hand book on restoration by 140t break down cranes · 2019. 10. 17. · 12 out rigger 06 04 04 04...

Hand Book on Restoration by 140T Break Down Crane\1

GOVERNMENT OF INDIA

( )

Ministry of Railways (Railway Board)

Hand Book On

Restoration by 140T Break Down Cranes

IRCAMTECH/MECH/GWL/RESTORATION/140T CRANE/1.0 April 2015

Maharajpur, Gwalior – 474005 (INDIA)

Ph: 0751 -2470803 & Fax: 0751 -2470841

Maharajpur, Gwalior – 474005 (INDIA)


Preface

During CMEs conference held in April-2013, various Railways were assigned the work of preparation of procedures for handling rescue, Relief and restoration at Accident sites. The Railways have submitted their draft procedures on 12.03.2015 at Railway Board for preparation of Hand Book on Rescue and Restoration work by CAMTECH/GWL.

The draft hand book is prepared on the subject matter for assistance to

Rescue and Restoration staff ARTs/ARMEs on IR. The sample pattern is provide for each type of activities to be carried out at accident sites. Factually, there are various types of rolling stocks are running over Indian Railways. Each stock is having its own class specific to –

a) Dimension (Length, Width & Height) b) Tare weight and capacity c) Coupling arrangement of the vehicles d) Load bearing member in respect to tackling with the help of crane

etc.

So, different methods of tackling by 140 Ton break Down Cranes would be required for different stocks and in different situations and it may not be possible to anticipate every condition thrown upon by the actual accidents/working sites and delineate the exact method of handling. Hence, in following paragraphs a humble effort has been made to cover this to the extent possible with the inputs from crane in-charges on the basis of actual site experiences. Each accident site presents unique condition in itself and hence common sense must be applied apart from the proven methods of handling the stock ensuring safety to the human being and to the crane as well as salvaging rolling stock to the extent possible.

A brief about preparation of the crane at the shed before leaving for accident site, arrangements to be made after reaching the site and also things to ensure before departure after restoration work has also been included for the benefit of the crane users.

As of now, primarily two makes of 140 T. cranes operating over Indian Railways viz. Gottwald and Cowans Sheldon, each having their own variants also. Users are advised to check the applicability of the given instructions in regard to their model of the crane. In the following heads, stock wise procedure has been given incorporating the guidelines specific to that stock for assistance in Restoration work of various rolling stocks.


Ordering of 140T Cranes and Preparation of Disaster Management Plan.

[ HLC Recommendation No.- 15(b) page No. 9 ]

The disaster management plan must interalia include “who is responsible for what activities in detail”.

1. Preparation and implementation of Disaster Management plan is the

responsibility of concerned GM/DRM.

2. Authority to order ART/ARMV/140TBreak Down Crane, CME/CMPE(D)/Sr

DME/DME, etc.

3. Senior most Railway officer at the site of the Accident shall be designated

site manager.

4. Management of Rescue operations - Primarily Mechanical and Medical

Departments. Assistance to be provided by all Railway Men (Irrespective

of their department) as needed.

5. Relief operations including care for the dead – Commercial, Medical and

RPF department.

6. Communication network- Telecom department.

7. Crowd control and law and order at site - RPF.

8. State police clearance for restoration - RPF

9. Restoration operations -

Rolling Stock – Mechanical Department

Fixed Infrastructure like Track, OHE, Signalling System etc.-

Concerned Departments.

10. Maintenance of SPART/ART and ARMV Rolling stock/140TBreak Down

Cranes including Rail-Cum-Road and Road Mobile Emergency vehicle

etc. – Mechanical Department.

11. Maintenance of Equipments kept in SPART/ART/ARMV for Rescue and

Restoration operations – concerned departments.

12. Media Management at site –

A. Site manager shall be the Chief spokesman at site and can be

assisted by the concerned branch officers, if needed.

B. PR/Commercial departments, to look after the media needs at

site.

13. Check list for the officers and supervisors must be issued in the form of

pocket booklet indicating do’s and don’ts for the benefit of :

a. First official reaching the site of accident

b. Senior most officer at the site

c. Divisional/ HQ control organization

d. Station Manager/Station Master


INDEX

SN Description Page

01 Preface 2

02 Ordering of 140T Cranes and Preparation of Disaster Management Plan.

3

03 Comparison between 140 Te. (Cowans Sheldon) & Gottwald Break Down Cranes.

6

04 Technical data of various 140 T Cranes. 7

05 Comparison between Old and New Gottwald 140T Cranes 15

06 Population of 140 T Cranes on IR 19

07 Safety Precautions for Crane Operators 20

08 Important instructions for Break Down Staff 22

09 Points to be kept in mind by Divisions for Accident Management 24

10 Suitable Wire Ropes, Chain slings for lifting of load. 26

11 Safety Devices and Fittings in 140 T DHBD Cranes. 27

12 Preparation of 140 Te. Crane for "in-train" formation 29

13 Precaution and instructions during crane "In-train" Running 30

14 Precaution during “intrain” running and separation of crane from ART 30

15 Precautions during preparation of crane at accident site for restoration works

31

16 Precautions and instructions for better performance of crane during restoration work at accident site

31

17 Precautions before and after shutting down the main engine 33

18 Preparation of crane for working at site 34

19 Preparation of crane for in-train running condition. 35

20 Precautions to be taken during 140T crane operation (Gottwald New) 36

21 Various Circuit of 140 T Crane. 37

22 Responsibility for correct carrying out of rules 41

23 Precautions when lifting with Cranes 41

24 Periodical examination of Cranes 42

25 Lubrication of crane 43

26 List of important material for crane special 44

27 Suitable wooden packings 45

28 Load Chart for 140 T Crane (Cowans Sheldon Old) 46

29 Load Chart for 140 T Crane (Gottwald New) 46a

30 Weight chart of Coaches and Wagons 47

31 Sample Proforma for Break Down Train Formation 47

32 Restoration of Locomotives 48

33 Restoration of Coaches 54

34 Restoration of EMUs/MEMUs/DEMUs 63

35 Restoration of Loaded BCN/BOXN Wagons 66

36 Restoration of derailed BTPN involved in Fire 74

37 Restoration of derailed Guard Brake Van by 140T crane 76

38 Restoration of Hot Axle/Cold Axle broken Wagon 77

39 FOB Works 79

40 Launching of Girders 80


SN Description Page

41 Track with super elevation - Precautions 85

42 Restoration in Tunnels 87

43 Restoration on Bridges 88

44 Rescue Platform 89

45 Use of Road Mobile Crane 89

46 PREPARATION BEFORE LEAVING THE SHED (Gottwald) 90

47 PREPARATION BEFORE LEAVING THE SHED (Cowan Sheldon Old)

91

48 PREPARATION BEFORE LEAVING THE SHED (Cowan Sheldon New)

92

49 AXLE BLOCKING (Gottwald New & Old) 93

50 AXLE BLOCKING (Cowan Sheldon Old) 93

51 AXLE BLOCKING (Cowan Sheldon New) 93

52 BOOM ERECTION ( Gottwald New & Old) 94

53 BOOM ERECTION ( Cowans Sheldon Old) 95

54 BOOM ERECTION ( Cowans Sheldon New) 97

55 PROPPING THE CRANE (Gottwald New & Old) 98

56 PROPPING THE CRANE ( Cowans Sheldon Old) 99

57 PROPPING THE CRANE ( Cowans Sheldon New) 100

58 COUNTERWEIGHT (Gottwald New & Old) 101

59 COUNTERWEIGHT ( Cowans Sheldon Old) 102

60 COUNTERWEIGHT ( Cowans Sheldon New) 103

61 OPERATING PRECAUTIONS (Gottwald New & Old) 104

62 OPERATING PRECAUTIONS ( Cowans Sheldon Old) 105

63 OPERATING PRECAUTIONS ( Cowans Sheldon New) 106

64 GENERAL PRECAUTIONS FOR HANDLING OF LOADS 108

65 PREPARING THE CRANE BEFORE LEAVING FOR SHED (GOTTWALD)

109

66 PREPARING THE CRANE BEFORE LEAVING FOR SHED ( Cowans Sheldon Old)

110

67 PREPARING THE CRANE BEFORE LEAVING FOR SHED ( Cowans Sheldon New)

112

68 Safety of Rescue Workers 113

69 STAFF DEPLOYMENT DIAGRAM FOR RESTORATION 114


Comparison between 140 Te. (Cowans Sheldon & Gottwald) Break Down Cranes

SN Name of the Parts

Cowans Sheldon (Old)

Cowans Sheldon (New)

Gottwald (Old) Gottwald (New)

01 Crane Jib Lattic construction

Box construction Welded tubular shape

Box construction

02 Super structure

Different Different Different

Different

03 Carriage Lateral Radial 4 prop arrangement

4 prop arrangement

04 Crane bogie Welded structure

Welded structure Bolster with primary & secondary suspension

Bolster with primary & secondary suspension

05 Relieving bogie

Exist Not exist Not exist

Not exist

06 Match Truck Different Different Different

Different

07 Ballast Wagon

Exist Not exist Not exist

Not exist

08 Hydraulic system

Elect-Hydraulic Hydro-Hydraulic Upgraded

Upgraded

09 Electrical Different Different Different Different

10 SLI Wylie/Mechanica Ascorel france Different (PAT)

Different (Mechanica)

11 Gear box and Winches

Different Different Different

Different

12 Out rigger 06 04 04

04

13 Out rigger arrangement

Pull out type Swing out type Swing cylinder Swing cylinder

14 Main Engine Cummins NT-743P 295 HP

Cummins NT-855 350 HP

Cummins tilted NTA-855 R 340 HP

Cummins tilted NTA-855 LBC 340 HP

15 Main Engine RPM

2100 rpm 2100 rpm 800-1800 rpm

800-1800 rpm

16 Brakes Mechanical linkage

TBU Disc brake Disc brake

17 “A” Frame Tie cylinders Folding linkage Folding linkage

Folding Gallows

18 Counter weight

32,12,1.5 Te. 7/ 7.9, 22.6 Te. 52,18,6,14 Te.

24,15,8 Te.

19 Drivers cabin Side Side Centre

Centre

20 Counter weight fastening

Beam lift jack Gallows Gallows

Gallows

21 Aux. Engine Ruston MK-IV/KOEL TA2

Lister Peter Different Kirloskar HA294


140 Te. DIESEL HYDRAULIC CRANE (Cowans Sheldon New )

TECHNICAL DATA:

01. 140 Te. Diesel Hydraulic Crane Make : COWANS SHELDON (England)

02. Main Hoist Lifting Capacity : Max. 140 T

03. Aux. Hoist Lifting Capacity : Max. 25 T

04. Hauling Capacity : Max. 10 T

05. Max. Travelling Speed without load : 20 KMPH

06. Max. Travelling Speed with load : 6 KMPH

07. Main Engine Make : Cummins India Ltd.

08. Main Engine HP : 360 HP

09. Main Engine Model No. : NTA 855 C

10. Aux.Engine Make : Lister Petter

11. Aux.Engine HP : 15.6 kw

12. Aux.Engine Model No. : LPA 3

13. Length of Crane over buffers : 13 meters

14. Total length including match truck : 28 meters

15. Crane Height above Rail Level : MMD according (EDO/T1043)

16. Crane width : MMD according (EDO/T1043)

17. Derrick wire Rope length : 317 meters; 32mm dia.

18. Main Hoist wire Rope length : 286 meters; 32mm dia.

19. Aux. Hoist wire Rope length : 113 meters; 22mm dia.

20. Hauling winch wire Rope length : 64 meters; 20mm dia.

21. Crane Max. Speed with ART : 90 KMPH

22. Weight of Crane in working order : 162/170 T (STD/HD CWT)

23. Weight of Crane in running order : 120 T

24. Match Truck Weight in running order : 80 T

25. Weight of standard duty CWT : 22.610+6.735 T (29.345T)

26. Weight of heavy duty CWT : 7.9 T (Total 37.245T)

27. Weight of special duty CWT : 6.735 T (+22.61 T on under carriage)

28. Jib complete weight : Not available

29. Axle load (R/B in loaded condition) : 20 T

30. Main Hoist Max. lift above Rail level : 13 meters

31. Main Hoist Max. lower below Rail level : 3 Anchor turns

32. Aux. Hoist Max. lift above Rail level : 17 meters

33. Aux. Hoist Max. lower below Rail level : 3 Anchor turns

34. JIB Min. Radius : 5.5 meters

35. Main Hook Hoist max. speed : 8 meters per minute

36. Aux. Hook Hoist max. speed : 15 meters per minute

37. Crane Slew maximum speed : 360 o in 2 minutes (0.5 rpm)

38. Haul in Max. speed : 30 meters per minute

39. No. of Travelling Motors : 02 Nos. Hydraulic Motors

40. Propping base : 6.0 m / 5.0 m / 3.4 m

41. Emergency Lowering : Facility not available


140 Te. DIESEL HYDRAULIC CRANE (Cowans Sheldon Old)

TECHNICAL DATA:

01. 140 Te. Diesel Hydraulic Crane Make : COWANS SHELDON (England)

02. Main Hoist Lifting Capacity : Max. 140 Te.

03. Aux. Hoist Lifting Capacity : Max. 25 Te.

04. Hauling Capacity : Max. 5 Te.

05. Max. Travelling Speed : 12 KMPH

06. Slow Travelling Speed : 6 KMPH

07. Main Engine Make : Cummins India Ltd. Pune

08. Main Engine HP : 295 HP

09. Main Engine Model No. : NT 743

10. Aux. Engine Make : Ruston/ KOEL

11. Aux. Engine HP : 14.6 HP

12. Aux. Engine Model No. : 1 YWA

13. Crane Carriage Length : 12.6 meters

14. Crane Height above Rail Level : 4.265 meters

15. Crane width : 3.2 meters

16. Derrick wire Rope length : 271 meters

17. Derrick Tie wire Rope length : 09 meters

18. Main Hoist wire Rope length : 282 meters

19. Aux. Hoist wire Rope length : 118 meters

20. Hauling winch wire Rope length : 60 Meters

21. Crane Max. Speed with ART : 75 KMPH

22. Crane Tare weight : 182 Te.

23. Relieving Bogie Tare weight : 10.8 Te.(each)

24. Match Truck Weight : 31.758 Te.

25. Ballast wagon weight : 30.530 Te.

26. Heavy Ballast weight : 32.205 Te.

27. Counter weight : 12.558 Te.

28. Jib complete weight : 9.976 Te.

29. Axle load (R/B in loaded condition) : 20 Te.

30. Main Hoist Max. lift above Rail level : 13 meters

31. Main Hoist Max. lower below Rail level : 4 meters

32. Aux. Hoist Max. lift above Rail level : 7 meters

33. Aux. Hoist Max. lower below Rail level : 3 meters

34. JIB Min. Radius : 5.5 meters

35. Main Hook Hoist speed : 3 meters per minute

36. Aux. Hook Hoist speed : 15 meters per minute

37. Main Hook Emergency lower : 5 Meters per minute

38. Crane Slew maximum speed : 360 o in 2 minutes (0.5 rpm)

39. Haul in Max. speed : 30 meters per minute

40. No. of Travelling Motors : 02 Nos. Hydraulic Motor


TECHNICAL DATA OF 140 Te. DIESEL HYDRAULIC CRANE (GOTTWALD NEW) Dimension:

1. Track Gauge : 1676 mm 2. Rim Diameter : New condition: 920 mm

Wear limit : 840 mm 3. Wheel set arrangement : (2A) (A2) 4. Distance between bogie pivots : 7500 mm 5. Distance between twin wheel set : 3000(1500) mm 6. Length ahead of buffer : 13290 mm 7. Draw and buffing gear : side buffers and screw couplings 8. Minimum travel curve : 175 mm 9. Maximum towing speed : 100 Kmph 10. Maximum wheel set load : 200 Kn 11. Total Weight in train formation : 120 Te. 12. Height in transport position : 3900 mm 13. Width in transport position : 3100 mm 14. Elevated curves : 140 mm

Brake System:

01. Primary : Dual-VD-P-12X10m.Z. 02. Secondary : 12 wheel disc-operated brakes # 780 mm

03. Parking brakes : spring-loaded brakes on 6 wheel sets Out riggers:

01. Base : 11.6 m x 6.0 m 02. Maximum support force : 2200 Kn 03. Out rigger cylinder : stroke 500 mm 04. Free on wheels base : 7.5 mm x 1.7 mm 05. Maximum wheel force : 350 Kn

Travel Gear

01. Driven wheel sets on each bogie : 01 02. Speed : 20 Kmph

Super structure

01. Cab : 1 seat/and 1 emergency seat 02. Over-Rear radius : 5.5 m/6.5 m

Diesel Engine

01. Type : Cummins NTA-855 02. Model : 6 cylinders in series Water cooled Exhaust turbo charger 03. Out put : 205 Kw AT 1800 RPM


04. Torque : 1158 nm at 1400 rpm 05. Cubic capacity : 1400 ccm 06. Fuel supply : 900 L. 07. Generator : 28 V, 55 A

Emergency Diesel Engine

01. Type : Kirlosker HA-294 02. Model : 2 cynder in series Air cooled, exhaust turbo charger 03. Out put : 16.9 Kw at 1800 rpm 04. Cubic capacity : 1884 ccm

Main Hoist

01. Type : Three stage planetary hoist with spring loaded multi disc brake

02. Rope diameter : 26 mm 03. Rope speed : Max. 72 m/min. 04. Hoist speed : Max. 04 m/min. 05. Hook block : 18 strand, 140 t 06. Hoist range : above track : 17.0 m Below track : 04.0 m

Auxiliary Hoist 01. Type : Two stage planetary hoist with spring

loaded multi disc brake 02. Rope diameter : 22 mm 03. Rope speed : Max. 60 m/min. 04. Hoist speed : Max. 15 m/min. 05. Hook block : 04 strand, 25 t 06. Hoist range : above track: 18.0 m Below track: 03.0 m

Slewing Gear 01. Type: Three stage planetary hoist with spring loaded multi disc

brake, Roller slew ring with external teething 03. Super structure speed : 0-1.0 rpm

Derricking Gear

01. Type : Three stage planetary hoist with spring loaded multi disc brake 02. Rope Diameter : 26 mm 03. Rope speed : Max. 28 m/min. 04. Derricking time : Approx. 165 sec. 05. Rope Tension : 2 X 14 strand, 2200 Kn


Counter Weight

01. 03 sections 02. Slab-1(transported on the match truck) : 24 Te. 03. Slab-2 (Transported on the match truck) : 15 Te. 04. Slab-3 (Transported on the under carriage) : 08 Te.

Boom

01. Length to the main hook : 18.75 mts. 02. Length to the Auxiliary hook : 19.5 mts. 03. Main hook working range : 5.5 m-17.0 m 04. Auxiliary hook working range : 6.5 m- 18.0 m

Match Truck

01. Length beyond buffer : 16.0 m 02. Distance between wheel sets : 2.0 m 03. Track Gauge : 1676 mm 04. Distance between bogie pivots : 11.30 m 05. Draw and Buffing Gear : side buffers & screw couplings 06. Turning radious : 175 m 07. Maximum towing speed : 100 Kmph 08. Max. wheel set load : 200 Kn 09. Total weight: Loaded : 80.0 T


TECHNICAL DATA OF 140 Te. DIESEL HYDRAULIC CRANE (GOTTWALD OLD)

Dimension:

1. Track Gauge : 1676 mm 2. Rim Diameter : New condition:915 mm

a. Wear limit : 860 mm 3. Wheel set arrangement : (2A) (A2) 4. Distance between bogie pivots : 7500 mm 5. Distance between twin wheel set : 1500 mm 6. Length ahead of buffer : 13300 mm 7. Draw and buffing gear : Hinged buffers and screw couplings 8. Minimum travel curve : 174 mm 9. Maximum towing speed : 75 Kmph 10. Overall weight : 200 t 11. Crane Weight in train formation : 120 Te. 12. Height in transport position : 3950 mm 13. Width in transport position : 3000 mm 14. Axle load in running order : 20 t 15. No. of vehicle. in running order : Crane with two 3 axle bogie + Match

truck with two 2 axle bogie

Brake System: 1. Primary : Dual-VD-P-12X10m.Z. 2. Secondary : 12 wheel disc-operated brakes # 780 mm

3. Hyd. Parking Brake : For Crane 142032 to 043 & 143001,02 4. Pneumatic Parking brake : For Crane 143003 to 143010

Out riggers:

1. Base ( Full propping) : 11.8 m x 6.0 m 2. Maximum support force : 2200 Kn 3. Out rigger cylinder : stroke 500 mm 4. Maximum wheel force : 350 Kn

Travel Gear

1. Driven wheel sets on each bogie : 01 2. Speed- Without load/With load : 12 Kmph/6kmph

Super structure

1. Cab : 1 seat/and 1 emergency seat 2. Over-Rear radius : 5.5 m/6.5 m

Diesel Engine

1. Type : Cummins(NTA-855R4)/CIL(NTA-855R-FPC)


2. Model : 6 cylinders in series Water cooled Exhaust turbo charger

3. Out put : 224 KW AT 1800 RPM 4. Torque : 1158 nm at 1400 rpm 5. Generator : 28 V, 55 A

Emergency Diesel Engine 1. Type : Kirlosker-TA 2/ Schule-TAF 2 2. Model : 2 cynder in series

Air cooled 3. Out put : 10.5 KW at 1800 rpm

Main Hoist 1. Type : Three stage planetary hoist with

spring loaded multi disc brake 2. Rope diameter : 26 mm 3. Rope speed : Max. 80 m/min. 4. Hoist speed : 2.5 m/min- 5 m/min. 5. Hook block : 16 strand, 140 t 6. Hoist range : above track : 16.5 m Below track : 04.0 m

Auxiliary Hoist 1. Type : Two stage planetary hoist with spring

loaded multi disc brake 2. Rope diameter : 22 mm 3. Rope speed : Max. 60 m/min. 4. Hoist speed : Max. 15 m/min. 5. Hook block : 04 strand, 25 t 6. Hoist range : above track: 17.8 m Below track: 03.0 m

Slewing Gear 1. Type: Three stage planetary hoist with spring loaded multi disc brake,

Roller slew ring with external teething. 2. Super structure speed : 0-1.0 rpm

Derricking Gear

1. Type : Three stage planetary hoist with spring loaded multi disc brake

2. Rope Diameter : 26 mm 3. Rope speed : Max. 28 m/min. 4. Derricking time : Approx. 90 sec.

Hauling Winch Capacity : 5 t Counter Weight

1. Standard duty : 29.2 Te.(5.2+6+18) 2. Heavy Duty : 43.2 Te. (29.2+14)


Jib

1. Length to the main hook : 18.00 mts. 2. Length to the Auxiliary hook : 18.85 mts. 3. Main hook working range : 5.5 m-16.0 m 4. Auxiliary hook working range : 6.5 m- 17.0 m

Match Truck

1. Length over buffer : 15.97 m 2. Distance between wheel sets : 2.0 m 3. Track Gauge : 1676 mm 4. Distance between bogie pivots : 11.30 m 5. Draw and Buffing Gear : Hinged buffers & screw couplings 6. Turning radius : 174 m 7. Maximum towing speed : 75 Kmph 8. Max. wheel set load : 20 t

Brake System of Match truck Air Brake, Parking brake

1. For Crane No. 142032 to 142037 : Disc Brake Hydraulic Brake

2. For Crane No. 142038 to 142043 : Tread Brake Mechanical Hand Brake

3. For Crane No. 143005 to 143010 : Tread Brake Mechanical Hand Brake

4. Lifting Beam Capacity : 2 nos.- 140 t, 70 t 5. Compressor : SAB WABC Axle

mounting recipro, 7.2 bar


140 t. Crane Specification with comparison between Old and New Gottwald cranes:

Sr No

Item Old Design (1986) New Design (1997)

Model No 1WDH 3WDH

RDSO Document reference number MP-MISC-118

(Rev-0.00)

MP-MISC-119

(Rev-0.00)

SPECIFICATIONS

1 Track Gauge 1676 mm 1676 mm

2 Length Of Crane Over Buffers 13300 mm 13300 mm

3 Length Of Match Truck Over Buffers 15970 mm 16000 mm

4 Overall Length 29270 mm 29300 mm

5 Width Of Crane 3000 mm 3100 mm

6 Width Of Match Truck 3000 mm 3000 mm

7 Min Track Curvature 174 m radius 174 m radius

8 Max Height Of Crane From Rail Level. 3950 mm 3900 mm

9 Overall Weight 200t 200t

10 Axle Load In Running Order 20t 20t

11 Tail Radius 5.5 m 5.5m, 6.5m

12 Propping Base 6m, 2.7m 6m, 5m, 2.9m

13 Jib/Boom 18 m long Box section

(Octagonal) 18.75 m long Box

section (Rectangular)

WHEEL

1 Wheel Dia (CRANE) 915 (new),

860 (cond)

920 (new),

840 (cond)

2 Wheel Dia (MATCH-TRUCK) 915 (new),

860 (cond)

1000 (new),

906 (cond)

COUNTERWEIGHT

1 Counterweight 4 pieces:

5.2T, 6T, 14T, 18T 3 pieces:

8T, 15T, 24T

2 Standard Duty 29.2t

(5.2 + 6 + 18) 47t at 5.5m

(24 + 15 + 8)

3 Heavy Duty 43.2t

(29.2 + 14) 47t at 6.5m

(24 + 15 + 8)

SELF TRAVEL SPEED

1 Travel With Load 6 km/h 6 km/h

2 Travel Without Load 12 km/h 20 km/h

3 Hauling Speed

(after high speed modification)

100 kmph

100 kmph

Safe Load Indicator

PAT, Germany/ Amrita

Lakshami Electronics,

Mechanica Systems

PAT, Germany,

Mechanica Systems


Sr No

Item Old Design (1986) New Design (1997)

CAPACITY / RANGE

1 Hauling Winch Capacity 5 t 5 t

2 Lifting Beam Capacity 2 nos.

140T & 70T

2 nos.

140T & 70T

3 Hooks Main (Ramshorn) - 140t

Auxiliary - 25t

Main (Ramshorn) - 140t

Auxiliary - 25t

4 Working Radius Main

Hoist

Maximum - 16 mtr

Minimum - 5.5 mtr

Maximum – 17mtr Minimum

- 5.5 mtr

5 Working Radius Aux

Hoist

Maximum - 17 mtr Minimum

- 6.5 mtr

Maximum - 18 mtr

Minimum - 6.5 mtr

6 Range Of Lift

(Main Hoist)

Above rail level - 16.5 mtr

Below rail level - 4 mtr

Above rail level - 17 mtr Below

rail level - 4 mtr

7 Range Of Lift

(Aux Hoist)

Above rail level - 17.8 mtr

Below rail level - 3 mtr

Above rail level - 18 mtr Below

rail level - 3 mtr

8 Max Capacity For Full

Propped And Full Cwt.

140 T at 8 m radius,

360 degree slewing

140 T at 8 m radius, 360 degree

slewing. Load moment

calculations and load charts are

different.

CRANE MOTION AND SPEEDS

1 Derricking 60 Sec from

max to min radius 165 sec

from max to min radius

2 Slewing 1 RPM 1 RPM

3 Main Hoist Lifting 2.5 Mtr. / min. 4 Mtr. / min.

4 Main Hoist Rapid

Lowering 5 Mtr. / min. 8 Mtr. / min.

5 Auxiliary Hoist Lifting 15 Mtr. / min. 15 Mtr. / min.

6 Auxiliary Hoist Rapid

Lowering 30 Mtr. / min. 30 Mtr. / min.


Sr.

No Item Old Design (1986) New Design (1997)

BRAKE SYSTEM:

1 Brakes crane

Air brake, Vacuum brake &

Parking brake (disc type)

Air brake, Vacuum brake &

Parking brake (disc type)

2 Auxiliary compressor

SAB WABCO,

axle mounted, reciprocating,

mounted outside, driven by

belt drive- 7.2 bar.

SAB WABCO, axle mounted,

reciprocating, fitted inside the

bogie, driven by pinion meshed

with the bull gear

Note - Mounting arrangement

for same is provided but aux.

Comp. not installed by JMP

MAIN DIESEL ENGINE

1 Make Cummins Cummins

2 Type NT 855 - R4 NTA 855 - LBC

3 Mounting Horizontal Vertical

4 Horse power 285 hp (224 kW) 263 hp (205 kW0

5 No of cylinder 6 6

6 Bore & stroke (mm) 140 X 152 140 X 152

7 Compression ratio 14.1:1 14.1:1

8 Lube oil sump capacity 28.2 liters 43 liters

9 RPM 2100 1800

10 Fuel tank capacity 1000 liters 900 liters

AUXILIARY DIESEL ENGINE

1 Make Schule Kirlosker

2 Type TA 2 HA 294

3 Horse power 14 hp (10.5 kW) 23 hp (16.9 kW)

4 RPM 1800 1800

GENERAL FEATURES

1 No. of vehicles in

running order

Crane with two 3 axle

bogies + Match truck with

two 2 axle bogies

Crane with two 3 axle bogies

+ Match truck with two 2 axle

bogies

2 Outriggers Swing out type, 4 nos. Swing out type, 4 nos.

3 Suspension crane Helical & disc spring Helical & disc spring

4 Suspension match truck Coil spring Coil spring

5 Rear Superstructure ‘A’ frame available

In place of 'A' frame, gallows

and bigger bridle of the old

design a single frame for

suspending CWT.

6 Gallows Fixed cwt. radius

permit the counterweight

assembly to be placed at 5.5 or

6.5 Mtr radius


Sr.

No Item Old Design (1986) New Design (1997)

7 Slewing arrangement Roller bearing type slewing

ring with internal spur gear

3 - stage planetary hoist with

spring loaded multi-disc brake

roller slewing ring with

external teething

8 Hydraulic oil tank

one single tank fitted in the

rear portion of the

superstructure

two internally connected tanks

just behind the cab

9 Fuel tank annular shaped tank above

the slewing ring

box shaped tank in the rear

portion of the superstructure

10 No. of pulleys in main

hoist 8 9

CONTROLS:

1 Counterweight All control in cab,

Single lever operation All controls in the rear of the

crane, three levers for control.

2 Hoists Separate lever for main and

auxiliary hoists Single joystick for main and

auxiliary hoists

3 Rapid motion switch Foot operated Switch on the top of joystick

for hoist operation


POPULATION OF 140 T CRANES ON IR:

Total 140 T Break Down Cranes are 74 numbers available over Indian Railways as on date and design wise population is as follows:-

NEI (COWANS)/JESSOP

(OLD DESIGN)

12 NOS

GOTTWALD

(OLD DESIGN )

22 NOS

GOTTWALD

(NEW DESIGN)

36 NOS

COWANS SHELDON

(NEW DESIGN)

04 NOS


Safety Precautions for Crane Operators

To understand the 140 T cranes and to operate the cranes efficiently and safely, the

operating personnel should follow the operating and maintenance manual supplied along

with the cranes. Some salient features (also included in the manuals) which if followed,

will ensure safety during operation are highlighted below:

1. Before raising the jib from match wagon, all blocking screws must be screwed

down until they are locked on the top of the spring or by Hydraulic Axle blocking.

2. Both the relieving bogies must be unloaded prior to raising the jib from match

wagon.

3. Before any movement of crane on its own power, operator must ensure proper

engagement of travel clutch and braking of travel brake.

4. In the operating area, the operator should assess the cant with the jib in line with

the track. If cant exceeds 13 mm, the crane should be levelled by using props

before load lifting because this crane in free on rail condition is suitable only with

counter weight on carriage. In this condition, there will be clearance in the side

bearers.

5. The operator must be thoroughly acquainted with the load charts provided in the

crane to assess the duty selection.

6. Special care is to be taken during propping of jacks. Packing below foot steps /

Propping chairs should be adequate and placed alternately, perpendicular and

parallel to the track, to give maximum load distribution. After applying jacks,

packing should be checked. The load should be lifted slowly just above the

ground and held there. Packing should be checked again to see if there is any

sinking of Propp.

7. If the crane is to be moved to another position, then the draw beam jacks should

be raised, the foot steps / Propping chairs removed, the draw beam retracted and

locked in position before any movement.

8. Before any slew motion, slew lock pin must be removed.

9. Before undertaking any lifting operation, the operator must be sure that the duty

selector of SLI is correctly set according to the configuration of the crane (i.e. free

on rail, or blocked, counter weight on super structure or carriage, heavy ballast

fitted etc.)

10. Extreme caution should be taken while working in super elevated track in free on

rail condition with counter weight or heavy ballast fitted to superstructure.


11. During fitting of heavy duty ballast to the superstructure, heavy ballast must be

raised fully, superstructure must brought in line with the track before introducing

ballast arm in to the heavy ballast, and locating pins must be engaged in the

support beam.

12. Swinging load is dangerous and should be avoided.

13. Emergency lower button should be operated only in case of emergency and the

operation should not be part of the normal working cycle.

14. During coupling of the relieving bogies with the crane, the operator should move

the crane close to the beam and the height and position of the beam should be

adjusted in such a way so that the base of the beam is in line with the carriage end

castings. This will prevent damage of the castings.

15. It is always better to lift the load from match truck end, if the derailment on the

same track. Because in this case the operator has to lift the match truck and

relieving bogie clear of the track. On the ballast wagon side the operator has to

remove the heavy ballast first, then the ballast wagon and one relieving bogie.

For removing either ballast wagon or match truck, lifting beam need not to be

used. The 30 Te. Double legged sling of 7 M long can be used with main hook for

this operation.

16. To reduce timing, operating personal should practice the operation in idle time.

Some operations may be combined to reduce timing i.e. while carrying out

blocking out operations of screws, ‘A’ frame should be raised thus saving the

time. Lifting of relieving bogies/ match truck / ballast wagon should be as

minimum as possible above the rail level, before slewing.

17. Since the maximum instantaneous load on an individual prop that may arise with

the crane being loaded to its capacity is around 150 Te., it is essential to prepare

the packing on the ground, using sleeper over wide area in order to prevent sink

age of props. In order to reduce time taken in restoration, it is advisable to take

the help of permanent way staff in levelling the ground and in building up of the

base for props.

18. Please remember that when you travel on own power with load on hook the axle

load on track is much higher than normal. Depute a person to check track for

sinkage and gauge during travel. Insist on PWI to give good attention to track

where necessary.

19. Before travelling the crane on own power, check the brake power. Apply brakes,

engage travel clutch and push the travel joystick for a short time to “Full”

position. If brakes are able to hold the crane, then the brake power is okay.


IMPORTANT INSTRUCTIONS FOR BREAK DOWN STAFF Following instructions must be followed by break down Incharges, Supervisors and staff while working at accident sites:- 01. After reaching at accident site, observation of site and damaged

wagons/coaches to be carried out to ensure safe and efficient restoration. 02. Crane driver as well as staff should be advised regarding lifting load and

operational activities, explaining situation of spot. 03. Necessary equipments, tools, wooden packings etc. should be unloaded

from ART without wasting time and be sent the same to the accident spot. 04. Before energizing 140 Te Crane on electrified section for operations,

ensure that OHE has been made dead /slewed and secured and power block has been taken with provision of written memo.

05. Suitable and sufficient space to be created for propping and choose the

wooden packings of required sizes, so that strong and sound propping can be ensured. i.e effective propping base must be created.

06. Lifting load must be assessed properly in accordance with the Crane

configuration & working radius. 07. Always take care of cant/super elevation while lifting the load. 08. Ensure that SLI is in working order (SLI bypass should be avoided) 09. Ensure availability and understanding of load charts. 10. Rail clamp must be used as and when required. 11. Always utilize suitable capacity chain sling and wire rope slings and insert

hooks only at suitable places on the wagons/coaches during lifting. 12. While lifting the load, close watch to be kept on crane wheels and the

same to be communicated through megaphones continuously for analyzing & observing the situation.

13. Proper work distribution among staff and supervisors to be ensured at site

to avoid contradiction. 14. Extreme care to be taken while removing and lifting entangled load.

Safety of the staff to be kept in mind during such operations.


15. The load should be lifted slowly just above the ground level and held

there because swinging load is dangerous and should be avoided. 16. Utilize wire ropes / chain slings in such a manner, that they can be

removed successfully from object after lifting and placing at suitable place. 17. While slewing the crane 360 with lifted load, keep close watch and all the

precautions to be taken for safety of the crane. 18. If the adjacent track is given safe for traffic, safety of staff must be

ensured from running trains by communicating arrival of trains on megaphone. Always keep Red flag/Red lamp for emergency.

19. If TSL is introduced at site for passing of trains, extreme care / vigil is

required especially infringements of crane, load, operating personnel w.r.t. working line must be checked. At the time of train movement from adjacent line, the crane working must be paused.

20. After assessing the accident site, Multiple propping base should be prepared

in advance or simultaneously with the help of P-Way staff, this will reduce overall restoration time.

21. When the crane is ready In-Train formation, following points to be

ensured – - Axle blocking to be removed - Travelling gear to be disengaged - Parking brake to be removed - Slewing lock to be applied - Boom to be locked on trestle.

22. Also before leaving the accident site, it should be ensured that material from Crane unit is not left behind.

****


POINTS TO BE KEPT IN MIND BY DIVISIONS FOR ACCIDENT MANAGEMENT

(Ref: Addl.M(M)’s letter No.99/M(M&P)/7/6 Dated 11.8.1999)

The following points may be kept in mind by the Divisions for Accident Management:- A. For accidents involving Passenger trains, the BD cranes and MFDs in either direction in

the vicinity of the site must immediately be ordered by the Control as a routine.

B. In case of Goods train accidents involving mainline, the following procedure should be followed:-

Movement of 140 Te BD cranes must have the approval of CMPE(D)/HQ who is overall incharge of the management of ARTs, and in his absence any Mechanical Officer in Headquarters. In rare cases, where both lines are affected and when delays in contacting Headquarters are envisaged, cranes may be ordered by Division, but this should only be an exception.

Movement of MFDs can be ordered by the Divisional Mechanical officers as desired by DRMs.

C. Incase of accidents in Yard not affecting through movement, the

derailment may be tackled using ramps to the extent possible and MFD/Crane ordered only if the derailment CAN NOT be tackled by Jacks(HRE). This decision may be taken by the Divisional officers at their discretion depending upon the information available from site.

D. ARTs should be turned out within the target time of 30 minutes by day

and 45 minutes during night. ARMV should be turned out within 20 minutes from double entry siding and 25 minutes from single entry siding during both day and night (zonal railways may decide target time).

E. Movement of ARTs to the accident spots should be given top priority and

should not be stopped enroute. It is the responsibility of the Controlling DRM and his Officers that no slackness is allowed in this regard.

F. ARTs should be moved to the base Depot as soon as the restoration work

is over. G. For a minor derailment involving a few wagons, as far as possible MFDs

should only be deployed leaving the crane at the base station in readiness to attend major accidents.

H. Wherever road approach is available, attempt should be made to take the

MFD equipment by road through lorry and for this purpose, departmental


lorry should be earmarked. Wherever department lorries are not available to move the MFD/HRE, private lorries may be invariably hired.

I. Wherever MFD/HRE is required to serve both BG and MG territory,

arrangement for moving MFD/HRE by Truck / lorry is a must. J. Mock trials of ART should be done earnestly as prescribed to test the

efficacy and correct any deficiency in the system. K. Whenever assistance of additional BD crane/MFD is required from

neighbouring division or adjacent Railways. CMPE or any other HOD of the Mechanical Department will do the necessary liaison.

***


SUITABLE WIRE ROPES, CHAIN SLINGS FOR LIFTING OF LOAD

[ For COWANS SHELDON 140 Te. OLD CRANE]

1. Two Leg Wire Rope sling (BS-1290) Capacity - 70 Te

Requirement - 2 Nos. Length - 6 Mtrs. Proof Load - 81 Te/Leg

2. Two Leg Wire Rope Sling (BS-1290) Capacity - 30 Te

Requirement - 2 Nos. 5 Mtr

Requirement - 2Nos. 7 Mtr. Proof Load - 42.4 Te

3. Single Leg Wire Rope Sling (BS-1290) Capacity - 70 Te

Requirement - 4 Nos Length - 6 Mtrs Proof Load - 105.4 Te


Requirement - 4 Nos. Length - 5 Mtrs. Proof Load - 81 Te


Requirement - 2 Nos Length - 4 Mtrs. Proof Load - 140 Te

6. Four Leg Wire Rope Sling (BS-1290) Capacity - 25 Te

Requirement - 1 No. Length - 4 Mtrs. Proof Load - 50 Te

7. Two Leg chain Sling (BS-1290) Capacity - 25 Te Requirement - 4 Nos.

8. Chain Sling (Without hook)-BS-1290)Capacity -10 Te Requirement - 4 Nos.


1. SAFETY DEVICES AND FITTINGS IN 140 T DHBD CRANES (Old Design Cowans Sheldon make)

A. For safe operations of the crane:

1. Automatic Safe Load Indicator

2. Cant Indicators: (a) Driver’s Cab (b) Crane Carriage

3. Mechanical (Radius Indicator on jib.

4. Limit Switches:(a) Main Host (b) Auxiliary Hoist (c) Derrick

5. Emergency Lower

6. Service Brakes for Gear Boxes:

(a) Main Hoist (b) Auxiliary Hoist (c) Derrick

(d) Slew (e) Haul

7. Air Brake System

8. Flood Lights: (a) Jib (b) Front (c) Rear

9. Horn: (a) Low Tone (b) High Tone

10. Windscreen Wiper

11. Rail Clips

B. Safety Checks/Testing Items

1. Wheel Profile

2. Ultrasonic Testing of Axles

3. Examination of Wire Ropes

4. Testing of Lifting Tackles:

(a) Wire Rope Slings (b) Chain Slings

5. Fire Extinguishers

C. Safety fittings on Crane

1. Slew Lock Pin

2. Travel Clutch Indicators

3. Laminated Bearing Spring Blocking Screws

4. Brake Rigging Items

5. Brake Crossbar Safety Straps

6. Hand Brakes

7. Spring Suspension Items

8. Laminated Spring Safety Straps on Axle Boxes

9. Buffers

10. Draft Gears & Screw Couplings

11. Lock Pins for Draw beams

12. Center Casting Lever Lock Pins

13. Retaining/Locking Plates for Counterweight Hanger Bolts

14. Front Window Self Sealing Weather Strip

15. Tumbler Pins for:

(a) Draw Beam Lock Pins (b) Blocking Screws

(c) Hand brakes (d) Lever Lock Pins

(e) Lifting Beams (f) Foot Plates

16. Key Plates

17. Centre Pivot bolts


D. For Safety of Main Engine

1. Low Radiator Water Level Low Mark

2. High Engine Water Temperature 93 ºC

3. Low Engine Lube Oil Pressure Below 1.38

Kg/cm2

4. High Engine Lube Oil Temperature 116 ºC

5. Engine Over speed latched Over speed -

2450 RPM

E. For Safety of Hydraulic system

1. High hydraulic Oil Temperature 70 ºC

2. Hydraulic Filter Block Indicators for

a) Boost Line Filters HE 21= 3 nos. & Filter Blocked

b) Return Line Filter HE 22 = 1 no. Filter Blocked

3. Flushing Valves HE 4

a) HE 2A Main Pump

b) HE 2B Main Pump

c) HE 3 Main Pump

4. Pressure Relief Valves

a) Cross line Relief Valves HE6 for

1. Main Hoist 2. Auxiliary Hoist 3. Derrick

4. Travel 5. Slew 6. Haul

b) Cross line Relief Valves HE 36 for

1. H/L Ballast Extension Beam

2. R/Bogie Coupling Pins = 2

c) Relief Valve HE14 for

1. Oil Cooler Motor

2. Derrick Tie Cylinder

d) Relief Valve HE 29 for Derrick Tie Cylinders

5. Low Boost Pressure Switches HE 31 for

a) Main Hoist

b) Auxiliary Hoist

c) Derrick

6. Non Return Valves

a) HE 27 - for Semi Rotary Hand Pump

b) HE 35 - for Boost Line Filters

7. Lock Valves

a) HC 2B - For Draw beam Jacks =6

b) HE 19 - for Derrick Tie Cylinders = 6

c) HE 46 - For relieving Bogie Coupling Pins = 2

d) HE 47 - For Travel Clutches = 2

e) HE 52 - For Counterweight jacks and Heavy Ballast Jacks = 2

8. Travel Differential


1. Preparation of 140 Te. Crane for "in-train" formation:

According to crane capacity, following instructions should be followed for better

performance of 140 Te. break down crane ensuring internal and external safety. Following points to be kept in mind for keeping 140 Te. Crane ready in all respects.

1. Feed pipe hoses between crane, match wagon, ballast wagon and relieving bogies should be connected. Feed pipe hoses of last vehicles should be kept on dummy and all isolating cocks except the last vehicle should be opened.

2. Hand brakes of match wagon, ballast wagon, relieving bogies and crane must be kept released but if the crane is stabled in the shed, wooden wedges must be inserted under the wheels of match & ballast wagons.

3. Connect AIR hose pipes between the vehicles.

4. BP /FP Angle Cock of match wagon, ballast wagon and crane to be kept open, otherwise Air brake will not be in function.

5. Travel clutch of both the trucks should be in disengaged position. Check mechanical indicator to ensure disengagement of travel clutch. (Physically ensure disengagement of Travel Gear)

6. Blocking screws of all the axle boxes should be lifted.

7. Slew lock pin of 140 Te. Crane should be in coupled position.

8. 12 Te. / 8 Te. Counter weight should be kept properly on crane carriage and hanger bolts locked with locking plate.

9. Brake power testing to be conducted, time-to-time in shed by attaching locomotive to ensure continuity in train formation. The test must be conducted in presence of break down supervisor.

10. Drain cocks of Air reservoirs of crane, match wagon and ballast wagon should be in closed position and leakage should not be there.

11. SA1 brake valve should be in released position and brake paddle should be locked with bolt.

12. Crane lifting tackles i.e. slings and other material should be kept systematically.

13. Rail clamps of the crane at both the ends should be secured with the hook.

14. All the draw beams / Outrigger should be in retracted condition and lock pin in inserted position.

15. In the locked condition of relieving bogies “ relieving bogie coupling pin” and “tumbler pin” should be in coupled position.

16. Transition coupling between crane, relieving bogies, match wagon and ballast wagon should be kept in tighten position.


2. Precaution and instructions during crane "In-train" Running:

During “in-train” formation, one crane man/Asstt should always be deputed to avoid unusuals with the crane. They must follow following instructions.

1. After starting of “intrain” formation”, the auxiliary engine of crane to be started first and then auxiliary compressor, so that crane brakes remain functional. MR pressure should not be less than 5.0 Kg/cm2.

2. After getting started auxiliary engine, battery charging to be ensured through ammeter.

3. Ensure auxiliary engine lube oil pressure between 1.8 Kg/cm² to 2.8 Kg/cm². Lube oil pressure should not drop below 1.5 Kg/cm².

4. For “in-train” formation, Red flag during day and red lamp during night should always be kept to utilize in emergencies. In case of any unusual or emergency, the emergency flap valve should be operated to stop the train. The same must immediately be communicated to the Breakdown Incharge/Supervisor on walkie-talkie.

5. Whenever train stops enroute following equipments to be checked:-

(a) Check the axle box condition by touching the axle box cover with hands for any rise of temperature of any of the axle boxes is rising abnormally. Information to be given to the break down incharge.

(b) Check following equipments/parts for unusual – Equalizing beam and its pin, brackets, leaf and coil springs, hangers, bolts, link and its pin and all transition couplings.

(c) Check whether lifting tackles are kept properly on match wagon and ballast wagon.

3. Precaution during “intrain” running and separation of crane from ART:

1. Before detaching the crane from ART, it must be ensured that MR pressure in the crane is not below 4.0 Kg/cm², because it is required for crane brake operation.

2. Brake pedal lock pin should be opened so that crane brake can be applied whenever required.

3. Before uncoupling the feed pipes, isolating cock should be closed.

4. After detaching the crane, apply crane self brakes by SA1 brake valve and ensure that crane brakes are working properly.

5. Check application & working of brakes.

6.


4. Precautions during preparation of crane at accident site for restoration works:

1. Axle box blocking screws to be blocked before unloading the relieving

bogies.

2. Start the main engine. If engine is cranking but not starting by operating “Key”, wait for 05 seconds and try again. This exercise should be done 2 to 3 time only. Do not repeat the operation of key frequently to avoid battery discharge.

3. Do not start travelling operation by the crane till MR pressure is created more than 5.0 Kg/cm². Ensure SA1 valve brake pedal in working order.

4. Avoid excessive tightening of derrick wire rope while lifting A-frame otherwise A-frame will not raise.

5. While lifting the jib from rester, it must be turned towards center so that resting table does not get damaged.

6. Select the duty, by duty selector switch according to lifting load.

7. Always choose suitable capacity lifting tackles according to work intensity.

8. Always choose the suitable place from where successful restoration can be undertaken.

5. Precautions and instructions for better performance of crane during restoration work at accident site:

1. Only authorized and competent break down officials shall deliver the instructions to the crane drivers while working at accident sites, but in case of any danger/unusual, any of the BDT staff can feed the indications to avoid unusual.

2. During restoration, Job (load) should not be dragged except hauling winch, but depending on requirement, only light load can be pulled, keeping crane jib “inline”.

3. Auxiliary hook to be utilized for lifting the load up to 25 Te. only. Beyond this load, main hook to be utilized.

4. Hauling operation should not be undertaken for more than 5.0 Te. loads, because hauling load is not shown by SLI.

5. Travelling operation should only be under taken when the jib is in “inline”. Limits of load lifting, given in the load chart, must be strictly followed.

6. If travel clutch does not engage, then: – (a) Release the crane brakes and observe clutch engagement. (b) Operate the joystick gradually.

7. During crane traveling, apply crane brakes for stopping the crane. Do not operate joystick reverse to stop the crane, because it will damage the system.


8. Always keep sharp observation over the crane wheels during restoration. Information regarding lifting of any wheels to be immediately communicated to the crane driver. Under such conditions, lifted load must be lowered and kept on ground level and propping to be examined thoroughly.

9. Speed selection should be changed only when crane is stopped completely.

10. Do not operate full joystick until travel clutch is inserted properly.

11. Before traveling, it must be ensured that, rail clamps have been removed, props removed and draw beam retracted and jib turned to “inline”

12. Before traveling, horn must be sounded to alert the staff.

13. Travel differential switch should be used only in slow speed operation when crane is unable to travel.

14. Duty selector switch must be set according to configuration.

15. Avoid dragging of tie cylinders with OHE wires while slewing the 140 Te. Crane.

16. Swinging load is always dangerous. The load should be lifted slowly just above the ground level and held for sometime to avoid swinging.

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

18. During operation, engine RPM should be gradually raised or reduced by the throttle lever. Always maintain the rpm as per requirement.

19. During restoration, two operations can be undertaken by this crane simultaneously but in exigencies, three operations may also be carried out.

20. To change the operation of crane, do not keep the joystick in operation, because it will damage the system of main joystick pump.

21. Main hoist emergency lower button should be operated only in case of emergency and the operation should not be part of the normal working.

22. Before undertaking lifting operation, the crane operator must be sure that duty selector of SLI is correctly set and SLI is in working order.

23. Do not override the SLI during restoration operation.

24. It is dangerous to work with the crane when MR pressure drops below 5.0 Kg/cm².

25. During operation, joystick must be operated gradually to keep the hydraulic system normal.

26. Do not use excessive electrical lighting at idle position, because batteries will get discharged.

27. Before under taking slewing movement, observe the train movement on the adjacent electrically charged line. Follow the G&SR rules strictly.


6. Precautions before and after shutting down the main engine (on completion of restoration works):

Precautions before shunting down the main engine

Precautions after shunting down the main engine

1. Check the battery ammeter. needle should be in + zone

1. After shutting down the main engine, all circuit breakers and battery isolator should be put “off”

2. Travel clutch should be disengaged. 2. Ignition key should be removed.

3. All the draw beams/ outriggers should be in retracted and locked position.

3. SA1 valve, brake foot pedal should be locked by inserting pin.

4. Relieving bogie-coupling pin should be in inserted position.

4. Material to be kept systematically on the crane.

5. Tie cylinders should be lowered completely.

5. All the transition couplings of the crane unit must be tighten.

6. Derrick wire rope should not be in loose position.

6. All the FP pipes and vacuum hose pipes should be coupled. FP cocks should be opened and outer most FP cock of last vehicle should be closed.

7. Before shutting down the main engine, it should be run on idle position for at least 3 minutes.

7. Heavy ballast and counter weight should be locked properly.

Attention:

If you are stabling/leaving the crane :–

(a) Ensure that wooden wedges have been inserted under

the wheels.

(b) Ensure that hand brakes of match wagon and ballast wagon have been applied.

(c) All doors of the crane have been closed and locked.


7. PREPARATION OF CRANE FOR WORKING AT SITE

Before uncoupling from the train do all the operations, i.e. uncoupling of hoses and starting of engine etc. mentioned in clause 6.1 to 6.4.6 of operators manuals.

Uncouple both the relieving Bogies as follows:

a) Remove the tumbler pins retaining the blocking screws above each of the Carriage Suspension Springs and screw down the blocking screws until they are locked down on to the top of the springs.

NOTE: Once locked these screw must NOT be adjusted against until the relieving bogies are re-coupled and loaded to the crane.

b) Ensure the wishbone Jack is in fully retracted position prior to unloading the relieving bogies.

c) Remove the tumbler pin retaining the crane casting lever-locking pin on the relieving bogies.

d) Exert a small amount of pull on the centre casting lever locking pin - at the same time slowly pump up (close the valve V2 and change the lever position P2 as shown in fig. 3) the relieving bogie jack until the locking pin slides out of centre casting lever.

e) With the locking pin withdrawn, lower off the main jack slowly (change the lever position to P(N) and open the valve V2 as shown in fig. 3 until the relieving bogie frame stops raising. The above operations have to be made for both the bogies.

f) Remove the slew-locking pin. g) Erect the 'A' frame erection switch to the raise position at the same time particular

care should be taken to ensure the derrick rope is kept in a reasonably tight condition.

NOTE: But should not cause jib bridle assembly to lift from the jib structure until the 'A' frame is fully erected.

h) Derrick the jib off the match wagon trestle until the main and aux. hoist blocks are clear off the match wagon.

NOTE : Both the relieving bogies must be unloaded prior to raising the jib from the match wagon trestle.

i) Check the gaps (Which should be about 2 to 3 mm approx.) between both top and bottom locating pads RB25 and RB26 (half-moon as shown in fig.1). If required load/unload the relieving bogie a bit to achieve these gaps.

WARNING: Do not operate the wishbone jack at all for this purpose. j) After gaps are found to be same take out the coupling pins. If required

load/unload the relieving bogie a little bit during this operation also. Uncouple both the relieving bogies in the same way. k) Move the crane slowly away from either relieving bogie. l) The relieving bogies can now be moved to any desired position either by towing

away in which case the hand-brakes will need to be released, or by the crane lifting it clear of the work area.


8. PREPARATION OF CRANE FOR IN-TRAIN RUNNING CONDITION

a) If the crane has been in the blocked condition, retract the jacks, remove the foot steps / Propping chairs and retract the draw beams / Outrigger. Lock draw-beams in the stowed position and stow the footsteps / Propping chairs. Bring the jib in line position.

b) Couple up relieving bogie as follows: NOTE: The carriage end castings and coupling pins on both ends of the carriage should be

thoroughly cleaned to remove all in grease dirt, dust etc. and re-greased prior to coupling. c) Place the relieving bogies as per matching mark on either side of the crane. NOTE: The relieving bogies are not interchangeable. d) Bring the relieving bogie into close proximity to the crane and apply hand brake. e) Using wishbone jacks of the relieving bogie jack the coupling beam (i.e. by hand pump

with lever position (I) and valve VI open as shown in fig. 3) to align the same with the pockets in carriage end castings. Use turn buckle whenever required to align the wishbone to the carriage end casting.

f) Release the carriage brake and move the crane very slowly to the relieving bogie. As soon as the coupling beam takes the lead of the pocket of end casting ( as shown in

fig.2) release the wishbone jack completely (i.e. by changing the lever position to position (2) as shown in fig. 3).

g) Travel the crane further so that the gaps between half-moon (RB25 & RB26) are minimum. If necessary load the relieving bogie a little bit as to achieve a gap of 2 to 3 mm approx. in both top and bottom half-moons (as shown in fig.).

WARNING: In no case should there be any sort of loading on wishbone jack after coupling beam has taken the lead of end casting pocket. This might damage the wishbone cylinder.

h) Engage the hydraulic coupling pins to lock the relieving bogie to the carriage. If required relieving bogies may have to load/unload during this operation.

i) Slew the superstructure in line to engage the slew lock pin. j) Derrick the jib down onto the match wagon trestle by pressing the override switch.

Slacken the derrick rope and lower 'A' frame until 'A' frame collapsed. k) Load the relieving bogies (by hand pump with lever position (2) and valve V2 open as

shown in fig. 3) until the centre casting locking pin slides into position by pushing on the handle and refit tumbler pin. Now close the valve V2 and bring the lever in neutral position (N).

l) Release the loading jack completely by opening the valve V2 slowly. m) Repeat these operations for the other end relieving bogie. n) Screw up all the blocking screws and refit the tumbler bogie. IMPORTANT: After coupling the relieving bogies and before travelling re-charge the spring

feed lubricators on the both relieving bogies and the carriage end castings with recommended lubricants.

o) Reconnect the coupling hoses between the relieving bogies and carriage. p) Coupling match wagon and ballast wagon to the crane. q) Re-connect the coupling hoses between the match wagon, ballast wagon and relieving

bogies. r) Depending on the type of hauling locomotives whether air braked or vacuum braked

please follow the operations laid down vide clauses 8.2, 8.3 & 8.4 of brake operating manual No. Z 1774 provided in operator's manual.


9. Precautions to be taken during 140 t. Crane Operation

(Gottwald New Design)

Before raising the Jib from Match-truck Axle Blocking operation must be done.

After lifting rear superstructure Gallows must be locked with main superstructure of Crane.

Uncouple Match-truck from crane (Screw-coupling as well as air brake hoses). Match-truck should be secured by the hand brake.

Before any movement of crane by its own power, operator must insure that travel gear has engaged & crane brakes in operational condition.

The crane should me made stable before carrying out further operations, according to position / Propping base either firm propping of crane (6 Mtr./ 5 Mtr. / 2.9 Mtr.) should be done or rail clamping must be carried out in case of free on rail operations.

Apply Parking brakes for maintaining rigidity of the crane.

Before lifting Jib it must be ensured that the crane is on straight track.

In operating area the operator as well as loading person should assess the track deviations of cants with jib in line with the track. Crane should be levelled by using outriggers(Propps).

The operator must be thoroughly acquainted with the load chart provided in the crane to assess the S.L.I. selection.

Special care to be taken during propping of jacks when the crane is to work on site. Proper Packing should be placed below Propp chair. For uniform load distribution Packing should be alternately perpendicular & parallel to the track. Packing should be checked for any sinking

The propping operation should be carried out until the wheel has just left the rail, There should be absolute no gap between in-rigger and out-rigger.

The load should properly secured and it should be lifted slowly just above the ground and hold it there. Propping should checked again for sinking.

If the crane is to be moved to another position, the propps should be raised outrigger should be retracted.

This crane is unsuitable on super-elevated track in free on rail operation with counterweight operation.

Swinging load is dangerous and should be avoided.


STARTING CIRCUIT OF 140 Te CRANE (Cowans Sheldon Old)

One No. Battery box is provided on the left side of crane super structure in which two batteries, of 12 Volts 210 Amps rating have been provided. These batteries feed 24 Volt DC supply to the LT electrical system. One 24 Volt alternator is provided to charge these batteries. For rotation of this alternator, drive is given through V-belts of main engine. The generating current of this alternator is 25 Amps on idle position and approx. 40 Amps on full speed of the main engine.

When Battery isolation switch "A1" is put "ON" in the driver's cabin, the supply of battery comes to wire No.1. As the negative terminal of the battery is connected to the crane body, negative charge is always available in the crane body. Further, ES-1 (Engine Start Key switch) is put "on" by operating engine “key” to position No.1 (Run position), the engine fuel solenoid IS-1 gets positive supply from wire No.11 and negative supply from crane body. The IS-1 gets energized and fuel supply goes to the main engine. Solenoid IS-1 gets electrical supply through 2DI (Low water timer relay) close interlock 8-9, 2D2 (Engine low lube oil pressure timer relay) NCI (9-10) and 2D3 (Engine over speed relay) NCI (10-11).

Further when ES-1 switch is kept on position No 2 (Start), solenoid coil gets battery positive supply through wire No 7 and solenoid gets energized. On energizing solenoid, self-starter bandex couples with the gear of main engine and supply of battery goes to the self-starter through solenoid contactor, which in turn rotates the self-starter for starting the main engine.

After starting the main engines, ES-1 (Engine starting switch) is released and it automatically gets run position. As soon as ES-1 comes to "Run" position, self starter stops rotation.

BATTERY OPERATED ELECTRICAL CIRCUITES.

1. Hand lamp : 4 hand lamp sockets of 24 Volt supply have been provided on the 140 Te crane. Two sockets on super structure -(i) Auxiliary engine room(ii) Pump compartment/engine room and two nos. on the middle portion of the carriage - one each is provided on both side of the carriage. Positive and negative supply is always available on the socket of carriage through wire No 30-0 of slip ring. The circuit is controlled by E2 circuit breaker of 10 Amps rating, provided on the carriage.

2. Cab Light (H8): It is a white coloured, 60 watt 24 volt capacity bulb, mounted on the roof of drivers cabin. It is provided for illumination in the driver's cabin. One E3 circuit breaker of 5 Amps rating is provided in driver's cabin on control compartment for switching "ON" and switching "off" the bulb. It gets supply from wire No. 31-0.

3. Windshield wiper motor (M2) - Windshield wiper motor is a two-pole permanent magnet DC motor. One small gearbox is mounted on the shaft of this motor. It operates the windscreen wiper, which cleans look out glass of the crane during rainy season. For operation of windshield wiper motor, one E4 circuit break of 5 Amps rating is provided on the control panel. It gets feed from wire No. 32-0.


4. Horns (H-9, H-10) : Horns are operated by the E5 circuit breaker of 20 Amps rating. It connects the supply to wire No.33. There are two push buttons i.e. ES-10 and ES-11, provided in the drivers cabin. One is provided for H-9 hi- tone horn which gets feed from wire No.34 and another is for H-10 law tone horn (Rear side) which gets supply from wire No.35. 5. SLI Gauge Light. To provide required illumination level in the various gauges and SLI, miniature bulbs are provided. They can be lit by E-6 circuit breaker of 5 Amps rating. It gets supply from wire No.150. 6. Engine House light(H-15) : For better illumination in the engine house, two lamps of 40 watts and 24 volt rating are provided on the crane super structure. One of them is provided in the auxiliary engine room and another in the pump compartment. These lamps can be operated by E-7 circuit breaker of 10 Amps rating. E-7 circuit breaker connects supply between wire No.5 & 153. Note: Above circuits come in function only when battery isolator is put "ON" while engine is in shut down condition.


Gauge Lights & Lighting Circuits of 140 Te. Crane (Main engine running position)

Different types of gauges are provided on Cowans Sheldon 140 Te. Crane to check the system pressure of fuel system, water-cooling system, engine lube oil system and hydraulic system. Apart from this, jib floodlight and front & rear crane head light circuit is also explained in this chapter.

1. Battery Ammeter (G1): Ammeter is provided on the control desk in drivers cabin and it gets supply from wire no. 3-6. Under shut down position of main engine, when any circuit breaker is kept on, this ammeter shows discharge indication in the discharge side. Similarly, when alternator starts charging in running condition of main engine, battery ammeter shows charging of batteries through ammeter shunt. Miniature bulb of 24 V, 0.3 W is provided in this meter to see the readings during night.

2. Engine fuel gauge (G2): This gauge shows fuel oil level in the main engine fuel tank. It gets electrical supply from wire no. 8. One sensor is provided in the main fuel tank to sense the fuel oil level, which gets supply from wire no. 13. It sends message of availability of fuel oil level to the fuel oil gauge, provided in the drivers cabin to enable the driver to understand the quantity of fuel oil.

3. Water temperature gauge (G3): This gauge is provided to observe temperature of engine coolant water. It gets electrical supply from wire no. 8. One water temperature sensor is installed on the engine coolant pipe, which works on the principle of thermo coupler. When coolant water becomes hot, sensor feeds the indication accordingly to the water temperature gauge through wire no 14, which can easily be seen in the drivers cabin.

4. Engine oil pressure gauge ( G4): Engines oil pressure gauge shows main engines lube oil pressure in running condition. It gets electrical supply from Wire No.8. For this purpose, one pressure sensor is provided on the lube oil pressure gallery of engine block. Sensor gets pressure of the system and sends indication accordingly to the gauge through Wire No.15.

5. Engine oil Temperature Gauge (G5): It is provided to show temperature of lube oil of main engine. It gets Electrical supply from Wire No.8. One sensor similar to thermo coupler is provided in the lube oil sump, which gets actual temperature of engine lube oil product and sends indication to the gauge according to rise in temperature through Wire No.16.

6. Hydraulic Oil Temperature Gauge (G6): This gauge is also provided in the driver’s cabin, which shows temperature of hydraulic oil. It gets electrical supply from Wire No.8. One sensor similar to thermo coupler is provided in the hydraulic tank, which absorbs rise and decrease of temperature and sends the same to the gauge through Wire No.17.

7. Engine Hour Run Gauge (G7): This gauge is provided to show the running of engine in hours as well as recording of the same. It is an electrically operated gauge, which gets electrical supply from Wire No.25. During running condition of main engine, it starts showing that how many hours engine has worked with cumulative recording in hours.


High Power Circuits of 140 Te. Crane

These circuits work only in main engine running condition and electrical

supply is fed to the circuit by the alternator. One 2K-1 contactor is provided in starting circuit of main engine. Normally

close inter lock (5-36) of this contactor controls closing and opening of these high power circuits i.e. Ventilator motor, floodlights and hydraulic circuits.

1. Cab Ventilation Fan (M3): The cab ventilation fan is provided in the

drivers cabin to exhaust the air from cabin to atmosphere. It is operated by E-8 , 5 Amps Circuit breaker through Wire No.37.

2. Jib Floodlight (H-11): Jib floodlight is provided in the mid portion of

the jib of 140 Te. Crane for providing required illumination level during load lifting at accident site. Floodlight is a 150 W, 24 V halogen lamp which is controlled by E-9 circuit breaker of 10 Amps rating through Wire No.38.

3. Front floodlight (H-12): These lamps are provided on the front side of

crane super structure at right and left side and works as headlights on the crane. These are the halogen lamps of 150 W, 24 V rating which can be operated by circuit breaker E-10 of 15 Amps rating through Wire No.39.

4. Rear floodlight(13): This headlight is provided in the A- Frame Section

of the Crane (tail of the super structure) to provide illumination in the Rear side. This is also halogen lamp of 70 W, 24 V rating which is operated by E-11 circuit breaker of 5 Amps rating through Wire No.40.

5. Hydraulic Control Circuit Breaker (E-12): This is main circuit breaker

of 15 Amps rating which provides electrical supply to all electro hydraulic circuit breakers of crane through Wire No.41.

6. E-13, 14 Circuit Breakers: These are the spare circuit breakers of 20

Amps rating. These are installed for the purpose of any additional circuits required in future.

Note: Engine RPM should not be less than 1500, when floodlight and head

light are being used.


Responsibility for correct carrying out of rules : (A). Crane man are responsible not only for the mechanical manipulation of

cranes but also for their safe operation and for seeing that all rules pertaining to their working are correctly carried out.

(B). In general, cranes working on break down operation or where a A-frame

or jib is likely to foul adjacent line, must work under the supervision of an officer or competent subordinate.

(C). In electrified section, before commencing the operation, the crane

supervisor / Driver will clearly indicate by a written memo to OHE department present at site to obtained power block and will operate the crane only after receiving the permit to work by authorized TRD staff after OHE has been made dead and earthed.

(D). During crane operation, the operator must be thoroughly conversant with

load chart to assess the duty selection. (E). Whenever 140 Te. Crane of ART is ordered to site of accident / derailment

is to be accompanied by an officer.

Precautions when lifting with Cranes : 01. The crane must not be used to lift more than the maximum safe working

load authorized at the radius. 02. Precautions should be taken to avoid load catching on obstructions as this

may seriously overload the crane. 03. Sudden shocks and jerks also tends to overload the cranes and tackles. 04. Shocks and jerks usually result from: (a). Mistake in signalling to the crane driver. (b). Want of observation by the crane driver. (c). Sudden application of brakes on crane. (d). Kinks in the chains. (e). Slipping of chain due to incorrect slinging or sling hooks not

properly secured 05. Lifting tackles i.e. hoisting chains, lifting chains, sling chains and wire

ropes should be of suitable capacity.


Periodical examination of Cranes : 01. 140 Te. Diesel hydraulic cranes of ART’s should be examined at intervals

regularly as prescribed by RDSO. 02. The Break down incharge / SSE nominated to do so are responsible for

the periodical examination of 140 Te. Break down cranes. 03. To ensure proper upkeep and reliability in safe working of 140 Te. Crane

at site, the following periodicity of schedules has been prescribed by RDSO. A. Cowans Sheldon (Old Crane)

S.N. Duration Working hours Set of schedule form

01. Daily Form “A”

02. Monthly 100 Form “B”

03. 3 Monthly 250 Form”C”

06. 6 Monthly 500 Form”D”

07. Yearly 1000 Form”E”

08. 2 Yearly 2000 Form”F”

09. 4 Yearly 4000 Form”G”

10. 8 Yearly 8000 POH

B. Cowans Sheldon (New Crane)










C. Gottwald (Old Crane)











D. Gottwald (New Crane) CIL Main Engine NTA 855 L



02. Monthly 125* Form “B”

06. 6 Monthly 250* Form”D”

07. Yearly 1500* Form”E”

08. 2 Yearly 6000* Form”F”

09. 4 Yearly 6000* Form”G”

10. 8 Yearly -- POH

* Whichever is earlier

KOEL Auxiliary Engine HA-294


01. Daily

02. Monthly 125*

06. 6 Monthly 250*

07. Yearly 1000*

08. 2 Yearly 2000*

09. 3 Yearly 3000*

10. 8 Yearly -- POH Sch.

04. Particulars of periodical examinations should be maintained in a register. 05. Any repair to be executed should be reported to the subordinate incharge

of the maintenance of the crane. 06. Record of such examinations entered in the register should be signed by

the maintenance supervisor. 07. Particulars of periodical examinations of 140 te. Crane should be recorded

in the prescribed schedule forms as laid down by the RDSO.

Lubrication of Cranes

01. Crane operator will be personally responsible for adequate and efficient lubrication of all bearing surfaces.

02. They will ensure that bearing surfaces are clean and free from dust, dirt.

This applies particularly in matching surfaces of clutch gear, center pivots, rollers and motion gears.

03. The crane driver should make certain that all working parts are clean and

before starting work every day, he should ensure that visible parts are adequately lubricated.

04. On 140 Te. Crane, make the locations and lubricants with grade wise to

be used for lubrication have been suggested by the manufacturer. The manufacturers recommendations for lubrication should be strictly followed.


dzsu Lis'ky gsrq vko';d lkeku dh lwph List of the Important Material for Crane Spl.

On ordering of Crane Special, following material should be kept in Staff Van before departure from Crane siding/Shed.

Dz- Lkkeku dk fooj.k la[;k Description of the material NOS.

1- Okkdh Vkdh lSV 04 u- Walkie Talkie Sets 04 Nos. 2- Eksxk Qksu 02 ua- Mega Phone 02 Nos. 3- Okkdh Vkdh pktZj 01 ua- Walkie Talkie Charger 01 No. 4- isVªksesDl ¼xSl½ 2 + +2 ua- Gas Patromax 02+02 Nos.

5- VkpZ ¼3 lsy½ 04 ua- Torch Three Cell 04 Nos. 6- flxuy VkpZ 01 ua- Signal Torch 01 No. 7- estfjax Vsi 01 ua- Measuring Tap 01 No. 8- gsyesV lQsn 04 ua- Helmate (Hard hate) 04 Nos. 9- gsyesV LVkQ 20 ua- Helmate Staff 20 Nos. 10- Pkknjsa 08 ua- Bed Sheets 08 Nos. 11- Rkfd;ss 05 ua- Pillows 05 Nos. 12- daEcy ¼lqijokbtj½ 08 ua- Blankets (Supervisor) 08 Nos. 13- daEcy LVkQ 20 ua- Blankets (Staff) 20 Nos. 14- >a.Mh yky rFkk gjh 02 ua- Red and Green Flags 02 Nos. 15- Ikkuh dh ckfYV;ka 01 ua- Water Buckets 01 Nos. 16- QLV ,M ckWDl 01 ua- First Aid Box 01 Nos. 17- iSM LVkEi eseks cqd 1+1+1 Memo Book and Pad, Stamp 1+1+1 No.

18- fMVsUlu QkeZ 04 ua- Detention form 04 Nos. 19- Nkrs 04 ua- Umbrellas 04 Nos. 20- isu fjyhQ Lizs 02 ua- Pain Relief Spray 02 Nos. 21- Lizs iai ¼vkWa[k /kqykbZ gsrq ½ 01 ua- Spray Pump for cleaning of eye 01 No. 22- gSaM iai ;wfuV 01 ua- Hyd. Hand Pump Unit 01 No. 23- 30@60 tSd 02 ua- 30/60 Te. Jacks 02 Nos. 24- 120@60 ,y lh tSd 01 ua- 120/60 Te. Jack 01 No. 25- fMLIysflax tSd 01 ua- Displacing Jack 01 No. 26- jksyj dSfjt 01 ua- Roller Carriage 01 No. 27- fjjsfyax fczt 01 ua- Re-railing Bridge 01 No. 28- dkmWa.Vj liksVZ 01 ua- Counter Support 01 No. 29- gkbZ izs'kj gkst 03 ua- High Pressure Hoses 03 Nos. 30- tujsVj lSV 01 ua- 3/2.5Kva Cap. Generator 01 No. 31- gSykstu ySai 02 ua- Halogen Lamp 02 Nos. 32- fLop cksMZ 01 ua- Elect. Switch Board 01 No. 33- ,DlVsa'ku cksMZ 01 ua- Elect. Extension Board 01 No. 34- fjap ckj 02 ua- Wrench Bar 02 Nos. 35- iats 02 ua- Punje 02 Nos. 36- dSejk 01 ua- Video Camera 01 No. 37- fdfpu dk lkeku 01 lSV Kitchen Material 01 Set

mailto:30@60

mailto:120@60


SUITABLE WOODEN PACKINGS

A. REQUIRED FOR 140 Te. CRANE:

[ COWANS SHELDON 140 Te. CRANE OLD]

1.Wooden Packing Size- 1800mmX300mmX300mm - 08 Nos.

2.Wooden Packing Size- 1200mmX300mmX300mm - 20Nos.

3.Wooden Packing Size- 1200mmX300mmX150mm - 24 Nos






TOTAL PACKINGS - 222 Nos.

NOTE: All packings must be recessed at the ends and bonded with 30X5 mm thick bond.

B. REQUIRED FOR 140 Te. CRANE:

[ COWANS SHELDON 140 Te. CRANE NEW]

SN Size Location Cubic

feet per packing

Required per Prop for 5' 3" Height

For 4 Nos Prop For 8 Nos Prop

No. of Packing

Cubic feet

No. of Packing

Cubic feet

1 6' X1' X 1' Ist Base 6 6 24 144 48 288

2 5' x 1' x 6" IInd

Base 2.5 5 40 100 40 100

3 4' x 1' x 6" IIIrd & IVth Base

2 8 32 64 64 128

4 3' x 1' x 9" Vth & Vith

Base 2.25 6 24 54 48 108

5 2' 6" x 1' x

9" Seventh

Base 1.875 3 12 22.5 24 45

6 2' 6" x 1' x

3"

Eight & Ninth Base

0.625 6 24 15 48 30

Total 15.25 34 156 399.5 272 699


LOAD CHART FOR 140 Te CRANE [ COWANS SHELDON OLD]

Duty Selector

0 t - 4, 32 t - 7

12 t - 2 MAIN HOIST

Duty Selector

0 t - 3, 32 t - 6

12 t - 1 AUXILIARY HOIST

Radius

in

meter

Coupled

ballast

weight

Free on rail Fully Propped Radius

in meter

Coupled

ballast

weight

Free on rail Fully Propped Slew Range Slew Range Slew Range Slew Range

O° 28° 360° O° 28° 360° O° 28° 360° O° 28° 360°

5.5 0 t 42 42 29 140 140 140

7.0 0 t 25 25 20 25 25 25

12 t 94 53 39 140 140 140 12 t 25 25 25 25 25 25

32 t 104 -- -- 140 140 140 32 t 25 -- -- 25 25 25

7.0 0 t 31 31 20 140 140 98

9.0 0 t 22 22 13 25 25 25

12 t 78 41 27 140 140 110 12 t 25 25 20 25 25 25

32 t 86 -- -- 140 140 140 32 t 25 -- -- 25 25 25

9.0 0 t 22 22 13 140 140 62

11.0 0 t 16 16 9 25 25 25

12 t 63 30 18.5 140 140 70 12 t 25 25 15 25 25 25

32 t 70 -- -- 140 140 101 32 t 25 -- -- 25 25 25

11.0 0 t 16 16 9 109 109 44

13.0 0 t 12 12 6 25 25 25

12 t 52 23 14 118 118 50 12 t 25 21 11 25 25 25

32 t 58 -- -- 130 130 58 32 t 25 -- -- 25 25 25

13.0 0 t 12 12 -- 79 79 34

15.0 0 t 9 9 4 25 25 25

12 t 44 18 9.5 85 85 38 12 t 25 17 9 25 25 25

32 t 49 -- -- 105 105 58 32 t 25 -- -- 25 25 25

15.0 0 t 9 9 -- 61 61 27

17.0 0 t 7 7 3 25 25 25

12 t 38 14 7 66 66 31 12 t 25 13.5 7 25 25 25

32 t 42 -- -- 85 85 47 32 t 25 -- -- 25 25 25

16.0 0 t 8 8 - 55 55 24

19.0 0 t 5 5 2 25 25 19

12 t 35 13 6 59 59 28 12 t 25 11 5 25 25 22

32 t 39 -- -- 70 70 42 32 t 25 -- -- 25 25 25

5.65 5.5 Activities and Timing particulars 1. 140 Te. Crane Energising with Aux. Hook = 15 min

B-End A-End 6.0 m 2. Full Propping = 30 min

R/B 140 Te. Cran R/B 3. Counter weight attaching = 08 min

4. Relieving Bogie removing = 12 min

5.0 M 5. Match Truck Removing = 30 min

6. Crane binding up with Aux. Hook = 20 min

11.15 M 7. Crane binding up with R/B + Match truck=1.10 hr

8. 360° Slewing without load = 2.5 min

PROPPING ARRANGEMENT


WEIGHT CHART OF COACHES AND WAGONS

SN Type of

Wagons &

Coaches

Tare weight

in Tonnes

Pay load

in Tonnes

Complete

weight in

Tonnes

One Trolly

weight in

Tonnes

Total

wheels

Type of

coupling

Open /

Covered

Vacuum/

Air Brake

01 BVZI 23.52 56.68 81.28 4.0 08 CBC Open Air Brake

02 BOX N 23.02 58.08 81.28 4.0 08 CBC Open Air Brake

03 BOXNNHA 23.17 65.23 88.40 4.0 08 CBC Open Air Brake

04 BOXNHL 20.60 71.00 91.60 4.0 08 CBC Open Air Brake

05 BOXNEL 23.10 76.90 100.00 4.0 08 CBC Open Air Brake

06 BOXNR 21.20 70.04 91.60 4.0 08 CBC Open Air Brake

07 BOXNAL 18.26 63.02 81.28 4.0 08 CBC Open Air Brake

08 BOXNHAM 23.10 68.18 91.28 4.0 08 CBC Open Air Brake

09 BOST 25.50 55.78 81.28 4.0 08 CBC Open Air Brake

10 BCN 27.20 54.08 81.28 4.0 08 CBC Covered Air Brake

11 BCNHL 20.80 70.80 91.60 4.0 08 CBC Covered Air Brake

12 BRN 23.30 68.29 91.60 4.0 08 CBC Flat Air Brake

13 BFNS 26.71 54.57 81.28 4.0 08 CBC Flat Air Brake

14 BOBRN 26.40 54.88 81.28 4.0 08 CBC Flat Air Brake

15 BOBRNHSM1 25.61 63.67 89.28 4.0 08 CBC Flat Air Brake

16 BOBY/BOBYNHS 25.2 66.40 91.60 4.0 08 CBC Open Air Brake

17 BTPN 27.0 54.28 81.28 4.5 08 CBC Covered Air Brake

18 BTPGLN 41.60 37.60 79.20 4.5 08 CBC Covered Air Brake

19 BTFLN 23.33 57.95 81.28 4.5 08 CBC Covered Air Brake

20 BLCA 19.10 61.00 80.10 4.0 08 CBC Flat Air Brake

21 BLLA 19.80 61.00 80.80 4.0 08 CBC Flat Air Brake

22 LWFAC 40.87 2.47 43.34 4.0 08 CBC Coach Air Brake

23 LWGFAC 45.90 4.80 50.70 4.0 08 CBC Coach Air Brake

24 LWACCW 41.60 5.12 46.72 4.0 08 CBC Coach Air Brake

25 LWGACCW 48.00 7.04 55.04 4.0 08 CBC Coach Air Brake

26 LWACCN 43.00 5.80 48.80 4.0 08 CBC Coach Air Brake

27 LWGACCN 50.50 8.00 58.50 4.0 08 CBC Coach Air Brake

28 LWFCZAC 42.27 6.24 48.51 4.0 08 CBC Coach Air Brake

29 LWSCZAC 42.27 8.00 50.27 4.0 08 CBC Coach Air Brake

30 LWLRRM 52.12 4.66 56.78 4.0 08 CBC Coach Air Brake

31 SCN 41.1 6.7 47.8 3.5 08 Transition Coach Air Brake 32 AC Ist 49.75 1.5 51.19 3.5 08 Transition Coach Air Brake 33 AC IInd 53.7 9.6 63.3 3.5 08 Transition Coach Air Brake 34 AC III 53.7 9.6 63.3 3.5 08 Transition Coach Air Brake 35 AC Chair Car 45.6 7.6 53.2 3.5 08 Transition Coach Air Brake 36 Pantry Car 41.5 2.0 43.5 3.5 08 Transition Coach Air Brake 37 VPU 38.0 16.0 54.0 3.5 08 Transition Coach Air Brake

SAMPLE PROFORMA FOR BREAK DOWN TRAIN FORMATION

SN Vehicle

No.

RLy Built Date POH Done POH Due Utilisation

01 44225 CR 1986-UK 22.02.98 PR 02.2006 140 Te. Crane

02 7179 CR 1980 BCN HS 04.09.01 MTN 10.2005 Crane Packing+OHE material

03 9216 CR 1979 ICF 04.09.01 MTN 10.2005 Crane Staff and Kitchen Van

04 78212 CR 1978 ICF 04.09.01 MTN 10.2005 Tool and Equipment Van

05 9523 CR 1981 BEML 04.09.01 MTN 10.2005 Re-railing Equipment Van

06 9383 CR 1980 ICF 04.09.01 MTN 10.2005 C&W, S&T & Elect. Van

06 9586 CR 1981 ICF 04.09.01 MTN 10.2005 Staff and Kitchen Van

07 357301 SC 1993 BCN HS 28.11.99 RYPS 01.2006 Engineering Material + OHE

08 120937 CR 1989 BRN HS 17.06.98 RWS 02.2004 Rails and Crossings


LOCOMOTIVES

1. Restoration of derailed locomotive in the dead end siding by 140 Te. Crane.

A- Preparation Chart :

S.N. Item/Status Action 01 OHE Working line OHE to be slewed. OHE of

adjacent line to be made dead or slewed depending on infringement.

02 Condition of props and availability of staff

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

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

04 No. of cranes required and Position of SLI duty selector

Two cranes. duty selector to be kept on No.1 (i.e. full prop with full counter weight)

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 loco adjustment

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 for restoration

Average – 2.0 hrs. minimum

B- Restoration Plan :

1 Observation 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.

2 Axle blocking –Carry out Axle Blocking ( for the method of Axle Blocking see P 29-31 )

3 Boom erection – For things to ensure before boom erection see P-


4 Do the propping of the crane – Detailed instructions given at P-

5 Select the counterweight as per load chart - Detailed instructions given at P-

6 Operation can now be started. Following Operating Precautions given at P- and General Precautions for handling of loads given at P- .

7 Locomotive should always be handled by two 140T break-down cranes if

required to be lifted from the ground completely or one by one lifting / slewing from either end method can be adopted. Suitable capacity wire ropes and D-Shackles/Bow shackles should be used.

8 However in case only one trolley has derailed, the locomotive can be re-railed with the help of one crane from derailed trolley side. Or otherwise also if the loco is not capsized, keeping the one end of it on the ground other end can be re-railed or tackled cautiously with the help of one crane provided it is free from any entanglement.


9 WDM3A and WDG3A class locomotives should be tackled at holes provided on the buffer plate with the help of D-shackles of adequate load capacity. This will ensure minimum damage to the sub-assemblies of Locomotive.


10 In case D-shackles of adequate capacity are not available, locomotives can be handled with the help of draw bar wire ropes placed across underneath the locomotive.

11 WDG-4 locomotives can be tackled with draw bar wire ropes as the buffer plate holes are not provided in this loco.

12 Before lifting of WDG3A class of locomotives, trolleys should be secured with loco chassis with proper fastening arrangements otherwise trolley will get detached during lifting, because the D-shackles provided in the locomotive for connecting the trolley with chassis can not take the load of trolleys.

13 In case, locomotive has fallen in a ditch after crossing sand hump or buffer, it can be lifted and kept on temporary tracks (laid upon engineering cribs) that can be connected with existing track.


14 Any accident stock lying very far from the reach of the crane, can be brought closer in

the reach with the help of HRE.

15 In case bogie has cracked or damaged to an extent that lowering on that may not be safe, spare dummy bogie should be arranged from the nearest loco shed.


16 Uncoupling of Bogies

In situations where it is needed to uncouple the bogies and run out as in above case , air brake pipe connections, TM cable connection, Centre Pivot cotter and other connections between bogie and chasis needs to be disconnected.Other such coonectios are listed as below-

Axle Generator cable

Speedometer cable

Bolster Pin etc

C- Procedure in Practice :

When diesel or AC locomotive enters in to the dead end siding and derails, it is re-railed with the help of two 140 T. cranes. Each crane at either end of adjacent track is placed from where working radius is kept not more than 8 meters. 1. One 140 Te crane is kept at one end on the adjacent track and other 140 Te.Crane

at another end.

2. Full propping is done for both the cranes and 50 Te/ 70 Te, 6 meters wire rope sling

with 50/70 ton ‘D’ shackles are used.

3. ‘D’ shackles are inserted in the lifting holes of buffer plates of loco at four places (For

locos having buffer plates) and both 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 is

permitted to do so for safe placement of loco trolleys on track.

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

Bolster Pin

Connection


COACHES

1.(A) RESTORATION OF COACHES IN ELECTRIFIED SECTION BY 140 Te. CRANE

A. Preparation 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.


Full propping to be done and 04 staff on each prop should be deputed.

03 Suitable packing and its size Wooden 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


09 Maximum working radius 13 meters by main hook.

10 Place where sling to be inserted

(under frame) Solbar



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.



18 Photography/Videography Videography of all critical operations and clues collection.

19 Average timing for restoration of each coach

Average – 55 minutes

Removing Entangled Coach:

01. Energize 140 Te. Crane, attach counter weight and ensure full propping for approach upto 18 mtrs radius.

02. Insert Aux. Hook in the solbar of coach at facing end and lift slowly with slewing actions.

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

04. If coach trolleys are in good condition, re-rail the coach by MFD/LUKAS Jacks.


Damaged Trolleys:

If the trolleys are damaged badly and re-railment is not possible then:- 01. Attach 70 Te. SWL and 30 Te. 5 Mtrs wire rope sling and eye-wire ropes. 02. Insert eye wire rope in the centre of the coach (under frame) and lift

slowly. 03. Place the job within 13 mtrs of radius anywhere at 360º. 04. If the coach body is damaged, then utilize 30 Te. 5 mtrs wire rope sling

with eye-wire rope without SWL. 05. Lift the coach and place away from the track within 13 mtrs.

B RESTORATION OF COACHES IN NON-ELECTRIFIED SECTIONS

In double line section, where lines are at minimum standard distance, the restoration can be executed with 140 Te. Crane by placing coaches on the adjacent track:-

01. First of all, remove front relieving bogie of crane and establish the crane near first derailed coach, keeping margin of approx. 1 meter distance.

02. Ensure complete propping and secure the trolleys of coach with the lashing chains and bolts.

03. Insert Aux. Hook in the solbar of near end of coach and lift.

04. Place this end away from the Ist draw beam (prop) because during lifting operation, coach normally creeps towards crane.

05. Again release the hook, and pick up the coach in the center by 30 Te. 5 mtrs wire rope and lift.

06. Keep jib “inline” (not more than 4ºC slew position), release props and travel the crane slowly free on rails.

07. Again ensure full propping and place one trolley of lifted coach on adjacent track adjusting slew degree and radius. Similarly keep other trolley on the track.

C Restoration of tilted coach:

01. If the trolleys of coach are intact, secure the trolleys with lashing chains so that trolleys remain with the coach structure.

02. But, if the trolleys are damaged or have got uncoupled, remove damaged trolleys first by Aux. hook.

03. Take 140 Te. crane near the coach, ensure complete propping and insert hook at this end.

04. Lift the near end. of tilted coach, it will get turned straight by this operation and further do next exercise for removing the coach.


D Restoration/Shifting of derailed and capsized coaches fallen down on the River Bank:

If the coaches have fallen down in to the river or river bank infringing track, first of all ensure that all passengers have been evacuated safely from the coaches. Thereafter the coaches should be shifted with the help of JCB machines. The heavy duty JCB machines should be hired from nearest towns/cities.

1. JCB machines should be deployed in case of earth work required for filling

the deep area as well as for making surface level for laying the damaged track.


2. After assessment of the accident site, if the coaches found tilted infringing track, the coaches may be Pushed/pulled out by JCB Machine maintaining safe distance between JCB & damaged coach. For faster clearance of the track, 3-4 JCB Machine may also be deployed for pushing/pulling for shifting it out of the track.

3. In case of non availability of passage for providing wire rope sling in the head stock or sole bar for deeply fallen down coaches in to the water, the assistance of JCB machine may be taken for lifting one end of coach by lifting nearest head stock and thus, passage to be created for crane hooks for final lifting.


E- Restoration Plan :


Before starting the rigging of the crane check


Required radius


2 Axle blocking – Carry out Axle Blocking ( for the method of Axle Blocking see P- )

3 Boom erection – for things to ensure before boom erection see P-

4 Do the propping of the crane – detailed instructions given at P-

5 Select the counterweight as per load chart - detailed instructions given at P-

6 Operation can now be started following Operating Precautions given at P- and General Precautions for handling of loads given at P- .

7 Buffer to buffer length of a coach is approximately 22 & 24 M for ICF and LHB respectively. So extra precaution is needed otherwise the load may hit with the crane body or jib.

8 Capsized stocks that cannot be salvaged may be toppled down. In such cases, hooks should be fixed in such a way that after the load is toppled down, the hooks should disengage easily. Toppling hooks (‘L’ type instead of ‘S’ type

10 But toppling should not be done when there is a deep ditch or trench adjacent to the track as there will be tendency to topple suddenly that may cause jerking in the crane and may cause toppling of the crane also.

11 Before lifting of a coach, it should be ensured that the center pivot cotter, BSS hanger and the safety strap of axle box guide arrangement are in good condition. Otherwise the bogie should be secured with the chassis with chains.


12 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.

13 Lifting beams (SWL) should preferably be used to tackle coaching stocks to prevent damage of the body whenever coach is to be salvaged.

14 While a load is lifted it should be guided by attaching ropes on diagonally opposite sides held by staff cautiously, to avoid pendulum like motion.

Double Line Section

15 In double line sections, it is better to work the crane from the adjacent line to which lies the accident coach.

Rope attached for guiding the load


16 Hence it is easier to handle coach lying beside the track.

17 After the coach is lifted, it must be guided by attaching ropes to make it perpendicular to the jib otherwise it may hit with the jib or crane body.

18 In case a coach lying on the same track on which crane is working, the coach should be first brought perpendicular to the jib by tackling one end keeping other end on the ground. Thereafter in this condition it can be handled without a danger to the crane body and the jib. (Or as explained in 20 below).

19 For the reasons mentioned above, a coach should not be re-railed on the same track on which 140 T crane is working in double line section.


20 Re-railing of coaches in Single Line Section( Salvageable Coaches)

1

2

In single line section the trolley of the coach in farther side of the crane may be re-railed, keeping the coach body still diagonal to the crane jib.

3

This end will be re-railed first.

Now the trolley near to the crane will be tackled and re-railed in such a manner that coach will move far from the crane rolling on the first re-railed trolley to avoid hitting with crane.

4

Now this end will be re-railed, pushing the coach farther on the previously re railed trolley.

Crane is moved to

tackle farther end.

Coach is

positioned

to leave

space for

crane

movement.


21 Re railing of coaches in Single Line Section( Capsized/Damaged Coaches)

In case the capsized or damaged coach is lying on the track, it should be placed perpendicular or diagonal to the jib and then thrown off the track.

22 Re railing Salvageable LHB coaches on same track

It is advisable to use two cranes in case an LHB coach is to be re-railed on the same track.

23 Use of Rail skates

Rail skates can be used in case of axle box bearing damage or for any other reason due to which the wheel cannot travel.


EMU/MEMU/DEMU

1. Restoration of derailed EMU/MEMU/DEMU.

A- Preparation 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.


Full propping to be done and 04 staff on each prop should be deputed.

03 Suitable packing and its size Wooden packing of size 4’x2’x14” and 6’x1’x12”


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




09 Maximum working radius 13 meters by main hook.

10 Place where sling to be inserted

(under frame) Solbar



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




18 Photography/Videography Videography of all critical operations and clues collection.

19 Average timing for restoration of each coach







Required radius







7 These stocks are fitted with Shaku Couplers except the Power/Motor cars which are provided with draw hook. This may be kept in mind that the Shaku Couplers cannot be coupled with CBC or Screw Coupling of a locomotive. But in case it is required to uncouple from Shaku coupler or the coupler got damaged, it should be hauled with restricted speed with some suitable arrangement of coupling.

8 Also, once Shaku Coupler is uncoupled it requires level and straight track to couple again. However wooden packings may be placed between the saku coupler body and the coach body (the plate supporting it ) before opening, this will prevent drooping of either end and maintain the alignment of two ends.

Shaku coupler in coupled condition


9 Apart from above these stocks are similar to Coaches. Hence for the methods of handling these stocks in double/single line sections in different conditions see the chapter ‘COACHES’.


WAGONS

Restoration of Loaded BCN/BOX-N by 140 Te. Crane

A. Preparation Chart :

S.N. Item/Status Action 01 OHE Working line OHE to be slewed. OHE of adjacent

line to be made dead.


Full propping to be ensured and 04 staff on each prop should be deputed.

03 Suitable packing and its size Wooden packing of size 4’x2’x14”/ 6’x1’x12”


05 Wire rope sling and SWL 70 Te. 6 mtrs sling (two leg) and 140 Te. SWL.




09 Maximum working radius 8 meters by main hook and 19 mtrs. By Aux. hook.

10 Place, where sling to be inserted In the center of wagon, under solbar, taking support of cross bar

11 Position of wagon trolley Lashing chain to be used for securing with structure.




15 Observation for suitable place Analyze suitable place for 360º slewing and placing of wagons.

16 Arrangement of rope for wagon adjustment





19 Average timing for restoration (per wagon)







Required radius







7 While handling accident wagons, not the length but it is the tonnage in case of loaded stock that is the critical factor.

8 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.

9 During lifting of any wagon stock fitted with CASNUB bogie, it should be ensured that center pivot U shackle lock is intact and side frame key of all wheels are intact otherwise bogie and wheels must be secured with chains to avoid detaching from wagons.


10 The load should be guided by attaching ropes on two diagonal ends of the load held by staffs.

11 Typical situation when one trolley is on the track and other trolley off the track, the stock can be handled with the help of CBC because that would be the closest point.

12 BOX N / BCN or other such wagons These stocks can be lifted by attaching slings with the main hook of the

crane.

13 BOBRN in Capsized condition

This wagon has no sole bar to facilitate hooking and hence center sill can be used for fixing the hooks.

14 BOX N HL

For stainless steel wagons like BOX N HL, for body cutting, plasma cutting machine or abrasive cutter should be used.

15 BOBYN & BOBRN wagons

In case CBC has got damaged, hooks can be fixed to the draft gear housing.

Center sill


16 BLC

Containers and BLC wagons should be lifted separately as it is very difficult to tackle it together.

17 BLC rakes are formed with modules of 5 wagons. In accidents involving BLC rake, the modules not affected should be detached from CBC. After that if possible draw bar pin may be opened to segregate the wagons in a module otherwise the draw bar may be gas cut. In this case it may be noted that moving of salvageable wagons will be difficult because there is no CBC. This can be hauled with restricted speed with some suitable arrangement of coupling.

18 BTPGLN ( LPG wagons) Concentration of gas in the area should be checked first by gas detector

before starting of the restoration work for safety. The representatives of oil companies should be called for supervision of

evacuation of gas and other safety measures.


C- Procedure in Practice : 01. Energize the crane, attach counter weight

and 140 Te. Cap. SWL with 140 Te. 6 meters long wire rope slings.

02. Move the crane and stable near the job. Ensure that center of the wagon is not more than 8 meters of radius.

03. Ensure full propping of crane with suitable size wooden packings on all 6 props.

04. Insert 70 Te. 6 meters “two leg” 02 wire rope sling in the solbar near cross bar

support in the centre of the wagon and lift slowly just above the ground.

05. Observe behavior of props and establish propping again, keeping load on

ground.

06. Lift the job again and place the wagon any where at 360º within 8 meters radius.

07. If the cant is persisting on the track, keep close watch over sinking of the

packings and lifting of crane wheels. One person should be deputed with

megaphone for safety.

(4) Restoration of damaged BCN/BOX N by 140 Te. Crane 1. If the loaded vehicle is damaged and considered beyond the limit of safe lifting,

advise commercial staff/officers for unloading. 2. After unloading of the vehicle, insert Aux hook

and remove the vehicle. 3. If it is not possible to unload the vehicle,

permission of competent authority must be obtained for toppling of the wagon.

4. After getting permission, inert 30T, 5 Mtrs

wire rope slings in the one side solbar and lift the same for toppling activities.

5. Again insert slings on one side solbar of the wagon taking support of cross member

and continue slewing and derricking as per requirement till unloading of the wagon. 6. Further insert 25 Te capacity hook in the supporting channel of center seal near

center pivot and lift accordingly. The wagon in this operation will get toppled completely.

7. Now, turned wagon can be kept anywhere at 360° within 18 meters radius. 8. Remember that trolleys should not be kept in the coupled position during toppling

operation. Both trolleys should be removed in the beginning.


Basic Assessment in Handling the Wagons:

The critical factor in handling loaded wagons is not the length but its tonnage.

• Loaded wagons should be unloaded first before throwing off track as it

may not be safe to lift loaded wagons or due to beyond reach of the

crane.

• During lifting of any wagon stock fitted with CASNUB bogie, it should be

ensured that centre pivot U-shackle lock is intact and side frame key of all

wheels are intact otherwise bogie and wheels must be secured with chains

to avoid detaching of the bogie from wagon during lifting.

• Empty wagon to be thrown off track should be guided by attaching ropes

on two diagonal ends held by staffs and then safely lowered by the side of

the track in case sufficient space not available.

• In a situation when one trolley is on the track and other trolley is off the

track, the stock can be handled with the help of CBC being the closest

point.

• In case CBC has got damaged, hooks can be fixed to the draft gear

housing.

• In case empty wagons are to be re-railed on track, they should be lifted

by attaching slings and draw bar tackles with the main hook of the crane.

• In case the empty wagon is to be thrown off track to side where there is a

deep ditch/trench, crane hooks should be fixed in such a way that after

the load is toppled down, the hooks get disengaged easily.


BOBRN in Capsized condition

• This wagon has no sole bar to facilitate hooking and hence centre sill can be used for fixing the hooks.

• In case the wagon has to be thrown off track, the wagon should be hold with the centre sill in overturned condition and lowered guided by attaching ropes diagonally.

BOX N HL Wagon

For stainless steel wagons like BOXN HL, for body cutting, plasma cutting machine or abrasive cutter should be used.


BLC Wagon

Containers and BLC wagons should be lifted separately as it is very difficult to tackle all the 5 units together.

BTPLGN ( LPG wagons) • Concentration of gas in the area should be checked first by gas detector

before starting of the restoration work for safety.

• The representatives of oil companies should be called for supervision of

evacuation of gas and other safety measures.


Restoration of derailed BTPN (Oil tank wagons) involved in fire.

Preparation Chart :

S.N. Item/Status Action

01. OHE Working line OHE to be slewed. OHE of adjacent line to be made dead.

02. Requirement of fire brigade Heavy duty fire brigade is called

02. Condition of props and availability of staff


03. Suitable packing and its size Wooden packing of size 4’x10”x6”and other suitable sizes.

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

05. Suitable wire rope sling 30 Te. 5 mtrs sling

06. Suitable chain sling as per requirement

25 Te. Capacity chain sling

07. Position of Cant on 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 and 19 mtrs. By Aux. hook.

10. Place, where sling to be inserted

Under frame barrel bracket

11. Position of wagon trolley Lashing chains to be used for securing with structure.

12. Lighting arrangement To be arranged during night/dark.

13. Observation for suitable place Analyze suitable place for 360º slewing and placing of wagons.

14. Arrangement of rope for tank wagon adjustment

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

15. Availability of Megaphone/ Communication


16. Photography/Vide0ography Videography of all critical operations and clues collections.

17. Average per oil tank timing for restoration


Generally, it is observed that after derailment of oil tank wagons, they catch fire, which in turn results internal explosions. In this situation, it is not possible to rerail the BTPN by MFD/LUKAS equipments because machine and breakdown staff may 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 Te 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 considered dangerous for running on the track.


2. Restoration of derailed Guard Brake van by 140 Te. Crane.

Preparation Chart:


adjacent line to be made dead.





05 Wire rope sling and SWL Only 30 Te. 5 Mtrs wire rope sling

06 Chain sling 25 Te. Capacity chain sling



09 Maximum working radius 11 meters by main hook and 19 mtrs. By Aux. hook.

10 Place, where sling to be inserted Barrel bracket/ Body bracket



13 Position of wagon trolley Lashing chain to be used for securing with structure.


15 Observation for suitable place Analyze suitable place for 360º slewing and placing of wagons.

16 Arrangement of rope for brake van adjustment

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




19 Average timing for per wagon restoration


01. Energize the crane, attach counter weight, move towards derailed

vehicle, establish the crane and ensure full propping. 02. For BVZI guard brake van : use 30 Te. 5 mtrs wire rope sling and insert

hook in the barrel bracket/body bracket. 03. Initiate lifting operation and place wagon any where at 360º within 11

meters radius. 04. For light weight brake van, use Aux. Hook with 25 Te. Chain sling, lift the job

and place within the range of 18 meters radius.


Restoration of Hot Axle/Cold Axle broken Wagons

Preparation Chart :

S.N. Item/Status Action 01 MFD/LUKAS power pack and 120/60

Te. Cap. Jacks with control table and hoses

Two jacks of 120/60 Te. Cap. and displacing jacks.

02 Suitable packing and its size Wooden packing of size 3’x1’x6”/ 3’x2’x6” and 04 iron plates.

03 Availability of Lashing chains and bolts

03 Lashing chains to be used for securing with structure.


05 Rail skates trolley 02 trolleys with 36/40 mm spanner

06 Availability of MFD tool box Should be available at site



09 Observation for suitable place Analyze suitable place for jack operation.




12 Average per wagon timing for restoration


If the Axle of any wagon has broken from axle box side due to hot axle, or cold axle breakage, in this situation, shifting of wagon takes place and sometimes derails. 1. These wagons are normally re-railed by

MFD/LUKAS equipment, and brought in the alignment on the track.

2. Rail Skates are inserted under the wheels of broken axle.

3. 32 mm bolt of the skate is tightened to establish the wheel completely in the container.


4. Each skate has two wheels, which should be observed for proper sitting on the rail

before moving the wagon.

5. Move the wagon slowly without jerk, attaching with the breakdown train or with

assisting loco, not more than 5 Kmph speed.

6. Wagon in this position can travel 10 to 12 KMs at a stretch for next block station

without changing the wheels.

7. This modification facilitates reduction in restoration timings and avoids toppling of such

axle broken wagons at accident sites.

8. But in case of non functioning of Rail Skate or defect in Rail Skate, the wagon should

be toppled by 140T crane after unloading by commercial deptt.


FOB WORK

Observation of site and load conditions



Required radius





5 Select the counter weight as per load chart - detailed instructions given at P-


7 The slings should be kept tight while erection of FOBs i.e. the load should not be released before final assembly because it is required to be manoeuvred for assembly. Also once the hook has dis-engaged it is difficult to engage it again at height.

c

8 Propping over sewage trench should be avoided, height of water hydrant at Stn. should also be considered before slewing of the crane.

9 When working in a situation where there is platform on the one side of the

crane the accessibility of the propping lever of that side should be ensured.


1. The slings should be kept tight while erection of FOBs i.e. the load should not be released before final assembly because it is required to be manoeuvred for assembly. Instead of wire rope, Chain sling is generally used.

2. Also once the hook is disengaged it is difficult to engage it again at height. 3. When working in a situation where there is platform on the one side of the

crane the accessibility of the propping lever of that side should be ensured. 4. Role of Manila Rope is very important in this type of activity.


LAUNCHING OF GIRDERS

A-Preparation Chart:


adjacent line to be made dead.





05 Wire rope sling and SWL 30 Te. 5 Mtrs or 50 T wire rope sling be used

06 Chain sling 25 Te. Capacity chain sling be used



09 Maximum working radius 11 meters by main hook and 19 mtrs. By Aux. hook as per load chart.

10 Place, where sling to be inserted As per Engineering deptt.


12 Availability of wooden wedges 04 wooden wedges for crane

13 Position of Girders Lashing chain to be used for securing with structure, Use Manila rope diagonally to arrest hanging load.


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

placing of Girders.

16 Arrangement of rope for Girder adjustment

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




19 Average timing for per Girder launching

Average – minutes






Required radius







7 Joint inspection between the involved departments viz. Mechanical, Engineering , S&T and TRD should be done as per Railway Board’s instruction for site verification / obstruction if any / location of propping base for crane / assessment of time etc. Prior permission from HQ to be obtained by presenting copy of DCN notice along with joint note.

8 Propping base should be prepared before ordering of crane, also strength of propping base should be adjudged properly before starting the work. It may be required to make temporary propping base with engineering cribs etc.

9 Props by temporary staging should be visible during crane operation.

10 Before commencement of the work, a certificate should be obtained from

Engineer In-charge or SSE/P-Way/Works that the Girder is safe for movement of the crane and temporary propping base is safe for propping.

11 The Steel Girder should be tackled with the help of suitable wire rope slings by wrapping around the main boom of the Girder.


12 Single Crane

If one crane is working, the launching / replacing of Girders should be started from the farthest end from the crane in case multiple spans are to be tackled.

13 Double Crane each from one direction Incase 2 cranes are working areas of 2 cranes may be earmarked during joint

inspection and both cranes will start working on furthest Girder from it in its area.

For safety, it may be ensured that 2 cranes are not working on adjacent spans.

14 Heavier / Longer Girders

2 cranes should be used for launching of heavier and longer girders. The cranes should be worked in prop condition over temporary staging made from the river bed.

Here, for replacing all three

girders, work should be started

from girder no.3.

1

3

2


Temporary staging for prop base



1. Joint inspection between the involved departments viz. Mechanical, Engineering

, S&T and TRD should be done as per Railway Board’s instruction for site

verification / obstruction if any / location of propping base for crane / assessment

of time etc.

2. Propping base should be prepared before ordering of crane, also strength of

propping base should be adjudged properly before starting the work. It may be

required to make temporary propping base with engineering cribs etc.

3. Props by temporary staging should be visible during crane operation

4. Before commencement of the work, a certificate should be obtained from

Engineer In-charge or SSE/P-Way/Works that the Girder is safe for movement of

the crane and temporary propping base is safe for propping.

5. The Steel Girder should be tackled with the help of suitable wire rope slings by

wrapping around the main boom of the Girder


TRACK WITH SUPER ELEVATION

1 Extreme caution should be taken while working in super elevated track.

2 After propping the crane leveling of the crane should be doubly ensured.

3 The crane should slew with load towards cant rail side i.e. higher ground level

side preferably as a measure of safety to the crane.

4 While de-rigging the crane, If super elevation is more and axles are floating

too much above the track, while lowering the props derailment of crane trolley

may occur. Hence it is better to break the axle blocking in such cases.

NOTE: When the crane works free-on-wheels in elevated curves of 40 mm or higher, the attached loads must be secured against pendulous swinging by means of the recovery winch or an auxiliary rope designed for the loading - as otherwise the standing stability of the crane is endangered - Danger of accidents !


NOTE: When it is required to be work on Free On Rail, It is only permitted when the 3rd counter weight (8t) is lying on the under carriage (frame mechanism is folded in!) in opposite direction to working position – otherwise the crane stability will be reduced – Danger of accidents!


TUNNELS


1 Match truck should be reversed before reaching the site, as it cannot be reversed in Cutting sections before the tunnels.

2 Jib cannot be raised inside tunnels. However loads at the mouth of tunnels can be handled cautiously. But load inside are required to be pulled outside.

3 Coupling should be removed before pulling the loads.

4 For petty loads and loads without infringements, winch can be used.

5 If load cannot be pulled, site can be cleared by cutting it in parts and then

pulling out the smaller parts. 6 No staff should remain inside tunnel while pulling of the load is in progress.

7 Gas cutting should be avoided in tunnels as smoke will not escape easily.


RESTORATION ON BRIDGES




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.



4 Do the propping of the crane – detailed instructions given at P- .On bridges temporary

staging would be necessary for propping.

5 Select the counter weight as per load chart - detailed instructions given at P-

6 Operation can now be started following Operating Precautions given at P- and General

Precautions for handling of loads given at P- .

7 Since lifting capacity of the crane on free on wheel is very limited accident

involved stock should be tackled by 140T crane in prop condition for that

temporary staging for propping should be made.

8 While working on Bridges in high current, safety precaution like life jacket etc.

must be taken by staff working at vulnerable locations.


RESCUE PLATFORM

1 Collapsible type rescue platform can be used for rescue of entrapped passenger. 25 T chain sling should be used for lifting of Rescue platform by 140T crane.

ROAD MOBILE CRANE

1 In case, the accident involved stock is not possible to be tackled safely by the crane, use of Road Mobile Equipment may be done to support the crane.


PREPARATION BEFORE LEAVING THE SHED ( 140T Gottwald New & Old Crane)

1 Whenever possible, crane shall be moved to accident site with jib trailing. Required marshalling at crane shed or any en route station can be done. This will help to avoid marshalling of MT after reaching accident site. At sites with embankment, cutting or other such conditions this may be very difficult.

2 Travel gear should be in disengaged position. Crane Driver may further ensure this by putting the crane in self propulsion and noting that it is not moving.

3 Crane Brake should be released.

Green indication is there for brake released.

4 Do not pull the crane when brakes are applied.

5 Boom should be locked in trestle.

Do not leave the boom unlock in trestle.

6 All side-mounted platforms should be lowered and outriggers should be folded. Ensure the mechanical locks are in locking position.

7 Additional Mechanical lock provided for out riggers should also be locked.

8 Do not leave the side mounted platform & outriggers in unlocked position.

9 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator water level and Oil level

in all the gearboxes. 10 Do not run engine in low oil level.

11

Release the parking Brake. See the green indication to ensure.

12 Do not haul with parking brake.

Locking lever

In Unlocked condition

In locked condition

Lock


PREPARATION BEFORE LEAVING THE SHED (140T Cowan Sheldon Old crane)

1 Whenever possible, crane shall be moved to accident site with jib trailing. Required necessary marshalling at crane shed or any en route station can be done. This will help to avoid marshalling of MT after reaching accident site. At sites with embankment, cutting or other such conditions this may be very difficult.

2 Travel gear should be in disengaged position. Crane Driver may further ensure this by putting the crane in self propulsion and noting that it is not moving.

3 Crane Brake should be released.


5 All Draw beam should be retracted.

Ensure the mechanical locks are in locking position.

6 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator water level, and grease in grease cups of both Relieving Bogies and Oil level in all the gearboxes.

7 Do not run engine in low oil level.


PREPARATION BEFORE LEAVING THE SHED (140T Cowan Sheldon New Crane)

1 Whenever possible, crane shall be moved to accident site with jib trailing. Required necessary marshalling at crane shed or any en route station can be done. This will help to avoid marshalling of MT after reaching accident site. At sites with embankment, cutting or other such conditions this may be very difficult.

2 Travel gear should be in disengaged position. Crane Driver may further ensure this by putting the crane in self propulsion and ensuring that it is not moving.

3 Crane Service & Parking Brakes should be released.

Make sure that brake blocks are released from wheels after releasing brakes.


5 All outriggers should be folded. Ensure the mechanical lock pins are in locked

position. 6 Additional Mechanical lock provided for out riggers should also be locked.

7 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator water level and Oil level

in all the gearboxes. 8 Do not run engine in low oil level.

9

Release the parking Brake. See the green indication to ensure.

10 Do not haul with parking brake applied.


AXLE BLOCKING (Gottwald Crane)

1 Check for Axle blocking pressure after giving line to undercarriage by pre selector switch.

2 Ensure engagement of the travelling gear.

3 Ensure application of brake confirmed by the “RED” indication.

4 Do not start crane operation without proper brake.

AXLE BLOCKING (Cowan Sheldon Old Crane)

1 Ensure all Blocking Screws are locked onto the springs.

2 Unload both Relieving Bogies.

3 Ensure engagement of the travelling gear.

4 Ensure application of brake.


AXLE BLOCKING (Cowan Sheldon New Crane)

1 Ensure Axle blocking before raising the Jib from Match Truck

2 Engage blocking pads before

raising the Jib

3 Ensure engagement of the travelling gear if required.

4 Ensure application of brake confirmed by the “RED” indication.


Lower Axle Blocking jacks to lock top of the spring. Engage Blocking Pads


BOOM ERECTION ( Gottwald New & Old Crane)

1 Before energizing 140T Crane on electrified section for operations, ensure that OHE has been made dead/slewed and secured and power block has been taken under written memo.

2 Secure rear section lock while rear section is fully lifted.

3 Do not erect boom without securing rear T-locks.

4 Check for rear section fully lifted by giving line to rear section Gallows through

pre selector switch (for Old Design). 5 While making vertical movement of

CWT Cylinder, a strict vigil is required since malfunctioning of ‘Proximity Switch’ may cause damage to rear end plate below the pulleys and CWT cylinder piston.

6 Do not erect boom without upper and lower legs junction locks of ‘A’ frame.

7

Depute 2 staff to go up and watch the revving and un revving of the derrick wire rope.

Do not run crane without watching of rope revving.

8

Derrick “IN” till boom heel sits on the PINs.

Do not stop boom Derrick “IN” until boom heel sits on pin.

9

Remove boom lock from the jib trestle.

Raise boom cautiously.

New Design Old Design

Lock


BOOM ERECTION ( Cowans Sheldon Old Crane)


2 While raising "A" frame- Keep Derrick Wire Ropes in reasonably slack condition

3 Ensure all Blocking Screws are locked onto the springs.

4 Unload both Relieving Bogies.

5 Remove Slew Lock Pin before

slewing.


6

With Derrick “IN” operation, Raise boom cautiously.


BOOM ERECTION ( Cowan Sheldon New Crane)


2 Check for “A” frame fully lifted.

3 Depute 01 staff to go up and watch the revving and

un revving of the derrick & Main Hoist wire rope.

Do not run crane without watching of rope revving.

4 Remove Slew Lock Pin before slewing.

5 Slew so that jib is free in trestle before lifting.

With Derrick “IN” operation, Raise boom cautiously.


PROPPING THE CRANE (Gottwald Crane)

1 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.

Depute one staff on each prop to observe. For marshy land,

sand bags can be used for making base for propping. Wooden

packing can also be provided under the out rigger arms leaving

some gap.

2 Do not prop the crane on the unstable ground.

Wooden packing provided should not be in contact with the arm body. 3 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.

4 Check the level of the crane by spirit level.

5 Use Rail Clips as an additional safety. Rail clips as were used in MG

Breakdown cranes are better since the sleeve prevent it from opening.

Rail clip MG

BD Crane

Rail clip BG BD Crane


PROPPING THE CRANE (Cowans Sheldon Old Crane)

1 Lock the Draw-beams in extended position. Packings should be in sound condition and placed alternately perpendicular and parallel to the track. Check condition of packings for indication of sinking.

2 When working in propped condition- Relieve Laminated Springs of weight of the crane.

3 Depute one staff on each prop to observe.

4 Do not prop the crane on the unstable ground.

Wooden packing provided should not be in contact with the arm body. 5 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.

6 Check the level of the crane by spirit level.

7 Use Rail Clips as an additional safety.


PROPPING THE CRANE (Cowans Sheldon New Crane)

1 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.

2 Ensure that Parabolic Springs are relieved of the weight of the crane and lock the Outriggers in extended position.

3 Depute one staff on each prop to observe.

4 Check the level of the crane by spirit level. Super elevation of the crane to be

corrected with props. 5 Use Rail Clips as an additional safety. Rail clips as were used in MG

Breakdown cranes are better since the sleeve prevent it from opening.

Rail clip MG

BD Crane

Rail clip BG

BD Crane


COUNTER WEIGHT (Gottwald Crane)

1 Select the total counter weight as per load chart for the load to be lifted.

2

Switch on boom bridging key.

Only used for keeping CWT on chassis, if it is not brought back in the operation, SLI safety will be bypassed.

Do not leave bridging key ON after setting up of CWT.

3 Switch ON key switch, which bridges safe load

indicator.

The crane should not be allowed to slew in this condition.

4 Pick up CWT and ensure locking of all.

5

Select the proper prop position by selector switch as required by the load chart.

6 Switch off boom bridging key. Switch off the key switch, which bridges safe load indicator.

7 Load chart should not be violated.

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.

8

After Rear operation or axle blocking operation pre-selector switch for oil transmission should be brought to “Neutral” position. .

Do not leave pre-selector switch in ON position.

9 Ensure the CWT switch is in proper position.

New Design Old Design


COUNTER WEIGHT (Cowans Sheldon Old Crane)

1 Remove slew lock pin.

2 Slew superstructure through 180 degree in line with track.

3 Slide over retaining / locking plate.

4 Slacken off nut on hanger bolts and swing hanger bolts clear of carriage.

5 Jack counter weight up to superstructure, using hydraulic jacks controlled from counter weight

jack control valve situated in the right hand slide of the carriage, For operation of this valve.

6 Slide over retaining latch.

7 Swing hanger bolts into position and tighten nuts using Tommy bar.

8 Re locate hanger bolt latches.

9 Retract counter weight jacks and ensure they are in the stowed position on the carriage.

10 Select the total counterweight as per load chart for the load to be lifted.

Method of Heavy Ballast weight couple

11 Fit counter weight to superstructure.

12 Release locking straps retaining heavy ballast to the ballast wagon.

13 Traverse crane to approach the ballast wagon.

14 Lift ballast with main hoist block from ballast wagon and place on carriage, locking

the ballast weight on the appropriate guide pins.

15 Crane can be slewed at 180⁰ on level track only. If there is a CANT in track i.e. difference between the track lines level from 13 mm to 140 mm, then before slewing the crane it should be properly propped and clamped with the track as the crane is unstable across track. SLI should be properly monitored during slewing.

16 Jack up the ballast weight to the desired height for engaging the support beams. This being control valve situated in the right hand side of the carriage. For operation of this valve.

17 Extend ballast support beams through ballast weight.

18 Lower ballast on to support beams ensuring the ballast weight locating pins are

engaged in the support beam.


COUNTER WEIGHT (Cowans Sheldon New Crane)

1 Select the total counterweight as per load chart for the load to be lifted.

2 Follow correct sequence of operations for attaching counterweights. First unlock,

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

3 Ensure counterweight (CWT) is correctly locked.

4 Load chart should not be violated.

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.

5 Ensure the CWT switch is in proper position.


OPERATING PRECAUTIONS (Gottwald Crane)

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

2 Neither lift Match Truck nor slew in Free on Rail condition.

3 Avoid jerk during operation. Pendulum motion of load is dangerous.

4 Don’t pull the load diagonally.

5 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. 6 Take care of wind forces on the boom as it is dangerous.

7 Do not operate crane in high wind force.

8 Do watch the props for any sign of caving by deputing one staff for each prop.

He should also watch carefully the rear wheels for any sign of lifting from the rail level.

9 Proper signalling is to be given to the crane driver. Driver should also cross- check the signal by ground staff with condition of load.

10 Do not give multi command to driver.

11 Emergency lower button (Rapid motion switch) should be operated only in

case of emergency and the operation should not be part of the normal working cycle.

12 Only crane in-charge should communicate with the crane driver. When required the senior most mechanical officer should give instruction to the crane in-charge.

13 The SLI does not relieve the crane user from his responsibility to thoroughly determine the weight of the load to be lifted and check the admissibility of the operation as per load chart.


OPERATING PRECAUTIONS (Cowans Sheldon Old Crane)


2 Neither lift Match Truck and nor slew in Free on Rail condition.









10 Proper signalling is to be given to the crane driver. Driver should also cross- check the signal by ground staff with condition of load.


12 Emergency lower button (Rapid motion switch) should be operated only in

case of emergency and the operation should not be part of the normal working cycle.




OPERATING PRECAUTIONS (Cowans Sheldon New Crane)

1 Ensure Safe Load Indicator (SLI) is in working condition. Set Safe Load Indicator (SLI) to Main Hoist (M.H.) or Auxiliary Hoist (A.H.) position as per requirement.


3 Neither lift Match Truck nor slew in Free on Rail condition.









11 Proper signalling is to be given to the crane driver. Driver should also cross- check the signal by ground supervisor with condition of load.



13 Emergency lower button (Rapid motion switch) should be operated only in case of emergency and the operation should not be part of the normal working cycle.




GENERAL PRECAUTIONS FOR HANDLING OF LOADS

1 Sometimes, loads are required to be toppled down. In such cases, hooks should be fixed in such a way that after the load is topped down, the hooks should disengage easily. Particularly while handling coaches, experience has shown that the hooks don’t disengage from load easily if fixed directly with the sole bar.

2 The toppling should be avoided where there is a deep ditch or trench adjacent to the track as there will be tendency to topple suddenly that may cause jerking in the crane or even toppling.

3 While a load is being lifted it should be guided by attaching ropes on diagonally opposite sides held by staff cautiously, to avoid pendulum like motion.

4 The load should be lifted slowly just above the ground level and held for some time to avoid swinging.

5 For easy fixing of sling hooks to a load, ropes can be used to bring the hooks to each side of the load.

6 Diagonal wheels of the crane on opposite sides should be observed for any sign of lifting.

7 During restoration, load should not be dragged except with the hauling winch. However, if it is extremely necessary, only light load can be pulled, keeping the crane jib “inline”.

8 Gas cutting should not be done in inflammable objects like oil tankers, fuel oil tank of locomotives etc.

Also any fire should be doused off completely before handling with the crane.

Rope attached for guiding the load


PREPARING THE CRANE BEFORE LEAVING FOR SHED (GOTTWALD)

1 Leave 8T cwt on the chassis in the direction of match truck for New Design Gotwald crane. Leave 5.2 T cwt on the chassis in the direction of match truck for Old Design Gottwald crane.

2 Unload CWT On the match Truck.

3 Boom out to 17 M radius for new design and 16 M for old design crane. For

this switch “ON” boom over bridge key (SLI By Pass Key). 4 Switch “ON” computer over bridge key. (SLI By Pass Key).

5 Boom down until both hooks lower into match truck well and boom rest pin

matches with the recess in trestle. 6 Boom down until boom slides fully into the boom rest to the lock position.

Operate the boom root cylinder in new design cranes. At this point, lock the boom in the trestle.

7 Unlock rear section with the help of lever. Lower rear section up to its last position (for New Design).

8 Derrick out until the ropes are slack over the operator’s cab. Slackness will help to negotiate the track curve.

9 Release axle blocking. Shift pre-selector switch in Driver Cab in Neutral position & secure Propp with PIN.

10 Brake hoses should be connected as per the requirement. Angle cocks should be opened only after release of Crane air brake.

Release parking brake in the last when the crane is going to be formed in train order.


PREPARING THE CRANE BEFORE LEAVING FOR SHED (COWANS SHELDON OLD)

1 Prior to coupling back relieving bogies, clean and regrease the Crane Carriage end castings and Coupling Pins on both ends

2 After coupling back the Relieving Bogies, top up grease cups (Spring Feed Lubricators) of both Relieving Bogies.

3 Lower the A frame keeping Derrick Wire Rope in a reasonably tight condition.

4 For "In-train" running -

Load the Relieving Bogies until Centre Casting Locking Pin slides into position and then release the Jack completely.

5 Remove 32 T CW and place at nominated location on Ballast Wagon.


6 Remove detachable Counterweight ( 12 T )and place at nominated location on Crane Carriage.

7 Load the Crane Springs by unscrewing the Blocking Screws. Ensure sufficient gap between top of Spring Buckle and screw for free movement of springs.

8 Disengage traveling Clutches.

9 Check that Draw Beam Jacks are fully retracted and locked.

10 Ensure that the coupling hoses between the carriage and relieving bogies (both end) are connected properly. Also ensure the same between match wagon and ballast truck of the crane.


PREPARING THE CRANE BEFORE LEAVING FOR SHED (COWANS SHELDON NEW)

1 For "In-train" running - Remove Counter Weights and place at nominated location on Match Truck.

2 Unload the Crane Springs by retracting Axle Blocking Jacks and ensure sufficient gap between top of Spring Buckle and Jack. Ensure blocking pads are removed/relieved and secured.

3 Disengage traveling Clutches.

4 Ensure Outrigger Jacks and Outriggers are retracted fully and locked in position.

5 Ensure that Slew Lock Pin is in locked

Position

6 Boom down until both hooks lower into match truck well and boom rest pin matches with the recess in trestle.

7 Derrick out until the ropes are slack over the operator’s cab. Slackness will help to negotiate the track curve.

8

Ensure that Slew Lock pin is in locked position.

9 Lower the A frame fully.

10 Release axle blocking.

Ensure Crane Service and Parking Brakes are released.


10 Brake hoses should be connected as per the requirement. Angle cocks should be opened only after release of Crane air brake.

Safety of Rescue Workers

1 Staff working in rescue operation must wear safety gears/PPEs (personal protection equipments ) like hand gloves, helmet , safety shoe etc. particularly those handling the hook engagement etc.

2 The staff should not come under a lifted load neither they should handle it manually without attaching rope for guiding.

3 If the adjacent track is given safe for traffic, safety of staff must be ensured from running trains by communicating arrival of trains on megaphone. Always keep Red flag/Red lamp for emergency.

4 While working on Bridges in high current, safety precaution like life jacket etc. must be worn by staff working at vulnerable locations.

5 While working in tunnels, No staff should remain inside tunnel while pulling of the load is in progress.

6 Ensure OHE block before starting rescue operation with crane in electrified section.

7 Safety during gas cutting of any part of a loaded stock.

8 Ropes should be used for guiding the lifted loads.

9 Wooden Wedges should be placed under wheels of a stock to avoid rolling

down. 10 Before slewing, everybody in the vicinity should be alerted.

11 Rescue site should be barricaded with the help of Safety cone and Barrier

tape. 12 Before tackling petroleum wagons, leakage detection for gas should be

carried. 13 First aid kit should be kept ready.


STAFF DEPLOYMENT DIAGRAM

hand book on restoration by 140t break down cranes · 2019. 10. 17. · 12 out rigger 06 04 04 04...

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