANDARD EXAMINATION OF 140t DIESEL HYDRAULIC BREAKDOWN (Gottwald / Cowans Sheldon) CRANE

GENERAL DESCRIPTION:

1. INTRODUCTION:

Initially, 24 nos. imported 140t diesel hydraulic breakdown cranes of Gottwald design (12 nos.) & Cowans Sheldon design i.e. Jessop/NEI make (12 nos.) were introduced over IR in 1986 & 1987 respectively. Accordingly, RDSO issued maintenance schedule for Gottwald & Cowans Sheldon design cranes vide Report nos. MP-727/90 January’1990 and MP-731/91 March’1991 respectively.

Later, upgraded versions of both makes were also imported & introduced in year 1998 & 2000 respectively. Again, RDSO issued maintenance schedule for 8 nos. Gottwald (upgraded) i.e. new design cranes vide Report no. MP.MI-19 (Rev.-00) September’2001. However, no maintenance schedule for 4 nos. Cowans Sheldon new design cranes was issued by RDSO.

Jamalpur workshop, E. Rly is responsible for maintaining & overhauling the Gottwald design cranes beside manufacturing in-house whereas Parel workshop, C.Rly. is responsible for maintaining & overhauling the Cowans Sheldon design cranes. Both workshops have been maintaining the same as per schedules issued earlier. However, over last 30 years there have been several changes in equipments/minor design modifications etc. due to obsolescence of equipments as well as up-gradation of equipments. As such, existing schedules for 140t diesel hydraulic breakdown cranes of Gottwald design & Cowans Sheldon design needed revision.

Meanwhile, Railway Board advised RDSO to make a common maintenance schedule for all variants of cranes like other rolling stocks duly incorporating all changes undertaken by concerned workshops over last 30 years. Moreover, ‘SAG Committee on maintenance of 140t cranes vide para 5.1 of their report’ recommended to introduce a new “Weekly Schedule” in between daily & monthly schedules. SAG Committee also recommended to include items like Wheel profile checking, UST of wheel axle etc. in the schedule to be elaborated by JAG Committee. ‘JAG Committee vide para no. 2.3.2 of their report’ on maintenance of 140t cranes dated 10.04.2017 recommended to include wheel related maintenance activities in the “Yearly Schedule” beside other recommendations.

Accordingly, a draft schedule for examination and maintenance of the various parts of 140t diesel hydraulic cranes viz. Gottwald & Cowans Sheldon cranes was evolved taking into account the recommendations of Original Equipment Manufacturers, Eastern Railway Loco Workshop, Jamalpur (responsible for indigenously manufacturing & maintaining Gottwald design cranes), Central Railway Loco Workshop, Parel (responsible for maintaining Cowans Sheldon design cranes) and suitably modified keeping in view the experience of the user Railways in the field of crane operation as well as maintenance and workshops involved in manufacturing & POH .

Also, RDSO introduced Weekly Schedule for the first time & incorporated other recommendations of SAG & JAG Committees & circulated the same to all user Railways.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 2 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Later, a meeting was held with consignees at STC, Secunderabad to obtain their feedback based on maintenance experience. Thereafter, draft maintenance schedule has been modified after incorporating inputs/suggestions/remarks of user Railways & Workshops and a revised common maintenance schedule no. MP.MI-37 (Rev.-00) June’2018 has been finalized and supersedes all previous schedules issued by RDSO.

The service periods of 140t cranes specified in this schedule for maintenance attention are the maximum allowable periods between successive examinations. Variation in operating conditions in different regions may make it necessary to carry out examination more frequently, or introduce examinations not scheduled herein. In such cases, the matter should be brought to the notice of the appropriate Sr. DME / Dy. CME (Crane) /DME, who alone is authorized to introduce any change in the standard examination detailed herein. Sr.DME/DME/AME in all such cases, will bring to the notice of the Motive Power Directorate of RDSO, for any modification to the schedules, giving full details.

The proposed common maintenance schedule has been prepared by incorporating suitably the inputs / comments / suggestion received from user Railways & POH shops based on their maintenance experiences. Although, every care has been taken to make this document free from errors, but if any discrepancy / shortcoming / irrelevant information is observed, the user Railways are requested to inform RDSO at the following email IDs: i. Joint Director/Director /MP/RDSO [email protected] ii. Dy. Director/MP/RDSO [email protected]

1.1 COMPARISON OF MAJOR FEATURES OF ALL VARAINTS OF CRANES: S.N Item Gottwald Old Gottwald New Cowans Old Cowans New 1. Max. Speed 100 km/h 100 km/h 75 km/h 100 km/h 2. Main Engine NTA 855-R4 CIL’s NT 855P / NTA 743 P/ NTA 855 C MTU’s OM 904-926LA 3. Aux. Engine KOEL HA-294 KOEL HA-294 KOEL TA2 ListerPeter LPA3 4. Jib Octagonal Rectangular Lattice structure Rectangular 5. A-frame / Mech. strut type Hydraulic Cwt. Hyd. tie cylinder Mech. strut Gallow arrgt. A-frame Gallow arrgt. type A-frame type A-frame 6. Crane Bogie 3-axled Co-Co, 3-axled Co-Co, Disc 3-axled Co-Co, 3-axled Co-Co, arrgt. & Disc & Coil & Coil Spring + Leaf Spring Parabolic Leaf suspension Spring + Damper Damper Spring+Damper 7. Match truck type Well type wagon Well type wagon Well type wagon Well type wagon 8. Match Truck CASNUB CASNUB 2 axled Bo-Bo CASNUB Bogie 22 HS 22 HS (ICF EMU) 22 HS 9. Ballast wagon NA NA 2 axled Bo-Bo NA (ICF EMU) 10. Relieving Bogies NA NA 4-wheeler with NA Leaf Spring 11. Outrigger nos. 4 4 6 4 12. Outrigger type Hyd. Swing out Hyd. Swing out Mech. Pull out Hyd. Swing out 13. Outrigger Pad nos 8 (4+4) 8 (4+4) 6 4 14. Outrigger Pad Small-Circular Small- Rectangular Square Circular type Large-Rectangular Large- Rectangular

2. REFERENCES:

The following documents are also required to be referred for further information:

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 3 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______i) Cranes: a) Operation, Maintenance & Service Manuals issued by M/s Gottwald. b) Operation, Maintenance & Service Manuals issued by M/s Cowans Sheldon.

ii) Main Engines: a) Operating and Maintenance Manual NT/ NTA 855 R4 & NT 855 P issued by M/s Cummins Engine Company, USA- For Gottwald Old & New Cranes. b) Operating and Maintenance Manual NT/ NTA 743 P issued by M/s Cummins Engine Company, USA- For Cowans Old Cranes. c) Operating and Maintenance Manual NT/ NTA 855 C issued by M/s Cummins Engine Company, USA- For Cowans New Cranes. d) Operating Maintenance Manual OM 904-926 LA Blue Tec issued by M/s MTU Ltd.- For Gottwald Cranes (manufactured by JMP W/s).

iii) Auxiliary Engines: a) Operating Maintenance Manual HA-294 issued by M/s Kirloskar Oil Engines Limited- For Gottwald Old & New cranes. b) Operating Maintenance Manual TA2 issued by M/s Kirloskar Oil Engines Limited - For Cowans Old Cranes. c) Operating Maintenance Manual LPA-3 issued by M/s Lister-Peter Engine Limited- For Cowans New Cranes. iv) Hydraulic System: a) Repair instruction manual for hydraulic motors (RDE-91001-01/1996) issued by M/s Rexroth. b) Operating instruction for pump distribution gear box (GFC 230 1048/Feb.’1998) issued by M/s Lohmann & Stolterfohnt.

v) Safe Load Indicator (SLI): User Manual & Trouble Shooting Manual issued by approved sources i.e. M/s PAT, M/s Mechanica, M/s Amrita Laxmi & M/s Hytech.

vi) Brake system: a) Manual BSI Brake Calliper (No. V/ H 97/ 065-01/1997) issued by M/s SAB WABCO. b) Manual for wheel mounting brake disc R 780 G (No. V/ H 97/ 065-03/1998) issued by M/s SAB WABCO. c) Maintenance manual for brake cylinder adjuster unit type PBACF (53 72GB / 1992) issued by M/s SAB WABCO.

3. Periodicity of maintenance of 140t diesel hydraulic breakdown cranes viz. Gottwald cranes and Cowans Sheldon cranes: i) Daily Schedule ii) Weekly Schedule or after 25 Hours* iii) Monthly Schedule or after 100 Hours* iv) Quarterly Schedule or after 250 Hours* v) Half-yearly Schedule or after 500 Hours* vi) Yearly Schedule or after 1000 Hours* vii) 2- Yearly Schedule or after 2000 Hours* viii) 4-Yearly Schedule or after 4000 Hours* ix) 8-Yearly Schedule (POH) or after 8000 Hours* Note: * indicates ‘whichever is earlier’

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 4 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

3.1 The following proposed periodicity of overhauling of 140t cranes are to be carried out by concerned Workshop:-

Sl. No. Schedule Life (Years) Cumulative life (Years) 1. 1st POH 8 8 2. 2nd POH 8 16 3. SPL MLR + Structural Audit 6 22 4. 3rd POH + Structural Audit 8 30 Note: Codal life of 140T DH BD Crane vide Rly. Bd.’s letter no. 2016/M (M&P) /175/ 3/A/T/ Codal life dated 14.02.17 is 30 years.

4. Main & Auxiliary Engine:

4.1 Periodicity of maintenance for Main Engine of M/s CIL (NTA 855-R4 & NTA 743 P): i) Daily Schedule ii) Weekly Schedule or after 25 Hours* iii) Monthly Schedule or after 100 Hours* iv) Quarterly Schedule or after 250 Hours* v) Half Yearly Schedule or after 500 Hours* - (Only lube oil change) vi) Yearly Schedule or after 1000 Hours* vii) 2-Yearly Schedule or after 2000 Hours*- (Air Cleaner/Filter & Belts of fuel pump, water pump, compressor, cooling fan & charging alternator change) viii) 4-Yearly Schedule or after 4000 Hours*- (Calibrate injectors, PT pump & adjust Valves) ix) Major Overhaul after 8 Years at the time of POH or after 8000 Hours*

4.2 Periodicity of maintenance for Main Engine of M/s MTU (OM 904-926 LA):

i) Daily Schedule ii) Half Yearly Schedule or after 500 Hours* - (Only lube oil change) iii) Yearly Schedule (V2) for adjusting valve clearance every 1st, 3rd, 5th & 7th Year iv) Additional work (M or Z2) every 2nd, 4th, 6th, 8th Yearly schedule v) Additional work (J3 or Z3) every 3rd, 6th, 9th Yearly schedule

Sl. No. Abbreviation Description of abbreviation used by MTU 1. Z Additional work (to be carried out Monthly) 2. V2 Yearly Schedule for adjusting the valve clearance every 1st, 3rd, 5th & 7th Yearly Schedule 3. M or Z2 Additional work every 2nd, 4th,6th, 8th Yearly schedule 4. J3 or Z3 Additional work every 2nd, 4th,6th, 8th Yearly schedule

4.3 Periodicity of maintenance of Auxiliary Engine of M/s KOEL (TA2 & HA-294) & M/s Lister-Peter (LPA-3):

i) Daily Schedule ii) Weekly Schedule or after 25 Hours* iii) Monthly Schedule or after 100 Hours* iv) Quarterly Schedule or after 250 Hours* v) Half Yearly Schedule or after 500 Hours* vi) Yearly Schedule or after 1000 Hours*

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 5 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______vii) 2- Yearly Schedule or after 2000 Hours* viii) 4- Yearly Schedule or after 4000 Hours* ix) Major Overhaul after 8 Years at the time of POH or after 8000 Hours*

4.4 High Speed Diesel: High speed diesel oil shall be to IS 1460:1995 read with Amendment-2 (Feb.’1999).

4.5 The filters, lubricants, oil change etc. provided in the various systems of engine are required to be changed as per the instructions of OEM. These are summarized below for information.

4.6 Filters of Main Engine & Auxiliary Engine:

Description Periodicity Lube Oil System 1 Full flow lube oil filter 500 hrs / Half yearly* 2 By-pass filter do Fuel Oil System 1 Fuel filter 500 hrs / Half yearly*

4.7 Lube Oil change periodicity of Main Engine, Auxiliary Engine & all Moving Equipments:

Description Periodicity 1 Lube Oil 500 Hrs / Half yearly * 2 Gear Box Oil 1000Hrs / Yearly*

Note: In case gear box unit is supplied by L&T, gear box oil shall not be changed during schedule maintenance because it is filled with long life lubricant oil (optimal long time PD 00 or IOC equivalent).

4.8 Recommended Lubricants for Main Engine models of M/s CIL make (NTA 855 & 743P) & M/s MTU make (OM 904-926 LA) & Auxiliary Engine models of M/s KOEL make (TA2 & HA-294) & M/s Lister-Peter make (LPA3):

S. No Name of Manufacturer Brand name 1 Indian Oil Corporation SERVO-PREMIUM CF4 15W40 2 Bharat Petroleum Corporation MAK CF4 15W40 3 Hindustan Petroleum Corporation Hylube Milcy Power 4 Valvoline Cummins Ltd Valvoline Power Supreme 15W40 5 Fuchs Lubricants 15W40 Cat-2/283.3

5. Hydraulic Oil for Pumps & Motors: 5.1 Recommended brands of anti wear Hydraulic Oil HLP-68 to IS: 11656-1992 / 10522 are as under:

S. No. Recommended equivalent brands of anti wear Hydraulic Oil HLP- 68 1 IOC Servo System HLP ‘N’- 68 / Servo System 46 2 HPC Enklo HLP- 68 3 BPC Bharat Hydrol – HLP-68/ Bharat Transmission Fluid C3, SAE 30 4 IBP IBPEXHD-68 / Shell Cornea 46 Oil ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 6 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

5.2 Recommended brands of ATF (Automatic Transmission Fluid) suffix A:

S. No. Recommended equivalent brands of ATF suffix A 1 IOC Servo Transfluid A 2 HPC HP ATF 3 BPC ATF A

5.3 Generally, both the oil types, ATF Suffix A & HLP 68 can be used. However, the oils should not be mixed. When converting to another oil type, the entire system must be drained and flushed, otherwise, it will not operate smoothly. The above recommended hydraulic oils shall be changed after one year / 1000hrs schedule.

However, the above recommended hydraulic oils shall be sent to laboratory for testing at the completion of every 6 (six) months or 500 hrs, whichever is earlier to check the following test parameters as per limits mentioned below:

S. No. Tests Limits 1 Kinematic Viscosity at 40ºC 62.2-74.8 2 Flash Point 210ºC 3 Total Acidity 1.5 (Max) 4 Pour Point 0ºC (Max) 5 Water Content Free from water in crackling test. Note: In case, limits are found OK, no oil change is required.

5.4 Topping up / Replacement of Hydraulic oil: a) During oil change and also during top-up, oil is recommended to be added through two stage filtration cart as per following specification:

Stage – I :- 25 micron absolute Stage – II :- 10 micron absolute Pump flow rate :- 20 lpm

Note: Details of the hydraulic oil filtration trolley is provided separately in RDSO Instruction Bulletin No. MP.IB. HYD.02.18.01 (Rev.- 0.00) b) In the absence of filtration trolley, oil must be added through at least an external oil filter with minimum retaining rate of 10µm so that cleanliness of oil is maintained.

6. Oils & Lubricants for other Crane Equipments:

6.1 For Gottwald Cranes (Old & New):-

S.No Fluid Cap. Recommended Oil & Grease Approx MOBIL SHELL IOC BPC HPC (in Ltrs) 1. Lube Oil for Pump 5.5 NA NA Servomesh Amocam HP 90 Distribution Gearbox SP 90 90 2. Lubrication Oil for 0.2 NA NA Servo MAK Hylube Chassis Air Premium CF4 - Milcy (Air Oiler only for CF4-15W40 15W40 Power ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 7 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Old design) 3. Lube Oil for Gear units: i) Slewing gear unit 15.5 ii) Main hoist gear unit 6.5 iii) Aux. hoist gear unit 6.5 iv) Derricking gear unit 9.5 NA NA Servomesh Amocam HP 90 v) Recovery winch 3.4 SP90 90 gear unit vi) Travel gear unit 12.0 4. Lube Grease for Bearings of Gear units: i) Main Hoist gear unit NA NA Servogem MP Lithon ii) Aux. Hoist gear unit EP2 Grease 3 EP - 2 iii) Derricking gear unit 5. Lube Grease for As per NA NA Servogem NA Lithon gear wheel / pinion require EP1 EP - 1 6. Lube Grease for ment. Servogem Bharat slew ring NA NA EP2 Comex Lithon 7. Lube Grease for compound EP - 2 axle gear unit DEP

6.2 For Cowans Sheldon Cranes (New)

S.No Fluid Cap. Recommended Oil and Grease Approx. MOBIL SHELL IOC BPC HPC (in Ltrs) 1. Lube Oil for Pump 5 NA NA Servo Bharat HP Gear Distribution Gearbox Super Spirol Oil XP- 85W140 85W140 80W90 2. Lubrication Oil for As per NA Hydro- Servo MAK - Turbinol- Chassis Air requir- vanne 2000 Ultra-40 T- 40 77 Compressor ement Rimula 3. Lube Oil for Gear units: i) Slewing gear unit 29 ii) Main Hoist gear unit 14 iii) Aux. Hoist gear unit 4 iv) Derricking gear unit 30 NA Omala SP 220 Bharat ENKLO - v) Recovery winch gear 4 220 / Amocam - 220 unit Omala 220 vi) Travel gear unit 35 EP2 4. Lube Grease for Bearings of: i) Main Hoist gear unit ii) Aux. Hoist gear unit iii) Derricking gear unit NA Alvania Servo Bharat Lithon 5. Lube grease for gear As per EPLF2 Gem Lanthex EP2 wheel / pinion require- EP-2 LFEP2 6. Lube grease for slew ment ring 7. Lube grease for axle gear unit

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 8 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______6.3 For Cowans Sheldon Cranes (Old)

S.No Fluid Cap. Recommended Oil and Grease Approx MOBIL SHELL IOC BPC HPC (in Ltrs) 1 Lube Oil for Pump 7.0 OIL, Servo BHARAT, Distribution Gearbox System -100 Hydrol - 100 2 Lubrication Oil for 7.0 NA NA OIL, Servo BHARAT NA Chassis of Air System - 68 Hydrol - 68 Compressor 3 Lube Oil for Gear units: i) Slewing gear unit ii) Main Hoist gear unit iii) Aux. Hoist gear unit OIL, Servo BHARAT, NA iv) Derricking gear unit 90.0 NA NA Transmission Transmission v) Recovery winch gear C-3, SAE-30 Fluid unit C-3,SAE-30 vi) Travel gear unit 4. Lube Grease for Bearings: i) Main Hoist gear unit As per ii) Aux. Hoist gear unit require NA NA Servogem-3 BHARAT – MP NA iii) Derricking gear unit ment: Grease 3

5 Lube grease for gear -do- NA NA Servo Bharat NA wheel / pinion Tak-40 Comex 6 Lube grease for slew Compound ring ‘H’ 7 Lube grease for axle gear unit 8 Grease for Relieving -do- NA NA Molykote: GN Plus as NA Bogie Primer & Molykote: BR 2 or Longterm Grease as Lubricant 7. Hydraulic Oil Pressure:

7.1 Maximum Working Pressure for High Pressure Hydraulic Hoses:

S. No. Description of Hoses Maximum Working Pressure (bar) Gottwald cranes Cowans Sheldon cranes 1. Main hoist (for Hoisting) 280 330 2. Main hoist (for Lowering) 280 108 3. Aux. hoist (for Hoisting) 280 290 4. Aux. hoist (for Lowering) 280 108 5. Derrick - in 280 330 6. Derrick - out 280 108 7. Slewing 250 220 8. Travelling 280 340 9. Hauling 280 200 10. Cooling (Radiator) Fan 280 100 11. Draw Beams (Cowans Old only) NA 170 12. Derrick-Tie Cylinder NA 25

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 9 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

7.2 Operating Pressure for Hydraulic Circuits of Gottwald & Cowans Sheldon cranes:

S. No. Hydraulic Operating Pressure (bar) Circuit Type Gottwald Cranes Cowans Sheldon Cranes Old New Old New 1. Power Ckt. I & II 280 280 As given in Para 7.1 above 2. Slewing Ckt. 200 200 220 220 3. Pilot Ckt. 32-40 32-40 30 55-70

8. WIRE ROPES:

8.1 Wire Rope Construction & Terminology used:

New wire rope when replaced shall be of standard construction as applicable to each variant of crane meeting technical requirements to IS - 2266/2002. Breaking strength of the wire rope shall not be less than 6 times the maximum static load on the rope.

8.2 Wire Rope Construction & it’s designation:

Wire rope standard construction designated as 6 x 37 18/12/6/1F(C) means:

“Wire Rope consists of 6 strands wounded helically over a Fiber Core. Each strand contains 37 wires wounded helically in succession i.e. 6 wires on one steel wire (core), then 12 wires and then again 18 wires respectively“.

8.3 Terminology used in Wire Ropes:

i) Wire (Round): A single circular rope of continuous length of metal drawn cold drawn from a rod. ii) Strand: An element of rope consisting of an assembly of appropriate shape and dimensions helically wound wires in one or more layer. iii) Core: The centre of a strand or the centre of a wire rope (which may be of Steel or Fibre). 8.4 Wire Rope Diameter Details:

S.No. Crane type Wire Rope Diameter (in mm) for Main Hoist Derrick Aux. Hoist Winch a. Gottwald Old 26 26 22 16 b. Gottwald New 26 26 22 18 c. Cowans Old 36 32 26 22 d. Cowans New 32 32 22 20

8.5 Wire Rope Inspection Criteria:

Wire ropes are consumable items with a limited life. Therefore, the complete length of wire ropes and rope fittings must be inspected daily. In addition, the wire rope must be examined by competent person at regular intervals. An examination should be necessarily carried out, if the rope is to be put back into service after a long period.

8.6 Conditions for discarding wire rope:

Wire rope must be discarded immediately, if following conditions are observed:

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 10 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

8.6.1 Breakage in wire of strand:

a) For Main Hoist & Derrick Wire Rope:

If the rope shows more than 5 wire breakages on a length of 6 x rope diameter (e.g. 6 x 26 mm = 156 mm) OR 10 wire breakages on a length of 30 x rope diameter (e.g. 30x26 mm = 780 mm).

b) For Auxiliary Hoist Wire Rope:

If the rope shows more than 5 wire breakages on length of 6 x rope diameter (e.g. 6 x 22 mm = 132 mm) OR 13 wire breakages on a length of 30 x rope diameter (e.g. 30x22mm = 660 mm).

8.7 Reduction in Rope diameter:

Reduction in rope diameter by 15% or more from the actual rope diameter in new condition over a length of 10 x rope diameter (e.g. 260mm for main hoist & derrick and 220 mm for auxiliary hoist rope). The part of rope passing over sheaves and drum is more vulnerable & shall be checked for diameter.

8.7.1 Reduction in Rope diameter due to wear or friction:

Reduction in rope diameter by 10% or more due to wear or friction with any member.

8.8 Rope deformations:

If deformations like waviness, loop formations, loose wires, nodes, rope thinning, misplaced outer wires, kinks and flat areas, are noticed on the rope.

8.9 Special observation on wire rope:

The wire breakages generally occur after a certain number of operating hours and then the number increases more quickly. It is recommended to keep watch on the condition of wire after any of wire breakage has started. Action for the discarding should to be taken as indicated above.

8.10 Functional Test:

After every rope change, functional test without load must be carried out. During the test, it should be ensured that rope runs smoothly.

8.11 Cleaning & Greasing:

Periodically cleaning & greasing of ropes, if recommended by OEM shall be done for proper and smooth running of ropes on drums & sheaves. Refer OEM’s manual.

8.12 Rope Change:

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 11 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______If rope change is necessary, then it must be ensured that a wire rope of the same type and breaking strength as follow the Steel Wire Rope to IS: 2266/2002 construction IWRC standard of the original wire rope in new condition is fitted. When a new wire rope is being mounted, ensure that it is not twisted. Prior to operating with a newly fitted rope, it must be ensured that the rope is properly placed and guided in the grooves of the rope drum, rope pulleys and the compensation rollers. It is always advisable to change both main hoist & derricking wire ropes together to ensure the same quality and to maintain the same inspection & maintenance intervals.

9. General Instructions for Gears

Generally, gears with considerable back-lash will continue to function reasonably well but with excessive noise. Abnormal back-lash on gears affects the life of other components in gear box due to vibration. Care should be taken while checking the back-lash on primary side gears because of cyclic variation of torque and speed of diesel engine. If premature gear wear or damage is noticed, it may be generally due to bearing trouble, mis-alignment, presence of foreign matter or insufficient lubrication. The first indication of defective gear(s) would be an increase in the noise level, which indicates rough operation. The following indications of undue wear and tear may be looked into, if gear damage is suspected:

i) Fractures a) Tooth face fracture generally occurs due to shock loads or foreign matter such as broken pieces of metal forced through gear teeth in mesh. b) Fatigue fracture generally occurs from the root of the tooth. c) Tooth corner fracture or tooth splinter occurs, generally due to misalignment of gear. Mis-alignment of gears also results in a great load on tooth corners.

ii) Tooth Face damage: a) Pitting- The working surface of the teeth is severely damaged by pitting or spilling over entire surface or at the base of the gear teeth. b) Deformation- This is due to too little back-lash which leads to frictional heating and softening of the case. c) Wear due to sliding- This is due to inadequate lubrication especially on gear meshes of high gear ratio. d) Development of grooves, roughing of the face or cavitation- This is due to abrasive foreign matter coming between the meshing teeth. e) Cracking of the Case-Hardened surface. f) Running hot- This is indicated by the development of blue colourations due to heat concentration which may be caused by inadequate lubrication. Pipelines may be choked or spray jet dislocated. Lubrication is vital to gears and therefore, nozzles must always be carefully checked during assembly and dismantling of the gears so as to always ensure a stream of oil to the gears.

Note: It is generally advisable to replace gears subjected to the defects mentioned above.

10. Tool Kit:

10.1 The following indicative list of tools, machines and accessories are applicable only for Gottwald design cranes:

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 12 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______S. No. Tools 1. Hammer - 800 g 2. Flat chisel 3. Oil spray can 4. Hand lever operated grease gun 5. 17 Double ended open jawed spanners, 8x10-55x60 6. 6 Single ended open-jawed spanners, 8/41/65/70/75/80 mm 7. 8 Hexagonal socket head wrench, SE 6/8/12/14/22/27/32 8. 4 Tubular hexagonal box spanners, 13x7/19x22/24x30/30x36 9. 4 Tommy bars for spanners, A 10/12/16/18 10. Standard Ratchet, ½” 11. Extension Piece 10” 12. Articulated square-drive socket adapter, 70 mm 13. Socket for wrenches, SW 17/19 14. Min. 3 Screw drivers 15. Light tester 16. Hose, DN 6/222bX5000 17. Pressure gauge, 0-400 bar with connection fitting 18. Union nuts 19. Cutting ring 20. Seeger Circlip ring pliers, A3/A4 21. Flat-nosed and cutting nippers 22. Pipe wrench 23. Sickle spanner 24. Hose, NW18X3 5000

10.2 The following indicative list of tools, machines and accessories are applicable only for Cowans Sheldon cranes:

S. No. Tools 1. A full set of A/F open ended spanner 2. A full set of A/F ring spanner 3. 75 mm capacity adjustable wrench 4. Spring Link Bolt spanner 5. Blocking Screw spanner 6. Set of Allen keys 1.5mm A/F to 17 mm A/F 7. 1.75 Lb Hand hammer 8. 10" Insulated Screw Driver (Std. Tip) 9. 6" Insulated Screw Driver (Std. Tip) 10. 4" Insulated Screw Driver (Std. Tip) 11. Set of Tommy Bars 16" Dia. 12. Adjustable Spanners 13. Pipe wrench 14. Feeler Gauge 15. A set of Extension piece of 150, 225, 300 & 375 mm drive extension 16. A set of Impact Socket C/W Ring & Pin 24, 30,36,45,& 65 mm A/F 17. Peg spanner for dismantling Jacks & Cylinder, manufactured Items. 18. Junior Hand Compressor (Grease gun) with connector 19. 1/2 & 2 Litre oil feeder 20. 0-70 & 0-400 Bar Pressure Gauges with Hose ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 13 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______21. 35 mm O/D x 8500 mm Long Hydraulic oil filling hose 22. Aluminium extension ladder 3.5 m closed 23. Charging unit for accumulator with pressure gauge & hose 24. Flushing unit of 15 HP capable of developing at least 1950 psi at 43 LPM 25. Hose crimping m/c having cap. to handle1.25" ID hoses including multi-spiral 26. Hose skiving tools 27. Hose cutting machine 28. Pipe bending c/w 6 sets of formers

11. General Instructions:

The high reliability of availability of cranes necessitates properly laid down maintenance schedules to be followed. A well-organized inspection is essential to ensure reliability and freedom from failure in service. There are certain fundamental requirements that are important to any successful maintenance program. These are:-

.1 A well-scheduled maintenance program including an adequate system of maintenance of records. All work done including methods and tools used must be in accordance with the manufacturer’s instructions, maintenance manual or any technical orders issued. Whenever any schedule examination except the daily is carried out all the items of the previous schedules should also be attended to.

.2 Adequate provision of well trained supervisors and skilled workmen shall be ensured. The team of staff shall comprise of 1 Supervisor (SSE), 2 drivers, 4 skilled staffs and 8 un-skilled staffs.

.3 Adequate provision of proper maintenance facilities and tools shall be ensured alongwith provision of lubricating oil, coolant etc. required to ensure satisfactory performance of major equipments & their sub-assemblies.

.4 All measuring devices such as torque wrenches, electric meters, lubricant dispensers etc. which require calibration should be checked quarterly or sooner, if required, for accuracy.

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

.6 In case any structural part is damaged and is to be rectified, ensure the following:

a) Direct flame should not damage cables, hoses & pipes. Must take all fire prevention measures for hoses, cables etc. from direct heat by shielding the flame. b) For any structural repair, ensure proper preheating. Use only recommended electrodes and argon shield welding. c) If welding is carried out on the crane, it is a wise precaution to disconnect SLI from both sides of the crane. Disconnect main battery while welding. Earth the respective structure directly.

.7 While carrying out the work of the schedule, all missing nuts, bolts, set-screws, cotters, split pins etc. must be REPLACED as and when found defective. Split pins and cotters once removed must not be used again, but new ones must be fitted. All loose nuts, setscrews etc. must be tightened. Wherever cotters or split pins are fitted, they must be of the correct size and so fitted that they bear against the nut or washer properly.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 14 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Examine and ensure that all locking devices, wherever provided, are properly secured. Replace all gaskets, seals, rubber items, washers etc. during schedules.

.8 Do not mix different brands of greases. Excessive lubrication is as harmful as inadequate lubrication.

.9 The fire extinguishers should be re-filled and maintained as per the schedule. Under no circumstances, should crane be allowed to leave the shed without its required number of fire extinguishers in working order. The staff while working under the crane or while standing over footboards / superstructure must not smoke or strike up fire nearby.

.10 All tools and parts should be accounted for and removed from the crane after schedule maintenance work has been performed. Check and ensure that no tools or replaced parts lie over the crane.

.11 Use of waste cotton on crane is PROHIBITED. Use lintless rags or wiping towels. The underframe and top surface of fuel tanks should be cleaned to remove dirt and oil. Spraying of water directly on electrical equipment should be avoided.

.12 Irrespective of the above, the concerned Workshops are requested to kindly repair the inside of Undercarriage of Match Truck & Ballast Wagon. If found damaged/corroded etc., the same shall be fully repaired during POH.

Crane shall be handed over to consignee after carrying out full load testing of crane and issuing satisfactory performance certificate of crane as “OK”.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 15 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Daily Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane

Crane No. ______Shed ______Rly______

Hours Meter Reading______Time From ______Time To______Date:.______

BEFORE STARTING THE ENGINES

1. MAIN ENGINE (Applicable only for M/s CIL NTA 855 & 743P):

1.1 Check engine oil level and top up, if necessary. ‘H’ mark must be maintained. 1.2 Check belt tension and condition of belts for cuts, fretting, cracking etc. 1.3 Check for loose foundation bolts. Tighten them, if required. 1.4 Fill/top-up radiator with distilled water / coolant additive which should be free from any suspended impurities such as clay, sand etc. Radiator cap should be fitted back after necessary fill up since this will cause aeration and overheating of the water coolant. 1.5 Fuel tank to be filled-up with clean diesel oil to ‘Fuel’ capacity. 1.6 Clean the engine.

Note: M/s MTU has not recommended any Daily Schedule. Refer MTU’s manual.

2. AUXILIARY ENGINE of M/s KOEL (TA2 & HA-294) & M/s Lister-Peter (LPA-3):

2.1 Check for engine sump oil. Top up, if necessary. 2.2 Fuel tank to be filled with clean diesel oil to “Full” capacity, if required. 2.3 Clean the engine.

3. SUPER STRUCTURE:

3.1 Check for the oil level in pump distribution box (P.T.O. unit) / splitter gear box. Top up, if necessary. 3.2 Check hydraulic oil level. Top up, if necessary. For this check, raising of gallows may be necessary. 3.3 Check for any leakage or damages of hoses and pipes. Rectify, if necessary. 3.4 Check the cablings connecting various parts of the electrical systems for physical damages. 3.5 Check Fire-extinguishers and First-Aid-Box in position and keep them in working order. 3.6 Top up air oiler supply, if necessary. 3.7 Drain condensate from both air reservoirs.

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

4. UNDER CARRIAGE:

4.1 Check spring suspension for any breakage or deficiency. 4.2 Check for damage and deficiency in the brake system including pipes and hoses. 4.3 Check travel clutch indicator cable and lubricate, if required. 4.4 Floor plate to be cleaned. Ensure it is free from oil and greasy substances. 4.5 Drain out condensate from all the air reservoirs.

Note: Even minor leakage of oil / air must be noted and eliminated. 5. MATCH TRUCK:

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 16 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______5.1 Check for breakage or deficiency in spring suspension system. 5.2 Check for damage and deficiency in the brake system including pipes and hoses. 5.3 Check leakage and functioning of hand brake.

AFTER STARTING THE ENGINES

6. MAIN ENGINE (Applicable only for M/s CIL NTA 855 & 743P):

6.1 Check leakages of fuel, oil, water and exhaust air supply and rectify, wherever required. 6.2 Check for any loose nut, bolt or fastener. Tighten them, if required. 6.3 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.) 6.4 Check lube oil pressure (operating pressure 3.5kg/cm2 at idle & 5kg/cm2 at rated speed respectively). 6.5 The main engine of cra ne shall be run at rated rpm for 30 minutes*. 6.6 Clean the engine after shut down. Note: M/s MTU has not recommended any Daily Schedule. Refer MTU’s manual.

7. AUXILIARY ENGINE of M/s KOEL (TA2 & HA-294) & M/s Lister- Peter (LPA-3):

7.1 Check for any leakage of oil. Rectify, wherever required. 7.2 Check for lose foundation of bolts. Tighten them, if required. 7.3 The auxiliary engine of crane shall be run at rated rpm for 15 minutes*. 7.4 Clean the engine after shut down. *Note: Running timings of Engines shall be strictly adhered to, being recommended by JAG committee on maintenance of 140t cranes vide para no. 2.4.1. of report.

8. SUPER STRUCTURE:

8.1 Check air pressure (Operating pressure to be 6.0 bar to 6.8 bar & 3.8 bar for brake cylinder); Rectify faults, if any. 8.2 Check pollution indicator of hydraulic oil filter. Replace the filter, if the indicator is at red mark or above 3 bar. (Check filter choke indication available in cab for Cowans Sheldon new crane). 8.3 Check hydraulic oil pressure of various circuits indicated above at Para 7.2 of General Description. 8.4 Check functioning of fans, lights, screen wipers and horns in cab. 8.5 Check leakage of oil, water and air. Rectify, wherever required. 8.6 Check that all limit switches are in working order. 8.7 Check that solenoid valves are not bridged (manually)

9. UNDER CARRIAGE:

9.1 Check for any leakages. Rectify, wherever required. 9.2 Check functioning of brake-rigging arrangement. 9.3 Check functioning of service brake.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 17 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______A. IMPORTANT REPAIRS (Observed by SSE/ JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

Certified that examination and repairs have been completed. If not, reasons as below:- Maintenance by:- i) Technicians/ MCMs (Mechanical): ii) Technicians/ MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 18 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

Weekly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane (At the completion of 25 working hours)

Crane No. ______Date ______Shed ______Rly.______

Hours Meter Reading ______Last Schedule Done & Date______

Time From ______To ______Time taken ______Hrs ______Minutes

Repeat previous schedule. Additionally, following activities may be carried out:

1. MAIN ENGINE (Applicable only for M/s CIL NTA 855 & 743P) and AUXILIARY ENGINES (M/s KOEL TA2 & HA-294 and M/s Lister- Peter LPA-3):

1.1 Check electrolyte level, specific gravity & voltage of batteries. A lead acid battery is fully charged with a specific gravity of 1.265 at 27°C and voltage should be 110V. To be topped up, if necessary with distilled water. The terminal should be adequately coated with petroleum jelly. 1.2 Check battery voltage. Repair, if required. 1.3 Check foundation tightness of auxiliary rotating machines. 1.4 Check coolant level in engine radiator. Use distilled water. 1.5 Clean dust pan and pre-cleaner on dry type air cleaners. 1.6 Clean crankcase breather. 1.7 Drain out water & sediments from water separator.

Note: M/s MTU has not recommended any Weekly Schedule. Refer MTU’s manual.

2. SUPER STRUCTURE:

2.1 Check hydraulic oil filter. 2.2 Check operation of hydraulic brake system. 2.3 Check operation of main, auxiliary & derrick limit switches. 2.4 Check operation of relays. 2.5 Check oil level in jib indicator. 2.6 Check pin socket fitment of amplifiers. 2.7 Check operation of SLI system - Joy-stick(s) & Duty selectors. 2.8 Check for any breakage in wire rope or damages. Rectify, if necessary. 2.9 Lubricate all sheaves and pedestal bearings of Main hoist & Auxiliary hoist, Jib foot pin and rollers and counterweight bolt pivots, if required (as per OEM’s manual)

Note: Even minor leakage of oil must be noted and eliminated. 2.10 Lubricate all pins, top & bottom tie pins, hand brake etc. and slew ring bearings, if required and applicable. 2.11 Lubricate main and auxiliary hoist load pin.

3. JIB & IT's EQUIPMENT:

3.1 Check free running for any damage in pulley, wire rope, bearing & pin for Main hoist and Auxiliary hoist pulley. Lubricate, if required. 3.2 Check all sheaves and bottom block bearings & lubricate.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 19 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______3.3 Lubricate jib head rest pin, if required. 3.4 Lubricate jib stop pivot pins & head rest pin. 3.5 Lubricate auxiliary hoist block hook swivel & cross head. 3.6 Lubricate main hoist block hook swivel & cross head. 3.7 Carry out load testing by lifting counterweights & perform crane operations.

4. UNDERCARRIAGE:

4.1 Lubricate relieving bogie coupling pins (only for Cowans old crane). 4.2 Lubricate centre & end draw beam rollers (only for Cowans old crane). 4.3 Lubricate blocking screws. 4.4 Lubricate travel clutch shafting. 4.5 Lubricate bogie pivot oil boxes. 4.6 Lubricate bogie rubbing pads. 4.7 Lubricate brake linkage pivot pins. 4.8 Check spring suspension for any breakage or deficiency. 4.9 Check travel indicator cable and lubricate.

5. MATCH TRUCK:

5.1 Check spring suspension for any breakage or deficiency. Rectify, if required. 5.2 Lubricate bogie side bearer oil boxes. 5.3 Lubricate bolster swing link pins. 5.4 Lubricate brake work and brake rigging. 5.5 Lubricate axle box guides and dash pots. 5.6 Lubricate trestle pad and trestle pivot with grease. 5.7 Lubricate hand brake threads.

6. RELIEVING BOGIES (Only for Cowans Sheldon Old Crane):

6.1 Check for breakage or deficiency in spring suspension system. Rectify, if required. 6.2 Check for damage and deficiency in the brake system including pipes and hoses. 6.3 Clean floor plate. Ensure it is free from oil and greasy substance. 6.4 Check leakage and functioning of parking brake. 6.5 Lubricate spring hanger pins. 6.6 Lubricate break linkage pivot pins. 6.7 Lubricate locking pins. 6.8 Lubricate adjusting screw. 6.9 Lubricate centre castings.

7. BALLAST WAGON (Only for Cowans Sheldon Old Crane):

7.1 Check for breakage or deficiency in spring suspension system. Rectify, if required. 7.2 Check for damage and deficiency in the brake system including pipes and hoses. 7.3 Check leakage and functioning of parking brake. 7.4 Lubricate bogie side bearer oil boxes. 7.5 Lubricate bolster swing link pins. 7.6 Lubricate brake work and brake rigging. 7.7 Lubricate axle box side bearer oil boxes. 7.8 Lubricate hand brake threads.

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

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 20 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 21 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Monthly Schedule for Maintenance of 140t Gottwald/Cowans Sheldon Crane (At the completion of 100 working hours)

Crane No. ______Date ______Shed ______Rly.______

Hours Meter Reading ______Last Schedule Done & Date______

Time From ______To ______Time taken ______Hrs ______Minutes

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE: 1.1 M/s CIL Model NTA 855 & 743P: 1.1.1 Clean the air intake filter. 1.1.2 Make sure that the vent hole in the fuel tank cap is clear.

1.2 M/s MTU Model OM 904-926 LA: 1.2.1 Check function of indicator lamps and warning system. 1.2.2 Check all equipments for leaks and condition. In the event of fluid loss, find the cause and rectify it. 1.2.3 Check the air intake duct between the air filter, charge air cooler and the engine for leaks and condition. In the event of leaks, find and rectify the cause. 1.2.4 Engine Cooling system: Check & adjust corrosion / anti-freeze protection. 1.2.5 Cooling & Heating system: Check radiator, cables and hoses for leaks and condition. In the event of fluid loss or damage, find and rectify the cause. Check for coolant quality & level, Top up, if required as per OEM manual. 1.2.6 Check exhaust system for leaks and condition. In the event of leaks or damage, find and rectify the cause. 1.2.7 Check all reservoirs, units, covers, bellows & protective caps for leaks and condition. In the event of fluid loss or damage, find and rectify the cause. 1.2.8 Check all lines, hoses and electrical cables for areas of abrasion and correct routing. 1.2.9 Charge the pressure reservoir.

2. AUXILIARY ENGINES of M/s KOEL (TA2 & HA-294) & M/s Lister-Peter (LPA-3):

2.1 Clean dust pan and pre-cleaner on dry type air cleaners. 2.2 Clean crank case breather.

3. SUPER STRUCTURE:

3.1 Check SLI, all electrical connections and functioning of all sensors. 3.2 Check that display of radius on the SLI console of the crane agrees with actual radius. 3.3 Check that all working parameters of load charts are in relation to SLI cut-off. 3.4 Check wire rope. Clean & lubricate as per Para 8 of General Description. If not complying with conditions indicated in Para 8, wire rope must be discarded. 3.5 Lubricate heavy lift ballast extension bearing surface, equalising beam, relieving bogie coupling pin, hand brake acme threads and check their working condition (applicable only for Cowans Sheldon old design crane). 3.6 Lubricate counter weight bolt pivot & threads, if applicable. 3.7 Lubricate telescopic tie rod bearings, sheave bearings and front strut bottom bearings (applicable only for Cowans Sheldon old design crane). 3.8 Lubricate slew lock-pin, bearing of cylinder for retractable arm.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 22 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______4. JIB:

4.1 Lubricate main and auxiliary snatch block swivel and sheave bearings. 4.2 Lubricate derrick pulley blocks & sheaves bearings only for Cowans Sheldon old crane. 4.3 Lubricate ropes with grease as per Para 8. 4.4 Clean & lubricate jib foot sliding surface (fork & pin) & rollers for Cowans Sheldon crane.

5. UNDER CARRIAGE:

5.1 Check travel brake equipment, linkage, linings, etc. and pneumatic systems. 5.2 Check functioning of outriggers and hydraulic cylinders. 5.3 Lubricate travel gears with grease and clutches shifts with grease. 5.4 Lubricate brake linkage, outriggers pins with oil & side bearer, hand brake threads and rail clip screws with grease for Cowans Sheldon crane). 5.5 Lubricate blocking screws & hanger bracket pins for Cowans Sheldon crane. 5.6 Lubricate bogie pivot oil boxes for Cowans Sheldon crane.

6. MATCH TRUCK AND BALLAST WAGON (Only for Cowans Sheldon Old crane):

6.1 Check for travel brake equipment, hoses, linkage, shoes etc. 6.2 Lubricate brake linkage pins with oil and side bearer with grease. 6.3 Lubricate hand brake threads & brake linkage pins with oil. 6.4 Lubricate trestle pad and trestle pivot with grease.

7. RELIEVING BOGIES (Only for Cowans Sheldon Old crane):

7.1 Check oil for enerpac and top up, if necessary. 7.2 Lubricate adjusting screws, centre castings, hanger bracket pins, locking pins and brake linkage pivot pins. 7.3 Lubricate wishbone beam bushes (First coat with Molykote GN plus paste and then apply Molykote long term 2 plus grease)

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):- S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS: S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 23 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Quarterly Schedule for Maintenance of 140t Gottwald/Cowans Sheldon Crane (At the completion of 250 working hours)

Crane No. ______Date ______Shed ______Rly.______

Hours Meter Reading ______Last Schedule Done & Date______

Time From ______To ______Time taken ______Hrs ______Minutes

Repeat previous schedules. Additionally, following activities may be carried out:

1. SUPER STRUCTURE:

1.1 Check windscreen wiper. Rectify faults, if any. 1.2 Lubricate slew gear teeth and winch gear box. 1.3 Lubricate face of extension beams for heavy ballast (applicable only for Cowans old design crane). 1.4 Lubricate limit switch chains. 1.5 Clean radiator cores thoroughly, if required.

2. JIB:

2.1 Check visually for defects / cracks of all structural components. 2.2 Lubricate drum, sheaves and jib stopper pad with grease.

3. UNDERCARRIAGE:

3.1 Check wear on brake lining. 3.2 Lubricate hand /parking brake shafting and pinions. 3.3 Lubricate in-riggers/out-riggers sliding surface. 3.4 Clean the gearbox in the area of the oil seals and check for leakages. If there is any sign of leakage, fit new seals as applicable.

4. MATCH TRUCK & BALLAST WAGON (Only for Cowans Sheldon Old design crane):

4.1 Check wear on brake lining. 4.2 Lubricate hand brake shafting and pinions. 4.3 Lubricate rubbing pads, pivot and head rest pins of match truck trestle.

5. RELIEVING BOGIES (Only for Cowans Sheldon old design crane):

5.1 Lubricate hand brake shafting, pinions and pivot pins.

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

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 24 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 25 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Half-yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane (At the completion of 500 working hours)

Crane No. ______Date ______Shed ______Rly. ______

Hours Meter Reading ______Last Schedule Done & Date______

Time From ______To ______Time taken ______Hrs ______Minutes

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINES of M/s CIL NTA 855 & 743P (to be done with the help of OEM):

1.1 Check all air cleaner connections for cracks, chafing etc. Tighten all air in-take connections. 1.2 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. 1.3 Change air cleaner element. 1.4 Change lubricating oil by-pass filter element and gasket. 1.5 Change fuel filter element and gasket.

2. AUXILIARY ENGINES of M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3 (to be done with the help of OEM):

2.1 Check valve tapped clearance (applicable only for Cowans Sheldon crane) 2.2 Service air filter, if required. 2.3 Renew lubricating oil filter element, if required. Note: Above job is to be done with help of authorized dealer of Main & Aux. Engine. 2.4 Drain sump. Flush out approved brand of flushing oil and re-fill with new oil. 2.5 Change/replace engine oil, if required. Note: Oil change periodicity may be extended, if oil condition is found satisfactory during lube oil analysis in a laboratory. 2.6 Clean the oil tank, fuel filter bowl and ceramic filter thoroughly / Re-new fuel filter element, as applicable. 2.7 Knock out soot from the exhaust silencer. 2.8 Clean the cooling air duct and space between cooling fins on cylinders.

3. SUPERSTRUCTURE:

3.1 Check all drive assemblies. 3.2 Check oil level and send it to M&C lab for spectrographic analysis & extend the life, if found OK as per OEM manual. Else top up, as necessary for following items of respective cranes (Refer Para 6 of General Description):

a) Main & Auxiliary hoist reduction unit. b) Derrick reduction unit & Recovery winch reduction unit. c) Slewing gear reduction unit d) Traction gear box e) Pump Distribution Gear box / Splitter Gear box f) Draw beam extension, Tie cylinders, Equalising beam, Relieving bogie coupling unit for Cowans Sheldon old design crane.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 26 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______3.3 Collect sample of hydraulic oil. Get it tested and replace, if clogging gauge pressure is more than 3 kg/cm2. Change return line filter element / filter of hydraulic tank (It shall be carried out with respective OEM). 3.4 Change fuel tank‘s filter element / filter. 3.5 Check fuel oil hoses for any damage and replace, if required. 3.6 Check the accumulator and recharge it. 3.7 Check ropes for damages / breakages. 3.8 Lubricate: a) Counterweight gallows with grease only for Gottwald make crane. b) Rope drum bearings with grease. c) Foot pedal in cab with oil. 3.9 Clean & re-grease jib foot sliding surface (fork & pin)

4. UNDERCARRIAGE:

4.1 Clean and lubricate with grease: a) Slewing gear teeth. b) Travelling gear reduction unit. c) Splined shaft d) Screw coupling and buffers. 4.2 Lubricate slewing ring bearing with grease through grease nipples. Refer Para 6 of General Description. 4.3 Lubricate bogie pivot with grease. 4.4 Lubricate bogie bolster pins with grease.

5. MATCH TRUCK & BALLAST WAGON (Only for Cowans Sheldon old design crane):

5.1 Clean and lubricate screw coupling and buffers with grease. 5.2 Lubricate bogie pivot with grease. 5.3 Lubricate bogie bolster pins with grease.

6. RELIEVING BOGIES (Only for Cowans Sheldon Old design crane): 6.1 Clean and lubricate screw coupling and buffers with grease: 6.2 Clean lubricate with grease wishbone beam bushes. 6.3 Collect sample of hydraulic oil from oil tank and relieving bogies, get it tested and replace, if required.

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):- S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS: S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 27 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane (At the completion of 1000 working hours)

Crane No. ______Date ______Shed ______Rly. ______

Hours Meter Reading ______Last Schedule Done & Date______

Time From ______To ______Time taken ______Hrs ______Minutes

Yearly Schedule to be carried out with the help of concerned W/shop & respective OEM.

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE:

1.1 M/s CIL NTA 855 & 743P:

1.1.1 Change/replace engine oil, if required. Note: Oil change periodicity may be extended, if oil condition is found satisfactory during lube oil analysis in a laboratory. 1.1.2 Replace new lube oil full flow filter element and gasket.

1.2 M/s MTU Model OM 904-926 LA: Repeat below mentioned schedule every alternate year i.e. 1st, 3rd, 5th & 7th year.

1.2.1 Check and adjust the valve clearance of the engine. 1.2.2 Check function of indicator lamps and warning systems.

2. AUXILIARY ENGINES (M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3):

2.1 Change paper element of the fuel filter. 2.2 Change the lube oil filter.

3. SUPER STRUCTURE:

3.1 Check oil water & air hoses. Change them, if necessary. 3.2 Check for corrosion. Repair, if required and paint. 3.3 Check setting of limit switches for proper cut-off with the help of OEM & Workshop. 3.4 Calibrate SLI system, jib inclinometer, load cell & slew encoder. 3.5 Check windows and doors for corrosion, proper fitting and locks. 3.6 Inspect drive assembly. 3.7 Change gear box oil. 3.8 Clean water and air cooler fans with water jet. 3.9 Clean radiator externally. 3.10 Clean fuel oil tank and flush. 3.11 Drain sediment from hydraulic oil tank.

4. UNDER CARRIAGE:

4.1 Check oil level of the travel gear box. 4.2 Check all brake equipments. 4.3 Lubricate gear shifting arrangements. 4.4 Lubricate the travel clutch indicator cable & guides only for Cowans Sheldon old crane. 4.5 Inspect axle box roller bearings & refill with grease, if required (As per OEM’s manual) ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 28 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______4.6 Check wheel diameter of crane wheels. It shall be as under:

S.No. Crane type Crane Wheel Diameter (New/Condemning in mm) a. Gottwald Old 915 / 860 b. Gottwald New 920 / 840 c. Cowans Old 915 / 840 d. Cowans New 915 / 813

4.7 WHEEL PROFILE CHECKING: IRS Thick Profile to RDSO Drg. no. CSL-3040 has been provided on the new crane wheels. Check for wheel wear as per RDSO Drg. no. CSL-2127/M. If wear is found beyond limit, the crane shall be sent for wheel turning.

4.8 UST OF WHEELS & AXLES: Check for defects of crane wheels & axles, if any as per norms. Rectify the same. Carry out Ultrasonic Testing on wheels & axles as recommended by SAG committee in para 5.1 of their report.

5. MATCH TRUCK (EXCEPT COWANS SHELDON OLD DESIGN CRANE):

5.1 Check all brake equipments. 5.2 Inspect axle box roller bearings & refill with grease, if required (As per OEM’s manual) 5.3 Match Truck is fitted with CASNUB 22HS bogies. Check wheel diameter of Match Truck wheels. It shall be as under:

S.No. Crane type M/Truck Wheel Diameter (New/Condemning limits in mm) a. Gottwald Old 1000 / 906 b. Gottwald New 1000 / 906 c. Cowans New 1000 / 906

5.4 WHEEL PROFILE CHECKING: IRS Worn Wheel Profile to RDSO Drg. no. WD-88021 has been provided on the new Match Truck wheels. Check for wheel wear i.e. root wear & tread wear as per RDSO Drg. no. WD-89060 /S-2. If wear is found beyond limit, the crane shall be sent for wheel turning.

5.5 UST OF WHEELS & AXLES: Check for defects of crane wheels & axles, if any as per norms. Rectify the same. Carry out Ultrasonic Testing on wheels & axles as recommended by SAG committee in para 5.1 of their report.

6. MATCH TRUCK, BALLAST WAGON & RELIEVING BOGIES (ONLY FOR COWANS SHELDON OLD CRANE):

6.1 Check wheel diameter of Match Truck, Ballast Wagon & Reliving Bogie wheels. It shall be as under:

S.No. Crane type Wheel Diameter (New / Condemning limits in mm) for: MATCH TRUCK BALLAST WAGON RELIEVING BOGIES a. Cowans Old 915 / 825 915 / 825 915 / 840

6.2 WHEEL PROFILE CHECKING: IRS Thick profile to RDSO Drg. no. CSL-3040 has been provided on the new Match Truck wheels. Check for wheel wear i.e. root wear & tread wear as per RDSO Drg. no. CSL-2127/M. If wear is found beyond limit, the crane shall be sent for wheel turning.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 29 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______6.3 UST OF WHEELS & AXLES: Check for defects of crane wheels & axles, if any as per norms. Rectify the same. Carry out Ultrasonic Testing on wheels & axles as recommended by SAG committee in para 5.1 of their report.

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

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians/ MCMs (Mechanical): ii) Technicians/ MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 30 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______2-Yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane (At the completion of 2000 working hours)

Crane No. ______Date ______Shed ______Rly.______

Hours Meter Reading ______Last Schedule Done & Date______

Time From ______To ______Time taken ______Hrs ______Minutes

2-Yearly Schedule to be carried out with the help of concerned W/shop & respective OEM

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE:

1.1 M/s CIL NTA 855 & 743P:

1.1.1 Check for turbocharger oil leakage. Tighten turbocharger mounting nuts. 1.1.2 Check engine blow-by, clean radiator, adjust injectors and valves. 1.1.3 Check wobble and eccentricity / alignment marks on rubber type damper. Discard damper, if misalignment is more than 1/16”. 1.1.4 Check belt tension and adjust as required. 1.1.5 Remove and clean air compressor breather element. 1.1.6 Clean the oil tank, fuel filter bowl and ceramic filter thoroughly.

1.2. M/s MTU:

1.2.1 Check the poly V-belt for wear and damage & replace, if required. 1.2.2 Change engine lube oil & filter (Ad Blue). Next change in 4th, 6th & 8th year respectively. 1.2.3 Renew coolant: When renewing the coolant, ensure that it contains 50% corrosion inhibitor / antifreeze by volume. This corresponds to antifreeze protection down to -37ºC. If there is loss of coolant, don’t top up by using only water, but also add an approved corrosion inhibitor / anti-freeze agent. Next change in 4th, 6th & 8th year respectively. 1.2.4 Clean the fuel filter element. 1.2.5 Replace fuel pre-filter with water separator (fixed to the chassis).

2. AUXILIARY ENGINES (M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3):

Change the paper element of air cleaner.

3. SUPERSTRUCTURE:

3.1 Check visually for tightness of slewing ring arrangement. Stud, nuts and loose bolts to be tightened, if required. 3.2 Check rota white cap on bolts / studs for spinning (only for Cowans Sheldon old crane).

4. UNDER CARRIAGE:

4.1 Check brake equipment for functioning. 4.2 Check vibration damper and repair them, if required.

5. MATCH TRUCK:

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 31 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

Check brake equipment for functioning.

6. RELIEVING BOGIES & BALLAST WAGON (only for Cowans Sheldon old crane):

Check brake equipment for functioning.

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

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 32 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______4-Yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane (At the completion of 4000 working hours)

Crane No. ______Date ______Shed ______Rly. ______

Hours Meter Reading ______Last Schedule Done & Date______

Time From ______To ______Time taken ______Hrs ______Minutes

4-Yearly Schedule to be carried out with the help of concerned W/shop & respective OEM

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE:

1.1 M/s CIL NTA 855 & 743P: 1.1.1 Check turbocharger end clearance. 1.1.2 Check crankshaft end clearance. 1.1.3 Check cylinder head valve seat. 1.1.4 Check condition for cylinder liners. 1.1.5 Check conditions of piston rings, replace if necessary. 1.1.6 Check accessory drive end clearance. 1.1.7 Check fan hub drive. 1.1.8 Check vibrator damper. 1.1.9 Replace fuel pump filter screen and magnet 1.1.10 Calibrate the PT Pump by replacing the necessary parts like magnetic filter, gasket set. 1.1.11 Clean and calibrate all injectors. 1.1.12 Clean injector inlet screens. 1.1.13 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.

1.2 M/s MTU: Refer 2-Yearly Schedule

2. AUXILIARY ENGINE (M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3):

Arrange for authorized dealer for engine manufacturer’s mechanic to check your engine completely- Refer Engine maintenance manual for details.

3. SUPER STRUCTURE:

Overhaul all direction control valves, ‘O Ring’ & seals and replace, if required.

4. Relieving Bogies (only for Cowans Sheldon old design crane):

Inspect axle box roller bearings & refill with grease (As per OEM’s manual)

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 33 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians/ MCMs (Mechanical): ii) Technicians/ MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 34 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane (At the completion of 8000 working hours)

To be carried out by concerned Workshop

Concerned POH Workshop shall jointly examine the crane to be overhauled with it’s In-charge for all damages / deficiencies / working problems / abnormalities and should verify with Consignee reports on crane failures at the time of receipt of crane for POH.

Then workshop shall carry out dimensional check on crane structural components such as undercarriage, superstructure, jib & match truck etc. for diagonal accuracy, tolerances, skewness, surface alignment, distortion, straightness of structures etc. with the help of relevant measuring instruments. Workshop should conduct weldment check using suitable techniques such as DPT, Radiography / X-ray, Ultrasonic testing or Magnetic Flaw Detection.

Thereafter, workshop should make a pre-shopping report comprising of all structural repairs, powerpack, hydraulic & pneumatic equipments, other assemblies/sub-assemblies, safety system including devices, electrical & controls and SLI system.

(a) MAIN ENGINE & AUXILIARY ENGINE

Crane No. ______Shed______Rly______

Hour Meter Reading______POH Date______

S.No Details of work to be carried out Condition/Action Sign. Remarks 1. Run main power pack before POH: 1.1 Check all motions of main circuit under propped condition. 1.2 Check all safety devices. 1.3 Check all load chart parameters in regard to recommended Limit Switch cut-off. 1.4 Check damages / deficiencies / working problems of crane. 1.5 With Jib in raised condition, uncouple two bottom cap screws each of both jib keeps & check:- a) Movement of jib foot pin rollers. b) Clearance between blocking screws and Springs / Bogie bolster. 2. Run auxiliary power pack before POH: 2.1 Check all motions of auxiliary circuit under propped condition. 2.2 Check all safety devices. 2.3 Check relevant load chart parameters w.r.t. recommended Limit Switch cut-off as per SLI equipment. 3. Dis-connect all sensing devices of main & auxiliary power pack (electrical) and all suction and delivery hoses from pumps mounted over splitter gear box / P.T.O.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 35 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______unit alongwith suction & return lines for fuel and also disconnect all radiator & oil cooler connections, as applicable. 4. Remove main & auxiliary power pack and lower for POH (Before removing, close all stop cocks (except auxiliary pumps Q8 & Q9 for Gottwald cranes). 5. Send the main & auxiliary power pack to respective authorised dealer / manufacturer for POH and load testing on test bed. 5.1 Drain out entire lube oil, hydraulic oil, fuel oil, coolant from Radiator & Oil from Oil Cooler etc. and store in drums. 5.2 Clean & flush the tank / tanks before re- filling with fresh oil & coolant. 6. On receipt of main & auxiliary engine after POH, assemble main power pack & auxiliary power pack in position. 7. Connect all pipes & hoses. 8. Connect all sensors & electrical connections. 9. Fill fresh lube, hyd. & fuel oil, coolant etc. 10. Run main power pack after POH: 10.1 Check all motions of main circuit under propped condition. 10.2 Check all safety devices. 10.3 Check all load chart parameters in regard to recommended Limit Switch cut-off. 11 Run auxiliary power pack after POH: 11.1 Check all motions of auxiliary circuit under propped condition. 11.2 Check all safety devices. 11.3 Check all load chart parameters in regard to recommended Limit Switch cut-off.

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

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 36 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians/ MCMs (Mechanical): ii) Technicians/ MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 37 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane (At the completion of 8000 working hours)

To be carried out by concerned Workshop

(b) HYDRAULIC SYSTEM INCLUDING ALL CYLINDERS, VALVES, PUMPS & MOTORS, A-FRAME, WINCH/DRUM/BARREL ASSEMBLIES, WIRE ROPES, PULLEYS and NYLON ITEMS

Crane No ______Shed______Rly______

Hour Meter Reading______POH Date______

S.No. Details of work to be carried out Condition / Action Sign. Remarks 1. Remove, Overhaul, Test & Refit. Check operations. 1.1 Disconnect all worn out hoses and pipes of all drum assemblies of superstructure. Replace with new, if required. 1.2 Disconnect all worn out hoses and pipes of undercarriage & Rotor/Rotary column. Replace with new, if required. 1.3 Disconnect all hydraulic connections after proper marking for draw beam cylinders and remove all draw-beams from carriage (only for Cowans Sheldon old design crane). 1.4 Open ‘A’ frame/Gallow Hyd. cylinders- (a) Cylinders & assly. - Gottwald old (b) Gallow Cylinders& assly. - Gottwald new (c) Tie Cylinders & Strut assly.- Cowans old (d) Cylinders & Strut assly.- Cowans new 1.5 Screw down the blocking screws of the crane until they are locked down on to top of the springs. Unload & uncouple the pins for both the relieving bogies (applicable only for Cowans old crane). 1.6 Dismantle all motion’s/winch’s machinery & inspect. Repair, as necessary (a) Main Hoist Drum/Barrel assembly. (b) Aux. Hoist Drum/Barrel assembly. (c) Derrick Drum/Barrel assembly. (d) Recovery Winch Drum/Barrel assembly (e) Pedestal bearings (f) Nylon blocks (g) Main Hoist Jib Head Pulleys (h) Auxiliary Hoist Jib Head Pulleys (i) Jib Bridle Pulleys (j) Derrick Pulleys & Equalising Pulley (k) Equalising Beam & Pulleys ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 38 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______(l) Telescopic Tie Rod Pulleys. (m) Main Hoist Wire Rope Guide Roller (n) Derrick Wire Rope Guide Rollers 1.7 WIRE ROPES: Uncouple, remove following wire ropes & test as mentioned above at Para 8: a) Derrick b) Main Hoist c) Auxiliary Hoist d) Hauling Winch e) Check Derrick Tie Ropes for equal length, wherever applicable. 1.8 Remove Hydraulic Tank cover & clean/flush the tank. 1.9 Remove hydraulic Equipments & Hydraulic Hose Assemblies. Inspect these assemblies and replace as required. 1.10 Check all cylinders, valves of superstructure & undercarriage. Replace, if required. 1.11 Drain out entire hydraulic oil and store in drum. Clean & flush the tank (before refilling with fresh hydraulic oil). After POH: 1.12 Keep all motion’s/winch’s machinery in position systematically: (a) Lubricate pedestal bearings & fit. (b) Main Hoist drum/barrel assembly. (c) Aux. Hoist drum/barrel assembly. (d) Derrick drum/barrel assembly. (e) Recovery Winch drum/barrel assembly (f) Change nylon blocks, if worn out. (g) Main Hoist Jib Head Pulleys (h) Auxiliary Hoist Jib Head Pulleys (i) Jib Bridle Pulleys (j) Derrick Pulleys & Equalising Pulley (k) Equalising Beam & Pulleys (l) Telescopic Tie Rod Pulleys. (m) Main Hoist Wire Rope Guide Roller (n) Derrick Wire Rope Guide Rollers 1.13 Connect all hoses & pipes of all drum assembly of superstructure. 1.14 Connect the hoses & pipes of Rotor/ Rotary column with undercarriage. 1.15 Assemble ‘A’ frame as applicable. 1.16 Fill up hydraulic oil (as recommended by OEM’s manual) into the hydraulic tank.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 39 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 40 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane (At the completion of 8000 working hours)

To be carried out by concerned Workshop

(c) SLEWING RING, GEAR BOXES & REDUCTION GEAR UNITS

Crane No. ______Shed______Rly______

Hour Meter Reading ______POH Date______

S. Details of work to be carried out. Condition/ Sign. Remarks No. Action Remove, Overhaul, Test & Refit. Check operations.

1.1 Lift superstructure and keep on trestle. 1.2 Check all Gear Boxes coupled with brake units. Replace/Repair using repair kits as applicable for:- (a) Main Hoist Gear Box complete (b) Auxiliary Hoist Gear Box complete (c) Derrick Hoist Gear Box complete (d) Slew Gear Box complete (e) Recovery/Hauling Winch Gear Box complete (f) Splitter Gear Box/PTO Unit complete 1.3 Check Travelling gear box, pneumatic cylinder and valves, as required. 1.4 Replace/renew gear boxes oil. 1.5 Slew Ring - Check Rota Bolts for Spinning. 1.6 Lubricate Slew Ring Bearings. 1.7 Lubricate Slew Gear. 1.8 Fitment of Slewing Ring: i) Levelling of slewing ring to be ensured. ii) Systematically replace all worn out loose rota bolts & nuts of slewing ring of superstructure & undercarriage. iii) Grease the slewing ring, bolts & bearings (Refer para-6). iv) Tighten the bolts with Tightening force :783.7± 6.6 kN - Gottwald crane Tightening torque:3.19 kNm - Cowans crane v) Follow the sequence strictly recommended by manufacturer. 1.9 Lift superstructure & keep on undercarriage above slewing ring. Follow manufacturer’s instructions while assembling.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 41 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2. Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 42 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane (At the completion of 8000 working hours)

To be carried out by concerned Workshop

(d) Electrical & Control System

Crane No ______Shed______Rly______

Hour Meter Reading ______POH Date______

S. Details of work to be carried out: Condition/ Sign. Remarks No. Remove, Clean, Check & Renew: Action 1 All Batteries & Connections: Recondition & Repair Battery boxes. Refit Batteries & Connect. 2 All Rotating Machines: Remove, Overhaul, Renew Carbon Brushes, Test & Refit. 3 All Junction Boxes: Check connection for tightness for all the Junction boxes 4 All Circuit Breakers: Remove, Overhaul, Test & Refit. Check operations. 5 All Switches: Remove, Overhaul, Test & Refit. Check operations. 6 All Relays: Remove, Overhaul, Test & Refit. Check operations. 7 All Sensors & SLI Equipment: Check connection for tightness. Clean, Check operation & test. 8 All Meters & Gauges: Remove, Overhaul, Calibrate & Refit. Check operations. 9 All Lamps & Bulbs: Check Operation. Renew bulbs, if required. 10 All Fault Indication Lamps: Check, Test all Fault Indication Lamps 11 All Solenoids & Controllers: Check connection for tightness. Clean renew, if required, Check operation & test. 12 Solenoids on Pump: Check operation. Test & Refit. 13 General Items: Check operation. Test & Refit.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 43 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians/ MCMs (Mechanical): ii) Technicians/ MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 44 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane (At the completion of 8000 working hours)

To be carried out by concerned Workshop

(e) PNEUMATIC, BRAKE SYSTEM & HAND BRAKE

Crane No ______Shed______Rly______

Hour Meter Reading ______POH Date______

Sl. Details of work to be carried out: Condition Sign Remarks No. Remove, Clean, Check, Renew & Refit. / Action The under mentioned system / components / parts should be examined in accordance with the procedure laid down in the OEM’s Crane Maintenance Manual:- A. BRAKE SYSTEM:- Remove, overhaul, test and refit the following items:- 1. BRAKE VALVES: a) Driver’s Brake Valve: b) Relay Valve for Crane c) Vacuum Air Proportional Valve for Crane, M/T & B/W. d) Vacuum Release Valve for Crane, M/T & B/W. e) Distributor Valve for Crane, M/T & B/W

2. OTHER VALVES (Safety Valves): a) Un-loader Valve b) MR Safety Valve c) Auto Drain Valve

3. CHECK VALVES: a) Strainer Check Valve & Choke Unit b) Double Check Valve c) Tubular Check Valve d) Soft Seated Check Valve e) Duplex Check Valve

4. BRAKE CYLINDERS

5. RESERVOIRS: a) Auxiliary Reservoirs for Crane, M/T & B/W. b) Main Reservoir for Crane c) Brake Supply Reservoir for Crane d) Vac. Chamber for VAP valve for Crane, M/T & B/W.

6. DRAIN COCKS: a) Drain Cocks for Crane Aux. & Brake supply reservoirs, M/T & B/W reservoirs ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 45 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______b) Drain Cock for Auto Drain Valve 7. CUT- OUT COCKS: a) Isolating cocks for Crane Distributor V/v, M/T & B/W. b) Self-locking Angle Cocks for Crane, M/T & B/W. c) MR Isolating Cock d) BSP Isolating Cock with vent e) Isolating Cock with sealing for VAP valve.

8. GAUGES: a). Duplex Pressure Gauge MR-BC b). Vacuum Gauge VC

9. FLEXIBLE HOSE CONNECTIONS FOR: a) Main Compressor b) Auxiliary Compressor c) Rotary/Rotor Column d) M/T & B/W

10. HOSE COUPLING: a) Hose coupling for Brake pipe for Crane, M/T & B/W. b) Hose coupling for MR pipe for Crane, M/T & B/W. c) Dummy & Rotary Coupling

11. Air & Vacuum Pipes & Fittings etc. Overhaul Air & Vacuum Brake Equipments

12. Bends: High level, Low level & Return bend

13. Springs: a) Return Spring b) Release Spring for M/T & B/W. B. HAND BRAKE UNITS: Remove, overhaul, test and refit in the following assemblies: 1. Superstructure: 2. Undercarriage: 3. Relieving Bogies: 4. Match Truck 5. Ballast wagon (only for Cowans old)

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

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 46 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 47 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane (At the completion of 8000 working hours)

To be carried out by concerned Workshop

(f) BASIC STEEL CONSTRUCTION, SUPERSTRUCTURE, CAB, JIB & EQUIPMENTS, UNDERCARRIAGE & BOGIES, ASSEMBLY & TESTING

Crane No ______Shed______Rly______

Hour Meter Reading ______POH Date______

S. Details of work to be carried out: Condition Sign. Remarks No. Remove, Overhaul, Test, Renew, if required & fit: / Action The under mentioned system / components / parts / assemblies / sub-assemblies should be examined in accordance with the procedure laid down in the OEM’s Crane Maintenance Manual:- 1. MATCH TRUCK FOR ALL CRANES: Place Match Truck inside the shop in repair bay & unload following crane accessories: a) Counterweights b) Lifting Beams c) Wire Ropes Slings & Chain Slings.

1.1 MATCH TRUCK & IT’s COMPONENTS:- a) Check Chassis. b) Check Jib Trestle for profile wear at Jib Head Rest. c) Lubricate Jib Trestle. d) Check Hand Rails. e) Check Draft Gears. f) Check Buffers. g) Check access ladders. h) Overhaul Bogies. i) Grease Axle Boxes.

1.2 CRANE ACCESSORIES: a) Check Counterweights for proper welding & holding/locking brackets, if provided. Repair, if necessary. b) Check Lifting Beams & repair, if required. c) Check Wire Ropes Slings & Chain Slings as per Para 8 of General Description of this MP.MI. Replace, as required. 2. RELIEVING BOGIES (only Cowans Old cranes): 2.1 Place crane with relieving bogies inside the shop: a) Screw down the blocking screws of the crane. b) Unload & uncouple relieving bogie coupling pins. c) Remove yoke beams & centre castings. 2.2 RELIEVING BOGIE & IT’s COMPONENTS:- ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 48 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

a) Check & Overhaul centre castings. b) Check Bogie Frames for alignment. c) Check Relieving Bogie Coupling Beams. d) Check Suspension Springs and Brackets. e) Check Lever and Slipper & Lever Lock Pin. f) Check Lateral Dampers. g) Check Yoke beams & bushes. h) Check Draft Gears. i) Check Screw Couplings. j) Check Side Buffers. k) Check access ladders. l) Check Foot Steps. m) Remove Laminated Springs & send for Testing. n) Inspect / Renew Spring Link Bolts, Brackets, Pins, Rocker Washers, Disc Springs. o) Check/Renew Axle Box Longitudinal & Lateral Liners p) Check /Renew Axle Box Guides for wear. q) Grease Axle Box Bearing. r) Grease all lubricating points. s) Assemble Relieving Bogies. 3. Ballast Wagon (only for Cowans Old cranes): 3.1 Place B/W inside the shop & unload heavy ballast.

3.2 BALLAST WAGON COMPONENTS (only for Cowans Old cranes): a) Check Chassis. b) Check Ballast Locking Arrangement. c) Check Hand Rails. d) Check Draft Gears. e) Check Buffers. f) Check access ladders. g) Overhaul Bogies. h) Grease Axle Boxes. 4. SUPERSTRUCTURE: a) Carry out dimensional check for diagonal accuracy. b) Check tolerances, skewness, surface alignment, distortion, straightness of structures etc. c) Check structural damages of superstructure & repair, as required. 4.1 DRIVER'S CAB: a) Check Driver's Seat b) Check Window Glasses & Side Shutter c) Replace Weather Strips. d) Check Cant Indicator / Level indicator. e) Check Slew Locking Pin. f) Check Cab Door Lock. g) Check Control Desk & Control Panel. h) Check Joystick & renew, if required. 4.2 JIB & EQUIPMENTS: a) Open out jib keeps & remove jib

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 49 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______b) Check structural damage of jib c) Check Radius Indicator provided on jib d) Check Jib keep Lock Plate e) Check Jib Bottom Rubbing Plate f) Check Jib Foot Pin & Rollers g) Check Jib Support Roller & Pins h) Check & inspect Jib stopper for alignment with jib i) Front Strut Bearings and Cap j) Snatch Blocks: Overhaul � Main Hoist Snatch Block- Pulleys, Bearings, Crosshead & Swivel. � Auxiliary Hoist Snatch Block- Pulleys, Bearings, Crosshead & Swivel. k) Telescopic Tie Rod: � Pulley Bearings � Grease Seal 5. UNDER CARRIAGE: a) Run out bogies. b) Carry out dimensional check for diagonal accuracy. c) Check tolerances, skewness, surface alignment, distortion, straightness of structures etc. d) Check structural damages of undercarriage & repair, as required. e) Check Carriage End Castings. f) Check cant indicator / sprit level indicator g) Check counterweight lock plates. h) Check access ladders. i) Check Rail Clips. Only for Cowans old design: j) Extend draw beams k) Check movement draw beam rollers l) Check draw beam lock pins. m) Check draw beams, it’s jacks & Extension Cylinder. n) Check footsteps of draw beams 5.1 CARRIAGE BOGIES: a) Open Carriage Bogie Pivot Pin Nuts, Remove Carriage from superstructure and keep on Trestle. b) Check bogie frames for alignment c) Check/Replace Blocking Screws (Relieving Screws) d) Check bogie rubbing pads e) Check centre pivots f) Check, clean & refill bogie pivot oil boxes. g) Remove Laminated Springs h) Check / Replace Spring Link Bolts, Pins, Rocker i) Washers & brackets. j) Check / Replace spring slide washers k) Check & reclaim Equaliser Beams & Bar Brackets l) Check Axle Box Guides for wear m) Check Axle Box Liners. n) Check Axle Box Greasing. o) Check Travel Clutch Indicators

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 50 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______p) Check Travel Clutch Cod Piece q) Check & Lube Travel Clutch Shaft r) Check Travel Gears & Lubricate s) Assemble bogies t) Renew Brake Blocks 6. ASSEMBLY & TESTING:

6.1 Assemble crane following manufacturer’s instructions: a) Place Carriage Bogies on track: b) Lift Undercarriage & place on Carriage Bogies with Slew Ring. c) Lift Superstructure body & place on Undercarriage. d) Fit Centre Pivot Pin Nuts. e) Fit draw/outrigger beams and make all connections. f) Place Counterweight in position on Carriage. g) Place Blue End & White End Relieving Bogie (only for Cowans old design crane). h) Fit Jib & Jib keeps. i) Connect Hydraulic Hose Assemblies & Clamp. j) Connect pneumatic hoses & connections. k) Check Air Brake operations & adjust brake rigging. l) Fit Machinery Enclosures after renewing gaskets & checking locks as applicable for following: � Hydraulic Tank. � Main Engine. � Auxiliary Engine. � Slew Gear Box. � Radiator and Oil Cooler � Driver's Cab m) Reeve Wire Ropes � Derrick. � Main Hoist. � Auxiliary Hoist. � Hauling Winch. n) Refill with fresh oil & water to levels indicated in OEM’s manual. o) Start Main Engine: � Carry out initial start-up checks. � Carry out tests and final checks. � Check all electrical operations. � Check all hydraulic operations. p) Set pressures, if applicable: q) Set all Limit Switches. r) Start Auxiliary Engine: � Repeat above activities similar to Main Engine. � Carry out testing and final checks. s) Place Match Truck & couple with crane. t) Load M/T with accessories u) Place Jib on Match truck. v) Conduct weighment of crane alongwith M/T on Weigh Bridge. ______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 51 of 52 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes ______

6.2 TESTING (to be witnessed by Consignee): a) Carry out final inspection of the crane, assemblies & sub-assemblies b) Carry out Load Test as per relevant Test Schedules/Load Chart parameters. c) Conduct load test at 25% over load also. d) Paint Crane. e) Renew Name Plates. f) Dispatch crane

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):- S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

B. SCHEDULE REPAIRS:- S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE 1. 2.

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

Maintenance by:- i) Technicians / MCMs (Mechanical): ii) Technicians / MCMs (Electrical): iii) Crane Drivers:

Checked by:- JE:- SSE:-

______Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 52 of 52