140T Crane Introduction

Objectives

• List 10 major crane items.

• Understand SLI functioning

• List 5 failure prone Hydraulic items.

• List 5 failure prone Pneumatic items.

• List 5 important consumable items.

2

General Arrangements

3

140T Gottwald Design Crane

Old Design New Design

4

Jib

Counter weight slabs

Rear frame A Frame Briddle

140T NEI(Cowans) Design Crane

Old Design New Design

History

• Introduced in ART in place of 75T steam crane in 1987

• 2 major variants of Gottwald Design – Old Design and New Design

• Old Design (1986 to 2001) – Imported #12&manufactured at JMP #10

• New Design (1998 to Till date) – Imported #8&manufactured at JMP #28

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Salient Features

• All motions hydraulically controlled except brake system.

• Provision of safe load indicators

• Quick response in motions

• Maxm. Speed 100 KMPH

• Loaded Wagon Handling

• Slewing by 360° with 140 Ton load at 6M radius.

Features of New Design over Old

• Cwt falling is sorted out by R/F

• Two positions of tail radius-5.5m & 6.5m

• Five positions of prop

• Jib length increased by one m

• Shear pin introduced in AUX hook

• External threads in slewing ring

Features of New Design

• No need of radiator cooling pump

• Vertical power pack

• Better design of fuel tank

• Direct gear pump is used for hyd oil cooling

Hyd Oil

• Low compressible

• Less viscosity w.r.t pressure

• Lubrication & anti wear quality

• High density

• Fire resistant

• Non toxic

• Good thermal conductivity

MAJOR CRANE ITEMS

11

Crane Bogie

• Each Fabricated bogie with three axle sets.

• Coil & Disc springs are fitted in suspension.

• CRU fitted on axle inside the wheel.

• Brake disc fitted each wheel.

Brake Cylinder Axle Blocking

Cylinder

Brake Disc

Super Structure

Main Engine NTA855 LBC

Aux. Engine

Hyd. Tank

Multi Spool Valve M1

Solenoid Valve

Cabin

Joy Stick

Engine Control Unit Display Board

Out Rigger Assly with Propping Cylinder

15 Propping Cylinder Out Rigger Cylinder

Used during propping the crane

Rear Assly with Counter Weight Slabs

Old(5T+14T+6T+18T)

New(8T+15T+24T)

Match Truck

• Used to rest jib.

• Keep main hoist & aux. hoist hook assly.

• Keep Counter weight slabs.

• Keep lifting tackles.

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Main hook assly Lifting Tackles

Jib

Match Truck

Main Engine(NTA 855 LBC)

18

• Six cylinder inline engine

• Power-290 HP

Main Engine

Suction Hose

Wire Ropes

Wire Ropes

Wire Rope Sling

Main Hoist Wire Rope

Derrick Hoist Wire Rope

Nylon Pulleys

• Used with wire ropes to hoist & lower the load.

• Main hook assly hangs through pulleys assembled on pin.

• Diagonal hoisting is prohibited as pulley’s edge s are damaged.

FAILURE PRONE HYDRAULIC ITEMS

Change Over Valve No-34

• Valve no-34 actuates hydraulically & works through pneumatically during axle blocking.

• Used for gear shifting arrangement in under carriage

Valve No-34

Valve Plate Assly

• It is a bridge of check valves.

• Used for control hydraulic supply to rear end cylinders

Rear Frame with Counter Weight Cylinder

Hyd. Valve Failure

• Causes

– Seal defective,

– Internal spring defective,

– Valve seat worn out

• O/H & replace the damaged seals.

• Cost of kit=80% of new item cost.

• Repair is uneconomical

• Hence replace.

Hyd. Hoses Failure

• Cause of failure

– End fittings damaged

– Rubber portion damages

– (pin hole,rupture)

– Wearing of surface in flange type end fittings

• Solution- Replace

FAILURE PRONE PNEUMATIC ITEMS

Air Brake Cylinder-Failure

• Causes

– Rusting and accumulation of dirt

– Seals and bellows damaged,

– Spring damaged.

• Over Haul & replace the seal kit.

Gear Shifting Cylinder

• Works pneumatically & used to shift the pinion of travelling gear box for engaging/disengaging with axle gear.

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Gear shifting cylinder

Pressure Reducing ValveDMV-9

Up to 5 Bar in U/C Up to 3.8 Bar in S/S

Oil Extractor

• Fitted before unloader valve in super structure.

• Remove the oil,dust from compressed air received from compressor.

Unloader Valve

• Used to keep system pneumatic pressure constant at 6.8 bars

• Fitted in super structure after oil extractor.

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Unloader valve

Hyd. Filters

Lube Oil Filter Fuel Oil Filter

Hyd. Filters

Return Line Filter

Slew Line Filter

Modifications done in 140T Crane

• In MT to accommodate HS Casnub bogie for speed upgradation up to 100 KMPH.

• Retro fitment of PTO Unit in Old Design.

• Implementation of Pure Air Brake System in all cranes.

• Introduction of Parker fittings & tubes to minimise the frequent leakages in Hyd circuit.

Continued-

• Change in design of Limit switch to achieve fine settings.

• Replacement of SHULE make auxiliary engine by KOEL make engine in OLD design crane.

• Speed Modification of 80 kmph to 100 kmph by providing Hyd dampers.

Hydraulic components

• Hyd. Pumps

– External tandem gear pumps

– Variable displacement axial piston pumps bent axis design or swash plate design.

• Hyd. Motors

• Hyd. Cylinders

• Hyd. Valves

• Control Blocks.

External Tandem Gear Pumps

(Q8+Q9) For Aux. Engine

External Gear Motors

Oil cooler motor

Axial Piston Pump Bent Axis Design

Q1 &Q2(for all operations except slew)

Axial Piston Pump Swash Plate Design

Q1 & Q2

Hyd. Motor

Hyd. Cylinders

Propping Cylinder

Hyd. Cylinders

Out Rigger Cylinder Axle Suspension Blocking Cylinder

Hyd. Cylinders

Counter Weight Cylinder Boom Root Cylinder

Thank you