HYDRAULIC SYSTEM OF 140T

BREAKDOWN CRANE
140 t BD Crane
 CONTENTS

INTRODUCTION TO HYDRAULICS
ADVANTAGES
SYMBOLS
MAJOR CRANE OPERATIONS (HYDRAULIC)
ELEMENTS OF HYDRAULIC SYSTEM
HOISTING OPERATION DETAILS
CIRCUIT DIAGRAM
 INTRODUCTION

What is HYDRAULICS?
PASCALS LAW- pressure applied on a
confined fluid is transmitted undiminished in
all direction and act with equal force on
equal area at right angle to them
 ADVANTAGE OF HYDRAULIC
SYSTEM
TRANSFER OF LARGE FORCES
SMOOTH ADJUSTMENT OF SPEED, TORQUE
AND FORCE
PROTECTION AGAINST OVER LOADING
SUITABLE FOR BOTH QUICK & SLOW
MOVEMENTS
SIMPLE CENTRAL DRIVE SYSTEM
HIGH POWER OUTPUT
REVERSIBLE ACTUATORS
 TYPES OF HYDRAULIC
CIRCUIT IN 140T CRANE

OPEN LOOP CIRCUIT-TANK PUMP

MOTOR TANK
CLOSED LOOP CIRCUIT PUMP
MOTOR PUMP
SYMBOLS
Symbols
 MAJOR CRANE
OPERATIONS
AXLE BLOCKING
OUTRIGGING
PROPPING
TRAVELLING
GALLOWS OPERATION
DERRICKING
HOISTING
SLEWING
 ELEMENTS OF HYDRAULIC
SYSTEM OF 140 T BD CRANE
VALVES
PUMPS
MOTORS
CYLINDERS
PIPES
OIL COOLER
OIL FILTERS
OIL TANK
 VALVES

PRESSURE CONTROL
NON RETURN
DIRECTION CONTROL
FLOW CONTROL
 PRESSURE CONTROL
VALVE
PRESSURE CONTROL VALVE

RELIEF VALVE SEQUENCE VALVE REDUCING VALVE

RELIEF VALVE
 NON RETURN VALVE
NON RETURN VALVES

SIMPLE NON RETURN VALVES PILOT OPERATED CHECK VALVES PRE FILL VALVES
Check Valve
 DIRECTION CONTROL
VALVE

This valve is used to start, stop and

change the direction of flow
Designation of DC valve
DC valve is designated by number of ports /
number of chambers. E.g. 4/2, 6/3 etc.
Used in main spool block M1 and M2
DIRECTION CONTROL
M1 UNIT
 FLOW CONTROL VALVE

Used to influence the speed of movement of

actuator by changing the opening of flow at
throttling point. e.g used in lamina brake
circuit in main hoist
 HYDRAULIC PUMPS

AXIAL PISTON PUMP

GEAR PUMP
BENT AXLE PUMP
GEAR PUMP
 Main Pump
HYDRAULIC PUMPS
Slewing
Pump
Control
circuit
Cooling
Pump
Oil cooler
Pump
Emergency
Pump
Pump

Type Variable axial piston: A7VO Variable axial Gear Gear Gear Gear
160 HD piston: A4
V71 HD

Make Rexroth Rexroth Rexroth Rexroth Rexroth Rexroth

Displacement 40-240 Q3 - 150 Q4 - 50 50 32 Q8 - 36

(lpm) 30 Q9 - 14

Max. pressure 280 Q3 200 30 140 60 Q8 280

(bar) Q4 - 30 Q9 30

Application Main hoist, Aux hoist, Slewing circuit Control Water Hydraulic oil Emergency
Traveling gear, Counter circuit cooling cooling stowage
weight, Derricking, recovery
winch, Outriggers,
Propping, Axle blocking

No of 2 1+ 1 1 1 1 1+1
Pumps/Crane

Designated as Q1 & Q2 Q3 & Q4 Q5 Q6 Q7 Q8 & Q9

Fitment P.T.O. Unit P.T.O. P.T.O. Unit Engine Engine Aux. Engine
Unit Mounted Mounted Mounted
 HYDRAULIC MOTOR

BENT AXIS TYPE AXIAL PISTON

MOTOR
GEAR MOTOR
BENT AXIS TYPE AXLE
PISTON MOTOR
Gear motor
 TYPES OF MOTORS
Type Main hoist Auxiliary hoist Derricking Slewing motor Winch motor Travel motor
motor motor motor

Fixed Fixed Fixed Fixed Fixed Fixed displacement

displacement displacement displacement displacement displacement A2FM180/61
A2FM180/61 A2FM 180/61 A2FM 180/61 A2FM180/61 A2F 63/61
& & &
*A2FM *A2FM *A2FE
125/61W- PAB 125/61W- PAB 63/61W-
XXO-S XXO-S VZ/100

Make Rexroth Rexroth Rexroth Rexroth Rexroth Rexroth

Displace 180 cc/rev 180 cc/rev 180 cc/rev 180 cc/rev 63 cc/rev 180 cc/rev
ment

Max 280 bar 280 bar 280 bar 280 bar 280 bar 280 bar
pressure

No of 1 1 1 1 1 2
motors/
Crane
 OTHER PARTS

HYDRAULIC PIPES
OIL TANK
RETURN LINE FILTER
OTHER PARTS
 MAJOR CRANE
OPERATIONS

OUTRIGGING
PROPPING
TRAVELLING
GALLOWS OPERATION
DERRICKING
HOISTING
SLEWING
 HOISTING OPERATION

PILOT CIRCUIT
POWER CIRCUIT
 PILOT CIRCUIT

PILOT PUMP Q5
PRESSURE RELIEF VALVE (30 BAR)
OPERATING LEVERS
TANK WITH HYDRAULIC OIL
SOLENOID VALVE
 POWER CIRCUIT

PUMP Q2
FLOW CONTROL
MAIN SPOOL BLOCK, M1
CHECK VALVES
MAIN HOIST MOTOR
LAMINA BRAKE
 ACTUAL OPERATION
ENGINE STARTED
PUMP Q5 AND Q2 STARTS PUMPING OIL
Q5 SENDS OIL TO LEVER THROUGH CHECK VALVE
LEVER MOVED BY DRIVER
OIL IN PILOT PRESSURE LINE MOVES TO DC VALVE IN M1
AND SAFETY CIRCUIT
DC VALVE IS ACTUATED
OIL FLOWS ACCORDING TO DESIRED OPERATION TO THE
MAIN HOIST MOTOR
HOISTING IS PERFORMED
DURING HOISTING DOWN OPERATION LAMINA BRAKE IS
ACTUATED
CIRCUIT DIAGRAM
 A Study of The Undercarriage
and Accessories of 140T Diesel
Hydraulic Breakdown Crane
 Undercarriage

It comprises of the following main systems.

Outriggers
Bogie
Brake System
Control Block
 Outriggers

Comprise of 4 swing type telescopic beams.

Each fitted with a vertical propping cylinder
at the end.
 Why prop?

Axles have a load bearing capacity limit of

20T.
The propping base is directly related to the
permissible load capacity, as shown by the
load charts.
 Propping Bases

Transport Position or Free on Rails.

2.9m
5.0m
6.0m
 Outrigging Operations

Consists of two operations:

Extension/ Retraction of the outrigging beam
by the middle control levers.
Extension/ Retraction of the prop cylinder by
the outermost control levers.
 Outrigger Beam

Secured by Socket/Safety pins.

Telescopic Beams.
Outrigger Beam moved out and extended
simultaneously by the outrigging cylinder
keeping the path of prop cylinder always in a
line perpendicular to the rails.
Leveling ensured with leveling devices.
 Re-Railing

A de-railed crane can be re-railed, by propping,

in the following manner.
Bogies re-railed independently, i.e. one after
another.
Outrigger beams extended to the middle
propping base.
Propping pads positioned and Crane raised.
 Re-Railing

Supposing the crane derailed to the left, the

left beam is retracted and the right beam
extended.
Above operation continued till the wheels are
above the rails or dislocated up to at most
50mm.
Propping cylinders are retracted and the
wheels lowered to the rails.
 Re-Railing

The outrigger beams are retracted.

The complete operation repeated for the
second bogie.
 Bogie

Crane consists of 2 bogies each supporting 3

axles.
It consists of the following parts
1. Suspension System and Axle/Suspension
Blocking System
2. Travel Gear Reduction Unit
 Bogie

3. Bolster
4. Side Frame
5. Wheel Sets
 Suspension System

A Suspension system consists of the

following units
Two pair of coil springs with a spring

inside another in a pair.

A pair of disc springs, included due to their

gradual release of friction thus providing

damping.
 Suspension System

The springs are located in a housing in the

side frame and support the bolster
In a recent design modification by using a
damper the speed has been increased from 75
kmph to 100 kmph
 Suspension Blocking

Bogie spring suspension is provided only for

hauling operations.
For self-propulsion and crane operation,
Suspension blocking is a must.It makes the
springs a solid block.
 Suspension Blocking

Suspension Blocking Arrangement

An suspension blocking cylinder mounted on
the side frame.
A cylinder is required for every suspension.
 Suspension Blocking

Sequence of operations
The suspension blocking levers are operated
upwards.
Springs form a solid block.
Brakes apply
All side mounted displays indicate Red.
Travel gear engages.
 Travel Gear Reduction Unit

Rexroth make,fixed displacement of 180cc

per revolution.
One motor in every bogie,driving one axle.
 Braking Arrangement

Disc-Braking employed.
A double jaw acts on the discs mounted on
the both sides of the wheel.
 Bolster

Rests on the suspension of the two sides.

Has the Pivot-Housing upon which the
undercarriage rests.
 Side Frame

Two side frames for each bogie.

Each Side frame in two parts, male and
female, joined with knuckle joints.
 Wheel Sets

Three wheel sets.

Driving axle has a split-gear mounted on a
hub.
Consists of two discs on the sides of a wheel
upon which the double jaw of the brake
cylinders act.
 Brake System

Dual Brake system

Air brake in self-propulsion.
Air/ vacuum in hauling/train formation.
Switch over carried out by two levers on both
sides.
A parking brake on one wheel on each axle
with a quick release system and Bowden
cables.
 Brake System

Status(Red/Green) can be read from the

displays mounted on the sides of the
undercarriage.
 Main Components of Brake
System
Air Reservoirs
Three 50l.and two 25l. for service
brake,one 25l. For parking, 14 l.,one 5l.
Tanks for instrument and display units.
Brake Cylinders
Twelve brake cylinders,single acting air
pressure cylinders.
 Main Components of Brake
System
Six brake cylinders have a spring loaded
assembly for mechanical emergency release
device
 Main Components of Brake
Systems
Air Compressor
Two air compressors one on each bogie.

The pinion of the compressor shaft in

mesh with the bull gear.

Compressor driven when crane in motion.
 Control Block

Levers
Propping
Outrigging
Suspension Blocking

Display Units
Quick Release Device
Air/Vacuum Brake Changeover
 POH & MAINTANANCE
PRACTICES OF 140T CRANE
 CRANE DESCRIPTION

JIB
A FRAME
HOOKS (MAIN & AUXILIARY)
UNDER CARRIAGE
BOGIES
SLEWING RING
ROTOR
ROPES &ROPE WINCHES
LAMINA BRAKES
 OUT RIGGERS
COUNTER WEIGHTS
TRACTION GEAR
MAIN POWER PACK
AUXILLARAY POWER PACK
CABIN
MATCH TRUCK
SLI SYSTEM
BRAKE SYSTEM etc.
 MAINTANANCE
SCHEDULES
NEW DESIGN OLD DESIGN
DAILY
DAILY
MONTHLY OR EVERY 100
MONTHLY OR EVERY HOURS
125 HOURS QUARTERLY OR 250 HOURS
SEMIYEARLY OR SEMIYEARLY OR EVERY
500 HOURS
EVERY 750 HOURS YEARLY OR EVERY 1000
YEARLY OR EVERY HOURS
1500 HOURS EVERY 2YRS OR 2000
HOURS
EVERY 2YRS OR 3000 EVERY 4YRS OR 4000
HOURS HOURS
EVERY 8YRS OR 8000
HOURS
 POH (8YRLY)

JIB
Jib removal
Bush & nylon pads visual checking
checking of jib pulleys
(bearings-collars &races)
replacement of whole bearing
 MAIN & AUXILIARY HOIST
VISUAL CHECK UP :
main hoist wire ropes(26mm)
auxiliary wire ropes(22mm)
gantry wire ropes(old design)
derrick wire ropes(26mm)
hook
chain
(rope is rejected if 5 wires are broken or10%
decrease in dia)
 TESTING OF WIRE ROPE

Cleaning of specimen (36 times of dia)

Fitment of cervical block cones on the
specimen
White metal casting
Testing on MAN chain m/c
(For 32mm dia-50.3T)
 Dismantling of jib stopper and replacement of
nylon rollers and pads if necessary
Bridle and equalizer beam replacement if required
Visual checking of A frame and necessary repairs
and legs are check for any distortion
Gallows frame distortion is checked and corrected
 Bogie run out
Cleaning and visual checking for cracks
Gear box side cover replacement
Gear locking arrangement checking and
replacement if required
Dismantling of coil springs and disc springs(free
height285mm)
Nylon pads in bolster are checked for wear
Brake cylinders are removed from hanger and
overhaul
 Bogie side frames,pins are checked and
appropriate greasing is provided
Visual checking of wheel sets for cracks,fractures
and damages(new wheel dia-920mm+/-1mm,min
dia-840mm)
Cleaning and visual checking of suspension
system
Brake disc and shoe liners of disc brakes are
checked and replaced if required
 DISMANTLING OF
OUTRIGGERS

Nylon pads and hose pipe fittings are

checked/replaced
Locking system and screw are checked/replaced
Outriggers cylinders and propping cylinders are
repaired/replaced
Outrigger pads-cleaning of knuckle joints and
greasing
 Collar and bearings of pulleys are replaced
All hydraulic and pneumatic pipelines,hoses,clamps
are checked and filter elements are replaced
Main engine is disassembled and sent to
OEM,CUMMINS INDIA,PUNE for POH
POH of auxiliary engine is done respective
OEMs(KIRLOSKAR)
 POH OF MATCH TRUCK

All necessary dimensions of the bogie are measured

and rectified accordingly
Side frame distortion is checked and rectified
Bogie center pivot,pivot nut and pivot bearing are
checked visually and replaced if damaged
Visual checking of all coil springs
Pads in bolsters are checked/replaced
Brake blocks are replaced
 PAINTING OF CRANE

Primer:epoxyd resins 2 component primer

Top coat: 2 component polyurethane high
solid material
 POWER PACK
It is the unit providing power for the
hydraulic and the pneumatic circuits for
various crane operations.

Consists of :
MAIN ENGINE
EMERGENCY ENGINE
 MAIN ENGINE

It is a CUMMINS 6 cylinder vertical

engine
( NTA 855).

Output: 205 Kw, at 1800 rpm.

Torque: 1158 N-m, at 1400 rpm.
Cubic Capacity: 1400 ccm.
Fuel supply: 900 lt.
Generator: 28 volts at 55 Amp.
 MAIN ENGINE cont..
SUBSYSTEMS:

Engine block
Fuel oil system
Lubrication system
Air intake system
Cooling system
MAIN ENGINE
 Engine block

Various auxiliaries attached are:

Power take off unit (PTO)

Compressor
Fuel pump
Over speed trip
Governor
 Power take off unit
Planet gears

Sun gear
 FUEL OIL SYSTEM
Fuel Solenoid

Fuel Pump To Engine

Fuel tank
900 Lt.

Water Separator
Fuel oil filter
 EMERGENCY ENGINE

Small 2 cylinder KIRLOSKAR engine (HA

294) operated for the purpose of packing
only,when the main engine fails.

Specifications:
Type: KIRLOSKAR HA 294
Output: 16.9 Kw, at 1800 rpm.
Capacity: 1884 ccm
 CONTROL SYSTEMS

Electrical control systems

Pneumatic control systems
Hydraulic control system
Safe load indicator system
 ELECTRICAL CONTROL SYSTEM

It is used for following operational controls:

Engine starting
Battery charging
Engine parameter measurement
Pilot line actuation for crane operation control
ENGINE STARTING
CHARGING CIRCUIT
 ENGINE PARAMETER
MEASUREMENT
Parameters measured:

R.P.M
Lube oil temperature
Lube oil pressure
Water temperature
 ENGINE PARAMETER
MEASUREMENT cont..

In addition we have following switches and

alarms:
Lube oil pressure switch
Lube oil pressure alarm
High water temperature switch
High water temperature alarm
Over speed switch
 PILOT LINE ACTUATION CONTROL
Main Engine Limit switch
07A

Relays

SLI - 63A Relays

Hydraulic
Solenoids
PNEUMATIC CONTROL SYSTEM

Used for :

Applying brakes
Actuating horns
Gear engagement
APPLYING BRAKES
GEAR ENGAGEMENT
 HYDRAULIC CONTROL
SYSTEM
We have hydraulic controls for:

Various crane operations

Outrigging & propping
Traction & axle blocking
Counterweight handling
 CRANE OPERATIONS

Hoisting
Derricking
Slewing
Winching
Travelling
 HYDRAULIC CIRCUITS
Hydraulic circuit for crane operation
consists of two parts:

Power circuit
Control circuit
 POWER CIRCUIT
MAIN ENGINE

PUMPS OPERATIONS

Q1 Main hoist, Aux. hoist, Winching &

Travelling
Q2 Derricking, Travelling, Charging
undercarriage cylinders
Q3 & Q4 Slewing, Lubrication

Q5 Pilot line supply

Q6 Hydraulic oil cooling

 POWER CIRCUIT cont..

Auxiliary Engine

PUMP OPERATIONS

Q8 All operations except travelling and

hoisting up
Q9 Pilot line supply
PUMPS
 POWER CIRCUIT cont..

MOTORS ( Bent axis motors ):

1. Winching motor
2. Derricking motor
3. Main hoist motor
4. Auxiliary hoist motor
5. Slewing motor
MOTORS
 CONTROL CIRCUIT

This is a circuit operating at 30 bar, controls the

power circuit. It has following parts:

MULTISPOOLS
PILOT LINE
ACTUATING SOLENOIDS
 MULTISPOOLS

There are two spools, MO4 & MO3 which

control the following motor operations:
SPOOL OPERATIONS

MO4 Winching, Auxiliary hoist, Main hoist,

Travelling
MO3 Undercarriage and gallows, Derricking,
Travelling
MULTISPOOLS
 PILOT LINE & ACTUATING
SOLENOIDS
Pilot line is a constant pressure 30 bar hydraulic
line, pressure being maintained by pump Q5.
It is actuated by solenoids which in turn are
controlled by limit switches and SLI systems.
PILOT LINE & ACTUATING
SOLENOIDS
OUTRIGGER & PROPPING

Driver can select the output of pump Q2 for

any of the following operations:
Derricking
Travelling
Counterweight handling
Outrigging & propping
OUTRIGGER & PROPPING cont..

STEPS:
1. Outrigging & propping selection for
pump Q2
2. Axle blocking
3. Outrigging & propping
 AXLE BLOCKING

During axle blocking the springs are compressed

fully, avoiding any sideways deflection.

Following operations are performed simultaneously:

1. Engagement pinion meshed with bull gear
2. Brakes are applied
 OUTRIGGER & PROPPING
cont..
Selection for outrigging & propping from cabin
transfers controls to levers SM125F.

propping

outrigging

Axle
blocking
COUNTERWEIGHT HANDLING

Three counterweights:
25 ton, 14 ton & 8 ton.

There are five hydraulic cylinders:

2 cylinders vertical movement
2 cylinders horizontal movement
1 cylinder increasing radius
COUNTERWEIGHT HANDLING
 SLI SYSTEM

It works on the principle of comparison of

load moment with reference values stored.

Sends alarm at 85% of reference value

Switches off overload relay under
overload conditions
 SLI SYSTEM cont..

Components
1. Central processing units
2. Boom angle sensor
3. Slew angle sensor
4. Load cell
5. Shear pin sensor
 SLI SYSTEM DESCRIPTION
Mechanica
CPU Display unit

Load cell

Electrical
Slew Angle Panel
Sensor

Shear Pin
Sensor

Boom Angle
Sensor
 CPU (Mechanica)

MX1 card K1: Overload cutoff

K2: Warning cutoff
K3: Hoist cutoff

MX3 card Power supply

MX5 card K1: Defunct.

K2:controls slewing right motion
K3:controls slewing left motion
K4:derricking motion
SAFE LOAD INDICATOR
OF 140 T CRANE
 Need for SLI System

Safe operation of Crane

Operators inability to correctly judge the
load moment
Less operator skill required
 Introduction

MS 3600 developed by Mechanica System, Pune

If operator approaches unsafe conditions, MS3600
LMI will warn the operator by an audio visual
alarm at 85% of the loading condition and if the
driver proceeds beyond this, some motions will be
blocked.
Provides User information of various counter
weight and prop positions, actual load being lifted,
radius of main hook and boom angle, slew angle,
rated load as given in load chart at selected crane
condition.
 System Description
Operators Display

The Central
Input Processing Output
Unit

Crane Electricals
System Description
 Sensors

Load Cell
Boom Angle Sensor
Slew Angle Sensor
Shear Pin
 Load Cell

Capacity 120T
Position - Left hand side of derricking rope
Senses tension in Derricking Rope due to load
being lifted and Boom Derricking

PRINCIPLE:
Strain Gauge bonded in Wheatstone Bridge
Resistance directly and linearly proportional to tension
Output amplified in preamplifier ckt
Load Cell
Load Cell
 Boom Angle Sensor

Utilizes single turn free rotation Potentiometric

sensor
Position - over the Boom first right hand side of the
operator cabin

PRINCIPLE:
Outer shell of sensor fitted to boom plate
Pendulum mass attached to the inner shaft suspended in
an oil chamber (to dampen vibrations)
Boom Angle Sensor
 Slew Angle sensor

Senses the slewing of crane superstructure

Position: On the top of the rotor at the dead centre
of the crane

PRINCIPLE:
Twin wipers with free rotation kept 90 apart
Outer housing fixed to Super Structure
Spindle coupled to centre of the Rotor
Slew Angle Sensor
Operators Display
 Operators Display

Rated Moment (Reference Moment)

Actual Moment
Radius / Angle Display
Slew Angle
Functional Keys
Test key
Radius / Angle Key
Data Key
Up / Down Key
Mute Key
 Operators Display

Warning Lamp
Overload
Counterweight Position
Prop Selection
LCD Display
Error
 Central Processing Unit

MX1 Card
MX3 Card
MX5 Card
Load Charts
Load Charts
Load Charts
System Description
 Fault Diagnosis Chart

No Display
Boom Angle or Radius Display incorrect
Slew Angle Displayed in correct
Actual Moment Displayed incorrect
Error code displayed
MX1 Card
MX3 Card
MX5 Card
No Display
Radius/Boom Angle Display
Incorrect
Slew angle Displayed Incorrect
Actual Moment Displayed
Incorrect
Display Error Codes
Thank You