introduction to - rskr.irimee.in

1

Introduction to

140 T Breakdown Crane

2

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

3

Salient Features

All motions hydraulically controlled except

brake system.

Provision of safe load indicators

Quick response in motions

Maximum Speed 100 KMPH

Loaded Wagon Handling

Slewing by 360° with 140 Ton load at 6M

radius.

4

Features of New Design over

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

Five positions of prop

Shear Pin in Auxilliary Hoist

Jib length increased by one meter

External threads in slewing ring

No need of radiator cooling pump

Better design of fuel tank

Direct gear pump is used for hydraulic oil cooling

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CONSTRUCTIONAL FEATURES OF 140T BD CRANE

140T crane is having the following assemblies incorporating hydraulic, pneumatic, electrical and electronic equipment

a) Match Truck

b) Jib

c) Undercarriage

d) Superstructure.

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7

140T Gottwald Design Crane

Old Design New Design

8

Jib

Counter

weight slabs

Rear

frameA FrameBridle

Match Truck

Used to rest jib.

Keep main hoist &

aux. hoist hook assly.

Keep Counterweight

slabs.

Keep lifting tackles.

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Main hook asslyLifting Tackles

Jib

Match Truck

JIB10

Jib/Boom 18.75m long

Minimum Working radius 5.5 meter

Maximum Working radius 18.0 meter

Jib main body is of hollow type and of box shape

Jib is lifted by two gantry ropes one of which is fitted with load sensing devices.

Boom angle sensor is mounted on the fork end inner side

CRANE UNDERCARRIAGE11

Crane undercarriage is pivoted on two bolsters which are mounted on three axle bogie wheels.

A Crane suspension in each bogie consists of four spring packs, each pack with two stacks of coil springs (inner and outer) and two stacks of disc springs diagonally arranged.

The spring suspension arranged can be blocked by axle blocking arrangement.

Crane Bogie

Each Fabricated

bogie with three axle

sets.

Coil & Disc springs

are fitted in

suspension.

Brake disc fitted on

each wheel.

Brake CylinderAxle Blocking

Cylinder

Brake Disc

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Super Structure

Main Engine

NTA855 LBCAux. Engine

Hyd. Tank

Multi Spool Valve

M1

Solenoid Valve

13

Cabin

Joy Stick

Engine Control

Unit

Display Board14

Rear Assly with Counterweight Slabs

Old(5T+14T+6T+18T) New(8T+15T+24T)

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Out Rigger Assembly with

Propping Cylinder16

Propping Cylinder Out Rigger

Cylinder

Used during propping the crane

Counter weights in B.D. Cranes:

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Description:The counterweight consists of 3 counterweight slabs :

Counterweight 1 -24 t Counterweight 2- 15 t Counterweight 3 -08 t

The counterweight slabs are combined by means of a connecting mechanism and spacer brackets and secured by means of locking claws onto the crane counterweight support.

DESIGN PARAMETERS OF A BREAKDOWN CRANE

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1. CAPACITY

• Capacity of a breakdown crane is usually expressed intonnes.140T is the capacity of the lifting hook. Loadmoment, defined as the load that can be lifted intonnes multiplied by the radius at which it is lifted.

• A 120T diesel crane which can lift this load at a radius of5 meters only so that its load moment is 600 tonne-metres. A crane with a bigger load moment is thebigger crane and cranes should not be compared bytheir hook load capacities only.

Today, breakdown cranes are classified into three categories:

1. Small: upto 700 tonne-metre load moment

2. Medium: 700 to 1000 tonne-metre load moment

3. Large: above 1000 tonne-metre load moment

By this definition, the 140T crane is a large crane.

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2. NUMBER OF AXLES

• No. of axles has an important bearing on the working of thecrane.

• If the number of axles is kept large to stay within axles loadlimitations, it will result in an unduly long crane that may requireextra time for attaching, detaching, preparation, etc.

• It is also likely to have lower running speeds.

• Cranes with a large number of axles usually have poor riding.

• It is, therefore, desirable to keep the number of axles as low aspossible.

3. TAIL RADIUS

• This is the maximum distance from the center of rotation to thetail of the revolving Superstructure.

• If the tail radius is small the crane will not get obstructed by thetail portion of its super structure while working.

• However, a small tail radius will increase the need for morecounter weights, which may require an additional ballastwagon, and consequently more setting up time.

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4. PROP BASE

• The effective span or area of the supporting base when outriggers are used to increase stability by making contact with

the ground at points farther from the centre line of the crane,

than the normal wheels/track position

• The size of this base is obviously very critical in the design of the

crane.

• A small prop base is advantageous while working in cuttings

while a large base is useful in embankments here the soil cannot

take heavy loads.

• The prop base, therefore, has to be carefully designed.

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5. BASIC CRANE MOTIONS

• Hoisting: The movement of the hook, main or auxiliary, with orwithout load, when being raised or lowered vertically, Jib

remaining stationary.

• Slewing: The movement of the superstructure along with jib

rotating about a vertical axis.

• Derricking: Raising and lowering of Jib in a vertical plane.

• Travelling: This is the self-travel of the crane.

6. WORKING RADIUS

The horizontal distance from the centre line of the lifting hook to

the centre about which the Crane slews.

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BASIC CRANE

MOTIONS

HOISTING

MOTION

DERRICKING

MOTION

SLEWING

MOTION

LONG TRAVEL

MOTION

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7. STABILITY

• Stability is based on the moments about the tippingfulcrum.

• The worst condition usually occurs when the jib is atright angles to the track.

• For a free on rail duty the fulcrum is the rail while forpropped duty, the prop bases are the fulcrum.

• The sum of the moments in front of the fulcrum plus apercentage of the load for stability margin must bebalanced by the sum of the moments behind thefulcrum.

• For this naturally the maximum load at the maximumradius is taken into consideration.

• Both frontal and backward stability are important.

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SPECIFICATIONS140 T CRANE

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SPECIFICATIONS –140 T CRANE

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Operation Control in Cabin

Left Hand Joystick Right Hand Joystick

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Derrick-

OUT

Derrick-

IN

Slew-

LEFT

Slew-

RIGHT

Main

Hoist-

DOWN

Main

Hoist-UP

Aux

Hoist-

UP

Aux

Hoist-

DOWN

TravellingWinching

PILOT

CHAIR

Crane Bogie

Special bogie designed by M/s Gottwald,

Germany.

Comprises of two 3-axled bogies

Fabricated all weld body steel bogie.

2.8 ton (without wheel) ,10.0 ton (with

wheel)

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Mechanical Parts associated

with Crane Working

Main Hoist

Auxilliary Hoist

Prop & Outriggers

Counter Weights

Slewing Ring

Wires and Ropes

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MAIN HOIST 30

AUXILIARY HOIST 31

Props32

Propping

CylinderIn-RiggerOut-

RiggerPropping

Slew Ring

Slewing ring is a large size roller

bearing mounted horizontally

and connecting undercarriage

and superstructure (while

permitting rotations of

Superstructure and under

carriage).

This is specially designed to

accommodate oscillating

moments

The slewing ring permits rotation

of the superstructure on under

carriage and accommodates

tilting movement as well as axial

and radial loads.

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SLI Items

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Load Cell

Fitted with derrick wire rope & senses actual load of main hoist.

Boom Angle Sensor

Fitted with jib &senses working radius of load.

Slew Angle Sensor

Fitted with super structure & senses slew angle.

Shear Pin

Fitted with aux. wire rope & senses actual load of aux. hoist

Load Cell & Boom Angle

Sensor

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Slew Angle Sensor & Shear

Pin

36

Display Board 37

Prop

position

CWT

position

Main Hook

positionTail Radius

position

Control

Lever in

Display

Board

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• No prop(Free on Rail)

• No prop Super elevated track (25 mm-140 mm)

• Full Prop at 6 m

• Prop at 5 m

• Half Prop at 2.9 m

Prop Position

• No Cwt

• Half Cwt(24T)

• Full Cwt(47T)

CWT Position

Continued

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•Main Hook

•Auxiliary Hook

Hook Position

•At 5.5 m

•At 6.5 m

Tail Radius Position

Load Charts

Load to be tackled as per Load Chart defined

Radius, Counterweight and tail radius

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Main Hoist- 5.5m Counterweight Radius 42

43Main Hoist-5.5m Counter Weight Radius

44Main Hoist- 6.5m Counter Weight Radius

45Main Hoist- 5.5m Counter Weight Radius

25-140 mm

Super-

elevated

Track

46Auxilliary Hoist- 5.5m &6.5 Counter Weight Radius

47Auxilliary Hoist-5.5m Counter Weight Radius

Propping-

• 5.0m

• 2.9m

48Auxilliary Hoist-5.5m Counterweight Radius

Propping-

• 5.0m

• 2.9m

49

RESTORATION

PLAN

Qualification of Crane men

A crane may only be worked/Handled by a

properly Trained/certified crane man.

The using Department is responsible that this

condition is observed.

Before an employee is allowed to work a crane,

he must be examined as to his competency to

do so and be certified.

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51

52Observation of site and load conditions

Before starting the rigging of the crane, check -

✓ Tonnage and dimension of the load to be lifted

✓ Required radius

✓ Hook height, slewing range, space for travelling

with load if needed etc.

Then tackle in conformity with the load chart and

propping condition.

Rigging

Sequence of operations from starting the crane

Axle Blocking ON/OF

Crane in train formation-Axle Blocking OFF

Self crane motion-Axle Blocking ON

Proper propping

Taking Cwt position as instructed

Jib IN-OUT

Hoist UP-DOWN

Slew LEFT-RIGHT

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Axle Blocking 54

In axle blocking operation

Travel gear engage.

Service Brake ON

Suspension spring in Home position.

Ensure engagement of the travelling gear.

Ensure application of brake

Do not start crane operation without proper brake.

55Permissible ground Force

Permissible Ground Force is to be checked according to the type of surface beneath outrigger pad

Natural ground

Medium Sand

Fine Sand, Firm

Counterweight combination and type of outrigger is determined

PROPPING THE CRANE

Observe site for propping

Nearest to the job

Space for prop

Condition of soil

Propping

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57PROPPING THE CRANE

Set the propping pads properly by strengthening the ground and placing the packing alternatively parallel and perpendicular to the track.

Ballasts base may be provided for strengthening.

For marshy land, sand bags can be used for making base for propping.

Do not prop the crane on the unstable ground.

Wooden packing provided should not be in contact with the arm body.

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In case an entangled load is required to be

handled, always work with full counter-weight and

full prop as the actual load may be much more

than what it may appear to be.

Check the level of the crane by spirit level.

Use Rail Clamps as an additional safety.

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COUNTER WEIGHT

1. Select the total counterweight as per load chart as per Load

2. Follow correct sequence of operations for attaching counterweights.

3. First unlock, then extend the Counterweight cylinder and swing in, then lift and lock. Similarly follow this procedure in reverse order for detaching counterweights.

4. Ensure counterweight (CWT) is correctly locked.

5. Load chart should not be violated.

6. Load estimation should be done properly and to avoid any untoward incident maximum possible safe operation may be adopted like full prop, full CWT etc.

7. Ensure the CWT switch is in proper position.

60OPERATING PRECAUTIONS

Do proper selection of lifting tackles (Chain & Wire rope sling).

Avoid jerk during operation. Pendulum motion of load is dangerous

Don’t pull the load diagonally.

Don’t pull a load which is stacked in the ground unless it is ensured that it will not offer resistance beyond the capability of the Crane.

Take care of wind forces on the boom as it is dangerous. Do not operate crane in high wind force.

Do watch the props for any sign of caving and also watch carefully the rear wheels for any sign of lifting from the rail level.

Only crane in-charge should communicate with the crane driver

Operate the joystick gradually

Do not lift the load to the excessive height from the ground level.

SLEW when load in HANGING condition

During slewing , observe the train movement on the adjacent electrically charged line.

Do not override the SLI during restoration.

Staff Needed for Crane Operation & Maintenance

Supervisor-1

Crane driver-1+1(Stand By)

Mistry -1

Technician-

2(Dsl fitter mech.)

1 Elec.

1 Gen.

Helper -8

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Deployment of Staff during Operation

Driver operates crane

from cabin

Gunner with two staff

for loading/unloading.

One staff at each prop

One staff watches the

wire ropes in drum

Supervisor is the gang

leader.

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Inbuilt Safety Features

Safe Load Indicator – For load, radius and slew angle

Limit Switches – For main hoist, auxiliary hoist and boom derricking

Proximity Switch – For safe working of vertical and horizontal cylinders at rear end

Overspeed switch – To prevent main engine overspeeding

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Safety Measures in Crane

Operation

Before starting the engine, check

Hydraulic oil level

Fuel oil level

Water level in radiator

After starting the engine, check

All pressure gauges

All temperature gauges

SLI System

65

Safety Measures

Visual checking of wire ropes

DO NOT bypass SLI system

Feed 4 data in display board

Visual checking of wire rope slings

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Precautions

• Prop as instructed

Select proper Counter weight slabs from Match truck

Crane body level be HORIZONTAL

Wheel just tends to LIFT the track

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Precautions

Select proper wire rope slings.

Staff deployed as instructed

Do not bypass SLI System

SLEW when load in HANGING condition

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Precautions

Only authorisedofficials deliver the instructions to the crane driver.

Operate the joystick gradually

Keep sharp observation over the crane wheels. Lifting of any wheels to be communicated to driver immediately.

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Precautions

Do not lift the load to the excessive height from

the ground level.

Do not override the SLI during restoration.

During slewing, observe the train movement on

the adjacent electrically charged line.

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RESTORATION OF COACHES IN ELECTRIFIED

SECTION BY 140 Te. CRANEPreparation Chart:

S.N Item/Status Action

01 OHE To be slewed towards coach movement and ensure

that OHE of adjacent line has been made dead.

02 Condition of props and

availability of staff

Full propping to be done and 04 staff on each prop

should be deputed.

03 Suitable packing and its size Wooden/synthetic packing of size 4’x2’x14” and

6’x1’x12”

04 Position of SLI duty selector To be kept on No. 1

05 Wire rope Sling and SWL 30 Te. 5 Mtrs sling and 70 Te. SWL as per

requirement

06 Chain sling as per requirement 25 Te. Capacity chain sling

07 Position of Cant of the track Should not be more than 140 mm

08 Position of SLI SLI should be kept in working.

09 Maximum working radius 16 meters by main hook.

10 Place where sling to be inserted (under frame) Solebar

S.

N.

Item/Status Action

11 Gas cutting equipment DA and Oxygen gas with equipment

12 Availability of wooden

wedges

04 wooden wedges

13 Position of coach trolley Lashing chain to be used for securing with

structure.

14 Lighting arrangement To be arranged during dark/night.

15 Observation for suitable place Analyze suitable place for 360º slewing and

placing the coach/damaged trolley.

16 Arrangement of rope for

coach adjustment

02 Nos. in sufficient length at both the ends of

coach.

17 Availability of Megaphone/

Communication

One person should be deputed with equipments

18 Photography/Videography Videography of all critical operations and clues

collection.

19 Average timing for

restoration of each coach

Average – 55 minutes

Restoration of derailed Locomotive in the dead end siding by

140 T Crane.Preparation Chart :

S. Item/Status Action

01 OHE Working line OHE to be slewed. OHE of adjacent line to be madedead.

02 Condition of props and availabilityof staff

All props to be prepared and 04 staff on each prop should bedeputed.

03 Suitable packing and its size Wooden/synthetic packing of size 4’x12”x12”/ 4’x10’x6”

04 No. of cranes required and Positionof SLI duty selector

Two cranes.duty selector to be kept on No. 1

05 Suitable wire rope sling 50/70 Te. 6 mtrs sling (both side eye)

06 Position of Cant on the track Should not be more than 140 mm

07 Position of SLI SLI should be kept in working.

08 Maximum working radius 09 meters by main hook

09 Place, where sling to be inserted All four buffer plates

10 Lighting arrangement To be arranged during night/dark.

11 Observation for suitable place Analyze suitable place for placing of loco.

12 Arrangement of rope for locoadjustment

02 Nos. in sufficient length at both the ends of loco

13 Availability of Megaphone/Communication

One person should be deputed with equipments

14 Photography/Videography Videography of all critical operations and clues collections.

15 Gas cutting equipment DA and Oxygen gas with equipment

16 Availability of wooden wedges 04 wooden wedges

17 Average per loco timing forrestoration

Average – 2.0 hrs. minimum

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Restoration of tilted coach:

1. If the trolleys of coach are intact, secure the

trolleys with lashing chains so that trolleys

remain with the coach structure.

2. But, if the trolleys are damaged or have got

uncoupled, remove damaged trolleys first by

Aux. hook.

3. Bring 140 T crane near the coach, ensure

complete propping and insert hook at this

end.

4. Lift the rear end. of tilted coach, it will get

turned straight by this operation and further

do next exercise for removing the coach.

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Removing Entangled

Coach Ensure full prop & attach Counter

Weight slabs.

Insert Auxilary Hook in the solebarof coach at facing end and lift slowly with slewing actions.

Remove entanglement of coach at another end also in the same manner

If coach trolleys are in good condition, re-rail the coach with the help of Jacks.

Extra precaution needs to be taken for handling entangled load as the actual load will be much more than what it may appear due to entanglement.

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Restoration of Coaches in

non-electrified sections

Restoration can be executed with 140 T

Crane by placing coaches on the

adjacent track:-

Insert Hook in the solebar of rear

end of coach and lift.

Again release the hook, and pick

up the coach in the center by 30 T 5

m wire rope and lift.

Lifting beams (SWL) should preferably

be used to tackle coaching stocks to

prevent damage of the body

whenever coach is to be salvaged

In double line sections, it is better to

work the crane from the adjacent line

to which lies the accident coach

making it easier to lift the coach

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Restoration of Loaded

BCN/BOX-N by 140 T Crane The load should be guided by attaching

ropes on two diagonal ends of the load

held by staffs

These stocks can be lifted by attaching

slings with the main hook of the crane.

Ensure that centre of the wagon is not

more than 8 meters of radius.

Insert 70 T 6 meters “two leg” 02 wire rope

sling in the solebar near cross bar support

in the centre of the wagon and lift slowly

just above the ground.

In many situations it is not safe to tackle

loaded wagons particularly BCN, due to

beyond reach or because of damaged

wagon it is necessary to unload the

wagon before tackling.

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Restoration of damaged

BCN/BOXN Advise commercial staff/officers for

unloading.

Insert Aux hook and remove the

vehicle.

. If it is not possible to unload the vehicle, the wagon should be

toppled.

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Again insert slings on one side solebar of the wagon taking support of

cross member and continue slewing and derricking as per

requirement till unloading of the wagon.

. Further insert 25T capacity hook in the supporting channel of center

seal near center pivot & lift accordingly . The wagon will get toppled

completely.

Generally, it is observed that after

derailment of oil tanks, they catch

fire, which in turn results internal

explosions. In this situation, it is not

possible to rerail the tanks by MFD

equipments because machine and

breakdown staff may have sustain

injuries due to explosions.

1. First of all, thorough inspection of accident site should be carried out and fire brigade is

called immediately.

2. High pressure foam power is sprinkled on the tanks involved in the fire.

3. Until and unless putting off the fire completely, 140 T crane should not be brought near

accident site.

4. If the track is available and fire is put off, crane is moved and propped fully and aux.

Hook/main hook is applied as per requirement on all four barrel brackets of the tank.

5. Now, Lift the wagon and keep anywhere at 360° within the radius of 18 meters.

6. In general, wagons involved in fire are removed/toppled and kept aside because such

wagons are always dangerous for running on the track.

Restoration of Oil Tanks by 140 T

Crane84

When diesel or AC

locomotive enters in

to the dead end

siding and derails, it is

rerailed with the help

of two cranes. Each

crane at either end

of adjacent track

from where working

radius is not more

than 8 meters.

1. One 140 T crane is kept at one end on the adjacent track and other 140 T at anotherend.

2. Full propping is done for both the cranes and 50 T, 6 meters wire rope sling with ‘D’shackles are used.

3. ‘D’ shackles are inserted in the lifting holes of buffer plates of loco on four places andboth cranes are allowed to lift the loco simultaneously.

4. Lifted loco should be slewed towards adjacent track by both the cranes.

5. One bogie of the loco is placed on track in first occasion and then another crane ispermitted to do so.

6. Lifted loco is always kept in dead condition during restoration operation.

Restoration of Diesel/AC Locomotives85

Precautions to be taken

at Site:

Crane should be ready in all respect.

Fuel oil,Hyd. Oil,Water upto proper level

All Pr, Temp.gauges & sensors in working condition

Axle Blocking in ON position

Observe site for propping

Nearest to the job

Temporary track made if needed

Space for prop

Condition of soil

OHE cut off taken if required

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