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160 TONNES TELESCOPIC BOOM BREAK DOWN CRANE
TELESCOPIC BOOM CRANE POWER REQUIREMENT
TELESCOPIC CRANE SUPERSTRUCTURE, DRIVE GEAR
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TELESCOPIC BOOM BREAKDOWN CRANE OPERATING
160 TONNES TELESCOPIC BOOM BREAK DOWN CRANE
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TELESCOPIC BOOM CRANE POWER REQUIREMENT

5.1.0   D I E S E L   E N G I N E.

5.1.1   The main diesel engine including any other diesel engines selected shall be well proven and reliable in service in tropical countries. Robust construction and low maintenance costs are of particular importance. The tenderer shall ensure that all spares for the engine including auxiliaries offered shall be available from the manufacturer. The make model and series of diesel engine selected should be one being manufactured in European countries and U.S.A., preferably, Cummins, Mercedes Benz,  Deutz and Caterpillar or equivalent.   

5.1.2   Adequate allowance shall be made for derating of the diesel engine under the extreme climatic conditions stated in Clause 2.4.0 of this specification.Filters for engine intake air shall be of adequate efficiency and capacity to ensure satisfactory performance under dusty conditions.The specification of the main and auxiliary diesel engines shall be as follows:

Main diesel engine:

-  Output (minimum) KW 200 /270 H.P, preferably 1800 rpm
-  4/6-cylinder in-line type allowing installation of the engine at the side of the crane for easy accessibility for maintenance works. V-type and under floor type will not be acceptable, unless the bidder explains the easy accessibility for maintenance purposes.
-  Water - cooled.
-   Bidder should also conform that the offered diesel engine have adequate capacity for the working of crane to handle the lifting capacity indicated at clause 2.1.6.10 “a to p”.

Auxiliary engine:

-  Output (minimum) 20 KW/27HP, preferably 1800 rpm
-  1-2 cylinders
-  hand start plus electric start

5.2.0   F U E L  &   L U B R I C A T I O N S.

5.2.1   High speed diesel oil to Pakistan Standard shall be normally used.

5.2.2   A fuel tank of efficient capacity for continuous operation for 24 hours shall be provided. Higher tank capacity will be preferred. Sight glass type fuel measuring gauge shall be provided on the fuel tank.

5.2.3.  The diesel engine should be fuel sufficient and suitable to work with H.S.D. oil specified below:

S.No

 Characteristics

 Test Method

Specifications

Winter (Nov-Feb)

Summer (Mar-Oct)

1

Flash point.

ASTM D 93

Min. 660C

2

Viscosity Kinematics at 400C.

ASTM 445

Min 1.5 Cst , Max 6.5 Cst

3

Pour point.

ASTM D 97

Max -6 0C

Max -0 0C

4

Carbon residue conradson.

ASTM 189/4530

% Mass Max 0.1

5

Ash.

ASTM D 482

% Mass Max 0.01

6

Water.

ASTM D 95

% Volume Max 0.05

7

Sulphur.

ASTM D1552/2622/4294

% Mass Max 0.5

8

Gross calorific value.

          -

Min 19000 BTU/ Ib

9

Cetane Index.

ASTM D 4737/976

Max 45

10

Corrosion copper strip        at 1000C.

ASTM D 130

No. 1

11

Density at 150C.

ASTM D 1298/4052

Min 0.82 Kg/L, Max 0.87 Kg/L

12

Distillation 90% recovery, 0C (0F) 

ASTM D 86

Max 365 (689)

13

Colour ASTM

ASTM D 1500

Max.3

14

Cloud Point 0C (0F) Winter/ Summer

ASTM D 2500

Max. 6(43)/ 9(48)

15

Sediment, % wt.

ASTM D 473

Max. 0.01

16

Strong acid number mg KOH/g

ASTM D 3242/ D-664

NIL

17

Total acid number mg KOH/g

ASTM D 3242/ D-664

Max. 0.5

5.2.4 The Tenderer shall indicate the diesel engine offered will work satisfactorily with the above type of fuel oil. Information regarding the extent of periodical maintenance requirements between general overhauls, based on the experience of other railroads shall be given.

5.2.5   Lubricants & greases for regular crane operation shall be specified by the tenderer. He shall make the maximum use of lubricants & grease available in Pakistan.

5.3.0   T R A N S M I S S I O N.

5.3.1   Only hydraulic (i.e. hydro-static) transmission of well proven design and proven reliability in break-down crane application (in tropical countries) shall be acceptable. The torque converter, hydraulic pumps and motors used in the transmission shall preferably be suitable for replacement and working in severe hot/dusty climate.

5.3.2   Adequate cooling capacity for the transmission unit shall be arranged so that the maximum temperature of the medium at any time under continuous rating conditions, in the ambient temperature as laid down shall not exceed that stipulated by the Makers. Tenderer shall furnish relevant data & test results of temperature reached to the satisfaction of the purchaser.

5.3.3   The components of the transmission drive system such as gearbox, cardan shafts etc. shall be of robust and well proven design. Consideration shall be given to the lubricating system so as to ensure efficient lubrication of the gears at all times under varying working conditions.

5.3.4.  The equipment used in the crane shall comply with the requirements clauses 44 and 45 of B.S. standard 1757 of 1981 or equivalent standard of UIC applicable to break down crane. The bidder shall submit equivalent standard for comparison.

5.3.5   The hydraulic system shall be so designed that there should be no necessity to disconnect and connect the hoses carrying out any crane operation including transfer of counter-weights etc.

5.3.6.  The pneumatic equipment used in the crane shall comply with the requirements clauses 45 & 47 of B.S 1757, 1981 or Chinese equivalent standard applicable to break down cranes. The bidder shall submit equivalent standard for comparison. A pneumatic circuit diagram has to be submitted by the tenderer.

5.4.0   C O O L I N G.

5.4.1 The cooling equipment shall be of well proven and shall be designed for maximum ambient temperature of 550 C.

5.4.2 The main diesel engine shall be water cooled, the radiator and fan
being of adequate capacity to cope with the service demands under the severest temperature conditions. The system must be adequately pressurized and vented to avoid all possibilities of cavitation.  Margin in cooling capacity shall be kept for fouling of radiators in service.

5.5.0   CONTROL   EQUIPMENT,  INSTRUMENTS  AND SAFETY  DEVICES.

5.5.1 Suitable and adequate control equipment including gauges, instruments and safety devices shall be provided for safe and satisfactory operation of the
crane. The equipment shall be so arranged on the control desk that it will be within easy reach of the crane driver/operator. 

5.5.2 The following minimum instrument / gauges shall be provided.

1 Diesel engine  

i)    Lubricating oil pressure gauge
ii)  Cooling water temperature gauge
iii)  Service hour-meter.
iv) Engine RPM indicator
v)  Fuel gauge.
vi)   Lubricating oil temperature gauge

2 Hydraulic         

i)     Transmission oil temperature gauge Transmission          

ii)    Transmission oil pressure gauge

3 Other gauges   

i)     Battery charge and discharge ammeter.

4 Indicators         

i)     Inclinometer: Safe load- Radius indicators for both free on rails and propped up (on level as well as super-elevated track) conditions. An additional indicator outside the cab shall be desirable.

5.5.3   All gauges shall be of proven and reliable design. Graduations of the gauges shall be in metric units. Gauges shall be indirectly illuminated.

5.5.4   The following audio visual signals & reference panel lights shall be provided in the cab:
i) Lubricating oil temperature excessive.
ii) Radiator water temperature excessive & hot engine alarm.
iii) Transmission hydraulic oil temperature excessive.
iv) Engine over speed.

5.5.5 The following safety device for safe working of crane shall be provided:

Electronic safe load indicator with automatic cut out for load moment increasing movement limits. The system will process data from propping base, boom length, boom angle, slewing angle, counterweight, tail radius and actual load.

The system should also give direct reading of important parameters like actual capacity, actual load, boom length, working radius propping condition etc. The safe load indicator shall be robust and reliable in design and shall be capable of working without problem in tropical climate.

  1. Hoist limit switch for main hoist.
  2. Lowering check valves, pressure relief valves and lock valve for hydraulic system.
  3. The following safety devices for engine shall be provided:-

Low water in radiator   power to transmission cut off and engine shut down after delay time on rise of cooling  water temperature.

Low lubricating oil power to transmission cut off and engine pressure shut down after delay time.

Engine speed to high power to transmission cut off and engine shut down after delay time.

5.5.6    The following safety interlocking devices of crane  shall be provided:

i) Train brake not operational if travel gears are engaged or suspension blocking is on

ii) Crane and self propelled travel motions not operational if suspension blocking is off

5.5.7   The following safety devices for safe working of crane shall be provided:

5.5.8   Makers shall clearly indicate the simultaneously working features of crane & provisions made for interlocking between the various motions, i.e. derricking, hoisting, slewing and travelling for the design of crane offered.  A chart showing possibilities of simultaneous operation of the various motions at the corresponding capacity of crane in terms of safe load, outreach and angle shall be submitted by the tenderer.

5.5.9   A pump operated by an auxiliary diesel engine shall be provided to permit the crane being brought to train hauling condition in case of main diesel engine failure.

5.5.10 The crane should be equipped with auxiliary diesel engine, with in case of main diesel engine failure can take over to bring the crane back in transport position.

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