1

TRAVERSER

MANUAL MULTI-TRACK ELECTRIC SURFACE

80 TONE CAPACITY

OPERATION & MAINTENANCE

2

TABLE OF CONTENT

Sr.No DESCRIPTION PAGE No.

1.0 TECHNICAL SPECIFICATION 03

2.0 TECHNICAL CHARACTERISTICS 04

3.0 GENERAL INFORMATION 07

4.0 PRINCIPLE OF OPERATION 08

5.0 INTRODUCTION TO COMPONENTS 09

6.0 ELECTRIC CIRCUIT & CONTROLS 10

7.0 ERECTION & INSTALLATION 11

8.0 COMMISSIONING 16

9.0 OPERATION & TROUBLE SHOOTING 17

10.0

MAINTENANCE CHECK UP AND

CAUTION 18

11.0 ANNEXURE 22

12.0 DRAWINGS 24 TO 46

3

1.0 TECHNICAL SPECIFICATION

.1 Type of Traverser : Surface Type

.2 Maximum carrying capacity : 80 t

.3 Effective length : 22610 mm

.4 Length of Bridging over piece : 1390 mm

.5 Total Length including Bridging : 25390 mm

over Piece

.6 Travelling speed with load : 100 m/min (Max)

(Reversible)

.7 Speed of hauling rope (nominal) : 45 m/min (max) at the 1st layer

.8 Maximum pull on the wire rope : 3.00 t

.9 Gauge of the track on the Traverser : 1676 mm (BG)

.10 Height of track on traverser : 240 ± 5 mm

from the top of runway tracks

.11 Size of the rails above the Traverser : 100 mm wide x 40 mm thick wear

resistant steel sections welded to

a complete built-up section

.12 Number of runway track : 9

.13 Number of wheels on runway track : 21 off

a) 11 nos. Non-driving Wheels

b)7 nos. Driving Wheels

c) 3 nos. Cabin-wheels

.14 Center distance of the Traverser track : 2730 + 3 mm

wheels

.15 Ground Clearance : 40 mm

.16 Size & type of travelling wheels : 500 mm tread dia (double flanged)

x 140 mm width

.17 Size of the wire rope : 20 mm nominal dia of 6 x 36 or 37

construction as per IS:2266.

.18 Length of wire rope : 125 m

.19 Operating voltage : 415 ± 10% V, 3 Ph, 50 ± 3% Hz AC

.20 Down Shop lead : 4NOs Shrouded Cu Conductor Wire

(3 Nos. phase)

4

2.0 TECHNICAL CHARACTERISTICS

2.1 ELECTRIC MOTOR

.1 Power : 55 kW

.2 Frame size : 280M,IS:1231

.3 Pole : 6

.4 Elect Spec : IS : 325

.5 Construction : B3

.6 Type : SLIP RING

.7 Enclosure : TEFC

.8 Rating : S4-40% at 150 Starts/hr.

.9 Phase : 3

.10 Voltage : 415 ± 10% V

.11 Frequency : 50 ± 3% Hz

.12 Insulation : Cl ‘B’ / CL ‘F’

.13 Terminal : TOP / LH

.14 Shaft : STD Double Extension.

.15 Ambient Temp : 50°C

.16 Temp rise : 70°C over ambient

.17 Protection : IP54

.18 Make : ALSTOM

5

2.2 HELICAL GEAR BOX

.1 Type : Helical

.2 Mounting : Horizontal foot

.3 Stage : 2

.4 Size : B 25 (ALLENBERRY)

.5 Center distance : Mfg. Std.

.6 Ratio : 8 : 1

.7 Arrangement : N (Allenberry Std.)

.8 Direction of Rotation : Reversible

.9 Input shaft : Standard

.10 Output shaft : Standard

.11 Enclosure : Totally enclosed

.12 Lubrication : Sump splash

.13 Qty & Gr of Lub Oil : 22 liters (approx)

(Servomesh40 of Indian Oil corporation)

.14 Housing : MS Fabricated

.15 Make : N.A.W

2.3 ELECTRO-HYDRAULIC THRUSTOR BRAKE

.1 Size : 400 mm

.2 Duty rating : Intermittent

.3 Type : Electro-hydraulic

.4 Braking Torque : > 125 Kgm

.5 Insulation : STANDARD

.6 Voltage : 415 ± 10% V

.7 Frequency : 50 ± 3% Hz

.8 Phase : 3

.9 Protection : IP 44

.10 Make : Bengal Technocrats

6

2.4 ELECTRO HYDRAULIC THRUSTOR BRAKE (PARKING)

.1 Size : 300 mm

.2 Duty rating : Intermittent

.3 Type : Electro-Hydraulic

.4 Braking Torque : 60 kgm

.5 Insulation : STANDARD

.6 Voltage : 415 ± 10% V

.7 Frequency : 50 ± 3% Hz

.8 Phase : 3

.9 Protection : IP 44

.10 Make : Bengal Technocrats

2.5 STEEL WIRE ROPE

.1 Size : 20 mm nominal dia

.2 Core : Fibre main core

.3 Construction : 6 x 36 or 37, IS: 2266

.4 Strand : Round

.5 Lay : Ordinary & RH

.6 Tensile design : 1570/1770 N/mm²

.7 Breaking load : 185 kN (Min)

.8 Length : 125 m

.9 Make : UMB

2.6 MASTER CONTROLLER (Cam type)

.1 Direction of movement : Fwd & Revs

.2 Type : MB61 (cam operated Joystick type lever

& with deadman handle)

.3 Rating : 25 A at 110 V AC

.4 Protection : IP44

.5 Make : Circuits & Controls

2.7 RESISTANCE BOX

.1 Type : TW2 + TW2

.2 Rest material : SS

.3 Grid type : Punched

.4 Rating : 10 mins

.5 Protection : IP33

.6 Ambient temp : 50°C

.7 Temp of resist : 275°C

.8 Make : Circuits & Controls

7

3.0 GENERAL INFORMATION

The traverser is a material handling equipment used in Railway Workshops. This traverser will

be used for transporting/shifting railway rolling stocks (BG) from one Workshop track to

another parallel workshop track in outdoor condition. The traverser has built-in adequate

safety margins to meet the normal impact during loading & unloading of rolling stocks.

Important features are noted below :

–The distance between the rope-turn-about-roller and center line of the track on traverser has

been optimized for smooth hauling with minimum side thrust and automatic release of

the hauling rope hook.

–Easy dismantling of the wheel assembly is possible without disturbing alignment of long driving

shaft.

–Spring suspension wheel at the back of the cabin to overcome the difficulty of 2 wheels in

one line.

–Resilient coupling is provided on the long driving shaft for easy alignment and increasing the

life of the supporting bearing block. Long driving shaft is supported by antifriction

spherical bearing block.

–One monorail joist and manually operated hoist has been provided in the ceiling of the

operator's cabin for maintenance/ handling of the driving equipments.

–Standard helical gearbox of reputed make has been provided to increase life of the driving

system.

–Day to day development are incorporated towards smooth and trouble free operation and

to minimize maintenance.

–Grease/oil lubrication provision has been provided for all the moving parts.

8

4.0 PRINCIPLE OF OPERATION

The Traverser consists of steel structure supported on wheels mounted on anti-friction

bearings & running on parallel rail tracks. One broad gauge track is fitted along the

length of the platform to receive BG rolling stocks. All the driving mechanism & control

system are mounted inside the operator's cabin, which is rigidly fixed on one side of the

traverser structure. The Power is collected by current collector mounted on the traverser.

Power is supplied to the slip ring motor through control cabinet. The motor is controlled

by a master controller through VVVF drive mechanism. To the extended shaft of the

motor a brake drum and an electro-hydraulic thruster brake is provided. Power is

supplied from the motor to the primary gear box through a brake drum type flexible

geared coupling. One half of the coupling acts as a brake drum and is positioned inside

a manually operated foot lever type mechanical brake which is provided for proper

operation and accurate inching. The output of the gear box is connected to a bearing

mounted counter-shaft on which 2 free (Not Keyed) spur pinions and one splined jaw

clutch is mounted. The jaw clutch is manually shifted and locked to engage either of

these spur pinions. One pinion is engaged to one spur gear to supply power to the

travelling mechanism, while the other supplies power to the hauling winch through a

separate spur gear mechanism. One resilient coupling is provided between clutch gear

box and helical gear box. The stability in hauling is achieved by two nos. electro-

hydraulic thruster brake provided on the long driving shaft which provides braking to the

traveling gear train during clutch shifting lever in hauling position and/or master controller

in ‘OFF’ position. Provision for manual operation is fitted to extended portion of motor.

When motor rotates and the jaw clutch is engaged to the traveling mechanism, the

traverser moves along the runway track and when the clutch is engaged to the hauling

mechanism, the winch pulls the rolling stock over the traverser platform. The traverser will

move with the rolling stock over its platform by the driving mechanism and transfer the

rolling stock to a parallel shifted workshop track, when moved and positioned at that

location.

9

5.0 INTRODUCTION TO COMPONENTS

A complete Traverser consists of the following items :-

ITEM DESCRIPTION No. OFF REMARKS

1 STRUCTURALS 1 FABRICATED

2 CABIN 1 FABRICATED

3 WHEEL, AXLE ASSY As specified ASSY

(POWER & IDLE)

4 DRIVING MECHANISM 1 ASSY

5 HAULING WINCH 1 ASSY

6 POWER COLLECTOR 1 ASSY

7 MANUAL OPERATION UNIT 1 ASSY

5.1 STRUCTURALS The Traverser structure is of welded construction, built-up from standard rolled sections

and plates. Different members of the structures are braced to each other to ensure

rigidity. The top of traverser platform is covered with steel chequered plates as per

IS:3502. Bogies are built-up for supporting the wheel and axle assembly. The arrangement

is made such that the Bogie assembly can be removed for maintenance without

disturbing the structure. The frame is made from standard rolled section rigidly stiffened

by stiffeners. Holes are provided in the structure for mounting drive unit equipments and

for fixing two no.’s rope-turn-about-rollers. Holes are also provided for mounting

operator's cabin. Machined plates of suitable thickness are welded to the structure to

obtain necessary levels of respective driving equipments.

5.2 CABIN The cabin is of double walled construction and the frame is built-up from rolled steel

sections. Two nos. doors are fitted at two sides of the cabin. Top of the cabin is covered

with industrial corrugated sheets. Moreover, resin bonded rockwool slab have been

provided in the side panels as well as above the false ceiling below the roof for heat

insulation & better working environment. Shock proof glass panels are fitted on all sides of

the cabin so that the operator can have a clear sight on all sides. Complete drive unit is

mounted inside the cabin. In addition, a few windows covered with BRC netting, exhaust

fan are provided for ventilation.

5.3 WHEEL, AXLE ASSEMBLY Machined double flanged wheels of 500 tread dia are fitted on machined axles with

antifriction type spherical roller bearings (two nos at each wheel). Distance pieces are

provided in between the bearings to keep the bearings in proper places. Wheels are

from forged Steel, C55 as per IS:1570, and machined to suit the existing rail profile. The

axle is made of Cl-5 as per IS:2004; forged steel and machined. Two bearing covers are

fitted on the two sides of the wheel to keep the bearings in position and also to protect

the bearings from dirt & abrasive particles as well as to store lubricant for the bearings.

Grease nipple is provided in the wheel assembly for greasing. Grease sealing grooves are

provided in the bearing cover. Both ends of the axle are supported in the bearing blocks.

The bearing blocks are fixed to the bogie frame by bolting. The driving wheels are fitted

with spur gears for driving the traverser.

10

5.4 DRIVING MECHANISM

The driving mechanism consists of a slip ring motor, coupling, electro -hydraulic thrustor

brake, helical gear box, jaw clutch, clutch shifting arrangement, gears. The driving motor

is of 55 kW, 6 pole and of frame size 280 M. It is connected to power supply through a

master controller. Power from the motor shaft is transmitted to the gear box input shaft

through gear-coupling. One electro-hydraulic thrustor brake acts over the brake drum

fitted on the motor extension shaft and a manually operated mechanical link foot lever

type brake is fitted on the brake drum. Power from G.B. output shaft is transmitted

through a resilient coupling to clutch gear box unit which consists of few gears and one

clutch shifting mechanism. Two number clutch pinions are freely mounted on rotating

powered shaft. One side of each pinion is having jaw teeth. One clutch having jaw teeth

on both sides is mounted on the splined rotating shaft. The clutch can be shifted to

engage either of the pinions. One of these pinions is engaged to the traveling

mechanism and the other is engaged to the hauling winch.

5.5 HAULING WINCH

The hauling winch consists of one drum assembly, wire rope & gear for taking power from

the drive unit. The winch is used to haul rolling stocks on the Traverser and off the

Traverser. Power is supplied from jaw clutch meshed pinion and gears. The full length of

the hauling rope is wound on the winch drum in 3/4 layers. Two number guide rollers

(CAPSTAN) are mounted in front of the winch for guiding the wire rope. A flaking unit is

provided between the drum and guide rollers for proper winding of wire rope on the

drum. Two number vertical rope turn about rollers are fixed at the two ends of the

Traverser for reversing the direction of wire rope. A special type hook is fixed at the free

end of the wire rope. The rope drum is fabricated from MS plate, welded and machined.

It is mounted on the spherical roller bearings and is fitted on the drum shaft. Provision is

made for fixing the wire rope on the drum.

5.6 POWER COLLECTOR

Electric power is supplied to overhead power conductors. These conductors consists of 4-

nos. shrouded copper wire. These conductors are supported by fabricated steel girders

which rest on intermediate masts. Power is supplied to the copper wire conductors from

supply bus bar. One power collector is mounted on the Traverser structure. The collector

consists of 4 nos. current collectors supported by insulators including 1no. collector for

neutral. The current collectors move with the Traverser and maintain a continuous

contact with the shrouded Cu conductors. Power from the copper conductors are

collected by the current collector and flows to the control cabinet / resistance box

through incoming cable.

11

5.7 MANUAL OPERATION UNIT

The Traverser can be operated manually in case of emergency during power failure. Two

operating handles are fitted at both sides of a bearing mounted shaft on which a chain

sprocket is fitted. This sprocket is connected to another sprocket, which is fitted on a

bearing mounted shaft through a chain. A clutch is fitted on the manual operation unit

shaft for engaging or disengaging the manual operation unit from the driving

mechanism. One limit switch is fitted with the clutch lever such that the drive mechanism

cannot be driven by electrical power when the clutch is engaged, which ensures safety

of the operator. By engaging the clutch to the brake drum mounted on the motor

extension shaft and releasing the thrustor brakes the Traverser can be made to travel or

haul manually. The chain sprocket drives the shaft on which a clutch is fitted. The clutch is

fitted with a number of pin which will be fitted on a brake drum fitted on the motor shaft.

When the manual handle rotates, the Traverser/winch will be operated through chain,

clutch, motor shaft, gear box system.

12

6.0 ELECTRIC CIRCUIT & CONTROLS

6.1 POWER SUPPLY :

415v ± 10%, 3ph+N, 50Hz Ac power is collected from overhead DSL of shrouded Cu

conductors. Power is supplied through current collectors to junction box (JB1) placed on

the top of tower on Traverser.

From JB1, collected power is transmitted to the main incoming isolator (JB2) which is

placed inside cabin and then JB2 to Control Panel which is placed inside cabin through

50sq mm PVC insulated Armoured copper cable.

6.2 CONTROL PANEL :

Two numbers of Step Down transformer are used in panel to get suitable voltage such as,

Lighting circuit voltage 220v, Hand lamp circuit voltage 24v. One number of voltmeter (0- 500v) with voltmeter selector switch, three numbers of

ammeter (0-150A/900A),control on & phase indicating lamps (R,Y,B)are placed on panel

wall. Sys on, Drive run, Drive fault , Thrustor brake & 2 other Parking brake fault indicating

lamps & an Emergency stop push button switch are also placed on panel wall. Isolating

switch is interlocked with the front door of the control panel. Control circuit wiring has done by 2.5sq mm Cu PVC 1.1 Kv grade flexible (standard)

cable inside panel. Power circuit wiring has done by 50 sq mm Cu 1.1 Kv grade flexible

(standard) cable inside panel for main motor and 4sq mm Cu PVC cable used for power

supply circuits. Drive Motor, Electro hydraulic thruster breaks, Master controller, Interior & Exterior lighting,

Revolving indicating lamps, Horn, Power sockets connection leads to be incorporated

inside panel. For these electrical wiring Armoured / Unarmoured Cu cables are used as

per actual requirements. The motor & electro- hydraulic thrustor brakes are connected in such a way that braking

takes place only when the motor is off.

6.3 MASTER CONTROLLER :

7 Steps notch with dead man handle operation provides four individual speed control

over speed of motion of traverser during traveling and as well as hauling. Local push button station is placed near master controller with Start, Emergency stop

and Horn push buttons for easy operation. Indicating revolving RED lights are interlocked with dead man handle.

6.4 RESISTANCE BOX :

10 mins rated punched stainless steel grid resistance box is connected to the control

panel & rotor contactor. Using of master controller operation resistance is cut out step by

step to get desire level of controlled speed.

13

6.5 LIMIT SWITCH :

Travel limit switch (2NO+2NC) is used to keep Traverser in motion in close condition and in

open condition only hauling is take place without Traverser movement. FWD & REV track

limit switches (1NO+1NC) are indicating extreme travel position of Traverser. After striking

FWD or REV track limit switch stopped the motor as well as motion of Traverser. Manual

limit switch is used when Traverser is operated by manually.

BEFORE STARTING :

CHECKING THE SUPPLY VOLTAGE BEFORE START. CHECKING EMERGENCY STOP NOT PRESSED ON.

MASTER CONTROLLER AT ZERO POSITION.

NO FAULT INDICATION LAMP ON

DURING TRAVELLING & HAULING :

AMMETER CURRENT IS UNDER DESIRE RANGE.

EXHAUST FAN MUST ON FOR COOLING OF RESISTANCE BOX.

AT HAULING, LOCKING SHOULD BE DONE PROPERLY.

ALL CONTROLS MUST BE OFF DURING MAINTENANCE.

MAIN INCOMING ISOLATOR & CONTROL SWITCH FROM CONTROL PANEL MUST OFF WHEN TRAVERSER IS NOT OPERATED.

14

7.0 ERECTION & INSTALLATION

7.1 GENERAL

The Traverser will be delivered at site in partly assembled condition as described under

clause 5.0. As a general rule the delivery is arranged in such a way that the erection work

at site is reduced to a minimum. The Traverser will be erected on the existing runway

track as per METCO drg no. 0-C3754-G, Rev B. For erection of the Traverser a crane must

be available at site with a hoisting capacity of approximately 20t.

7.2 INITIAL CHECK

The following initial checking are recommended :

–Runway track shall be preferably straight, level parallel & with minimum rail joint. –Inspection of track and its fixing arrangement.

–The center distance of the runway track shall be shown in the METCO General Arrangement

Drg. –The length of the track shall be checked with respect to the Traverser travel length and

position. –Length of down shop lead & clearance on either side of travel shall be checked as per

power collection tower position. –Clear passage of Traverser movement with the rolling stock on its platform.

7.3 ASSEMBLY PROCEDURE

.1 First of all the portals are to be placed parallel to each other a specified distance by help

of a suitable crane, stay and support. .2 The lower chords are to be fixed to the portals.

.3 The upper chords are also to be fixed to the portals.

.4 The vertical bracing and diagonals between the lower and upper chords are to be fixed.

.5 The track girder sections are to be fixed to the portals.

.6 Top tie and top bracings are to be fixed between the portals.

.7 Chassis girders are to be fixed to the portals with the help of suitable supports. The chassis

frames are to be fixed to the chassis girders and mechanical assembly on the chassis is

to be carried out. .8 The driving and non-driving wheel bogies are to be fixed to the structure and long driving

shaft to be mounted on the structure with proper alignment. .9 For assembly of various structural, mechanical and electrical items, refer METCO drg.

15

7.4 CHECKING AFTER ASSEMBLY

After completion of assembly, the exact gauge of track on Traverser is to be checked

with the help of a tape. Before checking, make sure that the runway track and track on

Traverser are exactly at an angle 90°. After checking, the Traverser can be lowered on

the runway track on which the Traverser will travel.

Check thoroughly the overall complete-ness for the assy of mechanical, structural and

electrical items. Electrical cabling and earthing must be satisfactory. Now the Traverser is

ready for trial run.

Temporary power connection / provision shall be arranged for a few meters trial run.

Check the trouble free operation of the Traverser during trial run.

The power collection tower shall be fitted to its position. The Down Shop leads & cables

shall be erected. It must be tested by an electric megger. The power shall be supplied to

the DSL.

The collection tower, Traverser etc. shall be tested against short circuit. All the electric

connection shall be carried out as per METCO electric circuit diagram. The limit switches

are to be adjusted during trial run if not adjusted before.

16

8.0 COMMISSIONING

8.1 GENERAL

After the Traverser is erected & kept on the runway track it must be first checked that all

components are correctly mounted & not damaged. These checks & adjustments could

be performed in accordance with the following instructions :-

CHECKS :

Prior to starting the motor the followings should be checked properly :-

–The machine must be thoroughly cleaned.

–The Drive, Control cabinet, Junction Boxes must be cleaned by using air blower. –All bolts & nuts must be adequately tightened.

–All electrical connections including earthing must be checked.

–Brake shoe lining must be free from oil & grease. The spring loaded nuts must be properly

adjusted. –Oil level of the gear boxes must be checked.

–The direction of movement of the Traverser and hauling system must be checked with

respect to the corresponding operating push buttons. –The Runway track must be free from any obstruction.

–Greasing & oiling must be done to all the open gears & pinions & also to every grease

nipples. –Easy operation of the jaw clutch shall be checked.

–One end of the wire rope shall be anchored to the rope drum & the wire rope shall be free

from any kink knots and damages. –The bridging over pieces shall be fitted to the Traverser and shall coincide with the shop

track.

8.2 STARTING UP

The Traverser shall be tested first in no-load condition. After checking, the Traverser shall

be started as follows :-

–The main isolating switch (MCCB) shall be `ON' to supply power to the Traverser. Then the

main control switch (MCCB) shall be `ON' to supply power to the control cabinet. The

Traverser frame, control cabinet, motor, brake etc shall be tested against any electrical

fault. –The `START' push button at the push button station shall be `ON'.

–The master controller shall be started in forward or reverse direction depending on the

position of the Traverser. Braking effect shall be noted by using brake.

17

9.0 OPERATION & TROUBLE SHOOTING

9.1 When the Traverser is properly installed, commissioned & load tested & testing report is

satisfactory, the operating instruction shall be given. The operator should be highly skilled & trained & must carefully study the operation & maintenance manual before starting

the motor. He must study all the components & understand its function properly. The

Traverser shall be aligned with the shop track from which the rolling stock is to be taken

on the Traverser by starting the motor & engaging the travelling mechanism. The shop

track & track on Traverser must be in the same line. The clutch lever shall be shifted to

hauling position thereby transmitting power to the rope drum. The long travel brakes must

hold the travelling mechanism. Master controller handle shall be operated for unwinding

the wire rope. The hook fitted at the end of the wire rope shall be fitted to the rolling

stock after passing it over the end rope turn about roller. Now the master controller

handle to be operated to wind the wire rope. The rolling stock shall be pulled towards

the Traverser and it will ride on the track on Traverser. When the rolling stock is on the

Traverser, the clutch shifting lever shall be shifted to travelling position. The Traverser shall

start to move longitudinally. The master controller handle shall be operated to suit the

direction of travel of the Traverser. The master controller shall be stopped ahead of the

destination track & by using the first one or two notches of the master controller as well as

the foot brake the exact alignment of tracks shall be achieved. The clutch shifting lever

shall be shifted to hauling position after aligning the Traverser track with the shop track.

The rope is unwound & fitted to the rolling stock after passing it over the end turn about

roller as required. The winch will be operated to wind the wire rope. As a result the rolling

stock will move to the shop track through bridging over piece.

9.2 OBSERVATIONS

The following observations are to be made during operation :-

.1 Bridging over piece and shop track should coincide during alignment.

.2 The wire rope should pass over the end turn-about-roller during hauling.

.3 Clutch lever should be in neutral position during starting of motor.

.4 Rolling stock should rest entirely on track on Traverser before travelling.

.5 The wire rope should not be wound at one place and slip over the drum flange.

18

9.3 TROUBLE SHOOTING

SL No. TROUBLE CAUSE REMEDY

1. Wheels & Improper lubrication. Use only recommended type of

Rollers are lubrication as per lubrication

not rotating. instruction. Also lubricate the

components regularly.

Damages in the bearing. Replace the bearing.

Jamming of the long driving Insert/replace shim at the bottom

shaft support bearing. of the bearing block, lubricate the

bearing regularly.

Foreign materials obstructing Remove foreign materials from the

gear. gear teeth.

2. Noise in the Wear of teeth. Replace the gear.

gear.

Gear centers are not parallel. Properly align the gear and pinion.

Lack of lubrication. Lubricate the gear properly.

Foreign materials in the gear Remove foreign materials from the

teeth. gear teeth.

3. Brakes are Excessive wear of brake shoe. Replace the Shoe.

not working. Insufficient adjustment

Adjust the tightening nut properly.

of tightening nut.

Oil or grease in the Shoe. Clean the brake shoe from the

oil/grease.

Insufficient oil in hydraulic Fill the thrustor with requisite

thurstor. hydraulic oil.

Faulty electric Check & rectify electric

connections. connections.

4. Limit Switch connections are not correct. Correctly connect all the

not cut-off. terminals.

Levers are not striking the limit switches.

Adjust the limit switch & striking

arm properly.

19

SL No TROUBLE CAUSE REMEDY

5. Noise in the Lack of lubrication. Use proper & sufficient lubrication.

wheel

Damage in the bearing. Replace the bearing.

Dust particles within the Clean the bearing & cover

bearing. properly.

6. Motor not Faulty connection. Test all the connections &

starting. rectify.

Armature coil damaged. Test the coils & repair if

damaged.

LS in manual operation unit is Check LS cut-off in manual

not cut-off. operation unit and rectify.

Bearing Jamming/noise in Replace the bearing & lubricate.

bearing.

Fault in the circuit. Test the circuit and rectify.

Low voltage. Check the voltage from

volt- meter and stop the motor.

7. Contactor Faulty connections. Check all the connection points.

burnt

immediately.

Jamming in the drive unit. Rectify the defects & lubricate.

Defect in control Replace the control transformer.

transformer.

Loose contact fittings. Properly check & rectify the

fittings before using the

contactor.

20

10.0 MAINTENANCE, CHECK-UP & CAUTIONS

10.1 GENERAL

Proper care & maintenance including oiling & greasing are essential for smooth & trouble

free operation. The need for overhauling depends, among other things, on the operating

time of the Traverser, loading-unloading conditions and skill of the operator. The time

interval between the inspection must, therefore be decided by the people responsible

for the operation of the Traverser, based on the field experience. The interval indicated in

this section should be considered as broad recommendations only. The following points

must be fulfilled: -

.1 The points where grease nipples have been provided are to be greased by grease gun

once after every 24 hours of operation.

.2 The open gears & pinions should be manually greased once in 24 hours of operation.

.3 Oil level of the gear boxes should be checked once in every week. Oil in the gear box

should be replaced after every 6 months of operation.

.4 The gears & pinions should be checked every week for unwanted abrasive particles,

which may erode the gear teeth.

.5 All the nuts should be checked & tightened every month.

.6 The DSL for power collection should be kept free from any obstruction which may cause

damage to electric cable as well as power collection arms.

.7 Proper care & maintenance of the control cabinet is essential without which smooth &

trouble free operation can not be obtained. The control cabinet & mainly the Drive are

to be properly cleaned by using an air blower both inside and outside.

.8 In case any fuse is blown it is to be replaced by a fuse of same rating. This is very

`IMPORTANT'. In no case, fuse of other rating should be used.

.9 In case contact of any contactor is burnt due to short circuit; it must be replaced by

spare contactor available from the manufacture of the contactor.

.10 In the case of cl.10.8 & 10.9, the reasons of the faults are to be traced & rectified before

further operation of the control cabinet.

.11 After some operating period, brakes may not work due to wear of shoe lining. In this

case tighten the spring-loaded nut.

.12 If the wear of the brake shoe linings are excessive and are reduced to a level where

rivets are exposed then replace the linings.

.13 Painting of the Traverser should be done once in every year as per painting clause of

METCO drawing No. 0-C3754-G, Rev B.

21

10.2 CHECK-UP

.1 Daily inspection & check up

.1 Greasing in the grease nipple, open gears & pinions. Oiling in the oil cups.

.2 Cleaning of track, floor, Traverser platform & exposed parts by air blower.

.3 Horn and lights.

.2 Weekly Inspection

.1 Cleaning of gear teeth.

.2 Oil level in the gear box.

.3 Checking for wear of brake shoe linings.

.3 Monthly Inspection

.1 Tightening of all bolts & nuts.

.2 Wear of bush bearings.

.3 Wear of gear teeth.

.4 Gear box oil condition.

.5 Limit switch cut-off position.

.6 Cleaning of control cabinet by air blower.

.4 Yearly Check-up

.1 Make a thorough check up of the complete mechanical parts, electrical parts & rail

track conditions. .2 Painting as per METCO general arrangement drg. .3 Greasing of all the bearings after thorough cleaning.

10.3 CAUTIONS

.1 Brake lining must be free from oil & grease.

.2 Horn must be in order.

.3 Earthing wire must be connected to structure & control cabinet.

.4 Fuses & contactors of proper rating must be used during replacement.

.5 The pit must be free from water.

.6 Rope guard & gear guards must not be removed during operation.

22

11.0 ANNEXURE

11.1 The following drawings are enclosed herewith :

.1 80t, Surface Type, multi-Track, Electric Traverser : 0-C3754-G Rev B

.2 Electric Circuit Diagram for : 3-3754-E1 /I C Electrically operated traverser : 3-3754-E1/II A

: 3-3754-E/III D

: 3-3754-E2/I B Seven sheets

: 3-3754-E2/II A

: 3-3754-E2/III B

: 3-3754-E2/IV B

.3 Cable Layout and cable scheduling : 3-3754-EC 0

.4 Current Collector & DSL Holding Arrgt. : 1-3754-CI A

11.2 Assembled spares can be selected & ordered by quoting the part no/clause no of

Technical Characteristics of METCO GA Drg No. 0-C3738-G ; Rev B.

SL No. Clause Description Make

Number

1. 3.1 ELECTRIC MOTOR ALSTOM

2. 3.2 HELICAL GEAR BOX NEW ALLENBERRY

3. 3.3 ELECTRO-HYDRAULIC BENGAL TECHNOCRATS

THRUSTOR BRAKE

4. 3.4 ELECTRO-HYDRAULIC BENGAL TECHNOCRATS

THRUSTOR BRAKE (PARKING)

5. 3.5 a) 500 mm DIA BRAKE DRUM METCO & NAW

TYPE GEAR COUPLING

b) RESILIENT COUPLING METCO

6. 3.6 STEEL WIRE ROPE USHA MARTIN LTD.

7. -- MASTER CONTROLLER CIRCUITS & CONTROLS

TYPE : MB61

23

11.3 The following reference drawings are enclosed. The spare parts may be

selected and ordered by referring the part numbers / plate reference and

quantity:-

.1 Wheel Assy (Power) 13 731 MO4 S01/I

.2 Wheel Assy (Power) 13 731 MO4 S01/II

.3 Wheel Assy (for Cabin Support) 12 007 MO 5/I

.4 Wheel Assy (for Cabin Support) 12 007 MO 5/II

.5 Wheel Assy (Idle) 13 125 MO4 S03/I

.6 Wheel Assy (Idle) 13 125 MO4 S03/II

.7 Flaking Unit 13 738 MO 6/I

.8 Flaking Unit 13 738 MO 6/II

.9 Clutch gear box unit 13 190 MO 07/I

.10 Clutch gear box unit 13 190 MO 07/II

.11 Driving Shaft Assy 143 061 MO7 S01

.12 Counter Shaft Assy 33 061 MO7 S02

.13 Clutch Shifter 23 061 MO7 S04

.14 Clutch Holder 33 061 MO7 S05

.15 Counter Shaft (Travel) 33 061 MO7 S03

.16 Counter Shaft (Hauling) 33 061 MO7 S04

.17 Clutch Shifting Arrgt 12 190 MO 8/I

.18 Clutch Shifting Arrgt 12 190 MO 8/II

.19 Haulage Drum 13 738 MO 9/I

.20 Haulage Drum 13 738 MO 9/II

.21 Manual Brake 12 978 MO 10

.22 Manual Operation Unit 12 492 MO 11/I

.23 Manual Operation Unit 12 492 MO 11/II

.24 Long Driving Shaft Assy 13 754 MO 12/I

.25 Long Driving Shaft Assy 13 754 MO 12/II

.26 Rope Turn About Roller 13 125 MO 13/I

.27 Rope Turn About Roller 13 125 MO 13/II

.28 Brake Assembly (Drum) 13 754 MO 15/I

.29 Brake Assembly (Drum) 13 754 MO 15/II

.30 Capstan 13 738 MO19 S01/I

.31 Capstan 13 738 MO19 S01/II

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46