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1
Introduction to
140 T Breakdown Crane
2
History
Introduced in ART in place of 75T steam
crane in 1987
2 major variants of Gottwald Design
– Old Design and New Design
Old Design (1986 to 2001)
Imported #12 &manufactured at JMP #10
New Design (1998 to Till date)
Imported #8 &manufactured at JMP #28
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Salient Features
All motions hydraulically controlled except
brake system.
Provision of safe load indicators
Quick response in motions
Maximum Speed 100 KMPH
Loaded Wagon Handling
Slewing by 360° with 140 Ton load at 6M
radius.
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Features of New Design over
Old Two positions of tail radius-5.5m & 6.5m
Five positions of prop
Shear Pin in Auxilliary Hoist
Jib length increased by one meter
External threads in slewing ring
No need of radiator cooling pump
Better design of fuel tank
Direct gear pump is used for hydraulic oil cooling
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CONSTRUCTIONAL FEATURES OF 140T BD CRANE
140T crane is having the following assemblies incorporating hydraulic, pneumatic, electrical and electronic equipment
a) Match Truck
b) Jib
c) Undercarriage
d) Superstructure.
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140T Gottwald Design Crane
Old Design New Design
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Jib
Counter
weight slabs
Rear
frameA FrameBridle
Match Truck
Used to rest jib.
Keep main hoist &
aux. hoist hook assly.
Keep Counterweight
slabs.
Keep lifting tackles.
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Main hook asslyLifting Tackles
Jib
Match Truck
JIB10
Jib/Boom 18.75m long
Minimum Working radius 5.5 meter
Maximum Working radius 18.0 meter
Jib main body is of hollow type and of box shape
Jib is lifted by two gantry ropes one of which is fitted with load sensing devices.
Boom angle sensor is mounted on the fork end inner side
CRANE UNDERCARRIAGE11
Crane undercarriage is pivoted on two bolsters which are mounted on three axle bogie wheels.
A Crane suspension in each bogie consists of four spring packs, each pack with two stacks of coil springs (inner and outer) and two stacks of disc springs diagonally arranged.
The spring suspension arranged can be blocked by axle blocking arrangement.
Crane Bogie
Each Fabricated
bogie with three axle
sets.
Coil & Disc springs
are fitted in
suspension.
Brake disc fitted on
each wheel.
Brake CylinderAxle Blocking
Cylinder
Brake Disc
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Super Structure
Main Engine
NTA855 LBCAux. Engine
Hyd. Tank
Multi Spool Valve
M1
Solenoid Valve
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Cabin
Joy Stick
Engine Control
Unit
Display Board14
Rear Assly with Counterweight Slabs
Old(5T+14T+6T+18T) New(8T+15T+24T)
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Out Rigger Assembly with
Propping Cylinder16
Propping Cylinder Out Rigger
Cylinder
Used during propping the crane
Counter weights in B.D. Cranes:
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Description:The counterweight consists of 3 counterweight slabs :
Counterweight 1 -24 t Counterweight 2- 15 t Counterweight 3 -08 t
The counterweight slabs are combined by means of a connecting mechanism and spacer brackets and secured by means of locking claws onto the crane counterweight support.
DESIGN PARAMETERS OF A BREAKDOWN CRANE
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1. CAPACITY
• Capacity of a breakdown crane is usually expressed intonnes.140T is the capacity of the lifting hook. Loadmoment, defined as the load that can be lifted intonnes multiplied by the radius at which it is lifted.
• A 120T diesel crane which can lift this load at a radius of5 meters only so that its load moment is 600 tonne-metres. A crane with a bigger load moment is thebigger crane and cranes should not be compared bytheir hook load capacities only.
Today, breakdown cranes are classified into three categories:
1. Small: upto 700 tonne-metre load moment
2. Medium: 700 to 1000 tonne-metre load moment
3. Large: above 1000 tonne-metre load moment
By this definition, the 140T crane is a large crane.
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2. NUMBER OF AXLES
• No. of axles has an important bearing on the working of thecrane.
• If the number of axles is kept large to stay within axles loadlimitations, it will result in an unduly long crane that may requireextra time for attaching, detaching, preparation, etc.
• It is also likely to have lower running speeds.
• Cranes with a large number of axles usually have poor riding.
• It is, therefore, desirable to keep the number of axles as low aspossible.
3. TAIL RADIUS
• This is the maximum distance from the center of rotation to thetail of the revolving Superstructure.
• If the tail radius is small the crane will not get obstructed by thetail portion of its super structure while working.
• However, a small tail radius will increase the need for morecounter weights, which may require an additional ballastwagon, and consequently more setting up time.
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4. PROP BASE
• The effective span or area of the supporting base when outriggers are used to increase stability by making contact with
the ground at points farther from the centre line of the crane,
than the normal wheels/track position
• The size of this base is obviously very critical in the design of the
crane.
• A small prop base is advantageous while working in cuttings
while a large base is useful in embankments here the soil cannot
take heavy loads.
• The prop base, therefore, has to be carefully designed.
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5. BASIC CRANE MOTIONS
• Hoisting: The movement of the hook, main or auxiliary, with orwithout load, when being raised or lowered vertically, Jib
remaining stationary.
• Slewing: The movement of the superstructure along with jib
rotating about a vertical axis.
• Derricking: Raising and lowering of Jib in a vertical plane.
• Travelling: This is the self-travel of the crane.
6. WORKING RADIUS
The horizontal distance from the centre line of the lifting hook to
the centre about which the Crane slews.
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BASIC CRANE
MOTIONS
HOISTING
MOTION
DERRICKING
MOTION
SLEWING
MOTION
LONG TRAVEL
MOTION
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7. STABILITY
• Stability is based on the moments about the tippingfulcrum.
• The worst condition usually occurs when the jib is atright angles to the track.
• For a free on rail duty the fulcrum is the rail while forpropped duty, the prop bases are the fulcrum.
• The sum of the moments in front of the fulcrum plus apercentage of the load for stability margin must bebalanced by the sum of the moments behind thefulcrum.
• For this naturally the maximum load at the maximumradius is taken into consideration.
• Both frontal and backward stability are important.
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SPECIFICATIONS140 T CRANE
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SPECIFICATIONS –140 T CRANE
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Operation Control in Cabin
Left Hand Joystick Right Hand Joystick
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Derrick-
OUT
Derrick-
IN
Slew-
LEFT
Slew-
RIGHT
Main
Hoist-
DOWN
Main
Hoist-UP
Aux
Hoist-
UP
Aux
Hoist-
DOWN
TravellingWinching
PILOT
CHAIR
Crane Bogie
Special bogie designed by M/s Gottwald,
Germany.
Comprises of two 3-axled bogies
Fabricated all weld body steel bogie.
2.8 ton (without wheel) ,10.0 ton (with
wheel)
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Mechanical Parts associated
with Crane Working
Main Hoist
Auxilliary Hoist
Prop & Outriggers
Counter Weights
Slewing Ring
Wires and Ropes
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MAIN HOIST 30
AUXILIARY HOIST 31
Props32
Propping
CylinderIn-RiggerOut-
RiggerPropping
Slew Ring
Slewing ring is a large size roller
bearing mounted horizontally
and connecting undercarriage
and superstructure (while
permitting rotations of
Superstructure and under
carriage).
This is specially designed to
accommodate oscillating
moments
The slewing ring permits rotation
of the superstructure on under
carriage and accommodates
tilting movement as well as axial
and radial loads.
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SLI Items
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Load Cell
Fitted with derrick wire rope & senses actual load of main hoist.
Boom Angle Sensor
Fitted with jib &senses working radius of load.
Slew Angle Sensor
Fitted with super structure & senses slew angle.
Shear Pin
Fitted with aux. wire rope & senses actual load of aux. hoist
Load Cell & Boom Angle
Sensor
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Slew Angle Sensor & Shear
Pin
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Display Board 37
Prop
position
CWT
position
Main Hook
positionTail Radius
position
Control
Lever in
Display
Board
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• No prop(Free on Rail)
• No prop Super elevated track (25 mm-140 mm)
• Full Prop at 6 m
• Prop at 5 m
• Half Prop at 2.9 m
Prop Position
• No Cwt
• Half Cwt(24T)
• Full Cwt(47T)
CWT Position
Continued
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•Main Hook
•Auxiliary Hook
Hook Position
•At 5.5 m
•At 6.5 m
Tail Radius Position
Load Charts
Load to be tackled as per Load Chart defined
Radius, Counterweight and tail radius
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Main Hoist- 5.5m Counterweight Radius 42
43Main Hoist-5.5m Counter Weight Radius
44Main Hoist- 6.5m Counter Weight Radius
45Main Hoist- 5.5m Counter Weight Radius
25-140 mm
Super-
elevated
Track
46Auxilliary Hoist- 5.5m &6.5 Counter Weight Radius
47Auxilliary Hoist-5.5m Counter Weight Radius
Propping-
• 5.0m
• 2.9m
48Auxilliary Hoist-5.5m Counterweight Radius
Propping-
• 5.0m
• 2.9m
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RESTORATION
PLAN
Qualification of Crane men
A crane may only be worked/Handled by a
properly Trained/certified crane man.
The using Department is responsible that this
condition is observed.
Before an employee is allowed to work a crane,
he must be examined as to his competency to
do so and be certified.
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52Observation of site and load conditions
Before starting the rigging of the crane, check -
✓ Tonnage and dimension of the load to be lifted
✓ Required radius
✓ Hook height, slewing range, space for travelling
with load if needed etc.
Then tackle in conformity with the load chart and
propping condition.
Rigging
Sequence of operations from starting the crane
Axle Blocking ON/OF
Crane in train formation-Axle Blocking OFF
Self crane motion-Axle Blocking ON
Proper propping
Taking Cwt position as instructed
Jib IN-OUT
Hoist UP-DOWN
Slew LEFT-RIGHT
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Axle Blocking 54
In axle blocking operation
Travel gear engage.
Service Brake ON
Suspension spring in Home position.
Ensure engagement of the travelling gear.
Ensure application of brake
Do not start crane operation without proper brake.
55Permissible ground Force
Permissible Ground Force is to be checked according to the type of surface beneath outrigger pad
Natural ground
Medium Sand
Fine Sand, Firm
Counterweight combination and type of outrigger is determined
PROPPING THE CRANE
Observe site for propping
Nearest to the job
Space for prop
Condition of soil
Propping
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57PROPPING THE CRANE
Set the propping pads properly by strengthening the ground and placing the packing alternatively parallel and perpendicular to the track.
Ballasts base may be provided for strengthening.
For marshy land, sand bags can be used for making base for propping.
Do not prop the crane on the unstable ground.
Wooden packing provided should not be in contact with the arm body.
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In case an entangled load is required to be
handled, always work with full counter-weight and
full prop as the actual load may be much more
than what it may appear to be.
Check the level of the crane by spirit level.
Use Rail Clamps as an additional safety.
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COUNTER WEIGHT
1. Select the total counterweight as per load chart as per Load
2. Follow correct sequence of operations for attaching counterweights.
3. First unlock, then extend the Counterweight cylinder and swing in, then lift and lock. Similarly follow this procedure in reverse order for detaching counterweights.
4. Ensure counterweight (CWT) is correctly locked.
5. Load chart should not be violated.
6. Load estimation should be done properly and to avoid any untoward incident maximum possible safe operation may be adopted like full prop, full CWT etc.
7. Ensure the CWT switch is in proper position.
60OPERATING PRECAUTIONS
Do proper selection of lifting tackles (Chain & Wire rope sling).
Avoid jerk during operation. Pendulum motion of load is dangerous
Don’t pull the load diagonally.
Don’t pull a load which is stacked in the ground unless it is ensured that it will not offer resistance beyond the capability of the Crane.
Take care of wind forces on the boom as it is dangerous. Do not operate crane in high wind force.
Do watch the props for any sign of caving and also watch carefully the rear wheels for any sign of lifting from the rail level.
Only crane in-charge should communicate with the crane driver
Operate the joystick gradually
Do not lift the load to the excessive height from the ground level.
SLEW when load in HANGING condition
During slewing , observe the train movement on the adjacent electrically charged line.
Do not override the SLI during restoration.
Staff Needed for Crane Operation & Maintenance
Supervisor-1
Crane driver-1+1(Stand By)
Mistry -1
Technician-
2(Dsl fitter mech.)
1 Elec.
1 Gen.
Helper -8
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Deployment of Staff during Operation
Driver operates crane
from cabin
Gunner with two staff
for loading/unloading.
One staff at each prop
One staff watches the
wire ropes in drum
Supervisor is the gang
leader.
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Inbuilt Safety Features
Safe Load Indicator – For load, radius and slew angle
Limit Switches – For main hoist, auxiliary hoist and boom derricking
Proximity Switch – For safe working of vertical and horizontal cylinders at rear end
Overspeed switch – To prevent main engine overspeeding
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Safety Measures in Crane
Operation
Before starting the engine, check
Hydraulic oil level
Fuel oil level
Water level in radiator
After starting the engine, check
All pressure gauges
All temperature gauges
SLI System
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Safety Measures
Visual checking of wire ropes
DO NOT bypass SLI system
Feed 4 data in display board
Visual checking of wire rope slings
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Precautions
• Prop as instructed
Select proper Counter weight slabs from Match truck
Crane body level be HORIZONTAL
Wheel just tends to LIFT the track
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Precautions
Select proper wire rope slings.
Staff deployed as instructed
Do not bypass SLI System
SLEW when load in HANGING condition
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Precautions
Only authorisedofficials deliver the instructions to the crane driver.
Operate the joystick gradually
Keep sharp observation over the crane wheels. Lifting of any wheels to be communicated to driver immediately.
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Precautions
Do not lift the load to the excessive height from
the ground level.
Do not override the SLI during restoration.
During slewing, observe the train movement on
the adjacent electrically charged line.
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RESTORATION OF COACHES IN ELECTRIFIED
SECTION BY 140 Te. CRANEPreparation Chart:
S.N Item/Status Action
01 OHE To be slewed towards coach movement and ensure
that OHE of adjacent line has been made dead.
02 Condition of props and
availability of staff
Full propping to be done and 04 staff on each prop
should be deputed.
03 Suitable packing and its size Wooden/synthetic packing of size 4’x2’x14” and
6’x1’x12”
04 Position of SLI duty selector To be kept on No. 1
05 Wire rope Sling and SWL 30 Te. 5 Mtrs sling and 70 Te. SWL as per
requirement
06 Chain sling as per requirement 25 Te. Capacity chain sling
07 Position of Cant of the track Should not be more than 140 mm
08 Position of SLI SLI should be kept in working.
09 Maximum working radius 16 meters by main hook.
10 Place where sling to be inserted (under frame) Solebar
S.
N.
Item/Status Action
11 Gas cutting equipment DA and Oxygen gas with equipment
12 Availability of wooden
wedges
04 wooden wedges
13 Position of coach trolley Lashing chain to be used for securing with
structure.
14 Lighting arrangement To be arranged during dark/night.
15 Observation for suitable place Analyze suitable place for 360º slewing and
placing the coach/damaged trolley.
16 Arrangement of rope for
coach adjustment
02 Nos. in sufficient length at both the ends of
coach.
17 Availability of Megaphone/
Communication
One person should be deputed with equipments
18 Photography/Videography Videography of all critical operations and clues
collection.
19 Average timing for
restoration of each coach
Average – 55 minutes
Restoration of derailed Locomotive in the dead end siding by
140 T Crane.Preparation Chart :
S. Item/Status Action
01 OHE Working line OHE to be slewed. OHE of adjacent line to be madedead.
02 Condition of props and availabilityof staff
All props to be prepared and 04 staff on each prop should bedeputed.
03 Suitable packing and its size Wooden/synthetic packing of size 4’x12”x12”/ 4’x10’x6”
04 No. of cranes required and Positionof SLI duty selector
Two cranes.duty selector to be kept on No. 1
05 Suitable wire rope sling 50/70 Te. 6 mtrs sling (both side eye)
06 Position of Cant on the track Should not be more than 140 mm
07 Position of SLI SLI should be kept in working.
08 Maximum working radius 09 meters by main hook
09 Place, where sling to be inserted All four buffer plates
10 Lighting arrangement To be arranged during night/dark.
11 Observation for suitable place Analyze suitable place for placing of loco.
12 Arrangement of rope for locoadjustment
02 Nos. in sufficient length at both the ends of loco
13 Availability of Megaphone/Communication
One person should be deputed with equipments
14 Photography/Videography Videography of all critical operations and clues collections.
15 Gas cutting equipment DA and Oxygen gas with equipment
16 Availability of wooden wedges 04 wooden wedges
17 Average per loco timing forrestoration
Average – 2.0 hrs. minimum
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Restoration of tilted coach:
1. If the trolleys of coach are intact, secure the
trolleys with lashing chains so that trolleys
remain with the coach structure.
2. But, if the trolleys are damaged or have got
uncoupled, remove damaged trolleys first by
Aux. hook.
3. Bring 140 T crane near the coach, ensure
complete propping and insert hook at this
end.
4. Lift the rear end. of tilted coach, it will get
turned straight by this operation and further
do next exercise for removing the coach.
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Removing Entangled
Coach Ensure full prop & attach Counter
Weight slabs.
Insert Auxilary Hook in the solebarof coach at facing end and lift slowly with slewing actions.
Remove entanglement of coach at another end also in the same manner
If coach trolleys are in good condition, re-rail the coach with the help of Jacks.
Extra precaution needs to be taken for handling entangled load as the actual load will be much more than what it may appear due to entanglement.
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Restoration of Coaches in
non-electrified sections
Restoration can be executed with 140 T
Crane by placing coaches on the
adjacent track:-
Insert Hook in the solebar of rear
end of coach and lift.
Again release the hook, and pick
up the coach in the center by 30 T 5
m wire rope and lift.
Lifting beams (SWL) should preferably
be used to tackle coaching stocks to
prevent damage of the body
whenever coach is to be salvaged
In double line sections, it is better to
work the crane from the adjacent line
to which lies the accident coach
making it easier to lift the coach
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Restoration of Loaded
BCN/BOX-N by 140 T Crane The load should be guided by attaching
ropes on two diagonal ends of the load
held by staffs
These stocks can be lifted by attaching
slings with the main hook of the crane.
Ensure that centre of the wagon is not
more than 8 meters of radius.
Insert 70 T 6 meters “two leg” 02 wire rope
sling in the solebar near cross bar support
in the centre of the wagon and lift slowly
just above the ground.
In many situations it is not safe to tackle
loaded wagons particularly BCN, due to
beyond reach or because of damaged
wagon it is necessary to unload the
wagon before tackling.
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Restoration of damaged
BCN/BOXN Advise commercial staff/officers for
unloading.
Insert Aux hook and remove the
vehicle.
. If it is not possible to unload the vehicle, the wagon should be
toppled.
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Again insert slings on one side solebar of the wagon taking support of
cross member and continue slewing and derricking as per
requirement till unloading of the wagon.
. Further insert 25T capacity hook in the supporting channel of center
seal near center pivot & lift accordingly . The wagon will get toppled
completely.
Generally, it is observed that after
derailment of oil tanks, they catch
fire, which in turn results internal
explosions. In this situation, it is not
possible to rerail the tanks by MFD
equipments because machine and
breakdown staff may have sustain
injuries due to explosions.
1. First of all, thorough inspection of accident site should be carried out and fire brigade is
called immediately.
2. High pressure foam power is sprinkled on the tanks involved in the fire.
3. Until and unless putting off the fire completely, 140 T crane should not be brought near
accident site.
4. If the track is available and fire is put off, crane is moved and propped fully and aux.
Hook/main hook is applied as per requirement on all four barrel brackets of the tank.
5. Now, Lift the wagon and keep anywhere at 360° within the radius of 18 meters.
6. In general, wagons involved in fire are removed/toppled and kept aside because such
wagons are always dangerous for running on the track.
Restoration of Oil Tanks by 140 T
Crane84
When diesel or AC
locomotive enters in
to the dead end
siding and derails, it is
rerailed with the help
of two cranes. Each
crane at either end
of adjacent track
from where working
radius is not more
than 8 meters.
1. One 140 T crane is kept at one end on the adjacent track and other 140 T at anotherend.
2. Full propping is done for both the cranes and 50 T, 6 meters wire rope sling with ‘D’shackles are used.
3. ‘D’ shackles are inserted in the lifting holes of buffer plates of loco on four places andboth cranes are allowed to lift the loco simultaneously.
4. Lifted loco should be slewed towards adjacent track by both the cranes.
5. One bogie of the loco is placed on track in first occasion and then another crane ispermitted to do so.
6. Lifted loco is always kept in dead condition during restoration operation.
Restoration of Diesel/AC Locomotives85
Precautions to be taken
at Site:
Crane should be ready in all respect.
Fuel oil,Hyd. Oil,Water upto proper level
All Pr, Temp.gauges & sensors in working condition
Axle Blocking in ON position
Observe site for propping
Nearest to the job
Temporary track made if needed
Space for prop
Condition of soil
OHE cut off taken if required
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