केवल कार्ाालर्ीन उपर्ोग हे तु

(For Official Use Only)

भारत सरकार GOVERNMENT OF INDIA

रे ल मंत्रालय MINISTRY OF RAILWAYS

MAINTENANCE AND OPERATION MANUAL

FOR
140T CRANES, ARTs, ARMEs & SPARTs
VOLUME – I (Part I – 140 T Break Down Crane)
IRCAMTECH/GWL/MECH/2022-23/ART/Manual/1.1
SEPTEMBER, 2022
Maintenance & Operation Manual Part I- 140 T BD Cranes

CONTENTS

Amendment and Revisions .................................................................................................................. 3

CHAPTER-1 ........................................................................................................................................... 7
RULES FOR THE WORKING OF CRANES ............................................................................................... 7
1. INTRODUCTION ................................................................................................................. 8
1.1 Application of Rules ............................................................................................................. 8
1.2 Classification of Cranes ........................................................................................................ 8
1.3 Traveling Cranes. Hire and Haulage Charges: -.................................................................... 9
1.4 Expenditure in connection with cranes, belonging to the Transportation Department: - . 9
1.5 Responsibility for Maintenance of Cranes: - ....................................................................... 9
2. OPERATION: ....................................................................................................................... 9
2.1 Qualifications and Examination of Crane men: - ................................................................. 9
2.2 Responsibility for correct carrying out of rules: ................................................................ 10
2.3 Special training for Crane men: ......................................................................................... 11
2.4 Code of signals: .................................................................................................................. 11
2.5 Precautions when lifting with cranes: ............................................................................... 11
2.6 Lifting tackle to be of suitable capacity: - .......................................................................... 12
2.7 Lifting Tackle to be tested: ................................................................................................ 13
3. MAINTENANCE: ............................................................................................................... 14
3.1 Overhauls:.......................................................................................................................... 14
3.2 Heavy Repairs : .................................................................................................................. 14
3.3 Running Repairs and Maintenance of Cranes: .................................................................. 14
3.4 Periodical Examinations of Cranes : .................................................................................. 15
CHAPTER-2 ......................................................................................................................................... 63
OPERATION OF 140T BREAK DOWN CRANE AND IMPORTANT INSTRUCTIONS ............................... 63
1. COMPARISON BETWEEN 140 T (COWANS SHELDON & GOTTWALD) BREAK DOWN
CRANES ............................................................................................................................ 64
2. 140T DIESEL HYDRAULIC CRANE (COWANS SHELDON NEW) .......................................... 65
3. 140 T DIESEL HYDRAULIC CRANE (COWANS SHELDON OLD) ........................................... 66
4. 140 T DIESEL HYDRAULIC CRANE (GOTTWALD NEW) ...................................................... 67
5. 140 T DIESEL HYDRAULIC CRANE (GOTTWALD OLD) ....................................................... 70
6. 140 T. CRANE SPECIFICATION WITH COMPARISON ......................................................... 73
A. Comparison between Old and New Gottwald cranes: ...................................................... 73
B. Comparison between Old and New Cowans Sheldon cranes: ........................................... 76
7. POPULATION OF 140 T CRANES ON IRs: .......................................................................... 79

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8. FORMATION WISE CLASSIFICATION OF 140T CRANES: ................................................... 81

9. SPECIAL SAFETY PRECAUTIONS FOR CRANE OPERATORS................................................ 81
10. IMPORTANT INSTRUCTIONS FOR BREAK DOWN STAFF .................................................. 83
11. POINTS TO BE KEPT IN MIND BY DIVISIONS FOR ACCIDENT MANAGEMENT .................. 83
12. SUITABLE WIRE ROPES, CHAIN SLINGS FOR LIFTING OF LOAD ........................................ 84
13. SAFETY DEVICES AND FITTINGS IN 140 T DHBD CRANES ................................................. 85
14. PREPARATION OF 140 T. CRANE FOR "INTRAIN" FORMATION: ...................................... 89
15. PRECAUTION AND INSTRUCTIONS DURING CRANE "INTRAIN" RUNNING: ..................... 89
16. PRECAUTION DURING “INTRAIN” RUNNING AND SEPARATION OF CRANE FROM ART: . 90
17. PRECAUTIONS DURING PREPARATION OF CRANE AT ACCIDENT SITE FOR RESTORATION
WORKS: ............................................................................................................................ 90
18. PRECAUTIONS AND INSTRUCTIONS FOR BETTER PERFORMANCE OF CRANE DURING
RESTORATION WORK AT ACCIDENT SITE: ........................................................................ 91
19. PRECAUTIONS BEFORE AND AFTER SHUTTING DOWN THE MAIN ENGINE (ON
COMPLETION OF RESTORATION WORKS): ...................................................................... 92
20. PREPARATION OF CRANE FOR IN-TRAIN RUNNING CONDITION ..................................... 94
21. PRECAUTIONS TO BE TAKEN DURING 140 T. CRANE OPERATION (GOTTWALD NEW
DESIGN)............................................................................................................................ 95
22. STARTING CIRCUIT OF 140 T CRANE (Cowans Sheldon) .................................................. 96
23. BATTERY OPERATED ELECTRICAL CIRCUITES. .................................................................. 96
24. GAUGE LIGHTS & LIGHTING CIRCUITS OF 140 T. CRANE ................................................. 97
25. HIGH POWER CIRCUITS OF 140 T. CRANE ........................................................................ 98
26. RESPONSIBILITY FOR CORRECT CARRYING OUT OF RULES: ............................................. 99
27. PRECAUTIONS WHEN LIFTING WITH CRANES: ................................................................ 99
28. PERIODICAL EXAMINATION OF CRANES: ......................................................................... 99
29. LUBRICATION OF CRANES .............................................................................................. 101
30. SUITABLE WOODEN PACKINGS ...................................................................................... 102
31. LOAD CHART FOR 140 T CRANE [COWANS SHELDON OLD]........................................... 103
32. (a) WEIGHT CHART OF COACHES AND WAGONS........................................................... 103
33. RESTORATION AT ACCIDENT SITES BY 140 T CRANES .................................................... 105
CHAPTER-3 ....................................................................................................................................... 167
TECHNICAL DESCRIPTION OF GOTTWALD 140 T BREAK DOWN CRANE ......................................... 167
1. TECHNICAL DATA OF 140 T GOTTWALD BREAK DOWN CRANE –New Design ............... 168
2. 140 T. CRANE DESCRIPTION WITH COMPARISON ......................................................... 169
3. POPULATION OF 140 T CRANES ON IR:.......................................................................... 173
4. STARTING CIRCUIT OF 140T GOTTWALD CRANE (Old Design) ...................................... 173
5. BATTERY OPERATED ELECTRICAL CIRCUITES. ................................................................ 173
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6. DASH BOARD GAUGE & INDICATOR ELECT. CIRCUITS OF 140 T (OLD DESIGN GOTTWALD
CRANE) ........................................................................................................................... 174
7. ELECTRICAL CIRCUIT OF 140T GOTTWALD (OLD DESIGN CRANE) ................................. 175
8. STARTING CIRCUIT OF 140T GOTTWALD CRANE (NEW DESIGN) FOR CUMMINS ENGINE
NTA 855 P 335 & NTA 855 LBC ...................................................................................... 176
9. DUTIES OF THE 140 TE. CRANE OPERATOR: .................................................................. 176
10. LOAD CHART FOR GOTTWALD 140 T. BREAK DOWN CRANE [NEW] ............................. 178
11. LOAD CHART FOR GOTTWALD 140 T. BREAK DOWN CRANE [OLD] .............................. 185
12. SAFETY DEVICES AND SAFETY FITTINGS ON GOTTWALD 140T CRANES ........................ 187
CHAPTER-4 ....................................................................................................................................... 190
DOs and DONTs for.......................................................................................................................... 190
Operation and Maintenance of 140T Gottwald Crane (New design).............................................. 190
CHECK SHEET FOR INSPECTION OF 140T BREAKDOWN CRANES .................................................... 204
APPENDIX-A ..................................................................................................................................... 210
MAINTENANCE SCHEDULES OF 140T CRANE .................................................................................. 210

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Maintenance & Operation Manual Part I- 140 T BD Cranes

CHAPTER-1

RULES FOR THE WORKING

OF CRANES

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1. INTRODUCTION
1.1 Application of Rules
These rules apply to the operation and maintenance of all Break Down cranes
belonging to the Mechanical Department. These rules also apply to the
operation of cranes belonging to the Engineering or Mechanical Department
when loaned to the Transportation Department, or when these cranes are
worked on the open line or in sidings where their working is governed by the
General and Subsidiary Rules.
The General Rule governing the attachment of traveling cranes to trains and the
Subsidiary Rules applying to the working of cranes is G.R.4.27. These rules are
reproduced in Appendix A.
1.2 Classification of Cranes
(A) Cranes belonging to the Railway are divided into three classes:-
a) Main Line Traveling Cranes
These types of cranes are fitted with match trucks, suitable wheels, axles, axles-
boxes and springs, buffers and other gear to enable them to run on the open
line. These are part of the rolling stock of the Railway and are numbered
accordingly, being marked with the name of the Department and the station to
which they are allotted.
b) Yard Traveling Cranes
These types of cranes are not fitted with the necessary gear for running on the
open line but are capable of being traversed from place to place in yards and
sidings, laid with standard 5’-6" gauge track.
c) Fixed and Special Cranes
These types of cranes, which move on special runways or gantries, or are fixed
in one place and cannot be traversed.
Yard Traveling Cranes and Fixed and Special Cranes are considered as part of
the dead stock of the station to which they are posted and are marked with the
name of the Department and station to which they belong.
(B) Main Line Traveling Cranes are further sub divided in to:-
a) Break-Down Cranes
Break-Down Cranes are attached to Break-down trains specifically for use in
break-down operations. These cranes must not be utilized for any other purpose
unless prior permission has been received/obtained from the CMPE(D&R)/Dy
CME(P&F) HQ.
A permanent sanction for the utilization of Break-down Cranes for the following
purposes has been given, and it is not necessary to obtain sanction when:-
a. Break-down cranes are used to hoist locomotives in order to facilitate repairs at
the Sheds where these Cranes are posted.
b. Break-down Cranes are used to load Narrow-Gauge locomotives/ NG coaches
on to the trucks for dispatch to Workshops, or to off-load these
locomotives/coaches from trucks on receipt from Shops after POH repairs.

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b) Traffic Cranes
Traffic Cranes are hand and Diesel cranes allotted to Stations and Yards for the
handling/Transshipment of heavy consignments.
1.3 Traveling Cranes. Hire and Haulage Charges: -
Statement showing the use of the traveling cranes, Stations at which traveling
cranes are stabled should be furnished to the traffic accounts office. A monthly
statement in Form Com/C-42 Rev. showing movements of the cranes during the
month, to enable the traffic accounts office to check accuracy of charges
collected and accounted for by stations. If there are no movement during a
month a Nil statement should invariably be submitted.
[ Authority: Para-1532 of Indian Railway Commercial Manual Vol-II]
1.4 Expenditure in connection with cranes, belonging to the
Transportation Department: -
Though Traffic Cranes are utilized for joint work of Commercial and
Transportation Department, the following items of expenditure will be borne
entirely by the Transportation Department for cranes posted at all depots unless
so specified:-
(i) Cost of Diesel/Lube oil etc.
(ii) Cost of repairs executed etc.
(iii) Wages of staff employed on cranes.
(iv) Cost of clothing for staff employed on cranes.
1.5 Responsibility for Maintenance of Cranes: -
Divisional Railway Managers (Operation/Mech.) are responsible for the running
repairs, maintenance and periodical examinations of cranes belonging to the
Transportation/Traffic & Mech. Departments.
SSE(Diesel)/SSE(C&W) of depots where Break down or other cranes are
posted are responsible for seeing that the cranes are maintained in good
condition. Diesel Traffic Cranes will be maintained by SSE(Diesel)/SSE(C&W)
nominated by the Divisional Railway Manager (Mechanical) of Division
concerned and the Diesel Break Down Cranes will be maintained by SSE/
(Diesel Sheds).
SSE(C&W) will be responsible for the maintenance of hand cranes. Sr
DME/DME will nominate the hand cranes to be maintained by each SSE(C&W).
Carriage Inspectors (CWI) will be responsible for the periodical examination of
hand cranes at depots where no SSE(C&W) is posted.
Periodical overhauls and heavy repairs to cranes will be carried out in the
Workshops, including Diesel Hydraulic 140 Te. Cranes.

2. OPERATION:
2.1 Qualifications and Examination of Crane men: -
A crane may only be worked/Handled by a properly Trained/certified crane man.
The using Department is responsible that this condition is observed.

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Before an employee is allowed to work a crane, he must be examined as to his

competency to do so and be certified. The employee will be examined by an
officer deputed to do so by the Divisional Railway Manager under whom he is
working. The Certificate is to be issued in the following format :-
"This is to certify that
Mr.............................................No......................................... has
on.........................................(date) passed the Test in the working of Diesel
/Hand cranes up to a maximum lifting capacity of....................tons, and is
thoroughly conversant with the rules for the operation of Cranes. He is
authorized to work Diesel/Hand cranes up to a maximum lifting capacity of
...........tons.
(Countersigned) Designation"
Note: In addition to the above, competency certificate are necessary both for
supervising and for conducting crane operation and are necessary for crane
supervisors, crane drivers and crane muccadam. Normally the crane operation
of Diesel Cranes is entrusted to crane drivers supervised by the crane
supervisors. Competency certificate both for supervising crane operation and for
operating cranes should be granted in the prescribed proforma appended below,
after due testing by authorized official who will be nominated for the purpose by
the Chief Mechanical Engineer.
(Proforma of Competency Certificate )
Name………………………………….Designation…………………………….. has
been tested by me and is certified competent to take charge of …………….. and
responsible for the correct and safe working operation of Diesel Crane of
………..tons capacity.
Date: Sr DME/DME/WM
Place:
Note: Competency Certificate for supervising crane operations are valid for a
period of three years only and have to be renewed from time to time. The
knowledge and proficiency of the staff concerned are to be tested before
renewal of this certificate
2.2 Responsibility for correct carrying out of rules:
a) Crane men 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. But when a crane is working under the
supervision of an Officer or Subordinate of the Power or Carriage & Wagon or of
the Mechanical or the Engineering Department, the crane man is responsible for
the manipulation of the crane only.
b) In general, cranes working on breakdown operations or where the balance
weight/Counter weight or Jib is likely to foul another adjacent line or on the open
line or when used for lifting unusually heavy or awkward consignments, must
work under the supervision of an Officer or Subordinate of the Power or
Carriage & Wagon or Mechanical or the Engineering Department.
c) In Electrified sections, before commencing the operation, the crane supervisor/
Driver/Muccadam will clearly indicate by a written memo to overhead traction

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distribution department officer or subordinate staff present at site to obtain

power block and will operate the crane only after receiving the permit to work
issued by the authorized traction staff after OHE has been made dead and
earthed.
d) Within station limits, before commencing the crane operation, the crane
supervisor/ Driver/Mucaddam will clearly indicate by a written memo to the
station master/Yard master on duty the nature of the work, the siding on which
the crane will work, the line or lines to be blocked or fouled during the crane
operation and the time required for crane operation and only on obtaining the
written permission from station master/Yard master as per specimen below,
operation will be commenced. On controlled section where running lines are
foul, the station master will not be given the permission except with the prior
approval of the section controller on duty. Record of such approval and
permission asked for and given, must be entered in red ink in the train signal
register/Station diary.
[Proforma of the Certificate from SS/SM/YM]
The crane is permitted to work on line No………...……/ Siding………
From………. hrs.………to……… line / siding and adjacent line no. ……. have
been protected by red banner flags and there will be no movement on the above
lines/siding till the crane working is completed and written memo to this effect is
received.
Date: Station Master
Time: Yard Master
Station Stamp:
e) In the event of 140T. Crane operation at site, the operator must be thoroughly
conversant with load charts provided on the crane to assess the duty selection.
Before undertaking any lifting operation, the operator must ensure that the duty
selector of SLI is correctly set according to the configuration of the crane (i.e.,
Free on Rail or Blocked or Counter weight on super structure or carriage, heavy
ballast fitted etc.).
NOTE: Whenever 140T. Diesel Hydraulic Crane of ART is ordered to site of
accident/Derailment is to be accompanied by an officer. The officer concerned
will be Sr.DME under whose control the crane is being placed, if Sr.DME is
unable to accompany due to any reason, DME or ADME may be deputed.
2.3 Special training for Crane men:
Staff who are unable to get proper training in the duties of crane men locally,
and who in the opinion of their local examining authority are not sufficiently
competent to carry out their duties with safety, should be recommended for a
course of training. Arrangements will then be made with the Chief Mechanical
Engineer for this training to be carried out in the nominated Workshops.
2.4 Code of signals:
The code of signals for controlling the movements of cranes is given in
Appendix B.
2.5 Precautions when lifting with cranes:

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The crane must not be used to lift more than the maximum safe working load
authorized at the radius at which the jib is set. The lifting capacity of the crane
under different conditions and at various radius is marked/displayed on the
crane, and these maximum loads must not be exceeded for any particular
condition of working.
Precautions should be taken to avoid loads catching on obstructions as this may
seriously overload the crane and tackle. Sudden shocks and jerks also tend to
overload the crane and tackle, and these should be avoided.
Shocks and jerks usually result from: -
i. Mistakes in signaling to the crane driver.
ii. Want of observation by the crane driver.
iii. Sudden application of the Crane break.
iv. Kinks in the chain.
v. Slipping of the chain due to incorrect slinging or sling hooks not properly secured.
In case of 140T Diesel Hydraulic Crane of ART, following precautions
should be taken.
i. Before undertaking any lifting operation, the operator must be sure that the duty
selector or SLI is correctly set according to the configuration of the Crane (i.e.,
FOR) or blocked counter weight on super structure or carriage, heavy ballast
weight fitted etc.
ii. This crane is unstable in super elevated track in free –on- rail condition with
counter weight or heavy ballast weight fitted to superstructure.
iii. Swinging load is dangerous and is to be avoided.
iv. Before raising the jib from the match truck (assuming the crane is in running
condition) all blocking screws must be screwed down until locked on the top of
the spring.
v. Both relieving bogies must be unloaded, prior to raising the jib from match truck.
vi. Before any movement of the crane by its own power, operator must be sure
about engagement of travel gear clutch and proper braking of travel brake.
2.6 Lifting tackle to be of suitable capacity: -
Lifting tackle, that is hoisting chains, lifting chains, sling chains and wire ropes
used for lifting hoisting or slinging should be of suitable capacity. Safe working
loads for different sizes of chains and wire ropes are given in Appendix D.
The following definitions apply to Chains and Wire Ropes: -
a) Hoisting Chains - are main chains of cranes, used for hoisting the load.
b) Hoisting Wire Ropes - are Main wire ropes of cranes used for hoisting the load.
c) Lifting Chains - are chains fitted to the jib sheaves of jib cranes for lifting
purposes.
d) Lifting Wire Ropes - are Wire Ropes fitted to the jib sheaves of jib cranes for
lifting purposes.
e) Sling Chains - Chains with a ring at one end and a hook at the other, either with
a single, double or multiple legs. Sometimes Sling Chains are made as endless
chains.
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f) Wire Rope Slings - Slings with wire ropes used instead of chains.
2.7 Lifting Tackle to be tested:
Lifting tackle, that is hoisting chains, lifting chains sling chains and wire ropes
used for lifting, hoisting or slinging shall be periodically tested and examined.
The instructions in regard to the testing and examination of chains and wire
ropes are given in the work shop orders of Zonal Railways. Appendix E.
Ordering of 140T Cranes and Preparation of Disaster Management Plan. [ HLC
Recommendation No.- 15(b)-page No. 9]
The disaster management plan must inter alia include “who is responsible for what
activities in detail”.
1. Preparation and implementation of Disaster Management plan is the
responsibility of concerned GM/DRM.
2. Authority to order ART/ARMV/140TBreak Down Crane, CME/CMPE(D)/Sr
DME/DME, etc.
3. Senior most Railway officer at the site of the Accident shall be designated site
manager.
4. Management of Rescue operations - Primarily Mechanical and Medical
Departments. Assistance to be provided by all Railway Men (Irrespective of their
department) as needed.
5. Relief operations including care for the dead – Commercial, Medical and RPF
department.
6. Communication network- Telecom department.
7. Crowd control and law and order at site - RPF.
8. State police clearance for restoration - RPF
9. Restoration operations -
a) Rolling Stock – Mechanical Department
b) Fixed Infrastructure like Track, OHE, Signalling System etc.- Concerned
Departments.
10. Maintenance of SPART/ART and ARMV Rolling stock/140TBreak Down Cranes
including Rail-Cum-Road and Road Mobile Emergency vehicle etc. –
Mechanical Department.
11. Maintenance of equipment kept in SPART/ART/ARMV for Rescue and
Restoration operations – concerned departments.
12. Media Management at site –
a) Site manager shall be the Chief spokesman at site and can be assisted by the
concerned branch officers, if needed.
b) PR/Commercial departments, to look after the media needs at site.
13. Check list for the officers and supervisors must be issued in the form of pocket
booklet indicating do’s and don’ts for the benefit of:
a) First official reaching the site of accident
b) Senior most officer at the site
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c) Divisional/ HQ control organization

d) Station Manager/Station Master
3. MAINTENANCE:
3.1 Overhauls:
The date of each examination of 140 T. Diesel hydraulic crane break down
crane should be painted plainly on the crane at marked location.
The 140 T. Diesel Hydraulic Cranes of ARTs will fall due for its periodical
overhaul every 08 years. Cranes will however be examined by the division as
per the schedules prescribed by RDSO circulated by ministry of Railways
incorporating the schedules prescribed by Central Railway Locomotive Work
shop Parel for Cowans Sheldon, UK 140 T. Cranes and prescribed by Jamalpur
Work shop for Gottwald 140 Cranes of Germany. The POH of Cowans
Boyed/Cowans Sheldon UK will be undertaken by Parel Workshop and the POH
of Gottwald Germany will be undertaken by Jamalpur Work shop.
Divisional Railway Manager (Optg.)/ (Mech.) will recommend cranes under their
control for overhaul to the Chief Operating Manager/Chief Mechanical Engineer
through their Divisional Mechanical authority who will arrange programme for
releasing cranes for acceptance for overhaul in Workshop in consultation with
Chief Work shop Manager Parel/Jamalpur. The breakdown cranes i.e. 140T
Diesel crane under the control of Divisional Railway Manager (Mechanical) will
recommend these cranes for over haul in Parel /JMP Workshop with
consultation of CWM/Parel/JMP.
3.2 Heavy Repairs :
If a crane requires heavy repairs, which cannot be executed by Running Sheds,
the Divisional Railway Manager (Mechanical) will represent the case to the Chief
Mechanical Engineer, who will arrange for the crane to be relieved for heavy
repairs in Parel Workshop/JMP Workshop.
3.3 Running Repairs and Maintenance of Cranes:
Divisional Railway Manager (Operating)/(Mech.) will be responsible for running
repairs and ordinary maintenance of cranes.
Breakdown Cranes are the direct responsibility of the Incharge ART of the
Depots where these cranes are stabled, and they will be responsible for
maintenance of the cranes in efficient condition and for the periodical
examinations for their safe working.
Other travelling Cranes will be maintained by SSE/Millwright organization
nominated to do so by their Divisional Railway Manager (Mechanical). Shed/Mill
Wright staff organized by the division will inspect monthly and carry out minor
repairs such as reduction of brass bearings, taking up slack on keys,
examination of piston rings, valves, under gears etc., and check up all gear
wheels for broken teeth or partially broken teeth and pinning them to avoid
further damage and also clean clutch cones and re-bearing where necessary.
All non breakdown cranes will be maintained by respective owning department
in accordance with the provision laid down.
All 140 T. Diesel hydraulic cranes of ARTs will be maintained by the
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SSE(Diesel) nominated to do so by their Sr DME/DME diesel Sheds where

these cranes are stabled and where there is only trip sheds are available, Sr
DME of the division will nominate the supervisor for maintenance of the crane
stabled at their depot. The maintenance of these cranes will be carried out in
accordance with the schedules prescribed by RDSO.
The day to day maintenance of match truck and ballast wagon of 140 T. Diesel
hydraulic break down cranes will be carried out by the SSE(C&W) of carriage
and Wagon department where these cranes are stabled.
Hand Cranes will be maintained in good repair by SSE(C&W). Divisional
Railway Managers (Mechanical) will nominate the cranes to be maintained by
each SSE(C&W) of carriage and Wagon department. Periodical Examinations of
Hand Cranes will be carried out by Carriage Inspectors at Depots, where no
SSE(C&W) is posted.
In case of cranes running with roller bearing axle boxes, all the axle boxes must
be examined for condition of their grease and the topping of these boxes with
fresh grease must be done after every six months.
NOTE: In addition to the above, the Ultrasonic flaw detector testing of the crane
axle boxes including match truck and relieving trucks must be carried out after
every 12 months and the result of testing should be recorded in the register.
Date of such testing also to be marked at the places as indicated above.
3.4 Periodical Examinations of Cranes :
All break down Cranes with their gears must be carefully examined at intervals
of not more than three months. At depots which are in charge of SSE(C&W,
they will be responsible for these examinations of Cranes. At depots where
SSE(C&W) are posted, they will be responsible to carry out periodical
examinations of hand cranes, at other depots. Hand Cranes will be examined by
Carriage Inspectors.
The 140 T. Diesel Hydraulic Cranes of ARTs/BDT shall be examined at intervals
regularly as prescribed by RDSO Document No.SD.CRMG date 04.07.2018 &
its Corrigendum Slip No.1 of August’2018 for Common Maintenance Schedule
for 140T diesel hydraulic breakdown cranes (Gottwald & Cowans Sheldon
design). The SSE(Diesel) at Diesel Sheds/Trip Sheds nominated to do so are
responsible for the periodical examination of 140 T. Diesel Cranes.
To ensure proper upkeep and reliability in safe working of 140 T. Diesel crane at
site, the periodicity of maintenance schedules have been prescribed by RDSO
which has been given in Chapter No.2 and detailed proformas are given in
Chapter No.6.
Particulars of periodical examinations of cranes will be maintained on a register
kept in the custody of the Subordinate in-charge of the depot to which the crane
is posted. Any repairs to be executed should be reported to the Subordinate in-
charges of the maintenance of the crane, a copy of this report to be sent to the
Divisional Railway Manager(M)/DRM(O) for their information.
Particulars of periodical examination of ARTs/BDT Cranes will be maintained in
a register to be kept in break down train. The periodical examination of all
cranes of ARTs/BDT will be followed as per the revised procedure. The record
of such examinations entered in the register will be signed by the maintenance
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Maintenance & Operation Manual Part I- 140 T BD Cranes

supervisor and countersigned by the officer incharge of ART/BDT.

Particulars of periodical examination of 140 T. Diesel hydraulic break down
cranes will be recorded in the prescribed schedule forms as laid down by RDSO
and are as under which have been indicated against each periodicity of
maintenance schedules.
Periodic Maintenance Schedules Set of Schedule Forms

* Daily Form A
* Monthly Form B
* Three Monthly Form C
* Six Monthly Form D
* Yearly Form E
* Two Yearly Form F
* Four Yearly Form G
* POH Form H
Officers of the Power/Diesel Shed and Carriage & Wagon Department will
periodically check that the registers showing particulars of examinations of
cranes are correctly maintained; those examinations are being made on due
dates and that the cranes are being kept in good condition.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

APPENDIX A.
(A) General and Subsidiary Rules Regarding Working of Cranes
G.R.4.27.
(a) Traveling cranes –
(i) No traveling crane shall be attached to a train until it has been certified by a duly
authorized person (Crane operator) that it is in proper running order, and with a
dummy/Match truck for the jib, if necessary.
(ii) When a crane is to work on any line provided with electric traction or any line
adjacent to it, the procedure and precaution as laid down under special
instructions shall also be followed.
(b) Working and care of cranes -
1. Crane men - All Crane men must be in possession of a competency certificate
issued by the Divisional Railway Manager (Mech.) under who he is working. The
Crane man is responsible for the efficiency of the crew working under him, who must
be trained men.
(c) in addition to the above, the sketches indicating the principal parts of 140T. diesel
hydraulic breakdown cranes with their load charts for the safe operation at site are
enclosed in annexure- A, B, C, D & E.
1. Lifting capacity - The lifting capacity of all cranes under different conditions and at
various radii to be painted on either side of the carriage or super structure of the
crane as well as the size of the chains and wire rope of each crane must be painted
in white letters on the jib.
2. Weight of balance weight box - The weight of the balance weight box of hand
traveling cranes must not be interfered with in any way. when the crane is in use, the
balance box must be at the extreme end of its tail. The weight contained in the
balance box should be painted conspicuously on both sides.
3. Repairs, Examination and Periodical Overhaul –
(a) The Divisional Railway Manager is responsible for their maintenance.
(b) All cranes with their gears and under gearing must be carefully inspected by the
SSE (loco)/SSE(C&W) or by the nominated supervisor at intervals of not more
than three months.
(c) The 140 T Diesel Hydraulic Cranes of ART/BDT are normally due for periodical
overhaul every 08 years. These cranes however be examined by division at
various intervals/Schedules as prescribed by RDSO incorporating with the
schedules as prescribed by Parel workshop for Cowans Sheldon crane &
Jamalpur workshop for Gottwald design cranes.
The examination of wire ropes and wire rope slings of 140 T Diesel hydraulic
crane will be done by the staff specially trained at divisional level as per the
procedure laid down in Workshop Orders. The Chains will however be sent to
Mechanical work shop Parel/Jamalpur for periodical inspection and testing.
4. Attachment of Cranes -
(a) No traveling Diesel cranes are to be worked or run-out on the Main line, except
under the supervision of a certified Crane man.
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(b) Before a traveling crane is allowed to run outside station limits, the jib must be
lowered on to its dummy/match truck, with the jib resting freely on the bolster. The
cams beneath the balance weight box or such contravene with which the crane is
fitted must brought in to use. on diesel cranes the outrigger girders/beams must be
pushed in and secured properly. on hand cranes the balance weight box must be
fixed close to the crane pillar. The grippers and all other fittings must be securely
stowed away and fastened to prevent their moving. The weight of the crane must be
taken on the springs. The crane man shall ensure this.
In case of 140T. diesel hydraulic cranes for “in-train” in-running/traveling condition,
ensure the following guidelines.
(i) load the relieving bogies (by operating hand pump) until the centre casting
locking pins slides into position and then release the loading jack completely.
(ii) Ensure that the heavy lift ballast weight is removed and placed on its proper
place on ballast truck provided with crane.
(iii) The detachable counter weight is also placed on its place provided on
carriage below the crane jib end side.
(iv) Load the crane springs by taking the weight of the crane ensuring that the
blocking screws are screwed up and ensure the gap between top of the
spring and screw is sufficient for free movement of springs while crane is in
running condition.
(v) The traveling gear box must be disengaged when traveling “in-train”.
(vi) All the six (6)/four (4) outriggers hydraulically operated telescopic draw
beams incorporating with hydraulic operated jacks which are inbuilt into
carriage, should be secured in their proper position and locked properly in
running condition.
(vii) 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.
IMPORTANT: After coupling the relieving bogies and before traveling recharge the
spring feed lubricants on the both relieving bogies and the carriage and castings with
recommended lubricants.
(c) The crane man is responsible for seeing that the aforesaid precautions have been
taken and the Guard will verify that the jib has been correctly lowered on the
dummy/match truck and the crane turning table has been locked by means of the
provision available on the crane.
(d) Where possible all cranes should travel with the jib to the rear (i.e., in trailing
direction) but where this is found impracticable, care must be taken to see that the
instructions regarding the securing of the jib have been fully observed.
(e) The JE/SSE (C&W) nominated for train Examination will certify in the Guard's
Memo Book if the crane is fit to run. Before certifying that the crane is fit to run, he
must ascertain from the Crane man that the above rules have been complied with.
5. 140 Ton Diesel Hydraulic Cranes:
140Ton diesel hydraulic cranes may run over any BG section of the Railway.

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6. Modifications on 140 T Old & New Gottwald Cranes to enhance hauling

speed potential to 100 Kmph.
RDSO has issued final speed certificate for hauling Gottwald design cranes (with
certain modifications) at 100 Kmph. Details of these modifications have already been
circulated to Zonal Railways so that cranes may be upgraded accordingly.
[ Rly Board’s letter No. 2001/(M&P)/175/6(Speed) dated 04.04.2003]
[ RDSO letter No. SD.C. Gottwald.A1.11 dated 26.03.2003]
(B) Maximum Permissible Speed (140 Ton Diesel Hydraulic BD crane,
Cowans Sheldon old)
1) Maximum permissible speeds on track with minimum standard of 90 R rails on
sleeper to M 14 density and 200 mm depth of ballast cushion below sleepers
which may consist of at least 75 mm clean and the rest in coked up condition,
on consolidated and stable formation shall not exceed the values given below:

Condition applicable for the speed Maxi. Permissible

Speed

a When hauled as trailing load with Jib resting on Match 75 KMPH

truck
NOTE: The crane should be marshaled as per the
relevant rules or the existing practices prevailing on the
Railways.

b When traveling on its own power with or without load 5 KMPH

as indicated in sketches LD/SK-615 Alt.-1 and 616
sheets 1&2 Alt.-1.
Notes:

i The load shall be brought to the shortest possible radius. The jib should
normally be brought parallel to the truck.

ii Based on the type and conditions of the Formation, the Crane Driver/Supervisor
should take adequate precautions to ensure that there is no settlement of
formation under the working crane.

iii During Crane working, a special watch Shall be kept on the condition on fish
plates. Any damaged fish plates should be replaced before allowing the traffic
on the restored track.

II For track of lower standard than that mentioned above the Chief Engineer
concerned shall decide the lower maximum permissible speed. In this
connection, Railway Board’s letter No. 65/WDO/SR/26 dt. 19/20.10.1966 may
be seen. When the Chief Engineer considers that the road bed is not compacted
or there is improper drainage, he may suitably restrict the maximum permissible
speed depending on the local conditions.

III The maximum permissible speed on curves to be decided on the basis of

existing provisions of the Indian Railways Permanent Way Manual.

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IV The Bridges shall be MGB 87, RBG or BGML standard drawings. The
movement of the crane on these bridges shall be restricted as follows:

Conditions applicable for the permissible speed Maximum

permissible
speed

I A) As a trailing load hauled by single WDM3A, WDG3A,

WDP4, WAM4, WAG5, WAG7, WAG9, WAP1, WAP4,
WAP5 or any other diesel or electric locomotive with jib
resting on Match Truck

B) Span other than between 12 m and 32 m{clear} 75 kmph

C) Span between 12 m and 32 m clear 60 kmph

II i) Driven by its own power with both relieving bogies 10 kmph

attached for hook load up to 10 T, jib radius up to 12 meters
and slew angle up to 28 degrees.
ii) Driven by its own power with jib resting on match truck
and with axle load as in sketch No. RDSO. SK.No.CR.748. 15 kmph
Alt.3
iii) Driven by its own power with both relieving bogies
attached to crane removable counter weight on super
structure, jib at 5.5 meters radius facing match truck, with
no hook load and with axle loads as shown in sketch No. 15 kmph
ID/SK/619 proposal 2.

GENERAL:

1 All permanent and Temporary speed restrictions in force and those imposed
from time to time due to track, bridges, curves, signaling and interlocking etc.
shall be observed.

2 A copy of the speed certificate must be available with crane whenever it has to
work on the Railway lines.

3 The use of crane which is likely to foul the overhead equipment on an electrified
section are subject to the conditions laid in SRs of zonal railways.

2. OPERATION:

a) Cranes are not to be operated between sunset and sunrise except in case of
emergency.

b) Under no circumstances must a crane be loose shunted or a loose shunt made

against a crane.

c) The bearing spring must be relieved of the weight of the crane by the means
provided, the outrigger girders must be fully extended to project equally on both

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sides of the crane and securely packed up and the claws or grippers must clip
the rails firmly. On hand cranes the cams beneath the balance weight box must
be traversed outwards to its full extend and clamped. The rising pulley block on
the chain just always be used when lifting loads above half lifting capacity of
hand cranes.

d) Two cranes of unequal lifting capacity must not be operated together to lift any
one heavy article, unless the lifting capacity of the smaller crane is at least equal
to half the weight to be lifted.

e) When crane is liable to foul another line during working, it must be in charge of a
responsible subordinate official such as an Inspector. The Station
Superintendent/ Manager at the either end of the section must be advised to
issue caution orders to the drivers of trains proceeding into the section. The
inspector in charge of the crane must when the crane is likely to foul another
line, protect that line with Banner flags and Hand signals in accordance with
SRs. Such banner Flags and Hand signals may only be removed on his
authority when the crane has stopped working and the jib has been placed
parallel to the track, clear of the adjacent road.

f) If it is desired to work a crane or cranes on a bridge, the permission of the

divisional engineer must first be obtained who will, if necessary, obtain the
sanction of Chief Engineer. The maximum weight to be lifted and maximum
radius and angle at which the crane jib will work should be given for guidance.

g) The 140-ton Diesel Hydraulic crane shall only be driven on the bridges as per
the speed certificate circulated by RDSO vide their letter No.
SL/CR/SPD/140T/Jessop dated 01/25.02.1991, 29.06/01.07.92 and 03.05.1994
or latest instructions.

h) When transportation crane is lent to any other department, for departmental

use, the charges for its use shall be as notified in rule 130(1) of IRCA goods and
traffic No. 41 part I (Vol. I ), for traffic charges of cranes and rule notified 130(2)
of IRCA goods traffic No. 141 part I (Vol.1) for cranes haulage charges
circulated from time to time under chief Commercial Managers’ advance rate
notification No. 83 of 1997 (goods) may be followed and if revised further should
be considered as fresh charges.

i) Posting of Rules: Mounted copies of rules for working cranes are to be

displaced on the back of the crane and on the back of the balance weight box of
the hand cranes.

In case of 140 T diesel hydraulic crane, mounted copies of rules/Load lifting

charts for working of these cranes to be displayed on either side of the crane
super structure or carriage whichever is suitable place.

8. Crane belonging to the Engineering or the Mechanical Departments must be

worked solely by certified crane men appointed by these departments and the
crane men are responsible for the proper working of the cranes.

Cranes use of, on the Electrified Area/ Section.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

a) All movement of the crane Jib shall be exercised with great care so as not to
foul overhead lines where possible the direct blast from crane chimney to
overhead lines or insulators should be avoided.

b) The 140 T diesel hydraulic crane provided with ‘A’ frame for derricking the Jib
when erected, the height is about 9 meters from the rail level when fully raised
and will in any case foul the overhead lines also foul/infringe with OHE portals.
In such cases, the overhead lines of the same track on which the 140 T crane is
working have to be slewed and if necessary to be grounded. The overhead
lines of the adjacent line are also required to be made dead. Slewing of OHE
wires will only be done in case when it is essential or obstructing crane working.

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APPENDIX – B
The code of signals for controlling the movements of the cranes is as under:

1) Call Attention: Crane driver’s attention must be called by short blast

of whistle before each movement is directed.

2) Lifting: Face the jib with the right arm held parallel to the
ground extended to the side of a body with the palm
upwards and move arm in an upward direction from
the shoulder several times.

3) Lowering: Face the jib with the right arm held parallel to the
ground extended to the side of a body with the palm
downwards and move arm in downward direction
from the shoulder several times.
4) Direction of travel: Face direction in which, it is required to travel at the
same time giving signal by swinging right arm from
rear to front.

No. 2 Lifting

Right hand parallel and extended from the shoulder with palm upwards moved in an
upward direction from the shoulder until the lift is completed.
No.3 -Lowering

Right hand held parallel and extended from the shoulder with the palm downwards

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Maintenance & Operation Manual Part I- 140 T BD Cranes

moved in downward direction from the shoulder until the lowering is completed.
No.4 Direction of Crane travel

Face direction of travel required at the same time giving signal by swinging the arm
nearest the crane driver from rear front in the direction of required travel.
No.5 – Travel of Cranes (OH cranes)

Face the job being lifted and give the direction of travel by extending right or left hand
parallel with the shoulder in the direction required.
No. 6 Slewing of Cranes (same as above)

No.7 Raising jib of Diesel cranes.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Right hand held parallel and extended from the shoulder in front of the body with
palm upwards moved in an upward direction from the shoulder several times.
No.8 Lower jib of the Cranes.

Same as No.7 except palm downwards moved in a downward direction from the
shoulder several times.
No. 9 Stop.

Right hand held above the head fully extended and open
No.10 Slowly

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Left hand held above the head fully extended and closed.
Note: This signal to precede any of the above in case of slow and slight movements.

5) Travel or Crab or Face the job being lifted and indicate the direction of
slowing movement by extending the right or left arm parallel with
the shoulder in the direction required.

6) Raising Jib Hold right arm parallel to the ground and extend from
the shoulder in front of the body with the palm upwards
and move in an upward direction from the shoulder
several times.

7) Lowering jib As No. 6 except that palm must be downwards and the
arm move in a downward direction from the shoulder
several times.

8) Slowly Hold left hand above the head fully extended and
closed. This signal is to precede any of the above in
case of slow movements being required.

9. Stop Right hand held above the head fully extended and
open.

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APPENDIX – C
1. The safe working loads for different sizes of chains are given in the following table.
Short link and pitched or Stud link chains Short link and pitched
calibrated * chains formula 9-d 2 or calibrated chains
formula 6-d 2 formula 6-d 2
Nominal diameter Safe Nominal Safe Nominal Safe
of chain working diameter of working diameter working
load chain load of chain load
Inch mm Ton Cwt Inch mm Ton Cwt SWG Ton Cwt
7/32* 5.6 … 5 1 25.4 9 0 … … …
1/4* 6.4 … 7 1.1/4 31.8 14 1 6 (0.192) … 4
9/32* 7.1 … 9 1.1/2 38.1 20 5 5 (0.212) … 5
5/16* 7.9 … 11 1.3/4 44.4 27 11 4 (0:232) … 6
11/32* 8.7 … 14 2 50.8 36 0 3 (0.252) … 7.1/2
3/8* 9.5 … 16 2 (0.278) … 9
13/32* 10.3 … 19 1 (0.300) … 10
7/16* 11.1 1 2
15/32* 11.9 1 6
½* 12.7 1 10
9/16* 14.3 2 0
5/8* 15.9 2 6
¾ 19.0 3 7
7/8 22.2 4 11
1 25.4 6 0
1.1/16 27.0 6 15
1.1/8 28.6 7 12
1.1/4 31.8 9 7
1.3/8 34.9 11 6
1.1/2 38.1 13 10
1.5/8 41.3 15 15
1.3/4 44.4 18 5
1.7/8 47.6 21 0
2 50.8 24 0
2.1/4 57.2 30 7
2.1/2 63.5 37 10
Notes:
1. The safe working in the above table and those stamped on tackle and entered
in the certificates are for vertical pull on a single length of chains under
conditions of steady loading and with the load absolutely free to move.
2. The safe working loads given in the above table for pitched or calibrated load
chains for hand operated pulley blocks apply only to sizes up to and including
5/8” diameter.
3. To obtain the safe working loads in tons for any intermediate size, use the
formula at the head of the respective column d 2, is the square at the nominal
diameter or the iron or steel in inches. The formula does not apply to pitched
or calibrated chains above 5/0” diameter.
II. The working load on the endless sling chains should not exceed the safe
working load on the single chain.
III. The safe working load on double sling chains is generally less than twice the
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Maintenance & Operation Manual Part I- 140 T BD Cranes

safe working load on a single chain and is given in the following table for different
sizes of chain with the two parts of the sling inclined at various angles.
Diameter of iron chain Safe working load for complete sling
o
30 600 900
Inch mm Ton Cwt Ton Cwt Ton Cwt
1/4 6.4 0 14 0 12 0 10
5/16 7.9 1 2 0 19 0 16
3/8 9.5 1 11 1 8 1 3
1/2 12.7 2 17 2 12 2 2
5/8 15.9 4 10 4 0 3 6
3/4 19.0 6 10 5 17 4 15
7/8 22.2 8 17 7 18 6 9
1 25.4 11 12 10 7 8 9
1.1/16 27.0 13 2 11 14 9 11
1.1/8 28.6 14 12 13 2 10 14
1.1/4 31.8 18 2 16 5 13 5
1.3/8 34.9 21 17 19 2 16 0
1.1/2 38.1 26 1 23 8 19 1
1.5/8 41.3 30 12 27 8 22 8
1.3/4 44.4 35 9 31 16 25 19
1.7/8 47.6 40 14 36 10 29 16
2 50.8 46 8 41 11 33 18
2.1/4 57.2 58 8 52 7 42 15
2.1/2 63.5 72 9 64 19 53 0
o
1.For normal lifting the angle between the parts of the sling should not exceed 90
2.In exceptional cases an angle between the two parts of the sling of not exceeding
1200 may be permitted, but in such cases the capacity of the complete sling is
reduced to that of a single chain of the same diameter.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

The safe working loads for wire ropes of 100-110 tons sq. inch tensile strength of wire
and 6x19.6x24 and 6x37 combinations are given below:
Circumferen 6X19 6X24 6X37
ce of rope Safe working load Safe working load Safe working load
Non Non Non
Pass. Pass Pass
Cranes pass. Cranes pass. Cranes pass.
Hoists Hoists Hoists
Hoists Hoists Hoists
Inch MM T C T C T C T C T C T C T C T C T C
3/4 19.0 0 6 0 3½ 0 2½ 0 5 0 3 0 2 … … … … … …
1 25.4 0 11 0 6½ 0 4½ 0 10 0 6 0 4 0 11 0 7 0 4
1.1/4 31.8 0 17 0 10 0 7 0 16 0 10 0 6 0 16 0 9 0 6
1.1/2 30.1 1 4 0 14 ½ 0 9½ 1 3 0 14 0 9 1 3 0 14 0 9
1.3/4 44.4 1 13 1 0 0 13 1 11 0 18 0 12 1 13 0 19 0 13
2 50.8 2 5 1 7 0 18 2 2 1 5 0 17 2 4 1 6 0 17
2.1/4 57.02 2 17 1 14 1 3 2 12 1 11 1 1 2 16 1 14 1 2
2.1/2 3 10 2 2 1 8 3 7 2 0 1 6 3 7 2 0 1 6
2.3/4 69.8 4 4 2 10 1 13 3 19 2 7 1 11 4 2 2 9 1 13
3 76.2 5 6 3 3 2 2 4 13 2 16 1 17 4 19 2 19 1 19
3.1/4 02.6 6 3 3 14 2 9 5 12 3 7 2 5 5 12 3 7 2 5
3.1/2 00.9 7 6 4 7 2 18 6 9 3 17 2 11 6 12 3 19 2 13
3.3/4 95.2 8 6 4 19 3 6 7 6 4 7 2 18 7 13 4 12 3 1
4 101.6 9 7 5 12 3 15 8 9 5 1 3 7 8 16 5 5 3 10
4.1/4 108.0 10 10 6 6 4 4 9 9 5 13 3 15 10 0 6 0 4 0
4.1/2 114.3 11 19 7 3 4 15 10 10 6 6 4 4 10 19 6 11 4 7
4.3/4 120.6 13 5 7 19 5 6 11 18 7 3 4 15 12 7 7 8 4 18
5 127.0 14 12 8 15 5 16 13 2 7 17 5 5 13 15 8 5 5 10
5.1/4 133.4 16 5 9 15 6 10 14 6 8 12 5 14 15 5 9 3 6 2
5.1/2 139.7 17 15 10 13 7 2 15 12 9 7 6 5 16 9 9 17 6 11
5.3/4 146.0 19 6 11 12 7 14 17 6 10 7 6 18 18 2 10 17 7 4
6 152.4 21 5 12 15 8 10 18 14 11 4 7 9 19 16 11 18 7 18
When used for hoists the safe working load of wire ropes is reduced according to
whether the hoist is used as a passenger or non passenger hoist. The reduced safe
working loads are given on the certificate.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

APPENDIX ‘D’
I. Testing of chains
[ Based on workshop orders of Zonal Railways.]
a) Testing of chains- The mechanical Department will carry out the testing of
hoisting, lifting and sling chains, Chain pulley blocks, belonging to all
departments of zonal Railway/ Divisions at nominated Workshop.
b) All crane Hoisting, lifting and sling chains in the possession of all departments
must be tested once in a year at nominated workshop.
Chains from Transportation Department Cranes will be sent for testing in sets
consisting of one double and one single, lifting and sling chains respectively.
Cranes should only be out of action when the main hoisting chain (where only
one is provided) is under test.
c) Chains and slings used by workshops/sheds and those of cranes in daily use
must be tested every six months under normal conditions and those
subjected to severe working conditions; are inspected more often say once in
three months.
d) Every chain must bear a number and the workshop Test Mark, to show that its
use for the above purposes has been authorized.
e) Every new chain and chain slings so procured shall then be sent to nominated
Workshop along with procurement documents, heat treatment and test
examination certificates issued by the manufacturer for testing, numbering and
entry in the special register maintained for this purpose, before they are put
into service. details such as maker’s name, safe working load, diameter of link
and length of chain, date put in service and date on which subsequently tested
must all be recorded.
f) Under no circumstances must a chain be cut down, lengthened, or have its
number altered except at nominated workshop.
g) When forwarding chains for testing to nominated CWM, it is important that the
chain number, overall length and diameter of link is entered on the advice note
under which the chain is dispatched, to facilitate identification with the entries
in the register.
h) The above instructions also apply to all cranes fitted with wire ropes in lieu of
chains.
i) Chains due for testing must be sent in by those in whose charge they are, to
concerned CWM l and these officers will deal with any enquiries or
communications which may be necessary.

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V. Safe working loads of Manila ropes of quality complying with Indian Stores
Department Specification G/Tax/11-7A are given below:
Circumference Total No. of Safe working load for new ropes
in yarn per Special quality marked with a Special quality marked with
rope black yarn in each of the a black yarn in one of the
strands of the cordage strands of the cordage
Inch MM Ton Cwt Ton Cwt
1 25.4 9 - 1¼ - 1
1¼ 31.8 12 - 2 - 1½
1½ 38.1 18 - 3 - 2¼
1¾ 44.4 24 - 4 - 3
2 50.8 33 - 5¼ - 4
2¼ 57.2 39 - 6¼ - 5
2½ 63.5 51 - 7¾ - 6
2¾ 69.8 60 - 9½ - 7¼
3 76.2 72 - 11 - 8¾
3¼ 82.6 84 - 13 - 10
3½ 88.9 99 - 15 - 11 ½
3¾ 95.2 111 - 17 - 13 ¼
4 101.6 129 - 19 - 15
4¼ 108.0 144 1 1 - 16 ½
4½ 114.3 162 1 4 - 18 ½
4¾ 120.6 180 1 6 1 0
5 127.0 201 1 9 1 4
5½ 139.7 243 1 15 1 7
6 152.4 288 2 1 1 12
6½ 165.1 339 2 8 1 17
7 177.8 393 2 15 2 3
8 203.2 513 3 11 2 15
9 228.6 648 4 8 3 9
10 254.0 801 5 8 4 4
11 279.4 969 6 11 5 0
12 304.8 1152 7 15 6 0
13 330.2 1356 9 0 7 0
14 355.6 1572 10 8 8 2
15 381.0 1800 12 0 8 2
16 406.4 2049 13 11 10 11
17 431.8 2316 15 5 11 17
18 457.2 2592 17 1 13 0
Note:
1. The above safe working loads are based on a factor of safety of eight on the
specified minimum breaking strength.
2. Manila rope is adversely affected by climatic conditions. The above safe loads
refer to rope recently tested in accordance with the rules.
II. Periodical Examination and Maintenance of Wire Ropes and Wire Rope
Slings:
Unlike chains and chain slings are not subjected to load test during service. They are
to be periodically examined visually.
Wire ropes in use on workshop/Shed/Other Depot cranes and other cranes in daily or
very frequent use must be removed at site every three months. Wire ropes used on
hand and steam cranes not in daily or frequent use may be removed for examination
at site every six months. In case of Breakdown cranes, however, the wire ropes

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Maintenance & Operation Manual Part I- 140 T BD Cranes

must be removed after they have been used on heavy breakdown operations for
examination.
In regard to para (i) wire ropes should not be sent to nominated workshop for
periodical test or examination, but should be examined as specified above and a
report may be submitted in Triplicate on the form (G.43.F or prescribed by railway) to
the CWM concerned. The requisitions for the forms referred to, should be submitted
to the controller of stores for the number required.
Method of periodical examination of wire ropes and wire rope slings:
a) Wire ropes and slings to be detached from cranes and thoroughly cleaned and
their length, circumference and diameter measured and recorded. The
circumference/ dia of wire rope should be measured at minimum three places
beginning with the eye end in shorter length rope and more in longer ropes, at
least 150 cm apart, with a suitable measuring device such as rope caliper. The
average or these readings will be the circumference/ diameter of the rope.
b) The wire ropes and slings are then to be carefully examined for strain and
distortion. Strain will be indicated by a reduction in the original circumference
of the rope or diameter which can generally be measured at the eye end.
c) Each strand should be examined for flat or fractured wires, and projecting
ends, if any should be broken off. If fractured wires are found in two or more
places it should be ascertained if they are on the same of separate strands.
The same also applies to flattened or strained wires. The position of strains or
fractures should be measured from the centre of the Hook.
d) No wire rope should be passed if in any length of 8 dias, the total No. of visible
broken wires exceeds 15% of the total No. of wires, or the ropes shows signs
of excessive wear, corrosion or other defects, which in the opinion of the
inspecting authority renders it unfit for service.
e) On completion of inspection and before it is fixed in position, the rope should
be well greased with Graphite water proof grease or by Holicoat which should
be well worked into the interstices of the strands.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Prescribed form
III. Particulars of Examination of Wire Ropes

Present min. circumference due

No. of strands in each rope and

number of wires in each strand

If anyone strand is bkn in more

Any other features such as flat

than one place give position &

No. of broken wires at each

and if fitted with hempen or

wires crushed or distorted

Date of last examination

Position of bkn strands
Circumference of rope
Crane No. & Capacity

No. of breaks in each

Date now examined

Double or 3-fold

Strands broken

other core

structure
Original

position
Single

strain
Block

No.of
to

1 2 3 4 5 6 7 8 9 10 11 12

* A rope with 6 strands and 37 wires in each strand would be thus 6 X 37.
Note: For instructions regarding examination of wire ropes see clauses (a) to (b) of
sub-para 2 of para 24.
Memo No……………………………………………………………………………...
Forwarded in triplicate to the CWM /Dy.CME for information and return with his remarks.
Station: …….
Date ………
Memo …………………………………………………………………………………
Returned to the DRM (Optg)./DRM (mech)……………………………………….
Signature/Works Manager……………

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Maintenance & Operation Manual Part I- 140 T BD Cranes

APPENDIX ‘D-1’
The standard “lifting tackles” for 140 T diesel hydraulic crane of accident relief train is
given below, together with a table showing how the lifting tackles can be sent for test
in two periods and have the crane still kept at work.

Standard equipment 1st period 2nd period

1. 140 T diesel HYD cranes (COWANS SHELDON) NE.1/UK DRG No.2231-

133/RDSO Drg No. 2 WDH 140 XE-9.01

Lifting tackles

2 1.Two leg wire rope sling 1.Two leg wire rope sling to 1.Two leg wire rope
to BS-1290 SWL 70 T, with BS-1290 SWL 70 T, with sling to BS-1290 SWL
hook and ring, length = 6 M hook and ring, length = 6 M 70 T, with hook and
ring, length = 6 M

a) Hook – 50 T S.W.L Hook Hook – 50 T S.W.L Hook Hook – 50 T S.W.L

higher tensile steel to BS- higher tensile steel to BS- Hook higher tensile
2903. Ultrasonically tested 2930. Ultrasonically tested steel to BS-2930.
for any flaws. for any flaws. Ultrasonically tested for
any flaws.

b) Ring- MAT-EN:14 A. Ring- MAT-EN:14 A. Ablong Ring- MAT-EN:14 A.

Ablong link of inside dia. link of inside dia. 890X540 Ablong link of inside
890X540 Matl  130 Matl  130 dia. 890X540 Matl 
130

c) Wire rope: single part Wire rope: single part Wire rope: single part
spliced endless sling  64. spliced endless sling  64. spliced endless sling 
Rope 6/49 construction Rope 6/49 construction steel 64. Rope 6/49
steel core with ordinary core with ordinary Thimbles. construction steel core
Thimbles. with ordinary Thimbles.

d) Proof load: 81T per leg Proof load: 81T per leg Proof load: 81T per
leg

e) Finish- Galvanized Finish- Galvanized Finish- Galvanized

4) Two leg wire Rope sling to Two leg wire Rope sling to Two leg wire Rope
sling to
BS-1290. S.W.L 25 Ton BS-1290. S.W.L 25 Ton with
with Hook & Ring .Length 2 Hook & Ring .Length 2 Nos = BS-1290. S.W.L 25
Nos = 5 M & 2 Nos =7 M 5 M & 2 Nos =7 M Ton with Hook & Ring
.Length 2 Nos = 5 M &
2 Nos =7 M

a) Hook- 25 Ton S.W.L.Hook Hook- 25 Ton S.W.L.Hook Hook- 25 Ton

Higher Tensile Steel to BS- Higher Tensile Steel to BS- S.W.L.Hook Higher
2903. Ultrasonically tested 2903. Ultrasonically tested Tensile Steel to BS-
for any Flaws. for any Flaws. 2903. Ultrasonically
tested for any Flaws.

b) Ring- MAT EN.14A. Ring- MAT EN.14A. Ablong Ring- MAT EN.14A.
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Maintenance & Operation Manual Part I- 140 T BD Cranes

Ablong Link of inside Dia Link of inside Dia 890x540 Ablong Link of inside
890x540 Matl  100. Matl  100. Dia 890x540 Matl 
100.

c) Wire Rope-Single part Wire Rope-Single part Wire Rope-Single part

spliced end less sling  44. spliced end less sling  44. spliced end less sling
Rope 6/36 construction Rope 6/36 construction steel  44. Rope 6/36
steel core with ordinary core with ordinary Thimbles. construction steel core
Thimbles. with ordinary Thimbles.

d) Proof Load-42.4 Ton per Proof Load-42.4 Ton per Proof Load-42.4 T per
leg. leg. leg.

e) Finish-Galvanized Finish-Galvanized Finish-Galvanized

4. Single Leg Wire Rope Single Leg Wire Rope Sling Single Leg Wire Rope
Sling to BS-1290. SWL 70 to BS-1290. SWL 70 Ton Sling to BS-1290. SWL
Ton with Hook & Ring. with Hook & Ring. Length = 6 70 T with Hook & Ring.
Length = 6 M M Length = 6 M

a) Hook – 70 T S.W.L Hook Hook – 70 T S.W.L Hook Hook – 70 T S.W.L

higher tensile steel to BS- higher tensile steel to BS- Hook higher tensile
2903. Ultrasonically tested 2903. Ultrasonically tested steel to BS-2903.
for any flaws. for any flaws. Ultrasonically tested for
any flaws.

Standard equipments 1st period 2nd period

b) Ring: MAT-EN:14 A. Ring: MAT-EN:14 A. Ablong Ring: MAT-EN:14 A.

Ablong link of inside dia. link of inside dia. 890X540 Ablong link of inside dia.
890X540 Matl  130 . Matl  130 . 890X540 Matl  130 .

c) Wire Rope-Double part Wire Rope-Double part Wire Rope-Double part

spliced endless sling  64. spliced endless sling  64. spliced endless sling 
Rope 6/49 construction Rope 6/49 construction steel 64. Rope 6/49
steel core with ordinary core with ordinary Thimbles. construction steel core
Thimbles. with ordinary Thimbles.

d) Proof Load -To 105.4 Proof Load -To 105.4 Tonne Proof Load -To 105.4T
Tonne

e) Finish- Galvanized Finish- Galvanized Finish- Galvanized

4. Single Leg Wire Rope Single Leg Wire Rope sling Single Leg Wire Rope
sling to BS-1290. SWL.50 to BS-1290. SWL.50 Ton sling to BS-1290.
Ton Max with Hook & Ring. Max with Hook & Ring. SWL.50 Ton Max with
Length = 5 M Length = 5 M Hook & Ring. Length =
5M

a) Hook- 50 Ton S.W.L. Hook Hook- 50 Ton S.W.L. Hook Hook- 50 Ton S.W.L.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Higher Tensile Steel to Higher Tensile Steel to Hook Higher Tensile

Steel toBS-2903.
BS-2903.Ultrasonically BS-2903.Ultrasonically Ultrasonically tested for
tested for any Flaws. tested for any Flaws. any Flaws.

b) Ring- MAT-EN-14 A. Ring- MAT-EN-14 A. Ablong Ring- MAT-EN-14 A.

Ablong link of inside dia. link of inside dia. 890X540 Ablong link of inside
890X540 Matl  120 Matl  120 dia. 890X540 Matl 
120

c) Wire Rope- Single Part Wire Rope- Single Part Wire Rope- Single Part
Spliced endless sling  64. Spliced endless sling  64. Spliced endless sling 
Rope 6/49 construction Rope 6/49 construction steel 64. Rope 6/49
steel core with ordinary core with ordinary Thimbles construction steel core
Thimbles with ordinary Thimbles

d) Proof Load-To 81 Ton Proof Load-To 81 Ton Proof Load-To 81 Ton

e) Finish- Galvanized Finish- Galvanized Finish- Galvanized

2. Single Leg Wire Rope Single Leg Wire Rope sling Single Leg Wire Rope
sling to BS-1290. SWL.70 to BS-1290. SWL.70 Ton sling to BS-1290.
Ton Max with soft eye both Max with soft eye both end. SWL.70 Ton Max with
end. Length = 4 M Length = 4 M soft eye both end.
Length = 4 M

a) Wire Rope-  76 Rope, Wire Rope-  76 Rope, steel Wire Rope-  76

steel core 6/49 construction core 6/49 construction with Rope, steel core 6/49
with soft eye at both end soft eye at both end size  construction with soft
size  575X1150 long 575X1150 long eye at both end size 
575X1150 long

b) Proof Load-To 140 Ton Proof Load-To 140 Ton Proof Load-To 140
Ton

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Maintenance & Operation Manual Part I- 140 T BD Cranes

APPENDIX – E
1.0 140 Ton DSL HYD Crane of BDT
[ Cowans Boyd/NEI. UK]

Sketch shows the principal parts of 140 Te. Dsl Hyd. Crane of BDT

A - Super structure of crane L - Tie Rod

B - Carriage Frame of crane M - Tie Cylinders ('A' Frame)
C - Front Relieving Truck N-1/N-2-Relieving Truck Inner Rack Hand
D - Crane Match Truck Pump to Release and Load the
E - Jib Resting Table Weight of Relieving Truck
F - Crane Jib O - Back Relieving Truck
G - Main Hoisting Hook P - Ballast Weight
H - Auxiliary Hoisting Hook Q - Haulage Drum
I - Derricking Drum R1-R2-R3 Draw Beams (Both side)
J - Main Hoisting Drum S - Counter Weight
K - Auxiliary Hoisting Drum
----

Note: Load Chart indicating safe working load operation (SWL) is enclosed.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

2.0 LOAD CHART OF 140 Te. CRANE (COWANS SHELDON)

STD DUTY CRANE - COUNTER WEIGHT ON CARRIAGE (SWL IN TONNES)
SLEEVE RANGE FULLY PROPPED FREE ON RIAL
STANDING LEVEL LEVEL TRACK 140MM SE
TRACK
± 28° 360° ± 28° 360° 360°
RADI OUT MH AH MH AH MH AH MH AH MH AH
US REACH
METE METER
RS
5.5 - 14 - 14 - 42 - 29 - - -
0 0
7 1.05 14 25 98 25 31 25 20 20 18.5 18.5
0
9 3.05 14 25 62 25 22 22 13 13 11.5 11.5
0
11 5.05 10 25 44 25 16 16 9 9 7..5 7..5
9
13 7.05 79 25 34 25 12 12 - 6 - 5
15 9.05 61 25 27 25 9 9 - 4 - 3.5
16 10.05 55 25 24 24 8 8 - 3.5 - 3
17 11.05 - 25 - 22 - 7 - 3 - 2.5
18 12.05 - 25 - 20 - 6 - 2.5 - 2
19 13.05 - 25 - 19 - 5 - 2 - 1.5
STD DUTY CRANE – COUNTER WEIGHT ON SUPPER (SWL IN TONNES)
SLEEVE RANGE FULLY PROPPED FREE ON RIAL
STANDING LEVEL LEVEL TRACK
± 28° 360° 0º(In line) ± 28° 360°
RADIUS OUT MH AH MH AH MH AH MH MH MH RH
METER REACH
S METER
5.5 - 14 - 14 - 94 - 53 - 39 -
0 0
7 1.05 14 25 11 25 78 25 41 25 27 25
0 0
9 3.05 14 25 70 25 63 25 30 25 18.5 20
0
11 5.05 11 25 50 25 52 25 23 25 14 15
8
13 7.05 85 25 38 25 44 25 18 21 9..5 11
15 9.05 66 25 31 25 38 25 14 17 7 9
16 10.05 59 25 28 25 35 25 13 15 6 8
17 11.05 - 25 - 25 - 25 - 13.5 - 7
18 12.05 - 25 - 25 - 25 - 12 - 6
19 13.05 - 25 - 22 - 25 - 11 - 5
HEAVY DUTY CRANE - (SWL IN TONNES)
SLEEVE RANGE FULLY PROPPED FREE ON RIAL
STANDING LEVEL LEVEL TRACK
± 28° 360° 0º(In line) ± 14°
RADIUS OUT MH AH MH AH MH AH MH AH
METERS REACH
METER
5.5 - 140 - 140 - 104 - 86 -
7 1.05 140 25 140 25 86 25 69 25
9 3.05 140 25 101 25 70 25 52 25

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Maintenance & Operation Manual Part I- 140 T BD Cranes

10 4.05 140 25 86 25 63 25 47 25
11 5.05 130 25 74 25 58 25 43 25
13 7.05 105 25 58 25 49 25 36 25
15 9.05 85 25 47 25 42 25 30 25
16 10.05 70 25 42 25 39 25 27 25
17 11.05 - 25 - 25 - 25 - 23
18 12.05 - 25 - 25 - 25 - 21.5
19 13.05 - 25 - 25 - 25 - 20
3.0 WARNINGS TO WIRE ROPE USERS (SK-1837)
1. Never over load a rope or rope sling
2. Never use a rope in which components are not in correct position & alignment
or without free articulation
3. Never place a hook or shackle round the rope to provide bight.
4. Never use an excessively corroded or worn rope or rope with flattened or
fractured/broken wires.
5. Never use a sling found frayed, elongated & distorted.
6. Never forget that the safe working load of a multiple leg sling decreases as the
angle between the legs increases also that with a 3 or 4 leg sling, two of the
legs may be taking the greater part, or even the whole of the load.
7. Special precautions must be taken and a larger size rope or sling should be
used -
a. When the exact load is in Doubt
b. When there is liability to Shock.
c. When the conditions are Abnormal or Severe.
d. When there is exceptional Hazard to life and Limb.
8. The following Precautions must always be strictly observed -
a. Do not cross, twist, kink or knot any rope or sling.
b. Do not drag a rope or sling from under a load.
c. Do not drop a rope or sling from a height
d. Do not roll loads over with a rope or sling
E. Do not use a Rope or Sling over Sharp Corners without Protective padding.
Remember that -
9. Wire Rope Slings and components must be periodically examined.
10. Special care should be taken to avoid snatch or sudden loads
11. Competent periodic inspection reduces hazard and increases safety.
4.0 WARNINGS TO CHAIN USERS (SK-1838)
1. Never over Load a chain or chain Sling
2. Never use a chain in which the links are locked or stretched or are without free
movement.
3. Never hammer a Chain to straighten a link or to force a link in to position.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

4. Never use an Excessive pitted Corroded or Worn Chain.

5. Never forget that the Safe Working Load of a Multiple Leg Sling decreases as
the angle between the legs increases, also that with a 3 or 4 sling, two of the
legs may be taking the greater part, or even the whole of the load.
6. Special precautions must be taken and a larger size Chain or Chain Sling
should be used -
a. When the exact load is in Doubt
b. When there is liability to Shock.
c. When the conditions are Abnormal or Severe.
d. When there is exceptional Hazard to life and Limb.
7. The following precautions must always be strictly observed -
a. Do not cross, Twist, Kink or Knot any Chain or Sling.
b. Do not drag a chain or sling from under a load.
c. Do not drop a chain or sling from a height
d. Do not roll loads over with a chain or sling
E. Do not use a chain or sling over sharp corners without protective padding.
8. Remember that -Mild steel Chain slings and components must be periodically
examined.
9. Remember that -Special care should be taken to avoid snatch or sudden loads
10. Remember that -Competent periodic inspection reduces hazard and increases
safety.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

APPENDIX – F

1. FOR 140 TONNE DSL HYD CRANECOWANS SHELDON

A METAL LIABLE TO BE ATTACHED STATING

BY STAMPING S.W.L. 70 T MAX. 0-900 LINK (MAT : EN -14 A)

ORDINARY THIMBLE

SINGLE PART SPLICED ENDLESS SLING

DRAFT
ø 64 ROPE-6/49 CONSTRTUCTION STEEL CORE

50 TONNE S.W.L. HOOK

HIGHER TENSILE STEEL
TO BS 2903-SEE ITEM 'L'

ORDINARY THIMBLE
PROOF LOAD 81 TONNES PER LEG

ITEM -A TWO LEG WIRE ROPE SLING TO BS. 1290 – ( 2 Nos. REQD)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

2. FOR 140 TONNE DSL HYD. CRANE COWANS SHELDON

CALC WEIGHT PER SLING - 375 KG.

LINK
A METAL LIABLE TO BE ATTACHED
STATING BY STAMPING S.W.L. 30 T MAX.
0-900
ORDINARY THIMBLE

SINGLE PART SPLICED ENDLESS SLING

ø 44 ROPE-6/36 CONSTRUCTION –
STEEL CORE
DRAFT

25 TONNE S.W.L. HOOK

HIGHER TENSILE STEEL
TO BS : 2903 SEE ITEM 'M'

ORDINARY THIMBLE

PROOF LOAD 42.4 TONNES PER LEG

2 NOS. L = 5M
ITEM -B TWO LEG WIRE ROPE SLING TO BS: 1290 – ( 2 Nos. REQD.) 2 NOS. L = 7M

CALC. WEIGHT PER SLING - 251 KG.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

3. FOR 140 TONNE DSL HYD. CRANE COWANS SHELDON

RING 250 T/DIA.

A METAL LABLE TO BE ATTACHED STATING MATERIAL 90 D A
BY STAMPING A OR OBLONG LINK OF INSIDE. 280X70
S.W.L. 25 T MAX. 0-600 MATL- ø 70
RING 180 1/DIA. (A)
FOUR LEG WIRE ROPE MATERIAL 65 D A (A)
SLING TO BS: 1290
[ 01 NO. REQD] ORDINARY THIMBLE

SINGLE PART SPLICED ø 32 ROPE –

STEEL CORE
DRAFT
6/36 CONSTRUCTION

PROOF LOAD AT 00. TO 50 TONNE

ORDINARY THIMBLE

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Maintenance & Operation Manual Part I- 140 T BD Cranes

4. FOR 140 TONNE DSL HYD. CRANE COWANS SHELDON

CALC. WEIGHT PER SLING-523 KG.

A METAL LABLE TO BE ATTACHED STATING

BY STAMPING
S.W.L. 70 T MAX.

LINK (MAT: EN -14 A)

ORDINARY THIMBLE

DOUBLE PART SPLICED ENDLESS SLING ø 64

ROPE 6/49 CONSTRUCTION FIBRE CORE

DRAFT

ORDINARY THIMBLE
70 TON S.W.L. HOOK
HIGHER TENSILE STEEL
TO BS: 2903-SEE ITEM 'K'

PROOF LOAD TO 105.4 TONNE

ITEM -C SINGLE LEG WIRE ROPE SLING TO BS: 1290 – (4 Nos. REQD.)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

5. FOR 140 TONNE DSL HYD. CRANE COWANS SHELDON

CALC. WEIGHT PER SLING-465 KG.

A METAL LABLE TO BE ATTACHED STATING
BY STAMPING
S.W.L. 50 T MAX.

LINK (MAT: EN -14 A)

ORDINARY THIMBLE

DRAFT

5M
DOUBLE PART SPLICED ENDLESS SLING ø 64
ROPE
6/49 CONSTRUCTION STEEL CORE

ORDINARY THIMBLE

50 TON S.W.L. HOOK

HIGHER TENSILE STEEL
TO BS: 2903-SEE ITEM 'K'
PROOF LOAD TO 81 TONNE

ITEM -D SINGLE LEG WIRE ROPE SLING TO BS: 1290 – (4 Nos. REQD.)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

6. FOR 140 TONNE DSL HYD. CRANE COWANS SHELDON

CALC. WEIGHT PER SLING-465 KG.

A METAL LABLE TO BE ATTACHED
STATING BY STAMPING
S.W.L. 70 T MAX.

SOFT EYE

ø 76 ROPE -STEEL CORE

DRAFT

SOFT EYE

PROOF LOAD TO 140 TONNE

ITEM -E SINGLE LEG WIRE ROPE SLING TO BS: 1290 – (2 Nos. REQD.)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

7.Technical Specification for Wire Rope Slings for 140T Diesel Hydraulic
Crane of Gottwald Make
A.70-ton Double Leg Wire Rope Sling (DRG No.: SK NO. JMP-CR-160/2003)
Double leg wire –rope sling complete with hook at one end oblong link at the
other end 6 m long each certified for 70 t safe working load at an included
angle of 90° suitable for use with Ramshorn hook 3WDH 140 CR-
5.2.7701.0087-2.

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
B.30 Ton Double Leg Wire Rope Sling (DRG No.: SK. NO.- JMP-CR- 161/2003)
Double leg wire–rope sling complete with hook at one end oblong link at the other
end 5 m long each certified for 30 t safe working load at an included angle of 90°
suitable for use with Ramshorn hook 3WDH 140 CR-5.2.7701.0087-2

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
C.70 Ton Single Leg Wire Rope Sling (DRG No.: SK No.- JMP/CR- 162/2003)
Single leg wire –rope sling 6 m long each certified for safe working load at 70 t
complete with hook at one end and oblong link at the other end to suit Ramshorn
hook 3WDH 140 CR-5. 2.7701.0087-2

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
D.50 Ton SINGLE LEG WIRE ROPE SLING (GOTTWAD)
(DRG No: SK. NO. – JMP/CR-163/2003) Single leg wire rope slings 5 M long, each
certified for safe working load of 50 t complete with hook at one end oblong link at
the other end to suit Ramshorn hook 3WDH 140 CR-5. 2.7701.0087-2.

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
E.70 Ton WIRE ROPE SLING (GOTTWALD)
[ DRG No: SK.NO. - JMP/CR-04/2017] Special Draw-bar wire-rope sling 70 t
capacity each, 4 m long suit Ramshorn hook 3WDH 140 CR-5.2.7701.0087-2

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes

F.25 Ton 4-LEG WIRE ROPE SLING (GOTTWALD)

[ DRG No.: SK. NO. – JMP/CR- 165/2003],4 leg wire-rope sling 25 t capacity 4 m
long for handling bogies.

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes

G 30 Ton DOUBLE LEG WIRE ROPE SLING (GOTTWALD)

DRG No.SK. NO. – JMP/CR- 161/2003, Double leg wire-rope sling 30 t capacity 5 m
long for handling bogies.

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes

H.12 Ton single leg chain sling 6m long

[DRG No.: SK. No.- JMP/CR-154/2003]

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes

I.6Ton double leg chain sling 4m long

[ DRG No: SK.No.- JMP/CR-155/2003]

DRAFT

J.28Ton double leg chain sling 5m long

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Maintenance & Operation Manual Part I- 140 T BD Cranes
[ DRG No.: SK.No.- JMP/CR-156/2003

DRAFT

WIRE ROPE USED IN 140T GOTTWALD CRANE (OLD & NEW DESIGN)

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Maintenance & Operation Manual Part I- 140 T BD Cranes
Jamalpur specification no. JMP/140T/GOTT/SPEC/04
A. WIRE ROPE USED IN 140T OLD DESIGN CRANE

1. Main Hoist Wire Rope (Old Design)- Wire rope of construction

35x7 (IWRC of special design, avoiding cross over between the JMP/CR- 184/
strands of the core & reducing the danger of internal rope 03 Alt-6
destruction), compact strands, self-lubricated, rotation resistant,
D26X400M, RGG, Langslay, ungalvanized, 1960 N/mm2,
minimum breaking load 519.5 KN with accessories.

2.Aux. Hoist Wire Rope (Old Design)- Wire rope of construction

35x7 (IWRC of special design avoiding cross over between the JMP/CR- 185/
strands of the core & reducing the danger of internal rope 03 Alt-5
destruction), compact strands, self-lubricated, rotation resistant,
D22x120M,RGG, Langslay,ungalvanized , 1960 N/mm2,
minimum breaking load 373 KN with accessories.

3.Derrick Wire Rope (Old Design)- Wire rope (left/right) of

construction 8x26 (IWRC) plastic impregnated, compact strands, JMP/CR- 186/
self-lubricated, A26x130M,RGG/LGG, ordina rylay, un- 03 Alt-6
galvanized, 1770 N/mm2, minimum breaking load 504.7 KN with
accessories .

4.Recovery Winch Wire Rope (Old Design)- Wire rope of JMP/CR- 187/
construction 35x7 (IWRC of special design avoiding cross over 03 Alt-8
between the strands of the core & reducing the danger of internal
DRAFT

rope destruction), compact strands , self-lubricated, rotation

resistant, D16x70M,RGG, Langslay, un-galvanized, 1960 N/mm2,
minimum breaking load 197.2 KN with accessories .

5a. Gantry Wire Rope (Old Design) - Wire rope of construction JMP/CR- 188
8x26 (IWRC) plastic impregnated, compact strands, self- A/ 03 Alt-4
lubricated, langs/ordinary, RGG, Galvanised, 1960N/mm2, Min.
breaking load 3080KN, 60x13000 mm fitted with socket at both
end G10+G10-90º with accessories

5b. Gantry Wire Rope (Old Design) - Wire rope of construction JMP/CR-188 B/
8x26 (IWRC) plastic impregnated, compact strands, self- 03 Alt-5
lubricated, langs/ordinary, RGG, Galvanised, 1960 N/mm2,Minm
breaking load 3080KN. 60x12100 mm fitted with socket at both
end G10+G10-90º with accessories.

B. WIRE ROPE USED IN 140T NEW DESIGN CRANE

1. Main Hoist Wire Rope (New Design)- Wire rope of construction JMP/CR-
35x7 (IWRC of special design avoiding cross over between the 189/03 Alt-6
strands of the core & reducing the danger of internal rope
destruction), compact strands, self-lubricated, rotation resistant,
D26X470M,RGG,Langslay,un-galvanized, 1960 N/mm2,
minimum breaking load 519.5 KN with accessories.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

JMP/CR- 190/
2.Aux. Hoist Wire Rope (New Design)- Wire rope of construction 03 Alt-7
35x7 (IWRC of special design avoiding cross over between the
strands of the core & reducing the danger of internal rope
destruction), compact strands, self-lubricated, rotation resistant,
D22x130M,RGG, Langslay, un-galvanized ,1960
N/mm2,minimum breaking load 373 KN with accessories.

3.Derrick Wire Rope (New Design)- Wire rope (Left/Right) of JMP/CR- 191/
construction 8x26 (IWRC) plastic impregnated, compact strands, 03 Alt-6
self-lubricated, A26x390M, RGG/LGG, ordinary lay, un-
galvanized, 1770 N/mm2, minimum breaking load 504.7 KN with
accessories.

4.Recovery Winch Wire Rope (New Design)- Wire rope of JMP/CR-

construction 35x7 (IWRC of special design avoiding cross over 192/03, Alt-5
between the strands of the core & reducing the danger of internal
rope destruction), compact strand, self-lubricated, rotation
resistant, D18x110M, LGG, Langsley, un-galvanized, 1960
N/mm2, minimum breaking load 246 KN with accessories

MAINTENANCE OF WIRE ROPE

Special care should be taken of wire rope during operation of crane otherwise it will
get damaged.
A. Maintenance of wire rope means two things DRAFT

(i) Shifting the points of wire by cutting of drum ends.

(ii) By changing the rope end
B. Lubrication of wire rope: - Wire rope is self lubricated to reduce internal
abrasion, to exclude external moisture and delay corrosion. In service, the initial
lubricant will tend to dry out due to long contact with atmosphere (air and water) and,
therefore, it is desirable to lubricate all rope at regular intervals. There are many
methods of applying lubricant, such as vertical or horizontal grease boxes through
which the rope runs, application by brush, leather groves, drip or by applying.
Lubrication will fit in at least one of these methods and regular lubrication is a factor
in prolonging the life of wire rope.
The lubricant should be of a light grade that may penetrate between the wires and
the strands of the rope before being wiped off or absorbed by surface dirt. It is very
desirable that the rope be clean and dry before application of lubricant.
REPLACEMENT OF WIRE ROPE
Wire rope get damaged during operation and need to replace due to following reason
(i) wire cut (if 05 no. wire cut in length equal to 6xdia of wire)
(ii) wire rope bent
(iii) cage formation
(iv) dimension changes
(v) external deformation

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Maintenance & Operation Manual Part I- 140 T BD Cranes
(vi) loosing flexibility
8. Technical Specification for Wire Rope Slings for 140T Diesel Hydraulic Crane
of Cowans Sheldon Make
[ RDSO Specification No. MP.CR.LT 2/91 & MP.CR.LT -1/90 with amendment-1]
1. Scope:
This specification is applicable for procurement of
i. Double leg wire rope slings of 70-ton, 50 ton and 30-ton capacity.
ii. Single leg wire rope slings of 70 ton and 50-ton capacities.
iii. Special draw bar sling of 70-ton capacity.
2. Reference Documents:
In this specification reference is made to following specifications –
IS:2266-1977 Steel wire ropes for general engineering purposes
(second revision) with amendment No.1
IS: 2315-1978 Thimbles for wire ropes.
IS: 2759-1969 Higher tensile steel point hooks for use with wire rope
thimbles.
IS: 2760-1980 Steel chain slings
IS: 2762-1982 Wire rope slings and sling legs (First revision)
IS: 3469-1974 Tolerances for closed die steel forgings (First revision)
DRAFT

(*Part-I to III)
3. Requirements:
The description, capacity, length and quantity required for different types of wire
ropes slings are indicated in annexure. All these slings shall be suitable for use on
140 Ton Ramshorn hook.
The slings shall be capable of withstanding to the tough break down operations and
shall be made as light as possible, by using alloy steel for links and hooks, so that
they can be separated to a distance of 10 to 12 meters when pulled by two or three
persons (about 100 Kg force) per leg.
4. Components:
4.1 Sigle part spliced/Endless grommet type sling legs/special draw bar sling:
4.1.1 Wire rope
a) The wire rope used in the manufacture of single part spliced sling legs shall
consists of 6 round strands over a steel core, right hand ordinary lay, galvanized
and shall conform to IS:2266-1977 with wire of tensile designation 1770.
b) Suitable construction of wire rope shall be selected to provide increased flexibility.
c) The safe working load shall not one-sixth of the minimum strength of wire rope
d) The wire rope shall be tested to a proof load as indicated in column 9 of annexure
4.1.2 Thimbles:
Each end of each part spliced/endless grommet type sling leg shall be fitted with a
galvanized thimble of the ordinary type conforming to IS:2315-1978, appropriate for
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Maintenance & Operation Manual Part I- 140 T BD Cranes
the size of the rope, and securely spliced thereto.
4.1.3 Hooks:
a) Suitable point hook of high tensile steel grade 80 ton with trapezoidal cross
section shall be provided. The manufacturer shall submit a sketch showing all the
dimensions of hook along with necessary strength calculations. The hook shall be
fitted with a safety device to prevent displacement of the load.
b) The tolerances of drop-forged hooks shall be as given in IS: 3469-1974.
c) All hooks shall before proof testing, be normalized by heating to a temperature
within 50 degree above the upper critical point of the steel used, followed by
cooling in still air.
d) Proof testing of hook shall conform to clause 9 of IS:2759-1969.
e) Depending on the size of the lot, if considered necessary, one sample hook shall
be selected and tested destruction by the application of test load as per procedure
laid down in IS: 2759-1969.
f) The inspection, certificate of test and examination shall be as per clause 11 of
IS:2759-1969.
g) The identification mark on hook shall be as indicated in IS: 2759-1969.
4.1.4 Splicing:
The splicing shall be done by mechanical means.
4.1.5 Serving:
That portion of the splice which contains the wire ends shall be neately and
DRAFT

effectively served with spun yarn or sezing strand to give protection to the user in
handling.
4.2 Oblong Link:
a) A suitable suspension link of high tensile steel grade 80 (T) shall be designed to
suite Ramshorn hook of 140 ton capacity. The manufacturer shall submit a sketch
showing all the dimensions of oblong link along with necessary strength
calculations.
b) The oblong link shall be normalized.
c) the tolerances on dimensions shall be as specified in IS: 2760-1980.
d) The link shall be tested to a proof load as indicated in column (8) of annexure
before assembly. The permanent set of the link shall not exceed 1% of its mean
breadth.
e) The procedure of testing of oblong link shall be as indicated in clause 11 of
IS:2760-1980.
f) The identification marks on oblong link shall be as indicated in IS:2760-1980.
Note: For special draw bar slings, clauses 4.1.2, 4.1.3 and 4.2 are not applicable.
5.0 Technical Data:
The tenderer while submitting proposal shall furnish complete technical data such as
size, dimensions, rate and material of oblong link and hook separately along with
construction, size and weight of wire rope, identifying details of deviations if any.
6.0 Inspection:
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Maintenance & Operation Manual Part I- 140 T BD Cranes
The wire rope slings will be inspected by the authorised Railway representative
nominated by the purchasing authority at the works of the manufacturer. The
necessary facilities shall be generated by the manufacturer or carrying out inspection
and various testing of wire rope slings.
7.0 Test Certificate:
With each consignment of slings, the manufacturer shall furnish a test certificate in
the form shown in the appendix B of IS: 2762-1982.
8.0 Maintenance:
The tenderer shall furnish the maintenance manual indicating the method of
maintenance of wire rope slings, periodicity of attentions, if any, procedure of testing,
etc.
9.0 Warranty:
The suppliers will withstand warranty for a period of atleast two years from the date of
commissioning for its satisfactory performance against any design/manufacturing
defect.
10.0 Packing:
The wire rope slings shall be suitably packed to avoid damage during transit.

Wire Rope Slings for 140 t Crane (Cowans Sheldon)

DRAFT

FIG-A FIG-B FIG-C

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Maintenance & Operation Manual Part I- 140 T BD Cranes

ANNEXURE-I
Ref. Qty/ Proof/
S.N Description Type Capacity Length Load/Leg
Fig. Crane Link
1 2 3 4 5 6 7 8 9
Single part
1.0 Double leg Sling A 70 ton 6M 02 140 t 81.0 t
spliced
Single part
2.0 Double leg Sling A 50 ton 7M 02 100 t 71.7.0 t
spliced
Single part
3.0 Double leg Sling A 30 ton 7M 02 60 t 42.4 t
spliced
Single part
4.0 Double leg Sling A 30 ton 5M 02 60 t 42.4 t
spliced
Endless
5.0 Single leg Sling B 70 ton 6M 04 140 t 105.4 t
Grommet
Endless
6.0 Single leg Sling B 50 ton 5M 04 100 t 81.0 t
Grommet
Special draw bar
7.0 C -- 70 ton 6M 02 -- 70.0 t
sling

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes

CHAPTER-2

OPERATION OF 140T BREAK DRAFT

DOWN CRANE AND

IMPORTANT INSTRUCTIONS

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Maintenance & Operation Manual Part I- 140 T BD Cranes
1. COMPARISON BETWEEN 140 T (COWANS SHELDON &
GOTTWALD) BREAK DOWN CRANES
Cowans
Name of the Cowans Gottwald Gottwald
SN Sheldon
Parts Sheldon (Old) (Old) (New)
(New)
Lattic Box Welded Box
01 Crane Jib
construction construction tubular shape construction
Super
02 Different Different Different Different
structure
4 prop 4 prop
03 Carriage Lateral Radial
arrangement arrangement
Bolster with Bolster with
Welded primary & primary &
04 Crane bogie Welded structure
structure secondary secondary
suspension suspension
Relieving
05 Exist Not exist Not exist Not exist
bogie
06 Match Truck Different Different Different Different
Ballast
07 Exist Not exist Not exist Not exist
Wagon
Hydraulic Hydro-
08 Elect-Hydraulic Upgraded Upgraded
system Hydraulic
09 Electrical Different Different Different Different
Mechanica, Mechanica,
10 SLI Wylie/Mechanica Ascorel france
DRAFT
Hytech Hytech
Gear box and
11 Different Different L & T, India. L & T, India.
Winches
12 Out rigger 06 04 04 04
Out rigger Swing Swing
13 Pull out type Swing out type
arrangement cylinder cylinder
1. Vertically
mounted
Horizontally
Cummins
mounted
Engine
Cummins
(i)Model- NTA
Engine
855 LBC,
(i) Model- NT
290HP
Cummins NT- Cummins NT- 855 R4,
14 Main Engine
743P 295 HP 855P 360 HP (ii)Model-NTA
320HP
855 P335,
(ii)Model-
270HP
NTA 855
(iii) Model-
FFC, 326HP
QSL-9,
305HP
2. Vertically

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Maintenance & Operation Manual Part I- 140 T BD Cranes
mounted MTU
Engine,
Model- OM
926 LA,
311HP
Main Engine
15 2100 rpm 2100 rpm 1800 rpm 1800 rpm
RPM
Mechanical Air brake Air brake,
TBU
linkage (Service (Service
Air brake,
16 Brakes Air brake, Brake), Brake),
Parking brake
Parking brake Parking brake Parking brake
(clasp type)
(clasp type) (Disc brake) (Disc brake)
Folding Folding Rear
17 “A” Frame Tie cylinders Folding linkage
linkage Section
Counter
18 32,12,1.5 T 6.7/ 7.9, 22.6 T 5.2,18,6,14 T 24,15,8 T
weight
19 Driver’s cabin Side Side Centre Centre
Counter
20 weight Beam lift jack Gallows Gallows Rear Section
fastening
Make-KOEL, Make-KOEL,
Ruston MK- Model-HA Model-HA
21 Aux. Engine Lister Peter
IV/KOEL TA2 DRAFT 294, 23HP at 294, 23HP at
1800 rpm 1800 rpm

2. 140T DIESEL HYDRAULIC CRANE (COWANS SHELDON NEW)

TECHNICAL DATA:
01. 140 T 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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 Ton 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
DRAFT

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 degrees 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

3. 140 T DIESEL HYDRAULIC CRANE (COWANS SHELDON OLD)

TECHNICAL DATA:
01. 140 T 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. 5 T
05. Max. Travelling Speed : 12 KMPH
06. Slow Travelling Speed : 6 KMPH
07. Main Engine Make : Cummins India Ltd. Pune
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 T
23. Relieving Bogie Tare weight : 10.8 T(each)
24. Match Truck Weight : 31.758 T
25. Ballast wagon weight : 30.530 T
26. Heavy Ballast weight : 32.205 T
DRAFT

27. Counter weight : 12.558 T

28. Jib complete weight : 9.976 T
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 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

4. 140 T DIESEL HYDRAULIC CRANE (GOTTWALD NEW)

TECHNICAL DATA (Dimensions)
Track Gauge : 1676 mm

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Maintenance & Operation Manual Part I- 140 T BD Cranes
1. Rim Diameter : New condition: 920 mm
Wear limit : 840 mm
2. Wheel set arrangement : (2A) (A2)
3. Distance between bogie pivots : 7500 mm
4. Distance between twin wheel set : 3000(1500) mm
5. Length ahead of buffer : 13290 mm
6. Draw and buffing gear : side buffers and screw couplings
7. Minimum travel curve : 175 M
8. Maximum towing speed : 100 Kmph
9. Maximum wheel set load : 200 KN
10. Total Weight in train formation : 120 T
11. Height in transport position : 3900 mm
12. Width in transport position : 3100 mm
13. Elevated curves : 140 mm
Brake System:
01. Service brake : 12 wheel disc-operated brakes 780 mm
02. Parking brakes : spring-loaded brakes on 6 wheel sets
Out riggers:
01. Base : 11.6 m x 6.0 m
DRAFT

02. Maximum support force : 2200 KN

03. Out rigger cylinder : stroke 500 mm
04. Free on wheels base : 7.5 M x 1.7 M
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 : Vertically mounted Engine 6 cylinders in series, Water cooled, Exhaust
turbocharger
02. Model : (A) Make- Cummins (i) NTA 855 P335, 270HP at 1800 rpm.
(ii) NTA 855 LBC, 290HP at 1800 rpm.
(iii) QSL-9, 305HP at 1800 rpm.
: (B) Make- MTU (iv) OM 926 LA, 311HP at 1800 rpm.
03. Output : 205 KW AT 1800 RPM
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Maintenance & Operation Manual Part I- 140 T BD Cranes
04. Torque : 1158 nm at 1400 rpm
05. Cubic capacity : 1400 ccm
06. Fuel Tank Capacity : 900 L.
07. Generator : 28 V, 55 A
Emergency Diesel Engine
01. Type :2 Cylinder in series
Air cooled, Exhaust turbo charger
02. Model :HA-294, Make-KOEL
03. Output : 23 HP (16.9 Kw) at 1800 rpm,
04. Cubic capacity : 1884ccm
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
DRAFT

Auxiliary Hoist
01. Type : Two stage planetary hoist with spring
loaded multi disc brake
02. Rope diameter : 22 mm
03. Rope speed : Max. 60 m/min.
04. Hoist speed : Max. 15 m/min.
05. Hook block : 04 strand, 25 t
06. Hoist range : above track: 18.0 m
Below track: 03.0 m
Slewing Gear
01. Type: Three stage planetary hoist with spring loaded multi disc brake,
Roller slew ring with external teething
02. Super structure speed : 0-1.0 rpm
Derricking Gear
01.Type : Three stage planetary hoist with
spring loaded multi disc brake
02.Rope Diameter : 26 mm
03.Rope speed : Max. 28 m/min.
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 T
03.Slab-2 (Transported on the match truck) : 15 T
04.Slab-3 (Transported on the under carriage) : 08 T
Boom
01.Length to the main hook : 18.75 mts.
02.Length to the Auxiliary hook : 19.5 mts.
03.Main hook working range : 5.5 m-17.0 m
04.Auxiliary hook working range : 6.5 m- 18.0 m
Match Truck
01.Length beyond buffer : 16.0 m
02.Distance between wheel sets : 2.0 m
03.Track Gauge : 1676 mm
04.Distance between bogie pivots : 11.30 m
05.Draw and Buffing Gear : side buffers & screw
Couplings
DRAFT

06.Turning radius : 175 m

07.Maximum towing speed : 100 Kmph
08.Max. wheel set load : 200 KN
09.Total weight: Loaded : 80.0 T

5. 140 T DIESEL HYDRAULIC CRANE (GOTTWALD OLD)

TECHNICAL DATA (Dimensions)
1. Track Gauge : 1676 mm
2. Rim Diameter : New condition:915 mm
a. Wear limit : 860 mm
3. Wheel set arrangement : (2A) (A2)
4. Distance between bogie pivots : 7500 mm
5. Distance between twin wheel set : 1500 mm
6. Length ahead of buffer : 13300 mm
7. Draw and buffing gear : Hinged buffers and screw couplings
8. Minimum travel curve : 174 M
9. Maximum towing speed : 100 Kmph
10. Overall weight : 200 T
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Maintenance & Operation Manual Part I- 140 T BD Cranes
11. Crane Weight in train formation : 120 T
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. Service Brake :12-wheel disc-operated brakes, 780 mm
2. Parking Brake : spring-loaded brakes on 6-wheel sets
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
5. 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
DRAFT

2. Over-Rear radius : 5.5 m

Diesel Engine
01. Type : Horizontally mounted Engine, 6 cylinders in series,
Water cooled, Exhaust turbo charger
02. Model : Make- Cummins :(i) NT 855 R4, 320HP at 1800 rpm.
:(ii) NTA 855 FFC, 326HP at 1800 rpm.
3. Output : 224 KW AT 1800 RPM
4. Torque : 1158 n-m at 1400 rpm
5. Generator : 28 V, 55 A
Emergency Diesel Engine
01. Type : 2 Cylinder in series
Air cooled, exhaust turbo charger
02. Model : HA-294, Make-KOEL
03. Output : 23HP (16.9KW) at 1800 rpm
04. Cubic capacity : 1884 ccm
Main Hoist
1. Type : Three stage planetary hoist with

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Maintenance & Operation Manual Part I- 140 T BD Cranes
spring loaded multi disc brake
2. Rope diameter : 26 mm
3. Rope speed : Max. 80 m/min.
4. Hoist speed : 2.5 m/min- 5 m/min.
5. Hook block : 16 strand, 140 t
6. Hoist range : Above track: 16.5 m
Below track: 04.0 m
Auxiliary Hoist
1. Type : Two stage planetary hoist with spring
loaded multi disc brake
2. Rope diameter : 22 mm
3. Rope speed : Max. 60 m/min.
4. Hoist speed : Max. 15 m/min.
5. Hook block : 04 strand, 25 t
6. Hoist range : Above track: 17.8 m
Below track: 03.0 m
Slewing Gear
1. Type: Three stage planetary hoist with spring loaded multi disc brake, Roller
slew ring with Internal teething. DRAFT

2. Super structure speed : 0-1.0 rpm

Derricking Gear
1. Type : Three stage planetary hoist with
spring loaded multi disc brake
2. Rope Diameter : 26 mm
3. Rope speed : Max. 28 m/min.
4. Derricking time : Approx. 90 sec.
Hauling Winch Capacity : 5T
Counter Weight
1. Standard duty : 29.2 T (5.2+6+18)
2. Heavy Duty : 43.2 T (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
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Maintenance & Operation Manual Part I- 140 T BD Cranes
2. Distance between wheel sets : 2.0 m
3. Track Gauge : 1676 mm
4. Distance between bogie pivots : 11.30 m
5. Draw and Buffing Gear : Hinged buffers & screw
couplings
6. Turning radius : 174 M
7. Maximum towing speed : 100 Kmph
8. Max. wheel set load : 20 T
Brake System of Match truck - : Air brake & Mechanical Hand brake
Lifting Beam Capacity : 2 nos.- 140 t, 70 t

6. 140 T. CRANE SPECIFICATION WITH COMPARISON

A. Comparison between Old and New Gottwald cranes:
Parameters Gottwald Crane
SN Item Old (1986) design - 1WDH New (1997) design -
3WDH
1 RDSO Document ref. MP-MISC-118 (Rev-0.00) MP-MISC-119 (Rev-
number 0.00)
2 Track gauge 1676 mm 1676 mm
3 No. of vehicles in Crane with two 3 - axle
DRAFT Crane with two 3 - axle
running order bogies + Match truck with bogies + Match truck
two 2 - axle bogies with two 2 - axle bogies

4 Length of crane over 13300 mm 13300 mm

buffers
5 Length of match truck 15970 mm 16000 mm
over 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 175 m radius
10 Max height of crane 3950 mm 3900 mm
from RL
11 Overall weight 200t 200t
12 Axle load in running 20t 20t
order
13 Tail radius 5.5 m 5.5m, 6.5m
14 Counterweight: 4 pieces: 5.2T, 6T, 14T, 3 pieces: 8T, 15T, 24T
18T
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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 Coil spring Coil spring
truck
20 Wheel dia crane 915 (new), 860 (cond) 920 (new), 840 (cond)
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 (i) Mechanica system (i) Mechanica system
(ii) Hytech (ii) Hytech
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 Maximum - 16 m Maximum - 17 m
hoist
Minimum - 5.5 m Minimum - 5.5 m
27 Working radius aux Maximum - 17 m Maximum - 18 m
DRAFT

hoist
Minimum - 6.5 m Minimum - 6.5 m
28 Range of Lift Main Above rail level - 16.5 m Above rail level - 17 m
hoist
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
Below rail level - 3 m Below rail level - 3 m
30 Max capacity when 130T at 6m radius (360 140T at 6m radius (360
fully propped with heay degree) 130T at 9m radius degree) 140T at 9.5m
duty cwt. (30 degree leftward & radius (30 degree
rightward) leftward & rightward)
31 Crane Motion and
Speeds:
Derricking 1 min from max to min 165 sec from max to min
radius radius
Slewing 1 RPM 1 RPM
Main hoist lifting 2.5 m/min 4 m/min
Main hoist rapid 5 m/min 8 m/min
lowering
Auxiliary hoist lifting 15 m/min 15 m/min
Auxiliary hoist rapid 30 m/min 30 m/min
lowering

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Maintenance & Operation Manual Part I- 140 T BD Cranes
Self travel speed:
travel with load 6 km/h 6 km/h
travel without load 12 km/h 20 km/h
Hauling speed: 100 kmph 100kmph
on 90R mainline std 75 kmph 60 kmph
track &above
on 52 kg mainline track 80 kmph
& above
32 Main Diesel Engine:
Make Cummins (A). Cummins
(B). MTU
Model (i) NT 855 R4 A.-(i) NTA 855 P 335
(ii) NT 855 FFC (ii)NTA 855 LBC
(iii)QSL-9
B.- (iv) OM 926 LA
Mounting Horizontal Vertical
Horse power (i) 320HP (i)270HP,
(ii) 326HP (ii) 290HP,
(iii) 305HP,
(iv) 311HP
No of cylinder 6 DRAFT
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 Kirlosker Kirlosker
Type/Model HA 294 HA 294
Horse power 23HP (16.9 KW) 23HP (16.9 KW)
RPM 1800 1800
34 Brakes crane Air brake, & Parking brake Air brake & Parking
(disc type) brake (disc type)
35 Brakes match truck Air brake, Mechanical hand Air brake, Mechanical
brake hand brake
Others:
36 'A' frame available Rear Section

37 Gallows fixed cwt. Radius (5.5m) permit the counterweight

assembly to be placed at
5.5 or 6.5 m radius

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Maintenance & Operation Manual Part I- 140 T BD Cranes
38 Slewing arrangement 3 - stage planetary hoist 3 - stage planetary hoist
with spring loaded multi- with spring loaded multi-
disc brake roller slewing disc brake roller slewing
ring with internal teeth ring with external teeth
39 Hydraulic oil tank one single tank fitted in the two internally connected
rear portion of the tanks just behind the cab
superstructure
40 Fuel tank annular shaped tank above box shaped tank in the
the slewing ring rear portion of the
superstructure
41 No. of pulleys in main 8 9
hoist
42 Controls:
Counterweight all control in cab, single all controls in the rear of
lever 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 100 kmph 100 kmph

in "In Train" formation
DRAFT

B. Comparison between Old and New Cowans Sheldon cranes:

Parameters Cowans Sheldon Crane

SN Item Old (1987) design New (1998) design

1 RDSO Document ref. MP-MISC-120 (Rev- MP-MISC-121 (Rev-
number 0.00) 0.00)
2 Track gauge 1676 mm 1676 mm
3 No. of vehicles in running Crane with two 3 - axle Crane with two 3-axle
order bogies + two relieving bogies + Match truck
bogies each with 2-axle with two 2-axle bogies.
+ one match truck with
two 2-axle bogies +
one ballast wagon with
two 2-axle bogies.
4 Length of crane over 21046 mm (including 13000 mm
buffers relieving 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 4010 mm 4160 mm
RL

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 16.3 m long Box
construction 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) - Main (Ramshorn) -
140t 140t
Auxiliary - 25t Auxiliary - 25t
DRAFT

26 Working radius Main hoist Maximum - 16 m Maximum - 16 m

Minimum - 5.5 m Minimum - 5.5 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
Below rail level - 4 m Below rail level - 4 m
29 Range of Lift aux hoist Above rail level - 17 m Above rail level - 17 m
Below rail level - 3 m Below rail level - 3 m
30 Max capacity when fully 140 T at 7 m radius, 140 T at 6 m radius,
propped with heay duty 360 degree slewing 360 degree slewing
cwt. and 10 m radius at 28 and at 9 m radius, 30
degree slewing. degree slewing
31 Crane Motion and Speeds:
Derricking 2 min from max to min 2 min from max to min
radius 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 15 m/min 30 m/min
lowering
Self travel speed:
travel with load 6 km/h 6 km/h

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
DRAFT
3000
33 Auxiliary compressor BROOMWADE, HYDROVANE,
superstructure superstructure
mounted, reciprocating, mounted, vane rotor,
driven by hydraulic driven by hydraulic
motor - 7.5 bar. motor - 7 bar.
34 Brakes crane Air brake, Vacuum Air brake, Vacuum
brake & Parking brake brake & Parking brake
(clasp type) (clasp type)
35 Brakes match truck Air brake, Vacuum Air brake, Vacuum
brake & Parking brake brake & Parking brake
(clasp type) (clasp type)
Others:
36 'A' frame available available

37 Gallows

38 Slewing arrangement Roller thrust bearing Three sets of rollers

type slewing ring with with interior teeth
external teeth

39 Hydraulic oil tank one single tank fitted in one single tank fitted in
the front portion of the the rear portion of the
superstructure superstructure
40 Fuel tank box shaped tank in the box shaped tank in the
centre portion of the rear portion of the
superstructure superstructure

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Maintenance & Operation Manual Part I- 140 T BD Cranes
41 No. of pulleys in main hoist 6 6
42 Controls:
Counterweight Two control in the front all controls in the rear
& One at rear of the of the crane, three
crane, three levers for levers for control.
control.
Hoists single joystick for main single joystick for main
and auxiliary hoists and auxiliary hoists
Rapid motion switch 75 kmph 100 kmph
Max. Travelling speed in "In
Train" formation

7. POPULATION OF 140 T CRANES ON IRs:

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

DRAFT

GOTTWALD (OLD DESIGN ) NEI (COWANS)/JESSOP (OLD DESIGN)

22 NOS 12 NOS

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Maintenance & Operation Manual Part I- 140 T BD Cranes

GOTTWALD COWANS SHELDON

(NEW DESIGN) (NEW DESIGN)
56 Nos. 04 NOS
DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
8. FORMATION WISE CLASSIFICATION OF 140T CRANES:
Sr. Type of crane Formation Details of formation
No (No. of
vehicle)
1. Match truck
1. Cowans Sheldon Old design 05 Nos
2. Relieving Bogie at “A” End.
(180T & 6 propping base) (app. 52.5 3. 140 T crane.
meters) 4. Relieving Bogie at “B” End.
5. Ballast wagon consisting of
32T counter weight.

1. Match truck
2 Cowans Sheldon New 02 Nos
2. 140 T crane.
design
(4 propping base)
3. Match truck
3 Gottwald Old design 02 Nos
4. 140 T crane.
(4 propping base)

5. Match truck
4 Gottwald New design 02 Nos
6. 140 T crane.
(4 propping base)

9. SPECIAL SAFETY PRECAUTIONS FOR CRANE OPERATORS

DRAFT

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:
a) Before raising the jib from match wagon, all blocking screws must be screwed
down until locked on the top of the spring.
b) Both the relieving bogies must be unloaded prior to raising the jib from match
wagon.
c) Before any movement of crane on its own power, operator must ensure proper
engagement of travel clutch and braking of travel brake.
d) 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.
e) The operator must be thoroughly acquainted with the load charts provided in the
crane to assess the duty selection.
f) 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.
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Maintenance & Operation Manual Part I- 140 T BD Cranes
g) 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.
h) Before any slew motion, slew lock pin must be removed.
i) 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.)
j) 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.
k) During fitting of heavy-duty ballast to the superstructure, heavy ballast must be
raised fully, superstructure must be 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.
l) Swinging load is dangerous and should be avoided.
m) Emergency lower button should be operated only in case of emergency and the
operation should not be part of the normal working cycle.
n) 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.
o) 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
DRAFT

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.
a. For removing either ballast wagon or match truck, lifting beam need not to be
used. The 30 T Double legged sling of 7 M long can be used with main hook for
this operation.
p) 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.
q) Since the maximum instantaneous load on an individual prop that may arise with
the crane being loaded to its capacity is around 150 T, 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.
r) 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.
s) 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.
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Maintenance & Operation Manual Part I- 140 T BD Cranes
10. IMPORTANT INSTRUCTIONS FOR BREAK DOWN STAFF
Following instructions must be followed by break down Incharges, Supervisors and
staff while working at accident sites: -
a. After reaching at accident site, observation of site and damaged wagons/coaches
to be carried out to ensure safe and efficient restoration.
b. Crane driver as well as staff should be advised regarding lifting load and
operational activities, explaining situation of spot.
c. Necessary equipments, tools, wooden packings etc. should be unloaded from
ART without wasting time and be sent the same to the accident spot.
d. 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.
e. 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.
f. Lifting load must be assessed properly and crane configuration and radius to be
determined accordingly.
g. Always take care of cant/super elevation while lifting the load.
h. Ensure that SLI is in working order.
i. Ensure availability and understanding of load charts.
j. Rail clamp must be used as and when required.
k. Always utilize suitable capacity chain sling and wire rope slings and insert hooks
DRAFT

only at suitable places on the wagons/coaches during lifting.

l. 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.
m. Proper work distribution among staff and supervisors to be ensured at site to
avoid contradiction.
n. Extreme care to be taken while removing and lifting entangled load. Safety of the
staff to be kept in mind during such operations.
o. The load should be lifted slowly just above the ground level and held there
because swinging load is dangerous and should be avoided.
p. Utilize wire ropes/chain slings in such a manner, that they are removed
successfully from object after lifting and placing at suitable place.
q. While slewing the crane 360 with lifted load, keep close watch and all the
precautions for this crane.
r. 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.

11. 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)

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 Maintenance & Operation Manual Part I- 140 T BD Cranes
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: -
i. 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.
ii. Movement of MFDs can be ordered by the Divisional Mechanical officers as
desired by DRMs.
c) In case 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) 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).
DRAFT

e) 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) F. ARTs should be moved to the base Depot as soon as the restoration work is
over.
g) 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) 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 neighboring
division or adjacent Railways. CMPE or any other HOD of the Mechanical
Department will do the necessary liaison.

12. SUITABLE WIRE ROPES, CHAIN SLINGS FOR LIFTING OF

LOAD
[ For COWANS SHELDON 140 T. CRANE]
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
4. Single Leg Wire Rope Sling (BS-1290)
Capacity - 50 T
Requirement - 4 Nos.
Length - 5 Mtrs.
DRAFT

Proof Load - 81 T
5. Single Leg Wire Rope Sling (BS-1290)
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
Requirement - 4 Nos.
8. Chain Sling (Without hook)-BS-1290) Capacity - 10 T
Requirement 4 Nos.

13. SAFETY DEVICES AND FITTINGS IN 140 T DHBD CRANES

(Old Design Cowans Sheldon make)

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 Maintenance & Operation Manual Part I- 140 T BD Cranes

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

DRAFT

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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
DRAFT

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

70 ºC
1. High hydraulic Oil Temperature

2. Hydraulic Filter Block Indicators for

Filter Blocked
a) Boost Line Filters HE 21= 3 nos. &
Filter Blocked
b) Return Line Filter HE 22 = 1 no.

3. Flushing Valves HE 4

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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

DRAFT

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

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8. Travel Differential

14. 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.
a) 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.
b) 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.
c) Connect vacuum hose pipes between the vehicles.
d) Air reducing valve cocks of match wagon, ballast wagon and crane to be kept
open, otherwise vacuum brake will not be in function.
e) Travel clutch of both the trucks should be in disengaged position. Check
mechanical indicator to ensure disengagement of travel clutch.
f) Blocking screws of all the axle boxes should be lifted.
g) Slew lock pin of 140 T. Crane should be in coupled position.
h) 12 T. Counter weight should be kept properly on crane carriage and hanger
DRAFT

bolts locked with locking plate.

i) 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.
j) Drain cocks of 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.
k) SA1 brake valve should be in released position and brake paddle should be
locked with bolt.
l) Crane lifting tackles i.e., slings and other material should be kept systematically.
m) Rail clamps of the crane at both the ends should be secured with the hook.
n) All the draw beams should be in retracted condition and lock pin in inserted
position.
o) In the locked condition of relieving bogies “relieving bogie coupling pin” and
“tumbler pin” should be in coupled position.
p) Transition coupling between crane, relieving bogies, match wagon and ballast
wagon should be kept in tighten position.

15. PRECAUTION AND INSTRUCTIONS DURING CRANE

"INTRAIN" RUNNING:
During “intrain” formation, one crane man/Asstt should always be deputed to avoid
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Maintenance & Operation Manual Part I- 140 T BD Cranes
unusual with the crane. They must follow following instructions.
a) 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.
b) After getting started auxiliary engine, battery charging to be ensured through
ammeter. After starting auxiliary engine, check battery charging by ammeter
readings.
c) 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.
d) 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.
e) Whenever train stops enroute following equipment to be checked: -
I. 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.
II. Check following equipment/parts for unusual – Equalizing beam and its pin,
brackets, leaf and coil springs, hangers, bolts, link and its pin and all transition
couplings.
III. Check whether lifting tackles are kept properly on match wagon and ballast
wagon. DRAFT

16. PRECAUTION DURING “INTRAIN” RUNNING AND

SEPARATION OF CRANE FROM ART:
a) 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.
b) Brake pedal lock pin should be opened so that crane brake can be applied
whenever required.
c) Before uncoupling the feed pipes, isolating cock should be closed.
d) After detaching the crane, apply crane self brakes by SA1 brake valve and
ensure that crane brakes are working properly.
e) 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.

17. PRECAUTIONS DURING PREPARATION OF CRANE AT

ACCIDENT SITE FOR RESTORATION WORKS:
a) Axle box blocking screws to be blocked before unloading the relieving bogies.
b) 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.

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c) 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.
d) Avoid excessive tightening of derrick wire rope while lifting A-frame otherwise A-
frame will not raise.
e) While lifting the jib from rester, it must be turned towards center so that resting
table does not get damaged.
f) Select the duty, by duty selector switch according to lifting load.
g) Always choose suitable capacity lifting tackles according to work intensity.
h) Always choose the suitable place from where successful restoration can be
undertaken.

18. 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.
DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 some time 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
DRAFT

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

19. 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,
should be in + zone all circuit breakers and battery isolator
should be put “off”
2. Travel clutch should be 2. Ignition key should be removed.
disengaged.
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 4. Material to be kept systematically on
should be in inserted position. the crane.
5. Tie cylinders should be lowered 5. All the transition couplings of the
completely. crane unit must be tightened.
6. Derrick wire rope should not be in 6. All the FP pipes and vacuum hose
loose position. pipes should be coupled. FP cocks
should be opened and outer most FP
cock of last vehicle should be closed.

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7. Before shutting down the main 7. Heavy ballast and counter weight
engine, it should be run on idle should 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.
1.9 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 this 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.
DRAFT

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
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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.

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
DRAFT

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.

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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.

21. PRECAUTIONS TO BE TAKEN DURING 140 T. CRANE

OPERATION (GOTTWALD NEW DESIGN)
a) Before raising the Jib from Match-truck Axle Blocking operation must be
done. DRAFT

b) After lifting rear superstructure Gallows must be locked with main

superstructure of Crane.
c) Uncouple Match-truck from crane (Screw-coupling as well as air brake hoses).
Match-truck should be secured by the hand brake.
d) Before any movement of crane by its own power, operator must ensure that
travel gear has engaged & crane brakes in operational condition.
e) 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.
f) Apply Parking brakes for maintaining rigidity of the crane.
g) Before lifting Jib, it must be ensured that the crane is on straight track.
h) 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).
i) The operator must be thoroughly acquainted with the load chart provided in
the crane to assess the S.L.I. selection.
j) 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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
k) The propping operation should be carried out until the wheel has just left the
rail, there should be absolutely no gap between in-rigger and out-rigger.
l) The load should properly secure and it should be lifted slowly just above the
ground and hold it there. Propping should be checked again for sinking.
m) If the crane is to be moved to another position, the props should be raised
outrigger should be retracted.
n) This crane is unsuitable on super-elevated track in free on rail operation with
counterweight operation.
o) Swinging load is dangerous and should be avoided.

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
DRAFT

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.

23. BATTERY OPERATED ELECTRICAL CIRCUITES.

1. Hand lamp: 4 hand lamp sockets of 24 Volt supply have been provided on the
140 T 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 colored, 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
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 driver’s 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.

24. GAUGE LIGHTS & LIGHTING CIRCUITS OF 140 T. CRANE

DRAFT

(Main engine running position)

Different types of gauges are provided on Cowans Sheldon 140 T 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.
a) 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.
b) 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.
c) 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 driver’s cabin.

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d) 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.
e) 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.
f) 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.
g) 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.

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.
DRAFT

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.
a) Cab Ventilation Fan (M3): The cab ventilation fan is provided in the driver’s
cabin to exhaust the air from cabin to atmosphere. It is operated by E-8, 5
Amps Circuit breaker through Wire No.37.
b) Jib Floodlight (H-11): Jib floodlight is provided in the mid portion of the jib of
140 T 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.
c) 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.
d) 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.
e) 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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
f) 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.

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 T Crane of ART is ordered to site of accident / derailment is to
be accompanied by an officer.

27. PRECAUTIONS WHEN LIFTING WITH CRANES: DRAFT

a) The crane must not be used to lift more than the maximum safe working load
authorized at the radius.
b) Precautions should be taken to avoid load catching on obstructions as this
may seriously overload the crane.
c) Sudden shocks and jerks also tend to overload the cranes and tackles.
d) Shocks and jerks usually result from:
i. Mistake in signaling to the crane driver.
ii. Want of observation by the crane driver.
iii. Sudden application of brakes on crane.
iv. Kinks in the chains.
v. Slipping of chain due to incorrect slinging or sling hooks not
vi. properly secured
e) 05.Lifting tackles i.e., hoisting chains, lifting chains, sling chains and wire
ropes should be of suitable capacity.

28. PERIODICAL EXAMINATION OF CRANES:

a) 140 T Diesel hydraulic cranes of ART’s will be examined at intervals regularly
as prescribed by RDSO.
b) The Break down incharge / SSE nominated to do so are responsible for the
periodical examination of 140 T Break down cranes.
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Maintenance & Operation Manual Part I- 140 T BD Cranes
c) To ensure proper upkeep and reliability in safe working of 140 T 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)

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
(C) Gottwald (Old Crane) DRAFT

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
(D) Gottwald (New Crane) CIL Main Engine
S.N. Duration Working hours Set of schedule form
01. Daily Form “A”
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
S.N. Duration Working hours Set of schedule form
01. Daily
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Maintenance & Operation Manual Part I- 140 T BD Cranes
02. Monthly 125*
03. 6 Monthly 250*
04. Yearly 1000*
05. 2 Yearly 2000*
06. 3 Yearly 3000*
07. 8 Yearly -- POH Sch.
d) Particular of periodical examinations should be maintained on a register.
e) 05. Any repair to be executed should be reported to the subordinate incharge of
the maintenance of the crane.
f) 06. Record of such examinations entered in the register will be signed by the
maintenance supervisor.
g) 07. Particulars of periodical examinations of 140T. Crane will be recorded in the
prescribed schedule forms as laid down by the RDSO.

29. LUBRICATION OF CRANES

a) Crane drivers will be personally responsible for adequate and efficient lubrication
of all bearing surfaces.
b) 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.
c) 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. DRAFT

d) On 140 T 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
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.
Description of the NOS.
material
Walkie Talkie Sets 04 Nos.
Mega Phone 02 Nos.
Walkie Talkie Charger 01 No.
2+2 Gas Patromax 02+02 Nos.
Torch Three Cell 04 Nos.
Signal Torch 01 No.
Measuring Tap 01 No.
Helmate (Hard hate) 04 Nos.
Helmate Staff 20 Nos.
Bed Sheets 08 Nos.
Pillows 05 Nos.
Blankets (Supervisor) 08 Nos.
Blankets (Staff) 20 Nos.
Red and Green Flags 02 Nos.
Water Buckets 01 Nos.
First Aid Box 01 Nos.
1+1+1 Memo Book and Pad, Stamp 1+1+1 No.
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Maintenance & Operation Manual Part I- 140 T BD Cranes
Detention form 04 Nos.
Umbrellas 04 Nos.
Pain Relief Spray 02 Nos.
Spray Pump for cleaning of eye 01 No.
Hyd. Hand Pump Unit 01 No.
30/60 Te. Jacks 02 Nos.
120/60 Te. Jack 01 No.
Displacing Jack 01 No.
Roller Carriage 01 No.
Re-railing Bridge 01 No.
Counter Support 01 No.
High Pressure Hoses 03 Nos.
3/2.5Kva Cap. Generator 01 No.
Halogen Lamp 02 Nos.
Elect. Switch Board 01 No.
Elect. Extension Board 01 No.
Wrench Bar 02 Nos.
Punje 02 Nos.
Video Camera 01 No.
Kitchen Material 01 Set

30. SUITABLE WOODEN PACKINGS

A. REQUIRED FOR 140 T CRANE: [ COWANS SHELDON 140 T CRANE]
1.Wooden Packing Size- 1800mmX300mmX300mm - 18 Nos.
2.Wooden Packing Size- 1200mmX300mmX300mm - 20Nos.
3.Wooden Packing Size- 1200mmX300mmX150mm - 24 Nos
4.Wooden Packing Size- 900mmX225mmX150mm DRAFT
- 50 Nos
5.Wooden Packing Size- 900mmX225mmX100mm - 30 Nos
6.Wooden Packing Size- 900mmX225mmX75mm - 30 Nos
7.Wooden Packing Size- 900mmX225mmX50mm - 30 Nos
8.Wooden Packing Size- 900mmX225mmX25mm - 30 Nos
TOTAL PACKINGS - 232 Nos.
NOTE: All packings must be recessed at the ends and bonded with 30X5 mm thick
bond.

B.REQUIRED FOR COWANS SHELDON 140 T 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

2 5' x 1' x 6" IInd Base 2.5 5 40 100 40 100

IIIrd & IVth

3 4' x 1' x 6" 2 8 32 64 64 128
Base

Vth & Vith

4 3' x 1' x 9" 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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
2' 6" x 1' x Eight &
6 0.625 6 24 15 48 30
3" Ninth Base

Total 15.25 34 156 399.5 272 699

31. LOAD CHART FOR 140 T CRANE [COWANS SHELDON OLD]

Duty Duty Selector
Selector 0 t - 3, 32 t - 6
0 t - 4, 32 t MAIN HOIST 12 t - 1 AUXILIARY HOIST
-7
12 t - 2
Coup Free on rail Fully Propped Coupl Free on rail Fully Propped
led Radiu ed
Radius Slew Range Slew Range Slew Range Slew Range
balla s in ballas
in
st O° 28° 360° O° 28° 360° mete t O° 28 360° O° 28° 360°
meter
weig r weigh °
ht t
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 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 12 t 78 41 27 140 140 110 9 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
1
9 12 t 63 30 18.5 140 140 70 12 t 25 25 15 25 25 25
32 t 70 -- -- 140 140 101 1 32 t 25 -- -- 25 25 25
0t 16 16 9 109 109 44 0t 12 12 6 25 25 25
1
11 12 t 52 23 14 118 118 50 12 t 25 21 11 25 25 25
32 t 58 -- -- 130 130 58 DRAFT
3 32 t 25 -- -- 25 25 25
0t 12 12 -- 79 79 34 0t 9 9 4 25 25 25
1
13 12 t 44 18 9.5 85 85 38 12 t 25 17 9 25 25 25
32 t 49 -- -- 105 105 58 5 32 t 25 -- -- 25 25 25
0t 9 9 -- 61 61 27 1 0t 7 7 3 25 25 25
12 t 38 14 7 66 66 31 12 t 25 13. 7 25 25 25
15 7. 5
32 t 42 -- -- 85 85 47 0 32 t 25 -- -- 25 25 25
0t 8 8 - 55 55 24 1 0t 5 5 2 25 25 19
16. 12 t 35 13 6 59 59 28 12 t 25 11 5 25 25 22
9.
0 32 t 39 -- -- 70 70 42 32 t 25 -- -- 25 25 25
0
5.65 5.5 Activities and Timing particulars
1. 140 Te. Crane Energising with Aux. Hook= 15 mts
B-En
140 T CRANE A-End 6.0 m 2. Full Propping
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

32. (a) WEIGHT CHART OF COACHES AND WAGONS

SN Type of Tare Pay Comple One Total Type Open / Vacuum/
Wagons & weight load in te Trolly wheels of Cover Air
Coaches in Tonnes weight weight coupli ed Brake
Tonnes in in ng
Tonnes Tonnes
01 BVZI 23.52 56.68 81.28 4.0 08 CBC Open Air Brake

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 Cover Air Brake
ed
11 BCNHL 20.80 70.80 91.60 4.0 08 CBC Cover Air Brake
ed
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 BOBRNHSM 25.61 63.67 89.28 4.0 08 CBC Flat Air Brake
1
16 BOBY/BOBYNH 25.2 66.40 91.60 4.0 08 CBC Open Air Brake
S
17 BTPN 27.0 54.28 81.28 4.5 08 CBC Cover Air Brake
ed
18 BTPGLN 41.60 37.60 79.20 4.5 08 CBC Cover Air Brake
ed
19 BTFLN 23.33 57.95 81.28 4.5 08 CBC Cover Air Brake
ed
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 47.50 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 48.40 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 50.60 8.00 58.50 4.0 08 CBC Coach Air Brake
28 LWFCZAC 42.27 6.24 48.51 DRAFT
4.0 08 CBC Coach Air Brake
29 LWSCZAC 42.27 8.00 50.27 4.0 08 CBC Coach Air Brake
30 LWLRRM 53.00 4.66 56.78 4.0 08 CBC Coach Air Brake
31 SCN 41.1 6.7 47.8 3.5 08 Transiti Coach Air Brake
on
32 AC Ist 49.75 1.5 51.19 3.5 08 Transiti Coach Air Brake
on
33 AC IInd 53.7 9.6 63.3 3.5 08 Transiti Coach Air Brake
on
34 AC III 53.7 9.6 63.3 3.5 08 Transiti Coach Air Brake
on
35 AC Chair 45.6 7.6 53.2 3.5 08 Transiti Coach Air Brake
Car on
36 Pantry Car 41.5 2.0 43.5 3.5 08 Transiti Coach Air Brake
on
37 VPU 38.0 16.0 54.0 3.5 08 Transiti Coach Air Brake
on
(b) 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 T 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 01.2006 Engineering Material + OHE
RYPS

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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
33. RESTORATION AT ACCIDENT SITES BY 140 T CRANES
(A) LOCOMOTIVES:

Restoration of derailed locomotive in the dead-end siding by 140 T 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 All props to be prepared and 04 staff on
availability of staff each prop should be deputed.
03 Suitable packing and its size Wooden packing of size 4’x12”x12”/
4’x10”x6”
DRAFT

04 No. of cranes required and Two cranes. duty selector to be kept on

Position of SLI duty selector No.1(i.e., full prop with full counter weight)
05 Suitable wire rope sling 50/70 T 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 All four buffer plates
inserted
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
adjustment of loco
13 Availability of Megaphone/ One person should be deputed with
Communication equipment
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
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Maintenance & Operation Manual Part I- 140 T BD Cranes
 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.

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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.

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.

DRAFT

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 cannot 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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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. DRAFT

16 Uncoupling of Bogies
In situations where it is needed to uncouple the bogies and run out
as in above case , air brake pipe connections, TM cable
connection, Centre Pivot cotter and other connections between
bogie and chasis needs to be disconnected.Other such coonectios
are listed as below-
 Axle Generator cable
 Speedometer cable
 Bolster Pin etc

C- Procedure in Practice:

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 140T crane is kept at one end on the adjacent track and other 140T Crane at
another end.
2. Full propping is done for both the cranes and 50T/ 70T, 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.
(B) COACHES
2.(A) RESTORATION OF COACHES IN ELECTRIFIED SECTION BY
140T CRANE
A. Preparation Chart:

S.N. Item/Status Action

01 OHE To be slewed towards coach movement and
ensure that OHE of adjacent line has been
made dead.
DRAFT

02 Condition of props and Full propping to be done and 04 staff on

availability of staff each prop should be deputed.
03 Suitable packing and its Wooden packing of size 4’x2’x14” and
size 6’x1’x12”
04 Position of SLI duty selector To be kept on No. 1
05 Wire rope Sling and SWL 30T 5 Mtrs sling and 70T SWL as per
requirement
06 Chain sling as per 25T Capacity chain sling
requirement
07 Position of Cant of the track Should not be more than 140 mm
08 Position of SLI SLI should be kept in working.
09 Maximum working radius 13 meters by main hook.
10 Place where sling to be (Under frame) Solbar
inserted
11 Gas cutting equipment DA and Oxygen gas with equipment
12 Availability of wooden 04 wooden wedges
wedges
13 Position of coach trolley Lashing chain to be used for securing with
structure.
14 Lighting arrangement To be arranged during dark/night.
15 Observation for suitable Analyze suitable place for 360º slewing and
place placing the coach/damaged trolley.
16 Arrangement of rope for 02 Nos. in sufficient length at both the ends
coach adjustment of coach.
17 Availability of Megaphone/ One person should be deputed with
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Maintenance & Operation Manual Part I- 140 T BD Cranes
Communication equipment
18 Photography/Videography Videography of all critical operations and
clues collection.
19 Average timing for Average – 55 minutes
restoration of each coach
Removing Entangled Coach:
01. Energize 140T Crane, attach counter weight and ensure full propping
for approach up to 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 T SWL and 30 T 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 T 5 mtrs wire rope sling with eye-
wire rope without SWL.
05. Lift the coach and place away from the track within 13 mtrs.
DRAFT

2(B) RESTORATIONS OF COACHES

IN NON-ELECTRIFIED SECTIONS
In double line section, where lines
are at minimum standard distance,
the restoration can be executed with
140 T 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 Its 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 T 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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
adjusting slew degree and radius. Similarly keep other trolley also on the
track.
2(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 T 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.
2(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.

DRAFT

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.

After assessment of the accident site, if the coaches found tilted infringing
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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

2. 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.

DRAFT

Earth work done in river bed during restoration, to facilitate

flow of river water
[ Photographs from Engineering Deptt.WCR during Harda accident
in 2015 in KNW-ET section ]
1E- 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 .

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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.

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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.

DRAFT

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)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Coach is
positioned to
leave space
for crane
movement. Crane is
moved to
1 2 tackle farther
In single line section the trolley of the coach in end.
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.

DRAFT

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.

4
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.

DRAFT

(C) EMU/MEMU/DEMU
Restoration of derailed EMU/MEMU/DEMU.

A- Preparation Chart :
S.N. Item/Status Action
01 OHE To be slewed towards coach movement
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
availability of staff each prop should be deputed.
03 Suitable packing and its Wooden packing of size 4’x2’x14” and
size 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 25 Te. Capacity chain sling
requirement
07 Position of Cant of the track Should not be more than 140 mm
08 Position of SLI SLI should be kept in working.
09 Maximum working radius 13 meters by main hook.
10 Place where sling to be (under frame) Solbar
inserted
11 Gas cutting equipment DA and Oxygen gas with equipment
12 Availability of wooden 04 wooden wedges
wedges
13 Position of coach trolley Lashing chain to be used for securing with
structure.
14 Lighting arrangement To be arranged during dark/night.
15 Observation for suitable Analyze suitable place for 360º slewing and
place placing the coach/damaged trolley.
16 Arrangement of rope for 02 Nos. in sufficient length at both the ends
coach adjustment of coach.
DRAFT

17 Availability of Megaphone/ One person should be deputed with

Communication equipments
18 Photography/Videography Videography of all critical operations and
clues collection.
19 Average timing for Average – 58 minutes
restoration of each coach
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 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
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
schaku 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.

Schaku coupler in coupled condition

DRAFT

Apart from above these stocks are similar to Coaches. Hence for the
9 methods of 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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
siemens, Bombardier 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.
DRAFT

(D) WAGONS
a) Restoration of Loaded BCN/BOX-N by 140 T. 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.
02 Condition of props and availability Full propping to be ensured and 04
of staff staff on each prop should be deputed.
03 Suitable packing and its size Wooden packing of size 4’x2’x14”/
6’x1’x12”
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Maintenance & Operation Manual Part I- 140 T BD Cranes
04 Position of SLI duty selector To be kept on No. 1
05 Wire rope sling and SWL 70 T 6 mtrs sling (two leg) and 140 T
SWL.
06 Chain sling as per requirement 25 T Capacity chain sling
07 Position of Cant of the track Should not be more than 140 mm
08 Position of SLI SLI should be kept in working.
09 Maximum working radius 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.
12 Gas cutting equipment DA and Oxygen gas with equipment
13 Availability of wooden wedges 04 wooden wedges
14 Lighting arrangement To be arranged during night/dark.
15 Observation for suitable place Analyze suitable place for 360º
slewing and placing of wagons.
16 Arrangement of rope for wagon 02 Nos. in sufficient length at both the
adjustment ends of coach.
17 Availability of Megaphone/ One person should be deputed with
Communication equipment
18 Photography/Videography Videography of all critical operations
DRAFT

and clues collections.

19 Average timing for restoration Average – 56 minutes
(per wagon)
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 While handling accident wagons, not the length but it is the tonnage in
case of loaded stock that is the critical factor.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
DRAFT

hauled with restricted speed with some suitable

arrangement of coupling.
18 BTPGLN (LPG wagons)
Concentration of gas in the area should be checked first
by gas detector before starting of the restoration work for
safety.
The representatives of oil companies should be called for
supervision of evacuation of gas and other safety
measures.
C- Procedure in Practice:
01. Energize the crane, attach counter weight
and 140 T Cap. SWL with 140 T 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 T 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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
06. Lift the job again and place the wagon anywhere 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.
b) Restoration of damaged BCN/BOX N by 140 T 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. DRAFT

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.
a) 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.
b) 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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.
c) 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.
d) In case CBC has got damaged, hooks can be fixed to the draft gear housing.

e) 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.
f) 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.

DRAFT

BOBRN in Capsized condition

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

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
BLC Wagon
j) Containers and BLC wagons should be lifted separately as it is very difficult to
tackle all the 5 units together.

BTPLGN (LPG wagons)

k) Concentration of gas in the area should be checked first by gas detector before
starting of the restoration work for safety.
l) The representatives of oil companies should be called for supervision of
evacuation of gas and other safety measures.

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes
(E) Restoration of derailed BTPN (Oil tank wagons) involved in
fire.
A-Preparation Chart :

S.N. Item/Status Action

01. OHE Working line OHE to be slewed. OHE of
adjacent line to be made dead.
02. Requirement of fire brigade Heavy duty fire brigade is called
02. Condition of props and All props to be prepared and 04 staff on
availability of staff each prop should be deputed.
03. Suitable packing and its Wooden packing of size 4’x10”x6”and other
size suitable sizes.
04. Position of SLI duty selector To be kept on No. 1
05. Suitable wire rope sling 30 T 5 mtrs sling
06. Suitable chain sling as per 25 T Capacity chain sling
requirement
DRAFT

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 Analyze suitable place for 360º slewing and
place placing of wagons.
14. Arrangement of rope for 02 Nos. in sufficient length at both the ends
tank wagon adjustment of tank.
15. Availability of Megaphone/ One person should be deputed with
Communication equipments
16. Photography/Vide0ography Videography of all critical operations and
clues collections.
17. Average per oil tank timing Average – 55 minutes
for 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 equipment because machine and breakdown staff may
sustain injuries due to explosions.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
First of all, thorough inspection of accident site
should be carried out and fire brigade is called
immediately.
a) High pressure foam is sprinkled on the tanks
involved in the fire.
b) Until and unless putting off the fire completely,
140T crane should not be brought near
accident site.
c) 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.
d) Now, Lift the wagon and keep anywhere at 360° within the radius of 18 meters.
e) In general, wagons involved in fire are removed/toppled and kept aside because
such wagons are always considered dangerous for running on the track.

(F) Restoration of derailed Guard Brake van by 140 T Crane.

DRAFT

A-Preparation Chart:
S.N. Item/Status Action
01 OHE Working line OHE to be slewed. OHE of
adjacent line to be made dead.
02 Condition of props and All props to be prepared and 04 staff on
availability of staff each prop should be deputed.
03 Suitable packing and its size Wooden packing of size 4’x2’x14”/
6’x1’x12”
04 Position of SLI duty selector To be kept on No. 1
05 Wire rope sling and SWL Only 30 T 5 Mtrs wire rope sling
06 Chain sling 25 T Capacity chain sling
07 Position of Cant of the track Should not be more than 140 mm
08 Position of SLI SLI should be kept in working.
09 Maximum working radius 11 meters by main hook and 19 mtrs. By
Aux. hook.
10 Place, where sling to be Barrel bracket/ Body bracket
inserted
11 Gas cutting equipment DA and Oxygen gas with equipment
12 Availability of wooden wedges 04 wooden wedges
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Maintenance & Operation Manual Part I- 140 T BD Cranes
13 Position of wagon trolley Lashing chain to be used for securing
with structure.
14 Lighting arrangement To be arranged during night/dark.
15 Observation for suitable place Analyze suitable place for 360º slewing
and placing of wagons.
16 Arrangement of rope for 02 Nos. in sufficient length at both the
brake van adjustment ends of BVZI.
17 Availability of Megaphone/ One person should be deputed with
Communication equipment
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 T 5 mtrs wire rope sling and insert
hook in the barrel bracket/body bracket.
03. Initiate lifting operation and place wagon anywhere at 360º within 11
meters radius.
04. For light weight brake van, use Aux. Hook with 25 T. Chain sling, lift the job
and place within the range of 18 meters radius.
(G) Restoration of Hot Axle/Cold Axle broken Wagons
DRAFT

Preparation Chart:
S.N. Item/Status Action
01 MFD/LUKAS power pack Two jacks of 120/60 T Cap. and
and 120/60 T Cap. Jacks displacing jacks.
with control table and 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 03 Lashing chains to be used for
and bolts securing with structure.
04 Availability of wooden 04 wooden wedges
wedges
05 Rail skates trolley 02 trolleys with 36/40 mm spanner

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Maintenance & Operation Manual Part I- 140 T BD Cranes
06 Availability of MFD tool box Should be available at site
07 Gas cutting equipment DA and Oxygen gas with equipment
08 Lighting arrangement To be arranged during night/dark.
09 Observation for suitable Analyze suitable place for jack
place operation.
10 Availability of Megaphone/
One person should be deputed with
Communication equipment
11 Photography/Videography Videography of all critical operations
and clues collections.
12 Average per wagon timing Average – 45 minutes
for restoration
If the Axle of any wagon has broken from axle box side due to hot axle, or cold axle
breakage, in this situation, shifting of wagon takes place and sometimes derails.
a) These wagons are normally re-railed
by MFD/LUKAS equipment, and
brought in the alignment on the track.
b) Rail Skates are inserted under the
wheels of broken axle.
c) 32 mm bolt of the skate is tightened to
establish the wheel completely in the
container.
d) Each skate has two wheels, which DRAFT

should be observed for proper sitting

on the rail before moving the wagon.
e) Move the wagon slowly without jerk, attaching with the breakdown train or with
assisting loco, not more than 5 Kmph speed.
f) Wagon in this position can travel 10 to 12 KMs at a stretch for next block station
without changing the wheels.
g) This modification facilitates reduction in restoration timings and avoids toppling
of such axle broken wagons at accident sites.
h) But in case of nonfunctioning of Rail Skate or defect in Rail Skate, the wagon
should be toppled by 140T crane after unloading by commercial deptt.
(H) FOB WORK
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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
5 Select the counter weight 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 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 maneuvered for assembly. Also, once the hook
has dis-engaged it is difficult to engage it again at height.

8 Propping over sewage trench should be avoided, height of water

DRAFT

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.

C- Procedure in Practice:
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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
(I) LAUNCHING OF GIRDERS

A-Preparation Chart:
S.N. Item/Status Action
01 OHE Working line OHE to be slewed. OHE of
adjacent line to be made dead.
02 Condition of props and All props to be prepared and 04 staff on
availability of staff each prop should be deputed.
03 Suitable packing and its size Wooden packing of size 4’x2’x14”/ 6’x1’x12”
04 Position of SLI duty selector To be kept on No. 1
DRAFT

05 Wire rope sling and SWL 30 T 5 Mtrs or 50 T wire rope sling be used
06 Chain sling 25 T Capacity chain sling be used
07 Position of Cant of the track Should not be more than 140 mm
08 Position of SLI SLI should be kept in working.
09 Maximum working radius 11 meters by main hook and 19 mtrs. By
Aux. hook as per load chart.
10 Place, where sling to be As per Engineering dept.
inserted
11 Gas cutting equipment DA and Oxygen gas with equipment
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.
14 Lighting arrangement To be arranged during night/dark.
15 Observation for suitable place Analyze suitable place for 360º slewing and
placing of Girders.
16 Arrangement of rope for 02 Nos. in sufficient length at both the ends
Girder adjustment of Girder.
17 Availability of Megaphone/ One person should be deputed with
Communication equipment
18 Photography/Videography Videography of all critical operations and
clues collections.
19 Average timing for per Girder Average – minutes
launching
B- Restoration Plan:
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 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
DRAFT

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.

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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.
DRAFT

Temporary
staging for prop
base

C- Procedure in Practice:
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
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Maintenance & Operation Manual Part I- 140 T BD Cranes
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 supe
r 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 !

DRAFT

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!
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Maintenance & Operation Manual Part I- 140 T BD Cranes

(J) TUNNELS

DRAFT

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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.

(K) RESTORATION ON BRIDGES

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
DRAFT

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 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
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 Since lifting capacity of the crane on free on
wheel is very limited accident involved stock
should be tackled by 140T crane in prop
condition for that temporary staging for propping
should be made.
8 While working on Bridges in high current, safety
precaution like life jacket etc. must be taken by
staff working at vulnerable locations.

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

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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. DRAFT

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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
Locking lever
locks are in locking position.

7 Additional Mechanical lock

provided for out riggers
should also be locked.

8 Do not leave the side mounted platform & outriggers in

unlocked position.
9 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator water
level and Oil level in all the gearboxes.
10 Do not run engine in low oil level.

Release the parking Brake. See the

green indication to ensure.
11

Do not haul with parking brake.

12 DRAFT

PREPARATION BEFORE LEAVING THE SHED

(140T Cowan Sheldon Old crane)
1 Whenever possible, crane shall be moved to accident
site with jib trailing. Required necessary marshalling at
crane shed or any en route station can be done. This will
help to avoid marshalling of MT after reaching accident
site. At sites with embankment, cutting or other such
conditions this may be very difficult.
2 Travel gear should be in disengaged position. Crane
Driver may further ensure this by putting the crane in self
propulsion and noting that it is not moving.
3 Crane Brake should be released.

4 Do not pull the crane when brakes are applied.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
5 All Draw beam should be
retracted. Ensure the
mechanical locks are in
locking position.

6 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator
water level, and grease in grease cups of both Relieving
Bogies and Oil level in all the gearboxes.
7 Do not run engine in low oil level.

PREPARATION BEFORE LEAVING THE SHED

(140T Cowan Sheldon New Crane)
1 Whenever possible, crane shall be moved to accident site
with jib trailing. Required necessary marshalling at crane
shed or any en route station can be done. This will help to
avoid marshalling of MT after reaching accident site. At
sites with embankment, cutting or other such conditions
this may be very difficult. DRAFT

2 Travel gear should be in disengaged position. Crane

Driver may further ensure this by putting the crane in self
propulsion and ensuring that it is not moving.
3 Crane Service & Parking Brakes should be released.

Make sure that

brake blocks are
released from
wheels after
releasing brakes.

4 Do not pull the crane when brakes are applied.

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
7 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator
water level and Oil level in all the gearboxes.
8 Do not run engine in low oil level.

Release the parking Brake.

See the green indication to ensure.
9

Do not haul with parking brake applied.

10

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.
DRAFT

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.

5 Do not start crane operation without proper brake.

AXLE BLOCKING (Cowan Sheldon New Crane)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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 Engage Blocking Pads
spring.
3 Ensure engagement of the travelling gear if required.

4 Ensure application of brake confirmed by the “RED”

indication.

5 Do not start crane operation without proper brake.

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. DRAFT

2 Secure rear Lock

section lock
while rear New Design
Old Design
section is fully
lifted.
3 Do not erect boom without securing rear T-locks.

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

section Gallows through pre selector switch (for Old
Design).
5 While making vertical
movement of CWT Cylinder,
a strict vigil is required since
malfunctioning of ‘Proximity
Switch’ may cause damage to
rear end plate below the
pulleys and CWT cylinder
piston.
6 Do not erect boom without upper and lower legs junction
locks of ‘A’ frame.
7 Depute 2 staff to go up and watch the
revving and un revving of the derrick
wire rope.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.

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 DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
4 Unload both
Relieving Bogies.

5 Remove Slew Lock

Pin before slewing.

DRAFT

6 With Derrick “IN” operation, Raise boom cautiously.

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
4 Remove Slew Lock Pin
before slewing.

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

With Derrick “IN” operation, Raise boom cautiously.

PROPPING THE CRANE

(Gottwald Crane)
1 Set the propping pads
properly by strengthening the
ground and placing the
packing alternatively parallel
and perpendicular to the
track. Ballasts base may be
provided for strengthening.
Depute one staff on each
prop to observe. For marshy
land, sand bags can be used
DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Rail clip MG
BD Crane

Rail clip BG BD
Crane

PROPPING THE CRANE

(Cowans Sheldon Old Crane)
1 Lock the Draw-
beams in
extended
position.
Packings should
be in sound
condition and
placed
alternately
perpendicular
and parallel to
the track. Check
condition of
packings for
DRAFT

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.

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PROPPING THE CRANE

(Cowans Sheldon New Crane)
1 Set the propping pads
properly by
strengthening the
ground and placing the
packing alternatively
parallel and
perpendicular to the
track. Ballasts base
may be provided for
strengthening. For
marshy land, sand
bags can be used for
making base for
propping.
2 Ensure that Parabolic DRAFT

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

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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
on chassis, if it is not brought back in the
boom operation, SLI safety will be bypassed.
bridgin
g key. New Design Old Design

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
5 selector switch as
required by the
load chart.
DRAFT

Switch off boom bridging key. Switch off the key

6 switch, which bridges safe load indicator.
7 Load chart should not be violated.

Load estimation should be done properly and to

avoid any untoward incident maximum possible
safe operation may be adopted like full prop, full
CWT etc.
8 After Rear operation or .
axle blocking operation
pre-selector switch for oil
transmission should be
brought to “Neutral”
position.
Do not leave pre-
selector switch in
ON position.

9 Ensure the CWT switch is in proper position.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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. DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
18 Lower ballast on to support beams ensuring the
ballast weight locating pins are engaged in the
support beam.
COUNTER WEIGHT
(Cowans Sheldon New Crane)
1 Select the total counterweight as per load chart for
the load to be lifted.
2 Follow correct sequence of operations for attaching
counterweights. First unlock, then extend the
Counterweight cylinder and swing in, then lift and
lock. Similarly follow this procedure in reverse order
for detaching counterweights.

3 Ensure DRAFT

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.

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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.
DRAFT

Driver should also cross- check the signal by

ground staff with condition of load.
10 Do not give multi command to driver.

11 Emergency lower button (Rapid motion switch)

should be operated only in case of emergency and
the operation should not be part of the normal
working cycle.
12 Only crane in-charge should communicate with the
crane driver. When required the senior most
mechanical officer should give instruction to the
crane in-charge.
13 The SLI does not relieve the crane user from his
responsibility to thoroughly determine the weight of
the load to be lifted and check the admissibility of
the operation as per load chart.
OPERATING PRECAUTIONS
(Cowans Sheldon Old Crane)
1 Do proper selection of lifting tackles (Chain & Wire
rope sling).
2 Neither lift Match Truck and nor slew in Free on Rail
condition.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
3 Remove Slew
Lock Pin before
slewing.

4 Avoid jerk during operation. Pendulum motion of

load is dangerous.
5 Don’t pull the load diagonally.

6 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.
7 Take care of wind forces on the boom as it is
dangerous.
8 Do not operate crane in high wind force.

9 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.
10 Proper signalling is to be given to the crane driver.
Driver should also cross- check the signal by ground
DRAFT

staff with condition of load.

11 Do not give multi command to driver.

12 Emergency lower button (Rapid motion switch)

should be operated only in case of emergency and
the operation should not be part of the normal
working cycle.
13 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.
14 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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

OPERATING PRECAUTIONS
(Cowans Sheldon New Crane)
1 Ensure Safe Load Indicator
(SLI) is in working condition.
Set Safe Load Indicator (SLI)
to Main
Hoist (M.H.) or Auxiliary Hoist
(A.H.) position as per
requirement.

2 Do proper selection of lifting tackles (Chain & Wire

rope sling).
3 Neither lift Match Truck nor slew in Free on Rail
condition.
4 Remove Slew Lock Pin before
slewing.

DRAFT

5 Avoid jerk during operation. Pendulum motion of

load is dangerous.
6 Don’t pull the load diagonally.

7 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.
8 Take care of wind forces on the boom as it is
dangerous.
9 Do not operate crane in high wind force.

10 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.
11 Proper signalling is to be given to the crane driver.
Driver should also cross- check the signal by ground
supervisor with condition of load.
12 Do not give multi command to driver.

13 Emergency lower button (Rapid motion switch)

should be operated only in case of emergency and
the operation should not be part of the normal
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Maintenance & Operation Manual Part I- 140 T BD Cranes
working cycle.
14 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.
15 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.
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
DRAFT

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 Rope attached
cautiously, to for guiding the
avoid pendulum load
like motion.
4 The load should be lifted slowly just above the
ground level and held for some time to avoid
swinging.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
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.

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

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
Release parking brake in the last when the crane is
going to be formed in train order.

PREPARING THE CRANE BEFORE LEAVING FOR SHED

(COWANS SHELDON OLD)
1 Prior to coupling back
relieving bogies,
clean and regrease
the Crane Carriage
end castings and
Coupling Pins on both
ends

2 After coupling back

the Relieving Bogies,
top up grease cups
(Spring Feed
Lubricators) of both
Relieving Bogies.

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
6 Remove detachable
Counterweight (12T) 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.

DRAFT

9 Check that Draw Beam

Jacks are fully retracted
and locked.

10 Ensure that the coupling hoses between the

carriage and relieving bogies (both end) are
connected properly. Also ensure the same
between match wagon and ballast truck of the
crane.
PREPARING THE CRANE BEFORE LEAVING FOR SHED
(COWANS SHELDON NEW)
1 For "In-train" running -
Remove Counter Weights and place at nominated
location on Match Truck.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
2 i. Unload the Crane
Springs by
retracting
ii. Axle Blocking
Jacks and ensure
sufficient gap
between top of
Spring Buckle
and Jack.
iii. 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

DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes
Safety of Rescue Workers
1 Staff working in rescue operation must wear safety
gears/PPEs (personal protection equipment ) 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
DRAFT

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.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

STAFF DEPLOYMENT DIAGRAM FOR GOTTWALD 140T CRANES

DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes

LOAD CHART OF NEW DESIGN COWANS SHELDON 140T CRANE

Crane Fully Propped 11.85 x 6.00 Mtrs STANDARD DUTY - FREE ON RAIL (FOR) COUNTER WEIGHT
Radi LIFTING ANDF
Outre MATCH TRUCK
us
ach in Standard duty CWT Heavy duty CWT 0 to 50 mm SE 0 to 140 mm SE LIFTING - FREE ON
in
Mtr RAIL
Mtr
360 360 SETTING UP FREEE
360 degrees 30 degrees 30 degrees 30 degrees 360 degrees 30 degrees
degrees degrees ON RAIL 140 mm SE
AH MH AH MH AH MH AH MH AH MH AH MH AH MH AH USE ON MAIN HOIST
5.5 140* 140 140 140 65 61 COUNTER WEIGHT
6 140 140 140 140 CRANE IS 60 54 13 DEGREE
7 1 103 25 140 25 117 25 140 25 NOT 48 25 43 25
Radius
SWL (Kg)
STABLE (Mtrs)
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 STABLE 28 25 6 23400
9.5 3.5 30** BACK 7 23400
WARDS
10 4 56 25 130 25 63 25 130 25 15 16 27 25 24 8 23400
11 5 48 25 120 25 55 25 120 25 13
DRAFT

14 24 24 20 9 23400

USE AUX. HOIST

11.1 5.1 117* 10 23400
13.5*
11.3 5.3 45* * 11 23400
12 6 42 25 110 25 48 25 110 25 10 11 21 20 10 18 12 23400
13 7 37 25 100 25 42 25 104 25 8* 9 18 18 8 15 13 20300
14 8 33 25 89 25 38 25 94 25 7* 8 16 16 7 13 14 17700
15 9 30.5* 25 78 25 34 25 86* 25 6* 7 14 14 6 12 15 15600
16 10 27 25 70 25 31 25 76 25 5* 6 13 13 5 11 16 13800
17 11 25 25 25 25 5 12 4 10
(* = Use override switch
(* = Use Aux. Hoist) (** = Marked crane duties according to Derrick in)
(* = Marked crane duties according RDSO specifications 2.4.10)
RDSO specifications 2.4.10)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

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 30 360 30 360 360 SET UP STANDARD

Radiu 360 degrees 13 degree 30 degree
each degree degrees degree degree degree DUTY CWT
s in
in Radius SWL
Mtr MH AH MH AH MH AH MH AH MH AH MH AH MH AH MH AH
Mtr (Mtrs) (Kg)
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
10 4 44 25 109 25 50 25 110 25 50 25 2.5 8 10 34000

USE AUX. HOIST

DRAFT

11 5 38 25 100 25 43 25 101 25 44 25 1.5 6 11 34000

USE AUX. HOIST

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

66.
14 8 26 25 25 29.5 25 76 25 32 25 3 14 31500

FORWARD
5
15 9 23 24.5 58 25 26.5 25 67 25 31 25 2 15 28000
51.
16 10 21 22 25 24 25 60 25 28 25 1.5 16 25000
5
17 11 20 25 25* 25 25 1

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Crane Fully Propped 12.76 x 3.40 Mtrs Special DUTY CRANE- FREE ON RAIL (FOR)
Outrea Standard duty CWT Heavy duty CWT 0 to 50 mm SE 0 to 140 mm SE
Radius
ch in
in Mtrs 360 degrees 30 degrees 360 degrees 30 degrees 360 degrees 360 degrees
Mtrs
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 DRAFT
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

(* = Use AUXILIARY HOIST)

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Maintenance & Operation Manual Part I- 140 T BD Cranes

CHAPTER-3

TECHNICAL DESCRIPTION OF
GOTTWALD 140 T BREAK
DOWN CRANE
DRAFT

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Maintenance & Operation Manual Part I- 140 T BD Cranes

1. TECHNICAL DATA OF 140 T GOTTWALD BREAK DOWN

CRANE –New Design
SN Description Dimensions
Dimensions
01 Track Gauge 1676 mm
02 Wheel Diameter New 920 mm
Wear limit 840 mm
03 Distance between bogie pivots 7500 mm
04 Distance between twin wheel 3000 (1500) mm
sets
05 Length ahead of buffer 13290 mm
06 Maximum Towing Speed 100 kmph
07 Maximum wheel set load 200 kN
08 Total weight in train formation 120 T
09 Height in transport position 3900 mm
10 Width in transport position 3100 mm
11 Elevated Curves 140 mm
Brake System
13 Secondary Air Brake(Service 12 wheels disk-operated brakes
Brake)
14 Parking Brake Spring-loaded brakes on 6 wheel sets
Outriggers
15 Base 11.6 m x 6.0 m
16 Maximum support force 2200 kN
17 Outriggers Cylinder Stroke DRAFT

500 mm
18 Free-on-wheels base 7.5 m x 1.7 m
19 Maximum wheel force 350 kN
Travel Gear
20 Driven Wheel Sets on each 1
bogie
21 Speed 20 kmph
Diesel Engine
22 Type 6-Cylinders in Series, water cooled
23 Model Make-Cummins
(i) NTA 855 P335
(ii) NTA 855 LBC
(iii) QSL-9
Make- MTU
(iv) OM 926 LA
24 Out put 205 kW at 1800 rpm
25 Torque 1158 Nm at 1400 rpm
26 Fuel tank capacity 900 lts.
27 Generator 28 Volt, 55 Amps
Emergency Diesel Engine
28 Type 2-Cylinders in series, air cooled
29 Model Kirloskar HA-294
30 Out put 16.9 kW at 1800 rpm
Main Hoist
31 Rope Diameter 26 mm
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Maintenance & Operation Manual Part I- 140 T BD Cranes

32 Rope Speed Max. 72 m/Minute

33 Hoist Speed Max. 4 m/Minute
34 Hook Block 18-strand 140 Te.
SN Description Dimensions
35 Hoisting range Below track 4.0 m
Slewing Gear
36 Type 3-Stage planetary hoist with spring
loaded multi disc brake with External
teeth
37 Superstructure Speed 0-1.0 rpm
Derricking Gear
38 Type 3-Stage planetary hoist with spring
loaded multi disc brake
39 Rope Diameter 26 mm
40 Rope Speed Max. 28 m/minute
41 Derricking time Approx. 165 Seconds
42 Rope tension 2x14 strand, 2200 kN
Counterweight
43 Slab-1 (transported on the 24 T
match truck)
44 Slab-2 (transported on the 15 T
Match truck)
45 Slab-3 (transported on the 8T
undercarriage)
Boom DRAFT

46 Length to the main hook 18.75 m

47 Length to the auxiliary hook 19.5 m
48 Main hook working range 5.5 m - 17.0 m
49 Auxiliary hook working range 6.5 m - 18.0 m
Match Truck
50 Length beyond buffer 16 m
51 Distance between wheel sets 2m
52 Track Gauge 1676 mm
53 Distance between bogie pivots 11.30 m
54 Draw and buffing gear Side buffers and screw couplings
55 Turning Radius 175 m
56 Maximum Towing Speed 100 kmph
57 Maximum Wheel Set Load 200 kN
58 Total Weight (Loaded) 80 T

2. 140 T. CRANE DESCRIPTION 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. MP-MISC-118 (Rev- MP-MISC-119 (Rev-0.00)
number 0.00)
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Maintenance & Operation Manual Part I- 140 T BD Cranes

2 Track gauge 1676 mm 1676 mm

3 No. of vehicles in Crane with two 3 - axle Crane with two 3 - axle
running order bogies + Match truck bogies + Match truck with
with two 2 - axle two 2 - axle bogies
bogies
4 Length of crane over 13300 mm 13300 mm
buffers
5 Length of match 15970 mm 16000 mm
truck over 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 175 m radius
10 Max height of crane 3950 mm 3900 mm
from RL
11 Overall weight 200t 200t
12 Axle load in running 20t 20t
order
13 Tail radius 5.5 m 5.5m, 6.5m
14 Counterweight: 4 pieces: 5.2T, 6T,
DRAFT
3 pieces: 8T, 15T, 24T
14T, 18T
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 Coil spring Coil spring
truck
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)
22 Safe load indicator Mechanica System Mechanica System Hytech
Hytech
23 Hauling winch 5T 5T
capacity
24 Lifting beam capacity 2 nos. - 140T & 70T 2 nos. - 140T & 70T

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Maintenance & Operation Manual Part I- 140 T BD Cranes

25 Hooks Main (Ramshorn) - 140t Main (Ramshorn) - 140t

Auxiliary - 25t Auxiliary - 25t
26 Working radius Main Maximum - 16 m Maximum - 17 m
hoist
Minimum - 5.5 m Minimum - 5.5 m
27 Working radius aux Maximum - 17 m Maximum - 18 m
hoist
Minimum - 6.5 m Minimum - 6.5 m
28 Range of Lift Main Above rail level - 16.5 m Above rail level - 17 m
hoist
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
Below rail level - 3 m Below rail level - 3 m
30 Max capacity when 130T at 6m radius (360 140T at 6m radius (360
fully propped with degree) degree)
heay duty cwt. 130T at 9m radius (30 140T at 9.5m radius (30
degree leftward & degree leftward & rightward)
rightward
31 Crane Motion and
Speeds:
Derricking 1 min from max to min 165 sec from max to min
radius radius
Slewing 1 RPM 1 RPM
Main hoist lifting 2.5 m/min 4 m/min
DRAFT

Main hoist rapid 5 m/min 8 m/min

lowering
Auxiliary hoist lifting 15 m/min 15 m/min
Auxiliary hoist rapid 30 m/min 30 m/min
lowering
Self travel speed:
travel with load 6 km/h 6 km/h
travel without load 12 km/h 20 km/h
Hauling speed: 100kmph 100kmph
on 90R mainline std 75 kmph 60 kmph
track & above
on 52 kg mainline 80 kmph
track & above
32 Main Diesel Engine:
Make Cummins (A). Cummins
(B). MTU
MODEL (i) NT 855 R4 A.-(i) NTA 855 P 335
(ii) NT 855 FFC (ii)NTA 855 LBC
(iii)QSL-9

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Maintenance & Operation Manual Part I- 140 T BD Cranes

B.-(iv) OM 926 LA
Mounting Horizontal Vertical
Horse power (i) 320HP (i)270HP,
(ii) 326HP (ii) 290HP,
(iii) 305HP,
(iv) 311HP
No of cylinder 6 6
Bore & stroke (mm) 140 X 152 140 X 152
Compression ratio 14.1:1 14.1:1
Lube oil sump 28.2 liters 43 liters
capacity
RPM 2100 1800
Fuel tank capacity 1000 liters 900 liters
33 Aux. Diesel Engine:
Make Kirlosker Kirlosker
Type/Model HA 294 HA 294
Horse power 23HP (16.9 KW) 23HP (16.9 KW)
RPM 1800 1800
34 Brakes crane Air brake, & Parking Air brake & Parking brake
brake (disc type)
DRAFT
(disc type)
35 Brakes match truck Air brake, Mechanical Air brake Mechanical hand
hand brake brake
Other details:
36 'A' frame available Rear Section

37 Gallows fixed cwt. Radius (5.5m) permit the counterweight

assembly to be placed at 5.5
or 6.5 m radius
38 Slewing arrangement 3 - stage planetary hoist 3 - stage planetary hoist with
with spring loaded multi- spring loaded multi-disc
disc brake roller slewing brake roller slewing ring with
ring with internal teeth external teeth
39 Hydraulic oil tank one single tank fitted in two internally connected
the rear portion of the tanks just behind the cab
superstructure
40 Fuel tank annular shaped tank box shaped tank in the rear
above the slewing ring portion of the superstructure
41 No. of pulleys in main 8 9
hoist
42 Controls:
Counterweight all control in cab, single all controls in the rear of the
lever operation crane, three levers for
control.
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Maintenance & Operation Manual Part I- 140 T BD Cranes

Hoists separate lever for main single joystick for main and
and auxiliary hoists auxiliary hoists
Rapid motion switch foot operated switch on the top of joystick
for hoist operation
Max. Travelling speed 100 kmph 100 kmph
in "In Train" formation

3. POPULATION OF 140 T CRANES ON IR:

Total 140 T Break Down Cranes are 94, available over Indian Railways as on date
and design wise population.
4. STARTING CIRCUIT OF 140T GOTTWALD CRANE (Old Design)
One No. battery box is provided inside the machinery room in which two batteries, of
12 Volts 150 Amps rating have been provided. These batteries feed 24 Volt DC
supply to the LT electrical system. One 24 Volt, 60 Amps 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 is put on at battery stand, the power supply of battery
goes to magnetic switch. Further, it supplies electrical power to self-starting motor. As
the negative terminal of the battery is connected to the crane body, negative charge
is always available in the crane body. Positive power supply comes from Battery via
dash board Ammeter circuit. Again, when push button start switch with (Main Engine
ignition Key switch must on) is pressed, the engine fuel solenoid valve gets positive
DRAFT

supply from dash board and negative supply from crane body. The self-start motor
pinion gets energized by power supply of magnetic switch and starts running by
meshing to main engine flywheel gear. On running of main engine, charging
indication is found by fluctuation of indicator in the Ammeter fitted with dash board in
front of operator. When alternator power supply is ok then crane must not be shut
down by put off main engine isolating switch.
5. BATTERY OPERATED ELECTRICAL CIRCUITES.
1. Socket: 4 Lamp sockets of 24 Volt DC supply have been provided with the 140 T
crane. One socket above the battery stand, second at the rear section, third in the
driver cabin and fourth near to machinery room light is provided. These are denoted
by 7x30,7x31,7x32 and 7x33.
2. Cab Light: It is a CFL, 11-watt 24 volt mounted on the roof of driver cabin. It is
provided for illumination in the driver cabin. Its circuits are controlled by MCB, 7F02.5,
16 AMP. It has been denoted by (14E220).
3. Front wiper motor (M2) - Front 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. Its
circuit is controlled by MCB, 7F02.4, 16 AMP. It has been denoted by (14E41). The
roof wiper motor is fitted with roof glass. It has been denoted by (14E42).
4. Slew Circuit: Slew solenoid valve (in two nos.) has denoted by (15Y112 &
15Y122). Slew left Ckt is controlled by Relay 19 K21 having circuit group (15x21.7).
Slew Right Ckt. is controlled by Relay 19 K11 having circuit group (15x21.8). It is also
controlled by MCB, 7F02.6, 16Amp. When slewing is not functioning then it can be
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fed power supply by circuit group (15x21.1). Because on running position of crane,
power supply is always available at connector point 1 of group (15x21). It is only for
emergency work with the crane on temporary basis.
5. Toggle Switch: It is fitted with Aux. Engine Panel. It is for interlocking system. It
means one engine will be in operation in one time.
a) Engine Machinery House light: For better illumination in the engine house,
two lamps of 40 watts and 24-volt rating are provided inside the engine machinery
house. One of them is provided at near the auxiliary engine and another on other
side of machinery house. the pump compartment. These lamps are controlled by
MCB, 7F02.5, 16 Amp. It has denoted by (14E221 & 14E222) having Ckt. group
(14x21.10).
Note: Above circuits come in function only when battery isolator is put "ON" while
engine is in shut down condition
6. DASH BOARD GAUGE & INDICATOR ELECT. CIRCUITS OF
140 T (OLD DESIGN GOTTWALD CRANE)
Main engine running position
Different types of gauges are provided on 140 T Crane to check the system pressure of
fuel system, water-cooling system, engine lube oil system and hydraulic system. Apart
from this, jib light and front & rear crane head light circuit is also explained in this
chapter.
a) Battery Ammeter: Ammeter is provided on the dash board in driver cabin and it
gets supply from battery for charging indication purpose. Under shut down
position of main engine, when any circuit breaker is kept on, this ammeter
DRAFT

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.
b) Engine fuel gauge: This gauge shows fuel oil level in the main engine fuel tank.
It gets electrical supply from group (7x21.26). One sensor is provided in the
main fuel tank to sense the fuel oil level, which gets supply from wire no. 26 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.
c) Water temperature gauge: This gauge is provided to observe temperature of
engine coolant water. It gets electrical supply from Dash Board. 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, which can easily be seen
in the driver’s cabin. It has range between 71 deg. to 93 deg.C.
d) Engine oil pressure gauge : Engines oil pressure gauge shows main engines
lube oil pressure in running condition. It gets electrical supply from group
(7x21.14). 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.
e) Engine oil Temperature Gauge : It is provided to show temperature of lube oil
of main engine. It gets Electrical supply from group No. (7x21.11). One sensor
similar to thermo coupler is provided in the lube oil sump, which gets actual
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temperature of engine lube oil product and sends indication to the gauge
according to rise in temperature through Wire No.11. It has range between 82
deg. to 107 deg.C.
f) Hydraulic Oil Temperature Gauge : 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.
h) Engine Hour Meter Gauge : 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 group (7x21.4). During running
condition of main engine, it starts showing that how many hours engine has
worked with cumulative recording in hours.
7. ELECTRICAL CIRCUIT OF 140T GOTTWALD (OLD DESIGN
CRANE)
These circuits work only in main engine running condition and electrical supply is fed
to the circuit by the alternator.
One ignition switch is provided in starting circuit of main engine. Normally one push
button start switch for starting and one push button stop switch is provided for engine
starting and stopping.
a) Cab Ventilation Fan: The cab ventilation fan is provided in the driver cabin to
exhaust the air from cabin to atmosphere. It is operated by MCB F02.4, 16
Amps. It is denoted by 14E-91 and 14E-92. One is left side and another on right
DRAFT

in the cabin. It is CFL having 11-watt power.

b) Jib light: Jib light is provided in the end portion of the jib of the Crane for
providing required illumination level during load lifting at accident site. Jib light
is a 100 W, 24 V halogen lamp which is controlled by MCB, 7F02.7 of 16 Amps
rating through group (14x21.11).
c) Front head light: This lamp is provided lighting on the front side of driver cabin
on the crane. It is the halogen lamp of 100 W, 24 V rating which operated by
MCB, 7F02.8 16 Amps rating through group (14x21.12). It is denoted by 14E-
232.
d) Super Structure Head light: This headlight is provided at 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 100 W, 24 V rating which is operated by
MCB, 7F02.8,16 AMPS. It is denoted by 14E-234 having group (14x21.13).
e) Hydraulic Solenoid valve Control: There are 13 elect. solenoid plug
(Mounted on solenoid valve) provided for hydraulic ckt control during crane
operation. 10 plugs are for winching, main hoisting, exhausting, derricking &
slewing. Remaining 2 plugs are for HLF CWT pressure switch & full CWT
pressure switch. Pressure switch is denoted by 19B52 (28 ton.) having group
(19x21.13) & 19B53 (43.2 ton.) having group (19x21.14).
f) MCB 4 AMP : It is provided for safety of SLI Circuit. It is fitted with dash board
in driver cabin.

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Note: Engine RPM should not be less than 1500, when floodlight and head light are
being used.
8. STARTING CIRCUIT OF 140T GOTTWALD CRANE (NEW
DESIGN) FOR CUMMINS ENGINE NTA 855 P 335 & NTA 855
LBC
One No. of battery box is provided in between Driver Cabin & Superstructure in
which two batteries of 12 Volt, 150/180 Amps rating have been provided. These
batteries feed 24 Volt DC supply to the starting the main engine. One 24 Volt, 60
Amp Alternator is provided to charge these batteries as well as power supply to
electrical accessories having electrical items of Crane itself, SLI system & CCTV
Webcam system.
Alternator is given drive through V-belt over coupling of main engine. The alternator
generating voltage is 24 V on idle position & 28 V on full speed of the main engine.
When battery isolation switch in put on at battery stand, the power supply of battery
goes to magnetic switch. Further, this magnetic switch supplies electrical power to
self-starting motor. As the negative terminal of the battery is connected to the crane
body, negative charge is always available in the crane body. Positive power supply
comes from batteries via dashboard Ammeter circuit. Again, when main engine
ignition switch is pressed from ‘’OFF” to ‘’ON’’, the engine fuel solenoid gets
positive power supply from dashboard & negative supply from crane body. A fluid
level switch is provided with engine Radiator for engine safety. As soon as engine
ignition switch is pressed from ‘’ON’’ to ‘’Start’’ , the self-start motor pinion gets
energized by power supply of magnetic switch & self pinion shifts & starts running
by meshing to main engine flywheel gear. On running of main engine charging
DRAFT

indication is found by fluctuation of indicator in the Ammeter fitted with dashboard.

Relay Panel: Electrical Circuit of Crane motion is divided as mentioned below:
Relay Panel SLI Panel
61X22: Rear end CKT 72X23: Wiper, Fan, Horn CKT
31X22: Derricking CKT 71X23: Light CKT
21X22: Slewing CKT 63X23: SLI CKT
12X22: Aux Hoist CKT
11X22: Main Hoist CKT
9X22: Aux engine CKT
7X22: Main engine CKT
Relay Panel: There are 14 Nos of 24 V (1NO+1 NC) Bosch Relay, 08
MCBs(16Amp) & 03 Nos MURR Relays, 02Nos of 50 Amp Bosch Relay & 01 No. of
150 Amp Bosch relay provided for its ckt. control.
SLI Panel:There are 08 Nos of MCBs(16Amp), 03 Nos MURR Relays & One 24 V
(1NO+1 NC) Bosch Relay.
9. DUTIES OF THE 140 TE. CRANE OPERATOR:
The crane operator has the following duties -
a) He must check whether the brakes and the emergency limit switch function

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prior to commencing work. He must watch the condition of the crane for any
visible defects.
b) He must see to it and ensure that the power to the overhead lines is switched
off prior to commencing work on the crane.
c) When he notices any defects which could be dangerous for operating safety,
he must stop crane operation.
d) He must report any defects on the crane to the supervisor responsible and to
his replacement on shift change.
e) He must ensure that all the controls are brought in to neutral or idling position
prior to supplying power to the drive assemblies.
f) He must ensure that all the controls are brought in to neutral or idling position
and that the power is shut off prior to exiting the control stand.
g) He must ensure that the crane is parked safely according to regulations when
crane operating and crane travel operation have been completed.
h) He must check whether the safety equipment such as the hoist height and
swing-out section limits must be activated prior to commencing crane
operation.
i) If the crane operator cannot observe the load during all crane motions or the
lifting gear when there is no load is on the hooks, he may only operate the
crane based on the instructions of a banks man.
j) The Crane operator must provide warning signals when required.
k) Loads or lifting gears must not be moved above persons during any crane
DRAFT

motions
l) The crane operator may only move loads attached manually when he has
received a signal from the person attaching the load, or the hand signaller or
the person nominated by the crane operating company. If signals must be
used to communicate with the crane operator, these signals must be agree
upon between the crane operator and the person responsible for the signals
before the signals are applied.
m) As long as load is suspended on the hook, the crane operator must keep his
hands near the controls.
n) The emergency limit switches must not be activated intentionally during
operation.
o) The crane operator must ensure that all the doors are closed and locked
during travel.
p) Cranes may not be subjected to stress beyond the respective highest
permissible loading.

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10. LOAD CHART FOR GOTTWALD 140 T. BREAK DOWN CRANE

[NEW]

DRAFT

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11. LOAD CHART FOR GOTTWALD 140 T. BREAK DOWN CRANE

[OLD]

DRAFT

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DRAFT

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12. SAFETY DEVICES AND SAFETY FITTINGS ON GOTTWALD

140T CRANES
Important Electrical Items of 140 T crane (New Design)
1. Main engine relay panel box.
Located in driver’s cabin
Consist of Relays, start relay, MCBs & connectors.
2. SLI Panel box
Located in driver’s cabin behind driver seat consists of relays, MCBs, Light ckt. SLI
CPU card & connectors.
3. Dash-board Items
(a) i. RPM meter
ii. Ignition switch
iii. Lube oil pressure gauge
iv. Lube oil temp. gauge
v. Water temp. gauge
vi. Fuel level gauge
vii. Toggle switch
(b) Indicator Lamp (LED type, 24 VDC)
i. For engine run
ii. For charging failure of battery
DRAFT

iii. For water level indicator of Radiator water level sensor

iv. For lube oil pressure
v. For lube oil temp.
vi. For water temp.
4. Engine Items
(a) Engine harness box
Consists all ckt connection of engine Sensors & switches fitted with main engine
i. Magnetic pick up
ii. Lube oil pressure sensor
iii. Lube oil pressure switch
iv. Water temp. switch.
v. Magnetic switch
vi. Self-starting motor (24 V, DC)
vii. Alternator ( 24V,DC)
5. Limit switch
Gear Cam Limit Switch
i. Main Hoist Limit Switch } Both are identical
ii. Auxiliary Hoist Limit Switch }
iii. Derricking Limit switch

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Location: Fitted with concerning gear box drum and driven by gear box through
reduction (an outer part of limit switch). The limit switches are pre-set.
Setting of main Hoist Limit Switch
i. At two feet distance between Main Snatch block Pulley and boom had main
pulley
ii. At two mtrs distance between snatch block pulleys and boom head.
Setting of Aux. Hoist Limit Switch
i) At 2 feet distance between Auxiliary snatch block pulleys and Auxiliary head
pulley.
ii) At 2 mtrs distance between main snatch block pulley and boom head:
iii) Setting of DERRICK limit switch – 04 Settings -
a) At 5 mtrs (steepest boom up).
b) At 5.5 meters.
c) At 17 mtrs (steepest boom down)
d) Approach of the boom for deposition inside trassel box. working range of boom
radius: 5.5 mtrs to 17 mtrs.
6. Hydraulic Solenoid Valve
(16 Nos) energized/activated by electrical plug.
Location:
i) 09 Nos at one place inside m/c room.
ii) 03 Nos at one place inside m/c room. DRAFT

iii) 02 Nos at rear portion for Horn.

iv) 02 Nos at rear end for vertical and Horizontal cylinder function.
v) 02 Nos for main Hoist up and down.
vi) 02 Nos for Auxiliary Hoist up and down.
vii) 02 Nos for DERRICK up and down.
viii) 02 Nos for Slewing left and right.
ix) 01 No for Winch out
x) 03 Nos for
a) Lamina brake open
b) Rapid action of main Hoist.
c) Rapid action of Auxiliary Hoist.
7. Pressure Switch for Slewing:
It makes Slewing function properly.
8. Proximity Switch
For safe working of vertical and Horizontal cylinder of rear end.
Location: Fitted with rear end.
9. Relay: 24 VDC, 10/20 Amps
Safety item which controls the electrical circuit of critical/Vital electrical items like limit
switch, engine items and panel items.

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10. Start Relay: (150 A, 24 VDC) fitted with main engine relay Panel box for crane
operation, its function is must.
11. Water Level Switch: Fitted with radiator of main engine. It supplies negative
power to fuel solenoid valve.
12. Over speed Switch: Fitted near main engine harness box. When engine rpm
exceeds the maximum limit, it trips out. Reset it, now main engine starts easily.
13. Fuel Solenoid Valve Location: Fitted with main engine at mid portion of
engine. It has two points a) Positive point circuit b) Negative point circuit.
Positive point circuit gets power supply from Ammeter and negative point
circuit controlled by water level sensor.
14. Trouble-shooting
When main engine not starting, check power supply at following point -
a) When weak cranking, check -
i) Battery power: Full charged battery easily starts engine: Specific Gravity must
be more than 1200 of distilled water of Batteries.
b) When strong cranking, but not starting, check power supply at -
i) Water level inside main engine radiator.
ii) Battery main switch.
iii) Ignition key switch.
iv) Magnetic switch.
v) Over speed switch.
vi) Self-starting motor. DRAFT

vii) Fuel solenoid valve.

Note: For crane operation by Auxiliary engine, main engine battery switch also must
be kept on.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

CHAPTER-4

DOs and DONTs for

Operation and Maintenance of 140T
Gottwald Crane (New design) DRAFT

Jamalpur Loco Works,

Eastern Railway

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Sl. DOs DONTs Repercussion if

No DOs/DONTs are not
followed
1 TO BRING THE CRANE IN TRAIN ORDER BEFORE LEAVING THE SHED
Travel gear should be in Do not leave Axle Travel gear will get
dis–engaged position blocking in “ON” damaged and
position suspension system will
not work
a)

Crane Brake should be Do not pull the crane Wheel will get skid due
released with indication when indication is to brake binding.
as “GREEN” “RED”, in any case.

b)

Boom should be locked Do not leave the boom Auxiliary boom head &
in trestle. unlock in trestle.
DRAFT
pulley will get damage.

c)

All side-mounted Do not leave the side Side platform and

platforms should be mounted platform & outrigger will damage.
lowered and outriggers outriggers in unlocked
should be folded and position.
d) locked properly.

e) Check for Hyd. Oil, Fuel Low level of fuel, coolant

Oil, Engine Lube oil, & Lubricant will damage
Radiator water level and components.
Oil level in all the
gearboxes.

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Check function of Aux.

Engine.

f)

Release the parking

Brake.

g)

2 RIGGING OF THE CRANE AFTER REACHING AT THE SITE

Before starting rigging
check (i) size of the load
to be lifted, (ii) required
radius and (iii) required
working cycle e.g., Hook
height, slewing range,
DRAFT

space for travelling the

load etc. These should
be in conformation with
a)
the load chart and with
reference to the site
condition for propping.

All stop valves for Hyd. Do not leave any of the The pumps may get
Lines should be opened stop valves closed. damaged or the Hyd.
before starting the System will seize.
engine.
b)

c) Before starting the Do not allow the Hyd. Hyd. Pump may be
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Maintenance & Operation Manual Part I- 140 T BD Cranes

engine check for Hyd. Level to go below the affected.

Oil, Fuel Oil, Engine lower-level indicator.
Lube oil, Radiator water
level, Oil level in all the
gearboxes and battery
water level.

After starting the engine

check Engine Lubricant
oil pressure and battery
charging current.
d)

Check for pilot pressure, Pilot pressure less than

it must be 30 bars. 30bar will cause wear &
tear hydraulic
components.
DRAFT

e)

Check for AIR pressure, Do not leave any air Air braking will be
it should like between leakage in the system. difficult.
6.5 –7.5 bars(kg/cm2).

f)

3 AXLE BLOCKING
Ensure engagement of
the travelling gear.

a)

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

b)

4 BOOM ERECTION:
Secure rear section lock
while rear section is fully
lifted.

a)

Depute 2 staff to go up
and watch the reveing
and unreeling of the wire
b) rope.

DRAFT

c) Derrick “IN” until boom

heels sit on the Jib foot
Pins.
d) Remove boom lock from
the jib trestle.

Raise boom cautiously

as per usual practice.

e)

5 PROPPING THE CRANE:

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Set the propping pads Do not prop the crane The prop may sink
properly on ground by on loose ground in any causing major accident
strengthening the case e.g. Toppling of crane.
ground. Depute one staff
on each prop to watch
its movement.
a)

Check the level of the

b) crane by spirit level.

6 COUNTERWEIGHT
Select the total During rigging of crane
counterweight with DRAFT
with full counterweight,
proper assessment of Full stroke of Differential
load, in consultation with cylinder, DEM
the load chart. 160/90X270 (Vertical
cylinder) should be
taken in downward
condition.
a)

Switch on boom bridging

key. 5-meter limit switch
should remain activated.

b)

c) Switch ON key switch,

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Maintenance & Operation Manual Part I- 140 T BD Cranes

which bridges safe load

indicator. The crane
should not be allowed to
slew in this condition.

Pick up the CWT as per

load chart.

d)

Select the proper prop Wrong selection causing

position by selector major accident e.g.,
switch as per required of toppling of crane.
load chart.

e)

DRAFT

Switch on S.L.I. switch

key to bring the
computer safety system
back in the circuit.
Check the correct mode
f) of stability.

g) Switch on boom key

switch, so that 5.5 mm
limit switch is in circuit.

Check if safe load

h)
indicator is in operation

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After fixing Cwt. On the

crane, the crane should
not be slewed unless
correct propping base is
selected on the mode
selector on the display
i) unit of the SLI system.

j) Load chart should be Do not miss to consult The current may be

followed in strictly. load chart in any subjected to unsafe
condition of working.
DRAFT working.
k) After Rear operation or Avoid parallel During Self travel of
axle blocking operation operation of U/C or Crane Pre selector
pre-selector switch for oil gallows and derricking switch must be in neutral
transmission should be or hoisting. position. Otherwise,
brought “Neutral” Piston of Propping
position. cylinder may be falling
down automatically.

l) Before starting work

make sure that computer
override key and boom
override key are
switched to working
position.

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Maintenance & Operation Manual Part I- 140 T BD Cranes

Ensure the CWT switch

is on proper position.

m)

7 OPERATION
a) Ensure proper selection
of lifting tackle (Chain &
Wire rope sling).
b) Avoid jerk during Don’t pull the load
operation. Pendulum diagonally.
motion of load not
permitted. Avoid
diagonal pull of the load.
c) Pull the load which are Don’t pull loads which
stacked in the ground are stuck in the ground
cautiously. It is ensured without close
that it will not offer supervision.
resistance beyond the
capability of the Crane.
d) Take care of High wind
forces on the boom as it
is dangerous.
DRAFT

e) Do watch for trend of soil

caving by watching the
prop level and spirit level
of the under frame of the
crane.
Ensure proper signalling
to the crane driver.
Driver should also
ensure cross- checking
the signal by ground
staff with condition of
f) load.

8 DERIGGING THE CRANE:

Leave 8T cwt on the
a) chassis in the direction
of match truck.

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Unload CWT On the

b)
match Truck

Boom out to 17M radius.

At this point derricking
c) out will be cut off by 17M
limit switch and SLI
system.
d) Switch “ON” boom over
bridge key.

e) Switch “ON” computer DRAFT

over bridge key.

f) Boom down until both

hooks lower into match
truck well.

h) Travel crane until boom

rest pin matches with the
recess in trestle.
i) Boom down until boom
slides fully into the boom
rest to the lock position.
At this point, lock the
boom in the trestle.

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j) Unlock rear section with

the help of lever.
k) Lower rear section
according to its last
position.
l) Derrick out until the
ropes are slack over the
operator’s cab. This
derricking out should be
retracted by “minimum
number of turns on
drum” limit switch (the
setting should be for
slackness just adequate
to negotiate designed
track curve)
m) OFF Axle blocking.

DRAFT

9 PREPAIRING CRANE FOR TRANSPORT

a) Parking brake “ON”
Brake hoses should be
connected as per the
requirement.
b)

c) Release parking brake in Do not forget releasing

the last when the crane parking brake.
is going to be formed in
train order.
10 MAINTENANCE CHECKING OF ENGINE
Engine should be Do not allow fuel level
maintained as per less than half of tank
a)
Manufacture’s capacity.
Maintenance Schedule.

IRCAMTECH/GWL/MECH/2022-23/ART/Manual/1.1 Page 200 of 210

Maintenance & Operation Manual Part I- 140 T BD Cranes

b) Clean fuel tank as per

maintenance schedule.
11 MAINTENANCE OF HYDRAULIC SYSTEM
Clean hoses and area, Do not open the Hyd.
around the equipment, System in a dirty
to be opened. Clean the environment.
tray in which the open
parts are kept.
a)

b) Do not over tighten any

leaking joints provided
with “O” rings/ seals.
Connected isolating
valves must be closed
before opening out any DRAFT

hoses.
c)

Ensure that no water is

mixed with the hyd. Oil
in the tank. Oil should be
tested in lab as per
guideline given in the
maintenance manual.
d)

12 ATTENTION TO WIRE ROPE

Replace wire ropes
when there is a
a) diametrical reduction in
its size by 5% or more
with respect to its normal
IRCAMTECH/GWL/MECH/2022-23/ART/Manual/1.1 Page 201 of 210
Maintenance & Operation Manual Part I- 140 T BD Cranes

diameter.

Replace wire rope if

there is any bend, kink,
abrasion, and uncoiling
or heavy corrosion.
b)

c) While revving / unreving

the wire rope on the
drum a person/ operator
must be watchful so that
there is no overlapping
of wire ropes, which may
cause damage to the
wire rope.
DRAFT

d) Proper greasing of wire Corrosion of wire rope

rope around fitting will take place.
clamps / sockets should
be done.
13 MAINTENANCE PRECAUTION FOR SAFETY DEVICES
All limit switches, force Don’t disturb the
and angle sensors must switching point of the
be cabled. limit switches.
Damaged cables must
immediately be
replaced. They should
always be kept
a) operational.

Check all limit switches Do not operate

when rigging to ensure computer over bridge
their functioning. key and boom over
b)
bridge key during
crane working. These
are only operated at
IRCAMTECH/GWL/MECH/2022-23/ART/Manual/1.1 Page 202 of 210
Maintenance & Operation Manual Part I- 140 T BD Cranes

time of rigging / de-

rigging.

The safe load indicator

does not relieve the
crane user from his
responsibility to
thoroughly determine the
weight of the load to be
lifted and check the
c) admissibility of the
operation according to
be lifting chart.

DRAFT

IRCAMTECH/GWL/MECH/2022-23/ART/Manual/1.1 Page 203 of 210

Maintenance & Operation Manual Part I- 140 T BD Cranes

APPENDIX-A

MAINTENANCE
SCHEDULES OF 140T
CRANE
(As per RDSO Maintenance Schedule no. MP.MI-37 (Rev.-00)
June'2018)

DRAFT

IRCAMTECH/GWL/MECH/2022-23/ART/Manual/1.1 Page 210 of 210

 qKfr {fFbR- td qildq Government of India-Ministry of Railways
wguun ofi6w sik qrfi dTr{ Research Designs & Standards Organisation
qIGFI\F - 226011 Lucknow -226011
EPBX (0522)2451200 otD (0522)2450115
Fax (0522) 2458500 DrD (0522) 2465310

No. SD.CRMG Date: 04.07.2018

The Chief Motive Power Engineer/Dsl,
1. Central Railway, CST Mumbai - 400 001.
2. Eastern Railway, Fairlie place, Kolkata - 700 OO1.
3. East Central Railway, Hajipu r - g44101 .

4. East coast Railway, Rail Vihar, B-2, Bhubaneshwar - Ts1 017

5. Northern Railway, Baroda House, New Delhi - 110 001.
6. North Central Railway, Allahabad - 211 OO1.
7. North Eastern Railway, Gorakhpur - 273 OO1.
8. Northeast Frontier Railway, Maligaon, Guwahat -791 011.
9. North Western Railway, Jaipur - 302 006.
10. southern Railway Park rown, chennai - 600 003.
11. south central Railway, Rail Nilayam, secunderabad - 500 or1 .
12. south Eastern Railway, Garden Reach, Kolkata - Too 043.
13. South East Central Railway, Bilaspur - 495 004.
14. South Western Railway, Hubli - 580 023.
15. Western Railway, Churchgate, Mumbai - 400 001.
16. West Central Railway, Jabalpur - 492 OO1
17.Dy. CME/JMP (Crane), Locomotive Ws Eastern Railway, Jamalpur - 811 214.
18. Dy. CME/PR (Diesel), Locomotive Ws Parel Central naituay, Mumbai - 40OOO1.

Sub: Common Maintenance Schedule for 14OT diesel hydraulic breakdown

cranes (Gottwald & Cowans Sheldon design).
Ref: Railway Board's letter no.2011lM (M&P)t17it3inn dated 04.0g.2017.

With reference to above, as per directives of Railway Board, a common

Maintenance Schedule no. MP.MI-37 (Rev.-00) June'2018 for 14Ot diesel hydraulic
breakdown cranes (Gottwald & Cowans Sheldon design) has been finaliied by
incorporating the recommendations of SAG & JAG committe"s, suggestions & inputs from
Jamalpur Wshop, Parel Wshop & user Railways. A copy of -tie same is enclosed
herewith for your klnd information & necessary action please.

This Maintenance Schedule supersedes the earlier schedule nos. Mp-721lg1

(Jan.'1990), MP-731/91 (Mar.'1991) & MP.MI- 19 (Sep.'2001) retated to l4OtGottwatd
&
Cowans Sheldon cranes issued by RDSO.
n \-#
DA: As above
YtiF,'26r\t,
(VUay Kumar Goel)
Jt. Director I Motive Power
for Director General (MP)
Copy to:

DME lP-ll, Railway Board, Rail Bhawan, New Delhi - 110 001. (Fax no.: 011-2g38 9696)
Scanned by CamScanner
 R.D.S.O
(For official use only)

,
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

Maintenance Schedule of
140t Diesel Hydraulic Gottwald & Cowans Sheldon
Breakdown Cranes

No. MP. MI-37

(Revision 00)
June’2018
_________________________________________________________

RESEARCH DESIGNS & STANDARDS ORGANISATION LUCKNOW - 226011

 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________

CONTENTS

S. No. DESCRIPTION Page Nos.

1 General Description 3-16
2 Daily Schedule 17-19
3 Weekly Schedule or 20-22
at the completion of 25 working hours
4 Monthly Schedule or 23-24
at the completion of 100 working hours
5 Quarterly Schedule or 25-26
at the completion of 250 working hours
6 Half-yearly Schedule or 27-28
at the completion of 500 working hours
7 Yearly Schedule or 29-31
at the completion of 1000 working hours
8 2-Yearly Schedule or 32-33
at the completion of 2000 working hours
9 4-Yearly Schedule or 34-35
at the completion of 4000 working hours
10 8-Yearly Schedule (POH) or
at the completion of 8000 working hours of:
a) Main & Auxiliary Engine 36-38
b) Hydraulic System including all Cylinders, Valves, Pumps & 39-41
Motors, A-Frame & Drum/Barrel/Winch Assemblies, Wire
Ropes & Pulleys, Nylon Items etc.
c) Slewing Ring, Gear Boxes and Reduction Gear units 42-43
d) Electrical & Control System 44-45
e) Pneumatic, Brake system & Hand Brake 46-48
f) Basic Steel Construction, Superstructure, Cab, Jib & 49-53
Equipments, Undercarriage & Bogie, Assembly & Testing

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 1 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
SCHEDULE OF STANDARD EXAMINATION OF
140t DIESEL HYDRAULIC BREAKDOWN (Gottwald / Cowans Sheldon) CRANE

GENERAL DESCRIPTION:

1. INTRODUCTION:

Initially, 24 nos. imported 140t diesel hydraulic breakdown cranes of Gottwald design (12
nos.) & Cowans Sheldon design i.e. Jessop/NEI make (12 nos.) were introduced over IR
in 1986 & 1987 respectively. Accordingly, RDSO issued maintenance schedule for
Gottwald & Cowans Sheldon design cranes vide Report nos. MP-727/90 January’1990
and MP-731/91 March’1991 respectively.

Later, upgraded versions of both makes were also imported & introduced in year 1998 &
2000 respectively. Again, RDSO issued maintenance schedule for 8 nos. Gottwald
(upgraded) i.e. new design cranes vide Report no. MP.MI-19 (Rev.-00)
September’2001. However, no maintenance schedule for 4 nos. Cowans Sheldon new
design cranes was issued by RDSO.

Jamalpur workshop, E. Rly is responsible for maintaining & overhauling the Gottwald
design cranes beside manufacturing in-house whereas Parel workshop, C.Rly. is
responsible for maintaining & overhauling the Cowans Sheldon design cranes. Both
workshops have been maintaining the same as per schedules issued earlier. However,
over last 30 years there have been several changes in equipments/minor design
modifications etc. due to obsolescence of equipments as well as up-gradation of
equipments. As such, existing schedules for 140t diesel hydraulic breakdown cranes of
Gottwald design & Cowans Sheldon design needed revision.

Meanwhile, Railway Board advised RDSO to make a common maintenance schedule for
all variants of cranes like other rolling stocks duly incorporating all changes undertaken
by concerned workshops over last 30 years. Moreover, ‘SAG Committee on
maintenance of 140t cranes vide para 5.1 of their report’ recommended to introduce
a new “Weekly Schedule” in between daily & monthly schedules. SAG Committee also
recommended to include items like Wheel profile checking, UST of wheel axle etc. in the
schedule to be elaborated by JAG Committee. ‘JAG Committee vide para no. 2.3.2 of
their report’ on maintenance of 140t cranes dated 10.04.2017 recommended to include
wheel related maintenance activities in the “Yearly Schedule” beside other
recommendations.

Accordingly, a draft schedule for examination and maintenance of the various parts of
140t diesel hydraulic cranes viz. Gottwald & Cowans Sheldon cranes was evolved taking
into account the recommendations of Original Equipment Manufacturers, Eastern
Railway Loco Workshop, Jamalpur (responsible for indigenously manufacturing &
maintaining Gottwald design cranes), Central Railway Loco Workshop, Parel
(responsible for maintaining Cowans Sheldon design cranes) and suitably modified
keeping in view the experience of the user Railways in the field of crane operation as
well as maintenance and workshops involved in manufacturing & POH .

Also, RDSO introduced Weekly Schedule for the first time & incorporated other
recommendations of SAG & JAG Committees & circulated the same to all user Railways.
____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 2 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
Later, a meeting was held with consignees at STC, Secunderabad to obtain their
feedback based on maintenance experience. Thereafter, draft maintenance schedule
has been modified after incorporating inputs/suggestions/remarks of user Railways &
Workshops and a revised common maintenance schedule no. MP.MI-37 (Rev.-00)
June’2018 has been finalized and supersedes all previous schedules issued by RDSO.
The service periods of 140t cranes specified in this schedule for maintenance attention
are the maximum allowable periods between successive examinations. Variation in
operating conditions in different regions may make it necessary to carry out examination
more frequently, or introduce examinations not scheduled herein. In such cases, the
matter should be brought to the notice of the appropriate Sr. DME / Dy. CME (Crane)
/DME, who alone is authorized to introduce any change in the standard examination
detailed herein. Sr.DME/DME/AME in all such cases, will bring to the notice of the Motive
Power Directorate of RDSO, for any modification to the schedules, giving full details.
The proposed common maintenance schedule has been prepared by incorporating
suitably the inputs / comments / suggestion received from user Railways & POH shops
based on their maintenance experiences. Although, every care has been taken to make
this document free from errors, but if any discrepancy / shortcoming / irrelevant
information is observed, the user Railways are requested to inform RDSO at the
following email IDs:
i. Joint Director/Director /MP/RDSO mp.directorem@gmail.com
ii. Dy. Director/MP/RDSO mp.ddelectmachines@gmail.com

1.1 COMPARISON OF MAJOR FEATURES OF ALL VARAINTS OF CRANES:

S.N Item Gottwald Old Gottwald New Cowans Old Cowans New
1. Max. Speed 100 km/h 100 km/h 75 km/h 100 km/h
2. Main Engine NTA 855-R4 CIL’s NT 855P / NTA 743 P/ NTA 855 C
MTU’s OM 904-926LA
3. Aux. Engine KOEL HA-294 KOEL HA-294 KOEL TA2 ListerPeter LPA3
4. Jib Octagonal Rectangular Lattice structure Rectangular
5. A-frame / Mech. strut type Hydraulic Cwt. Hyd. tie cylinder Mech. strut
Gallow arrgt. A-frame Gallow arrgt. type A-frame type A-frame
6. Crane Bogie 3-axled Co-Co, 3-axled Co-Co, Disc 3-axled Co-Co, 3-axled Co-Co,
arrgt. & Disc & Coil & Coil Spring + Leaf Spring Parabolic Leaf
suspension Spring + Damper Damper Spring+Damper
7. Match truck type Well type wagon Well type wagon Well type wagon Well type wagon
8. Match Truck CASNUB CASNUB 2 axled Bo-Bo CASNUB
Bogie 22 HS 22 HS (ICF EMU) 22 HS
9. Ballast wagon NA NA 2 axled Bo-Bo NA
(ICF EMU)
10. Relieving Bogies NA NA 4-wheeler with NA
Leaf Spring
11. Outrigger nos. 4 4 6 4
12. Outrigger type Hyd. Swing out Hyd. Swing out Mech. Pull out Hyd. Swing out
13. Outrigger Pad nos 8 (4+4) 8 (4+4) 6 4
14. Outrigger Pad Small-Circular Small- Rectangular Square Circular
type Large-Rectangular Large- Rectangular

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 3 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
2. REFERENCES:
The following documents are also required to be referred for further information:

i) Cranes:
a) Operation, Maintenance & Service Manuals issued by M/s Gottwald.
b) Operation, Maintenance & Service Manuals issued by M/s Cowans Sheldon.

ii) Main Engines:

a) Operating and Maintenance Manual NT/ NTA 855 R4 & NT 855 P issued by M/s
Cummins Engine Company, USA- For Gottwald Old & New Cranes.
b) Operating and Maintenance Manual NT/ NTA 743 P issued by M/s Cummins
Engine Company, USA- For Cowans Old Cranes.
c) Operating and Maintenance Manual NT/ NTA 855 C issued by M/s Cummins
Engine Company, USA- For Cowans New Cranes.
d) Operating Maintenance Manual OM 904-926 LA Blue Tec issued by M/s MTU
Ltd.- For Gottwald Cranes (manufactured by JMP W/s).

iii) Auxiliary Engines:

a) Operating Maintenance Manual HA-294 issued by M/s Kirloskar Oil Engines
Limited- For Gottwald Old & New cranes.
b) Operating Maintenance Manual TA2 issued by M/s Kirloskar Oil Engines Limited
- For Cowans Old Cranes.
c) Operating Maintenance Manual LPA-3 issued by M/s Lister-Peter Engine
Limited- For Cowans New Cranes.
iv) Hydraulic System:
a) Repair instruction manual for hydraulic motors (RDE-91001-01/1996) issued by
M/s Rexroth.
b) Operating instruction for pump distribution gear box (GFC 230 1048/Feb.’1998)
issued by M/s Lohmann & Stolterfohnt.

v) Safe Load Indicator (SLI):

User Manual & Trouble Shooting Manual issued by approved sources i.e. M/s PAT,
M/s Mechanica, M/s Amrita Laxmi & M/s Hytech.

vi) Brake system:

a) Manual BSI Brake Calliper (No. V/ H 97/ 065-01/1997) issued by M/s SAB
WABCO.
b) Manual for wheel mounting brake disc R 780 G (No. V/ H 97/ 065-03/1998)
issued by M/s SAB WABCO.
c) Maintenance manual for brake cylinder adjuster unit type PBACF (53 72GB /
1992) issued by M/s SAB WABCO.

3. Periodicity of maintenance of 140t diesel hydraulic breakdown cranes viz.

Gottwald cranes and Cowans Sheldon cranes:
i) Daily Schedule
ii) Weekly Schedule or after 25 Hours*
iii) Monthly Schedule or after 100 Hours*
iv) Quarterly Schedule or after 250 Hours*
v) Half-yearly Schedule or after 500 Hours*
vi) Yearly Schedule or after 1000 Hours*

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Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 4 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
vii) 2- Yearly Schedule or after 2000 Hours*
viii) 4-Yearly Schedule or after 4000 Hours*
ix) 8-Yearly Schedule (POH) or after 8000 Hours*
Note: * indicates ‘whichever is earlier’

3.1 The following proposed periodicity of overhauling of 140t cranes are to be carried
out by concerned Workshop:-

Sl. No. Schedule Life (Years) Cumulative life (Years)

1. 1st POH 8 8
nd
2. 2 POH 8 16
3. SPL MLR + Structural Audit 6 22
4. 3rd POH + Structural Audit 8 30
Note: Railway Board’s letter no. 2016/M (M&P) /175/ 3/A/T/Codal life dated
14.02.17.

4. Main & Auxiliary Engine:

4.1 Periodicity of maintenance for Main Engine of M/s CIL (NTA 855-R4 & NTA 743 P):
i) Daily Schedule
ii) Weekly Schedule or after 25 Hours*
iii) Monthly Schedule or after 100 Hours*
iv) Quarterly Schedule or after 250 Hours*
v) Half Yearly Schedule or after 500 Hours* - (Only lube oil change)
vi) Yearly Schedule or after 1000 Hours*
vii) 2-Yearly Schedule or after 2000 Hours*- (Air Cleaner/Filter & Belts of fuel pump,
water pump, compressor, cooling fan & charging alternator change)
viii) 4-Yearly Schedule or after 4000 Hours*- (Calibrate injectors, PT pump & adjust
Valves)
ix) Major Overhaul after 8 Years at the time of POH or after 8000 Hours*

4.2 Periodicity of maintenance for Main Engine of M/s MTU (OM 904-926 LA):

i) Daily Schedule
ii) Half Yearly Schedule or after 500 Hours* - (Only lube oil change)
iii) Yearly Schedule (V2) for adjusting valve clearance every 1 st, 3rd, 5th & 7th Year
iv) Additional work (M or Z2) every 2nd, 4th, 6th, 8th Yearly schedule
v) Additional work (J3 or Z3) every 3rd, 6th, 9th Yearly schedule

Sl. No. Abbreviation Description of abbreviation used by MTU

1. Z Additional work (to be carried out Monthly)
2. V2 Yearly Schedule for adjusting the valve clearance every 1 st, 3rd,
5th & 7th Yearly Schedule
3. M or Z2 Additional work every 2nd, 4th,6th, 8th Yearly schedule
4. J3 or Z3 Additional work every 2nd, 4th,6th, 8th Yearly schedule

4.3 Periodicity of maintenance of Auxiliary Engine of M/s KOEL (TA2 & HA-294) & M/s
Lister-Peter (LPA-3):

i) Daily Schedule
ii) Weekly Schedule or after 25 Hours*
____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 5 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
iii) Monthly Schedule or after 100 Hours*
iv) Quarterly Schedule or after 250 Hours*
v) Half Yearly Schedule or after 500 Hours*
vi) Yearly Schedule or after 1000 Hours*
vii) 2- Yearly Schedule or after 2000 Hours*
viii) 4- Yearly Schedule or after 4000 Hours*
ix) Major Overhaul after 8 Years at the time of POH or after 8000 Hours*

4.4 High Speed Diesel:

High speed diesel oil shall be to IS 1460:1995 read with Amendment-2 (Feb.’1999).

4.5 The filters, lubricants, oil change etc. provided in the various systems of engine are
required to be changed as per the instructions of OEM. These are summarized below for
information.

4.6 Filters of Main Engine & Auxiliary Engine:

Description Periodicity
Lube Oil System
1 Full flow lube oil filter 500 hrs / Half yearly*
2 By-pass filter do
Fuel Oil System
1 Fuel filter 500 hrs / Half yearly*

4.7 Lube Oil change periodicity of Main Engine, Auxiliary Engine & all Moving
Equipments:

Description Periodicity
1 Lube Oil 500 Hrs / Half yearly *
2 Gear Box Oil 1000Hrs / Yearly*

Note: In case gear box unit is supplied by L&T, gear box oil shall not be changed during
schedule maintenance because it is filled with long life lubricant oil (optimal long
time PD 00 or IOC equivalent).

4.8 Recommended Lubricants for Main Engine models of M/s CIL make (NTA 855 &
743P) & M/s MTU make (OM 904-926 LA) & Auxiliary Engine models of M/s KOEL
make (TA2 & HA-294) & M/s Lister-Peter make (LPA3):

S. No Name of Manufacturer Brand name

1 Indian Oil Corporation SERVO-PREMIUM CF4 15W40
2 Bharat Petroleum Corporation MAK CF4 15W40
3 Hindustan Petroleum Corporation Hylube Milcy Power
4 Valvoline Cummins Ltd Valvoline Power Supreme 15W40
5 Fuchs Lubricants 15W40 Cat-2/283.3

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 6 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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5. Hydraulic Oil for Pumps & Motors:
5.1 Recommended brands of anti wear Hydraulic Oil HLP-68 to IS: 11656-1992 / 10522
are as under:

S. No. Recommended equivalent brands of anti wear Hydraulic Oil HLP- 68

1 IOC Servo System HLP ‘N’- 68 / Servo System 46
2 HPC Enklo HLP- 68
3 BPC Bharat Hydrol – HLP-68/ Bharat Transmission Fluid C3, SAE 30
4 IBP IBPEXHD-68 / Shell Cornea 46 Oil

5.2 Recommended brands of ATF (Automatic Transmission Fluid) suffix A:

S. No. Recommended equivalent brands of ATF suffix A

1 IOC Servo Transfluid A
2 HPC HP ATF
3 BPC ATF A

5.3 Generally, both the oil types, ATF Suffix A & HLP 68 can be used. However, the oils
should not be mixed. When converting to another oil type, the entire system must be
drained and flushed, otherwise, it will not operate smoothly. The above recommended
hydraulic oils shall be changed after one year / 1000hrs schedule.

However, the above recommended hydraulic oils shall be sent to laboratory for testing at
the completion of every 6 (six) months or 500 hrs, whichever is earlier to check the
following test parameters as per limits mentioned below:

S. No. Tests Limits

1 Kinematic Viscosity at 40ºC 62.2-74.8
2 Flash Point 210ºC
3 Total Acidity 1.5 (Max)
4 Pour Point 0ºC (Max)
5 Water Content Free from water in crackling test.
Note: In case, limits are found OK, no oil change is required.

5.4 Topping up / Replacement of Hydraulic oil:

a) During oil change and also during top-up, oil is recommended to be added through two
stage filtration cart as per following specification:

Stage – I :- 25 micron absolute

Stage – II :- 10 micron absolute
Pump flow rate :- 20 lpm

Note: Details of the hydraulic oil filtration trolley is provided separately in RDSO
Instruction Bulletin No. MP.IB. HYD.02.18.01 (Rev.- 0.00)

b) In the absence of filtration trolley, oil must be added through at least an external oil filter
with minimum retaining rate of 10µm so that cleanliness of oil is maintained.

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 7 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
6. Oils & Lubricants for other Crane Equipments:
6.1 For Gottwald Cranes (Old & New):-
S.No Fluid Cap. Recommended Oil & Grease
Approx MOBIL SHELL IOC BPC HPC
(in Ltrs)
1. Lube Oil for Pump 5.5 NA NA Servomesh Amocam HP 90
Distribution Gearbox SP 90 90
2. Lubrication Oil for 0.2 NA NA Servo MAK Hylube
Chassis Air Premium CF4 - Milcy
(Air Oiler only for CF4-15W40 15W40 Power
Old design)
3. Lube Oil for Gear units:
i) Slewing gear unit 15.5
ii) Main hoist gear unit 6.5
iii) Aux. hoist gear unit 6.5
NA NA Servomesh Amocam HP 90
iv) Derricking gear unit 9.5
v) Recovery winch 3.4 SP90 90
gear unit
vi) Travel gear unit 12.0
4. Lube Grease for Bearings of Gear units:
i) Main Hoist gear unit NA NA Servogem MP Lithon
ii) Aux. Hoist gear unit EP2 Grease 3 EP - 2
iii) Derricking gear unit
5. Lube Grease for As per NA NA Servogem NA Lithon
gear wheel / pinion require EP1 EP - 1
6. Lube Grease for ment. Servogem Bharat
slew ring NA NA EP2 Comex Lithon
7. Lube Grease for compound EP - 2
axle gear unit DEP
6.2 For Cowans Sheldon Cranes (New)
S.No Fluid Cap. Recommended Oil and Grease
Approx. MOBIL SHELL IOC BPC HPC
(in Ltrs)
1. Lube Oil for Pump 5 NA NA Servo Bharat HP Gear
Distribution Gearbox Super Spirol Oil XP-
85W140 85W140 80W90
2. Lubrication Oil for As per NA Hydro- Servo MAK - Turbinol-
Chassis Air requir- vanne 2000 Ultra-40 T- 40 77
Compressor ement Rimula
3. Lube Oil for Gear units:
i) Slewing gear unit 29
ii) Main Hoist gear unit 14
iii) Aux. Hoist gear unit 4
iv) Derricking gear unit 30 NA Omala SP 220 Bharat ENKLO -
v) Recovery winch gear 4 220 / Amocam - 220
unit Omala 220
vi) Travel gear unit 35 EP2
4. Lube Grease for Bearings of:
____________________________________________________________________________________________
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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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i) Main Hoist gear unit
ii) Aux. Hoist gear unit
iii) Derricking gear unit NA Alvania Servo Bharat Lithon
5. Lube grease for gear As per EPLF2 Gem Lanthex EP2
wheel / pinion require- EP-2 LFEP2
6. Lube grease for slew ment
ring
7. Lube grease for axle
gear unit
6.3 For Cowans Sheldon Cranes (Old)
S.No Fluid Cap. Recommended Oil and Grease
Approx MOBIL SHELL IOC BPC HPC
(in Ltrs)
1 Lube Oil for Pump 7.0 OIL, Servo BHARAT,
Distribution Gearbox System -100 Hydrol - 100
2 Lubrication Oil for 7.0 NA NA OIL, Servo BHARAT NA
Chassis of Air System - 68 Hydrol - 68
Compressor
3 Lube Oil for Gear units:
i) Slewing gear unit
ii) Main Hoist gear unit
iii) Aux. Hoist gear unit OIL, Servo BHARAT, NA
iv) Derricking gear unit 90.0 NA NA Transmission Transmission
v) Recovery winch gear C-3, SAE-30 Fluid
unit C-3,SAE-30
vi) Travel gear unit
4. Lube Grease for Bearings:
i) Main Hoist gear unit As per
ii) Aux. Hoist gear unit require NA NA Servogem-3 BHARAT – MP NA
iii) Derricking gear unit ment: Grease 3

5 Lube grease for gear -do- NA NA Servo Bharat NA

wheel / pinion Tak-40 Comex
6 Lube grease for slew Compound
ring ‘H’
7 Lube grease for axle
gear unit
8 Grease for Relieving -do- NA NA Molykote: GN Plus as NA
Bogie Primer & Molykote: BR 2 or
Longterm Grease as
Lubricant

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7. Hydraulic Oil Pressure:
7.1 Maximum Working Pressure for High Pressure Hydraulic Hoses:
S. No. Description of Hoses Maximum Working Pressure (bar)
Gottwald cranes Cowans Sheldon cranes
1. Main hoist (for Hoisting) 280 330
2. Main hoist (for Lowering) 280 108
3. Aux. hoist (for Hoisting) 280 290
4. Aux. hoist (for Lowering) 280 108
5. Derrick - in 280 330
6. Derrick - out 280 108
7. Slewing 250 220
8. Travelling 280 340
9. Hauling 280 200
10. Cooling (Radiator) Fan 280 100
11. Draw Beams (Cowans Old only) NA 170
12. Derrick-Tie Cylinder NA 25

7.2 Operating Pressure for Hydraulic Circuits of Gottwald & Cowans Sheldon cranes:

S. No. Hydraulic Operating Pressure (bar)

Circuit Type Gottwald Cranes Cowans Sheldon Cranes
Old New Old New
1. Power Ckt. I & II 280 280 As given in Para 7.1 above
2. Slewing Ckt. 200 200 220 220
3. Pilot Ckt. 32-40 32-40 30 55-70
8. WIRE ROPES:
8.1 Wire Rope Construction & Terminology used:
New wire rope when replaced shall be of standard construction as applicable to each
variant of crane meeting technical requirements to IS - 2266/2002. Breaking strength of
the wire rope shall not be less than 6 times the maximum static load on the rope.

8.2 Wire Rope Construction & it’s designation:

Wire rope standard construction designated as 6 x 37 18/12/6/1F(C) means:

“Wire Rope consists of 6 strands wounded helically over a Fiber Core. Each strand
contains 37 wires wounded helically in succession i.e. 6 wires on one steel wire (core),
then 12 wires and then again 18 wires respectively“.

8.3 Terminology used in Wire Ropes:

i) Wire (Round): A single circular rope of continuous length of metal drawn cold drawn
from a rod.
ii) Strand: An element of rope consisting of an assembly of appropriate shape and
dimensions helically wound wires in one or more layer.
iii) Core: The centre of a strand or the centre of a wire rope (which may be of Steel or
Fibre).

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8.4 Wire Rope Diameter Details:
S.No. Crane type Wire Rope Diameter (in mm) for
Main Hoist Derrick Aux. Hoist Winch
a. Gottwald Old 26 26 22 16
b. Gottwald New 26 26 22 18
c. Cowans Old 36 32 26 22
d. Cowans New 32 32 22 20

8.5 Wire Rope Inspection Criteria:

Wire ropes are consumable items with a limited life. Therefore, the complete length of
wire ropes and rope fittings must be inspected daily. In addition, the wire rope must be
examined by competent person at regular intervals. An examination should be
necessarily carried out, if the rope is to be put back into service after a long period.

8.6 Conditions for discarding wire rope:

Wire rope must be discarded immediately, if following conditions are observed:

8.6.1 Breakage in wire of strand:

a) For Main Hoist & Derrick Wire Rope:

If the rope shows more than 5 wire breakages on a length of 6 x rope diameter
(e.g. 6 x 26 mm = 156 mm) OR 10 wire breakages on a length of 30 x rope
diameter (e.g. 30x26 mm = 780 mm).

b) For Auxiliary Hoist Wire Rope:

If the rope shows more than 5 wire breakages on length of 6 x rope diameter (e.g.
6 x 22 mm = 132 mm) OR 13 wire breakages on a length of 30 x rope diameter
(e.g. 30x22mm = 660 mm).

8.7 Reduction in Rope diameter:

Reduction in rope diameter by 15% or more from the actual rope diameter in new
condition over a length of 10 x rope diameter (e.g. 260mm for main hoist & derrick
and 220 mm for auxiliary hoist rope). The part of rope passing over sheaves and drum is
more vulnerable & shall be checked for diameter.

8.7.1 Reduction in Rope diameter due to wear or friction:

Reduction in rope diameter by 10% or more due to wear or friction with any member.

8.8 Rope deformations:

If deformations like waviness, loop formations, loose wires, nodes, rope thinning,
misplaced outer wires, kinks and flat areas, are noticed on the rope.

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8.9 Special observation on wire rope:

The wire breakages generally occur after a certain number of operating hours and then
the number increases more quickly. It is recommended to keep watch on the condition of
wire after any of wire breakage has started. Action for the discarding should to be taken
as indicated above.

8.10 Functional Test:

After every rope change, functional test without load must be carried out. During the test,
it should be ensured that rope runs smoothly.

8.11 Cleaning & Greasing:

Periodically cleaning & greasing of ropes, if recommended by OEM shall be done for
proper and smooth running of ropes on drums & sheaves. Refer OEM’s manual.

8.12 Rope Change:

If rope change is necessary, then it must be ensured that a wire rope of the same type
and breaking strength as follow the Steel Wire Rope to IS: 2266/2002 construction IWRC
standard of the original wire rope in new condition is fitted. When a new wire rope is
being mounted, ensure that it is not twisted. Prior to operating with a newly fitted rope, it
must be ensured that the rope is properly placed and guided in the grooves of the rope
drum, rope pulleys and the compensation rollers. It is always advisable to change both
main hoist & derricking wire ropes together to ensure the same quality and to maintain
the same inspection & maintenance intervals.

9. General Instructions for Gears

Generally, gears with considerable back-lash will continue to function reasonably well but
with excessive noise. Abnormal back-lash on gears affects the life of other components
in gear box due to vibration. Care should be taken while checking the back-lash on
primary side gears because of cyclic variation of torque and speed of diesel engine. If
premature gear wear or damage is noticed, it may be generally due to bearing trouble,
mis-alignment, presence of foreign matter or insufficient lubrication. The first indication of
defective gear(s) would be an increase in the noise level, which indicates rough
operation. The following indications of undue wear and tear may be looked into, if gear
damage is suspected:

i) Fractures
a) Tooth face fracture generally occurs due to shock loads or foreign matter such as
broken pieces of metal forced through gear teeth in mesh.
b) Fatigue fracture generally occurs from the root of the tooth.
c) Tooth corner fracture or tooth splinter occurs, generally due to misalignment of
gear. Mis-alignment of gears also results in a great load on tooth corners.

ii) Tooth Face damage:

a) Pitting- The working surface of the teeth is severely damaged by pitting or
spilling over entire surface or at the base of the gear teeth.
b) Deformation- This is due to too little back-lash which leads to frictional
heating and softening of the case.
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c) Wear due to sliding- This is due to inadequate lubrication especially on gear
meshes of high gear ratio.
d) Development of grooves, roughing of the face or cavitation- This is due to
abrasive foreign matter coming between the meshing teeth.
e) Cracking of the Case-Hardened surface.
f) Running hot- This is indicated by the development of blue colourations due
to heat concentration which may be caused by inadequate lubrication. Pipelines
may be choked or spray jet dislocated. Lubrication is vital to gears and therefore,
nozzles must always be carefully checked during assembly and dismantling of the
gears so as to always ensure a stream of oil to the gears.

Note: It is generally advisable to replace gears subjected to the defects

mentioned above.

10. Tool Kit:

10.1 The following indicative list of tools, machines and accessories are applicable
only for Gottwald design cranes:
S. No. Tools
1. Hammer - 800 g
2. Flat chisel
3. Oil spray can
4. Hand lever operated grease gun
5. 17 Double ended open jawed spanners, 8x10-55x60
6. 6 Single ended open-jawed spanners, 8/41/65/70/75/80 mm
7. 8 Hexagonal socket head wrench, SE 6/8/12/14/22/27/32
8. 4 Tubular hexagonal box spanners, 13x7/19x22/24x30/30x36
9. 4 Tommy bars for spanners, A 10/12/16/18
10. Standard Ratchet, ½”
11. Extension Piece 10”
12. Articulated square-drive socket adapter, 70 mm
13. Socket for wrenches, SW 17/19
14. Min. 3 Screw drivers
15. Light tester
16. Hose, DN 6/222bX5000
17. Pressure gauge, 0-400 bar with connection fitting
18. Union nuts
19. Cutting ring
20. Seeger Circlip ring pliers, A3/A4
21. Flat-nosed and cutting nippers
22. Pipe wrench
23. Sickle spanner
24. Hose, NW18X3 5000

10.2 The following indicative list of tools, machines and accessories are applicable
only for Cowans Sheldon cranes:

S. No. Tools
1. A full set of A/F open ended spanner
2. A full set of A/F ring spanner
3. 75 mm capacity adjustable wrench
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4. Spring Link Bolt spanner
5. Blocking Screw spanner
6. Set of Allen keys 1.5mm A/F to 17 mm A/F
7. 1.75 Lb Hand hammer
8. 10" Insulated Screw Driver (Std. Tip)
9. 6" Insulated Screw Driver (Std. Tip)
10. 4" Insulated Screw Driver (Std. Tip)
11. Set of Tommy Bars 16" Dia.
12. Adjustable Spanners
13. Pipe wrench
14. Feeler Gauge
15. A set of Extension piece of 150, 225, 300 & 375 mm drive extension
16. A set of Impact Socket C/W Ring & Pin 24, 30,36,45,& 65 mm A/F
17. Peg spanner for dismantling Jacks & Cylinder, manufactured Items.
18. Junior Hand Compressor (Grease gun) with connector
19. 1/2 & 2 Litre oil feeder
20. 0-70 & 0-400 Bar Pressure Gauges with Hose
21. 35 mm O/D x 8500 mm Long Hydraulic oil filling hose
22. Aluminium extension ladder 3.5 m closed
23. Charging unit for accumulator with pressure gauge & hose
24. Flushing unit of 15 HP capable of developing at least 1950 psi at 43 LPM
25. Hose crimping m/c having cap. to handle1.25" ID hoses including multi-spiral
26. Hose skiving tools
27. Hose cutting machine
28. Pipe bending c/w 6 sets of formers

11. General Instructions:

The high reliability of availability of cranes necessitates properly laid down maintenance
schedules to be followed. A well-organized inspection is essential to ensure reliability
and freedom from failure in service. There are certain fundamental requirements that are
important to any successful maintenance program. These are:-
.1 A well-scheduled maintenance program including an adequate system of maintenance of
records. All work done including methods and tools used must be in accordance with the
manufacturer’s instructions, maintenance manual or any technical orders issued.
Whenever any schedule examination except the daily is carried out all the items of the
previous schedules should also be attended to.
.2 Adequate provision of well trained supervisors and skilled workmen shall be ensured.
The team of staff shall comprise of 1 Supervisor (SSE), 2 drivers, 4 skilled staffs and 8
un-skilled staffs.
.3 Adequate provision of proper maintenance facilities and tools shall be ensured alongwith
provision of lubricating oil, coolant etc. required to ensure satisfactory performance of
major equipments & their sub-assemblies.

.4 All measuring devices such as torque wrenches, electric meters, lubricant dispensers
etc. which require calibration should be checked quarterly or sooner, if required, for
accuracy.

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.5 Periodic maintenance of the crane should be done after it is placed on level track and
parking brakes of crane and match truck applied.

.6 In case any structural part is damaged and is to be rectified, ensure the following:

a) Direct flame should not damage cables, hoses & pipes. Must take all fire prevention
measures for hoses, cables etc. from direct heat by shielding the flame.
b) For any structural repair, ensure proper preheating. Use only recommended
electrodes and argon shield welding.
c) If welding is carried out on the crane, it is a wise precaution to disconnect SLI from
both sides of the crane. Disconnect main battery while welding. Earth the respective
structure directly.

.7 While carrying out the work of the schedule, all missing nuts, bolts, set-screws, cotters,
split pins etc. must be REPLACED as and when found defective. Split pins and cotters
once removed must not be used again, but new ones must be fitted. All loose nuts,
setscrews etc. must be tightened. Wherever cotters or split pins are fitted, they must be
of the correct size and so fitted that they bear against the nut or washer properly.
Examine and ensure that all locking devices, wherever provided, are properly secured.
Replace all gaskets, seals, rubber items, washers etc. during schedules.

.8 Do not mix different brands of greases. Excessive lubrication is as harmful as

inadequate lubrication.

.9 The fire extinguishers should be re-filled and maintained as per the schedule. Under no
circumstances, should crane be allowed to leave the shed without its required number of
fire extinguishers in working order. The staff while working under the crane or while
standing over footboards / superstructure must not smoke or strike up fire nearby.
.10 All tools and parts should be accounted for and removed from the crane after schedule
maintenance work has been performed. Check and ensure that no tools or replaced
parts lie over the crane.
.11 Use of waste cotton on crane is PROHIBITED. Use lintless rags or wiping towels. The
underframe and top surface of fuel tanks should be cleaned to remove dirt and oil.
Spraying of water directly on electrical equipment should be avoided.
.12 Irrespective of the above, the concerned Workshops are requested to kindly repair the
inside of Undercarriage of Match Truck & Ballast Wagon. If found damaged/corroded
etc., the same shall be fully repaired during POH.

Crane shall be handed over to consignee after carrying out full load testing of crane and
issuing satisfactory performance certificate of crane as “OK”.

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Daily Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane

Crane No. ______________ Shed __________________________ Rly__________________

Hours Meter Reading__________ Time From _______Time To________ Date:.__________

BEFORE STARTING THE ENGINES

1. MAIN ENGINE (Applicable only for M/s CIL NTA 855 & 743P):
1.1 Check engine oil level and top up, if necessary. ‘H’ mark must be maintained.
1.2 Check belt tension and condition of belts for cuts, fretting, cracking etc.
1.3 Check for loose foundation bolts. Tighten them, if required.
1.4 Fill/top-up radiator with distilled water / coolant additive which should be free from any
suspended impurities such as clay, sand etc. Radiator cap should be fitted back after
necessary fill up since this will cause aeration and overheating of the water coolant.
1.5 Fuel tank to be filled-up with clean diesel oil to ‘Fuel’ capacity.
1.6 Clean the engine.

Note: M/s MTU has not recommended any Daily Schedule. Refer MTU’s manual.

2. AUXILIARY ENGINE of M/s KOEL (TA2 & HA-294) & M/s Lister-Peter (LPA-3):
2.1 Check for engine sump oil. Top up, if necessary.
2.2 Fuel tank to be filled with clean diesel oil to “Full” capacity, if required.
2.3 Clean the engine.

3. SUPER STRUCTURE:
3.1 Check for the oil level in pump distribution box (P.T.O. unit) / splitter gear box. Top up, if
necessary.
3.2 Check hydraulic oil level. Top up, if necessary. For this check, raising of gallows may be
necessary.
3.3 Check for any leakage or damages of hoses and pipes. Rectify, if necessary.
3.4 Check the cablings connecting various parts of the electrical systems for physical
damages.
3.5 Check Fire-extinguishers and First-Aid-Box in position and keep them in working order.
3.6 Top up air oiler supply, if necessary.
3.7 Drain condensate from both air reservoirs.

Note: Even minor leakage of oil must be noted and eliminated.

4. UNDER CARRIAGE:
4.1 Check spring suspension for any breakage or deficiency.
4.2 Check for damage and deficiency in the brake system including pipes and hoses.
4.3 Check travel clutch indicator cable and lubricate, if required.
4.4 Floor plate to be cleaned. Ensure it is free from oil and greasy substances.
4.5 Drain out condensate from all the air reservoirs.

Note: Even minor leakage of oil / air must be noted and eliminated.

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5. MATCH TRUCK:

5.1 Check for breakage or deficiency in spring suspension system.

5.2 Check for damage and deficiency in the brake system including pipes and hoses.
5.3 Check leakage and functioning of hand brake.

AFTER STARTING THE ENGINES

6. MAIN ENGINE (Applicable only for M/s CIL NTA 855 & 743P):
6.1 Check leakages of fuel, oil, water and exhaust air supply and rectify, wherever required.
6.2 Check for any loose nut, bolt or fastener. Tighten them, if required.
6.3 Check gauge and indicators for engine speed, ammeter, lube oil temperature, lube oil
pressure, water temperature indicator and fuel indicator in driver’s cab. (For details refer
Engine Maintenance Manual.)
6.4 Check lube oil pressure (operating pressure 3.5kg/cm2 at idle & 5kg/cm2 at rated speed
respectively).
6.5 The main engine of crane shall be run at rated rpm for 30 minutes*.
6.6 Clean the engine after shut down.
Note: M/s MTU has not recommended any Daily Schedule. Refer MTU’s manual.

7. AUXILIARY ENGINE of M/s KOEL (TA2 & HA-294) & M/s Lister- Peter (LPA-3):

7.1 Check for any leakage of oil. Rectify, wherever required.

7.2 Check for lose foundation of bolts. Tighten them, if required.
7.3 The auxiliary engine of crane shall be run at rated rpm for 15 minutes*.
7.4 Clean the engine after shut down.
*Note: Running timings of Engines shall be strictly adhered to, being recommended by
JAG committee on maintenance of 140t cranes vide para no. 2.4.1. of report.

8. SUPER STRUCTURE:
8.1 Check air pressure (Operating pressure to be 6.0 bar to 6.8 bar & 3.8 bar for brake
cylinder); Rectify faults, if any.
8.2 Check pollution indicator of hydraulic oil filter. Replace the filter, if the indicator is at red
mark or above 3 bar. (Check filter choke indication available in cab for Cowans
Sheldon new crane).
8.3 Check hydraulic oil pressure of various circuits indicated above at Para 7.2 of General
Description.
8.4 Check functioning of fans, lights, screen wipers and horns in cab.
8.5 Check leakage of oil, water and air. Rectify, wherever required.
8.6 Check that all limit switches are in working order.
8.7 Check that solenoid valves are not bridged (manually)

9. UNDER CARRIAGE:

9.1 Check for any leakages. Rectify, wherever required.

9.2 Check functioning of brake-rigging arrangement.
9.3 Check functioning of service brake.

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A. IMPORTANT REPAIRS (Observed by SSE/ JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.
B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.
Certified that examination and repairs have been completed. If not, reasons as below:-
Maintenance by:- i) Technicians/ MCMs (Mechanical):
ii) Technicians/ MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

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Weekly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane
(At the completion of 25 working hours)

Crane No. _________________ Date ____________ Shed _________________Rly.________

Hours Meter Reading __________Last Schedule Done & Date__________________________

Time From ___________ To _______________Time taken _________ Hrs _________Minutes

Repeat previous schedule. Additionally, following activities may be carried out:

1. MAIN ENGINE (Applicable only for M/s CIL NTA 855 & 743P) and AUXILIARY
ENGINES (M/s KOEL TA2 & HA-294 and M/s Lister- Peter LPA-3):

1.1 Check electrolyte level, specific gravity & voltage of batteries. A lead acid battery is fully
charged with a specific gravity of 1.265 at 27°C and voltage should be 110V. To be
topped up, if necessary with distilled water. The terminal should be adequately coated
with petroleum jelly.
1.2 Check battery voltage. Repair, if required.
1.3 Check foundation tightness of auxiliary rotating machines.
1.4 Check coolant level in engine radiator. Use distilled water.
1.5 Clean dust pan and pre-cleaner on dry type air cleaners.
1.6 Clean crankcase breather.
1.7 Drain out water & sediments from water separator.

Note: M/s MTU has not recommended any Weekly Schedule. Refer MTU’s manual.

2. SUPER STRUCTURE:

2.1 Check hydraulic oil filter.

2.2 Check operation of hydraulic brake system.
2.3 Check operation of main, auxiliary & derrick limit switches.
2.4 Check operation of relays.
2.5 Check oil level in jib indicator.
2.6 Check pin socket fitment of amplifiers.
2.7 Check operation of SLI system - Joy-stick(s) & Duty selectors.
2.8 Check for any breakage in wire rope or damages. Rectify, if necessary.
2.9 Lubricate all sheaves and pedestal bearings of Main hoist & Auxiliary hoist, Jib foot pin
and rollers and counterweight bolt pivots, if required (as per OEM’s manual)

Note: Even minor leakage of oil must be noted and eliminated.

2.10 Lubricate all pins, top & bottom tie pins, hand brake etc. and slew ring bearings, if
required and applicable.
2.11 Lubricate main and auxiliary hoist load pin.

3. JIB & IT's EQUIPMENT:

3.1 Check free running for any damage in pulley, wire rope, bearing & pin for Main hoist and
Auxiliary hoist pulley. Lubricate, if required.
3.2 Check all sheaves and bottom block bearings & lubricate.
3.3 Lubricate jib head rest pin, if required.

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3.4 Lubricate jib stop pivot pins & head rest pin.
3.5 Lubricate auxiliary hoist block hook swivel & cross head.
3.6 Lubricate main hoist block hook swivel & cross head.
3.7 Carry out load testing by lifting counterweights & perform crane operations.

4. UNDERCARRIAGE:

4.1 Lubricate relieving bogie coupling pins (only for Cowans old crane).
4.2 Lubricate centre & end draw beam rollers (only for Cowans old crane).
4.3 Lubricate blocking screws.
4.4 Lubricate travel clutch shafting.
4.5 Lubricate bogie pivot oil boxes.
4.6 Lubricate bogie rubbing pads.
4.7 Lubricate brake linkage pivot pins.
4.8 Check spring suspension for any breakage or deficiency.
4.9 Check travel indicator cable and lubricate.

5. MATCH TRUCK:

5.1 Check spring suspension for any breakage or deficiency. Rectify, if required.
5.2 Lubricate bogie side bearer oil boxes.
5.3 Lubricate bolster swing link pins.
5.4 Lubricate brake work and brake rigging.
5.5 Lubricate axle box guides and dash pots.
5.6 Lubricate trestle pad and trestle pivot with grease.
5.7 Lubricate hand brake threads.
6. RELIEVING BOGIES (Only for Cowans Sheldon Old Crane):

6.1 Check for breakage or deficiency in spring suspension system. Rectify, if required.
6.2 Check for damage and deficiency in the brake system including pipes and hoses.
6.3 Clean floor plate. Ensure it is free from oil and greasy substance.
6.4 Check leakage and functioning of parking brake.
6.5 Lubricate spring hanger pins.
6.6 Lubricate break linkage pivot pins.
6.7 Lubricate locking pins.
6.8 Lubricate adjusting screw.
6.9 Lubricate centre castings.

7. BALLAST WAGON (Only for Cowans Sheldon Old Crane):

7.1 Check for breakage or deficiency in spring suspension system. Rectify, if required.
7.2 Check for damage and deficiency in the brake system including pipes and hoses.
7.3 Check leakage and functioning of parking brake.
7.4 Lubricate bogie side bearer oil boxes.
7.5 Lubricate bolster swing link pins.
7.6 Lubricate brake work and brake rigging.
7.7 Lubricate axle box side bearer oil boxes.
7.8 Lubricate hand brake threads.

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A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.
B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed, if not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

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Monthly Schedule for Maintenance of 140t Gottwald/Cowans Sheldon Crane
(At the completion of 100 working hours)

Crane No. _________________ Date ____________ Shed _________________Rly.________

Hours Meter Reading __________Last Schedule Done & Date__________________________
Time From ______________ To _______________Time taken ________Hrs _______Minutes

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE:
1.1 M/s CIL Model NTA 855 & 743P:
1.1.1 Clean the air intake filter.
1.1.2 Make sure that the vent hole in the fuel tank cap is clear.
1.2 M/s MTU Model OM 904-926 LA:
1.2.1 Check function of indicator lamps and warning system.
1.2.2 Check all equipments for leaks and condition. In the event of fluid loss, find the cause
and rectify it.
1.2.3 Check the air intake duct between the air filter, charge air cooler and the engine for leaks
and condition. In the event of leaks, find and rectify the cause.
1.2.4 Engine Cooling system: Check & adjust corrosion / anti-freeze protection.
1.2.5 Cooling & Heating system: Check radiator, cables and hoses for leaks and condition. In
the event of fluid loss or damage, find and rectify the cause. Check for coolant quality &
level, Top up, if required as per OEM manual.
1.2.6 Check exhaust system for leaks and condition. In the event of leaks or damage, find and
rectify the cause.
1.2.7 Check all reservoirs, units, covers, bellows & protective caps for leaks and condition. In
the event of fluid loss or damage, find and rectify the cause.
1.2.8 Check all lines, hoses and electrical cables for areas of abrasion and correct routing.
1.2.9 Charge the pressure reservoir.

2. AUXILIARY ENGINES of M/s KOEL (TA2 & HA-294) & M/s Lister-Peter (LPA-3):
2.1 Clean dust pan and pre-cleaner on dry type air cleaners.
2.2 Clean crank case breather.
3. SUPER STRUCTURE:
3.1 Check SLI, all electrical connections and functioning of all sensors.
3.2 Check that display of radius on the SLI console of the crane agrees with actual radius.
3.3 Check that all working parameters of load charts are in relation to SLI cut-off.
3.4 Check wire rope. Clean & lubricate as per Para 8 of General Description. If not
complying with conditions indicated in Para 8, wire rope must be discarded.
3.5 Lubricate heavy lift ballast extension bearing surface, equalising beam, relieving bogie
coupling pin, hand brake acme threads and check their working condition (applicable
only for Cowans Sheldon old design crane).
3.6 Lubricate counter weight bolt pivot & threads, if applicable.
3.7 Lubricate telescopic tie rod bearings, sheave bearings and front strut bottom bearings
(applicable only for Cowans Sheldon old design crane).
3.8 Lubricate slew lock-pin, bearing of cylinder for retractable arm.

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Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 22 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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4. JIB:
4.1 Lubricate main and auxiliary snatch block swivel and sheave bearings.
4.2 Lubricate derrick pulley blocks & sheaves bearings only for Cowans Sheldon old crane.
4.3 Lubricate ropes with grease as per Para 8.
4.4 Clean & lubricate jib foot sliding surface (fork & pin) & rollers for Cowans Sheldon crane.

5. UNDER CARRIAGE:
5.1 Check travel brake equipment, linkage, linings, etc. and pneumatic systems.
5.2 Check functioning of outriggers and hydraulic cylinders.
5.3 Lubricate travel gears with grease and clutches shifts with grease.
5.4 Lubricate brake linkage, outriggers pins with oil & side bearer, hand brake threads and
rail clip screws with grease for Cowans Sheldon crane).
5.5 Lubricate blocking screws & hanger bracket pins for Cowans Sheldon crane.
5.6 Lubricate bogie pivot oil boxes for Cowans Sheldon crane.

6. MATCH TRUCK AND BALLAST WAGON (Only for Cowans Sheldon Old crane):
6.1 Check for travel brake equipment, hoses, linkage, shoes etc.
6.2 Lubricate brake linkage pins with oil and side bearer with grease.
6.3 Lubricate hand brake threads & brake linkage pins with oil.
6.4 Lubricate trestle pad and trestle pivot with grease.

7. RELIEVING BOGIES (Only for Cowans Sheldon Old crane):

7.1 Check oil for enerpac and top up, if necessary.
7.2 Lubricate adjusting screws, centre castings, hanger bracket pins, locking pins and brake
linkage pivot pins.
7.3 Lubricate wishbone beam bushes (First coat with Molykote GN plus paste and then apply
Molykote long term 2 plus grease)

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE
1.
2.
B. SCHEDULE REPAIRS:
S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE
1.
2.

Certified that examination and repairs have been completed, if not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 23 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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Quarterly Schedule for Maintenance of 140t Gottwald/Cowans Sheldon Crane
(At the completion of 250 working hours)

Crane No. _________________ Date ____________ Shed ______________ Rly.__________

Hours Meter Reading ___________Last Schedule Done & Date_________________________

Time From _____________ To _______________Time taken ________Hrs ________Minutes

Repeat previous schedules. Additionally, following activities may be carried out:

1. SUPER STRUCTURE:

1.1 Check windscreen wiper. Rectify faults, if any.

1.2 Lubricate slew gear teeth and winch gear box.
1.3 Lubricate face of extension beams for heavy ballast (applicable only for Cowans old
design crane).
1.4 Lubricate limit switch chains.
1.5 Clean radiator cores thoroughly, if required.

2. JIB:

2.1 Check visually for defects / cracks of all structural components.

2.2 Lubricate drum, sheaves and jib stopper pad with grease.

3. UNDERCARRIAGE:

3.1 Check wear on brake lining.

3.2 Lubricate hand /parking brake shafting and pinions.
3.3 Lubricate in-riggers/out-riggers sliding surface.
3.4 Clean the gearbox in the area of the oil seals and check for leakages. If there is any sign
of leakage, fit new seals as applicable.

4. MATCH TRUCK & BALLAST WAGON (Only for Cowans Sheldon Old design crane):

4.1 Check wear on brake lining.

4.2 Lubricate hand brake shafting and pinions.
4.3 Lubricate rubbing pads, pivot and head rest pins of match truck trestle.

5. RELIEVING BOGIES (Only for Cowans Sheldon old design crane):

5.1 Lubricate hand brake shafting, pinions and pivot pins.

A. IMPORTANT REPAIRS (Observed by SSE/JE/Driver):-

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 24 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed, if not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 25 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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Half-yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane
(At the completion of 500 working hours)

Crane No. _________________ Date ____________ Shed ______________Rly. __________

Hours Meter Reading ___________Last Schedule Done & Date_________________________
Time From ____________ To _______________Time taken ________ Hrs _________Minutes

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINES of M/s CIL NTA 855 & 743P (to be done with the help of OEM):
1.1 Check all air cleaner connections for cracks, chafing etc. Tighten all air in-take
connections.
1.2 Remove, clean and inspect dry type air cleaner for hole and tears. Check gaskets / ‘O’
rings for damage. Paper type elements should be cleaned by compressed air, in the
direction flow opposite to the flow of air. Discard element even, if a pin-hole exists.
1.3 Change air cleaner element.
1.4 Change lubricating oil by-pass filter element and gasket.
1.5 Change fuel filter element and gasket.

2. AUXILIARY ENGINES of M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3 (to be
done with the help of OEM):
2.1 Check valve tapped clearance (applicable only for Cowans Sheldon crane)
2.2 Service air filter, if required.
2.3 Renew lubricating oil filter element, if required.
Note: Above job is to be done with help of authorized dealer of Main & Aux. Engine.
2.4 Drain sump. Flush out approved brand of flushing oil and re-fill with new oil.
2.5 Change/replace engine oil, if required.
Note: Oil change periodicity may be extended, if oil condition is found satisfactory during
lube oil analysis in a laboratory.
2.6 Clean the oil tank, fuel filter bowl and ceramic filter thoroughly / Re-new fuel filter
element, as applicable.
2.7 Knock out soot from the exhaust silencer.
2.8 Clean the cooling air duct and space between cooling fins on cylinders.
3. SUPERSTRUCTURE:
3.1 Check all drive assemblies.
3.2 Check oil level and send it to M&C lab for spectrographic analysis & extend the life, if
found OK as per OEM manual. Else top up, as necessary for following items of
respective cranes (Refer Para 6 of General Description):

a) Main & Auxiliary hoist reduction unit.

b) Derrick reduction unit & Recovery winch reduction unit.
c) Slewing gear reduction unit
d) Traction gear box
e) Pump Distribution Gear box / Splitter Gear box
f) Draw beam extension, Tie cylinders, Equalising beam, Relieving bogie coupling unit
for Cowans Sheldon old design crane.

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Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 26 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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3.3 Collect sample of hydraulic oil. Get it tested and replace, if clogging gauge pressure is
more than 3 kg/cm2. Change return line filter element / filter of hydraulic tank (It shall be
carried out with respective OEM).
3.4 Change fuel tank‘s filter element / filter.
3.5 Check fuel oil hoses for any damage and replace, if required.
3.6 Check the accumulator and recharge it.
3.7 Check ropes for damages / breakages.
3.8 Lubricate:
a) Counterweight gallows with grease only for Gottwald make crane.
b) Rope drum bearings with grease.
c) Foot pedal in cab with oil.
3.9 Clean & re-grease jib foot sliding surface (fork & pin)
4. UNDERCARRIAGE:
4.1 Clean and lubricate with grease:
a) Slewing gear teeth.
b) Travelling gear reduction unit.
c) Splined shaft
d) Screw coupling and buffers.
4.2 Lubricate slewing ring bearing with grease through grease nipples. Refer Para 6 of
General Description.
4.3 Lubricate bogie pivot with grease.
4.4 Lubricate bogie bolster pins with grease.
5. MATCH TRUCK & BALLAST WAGON (Only for Cowans Sheldon old design crane):
5.1 Clean and lubricate screw coupling and buffers with grease.
5.2 Lubricate bogie pivot with grease.
5.3 Lubricate bogie bolster pins with grease.
6. RELIEVING BOGIES (Only for Cowans Sheldon Old design crane):
6.1 Clean and lubricate screw coupling and buffers with grease:
6.2 Clean lubricate with grease wishbone beam bushes.
6.3 Collect sample of hydraulic oil from oil tank and relieving bogies, get it tested and
replace, if required.
A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-
S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE
1.
2.
B. SCHEDULE REPAIRS:
S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE
1.
2.
Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:
Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 27 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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Yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane
(At the completion of 1000 working hours)

Crane No. _________________ Date ____________ Shed ________________Rly. ________

Hours Meter Reading __________Last Schedule Done & Date_________________________
Time From ___________To _______________Time taken _________ Hrs _________Minutes

Yearly Schedule to be carried out with the help of concerned W/shop & respective OEM.

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE:

1.1 M/s CIL NTA 855 & 743P:

1.1.1 Change/replace engine oil, if required.
Note: Oil change periodicity may be extended, if oil condition is found satisfactory during
lube oil analysis in a laboratory.
1.1.2 Replace new lube oil full flow filter element and gasket.
1.2 M/s MTU Model OM 904-926 LA:
Repeat below mentioned schedule every alternate year i.e. 1 st, 3rd, 5th & 7th year.
1.2.1 Check and adjust the valve clearance of the engine.
1.2.2 Check function of indicator lamps and warning systems.
2. AUXILIARY ENGINES (M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3):

2.1 Change paper element of the fuel filter.

2.2 Change the lube oil filter.

3. SUPER STRUCTURE:

3.1 Check oil water & air hoses. Change them, if necessary.
3.2 Check for corrosion. Repair, if required and paint.
3.3 Check setting of limit switches for proper cut-off with the help of OEM & Workshop.
3.4 Calibrate SLI system, jib inclinometer, load cell & slew encoder.
3.5 Check windows and doors for corrosion, proper fitting and locks.
3.6 Inspect drive assembly.
3.7 Change gear box oil.
3.8 Clean water and air cooler fans with water jet.
3.9 Clean radiator externally.
3.10 Clean fuel oil tank and flush.
3.11 Drain sediment from hydraulic oil tank.

4. UNDER CARRIAGE:

4.1 Check oil level of the travel gear box.

4.2 Check all brake equipments.
4.3 Lubricate gear shifting arrangements.
4.4 Lubricate the travel clutch indicator cable & guides only for Cowans Sheldon old crane.
4.5 Inspect axle box roller bearings & refill with grease, if required (As per OEM’s manual)
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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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4.6 Check wheel diameter of crane wheels. It shall be as under:
S.No. Crane type Crane Wheel Diameter (New/Condemning in mm)
a. Gottwald Old 915 / 860
b. Gottwald New 920 / 840
c. Cowans Old 915 / 840
d. Cowans New 915 / 813
4.7 WHEEL PROFILE CHECKING: IRS Thick Profile to RDSO Drg. no. CSL-3040 has
been provided on the new crane wheels. Check for wheel wear as per RDSO Drg. no.
CSL-2127/M. If wear is found beyond limit, the crane shall be sent for wheel turning.
4.8 UST OF WHEELS & AXLES: Check for defects of crane wheels & axles, if any as per
norms. Rectify the same. Carry out Ultrasonic Testing on wheels & axles as
recommended by SAG committee in para 5.1 of their report.

5. MATCH TRUCK (EXCEPT COWANS SHELDON OLD DESIGN CRANE):

5.1 Check all brake equipments.
5.2 Inspect axle box roller bearings & refill with grease, if required (As per OEM’s manual)
5.3 Match Truck is fitted with CASNUB 22HS bogies. Check wheel diameter of Match Truck
wheels. It shall be as under:

S.No. Crane type M/Truck Wheel Diameter (New/Condemning limits in mm)

a. Gottwald Old 1000 / 906
b. Gottwald New 1000 / 906
c. Cowans New 1000 / 906
5.4 WHEEL PROFILE CHECKING: IRS Worn Wheel Profile to RDSO Drg. no. WD-88021
has been provided on the new Match Truck wheels. Check for wheel wear i.e. root wear &
tread wear as per RDSO Drg. no. WD-89060 /S-2. If wear is found beyond limit, the crane
shall be sent for wheel turning.
5.5 UST OF WHEELS & AXLES: Check for defects of crane wheels & axles, if any as per
norms. Rectify the same. Carry out Ultrasonic Testing on wheels & axles as
recommended by SAG committee in para 5.1 of their report.

6. MATCH TRUCK, BALLAST WAGON & RELIEVING BOGIES (ONLY FOR COWANS
SHELDON OLD CRANE):
6.1 Check wheel diameter of Match Truck, Ballast Wagon & Reliving Bogie wheels. It shall
be as under:

S.No. Crane type Wheel Diameter (New / Condemning limits in mm) for:
MATCH TRUCK BALLAST WAGON RELIEVING BOGIES
a. Cowans Old 915 / 825 915 / 825 915 / 840

6.2 WHEEL PROFILE CHECKING: IRS Thick profile to RDSO Drg. no. CSL-3040 has been
provided on the new Match Truck wheels. Check for wheel wear i.e. root wear & tread
wear as per RDSO Drg. no. CSL-2127/M. If wear is found beyond limit, the crane shall be
sent for wheel turning.

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Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 29 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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6.3 UST OF WHEELS & AXLES: Check for defects of crane wheels & axles, if any as
per norms. Rectify the same. Carry out Ultrasonic Testing on wheels & axles as
recommended by SAG committee in para 5.1 of their report.

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.
Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians/ MCMs (Mechanical):

ii) Technicians/ MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 30 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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2-Yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane
(At the completion of 2000 working hours)

Crane No. _________________ Date ____________ Shed ________________Rly._________

Hours Meter Reading __________Last Schedule Done & Date__________________________
Time From ____________ To _______________Time taken _________Hrs ________Minutes

2-Yearly Schedule to be carried out with the help of concerned W/shop & respective OEM

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE:

1.1 M/s CIL NTA 855 & 743P:

1.1.1 Check for turbocharger oil leakage. Tighten turbocharger mounting nuts.
1.1.2 Check engine blow-by, clean radiator, adjust injectors and valves.
1.1.3 Check wobble and eccentricity / alignment marks on rubber type damper. Discard
damper, if misalignment is more than 1/16”.
1.1.4 Check belt tension and adjust as required.
1.1.5 Remove and clean air compressor breather element.
1.1.6 Clean the oil tank, fuel filter bowl and ceramic filter thoroughly.

1.2. M/s MTU:

1.2.1 Check the poly V-belt for wear and damage & replace, if required.
1.2.2 Change engine lube oil & filter (Ad Blue). Next change in 4 th, 6th & 8th year respectively.
1.2.3 Renew coolant: When renewing the coolant, ensure that it contains 50% corrosion
inhibitor / antifreeze by volume. This corresponds to antifreeze protection down to -37ºC.
If there is loss of coolant, don’t top up by using only water, but also add an approved
corrosion inhibitor / anti-freeze agent. Next change in 4 th, 6th & 8th year respectively.
1.2.4 Clean the fuel filter element.
1.2.5 Replace fuel pre-filter with water separator (fixed to the chassis).

2. AUXILIARY ENGINES (M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3):

Change the paper element of air cleaner.

3. SUPERSTRUCTURE:

3.1 Check visually for tightness of slewing ring arrangement. Stud, nuts and loose bolts to be
tightened, if required.
3.2 Check rota white cap on bolts / studs for spinning (only for Cowans Sheldon old crane).

4. UNDER CARRIAGE:

4.1 Check brake equipment for functioning.

4.2 Check vibration damper and repair them, if required.

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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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5. MATCH TRUCK:

Check brake equipment for functioning.

6. RELIEVING BOGIES & BALLAST WAGON (only for Cowans Sheldon old crane):

Check brake equipment for functioning.

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.
B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 32 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
4-Yearly Schedule for Maintenance of 140t Gottwald / Cowans Sheldon Crane
(At the completion of 4000 working hours)

Crane No. _________________ Date ____________ Shed _____________ Rly. __________

Hours Meter Reading __________Last Schedule Done & Date_________________________
Time From ___________ To _______________Time taken _______ Hrs __________ Minutes

4-Yearly Schedule to be carried out with the help of concerned W/shop & respective OEM

Repeat previous schedules. Additionally, following activities may be carried out:

1. MAIN ENGINE:

1.1 M/s CIL NTA 855 & 743P:

1.1.1 Check turbocharger end clearance.
1.1.2 Check crankshaft end clearance.
1.1.3 Check cylinder head valve seat.
1.1.4 Check condition for cylinder liners.
1.1.5 Check conditions of piston rings, replace if necessary.
1.1.6 Check accessory drive end clearance.
1.1.7 Check fan hub drive.
1.1.8 Check vibrator damper.
1.1.9 Replace fuel pump filter screen and magnet
1.1.10 Calibrate the PT Pump by replacing the necessary parts like magnetic filter, gasket set.
1.1.11 Clean and calibrate all injectors.
1.1.12 Clean injector inlet screens.
1.1.13 Clean and tighten all electrical connections.

Note: Arrange for authorised dealer for engine manufacturer’s mechanic to check your
engine completely- Refer Engine maintenance manual for details.

1.2 M/s MTU: Refer 2-Yearly Schedule

2. AUXILIARY ENGINE (M/s KOEL TA2 & HA-294 & M/s Lister-Peter LPA-3):
Arrange for authorized dealer for engine manufacturer’s mechanic to check your engine
completely- Refer Engine maintenance manual for details.

3. SUPER STRUCTURE:
Overhaul all direction control valves, ‘O Ring’ & seals and replace, if required.

4. Relieving Bogies (only for Cowans Sheldon old design crane):

Inspect axle box roller bearings & refill with grease (As per OEM’s manual)

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Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 33 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

B. SCHEDULE REPAIRS:

S. No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed, if not, reasons as below:-

Maintenance by:- i) Technicians/ MCMs (Mechanical):

ii) Technicians/ MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 34 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane
(At the completion of 8000 working hours)
To be carried out by concerned Workshop

Concerned POH Workshop shall jointly examine the crane to be overhauled with it’s In-charge
for all damages / deficiencies / working problems / abnormalities and should verify with
Consignee reports on crane failures at the time of receipt of crane for POH.

Then workshop shall carry out dimensional check on crane structural components such as
undercarriage, superstructure, jib & match truck etc. for diagonal accuracy, tolerances,
skewness, surface alignment, distortion, straightness of structures etc. with the help of relevant
measuring instruments. Workshop should conduct weldment check using suitable techniques
such as DPT, Radiography / X-ray, Ultrasonic testing or Magnetic Flaw Detection.

Thereafter, workshop should make a pre-shopping report comprising of all structural repairs,
powerpack, hydraulic & pneumatic equipments, other assemblies/sub-assemblies, safety
system including devices, electrical & controls and SLI system.

(a) MAIN ENGINE & AUXILIARY ENGINE

Crane No. __________________Shed________________________Rly__________________

Hour Meter Reading_____________________________________ POH Date_____________

S.No Details of work to be carried out Condition/Action Sign. Remarks

1. Run main power pack before POH:
1.1 Check all motions of main circuit under
propped condition.
1.2 Check all safety devices.
1.3 Check all load chart parameters in regard
to recommended Limit Switch cut-off.
1.4 Check damages / deficiencies / working
problems of crane.
1.5 With Jib in raised condition, uncouple two
bottom cap screws each of both jib keeps
& check:-
a) Movement of jib foot pin rollers.
b) Clearance between blocking screws and
Springs / Bogie bolster.
2. Run auxiliary power pack before POH:
2.1 Check all motions of auxiliary circuit
under propped condition.
2.2 Check all safety devices.
2.3 Check relevant load chart parameters
w.r.t. recommended Limit Switch cut-off
as per SLI equipment.
3. Dis-connect all sensing devices of main
& auxiliary power pack (electrical) and all
suction and delivery hoses from pumps
mounted over splitter gear box / P.T.O.
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Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 35 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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unit alongwith suction & return lines for
fuel and also disconnect all radiator & oil
cooler connections, as applicable.
4. Remove main & auxiliary power pack and
lower for POH (Before removing, close all
stop cocks (except auxiliary pumps Q8 &
Q9 for Gottwald cranes).
5. Send the main & auxiliary power pack to
respective authorised dealer /
manufacturer for POH and load testing
on test bed.
5.1 Drain out entire lube oil, hydraulic oil, fuel
oil, coolant from Radiator & Oil from Oil
Cooler etc. and store in drums.
5.2 Clean & flush the tank / tanks before re-
filling with fresh oil & coolant.
6. On receipt of main & auxiliary engine
after POH, assemble main power pack &
auxiliary power pack in position.
7. Connect all pipes & hoses.
8. Connect all sensors & electrical
connections.
9. Fill fresh lube, hyd. & fuel oil, coolant etc.
10. Run main power pack after POH:
10.1 Check all motions of main circuit under
propped condition.
10.2 Check all safety devices.
10.3 Check all load chart parameters in regard
to recommended Limit Switch cut-off.
11 Run auxiliary power pack after POH:
11.1 Check all motions of auxiliary circuit
under propped condition.
11.2 Check all safety devices.
11.3 Check all load chart parameters in regard
to recommended Limit Switch cut-off.

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S. No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 36 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians/ MCMs (Mechanical):

ii) Technicians/ MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 37 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________

8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane
(At the completion of 8000 working hours)

To be carried out by concerned Workshop

(b) HYDRAULIC SYSTEM INCLUDING ALL CYLINDERS, VALVES,

PUMPS & MOTORS, A-FRAME, WINCH/DRUM/BARREL ASSEMBLIES,
WIRE ROPES, PULLEYS and NYLON ITEMS

Crane No __________________Shed________________________Rly__________________

Hour Meter Reading_____________________________________ POH Date_____________

S.No. Details of work to be carried out Condition / Action Sign. Remarks

1. Remove, Overhaul, Test & Refit.
Check operations.
1.1 Disconnect all worn out hoses and pipes
of all drum assemblies of superstructure.
Replace with new, if required.
1.2 Disconnect all worn out hoses and pipes
of undercarriage & Rotor/Rotary column.
Replace with new, if required.
1.3 Disconnect all hydraulic connections
after proper marking for draw beam
cylinders and remove all draw-beams
from carriage (only for Cowans
Sheldon old design crane).
1.4 Open ‘A’ frame/Gallow Hyd. cylinders-
(a) Cylinders & assly. - Gottwald old
(b) Gallow Cylinders& assly. - Gottwald new
(c) Tie Cylinders & Strut assly.- Cowans old
(d) Cylinders & Strut assly.- Cowans new
1.5 Screw down the blocking screws of the
crane until they are locked down on to
top of the springs. Unload & uncouple
the pins for both the relieving bogies
(applicable only for Cowans old crane).
1.6 Dismantle all motion’s/winch’s machinery
& inspect. Repair, as necessary
(a) Main Hoist Drum/Barrel assembly.
(b) Aux. Hoist Drum/Barrel assembly.
(c) Derrick Drum/Barrel assembly.
(d) Recovery Winch Drum/Barrel assembly
(e) Pedestal bearings
(f) Nylon blocks
(g) Main Hoist Jib Head Pulleys
(h) Auxiliary Hoist Jib Head Pulleys
(i) Jib Bridle Pulleys
(j) Derrick Pulleys & Equalising Pulley
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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
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(k) Equalising Beam & Pulleys
(l) Telescopic Tie Rod Pulleys.
(m) Main Hoist Wire Rope Guide Roller
(n) Derrick Wire Rope Guide Rollers
1.7 WIRE ROPES: Uncouple, remove
following wire ropes & test as mentioned
above at Para 8:
a) Derrick
b) Main Hoist
c) Auxiliary Hoist
d) Hauling Winch
e) Check Derrick Tie Ropes for equal
length, wherever applicable.
1.8 Remove Hydraulic Tank cover &
clean/flush the tank.
1.9 Remove hydraulic Equipments &
Hydraulic Hose Assemblies. Inspect
these assemblies and replace as
required.
1.10 Check all cylinders, valves of
superstructure & undercarriage.
Replace, if required.
1.11 Drain out entire hydraulic oil and store in
drum. Clean & flush the tank (before
refilling with fresh hydraulic oil).
After POH:
1.12 Keep all motion’s/winch’s machinery in
position systematically:
(a) Lubricate pedestal bearings & fit.
(b) Main Hoist drum/barrel assembly.
(c) Aux. Hoist drum/barrel assembly.
(d) Derrick drum/barrel assembly.
(e) Recovery Winch drum/barrel assembly
(f) Change nylon blocks, if worn out.
(g) Main Hoist Jib Head Pulleys
(h) Auxiliary Hoist Jib Head Pulleys
(i) Jib Bridle Pulleys
(j) Derrick Pulleys & Equalising Pulley
(k) Equalising Beam & Pulleys
(l) Telescopic Tie Rod Pulleys.
(m) Main Hoist Wire Rope Guide Roller
(n) Derrick Wire Rope Guide Rollers
1.13 Connect all hoses & pipes of all drum
assembly of superstructure.
1.14 Connect the hoses & pipes of Rotor/
Rotary column with undercarriage.
1.15 Assemble ‘A’ frame as applicable.
1.16 Fill up hydraulic oil (as recommended by
OEM’s manual) into the hydraulic tank.

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 39 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 40 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane
(At the completion of 8000 working hours)

To be carried out by concerned Workshop

(c) SLEWING RING, GEAR BOXES & REDUCTION GEAR UNITS

Crane No. __________________Shed________________________Rly__________________

Hour Meter Reading ____________________________________POH Date______________

S. Details of work to be carried out. Condition/ Sign. Remarks

No. Action
Remove, Overhaul, Test & Refit.
Check operations.

1.1 Lift superstructure and keep on trestle.

1.2 Check all Gear Boxes coupled with brake units.
Replace/Repair using repair kits as applicable for:-
(a) Main Hoist Gear Box complete
(b) Auxiliary Hoist Gear Box complete
(c) Derrick Hoist Gear Box complete
(d) Slew Gear Box complete
(e) Recovery/Hauling Winch Gear Box complete
(f) Splitter Gear Box/PTO Unit complete
1.3 Check Travelling gear box, pneumatic cylinder and
valves, as required.
1.4 Replace/renew gear boxes oil.
1.5 Slew Ring - Check Rota Bolts for Spinning.
1.6 Lubricate Slew Ring Bearings.
1.7 Lubricate Slew Gear.
1.8 Fitment of Slewing Ring:
i) Levelling of slewing ring to be ensured.
ii) Systematically replace all worn out loose rota bolts
& nuts of slewing ring of superstructure &
undercarriage.
iii) Grease the slewing ring, bolts & bearings (Refer
para-6).
iv) Tighten the bolts with
Tightening force :783.7± 6.6 kN - Gottwald crane
Tightening torque:3.19 kNm - Cowans crane
v) Follow the sequence strictly recommended by
manufacturer.
1.9 Lift superstructure & keep on undercarriage above
slewing ring. Follow manufacturer’s instructions
while assembling.

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 41 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.
Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 42 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane
(At the completion of 8000 working hours)

To be carried out by concerned Workshop

(d) Electrical & Control System

Crane No __________________Shed________________________Rly__________________

Hour Meter Reading ______________________________________POH Date____________

S. Details of work to be carried out: Condition/ Sign. Remarks

No. Remove, Clean, Check & Renew: Action
1 All Batteries & Connections: Recondition &
Repair Battery boxes. Refit Batteries & Connect.
2 All Rotating Machines: Remove, Overhaul, Renew
Carbon Brushes, Test & Refit.
3 All Junction Boxes:
Check connection for tightness for all the Junction
boxes
4 All Circuit Breakers:
Remove, Overhaul, Test & Refit. Check operations.
5 All Switches:
Remove, Overhaul, Test & Refit. Check operations.
6 All Relays:
Remove, Overhaul, Test & Refit. Check operations.
7 All Sensors & SLI Equipment:
Check connection for tightness.
Clean, Check operation & test.
8 All Meters & Gauges:
Remove, Overhaul, Calibrate & Refit.
Check operations.
9 All Lamps & Bulbs:
Check Operation. Renew bulbs, if required.
10 All Fault Indication Lamps:
Check, Test all Fault Indication Lamps
11 All Solenoids & Controllers:
Check connection for tightness.
Clean renew, if required, Check operation & test.
12 Solenoids on Pump:
Check operation. Test & Refit.
13 General Items:
Check operation. Test & Refit.

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 43 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians/ MCMs (Mechanical):

ii) Technicians/ MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 44 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane
(At the completion of 8000 working hours)

To be carried out by concerned Workshop

(e) PNEUMATIC, BRAKE SYSTEM & HAND BRAKE

Crane No __________________Shed________________________Rly__________________

Hour Meter Reading ______________________________________POH Date____________

Sl. Details of work to be carried out: Condition Sign Remarks

No. Remove, Clean, Check, Renew & Refit. / Action
The under mentioned system / components / parts
should be examined in accordance with the
procedure laid down in the OEM’s Crane
Maintenance Manual:-
A. BRAKE SYSTEM:-
Remove, overhaul, test and refit the following items:-
1. BRAKE VALVES:
a) Driver’s Brake Valve:
b) Relay Valve for Crane
c) Vacuum Air Proportional Valve for Crane, M/T & B/W.
d) Vacuum Release Valve for Crane, M/T & B/W.
e) Distributor Valve for Crane, M/T & B/W

2. OTHER VALVES (Safety Valves):

a) Un-loader Valve
b) MR Safety Valve
c) Auto Drain Valve

3. CHECK VALVES:
a) Strainer Check Valve & Choke Unit
b) Double Check Valve
c) Tubular Check Valve
d) Soft Seated Check Valve
e) Duplex Check Valve

4. BRAKE CYLINDERS

5. RESERVOIRS:
a) Auxiliary Reservoirs for Crane, M/T & B/W.
b) Main Reservoir for Crane
c) Brake Supply Reservoir for Crane
d) Vac. Chamber for VAP valve for Crane, M/T & B/W.

6. DRAIN COCKS:
a) Drain Cocks for Crane Aux. & Brake supply
reservoirs, M/T & B/W reservoirs
b) Drain Cock for Auto Drain Valve
7. CUT- OUT COCKS:
____________________________________________________________________________________________
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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
a) Isolating cocks for Crane Distributor V/v, M/T & B/W.
b) Self-locking Angle Cocks for Crane, M/T & B/W.
c) MR Isolating Cock
d) BSP Isolating Cock with vent
e) Isolating Cock with sealing for VAP valve.

8. GAUGES:
a). Duplex Pressure Gauge MR-BC
b). Vacuum Gauge VC

9. FLEXIBLE HOSE CONNECTIONS FOR:

a) Main Compressor
b) Auxiliary Compressor
c) Rotary/Rotor Column
d) M/T & B/W

10. HOSE COUPLING:

a) Hose coupling for Brake pipe for Crane, M/T & B/W.
b) Hose coupling for MR pipe for Crane, M/T & B/W.
c) Dummy & Rotary Coupling

11. Air & Vacuum Pipes & Fittings etc.

Overhaul Air & Vacuum Brake Equipments

12. Bends: High level, Low level & Return bend

13. Springs:
a) Return Spring
b) Release Spring for M/T & B/W.
B. HAND BRAKE UNITS: Remove, overhaul, test and
refit in the following assemblies:
1. Superstructure:
2. Undercarriage:
3. Relieving Bogies:
4. Match Truck
5. Ballast wagon (only for Cowans old)

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 46 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
B. SCHEDULE REPAIRS:

S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE

1.
2.

Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 47 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
8-Yearly Schedule (POH) for Maintenance of 140t Gottwald & Cowans Sheldon Crane
(At the completion of 8000 working hours)

To be carried out by concerned Workshop

(f) BASIC STEEL CONSTRUCTION, SUPERSTRUCTURE, CAB,

JIB & EQUIPMENTS, UNDERCARRIAGE & BOGIES, ASSEMBLY & TESTING

Crane No __________________Shed________________________Rly__________________

Hour Meter Reading ______________________________________POH Date____________

S. Details of work to be carried out: Condition Sign. Remarks

No. Remove, Overhaul, Test, Renew, if required & fit: / Action
The under mentioned system / components / parts /
assemblies / sub-assemblies should be examined in
accordance with the procedure laid down in the
OEM’s Crane Maintenance Manual:-
1. MATCH TRUCK FOR ALL CRANES:
Place Match Truck inside the shop in repair bay &
unload following crane accessories:
a) Counterweights
b) Lifting Beams
c) Wire Ropes Slings & Chain Slings.

1.1 MATCH TRUCK & IT’s COMPONENTS:-

a) Check Chassis.
b) Check Jib Trestle for profile wear at Jib Head Rest.
c) Lubricate Jib Trestle.
d) Check Hand Rails.
e) Check Draft Gears.
f) Check Buffers.
g) Check access ladders.
h) Overhaul Bogies.
i) Grease Axle Boxes.

1.2 CRANE ACCESSORIES:

a) Check Counterweights for proper welding &
holding/locking brackets, if provided. Repair, if
necessary.
b) Check Lifting Beams & repair, if required.
c) Check Wire Ropes Slings & Chain Slings as per
Para 8 of General Description of this MP.MI.
Replace, as required.
2. RELIEVING BOGIES (only Cowans Old cranes):
2.1 Place crane with relieving bogies inside the shop:
a) Screw down the blocking screws of the crane.
b) Unload & uncouple relieving bogie coupling pins.
c) Remove yoke beams & centre castings.
2.2 RELIEVING BOGIE & IT’s COMPONENTS:-
____________________________________________________________________________________________
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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________

a) Check & Overhaul centre castings.

b) Check Bogie Frames for alignment.
c) Check Relieving Bogie Coupling Beams.
d) Check Suspension Springs and Brackets.
e) Check Lever and Slipper & Lever Lock Pin.
f) Check Lateral Dampers.
g) Check Yoke beams & bushes.
h) Check Draft Gears.
i) Check Screw Couplings.
j) Check Side Buffers.
k) Check access ladders.
l) Check Foot Steps.
m) Remove Laminated Springs & send for Testing.
n) Inspect / Renew Spring Link Bolts, Brackets, Pins,
Rocker Washers, Disc Springs.
o) Check/Renew Axle Box Longitudinal & Lateral Liners
p) Check /Renew Axle Box Guides for wear.
q) Grease Axle Box Bearing.
r) Grease all lubricating points.
s) Assemble Relieving Bogies.
3. Ballast Wagon (only for Cowans Old cranes):
3.1 Place B/W inside the shop & unload heavy ballast.

3.2 BALLAST WAGON COMPONENTS

(only for Cowans Old cranes):
a) Check Chassis.
b) Check Ballast Locking Arrangement.
c) Check Hand Rails.
d) Check Draft Gears.
e) Check Buffers.
f) Check access ladders.
g) Overhaul Bogies.
h) Grease Axle Boxes.
4. SUPERSTRUCTURE:
a) Carry out dimensional check for diagonal accuracy.
b) Check tolerances, skewness, surface alignment,
distortion, straightness of structures etc.
c) Check structural damages of superstructure & repair,
as required.
4.1 DRIVER'S CAB:
a) Check Driver's Seat
b) Check Window Glasses & Side Shutter
c) Replace Weather Strips.
d) Check Cant Indicator / Level indicator.
e) Check Slew Locking Pin.
f) Check Cab Door Lock.
g) Check Control Desk & Control Panel.
h) Check Joystick & renew, if required.
4.2 JIB & EQUIPMENTS:
a) Open out jib keeps & remove jib

____________________________________________________________________________________________
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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
b) Check structural damage of jib
c) Check Radius Indicator provided on jib
d) Check Jib keep Lock Plate
e) Check Jib Bottom Rubbing Plate
f) Check Jib Foot Pin & Rollers
g) Check Jib Support Roller & Pins
h) Check & inspect Jib stopper for alignment with jib
i) Front Strut Bearings and Cap
j) Snatch Blocks: Overhaul
� Main Hoist Snatch Block- Pulleys, Bearings,
Crosshead & Swivel.
� Auxiliary Hoist Snatch Block- Pulleys, Bearings,
Crosshead & Swivel.
k) Telescopic Tie Rod:
� Pulley Bearings
� Grease Seal
5. UNDER CARRIAGE:
a) Run out bogies.
b) Carry out dimensional check for diagonal accuracy.
c) Check tolerances, skewness, surface alignment,
distortion, straightness of structures etc.
d) Check structural damages of undercarriage & repair,
as required.
e) Check Carriage End Castings.
f) Check cant indicator / sprit level indicator
g) Check counterweight lock plates.
h) Check access ladders.
i) Check Rail Clips.
Only for Cowans old design:
j) Extend draw beams
k) Check movement draw beam rollers
l) Check draw beam lock pins.
m) Check draw beams, it’s jacks & Extension Cylinder.
n) Check footsteps of draw beams
5.1 CARRIAGE BOGIES:
a) Open Carriage Bogie Pivot Pin Nuts, Remove
Carriage from superstructure and keep on Trestle.
b) Check bogie frames for alignment
c) Check/Replace Blocking Screws (Relieving Screws)
d) Check bogie rubbing pads
e) Check centre pivots
f) Check, clean & refill bogie pivot oil boxes.
g) Remove Laminated Springs
h) Check / Replace Spring Link Bolts, Pins, Rocker
i) Washers & brackets.
j) Check / Replace spring slide washers
k) Check & reclaim Equaliser Beams & Bar Brackets
l) Check Axle Box Guides for wear
m) Check Axle Box Liners.
n) Check Axle Box Greasing.
o) Check Travel Clutch Indicators

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 50 of 52
 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________
p) Check Travel Clutch Cod Piece
q) Check & Lube Travel Clutch Shaft
r) Check Travel Gears & Lubricate
s) Assemble bogies
t) Renew Brake Blocks
6. ASSEMBLY & TESTING:

6.1 Assemble crane following manufacturer’s

instructions:
a) Place Carriage Bogies on track:
b) Lift Undercarriage & place on Carriage Bogies with
Slew Ring.
c) Lift Superstructure body & place on Undercarriage.
d) Fit Centre Pivot Pin Nuts.
e) Fit draw/outrigger beams and make all connections.
f) Place Counterweight in position on Carriage.
g) Place Blue End & White End Relieving Bogie (only
for Cowans old design crane).
h) Fit Jib & Jib keeps.
i) Connect Hydraulic Hose Assemblies & Clamp.
j) Connect pneumatic hoses & connections.
k) Check Air Brake operations & adjust brake rigging.
l) Fit Machinery Enclosures after renewing gaskets &
checking locks as applicable for following:
� Hydraulic Tank.
� Main Engine.
� Auxiliary Engine.
� Slew Gear Box.
� Radiator and Oil Cooler
� Driver's Cab
m) Reeve Wire Ropes
� Derrick.
� Main Hoist.
� Auxiliary Hoist.
� Hauling Winch.
n) Refill with fresh oil & water to levels indicated in
OEM’s manual.
o) Start Main Engine:
� Carry out initial start-up checks.
� Carry out tests and final checks.
� Check all electrical operations.
� Check all hydraulic operations.
p) Set pressures, if applicable:
q) Set all Limit Switches.
r) Start Auxiliary Engine:
� Repeat above activities similar to Main Engine.
� Carry out testing and final checks.
s) Place Match Truck & couple with crane.
t) Load M/T with accessories
u) Place Jib on Match truck.
v) Conduct weighment of crane alongwith M/T on
Weigh Bridge.
____________________________________________________________________________________________
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 Maintenance Schedule of 140t Diesel Hydraulic Gottwald & Cowans Sheldon Breakdown Cranes
___________________________________________________________________________________________

6.2 TESTING (to be witnessed by Consignee):

a) Carry out final inspection of the crane, assemblies &
sub-assemblies
b) Carry out Load Test as per relevant Test
Schedules/Load Chart parameters.
c) Conduct load test at 25% over load also.
d) Paint Crane.
e) Renew Name Plates.
f) Dispatch crane

A. IMPORTANT REPAIRS (Observed by SSE/JE /Driver):-

S.No. NATURE OF DEFECT ACTION TAKEN ANY PART RENEWAL SIGNATURE
1.
2.
B. SCHEDULE REPAIRS:-
S.No. ITEM OBSERVATION ACTION TAKEN ANY PART RENEWAL SIGNATURE
1.
2.
Certified that examination and repairs have been completed. If not, reasons as below:-

Maintenance by:- i) Technicians / MCMs (Mechanical):

ii) Technicians / MCMs (Electrical):
iii) Crane Drivers:

Checked by:- JE:- SSE:-

____________________________________________________________________________________________
Motive Power Directorate (HYD), RDSO, Lucknow No. MP. MI-37 (Rev. 00) June’2018 Page 52 of 52
 Maintenance & Operation Manual Part II- ART & ARME
केवल कार्ाालर्ीन उपर्ोग हे तु
(For Official Use Only)

भारत सरकार GOVERNMENT OF INDIA

रे ल मंत्रालर् MINISTRY OF RAILWAYS

MAINTENANCE AND OPERATION MANUAL

FOR
140T CRANES, ARTs, ARMEs & SPARTs
VOLUME I (Part - II – ART & ARME)
IRCAMTECH/GWL/MECH/2022-23/ART/Manual/1.1
September, 2022

CH/GWL/MECH/2022-23/ART/Manual/1.1 Pag
Maintenance & Operation Manual Part II- ART & ARME
Table of Content

1 INTRODUCTION ...................................................................................................6
1.1. ART Classification and types ......................................................................6
1.2. ARME Classification & types .......................................................................6
2. OPERATIONS.......................................................................................................6
2.1. Organizational issues, such as yardsticks and selection criteria to provide
suitable personnel. ......................................................................................6
2.2. Staffing Yard Stick of ART & ARME (Including standby gang as RG/LR)
Staff required for A&B class ART for restoration by HRE ............................7
2.3. Staff required for ARME at the accident site. ..............................................8
2.4. Staff required for CRACK TEAM .................................................................9
2.5. Deployment and work distribution of break down staff at accident site for
HRE .............................................................................................................9
2.6. Composition of ART & ARME ...................................................................10
2.7. Staff deployment for Operation and Maintenance – ART ..........................12
2.8. Kitchen Management: ...............................................................................15
2.9. RELIEF AND RESCUE CRACK TEAMS: .................................................16
2.10. Turning out of ARTs/ARMVs: ....................................................................16
2.11. Relief and Rescue Operation by ARME staff: ...........................................17
2.12. Layout Drawings of ART coaches. ............................................................18
2.13. Details of Layout drawings for ART/ARME ...............................................19
2.14. Staff Management & Suggested ART/ARME Gangs: ...............................24
2.15. Disaster and Train Accident ......................................................................39
2.16. Characteristic of railway accident ..............................................................40
2.17. Consequence of disaster on a victim caused due to train accident ...........42
2.18. Rescue ......................................................................................................42
2.19. Rescue Organizing ....................................................................................45
2.20. RESCUE PLAN .........................................................................................46
2.21. SAFETY IN RESCUE OPERATIONS .......................................................47
2.22. SEARCH & EXTRICATION METHODOLOGIES ......................................48
2.23. ROPES CHAINS AND SLINGS ................................................................49
2.24. VARIOUS EQUIPMENTS USED IN RESCUE OPERATIONS ..................50
2.25. OPERATING INSTRUCTIONS FOR ELECTRICAL HAND.......................52
2.26. OPERATING INSTRUCTION FOR HYDRAULIC RESCUEDEVICE (HRD) .
..................................................................................................................60

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2.27. OPERATING INSTRUCTIONS FOR PNEUMATICRESCUE DEVICE .....70
2.28. OTHER EQUIPMENTS .............................................................................76
2.29. RELIEF AND RESCUE OPERATION ON PASSENGERTRAIN DURING
GOLDEN HOUR ......................................................................................81
2.30. TOOLS AND GENERATORS ...................................................................95
2.31. Mock Drills.................................................................................................95
2.32. Monitoring Organisation: ...........................................................................95
2.33. Divisional Monitoring Organization (DMO): ...............................................95
2.34. Jurisdiction and Beat: ................................................................................95
2.35. ART staff Training: ....................................................................................95
2.36. Road Mobile Accident Relief Vans: ...........................................................96
2.37. Data Bank: ................................................................................................96
2.38. PPEs: ........................................................................................................96
3. MAINTENANCE ..................................................................................................96
3.1. Maintenance Schedules for ART/ARME ...................................................96
3.2. TRIP SCHEDULE EXAMINATION PROFORMA ......................................98
3.3. SCHEDULE 'A' EXAMINATION PROFORMA [EVERY MONTH] .............99
3.4. SCHEDULE 'B' EXAMINATION PROFORMA [Three Monthly] ...............100

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Maintenance & Operation Manual Part II- ART & ARME
1 INTRODUCTION

Accidents and Disasters are unpredicted and unavoidable. Indian Railway has its
own mechanism to deal with rescue and restoration work during accidents and
disaster is ART & ARME.

Accidents: Any unusual event which affects the safety and transportation of Railway
in the form of damaging rolling stock, permanent structure and serious injuries /
causalities to the Railway passengers / Railway staff is known as Rail accidents. Any
accidents involving more than 100 injuries should be termed as disasters.

Disasters: Disasters in Railway context is defined as a major accident leading to

serious casualties and interruption of trains till long duration of time.

Disasters are caused by human mistakes and equipment failures. i.e. Collisions,
Derailments, Fire, Natural Calamities, Sabotages.
1.1. ART Classification and types
• Class A
• Class B
• Class C
1.2. ARME Classification & types
• Scale – I
• Scale - II

2. OPERATIONS
2.1. Organizational issues, such as yardsticks and selection criteria to
provide suitable personnel.
1. The staff for deployment in Accident Relief Trains should be carefully chosen.
They should be physically fit, must have stamina to do strenuous work for long
extended hours.
2. Average age of unskilled persons working in ART/ARME/140 T Crane should
not be more than 50 years. The upper age limit for artisans should be 52 and
of supervisors, it should be not more than 52 years. Older persons, who can’t
perform strenuous duties, should gradually be withdrawn from ART/ARME's.
3. ART staff inducted for Breakdown duties must be qualified. They must
possess a certificate in any course from ITI.
4. Staff deployment for Accident Relief Train should be as under:
• All nominated staff attached to break down should be deployed at accident
site.
• Only core staff will be permanently deployed for the maintenance of break
down crane and ART equipment.
• But the staff other than maintenance gangs when not required for break
down duties shall carry on their normal work at ROH, IOH, and Diesel Trip
Shed etc.
5. In “A” class ART total 44+14=58 staff nominated should be deployed at
accident site to facilitate simultaneous operation of crane and HRE. Total staff
in “A” class ART for crane operation should be 35 and staff in "A" class ART
for LUKAS/MFD operation should be 23.
6. Only core staff required for maintenance of break down crane and ART
equipment would remain with ART permanently attached to carry out:

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Maintenance & Operation Manual Part II- ART & ARME
• DAILY CHECKS
• SCHEDULES
• MAINTENANCE OF RE-RAILING EQUIPEMENT
• EXAMINATION OF WIRE ROPES
• GENERAL UPKEEP OF TOOLS AND EQUIPMENTS
7. Only 13 staff for the purpose of maintenance of breakdown and ART
equipment in “A” class ART has been identified. When not required for break
down duties, then other 31 staff out of Total 44 would carry on their normal
work at ROH, IOH, Diesel Trip Shed and Diesel Sheds etc.
8. Only 9 staff for the purpose of maintenance of ART equipment in "B" Class
ART has been identified. When not required for Break Down duties, then other
14 staff out of total 23 would carry on their normal work at ROH, IOH, Diesel
Trip Shed and Diesel Sheds etc.
9. Training should be imparted to ART staff at induction stage followed by
refresher course at an interval of five years. The training and the course
should cover following areas.
• Knowledge of HRD, HRE and other equipment both in operation and
maintenance.
• Safety practice to be observed at accident site
• General management at accident site such as fixing of luminous Barrier
tape to ward off inquisitive unauthorized persons, and matters of other
general discipline.
10. Training of staff deployed in ART & for Break Down Crane Operation:
Crane operators and crane assistants should be imparted training at induction
stage followed by refresher course at an interval of 3 years. The training and
the course should cover following areas:
• Knowledge of breakdown crane, its lifting capacity and preparation of
crane.
• Crane safety such as propping of crane on level and super elevated track.
Safety to be observed in slewing, derricking operation and traveling.
• Knowledge of breakdown crane, its lifting capacity and preparation of
crane.
• Crane safety such as propping of crane on level and super elevated track.
Safety to be observed in slewing, derricking operation and traveling.
• Knowledge about the defects on crane and daily checks to be carried out
• Knowledge of crane schedules
• Knowledge of wire rope slings and chains and their periodical examination.
• Knowledge of emergency operation of crane in the event of failure of Main
Engine at accident site.
2.2. Staffing Yard Stick of ART & ARME (Including standby gang as RG/LR)
Staff required for A&B class ART for restoration by HRE
SN Type of Staff Staff required to be deployed
A MFD/LUKAS Operation Gang
01 SSE/SE 01
02 JE-I/JE-II 01
03 Technicians 02
04 Fitters (Including Kitchen man) 08
05 Welder 02

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06 Khalasis 08
07 Welder Khalasi 01
TOTAL 23
B Electrical Gang
01 Elect. Supervisor 01
02 Electrical Fitters 03
03 Electrical Khalasis 03
TOTAL 07
C Telecom. Gang
01 Tele. Inspector 01
02 TCM Fitters 02
03 TCM Khalasi 01
TOTAL 04
D C&W Gang
01 Section Engineer 01
02 C&W Fitters 02
03 C&W Khalasi 02
TOTAL 05
E Engineering Gang
01 JE-II (P. Way) 01
02 Mukaddam/Gangman 03
TOTAL 04
Total Complement of Staff 42
Note: If ART is maintained by Diesel sheds then only 05 C&W staff as shown at Item
No. D should be nominated
2.3. Staff required for ARME at the accident site.
SN Type of Staff Work Distribution Staff required to
be deployed
A MECHANICAL STAFF
01 Supervisor For Supervision 01
02 Fitters (Including Kitchen man) For Rescue Operation 03
03 Welder For Cutting works 02
04 Khalasis For loading/Unloading 06
05 Welder Khalasi To assist Welder 01
TOTAL 13
B Electrical Gang
01 Elect. Supervisor For Elect Lighting 01
02 Electrical Fitters For Elect Lighting 02
03 Electrical Khalasis For Elect Lighting 02

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TOTAL 05
C Telecom. Gang
01 Tele. Inspector For Telecom 01
02 TCM Fitters For Telecom 01
03 TCM Khalasi For Telecom 01
TOTAL 03
D Medical
01 Doctor’s For Medical Aid 02
02 Dresser For Medical Aid 02
03 Nurses For Medical Aid 03
04 Pharmacist For Medical Aid 01
05 Safai Wala/H.A. For Medical Aid 04
TOTAL 12
D R.P.F Staff
01 Inspector For Relief & Rescue 01
02 Constable For Relief & Rescue 02
TOTAL 03

Total Complement of Staff 36

2.4. Staff required for CRACK TEAM

SN Type of Staff Work Distribution Staff required to
be deployed
A MECHANICAL STAFF
01 Mechanical Deptt. Relief/Rescue 04
B MEDICAL STAFF
02 Medical Deptt. Relief/Rescue 02
TOTAL STAFF 06
2.5. Deployment and work distribution of break down staff at accident site
for HRE
S.No Category Staff Scale Name of Duties
Staff
1 SSE 01 9300- Sh. 1.Overall incharge of BDT
34000 2.To Plan Line of Action
3.To maintain liaison with
other Department
2 1. Direct Incharge of
MFD/LUKAS for efficient
and safe operation.
2. For efficient and safe
working of MFD/LUKAS
equipment's and staff.
3. Responsible for
Maintenance of hydraulic
equipment's
3 1. For ensuring safety by
Megaphone and operation
of motor & pump.
2. Will maintain other
electrical equipment given

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time to time.
1. To unload & transport
LUKAS/MFD equipment's.
2. To apply hydraulic jacks
& lift, Traverse & Rerail the
vehicle.
3. To transport wooden
packing to and from material
van to site of operation.
4. To build wooden packing
bases under the jacks &
under the wagon body
during Rerailing operation.
1. Will remain in toolvan
/gen./MFD/LUKAS van
during whole relief
operations.
2. Will maintain handout
tools, equipment's,
petromexes and other items
and receive back the same
for correct accountal.
1. To unload & transport
LUKAS/MFD equipment's
and packings.
2. To apply hydraulic jacks
& lift, traverse & Rerail the
vehicle.
3. To transport wooden
packing to and from material
van to site of operation.
4. To build wooden packing
bases under the jacks &
under the wagon body
during Rerailing operation.
1.To unload & transport
LUKAS/MFD equipment's
and packings
2. Will maintain handout
tools, equipment's,
petromexes and other items
and receive back the same
for correct accountal. 09
Welder 01 5200-20200 Sh.

2.6. Composition of ART & ARME

Vide Railway Boards letter no. 99/M/(M&P)/7/6 dated 24.09.1999, the stress was laid
down in restricting the length of ARTs to avoid delays in movement to site and
problem in placement of crane/Tool vans etc. In “A” and “B” class ART, total number
of coaches was proposed as 6 numbers only. In “A” class ART, by including crane as
1st and 2nd vehicle, the total number of vehicles were proposed not be more than 8.
But in the present scenario, there was a need to review the old composition
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consequent upon introduction of HLC recommendations & present requirement of
space for storing tools and equipment. The revised composition will be as under -

2.6.1 In “A” class ART Total number of coaches will be 5+3 wagons with one
140 T Crane.
1st vehicle will 140 T capacity diesel/steam break down crane with Match
be Truck
2nd vehicle will RT/BCN HS (Crane packing Van and heavy tools, wire ropes &
be OHE material
3rd vehicle will Crane Staff and Kitchen Van.
be
4th vehicle will BRN HS (containing Rails and Crossings).
be
5th vehicle will BCN HS (complete Engineering Material and OHE items)
be
6th vehicle will Tool and Equipment Van (All critical mechanical tools, office,
be and Fire fighting section. Provision of guard seat with guard van
valve)
7th vehicle will C&W, Elect. and Telecom.Van (Material of Telecom, Elect. &
be C&W)
8th vehicle will Re-railing Equipment Van (MFD/LUKAS equipment and its
be material)
9th vehicle will Staff and Kitchen Van (MFD/LUKAS staff and Kitchen).
be

2.6.2 In “B” class ART total number of vehicles would be 6 since ART would
be without Break down crane and Match Truck. The composition would
be same as above.

2.6.3 More often than not only LUKAS/MFD is ordered without Break down
crane, Break down crane too ordered without Lucas/MFD. If only
LUKAS/MFD is ordered then the Break down formation would be as
under:
1st vehicle will BRN HS (containing Rails and Crossings).
be
2nd vehicle will BCN HS (complete Engineering Material and OHE items)
be
3rd vehicle will Tool and Equipment Van (All critical mechanical tools, office,
be and Fire fighting section. Provision of guard seat with guard van
valve)
4th vehicle will C&W, Elect. and Telecom. Van (Material of Telecom, Elect. &
be C&W)
5th vehicle will Re-railing Equipment Van (MFD/LUKAS equipment and its
be material)
6th vehicle will Staff and Kitchen Van (MFD/LUKAS staff and Kitchen).
be

2.6.4 If only Break down Crane is ordered then the formation of Break down
train would be as under:
1st vehicle will be 140 Te. Capacity diesel/steam break down crane
with Match Truck.
2nd vehicle will be RT/BCN HS (Crane packing Van and heavy tools,
wire ropes.
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3rd vehicle will be Crane Staff and Kitchen Van.
Note: Seating arrangement for staff will be available in both formations according to
the staff requirement.

2.6.5 Composition of ARME

1st vehicle will be Auxiliary Van (RHV) to RDSO Sketch No. CG-K 4044
(Vestibule)
2nd vehicle will Medical Relief Van (RH) to RDSO Sketch No. CG-K 4046
be (Vestibule)
2.7. Staff deployment for Operation and Maintenance – ART
a. Total nominated staff attached to break down will have to be deployed at
accident site.
b. Only core staff will be permanently deployed for the maintenance of break
down Crane and ART equipment.
c. The staff other than maintenance gangs when not required for break down
duties would carry on their normal work at ROH, IOH, Diesel Trip sheds and
Diesel Sheds etc.
1. In “A” class ART total 44+14=58 staff nominated should be deployed at
accident site to facilitate simultaneous operation of crane and HRE.
Total staff in “A” class ART for Crane operation should be 35 in “A”
class ART and for Lukas/MFD operation should be 23.
2. Deployment and distribution of staff on “A” class ART only for
Crane operation would be as under:

S.N Designation No. Duties at accident site

of
staff
1 Sr.Section Engineer 1 Over all incharge of Accident Relief
Train
2 Sr.Section Engineer/JE 1 Efficient, safe working, maintenance
and upkeep of ART
3 Crane operator 2 Efficient and safe working of crane
(MCM if available)
4 Highly skilled fitter Gr.I 5 Propping and securing of crane,
transportation of wooden packing and
material
5 Highly skilled fitter Gr.II 4 For slinging relieving bogies,
attaching 12, 32 t ballast & clearing
match and ballast wagons/coaches
6 Highly skilled welder 2 To carry out Oxy-Acetylene cutting
7 Diesel Mechanic cum 1 Assist crane operators in safe
Crane assistant Gr.I operation maintenance of crane
8 Technicians Gr.II 1 Assist crane operators in safe
(Electrical cum crane operation of crane and maintenance
assistant) of elect. equipment.
9. Helper khalasis 14 Assist HSF fitter in the tasks
mentioned above.
10 Welder Khalasi 1 Assist fitter in the tasks mentioned
above.
11 Kitchen work 3 Management and supervision of
Kitchen and cooking of meals.
Total staff 35

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3. Staff Deployment on “A” class ART for only LUKAS/MFD
operation:

S.N Designation No. Duties at accident site

of
staff
1 SSE/Section Engineer 1 Efficient, safe working, maintenance
and upkeep of ART
2 Jr. Engineer 1 Safe operation of HRE, HRD and DG
sets
3 Highly skilled fitter Gr.I 4 Safe operation of control table of HRE
4 Highly skilled fitter Gr.II 5 Safe operation of power pack unit and
for making hydraulic connection.
5 Helper khalasis 7 Assist HSF fitter in the tasks
mentioned above
6 Highly skilled welder 2 To carry out Oxy-Acetylene cutting
7 Welder Helper Khalasis 1 He will assist HS welder in the task
mentioned above
8 Kitchen work 2 Management and supervision of
Kitchen and cooking of meals.
Total staff 23

Only 13 staff for the purpose of maintenance of break down crane and ART
equipment in “A” class ART would be deployed. When not required for break
down duties then other 31 staff out of total 44 would carry on their normal
work at ROH, IOH, Diesel trip shed and Diesel Shed etc. (See item No.2 & 4)

4. Deployment of maintenance staff in “A” class ART would be as

under:

S Designation No. of Duties at accident site

N staff
1 Sr.Section Engineer (L) 1 Over all supervision and 140T crane
maintenance
2 Sr.Section Engineer 1 Re-railing equipment maintenance
3 Crane Operator 1 Daily checks and keeping the crane
ready at all time
4 Crane assistant cum 1 Daily check and schedules
D/Mech
5 Crane assistant cum 1 Daily check and schedules
Tech Elect.
6 Highly skilled Gr.I fitter 2 Maintenance of re-railing equipment and
for examination of wire ropes, chains,
slings, etc.
7 Highlt skilled Gr.II fitter 2 General upkeep of Tool and packing van
8 Helper khalasis 4 Assist above staff in upkeep and
maintenance.
Total staff 13

Only 9 staff for the purpose of maintenance of ART equipment in "B" class
ART would be deployed. When not required for break down duties then other
14 staff out of total 23 would carry on their normal work at ROH, IOH, Diesel
trip shed and Diesel Shed etc. (See item No.6)

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5. Deployment of staff for 140 T Crane/Special:

S.N Designation No. Duties at site

of
staff
1 Sr.Section Engineer 1 Over all incharge of Crane/Special
2 Junior Engineer 1 Efficient and safe working, by 140 Te.
Crane
3 Crane operator 2 Efficient and safe working, of 140 Te.
Crane
4 Diesel Mechanic cum 1 Assisting crane operators in safe
Crane assistant Gr.I operation of crane
5 Technicians Gr.II 1 Assisting crane operators in safe
(Electrician cum crane operation of crane
assistant)
6 Highly skilled fitter Gr.I 2 Propping and securing of crane,
transportation of wooden packing and
material
7 Highly skilled fitter Gr.II 3 For slinging relieving bogies, attaching
counter weight and clearing match and
ballast wagons/coaches.
8 Highly skilled welder 1 To carry out Oxy-Acetylene cutting
9 Helper khalasis 6 Assist HSF fitter in the tasks mentioned
above.
10 Kitchen Staff 2 Management and supervision of Kitchen
and cooking of meals.
Total staff 20

6. Deployment of staff in “B” Class ART/SPART for Lucas/ MFD

operation would be as under:

S.N Designation No. of Duties at accident site

staff
1 Sr.Section Engineer 1 Efficient, safe working, maintenance and
upkeep of ART
2 Jr. Engineer 1 Safe operation of HRE, HRD and DG
sets
3 Highly skilled fitter Gr.I 4 Safe operation of control table of HRE
4 Highly skilled fitter Gr.II 5 Safe operation of power pack unit and
for making hydraulic connection.
5 Helper khalasis 7 Assist HSF fitter in the tasks mentioned
above
6 Highly skilled welder 2 To carry out Oxy-Acetylene cutting
7 Welder Helper Khalasis 1 He will assist HS welder in the task
mentioned above
8 Kitchen work 2 Management and supervision of Kitchen
and cooking of meals.
Total staff 23

7. Deployment of maintenance staff in “B” class ART/SPART would

be as under:

S.N Designation No. of Duties at accident site

staff
1 Sr.Section Engineer 1 Over all supervision and ART/SPART
equipment maintenance
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2 Highly skilled Gr.I 2 Maintenance of re-railing equipment and
other ART/SPART equipment.
3 Highly skilled Gr.II 2 General up keep of tool van, packing
van, and for replenishing the material
consumed.
4 Helper khalasi 4 Assist above staff in up keep and
maintenance.
Total staff 9
2.8. Kitchen Management:
All ARTs on IR must make their own arrangements for catering and should not
depend on commercial department for provision of food. ART In-charges must
appoint 5 persons from amongst the staff as a purveyor of provisions. It would be
their business to provide meals etc. to staff supervisors and officers attached to
breakdown train. It is also recommended that break down staff should not be fed on
potatoes and besan alone. To balance the diet of carbohydrate they must be given
protein as well. Therefore, the diet must include vegetables etc.

2.8.1. Deployment of Staff in the Kitchen for “A” & “B” class ART and
SPART:
Dept Designation No. Duties at accident site
of
staff
Mech. Artisan/Khalasi 3 Over all supervision and management
of Kitchen, cooking of meals.
Elect. Electrician/Khalasi 1 Assistance in cooking and serving of
meals
Engg/S&T Khalasi/Gangman 1 Assistance in cooking and serving of
meals
TOTAL 5
2.8.2. Scale of Rations for ART:
(Ref: Appendix IV of committee’s report of 1985)
Scale of ration proposed for 40 breakdown staff attached to the ART, to be
purchased from local market and replaced after every trip.
1. Puri 80 Kg.

a. Atta 35.5 Kg.

b. Maida 17.5 Kg.
c. Veg. Ghee 12.00 Kg.
d. Ground nut oil 0.530 Kg.
e. Tata Salt 1.060 Kg.

2. Cooked Vegetables 40 Kg.

a. Potatoes 19.5 Kg
b. Beson (flour) 7.0 Kg
c. Onions 1.0 Kg
d. Ground nut oil 1.8 Kg.

3. Tea for 60 Cups

a. Tea dust 0.305 Kg.

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b. Sugar 3.2 Kg.
c. Milk 20 Kg

4. Cooked Rice 20 Kg.

a. Raw Rice : 08 Kg.

5. Cooked Dal (Fried) 20 Kg.

a. Tuar Dal(Arhar) 3.350 Kg.

b. Ground Nut oil 0.325 Kg.
c. Onion 1.100 Kg.
d. Coriander Seeds 0.075 Kg.
e. Chilly Powder 0.075 Kg.
f. Turmeric Powder 0.025 Kg.
g. Jeera 0.075 Kg.
h. Mustad 0.075 Kg.
i. Tata Salt 0.100 Kg.

6. Salt for Service : 1.0 Kg.

7. Condensed Milk : 10.0 Tins
8. Other common items : (As per standard Proforma)

Note: Potatoes’ and Onions may be replaced every two weeks if not used. Scale
fixed jointly by maintenance loco Inspector/In-charge of Break Down & the
commercial inspector of BSL Div.(Appendix-IV)

2.9. RELIEF AND RESCUE CRACK TEAMS:

A. Crack Teams at Each Zonal Railway HQ with containerization equipment to be
introduced:
i. Zone is proposed to have a professionally trained crack team of rail rescue
experts and containerized equipment based at head quarter Jabalpur, to be
rushed to any major accident site by air or land route.
ii. Each division is required to frame crack team consisting of representatives of
Medical, Mech., Elect. S&T and RPF departments.

B. Functioning of crack tram – As soon as alarm hooters are sounded, the

nominated team shall proceed to the site of accident by first available train or
by road. The crack team will carry prescribed tool kits consisting of -
i. S&T kit,
ii. Lighting kit,
iii. First Aid kit,
iv. Rescue kit etc.

On reaching at accident site, the crack team shall perform following activities: -
a. Extrication/removal of injured passengers from the coach.
b. First Aid to the injured.
c. Provide succour and help to the passengers at site.
d. Relieve panic and create re-assurance among passengers.

2.10. Turning out of ARTs/ARMVs:

Immediately after the accident alarm siren/hooter is sounded, all staff earmarked for
accident relief train shall report at the nominated place and others at the station. All
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officials concerned shall report at the Medical Van if ordered, and proceed with the
medical van or to undertake any other duty that may be assigned to them. The Crew
Lobby In-Charge/TPC/TLC on-duty shall immediately take action to:-
a. Arrange for locomotive. Any locomotive available should be utilized, preferably
Diesel Loco, in OHE Territory.
b. Call the loco crew and accident train relief staff.
c. Turn out the accident relief train quickly to the site of the accident.

i. Target time for turning out the Medical Van:-

In case of double exit siding - 15 Minutes (20 minutes given in S.Rly)
In case of single exit sidings - 20 Minutes (25 minutes given in S.Rly)
The time is reckoned from the time of ordering to the time of dispatch.

Note: Instructions given in Accident manual of zonal railway should be

followed for target time for turning out ARME/ARMV.

Target time for turning out the Break down trains:-

During Day– 30 Minutes
During Night– 45 minutes
The time is reckoned from the time of ordering to the time of leaving the shed.
ii. An accident relief train when proceeding to the site of accident will have
precedence over all other trains. A break down train/Tower wagon must not be
detained for Guard, and must leave with the In-charge of Breakdown train. A
Guard must be quickly arranged later.
iii. ARMVs would also be given priorities in the return journey also as they may
be required at other locations too.
2.11. Relief and Rescue Operation by ARME staff:
ARME In-charge shall counsel all the nominated teams in train running position,
regarding nature of accident and relief work to be carried out at accident site. He
shall distribute following main activities among 6 rescue teams as under –

A-Team:
1. The team will apply Hydraulic rescue device and Power cold cutter on
damaged/capsized coaches.
Team will develop suitable space on the coaches for entry of B-team for removing
injured/dead passengers.

B-Team:
1. On reaching ARME at accident site, the team shall ensure unloading of Power
cutter, Ladders, jacks and chain saw, Gas cutting equipment, etc.
2. The team will enter in to the damaged/capsized coaches and remove Injured/dead
with the help of stretchers.

C-Team:
1. On reaching ARME at accident site, the team shall ensure unloading of medical
items as per instructions of Doctor like Stretchers, Body bags & first aid boxes etc.
2. The team will remove dead bodies for keeping in body bags and shift injured as
well as dead in the tent at specified places.

D-Team:
1. The team will be responsible for unloading of Tents, Chairs, Tables, Umbrellas,
Garden umbrellas and install them at specified spots.
2. The team will provide other required items also to the A & B teams, as and when
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required.

E-Team:
1. During night, the team will unload, lighting equipment like, inflatable lighting tower,
Halogen lamps, DG sets, Hand lamps & distribution boards etc. and responsible for
providing lighting arrangement during relief and rescue.
2. During day time, the team will assist to B&C-Teams in first aid activities. The
Barrier tap will also be provided for covering of site of accident.

F-Team:
1. The team will arrange tea, coffee and drinking water to the injured and suffered
passengers at accident site.
2. Team will perform other duties also as per instructions of ARME Incharge.

Note: Before starting the rescue work, Photography/Videography of coaches should

be done by deputing trained/expert camera person for clue collection & finding cause
of accident. Permission should also be taken from officer present at site of accident &
same should be repeated to on duty controller immediately.

2.12. The following Layout Drawings of ART coaches have been prepared
after consulting Supervisors and Officers of CRWS, Bhopal and with
inputs from various ART incharges.
Sr.No. Description of Rolling stock Proposed Drawing No.
1 Tool and Equipment van TAEV-003 RT
2 C&W, Electrical and Telecom van CETV-004 RT
3 Re-railing Equipment van RREV-005 RT
4 Staff and Kitchen van SKV-006 RT
5 Crane Staff and Kitchen van CSKV-003 RT
6 Engineering and OHE Material van EOM-002 BCNHS
7 Crane Packing and OHE Material van CPOM-002 BCNHS or RT

2.12.1 Marshalling of “A”-Class ART:

1st vehicle 140 T capacity Diesel Hydraulic break down crane with
Match Truck
2nd vehicle BCN HS (Crane packing Van and heavy tools, wire ropes &
OHE material)
3rd vehicle Crane Staff and Kitchen Van.
4th vehicle BRN HS (containing Rails and Crossings).
5th vehicle BCN HS (complete Engineering Material and OHE items)
6th vehicle Tool and Equipment Van (All critical mechanical tools,
office, and Firefighting section. Provision of guard seat with
guard van valve)
7th vehicle C&W, Elect. and Telecom Van (Material of Telecom, Elect. &
C&W)
8th vehicle Re-railing Equipment Van (MFD/LUCAS equipment and its
material)
9th vehicle Staff and Kitchen Van (MFD/LUCAS staff and Kitchen)

2.12.2 Marshalling of “B”-Class ART:

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1st vehicle BRN HS (containing Rails and Crossings).
2nd vehicle BCN HS (complete Engineering Material and OHE items)
3rd vehicle Tool and Equipment Van (All critical mechanical tools,
office, and Fire
fighting section. Provision of guard seat with guard van valve)
4th vehicle C&W, Elect. and Telecom. Van (Material of Telecom, Elect. &
C&W)
5th vehicle Re-railing Equipment Van (MFD/LUCAS equipment and its
material)
6th vehicle Staff and Kitchen Van (MFD/LUCAS staff and Kitchen).

2.12.3 Benefits:

1. There will be saving of an average 1-2 Wagons/Coaches per ART (A and B

class both). The average earning of a wagon per day (as per year book 2011-
12) is Rs. 17534/- Per day. The total No. of ARTs on IR are 208 at
present. Therefore, the total expected saving on implementation of proposed
system by taking approx. 200 vehicles to be released for traffic use, would be
approx. Rs.17534X200 = Rs. 3506800/- per day and thus, annual saving =
Rs. 3506800 X365 = Rs. 1,27,99,82000/-
2. As per proposed new Marshalling Order, all the coaching stock will be
vestibuled with the introduction of new layout drawings for easy movement of
break down staff from one coach to another coach.
3. Safe and systematic stacking of all Tools and Equipment in each coach /
wagon will facilitate easy loading and unloading of ART equipment at accident
sites which in turn reduce time taken for rescue and restoration activities.
2.13. Details of Layout drawings for ART/ARME
Details of Layout drawings are given in the table for clear understanding of suitability
for ART composition.
Drawing No. and Drawing
Nomenclature {TAEV-003} RT
1. Space for fire extinguishers is shown
TOOL AND 2.Space for breathing apparatus, bench vice and water buckets
EQUIPMENT VAN is shown.
3. Provision of 4-tier almirah for keeping spares is shown.
4. Provision of Guard van valve is shown as this coach will be
the last vehicle.
5. Provision of 3-Tier almirah for keeping shoes, Jackets
Helmets F/A Box, Raincoat, Mask , Torch & cutting machines
etc.
6. Provision of 2 Nos. berths for ART Reserve staff for
issuing tools and equipment.
7. Provision of Inspection schedule board , Sectional diagram
for ART beat, Mobile charging facilities, AC -2 tier berths, Office
table, chairs, lockers, Staff
nomination board, competency certificate board & Office
almirah is shown.
8. Provision of 2-tier rake with top slanting and 4-tier almirah
for keeping
valuable tools, cameras, imprest and gas detector is shown
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9. Standard space for keeping pinch bars solson tools and
small chisels is shown
10. Space for Tea service counter for officers & Staff is shown

Drawing No. and New Drawing

Nomenclature { CETV-004 } RT
C&W, C&W Material
ELECTRICAL 1. Provision of 3-tier rake size 3150 x 700 mm is shown for
AND TELECOM setting of C&W material.
VAN 2. 4- Tier shelf size 900 x 760 mm & 3-Tier rake for keeping all
type of nuts &
bolts is shown.
3. Provision of chequred sheet for floor is shown for minimizing
floor damages
during handling.
Electrical Equipment.
1. Provision of 3-tier shelf for keeping DG Sets, Lamps,
Reflectors, Elect.
cables is shown.
2. Space for 11/6KVA stationery DG Sets and rectifiers is
shown.
3. Space for 200 Ltrs. barrels and other lubricants is shown.
4. Space for 12 Nos. telescopic stands is shown.
5. Provision of One berth with box below is shown for Elect.
Staff.
6. Provision of 4-Tier rake for keeping maintenance kit,
spares & valuable
items.
Telecom Equipment.
1. Provision of 4-ties almirah for keeping charger, mega phone,
walkie-talkie
& maintenance kit is shown both sides.
2. Provision of 2-tier rake for keeping VHF sets, telecom wires,
battery, PCP set & tent is shown.
3. Provision of 0ne berth with box below for telecom staff is
shown.
4. Provision of 2-tier rake for keeping S&T Store, spares DG
Sets etc. is
shown.
5. Provision of 1400 mm F/SL Door & one 782 mm standard
door for easy unloading of material is shown.

Drawing No. and New Drawing

Nomenclature { RREV-005 } RT
RE-RAILING 1. Provision of 4-tier almirah for keeping Seal kits,
EQUIPMENT Maintenance tools valuable spares of hydraulic jacks and power
VAN pack is shown
2. Provision of sufficient space for Petrol and Diesel power
packs is shown.
3. Provision of 1535 mm door is shown for easy unloading
and loading of
HRE.
4. Provision of Single Tier rake size 2300 x 275 x 740 for
keeping jacks, hand
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Maintenance & Operation Manual Part II- ART & ARME
pumps and re-railing bridges is shown.

5. Provision of 2-Tier rake and 5 pegs for hydraulic hose pipes

and LC jacks is shown.
6. Provision of sufficient space for keeping DA & Oxygen gas
cylinders and cutting torches.
7. Provision of 1535 mm door for easy unloading of packing
and gas cylinders.
8. Provision of 2-tier rakes both sides for keeping wooden
packing, lashing chains, Wire Ropes, and Ladders.
9. Provision of vestibule at both the ends of coach.

10. Provision of chequred steel sheet on floor for easy handing

of material.
11. Provision of space for keeping oil barrels an lubricants.
12. As per marshalling, this is not the rear most vehicle hence
guard seat is not required

Drawing No. New Drawing

and { SKV-006 } RT
Nomenclature
1. Provision of vestibule at both ends is shown
STAFF AND 2. Provision of bathroom in one toilet for taking bath for
KITCHEN VAN officers & supervisors
3. Provision of Guard van valve with hinged berth for guard and
box below.
4. Provision of 4 Nos. AC-2 berths for Officers.
5. Provision of 6 Nos. Normal cushioned berths for supervisors.
6. Dining room is deleted as not utilized practically by staff.
The space of dinning has been utilized for kitchen as well as
developing one Guard seat near door.
7. Provision of Space for fire extinguishers
8. Provision of 3-Tier shelf for keeping kitchen material and
utensils
9. Provision of 230 ltrs. cap. fridge
10. Provision of sink with drain board below and plate rake
above.
11. Provision of platform for LP Gas cooking range & gas
cylinder.
12. Provision of almirah for keeping store
13. Provision of suitable size exhaust fan above window.
14. Provision of partition door with rectangular cut at top for
Thali for BDT staff.
15. Provision of 3 - tier cushioned berths = 32 nos. and
lockers below.
16. Space for deep freezer and hot case is not required.
17. Provision of 230VAC/110VDC, 35 Amps Rectifier & water
cooler 80/40 Lts. capacity.

Drawing No. and New Drawing

Nomenclature { CSKV-003 } RT
CRANE STAFF 1. Provision of vestibule at both ends is shown

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Maintenance & Operation Manual Part II- ART & ARME
AND KITCHEN 2. Provision of bathroom in one toilet for taking bath for officers
VAN & supervisors
3. Provision of Guard van valve with hinged berth for guard and
box below.
4. Provision of 4 Nos. AC-2 berths for Officers.
5. Provision of 6 Nos. Normal cushioned berths for supervisors.

6. Dinning room is deleted as not utilized practically by staff.

The space of dinning has been utilized for kitchen as well as
developing one Guard seat near door.
7. Provision of Space for fire extinguishers

8. Provision of 3-Tier shelf for keeping kitchen material and

utensils
9. Provision of 230 ltrs. cap. fridge
10. Provision of sink with drain board below and plate rake
above.
11. Provision of platform for LP Gas cooking range & gas
cylinder.
12. Provision of almirah for keeping store
13. Provision of suitable size exhaust fan above window.
14. Provision of partition door with rectangular cut at top for Thali
for BDT staff.
15. Provision of 3 - tier cushioned berths= 32 nos. and lockers
below.
16. Space for deep freezer and hot case is not required.
17. Provision of 230VAC/110VDC, 35 Amps Rectifier & water
cooler 80/40 Lts. capacity.

Drawing No. and New Drawing

Nomenclature { EOM-002 } BCNHS
ENGINEERING 1. Provision of transition coupling and both side buffers
AND OHE 2. Space for engineering heavy material i.e. Sleepers, wooden
MATERIAL VAN sleepers size 2560 mm
3. Provision of modified doors for easy opening
4. Provision of 4-Tier rake size 6000X1800 mm for engineering
tools, machines and equipment
5. Provision of Box for OHE material Size 2300X1250 mm.
6. Space for CST-9 Sleepers size 2560mm

Drawing No. and New Drawing

Nomenclature { CPOM-002 } BCNHS OR RT
CRANE PACKING 1. Provision of transition coupling and both side buffers
AND OHE 2. Space for keeping 140Te./75Te. Crane packings size 2560
MATERIALVAN mm
3. Provision of modified doors for easy opening
4. Provision of 06 nos. tube lights for easy handling of crane
material.
5. Provision of Box for OHE material Size 2300X1250 mm.
6. Provision of two tier rake for small packings and wire ropes &
crane

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wire ropes
7. 4-Tier almirah for crane items and linen size 6.5'X3'X2'
8. Provision of two berths for staff.
9.Space for keeping DA& Oxygen gas
10.cylinders
11.Two tier rake for oil barrels and hydraulic hand pumps and
jacks
12.Two tier rake for keeping D-Shackles and fire extinguishers
13. Suitable space for keeping heavy crane packing for
140/75Te. (Cranes size 2560 mm)

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2.14. Staff Management & Suggested ART/ARME Gangs:
Taking in to consideration, the nature of the work and the job contents, it is recommended that following strength of the ART gang
as standard manpower for two classes of ARTs and ARMEs should be deployed.
"A" Type of Crane Gang Restoration Gang Electrical Gang Telecom. Gang C&W Gang
Class Crane (Measurement
ART )
Cowans Supervisor-1 Sup.(Mech.) -1 Sup. - 1 Insp.- Sup.(Mech.)-1
Sheldon 140 Crane Driver-2 Fitters-10 Fitters-3 TCM Fitters-2 Fitters-5
T. Crane Asstt. Crane Driver-2 Welders-2 Khalasis-3 Khalasi-1 Khalasis-7
Out rigger Khalasis-14 Khalasis-1 TOTAL-7 TOTAL-4 TOTAL-13
TOTAL-19 Welder Khalasi-1
TOTAL-15

Gotwald 140 Supervisor-1 Super. (Mech.)-1 Sup. - 1 Insp.-1 Sup.(Mech.)-1

T. Crane Crane Driver-2 Fitters-6 Fitters-3 TCM Fitters-2 Fitters-5
Asstt. Crane Driver-2 Welders-2 Khalasis-3 Khalasi-1 Khalasis-7
Out rigger Khalasis-10 Khalasis-2 TOTAL-7 TOTAL-4 TOTAL-13
TOTAL-15 Welder Khalasi-1
TOTAL-12

"B" Super. (Mech.)-1 Sup.-1 Insp.-1 Super.(Mech.)-

Class JE-II-1 Fitters-3 TCMFitters-2 1
ART Fitters-10 Khalasis-3 Khalasi-1 Fitters-2
Welders-2 TOTAL-7 TOTAL-4 Khalasis-1
Khalasis-8 TOTAL-4
Welder Khalasi-1
TOTAL-23

ARMV SCAL-E-I Medical staff Supervisor-1 Sup.-1 Insp.-1 RPF Staff

Staff Doctor-2 Welders-2 Fitter-2 Tech.-1 Insp.-1
Dresser-2 Fitters-3 Khalasi-2 Khalasi-1 Constable-2
Nurse-3 Khalasis-6 TOTAL -5 TOTAL - 3 TOTAL-3
Pharmasist-1 Welder kh-1
Safaiwala-4 TOTAL-13

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TOTAL-12
SPART 3-Coach Medical staff Supervisor-2 Sup.-1 Insp. - 1 RPF Staff
Staff Doctor - 2 Welders-2 Fitter - 2 Tech. - 1 Insp.-1
Dresser - 2 Fitters-8 Khalasi -2 Khalasi-1 Constable-2
Nurse - 3 Khalasis-10 TOTAL-5 TOTAL - 3 TOTAL-3
Pharmasist-1 Welder kh.-1
Safaiwala-4 TOTAL-23
TOTAL-12

Crack -- -- Mechanical-4 -- -- --
Team Medical-2
TOTAL-6

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