Chapter-2 Operation of 140T Crane

CHAPTER - 2
OPERATION OF 140 Te.

BREAK DOWN CRANE
AND
IMPORTANT
INSTRUCTIONS
Operation Manual for Working of ART\ARME\140 Te. Cranes\1

2.1 Comparison between 140 Te. (Cowans Sheldon & Gottwald)
Break Down Cranes
Name of the Cowans Cowans
SN Gottwald (Old) Gottwald (New)
Parts Sheldon (Old) Sheldon (New)
01 Crane Jib Lattic Box construction Welded tubular shape Box construction
construction
02 Super Different Different Different Different
structure
03 Carriage Lateral Radial 4 prop arrangement 4 prop arrangement
04 Crane bogie Welded Welded structure Bolster with primary & Bolster with primary &
structure secondary suspension secondary suspension
05 Relieving Exist Not exist Not exist Not exist
bogie
06 Match Truck Different Different Different Different
07 Ballast Exist Not exist Not exist Not exist

Wagon
08 Hydraulic Elect-Hydraulic Hydro-Hydraulic Upgraded Upgraded
system
09 Electrical Different Different Different Different
10 SLI Wylie/Mechanica Ascorel france Different (PAT) Different (Mechanica)
11 Gear box and Different Different Different Different

Winches
12 Out rigger 06 04 04 04
13 Out rigger Pull out type Swing out type Swing cylinder Swing cylinder
arrangement
14 Main Engine Cummins Cummins Cummins tilted Cummins
NT-743P NT-855P NTA-855 R4 NTA-855 LBC
295 HP 360 HP 340 HP 340 HP
15 Main Engine 2100 rpm 2100 rpm 2100 rpm 1800 rpm
RPM
16 Brakes Mechanical TBU Air brake,Vacuum Air brake,Vacuum brake,
linkage Air brake,Vacuum brake, Parking brake Parking brake
Air brake,Vacuum brake, Parking (Disc brake) (Disc brake)
brake, Parking brake(clasp type)
brake(clasp type)
17 “A” Frame Tie cylinders Folding linkage Folding linkage Folding Gallows
18 Counter 32,12,1.5 Te. 6.7/ 7.9, 22.6 Te. 5.2,18,6,14 Te. 24,15,8 Te.
weight
19 Drivers cabin Side Side Centre Centre
20 Counter weight Beam lift jack Gallows Gallows Gallows

fastening
21 Aux. Engine Ruston MK- Lister Peter TA2 Kirloskar HA294
IV/KOEL TA2

2.2 140 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 : 12 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 P
10. Aux.Engine Make : LPA-3
11. Aux.Engine HP : 20.9 kw
12. Aux.Engine Model No. : LPA 3
13. Length of Crane over buffers : 13 meters
14. Total length including match truck : 27.97 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 : 100 KMPH
22. Weight of Crane in working order : 152/160 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 : 4 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 : 4 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

2.3 140 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

2.4 TECHNICAL DATA OF 140 Te. DIESEL HYDRAULIC CRANE
(GOTTWALD NEW)
Dimensions:
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
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
02. Rope Diameter : 26 mm
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
04. Distance between bogie pivots : 11.30 m
05. Draw and Buffing Gear : side buffers & screw
couplings
06. Turning radious : 175 m
08. Max. wheel set load : 200 Kn
09. Total weight: Loaded : 80.0 T

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

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
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
4. Hoist speed : 2.5 m/min- 5 m/min.
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
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
2. Rope Diameter : 26 mm
4. Derricking time : Approx. 90 sec.
Hauling Winch Capacity :5t

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
4. Distance between bogie pivots : 11.30 m
5. Draw and Buffing Gear : Hinged buffers & screw
couplings
6. Turning radius : 174 m
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

2.6 140 t. Crane Specification with comparison
A. Comparison between Old and New Gottwald cranes:
Parameters Gottwald Crane
Sr Item Old (1986) design - New (1997) design
1WDH - 3WDH
1 RDSO Document ref. number MP-MISC-118 (Rev-0.00) MP-MISC-119 (Rev-
0.00)
2 Track gauge 1676 mm 1676 mm
3 No. of vehicles in running order Crane with two 3 - axle bogies + Crane with two 3 - axle
Match truck with two 2 - axle bogies + Match truck
bogies with two 2 - axle bogies
4 Length of crane over buffers 13300 mm 13300 mm
5 Length of match truck over 15970 mm 16000 mm

buffers
6 Overall length 29270 mm 29300 mm
7 Width of crane 3000 mm 3100 mm
8 Width of match truck 3000 mm 3000 mm
9 Min track curvature 174 m radius 174 m radius
10 Max height of crane from RL 3950 mm 3900 mm
11 Overall weight 200t 200t
12 Axle load in running order 20t 20t
13 Tail radius 5.5 m 5.5m, 6.5m
14 Counterweight: 4 pieces: 5.2T, 6T, 14T, 18T 3 pieces: 8T, 15T, 24T
std duty 29.2t (5.2 + 6 + 18) 47t (24 + 15 + 8) at 5.5m
heavy duty 43.2t (29.2 + 14) 47t (24 + 15 + 8) at 6.5m
15 Outriggers Swing out type, 4 nos. Swing out type, 4 nos.
16 Propping base 6m, 2.7m 6m, 5m, 2.9m
17 Jib/Boom 18 m long Box section 18.75 m long Box section
(octagonal) (rectangular)
18 Suspension crane Helical & disc spring Helical & disc spring
19 Suspension match truck Coil spring Coil spring
20 Wheel dia crane 915 (new), 860 (cond) 920 (new), 840 (cond)

Sr Item Old (1986) design - New (1997) design
1WDH - 3WDH
21 Wheel dia match truck 915 (new), 860 (cond) 1000 (new), 906 (cond)
crane no 143005 to 143010 -
1000 (new), 906 (cond)
22 Safe load indicator PAT, Germany/ Amrita PAT, Germany
Lakshami Electronics,
Mechanica Systems
23 Hauling winch capacity 5t 5t
24 Lifting beam capacity 2 nos. - 140T & 70T 2 nos. - 140T & 70T
25 Hooks Main (Ramshorn) - 140t Main (Ramshorn) -
140t
Auxiliary - 25t Auxiliary - 25t
26 Working radius Main hoist Maximum - 16 m Maximum - 17 m
Minimum - 5.5 m Minimum - 5.5 m
27 Working radius aux hoist Maximum - 17 m Maximum - 18 m
28 Range of Lift Main hoist Above rail level - 16.5 m Above rail level - 17 m
Below rail level - 4 m Below rail level - 4 m
29 Range of Lift aux hoist Above rail level - 17.8 m Above rail level - 18 m
30 Max capacity when fully 140 T at 8 m radius, 360 degree 141 T at 8 m radius, 360
propped with heay duty cwt. slewing and 9 m radius at 30 degree slewing. Load
degree slewing. moment calculations and
load charts are different.
31 Crane Motion and Speeds:
Derricking 1 min from max to min radius 165 sec from max to min
radius
Slewing 1 RPM 1 RPM
Main hoist lifting 2.5 m/min 4 m/min
Main hoist rapid lowering 5 m/min 8 m/min
Auxiliary hoist lifting 15 m/min 15 m/min
Auxiliary hoist rapid lowering 30 m/min 30 m/min
Self travel speed:
travel with load 6 km/h 6 km/h
travel without load 12 km/h 20 km/h
Hauling speed:

on 90R mainline std track & 75 kmph 60 kmph
above
on 52 kg mainline track & 80 kmph
above
32 Main Diesel Engine:
Make Cummins Cummins
Type NT 855 - R4 NTA 855 - P
Mounting Horizontal Vertical
Horse power 285 263
No of cylinder 6 6
Bore & stroke (mm) 140 X 152 140 X 152
Compression ratio 14.1:1 14.1:1
Lub oil sump capacity 28.2 liters 43 liters
RPM 2100 1800
Fuel tank capacity 1000 liters 900 liters
33 Aux. Diesel Engine:
Make Schule Kirlosker
Type TA 2 HA 294
Horse power 14 (10.5 KW) 23 (16.9 KW)
RPM 1800 1800
33 Auxiliary compressor SAB WABCO, axle mounted, SAB WABCO, axle
reciprocating, mounted outside, mounted, reciprocating,
driven by belt drive- 7.2 bar. fitted inside the bogie,
driven by pinion meshed
with the bull gear - 7 bar
34 Brakes crane Air brake, Vacuum brake & Air brake, Vacuum brake
Parking brake (disc type) & Parking brake (disc
type)
35 Brakes match truck Air brake, Parking brake (disc Air brake, Parking brake
type) (clasp type)
Air brake, Parking brake (clasp
type) in crane numbers 142038
to 142043 & 143001 to 143010
Others:
36 'A' frame available In place of 'A' frame,
gallows and bigger bridle
of the old design a single
frame for suspending cwt
has been designed.

37 Gallows fixed cwt. radius permit the counterweight
assembly to be placed at
5.5 or 6.5 m radius
38 Slewing arrangement Roller bearing type slewing ring 3 - stage planetary hoist
with internal spur gear with spring loaded multi-
disc brake roller slewing
ring with external teeth
39 Hydraulic oil tank one single tank fitted in the rear two internally connected
portion of the superstructure tanks just behind the cab
40 Fuel tank annular shaped tank above the box shaped tank in the
slewing ring rear portion of the
superstructure
41 No. of pulleys in main hoist 8 9
42 Controls:
Counterweight all control in cab, single lever all controls in the rear of
operation the crane, three levers
for control.
Hoists separate lever for main and single joystick for main
auxiliary hoists and auxiliary hoists
Rapid motion switch foot operated switch on the top of
joystick for hoist
operation
Max. Travelling speed in "In 100 kmph 100 kmph
Train" formation

B. Comparison between Old and New Cowans Sheldon cranes:
Parameters Cowans Sheldon Crane

Sr Item Old (1987) design New (1998) design
1 RDSO Document ref. number MP-MISC-120 (Rev-0.00) MP-MISC-121 (Rev-0.00)
2 Track gauge 1676 mm 1676 mm
3 No. of vehicles in running Crane with two 3 - axle bogies + Crane with two 3-axle bogies
order two relieving bogies each with 2- + Match truck with two 2-axle
axle + one match truck with two bogies.
2-axle bogies + one ballast
wagon with two 2-axle bogies.
4 Length of crane over buffers 21046 mm (including relieving 13000 mm

bogies)
5 Length of match truck over 16770 mm 14967 mm
buffers
6 Overall length 52.686 m 27.967 m
7 Width of crane 3080 mm 3200 mm
8 Width of match truck 2845 mm 3000 mm
9 Min track curvature 174 m radius 175 m radius
10 Max height of crane from RL 4010 mm 4160 mm
11 Overall weight 300 t 200t
12 Axle load in running order 20 t 20t
13 Tail radius 5.5 m,6.5 m 5.5 m, 6.5 m
14 Counterweight: 2 pieces: 13.7T, 32T 3 pieces: 6.7T, 7.9T, 22.6T
std duty 13.7 t 29.3T (22.6 + 6.7)
heavy duty 45.7 t (13.7 t+ 32 t) 37.2T (22.6 + 6.7 + 7.9)
15 Outriggers Pull out type, 6 nos. Swing out type, 4 nos.
16 Propping base 6m, 5m, 4m 6m, 5m, 3.4m
17 Jib/Boom 16 m long Lattice construction 16.3 m long Box section
(rectangular)
18 Suspension crane Laminated springs Parabolic springs
19 Suspension match truck Coil springs Coil springs
20 Wheel dia crane 915 (new), 813 (cond) 915 (new), 813 (cond)
21 Wheel dia match truck 952 (new), 813 (cond) 1000 (new), 906 (cond)
22 Safe load indicator Wylie, UK Ascorel, France
23 Hauling winch capacity 5t 10 t

24 Lifting beam capacity 2 nos. - 140T & 70T 2 nos. - 140T & 70T
25 Hooks Main (Ramshorn) - 140t Main (Ramshorn) - 140t
Auxiliary - 25t Auxiliary - 25t
26 Working radius Main hoist Maximum - 16 m Maximum - 16 m
27 Working radius aux hoist Maximum - 19 m Maximum - 17 m
Minimum - 7 m Minimum - 7 m
28 Range of Lift Main hoist Above rail level - 13 m Above rail level - 13 m
29 Range of Lift aux hoist Above rail level - 17 m Above rail level - 17 m
30 Max capacity when fully 140 T at 7 m radius, 360 140 T at 6 m radius, 360
propped with heay duty cwt. degree slewing and 10 m radius degree slewing and at 9 m
at 28 degree slewing. radius, 30 degree slewing
31 Crane Motion and Speeds:

Derricking 2 min from max to min radius 2 min from max to min radius
Slewing 0.5 RPM 0.5 RPM
Main hoist lifting 3 m/min 4 m/min
Main hoist rapid lowering 5 m/min 8 m/min
Auxiliary hoist lifting 15 m/min 15 m/min
Auxiliary hoist rapid lowering 15 m/min 30 m/min
Self travel speed:
travel with load 6 km/h 6 km/h
travel without load 12 km/h 20 km/h
Hauling speed:
on 90R mainline std track & 75 kmph 75 kmph
above
on 52 kg mainline track & 100 kmph
above
32 Main Diesel Engine:
Make KIRLOSKAR CUMMINS CUMMINS
Type NT 743 P NTA 855-C
Mounting Horizantal Horizantal
Horse power 295 360
No of cylinder 6 6
Bore & stroke (mm) 130 X 152 140 x152
Compression ratio 14.1:1 14.5:1
Lub oil sump capacity 40 litres 34 litres
RPM 2100 2100
Fuel tank capacity 1000 litres 550 litres

33 Aux. Diesel Engine:
Make Ruston Lister- Petter: LPA-3
Type Mk- IV 3 Cylinder naturally aspirated
Horse power 14.6 (10.9 KW) 20.9 (15.6 KW)
RPM 2000 RPM 3000
33 Auxiliary compressor BROOMWADE, superstructure HYDROVANE,
mounted, reciprocating, driven by superstructure mounted,
hydraulic motor - 7.5 bar. vane rotor, driven by
hydraulic motor - 7 bar.
34 Brakes crane Air brake, Vacuum brake & Air brake, Vacuum brake &
Parking brake (clasp type) Parking brake (clasp type)
35 Brakes match truck Air brake, Vacuum brake & Air brake, Vacuum brake &
Parking brake (clasp type) Parking brake (clasp type)
Others:
36 'A' frame available available
37 Gallows
38 Slewing arrangement Roller thrust bearing type slewing Three sets of rollers with
ring with external teeth interior teeth
39 Hydraulic oil tank one single tank fitted in the front one single tank fitted in the
portion of the superstructure rear portion of the
superstructure
40 Fuel tank box shaped tank in the centre box shaped tank in the rear
portion of the superstructure portion of the superstructure
41 No. of pulleys in main hoist 6 6
42 Controls:
Counterweight Two control in the front & One at all controls in the rear of the
rear of the crane, three levers for crane, three levers for
control. control.
Hoists single joystick for main and single joystick for main and
auxiliary hoists auxiliary hoists
Rapid motion switch
Max. Travelling speed in "In 75 kmph 100 kmph
Train" formation

2.7 POPULATION OF 140 T CRANES ON IR:
Total 140 T Break Down Cranes are 74, available over Indian Railways as on
date and design wise population is as follows:-
GOTTWALD NEI (COWANS)/JESSOP

(OLD DESIGN ) (OLD DESIGN)
22 NOS 12 NOS
GOTTWALD COWANS SHELDON

(NEW DESIGN) (NEW DESIGN)
36 NOS 04 NOS

2.8 Special Safety Precautions for Crane Operators
To understand the crane and operate the crane efficiently and safely, the operating
personnel should follow the operating and maintenance manuals supplied along with the
cranes. Some salient features (included also 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 locked on the top of the spring.
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 leveled 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 footsteps

should be sound 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.
7. If the crane is to be moved to another position, then the draw beam jacks should
be raised, the footsteps 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 leveling 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 traveling 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.

2.9 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 140T Crane on electrified section for

operations, ensure that OHE has been made dead /slewed and
secured and power block has been taken providing 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.
06. Lifting load must be assessed properly and crane configuration

and radius to be determined accordingly.
07. Always take care of cant/super elevation while lifting the load.
08. Ensure that SLI is in working order.
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 are
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 for this 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.
****

2.10 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 T BD cranes must have the approval of
CMPE/Hqrs 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 CANNOT
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 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.
***

2.11 SUITABLE WIRE ROPES, CHAIN SLINGS FOR LIFTING OF LOAD
[ For COWANS SHELDON 140 T. CRANE]
1. Two Leg Wire Rope sling (BS-1290)

Capacity - 70 T
Requirement - 2 Nos.
Length - 6 Mtrs.
Proof Load - 81 T/Leg
2. Two Leg Wire Rope Sling (BS-1290)
Capacity - 30 T
Requirement - 2 Nos. 5 Mtr
Requirement - 2Nos. 7 Mtr.
Proof Load - 42.4 T
3. Single Leg Wire Rope Sling (BS-1290)
Capacity - 70 T
Requirement - 4 Nos
Length - 6 Mtrs
Proof Load - 105.4 T
Capacity - 50 T
Length - 5 Mtrs.
Proof Load - 81 T
Capacity - 70 T
Requirement - 2 Nos
Length - 4 Mtrs.
Proof Load - 140 T
6. Four Leg Wire Rope Sling (BS-1290)
Capacity - 25 T
Requirement - 1 No.
Length - 4 Mtrs.
Proof Load - 50 T
7. Two Leg chain Sling (BS-1290) Capacity - 25 T
8. Chain Sling (Without hook)-BS-1290)Capacity -10 T

2.12 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

2.13 Preparation of 140 T. Crane for "intrain" formation:
According to crane capacity, following instructions must be followed for better

performance of 140 T. break down crane ensuring internal and external safety – Following
main points must be kept in mind for keeping 140 T. 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 vacuum hose pipes between the vehicles.
4. Air reducing valve cocks of match wagon, ballast wagon and crane to be kept
open, otherwise vacuum 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.
6. Blocking screws of all the axle boxes should be lifted.
7. Slew lock pin of 140 T. Crane should be in coupled position.
8. 12 T. 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 vacuum reservoirs of crane, match wagon and ballast wagon
should be in closed position and leakage should not be there from proportional
valve to release valve. In case of any leakage, vacuum brake will not work.
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 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.

2.14 Precaution and instructions during crane "Intrain" Running:
During “intrain” 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. After starting auxiliary engine, check battery charging
by ammeter readings.
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 “intrain” 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.
2.15 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. Destroy the vacuum of vacuum release valve to release the vacuum
brakes. The vacuum release valves are provided on the crane, match
wagon and ballast wagon.

2.16 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 traveling 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.
2.17 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 T. only. Beyond this
load, main hook to be utilized.
4. Hauling operation should not be undertaken for more than 5.0 T. loads, because
hauling load is not shown by SLI.
5. Traveling 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 T. 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.

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

the main engine main engine
1. Check the battery ammeter. needle 1. After shutting down the main engine, all
should be in + zone 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 should be in 3. SA1 valve, brake foot pedal should be
retracted and locked position. locked by inserting pin.
4. Relieving bogie-coupling pin should
4. Material to be kept systematically on the
be in inserted position. crane.
5. Tie cylinders should be lowered 5. All the transition couplings of the crane
completely. unit must be tighten.
6. Derrick wire rope should not be in
6. All the FP pipes and vacuum hose pipes
loose position. 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 7. Heavy ballast and counter weight should
engine, it should be run on idle be locked properly.
position for at least 3 minutes.
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.

2.19 PREPARATION OF CRANE FOR WORKING AT SITE
Before uncoupling from the train do all the operations, i.e. uncouple of hoses and starting
of engine etc. mentioned vide 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.

2.20 PREPARATION OF CRANE FOR IN-TRAIN RUNNING CONDITION
a) If the crane has been in the blocked condition, retract the jacks, remove the footsteps and
retract the draw beams. Lock draw-beams in the stowed position and stow the footsteps.
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 o 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.

2.21 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.

2.22 STARTING CIRCUIT OF 140 T CRANE (Cowans Sheldon)
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.
2.23 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.

2.24 Gauge Lights & Lighting Circuits of 140 T. 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.

2.25 High Power Circuits of 140 T. 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.

2.26 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.
2.27 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.

2.28 Periodical examination of Cranes :
01. 140 Te. Diesel hydraulic cranes of ART’s will 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”
04. 6 Monthly 500 Form”D”
05. Yearly 1000 Form”E”
06. 2 Yearly 2000 Form”F”
07. 4 Yearly 4000 Form”G”
08. 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”
03. 6 Monthly 250* Form”D”
04. Yearly 1500* Form”E”
05. 2 Yearly 6000* Form”F”
06. 3 Yearly 6000* Form”G”
07. 8 Yearly -- POH
* Whichever is earlier
KOEL Auxiliary Engine HA-294

01. Daily
02. Monthly 125*
03. 6 Monthly 250*
04. Yearly 1000*
05. 2 Yearly 2000*
06. 3 Yearly 3000*
07. 8 Yearly -- POH Sch.
04. Particular of periodical examinations should be maintained on 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 will be signed by the
maintenance supervisor.
07. Particulars of periodical examinations of 140T. Crane will be recorded in
the prescribed schedule forms as laid down by the RDSO.
2.29 Lubrication of Cranes
01. Crane drivers 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 each 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

2.30 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.
Lkkeku dk fooj.k la[;k Description of the material NOS.
Dz-
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- isVªkes sDl 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

2.31 SUITABLE WOODEN PACKINGS
A. REQUIRED FOR 140 Te. CRANE: [ COWANS SHELDON 140 Te. CRANE]
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]
Required For 4 Nos Prop For 8 Nos Prop

Cubic
per Prop
SN Size Location feet per No. of Cubic No. of Cubic
for 5' 3"
packing Packing feet Packing feet
Height
1 6' X1' X 1' Ist Base 6 6 24 144 48 288
IInd
2 5' x 1' x 6" 2.5 5 40 100 40 100
Base
IIIrd &
3 4' x 1' x 6" IVth 2 8 32 64 64 128
Base
Vth &
4 3' x 1' x 9" Vith 2.25 6 24 54 48 108
Base
2' 6" x 1' x Seventh
5 1.875 3 12 22.5 24 45
9" Base
Eight &
2' 6" x 1' x
6 Ninth 0.625 6 24 15 48 30
3"
Base
Total 15.25 34 156 399.5 272 699

2.32 LOAD CHART FOR 140 T CRANE [ COWANS SHELDON ]
Duty Selector Duty Selector

0 t - 4, 32 t - 7
MAIN HOIST 0 t - 3, 32 t - 6 AUXILIARY HOIST
12 t - 2 12 t - 1
Radius Coupled Free on rail Fully Propped Coupled Free on rail Fully Propped
Radius
in ballast Slew Range Slew Range ballast Slew Range Slew Range
in meter
meter weight O° 28° 360° O° 28° 360° weight O° 28° 360° O° 28° 360°
0t 42 42 29 140 140 140 0t 25 25 20 25 25 25
5.5 12 t 94 53 39 140 140 140 7.0 12 t 25 25 25 25 25 25
32 t 104 -- -- 140 140 140 32 t 25 -- -- 25 25 25
0t 31 31 20 140 140 98 0t 22 22 13 25 25 25
7.0 12 t 78 41 27 140 140 110 9.0 12 t 25 25 20 25 25 25
32 t 86 -- -- 140 140 140 32 t 25 -- -- 25 25 25
0t 22 22 13 140 140 62 0t 16 16 9 25 25 25
9.0 12 t 63 30 18.5 140 140 70 11.0 12 t 25 25 15 25 25 25
32 t 70 -- -- 140 140 101 32 t 25 -- -- 25 25 25
0t 16 16 9 109 109 44 0t 12 12 6 25 25 25
11.0 12 t 52 23 14 118 118 50 13.0 12 t 25 21 11 25 25 25
32 t 58 -- -- 130 130 58 32 t 25 -- -- 25 25 25
0t 12 12 -- 79 79 34 0t 9 9 4 25 25 25
13.0 12 t 44 18 9.5 85 85 38 15.0 12 t 25 17 9 25 25 25
32 t 49 -- -- 105 105 58 32 t 25 -- -- 25 25 25
0t 9 9 -- 61 61 27 0t 7 7 3 25 25 25
15.0 12 t 38 14 7 66 66 31 17.0 12 t 25 13.5 7 25 25 25
32 t 42 -- -- 85 85 47 32 t 25 -- -- 25 25 25
0t 8 8 - 55 55 24 0t 5 5 2 25 25 19
16.0 12 t 35 13 6 59 59 28 19.0 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 mts
B-End 140 Te. Crane A-End 6.0 m 2. Full Propping = 30 mts
R/B R/B 3. Counter weight attaching = 08 mts
4. Relieving Bogie removing = 12 mts
5.0 M 5. Match Truck Removing = 30 mts
6. Crane binding up with Aux. Hook = 20 mts
11.15 M 7. Crane binding up with R/B + Match truck = 1.10 hr
8. 360° Slewing without load = 2.5 mts
PROPPING ARRANGEMENT

2.33 WEIGHT CHART OF COACHES AND WAGONS
SN Type of Tare weight Pay load Complete One Trolly Total Type of Open / Vacuum/
Wagons & in Tonnes in Tonnes weight in weight in wheels coupling Covered Air Brake
Coaches Tonnes Tonnes
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 RLy Built Date POH Done POH Due Utilisation

No.
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

2.34 RESTORATION AT ACCIDENT SITES BY 140 T CRANES
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 All props to be prepared and 04 staff on each
staff 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 Two cranes. duty selector to be kept on No.1
of SLI duty selector (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 02 Nos. in sufficient length at both the ends of
adjustment loco
13 Availability of Megaphone/ One person should be deputed with
Communication 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 Average – 2.0 hrs. minimum
restoration
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 91 )
3 Boom erection – For things to ensure before boom erection see P- 92-94
4 Do the propping of the crane – Detailed instructions given at P- 95-97
5 Select the counterweight as per load chart - Detailed instructions given at P-98-100
6 Operation can now be started. Following Operating Precautions given at P-101-104
and General Precautions for handling of loads given at P- 105.
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
Bolster Pin
Connection
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.

COACHES
1.(A) RESTORATION OF COACHES IN ELECTRIFIED SECTION
BY 140 T CRANE
A. Preparation Chart:
01 OHE To be slewed towards coach movement and
ensure that OHE of adjacent line has been made
dead.
02 Condition of props and Full propping to be done and 04 staff on each
availability of staff 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 (under frame) Solbar
inserted
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 02 Nos. in sufficient length at both the ends of
adjustment coach.
17 Availability of Megaphone/ One person should be deputed with equipments
Communication
collection.
19 Average timing for restoration Average – 55 minutes
of each coach
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.
1(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 also on the track.
1(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.

1(D) Restoration/Shifting of derailed and capsized coaches fallen off
the track/embankment and lying low on River bed :
If the coaches have fallen off the track/embankment and lying low on river bed,
first of all ensure that all passengers have been evacuated safely from the
coaches. Thereafter, the coaches can be shifted with the help of JCB/Poclain
machines. The heavy duty JCB/Poclain machines can be hired from nearest
available private operators on hire basis.
1. JCB/Poclain machines can also be deployed in case of earth work required

for filling the deep area as well as for making good the embankment side
slopes for laying the restored track.

2. After assessment of the accident site, if the coaches found tilted infringing
track, the coaches may be Pushed/pulled out by JCB/Poclain Machine
maintaining safe distance between JCB & damaged coach. For faster
clearance of the track, 3-4 JCB/Poclain Machines or more may also be
deployed for pushing/pulling for shifting it out of the track.
Two Poclains working for shifting the coaches
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/Poclain 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.
Earth work done in river bed during restoration, to

facilitate flow of river water
[ Photographs from Engineering Depptt.WCR during Harda accident in 2015

in KNW-ET section ]

1E- 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-91 )
3 Boom erection – for things to ensure before boom erection see P- 92-94
4 Do the propping of the crane – detailed instructions given at P- 95-97
5 Select the counterweight as per load chart - detailed instructions given at P-98-100
6 Operation can now be started following Operating Precautions given at P-101-104 and
General Precautions for handling of loads given at P-105 .
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.
Rope attached for guiding the load
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.
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)
Coach is
positioned
to leave
space for
crane
movement. Crane is moved to
tackle farther end.
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.
This end will be re-railed first.
3
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.
Now this end will be re-railed, pushing
the coach farther on the previously re
railed trolley.

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
Restoration of derailed EMU/MEMU/DEMU.
A- Preparation Chart :
01 OHE To be slewed towards coach movement and
ensure that OHE of adjacent line has been
made dead.
02 Condition of props and Full propping to be done and 04 staff on each
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 (under frame) Solbar
inserted
13 Position of coach trolley Lashing chain to be used for securing with
structure.
14 Lighting arrangement To be arranged during dark/night.
placing the coach/damaged trolley.
16 Arrangement of rope for coach 02 Nos. in sufficient length at both the ends of
adjustment coach.
collection.
of each coach


• Required radius
General Precautions for handling of loads given at P- 105.
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

Apart from above these stocks are similar to Coaches. Hence for the methods of
9 handling these stocks in double/single line sections in different conditions see the
chapter ‘COACHES’.
10 For uncoupling of shaku coupler, help of
locomotive for pulling of rake may be
taken. In case of non availability of loco,
the uncoupling may be done by providing
hydraulic jack under the shaku coupler &
taking precautions mentioned in earlier
para.
11 Suitable size wooden wedges should be

inserted between coupler body & coach
body & wooden piece should be placed on
piston head before lifting operation
12 In case of axle breakage inside the track,

the auxiliary truck/Rail skate should not be
provided below culprit wheel. This
arrangement will not work. This provision
is suitable only for hot axle coach or
breakage of axle outside the wheel.
13 In new EMU coaches like siemense,
Bomwardier etc, the safety wire rope is
provided between superstructure & Trolley
but in old coaches, some times this rope is
not provided hence before starting lifting of
trolley, lashing chains should be provided
to avoid falling of trolley during restoration.

WAGONS
1. Restoration of Loaded BCN/BOX-N by 140 T. Crane
A-Preparation Chart :
01 OHE Working line OHE to be slewed. OHE of adjacent
line to be made dead.
02 Condition of props and availability Full propping to be ensured and 04 staff on each
of staff 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.

placing of wagons.
16 Arrangement of rope for wagon 02 Nos. in sufficient length at both the ends of
adjustment coach.
17 Availability of Megaphone/ One person should be deputed with equipments
Communication
collections.
(per wagon)

• Required radius
2 Axle blocking – Carry out Axle Blocking ( for the method of Axle Blocking see P- 91 )
3 Boom erection – for things to ensure before boom erection see P-92-94

General Precautions for handling of loads given at P- 105.
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.
Center sill
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.

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.

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.
(2) 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 sill 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.

3. Restoration of derailed BTPN (Oil tank wagons) involved in
fire.
A-Preparation Chart :
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 All props to be prepared and 04 staff on each prop
availability of staff should be deputed.
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 25 Te. Capacity chain sling
requirement
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 In empty, 16 meters by main hook and 19 mtrs. By
Aux. hook.
10. Place, where sling to be Under frame barrel bracket
inserted
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 02 Nos. in sufficient length at both the ends of tank.
wagon adjustment
15. Availability of Megaphone/ One person should be deputed with equipments
Communication
16. Photography/Vide0ography Videography of all critical operations and clues
collections.
17. Average per oil tank timing for Average – 55 minutes
restoration
B- Procedure in Practice :
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 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.

4. Restoration of derailed Guard Brake van by 140 Te. Crane.
A-Preparation Chart:
adjacent line to be made dead.
02 Condition of props and All props to be prepared and 04 staff on each
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.
placing of wagons.
16 Arrangement of rope for brake 02 Nos. in sufficient length at both the ends
van adjustment of BVZI.
18 Photography/Videography Videography of all critical operations and
clues collections.
19 Average timing for per wagon Average – 35 minutes
restoration
B- Procedure in Practice :
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.

5. Restoration of Hot Axle/Cold Axle broken Wagons
Preparation Chart :

01 MFD/LUKAS power pack and 120/60 Two jacks of 120/60 Te. Cap. and displacing
Te. Cap. Jacks with control table and jacks.
hoses
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 03 Lashing chains to be used for securing
bolts 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.

collections.
12 Average per wagon timing for Average – 45 minutes
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.

2.35 FOB WORK
Observation of site and load conditions

• Required radius
5 Select the counter weight as per load chart - detailed instructions given at P-98-100
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.
2.36 LAUNCHING OF GIRDERS
A-Preparation Chart:

adjacent line to be made dead.
02 Condition of props and All props to be prepared and 04 staff on each
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.
placing of Girders.
16 Arrangement of rope for Girder 02 Nos. in sufficient length at both the ends
adjustment of Girder.
18 Photography/Videography Videography of all critical operations and
clues collections.
19 Average timing for per Girder Average – minutes
launching

• 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.
Here, for replacing all three

girders, work should be started
from girder no.3.
3
2
1
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.
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

2.37 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!

2.38 TUNNELS
Restoration Plan :
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.

2.39 RESTORATION ON BRIDGES
• Required radius
4 Do the propping of the crane – detailed instructions given at P-95-97 .On bridges
temporary staging would be necessary for propping.
5 Select the counter weight as per load chart - detailed instructions given at P-98-100
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.

2.40 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.
2.41 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.

2.42 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.

Lock
In locked condition
Do not leave the boom unlock in trestle.
In Unlocked condition
6 All side-mounted platforms should be lowered

and outriggers should be folded. Ensure the
mechanical locks are in locking position. Locking lever
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.
Release the parking Brake.

11 See the green indication to ensure.
Do not haul with parking brake.

12

(140T Cowan Sheldon Old crane)
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.
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.

(140T Cowan Sheldon New Crane)
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.
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.
Release the parking Brake.

9 See the green indication to ensure.
Do not haul with parking brake applied.

10

2.45 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.
2.46 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.
2.47 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
Lower Axle Blocking
jacks to lock top of the
spring. Engage Blocking Pads
3 Ensure engagement of the travelling gear if required.
4 Ensure application of brake confirmed by the “RED” indication.

2.48 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 Lock
section is fully lifted.
New Design
Old Design
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.

2.49 BOOM ERECTION
( Cowans Sheldon 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 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.
2.50 BOOM ERECTION

( Cowan Sheldon New 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 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.

2.51 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

(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.

(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

2.54 COUNTER WEIGHT
(Gottwald Crane)
1 Select the total counter weight as per load chart for the load to be lifted.
2 Switch Only used for keeping CWT on chassis,

on if it is not brought back in the operation,
boom SLI safety will be bypassed.
bridgin New Design Old Design
g key.
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.
Select the proper prop

position by selector switch
5
as required by the load
chart.
Switch off boom bridging key. Switch off the key switch, which bridges safe
6
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.

2.55 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.
2.56 COUNTER WEIGHT
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.

2.57 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.

(Cowans Sheldon Old Crane)
2 Neither lift Match Truck and nor slew in Free on Rail condition.
rail level.
check the signal by ground staff with condition of load.

working cycle.
crane in-charge.
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.
rail level.
check the signal by ground supervisor with condition of load.

working cycle.
crane in-charge.

2.60 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 Rope attached for guiding the load
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.

2.61 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.

2.62 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.

2.63 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.
2.64 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.

2.65 STAFF DEPLOYMENT DIAGRAM FOR
GOTTWALD 140T CRANES

LOAD CHART OF NEW DESIGN COWANS SHELDON 140T CRANE - UDHNA
Crane Fully Propped 11.85 x 6.00 Mtrs STANDARD DUTY - FREE ON RAIL (FOR) COUNTER WEIGHT
Radi Outre LIFTING ANDF MATCH
us in ach in Standard duty CWT Heavy duty CWT 0 to 50 mm SE 0 to 140 mm SE TRUCK LIFTING - FREE
Mtr Mtr ON RAIL
360 360 SETTING UP FREEE ON RAIL
360 degree 30 degree 360 degree 30 degree 30 degree 30 degree
degree degree 140 mm SE
M
AH MH AH MH AH MH AH AH MH AH MH AH MH AH USE ON MAIN HOIST
H
5.5 140* 140 140 140 65 61 COUNTER WEIGHT
6 140 140 140 140 CRANE IS 60 54 13 DEGREE
NOT Radius
7 1 103 25 140 25 117 25 140 25 48 25 43 25 (Mtr)
SWL (Kg)
STABLE
8 2 81 25 140 25 92 25 140 25 BACKWAR 40 25 34 25 4.856* 23400
CRANE IS
9 3 66 25 140 25 75 25 140 25 DS 34 25 NOT 28 25 6 23400
9.5 3.5 30** STABLE 7 23400
1 BACK
10 4 56 25 130 25 63 25 130 25 16 27 25 WARDS 24 8 23400
5
1
11 5 48 25 120 25 55 25 120 25 14 24 24 20 9 23400
3
11.1 5.1 117* 10 23400
11.3 5.3 45* 13.5** 11 23400
USE AUX. HOIST

1
12 6 42 25 110 25 48 25 110 25 11 21 20 10 18 12 23400
0
8
13 7 37 25 100 25 42 25 104 25 9 18 18 8 15 13 20300
*
7
14 8 33 25 89 25 38 25 94 25 8 16 16 7 13 14 17700
*
6
15 9 30.5* 25 78 25 34 25 86* 25 7 14 14 6 12 15 15600
*
5
16 10 27 25 70 25 31 25 76 25 6 13 13 5 11 16 13800
*
17 11 25 25 25 25 5 12 4 10
(* = Use override switch to
(* = Use Aux. Hoist) (** = Marked crane duties according Derrick in)
(* = Marked crane duties according RDSO specifications 2.4.10)
RDSO specifications 2.4.10)

Crane Fully Propped 12.34 x 5.00 Mtrs FREE ON RAIL (FOR) 0- 140 mm SE MATCH TRUCK
Standard duty CWT Heavy duty CWT Heavy Duty CWT With No CWT 10 Degree
Outr 360 30 360 30 360 360 SET UP STANDARD
Radiu 13 degree 30 degree
each degree degree degree degree degree degree DUTY CWT
s in
in M Radius
Mtr MH AH MH AH MH AH MH AH MH AH MH AH AH MH AH SWL (Kg)
Mtr H (Mtr)
5.5 123 140 138 140 87 26 5.5 61000
6 104 140 117 140 81 22 6 54000
7 1 79 25 140 25 89 25 140 25 71 25 6 17 7 43000
8 2 63 25 130 25 71 25 131 25 63 25 5 12 8 34000
9 3 52 25 119 25 59 25 120 25 56 25 4 10 9 34000
USE AUX. HOIST

10 4 44 25 109 25 50 25 110 25 50 25 2.5 8 10 34000
USE AUX. HOIST

11 5 38 25 100 25 43 25 101 25 44 25 1.5 6 11 34000
12 6 33 25 90 25 37.5 25 93 25 39 25 0.5 5 12 34000
13 7 29 25 77 25 33 25 86 25 35 25 4 13 34000
CRANE IS NOT STABLE

14 8 26 25 66.5 25 29.5 25 76 25 32 25 3 14 31500
FORWARD
15 9 23 24.5 58 25 26.5 25 67 25 31 25 2 15 28000
16 10 21 22 51.5 25 24 25 60 25 28 25 1.5 16 25000
17 11 20 25 25* 25 25 1

Crane Fully Propped 12.76 x 3.40 Mtrs Special DUTY CRANE- FREE ON RAIL (FOR)
Radiu Outre Standard duty CWT Heavy duty CWT 0 to 50 mm SE 0 to 140 mm SE
s in ach in 360 30 360
Mtr Mtr 30 degree 360 degree 360 degree
degree degree degree
MH AH MH AH MH AH MH AH MH AH MH AH
5.5 73 140 83 140 21 17.5
6 63.5 132 72.5 140 18.5 16
7 1 50 25 113 25 57 25 116 25 14.3 15.4 12.7 13.5
8 2 40.5 25 102 25 46.5 25 104 25 11.2 12.4 9.8* 10.85
9 3 33.5 25 89 25 39 25 94 25 8.8* 10 7.6* 8.75
10 4 28.5 25 73 25 33 25 85 25 7* 8.1 5.9* 7
11 5 24.5 25 61 25 28.5 25 71 25 5.5* 6.55 4.5* 5.6
12 6 21.5 23 52 25 25 25 61 25 4.3* 5.3 3.4* 4.4
13 7 18.5 20 45 25 22 24 53 25 3.3* 4.3 2.5* 3.4
46.
14 8 16.5 18 39 25 19.5 21 25 2.5* 3.4 1.7* 2.6
5
15 9 14.5 16 34 25 17.5 19 41 25 1.8* 2.6 1.05* 1.9
36.
16 10 13 14.5 30 25 15.5 17 25 1.2* 2 0.5* 1.3
5
15.
17 11 13 25 25 1.4 0.75
5
(* = Use AUXILIARY HOIST)

Chapter-2 Operation of 140T Crane

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Chapter-2 Operation of 140T Crane

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CHAPTER - 2

OPERATION OF 140 Te.

Operation Manual for Working of ART\ARME\140 Te. Cranes\1

07 Ballast Exist Not exist Not exist Not exist

10 SLI Wylie/Mechanica Ascorel france Different (PAT) Different (Mechanica)

11 Gear box and Different Different Different Different

20 Counter weight Beam lift jack Gallows Gallows Gallows

Operation Manual for Working of ART\ARME\140 Te. Cranes\2

Operation Manual for Working of ART\ARME\140 Te. Cranes\3

Operation Manual for Working of ART\ARME\140 Te. Cranes\4

Emergency Diesel Engine

Operation Manual for Working of ART\ARME\140 Te. Cranes\6

01. Length to the main hook : 18.75 mts.

01. Length beyond buffer : 16.0 m

Operation Manual for Working of ART\ARME\140 Te. Cranes\7

1. Track Gauge : 1676 mm

1. Base ( Full propping) : 11.8 m x 6.0 m

1. Driven wheel sets on each bogie : 01

Operation Manual for Working of ART\ARME\140 Te. Cranes\8

Operation Manual for Working of ART\ARME\140 Te. Cranes\9

1. Standard duty : 29.2 Te.(5.2+6+18)

1. Length to the main hook : 18.00 mts.

1. Length over buffer : 15.97 m

Brake System of Match truck Air Brake, Parking brake

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

Operation Manual for Working of ART\ARME\140 Te. Cranes\10

4 Length of crane over buffers 13300 mm 13300 mm

5 Length of match truck over 15970 mm 16000 mm

Operation Manual for Working of ART\ARME\140 Te. Cranes\11

Operation Manual for Working of ART\ARME\140 Te. Cranes\12

Operation Manual for Working of ART\ARME\140 Te. Cranes\13

Operation Manual for Working of ART\ARME\140 Te. Cranes\14

Parameters Cowans Sheldon Crane

4 Length of crane over buffers 21046 mm (including relieving 13000 mm

22 Safe load indicator Wylie, UK Ascorel, France

23 Hauling winch capacity 5t 10 t

31 Crane Motion and Speeds:

Operation Manual for Working of ART\ARME\140 Te. Cranes\16

Operation Manual for Working of ART\ARME\140 Te. Cranes\17

GOTTWALD NEI (COWANS)/JESSOP

GOTTWALD COWANS SHELDON

Operation Manual for Working of ART\ARME\140 Te. Cranes\18

6. Special care is to be taken during propping of jacks. Packing below footsteps

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

Operation Manual for Working of ART\ARME\140 Te. Cranes\19

12. Swinging load is dangerous and should be avoided.

Operation Manual for Working of ART\ARME\140 Te. Cranes\20

Following instructions must be followed by break down

01. After reaching at accident site, observation of site and

02. Crane driver as well as staff should be advised regarding lifting

03. Necessary equipments, tools, wooden packings etc. should be

04. Before energizing 140T Crane on electrified section for

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

06. Lifting load must be assessed properly and crane configuration

08. Ensure that SLI is in working order.

09. Ensure availability and understanding of load charts.

10. Rail clamp must be used as and when required.

13. Proper work distribution among staff and supervisors to be

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

Operation Manual for Working of ART\ARME\140 Te. Cranes\22

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

 Movement of MFDs can be ordered by the Divisional

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