Maintain and Operate 140T Cranes, ARTs & ARMEs

GOVERNMENT OF INDIA
( )
Ministry of Railways (Railway Board)
MAINTENANCE AND OPERATION

MANUAL
FOR
140T CRANES, ARTs & ARMEs
IRCAMTECH/GWL/MECH/ART/1.0
December - 2015
Maharajpur, Gwalior – 474005 (INDIA)

Ph: 0751 -2470803 & Fax: 0751 -2470841
Go to Chapter contents
MAINTENANCE
AND
OPERATION MANUAL
FOR
140T CRANES
ARTs
&
ARMEs
DISCLAIMER
This “Maintenance and Operational Manual for 140T Cranes, ARTs

& ARMEs” is solely for the purpose of reference and to be taken as
a guide for Railway Staff dealing with Relief and Rescue operations
under Disaster Management.
The guidelines in the Manual will not supersede any standing

instructions issued by Railway Board/RDSO/Zonal Railways & the
same shall prevail. In case of any doubt, codal provisions and the
latest Railway Board/RDSO circulars/Letters/Zonal Accident
Manual/Zonal Disaster Management Plan on the concerned subject
should be referred to.
FORWORD
Indian Railway is a vast system comprising of nearly 64000 route kilometres

with over 7000 block stations and holding nearly 9000 locomotives, 43500
Passenger coaches, 7500 Electrical and Diesel Multiple Units and 220 thousand
wagons. Further the IR system has 13.62 Lakh strong work force, handles 20
Million Passengers and 2.45 Million Tonnes of freight and earns Rs.245 Crores
on daily basis.
Presently, there are 163 Accident Relief Medical Vans (ARMVs), and 208
Accident Relief Trains (A Class, B class & Self Propelled ARTs) stationed at
strategic locations over BG & MG network in the Indian Railway system so as
to cover an area not beyond a distance of 150 to 200 kms.
The first ever attempt in the direction of standardisation of ART equipments
was done in 1963 through a report submitted by a committee constituted by
Railway Board. Based on recommendations of this committee, the accident
relief trains were re-organised by all the Railways on their system.
The second such attempt was made by Railway Board for re-organising the
ARTs in 1982 by constituting a committee of three CMPE (R&L)s. The
committee submitted their report on “Re-organisation and Modernisation of the
Accident Relief Trains” in January-1985.
A major step was taken in this direction by Ministry of Railways in April-2003
when Railway Board constituted a High level committee to review Disaster
management system over Indian Railways which gave its 111 recommendations
for strengthening and streamlining the disaster management system. The report
gave the detailed recommendations for technological and managerial inputs in
order to quicken the pace of relief and rescue operations.
Indian Railways again constituted a committee of concerned JAG officers in
Delhi division for review of ART equipments in 2009 but the committee report
was not accepted due to some reservations shown by Railway Board. Further in
2011, a committee of three Railway Board’s Directors was constituted for
review of the HLC recommendation No 13, 69, 75 and 102 and to recommend
latest equipments for ART and ARME. The committee submitted his report on
14/10/2011 which was accepted and circulated to all Zonal Railways in
February 2012.
In the backdrop of all these developments in this field, this project team took up
the task of further streamlining the Standard Lists of Tools and Equipments in
ARTs, ARMEs & SPARTs in view of modern day requirements. CAMTECH
has also prepared seven nos. standard layout drawings of all rolling stock in
these trains. This will standardize the composition of ART (A-class) to 09 nos
including 140 T. Break Down Crane in comparison to present availability of 9
to 12 nos of vehicles in most of the ARTs in Zonal Railways. A manpower
benchmarking has also been recommended for standardization across the IR.
(Hemant Kumar)
Member/Mechanical
Railway Board
PREFACE
1. Every Zonal Railway is following different Standard Lists of items for
ARTs & ARMEs at present. These lists are basically derived from the report of
1985 on “Re-organisation and Modernisation of the Accident Relief Trains”
and supplemented by 2003 report given by High level committee on disaster
management. They are further supplemented by Railway Board letters
pertaining to standardisation/inclusion of certain items. It has been observed
that all Zonal Railways have followed these reports and instructions to the
extent possible. It has also been noticed that there is need to delete items
pertaining to steam cranes and vacuum brake rolling stock etc. There was a
need to review the quantity of various items based on the experience of various
ART/ARME incharges at accident sites.
2. There has been no effort in the field of standardisation of layouts of
various coaches/wagons in ART composition. However the layout of two
coaches present in ARME composition were standardised by RDSO. This has
resulted in each ART following a different layout style for safe stacking of
materials. As a result, it has also led to variance in number of rolling stocks in
ARTs of each Zonal Railway.
3. Manpower benchmarking for ART has also been an untouched area in
Indian Railways after 1985. CAMTECH has reviewed benchmarking norms on
the basis of factual requirement in the field considering Central Railway bench
marking issued in 2004 and recommends new manpower benchmarking norms
based on discussions with various ART incharges.
We, express our sincere gratitude to Shri Pramod Kumar, Director
General/NAIR and Shri Rakesh Vatash AM(ME) for providing us an
opportunity to take up this important assignment in the CAMTECH.
We are also grateful to Sh. Vivek Khare, EDME (Traction), Railway Board,
CWM/Jamalpur, CWM/Parel, Sh.Manish Jain DME(P)-II,Railway Board, for
encouraging us and providing their valuable guidance to finalase this project
and to prepare maintenance and operation manual for ARTs, ARMEs & 140 T
Cranes.
In the end, we are thankful to staff of all divisional ARTs, ARMEs,
CRWS/Bhopal, West Central Railway, Central Railway, South west Railway,
South Central Railway, Western Railway for rendering their requisite help to us
in collection of data.
(K.P.Yadav)
Director/Mechanical
CONTENTS
CHAPTER NO. 1 Rules for the working of Cranes
CHAPTER NO. 2 Operation of 140 T. Break Down Crane &

Important Instructions
CHAPTER NO. 3 Deployment of Break Down Staff and

Composition of ARTs
CHAPTER NO. 4 Important Rules for ARTs/ARMEs & SPARTS
CHAPTER NO. 5 Important Letters from Railway Board & RDSO
CHAPTER NO. 6 Record Keeping and Certification
CHAPTER NO. 7 Technical Description of GOTTWALD 140T.

Break Down Crane
CHAPTER NO. 8 DO’s and DON’Ts for COWANS SHELDON 140 T.

New Design Crane.
DO’s and DON’Ts for GOTTWALD 140 T. New
Design Crane.
CHAPTER NO. 9 Operation of Hydraulic Re-railing Equipments

(HREs)MFD & LUKAS
CHAPTER NO. 10 Standard Lists for ART, ARME, SPARMV & SPART
CHAPTER NO. 11 Dealing with LPG & Ammonia Gas
CHAPTER NO. 12 Drawings and Layouts for Composition of

ART/SPART/ARME on IR.
CHAPTER NO. 13 Relief and Rescue Operation on Passenger Train
CHAPTER NO. 14 Infrastructural Facilities for Maintenance of 140
CHAPTER NO. 15 High Speed SPART
Appendix – I Chains & Chain Slings
CONTENTS
Paragraph CHAPTER NO. 1 Page
Rules for the working of Cranes

Introduction
I. Ordering of 140T cranes & preparation of Disaster Management Plan 02
I. Application of Rules 03
II. Classification of Cranes 03
III. Traveling Cranes, Hire and Haulage Charges 04
IV. Expenditure in connection with cranes 04
V Responsibility for maintenance of cranes 04
Operation
I. Qualification and Examination of Crane men 05
II. Responsibility for correct carrying out of Rules 06

III. Special Training for Crane men 07
IV. Code of Signals 07
V. Precautions when lifting with cranes 07
VI. Lifting Tackle to be of suitable capacity 08
VII. Lifting Tackle to be tested 09
Maintenance and Repair of Cranes
I. Overhauls 10
II. Heavy Repairs 10
III. Running Repairs and maintenance of Cranes 10
IV. Periodical Examination of Cranes 11
APPENDIX 'A'
General and Subsidiary Rules regarding Working of Cranes
GR.4.27 a. Traveling Cranes - Attaching to trains 13
b. Working and care of cranes 13
1. Crane men 13
c. 1. Lifting Capacity 13
2. Weight of Balance Box 13
3. Repairs, Examination and POH 13
6. Attachment of Cranes 14
(b) Crane traveling outside station limit 14
(c) Responsibility of Crane man and Guard 14
(d) Jib to be trailing 15
(e) Train Examiner to certify Crane fit to run 15
(f) Trains to which cranes may be attached 15
(g) Dummy trucks additional to match trucks 15
7. 140T Diesel Hydraulic Cranes 15

Maximum permissible speed (140 T crane) 16
Operation (a) Cranes not to be operated at night 17
(b) Cranes not to be loose shunted 17
(c) Order of Cranes before lifting 17
(d) Two cranes used for lifting one load 17
(e) Precautions when crane may foul another line 17
(f) Cranes on bridges 18
(g) 140 Te. Crane on Bridges 18
(h) Charges for loan of crane 18
(i) Posting of rules 18
Cranes belonging to Engineering and Mechanical Departments 18
Cranes - Use of on Electrified area 18
APPENDIX 'B'
Code of Signals for controlling movement of Cranes 19 to 22
APPENDIX 'C'
I. Safe working loads for chains 23
II. Endless sling chains 24
III. Double sling chains 24
IV. Safe working loads for wire ropes 25
APPENDIX 'D'
I. Testing of Chains 26
II. Testing and Examination of wire ropes 28
III. Form for Examination reports on wire ropes 29
APPENDIX I 'D'
1. Standard lifting tackles for 140 T diesel hydraulic break down crane 30 to 31
II. Standard equipment of chains for all cranes 32 to 33
APPENDIX 'E'
140 T Diesel Hydraulic Breakdown cranes ( Cowans sheldon) 32

Load chart for 140 T crane (Cowans sheldon) 33
Warning to wire rope users 34
Warning to chain users 35
APPENDIX 'F'
01 70 T capacity two leg wire rope sling for 140 T crane 36
02 30 T capacity two leg wire rope sling for 140 T crane 37
03 25 T capacity four leg wire rope ordinary thimble 38
04 Single leg wire rope sling 70 T capacity 39
05 Single leg wire rope sling 50 T capacity 40
06 Single leg wire rope sling (soft eye) 70 T capacity 41
07 Technical specification for procurement of wire rope slings for 42
140T crane of Gottwald make
a. 70T double leg wire rope sling 42
b. 30T double leg wire rope sling 42
c. 70T single leg wire rope sling Go43
to Chapter contents
d. 50T single leg wire rope sling 43
e. 70T wire rope sling (Gottwald) 43
f. 25T four leg wire rope sling (Gottwald) 44
g. 5 T double leg chain sling (Gottwald) 45
h. Sling rope (Gottwald) 45
08 Technical specification for procurement of wire rope slings for 46-49
140T Diesel Hydraulic Crane of COWANS SHELDON make
09 LOCATION OF ACCIDENT RELIEF TRAINS [ ARTs ] ON IR 50-52
CHAPTER NO. 2
Operation of 140 T. Break Down Crane & Important Instructions
01 Comparative Technical Data of 140 T Cowans Sheldon and 140 Te. 02
Gottwald Break Down Cranes.
02 Technical data of 140 Te. Crane (Cowans Sheldon New) 03
03 Technical data of Cowans Sheldon 140 Te. Crane (Old) 04
04 Technical data of 140 Te. Crane (Gottwald New) 5-7
05 Technical data of 140 Te. Crane (Gottwald old) 8-10
06 140T crane specification with comparision between old & new 11-14
Gottwald cranes
07 Population of 140T cranes on IR 15
08 Safety precautions for crane operators 16-17
09 Important instructions for break down staff 18-19
10 Points to be kept in mind by Divisions for accident management 20-21
11 Suitable wire ropes and chain slings for lifting of load 22
12 Safety devices and safety fittings on 140 T Cowans Sheldon break 23-24
down cranes
13 Preparation of 140 Te. crane for "In Train Formation" 25
14 Precautions during 140 Te. crane "In Train Running" 26
15 Precautions during 140 Te. crane "In Train Running" and separation 26
of crane from ART
16 Precaution during preparation of crane at accident site for 27
restoration work.
17 Precautions and instructions for better performance of crane during 27-28
restoration work at accident site.
18. Precautions before and after shutting down the main engine 29
(on completion of restoration work)
19. Preparation of crane for working at site. 30
20. Preparation of crane for "In Train Running" condition 31
21 Precations to be taken during 140T crane operation (Gottwald New) 32
22. Starting circuit of 140 Te. Crane (Cowans Sheldon) 33
23. Battery operated electrical circuits of 140 Te. Crane 33-34
24. Gauge lights and lighting circuits of 140 Te. Crane 35
25. High power circuits of 140 Te. Crane 36
26. Responsibility for correct carrying out of rules for 140 Te. Cranes 37
27. Precautions when lifting with cranes 37
28. Periodical examination of cranes 38
29. Lubrication of cranes 39
30. List of the required material for ordering of "Crane Special" 40
31. Suitable wooden packing required for 140 T crane 41 contents
Go to Chapter
32. Load chart and propping arrangement for 140 T crane 42
33. Weight chart of coaches and wagons for lifting by 140 Te. crane 43
34. Sample Proforma for Break Down Train formation 43
Restoration at Accident sites by 140T cranes 44
35. Restoration of Derailed Locomotive in the Dead End siding by 140 44-49
T crane
36 Restoration of coaches in electrified section by 140 Te. Crane 50-51
37 Restoration of coaches in non electrified sections by 140 Te. Crane 51-56
38 Restoration of Derailed EMU/MEMU/DEMU 57-59
39 Restoration of loaded BCN/BOX -N by 140 Te. crane 60-67
40 Restoration of derailed oil tank wagons involved in fire 68-69
41 Restoration of derailed GD brake Van by 140 Te.Crane 70-72
42 FOB Work 73
43 Launching of Girder 74-77
44 Restoration on Track with super elevation 78-79
45 Restoration work in Tunnel 80
46 Restoration work on Bridges 81
47 Rescue Plateform 82
48 Road mobile Crane 82
49 Preparation before leaving the shed (140T Gottwald new & old) 83
50 Preparation before leaving the shed (140T Cowans Sheldon old) 84
51 Preparation before leaving the shed (140T Cowans Sheldon new) 85
52 Axle Blocking Gottwald Crane 86
53 Axle Blocking Cowans Sheldon Old Crane 86
54 Axle Blocking Cowns Sheldon New Crane 86
55 Boom Errection (Gottwald new & Old crane) 87
56 Boom Errection (Cowans Sheldon Old crane) 88-89
57 Boom Errection Cowans Sheldon new crane 90
58 Propping the Crane (Cowans Sheldon old crane ) 92
59 Propping the Crane (Cowans Sheldon New crane ) 93
60 Counter Weight (Gottwald Crane ) 94
61 Counter Weight (Cowans Sheldon old crane) 95
62 Counter Weight (Cowans Sheldon New crane) 96
63 Operating Precuations (Gottwald crane) 97
64 Operating Precuations (Cowns Sheldon old crane) 98
65 Operating Precuations ( Cowans Sheldon New crane) 99-100
66 General Precautions for Handling of load 101
67 Preparing the Crane before leaving for shed (Gottwald) 102
68 Preparing the Crane before leaving for shed (Cowans Sheldon Old) 103-104
69 Preparing the Crane before leaving for shed (Cowans Sheldon New) 105-106
70 Staff deployment Diagrame for Gottwald 140T crane 107
CHAPTER NO. 3
Deployment of Break Down Staff and Composition of ARTs
1 Organizational issues, such as yard stick and selection criteria to provide 2
suitable personnel
2 Review of staffing yard stick of ART & ARME 4
3. Staff required for A & B Class ARTs for restoration by MFD/LUKAS 5
4. Staff required for ARME for working at Accident site 6 contents
Go to Chapter
5. Deployment and work distribution of breakdown staff at accident site for 8
restoration by 140 T crane
6. Deployment and work distribution of break down staff at accident site 9
for restoration by MFD/LUCAS
7. Composition of ART & ARME 10
8. Staff deployment for Accident Relief Trains (Operation & 11
Maintenance)
9 Kitchen management for ARTs 14
10. Duties of Railway officials in case of accident 15
11. Relief and rescue Crack Teams 16
12. Special disaster management team of RPF 16
13. Turning out of ARTs & ARMEs 16
14. Duties of ARME incharge 17
15. Duties of RPF staff on reaching at accident site 18
16. Relief and Rescue operation by ARME staff 19
17. Staff management and suggested gangs 20
18. Selection of ART/ARME staff 21
19. Physical fitness of staff 21
17. Accident proneness of staff. 21
18. Reaction time 21
19. Skill of artisans selected for gangs` 21
20. Team spirit of staff 21
21. Sincerity, willingness and obedience 22
22. Attendance of staff 22
23. Leadership among staff 22
24. Railway quarters-allotment 22
25. Provision of uniform for ART/ARME staff 22
26. Mock drills 23
27. Monitoring organization 23
28. Divisional monitoring organization (DMO) 23
CHAPTER NO. 4
Important Rules for ARTs/ARMEs & SPARTS
1. Ordering of Break Down Trains/Medical Van 02
2. What do you understand by term "Break down" 03
3. Break down allowance rules for staff 03
4. Travelling allowance - Rules for drawl of daily allowance, rates of daily 05
allowance.
5. Over time sample calculation for break down staff. 06
6. Rules for gazetted officers, loco inspectors and running staff 07
7. Break down allowance as monetary incentive to ART/ARME staff 07
8. Deligation of Powers for procurement of ART/SPART/ARME items 08-09
a. HLC Recommendations
b. Indian Railway Finance code correction slip No. 72
9. Syllabus for foundation course for ART staff 10
10. Syllabus for refresher course for ART Staff 10 contents
Go to Chapter
11. Syllabus for development course for 140 T Crane Drivers 11
12. Syllabus for Crane operators for Gottwald 140T crane (New & Old) for 12-13
mandatory/Refresher course .
CHAPTER NO. 5
Important Letters from Railway Board & RDSO
01 Railway Board's L.No. E(P&A)II-2015/F.E.2/2 dated 27.10.2015 02
–Payment of cash in lieu of free food, in exceptional
circumstances to the Non Gazetted staff engaged in break down
duties.
02 Railway Board's L.No. 2010/Tele/11 (2)/3 Pt.dated 10.04.2015 - 03
Provision of CUG connections to Break Down Staff of ARTs and
140T cranes
03 Railway Board's L.No. 2012/M(M&P)/RSP/7/RB/Pt.2012- 04
13.dated 04.04.2013 –High Speed self Propelled SPART for
NER.
04 Railway Board's L.No. 2012/F(X)II/5/8 dated 30.05.2012 – 05
Deligation of powers to General Managers to sanction cash
imprest- Amendment in para 1050 of Indian Railway Finance
code Vol-I
05 Railway Board's L.No. 2003/M(M&P)/7/DM/Status/pt. dated 07
04.01.2013 on Stainless steel cutting facilities on ARTs
06 Railway Board's L.No. 2011/M(M&P)/1063/48/HRE dated 08
25.03.2011 on Stainless steel cutting facilities on ARTs
07 Railway Board's L.No. 2009/Safety(DM)/6/12/comments dated 9
09.02.2012 on HLC revision
08 Railway Board's L.No. 2003/M(M&P)/7/DM/Status/Pt.dated 11
31.12.2012 on constitution of review committee for HLC
09 Railway Board's L.No. 2007/M(C)/141/1 dated 03.11.2008 on 12
IOH/POH periodicity of ICF design OCVs.
10 CRLy L.No. T.153.L5.HLC.57 dated 18.10.2004 on Sactioned 13
strength of ART staff for ARTs
11 Railway Board's L.No. 2002/SEC.(Cr.)/45/47 dated 27.03.2003 15
on Police clearance (Hindi).
12 Railway Board's L.No. 2007/Safety(DM)/RM/01 dated 16
10.10.2008 on Revision of HLC recommendation.
13 CRLy Letter No. D.O.No. T1.02.LI/Genl/Loco dated 08.08.2008 18
on Accident restoration.
14 CRLy L.No.T.651.L.S.ART.Policy dated 04.09.2006 on ordering 21
of ART from adjoining foreign RLys in case of accidents.
15 CRLy. L.No. T.153.L.5.HLC.57 dated 31.05.2006. on 22
nomination of staff for 140 T. crane
16 CRLy. L.No. T.651.L.3.140.T.Crane dated 12.02.2004 on 24
movement of 140t. Crane for other than break down work.
17 CRLy. L.No. T.651.L.3.140.T.Crane dated 14.11.2002. on 25
utilization of break down cranes for non break down purposes.
18 CRLy. L.No. T.651.L.3.140.T.Crane dated 06.06.1999. on 26
operation and movement of 140 T cranes.
19 Minutes of 3rd CMG meeting held at JMP on Sep-23rd & 24th 29-37
,2004
20 CRLy HQ L.No.T.651.L.3.B.D.Crane dated 17.01.2005 on 38
Movement of 140T BD Cranes for other than Break Down Work.
21 CRLy HQ L.No.T.651.L.3.B.D.Crane dated 17.01.2005 on 38
Movement of 140T BD Cranes for other than Break Down Work.
22 Railway Board's L.No.E(P&A)/II-2007/II/4/3 dated 25.09.2009 42
on Revision of rates of break down allowance.
23 CRLy L.No. T.651.L.3.B.Crane. dated 29.09.2005 on Policy on 43
crane operator for 140 T. Crane
24 Railway Board's L.No. 95/(c&w)/1467/16 dated 11.12.1996 on 44
CMPE(R&L) conference held at calcutta
25 Railway Board's L.No. 99M(M&P)/7/6 dated 24.09.99 on 48
Disaster Management
26 RDSO's L.No. SL/CR/SPD/140 T/Jessop dated 15.17/12/03 - 50
Amendment to speed certificate for 140 T DSL break down crane
of Cowans Sheldon
27 Railway Board's L.No. 2004/TG-V/2/5 dated 23.06.04 Rendering 51
of assistance to stranded and injured train passengers.
28 Joint circular No. 2 52
29 Proposal for creation of one Sr. Scale post of DME in open line 54
for Disaster Management
30 Railway Boards Letter No. 99/M/M&P/7/6 dated 12.09.2002 - 55
Management of Accident Relief Trains.
31 Railway Board's L.No. 2002/Safety-I/23/4 dated 13.08.03 57
periodic examination and safety certification of departmental
rolling stock
32 Practical exercise of Tools and Equipments of ARME/ART 58
33 Practical training of "Crack Rescue and Relief Teams" 59
34 Railway Board's L.No. 2003/M(M&P)/DM/7(13) dated 16.07.04 60
35 Railway Board's L.No. 87/W-3/Tele/TN/23 dated 06.08.99 - 61
Provision of Communication facilities in ARTs/ARMEs.
36 Railway Board's L.No. Safety-I/12/12 dated 07-1999 - Video 62
Filming of Accident site and restoration work.
37 Railway Board's L.No. 93/Safety-I/6/1 dated 10.12.1993 - Video 63
Filming of restoration - work of various accidents.
38 Minutes of CMG meeting held at JMP on 24th & 25th april-2000 64-71
39 Railway Board's L.No. 2002/SEC(Cr.)/45/47 dated 27.03.2003 72
on clearance by state police in case of Railway Accident
(English)
40 Railway Board's L.No. 2002/Sec (CR)/45/47 dated 07.02.2003 - 73
Clearance by State Police in case of Railway accidents.
41 Railway Board's L.No. 2004/M&P/7/DM (107) dated 09.11.2004 74
- Fire Fighting Equipments in ARTs and training of ART staff.
42 Nomination of staff for 140 T. Crane 75
43 Inspection of ARTs by DRMs 76
44 Inspection of ART/ARMEs by Divisional officers 77-78
45 Nomination and attendance of staff for ART/ARME at accident 79
site
CHAPTER NO. 6
Record Keeping and Certification
Form Particulars Page

No.
ART-1 Proforma for overdue inspection of officers and supervisors of 5
Accident Relief Trains/ARME/SPART
ART-2 Proforma for Break down site report 6
ART-3 Proforma for competency certificate for crane drivers 7
ART-4 Proforma for provisional competency certificate for 140 Te. Crane 8
supervisors
ART-5 Proforma for maintaining Accident Diary in Control Office. 9
ART-6 Proforma for Inspection of ARTs 11
ART-7 Proforma for Inspection of ARMEs 14
ART-8 Proforma for Inspection of SPARMVs 16
ART-9 Proforma for Inspection of SPARTs 17
ART-9 Proforma for ordering of Crane Special 20
ART-10 Proforma for fixation of Hire Charges for MFD/LUCAS 22
ART-11 Proforma for fixation of Hire Charges for 140 Te. crane. 23
ART-12 Proforma for Video Camera Register 24
ART-13 Proforma for Equipment Testing Register 25
ART-14 Proforma for Testing particulars of Chain slings 26
ART-15 Proforma for Testing particulars of Wire Rope slings 27
ART-16 Proforma for ART/ARME/SPART Ordering Particulars. 28
ART-17 Proforma for 140 Te. Crane SPL Ordering particulars. 29
ART-18 Proforma for 140 Te Crane/SPL Debit particulars. 30
ART-19 Proforma for maintaining parts of MFD/LUCAS Power pack . 32
ART-20 Proforma for maintaining Particulars of chains & wire rope slings 33
ART-21 Proforma for maintaining particulars of MFD Equipment. 34
ART-22 Proforma for Work distribution among staff for MFD working. 35
ART-23 Proforma for work distribution among staff for crane working. 36
ART-24 Proforma for maintaining MFD Petrol Pump set. 37
ART-25 Proforma for maintaining MFD Diesel power pump set. 38
ART-26 Proforma for Master Defect Card of 140 Te. DSL Hyd. break 39
down Crane.
ART-27 Proforma for parts of 140 Te. Crane changed during the year. 40
ART-28 Proforma for 140 Te Diesel Hyd. Bk.Dn. crane Schedule/ Unschedule 41
repair statement.
ART-29 Proforma for Break down staff training particulars. 42
ART-30 Proforma for Break down ordering at a glance. 43
ART-31 Proforma for site observation joint Report for Crane/Special 44
ART-32 Proforma for Retrieval of accidented coaches/Crane special work 44
ART-33 Proforma for Inspection Register for ART 45
ART-34 Proforma for Inspection Register for ARME/SPART 46
ART-35 Proforma for Elgi make compressor for Air Bag 47
ART-36 Proforma for Daily maintenance schedule of HS SPART 48
ART-37 Proforma for Log book for SPART 50
ART-38 Proforma for Schedule for Cummins make engine of HS SPART for 51
AMC- Daily/Weekly
AMC- 6 monthly
AMC- Yearly
Form Particulars Page
No.
AMC- 1500 hrs. check
AMC- 6000 hrs. or 02 years check
ART-43 Proforma for Maintenance schedules of high pressure compressor 56
ART-44 Proforma for Maintenance schedules for ASKA tower light. 57
ART-45 Proforma for Maintenance schedules for LUKAS Power pack 58
(Petrol).
ART-46 Proforma for Maintenance schedules for LUKAS Power pack 59
(Diesel).
ART-47 Proforma for Maintenance of MFD Power Pack & Jacks (Weekly) 60
ART-48 Proforma for Maintenance of MFD Power Pack & Jacks (Monthly) 61
ART-49 Proforma for Maintenance of MFD Power Pack & Jacks (QLY) 62
ART-50 Proforma for Maintenance of MFD Power Pack & Jacks (HLY) 63
ART-51 Proforma for Maintenance of MFD Power Pack & Jacks (Yearly) 64
ART-52 Schedule of 140 Te. Crane(Gottwald) under AMC 65
ART-53 Schedule of 140 Te. Crane(Gottwald) under AMC 68
ART-54 Schedule of double acting 530 bar LUKAS (HRE) under AMC 73
ART-55 Proforma for service charges for attention to 530 bar double acting 82
LUKAS (HRE) consisting 20 jacks, power pack, control stand, roller
carriage & compressor for Air bag
ART-56 Schedule of 140 Te. Crane for visit under AMC for main engine. 84
ART-57 Schedule of 140 Te. Crane(Gottwald) for visit under AMC for main 87
engine.
ART-58 Schedule of 140 Te. Crane(Gottwald) for visit under AMC. 91
ART-59 Proforma for Trip Schedule examination of ART rake. 116
ART-60 Proforma for Sch. “A” examination of ART rake. 117
ART-61 Proforma for Sch. “B” examination of ART rake. 118
ART-62 Proforma for Kitchen Ration Consumption for ART/SPART 119
ART-63 Proforma for ART/ARME/SPART Imprest expenditure & accountal
register
ART-64 Proforma for maintaining Fuel and Lubricant consumption
ART-65 Proforma for Log Book of ART/ARME
CHAPTER NO. 7
Technical Description of GOTTWALD 140T. Break Down Crane
1 Technical data of 140 Te Gottwald break down Crane 2-3
2 Duties of Gottwald 140 Te Crane Operator 4
3 Load Charts for Gottwald 140 Te .break down crane 5
CHAPTER NO. 8
DO’s and DON’Ts for COWANS SHELDON 140 T. New Design Crane.
1 DO’s for Operation of Crane 01
2. DON’Ts for Operation of Crane 07
3. DO’s for Air Brake (General) Operation 10
4. DO’s for Self propelling mode operation 12
5. DO’s for Air Brake (Train formation) Operation 14
6. DON’Ts for Air Brake Operation 16
7. DO’s for Hydraulic Operation 17
8. DON’Ts for Hydraulic Operation 20
9. DO’s for Electrical (General) Operation 22 contents
Go to Chapter
10. DO’s for Electrical (Starting main Engine) Operation 23
11. DO’s for Electrical (Starting Auxiliary Engine) Operation 25
12. DO’s for Main & Auxiliary Hoist Operation 27
13. DO’s for Derrick Operation 28
14. DO’s for Slewing Operation 29
15. DO’s for Hauling Operation 30
16. DO’s for Travelling Operation 31
17. DON’Ts for Electrical Operation 33
18. DO’s for safe load Indicator (SLI) Operation 35
19. DON’Ts for safe load Indicator (SLI) Operation 38
DO’s and DON’Ts for GOTTWALD 140 T. New Design Crane.
1 Bringing the 140 T. crane in Train order before leaving the shed 02
2. Rigging of the Crane after reaching at the site 03
3. Axle Blocking 05
4. Boom Errection 05
5. Propping the Crane 06
6. Counter Weight attachment 07
7. Operation of 140 T Crane 09
8. De-Rigging the Crane 10
9. Preparing 140 T. Crane for transport 12
10. Maintenance checks of Engine 12
11. Maintenance of Hydraulic System 12
12. Attention to Wire Rope 13
13. Maintenance Precautions for Safety Devices 14
CHAPTER NO. 9
Operation of Hydraulic Re-railing Equipments (HREs)
MFD & LUKAS
PART-I
MFD Make HRE
9.0 MFD Re-railing system 2
9.1 Special Features 3
9.2 Hydraulic Power System 4
9.3 Small Pump sets 5
9.4 Hand Pumps 6
9.5 Control Unit 6
9.6 Lifting Jack Series 400 6
9.10 Single Piston Jacks EH-350 & EH-200 10
9.11 Single Piston Jacks EH-100 10
9.12 Tilting Jack 10
9.13 Equipment for lateral displacement 11
9.14 Re-Railing Bridges 11
9.16 Equipment for up-righting operations 15
9.17 Auxiliary Trucks 15
9.18 Accessories 16
a. Axle Pusher Unit 17
b. High Pressure Hoses 17
c. Distribution Valve 17
d. Bogie Suspensions 18
e. Rescue Devices & Accessories 18
f. Air Bags & Accessories 18
9.19 LUKAS Make HRE
1. Intelligent Traversing System 19
2. A wide range right solutions 19
3. Light Weight components 19
4. Equipment is made in Germany 19
5. System includes various components 20
6. Main advantages at a glance 20
7. Control huge forces with precision from a safe distance series 20
6 pumps
8. Compact power unit for lifting & traversing 21
a. Compact power unit 22
b. Advantages 22
9. Compact power unit for lifting 22
a. Motor Pumps with gasoline 22
b. Advantages 22
10. High performance Hand Pumps 23
a. Advantages 23
11. Safe operation; the control desk 24
12. Hydraulic hoses; Fast and safely connected 25
13. Telescopic Jacks 25
a. Optimized surfaces 26
b. Integrated hose break safety valve 26
c. Perfect co-ordination 26
d. Machine on the job 26
14. Stacking Sets 27
15. Base plates 28
16. Special Jack for low floor vehicles 28
a. Internal Jacks 28
b. Types of jacks 29
17. Duo Traversing Unit 29
a. Advantages 29
b. Machine on the job 30
18. Secured base for Traversing 31
a. Re-Railing Bridges 31
b. Connecting Re-Railing Bridges 31
c. Machine on the job 32
19. Re-Railing Accessories 32
a. Tilting Jack 32
b. On the Job 32
c. Axle Pusher 33
d. On the Job 33
20. Uprighting System 33
a. Machine on the job 33
21. Pulling Device 34
a. Separating wedged vehicles with pulling equipment 34
22. For fast and Precise Re-Railing 35
a. Compact Traversing unit for light Rail vehicles 36
b. Advantages 36 contents
Go to Chapter
23. Emergency Pneumatic Air Bag for Lifting 36
a. VETTER – Emergency air bag 36
b. Mini lifting Bags 37
c. Double controller 8 bar 37
24. LUKAS hydraulic Rescue Device (HRD) 38
a. For optimal cutting: cutters 38
b. For Spreading, Squeezing & peeling 38
c. Covering large distances: Rescue Ramps 39
d. High Performance Power Units 40
e. Lliberty with hydraulic HRD 42
f. Advantages 42
g. Examples of applications 43
PART-II
Operating Instructions for 530 Bar Double Acting LUKAS, HRE
1.0 Designated use of the machine 03

Organi
2.0 Organizational measures 03
3.0 General safety instructions 04
4.0 Instructions for maintenance and service 04
5.0 Function of individual components 05
6.0 Installation of individual components 08
7.0 Operation 12
8.0 Op Optional components for further applications 19
9.0 Dismantling of components 21
10.0 Preventive and corrective maintenance 22
11.0 Repairs 23
12.0 Technical data 25
CHAPTER NO. 10
Standard Lists for ART, ARME, SPARMV & SPART

1.0 General 2
2.0 Technical description of critical equipments of ARTs/SPARTs 3
2.1 Hydraulic Re-railing equipments ( HRE) LUKAS 3
2.2 Hydraulic Re-railing equipments ( HRE) LUKAS – Single acting 5
2.3 Pneumatic Lifting Air Bags 6
2.4 Multipurpose self powered carbide tipped bullet chain saw 7
2.5 Portable electrically operated (Tools ) equipments 7
2.6 Emergency Inflatable portable lighting tower 9
2.7 Portable electrically operated power tools ( BOSCH make) 10
2.8 Self contained Air breathing apparatus 11
2.9 High Pressure Air Compressor 12
2.10 Under water cutting equipment ( PETROGEN) 13
2.11 Safe Access Rope Ladder 13
2.12 Rail Skate 14 contents
Go to Chapter
2.13 Breath Alcohol Detector 14
2.14 Paragon Instrumentation Engg. Make set of Gauges 15
A List of Tools and Equipments required in “A” & “B” Class ARTs 01-17
2. List of Tools and Equipments for ARMEs on IR. 01-16
3. List of Tools and Equipments for SPARMV on IR. 01-15
4. List of Tools and Equipments for SPARTs on IR. 01-17
CHAPTER NO. 11
Dealing with LPG & Ammonia Gas
1 Dealing of LPG product : Product information 2
2 Leakages in LPG Tank Wagons 3
3 Precautions to be taken during leakages 4
4 Do's and Don'ts for tackling leakages of Tank wagons 5
5 Tackling LPG Wagon derailments/Accidents 5
6 Hazardous Gas Emergencies : Ammonia Gas 6
7 Precautions to be observed for leaky Ammonia Tank wagons 6
8 Do's and Don'ts for tackling leakages of Ammonia from tank wagons 7
9 Important tools to handle LPG/Ammonia Gas emergencies 7
10 Emergency contact numbers of IOC/BPC/HPC officials dealing with LPG 8-9
and Ammonia.
CHAPTER NO. 12
Drawings and Layouts for Composition of ART/SPART/ARME on IR.

ART:
01 Marshalling of “A” Class ART 2
02 Marshalling of “B” Class ART 2
03 Benefits of Revised marshalling 3-4
04 Details of Newly developed lay out drawings for ART/SPART/ARME 5-8
SN Type of Stock Drawing No. Page No.
1 Crane Packing and OHE Material van CPOM-002 BCNHS 9
2 Crane Staff and Kitchen van CSKV-003 RT 10
3 Engineering and OHE Material van EOM-002 BCNHS 11
4 Tool and Equipment van TAEV-003 RT 12
5 C&W, Electrical and Telecom van CETV-004 RT 13
6 Re-railing Equipment van RREV-005 RT 14
7 Staff and Kitchen van SKV-006 RT 15
ARME:
1 Lay out of Auxiliary Van for ARME CG-K-4044 16
2 Lay out of Medical Van for ARME CG-K-4046 17
SPART:
1 Lay out of Tool Van with Equipments SK.DP-3716 18
2 Lay out of Medical Van SK.DP-3720 19
3 Lay out of Converted SPART (Existing 2-Coach SK.DP-3718 20
SPART to 3 Coach SPART)
4 Lay out of Converted SPART(Existing 2-Coach SK.DP-3714 21
SPARMV to 3-Coach SPART)
CHAPTER NO. 13
Relief and Rescue Operation on Passenger Train
Introduction 02
1 Disasters and Train Accidents 04
2 Characteristics of Railway Accidents 07
Various scenarios of Railway Accidents 08
3 Rescue 11
4 Rescue Organizing 15
5 Rescue Plan 16
6 Safety in Rescue Operations 18
7 Search and Extraction Methodologies 20
8 Ropes, Chains and Slings 22
9 Various Equipments used in Rescue Operations 24
10 Operating Instructions for Electrical Hand Tools and Generators 26
11 Operating Instructions for Hydraulic Rescue Device 42
12 Operating Instructions for pneumatic Rescue Device 54
13 Other Equipments 62
14 Relief and Rescue Operation on Passenger Train during Golden 71
Hour
15 Rescue of Trapped Passengers focusing on Medical stabilization 80
and safe shifting.
PART-II
01 Work distribution among ARME staff at Accident site: Team 01
formation
02 Crack Team Formation 03
03 Duties of ARME/SPARMV Incharge 04
04 Work distribution of “A” Team 07
05 Work distribution of “B” Team 08
06 Work distribution of “C” Team 09
07 Work distribution of “D” Team 10
08 Work distribution of “E” Team 11
09 Work distribution of “F” Team 12
10 Duties of Guard in case of Train Accident 13
11 Duties of conductor/TS/TTE in case of accident 15
12 Duties of Loco pilot & Asstt. Loco Pilot in case of Accident 17
13 Duties of DRM in case of Accident 18
14 Duties of AC Coach attendant/Mechanic at Accident site 19
15 Duties of officer incharge present at accident site 20
16 Duties of RPF staff at Accident site 22
CHAPTER NO. 14
Infrastructural Facilities for Maintenance of 140 T. Cranes
ARTs, ARMEs & SPARTs
1. Introduction 03
2. Scope of maintenance & location of the shed 03
3 Description of shed layout 03
4 Shed Lighting 04
5 Fuel Supply 04
6 Fire Fighting Equipments 04
7 Supervisor cum computer Room for ART incharge & 140 T Crane 04
Supervisor
8 Staff Room 04
9 Lifting tackles Room 05
10 Consumables/ store room 05
11 Compressor Room 05
12 Electrical Room with Battery charger 05
13 Toilet & washing Room 05
14 ART stabling line 06
15 Summary of 140t crane shed lay out 06
CHAPTER NO. 15
High Speed SPART
01 Introduction 2
02 Technical specification of HS SPART 3
03 Environmental conditions governing HS SPART 3
04 Details of SPART rake with ZF transmission 4
05 Details of SPART rake with VOITH transmission 4
06 Composition details of SPART 5
07 Various lay outs of SPART
A. Lay out of converted SPART 6
B. General lay out of Supervisory Van (with SAN equipments) 7
C. General Layout of Medical Van 8
D. General Lay out of Tool Van ( SAN Equipment ) 9
E. General Lay out of Supervisory Van 10
08 CUMMINS Engine of SPART 16
09 Air Intake arrangement in supervisory & Tool Van 17
10 Exhaust Arrangement in Supervisory & Tool Van 18
11 Water cooling system in Supervisory & Tool Van 19
12 Water raising apparatus system in supervisory van 19
13 Fuel system in Supervisory van 20
14 Hydraulic Transmission of HS SPART 21
15 Air Connections of transmission 22
16 Oil filling of turbo transmission 23
17 Operation of turbo transmission 23
18 Maintenance schedule of turbo transmission 24
19 Trouble shooting of turbo transmission 24
20 Spring coupling between engine and transmission 26
21 SAN axle drive gear box 27
22 Wheel & Axle (powered) 27
23 SAN Axle drive : maintenance schedule 29
24 Torque arm 30
25 Cardan shaft 31
26 Recommended oils & Lubrications 35
27 SAN Skid arrangement 34
28 HS SPART – Operation & Electrical system 36
29 Table for position of SPARTs & SPARMVs on IR 45
30 Schedule of standard examination of BG SPART 48
A Daily 52
B Weekly 53
C Half Yearly 55
D Yearly 57
E 2-Yearly 58
F 4-Yearly 59
G 12 Yearly Schedule 64
31 Electrical Schedules 72
ANNEXURE – I
Chains & Chain Slings
TECHNICAL CONSIDERATIONS FOR PROCUREMENT INSPECTION, TESTING AND

REPAIRS OFCHAINS, CHAIN SLINGS AND THEIR COMPONENTS
Chapter I Specifications for Chains & Chain Slings 1-2
Chapter II Grades of Chains 3
Chapter III Technical Considerations for choosing slings 4-5
Chapter IV Procurement of chains, chain Slings and their 6-7

components
Chapter V Manufacture of Chain Slings in Railway Workshops 8-9
Chapter VI Working Loads 10-11
Chapter VII Periodical inspection and repairs to Chains & Slings 12-14
Chapter VIII Procedure for Identification, Repairs and Heat 15-19

Treatment to chains/slings
Chapter IX Information to be supplied during enquiry or order 20-27
CHAPTER - 1
RULES FOR THE

WORKING OF
ARTs/ARMEs/SPARTs
&
140T.BD CRANES
Operation Manual for Working of ART\ARME\140 Te. Cranes\1
CHAPTER – 1
RULES FOR THE WORKING OF CRANES
Ordering of 140T Cranes and Preparation of Disaster Management Plan.

[ HLC Recommendation No.- 15(b) page No. 9 ]
The disaster management plan must interalia include “who is responsible for what
activities in detail”.
1. Preparation and implementation of Disaster Management plan is the responsibility

of concerned GM/DRM.
2. Authority to order ART/ARMV/140TBreak Down Crane, CME/CMPE(D)/Sr
DME/DME, etc.
3. Senior most Railway officer at the site of the Accident shall be designated site
manager.
4. Management of Rescue operations - Primarily Mechanical and Medical
Departments. Assistance to be provided by all Railway Men (Irrespective of their
department) as needed.
5. Relief operations including care for the dead – Commercial, Medical and RPF
department.
6. Communication network- Telecom department.
7. Crowd control and law and order at site - RPF.
8. State police clearance for restoration - RPF
9. Restoration operations -
Rolling Stock – Mechanical Department
Fixed Infrastructure like Track, OHE, Signalling System etc.- Concerned
Departments.
10. Maintenance of SPART/ART and ARMV Rolling stock/140TBreak Down Cranes
including Rail-Cum-Road and Road Mobile Emergency vehicle etc. – Mechanical
Department.
11. Maintenance of Equipments kept in SPART/ART/ARMV for Rescue and
Restoration operations – concerned departments.
12. Media Management at site –
A. Site manager shall be the Chief spokesman at site and can be assisted
by the concerned branch officers, if needed.
B. PR/Commercial departments, to look after the media needs at site.
13. Check list for the officers and supervisors must be issued in the form of pocket
booklet indicating do’s and don’ts for the benefit of :
a. First official reaching the site of accident
b. Senior most officer at the site
c. Divisional/ HQ control organization
d. Station Manager/Station Master
INTRODUCTION
I. Application of Rules -
1. 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.
2. 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.
II. Classification of Cranes -
1. Cranes belonging to the Railway are divided into three classes :-
(i) Main Line Traveling Cranes, which 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.
(ii) Yard Traveling 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.
(iii) Fixed and Special Cranes, are 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.
2. Main Line Traveling Cranes are further sub divided in to :-
(i) Break-Down Cranes, these 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.
(ii) Traffic Cranes, these are hand and Diesel cranes allotted to Stations and
Yards for the handling/Transshipment of heavy consignments.
III. 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 ]
IV. 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.
V. 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). Loco Inspectors will be
responsible for the periodical examinations of the cranes posted at depots where there is
no SSE(Loco).
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.
OPERATION :
I. 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.
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"
Chief Mech. Engineer.
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.
II. 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
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 140 Te. 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 140 Te. 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.
III. 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.
IV. Code of signals :-
The code of signals for controlling the movements of cranes is given in Appendix C.
V. Precautions when lifting with cranes :
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 140 Te. Diesel Hydraulic Crane of ART, following precautions should be
taken.
1. 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.
2. This crane is unstable in super elevated track in free –on- rail condition with
counter weight or heavy ballast weight fitted to superstructure.
3. Swinging load is dangerous and is to be avoided.
4. 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.
5. Both relieving bogies must be unloaded, prior to raising the jib from match truck.
6. 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.
VI. 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 :-
(1) Hoisting Chains - are main chains of cranes, used for hoisting the load.
(2) Hoisting Wire Ropes - are Main wire ropes of cranes used for hoisting
the load.
(3) Lifting Chains - are chains fitted to the jib sheaves of jib cranes for lifting
purposes.
(4) Lifting Wire Ropes - are Wire Ropes fitted to the jib sheaves of jib cranes
for lifting purposes.
(5) Sling Chains - Chains with a ring at one end and a hook at the other,
either with a single, double or multiple legs. Some times Sling Chains are
made as endless chains.
(6) Wire Rope Slings - Slings with wire ropes used instead of chains.
VII. 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.
--------------
MAINTENANCE AND REPAIRS OF CRANES
I. Overhauls :
The date of each examination of 140 Te. Diesel hydraulic crane break down crane
should be painted plainly on the crane at marked location.
The 140 Te. 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 Te. Cranes and prescribed by Jamalpur Work shop for Gottwald 140
Te.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.
II. 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.
III. 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 SSE(Loco)/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 in Appendix E.
All 140 Te. Diesel hydraulic cranes of ARTs will be maintained by the
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 Te. 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.
Axle boxes of cranes and match trucks, Relieving bogies running with plain
bearings must be repacked every month. This will be the responsibility of the
Subordinate, who is responsible for the repairs and maintenance of the crane. Dates of
last repacking of axle boxes must be clearly marked on the carriage girder of cranes and
on the sole-bars of match trucks.
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.
IV. 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(Loco)/SSE(C&W) or
SE(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 Te. Diesel Hydraulic Cranes of ARTs/BDT will be examined at intervals
regularly as prescribed by RDSO. The SSE(Diesel) at Diesel Sheds/Trip Sheds
nominated to do so are responsible for the periodical examination of 140 Te. Diesel
Cranes.
To ensure proper upkeep and reliability in safe working of 140 Te. Diesel crane at
site, the periodicity of maintenance schedules have been prescribed by RDSO which has
been given in Chapter No.2.
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 appendix F. The record of such
examinations entered in the register will be signed by the maintenance supervisor and
countersigned by the officer incharge of ART/BDT.
Particulars of periodical examination of 140 Te. 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
Officers of the Power and Carriage & Wagon Department will periodically check
that the registers showing particulars of examinations of cranes are correctly maintained;
that examinations are being made on due dates and that the cranes are being kept in good
condition.
APPENDIX 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 140 te.
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 Te. 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 Te. 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.
6. 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.
(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.
(f) Other traveling crane shall ordinarily be hauled by Goods trains. Not more
than two cranes are to be attached to a trains. If there is no Goods train on the section, it
may be attached to Mixed trains. When attached to a Mixed train, the crane must be
placed amongst the goods wagons. A crane may only be attached to a Passenger train
with the Chief Passenger Transportation Manager (CPTM)s permission.
(g) When the jib of a traveling crane projects beyond the truck, an additional
truck shall be attached to act as a dummy.
7. 140 ton Diesel Hydraulic Cranes:
140 ton diesel hydraulic cranes may run over any BG section of the Railway.
7. 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 sothat 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 )
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 as 5 KMPH

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 dtd. 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.
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 degree.
ii) Driven by its own power with jib resting on match truck and 15 kmph
with axle load as in sketch No. RDSO. SK.No.CR.748.Alt.3
iii) Driven by its own power with both relieving bogies attached to 15 kmph
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. 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 S.Rs of zonal railways.
7. 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 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 which ever 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.
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.
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 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.
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.
APPENDIX-B Contd----
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
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.
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 or
calibrated * chains formula 9-d 2 calibrated chains
formula 6-d 2 formula 6-d 2
Nominal dia Safe Nominal dia Safe Nominal dia Safe
Meter of chain working Meter of chain working Meter of working
load load 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 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

30o 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
1. For normal lifting the angle between the parts of the sling should not exceed 90 o
2. In exceptional cases an angle between the two parts of the sling of not exceeding 120 0 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.
IV. 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:
Circumference 6X19 6X24 6X37

of rope Safe working load Safe working load Safe working load
Cranes Non pass. Pass. Cranes Non pass. Pass Cranes Non pass. 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.
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 chains 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.
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/Sheds./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 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 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.
Prescribed form
III. Particulars of Examination of Wire Ropes
Crane Single Original Present No.of No. of Positi If any No. Any Date of Date
No. & Double Circumf min. Strands strands on of one of other last now
Capa or 3 erence circum broken in each bkn strand broke features exami- examin
city fold of rope ference rope strand is bkn n such as nation ed
Block due to and s in wires flat
strain number more at wires
of wires than each crushed
in each one positi or
strand place on distorte
and if give d
fitted positi structur
with on & e
hempen No.
or other of
core break
s in
each
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……………
APPENDIX 1 ‘D’
The standard “lifting tackles” for 140 Te. 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 equipments 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 to 1.Two leg wire rope sling to 1.Two leg wire rope sling to
BS-1290 SWL 70 T, with hook BS-1290 SWL 70 T, with hook BS-1290 SWL 70 T, with
and ring, length = 6 M and ring, length = 6 M 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 Hook
higher tensile steel to BS-2903. higher tensile steel to BS-2930. higher tensile steel to BS-
Ultrasonically tested for any Ultrasonically tested for any 2930. Ultrasonically tested
flaws. flaws. for any flaws.
b) Ring- MAT-EN:14 A. Ablong Ring- MAT-EN:14 A. Ablong Ring- MAT-EN:14 A.
link of inside dia. 890X540 Matl link of inside dia. 890X540 Matl Ablong link of inside dia.
 130  130 890X540 Matl  130
c) Wire rope: single part spliced Wire rope: single part spliced Wire rope: single part
endless sling  64. Rope 6/49 endless sling  64. Rope 6/49 spliced endless sling  64.
construction steel core with construction steel core with Rope 6/49 construction steel
ordinary Thimbles. ordinary Thimbles. core with ordinary Thimbles.
d) Proof load: 81 Te. per leg Proof load: 81 Te. per leg Proof load: 81 Te. 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 with BS-1290. S.W.L 25 Ton with BS-1290. S.W.L 25 Ton with
Hook & Ring .Length Hook & Ring .Length Hook & Ring .Length
2 Nos = 5 M & 2 Nos =7 M 2 Nos = 5 M & 2 Nos =7 M 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 S.W.L.Hook
Higher Tensile Steel to BS-2903. Higher Tensile Steel to BS- Higher Tensile Steel to BS-
Ultrasonically tested for any 2903. Ultrasonically tested for 2903. Ultrasonically tested
Flaws. any Flaws. for any Flaws.
b) Ring- MAT EN.14A. Ablong Ring- MAT EN.14A. Ablong Ring- MAT EN.14A.
Link of inside Dia 890x540 Link of inside Dia 890x540 Ablong Link of inside Dia
Matl  100. Matl  100. 890x540 Matl  100.
c) Wire Rope-Single part spliced Wire Rope-Single part spliced Wire Rope-Single part
end less sling  44. Rope 6/36 end less sling  44. Rope 6/36 spliced end less sling  44.
construction steel core with construction steel core with Rope 6/36 construction steel
ordinary Thimbles. ordinary Thimbles. core with ordinary Thimbles.
d) Proof Load-42.4 Ton per leg. Proof Load-42.4 Ton per leg. Proof Load-42.4 Te per leg.
e) Finish-Galvanized Finish-Galvanized Finish-Galvanized
4. Single Leg Wire Rope Sling to Single Leg Wire Rope Sling to Single Leg Wire Rope Sling
BS-1290. SWL 70 Ton with BS-1290. SWL 70 Ton with to BS-1290. SWL 70 Te with
Hook & Ring .Length = 6 M Hook & Ring .Length = 6 M Hook & Ring .Length = 6 M
a) Hook – 70 T S.W.L Hook higher Hook – 70 T S.W.L Hook Hook – 70 T S.W.L Hook
tensile steel to BS-2903. higher tensile steel to BS-2903. higher tensile steel to BS-
Ultrasonically tested for any Ultrasonically tested for any 2903. Ultrasonically tested
flaws. flaws. for any flaws.
Standard equipments 1st period 2nd period
b) Ring: MAT-EN:14 A. Ablong Ring: MAT-EN:14 A. Ring: MAT-EN:14 A.
link of inside dia. 890X540 Ablong link of inside dia. Ablong link of inside dia.
Matl  130 . 890X540 Matl  130 . 890X540 Matl  130 .
c) Wire Rope-Double part Wire Rope-Double part Wire Rope-Double part
spliced end less sling  64. spliced end less sling  64. spliced end less sling 
Rope 6/49 construction steel Rope 6/49 construction steel 64. Rope 6/49 construction
core with ordinary Thimbles. core with ordinary Thimbles. steel core with ordinary
Thimbles.
d) Proof Load -To 105.4 Tonne Proof Load -To 105.4 Tonne Proof Load -To 105.4 Te
4. Single Leg Wire Rope sling Single Leg Wire Rope sling Single Leg Wire Rope
to BS-1290. SWL.50 Ton to BS-1290. SWL.50 Ton sling to BS-1290. SWL.50
Max with Hook & Ring. Max with Hook & Ring. Ton Max with Hook &
Length = 5 M Length = 5 M Ring. Length = 5 M
a) Hook- 50 Ton S.W.L. Hook Hook- 50 Ton S.W.L. Hook Hook- 50 Ton S.W.L.
Higher Tensile Steel to Higher Tensile Steel to Hook Higher Tensile Steel
BS-2903.Ultrasonically tested BS-2903.Ultrasonically toBS-2903. Ultrasonically
for any Flaws. tested for any Flaws. tested for any Flaws.
b) Ring- MAT-EN-14 A. Ring- MAT-EN-14 A. Ring- MAT-EN-14 A.
Ablong link of inside dia. Ablong link of inside dia. Ablong link of inside dia.
890X540 Matl  120 890X540 Matl  120 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  64.
Rope 6/49 construction steel core Rope 6/49 construction steel Rope 6/49 construction steel
with ordinary Thimbles core with ordinary Thimbles core with ordinary Thimbles
d) Proof Load-To 81 Ton Proof Load-To 81 Ton Proof Load-To 81 Ton

2. Single Leg Wire Rope sling Single Leg Wire Rope sling Single Leg Wire Rope
to BS-1290. SWL.70 Ton to BS-1290. SWL.70 Ton sling to BS-1290. SWL.70
Max with soft eye both end. Max with soft eye both end. Ton Max with soft eye
Length = 4 M Length = 4 M both end. Length = 4 M
a) Wire Rope-  76 Rope, steel Wire Rope-  76 Rope, steel Wire Rope-  76 Rope,
core 6/49 construction with soft core 6/49 construction with soft steel core 6/49 construction
eye at both end size  575X1150 eye at both end size  with soft eye at both end size
long 575X1150 long  575X1150 long
b) Proof Load-To 140 Ton Proof Load-To 140 Ton Proof Load-To 140 Ton
APPENDIX – E
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.
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°
RADIUS OUT MH AH MH AH MH AH MH AH MH AH
METERS REACH
METER
5.5 - 140 - 140 - 42 - 29 - - -
7 1.05 140 25 98 25 31 25 20 20 18.5 18.5
9 3.05 140 25 62 25 22 22 13 13 11.5 11.5
11 5.05 109 25 44 25 16 16 9 9 7..5 7..5
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)
STANDING LEVEL LEVEL TRACK
± 28° 360° 0º(In line) ± 28° 360°
RADIUS OUT MH AH MH AH MH AH MH MH MH RH
METERS REACH
METER
5.5 - 140 - 140 - 94 - 53 - 39 -
7 1.05 140 25 110 25 78 25 41 25 27 25
9 3.05 140 25 70 25 63 25 30 25 18.5 20
11 5.05 118 25 50 25 52 25 23 25 14 15
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)
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
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
WARNINGS TO WIRE ROPE USERS
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.
REMEMBER THAT -
10. Special care should be taken to avoid snatch or sudden loads
REMEMBER THAT -
11. Competent periodic inspection reduces hazard and increases safety.
S K No. 1837
WARNINGS TO CHAIN USERS
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.
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.
REMEMBER THAT -
8. Mild steel Chain slings and components must be periodically
examined.
REMEMBER THAT -
9. Special care should be taken to avoid snatch or sudden loads
REMEMBER THAT -
S K No. 1838
APPENDIX – F
FOR 140 TONNE DSL HYD CRANECOWANS SHELDON
A METAL LIABLE TO BE
ATTACHED STATING BY LINK (MAT : EN -14 A)
STAMPING S.W.L. 70 T MAX. 0-900
ORDINARY THIMBLE
SINGLE PART SPLICED ENDLESS SLING
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)

FOR 140 TONNE DSL HYD. CRANE CALC WEIGHT PER SLING - 375 KG.
COWANS SHELDON
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
25 TONNE S.W.L. HOOK

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.
FOR 140 TONNE DSL HYD. CRANE
COWANS SHELDON
RING 250 T/DIA.
A METAL LABLE TO BE ATTACHED MATERIAL 90 D A
STATING 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
6/36 CONSTRUCTION
PROOF LOAD AT 00. TO 50 TONNE

ORDINARY THIMBLE

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
ORDINARY THIMBLE
70 TON S.W.L. HOOK

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.)
COWANS SHELDON
CALC. WEIGHT PER SLING-465 KG.

STATING BY STAMPING
S.W.L. 50 T MAX.
LINK (MAT: EN -14 A)
ORDINARY THIMBLE
DOUBLE PART SPLICED ENDLESS

SLING ø 64 ROPE
6/49 CONSTRUCTION STEEL CORE
5M
ORDINARY THIMBLE
50 TON S.W.L. HOOK

TO BS : 2903-SEE ITEM 'K'
PROOF LOAD TO 81 TONNE
ITEM -D SINGLE LEG WIRE ROPE SLING TO BS: 1290 – ( 4 Nos. REQD.)
COWANS SHELDON
CALC. WEIGHT PER SLING-465 KG.

STATING BY STAMPING
S.W.L. 70 T MAX.
SOFT EYE
ø 76 ROPE -STEEL CORE

6/49 CONSTRUCTION
SOFT EYE
PROOF LOAD TO 140 TONNE
ITEM -E SINGLE LEG WIRE ROPE SLING TO BS: 1290 – ( 2 Nos. REQD.)
Technical Specification for procurement of Wire Rope Slings for 140T Diesel Hydraulic
Crane of Gottwald Make
70 ton Double Leg Wire Rope Sling (DRG No. : IWDH 140 CR-9. 2.80071431-4) :- 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 2.7701.0087-2.
OVAL LINK
DIMENSIONS – 80 X 270 X 500 mm
ROPE
TYP 8X41 WS SE zn 1960
NOMINAL DIA. 68 mm
HOOK AND HOOK SECURITY SIMILAR AS PER

DIN 7540
NOMINAL SIZE 34
WITH WELDED LINK 65X120X250 mm
PRESSING AS PER DIN 3093
30 Ton Double Leg Wire Rope Sling (DRG No. : IWDH 140 CR-9. 2.80071432-4) :- 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 2.7701.0087-2
OVAL LINK
DIMENSIONS- 57 X 250 X 400 mm
ROPE 48 DIN 3064 SE 1770

HOOK TYP NO. 03.627.290
70 Ton Single Leg Wire Rope Sling (DRG No. : IWDH 140CR-9. 2.80071433-4):- 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
2.7701.0087-2
OVAL LINK
DIMENSIONS- 75 X 200 X 400 mm
ROPE
ENDLESS, GRUMMET TYP 7 X 36 WS SE bk 1770
NOMINAL DIA. 72 mm
HOOK SIMILAR AS PER DIN 7540

NOMINAL SIZE 35
WITH WELDED LINK 65 X 120 X 250 mm
50 Ton SINGLE LEG WIRE ROPE SLING (GOTTWAD)
(DRG No. : IWDH 140 CR-9 2.8007.1434)
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 2.7701.0087-2.
OVAL LINK
DIMENSION 68 X 250 X400

ROPE ENDLESS GRUMMT TYP
CONSTR. 7 X 6 X 36 WS SE bk 1770
NOMONAL DIA. Ø 60 mm
HOOK SIMILAR AS PER DIN 7540
NOMINAL SIZE 34
WITH WELDED LINK
70 Ton WIRE ROPE SLING (GOTTWALD)
[ DRG No. : IWDH 140 CR-9 2.8007.1435-4 ]
Special Draw-bar wire-rope sling 70 t capacity each,

4 m long suit Ramshorn hook 2.7701.0087-2
ROPE 57 DIN 3064 SE bk 1770
PRESSING AS PER 3093
25 Ton 4-LEG WIRE ROPE SLING (GOTTWALD)
[ DRG No. : IWDH 140 CR-9 2.8007.1436 ]
4 leg wire-rope sling 25 t capacity 4 m long for handling

bogies.
OVAL LINK
DIMENSIONS 54 X 250 X 400 mm
ROPE 28 DIN 3066 FE bk 1770

HOOK AS PER DIN 7540
NOMINAL SIZE 6.3
5 Ton DOUBLE LEG CHAIN SLING (GOTTWALD)
[ DRG No. : IWDH 140 CR-9

2.7503.0020-4 ]
Double leg chain slings grade M

complete with hook at one end and
oblong link at the other end each
certified for 5 t safe working load at an
included angle 90º, 4 m long to suit
auxiliary hook 2.7700.0143-3
SLING ROPE (GOTTWALD)
[ DRG No. : IWDH 140 CR-8 2.3007.1448-4 ]
BREAKING LOAD MIN. 2100 Kn

SPLICED
12000
WIRE ROPE CLAMP
BREAKING LOAD
MIN. 2100 KN
Technical Specification for procurement of 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 fogings (First revision)
(*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, sothat 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
4.1.1.1 The wire rope used in the manufacture of single part spliced sling legs shall
consist of 6 round strands over a steel core, right hand ordinary lay, galvanised
and shall conform to IS:2266-1977 with wire of tensile designation 1770.
4.1.1.2 Suitable construction of wire rope shall be selected to provide increased
flexibility.
4.1.1.3 The safe working load shall not one-sixth of the minimum strength of wire rope
4.1.1.4 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
the size of the rope, and securely spliced thereto.
4.1.3 Hooks:
4.1.3.1 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 alongwith necessary strength calculations. The hook shall be
fitted with a safety device to prevent displacement of the load.
4.1.3.2 The tolerances of drop-forged hooks shall be as given in IS: 3469-1974.
4.1.3.3 All hooks shall before proof testing, be normalized by heating to a temperature
within 50 degrre above the upper critical point of the steel used, followed by
cooling in still air.
4.1.3.4 Proof testing of hook shall conform to clause 9 of IS:2759-1969.
4.1.3.5 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.
4.1.3.6 The inspection, certificate of test and examination shall be as per clause 11 of
IS:2759-1969.
4.1.3.7 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 effectively
served with spun yarn or sezing strand to give protection to the user in handling.
4.2 Oblong Link:
4.2.1 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 alongwith necessary strength calculatuions.
4.2.2 The oblong link shall be normalized.
4.2.3 the tolerances on dimensions shall be as specified in IS: 2760-1980.
4.2.4 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 exeed 1% of its mean breadth.
4.2.5 the procedure of testing of oblong link shall be as indicated in clause 11 of IS:2760-
1980.
4.2.6 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 alongwith construction,
size and weight of wire rope, identifying details of deviations if any.
6.0 Inspection:
The wire rope slinbgs 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 suitabily packed to avoid damage during transit.
Wire Rope Slings for 140 t Crane (Cowans Sheldon)
FIG-A FIG-B FIG-C
ANNEXURE-I
S.N Description Ref. Type Capaci Length Qty/ Proof/ Load/Leg

Fig. ty Crane Link
1 2 3 4 5 6 7 8 9
1.0 Double leg A Single part 70 ton 6M 02 140 t 81.0 t
Sling spliced
2.0 Double leg A Single part 50 ton 7M 02 100 t 71.7.0 t
Sling spliced
Sling spliced
Sling spliced
5.0 Single leg B Endless 70 ton 6M 04 140 t 105.4 t
Sling Grommet
6.0 Single leg B Endless 50 ton 5M 04 100 t 81.0 t
Sling Grommet
7.0 Special draw C -- 70 ton 6M 02 -- 70.0 t
bar sling
Annexure-II
LOCATION OF ACCIDENT RELIEF TRAINS [ ARTs ] ON IR
Railway Class Nos. Divisions/Depots

CR A 06 Kurla, Bhuswal, Manmad, , Ajni, Daund, Miraj Jn.,
B 05 Kalyan, Igarpuri, , Amla, Wardha, Wadi
SP 00 Nil
NCR A 03 Jhansi, Agra, Kanpur,
B 02 Allahabad, Banda
SP 00
WCR A 06 Jabalpur, New Katni Jn., Kota, Itarsi, Bina, Gangapur City,
B 02 Bhopal, Bokaro Steel City,
SP 00
ER A 03 Howrah Loco Shed, Asansol, Sahibganj,
B 06 Bandel Jn., Rampur Hat, Belighata, Ranaghat Jn., Andal Jn., , Malda Town,
SP 02 Burdhman, Beliaghata
ECR A 09 Samstipur, Sonpur, Dhandbad, Mughalsarai, Jhajha, Barwadih, Saharsa,
Darbhanga, Narkatiaganj
B 08 Danapur, Barka Kana, Gomoh Jn., Chopan Jn., Pathardih Jn., Gaya, Dehri On
Sone, Barauni Jn.
SP 00
NR A 09 Delhi, Ludhiana, Pathankot, Lucknow, Moradabad, Rosa, Ambala, Bhatinda,
Rewari,
B 04 Tundla, Ferojpur, Amritsar, Faizabad,
SP 01 Saharanpur.
NWR A 06 Jaipur, Jodhpur, Lalgarh Jn., Churu Jn., Hanumangarh Jn., Abu Road,
B 02 Suratgarh, Samdhari Jn.
SP 01 Merta Road
NER A 08 Bareily City, Kasganj, Lucknow, Goarakhpur, Mailani, Gonda, Chhapra
Kacheri,
B 02 Gonda, Mau.
SP 01 MUV
NFR 12 New Guwahati, Lumding (MG), Katihar(MG), New Jalpaiguri,
A Badarpur(MG), Tinsukia, Ragapara(MG), Alipurduar(MG), Katihar,
Lumding, Silguri(MG), New Guwahati(MG)
B 01 New Bongaigaon
SP 00 Nil
SR 11 Arakkonam, Tiruchirapali(MG), Villupuram Jn. (MG), Madurai,
A Madurai(MG), Sengottai(MG), Pollachi(MG), Erode, Shoranur Jn., Quillon,
Quillon(MG)
B 12 Basin Bridge, Tondiarpet, Marshalling Yard, Jolarpettal, Chennai Egmore,
Tiruchirapalli, Villupuram, rsikere, Manglore, Trivendram, Emakulam
Marshalling Yard
SP 00 Nil
SWR A 04 Hubli, Mysore(MG), Banglore, Gadag Jn. (MG).
B 01 Castle Rock.
SP 00
SCR A 10 Secunderabad, Kagipet, Purna, Gooty, Vijaybada, Rajahmundry, Akola(MG),
Nizamabad(MG), Guntakal(MG), Pakala(MG),
B 05 Bellampalli, Kacheguda, Guntakal, renigunta, Bitragunta.
SP 02 Secunderabad, Vijaywada.
Railway Class Nos. Divisions/Depots
SER A 07 Adra, Hatia, chakradharpur, Bondamunda, Kharagpur, Kantabanji, Kirundal.
B 04 TATA, Dongapushi, Santragachi, Jharsuguda.
SP 01 Jharsuguda.
ECOR A 03 Khurda Road, Sambhalpur, Visakhapatnam.
B 06 Talcher, Palasa, Bhadrak, Koraput, Rayagada, Cuttack.
SP 01 Cuttack.
SECR A 05 Bilaspur, Nagpur, Bhilai, Shadol, Gondia,
B 00
SP 00
A 13 Udhna Jn., Vadodara, Kankaria, Ratlam, Rajkot, Mhow(MG), Nimach(MG),
WR Gandhidham(MG), R Pratapnagar(MG), Phulera(MG), Sabarmati(MG),
Bhavnagar(MG), Jetalsar Jn.(MG).
B 02 Valsad, Ujjain,
SP 01 Bandra
Indian A 115
Railway
B 60
SP 10
Total 185
LIST OF BG ARMVs
Railway Nos. Divisions/Depots
CR 11 BYCULLA(BY), KALYAN(KYN), IGATPURI(IGP), BHUSAWAL(BSL),
AJNI(AQA), AMLA(AMF), WARDHA(WR), SHOPAPUR(SUR), DAUND(DD),
WADI, MIRAJ(MJR).
NCR 05 JHANSI(JHS), AGRA(AGC), BANDA(BNDA), ALLAHABAD(ALD),
KANPUR(CNB).
WCR 08 BHOPAL(BPL), ITARSI(ET), BINA(BNA), JABALPUR(JBP), NEW
KATNI(NKJ), BOKARO STEEL CITY(BKSC), KOTA(KTT), GANGAPUR
CITY(GCC).
ER 09 CHOPAL(CPU), HOWRAH(HWH), AZIMGANJ(AZ), ASANSOL(ASN),
MALDA TOWN(MLDT), SAHIBGANJ(SBJ), JAMALPUR(JMP),
BELIAGHATA(BGA), RANAGHAT JN (RHA).
ECR 08 MUGHALSARAI(MGS), GAYA(GYA), JHAJHA(JAJ), DANAPUR)(DNR),
DHANBAD(DHN), BARWADIH(BRWD), BARAUNI(BJU), SONPUR(SEE).
NR 14 DELHI(DLI), AMBALA(UMB), BHATINDA(BTI), SAHARANPUR(SRE),
FIROJPUR(FZR), AMRITSAR(ASR), LUDHIYANA(LDH),
PATHANKOT(PTK), MORADABAD(MB), ROSA(RAC), LAKSAR(LRJ),
TUNDLA(TDL), LUCKNOW(LKO), FAIZABAD(FD).
NWR 07 SURATGARH(SOG), JODHPUR(JU), MERTAROAD, ABU ROAD(ABR),
AJMER(ALI), JAIPUR(JP), BANDIKUIN(BKI).
NER 04 GONDA Jn.(GD), MAU Jn.(MUJ), CHAPRA(CPR), GPORAKHPUR(GKP).
SR 14 CHENNAI CENTRAL, ARAKKONAM(AJJ), JOLARPETTAI(JTJ),

ERODE(ED), TONDIARPET(TNPN), NADYRAU(MDU), ARSIKERE(ASK),
SHORANUR(SRR), MANGLORE(MAQ), ERNAKULAAM(ERS),
TRIVENDRAM(TVC), QUILON(QLN), ARSIKERE, HARIHAR.
SCR 11 HUBLI(UBL), GHORPUR(GPR), CASTLE ROCK(CLR),
SECUNDERABAD(SC), KAJIPET(KZJ), VIJAYBADA(BZA), RAJA
HMUNDRI(RJY), BITRAGUNTA(BTTR), PURNA(PAU), GOOTY(GY).
SER 10 ADRA(ADA), HATIA(THE), CHAKRADHARPUR(CKP),
BONDAMUNDA(BNDM), BONGAPOSI(DPS), TATANAGAR(TATA),
KHARGPUR(KGP), SANTRAGACHI(SRC), BONGARAGARH(DGG), KANTA
BANJI(KBJ).
SWR 02 BANGLORE(SBC), MYSORE(MYS),
SECR 04 BILASPUR(BSP), BHILAI(BIA), SHADOL(SDL), NAGPUR(NGP).
ECoR 06 KHURDA ROAD(KUR), BHADRAK(BHC), PALASA(PSA),
SAMBALPUR(SBP), KORAPUT(KRPU) VISHAKAPATNAM(VSKP).
WR 10 VALSAD(BL), UDAN(UDN), MUMBAI CENTRAL(MCT), VADODARA(BRC),
AHMEDABAD(ADI), RATLAM(RTM), UJJAIN(UJN), RAJKOT(RJT),
HAPA(HAPA), PORBUNDER(PBR).
Total 129
Annexure-IA
LIST OF MG ARMVs
CR
ER
NR 01 REWAR(RE).
NWR 04 Churu(CUR), Hanumangarh(HMH),Lalgarh(IGH), Samdhari(SMR).
NER 08 Bareily(BC), Kasganj(KSJ), Pilibhit(PBE), Lucknow(LKO), Mailani(MLN),
Gorkhpur(GKP), Gonda(GD), Chhapra Kacheri, (CI).
ECR 04 Samastipur(SPJ), Darbhanga, Narkatiaganj(NKE), Saharsah(SHC).
NFR 6 Alipurdwar(APDJ), Ragapara(RPAN), Badarpur(BPB), Katihar(KIR),
Lumding(lmd), Siliguri(SGPT)
SR 6 Tiruchirapali(MG), Mayaladuttrai, Villpuram, Madurai, Lsengottai, Quilon.
SCR 5 Nizamabad(NZB), Akola(A), Guntakal(GTL), Pakala(PAK), Gadag(GDG).
SER 0
WR 09 Sabarmati(SBI), MHOW(MHOW), Parel (PL), Ghandidham((GIM),
Ranapratapnagar(RPZ), Palanpur (PNU), Bhavnagar (BVP), Jetalsar (JLR),
NCR 01 IDGAH(IDH),
NWR 01 Chittaurgarh (COR).
Total 45
CHAPTER - 2
OPERATION OF 140 Te.

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

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

Winches
12 Out rigger 06 04 04 04
13 Out rigger Pull out type Swing out type Swing cylinder Swing cylinder
arrangement
14 Main Engine Cummins Cummins Cummins tilted Cummins tilted
NT-743P NT-855 NTA-855 R NTA-855 LBC
295 HP 350 HP 340 HP 340 HP
15 Main Engine 2100 rpm 2100 rpm 800-1800 rpm 800-1800 rpm
RPM
16 Brakes Mechanical TBU Disc brake Disc brake
linkage
17 “A” Frame Tie cylinders Folding linkage Folding linkage Folding Gallows
18 Counter 32,12,1.5 Te. 7/ 7.9, 22.6 Te. 52,18,6,14 Te. 24,15,8 Te.
weight
19 Drivers cabin Side Side Centre Centre
20 Counter weight Beam lift jack Gallows Gallows Gallows

fastening
21 Aux. Engine Ruston MK- Lister Peter Different Kirloskar HA294
IV/KOEL TA2
2.0 140 Te. DIESEL HYDRAULIC CRANE (Cowans Sheldon New )
TECHNICAL DATA:
01. 140 Te. Diesel Hydraulic Crane Make : COWANS SHELDON (England)
02. Main Hoist Lifting Capacity : Max. 140 T
03. Aux. Hoist Lifting Capacity : Max. 25 T
04. Hauling Capacity : Max. 10 T
05. Max. Travelling Speed without load : 20 KMPH
06. Max. Travelling Speed with load : 6 KMPH
07. Main Engine Make : Cummins India Ltd.
08. Main Engine HP : 360 HP
09. Main Engine Model No. : NTA 855 C
10. Aux.Engine Make : Lister Petter
11. Aux.Engine HP : 15.6 kw
12. Aux.Engine Model No. : LPA 3
13. Length of Crane over buffers : 13 meters
14. Total length including match truck : 28 meters
15. Crane Height above Rail Level : MMD according (EDO/T1043)
16. Crane width : MMD according (EDO/T1043)
17. Derrick wire Rope length : 317 meters; 32mm dia.
18. Main Hoist wire Rope length : 286 meters; 32mm dia.
19. Aux. Hoist wire Rope length : 113 meters; 22mm dia.
20. Hauling winch wire Rope length : 64 meters; 20mm dia.
21. Crane Max. Speed with ART : 90 KMPH
22. Weight of Crane in working order : 162/170 T (STD/HD CWT)
23. Weight of Crane in running order : 120 T
24. Match Truck Weight in running order : 80 T
25. Weight of standard duty CWT : 22.610+6.735 T (29.345T)
26. Weight of heavy duty CWT : 7.9 T (Total 37.245T)
27. Weight of special duty CWT : 6.735 T (+22.61 T on under carriage)
28. Jib complete weight : Not available
29. Axle load (R/B in loaded condition) : 20 T
30. Main Hoist Max. lift above Rail level : 13 meters
31. Main Hoist Max. lower below Rail level : 3 Anchor turns
32. Aux. Hoist Max. lift above Rail level : 17 meters
33. Aux. Hoist Max. lower below Rail level : 3 Anchor turns
34. JIB Min. Radius : 5.5 meters
35. Main Hook Hoist max. speed : 8 meters per minute
36. Aux. Hook Hoist max. speed : 15 meters per minute
37. Crane Slew maximum speed : 360 o in 2 minutes (0.5 rpm)
38. Haul in Max. speed : 30 meters per minute
39. No. of Travelling Motors : 02 Nos. Hydraulic Motors
40. Propping base : 6.0 m / 5.0 m / 3.4 m
41. Emergency Lowering : Facility not available
3.0 140 Te. DIESEL HYDRAULIC CRANE (Cowans Sheldon
Old)
TECHNICAL DATA:
01. 140 Te. Diesel Hydraulic Crane Make : COWANS SHELDON (England)
02. Main Hoist Lifting Capacity : Max. 140 Te.
03. Aux. Hoist Lifting Capacity : Max. 25 Te.
04. Hauling Capacity : Max. 5 Te.
05. Max. Travelling Speed : 12 KMPH
06. Slow Travelling Speed : 6 KMPH
07. Main Engine Make : Cummins India Ltd. Pune
08. Main Engine HP : 295 HP
09. Main Engine Model No. : NT 743
10. Aux. Engine Make : Ruston/ KOEL
11. Aux. Engine HP : 14.6 HP
12. Aux. Engine Model No. : 1 YWA
13. Crane Carriage Length : 12.6 meters
14. Crane Height above Rail Level : 4.265 meters
15. Crane width : 3.2 meters
16. Derrick wire Rope length : 271 meters
17. Derrick Tie wire Rope length : 09 meters
18. Main Hoist wire Rope length : 282 meters
19. Aux. Hoist wire Rope length : 118 meters
20. Hauling winch wire Rope length : 60 Meters
21. Crane Max. Speed with ART : 75 KMPH
22. Crane Tare weight : 182 Te.
23. Relieving Bogie Tare weight : 10.8 Te.(each)
24. Match Truck Weight : 31.758 Te.
25. Ballast wagon weight : 30.530 Te.
26. Heavy Ballast weight : 32.205 Te.
27. Counter weight : 12.558 Te.
28. Jib complete weight : 9.976 Te.
29. Axle load (R/B in loaded condition) : 20 Te.
30. Main Hoist Max. lift above Rail level : 13 meters
31. Main Hoist Max. lower below Rail level : 4 meters
32. Aux. Hoist Max. lift above Rail level : 7 meters
33. Aux. Hoist Max. lower below Rail level : 3 meters
34. JIB Min. Radius : 5.5 meters
35. Main Hook Hoist speed : 3 meters per minute
36. Aux. Hook Hoist speed : 15 meters per minute
37. Main Hook Emergency lower : 5 Meters per minute
38. Crane Slew maximum speed : 360 o in 2 minutes (0.5 rpm)
39. Haul in Max. speed : 30 meters per minute
40. No. of Travelling Motors : 02 Nos. Hydraulic Motor
4.0 TECHNICAL DATA OF 140 Te. DIESEL HYDRAULIC CRANE

(GOTTWALD NEW)
Dimension:
1. Track Gauge : 1676 mm
2. Rim Diameter : New condition: 920 mm
Wear limit : 840 mm
3. Wheel set arrangement : (2A) (A2)
4. Distance between bogie pivots : 7500 mm
5. Distance between twin wheel set : 3000(1500) mm
6. Length ahead of buffer : 13290 mm
7. Draw and buffing gear : side buffers and screw couplings
8. Minimum travel curve : 175 mm
9. Maximum towing speed : 100 Kmph
10. Maximum wheel set load : 200 Kn
11. Total Weight in train formation : 120 Te.
12. Height in transport position : 3900 mm
13. Width in transport position : 3100 mm
14. Elevated curves : 140 mm
Brake System:
01. Primary : Dual-VD-P-12X10m.Z.
02. Secondary : 12 wheel disc-operated brakes # 780 mm
03. Parking brakes : spring-loaded brakes on 6 wheel sets
Out riggers:
01. Base : 11.6 m x 6.0 m
02. Maximum support force : 2200 Kn
03. Out rigger cylinder : stroke 500 mm
04. Free on wheels base : 7.5 mm x 1.7 mm
05. Maximum wheel force : 350 Kn
Travel Gear
01. Driven wheel sets on each bogie : 01
02. Speed : 20 Kmph
Super structure
01. Cab : 1 seat/and 1 emergency seat
02. Over-Rear radius : 5.5 m/6.5 m
Diesel Engine
01. Type : Cummins NTA-855
02. Model : 6 cylinders in series
Water cooled
Exhaust turbo charger
03. Out put : 205 Kw AT 1800 RPM
04. Torque : 1158 nm at 1400 rpm
05. Cubic capacity : 1400 ccm
06. Fuel supply : 900 L.
07. Generator : 28 V, 55 A
Emergency Diesel Engine

01. Type : Kirlosker HA-294
02. Model : 2 cynder in series
Air cooled, exhaust turbo charger
03. Out put : 16.9 Kw at 1800 rpm
04. Cubic capacity : 1884 ccm
Main Hoist
01. Type : Three stage planetary hoist with
spring loaded multi disc brake
02. Rope diameter : 26 mm
03. Rope speed : Max. 72 m/min.
04. Hoist speed : Max. 04 m/min.
05. Hook block : 18 strand, 140 t
06. Hoist range : above track : 17.0 m
Below track : 04.0 m
Auxiliary Hoist
01. Type : Two stage planetary hoist with spring
loaded multi disc brake
06. Hoist range : above track: 18.0 m
Below track: 03.0 m
Slewing Gear
01. Type: Three stage planetary hoist with spring loaded multi disc
brake, Roller slew ring with external teething
03. Super structure speed : 0-1.0 rpm
Derricking Gear
02. Rope Diameter : 26 mm
04. Derricking time : Approx. 165 sec.
05. Rope Tension : 2 X 14 strand, 2200 Kn
Counter Weight
01. 03 sections
02. Slab-1(transported on the match truck) : 24 Te.
03. Slab-2 (Transported on the match truck) : 15 Te.
04. Slab-3 (Transported on the under carriage) : 08 Te.
Boom
01. Length to the main hook : 18.75 mts.

02. Length to the Auxiliary hook : 19.5 mts.
03. Main hook working range : 5.5 m-17.0 m
04. Auxiliary hook working range : 6.5 m- 18.0 m
Match Truck
01. Length beyond buffer : 16.0 m

02. Distance between wheel sets : 2.0 m
04. Distance between bogie pivots : 11.30 m
05. Draw and Buffing Gear : side buffers & screw
couplings
06. Turning radious : 175 m
08. Max. wheel set load : 200 Kn
09. Total weight: Loaded : 80.0 T
5.0 TECHNICAL DATA OF 140 Te. DIESEL HYDRAULIC CRANE
(GOTTWALD OLD)
Dimension:

2. Rim Diameter : New condition:915 mm
a. Wear limit : 860 mm
3. Wheel set arrangement : (2A) (A2)
4. Distance between bogie pivots : 7500 mm
5. Distance between twin wheel set : 1500 mm
6. Length ahead of buffer : 13300 mm
7. Draw and buffing gear : Hinged buffers and screw couplings
8. Minimum travel curve : 174 mm
10. Overall weight : 200 t
11. Crane Weight in train formation : 120 Te.
12. Height in transport position : 3950 mm
13. Width in transport position : 3000 mm
14. Axle load in running order : 20 t
15. No. of vehicle. in running order : Crane with two 3 axle bogie + Match
truck with two 2 axle bogie
Brake System:
1. Primary : Dual-VD-P-12X10m.Z.
2. Secondary : 12 wheel disc-operated brakes # 780 mm
3. Hyd. Parking Brake : For Crane 142032 to 043 & 143001,02
4. Pneumatic Parking brake : For Crane 143003 to 143010
Out riggers:
1. Base ( Full propping) : 11.8 m x 6.0 m

2. Maximum support force : 2200 Kn
3. Out rigger cylinder : stroke 500 mm
4. Maximum wheel force : 350 Kn
Travel Gear
1. Driven wheel sets on each bogie : 01

2. Speed- Without load/With load : 12 Kmph/6kmph
Super structure
1. Cab : 1 seat/and 1 emergency seat
2. Over-Rear radius : 5.5 m/6.5 m
Diesel Engine
1. Type : Cummins(NTA-855R4)/CIL(NTA-855R-FPC)
2. Model : 6 cylinders in series
Water cooled
Exhaust turbo charger
3. Out put : 224 KW AT 1800 RPM
4. Torque : 1158 nm at 1400 rpm
5. Generator : 28 V, 55 A
1. Type : Kirlosker-TA 2/ Schule-TAF 2
2. Model : 2 cynder in series
Air cooled
3. Out put : 10.5 KW at 1800 rpm
Main Hoist
4. Hoist speed : 2.5 m/min- 5 m/min.
6. Hoist range : above track : 16.5 m
Below track : 04.0 m
Auxiliary Hoist
1. Type : Two stage planetary hoist with spring
6. Hoist range : above track: 17.8 m
Below track: 03.0 m
Slewing Gear
1. Type: Three stage planetary hoist with spring loaded multi disc brake,
Roller slew ring with external teething.
2. Super structure speed : 0-1.0 rpm
Derricking Gear
2. Rope Diameter : 26 mm
4. Derricking time : Approx. 90 sec.
Hauling Winch Capacity :5t
Counter Weight
1. Standard duty : 29.2 Te.(5.2+6+18)

2. Heavy Duty : 43.2 Te. (29.2+14)
Jib
1. Length to the main hook : 18.00 mts.

2. Length to the Auxiliary hook : 18.85 mts.
3. Main hook working range : 5.5 m-16.0 m
4. Auxiliary hook working range : 6.5 m- 17.0 m
Match Truck
1. Length over buffer : 15.97 m

2. Distance between wheel sets : 2.0 m
4. Distance between bogie pivots : 11.30 m
5. Draw and Buffing Gear : Hinged buffers & screw
couplings
6. Turning radius : 174 m
8. Max. wheel set load : 20 t
Brake System of Match truck Air Brake, Parking brake
1. For Crane No. 142032 to 142037 : Disc Brake

Hydraulic Brake
2. For Crane No. 142038 to 142043 : Tread Brake
Mechanical Hand Brake
3. For Crane No. 143005 to 143010 : Tread Brake
Mechanical Hand Brake
4. Lifting Beam Capacity : 2 nos.- 140 t, 70 t
5. Compressor : SAB WABC Axle
mounting recipro, 7.2 bar
6.0 140 t. Crane Specification with comparison between Old and
New Gottwald cranes:
Sr
Item Old Design (1986) New Design (1997)
No
 Model No 1WDH 3WDH
MP-MISC-118 MP-MISC-119
 RDSO Document reference number
(Rev-0.00) (Rev-0.00)
 SPECIFICATIONS
1 Track Gauge 1676 mm 1676 mm
2 Length Of Crane Over Buffers 13300 mm 13300 mm
3 Length Of Match Truck Over Buffers 15970 mm 16000 mm
4 Overall Length 29270 mm 29300 mm
5 Width Of Crane 3000 mm 3100 mm
6 Width Of Match Truck 3000 mm 3000 mm
7 Min Track Curvature 174 m radius 174 m radius
8 Max Height Of Crane From Rail Level. 3950 mm 3900 mm
9 Overall Weight 200t 200t
10 Axle Load In Running Order 20t 20t
11 Tail Radius 5.5 m 5.5m, 6.5m
12 Propping Base 6m, 2.7m 6m, 5m, 2.9m
18 m long Box section 18.75 m long Box
13 Jib/Boom
(Octagonal) section (Rectangular)
 WHEEL
915 (new), 920 (new),
1 Wheel Dia (CRANE)
860 (cond) 840 (cond)
915 (new), 1000 (new),
2 Wheel Dia (MATCH-TRUCK)
860 (cond) 906 (cond)
 COUNTERWEIGHT
4 pieces: 3 pieces:
1 Counterweight
5.2T, 6T, 14T, 18T 8T, 15T, 24T
29.2t 47t at 5.5m
2 Standard Duty
(5.2 + 6 + 18) (24 + 15 + 8)
43.2t 47t at 6.5m
3 Heavy Duty
(29.2 + 14) (24 + 15 + 8)
 SELF TRAVEL SPEED
1 Travel With Load 6 km/h 6 km/h
2 Travel Without Load 12 km/h 20 km/h
Hauling Speed 100 kmph

3 100 kmph
(after high speed modification)
PAT, Germany/ Amrita
PAT, Germany,
 Safe Load Indicator Lakshami Electronics,
Mechanica Systems
Mechanica Systems
S
N
 CAPACITY / RANGE
1 Hauling Winch Capacity 5t 5t
2 nos. 2 nos.
2 Lifting Beam Capacity
140T & 70T 140T & 70T
Main (Ramshorn) - 140t Main (Ramshorn) - 140t
3 Hooks
Auxiliary - 25t Auxiliary - 25t
Working Radius Main Maximum - 16 mtr Maximum – 17mtr Minimum
4
Hoist Minimum - 5.5 mtr - 5.5 mtr
Working Radius Aux Maximum - 17 mtr Minimum Maximum - 18 mtr
5
Hoist - 6.5 mtr Minimum - 6.5 mtr
Range Of Lift Above rail level - 16.5 mtr Above rail level - 17 mtr Below
6
(Main Hoist) Below rail level - 4 mtr rail level - 4 mtr
Range Of Lift Above rail level - 17.8 mtr Above rail level - 18 mtr Below
7
(Aux Hoist) Below rail level - 3 mtr rail level - 3 mtr
140 T at 8 m radius, 360 degree
Max Capacity For Full 140 T at 8 m radius, slewing. Load moment
8
Propped And Full Cwt. 360 degree slewing calculations and load charts are
different.
 CRANE MOTION AND SPEEDS
60 Sec from 165 sec
1 Derricking
max to min radius from max to min radius
2 Slewing 1 RPM 1 RPM
3 Main Hoist Lifting 2.5 Mtr. / min. 4 Mtr. / min.
Main Hoist Rapid

4 5 Mtr. / min. 8 Mtr. / min.
Lowering
5 Auxiliary Hoist Lifting 15 Mtr. / min. 15 Mtr. / min.

Auxiliary Hoist Rapid
6 30 Mtr. / min. 30 Mtr. / min.
Lowering
Sr.
No
BRAKE SYSTEM:
Air brake, Vacuum brake & Air brake, Vacuum brake &
1 Brakes crane
Parking brake (disc type) Parking brake (disc type)
SAB WABCO, axle mounted,

reciprocating, fitted inside the
SAB WABCO, bogie, driven by pinion meshed
axle mounted, reciprocating, with the bull gear
2 Auxiliary compressor
mounted outside, driven by Note - Mounting
belt drive- 7.2 bar. arrangement for same is
provided but aux. Comp. not
installed by JMP
 MAIN DIESEL ENGINE
1 Make Cummins Cummins
2 Type NT 855 - R4 NTA 855 - LBC
3 Mounting Horizontal Vertical
4 Horse power 285 hp (224 kW) 263 hp (205 kW0
5 No of cylinder 6 6
6 Bore & stroke (mm) 140 X 152 140 X 152
7 Compression ratio 14.1:1 14.1:1
8 Lube oil sump capacity 28.2 liters 43 liters
9 RPM 2100 1800
10 Fuel tank capacity 1000 liters 900 liters
 AUXILIARY DIESEL ENGINE
1 Make Schule Kirlosker
2 Type TA 2 HA 294
3 Horse power 14 hp (10.5 kW) 23 hp (16.9 kW)
4 RPM 1800 1800
 GENERAL FEATURES
Crane with two 3 axle Crane with two 3 axle bogies
No. of vehicles in
1 bogies + Match truck with + Match truck with two 2 axle
running order two 2 axle bogies bogies
2 Outriggers Swing out type, 4 nos. Swing out type, 4 nos.
3 Suspension crane Helical & disc spring Helical & disc spring
4 Suspension match truck Coil spring Coil spring
In place of 'A' frame, gallows
and bigger bridle of the old
5 Rear Superstructure ‘A’ frame available
design a single frame for
suspending CWT.
permit the counterweight
6 Gallows Fixed cwt. radius assembly to be placed at 5.5 or
6.5 Mtr radius
Sr.
No
3 - stage planetary hoist with
Roller bearing type slewing spring loaded multi-disc brake
7 Slewing arrangement
ring with internal spur gear roller slewing ring with
external teething
one single tank fitted in the
two internally connected tanks
8 Hydraulic oil tank rear portion of the
just behind the cab
superstructure
annular shaped tank above box shaped tank in the rear
9 Fuel tank
the slewing ring portion of the superstructure
No. of pulleys in main
10 8 9
hoist
 CONTROLS:
All control in cab, All controls in the rear of the
1 Counterweight
Single lever operation crane, three levers for control.
Separate lever for main and Single joystick for main and
2 Hoists
auxiliary hoists auxiliary hoists
Switch on the top of joystick

3 Rapid motion switch Foot operated
for hoist operation
7.0 POPULATION OF 140 T CRANES ON IR:
Total 140 T Break Down Cranes are 74 numbers available over Indian
Railways as on date and design wise population is as follows:-
GOTTWALD NEI (COWANS)/JESSOP

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

(NEW DESIGN) (NEW DESIGN)
36 NOS 04 NOS
8.0 Special Safety Precautions for Crane Operators
To understand the crane and operate the crane efficiently and safely, the operating
personnel should follow the operating and maintenance manuals supplied along with the
cranes. Some salient features (included also in the manuals) which if followed will ensure
safety during operation are highlighted below:
1. Before raising the jib from match wagon, all blocking screws must be screwed
down until locked on the top of the spring.
2. Both the relieving bogies must be unloaded prior to raising the jib from match
wagon.
3. Before any movement of crane on its own power, operator must ensure proper
engagement of travel clutch and braking of travel brake.
4. In the operating area, the operator should assess the cant with the jib in line with
the track. If cant exceeds 13 mm, the crane should be leveled by using props
before load lifting because this crane in free on rail condition is suitable only with
counter weight on carriage. In this condition, there will be clearance in the side
bearers.
5. The operator must be thoroughly acquainted with the load charts provided in the
crane to assess the duty selection.
6. Special care is to be taken during propping of jacks. Packing below footsteps

should be sound and placed, alternately, perpendicular and parallel to the track, to
give maximum load distribution. After applying jacks, packing should be
checked. The load should be lifted slowly just above the ground and held there.
Packing should be checked again to see if there is any sinking.
7. If the crane is to be moved to another position, then the draw beam jacks should
be raised, the footsteps removed, the draw beam retracted and locked in position
before any movement.
8. Before any slew motion, slew lock pin must be removed.
9. Before undertaking any lifting operation, the operator must be sure that the duty
selector of SLI is correctly set according to the configuration of the crane (i.e. free
on rail, or blocked, counter weight on super structure or carriage, heavy ballast
fitted etc.)
10. Extreme caution should be taken while working in super elevated track in free on
rail condition with counter weight or heavy ballast fitted to superstructure.
11. During fitting of heavy duty ballast to the superstructure, heavy ballast must be
raised fully, superstructure must brought in line with the track before introducing
ballast arm in to the heavy ballast, and locating pins must be engaged in the
support beam.
12. Swinging load is dangerous and should be avoided.
13. Emergency lower button should be operated only in case of emergency and the
operation should not be part of the normal working cycle.
14. During coupling of the relieving bogies with the crane, the operator should move
the crane close to the beam and the height and position of the beam should be
adjusted in such a way so that the base of the beam is in line with the carriage end
castings. This will prevent damage of the castings.
15. It is always better to lift the load from match truck end, if the derailment on the
same track. Because in this case the operator has to lift the match truck and
relieving bogie clear of the track. On the ballast wagon side the operator has to
remove the heavy ballast first, then the ballast wagon and one relieving bogie.
For removing either ballast wagon or match truck, lifting beam need not to be
used. The 30 Te. Double legged sling of 7 M long can be used with main hook for
this operation.
16. To reduce timing, operating personal should practice the operation in idle time.
Some operations may be combined to reduce timing i.e while carrying out
blocking out operations of screws, ‘A’ frame should be raised thus saving the
time. Lifting of relieving bogies/ match truck / ballast wagon should be as
minimum as possible above the rail level, before slewing.
17. Since the maximum instantaneous load on an individual prop that may arise with
the crane being loaded to its capacity is around 150 Te., it is essential to prepare
the packing on the ground, using sleeper over wide area in order to prevent sink
age of props. In order to reduce time taken in restoration, it is advisable to take
the help of permanent way staff in leveling the ground and in building up of the
base for props.
18. Please remember that when you travel on own power with load on hook the axle
load on track is much higher than normal. Depute a person to check track for
sinkage and gauge during travel. Insist on PWI to give good attention to track
where necessary.
19. Before traveling the crane on own power, check the brake power. Apply brakes,
engage travel clutch and push the travel joystick for a short time to “Full”
position. If brakes are able to hold the crane, then the brake power is okay.
9.0 IMPORTANT INSTRUCTIONS FOR BREAK DOWN
STAFF
Following instructions must be followed by break down

Incharges, Supervisors and staff while working at accident sites:-
01. After reaching at accident site, observation of site and

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

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

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

operations, ensure that OHE has been made dead /slewed and
secured and power block has been taken providing written
memo.
05. Suitable and sufficient space to be created for propping and

choose the wooden packings of required sizes, so that strong
and sound propping can be ensured.
06. Lifting load must be assessed properly and crane configuration

and radius to be determined accordingly.
07. Always take care of cant/super elevation while lifting the load.
08. Ensure that SLI is in working order.
09. Ensure availability and understanding of load charts.
10. Rail clamp must be used as and when required.
11. Always utilize suitable capacity chain sling and wire rope slings
and insert hooks only at suitable places on the wagons/coaches
during lifting.
12. While lifting the load, close watch to be kept on crane wheels
and the same to be communicated through megaphones
continuously for analyzing & observing the situation.
13. Proper work distribution among staff and supervisors to be

ensured at site to avoid contradiction.
14. Extreme care to be taken while removing and lifting entangled

load. Safety of the staff to be kept in mind during such
operations.
15. The load should be lifted slowly just above the ground level and
held there because swinging load is dangerous and should be
avoided.
16. Utilize wire ropes/chain slings in such a manner, that they are
removed successfully from object after lifting and placing at
suitable place.
17. While slewing the crane 360 with lifted load, keep close watch
and all the precautions for this crane.
18. If the adjacent track is given safe for traffic, safety of staff
must be ensured from running trains by communicating arrival
of trains on megaphone. Always keep Red flag/Red lamp for
emergency.
****
10.0 POINTS TO BE KEPT IN MIND BY DIVISIONS FOR
ACCIDENT MANAGEMENT
(Ref: Addl.M(M)’s letter No.99/M(M&P)/7/6 Dated 11.8.1999)

The following points may be kept in mind by the Divisions for
Accident Management:-
A. For accidents involving Passenger trains, the BD cranes and MFDs in
either direction in the vicinity of the site must immediately be ordered by
the Control as a routine.
B. In case of Goods train accidents involving mainline, the
following procedure should be followed:-
 Movement of 140 Te BD cranes must have the approval of
CMPE/Hqrs who is overall incharge of the management of
ARTs, and in his absence any Mechanical Officer in
Headquarters. In rare cases, where both lines are affected
and when delays in contacting Headquarters are envisaged,
cranes may be ordered by Division, but this should only be
an exception.
 Movement of MFDs can be ordered by the Divisional

Mechanical officers as desired by DRMs.
C. Incase of accidents in Yard not affecting through movement,

the derailment may be tackled using ramps to the extent
possible and MFD/Crane ordered only if the derailment CANNOT
be tackled by Jacks(HRE). This decision may be taken by the
Divisional officers at their discretion depending upon the
information available from site.
D. ARTs should be turned out within the target time of 30 minutes

by day and 45 minutes during night. ARMV should be turned
out within 20 minutes from double entry siding and 25 minutes
from single entry siding during both day and night (zonal
railways may decide target time).
E. Movement of ARTs to the accident spots should be given top
priority and should not be stopped enroute. It is the
responsibility of the Controlling DRM and his Officers that no
slackness is allowed in this regard.
F. ARTs should be moved to the base Depot as soon as the
restoration work is over.
G. For a minor derailment involving a few wagons, as far as
possible MFDs should only be deployed leaving the crane at the
base station in readiness to attend major accidents.
H. Wherever road approach is available, attempt should be made

to take the MFD equipment by road through lorry and for this
purpose, departmental lorry should be earmarked. Wherever
department lorries are not available to move the MFD/HRE,
private lorries may be invariably hired.
I. Wherever MFD/HRE is required to serve both BG and MG

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

test the efficacy and correct any deficiency in the system.
K. Whenever assistance of additional BD crane/MFD is required
from neighbouring division or adjacent Railways. CMPE or any
other HOD of the Mechanical Department will do the necessary
liaison.
***
11.0 SUITABLE WIRE ROPES, CHAIN SLINGS FOR LIFTING OF LOAD
[ For COWANS SHELDON 140 Te. CRANE]
1. Two Leg Wire Rope sling (BS-1290)

Capacity - 70 Te
Requirement - 2 Nos.
Length - 6 Mtrs.
Proof Load - 81 Te/Leg
2. Two Leg Wire Rope Sling (BS-1290)
Capacity - 30 Te
Requirement - 2 Nos. 5 Mtr
Requirement - 2Nos. 7 Mtr.
Proof Load - 42.4 Te
3. Single Leg Wire Rope Sling (BS-1290)
Capacity - 70 Te
Requirement - 4 Nos
Length - 6 Mtrs
Proof Load - 105.4 Te
Capacity - 50 Te
Length - 5 Mtrs.
Proof Load - 81 Te
Capacity - 70 Te
Requirement - 2 Nos
Length - 4 Mtrs.
Proof Load - 140 Te
6. Four Leg Wire Rope Sling (BS-1290)
Capacity - 25 Te
Requirement - 1 No.
Length - 4 Mtrs.
Proof Load - 50 Te
7. Two Leg chain Sling (BS-1290) Capacity - 25 Te
8. Chain Sling (Without hook)-BS-1290)Capacity -10 Te
12.0 SAFETY DEVICES AND FITTINGS IN 140 T DHBD CRANES
(Old Design Cowans Sheldon make)
A. For safe operations of the crane:

1. Automatic Safe Load Indicator
2. Cant Indicators: (a) Driver’s Cab (b) Crane Carriage
3. Mechanical (Radius Indicator on jib.
4. Limit Switches:(a) Main Host (b) Auxiliary Hoist (c) Derrick
5. Emergency Lower
6. Service Brakes for Gear Boxes:
(a) Main Hoist (b) Auxiliary Hoist (c) Derrick
(d) Slew (e) Haul
7. Air Brake System
8. Flood Lights: (a) Jib (b) Front (c) Rear
9. Horn: (a) Low Tone (b) High Tone
10. Windscreen Wiper
11. Rail Clips
B. Safety Checks/Testing Items
1. Wheel Profile
2. Ultrasonic Testing of Axles
3. Examination of Wire Ropes
4. Testing of Lifting Tackles:
(a) Wire Rope Slings (b) Chain Slings
5. Fire Extinguishers
C. Safety fittings on Crane
1. Slew Lock Pin
2. Travel Clutch Indicators
3. Laminated Bearing Spring Blocking Screws
4. Brake Rigging Items
5. Brake Crossbar Safety Straps
6. Hand Brakes
7. Spring Suspension Items
8. Laminated Spring Safety Straps on Axle Boxes
9. Buffers
10. Draft Gears & Screw Couplings
11. Lock Pins for Draw beams
12. Center Casting Lever Lock Pins
13. Retaining/Locking Plates for Counterweight Hanger Bolts
14. Front Window Self Sealing Weather Strip
15. Tumbler Pins for:
(a) Draw Beam Lock Pins (b) Blocking Screws
(c) Hand brakes (d) Lever Lock Pins
(e) Lifting Beams (f) Foot Plates
16. Key Plates
17. Centre Pivot bolts
D. For Safety of Main Engine
1. Low Radiator Water Level Low Mark
2. High Engine Water Temperature 93 ºC
3. Low Engine Lube Oil Pressure Below 1.38
Kg/cm2
4. High Engine Lube Oil Temperature 116 ºC
5. Engine Over speed latched Over speed -
2450 RPM
E. For Safety of Hydraulic system
1. High hydraulic Oil Temperature 70 ºC
2. Hydraulic Filter Block Indicators for
a) Boost Line Filters HE 21= 3 nos. & Filter Blocked
b) Return Line Filter HE 22 = 1 no. Filter Blocked
3. Flushing Valves HE 4
a) HE 2A Main Pump
b) HE 2B Main Pump
c) HE 3 Main Pump
4. Pressure Relief Valves
a) Cross line Relief Valves HE6 for
1. Main Hoist 2. Auxiliary Hoist 3. Derrick
4. Travel 5. Slew 6. Haul
b) Cross line Relief Valves HE 36 for
1. H/L Ballast Extension Beam
2. R/Bogie Coupling Pins = 2
c) Relief Valve HE14 for
1. Oil Cooler Motor
2. Derrick Tie Cylinder
d) Relief Valve HE 29 for Derrick Tie Cylinders
5. Low Boost Pressure Switches HE 31 for
a) Main Hoist
b) Auxiliary Hoist
c) Derrick
6. Non Return Valves
a) HE 27 - for Semi Rotary Hand Pump
b) HE 35 - for Boost Line Filters
7. Lock Valves
a) HC 2B - For Draw beam Jacks =6
b) HE 19 - for Derrick Tie Cylinders = 6
c) HE 46 - For relieving Bogie Coupling Pins = 2
d) HE 47 - For Travel Clutches = 2
e) HE 52 - For Counterweight jacks and Heavy Ballast Jacks = 2
8. Travel Differential
13.0 Preparation of 140 Te. Crane for "intrain" formation:
According to crane capacity, following instructions must be followed for better

performance of 140 Te. break down crane ensuring internal and external safety – Following
main points must be kept in mind for keeping 140 Te. Crane ready in all respects.
1. Feed pipe hoses between crane, match wagon, ballast wagon and relieving
bogies should be connected. Feed pipe hoses of last vehicles should be kept on
dummy and all isolating cocks except the last vehicle should be opened.
2. Hand brakes of match wagon, ballast wagon, relieving bogies and crane must
be kept released but if the crane is stabled in the shed, wooden wedges must
be inserted under the wheels of match & ballast wagons.
3. Connect vacuum hose pipes between the vehicles.
4. Air reducing valve cocks of match wagon, ballast wagon and crane to be kept
open, otherwise vacuum brake will not be in function.
5. Travel clutch of both the trucks should be in disengaged position. Check
mechanical indicator to ensure disengagement of travel clutch.
6. Blocking screws of all the axle boxes should be lifted.
7. Slew lock pin of 140 Te. Crane should be in coupled position.
8. 12 Te. Counter weight should be kept properly on crane carriage and hanger
bolts locked with locking plate.
9. Brake power testing to be conducted, time-to-time in shed by attaching
locomotive to ensure continuity in train formation. The test must be conducted
in presence of break down supervisor.
10. Drain cocks of vacuum reservoirs of crane, match wagon and ballast wagon
should be in closed position and leakage should not be there from proportional
valve to release valve. In case of any leakage, vacuum brake will not work.
11. SA1 brake valve should be in released position and brake paddle should be
locked with bolt.
12. Crane lifting tackles i.e. slings and other material should be kept systematically.
13. Rail clamps of the crane at both the ends should be secured with the hook.
14. All the draw beams should be in retracted condition and lock pin in inserted
position.
15. In the locked condition of relieving bogies “ relieving bogie coupling pin” and
“tumbler pin” should be in coupled position.
16. Transition coupling between crane, relieving bogies, match wagon and ballast
wagon should be kept in tighten position.
14.0 Precaution and instructions during crane "Intrain" Running:
During “intrain” formation, one crane man/Asstt should always be deputed
to avoid unusuals with the crane. They must follow following instructions.
1. After starting of “intrain” formation”, the auxiliary engine of crane to be
started first and then auxiliary compressor, so that crane brakes remain
functional. MR pressure should not be less than 5.0 Kg/cm2.
2. After getting started auxiliary engine, battery charging to be ensured
through ammeter. After starting auxiliary engine, check battery charging
by ammeter readings.
3. Ensure auxiliary engine lube oil pressure between 1.8 Kg/cm² to 2.8
Kg/cm². Lube oil pressure should not drop below 1.5 Kg/cm².
4. For “intrain” formation, Red flag during day and red lamp during night
should always be kept to utilize in emergencies. In case of any unusual or
emergency, the emergency flap valve should be operated to stop the train.
The same must immediately be communicated to the Breakdown
Incharge/Supervisor on walkie-talkie.
5. Whenever train stops enroute following equipments to be checked:-
(a) Check the axle box condition by touching the axle box cover with
hands for any rise of temperature of any of the axle boxes is rising
abnormally. Information to be given to the break down incharge.
(b) Check following equipments/parts for unusual – Equalizing beam
and its pin, brackets, leaf and coil springs, hangers, bolts, link and
its pin and all transition couplings.
(c) Check whether lifting tackles are kept properly on match wagon
and ballast wagon.
15.0 Precaution during “intrain” running and separation of crane
from ART:
1. Before detaching the crane from ART, it must be ensured that MR
pressure in the crane is not below 4.0 Kg/cm², because it is required for
crane brake operation.
2. Brake pedal lock pin should be opened so that crane brake can be applied
whenever required.
3. Before uncoupling the feed pipes, isolating cock should be closed.
4. After detaching the crane, apply crane self brakes by SA1 brake valve and
ensure that crane brakes are working properly.
5. Destroy the vacuum of vacuum release valve to release the vacuum
brakes. The vacuum release valves are provided on the crane, match
wagon and ballast wagon.
16.0 Precautions during preparation of crane at accident site for
restoration works:
1. Axle box blocking screws to be blocked before unloading the relieving bogies.
2. Start the main engine. If engine is cranking but not starting by operating “Key”, wait
for 05 seconds and try again. This exercise should be done 2 to 3 time only. Do not
repeat the operation of key frequently to avoid battery discharge.
3. Do not start traveling operation by the crane till MR pressure is created more than
5.0 Kg/cm². Ensure SA1 valve brake pedal in working order.
4. Avoid excessive tightening of derrick wire rope while lifting A-frame otherwise A-
frame will not raise.
5. While lifting the jib from rester, it must be turned towards center so that resting table
does not get damaged.
6. Select the duty, by duty selector switch according to lifting load.
7. Always choose suitable capacity lifting tackles according to work intensity.
8. Always choose the suitable place from where successful restoration can be
undertaken.
17.0 Precautions and instructions for better performance of crane

during restoration work at accident site:
1. Only authorized and competent break down officials shall deliver the instructions
to the crane drivers while working at accident sites, but in case of any
danger/unusual, any of the BDT staff can feed the indications to avoid unusual.
2. During restoration, Job (load) should not be dragged except hauling winch, but
depending on requirement, only light load can be pulled, keeping crane jib
“inline”.
3. Auxiliary hook to be utilized for lifting the load up to 25 Te. only. Beyond this
load, main hook to be utilized.
4. Hauling operation should not be undertaken for more than 5.0 Te. loads, because
hauling load is not shown by SLI.
5. Traveling operation should only be under taken when the jib is in “inline”. Limits
of load lifting, given in the load chart, must be strictly followed.
6. If travel clutch does not engage, then: –
(a) Release the crane brakes and observe clutch engagement.
(b) Operate the joystick gradually.
7. During crane traveling, apply crane brakes for stopping the crane. Do not operate
joystick reverse to stop the crane, because it will damage the system.
8. Always keep sharp observation over the crane wheels during restoration.
Information regarding lifting of any wheels to be immediately communicated to
the crane driver. Under such conditions, lifted load must be lowered and kept on
ground level and propping to be examined thoroughly.
9. Speed selection should be changed only when crane is stopped completely.
10. Do not operate full joystick until travel clutch is inserted properly.
11. Before traveling, it must be ensured that, rail clamps have been removed, props
removed and draw beam retracted and jib turned to “inline”
12. Before traveling, horn must be sounded to alert the staff.
13. Travel differential switch should be used only in slow speed operation when crane
is unable to travel.
14. Duty selector switch must be set according to configuration.
15. Avoid dragging of tie cylinders with OHE wires while slewing the 140 Te. Crane.
16. Swinging load is always dangerous. The load should be lifted slowly just above
the ground level and held for sometime to avoid swinging.
17. Do not lift the load to the excessive height from the ground level.
18. During operation, engine RPM should be gradually raised or reduced by the
throttle lever. Always maintain the rpm as per requirement.
19. During restoration, two operations can be undertaken by this crane
simultaneously but in exigencies, three operations may also be carried out.
20. To change the operation of crane, do not keep the joystick in operation, because it
will damage the system of main joystick pump.
21. Main hoist emergency lower button should be operated only in case of emergency
and the operation should not be part of the normal working.
22. Before undertaking lifting operation, the crane operator must be sure that duty
selector of SLI is correctly set and SLI is in working order.
23. Do not override the SLI during restoration operation.
24. It is dangerous to work with the crane when MR pressure drops below 5.0
Kg/cm².
25. During operation, joystick must be operated gradually to keep the hydraulic
system normal.
26. Do not use excessive electrical lighting at idle position, because batteries will get
discharged.
27. Before under taking slewing movement, observe the train movement on the
adjacent electrically charged line. Follow the G&SR rules strictly.
18.0 Precautions before and after shutting down the main engine (on
completion of restoration works):
Precautions before shunting down Precautions after shunting down the

the main engine main engine
1. Check the battery ammeter. needle 1. After shutting down the main engine, all
should be in + zone circuit breakers and battery isolator
should be put “off”
2. Travel clutch should be disengaged. 2. Ignition key should be removed.
3. All the draw beams should be in 3. SA1 valve, brake foot pedal should be
retracted and locked position. locked by inserting pin.
4. Relieving bogie-coupling pin should
4. Material to be kept systematically on the
be in inserted position. crane.
5. Tie cylinders should be lowered 5. All the transition couplings of the crane
completely. unit must be tighten.
6. Derrick wire rope should not be in
6. All the FP pipes and vacuum hose pipes
loose position. should be coupled. FP cocks should be
opened and outer most FP cock of last
vehicle should be closed.
7. Before shutting down the main 7. Heavy ballast and counter weight should
engine, it should be run on idle be locked properly.
position for at least 3 minutes.
Attention:
If you are stabling/leaving the crane :–
(a) Ensure that wooden wedges have been inserted under

the wheels.
(b) Ensure that hand brakes of match wagon and ballast
wagon have been applied.
(c) All doors of the crane have been closed and locked.
19.0 PREPARATION OF CRANE FOR WORKING AT SITE
Before uncoupling from the train do all the operations, i.e. uncouple of hoses and starting
of engine etc. mentioned vide clause 6.1 to 6.4.6 of operators manuals.
Uncouple both the relieving Bogies as follows:
a) Remove the tumbler pins retaining the blocking screws above each of the Carriage
Suspension Springs and screw down the blocking screws until they are locked down on to
the top of the springs.
NOTE: Once locked these screw must NOT be adjusted against until the relieving bogies
are re-coupled and loaded to the crane.
b) Ensure the wishbone Jack is in fully retracted position prior to unloading the relieving
bogies.
c) Remove the tumbler pin retaining the crane casting lever-locking pin on the relieving
bogies.
d) Exert a small amount of pull on the centre casting lever locking pin - at the same time
slowly pump up (close the valve V2 and change the lever position P2 as shown in fig. 3)
the relieving bogie jack until the locking pin slides out of centre casting lever.
e) With the locking pin withdrawn, lower off the main jack slowly (change the lever position
to P(N) and open the valve V2 as shown in fig. 3 until the relieving bogie frame stops
raising. The above operations have to be made for both the bogies.
f) Remove the slew-locking pin.
g) Erect the 'A' frame erection switch to the raise position at the same time particular care
should be taken to ensure the derrick rope is kept in a reasonably tight condition.
NOTE: But should not cause jib bridle assembly to lift from the jib structure until the 'A'
frame is fully erected.
h) Derrick the jib off the match wagon trestle until the main and aux. hoist blocks are clear off
the match wagon.
NOTE : Both the relieving bogies must be unloaded prior to raising the jib from the match
wagon trestle.
i) Check the gaps (Which should be about 2 to 3 mm approx.) between both top and bottom
locating pads RB25 and RB26 (half-moon as shown in fig.1). If required load/unload the
relieving bogie a bit to achieve these gaps.
WARNING: Do not operate the wishbone jack at all for this purpose.
j) After gaps are found to be same take out the coupling pins. If required load/unload the
relieving bogie a little bit during this operation also.
Uncouple both the relieving bogies in the same way.
k) Move the crane slowly away from either relieving bogie.
l) The relieving bogies can now be moved to any desired position either by towing away in
which case the hand-brakes will need to be released, or by the crane lifting it clear of the
work area.
20.0 PREPARATION OF CRANE FOR IN-TRAIN RUNNING CONDITION
a) If the crane has been in the blocked condition, retract the jacks, remove the footsteps and
retract the draw beams. Lock draw-beams in the stowed position and stow the footsteps.
Bring the jib in line position.
b) Couple up relieving bogie as follows:
NOTE: The carriage end castings and coupling pins on both ends of the carriage should be
thoroughly cleaned to remove all in grease dirt, dust etc. and re-greased prior to coupling.
c) Place the relieving bogies as per matching mark on either side of the crane.
NOTE: The relieving bogies are not interchangeable.
d) Bring the relieving bogie into close proximity to the crane and apply hand brake.
e) Using wishbone jacks of the relieving bogie jack the coupling beam (i.e. by hand pump
with lever position (I) and valve VI open as shown in fig. 3) to align the same with the
pockets in carriage end castings. Use turn buckle whenever required to align the wishbone
to the carriage end casting.
f) Release the carriage brake and move the crane very slowly to the relieving bogie.
As soon as the coupling beam takes the lead of the pocket of end casting ( as shown in
fig.2) release the wishbone jack completely (i.e. by changing the lever position to position
(2) as shown in fig. 3).
g) Travel the crane further so that the gaps between half-moon (RB25 & RB26) are minimum.
If necessary load the relieving bogie a little bit as to achieve a gap of 2 to 3 mm approx. in
both top and bottom half-moons (as shown in fig.).
WARNING: In no case should there be any sort of loading on wishbone jack after coupling
beam has taken the lead of end casting pocket. This might damage the wishbone cylinder.
h) Engage the hydraulic coupling pins to lock the relieving bogie to the carriage. If required
relieving bogies may have to load/unload during this operation.
i) Slew the superstructure in line to engage the slew lock pin.
j) Derrick the jib down onto the match wagon trestle by pressing the override switch.
Slacken the derrick rope and lower 'A' frame until 'A' frame collapsed.
k) Load the relieving bogies (by hand pump with lever position (2) and valve V2 open as
shown in fig. 3) until the centre casting locking pin slides into position by pushing on the
handle and refit tumbler pin. Now close the valve V2 and bring the lever in neutral
position (N).
l) Release the loading jack completely by opening the valve V2 slowly.
m) Repeat these operations for the other end relieving bogie.
n) Screw up all the blocking screws and refit the tumbler bogie.
IMPORTANT: After coupling the relieving bogies and before travelling re-charge the
spring feed lubricators on the both relieving bogies and the carriage end castings with
recommended lubricants.
o) Reconnect the coupling hoses between the relieving bogies and carriage.
p) Coupling match wagon and ballast wagon to the crane.
q) Re-connect the coupling hoses between the match wagon, ballast wagon and relieving
bogies.
r) Depending o the type of hauling locomotives whether air braked or vacuum braked please
follow the operations laid down vide clauses 8.2, 8.3 & 8.4 of brake operating manual No.
Z 1774 provided in operator's manual.
21.0 Precautions to be taken during 140 t. Crane Operation
(Gottwald New Design)
 Before raising the Jib from Match-truck Axle Blocking operation must be done.
 After lifting rear superstructure Gallows must be locked with main

superstructure of Crane.
 Uncouple Match-truck from crane (Screw-coupling as well as air brake hoses).

Match-truck should be secured by the hand brake.
 Before any movement of crane by its own power, operator must insure that travel
gear has engaged & crane brakes in operational condition.
 The crane should me made stable before carrying out further operations,
according to position / Propping base either firm propping of crane (6 Mtr./ 5
Mtr. / 2.9 Mtr.) should be done or rail clamping must be carried out in case of free
on rail operations.
 Apply Parking brakes for maintaining rigidity of the crane.
 Before lifting Jib it must be ensured that the crane is on straight track.
 In operating area the operator as well as loading person should assess the track
deviations of cants with jib in line with the track. Crane should be levelled by using
outriggers(Propps).
 The operator must be thoroughly acquainted with the load chart provided in the
crane to assess the S.L.I. selection.
 Special care to be taken during propping of jacks when the crane is to work on
site. Proper Packing should be placed below Propp chair. For uniform load
distribution Packing should be alternately perpendicular & parallel to the track.
Packing should be checked for any sinking
 The propping operation should be carried out until the wheel has just left the rail,
There should be absolute no gap between in-rigger and out-rigger.
 The load should properly secured and it should be lifted slowly just above the
ground and hold it there. Propping should checked again for sinking.
 If the crane is to be moved to another position, the propps should be raised

outrigger should be retracted.
 This crane is unsuitable on super-elevated track in free on rail operation with

counterweight operation.
 Swinging load is dangerous and should be avoided.
22.0 STARTING CIRCUIT OF 140 Te CRANE (Cowans Sheldon)
One No. Battery box is provided on the left side of crane super structure in which
two batteries, of 12 Volts 210 Amps rating have been provided. These batteries feed 24
Volt DC supply to the LT electrical system. One 24 Volt alternator is provided to charge
these batteries. For rotation of this alternator, drive is given through V-belts of main
engine. The generating current of this alternator is 25 Amps on idle position and approx. 40
Amps on full speed of the main engine.
When Battery isolation switch "A1" is put "ON" in the driver's cabin, the supply of
battery comes to wire No.1. As the negative terminal of the battery is connected to the
crane body, negative charge is always available in the crane body. Further, ES-1 (Engine
Start Key switch) is put "on" by operating engine “key” to position No.1 (Run position),
the engine fuel solenoid IS-1 gets positive supply from wire No.11 and negative supply
from crane body. The IS-1 gets energized and fuel supply goes to the main engine.
Solenoid IS-1 gets electrical supply through 2DI (Low water timer relay) close interlock 8-
9, 2D2 (Engine low lube oil pressure timer relay) NCI (9-10) and 2D3 (Engine over speed
relay) NCI (10-11).
Further when ES-1 switch is kept on position No 2 (Start), solenoid coil gets battery
positive supply through wire No 7 and solenoid gets energized. On energizing solenoid,
self-starter bandex couples with the gear of main engine and supply of battery goes to the
self-starter through solenoid contactor, which in turn rotates the self-starter for starting the
main engine.
After starting the main engines, ES-1 (Engine starting switch) is released and it
automatically gets run position. As soon as ES-1 comes to "Run" position, self starter
stops rotation.
23.0 BATTERY OPERATED ELECTRICAL CIRCUITES.

1. Hand lamp : 4 hand lamp sockets of 24 Volt supply have been provided on the 140 Te
crane. Two sockets on super structure -(i) Auxiliary engine room(ii) Pump
compartment/engine room and two nos. on the middle portion of the carriage - one each is
provided on both side of the carriage. Positive and negative supply is always available on
the socket of carriage through wire No 30-0 of slip ring. The circuit is controlled by E2
circuit breaker of 10 Amps rating, provided on the carriage.
2. Cab Light (H8): It is a white coloured, 60 watt 24 volt capacity bulb, mounted on the
roof of drivers cabin. It is provided for illumination in the driver's cabin. One E3 circuit
breaker of 5 Amps rating is provided in driver's cabin on control compartment for
switching "ON" and switching "off" the bulb. It gets supply from wire No. 31-0.
3. Windshield wiper motor (M2) - Windshield wiper motor is a two-pole permanent
magnet DC motor. One small gearbox is mounted on the shaft of this motor. It operates
the windscreen wiper, which cleans look out glass of the crane during rainy season. For
operation of windshield wiper motor, one E4 circuit break of 5 Amps rating is provided on
the control panel. It gets feed from wire No. 32-0.
4. Horns (H-9, H-10) : Horns are operated by the E5 circuit breaker of 20 Amps rating. It
connects the supply to wire No.33. There are two push buttons i.e. ES-10 and ES-11,
provided in the drivers cabin. One is provided for H-9 hi- tone horn which gets feed from
wire No.34 and another is for H-10 law tone horn (Rear side) which gets supply from wire
No.35.
5. SLI Gauge Light. To provide required illumination level in the various gauges and
SLI, miniature bulbs are provided. They can be lit by E-6 circuit breaker of 5 Amps rating.
It gets supply from wire No.150.
6. Engine House light(H-15) : For better illumination in the engine house, two lamps of
40 watts and 24 volt rating are provided on the crane super structure. One of them is
provided in the auxiliary engine room and another in the pump compartment. These lamps
can be operated by E-7 circuit breaker of 10 Amps rating. E-7 circuit breaker connects
supply between wire No.5 & 153.
Note: Above circuits come in function only when battery isolator is put "ON" while engine
is in shut down condition.
24.0 Gauge Lights & Lighting Circuits of 140 Te. Crane
(Main engine running position)
Different types of gauges are provided on Cowans Sheldon 140 Te. Crane to check
the system pressure of fuel system, water-cooling system, engine lube oil system and
hydraulic system. Apart from this, jib floodlight and front & rear crane head light circuit is
also explained in this chapter.
1. Battery Ammeter (G1): Ammeter is provided on the control desk in drivers cabin
and it gets supply from wire no. 3-6. Under shut down position of main engine,
when any circuit breaker is kept on, this ammeter shows discharge indication in the
discharge side. Similarly, when alternator starts charging in running condition of
main engine, battery ammeter shows charging of batteries through ammeter shunt.
Miniature bulb of 24 V, 0.3 W is provided in this meter to see the readings during
night.
2. Engine fuel gauge (G2): This gauge shows fuel oil level in the main engine fuel
tank. It gets electrical supply from wire no. 8. One sensor is provided in the main
fuel tank to sense the fuel oil level, which gets supply from wire no. 13. It sends
message of availability of fuel oil level to the fuel oil gauge, provided in the drivers
cabin to enable the driver to understand the quantity of fuel oil.
3. Water temperature gauge (G3): This gauge is provided to observe temperature
of engine coolant water. It gets electrical supply from wire no. 8. One water
temperature sensor is installed on the engine coolant pipe, which works on the
principle of thermo coupler. When coolant water becomes hot, sensor feeds the
indication accordingly to the water temperature gauge through wire no 14, which
can easily be seen in the drivers cabin.
4. Engine oil pressure gauge ( G4): Engines oil pressure gauge shows main
engines lube oil pressure in running condition. It gets electrical supply from Wire
No.8. For this purpose, one pressure sensor is provided on the lube oil pressure
gallery of engine block. Sensor gets pressure of the system and sends indication
accordingly to the gauge through Wire No.15.
5. Engine oil Temperature Gauge (G5): It is provided to show temperature of lube
oil of main engine. It gets Electrical supply from Wire No.8. One sensor similar to
thermo coupler is provided in the lube oil sump, which gets actual temperature of
engine lube oil product and sends indication to the gauge according to rise in
temperature through Wire No.16.
6. Hydraulic Oil Temperature Gauge (G6): This gauge is also provided in the
driver’s cabin, which shows temperature of hydraulic oil. It gets electrical supply
from Wire No.8. One sensor similar to thermo coupler is provided in the hydraulic
tank, which absorbs rise and decrease of temperature and sends the same to the
gauge through Wire No.17.
7. Engine Hour Run Gauge (G7): This gauge is provided to show the running of
engine in hours as well as recording of the same. It is an electrically operated
gauge, which gets electrical supply from Wire No.25. During running condition of
main engine, it starts showing that how many hours engine has worked with
cumulative recording in hours.
25.0 High Power Circuits of 140 Te. Crane
These circuits work only in main engine running condition and electrical
supply is fed to the circuit by the alternator.
One 2K-1 contactor is provided in starting circuit of main engine. Normally

close inter lock (5-36) of this contactor controls closing and opening of these high
power circuits i.e. Ventilator motor, floodlights and hydraulic circuits.
1. Cab Ventilation Fan (M3): The cab ventilation fan is provided in the
drivers cabin to exhaust the air from cabin to atmosphere. It is operated
by E-8 , 5 Amps Circuit breaker through Wire No.37.
2. Jib Floodlight (H-11): Jib floodlight is provided in the mid portion of

the jib of 140 Te. Crane for providing required illumination level during
load lifting at accident site. Floodlight is a 150 W, 24 V halogen lamp
which is controlled by E-9 circuit breaker of 10 Amps rating through Wire
No.38.
3. Front floodlight (H-12): These lamps are provided on the front side of
crane super structure at right and left side and works as headlights on the
crane. These are the halogen lamps of 150 W, 24 V rating which can be
operated by circuit breaker E-10 of 15 Amps rating through Wire No.39.
4. Rear floodlight(13): This headlight is provided in the A- Frame Section

of the Crane (tail of the super structure) to provide illumination in the Rear
side. This is also halogen lamp of 70 W, 24 V rating which is operated by
E-11 circuit breaker of 5 Amps rating through Wire No.40.
5. Hydraulic Control Circuit Breaker (E-12): This is main circuit breaker

of 15 Amps rating which provides electrical supply to all electro hydraulic
circuit breakers of crane through Wire No.41.
6. E-13, 14 Circuit Breakers: These are the spare circuit breakers of 20

Amps rating. These are installed for the purpose of any additional circuits
required in future.
Note: Engine RPM should not be less than 1500, when floodlight and head
light are being used.
26.0 Responsibility for correct carrying out of rules :
(A). Crane man are responsible not only for the mechanical manipulation of
cranes but also for their safe operation and for seeing that all rules
pertaining to their working are correctly carried out.
(B). In general, cranes working on break down operation or where a A-frame

or jib is likely to foul adjacent line, must work under the supervision of an
officer or competent subordinate.
(C). In electrified section, before commencing the operation, the crane

supervisor / Driver will clearly indicate by a written memo to OHE
department present at site to obtained power block and will operate the
crane only after receiving the permit to work by authorized TRD staff after
OHE has been made dead and earthed.
(D). During crane operation, the operator must be thoroughly conversant with
load chart to assess the duty selection.
(E). Whenever 140 Te. Crane of ART is ordered to site of accident / derailment
is to be accompanied by an officer.
27.0 Precautions when lifting with Cranes :
01. The crane must not be used to lift more than the maximum safe working
load authorized at the radius.
02. Precautions should be taken to avoid load catching on obstructions as this
may seriously overload the crane.
03. Sudden shocks and jerks also tends to overload the cranes and tackles.
04. Shocks and jerks usually result from:
(a). Mistake in signalling to the crane driver.

(b). Want of observation by the crane driver.
(c). Sudden application of brakes on crane.
(d). Kinks in the chains.
(e). Slipping of chain due to incorrect slinging or sling hooks not
properly secured
05. Lifting tackles i.e. hoisting chains, lifting chains, sling chains and wire
ropes should be of suitable capacity.

28.0 Periodical examination of Cranes :
01. 140 Te. Diesel hydraulic cranes of ART’s will be examined at intervals
regularly as prescribed by RDSO.
02. The Break down incharge / SSE nominated to do so are responsible for
the periodical examination of 140 Te. Break down cranes.
03. To ensure proper upkeep and reliability in safe working of 140 Te. Crane
at site, the following periodicity of schedules has been prescribed by
RDSO.
A. Cowans Sheldon (Old Crane)

S.N. Duration Working hours Set of schedule form
01. Daily Form “A”
02. Monthly 100 Form “B”
03. 3 Monthly 250 Form”C”
06. 6 Monthly 500 Form”D”
07. Yearly 1000 Form”E”
08. 2 Yearly 2000 Form”F”
09. 4 Yearly 4000 Form”G”
10. 8 Yearly 8000 POH
B. Cowans Sheldon (New Crane)

C. Gottwald (Old Crane)


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

02. Monthly 125* Form “B”
06. 6 Monthly 250* Form”D”
07. Yearly 1500* Form”E”
08. 2 Yearly 6000* Form”F”
09. 4 Yearly 6000* Form”G”
10. 8 Yearly -- POH
* Whichever is earlier
KOEL Auxiliary Engine HA-294

01. Daily
02. Monthly 125*
06. 6 Monthly 250*
07. Yearly 1000*
08. 2 Yearly 2000*
09. 3 Yearly 3000*
10. 8 Yearly -- POH Sch.
04. Particular of periodical examinations should be maintained on a register.

05. Any repair to be executed should be reported to the subordinate incharge
of the maintenance of the crane.
06. Record of such examinations entered in the register will be signed by the
maintenance supervisor.
07. Particulars of periodical examinations of 140 te. Crane will be recorded in
the prescribed schedule forms as laid down by the RDSO.
29.0 Lubrication of Cranes
01. Crane drivers will be personally responsible for adequate and efficient
lubrication of all bearing surfaces.
02. They will ensure that bearing surfaces are clean and free from dust, dirt.
This applies particularly in matching surfaces of clutch gear, center pivots,
rollers and motion gears.
03. The crane driver should make certain that all working parts are clean and
before starting work each day, he should ensure that visible parts are
adequately lubricated.
04. On 140 Te. Crane, make the locations and lubricants with grade wise to
be used for lubrication have been suggested by the manufacturer. The
manufacturers recommendations for lubrication should be strictly followed

30.0 dzsu Lis'ky gsrq vko';d lkeku dh lwph
List of the Important Material for Crane Spl.
On ordering of Crane Special, following material should be kept in Staff Van before
departure from Crane siding/Shed.
Lkkeku dk fooj.k la[;k Description of the material NOS.
Dz-
1- Okkdh Vkdh lSV 04 u- Walkie Talkie Sets 04 Nos.
2- Eksxk Qksu 02 ua- Mega Phone 02 Nos.
3- Okkdh Vkdh pktZj 01 ua- Walkie Talkie Charger 01 No.
4- isVªksesDl ¼xSl½ 2 + +2 Gas Patromax 02+02 Nos.
ua-
5- VkpZ ¼3 lsy½ 04 ua- Torch Three Cell 04 Nos.
6- flxuy VkpZ 01 ua- Signal Torch 01 No.
7- estfjax Vsi 01 ua- Measuring Tap 01 No.
8- gsyesV lQsn 04 ua- Helmate (Hard hate) 04 Nos.
9- gsyesV LVkQ 20 ua- Helmate Staff 20 Nos.
10- Pkknjsa 08 ua- Bed Sheets 08 Nos.
11- Rkfd;ss 05 ua- Pillows 05 Nos.
12- daEcy ¼lqijokbtj½ 08 ua- Blankets (Supervisor) 08 Nos.
13- daEcy LVkQ 20 ua- Blankets (Staff) 20 Nos.
14- >a.Mh yky rFkk gjh 02 ua- Red and Green Flags 02 Nos.
15- Ikkuh dh ckfYV;ka 01 ua- Water Buckets 01 Nos.
16- QLV ,M ckWDl 01 ua- First Aid Box 01 Nos.
17- iSM LVkEi eseks cqd 1+1+1 Memo Book and Pad, Stamp 1+1+1 No.
18- fMVsUlu QkeZ 04 ua- Detention form 04 Nos.
19- Nkrs 04 ua- Umbrellas 04 Nos.
20- isu fjyhQ Lizs 02 ua- Pain Relief Spray 02 Nos.
21- Lizs iai ¼vkWa[k /kqykbZ 01 ua- Spray Pump for cleaning of eye 01 No.
gsrq ½
22- gSaM iai ;wfuV 01 ua- Hyd. Hand Pump Unit 01 No.
23- 30@60 tSd 02 ua- 30/60 Te. Jacks 02 Nos.
24- 120@60 ,y lh tSd 01 ua- 120/60 Te. Jack 01 No.
25- fMLIysflax tSd 01 ua- Displacing Jack 01 No.
26- jksyj dSfjt 01 ua- Roller Carriage 01 No.
27- fjjsfyax fczt 01 ua- Re-railing Bridge 01 No.
28- dkmWa.Vj liksVZ 01 ua- Counter Support 01 No.
29- gkbZ izs'kj gkst 03 ua- High Pressure Hoses 03 Nos.
30- tujsVj lSV 01 ua- 3/2.5Kva Cap. Generator 01 No.
31- gSykstu ySai 02 ua- Halogen Lamp 02 Nos.
32- fLop cksMZ 01 ua- Elect. Switch Board 01 No.
33- ,DlVsa'ku cksMZ 01 ua- Elect. Extension Board 01 No.
34- fjap ckj 02 ua- Wrench Bar 02 Nos.
35- iats 02 ua- Punje 02 Nos.
36- dSejk 01 ua- Video Camera 01 No.
37- fdfpu dk lkeku 01 lSV Kitchen Material 01 Set

31.0 SUITABLE WOODEN PACKINGS
A. REQUIRED FOR 140 Te. CRANE: [ COWANS SHELDON 140 Te. CRANE]
1.Wooden Packing Size- 1800mmX300mmX300mm - 08 Nos.
2.Wooden Packing Size- 1200mmX300mmX300mm - 20Nos.
3.Wooden Packing Size- 1200mmX300mmX150mm - 24 Nos

TOTAL PACKINGS - 222 Nos.
NOTE: All packings must be recessed at the ends and bonded with 30X5 mm thick
bond.
B. REQUIRED FOR 140 Te. CRANE:

[ COWANS SHELDON 140 Te. CRANE NEW]
Required For 4 Nos Prop For 8 Nos Prop

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

32.0 LOAD CHART FOR 140 Te CRANE [ COWANS SHELDON ]
Duty Selector Duty Selector

0 t - 4, 32 t - 7
MAIN HOIST 0 t - 3, 32 t - 6 AUXILIARY HOIST
12 t - 2 12 t - 1
Radius Coupled Free on rail Fully Propped Coupled Free on rail Fully Propped
Radius
in ballast Slew Range Slew Range ballast Slew Range Slew Range
in meter
meter weight O° 28° 360° O° 28° 360° weight O° 28° 360° O° 28° 360°
0t 42 42 29 140 140 140 0t 25 25 20 25 25 25
5.5 12 t 94 53 39 140 140 140 7.0 12 t 25 25 25 25 25 25
32 t 104 -- -- 140 140 140 32 t 25 -- -- 25 25 25
0t 31 31 20 140 140 98 0t 22 22 13 25 25 25
7.0 12 t 78 41 27 140 140 110 9.0 12 t 25 25 20 25 25 25
32 t 86 -- -- 140 140 140 32 t 25 -- -- 25 25 25
0t 22 22 13 140 140 62 0t 16 16 9 25 25 25
9.0 12 t 63 30 18.5 140 140 70 11.0 12 t 25 25 15 25 25 25
32 t 70 -- -- 140 140 101 32 t 25 -- -- 25 25 25
0t 16 16 9 109 109 44 0t 12 12 6 25 25 25
11.0 12 t 52 23 14 118 118 50 13.0 12 t 25 21 11 25 25 25
32 t 58 -- -- 130 130 58 32 t 25 -- -- 25 25 25
0t 12 12 -- 79 79 34 0t 9 9 4 25 25 25
13.0 12 t 44 18 9.5 85 85 38 15.0 12 t 25 17 9 25 25 25
32 t 49 -- -- 105 105 58 32 t 25 -- -- 25 25 25
0t 9 9 -- 61 61 27 0t 7 7 3 25 25 25
15.0 12 t 38 14 7 66 66 31 17.0 12 t 25 13.5 7 25 25 25
32 t 42 -- -- 85 85 47 32 t 25 -- -- 25 25 25
0t 8 8 - 55 55 24 0t 5 5 2 25 25 19
16.0 12 t 35 13 6 59 59 28 19.0 12 t 25 11 5 25 25 22
32 t 39 -- -- 70 70 42 32 t 25 -- -- 25 25 25
5.65 5.5 Activities and Timing particulars
1. 140 Te. Crane Energising with Aux. Hook= 15 mts
B-End 140 Te. Crane A-End 6.0 m 2. Full Propping = 30 mts
R/B R/B 3. Counter weight attaching = 08 mts
4. Relieving Bogie removing = 12 mts
5.0 M 5. Match Truck Removing = 30 mts
6. Crane binding up with Aux. Hook = 20 mts
11.15 M 7. Crane binding up with R/B + Match truck = 1.10 hr
8. 360° Slewing without load = 2.5 mts
PROPPING ARRANGEMENT

33.0 WEIGHT CHART OF COACHES AND WAGONS
SN Type of Tare weight Pay load Complete One Trolly Total Type of Open / Vacuum/
Wagons & in Tonnes in Tonnes weight in weight in wheels coupling Covered Air Brake
Coaches Tonnes Tonnes
01 BVZI 23.52 56.68 81.28 4.0 08 CBC Open Air Brake
02 BOX N 23.02 58.08 81.28 4.0 08 CBC Open Air Brake
03 BOXNNHA 23.17 65.23 88.40 4.0 08 CBC Open Air Brake
04 BOXNHL 20.60 71.00 91.60 4.0 08 CBC Open Air Brake
05 BOXNEL 23.10 76.90 100.00 4.0 08 CBC Open Air Brake
06 BOXNR 21.20 70.04 91.60 4.0 08 CBC Open Air Brake
07 BOXNAL 18.26 63.02 81.28 4.0 08 CBC Open Air Brake
08 BOXNHAM 23.10 68.18 91.28 4.0 08 CBC Open Air Brake
09 BOST 25.50 55.78 81.28 4.0 08 CBC Open Air Brake
10 BCN 27.20 54.08 81.28 4.0 08 CBC Covered Air Brake
11 BCNHL 20.80 70.80 91.60 4.0 08 CBC Covered Air Brake
12 BRN 23.30 68.29 91.60 4.0 08 CBC Flat Air Brake
13 BFNS 26.71 54.57 81.28 4.0 08 CBC Flat Air Brake
14 BOBRN 26.40 54.88 81.28 4.0 08 CBC Flat Air Brake
15 BOBRNHSM1 25.61 63.67 89.28 4.0 08 CBC Flat Air Brake
16 BOBY/BOBYNHS 25.2 66.40 91.60 4.0 08 CBC Open Air Brake
17 BTPN 27.0 54.28 81.28 4.5 08 CBC Covered Air Brake
18 BTPGLN 41.60 37.60 79.20 4.5 08 CBC Covered Air Brake
19 BTFLN 23.33 57.95 81.28 4.5 08 CBC Covered Air Brake
20 BLCA 19.10 61.00 80.10 4.0 08 CBC Flat Air Brake
21 BLLA 19.80 61.00 80.80 4.0 08 CBC Flat Air Brake
22 LWFAC 40.87 2.47 43.34 4.0 08 CBC Coach Air Brake
23 LWGFAC 45.90 4.80 50.70 4.0 08 CBC Coach Air Brake
24 LWACCW 41.60 5.12 46.72 4.0 08 CBC Coach Air Brake
25 LWGACCW 48.00 7.04 55.04 4.0 08 CBC Coach Air Brake
26 LWACCN 43.00 5.80 48.80 4.0 08 CBC Coach Air Brake
27 LWGACCN 50.50 8.00 58.50 4.0 08 CBC Coach Air Brake
28 LWFCZAC 42.27 6.24 48.51 4.0 08 CBC Coach Air Brake
29 LWSCZAC 42.27 8.00 50.27 4.0 08 CBC Coach Air Brake
30 LWLRRM 52.12 4.66 56.78 4.0 08 CBC Coach Air Brake
31 SCN 41.1 6.7 47.8 3.5 08 Transition Coach Air Brake
32 AC Ist 49.75 1.5 51.19 3.5 08 Transition Coach Air Brake
33 AC IInd 53.7 9.6 63.3 3.5 08 Transition Coach Air Brake
34 AC III 53.7 9.6 63.3 3.5 08 Transition Coach Air Brake
35 AC Chair Car 45.6 7.6 53.2 3.5 08 Transition Coach Air Brake
36 Pantry Car 41.5 2.0 43.5 3.5 08 Transition Coach Air Brake
37 VPU 38.0 16.0 54.0 3.5 08 Transition Coach Air Brake
SAMPLE PROFORMA FOR BREAK DOWN TRAIN FORMATION
SN Vehicle RLy Built Date POH Done POH Due Utilisation

No.
01 44225 CR 1986-UK 22.02.98 PR 02.2006 140 Te. Crane
02 7179 CR 1980 BCN HS 04.09.01 MTN 10.2005 Crane Packing+OHE material
03 9216 CR 1979 ICF 04.09.01 MTN 10.2005 Crane Staff and Kitchen Van
04 78212 CR 1978 ICF 04.09.01 MTN 10.2005 Tool and Equipment Van
05 9523 CR 1981 BEML 04.09.01 MTN 10.2005 Re-railing Equipment Van
06 9383 CR 1980 ICF 04.09.01 MTN 10.2005 C&W, S&T & Elect. Van
06 9586 CR 1981 ICF 04.09.01 MTN 10.2005 Staff and Kitchen Van
07 357301 SC 1993 BCN HS 28.11.99 RYPS 01.2006 Engineering Material + OHE
08 120937 CR 1989 BRN HS 17.06.98 RWS 02.2004 Rails and Crossings

RESTORATION AT ACCIDENT SITES BY 140 T CRANES
LOCOMOTIVES:
1. Restoration of derailed
locomotive in the dead end
siding by 140 Te. Crane.
A- Preparation Chart :
S.N. Item/Status Action
01 OHE Working line OHE to be slewed. OHE of
adjacent line to be made dead or slewed
depending on infringement.
02 Condition of props and availability of All props to be prepared and 04 staff on each
staff prop should be deputed.
03 Suitable packing and its size Wooden packing of size 4’x12”x12”/ 4’x10”x6”
04 No. of cranes required and Position Two cranes. duty selector to be kept on No.1
of SLI duty selector (i.e. full prop with full counter weight)
05 Suitable wire rope sling 50/70 Te. 6 mtrs sling (both side eye)
06 Position of Cant on the track Should not be more than 140 mm
07 Position of SLI SLI should be kept in working.
08 Maximum working radius 09 meters by main hook
09 Place, where sling to be inserted All four buffer plates
10 Lighting arrangement To be arranged during night/dark.
11 Observation for suitable place Analyze suitable place for placing of loco.
12 Arrangement of rope for loco 02 Nos. in sufficient length at both the ends of
adjustment loco
13 Availability of Megaphone/ One person should be deputed with
Communication equipments
14 Photography/Videography Videography of all critical operations and clues
collections.
15 Gas cutting equipment DA and Oxygen gas with equipment
16 Availability of wooden wedges 04 wooden wedges
17 Average per loco timing for Average – 2.0 hrs. minimum
restoration
B- Restoration Plan :
1 Observation of site and load conditions

Before starting the rigging of the crane, check -
 Tonnage and dimension of the load to be lifted
 Required radius
 Hook height, slewing range, space for travelling with load if needed etc.
Then tackle in conformity with the load chart and propping condition.
2 Axle blocking –Carry out Axle Blocking ( for the method of Axle Blocking see P 29-31 )
3 Boom erection – For things to ensure before boom erection see P- Go to Chapter contents
4 Do the propping of the crane – Detailed instructions given at P-
5 Select the counterweight as per load chart - Detailed instructions given at P-
6 Operation can now be started. Following Operating Precautions given at P- and
General Precautions for handling of loads given at P- .
7 Locomotive should always be handled by two 140T break-down cranes if

required to be lifted from the ground completely or one by one lifting / slewing
from either end method can be adopted. Suitable capacity wire ropes and D-
Shackles/Bow shackles should be used.
8 However in case only one trolley has derailed, the locomotive can be re-railed with the
help of one crane from derailed trolley side.
Or otherwise also if the loco is not capsized, keeping the one end of it on the ground
other end can be re-railed or tackled cautiously with the help of one crane provided it is
free from any entanglement.

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

10 In case D-shackles of adequate capacity are not available, locomotives can be handled
with the help of draw bar wire ropes placed across underneath the locomotive.
11 WDG-4 locomotives can be tackled with draw bar wire ropes as the buffer plate holes
are not provided in this loco.
12 Before lifting of WDG3A class of locomotives, trolleys should be secured with

loco chassis with proper fastening arrangements otherwise trolley will get
detached during lifting, because the D-shackles provided in the locomotive for
connecting the trolley with chassis can not take the load of trolleys.
13 In case, locomotive has fallen in a ditch after crossing sand hump or buffer, it can be
lifted and kept on temporary tracks (laid upon engineering cribs) that can be connected
with existing track.

14 Any accident stock lying very far from the reach of the crane, can be brought closer in
the reach with the help of HRE.
15 In case bogie has cracked or damaged to an extent that lowering on that may not be
safe, spare dummy bogie should be arranged from the nearest loco shed.

16 Uncoupling of Bogies
In situations where it is needed to uncouple the bogies and run out as in above case ,
air brake pipe connections, TM cable connection, Centre Pivot cotter and other
connections between bogie and chasis needs to be disconnected.Other such
coonectios are listed as below-
 Axle Generator cable
 Speedometer cable
 Bolster Pin etc
Bolster Pin
Connection
C- Procedure in Practice :
When diesel or AC locomotive enters in to the dead end siding and derails, it is re-
railed with the help of two 140 T. cranes. Each crane at either end of adjacent track is
placed from where working radius is kept not more than 8 meters.
1. One 140 Te crane is kept at one end on the adjacent track and other 140 Te.Crane
at another end.
2. Full propping is done for both the cranes and 50 Te/ 70 Te, 6 meters wire rope sling
with 50/70 ton ‘D’ shackles are used.
3. ‘D’ shackles are inserted in the lifting holes of buffer plates of loco at four places (For
locos having buffer plates) and both cranes are allowed to lift the loco
simultaneously.
4. Lifted loco should be slewed towards adjacent track by both the cranes.
5. One bogie of the loco is placed on track in first occasion and then another crane is
permitted to do so for safe placement of loco trolleys on track.
6. Lifted loco is always kept in dead condition during restoration operation.

COACHES
1.(A) RESTORATION OF COACHES IN ELECTRIFIED SECTION
BY 140 Te. CRANE
A. Preparation Chart:
01 OHE To be slewed towards coach movement and
ensure that OHE of adjacent line has been made
dead.
02 Condition of props and Full propping to be done and 04 staff on each
availability of staff prop should be deputed.
03 Suitable packing and its size Wooden packing of size 4’x2’x14” and 6’x1’x12”
04 Position of SLI duty selector To be kept on No. 1
05 Wire rope Sling and SWL 30 Te. 5 Mtrs sling and 70 Te. SWL as per
requirement
06 Chain sling as per requirement 25 Te. Capacity chain sling
07 Position of Cant of the track Should not be more than 140 mm
09 Maximum working radius 13 meters by main hook.
10 Place where sling to be (under frame) Solbar
inserted
13 Position of coach trolley Lashing chain to be used for securing with
structure.
14 Lighting arrangement To be arranged during dark/night.
15 Observation for suitable place Analyze suitable place for 360º slewing and
placing the coach/damaged trolley.
16 Arrangement of rope for coach 02 Nos. in sufficient length at both the ends of
adjustment coach.
17 Availability of Megaphone/ One person should be deputed with equipments
Communication
collection.
19 Average timing for restoration Average – 55 minutes
of each coach
Removing Entangled Coach:
01. Energize 140 Te. Crane, attach

counter weight and ensure full
propping for approach upto 18 mtrs
radius.
02. Insert Aux. Hook in the solbar of
coach at facing end and lift slowly
with slewing actions.
03. Remove entanglement of coach at
another end also in the same manner.
04. If coach trolleys are in good condition, re-rail the coach by MFD/LUKAS Jacks.

Damaged Trolleys:
If the trolleys are damaged badly and re-railment is not possible then:-
01. Attach 70 Te. SWL and 30 Te. 5 Mtrs wire rope sling and eye-wire ropes.
02. Insert eye wire rope in the centre of the coach (under frame) and lift
slowly.
03. Place the job within 13 mtrs of radius anywhere at 360º.
04. If the coach body is damaged, then utilize 30 Te. 5 mtrs wire rope sling
with eye-wire rope without SWL.
05. Lift the coach and place away from the track within 13 mtrs.
1(B) RESTORATION OF COACHES IN NON-ELECTRIFIED SECTIONS
In double line section, where lines are at minimum standard distance, the
restoration can be executed with 140 Te. Crane by placing coaches on the
adjacent track:-
01. First of all, remove front
relieving bogie of crane and
establish the crane near first
derailed coach, keeping margin
of approx. 1 meter distance.
02. Ensure complete propping and
secure the trolleys of coach
with the lashing chains and
bolts.
03. Insert Aux. Hook in the solbar
of near end of coach and lift.
04. Place this end away from the Ist draw beam (prop) because during lifting
operation, coach normally creeps towards crane.
05. Again release the hook, and pick up the coach in the center by 30 Te. 5
mtrs wire rope and lift.
06. Keep jib “inline” (not more than 4ºC slew position), release props and
travel the crane slowly free on rails.
07. Again ensure full propping and place one trolley of lifted coach on
adjacent track adjusting slew degree and radius. Similarly keep other
trolley on the track.
(C) Restoration of tilted coach:
01. If the trolleys of coach are intact, secure the
trolleys with lashing chains so that trolleys
remain with the coach structure.
02. But, if the trolleys are damaged or have got
uncoupled, remove damaged trolleys first by
Aux. hook.
03. Take 140 Te. crane near the coach, ensure
complete propping and insert hook at this end.
04. Lift the near end. of tilted coach, it will get
turned straight by this operation and further
do next exercise for removing the coach.

D- Restoration Plan :

Before starting the rigging of the crane check
 Required radius
2 Axle blocking – Carry out Axle Blocking ( for the method of Axle Blocking see P- )
3 Boom erection – for things to ensure before boom erection see P-
4 Do the propping of the crane – detailed instructions given at P-
5 Select the counterweight as per load chart - detailed instructions given at P-
6 Operation can now be started following Operating Precautions given at P- and General
Precautions for handling of loads given at P- .
7 Buffer to buffer length of a coach is approximately 22 & 24 M for ICF and LHB
respectively. So extra precaution is needed otherwise the load may hit with the
crane body or jib.
8 Capsized stocks that cannot be
salvaged may be toppled down. In
such cases, hooks should be fixed in
such a way that after the load is
toppled down, the hooks should
disengage easily. Toppling hooks (‘L’
type instead of ‘S’ type
10 But toppling should not be done when there is a deep ditch or trench adjacent
to the track as there will be tendency to topple suddenly that may cause
jerking in the crane and may cause toppling of the crane also.
11 Before lifting of a coach, it should be ensured that the center pivot cotter, BSS
hanger and the safety strap of axle box guide arrangement are in good
condition. Otherwise the bogie should be secured with the chassis with chains.

12 Extra precaution needs to be taken for handling entangled load as the actual
load will be much more than what it may appear due to entanglement.
13 Lifting beams (SWL) should preferably be used to tackle coaching stocks to
prevent damage of the body whenever coach is to be salvaged.
14 While a load is lifted it should be guided by attaching ropes on diagonally

opposite sides held by staff cautiously, to avoid pendulum like motion.
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
Go toto
Chapter contents
which lies the accident coach.
16 Hence it is easier to handle coach lying beside the track.
17 After the coach is lifted, it must be guided by attaching ropes to make it
perpendicular to the jib otherwise it may hit with the jib or crane body.
18 In case a coach lying on the same track on which crane is working, the coach
should be first brought perpendicular to the jib by tackling one end keeping other
end on the ground. Thereafter in this condition it can be handled without a
danger to the crane body and the jib. (Or as explained in 20 below).
19 For the reasons mentioned above, a coach should not be re-railed on the
same track on which 140 T crane is working in double line section.

20 Re-railing of coaches in Single Line Section( Salvageable Coaches)
Coach is
positioned
to leave
space for
crane
movement. Crane is moved to
tackle farther end.
1 2
In single line section the trolley of the coach in farther side of the crane may be
re-railed, keeping the coach body still diagonal to the crane jib.
This end will be re-railed first.
3
Now the trolley near to the crane will be tackled and re-railed in such a manner
that coach will move far from the crane rolling on the first re-railed trolley to avoid
hitting with crane.
Now this end will be re-railed, pushing
the coach farther on the previously re
railed trolley.
4

21 Re railing of coaches in Single Line Section( Capsized/Damaged Coaches)
In case the capsized or damaged coach is lying on the track, it should be placed
perpendicular or diagonal to the jib and then thrown off the track.
22 Re railing Salvageable LHB coaches on same track
It is advisable to use two cranes in case an LHB coach is to be re-railed on the
same track.
23 Use of Rail skates
Rail skates can be used in case of axle box bearing damage or for any other
reason due to which the wheel cannot travel.

EMU/MEMU/DEMU
1. Restoration of derailed EMU/MEMU/DEMU.
A- Preparation Chart :
01 OHE To be slewed towards coach movement and
ensure that OHE of adjacent line has been
made dead.
02 Condition of props and Full propping to be done and 04 staff on each
03 Suitable packing and its size Wooden packing of size 4’x2’x14” and
6’x1’x12”
05 Wire rope Sling and SWL 30 Te. 5 Mtrs sling and 70 Te. SWL as per
requirement.
09 Maximum working radius 13 meters by main hook.
10 Place where sling to be (under frame) Solbar
inserted
13 Position of coach trolley Lashing chain to be used for securing with
structure.
14 Lighting arrangement To be arranged during dark/night.
placing the coach/damaged trolley.
16 Arrangement of rope for coach 02 Nos. in sufficient length at both the ends of
adjustment coach.
collection.
of each coach


 Required radius

7 These stocks are fitted with Shaku Couplers except the Power/Motor cars which are
provided with draw hook. This may be kept in mind that the Shaku Couplers cannot be
coupled with CBC or Screw Coupling of a locomotive. But in case it is required to
uncouple from Shaku coupler or the coupler got damaged, it should be hauled with
restricted speed with some suitable arrangement of coupling.
8 Also, once Shaku Coupler is uncoupled it requires level and straight track to couple
again. However wooden packings may be placed between the saku coupler body and
the coach body (the plate supporting it ) before opening, this will prevent drooping of
either end and maintain the alignment of two ends.
Shaku coupler in coupled condition

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

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

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

WAGONS
(3) Restoration of Loaded BCN/BOX-N by 140 Te. Crane
Preparation Chart :
01 OHE Working line OHE to be slewed. OHE of adjacent
line to be made dead.
02 Condition of props and availability Full propping to be ensured and 04 staff on each
of staff prop should be deputed.
03 Suitable packing and its size Wooden packing of size 4’x2’x14”/ 6’x1’x12”
05 Wire rope sling and SWL 70 Te. 6 mtrs sling (two leg) and 140 Te. SWL.


09 Maximum working radius 8 meters by main hook and 19 mtrs. By Aux.
hook.
10 Place, where sling to be inserted In the center of wagon, under solbar, taking
support of cross bar
11 Position of wagon trolley Lashing chain to be used for securing with
structure.
placing of wagons.
16 Arrangement of rope for wagon 02 Nos. in sufficient length at both the ends of
adjustment coach.
17 Availability of Megaphone/ One person should be deputed with equipments
Communication
collections.
(per wagon) Go to Chapter contents

 Required radius

7 While handling accident wagons, not the length but it is the tonnage in case of loaded
stock that is the critical factor.
8 In many situations it is not safe to

tackle loaded wagons particularly
BCN, due to beyond reach or
because of damaged wagon it is
necessary to unload the wagon
before tackling.
9 During lifting of any wagon stock fitted

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

10 The load should be guided by attaching ropes on two diagonal ends of the load
held by staffs.
11 Typical situation when one trolley is on the track and other trolley off the track, the stock
can be handled with the help of CBC because that would be the closest point.
12 BOX N / BCN or other such wagons
These stocks can be lifted by attaching slings with the main hook of the
crane.
13 BOBRN in Capsized condition

This wagon has no sole bar to facilitate hooking and hence center sill can be
used for fixing the hooks.
Center sill
14 BOX N HL
For stainless steel wagons like BOX N HL, for body cutting, plasma cutting
machine or abrasive cutter should be used.
15 BOBYN & BOBRN wagons
In case CBC has got damaged, hooks can be fixed to the draft gear housing.

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

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

01. Energize the crane, attach counter weight
and 140 Te. Cap. SWL with 140 Te. 6
meters long wire rope slings.
02. Move the crane and stable near the job.

Ensure that center of the wagon is not more
than 8 meters of radius.
03. Ensure full propping of crane with suitable size wooden packings on all 6 props.
04. Insert 70 Te. 6 meters “two leg” 02 wire rope sling in the solbar near cross bar
support in the centre of the wagon and lift slowly just above the ground.
05. Observe behavior of props and establish propping again, keeping load on
ground.
06. Lift the job again and place the wagon any where at 360º within 8 meters radius.
07. If the cant is persisting on the track, keep close watch over sinking of the
packings and lifting of crane wheels. One person should be deputed with
megaphone for safety.
(4) Restoration of damaged BCN/BOX N by 140 Te. Crane
1. If the loaded vehicle is damaged and considered beyond the limit of safe lifting,
advise commercial staff/officers for unloading.
2. After unloading of the vehicle, insert Aux hook

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

permission of competent authority must be
obtained for toppling of the wagon.
4. After getting permission, inert 30T, 5 Mtrs

wire rope slings in the one side solbar and lift
the same for toppling activities.
5. Again insert slings on one side solbar of the wagon taking support of cross member
and continue slewing and derricking as per requirement till unloading of the wagon.
6. Further insert 25 Te capacity hook in the supporting channel of center seal near
center pivot and lift accordingly. The wagon in this operation will get toppled
completely.
7. Now, turned wagon can be kept anywhere at 360° within 18 meters radius.
8. Remember that trolleys should not be kept in the coupled position during toppling
operation. Both trolleys should be removed in the beginning.

Basic Assessment in Handling the Wagons:
The critical factor in handling loaded wagons is not the length but its
tonnage.
• Loaded wagons should be unloaded first before throwing off track as it
may not be safe to lift loaded wagons or due to beyond reach of the
crane.
• During lifting of any wagon stock fitted with CASNUB bogie, it should be
ensured that centre pivot U-shackle lock is intact and side frame key of all
wheels are intact otherwise bogie and wheels must be secured with chains
to avoid detaching of the bogie from wagon during lifting.
• Empty wagon to be thrown off track should be guided by attaching ropes

on two diagonal ends held by staffs and then safely lowered by the side of
the track in case sufficient space not available.
• In a situation when one trolley is on the track and other trolley is off the
track, the stock can be handled with the help of CBC being the closest
point.
• In case CBC has got damaged, hooks can be fixed to the draft gear
housing.
• In case empty wagons are to be re-railed on track, they should be lifted

by attaching slings and draw bar tackles with the main hook of the crane.
• In case the empty wagon is to be thrown off track to side where there is a
deep ditch/trench, crane hooks should be fixed in such a way that after
the load is toppled down, the hooks get disengaged easily.

BOBRN in Capsized condition
• This wagon has no sole bar to facilitate hooking and hence centre sill can
be used for fixing the hooks.
• In case the wagon has to be thrown off track, the wagon should be hold
with the centre sill in overturned condition and lowered guided by
attaching ropes diagonally.
BOX N HL Wagon
For stainless steel wagons like BOXN HL, for body cutting, plasma cutting
machine or abrasive cutter should be used.

BLC Wagon
Containers and BLC wagons should be lifted separately as it is very

difficult to tackle all the 5 units together.
BTPLGN ( LPG wagons)

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

Restoration of derailed BTPN (Oil tank wagons) involved in fire.
Preparation Chart :
01. OHE Working line OHE to be slewed. OHE of adjacent line
to be made dead.
02. Requirement of fire brigade Heavy duty fire brigade is called
02. Condition of props and All props to be prepared and 04 staff on each prop
availability of staff should be deputed.
03. Suitable packing and its size Wooden packing of size 4’x10”x6”and other suitable
sizes.
04. Position of SLI duty selector To be kept on No. 1
05. Suitable wire rope sling 30 Te. 5 mtrs sling
06. Suitable chain sling as per 25 Te. Capacity chain sling
requirement
07. Position of Cant on the track Should not be more than 140 mm
08. Position of SLI SLI should be kept in working.
09. Maximum working radius 16 meters by main hook and 19 mtrs. By Aux. hook.
10. Place, where sling to be Under frame barrel bracket
inserted
11. Position of wagon trolley Lashing chains to be used for securing with
structure.
12. Lighting arrangement To be arranged during night/dark.
13. Observation for suitable place Analyze suitable place for 360º slewing and placing
of wagons.
14. Arrangement of rope for tank 02 Nos. in sufficient length at both the ends of tank.
wagon adjustment
15. Availability of Megaphone/ One person should be deputed with equipments
Communication
16. Photography/Vide0ography Videography of all critical operations and clues
collections.
17. Average per oil tank timing for Average – 55 minutes
restoration
Generally, it is observed that after derailment of oil tank wagons, they catch fire, which
in turn results internal explosions. In this situation, it is not possible to rerail the BTPN
by MFD/LUKAS equipments because machine and breakdown staff may sustain injuries
due to explosions.

1. First of all, thorough inspection of accident site
should be carried out and fire brigade is called
immediately.
2. High pressure foam power is sprinkled on the
tanks involved in the fire.
3. Until and unless putting off the fire completely,
140 Te crane should not be brought near
accident site.
4. If the track is available and fire is put off, crane is moved and propped fully and aux.
hook/main hook is applied as per requirement on all four barrel brackets of the tank.
5. Now, Lift the wagon and keep anywhere at 360° within the radius of 18 meters.
6. In general, wagons involved in fire are removed/toppled and kept aside because
such wagons are always considered dangerous for running on the track.

2. Restoration of derailed Guard Brake van by 140 Te. Crane.
Preparation Chart:
adjacent line to be made dead.
02 Condition of props and All props to be prepared and 04 staff on each
05 Wire rope sling and SWL Only 30 Te. 5 Mtrs wire rope sling
06 Chain sling 25 Te. Capacity chain sling
09 Maximum working radius 11 meters by main hook and 19 mtrs. By
Aux. hook.
10 Place, where sling to be inserted Barrel bracket/ Body bracket
13 Position of wagon trolley Lashing chain to be used for securing with
structure.
placing of wagons.
16 Arrangement of rope for brake 02 Nos. in sufficient length at both the ends
van adjustment of BVZI.
18 Photography/Videography Videography of all critical operations and
clues collections.
19 Average timing for per wagon Average – 35 minutes
restoration
01. Energize the crane, attach counter weight, move towards derailed
vehicle, establish the crane and ensure full propping.
02. For BVZI guard brake van : use 30 Te. 5 mtrs wire rope sling and insert
hook in the barrel bracket/body bracket.
03. Initiate lifting operation and place wagon any where at 360º within 11
meters radius.
04. For light weight brake van, use Aux. Hook with 25 Te. Chain sling, lift the job
and place within the range of 18 meters radius.

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

01 MFD/LUKAS power pack and 120/60 Two jacks of 120/60 Te. Cap. and displacing
Te. Cap. Jacks with control table and jacks.
hoses
02 Suitable packing and its size Wooden packing of size 3’x1’x6”/ 3’x2’x6” and
04 iron plates.
03 Availability of Lashing chains and 03 Lashing chains to be used for securing
bolts with structure.
05 Rail skates trolley 02 trolleys with 36/40 mm spanner
06 Availability of MFD tool box Should be available at site

09 Observation for suitable place Analyze suitable place for jack operation.
collections.
12 Average per wagon timing for Average – 45 minutes
restoration
If the Axle of any wagon has broken from axle box side due to hot axle, or cold axle
breakage, in this situation, shifting of wagon takes place and sometimes derails.
1. These wagons are normally re-railed by

MFD/LUKAS equipment, and brought in
the alignment on the track.
2. Rail Skates are inserted under the
wheels of broken axle.
3. 32 mm bolt of the skate is tightened to
establish the wheel completely in the
container.
4. Each skate has two wheels, which should be observed for proper sitting on the rail before
moving the wagon.
5. Move the wagon slowly without jerk, attaching with the breakdown train or with assisting
loco, not more than 5 Kmph speed.
6. Wagon in this position can travel 10 to 12 KMs at a stretch for next block station without
changing the wheels.
7. This modification facilitates reduction in restoration timings and avoids toppling of such
axle broken wagons at accident sites.
8. But in case of non functioning of Rail Skate or defect in Rail Skate, the wagon should be
toppled by 140T crane after unloading by commercial deptt.
FOB WORK
Observation of site and load conditions
 Required radius
5 Select the counter weight as per load chart - detailed instructions given at P-
7 The slings should be kept tight while erection of FOBs i.e. the load should not
be released before final assembly because it is required to be manoeuvred for
assembly. Also once the hook has dis-engaged it is difficult to engage it again at
height.
c
8 Propping over sewage trench should be avoided, height of water hydrant at
Stn. should also be considered before slewing of the crane.
9 When working in a situation where there is platform on the one side of the
crane the accessibility of the propping lever of that side should be ensured.
1. The slings should be kept tight while erection of FOBs i.e. the load should not
be released before final assembly because it is required to be manoeuvred for
assembly. Instead of wire rope, Chain sling is generally used.
2. Also once the hook is disengaged it is difficult to engage it again at height.
3. When working in a situation where there is platform on the one side of the
crane the accessibility of the propping lever of that side should be ensured.
4. Role of Manila Rope is very important in this type of activity.
LAUNCHING OF GIRDERS
A-Preparation Chart:

adjacent line to be made dead.
02 Condition of props and All props to be prepared and 04 staff on each
05 Wire rope sling and SWL 30 Te. 5 Mtrs or 50 T wire rope sling be used
06 Chain sling 25 Te. Capacity chain sling be used
09 Maximum working radius 11 meters by main hook and 19 mtrs. By
Aux. hook as per load chart.
10 Place, where sling to be inserted As per Engineering deptt.
12 Availability of wooden wedges 04 wooden wedges for crane
13 Position of Girders Lashing chain to be used for securing with
structure, Use Manila rope diagonally to
arrest hanging load.
placing of Girders.
16 Arrangement of rope for Girder 02 Nos. in sufficient length at both the ends
adjustment of Girder.
18 Photography/Videography Videography of all critical operations and
clues collections.
19 Average timing for per Girder Average – minutes
launching
 Required radius
7 Joint inspection between the involved departments viz. Mechanical,
Engineering , S&T and TRD should be done as per Railway Board’s instruction
for site verification / obstruction if any / location of propping base for crane /
assessment of time etc. Prior permission from HQ to be obtained by
presenting copy of DCN notice along with joint note.
8 Propping base should be prepared before ordering of crane, also strength of
propping base should be adjudged properly before starting the work. It may be
required to make temporary propping base with engineering cribs etc.
9 Props by temporary staging should be visible during crane operation.
10 Before commencement of the work, a certificate should be obtained from

Engineer In-charge or SSE/P-Way/Works that the Girder is safe for movement
of the crane and temporary propping base is safe for propping.
11 The Steel Girder should be tackled with the help of suitable wire rope slings by
wrapping around the main boom of the Girder.
12 Single Crane
If one crane is working, the launching / replacing of Girders should be started
from the farthest end from the crane in case multiple spans are to be tackled.
Here, for replacing all three

girders, work should be started
from girder no.3.
3
2
1
13 Double Crane each from one direction

Incase 2 cranes are working areas of 2 cranes may be earmarked during joint
inspection and both cranes will start working on furthest Girder from it in its
area.
For safety, it may be ensured that 2 cranes are not working on adjacent spans.
14 Heavier / Longer Girders

2 cranes should be used for launching of heavier and longer girders.
The cranes should be worked in prop condition over temporary staging made
from the river bed.
Temporary
staging for prop
base
1. Joint inspection between the involved departments viz. Mechanical, Engineering ,

S&T and TRD should be done as per Railway Board’s instruction for site
verification / obstruction if any / location of propping base for crane / assessment
of time etc.
2. Propping base should be prepared before ordering of crane, also strength of
propping base should be adjudged properly before starting the work. It may be
required to make temporary propping base with engineering cribs etc.
3. Props by temporary staging should be visible during crane operation
4. Before commencement of the work, a certificate should be obtained from
Engineer In-charge or SSE/P-Way/Works that the Girder is safe for movement of
the crane and temporary propping base is safe for propping.
5. The Steel Girder should be tackled with the help of suitable wire rope slings by
wrapping around the main boom of the Girder
TRACK WITH SUPER ELEVATION
1 Extreme caution should be taken while working in super elevated track.
2 After propping the crane leveling of the crane should be doubly ensured.
3 The crane should slew with load towards cant rail side i.e. higher ground level
side preferably as a measure of safety to the crane.
4 While de-rigging the crane, If super elevation is more and axles are floating
too much above the track, while lowering the props derailment of crane trolley
may occur. Hence it is better to break the axle blocking in such cases.
NOTE: When the crane works free-on-wheels in elevated curves of 40 mm or higher,

the attached loads must be secured against pendulous swinging by means of the
recovery winch or an auxiliary rope designed for the loading - as otherwise the
standing stability of the crane is endangered - Danger of accidents !
NOTE: When it is required to be work on Free On Rail, It is only permitted when the
3rd counter weight (8t) is lying on the under carriage (frame mechanism is folded in!)
in opposite direction to working position – otherwise the crane stability will be reduced
– Danger of accidents!
TUNNELS
1 Match truck should be reversed before reaching the site, as it cannot be

reversed in Cutting sections before the tunnels.
2 Jib cannot be raised inside tunnels. However loads at the mouth of tunnels
can be handled cautiously. But load inside are required to be pulled outside.
3 Coupling should be removed before pulling the loads.
4 For petty loads and loads without infringements, winch can be used.
5 If load cannot be pulled, site can be cleared by cutting it in parts and then
pulling out the smaller parts.
6 No staff should remain inside tunnel while pulling of the load is in progress.
7 Gas cutting should be avoided in tunnels as smoke will not escape easily.
RESTORATION ON BRIDGES
 Required radius
4 Do the propping of the crane – detailed instructions given at P- .On bridges temporary
staging would be necessary for propping.
5 Select the counter weight as per load chart - detailed instructions given at P-
7 Since lifting capacity of the crane on free on wheel is very limited accident
involved stock should be tackled by 140T crane in prop condition for that
temporary staging for propping should be made.
8 While working on Bridges in high current, safety precaution like life jacket etc.
must be taken by staff working at vulnerable locations.
RESCUE PLATFORM
1 Collapsible type rescue platform can be used for rescue of entrapped passenger. 25 T
chain sling should be used for lifting of Rescue platform by 140T crane.
ROAD MOBILE CRANE

1 In case, the accident involved stock is not possible to be tackled safely by the
crane, use of Road Mobile Equipment may be done to support the crane.
PREPARATION BEFORE LEAVING THE SHED
( 140T Gottwald New & Old Crane)
1 Whenever possible, crane shall be moved to accident site with jib trailing.
Required marshalling at crane shed or any en route station can be done. This
will help to avoid marshalling of MT after reaching accident site. At sites with
embankment, cutting or other such conditions this may be very difficult.
2 Travel gear should be in disengaged position. Crane Driver may further ensure
this by putting the crane in self propulsion and noting that it is not moving.
3 Crane Brake should be released.
Green indication is there for brake released.
4 Do not pull the crane when brakes are applied.
5 Boom should be locked in trestle.

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

and outriggers should be folded. Ensure the
mechanical locks are in locking position. Locking lever
7 Additional Mechanical lock provided for

out riggers should also be locked.
8 Do not leave the side mounted platform & outriggers in unlocked position.
9 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator water level and Oil level
in all the gearboxes.
10 Do not run engine in low oil level.
Release the parking Brake.

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

12
(140T Cowan Sheldon Old crane)
Required necessary marshalling at crane shed or any en route station can be
done. This will help to avoid marshalling of MT after reaching accident site. At
sites with embankment, cutting or other such conditions this may be very
difficult.
this by putting the crane in self propulsion and noting that it is not moving.
3 Crane Brake should be released.
5 All Draw beam should be retracted.

Ensure the mechanical locks are in
locking position.
6 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator water level, and grease
in grease cups of both Relieving Bogies and Oil level in all the gearboxes.
(140T Cowan Sheldon New Crane)
Required necessary marshalling at crane shed or any en route station can be
done. This will help to avoid marshalling of MT after reaching accident site. At
sites with embankment, cutting or other such conditions this may be very
difficult.
this by putting the crane in self propulsion and ensuring that it is not moving.
3 Crane Service & Parking Brakes should be released.
Make sure that brake
blocks are released from
wheels after releasing
brakes.
5 All outriggers should be folded. Ensure the mechanical lock pins are in locked
position.
6 Additional Mechanical lock provided for out riggers should also be locked.
7 Check for Hyd. Oil, Fuel Oil, Engine Lube oil, Radiator water level and Oil level
in all the gearboxes.

9 See the green indication to ensure.
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.
AXLE BLOCKING
(Cowan Sheldon Old Crane)
1 Ensure all Blocking Screws are locked onto
the springs.
2 Unload both Relieving

Bogies.
3 Ensure engagement of the travelling gear.
4 Ensure application of brake.
AXLE BLOCKING
(Cowan Sheldon New Crane)
1 Ensure Axle blocking before raising the Jib from Match Truck
2 Engage blocking pads before

raising the Jib
Lower Axle Blocking
jacks to lock top of the
spring. Engage Blocking Pads
3 Ensure engagement of the travelling gear if required.
4 Ensure application of brake confirmed by the “RED” indication.
BOOM ERECTION
( Gottwald New & Old Crane)
1 Before energizing 140T Crane on electrified section for
operations, ensure that OHE has been made
dead/slewed and secured and power block has been
taken under written memo.
2 Secure rear section lock while rear Lock
section is fully lifted.
New Design
Old Design
3 Do not erect boom without securing rear T-locks.
4 Check for rear section fully lifted by giving line to rear section Gallows through
pre selector switch (for Old Design).
5 While making vertical movement of
CWT Cylinder, a strict vigil is required
since malfunctioning of ‘Proximity
Switch’ may cause damage to rear
end plate below the pulleys and CWT
cylinder piston.
6 Do not erect boom without upper and lower legs junction locks of ‘A’ frame.
7 Depute 2 staff to go up and watch the revving and un

revving of the derrick wire rope.
Do not run crane without watching of rope revving.
8 Derrick “IN” till boom heel sits on the PINs.
Do not stop boom Derrick “IN” until boom heel sits on pin.
9 Remove boom lock from the jib trestle.
Raise boom cautiously.
BOOM ERECTION
( Cowans Sheldon Old Crane)
1 Before energizing 140T Crane on electrified
section for operations, ensure that OHE has
been made dead/slewed and secured and
power block has been taken under written
memo.
2 While raising "A" frame-
Keep Derrick Wire Ropes in reasonably
slack condition
3 Ensure all Blocking Screws

are locked onto the springs.
4 Unload
both
Relieving
Bogies.
5 Remove Slew Lock Pin before

slewing.
6 With Derrick “IN” operation, Raise boom cautiously.
BOOM ERECTION
( Cowan Sheldon New Crane)
1 Before energizing 140T Crane on electrified section for
operations, ensure that OHE has been made
dead/slewed and secured and power block has been
taken under written memo.
2 Check for “A” frame fully lifted.
3 Depute 01 staff to go up and watch the revving and

un revving of the derrick & Main Hoist wire rope.
Do not run crane without watching of rope revving.
4 Remove Slew Lock Pin before slewing.
5 Slew so that jib is free in trestle before lifting.
With Derrick “IN” operation, Raise boom cautiously.
PROPPING THE CRANE
(Gottwald Crane)
1 Set the propping pads properly by strengthening the ground
and placing the packing alternatively parallel and perpendicular
to the track. Ballasts base may be provided for strengthening.
Depute one staff on each prop to observe. For marshy land,
sand bags can be used for making base for propping. Wooden
packing can also be provided under the out rigger arms leaving
some gap.
2 Do not prop the crane on the unstable ground.
Wooden packing provided should not be in contact with the arm body.
3 In case an entangled load is required to be handled, always work with full
counter-weight and full prop as the actual load may be much more than what
it may appear to be.
4 Check the level of the crane by spirit level.
5 Use Rail Clips as an additional safety. Rail clips as were used in MG

Breakdown cranes are better since the sleeve prevent it from opening.
Rail clip MG
BD Crane
Rail clip BG
BD Crane
PROPPING THE CRANE
(Cowans Sheldon Old Crane)
1 Lock the Draw-beams in
extended position. Packings
should be in sound condition
and placed alternately
perpendicular and parallel to
the track. Check condition of
packings for indication of
sinking.
2 When working in propped

condition- Relieve Laminated
Springs of weight of the crane.
3 Depute one staff on each prop to observe.
4 Do not prop the crane on the unstable ground.

Wooden packing provided should not be in contact with the arm body.
5 In case an entangled load is required to be handled, always work with full
counter-weight and full prop as the actual load may be much more than what
it may appear to be.
6 Check the level of the crane by spirit level.
7 Use Rail Clips as an additional safety.
PROPPING THE CRANE
(Cowans Sheldon New Crane)
1 Set the propping pads properly by
strengthening the ground and
placing the packing alternatively
parallel and perpendicular to the
track. Ballasts base may be
provided for strengthening. For
marshy land, sand bags can be
used for making base for
propping.
2 Ensure that Parabolic Springs are
relieved of the weight of the crane
and lock the Outriggers in
extended position.
3 Depute one staff on each prop to observe.
4 Check the level of the crane by spirit level. Super elevation of the crane to be
corrected with props.
5 Use Rail Clips as an additional safety. Rail clips as were used in MG
Breakdown cranes are better since the sleeve prevent it from opening.
Rail clip MG
BD Crane
Rail clip BG
BD Crane
COUNTER WEIGHT
(Gottwald Crane)
1 Select the total counter weight as per load chart for the load to be lifted.
2 Switch Only used for keeping CWT on chassis,

on if it is not brought back in the operation,
boom SLI safety will be bypassed.
bridgin New Design Old Design
g key.
Do not leave bridging key ON after setting up of CWT.
3 Switch ON key switch, which bridges safe load

indicator.
The crane should not be allowed to slew in this
condition.
4 Pick up CWT and ensure locking of all.
Select the proper prop

position by selector switch
5
as required by the load
chart.
Switch off boom bridging key. Switch off the key switch, which bridges safe
6
load indicator.
7 Load chart should not be violated.
Load estimation should be done properly and to avoid any untoward incident
maximum possible safe operation may be adopted like full prop, full CWT etc.
8 After Rear operation or axle
blocking operation pre-selector
switch for oil transmission should
be brought to “Neutral” position. .
Do not leave pre-selector
switch in ON position.
9 Ensure the CWT switch is in proper position.
COUNTER WEIGHT (Cowans Sheldon Old Crane)
1 Remove slew lock pin.
2 Slew superstructure through 180 degree in line with track.
3 Slide over retaining / locking plate.
4 Slacken off nut on hanger bolts and swing hanger bolts clear of carriage.
5 Jack counter weight up to superstructure, using hydraulic jacks controlled from counter weight
jack control valve situated in the right hand slide of the carriage, For operation of this valve.
6 Slide over retaining latch.
7 Swing hanger bolts into position and tighten nuts using Tommy bar.
8 Re locate hanger bolt latches.
9 Retract counter weight jacks and ensure they are in the stowed position on the carriage.
10 Select the total counterweight as per load chart for the load to be lifted.
Method of Heavy Ballast weight couple

11 Fit counter weight to superstructure.
12 Release locking straps retaining heavy ballast to the ballast wagon.
13 Traverse crane to approach the ballast wagon.
14 Lift ballast with main hoist block from ballast wagon and place on carriage, locking
the ballast weight on the appropriate guide pins.
15 Crane can be slewed at 180⁰ on level track only. If there is a CANT in track i.e.
difference between the track lines level from 13 mm to 140 mm, then before
slewing the crane it should be properly propped and clamped with the track as the
crane is unstable across track. SLI should be properly monitored during slewing.
16 Jack up the ballast weight to the desired height for engaging the support beams.
This being control valve situated in the right hand side of the carriage. For operation
of this valve.
17 Extend ballast support beams through ballast weight.
18 Lower ballast on to support beams ensuring the ballast weight locating pins are
engaged in the support beam.
COUNTER WEIGHT
1 Select the total counterweight as per load chart for the load to be lifted.
2 Follow correct sequence of operations for attaching counterweights. First unlock,

then extend the Counterweight cylinder and swing in, then lift and lock. Similarly
follow this procedure in reverse order for detaching counterweights.
3 Ensure counterweight
(CWT) is correctly locked.
4 Load chart should not be violated.
Load estimation should be done properly and to avoid any untoward incident
maximum possible safe operation may be adopted like full prop, full CWT etc.
5 Ensure the CWT switch is in proper position.
OPERATING PRECAUTIONS
(Gottwald Crane)
1 Do proper selection of lifting tackles (Chain & Wire rope sling).
2 Neither lift Match Truck nor slew in Free on Rail condition.
3 Avoid jerk during operation. Pendulum motion of load is dangerous.
4 Don’t pull the load diagonally.
5 Don’t pull a load which is stacked in the ground unless it is ensured that it will
not offer resistance beyond the capability of the Crane.
6 Take care of wind forces on the boom as it is dangerous.
7 Do not operate crane in high wind force.
8 Do watch the props for any sign of caving by deputing one staff for each prop.
He should also watch carefully the rear wheels for any sign of lifting from the
rail level.
9 Proper signalling is to be given to the crane driver. Driver should also cross-
check the signal by ground staff with condition of load.
10 Do not give multi command to driver.
11 Emergency lower button (Rapid motion switch) should be operated only in

case of emergency and the operation should not be part of the normal
working cycle.
12 Only crane in-charge should communicate with the crane driver. When
required the senior most mechanical officer should give instruction to the
crane in-charge.
13 The SLI does not relieve the crane user from his responsibility to thoroughly
determine the weight of the load to be lifted and check the admissibility of the
operation as per load chart.
(Cowans Sheldon Old Crane)
2 Neither lift Match Truck and nor slew in Free on Rail condition.
rail level.
check the signal by ground staff with condition of load.

working cycle.
crane in-charge.
1 Ensure Safe Load Indicator (SLI) is in
working condition. Set Safe Load
Indicator (SLI) to Main
Hoist (M.H.) or Auxiliary Hoist (A.H.)
position as per requirement.
3 Neither lift Match Truck nor slew in Free on Rail condition.
rail level.
check the signal by ground supervisor with condition of load.
working cycle.
crane in-charge.
GENERAL PRECAUTIONS FOR HANDLING OF LOADS
1 Sometimes, loads are required to be

toppled down. In such cases, hooks
should be fixed in such a way that
after the load is topped down, the
hooks should disengage easily.
Particularly while handling coaches,
experience has shown that the hooks
don’t disengage from load easily if
fixed directly with the sole bar.
2 The toppling should be avoided where there is a deep ditch or trench adjacent
to the track as there will be tendency to topple suddenly that may cause
jerking in the crane or even toppling.
3 While a load is being lifted

it should be guided by
attaching ropes on
diagonally opposite sides
held by staff cautiously, to
avoid pendulum like Rope attached for guiding the load
motion.
4 The load should be lifted slowly just above the ground level and held for some
time to avoid swinging.
5 For easy fixing of sling hooks to a load, ropes can be used to bring the hooks
to each side of the load.
6 Diagonal wheels of the crane on opposite sides should be observed for any
sign of lifting.
7 During restoration, load should not be dragged except with the hauling winch.
However, if it is extremely necessary, only light load can be pulled, keeping the
crane jib “inline”.
8 Gas cutting should not be done in inflammable objects like oil tankers, fuel oil
tank of locomotives etc.
Also any fire should be doused off completely before handling with the crane.
PREPARING THE CRANE BEFORE LEAVING FOR SHED (GOTTWALD)
1 Leave 8T cwt on the chassis in the direction of match truck for New Design
Gotwald crane.
Leave 5.2 T cwt on the chassis in the direction of match truck for Old Design
Gottwald crane.
2 Unload CWT On the match Truck.
3 Boom out to 17 M radius for new design and 16 M for old design crane. For
this switch “ON” boom over bridge key (SLI By Pass Key).
4 Switch “ON” computer over bridge key. (SLI By Pass Key).
5 Boom down until both hooks lower into match truck well and boom rest pin
matches with the recess in trestle.
6 Boom down until boom slides fully into the boom rest to the lock position.
Operate the boom root cylinder in new design cranes. At this point, lock the
boom in the trestle.
7 Unlock rear section with the help of lever. Lower rear section up to its last
position (for New Design).
8 Derrick out until the ropes are slack over the operator’s cab. Slackness will
help to negotiate the track curve.
9 Release axle blocking. Shift pre-selector switch in Driver Cab in Neutral
position & secure Propp with PIN.
10 Brake hoses should be
connected as per the
requirement. Angle cocks
should be opened only after
release of Crane air brake.
Release parking brake in the last when the crane is going to be formed in
train order.
PREPARING THE CRANE BEFORE LEAVING FOR SHED
(COWANS SHELDON OLD)
1 Prior to coupling back relieving
bogies, clean and regrease the
Crane Carriage end castings
and Coupling Pins on both ends
2 After coupling back the

Relieving Bogies, top up grease
cups (Spring Feed Lubricators)
of both Relieving Bogies.
3 Lower the A frame keeping Derrick Wire Rope in a reasonably tight condition.
4 For "In-train" running -

Load the Relieving Bogies until
Centre Casting Locking Pin slides
into position and then release the
Jack completely.
5 Remove 32 T CW and place at

nominated location on Ballast
Wagon.
6 Remove detachable Counterweight (
12 T )and place at nominated location
on Crane Carriage.
7 Load the Crane Springs by

unscrewing the Blocking Screws.
Ensure sufficient gap between top of
Spring Buckle and screw for free
movement of springs.
8 Disengage traveling Clutches.
9 Check that Draw Beam Jacks are

fully retracted and locked.
10 Ensure that the coupling hoses between the carriage and relieving bogies
(both end) are connected properly. Also ensure the same between match
wagon and ballast truck of the crane.
PREPARING THE CRANE BEFORE LEAVING FOR SHED
(COWANS SHELDON NEW)
Remove Counter Weights and place at nominated location on Match Truck.
2 Unload the Crane Springs by retracting
Axle Blocking Jacks and ensure
sufficient gap between top of Spring
Buckle and Jack.
Ensure blocking pads are

removed/relieved and secured.
3 Disengage traveling Clutches.
4 Ensure Outrigger Jacks and Outriggers are retracted fully and locked in position.
5 Ensure that Slew Lock Pin is in locked

Position
6 Boom down until both hooks lower into match truck well and boom rest pin
7 Derrick out until the ropes are slack over the operator’s cab. Slackness will
help to negotiate the track curve.
8 Ensure that Slew Lock pin is in locked position.
9 Lower the A frame fully.
10 Release axle blocking.
Ensure Crane Service and Parking Brakes are released.

10 Brake hoses should be
connected as per the
requirement. Angle cocks
should be opened only after
release of Crane air brake.
Safety of Rescue Workers

1 Staff working in rescue operation must wear safety gears/PPEs (personal
protection equipments ) like hand gloves, helmet , safety shoe etc. particularly
those handling the hook engagement etc.
2 The staff should not come under a
lifted load neither they should handle
it manually without attaching rope for
guiding.
3 If the adjacent track is given safe for traffic, safety of staff must be ensured
from running trains by communicating arrival of trains on megaphone.
Always keep Red flag/Red lamp for emergency.
4 While working on Bridges in high current, safety precaution like life jacket etc.
must be worn by staff working at vulnerable locations.
5 While working in tunnels, No staff should remain inside tunnel while pulling of
the load is in progress.
6 Ensure OHE block before starting rescue operation with crane in electrified
section.
7 Safety during gas cutting of any part of a loaded stock.
8 Ropes should be used for guiding the lifted loads.
9 Wooden Wedges should be placed under wheels of a stock to avoid rolling

down.
10 Before slewing, everybody in the vicinity should be alerted.
11 Rescue site should be barricaded with the help of Safety cone and Barrier
tape.
12 Before tackling petroleum wagons, leakage detection for gas should be
carried.
13 First aid kit should be kept ready.
STAFF DEPLOYMENT DIAGRAM FOR
GOTTWALD 140T CRANES
CHAPTER - 3
DEPLOYMENT OF
BREAK DOWN STAFF
AND
COMPOSITION OF
ARTs
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 Te. 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 not perform strenuous duties,
should gradually be withdrawn from ART/ARME's.
3. ART staff inducted for Breakdown duties must be qualified. They must posses 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, 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:
- DAILY CHECKS
- SCHEDULES
- MAINTENANCE OF RE-RAILING EQUIPEMENT
- EXAMINATION OF WIRE ROPES
- GENERAL UPKEEP OF TOOLS AND EQUIPMENT
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.
- How to work in close coordination with other supporting agencies such as fire
brigade, police and local voluntary organization etc. at the time of Railway
accident.
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 5 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.
Review of Staffing Yard stick of ART/ARME.
[Ref: HQ (CSTM) letter no. T.153.L.5.ART Review dated 18.02.2003 ].
-----
Staff required for “A”Class ART with 140 Te. Cowans Sheldon Crane
SN Type of Staff Existing Staff required to be

deployed
A 140 Te. Crane Operation Gang
01 Section Engineer 01 01
02 JE-II/I 01 01
03 Crane Operator 02 02
04 Diesel Mech & Electrician 02 02
05 Technicians 02 02
06 Fitters (Including Kitchen man) 04 10
07 Welder 02 02
08 Outrigger Khalasis 14 14
09 Welder Khalasi 01 01
TOTAL 29 35
B Electrical Gang
01 Elect. Supervisor -- 01
02 Eletrical Fitters 03 03
03 Electrical Khalasis 02 03
TOTAL 05 07
C Telecom. Gang
01 Tele. Inspector -- 01
02 TCM Fitters 02 02
03 TCM Khalasi 01 01
TOTAL 03 04
D C&W Gang
02 C&W Fitters -- 05
03 C&W Khalasi -- 07
TOTAL 01 13
E Engineering Gang
01 JE-II (P. Way) -- 01
02 Mukaddam/Gangman 03 03
TOTAL 03 04
Total Complement of Staff 41 63
Staff required for “A” &”B”Class ARTs for Restoration by MFD/Lukas
SN Type of Staff Existing Staff required to be

deployed
A MFD Operation Gang
01 SSE/SE 01 01
02 JE-I/JE-II 01 01
03 Technicians 02 02
04 Fitters (Including Kitchen man) 04 08
05 Welder 01 02
06 Khalasis 10 08
07 Welder Khalasi 01 01
TOTAL 20 23
B Electrical Gang
01 Elect. Supervisor -- 01
02 Eletrical Fitters 03 03
03 Electrical Khalasis 02 03
TOTAL 05 07
C Telecom. Gang
01 Tele. Inspector -- 01
02 TCM Fitters 02 02
03 TCM Khalasi 01 01
TOTAL 03 04
D C&W Gang
02 C&W Fitters 02 02
03 C&W Khalasi 02 02
TOTAL 05 05
E Engineering Gang
01 JE-II (P. Way) -- 01
02 Mukaddam/Gangman 03 03
TOTAL 03 04
Note: If ART is maintained by Diesel sheds then only 05 C&W staff as shown at Item No.D
should be nominated.
Staff required for ARME
SN Type of Staff Work Distribution Existing Staff required
to be deployed
A MECHANICAL STAFF
01 Supervisor For Supervision 01 01
02 Fitters (Including Kitchen man) For Rescue Operation 02 03
03 Welder For Cutting works 02 02
04 Khalasis For loading/Unloading 06 06
05 Welder Khalasi To assist Welder -- 01
TOTAL 11 13
B Electrical Gang
01 Elect. Supervisor For Elect Lighting -- 01
02 Eletrical Fitters For Elect Lighting 02 02
03 Electrical Khalasis For Elect Lighting -- 02
TOTAL 02 05
C Telecom. Gang
01 Tele. Inspector For Telecom -- 01
02 TCM Fitters For Telecom -- 01
03 TCM Khalasi For Telecom -- 01
TOTAL 00 03
D Medical
01 Doctor’s For Medical Aid 02 02
02 Dresser For Medical Aid 01 02
03 Nurses For Medical Aid 03 03
04 Pharmasist For Medical Aid 01 01
05 Safai Wala/H.A. For Medical Aid 04 04
TOTAL 11 12
D R.P.F Staff
01 Inspector For Relief & Rescue 01 01
02 Constable For Relief & Rescue 02 02
TOTAL 03 03
Staff required for CRACK TEAM
SN Type of Staff Work Distribution Existing Staff required

to be deployed
A MECHANICAL STAFF
01 Mechanical Deptt. Relief/Rescue NIL 04
02 Medical Deptt. Relief/Rescue NIL 02
TOTAL STAFF 06
DEPLOYMENT
AND
WORK DISTRIBUTION
OF
BREAK DOWN STAFF
AT
ACCIDENT SITE
DEPLOYMENT AND WORK DISTRIBUTION OF BREAK DOWN STAFF AT ACCIDENT SITE
(REF:- CRLY.HQ office Letter No. T.651.L.3/140Te. Dated 14.03.1991 (140 Te. CRANE OPERATION )
SN Category Staff Grade Name of the Staff Duties
1.Overall incharge of BDT and 140 Te. crane
01 SSE 01 7450-11500 Sh. 2.To Plan Line of Action at accident site
6500-10500 3.To maintain liaison with other Departments
Sh. 1.Responsible for smooth and safe operation of 140 Te. crane.
02 J.E 01 5500-9000 2.For efficient and safe working of Crane and Staff
3.Responsible for proper maintenance and operational parameters of 140 Te. Crane.
03 Crane 02 5500-9000 Sh. 1.For operation of the 140 Te. Crane in shifts at Accident Site.
Operator 4500-7000 Sh. 2.Responsible for safe working at accident site and checking of Crane
04 Crane/Asstt. 1.To assist Crane operator in pre-start checks.
2.To secure hand brake of match wagon, ballast wagon and relieving bogies after
being detached.
a. Dsl/Mech. 01 4500-7000 Sh. 3.Release air brakes of 140Te.Crane prior to operation of the Crane
3050-4590 4.Will be vigilant to observe unusual sounds in the Crane and stability of Crane
operation standing on Left hand side.
5.Will be responsible for general upkeep of 140 Te.Crane at Accident sites.
1.Will monitor derrick operation for safe working.
2.He will keep close watch for checking of leakages on Hydraulic, Electrical & Fuel
pipe lines while Crane is at site and in operation and be vigilant for unusual
b. Elect. 01 4500-7000 Sh. occurrence.
3.Will operate Fire extinguishers in case of fire on 140 Te. Crane.
4.Will be vigilant for unsafe condition and stability of Crane in operations ,standing on
Right hand side.
Sh. 1. Will remain in Toolvan/Gen./MFD van,during whole relief operations for ART management.
05 Dsl/Mech. 02 4500-7000 Sh. 2. Will maintain handout tools, equipment's, petromaxes, Kitchen Car and other items and receive
3050-4590 back the same for correct accountal. Will take photo of accident site
Sh. Sh. 1.Transport of Packings to and from Material Van and Crane site.
Sh. 2.Proping and securing of Crane (All the 6 props of 140 Te.Crane)
06 Skilled Gr.I 06 4500-7000 Sh. 3.Continuous vigilant watch on crane wheels and stability of props, packings and
Sh. communicate to Crane Driver and supervisor through walkie talkie sets while Crane
SH. in operation.
07 Skilled Gr.II 04 4000-6000 Sh. 1.Slinging operations for main hook/Aux. hooks on loads ,Vehicles to be lifted
Sh. 2.Will be assisted by Unskilled from Packing gang for applying hooks.
Sh. Sh. 1.Transport of Packings to and from Material Van and Crane site.
Sh. Sh. 2.Proping and securing of Crane (All the 6 props of 140 Te.Crane)
08 Unskilled 10 2650-4000 Sh. Sh. 3.Continuous vigilant watch on crane wheels and stability of props, packings and
Sh. Sh. communicate to Crane Driver and supervisor through walkie talkie sets while Crane
Sh. Sh. in operation.
09 Unskilled 02 2650-4000 Sh. Sh. 1.Slinging operations & propping for Main hook/Aux. hooks on loads, Vehicles to be lifted
2550-3200 Sh. Sh. 2.Will be assisted by Unskilled from Packing gang for applying hooks & propping.
Sh. Sh. 1.Slinging operations & propping for Main hook/Aux. hooks on loads, Vehicles to be lifted
10 Unskilled 02 3050-4590 Sh. Sh. 2.Will be assisted by Unskilled from Packing gang for applying hooks & propping.
11 Welder 02 4500-7000 Sh. 1. To carry out cutting of infringements of damaged vehicles, rails, etc.
2. To help in carrying out operations mentioned above.
12 Welder 01 3050-4590 Sh. 1. To carry out cutting of infringements of damaged vehicles, Rails, etc.
Helper 2650-4000 Sh. 2. To unload and transport gas welding equipment's and to help welder in carrying out
operations mentioned above.
Total 35
DEPLOYMENT AND WORK DISTRIBUTION OF BREAK DOWN STAFF AT ACCIDENT SITE
(REF:- CRLy.HQ office operating branch Letter No. T.651.L.3/140Te. Dated.14.03.1991.)
M.F.D OPERATION (Hydraulic Rerailing Equipment operation ):
SN Category Staff Grade Name of the Staff Duties
1.Overall incharge of BDT
01 S.S.E./S.E 01 6500-10500 Sh. 2.To Plan Line of Action
3.To maintain liaison with other Departments
1.Direct Incharge of MFD for efficient and safe operation.
02 J.E-I/J.E.- II 01 5500-9000 Sh. 2.For efficient and safe working of MFD equipment's and staff.
3.Responsible for Maintenance of hydraulic equipment's
03 DSL/Mech./ 01 4500-7000 Sh. 1. For operation of control table.
Fitters 2. Will maintain MFD equipment's for safe working and accompany BDT at site.
04 DSL/Mech./ 01 4500-7000 Sh. 1. For ensuring safety by Megaphone and operation of motor & pump.
Fitters 2. Will maintain other electrical equipments given time to time.
05 DSL/Mech./ 05 4500-7000 Sh. 1. To unload & transport LUCAS/MFD equipment's.
Fitters Sh. 2. To apply hydraulic jacks & lift, Traverse & Rerail the vehicle.
Sh. 3. To transport wooden packing to and from material van to site of operation.
Sh. 4. To build wooden packing bases under the jacks & under the wagon body during
Rerailing operation.
06 DSL/Mech./ 02 4500-7000 Sh. 1. Will remain in toolvan /gen./MFD van during whole relief operations.
Fitters Sh. 2. Will maintain handout tools, equipment's, petromexes and other items and receive
back the same for correct accountal.
Sh. Sh. 1. To unload & transport LUCAS/MFD equipment's and packings.
Sh. Sh. 2. To apply hydraulic jacks & lift, traverse & Rerail the vehicle.
07 Unskilled 2+4 2650-4000 Sh. Sh. 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.
08 Unskilled 02 2650-4000 Sh. 1.To unload & transport LUCAS/MFD equipment's and packings
Sh. 2. Will maintain handout tools, equipment's, petromexes and other items and receive
Sh. back the same for correct accountal.
2. To help in carrying out operations mentioned above.
Helper 2. To unload and transport gas welding equipment's and to help welder in carrying out
operations mentioned above.
11 Kitchen Staff 02 4500-7000 Sh. 1. Complete Kitchen management and loading/unloading of Inflatable lighting Tower
Total 23
COMPLEMENT OF STAFF
01. S.S.E - 01
02. S.E - 01
03. J.E - I / II - 01
04. CRANE OPERATOR - 02
05. CRANE ASSTT.(1 MECH.+1 ELECT.) - 02
06. SKILLED GR-I - 10
07. SKILLED GR-II - 06
08. SKILLED GR-III - 07
09. UNSKILLED - 24
10. WELDER - 02
11. WELDER HELPER - 02
TOTAL - 58

Composition of ART:
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 were proposed as 6 numbers only. In “A” class ART, by including crane as 1st
and 2nd vehicle, the total number of vehicles shall not be more than 8. But in the present
scenario, there was a need to review the old compostion consequent upon introduction of
HLC recommendations & present requirement of space for storing tools and equipments.
The revised compostion will be as under -
1. In “A” class ART Total number of coaches will be 5+3 wagons with one Crane.
1st vehicle will be 140 Te. capacity diesel/steam break down crane with Match Truck
2nd vehicle will be BCN HS (Crane packing Van and heavy tools, wire ropes & OHE material
3rd vehicle will be Crane Staff and Kitchen Van.
4th vehicle will be BRN HS (containing Rails and Crossings).
5th vehicle will be BCN HS (complete Engineering Material and OHE items)
6th vehicle will be Tool and Equipment Van (All critical mechanical tools, office, and Fire
fighting section. Provision of guard seat with guard van valve)
7th vehicle will be C&W, Elect. and Telecom.Van (Material of Telecom, Elect. & C&W)
8th vehicle will be Re-railing Equipment Van (MFD/LUCAS equipments and its material)
9th vehicle will be Staff and Kitchen Van (MFD/LUCAS staff and Kitchen).
1. 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. More often that not only LUCAS/MFD is ordered without Break down crane,
Break down crane too ordered without Lucas/MFD. If only LUCAS/MFD is ordered
then the Break down formation would be as under:
1st vehicle will be BRN HS (containing Rails and Crossings).
2nd vehicle will be BCN HS (complete Engineering Material and OHE items)
3rd vehicle will be Tool and Equipment Van (All critical mechanical tools, office, and Fire
4th vehicle will be C&W, Elect. and Telecom.Van (Material of Telecom, Elect. & C&W)
5th vehicle will be Re-railing Equipment Van (MFD/LUCAS equipments and its material)
6th vehicle will be Staff and Kitchen Van (MFD/LUCAS staff and Kitchen).
3. 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 BCN HS (Crane packing Van and heavy tools, wire ropes.
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.
4. Composition of ARME
1st vehicle will be Auxiliary Van (RHV) to RDSO Sketch No. CG-K 4044 (Vestibuled)
2nd vehicle will be Medical Relief Van (RH) to RDSO SKetch No. CG-K 4046 (Vestibuled)
Staff Deployment for Accident Relief Trains
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 equipments.
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 Designation No. of Duties at accident site

N staff
1 Sr.Section Engineer(L) 1 Over all incharge of Accident Relief Train
2 Section Engineer(L)/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 Crane 1 Assist crane operators in safe operation
assistant Gr.I maintenance of crane
8 Technicians Gr.II (Electrical 1 Assist crane operators in safe operation of crane
cum crane assistant) and maintenance of elect. equipments.
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
12 Skilled C&W Staff 6 For Hook, slinging work and binding of lashing
chains.
3. Staff Deployment on “A” class ART for only LUCAS/MFD operation:

N staff
1 SSE/Section Engineer(L) 1 Efficient, safe working, maintenance and upkeep
of ART
2 Jr. Engineer(L) 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
7 Welder Helper Khalasis 1 He will assist HS welder in the task mentioned
above
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:

N staff
1 Sr.Section Engineer (L) 1 Over all supervision and crane maintenance
2 Section Engineer(L) 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 Tech 1 Daily check and schedules
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)
5. Deployment of staff for 140 Te. Crane/Special:
S Designation No. of Duties at site
N staff
1 Sr.Section Engineer(L) 1 Over all incharge of Crane/Special
2 Junior Engineer (L) 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 Crane 1 Assisting crane operators in safe operation of
assistant Gr.I crane
5 Technicians Gr.II (Electrician 1 Assisting crane operators in safe operation of
cum crane assistant) crane
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.
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:
N staff
1 SSE/Section Engineer(L) 1 Efficient, safe working, maintenance and upkeep
of ART
2 Jr. Engineer(L) 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
7 Welder Helper Khalasis 1 He will assist HS welder in the task mentioned
above
cooking of meals.
Total staff 23
Deployment of maintenance staff in “B” class ART/SPART would be as under:

N staff
1 Section Engineer(L) 1 Over all supervision and ART/SPART equipment
maintenance
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
7. 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 incharges 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.
Deployment of Staff in the Kitchen for “A” & “B” class ART and SPART:
Dept Designation No. of Duties at accident site

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
Scale of Rations for ART:
(ApendixIV of committee’s report of 1985)
Scale of ration propsed for 40 break down 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 Vegitables : 40 Kg.
a. Potatos : 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.
b. Sugar : 3.2 Kg.
c. Milk :
4.0 Cooked Rice : 20 Kg.
a. Raw Rice : 08 Kg.
5.0 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.
6.0 Salt for Service : 1.0 Kg.
7.0 Condensed Milk : 10.0 Tins
8.0 Other common items : (As per standard Proforma)
Note: Potatos and Onions may be replaced every two weeks if not used. Scale fixed jointly by maintenance
loco Inpector/Incharge of Break Down & the commercial inspector of BSL Div.(Apendix-IV)
BASIC DUTIES IN CASE OF ACCIDENT
The senior most officials at site is required to take overall charge and
co-ordinate to the relief measures. Duties may be summarized in the
following order.
P = Protect
R = Report
A = Assist
01. Protection of the Site of Accident.

02. Information of the Accident to control as asking for assistance-
Ordering of BDT, emergency lighting.
03. Kilometerage or Station both at which accident occurred.
04. Time and date of accident
05. Number and description of the train
06. Nature of Accident.
07. Number of people killed/injured.
08. Extent of damage.
09. Cause of accident.
10. Probable detention to Train.
11. Nature of assistance required.
12. Rescue and Medical Relief - Cares of dead and injured.
13. Protection of property.
14. Assistance to Passengers - Drinking water, Meals, Enquiry counter.
15. Preservation of clues - Conditions of points, Signals, levers.
16. Recording evidence in brief, Joint check of track, rolling stock.
17. Arrange constant manning of portable phone.
18. Take written statements of independent witnesses.
RELIEF AND RESCUE CRACK TEAMS:
A) Crack Teams at Each Zonal Railway HQ with containerisation equipment to be

introduced :
(i) Zone is proposed to have a professionally trained crack team of rail rescue experts and
containerised 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: -
1. Extrication/removal of injured passengers from the coach.
2. First Aid to the injured.
3. Provide succour and help to the passengers at site.
4. Relieve panic and create re-assurance among passengers.
Special Disaster management team of RPF:
Special disaster management team of RPF has to be set up at Jabalpur, Bhopal & Kota for
proceeding support to relief and restoration at the site of accident. They shall also reach at
accident site by first available means.
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 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 Loco Foreman /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 in S.Rly)
In case of single exit sidings - 20 Minutes.(25 minutes in S.Rly)
The time is reckoned from the time of ordering to the time of despatch.
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.
Duties of ARME Incharge –
1. On getting ordering of ARME for accident site, he shall reach on ARME immediately.
2. After getting attendance of ARME staff, he shall ensure timely dispatch of ARME from base
station.
3. He will ensure provision of BPC to the ARME loco Driver.
4. He shall counsel ARME staff regarding nature of relief will be provided, in the running train.
5. He will ensure proper nomination of staff for making team for each activity before reaching ARME
at accident site.
6. He shall keep VHF set in “ON” position for communication between ARME and Control Office.
7. ARME incharge will collect information regarding nature of accident and involvement of number
of coaches in the accident.
8. Operation of cold cutting equipments like Hydraulic Rescue Device, Power Cold Cutter and
Portable Electrically operated cutting and boring tools should be checked in the running train.
9. He shall give instructions for preparation of coffee and tea for injured passengers.
10. He will check functioning of portable DG sets for operation of electrical machines and lighting
equipments.
11. On reaching at accident site, he shall contact guard and driver of accidented train on walkie –talkie /
VHF set for collection of information regarding accident and nature of assistance required.
12. He shall give instructions to the nominated team leaders of ARME to unload relief materials
immediately. Incharge will carry video/digital camera and proceed for observation of accident site.
13. Incharge will decide extrication of injured passengers on priority manner.
14. He will ensure proper utilisation of cold cutting equipments so that passengers will not get injuries
due to wrong operation of such equipments.
15. He will relieve panic and create reassurance among injured passengers.
16. Injured and dead passengers will be removed and kept at specified/nominated spots in the presence
of ARME incharge.
17. He will maintain liaison with other departments like, Commercial, RPF and Medical departments
for smooth and efficient relief measures.
18. He shall communicate progress of relief, time-to-time to control office staff on ECP/PCP sets with
the consultation of site incharge.
Duties of R.P.F Staff:
On reaching at accident site, RPF Staff shall perform his duties as under -
1. Extricate the passenger from damaged coach and shall provide first aid to them. He
shall assess the affected passengers also at accident site.
2. He shall ensure safety and security of the relative/dependents of injured passengers

as well as security of Railway property.
3. He shall collect and protect clues of accident i.e. security of P.Way material, fish
plates & nut bolts etc. and other related material caused derailment. He shall keep
close watch on the clues for dislocation by the persons.
4. He shall cover the site of accident by Barrier taps to avoid theft in the accidental
coaches by out siders.
5. He shall keep away the outsiders from accidented coaches with the help of loud
hailers.
6. He shall ensure continuous monitoring of the suspected items and clues, caused
accident, to understand fact of incident for conclusion during investigation.
7. He shall be responsible for extinguishing the fire, in case of fire in the coaches.
8. He shall assist civil police/GRP in the enquiry proceedings of accident case.
9. He shall ensure security of luggage and parcel of passengers in the damaged /

capsized coaches.
Relief and Rescue Operation by ARME staff:
ARME incharge 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.
2. 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 equipments, 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
required.
E-Team:
1. During night, the team will unload, lighting equipments 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 C-Team 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
STAFF MANAGEMENT:
(Boards letter No. 66-M(M&P)/7/2 dated 04.11.1968)

(CRLy./CSTM Letter No. T.651.L.3/140 T dated 14.03.1991)
1.0. The suggested ART 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 Electrical Telecom. C&W

Class Crane Gang Gang Gang Gang
ART (Measurement)
Cowans Supervisor -1 Sup. (Mech.) -1 Sup. - 1 Insp. - 1 Sup. (Mech.) -1
Sheldon Crane Drivers -2 Fitters- 10 Fitters- 3 TCMFitters-2 Fitters- 5
140 Te. Asstt. Crane Driver -2 Welders-2 Khalasis-3 Khalasi - 1 Khalasis-7
Crane Out rigger Khalasis-14 Khalasis-1 TOTAL -7 TOTAL -4 TOTAL -13
TOTAL - 19 Welder Khalasi-1
TOTAL -15
Gotwald Supervisor -1 Super. (Mech.) -1 Sup. - 1 Insp. - 1 Sup. (Mech.) -1

140 Te. Crane Drivers -2 Fitters- 6 Fitters- 3 TCMFitters-2 Fitters- 5
Crane 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.)-1

Class JE-II - 1 Fitters- 3 TCMFitters-2 Fitters- 2
ART Fitters- 10 Khalasis-3 Khalasi - 1 Khalasis-1
Welders-2 TOTAL -7 TOTAL -4 TOTAL -4
Khalasis-8
Welder Khalasi-1
TOTAL -23
ARMV SCALE-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
Total - 12
Crack -- -- Mechanical-4 -- -- --
Team Medical-2
Total - 6
2.0 Selection of ART/ARME STAFF:
2.1 Since the staff nominated to work on ART/ARME/140Te Crane gang has to work long hours,
perform and arduous duties, lift heavy loads and work in close co-ordination and co-operation with
each other as a close knit team, it is essential that they are selected with great care so as to get the
best results out of the team. The following criteria for the selection of staff to work on
ART/ARME/140Te. Crane gang:
2.2 Physical Fitness:
He should be physically fit and capable of doing hard work. He should be strong and possess
excellent stamina to do long hours of work without getting fatigued. A person who gets quickly
fatigued is not only incapable of giving well out put but is also unsafe and may endanger lives of
his co-workers. So, only those who enjoy robust health should be chosen for ART work.
2.3 Accident Proneness:
An accident prone person is not only a menace to himself but it also a potential danger to the lives
of his colleagues. It is therefore necessary to examine the service records as well as the actual
habits to check how careful a person is in his work and how safe his working habits are.
2.4 Reaction time:
Since the relief work needs quick response to orders as well as the fast changing situations to avoid
personal injuries or injuries to others and for quickness of work, it is essential that the person has
excellent reaction time for quick response to situation and is always alert.
2.5 Skill:
The Artisans selected for the gang must be dexterous and possess more than average skill. They
must show aptitude in their own field or work. Similarly, even unskilled staff must be tested for
the correct aptitude for the job.
2.6 Team Sprit:
The entire relief operations depend on team work, mutual trust and close co-operation and co-
ordination amongst the members. Any person not meeting these requirements has therefore no
place in the gang. The individualist or egoist person should be kept out of this gang.
2.7 Intelligence and resourcefulness:
The situations at the site of accident are varied and require lot of resourcefulness and ingenuity in.
2.8 Sincerity, willingness and obedience:
The persons must show his willingness to work on this job of relief operations and must be sincere
in his duties. He must be obedient so as to avoid friction, etc.
2.9 Attendance:
Only those regular in attendance should be taken on this gang so that every time there is a call,
they invariably report on duty. Since the gang strength is based on assumption that every body
will present himself, even a single person remaining absent can cause upsetting the team work.
Even after nomination, if a person is found absconding, he should be removed from the gang
immediately.
2.10 Leadership:
A few persons should be those who show leadership qualities who can act as guide and group
leaders of the available staff.
3.0 Railway Quarters:
3.1 Besides being an incentive to the staff to volunteer to work on the ART gang, it is also in the
best interests of the administration to provide proper residential accommodation to every person
nominated for the ART gang. So, adequate no. of Quarters for the entire gang should be ear-
marked as ART quarters. Tendency of the staff to use this as a means of getting a house allotted on
priority should be curbed.
3.2 Quarters for ART/Crane Staff must be as close as possible to the ART stabling siding.
4.0 Uniforms:
4.1 It is recommended that all the ART gang staff should have orange badge with maroon lettering
indicating their names and the trades to identify them for specific work. The uniforms are to be
kept in ART and are to be issued only while proceeding to the site of the accident.
4.2 Working conditions have already been examined carefully at the site of accidents and
requirements of protective clothing and are convinced that ART staff should be supplied with two
sets of tough uniforms once every two years.
4.3 The uniform should be such as to make the staff look smart and give a feeling of pride
and special belonging to a particular task force. It should also afford protection and
identification under all conditions of working including night working. The committee considered
the various styles of uniform in use by relief gangs and the fire fighting staff and recommended the
following:
1. Recto reflecting Jacket - Bright Orange

2. Pants - Dark Brown
3. Shirts - Light Blue shirt
3. Shoes - Ammunition boots(Safety shoes)
4. Helmet (Hard Hat) - Orange Fibre Glass
5.0 Mock Drills:
5.1 In addition to the staff undergoing training courses suggested earlier, there should be regular
drills every month to keep the staff alert and efficient. During these drills, the staff should train as
if there is an accident and all shortcomings notice should be eliminated till perfect co-ordination is
achieved in starting the relief train work in the least possible time.
6.0 Monitoring Organisation:

6.1 To ensure that the instructions contained in the maintenance manual are fully carried out, it is
necessary to Monitor the entire aspect of the working of the ART/ARME/140Te. Crane
closely both at the Divisional Level as well as at the HQRS Level. It is noticed that at
present the ART/ARME/140Te. Crane does not receive proper attention at an
appropriate level and the neglect and deterioration of the standards follows with
serious effects on efficiency of the relief operations. For achieving excellent performance
out of ART/ARME/140Te. Crane and its staff, it is essential that a Good Monitoring Organization
is set up on the Division and also in the HQRS under the Control of the Sr Divisional Mechanical
Engineer and Chief Mechanical Engineer respectively.
7.0 Divisional Monitoring Organization (DMO):
Under the Sr. Divisional Mechanical Engineer, There should be a separate

experienced Divisional Mechanical Engineer (ART) only for the work of
ARTs/ARMEs/140Te. Crane. He should be responsible for upkeep and maintenance of all
ARTs/ARMEs/140Te. Cranes on the Division and training ART/ARME/Crane staff in the
manner laid down in the chapter VII of manual for modernization of ARTs. He will be
assisted by one experienced inspector in appropriate grade of say Rs. (9300 – 34800)GP
4600/- Who himself should be fully trained for the ART/ARME/Crane work. In addition,
they will attend all serious accidents where possible to do so and make recommendations,
improvements, modifications, etc. As considered necessary based on the experience gained
by them and staff while supervising/doing relief work at the site of the accident.
Implementation of their own recommendations, follow up of the recommendations of the
accident enquiry committees and High Level Committee concerning the ART/ARME/140
Te. Crane and the policy directives issued by the head quarters monitoring organization
will be one of their main functions.
****
CHAPTER - 4
IMPORTANT RULES
FOR
ARTs/ARMEs & SPARTs
ORDERING OF BREAK DOWN TRAIN/MEDICAL VAN
[SAMPLE: CRly Accident Manual Para-405(1)&(2)]
On receipt of advise of an accident, the CHC/Dy CHC(P) and on an uncontrolled
section the Station Master of the Terminal station, shall order Medical Van and / or Break
Down/Tower wagon in consultation with PCOR and Mechanical officer as necessary.
Sounding of Accident Alarm Hooters

Electric Alarm Siren/Steam Hooters are provided in the loco shed at stations where
accident relief train /Medical Van are stabled. The Siren /Hooter must be sounded
immediately after notice of accident is received requiring the Medical Van/Break
Down Train.
Following Codes are prescribed for sounding alarm Siren/Hooter.
SN Blasts Description
01 02 long Blasts each of 45 seconds For Accident in Loco/Yard at Home station
duration with 05 seconds break. requiring Break Down Train only.
02 03 long Blasts each of 45 seconds For Accidents out side Home station
duration with 05 seconds break. requiring Break Down Train only.
03 04 long Blasts each of 45 seconds For Accidents at Home station requiring

duration with 05 seconds break. Medical Van and Break Down Train.
04 05 long Blasts each of 45 seconds For Accidents out side the Home station
duration with 05 seconds break. requiring Medical Van and Break Down
Train.
05 01 long Blast of 90 seconds duration For cancellation of Medical Van/Break Down
Train.
Note: - The Alarm Signal shall be repeated twice with an interval of 05 minutes
Between each code signal.
Target Time for turning out the Medical Van/Break Down Train.
The target time for turning out the ARTs/ARMVs differ from Railway to Railway. However,
common practice for turning out ARTs and ARMVs in most of the zonal Railways is given
as under for information.
SPART/MEDICAL VAN
In case of double exit siding : 20 Minutes
In case of single exit siding : 25 Minutes
BREAK DOWN TRAIN
During Day : 30 Minutes
During Night : 45 Minutes
Note: Zonal Railways should follow their accident manuals for detailed
procedure of ordering.
What do you understand by the term "Break Down" for the purpose
of concessions for attending to break down duties?
Break down may be any accident which involves the calling out of a break down train or
engine with special staff or equipment (including MFD equipment and traffic crane) from
the nearest break down train depot or shed, or breach or wash-away on the line which
interrupts normal traffic. The following which interrupt normal traffic on running lines will
also be treated as "break down"-
1. Snapping of overhead electric traction/lines which involves calling out of
Tower wagon or break down lorry.
2. Damage/bursting of points requiring the attendance of a "break down"/

Repair/Maintenance gang.
3. Break Down of interlocked lifting barriers.
4.Total interruption of communications/Telecommunication or of power

Supply.
(1420(4) RII& R.B's No.E(P&A) II/91/BDA/1/DC/JCM of 13.08.91)
BREAK DOWN ALLOWANCE RULES FOR STAFF
1420. Railway employees deputed for break down duties will be

entitled to the following:-
Consequent upon the decision taken by the Government on the recommendations of the Six
Central Pay Commission relating to various allowance, the Board have decided that the rates of
Breakdown Allowance indicated in this Ministry letter No. E(P&A)II-98-BDA-I dated 25.05.1999
may be revised as under:-
S Category Revised Pay Structure Amount of
N Breakdown
Pay Band Grade Allowance/
Pay month
1 Helper Gr.II/Helper Gr.I/Other Gr. -15 (4440-7440) 1300* Rs. 80 p.m.
‘D’staff -15 (4440-7440) 1400*
-15 (4440-7440) 1650*
PB-1(5200-20200) 1800
2 Technician Gr.III PB-1 (5200-20200) 1900 Rs. 120 p.m.
3 Technician Gr.II PB-1 (5200-20200) 2400 Rs. 160 p.m.
Technician Gr.I PB-1 (5200-20200) 2800
Supervisors (Erist while mistry) PB-1 (5200-20200) 2800
4 Sr. Technician/Junior Engineer and PB-2 (9300-34800) 4200 Rs. 200 p.m.
staff in Higher Scales & above
(*Till placed in PB-1)
2. The rate of this allowance will be increased by 25% whenever the Dearness Allowance
payable on the revised pay structure goes up by 50%.
3. These orders take effect from the date of issue of this letter.
4. In exercise of the powers conferred by the proviso to Article 309 of the Constitution, the
President is pleased to direct that Rule 1420 of Indian Railway Establishment Code,
Volume-II, 1987 edition (2005 reprint edition) may be amended as in the Advance
Correction Slip No. 10 enclosed.
5. This has the sanction of the President and issues with the concurrence of the Finance
Directorate of the Ministry of Railways .
a. This allowance will be treated as a compensatory allowance for all purposes.
b. The allowance will not be admissible to the railway servants who have failed
to turn out for the break down duties within the stipulated time.
(ii) Priority in allotment of quarters, particularly for quarters near the running
sheds or carriage and wagon depots, as the case may be.
(iii) Supply of free food, departmentally or otherwise, during the period they are
engaged in break down duties. If arrangement of supply of free food is not
possible, cash in lieu thereof may be paid to non gazetted staff.
(iv) Payment for overtime work in accordance with the normal rules, time taken
in the traveling to the site of accident and back shall also be reckoned for
payment of overtime.
(v) Payment of full Daily allowance at the rates applicable to ordinary localities
without the stipulation that they should be out of headquarters beyond 8
kilometers for a period exceeding 12 consecutive hours.
a. Daily allowance at full rates as above will be admissible for each break down
occurring at different places on the same day.
2. All other non gazetted staff of all departments who are called out in
connection with accidents / break downs, including the supervisors staff shall
be allowed the concession enumerated in clauses (iii), (iv), & (v) of sub rule (1)
3. Gazetted staff who are called out in connection with accidents / break downs
shall be allowed the concessions enumerated in clauses (iii) & (v) of sub rule
(1). Cash in lieu of free food shall however not be admissible to them.
(Authority: Railway Board's letter No. E(P&A)II-98/BDA-1 dated 25.05.1999)
The concessions of payment of full daily allowance for attending to break down duties
will be allowed to a staff in addition toTA/DA, if any, he might earn in due
performance of day to day work on the same day.
(Railway Board's letter No. F(E)I-70/AL16/1 of 17.12.70)

Supply of free food, departmentally or otherwise during the period they are engaged in break
down duties. Free food or cash in lieu thereof is admissible to running staff also who work break
down relief trains in connection with accidents.
(Railway Board's letter No.E(P&A)II-78/BD-2 of 22.06.79)
TRAVELLING ALLOWANCE
Different kind of travelling allowance:

1. Daily Allowance
2. Mileage Allowance
3. Conveyance Allowance
4. Consolidated Travelling Allowance
5. Actual Cost of travelling
RULES FOR DRAWL OF DAILY ALLOWANCE
Daily allowance may be drawn by a Railway servant who is not in receipt of a permanent
travelling allowance on any day on which he proceeds on tour beyond a radius of 8 Kms. from his
headquarter.
- Full daily allowance for absence from headquarter exceeding 12 hours

- 70% of that for absence exceeding 6 hours but not exceeding 12 hours.
- 30% of the rate for absence of 6 hours or less in a calendar day from
midnight to midnight.
(Railway Board's letter No. E(P&A)II-81/RS-6 of 13.03.84)
RATES OF DAILY ALLOWANCE
In supersession of rule 1611-IREC-VolII(2005 Edn.) & Board’s letter No. F(E)1/98/AL-28/9 dated
24.04.1998, the grpuping of grade pay ranges and the rates of Daily Allowance are revised as
follows with effect from 1st September,2008, subject to the existing conditions:
SN Grade Pay Daily allowance (per day)

1. Officers drawing grade pay of Rs. 10000/- and above and Rs. 520 (Now, 650/-)
those in pay scales of HAG+ and above.
2. Officers drawing grade pay of Rs. 7600/- to Rs. 8900/- Rs. 460 (Now, 575/-)
5. Officers drawing grade pay of below Rs. 4200/- Rs. 220 (Now, 275/-)
The TA/DA rates mentioned in para 2D(b & c) ( mileage for Road journey by taxi/own car/auto
rickshaw/own scooter/bicycle etc.) and para (3) (daily allowance on tour) of this annexure, shall
automatically increase by 25% whenever dearness allowance payable on the revised pay structure
goes up by 50%.
OVER TIME CALCULATION
All Railway workers governed by HOER can be called upon to render duty
beyond rostered hours of duty and even beyond statutory limits of hours. When a
Railway servant is required to work extra hours, he will be compensated by grant of over
time payment at the rate of 1.5 times the ordinary rate of pay for working beyond the
rostered hours and up to the statutory limit of hours of work and for working more than
the statutory limit of working hours at twice the ordinary rate of pay. Over time will be
calculated on two weekly basis in case of "Intensive" and "Continuous workers".
Staff working in loco sheds, maintenance staff of Elect. Car and Diesel Sheds are
classified as Continuous workers.
(Railway Board's letter No. E(LL)73HER(MA)/3 of 11.06.74 & 29.07.74 and
E(LL)80/80/HER/54 of 27.11.80)
ROSTERED HOURS OF DUTY
Standard hours of duty which will be -

1. 42 hours a week in the case of "Intensive" workers.
2. 48 hours a week in the case of "Continuous" & "Essentially
Intermittent" workers.
NOTE:- The daily statutory limits should be arrived at by dividing the prescribed weekly
statutory limits by 6. Thus in the case of "Intensive" "Continuous" and "Essentially
Intermittent" employees, the daily hours will be 7.5, 9, 12.5 respectively.
(Railway Board's letter No.E(LL)75/HER/RLT/16 of 18.06.76)
The following formulae may be adopted for calculating the hourly rate of
over time for different categories of staff-
[Hourly rate of pay = Period of averaging X 1 of monthly rate of pay

for average group] No.rostered hrs.in 30
averaging period
For example: Pay- 3370 & OT- 42 hours
DA- 1384 Total= Rs.4751 = 14 days X 1 = 205.7
96 Hrs. 30
Now, 4751 = Rs.23.06 per hour, 1.5 times rate =23.06+11.53 =34.59
206 Twice rates = Rs. 46.12
Amount for 12 hours = 34.59X12 = Rs.415
Amount for 30 hours = 46.12X30 = Rs.1383.6 Thus, total =Rs.1798.60
[Hourly rate of pay = 1 X 1
for non average group] No.of daily rostered hrs. 30
of the monthly rate of pay
(Railway Board's letter No. E(LL)74/HER/RLT/11 of 07.08.75)
Gazetted officers:
Gazetted staff supervising break down duties at the site of accidents/break down
shall be granted full daily allowance without any specification regarding distance from
Hqrs. or the period of absence form Hqr. on par with Non-gazetted staff, under Rules
1420 RII and 1614 RII, in terms of instructions issued vide Board's letter No. F(E)I-
87/AL-8/1 of 20.07.90 .
Daily allowance admissible under Rule 1614 RII (normal) is distinct from the daily
allowance under Rule 1420 RII and one need not be linked by the other. Thus on any day
when a staff performs any out station duty which qualifies for DA under Rule 1614 RII
and the same day attends to any Break Down duty which qualifies for DA under Rule
1420 RII, he shall be eligible to draw a total DA of more than one day's DA. The DA
under 1420 RII would be limited to one days DA for attending a particular Break down in
a day, even if more than one trip is made to the site of Break Down on that day.
Ref : [ R.B.'s No.F(E) 1/87/AL-8/1 of 20.07.1990 ]
Loco Inspectors:
Break down allowance in lieu of Kilometrage at the rate of 160 kms per day shall
be admissible to Loco Inspectors without any stipulation that they should be out of head
quarter beyond 08 Kilometers , in the event of attending Break Down duty.
Ref : [ R.B.'s No. E(P&A) II/83/RS8 - 10 (IV) of 21.02.93 ].
Running Staff:
Supply of free food, departmentally or otherwise during the period they are
engaged in break down duties. Free food or cash in lieu thereof is admissible to running
staff also who work break down relief trains in connection with accidents.
(Railway Board's letter No. E(P&A)II-78/BD-2 of 22.06.79 & E(P&A)II-2015/F.E.2/2, RBE No. 134/2015 dated 27.10.2015)
Breakdown allowance as monetary incentive to ART/ARME staff:

Restoration at accident site with the help of sophisticated ART/ARMV equipments
is a highly skilled and challenging work. Therefore, only nominated trained staffs are
required to attend the BD duties. Generally each ART/ARMV has nominated 40-45 staff
from Mechanical department. To attract good staff, they are given monthly allowance
and railway quarter near station area. The allowance is given to these nominated staff
for remaining alert and available round the clock for moving with the ART/ARMV in
allowed time ever after duty hours. BD allowance has not changed for quit some time
and is now very meager which has resulted in reluctance among the staff to join break
down gang. Moreover now with improved loan facilities and HRA, railway housing has
also lost its charm particularly in big towns.
In order to encounter this problem and to attract competent staff, it is necessary

to increase the rate of BD allowance. Central railway in past has referred this to Railway
Board vide letter no. T.651.L.5/ART/Policy dated 09.08.2005. West Central has also
proposed revision in the rates of BD allowance vide letter No. WCR/M/L/05/127 Vol-II
dated 02.08.2005. The matter is under consideration at Railway Board’s level.
Delegation of powers for procurement of ART/SPART/ARME items
Following recommendations are available in HLC recommendations April-2003 and

Railway Board’s revised letters pertaining to cash imprest for maintenance of ARTs/ SPARTs/
ARMEs by nominated incharges.
HLC Recommendations
1. HLC 36- Purchase Powers:- Divisional and HQ Mechanical and Medical officers to be
given purchase powers of Stores Officers for ART/ ARME rolling stock and all
equipments contained therein inline with such powers already given to
Engineering officers.
2. HLC 37- Procurement of ART/ ARMV equipments:- No item/ equipment shall be

banned while being purchased for ART/ ARMV/ breakdown crane. No circular/
orders restricting the purchase procedure/ powers for ART/ ARMV/ crane
equipments shall be applicable unless issued by Railway Board (MM & FC).
3. HLC 38- Standing spot purchase committee for ART/ ARMV:- To avoid any
deficiency in keeping the ART/ ARMV/ Crane equipment in good fettle, each
division should have a Standing Spot Purchase committee for ART/ ARMV
which inter alia should include DME/ Sr. DME, DAO/ Sr. DAO & DMO/ Sr.
DMO as permanent members and DEE G)/ Sr. DEE (G) & DSTE/ Sr. DSTE as
additional member as per requirement. Similarly, Standing Spot Purchase
Committee at SAG level should exist at each Zonal railway headquarters.
4. HLC 39 – Full powers for sanctioning cash imprest:- For maintaining ART/ ARMV/
Crane to be given to CME without Finance concurrence.
5. HLC 40- Individual purchase ceiling for ART/ ARMV/ Crane equipment:- Rs.
1000/- to be enhanced to Rs. 10000/- under normal circumstances and upto Rs.
50000/- with the approval of DRM/ CMPE/ CRSE without finance vetting.
6. HLC 41- Cash imprest for ARMV incharges:- A monetary imprest is required to be
provided at the accident site for expeditious procurement of small items like
fuel, food materials etc which may be essential when ARMV has to remain at
accident site for longer periods. Cash imprest of Rs 5000/- can be provided to
ARMV incharge for use during exigencies at the accident site.
7. HLC 42- Cash imprest with ART incharge:- The imprest with all ART incharges should
be raised to Rs. 25000/- as also recommended by RSRC.
8. Indian Railway Finance Code correction slip No. 72:
1050: Cash imprest- An imprest is a standing advance of a fixed sum of money placed at the
disposal of an individual to meet the following types of expenditure:-
1. Petty office expenses

2. Cost of raw materials for the diet of indoor patients of hospitals.
3. Emergent charges which can not be foreseen.
4. Expenses on repairs and maintenance of ART/ ARMV, up to Rs. 12500/- in each case and
expenses on repairs and maintenance of cranes, up to Rs. 10000/- in each case.
5. Other petty expenses upto an amount of Rs. 2000/- in each case. Emergent petty advances,
may also be made on the responsibility of the imprest holder out of imprest money placed
at his disposal.
(Authority: Railway Board’s letter No. No. 2012/F(X)II/5/8, dated 30.05.2012)
TRAINING OF ART STAFF
A - SYLLABUS FOR FOUNDATION COURSE FOR ART STAFF

(Duration 4 weeks)
I. Types of Rolling stock on Indian Railways - Design - Constructional features - Capacity Tare/Gross
Weight - Method of lifting with crane as well as with jacks.
II. General causes of derailments - Limits and tolerances permitted on Rolling stock and P.Way
Standards laid down for maintenance of Rolling stock and P.Way.
III. Method of dealing with derailed and capsized Rolling stock - Dealing with telescoped and
Interlocked rolling stock.
IV. Composition of relief trains of various classes. Principles of working of relief trains - Design and
constructional features of various cranes - Crane working - Precaution to be taken while working with the
cranes. Features of hydraulic rerailing equipment & Description Method of handling various types of
communication equipment.
V. Classification of Accidents - Action to be taken in case of an accident - the responsibilities of

various agencies - operation of relief trains - general rules regarding working of ARTs - hooter codes -
attendance of various staff - precautions while running ARTs, etc.
VI. Description and - Handling of various communication equipments provided in ART, Features of
different types of generators and electrical lighting equipment worked on ARTs - their maintenance and
trouble shooting.
VII. Introduction to First Aid, Techniques of dealing with injured persons trapped in debris - dealing
with injured passengers.
VIII. Type of Fire extinguishers - Method of the fighting under different circumstances - Use of gas
masks and air breathing equipment - precaution to be taken while gas cutting.
IX. Accident enquiries - importance of preserving the evidences. Procedure of conducting Accident
enquiries.
X. Practical training in loco sheds and C&W sheds - use of various equipments.
B. SYLLABUS FOR REFRESHER COURSE FOR ART STAFF

(Duration 2 weeks)
Once in 3 years.
I. Overview of various Rolling stock on Indian Railways - Method of handling derailed Rolling stock -
Limits and tolerances permitted in Rolling stock and P.Way maintenance.
II. Classification of Accidents - Composition of ARTs - general principles of working of ARTs various
equipments in ARTs, including the equipments added during the last 3 years.
III. Action in case of an accident - responsibilities of various agencies. Precautions to be taken while
moving ARTs and while working at the Accident sites - handling of various equipments.
IV. Case studies of typical accidents during the last 3 years - detailed discussions of cases and
remedies.
Syllabus for Development Course for 140 Te. Crane Drivers
(COWANS SHELDON)
MODULE PLAN
Code : DTC/ET/BDT/C/D
Objective : To upgrade knowledge of Crane Drivers in operation of

COWANS SHELDON 140 Te. Break down Crane.
Resources : Lectures/Projector/Model Room and Practical Demonstration.

Duration : 15 Working Days
S.N Module Code Module Time
(Hrs)
01 DTC/ET/BDT/C/D/01 General Introduction. 2.00
02 DTC/ET/BDT/C/D/02 Introduction of Cowan's Sheldon 140 Te. Crane. 3.00
03 DTC/ET/BDT/C/D/03 Brief description and function of 140 Te. Crane. 2.00
04 DTC/ET/BDT/C/D/04 Various parts of 140 Te. Crane and comparison with other Cranes. 2.00
05 DTC/ET/BDT/C/D/05 Technical description of 140 Te. Crane and Wire Rope Slings. 3.00
06 DTC/ET/BDT/C/D/06 Important instructions for 140 Te. Crane Drivers 2.00
07 DTC/ET/BDT/C/D/07 Safety devices and safety fittings of 140 Te. Crane. 4.00
08 DTC/ET/BDT/C/D/08 Preparation of 140 Te. Crane for in train formation. 3.00
09 DTC/ET/BDT/C/D/09 Precautions for in train formation and separation of Crane from 2.00
Accident Relief Train.
10 DTC/ET/BDT/C/D/10 Precautions during preparation at accident site for restoration works. 3.00
11 DTC/ET/BDT/C/D/11 Precautions before and after shutting down the main engine (on 3.00
completion of restoration works).
12 DTC/ET/BDT/C/D/12 Brief description of starting circuit of 140 Te. Crane. 2.00
13 DTC/ET/BDT/C/D/13 Battery operated Elect. Circuits (engine shutting down condition) 3.00
14 DTC/ET/BDT/C/D/14 Function of safe load indicator system. 4.00
15 DTC/ET/BDT/C/D/15 Recording of readings of various gauges and utilization of gauges. 3.00
16 DTC/ET/BDT/C/D/16 Brief description of 140 Te.Crane Indication Circuits. 2.00
17 DTC/ET/BDT/C/D/17 Brief description of lighting circuit. 2.00
18 DTC/ET/BDT/C/D/18 Description of important Electrical equipments viz. Battery, Self 3.00
Starter, Relays, Solenoids, Circuit Breakers etc.
19 DTC/ET/BDT/C/D/19 Description and function of travel clutch, its indications and Elect. 3.00
limit switches.
20 DTC/ET/BDT/C/D/20 Basic Hydraulics. 2.00
21 DTC/ET/BDT/C/D/21 Brief description of hydraulic equipments of 140 Te. Crane i.e. 5.00
hydraulic pumps, valves, motors, filters, hoses, oil cooler, pressure
gauges, Aux. compressors etc.
22 DTC/ET/BDT/C/D/22 140 Te. Crane operation i.e. hauling, slewing, main hoisting, Aux. 5.00
hoisting, traveling, derricking and emergency stowage system.
23 DTC/ET/BDT/C/D/23 Brake system of 140 Te. Crane i.e. vacuum brake system, Air brake 5.00
system, self-brake, parking brake (hand brake), match wagon and
ballast wagon brake system, Air charging system and safety valves.
24 DTC/ET/BDT/C/D/24 Daily checking of 140 Te. Crane by Crane Driver. 3.00
25 DTC/ET/BDT/C/D/25 Trouble shooting of hydraulic and Electronic/Elect. systems. 5.00
26 DTC/ET/BDT/C/D/26 Brief description of bogie of 140 Te. Crane. 3.00
27 DTC/ET/BDT/C/D/27 Case studies of various types of accidents/ derailments and 3.00
procedure of restoration.
28 DTC/ET/BDT/C/D/28 Code of Signals and various Indications 2.40
29 DTC/ET/BDT/C/D/29 Open session for group discussion 3.00
30 DTC/ET/BDT/C/D/30 Examination and Certification 2.20
Total 90.0
Course content for Gottwald 140T New/Old design Crane Operators for
Mandatory / Refreshers courses
Duration: 04 weeks
st
1 Week
1. Visit to crane shop & Introduction of 140T B.D. Crane

2. Lecture /Demonstration on fitment of different wire ropes used in 140 T
Crane
3. Demonstration and Lecture on equipments fitted on S/Structure &
U/Carrige.
4. Lecture/demonstration on electrical system used in 140T crane (Engine
connections, Introduction with SLI System)
5. Demonstration & Lecture on elect. Circuit of Lights, fan, wiper & its
functioning.
6. Discussion on pneumatic system used in 140T crane basic introduction of
pneumatic valve, pne. Cylinder & pne. Components etc.
7. Discussion on Hydraulic system used in 140 T crane. Tracing of
pneumatic Ckt.
8. Discussion on hydraulic system used in 140 T crane. Brief introduction
about Hyd. Components (Hyd. Cylinder, Hyd valve, Hyd Motor).
9. Details of power pack and primary maintenance ( Main & Aux. Engine)
2nd Week
1. Details of Hoses & End fittings.

2. Discussion on main engine & auxiliary engine. Brief Introduction of major
parts.
3. Familiarization with cabin items, controlling levers etc. Demonstration &
Lecture on operator Cabin.
4. Detail discussion on operation of main hoist Auxiliary hoist & derrick
motion.
5. Detail discussion of self travelling system of crane brake, parking brake
operation. Axle blocking operation & its importance. Discussion on crane
brake, parking brake operation.
6. Sequence of operations for crane rigging – Jib up from trestle, Crane
detach from M/truck, Crane propping & CWT taking operation.
7. Sequence of operations for crane derigging
8. Sequence of operations of slewing motion & winching motion.
9. Demonstration & lecture on match truck items of crane.
10.Details & maintenance about Nylon pulley & bearing.
3rd Week
1. Demonstration on CWT taking systems.

2. Details of S/S locking device, CWT locking device & chasis locking device.
3. Discussion on selection of wire rope slings & chain slings & its upkeep.
4. SLI system & its functioning and related electcrical circuit.
5. Discussion on dash board of cabin, switch board, Relay, wiring and its
function.
6. Load chart and how to read it.
7. Wiring and connection arrangement and function of junction box. Tracing
of electrical CKt..
8. Introduction to RDSO maintenance schedule.
9. Operations to be done by crane driver and other members of nominated
crew.
10.Details of bogie & its maintenance.
4th week
1. Technical specification of 140T crane.

2. Trouble shooting of engine starting.
3. Demonstration & Lecture regarding setting of limit switches. Explaining
Solenoid valves etc.
4. Safety aspects for operation of crane and trouble shooting of pneumatic
system.
5. Discussion on reiving and dereiving of all wire ropes on rope drum.
6. Explaining lubrication of slewing ring.
7. Explaining filling of hyd. Oil, diesel & gear oil.
8. Open discussion.
9. Discussion on trouble shooting.
10.Do’s and Don’ts.
CHAPTER - 5
IMPORTANT LETTERS
FROM
RAILWAY BOARD
AND
RDSO
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
No.: E(P&A)II-2015/F.E.2/2 RBE No. 134/2015

New Delhi, dated 27.10.2015
The General Managers

All Indian Railways & Production Units etc.
SUB: Payment of cash in lieu of free food, in exceptional circumstances to the non-
gazetted staff engaged in Break Down duties.
Ref: PNM/NFIR Item No. 10/2015.
1. National federation of Indian Railway men have raised the issue regarding payment
of diet allowance to staff attending break down duties. The issue was discussed in
the PNM Meeting and it has been decided to reiterate the relevant provision of para
1420 of IREC-II. All non gazetted staff called for break down duties are eligible for
supply of free food, departmentally or otherwise, during the period they are
engaged in break down duties, however where it is not possible to make
arrangement for supply of free food, in exceptional circumstances, cash in lieu
thereof may be paid to the non gazetted staff including Gang men and Trolley men
engaged in break down duties, at the rates fixed by General Manager in consultation
with FA& CAO.
2. Cash compensation in lieu of free food however shall not be admissible to gazetted
staff who are called out in connection with accidents/break down.
3. Kindly acknowledge the receipt.
(Salim Md. Ahmad)

Dy.Director /E(P&A)-II
Railway Board.
Copy to: (i) FA&CAOs all Indian Railways.

(ii) Dy Comptroller & Auditor General of India (Railways)
(iii) CSTEs , all Indian Railways for information and actions
For Financial Commissioner/Railways New Delhi dated 27.10.2015
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No.: 2010/Tele/11 (2)/3 Pt. New Delhi, dated 10.04.2015

All Indian Railways
TELECOM CIRCULAR NO. 5/2015
SUB: Provision of CUG connections to Break Down Staff of ARTs and 140T cranes.
The matter of provision of CUG connections to Break Down staff of ARTs and 140T
cranes has been considered by Board and it has been decided that 6904 nos. CUG
connections shall be provided to these break down staff as detailed in the annexure.
2. The CUG connections shall be provided in plan “C” rentals for the same shall be
born by Railway administration. Monthly call charges limit allowed shall be zero.
3. Railway may foloow the principle of expenditure neutrality for provision of theses
CUG connections as per existing policies.
4. Please acknowledge the receipt.
(Harish Pawaria)
Director /Telecom
Phone 011-23388504.
Copy to: (i) FA&CAOs all Indian Railways.

(ii) Dy Comptroller & Auditor General of India (Railways)
(iii) CSTEs , all Indian Railways for information and actions
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No.: 2012/M(M&P)/RSP/7/RB/Pt. 2012-13 New Delhi, dated 4th Apr, 2013
CMPE,
North Eastern Railway,
Gorakhpur.
SUB: High Speed Self Propelled SPART for Lalkuan of NER/IZN Div.
REF: CMPE/NER’s letter No. M/244/3/Prog/2012-13/Loco dated 09.01.13.
With reference to above, based on the instructions already issued from time to time and
practice being followed by Zonal Railways, 3-Coach Self Propelled ART/ARMV is required to
house broadly the following group of equipment:-
(i) All the equipment notified for Class-I ARMVs.
(ii) All emergency rescue / extrication equipment. This would include but not be
limited to Hydraulic Rescue Device, Plasma & Gas cutting equipment, ladders etc.
with all accessories.
(iii) Necessary equipment for side lighting including but not limited to gen-sets,
inflatable tower lights, luminaries, fittings, cables etc. with all accessories.
(iv) One set of Hydraulic Re-railing Equipments with all accessories, packing etc.
(v) Other general tools and equipment needed for rescue / extrication relief operations
at accident site as well as maintenance of the ART/ARMV like hand tools, powered
tools, portable gen-sets, oils, lubricants etc.
(vi) Furniture items such as chairs, tables, tents, almirahs, racks, kitchen equipment and
supplies etc.
(vii) Essential spare parts for C&W, measuring instruments, fire extinguishing
equipments etc. and other items related to accident site handling.
Guidance may also be taken from Tool van & Medical Van layouts issued by RDSO
vide drawing nos. SK.DP-3716 & SK.DP – 3720. Further action by Zonal Railways
may be taken accordingly.
(Manish Jain)
Director Mech. Engg. (P)II,
Railway Board.
Copy to: CMEs/ All Zonal Railways.
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No.: 2012/F(X)II/5/8 New Delhi, dated 30/05/2012
The General Manager, All Indian Railways,

Including CLW, DLW, ICF, RCF, Rail Wheel Factory and
Metro Railway, Kolkata.
The General Manager (Const.), N.F. Railway, Guwahati.

CAOs (Constn.), All Indian Railways (except NF Railway).
The Director General and Ex-Officio General Manager, RDSO, Lucknow.
The General Manager, CORE, Allahabad.
CAO, MTP/ Mumbai, DLMW, Patiala and COFMOW, New Delhi.
Sub: Delegation of Powers to General Managers to sanction Cash Imprests-

Amendment in Para 1050 of Indian Railway Finance Code, Volume I.
Para 1050 of Indian Railway Finance Code, Volume-I may be amended as per enclosed
Advance Correction Slip No. 72.
2. Further, as already indicated in para 1051, an imprest should be fixed in consultation with
associate finance.
3. Please acknowledge receipt.
(Sunil Kumar)
Director Finance (Exp.)II,
Railway Board.
No. 2012/F(X)II/5/8 New Delhi, dated 30/05/2012
Copy to: Dy. Controller & Auditor General of India (Railways), Room No. 224, Rail
Bhawan, New Delhi with 45 spare.
FA&CAOs, All Indian Railways including Production units.
FA&CAO(C)s, All Indian Railways.
(Sunil Kumar)
Director Finance (Exp.)II,
Railway Board.
Advance Correction Slip No. 72
1050: Cash Imprests – An Imprest is a standing advance of a fixed sum of money placed
at the disposal of an individual to meet the following types of expenditure:-
(1) Petty Office expenses.

(2) Cost of raw materials for the diet of indoor patients of hospitals.
(3) Emergent charges which cannot be foreseen.
(4) Expenses on repairs and maintenance of ART/ARMV, upto Rs. 12,500/- in each
case and expenses on repairs and maintenance of cranes, up to Rs. 10,000/- in each
case.
(5) Other petty expenses upto an amount of Rs. 2,000/- in each case. Emergent petty
advances, may also be made on the responsibility of the imprest holder out of
imprest money placed at his disposal.
(Authority: File No. 2012/F(X)II/5/8, dated 30/05/2012)
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No. 2003/M (M&P)/7/DM/Status/Pt. New Delhi, dated 04.01.2013
Chief Mechanical Engineer,

Eastern Railway,
Kolkata
Sub: Developing Stainless Steel cutting facilities on ARTs.

Ref: Board’s letter No. 2011/M (M&P)/1063/48/HRE dt. 25.3.2011 addressed to GM
(Mech) of all Zonal Railways (Copy enclosed).
Please refer to Board’s letter under reference on the subject cited above, in this context, it is
mentioned that no response has been received in Board’s office so far from Eastern Railway in
respect of the work regarding development of the specifications for equipment i.e. Abrasive
cutting tool allotted to them.
In case Eastern Railway is unable to develop the specifications, Railway Board would need
to consider allocating the work to another Zonal Railway.
Receipt of this letter may please be acknowledged.
Enc: As above (Manish Jain)

Director Mech. Engg. (P) II
Railway Board
Copy for information to:
CMPE/ NE Railway, Gorakhpur. This is w.r.t. letter No.

M/27/2/Disaster Management/OPTG/Part-9 dt. 28.12.2012.
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No. 2011/M (M&P)/1063/48/HRE New Delhi, dated 25.03.2011
G.M. (Mechanical),
All Indian Railways
Sub: Developing Stainless Steel cutting facilities on ARTs.

Ref: i) Railway Board’s letter No. No. 2003/M (M&P)/7/2 dated 26.11.2010.
Please refer to item 4 of Board’s letter under reference wherein all Zonal Railways were
asked to furnish comments on equipments which are available with them for cutting Stainless Steel
Wagons & Coaches (LHB) at accident site. NR, NFR, ECR and NWR have not yet submitted the
required information.
Since introduction of SS wagons and Coaches is picking up pace, it is essential to quickly

develop commensurate capabilities in ARTs. However, based on the replies, it is seen that only
few Zonal Railways are planning and working in this direction.
In view of above, the three types of equipment listed in the table hereunder are identified
for inclusion in ART as first step. It has been decided that the respective zonal railways listed
should work on standardization of equipment requirement.
S. Equipment Zonal Railways

No. nominated
1. Cold cutting hydraulic equipment South Central
2. Plasma cutting portable equipment Western
3. Abrasive cutting tool Eastern
The respective zonal railways listed above should develop the specifications for equipment
allotted to them after interacting with more than one supplier. They should also take inputs from
other zonal railways. Based on interactions/ inputs/ trials etc., the nominated Zonal Railways
should submit to Board the following within 2 months.
1. Technical Specification – Keeping in view the requirement of thickest section to be cut.

2. Approximate cost.
3. List of likely suppliers
Other zonal Railways should also be consolidate their experience & share with the above 3
railways to enable quick and comprehensive exercise.
(Manish Jain)
Director Mech. Engg. (P) II
Railway Board
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No.2009/Safety (DM)/6/12/Comments New Delhi, dated 09.02.2012
General Managers,
All Indian Railways
Sub: High Level Committee’s Recommendations No. 13,69, and 102 on

Disaster Management.
A committee was constituted by the Ministry of Railways to suggest methodology for

implementation of the four pending recommendations No. 13, 69, 75 and 102 of High Level
Committee on Disaster Management. Based on this committee’s report which has been accepted
by the Board (MT), the following actions are to be taken at the zonal railways level.
(a) Recommendation No. 13: Railways should form Professionally trained crack team which can
be located at 3 locations viz. Bangluru(SWR), Kharagpur(SER) and Lucknow(NR) to start with
Provision of Safety Park at these locations has already been communicated to these zonal railways.
Railways should plan to give training to 50-70 Trainers per zone and for crack teams and these
trainers can then provide training in their zones specially to on board and front line staff of
Railways. Other details are included in the committee’s reports (copy enclosed).
Recommendation pertaining to provision of containerized hospitals has been dropped.
Instead the existing ARMVs should be upgraded suitably.
(b) Recommendation No. 69: the recommendation pertaining to provision of synthetic packing in
all ARTs with 140 tonne crane in lue of wooden package has been dropped.
(c) Recommendation No. 75 : The recommendation pertaining to provision of Nylon slings has
been dropped. However, the Nylon slings can be kept in addition to the wire ropes/
slings/chains.
(d) Recommendation No. 102: The recommendation to pertaining to manual on reuse, relief and
restoration management has been dropped.
(e) The listed 13 equipments as contained in the committee’s report (page 7) should be added to
the ARMV /ART to upgrade Disaster Management System in Indian Railways.
(f) The following action should be taken for moving closure to the idle of Golden One Hour Rule.
i. The on-board staff should be provided intensive training and suitable equipment for
providing relief and rescue during the Golden Hour. The Railway staff should be given full
training to work as Medical First Responders and contractor’s staff should be given general
training in rescue.
ii. A chain of command should be specified for smooth operations at accident site, till the
ARMV/ART reaches. For eg guard – Train Superintendent – Loco Pilot and so on, so that even
if a key official is injured, the next in line can assume the command of the team.
iii. The officer reaching the site in ART should submit a formal report of the activities under
taken by on board staff and the erring staff should be given exemplary punishment.
Please acknowledge receipt of this letter and confirm the appropriate action on the above.
(Sd.)
(Sunil Kumar)
Advisor (Safety)
Railway Board
GOVERNMENT OF INIDA
(RAILWAY BOARD)
No: 2003/M(M&P)/7/DM/Status/pt. New Delhi, dated 31.12.2012
Chief Mechanical Engineer

All Zonal Railways
Sub: Report of Committee constituted to review the recommendation nos. 13, 69, 75 and 102
of High Level Committee (HLC) constituted on Disaster Management (DM).
Ref: i) Railway Board’s letter No. 2009/M(M&P)/ Safety (DM)/6/12/ Committee dated
09.02.2012
ii) Board’s letter of even number dated 11.05.2012.
Please refer to Board’s letters under reference on the subject cited above. In this context, it is
mentioned that references have been received from N.E and S.C. Railways in response to Para E of
Report of committee constituted to review the recommendation nos. 13, 69, 75 and 102 on High
Level Committee on Disaster Management. Based on these references, please find enclosed the list
of item duly indicating the place to keep each item and department responsible for procuring the
same. Specific remarks against items 5, 7, 11 &13 may also be noted. It has also been decided to
defer item 6 (MFR Kit with splint) at present.
This issues with the consent of Safety and Health Directorates of Railway Board.
(Manish Jain)
Dir. Mech. Engg. (P)II
Railway Board
Encl: As above
ü GOVERNMENT OF INDIA
ü (RAILWAY BOARD)
No.2007/M(C)/141/1 New Delhi, dated 03.11.08.
The Chief Mechanical Engineer

E.C. Railway
Hajipur.
Sub: IOH/POH periodicity of ICF design OCVs.

Ref: (i) Board’s letter of even No. dated 26.9.08.
(ii) ECR’s letter No. ECR/MEC/CHG/416 Pt.II dated 30.10.08.
In terms of Board’s letter referred to above, it has been legislated that OCVs
which form a part of standard rake composition of M/E trains shall be dealt with
for IOH/POH at an interval of 9/18 months. The scope of activities during IOH
has also been stipulated therein.
Accordingly, OCVs like WGCB (Pantry Car), VP/VPH/VPHX/A/PU/VPR (various

categories of Parcel Vans). PP (Postal Vans) etc. are required to be dealt with
under this category.
All other OCVs shall follow an IOH/POH periodicity of 12/24 months as has also
been mentioned in Board’s letter referred to above. Only as a matter of
exception, a POH periodicity of 3.5 years for ART coaches, as communicated
vide Board’s letter No. 2003/M(M&P)/7/DM(79) dated 3.6.2003 may be
continued with. An IOH may however be carried out at regular intervals
of 6 months for such ART coaches.
Sd/-
(Arvind Nautiyal)
Dir Mech. Engg.(Coaching)
Railway Board.
Copy for information to:The Chief Mechanical Engineers, All Indian Railways.
CENTRAL RAILWAY HQ’s OFFICE
OPERATING BRANCH
MUMBAI CST
No.T.153.L5.HLC.57 Dt. 18-Oct-04.
Sr.DME(Fr.& OP) BB,

Sr.DME(D) CLA
Sr.DEE(TRS) KYN
Sr.DME PAR, SUR, BSL, NGP.
Sub: Sanctioned strength of staff for ‘A’ & ‘B’ Class ART and ARMV on
CENTRAL RAILWAY
Ref: HLC’s recommendation Item No. 57.
High – level committee’s recommendation at item No.57 is reproduced below:-
57 Nominated staff for ARMV and ART – the present pattern of Zonal Railways
staffing is not found to be adequate in case of serious accidents Railway Board
involving heavy casualties. There is a need to nominate more (Mech. & Health Dtes.)
trained staff for each ARMV/ART. M+3
In compliance to HLC’s above mentioned recommendation the revised strength of staff

for “A” & “B”Class ART and ARMV on Central railway will now be as under:-
Revised Sanctioned Strength of staff in ‘A’ CLASS ARTs.
S.N. Category Revised sanctioned

strength
A.1 CRANE GANG
1 Supervisor 2
2 Crane Driver 2
3 Assistant Crane Driver 4
4 Outrigger Khalasi 14
Total 22
A.2 RESTORATION GANG
5 Supervisor (Mech.) 2
6 Fitters 12
7 Welders 1
8 Khalasis including one welder Khalasis 7
Total 22
A.3 C&W GANG
9 Supervisor (C&W) 1
10 Fitters 2
11 Khalasis 5
Total 8
Grand Total (A.1+A.2+A.3) 52
Sanctioned Strength of staff in ‘B’ Class ART

strength
B.1 RESTORATION GANG
1 Supervisor (Mech) 2
2 Fitters 12
3 Welders 2
4 Khalasis including one welder Khalasis 7
Total 23
B.2 C&W GANG
5 Supervisors (C&W) 1
6 Fitters 2
7 Khalasis 5
Total 8
GRAND TOTAL (B.1+B.2) 31
The sanctioned strength of staff in ARMV as conveyed vides this office letter of even
numbered dated 27 Sept. 2003 is reproduced below for ready reference.
Sanctioned Strength of staff in ‘ARMV’

strength
1 Supervisor (Mech) 1
2 Electric Fitters 2
3 Welders 3
4 Fitters 5
5 Khalasis 7
Total 18
This has the approval of CME.
Sd/-
(Sanjay Gupta)
Dy.CME(P&F)
C/- FA&CAO CST, Mumbai for information.
Encl:- CMEs approval.
2002/sec.(Cr.)/45/47
VI-24022/11/2002-PM.
2-
3-
4-
5-
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No. 2007/Safety(DM)/RM/1 New Delhi, dated 10.10.08.
General Manager, C.R. Mumbai

All Indian Railways including
General Manager, Kolkata Metro
Chief Administrative Officer, COFMOW.
Sub: Revision in the Recommendations of the High Level

Committee on Disaster Management.
The Ministry of Railways constituted a High Level Committee in September, 2002

to review Disaster Management system over Indian Railways and to give
recommendation for strengthening and streamlining the same. The committee
gave 111 recommendations in March 2003 all of which were accepted by hone’ble
MR.
As of now 90 recommendations out of 111 have been implemented on all the

zonal railways. However, no tangible progress has taken place on some of the
recommendations despite all out efforts by the railways. On the other hand,
during the past 2-3 years several initiatives were taken by the other Ministries /
departments under Government of India to strengthen disaster management at
the national level encompassing all the stake holders not confining to the railways
alone.
In view of the above, Board set up a committee to examine these

recommendations on which there was no tangible progress in the past 5 years
where a revised approach appeared to have been necessitated in the light of
subsequent development. The committee deliberated on these recommendations
and has given their views/suggestions as to the future course of the action which
has been accepted by the Board and approved by hon’ble MR.
The original recommendations and revised recommendations/status are as

under:-
1. Recommendations No.3: to improve the response time, feasibility of

entering into a tie up with reputed civil/private hospitals may be explored so that
additional ARMV’s can be stationed at intervals not exceeding 100 Kms each even
in places where Railway Medical infrastructure is not available.
Revised Recommendation No.3: There should be no further proliferation of

ARMV’s beyond the existing no. unless warranted by creation of new lines, gauge
conversion etc.
2. Recommendations No.4: to have MOU with State Governments as per
which Railways were to provide road mobile accident rescue and relief vans and
state governments were to provide necessary medical/paramedical support for
their manning.
Revised Status of Recommendation No.4: Not accepted in view of the

emerging holistic approach on disaster management. Such an arrangement with
the state govts is not easy to manage and is impractical. Moreover, it is desired
that whatever is done by individual stakeholder line of command has to be well
defined otherwise the system would not work.
3. Recommendation No.5: Pertaining to read mobile rescue ambulance @ 1

per zone to be based at divisional hospitals.
Revised Status of Recommendation No.5: Not accepted due to country-wide

initiatives on disaster management under the guidelines of NDMA. Road mobile
medical ambulances are being proliferated and upgraded by the civil/private
hospitals and NGOs to facilitate medical rescue incidentical to all types of
disastrous events. Introduction of road mobile rescue vehicle on the railway’s
expense will be an underutilized redundant effort.
4. Recommendation no. 9: Pertaining to emergency rail-cum-road vehicle

feasibility to be explored after field trail of one vehicle on WCR.
Revised Recommendation No.9: One emergency rail cum road vehicle under
procurement by COFMOW should be based at the location near a metro town (to
be decided by Mechanical Directorate in the Board’s office) on trial basis. Further
proliferation beyond this trial vehicle should be with the approval of the Board.
5. Recommendation No.17: Pertaining to gradual upgradation of

zonal/divisional control rooms to become multi disaster resistant and fully
equipped with all back up systems capable of sustaining for a week.
Revised Recommendation No.17 : All the divisional/headquarter control rooms

should have one such room which can routinely be used for some purpose like
daily control room meetings to ensure that all the equipment and infrastructure
provided is maintained in good working order. Facility should be provided in this
room for communication, TV with cable connection for obtaining inputs through
media reporting and other bare essential necessities like snacks and beverages to
sustain the staff employed in management of Disaster/Accidents in the control
room.
Please acknowledge this letter and take necessary action as per revised
recommendations under advise to this office.
(Amitabh)
Director (Safety)
Railway Board.
Ranjit Khosla Headquarter’s Office
Chief Mechanical Engineer (Mechanical Branch)
CST Mumbai–400001.
D.O.No.T1.02.LI/Genl/Loco August 8, 2008.
My dear Lal, Jain, Kapoor, Jain

Dear Mrs. Ravi Kumar.
Sub: Accident – Restoration.
Of late, need has been felt for reiterating the steps required to be taken for
facilitating restoration in case of derailments/accidents resulting in obstruction to
through running. Detailed below are some such steps. While the list may not be
adequate / exhaustive, since each accidents is unique in its own way. I am sure,
action along the lines suggested would go a long way towards speeding up
restoration. Some of the items listed below may appear to be very elementary
and obvious. However, there appears to be need to list them so that they are not
lost sight of:-
a) In case the accident involves more than one loaded wagon/coach/loco, it

would be desirable to order/ARTs from both sides.
b) It would also be useful to order any MFDs available near the accident spot,
particularly if they are closer to the accident site.
c) If the accident is in electrified territory and OHE has been affected,

ARTs/MFDs must be moved by Diesel Locos. Even if ARTs/MFDs are to be
started by electric loco to save time. a diesel loco should be provided at the
first available opportunity. It may be prudent to even stable on express
train and provide its diesel loco for the purpose. In case of any doubt,
CPTM may be consulted.
d) Whenever loaded wagons are involved, invariably labour should be

arranged for unloading the wagons. This could be done either through
Engineering Contractors or alternatively Goods sheds are a known source
for ready availability of labour. If necessary, the labour may be moved by
specials/ Lorries to save time.
e) One of the advantages of unloading / partially unloading the wagons is that

on most occasions it would enable more that one wagon being tackled
from one propping up position, whereas if the wagon is loaded, each
wagon may require more than one propping up of the crane.
f) Whenever any loaded freight stock or passenger trains is involved, it is
necessary that Commercial Officers be available at the accident site.
g) Mechanical, Engineering, Operating and Commercial officers should man

the Divisional Control Rooms round the clock.
h) In case movement by road is faster, at least the Mechanical safety and

Engineering Branch Officers must move by road, so that they can reach the
site before arrival of the ART and plan restoration. This would also help in
their seeking necessary assistance from adjoining Divisions/HQ: even
before arrival of the ART.
i) In case the restoration is likely to go on after sunset, arrangements must

be made in advance for providing adequate lighting.
j) In case both the lines of a double line section are blocked, the objective
should be to restore one line first, even it is means delay in clearing the
second line. Therefore, only the bare minimum and absolutely essential
restoration activity should be carried out from the second line.
k) In view of the reducing trend of accidents over the years, officers and Sr.
Supervisors appear to be lacking in skills necessary for using the 140 T.
Diesel Crane and the Hyd. Re-railing Equipment. It is therefore suggested
that in case of any accidents on adjoining Divisions at least one Mechanical
Officer, one C&W supervisor and one Loco Inspector should be sent to the
accident site with a view to give them adequate exposure. Not only would
it be a learning experience, but they may also be able to contribute
towards restoration by giving valuable suggestions to the Officers
conducting relief operations.
l) Immediate action should be taken to clear the rolling stock on rails on

either side of the derailed stock from the accident site. This would
facilitate restoration activities.
m) As far as possible, the stations on either side of the accident spot should be
kept free to facilitate shunting or for placement of any stock which is
brought from the accident site. Stabled loads/ rakes if any, should be
removed from these stations.
n) It is always useful to have a Diesel Loco on either side of the accident site.
Creating gaps by moving apart the derailed stock facilitates after fasten
restoration. Arrangement should therefore be made to have a spare Diesel
loco on either side of the accident spot.
o) On arrival at site, the Sr.DME should quickly assess the quantum of oxy-
acetylene gas/welders required, and, if necessary, additional gas/welders
should be call for from Depots/Workshops.
p) At the first sign of the Crane giving problems, HQ must be informed so that
necessary assistance in the form of technical guidance/ Millwright staff/
additional crane could be arranged.
q) Arrangements for adequate meals/tea etc. are required to be made for

staff/labour at site.
r) On need, basis, additional staff can be moved to site from other Depots to
provide relief to the ART staff.
I would suggest that the officers concerned may be advised of the action to
be taken, should the need arise.
With best wishes Yours sincerely,

(Ranjit Khosla)
Shri J.N.Lal, DRM/BB
Shri Anirudh Jain, DRM/BSL
Shri Ashwani Kumar Kapoor, DRM/NGP
Shri D.K.Jain, DRM/PA
Smt. R. Ravi Kumar, DRM/SUR.
Copy to : AGM, CSO, COM

: Secretary to GM – For kind information of GM
Central Railway Headquarter’s Office
Mechanical Branch
CST Mumbai-400001.
NO.T.651.L.S.ART.Policy September 4, 2006.
SR.DME(FR & OP)/BB

SR.DME NGP, BSL, SUR, PAR.
Sub: Ordering of ART from adjoining foreign Railways

in case of Accidents.
There have been cases where ordering of ART from adjoining Foreign Railways,
when required, in case of accidents, has been delayed. There is an impression
that prior permission from HQ. is required in such cases.
It is, therefore, clarified that ARTs of adjoining Foreign Railways should be order
immediately by the Division, if required, in case of accidents, without waiting for
any permission from Headquarters. Headquarters, only has to be informed
about the decision taken.
However, in case of any difficulty in getting the required assistance from

adjoining Railway. CME/CMPE(D) should be informed immediately about
assistance required.
(Pradeep Kumar)
Chief Mechanical Engineer
Copy to: DRM BB, BSL, NGP, SUR, PA.

: CSO/CSTM.`
MOST IMPORTANT
Central Railway COM Office

Mumbai / CSTM
No. T.153.L.5.HLC.57 Date: 14th Aug.06
SR.DME(FR & OP)/BB

SR.DME(D)/CLA
SR.DEE(TRS) KYN
SR.DME NGP, BSL, SUR, PA.
Sub: Nomination & attendance of staff for ART/ARMV at accident site.
Sanctioned strength of staff for A&B class ART and ARMV on Central railway was
circulated vide this office letter on even number dated 18.10.2004. The copy of
the same is once again enclosed for ready reference.
Vide this office letter of even number dated 25.04.05, 24.05.06 (copies
enclosed), divisions were advised to submit the compliance of the nomination of
sanctioned staff for ART/ARMV.
Vide this office letter of even number dated 31.05.2006 (copy enclosed),
divisions were advised the requirement & asked to nominate staff for 140 t
DHBD crane at A Class ART accordingly.
Vide this office letter of even number dated 05.06.2006 (copy enclosed) divisions
were advised to ensure that the sanctioned strength of staff are nominated for
the ART/ARME & the sanctioned strength of staff should attend the accident site
without fail.
All above instructions are once again reiterated for necessary

compliance on top priority.
(A.Rastogi)
For COM
DA: As stated.
C/- DRM BB, PA, SUR, BSL, NGP: For information please.
Central Railway COM Office
Mumbai / CSTM
No. T.153.L.5.HLC.57 Date: 31st May 06
SR.DME(FR & OP)/BB

SR.DME(D)/CLA
SR.DME NGP,PA, BSL, SUR.
Sub: Nomination of staff for 140 t DHBD crane at A Class ART.

Ref: 1.This office letter No. T.153.L.5.HLC.57 dated 18.10.2004.
2.This office letter No.T.651.L.5.Crane Driver dated 29.09.05
& 19.01.2006.
Vide this office letter T.153.L.5.HLC.57 dated 18.10.2004. Division were advised
the sanctioned strength of staff for the ART/ARME.
The staff required for day-to-day maintenance of 140 t DHBD crane is to be

nominated by divisions. Similarly, divisions were advised for creation of two
posts of JE-I/II for crane operation vides this office letter No. T.651.L.5. Crane
Driver dated 29.09.2005 & 19.01.2006.
The staff required for day to day maintenance of 140 t DHBD crane is:-
S Designation No.Of Duties at homing Remarks

N staff shed
1 SSE/ART 01 Overall supervision & Mostly available at all ART
maintenance of ART locations having 140 t crane.
2 SSE/SE 01 Overall supervision &
(Crane) maintenance of Crane
3 JE-I/II 02 Efficient & safe operation
(Crane Of crane & keeping crane
Operation) ready at all the time
4 Crane assistant cum 02 Daily checks &
Diesel Mechanics Maintenance
Gr.I/II schedules of the crane
5 Crane assistance Cum 02 Daily checks and
Electrician Gr. I/II maintenance
schedule of the crane
6 Helper Khalasis 06 To assist all above staff for
up keep of the crane
Total staff 14
Therefore Division should ensure that the above posts/staff are available with them.
The necessary feedback may please be given to this office.
(A.Rastogi)
Dy.CME(P&F)
CENTRAL RAILWAY COM’s Office
CST Mumbai
No. T.651.L.3.140.T.Crane Date: 12/02/04.
Sr.DME BB, PA, NGP.
Sub: Movement of 140 T crane for other than

Break down work.
Ref: HQ. letter No. T.651.L.651.L3.140T Crane Dt. 6.6.99.
Recently it is seen that Sr.DMEs of the division are asking last minute CPC for
permitting movement of 140 t crane for Engg. Work on their division.
This is not in order and Sr.DMEs are once again reminded to read above referred
letter.
All Sr.DMEs should ask their Sr.DENs to plan movement well in advance so that
following is ensured & there is sufficient time for all of below:-
a) Visit of 140 t crane Supervisor to site

b) Certificate from Sr.DME BSL or SUR to reach HQ.
c) Formal approval of CMPE/D on file.
Responsibility for arranging all formalities for obtaining permission and resultant
failure of sanctioned traffic block would entirely be of the Sr.DME concerned.
It may be added here that Sr.DMEs should not expect that informing their
requirement on telephone or PC-message would suffice. A written certificate from
Sr.DME/SUR or BSL is necessary.
(Sanjay Gupta)
Dy.CME (P&F)
C/- Sr.DME – BSL, SUR

Sr. DEN- BB, BSL, NGP, PA, SUR
O/c to CMPE/S for information.
CST Mumbai
No. T.651.L.3.140.T.Crane Date: 14.11.02.
DRM/ BB, BPL, BSL, SUR, JBP,NGP, JHS.
Sub: Utilization of breakdown cranes for

Non-break down purposes.
Recently cases have come to light in that division have use Breakdown cases for
non-break down purpose without taking permission from HQ office. Since these
cranes are also required for Inter Rly./ Inter Divisional movement such practices
are incorrect.
Instructions on above subject have been circulated earlier. The same are being
reiterated. Copies of instructions issued by CMPE (R&L) vide DO L. No.
T.102.L1. Gen. Loco dt. 20.6.1991 to all DRMs, CME(O&C)’s letter to all
Sr.DMEs/DMEs letter No.T.651.L.3.140.T. Crane dt. 03.05.1999 & 06.06.1999 are
enclosed for reference.
Kindly ensure strict adherence.
(Anil Mishra)
CME(O&C)
Central Railway HQRS OFFICE
OPERATING BRANCH
CSTM.
NO.T.651 L.3.140.T.Crane Date: 06.06.1999
SR.DME(G) BB
SR.DME(COG)BB
SR.DME BSL, BPL, JHS,JBP, NGP.
DME/SUR.
Sr.DME (D)/ET, NKJ, PA &CLA
DME(D) AGC, JHS, KYN.
Sub: Operation and Movement of 140 ton crane.
It has been seen that 140 ton crane attached to you is being frequently called
for works relating to Civil Engineering works like Girder launching etc.
In view of the experience gathered, it has been decided that in future, no 140
ton crane shall be allowed for such departmental activities unless following
points have been ensured in advance.
1. Breakdown incharge and Crane operator have seen the site in advance
and have acquainted themselves with the work which is required to be
done.
2. Civil Engineering Department has submitted detailed site plant and flow
chart indicating the activities in sequential manner.
3. The weight of every item which needs to be lifted, the distance to which
height it has to be moved and the angle at which it has to be lifted
should be clearly brought out in the site plan.
4. Mechanical officer who is nominated to accompany the 140 ton crane in
such occasions shall ensure that he has acquainted himself with the
constraints at the site like cutting, embankment, fixed structure etc. so
that no unforeseen problem is encountered at site during actual
operation.
5. Prior permission of Hqrs has been taken.
Sr.DME incharge of 140 ton crane shall permit for such works only after he is
satisfied himself of all the requirements as listed out above.
Please ensure that these instructions are noted by all the supervisors and officers
concerned with the working of 140 ton breakdown crane.
(P.K.BAJPAI)
CME(O&C)
CST Mumbai
No. T.651.L.3.140.T.Crane Date: 03.05.99
SR.DME BSL, JHS

SR.DME(DSL)NKJ,ET
DME(DSL)JHS.
Sub: Operation and movement of 140 T Crane.
Following instructions in this connection are reiterated.
1. No movement of 140 T crane shall be carried out without the permission of

HQ. this will include both accident restoration cases or Non accident related cases(i.e.
Engg. Girder Launching work etc.) HQ’s permission shall be sought through HQ. PCOR
on duty and CPC message No. to this effect shall be taken from him. Only in cases
involving serious/Main line accidents shall the Sr.DME/DME/AME shall have power to
order the 140 T crane on his own, however even in such cases HQ. shall be advised
of the facts at the earliest possible time.
2. Sr.DME/DME/AME of the base depot of 140 T crane shall invariably accompany

all movements of 140T crane, out side the base depot.
3. In case SLI (safe load indicator) of the 140 T crane is defective, crane
operator, crane supervisor, Mechanical Officer incharge at site shall take all possible
precautions to ensure that safe load limits for various condition of service are not
exceeded under any circumstances.
In case of any defect developing in the 140 T crane which can not be attended by
base depot immediate help of PR shops shall be sought by Sr.DME/DME/AME of the
base depot under advice to Headquarters.
A crane manual has been developed by HQ. All divisions will ensure that a copy of
the same is taken form HQ. This manual covers operation of 140 T crane as well as
other break down cranes.
(L.C.TRIVEDI)
DY.CME(P&F)
12. Manning of Crane :-
Ensure proper upkeep and operation of 140 T breakdown crane at base station. It was
decided that:-
(a) Diesel Hydraulic cranes are very costly and technically the most sophisticated
equipment having diesel operated power pack, hydraulic controls and gear boxes for
motion and computerized electronic controls and safety equipments on board.
Therefore, the crane drivers should be in the rank of supervisors – preferably diploma
holders in order to understand the crane and operate it in desired manner. These
crane operators should be put in position by each Railway and Board advised by
31.12.96
(b) A diploma holder supervisor in Electrical or Electronics branch should also be

included in the B.D. Gang for trouble shooting and basic maintenance of crane at base
station. The compliance report should be advised to Board by 31.12.96.
(c) Other skilled and unskilled staff deputed in B.D. gang should be preferably ITI
passed candidates.
Minutes of 3rd Crane Maintenance Group Meeting held at
Jamalpur on September 23 & 24, 2004.
Review of 2nd CRMG held at Chennai on 1st and 2nd July 2002.
Para (C) 5- Preventive maintenance of cranes in open line
In some Railways maintenance of 140 T BD crane is done by the nearest diesel shed.
This has resulted in dilution of responsibility for maintenance between open line and
diesel shed. Railways should nominate one Junior scale officer as the officer in charge
of crane to ensure complete accountability of the general health of crane and its spares
procurement directly or through Jamalpur.
The crane should not be parked under OHE to ensure proper maintenance of the crane.
Wherever possible a covered shed should be provided. At locations where thefts from
BD crane are likely the covered shed should be provided with collapsible gates.
Railway should create facility for conducting weekly drill which should consist of
simulating the crane use at accident sites. This facility should also be used for
imparting training to the user during pre commissioning.
Mock drill of the crane operation should be conducted at regular interval.
All CME’s and officers of HQ/Divisions must check the maintenance schedule forms
being filled up by the maintenance team to check the effectiveness of the maintenance.
The officer and supervisors incharge of the crane should be provided with mobile
phones with built in high resolution camera to ensure multimedia connectivity with
Jamalpur /Parel. Mobile gang of Jamalpur and Parel should also have similar phones
with, camera ( 8 for Jamalpur and 4 for Parel) to ensure quick appreciation of field
problem and their trouble shooting.
CR confirmed that supervisors and staff of Parel Workshop are checking that schedules
are carried out and form filled while visiting crane depots.
Para (C) 7- Availability of infrastructure, tools & spares.
RDSO has circulated a drawing RDSO SK No. CR-833 for the shed to be constructed in
division for crane maintenance. RDSO should also circulate the infrastructure required
for basing 140 T crane in divisions, covering stabling facilities, Pit, covered shed,
battery charging facility, storage area for lifting tackles, materials handling facilities
and tools etc.
Para (C) 12 – Bulking of crane spares/Rate contract.
Jamalpur gave the current position of materials received against vetted indents
received from zonal railways in 2001-02 (151 items for old design crane and 69 items
for new design crane). Railways should collect it from Jamalpur. Some of the items
from 151/69 items list were not necessarily required as such they have not been
purchased.
Railway Board finalized rate contract for critical hydraulic and pneumatic items in
May/June’2003. Railways may send the vetted indent for these items as circulated by
CME/ER/CCC in his letter dated 24.06.04. The letter and the list is available on
Jamalpur’s website.
CR informed that Rate Contract for spares for 12 nos. of 140T Old design Cowans
Sheldon Cranes was placed on 22.03.04 which is yet to materialize pending Railway
Board’s clearance regarding obsolescence of some items.
Rate contract for 4 nos. new design Cowans Sheldon crane is yet to be floated. CR
informed that warranty of 3 cranes have already expired.
2. New Items
1. Maintenance problems reported by Railways
Engine, Hydraulic system, pneumatic system, SLI etc. Review of the need for the
axle mounted compressor in future in view of air brake conversion of ART’s.
Railways sent the nature of problems faced in crane in above systems. The
problems were complied by Jamalpur and discussed in the meeting. Some of the
decision taken are as follows:-
a) Axle / Bogie mounted Compressor.

NF,ER and WR have not converted all the ART’s to air brake.
Axle / Bogie mounted compressor will be removed from the crane by divisions
where ART has been converted to air brake.
RDSO should study the feasibility of fitting auxiliary engine mounted compressor in
Gottwald cranes similar to that fitted in the Cowans crane.
Jamalpur will not fit bogie mounted compressors in the new design crane
manufacture from the next lot of 12 cranes.
b) Boom head crack of new design crane.
From the 8 cranes supplied by Gottwald in 1997, boom head of 3 cranes (Gonda,
Ratlam, Delhi) have already cracked and have been replaced. Jamalpur shuld
contact M/s Gottwald for replacement of booms in balance. 5 cranes imported in
1997 under warranty.
c) Splined shaft breakage of Q6+Q7 pump
Jamalpur to find the alternative design of pump in consultation with M/s Rexroth
for time being the crane user should send vetted indents for the shaft, seal coupling
and bearing to Jamalpur for procurement. The details of these items was given
during the meeting.
d) 70 T single leg wire rope slings - Wrong dimension of oblong link.
Every Railway informed that this sling is not used. It was decided that use of this
sling should be deleted from the standard list of slings to be supplied during
manufacture of new cranes. Railways who are using this sling and facing the
problem due to the oblong link size may get the oblong link replaced by the sling
manufacturer for which detail was given by Jamalpur during the meeting.
e) Chain Slings – Breakage and use with Main Hook.
Some railways have reported breakage of chain slings. Jamapur has revised the
drawing. All new purchase should be as per the revised drawings and from
approved sources.
Many Railways have reported that the chain slings cannot be used with the hook
due to smaller size oblong link. The chain slings are not recommended for use with
main hook as the maximum capacity of the chain slings is 25 T.
f) Groove formation in A frame by Derrick wire rope.
Due to shortening of A frame in old design crane by 400 mm this problem has
arisen. Railways should enlarge the size of groove in A frame if the wire is still
touching the A frame (careful gas cutting and grinding)
g) Failure of engine items viz. magnetic switch, regulator hour cum rpm meter
etc.
Railway should enter into AMC with Cummins. Till such time AMC is finalized , low
value and failure prone items may be stocked by crane users. Purchase should be
only from Cummins authorized dealer as per Cummins part member. Since there
are different designs of engines fitted in the crane, the ordering should be done
after consultation with the nearest authorized dealer of Cummins. For the engine
related problem Railways should contact the nearest Cummins dealer.
h) Leakage due to failure of Hose assemblies
New purchase of hose assemblies should be done as per the specification circulated
by Jamalpur and from approved source. Maintenance should be improved to
prevent the failure of hose due to rubbing.
i) Leakage from pipeline joints.
New purchase of pipe and fitting should be done as per approved brand and makes
as circulated in crane CD version March 04.
j) Failure of seal kit of hydraulic cylinders
The standard seal kits and its make/brand have been incorporated in the drawings.
The vendors for hydraulic cylinders (different vendors for different cylinders – refer
Jamalpur Specification No. JMP/140T/GOTT/SPEC/15) have also been approved.
Seal kits should be purchased only from the approved vendor for the hydraulic
cylinder.
k) Failure of coil springs and Disc Springs.
Railways should take coil spring only from Jamalpur. The disc spring should be
purchased only from approved vendor ( M/s Gala Springs, Mumbai.)
l) Failure of limit Switch:
Limit switch should be purchased only of imported make. Limit switch of new
design crane can be used in old design crane also except for recovery winch which
is not critical. The detail of the limit switch of imported make was given by
Jamalpur during the meeting.
m) Failure of components of SLI system.
Railway should finalise AMC for SLI system with any of the three approved
venders. Staff should be trained for attending to minor repairs/loose connection
and for detecting the defective components. M/s Amrita Lakshami and M/s
Mechanica System are ready to provide training at Hyderabad/Pune respectively.
n) Requirement of filters for imported Cummins engines.
The filters should be indigenised in consultation with M/s Cummins. This may need
change of the filter causing also increasing the initial cost. But in the long run it
will work out to be cheaper as the imported filter elements are costly.
o) Engine starting problems
Most of the problems of engine not starting have been due to problem in fuel
system, lub oil system or battery. Railways should ensure proper maintenance
system like use of lubricating oil, change of lub oil, change of filters, cleaning fuel
lines regularly, checking of battery and keeping it in fully charged condition.
p) Failure of pneumatic brake system and sticking of pneumatic valves like brake
cylinders, parking brake not working, DC valve, indicators, relay valves etc.
Most of the problems are related to the dirt and moisture in the pneumatic
systems.Railways should ensure proper cleaning of filters in the pneumatic system.
RDSO should examine the possibility of fitting air drier in pneumatic system within
3 months.
RDSO should also revise the maintenance schedule of old and new design crane and
make the attention to pneumatic system uniform.
q) Defect in SM12IF, NG12, solenoid valves and other hydraulic components .
Most of the problems are related to the dirty oil. Gottwalds’s recommendation
-------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------
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Oil in the crane. RDSO should modify this filtration unit so that it can be mounted
on the crane and made a part of it.
Jamalpur and Parel should buy a oil testing equipments so that the cleanliness of
the oil from the crane can be checked at an interval of 6 months to start with.
r) Twisting of counter gallows frame.

The problem has been reported by most of the users of old design crane. The
problem occurs due to wrong operation at the time of derigging. To prevent the
twisting it should be fastened in a balanced manner. The staff should be trained not
to use short cut of securing one of the slings provided for breaking A frame foldable
joint.
s) Wire ropes getting down from pulleys.
Frequent cases are taking place, especially in the divisions where new cranes have
been commissioned where either the wire ropes come out of the pulley or it
entangles in the rope drum. Both problems occur due to wrong operation or the
staff not being vigilant during rope winding on the drum.
Railways should train their staff to avoid lateral pull and dragging to prevent ropes
coming out from the pulley. Wire rope reveeing on drum should be under constant
watch during raising the main and aux hoist and jib derricking up. Proper
maintenance of rope tensioning device should also be ensured.
t) Maintenance of hydraulic brake cylinders
It was decided to continue with the existing hydraulic brake cylinder designs in the
old design Gottwald crane No. 142032 to 142043 and 143001 to 143002. Jamalpur
may however convert one or two crane during POH to generate the spare pool of
the obsolete brake cylinders.
u) Heavy wire rope slings.
Jamalpur should procure one crane set of polyester slings and conduct trial at
Jamalpur
v) High speed vibrations
ECoR reported heavy vibrations in the crane at 100 kmph, RDSO should examine
the issue.
w) Self starting of the auxiliary engine
It was decided to continue with the manual starting system of the auxiliary engine in
the old design crane. Instead the new design cranes should also be occasionally
tested for manual starting.
x) Testing of wire ropes and sings
RDSO to include the wire rope and sling testing and lubrication schedule in the
revised maintenance schedule.
(i) CR stated that old design Cowans Sheldon cranes are running with zero defects
after POH including defects of Main Engine, since all reported defects till date have
been attended.
(ii) The defects in new design Cowans Sheldon Cranes could not be attended due to
non-availability of the spares for 3 cranes whose warranty has expired.
2. Modification for high speed operation.

Following cranes have been modified for high speed.
ECoR Kanatamanjhi – 143006

ECR Dhanbad – 142267(Barwadih)
ECR Danapur - 143010
ER Sealdah – 143007
NER Izziatnagar Gonda – 142266
NR Moradabad – 143005
NR Ferojpur – 142040 (Ludhiana)
SER confirmed during the meeting that 143009 (BKSC) and Chakaradharpur – 142272
have also been modified .
For the following cranes all the materials have been supplied Railways should complete
the modification by Oct. 2004.
NCR Allahabad – 142270(Kanpur

NFR NJP/Kathiyar – 142269
NR Delhi – 142271
SWR Hubli – 142268
WR Ratlam – 142265
NR Ambala – 143008 (Bhatinda)
All new design cranes ( 144001 to 144011) under manufacture at Jamalpur are being
turned out with high speed modification.
Rest of the 15 crane are waiting for HS Casnub bogie. It was decided that RB will place
order for 30 plus 6 ( for manufacture ) sets of the Casnub bogies immediately.
ECoR Khura Road – 142034

ECR Mughalsarai - 142033
ECR Dhanbad - 143001
ECR Sonepur – 143003
ER Asansol - 142039
ER Howrah – 142037
ER MLDT – 143004 (Sahebganj)
KRC Kokan Railway - 142043
NFR Guwahati/Lumbding – 143002
NFR Tinsukia – 142042
NR Lucknow - 142038
SECR Bilaspur – 142032
SECSR Raipur - 142041(Bhilai)
SER Kharagpur – 142036
SER Bandamunda - 142035
3. AMC of cranes or their Sub-system:
To ensure that 140 t crane get full maintenance attention, railways may enter into
AMC at those locations where railways find it difficult to do the maintenance work
within in-house resources. Such AMC may be either comprehensive or only for
specific sub-systems ( line engine or SLI). However, it must be ensured that AMC’s
are only with OEM’s or their agents specifically authorized to under take such work.
CR stated that there was no response for AMC for SLI of Old design crane. The
existing system has been declared obsolete by the OEM.
4. Staff for operation and maintenance of the cranes, including training and
selection issues
As per decision in para 20 of first CRMG (April 2000) circulate vide RB’s letter
number 2000/M(M&P)/175/1 dt. 16.05.00 it was decided that all new induction for
operation and maintenance staff or 120/140 T cranes should be drawn from diesel
sheds.
At least 16 staff should be trained for crane operation
However the areas were expertise of the crane is lacking are Hydraulics and
Electronics.Though IRIMEE is utilizing the facilities of ATI/ Dasnagar for hydraulics
training. It is considered insufficient as no. of courses per year and nos. of
participants per course is not sufficient to cover the Indian Railways requirement.
This can be judge from the phenomenal response this course gets.
Railways should induct atleast 2 supervisors and 2 Technicians from hydraulic and
electronic fields in the maintenance team of 140 T crane.
CR stated that adequate maintenance staff for 16 nos. Cowans Sheldon Cranes has
not been nominated by any depot. There is no staff with electronic background for
maintenance of SLI.
5. Presentation by JMP regarding vendor development specifications for spares

/ parts catalogue etc.
(i) Adoption of PL members allotted by Jamalpur by all Railways.

(ii) Procurement of materials from approved vendors only.
PL Number for about 2717 items allotted after approval by CME and COS/ER. This
PL number should be used by all Railways for 140 T crane.
Jamalpur specification for 17 groups of items issued, which contains guideline for
procurement.
The approved vendor directory has been issued in Mar’2004
Crane maintenance spare parts catalogue for old design crane was released by the
AM/ME. This will be circulated to all Railways within 3 months on hard as well as
soft copies.
All the information except the material portion is also available on the Website at
www.jmper.com.
Three feature of the website should utilized by the crane users to increase co-
ordination with Jamalpur:-
 Crane User database – Names, Designation, Telephone, Fax, e-mail numbers of
the crane users are available. To facilitate the current position users should
check the information and mail any changes if required.
 Message board-can be used to create discussion subjects to share the
experience between crane users.
 Position of material – the stock position of critical items have been posted on
the website. This will also contain the stock position of Railways. Railways
should e-main only the PL. Number and the nos. available in stock to Jamalpur
to enable us to update it in the site. Subsequently whenever spares are
consumed, the information should again be sent to Jamalpur.
6. Revision of maintenance schedule issued by RDSO:

Railways pointed out certain discrepancies in the maintenance schedules
issued by RDSO for old and new design crane. For example
 No schedule for bogie and under carriage maintenance.

 Tightening of slewing ring nuts in 2Y schedule which is not possible.
 Schedule for hydraulic and pneumatic system in old and new design crane
differs widely.
 No schedule for testing and lubrication of wire ropes and slings.
 Recommended oil/grease for different systems are large in number which
needs unification. Jamalpur sent a proposal for this vide letter
no.N/C/R/59D/VOL-IV/90 dated 12.10.02.
RDSO should modify the maintenance schedule after taking feedback from all
Railways.
Sd/-
(Sunil Bajpai)
Director Mech.Engg.(P)II
Railway Board.
No.2004/M/(M&P)/175/1(CMG) New Delhi, dated Novermerb 2004.
To,
CMEs/ All Indian Railways
CWM/JMP/ER
CWM/PR/CR
EDS(MP)/RDSO
CME/KRC.
OPERATING BRANCH
MUMBAI CST.
NO.T.651 L.3.B.D. Crane Dt. 17th January2005
SR.DME(FR&OP)/BB, SR.DME(COG)/BB
SR.DME (D)PA
SR.DME PA, SUR, BSL, NGP.
SR.DEN BB, BSL, PA, SUR, NGP.
Sub: Movement of 140 T Breakdown cranes for other than

Breakdown Work.
Ref: This office letter No. even dated 12.02.2004.
It is seen that divisions are asking permission for utilization of Breakdown cranes
for other than Breakdown work without following proper procedure laid down for
the purpose .
The instructions for Movement of 140 T Breakdown crane for other than
Breakdown work are already issued vide this office letter of even numbered dated
12.02.2004.
All Sr.DENs are advised to follow the proper procedure for asking permission for
utilization of Breakdown cranes for other than break down work, which is
reproduced below:-
1. Sr.DEN will plan movement in well advance & will asked to Sr.DME concern to
ensure the following formalities in time.
a) Breakdown in charge (Crane in charge supervisor) and Crane operator have

seen the site in advance & have acquainted themselves with the work which is
required to be done.
b) Civil Engg. Dept. has to submit detailed site plan in advance & flow chart
indicating the activities in sequential manner.
c) The weight of every item which need to be lifted, the distance to which height
it has to be moved & the angle at which it has to be lifted should be clearly
brought in the site plan.
d) Mechanical Officer who is nominated to accompany the crane in such occasion

shall ensure that he has acquainted himself with the constraint at the site like
cutting, embankment, fixed structure etc. so that no unforeseen problem is
encountered at the site during actual operation.
2. Sr.DME will ensure all above formalities are fulfilled. Responsibility if arranging
all formalities for obtaining permission & resultant failure of sanctioned traffic
block would entirely be jointly of Sr.DME & Sr.DEN concern.
3. Following the above, Sr DME will ask this office for permission for utilization of
break down cranes for other than break down work, in writing certifying that it
is safe to work the crane as planned.
4. This office will give the permission after approval of CMPE(D)either in written
or in terms of HQ CPC message or both.
Please ensure that all supervisors & officers concerned with the work note
these instructions.
(Sanjay Gupta)
Dy.CME (P&F)
Central Railway COM’s OFFICE
MUMBAI CST.
NO.T.651 L.3.B.D. Crane Dt. 22.12.09.
DRM BB SUR PA BSL NGP.
Sub: Movement of 140 T Breakdown cranes for other than
Breakdown Work.
Ref:This office letter No. even dated 17.01.2005,12.02.2004
and 06.06.1999.
It is seen that divisions are asking permission for utilization of Breakdown cranes
for other than Breakdown work without following proper procedure laid down for
this purpose .
The instructions for Movement of 140 T Breakdown crane for other than
Breakdown work reiterated below which have already been issued vide this
office letters of even No. under reference.
1. Sr.DEN will plan movement in well advance & will asked to Sr.DME concern to
ensure the following formalities in time.
a) Breakdown in charge (Crane in charge supervisor) and Crane operator have
seen the site in advance & have acquainted themselves with the work which is
required to be done.
b) Civil Engg. Dept. has to submit detailed site plan in advance & flow chart
indicating the activities in sequential manner.
c) The weight of every item which need to be lifted, the distance to which height
it has to be moved & the angle at which it has to be lifted should be clearly
brought in the site plan.
d) Mechanical Officer who is nominated to accompany the crane in such occasion
shall ensure that he has acquainted himself with the constraint at the site like
cutting, embankment, fixed structure etc. so that no unforeseen problem is
encountered at the site during actual operation.
2. Sr.DME will ensure all above formalities are fulfilled. Responsibility of
arranging all formalities for obtaining permission & resultant failure of
sanctioned traffic block if any would entirely be of Sr.DME & Sr.DEN
concerned.
3. Following the above, Sr DME will ask this office for permission for utilization of
break down work for other than break down work, in writing atleast two days
in advance certifying that it is safe to work the crane as planned.
4. This office will give the permission either in written or in terms of HQ. CPC
message or both provided no prior permission has been given to another 140 T
crane on Central Railway from the same dates.
You are requested to kindly ensure that all supervisors and officers concerned
with the work note and follow these instructions.
(Rakesh Bahl)
CMPE(D)/CSTM.
CENTRAL RAILWAY HQ. Office
Optg. Branch
Mumbai
No.T.153.L.5. HLC.59 Date: 10 Oct. 2006
SR.DME(FR&OP)/BB,
SR.DME (D)CLA
SR.DEE(TRS)/KYN
Sub: Formation of ART.
Ref: This office letter No. even dated 19.09.2006.
Kindly connect this office letter of even number (copy attached) in which the
formation of ARTs is standardized. It is further clarified that:-
A & B Class ARTs Formation:-
S Sub Description A Class B Class

N Unit ART ART
1 140 T Crane 140 T capacity diesel crane with Crane 1 -
Unit Match Truck
2 One equipment van for crane such as 1 -
packing, Fuel oil , chain slings and other
equipment required for crane operations.
3 One staff & kitchen car for crane gang staff 1 -
with office.
4 MFD/LUKAS One equipment van containing HRE, 1 1
HRE packing, compressor, C&W equipment etc.
5 UNIT One staff and kitchen car for ART staff with 1 1
office
6 One equipment van for electrical, OHE, 1 1
Telecommunication equipment etc.
7 One BCNA, HS containing engineering 1 1
material.
8 One BRNA HS containing P-Way materials 1 1
Total 8 5
The requirement of coaching staff for ART/ARMV will be determined on above

formation only.
The coaches /wagons in ART formation in addition to the above are to be taken out
from the formation and its equipment is to be adjusted in remaining coaches / wagons.
All divisions are requested to streamline the formation of their ARTs accordingly.
(A.Rastogi)
DY.CME(P&F)
For COM.
(RAILWAY BOARD)
RBE No. 177/2009
No.E(P&A) II-2007/II 4/3 New Delhi, dated 25/09/2009
The General Managers/OSD1 /CAO5

All Indian Railways & Prod. Units.
(As per mailing lists No. 1&2).
Sub: Revision of rates of Breakdown Allowance.
Consequent upon the decision taken by the Government on the recommendations of the Six
Central Pay Commission relating to various allowance, the Board have decided that the rates of
Breakdown Allowance indicated in this Ministry letter No. E(P&A)II-98-BDA-I dated 25.05.1999
may be revised as under:-
S Category Revised Pay Structure Amount of
N Breakdown
Pay Band Grade Allowance/
Pay month
1 Helper Gr.II/Helper Gr.I/Other Gr. -15(4440-7440) 1300* Rs. 80 p.m.
‘D’staff -15(4440-7440) 1400*
-15(4440-7440) 1650*
PB-1(5200-20200) 1800
2 Technician Gr.III PB-1 (5200-20200) 1900 Rs. 120 p.m.
3 Technician Gr.II PB-1 (5200-20200) 2400 Rs. 160 p.m.
Technician Gr.I PB-1 (5200-20200) 2800
Supervisors (Erist while mistry) PB-1(5200-20200) 2800
4 Sr. Technician/Junior Engineer and PB-2(9300-34800) 4200 Rs. 200 p.m.
staff in Higher Scales & above
(*Till placed in PB-1)

2. The rate of this allowance will be increased by 25% whenever the Dearness Allowance payable on
the revised pay structure goes up by 50%.
3. These orders take effect from the date of issue of this letter.
4. In exercise of the powers conferred by the proviso to Article 309 of the Constitution, the President
is pleased to direct that Rule 1420 of Indian Railway Establishment Code, Volume-II, 1987 edition
(2005 reprint edition) may be amended as in the Advance Correction Slip No. 10 enclosed.
5. This has the sanction of the President and issues with the concurrence of the Finance Directorate of
the Ministry of Railways .
Sd/-
(Chandar Prakash)
Joint Director Estt.(P&A)
Railway Board
No.E(P&A)II-2007/II 4/3 New Delhi, dated 25.9.2009.
Copy (with 40 spares) forwarded to the Deputy Comptroller and Auditor General of India (Railways)
Room No. 224, New Delhi – 110001.
Sd/-
For Finance Commissioner/Railways
OPERATING BRANCH
MUMBAI CST.
NO.T.651 L.3.B./Crane Crane Dt. 29th September 2005
SR.DME(FR&OP)/BB,
SR.DME (D)CLA
Sub: Policy on Crane Operator for 140 T Crane

Ref: Railway Board’s letter No. 95( R&L)/467/16 dated 11.12.1996.
Railway Board vide letter No. 95 (R&L)/467/16 dated 11.12.1996 has circulated
the points noted and decision taken in the CMPE (R&L)s conference held at
Calcutta on 29th & 30th October, 1996. Meeting was chaired by MM.
The decision taken in above conference on manning of cranes is enclosed as

Annexure ‘A’ for your information.
According to the decision the crane driver should be in the rank of Supervisors
preferably Diploma holder in order to understand the crane and operate it in
desired manner.
It is now directed that for the operation of 140 T cranes, 2 supervisory posts in
the Grade JE-I/JE-II should be created and designated as JE (Crane Operator).
These Jr. Engineers may be drawn from the cadre of C&W or Diesel Loco
depending on where the crane is homed.
The formal approval of CME for above directive is enclosed as Annexure ‘B’ for
your information.
Divisions are required to process creation of 2 supervisory posts/crane in the

Grade JE-I/JE-II to be designated as JE(Crane Operator) under respective cadre
of C&W or Diesel Loco & should obtain the necessary money value from
matching or by surrendering posts of Crane Drivers.
The progress may be advised to this office.
(Sanjay Gupta)
Dy.CME(P&F)
GOVERNMENT OF INDIA
MINISTRY OF RAILWAY
RAILWAY BOARD
NO.95/(C&W)/467/16 New Delhi, Dated 11.12.1996
C. M. Es
Northern Railway, New Delhi

N.E. Railway, Gorakhpur
N.F. Railway, Guwahati
S. Railway, Madras
S.E. Railway, Calcutta
S.C.Railway, Secunderabad
W.Railway, Bombay
C. Railway, Bombay
E. Railway, Calcutta
The D.G.
R.D.S.O.
Lucknow.
Sub: Points noted and decisions taken in the CMPE

(R&L)’s conference held at Calcutta on 29th & 30th
October 1996.
Enclosed, please find a copy of the points noted and decisions taken in the
COMPE(R&L)’s conference held at Calcutta on 29th & 30th October 1996 to
discuss (A) B.D. Crane and connected problems: (B) Steam locos and fuel and
(c) Planning staff and safety. You are requested to take necessary action as
mentioned therein.
(S.K.Tripathi)
For Mech. Engineer (P) II,
Railway Board.
POINTS NOTED AND DECISION TAKEN LIN THE CMPE(R&L)’s CONFERENCE
HELD AT CALCUTTA ON 29TH & 30TH OCT. 96
Present :-
Railway Board S/Shri L.K.Sinha MM

Jasbir Pal Singh (AM[PL])
S. Dhasarathy, EDME (Traction)
SK. Tripathai, DME (P)II
Railways
CR S/Shri Kaushal Kishore, CWM/Parel

LC Trivedi, Dy.CME (R&L)
ER AK Ghosh CWE
B.B.Kar, CMPE (R&L)
NR A.K Sanwalka, CMPE (DSL)
NER Keshav Dev CMPE (R&L)
NFR Puthia, Sr.DME N. Bongaigao
SR S.Sriniwasan, CMPE(DSL)
SCR BM Shyam Singh , CMPE (R&L)
SER MC Jain, CMPE(R&L)
WR SC Gupta, CMPE (R&L)
Jamalpur Workshop A.K Tiwari CWM

DC Sharme Dy.CME
Cowans Sheldon Team Members for Presentation
S/Shri Peter Fraser
Akhil Gupta
Maj. Gen. TV Manoharan
The meeting was held in 3 sessions. The minutes are accordingly made in 3 parts
namely:-
(A) Breakdown crane and connected problems

(B) Steam Locos and fuel
(c) Running staff and safety.
12. Manning of Cranes
To ensure proper upkeep and operation of 140 T breakdown cranes at base

stations, it was decided that:-
(a) Diesel Hydraulic cranes are very costly and technologically the most
sophisticated equipment having diesel operated power pack, hydraulic controls
and gear boxes for motion and computerized electronic controls and safety
equipment on board. Therefore the crane drivers should be in the rank of
supervisors – preferably diploma holders in order to understand the crane and
operate it in desired manner. These crane operators should be put in position
by each Railway and Board advised by 31.12.1996.
(b) A diploma holder supervisor in Electrical or Electronics branch should also be

included in the B.D. Gang for trouble shooting and basic maintenance of cranes
at base stations. The compliance report should be advised to Board by
31.12.1996.
(c) Other skilled and unskilled staff deputed in B.D. Gang should be preferably ITI
passed candidates.
CENTRAL RAILWAY COM’s OFFICE
CST Mumbai
NOTE
No. Dt. 27.09.2005.
Sub: Policy on Crane Operation for 140 T Crane.

Presently on C.Rly. there are 4 nos. of 140 T crane named at BSL, AQ, DD and
CLA/Diesel Shed.
Presently, the work of crane operation (driving) is done either by crane drivers in the
artisan category or informally by supervisors who have been trained for operation of the
crane. The position at each location is given in Annexure (Pg. 12).
The subject of crane operation by supervisors was discussed in CMPE (R&L)’s conference
held at Kolkata on 29th & 30th October 1996 with MM in the chair and AM (ME) &
EDME(TR) also present. Decision taken during the conference were communicated to all
Railways vide Rly. Bd’s L. No. 95(R&L)/467/16 dated 11.12.1996. In this letter at (Pg.7)
Para 12(a), it is clearly stated that crane driver should be in the rank of supervisor –
preferably a diploma holder.
With the experience of the 140 T Crane at BSL and DD where supervisors have been
trained and have been operating the 140 T crane for a number of years it is felt that this
system is appropriate and needs to be formalized at other locations also.
In view of the above it is proposed that for the operation of 140 T crane, 2 supervisory
posts in the grade JE-I/JE-II should be created and designated as JE(Crane Optns.).
These Jr. Engineers may be drawn from the cadre of Carriage & Wagon or Diesel Loco
depending on where the crane is homed.
These supervisors will continue to be a part of the cadre of either carriage wagon or loco
from which they will be selected and will work up to the grade of section engineer as
crane operators. They will continue to seek promotion in their cadre and when they
become due for Sr. Section Engineer, they can be considered as in-charge of ART for
which they will be suitable after working as crane operators for many years.
The post of crane drivers which is presently manned by the old steam staff who have
lower lever of education and will be retiring shortly, can be surrendered to make up for
the creation of the posts of crane drivers at the locations where diesel 140 T crane has
arrived. Further, matching surrender could be provided from the existing carriage
wagon of diesel loco cadre for creation of 2 posts in the grade of JE-I at each 140 T
crane location.
CMPE(D) and CME are requested to please approve the above so that the decisions can
be directed accordingly.
Sd/-
Dy.CME (P&F)
CMPE (D)
CME
Government of India
Ministry of Railways
Railway Board
No. 99 M(M&P)/7/6 New Delhi dated 24.09.99
The General Managers (OL)
All Zonal Railways
Sub: Disaster Management.
Ref: This office letter of even No. dated 11.08.99.
***
A presentation was made to the Board on the important subject of “Disaster
Management” on 23.08.99. A copy of the presentation is enclosed for your information,
perusal to the presentation, the following decisions were taken. These may please be
implemented:
1. COMPOSITION OF ARTs/ARMEs:
The committee of 3 CMPEs (R&L) nominated by the Board in its report submitted
in Jan 85 had laid down the following composition of a maximum number of six
vehicles only as shown below for ‘A’ class ARTs.
i) 140 T capacity diesel crane with Match Truck
ii) One equipment van containing HRE, Generator, Compressor etc.
iii) Two Staff Van including kitchen car
iv) One BFR containing engineering materials
v) One BFU containing Bulldozer and other heavy material; and
vi) One van containing material for OHE (for electrified section only).
It is, however, seen that Railways are having 8 to 18 vehicles in their ARTs. As
large unwieldy ART rakes cause delays in movement to sites and problems in
placement of cranes/Tool Vans etc. ART composition must henceforth be in
accordance with the above criteria. In any case the total number should not exceed
8 in case of electrified section and 7 on other sections.
2. ENABLING PROMPT REPAIRS TO EQUIPMENT:
In order to ensure prompt and immediate repairs to any defective ART/ARME
equipment, adequate powers may be delegated to DRMs/Sr. DMEs as was done in
the case of repair of Track machines.
3. PROVISION OF HRDs IN ARTs:
Over the next 2 years, all ‘A’ class ARTs (the ones provided with Accident Relief
Cranes) must be provided with one set of Hydraulic Rescue Device (Cold Cutting
Equipment) to be used as spare in case of major accidents and also for attending to
Tank Wagon accidents.
4. DELAYS IN MOVEMENT OF ART/ARMEs:
All delays in turning out of ARTs/ARMEs must be immediately investigated and
the time limits for turning out must be strictly adhered to. Every accident enquiry
should specifically comment on and fix responsibility in case of delays in
movement beyond the prescribed limits.
5. DUAL BRAKE CONVERSION:
All existing vacuum brake BG ARME stock must be converted into dual brake or air brake
in the next 6 months i.e. by March 2000. Conversion of ARMEs located near major
workshops must be completed within the next two months i.e. by Nov. 1999.
6. MOCK DRILLS:
Mock drills must be frequently conducted to ensure Crane Driver and other staff report in
time and the ART/ARMEs are indeed started in time. During these drills, handling of
Accidents Relief Cranes/HRDs/HREs and other rescue equipment, response time of
ARTs/ARMEs and staff skills should be closely monitored.
7. QUALITY OF BREAKDOWN STAFF:
In terms of recommendations of Report on Reorganization and modernization of Accident

Relief Train, ART gang should be exclusively provided. It must be ensured that within the
sanctioned strength at least 2 sets of capable and committed persons are in each
Breakdown Gang. It is equally important that breakdown gangs are not saddled with
inefficient persons who have other agenda such as out of turn allotment of Railway quarter
etc. and such persons should be summarily weeded out.
8. OVERAGED STOCK:
It is generally preferred to have coaches less than 30 years of age only in the
ARTs/ARMEs. Adequate provision is available in the RSP for converting suitable coaches
for this function. As on date, 248 coaches in BG and 88 coaches in MG are over aged.
These numbers may perhaps come down as the composition of the ARTs is pruned down
as detailed in para 1. A drive must, however, be taken to ensure that ARTs and ARMEs
are equipped with coaches less than 30 years of age.
9. SPEED OF ARTs/ARMEs:
The action must be taken to ensure that the prevailing CRS sanction on various section on
your Railway, particularly on sections recently converted from MG to BG, enable
movement of ARTs/ARMEs at the maximum possible speeds. Wherever the sanction for
ARTs are at speeds below 75 KMPH and ARMEs at speeds below 100 KMPH (in BG)
such sanctions must be reviewed to optimize the speed of movement.
This is issued with the approval of MM, MT and CRB.
( S Dhasarathy )
Additional Member (ME)
Railway Board.
DA as above
Government of India
Research Design & Standard Organization,
No.SL/CR/SPD/140 T/JESSOP Lucknow, dated 15/17.12.2003.

General Manager (Engg)
1. Central Railway, CST Mumbai

2. West Central Railway, Jabalpur.
Sub:- Amendment to speed certificate for 140t BG
diesel hydraulic break down cranes supplied
by M/s Jessop & Co. Kolkata.
Ref:- i) Speed Certificate issued vide letter of even No. dt. 1/25.2.91
ii) Amendments to speed certificate vide letters of even
No. dt.15.6.92 & dt. 03.05.94/
*****
Vide RDSO's Speed certificate at reference (i) and amendments at reference (ii)
respectively, 140t Jessop make diesel hydraulic break down crane was cleared for operation
at a maximum speed of 75 kmph with certain conditions of bridges. To facilitate faster
relief and salvaging operations, the earlier conditions on bridges for the case when the crane
is hauled by locomotive have been reviewed and the following amendment to the above
mentioned speed certificate is made :
1. Clause (i) of para 3.2.1 (a) shall be replaced as :-
(i) As trailing load hauled by single WDM2, WAM4 or any other diesel or electric
locomotive with jib resting on match truck.
A) All standard spans of BGML, MBG - 1987 & RBG except 75 kmph
RBG spans of 18.3 m & 24.4 m (both clear)
B) RBG Span 24.4m (clear) 70 kmph
C) RBG Span 18.3m (clear) 60 kmph
Sd/-
( S.K. Sinha )
Director, Standards/
Motive Power
Government of India
Railway Board,
No.2004/TG-V/2/5 New Delhi, dated 23.06.2004
General Managers
All Zonal railways.
Sub:- Rendering of Assistance to Stranded and injured train passengers
*****
Commissioner of Railway Safety, North Eastern Circle on the above accident
recommended as under:-
TTE must remain at the accident site to render assistance to the stranded and injured
train passengers unless and otherwise permitted to leave the accident site by the
DRM/ADRM.
2. Instructions have been issued vide this Office letter No.2003/TG-V/2/14 dated
15.12.2003 (copy enclosed) that immediately after the accident takes place, the concerned
ticket checking staff manning the coaches should assist the Guard and train crew in
assessing the site of accident and ascertain the casualties/injuries taken place in their
respective coaches and in the unreserved compartments as well. The rough assessment
made by ticket checking staff should be given to Captain of the train who should hand over
it to the Guard for further communication to the controller without any delay.
3. In addition, comprehensive duties of ticket checking staff at accident site have also
been stipulated in Accident Manual, which are as under:-
 Make adequate arrangement of refreshment and drinking water to the affected
passengers.
 Arrange for prompt road transport for evacuating stranded passengers.
 Arrange for adequate number of licensed porters for carrying passengers luggage and
parcels.
 Arrange for payment of ex-gratia.
 Arrange for collecting the belongings of the injured and dead and handling them
over on satisfactory proof of ownership being obtained.
 Arrange to make over the dead bodies to the police for further necessary action.
 Arrange to set up enquiry cum information centers at important station enroute for
giving information to the public.
4. Board desires that the extent instructions and procedure as stated above may be
reiterated for strict compliance. The ticket checking staff should also be directed that they
will not leave the accident site without permission of site in charge.
Please acknowledge receipt.
Sd/-
Director, Traffic Control
Railway Board.
APPENDIX
OFFICE OF THE
CHIEF OPERATING MANAGER
MUMBAI CST
Circular No. 2
140 Tonne DSL HYD Breakdown Crane.
1. These cranes will be operated by DRMs of concerned divisions, who will ensure
that driving staff trained and passed in their operation by the Sr. Foreman/Sr. Section
Engineer nominated. The foreman will periodically inspect the cranes. Staff passed in
operation should be given a certificate signed by the concerned Sr.DME that he is
authorized to handle these cranes.
2. The day to day maintenance and the periodical schedule will be carried out in
accordance with the schedules prescribed by RDSO, together with the schedule prescribed
by CWM/PR and this should be strictly adhered to.
3. The POH of these cranes will be under taken in Parel Workshop. During POH all
the items that are laid down for POH repairs by RDSO, as also incorporating all other
items laid down in different period of schedules, and also items laid down in different
period of schedules, and also the items which have been booked for repairs by operator/in
charge of the cranes will be attended thoroughly during POH of these cranes.
( L C Trivedi) ( M P Roy)
for GM/(Optg)CSTM for GM (Mech)CSTM
Maintenance of Relief and Rescue equipments and
responsibilities of officer incharges:
[Accident Manual Rule No. 610 (F)]
Divisional Mechanical Engineer (Sr. Scale Officer) is responsible for the complete
ARTs/ARMVs/140Te.Crane as unit. He must ensure that deficiencies are made good after use,
every time, by all the departments concerned. He must ensure that the
ARTs/ARMVs/140Te.Crane/Crack Team staff is fully conversant with the use of all the Tools and
equipments provided in the Relief trains. He must personally inspect the ARTs/ARMVs and its
tools and equipments quarterly.
Accident Manual Rule No. 610 (A) -

SSE /SE or other supervisors inharge of ARTs/ARMVs/140 Te crane/Crack Team are responsible
to ensure that these are always fully equipped as per prescribed Standard List and all Tools and
Equipments are in working order.
Accident Manual Rule No. 401(3)

The incharge of a Break Down Train / Tower wagon is responsible for seeing that the train is fully
equipped with necessary tools and is in running order. He is also responsible for seeing that these
are marshalled properly and kept stabled in a convenient siding ready to move out.
Item 21: Gazetted Supervision for 140 Te.Crane Operation and Maintenance:
[Railway Board’s. L.No.2000/M(M&P)/175/1 Dtd. 16.05.2000.]
Railways should provide gazetted level supervision at all 120 T/140T crane sites. Railways
requested for sanction of an officer, preferably Sr. Scale, exclusively for looking after the
operation and maintenance of sophisticated high capacity (140T) cranes.
(Sample format)
WEST CENTRAL RAILWAY DRM(M)'S OFFICE

BPL/KTT/JBP
No. BPL/M/106/Disa. DATE: 31.10.2004
CME (CSTM)
Sub : Proposal for creation of one Sr. Scale gazetted post of DME (Disaster)
In the Division in Gr. Rs. ( 8000 – 13000 ) RSRP.
Ref : 1. Railway Boards Letter No.2000/M(M&P)/175/1/minutes of CMG
meeting dated 16.05.2000 .
2. Railway Boards Letter No.98/C&IS/COMP/Policy dated 02.11.98
3. HQ/CRLy Letter No. T.651.L.3 Crane meeting dated 28.04.2000.
Each Division also homes A class ARTs/ARMV and 140 Te. Diesel Hydraulic
crane. It is absolutely necessary to keep ARTs/ARMVs and 140Te. Crane in extremely good
working condition at all the times because of its extreme vital and essential nature of Railway
operations.
The ARTs/ARMVs and 140 Te Crane have been attached with the Mechanical
department without providing any provision in the gazetted setup to take care of the maintenance
and operational needs of the ARTs/ARMVs and 140 Te.crane.
Under the existing system, one of the ADME, looking after loco
operation/Maintenance and C&W activities, has been assigned additional responsibility of
ART/ARMV/140 Te. Crane maintenance. Apart from day today supervision, as per extent
instructions, ADME is also require to accompany whenever these are ordered at accident sites.
This adversely affects Loco/C&W maintenance and operational activities of the Division. Now it
is felt that an additional post of DME (Disaster) is required essentially for ARTs/ARMVs/140 Te.
Crane maintenance and operation. He will be responsible for ART, MFD, Crack Team & 140T
Diesel Hydraulic crane maintenance and operation.
MONEY VALUE CALCULATION FOR CREATION OF POST OF DME (Disaster).
Grade Rs. 10000-15200 = 25200/2 = 12600.0

DA: 37% = 4662.00
Misc. Charges 10% = 1260.00
Leave Salary 11% = 1386.00
D.C.R.G 1/8% = 1575.00
TOTAL = 21483.00
Hence Annual Value; Rs, 21483 X 12 =257796/- Per year
For DRM(M)
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No. 99/M(M&P)/7/6 New Delhi, dated 12th September 2002
Chief Mechanical Engineers,

All Indian Railways.
Sub: Management of Accident Relief Trains.
1. During CMPE (R&L)'s conference held in Chennai on 1st & 2nd July 2002, MM had
especially emphasized the following points.
 The ARTs must be self- sufficient to look after the needs of its staff who some
times have to work for days together. Basic facilities such as tents and chairs must
be provided in all ARTs for setting up Control Rooms.
 All ART in charge to ensure that sufficient food is available to feed the breakdown
staff and tea and biscuits should be provided to them at regular intervals.
 It is necessary to provide for easy identification of ART/ARMV staff. They should
be provided distinctive bright colour jackets and helmets. (Specifications attached).
 The commander, who is to direct the activities of his staff, should also be easily
identifiable at work site. Without such identification, the work suffers because
every person tries to give instructions. In case of conflicting command, there could
be a serious accident.
 Within one month, each railway to achieve. -
- 110 KMPH maximum speed for at least one ARME.
- 100 KMPH maximum speed for one ART, by upgrading wagon stock to
high speed design.
 The ART staff should be scanned and non performers weeded out.
 Mock trials should be conducted with timed response.
2. While reviewing relief operations in some of the recent accidents, it is seen that none of the
above items had been implemented. This has been viewed seriously.
3. Board desires immediate implementation of above items in the next 3 months. Member
Mechanical will thereafter personally inspect Accident Relief Trains in a random manner and Sr.
DME/DME and CMPE (R&L) or equivalent incharge of relief operations of the Division/Railway
will be held personally accountable for any deficiency noticed.
Please ensure strict compliance.
( Shakeel Ahmed )
Exec. Dir. Mech. Engg. (Traction)
Railway Board.
ANNEXURE
SPECIFICATION OF THE ITEMS RECOMMENDED BY RAILWAY BOARD.
S.N Description of Specification Quantity

Material
1 Inflatable and Single pole type in square size the detachable 2 2 Nos.
collapsible hill meters walls totally enclosed with doors and 2
tent size 7 meters windows height 2.27 meters made out of water
by 7 meters proof canvas in olive green shade ground sheet
250 GSM PVC material with eyelets for main
room also accessories bamboo poles, wooden
pegs, wooden mallets packed in canvas bag.
2 Bright orange NOMAX jackets made from Nomax material of For

NOMAX Jackets 6 ounces stitched with Zipper sides also made nominated
of NOMAX and with metallic teeth with Bk. Down
overlapping flap and metallic press buttons. Staff
3 Dark Brown Dark Brown NOMAX pants made from Nomax For
NOMAX Pants material of 4,5 to 6 ounces stitched with nominated
NOMAX threads. Bk. Down
Staff
4 Helmets heat and With special structured brim designed for For
chemical resistant. additional side protection with ratched type nominated
head band and sweat band, snugger chin strap, Bk. Down
in white, red, yellow and green colours Staff
GOVERNMENT OF INDIA
(RAILWAY BOARD)
No. 2002/Safety-I/23/4 New Delhi, dated 13th August, 2003
The General Managers,

All Indian Railways.
Sub: Periodic Examination and Safety certification of

Departmental Rolling Stock.
***
1. The periodic examination/Inspection and safety certification of the wheels, under gear
and structure of the departmental rolling stock( including Self Propelled Vehicles) for
example, Tower Wagon, Material Wagon/Ballast Train/PQRS train Camping Coaches, Self
Propelled ARTs, ARMEs and OHE Wiring Trains are mandatory in terms of IRCA Part-
III Rule No. 3.2.1, IRCA Part-IV Rule No. 2.1 and Para 20317 of AC Traction Manual
Volume –II, Part-I to ensure Safety of Train Operation. These mandatory provisions are
the basis for granting permission to start trains (Including Self Propelled Vehicles) by the
Station Master and the Guard under GR-4.35 & 4.62. However, it is noted from the past
incidents/Accidents that these mandatory provisions are not being complied with by the
concerned Supervisor incharge/Custodian (of other departments than Mechanical)
responsible for their safe operation.
2. In view of above, Board (MM, ME,ML,MT & CRB) have decided that the Zonal Railways
shall ensure that the enclosed procedure is strictly followed for periodic examination and
safety certification of the Departmental Rolling Stock (including Self Propelled Vehicles)
Please acknowledge the confirm compliance
(ARUN ARORA)
Director, Mech. Engg. (Frt.)
Copy to:1. CMEs (OL) &CSOs (All Indian Railways): For information and
necessary action please.
2. CCRS - For kind information.
ANNEXURE
No. 2002/Safety-I/23/4
Sub: Periodic Examination and Safety certification of
Departmental Rolling Stock.
---
1. Examination and certification of the safety of wheels, under Gear and Structure
of Break Down Crane is the responsibility of the Mechanical Supervisor( Loco
foreman/Diesel Foreman/SSE(C&W) who is the custodian of the Crane. The safety
certification shall be carried out at a Periodicity of 30 Days. Similarly, Self Propelled
ART, ARMEs are also to be examined and certified for the safety of structure and under
gear at a periodicity of 30 days by the nominated mechanical supervisor (TXR/Diesel
Foreman/Locoforeman/SSE(C&W)/SE(C&W).
(Sample format)
West Central Railway DRM (M)’S Office
Bhopal
No. BPL/M/106/DM/01 Date: 25.02.2004
All ARME/ART Incharges

Bhopal Division
SUB: Practical exercise of Tools and Equipments of ARME & ART.

REF: CSO/JBP letter No. WCR/JBP/T-320/Insp.Jan-08 dated 19.01.04
****
It is observed that regular testing and proper maintenance of ARME/ART equipments is
not being ensured by concerned staff. It is once again pointed out by CSO/JBP during his visit to
BPL/ART on 14.01.2004, that most of the staff is not fully aware of the operation and handling of
newly commissioned equipments and other critical tools & equipments.
It is therefore proposed to carryout intensive practical exercise for timely equipment

testing, apart from existing daily/weekly routine testing with immediate effect in presence of
ARME/ART Incharge and SSE(G) as per schedule given below to ensure proper functioning and
handling of all equipments by each nominated fitter.
SN Base Depot of Date of Practical Submission of report of

ARME/ART Exercise practical exercise to SSE(Disas.)
(Every month) (Every Month)
01 ARME/ET 4th and 5th 6th
02 ARME/BPL 8th and 9th 10th
03 ARME/BIN 12th and 13th 14th
04 ARME/GUN 17th and 18th 19th
05 ART/BPL 21st and 22nd 23rd
06 ART/BIN 25th and 26th 27th
08 SPART/GUN 28th and 29th 29th
During practical exercise, all precautions should be taken as laid down in the manufacturers
operation and maintenance manuals and complete safety of staff and equipments should be
ensured strictly by ARME/ART Incharges. The testing particulars of each equipment and tool
should be recorded in the Equipment Testing Register by ARME/ART Incharge personally so that
such items can be kept in good fetal at all the times.
Kindly follow the instructions strictly
(Shobhit Tondan)
Sir DME/BPL
Copy for necessary actions to:

SSE(G)/ET, SSE(G)/BPL, SSE(G)/BIN, SE(C&W)/GUN, SSE(Disaster/HQ)/BPL,
SSE(C&W/HQ)/BPL, SLI(HQ)/BPL, COS/BPL, OS-I(Disaster)/BPL.
(Sample format)
West Central Railway DRM (M)’S Office

Bhopal
No. BPL/M/106/DM/01 Date: 19.07.2004
All ARME/ Incharges

Bhopal Division.
SUB: Practical Training of Crack rescue and relief teams.

REF: CMPE(D&R)/JBP letter No. WCR/D/04/302 POM
dated 14.07.2004
****
It is observed that practical training of crack team is not being ensured by depot incharges.
It is therefore proposed to carryout intensive practical exercise once in a month for timely
equipment testing, in presence of ARME/ Incharge and SSE(G) as per schedule given below to
ensure proper functioning and handling of all equipments by each nominated crack team fitter.
SN Base Depot of Date of Practical Submission of report of

Crack Team Training practical Training to
(Every month) SSE(Disas.)/BPL
01 Crack Team/ET 4th and 5th 6th
02 Crack Team /BPL 8th and 9th 10th
03 Crack Team /BIN 12th and 13th 14th
04 Crack Team /GUN 17th and 18th 19th
During practical exercise, all precautions should be taken as laid down in the manufacturers
operation and maintenance manuals and complete safety of staff and equipments should be
ensured strictly by ARME/Incharges. The testing particulars of each equipment and tool should be
recorded in the Equipment Testing Register by ARME/Incharge personally so that such items can
be kept in good fetal at all the times.
Kindly follow the instructions strictly.
(Shobhit Tondan)
Sr DME/BPL
Copy for necessary actions to:
SSE(G)/ET, SSE(G)/BPL, SSE(G)/BIN, SE(C&W)/GUN, SSE(Disaster/HQ)/BPL,

SSE(C&W/HQ)/BPL, SLI(HQ)/BPL, COS/BPL, OS-I(Disaster)/BPL.
SSE(Elect.), SSE(Telecom) & Sr DMO/BPL
GOVERNMENT OF INDIA
RAILWAY BOARD
No.2003/M(M&P)/DM/7(13) New Delhi, dated July 16 2004
General Managers
All Indian Railways
Sub:- Implementation of the recommendations of High Level Committee

on Disaster Management.
*****
The High Level Committee on Disaster Management has recommended (Item

No.13) that each zone should have a professional trained Crack Team of Rail Rescue
Experts who can be rushed to accident site at short notice.
It has been decided in consultation with Health Directorate that the composition of
the Crack Team shall be as under:-
Medical (Doctors) 2 persons

Mechanical 4 persons
(Rescue workers/ART staff)
It may be ensured that rescue workers deployed for such duty are able bodied
persons, preferably less than 45 years of age and adequately trained, which will make
them suitable for rescue work.
(Sunil Bajpai)
Director Mech. Engg.
Railway Board.
GOVERNMENT OF INDIA
(RAILWAY BAORD)
No. 87/W-3/Tele/TN/23 New Delhi dated 06.08.1999

All Indian Railways
Sub: Provision of Communication Facilities

......
It has been decided to liberalize the provision of telecommunication facilities in the

Railways. The following steps may please be taken in this regard -
1. SATELLITE COMMUNICATION:
1.1 Class-A Accident Relief Trains and ARME-I's should be provided with one IRIDIUM or
equivalent Satellite Phone each. This phone will enable to establish communication from
any accident/disaster site to any other place having DOT telephone facility/IRIDIUM
phone.
1.2 Each Division and Zonal Railway Headquarter should also have two such phones to be
exclusively used for emergency communication in case of disaster/accident. These phones
should be made available during such emergencies only to the officers proceeding to the
site of accident/disaster.
1.3 Logbook for the use of these telephones should be maintained with the details of use and
reviewed periodically by the respective controlling officers.
2. DOT PHONE
2.1 All Branch Officers in the Division may be provided with DOT telephones, both in office
and at residence with STD facility having dynamic locking arrangements. Other officers
and offices can also be provided with these facilities with the approval of General Manager
and the concurrence of FA&CAO.
3. Instructions in force on the number of calls and maintenance of record for utilization of
STD facilities should continue to be followed.
4. This issues with the concurrence of Finance Directorate of the Railway Board.
( Akhil Agrawal )
Executive Director/Telecom Development
Railway Board
GOVERNMENT OF INDIA
(RAILWAY BAORD)
No. Safety-1/12/12 New Delhi dated .07.1999

All Indian Railways
Sub: Derailment of 1034 Up Pushpak Express between Ata & Orai

stations of Jhansi-Kanpur section of Jhansi Division of Central
Railway on 17.5.1994
....
The Commissioner of Railway Safety, Central Circle para 8 of his preliminary Enquiry
Report into the above accident has recommended that the Jhansi division had arranged a video film
covering all the aspects of damages of track and rolling stock and other features relevant to
ascertaining the cause of the accident. Such a film had indeed proved to be of immense value to
the present investigation.
Board in this connection had already issued detailed instructions to Railways vide Board's
L.No. 92/Safety-3 dated 10.12.1993. Board has accepted this recommendation of the CRS and
direct to the Railways that in future, whenever, any serious accident occurs a video film of the
accident site and restoration work should be prepared.
Please acknowledge the receipt.
( O D Gulwani )
Jt. Director Safety
Railway Board
Copy to: DO/CRS (with 30 copies) w.r.t. his note No. 94/Safety
(A&R)/1/9 dated 2.6.94.
GOVERNMENT OF INDIA
(RAILWAY BAORD)
No. 93/Safety-I/6/1 New Delhi dated 10.12.1993

All Indian Railways
Sub: Video Filming of restoration - work of various accidents.

----
The extant instructions on dealing with press and media underline the need of
feeding quick and accurate information in the unusual occurrences and train accidents.
On most of the occasions, the machinery gets into motion quite efficiently, but
some times the projection in media is not given adequate attention. M.R. has expressed his
displeasure on the lack of adequate, proper and quick communication between the executive
branches and the PR units of the zonal railways.
Though a large volume of records are maintained on the railways on accident and
their restoration were followed by detailed enquiries, as audio visual records of the same are
generally available on the railways. It has been decided by the Board that in case of serious
accidents, zonal railways should not only cover the restoration work for the use by the press and
media, but also keep video filming of the restoration work to draw lessons from the lapses
committed in the process. Such coverage of video filming can be used, subsequently, in the
various training institutes as well. For this purpose, wherever necessary, video cameras may be
taken on hire.
DA: NIL
(K.C......)
Director Safety
Railway Board
Hkkjr ljdkj GOVERNMENT OF INDIA
jsy ea=ky; MINISTRY OF RAILWAYS
(jsyos cksMZ RAILWAY BAORD)
No.2000/M(M&P)/175/1
Date: 16.05.2000
Minutes of the Crane Maintenance Group Meeting

held at Jamalpur on 24th & 25th April, 2000.
The following officers attended the meeting -
S/Shri
Railway Board IRIMEE
KL Chhabra, ED(Dev.) Arvind Mathur, Director
AK Khosla, DME(P)II Arjun Mundia, Prof.
Mukund K Sinha, Asstt. Prof.
Central Railway
PS Gupra, CWM/Parel North Eastern Railway
U Borbankar, Sr.DME/NKJ DK Srivastava, Sr.DME/Gonda
LC Trivedi, Dy.CME(P&F) S Lahiri, Sr.DME/Siligurai
MM Quireshi, AWM/Parel Gauri Shankar, Dy. CME(O&F)
Eastern Railway Northeast Frontier Railway

Nikhilesh Jain, CWM/JMP KK Mazumdar, Dy.CME(R&L)
SM Bhardwaj, CWE
AK Tiwari, CME(O&C)
DC Sharma, Dy.CME/JMP Southern Railway

Akhilelsh Mishra, AWM/JMP GH Radhakrishnan, DY.CME(R&L)
RN Saha, DME(P)/ASN
AK Gupta, Dy. CME/JMP South Central Railway

Pankaj Singh, DME(P)/DHN BM Shyam Singh, CMPE(R&L)
K Ramnaiya, DME(P)/HWH U Subba Rao, Sr.DME(C&W)/Hubli
AK Sinha, Dy. CME(O&C)/MGS
South Eastern Railway
RDSO BL Harijan, CMPE(R&L)
MP Sinha, Dir.Std.(MP) TV Subba Rao, Sr.DME/CKP
Northern Railway Western Railway

Vijay Kumar, Sr.DME/Ludhiana P Agarwal, CMPE(R&L)
NS Patial, Sr.DME/Ratlam
Railways 1.ED (Dev.)/Railway Board and CWM/JMP welcomed the delegates
to the inaugural Crane Maintenance Group meeting and expressed the
hope that this Forum shall address various issues viz. training of operators
and maintenance staff, procurement of maintenance spares, preventive
maintenance schedules etc. which affect the reliability and availability of
Breakdown Cranes, 140 T Cranes in particular, and also improve
Railways' effectiveness in tackling accidents.
Shri DC Sharma, Dy.CME (Cranes) presented an Overview of the crane

manufacturing activities at Jamalpur workshop. The presentation
highlighted the milestones and the shortcomings. A list of areas where
assistance is required was also discussed.
All Railways 2. Installation of PCs at all Crane Sites :

CWM/JMP, Parel
Railway Board has delegated powers to all GMs, DRMs, PHODs and
SAG officers heading independent establishment (vide Railway Board's
letter no. 98/C&IS/Comp./Policy, dated 02.11.98) for purchase of PCs
every year. It was decided that under these powers all 140 T Crane
location shall install one PC with FAX, Modem and e-mail facilities. This
should be completed by September '2000.
All Railway 3. Review of Hire Charges for 120T/140T Cranes:

JDTC(G)/Rly.Bd.
Railways complained that the existing guidelines for hire charges of
120T/140T Crane have not correctly been laid down and the hire charges
stipulated at present are extremely low and not commensurate with the
high cost of these cranes. This needs to be reviewed immediately by
Board's Traffic (Commercial) Directorate.
EDS(M)/RDSO 4. Issue of Crane Maintenance schedule forms by RDSO :

All Railways
RDSO shall issue schedule forms to be followed by all cranes users
during periodic maintenance schedules of the new Gottwald Cranes
recently received. This must be done by Aug.'2000.
For the Old Gottwald as well as CowansC5ranes RDSO should issue

revised schedule forms for all types of preventive maintenance schedules
as well as POH, based on the experience gained by Railways and JMP and
Parel Workshops so far. During each schedule, users must inspect the
crane for structural damages in vulnerable areas like Match Truck, 'A'
frame, Gallows, Boom and load pulleys etc. and this check should be
incorporated in the new schedule forms to be issued by RDSO alongwith
sketches of vulnerable areas.
5. Annual Maintenance Contracts :
CWM/JMP 5.1 Engine :
CWM/Parel
All Railways So far none of the railways have entered into an Annual Maintenance
Contract with Cummins for overhaul of the diesel engine of the 1.10 T
Crane. NR advised that they had an AMC with Cummins for Delhi crane.
This crane has since been transferred to LDH. NR is now in the process
of finalizing terms and conditions for a comprehensive Annual
Maintenance Contract for diesel engine of 140 T Cranes on the lines of
AMC entered into by NR for Cummins Diesel engine fitted on DMUs.
It was decided that JMP workshop shall prepare model terms &
conditions for Diesel engine Annual Maintenance Contract and circulate
to all Railways.
All Railways 5.2 Hydraulics :
The Group after deliberating on the overhaul requirements of hydraulic

circuits and equipment decided that no AMC would be required for these
items at this stage.
All Railways 5.3 Safe Load Indicators (SLI):

CMEs/ER & CR
CWM/Parel Functioning of Safe Load indicators on old Cranes supplied by Gottwald
CWM/JMP and Cowans was discussed. It was decided that keeping in view the
reliability problem of this equipment Railways need to go in for AMC of
Safe Load Indicator system on the old cranes and that JMP Workshop
should finalize the AMC for the Gottwald design crane and Parel
Workshop for Cowans design crane and operation of the AMC shall be by
respective Sr.DMEs. Some sources of SLI are available with JMP
Workshop and these can be tried out by Parel Workshop.
EDME(Tr.) 6. Rationalization of Crane types on Railways:

DME(P)II
CWM/JMP suggested that to facilitate inventory control and training of
experts for maintenance and operation cranes of one type should all be
concentrated preferably on the same Railway or at best on adjoining
railways. This shall be examined by Railway Board.
EDS(MP)/RDSO 7. Standardization of infrastructural requirements for basing 140 T

Cranes:
RDSO should standardize the infrastructural requirements for basing 140

T cranes. The requirement shall cover stabling facilities, Pit, covered
shed, battery charging facility, storage area for lifting tackles, material
handing facilities and tools etc. This should be done by July'2000.
CME/ER & CR 8. Service Engineering Group :
CWM/JMP &
Pare;
All Railways
All Railways expressed the need for continuing the Service Engineering
Group (SEG) by JMP and Parel Workshops. For this purposed, the
Railways must accept necessary debits raised by JMP and Parel
Workshopsl. JMP shall ensure that adequate staff and supervisors are got
trained in various critical areas viz - hydraulics etc. SEG should start
visiting the respective cranes with effect from May'2000. Similar action
shall be taken by Parel for Cowans Cranes.
AWM/Crane Design/JMP Shri Akhilesh Mishra gave an excellent

presentation on Service Engineering Group and on the prospects of
effecting quantum improvements in the work done by SEG through the
selling up of a virtual private network which shall make possible a
continuous dialogue among crane users and JMP workshop. CWM/JMP
should send the proposal to Railway Board for further action.
Dir/IRIMEE 9. Training in operation & Maintenance of 140 T cranes:

CWM/JMP
ED(Trg&MPP)
Lack of adequate training facilities for operation and maintenance of 140
T breakdown cranes of various types was identified as an area of major
weakness. It was decided that IRIMEE shall be the nodal center for
training of all supervisors, officers and staff of 140 T cranes. For this
purpose, IRIMEE shall start arranging basic grounding training of
operators/Crane Drivers, Maintenance supervisors, staff and officers at FT
followed by theoretical classes for crane maintenance and operations in
association with Jamalpur Workshop. IRIMEE shall also develop in house
expertise in hydraulics. ED (Trg.&MPP) should issue necessary directives
to IRIMEE in this regard and also direct IRIMEE to develop detailed
training modules separately for operators, maintenance staff, supervisors
and officers. Director/IRIMEE requested Railways to nominate officials
who are experts in the field of maintenance and operation of 140 T cranes
and can help the institute make a good beginning. Railways should send
bio data of such officials to IRIMEE by May 2000.
CME/ER&CR 10. Operators/Crane driver certification:

CWM/JMM & PR
all Railway
At present there is no formal system of imparting training for
operators/crane drivers before certification for operation of 140 T cranes.
It was decided that the possibility of setting up a simulator for cranes be
examined by RDSO. It was also decided that operator training shall
continue as before at JMP and PR workshops will such time IRIMEE
starts organizing specific courses for crane drivers/operators. Operator
certification can be done by Sr.DME/DME after giving hands on training
to the operator at a crane site on individual Railways.
CME(O&C)ER 11. Issue of crane working Manual
CWM/PR/Cr.
Shri DC Sharma
Shri D C Sharma new Sr.DME/ALD/WR was entrusted with the
responsibility of preparing a crane working manual for the Gottwald
design crane in consultation with CME(O&C)/ER. CWM/PR shall
arrange preparation and issue of crane working manual for Co wans
design cranes in consultation with CME(O&F)/CR.
All Railways 12. CRS Sanction for 140 T Cranes :
ER, NE, NF, SE, WR and SCR were asked to expedite obtaining of CRS
sanction for operation of new Gottwald design cranes on the basis of
speed certificate issued by RDSO. CR, SR, SC & WR were asked to
expedite obtaining CRS sanction for operation of new Cowans cranes to
be supplied during the year on the basis of interim speed certificate issued
by RDSO.
All Railways were asked to obtain necessary CRS sanction for operation
of all types of 140 T cranes available on IR to provide flexibility of
operation.
All Railways 13. Consolidation of requirements of Maintenance Spares :
CME/ER, CR]
CWM/JMP & It was decided that JMP Workshop and Parel Workshop shall be the nodal
Parel shops for consolidation of maintenance spares for Gottwald design and
Cowans design cranes respectively. Keeping in view the need for
ensuring near 100% availability and reliability of 140 Te. Breakdown
Cranes, it was decided that vetted indents for their requirement of urgent
maintenance spares (lists as finalised during the meeting) for new
Gottwald type cranes by ER, NR NE, SC, SE and WR and for the old
Gottwald cranes by NR, ER, SE and SR shall be sent to JMP Workshop
for consolidation and purchase latest by first week of June '2000. The
following breakup was decided for purchase of spares for cranes of new
design :
Purchase of Spares for Gottwald Cranes of New Design

Railway Complete List Curtailed List
Northern Railway One Set One Set
North Eastern Railway One Set Nil
N.F.Railway NIl One Set
Western Railway Nil One Set
Eastern Railway Nil One Set
South Central Rly. Nil One Set
South Eastern Rly. One Set Nil
ER shall, thereafter, expedite complete procurement so that there is no

hold up as finalisation of Rate Contract for all the imported spares for
Gottwald design cranes on lines similar to Cowans cranes by Railway
Board would take some more time.
CME/ER, CR 14. Spare Wheel Sets and Capital Spares :
CWM/JMP &
Parel
It was decided that complete number of wheel sets must also be provided
as maintenance spares for the old and new cranes. Necessary planning for
this purpose should be done by JMP and Parel Workshops and
confirmation sent to Board's office. The spare wheel sets will be held by
JMP and Parel Workshops. Railways needing wheel sets for replacing the
condemned wheel sets will arrange collecting the same from respective
shops and return the condemned wheel sets for rediscing.
Jamalpur Workshop has circulated a list of capital spares to be stocked by

Railways to ensure higher availability of cranes. To economize and with
a view to take advantage of quantity of scale, it was decided that Jamalpur
Workshop shall draw a consolidated list of capital spares required for
Gottwald cranes both old and new design. Only JMP Workshop shall
stock these spares for all the Railways deploying Gottwald cranes and
supply as and when required by any Railway. Similar action would be
taken by Parel Workshop of CR for Cowans cranes. ER & CR should
furnish consolidated proposals for sanction of capital spares under RSP.
Funds provided under RSP against capital spares for 140 T cranes must be
fully utilized by ER during the year.
EDRS(P)/Rly.BD 15. Rate contract for maintenance spares :
JMP Workshop has finalized a list of maintenance spares for Gottwald

design cranes for rate contract similar to one for Cowans cranes. This
excludes the items already indigenised successfully. Stores Directorate
should expedite finalization of rate contract.
CME/ER 16. Manufacturing programme of 140 T cranes at JMP

CWM/JMP
EDRS(P)/Rly.Bd
JMP has manufactured 3 Nos. 140 T cranes during 1999-2000. JMP
Workshop must ask for commensurate amount of funds for manufacture
140 T cranes as per the production programme under WMS. Railways to
whom the cranes are allotted may accept the debits against relevant RSP
provision of ER. JMP plans to manufacture 4 Nos. 140 T cranes during
2000-2001. For this purpose, procurement of kits needs to be expedited
by Rly. Bd.
All Railways 17. Failure reports of 140 T cranes

CWM/JMP & PR
Dir./IRIMEE All failures of 140T cranes must be directly reported by user Railways to
EDS(MP)RDSO RDSO, JMP Workshop, PR Workshop & IRIMEE as per the format at
annexure 'A'. RDSO should prepare a system for codification of failures
of 140 T cranes in the next 3 months and start analyzing the failures as is
being done in case of Dsl. Locos.
All Railways 18. Review utilization of cranes and availability of maintenance
infrastructure :
In order to review the utilization of 140 T cranes and availability of

requisite maintenance infrastructure, Railways were asked to furnish
information as per proforma at annexure 'B' & 'C' to Bd.'s Office, in hard
copy as well as floppy latest by 31st May 2000. A copy should be sent by
E Mail dmep2 @ rb.railnet.gov.in with copy to edmeh@railnet.gov.in.
EDS(MP)/RDSO 19. Crane maintenance group meeting and secretarlat :

All Railways
The next crane maintenance group meeting shall be held at PR Workshop
on Central Railway . Motive Power Dte of RDSO shall be the nodal
agency for preparation of agenda for all future crane maintenance group
meetings and for monitoring action taken on decisions taken during the
group's deliberation.
All Railways 20. Feeder cadre for maintenance & operations
Different Railways have been following different practices for induction

of man power for operation and maintenance of cranes. It was decided
that all new induction for operation & maintenance staff for 120/140 T
cranes should be drawn from Diesel Sheds with a view to provide
necessary expertise and avenue for promotion so that there is no
stagnation.
EDME(Tr) 21. Gazetted Supervision for crane operation & Maintenance
Railways should provide gazetted level supervision at all 120/140 Te.

crane sites. Railways requested for sanction of an officer, preferably
Sr.Scale, exclusively for looking after the operation & maintenance of
sophisticated high capacity (140 T) cranes. This will be examined by
Railway Board.
All Railways 22. Approved Vendor list :

CWM/JMP
Approved vendors lists for maintenance spares of 140 Te. cranes shall be
circulated periodically by JMP & PR Work shops.
JMP Workshop has provided a draft copy of the vendors list of the old
crane. Vendors list for the items of new crane would be prepared in due
course, however as the equipment used on the cranes is similar the vendor
list covers most of the equipments of the new crane as well. Comments
on the performance of vendors included in the list must be sent to JMP
Workshop within a month for modification of the list. JMP Workshop
must then re-circulate the final copy of the vendor's list.
Periodic vendor meets shall be organized by ER and CR in which all

Railways should participate.
CWM/JMP 23. DOs and DONTs for Crane operation:
CWM/Parel
List of DOs and DONTs for old cranes should be finalised by Jamalpur
and circulated to all Railways. Similarly for Cowans Cranes Parel
Workshop shall prepare the Dos and Dont's.
CWM/JMP 24. Quality Audits of Crane Manufacture:

EDS(MP/RDSO
It was decided that stage inspection by RDSO is no longer required and
should be discontinued as it has been done in the PUs. In place of this
periodical quality audit of the systems at Jamalpur should be carried out
by RDSO.
All Railways 25. Crane utilisation for purposes other than breakdown:
It was decided that crane utilisation for activities other than accident relief
cases must be controlled. This is a very costly asset and its proper upkeep
for breakdown relief operation is necessary.
CWM/JMP 26. Pendulum Type Angle Indicator:

Jamalpur Workshop was asked to provide pendulum type angle indicator
in all cranes manufactured henceforth.
( KL Chhabra )
Executive Director (Dev.)
Railway Board
Copy to : CMEs/All Zonal Railways, Director/IRIMEE/JMP
EDS (MP)/RDSO
CWM/JMP/ER &
CWM/Parel/CR
ED (Trg.& MPP)/Railway Board
EDRS (P)/Railway Board
EDME (Tr.)/Rly.Board.
JDTC(G)/Rly.Board.
Encls: Annexure 'A'

Annexure 'B'
Annexure 'C'
Annexure IIIA
No. 2002/Sec(Cr.)/45/47 Rail Bhavan, New Delhi dated March, 27,2003

Sub : Clearance by State Police in case of railway accidentsdue to suspected subotage.
Ref : Ministry of Home Affairs' letter No. VI-24022/11/2002-PM-I,dated 24.12.2002

addressed to Home Secretaries of all States (copy enclosed).
.....
The issue of expeditious clearance by the State Policy in case of railway accidents,
where sabotage is suspected, has been engaging Ministry of Railways (Railway Board)'s attention
for a long time. It is noticed that sometimes rescue operations are hampered due to delayed and
reluctant clearance by the State Police.
2. It is pertinent to mention that there are two different tasks to be accomplished on war
footing after a railway accident involving human lives is concerned i.e. a) Quick Rescue
Operation; and b) Restoration of rail traffic. It is clarified that in case of railway accidents
permission of the State Government or clearance of the police is not required for launching rescue
operations for the purpose of saving human lives, which inter alia may also involve
handling/shifting the rolling stock (locomotives, wagons and coaches) for extricating the trapped
passengers. However, police clearance is required for restoration works at all the site of accident,
if sabotage is suspected.
3. To avoid any delay in launching the rescue operations for saving as many human lives as
possible and for early restoration of rail traffic, the above issue has been taken up with the Ministry
of Home Affairs. Consequently, Ministry of Home affairs vide their letter ibid have directed the
Home Secretaries of all States to issue suitable instructions to the concerned authorities for taking
prompt action and to expedite clearance certificate in the event of a rail accident, when sabotage is
suspected.
4. The contents of this letter may be widely published among the railway officers staff and
displayed in all ARTs, ARMEs so that a general awareness created amongst all those engaged in
rescue activities.
5. This letter supersedes the Railway Board’s letter of even number dt. 07.02.2003.
(ATUL PATHAK)
Director Crime Prevention
Railway Board
Copy to the Chief Security Commissioners. All Zonal Railways for information.
No. 2002/Sec(CR)/45/47 New Delhi dated 07.02.2003

Central Railways,
Mumbai.
Sub : Clearance by State Police in case of railway accidents.
Ref : Ministry of Home Affairs' letter No. VI-24022/11/2002-PM-I
dated 24.12.2002 addressed to Home Secretaries of all States
(copy enclosed).
.....
The issue of expeditious clearance by the State Police in case of railway accidents
has been engaging Ministry of Railways (Railway Board)'s attention for a long time. It is noticed
that sometimes rescue operations are hampered due to delayed and reluctant clearance by the State
Police.
2. It is pertinent to mention that there are two different tasks to be accomplished on war
footing after a railway accident involving human lives is concerned i.e. a) Quick Rescue
Operation; and b) Restoration of rail traffic. It is clarified that in case of railway accidents
permission of the State Government or clearance of the police is not required for launching rescue
operations for the purpose of saving human lives, which inter alia may also involve
handling/shifting the rolling stock (locomotives, wagons and coaches) for extricating the trapped
passengers. However, police clearance is required for restoration works at all the site of accident.
3. To avoid any delay in launching the rescue operations for saving as many human lives as
possible and for early restoration of rail traffic, the above issue has been taken up with the Ministry
of Home Affairs. Consequently, Ministry of Home affairs vide their letter ibid have directed the
Home Secretaries of all States to issue suitable instructions to the concerned authorities for taking
prompt action and to expedite clearance certificate in the event of a rail accident.
4. The contents of this letter may be widely published among the railway officers staff and
displayed in all ARTs, ARMEs so that a general awareness created amongst all those engaged in
rescue activities.
Please acknowledge.
(ATUL PATHAK)
Director Crime Prevention
Railway Board
Copy to the Chief Security Commissioners. All Zonal Railways for information.
Government of India
Ministry of Railways, Railway Board, New Delhi
No.2004/M&P/7/DM(107) Date: 9th Nov. 2004
All Indian Railways
Sub:- Fire Fighting equipments in ARTs and training of ART Staff

Ref:- High Level Committee recommendations No. 107
****
The High Level Committee in introduction to their report have noted that in most Railway
accidents, relief arrives quickly from within the vicinity of the accident.
With this objective, the Committee have made following recommendations:
1. MOU's with State Government to provide rescue and relief assistance (Item 4)
2. Divisions to be aware of local, civil, army and other resources (Item 14)
3. Creation of a Disaster Management Plan, taking into account the resources available with
them and in their neighborhood (Item 15)
Even when there are no casualties, quick response is important in case of fires because of
the rapidity with which the situation worsens. It is, therefore, imperative that IR make use of the
local Fire Services (and in case of tank wagons, the oil industry's resources) for ensuring timely
and effective response. This aspect may be taken care of while taking action on the
recommendations highlighted above.
Fire fighting capabilities have traditionally been maintained on ARTs, especially because
large fires can get started during cutting and welding work at accident sites (due to spillage of
flammable material). Therefore, the high level committee have recommended that ARTs
capabilities in fighting fires must be enhanced too.
Based on feedback received from some railways, a portable water mist fire fighting system
is reported to be effective in tackling even large fires and does not require much training in
handling the equipment. Till such time there is further development in fire fighting technology,
use of such equipment is recommended on trial for at least one ART on each railway. Based on
experience gained, the system can be extended to other ARTs in future.
Further, to enhance the fire fighting capabilities of the ART personnel, Board have issued
instructions for one week of training per team of two ART Supervisors, four artisans and four
helpers at the National Fire Service College, Nagpur. Alternatively, services of any other institute,
like the Fire Safety Management Academy (Rohini, New Delhi) available in the neighborhood of
the ART could also be used.
Board (MM) desires that necessary arrangements to tackle fire related incidents on
the above lines are adopted on your railway and compliance intimated to Board.
Sd/- ( Sunil Bajpai )

Director, Mech. Engg. (P) II
Railway Board
CENTRAL RAILWAY COM OFFICE
MUMBAI CSTM
NO. BB.61.5.111.657 DATE : 31 May 2006
Sr. DME (Fr&OP) BB,
Sr. DME CLA
Sr. DME NGP,PA,BSL,SUR
Sub : Nomination of staff for 140 t. DHBD crane at “A” class ART.
Ref : 1. This office letter No. T.153.L.5.HLC.57 dated 18.10.2004.
2. This office letter No. T.651.L.5.Crane Driver dated 29/09/2005 & 19/01/2006.
…..
Vide this office letter No. T.153.L.5.HLC.57 dated 18.10.2004, Divisions were
advised the sanctioned strength of staff for the ART/ARME.
The staff required for day-to-day maintenance of 140 t DHBD crane is to be

nominated by divisions. Similarly, divisions were advised for creation of two posts of
JE.I/II for crane operation vides this office letter No. T.651.L.5.Crane Driver dated
29.09.2005 & 19.01.2006.
The staff required for day-to-day maintenance of 140 t. DHBD crane is
SN Designation No. of Duties at homing shed Remarks

staff
1. SSE/ART 01 Overall supervision & Mostly available at
maintenance of ART all ART locations
having 140 t crane.
2. SSE/SE (Crane) 01 Overall supervision &
maintenance of crane
3. JE.I/II (Crane 02 Efficient & safe operation of
Operations) crane & keeping crane ready at
all the time.
4. Crane assistant cum 02 Daily checks & maintenance
Diesel Mechanics schedules of the crane
Gr.I/II
5. Crane assistant cum 02 Daily checks & maintenance
Electrician Gr.I/II schedules of the crane.
6. Helper Khalasis 06 To assist all above staff for
upkeep of the crane
Total staff 14
Therefore, Divisions should ensure that the above posts/staff are available with
them. The necessary feedback may please be given to this office.
(A.RASTOGI)
DY. CME (P&F)
CENTRAL RAILWAY
H.C. JOSHI Office of the Chief Safety Officer,

Chief Safety Officer Chhatrapati Shivaji Terminus
Mumbai-400 001
No. T.102.P.ARTs/ARMEs Date: 04/10/2004
My dear Pathak, Sinha, Jha, Braj Mohan & Agrawal
Sub : Inspection of ARTs by DRM.
Ref : This Office D.O. No. T.361/P/ART-ARME

Dated 22/11/2002
____
In partial modification of earlier instructions, it is now decided that Divisional

Railway Managers will inspect ARTs once in every six months and submit the report to
the Headquarter accordingly.
With best wishes.

Yours Sincerely,
Sd/-
( H.C. JOSHI )
Shri Madhav Pathak, D.R.M./BB.

Shri N.C. Sinha, D.R.M./NGP
Shri Vipin Jha, D.R.M. / SUR
Shri Braj Mohan, D.R.M. /Pune
Shri G.C. Agrawal, D.R.M. / BSL
CENTRAL RAILWAY Office of the

Chief Operation Manager,
1st Flr, Annex Bldg.
CST Mumbai- 400001
Phone (Rly) 54210
MTNL 22697275
No. T/651/L.5/ART/Policy
Dtd. 31/03/2004
Sr.DME (Fr.Op), Mumbai

Sr.DEE(TRS) Kalyan
Sr. DME (Dsl) Kurla
Sr. DME, BSL, NGP & PA, SUR
Sub : Inspection of ART/ARMEs by Officers.

Ref : Our letter of even No. dt. 25/03/2004.
_______
In reference to the above, the revised schedule with minor corrections is
enclosed. Sr. DME’s are requested to put up the revised schedule once again to
DRMs.
Sd/-
( SANJAY GUPTA)
Dy.CME(P&F)
Encl: As above.
PERIODICAL INSPECTIONS OF ART/ARME BY DIVISIONAL OFFICERS.
…….
Name of ART/ARME
SN Desig. of inspecting Official Periodicity Done Due
1. DRM Six Monthly
2. SR. DME (P)* Quarterly
3. DME * Quarterly
4. ADME * Monthly
5. Sr DSO Quarterly
6. SR.DSTE/DSTE Quarterly
7. ADSTE Quarterly
8. SR.DEN/DEN Quarterly
9. ADEN Monthly
10. SR.DEE(G)/ADEE(G) Quarterly
11. Sr DEE(TRD)/ADEE(TRD) Quarterly
12. M.S. Quarterly
13. Sr.DMO/DMO Quarterly
MOST IMPORTANT
CENTRAL RAILWAY COM OFFICE

MUMBAI CSTM
No. T.153.L.5.HLC.57 DATE : 5 June 2006
Sr. DME(Fr&Op) BB,

Sr.DME(D) CLA
Sr.DEE(TRS)KYN
Sr.DME BSL,NGP,SUR, PA
Sub :Nomination & attendance of staff for ART/ARMV at accident site.

…..
On one incident on BB division, the ART staff attendance at breakdown site was less than
the sanctioned staff strength & CRS Central Circle has expressed displeasure on this issue.
Sanctioned strength of staff for “A” & “B” class of ART and ARMV on Central Railway were
advised to divisions vide this office letter of even number dated 18.10.2004 (Copy enclosed).
It is the responsibility of the officer in charge of the ART/ARME, to ensure that the
sanctioned strength of staff are nominated for the ART/ARME & the sanctioned strength of staff
should attend the accident site without fail.
If any staff from nominated list are on leave / sick / out of station on duty, etc., the staff
nominated in the additional gang / depot staff are to be advised to attend the breakdown duties.
In case they are not able to board the ART/ARME in time, they should reach the accident site by
road or some other means.
In view of above, once again, all concerned divisional officers are requested to kindly
ensure the compliance of these instructions & necessary feedback to be submitted to this office
for kind perusal of CME.
Sd/-
( A.RASTOGI )
DY.CME(P&F)
CHAPTER - 6
RECORD KEEPING
AND
CERTIFICATION
PROFORMAS AND CERTIFICATES
Following Standard Proformas for maintaining registers and files/statements to be

maintained by the responsible Break Down Incharges and necessary records to be kept in
the break down section/ART/ARME/SPART.
Form Particulars To be filled Periodicity To be sent To
No. up by
ART-1 Proforma for overdue inspection of ART/ARME/SPART Monthly Div.Officers &
officers and supervisors of Accident Incharge concerned
Relief Trains/ARME/SPART Supervisors
ART-2 Proforma for Break down site report ART/ARME/SPART Every Sr.DME
Incharge ordering
ART-3 Proforma for competency certificate for Sr.DME Yearly B.D. Section
crane drivers
ART-4 Proforma for provisional competency Sr.DME 6 monthly B.D. Section
certificate for 140 Te. Crane supervisors
ART-5 Proforma for maintaining Accident PCOR Every Control Office
Diary in Control Office. ordering
ART-6 Proforma for Inspection of ARTs Inspecting Officer Quarterly B.D. Section
ART-7 Proforma for Inspection of ARMEs Inspecting Officer Monthly ARME incharge
ART-8 Proforma for Inspection of SPARMVs Inspecting Officer Monthly ARME incharge
ART-9 Proforma for Inspection of SPARTs Inspecting Officer Monthly SPART Incharge
ART-9 Proforma for ordering of Crane Special ART Incharge Every B.D. Section
ordering
ART-10 Proforma for fixation of Hire Charges ART Incharge Yearly Sr.DME
for MFD/LUCAS
ART-11 Proforma for fixation of Hire Charges ART Incharge Yearly Sr.DME
for 140 Te. crane.
ART-12 Proforma for Video Camera Register ART/ARME/SPART Every ord. B.D. Section
Incharge
ART-13 Proforma for Equipment Testing ART/ARME/SPART Monthly B.D. Section
Register Incharge
ART-14 Proforma for Testing particulars of ART Incharge 6 Monthly CMW/ PR
Chain slings
ART-15 Proforma for Testing particulars of Wire ART Incharge 6 Monthly CWM/ PR
Rope slings
ART-16 Proforma for ART/ARME/SPART ART/ARME/SPART Every B.D. Section
Ordering Particulars. Incharge ordering
ART-17 Proforma for 140 Te. Crane SPL ART Incharge Every B.D. Section
Ordering particulars. ordering
ART-18 Proforma for 140 Te Crane/SPL Debit ART Incharge Every Concerned
particulars. ordering Officer
ART-19 Proforma for maintaining parts of ART Incharge Once ART/B.D.
MFD/LUCAS Power pack . Section
ART-20 Proforma for maintaining Particulars of ART Incharge Once ART/B.D.
chains & wire rope slings Section
ART-21 Proforma for maintaining particulars of ART Incharge Once ART/B.D.
MFD Equipment. Section
ART-22 Proforma for Work distribution among ART Incharge Yearly B.D. Section +
staff for MFD working. Sr.DME
ART-23 Proforma for work distribution among ART Incharge Yearly B.D. Section +
staff for crane working. Sr.DME
Form Particulars To be filled Periodicity To be sent To
No. up by
ART-24 Proforma for maintaining MFD Petrol ART Incharge Once ART/B.D. Section
Pump set.
ART-25 Proforma for maintaining MFD Diesel ART Incharge Once ART/B.D. Section
power pump set.
ART-26 Proforma for Master Defect Card of ART Incharge Every ART/B.D. Section
140 Te. DSL Hyd. break down Crane. Attention
ART-27 Proforma for parts of 140 Te. Crane ART Incharge Every Sr.DME + B.D.
changed during the year. Attention Section
ART-28 Proforma for 140 Te Diesel Hyd. Bk.Dn. ART Incharge Every Sr.DME+ B.D.
crane Schedule/ Unschedule repair Attention Section
statement.
ART-29 Proforma for Break down staff training ART Incharge Yearly Sr.DME+ B.D.
particulars. Section
ART-30 Proforma for Break down ordering at a ART Incharge Monthly ART/B.D. Section
glance.
ART-31 Proforma for site observation joint Concerned Before CMPE (D)
Report for Crane/Special Officer Ordering
ART-32 Proforma for Retrieval of accidented Sr.DME Before DRM + CME
coaches/Crane special work ordering
ART-33 Proforma for Inspection Register for ART Incharge As per Req. ART
ART
ART-34 Proforma for Inspection Register for ARME Incharge As per Req. ARME/SPART
ARME/SPART
ART-35 Proforma for Elgi make compressor for ARME Incharge As per Req. ARME/SPART
Air Bag
ART-36 Proforma for Daily maintenance SPART Incharge As per Req. SPART
schedule of HS SPART
ART-37 Proforma for Log book for SPART SPART Incharge As per Req. SPART
ART-38 Proforma for Schedule for Cummins SPART Incharge As per Req. SPART
make engine of HS SPART for AMC-
Daily/Weekly
make engine of HS SPART for AMC- 6
monthly
Yearly
1500 hrs. check
6000 hrs. or 02 years check
ART-43 Proforma for Maintenance schedules of ART Incharge As per Req. ART
high pressure compressor
ART-44 Proforma for Maintenance schedules for ART Incharge As per Req. ART
ASKA tower light.
LUKAS Power pack (Petrol).
LUKAS Power pack (Diesel).
ART-47 Proforma for Maintenance of MFD ART/SPART Every B.D. Section
Power Pack & Jacks (Weekly) Incharge Ordering
ART-48 Proforma for Maintenance of MFD ART/SPART Every 25 B.D. Section
Power Pack & Jacks (Monthly) Incharge running hrs
Power Pack & Jacks (QLY) Incharge running hrs
Power Pack & Jacks (HLY) Incharge running hrs
Power Pack & Jacks (Yearly) Incharge running hrs
ART-52 Schedule of 140 Te. Crane(Gottwald) 140 Te, crane As per B.D. Section
under AMC Incharge OEM
ART-53 Schedule of 140 Te. Crane(Gottwald) 140 Te, crane As per B.D. Section
under AMC Incharge OEM
ART-54 Schedule of double acting 530 bar ART Incharge As per B.D. Section
LUKAS (HRE) under AMC OEM
ART-55 Proforma for service charges for ART Incharge As per B.D. Section
attention to 530 bar double acting OEM
LUKAS (HRE) consisting 20 jacks,
power pack, control stand, roller carriage
& compressor for Air bag
ART-56 Schedule of 140 Te. Crane for visit under 140 Te, crane As per B.D. Section
AMC for main engine. Incharge OEM
ART-57 Schedule of 140 Te. Crane(Gottwald) for 140 Te, crane As per B.D. Section
visit under AMC for main engine. Incharge OEM
ART-58 Schedule of 140 Te. Crane(Gottwald) for 140 Te, crane As per B.D. Section
visit under AMC. Incharge OEM
ART-59 Proforma for Trip Schedule examination SSE(C&W) As per B.D. Section
of ART rake. Incharge OEM
ART-60 Proforma for Sch. “A” examination of SSE(C&W) As per B.D. Section
ART rake. Incharge OEM
ART-61 Proforma for Sch. “B” examination of SSE(C&W) As per B.D. Section
ART rake. Incharge OEM
ART-62 Proforma for Kitchen Ration ART Incharge Every ART
Consumption for ART/SPART ordering.
ART-63 Proforma for ART/ARME/SPART ART Incharge Each ART/ARME/SPART
Imprest expenditure & accountal register procurement
ART-64 Proforma for maintaining Fuel and ART Incharge Every ART/ARME/SPART
Lubricant consumption ordering
ART-65 Proforma for Log Book of ART/ARME ART/ARME Every B.D. Section
Incharge ordering
Proforma No. ART-1
[Sample Format]
…………………… RAILWAY DRM (M)' s Office,

A/B/C
No. BPL/M//ART/INSPECTION Date: 00/00/0000
Sub:- Overdue Inspection of officers and supervisors of

Accident Relief Train/ARME.
Ref:-1. Central Railway Accident Manual Para 401(5a).
2. Railway Board's letter no. 99/AM(M) Inspections dated 16.08.99.
-------
OFFICERS
Sr. Description Inspn. Last dt. of Next dt. of Remark

No. Period Inspn. Inspn.
01. Sr. DME (D) QLY
DME (D)
02. Sr. DME QLY
03. Sr. DSTE QLY
DSTE
04. Sr. DEN QLY
DEN
05. Sr. DEE (G) QLY
DEE (G)
06. Sr DSO QLY
07. M.S. QLY
08. DME QLY
09. ADSTE QLY
10. ADME (BDT) MLY
11. ADME (G) MLY
12. ADEE (G) MLY
13. ADEN MLY
SUPERVISORS
01. SSE (LOCO) MLY

02. SSE (C&W) MLY
03. SSE (S&T) MLY
04. LOCO Insp. MLY
05. SSE (ELECT/MAINT) MLY
For information & necessary action please.
for DRM (M)/A/A/A

C/- DRM
ADRM for kind information please.
Sr.DSO
Proforma No. ART-2
BDT SITE REPORT
Ordering No.:- During the month:- During Year:-
1. Date of ordering :
2. D.C Message No. :
3. C.P.C.Message No.:
4. Ordered for: I. Section II. Division
5. Whether complete BDT ordered or MFD/LUKAS:
6. Nature of Accident / Derailment:
7. BDT left Shed at: Arr. Lobby Arr. ……… Stn. Left ………… Stn.
8. Name of the Supervisors 1. 2.
9. Total Staff accompanied A.R.T:
10.Description of work done:_________________________________
________________________________________________________
________________________________________________________
11. BDT left Site at Section Station Date

12. BDT arrived Homing Station at Date
13.Total working hrs. :
14. Performance of Equipments :
15. Performance of Staff :
16. Any declaration of Cash award : Rs. Declared by

17. Senior most officer present at site:
18. Unusual if any:
Signature of B.D.T Incharge

Copy for information to: Date :
Sr DME, DME, AME(BDT)
Proforma No. ART-3
[ Sample Format ]
WEST CENTRAL RAILWAY

DIESEL LOCO SHED ET
COMPETENCY CERTIFICATE
SHRI RAMSUKH CRANE DRIVER I
has been examined by me and certified to be competent to operate correct and safe working
of 140 Te. Diesel hydraulic crane of “A” class Accident Relief Train (ART) based at Itarsi in
Bhopal Division
This certificate shall be valid up to 01.09.2004
Date : 01.09.2003
ADME (BDT) Sr.DME (D)

DIESEL LOCO SHED DIESEL LOCO SHED
ITARSI ITARSI

Proforma No. ART-4
[ Sample Format ]
WEST CENTRAL RAILWAY

DIESEL LOCO SHED ET
PROVISIONAL COMPETENCY CERTIFICATE
SHRI R. K. SAXENA, SECTION ENGINEER (BDT)
has been examined by me and provisionally certified to be competent to ensure correct and safe
working of 140 Te. Diesel hydraulic crane of “A” class Accident Relief Train (ART) based at Itarsi
in Bhopal Division.
This certificate shall be valid up to 30.04.2004
Date : 01.11.2003
ADME (BDT) Sr.DME (D)

DIESEL LOCO SHED DIESEL LOCO SHED
ITARSI ITARSI

Proforma No. ART-5
ACCIDENT DIARY
1. Location:--------------------------------------------------------------------------------------------
2. Date of Accident:----------------------------------Actual Time of Accident-------------------
3. Information received from:
a. Name:------------------------------------Designation:----------------------Time:---------------
b. Details:------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------
------------------ 4.Officers advised:
a. DRM, ADRM, Sr DOM, Sr DME,DSO, Sr DMO,Sr DEE(TRO), Sr DEE(TRD), CMS, AOM,
AME, AEE
b. All respective Controls must be advised.
c. Concerned AO/TI,SLI,LI and SCs.must be advised
5.Break Down/Medical van/Tower wagon/Restoration particulars:
SN Description HOMING STATION
1 Break Down Ordered A B C D
2 BDT left loco shed
3 BDT arrived at Stn./Site
4 Work Started
5 Rerailment completed (Time & Date)
6. Track given safe: UP Track:- Time:------------------------ Date:-----------------------------
DN Track:- Time:----------------------- Date:-----------------------------
7. OHE given safe: UP Track:- Time:----------------------- Date:-----------------------------
DN Track:- Time:----------------------- Date: -----------------------------
8. S&T restoration: Time:----------------------- Date:-----------------------------
9. Details of Rerailment:
S Rly Wagon/ Type L/E Contents Position Details of Time of
N Coach No. from Derailment Rerailment/
Engine Toppled
01
02
03
04
05
06
07
10.Whether Central Control advised ( Yes / No ) Time:-----------------------------------------

11.Civil Authorities advised:-------------------------------------------------------------------------
12.Train Particulars:
Train Loco Base Load Driver Asstt. Guard HQ
No. No.
13. BPC Particulars:
SN Issue Station BPC No. Date % Of Brake Power
01
02
03
14.PRO Particulars:
SN Wagon No. POH ROH OILING B/Date R/Date
15.Officers left for Site/reached at Site:1. 2. 3. 4.

16.Officer Incharge at Site:--------------------------------------------------------------------------
17.Prima facie Cause:-------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------
Repeated by:-------------------------------------Time:---------------------------- Date:-----------
18.Forecast Time given: Rerailment----------Track:----------OHE:------------S&T-------------
Actual Time Taken: Rerailment----------Track:----------OHE:------------S&T------------
19.Track given safe: Time:---------------------Speed----------------------------------------------
20.Time of first train started after normal working resumed-----------------------------------
21.TSL/REGULATION/DETENTION/CANCELLATION Particulars:
a. TSL introduced at-----------------------hrs on UP/DN line
b. TSL cancelled at-------------------------hrs
c. Trains worked on TSL:
SN Train No. Time lost SN Train No. Time lost
d. Trains Regulated:
SN Train No. Station From to Total
Detention
e.Trains Detained:
SN Train No. Station From To Due to Total
Detention
Trains Cancelled: 1. 2. 3. 4. 5. 6.
Proforma No. ART-6
Inspection of ARTs
[Railway Board’s letter no. 99/AM(M) Inspections dated 16.08.99]
As per letter mentioned above, instructions have been received that inspection should be done
regularly by the officer incharges of ART and availability of all standard equipments as well as any
additional equipments, which may have been provided on Break down Train should be ensured.
SN Description Status
01 Condition of Rolling Stock:
1. Whether due/overdue POH.
2. Present Condition.
3. Brake gear and brake system Continuity.
4. General cleanliness.
5. Check C&W items as per standard list.
02 Hydraulic Re-railing Equipments:
1. Running of power pack under load and no load conditions,
pressure setting.
2. Whether consumables and other spares are available in
sufficient numbers and action taken for procurement.
3. Availability & condition of hydraulic oil and hydraulic hoses.
4. Condition of wire ropes & Chain slings.
5. Check availability of Hydraulic Jacks as per standard list.
6. Check all the jacks are operated smoothly and properly while
lifting & lowering.
7. Check oil leakages of hydraulic hose connections, oil seals of
jacks.
03 Generators—fixed or portable:
1. Check running, condition of brushes and availability of spares.
2. Check whether spares and maintenance tools are available.
04 Lighting equipments:
1. Check all lighting stands, reflectors,
Conditions of cables, switches etc.
2. Check whether spare bulbs,switch boards, cables are available.
3. Check working of Inflatable lighting tower.
4. Check plastic body torches and cells.
05 Gas Petromax:
1. Check proper burning/lighting, spare mantles, glasses etc.
06 S&T Equipments:
1. Whether public address system is in working condition.
2. Check VHF sets for proper working.
3. Walkie talkie sets for working, Condition of batteries.
4. Field telephones for proper working and condition of cables
5. Check DECT-Exchange mobile phone.
6. Check other equipments as per HLC.
7. Check working of Satellite phone
SN Description Action taken
07 Fire fighting equipment:
1. Refilling dates & general condition of all fire extinguishers.
2. Self contained breathing apparatus.
3. Availability and condition of Fire Fighting Suits
08 Detonators & LED lamps:
1. Availability and replacement due time.
09 Compressor:
1. Check for working and availability of spares.
10 Gas cutting equipments:
1.Condition of torches, availability of acetylene and oxygen
cylinders.
2. Check working of portable Plasma cutting equipment
11 Wooden Packings:
1. Availability and adequacy of hard wood packing of different
sizes.
2. Availability of sufficient wooden wedges.
12 Cold cutting equipment & HRD for cutting stainless steel:
1. Check working, availability of spares disc. Spark plug and
maintenance tools. ask for demonstration and see if staff is
conversant with its use.
13 140 Te.Crane:
1.Check whether the "Special safety precautions for operation of
140 Te.cranes" are prominently displayed in the driver's cab
both in English and vermacular. Refer Board's letter
No.99/M(M&P)/7/8 dated Aug.1999.
2. Availability of consumables for the crane.
3. Availability of at least two sets of well-trained operating staff.
4. Check all the operations of 140 Te crane
5. Check working of Aux. engine
6. Check whether schedules of crane are being carried out in time
14 Kitchenware:
1. Check all kitchen ware for cleanliness.
2. Check availability of water, date on which water was filled.
3. Check availability of milk, biscuits, coffee, tealeaf and their
expiry dates.
4. Availability of proper plates, cups and saucer.
5. Check availability of eatables, cooking gas and ration.
6. Check accountal of Free food imprest.
7. Check accountal of Break down Imprest.
15 Books, Registers and Manuals:
1. Check availability of Accident Manual and G&SR book.
2. Check Inspection Register,Chain & Wire rope register, tools &
equipment register
3. Dead stock register & ART log book.
4. Check equipment testing register & maintenance schedule
registers.
16 1. Check availability of Red and green banners, torch, cells,
transition coupling, tent, Garden umbrella etc.
SN Description Action taken
17 Video Camera & Digital still camera:
1. Check Video handy cam Camera and digital camera and its
flash for proper operation.
2. Check whether record of videography avl. in Register
18 Cellular Mobile Phone & other phones:
1. Check Group Mobile Phone.
2. Check other phones also for availability and functioning.
19 Computer with Fax modem and e-mail facility:
1. Availability of upgraded computer and Printer
2. FAX Machine & charging facilities for laptop computer & cell
phone.
20 Power Chain Saw:
1. Check functioning of Portable Chain Saw - 1500 w, 230 V
2. Check maintenance records of all such equipments
21 Breath Analyser:
1. Check Breath Analyser with digital display.
22 Set of sppaners, Tools/ Solson's Tools :
1. Check availability of Tools and spanners
2. POP Small spanner/wrench
3. POP Big sppaner/wrench.
4. POP Hex Keys
5. POP Multi wrench ratchet type.
Tools and Equipments:
1. Check tools, gauges, spanners etc. are available in ART as per
revised list.
2. Check availability of measuring instruments and its calibration.
3. Other machines available in ART.
4. Check electrically operated cutting tools.
5. Check availability of oils and greases.
23 Safety jackets & Helmets:
1. High visibility light weight jacket.
2. Fire man Helmets.
3. Fire Nomex Jacket
4. Uniform of Staff
5. Fire resistant Knitted nomex Gloves.
6. Water Jackets if available etc.
24 First aid equipments:
1. Check the First aid box and its contents for their availability as
per list.
2. Check the stretchers and their condition.
3. Check whether First aid box material has been inspected &
replaced as per schedule.
25. Engineering tools and OHE equipments
1. Check availability of engineering and OHE items as per standard
list.
Date : Name of the Officer :
ART Depot : Designation :
Proforma No. ART-7
Inspection of ARMEs
[Railway Board's letter no. 99/AM(M) Inspections dated 16.08.99]
As per HQ letter mentioned above, instructions have been received that inspection should be
done regularly by the officers incharges of ARMEs and availability of all standard equipments as well as
any additional equipments, which may have been provided on break down should be ensured.
01 Condition of Rolling stock :
1. Whether Due/over due POH.
2. Due/Over due maintenance schedule.
3. Mechanical condition (Brake gear, wheel, etc.) Clean
liness.
4. General Cleanliness of train.
02 Cold cutting equipment (HRD):

1. Whether in working order, physical trial to be
done.
2. Availability of spares (cutters, spreader, disc, spark plug, hoses,
oils and tools).
3. Availability of cutogen and DA and O2 cylinders.
4. Working to be checked by physical trial.
03 Portable Generators :
1. Whether 3/2 KVA generators are available in working order
(actual trial to be done by starting it).
2. Availability of petrol/diesel & maintenance kit.
3. Condition of brushes, and availability of spares.
04 Lighting equipments :
1. Check availability of lamps, reflectors, stands, cable, switch
boards.
2. Availability of two nos. Emergency inflatable lighting towers, its
lamp and maintenance kit.
3. Availability of LPG Patromaxes, its mantles & glasses.
4. Availability of plastic body torches, cells and bulbs.
5. Trial to be done to check working.
05 Availability of drinking water and eatables :

1. Check availability of water, date of which water was filled.
2. Check availability of milk, biscuits, coffee, tea leaf, sugar and their
expiry dates.
3. Availability of proper plates, Tea thermos steel, aqua guard,
kerosene oil & stove, cups and saucers, LPG connection etc.
06 Lifting appliances and Tools:
1. Check availability and functioning of 20 & 30 te. Capacity jacks,
digging equipments and tools,
2. Check functioning of Tirfors
3. Check availability of Electrically operated Chain saw
07 General Stores and Fire fighting equipments:

1. Check availability of Barrier tape, hand umbrellas, rain coat, gum
boots, safety shoes, staff uniform, helmets, high visibility jackets,
respiratory mask.
2. Check availability of Red and green banners, hand signals,
detonators, Fusee, aluminium ladders, electric machine, charging
facility for laptop & mobile, wrist bands, digital video & still
cameras and safe locker, transition coupling, tents, etc.
3. Check availability of DCP and mech. Foam type fire
extinguishers and their refills.
4. Check availability of suitable size wooden packings.
08 Telecommunication Equipments:
1. Check availability of Megaphone, walkie talkie sets and mobile
phone,
2. Check VHF sets, satellite phone, wireless PA system etc.
09 Other Items:
1. Check nomination of crack team staff.
2. Details of doctors, hospitals, Nursing homes, defence
establishments etc.
3. List of nominated staff for ARMV & their duty list.
4. AMC for critical equipments
5. Compliance of HLC recommendations.
10 Books, Manuals and Records:

1. Check availability of Accident Manual, G & SR, IRCA part-IV, log
book, equipment testing register, schedule register, ARME
inspection register & First aid manual etc.
11 Medical Items:
1. Check containing of augmented first aid boxes.
2. Check collapsible coffins and body bags.
3. Check portable generator set and lights
4. Check availability of items as per IRMM-2000 Vol.II
Date : Name of the Officer :

ARME Depot : Designation :
Proforma No. ART-8
Check List for Inspection of SPARMV

[Railway Board's letter no. 99/AM(M) Inspections dated 16.08.99]
done immediately by the officers incharge of SPARMVs and availability of all standard equipments as
well as any additional equipments, which may have been provided on SPARMV should be ensured.
01 Condition of Rolling stock :
1. Whether Due/over due POH.[ POH-3.5 Years ]
3. Mechanical condition (Brake gear, wheel, etc.) and
Cleanliness.
4. General Cleanliness of SPARMV.
5. present condition of rolling stock
1. Whether in working order, physical trial to be done.
2. Availability of spares (cutters, spreaders, spark plug, hoses, oils and
tools).
3. Availability & working of portable electrically operated cold cutting
tools i.e. trepanner,channel cutter,shell shearer, Nibblar & Bar cutter
etc.
4. Availability of cutogen with back fire arrestor and DA and
Oxygen Gas cylinders.
5. Check pressure gauges, safety goggles, gloves & leg guards for
welder.
03 Portable/Fixed Generators :
1. Whether 3/2 KVA/50 KVA generators are available in working order
2. Availability of petrol/Diesel/Kerosene & maintenance kit.
4. Check equipment testing register & maintenance schedules
1. Check availability of lamps, reflectors, stands, cables, switch boards.
2. Availability of two nos. Emergency inflatable lighting towers, its lamp
and maintenance kit.
5. Trial to be done to check working of lighting equipments.
expiry dates.
3. Availability of proper plates, Tea thermos steel, aqua guard, kerosene
oil & stove, cups and saucers, LPG connection etc.
4. Check kitchenware and utensils
1. Check availability and functioning of 20 & 30 te. Capacity Jacks,
digging equipments and tools,
2. Check functioning of Tirfors
3. Check availability of Electrically operated Chain saw
1. Check availability of Barrier tape, hand umbrellas, rain coat, gum
boots, safety shoes, staff uniform, helmets, high visibility jackets,
respiratory mask.
2. Check availability of Red and green Flags/banners, hand signals,
detonators, Fusee, aluminium ladders, charging facility for laptop &
mobile, wrist bands, digital video & still cameras and safe locker,
transition coupling, modular inflatable tent etc.
3. Check availability of DCP and mech. Foam type fire extinguishers and
their refills.
phones,
09 Other Items:
1. Check nomination of crack team staff if formed.
2. Details of doctors, hospitals, Nursing homes, defence establishments
etc.
3. List of nominated staff for SPARMV & their duty list.
6. Check availability and condition of fitter tools.
7. Check availability of C&W items, Nuts, bolts, linen items etc.
8. Check availability of Engineering material

1. Check availability of Accident Manual, G & SR, IRCA part-IV, SPARMV
Log Book, Equipment Testing Register, Schedule Register,SPARMV
Inspection Register & First aid manual etc.
11 Medical Items:
Date : Name of the Officer:

SPARMV Depot : Designation :
Proforma No. ART-(a)
Check List for Inspection of SPART

[Railway Board's letter no. 99/AM (M) Inspections dated 16.08.99]
done as per board's guidelines by the officers incharge of SPART and availability of all standard
equipments as well as any additional equipments, which may have been provided on break down
should be ensured.
01 Condition of Rolling stock:
1. Whether Due/over due POH.
3. Mechanical condition (Brake gear, wheel, etc.)
4. General Cleanliness of train.

1. Whether in working order, physical trial to be
done.
2. Availability of spares (cutters, spreader, disc, spark plug, hoses,
oils and tools).
3. Availability of cutogen and DA and O2 cylinders.
4. Working to be checked by physical trial.
5. Ckeck portable electrically operated cutting tools if available.
03 Portable Generators :
1. Whether 3/2 KVA generators are available in working order
2. Availability of petrol/diesel & maintenance kit.
1. Check availability of lamps, reflectors, stands, cable, switch
boards.
2. Availability of two nos. Emergency inflatable lighting towers, its
lamp and maintenance kit.
5. Trial to be done to check working.

expiry dates.
3. Availability of proper plates, Tea thermos steel, aqua guard,
kerosene oil & stove, cups and saucers, LPG connection etc.
06 Hydraulic re-railing equipments:

1. Running of power pack under load and no load conditions,
pressure setting.
2. Whether consumables and other spares are available in
sufficient numbers and action taken for procurement.
3. Availability & condition of hydraulic oil and hydraulic hoses.
4. Check availability of Hydraulic Jacks as per standard list.
5. Check all the jacks are operated smoothly and properly while
lifting & lowering.
6. Check oil leakages of hydraulic hose connections, oil seals of
jacks.
7. Check Inflatable Air Bags and its tools etc.
1. Check availability and functioning of 20 & 30 te. Capacity
jacks, digging equipments and tools etc.
2. Check functioning of Tirfors & condition of wire rope.
3. Check availability of Electrically operated Chain saw.

1. Check availability of Barrier tape, hand umbrellas, rain coat,
gum boots, safety shoes, staff uniform, helmets, high visibility
jackets, respiratory mask.
2. Check availability of Red and green banners, hand signals,
detonators, Fusee, aluminium ladders, electric machine,
charging facility for laptop & mobile, wrist bands, digital video &
still cameras and safe locker, transition coupling, Inflatable tent,
etc.
3. Check availability of DCP and mech. Foam type fire
extinguishers and their refills.
phone.
10 Other Items:
1. Check nomination of crack team staff.
2. Details of doctors, hospitals, Nursing homes, defence
establishments etc.
3. List of nominated staff for SPART & their duty list.
5. Check plastic chairs and tables.

1. Check availability of Accident Manual, G & SR, IRCA part-IV, log
book, equipment testing register, schedule register, SPART
inspection register & First aid manual etc.
12 Medical Items:
Date : Name of the Officer:

SPART Depot : Designation :
Proforma No. ART-9
ORDERING OF CRANE SPECIAL

01. CPC Message No.......................................................................................................
....................................................................................................................................
02. DC Message No.......................................................................................................
....................................................................................................................................
03. Crane Ordering date....................................Time......................................
04. Crane ordered for ..............................Section....................................Div................
05. Nature of work..........................................................................................................
....................................................................................................................................
06. Spot Km. No. ..........................................................................................................
07. Crane/Spl left shed at ...................................with loco No......................................
08. Drivers lobby arrival.....................dep..........................Extra time..........................
09 Name of the Driver...................................... Guard.................................................
10. Officer incharge on duty...........................................................................................
11. Supervisors on duty 1....................................... 2.............................................
12. ART Gang nominated ..............................................................................................
13. Name of the crane driver .........................................................................................
14. Total staff available...................................................................................................
....................................................................................................................................
15. Detention at GC-5 from..........................to..........................extra time.....................
16. ET Stn. arrival at .................................Dep..........................extra time....................
17. Crane special arrived at Stn..........................marshaling done..................................
18. Crane arrived at site .................................................................................................
19. Crane ready at ...................................work started at ..............................................
20. OHE grounded and power block granted at .............................................................
21. Work completed at ...................................................................................................
22. Crane left site at ..................................... arrived at next Stn....................................
23. Shunting performed from .......................to.......................extra time........................
24. Crane left Stn........................at..................................................................................
25. Crane arrived ET at ....................... Dep.........................extra time..........................
26. Crane arrived in Diesel shed at ....................................On Date..............................
27. Remarks...................................................................................................................
Proforma No. ART-10
[ Sample Format ]
STATEMENT SHOWING FIXATION OF HIRE CHARGES FOR HYDRAULIC

RE-RAILING EQUIPMENTS (M.F.D)
1. Description of Plant/Machinery: = M.F.D

2. Cost of Plant/Machinery as per market Rate:-
(In terms of Railway Board’s letter No.86/RSF/538/1(GP–116) A dated 30.05.1986.)
Basic Cost of M.F.D: =Rs.10000000.00
ED 15% +SPL ED 5%: =Rs.2000000.00
C.S.T charges 4% : =Rs.400000.00
Total Cost of the M.F.D: =Rs.12400000.00
 Add 7% freight & Incidental charges: =Rs.868000.00
 Add 12.5% Supervision charges: =Rs.1550000.00
TOTAL: =Rs.14818000.00
3.ANNUAL MACHINE & SPARES CHARGES
Rate of Interest 10%: =Rs.1481800.00
Sinking Fund Payment 6.27%: =Rs.929088.00
Maintenance & Repair charges 10% cost of Machine:=Rs.1481800.00
Total annual machine & Spares Cost: =Rs.3892688.00
4.ANNUAL MANPOWER CHARGES
No. of Staff-18 Supervisors –02 Officer –01
Gross Pay-Rs.6000/month (8000+11000/month) 12000/month
Pay +DA total: =Rs.139000.00
DCRG 1/8th of Pay: =Rs.17375
TOTAL: =Rs.156375.00
Leave Salary 1/12 X Gross: =Rs.13031.00
Misc.charges1/10th X Gross: =15637.00
Total: =Rs.185043.00
Supp. 12.5% of total: =Rs.23130.00
GRAND TOTAL: =Rs.208173.00
Hence,Annual Manpower Charges: =Rs.2498076.00
5.Utilisation of M.F.D working per year: =04 days per month

Or 4 X 24 =96 hrs. per month: =96 X 12 =1152 hrs.per year
Annual Machine & Spare Charges +Annual Staff Charges:=Rs.3892688+2498076

=Rs.6390764.00
TOTAL M.F.D CHARGES PER HOUR FOR HIRING: =Rs. 5547.00
Proforma No. ART-11
[ Sample Format ]
STATEMENT SHOWING FIXATION OF HIRE CHARGES FOR

140 Te. DIESEL HYDRAULIC BDT CRANE
1. Description of Plant/Machinery : 140 Te. Dsl Hyd Crane.

2. Cost of Plant/Machinery as per Market Rate :
[ In terms of Railway Board's letter No. 64/W2/56 of 23.02.1986 ]
Basic cost of crane : Rs. 2,40,000,00

ED 15% + Spl. ED 5% : Rs. 48,00,000
CST @ 4% : Rs. 9,60,000
Total cost of the crane : Rs, 2,97,60,000
* Add 7% freight and : Rs. 58,03,200
Incidental charges
* Add 12.5% supervision charges : Rs. 37,20,00
Total : Rs. 3,55,63,200
3. ANNUAL MACHINE & SPARES CHARGES :

Rate of interest 10% : Rs. 35,56.320
Sinking fund payment @ 6.27% : Rs. 22,31,590
Maintenance & repair charges @ 10% : Rs. 35,56,320
of Cost of Machine
Total Annual Charges : Rs 93,44,230
4. ANNUAL MANPOWER CHARGES :

Nos. of staff _ 33, supervisors - 3, officers - 1
Monthly charges ;
PAY + DA : Rs. 2,32,894
DCRG (1/8th of Pay) : Rs. 29,112
Total : Rs. 2,62,006
LEAVE SALARY :
(1/11 X GROSS) : Rs. 23,819
Misc (1/10 X GROSS) : Rs. 2,6201
GRAND TOTAL : Rs. 3,12,026
SUPP.12.5% OF TOTAL : Rs. 39, 003
GRAND TOTAL : Rs. 3,51,029
Hence Annual charges : Rs. 42,12,351
5. UTILISATION OF CRANE : Crane working/Year - 280 hrs. (Avg.)

6. PER HOUR COST OF OPERATION OF CRANE :
Annual Machine & Spare charges + Annual Staff charges
Rs. 93, 44,230 + Rs. 42,12,351 = Rs. 1,35,56,581
Hence Total Charges Per Hour=RS. 13556581/280=48416.36
TOTAL CRANE CHARGES PER HOUR FOR HIRING = Rs. 50,000/-
Proforma No. ART-12
Video Camera Register
SN Date CPC Message Accident No. of Video/Photos Remarks
No. Spot Video/Photographs given to
taken safety branch
or not
Proforma No. ART-13
EQUIPMENT TESTING REGISTER
EQUIPMENTS NAME:
SN Testing Date Signature Signature Officer Incharge Remarks

Technician Supervisor
Proforma No. ART-14
TESTING PARTICULARS OF CHAIN SLING
Capacity: 25 Te. Testing Period: 6 Months
Quantity Recommended: 04 Nos. Quantity Available:
SN Chain Sling No. Sent to Received Detained Put in Testing Particulars Remarks
Parel from at Parel Service
Parel (Months) Testing Next Due
Date for
Testing
01
02
03
04
Proforma No. ART-15
TESTING PARTICULARS OF WIRE ROPE SLING
Capacity: 30 Te. Testing Period: 6 Months
Quantity Recommended: 02 Nos. Quantity Available: 02
SN Description Last Inspection Inspection Due Remarks

01 Two Leg
05 Meters
No. 36745/01
02
03
04
Proforma No. ART-16
BDT SECTION ……….
BDT ORDERING PARTICULARS
SN Date Message Ordered for Shed Time taken Itarsi Total time Accident/
No. Dep. before dep. Station from Derailment
From shed ordering to particulars
stn. dep
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Proforma No. ART-17
BDT SECTION …………
140 Te. CRANE/SPL ORDERING PARTICULARS

S Date of Message Place of Crane left Arrived Total Total Nature of Name Total
N Ordering No. & Time Work from shed in shed Hrs. Earned Work of charges
utilized KMS Dept. in Rs.
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Proforma No. ART-18
BDT SECTION ……………
140 Te. CRANE/SPL DEBIT PARTICULARS
S Section Station Date of work Nature of Deptt. T.V No. Amount Debit Remar
N done work & Date in Rs. accepted k
or not
1
10
11
12
13
14
15
16
17
18
19
[Sample Format ]
POSITION OF 140 Te. DIESEL HYDRAULIC CRANES SUPPLIED TO ZONAL

RAILWAYS UNDER RAILWAY Board's CONTRACT NO.
84/RSF/174/2 (GP-102. dated 06.12.1985)
12 Nos. OF COWANS SHELDON. U.K.
SN CRANE NO. Location & Date of Date of

C/S IR Zonal RLY RLY Receipt Commission
01 2251 140501 44225 ET / C.RLY 13.07.88 02.03.89
02 2252 140502 566 RTM / W.RLY 07.09.88 11.05.89
03 2253 140503 14001 KZJ / SC.RLY 09.09.88 23.05.90
04 2254 140504 44226 NKJ / C.RLY 23.10.88 27.04.89
05 2255 140505 44227 JHS / C.RLY 10.01.89 26.06.89
06 2256 140506 44228 BSL / C.RLY 16.12.89 15.05.90
07 2257 140507 568 KKF / W.RLY 00-12.89 08.12.89
08 2258 140508 569 KTT / W.RLY 19.11.89 15.12.90
09 2259 140509 14002 BZA / SC.RLY 30.05.90 27.07.90
10 2260 140510 14003 GTY / SC.RLY 22.10.90 26.10.90
11 2261 140511 140511 GYH / NF.RLY 29.04.91 09.06.91
12 2262 140512 31296 ER / SC.RLY 22.03.92 22.03.92
PERIODICAL OVERHAULING (POH) OF THESE CRANES HAVE BEEN UNDER

TAKEN IN PAREL WORK SHOP OF C.RLY.
THE DETAILS OF POH REPAIRES GIVEN ARE AS UNDER
SN CRANE NO. Location & Date Date off

C/S IR Zonal RLY taken for POH in the
RLY POH month
01 2254 140504 44226 NKJ / C.RLY 30.07.97 29.11.97
02 2251 140501 44225 ET / C.RLY 03.12.97 26.02.98
03 2252 140502 566 RTM / W.RLY 03.03.98 05.06.98
04 2255 140505 44227 JHS / C.RLY 05.06.98 04.09.98
05 2257 140507 568 KKF / W.RLY 05.09.98 04.12.98
06 2253 140503 14001 KZJ / SC.RLY 05.12.98 06.03.99
07 2256 140506 44228 BSL / C.RLY 07.03.99 20.06.99
08 2259 140509 14002 BZA / SC.RLY 06.07.99 07.10.99
09 2258 140508 569 KTT / W.RLY 09.10.99 18.01.2000
10 2260 140510 14003 GTY / SC.RLY 25.02.2000 9.5.2001
11 2261 140511 140511 GYH /NF.RLY 11.2001
12 2262 140512 31296 ER/SC. Rly
Proforma No. ART-19
Parts of the MFD Power Pack
Important Parts of MFD item is given as under for information & Record.
SN Description Cost in FOB Cost in Rs.
1 Power Pack - SACH STEMO - 282
2 Pump Unit
3 Axle Pusher
4 Distribution valve
5 Distance bar type II
6 High pressure hoses, per pair
7 Re-railing bridge 4.5 Mtrs.
11 Displacing jack
12 Step jack without claw
13 Telescopic jack HC 60/30
14 Telescopic jack LC 60/30
15 Telescopic jack HC 120/60
16 Telescopic jack LC 120/60
17 Multi stage jack 60 Te complete with 4

pairs of support
18 Haulage Rescue device
19 Tilting jack 20 Te
20 Control Table
21 Roller Carrier (Trolley)
Total Cost
Proforma No. ART-20
TECHNICAL PARTICULARS OF CHAINS AND WIRE ROPE SLINGS
Slings Capacity Proof Lengt Quantit SPECIFICATION Quantity Calculated Girth of

SWL Load in h y Required weight wire
Te. availabl Rope
Hook Ring/Link Rope/
e
Chain
Two Leg Chain 25 Te. 36 Te. 05 Mts 05 Nos. 20 Te. 280X170 mm Chain Size 28 04 Nos. 231 Kg --
Sling 0-90° per Leg SWL 70.66 dia mm
Hook
Single Leg 10 Te. 20 Te. 6 mts 4 nos. 8 Te. 280X170 mm 20 mm 04 Nos. 133 Kg
Chain Sling SWL link --
Hook
Two Leg Chain 05 Te. 7.1 Te. 4 mts 1 no. 4 Te. 280X170 mm 12 mm 02 Nos. 80 Kg
Sling SWL link --
Hook
Single Leg 70 Te. 105.4 Te. 6 mts 4 nos. 70 Te. 890X540 mm Rope dia 04 Nos. 523 Kg 201.19
Wire Rope SWL link 64 mm 6X49 mm
Sling Hook cons steel
core
Single Leg 70 Te. 140 Te. 4 mts 2 nos. -- soft eye both Rope dia 02 Nos. 145 Kg 238.64
Wire Rope end 6X49 cons mm
without Hook, L-1150 mm steel core
soft eye both W-575 mm
Two Leg Wire 70 Te 81 Te. 6 mts 2 nos. 50 Te. 890X540 mm Rope dia 02 Nos. 780 Kg 201.19
Rope Slings 0-90.° SWL 64 mm 6X49 mm
Hook cons steel
core
Single Leg 50 Te. 81 Te. 5 mts 4 nos. 50 Te. 890X540 mm Rope dia 04 Nos. 465 Kg 201.149
Wire Rope SWL link 64 mm 6X49 mm
Sling Hook cons steel
core
Two Leg Wire 30 Te. 42.4 Te. 7 mts 2 nos. 25 Te. 890X540 mm Rope dia 02 Nos. 138.16
Rope Slings 0-90° per leg SWL link 44 mm 6X36 mm
Hook cons steel
core
Two Leg Wire 30 Te. 42.4 Te. 5 mts 2 nos. 25 Te. 890X540 mm Rope dia 02 Nos. 138.16
Rope Slings per leg SWL link 44 mm 6X36 mm
Hook cons steel
core
Four Leg Wire 25 Te. 50 Te. 4 mts 1 no. 25 Te. 250 dia ring Rope dia 01 No.
Rope Sling 0-60° SWL 32 mm 6X36
without Hook Hook cons steel
core
Proforma No. ART-21
[Sample Format ]
PARTICULARS OF THE M.F.D EQUIPMENT

(HOESCH MASCHINE FABRIC DEUTSCHLAND)
Date of Commissioning :- 14.09.1987
Received :-Under Railway Board's Contract No.

86/RSF/538/1-(GP-116) A & B dated 30.05.1986/22.07.87
S Item Type of Qty Lifting Operatin Constr Piston Stroke Total Total
N Equipment avl. Capacit g uction Big Small Weight Cost
y Pressure Height
1 Jack Telescopic
HC
04 120/60
Te.
300 Bar 435 mm 240 mm 254 mm 85 kg FOB.5879
Telescopic 02 120/60 300 Bar 250 mm 88.5 86.5 60 kg FOB.5155

LC Te. mm mm
Telescopic 04 60/30Te 300 Bar 460 mm 270 mm 290 mm 60 kg FOB.4697
HC .
Telescopic 02 60/30Te 300 Bar 250 mm 105 mm 105 mm 40 kg FOB.3734
LC .
Multistage 02 60 Te. 300 Bar 230 mm 85 mm -- 35 kg FOB.5412
Jack
Step Jack 03 35 Te. 300 Bar 1100mm 825 mm -- 70 kg FOB.5258
Tilting Jack 01 20 Te. 300 Bar 597 mm 400 mm -- 30 kg FOB.23136
Displacing Jack 02 10/6 Te 300 Bar 575 mm 350 mm -- 16.5 kg FOB.1908
Haulage Device 01 25 Te. 300 Bar 1751mm -- 90 kg FOB.25790
2 Re-railing Carrying
Capacity
Qty Avl Length Width Height Weight Total
Cost
Bridge
60 Te. at a 01 4.5 mts 280 mm 180 mm 175 kg FOB.6548
free span 01 3.3 mts 280 mm 180 mm 128 kg FOB.5169
01 2.2 mts 280 mm 180 mm 88 kg FOB.3329
01 1.2 mts 280 mm 180 mm 47 kg FOB.1856
3 Roller 60 Te. 2+1 mm mm 115 mm 66 kg
Carriage
Equipments Qty Max. Working of Relief Weight Total

Avl Working control Valves Valve Cost
Pressure Setting
Control Desk 02 300 Bar 04 300 Bar 40 Kg.
4
Hand Pump 01 300 Bar 02 300 Bar 75 Kg.
5
(Sample) Proforma No. ART-22
WORK DISTRIBUTION AMONG STAFF FOR MFD WORKING
1. ART/MFD Management:
Shri M.A.Mali + B.M.Singh+ Sudhakar
2. Spot observation & MFD operation:
Shri Mahadeo
3. Accident Site Photograph :
Shri M.A.Mali
4. Loading/Unloading of Welding Equipments:
Pradeep+ Sopan
5. Power Pack Unloading & loading:
Ajeet Chaudhary+Nanhelal+Naval
+Ashok Firke+Komal Singh Yadav
6. Control Desk, Displacing jack unloading/loading & Operation :
Madhukar Patil+Ashok Chaurey+Ramdass
7. Re-railing Bridge & Counter support:

Sewalkar+Sajjan+Hari
Vanarsi+Damodar+Shaligram
8. Jacks and Pipes:
Shakeel+Vinod+Nandlal
9. Trolley & Panje :
Makode+Dileep+Narayan
10. Reserve/Packing/Tool Box/MFD unloading:
Sunder+Krishna
11. Megaphone for safety/Hydraulic Pipes & light weight equipment:
A.H.Shaha+Girish
12. Kitchen/Packing loading & unloading:
Ajay Shrivas+Mulloo Singh+Sunil Kumar Vani
13. Miscellaneous Work:
Shri Ramesh Singh
Jacks- Rerailing Bridge–Trolley Operations
1. Mahadeo 2. Sewalkar 3. Shakeel 4. Sajjan 5. Shligram 6. Damodar 7. Hari Vanarsi
8. Vinod 9. Nand Lal 10. Dileep 11. Narayan
DEPLOYMENT FOR SIDES
LEFT RIGHT
1. Mahadeo 1. G.B.Makode
2. Sunderlal 2. Shewalkar
3. Krishna Singh 3. Shekh Shakeel
4. Nanhelal 4. Naval Kishore
5. Ramdass 5. Ashok Firkey
6. Girish 6. Komal Singh Yadav
7. Sajjan Singh 7. Ashok Chourey
8. Nandlal 8. Shaligram
9. Vinod Malviya 9. Hari Vanarsi
POWER PACK/CONTROL DESK OPERATION
1. Ajeet Chaudhary
2. Madukar Bhaidass
Proforma No. ART-23
WORK DISTRIBUTION AMONG STAFF FOR CRANE WORKING

1. ART Management:
Shri M.A.Mali + B.M.Singh + Sudhakar
2. HOOK:
Shri Madhukar Patil
3. MEGA PHONE :
Shri A.H.Shah
4. Relieving Bogie Loading Unloading:

FRONT : Sewalkar
REAR : Ajeet Chaudhary
5. Match truck/Crane Uncoupling/Coupling:

Madhukar + Standby Crane Driver
6. Crane Safety during shunting :
M.A.Mali
7. Kitchen & Inflatable Lighting Tower:

Ajay Shrivas + Sunil Vani
8. Miscellaneous Work:
Ramesh Singh + Mulloo Singh
9. Panje, Wire Rope & Wodden Skats :

Mahadeo + Makode
DEPLOYMENT FOR SIDES:
RIGHT SIDE “A” GANG LEFT SIDE “B” GANG
1. Sewalkar 1. Mahadeo Bhagvan

2. Krishna Singh 2. Sunderlal
3. Shakeel 3. Ajeet Chaudhary
4. Makode 4. Nand Lal
5. A.H.Shaha 5. Damodar
6. Sajjan Singh 6. Hari Vanarsi
7. Vinod Kumar 7. Narayan
8. Komal Singh Yadav 8. Ramdass
9. Dileep Kumar 9. Naval Kishore
10.Girish Chand 10.Ashok Chaurey
11.Ashok Firke 11.Nanhelal
12.Shaligram 12.Sudhakar
NOTE: The wooden Packings will be unloaded and loaded by all Artisans as well as all
Helper Khalasis strictly at Accident Site without any confusion.
Proforma No. ART-24
[ Sample Format ]
MFD PETROL PUMP SET

Technical Data:
1. Horse Power : 10.6 HP
2. Out Put : 8.1 kW
3. RPM : 3000
4. Direction of Engine rotation : Anti-clockwise.
5. Piston Displacement : 337 cm3
6. Ignition : Transistorized-magneto
7. Spark advance : 25 Deg. before TDC
8. Contact breaker gap : 0.7 - 0.8 mm
9. Spark Plug : NGK-R BPR 6EC JAPAN
10.Carburetor : Horizontal Type Butterfly
11.Fuel Used : Pure Unleaded Petrol
12. Engine Type : Four Stroke
General:
1. Make : HONDA JAPAN
2. Supplier : Compair Equipments Co. Mumbai
3. Year of Manufacturing : 2002
4. Date of Commissioning : January-2003
5. Last Overhauling done : Under Warranty
6. Capacity of Hydraulic oil Sump : 65 Lts.
7. Maximum Operating Pressure : 300 Bar
Proforma No. ART-25
MFD DIESEL POWER PUMP SET

Technical Data:
1. Horse Power :-10 HP
2. Out Put :-7.46 kW
3. RPM :-3000
4. Piston Stroke :-90 mm
5. Engine Type :-Single Cylinder Combustion type

Four stroke
6. Type of pump :-Axial Piston fixed Displacement

Pump
7. Fuel Tank Capacity :-5.5 Liters
8. Hydraulic Tank Capacity :- 65 Liters
9. Complete Weight without Oil :-59 Kg
10. Compression Ratio :-17.5:1
11. Cylinder Bore :-85 mm

General:
1. Make :-GREAVES LTD.
2. Supplier :-Francis Klein & Co.Pvt.Ltd. Bangalore
3. Year of Manufacturing :-1986
4. Collected from COS. :-31.12.1997
5. Date of Commissioning at ET :-07.01.1998
6. Last Servicing done :-28.10.2004
7. Capacity of Hydraulic oil Sump :-65 Lts.
8. Weight of the complete set with oil :-130 Kg
9. Maximum Operating Pressure :-300 Bar

Proforma No. ART-26
MASTER DEFECT CARD
140 Te. DIESEL HYDRAULIC BREAK DOWN CRANE
SN DATE NAME OF COMPONENT DEFECT FOUND REMARKS
Proforma No. ART-27
STATEMENT SHOWING PARTS OF 140 Te. CRANE CHANGED DURING THE YEAR
[ MARCH......TO APRIL....]
SN CAT No. Name of the Item System Date Quantity Balance Remarks
provided Provided Quantity
Proforma No. ART-28
140 Te. DIESEL HYDRAULIC BREAK DOWN CRANE
SCHEDULE/UNSCHEDULE REPAIR STATEMENT
[ FROM.......TO.......]
SN DATE TIME (Hrs.) TOTAL HOURS Reasons

From To From To Actual Total
Proforma No. ART-29
BREAK DOWN STAFF TRAINING PARTICULARS
SN Name of Desig. Foundation Refresher Specialized First Fire Other

Employee Course Course Course Aid Fighting Training
[4 Weeks] [2 Weeks] Course Course
Proforma No. ART-30
BREAK DOWN ORDERING AT A GLANCE
SN Month 1991 1992 1993 1994 2003 2004
01 JAN
02 FEB
03 MAR
04 APR
05 MAY
06 JUN
07 JUL
08 AUG
09 SEP
10 OCT
11 NOV
12 DEC
AVE.
TOTAL
Proforma No. ART-31
SITE OBSERVATION JOINT REPORT

[ For ordering of 140 Te. Crane as Crane/ Special ]
SN Description Remarks
01 Block section where 140 Te. Crane is

required to be ordered.
02 Nature of work.
03 Whether approval of competent

authority has been taken or not for
carrying out this work.
04 Whether work site has been jointly

examined by Engineering representative
and 140 Te. crane Break Down
Incharge.
05 Whether Operating department has

been consulted for power and traffic
block for proposed date and time.
06 Track on which block is required and

anticipated time in hours.
07 Name of entering and clearing stations

for 140 Te. Crane as well as Tower
wagon.
08 Whether DCN has been prepared or not

in the prescribed format.
09 Whether Divisional Mechanical officer

has been consulted or not for ensuring
availability of 140 Te. crane on
proposed date and time.
10 How many Mail express and Passenger

trains will suffer during the block
operation.
Signature of Sr DEN
ART-32
Proforma for Retrieval of accidented coaches/Crane special work (Sample format)
Forecasting of Retrieval of accidental Coaches by 140T Crane between enroute stations.
Time in Minutes
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 192
S Description of work Time from to
N
(Min)
1. Two tower wagons will 9.20
leave AGQ on Dn line
2. Tower wagon arrival at 15 9:20 9:35
site
3. BSL 140T Crane + Crane 20 9:35 9:55

will reach at site
4. OHE on Dn line slewed 50 9:35 10.25
5. Both 140T Cranes ready 25 10:25 10:50
6. Coach No. EC/00302 10 10:50 11:00

tackled and re-railed.
7. Both 140T Cranes 20 11:00 11:20
winding up.
Precedence to 2134 Up.
8. Both 140T Cranes and 2 11:20 11:22
coach No. EC/00302 site
dip.
9. Both 140T Cranes + re- 15 11:22 11:37
railed
Precedence to 2628 Up 12:05
Precedence to 1068 Up 12:15
10 OHE restoration by 2 70 11:22 12:32
tower Wagons and
clearing in AGQ
11 Total Time 3’12” 09:20 12:32
SUMMARY:
Traffic & Power block on : Dn line 09:20 to 12:32 =
3’12”
Traffic & Power block on : Up line 10:25 to 11.20 = 55”
2134 Up will run on DSL from KNW to BSL
2628 Up – Already on DSL, 140T Cranes to be in-
lined for passing 2628 Up
1068 Up will run with AC loco
No M/Exp Train on Dn line affected
Train No. 1387 Dn to be regulated at BSL from 9.25
Hrs. to 10.30 Hrs.
Proforma No. ART-33
West Central Railway

Date:...............
dz- fujh{k.k fVIif.k;ka czsdMkmu izHkkjh }kjk dh
SN Inspection Notes xbZ dk;Zokgh
Action taken by ART Incharge
Proforma No. ART-34
if'pe e/; jsy

West Central Railway
Date:...............
dz- fujh{k.k fVIif.k;ka nq?kZVuk jkgr fpfdRlk ;ku
SN Inspection Notes izHkkjh }kjk dh xbZ dk;Zokgh
Action taken by ARME Incharge
Proforma No. ART-35
Maintenance Schedule for ELGI make Compressor for Air Bag

Follow the Maintenance Schedule described in this proforma for trouble free service
S Sch. Periodicity Maintenance Required

N
1. Daily or before compressor starting a) Check oil level
b) Drain condensate water from Air
receiver
c) Check belt tension
2. 150 hours or 10 days a) Relieve moisture and dirt from air
receiver
b) Carry out first oil change
3. 250 hours or 20 days a) Observe noise and vibration
b) Check fasteners
c) Check air leaks
d) Check pressure setting
e) Check inlet air filter
4. Every 500 hours or 1 month a) Change oil
b) Check breather Valve
c) Tighten all the wires
d) Clean the air filter element
5. Every 1000 hours or 3 months a) Inspect valves
b) Check packings
c) Check NRV
d) Change filter elements
e) Change breather valve
f) Check pressure setting
g) Check fasteners
6. Every 2500 hours or 1year a) Annual preventive maintenance with the
tuneup kit Clean coolers
7. Every 2 years a) Clean and test Air receiver
b) Change safety valves
8. Every 7500 hours or 3 years a) Overhaul the compressor
Proforma No. ART-36
Daily Maintenance Schedule of HS SPART
Part-1. Main Engine Date:
S.N. Items to be Checked Staff Van Tool Van
Observation Remark Observation Remark

1 Check engine oil level and fill
if required.
2 Check engine fuel oil level
and fill if required.
3 Check coolant level and fill if
required.
4 Remove sediments from fuel
filter.
5 Inspect all belts for tension
and any misalignment.
6 Check all pipe lines for
leakage.
7 Check radiator fan for
looseness, crack and bend and
ensure tightness, if found
loose.
8 Check red-band of vacuum
indicator fitted on air inlet
filter. (Clean external filter
element if red mark is
appeared)
9 Check electrolyte level of
battery and fill if required.
10 Check the reading of S.G. of
battery and charge if found
below 1.18.
After above checks, start the Main Engine and note the following Readings-
1 Engine lube oil pressure
a) At idle speed (1-2
kg/cm²)
b) At 1800 rpm (3-7
kg/cm²)
2 Lube oil temperature
(75°C-105°C)
3 Cooling water temperature
(75°C-95°C)
Part-II. 125 KVA DA set Date:
S.N. Items to be Checked Supervisor Van Tool Van
Observation Remark Observation Remark

1 Check engine oil level and fill if required.
2 Start the engine and check leakage of oil.
3 Check coolant level and fill if required.
4 Check radiator fan for looseness/ crack. Also
check tightness of it.
5 Check red-band of vacuum indicator fitted
on air inlet filter. (Clean external filter
element if red mark is appeared)
6 Remove sediments from fuel filter.
7 Inspect all belts for tension and any
misalignment..
8 Check electrolyte level of battery and fill if
required.
9 Check the reading of S.G. of battery and
charge if found below 1.18.
Part-III. Transmission System

1 Check hydraulic oil level and refill if
required.
2 Check oil level of axle drive and fill
the oil if required.
3 Check all connections for any
leakage and damage.
4 Check nuts/bolts of cordon shaft and ensure
tightness.
5 Check components oil level and fill if
required.
Signature : Signature :
Name of supervisor: Name of Technician:
Designation : Designation :
Proforma No. ART-37
Log Book for HS SPART
Date Staff Van Tool Van Driver/

Reasons Supervisor
125 KVA DA Main Engine 125 KVA DA Main Engine for
Start Stop Total Run Start Stop Total Run Start Stop Total Run Start Stop Total Name&
(Hrs) (Hrs) (Hrs) (Hrs) (Hrs) (Hrs) (Hrs) (Hrs) (Hrs) (Hrs) (Hrs) Run Utilization Signature
(Hrs)
Proforma No. ART-38
SCHEDULE FORM FOR CUMMINS MAKE ENGINE OF HS SPART UNDER AMC
Contract Agreement No.:

Validity of contract:
Date of visit: Visit no.:
Engine serial no.: Engine model:
Engine hours:
Name of the Service Engineer:
S. Nature of
System Item to be attended Item Qty Cost Remarks
N.
“A” CHECK (Daily/Weekly):
1) Clean precleaner dust pan weekly

AIR 2) Check the air cleaner restriction,
01.
SYSTEM clean/change air cleaner element if
required.
1) Engine oil level/Condition/Grade
LUBRICAT 2) Lube oil suction pipe for leak/ crack
02. ION
SYSTEM 3) Oil leakage if any( specify leakages)
4) Bypass filter type/ Condition if any
1) Check Coolant level
COOLING
03. 2) Water leakage if any (specify leakages)
SYSTEM
3) Engine cleanliness
FUEL 1) Drain sediment from fuel tank
04.
SYSTEM 2) Fuel leakages, if any
1) Drain Air tank
Other 2) Check and correct leaks
05. maintenan
3) Drain fuel filter/Water separator daily
ce
4) Check oil level of marine gear and raw
water pump
Total Cost (including 12.36 % VAT)
Service Engineer’s remarks:
Customer’s remarks:
Service Engineer’s signature Signature of SSE (ART)

Name: Name:
Date: Date:
Proforma No. ART-39

Engine hours:
S. Nature of
N.
“B” CHECK (Every 300 hrs. or 6 Months):
AIR 1. Clean/change crank case breather

01.
SYSTEM 2. Check air piping
1. Change Engine oil
2. Chane engine full flow oil filter
LUBRICAT
02. ION 3. Change by pass filter
SYSTEM
4. Change marine gear oil
5. Record oil pressure
1. Check Coolant inhibitor. Add coolant
COOLING
03. concentrate, if required.
SYSTEM
2. Check heat exchanger zinc plugs
1. Check Hyd. Gov.Oil ( if applicable)
2. Check throttle linkage
3. Lubricate ball joints of the throttle linkage
FUEL of Hyd. Gov.
04.
SYSTEM
4. Change fuel filter
5. Clean Fuel tank breather
6. Check Aneroid oil

Name: Name:
Date: Date:
Proforma No. ART-40

Engine hours:
S. Nature of
N.
“C” CHECK (1500 hrs. or 01 Year):
AIR
01. Repeat A&B check of Air system
SYSTEM
LUBRICAT
02. ION Repeat A&B check of Lubrication System
SYSTEM
COOLING
03. Repeat A&B check of Cooling System
SYSTEM
1. Repeat A&B check of Fuel System
2. Change Hyd. Gov. oil.
FUEL 3. Change Aneroid oil
04.
SYSTEM 4. Check aneroid adjustment.
5. Replace aneroid breather.
6. Clean fuel tank from inside.
1. Repeat A & B Check.
Other 2. Inspect parts of Alternator/Starter and
05 Maintenan replace if required.
ce system 3. Check air cleaner, Evacuator valve and
change if required.

Name: Name:
Date: Date:
Proforma No. ART-41

Engine hours:
S. Nature of
N.
First 1500 Hrs Check:
1. All steps of C Check.

2. Adjust injectors and valves.
3. Replace Rocker Cover Gasket

Name: Name:
Date: Date:
Proforma No. ART-42

Engine hours:
S. Nature of
N.
“D” CHECK (6000 hrs or 02 Years):
1. Repeat A, B & C Checks.

2. Clean Turbocharger compressor wheel
AIR and diffuser if required.
01.
SYSTEM
3. Check Turbocharger bearing clearance.
4. Tighten manifold nuts or capscrews.
LUBRICAT
02. ION 1. Repeat A, B & C Checks.
SYSTEM
COOLING
03. 2. Change Coolant
SYSTEM
3. Descale Cooling system.
2. Clean & Calibrate injectors if required.
FUEL 3. Replace Rocker Cover Gaskets.
04.
SYSTEM
4. Check fuel pump Calibration.
5. Repace Aneroid belows & calibrate if
provided.
1. Repeat A, B & C Checks
Other 2. Check vibration damper.
05. maintenan
ce 3. Check Air compressor.
4. Check safety controls.

Name: Name:
Date: Date:
Proforma No. ART-43
Maintenance Schedules of High Pressure Compressor
To keep the machine in good working condition, it must be cleaned very thoroughly.
Having been designed and built according to the most advanced technological criteria, this type
of filling station requires very limited preventive and routine maintenance operations.
However, it is essential to follow the indications given in the proforma very carefully and to follow
the intervals between operations as suggested.
The following paragraph enables all the routine and additional maintenance operations carried
out on the machine to be recorded. This paragraph should be filled in carefully and any
operations carried out to solve problems should also be recorded.
SN INTERVALS
X 1 day 15 min. 30 min. 25 h 50 h 125 h 250 h 500 h 1000 h 5000 h
1. Replace the activated
carbon cartridge.
2. Check the compressor
oil level
3. First, change
compressor oil
4. Change compressor oil
5. Intake filter cartridge
6. Operation of the end
safety valve
7. Operation and tightness
of the filling valve
8. Alignment of the
compressor needle with
the zero when the
compressor is de-
pressurised
9. Tightning of the cooling
pipes
10. Tightening of the
connecting pipes
11. Belt tension and wear
12. Hose replacement
nd rd
13. 2 and 3 stage intake
and discharge valves
14. Internal cleaning of end
separator
15. Tightening of all the
screws
16 General cleaning
17 Replacement of the
external casing of the
strainer filter
st
18 Replacement of 1 stage
head
 = Replacement
o = Inspection, cleaning
Proforma No. ART-44
Maintenance Schedule for ASKA Tower Light
Inflatable Emergency Lighting Tower
PREVENTIVE MAINTENANCE SCHEDULE
MAINTENNACE 5 Hrs. 25 50 100 150 200 250 300

OPERATION or Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs.
Daily
Check Oil Level and √
Condition
Change Oil √
Check and clean the √ √ √ √ √ √ √
air cleaner
Replace the air √ √
cartridge
Replace foam filter √
Clean the cooling √ √ √
system
Clean the spark plug & √ √ √ √ √ √
adjust spark plug gap,
if required
Replace spark plug √
Clean the fuel √
system/carburetor
Change fuel filter √
element
Adjust valve √
clearances
Remove combustion √
chamber deposits
NOTE :
1. Change the Oil after 25 Hrs, If Operating under heavy Load Conditions.
2. Replace or clean the air filter after 25 Hrs If operating under dusty conditions.
Proforma No. ART-45
Maintenance Schedule for LUKAS power Pack (Petrol)
Sr. Schedule Items to be checked Nature of Qty Remarks

No. periodicity Item
01 First 05 hours 1. Change oil
02 Every 05 hours 1. Check oil level.
or daily 2. Clean figure guard and
around muffler.
03 Every 25 hours 1. Change oil if operating
or every season under heavy high
ambient temperature.
2. Service oil cleaner oil
foam element, pre-
cleaner if equipped.
3. Service air cleaner
cartridge if no pre-
cleaner.
04 Every 50 hours 1. Check oil level.
or every season 2. Clean and inspect spark
arrester, if equipped.
05 Every 100 1. Service air cleaner
hours or every cartridge if equipped
season pre-cleaner.
2. Replace in-line fuel filter
if equipped.
3. Clean cooling system
4. Clean or replace spark
plug.
Proforma No. ART-46
Maintenance Schedule for LUKAS power Pack (Diesel)
Sr. Schedule Items to be checked Nature of Qty Remark

No. periodicity Item
01 Every 8-15 1. Check oil level.
operating hours 2. Check combustion and
cooling air intake zone.
3. Check air- cleaner
maintenance indicator.
02 Every 250 1. Change engine oil.
operating hours 2. Check and adjust valve
clearance. (Not
applicable with
automatic self adjusting
valve clearance
models0
3. Clean cooling area.
4. Check screw
connections.
5. Clean mesh insert for
exhaust.
03 Every 500 1. Clean the oil filter.
operating hours 2. Dry type air cleaner
maintenance.
04 Once a year 1. Siphon water out of the
fuel tank.
Note: 1. Only carry out maintenance work with the engine switched off.
2. Observe all relevant laws and regulations governing the handling and disposal of
used oil, filters and cleaning agents.
3. Protect the starting key against un-authorized use.
4. On engine with an electric starter, disconnect the battery’s negative terminal.
5. When maintenance work has been completed, check that all tools have been
removed from the engine and all protective guards fitted again.
6. Before starting the engine, ensure that there no persons in the danger area close
to the engine or equipment.
Proforma No. ART-47
MAINTENANCE SCHEDULE OF HYDRAULIC RE-RAILING EQUIPMENT

SCHEDULE : WEEKLY
POWER PACK NO.......................DATE.......................DEPOT.........................RLY............................
The under mentioned parts to be examined with the procedure laid down in the maintenance schedule.
-----------------------------------------------------------------------------------------------------------------------------
S.No. Item Condition Action taken
-----------------------------------------------------------------------------------------------------------------------------
1. PETROL POWER PACK:

1.1 Check Engine & Gear box oil level.
If required, fill up the oil to the upper level
1.2 Check the petrol level. If required, fill up to the upper level
1.3 Check the Oil level of Hydraulic tank
1.4 Starting and running of the unit daily for 15 minutes
2. CONTROL DESK [ PETROL]:

2.1 Check the operation of control levers
2.2 Check oil leakage from control desk and clean it
3. DIESEL POWER PACK:
3.1 Check Engine gear box oil level. If required
fill up the oil to the upper level.
3.2 Check the fuel level. If required, fill to the upper level
3.3 Check the oil level of Hydraulic tank.
3.4 Starting and running of the unit daily for 15 minutes
4. CONTROL DESK [ DIESEL]:
4.1 Check the operation of control lever.
4.2 Check oil leakage from control desk and clean it.
5. HYDRAULIC JACK:
5.1 Clean all Jacks with cloth.
6. HYDRAULIC ACCESSORIES:
6.1 Clean all the hydraulic hoses, roller carriage
& Re-railing bridges etc.
ANY SPECIAL REPAIR OBSERVED:
Signature of Technician.
Token No.................
Signature of ART supervisor
Proforma No. ART-48
SCHEDULE : MONTHLY/ 20 RUNNING HRS OR AFTER EVERY BREAK DOWN WORKING
-----------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
1.1 Start the engine at full throttle.
1.2 Check the pressure on control desk, it should be 300 bar
1.3 Check Oil leakage from engine, Pump, Return line filter
and fittings. Attend if required

2.1 Check 300 bar pressure on control desk.
Re-adjust if required
2.2 Check oil leakage from control desk & its fittings.
Attend if required.
3.1 Clean air cleaner
3.2 Check oil level of air cleaner. Fill if necessary.
3.3 Check oil level of Crank case. Fill if necessary.
3.4 Check the pressure on control desk, it should be 300 bar.
3.5 Check oil leakage from engine, pump, return line filter
& fittings. Attend if required.
4.1 Check 300 bar pressure on control desk.
Re-adjust if required.
Attend if required.
5. HYDRAULIC JACK:
5.1 Check all Jacks with or without load on 300 bar pressure.
If found oil leakage, check the rubber buckets and change it.
Attend if required.
6.1 Check the roller carriage for any mechanical damage.
If found damaged, repair or change it.
6.2 Check oil leakage from hydraulic hose & end fitting couplers
Token No.................
Proforma No. ART-49
SCHEDULE : QUARTERLY OR AFTER 50 RUNNING HRS
-----------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
1.1 Tighten all foundation bolts.
1.2 Clean the return line filter of hydraulic oil tank
1.3 Clean the fix half fittings of pump unit & check for leakage.
1.4 Clean air cleaner properly.
1.5 Clean the hydraulic return line filter of Pump set.

2.1 Clean high pressure hydraulic filter
2.2 Clean fix half fittings of control desk
3.1 Clean breather element
3.2 Replace oil of Air cleaner
3.3 Clean the return line filter of hydraulic oil tank.
3.4 Clean the fix half fittings of pump unit & check for leakage
3.5 Tighten all foundation bolts
3.6 Clean the hydraulic return line filter of pump set.
4.1 Clean high pressure hydraulic filter
4.2 Clean fix half fittings of control desk.
5. HYDRAULIC JACK:
5.1 Check all Jacks with or without load on 300 bar pressure.
If found oil leakage, check the rubber buckets and change it.
6.1 Clean and lubricate the roller carriage shaft and rollers
6.2 Clean all hydraulic hose end fitting couplers.
6.3 Visual check of all hydraulic hoses for mechanical damage
6.2 Clean the all Jacks fix half end fittings thoroughly
Token No.................
Proforma No. ART-50
SCHEDULE : Half Yearly or after 100 Hrs. working.
-----------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
1.1 Check the spark plug.
1.2 Check the fuel strainer.
1.3 Change the crank case lube oil SAE 10W30 or equivalent.
2 DIESEL POWER PACK:

2.1 Clean head/cylinder fins.
2.2 Clean Lube oil filter
2.3 Clean injectors
2.4 Replace oil 20W40 of crank case
Token No.................
Signature of ART Supervisor
Proforma No. ART-51
SCHEDULE : Yearly or after 300 Hrs. working.
-----------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
1.1 Checked the valve clearance and readjust if require
1.2 Clean the hydraulic oil tank
1.3 Clean engine fuel oil tank
1.4 Check hydraulic oil sample in lab if found
unsatisfactory replace it.
1.5 Examine pump drive coupler and change if necessary
1.6 Change the return line filter of hydraulic oil tank.
1.7 Change the fix half seal kit on pump unit
1.8 Clean the engine fuel oil tank and change the fuel oil
in second yearly or after 600 working hours.
2. CONTROL DESK [ PETROL ]:
2.1 Change high pressure hydraulic filter.
2.2 Check seal of fix half and changed if required.
3.1 Check tightness of delivery line union.
3.2 Check rocker arm clearance.
3.3 Replacement fuel filter cartridge.
3.4 Clean the hydraulic oil tank.
3.5 Check hydraulic oil sample in lab if found
unsatisfactory replace it.
3.6 Examine pump drive coupler and change if necessary
3.7 Change the return line filter of hydraulic oil tank.
3.8 Change the fix half seal kit on pump unit.
3.9 Clean the engine fuel oil tank and change the fuel oil
in second yearly or after 600 working hours.
4. CONTROL DESK [ DIESEL ]:
4.1 Change high pressure hydraulic filter.
4.2 Check seal of fix half and changed if required.
5. HYDRAULIC JACK:
5.1 Check the cylinder of jack for scoring/scratching, if
found scored remove the score by polish paper.
5.2 Check the buckets. If found crack/perished, change it.
5.3 Change the seal kit of all jacks fix half.
6.1 Change the seal kit of all hose's loose half. (Hose fitting)
6.2 Overhaul the roller carriage.
6.3 Clean air breather cum filter of hand pump and check
operation.
Token No................. Signature of ART Supervisor
Proforma No. ART-52
MAINTENANCE SCHEDULE FORM FOR VISIT UNDER AMC FOR 140 T.
CRANE(GOTTWALD MAKE)
A. List of “Must Change” Items of 140 t .Crane (except main engine) to be
replaced during maintenance schedules.
S Maintenanc Items to be replaced Remarks
N e Schedules
1 Daily Nil
2 Monthly Nil
3 Half yearly 1)Lube oil filter of auxiliary engine
2) lube oil of Auxiliary engine
4 Yearly 1) Micro fuel filter insert of auxiliary engine

2) Grease of wheel set bearings
3) gear box oil of
a) Pump distribution gearbox
b) Slewing gearbox
c) main hoist gearbox
d) Auxiliary hoist gear box
e) Derrick gear box
f)recovery winch gear box
g) traveling gear box
5 Two yearly I) Hydraulic oil

II) ’O’ rings, gaskets, oil seals of engine mounted air
compressor
6 Three yearly Nil
B. List of Items of 140 T Crane to be replaced on “Condition Basis” (except main

engine)
S Maintenance Items to be checked/replaced Remarks
N Schedules
1 Daily 1)Slewing gear pump filter
2) Hoses, connections, attachments of rotary lead through
3) Lighting elements
4) Jib rope pulley
5) Main hoist and auxiliary hoist hook locks
6) Cab glass panes
2 Monthly 1) Hydraulic oil tank filter inserts
2) Breather filter of slewing gear reduction unit
3) Damaged items of Derrick rope pulley and rope guides
4) Damaged items of deflection rolls on recovery winch
5) Seals of door connection of switch cabinet
6) lighting elements.
3 Half yearly 1) Sealing ring of lube oil filter of auxiliary engine
2) V belts of Auxiliary generator and blower fan drive of
auxiliary engine.
3) Breather filter cartridge of haudraulic oil tank
4) Vent filter of pump distribution gear box
5) Faulty pressure gauges mounted behind the cap
4 Yearly 1) Sealing ring of micro-fuel filter insert of auxiliary engine
2) Brake pads
3) Brake pads holder
4) Carbon brushes of starter and alternator of auxiliary
engine
5) Bearing of alternator of auxiliary engine
5 Two yearly 1) Pipes and connections of engine mounted air
compressor
2) Worn out parts of engine mounted compressor
6 Three yearly 1) Nozzle along with sealing washer of injectors of auxiliary
engines
2) Worn out parts of PT pump
C. Check list of Lubrication Points of 140 T. Crane
S Maintenance Items to be Lubricated Lubricant used Remarks
N Schedules
1 Daily Nil
2 Monthly 1) Counterweight cylinders and jib Grease (Servogem EP- 2)
root point cylinders
2) Bogie hinge Grease (Servogem EP- 2)
3) Slew ring Grease (Servogem EP- 2)
4) Gear wheel and pinion Grease (Servogem EP- 1)
5) Axle gear unit Grease (Servogem EP- 2)
6) Outer gear beams Grease (Servogem EP- 2)
7) Outer rigger pads Grease (Servogem EP- 2)
8) Super structure locking device Grease (Servogem EP- 2)
9) Bogie side bearers
10) Jib support Grease (Servogem EP- 2)
11) Bogie pivots screw couplings and Grease (Servogem EP- 2)
buffers, Grease (Servogem EP- 2)
12) Door hinges and lock in the cab
13) Slide trucks of seat Grease (Servogem EP- 2)
14) Match truck trestle liners
15) Match truck bogie pivots and Grease (Servogem EP- 2)
bolster Grease (Servogem EP- 2)
16) Battery terminals Grease (Servogem EP- 2)
17) Wire ropes Petroleum jelly
Graphite grease
3 Half yearly 1) Main hoist gear box Grease (Servogem EP- 2)
2) Auxiliary hoist gear box Grease (Servogem EP- 2)
3) Derrick gear box Grease (Servogem EP- 2)
4) Recovery winch gearbox Grease (Servogem EP- 2)
5) Main hoist rope drum Lubricating Oil
6) Auxiliary hoist rope drum Lubricating Oil
7) Derrick rope drum Lubricating Oil
8) Recovery winch rope drum Lubricating Oil
9) Screw couplings and buffers of Grease (Servogem EP- 2)
match truck
4 Yearly Starter drive assembly of auxiliary Grease (Servogem EP- 2)
engine
5 Two yearly All the above items
6 Three yearly All the above items
D. Other items checked during visit:
S Maintenance Defect Noticed Attention

N Schedules
01 Pre programmed display board Programme chip
component(MX-4) of SLI System replaced
02 Shear pin sensor of Auxiliary Hoist was Same cable was replaced
malfunctioning. 4-core shielded
instrumentation cable between sensor and
pre-Amplifier board was defective
Proforma No. ART-53
MAINTENANCE SCHEDULE FORM FOR VISIT UNDER AMC FOR 140 T.
CRANE(GOTTWALD MAKE)
A. List of “Must Change” Items of 140 t .Crane (except main engine) to be replaced
during maintenance schedules.
S Maintena Items to be replaced Nature of Quant Total Remarks
N nce item ity cost
Schedules
1 Daily Nil
2 Monthly Nil
3 Half yearly 1) Lube oil filter of auxiliary engine Consumab
2) lube oil of Auxiliary engine le
4 Yearly 1) Micro fuel filter insert of auxiliary

engine 2) Grease
of wheel set bearings
3) gear box oil of
a) Pump distribution gearbox
b) Slewing gearbox
c) main hoist gearbox
d) Auxiliary hoist gear box
e) Derrick gear box
f)recovery winch gear box
g) traveling gear box
5 Two yearly 1) Hydraulic oil
2) ’O’ rings, gaskets, oil seals of engine
mounted air compressor
6 3- yearly Nil
B. List of Items of 140 T Crane to be replaced on “Condition Basis” (except main engine)
S Maintena Items to be checked/replaced Nature of Quant Total Remarks
N nce item ity cost
Schedules
1 Daily 1)Slewing gear pump filter
2) Hoses, connections, attachments of
rotary lead through
3) Lighting elements
4) Jib rope pulley
5) Main hoist and auxiliary hoist hook
locks
6) Cab glass panes
2 Monthly 1) Hydraulic oil tank filter inserts
2) Breather filter of slewing gear
reduction unit
3) Damaged items of Derrick rope
pulley and rope guides
4) Damaged items of deflection rolls on
recovery winch
5) Seals of door connection of switch
cabinet
6) lighting elements.
S Maintena Items to be checked/replaced Nature of Quant Total Remarks
N nc item ity cost
Schedules
3 Half yearly 1) Sealing ring of lube oil filter of Consumab
auxiliary engine le
2) V belts of Auxiliary generator and
blower fan drive of auxiliary engine.
3) Breather filter cartridge of hydraulic
oil tank
4) Vent filter of pump distribution gear
box
5) Faulty pressure gauges mounted
behind the cap
4 Yearly 1) Sealing ring of micro-fuel filter insert
of auxiliary engine
2) Brake pads
3) Brake pad holders
4) Carbon brushes of starter and
alternator of auxiliary engine
5) Bearing of alternator of auxiliary
engine
5 Two yearly 1) Pipes and connections of engine
2) Worn out parts of engine mounted
compressor
6 Three 1) Nozzle along with sealing washer of
yearly injectors of auxiliary engines
C. Check list of Lubrication Points of 140 T. Crane
S Maintena Items to be Lubricant used Natu Quan Total Remarks

N ncSchedul Lubricated re of tity cost
es item
1 Daily Nil
2 Monthly 1) Counterweight Grease (Servogem EP- 2)
cylinders and jib root
point cylinders Grease (Servogem EP- 2)
2) Bogie hinge Grease (Servogem EP- 2)
Grease (Servogem EP- 1)
3) Slew ring
4) Gear wheel and pinion Grease (Servogem EP- 2)
5) Axle gear unit Grease (Servogem EP- 2)
6) Outer gear beams Grease (Servogem EP- 2)
7) Outer rigger pads
8) Super structure Grease (Servogem EP- 2)
locking device Grease (Servogem EP- 2)
9) Bogie side bearers Grease (Servogem EP- 2)
10) Jib support
11) Bogie pivots screw Grease (Servogem EP- 2)
couplings and buffers,
12) Door hinges and lock
in the cab
13) Slide trucks of seat Grease (Servogem EP- 2)
14) Match truck trestle Petroleum jelly
liners 15) Graphite grease
Match truck bogie pivots
and bolster
16) Battery terminals
17) Wire ropes
3 Half yearly 1) Main hoist gear box Grease (Servogem EP- 2)
2) Auxiliary hoist gear Grease (Servogem EP- 2)
box
3) Derrick gear box Grease (Servogem EP- 2)
4) Recovery winch
gearbox
5) Main hoist rope drum Lubricating Oil
6) Auxiliary hoist rope Lubricating Oil
drum
7) Derrick rope drum Lubricating Oil
8) Recovery winch rope Lubricating Oil
drum
9) Screw couplings and Grease (Servogem EP- 2)
buffers of match truck
4 Yearly Starter drive assembly Grease (Servogem

of auxiliary engine EP- 2)
5 Two All the above items
yearly
6 Three All the above items
yearly
D. Other items checked during visit:
S Maintena Defect Noticed Attention Nature Quanti Total Remark

N nce of item ty cost s
Schedules
01 Leakage of hydraulic oil Complete
through MO-4 control block control block
was found was opened and
“O” Ring was
replaced
02 Main hoist load cell sensor was Soldering done
defective due to soldering and sensor
worked out made functional
03 Two nos. electrical connectors Connectors
of solenoid valve were replaced
defective
E. Any Emergency Visit (Within 24 Hrs. of break down):
S Mainten Attention to be given to the Attended or Natur Quan Tota Remar

N ance system not e of tity l ks
Schedul item cost
es
F. Service Charges for attention to maintenance schedules and other repairs:
S Maintena Attention to be given to the Attended or not Nature Quant Total Remark
N nce system of ity cost s
Schedule item
s
Hydraulic system including all
pumps, motors, cylinders and
valves etc.
Pneumatic system and brake
system etc.
Electrical and control system
including safe load indicator
(SLI) etc.
Slewing gear, gear drives,
reduction gear units and
bearings etc.
Structural items like
superstructure under carriage,
bogie, Cab, match truck, wire
ropes, lifting tackles, shelves
and drums etc.
Total cost
12.3% Service Tax
Grand Total
Proforma No. ART-54
MAINTENANCE SCHEDULE SERVICE VISIT REPORT UNDER AMC FOR
DOUBLE ACTING 530 BAR LUKAS (HRE)
CUSTOMER : SSE/ART/…. LOCATION : ………….

LOA/AMC No. : ………………………………………. VISIT No. : Ist
SERVICE ENGINEER: ………………………………….. DATE OF VISIT: …………
POWER PACK:
MODEL : REF NO. :
ENGINE MODEL & TYPE : ENGINE SL NO. :
S Schedule Items to be checked/Replaced Nature of Quant Total Remarks

N Periodicit item ity cost
y
1 Check the hydraulic, lubricating oil
leakages and attend if necessary
2 Check the lubricating oil in the
power pack sump and top
up/replace if necessary
03 Check the hydraulic oil level and
top up/Replace if contaminated
04 Clean the carburetor
05 Clean the air filter and replace if
necessary
06 Check the operating pressure under
load
07 Check performance of the power
pack by operating the re-railing
system under load
08 Check the rewind starter rope
condition
09 Check the condition of power pack
hand valve
10 Start the power pack and observe
any abnormal sound
11 Check all fastenings like bolts and
nuts of power pack
12 Check any damages to the power
pack
13 HRE Manual Check whether there are any loose
para 13110 hydraulic screw connections on the
page-18
devices and hoses, tighten them if
necessary
14 ” Check the mechanical parts, valves
and hoses of power pack for
mechanical damage
15 ” Check whether the signs ,
warnings, operation and control
symbols and other markings
(Colour markings) are complete and
perfectly legible.
16 ” Check whether all safety
covers(Engine: protective cover,
exhaust pipe cover), hoop guard
etc. are available and in perfect
condition
17 OEM Manual Clean finger guard and around
page-4
muffler
Daily
18 50 hrs. Clean and inspect spark arrester
19 100 hrs. Replace air cleaner cartridge
20 100 hrs. Replace oil filter
21 100 hrs. Replace in line fuel filter
22 100 hrs. Clean cooling system
23 100 hrs. Clean or Replace spark plug
24 200 hrs. Replace Extended life series air
cleaner cartridge
25 200 hrs. Check valve clearance
CONTROL TABLE:
MODEL : REF NO. : Sr. No. :

y
01 Clean all the couplings
02 Attend any leaks from control table
like hand valves, traverse pin valve
and couplers etc.
03 Check system pressure in pressure
gauge under load (i.e. 530 Bar)
04 Check any damages to the control
table
05 HRE Check whether there are any loose
Manual hydraulic screw connections on the
para 13110 devices and hoses, tighten them if
page-18 necessary
06 ” Check the mechanical parts, the
valves and the hoses of control
table for mechanical damage.
07 ” Check whether the signs, warnings,
operation and control symbols and
other markings (colour markings)
are complete and perfectly legible.
08 ” Check whether all safety covers are
available and in perfect condition
JACKS:
MODEL : REF NO. : QTY :
y
02 Remove the piston guard plate and
clean the guide ring top for any
dust or foreign particles on the
plate
03 Check performance of Jacks under
no load at system pressure
04 Check for any hydraulic oil leakages
under no load and attend if
necessary
05 Check any scratches and damages
on piston surface
06 Tighten the base plate holding bolts
if required
nuts of Jack
08 HRE Manual Check whether each single piston
para 11.1 retracts smoothly?
page-21
09 ” Check whether there are any loose
hydraulic screw connections on the
devices and hoses tighten them if
necessary.
10 ” Check the mechanical parts, the
valves and the hoses of cylinders
for mechanical damage.
11 ” Check whether the signs, warnings,
operation and control symbols and
other markings(colour markings)
are complete and perfectly legible.
12 ” Check whether all safety covers are
available and in perfect condition
13 ” Check the condition of the
accessories (Base plates, header
plates etc.)
14 ”
HYDRAULIC HOSES:
MODEL(Function/ Colour) : REF NO. : QTY :
y
01 Clean all the couplings, Hoses &
Dust Caps
02 Check any crack on the hoses and
replace if necessary
03 Check all couplers of the hoses and
replace if damaged
04 Check all the hoses under load/No-
load at system pressure
05 Check any oil leaks from joints and
couplings and attend if necessary
06 Store the hoses on roller drum
07 OEM Visual checks to be carried out for
Manual following possible defects
Para 5.1 a. Damages of the surface and the
Page.7 interior ( e.g. chafe marks, cuts
or fissures)
b. Embrittlement of the
surface(Fissuration of the hose
material)
c. Deformation like separation of
material layers, blister formation,
squeezing or break spots
d. Leakage points
e. Emerging of the hose from the
end fittings
f. Damages or deformations of the
end fittings
g. Corrosion of the end fittings or
the metal inlets
ROLLER CARRIAGE with built in Traversing unit:
MODEL : REF NO. :
y
01 Clean all the couplings, out side
surfaces & Dust Caps
02 Check the traversing unit under No-
Load at system pressure
03 Check any leak from Piston and
Couplers and attend it
04 Check any scratches on Piston and
replace if necessary
05 Check any damages of notches and
edges of the roller carriage and
attend it
06 Check the catch of the Traversing
Jack and grease the catch pin
RE-RAILING BRIDGE:
SIZE : REF NO. : QTY :

y
01 Clean the surface of the bridge
02 Check edges and holes of the
bridge and attend/Replace if
necessary
03 Check all handle fastenings like
bolts and nuts
04
STACKING SET :
MODEL: REF NO. : QTY :
y
01 Clean all stacking rings and pistons
02 Check stacking rings, Pistons and
Fork lever for any structural
damage and replace or rectify.
03
AXLE PUSHER :
y
01 Clean the surface of the frame
nuts
03
TILTING SET :
y
01 Clean the couplings
clean the guide ring top for any
dust or foreign particles on the
plate
03 Check performance of Jacks under
No-Load at system pressure
04 Check for any hydraulic oil leakage
under No-Load and attend it
05 Check any scratches and damages
on Piston surface
nuts of Jacks
07 Check Radius plate and rectify or
Replace if damaged
0
8
LIFTING BELT & CLAW JACKS :
y
01 Check the condition of Lifting belt and
Holding rope, replace if damaged
02 Check for rusting, clean and apply
grease
clean the guide ring top for any dust or
foreign particles on the plate
04 Check performance of Jacks under No-
under No-Load and attend it.
06 Check any scratches and damages on
piston surface
07 Check all fastening like bolts and nuts
of Jacks
08 Check condition of claw jack base plate
09 Check condition of shackle
10
PULLING DEVICE :
y
clean the guide ring top for any dust or
foreign particles on the plate
03 Check performance of Jacks under No-
under No-Load and attend it.
05 Check any scratches and damages on
piston surface
06 Check all fastening like bolts and nuts
of Jacks
07 Check condition of Pulling rope,
holding ropes, shackle and Rail
attachments
HAND PUMP :
y
01 Clean the couplers and Hand Pump
02 Check the performance of Hand Pump
under No-Load or Load at system
pressure
03 Check the oil level, top up if required
under No-Load and attend it
05 Check all fastenings like bolts and nuts
of Hand Pump
AIR COMPRESSOR FOR 40 T AIR BAG [ KAESER MAKE]:
y
01
02
03
04
05
06
07
08
09
10
11
12
13
POWER TESTING :
S STEPS Procedure Nature of Quant Total Observations
N item ity cost
01 Step-1 Connect the hoses of HRE system, Start the
Power pack and close the drain valve of the
power pack
02 Step-2 Close the drain valves of the control table
while all the 3/3 way valves are in neutral
position. The pressure at the gauge on
control table should be 500 to 530 Bar
03 Step-3 Operate the control valves of 3/3 way valves
to lifting position. After position of Jacks
fully extended, read the pressure at the
control table. It should be 500-530 Bar
04 Step-4 At fully extended position of the jack, the
gauge on the control table will indicate 500-
530 Bar pressure. Check the cylinder for any
leakage(from coupling connectors and
from/between Piston and guide ring). In
case any irregularity is observed, the repair
should be carried out as per the instructions
provided in trouble shooting portion of OEM
Manual.
Proforma No. ART-55
Service Charges for attention to 01 set 530 Bar Double acting Lukas Make HRE
consisting of 20 Nos. Jacks, Power Pack, Control Stand, Roller Carriage along with
Air Compressor for Lifting Air Bag and sub assemblies of equipments:
S Maintena Attention to be given to the Attended or not Nature Quant Total Remark
N n system of ity cost s
Schedules item
Power Pack
Control Table
Hydraulic Jacks
Hydraulic Hoses
Roller Carriage with Built in
Traversing Unit
Re-Railing Bridges
Stacking Set
Axle Pusher
Tilting Set
Lifting Belt and Claw Jacks
Pulling Device
Hand Pump
Air Compressor
Power Testing
Total cost
12.36% Service Tax
Grand Total
PARTS NEEDS TO BE REPLACED :

S Description Part Nature of Quant Total Remarks
N Reference No. item ity cost
01
02
03
04
05
06
07
SERVICE ENGINEER’S COMMENTS :

S Description
N
01
CUSTOMER’S COMMENTS :
S Description
N
01
Service Engineer’s Signature: Signature of SSE(ART)
Service Engineer’s Name: Name of SSE(ART)
Proforma No. ART-56
Contract Agreement No. AMC VISIT NO - Div. / M / 140T
Crane / AMC dated DATE OF VISIT - ……………………
MAINTENANCE SCHEDULE FORM FOR VISIT UNDER AMC FOR MAIN
ENGINE OF 140 T CRANE
A. List of “Must Change” Items of main engine to be replaced during
maintenance schedule:
S Maintenance Nature of Total
Items to be replaced Qty Remarks
N Schedules item cost
01 Daily Nil
02 Monthly Nil
1) Engine lube oil Consumable 40 lts.
03 Six Monthly
2) Fuel filter Consumable 01 no.
04 Yearly 1) Rocker cover gasket Consumable 03 no.
1) Repair kit of Turbo 01 no.

2) Air cleaner Inner & Outer 01 no.
Consumable
elements Each
05 Two Yearly 3) Belts
a) Radiator Fan 02 no.
Consumable
b) Water Pump each
c) Alternator
1) Cups & O rings of
06 Three Yearly injector
2) PT Pump parts Spares
B. List of Items of Main Engine to be replaced on condition basis:
01 Daily Nil
Belts
a) Radiator Fan 02 no.
02 Monthly Consumable
b) Water Pump each
c) Alternator
1) Crank case Breather Spare 01 no.
03
Six Monthly
2) Fuel tank Breather Spare 01 no.
1) Flexible mounting rubber Consumable 04 no.

04 Yearly 2) Broken/lost bolts of
Consumable
engine mounting
3) Hoses, connecting parts,
Consumable
clamps of cooling system
1) Vacuum indicator Spare 01 no.
2) Hoses of fuel line Consumable

3) Hoses & clamps of lube
Consumable
oil line
4) Head gasket Consumable
5) Rocker Housing gasket Consumable 03 no.

05 Two Yearly
6) Seals of lube oil system Consumable
7) All hoses, clamps,
couplings, O rings of Consumable
Cooling system
8) Radiator anti-vibration
Spare
mounting
9) Water pump Spare 01 no.
Push rods, adjusting nuts & screws of
06 Three Yearly Spares
valves
\
C. Other items checked during visit:

Defect noticed Attention paid Qty Remarks
01
02
03
04
D. Any Emergency visit:
S Maintenance Attention to be Attended or Nature of Total

Qty Remarks
N Schedules given to the system not item cost
01
02
03
04
E. Service charges for attention to maintenance schedule other repairs:
S Maintenance Attention to be given Attended or Nature of Total

Qty Remarks
N Schedules to the system not item cost
01 AIR SYSTEM
02 OIL SYSTEM
03 COOLING SYSTEM
04 FUEL SYSTEM
05 GENERAL
06 ENGINE TESTING
Total cost
12.36% Service Tax
Grand Total
F. Service Engineer’s comments:
G. Customer’s comments:
Signature of Service Engineer - Signature of SSE (ART)

Name - Name –
Date - Date -
Contract Agreement No. AMC VISIT NO -

…………………….
Proforma No. ART-57
Div / M / 140T Crane / AMC dated 17/10/07 DATE OF VISIT - ……………………
MAINTENANCE SCHEDULE FORM FOR VISIT UNDER AMC FOR 140 T. CRANE
(GOTTWALD MAKE)
List of “Must Change” Items of 140 t .Crane (except main engine) to be replaced during
maintenance schedules.
S Maintenance Nature Total

N Schedules of item cost
1 Daily Nil
2 Monthly Nil
1) Lube oil filter of auxiliary engine.
3 Half yearly
2) Lube oil of Auxiliary engine
1) Micro fuel filter insert of auxiliary engine.
3) Gear box oil of
 Pump distribution gearbox,
 Slewing gearbox,
4 Yearly
 Main hoist gearbox
 Auxiliary hoist gear box
 Derrick gear box
 Recovery winch gear box
 Traveling gear box
1) Hydraulic oil,
5 Two yearly 2) ‘O’ rings, gaskets, oil seals of engine
6 Three yearly Nil
A. List of Items of 140 T Crane to be replaced on “Condition Basis” (except main engine)
1. Slewing gear pump filter
2. Hoses, connections, attachments of
rotary lead through
3. Lighting elements
1 Daily
4. Jib rope pulley
5. Main hoist and auxiliary hoist hook
locks
6. Cab glass panes
2 Monthly 1. Hydraulic oil tank filter inserts
2. Breather filter of slewing gear reduction
unit,
3. Damaged items of Derrick rope pulley
and rope guides,
4. Damaged items of deflection rolls on
recovery winch,
5. Seals of door connection of switch
cabinet,
6. Lighting elements.
1. Sealing ring of lube oil filter of
auxiliary engine.
2. V belts of Auxiliary generator and
3 Half yearly 3. Breather filter cartridge of hydraulic oil
tank.
4. Filter of pump distribution gear box.
5. Faulty pressure gauges mounted behind
the cap.
1. Sealing ring of micro-fuel filter insert of

auxiliary engine.
2. Brake pads.
4 Yearly 3. Brake pads holder.
4. Carbon brushes of starter and alternator
of auxiliary engine.
5. Bearing of alternator of auxiliary engine
1. Pipes and connections of engine

mounted air compressor.
5 Two yearly
2. Worn out parts of engine mounted
compressor
1) Nozzle along with sealing washer of

6 Three yearly injectors of auxiliary engines.
B. Check list of Lubrication Points of 140 T. Crane
Maint.
S Nature of Total
Schedul Items to be Lubricated Lubricants Used Qty Remark
N item cost
e
1. Daily Nil
1. Counterweight
point cylinders.
2. Bogie hinge.
3. Slew ring.
4. Gear wheel and pinion.
5. Axle gear unit.
6. Outer gear beams.
7. Outer rigger pads.
8. Super structure locking
device.
9. Bogie side bearers.
2 Monthly Grease (Servogem EP- 2)
10. Jib support
11. Bogie pivots screw
12. Door hinges and lock in
the cab.
13. Slide trucks of seat.
14. Match truck trestle
liners
15. Match truck bogie
pivots and bolster.
16. Battery terminals
Petroleum jelly
17. Wire ropes
Graphite grease
1. Main hoist gear box. Grease (Servogem EP- 2)
2. Auxiliary hoist gear
box. Grease (Servogem EP- 2)
3. Derrick gear box. Grease (Servogem EP- 2)
4. Recovery winch
gearbox. Lubricating Oil
Half 5. Main hoist rope drum. Lubricating Oil
3
yearly 6. Auxiliary hoist rope
drum. Lubricating Oil
7. Derrick rope drum. Lubricating Oil
8. Recovery winch rope
drum. Grease (Servogem EP- 2)
9. Screw couplings and
Starter drive assembly of

4 Yearly Grease (Servogem EP- 2)
auxiliary engine
Two
5 All the above items
yearly
Three
yearly
C. Other items checked during visit:

S
Defect Noticed Attention paid
N
Pre programmed display board component(MX-4) of SLI
01 Programmed chip replaced
System
Shear pin sensor of Auxiliary Hoist was malfunctioning.
02 4-core shielded instrumentation cable between sensor Same cable was replaced
and pre-Amplifier board was defective
D. Any Emergency Visit (Within 24 Hrs. of break down):

Maint.
S Attention to be given to Nature Total Remar
Schedul Attended or not Qty
N the system of item cost k
e
1.
2.
E. Service Charges for attention to maintenance schedules and other

repairs:
Maint.
S Attended or Nature Total Remar
Schedul Attention to be given to the system Qty
N not of item cost k
e
Auxiliary Engine
Hydraulic system including all pumps,

motors, cylinders and valves etc.
Pneumatic system and brake system etc.
1. Electrical and control system including

safe load indicator (SLI) etc.
Slewing gear, gear drives, reduction gear
units and bearings etc.
Structural items like superstructure
under carriage, bogie, Cab, match truck,
wire ropes, lifting tackles, shelves and
drums etc.
Total cost
12.36% Service Tax
Grand Total
Signature of Service Engineer - Signature of SSE (ART) AQ

Name - Name -
Date - Date -
Proforma No. ART-58
Contract Agreement No. AMC VISIT NO - …………………….

Div / M / 140T Crane / AMC dated 17/10/07 DATE OF VISIT - ……………………
(GOTTWALD MAKE)
F. List of “Must Change” Items of 140 t .Crane (except main engine) to be replaced during
1 Daily Nil
2 Monthly Nil
3 Half yearly
6) Gear box oil of
4 Yearly
3) Hydraulic oil,
6 Three yearly Nil
G. List of Items of 140 T Crane to be replaced on “Condition Basis” (except main engine)

rotary lead through
1 Daily
10. Jib rope pulley
locks
12. Cab glass panes
unit,
and rope guides,
recovery winch,
cabinet,


auxiliary engine.
tank.
the cap.

auxiliary engine.
7. Brake pads.

5 Two yearly
compressor

H. Check list of Lubrication Points of 140 T. Crane
S Maint. Nature of Total
Items to be Lubricated Lubricants Used Qty Remark
N Schedule item cost
1. Daily Nil
18. Counterweight Grease (Servogem EP- 2)
point cylinders.
19. Bogie hinge. Grease (Servogem EP- 2)
20. Slew ring. Grease (Servogem EP- 2)
21. Gear wheel and Grease (Servogem EP- 1)
pinion.
22. Axle gear unit. Grease (Servogem EP- 2)
23. Outer gear beams. Grease (Servogem EP- 2)
24. Outer rigger pads. Grease (Servogem EP- 2)
25. Super structure Grease (Servogem EP- 2)
locking device.
2 Monthly 26. Bogie side bearers. Grease (Servogem EP- 2)
27. Jib support Grease (Servogem EP- 2)
28. Bogie pivots screw Grease (Servogem EP- 2)
29. Door hinges and lock Grease (Servogem EP- 2)
in the cab.
30. Slide trucks of seat. Grease (Servogem EP- 2)
31. Match truck trestle Grease (Servogem EP- 2)
liners
32. Match truck bogie Grease (Servogem EP- 2)
pivots and bolster.
33. Battery terminals Petroleum jelly
34. Wire ropes Graphite grease
11. Auxiliary hoist gear
box. Grease (Servogem EP- 2)
13. Recovery winch
gearbox. Lubricating Oil
14. Main hoist rope drum. Lubricating Oil
3 Half yearly
15. Auxiliary hoist rope
drum. Lubricating Oil
17. Recovery winch rope
drum. Grease (Servogem EP- 2)
18. Screw couplings and

auxiliary engine
Two
yearly
Three
yearly
I. Other items checked during visit:
Maint.
S Nature Total Remar
Schedul Defect Noticed Attention Paid Qty
N of item cost k
e
Leakage of hydraulic oil Complete control block
1. through MO-4 control was opened and “O” Ring
block was found was replaced
Main hoist load cell
Soldering done and sensor
2. sensor was defective due
made functional
to soldering worked out
Two nos. electrical
3. connectors of solenoid Connectors replaced
valve were defective
J. Any Emergency Visit (Within 24 Hrs. of break down):
Maint.
e
1.
2.
K. Service Charges for attention to maintenance schedules and other
repairs:
Maint.
S Attention to be given to the Nature Total Remar
N system of item cost k
e
Auxiliary Engine
Hydraulic system including all

pumps, motors, cylinders and
valves etc.
Pneumatic system and brake system
etc.
Electrical and control system
1. including safe load indicator (SLI)
etc.
Slewing gear, gear drives, reduction

gear units and bearings etc.

under carriage, bogie, Cab, match
truck, wire ropes, lifting tackles,
shelves and drums etc.
Total cost
12.36% Service Tax
Grand Total
Signature of Service Engineer - Signature of SSE (ART) AQ
Name - Name -
Date - Date -
SERVICE REPORT OF CUMMINS MAKE ENGINE OF 140 T CRANE OF ART UNDER AMC

Engine serial no.: 25290737 Engine model: NTA 855 LBC
Engine hours:
A. Monthly maintenance schedule:
S. Nature of
N.
BEFORE STARTING THE ENGINE:
1) Air cleaner/”O” Ring/Piping

2) Vacuum indicator
3) Aspirator tube/check valve & its
hoses/clamps
4) Turbocharger condition
AIR 5) Exhaust piping/silencer for leakage
01.
SYSTEM
6) Bolts Exhaust manifold
7) Clamp condition/fitment okay
8) Hose between air cleaner & air intake/air
intake & turbocharger
9) Pre-cleaner condition OK
2) Last 300 Hrs. Maintenance date/Hours
OIL 3) Lube oil suction pipe for leak/ crack
02.
SYSTEM
4) Oil leakage if any( specify leakages)
5) Bypass filter type/ Condition
S. Nature
System Item to be attended Qty Cost Remark
N. of Item
1) Coolant level/pH/ppm
2) Corrected ppm/pH after adding CR element
3) Water leakage if any (specify leakages)
5) Greasing fan hub/Idler pulley
6) Water pump/fan belt tension & alignment
COOLING 7) Pulley condition/Belt/Wear on pulley
03.
SYSTEM
8) Air vent line
9) Radiator H.E. condition
10) Radiator cap/Expansion Tank cap
11) Water pump suction piping for
leakage/crack
12) Shroud radiator position
1) Fuel tank cap fitted
FUEL
04. 2) Water separator draining
SYSTEM
3) Fuel leakages, if any
1) RPM meter/Cable working
2) Safety control/NRV working
3) Crank case Breather
05. GENERAL
4) Front/Rear foundation bolts
5) Guard plate fitted
6) Battery/Starter/Cables
AFTER STARTING THE ENGINE:
1) All gauges working
2) Alternator charging
3) Smoke condition
4) Sound
5) Load trial taken
6) Engine performance
7) Engine status
B. Other items checked during visit:

Defect noticed Attention paid Qty Remarks
01
02
03
04
C. Any Emergency visit:
S Maintenance Attention to be Attended or Nature of Total

Qty Remarks
N Schedules given to the system not item cost
01
02
03
04
D. Service charges for attention to maintenance schedule other repairs:
S Maintenance Attention to be given Attended or Nature of Total

Qty Remarks
N Schedules to the system not item cost
01 AIR SYSTEM
02 OIL SYSTEM
03 COOLING SYSTEM
04 FUEL SYSTEM
05 GENERAL
06 ENGINE TESTING
Total cost
12.36% Service Tax
Grand Total
Service Engineer’s signature Signature of SSE(ART) Ajni

Name: Name:
Date: Date:

Engine hours:
S. Action
System Item to be attended Observation Remarks
N. taken

11) Vacuum indicator
hoses/clamps
AIR 14) Exhaust piping/silencer for leakage
01.
SYSTEM
17) Hose between air cleaner & air
intake/air intake & turbocharger
02. OIL SYSTEM 8) Lube oil suction pipe for leak/ crack
S.
System Item to be attended Observation Action taken Remark
N.
COOLING
03. 14) Corrected ppm/pH after adding CR element
SYSTEM
19) Pulley condition/Belt/Wear on pulley
20) Air vent line
leakage/crack
FUEL
SYSTEM
05. GENERAL
10) Smoke condition
11) Sound
12) Load trial taken
14) Engine status

Name: Name:
Date: Date:
…………………….
Div / M / LUCAS / AMC dated 16/11/07 DATE OF VISIT -
……………………
MAINTENANCE SCHEDULE SERVICE VISIT REPORT UNDER AMC FOR

DOUBLE ACTING 530 BAR LUKAS (HRE)
1) POWER PACK:
MODEL : REF NO. :
ENGINE MODEL & TYPE : ENGINE SL NO. :
Schedule Nature of Total

SN Items to be checked/Replaced Qty Remark
Periodicity item cost
Check the hydraulic, lubricating oil leakages
01
and attend if necessary.
Check the lubricating oil in the power pack
02
sump and top up/replace if necessary.
Check the hydraulic oil level and top
03
up/Replace if contaminated.
04 Clean the carburetor.
05 Clean the air filter and replace if necessary.
06 Check the operating pressure under load.
Check performance of the power pack by
07
operating the re-railing system under load.
08 Check the rewind starter rope condition.
09 Check the condition of power pack hand valve.
Start the power pack and observe any abnormal
10
sound.
Check all fastenings like bolts and nuts of
11
power pack.
12 Check any damages to the power pack.
HRE
Check whether there are any loose hydraulic
Manual
13 screw connections on the devices and hoses,
para 13110
tighten them if necessary
page-18
Check the mechanical parts, valves and hoses
14 ”
of power pack for mechanical damage.
Check whether the signs , warnings, operation
and control symbols and other markings
15 ”
(Colour markings) are complete and perfectly
legible..
Check whether all safety covers(Engine:
protective cover, exhaust pipe cover), hoop
16 ”
guard etc. are available and in perfect
condition.

OEM Manual
page-4
17 Daily Clean finger guard and around muffler

18 50 hrs. Clean and inspect spark arrester
19 100 hrs. Replace air cleaner cartridge
20 100 hrs. Replace oil filter
21 100 hrs. Replace in line fuel filter
22 100 hrs. Clean cooling system
23 100 hrs. Clean or Replace spark plug
Replace Extended life series air cleaner
24 200 hrs.
cartridge
25 200 hrs. Check valve clearance
2) CONTROL TABLE:
MODEL : REF NO. : Sr. No. :


Attend any leaks from control table like hand
02
valves, traverse pin valve and couplers etc.
Check system pressure in pressure gauge under
03
load (i.e. 530 Bar)
04 Check any damages to the control table
HRE
Manual Check whether there are any loose hydraulic
05 para 13110 screw connections on the devices and hoses,
page-18 tighten them if necessary
” Check the mechanical parts, the valves and the

06
hoses of control table for mechanical damage.
” Check whether the signs, warnings, operation
07 and control symbols and other markings (colour
markings) are complete and perfectly legible.
” Check whether all safety covers are available
08
and in perfect condition
3) JACKS:


Remove the piston guard plate and clean the

02 guide ring top for any dust or foreign particles
on the plate
Check performance of Jacks under no load at
03
system pressure
Check for any hydraulic oil leakages under no

04
load and attend if necessary
Check any scratches and damages on piston

05
surface
06 Tighten the base plate holding bolts if required
07 Check all fastenings like bolts and nuts of Jack
HRE
Manual Check whether each single piston retracts
08
para 11.1 smoothly?
page-21
Check whether there are any loose hydraulic
09 ” screw connections on the devices and hoses
tighten them if necessary.
Check the mechanical parts, the valves and the
10 ”
hoses of cylinders for mechanical damage.
Check whether the signs, warnings, operation

11 ” and control symbols and other markings(colour
markings) are complete and perfectly legible.
Check whether all safety covers are available

12 ”
and in perfect condition
Check the condition of the accessories (Base

13 ”
plates, header plates etc.)
4) HYDRAULIC HOSES:

01 Clean all the couplings, Hoses & Dust Caps
Check any crack on the hoses and replace if

02
necessary
Check all couplers of the hoses and replace if

03
damaged
Check all the hoses under load/No-load at

04
system pressure
Check any oil leaks from joints and couplings

05
and attend if necessary
06 Store the hoses on roller drum
Visual checks to be carried out for following
possible defects
a. Damages of the surface and the
interior ( e.g. chafe marks, cuts
or fissures)
b. Embrittlement of the
surface(Fissuration of the hose
material)
OEM
c. Deformation like separation of
Manual
07 material layers, blister
Para 5.1
formation, squeezing or break
Page.7
spots
d. Leakage points
e. Emerging of the hose from the
end fittings
f. Damages or deformations of the
end fittings
g. Corrosion of the end fittings or
the metal inlets
5) ROLLER CARRIAGE with built in Traversing unit:
MODEL : REF NO. :

Clean all the couplings, out side surfaces &
01
Dust Caps
Check the traversing unit under No-Load at

02
system pressure
Check any leak from Piston and Couplers and

03
attend it
Check any scratches on Piston and replace if
04
necessary
Check any damages of notches and edges of the
05
roller carriage and attend it
Check the catch of the Traversing Jack and

06
grease the catch pin
6) RE-RAILING BRIDGE:


01 Clean the surface of the bridge
Check edges and holes of the bridge and

02
attend/Replace if necessary
03 Check all handle fastenings like bolts and nuts
7) STACKING SET :


01 Clean all stacking rings and pistons
Check stacking rings, Pistons and Fork lever

02 for any structural damage and replace or
rectify.
8) AXLE PUSHER :

01 Clean the surface of the frame
02 Check all fastenings like bolts and nuts

9) TILTING SET :

on the plate
Check performance of Jacks under No-Load at
03
system pressure
Check for any hydraulic oil leakage under No-

04
Load and attend it
Check any scratches and damages on Piston

05
surface
06 Check all fastenings like bolts and nuts of Jacks

Check Radius plate and rectify or Replace if
07
damaged
10) LIFTING BELT & CLAW JACKS :


Check the condition of Lifting belt and Holding
01
rope, replace if damaged
02 Check for rusting, clean and apply grease
on the plate
04
system pressure

Check for any hydraulic oil leakages under No-

05
Load and attend it.
06
surface
07 Check all fastening like bolts and nuts of Jacks
08 Check condition of claw jack base plate
09 Check condition of shackle
10 PULLING DEVICE :


on the plate
03
system pressure

04
Load and attend it.

05
surface
06 Check all fastening like bolts and nuts of Jacks
Check condition of Pulling rope, holding ropes,
07
shackle and Rail attachments
11 HAND PUMP :

01 Clean the couplers and Hand Pump

Check the performance of Hand Pump under
02
No-Load or Load at system pressure
03 Check the oil level, top up if required

04
Load and attend it
Check all fastenings like bolts and nuts of Hand

05
Pump
12 AIR COMPRESSOR FOR 40 T AIR BAG [ KAESER MAKE]:

0.5
01 Check the crankcase oil level. Consumable
lit.
02 Daily+ Drain condensate from the air receiver.
Drain condensate from the pressure
03
regulator.
Check all electrical terminals & tighten if
04 50 h after
necessary.
initial start
up Consumable 0.5
05 Change the compressor oil.
lit.
06 Check & clean the air filter.
Every 500
07 h at least Check & clean the check valve.
once a year
08 Check the pressure relief valve.
09 Variable Change the compressor oil. Consumable 0.5
lit.
10 Every Check correct function of the cylinder head
3,000 h & valves.
11 Change the motor bearings.
Every
12 10,000 h Carry out a general compressor overhaul.
13 POWER TESTING :

Connect the hoses of HRE system, Start the
01 Step-1 Power pack and close the drain valve of the
power pack
Close the drain valves of the control table while
all the 3/3 way valves are in neutral position.
02 Step-2
The pressure at the gauge on control table
should be 500 to 530 Bar
Operate the control valves of 3/3 way valves to
lifting position. After position of Jacks fully
03 Step-3
extended, read the pressure at the control table.
It should be 500-530 Bar
At fully extended position of the jack, the
gauge on the control table will indicate 500-530
Bar pressure. Check the cylinder for any
leakage(from coupling connectors and
04 Step-4
from/between Piston and guide ring). In case
any irregularity is observed, the repair should
be carried out as per the instructions provided
in trouble shooting portion of OEM Manual.
Service Charges for attention to 01 set 530 Bar Double acting Lukas Make HRE consisting of 20
Nos. Jacks, Power Pack, Control Stand, Roller Carriage along with Air Compressor for Lifting
Air Bag and sub assemblies of equipments

Power Pack
Control Table
Hydraulic Jacks
Hydraulic Hoses
Roller Carriage with Built in Traversing Unit
Re-Railing Bridges
Stacking Set
01
Axle Pusher
Tilting Set
Lifting Belt and Claw Jacks
Pulling Device
Hand Pump
Air Compressor
Power Testing
Total cost
12.36% Service Tax
Grand Total
PARTS NEEDS TO BE REPLACED :

S Description Part Reference Nature of Quanti Total Remarks
N No. item ty cost
0
1
0
2
0
3
0
4
0
5
SERVICE ENGINEER’S COMMENTS :
CUSTOMER’S COMMENTS :
Name - Name -
Date - Date -

…………………….
Div / M / 140T Crane / AMC dated 17/10/07 DATE OF VISIT -
……………………
(GOTTWALD MAKE)
List of “Must Change” Items of 140 t .Crane (except main engine) to be replaced during

1 Daily Nil
2 Monthly Nil
3 Half yearly
9) Gear box oil of
4 Yearly
5) Hydraulic oil,
6 Three yearly Nil
L. List of Items of 140 T Crane to be replaced on “Condition Basis” (except main engine)

rotary lead through
1 Daily
16. Jib rope pulley
locks
18. Cab glass panes
unit,
and rope guides,
recovery winch,
cabinet,


auxiliary engine.
tank.
the cap.

auxiliary engine.
12. Brake pads.

5 Two yearly
compressor

M. Check list of Lubrication Points of 140 T. Crane
Maint.
Schedul Items to be Lubricated Lubricants Used Qty
N of item cost k
e
1. Daily Nil
35. Counterweight Grease (Servogem EP- 2)
point cylinders.
36. Bogie hinge. Grease (Servogem EP- 2)
37. Slew ring. Grease (Servogem EP- 2)
38. Gear wheel and Grease (Servogem EP- 1)
pinion.
39. Axle gear unit. Grease (Servogem EP- 2)
40. Outer gear beams. Grease (Servogem EP- 2)
41. Outer rigger pads. Grease (Servogem EP- 2)
42. Super structure Grease (Servogem EP- 2)
locking device.
2 Monthly 43. Bogie side bearers. Grease (Servogem EP- 2)
44. Jib support Grease (Servogem EP- 2)
45. Bogie pivots screw Grease (Servogem EP- 2)
46. Door hinges and lock Grease (Servogem EP- 2)
in the cab.
47. Slide trucks of seat. Grease (Servogem EP- 2)
48. Match truck trestle Grease (Servogem EP- 2)
liners
49. Match truck bogie Grease (Servogem EP- 2)
pivots and bolster.
50. Battery terminals Petroleum jelly
51. Wire ropes Graphite grease
20. Auxiliary hoist gear Grease (Servogem EP- 2)
box.
22. Recovery winch Grease (Servogem EP- 2)
gearbox.
Half 23. Main hoist rope drum. Lubricating Oil
3 Lubricating Oil
yearly 24. Auxiliary hoist rope
drum.
26. Recovery winch rope Lubricating Oil
drum.
27. Screw couplings and Grease (Servogem EP- 2)
auxiliary engine
Two
yearly
Three
yearly
N. Other items checked during visit:
Maint.
Schedul Defect Noticed Attention Paid Qty
N of item cost k
e
O. Any Emergency Visit (Within 24 Hrs. of break down):

Maint.
e
1.
2.
P. Service Charges for attention to maintenance schedules and other
repairs:
Maint.
S Attended or Nature Total Remar
Schedul Attention to be given to the system Qty
N e
not of item cost k
Auxiliary Engine
Hydraulic system including all pumps,

motors, cylinders and valves etc.
Pneumatic system and brake system etc.
Electrical and control system including

1. safe load indicator (SLI) etc.
Slewing gear, gear drives, reduction gear

units and bearings etc.

under carriage, bogie, Cab, match truck,
wire ropes, lifting tackles, shelves and
drums etc.
Total cost
12.36% Service Tax
Grand Total
Name - Name -
Date - Date -

Engine hours:
S. Nature of
N.

20) Vacuum indicator
hoses/clamps
AIR
01. 23) Exhaust piping/silencer for leakage
SYSTEM
26) Hose between air cleaner & air
intake/air intake & turbocharger
OIL 13) Lube oil suction pipe for leak/ crack
02.
SYSTEM
S. Nature
System Item to be attended Qty Cost Remark
N. of Item
COOLING
03. 26) Corrected ppm/pH after adding CR element
SYSTEM
31) Pulley condition/Belt/Wear on pulley
32) Air vent line
leakage/crack
FUEL
SYSTEM
05. GENERAL
17) Smoke condition
18) Sound
19) Load trial taken
21) Engine status

Name: Name:
Date: Date:
Proforma No. ART-59
(C&W)
TRIP SCHEDULE EXAMINATION
Coach No. Date:
S
Items attended Remarks
N
01. Coaches washed from outside and inside thoroughly.
02. Examination of under frames
03. Examination of bogie frames
04. Examination of springs
05. All under gear components examined and repaired.
06. All moving rubbing parts lubricated.
07. Dash pot oil checked.
08. Wheel tyre profiles visually examined and gauged.
09. Alarm signal apparatus tested.
10. Brake gear checked and adjusted that the piston stroke is
within the limit.
11. Testing of air brake system including SAB, DV and angle

cocks.
12. Doors & Window fittings checked.
13. Vestibule assemblies checked.
14. Water pipe connection, flushing valves checked.
15. Disinfected of coaches
Signature of Fitter: ------------------------------ Signature of Supervisor: ------------
Date:---------------------------------------------- Date:--------------------------------------
Proforma No. ART-60
(C&W)
SCHEDULE 'A' EXAMINATION PROFORMA [EVERY MONTH]
Coach No. Date:
S
Items attended Remarks
N
01. All under gear components examined
02. All moving rubbing parts lubricated.
03. Dash pot oil checked
04. Side bearer bath oil checked
05. Wheel tyre profile visually examined.
06. Alarm signal apparatus tested.
07. Brake gear checked & Piston stroke within the limit.
08. All items of door fastening & window safety catches checked.
09. Water pipe connections, flushing valves, cocks checked.
10. Air brake system including SAB, DV tested for proper functioning.
11. Intensive cleaning of coaches.
12. Intensive cleaning of lavatory pans and commode with vim.
13. Painting of commode chutes from inside and outside with black paint.
14. Thorough flushing of tanks.
15. Thorough dis-infection of all compartments.
16. Examination and replacement, where necessary of brake gear pins,
split pins, safety loops/brackets
17. Examination for wear and replacement where necessary, of brake
hanger pins, brake block and brake heads.
18. Thorough inspection and repairs of draw gear.
19. Thorough inspection and repairs of buffers.
20. Inspection and repairs of commode Chutes.
21. Testing of air brake system for proper application and releasing time
of brake cylinders and manual releasing.
22. Coaches washed and cleaned thoroughly from out side and inside.
Date:---------------------------------------------- Date:--------------------------------------
Proforma No. ART-61
(C&W)
SCHEDULE 'B' EXAMINATION PROFORMA [Three Monthly]
Coach Nos. Date:
Remarks
SN Items attended
01. All items of schedule 'A'
02. Greasing of laminated bolster springs of ICF coaches with

soft graphite grease.
03. Painting of lavatories from inside.
04. Thorough inspection and repairs of brake gear components.
05. Examination, over hauling and testing of alarm chain

apparatus.
06. Testing & repairs of roof.
07. Thorough checking of trough floor, turn unders etc from

underneath for corrosion.
08. Touching up of painting if faded or soiled.
Date:---------------------------------------------- Date:--------------------------------------
Proforma No. ART-62
Standard Proforma for Scale of Rations for ART/SPART:
(Based on Apendix-IV of committee’s report of 1985)
Scale of ration propsed for 40 break down staff attached to the ART, to be purchased from local market and
replaced after every trip. Additional items may be procured as per requirement only.
1.0 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.
2.0. Cooked Vegitables : 40 Kg.
a. Potatos : 19.5 Kg.
b. Beson (flour) :7.0 Kg.
c. Onions :1.0 Kg.
d. Ground nut oil :1.8 Kg.
3.0. Tea for 60 Cups
a. Tea dust : 0.305 Kg.
b. Sugar : 3.2 Kg.
c. Milk : (As per requirement)
4.0 Cooked Rice : 20 Kg.
a. Raw Rice : 08 Kg.
5.0 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.
6.0 Salt for Service : 1.0 Kg.
7.0 Condensed Milk : 10.0 Tins
8.0 Other common items : (As per standard Proforma)
a. Biscuits : 12 Packets (each packet 300 gms.)
b. Papad : 05 Packets
c. Water Bottels : 300 Botteles
d. Pickle : 01 Kg.
e. Beaten Rice : 5 Kg.
f. Nutreala : 10 Packets ( each packet 200 gms.)
g. Ground Nut : 2.0 Kg.
h. Moong Dal Badi : 10 Packets (each packet 200 gms.)
i. Glucon D : 02 Kg. (Only for summer season)
j. Green Vegitables : As per requirement at site
Note: Potatos and Onions may be replaced every two weeks if not used. Scale fixed jointly by maintenance loco
Inpector/Incharge of Break Down & the commercial inspector of BSL Div.(Apendix-IV of 1985).
Proforma No. ART-63
Proforma for ART/ARME/SPART Imprest Expenditure & Accountal Register
Date of Quantity Voucher/Invoice Total Sig of Sign of

Description Required
SN purchase of item No. cost SSE/ART controlling
of Item for
officer
Proforma No. ART-64
Proforma for maintaining Fuel & Lubricant Consumption
Type of Oil:
Quantity Quantity Available Remarks for Quantity Sign of

Date of Mode of Received Issued balance consumption released ART
SN
purchase purchase if supervisor
available
Proforma No. ART-65
Sign of
Controlling
officer
Sig. of ART
Incharge
Reason for
Delay
Shed arrival
Departure
out Stn.
Yard
Time Left
Accident site
Time work
Completed
Time work
Proforma for Log Book of ART/SPART/ARME
started
Arrival at
Accident
Spot
Spot
Departure
for Accident
spot
Avg. Speed
Time on Run
Destination
arrival
Sattion
Departure
Station
Arrival
Line
Departure
Time of
Ready
Time of
Ordering
Time of
Accident
Distance
in Kms
Destination
Date
SN
CHAPTER - 7
TECHNICAL
DESCRIPTION
OF
GOTTWALD 140 Te.

BREAK DOWN CRANE
TECHNICAL DATA OF 140 Te. GOTTWALD BREAK DOWN CRANE
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 sets 3000 (1500) mm
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 Te.
09 Height in transport position 3900 mm
10 Width in transport position 3100 mm
11 Elevated Curves 140 mm
Brake System
12 Primary Dual-VD-P-12X10' mZ
13 Secondary 12 wheels disk-operated brakes
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 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 bogie 1
21 Speed 20 kmph
Diesel Engine
22 Type Cummins NTA-855
23 Model 6-Cylinders in Series, water cooled
24 Out put 205 kW at 1800 rpm
25 Torque 1158 Nm at 1400 rpm
26 Fuel Supply 900 lts.
27 Generator 28 Volt, 55 Amps
28 Type Kirloskar HA-294
29 Model 2-Cylinders in series, air cooled
30 Out put 16.9 kW at 1800 rpm
Main Hoist
31 Rope Diameter 26 mm
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
37 Superstructure Speed 0-1.0 rpm
Derricking Gear
38 Type 3-Stage planetary hoist with spring
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 match truck) 24 Te.
44 Slab-2 (transported on the Match truck) 15 Te.
45 Slab-3 (transported on the undercarriage) 8 Te.
Boom
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 Te.
Duties of the 140 Te. Crane Operator:
The crane operator has the following duties -
1. He must check whether the brakes and the emergency limit switches function prior to
commencing work. He must watch the condition of the crane for any visible defects.
2. He must see to it and ensure that the power to the over head lines is switched off prior to
commencing work on the crane.
3. When he notices any defects which could be dangerous for operating safety, he must stop
crane operation.
4. He must report any defects on the crane to the supervisor responsible and to his replacement on
shift change.
5. He must ensure that all the controls are brought in to neutral or idling position prior to
supplying power to the drive assemblies.
6. He must ensure that all the controls are brought in to neutral or idling position and that the
power is shutt off prior to exiting the control stand.
7. He must ensure that the crane is parked safely according to regulations when crane operating
and crane travel operation have been completed.
8. 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.
9. If the crane operator can not 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.
10. The Crane operator must provide warning signals when required.
11. Loads or lifting gears must not be moved above persons during any crane motions
12. 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.
13. As long as load is suspended on the hook, the crane operator must keep his hands near the
controls.
14. The emergency limit switches must not be activated intentionally during operation.
15. The crane operator must ensure that all the doors are closed and locked during travel.
16. Cranes may not be subjected to stress beyond the respective highest permissible loading.
Load Chart for Gottwald 140 Te .Break Down Crane
CHAPTER - 8
DO’S AND DON’TS

FOR
140 Te. CRANES
140 Te. GOTTWALD
BREAK DOWN CRANE
DO’S AND DON’TS

Repercussion if
SL
DOs/DONTs
No DOs DONTs
are not
:
followed
1 TO BRING THE CRANE IN TRAIN ORDER BEFORE LEAVING THE SHED
Travel gear should be in dis– Do not leave Axle blocking in Travel gear will
engaged position “ON” position get damaged and
suspension
system will not
Work
a)
Crane Brake should be released with Do not pull the crane when Wheel will get
indication as “GREEN” indication is “RED”, in any skid due to
case. brake binding.
b)
Boom should be locked in trestle. Do not leave the boom unlock Auxiliary boom
in trestle. head & pulley
will get damage.
c)
All side-mounted platforms should Do not leave the side mounted

be lowered and outriggers should be platform & outriggers in
folded and locked properly. unlocked position.
d)
2
Check for Hyd. Oil, Fuel Oil,
Engine Lub oil, Radiator water level
and Oil level in all the gearboxes.
e)
Check function of Aux. Engine.
f)
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 eg. Hook height, slewing
range, space for travelling the load
etc. These should be in
conformation with the load chart
and with reference to the site
condition for propping.
a)
3
All stop valves for Hyd. Lines Do not leave any of the stop The pumps may
should be opened before starting the valves closed. get damaged or
engine. the Hyd. System
will size.
b)
Before starting the engine check for Do not allow the Hyd. Level to Hyd. Pump may
Hyd. Oil, Fuel Oil, Engine Lub oil, go below the lower level be affected.
Radiator water level, Oil level in all indicator.
the gearboxes and battery water
level.
c)
After starting the engine check

Engine Lubricant oil pressure and
battery charging current.
d)
Check for pilot pressure, it must be

30 bars.
e)
4
Check for AIR pressure, it should Do not leave any air leakage in Air braking will
like between 6.5 –7.5 bars. the system. be difficult.
f)
3 AXLE BLOCKING
Ensure engagement of the travelling
gear.
a)
Ensure application of 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 revving and unreeling of the
derrick wire rope.
b)
5
c) Derrick “IN” until boom heels sit on
the PINs.
Remove boom lock from the jib
trestle.
d)
Raise boom cautiously as per usual

practice.
e)
5 PROPPING THE CRANE

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

level.
6
6 COUNTERWEIGHT
Select the total counterweight with
proper assessment of load, in
consultation with the load chart.
a)
Switch on boom bridging key. 5-

meter limit switch should remain
activated.
b)
c) Switch ON key switch, 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 position by Wrong selection

selector switch as per required of causing major
load chart. accident e.g.
toppling of
e) crane.
7
Switch on S.L.I. switch key to bring
the computer safety system back in
the circuit. Check the correct mode
of stability.
f)
g) Switch on boom key switch, so that

5.5 mm limit switch is in circuit.
Check if safe load indicator is in

operation
h)
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 unit
of the SLI system.
i)
Load chart should be followed in Do not miss to consult load The current may
j) Toto. chart in any condition of be subjected to
working. unsafe working.
After Rear operation or axle Avoid parallel operation of U/C
blocking operation pre-selector or gallows and derricking or
k)
switch for oil transmission should be hoisting.
brought “Neutral” position.
8
Before starting work make sure that
computer override key and boom
override key are switched to
working position.
l)
Ensure the CWT switch is on proper

position.
m)
7 OPERATION
Ensure proper selection of lifting
tackle (Chain & Wire rope sling).
a)
Avoid jerk during operation. Don’t pull the load diagonally.

Pendulum motion of load not
b)
permitted. Avoid diagonal pull of
the load.
Pull the load which are stacked in Don’t pull loads which are
the ground cautiously. It is ensure stuck in the ground without
c)
that it will not offer resistance close supervision.
beyond the capability of the Crane.
Take care of High wind forces on
d)
the boom as it is dangerous.
9
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 load.
f)
8 DERIGGING THE CRANE:

Leave 8T cwt on the chassis in the
direction of match truck.
a)
Unload CWT On the match Truck
b)
Boom out to 17M radius. At this

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

key.
10
Boom down until both hooks lower
into match truck well.
f)
Travel crane until boom rest pin

g)
Boom down until boom slides fully

into the boom rest to the lock
position. At this point, lock the
boom in the trestle.
h)
Unlock rear section with the help of

lever.
i)
Lower rear section according to its

j)
last position.
Derrick out untill the ropes are slack
over the operator’s cab. This
derricking out should be retrcted by
k) “minimum number of turns on
drum” limit switch ( the setting
should be for slackness just
adequate to negotiate designed track
curve)
11
OFF Axle blocking.
l)
9 PREPAIRING CRANE FOR TRANSPORT

Parking brake “ON”
a)
Brake hoses should be connected as

per the requirement.
b)
Release parking brake in the last Do not forget releasing parking

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

schedule.
11 MAINTENANCE OF HYDRAULIC SYSTEM
Clean hoses and area, around the Do not open the Hyd. System
equipment, to be opened. Clean the in a dirty environment.
tray in which the open parts are
kept.
a)
12
Do not over tighten any leaking
b) joints provided with “O” rings/
seals.
Connected isolating valves must be
closed before opening out any 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
diametrical reduction in its size by
5% or more with respect to its
normal diameter.
a)
Replace wire rope if there is any

bend, kink, abrasion, and uncoiling
or heavy corrosion.
b)
13
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.
d) Proper greasing of wire rope around Corrosion of
fitting clamps / sockets should be wire rope will
done. take place.
13 MAINTENANCE PRECAUTION FOR SAFETY DEVICES
All limit switches, force and angle Don’t disturb the switching
sensors must be cabled. point of the limit switches.
Damaged cables must immediately
be replaced. They should always be
kept operational.
a)
Check all limit switches when Do not operate computer over

rigging to ensure their functioning. bridge key and boom over
bridge key during crane
working. These are only
operated at time of rigging / de-
rigging.
b)
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 admissibility
of the operation according to be
lifting chart.
c)
14
140 Te. COWANS SHELDON
BREAK DOWN CRANE
DO’S AND DON’TS
INDEX
Sr. Description Page

Nos.
1 DO’s for Operation 1-6
2 DON’Ts for Operation 7-9
3 DO’s for Air Brake (General) Operation 10-11
4 DO’s for Self Propelling Mode Operation 12-13
5 DO’s for Air Brake (Train Formation) Operation 14-15
6 DON’Ts for Air Brake Operation 16
7 DO’s for Hydraulic Operation 17-19
8 DON’Ts for Hydraulic Operation 20-21
9 DO’s for Electrical (General) Operation 22
10 DO’s for Electrical (Starting Main Engine) Operation 23-24
11 DO’s for Electrical (Starting Auxiliary Engine) Operation 25-26
12 DO’s for Main & Auxiliary Hoist Operation 27
13 DO’s for Derrick Operation 28
14 DO’s for Slewing Operation 29
15 DO’s for Hauling Operation 30
16 DO’s for Traveling Operation 31-32
17 DON’Ts for Electrical Operation 33-34
18 DO’s for Safe Load Indicator (SLI) Operation 35-37
19 DON’Ts for Safe Load Indicator (SLI) Operation 38-39
DO’s for Operation
140T Breakdown Cranes of Cowans Sheldon New Design
Sr. DO’s Illustration
No
1 Ensure crane operator is competent
and acquainted with load charts.
2 Before raising Jib from Match Truck-

(i) Lower Axle Blocking jacks to lock top of
the spring.
(ii) Engage blocking pads.
3 When working in propped condition,

ensure -
(i) Parabolic Springs are relieved of the
weight of the crane and lock the
Outriggers in extended position.
(ii) Packings are in sound condition and

placed alternately perpendicular and
parallel to the track. Check condition
of packings for indication of sinking.
1
No
4 While raising "A" frame, keep Derrick
Wire Ropes in reasonably slack
condition.
5 Prior to lifting any load, ensure-

(i) Correct counterweight duty selection.
(ii) There are no kinks in chain/wire ropes.
(iii) Correct slinging and proper securing of

sling hooks.
6 While lifting load -

(i) Work crane with shortest possible
radius.
2
No
(ii) Use Rail Clips.
(iii) Watch packings under props, all

wheels of crane, condition of rail fish
plates and soil formation under the
crane
7 Remove Slew Lock Pin before Slewing

operation.
8 Before moving crane to other

position-
(i) Raise Outrigger Jacks.
(ii) Remove Footsteps, retract extension

cylinder, swing-in swing cylinder and
lock them in position.
3
No
9 When working Free-On-Rail, travel
keeping the jib parallel to the track.
10 Before any self propelled movement of

crane, ensure engagement of travel
Clutches and test proper functioning of
travel Brakes.
11 When working in electrified section,

follow laid down procedures and
precautions.
12 When lowering "A" frame, keep

Derrick Wire Rope in a reasonably tight
condition.

(i) Remove Counter Weights and place at
nominated location on Match Truck.
4
No
(ii) Unload the Crane Springs by retracting

Axle Blocking Jacks and ensure
sufficient gap between top of Spring
Buckle and Jack.
(iii) Disengage traveling Clutches.
(iv) Ensure Outrigger Jacks and Outriggers

are retracted fully and locked in
position.
(v) Ensure that Slew Lock Pin is in locked

position
14 While hoisting or lowering, keep a

watch on wire ropes for slackening or
bird caging.
5
No
15 Ensure sufficient fuel oil level.
16 Before operating Hauling Winch,

ensure that Crane is in line and Slew
Lock Pin is in locked position.
6
DON’Ts for Operation
Sr. DON’Ts Illustration
No
1 Do not loose shunt the crane under
any circumstances.
2 Do not attach crane to a train until it is

in proper running order.
3 Do not operate two cranes of unequal

lifting capacity together to lift any
heavy load unless the lifting capacity of
the smaller crane is at least half the
weight to be lifted.
4 Do not exceed 10 seconds of

continuous cranking of Engine and
pause before making another attempt.
5 Do not operate the Engine any longer

than is absolutely necessary when any
of the warning systems are activated.
Do not restart until the fault is
corrected.
7
No
6 Do not operate crane unless load /
radius / slew degree / prop positions
are ascertained as per load chart.
7 Do not exceed safe working load of the

crane / rated capacities during normal
operation.
8 Do not lift Match Truck and slew in

Free-On-Rail condition.
9 Do not allow jib to lift from trestle until

"A" frame is fully erected.
10 Do not slew crane on gradient / super

elevated track without propping.
8
No
11 Do not generate a swinging load by
excessive braking and suddenly
returning the Joystick to neutral
position while slewing.
12 Do not allow anyone between

outrigger and undercarriage while
setting outriggers.
9
DO’s for Air Brake (General) Operation
No.
1 Drain moisture from reservoirs
regularly.
2 Ensure angle cocks are ‘closed’ or

‘open’ as required.
3 Keep hose pipes with couplings on

dummy plugs.
4 Keep Isolating cocks (B4 & A4) ‘open’.
5 Keep Emergency brake valve (B-2)

‘closed’.
10
No.
6 Keep Distributor valve (B16) in ‘ON’
position by isolating cock control lever.
7 Check system pressure in the duplex

pressure gauge.
8 When system pressure reaches 3.8

Kg/cm2, check that parking brakes are
released.
9 Check Brake pipe pressure on the

duplex pressure gauge is 5 Kg/cm2
when driver's brake valve (B-1) is in
released position.
10 Before coupling feed pipe and brake

pipe hoses of crane with Match Truck
or Loco, open angle cocks for a while
to drain the moisture and dirt.
11
DO’s for Self Propelling Mode Operation
No.
1 Keep Goods/Passenger brake control
lever (B-20) in ‘Passenger mode’.
2 Keep Isolating Cock control lever (B-

19) in ‘ON’ position.
3 Keep Isolating Cock (B-23) (connected

with the Distributor Valve) ‘open’.
4 Keep Isolating Cocks (B-23) for service

brake and parking brake ‘open’.
5 Keep Isolating Cock (B-4) in driver's

cabin and (A-4) in superstructure
‘open’ and Emergency brake valve (B-
2) ‘closed’.
12
No.
6 Keep Angle cocks of feed pipe and
brake pipe ‘open’ when Match Truck is
coupled with crane. Keep Angle Cocks
of other end ‘closed’.
13
DO’s for Air Brake (Train Formation) Operation
No.
1 Connect Feed Pipe and Brake Pipe of
Crane with those of Match Truck and
other end of Match Truck with
Locomotive. ‘Open’ angle cocks and
keep Angle Cocks of other end ‘closed’.
2 Keep Isolating cock control lever (B-19)

in ‘ON’ position.
3 Keep Goods/Passenger brake control

lever (B-20) in ‘Passenger mode’.
4 Keep Isolating Cock (B-4) in driver's

cabin in ‘Closed’ position. Make sure
that Emergency brake valve (B-2) is in
‘closed’ position.
5 Keep Driver's Brake Valve (B-1) in

Driver's Cabin in brake release
position.
14
No.
6 Keep Isolating Cock (B-23) connected
with Distributor Valve ‘open’.
7 Keep Isolating Cocks (B-23) for service

brake and parking brake ‘open’.
8 Check brake applications several times

before moving the crane.
9 Make sure that brake blocks are

released from wheels after releasing
brakes.
15
DON’Ts for Air Brake Operation
No.
1 Do not release parking brakes
manually till crane is ready to be
hauled by a Locomotive.
2 Do not put Isolating Cock (B-23)

connected to the parking brakes in
‘closed’ position.
3 Do not travel Crane till brake pipe

pressure reaches 5 Kg/cm2. Wait for
about 30 seconds in passenger mode
and 70 seconds in Goods mode for
allowing brakes to release.
4 Do not put Isolating Cock control lever

(B-19) in ‘closed’ position. It should
always be kept in 'ON' position during
‘IN-TRAIN’ formation.
16
DO’s for Hydraulic Operation
No.
1 Ensure hydraulic oil level in hydraulic
tank on oil level gauge is between low
and high mark.
2 Hydraulic oil filling- connect

detachable coupling between oil drum
and Hydraulic tank, top up oil by semi
rotary hand pump up to level. Remove
detachable coupling. Drain
approximately 55 liters of oil from
tank drain.
3 Ensure change over lever on D800

junction box is in Main Engine /
Auxiliary Engine position as required.
4 Ensure travel clutch is in disengaged

position for all operations except self
travel motion.
5 Follow correct sequence of operations

for propping the Outriggers – i.e.
i) Unlock Outrigger, swing out & lock
ii) Extend extension cylinder & lock
iii) Finally extend outrigger jack
17
No.
6 When retracting outriggers, first
retract jack, then unlock & retract the
extension cylinder and then remove
lock pin before swinging in. Lock
outrigger in stowing position.
7 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.
8 Ensure proper engagement of

counterweight lifting cylinders in the
slots.
9 Ensure counterweight (CWT) lock is in

correct position.
10 When using hand lever operations for

lifting counterweight (CWT) to bring it
in fully lifted position, ensure that only
lifting operation is done.
18
No.
11 When using hand levers on L010 Block
(PVG120/6) for all operations, ensure
proper supervision.
19
DON’Ts for Hydraulic Operation
No.
1 Do not operate the engine below low
hydraulic oil level.
2 Do not operate emergency system

without changing lever on D800 Block.
3 Do not travel in convoy without

disengaging travel clutch.
4 Do not extend outrigger before

swinging out.
5 Do not swing in the outrigger before

retracting outrigger jack and extension
cylinder.
20
No.
6 Do not lift counter weight in
improperly engaged position.
7 Do not operate crane without

ensuring proper locking of
Counterweight.
8 Do not use Counterweight hand lever

for lowering when locked.
9 Do not operate crane with hand levers

without proper supervision.
10 Do not allow any person to enter

between outrigger and carriage.
21
DO’s for Electrical (General) Operation
No.
1 Properly secure all electrical
connections using proper tools &
equipments.
2 Check and test all electrical circuits

periodically.
3 Keep Emergency stop button in ‘Pull’

position.
22
DO’s for Electrical (Starting Main Engine) Operation
No.
1 Ensure proper earthing of Battery.
2 Keep Battery Isolator Switch in `ON'

position.
3 Keep all four emergency stops in ‘Pull’

position.
4 Keep Engine Key Switch in 1st position

of engine key switch.
5 Ensure that all gauges indicate their

respective readings.
23
No.
6 Ensure correct Battery
charging/discharging indication in
Driver's Cabin.
7 Ensure that Hydraulic Filter Clogging

Indication Light is not glowing.
8 Keep Engine Key Switch in 2nd (start)

position of engine key switch.
9 Ensure that all indications are normal,

after starting the Main Engine.
10 Operate controls (Joysticks) carefully

from Driver's Cabin.
24
DO’s for Electrical (Starting Auxiliary Engine) Operation
No.
1 Keep Selector Switch in Driver’s cabin
to ‘Emergency Stowage’ position.
2 Keep Main Engine & Auxiliary Engine

changeover lever in ‘pulled up’
position for Auxiliary Engine.
3 Keep throttle cable lever in fully

pulled "out" position in Driver’s cabin.
4 Switch ON Main Battery Isolator

Switch.
5 Ensure that indication lamp is glowing

after keeping Engine Key Switch in 1st
position.
25
No.
6 Keep Engine Key Switch in ‘ON’
position.
7 Operate controls (Joysticks) with care

from Driver's Cabin.
26
DO’s for Main & Auxiliary Hoist Operation
No.
1 Set Safe Load Indicator (SLI) to Main
Hoist (M.H.) or Auxiliary Hoist (A.H.)
position as per requirement.
2 Ensure that Wire Ropes are not slack.
3 Ensure that ‘Service limits’ of Limit

switches are set within operating
range.
4 Ensure ‘Ultimate limits’ of Ultimate

Limit switches are within operating
range.

normal working condition.
27
DO’s for Derrick Operation
No.
1 Keep Selector Switch to ‘Derrick’
position.
2 Ensure that Wire Ropes are not slack.
3 Ensure that ‘Service limits’ of Limit

switches are within operating range.
4 Ensure ‘Over limit’ of Over Limit

switch is within operating range.

28
DO’s for Slewing Operation
No.
1 Keep Selector Switch to ‘Slew’
position.
2 Ensure slew lock pin is

removed/disengaged.
3 Ensure proper locking of

counterweight.

29
DO’s for Hauling Operation
No.
1 Keep Selector Switch to ‘Haul’
position.
2 Keep Slew Lock Pin in ‘locked’

position.
3 Engage Rail Clips on rail.
4 Ensure Service limits of Limit switch

are within operating range.
30
DO’s for Traveling Operation
No.
1 Keep Selector Switch to ‘Travel’
position.
2 Keep Slew Lock Pin in ‘locked’

position.
3 Keep Travel Clutch in ‘Engaged’

position.
4 Ensure that Crane is at 00 or 1800

with track i.e. ‘In Line’.
5 Keep Outriggers in ‘Stowing’

position.
31
No.
6 Keep Rail Clips on hook.
32
DON’Ts for Electrical Operation
No.
1 Do not bypass electrical circuit.
2 Do not disturb safety devices.
3 Do not tamper electrical settings of

limit switches, pressure switches and
temperature switches.
4 Do not neutralise Safe Load Indicator

(SLI) during operation.
5 Do not displace sensors from their

position.
33
No.
6 Do not conduct welding on crane
unless battery connections are
disconnected and proper earthing is
ensured.
7 Do not crank starter motor of Engine

for more than 10 seconds.
8 Do not start Auxiliary Engine when

Main Engine is running or vice-versa.
34
DO’s for Safe Load Indicator (SLI) Operation
No.
1 Ensure that the Safe Load Indicator
(SLI) system is working correctly
before starting the actual work at
site and Safe Load Indicator (SLI)
system has performed its self
diagnostic checks.
2 Ensure that different boxes / sub

assemblies of Safe Load Indicator
(SLI) system are in water proof and
good physical condition.
3 Check that the Safe Load Indicator

(SLI) shows the duty selected by
pushing start (*) button on the
system display.
4 Operate all joysticks smoothly and

without jerk. This will maintain
accuracy of readings on the display
panel of Safe Load Indicator (SLI)
system.
5 Ensure change of the hoist winch (on

SLI display) is performed only
without any load on the hooks.
35
No.
6 Crane must be used free on rails only
after fixing rail clamps on rails.
Ensure rail clamps are not under
tension.
7 Check frequently for any loose fitting

of sensors / detectors, sub-
assemblies and entire Safe Load
Indicator (SLI) system.
8 Always check crane configuration

and compare with the indications on
the Safe Load Indicator (SLI) system.
9 Ensure Crane is leveled while

working at site otherwise Safe Load
Indicator (SLI) will not give actual
position of radius and slope angle
sensing.
10 Driver must check slew angle limits

on Safe Load Indicator (SLI) system’s
display screen while working on free-
on-rail configuration.
36
No.
11 Confirm on the screen of Safe Load
Indicator (SLI) system that:
While hauling, rail clamps are
clamped to rails.
12 Ensure Slew lock pin is removed /

unlocked before starting slewing.
13 Examine following of Safe Load

Indicator (SLI) system weekly in all
respects-
Load pin on main hoist / auxiliary
hoist for security and its cable
connections.
37
DON’Ts for Safe Load Indicator (SLI) Operation
No.
1 Do not use main and auxiliary hoist
hooks at a time. Safe Load Indicator
(SLI) system will show only one
sensing at a time, which may be
incorrect.
2 Do not toggle between main and

auxiliary hoist winch (on SLI display)
with load on hooks.
3 Do not expose the components of

the system directly to pressurized
water or steam during cleaning
operation.
4 Do not operate the crane near or

below high power lines / grids, the
Safe Load Indicator (SLI) system will
not function correctly or damages to
it may occur.
5 Avoid using the Safe Load Indicator

(SLI) system during a thunderstorm;
it may damage the sensitive parts of
the system.
38
No.
6 Do not undertake the welding work,
when Safe Load Indicator system is in
live condition or simply attached
with input power. Isolate it
completely first from both sides.
7 Do not exceed any limit, stop

immediately and check on Safe Load
Indicator system’s screen.
8 Do not use hauling winch with load

on the hooks.
9 Do not swing or oscillate the hook

load, otherwise Safe Load Indicator
(SLI) system will not show accurate
hook load.
10 Do not exceed the slew angle limit as

it can endanger stability of crane.
39
CHAPTER - 9
Operation of Hydraulic Re-Railing
Equipments [HREs]
MFD & LUKAS
INDEX
Sr Description Page
No.
9.0 MFD Re-railing system 2
9.1 Special Features 3
9.2 Hydraulic Power System 4
9.3 Small Pump sets 5
9.4 Hand Pumps 6
9.5 Control Unit 6
9.10 Single Piston Jacks EH-350 & EH-200 10
9.11 Single Piston Jacks EH-100 10
9.12 Tilting Jack 10
9.14 Re-Railing Bridges 11
9.16 Equipment for up-righting operations 15
9.17 Auxiliary Trucks 15
9.18 Accessories 16
a. Axle Pusher Unit 17
b. High Pressure Hoses 17
c. Distribution Valve 17
d. Bogie Suspensions 18
e. Rescue Devices & Accessories 18
f. Air Bags & Accessories 18
Hydraulic Re-railing Equipment of light-metal alloy with re-pressures
system [ MFD ]
Hegenscheidt-MFD re-railing system – high safety and ease of operation:
For more than 100 years, Hegenscheidt-MFD has been a reliable partner to railway organizations.
The acknowledged high level of Hegenscheidt-MFD railway technique is based on continuous and
close co-operation with the leading railway organizations in the world. Due to its intensive
dedication to the search for solutions to overcome problems occurring with railway traffic, 1926
developed re-railing equipment has become the basis of current re-railing technique all over world.
Today Hegenscheidt –MFD re-railing equipment renders its contribution to the maintenance &
restoration of railway traffic in more than 70 countries in the world.
The double-acting re-pressure system, which has already been well proved in the field of industrial
hydraulics, is also incorporated in the Hegenscheidt-MFD re-railing equipment. Thus all operations
of lifting, lowering, pushing and pulling can be completely controlled accurately to the mm and
corrected so that the maximum level of safety is achieved.
The individual components of the Hegenschidt-MFD re-railing system are adapted to each other in
relation to their size, lifting height, carrying capacity and power in such a way that they meet the
latest trends of Railway technique . Consequently, as a result, a method has been found to connect
rescue devices and air bags to the Hegenscheidt –MFD re-railing system by means of newly
developed pressure intensifiers and hydraulically driven air compressors.
The design of the system is such that according to the composition of the components all types of
rail vehicles , locomotives and power cars, steelworks cars including the heaviest vehicles can be
raised and re-railed.
Additionally this system is particularly suitable for raising and displacing bridges and other heavy
loads.
Hegenscheidt –MFD re-railing equipment can be used on both single and multi track lines. In the
case of multi track lines the secondary track is not blocked and, moreover, it is not necessary to
remove the contact wires of electrified lines.
Hegenscheidt –MFD re-railing system is subject to the highest safety requirement which is proved
by its characteristic features such as ease of operation, simple handling, stable design and stability
under load.
Special features :
 Double-acting hydraulic re-pressure system (300 bar)
 Fully controllable operations of lifting, lowering, pushing and pulling accurately to the mm
 High stability of the jacks under load due to integral bottom flange
 Hydraulically releasable return valves to secure the load against accidental lowering in case
of pressure loss (e.g) hose severance)
 Protection of the jacks against overload or mis-operation by means of two integral overload
valves per jack
 Jerk-free operation of the jacks even under full load.
 Reduced wear due to roller-burnished and hard-anodized contact surfaces
 Computer calculated designs and use of high-strength light metal alloy
 Extensive integrated jack programme covering all normally occurring modes of application
 Reliable and safe operation covering a wide temperature range of -40 degree C up to +70
degree C.
 Easy and quick connection of the individual components by means of manually screwed
hose coupling with positive colour coding
 No oil leakage during coupling or uncoupling of the jacks
 Coupling/Uncoupling also possible under load
 Light re-railing bridges manufactured from profile sections which have been computer
calculated and optimized as to static and dynamic properties
 Operation of the entire system by one operator from the control desk so that workers need
not enter the load area
 Integrated “dead man control” which ensures that each control valve immediately and
automatically goes into the natural position as soon as the operator releases the lever, this is
essential for safety reasons
 Possibility to use rescue devices by means of pressure intensifiers
 Possibility to use pneumatically operated air bags by connecting a compressor driven by its
own integrated combustion or electromotor
 All system components are weight-optimized to ensure easy portability
Hydraulic Power systems
Pump set with Order Output Oil Usable Power Length Width Height Weight**
No. itr/min. capacity capacity kW mm mm mm Kg
ltr. Ltr
Four-stroke engine* 02-4000 11.3 68 60 8.1 1160 570 785 93
Diesel engine* 02-6000 11.0 68 60 6.3 1160 570 896 108
Electric motor 02-8000 9.45 68 60 4 1160 570 900 100
Electric motor with 4fold 02-8400 9.45 68 60 4 1160 570 1200 132
control block
* also available with electric starter ** Excluding oil
Small pump sets:
The Small pump sets have been specially developed by MFD for light construction vehicles which
are mainly used by suburban transport operators. They have a reduced oil capacity, lower weight
and appropriated low price.
No. itr/min capacity capacity kW mm mm mm Kg
ltr. Ltr
Four-stroke engine 02-4020 2.88 25 20 2.9 1000 485 618 48
Four-stroke engine with 02-4220 2.88 25 20 2.9 1000 485 874 74
2-fold control block
Electric motor 02-8020 2.25 25 20 1.5 1000 485 533 55
No. itr/min capacity capacity kW mm mm mm Kg
ltr. Ltr
Electric motor with 02-8220 2.25 25 20 1.5 1000 485 874 71
Electric motor with 02-8320 2.25 25 20 1.5 1000 485 874 74
Add-on hydraulic 02-9000 Approx.10 68 60 -- -- -- -- --

** Excluding oil
Hand Pumps
The hand pump is on independent and complete unit for minor re-
railing operations particularly where no separate power supply is
available or if a pump set with combustion engine cannot be used
e.g. due to explosion hazard. Due to the re-pressure system, the hand
pump can perform all functions such as lifting, lowering, pushing
and pulling without restriction and with full working pressure of 300
bar.
Type Order Output Oil Usable Length Width Height Weight
No. cm3 capacity capacity (mm) mm Mm Kg
/Double ltr. Ltr Transport
stroke position
HP 2/20 02-1220 35 20 18 1300/680 450 730 68
2 connections
HP 2/30 02-1230 35 30 28 1300/680 450 730 75
2 connections
HP 3/20 02-1320 35 20 18 1300/680 450 730 70
3 connections
HP 3/30 02-9000 35 30 28 1300/680 450 730 77
3connections
Control Unit:
The control unit is the central point from which all operations of the
re-railing process can be controlled. It allows the connection of four
hydraulic components. This can be increased by using distribution
valves (Order No. 09-2200 and 09-2201).
It is arranged in a portable frame with stable legs. All in-built parts

are protected by a cover with integral tray for tools, etc.
Length : 790 mm
Width : 720 mm
Height : 980 mm
Lifting jack series 400:

These lifting jacks made high strength light metal alloy operate with the hydraulic re-pressure
system at 300 bar. A releasable return valve with the pressure protection at both ends is mounted on
the fixed integral bottom flange with ensures optimum stability. Thus any accidental lowering of
the load (for instance in case of hose severance) is prevented. Furthermore the lifting jacks are
completely protected against overload and pressure multiplication. Safe and jerk free operation is
guaranteed even under full load.
With all lifting jacks of low construction, it is possible to extend the stroke step by step by using
piston support pieces and cylinder support rings (support set).
Type of Jack EH 400-250 TH 400/200-250 EH 400-470 TH 400/200-470
Order 04-1041 04-1042 04-2041 04-2042
Closed height mm 250 250 470 470
Number of Pistons 1 2 1 2
Total stroke mm 122 230 320 635
Stroke I mm 122 122 320 320
Stroke II mm -- 108 -- 315
Rated force I kN 400 400 400 400
Effective force I kN 495 495 495 495
Rated force II kN -- 200 -- 200
Effective force II kN -- 191 -- 191
Oil capacity ltr 2.0 2.7 5.3 7.3
Weight kg 30 31 45 48
Usable with support rings yes yes On request On request
Stroke extension mm 360 360 On request On request
Type of Jack EH 600-250 TH 600/300- EH 600-450 TH 600/300-450 EH 600-130 TH 600/300/
250 100-170
Order No. 04-1061 04-1062 04-2061 04-2062 04-1065 04-1069
Closed height mm 250 250 450 450 130 170
Number of Pistons 1 2 1 2 1 3
Total stroke mm 110 215 278 566 45 204
Stroke I mm 110 110 278 278 45 78
Stroke II mm -- 105 -- 288 -- 63
Stroke III mm -- -- -- -- -- 63
Rated force I kN 600 600 600 600 600 600
Effect. force I kN 681 681 681 681 581 681
Rated force II kN -- 300 -- 300 -- 300
Effect. force II kN -- 285 -- 285 -- 285
Rated force III kN -- -- -- -- -- 100
Effect. force III kN -- -- -- -- -- 72
Oil capacity ltr 2.5 3.5 6.3 9.1 0.9 2.5
Weight kg 37 38 54 58 22 28
Usable with yes yes On request On request Yes Yes
support rings
Stroke extension mm 320 320 On request On request On request 228

All jacks of the four series complement each other as to their
lifting capacities as well as closed heights and pistons strokes so
that they are fully compatible with each other. For instance, with
the series 1200, a lifting operation started with a jack of low
construction can be continued with a jack of high construction,
when the stroke of the low one has reached its limits. In this
case, a total stroke of more than 658 mm is achieved.
Type of Jack EH 900-250 TH 900/450-250 EH 900-425 TH 900/450-425

Order No. 04-1091 04-1092 04-2091 04-2092
Closed height mm 250 250 425 425
Number of pistons 1 2 1 2
Total stroke mm 97 185 250 500
Stroke I mm 97 97 250 250
Stroke II mm - 88 -- 250
Rated Force I KN 900 900 900 900
Effective force I KN 896 896 896 896
Rated Force II KN -- 450 -- 450
Effective Force II -- 429 -- 429
Oil capacity ltr 2.9 4.2 7.5 11.0
Weight Kg 48 49 63 66
Usable with support Yes Yes On request On request
rings
Stroke extension mm 300 300 On request On request
On special request, three-piston jacks are also supplied out of this series.
Flat-type jacks (pancake design) have been developed within the series 600 and 1200 in order to
deal with extremely low lifting points. With these jacks the stroke can be extended by means of
support sets so that it is possible to continue the work with a jack of standard low construction if
necessary when all the support pieces have been placed in position.
Type of Jack EH 1200-250 TH 1200/600-250 EH 1200-420 TH 1200/600-420 EH 1200-140

Order No. 04-1121 04-1122 04-2121 04-2122 04-1125
Closed height mm 250 250 420 420 140
Number of pistons 1 2 1 2 1
Total stroke mm 90 180 243 488 41
Stroke I mm 90 90 243 243 41
Stroke II mm - 90 -- 245 --
Rated Force I KN 1200 1200 1200 1200 1200
Effective force I KN 1140 1140 1140 1140 1140
Rated Force II KN -- 600 -- 600 --
Effective Force II -- 581 -- 581 --
Oil capacity ltr 3.4 5.1 9.2 14.0 1.6
Weight Kg 56 57 75 79 45
Usable with support Yes Yes On request On request Yes
rings
Stroke extension 260 260 On request On request On request
mm
On special request, three-piston jacks are also supplied out of this series. Additional to the above
mentioned jacks, it is also possible to supply jacks with a capacity of 1,500 KN, 1,600 KN, 2,000
KN and more.
Lifting jacks and accessories
Single-piston jacks EH 350 and EH 200:

These jacks can be used for various jobs when fitted with different
add-on units :
1. By using the claw (order no. 04-0041-01) long strokes are

attained from low lifting points.
2. When fitted with the pressure head (supplied as a standard
accessories) this jack is used where long strokes are required
from high lifting points.
3. When used in conjunction with the head piece (order no. 06-
2352) and rounded head piece (order no. 06-2353) together
with the rocker bearing support (order no. 06-3351) this jack
forms an important part of the up-righting device.
Single-piston jack EH 100:

The single-piston jack has been designed for use with inside lifting
points as sometimes found on tramway and Metro cars.
The outer body can be brought into line with the corresponding
lifting devices by use of various adaptors, threaded connections and
inserted items. The bayonet catch can be positioned on the upper
part, the middle or any other place.
The jacks can also be supplied with a longer or shorter stoke.

Tilting jack:
The Tilting jack is used for lifting two-axle vehicles and putting them back on the track. During this
operation, the tilting jack performs the lifting motion and lateral displacement simultaneously and
the associated hooked wheel stop prevents the wheel from coming down beyond the rail.
Type EH 350- TH 350-658 EH 200-658 EH 100-380 EH 100-455 EH 200-597

1030 Without (Tilting jack with
With claw claw tilting and
stopping device)
Order No. 04-0041-P 04-0041 04-0021-1* 04-0010 04-0011 04-0021-2
Closed height mm 1030 1030 658 380 455 597
Height of outer body mm -- -- -- 735 810 --
Number of pistons 1 1 1 1 1 1
Total stroke mm 825 825 416 225 300 400
Rated force kN 350 350 200 100 100 200
Effective force kN 339 339 190 115 115 199
Oil Capacity ltr 9.3 9.3 2.6 0.87 1.15 2.7
Weight kg 125 70 41 24/5 27/8 57/16
Height of claw mm 105 -- 100 -- -- --
*incl. rocker bearing support
Equipment for lateral displacement:

Pushing and pulling of the lateral
displacing equipment enables derailed
vehicles (which have already been
lifted) to be traversed and aligned
accurately on the track.
Amongst other things, this equipment

allows rigid connection of the
components to be used for the lateral
displacement. This ensures safe securing of the load even in case of super-elevations. The
components for the lateral displacement described below should be selected in accordance with the
requirements.
Re-railing Bridges:
The bridges are hollow extruded sections of high-
strength light-metal alloy. The surface is protected
against corrosion by a special treatment.
All bridges can be coupled together and are equipped

with four handles which can be pushed in. The upper
side is provided with bores to accommodate the
counter support.
The carrying capacity of the re-railing bridges (total height 180 mm/95 mm is 600/100 kN over a
free span of 1.5 m. For higher loads, the bridge must be supported over the full length in which case
the carrying capacity is increased to 1200/600 kN per roller carriage.
Bridge Coupling:
The bridge coupling is used for joining two re-railing bridges. When ordering this item the overall
height of the bridge (see table) must be noted.
Type Order No. Height Length Width Weight

mm mm mm Kg.
AB 4500-180 05-2450 180 4500 280 175
AB 3300-180 05-2330 180 3300 280 128
AB 2250-180 05-2225 180 2250 280 88
AB1200-180 05-2120 180 1200 280 47
BK 180 05-2000 180 -- -- 37.5
Type Order No. Height Length Width Weight

mm mm mm Kg.
AB 4500-95 05-1450 95 4500 280 125
AB 3300-95 05-1330 95 3300 280 92
AB 2250-95 05-1225 95 2250 280 63
AB1200-95 05-1120 95 1200 280 34
BK 95 05-1000 95 -- -- 22
Displacing jack:
The displacing jack has a pushing force of 120 kN and a pulling force of 60 kN. Thus it allows
both pushing and pulling of lifted loads during the lateral displacement. This is an essential
advantage of the re-pressure system.
Furthermore the displacing jack is also used as part of the axle pusher unit.
Type Order Closed Number Total Rated Effective Rated Effective Oil Weight
No. Height of stroke pushing pushing pulling pulling capacity kg
mm pistons mm force kN force kN force kN force kN ltr
EH 120/60-575 05-011 575 1 350 120 129 60 57.8 1.5 16.5
Single-counter support Twin Counter support Twin head socket
To be inserted into the bores of To be nested in one pocket of the
the re-railing bridge, it is used to Used only as twin arrangement in roller carriage and used to
locate the displacing jack. combination with the twin head accommodate two parallel
socket. working displacing jacks. Used
only in combination with a twin
counter support.
Equipment for lateral displacement:

The roller carriages are used for traversing the load on the re-railing bridge. Well dimensioned
rollers with maintenance-free bearings permit easy lateral transport requiring only little force. Load
indications for the roller carriage are as per chart.
Roller carriage 150 kN
Provided with two pockets to accommodate for instance a

displacing jack, a distance bar or stopping device.
Due to the extremely low construction height, this type of roller
carriage is mainly used with tramway and Metro cars.
Roller carriage 150 kN with plate
With detachable rotating and sliding plate to compensate

for radial forces occurring when loads lifted on one end
only are being displaced.
Roller carriage 600 kN/1200 kN

Provided with two pockets to accommodate a displacing jack, a distance bar or stopping device.
Roller carriage 600 kN/1200 kN with plate
With detachable rotating and sliding plate to compensate for

radial forces occurring when loads lifted on one end only are
being displaced.
Type Designation Order No. Max. Total Total Weight Weight of the
Roller carriage load height height with Kg detachable
kN mm plate mm plate kg
RW 150 150 kN, without plate 05-1015 150 66 -- 18 --
RWP 150 150 kN, with plate 05-1016 150 66 101 18 11.5
RWP 600 600 kN, with plate 05-2062 600 108 140 58 24
RWP 1200 1200 kN, with plate 05-2122 1200 108 140 70 24
Stopping device for roller carriages:

Used in combination with one counter
support for locking the roller carriages when
relocating the displacing jacks (especially in
case of super-elevations)
Distance bar type I:
To couple two roller carriages,

length continuously adjustable
from 1027 mm to 1904 mm.
Distance bar type II
To couple two roller carriages, length continuously adjustable from 1050 mm to 2645 mm.
Equipment for up-righting operations:
This equipments is used for raising overturned
vehicles. It consists mainly of the single-piston jacks
350 kN (order no.04-0041) with head pieces, rounded
head pieces and rocker bearing supports together with
the lifting cable ladders.
Lifting cable ladder, carrying capacity 350 kN:

This replaces the missing fixed points on an
overturned vehicle to locate the lifting jacks.
It consists of:
 Lifting cable ladder 3025 mm long.

 Fixing bolt.
 Fastening rope 4 m long.
 Retaining rope 6 m long.
Rocker bearing supports.

Used to compensate the angular movement of the
jack and for safely transmitting the counter force to the ground.
Head piece and rounded head piece

Used to accommodate the loops of the lifting cable ladder in place of the pressure head of the jack.
Haulage device:
Used either for moving rail-guided vehicles with
blocked axles or for putting apart vehicles which are
locked together due to accident. The device is
attached to the track by means of rail blocks, wedges
and retaining ropes. It can also be used to raise
overturned vehicles: tractive power 250 kN.
Weight approx. 107 kg plus accessories (2 rail blocks,
4 wedges swivels, fastening rope, pulling rope and
retaining rope)
Order no.07-1250.
Auxiliary trucks:
Used to move vehicles when important travelling gear parts are defective. The individual
components of the auxiliary truck can be assembled on site. The damaged vehicle can then be
hauled to the nearest station/workshop for repair.
Type Order No. Carrying capacity kN Weight kg

HAW 160 08-1160 160 110
HAW 220 08-2220 220 480
Accessories:
Axle pusher unit:
To be used in combination with the displacing

jack to move a wheel resting on the rail by its
flange or if necessary as an auxiliary device for
the lateral displacement of a lifted vehicle.
This device often saves a complete lifting

operation, it consists of two retaining ropes with
hooks and bolts together with across beam of
light-metal alloy.
High-pressure hoses:
The high-pressure hoses bound in pairs serve to
connect the control desk, pump set and hydraulic
components. The screw couplings at both ends of the
hoses are provided with oil retaining valves so that oil
leakage is prevented even in uncoupled condition. The
screw couplings can be coupled manully under
residual pressure. Coupling under working under
pressure is also possible by means of suitable tools.
The hose couplings shown are to extend the hoses to
the required length.
Pair of high-pressure hoses

Length: 5 m
Order No. : 09-2005
Length : 10 m
Order No. 09-2010
Hose coupling Order No.
09-2101
Distribution Valve:
For connecting an additional hydraulic component.

Distribution valves with regulators are able to compensate for any loss of pressure in the pipes so
that simultaneous lifting or lowering of the jacks is possible.
Bogie suspensions:
To be used for bogies which are not
firmly attached to the vehicle. Type A
is hooked on the vehicle frame.
Type B clamps itself additionally to
the vehicle frame during the lifting
process.
Rescue devices and accessories:

As supplements to the re-railing system
Hegenscheidt-MFD offers rescue devices.
These devices can be operated in conjunction
with the re-railing hydraulics by means of a
pressure intensifier which has been developed
especially for this purpose. For detailed
information, MFD dealer may be approached.
Air bags and accessories:

In case of difficult re-railing
situations (extremely low lifting
points, derailments close to tunnel
walls, etc.) the use of air bags has
proved to be very favourable.
The drive unit features to mobile

compressor equipped with its own
prime mover in the form of either on
internal combustion engine or an
electrical motor.
An important feature is that due to

this design, the available amount of
compressed air almost unlimited
(more than 1.2 m3/min at 7 bar).
LUKAS HRE
INDEX
SN Description Page
9.19 LUKAS Make HRE
1. Intelligent Traversing System 19
2. A wide range right solutions 19
3. Light Weight components 19
1. Equipment is made in Germany 19
2. System includes various components 20
3. Main advantages at a glance 20
4. Control huge forces with precision from a safe distance series 20
6 pumps
5. Compact power unit for lifting & traversing 21
a. Compact power unit 22
b. Advantages 22
6. Compact power unit for lifting 22
a. Motor Pumps with gasoline 22
b. Advantages 22
7. High performance Hand Pumps 23
a. Advantages 23
8. Safe operation; the control desk 24
9. Hydraulic hoses; Fast and safely connected 25
10. Telescopic Jacks 25
a. Optimized surfaces 26
b. Integrated hose break safety valve 26
c. Perfect co-ordination 26
d. Machine on the job 26
11. Stacking Sets 27
12. Base plates 28
13. Special Jack for low floor vehicles 28
a. Internal Jacks 28
b. Types of jacks 29
14. Duo Traversing Unit 29
a. Advantages 29
15. Secured base for Traversing 31
a. Re-Railing Bridges 31
b. Connecting Re-Railing Bridges 31
c. Machine on the job 32
16. Re-Railing Accessories 32
a. Tilting Jack 32
b. On the Job 32
c. Axle Pusher 33
d. On the Job 33
17. Up-righting System 33
SN Description Page
a. Machine on the job 33
18. Pulling Device 34
a. Separating wedged vehicles with pulling equipment 34
19. For fast and Precise Re-Railing 35
a. Compact Traversing unit for light Rail vehicles 36
b. Advantages 36
20. Emergency Pneumatic Air Bag for Lifting 36
a. VETTER – Emergency air bag 36
b. Mini lifting Bags 37
c. Double controller 8 bar 37
21. LUKAS hydraulic Rescue Device (HRD) 38
a. For optimal cutting: cutters 38
b. For Spreading, Squeezing & peeling 38
c. Covering large distances: Rescue Ramps 39
d. High Performance Power Units 40
e. Liberty with hydraulic HRD 42
f. Advantages 42
g. Examples of applications 43
LUKAS Make HRE
The well-conceived re-railing system from LUKAS has been the solution of choice for
Re-Railment on IR for decades. Choose genuine quality and a product that enables
you to re-rail quickly, precisely and safely. This ensures that Railway tracks are
available for traffic again as fast as possible and that our down time costs are
minimized.
1.0 Intelligent traversing system

With LUKAS double-acting DUO traversing system, we can move the load in both the
directions along the entire length of a Re-railing bridge with absolute precision at a
safe distance from the control desk without any manual intervention.
2.0 A wide range right solutions:
As a specialist in re-railing technology, LUKAS has offered the greatest variety of

products in this area. The wide range of
choices ensures that we use precisely those
systems that suit our requirements best.
LUKAS special customer-oriented technical
team offers us expert, solutions-based
advice. In addition, LUKAS also supplies
with devices for up-righting vehicles, as well
as superior hydraulic and pneumatic rescue
tools.
3.0 Light weight components:
All the components of the re-railing system are kept as small and light as possible to
enable fast transport, efficient setup and easy handling. This enables us to start re-
railing sooner, saving our valuable time at accident site.
4.0 Made in Germany - developed in cooperation with Deutsche

Bahn
LUKAS produces re-railing equipment in Germany, meeting the specified quality

standards. This equipment was developed in 1961 in close cooperation with Deutsche
Bahn. Since then, it has been further developed and improved in cooperation with
well-known international railway companies.
5.0 The system includes:
a. Motor pump
b. Control desk
c. Telescopic ram
d. DUO traversing unit
e. Mechanical accessories, such as re-railing bridge, Roller carriage and
distance bars
f. Pulling device
g. Long stroke jack and accessories for up-righting overturned rail vehicles
6.0 Main advantages at a glance:
a. DUO traversing unit:

Non-intermittent traversing over the entire length of the bridge
b. Compact design and lightweight components for efficient setup
c. Practical quick-lock couplings for easier operation
d. More power to 530 bar operating pressure
e. Customer-oriented consulting with decades of experience of lukas
LUKAS re-railing systems operate with hydraulic power, enabling even the heaviest
Railway wagons/ vehicles to be lifted and traversed with ease. The necessary oil
pressure is generated by a higher capacity pump, while high-precision valves control
the extension and retraction of the hydraulic cylinders.
7.0 Control huge forces with precision from a safe distance

Series 6 Pumps:
Powerful Series 6 pumps are used to

generate the hydraulic pressure for
the devices from the LUKAS re-railing
system. We can choose between
pumps powered by Diesel, gasoline,
or electricity. Because of their
compact design, these pumps are
lightweight and made for easy handling. An additional advantage are the quick
connect couplers, simplifying the connection of the pump.
Type GC-6 PC-6 DC-6
Oil output rate:

5.9 / 2.5 l/min 5.3 / 2.3 l/min 5.3 / 2.3 l/min
low pressure/high pressure
Usable oil quantity 35 l 35 l 35 l
Engine 4-stroke gasoline engine 220 V / 400 V - 50 Hz Diesel
Power 3.5 kW 2.2 kW 5 kW
Dimensions l x w x h 560 x 540 x 665 mm 560 x 540 x 695 mm 550 x 480 x 750 mm
Weight (without oil) 55 kg 61 kg 81 g
8.0 Compact power units: for lifting and traversing
Compact power unit:
Use the compact power unit for traversing

with a DUO traversing unit. This also
unites power and control in a single
device. It is available with a gasoline and
can operate two or four jacks from a safe
distance.
Advantages
Valves can be fitted for every system on a modular basis.

Two working speeds: rapid extension without load and controlled, slower lifting with
load.
Less weight to variable capacity of oil reservoir up to max. 24 L.
Compact design for convenient transport.
Units with gasoline engine GC6-2DV GC6-4DV
Lifting with 2 jacks 4 jacks
Traversing with 1 DUO traversing unit 1 DUO traversing unit
Oil output rate LP / HP 4.7 / 1.45 l/min 4.7 / 1.45 l/min
Dimensions l x w x h 560 x 470 x 990 mm 560 x 565 x 990 mm
Weight (without oil) 52.5 kg 58.5 kg
9.0 Compact power units for lifting.
Motor pumps with gasoline:
When lifting with telescopic

jacks, the best solution is to
use motor pumps GC6-
2D/PC6-2D. They combine the
hydraulic pump and control
valves in one unit easy to
operate and instantly ready for
use. With the intuitive
controller, the lifting and
lowering speed of each jack
can be regulated with
precision. Important: A hand pump must be used for horizontal traversing with the
compact traversing unit.
Advantages:
a. Two working speeds: rapid extension without load and controlled, slower lifting
with load.
b. Less weight thanks to variable capacity of oil reservoir up to max. 24 l.
c. Compact design for convenient transport.
Units with gasoline engine GC6-2D GC6-4D
Lifting with 2 jacks 4 jacks
Oil output rate: low pressure/high

pressure 4.7 / 1.45 l/min 4.7 / 1.45 l/min
Weight (without oil) 49.5 kg 55.5 kg
10.0 High-Performance Hand Pumps.
The robust, two-stage hand pumps are ready at any time in case of an emergency.
They offer the option to use the telescopic jacks in environments with a risk of
explosion. These high-performance hand pumps can be used to lift or traverse the
load with one or two compact traversing units. With these hand pumps, you can work
quickly and precisely at all times.
ZPH 3/4-1D / ZPH 3/8-1D
for one double-acting jack
ZPH 3/8-1D
ZPH 3/4-2D / ZPH 3/8-2D
for two double-acting jacks
Advantages:
1. Rapid traversing possible to the high output rate of the pump

2. Suitable for use in environments where risk of explosion, such as tunnels or under
ground shafts.
3. Effort less work to low leverage forces
ZPH 3/8-1D ZPH 3/8-2D
3 3
Oil output rate: low pressure 10.8 cm 10.8 cm
3 3
Oil output rate: high pressure 4.2 cm 4.2 cm
Capacity of oil reservoir 10.5 l 10.5 l
Usable quantity 8l 8l
Dimensions: l x w x h 915 x 230 x 182 mm 940 x 260 x 182 mm
Weight 18.2 kg 21 kg
ZPH 3/4-1D
ZPH 3/4-1D ZPH 3/4-2D
Oil output rate: low pressure 10.8 cm³ 10.8 cm³

Oil output rate: high pressure 4.2 cm³ 4.2 cm³
Capacity of oil reservoir 5.25 l 5.25 l
Usable quantity 4l 4l
Weight 15 kg 16 kg
11.0 Safe operation: The control Desk
The intelligent control desk enables us to control all work with a high degree of
precision. The control valves enable to lift, lower, traverse and position the vehicle
from a safe distance. For our safety, the valves are clearly arranged and have an
automatic spring reset (dead-man safety system). Important: The modular design
means that we can adapt the valve combination precisely to your specific needs.
We can choose between two variants
CT7-6/3DV CT7-6/4DVV
Lifting/lowering valves 3 4
Traversing with 1 DUO traversing unit 2 DUO traversing unit
Dimensions: l x w x h 805 x 700 x 1,100 mm 1,025 x 700 x 1,070 mm
12.0 Hydraulic hoses: fast and safely connected
Series 6 Motor Pumps Series 6 Compact Power Units

Connection: 2x hose 10 m black -
Control desk – motor pump Weight 4.4 kg -
Connection: Hose pair 10 m red/red Hose pair 10 m red/red
Control desk – lifting jacks Weight 7 kg Weight 7 kg
Connection: Hose pair 10 m red/red Hose pair 10 m yellow/yellow
Control desk – DUO traverse Weight 7 kg Weight 7 kg
jack
Anchor jack Hose 10 m black Hose 10 m black
- Weight 4.4 kg Weight 2.75 kg
HP 25 / T 185 R HP 50 / T 400 R
HP 10/T 280 R 130/115 R
HP 25 / T 185 R HP 50 / T 185 R HP 65 / T 500 R
12.0 Telescopic Jacks:
Beside their enormous strength, telescopic Jacks also feature thought-out design.
High-strength, light alloy aluminum makes them resistant to corrosion and easy to
maintain. In this telescopic design, they combine long piston strokes with a very
small retracted height.
1. Optimized surfaces
The surfaces of the piston rods are hard-anodized to protect against damage;
the piston guard plates are corrugated and are made from high-strength steel.
Best quality for a long service life also.
2. Integrated hose-break safety valve
The LUKAS hose pairs have an integrated quick stop feature that prevents the
uncontrolled lowering of the load, for example if the hose has been damaged
3. Perfect coordination
The piston strokes and forces of the various cylinders are coordinated down to
the last detail. It means that we remain in control even in difficult situations - fast
and safe.
On the job
HP 10 I T 280 R HP 25 I T 185 R HP 25 I T 450 R
Piston lifting force 1 / 2 / 3 650 / 301 / 104 kN 650 / 301 kN 650 / 301 kN
Piston stroke 1 / 2 / 3 94 / 95 / 90 mm 95 / 90 mm 228 / 223 mm
Total stroke 279 mm 185 mm 451 mm
Height 220 mm 220 mm 385 mm
Oil volume 1.4 l 1.3 l 2.8 l
Weight 14.8 kg 14.8 kg 23.8 kg
HP 30 I T 500 R HP 50 I T 185 R HP 50 I T 400 R
Piston lifting force 1 / 2 650 / 301 kN 1,066 / 504 kN 1,066 / 504 kN

Piston stroke 1 / 2 250 / 250 mm 89 / 96 mm 195 / 204 mm
Oil volume 3.25 l 2l 4.3 l
Weight 26.0 kg 24 kg 41 kg
HP 60 I 45 HP 65 I T 500 R HP 130 I 115 R
Piston lifting force 1 / 2 600 kN 1,665 / 703 kN 1,348 kN

Piston stroke 1 / 2 45 mm 250 / 251 mm 115 mm
Oil volume 0.51 l 8.8 l 2.9 l
Weight 25 kg 69 kg 53 kg
13.0 Stacking sets:

If we are facing with the need of an extra ordinary long stroke, the stacking sets can be
used to increase the maximum lifting height by up to 495 mm. Depending on the number
and height of piston and stacking rings, these accessories are provided.
Stacking set for HP 10/T, HP 25/T HP 50/T 185 R HP 50/T 400 R

Stacking ring, number / height 4 / 65 mm 4 / 65 mm 2 / 150 mm
1/20 mm + 1/123 mm
Piston ring, number / height 3/65 mm + 1/45 mm 3/65 mm + 1/45 mm
+ 1/150 mm
Fork levers, quantity 1 1 1
Max. stroke extension 260 mm 260 mm 360 mm
Total weight 14.5 kg 21 kg 22.2 kg
Stacking set for HP 60/45 HP 65/T HP 130/115 R

Stacking ring, number / height 2/31 mm 3/133.4 mm 1/110 mm + 4/95 mm
1/20 mm + 2/135 mm
Piston ring, number / height 1/42 + 2/30 mm 5 / 95 mm
+ 1/100 mm
Fork levers, quantity 1 1 1
Max. stroke extension 107 mm 400 mm 495 mm
Total weight 3.3 kg 42 kg 47 kg
14.0 Base plates:
Safety first. The base plates increase the jack’s ground area and improve its
stability many times over it. It is essential for all lifting tasks.
Base plate for HP 10 / T... HP 25 / T... HP 30 / T...

Base plate for HP 50 / T... HP 65 / T...

Weight 9 kg 24.5 kg
15. Special jack for low-floor vehicles:
a. Internal jacks:
Some vehicles have to be lifted from the inside because of low ground clearance. These
vehicles are equipped with adapters in the floor for internal jacks. In this case, you insert
the LUKAS internal jacks into the floor of the vehicle with the pistons facing downwards
and extend them slowly. This enables you to lift the vehicle safely at several points.
As the adapters in vehicle floors can vary, the adapter sleeves and the jacks can be
modified according to the special needs.
b. Types
The HP 10/250 R is available with two standard adapters as an option:
a. with bayonet fitting
b. with trapezoidal thread
Both jacks are double-acting and are retracted hydraulically
16.0 DUO Traversing Unit:
The DUO traversing unit allows us to perform the complete task from a safe distance
without manual conversion.
Advantages:
1. Movement in two directions over the entire length of the bridge

2. Control from the control desk – at a safe distance
3. Integrated sliding plates compensate for the bowing of the vehicle
4. Adjustable distance bars connect the roller carriages and enable safe traversing on
the bridge.
On the job
DUO traversing unit
Push/ pull force 170 / 90 kN

Stroke 320 mm
Dimensions*: l x w x h 668 x 360 x 174 mm
Weight 23 kg
DUO traversing unit, heavy load

Push/ pull force 337 / 207 kN
Stroke 320 mm
Dimensions* 653 x 320 x 186 mm
Weight 42 kg
Roller carriage for bridges

Permissible load 750 kN
Height 112 mm
Weight 42 kg
Heavy load roller carriage for

bridges
Permissible load 1,000 kN

Height 140 mm
Weight 63 kg
Adjustable distance bars (set)
Short Long
Length max./min. 1,830 / 1,030 mm 2,800 / 1,500 mm
Weight 40 kg 59 kg
17.0 A secure base for traversing.
Re-railing bridges:
The re-railing bridge is used as soon as you have raised the derailed vehicle. You can
then move the vehicle side-ways with one or two roller carriages and the DUO
traverse unit. When the vehicle is in the right position, lower it on to the rails.
Connecting re-railing bridges: You can extend the bridges with connecting
elements, enabling you to respond to various track widths. Important: The connection
points must be supported securely.
Height 85 mm ( low- floor vehicles) Height 140 mm
Length m 1.1 2.2 Length m 1.1 2.2 3.3 4.4
Width mm 350 350 350 Width mm 350 350 350 350
Weight kg 33 66 98 Weight kg 40 81 117.5 163
Height1 84 mm
Length m 1.1 2.2 3.3 4.4 Connection elements for bridges
Width mm 350 350 350 350 Height mm 85 140 184
Weight kg 70 140 210 280 Weight kg 9.6 18 21
Full support 350 kN 1,000 kN 1,200 kN

with 1 m distance between supports 60 kN 500 kN 900 kN
with 1.43 m distance between supports 50 kN 400 kN 650 kN

On the job
18. Re-railing accessories.

Tilting jack:
Depending on the model, you can rerail

some vehicles with a HP 25 / K 400 R
jack, radius plate and wheel stop with
minimal effort. The diagonal stroke
movement lifts and traverses the rail
vehicle at the same time. The wheel
stop stops the traverse movement as
soon as the wheels are positioned over
the rails. Additionally, the tilting jack is
used for up-righting rail vehicles with
the lifting belt. For further information
see the next sub head, "Up-righting".
On the job
Required components
Tilting jack HP 25 / K 400R

Radius plate
Wheel stop
Weight 18.6 kg
Axle pusher:
If you accidentally lowered the load with the wheel flange on the rails, the axle pusher will
handle the last step and push the vehicle into the track. Important: To operate this system you
also need cylinder LZM 10/160 and the appropriate piston guard plate. Both components are
not included in the scope of delivery of the axle pusher.
LZM 10/160 Axle pusher

Stroke 160 mm LZM 10/160
Lifting force 100 kN
Weight 3.8 kg 11 kg
On the job
19. Up-righting System:

Up-righting system is the perfect answer in case of an accident with an overturned rail vehicle that
can not be rescued with a 140T crane. This enables you to upright over turned rail vehicles with
ease, so that you can subsequently rerail them
Mode of operation:
You place the lifting belt 4 around the overturned rail vehicle and fasten it to the frame with a
holding rope 5 and shackle 6 . A jack (HP 25 / K 400 R) and a radius plate 3 are used to start lifting
the vehicle gently and securely. Using the tilting jack 2 and then the claw jack 1, lift the vehicle onto
the sling before using a second claw jack when the first is fully extended, continuing the up-righting
work.
On the job
Lifting with the claw jack
The claw jack is supplied with a base plate so

that it can be used to lift loads, such as Wagons.
1 2 3 4 5 6
Claw jack Tilting jack Radius Sling Holding Shackle
HP 50/ P 850R HP 25/ K 400R plate rope
Permissible load - 400 kN 250 kN
Pressure 520 kN 266 kN - - -
Stroke 850 mm 400 mm - - - -
Height (retracted) 1,150 mm 599 mm - - - -
Oil volume 8l 1.55 l - - - -
Weight 52 kg 22 kg 7 kg 51 kg 15 kg 12.8 kg
20.0 Pulling device:
Separating wedged vehicles with the pulling equipment:
The powerful pulling device is used whenever vehicles are wedged together due to an accident.
This simple but powerful product can also be used as a fast and safe way to unblock the way when
a train is jammed between the walls of a tunnel or bridge or when an obstacle blocks the track.
Benefit: The device can be fastened to the rails or a ground anchor, independent from the track
width. The pulling device consists of a 9.5 m pulling rope and a pulling jack with holding ropes and
rail attachments.
Pulling device PUD200
Pulling force 220 kN

Oil volume 1l
Weight 194 kg
On the job
21.0 For fast and precise re-railing:
Compact traversing unit for light rail vehicles:
The best solution for traversing light rail vehicles is the compact traversing unit, which
allows you to rerail with absolute precision. This is thought through in detail to ensure that
your rescue mission runs smoothly and safely. Use one or two units, depending on the
weight of the accidental vehicle.
Advantages
1. Easy transport to low weight and compact dimensions
2. Fast change of direction directly on the hand pump
3. Moving light alloy sliding plates compensate the bowing of the vehicle
4. Minimal friction resistance to stainless steel sliding surfaces
On the job
Transverse movement to 300 mm
Dimensions l x w x h 865 x 375 x 153 mm
Weight 73 kg
Permissible loads:
Single-point lifting: 200 kN (20 t)
i.e. rail vehicles weighing up to 400 kN (40 t)
Two-point lifting 2 x 150 kN (15 t)

i.e. rail vehicles weighing up to 600 kN (60 t)
22.0 Emergency pneumatic Air Bag for lifting:
VETTER - Emergency Pneumatics

On the job
Sister company of LUKAS, M/s Vetter, offers world-

wide leading emergency pneumatic bags. Vetter
lifting bags are very useful accessories for rail road
accidents. With their low insertion height of just 25
mm in certain cases, they are perfectly suited for first
lifts. The aramide-reinforced bags are enormously
powerful and are capable to lift even large loads: their lifting force ranges from 31 to 68 tonnes per
bag. The low weight enables you to respond quickly and flexibly in an emergency.
more rescue products in

the general catalogue
"Vetter Rescue Products" and at www.vetter.de
Mini lifting bags: V31 V40 V54 V68
Max. lifting force 31,400 kg 39,600 kg 54,400 kg 67,700 kg

Max. extension height 37.0 cm 40.2 cm 47.8 cm 52.0 cm
Dimensions 65 x 69 cm 78 x 69 cm 86 x 86 cm 95 x 95 cm
Insertion height 2.5 cm 2.5 cm 2.5 cm 2.5 cm
Nominal content 57.5 l 75.0 l 124.2 l 161.9 l
Air requirement at 8 bar 517.5 l 675.0 l 1,117.8 l 1,457.1 l
Max. working pressure 8 bar 8 bar 8 bar 8 bar
Test pressure 12 bar 12 bar 12 bar 12 bar
Burst pressure 38.0 bar 38.0 bar 36.0 bar 32.5 bar
Weight 9.5 kg 11.8 kg 17.2 kg 21.9 kg
Double controller 8 bar:

Plastic housing, dead-man safety system
Inflation hose, 5 m, yellow
Inflation hose, 10 m, red
Inflation hose, 10 m, yellow
Pressure reducer 200/300 bar with manual connection
High-pressure compressors can be delivered
with gasoline or electric motors.
23. LUKAS Hydraulic Rescue Device [ HRD ]:
The world’s leading rescue tools from LUKAS are very easy to use and deliver good
performance. Their performance makes all the difference when you really need it, on the
job. Choosing the right tool is vital when accidents occur in coaching stock, so that you
can create rescue openings and also open jammed doors, safely and efficiently.
For optimal cutting: On the job

Cutters
S 700 - ALPHA CUTTER, S510, S311

This innovative and better cutter gives you
maximum power reserves. Also S510 and its
light weight counter-part, the S311, are
characterized by a well-balanced set of
features that are specially tailored to metal
constructions.
Cutter S700 S510 S311
Cutting class acc. EN 13204 BC 182H-21 BC 180H-19 BC 150G-14

Blade opening 185 mm 182 mm 150 mm
3
Oil volume 325 cm 150 cm³ 98 cm³
Dimensions: l x w x h 778 x 300 x 258 mm 772 x 245 x 165 mm 705 x 201 x 163 mm
For spreading, squeezing and peeling:
SP 510 - POWERFUL, WIDE-OPENING SPREADER
The great power, enormous spreading distance
and intuitive handling of this tool enable you to
perform fast and secure rescue work on heavy
rail vehicles.
SP 310 - THE VERSATILE TOP SPREADER

It offers a perfect mix of power, weight, opening
width and handling. Its flexibility has impressed
rescue organizations and Railway throughout the
world.
Spreader: SP310 SP510
Spreading force 46 to 256 kN 62 to 230 kN

Spreading distance 720 mm 800 mm
Squeezing force 122 kN 70.4 kN
Pulling distance up to 604 mm 665 mm
Pulling force up to 51 kN 55 kN
Oil volume 243 cm³ 425 cm³
Covering large distances: Rescue rams
The two-stage telescopic rams R 420 and R 424 are used to push material blocking your path
out of the way. For example to widen rescue openings or to support lifting work.
Telescopic rescue ram R 420 R 424

Total stroke 575 mm 875 mm
Stroke/lifting force, piston 1 295 mm / 266 kN 445 mm / 266 kN
Stroke/lifting force, piston 2 280 mm / 133 kN 430 mm / 133 kN
Extended length 1,055 mm 1,500 mm
3
Oil volume 1,410 cm 2,139 cm3
Weight 16.8 kg 21.0 kg
High performance power units
P 650 - RESCUE with TURBO FUNCTION

Rescue at twice the speed. Every second counts in
rescues, which is why LUKAS has provided its P650
series with a turbo function. With a one hand movement,
you can double the oil flow to one tool in order to work
twice as fast. Available with Diesel/Petrol or gasoline, for
simultaneous use of two rescue tools.
SIMO Power (2 tools)
Motor: 4-stroke gasoline motor

Oil output rate: Gasoline: 2 x 2.8 l/min - 2 x 0.8 l/min /
Turbo oil output rate: Gasoline: 1 x 5.6 l/min - 1 x 1.6 l/min /
Usable oil quantity 4.5 – 5.0 l
Dimensions: l x w x h P650 SG 525 x 440 x 452 mm /

P650 SE 525 x 440 x 452 mm
Weight: P650 SG 54 kg / P650 SE 49 kg
P 620 OG - FOR MOBILE USE:

This lightweight power units prove their advantages in rough terrain. The low weight allows
you to respond flexibly and to switch locations quickly.
P 620 OG
4-stroke gasoline motor 1.3 kW

Oil output rate: low
pressure: 2.45 l/min
Oil output rate: high
pressure: 0.5 l/min
Capacity of oil reservoir: 2l
Usable oil quantity: 1.6 l
Dimensions: l x w x h 360 x 300 x 390 mm
Weight: 15 kg
Discover the liberty with Hydraulic:
With the help of advanced electro-hydraulics,

LUKAS engineers have managed to progress
from a large and heavy complete set to a
compact and powerful one. With no loss of
performance. They work with any 230V power
plug or powerful lithium-Ion batteries for
maximum flexibility.
Cutter 700 E
Blade opening 185 mm
Weight 24 kg
Spreader SP 300 E
Spreading force 34-112 kN
Spreading distance 605 mm
Pulling force up to 23 kN
Pulling distance 495 mm
Weight 20.9 kg0
Rescue ram R 411 E

Piston stroke 360 mm
Lifting force 103 kN
Retracted length 545 mm
Extended length 905 mm
Extended length with extension 1,205 mm
Weight 17.7 kg
Advantages
1. Liberty of performing optimal rescues
2. Liberty of working without power units and hoses
3. Liberty of operating independently in battery mode
Note: You will find more rescue products in the general catalogue "Lukas Rescue Tools"
and at www.lukas.com
Examples of application:
Part-II
Operating Instructions
for
530 Bar Double Acting
LUKAS, HRE
Operation Manual for Working of

ART\ARME\140 Te. Cranes\1
CONTENTS
Para page
1.0 Designated use of the machine 22
Organi Organisational measures

2.0 22
3.0 General safety instructions 22
4.0 Instructions for maintenance and service 23
5.0 Function o f individual components 24
6.0 Installation of individual components 26
7.0 Operation 28
8.0 Op Optional components for further applications 33
9.0 Dismantling of components 34
10.0 Preventive and corrective maintenance 35
11.0 Repairs 36
12.0 Technical data 37
1.0 Designated use of the machine:
1.1 The machine has been built in accordance with state-of-the-art standards and the
recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of
the user or of third parties, or result in damage to the machine and to other material
property.
1.2 Only use the machine if in technically perfect condition and in accordance with its
designated use and the instructions set out in the operating manual, bearing in mind
safety considerations and the potential hazards. Any malfunctions, especially those
which could affect the safety of the machine, should therefore be rectified immediately.
1.3 The machine is designed exclusively for operation and controlling rerailing
equipment. Use of the machine for purposes other than those mentioned above, e.g. to
drive and control other hydraulic systems, is considered contrary to its designated
use. The manufacturer/supplier cannot be held liable for any damage resulting from
such use. The risk of such misuse lies entirely with the user.
Operation of the machine in accordance with its designated use also includes observing
the instructions set out in the operating manual and complying with the inspection and
maintenance directives.
2.0 Organizational measures

2.1 The operating instructions must always be at hand at the place of use of the
machine.
2.2 In addition to the operating instructions, observe generally applicable legal and other
mandatory regulations on accident prevention and environmental protection. This
includes in particular the wearing of working or protective clothing, a helmet with visor or
goggles and protective gloves.
2.3 To avoid the risk of injuries, the machine may only be operated by a specially
trained operator who has undergone safety training.
2.4 Observe all safety instructions and warnings displayed on the machine. Make sure
that safety instructions and hazard warnings displayed on the machine are always
complete and perfectly legible.
2.5 Never make any modifications, additions or conversions to the machine which could
affect safety without the supplier’s approval. This also applies to the installation and
adjustment of safety devices and valves.
2.6 Spare parts must comply with the technical requirements specified by the
manufacturer.
Spare parts from original equipment manufacturers can be relied upon to do so. It is
only permitted to use original LUKAS accessories and system components.
2.7 Change hydraulic hoses within stipulated and appropriate intervals, even if no
safety-relevant defects have been detected. This must be done after 10 years at the
latest.
2.8 Adhere to prescribed intervals or those specified in the operating instructions for
routine checks and inspections.
3.0 General safety instructions:
3.1 In the event of malfunctions, stop the machine immediately and lock it. Have any
defects rectified immediately.
3.2 Before starting up or setting the machine in motion and during operation of the
machine, ensure that nobody is placed at risk by starting up the machine.
3.3 Before setting the machine in motion, always check that the accessories have
been safely stowed away.
3.4 Make sure that lighting is sufficient during work.
3.5 Avoid any operation that might be a risk to machine stability.
3.6 Check the machine at least after every operation for obvious damage and
defects. Report any changes (incl. changes in the machine’s working behaviour) to
the relevant organisation/person immediately. If necessary, stop the machine
immediately and lock it. Check all lines, hoses and screwed connections for leaks
and externally visible damage. Rectify any damage immediately. Splashed oil may
cause injury and fires.
3.7 Check all safety equipment for completeness and perfect condition:
- Instruction markings and warning signs (safety instructions)
- Check that safety cover (e.g. motor safety covers, heat shields etc.) are present
and that they are in good condition.
3.8 Working beneath loads is not permitted if they are lifted only by hydraulic
cylinders. If such work is indispensable, sufficient mechanical supports are needed
additionally.
3.9 Make sure that hoses are not mechanically stressed (pulling, bending etc.).
4.0 Instructions for maintenance and service

4.1 In order to perform maintenance and service work, tools and workshop equipment
appropriate to the task in hand are absolutely indispensable. Work on the hydraulic
system may be carried out only by personnel possessing special knowledge and
experience with hydraulic equipment.
4.2 Before starting work, clean the machine, especially connections and threaded
unions, of any traces of oil, fuel or preservatives. Never use aggressive cleaning
agents. Use lint-free cleaning cloths and observe meticulous cleanliness in particular
during reassembly.
4.3 During dismantling of machines, ensure that hydraulic liquids draining out are
collected completely, so that they cannot seep into the ground. They must then be
disposed properly in accordance with the relevant regulations.
4.4 Always tighten any screwed and thread connections that have been loosened
during maintenance and repair. Observe the stipulated tightening torques.
4.5 Work on the electrical system or equipment may only be carried out by a skilled
electrician himself or by specially instructed personnel under the control and
supervision of such electrician and in accordance with the applicable electrical
engineering rules.
4.6 The electrical equipment of machines is to be inspected and checked at regular
intervals. Defects such as loose connections or scorched cables must be rectified
immediately.
4.7 Aggressive media (acid, lye, solvent, vapour) can damage the machine. The
entire machine must be cleaned if, as an exception, it must be operated in such
conditions or comes into contact with these materials. Additionally, the machine must
be checked as described under 3060.
Drive and control system; lifting cylinder and DUO traversing system:
5.0 Function of individual components

5.1 Power pack (figure section, Fig. 1)
The power pack serves as the hydraulic pressure generator for the whole system. It
can be driven by an electric motor (1-phase/3-phase motor, 1.1) or a combustion
engine (petrol, 1.14 or diesel, 1.15). The integrated radial piston pump has a
- Low-pressure circuit = LP,
- High-pressure circuit = HP.
The following valves are also integrated:
- Pressure stop valve for low pressure in the pump (in the oil reservoir),
- Relief valve (1.9) for depressurised circulation,
- Pressure limiting valve (1.12) for HP
- Hydraulic couplings for connecting the hoses to the control desk:
- Quick coupler plug (1.10) for pressure connection P,
- Quick coupler sleeve (1.11) for return connection T,
Four folding handles (1.8) are fitted to facilitate handling.
5.2 Control desk (figure section, Fig. 2)
The control desk serves to control the different cylinders within the complete “rerailing
equipment” system, which includes the following components:
- “Lifting valve” (2.1) (valve type G 4/3) for controlling lifting cylinders (with hydraulic
retraction) or, if necessary, single-acting cylinder components,
- “Shifting valve” (2.2) (valve type G 4/3) for operating a double-acting traversing
cylinder with an accompanying tip valve (2.3) for hydraulic lifting of the integrated
anchor cylinder,
- Pressure stop valve (2.4). This manual pressure stop valve switches the flow of the
high pressure loop of the power pack to bypass and disconnects the hydraulic loop
of the lifting cylinders and the traversing system
- Pressure gauge (2.5) for displaying the current working pressure.
The control desk is a “side desk”: it is mounted on a base.
Up to 4 lifting cylinders (according to circuit diagram: H1...H4) and up to 2 DUO
traversing systems (acc. to circuit diagram: V1, V2) can be connected simultaneously
to the control desk CT7-6/4DVV (see circuit diagram) (without further accessories), or
up to 3 lifting cylinders and 1 DUO traversing system to the control desk CT7-6/4DV
(see circuit diagram), or up to 4 lifting cylinders and 1 DUO traversing system to the
control desk CT7-6/3DV (see circuit diagram). (see figure section, chapter 12200)
5.3 Lifting cylinder (figure section, Fig. 3)
5.3.1 Description
Design: telescopic cylinders with 2 or 3 piston stacks. This results in a low-profile
design with large strokes. The forces applied in individual stacks vary. All LUKAS
telescopic cylinders are named according to the lifting capacity (approx. value) in
kN/10 (formerly: tons) of the smallest piston and the resulting total stroke of all
stacks, i.e. the lifting capacity of the larger piston (with a smaller stroke) is
accordingly higher (see data sheets).
All lifting cylinders are designed with a hydraulic retraction function:
The extending movement is carried out by means of LP or HP (depending on the

load). The retracting movement is always carried out by means of a pressure limited
to 30 MPa, which allows greater precision when retracting.
All lifting cylinders have two connecting blocks with safety valve 58 MPa (3.6/3.7), to
prevent the cylinder from being damaged in the event of overload.
The full-room connection is in the lower part (3.7) of the cylinders. The
rod connection is in the upper part (3.6) of the cylinders.
5.3.2 Use
For general usage, usage in case of emergency and technical data, please refer to
the operating instructions supplied with each cylinder.
5.4 DUO traversing system (see figure section, Fig. 4)
5.4.1 Application range
The DUO traversing system, comprising roller carriages (4.5), connecting rods (4.4)
and rerailing bridge(s) (4.1), is intended for shifting a raised rail vehicle transversely
to the rails.
5.4.2 Roller carriage with guide tongues (4.5)
The roller carriage is designed for carrying/shifting heavy loads. The roller carriage
consists of a stable box frame with 4 rollers fitted with heavy-duty plain bearings. This
configuration produces an optimum coefficient of friction combination between the
carriage and the rerailing bridge, to prevent the carriage from rolling off autonomously
when the bridge is effectively in a horizontal position (please note chapter 7310).
The carriage is moved on the rerailing bridge by a DUO traversing cylinder secured in
a bracket (4.12) on the roller carriage. The traversing cylinder can be secured and
removed again very easily.
5.4.3 Connecting rods (4.4)
These are used in pairs and connect the roller carriages for 2-point shifting. This
guarantees that the roller carriage is synchronously shifted not only by frictional
connection (via the vehicle to be traversed), but by positive locking.
The rods can be precisely adjusted to the space between the lifting points by carrying
out a rough adjustment (4.9) and a precision adjustment (4.10). They are simply
secured in the roller carriage couplings (4.11) of both carriages.
5.4.4 DUO traversing cylinder (4.2) The cylinder
has a double-acting design:
The movements in both directions are carried out with LP or HP depending on the
load. Extension and retraction are carried out with the full system pressure of 53
MPa, in order to fully utilise the tractive force of the traversing cylinder. An attachment
at the end of the piston rod (4.13) is for connecting to the roller carriage.
5.4.5 Anchor cylinder on the DUO traversing cylinder (4.3)
The integrated anchor cylinder (4.3) is designed as a single-acting cylinder with

return spring: the spring pushes the anchor down via the lower contact surface of the
traversing cylinder, locking the entire traversing cylinder in an opening in the bridge in
the process, and thus serves to abut the shifting movement. To shift the traversing
cylinder, the anchor is hydraulically lifted; then the traversing cylinder can be shifted
by activation.
With the aid of this special equipment, the LUKAS system permits shifting in
both directions over several bridge sections without the operating personnel
needing to pass beneath the load!
5.5 Hoses with rapid-action hose couplings
All hoses have colour markings and are equipped with rapid-action hose couplings in
such a way that they cannot be confused during connection.
Some of the rapid-action hose couplings have special functions and may therefore
not be unscrewed from the hoses and/or interchanged!
5.5.1 Hoses between power pack and control desk
- Pressure connection - black, NW10 - Return
connection - black, NW10
5.5.2 Hoses between control desk and lifting cylinders
Cylinder piston end - red, NW06 —> extension,
Cylinder rod end - blue, NW06 —> retraction.
5.5.3 Hoses between control desk and DUO traversing unit
Cylinder piston end - red, NW06 —> extension,
Cylinder rod end - blue, NW06 —> retraction,
Anchor cylinder - black, NW10 —> retracting anchor cylinder.
5.5.4 Quick coupler plug with overload protection
All hoses are provided with a quick coupler plug with safety valve (referred to as D-
plug). This is a safety measure to prevent cylinder overload. The plug is always
located on the end of the hose that is involved in the return from the cylinder rod end
to the control desk/power pack. If this hose is not properly connected due to incorrect
operation and the cylinder piston end is pressurised, a much higher pressure than the
permissible system pressure may occur at the rod end due to its the smaller area.
This could destroy the cylinder. This is where the relief valve (response value approx.
1.5 MPa) comes in - the oil will leak out via the coupling.
In this event, the control valve of the corresponding cylinder must be immediately set
to the neutral position. The hose can then be coupled without tools or other aids.
Bind/dispose leaked oil; if applicable, dispose contaminated soil in
accordance with the regulations!
6.0 Installation of individual components:

Warning
Prior to installation of the system components, the vehicle to be set upright / lifted /
shifted must be properly secured against rolling off in accordance with the
applicable guidelines for the railway area in question!
The components are installed:
6.1 Power pack

The power pack must be installed in an appropriate place (safe location / level
surface / sufficient distance from vehicles and loads).
6.2 Control desk
The control desk must be installed in an appropriate place so that the object to be
lifted and shifted can be observed from a sufficiently safe distance; if necessary,
hoses should be extended.
6.3 Lifting cylinder
Strictly adhere to the following points when installing the lifting cylinder:
- The supporting area must be level and non-slip!
- Never place cylinder on a yielding support!
- Use cylinder with base and piston guard plate!
- Use pressure-resistant, non-slip intermediate layers (copper or aluminium

sheeting) between the piston guard plate and load jacking point if necessary!
6.4 Hydraulic connection of devices (hoses)
When connecting the hoses, be aware of the following basic functions of the quick
couplers:
Before coupling, unlock the connection socket by turning the sleeve to position X.
Retract sleeve and connect plug and socket. Release sleeve and turn it to position Y.
Now the connection has been made and locked. Uncoupling is performed in the
reverse order.
Connection of the hoses is possible only when they are de-pressurized.
In order to prevent contamination of the tool lines, protect the couplings with the
dust caps supplied.
6.4.1 Connection between power pack and control desk
- The P and T connections of the power pack and control desk (see also Figs. 1, 2)
are connected by black individual hoses.
6.4.2 Connection between control desk and the lifting cylinders and other
cylinders with and without hydraulic retraction (see also Figs. 2, 3, 4, 5 and
circuit diagram)
The lifting valves (2.1) (H1...H4 with connections according to circuit diagram: A2, A3,
A4, A5 and B2, B3, B4, B5) of the control desk are linked to the connections of the
cylinders by means of red/blue hose pairs. (A2-5 = red; B2-5 = blue).
Single-acting cylinders do not require the blue hose connection.
Note:
Lifting cylinders can be connected to all 6 control valves, since they all provide the
same functionality. However, the control valves 2...5 (H1...H4 in the circuit diagram)
should be preferred, since these provide a pressure limit of 30 MPa for precise
retraction. Valves 1 and 6 (V1 and V2 in the circuit diagram) are basically designed
for the traversing unit and also operate in the direction of retracting to achieve as
high a pulling force as possible with 50 MPa.
6.4.3 Connection between control desk and traversing cylinders (see Fig. 2) The
traversing valves (2.2) on the control desk (V1, V2 with connections acc. to circuit
diagram: A1, A6 and B1, B6) are connected to the two connections on the traversing
cylinder by red/blue hose pairs: red hose on connection A, blue hose on connection
B. The tip valves (2.3) on the control desk (T1, T2 with connections acc. to circuit
diagram C1, C6) are linked to the anchor cylinders on the traversing cylinder by black
single hoses.
Note:
DUO traversing systems can only be connected to control valves 1 and 6, since
only these valves provide the functionality of a tip valve to control the anchor cylinder
on the traversing cylinder!
6.4.4 Permissible hose lengths
All LUKAS hoses have the standard hose length of 10m. The
following applies for the maximum lengths:
- Power pack per control desk: 2 x 10m
- Control desk per cylinder: 2 x 10m However,
please observe the following:
Long hose lengths between the anchor cylinder of the traversing cylinder and the
control desk and/or power pack and control desk may lead to delayed (spring-loaded)
extension of the anchor cylinder through banking-up pressure, particularly when the
total length is 4x10m. This must be taken into account during operation; in particular
the hydraulic oil should be changed at low temperatures!
7.0 Operation
7.1 Drive power pack (see figure section, Fig. 1)
7.1.1 Initial commissioning:
Prior to initial commissioning, the oil tank must be filled with hydraulic oil, filler
aperture (1.13), oil level show glass (1.6), DC-6 venting screw (1.15-1). In the case of
power packs with combustion engines, add fuel, filler aperture (1.14-2, DC-6: 1.15-2),
and engine oil: see separate operating instructions for combustion engines. Prior to
each subsequent commissioning procedure, check hydraulic oil level in the oil tank.
In the case of power packs with combustion engines, fill with fuel and check engine
oil (see separate operating instructions for combustion engines).
7.1.2 Venting of pump during commissioning or after oil change:

- Remove oil filler cap (1.13) completely.
- Slowly fill the oil container with hydraulic oil (check correct oil level in the show
glass!). The air escapes slowly during filling.
- Power packs with diesel combustion engine (DC-6):

> Before filling in oil, screw out the venting screw completely.
> After filling wait some minutes and then screw in venting screw tightly.
- Prior to motor/engine start: open pressure relief valve (1.9) (turn it to the left); to
remove the remaining air as far as possible, instead of starting the motor/engine
straight away:
- Power packs with combustion engine (GC-6):
> Pull the spark plug socket from the spark plug (gasoline 1.14),
> Slowly pull the cable starter (1.14-1) all the way out several times,
> Fit the spark plug socket again,
> Start engine with the cable starter.
- Power packs with electric motor:
> Switch the motor on and immediately off again several times in succession
(1.2) so that it turns over slowly. Make sure that the motor has come to a standstill
before it is started again.
This enables the pump to draw in slowly and be vented effectively. The oil tank is
fitted with an automatic vent, so no further venting measures are required.
7.1.3 General operation
Before starting the motor/engine:
- Verify that the pressure relief valve ( 1.9 ) is open (turned to the left) >
depressurised oil circulation,
- Verify that the hoses leading to the control desk are connected.
- Start motor/engine:
- Combustion engine: see separate operating instructions.
- Electric motor: connect power pack to power supply (observe current potential!).
Press on/off switch.
- Close pressure relief valve ( 1.9 ) completely (turn it to the right) after connecting
the hoses leading to the control desk.
7.2 Control desk (see figure section, Fig. 2)
Ensure that the control desk is a sufficiently safe distance from the loads that are to
be lifted or shifted.
The operation status will be established by throwing the lever of the pressure stop
valve in vertical position (till stopper).
7.2.1Control of lifting cylinder with hydraulic retraction by means of lifting
valve:
7.2.1.1 Lifting
- Actuate the valve (circuit diagram pos. H1...H4) for the corresponding cylinder
(marked): ”HEBEN” (lifting) = pull operating lever backwards (logic acc. to EN1494).
7.2.1.2 Lowering
- Actuate the valve (circuit diagram pos. H1...H4) for the corresponding cylinder
(marked): ”SENKEN” (lowering) = carefully push operating lever forwards (logic acc.
to EN1494).
7.2.1.3 Note on the hose system
Hose couplings with yellow-zinced securing bush and black-zinced (or bronzed)
sealing unit are equipped with a “rapid halt function” which will block the oil return
flow from the cylinder if, for example, a hose is ruptured, thus preventing the load
from slumping.
When lowering a very heavy load or switching the lifting valve to the “SENKEN”
(lowering) position too quickly, the rapid halt function may engage unnecessarily. It
will then no longer be possible to retract the cylinder. If this is the case, switch the
lifting valve to “HEBEN” (lifting) again until the cylinder starts to extend.
Carefully start the lowering procedure again.
7.2.1.4 General precaution for operation
Attention!
For safety reasons the control desk functions may only be enabled by opening
(counter clockwise rotation to vertical lever position) of the ball valve (2.4) as long as
minimum one appropriate skilled operator is standing directly by the control desk.
In case of an emergency this operator could close the ball valve with one hand, the
hydraulic loop to all lifting cylinders and traversing systems will be interrupted
immediately. Thereby the manual pressure stop valve disconnects the hydraulic
supply of the control desk form the pump.
The manual pressure stop valve does not accomplish the „EMERGENCY-STOP“-
function, i. e. the cylinders can still move by actuation of the control levers. This is
possible because of the residual pressure in the hydraulic system or an external load
on the cylinders.
By closing the ball valve you should take note that the pressure in the control desk
will only be de-pressurised during the switching operation. At normal operations it is
recommended to switch the lever slowly. The residual pressure in the control desk
could be read off the pressure gauge (2.5).
7.3 DUO traversing system

7.3.1 Bridge installation
The bridge is placed across the tracks and carefully supported by wooden planks.
Please ensure that:
- The maximum load of the bridge is not exceeded:
Bridge Installation Height
184mm 140mm 85mm
7.24 in. 5.51 in. 3.35 in.
900 kN 500 kN 80 kN
1 m/ 3.28 ft. 202,320 lbs 110,000 lbs 17,600 lbs
1.43 m/ 4.69 ft. 650 kN 400 kN 60 kN

146,120 lbs 88,000 lbs 13,200 lbs
1200 kN 700 kN 80 kN
269,760 lbs 154,000 lbs 17,600 lbs
1 m/ 3.28 ft. 200 kN 20 kN

300 kN 44,000 lbs 4,400 lbs
66,000 lbs
- The bridge is horizontally aligned:

The angle of the bridge may not exceed 3°.
For safety reason it must be made absolutely sure that the load to be lifted/up
righted/shifted is secured against eventual uncontrolled sliding into any
direction. The most critical moment during lateral displacement is when the
anchor cylinder is disengaged from its slot in the re-railing bridge. Therefore
prior to disengaging the anchor cylinder, the risk of uncontrolled sliding must
be eliminated by suitable countermeasures such as e. g. wedging the roller
carriage etc.
If one bridge is not long enough, a second bridge can be screwed on by means of
connecting elements.
7.3.2 Installation of the DUO traversing system:
7.3.2.1 Arrangement of roller carriages / DUO traversing cylinders

The traversing cylinder can be used for pushing and for pulling.
Pushing is the preferable application:
- Greater forces are available,
- As a result of the connection with the roller carriage, the cylinder attempts to move
the load towards the centre of the bridge (prevents running away towards the edges
of the bridge),
- Increased safety for the operator, since they do not need to step under the load
during setting up.
In the arrangement for pulling, shorter bridges can be used (in particular with the
cylinder arranged for two-point lifting between the roller carriages), but the risk to the
operator and the machine is greater; in particular it is difficult to observe the hoses
during the shifting process (connecting rod!).
7.3.2.2 1-point lifting: use of the roller carriage

- Position roller carriage (4.5) on bridge (4.1).
- Position traversing cylinder (4.2) on bridge and secure at bracket (4.12) on the
roller carriage.
- Engage guide plates (4.7) in traversing cylinder on both sides, pull up slider (4.8),
insert guide plates until they can be locked by pressing down the slider.
- Align slide plate (4.6) in the centre position (in relation to possible transverse
shifting) on the roller carriage.
- Place the required lifting cylinder (3.5) centrally on the slide plate (4.6); always
use the base plate (3.1) and piston guard plate (3.12)!
- Adjust the roller carriage/lifting cylinder and traversing cylinder on the bridge (4.1)
until the anchor (4.3) engages in an opening in the bridge (4.1). This can be
performed either manually or controlled hydraulically (see section 7325).
- Establish the hydraulic connection with the control desk acc. to section 6430.
- Bring the lifting cylinder centrally beneath the load jacking point and connect
hydraulically with control desk. Lifting can now be performed.
Important
The sliding surfaces between the slide plate of the roller carriage (3.3) and the
mounted slide plate (3.2) must be kept clean.
7.3.2.3 2-point lifting: use of roller carriages and connecting rods
- Assemble the first roller carriage (4.5) and traversing cylinder according to 7322
and position centrally beneath jacking point.
- Position the second roller carriage (4.5) with mounted lifting cylinder on the bridge
and roll it manually centrally beneath 2nd jacking point.
- Engage pair of connecting rods (4.4) between the roller carriages after adjusting
the distance via threaded spindles (4.10) in the roller carriages (engaging points 4.11
and 3.13).
Important: adjust both connecting rods to same length!
- Establish the hydraulic connection with the control desk acc. to section 6430.
- Hydraulically connect both lifting cylinders with the control desk. Lifting can now be
performed.
7.3.2.4 Before shifting

- Check all hose connections for correct connection acc. to section 6430,
- Start the driving power pack. Make sure that the relief valve on the power pack is
closed.
- Before you start shifting, make sure that the wheel sets of the rail vehicle are lifted
high enough above the rail so that rail and wheel set do not touch.
7.3.2.5 Extending/retracting the traversing cylinders without/with load
Condition: the anchor of the anchor cylinder on the traversing cylinder must be
locked in the bridge opening:
- At the control desk, slowly actuate the traversing valve (2.2) (acc. to circuit
diagram V1, V2):
- Pull hand lever backwards: piston of the traversing cylinder extends.

- Release the spring-loaded lever to hold the piston;
- Push the hand lever forward: piston of the traversing cylinder retracts.
7.3.2.6 Automatically shifting the traversing cylinder
If the total stroke of the traversing cylinder is utilised and the shifting distance is still
not sufficient, the traversing cylinder must be adjusted:
- Lift the holding anchor of the anchor cylinder by pressing the spring-loaded tip
valve (2.3) T1, T2; keep the tip valve depressed: red signal pin (5.5) protrudes.
- Retract the traversing cylinder again in the opposite direction by means of the
traversing valve.
- After a partial stroke of the traversing cylinder piston, release the tip valve: red
signal pin must be retracted as far as edge of housing.
- Continue to actuate the hand lever of the traversing valve (2.2) (V1 V2) until the
anchor automatically falls into the next opening.
- Stop movement by releasing the hand lever of the traversing valve.
The shifting procedure can be repeated as many times as required (provided the
bridge is long enough) in both directions.
Note:
If the anchor cannot be lifted (due to non-positive setup), the traversing cylinder must
be shifted slightly in the direction opposite to that in which it has previously been
moved. The anchor can then be lifted.
7.3.2.7 Shifting the load in the opposite direction
If the load is unintentionally shifted beyond its destination, the traversing cylinder is
simply moved in the opposite direction.
7.4 Lifting cylinder:
7.4.1 Initial commissioning
Prior to commissioning, the cylinders must be vented!
- Extend cylinder pistons without load approximately half way,
- Turn cylinder upside down, the highest point of the cylinder must be below the
control desk connections,
- Extend piston about twice by means of the corresponding valve on the control
desk, so that air can escape from the cylinder and hoses.
7.4.2 Warning
Prior to installation of the cylinders, the vehicle to be set upright / lifted / traversed
must be
properly secured against rolling off
in accordance with the applicable guidelines for the railway area in question.
Do not stand below suspended loads: if in exceptional cases this cannot be avoided,
these loads must mechanically be
sufficiently secured against movement in any direction!
7.4.3 Safety note

Before installing and dismounting components, you must:
- Switch off the drive motor/engine on pump power pack!
- Set lifting valves, shifting valves and stop valves to “0” position!
Always observe the load while it is being moved by means of the cylinder!
7.4.4 Connection of hoses
- Establish connection between lifting cylinders and control desk.
- Do not connect hoses to the control desk and then to the cylinders until they have
been secured in their final position.
7.4.5 General instructions for the installation/operation of all cylinders
- The supporting area must be level and non-slip!
- The supporting area must be a continuous level surface (not a grating, gravel
etc.)!
- Never place cylinder on a yielding support!
- To avoid damaging the piston, never use a cylinder without piston guard plates!
- LUKAS piston guard plates are specially designed:
- To reduce the risk caused by excess off-center load, the support area is
reduced.
- To prevent a slipping of the load, a grooved surface is provided
- If necessary, use a sufficiently pressure-proof support between the piston guard
plate and load jacking point!
- Always use LUKAS base plates!
- Observe centred load initiation on the pistons! Find a more favourable load
application point if necessary!
When the extended piston is exposed to critical off-center load, considerable wear
and tear to piston and guide ring might be the consequence. This will reduce the
lifetime of the jack considerably. Therefore, you must strictly adhere to the following
operating instruction:
- Only cylinders and cylinder components that are in perfect condition may be
used!
- In no circumstances may piston guard plates be removed! (Risk of destroying
the piston.)
- Always support and secure the raised load!
Operation:
- Connect hoses only after these preparations have been made!
- Always make sure that loads are lifted parallel!
7.4.6 Base plates (3.1)
Base plates must always be used to:
- Increase the base area of the cylinders,
- Increase static stability,
- Level out unevenness of the ground.
Secure the base plates radially on the cylinder body with the aid of 3 wing nuts.
8.0 Optional components for further applications

8.1 Multistage sets for telescopic cylinders (see figure section and technical
appendix)
8.1.1 Description
Multistage sets enlarge the maximum stroke of a cylinder. For space reasons,
cylinders with large strokes often cannot be used due to their large overall height.
Multistage sets make it possible to use cylinders with a small overall height to lift
loads high.
Multistage sets consist of:

- Several stacking rings,
- Several piston plates of various lengths: 1 piston
plate 1 (shorter overall height), 2...3 piston plate 2
(longer overall height),
- Fork lever.
8.1.2 Installation / operation:
- Raise the load with the cylinder, using the standard piston guard plate.
- Place the first stacking ring (pos. 7) centrally on the cylinder body with the fork
lever.
Caution under load!
- Lower the load onto this stacking ring and retract the piston.
- Remove standard piston guard plate from the cylinder. Caution under load!
- Insert first piston plate (pos. 8) with neck in piston centring device (use fork lever!).
- Completely extend load again by means of piston.
- Position second stacking ring (pos. 9) with fork lever.
- Lower the load onto this stacking ring.
- Insert second piston plate (pos. 10) with neck into centring device of the first plate
(use fork lever!)
- Completely extend load again by means of piston.
- Proceed according to the same cycle...
8.1.3 Note:
- For safety reasons, do not exceed the permissible total number of piston plates
and stacking rings per set (e.g. as a result of using individual elements from a further
set that is not required).
8.2 Axle pusher (see figure section, Fig. 5)
8.2.1 Description
The axle pusher is used to press rail vehicles into their tracks where the wheel flange
has been placed on the rail during the previous rerailing procedure. The time required
for carrying out an additional shifting procedure can thus be saved.
The axle pusher consists of one crosshead (5.1) with two hooks (5.2). A cylinder LZM
10/160 (5.3) with piston guard plate (5.4) is inserted in the accommodation opening
(5.5) of the crosshead.
8.2.2 Installation / operation:
- Place the crossbeam over the rail section and fix it on both sides of the wheel by
means of the hooks, align the hooks parallel and at right angles to the rail.
- Support the accommodation opening in the crosshead at rail level.
- Clamp the cylinder LZM 10/160 into the accommodation opening with the wing nut;
fit the piston guard plate.
- Connect the red hose of the hose pair or the black individual hose to the cylinder’s
pressure connection.
Important! With the LZM 10/160, the blue hose is not required and may therefore not
be connected to the control desk!
- At the control desk, actuate the lifting valve H1...H4 belonging to the hose,
- If the piston guard plate presses on the rim, carefully continue to press until the
wheel drops onto the rail.
9.0 Dismantling of components:
9.1 Lifting cylinder, DUO traversing system and optional components
Dismantle the components in the reverse order of the installation sequence. First of
all the lifting cylinders must be completely retracted by actuating the appropriate
valve on the control desk.
Before final dismantling of the devices it is absolutely essential to ensure that

- The load is in a stable, immovable position
- All lifting cylinders have been completely retracted, then
- The drive motor/engine must be shut down, after
- All hoses have been depressurised!
To do this, proceed as follows: (Fig. 2)
- Switch control valves (2.1) H1...H4 and (2.2) V1, V2 on the control desk
temporarily to “SENKEN” (lowering), then switch them to the centre position
(pressure relief of hoses).
- Open the pressure relief valve (1.9) on the power pack.
- Disconnect the DEPRESSURISED hoses in this order:
- Hose red
- Hose blue
- Hoses black.
10.0 Preventive and corrective maintenance
10.1 General instructions concerning power pack, control desk and cylinder
components
After each operating procedure the components must be checked for perfect
operation (clean them first if necessary):
- Lifting cylinders: have all pistons been completely retracted? If not, check whether
each piston can be retracted smoothly (cylinders/pistons OK?)
- Check whether there are any loose hydraulic screw connections on the devices
and hoses; tighten them if necessary.
- Check the mechanical parts, the valves and the hoses of power pack, control desk
and cylinders for mechanical damage.
- Check whether the signs, warnings, operation and control symbols and other
markings (colour markings) are complete and perfectly legible.
- Check whether all safety covers (engine: protective cover, exhaust pipe cover),
hoop guard etc. are present and in perfect condition.
10.2 Hydraulic system leakage

- Check devices for oil loss and replace defective seals if necessary.
Important:
Carry out the following procedures over an oil pan; dispose of used oil!
10.3 Check / change hydraulic oil
- Check oil level of the motor/engine pumps and hand pumps after each operation,
fill up oil if necessary (see oil recommendation).
- Replace hydraulic oil after approximately 50 operations, but no later than every two
years.
10.4 Motor/engine pumps

Open oil drain plug, carefully allow all the oil to drain out, flush tank, close oil drain
plug, open oil tank cap and add fresh hydraulic oil.
10.4.1 Hand pumps
Unscrew oil tank cap, carefully allow all the oil to drain out, flush and add fresh
hydraulic oil.
10.5 Cylinders
To remove the oil remaining in the piston main zone and piston ring zone, unscrew
both couplings from the connecting blocks if necessary and carefully allow all the oil
to drain out; then flush and add fresh hydraulic oil. Screw couplings in tightly and
tighten them to 80 Nm torque. Vent cylinders as specified in the description! Select
hydraulic oil according to ambient operating temperatures: recommended range of
viscosity: 10..200 (mm2/sec).
10.6 Annual maintenance
Irrespective of the aforementioned maintenance procedures, an annual check must
be carried out to ensure that the complete system is functioning properly.
11.0 Repairs
11.1 General
In all system components, only genuine LUKAS spare parts as listed in the spare
parts list may be replaced, as it is absolutely essential to use or observe any special
tools, assembly notes, safety aspects and checks that might be required for this
purpose. This work must be carried out by qualified/trained personnel only.
11.2 Repairs to cylinders
Before opening the cylinders, make sure that they have been depressurised. For
repairs, see operating instructions for cylinder.
11.3 Repairs to hand pump
For repairs to hand pump see operating instructions for hand pump.
11.4 Repairs to hoses
Repairs to hoses must be limited to replacing connection nipples and hydraulic
couplings. Defective hoses (damaged outer hose cover, buckled hoses, faulty metal
bonds and union nuts) may under no circumstances remain in use.
Hoses display the date of manufacture and must be exchanged after 10 years at
the latest or earlier if exposed to extreme environmental conditions (heat, dust,
aggressive media)
11.5 Problems / trouble Shooting-

Inde C=
x: P = Problem; S = Symptom; Check
11.5.
10 P: Pump fails to deliver oil:
S: No pressure reading on control desk pressure gauge (neither LP nor HP) C:

Hoses connected properly etc.
If the hydraulic oil is filled up for the first time or changed, the pump system must
be thoroughly vented according to section 7410.
11.5.2 P: System pressure (530 bar) is not reached

C: Pump delivers properly; hoses connected.
- Pressure set at HP shut off valve is too low due to setting properties.
- Setting must be carried out by authorised dealer or at the manufacturer’s factory.
11.5.3 P: Cylinder pistons cannot be extended

C: No pressure on control desk pressure gauge.
Hand wheel of relief valve on the power pack (1.9) not closed.
11.5.4 P: Cylinder pistons cannot be retracted

C: Hand wheel of relief valve on the power pack (1.9) not closed.
11.5.4.1 P: Rapid halt on cylinder has locked and blocks the retraction
movement
C: Unlock rapid halt according to section 7220.
11.5.5 P: Hoses cannot be connected
C: Hoses are under pressure since they have accidentally been disconnected without
being depressurised
- Open union nut on hose. Procedure:
- Cover against oil spray!

- Hose is being depressurised. Caution: oil spray!
- Tighten union nut again. MA=45 Nm.
11.5.6 P: Anchor of the anchor cylinder on the DUO traversing cylinder does not
respond when the tip valve is actuated: red signal pin is not protruding
C: Pressure gauge displays pressure, the tip valve of the connected hose is actuated,
hose is coupled with connection C of the DUO traversing cylinder.
S: After shifting, the conical part of the anchor touches the inclining flank of the bridge
recess and cannot therefore be lifted out hydraulically: make the traversing cylinder
move into the opposite direction by briefly actuating the traversing valve, so that the
anchor will withdraw from the flank.
11.5.7 P: No pressure on the control valves
C: Pressure stop valve active (lever in horizontal position) and for this reason the
hydraulic system is not unlocked.
If the defects cannot be repaired, contact an authorised LUKAS dealer or the

LUKAS service department directly. The address:
LUKAS Hydraulik GmbH, Weinstraße 39, D-91058 Erlangen, Germany;

Postfach 2560, D-91013 Erlangen, Germany; Service tel.: +49 9131-698348;
Fax: +49 9131-698353.
12.0 Technical data:

(see figure section and technical appendix for complete system)
12.1 Hydraulic power pack see data sheet, see

circuit diagram.
Delivery without oil; select oil acc. to ambient temperature.
12.2 Control desk

see data sheet, see circuit diagram.
12.3 Lifting cylinder

see data sheets for existing components.
12.4 DUO traversing system
12.5 Accessories
12.6 Oil recommendations

Oil for LUKAS hydraulic devices: mineral oil in accordance with DIN 51524 and
others
Range of oil Viscosity
temperature rating Remarks
A - 24 ... + 30 °C HL 5
B - 18 ... + 50 °C HLP 10
C - 8 ... + 75 °C HLP 22
D + 5 ... + 80 °C HLP 32
E - 8 ... + 70 °C HF - E 15 biodegradable
Recommended range of viscosity: 10..200 (mm2/sec).
For mineral oils in accordance with DIN 51524, temperature ranges acc. to datasheet
(technical appendix) apply.
CHAPTER - 10
STANDARD LISTS
OF
TOOLS AND EQUIPMENTS
FOR
A” & B” CLASS ARTs,
ARME, SPARMV & SPART
ON
INDIAN RAILWAYS
1
General:
Critical review of standard list of ART tools and equipments in various
ARTs has revealed that at most of the ART sections standard list of tools
and equipments circulated in 1985 is being followed with some minor
local adjustments. This old standard list is having total 22 categories and
approx 553 items under these categories.
After thorough review of each and every item in this standard list, the
total categories have been reduced to 21 with total complement of 537
items. The items deleted are 55 nos, items newly added are 12 nos and
items for which quantity/specifications revised are 34 nos.
Proposed Revised Standard List of Tools and Equipments to be kept

in “A” & “B” Class ARTs is given in this chapter. This has been
prepared after consultation with various ART incharges of Zonal
Railways. Standard lists for ARME, SPARMV & SPART are also
mgiven in this chapter. Tese revised Standard Lists contains all the
Railway Board instructions till date, and non relevant items pertaining to
Steam Cranes and Vacuum Brake Rolling stock have been deleted.
Technical description of all critical tools and equipments of ARTs &

SPARTs alongwith specifications have also been given in this chapter for
better understanding of safe functioning of equipments at accident sites.
2
Technical description of Critical Equipments of ARTs/SPARTs
Technical description of all critical tools and equipments provided in the ARTs/SPARTs are
given in this chapter for better understanding of functioning of equipments. The utilisation of
equipment and technical details are also given for each equipment for safe application at
accident sites.
1) Hydraulic Re-railing Equipment (HRE) LUKAS

(530 bar Double Acting Petrol Engine Driven)
 Application –
The particular set of equipment is specifically required for various applications such
as re-railing / lifting derailed rolling stock, toppling of vehicle & pulling the vehicle
etc.
 Make –
LUKAS Hydraulik GmbH
Germany.
 Name of Suppliers –
1.M/s PAN India Ltd.
105, Phase IV, Udyog Vihar,
Gudgaon.
Phone – 0124 2347711, 4015053
Fax – 0124 2346646, 2342880
2.
 Description –
Hydraulic re-railing equipment is
the heart of ART. The equipment
consisting of power pack
(Hydraulic pump driven by petrol
engine) provides the hydraulic
power. The same power is
controlled & distributed through
control table to the hydraulic
telescopic jacks. The same can be
used for various applications such
as re-railing/lifting of derailed
rolling stock, toppling of vehicle
and pulling the vehicle etc.
 Specifications – The H. R. E. Equipment is containing following sub units.
1. LUKAS 530 bar double acting Power pack Petrol Engine (GC-3) – 2 nos,
2. Control Table (CT 1F) – : 2 nos,
3. Foot for control table – : 2 nos,
4. Two way distributor valve – : 1 no,
5. Hose Pair (10 mtr. Long) Red & Blue, Hose Pair (10 mtr. Long) Yellow &
Blue, Hose Pair (10 mtr. Long) BLACK – : 2 set each,
6. Claw Jack (50 t. / 850 mm) - : 2 nos,
7. Radius Plat,
3
8. Telescopic Jack (10 t. / 160 mm)
9. Telescopic Jack 25 t. / 185 mm,
11. Tilting telescopic Jack 25 t. / 450 mm,
14. Pulling Jack 25 t. / 450 mm,
15. Gauge rod for pulling,
16. Portable hand pump,
17. Lifting belt Set for connecting elements,
18. Roller carriage without traversing Jack,
19. Roller carriage with traversing Jack,
20. Sliding plate,
21. Re-railing Bridge 4.40 Mtrs length / 140 mm. height,
22. Re-railing Bridge 3.25 Mtrs. length,
23. Re-railing Bridge 2.20 Mtrs. length / 140 mm. height,
24. Re-railing Bridge 1.10 Mtrs. length / 140 mm. height,
25. Adjustable distance bar,
26. Resetting device for Roller carriage,
27. Holding rope,
28. Base plate 10 t. / 250 mm,
31. Stacking set 50 t. 175 R / 165 R,
32. Axle pusher,
33. Piston guard,
34. Tool Box,
35. Pulling Device 20 t.,
36. Two way oil distributor,
37. Quick connect coupling.
38. Lukas hand pump, two stage ZPH 3/8 – 2D,
4
2) Hydraulic Re-railing Equipment (HRE) LUKAS – Single acting
(450 bar Single Acting Diesel Engine Driven)
 Application –
The particular set of equipment is specifically required for various applications such
as re-railing / lifting of derailed rolling stock, toppling of vehicle & pulling the
vehicle etc.
 Make –
LUKAS Germany.
 Name of Supplier – M/s PAN India Ltd. Gudgaon, INDIA.
 Specifications –
The H. R. E. Equipment is containing following sub units.
1. LUKAS 450 bar Power package Diesel Engine,

2. Control Table,
3. Two way distributor valve,
4. Oil return hose (10 mtr. Long) YELLOW,
5. High pressure hose (10 mtr. Long) RED,
6. High pressure hose (10 mtr. Long) GREEN,
7. High pressure working pipe (10 mtr. Long),
8. Claw Jack 40 t. / 720 mm,
9. Radius Plate,
15. Step Jack 75 t. / 200 mm,
16. Pulling Jack 20 t. / 400 mm,
17. Gauge rod for pulling,
18. Portable hand pump,
19. Lifting belt,
20. Set for connecting elements,
21. Roller carriage without traversing Jack,
22. Roller carriage with traversing Jack,
23. Sliding plate,
24. Frame support 150mm x 130mm x 350mm,
32. LUKAS manual,
33. Pulling device 20 t.
5
3) Pneumatic Lifting Air bags
 Application –
The set of equipment is specifically required for lifting rolling stock especially
where hydraulic jacks can not be placed below vehicle due to constraints of space
availability. This equipment is termed as life saving equipment as it provides stable
& quick lifting action.
 Make –
KAESAR KOMPRESSOREN GmbH
Germany.
 Name of Supplier –
M/s PAN India Ltd.
105, Phase IV, Udyog Vihar,
Gudgaon.
Phone – 0124 2347711, 4015053
Fax – 0124 2346646, 2342880
 Specifications –
The pneumatic H. R. E. Equipment is containing following sub units.
1. Compressor Premium – Car 250 / 30 W – 1 No,
2. Lifting bag (Inflatable air bag) 40 t capacity – 2 Nos,
3. Control Panel – 1 No,
4. Pressure reducer – 1 No,
5. Inflatation hose ( 5 Mtr) YELLOW – 1 No,
6. Inflatation hose ( 10 Mtr) RED – 1 No,
7. Inflatation hose ( 10 Mtr) GREEN – 1 No,
 Rating –
1) Max Pressure 10 BAR with free air delivery 150 L.P.M.,
2) Single Tank of capacity 28 Ltrs. with working pressure 11 BAR,
3) Motor 1.3 kW, 230 Volt, 50 Hz, 16 Amp max current, 3000 rpm ( with thermal
protection),
4) Time required to charge system from 3 to 8 BAR is 53 secs,
5) Weight of entire unit 43 Kg,
 Features –
The Air bags are lightweight & versatile. These air bags come with duel controller
with quick double action connectors. The feature enables the operator to work
quickly.
6
4) Multipurpose Self Powered Carbide Tipped Bullet Chain Saw
 Application -
The equipment is not much useful for stripping out wooden objects, felling trees,
pruning tree branches causing infringement in relief / rescue / restoration work. Also
the same equipment can be used for cutting of tree branches on O. H. E. lines. This
chain saw can cut 18 gauge sheet metal also. It is advised that only ordinary chain
saw to be procured for ARTs for normal operation not bullet chain saws.
 Make / Model –
Petrol Driven Carbide tripped CHAIN SAW (SHARPEX 667)
M/s. S. B. Drive Power Ltd.
1, Aman Chambers, 113 New Queens Road, Mumbai – 400 004.
Phone – 022 – 56353401 / 02
 Description – ARTs must have one CHAIN SAW/ bullet chain saw.” The
equipment is consisting of petrol engine (single cylinder air cooled two stroke 70
cc), 0.8 ltr fuel tank, Centrifugal three shoe type clutch, rim & drum type sprocket,
Carbide tipped cutting chain (chain speed 98 ft / sec). The equipment is weighing
just 9.5 kg with features such as adjustable chain lubrication, maintenance free
electronic ignition, anti vibration system, ergonomically design with outstanding
operator comfort.
5) Portable Electrically Operated (TOOLS) equipments
 Application –
The set of portable
electrically operated tool
set useful in relief / rescue
operations at accident sites.
7
1) TREPANNER :Useful for boring holes up to 2” to 4” in coach roof & panel.
(Weight 3.5 kg)
2) SHELL SHEAR : Useful for cutting window bottom channels and pillars.
3) CHANNEL CUTTER – Useful for shearing sheet mental panels of coach body
and roof, etc.
4) BAR CUTTER – Useful for cutting window bars, bench support steps etc.
 Models suitable –
1) TRE-PANNER (Model – 9011), 2) SHELL SHEAR (Model – 9021)
3) CHANNEL CUTTER (Model – 9031), 4) BAR CUTTER (Model – 9001)
 Description –
1) TRE-PANNER : Weight 3.5 kg.

This equipment is specially used for creating
hole (up to 100 mm) in steel sheet max 5
mm, the same is essential for entry of any
tool like Spreader, shell shear for widening
in rescue operation.
This equipment features light weight, fast
working, low Maintenance works on 110
volt single phase. Because of this, single
person can operate at any height & difficult
approach conditions and can create hole
from 10 mm to 100 mm within 2 to 3 min.
2) SHELL SHEAR: Weight 6 kg.

This equipment is special type of equipment for
shearing sheet, metal panel of rolling stock. It
can cut M. S. sheet up to 3 mm thickness. The
same can cut panel below the window channel
to create opening.
This equipment features light weight, long life,
fast working, low Maintenance works on 110
volt single phase. The tool can work at a very
high speed with reciprocating motion of piston
creates very high force to cut sheet as paper. By
considering above features, the single person can easily cut sheet at a speed of ½
meter / min with this equipment. Also the chips produced during cutting operation
are harmless & cold.
3) CHANNEL CUTTER: Weight 4 kg.
4)
Channel cutter is mainly used for cutting of
channel below the window of vehicle as well
as vertical support pillar during rescue
operation.
8
Special innovative feature of this equipment is that during cutting operation, metal
chips produced during operation are collected in special chamber & helps the
operator from injuries. The motor of this equipment specially designed with rare
earth magnets to give high torque & power to the cutting tool.
4) BAR CUTTER: Weight 4 kg.
This equipment is used for cutting of
window bars of passenger coach, round
bars (up to 13 mm dia.) pipes
(up to 30 mm), bench supports as well as
minor structural elements such as foot steps
(up to 5 mm thick).
6) Emergency Inflatable Portable Tower
Lighting:
 Application –
These inflatable lighting towers are a revolutionary concept in illumination &
lighting. It is highly useful at rescue / relief operation sites as well as for restoration
works. As the equipment is portable & compact, it can be transported easily at the
site & can be used quickly.
M/s. A.S.K.A. Equipments Ltd.
Opp. Hislop Collage, Civil lines,
Nagpur.
 Specification –
a) Power source 3.5 HP 3000 rpm Brigg & Stratton petrol engine coupled to
alternator 1.2 kVA, 230 volt.
b) The inflatable tower is of 4.5 meter in height cylindrical balloon made of
polyester treated with polyurethane (water proof)
c) Light source 400 Watt Metal halide capable of producing light illumination of
42000 Lumens, the same is sufficient to cover 10,000 Sq. mtrs.
d) The whole equipment weighs only 45 Kg with size 54 X 33 X 55 cm when folded
The Emergency Inflatable Portable

Tower Lighting is compact in size,
light in weight & provides
extraordinary illumination. It will
eliminate need of carrying large
generators with maze of wires at
accident sites.
9
7) (BOSCH MAKE) Portable Electrically Operated Power Tools:
 Application –
The set of portable electrically operated tool set useful in relief / rescue work
1) Bosch make reciprocating saw
2) Bosch make portable power drill machine
 Description –
1) Reciprocating saw:
This equipment is specialize equipment for shearing sheet metal panel of rolling
stock. Also the same can be used to make plunge cuts (pocket cuts) in softer material
such as wood or building material for wall without making hole.
This equipment features light weight, long life, fast working, low Maintenance. The
tool can work at a very high speed with reciprocating motion of piston creates very
high force to cut sheet as paper. This equipment is having special features such as
a) Lock Jaw ( blade holder) precise holding of blade,

b) Locking collar for easy attachment or detachment of blade,
c) Pivoting footplate with release button for providing guidance (surface
contact) for easy & effortless operation,
d) three projection positions to optimise blade life,
e) Variable speed controlled Trigger switch,
f) Convenient snap able Saw hook
10
2) Portable power drill machine:
This equipment is specially used for creating hole in steel sheet, the same is essential
for entry of any tool like Spreader, shell shear for widening rescue operation.
Specifications –
Rated power 550 watt, max torque 11.5 N-m,
chuck clamping range 1 – 13 mm, drill range in (steel 13 mm & in wood 32 mm.)
weight 1.9 kg.
This equipment features double insulated body, keyless chuck, thumbwheel for
speed selection, Depth stop, light weight, Because of above features a single person
can operate at difficult approach condition and can create holes.
8) Self contained Air breathing Apparatus

 Application – The equipment such as self contained air breathing apparatus can be
used in relief & rescue operation in smoke filled trains on fire or to rescue passenger
trapped within accident involved trains. The same can be used in accident involving
LPG / Hazardous gases.
 Manufacturer –
Model CENTURION, Make Vijay Sabre Safety Ltd.
Capacity: 6 lits capacity, 300 Bar pressure, duration effective 45 Min & working 35
mins, Cylinder dia 140 mm, Weight of charged apparatus 17.3 kg, Whistle setting 68
BAR.
11
Cylinder having ‘I.S.I.’ mark (BIS 10245 part II). The equipment is having centre
adjustment buckle with independent shoulder straps & harness made of flame
retardant webbing. The cylinder strap features cam-lock mechanism.
The weight of apparatus concentrates on hips of wearer to reduce back stress &
fatigue. The back plate is made of material durable, flexible, chemical & heat
resistance, light weight & anti static. The system gives warning when 80% air is
consumed.
9) High Pressure Air Compressor

 Application – The same equipment is required for charging air cylinder of air
breathing apparatus.
MCH-16/D Set No. 0001 AEROTECNICA COLTRI S.r.l. Breascia Italy
M/s. JYO Tech Engineering & Marketing Consultant.
Opp. Hislop Collage, Civil lines,Nagpur.
a) Capacity 260 L. P. M.,
b) Cylinder dia 95 / 38 / 14 mm ,
c) Max non continuous peak pressure 225 BAR,
d) Max non continuous working pressure 330 BAR,
e) Speed 1550 rpm.,
f) Diesel engine make YANMAR, power 5.5 kw (7.5 hp),
g) Weight approx 136 kg.
 Feature – The main features of air compressor unit are as follows –
The unit is having three compression stages, 3 cylinders, forced air cooling by means of
large diameter fan, splash lubrication with immersed pins, stainless steel cooling pipes.
The system is equipped with air filtration unit.(activated carbon filter and molecular
sieve).
12
10) (PETROGEN) Under water cutting equipment
Application – The above mentioned
equipment is basically a Oxy-gasoline
torch system. It is the most versatile
cutting device, the same can cut even
under water.
 Name of Manufacturer –
M/s Petrogen International ltd.
P. O. Box – 1778, San Leandro,
CA 94577
M/s M/s Deccan Automobile Co.
61, Jagannath Shankarseth Road,
Nagindas Mansion, Opera House,
Mumbai – 400 004
Phone – 2382 3024 Fax – 2385 7939
 Specification – Petrogen equipment is having following items -

a) Torch 20” with 90 degree handle,
b) Gasoline tank 2.5 gallons,
c) 2 cutting tips,
d) 20 feet gasoline hose assembly,
e) 25 feet oxygen hose assembly,
f) Oxygen back flash arrestor,
g) Spark striker,
 Features – The equipment can cut through -
a) 12 inch mild steel shaft in 3 mins.
b) 4 inch manganese steel dipper tooth shank in less than 1 min.
c) 10 gauge steel at 51 inches / min.
d) 52 kg rail piece in 40 sec.
e) 11 inch armour plate at 6-1/2 inch / min.
f) straight hole through 10 inch armour plate in 50 sec.
g) All above tasks without pre-heating
Petrogen tank are tested at 100 p.s.i. The tank is constant pressure fuel tank hence can
work at a depth of 600 feet.
11) Safe Access Rope Ladder

 Application – It is the general purpose
Foldable rope ladder applicable at
Restoration / relief work sites.
M/s. BEST TOOLS MART.
Chowk Bazar, Bhusawal
Phone – 02582-24652
Safe access rope ladder of Polypropylene rope (12 mm dia) with Aluminium rungs,
ladder size 30 feet, confirming IS 5175.
13
12) RAIL SKATE:
 Application – Rail skate is important item of ART as it is essential for clearing
rolling stock involved in Hot Box / Journal breakage cases. Rail skate can be proved
very useful in transportation of wagon/coaches disabled in mid section due to Hot
Box / Journal breakage etc.
 These skates are available in open market. These may be procured on requirement
basis in the ARTs and SPARTs. These skates may be fabricated & developed in
workshops also. Locally manufactured rail skates are available in the ART of Diesel
Shed Itarsi which were developed by Loco Workshop/Parel in CRLy.

13) Breath Alcohol Detector:

 Application – The equipment is specifically recommended to kept in ART for
detecting the alcohol consumed staff/person involved in accident .
Victory make Model V – 701 D
a) Size 150 mm X 88 mm X 35 mm,
b) Weight 300 gms. (batteries included),
c) Capacity – 50 to 70 test on single charge,
d) Battery – 6 volt NI-CD,
e) Temp range – 0 to 70 degrees,
f) Display – Digital meter with buzzer for fail indicator,
g) Alarm – Factory set at unacceptable level of alcohol.
14
14) Paragon Instrumentation Engr. make set of Gauges:
 Application – At the time of finding out of the root cause of the derailment, these
specially designed gauges can be used for measurement of culprit vehicle, rail or
other mechanical components.
1) Folding type wheel diameter gauge [Model WD – 1 (M)]
2) Digital wheel diameter gauge [Model WD – 1 (D)]
3) Buffer Height gauge [Model BHG – 3 (CBC)]
4) Rail profile gauge cum recorder [Model RPG – 2]
M/s. Paragone Instrumentation Engineers Pvt. Ltd.
200 – Station road,
Roorkee – 247 667
Phone – 01332 – 272386, 272863
 Description –
1) Folding type wheel diameter gauge
[Model WD – 1 (M)]
This gauge is fitted with Mitutuyo

micrometer assembly.
Measuring accuracy – < 0.1 mm
Least count – 0.01 mm
Applicability – B.G. Wheels
Operation by – Single person only
2) Digital wheel diameter gauge

[Model WD – 1 (D)]
Measuring accuracy – +/- 0.01 mm

Least count – +/- 0.01 mm
Applicability – B.G. Wheels
Range – 800 – 1010 mm
3) Buffer Height gauge

[Model BHG – 3 (CBC)]
Model consist of foldable track base on while vertical column with a telescopic
measuring scale is provided. The column has vertical bubble & foldable for
compactness and ease of storage. Accuracy – 1 mm.
4) Rail profile gauge cum recorder
[Model RPG – 2]
The gadget draws exact profile of rail head &

determines loss of weight & wear of rail head.
15
LIST OF TOOLS & EQUIPMENTS REQUIRED IN “A” & “B” CLASS ARTs
Cat. DESCRIPTION Recommended Recommended Recomme
S.N. for "A" Class for "B" ndations
ART Class ART of HLC
CATEGORY No.1
GENERATORS & ELECTIRCAL EQUIPMENTS
1 GENERATOR- Diesel driven 15 KVA/ 5/6 KVA (02 Nos.) 01 Set 01 Set
220/230V fixed complete with switch board and
accessories.
2 PORTABLE GENERATOR- Petrol start / K-Oil driven 1.5/2/3 Min.07 sets Min. 07
KVA 220/230V with integral switch Board. sets
3 Portable Switch board with 4 water proof Industrial Sockets 10 sets 06 sets
each capable of taking 500 watt load & 2 Mtrs. 15 Amp
Cap. PVC insulated copper lead with plug on One end.
4 Weather proof flood light fitting 500W (Halogen fitting) 10 Nos 05 nos
with 15 meters lead and weather proof plug.
5 Weather proof light fitting 1000 watts (Halogen fitting) with 04 Nos 02 Nos
15 meters lead and weather proof plug.
6 Complete Luminary fitting with 150 W Metal Halide lamp 15 Nos. 10 Nos.
and control gear.
7 Main Cable for fixed generators 15 amps capacity 3 core 10 300 Mtrs 300 Mtrs
Sq.mm armoured PVC Insulated & PVC sheathed 2 x 150
mtrs.
8 Drum on fixed stand for main elect. Cable. 02 Nos. 01 No.
9 30 meters 3 core, 15 Amps cable on spool with Plug. 10 Nos. 08 Nos.
On free end & one socket on fixed end.
10 Stand flood lights approx.2000 mm height 20 Nos. 10 Nos.
11 Metal Rectifier for charging 2 TL batteries at a time 02 Nos. 02 Nos.
230 V AC / 110 V DC, 60 Amp.
12 Spare lamp for 500 Watts Halogen light fitting 10 Nos. 05 Nos.
13 Spare lamp for 1000 Watts Halogen light fitting 04 Nos. 02 Nos.
14 100 Watts gas filled bulbs bayonet type. Required complete 06 Nos. 4 Nos.
with holder in wire cage, handle and hooks &
5 Mtrs wires with plug.
15 Telescopic masts 6 meters high. 04 Nos. 02 Nos.
16 Halogen lamps with 100 meters wire & pin 08 Nos 06 Nos
17 Tool kit for Generator set as per make of GEN Set 02 sets 01 set
comprising of 254 mm cutting pliers - 01, screw driver
round 300 mm, 150 mm, 100 mm - 03 nos., knife - 01 No.,
Hammer DP - 01 No., Spanner DE - 03 mm to 19mm in
step of 1.5 mm & sockets spanner with lever
3 mm to 19 mm.
18 Diesel Oil 200 Ltrs 100 Ltrs
19 Petrol 10 Ltrs 05 Ltrs
20 Kerosene Oil 200 Ltrs 150 Ltrs
21 Aluminium telescopic ladder. 02 Nos. 01 Nos.
22 Polythene container 20Ltr. Capacity for handling kerosene 06 Nos. 04 Nos.
oil & pouring into auxiliary tank of engine.
23 Oil measuring can of 01 ltr, 2 Ltr, 5 ltr capacity. 01 No. each 01 No. each
24 Lubricating oil 40 Ltrs. 30 Ltrs.
25 Insulation tape PVC in roll of 10 mtrs. 20 Nos. 16 Nos.
1
26 Hand driven centrifugal pump separate for each type of oil. 04 Nos. 04 Nos.
27 Garden umbrella size 48 Inch X 10 Inch( H-Nylon) cloth. 03 Nos. 03 Nos.
CATEGORY No.2
ILLUMINATION (OTHER THAN ELECTRICAL)
1 Battery Operated Lamps/LED Minor lamp Min. 06 Nos Min. 06 Nos
2 Spare batteries for Lamps/LED Charging unit 06 Nos. 06 Nos.
3 Spare Reflectors/Glass for battery lamps 06 Nos. 06 Nos.
4 Plastic body 4 cell torches/Dry cell LED torches 12 Nos. 06 Nos.
5 Spare torch bulb 6.2 volts for 4 cell torches 12 Nos. 12 Nos.
6 3 Cell torches 10 Nos. 06 Nos.
7 Spare Bulb for 3 cell torch 24 Nos. 12 Nos.
8 Emergency Inflatable Lighting towers with light source 4.5 04 Nos. 4 Nos. HLC No.60
meters high fitted with 400 watt metal Halide Lamp to
illuminate an area of 10000 Square meters with 3.5 BHP
engine and alternator 1.2 KVA 230 volts of weight not
exceeding 45 kg.
9 Spare Blowers (Ralli Wolf NWB Blower), 350 watts, 250 V 02 Nos. 02 No. Only one to be
fitted/tower
DC & AC 50Hz., 1.6 Amps, capacity 1.5M3/Min.
10 Tool kit with spare Halide lamps for inflatable lighting 04 Nos. 04 Nos.
tower.
11 Dry cells 06 Dozen 06 Dozen
CATEGORY No.3
CUTTING EQUIPMENTS
1 Cutting torch with hoses, nozzle sets and accessories with 02 Sets 2 Sets
back fire arrestor.
2 Pressure Gauge OXYGEN (Double type) 02 Nos 2 Nos
3 Pressure Gauge ACCETELENE (Double type) 02 Nos 2 Nos
4 OXYGEN Cylinder 150 Cu. Ft. 06 Nos 06 Nos
5 ACCETELENE Cylinder 150 Cu. Ft. 03 Nos 03 Nos
6 Safety Goggles for welder 02Pairs 2 Pairs
7 Gloves – Leather made 04 Pairs 04 Pairs
8 Leg Guards 02 Pairs 2 Pairs
9 Tool sets for maintenance 01 Set 01 Set
10 Portable plasma cutting equipment for cutting SS 01 set 01 set As per Rly
coaches/wagons Board letter
11 Leather appron for welder. 02 Nos. 02 Nos.
12 High capacity HRD for cutting stainless steel 01 set 01 set Boards
coaches/wagons. letter
09/02/2012
CATEGORY No.4
HYDRAULIC RE-RAILING EQUIPMENT :
1 Hydraulic Re-railing Equipment set (LUCAS / MFD) 1 set 1 set
2 Spare power pack and control table and roller carriage with 1 each 1 each
traversing jack for Hyd. Re-railing equipment.
3 Hydraulic Oil for LUCAS/MFD re-railing equipment with 200 ltrs 200 ltrs
container.
4 Journal Jack similar to Duff Norton No. 111-C-2 or BEMCO 2 Nos 2 Nos
Model 15-J-10 Capacity minimum - 15 Te.
Height - 10" Lift - 5". Go to Chapter contents
2
CATEGORY No.5
WIRE ROPE SLING & SHACKLES
1 Wire rope sling single part spliced type with ordinary 02 Nos. --
galvanized (Medium) Thimbles of both ends wire rope dia
48 mm effective length 3 mtrs.
2 Wire rope sling single part spliced type with ordinary 02 Nos. --
galvanized (Medium) Thimbles of both ends wire rope dia
48 mm effective length 6 mtrs.
3 Shackle Fabricated 10 Ton capacity. 06 Nos. 02 Nos.
7 Bow Shackle 10 Ton capacity 06 Nos. 2 Nos.
8 Bow Shackle 20 Ton capacity. 06 Nos. 2 Nos.
9 Bow Shackle 50 Ton capacity. 06 Nos. 2 Nos.
10 Derrick Tie rope dia 76mm,(6X49),9 Mtrs. Long for 140T 1 No. -
crane
11 Derrick rope dia 23mm,(6X36),271 Mtrs. Long for 140T 1 No. -
crane
12 Main hoist wire rope dia 36mm, (6X36),282 Mtrs. Long for 1 No. -
140T crane
13 hoist wire rope dia 26mm, (6X36),118 Mtrs. Long for 140T 1 No. -
crane
Note: - Items from Sr. No. - 10 to 13 to be kept in Parel Work Shop under centralized store.
CATEGORY No.6
CHAIN AND WIRE ROPE SLINGS (Required for 140 Te. Cowans Sheldon Diesel Crane)
1 Two leg chain sling 25 Te length 5 mtrs. 4 Nos. -
2 Single leg chain sling 10 Te. length 6 mtrs. 4 Nos. -
3 Single leg wire rope sling without hook soft both end 2 Nos -
70 Te. length 6 mtrs.
4 Two leg wire rope sling 70 Te. length 6 mtrs. 2 Nos -
5 Two leg wire rope sling 50 Te. length 5 mtrs. 2 Nos -
6 Two leg wire rope sling 30 Te length 7mtrs. 2 Nos -
7 Two leg wire rope sling 30 Te length 5mtrs. 2 Nos -
CHAIN AND WIRE ROPE SLINGS (Required for 140 Te. Gottwald Diesel Crane).
8 7 Te. double leg alloy steel chain sling 4 mtrs. long 02 Nos. -
9 28 Te. double leg alloy steel chain sling 5 mtrs. Long 04 Nos. -
10 12.5 Te. Single leg alloy steel chain sling 6 mtrs. Long 04 Nos -
11 70 Te. double leg Wire Rope Sling 6 mtrs. Long 68 mm dia 02 Nos. -
12 30 Te. double leg Wire Rope Sling 5 mtrs. Long, 48 mm 04 Nos. -
dia
13 50 Te. Single leg Wire Rope Slings 5 mtrs.Long, 60 mm dia 04 Nos. -
14 70 Te. Single leg Wire Rope Slings 6 mtrs. Long, 72 mm 04 Nos. -
dia
15 70 Te. Special Draw Bar Wire Rope Slings 4 mtrs. Long, 02 Nos. -
57 mm dia
16 28 Te. 4 leg Wire Rope Slings 4 mtrs long 28 mm dia 01 No. -
3
17 Main Hoist Wire Rope Star Lift, D26X470M, RGG Langslay, 01 No. -
520 KN, 1960 N/mm.sq. with accessories
18 Auxiliary Hoist Wire Rope Star Lift, D22X130M, RGG Lang 01 No. -
slay, 373 KN, 1960 N/mm. sq. with accessories
19 Derrick Wire Rope D26X390M RGG Lang slay, 585 KN, 01 No. -
1960 N/mm. sq. with accessories
Note: - Items from Sr. No. - 18 and 19 to be kept in JMP/Parel Work Shop under centralized store.
CATEGORY No.7
OTHER MECHANICAL ITEMS
1 Trolley for seized roller bearing wheels of loco and wagon 2 Sets 2 Sets
2 Universal Pulling & lifting machine TIRFOR T. 35 or similar 04 Nos. 2 Nos HLC No. 76
or SAMSON MAJOR, 5.2 Ton Capacity for pulling & 3.2 Ton
capacity for lifting.
3 Block Differential Pulley with Chain of 3 Ton capacity hand 1 No. 1 No.
operated with 3.2 Ton 'D' shackle at other end.
4 Rail claw for maintaining gauge when tie bar broken/rail 08 Nos. 06 Nos.
spread out .
5 Wheel Barrow (Tubular steel stock truck ) 04 Wheels push 1 No. 1 No. HLC No. 89
trolley.
6 Inflatable Air bag capacity min 40 Te. with suitable capacity 1 Set 1 Set HLC No.64
Air Compressor supplied with HRE Unit.
7 Nibbler (Portable Electrically Operated Tool) 2 Nos. 02 Nos.
CATEGORY No.8
FITTER TOOLS
1 Bench Vice 6" (150 mm) 1 No. 1 No.
2 Bag Tool / Tool box 04 nos. 02 nos.
3 Hack Saw 305 mm to 407 mm ( Adjustable ) 2 Nos 2 Nos
4 Blades for Hack Saw 300 x 12.5 x 1.00 mm and 350 x 32 x 12 each 06 each
1.6 mm
5 Bar Pinch Ram pattern 04 Nos. 02 nos.
6 Bars Tommy 2' 6" x 7/ 8" (765 mm x 22 mm) 06 Nos. 04 Nos.
7 Chisel cross cut 04 Nos. 2 Nos.
8 Chisel half round 9" long 04 Nos. 2 Nos.
9 Chisel flat 9" long 06 Nos. 4 nos.
10 Chisels rod flat 1" dia x 2' 6" long 04 Nos 2 Nos
11 Tongs of sorts 4 nos. 4 nos.
12 File Flat bastard (400 mm ) long 2 Nos 2 Nos
13 File half round smooth (400 mm) long 2 Nos 2 Nos
14 File 20 mm round bastard 400 mm long 2 Nos 2 Nos
15 File 20 mm square bastard 400 mm long 2 Nos 2 Nos
16 File half round bastard 400 mm long 2 Nos 2 Nos
17 Hammer sledge 7 lbs (3.2 Kg) 04 Nos 2 Nos
18 Hammer ball pane 1. 1/2 lbs (0.67 Kg or 600 gms) 06 Nos. 04 Nos
19 Hammer lead 6 lbs. 02 Nos 2 Nos
20 Punches steel of sizes (1/8", 1/4", 3/8") 12 Nos 12 Nos
21 Pliers Electrician and nose plier 200 mm long 02 each 01 each
4
22 Center Punch 1 No. 1 No
23 Spanner Box ( 10 to 50 mm) 02 Set 1Set
24 Single ended spanner 55, 60 & 65 mm 02 each 1 each
25 Spanner Double ended 8 x 10 mm 04 Nos 2 Nos
26 Spanner Double ended 13 x 17 mm 04 Nos 2 Nos
27 Spanner Double ended 19 x 22 mm, 20 x 22 mm 04 Nos each 02 Nos.
each
28 Spanner Double ended 24 x 27 mm 04 Nos 2 Nos.
32 Spanner DE ring & open 1/4 " x 5/16" 04 Nos 2 Nos.
40 Spanner DE ring & open 15/16 " x 1" 04 Nos 2 Nos.
41 Spanner DE ring & open 1 1/8 " x 1 1/4" 04 Nos 2 Nos.
42 Spanner DE ring & open 1 1/4 " x 1 1/16" 04 Nos 2 Nos.
43 Spanner DE ring & open 1 5/16" x 1 1/8" 04 Nos 2 Nos.
44 Allen key 1 mm to 25 mm 02 Sets 01 Set
45 Allen key size 1/8", 3/8", 1/4", 5/16" 3/8", 7/16", 1/2", 02 Sets 01 Set
9/16", 5/8", 11/16", 3/4", 13/16", 7/8", 15/16"
46 Steel scale for measuring 6",12",24" 02 each. 01 each

47 Screw driver 6", 12" & 18" 04 Nos. each 02 Nos.
each.
48 Screw driver 4", 8" & 10" 04 Nos. each 02 Nos.
each.
49 Drill machine 02 Nos. 1 No.
50 Drill 1mm to 13 mm (carbide tips suitable for carton SS) 03 each 03
Nos.each
51 Adjustable Spanner 06", 12" & 18" 02 Nos. each 1 No.each
52 Pipe wrench 10", 14", 18"& 24" 02 Nos.each 1No.each
53 Wrenches pipe chain 1/2 " to 3 " 02 Nos. 1 No.
54 SOLSON's Tool set consisting of following:- 01 Set 01 Set
a Spanner SP-622
b Spanner 1541
c Hex Key PKMMBS
d Pipe wrench 2060
e Pipe wrench 1030
f Multiwrench MWRD 10
g Multiwrench MW A-1 & A-2
h Ratchet wrench RWMM 12
i Ratchet wrench RWSAE 12
5
55 Test plate with Master gauge (Air Brake) 2 Nos 2 Nos
56 Axes felling Canadian ( 2 Kgs) 2 Nos 2 Nos
57 Pick Axes 3 Kg 06 Nos 03 Nos
58 Shovels round nose T 16 Kgs 685 mm long handle 06 Nos 03 Nos
59 Handle wooden for shovels 685 mm long as spare 04 Nos 2 Nos
CATEGORY No.9
MEASURING INSTRUMENTS
1 Magnifying glass 6" 2 Nos 2 Nos
2 Calipers 6" (150 mm) out side 1 No. 1 No.
3 Calipers 6" (150 mm) inside 1 No. 1 No.
4 Wheel and tyre gauge for Diesel and AC Loco 1 No. 1 No.
5 Gauge tyre (C&W) 1 No. 1 No.
6 Gauge Buffer height 1 No. 1 No.
7 Spring loaded Wheel distance measuring gauge Model 1 No. 1 No. HLC No.77
equivalent to PIE Model No.WG-1
8 Spring loaded Wheel diameter measuring gauge Model 1 No. 1 No. HLC No.77
equivalent to PIE Model No.WD-0
9 Spring loaded track measuring gauge 1 No. 1 No. HLC No.77
10 Tread wear measuring gauge model equivalent to PIE 1 No. 1 No.

model No. TWG-1(BGL) for B.G. locos.
11 P-way measuring kit 1 set 1 set
12 Measuring Steel tape 16 mm width and 30 meters long 2 Nos. 2 Nos.
13 Measuring tape steel 2 meter 4 Nos. 4 Nos.
14 Feeler gauge 100 mm long 0.03 mm to 1 mm 2 Nos. 2 Nos.
15 Buffer projection gauge 1 No. 1 No.
16 CBC Height gauge 1 No. 1 No.
CATEGORY No.10
WOODEN PACKINGS
1 Wooden Packing 300 x 300 x 25 mm. 30 Nos. 30 Nos.
8 Wooden Packing 900 x 300 x 100 mm. 30 Nos. 10 Nos
9 Wooden packing 1200 X 300 X 150 mm 24 Nos. -
10 Wooden Packing 1200x300x300 mm. corner Prop 10 Nos. -
11 Wooden Packing 1800 X 300 X 300 mm 8 Nos. -
12 Joint Wooden Packing 750X450X150 mm for MFD 20 Nos. 20 Nos.
13 Wooden wedges with 1 " dia hole 30 Nos. 30 Nos.
Note:- All wooden packings must be recessed at the ends & bonded with 30 X 5 mm thick MS strip band.
CATEGORY No.11
OILS & GREASES (WITH CONTAINERS)
1 Kerosene Oil grade II quality in 20 lts can 200 Lts. 150 Lts
2 Soft Grease (SG-3) 25 Kgs 10 Kgs
6
3 Graphite grease for wire ropes special for crane 5 Kgs -
4 Petrol 50 Lts 30 Lts
5 Diesel Oil for 140 Te. Crane + MFD power pack 02 Barrels 01 Barrel
6 Engine Oil SAE-30/40 Oil 20 Ltrs. 15 Ltrs.
7 SS-68 Hyd.Oil for 140 Te.Dsl. Hydraulic Break Down Crane 200 Ltrs -
8 Pump for drawing oil from 180/205 lit drum 02 Nos. 01 No.
9 Pump for drawing oil from 20 lits Tin/drum 02 Nos. 01 No.
10 Servo Super 20 W40 engine oil for 140 Te. Crane 40 ltrs. -
11 Servo grease MP 20 Kg -
12 Servo Cot -140 20 Kg -
13 Servo Tak - 40 05 Kg -
14 OKS - 410 05 Kg -
OILS & GREASES (WITH CONTAINERS) FOR 140 Te. GOTTWALD CRANE.
15 Engine Lube Oil (15W40) 50 Lts. -
16 Hydraulic Oil (HLP-68) as per IS 11656-1992 420 Lts. -
17 Gear Box Oil (HP-90) 105 Lts. -
18 Servo Cot (Camex Compound) 180 Kg -
19 Servo gem Grease 20 Kg. -
20 Coolant (Premix) for Engine 10 Lts. -
CATEGORY No.12
C&W ITEMS
1 Screw Coupling hooks (Draw bar hook) 02 No. 02 No.
2 Screw Coupling with shackles and pins 02 No. 02 No.
3 Transitional coupling complete with clevis pin 02 No. 02 No.
4 Buffer Plunger (large) complete 02 Nos. 02 Nos.
5 Hanger for Bolster Spring suspension (ICF) with pin, stone 4 Nos each 4 Nos each
and hanger block.
6 Angle cock (Bogie cut out cock) 2 Nos.each 2 Nos.each
7 Draw hook with bar & draft key 2 sets 2 sets
8 Bolster spring ICF (AC & Non AC) 1 No.each 1 No.each
9 Axle Box spring (AC & Non AC) 2 Nos.each 2 Nos.each
10 Equalising stay rod (AC & Non AC) 2 Nos.each 2 Nos.each
11 Anchor link (ICF) 2 Nos.each 2 Nos.each
12 Bypass coupling set for Air brake stock (Fly coup.). 2 sets 2 sets
13 Coil spring for casnub bogie (Outer, Inner & Snubber) 6 Nos each 6 Nos each
14 Side frame key for casnub bogie 24 Nos 24 Nos

15 Adopter for casnub bogie (Wide Jaw & Narrow Jaw) 4 Nos each 4 Nos each
16 Elastomeric pads 10 Nos each 10 Nos

each
17 BP & FP Air Hose with MU washer 20 Nos. each 10 Nos. each
18 Wedge block for casnub bogie 04 Nos. each 4 Nos. each
19 Metal bonded pad Side bearer 08 Nos. each 4 Nos. each
20 Bolts for Center pivot 08+08 Nos. 8 Nos.
21 Knuckle 2 Nos each 2 Nos each
7
22 Lock Piece 2 Nos each 2 Nos each
23 Dash pot ICF 4 Nos. 4 Nos
24 Hanger for ICF 4 Nos. 4 Nos
25 Hanger pin for ICF 6 Nos. 6 Nos.
26 Safety strap ICF 6 Nos. 6 Nos.
27 Wooden wedges 10 Nos. 10 Nos.
28 Skids 06 Nos 06 Nos
29 Dummy buffer face 02 Nos 02 Nos
30 Clamp for coupling CBC & Screw coupling 01 No. 01 No.
CATEGORY No.13
GENERAL STORES
1 Bolt M.S. Hexagonal heads 10 x 110 mm 30 Nos. 30 Nos.
8 Bolt M.S. Hexagonal heads 20 x100 mm 10 Nos. 10 Nos.
15 Nut M.S. Hexagonal heads 10 mm 30 Nos. 30 Nos.
22 Gunny Bags large size 38" x 28 " 12 Nos. 12 Nos.
23 Handle wooden for sledge hammers as 36" long 02 Nos. 02 Nos.
24 Handle wooden for hand hammers as 16" long 02 Nos. 02 Nos.
25 Handle wooden for files for spares 125 mm long 02 Nos. 02 Nos.
26 Rope Manila approx. 115 mm circumference 150 ft 50 ft
27 Red & White Luminescent barrier tap 500 Mtrs. 250 Mtrs. HLC No.72
28 Scrap Plate 5/8" x 10" x 24" 12 Nos 10 Nos
29 Padlock with duplicate keys 65 / 75 mm size 12 Nos. 08 Nos.
30 Measuring cans conical pouring type capacity -1 Ltrs, 01 Set 01 set
2 Ltrs, 5 ltrs & 50 ml- 1 set of four
31 Difference sizes Funnels for oil 1 set of 3 Nos 1 set of 3
Nos
32 Oil feeder 2 liters capacity 02 Nos. 02 Nos.
33 Lashing chains 1/2" dia x 15 ft length. 02 Nos. 02 Nos.
8
34 Lashing chains 5/8" dia x 10 ft length 02 Nos. 02 Nos.
35 Lashing chains 5/8" dia x 20 ft length 02 Nos. 02 Nos.
36 -do- 3/4 " dia 50 Ft length with width (20 mm) 02 Nos. 02 Nos.
37 Lamp hand signal Tri Colour torch 02 Nos. 02 Nos.
38 LED Flasher type (Tail Lamp) 02 Nos. 02 Nos.
39 Flags Banner (Track) 02 Nos. 02 Nos.
40 Poles for Flag Banner 02 Nos. 02 Nos.
41 Flags Hand Signal Green 45 x 10 cm 04 Nos. 04 Nos.
42 Flags Hand Signal Red 45 x 10 cm 04 Nos. 04 Nos.
43 Board Last Vehicle (LV) 02 Nos. 02 Nos.
44 Fog Signals ( one box of 10 Detonators) 02 Nos. 02 Nos.
45 Elect. Flashing Hand Signal Lamp 04 Nos. 02 Nos.
46 Blanket woollen superior quality 80 Nos. 50 Nos
47 Bed Sheet Khadi 80 Nos. 50 Nos
48 Pillows with cover 30 Nos 20 Nos
49 Pillows cover 30 Nos 10 Nos
50 Towels bath 20 Nos 10 Nos
51 GI Box for keeping linen As per requd. As per
requd.
52 Alluminium Ladder 6 ft long 01 No. 1 No.
53 Telescopic Alluminium ladder 6/11 mtr. Height 02 each 2 No.each HLC No.82
54 Hand umbrellas water proof and electric shock proof 25 Nos 15 Nos
55 Rain Coat 2 Pieces 75 Nos 50 Nos
56 Uniform for ART staff(Dark brown pant & light blue shirt) 2 Pairs / 2 Pairs /
person person
57 High visibility jackets ( for summer & winter) 75 Nos 50 Nos HLC No.85
58 Gum Boots/Jungle Shoe 75 Nos 50 Nos
59 Heavy duty safety shoes 75 Nos 50 Nos
60 Helmet Heat and chemical resistant 75 Nos 50 Nos
61 Rope Manilla Nylon 100 mts 01 roll 01 roll As per
Board letter
CATEGORY 14
GENERAL STORES LIST OF UTENSILS & STORES FOR ONE KITCHEN CAR(ONLY WHERE
KITCHEN CAR IS PROVIDED)
1 Tumbler Stainless steel (Glass) 50 Nos 50 Nos
2 Glass tumblers 250 ML Capacity 12 Nos 12 Nos
3 Tea cups and saucers B/china 6 Ozs capacity 24 Nos 24 Nos
4 Cut glass superior 24 Nos 24 Nos
5 Tea spoons stainless steel 50 Nos 50 Nos
6 Desert spoon stainless steel 12 Nos 12 Nos
7 Kitchen spoon stainless steel 4 Nos 4 Nos.
8 Knives cook large 230 mm long blade with handle 4 Nos 4 Nos.
9 Stainless Steel Bhagona with cover 6 Nos 4 Nos.
10 Frying pan aluminum 300 mm dia 2 Nos 2 Nos
11 Stainless Steel Palta 2 Nos 2 Nos
12 Ghamela with handles (Kadai), i.e. pan with handles 2 Nos 2 Nos
16" dia 6" deep
9
13 Pressure Cooker 10 Ltr. Capacity 2 Nos 2 Nos
14 Compartment Thallies Steel 24"/15" to 18" Dia 50 Nos 50 Nos
Approximately
15 Katories stainless steel 3" approximately 50 Nos 50 Nos
16 Parat Stainless Steel 4 Nos 4 Nos.
18 Wooden board with roller for pastry 4 Nos 2 Nos
19 Puri machine 2 Nos 2 Nos
20 Jhara for Puri 2 Nos 2 Nos
21 Iron Tawa 12" dia 2 Nos 2 Nos
22 Stainless steel Tray size 15"x 11 1/2" 4 Nos 4 Nos.
23 Serving tray Plastic 4 Nos 4 Nos.
24 Hot case 3 1/2 Ltr. & 5 Ltr. Cap. 1 each 1 each
25 Tea 1 kg 1 kg
26 Sugar in Tin 10 Kg. 10 Kg.
27 Biscuits 5 Kg. 5 Kg.
28 Coffee 200 Gram 100 Gram
29 Condensed milk / Powder milk 3 kg 1 kg
30 LPG Connection with stove and spares gas cylinders 2 set 1 set
31 Gas lighter 2 Nos 2 Nos
32 Safety Matches 2 Packets 2 Packets
34 Paper Plate 200 Nos 200 Nos
35 Paper glass (Thermocol) 200 Nos 200 Nos
36 Tea thermos 1 liter capacity 2 Nos 2 Nos
37 Tea thermos Steel 20/10 liter capacity 2 Nos. 2 Nos.
38 Tea Strainer 6 Nos 6 Nos
39 Kettle Stainless steel 2 liters capacity 2 Nos 2Nos
40 Steel container1Kg cap.for storage of kitchen raw masala 12 Nos 12 Nos
41 Steel containers for keeping food raw material 6 Nos 6 Nos
42 Water Chalties 4 Ltr capacity 6 Nos 6 Nos
43 Steel Bucket 20 Ltr. Cap. 4 Nos 4 Nos.
44 Jug Stainless steel Cap. 2 Ltrs 3 Nos 3 Nos
45 Stainless steel drinking water containers with handles and 4 Nos 4 Nos.
covers 50 lit Capacity
46 Water Thermos 5 ltrs & 16 ltrs capacity 1 No.each 1 No.each
47 Aqua Guard for water filtration 230 V AC/110 V DC 2 Nos 2 Nos
48 Soap Toilets (Soap Cake) 4 Nos 4 Nos.
49 Duster Cloth 12 Nos 12 Nos
51 Water storage tank (Syntax capacity 1000 Ltrs) As per req. As per req.
52 Duster cloth (Khadi) 1 Mtr length 10 Nos 10 Nos
53 Cooking apron & cap 4 sets 4 sets
54 Ration as per req. as per
req.
55 Cooking Toyes 2 sets 2 sets
56 Vim Powder/Bar for cleaning of Kitchen wares 4 Kg. 4 Kg.
57 Water cooler 230V AC/110 V DC 1 No 1 No
58 Mixure Grinder 230 V AC/110V DC 1 Nos. 1 Nos
10
CATEGORY No.15
FIRE FIGHTING EQUIPMENTS
1 Sand filled buckets (Buckets fire standard 300 mm) 04 Nos 04 Nos
2 Water buckets. GI 04 Nos 04 Nos
3 Water mist and Café fire fighting back pack system (High 02 Nos. 02 Nos.
pressure) 10 lts. Capacity.
4 Steel body cylinders 200 bar with tools for item.3 01 No. 01 No..
5 Minimaxes 9.0 Lts. Cap., Nitrogen type Fire Extinguishers 10 Nos 10 Nos
6 Explosion meter (Explosive Gas Detector) 01 No. 1 No
7 Self contained breathing apparatus with spare cylinders 4 sets 1 set HLC No.63
8 Fire Resistant / fighting suit complete 02 Nos 02 Nos
CATEGORY No.16
ENGINEERING ITEMS
A- P-Way Material
1 Rails 52 Kg.(13 mts long) with holes at ends for fish bolts 20 Nos. 20 Nos.
2 Sleepers steel 171 lb/Tie-Tek sleepers (PVC) with all fittings 600 Nos 600 Nos
3 52 Kg fish plates 20 pairs 20 pairs
4 52 Kg. Fish bolts 80 Nos. 80 Nos.
5 60 Kg./52 Kg. and 52 Kg. 90 R combination fish plates 04 set each 04 set each
6 52 Kg. Joggle fish plates 04 sets 04 sets
7 ERC (RDSO T-3701) 500 Nos. 500 Nos.
8 G.R Sole plates (RDSO T-3703 & RDSO T-3711) 250 each 250 each
9 GFN Liner ( RDSO T-3702) 500 Nos. 500 Nos.
10 GFN Liner ( RDSO T-3706) 500 Nos. 500 Nos.
11 Combination GFN Liner ( RDSO T-3707) & (T-3708) 100 sets 100 sets
12 Hook Bolts 50 Nos. 50 Nos.
13 Plate screw T-3911 25 Nos. 25 Nos.
14 Plate screw T-3912 50 Nos. 50 Nos.
15 Plate Screw T-3915 25 Nos. 25 Nos.
16 Wooden Blocks 500 mm long 10 Nos. 10 Nos.
17 STO Sleepers for 52 Kg section, 1:12 & 1:8.5 1 set each 1 set each
18 Built up Crossing for 52 Kg. section 1:12 & 1:8.5 1 No. each 1 No. each
19 Switches complete with fittings for 52 Kg. section 1:12 & 1 set each 1 set each
1:8.5
B Tools and Equipments
20 Rail Dolly with attachment to transport concrete sleepers 04 Nos. 04 Nos.
21 Abrasive Rail Cutter with min 12 nos. spare disc 2 sets 2 sets
22 Rail Drilling machine 02 Nos. 02 Nos.

23 Drill Bits 28 mm, 30 mm & 32 mm 03 Nos. each 03 Nos.
each
24 Non-infringing lifting jacks mechanical/Hydraulic,Cap-9T 04 Nos. 04 Nos.
25 Gas Cutting Equipment 02 Set 02 Set
26 Box spanner suitable for Rail/Plates screw 02 Nos. 02 Nos.
27 Fish Bolts spanner 02 Nos. 02 Nos.
11
28 Rail Tongs 10 Nos. 10 Nos.
29 Crow bar 20 Nos. 20 Nos.
30 Rake Iron Ballast 10 Nos. 10 Nos.
31 Shovel with handle 10 Nos 10 Nos.
32 Iron Pan 10 Nos. 10 Nos.
33 Pick Axe with handle 10 Nos. 10 Nos.
34 Safety Helmet 20 Nos. 20 Nos.
35 Rain Coat 20 Nos. 20 Nos.
36 Gloves 40 pairs 40 pairs
37 Gauge cum level 6 nos. 6 nos.
38 Track measuring equipments set 2 sets 2 sets
39 Hand signal lamps 2 Nos. 2 Nos.
40 Hand signal flags (Green & Red) 2 nos. each 2 Nos. each
41 Banner flag 2 nos. 2 Nos
42 Detonators 12 Nos. 12 Nos.
43 Steel Buckets and Mugs 2 sets 2 sets
44 Umbrella 10 Nos. 10 Nos.
45 Poles for Flag Banner 4 Nos. 4 Nos.
46 Walkie-Talkie sets 5 sets 5 sets
47 Folding/Plastic chairs 4 Nos. 4 Nos.
48 Centre Table (Plastic) 1 No. 1 No.
49 Consumables As per Req As per Req
50 White Chalk 01 Box 01 Box
51 Hammer keying /spiking 07 lb 06 Nos 06 Nos.
52 Beater with handle 40 Nos. 40 Nos.
53 Jim Crow with rod 1 No 1No.
54 Phowrah with handle 5 Nos. 5Nos.
55 Dip Lorry 2 set 2 set
56 Tent including kanath, ropes, pegs etc. 1 set 1 set
57 Clamp points 2 Nos. 2Nos.
58 Measuring tapes 15 and 30 meters 2 Nos each 2 Nos each
59 Torch 3 cell 20 Nos. 20 Nos.
60 Balloon Light 04 Nos 04 Nos.
61 Champering kit 1 set 1 set
62 Hooter big and small 01 No each 1 No each
63 Lighting Arrangement with portable generator set cap-5KVA 1 set 1 set
and 12 strands with lamps 200 Watt and 500 meters cable
64 Tree cutting Machine 2 Nos. 2 Nos.

65 Ramp for loading /unloading of heavy excavators 1 Set _
equipment
66 First Aid Box 1 No. 1 No.
CATEGORY No.17
MEDICAL EQUIPEMENTS
1 First Aid Boxes 02 Nos. 01 No.
2 Stretcher with Blanket and Canvas bag 04 Nos. 02 Nos.
12
CATEGORY No.18
SIGNALLING AND TELECOMMUNICATION EQUIPMENTS
1 Inspection Book 01 No. 01 No.
2 Magneto Telephone/Group telephone with DTMF signalling 04 Nos. 04 Nos.
operated on ¾, 5V
3 Dry cells large 6-I Cells 1.5 Volt each for Magneto Phones 48 Nos. 48 Nos.
or Torch cells R-20 size, 1.5 V for group telephone
4 PVC Insulated, PVC Sheathed twin core cable 500 Mtr. 500 Mtr.
5 Dynamic Micro phone with 15 mtrs lead & floor stand. 2 Nos 1 No.
6 Loud Speaker horn type 5/10 Watts 04 Nos. 02 Nos.
7 Amplifier of min. 20 W power output operating on 2 DC 02 Nos. 01 No.
( Charging interface for cordless microphone)
8 Microphone for cordless PA system 02 Nos. 02 Nos.
9 12 V Storage Battery with appropriate battery charger 02 Sets 01 Set
10 Megaphones transistorised (min. 10W each) complete with 03 Nos. 03 Nos.
battery
11 Portable Stand for Loud Speaker with telescopic adjustable 02 Nos. 01 No.
height from 1.5 Meter to 3 meters
12 Field Service PVC insulated Cable 500 Mtrs. 500 Mtrs.
13 Push button Auto telephone with Tone/Pulse switching 04 Nos. 02 Nos.
facility.
14 Portable Generator Set Petrol start and Kerosene oil run 02 Nos. 02 Nos.
(Honda 750 W or equa.)
15 VHF Set 25 Watts along with accessories. 02 Nos. 02 Nos.
16 Walkie Talkie Sets (5 W VHF) with 100 % spare batteries 30 Nos. 20 Nos. HLC No.96
17 Battery Charger for 5 W VHF Set 08 Nos. 08 Nos.
18 Folding Table 01 No. 01 No.
19 Folding Chair 04 Nos. 04 Nos.
20 Beach Umbrella 01 No. 01 No.
21 Light weight pre-fabricated water proof tent 01 No. 01 No.
22 Bell Hailer 6 V DC 04 No. 01 No.
23 Multimeter digital (Motwani) or equivalent 01 No. 01 No.
24 Extension board for Power supply (Mains) 04 Nos. 04 Nos.
25 Hand held torch of 3 cells complete with dry cells 04 Nos. 04 Nos.
26 Jointing Kit & material for cables and overhead wires As per Req. As per Req.
(this is to be decided by the Railways) Cable jointing
material with overhauling material to be kept in one box.
27 Tool box containing: -

Soldering Iron 10 W/12 V, 10 W/220 V & 65 W/220 V. 01 No. each 01 No. each
Long Nose Plier 01 No. 01 No.
Cutter Diagonal 01 No. 01 No.
Box Spanner 6,5.5 and 5 mm 01 No. each 01 No. each
Hammer Steel 750 grams 01 No. 01 No.

Hammer Wooden 01 No. 01 No.
Adjustable Spanner (300 mm) 01 No. 01 No.
Screw Driver 8" (200 mm) 01 No. 01 No.
Screw Driver 10" (250 mm) 01 No. 01 No.
13
Mains Tester (230 Volts) 01 No. 01 No.
Electrical Insulation Tape 12 mm x 15 meters 01 No. 01 No.
Resin Core 500 gm 500 gm
28 Portable communicator set of Train Radio system where 2 Nos. 02 Nos.
applicable alongwith charger
29 Digital voice recorder and CD/DVD player having USB 2 Nos. 02 Nos.
interface
30 2 wire Portable control phone in a suitable box with dry 2 sets 2 sets
cells
31 Telescopic pole of minimum 6 Mtrs. height with its bracket 2 Nos. 2 Nos.
opening space atleast 350 mm.
32 Emergency socket plan of the Division/Neighbouring Div. 1 set 1 set
33 Cellular Phones 4 Nos. 4 Nos.

34 Satellite phone (SAT Phone miniature Type) which supports 1 No. 1 No.
video, audio and text features
35 FAX Machine (Plain paper) 01 No. 01 No.
36 4 Wire portable control phone in a suitable box with dry 2 sets 2 sets
cells
37 Tapping transformer 1120:1120, 1120:600-02 02 Nos. 02 Nos.
38 2 Nos. 2 Nos.
Terminating transformer (1120:470)
39 WLL Exchange having 50 wire capacity . 1 set 1 set HLC No. 97
40 1 set 1 set HLC No. 99
PC along with high speed satellite modem/Data card
(Dongle)
41 Fixed Cellular Terminals (FCT) (one of which compatible 04 Nos. 04 Nos.
with 3G SIM)
CATEGORY No 19
OHE ITEMS & EQUIPMENTS
A T&P Items
1 Pull lift 1.5 T 01 Nos 01 Nos
2 Tirfor 1.6 T 01 Nos 01 Nos
3 Tirfor 3 T 01 Nos 01 Nos
4 Single sleeve pulley 02 Nos 02 Nos
5 Double sleeve pulley 01 Nos 01 Nos
6 Manila rope 50 M 50 M
7 Come along clamp (Universal) 04 Nos 04 Nos
8 Come along catenary clamp 02 Nos 02 Nos
9 "D" Shackle 08 Nos 08 Nos
10 Hammer 8 pound 01 Nos 01 Nos
11 Extension ladder Alluminium 11 Mtrs Adjustable 1 No 1 No
12 Emergency mast complete 1 No 1 No
13 Spike 15 Nos 15 Nos
14 Wire rope sling 1 mtr. 2 Nos 2 Nos
15 Wire rope sling 1.5 mtrs 2 Nos 2 Nos
16 Discharge Rod 2 Nos 2 Nos
17 M.S. BOX 2 Nos 2 Nos
18 Pad lock ( 50 mm) 2 Nos 2 Nos
14
19 Sling wire rope 9 M 1 No
B OHE Items
1 Catenary splice 4 Nos 4 Nos
2 Suspension clamp with nut & bolt 02 Nos 02 Nos
3 Suspension bkt (Std) 03 Nos 03 Nos
4 Suspension bkt (large) 02 Nos 02 Nos
5 C-Clamp (STD) 02 Nos 02 Nos
6 C-Clamp (Large) 02 Nos 02 Nos
7 Large BT Tube 3.10 01 Nos 01 Nos
8 STd. BT Tube 3.10 02 Nos 02 Nos
9 RT (1.10 M) 02 Nos 02 Nos
10 Catenary clip 10 Nos 10 Nos
11 Catenary dropper clip 50 Nos 50 Nos
12 Contact dropper clip 20 Nos 20 Nos
13 PG 1030 10 Nos 10 Nos
14 PG 1041 10 Nos 10 Nos
15 RE drum with S S Rope (3:1) 01 Nos 01 Nos
16 GI Nut bolt 16 x 50 x 38 25 No 25 No
17 GI nut bolt 20 x 65 mm 30 Nos 30 Nos
18 GI nut bolt 16 x 360 x 150 mm 25 Nos 25 Nos
19 GI nut bolt 16 x 260 x 100 mm 10 Nos 10 Nos
20 Bulldog clamp 10 Nos 10 Nos
21 T.T. Sleeve 02 Nos 02 Nos
22 STD. Steady Arm 04 Nos 04 Nos
23 Double strap 04 Nos 04 Nos
24 BT Insulator 03 Nos 03 Nos
25 ST Insulator 03 Nos 03 Nos
26 9 Te. Insulator 04 Nos 04 Nos
27 Solid core 01 Nos 01 Nos
28 S.S. fastener BT+ST 12 Nos 12 Nos
29 Adopter 02 Nos 02 Nos
30 Top fitting 02 Nos 02 Nos
31 Cate. ending cone 02 Nos 02 Nos
32 Cont. ending cone 02 Nos 02 Nos
33 large wire ending cone 01 No 01 No
34 Contact splice 04 Nos 04 Nos
CATEGORY No.20
BOOKS, MANUALS & RECORDS
1 Accident Manual 1 No 1 No
2 G & SR Rule Book 1 No 1 No
3 First Aid Manual 1 No 1 No
4 Conference Rules Part III & IV for Train examining staff 2 Nos 2 Nos
5 Safety First Instruction Book 01 No 1 No
6 Maintenance & Operation manual for ARTs/ARMEs/140T cr 01 No 1 No
7 Working Time table 01 No 1 No
15
8 ART Log book 1 No 1 No
9 Attendance register 1 No 1 No
10 Equipment testing register 1 No 1 No
11 Dead stock register 1 No 1 No
12 Chain & wire rope testing register 1 No -
13 Maintenance manuals of the equipments 1 No 1 No
14 ART Inspection register 1 No 1 No
15 Inspection schedule display board 1 No 1 No
16 Fire Fighting Instruction book 1 No 1 No
17 Copy of the recommendations of High Level Committee's 1 No 1 No
Report on Disaster Management
18 Manuals and drawings of 140 Te Crane 1 each -
19 IRPWM (P-Way Manual) 01 Set. 01 Set.
20 A.C. Traction Manuals 01 Set. 01 Set.
21 S&T Manuals 01 Set. 01 Set.
22 Maintenance Manual for Coaches. 01 Set. 01 Set.
23 Maintenance Manual for Wagons 01 Set. 01 Set.
24 Commercial Manual. 01 Set. 01 Set.
CATEGORY No.21
MISCELLANEOUS GROUP
1 One Digital still camera with 5/6 floppy discs + Battery with 1 No. 1 No. HLC No.65
connecting cord and required peripherals.
2 One Digital Video handy cam Camera with film for video 1 No. 1 No.
filming of the restoration work
3 Plastic Moulded Chairs ( stackable ) 20 Nos 20 Nos HLC No.74
4 Garden Umbrella 2 Nos. 2 Nos.
5 Light weight Tent pre-fabricated water proof for ART 02 Nos 02 Nos
equipments & crane equipments
6 Charging facilities for Lap-Top Computer / Cell phone & As per As per HLC No.67
Camera requirement requirement
7 Almirah with safe locker for keeping valuable items and 03 Nos. 2 Nos.
Imprest
8 Power Chain Saw Cutter 1 No. 1 No.
9 Digital Breath Analyser 2 Nos. 2 Nos.
10 safety Cone 6 nos. 6 nos. Board letter
11 Safe steel cash box for imprest money 01 No. 1 No.
12 Life Jackets(Water rescue) 100 Nos 100 Nos Board letter
13 Scene tape 6 rolls 6 rolls Board letter
14 Net connector (Dongal) (USB) of any service provider 01 No. 1 No.
15 Water jet unit for removing garbage/bio-toilet effluent of 01 Set I Set
damaged Bio-Toilet tanks
NOTES:- on Next page.
16
NOTES:-
1. In addition to above, the following equipments to be provided for 140 t. Gottwald crane unit only as
recommended by B. Dixit & Quraishi committee for 140 t . Gottwald new design crane.
Sr. Description Quantity Recommen

No. dations of
1 Digital/ conventional Vernier Calliper ( Mitutoyo make-18" size) 01 No B. Dixit &
Quraishi
2 Branded digital Multi-Meter ( Capable of showing ranges of Resistance, 01 No committeee
Voltages, Current and Temperature on 140 t.
3 F.M.band Transmitter Set (2 Nos) & receiver set (6 Nos) 01 Set Gottwald
new design
4 Electronic Continuity tester 01 No
crane.
5 Automatic Fall Preventation device ( Tractel Make- Model BLOCFOR-20 ) 01 No
with full body harness & anchorage device Model UEE 307 B.
6 Odysse Ascender (Make ACSTAFE) 01 No
17
List of Tools & Equipments for ARMEs on Indian Railways
Sr. Description Quantity Recommend-

No ation of HLC
CATEGORY No.1
Illumination: Electrical Equipments
1 Portable Generator set 3/2 KVA on anti vibration mounts, 230/250 V 2 Nos.
with integral switch, spare spark plug & its spanners.
2 Main cable fixing from DG set to terminal board, 3 core cable 10 100 Mtrs
sq.mm PVC insulated
3 Tool kit for maintenance of portable generator set as per make of 2 sets
Gen.Set
4 Portable Switch board with 4 water proof industrial sockets each 4 Nos.
capable of taking 500 watt load and 2 mtrs 15 amps capacity PVC
insulated copper leads with plug at each end.
5 Stand flood light 1.8/2.5 meter high. 6 Nos.

6 500 Watt Halogen lamp with water proof fitting, 200 meter 15 amps 6 Nos.
capacity lead with plug on one end and suitable arrangement for
keeping cable.
7 Hand lamp with Electrical cable. 5 Nos.
8 Insulation tape 3/4" 10 Nos.
9 Oil measuring cane, set consisting of (200ml, 500ml, 1 Ltr, 2 Ltr & 5 Ltr) 1 set
10 Kerosene Oil 50 Ltrs.

11 Petrol 2 Ltrs.
12 Tool set complete with cutting pliers, hammers, screw drivers, knife 1 set
etc.
13 Earthing rod for earthing OHE 2 Nos.
14 Alluminium Telescopic ladder 2 Nos.
15 Lubricating Oil (SAE - 30) 5 Ltrs.
CATEGORY No.2
Illumination : Other than Electrical
1 Emergency inflatable lighting towers with light source 4.5 meters high 2 Nos. HLC 60
fitted with 400 watt metal Halide lamp to illuminate an area of 10000
square meters with 3.5 BHP Brigg Straton engine and alternator 1.2
KVA 230 volts of weight not exceeding 45 Kgs.
2 Spare Blowers (Ralli Wolf NWB Blower), 350 watts, 250 V DC & AC 02 Nos. Only one to be
fitted/tower
50Hz., 1.6 Amps, capacity 1.5M3/Min.
3 Tool kit with 2 spare Halide lamps for inflatable lighting towers. 2 Nos.
4 Battery Operated Lamps Min. 06 Nos Board’s letterdated
26.02.2014
5 Spare batteries for Lamps 06 Nos.
6 Spare Reflectors/Glass for battery lamps 06 Nos.
7 Plastic body LED type torches 6 Nos.
8 3-Cell torches 8 Nos.
9 Spare bulb for 3 cell torches 12 Nos.
1
No ation of HLC
CATEGORY No.3
Oxy-Fuel Cutting Equipments
1 Cylinder Oxygen (150 Cu.ft) 4 Nos.
2 Cylinder Acetylene (150 Cu.ft.) 2 Nos.
3 Cutting torch with Hoses-Nozzles and accessories with pipe blow CR 2 sets
and CH type and Nozzle cutogen 1/16" and 3/16"
4 Spare nozzle 1/16" & 3/16" 2 each
5 Pressure gauge Oxygen (Double type) 2 Nos.
6 Pressure gauge Acetylene (Double type) 2 Nos.
7 Safety Goggle for welder 2 pairs
8 Gloves and leg guards of levlar heat resistant 12 pairs
9 Tool set for maintenance (Similar to SOLSONS) 1 set
10 Portable Plazma cutting equipment for cutting SS coaches/wagons. 1 set
CATEGORY No.4
Rescue and Relief Equipments
1 Hydraulic Rescue Device (Cold cutting equipment) with spare power 1 set
pack.
2 Spare cutter blades 1 set
3 Spare tips for spreader 1 set
4 Hydraulic hoses (Spare set for replacement) 1 each
5 Hydraulic Oil with container for HRD 50 Ltrs
6 Nose plier, Electrician plier 200mm long, and Outer circlip plier 1 each
7 Screw spanners 12" 1 No.
8 Tool kit for HRD maintenance 1 set
9 Petrol 25 Ltrs.
10 Screw driver 6" & 12" 2 Nos. each
11 Portable electrically operated cutting tools (Nibbler, Sabre Saw, Jig 2 Sets
Saw, Hole Saw) with blades.
CATEGORY No.5
Lifting Appliances
1 Hydraulic hand operated jack 20 ton capacity closed height 250mm, 2 Nos.
lift 150mm
lift 150mm
3 Jack operating handle 4 Nos.
4 Spare Hyd. Oil for jacks 10 Ltrs.
CATEGORY No.6
Other Mechanical Equipments
1 Universal pulling & lifting machine (TIRFOR SAMSON MAJOR) 2 Nos. HLC No.76
1) 3.2 Ton capacity for lifting
2) 5.2 Ton capacity for pulling
2
No ation of HLC
2 Block differential pulley with chain 3 ton capacity 1 No.
3 Saw Hand 20" 1 No.

4 Power Chain Saw (Electrically operated) 1 No.
5 Light weight synthetic pre-fabricated water proof tent for Mechanical 01 No.
equipments
CATEGORY No.7
Tools and Accessories
1 Bench vice 150mm 1 No.
2 Hacksaw 305 mm to 407 mm adjustable 1 No.
3 Hacksaw blade 300 x 12.5 x 1.00 mm or 350 x 2 x 1.6 mm 6 Nos.
4 Pick Axes 3 Kg 3 Nos.
5 Axes Felling 6 Nos.
6 Hand hammer ball pane 600 gms 5 Nos.
7 Sledge hammer 3.2 Kg 4 Nos.
8 Steel pin punches 3 mm, 6 mm, 10 mm 6 Nos.
9 Centre punch 1 No.
10 Chisel cross cut 6 Nos.
11 Wire punch 1" dia 4 Nos.
12 Chisel rod flat 1" dia x 2'-6" long 4 Nos.
13 Bars Tommy 7/8"x2'-6" long 4 Nos.
14 File flat bastard (400 mm long) 1 No.
15 File 20 mm round bastard 400 mm long 1 No.
16 File 20 mm square bastard 400 mm long 1 No.
17 File half round bastard 400 mm long 1 No.
18 Plastic Bucket Cap. 10 Ltrs. 4 Nos.
19 GI Bucket Cap. 15 Ltrs. 4 Nos.
20 Goggles made from heat resistant plastic material 4 pairs
21 Spanner Box 10mm, 19mm, 24mm, 27mm, 30mm, 32mm, 40mm 1 set each
22 Spanner double ended 8x10mm, 13x17mm, 19x22mm, 24x27mm, 2 Nos. each
30x32mm, 36x41mm
23 Shovel round nose T 16 Kg 685mm long handle 6 Nos.
24 Navghan (Singada) 2 Nos.
25 Beaters with handle 3 Nos.
26 Phawrah country 3 Nos.
27 Tongs of sorts 455mm 4 Nos.
29 Calipers 6" outside 1 No.
30 Calipers 6" inside 1 No.
31 Measuring steel tape 100 ft (30 mtrs) (16mm width) 1 No.
32 SOLSON's Tool set consisting of following:- 1 set
a Spanner SP-622
3
b Spanner 1541
c Hex Key PKMMBS
d Pipe wrench 2060
e Pipe wrench 1030
i Ratchet wrench RWSAE 12
CATEGORY No.8
General Stores
1 Bolt MS Hex head of different sizes 10 Kg.
2 Nuts MS Hex of different sizes 5 Kg.
3 Handle wooden/bamboo for sledge hammer 36" long 2 Nos.
5 Rope Nylon (one bundle of 12mm dia) 100 mtrs
6 Barrier tape 200 mtrs.
7 Pad lock (Godrej make with duplicate keys) 10 Nos.
8 Hand umbrellas water proof and electric shock proof 10 Nos.
9 Rain coat in two pieces 30 Nos.
10 Oil measuring cans conical pouring type 1) 1 lit. cap. 2) 2 lit. cap. 3) 1 No. of
5 lit. cap. & 10 lit. cap. each
11 Lamp hand signal (Tri colour) 2 Nos.
12 Fog signals (Detonators) 20 Nos.
13 Fusee signals 2 Nos.
14 Flag hand signal (green) 45x10 cms 4 Nos.
15 Flag hand signal (Red) 45x10 cms 4 Nos.
16 Board Last vehicle (LV) 1 No.
17 Gum Boots (Free size) 30 pairs
18 Heavy duty safety shoes 30 pairs
19 Flag Banner (Red) with track poles 2 Nos.
20 Alluminium ladder 6 ft. long 1 No.
21 Self supporting Aluminum ladder 5' & 10' 1 each HLC No.82
22 Telescopic Aluminum ladder 6/8 Meter & 11 Mtr. 1 each HLC No.82
23 Helmet (Heat and chemical resistant) 30 Nos.
24 Rope Manila 1" dia 50 ft.
25 Plastic Moulded Chairs 20 Nos. HLC No.74
26 Folding Table - 115x74x71 cm 1 No. HLC No.85
27 LPG connection with spare gas cylinder 1 set
28 Gas lighter 2 Nos.
29 Safety match boxes 2 Boxes
30 Paper Plates 300 Nos.
4
No ation of HLC
31 Glass paper (Thermocol) 300 Nos.
32 Tea spoon (S/S) 12 Nos.
33 Stainless Steel Bhagona with cover Medium size 2 Nos.
34 Stainless Steel Kettle 2 Ltrs. & 4 1/2 Ltr 1 each
35 Tea Strainer 6 Nos.
36 Tea cup & Saucers 12 Nos.
37 Desert spoon 6 Nos.
38 Biscuits 10 Kg.
39 Tea leaf 1 Kg.
40 Milk Powder 5 Kg.
41 Coffee 1 Kg.
42 Sugar 10 Kg.
43 Steel containers of suitable capacity for keeping Food, Raw material 4 Nos.
etc.
44 Tea Thermus Steel (SS) 20/10 Ltr. Cap. 2 Nos.
45 Water container (SS) with cover 16 Ltrs. Cap. With Water filter. 2 Nos.
46 Steel glass 12 Nos.
47 Stainless steel Jug (Cap. 2 Ltrs) 2 Nos.
48 Thermos 1 Ltr. Cap. (For tea) 2 Nos.
49 Duster (Khadi cloth) 12 Nos.
50 Khadi cloth 5 Mtr.
51 Water storage tank 1000 Ltr. Cap. 1 No.
52 Soap bar 4 Nos.
53 Soap toilet 4 Nos.
54 Soap dish 2 Nos.
55 Aqua Guard for water filtration 1 No.
56 Cotton Darri size 9'x12' 6 Nos.
57 Electric operated drill machine 230 V with extension cable 50 M upto 1 No.
1/2" Cap. With 10 Nos. 10mm spare drill bit
58 Portable Angle grinder similar to Model Bosch GWS-20-180 2000 W 2 Nos.
with 20 Nos. spare grinding wheel
59 Garden Umbrella with stand 2 Nos.

60 Charging facility for lap top Computer As per HLC No.67
Rqmt.
61 High visibility jackets (white cross on Red back ground). 30 each. HLC No.85
62 Wrist band with serially numbered plastic tockens ( 1 to 100) with 100 Nos. HLC No.81
taps
63 Respiratory Mask 2 units
64 Goggles 6 sets
65 Digital Video & Still Camera with 5-6 floppy disc 1 each HLC No.65
66 Almirah with safe locker for keeping valuable items 1 No.
5
No ation of HLC
67 Kerosene Oil Stove 5 Ltrs. Cap 1 No
68 Portable rail trolley 1 No HLC No.89
69 Staff Uniform - Dark brown pant & light blue shirt 30 Nos.
70 Woollen Blankets 10 Nos.
71 Bed Sheets 25 Nos.
72 Pillows 10 Nos.
73 Pillow Covers 20 Nos.
CATEGORY No.9
Wooden Packing
1 Wooden Packing 300x300x25 mm 3 Nos.
Note : All packing must be recessed at the end & bonded with 30x5 mm thick MS strip bend.
CATEGORY No.10
Telecommunication Equipments
1 Inspection book 1 No
2 Bell Hailer 6 V DC 3 Nos.
3 4 wire emergency portable control telephone set with accessories 1 set
DTL 10093
4 Hand held walkie talkie sets with battery charger 10 sets
5 Charging facility for Laptop, Cell phone and camera 1 Unit HLC No.67
6 Fixed Cellular Terminals (FCT) 4 Nos.
7 VHF set, 25 Watts along with accessories. 2 Nos.
8 Multimeter Digital alongwith took kit 1 Unit
9 Hand held torch of 3 cells complete with dry cell 4 Nos.
Torch cells 36 Nos.
10 Satellite phone 1 No
11 Wireless PA System 1 Unit
12 Light weight synthetic pre-fabricated water proof tents for 01 Nos
communication centre at site & Telecom equipments
13 Emergency socket plan of the division/Neighbouring Div 01 Set
14 Push Button Auto Telephone with tone/Pulse 02 Nos.
15 Digital Voice Recorder 01 No.
16 Field service Telephone cable insulated PVC (D-8 Wire) 500 mtrs
17 5 pair switch board cable with EC plug and socket 500 mtrs.
18 Flexible wire 100 mtrs.
19 4-Wire auto tone dialler 01 No.
6
CATEGORY No.11
Fire Fighting Equipments
1 Dry chemical powder type fire extinguisher 5 Kg Cap. 6 Nos. HLC No.85
2 Nitrogen type Fire Extinguisher 9 Kg. Cap. 4 Nos.
3 Spare Re-fill powder for DCP Fire extinguisher. (1 pkt of 5 Kg. Cap.) 6 Pkts.
4 Spare Cartridge for DCP type fire extinguisher 6 Nos.
5 Spare refill for mechanical foam type fire extinguisher 4 Nos.
6 Fire fighting suit complete 2 Nos.
7
No ation of HLC
CATEGORY No.12
Books & Manuals
1 Accident manual 1 No.
2 G&SR Rule book 1 No.
3 Conference rule Part III & IV for TXR staff 1 No.
4 Safety first instruction book 1 No.
5 Working time table 1 No.
6 ARME Log book 1 No.
7 Attendance register 1 No.
8 Equipment register 1 No.
9 Dead stock register 1 No.
10 Equipment testing register 1 No.
11 Register for the periodical schedules of ARME equipment 1 No.
12 Maintenance manual of the equipments. 1 No.
13 ARME Inspection register 1 No.
14 Inspection schedule board (White writing board) 1 No.
15 Transportation manual 1 No.
16 First Aid manual 1 No.
17 Copy of the high level committee report on disaster management 1 No.
18 Manual on rescue, relief and restoration management 1 No. HLC No.102
19 Medical Manual 1 No.

Category No. 13
Other Items
1 Details of local resources like local doctors, Hospitals, Nursing homes, 1 Unit HLC No.14
official of civil administration, defence establishment, Paramilitary
establishment, boat men, Road cranes/ Bulldozers, Fire bridged
Stations, Road transport depot etc.
2 List of nominated staff for ARMV 1 Unit HLC No.57
3 Duty list of all ARMV staff and supervisor for extricating injured as 1 Unit HLC No. 87
well as dead
4 AMC's for critical equipment with period 1 Unit HLC No. 94
5 Life Detector 1 Set As per Rly Board
6 Scene Tape 6 rolls As per Rly Board
7 Rope Manila Nylon 100 meters 1 roll As per Rly Board
8 Safety Cone 6 rolls As per Rly Board
9 MFR Ki with splints 5 Sets As per Rly Board
10 Portable Defibrillator 1 No. As per Rly Board
11 Life Jackets ( Water Rescue) 100 Nos. As per Rly Board
8
No ation of HLC
Category No. 14
Medical Equipments/Items
1 Augmented First Aid Boxes. 2 Nos. HLC No.85
2 Light weight synthetic pre-fabricated water proof tents for Medical 2 Nos HLC No.85
staff & injured passengers
3 Foldable chairs 4 Nos HLC No.85
4 Portable fire extinguishers 2 Nos HLC No.85
5 Readymade splints for arm & forearm 25 Nos HLC No.85
6 Readymade slings 25 Nos HLC No.85
7 One Portable generator set with sufficient reserve fuel 1 set HLC No.85
8 Battery Operated head lights for medical and paramedical staff 5 Nos HLC No.85
9 Inj. & tablets, Analgine be replaced by Inj. & tablet paracetamol - HLC No.85
10 Dettol to be replaced by betadine/cidex unit As per Req. HLC No.85
11 Anti-inflammatory, Analgesic & antibiotic ointments for local for each unit HLC No.85
application and lotions to be replaced by sets of anti-inflammatory,
analgesic, antiseptic, aerosol, sprays unit for unit.
12 Dressings in autoclaved drums to be replaced by pre-sterilized As per Req. HLC No.85
disposal dressing of assorted sizes.
13 Seldinger nine - Tracheotomy set (1 Number) is to be provided 1 No. HLC No.85
14 Inflatable tourniquet ( 10 Nos) are to be provided. 10 Nos. HLC No. 85
15 Spinal splint (10 Nos) are to be provided. 10 Nos. HLC No.85
16 Phuadephia Cervical Coller 5 Nos
CONTENTS FOR SCALE - I (as per IRMM-2000 Vol.II)
1.1 V.Fluids in disposable plastic transfusion bottles.
a) 5% Glucose 5 Nos
b) Normal saline 5 Nos
c) Plasma expander like low molecular dextran 5 Nos
2 a) Disposable sterile infusion sets 12 Nos
b) Venflow 5 Nos
3 Sterile disposable syringes
a) 2 ml 20 Nos
b) 5 ml 10 Nos
c) 10 ml 10 Nos
d) 20 ml 10 Nos
disposable needles. 50 Nos
4 Inj Pentazocine 50 amps
5 Inj. Atropine sulphate 0.65 mg or 0.6 mg 10 amps
6 Inj.Diclofenac sodium 3 ml 50 amps
7 Inj Adrenaline 1:1000 strength amps 5 amps
9
No ation of HLC
8 Inj Buprenorphine 10 Nos
9 Inj Lignocaine hydrochloride without adrenaline 2% vial of 50 ml. 5 vials
10 Inj Ampicillin 250 mg/vial. 20 vials
a) Amoxycillin 100 cap in
strips
11 Inj Dopamine 5 ml. 10 amps
12 Inj Dexamethasone each vial containing 4 mg 10 vials
13 Inj Diazepam 10 mg 10 amps
14 Inj Pheneramine maleate 6 amps
15 Inj Ranitidine 6 amps
16 Inj Deriphylline 6 amps
17 Nifedipine liquid capsule for sublingual use 6 caps
18 Inj Paracetamol 2 ml I.M 6 amps
19 Inj Dicyclomine Hcl 2 ml I.M 6 amps
20 Inj Metoclopramide 10 amps
21 Inj Lasix 12 amps
22 Surgical spirit 350 ml in wax stoppered bottle 2 bottles
23 Solution of lodine 2% 120 ml in stoppered bottle/Povidone Iodine 2 bottles
solution
24 Chloroxylenol or similar antiseptic 120 ml 2 bottles
25 Sterile paraffin tulle 10 cm x 10 cm or equivalent in tins of 24 pieces 5 tins/packets
26 Lignocaine jelly in tube 1 No

27 Redistilled water for inj 10 ml vials 10 vials
28 Paracetamol tablets 0.5 Gm in strip 100 tab
29 Tab Diazepam 5 mg 50 tab in
strips
30 Tab pheneramine maleate 50 in strips
31 Oral rehydration powder 12 pkts
32 Tab Diclofenac sodium 100 tab in
strips
33 Tab Prochlorperazine 5 mg 50 in strips
34 Tab Dicyclomine Hcl 50 in strips
35 Tab Metronidazole + Furazolidine 100 tab in
strips
36 Tab Antacids 100 in strips
37 Tab Salbutamol 4 mg 50 in strips
38 Tab Metoclopramide hydrochloride 30 in strips
39 Coronary vasodilator sublingual (Sorbitrate 10 mg) 50 in strips
40 Nasal drops 3 vials
41 Tinidazole (300 mg) 100 in strips
10
No ation of HLC
42 Chlorampshenicol eye applicaps in bottles of 25 2 Nos
43 Anti infective or antiseptic insufflation powder 10 gms container. 5 Nos
44 Surgeon's instruments and ligature in a case containing the following
a) Liston's Amputation knife 1 No
b) Bard Parker scalpel handle size no.4 2 Nos
c) B.P. Blade for above 1 Packet
d) Amputation saw 1 No
e) Probe sinus 20 cm 1 No
f) Director butterfly wing 1 No
g) Forceps bone 18 cm 1 No
h) Needle holder universal 2 Nos
i) Scissors blunt pointed 12 cm S.S 1 No
j) Scissors sharp pointed 15 cms S.S 1 No
k) Artery forceps spencer wells 12 cm S.S. 10 Nos
l) Razor safety with packet of 5 blades in case 1 No
m) Catheter male G.S.size 8 & 12 1 each
n) Tourniquet Esmarch (I.R. Bandage) 2 Nos
o) Suture needle cutting curved and straight assorted size in vulcanite 5 each
case
p) Ligature catgut chromic with straight needles of 50 mm and 5 each
curved needles of 40 mm attached in sealed tubes
q) Ligature nylon medium 50 strands
r) Ligature catgut plain in sealed tube with needles size 0 & 1 6 each
45 Forceps tongue S.S 1 No
46 Mouth Gag. Adult and child size 1 No. each
47 Airways plastic or rubber, child and adult size 2 each
48 Sponge holder 20 cm long S.S 4 Nos
49 Scissors surgical 12 cm blunt and sharp pointed S.S. 3 Nos
50 Forceps dissecting 12 cm toothed S.S. 1 No
51 Forceps dissecting 12 cm non toothed S.S. 1 No
52 Forceps dressing 12 cm S.S. 3 Nos
53 Forceps cheatle S.S. 2 Nos
54 Corneal loupe 1 No
55 Tracheostomy set in a case labelled 'sterile', consisting of 1 No
tracheostomy tube with tapes, one scalpel with blade, one sharp
hook, two artery forceps, mosquito silk suture, one blunt hook and
double hook retractor, sterile gauze
56 Labelled cut-open set sterilized in a case consisting of : 1 B.P. Scalpel 1 No

with blade No. 4, 2 Nos. mosquito artery forceps, one fine dissecting
forceps, one I.V. Cannula, silk thread, one needle connected
polythene tube gauze.
11
No ation of HLC
57 Eye lid retractor 1 No
58 Eye spud S.S. 1 No
59 Eye fixation forceps S.S. 1 No
60 Rubber catheter sizes 4, 6 & 8 1 No each
61 Foley's catheter universal size 2 Nos
62 Tourniquet Esmarch's (I.R. bandages and card in tin case) 2 Nos
63 Stethoscope binaural 3 Nos
64 Sphygmomanometer 2 Nos
65 Scissors Mayo 7" straight 1 No
66 Bowls lotion 25 cm, 20 cm, 16 cm diameter E.I. 2 Nos.each
67 Trays instrument and dressing with cover 30 x 25cm, 25 x 20 cm, 1 No each
25 x 15 cm all S.S.
68 Tray kidney size 25 cm and 20 cm 2 Nos.each
69 Brush nail 5 Nos
70 Apron operation plastic 5 Nos
71 Apron operation, longcloth to be kept in sterile drums 5 Nos
72 O.T. Slippers size 7, 8 2 Nos.each
73 Face mask disposable 10 Nos
74 Head cap disposable (Surgeon) 10 Nos
75 Towels operation surgical 100 x 60 cm in sterile drums 20 Nos
76 Gloves surgical size 6½", 7", 7-½" sterile disposable assorted size 10 Nos
77 Coats surgeons 5 Nos
78 Towels hands surgeons (In Polythene bag) 10 bags
79 Soap toilet in case-cakes 5 Nos
80 Stopper loosener 1 No
81 Operation table tubular steel with sponge rubber mattress 1 No
82 Shadowless lamps 30 cm dia or angle poise and fixed on side panel 1 No
83 Trolley anesthetic without castor with stand for oxygen cylinder 1 No
84 Oxygen cylinder 1320 Ltr. Capacity with key 1 No
85 Inj ketamine hydrochloride 5 amps
86 Mask Oxygen, polythene (big and small) 1 No.each
87 Portable resuscitation kit in a bag containing: 1 No
a) Automatic resuscitator with provision for positive pressure
ventilation, inspiratory, expiratory flow adjustments.
b) Manual resuscitator (Ambu's Bag)
c) Oxygen cylinder (small) Ventimask with tubes
d) Suction (Manual and automatic)
e) Intubation set with laryngoscope, endotracheal tubes of all sizes.
f) Stethoscope, sphygmomanometer, Hammer, Spatula, torch,
thermometer
12
No ation of HLC
g)I.V. Rod in two (folded) disposable IV set, adhesive plasters,
sterilised gauge, bandage scissors, dissecting & tissue forceps,
haemostatic forceps, needle holder, disposable syringe & needle,
Splint.
88 Revolving stool 2 Nos

89 Trolley instrument without castors & with castors and glass top 1 No.each
90 Steriliser instrument portable with two burner spirit stove sizes 1 No
30 x 20 x 15 cms & 20 x 10 x 10 cms
91 Gauge cut in assorted sizes and packed in dressing drum 23 x 25 cms 20 Mtrs /
sterilised 200 FFP
92 Wool cotton absorbent cut to size and sterilised in drum 23 x 25 cm 2 kg / 4
pairs
93 Wool cotton absorbent packet of 500 Gms 10 Pkts
94 Bandage loose woven compressed 7.5 cm wide and 4.5 Mtr long 100 Nos
95 Bandage loose woven compressed 10 cm wide and 4 mtr long 100 Nos
96 Bandage adhesive 7.5 cm wide in sealed tins 2 Nos
97 Bandage triangular 130 x 90 x 90cm (SJAB) 30 Nos
98 Adhesive plaster 2.5 cm x 5 Mtr 3 Nos
Adhesive plaster 10 cm x 5 Mtr 3 Nos
99 Scissors Mayo 7" 1 No
100 Mackintosh 1 Mtr size 5 Nos
101 Swab sticks in bundles of 25 wrapped in cloth bag and sterilized in 50 Nos
drums
102 Spirit methylated in wax stoppered bottles of 250 ml each 4 bottles
103 Ready made plaster of Paris bandage 10 cm & 15 cms sizes in tins 20 bandages
of each size
104 Corrugated rubber drain for operation 1 sheet
105 Pins safety assorted sizes in packets of 10 4 sets
106 Thomas splint adult and child size 2 Nos
107 Splint arm and forearm wooden set of 6 2 sets
108 splint thigh wooden liston set of 6 3 sets
109 Hammer 400 Gms 1 No
110 Chisel 2.5 cms wide 1 No
111 Saw 30 cm long 1 No
112 Clasp knife 2 Nos
113 Cork screw opener 1 No
114 Matches safety packet of one dozen boxes 1 Pkt
115 Torch Eveready 4 cell (compact hand carrying) 10 Nos
116 Bulbs for torches (spare) 5 Nos
117 Water bottle with drinking cup and strap 1 ltr 5 Nos
118 Basin wash hand E.I. 35 cms dia 5 Nos
119 Buckets plastic 5 ltrs capacity 5 Nos
13
No ation of HLC
120 Jug water E.I. 2 ltr capacity 2 Nos
121 Stove primus/LPG stove 2 Nos
122 Day carrier 1 No
123 Kerosene oil in 5 ltrs tin 1 Tin
124 LPG petromax 1.5/2 ltr 5 Nos
125 Note book with pencil 5 Nos
126 Memo pad with carbon paper 5 Nos
127 Book for noting injury particulars identification etc 5 Nos
128 Skin marking pencil 2 Nos
129 Ground sheet size 200 x 120 cm 2 Nos
130 Brassards arm with red cross 50 Nos.
131 Haversack each containing the following 5 Nos
a) Roller bandages 10 Nos
b) Triangular bandages 2 Nos
c) Tab. Paracetamol 20 in strips
d) Sterile adhesive strip dressing standard size 40 Nos
e) Antiseptic cream (25 Gm) 1 tube
f) Chloramphenicol eye applicaps in plastic box 10
g) Torch (3 cell) 1
h) Arm brassard red cross 5 Nos
i) Memo pad with pencil 1
j) Tally cards 10 cm x 7 cm with eyelets & tapes 12
k) Disposable sterilized syringes with needle 2 cc 2
l) Inj Diclofenac sodium 2 amps
m) Safety pins 10 Nos
n) Esmarch tourniquet 1 No
o) Wooden splint set of 6 1 set
p) Analgesic aerosol spray 1
q) Analgesic antiseptic spray 1
132 Sterile adhesive strip dressing standard size box of 150 1 Box
133 Cups feeding E.I (200ml) 5 Nos
134 Mug polythene 300 ml capacity 5 Nos
135 Hot water bags IR with cover & ice cap 5 Nos
136 Spittoons 5 Nos
137 Bed sheets cotton white 2.1 x 1.5 mtr 40 Nos.
138 Pillow cotton 50 x 20 cms with 2 water proof covers for each pillow 20 Nos.
139 Sarees cotton white 5.5 Mtr 10 Nos
140 Lungis cotton white 2 Mtr each 20 Nos.
141 Shirts open in front with half sleeves large size 20 Nos.
142 Water proof sheeting 1 x 1 mtr in pieces 20 Nos.
14
No ation of HLC
143 Sand bags 30 cm x 15 cm 10 Nos
144 Hand punkhas 10 Nos
145 Shrouds long cloth 2.1 mtr x 1.5 mtr 40 Nos
146 Backrest wooden 1 No
147 Camps stool folding 2 Nos
148 Camps table folding 2 Nos
149 Blankets woolen/cotton according to climate 50 for BG
150 Bed pan E.I. slipper shaped 4 Nos
151 Urinal male E.I 4 Nos
152 Urinal female E.I 2 Nos
153 Milk powder 450 Gms or Milk condensed 2 Tins
154 Sugar in lever lid tin in 0.5 Kg/1 Kg poly pack 2 Kgs 4 tins
155 Tea in sealed tin of 500 Gms (250 Gms packs 2) 1 tin
156 Coffee(instant)100 Gms in sealed tins 2 Tins
157 Table spoons SS 5 Nos
158 Tea spoons SS 10 Nos
159 Tea pot 1No
160 Tumbler polythene or disposable glass (400 ml capacity) 40 Nos.
161 Cork screw 1 No
162 Tin Opener 1 No
163 Bucket with flat cover polythene size 5 ltr 2 Nos
164 Kettle aluminium size 3 ltr 1 No
165 Degchi aluminium with cover 20,18,15 & 10 cms dia set of 4 1 set
166 Sterile/mineral water 25 bottles
167 Bucket G.I 5 ltr capacity 2 Nos
168 Polythene carbuoys with handle and stopper 18 Ltr capacity 2 Nos
(for drinking water)
169 Stretcher folding SJA pattern(aluminium) 10 Nos
170 Umbrella hand 5 Nos
171 Rain coat plastic with hood (like ladies raincoat) 5 Nos
172 Gum boots standard and large 2 Nos each
173 Breath analyser 1 No
174 Vials for collection of blood samples for testing alcohol content 5 Nos
175 Dictaphone 3 No
176 Stair case steel 2 Nos
177 Shelter as per specification given below: 1 No
Shelter BIVOUAC 420 cm x 420 cm x 240 cm made of light single fly
canvas with the fly extended to the ground on the two sides and
open at the two ends. On both sides there should be hoods attached
to the top to prevent rain beating in. Tents made of white and blue
fabric complete with bamboo poles without joints, iron pegs hammer
and salits
15
No ation of HLC
178 Under water seal 1 No
179 Foot operated suction machine 1 No
Augmented First Aid Box (2 Nos.) HLC No. 85
1 Band aid strips (1.9 x 7.2 cms) 20
2 Povidone Iodine solution (500 ml) 1
3 Surgical pad 7.5 cm x 20 cm 5
4 Antiseptic Cream 1
5 Safety pins 10
6 Adhesive Plaster 2.5 to 5 mtrs 2
7 Disposable spirit swabs (box of 20) 1
8 Chloramphenicol eye applicaps in bottle of 50 1
9 Orohydrate pwd. Pkts 5
10 Tab. Antacid/digene 30
11 Anti-inflamatory spray 1
12 Antiseptic spray dressing 1
13 Pencil torch 1
14 Liquid Paraffin drops 5 ml bottle 1
15 Voveron Emulgel 1
16 Otrivin Nasal drops 1
Contents to be used by qualified Doctor
17 Disposable syringes 5 ml 5
18 Disposable needles 23 G 5
20 IV set disposable 2
21 Venflow 2
22 Laryngoscope, adult & child 1
23 Sphygmanometer (Aneroil type ) 1
24 Stethoscope 1
25 Tab.Sorbitrate 10 mg 10
26 Tab.Paracetamol 500 mg 50
27 Syrup Paracetamol 1
28 Syrup Brufen 1
29 Syrup Anti spasmodicdrops 1
30 Anti spasmodic drops 2
31 Tap.Brufen 500 mg / Diclofenac sodium 300 mg 50
32 Tab.Diazepam 5 mg 10
33 Nefidipine liquid caps 5 mg. for sub lingual use 10
34 Tab.Ranitidine 300 mg 10
35 Tab.Domstal 10mg/Reglan 10mg 10
36 Tab.Spasmindom 20mg 10
16
No ation of HLC
37 Tab.Cetrizine 10mg 10
38 Tab. Asprin soluble 100/150 mg/Disprin 10
39 Tab.Metronidazole-400mg+ Furazolidine 20
40 Tab.Salbutamol 4 mg 10
41 Inj.Adrenaline 1ml 2
42 Inj.Efcorline 100mg 2
43 Inj.Atropine 1ml 2
44 Inj.Diazepam 5 mg 2
45 Inj.Buscopan 2
46 Inj.Pheniramine Maleate 25mgm/Inj.Avil 2
47 Inj.Deriphyllin 2
48 Inj.Lasix 40 mgm 5
49 Inj.Diclofenac Sodium 3ml Ampule 1ml/25mgm 2
50 Inj.Domstal 10 mgm/Reglan 10mg 2
51 Inj.Pentazocine 2
52 Inj.Glucose 25% 5
53 Inj.Ranitidine 2
54 Inj.Buprenorphine 0.03-0.06mg/1 ml 2
55 Inj.Buprenorphine 0.03-0.06 mg/2 ml 2
56 Ringers soslution-450ml 1
57 Inj.Normal saline 0.9% 450 ml 1
58 Injury card 1
59 A pair of gloves (size 7) 1
FOR STATIC FIRST AID BOXES
60 Triangular Bandages compressed 2
61 Roller bandage (7.5 cms X 4Mtr) 5
62 Esmarch's Tourniquet 1
63 Splints wooden extensible (Set of 6) 1
64 Airway plastic (medium) 1
65 Airway plastic (small) 1
66 Ambu Bag (Adult & child) 1
67 Endotracheal tube disposable-Adult 1
68 Endotracheal tube disposable-Child 1
69 Curved Artery Forceps 6" 1
70 Scissors Surgical Mayo's 8" 1
71 Needle holder medium size, straight 1
72 Toothed dissecting forceps, medium size 1
73 Chromic catgut with cutting needle 2
74 Suction pump-foot/hand operated (portable.) 1
75 Portable Oxygen cylinders with accessories. 1
17
18
List of Tools & Equipment for SPARMV on Indian Railway

No ation of HLC
CATEGORY No.1

1 Diesel driven 50 KVA capacity 230 V. fixed generator complete 1 No.
with switchboard and Accessories.
sq.mm PVC insulated
Gen.Set
6 Stand flood light 1.8/2.5 meter high. 6 Nos.

keeping cable.
10 Oil measuring can, set consisting of (200ml, 500ml, 1 Ltr, 2 Ltr & 5 1 set
Ltr)
12 Petrol 2 Ltrs.
13 Tool set complete with cutting pliers, hammers, screw drivers, knife 1 set
etc.
15 Alluminium Telescopic ladder 1 No
16 Lubricating Oil (SAE - 30) 5 Ltrs.
CATEGORY No.2

square meters with 3.5 BHP engine and alternator 1.2 KVA 230 volts
of weight not exceeding 45 Kgs.
3 Petromax LPG (CLIX TYPE) with Auto ignition system as per IS Min. 06 Nos.
specification.
4 Spare Mantles & Glass for Petromax 4 Nos
5 Plastic body LED torches 6 Nos.
6 3-Cell torches 4 Nos.
1
No ation of HLC
CATEGORY No.3
Oxy-Fuel Cutting Equipments
2 Cylinder Acetylene (150 Cu.ft.) 1 No.
3 Cutting torch with Hoses-Nozzles and accessories with pipe blow CR 2 sets
and CH type and Nozzle cutogen 1/16" and 3/16"
9 Tool set for maintenance (Similar to SOLSONS) 1 set
10 Portable Plazma cutting equipment for cutting SS Coach/Wagons 1 Set
CATEGORY No.4
1 Hydraulic Rescue Device (Cold cutting equipment) with spare power 1 set
pack
6 Portable set of electrically operated cutting tools comprising of 2 sets
Trepanner, Bar cutter, Channel cutter and shell shearer for relief and
rescue of trapped passengers
7 Nose plier, Electrician plier 200 mm long, and Outer circlip plier 1 each
10 Petrol 25 Ltrs.
CATEGORY No.5
Lifting Appliances
lift 150mm
lift 150mm
4 Spare Hydraulic Oil for jacks 20 Ltrs.
CATEGORY No.6
4 Power Chain Saw (Electrically operated) 1 No. Go to Chapter contents
2
No ation of HLC
CATEGORY No.7
1 Bench vice 150mm 1 No.
4 Pick Axes 3 Kg 3 Nos.
30x32mm, 36x41mm
32 SOLSON's Tool set consisting of following:- 1 set
a Spanner SP-622
b Spanner 1541
c Hex Key PKMMBS
d Pipe wrench 2060
e Pipe wrench 1030
i Ratchet wrench RWSAE 12 Go to Chapter contents
3
No ation of HLC
CATEGORY No.8
General Stores
7 Pad lock(Godrej make with duplicate keys) 10 Nos.
9 Rain coat two pieces 30 Nos.
10 Oil measuring cans conical pouring type 1) 1 lit. cap. 2) 2 lit. cap. 1 No. of
3) 5 lit. cap. & 10 lit. cap. each
25 Plastic moulded chairs 20 Nos. HLC No.74
26 Folding table. 115x74x71 cm 1 No. HLC No.85
33 Stainless Steel Bhagona with cover, Medium size 2 Nos.
38 Biscuits 10 Kg.
39 Tea leaf 1 Kg.
41 Coffee 1/2 Kg.
4
No ation of HLC
42 Sugar 10 Kg.
43 Steel container of sufficient capacity for keeping Food & Raw 4 Nos.
material.
44 Tea Thermos Steel (SS) 20/10 Ltr. Cap. 2 Nos.
45 Water container (SS) with cover 50 Ltr. Cap. 1 No.
52 Soap bar 4 Nos.
54 Soap dish 2 Nos.

60 Charging facility for lap top Computer As per Rqmt. HLC No.67
61 High visibility jackets (Red cross on White back ground) 30 Nos. HLC No.85
62 Wrist band with serially numbered plastic tockens ( 1 to 100) with 100 Nos. HLC No.81
taps
64 Goggles 6 sets
equipments
68 Kerosene Oil Stove 5 Ltrs. Cap 1 No
70 Staff Uniform - Dark brown pant & light blue shirt 2
pair/person
71 Steel Container for keeping Food, Raw materials. 06 Nos.
72 Steel Bucket 10 ltrs capacity 02 Nos.
CATEGORY No.9
Wooden Packings
6 Wooden wedges 10 Nos.
Note : All packing must be recessed at the end & bonded with 30x5 mm thick MS strip bend. Go to Chapter contents
5
No ation of HLC
CATEGORY No.10
2 Megaphone transistorized 2 watts to work on 9 volt dry battery cells. 3 Nos.
3 4 wire emergency portable control telephone set with accessories DTL 1 set
10093
6 Mobile cellular telephone 4 sets
12 Light weight synthetic pre-fabricated water proof tent for Telecom 01 No.
equipments.
CATEGORY No.11
2 Mechanical foam type Fire Extinguisher 9 Kg. Cap. 4 Nos.
5 Spare refill for mechanical foam type fire extinguisher 4 Nos.
6 Fire Resistant suit complete 2 Nos.
CATEGORY No.12
Books & Manuals
6 SPARMV Log book 1 No.
11 Register for the periodical schedules of SPARMV equipment 1 No.
13 SPARMV Inspection register 1 No.
14 Inspection schedule board 1 No.
17 Copy of the high level committee report on Disaster Management 1 No.
6
No ation of HLC
Category No. 13
Other Items
2 List of nominated staff for SPARMV 1 Unit HLC No.57
3 Duty list of all SPARMV staff and supervisors for extricating injured as 1 Unit HLC No. 87
well as dead
4 AMC's for critical equipments with record of periodicity 1 Unit HLC No. 94
5 Life Detector 1 Set As per Rly Board
6 Scene Tape 6 rolls As per Rly Board
7 Rope Manila Nylon 100 meters 1 rolls As per Rly Board
8 Safety cone 6 rolls As per Rly Board
9 MFR Kit with splints 5 sets As per Rly Board
10 Portable Defibrillator 1 No. As per Rly Board
11 Life jackets (Water rescue) 100 nos. As per Rly Board
Category No. 14
2 Ten Coffins and body bags in an under slung area below under frame 10 Nos HLC No. 80
of the coach.
3 Light weight synthetic pre-fabricated water proof tents for Medical 2 Nos HLC No.85
staff & injured passengers
4 Luminous jackets duly containing white cross on red back ground for 30 Nos. HLC No.85
use by rescue workers
8 Readymade slings 25 Nos HLC No.85
13 Anti-inflammatory, Analgesic & antibiotic ointments for local for each unit HLC No.85
application and lotions to be replaced by sets of anti-inflammatory,
analgesic, antiseptic, aerosol, sprays unit for unit.
14 Dressings in autoclaved drums to be replaced by pre-sterilized As per Req. HLC No.85
disposal dressing of assorted sizes.
18 Phuadephia Cervical Coller 5 Nos.
7
No ation of HLC
1 V.Fluids in disposable plastic transfusion bottles.
a) 5% Glucose 5 Nos
b) Venflow 5 Nos
a) 2 ml 20 Nos
b) 5 ml 10 Nos
c) 10 ml 10 Nos
d) 20 ml 10 Nos
strips
solution
25 Sterile paraffin tulle 10 cm x 10 cm or equivalent in tins of 24 pieces 5tins/packets
29 Tab Diazepam 5 mg 50 tab in trips
31 Oral rehydration powder 12 pkts Go to Chapter contents
8
No ation of HLC
strips
strips
36 Tab Antacids 100 in strips
41 Tinidazole (300 mg) 100 in strips
case
p) Ligature catgut chromic with straight needles of 50 mm and curved 5 each
needles of 40 mm attached in sealed tubes
9
No ation of HLC
55 Tracheostomy set in a case labelled 'sterile', consisting of 1 No
tracheostomy tube with tapes, one scalpel with blade, one sharp
hook, two artery forceps, mosquito silk suture, one blunt hook and
double hook retractor, sterile gauze
forceps, one I.V. Cannula, silk thread, one needle connected
polythene tube gauze.
25 x 15 cm all S.S.
69 Brush nail 5 Nos
10
No ation of HLC
thermometer
Splint.

30 x 20 x 15 cms & 20 x 10 x 10 cms
sterilised 200 FFP
pairs
drums
103 Ready made plaster of Paris bandage 10 cm & 15 cms sizes in tins 20 bandages
of each size
122 Day carrier 1 No Go to Chapter contents
11
No ation of HLC
g) Torch (3 cell) 1
j) Tally cards 10 cm x 7 cm with eyelets & tapes 12
136 Spittoons 5 Nos
149 Blankets woollen/cotton according to climate 50 for BG Go to Chapter contents
12
No ation of HLC
159 Tea pot 1No
161 Cork screw 1 No
162 Tin Opener 1 No
175 Dictaphone 3 No
canvas with the fly extended to the ground on the two sides and
open at the two ends. On both sides there should be hoods attached
to the top to prevent rain beating in. Tents made of whit
Augmented First Aid Box (2 Nos.) HLC No. 85
5 Safety pins 10
9 Orohydrate pwd. Pkts 5 Go to Chapter contents
13
No ation of HLC
13 Pencil torch 1
21 Venflow 2
24 Stethoscope 1
28 Syrup Brufen 1
45 Inj.Buscopan 2
52 Inj.Glucose 25% 5 Go to Chapter contents
14
No ation of HLC
53 Inj.Ranitidine 2
58 Injury card 1
64 Airway plastic (medium) 1
15
Standard List of Tools & Equipments for SPART(3-Coach) on Indian Railways

No ation of HLC
CATEGORY No.1
01 Diesel driven 125 KVA capacity fixed generator complete with switchboard and 02 Nos.
Accessories.
sq.mm PVC insulated.
Gen.Set
06 Telescopic Stand flood light 1.8/2.5 meter high. 08 Nos.

keeping cable.
08 250 Watt metal halide lamps with water proof fitting, 200 meter 15 06 Nos.
amps capacity lead with plug on one end and suitable arrangement for
keeping cable.
11 Oil measuring cane, set consisting of (200ml, 500ml, 1 Ltr, 2 Ltr & 01 set
5 Ltr)
13 Diesel Oil in 200 lts drum 200 Lts.
14 Petrol 02 Ltrs.
15 Tool set complete with cutting pliers, hammers, screw drivers, 01 set
knife etc.
17 Alluminium Telescopic ladder 01 No
18 Lubricating Oil (For DG sets) 20 Ltrs.
19 Battery Charger 230 volts/110 Volts DC, 60 Amps 02 Nos.
CATEGORY No.2
square meters with 3.5 BHP engine and alternator 1.2 KVA 230 volts
of weight not exceeding 45 Kgs.
02 Spare Tower Cloth special febric cylindrical shape. 01 No.
03 Spare Blower 02 Nos.
05 Petromax LPG (CLIX-TYPE) with Auto ignition system as per Min. 06
IS specification. Nos.
1
No ation of HLC
06 Spare Mantles & Glass for Petromax 04 Nos
07 Plastic body LED torches 10 Nos.
08 3- Cell torches 10 Nos.
10 Dry Cells 03 Dozens
11 Search Light Chargeable 04 Nos.
CATEGORY No. 3
Cutting Equipments
01 Petrogen(Oxy-Gasolene) fast cutting torches for cutting large section 01 set HLC No.61
steel structures and for under water cutting) Acetylene is not required.
Works on Oxygen, Petrol or Diesel Only.
02 Cane filled with Petrol 20 Ltrs.
04 Cylinder Acetylene (150 Cu.ft.) 2 Nos.
05 Cutting torch with Hoses-Nozzles and accessories with back fire 2 sets
arrestor, pipe blow CR and CH type and Nozzle cutogen 1/16" and
3/16"
11 Leather Apron for Welder 2 Nos.
12 Tool set for maintenance 1 set
13 Plazma cutting equipments (complete set) 1 Set
CATEGORY No. 4
01 Hydraulic Rescue Device [HRD] (Cold cutting equipment) with spare 1 set
power pack.
06 Portable set of electrically operated cutting tools comprising of 1 set HLC No.62
Trepanner, Bar cutter, Channel cutter and shell shearer for relief and
rescue of trapped passengers
07 Nose plier, Electrician plier 200 mm long, and Outer circlip plier 1 each
10 Petrol 25 Ltrs.
11 Diesel Oil 501 Lts.
2
No ation of HLC
CATEGORY No.5
Hydraulic Re-railing Equipments
1 Hydraulic Re-railing equipment set (complete) (LUCAS / MFD) 1 set
2 Spare power pack and control table and roller carriage with traversing 1 each
jack for Hyd. Re-railing equipment.
3 Hydraulic Oil for LUCAS/MFD re-railing equipment with container. 200 ltrs
4 Journal Jack similar to Duff Norton No. 111-C-2 or BEMCO Model 15-J- 2 Nos
10 Capacity minimum - 15 Te. Height - 10" Lift - 5".
CATEGORY No.6
Lifting Appliances
1 Inflatable Air bags ( 2 Nos. round type and 2 Nos. rectangular type) 1 set each HLC No.64
2 Hydraulic hand operated jack 20 ton capacity closed height 250mm, lift 2 Nos.
150mm
3 Hydraulic hand operated jack 30 ton capacity closed height 285mm, lift 2 Nos.
150mm
5 Spare Hydraulic Oil for jacks 20 Ltrs.
CATEGORY No.7
4 Power Chain Saw (Electrically operated) 1 No.
Trolley for seized roller bearing wheels of Loco, Coach & wagons 1 Set
(Wheel Skate)
Rail claw for maintaining gauge 2 Nos.
4-Wheeled hand push trolley 1 No.
CATEGORY No.8
1 Bench vice 150 mm 1 No.
4 Pick Axes 3 Kg. 3 Nos.
3
No ation of HLC
30x32mm, 36x41mm
32 Spring loaded measuring gauges (Track and Rolling stock) 1 set HLC No.77
33 SOLSON's Tool set (As per req.) 1 set
equipments
CATEGORY No.9
General Stores
7 Pad lock(Godrej make with duplicate keys) 10 Nos.
9 Rain coat two pieces 30 Nos.
10 Oil measuring cans conical pouring type 1) 1 lit. cap. 2) 2 lit. cap. 3) 5 1 No. of
lit. cap. & 10 lit. cap. each
4
No ation of HLC
25 Plastic moulded chairs 20 Nos. HLC No.74
26 Folding table. 115x74x71 cm 1 No. HLC No.85
33 Stainless Steel Bhagona with cover, Medium size 2 Nos.
38 Biscuits 10 Kg.
39 Tea leaf 1 Kg.
41 Coffee 1/2 Kg.
42 Sugar 10 Kg.
43 Steel container of sufficient capacity for keeping Food & Raw material. 4 Nos.
44 Tea Thermus Steel (SS) 20/10 Ltr. Cap. 2 Nos.
45 Water container (SS) with cover 50 Ltr. Cap. 1 No.
52 Soap bar 4 Nos.
54 Soap dish 2 Nos.
5
No ation of HLC
60 Charging facility for lap top Computer As per Rqmt. HLC No.67
61 High visibility jackets (Red cross on White back ground) 30 Nos. HLC No.85
62 Wrist band with serially numbered plastic tockens ( 1 to 100) with taps 100 Nos. HLC No.81

64 Goggles 6 sets
67 Inflatable tent 1 No. HLC No.68
68 Kerosene Oil Stove 5 Ltrs. Cap. 1 No
70 Staff Uniform - Dark brown pant & light blue shirt 2
pair/person
71 Stainless Steel Palta 01 No.
72 Ghamela with handle ( Kadai) i.e. pan with handles 16" dia, 6" deep 01 No.
73 Pressure Cooker 10 Ltrs. Capacity 01 No.
74 Compartment thalies steel 15" to 18" dia 25 Nos.
75 Kotries stainless steel 3" approx. 25 Nos.
76 Parat stainless steel 02 Nos.
77 Wooden Board with roller for pastry 01 No.
78 Puri Machine 01 No.
79 Jhara for puri 01 No.
80 Iron Tawa 12" dia 01 No.
81 Mixure Grinder 230 V AC/110V DC with pots. 1 No.
82 Kitchen Ration As per
Rqmt.
83 Cooking toyes 01 set
84 Steel Containers for keeping Food, Raw materials. 08 Nos.
85 Steel Bucket 10 ltrs capacity 02 Nos.
CATEGORY No.10
Wooden Packings
10 Wooden wedges 10 Nos.
Note : All packing must be recessed at the end & bonded with 30x5 mm thick MS strip bend.
6
No ation of HLC
CATEGORY No.11
C&W Items
1 BP Air hose 06 Nos.
2. FP Air Hose 04 Nos.
3. MU Washers 12 Nos.
4. Coupling hooks 02 Nos.
5. Screw coupling with shakle & pins 03 Nos.
CATEGORY No.12
2 Megaphone transistorized 2 watts to work on 9 volt dry battery cells. 3 Nos.
3 4 wire emergency portable control telephone set with accessories DTL 1 set
10093
6 Mobile cellular telephone 4 sets
12 Light weight synthetic pre-fabricated water proof tent for Telecom 01 No.
equipments.
CATEGORY No.13
4 Fire Resistant suit complete 2 Nos.
CATEGORY No.14
Books & Manuals
6 SPART Log book 1 No.
11 Register for the periodical schedules of SPART equipment 1 No.
13 SPART Inspection Register 1 No.
14 Inspection schedule board (White writing board) 1 No.
7
No ation of HLC
17 Copy of the high level committee report on Disaster Management 1 No.
20 SPART Main engine parts catalogue manual 1 No.
21 Main Engine Maintenance Manuals ( Electrical & Mechanical) 1 No.
CATEGORY No. 15
Other Items
2 List of nominated staff for SPART 1 Unit HLC No.57
3 Duty list of all SPART staff and supervisor for extricating injured as well 1 Unit HLC No. 87
as dead
4 AMC's for critical equipments with record of periodicity 1 Unit HLC No. 94
CATEGORY No.16
MISCELLANEOUS GROUP
1 One Digital still camera with multimedia storage card with connecting 1 No. HLC No.65
cord and required peripherals.
2 One Digital Video handy cam Camera with multimedia storage card for 1 No.
video filming of the restoration work.
3 Plastic Moulded Chairs ( stackable ) 10 Nos HLC No.74
4 Garden Umbrella 1 Nos.
5 Light weight Tent pre-fabricated water proof for ART equipments & 01 Nos
crane equipments.
6 Charging facilities for Lap-Top Computer / Cell phone & Camera As per HLC No.67
requirement
7 Almirah with safe locker for keeping valuable items and Imprest 02 Nos.
9 Digital Breath Analyser 1 Nos.
10 safety Cone 6 nos. Board letter
11 Safe steel cash box for imprest money 01 No.
12 Life Jackets(Water rescue) 100 Nos Board letter
13 Scene tape 6 rolls Board letter
CATEGORY No. 17
2 Ten Coffins and body bags in an under slung area below under frame 10 Nos HLC No. 80
of the coach.
3 Light weight synthetic pre-fabricated water proof tents for Medical staff 2 Nos HLC No.85
& injured passengers
4 Luminous jackets duly containing white cross on red back ground for 30 Nos. HLC No.85
use by rescue workers
8 Readymade slings 25 Nos HLC
Go to Chapter No.85
contents
8
No ation of HLC
13 Anti-inflammatory, Analgesic & antibiotic ointments for local application for each HLC No.85
and lotions to be replaced by sets of anti-inflammatory, analgesic, unit
antiseptic, aerosol, sprays unit for unit.
14 Dressings in autoclaved drums to be replaced by pre-sterilized disposal As per Req. HLC No.85
dressing of assorted sizes.

18 Phuadephia Cervical Coller 5 Nos.
1 V.Fluids in disposable plastic transfusion bottles.
a) 5% Glucose 5 Nos
b) Venflow 5 Nos
a) 2 ml 20 Nos
b) 5 ml 10 Nos
c) 10 ml 10 Nos
d) 20 ml 10 Nos
strips
9
No ation of HLC
solution
25 Sterile paraffin tulle 10 cm x 10 cm or equivalent in tins of 24 pieces 5
tins/packets
29 Tab Diazepam 5 mg 50 tab in
strips
31 Oral rehydration powder 12 pkts
strips

strips
36 Tab Antacids 100 in
strips
41 Tinidazole (300 mg) 100 in
strips
10
No ation of HLC
case
p) Ligature catgut chromic with straight needles of 50 mm and curved 5 each
needles of 40 mm attached in sealed tubes
55 Tracheostomy set in a case labelled 'sterile', consisting of tracheostomy 1 No
tube with tapes, one scalpel with blade, one sharp hook, two artery
forceps, mosquito silk suture, one blunt hook and double hook
retractor, sterile gauze

forceps, one I.V. Cannula, silk thread, one needle connected polythene
tube gauze.

25 x 15 cm all S.S.
69 Brush nail 5 Nos
11
No ation of HLC
thermometer
Splint.

30 x 20 x 15 cms & 20 x 10 x 10 cms
sterilised 200 FFP
pairs
12
No ation of HLC
drums
103 Ready made plaster of Paris bandage 10 cm & 15 cms sizes in tins 20
bandages
of each size
122 Day carrier 1 No
g) Torch (3 cell) 1
j) Tally cards 10 cm x 7 cm with eyelets & tapes 12Go to Chapter contents
13
No ation of HLC
136 Spittoons 5 Nos
149 Blankets woolen/cotton according to climate 50 for BG
159 Tea pot 1No
161 Cork screw 1 No
162 Tin Opener 1 No
14
No ation of HLC
175 Dictaphone 3 No
canvas with the fly extended to the ground on the two sides and open
at the two ends. On both sides there should be hoods attached to the
top to prevent rain beating in. Tents made of white and blue fabric
complete with bamboo poles without joints, iron pegs hammer and
salits

Augmented First Aid Boxes (2 Nos.) HLC No. 85
5 Safety pins 10
9 Orohydrate pwd. Pkts 5
13 Pencil torch 1
21 Venflow 2
15
No ation of HLC
24 Stethoscope 1
28 Syrup Brufen 1
45 Inj.Buscopan 2
52 Inj.Glucose 25% 5
53 Inj.Ranitidine 2
58 Injury card 1
64 Airway plastic (medium) 1 Go to Chapter contents
16
No ation of HLC
17
CHAPTER - 11
DEALING WITH
LPG
AND
AMMONIA GAS
DEALING OF LPG PRODUCT
Product Information:
Important properties of LPG from point of view of safe handling and tackling
emergencies are as under:
1. LPG is a mixture of mainly propane ( 25% to 45%) and butane (75% to 55%) and some quantity
of propylene and butylene.
2. As liquid, LPG is lighter than water (density 0.52 to 0.57 gm/cc at 15C). As gas, LPG is 1.4 to
2.1 times heavier than air. When liquid LPG converts to gas in case of leakage to atmosphere, it
expands heavily (230 to 270 times). During leakage in still air, LPG tends to settle at floor level.
3. Volumetric expansion of LPG with temperature is 10 times that of water and 100 times that of
steel. Adequate vapour space should there be left in LPG pressure vessel and it should never be
overloaded. Leakages will increase with rise of temperature.
4. LPG is highly inflammable. It becomes explosive when mixed with air more than 2% by
volume.
5. LPG catches fire instantly on coming in contact with a source of ignition such as flame, spark,
lighted match, cigarette, beedi etc. Without source of ignition, LPG will not catch fire till 410C.
6. In case of continuous LPG leak, a source of ignition even far away can ignite the escaping
vapours. The fire may also travel back to the source of leak, engulfing the leaky wagon.
7. Normally LPG is stored in refrigerated state ( boiling point -15C to 0C).
8. When pressure is released and liquid LPG changes to vapour, heat required for vaporisation is
picked up from surroundings. The liquid product while evaporating can become cold enough to
cause frost burns on bare flesh. Protective gloves should be worn when there is possibility of
skin contact with liquid LPG. During evaporation from leak source, water vapour also condenses
from the air forming a visible cloud.
9. LPG is not poisonous. It does not contain toxic gases like carbon-monoxide. However when a
person comes in contact with large amount of LPG in a closed space, difficulty of breathing can
occur due to lack of oxygen. Liquid LPG handled without protective clothing can cause cold
burns.
10. Warning symptoms when breathed in sufficient quantities – stomach upset and headache.
11. To facilitate detection of LPG leakage, it is mixed with ethyl merceptan to impart a foul odour
resembling that of rotten eggs.
Note: A wagon which has held LPG earlier and is “empty” is potentially dangerous. In this state, in
case of a leaking or open valve, air can diffuse inside and mix with residual LPG at atmospheric
pressure to form an explosive mixture. Valves and bleeder caps of “Empty” wagons should always
be kept closed.
Leakages in LPG Wagons:
Leakage occurs from barrels of tank wagons due to –
Damaged barrel.
Defective dome fittings – improperly tightened or become loose during run.
Defective valve seals, gaskets and corrosion from seating area.
Precautions to be taken during leakages:
1. Nearest Railway authority, oil company and fire brigade to be informed. Directions
should be obtained from Divisional Carriage Controller.
2. When leakage is detected, all lights and fires in vicinity should be extinguished / removed.
Incandescent electric lights can be used. As LPG vapour mixed with air remains suspended
at a lower level, this area must be kept free from sources of ignition.
3. Lanterns or signal lamps should be kept on side from which wind is blowing and as high as
possible. Locomotives should be kept away from site.
4. Personnel should keep to the windward side of the leakage.
5. Spectators should be kept away and instructed not to smoke.
6. Earth should be spread over the surface on which LPG has leaked.
7. In case inspection of dome fittings is required to be done, the wagon has to be moved to a
non-wired lined. Alternately, power block with protective earthing on both sides has to be
taken to inspect the dome fittings.
8. In case of leakage from dome fittings, a trained fitter equipped with proper tools should
first identify the location of leakage using soap water, and then attend as under-
Leakage around Valve securing bolts – tighten the bolts using non-sparking tools.
Excessive force not to be used. If leakage persists, it indicates defective seal.
Leakage from Eduction Valve – Tighten the valve from wheel without using excessive
force. If leakage does not stop, it indicates defective valve seal.
Leakage from Safety Valve – It may be due to valve performing its function of relieving
extra pressure or due to defect. Pouring of cold water over outer surface of barrel can
help to reduce leakage.
Leakage from Thermometer Well – Very dangerous situation as thermometer well is
practically the part of barrel. Tighten top nut to stop the flow of liquid. Do not
overtighten as removal of nut will worsen the situation.
Physical damage to barrel – immediately isolate the tank and notify all concerned.
9. Leaky wagon should be removed to an open area if so advised by control.
10. Arrange for sufficient quantity of water and activate the existing fire-fighting system to
handle any emergency.
Dos and Don’ts:
Dos:
 Ensure quick and accurate information to Divisional Control.
 Subsequently arrange for local resources.
 Ensure no ignition sources near leaky wagon. Affix labels of “Dangerous” and
“Not to be loose shunted” on both sides of the wagon or attach a red flag.
 Check for sparking due to loose brake shoes or hot axles.
 Leakage can be checked by smell, hissing sound or ice-formation on dome.
 In case of leakages from valves, check that they are closed.
 In case of heavy leakage, isolate the wagon on the advise of control. Keep the
wagon cool by spraying water.
 Guard wagon should always be available during shunting.
Don’t’s:
 Do not smoke.
 Do not keep fuel oil, lubricant oil and debris accumulated in engine rooms.
 Do not carry lighted cigarettes, kerosene signal lamps near the vicinity of leaky
wagon.
 Don’t use steel hammers or other such tools for checking / tapping. Only rubber /
Teflon or brass / beryllium-copper non-sparking tools are permitted for handling
LPG wagons.
 No loose / fly shunting is to be carried out.
Other Suggestions:
 Extent of leak can be detected by soap-water.

 If leaky valves are found hard to operate, excessive force should never be used.
 No hammering is permitted on tank barrel.
 Headers of eduction valves should always be blanked by pluggers.
 In case of heavy leakage and vapour cloud formation, OHE traction and Diesel
locomotives in yard can be shut down.
Tackling LPG wagon derailments / accidents:

 Explosive meter should be used to measure the extent of leakage and decide
appropriate restoration measures.
 No smoking / gas cutting, lighting of stoves is to be permitted in the affected area.
 Nearest fire Brigade and Oil Company team to be called to site.
 For re-railing operations, Diesel crane needs to be fitted with spark arrester.
 Only water is permitted for LPG wagon fire control. In case of fire, all attempts
should be made to keep the upper portion of the barrel cool by spraying water,
else the barrel can explode due to heat and cause heavy loss.
HAZARDOUS GAS EMERGENCIES
AMMONIA:
Important properties of Ammonia from point of view of safe handling and tackling emergencies
are as under:
1. Ammonia is a poisonous gas with characteristic pungent odour. The gas causes irritation of eyes,
respiratory tract above 140 ppm. Ammonia gas is poisonous in concentrations above 5000 ppm.
2. Explosive Limit (Flammable limit) – 15% to 28%
3. It is extremely soluble in water and organic solvents. In case of leakages, a water curtain dissolves
the leaking gas. The eyes and skin of affected personnel should be washed with sufficient quantity of
water.
4. Dry ammonia is not corrosive to most material – however with the addition of moisture it is
corrosive to metals such as copper, zinc and their alloys and galvanized surfaces.
5. It has a boiling point of –33.3C and specific gravity of 0.77.
Precautions to be observed for leaky Ammonia tank wagons:
1. Nearest Railway authority , fertilizer company and fire brigade to be informed. Directions
should be obtained from Divisional Carriage Controller.
2. The pungent odour of ammonia gives warning of its presence well before dangerous concentrations
are achieved.
3. In case of leakage, personnel should keep to windward side of leak. Breathing apparatus and
goggles to protect the eyes from irritation are required in cases of heavy leakage. Leaky wagon
should be immediately isolated to an open area.
4. In case inspection of dome fittings is required to be done, the wagon has to be moved to a non-wired
lined. Alternately, power block with protective earthing on both sides has to be taken to inspect the
dome fittings.
5. In case of leakage from dome fittings, a trained fitter equipped with proper tools should first
identify the location of leakage, and then attend as under-
 Leakage around Valve securing bolts – tighten the bolts until leakage stops. Excessive force not
to be used. If leakage persists, it indicates defective seal.
 Leakage from Eduction Valve – Tighten the valve handle from hand without using excessive
force. If leakage does not stop, it indicates defective valve seal.
 Leakage from Safety Valve – It may be due to valve performing its function of relieving extra
pressure or due to defect.
 Leakage from Thermometer Well – Very dangerous situation as thermometer well is practically
the part of barrel. Tighten top nut to stop the flow of liquid. Do not overtighten as removal of
nut will worsen the situation.
 Physical damage to barrel – immediately isolate the tank and notify all concerned.
6. A leaky wagon which has been emptied should be properly stenciled and returned for repairs to the
owning fertilizer company. Such a wagon can be put back in service after repairs only after being
given a hydraulic test.
Dos and Don’ts:
Dos:
 Ensure quick and accurate information to Divisional Control.
 Subsequently arrange for local resources.
 The affected area should be cordoned and personnel should stay in the upwind direction as far as
possible.
 Attempts to be made to locate and plug the source of leakage.
 Spray sufficient quantity of water to dissolve the ammonia. Fire brigade at site can spray water
around the leak source to form a water curtain.
 First aid- Eyes and skin should be washed with sufficient quantity of water to dissolve the
ammonia. For unconscious victims, artificial respiration may be done.
 Breathing Apparatus / canister respirator with ammonia filter and protective goggles are to be
used by personnel approaching leaky wagons. In case of emergency, wagon can also be
approached applying a wet handkerchief over the face to dissolve the ammonia vapours.
 Tank should be shifted to an isolated place if so advised by the control.
Don’t’s:
 Source of ignition should not be allowed near the leaky wagons.
 Direct contact with ammonia is to be avoided as it causes ice and caustic burns.
 Ammonia should not be inhaled directly – a moist cloth should always be used for protection.
 Oil or ointment should not be used on affected part of body.
 No attempt should be made for carrying out welding repairs on leaky wagon.
Important Tools to handle LPG / Ammonia gas emergencies:

 Spark proof tool set (rubber / teflon / brass / beryllium-copper tools) consisting of set of
spanners, chisel, ball peen hammer, blanking flanges, eduction valve pluggers and adopters,
Teflon tape and M-seal epoxy adhesive.
 Protective hand gloves, helmet.
 Explosive meter.
 Intrinsically safe torches.
 Breathing aids – A canister respirator with LPG/Ammonia and dust filters can be used in open
spaces with upto moderate gas leakage. For heavier gas concentrations, breathing apparatus with
oxygen cylinder is required.
 Clear protective goggles.
 Plenty of water, buckets and water-spraying arrangement.
EMERGENCY CONTACT NUMBERS
1. IOC/Koyali (STD code 0265)
SN Designation Name Contact No.
1 Disaster Control 2237300 2237400

Room/IOC Koyli 2233346 2233347
2 Central Control 2232327 2230556
Room/IOC Koyli
3 Fire & Safety Officer 2237443 (Off)
2236443 (Res)
4 Fire & Safety Officer 2237447 (Off)
2236447 (Res)
5 DGM /RC 2237449
6 Sr Production Manager 2237405 (Off)
/ LPG 2386520 (Res)
7 Manager LPG 2237431 (Off)
2390755 (Res)
8 Manager LPG 2237461 (Off)
2393337 (Res)
9 Sr. Manager 2237434 (Off)
2392052 (Res)
10 Sr Manager 2237076 (Off)
2232733 (Off)
2236056 (Res)
2265144 (Res)
11 Gujarat Refinery Siding 2237541
12 Railway TXR 47255
GR Siding (Rly Auto phone)
Peripheral Territory Managers/IOC
1 Territory Manager, IOC 079-3832160 (Off)

Ahmedabad 3832152 (Fax)
6764738 (Res)

Bharuch 02642-240160 (Res)
3 Territory Manager, IOC Surat 0261- 2860688 (Off)
2860715(Fax)
2239091(Res)
Ratlam 264386(Res)
3. Peripheral Territory Managers/BPC:

1 Territory Manager 02694-224928 (Off)
BPCL LPG Bottling Plant, 079-7491001(Res)
Distt. Kheda 98240 03962 (Mob)
Ahmedabad
2 Safety Officer 98244 10242 (Mob)
BPCL LPG Bottling Plant,
Distt. Kheda
Ahmedabad
3 Territory Manager 0261-2841564 (Off)
BPCL LPG Bottling Plant, 98254 16055 (Mob)
Distt. Surat
Hazira
4. Peripheral Territory Managers/HPC:

1 Plant Manager 079-3270186 (Off)
LPG Bottling Plant 3270187 (Off)
Gandhinagar 3231011 (Res)
2 Plant Manager 02646-274184 (Off)
Bottling Plant 274182 (Off)
Ankleshwar 274129 (Off)
246283(Res)
5. Control Rooms - Fertilizer Plants:
SN
Designation Name Contact No.
1 Control Room GNFC 237607
Bharuch
2 Control Room KRIBHCO 0261-2802346
Hazira 2802479
3 Sr Manager Offsite 0261-2802583
KRIBHCO Hazira
4 Manager Safety 0265-2242451
GSFC, Baroda 2242651
2242851
Ext 2777, 3077
2242332 (Res)
5 Offsite Control Room 0265-2232327
GSFC, Baroda 2242451
2242651
2242851
Ext 3535
CHAPTER - 12
DRAWINGS
AND
LAYOUTS
FOR
COMPOSITION
OF
ART/SPART/ARME

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
I. Marshalling of “A”-Class ART:

1st vehicle 140 Te. 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 Fire
7th vehicle C&W, Elect. and Telecom Van (Material of Telecom, Elect. & C&W)
8th vehicle Re-railing Equipment Van (MFD/LUCAS equipments and its material)
9th vehicle Staff and Kitchen Van (MFD/LUCAS staff and Kitchen)
II. Marshalling of “B”-Class ART:

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
4th vehicle C&W, Elect. and Telecom.Van (Material of Telecom, Elect. & C&W)
5th vehicle Re-railing Equipment Van (MFD/LUCAS equipments and its material)
6th vehicle Staff and Kitchen Van (MFD/LUCAS staff and Kitchen).
1. 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 Equipments in each coach / wagon will
facilitate easy loading and unloading of ART equipments at accident sites which in turn
reduce time taken for rescue and restoration activities.
2. Future Suggestions:
1. For faster Implementation, responsibility should be fixed to the appropriate level , if Railway
Board’s instructions are not followed in toto in a time bound manner.
2. CAMTECH/GWL to be made the nodal agency for deciding advanced maintenance of

Tools/Equipments/Rolling stock of ART.
3. Training Modules for each Critical Equipment/Power Pack/Restoration activity should be

developed by CAMPTECH/GWL for Artisan staff and Supervisors and suitable Training to
be given by CAMTECH /GWL and Practical training to be given in the Divisions.
4. Standardisation of Preventive Maintenance Schedule Forms should be done for all critical
Equipments of ART by RDSO and CAMTECH and circulated to all Zonal Railways for
implementation.
3. References:
1. CMPE(R & L) committee’s Report on “Re-organisation and Modernisation of Accident

Relief Trains” circulated in 1985.
2. High Level Committee’s Report on Disaster Management circulated in April-2003.
3. Report of High level Safety Review committee of February 2012.
4. Report submitted by JA Grade committee to Railway Board for review of existing

equipments of ARTs/ARMVs/SPARTs/SPARMVs in December 2009.
5. Report of Railway Board Director level committee constituted to review

recommendations no. 13, 69, 75 and 102 of HLC Committee on Disaster Management
(DM) vide Board’s letter No. CRB-I/2011/73/6, Dated: 15.03.2011.

6. Inclusion of additional 13 items in ARTs/ARMVs by Railway Board vide their letter No.
2003/M/ (M&P)/7/DM/Status/Pt, Dated 31.12.2012.
7. Bench marking of ART/ARME Staff for day to day maintenance of equipments & tools
of standard lists & ART/ARME rolling stock, circulated by CME/CRLy vide letter No.
T.153.L5.HLC.57 dated 18.10.2004.
8. Indian Railways Year Book 2011-2012.

Details of Newly developed Layout drawings for ART/ARME.
Details of Newly developed 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 is shown.
EUQIPMENT 3. Provision of 4-tier almirah for keeping spares is shown.
VAN 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
equipments.
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
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 setting of C&W
AND material.
TELECOM 2. 4- Tier shelf size 900 x 760 mm & 3-Tier rake for keeping all type of nuts &
VAN bolts is shown.
3. Provision of chequred sheet for floor is shown for minimizing floor damages
during handling.
Electrical Equipments.
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 Equipments.
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 isGo
shown.
to Chapter contents
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.

Nomenclature { RREV-005 } RT
RE-RAILING 1. Provision of 4-tier almirah for keeping Seal kits, Maintenance tools
EQUIPMENT valuable spares of hydraulic jacks and power pack is shown
VAN 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
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 packings and gas
cylinders.
8. Provision of 2-tier rakes both sides for keeping wooden packings, 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 and lubricants
12. As per marshalling, this is not the rear most vehicle hence guard seat is not
required

Nomenclature { SKV-006 } RT
1. Provision of vestibule at both ends is shown
STAFF AND 2. Provision of bathroom in one toilet for taking bath for officers &
KITCHEN supervisors
VAN 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. Go to Chapter contents
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.

Nomenclature { CSKV-003 } RT
CRANE STAFF 1. Provision of vestibule at both ends is shown
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.

Nomenclature { EOM-002 } BCNHS
1. Provision of screw coupling and both side buffers
2. Space for engineering heavy material i.e. Sleepers, wooden sleepers size
ENGINEERING 2560 mm
AND OHE 3. Provision of modified doors for easy opening
MATERIAL 4. Provision of 4-Tier rake size 6000X1800 mm for engineering tools,
VAN machines and equipments
5. Provision of Box for OHE material Size 2300X1250 mm.
6. Space for CST-9 Sleepers size 2560mm

Nomenclature { CPOM-002 } BCNHS
1. Provision of screw coupling and both side buffers
CRANE 2. Space for keeping 140Te./75Te. Crane packings size 2560 mm
PACKING 3. Provision of modified doors for easy opening
AND OHE 4. Provision of 06 nos. tube lights for easy handling of crane material.
MATERIAL 5. Provision of Box for OHE material Size 2300X1250 mm.
6. Provision of two tier rake for small packings and wire ropes & crane
VAN
wire ropes
7. 4-Tier almirah for crane items and linen size 6.5'X3'X2'
Provision of two berths for staff.
Space for keeping DA& Oxygen gas

cylinders
Two tier rake for oil barrels and hydraulic hand pumps and jacks
Two tier rake for keeping D-Shackles and fire extinguishers
Suitable space for keeping heavy crane packings for 140/75Te. Cranes size
2560mm

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5
CHAPTER - 13
RELIEF AND RESCUE
OPERATION
ON
PASSENGER TRAIN
INTRODUCTION
During CMEs conference held in April-2013, various Railways were assigned the work
of preparation of procedures for handling rescue, Relief and restoration at Accident sites. The
Railways have submitted their draft procedures on 12.03.2015 at Railway Board for
preparation of chapter on Rescue & Relief Operation by HRD (Hydraulic Rescue Device) &
Electrically Operated Equipments.
This chapter is prepared for assistance to Rescue and Relief staff of SPARTs/ARMEs
on IR. The sample pattern is provided for each type of activities to be carried out at accident
sites for creating and using access for rescue of trapped passenger including use of rescue
equipment under various scenarios.
The aim of rescue is to save life and minimize further injury to people and damage to property.
Common rescue functions are to access, support and remove, trapped people in the course of
rescue operations, another is to assist in evacuating the dead and provide support on request
to other services, authorities or specialist teams.
So, different way of tackling by Hydraulic Rescue Device would be required for different
situations and it may not be possible to anticipate every condition thrown upon by the actual
accidents/working sites and delineate the exact method of handling. Hence, in following
paragraphs a humble effort has been made to cover this to the extent possible with the inputs
from SPARTs/ARME in-charges on the basis of actual site experiences. Each accident site
presents unique condition in itself and hence common sense must be applied apart from the
proven methods of handling the situation ensuring safety to the human being.
In addition to the above, the need of organized rescue and relief operation during first
hour (called Golden Hour) has been emphasized by the high level committee on Disaster
Management. Every railway men on duty in the train has clearly defined duties in case of
accidents and they engaged immediately in rescue/ relief. Similarly large number of railway
men traveling by train and other volunteers also respond to the emergency and help
passengers. However in absence of any organized effort visible, despite crucial rescue and
relief work undertaken by railway men, the railways are adversely criticized by media and role
of outside volunteers often with insignificant contribution becomes a matter of praise.
Therefore an effort has been made to assign specific duties to each railway employee in such
a way that statuary safety requirements of train protection and information to control are met
by crew and guard. The ticket checking and other staff commence rescue/ relief operation
immediately by forming a team including doctors and protection staff. Driver and guard latter
join the Golden Hour rescue team for ensuring rescue and relief action best suited. The
Golden Hour rescue and relief team completely controls the operation, ensures continuous
information to control seeking specific assistance and securing information for assisting the
passenger involved in the accident.
PART-I
1.0 DISASTERS AND TRAIN ACCIDENTS
Disaster:
A Disaster is an unusual occurrence characterised by sudden calamity, causing
great material damage, loss and distress.
A Railway Disaster is a serious train accident or an untoward event of grave

nature, either on the railway premises or arising out of railway activity in that
area, due to natural or man-made causes, that may lead to loss of many lives
and /or grievous injuries to a large number of people, and/or severe disruption
of traffic, necessitating large scale of help from other government/Non-
Government and Private Organisations.
Types of disasters causing interruption to train services:
Human/Equipment failure:
The disasters/accidents may be caused by human/equipment failure, which may
affect normal movement of train services with loss of human life or property or
both. These include:
 Collisions
 Derailments
 Accidents at manned or unmanned level crossings.
 Fire or explosion in trains
 Miscellaneous
Natural calamity:
Natural calamity can also cause serious repercussion with loss of life/property.
This includes:
 Landslides.
 Storms/ Cyclones.
 Earthquake.
 Floods.
IRCAMTECH/MECH/GWL/Relief & Rescue Operation by HRD/4

Sabotage:
Sabotage, i.e. causing deliberate loss of life and/or damage to property,

includes:
 Setting fire to train, Railway installations etc.
 Bomb blast.
 Placing obstructions on track to cause disruption to railway traffic.
 Tampering with railway fittings causing accidents.
Train accidents
Train accident is an accident that involves a train. Train accidents are further
classified as:
 Consequential train accidents.
 Other train accidents.
Consequential train accidents
These include train accidents having serious repercussion in terms of either one
or many or all of the following: -
 Loss of human life.
 Grievous injuries to Passengers.
 Loss of railway property.
 Disruption to rail traffic.
Train accident under following classification will be termed as

consequential train accidents: -
 Collisions
Collisions are the worst kind of accidents and are of three types viz.
 Head on collision
 Rear collision
 Side collision
 Fire or explosion in trains
This shall include all cases of physical fire or smoke emission resulting
in death or injury or damage to property.

Level crossing accidents
Applies to accidents at Level Crossings, i.e. at the intersection of the roads

with railway track at the same level.
 Derailment
Off loading of wheel or wheels causing detention or damage to rolling stock/

permanent way.
 Miscellaneous
All other train accidents that are not covered under the earlier categories are to
be treated as miscellaneous accidents.
 Other train accidents
These include:
 Averted collisions
 Breach of Block Rules
 Train passing signal at danger

2.0 CHARACTERISTICS OF RAILWAY ACCIDENTS
Like other accidents, Railway accidents have the following characteristics:
 they usually happen unexpectedly, without warning;

 they may result in fatalities and injuries;
 they attract media attention;
 they cause psychological problems for the survivors, rescuers and
families.
Railway accidents can be caused by:
 Technical and other reasons (condition of the railway line,

breakdown of vehicles, failure of railway signal, human factors
and other reasons);
 Natural and other disasters (earthquake, flood, avalanche, fire,
dangerous goods accidents, human factor and other disasters);
 Sabotage.
Various scenarios of Railway accidents may be the result of: train crashes,
train collisions, train derailment, train fire or fire in the vicinity of the railway
line, explosion on the train and damage to the railway line (rock slide,
avalanche, flooding, etc.)
All of the above cases can cause damage to the locomotive and to one or more
coaches, as well as over-turning individual rail vehicles. However, the number
of fatalities and injuries is the highest in the collision of passenger trains or in
the collision of passenger and goods trains. The consequences of dangerous
goods transportation accidents may also be very serious because of the greater
quantities of goods carried in comparison to road transport. Additional
difficulties would be experienced during protection and rescue operations when
train accidents occur in difficult-to-access terrain or in the event of a train
derailing into water.

Collision of
Trains
resulting of
coaches
climbing over
other
Derailment of
Train resulting
damage to
End body of
coach.
Collision of
Passenger and
Goods Trains

Fire in Train
Capsized
coaches fallen
into water body
Coaches
climbing over
other

Consequence of disaster on a victim caused due to train accident
The initial response of a victim following a disaster is called Disaster

Syndrome.
A victim’s initial response is in three stages, viz.
• Shock stage,
• Suggestible stage and
• Recovery stage.
In the Shock Stage victims are stunned, dazed and apathetic.
In the Suggestible Stage victims tend to be passive and willing to take

directions from rescue workers.
The Recovery stage in case of a railway accident consists of three phases.

These three phases are determined by the time factor and also by the extent of
specialized assistance available.
• Firstly, it begins with the spontaneous reaction of men available on the

train at the time of the accident.
• Thereafter the second phase continues with contributions made in rescue
and relief work by men and material available locally in nearby areas of
the accident site.
• The third and longest phase consists of meticulously planned action by
trained Disaster Management teams who arrive at the accident site to
carry out rescue and relief operations
With the above scenario in mind, it is necessary to take firm and quick
decisions to save lives and property. To achieve these objectives railways have
a well – defined action plan that is successfully executed by the coordinated
efforts of different disciplines all of whom function as a team.

3.0 RESCUE
AIM:
The aim of rescue is to save life and minimize further injury to people and damage to
property.
FUNCTIONS:
Common rescue functions are to:
 Access, support and remove, trapped people in the course of rescue operations
 Assist in evacuating the dead and
 Provide support on request to other services, authorities or specialist teams.
PLANNING:
 List the types of entrapment
 List the types of releases
 Define a structure of search and rescue team
 List out the duties of team members
IMPORTANT POINTS:
 Rescue occurs in phases
 Each phase must be completed before beginning of the next
 Method to use = SAVER
S = Systematic
A = Approach to
V = Victim
E = Entrapment
R = Rescue
TYPES OF ENTRAPMENT:
MECHANICAL ENTRAPMENT:
The train compartment/coach is blocked up or damaged in such a manner that the
occupants are unable to normally exit the compartment.
PHYSICAL ENTRAPMENT:
Type I: The occupants are injured in such a manner that additional space is
required for providing relief/rescue and remove the casualty.
Type II: The casualty is pinned by the wreckage either by encasement or by
impalement.

TYPES OF RELEASE:
CONTROLLED RELEASE:
Due to the stable condition of the casualty, time can be taken for
disentanglement providing appropriate care and extrication is possible.
IMMEDIATE RELEASE OR ‘RAPID EXTRICATION”

The condition of the casualty deteriorates markedly and is thus life
threatening.
The casualty is removed immediately for advanced life support and/or
transport to hospital.
The presence of danger is also a prerequisite for immediate release
NOTE:
 Immediate release is an important act in extrication.

 Serious consideration on situation required otherwise more
damage is possible
THE PSYCHOLOGY OF RESCUE:

 Any situation that requires a rescue operation has, by definition, either
dangerous or potentially dangerous elements.
 People tend to react differently to danger, but the most general responses are
anxiety and fear, perhaps the most powerful of all emotions.
 It should be remembered that it is not just the victim who faces the danger.
The rescuer must enter the site of the dangerous situation and face the same
danger in order to rescue the victim.
 Dangers are still often present when the main danger has passed.
 The biggest difference between the victim and the rescuer is that the rescuer is
better able to cope with, or handle, the situation.
 The rescuer has the knowledge and the resources to minimise risk and to
remedy the situation.
 It is normal to be anxious and feel fear in the face of danger. These emotional
reactions are common to both victim and rescuer.
 Many other emotional responses may become manifest during a rescue
situation—pity, disgust, contempt, pride, concern and many more.
 Urgency and pressures of the situation, thus lowering the efficiency of the
overall operation.
 The rescuer must be aware of the psychological needs of victims, not just their
physical needs, and be prepared to meet those psychological needs.

QUALITIES OF A GOOD RESCUER:
Rescue work is not an easy task, not necessarily a glamorous one. Not all people are
suited to such work. Physical fitness, personality and emotional stability are the
factors involved in determining one’s suitability.
Ideally, the rescuer will have the following qualities:
 Interest: A genuine interest in rescue work, not just peer pressure, trying to
impress people etc.
 Training: Will to continually undergo training to maintain a professional

standard.
 Dependability: The lives of victims and team members rely upon

dependability.
 Initiative: The nature of rescue operations means that it is often impossible to

closely supervise each team member. Everyone must be able to see what needs
doing, set priorities, and do the tasks at hand.
 Versatility: Each situation is unique. An individual must be able to apply a

wide range of skills and knowledge to different situations.
 Co-operation: Rescue work is usually a team effort and cooperation with

others is vital.
 Physical fitness: Rescue work of any kind is physically demanding and often
continues for long periods. Any physical limitations must be recognized and
taken into consideration.
 Leadership qualities: Leadership qualities are required by all rescuers at

various times and to varying degrees. Capable leadership by trained rescuers
means that many more untrained personnel may be used.
 Control over fears (phobias): Rescuers must know what they can and cannot
do. Part of this knowledge consists of being aware of any phobias. It is also
vital that the leader of a rescue team knows of any phobias in team members.
Some phobias can seriously affect a rescuer. Phobias include:
i. Fear of the sight of blood
ii. Fear of heights
iii. Fear of confined spaces, and
iv. Fear of water or drowning.
 Uniform and bearing: Appearance must instill confidence in others.

PERSONAL BEHAVIOUR:
The conduct of individuals tells a lot about their psychological make-up or

personality. Given the nature of rescue work, it is particularly important that personal
conduct does not aggravate matters. Personal behaviour must assist in creating a
feeling that the situation is in competent hands and everything possible is being done
to rescue and care for the victims. Important general areas of conduct or behaviour
include:
 Attitude—Maintain a serious, professional attitude to gain confidence and

support. Arrogance and superiority create instant antagonism. Loud talking,
joking and horseplay reduce credibility and create a feeling of resentment and
disgust. They add to the confusion, hinder the work and add to the state of
anxiety of the victims. Rescuers cannot consider themselves professional if
they add to the confusion by loud shouting or frantic gestures.
 Emotions—Emotions are hard to control in the best of circumstances. In a

disaster, the control of emotions is a very difficult task. Every effort is to be
made to prevent emotions from influencing good judgment and competence.
The rescuer must remain calm and be sympathetic without becoming
emotionally involved, regardless of the excitement and the severity of the
incident.
 Courtesy—Courtesy, tact and good judgment are vital. To quickly and

effectively complete the rescue task, give courtesy to all concerned.

4.0 RESCUE ORGANISING
It consists of organization of
1. Rescue team 2. Work area
Rescue Team Organising
Rescue team comprises of Team leader, Technical rescuers, Safety Officer, Medical
assistant and General assistant.
Team Leader
 to be easily recognized by all by distinctive clothing
 conducts reconnaissance of accident scene
 directs proceedings and team functions
 Liaises with other units.
 Ensure safety of casualties, rescue workers & bystanders for the duration
of the rescue
 Disconnecting batteries of coach, assess stabilization control, protect the
casualty, glass remover, cover sharp edges
Technical Rescuer
Responsible for all technical tasks:
 stabilization
 glass management
 gaining access
 disentanglement
General Assistant
 Assembles equipment for use as required

 Attends the lever on the hydraulic rescue equipments
 Attends all materials, if necessary also the logistics – act as a Logistics
Coordinator for transporting equipment to the actual place of work.
Work Area Organization

It includes
 Selection of appropriate work area
 Emergency vehicles safe parking
 Selection of a place for dumping removed and unwanted materials.
 Tool and equipment staging area
 Fire prevention Go to Chapter contents

5.0 RESCUE PLAN
The success of rescue operations depends principally on the team leader conducting a
quick and thorough reconnaissance of the situation and then, through the appreciation
process, developing a workable plan.
The Reconnaissance
Every member of a rescue team must be trained in rescue reconnaissance. In many

instances the team leader will be responsible for a number of tasks, and personnel
deployed must be able to conduct reconnaissance and to report observations back to
the leader. Exploit all sources to obtain information regarding casualties, damage and
likely hazards.
The team leader’s reconnaissance should aim for an accurate assessment of:
 The number and location of casualties

 Dangerous situations such as leaking fuel, gas, electricity, overhanging
walls, unsafe structural components, or
 Anything else which may endanger rescue personnel or survivors
 Access to the casualties or task
 The extent and type of the damage
 Appropriate services and support agencies
 Available resources, both personnel and equipment, and
 The time the task will take with available resources.
The Appreciation Process
The appreciation process is a simple method of problem-solving which is effective in

rescue situations. It involves the logical assessment of the situation and the
reconnaissance, and results in the formation of a workable plan.
Experienced rescue operators may use intuition and experience to enhance this
decision making tool.
The appreciation process has the following steps:
a. Define the problem—clearly define the problem to be solved or the task to be

accomplished. The problem may be too large or complex to tackle easily, and may be
divided into a number of manageable elements, each with a set aim.
b. State the aim—the aim is a clear statement of what the team has to achieve in
order to solve the problem. The aim must be clear, concise, and achievable and
expressed in positive terms. The aim will form the mission statement in an operational
briefing, and should be as simple as, for example, ‘to rescue the passenger from the
capsized coach’.
c. Consider the factors—Factors are points relevant to the problem that has to be
solved. Factors to consider in an operational situation may include:
 number and location of casualties Go to Chapter contents

 time and space
 topography
 weather
 available resources, both personnel and equipment
 support requirements and availability
 communications
 logistics, and
 priority of tasks.
Each factor will lead to one or more logical deductions. The leader should be in
a position to say, “if that is the case—then this is the solution”
Factors in an appreciation may be set out as in the following example:
Factor The casualty’s legs are trapped under a heavy steel structure.
Deduction The rescue team must use cutting and lifting equipment to free the
casualty.
d. Plan—The plan will result from the choice of the best solution open. That is,
it will be the solution with the most advantages and the least disadvantages.
The plan must be simple, and it must relate directly to the aim. When
completed, check the plan against the following test questions:
 Is the reasoning sound?

 Is it set out in logical order?
 Is everything in it relevant to the problem?
 Has anything relevant been left out?
 Is it free of uncertainties and ambiguities?
 Is it accurate (positions, timings and so on)?
 Has the aim been kept in mind throughout?
 Can the plan achieve the aim?

6.0 SAFETY IN RESCUE OPERATIONS
 Rescue involves training of individual and team in various skills.
 Pay a great deal of attention to safety measures as rescuers safety is prime
important.
 No compromise on basic and simple safety precautions.
BASIC PRECAUTIONS:
Regularly and carefully check equipments, both before and after use.
Adhere to standard techniques, practices, safety limits and margins in the rescue field.
PROTECTIVE CLOTHING AND SAFETY:

Use, maintain and replace all Personal and Protective Equipment (PPE) such as
helmet, protective clothing, safety goggles and safety boots in accordance with the
laid down systems..
CASUALTY SAFETY:
The safety of casualties is of prime importance. Make every effort, including the use
of protective equipment, to ensure that casualties come to no further harm once a
rescue team arrives at the scene
EQUIPMENT SAFETY:
Use all equipments in close compliance with manufacturers’ operating instructions,
and follow these basic safety rules for rescue tools and equipments:
 Wear safety goggles and gloves when using power tools such as disc
cutters or saws, and take care to avoid jamming blades.
 When it is necessary to cut in close proximity to a trapped casualty, direct
the cutting blades away from the casualty’s body where possible, and
protect the casualty’s body with shielding.
 Many items of equipment have been specifically designed for particular
tasks. Give careful safety consideration before any modification of
equipment or method of use is attempted.
 Use only blades, fuel, oil, hydraulic fluid and parts that are recommended
by the manufacturer.
 Never refuel petrol-driven motors while they are hot, and keep them apart
from fuel supplies and casualties.
 In load-lifting operations, take care to continually pack under the load to
prevent total collapse in the event of equipment slippage or failure.
 Adhere to all specific safety procedures for rescue equipment, and carry
out regular and careful safety checks before and after use. Go to Chapter contents

CORRECT LIFTING TECHNIQUES:
At all levels of rescue training and operations, rescuers will be required to lift,
haul or push loads and must be trained to handle these tasks properly and
safely.
There is a serious risk of spinal or abdominal muscle injury is involved due to

incorrect lifting. The following points detail correct lifting techniques:
 As the leg and thigh muscles are stronger than those of the arms,
back or abdomen, these are the muscles to use for safe lifting.
 During a lifting operation, crouch down with knees bent, back
straight and feet properly placed to bear the load
 Grip the load correctly and start the lift by the thrust of the legs, and
continue this thrust until the legs are straight. Keep the load close to
the body and keep the back straight. In this way, the strain involved
is placed on the leg muscles, and the possibility of back or
abdominal injury is greatly reduced.
 Lower loads in the reverse manner to the lifting techniques.

7.0 SEARCH & EXTRICATION METHODOLOGIES
OBJECTIVES:
 Knowing the two ways of approaching a located trapped victim.

 List the five factors to analyze when evaluating access conditions
 Procedure for penetrating different materials, viz. wood/fibre, metal etc.
INTRODUCTION:
 If a coach is involved, the emergency exits at the sides provide
ambulatory occupants with a means of escape and also provide good
access for crews assigned to interior rescues
• A large portion of the passenger area is made up of window, if
all the exits blocked, then remove
• Window glass
• Window bars
 Interior procedures used to free victims after access has been gained
by breaching door/windows.
 Careful inspection of the components responsible for victims
entanglement provide a basis for selection of Tools, Equipment &
Accessories (TEA) and procedures.
 Opening exits or simply cutting windows and side body may open up
enough space for removing victims immobilized on backboard.
APPROACH STRATEGIES:
Once the search has ended and the trapped victim has been located, it is
then necessary to make a decision on how to approach the victim.
Vertical Approach: Access into victim is made from either above or below.
Horizontal Approach: Access into victim is made from either side.
EVALUATING ACCESS CONDITIONS:

• Ensure presence of any hazards
• Proceed to victim location
• Mitigate hazards, if any
• Establish Safety Zones and Escape Routes
• Secure your access area and remove rubble
• Non – AC coaches have two emergency exit windows on each side
and AC coaches have one emergency exit window on each side.
• Extrication of critically injured should be done under medical
supervision as far as possible.

• In case medical supervision is not available, then critically injured
should be taken out on stretchers/bed sheets.
• In case of a collision, normally it is the end coaches which are badly
smashed.
These are invariably unreserved General Second class coaches.
• Maximum number of Railway staff and extra volunteers from amongst
passengers should be directed to GS coaches for forming of groups,
and taking out critically injured passengers
PROCEDURES FOR CUTTING AND PENETRATING MATERIALS:
Horizontal Approach:
 Cut a rectangular access hole, large enough to permit access (70 cm

all sides)
 Remove the piece, you have cut.
 Protect against any sharp edges by filing, covering them, or bending a
metal back.
Vertical Approach:
 Mark a square or a rectangular hole large enough to permit access (70

cm all sides)
 Make a small hole approximately 70mm diameter in the center of the
piece, that will be used to lift the cut portion.
 Cut to marked sides of the square.
 Then lift out the piece using the hole in the center.
 Protect against any sharp edges by filing, covering them, or bending
metal back.

8.0 ROPES CHAINS AND SLINGS
INTRODUCTION:
Rescue incidents call for the use of ropes of various types for rescue
rigging applications, and for chains and heavy-duty slings for haulage,
anchorage and lifting purposes.
ROPE:
 Rope is one of the most important tools of the rescue team, and
rescuers use a range of rope types for specific applications.
 All will give valuable service provided they are appropriately cared for,
inspected and maintained.
TYPES OF ROPE:
The ropes in common use by rescue teams can be categorized as follows:

a) Rescue ropes including nylon fibre rope.
b) General purpose rope including synthetic and natural fibre rope,
and
c) Flexible steel wire rope (SWR).
PRECAUTIONS IN OPERATIONS:
Do not bend wire ropes sharply at any point. As a general rule, the smallest
diameter around which a SWR should be bent should be approximately ten
times the diameter of the rope anything less than this will cause damaging
uneven stresses on the rope.
INSPECTION OF STEEL WIRE ROPES (SWRs):
Regularly inspect SWRs in the following manner:

 Visual examination for strand cut, Kinks and damage.
 Periodically certification by millwright
STORAGE OF STEEL WIRE ROPES:
 Store wire ropes under cover in a clean, dry place and in such a
manner that no part touches the ground.
 Never lay a SWR on concrete or other floors for storage, as these have
an adverse effect on the steel. Regular inspection for the presence of
corrosion is necessary.

PRECAUTIONS IN OPERATION OF ROPE, CHAINS AND SLINGS
 Do not bend wire ropes or chain slings around too sharp an angle. As
a general rule, the smallest diameter around which a SWR should be
bent should be approximately ten times the diameter of the rope
anything less than this will cause damaging uneven stresses on the
rope.
 Insert packing between the sling and the edges of the load to prevent
the sling coming into contact with sharp edges.
 Avoid shock lifting or snatching loads.
 Don’t drag slings along the floor or ground.
 Never shorten slings by knotting.
 Avoid tip loading of hooks.
 Always remove twist from slings before use.

9.0 VARIOUS EQUIPMENTS USED IN RESCUE OPERATIONS
ELECTRICAL HAND TOOLS AND GENERATOR
(Specification to MP-0.0800.44 (Rev-04 April 2013)
Portable Generator set.

Power Saber Saw
Reciprocating saw.
Tre-panner
Angle Grinder
Panel shear machine
Nibbler Machine
HYDRAULIC RESCUE DEVICE [HRD]

(Specification to COFMOW/IR/HRD/2014)
Hydraulic power pack (Petrol/Diesel)

Hydraulic Cutter
Hydraulic Spreader
Control table
Hydraulic High Power hoses
Hydraulic hand Pump
PNEUMATIC RESCUE DEVICE
Air Compressor
Air Cylinder
High Pressure Lifting Air Bags
STAINLESS STEEL CUTTING EQUIPMENT
Plasma Cutting machine

Hydraulic stainless steel Rescue Device
OTHER EQUIPMENTS
Under water cutting Equipment

Water Mist Fire fighting Equipment
Breathing Apparatus
Life detector
LIGHTING EQUIPMENT
Inflatable lighting Tower

SOME BASIC OPERATING PRINCIPLES FOR AN EFFICIENT RESCUE
OPERATION:
1) Anticipate long term operations and plan for replenishment of

consumables.
2) Keep energy conductors like air hoses, electric extension cords, and
hydraulic lines etc. as short as possible
3) Particularly when operating pneumatic and hydraulic systems with long
hoses, consider jogging the tool against the work piece to counter act
the friction loss in order to prevent outrunning. When operating tools,
try to maintain a firm and balanced body position, and try not to over
reach.
4) Hydraulic Power Hoses are used to connect pumping unit with control
desk and hydraulic equipments. The male and female coupling of the
hoses is machined with high precision and oil pressure is sealed with
the help of single ‘O’ ring. Hence the above hoses should not be
dragged on the floor since small dent/scratches/dust entry will affect
the performance of the hydraulic equipments. It may even result in
rendering the hoses incapable of attaching with HRD equipments. The
operator should hold clean lint less cloth and ensure to wipe the
coupling before attaching to the equipments. The dust cap should be
provided immediately on uncoupling the hose from the equipment.
5) Some techniques to keep your blades/bits cool:
• Ensure adequate lubrication, water or oil
• If dry cutting, pull tool blade/bit out of cut every 10 to 20 seconds to
run in ambient air to cool.
• Make sure a properly dressed/sharp bit/blade is in the power tool.
• If the motor is too hot to touch you may need to switch it off, or
change tool to cool the systems.

10.0 OPERATING INSTRUCTIONS FOR ELECTRICAL HAND
TOOLS AND GENERATORS
GENERATOR SET:
This is required to
produce electric power
by using petrol/Diesel
as fuel.
1. Keep the ON/OFF

switch in ‘ON’
position.
2. For cold starting,

move the ‘Choke
lever’ (white colour)
to ‘ON’ position by
moving to Left hand
side.

3. Start the Generator
by pulling the recoil
rope.
4. After starting the

engine, shift the Choke
lever to ‘OFF’ position
by moving to Right
hand side.
5. Push the fuel release

lever (black colour) in
‘ON’ position by
moving to Right hand
side.
.
6. Connect the plug of
Step Up/Down unit to
the generator through
socket.

7. Connect the plug of
Cold cutting
equipment to the socket
of the Step
Up/Down unit.
8. Put the breaker

switch at the rear of
Step Up/Down unit to
‘ON’.
9. Put the Main switch

at the front of Step
Up/Down unit to ‘ON’.
The Cold cutting

equipment is now
ready for use.
POWER SABER SAW:
The saber saw

consists of a
reciprocating
cutting toothed
blade, to cut
through various
materials. It is
advantageous
when cutting
into tight
crevices.

1.Press the slider
down ward
2. Insert the saw

blade in to the
slot.
3. Release the
slider and ensure
that the blade is
held firmly.
4. Set machine on
work piece and
switch it on.
Ensure that the
bottom edge of the
base plate rests on
the surface of the
work piece.

RECIPROCATING SAW:
It is a type of saw in
which the cutting
action is achieved
through a push and
pull reciprocating
motion of the blade
1. Select suitable blade

for the work piece .
2. Rotate the locking

colour counter clock
wise until it clicks and
locks in the open
position.

3. Insert the blade in
to the blade holder.
4. The locking collar

automatically rotates
clock wise and locks
the blade in place.
5. Press the release

button to adjust the
foot plate.
6. Adjust the foot

plate for proper
height.

7. Press the foot plate
edge on the work
piece and press the
trigger to start
operation.
8. Move machine to a
vertical position
and continue to saw
along the cutting line.
TRE-PANNER:
It is an electric
power tool
designed to
make round hole
of minimum
45 mm
diameter. It also
has provision
for fitment of
additional
attachment for
enlargement of
hole up to 100
mm diameter.

1. Select the hole
saw for
appropriate
hole size to be
done in the sheet.
Fix the hole saw

in the chuck by
rotating clock
wise direction.
3. Position it to
enter the locking
pin freely.
4. Rotate the
locking screw
until it tighten up.
5. Ensure the
locking pins screw
properly seated.

6. Insert the drill in
to the key chuck
and tight the Allen
screw.
7. Use Allen key

for proper tight of
the screw.
8. Using winged
screw, adjust the
ancillary handle
for comfort
positioning
9. To start the
machine, press
On/Off switch and
keep it depressed.
For
continuous
operation, lock the
pushed On/Off
switch by pressing
the Lock switch.

10. Drill the pilot hole
at the required point
in the sheet metal by
the drill bit of
trepanner.
11. This hole will act

as the pilot hole for
operation of the
circular saw.
12. Continue the

operation of the
trepanner until
circular hole is made
in the sheet metal.

ANGLE GRINDER:
An angle grinder
is a hand-held
power tool used
for cutting,
grinding and
polishing.
1. Select suitable
cutting / grinding
disc for
operation.
Place the disc on

to the centering
collar.
2. Rotate the
grinding disc
until the notches
of the grinding
disc coincide
with the cams of
the centering
collar.

3. Rotate the grinding
disc until the notches
of the grinding disc
coincide with the
cams of the centering
collar
4. Press the cutting

wheel into the holder.
5. Rotate the wheel in

clock wise direction
applying precise, until
the wheel can be
heard to engage
6. Insert the charged

battery in to the grip
until it engages
noticeably.

7. To start the
machine press the
On/Off switch
forward (to lock-on,
press the On/Off
switch further to the
front till it engages)
8. Start cutting with

moderate feed and
depth along the
cutting line.

PANEL SHEAR MACHINE:
The equipment is
designed to cut
through body
panel of a coach.
1. Place bottom
dirt shield.
2. Insert side dirt

shield.

3. Press the spring
loaded slider forward.
4. Insert the blade in

to the slot and release
the slider
5. Ensure the proper

seating of the blade.
6. Insert the dust

extractor in to the slot.

7. Press the trigger to
operate.
NIBBLER MACHINE
It has unique cutting

head designed for
cutting in various
directions without
removing the tool.

11.0 OPERATING INSTRUCTION FOR HYDRAULIC RESCUE
DEVICE (HRD)
PETROL/DIESEL POWER PACK:
POWER PACK
The power pack
(pumping unit) is
available with petrol
or diesel engines.
The power pack
generates required
hydraulic pressure to
operate hydraulic
ramp jacks &
Hydraulic rescue
devices like cutters
and spreaders.
1.1. Oil control
valve lever has
three positions.
a. Horizontal-
Oil supply is
‘CUT’.
b. Downward-
Oil is directed
to equipment
connected to
Right hand
side.
c. Upward- Oil
is directed to
the equipment
connected to
Left hand
side.
2. Position the oil
direction control
valve knob in
‘Neutral’ position.

3. Keep the accelerating
lever in ‘Slow’ position.
4. Start the engine by

pulling the recoil rope.
5.To connect quick fix

coupling remove cap
from coupling head and
connect.
6. Pull back the outer

ring of the female
coupling and push the
male coupling into the
female coupling.

coupling.
8. Red hose pipes to be

coupled.
9. Green hose pipes to

be coupled.

HYDRAULIC EXPANDER:
Facilitates spreading,
pulling, peeling especially
mangled vehicle parts in
accidents.
1. Connect the male and

female port of the quick
fix coupling in same
coloured high pressure
hoses of the power pack
and expander.
2. Put Oil control valve

lever to the respective
position to which oil has to
be supplied.

3. Hold the device
firmly by both hands
and ensure that the
jaws are in folded
condition.
4. Insert the folded jaw

in to the Hole/gap
where which the metal
sheet has to be
expanded/sheared.
5. Slowly rotate the

handle grip in
clock-wise direction
to expand the
jaws for
tearing/expanding the
sheet.

HYDRAULIC CUTTER:
Facilitate cutting
widow bars, flats
etc.,
1. Connect the cutter

with Power pack.
2. Put Oil control valve

lever to the
respective position
to which oil has
to be supplied.
3. Hold the device

firmly by both hands
and rotate the
‘Handle grip’ in clock
wise direction to
open the knife.

4. Position the metal
bar/rod in between the
knife.
5. Rotate the handle in

anticlockwise
direction to scissor
the bar.

METHOD OF MARKING, DRILLING AN CUTTING TO EVACUATE
ENTRAPPED PASSENGERS FROM ACCIDENT INVOLVED COACH
Marking on side
Body of the coach
below windows
Drilling holes on Marked

area. Multiple holes should
be made using Hole-saw.
Cutter should be used for
cutting the sheet of the coach
body and expanding the
hole/gap for man entry

Opening of side body with
spreader and cutting of
window bars simultaneously.
The coach body should be
cut below the suitable
window upto the seat level
using Hole-saw and HRD
spreader. The top Bar of the
window should not be cut
and removed to facilitate
hanging of ropes, etc.
Opening by spreader

Cutting window corners by
cutter.
Complete removal of cut

portion.

METHOD OF PULLING OUT THE JAMMED DOORS IN AN
ACCIDENT INVOLVED COACH.
During accident, doors of coaches get jammed and passengers are entrapped .
In this condition the method of utilizing the spreader and chains to open the
jammed doors is illustrated below:
Connecting Chains on both

side doors with Spreader
in fully open condition
Close the Spreader to pull

the jammed door.

METHOD OF MAKING EFFECTIVE GAP WHEN THE COACH BODY
PILLARS ARE DIFFICULT TO OPEN UP WITH SPREADER TOOL.
Rescue Ram which

operates on the same
hydraulic power pack can
also be used to make clear
effective gap, particularly
when the coach side body
pillars are difficult to open
up with spreader tool.

12.0 OPERATING INSTRUCTIONS FOR PNEUMATIC RESCUE
DEVICE
AIR COMPRESSOR
Compressor Unit
1. Turn the engine

switch to the ON
position .
2. Turn the drain

cock to ON and
drain the kerosene
from the carburetor.

3. Turn the fuel cock
to the START position
.
4. Raise the throttle

lever slightly
5. Pull the choke rod

for cold starting.
6 .Pull the starter grip

lightly until
resistance is felt, then
pull briskly

7. Keep the started
engine for few
moments and then
push the choke in old
position and turn the
fuel cock to the RUN
position.

AIR BAG:
Air bags have extremely

low shut height and high
lifting capacity with low
pressure (8 Kg/Cm2)
making it suitable at
rescue/re-railing at
intricate places.
Dual Controller
1. Connect the GREEN

connection hose to the
outlet valve of the
compressor.
2. Ensure proper
coupling .

3. Connect the other end
of the hose to the input
coupling of the controller

locking of the coupling
with a click sound. For
safety, turn the brass
sleeve of the coupling
opposite to the safety pin
5. Connect the YELLOW

connection hose to the
output coupling of the
controller and ensure the
coupling
6. Connect the other end

of the hose to the Air bag
nozzle and ensure the
coupling.
7. Place the deflated

Go air
to Chapter contents

bag below the object
which has to be lifted
with proper flat packing.
8. Open the outlet valve

of the compressor.
9. Push the YELLOW

switch lever in order to
inflate the lifting bag. In
doing this, observe the
corresponding pressure
gauge.
10. If the required

operating pressure for the
lift height is reached,
then terminate the
inflation procedure by
releasing the switch
lever. Maximum
operating pressure is 8
bar.

AIR CYLINDER:
AIR CYLINDER
1. Remove the
cylinder cap
2. Connect the
pressure regulator
assembly to the
cylinder
3. Ensure proper
tightness of the
regulator valve seat

4. Connect the free
end of the connection
hose from the
regulator to the input
coupling of the
controller.
5. Open the pressure

valve with a plug
spanner and observe
the gauge for
maximum 8 bar
pressure.
6. Proceed further as
per item No. 5,6,7,9
and 10 .as in AIR
BAG above

13.0 OTHER EQUIPMENTS
BREATHING APPARATUS:
A self-contained breathing
apparatus is used when
extremely toxic chemicals
are present, in an oxygen-
deficient atmosphere, or
when the contaminant or
concentration is not
known.
SCBA's consist of a bottle
(tank or cylinder), carrying
assembly, gauge, safety
valve, and a full face piece.
The bottle is equipped with
an alarm to warn the
wearer when air in the tank
is getting low (about 25%
of the tank air remains).
UNDER WATER CUTTING EQUIPMENT
Capable of cutting window bars, window frame channels, body panel

sheets, roof sections as well as various body sections of coach submerged
under water as well as above water.
The equipment is provided with:
• Constant pressure fuel tank

• Cutting torch
• Igniter
• Air carry tank
• Oxygen flash back arrestor
• Oxygen and gasoline hoses

WATER MIST FIRE-FIGHTING EQUIPMENT
• Water Mist Based fire fighting system utilizes very fine water
spray to extinguish fire.
• Water droplets with size of 1 to less than 1000 micron are referred
to as mist.
• The water mist when used in fire fighting systems creates a blanket
thus making the atmosphere inert around the fire.
• This results in effective and rapid fire extinguishing. The
compressed air foam (CAF) used along with water mist further
enhances the fire extinguishing power.
First Responder to Fire.

Suitable for metal fires &
Electrical installations.
Provided with:
• Fire fighting gun
consists of Stainless
Steel Nozzle.
• Main Vessel made of
Aluminium Alloy 10
ltr. capacity.
• One Compressed air
cylinder with
minimum rating of 2
ltr x 200 Bar
• Hose length 1.3 meters

OXY-FUEL FLAME CUTTING
EQUIPMENT AND SUPPLIES:
In order to perform oxy-fuel flame cutting, the following equipment is

required as a minimum:
 Oxygen
 Fuel gas(Acetylene gas)
 Pressure regulators
 Hoses and fittings
 Torch
 Cutting tips
 Tip cleaners
 Strikers
 Protective clothing and safety equipment.
ACETYLENE SAFETY PRECAUTIONS:
• Keep cylinders away from overhead welding or cutting. Hot slag

may fall on a cylinder and melt the fusible plug.
• Acetylene forms readily explosive compounds with copper, silver,
and mercury.
• Always store acetylene cylinders in an upright position. If the
cylinder had been laid down on its side put in the upright position for
at least 3 hours before using.
PRESSURE REGULATORS
Regulators are pressure-controlling devices that reduce high pressures
to a desired working pressure. A pressure adjusting screw adjusts
these regulators. Regulators may be single or two stage.
REGULATOR SAFETY PRECAUTIONS

 Regulators to be kept in good fettle.
 To be free from oil, Grease & dirt.
 Gauges to be regularly calibrated.
HOSES AND FITTINGS
 Oxygen hoses in India are colour coded Green/Black/Blue. The
fittings have right handed threads and smooth outside surface.
 The fuel gas hoses are colour coded Red/Orange. The fittings have
left hand thread and a notch on the outside.
.
HOSE AND FITTINGS SAFETY PRECAUTIONS
 No interchange of hoses between oxygen and acetylene.
 Regular check to be carried out for kinks, cuts, burns etc.,

OXY- ACETYLENE GAS CUTTING EQUIPMENT

CUTTING TORCHES
Hand torch: It is equipped with a one piece body with valves to control
the flow of preheated oxygen and fuel gas, a spring loaded valve for
the cutting oxygen, tubes carrying the gases to the head which accepts
the cutting tip.
Machine Torch: A torch equipped with valves controlling oxygen, fuel

gas and cutting oxygen with tubes encased in a body with a head to
accept the cutting tip.
All torches are to be fitted with back fire arresters in oxygen and fuel
line.
TORCH SAFETY PRECAUTIONS
 A fire extinguisher should always be at hand when flame cutting for

use if an emergency arises.
 Always extinguish a torch whenever it is not in your hand.
 If a torch backfires, shut it down, find the trouble, and remedy it
before continuing to use the torch.
 Be careful that a torch is not being directed at another person when
lighting.
 Be sure that the area where the cutting/welding is to be performed
is clear of any hazardous or flammable materials.
Battery operated bar cutters for window bar cutting:
Bar Cutters are extremely reliable, powerful and easy to use. Both battery-powered
and mains-powered tools are available.
Able to cut up to 40 mm high-tensile rebar, these tools are powerful, safe to use and
proven to be robust.

PLASMA CUTTING EQUIPMENT
Plasma cutting is ideal for cutting stainless steel, and non-ferrous material
less than 1 inch thick. Oxy-fuel cuts by burning, or oxidizing, the metal it is
severing. It is therefore limited to steel and other ferrous metals which support
the oxidizing process. Metals like aluminium and stainless steel form an oxide
that inhibits further oxidization, making conventional oxy-fuel cutting
impossible. Plasma cutting, however, does not rely on oxidation to work, and
thus it can cut aluminium, stainless and any other conductive material.
Plasma cutting is a process that uses a high velocity jet of ionized gas that is
delivered from a constricting orifice. The high velocity ionized gas i.e. the
plasma, conducts electricity from the torch of the plasma cutter to the work
piece. The plasma heats the work piece, melting the material. The high
velocity stream of ionized gas mechanically blows the molten metal away,
severing the material.

LIFE DETECTOR
• To rapidly detect and locate victims of collapsed buildings and

coaches.
• Life Detector essentially converts the entire collapsed structure into a
large sensitive microphone to pinpoint signals from the trapped victims.
• The seismic and acoustic sensors of the system convert vibrations
created by the live victim into audible and visual signals.
The life detector utilizes radio waves to detect the breathing and movement of
survivors. Insertion of antennas into rubble ensures that search operations
can be carried out without interference caused by noise from the surrounding
area.
TELESCOPIC LADDER
Telescopic Aluminum ladder is one of the most useful items in rescue
operation.

LIGHTING
Whenever disaster strikes, working at night can increase the dangers involved
with rescue work due to shadows, glare and poor vision associated with
artificial lighting systems.
One of the very useful lighting systems available with rescue team is portable
inflatable tower light.
The system consists of inbuilt,

Gen-set of 1.2KVA, Two
blowers and 400W metal
halide lamp.
PROCEDURE OF OPERATION:
 First switch on the gen

set.
 Switch on blowers to
inflate the cloth at a
height of 4.5 meters
from the ground level.
 Switch on the lamp
which illuminates the
area depending on the
height.

Positioning Lighting
Little in the way of guidance can be given when lighting the rescue scene
because all scenes vary greatly, but the following points are valid for most
situations:
 Position lights as high as possible to illuminate the area required.

 If working at heights, do not shine lights from below to illuminate the
situation.
 Rescuers on rooftops can suffer a temporary and unsafe loss of night
vision by looking down into lights. This can be minimized by the use of
defused light sources such as tower lights than spot lights in the
ground.
 If lights cannot be positioned above the scene, use hand lights or
helmet-mounted lights only, controlled by the rescuers working at the
height.
 If temporarily blinded or suffering a loss of night vision for any reason,
stay still and do not move until night vision returns.
 Illuminate a rescue scene with a soft, medium-density light for
movement within the area, and illuminate the particular work scene
with higher-intensity lights such as spot lights.
 Position lights so that large shadows are minimized.
 Keep lighting leads away from dangerous areas where damage is likely
to occur.

14.0 RELIEF AND RESCUE OPERATION ON PASSENGER
TRAIN DURING GOLDEN HOUR
INTRODUCTION:
Need of organized rescue and relief operation during first hour (called
Golden Hour) has been emphasized by the high level committee on
Disaster Management. Every railway men on duty in the train has
clearly defined duties in case of accidents and they engaged
immediately in rescue/ relief. Similarly large number of railway men
travelling by train and other volunteers also respond to the emergency
and help passengers. However in absence of any organized effort
visible, despite crucial rescue and relief work undertaken by railway
men, the railways are adversely criticized by media and role of outside
volunteers often with insignificant contribution becomes a matter of
praise. Therefore an effort has been made to assign specific duties to
each railway employee in such a way that statuary safety requirements
of train protection and information to control are met by crew and guard.
The ticket checking and other staff commence rescue/ relief operation
immediately by forming a team including doctors and protection staff.
Driver and guard latter join the Golden Hour rescue team for ensuring
rescue and relief action best suited. The Golden Hour rescue and relief
team completely controls the operation, ensures continuous information
to control seeking specific assistance and securing information for
assisting the passenger involved in the accident.

RELIEF AND RESCUE WORK ON PASSENGER TRAIN DURING GOLDEN HOUR
Time in Driver Asstt. Guard TS/Sr. Cond. TTEs AC Att/AC

Minutes
Dr. Mechanic.
Experiences unusual Experiences If experiences unusual Experiences unusual Experiences Experiences
-3 jerk/ sound, drop in unusual jerk/ jerk/ sound, drop in jerk/ sound unusual jerk/ unusual jerk/
B.P. Pressure/ sound, drop B.P. Pressure/ Vacuum, sound sound
Vacuum in informs to Driver on
B.P. Pressure/ walkie talkie.
Vacuum .
Observes gauges and Observes Observes gauges and Observes Train Observes Train Observes Train
-2 train formation in rear gauges and train formation in front formation formation formation
train and informs the Driver.
formation in
rear.
Train comes to stop Flasher light Keeps a watch on the Carryout observations Carryout Carryout
-1 on its own or driver put "on" and train. outside the coach as observations observations
stops the train by A-9 Helps the soon as the train outside the coach outside the
in emergency. Driver stops out of course as soon as the coach as soon as
Flasher light put "on" train stops out of the train stops
and informes to course. out of course.
Guard on walkie talkie
Comes out of cab, Mans the loco Noting down the time of Calling out all the On hearing Gives information
0 inspects the train cab accident and becomes conductors / TTEs accident whistles/ immediately to
formation, receives vigilant. with the help of AC call from Sr. all TTEs as per
information from attendant. Conductor, rushing instructions of
guard and confirms towards Sr. Sr.conductor.
the accident and Conductor along
sounds whistles for with Doctors,
accidents. RPF/GRP, Railway
Takes out the Received Applied hand brake of Employees and
detonators and fusee instructions Guard brake van/LV. Volunteers,

signals. Gives for protecting Taking out detonators, observing condition
2 instructions to the train. Red Flag / Lamp, ECP of adjacent
Asstt.Driver for Phone, Fusee, torch coaches.
protection of train (during night ) and walkie
from ahead. talkie set .
Ensuring that Asstt. Getting down
3 Driver has got down from loco
4 from Loco with 8
detonators, Red
with 8
detonators,
As per pre-
5 flag/Lamp and ECP
set.
ECP set and
Red flag / instructions,
Lamp. taking out one
Giving complete Protection of After getting down from stretcher, First
6 information of adjacent line guard brake, noting the aid box material,
Starts forming rescue All the TTEs with blankets, bed
7 accident to Guard on
walkie talkie and
is done,
placing 4
KM No.and proceeding
for observing accidented- teams. Each team will above staff come sheets and torch
sounding continuous detonators as train. be assigned 3 to Sr.conductor/TS etc, and makes
whistles of Accident. per GR 6.03. Gives information to adjacent coaches for nomination of available the
Providing Wooden (Protects rear control and rushes behind preferably with relief teams. above material to
wedges under the of the train the train for protection of concerned TTE as nominated
loco wheels. after train on same line. leader. Each team will Conductors/TTE's
protecting (Protects front of the consist of - [T-1] and joins rescue
front of the train FIRST if Driver & Conductor/ TTE – 1 team.
train also if Asstt. Dr. is injured.) (Leader)
2. Doctor - 1
guard is
3. AC Mech./Railway
injured.) employee - 1
4. Volunteers -3
5- Rly. employee-
Messenger (1)
6. RPF/GRP staff - 1
If VHF set is available T-2
8 on loco, gives
T-3
9 information to control
about assistance
T-4
10 required.
Gives information to
T-5
11 station master/
control on mobile T-6
12 phone if available.
Directing local public T-7
13 approaching the Loco
Protection of T-8
14 cab to Sr. conductor
/TS. same line
Guidelines for rescue and relief teams:
15 Waiting for arrival of
Asstt. Driver.
from front by
placing 4 1. Formation of teams T1 to T8.
16 detonators
and locating
2. Each team to cover 3 adjacent coaches.
3. Team composition:
17 pole for fixing
ECP/PCP
1. Conductor/ TTE – Leader (1)
(Preferably own coaches)
Comes back immediately
18 after protecting the train
2. Doctor - 1
3. AC Mechanic - 1
19 and meets the
Sr.Conductor/TS at GHC
4. Volunteers -3
5- Rly. employee-1
20 site and connects
ECP/PCP phone
6. RPF staff - 1
4. First team to be dispatched to worst affected coaches and
21 so on.
ECP/PCP
22 phone
5. All rescue and relief activities to be channelised through GH
Management team.
23 connected
near accident Duties of rescue/ relief team:
24 site and
repeated
1. Consolation to the injured passengers.
2. Arranging bandage /Dressing for injured.
Remains in
25 details of
accident to
communication with
3. Removing dead bodies from coaches and securing on
blankets.
control, receives
control. 4.Assessment of passengers involved in accident.
instructions and informs
Going back 5. Messenger goes to give information to Sr.conductor/guard.
details as received from
on loco for 6.Team leader with the help of RPF, ensures the safety and
rescue teams. Demands
further security of luggage of dead or injured passengers and provides
urgent assistance in close
instructions. label on luggage accordingly.
coordination with Golden
Driver proceeds to Mans the loco
26 GHC site. The cab cab.
Hour rescue team
members.
remains manned by
Asstt. Driver.
Mans the cab or joins or joins the
27
Golden Hour control GHC site
28 team at GHC site.
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

SPECIAL INSTRUCTIONS:
1. When driver and Asstt. Driver are seriously injured and do not talk to Guard on Walkie-Talkie, the Guard shall first protect the
train from front.
2. The information’s received through messenger of rescue team shall be repeated by Guard to controller regularly on ECP/PCP.
3. Senior conductor/Train Superintendent and Guard shall dispatch injured passengers for medical attention by train coming from
other directions or in road vehicles arranged by local volunteers with their help. While sending the injured passengers they shall
note down the name of passengers with their addresses and details of luggage and also the name of hospitals, train numbers,
vehicle numbers and volunteers, who accompanied injured passengers. This information shall be repeated by guard to the control.
4. The RPF shall take care of the belongings of injured/dead passengers and will identify their luggage by sticking a label on
luggage.
5. After protecting the train by placing detonators at 600-600-10-10 the Assistant Driver shall post a competent railway employee (if
found) with red flag/lamp about 45 meters away from last detonator as per GR 6.03.
6. If any level crossing is located nearby the site of accident the Guard shall relay the details of accident to the control either through
ECP set or through the neighboring station master for ordering of ARME/ART.
7. If any mobile service is operating, the RPF/GRP staff shall request such passengers, who are having mobile phone to help guard in
relaying the details of accident to the control for prompt help.
8. In case of fire accident, the fire extinguishers available on the train shall be used to put off the fire by train conductors, TTEs and
AC attendants and the act of detaching the affected coach shall be accomplished simultaneously.
9. Driver and guard shall request for assistance from the local volunteers and passerby.

10. While forming the rescue team the TTEs should be given to look after those affected coaches, which were originally manned by
them. Doctors, railway employees and other volunteers, who were travelling in the coach shall be the member of rescue team
under the leadership of TTE.
11. The first rescue team shall be directed to attend the most affected coach and RPF staff shall also be deputed to such coaches for
helping the team and securing the belongings of dead/seriously injured passengers.
12. Any senior railway officers reaching on accident site shall contact golden hour control site and will take responsibility of rescue
and relief work. The work at golden hour control site shall be prioritized as per urgency and importance.
13. If there is level crossing nearby, the gate man shall inform the station master and shall render himself for assistance in rescue
operations after ensuring that gate is kept in closed position.
14. The volunteers who had shown a high sense of dedication and did exemplary work done during rescue/restoration should be
recognized by giving certificate of honour and suitable monetary awards.
********

Formation of Relief Teams
Team
T-1 T-2 T-3 T-4 T-5 T-6 T-7 T-8
contents
TTE/Rly
1 TTE TTE TTE TTE
Emp.
Rly Emp. Rly Emp. Rly Emp.
2
RPF/GRP - RPF/GRP - RPF/GRP - RPF/GRP -
3
Doctor Doctor Doctor Doctor Doctor Doctor Doctor Doctor
Catering Catering Catering Catering Catering Catering
4 AC Mech. AC Atten.
Staff Staff Staff Staff Staff Staff
5
Rly Emp. Rly Emp. Rly Emp. Rly Emp. Rly Emp. Rly Emp. Rly Emp. Rly Emp.
6
Volunteer Volunteer Volunteer Volunteer Volunteer Volunteer Volunteer Volunteer
7
8

15.0 Rescue of Trapped Passengers Focusing on Medical
Stabilization, Safe Shifting etc.
INTRODUCTION:
In any passenger carrying train involved in accidents, trauma patient, if not
given medical attention within first hour, the chances of his ultimate recovery
reduces drastically
The SPART/ARMV reaches the site of accidents with resources and manpower
primarily for the rescue of passengers. Within the available resources, how the
rescue operation will be carried out manually as well as with the help of new
modified stretcher cloth, rope, ladder, and modified stretcher is focused with
help of drill pictures, specially where the coaches jumbled over each other.
 Opening emergency window from inside for man entry-
 Cutting the window bar and entry into coach
 Rescuing the passenger with manual skill


 Rescuing the trapped passenger with the help of ladder
 Trapped passenger laid on conventional stretcher
 Difficulty being faced in rescuing the trapped passenger by conventional

stretcher from Sleeper Coach Go to Chapter contents

 A New modified stretcher has been developed to overcome difficulty in
conventional stretcher

NEW DESIGN STRETCHER FOR SPART/ARMV
With the existing stretcher in the SPART/ARMV, it was very

difficult to provide rescue to injured passengers from coach coupe to
doorway or another coupe having emergency exit window because
enough space is not available for negotiating the stretcher.
Therefore WCR/HQ has designed and fabricated a stretcher for

rescue relief work of injured passengers from accident involved coaches.
Existing stretcher is 2030 mm long (overall) with cloth length 1610

mm and its width is 550 mm. It has steel pipes on the sides which make
it necessary to lift injured passenger for placing on the stretcher. The new
design stretcher has size; 1590 mm (Length) and 580 mm (width). Due to
short length, it is easy to manoeuvre this stretcher inside the coach.
In New design stretcher, steel pipe is not used . It is made of folded

type cloth bag. To provide lengthwise rigidness, a 1530 mm (L) 210 mm
(W), and 12 mm thick compreg-ply-piece is inserted in the bag provided
in the middle portion. This new stretcher has been successfully tried in
rescuing passengers from GS, Sleeper, AC-III and AC-II tier coaches at
JBP.
In this stretcher, a Velcro is fitted, removable parachute cloth is
fitted to remove cloth in case of blood spots or dirtiness.
Special feature of new stretcher is that an injured passenger can be

placed on stretcher without lifting him. The supportive belt attached with
the stretcher is slid under the injured’s leg, waist and head, and injured
person is gently shifted to stretcher and then to doorway by lifting with
attached loops. New stretcher is very useful to the persons having
spine/neck/head injuries.
It should be noted that an injured person lifted with new design

stretcher is to be placed in standard stretcher along with modified
stretcher kept on the doorway (or coupe with emergency exit) and
secured with ropes. After that, the injured person should be moved out
from coach alongwith the standard stretcher.



Layout drawing of modified stretcher:

Injured is lifted for placing in standard stretcher
Standard Stretcher kept on [Note : for laying injured on the normal
berth stretcher, fully uplift of inured is needed.]
Injured is placed in
Trying to take out injured
standard stretcher
person on standard stretcher.
Standard stretcher is getting stuck

Loop of stretcher
Bag for inserting the
Ply to strengthen the new ply in new stretcher
New design stretcher stretcher
Process of Shifting of
Inserting ply in new New design stretcher being injured on the new
stretcher Secured after inserting the stretcher ( Injured is not
ply in new stretcher. needed to fully lift in this
stretcher.)
Process showing Process showing supportive

supportive belt attached Process showing supportive belt belt attached with head side
with leg side stretcher attached with waist side stretcher stretcher being slid slowly
being slid slowly under the being slid slowly under the under the injured’s head .
injured’s leg. injured’s waist .

Stretcher is fully under Now injured can be
the injured’s body lifted along with new
stretcher.
Injured being taken out to doorway.
Injured along with new Injured secured with the rope

stretcher being placed on before taking out of coach.
standard stretcher .

PART-II

1.0 ooooo (Hooter codes as per Accident Manual) HOOTER SOUNDING
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dz s d Vhe jokuk ?kk;y ;kf=;ks a dk euks c y c<+ k ;s j[kuk
;Fkk la H ko iz F ke mipkj djuk
ACTIVITIES BY ARME/SPART INCHARGE

1- gw V j lq u us ds i'pkr~ ,-vkj-,e-bZ dh pkch ys d j rq j Ur ,-vj-,e-bZ - dks [kks y uk A
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Hks t uk
5- le;≤ ij da V ª k s y dks ;k nq ? kZ V uk LFky ij mifLFkr vf/kdkfj;ks a dks vius dk;Z dh iz x fr dh tkudkjh ns u k
A-Team B-Team
C-Team D-Team E-Team F-Team
4 -Staff 4 -Staff
4 -Staff 4 -Staff 4 -Staff 4 -Staff
1-dksYM dfVax midj.kksa 1- cqyVs pSu lkW] ikoj 1-esfMdy Vhe ds lkFk 1- VaSUV dk lkjk lkeku] 1-jkr ds le; DG lsV 1- ikuh] pk;] dkQh
dks nq?kZVukxzLr dksp esa dVj] tSd] lh<+h] dfVax esfMdy dk lkeku est+] dqlhZ] Nkrs vkfn mrkjdj LFky ij ys fcLdqV ?kk;y ;kf=;ksa
vko';drkuqlkj mi;ksx midj.k] xkM+h ls mrkjdj LVsªpj] ckWMh cSx vkfn mrkjdj nq?kZVuk LFjy tkuk o izdk'k dh dks nsuk rFkk mUgsa
djuk A nq?kZVuk LFky ij j[kuk A mrkjdj nq?kZVuk LFky ij ij ys tkuk o yxkuk A O;oLFkk lqfuf'pr djuk lkaRouk nsuk A
2- ?kk;y ;kf=;ksa dks 2- dksp esa vUnj tkdj ykuk A 2- fnu dk le; gS rks 2- ARME bapktZ
2- 'A' Vhe o “B” Vhe
ckgj fudkyus ds fy;s ?kk;y@ewfNZr ;kf=;ksa dks 2- e`r ?kksf"kr ;k=h dks izFkeksipkj esa yxkrkj
dks vko';drkuqlkj ds funsZ'kkuqlkj
dksp esa vUnj tkus dk LVªspj esa mfpr rjhds ls ckWMh cSx esa j[kdj ,oa enn djuk o nq?kZVuk
vU; midj.k nsuk A vU; dk;Z djuk A
jkLrk cukuk A j[kdj ckgj fudkyuk A VSx yxkdj mfpr LFkku LFky ij cSfj;j Vsi
ij j[kuk A yxkuk A
ooooo (Hooter codes as per Accident Manual) HOOTER SOUNDING
Extricate injured passengers from coacch
Departure of Crack Team from Div. Support in moral for injured passengers
First aid to injured passengers
ACTIVITIES BY ARME/SPART INCHARGE
1- After hearing hooter codes, collection of key of ARME/SPART & immediately opening of coaches
2- Taking attendace of staff & giving instructions to them for readiness with rescue material.
3- Collection of detailed information of accident on control phone, walkie-talkie or mobile phone.
4- After reaching at accident site, he will do inspection of accident site & ensure work distribution among ARME staff
5- Communicating progress of work to officers available at accident site as well as control office time to time.
A-Team B-Team C-Team D-Team E-Team F-Team

4 -Staff 4 -Staff 4 -Staff 4 -Staff 4 -Staff 4 -Staff
1.Team will apply HRD 1. After reaching,team 1. After reaching,team shall 1. Unloading of 1. During night, tean will 1. Arrangement of tea,
& cutters on damaged shall ensure unloading of ensure unloading of medical tents,chairs,tables, unload, lighting equipments coffee & drinking
coaches. power cutter, ladders, items as per direction of on umbrellas, garden like, inflatable lighting water to the injured &
jacks, chain saw, cutting duty doctor like stretchers, umbrellas & fixing at tower,helogen lamps, DG suffered passengers at
sets,hand lamps & distribution
2. Team will develop equipments etc. body bags & first aid boxes spot. boards etc & responsible for
site.
suitable space on the etc. providing lighting arrangements
coaches for entry of “B” 2. The team will enter in to 2. Shall provide other during rescue operation. 2. Team will perform
team for injured/dead the damaged coaches & 2. Team will remove dead items also to “A”&”B” 2.During day,team will assist to other duties also as per
passengers remove injured/ dead with bodies for keeping in body teams as & when “C” team in first aid, the barrier instructions of ARME
the help of stretchers. bags & shift injured in the required. tape will also be provided for incharge.
tents at specified places. covering of site.

2.0 Crack Team
On getting information of Rail accident, nominated staff of crack team shall rush to the site of
accident immediately with Accident Relief Kit. As per high Level Committee
recommendation item No.13, each zone should have a professionally trained crack team of
Rail Rescue experts (Mechanical and Medical officers) based at HQrs who should rush to the
site of accident at short notice.
This group should continuously be exposed to the latest rescue, extrication techniques and
medical Relief. This group should also support the accident rescue and Relief arrangements
made by Divisions at the site of accident.
Relief and Rescue work should be continued by crack team considering usefulness of golden
hour for trapped passengers. On Duty SSE(C&W)/Loco available at Stn/Pass yard should
also proceed with crack team to the site of accident.
Øs d Vhe
tSls gh jsy nq?kZVuk dh lwpuk izkIr gksrh gS] Øsd Vhe ds ukfer deZpkjh
vko';d lkeku ¼nq?kZVuk jkgr fdV½ rFkk izFkeksipkj dk lkeku ysdj fcuk
fcyEc fd, jsy vFkok jksM tks Hkh lk/ku miyC/k gSa] mlds ek/;e ls nq?kZVuk
LFky ds fy, izLFkku djsaxs ,oa ogka tkdj Qals gq, thfor ,oa ?kk;y ;kf=;ksa
dks fudkydj ?kk;yksa dk izkFkfed mipkj djsaxs rFkk lHkh dks <kWa<l ca/kk,saxs fd
nq?kZVuk jkgr xkM+h vkus okysh gS ftlesa lHkh rjg ds mipkj ,oa jkgr dh
O;oLFkk,a gSa] vki lHkh dks iw.kZ jkgr iznku dh tk,xh ,oa xarO; rd lqjf{kr
igqp
a k;k tk,xk-
bl izdkj jkgr xkM+h igqp a us ds igys xksYMu vkWoj dk mi;ksx djrs gq,
;kf=;ksa dh tku cpkus dk dk;Z djsaxs- Øsd Vhe ds lkFk f'¶V ds vkWu M;wVh
SSE(P)@ofj-ij;Zos{kd Hkh nq?kZVuk LFky ij tk,axs-
3.0 Duties of ARME/SPART Incharge
1. After ordering of ARME/SPART, he shall reach on ARME/SPART immediately.

2. After taking attendance & strength of staff , he shall make arrangements to depart ARME
/SPART within stipulated time.
3. He will ensure timely attachment of Loco on ARME or Engine starting of SPART and shall
issue BPC to Loco Pilot and Guard.
4. He shall council his staff about the proposed Rescue & Relief work at accident site as per
information received from controller .
5. In case nominated expert staff does not appear on duty, he shall make arrangement of another
competent staff.
6. He shall ensure VHF set /satellite phone in “on” condition.
7. Each & every information pertaining to accident shall be collected by ARME/SPART
Incharge in running condition of ARME/SPART.
8. All cold cutting equipments shall be kept in working order.
9. If necessary, tea, coffee shall be prepared by ARME/SPART staff for passengers .
10. Chlorination of drinking water should be ensured by Incharge for passengers.
11. All the DG sets should be checked for their functioning and proper working order.
12. Before reaching at accident site, He shall talk to Loco pilot and Guard and available railway
staff on Walke talkie /Mobile phone to collect every desired information for assistance in
easy Rescue operation at accident site .
13. After reaching ARME/SPART at accident site, he shall give instructions to all nominated
teams to unloaded their respective Rescue materials and he himself proceed to the site of
accident with video Camera etc.
14. He shall be responsible to analyze order of priority of extrication of trapped passengers in the
following manner -
I. Such trapped passengers who had sustained grievous injury and bleeding in
body .
II. All other trapped passengers.
III. All other injured passengers.
15. He shall be responsible for safe and proper application of cold cutting equipments to avoid
injury to trapped passengers during relief & Rescue operation .
16. During rescue , moral support and inspiration should be kept in mind for passengers.
17. After rescue and relief operations, the passenger should be transferred for proper treatment.
18. Liaisioning must be maintained among other Railway departments like commercial, RPF,
Medical, Operating etc for assistance in proper relief and rescue operation.
Progress of the relief/Rescue work and assistance required should be given to the officer present
at accident site and Control office through ECP/PCP/Mobile phone
ARME ba p ktZ ds drZ O ;
1- ARME vkWMZj gksrs gh rqjar nq?kZVuk fpfdRlk jkgr xkM+h ij igqp

a uk-
2- deZpkfj;ksa dh mifLFkfr ysdj ARME dks rqjar nq?kZVuk LFky ds fy, izLFkku
djkus dh O;oLFkk djuk-
3- ARME esa yksdks yxrs gh Mªkboj ,oa xkMZ dks BPC nsuk lqfuf'pr djuk-
4- nq?kZVuk jkgr xkM+h dh pyrh gqbZ fLFkfr esa gh mifLFkr deZpkfj;ksa dks muds
dk;Z ds ckjs esa iqu% ,d ckj voxr djkuk-
5- ;fn dksbZ deZpkjh fdlh dkj.ko'k ugha vkrk gS rks mlds LFkku ij nwljs
deZpkjh dks fu;qDr djuk-
6- rqjUr V.H.F. lSV vkWu djkuk-
7- pyrh xkM+h esa gh daVkª sy ls laEcU/k LFkkfir djds nq?kZVuk laca/kh gj laHko
tkudkjh izkIr djuk-
8- dksYM dfVax midj.kksa dks pkyw fLFkfr esa djuk-
9- pk; rFkk dkWQh cukus gsrq funs'Z k nsuk-
10- ikuh dh Vafd;ksa esa Dyksjhu dh xksfy;ka Myokuk-
11- Mh-th-lSV pkyw djus ds funs'Z k nsuk ,oa mudk pkyw fLFkfr esa gksuk lqfuf'pr
djuk-
12- nq?kZVuk LFky ij igqapus ds iwoZ nq?kZVukxzLr xkM+h ds xkMZ@Mªkboj ;k ogka
mifLFkr jsy deZpkjh ls okWdh&VkWdh@V.H.F. lSV ij ckr djds nq?kZVuk ds ckjs
esa gj laEHko tkudkjh izkIr djuk rkfd dk;Z djus esa dfBukbZ u gks-
13- xkM+h ds nq?kZVuk LFky ij igqaprs gh leLr Vheksa dks viuk&viuk lkeku mrkjus
ds funss'Z k nsuk ,oa Lo;a dSejs ds lkFk nq?kZVuk LFky ds fy, izLFkku djuk-
14- nq?kZVuk LFky ij igqapdj igys fdl dksp ij rFkk fdu ;kf=;ksa dks ckgj
fudkyuk gS mldk fuEu rjhds ls fu/kkZj.k djuk &
i) ,sls ?kk;y ;k=h ftudk rsth ls [kwu cg jgk gks
ii) thfor Qals gq;s ;k=h
iii) ewfNZr ;k=h
15- dksYM dfVax midj.kksa dk lgh rjhds ls iz;ksx lqfuf'pr djuk rkfd midj.kksa
dh otg ls dksbZ ;k=h ?kk;y u gksus ik;s vkSj u gh midj.kksa ds pyus ls
?kcjkgV dh fLFkr cus A
16- ;kf=;ksa dks fudkyrs le; mudk gkSlyk@eukscy c<+kuk A
17- ;kf=;ksa dks fudkydj lgh LFkku ij igqapkuk
18- jsyos ds nwljs foHkkx tSls dkeZf'k;y] vkj ih ,Q] esfMdy vkfn ls yxkrkj
laidZ cuk;s j[kuk rkfd jkgr dk;Z lqpk: :i ls py lds A
19- vius dk;Z izxfr dh lwpuk le;≤ ij ECP ls daVkª sy ,oa ogka ij ekStwn
jsy vf/kdkfj;ksa dks nsuk A
4.0 'A' Vhe deZ p kfj;ks a dk foLr` r dk;Z
¼la [ ;k&04½
eq [ ; dk;Z % & dks Y M dfVa x midj.ks a dk iz ; ks x djrs gq , nq ? kZ V ukxLr dks p ls
?kk;y ;kf=;ks a dks fudkyus gs r q i;kZ I r txg cukuk A
1- ARME vkMZj gksrs gh rqjar xkM+h ij mifLFkr gksuk ,oa bapktZ dks viuh mifLFkr
nsuk A
2- pyrh xkM+h esa gh dksYM dfVax midj.kksa dks gkWyesVªks e'khu ds lkFk diy djuk
,oa mudks pkyw fLFkfr esa djds ns[kuk A
3- nq?kZVuk LFky ij igqapus ds iwoZ xkM+h dh pkyw fLFkr esa gh ARME bapktZ ,oa
nq?kZVukxzLr xkM+h ds xkMZ ds chp gks jgh ckrphr dks /;kuiwoZd lquuk rkfd vkns'k
feyus ij dk;Z djus esa dfBukbZ u gksA
4- ARME ds nq?kZVuk LFky ij #drs gh dksYM dfVax ds leLr midj.kksa tSls dVj]
LiszMj] foaMks ckj dVj] Xykl dVj ,oa gkyeSVkª se'khu vkfn mrkjdj rFkk mUgsa ysdj
rqjar nq?kZVukxzLr dksp ftlesa ;k=h Qals gS ogka ij tkuk ,oa vko';drkuqlkj mudk
mi;ksx djuk A
5- vkns'k feyrs gh dksp esa lgh LFkku ij midj.kksa dk iz;ksx djrs gq, dksp esa vUnj
tkus ds fy, i;kZIr txg cukuk rkfd ?kk;y ;kf=;ksa dks lqpk: :i ls ckgj
fudkyk tk lds A
6- dksYM dfVax midj.kksa dk iz;ksx djrs le; lko/kkuh cjruk rkfd mudk mi;ksx
djrs le; dksbZ ;k=h ?kk;y u gks vkSj u gh ;kf=;ksa esa Hk; mRiUu gks A
7- tSls gh izFke dksp esa txg cu tkrh gS ,oa jkgr dk;Z iw.kZ gksrk gS] rqjar vxys
nq?kZVukxzLr dksp ftlesa ;k=h Qals gks ogkWa igWp
aq uk rFkk mijksDr izfdz;k nksgjkuk A
8- mijksDr jkgr izfdz;k rc rd tkjh jgsxh tc rd fd lEiq.kZ ?kk;y@ewfNZr ;kf=;ksa
dks ckgj u fudky fy;k tk, A
5.0 'B' Vhe deZ p kfj;ks a dk foLr` r dk;Z
¼la [ ;k&04½
eq [ ; dk;Z % dks p ds vUnj iz o s ' k dj ?kk;y@ew f NZ r ;kf=;ks a dks LVz s a p j

ij j[kdj ckgj fudkyuk A
vU; dk;Z %&
1- ARME vkMZj gksrs gh rqjr

a xkM+h ij igqapuk rFkk bapktZ ds ikl viuh mifLFkr
nsuk A
2- ARME esa baftu yxkus esa enn djuk A
3- xkM+h ds nq?kZVuk LFky ij #drs gh dksYM dfVax midj.kksa ds vykok vU; midj.k
tSls cqyVs pSu lkW] VQZj] ikoj dVj] tSd] lh<+h] vfXu'kked ;a=] xSl dfVax midj.k]
Mh,@vkDlhtu flysUMj xkM+h ls mrkjdj nq?kZVuk LFky ij j[kuk A
4- 'A' Vhe tSls gh dksp esa vUnj tkus ds fy, i;kZIr txg cuk ysrh gS] rqjar dksp
esa vUnj tkdj ?kk;y@ewfNZr ;kf=;ksa dks LVªspj esa mfpr rjhds ls j[kdj ckgj
fudkyuk A
5- ;fn dksp esa vUnj tkus dh txg <wa<us ij feyrh gS rks vius foosd dk Lrseky
djrs gq, dksp ds vUnj tkdj dksp ds njokts] f[kM+dh [kksyuk rFkk ?kk;y ;kf=;ksa
dks ckgj fudyuk A
6- thfor ,oa v{ke ;kf=;ksa dks ckgj fudkyus esa enn djuk A
6.0 'C' Vhe deZ p kfj;ks a dk foLr` r dk;Z
¼la [ ;k&04½
eq [ ; dk;Z % & es f Mdy Vhe ds lkFk jgdj ?kk;y@ew f NZ r ;kf=;ks a dk

iz F keks i pkj djuk A
vU; dk;Z %&

1- ARME vkMZj gksrs gh rqjar xkM+h ij mifLFkr gksuk ,oa ARME bapktZ dks
viuh mifLFkr nsuk A
2- xkM+h ds nq?kZVuk LFky ij #drs gh esfMdy Vhe ds lkFk esfMdy dk lkeku

LVsªpj] ckWMh cSx vkfn mrkjdj nq?kZVuk LFky ij ykuk A
3- ftu ;kf=;ksa dks ekewyh pksVsa vkbZ gS mudk QLVZ ,M ckWDl dh lgk;rk ls
izFkeksipkj djuk A
4- tSls gh “B” Vhe nq?kZVukxzLr dksp ls ?kk;y@ewfNZr ;kf=;ksa dks LVªspj ij j[krh
gS] rks mUgsa rqjar MkDVj ds ikl ykuk rFkk izFkeksipkj Hkh djuk A
5- ;fn MkDVj fdlh ;k=h dks e`r ?kksf"kr djrs gS rks mls ckWMh cSx esa j[kdj
,oa VSx yxkdj VSUV esa mfpr LFkku ij j[kuk A
7.0 'D' Vhe deZ p kfj;ks a dk foLr` r dk;Z
¼la [ ;k&03½
eq [ ; dk;Z % Vs U V yxkuk] dq l hZ ] es t + ] Nkrs vkfn yxkuk
vU; dk;Z %&

1- ARME vkMZj gksrs gh rqjar xkM+h ij mifLFkr gksuk ,oa ARME bapktZ
dks viuh mifLFkr nsuk A
2- nq?kZVuk LFky ij xkM+h #drs gh rqjar VaSUV dk lkjk lkeku] est+] dqlhZ] Nkrs
vkfn mrkjdj nq?kZVuk LFjy ij ys tkuk A
3- mfpr LFkku ns[kdj VsUV ,oa Nkrs yxkuk A
4- dksYM dfVax midj.kksa ds vykok ;fn vU; midj.kksa ds iz;ksx dh vko';drk

iM+rh gS rks vkns'kkuqlkj mudk iz;ksx djuk A ;g midj.k 'B' xsax nq?kZVukLFky
ij mrkjdj yk,xh A
8.0 'E' Vhe deZ p kfj;ks a dk foLr` r dk;Z
¼la [ ;k&03½
eq [ ; dk;Z % &jkf= ds le; iz d k'k dh O;oLFkk djuk ijUrq ;fn fnu

dk le; gS rks iz F keks i pkj es a enn djuk A
vU; dk;Z %&
1- ARME vkMZj gksrs gh rqjar xkM+h ij igqapuk ,oa bapktZ dks viuh
mifLFkr nsukA
2- pyrh xkM+h esa izdk'k laca/kh midj.kksa dks pkyw fLFkfr esa djuk lqfuf'pr
djuk A
3- jkr ds le; nq?kZVuk LFky ij xkM+h #drs gh DG lsV mrkjdj LFky ij

ys tkuk rkfd mlls vU; midj.k tSls cqysV pSu lk] ikoj dVj vkfn
pyk;s tk ldsa A
4- ;fn fnu dk le; gS rks izFkeksipkj esa yxkrkj enn djukA
5- nq?kZVuk LFky ij cSfj;j Vsi yxkuk vkfn A
9.0 'F' Vhe deZ p kfj;ks a dk foLr` r dk;Z
¼la [ ;k&04½
eq [ ; dk;Z % pk;] dkQh] fcfLdV] ikuh ys d j ;kf=;ks a ds ikl tkdj

mUgs a ns u k A
vU; dk;Z %&
1- ARME vkMZj gksrs gh xkM+h ij igqapuk ,oa viuh mifLFkfr nsuk A
2- ikuh dh Vafd;ksa esa Dyksjhu dh xksfy;ksa Mkyuk A
3- pyrh xkM+h esa pk; rFkk dkQh cukuk ,oa mUgsa FkeZl esa j[kuk A
4- ARME ds nq?kZVuk LFky ij igqaprs gh ikuh] pk;] dkQh] fcfLdqV ysdj

?kk;y ,oa vU; ;kf=;ksa ds ikl ys tkdj mUgsa nsuk rFkk lkFk gh lkFk
lkaURouk iznku djuk A
10.0 nq?kZVuk gksus ij xkMZ ds drZO; ¼fu;e 306] 801½ %
1- nq?kZVuk dk le;] rkjh[k rFkk LFky dk fdyksehVj rqjUr uksV djsxk-

2- xkM+h ds gS.M czsd yxkdj xkM+h dh lqj{kk lqfu'pr djsxk-
3- cktw dh ykbu dk vkxs dh vksj cpko lqfuf'pr djus ds fy;s baftu dh vksj
çLFkku djrs le; cktw okyh ykbu ds Qkmy gksus dk losZ djsxk] lkFk ghs vko';d
lgk;rk dk vkadyu djsxk- cktw okyh ykbu dk vkxs dh vksj cpko lqfuf'pr djus
ds i'pkr~ ihNs dh vksj viuh ykbu dk cpko Lo;a ;k xsaxesu] xsVesu ;k fdlh
l{ke jsy deZpkjh dh lgk;rk ls djsxk- (GR 6.03).
4- miyC/k o ,df=r fd, x, MkWDVjksa] Lo;a lsodksa] jsy vf/kdkjh@jsy deZpkfj;ksa ds
lg;ksx ls ?kk;yksa dks çkFkfed fpfdRlk nsus rFkk muds tkueky dh j{kk djus dk
nkf;Ro iwjk djsxk rFkk bldh çfof"V xkMZ tjuy esa djsxk-
5- RPF/GRP/flfoy iqfyl dh lgk;rk ls ;kf=;ksa ds lkeku] jssyos çkWiVË] Mkd vkfn dh
lqj{kk djsxk-
6- ?kk;yksa ,oa e`rdksa dk losZ djsxk rFkk jksfyax LVkd ds uqd'kku dk vkdyu djsxk]
miyC/k@mfpr ek/;e ls rqjUr cktw okys LVs'ku ekLVj ;k daVªksyj dks nq?kZVuk dh
lwpuk nsxk o vko';d lgk;rk dh ekax djsxk- ;fn vleFkZ xkM+h ds baftu dks
fMVSp djus dh vko';drk iM+rh gS] rks baftu dkVus ls igys ,lvkj 6-09-1 dk
ikyu lqfuf'pr djsxk-
7- xaEHkhj ?kk;yksa dks LFkkuh; O;fDr;ksa@jksM VªkaliksVZjksa dh lgk;rk ls ut+nhd ds vLirkyksa
dks Hkstxs k- ?kk;yksa dh la[;k] mudk fooj.k] Hksts x, okgu dk uEcj ,oa fdl
vLirky dks Hkstk gS bldk fooj.k uksV djsxk-
8- fVfdV pSfdax LVkQ@vU; dkWef'kZ;y LVkQ vFkok vU; deZpkjh@Lo;a lsodksa dh
lgk;rk ls ?kk;yksa rFkk izHkkfor ;kkf=;ksa ds fy, pk;] dkWQh] ikuh ,oa fjÝS'keSVa dh
O;oLFkk djsxk-
9- ;fn laHko gks rks nq?kZVuk ds lEHkkfor dkj.kkssa dk irk yxk,xk ,oa lk{;ksa dks lqjf{kr
j[ksxk-
10- ART/ARME ds vkus rd daVªksy vkWfQl ls lrr~ lEidZ cuk;s j[kus gsrq ECP/PFT
ij ,d jsy deZpkjh dks yxk,xk rFkk fdlh ofj"B jsy vf/kdkjh ds vkus rd nq?kZVuk
LFky ij çHkkjh ds :Ik esa dk;Z djsxk-
11- lgk;rk izkIr djus ds fy, lehiorhZ xsV vFkok LVs'ku@vLirky esa Vªsu ij miyC/k
jsy deZpkfj;ksa ;k Lo;a lsodksa dks Hkstuk lqfuf'pr djsxk-
12- fu;fer fpfdRlk lgk;rk miyC/k gksus ls jkgr dk;Z esa enn djus ds fy, deZpkfj;ksa
;k Lo;a lsodksa dh Vksfy;ka cukuk-
13- çHkkfor ;kf=;ksa dks gj lEHko lgk;rk nsus ds fy, xkM+h esa ;k=k dj jgs jsy lqj{kk
cy@vU; deZpkfj;kssa] ;fn gSa rks budk mi;ksx djds ?kk;yksa dks lqjf{kr LFkku ij
ykuk] is;ty O;oLFkk djuk vkSj ;kf=;ksa ds lkeku dh RPF LVkQ }kjk lqj{kk djkuk-
14- xkM+h ds daMDVj vkfn dks e`r@?kk;yksa dh igpku djus rFkk fyLV cukus esa lgk;rk
djuk-
15- daVªksy ls ijke'kZ djds is;ty] [kk|&lkexh rFkk ladVxzLr ;kf=;ksa dh vkxs dh ;k=k
dh O;oLFkk djkuk-
16- daVªksy ls ijke'kZ djds tkap djs fd ;fn xkM+h ds vkxs vkSj ihNs ds Hkkx
nq?kZVukxzLr ugha gSa rks mls fudVrË LVs'kuksa ij lqj{kkiwoZd Hkstk tk,] ftlls fd
,vkj,ebZ dks nq?kZVukLFky ds fudVre Hkstk tk lds-
17- nq?kZVuk LFky dks ughaa NksM+sxk tc rd fd mls l{ke vf/kdkjh }kjk vuqefr ugha nh
tk,-
18- xkMZ ds grkgr@?kk;y gksus ij xkMZ dh M~;wVh Vªsu esa miyC/k vU; l{ke jsy
lsod@lsodksa }kjk ;kstuk c) rjhds ls dh tk,xh-
11.0 nq?kZVuk gksus ij daMDVj@xkM+h v/kh{kd@py fVfdV ijh{kd@dsVfjax
LVkQ ds drZO; ¼fu;e 310] 802½ %
xkMh v/kh{kd @daMDVj@fVdV pSfdax LVkQ rFkk dsVfjax LVkQ dks ?kk;y
;kf=;ksa dh lgk;rk ds fy;s nq?kZVuk LFky ij gj lEHko iz;kl djuk pkfg;s A
1- nq?kZVukxzLr ;kf=;ksa dks lkaRouk nsaxs rFkk jkgr ,oa cpko dk;Z lqfuf'pr djsaxs A
2- ?kk;yksa dh fpfdRlk ds fy;s Vªus esa ;k=k dj jgs MkDVjksa ls lgk;rk ekaxsxs A
3- ?kk;y ,oa izHkkfor ;kf=;ksa ds fy;s dher fy;s fcuk ihus dk ikuh rFkk
fjÝs'kesVa dk izc/a k djsaxs A
4- ;kf=;ksa dks le; ij vko';d lwpuk;sa iznku djsaxs A
5- e`r ,oa ?kk;y ;kf=;ksa dk fooj.k ,df=r djsaxs A
6- izR;{kn'khZ ;kf=;ksa }kjk crk;s x;s fooj.k dks fy[ksaxs rFkk mudk irk ,oa uke
uksV djsxa s A
7- ;kf=;ksa ds lkeku rFkk jsyos izkiVhZ dh j{kk djsaxs A
8- jsyos LVkQ ,oa esfMdy Vhe dks e`r ;kf=;ksa dh igpku djus esa lgk;rk djsaxs
rFkk ?kk;yksa dks QLV ,M lgk;rk iznku djsaxsA
9- e`r rFkk ?kk;y O;fDr;ksa dh lwph cukuk A ;fn MkWDVj miyC/k gks rks] e`r]
xEHkhj pksV rFkk lk/kkj.k pksV okyksa dk oxhZdj.k djsa A
10- ifgpku lfgr e`r rFkk ?kk;yksa ds fooj.k] vkj{k.k pkVZ] fVdVksa ;k xkM+h esa
;k=k dj jgs lg ;kf=;ksa ls izkIr djsaxs A
11- ;k=k dj jgs ;kf=;ksa] deZpkfj;ksa ds uke] fVdV ua- rFkk Js.kh] dksp ua-] muds
irs ,oa pksV dk izdkj vkfn Hkh uksV djasxs A
12- pksV yxus dh fLFkfr esa ;kf=;ksa ds lkeku dks daMDVj }kjk rFkk ;k=h dh
e`R;q gks tkus ij fooj.k ds lkFk vkj-ih-,Q@th-vkj-ih- dks lqiqnZ djds ikorh
izkIr djsaxs A
13- ;kf=;ksa ds izek.k fjdkMZ djuk A ;fn dqN ;k=h ckn esa izek.k nsrs gS rks muds
uke rFkk irs Hkh fjdkMZ fd;s tWk;ssaxs A
14- mu e`r vFkok ?kk;y O;fDr;ksa dk Hkh fjdkMZ j[ksaxs] ftUgsa LFkkuh; O;fDr;ksa
}kjk igys gh ys tk;k x;k gS A
15- lqj{kk] fuxjkuh rFkk yxst dk mfpr fMLiksty% jsy izksVsD'ku QkslZ rFkk
dkWef'Zk;y LVkQ nq?kZVuk LFky ij e`r rFkk ?k;y ;kf=;ksa ds lkeku dh lqj{kk]
fuxjkuh rFkk mfpr fMLiksty djsaxsA dkWef'Zk;y LVkQ yxst ij yscy yxk,xk
rFkk <sjh cuk,xk A ;g lkeku vkj-ih-,Q }kjk viuh fuxjkuh esa j[kk tk,xk
rFkk vko';d iwNrkN ds ckn mlds ekfyd dks gh iznku fd;k tk,xk A
12.0 nq?kZVuk gksus ij pkyd rFkk lgk;d pkyd ds drZO; ¼fu;e 307]
308½ %
1- rqjUr xkM+h [kM+h djsxk] yksdks dh ¶ys'kj ykbV vkWu djsxk rFkk gSM ykbV dks
vkWQ dj nsxk A
2- vkus okyh xkMh ds pkyd dks psrkouh nsus ds fy;s ckj&ckj NksVh lhfV;kWa
ctk,xk A
3- ¼th-vkj 6-03½ ds vuqlkj loZizFke cktw dh ykbu dk cpko djsxk rRi'pkr~

viuh ykbu dk cpko djsxk rFkk xkMZ ds lkFk okdh&Vkdh lSV ij rqjUr
lwpukvksa dk vknku&iznku djsxk A
4- miyC/k lk/kuksa ¼ECP/PCP lSV vFkok xsV½ ds ek/;e ls dUVªky

s vkfQl rFkk
cktw ds LVs'kuksa dks nq?kZVuk dh tkudkjh nsxk A
5- pkyd yksdks dks vuesUM ugha NksMxs k rFkk rduhdh :i ls Vsªu dks lajf{kr
j[kus ds fy;s vko';d lko/kkfu;kWa lqfuf'pr djsxkA
6- nq?kZVuk ds nkSjku jksfyax LVkWd rFkk yksdkseksfVo dks gq;s uqd'kku ,oa lgk;rk dh
ekax ds vkWdyu esa xkMZ dks gj laEHko lgk;rk iznku djsxk A
7- ;fn pkyd ny dh e`R;q gks tkrh gS ;k xEHkhj :i ls ?kk;y gks tkrs gS rks
budh M~;Vw h Vªsu esa miyC/k fdlh vU; l{ke jsy deZpkjh }kjk lEiUu dh
tk,xh A
-----------0------------
13.0 nq?kZVuk gksus ij eaMy jsy izca/kd ds drZO; ¼fu;e 330]823½%
i) lqfuf'pr djrs gS fd izR;sd foHkkx }kjk mfpr lgk;rk nh tk jgh gS A
ii) ;g lqfuf'pr djuk fd dUVªky s dk;kZy; esa ,d okgu iwjs le; miyc/k gksus
ds vykok Mªkbojksa ds fooj.k ds lkFk vko';d la[;k esa eksVj okgu miyC/k
gS A
iii) ;g rqjUr fu.kZ; djuk fd fdl vf/kdkjh dks lM+d ekxZ] ,-vkj-Vh- rFkk
fpfdRlk;ku ls tkuk pkfg, A
iv) dUVªky
s dk;kZy; esa jgus ds fy;s vf/kdkjh dks ukfer djuk A
v) ;fn og nq?kZVuk LFky ds fy, jokuk gksrs gS rks vij e.My jsy izca/kd dks
dUVªky
s dk;kZy; esa izHkkjh ds :i esa rSukr djsaA
vi) rksM+QksM ds ekeys esa jkT; ds x`g lfpo@eq[; lfpo ;k vU; vf/kdkfj;ksa dks
iqfyl v/kh{kd ds rqjUr mifLFkr gksus ds fy, lwpuk dh O;oLFkk djsa A
vii) LFky ij ofj"Bre vf/kdkjh rFkk nq?kZVuk izca/kd ds :i esa dk;Z djuk A
viii) tgkWa fd lh-vkj-,l- vFkok ofj"B iz'kklfud vf/kdkfj;ksa }kjk tkWap vk;ksftr
dh tkuh gks ysfdu dqN ekeyksa esa rRdky tkWap djuk t:jh gS] ,sls ekeyksa esa
eaMy vf/kdkfj;ksa }kjk izkjafHkd tkWap dh O;oLFkk djuk A
ix) xaHkhj nq?kZVuk ds fjiksVjZ ds fy, nks vf/kdkfj;ksa dks fu;qDr djuk A
x) i;Zos{kdksa }kjk la;D
q r fujh{k.k vkSj jhfMaXl ysus dh O;oLFkk djuk A
14.0 nq?kZVuk LFky ij ,lh dksp vVs.MsUV@esdsfud ds drZO;%
1- nq?kZVuk gksrs gh dksp ls ckgj vkdj ofj"B daMDVj ls laidZ djsxk ,oa Lo;a
dks lgk;rk ds fy, lefiZr djsxk A
2- ofj-daMDVj ds funsZ'kkuqlkj ukfer lgk;rk Vhe ds lkFk dk;Z djus ds fy,

Lo;a dks ukfer djk;sxk A
3- ukfer lgk;rk Vhe ds lkFk dk;Z djus ds iwoZ fuEufyf[kr miyC/k lkexzh vius
lkFk ys tk;sxk %&
v- i;ZkIr dEcy rFkk csM'khV vius lkFk j[ksxk A

c- vius ikl miyC/k ckdh&VkWdh dks ofj-daMDVj dks lkSisxk
l- QLVZ&,M ckWDl lkFk esa ysxk A
n- ;fn LVsªpj miyC/k gS rks LVsªpj dks Hkh vius lkFk j[ksxk
/k- ;fn vkx yxus dk irk pyrk gS rks vfXu'kked ;a=ksa dks vius lkFk
nq?kZVukxzLr dksp ds ikl ys tk;sxk ,oa vkx cq>kus esa lgk;rk djsxk A
4- ?kk;y ,oa e`r ;kf=;ksa dks fudkyus rFkk mfpr LFkku ij ys tkus dh izfØ;k esa
;ksxnku djsxk A
15.0 nq?kZVuk LFky ij mifLFkr izHkkjh vf/kdkjh ds drZO;%
¼fu;e 309] 824½%
tc rd nq?kZVuk jkgr lgk;rk xkMh vFkok dksbZ ofj"B vf/kdkjh nq?kZVuk LFky ij ugh vk
tkrk] mifLFkr ofj"B jsy vf/kdkjh dks nq?kZVuk jkgr dk;Z dk bapktZ gksuk pkfg;s A mls ;g
lqfuf'pr djuk pkfg;s fd nq?kZVuk dk fooj.k dUVªksyj dks Bhd izdkj ls fjiksVZ dj fn;k x;k
gS rFkk ;fn lgk;rk dh ekax gS rks mldk mfpr izcU/k gks jgk gS A
1- nq?kZVuk LFky ij jsy deZpkfj;ksa rFkk Lo;a lsodksa dks ,df=r djsxk
2- ifjLFkfr;ksa ds vuq:i vPNs ls vPNs laEHko rjhds ls izR;sd O;fDr dks M;wVh iznku
djsxk A
3- mifLFkr iqfyl deZpkfj;ksa] lsuk ds tokuksa rFkk jsy lqj{kkcy ds tokuksa dks Bhd izdkj ls
M;wVh vkoafVr djsxk A
4- Lo;a lsodksa dh lgk;rk ls jkgr dk;Z izkjEHk djsxk A
5- iksVZscy VsfyQksu ij deZpkjh dh fujUrj O;oLFkk djuk A
6- izHkkfor xkM+h vkSj lehiorhZ ykbuksa dk vko';d cpko lqfuf'pr djuk
7- 'kh?kz ewY;kadu djuk ,oa fu;fer lwpuk izlkfjr djuk A
8- LFky ij izFkeksipkj nsus] vkgrksa dks lehiLFk nok[kkuksa @ vLirkyksa vkfn esa ys tkus dh
O;oLFkk,Wa lqfuf'pr djuk A
9- e`rdksa ds 'kjhj] ;fn dksbZ gks rks ns[kHkky djus] yk'kksa dh igpku] lehiorhZ LVs'kuksa ij
yk'kksa dks ys tkus] iqfyl vkfn dks lwfpr djus dh O;oLFkk djuk A
10- ladVxzLr ;kf=;ksa dks izkFkfedrk ls ,sls LVs'kuksa dks ys tkus dh O;oLFkk djuk tgkWa
is;ty] [kkuiku vkfn fd lqfo/kk,Wa miyC/k gksa A okf.kT; vf/kdkjh dks mudh lgk;rk ds
fy, fu;qDr djsaA
11- ;fn lk{;kas dks lqjf{kr j[kk vkSj uksV fd;k gks rks ,-vkj-Vh- Øsuksa vkfn dks lehi
igqWapkus gsrq LFky ls xkM+h ds vizHkkfor Hkkx dks fudkyus dh O;oLFkk djuk A
12- ;fn rksM&QksM dh vk'kadk gks rks Mh-vkbZ-th-@,l-ih- dks lwfpr fd;k tk, rFkk mudh
vuqefr dh izfr{kk djsa A
13- nq?kZVuk {ks= dk i;kZIr :i ls lqj{kk rFkk laj{k.k lqfuf'pr djuk A
14- cpko dk;kZsa dk lapkyu] lk{;ksa dks lqjf{kr j[kuk rFkk LFkkukUrj.k dk;Z esa fof'k"V dk;ksZa
ds fy, vf/kdkfj;ksa vkSj@;k deZpkfj;ksa dks rSukr djsaA
15- loZ lacaf/krksa dks 'kh?kz Qksu ;k rkj }kjk nq?kZVuk dh lwpuk tkjh djus dh O;oLFkk djuk
A
16- d½ lqfo/kktud LFkkuksa ij iwNrkN d{k [kksyus dh O;oLFkk
djuk A
[k½ lacfa /kr tkudkjh nq?kZVuk ykWx ds :i esa fjdkMZ djsa A
17- ;kf=;ksa dk ;kukUrj.k] xkfM+;ksa dk ekxZ ifjorZu] ;krk;kr dk izfrca/k] ;fn t:jh gks rks
nksgjh xkfM;ka pykus gsrq eaMy dUVªksy dk;kZy; vkSj iz/kku dk;kZy;ksa ds lkFk lh/ks lEidZ
O;oLFkk djuk A
18- fuiVk, x, dk;ksZa dh izxfr dh lwpuk dUVªksy dk;kZy; dks nsrs jgsa A
19- iVjh ij p<us ds ckn LFky ls {kfrxzLr okguksa dks rqjUr gVkuk rFkk mUgsa pykus ds fy,
;ksX; izekf.kr djuk A
20- jkf= rFkk va/ksjs dh gkyr esa {ks= esa i;kZIr izdk'k lqfuf'pr djuk A
21- izpfyr fu;eksa ds vuqlkj 'kh?kzrk ls vuqxzg ds :i esa Hkqxrku dh O;oLFkk djkuk A
22- deZpkfj;ksa ds fy;s le; ij Hkkstu dh O;oLFkk djuk tgkWa visf{kr ;k vuqer gS A
23- tgkWa eky mrkjuk t:jh gS] Jfedksa dh O;oLFkk djuk A
24- ;g lqfuf'pr djuk fd okf.kT; deZpkfj;ksa }kjk Hkjs gq, eky fMCcs vkSj ijs"k.kksa ds
fooj.k fy[ks tkrs gS A
25- ;g lqfuf'pr djuk fd] jsyos deZpkjh fof'k"V ckag ifV~V;kWa cka/ks gq, gS
16.0 nq?kZVuk LFky ij jsy lqj{kk cy ds drZO; ¼fu;e 506½%
nq?kZVuk LFky ij igWp q us ds i'pkr jsy lqj{kk cy viuh lkekU; M;wVh ds vfrfjDr
fuEufyf[kr drZO;ksa dk fuokZg Hkh djsaxs A
1- dksp esa ncs gq, ;kf=;ksa dks fudkysxsa] ?kk;yksa dks QLVZ,M iznku djsaxs A nq?kZVuk
LFky ij ?kk;yksa rFkk izHkkfor ;kf=;ksa dk vkadyu djsxsa A
2- nq?kZVuk esa ?kk;y ;kf=;ksa ds lacaf/k;ksa@lkfFk;ksa dh lqj{kk djsaxs rFkk jsyos izkWiVhZ dh
lqj{kk djsaxs A
3- jsy ykbu lqj{kk] fQ'k IysV] cksYV~l rFkk vU; lacaf/kr eVsfj;y vkfn dh j{kk djsaxs
rkfd dksbZ O;fDr budks ifjofrZr@LFkkukUrfjr u dj nsa A
4- nq?kZVuk LFky ij iksy xkM dj csfj;j Vsi dh lgk;rk ls doj djsaxs ftlls fd
ckgjh O;fDr pksjh ds mn~ns'; ls dksp esa u ?kql lds A
5- ykmM+ gsyj dh lgk;rk ls nq?kZVukxzLr dkspksa ds ikl vkus okys ckgjh O;fDr;ksa dks
nwj j[ksaxs A
6- nq?kZVuk LFky ij lansgkLin enksa dh fuxjkuh djsaxs rFkk lk{;ksa dks uksV djsaxs ftlls
fd ?kVuk ds ekeys esa mi;ksxh rF; lkeus vk lds A
7- nq?kZVuk LFky ij ;fn vkx yxh gks rks vkx cq>k,Wxsa A
8- nq?kZVuk dsl dh tkWp a izfdz;k esa th-vkj-ih-@flfoy iqfyl dh enn djsaxs A
9- ;kf=;ksa ds eky rFkk iklZyksa] {kfrxzLr eky vkSj iklZy ;kuksa vkfn dh lqj{kk Hkh
lqfuf'pr djsaxs A
10- lqj{kk] fuxjkuh rFkk yxst dk mfpr fMLiksty% jsy izksVD s 'ku QkslZ rFkk dkWef'Z;y
LVkQ nq?kZVuk LFky ij e`r rFkk ?k;y ;kf=;ksa ds lkeku dh lqj{kk] fuxjkuh rFkk
mfpr fMLiksty djsaxsA dkWef'Zk;y LVkQ yxst ij yscy yxk,xk rFkk <sjh cuk,xk
A ;g lkeku vkj-ih-,Q }kjk viuh fuxjkuh esa j[kk tk,xk rFkk vf/kdkjdrkZ dks
gh iznku fd;k tk,xk
CHAPTER – 14
INFRASTRUCTURAL
FACILITIES
FOR
MAINTENANCE
OF
ARTs/140T.
CRANES/ARMEs &
SPARTs
Infrastructural facilities for Maintenance of 140 Te. Cranes\ ARTs\ARMEs\SPARTs\1
Facilities for Maintenance of 140T cranes & ARTs
1.0 Introduction
1.1 140T diesel hydraulic breakdown cranes were first introduced in 1986-87. Thereafter,
another lot of such type of cranes with improved features was introduced in 1998.
Based on the decision/ suggestions taken during Crane Maintenance Group meeting
held in Jamalpur on 24th and 25th April, 2000, the shed layout drawing was drawn
and issued to all user Railways on 21/22.12.2000. It has now been decided in
subsequent CRMG held at Jamalpur on 23rd and 24th September' 2004 that RDSO
should also circulate the infrastructure required for basing 140t cranes in division,
covering stabling facilities, pit, covered sheds, battery charging facility, storage area
for lifting tackles, material handling facilities and tools etc.
2.0 Scope of maintenance and location of the shed
2.1 The shed shall be used as a satellite shed for carrying out maintenance excluding
IOH/POH.
2.2 140 T crane maintenance shed shall be located at a convenient place so that the
entry and exit of crane from the shed is easier depending upon the beat of the crane.
3.0 Shed layout
3.1 The shed shall have the facility for day-to-day maintenance of 140T crane till it is sent
for IOH / POH.
3.2 IOH & POH of 140t crane will be carried out at workshops nominated by the Zonal
Railways.
3.3 The shed shall be provided with one repair / maintenance bay with single level
working floor arrangement. Two portable type platforms as indicated in the RDSO
drawing no. SK. CR–833 to attend the crane above crane platform level shall be
manufactured. The drawing of the portable type platforms may be obtained from
Parel Workshop, Central Railway. This facilitates simultaneous and inspection and
servicing as well as repairs of the under floor and above floor equipments of the
crane.
3.4 The Shed structure and the roof shall be so constructed such that it provides plenty of
natural daylight, with provision of glazing if necessary.
3.5 The pit shall have convex flooring with efficient draining system.
3.6 Adequate hydrants shall be provided for convenient washing of floor. These shall not
be used for washing the crane.
3.7 Roof extractors should be provided to expel harmful diesel fumes.
3.8 Care shall be taken to make the Shed dust proof to the extent possible. Rolling
shutters of robust design should be provided on all entrances to prevent dirt and dust
from entering the Shed, especially when the weather is windy or stormy.
3.9 The Shed building shall include the following facilities:
 Supervisor cum Computer room for ART Incharge & 140T crane supervisor
 Staff room
 Lifting Tackle room
 Consumables room
 Compressor room
 Electrical room
 Toilet
4.0 Shed Lighting
4.1 Adequate lighting inside the Shed shall be provided.
4.2 Pits should be provided with bulkhead fittings for direct lighting of the under gear.
Points shall be available at all levels and in the pits for the use of hand lamps with
flexible leads.
4.3 Plug points for portable tools/ battery charging should be made available at
convenient points.
5.0 Fuel Supplies
5.1 Fuelling of 140 T crane shall be done outside the shed so as to prevent any fire
hazards due to spilling of fuel in the working area.
5.2 The existing fuel filling facilities in station yard shall be used for filling fuel in 140 T
crane.
6.0 Fire fighting equipments
6.1 Fire fighting equipment should be provided in consultation with the local Fire Station
authorities. They shall also be consulted on the actual location of various water
hydrants, type of fire extinguishers, and other equipment.
6.2 At least 10 buckets of the sand shall be provided for extinguishing fire.
7.0 Supervisor cum Computer Room for ART Incharge & 140 T crane supervisor:
7.1 It shall have adequate furniture like table and chairs. It shall also have proper
communication system like Railway Telephone & P&T phone.
7.2 The room shall have facility for maintenance of record and store.
7.3 It shall be provided with one wash- basin, & mirror for use.
7.4 It shall have a computer with all its peripherals/accessories installed in a separate air -
conditioned cabin with false roofing constructed specially for the purpose. It should
have proper lighting arrangement.
7.5 It shall have almirah for keeping spares related to maintenance of microprocessor
control based safety system installed on the cranes.
8.0 Staff Room:
8.1 It shall have adequate furniture like table, chairs and proper communication system.
8.2 The room shall have sufficient number of pigeon-hole almirahs with locking
arrangement depending upon staff strength and also for keeping tools and other
necessary items.
8.3 The room should have also necessary facilities like working table, bench vice etc. for
carrying out some minor mechanical fittings.
8.4 It shall be provided with one wash- basin & mirror for use.
9.0 Lifting Tackles Room

9.1 It shall have proper racks along the sides of the room so as to facilitate proper
storage of spare / damaged lifting tackles/ slings. Damaged lifting tackles /slings must
be separately kept and properly marked.
9.2 It shall also have rack type arrangement for keeping spare packing /sleepers of
various sizes stacked separately, which are used for propping of the crane.
10.0 Consumables/Store Room
10.1 Adequate stock of recommended lubricating greases, oils, hydraulic oils shall be
stored for trouble free maintenance of 140t crane. Consumables for ART
equipments should also be kept separately.
10.2 Adequate number of steel almirahs shall be provided for proper stocking of spares
for diesel engines (Main and Auxiliary), compressors, hydraulic pumps, hydraulic
motors, hydraulic cylinders, hoses, valves etc. Separate almirah for ART
equipments may be kept in room.
10.3 Suitable trolleys should be provided for movement of materials, to avoid damage to
components.
10.4 A section of the room shall be used separately for storage of oil. Care shall be
taken to ensure against mixing of oils of different brands.
11.0 Compressor Room:
11.1 Provision of compressed air shall be done and care shall be taken to ensure that the
air compressor is installed in a suitable place to minimize noise pollution.
11.2 Compressed air pipeline shall be so laid that additional tapping points can be
installed as and when required.
11.3 Compressed air points shall be provided near crane pit at convenient locations.
11.4 A section of the room shall be used separately as tool room and shall be utilized for
the safe keeping of hand power tools, torque wrenches, special hand tools, gauges
etc for maintenance of crane.
12.0 Electrical room with battery charger
12.1 The room shall be used for electrical maintenance. A section of room shall be used
for battery charging.
12.2 Care should be taken to provide exhausters to exhaust harmful fumes etc. from the
room.
12.3 It should be possible to directly charge the batteries, while in position on the14Ot
crane, with points available beside the pits.
12.4 The room shall have the facility for day-to-day maintenance of electrical equipment
and controls.
13.0 Toilet and Washing Room
13.1 Proper toilets and washing room for supervisor and staff shall be provided.
14.0 ART Stabling line
14.1 Accident Relief Train stabling line should be well maintained. Both side minimum
3.0 Meters wide CC pathway should also be provided for easy movement of staff
and inspecting officials. This pathway should be fit for movement of listers also.
14.2 Adequate lighting along the pathways shall be provided at a distance of 10 meters
from each pole with water proof lighting fittings.
14.3 Plug points for portable tools/ battery charging should be made available at
convenient points near apthways.
14.4 ART & 140T Crane unit may be marshaled in same line to avoid delay in shunting
for turning out from ART section.
Summary:
1. 140T Crane Shed Lay Out:
1. Shed Length= 35000 mm/45000 mm [ Proposed 52000 mm for old cowans sheldon]
2. Width = 12000 mm
3. Height over all = 10500 mm
4. Height Up to pillar= 8000 mm
5. Pit length = 12000 mm
6. Pit Height = 1050 mm
7. Pit Width = 1300 mm
8. Portable platforms = 6000X1250 mm
9. Provision of Pillar Jib Crane 2T = 01 No.
10. Rolling Shutter’s Height = 6000 mm
11. Rolling Shutter’s Width = 5000 mm
12. Floor Area = 35000/45000 X 12000 mm
13. Provision of Road Way for ART Section
14. Crane Height = 4265 mm
15. Crane width = 3200 mm
16. Provision of both side path way for ART
a. Shed with one Repair/ Maintenance-bay with single level working floor.
b.Two portable type platforms to attend the crane.
c. Platform drawings are available in Parel workshop.
d. Shed structure and roof should provide natural day-light.
e. Pit shall have convex flooring with efficient draining.
 Hydrants for washing of floor not for washing of crane.
 Roof extractors should be provided to expel harmful diesel fumes.
 Make the shed dust proof to the extent possible.
 Rolling shutters at both the entrances to prevent dirt and dust etc..
2. 140T Crane Shed Building:
1. Supervisors / Computer Room
2. Staff Room
3. Lifting tackle Room
4. Consumables Room
5. Compressor Room
6. Electrical Room
7. Staff Toilet & Washing Room
8. Cycle Stand
3. Shed Lighting:
 Adequate modern Lighting inside the shed.
 Pit should be provided with bulk head fittings for direct lighting of under gear.
 Points should be available for hand lamps.
 Plug points for portable tools/ battery charging.
4. Fuel Supplies
In general, Fueling of 140T Crane should be done out side the shed to prevent fire
hazards.
5. Fire Fighting
a. Fire fighting Equipments should be provided in consultation with Local fire authorities.
b. Type of fire Extingushers & total Nos. should be decided with local authorities
c. 10 Nos Sand buckets should be provided in shed area.
6. Supervisor Cum Computer Room, Size: 4000 x4000 mm

1. Adequate furniture like table and chairs.
2. Telephone for communication.
3. Facility for maintenance of Record and store.
4. Wash basin and mirror.
5. Computer /Printer installed in air conditioned cabin.
6. Suitable size almirah for keeping spares for maintenance.
7. Staff Room, Size 5000 X4000 mm

 Adequate furniture like table, chairs and communication system be provided.
 Sufficient pigeon-hole Almirah with locking for keeping tools and items.
 Working table, bench vice for mechanical fitting.
 One wash basin and mirror for use
8. Lifting tackle Room, Size 6000 X4000 mm:
1. Proper Racks along the sides for storage of spares, damaged tackles/slings.
2. Racks for keeping spare packings/sleepers.
9. Consumables/Store Room, Size 4000 X4000 mm:
 For Stock of Recommended lubricating greases, oils, hydraulic oils for 140 T crane.
 Steel Almirah for storing of Main and Auxiliary engine spares, compressor, hydraulic
pumps, motors, cylinders, hoses, valves etc.
 Suitable trolleys for transportation of material.
Section for storage of oil – care for mixing of oils.
10. Compressor Room, Size 4000 X4000 mm:
1. Provision of compressed air.

2. Compressor at suitable place to minimize noise pollution.
3. Safe Air pipe lines.
4. Air points to be provided near crane pit.
5. A section for tool room for hand power tools, wrenches, electrical instrument, gauges
etc be provided.
11. Electrical Room with Battery charger, Size 4000 X4000 mm:
 For Electrical Equipments maintenance.

 For Battery charging with exhauster.
 Charging point beside the pit for 140 T crane Batteries.
12. Toilet and washing Room, Size 2000 X 4000 mm:
 Proper toilet, wash room for supervisors.

 Toilet and wash room for staff.
 Washing Cleaning Agents in store
13. Cycle Stand, Size 15 m X 7 m:
 With the provision of Shed.

 PCC Floor for vehicles.
 Lighting arrangement for cycle stand
14. Details of Lay out Drawing No. RDSO SK No. CR-833.
 Length of the crane shed for Gottwald & new Cowans sheldon – 35000 mm.
 Length of the crane shed only for Jessop Crane – 45000 mm.
 Translucent sheets should be used for sun light.
 Lighting inside & out side the shed & pits.
 Drainage in the Pits & Shed be prepared.
 Water supply line should be laid.
 Rolling shutter Doors should be provided.
 Location of Crane pit should be as per crane beat.
 04 Nos. Portable platforms with one stair case.
15.Details of Lay out Drawing for ART/SPART/ARME & 140T crane Depot:
 Length of ART Line: Approx. 224 Meters

 Length of SPART/ARME Line: Approx. 120 Meters
 Length of engine reversing line: Approx. 120 Meters
 Length of 140T crane line: Approx. 378 Meters
 Length of maintenance pathways: 04 nos. ( size 120 m x 4m & 60 m x 4m)
 Length of ART Secttion approach Road: As per requirement (4 m wide)
 Length of main approach Road: As per requirement (4 m wide)
 Provision of double exit if possible
 140T Crane prop base for load lifting
 Provision of cycle stand
 Provision of Boundary wall for ART Section.
Room Details Size
01 Supervisors/ Computer 4mX4m
02 Staff room 5mX4m
03 Lifting Tackle 6mX4m
04 Consumable/Store 4mX4m
05 Compressor 4mX4m
06 Electrical (G) 4mX4m
07 Toilet/Washroom 2mX4m
08 Cycle stand 15m X7 m
Drawing No. 01
Room Details Size
01 Supervisors/ Computer 4mX4m
02 Staff room 5mX4m
03 Lifting Tackle 6mX4m
04 Consumable/Store 4mX4m
05 Compressor 4mX4m
06 Electrical (G) 4mX4m
07 Toilet/Washroom 2mX4m
08 Cycle stand 15m X7 m
Drawing No. 02
CHAPTER - 15
High Speed Self Propelled
Accident Relief Train
(HS SPART)
INDEX
01 Introduction 2
02 Technical specification of HS SPART 3
03 Environmental conditions governing HS SPART 3
04 Details of SPART rake with ZF transmission 4
05 Details of SPART rake with VOITH transmission 4
06 Composition details of SPART 5
07 Various lay outs of SPART
A. Lay out of converted SPART 6
B. General lay out of Supervisory Van (with SAN equipments) 7
C. General Layout of Medical Van 8
D. General Lay out of Tool Van ( SAN Equipment ) 9
E. General Lay out of Supervisory Van 10
08 CUMMINS Engine of SPART 16
09 Air Intake arrangement in supervisory & Tool Van 17
10 Exhaust Arrangement in Supervisory & Tool Van 18
11 Water cooling system in Supervisory & Tool Van 19
12 Water raising apparatus system in supervisory van 19
13 Fuel syasten in Supervisory van 20
14 Hydraulic Transmission of HS SPART 21
15 Air Connections of transmission 22
16 Oil filling of turbo transmission 23
17 Operation of turbo transmission 23
18 Maintenance schedule of turbo transmission 24
19 Trouble shooting of turbo transmission 24
20 Spring coupling between engine and transmission 26
21 SAN axle drive gear box 27
22 Wheel & Axle (powered) 27
23 SAN Axle drive : maintenance schedule 29
24 Torque arm 30
25 Cardan shaft 31
26 Recommended oils & Lubrications 35
27 SAN Skid arrangement 34
28 HS SPART – Operation & Electrical system 36
29 Table for position of SPARTs & SPARMVs on IR 45
30 Schedule of standard examination of BG SPART 48
A Daily 52
B Weekly 53
C Half Yearly 55
D Yearly 57
E 2-Yearly 58
F 4-Yearly 59
G 12 Yearly Schedule 64
31 Electrical Schedules 72
INTRODUCTION
As per High level committee recommendation No. 2, committee has recommended that self
propelled ARTs & ARMVs to be bundeled in to a 3-coach train to be called SPART (Self
propelled Accident Relief Train). These were proposed to be deployed @ of one SPART per
division.
HS-SPART is fitted with the world’s best technology power pack to enable rescue equipment
to reach the accident site at faster pace and help speedy rescue and restoration work.
HS-SPART is heavy-duty power car fitted with Twin Power Pack, specially designed for
executing rescue jobs during unfortunate event of Railway accident.
First rake with ZF transmission has been manufactured in 2009. First rake with Voith
transmission has been manufactured in 2012-13. Rake of SPART consists of 3 coaches – one
supervisory van, one tool van and one medical van. Maximum speed of HS SPART is 115
kmph on Rajdhani track (Test speed 130 Kmph).
HS-SPART is a high speed self propelled accident relief train with horizontal under slung
diesel engines and hydraulic transmissions (twin power pack). The train/vehicle consisting of
one Supervisor cum kitchen van – SV (driving power coach I -DPC I), one Medical Van –
MV (trailing coach - TC) and one Tool van –TV (driving power coach II - DPC II). The
vehicle can be operated with single/twin power-packs from any cabin and also there is a
provision of switching off of any power-pack as per operational speed equirement.
The HS – SPART is used for quick mobility to the place of application at high traction speed,
for erection work, accident relief, handling of light loads and for work on permanent ways as
well as breakdown of tracks. Its main feature is its quick mobility to the place of application
at high traction speeds at site.
1. Technical Specification of HS-SPART
Equipment Specification no. : ICF/MD/SPEC-173, Issue status :01, Rev. Status:02

HS SPART Formation : Supervisory cum Kitchen Van (DPC 1) + Medical
Van (TC) +Tool Van (DPC 2)
Engine : Cummins NTA14R under slung Engine 430HPx2no.
Transmission : Voith or ZF
Cardan shaft : Voith or GKG
Axle Drive Gear Box : SAN – two stage / 3.671: 1 or ZF
125 KVA DA set : BHEL EML TA 2810 VS, & CIL 6 BTAA 5.9 G2
Max. Operating speed : 105 km/h (Mainline Track)
115 km/h (Rajdhani Track)
130 km/h for the purpose of testing
2. ENVIRONMENTAL CONDITIONS GOVERNING HS-SPART
i) Ambient temperature : 55 deg. C

ii) Altitude : 0-160 m above mean sea level
iii) Humidity : 100% saturation during rainy season
iv) Rainfall : Very heavy in certain areas. The HS-SPART is
designed to permit its running at 10 km/h with a
flood water level of 178 mm above rail.
v) Atmosphere during hot weather: HS-SPART is designed to operate in Extremely
dusty, Desert terrain in long stretches.
vi) Coastal area : HS-SPART is designed to work in coastal areas in
humid and salt laden atmosphere
vii) Vibration : The equipment, sub-system & their mounting
arrangement are designed to withstand the
vibration and shocks encountered in service.
3. Details of SPART rake with ZF transmission
 Diesel Engine : Cummins NTA 14R

(320 kW @1900 rpm gross Continuous)
 Transmission : ZF FRIEDRICHSHAFEN AG,
GERMANY -6 HP 902 R
 Cardan shaft : M/s GEBRUEDER KEMPF GmbH,
GERMANY –1024.3100.GAO
 Axle Drive : ZF FRIEDRICHSHAFEN AG,
GERMANY -D-SK 16 WD-H
 AVM FOR SKID : TERRELYBORG, UK.
- 17/1550/1 16x5010-00929-02
4. Details of SPART rake with Voith transmission
 Diesel Engine : Cummins NTA 14R

(320 kW @1900 rpm gross Continuous)
 Transmission : VOITH TURBO
TRANSMISSION – T 211 r.3
 Spring Coupling : M/s VOITH TURBO HDSD 400
 Cardan shaft : M/s VOITH TURBO ST 225.7
 Axle Drive : M/s SAN (Two stage, Helical and Bevel)
 Wheel dia : 952mm
4. Compositin details of SPART
4.1 Details of Supervisor Van (DPC):
• Under frame mounted engine and Transmission
• Emergency inflatable lighting tower.
• Inflatable air bag and inflatable tent.
• Supervisor’s room.
• Water cooler with water filter
• Kitchen
• Refrigerator
• Inter vehicle couplers for power from 125 KVA Genset
• Under slung multi purpose boxes.
4.2 Details of Medical Van:
• Doctor’s room, store room with fridge, ward with 12 beds, sterlizer cubicle, Autoclave cubicle
and operation theatre.
• Operation theater has operation table , portable boyle’s apparatus, sink with elbow operated
tap, Racks for drug and dressings, pulse oximeter, surgical tools, surgical apparatus and
surgical trolley.
• Under slung coffins.
• Operation Theater is air conditioned.
• Wards with 12 beds is non AC
• Inter vehicle couplers for power from 125 KVA Gen set.
4.3 Details of Tool Van (DPC):
• Under frame mounted engine and Transmission

• Roof mounted Radiator
• On board 125 kva Generator
• 4 Nos. Flood lights
• Space for rails and engineering materials
• 3 tier rack for electrical and S&T equipments and hydraulic hoses
• Space for wooden packing, Rail cutting and Drilling machine
• Hydraulic rescue Tools
• Bench vice
• Cupboard for measuring instruments
• Foldable Ladder
• Provision for Jacks, foldable ladder, rope bundles, tents, fitter tools, Re-railing hydraulic
equipments, Hydraulic hoses, oxy acetyline gas cylinders & cutting equipments, etc.
Under slung multi purpose box.
5. Various Layout of SPART
5.1 LAYOUT OF CONVERTED SPART

5.2 GENERA LAYOUT OF SUPERVISORY VAN (WITH SAN EQUIPMENTS)

5.3 GENERAL LAYOUT OF MEDICAL VAN

5.4 GENERAL LAYOUT OF TOOL VAN (WITH SAN EQUIPMENT)

5.5 GENERA LAYOUT OF SUPERVISORY VAN

5.6 GENERAL LAYOUT OF MEDICAL VAN

5.8 GENERAL LAYOUT OF TOOL VAN

5.9 EQUIPMENT DETAILS IN SUPERVISOR
VAN

5.10 EQIPMENTS DETAILS IN MEDICAL VAN

5.11 EQIPMENTS DETAILS IN TOOL VAN

6. CUMMINS ENGINE OF SPART
6.1 SPECIFICATIONS :
Four – Stroke Cycle , Turbocharged

In-Line, 6 Cylinder Diesel Engine
 Model : NTA 14R
 Power Rating : 430 hp
 Rated Speed : 1900 rpm
 Displacement : 850 Cu.in
 Oil Capacity : 34 litres (Engine sump)
 Coolant capacity : 21 Litres (Engine only0
 Dry Weight : 1367 Kg
The HS SPART is powered by turbo -charged engine of robust construction to

withstand heavy traction & buffing shock during running operations. The engine shall
have water-cooled liners & heads and oil cooled pistons.
6.2 Maintenance Schedules

 A – Check : Daily
 B – Check : Every 250 hours or 6 months
 C – Check : Every 1500 hours or 1 year
 D – Check : Every 6000 hours or 2 years
7. AIR INTAKE ARRANGEMENT IN SUPERVISORY AND TOOL VAN
Supervisory Van
Tool Van
Air Intake arrangement in HS SPART has following features –
 Heavy duty vertical mounted Air cleaners are provided.

 Air cleaners are positioned inside the coach.
 Air cleaner sucks the fresh air from outside of the coach through a duct mounted
on coach wall.
 Appropriate Piping is routed through the floor to the engine turbo air inlet point.
 Flexible joints are provided in piping to accommodate vibrations.
8. EXHAUST ARRANGEMENT IN SUPERVISORY AND TOOL VAN
9. WATER COOLING SYSTEM IN SUPERVISORY AND TOOL VAN
10. WATER RAISING APPRATUS SYSTEM IN SUPERVISORY AND TOOL VAN
11. FULE SYSTEM IN SUPERVISORY & TOOL VAN AND 125KVA DA SET
12. Hydraulic Transmission of HS SPART
12.1 VOITH TURBO TRANSMISSION
SPECIFICATIONS :
The turbo transmission T 211 r.3transmission T 211 r.3 is designed for installation in rail vehicles
Model : T 211 r.3T 211 r.3
 Max. Input Power : 320 kW320 kW
0
 Operating oil temp : Max 130Max 130 C
 Oil Capacity : 7575 Liters (Initial Fill)
 Dry Weight : 1200200 kg (With Oil & Spring Coupling)
VOITH TURBO TRANSMISSION T211r.3 [ INTERNALS ]
12.2 AIR CONNECTIONAIR CONNECTIONS OF T211r.3 TRANSMISSION
1 Connection to reversing unit direction of ring unit direction of rotation A

2 Connection to reversing unit dirto reversing unit direction of rotation B
3 Control air line to sensor valve sor valve
4 Control air line from sensor valve rom sensor valve
5 Control air line to main control valve control valve
6 Control air line to governControl air line to governor
12.3 Oil Filling to Turbo Transmission
1 Open the seal cover on the oil filler neck.

2 Fill filtered power transmission oil at the oil filler neck until it reaches the maximum mark on
the oil level sight glass.
3 The total oil volume, not including the volume of pipelines and the heat exchanger, is approx.
75 litres.
4 Close the seal cover on oil filler neck.
5 Start the diesel engine and allow to idle for approx. three minutes. The pipelines and the heat
exchanger fill with oil.
6 Stop the diesel engine.
7 Check the oil level at the oil level sight glass within two minutes of stopping the engine.
8 If necessary, top up power transmission oil
12.4 Operation of Turbo Transmission

12.4.1 Starting and Moving Off
1 Make sure that the vehicle is at standstill.

2 Start the diesel engine.
3 Select the direction of travel required.
4 Issue a traction command. Now, The turbo transmission is in traction mode.
12.4.2 Changing the Direction of Travel
1 Withdraw the traction command.
2 Brake the vehicle to a standstill.
3 Select for the direction of travel required.
4 Issue a traction command.
12.5 Maintenance Schedule of T211r.3 Turbo Transmission
Have the specified maintenance work performed by competent personnel in accordance with the
deadlines given. Use only original Voith spare parts. Maintenance tasks may have to be performed
earlier than the time specified.
1 Depending on which is reached first.

2 Driving hours are the sum of all operating hours with a vehicle speed greater than 1 km/h.
At regular intervals, ideally on a daily basis, check to ensure that the turbo transmission contains
the specified amount of power transmission fluid. If necessary, top up the power transmission oil
with the same oil grade.
12.6 Trouble Shooting of T211r.3 Turbo Transmission

Possible Malfunctions
1 Malfunction of the reversing gear
2 No or insufficient traction
3 Malfunctions during shifting of gears
4 Oil too hot
A. Malfunction of the reversing gear
Causes :
1 No control air from “vehicle control system” in line 618 to sensor valve.
2 Sensor valve sticky.
3 Limit switch in sensor valve defective
4 Control air line for main control valve is not vented.
Solution :
1 Check for air supply & correct the same.
2 Remove sensor valve and enable piston to run freely.
3 Remove cover of reversing unit and Check limit switch.
4 Vent the air line of main control valve.
B. No or insufficient traction
Causes :
1 Not enough oil in transmission.
2 Oil too cold.
3 Incorrect oil grade or exhausted oil
4 Water in the oil or Filter clogged with oil emulsion.
5 No control pressure in line of main control valve
6 Engine does not reach full load speed.
7 Limit switch defective
8 No or too low filler pump pressure
9 Main control valve control piston blocked
Solution :
1 Check oil level.
2 Brake vehicle and move master controller several times between driving and idling settings
until oil reaches operating temperature.
3 Change oil.
4 Check heat exchanger for leaks, seal if necessary. Change oil and Change filter
5 Correct the malfunction on the vehicle
6 Correct the fault on the engine
7 Remove cover of reversing unit and Check limit switch
8 Dismantle pressure relief valve and check
9 Remove main control piston and check
C. Malfunctions during shifting of gears

Causes :
1 Governor does not switch to 2nd gear. Control pin in governor blocked.
2 Main control piston or pilot control piston blocked.
3 Engine does not reach full load speed.
4 No or too low control pressure, main control piston 411 does not switch to position for 2nd
gear.
5 Control pump defective
Solution :
1 Remove governor and enable control pin to run freely.
2 Remove main control piston and pilot control piston & check.
3 Correct the fault on the engine.
4 Check control pressure & correct.
5 If there is no pressure, remove pumps and check.
D. Oil too Hot

Causes :
1 Residues in heat exchanger.
2 Intake filter or pressure filter choked.
3 Governor does not switch to 2nd gear. Control pin in governor blocked.
Solution :
1 Clean interior of heat exchanger.
2 Remove and clean intake filter and pressure filter.
3 Remove governor and enable control pin to run freely.
13. SPRING COUPLING BETWEEN ENGINE AND TRANSMISSION
The Spring Coupling is a resilient coupling that transmits the torque from the engine to the
transmission.
Make : VOITH TURBO

Model : HDSD 400
 Suitable for direct mounted transmissions with engine
 Easy to couple / slide over on to the transmission input shaft
 Pre-oil filled
14. SAN AXLE DRIVE G E A R B O X
The final drives consists of high quality cast steel housings which are precision machined. The gears
and shafts are manufactured out of superior quality alloy steel (carburised, hardened and ground)
and are supported by antifriction bearings of adequate capacity & assembled in to the housings.
The gears & bearings are force lubricated. The lubricating pump is driven by the bevel pinion shaft.
The final drive is an axle mounted gear box with reaction member fastened to bogie frame.
 Weight of axle drive with axle and wheels including oil : 2350 Kg.
 Sump capacity : Approx. 25 Ltrs
 Type of Oil : EP 90 or HP 90
14.1 SAN AXLE DRIVE – TECHNICAL DATA
WHEEL & AXLE (POWERED)
Wheel used for the car is of 952 mm diameter. The axle is mounted with Bevel gear of Final drive
through oil injection fit. Axle is so machined for the oil injection fit with the wheel and bearings of
final drive and axle box. Two powered axles are used in the car.
TECHNICAL DATA :
1. Material : As per IRS specification R 43-92
2. Total length : 2362 +0.5 mm -0.0 mm
3. Centre distance between bearings axle box : 2210 ±0.5 mm
4. Capacity : 17.5t
5. Axle weight : 505 Kgs.
6. Qty per power pack : 1 No.
Internals of Axle Drive Gear Box
14.2 SAN AXLE DRIVE : MAINTENANCE SCHEDULE
15. TORQUE ARM
Torque arm is a member which holds the final drive on the axle and the material confirms to steel
IS:2004 Class 3. One end of torque arm is fixed to the final drive through the pin and the other end is
fixed to the brackets which is a welded structure of bogie frame.
Torque Arm Section View
Torque arm assembly mainly consists of torque arm, spherical joint, spring disc and locating pin.
Torque arm is a member which holds the final drive on the axle and the material confirms to steel
IS:2004 Class 3. One end of torque arm is fixed to the final drive through the pin and the other end
is fixed to the brackets which is a welded structure of bogie frame.
Spherical joint comprises of ball joint swivels in the ball housing which in turn takes care the
swiveling movement of final drive with respect to the axle centre during the running of car. Ball
housing held by circlips at one end of the torque arm.
Spring disc held between end plates is of rubber material which absorbs the dampness developed.
Pre-compression of spring disc to be maintained for the specified value by tightening the castle nut at
the end of torque arm.
MAINTENANCE INSTRUCTIONS :
 Check the tightness & locking of fasteners.

 Lubrication of spherical joint to be done as and when required.
 Spring disc to be checked physically, if found damaged replace it.
 Pre-compression of spring disc to be maintained for the specified value by tightening
the castle nut at one end of torque arm
 Spherical joint and bushes are checked for wear.
 Circlips and split pins if failed, replace them.
16. CARDAN SHAFT (Voith St 225.7)
1 M16 Bolts
2 Connection flange – Output of Transmission
3 Universal joint shaft flange
4 Lubrication nipple
5 Profile protection
6 Plug screw
7 Arrow marks
8 Connection flange
IMPORTANT :
1 Please check the alignment of the forks. e alignment of the forks.

2 The arrow marks (->) and point markings must line up) and point markings must line up. The
sliding sections are pThe sliding sections are paired and should not be mixed up. e mixed up.
3 Tighten bolts (1) to tightening toto tightening torque specified
4 Lubricate the shaft with the lubricating nipple aft with the lubricating nipple before the putting
the vehicle before the putting the vehicle into operation.
LUBRICATION :
Lubricate Sliding Section
Grease each sliding section on the univer ing section on the universal joint shafts with a maximum of
40 gm of aximum of 40 gm of grease
.
Due to existing axle forces, press in lubricant to xle forces, press in lubricant to a maximum of 15 bar.
Lubricating points on the joints
• Grease each joint via a lubricating nipple unt int via a lubricating nipple until the lubricant
visibly escap il the lubricant visibly escapes at all four sealing lips.
MAINTENANCE
Interval Activity
Once after 500 diesel engine-operating • Lubricate joints • Check screw connections
hours after taking into operation -into and connecting Flanges Check screw
operation connections and
• Lubricate joints • Inspect universal joint
Every 1250 diesel engine-operating hours
shaft visuallyInspect universal joint shaft
or every 3 months operating
visually
Every 5000 diesel engine-operating hours • Lubricate joints • Inspect screws & flanges •
or every 12 months operating Inspect universal joint shaft visually •
Lubricate sliding section flanges Inspect
universal joint shaft visually Lubricate sliding
section
Every 30,000 diesel engine- • Change the universal jointChange the
operatingoperating hours universal joint shaft
TROUBLE SHOOTING :
1 Strong Vibrations, Unusual Running Noises
Cause Remedy
Insufficient radial or lateral run-out of the Remove universal joint shaft and check
mounting flanges concentricity and thrust accuracy.
Worn sliding section Replace the cardan shaft
Loose flanged fitting Retighten screws to specified tightening

torque
Imbalance Remove and rebalance universal joint shaft
2 High Temperature in the Area around the Joint
Cause Remedy
1. Remove universal joint shaft and replace cross link
assembly.
Bearing damage
2. Rebalance universal joint shaft
17. SAN SKID ARRANGEMENT
18. Recommended Oils and Lubrication
19. HS-SPART – Operation & Electrical System
19.1 GENERAL DESCRIPTION
HS-SPART is a high speed self propelled accident relief train with horizontal under slung diesel
engines and hydraulic transmissions (twin power pack). The train/vehicle consisting of one
Supervisor cum kitchen van – SV (driving power coach I -DPC I), one Medical Van – MV (trailing
coach - TC) and one Tool van -TV (driving power coach II - DPC II). The vehicle can be operated
with single/twin power-packs from any cabin and also there is a provision of switching off of any
power-pack as per operational speed requirement.
19.2 TRACTION POWER PACK
HS-SPART Electrical Control system is designed to control simultaneously two identical under slung
Diesel Hydraulic Traction Power Packs for high speed operation. The system is provided with two
control desks, at each end of supervisor van and tool van cabins. The HS-SPART is three-car
formation / unit [Supervisor Van (SV), Medical Van(MV) and Tool Van(TV)] with its both power
packs mounted under-slung of Supervisor Van and tool van. The car with one diesel hydraulic
traction power pack & 125 KVA DA set is known as Supervisor van and other diesel hydraulic
traction power pack & 125 KVA DA set is known as tool van. These cars also houses total control
system over board in a console referred as control cubicle and is located behind driver’s desk in the
driver cabin of Supervisor Van and tool van. The control cubicle in the supervisor van’s, drives cabin
houses controls for Drive function, Circuit Breakers and operates in conjunction with driver desk and
similarly in tool van.
The controls are provided for operation of HS-SPART with single/twin power-packs including 125
KVA DA set controls, controlled from driver’s cab of either Supervisor Van/Tool Van.
Its diesel-electric drive allows a condition readiness for operation and the operation by means of
supply of electric power for control and auxiliary equipment at accident site.
Each of the two power cars of HS-SPART is powered by one no. under floor mounted horizontal
diesel engine transmitting power to one no. of under slung hydraulic transmission through torsionally
flexible couplings and Cardan shafts. From transmissions, drive is taken to one end drive gear box
mounted on inner axle of bogie through Cardan shaft connections.
The Driver Desk consists of Master Controller, (Throttle, Forward/Reverse selection and dead man’s
control) driver control switch, guard control switch, push button switches for remote operation of
traction and 125KVA DA SET, all pneumatic gauges, brake valves, indication lamps, horn and wiper
controls.
The control cubicle and driver desk are two separate independent units. These two units are
electrically coupled inside the coach through multiples of 19 core cable with plug-in type Wago
connectors. Also these two units are electrically interfaced with external circuit like Traction engine,
125KVA DA SET, Transmission, water raising apparatus, etc.
The total electrical scheme uses different voltage system viz., 24VDC, 110VDC, 110VAC, 230VAC
and 415VAC nominal. Engine control system and Engine & Transmission monitoring gauges are
powered with 24VDC. Rest of control scheme including drive controls are powered with 110VDC,
110VAC, 230VAC and 415VAC. The starting of the engine is by means of an axial throw type of
electrical starter motor.
All Controls, Auxiliary and power cable conductors are of copper with adequate current carrying
capacity used in sizes of 1.5 Sq mm, 2.5 Sq mm, 4 Sq mm ,6 Sq mm, 10 Sq mm ,25 Sq mm, 35 Sq
mm , 50 Sq mm and 70 Sq mm They are thin walled Electron beam irradiated flexible elastomeric
type cables.
All branches of the circuit are protected by Circuit breakers of Thermal over loadtype and fuses,
which protect the system under fault conditions.
Driver & Guard controls of either end Driver Cabins utilize single set of three different keys to
operate 1) Master Controller (MC) 2) Driver Control Switch (DCS) 3) Guard Control Switch
(GCS)These keys are located on Driver desks of both Supervisor Van and Tool van.Master Controller
& Driver Control Switch Keys are handled by the Driver and Guard Control switch key handled by
the Guard. It is very important that only one set ofabove said three keys should be given to Driver &
Guard for the entire formation of HS SPART. Adequate facilities are provided for easy access,
maintenance and replacement of the Electrical Control equipment.
For safe and satisfactory operation of HS SPART, adequate controls are providedincluding Gauges,
Indicating lamps and safety devices in the driver’s cabin and soarranged within easy reach and sight
of the driver. It is essentially made that the vehicle is self protective in operation and hence are
provided with certain protectivesafety devices to protect the traction engine, transmission and 125
KVA DA set against operational hazards. More emphasis is on the ergonomical & fail-safe method of
Design adopted in the control circuit. The circuit caters sufficient & essential interlocks, which makes
the system more stable.
Note : When the vehicle is parked, both 110 V and 24 V Battery source should beisolated by means
of separate Rotary switches and knife switches on the Control cubicle and Driver desk of Supervisor
& Tool van.
19.3 SUPERVISOR VAN AND TOOL VAN
The traction diesel engines of horizontal under slung version are of proven design and are of
Cummins NTA 14R make which are fitted with individual throttling module known as Multiple Unit
Throttle Control (MUTC). The MUTC is a bank of 4 electrical solenoid valves and each solenoid
valve when powered with 24VDC opens a calibrated orifice, to give a metered quantity of fuel to the
engine. Thus these solenoid valves when operated in specific combination and order will regulate
engines to deliver corresponding power. Also, the diesel engine comes with major accessories such
as starter motor, main fuel solenoid, 24VDC alternator, water pump, hydraulic pump, gauges &
sensors and safety switches.
The continuous rated output of diesel engine is 430hp under environmental conditions and continuous
Tractive effort available at various speeds under adverse climatic conditions. The diesel engine is
provided with flywheel mounted flexible couplings of adequate capacity to withstand high deflection
and torque (at starting, stopping and due to any misfiring of the cylinders) so that no damage is
caused to transmission and engine components in service. Engine driven alternator of adequate
capacity is provided with inbuilt charger for charging the 24V starter battery.
19.4 125 KVA DA SET
The electrical installation of the vehicle is supplied with power by means of a diesel alternator set
(DA SET). The three-phase alternating current is generated by DA set which consist of a Diesel
engine and an alternator which is accommodated in the rear side of the Control cubicle. All control
devices are accommodated in the driver’s cab and are arranged, so that they can be reached from the
driver’s seat in accordance with importance. In the control cubicle the remote-controlled switching
devices (fuses, circuit breaker, timers, pcc1302, contactors, overload relays etc) are mounted.
The Supervisor van and Tool van of vehicles are provided on board with a 125KVA DA set in each
van.
Both the DA set is required to work at an accident site and controls are accordingly provided so that
these can be worked independently or as a combined unit.
Two Nos. of 125KVA DA Set with necessary control panel (integrated into the Traction Control
cubicle, to conserve space) and control features to facilitate working of either of the DA Set for the
requirement of propulsion and other controls during movement and at the accident site.
The 415V, 3 phase power supply from the 125KVA DA set (situated in Supervisory van and Tool
van) will be taken to the three coaches through inter vehicular power couplers for power supply to the
loads in the respective coaches.
The input power supply to the air compressor, traction engine cooling fan (Roof Mounted Radiator),
water Raising Apparatus and RMPU is 3 phase 415 V ac supply and other electrical loads.
The Diesel engine is a series-manufactured six-cylinder four-stroke Diesel engine having an engine
performance of 154HP @ 1500 RPM.
The nominal rating of the generator is 125kVA @ 1500 RPM

The three-phase alternator output is adjusted to generate and regulate voltage of 415v +/- 15v at a
Frequency of 50 Hz.
An electrical starter is installed for starting the Diesel engine of diesel alternator set. The starter is fed
by two batteries 12V, 120Ah connected in series.
All the lights & fans are rated for 1 ph, 110 VAC. The 3 ph, 415 VAC output of DA Set is stepped
down to 1 ph, 110 VAC through a 3 KVA step down transformer.
110V, 120 Ah battery low maintenance lead acid storage batteries are used for control systems and
emergency lights and fans.
For charging the 110V, 120 Ah batteries, a 415V ac input /110V dc output, battery charger will be
provided in Supervisor Van and Tool Van.
For charging the 24V, 290 Ah batteries, a 230V ac input /24V dc output battery charger will be
provided in Medical Van.
19.4 OPERATIONS OF 125KVA DA SET

The 125KVA DA set operations and control panel is provided inside the driver’s cab of Supervisory
van, Medical van and Tool van integrated with control cubicle.
Each DA set is provided with independent MCCB with suitable protection arrangement and
facilitated for feeding power supply to coach loads as well as external loads.
In the three car formation, power supply for all coach as well as external load is distributed through
two feeders. Hence, both 125KVA DA sets provided in supervisory van and tool van is provided with
two feeder contactors feeder-1 & feeder-2.
Power supply for external loads is possible to feed from any one of the feeders in the event of
operation of any one of the 125KVA DA set.
Main contactor of any one of the alternator in the train formation is possible to switch “ON” from any
of the cabs. Alternator output is provided with Alternator earth leakage relay, fuses, MCCB, current
transformer and core balanced current transformer, etc.
An interlock is provided in such a way that main traction engine can be started only when 125 KVA
DA set power supply is available on feeders in order to ensure the power supply availability for main
traction radiator motors.
Whenever one feeder supply is used for coach load the other feeder can be madeavailable for external
loads in the event of accident at site.
Power supply on feeders is tripped in the event of de-coupling of inter-vehiclecoupler.
An exclusive contactor is provided for feeding power supply directly from a particular125KVA DA
set for external loads in both supervisory van and tool van.
Feeder-1 & Feeder-2 is protected against over load and earth leakage. Feeder selection/external
power feed is possible from any one of the driver’s cab.
A dedicated termination arrangement is provided in the bottom row of the control cubicle for feeding
power supply to internal and external loads.
All electrically operated motors are protected with MPCB with suitable contactors and the same are
inside the control cubicle.
Triple pole MCB’s suitable for 415v three phase operation is provided for the following equipments.
1) Kitchen loads.2) Lighting transformer (for primary and secondary) 3) Flood lights.4) Battery
charger for control battery & battery charger for starter battery.5) Accident relief machineries.
The control panel (for supervisory van & tool van) also consists of MCB’s, relay and rotary switches
for distribution of power supply to lights and fans.
An interlock is provided in such a way that the main radiator motor for the traction engine is switched
‘on’ automatically whenever the main traction engine is started,for which availability of feeder
supply is provided through a suitable feeder provingrelay.
Manual / auto start / stop control is provided for all the electrically operated motors.
The starting of 125 KVA DA set in supervisory van and tool van are possible in any of the driving
cabs.
125 KVA DA set diagnostic panels (HMI of PCC1302) are provided inside control cubicle of the
driver’s cab as an integrated part.
MCB’s and toggle switches for all lights and fans are in the driver’s cab. Also, all controls of exterior
lights like headlight, taillight, marker light, flasher light etc., are in the Driver Desk.
Signal bell and emergency bell (electrical type) is provided on the control cubicle.
19.5 OVERVIEW OF PCC1302 of DA SET
The PCC 1302 is a microprocessor based controller for DG set consisting of monitoring, metering
and control system. The control provides a simple operator interface to the genset’s digital voltage
regulation, engine speed control, and protective functions.
The control is designed for mounting on the generator set. The PCC1302 series control is usually
powered from the generator set starting batteries and works over a voltage range from 8 to 30VDC
and is designed for connection of a 24VDC control system.
The PCC1302 genset control kit includes the PCC1302 control board (12 / 24V control assembly
with run and start drivers) and the operator panel. An operator panel can be used as a user interface.
For more details refer manufacturer’s operation manual.
19.6 EXTERNAL POWER OUTPUT SUPPLY
During stationary operation, feeding to the electrical installation is provided from the local network
via terminal connector along side the superstructure.NOTE: Voltage 415V three-phase current,
frequency 50 Hz.
The diesel set can also be employed as an emergency generator set in order to use power-operated
machines at the place of application such as welding machines, drilling and boring machines, and to
illuminate the site, if required. All connectors can be used at the same time, each circuit being capable
for full load operation. The total output power supply is designed for 125KVA maximum. The
control operation of traction duty can not be used when both DA sets are used independently at site.
19.7 CONTROL CUBICLE

Control Cubicle consists of 125KVA DA SET controls, Traction Controls, Feeder Change-over
controls, switches of Fans & Lights of cabin. All Indication Lamps and monitoring controls like,
Meters, Gauges and also HMI of PCC1302 of 125KVA DA SET is provided on the control cubicle.
All Relays & Timers, Circuit Breakers & Fuses, Rotary switches, Gauges & Meters, Power &
Control diodes, Bells, Hand lamp socket, power contactors for switching light and fan circuits, Power
switches for 24VDC, 110VDC, 110VAC, 230VAC and 415VAC selection and other minor
equipments are housed in Control cubicle of Supervisory Van and Tool Van.
A set of CB’s in Control Cubicle is provided for the protection of cab lights, cab fans, head & tail
lights, front flasher light.
19.8 DRIVER DESK
All traction related Indication lamps, Driver Control Switch, Master Controller, Pneumatic Brake
Valves with Gauges, Fault indicating Flasher lamp & Hooter, Push buttons, Hand lamp socket,
Rotary switches, Electrical & Pneumatic Switch controls, DC-DC Converter for Head Light & Front
Flasher Unit, Pressure switches & Magnet Valves for Brake control are housed in Driver desk of
Supervisor Van and Tool Van.
Speed Recorder cum Indicator is provided inside Driver cab of Supervisor Van and Tool Van for
recording and indicating actual speed, time and distance traveled by the vehicle.
An electrical signal bell system is provided between driver’s cab on Control cubicle consisting of
single stroke bell & two push buttons on either side of Driver desk in each driving cabs for
communication between Driver and Guard of either DPC coaches. In addition to signal bell, an
emergency bell is also provided in the same location with one push button on Driver desk of each
driving cabs for interchanging signal in case of any emergency communication. This Emergency
alarm system is also provided with external indication lamp one on each Control Cubicle of each
driving cabs of each coach.
Both the DPC I & II are provided with standard railway head lights at both ends of the vehicle. Each
head light unit has two lamps. The input to these lamps is given from a DC-DC Converter mounted
inside Driver desk, which operates on 110 Volts DC input and gives 24 Volts DC output. Controls for
respective Head Lights are provided on either side of the vehicle through switches on the Driver desk
respectively. It can also be controlled for Bright and Dim features.
The tail lights and marker lights for vehicle are provided at both ends of unit. Each tail light and
marker light unit has two lamps. The input of the lamps are directly controlled by 110 Volts DC
through respective tail light and marker light Switches, which are provided on either side of the unit
in the Driver desks respectively.
One Flasher Light is mounted on each end of the unit. The flashing action is obtained from an
Electronic Flashing Unit mounted inside the Driver desk. The input to flasher unit is 110 Volts DC.
The flasher output is a 24 Volts DC pulsed output, which causes the flashing action.
Traction engine radiators are mounted on the roof top of Supervisor Van and Tool Van. The fans of
these radiators are electrically driven. A water pump is mounted in under slung of Supervisor Van
and Tool Van to fill water for Engine Radiators. This is provided to avoid cumbersome action of
operator climbing over the car and 25kV high voltage hazard of overhead traction electrification.
The pump can be switched on by a “Water pump start / stop push button” provided either side near
the Transmission Valve panel under slung of the transmission and also on the control cubicle. Refer
mechanical section for more details of this equipment under subheading - “Water raising apparatus”.
24V, 290 Ah and 24V, 120 Ah low maintenance lead acid storage batteries are provided for the
purpose of traction engine and 125KVA DA set starting respectively.
19.9 CONTROL AND INSTRUMENTATION

Adequate control equipment including gauges, instruments, and safety devices for safe & satisfactory
operation of the vehicle are provided taking utmost care in interlock and safeties. The equipment and
controls are arranged in driving cab that they facilitate easy access for operation and maintenance,
interlocks are provided such that vehicle can be operated from one DPC only at a time. While the
starting and shutting-off of individual engine can be done from each driving power car normally, the
driver should be able to start the engines one by one and shutdown all the engines. Power on-off
indication for each power pack is provided on driver’s desk of each driving cab.
The equipment of the control of the main transmission is operated remotely on the multiple unit
system. The control circuits are permit operation of trains of maximum three coach comprising two
Driving Power Coaches and the master controller in any driving compartment.
Control gears of all apparatus and connections are necessary for the safe efficient operation of trains
of the equipment in the multiple units.
An alternative source of the supply for controls and emergency lighting in the event of supply failure
and for their automatic switching in the case of failure from battery is provided.
Protection and isolation of all control and auxiliary circuits are by means of circuit breakers and
manually operated isolating switch fuse units.
All control equipments like relay, magnet valves, solenoid contactor and MCB’s are segregated
according to different voltage in control cubicle behind the driver seat.
19.9 JUMPERS AND COUPLERS
The train lines on each coach are connected to five 19 pin inter-vehicle electrical couplers designated
as A, B, C, D & E at each end through jumper cables and sockets arranged so that train units are
coupled electrically.
19.10 CONTROL AND AUXILIARY CIRCUITS

All circuits are protected by fuses and circuit breakers of appropriate ratings and type.
19.11 INDICATION LIGHTS

Indication lights of high intensity “LED” type are provided in the driving cabs of each driving power
car and built in redundancy, in case of failure of one LED, the indication is still available.
19.12 HEAD LIGHTS

The HS SPART is fitted with two headlights in the front, and two in the rear. The head light unit of
each has provision of two filaments. The main filament is 100W and other is 90W which operates on
24V D.C. The input to this lamp is given through a DC-DC converter which operates on 110 V DC
and gives 24 V DC output.
19.13 TAIL LIGHT AND MARKER LIGHT

One marker lamp and one tail lamp are mounted in the same unit with proper isolation. Two such
units are mounted on each end of the car. The lamp holders and terminal blocks for termination are
provided inside the unit.
19.14 FLASHER LIGHT

One flasher light is mounted externally on each end of the cabin. The flashing action is obtained from
an electronic flasher unit mounted under the driver’s Desk. The flasher O/P is a 24V pulsed output
which causes the flashing action. The input to the flasher unit is 110VDC. The lamp unit contains
bulb with holder along with one spare lamp provided inside the lamp unit itself.
19.15 COMPRESSOR UNIT

1. The compressor unit is accommodated in the superstructure (under slung) and is driven by a
three-phase squirrel-cage motor. The compressor unit is switched ON and OFF through a differential
pressure governor switch.
20. Statement showing position of SPART & SPARMV over Indian Railways.
Railways Divisions Location & Location & Total 02 Coach/

Type (SPART) Type (SPART + 03 Coach
(SPARMV) SPARMV)
Mumbai -- Kalyan 1 02 Coach
CENTRAL Pune Pune -- 1 03 Coach
Sholapur Sholapur -- 1 03 Coach
Bhusawal Bhusawal -- 1 03 Coach
Nagpur -- Amla 1 03 Coach
Total 03 2 05
Howrah Burdwan -- 1 02 Coach
EASTERN Asansol Asansol -- 1 03 Coach
Malda Town Jamalpur -- 1 03 Coach
Sealdah Beliaghata -- 1 02 Coach
Total 4 0 4
NORTHERN Delhi Delhi -- 1 03 Coach
AmbalA -- Sharanpur 1 02 Coach
Ferojpur Budgam -- 1 02 Coach
Moradabad Moradabad -- 1 03 Coach
Lucknow Lucknow -- 1 03 Coach
Total 4 1 5
Lucknow Lucknow Gorakhpur 2 03 Coach
North (LKO)
Eastern 02 Caoch
(GKP)
Varanasi Manduadih -- 1 02 Coach
Izzatnagar Lal Kuan -- 1 03 Coach
Total 3 1 4
Katihar -- -- --
NORTHEAS Rangia Rangia -- 1 03 Coach
T Lumding -- Guhawati 1 02 Coach
FRONTIER Tinsukia -- -- --
Alipurduwar Alipurduwar -- 1 03 Coach
Total 2 1 3
Chennai Chennai central -- 1 03 Coach
Madurai -- -- --
SOUTHERN Salem -- -- --
Tiruchirapalli -- -- --
Palghat Shoranur -- 1 03 Coach
Trivendrum -- -- --
Total 2 0 2
Railways Divisions Location & Location & Total (SPART 02 Coach/
Type Type + SPARMV) 03 Coach
(SPART) (SPARMV)
Secunderaba Secunderabad Secunderabad 2 03 Coach
SOUTH d (SPART)
CENTRAL 02 Coach
(SPARMV)
Guntakal -- -- --
Nanded Nanded -- 1 03 Coach
Vijaywada Vijaywada -- 1 03 Coach
Hyderabad -- -- --
Guntur -- -- --
Total 3 1 4
Adra -- -- --
SOUTH Chakradharp Chakradharp -- 1 03 Coach
EASTERN ur ur
Kharagpur -- Kharagpur 1 03 Coach
Ranchi -- -- --
Total 1 1 2
Mumbai Bandra -- 1 03 Coach
Ratlam -- -- --
WESTERN Rajkot -- -- --
Ahemdabad Ahemdabad -- 1 03 Coach
Varodara -- Varodara 1 03 Coach
Bhavnagar -- -- --
Total 2 1 3
Dhanbad -- -- --
EAST Danapur Danapur -- 1 03 Coach
CENTRAL Mughalsarai -- Mughalsarai 1 03 Coach
Samastipur -- -- --
Sonepur Sonepur -- 1 03 Coach
Total 2 1 3
Khurda Road Khurda road -- 1 03 Coach
EAST Sambhalpur Sambalpur -- 1 03 Coach
COAST Waltair Waltair -- 1 03 Coach
3 0 3
NORTH Allahabad -- Allahabad 1 02 Coach

CENTRAL
Jhansi Bhanda , -- 2 02 Caoch (Banda)
03 Coach
Gwalior (GWL)
Agra Mathura -- 1 03 Coach
Total 3 1 4
Jaipur -- Jaipur 1 03 Coach
NORTH Ajmer Udaypur -- 1 03 Coach
WESTERN Jodhpur -- -- --
Bikaner -- -- --
1 1 2
Railways Divisions Location & Location & Total (SPART + 02 Coach/
Type Type SPARMV) 03 Coach
(SPART) (SPARMV)
Bilaspur Bilaspur -- 1 03 Coach
SOUTHEAS- Raipur -- -- --
T CENTRAL Nagpur Gondia -- 1 03 Coach
Total 2 0 2
SOUTH Hubli -- -- --
WESTERN Banglore -- -- --
Mysore Mysore -- 1 03 Coach
1 0 1
WEST Jabalpur -- -- --
CENTRAL Bhopal Guna -- 1 03 Coach
Kota -- -- --
Total 1 0 1
G. Total Total Division 37 11 48 02 Coach (11
= 68 Nos.)
03 Coach (37
Nos.)
SCHEDULE OF STANDARD EXAMINATION OF BG SPART
{RDSO Document No. MP – MISC. - 147 (REV. – 0.00)}
1. Introduction :
The schedule for examination and maintenance of SPART/SPARMV has been prepared
taking into account the recommendation of OEM and suitably modified based on feedback
received from SPART/SPARMV users.
The service periods of SPART/SPARMV specified in this schedule for maintenance

attention are the maximum allowable periods between successive examinations. Variations 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/DME, who alone is authorised to
introduce any change in the standard examination detailed herein. Sr.DME/DME in all such
cases, will bring to the notice of the Motive Power Directorate of RDSO &
ED/CAMTECH, for any modification to the schedules, giving full details.
2. References :
The following documents are also required to be referred for further information.
i) Operation and Maintenance Manual, Bulletin No. 3243773-05 (December, 2003),
Cummins India Limited.
ii) DHMU : Operation and Maintenance Manual for Power Packs/ Controls ( Issue No.2 )
issued by M/s KPC, Pune, No. 2723000070.
iii) Operating Instruction for VOITH – turbo Transmission model T211rz issued by M/s
KPC, Pune, No. 272300006400.
iv) Instruction and Maintenance Manual for Kirloskar – Axle drive V 17 (M) issued by
M/s KPC, Pune, No. 2723000069.
v) Instruction and Maintenance Manual for Compressor 2EC38 No. 272100046100.
vi) INDIAN RAILWAYS: Maintenance Manual for BG Coaches, December (1995)
issued by IRCAMTECH,Gwalior.
vii) Maintenance Manual for AC/DC EMU & MEMU Bogie and Under gear Manual No.
CMI-K001(April,2000) issued by RDSO.
3. Scope of Maintenance Schedule:
This booklet covers maintenance schedule for different assemblies & components under
different heads, as under:
PART – I : Engine, Brake, Compressor, etc. of SPART/SPARMV

PART – II : Electrics & control of SPART/SPARMV.
PART– III : Hydraulic transmission, Axle drives gearbox, Cardan shaft and other
accessories of SPART/SPARMV.
PART – IV : Schedule of Coach body, Under frame, Bogie of SPART/SPARMV.
4. Periodicity of maintenance of CIL engine, Electrics & Controls, Brake equipments:
i) Daily Schedule. - Daily
ii) Weekly Schedule - Weekly
iii) Half-yearly Schedule. - 6 months ± 5 days
iv) Yearly Schedule - 12 months ± 7 days
V) 2 - Yearly Schedule. - 24 months ± 7 days.
VI) 4 - Yearly Schedule (D-check) - 48 months ± 7 days.
VI) E-check - 12 years on condition basis
5. Type and periodicity of schedules of Coach body, Under frame, Bogie assembly, Brake
rigging:
i) Weekly . - 7 days
ii) Schedule ‘A’ - 1 month ± 3 days
iii) Schedule ‘B’ - 3 months ± 7 days.
iv) IOH - 24 months ± 15 days.
v) POH - 48 months ± 15 days.
6. Schedules of Periodical Overhauling(POH)of Major Items :
i) CIL Engine : 12 years on condition basis

ii) Compressor : 4 years
iii) Hydraulic Transmission : 12 years
iv) Axle Drive Gear Box : 12 years
v) Coach body & Under-gear : 48 months
7. Based on the recommendations of OEM, the periodicity of change of filters and oil in
various systems of SPART/SPARMV are summarised below for information.
Schedule Periodicity
Description Daily weekly Half Yearly 2- 4-Yearly
yearly Yearly
Engine
Oil change - -  - -
L.O Filter change - -  - -
L.O by-pass Filter change 
Fuel filter change - -  - -
Cooling System
Hydraulic oil change - - -  - -
Filter change - - -  - -
Transmission
Oil change - - - -  -
Filters change - - - - 
Axle drive
Oil change - - - *- -
* First oil change after 50 hours of operation, and there after in every 2 yearly shecdule.
7.1 Recommended Lubricants for Engine lube oil:
S.No Name of Manufacturer Brand name

1. Indian Oil Corporation SERVO-PREMIUM CF4 15W40
2. Hindustan Petroleum Corporation Hylube Milcy Power
3 Bharat Petroleum Corporation MAKCF4-15W40
4. Valvoline Cummins Limited Valvoline Power Supreme 15 W40
7.2 Recommended Hydraulic oils for cooling system of CIL engine.
IOC - Servo System – 68

HP - Enklo – 68
BP - Hydrol – 68
7.3 Cleaning of Hydraulic oil :
Hydraulic oil is required to be periodically cleaned by Centrifuge Cleaning arrangement.

During oil change and also during top-up, oil should be added through Centrifuge Cleaning
arrangement so that cleanliness of oil is maintained.
7.4 High speed Diesel:
The high speed diesel oil shall be to IS 1460: 1995 read with Amendment 2 (February’1999)
8. Recommended Transmission oil & ADGB oil, used in SPART/SPARMV
8.1 Transmission Oil:

Supplier Brand Name
IOC SERVO TORQUE 10
8.2 Axle Drive Gear Box (ADGB) oil :

Supplier Brand Name
IOC Survogear HP-90
BPC Bharat spiral EP - 90
HPC HP Gear oil EP - 90
9. Recommended oils for coaches of DPC, DTC :
9.1 Dashpot oil
Supplier Brand Name

IOC Servoline 100
BPC Bharat Univol -100
HPC Yantrol - 100
10. General Instructions :
10.1 The intensive utilisation of the SPART/SPARMVs necessiates properly laid down
maintenance schedules to be followed. A well organised inspection is essential to ensure
reliability and freedom from failure in service.
10.2 There are certain fundamental requirements that are important to any successful maintenance
programme. These are:-
.1 Adequate provision of well trained supervisors and skilled workmen.
.2 Adequate provision of proper maintenance facilities and tools.
.3 Adequate time for scheduled maintenance work to be completed properly before a

SPART/SPARMV is released for its next trip.
.4 Provision of lubricating oil, water treatment etc. required to ensure satisfactory engine
performance.
.5 A well scheduled maintenance programme including an adequate system of

maintenance of records.
.6 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, set screws etc. must be tightened. Where ever 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, where ever provided,
are properly secured.
.7 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.
.8 All tools and parts should be accounted for and removed from the SPART/SPARMV
after any maintenance work has been performed.
.9 All work done including methods and tools used must be in accordance with the
manufacturers instructions, maintenance manual or any technical orders issued.
.10 Do not mix different brands of greases. Excessive lubrication is as harmful as
inadequate lubrication.
.11 Use of waste cotton on SPART/SPARMV 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. Interior of cab, all windows, head/light and warning light lenses and interior
of the passenger compartment etc., must be thoroughly cleaned.
.12 The fire extinguishers should be refilled and maintained as per the schedule. Under no
circumstances should any SPART/SPARMV be allowed to leave the shed without its
required number of fire extinguishers in working order.
Note: During any schedule examination, All items of the lower lower schedule should
also be carried out.
(CIL Engine, Brake power, Compressor etc.)
DAILY SCHEDULE
DPC/DTC No: Cumulative km.

Date : Cumulative hrs.
S.No Details of work to be carried out Action taken Remarks

A. CONDITION: DIESEL ENGINE STOPPED
1. Oil & Water filling
Check and top-up if necessary:
a) Lube oil
b) Fuel oil
c) Coolant
d) Hydraulic oil
e) Compressor oil
2. Drain residue from
a) Air reservoirs.
b) Intercooler of compressor.
c) After cooler of pneumatic circuit.
B. CONDITION : DIESEL ENGINE RUNNING
3. Mechanical (General examination)
a) General visual checking to be made to
detect loose, defective, missing or leaky parts
in the following systems:
i) Cooling water
ii) Lube oil
iii) Fuel oil
iv) Air intake & exhaust
v) Pneumatic system
b) Ensure proper working of all gauges.
(DPC & DTC)
4. Check and ensure that hydraulic valve is
fully open
5. Check for noise free operation of radiator
fan. (Hydraulic oil temperature should not be
more than 70º)
6. Check operation of compressor to ensure
that there is no noise and vibration.
7. Check working of wiper
8. Check working of horn.
Repairs booked by driver

1.
2.
SSE (ART/ARMV) Name & Sign SUP Name & Sign
(CIL Engine, Brake power, Compressor etc.)
WEEKLY SCHEDULE
DPC/DTC No.: Cumulative km.

Repeat all checks of Daily Schedule

A. CONDITION : DIESEL ENGINE STOPPED
1. General check :
Check tightness of foundation/ mounting
bolts of the following :
a) Engine,
b) Radiators,
c) Compressor,
d) Radiator fan,
e) Inlet & Exhaust manifolds.
2. Engine fuel system
A.
Drain sediments from water separator.
B. Check and clean fuel tank level gauge.
3. V-Belts:
Check the belts for correct tension and
serviceability:
a) Compressor
b) Water pump.
c) Alternator
4. Engine air intake system
a) Remove and clean dust pan.
b) Check for complete red band on vacuum
indicator. Clean outer element only with dry
compressed air from inside to outside.
(Note: Replace outer element after 4/5

cleanings or as soon as red band appears
immediately even after cleaning. )
5. Clean the following items with dry

compressed air.
a) Panel filter. (engine room)
c) Outer body of engine air intake filters.
6. Check for red indication on return line filter

on hydraulic tank. If red, change the filter.
7. Breathers: (Check, clean & re-fit)
A. Crank case breather,
B. Compressor breather
C. Fuel Tank breather
D. Hyd. Tank breather
B. CONDITION : DIESEL ENGINE RUNNING
8. Cooling water system
Check that vent pipes in the system are
open.
9. Check and record:
a) Engine lube oil pressure:
Permissible values;
*1-2 kg/ cm.2 at idle
*3-7 kg/cm2 at 1800rpm
b) Lube oil temp: Should lie between
75°C - 105°C .
c) Cooling water temp : below 95°C
10. Pneumatic system (DPC, DTC)
a) Time for charging the main air 10 min.

reservoir from 0 to 7 kg/cm2.
b) MR cut in pressure. 6 ± 0.1 kg/cm2
c) MR cut out pressure. 7 ± 0.1 kg/cm2
d) MR safety valve starts 7.75 kg/cm2
blowing off at.
11. Check and record the following :
a) Brake Cylinder Pressure.

DPC – 1.6 kg./cm.2
DTC – 3.5 kg./cm.2
b) BP pressure : 5.0 kg./ cm.2
c) Feed .Pipe Pressure 6.0 kg./ cm.2
d) Parking Brake pressure 3.5 kg./ cm.2
12. Functional Test : (DPC & DTC)
a) A9 valve : Apply & Release

Satisfactory
b) SA9 valve : ---do----
c) Deadman’s device : ---do----
13. Check safety valve operation of compressor

1.
2.
( CIL Engine, Brake power, Compressor etc.)
HALF-YEARLY SCHEDULE

Repeat all checks of Daily & Weekly Schedules
S.No Details of work to be carried out Basis of changes Remarks

Condition Compulsory
CONDITION : DIESEL ENGINE STOPPED
1. Engine Lube Oil System

A L.O Filter Yes
B. By-pass filter Yes
C. Change of oil Yes
2. Engine Fuel System
A. Fuel Filter Yes
B. Magnetic filter screen Yes
3. Air System
A. Inner Element Yes
Outer Element Yes
4, Hydraulic System
A. Hydraulic oil filter Yes
B Strainer Yes
5, Belts
A. Alternator Yes
B. Water Pump Yes
6. Check for proper MUTC (multiple Unit
Throttle Controller) operation
7. Pneumatic System
A Lubricate brake valve cam of A-9 & SA-9
brake valves
B Clean after cooler externally by blowing
compressed air.
C Blow down air reservoirs with compressed
air and clean.
8. Fuel injectors and valves ( only during first
half-yearly and then during POH)
a. Adjust fuel injectors.
b) Check and ensure valve clearance as:
- Inlet : 0.36 mm
- Exhaust : 0.69 mm.
Replace Rocker cover gasket & tighten the
cover cap screw to 45 Nm
9. Cooling System
A. Inhibitor corrosion element Yes
B. Test kit Yes
C.
Coolant :
a) Engines provided with Borate base coolant

(i,e. Coolant Additive Concentrate-CAC):
 Visually check coolant colour:
(i) If pink, pH is within limit (8.5 to 10.0): no CAC
to be added.
(ii) If colourless, add CAC Yes
 Check CAC concentration with Test
strip & ensure value in unit per litre > 0.6.
b) Engines provided with corrosion resistant (CR)
Check coolant for pH (8.5 – 10) & PPM value
(3500 – 5000) for chromate concentration –
If pH is below 8.5, add pH controller
If PPM below 3500 – Add PPM controller
If PPM above 5000 – Dilute coolant
Water used should have the following
maximum levels :
Calcium Magnesium: 170 PPM
(CaCO3+MgCO3)
. Chloride : 40 PPM (as Cl)
. Sulphur : 100 PPM (as SO4)
10. Hydraulic oil to be checked for water
contamination, dirt by draining sample from the
bottom plug.
11. Compressors;
i) Remove and clean the oil bath air filter. Yes
ii) change oil. Yes
12. Check air piping. Visually inspect hoses, pipes
for damages/cracks and clamps for looseness.
13. Test fire extinguisher & re-fill, if necessary. Yes
CONDITION : DIESEL ENGINE RUNNING
14. Check for leak-offs from Radiator pump & motor
in the hydraulic systems. Remove leak-off hose
and collect oil in measuring jar for one minute.
Permissible leak-off < 2.5 litres/min.
15. Check for leakages in the system.
16. Check working of radiator fan:
Raise the water temperature and check up
opening up of radiator fan thermatic valve.
Thermatic valve should pick up at 82 0 C and
fully open at 92 0 C.
Radiator fan RPM can be measured with
tachometer at fan shaft end.
Roof mounted Min. : 800
radiator Max. : 2200
1.
YEARLY SCHEDULE
Repeat all checks of Daily, Weekly & Half-yearly Schedules.

1, Hydraulic System
A. Hydraulic oil filter Yes
B Hydraulic oil Yes
2. Check water pump for free rotation
3. Cooling System
A. Inhibitor corrosion Yes
B. Test kit Yes

1.
2.
3.
TWO-YEARLY SCHEDULE

Repeat all checks of Daily, Weekly, Half-yearly & Yearly Schedule

1. Air System
A. Inner Element Yes
B. Outer Element Yes
3. Flexible coupling
A. Inspect visibly for distortion / breakage
B. Check & ensure rubber hardness < 60-
shore.
C. Check condition of rubber blocks Yes

1.
2.
3.
FOUR-YEARLY SCHEDULE
PART - A
Repeat all checks of Daily, Weekly , Half-yearly & Yearly Schedules.
S.No Details of work to be carried out Condition/action Remarks.
Air Intake & Exhaust System
1. Turbocharger
i) Check oil leakages through intake &
exhaust seals.
ii) Check turbocharger shaft end clearance
with a dial depth gauge (value: 0.05mm to
0.13 mm ).
iii) Repair the turbo with repair kit.
2. Check for leakage in air intake system, if
any, rectify the same with necessary parts.
3. Replace air cleaner inner & outer filter
elements
4. Check vacuum indicators for functioning of
reset button & external damages and replace
if necessary
5. Check for leakage from exhaust system, if
any, rectify the same with necessary parts.
6. Check & replace hoses & clamps of air
intake pipings on condition basis.
7. Check air intake and exhaust piping
supports. Take corrective action accordingly.
8. Clean the engine room panel filters by dry
compressed air and replace if necessary.
Fuel System
1. Clean water separator assembly
2. Replace fuel filter element.
3. Replace all fuel line hoses.
4. Calibrate the injectors after replacing the
cups and O-rings.
5. Calibrate the PT pump by replacing the
necessary parts need to be changed for
calibration ( magnetic filter, gasket set, etc.)
6. Adjust valve. Check the conditions of push
rods, adjusting nut & screws, if necessary
replace.
7 Check fuel lines & connections for leakage.

8 Check fuel pump linkages.
9 Check actuator functioning.
10. Clean thoroughly fuel tank with steam and
detergents and dry the tank with air blast.
Lubricating Oil System
1. Replace engine oil.

2. Replace full flow & bypass filter elements.
3. Replace all oil line hoses & clamps.
4. Check external oil leakage from head
gasket/rocker housing gasket, seals, etc. If
necessary, replace the same.
Cooling System
1. Flush cooling water tank. Replenish with

CAC and water .
Replace CR element of system with CAC for
DPCs having CR element.
Check for concentration.
2. Replace water pump drive belts.
3. Replace all hoses, clamps & coupling O-
Rings of cooling system pipe lines and
radiator assembly.
4. Remove radiator assembly (RMR) from the
mounting & clean the radiator assembly.
5. Check all radiator Anti Vibration Mountings

and replace if necessary.
Hydraulic System
1. Replace hydraulic oil.
2. Replace hydraulic oil return filter.

3. Replace vent pump belts.
4. Clean hydraulic system strainer.
5. Check thermatic valve operation.
6. Externally clean & check leak-offs from main
hydraulic & ventilation pump at rated speed.
Radiator fan pump : < 2.5 litres/min.
Vent fan pump : < 0. 8 litres/min
7. Externally clean & check leak-offs from main
hydraulic & ventilation motor at rated speed.
Radiator fan motor : < 2.25 litres/min.
Vent fan motor : < 0. 8 litres/min
8. Externally clean & check radiator fan
operation
9. Externally clean & check vent fan operation
10. Hoses:
i) Replace all hydraulic pressure
line hoses.
ii) Replace all hydraulic leak-off &
return line hoses on condition
basis.
11. Clean hydraulic oil cooler externally.
12. Check & set hydraulic system pressure at
180 bar
13. Compressor :
i) Dismantle and overhaul.
ii) Replace worn out parts.
iii) Replace all ‘O’ rings, gaskets, oil
seals.
iv) Assemble and run the compressor
to evaluate its performance.
14. Pneumatic system :
i) Dismantle and overhaul all brake
valves.
ii) Replace all ‘O’ rings seals and
gaskets.
iii) Assemble and test to evaluate
their performance.
iv) Check all gauges with master
gauge and replace/repair the
defective ones.
15. Check Vibration damper, replace if

necessary.
16. Check for the leakages in various systems

Repairs advised by Shed in Pre-Shopping
report.
PART - B
List of components to be changed
1. Air system
A Air cleaner hose Yes
B. Elbow Yes
C. Vacuum indicator Yes
D. Dust cap Yes
2. Lube system
A. Hose turbo drain Yes
B. Clamp Yes
C. Gasket Yes
D. Turbo oil supply hose Yes
E. BP hose Yes
F. LOF hose Yes
G. Plain pipe elbow Yes
H. Male connector Yes
3. Fuel system
A. Hose flexible Yes
B. Calibration & conditioning
Fuel pump
Yes
Injector
Yes
Tappet Cover gasket Yes
Gasket, PT pump Yes
Spider, jaw coupling Yes
4. Cooling system
A. Gasket Yes
B. Thermostat seal Yes
C. Thermostat Yes
D. Water pump Yes
E. Pipe coupling (1.5’’ and 2.5’’) Yes
F. Hose Yes
G. Thermostat housing gasket Yes
H. Anti-vibration mounting Yes
I. Radiator cleaning Yes
5. Exhaust system
Turbo repair kit Yes
Turbo mounting stud Yes
Hex nut Yes
Turbo gasket Yes
6. Hydraulic system
Hose, Pump Leak-off
Yes
Hose, Pump suction
Yes
Hose, Delivery to Suction pipe Yes
Hose, Hydraulic block Yes
Hose, Motor 1 & return Yes
Hose, to pressure regulator Yes
Hose, to pressure gauge Yes
Hose, to oil cooler Yes
Hose, cooler to socket Yes
Hose, Sck. Rtn S/pipe Yes
Hose, suction pipe to return block
Yes
Hose, Pump & T/valve
Yes
Hose, T/valve 7 Return block Yes
Hose, Motor return (1) Yes
Hose, PRV & return socket Yes
Hose, return socket to block Yes
Dowty washer Yes
Radiator AVM Yes
Cap screw Yes
Lock washer Yes
Washer Yes
Clean radiator fan. Check its operation Yes
Clean hydraulic oil cooler Yes
7. Compressor:
Components change Yes
‘O’ rings, gaskets, oil seals
Yes
8. Pneumatic system:
‘O’ rings, gaskets, oil seals Yes
Check gauges and replace defective one
Yes
9. Check vibration damper, replace if necessary Yes
10. Yes
Belts: a) Alternator Yes
b) Water pump
TWELVE-YEARLY SCHEDULE
(E-Check of Engine)
Engine serial number : Cumulative km.

Date: Cumulative km.

Major Engine Overhaul
Inspect the following & overhaul:
1.  Accessory Drive
 Accessory Drive Seal
 All Bearings
 Camshafts
 Cam Followers
 Crankshaft
 Crankshaft Journals
 Front and Rear Crankshaft Seals
 Front Gear Train
 Rear Gear Train
 Cylinder Head
 Rocker lever assembly
 Intake & Exhaust valve
 Injectors
 Pistons
 Piston Rings
 Connecting Rods
 Turbocharger
 Lubricating Oil Pump
 Oil Cooler
 PT pump and drive system
 Water pump
 Other remaining items on condition
basis
2. Change all seals, gaskets and O’rings
Note: Detailed Overhaul instructions to be obtained from Cummins India.
( Hydraulic Transmission, Axle Drive, Cardan Shaft)
DAILY SCHEDULE


1. Externally clean and check for leakages in
transmission line.
2. Externally clean and check for leakages of oil in
axle drive by running the engine.
3. Check proper working of :
i)Transmission oil temperature gauge.
ii)Transmission oil pressure gauge .
4. Check oil level of axle drive & top up if Yes
necessary.
5. Check oil level of transmission & top up if Yes
necessary.
6. Check tightness of flange bolt of cardan shaft. Do
greasing if required.
7.** Change ADGB oil after first 50 hours of operation.
Not to be repeated during the subsequent trip
schedules.

1.
2.
3.
( Hydraulic Transmission, Axle Drive,Cardan Shaft)
WEEKLY SCHEDULE


1. Check the condition of flexible coupling
securing bolts.
2. Check the tightness of the following:
i) Engine transmission mounting bolts.
ii) Flange joint bolts:
a) between engine and transmission.
b) between transmission and axle drives.
iii) Axle drive & torque arm securing bolts
(420 Nm)
iv) Mounting bolts of torque reaction arm.
(790 Nm)

1.
2.
3.
HALF YEARLY SCHEDULE

Repeat all checks of Daily & Weekly schedules

1. Transmission:
A. Oil - 1st change after 50 hrs. service and Yes
subsequently in Two yearly schedule.
B. Yes
All filters - 1st change after 50 hrs. service and
subsequently in Two yearly schedule.
2. Check for abnormal play in universal joint of
cardan shaft. Repair if necessary.
3. Lubricate rolling & sliding part of cardan shaft
with grease
4. Check for the leakages in thesystem
1.
2.
3.
TWO YEARLY SCHEDULE

Repeat all checks of Daily, Weekly & Half yearly schedules
2. Check for metal particle inside transmission.
Flush and change oil Yes
3. Change Filter Yes
4. Check for proper function of Forward/Reverse
mechanism
5. Check for control piston for any burr & dress if
necessary.
6. Visually check-
i) Bearing condition
ii) Monitor for high temperature and
abnormal noise
7.
Cardan shaft-
a) Check for specified torque tightness of joint
flange bolts (140 Nm).
b) Grease at spline section till old grease comes
out.
8. Axle drive-
a) Check for oil leakage
b) Clean breather
c) Take sample of oil. Check for metal particle
d) Top up oil if necessary
9. Check for –
i) Oil leakage
ii) Condition of hoses
iii) Pneumatic & hydraulic joints
1.
2.
FOUR YEARLY SCHEDULE

Repeat all checks of Daily, Weekly, Half-yearly & Two yearly schedules
1. Transmission:
Check control parts for proper operation

tightness and wear :
i) Governor,
ii) Sensor valves,
iii) Reverse gear operating cylinder,
iv) Main control valve.
2. Axle drive Gear box :
i) Subject all parts to an intermediate

inspection.
ii) Check the wear pattern on the bevel gear
drive.
iii) Check the taper roller bearings for proper
axial clearance.(Refer 8.5 of Axle
drive -V17 Maintenance manual ).

1.
2.
3.
TWELVE YEARLY (144 Months ) Overhauling Schedule


1. Overhaul of Transmission
A. Completely dismantle & overhaul transmission
Filter element Yes
Filter Cartridge Yes
Seal Yes
Gasket Yes
All Bearings Yes
‘O’ ring, seal, sealing ring, piston ring Yes
Suspension roller Yes
Breather filter Yes
Bush Yes
Circlip Yes
Pin Yes
Union / Banjo Joint Yes
B. After Overhaul of Transmission:
Test run to be carried out to ensure proper
operation of the overhauled transmission.
After 50 hrs. run, oil must be drained and
filtered. Filter on delivery side of filling pump
must be replaced.
Filters on suction side of filling pump and
secondary lubricating pump are required to be
cleaned and fitted.
2. Overhaul of Axle Drive :
Subject all components to major inspection
and replace if necessary. (Refer : Axle drive -
V17 Maintenance manual for assembly &
disassembly)
report.
(ELECTRICS & CONTROL)
DAILY SCHEDULE

S.No. Details of work to be carried out Action taken Remark

1 Check following items for unusual sound, high
temperature and odour.
A Aux. Alternator
B 24 volt battery charging alternator
2. Check the MUTC operation by raising throttle
notch (engine)
A. Check the performance of RPM indicator
3. Check charging rate and voltage of auxiliary
generator in each notch.
Charging voltage should be above 110 volt
4. Check following electrical equipment for loose
connection and for proper working.
A Switches.
B Lights
C MCBs
D Check working of indication lights on driver
panel by indication test switches
5. Check proper securing of trainline couplers
6. Start engine and check the following:
A Operation of self starter (local and remote)
B Drivers and guards key switches
C Proper working of relays and their sequence

1.
2.
(ELECTRICS & COTROLS)
WEEKLY SCHEDULE
1 Check IR value between control and ground. Ensure
minimum 1 mega ohm
2 Master controller
A Open the cover and clean the master controller.
B Check and ensure proper operation of the contactors
and interlocks.
C Clean the cams and contactors.
D Check visually connections for tightness.
E Check and ensure proper working of Deadman's
application device.
F Lubricate with light machine oil all bush bearings,
hinges and rollers (wipe out the excessive oil)
3 AUXILIARY RECTIFIER CUM REGULATOR
A Open the rectifier box cover and clean the rectifier with
compressed air of 3kg/cm2 and look for any abnormality
like heating etc.
4. AUX. ALTERNATOR
a Blow out aux. alternator with dry compressed air; of
3kg/cm2, Open cover and tighten loose connections.
5. RELAY BOX
A Clean all relays and their covers properly.
B Check and tighten , fastening nuts and bolts.
C Operate the relay by hand and ensure proper operation.
D Clean contacts of all relays
6. Check 24 volts alternator out put which should be min-
25 V &max-27 V. If varies, attend and overhaul if
necessary
7. BATTERIES
A Clean batteries, battery boxes, tighten the terminal lugs
and apply petroleum jelly on all terminals.
B Ensure that the plugs are clean

C Check and record specific gravity
Specific gravity should be (1200-1240)
D Check electrolyte level & to be maintained up to green
mark of indicator
E Check if any battery is having reverse polarity
F Check and record battery voltage.
Should be min -1.8 V, max -2.2 V
6. SAFETY DEVICES
A Ensure that oil pr. switch is in proper working order
Setting of OPS (P/U-1kg/cm2,D/O-0.8kg/cm2)
B Ensure proper working of hot water temp. Safety
device.
LED indication should come & buzzer should sound
and transmission should cut off when water temperature
exceeds 95°C.
C Ensure proper working of low cooling water level safety
device.
On pickup engine should shut down along with LED
indication and buzzer should sound
D Ensure proper working of engine over speed safety
device.
Raise engine RPM by pressing governor plunger.
Engine should shutdown along with LED indication and
buzzer should sound.
E Check proper working of all interlocks of the cab
7 Record voltage of 24 volt alternator in each notch
Voltage of 24 volt alternator should be Min – 25 V and
Max 27 V.
8 Check electrolyte level of batteries.
Electrolyte level should be maintained up to green mark
of level indicator fitted on each cell
9 Stop the engine and blow all electrical components with
dry compressed air of 3kg/cm2.
10 Check the following safety items

A Pull passenger alarm chain. Buzzer should sound in the
Driver’s cab.
B
Guard & Driver communication
On pressing the buzzer button in one cabin, buzzer should
sound in other cabin.
C Signal bell
D Headlight, flasher lights, tail lamps, emergency
headlights.
11 Check V belts of Aux. alternator (24 volts), (110 V)
12. Check tightness of 6 pin socket on TRM & operation of
transmission solenoid valve.
1
2
SSE (ART/ARMV) Name & Sign SUP Name &
Sign
(ELECTRICS & CONTROLS)
HALF YEARLY SCHEDULE

Repeat all checks of Weekly Schedule

S.No Details of work to be carried out Action taken Remark
1 Check tightness of aux. alternator. foundation bolts. If
found loose, tighten
2 Check connection of the following
(a) MUTC
(b) Starter
(c) 24V Alternator
(d) All Terminal boards and junction boxes
3 Check and ensure that none of the cams is damaged
or cracked.
1
2
3
4
5
SSE (ART/ARMV) Name & Sign SUP Name &
Sign
(ELECTRICS & COTROLS)
TWO YEARLY SCHEDULE

Repeat all checks of Half Yearly Schedule

1 Check in situ
(a) All Safety control
(b) Signal/Alarm bell
2 Remove and overhaul the following
(a) Starter
(b) 24 V Alternator
3. Check MUTC operation
1
2
3
(ELECTRICS & CONTROLS)
POH EXAMINATION

Repeat all checks of Two- Yearly Schedule
1 Remove, over haul , test on test bench and fit
A Relays
B MUTC
C Voltage regulator
D All safety devices (low water, low l/oil
pressure, water temperature, OST)
2 Check all electrical equipment for high
temperature, unusual sound and odour,
including aux. alternator, 24 V alternator and
starter motor,
3 Batteries
a. Remove and recharge
b. Clean and paint battery boxes
4 Miscellaneous
a. Blow out electrical wiring panel and
remove dust and dirt with dry air
b. Check all switches and push buttons for
proper working
c. Check all circuit breakers for ‘ON’ and
‘OFF’ operations
d. Clean throttle tips and check for proper
operation.
e. Check all gauges for proper working and
readings to be noted down on idle as well
as on 8th notch.
f. Blow out switch gear box.

report.
(Coach body, Under frame, Bogie, Brake rigging etc.)
Weekly Schedule
(On rake)
DPC/TC No.: Cumulative km.

Date : Cumulative Hrs.
No. Details of work to be carried out Condition/Action Remarks

1.0 Coach
1.1 Coach should be washed both from outside and

inside.
2.0 Shell
2.1 Visually check body panels/end walls for

damages.
2.2 Visually inspect destination boards brackets.
2.3 Visually inspect window bars for
damage/missing.
2.4 Examine body side doors for working/damages.
2.5 Inspect door handles for damages/missing.
2.6 Inspect vestibule and its Rubber fittings for
damages/missing, repair if necessary.
2.7 Visually check vestibule fall plate, mounting
brackets, pins and lock lever for ease of
operation, damages/deficiency.
3.0 Under frame
3.1 Visually examine centre pivot mounting bolts

and attend if needed.
3.2 Check condition of head stock/sole bar.
3.3 Visually inspect centre pivot cover.
4.0 Bogie
4.1 Bogie frame

4.1.1 Examine visually the condition of bogie side
frame, transom, longitudinal, bolster etc. at all
welded locations.
4.1.2 Examine rubber stopper/stop screw of axle box
crown for damage/missing/loose.
4.1.3 Inspect axle box safety straps/loops for
damage/broken/missing.
4.1.4 Bolster safety straps/loops for
damage/broken/missing.
4.1.5 Brake hanger brackets for damages.
4.1.6 Inspect safety brackets for brake hanger pins.
4.1.7 Check visually BSS hanger brackets.
4.1.8 Examine visually anchor link brackets.
4.2 Primary Suspension
4.2.1 Visually examine axle box springs for breakage.

4.2.2 Visually examine dashpot oil filling special
screw for deficiency.
4.2.3 Check oil leakages in dashpot through defective
seals/vent screws.
4.2.4 Visually examine axle box clearance.
4.3 Secondary Suspension
4.3.1 Visually examine bolster springs

breakages/damages.
4.3.2 Visually examine Bolster lower spring beam.
4.3.3 Visually examine BSS hangers, hanger blocks,
BSS pins.
4.3.4 Visually examine equalizing stay rods and pins
(small and big).
4.3.5 Visually check anchor links.
4.3.6 Visually examine the anchor link securing bolts
and attend if needed.
4.3.7 Visually examine Equalizing stay brackets.
4.3.8 Examine and attend safety loops of bolster.
4.3.9 Check and attend safety loops of Equalizing
stay rod.
4.3.10 Examine vertical shock absorbers for damages.
4.4 Brake rigging
4.4.1 Check brake gear and adjust so that the piston

stroke is within the limit.
4.4.2 Examine brake beams breakages/damages.
4.4.3 Check and attend brake beam safety wire
ropes/safety straps.
4.4.4 Check and attend brake shoe head and key and
replace if necessary.
4.4.5 Check and replace worn brake blocks.
4.4.6 Visually inspect brake hangers, brake gear pins
and cotters/split pins and replace if necessary.
4.4.7 Visually inspect damaged/missing brake gear
bushes and replace if necessary.
5.0 Brake System
5.1 Air brake system

5.1.1 Conduct brake test as per rake test and attend
leakages and defective components if any.
5.1.2 Visually inspect for damage on brake pipe, feed
pipe and hose coupling.
5.1.3 Visually inspect suspension bracket for air

brake equipment and anti pilferage device for
any defect and rectify.
5.1.4 Check passenger alarm by pulling the chain
with spring balance with 6.4kg to 10kg force.
5.1.5 Carry out manual brake release test to ensure
proper function of release lever.
5.1.6 Check and adjust brake gear to achieve correct
piston stroke.
5.1.7 Service application, release test of every coach
of the rake to ensure full brake power.
5.1.8 Carry out guard van valve test to ensure proper
functioning of guard van valve.
5.1.9 Examine slack adjuster for damage and mal
functioning and subsequent replacement.
6.0 Draw gear
6.1 Check and replace damage/missing split

pins/cotter/rivets.
6.2 Examine draw hook, draw bars and rubber
pads for damages.
6.3 Check conditions of the screw coupling and its
components and replace if required.
6.4 Check condition of draw beam and locating
pins on it.
6.5 Examine visually draft key locking pins.
7.0 Buffing gear
7.1 Visually examine buffer plungers for

damage/drooping/stroke length.
7.2 Examine buffer mounting bolts and attend if
necessary.
7.3 Examine visually buffer casing for
cracks/damages.
8.0 Running gear
8.1 Examine visually axle box for grease oozing

out, warm box if any.
8.2 Visually examine wheel tyre profile and
thickness of tyre and check with tyre profile
gauge if they appear to be near condemning
limit.
8.3 Visually inspect axle box covers.
8.4 Inspect wheel tread for shattered rim, spread
rim, shelled tread, thermal cracks, heat checks.
9.0 Seats and berths
9.1 Examine middle and upper berth chains.

9.2 Examine the holding/securing brackets for
seats and berths and attend if necessary.
9.3 Examine snack tables for damages and rectify
if necessary.
9.4 Examine and repair damaged upholstery
cushions and curtains.
9.5 Wooden seats and frames should be cleaned.
9.6 Cushion should be cleaned with duster. Oil or
head stain and dirty spots if any should be
cleaned with mild soap solutions and wipe dry.
10.0 Doors
10.1 Examine doors for proper functioning and

securing with hinge pivots. Doors should not
graze with floor or door sill plates.
10.2 Examine door locks, latches firmly secured with
correct sized screws and properly/smoothly
engaging in their slot. The tongue of gravity
type latch should be in proper alignment with its
slot plate.
10.3 Visually examine window shutters for smooth
working and proper locking.
10.4 Examine visually rolling shutters/sliding doors
of vestibule for smooth working.
11.0 Windows
11.1 Check window-balancing mechanism for proper

function.
11.2 Examine window safety catches for proper
engagement in their slots.
11.3 Check lavatory banjo shutters for
damage/missing.
11.4 Window bars should be provided and fixed in
prescribed manner and replaced if damaged.
11.5 Check the availability of emergency exits in
coaches. Examine and attend if necessary.
12.0 Interior fittings
12.1 Examine laminated panels and mouldings for

damage/cracks.
12.2 Visually inspect amenity fittings, replace if
found damaged/deficient.
12.3 Examine tower bolts of backrests for proper

working.
12.4 Examine ventilation grills for damages.
12.5 Examine luggage racks/bunks for breakage.
13.0 Lavatory and lavatory fittings
13.1 Check lavatory hinge door for proper function

13.2 Examine lavatory door latches/tower bolts for
proper function
13.3 Examine push cock and flush valve for proper
function
13.4 Check and attend leakage in pipes, pipe fittings and
shower roses
13.5 Clean drain grills and drain holes in bathroom and
wash basin if found chocked
13.6 Check and replace damaged/missing mirrors /
shelves / soap dishes
13.7 Examine squatting pans and foot rest for damages

1.
2.
NOTE :- Care should be taken not to keep SPART/SPARMV in stationary condition for a long time. It
should be shunted up and down at least once in a week.
(Coach body, Under frame, Bogie, Brake, Brake rigging etc.)
MONTHLY SCHEDULE-`A’
(On rake at nominated primary depot. )

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

1.0 Repeat all items of Weekly Schedule
2.0 Coach
Disinfect and spray insecticide at corner and
2.1
crevices of coaches after washing all coaches.
2.2 Intensive cleaning of coach
3.0 Bogie
3.1 Bogie frame
Examine oil level in side bearer oil-bath and oil-
3.1.1
filling cap replenish oil if needed.
3.2.1 Add specified grade of oil in dashpot.
3.4 Brake rigging
3.4.1 Check and attend brake block adjuster.
3.4.2 Examine and attend brake levers.
Examine and attend floating lever suspension
3.4.3
brackets.
4.0 Seats
4.1 Disinfect the seats and frames.
Intensive cleaning of lavatory pans and
5.1
commode with cleaning agent

1.
2.
QUARTERLY SCHEDULE-`B’
(On rake at nominated primary depot. )

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

1.0 Repeat all items of Weekly & Monthly Schedule
2.0 Under frame
Examine trough floor, turn under and other under
2.1
frame members from underneath for corrosion.
3.0 Bogie
4.3 Secondary Suspension
4.3.1 Check bolster clearance.
6.2 Thorough flushing of water tanks

1.
2.
IOH Schedule
(Sick line at nominated primary depot.)

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

1.0 Repeat all items of Quarterly Schedule
2.0 Shell
2.1 Thoroughly clean and remove dust, rust

accumulated at pillars through turn under holes
with coir brush and compress air.
2.2 Examine for corrosion of sole bar and other under
frame members with torch light or inspection
lamp.
2.3 Touch up damaged paint both inside and outside.
2.4 Check roof ventilator for damages.
3.0 Bogie
3.1 Bogie frame

3.1 Examine condition of wearing piece and wearing
plate.
3.1 Check and attend axle guide assembly if
necessary.
3.2 Check axle box clearance with gauge.
3.3 Bogie to be run out if found necessary during this Schedule and following should be
done:
3.1 Examine and replace all the brake gear
components found deficient/worn out.
3.2 Examine and replace primary and secondary
suspension components as required.
3.3 Examine wheel profile and thickness and gauge if
in case they appear to be near condemning limit.
4.0 Brake System
4.1 Single Car Testing of the coach

5.0 Draw gear
5.1 Ensure that wear on screw coupling shackle pins,

trunion pins, shackle/link holes and draw hook
holes should not exceed 3mm.
5.2 Ensure that wear at any section on draw hook
should not exceed 10mm.
No. Details of work to be carried out Condition/Action Sign. Remarks
6.0 Buffing gear
6.1 Ensure the length is within 584-635mm.

6.2 Inspect buffer plunger false plate for wear and
profile.
7.0 Running gear
7.1 Check with wheel distance gauge for loose or

tight wheel (IOH).
8.0 Flooring
8.1 Inspect and attend torn/damaged/cracked PVC

flooring.
8.2 Examine and attend opened PVC joints.
8.3 Examine Drain holes in trough floor for
accumulation of water due to clogging if noticed.
Inspect affected area for corrosion.
Periodical Overhaul (48 months)

(As per the recommendation No. 79 of High Level Committee on Disaster Management
over Indian Railways- April 2003 & may be extended to 48 months)
DPC/DTC No. Cumulative km.

Date: Cumulative Hrs.
No. Details of work to be carried out Condition/Action Remark
The following sequence of work should be

generally followed during POH of coach:
1. Verification of deficiencies.
2. Pre-inspection and Lifting of coach body
3. Stripping
4. Body repair.
5. Fitting of Water Tank, Plumbing & Leakage testing
6. Repair of internal panels
7. Fitment of shutters
8. Fitment of doors
9. Fitment of berths and seats
10. Repair, maintenance & fitment of draw and buffing
gears
11. Painting and finishing
12. Repair and maintenance of bogie
13. Repair and maintenance of brake system
14. Repair and maintenance of rolling gear
15. Lowering of coach body on bogies.
16. Brake Testing
17. Testing of branch wiring
18. Testing of electrical equipment
19. Final Inspection & Dispatch
Repairs advised by Shed in Pre-Shopping report.
NOTE: POH of the coaches is to be done as per the details given in the following Maintenance
Manuals:
i) Maintenance Manual for BG coaches of ICF design (2002) issued by IRCAMTECH, Gwalior.
ii) Maintenance Manual for AC/DC EMU & MEMU Bogie and under gear Manual No. CMI-K001
(April, 2000) issued by RDSO, LKO.
APPENDIX-I Chain & Chain Slings
APPENDIX - I
CHAINS
&
CHAIN SLINGS
RDSO REPORT No. STEAM LOCO. 703/70

(REVISED IN MAY 1977)
MAY 1977
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW – 226011 Go to Chapter contents
Operational Manual for Working of ART/ARME//140Te Crane/1

TECHNICAL CONSIDERATIONS
FOR
PROCUREMENT
INSPECTION, TESTING AND REPAIRS
OF
CHAINS, CHAIN SLINGS AND THEIR
COMPONENTS

INDEX
Chapter No. Subject Page

No.
Chapter I Specifications for Chains & Chain Slings 1-2
Chapter II Grades of Chains 3
Chapter III Technical Considerations for choosing slings 4-5
Chapter IV Procurement of chains, chain Slings and their 6-7

components
Chapter V Manufacture of Chain Slings in Railway Workshops 8-9
Chapter VI Working Loads 10-11
Chapter VII Periodical inspection and repairs to Chains & Slings 12-14
Chapter VIII Procedure for Identification, Repairs and Heat 15-19

Treatment to chains/slings
Chapter IX Information to be supplied during enquiry or order 20-27

CHAPTER I
1. SPECIFICATIONS FOR CHAINS AND CHAIN SLINGS
1.1 Railways were earlier procuring wrought iron chains to IRS specification
H.3. This specification also permits supply of mild steel chains to BS-590 in
lieu, for sizes up to and including 1.25” (31 mm). due to non-availability of
wrought iron chains, procurement made in recent years have been mostly to
BS-590.
1.2 The British Standards Institution has also published specifications on chains
of higher grdaes namely BS:1663 for grade 40 and BS: 3113 for grade 60.
Recently ISI have also published the following specifications on chains.
IS:2429-70 Round steel short link chain (electric built welded)

- Grade 30, non calibrated.
IS: 3109 – 70 Round steel short link chains (electric butt welded) – Grade
40; non calibrated.
IS: 6217-71 Round steel short link chains (electric butt welded) – Grade
63; non calibrated for lifting purpose.
IS: 6215-7171 Round steel short link chains (electric butt welded) – Grade
80; non calibrated for lifting purpose.
IS: 3814-67 Metal arc welded short link non-calibrated steel chains, grade 30
for lifting purpose.
Of these IS specifications, use of chains to IS: 3814-67 and IS:6215-71 is not

permitted for crane operation purpose. Chanis to other IS specifications can
however, be used.
1.3 As on date, the specifications to which chains, chain slings and their
components can be accepted by Railways are as follows :
1.3.1 CHAINS :
i. Short link chain Gr. 30 IS-2429 - Electric resistance or
flash butt welded
ii. Short link chain Gr. 40 IS-3109 - Electric resistance or
flash butt welded
iii. Mild Steel Chain Gr. 30 to BS-590.
iv. Higher tensile steel chains Gr. 40 to BS-1663
v. Alloy steel lifting chains Gr. 60 to BS-3113
1.3.2 IS has also published a specification IS; 2760-72 on chain slings. This
standard deals only with mild steel components corresponding to

trade 30. India Standards on chain slings to grade 40 and grade 63 are
under preparation.
These can be followed when published and adopted for Railway use.
Till such time, for making chain slings to grade 40 and grade 63, sizes
of components as given in IS: 2760-72 with materials as specified in
IS-3109-70 for 40 chain and IS:6217-71 for grade 63 chain
respectively should be used.
Chain and slings to BS 2902 to BS 2902 grade 40 can also be used

provided these suit dimensionally.
1.3.3 HOOKS :
Hooks to any of the following specification can be used –
1. Point hooks with shank for general engineering purpose-IS-

3815.
2. Eye hooks for use with chain IS:3822 (grade 30 and grade 40)
3. Eye hooks for use with wire rope slings IS:2750 grade 30 and
IS grade 40
4. Mild steel forged Ramshorn hook – IS: 5749-70
1.4 Specifications NOT be used for procurement of chains and chain

slings.
1.4.1 IS Specification 3814 covers metal arc welded short link chains to
Gr.30. As the title suggests this specification is meant for chains
produced by small scale manufactures by metal arc. welding. The
welding procedure and techniques to be adopted have to be of a high
order and through tests regarding quality of welding and the standard
of welders have to be done. Such independent vigorous inspection
and testing may not be possible in all cases and the quality of welding
cannot, therefore, be uniformly ensured. In view of this, it is
recommended that chains to IS: 3814 should not be used for general
lifting purpose.
1.4.2 IS Specification 6215-71 dealing with Gr. 80 alloy steel chain is not
recommended, because it would be difficult to make complete sling
with nothing hook and other components. It would also be
exorbitantly costly.

CHAPTER II
2.0 GRADES OF CHAINS :
The grade numbers 30,40 and 63 of the IS Specifications (corresponding to

L,M,S grades of ISO) are directly related to the mean atleast at guaranteed minimum
breaking loads of the chains. The higher the grade number, the stronger the steel. The
mean stresses for different grades, at the guaranteed minimum breaking load given
below :
Grade of the chain Mean stress at guaranteed minimum

Gr. 30 – (ISO-L) 300 MN/m2
Gr. 40 – (ISO-M) 400 MN/m2
Gr. 63 – (ISO-S) 630 MN/m2
2.1 Higher tensile steel and Alloy steel chains :
Use of higher tensile steel or alloy chains to Gr. 40 and Grade 63 has the
advantage of reducing the weight of the chain for same lifting capacity. Using hooks and
other links of matching steel with these chains, the overall weight of the sling can be
reduced considerably, particularly for multi-legged slings. This reduction in weight not
only reduces the overall weight lifted, but also make easier handling of the sling. The
present trend is, therefore, to go for such chains and the Railways should also not
hesitate in ordering for Gr. 40 chains to IS:3109 or Gr. 63 chains to IS : 6217.

CHAPTER III
3.0 TECHNICAL COSIDERATIONS FOR CHOOSING SLINGS :
3.1 Capacity :
While ordering chains and slings, it should be borne in mind that no purpose will be
served if the capacity of the sling is more than that of the crane with which it is intended
to be used. Also, when ordering slings for more cranes, slings to suit the maximum
capacity of the crane have to be provided for as otherwise the crane cannot be utilized to
its maximum capacity.
3.2 Slings for use with ramshorn hook :
With a ramshorn hook, 2 slings are to be used simultaneously and slings have,
therefore, to be ordered in pairs (unless a central shackle is provided with the hook for
handling light loads). As 2 slings are required for ramshorn hook, 3-legged or 4- legged
slings will not be of any advantage for use with this hook. Only single legged or 2-
legged slings should be ordered for use with ramshorn hook.
3.3 Size of ring/oblong link (Suspension link) :
The size of the ring/oblong link should be carefully decided to enable the sling to
be used with the hook of the in other words, the ring/oblong link should be sufficiently
big to enable to go on the crane hook. It is a good practice to ensure that any sling can be
put on a crane hook of 5 times its capacity.
3.4 Plane of the hook (s) :
Normally, the hooks of the multi-legged slings should be in the same plane as the
top ring as this is advantageous. The specifications, however, permit the hooks being in
a plane at right angle to that of the ring. Slings of this type can be ordered only if they
are considered specially advantageous for any particular application.
3.5 Length of the sling :
The length of the sling should be decided taking into account the (difference in
maximum) height between the crane hook and the object to be lifted. It should raised or
lowered to any desired. The length of the sling should be made as short as possible as
shorter sling is lighter and permits a higher range of lift of lift of the object.
In the case of multi-legged slings, a short sling while used for, lifting wide
objects, any have large included angle between the legs. This will reduce the capacity of
the sling should, therefore, not be unduly short so as to have on included angle higher
than 90 degree between the legs.
It is normally impossible to work exactly to the ordered length and it is a normal

practice to work to the nearest length. For small sizes (up to 12 mm) the difference

between ordered length and actual length will be negligible but it will be appreciable for
sizes 25 mm or more. As it is impossible to work to tolerances, the ordered length
should be the minimum acceptable length.
Where it is essential that ordered length should not be exceeded, this should be
specifically stipulated.
4. PROCUREMENT OF CHAINS, CHAIN SLINGS & THEIR

COMPONENTS :
4.1 Further procurement of chains and chain slings may be to any one of the
specifications mentioned in para 1.2 depending on their ready availability, price etc.
Normally, attempts should be made to procure chains to relevant IS specifications
only, but chains offered to BS Specifications, if found suitable and cheaper, may also
be accepted. Adequate steps should be taken to identify the chains and chain slings to
the various specifications and to do proper heat treatment after periodical repairs.
4.2 Source of Procurement :
Procurement of chains and chain slings should be made only from repaired
manufacturers. The under mentioned extract from IS-2429 clearly indicates the
importance attached to this aspect :
“The reliability of chains is an important factor, and, therefore, it is

recommended that supplies should be obtained from manufacturers possessing
adequate facilities for heat treatment and employing competent staff for detailed
inspection.”
Similar remarks are given in the forewords of other and testing IS specifications
for chains, hooks and chain slings.
4.3 Information to be supplied during enquiry or order :
The information to be supplied during enquiry or order of chains, chain slings,

hook or other components is given in the annexure I. for chains and chain slings, the
capacity should be the consideration and any grade of chain meeting with grade of
chain meeting with this requirement can be accepted. The enquiry should therefore,
not specify any particular grade of chain unless a particular gradeis required for
manufacture of a sling whose other components material, specification etc. have
already been decided (see para 5.1). At the time of ordering however, based on the
earlier tender offer, the details including grade etc. can be stipulated.
4.4 Conditioning of acceptance :
The acceptance of the chains and chain slings their components should be done
only after these are independently inspected on behalf of be Railways. In view of the
purpose for which the above are required . These should not be accepted normally on
manufacturer’s certificate only. In this connection, extract from the foreword of
IS:2429 is reproduced below :

“ Users are warned that the chains shall not be taken as complying of a with this
standard, unless the specified tests have been made and the test requirements obtained in
the presence of competent person representing the purchaser. Where the quantity of
chain ordered is insufficient to warrant the expense of special inspection, it is
recommended that the chain should be sent to a recognised test house for the specified
tests and examination.”
Similar remarks have been given in the forewords of other IS and BS specifications for
chains and chain slings.
4.5 Certificate of test and examination :
Each and every chain, hook or chain sling is to be subjected to proof load test after
heat treatment and a test certificate by the manufacturer is to be invariably supplied for
each chain hook or chain sling as the case may be. Samples of chain and hook are also
to be destructively tested as per the respective individual specifications. This certificate
will contain proof load, breaking load on test sample, energy absorption factor, heat
treatment etc. Sample test certificates are furnished in annexure II.
Railways should always obtain test certificates and link them immediately, as
subsequent repairs and heat treatment will be done based on the information furnished in
the certificates. Where chains are bought and slings are made by railway the users, after
the necessary tests are carried out. Use of chains or chain slings not covered by test
certificates should not be permitted.

CHAPTER-V
Manufacture of Chain slings in Railway workshops

5.1. Materials for chains and sling components: -
If chains are procured from private manufactures and slings are made in Railway
workshops using these chains, it is necessary that the hook and other transition and
intermediate links, rings etc., should be of matching materials. This is necessary not only
to ensure that the other components which are not normally destructively tested have
adequate strength, but also that the whole slings can be subjected to the same heat
treatment without any adverse effects.
5.2. Supply lengths :
When chains are procured from outside sources for manufacture of slings in Railway
Workshops, the length (s) in which the chains are to be supplied, should be carefully
decided. As each length will have to be subjected to a proof load test before supply,
ordering a large number of small lengths will increase the number of proof tests to be
conducted and thereby increase the cost of the chains. The followings procedure is to
be deciding the supply lengths:
I. The minimum length of chain for making the required minimum slings length (or
slightly more as indicated in para3.5) is to be found by subtracting the effective
lengths of suspension link, all intermediate links and the hook.
II. The plane of the hook should normally be the……………………. same as that
of the suspension link unless it is specifically desired otherwise. The number of
links of the chains to get the hook to the desired plane should be odd or even
depending on the number of intermediate links. If necessary, the length of the
chain (number of links as found by I. above) be increased by one more links, to
get the hook to the desired plane.
III. The length as obtained from II. Above may be multiplied by 2,3or 4 as the case
may be, to have the longest possible and convenient supply length.
IV. To make 2 slings legs out of one supply length, one link will have to be cut and
one extra link will therefore, be required. Similarly, 2 extra links are required for
making 3 slings legs and 3 extra links for making 4 slings legs. The required
number of extra links should be added to the length arrived at III. Above.
5.3. Permissible tolerances:
The Permissible variation between the actual lengths used for the various legs of the
same slings is limited. A close tolerance should, therefore, be specified for permissible

variation between the actual length and the theoretical length for chains ordered for
making multi legged slings.
5.4. Hooks:
Eye hooks for attachment to chains will be required for manufacture of chain slings.
These are different from the hooks for wire rope sling and the shank hooks required for
cranes. While taking an enquiry or it should, therefore, be specifically stated that
eye hooks for chain slings are required.

CHAPTER-VI
6.0 Working Loads
6.1. For normal conditions of use the maximum permissible load (safe working load)
should not exceed one -half the specified proof load. When the conditions of use
are exceptionally hazard one or severe the permissible working load should be
substantially less than one half the proof load.
Where there is special risk of injury, a safe working load of not more than
0.75 times the normal safe working load should be adopted. For sling assemblies
where chains will be subjected to shock or heavy wear or will be required to work
over pulleys, or will be used for lifting vessels containing molten metal or heated
liquids, or where links are liable to be bent or indented by severe localized pressure
as when a single sling is reeved round a load having a hard irregular surface the
safe working load should not exceed 0.6 times the normal safe load.
6.2. In case of multiple leg slings, it is essential that the safe working load of any leg is
not exceeded.
6.2.1. Two leg slings:
The load lifted by two less slips must be reduced as the angle between the legs
increases. The loads given in the table of safe working loads for two-leg slings are
the greatest which can be lifted without exceeding the specified half working load
of the chains each leg. It is recommended that wherever possible the included
angle between the legs should not exceed 90°.
6.2.2. Three leg slings:
Three leg slings are often used for lifting articles which do not been themselves to
lifting by single or two leg slings. Owings to the variety of conditions under which
such slings may be used it is not possible to specify safe working loads. Users are
recommended to draw up their own tables of safe working loads; with due regard
the particular conditions of service.
Assuming equal load distribution on each leg of a three- leg slings (a condition
rarely operative), the table of safe working loads for a two-leg slings can be used
to reduce the load for a three-legs slings for any given angle between the legs and
the vertical; e.g. for angle of 30° between the legs and the vertical, the load is 50
percent greater than for a two leg slings with included angle of 60°.
As load distribution may be unequal, caution is advisable in fixing
appropriate working loads.
6.2.3. Four leg slings:

In making allowance for the angle the of four leg slings, assuring equal load
distribution for the angle of four leg slings, Assuring equal load distribution, the
angle which applies is that between the diagonally opposite legs.
Four-leg slings are suitable for lifting boxes, platforms or containers which have
some inherent flexibility tending to equalize the load distribution on the legs of
slings.
They are also used for lifting articles such as structures castings, etc., etc., where
the centre of gravity of load is not central with the four points of suspension. Also
the slinging points may be at different levels, resulting in unequal angles and
loadings of the slings legs. In such instances users should evaluate the appropriate
safe working loads to suit the particular conditions of service, care being taken that
the tension in the heaviest loaded leg does not exceed the maximum permissible
working load of one leg, taking into account the sling angularity.
Some American manufacturers give the same rating (safe working loads) for triple
and quadruple slings, as in a quadruple slings, load distribution may be more
uneven than in a triple slings.
6.3. It is recommended that the safe working load of a receivable collar slings used in
chock hitch should not exceed ¼ of the proof load.
6.4. Any change in the normal factors or any abuses will lessen the load the chain will
withstand. Some examples of such changes are given below:-
 Twisting of the chain

 Disfigurement
 Deterioration of the chain by strain, usage, weathering, corrosion or lapse of time.
 Acceleration in the rate of application of the load or jerking
 Variation in the angle of the load to some sharpen angle resulting from the
configuration or structure of the material constituting the load
 Use for a purpose other than that for which the particular type chain was intended.
 Use for carrying an excess load.

Chapter –VII
7.0 Periodical inspection and repairs of chains & slings
Periodical inspection and repairs of chains/slings will permit longer life and
lower chain costs. The chains and slings should, therefore, be inspected regularly
and sufficient chains/ chain sling should be maintained as spares for timely
withdrawal and inspection of all chains and slings, without affecting the regular
work.
Accurate records should be maintained regarding the periodical inspection
repairs and testing done to the chains/slings.
7.1. Periodical inspection:
1. Normally chains/ slings can be inspected once in six months. where the
working conditions are severe, as indicated in Para 6.1, it is better if the
chains are inspected more often any once in 3 months.
2. During periodical inspection of the chains and slings, every link of chain and
every attachment should be individually examined inspection should be
carefully done for the following-
Tracks*, Nicks, Bending or opening, the weld.
Stretched elongated or broken links or attachments.
Norn or deformed links or attachments.
Louged (Formation of sockets) links or attachments.
Links not working freely.
Bread in throat opening of hooks.
Wear in pins, shackle and pin hooks etc.
Won hardening of wrought iron links and components.
3. Chains which are found in good condition can be puf back in service. If
periodical testing is due, this has to be done before the chain is sent out for
service .Chains which are not too badly damaged or won out, can be repaired.
4. The chain should be withdrawn from service if the links are distorted or ent or
show other defects, even if the wear is not excessive. It would be dangerous
to the any mild steel chain which has been overstrained as there are

possibilities of embrittlement of chain occurring after cold working. Link

stretch or visible information of links is an indication that the chain has been
subjected shock load or of conditions of general over load. On no accounts
should chain be used if the links lave stretched to such an extent as to restrict
their free movement.
* In wrought iron chains slings, detection of minute cracks in the metal can be
made by fire test and should be applied in case of doubt.
* This can be detected more annealing by a characteristic shining showing bruised

surfaces. This can be removed by annealing.
7.2. Permissible wear in chains:
1. There are no definite standards as to the amount of wear which can be

permitted before the chain is withdrawn from service and this is largely
a matter of experience. Special care is necessary when the rate of wear
is known to be rapid and the loss of strength right reaches dangerous
proportions before the chain is due for examination again.
2. The wear will be detected at bearing points of the chain, joining links
and attachments. For measuring the mean diameter, the method
specified in Appendix B of IS2429/3109 can be followed.
3. Wrought Iron Chains: - In wrought iron hand made chains, the bar iron
is normally 1/32"over size. This is to ensure that the links will be of the
specified size of the chain after bending and scaling. For such chain, it
is generally a good practice to accept a permissible wear of 1/16 th of an
inch for each inch of the specified size of the chain (i.e.6.25%loss on
the measurement).
4. Mid steel/Higher tensile steel/alloy steel chains:- For machine made

chains, because of greater uniformity of cross sec. and finish, a higher
wear limit upto 8% on the dia. can be allowed.
7.3. Periodical repairs heat treatment and testing :
1. Repairs: - All the chains and slings should normally be repaired and
proof-tested once in 12 months. Where the working conditions are severe,
as indicated in Para 6.1the chains should preferably be repaired and tested
once in 6 months.

2. Heat treatment:-The basic difference between wrought iron chains and

mild steel/ higher tensile steel/alloy steel chains is that the former
requires periodical heat treatment. The reasons for this are:-
Steel does not suffer from extreme surface hardening due to

rubbing and abrasion to which wrought iron is subjected. It is to relieve
surface hardness that the wrought iron is annealed and not to relieve
hardness due to cold work.
Prolonged or recurrent melting of mild steel is like to have a cumulative

effects and serious loss of ductility may result. The tensile strength may
get seriously reduced, resulting in rapid wear and elongation.
The recommended temperatures for wrought iron are dangerous for mild
steel because of the danger of excessive grain growth and precipitation of
carbon as films of carbide at grain boundaries. Periodical heat treatment
of steel is, therefore undesirable.
Wrought iron chains/slings should, therefore, be annealed periodically

once in 12 months, whether any repair were done to it or not. For slings
used with molten metal or slag or subjected to severe working conditions,
the period should be reduced to 6 month.
Mild steel, higher tensile steel and alloy steel chains should not be given
any periodical heat treatment. However, in the case of chains which are
repaired the material in the region of welds is overheated and may be left
in an unsatisfactory metallurgical condition and for these reasons, all
steel chains require heat treatment before being put into use after repair.
The heat treatment after repairs should be the same as was given at the
time of manufacture. It is emphasized that heat treatment different from
that given during manufacture can cause a serious reduction in
mechanical properties.
7.4. Testing:
The proof-testing it to be done after heat treatment. It should not be waved even if
the chain /sling is found in good condition and no repairs /heat treatment are done
to it. The proof load will be twice the safe working load, unless a higher proof
load is stipulated, because of the severe working conditions.
7.4.1. During proof testing all the links and attachments should be examined for
cracks and other defects under the load. Elongation under the load and after
releasing the load should be carefully noted and recorded. There should be
permanent set and if any is found to have taken place, the chain sling will be
considered to have failed the test.
7.5. Storing and Lubrication of Chains: -

Proper storage, usually on frames, assumes quick and easy care, classification,
and inventory of chains. Lubrication of chains for prolonged storage is desirable
to avoid disintegration through rusting. However, chains should not be lubricated
when in use, since this might make them dangerous to handle. Chains should be
cleaned occasionally to remove damaging abrasive grip.
7.6. Safety recommendation:
The safety recommendations for the use, care, storage and maintenance of chains
slings are given in Annexure-III/I.

CHAPTER-VIII
8.0 Procedure for Identification, Repairs and Heat Treatment to Chains/Slings
8.1. During periodical repairs and testing, it is necessary to know the safe working load
of the chain and the heat treatment initially given at the time of manufacture. All the
relevant IS & BS Specifications insists that identification marking should be legible
stamped on all and links of the chain or upon idle links permanently attached to the end
links of the chain or upon idle links permanently attached to the end links to identify-
I. Manufacture of the chain.

II. Safe working load of the chain.
III. Type of heat treatment given to chain
IV. Reference mark to indicate the order to which the chain has been supplied.
The initial and the latest test certificates for each chain should invariably be connected
before repairs are undertaken to give the chains/slings proper heat treatment and subject
them to the appropriate loads during proof testing.
8.2. Repair of chains :

In supersession of any previous instructions, the following procedures should be
followed for repairs to chains.
8.3. Wrought Iron Chains to IRS H-3 (If still in use in the railways)
(a). Identification
The bar end used in wrought iron short link crane chain is intentionally somewhat larger
than the nominal size. Wrought iron hand welded lifting chain is normally forge welded
at one end of each link end in consequence, to welds follow at the same end of each link
in succession. Whether end or side welded, the weld in wrought iron forge welded chain
is invariable scarfed or jumped the weld being at to angle to and appreciable greater in
area than the cross- section at right angle to the eye end in the links. When end welded,
the eye end at the weld is somewhat larger than the remainder of the link and is likely to
be oval i.e. flatter in the plane of the links. In the wrought iron crane chain, the links in
manufacture are slightly bowed at side but in wrought iron block chain, the sides of the
links are more nearly parallel.
In cases, where the above means of Identifications are insufficient and where is
still long time, doubt nicking and bending the material in a link will normally now fiber
in case of wrought iron. In Exceptional cases etching on chemical analysis under
laboratory conditions may be necessary.
(b). Repairs:
i). Material for replacing links:

Due to non-availability of wrought iron for repairs, cannibalization may have to be

resorted. In case, a large number of wrought iron chains of a particular size are
available, a few of these chains size can be cannibalization for repairs of the same
or similar size , without any detriment to, the lifting capacity. If this is not feasible,
steel to IS 2073-70 class C14 may be used for manufacture of individual links.
ii). Method of repair:
Electrical flash butt welding or resistance butt welding of replace links is an

acceptable method of repair wherever suitable machines are available. Otherwise,
forge welding under adequate supervision can be adopted.
( c) Heat treatment:
i) Periodical Heat treatment:

a) Chains and slings, in which all the links and attachments are of wrought iron,
should be annealed periodically as follows.
The method to e followed for annealing should normally be “close annealing”,
the chain or lifting tackles required to be placed in a single layer in a gas or oil
fired muffle furnace, heated to temperatures given in tables below, out of
contact with the air and held at this temperature for the time specified.
Thereafter they should be allowed to cool slowly either in the furnace or by air
at room temperature. Close annealing prevents oxidation and subsequent
scaling of the surface of the metal and the chain is heated more uniformly than
in other types of furnaces. Coal or coke may also be used for a close annealing.
Table
In a of chain Annealing Time of hold at
link in mm temperature temperature.
0.3 to 12.5 640- 6600 C 30 min
16 to 25 640- 6600 C 60min
28 to 40 640 – 6600 C 90min
40 to 51 640 – 6600 C 130 min

b) Wrought iron chains where some of the links have been replaced by links made
out of steel to IS:2073, should be heated uniformly to a temperature above
AC3 for the steel, soaked at this temperature for a suitable length of time and
then allowed to cool in air protected from draught. This treatment should also
be done periodically.
ii) Heat treatment after repairs:

Same as given in (i) above.
(d). Proof Testing:
After repairs and heat treatment, the chain should be proof- tested as per clause 17
of ` IRS H3-53.
8.4 MILD STEEL CHAIN GR.30 TO IS:2429-70
1. Identification:
The specification permit to the following heat treatment to these chains:

(a) Stress relieving by heating by heating to temperature sufficiently below the
critical range (600-650°C) followed by uniform cooling; or
(b) Normalizing by heating to temperature within 50°C above the upper critical
point of the steel used, followed by cooling in still air; or
(c) Hardening and temperature by heating to a temperature within 50°C above
the upper critical point of the steel used, followed by quenching in oil or
water and tempering.
The identification of the chains can be easily done as identification marks are to
be provided as per requirements of the specification as below:
“Quality marking – Each twentieth link subject to a minimum distance of 1m
shall be legibly stamped as follows:-
(a) Stress relieved chain with the mark SRS.

(b) Normalized hardened and tempered chain with the mark 3.
2. Repairs:
i) Material for replace links.

Mild steel to IS-226 can be used.
ii) Method of repair.
Electric flash butt welding or resistance butt welding of replace links is

an acceptable method of repair wherever suitable machines exist. Alternatively,
forge welding under adequate supervision can be adopted.
In case, these methods are not possible, are welding of the replace links can be
don; provided the welders are qualified and competent.

3. Heat treatment
i) Periodical heat treatment.
Periodical heat treatment of these chains should not be done.
ii) Heat treatment after repairs.
After repair, the chain should be given the same heat treatment as per
details given in the test certificates supplied by the chain manufacturers.
3. Proof testing.
After repairs, the chains should be proof- tested and inspected as per
clause 8.2 and Table I of IS-2429.
8.5 STEEL CHAINS TO IS 3109 (PART I)- 1970, Grade 40
1. Identification.
The specification lays down that the chain before proof-testing shall be
hardened and tempered and shall be marked at each interval of 1m. or every 20th
link by the symbol 4.
2. Repairs.
i) Material for replace links.

Steel to Cl.3 of IS-1875 can be used for making replace links.
ii) Method of repair.
Electric flash butt welding or resistance butt welding of replace links is

an acceptable method of repair wherever suitable machines exist. Forge welding
or blow pipe welding is totally unsuitable.
3. Heat treatment.
i) Periodical heat treatment.

Periodical heat treatment heat of these chains should not be done.
ii) heat treatment after repairs.
After repair, the chain should be subjected to the same heat
treatment as mentioned in the manufacturer’s test certificate.
4. Proof testing.
After repairs, the chain should be proof-tested and inspected as per

clause 8.2 and Table I of IS-3109.
8.6 STEEL CHAINS TO IS 6217-71 Grade-63.
1. Identification.
As per the specifications, all chains before testing shall be hardened by

heating to a temperature within 50°C above the upper critical point of the steel

used, followed by quenching in oil, brine or water at a suitable temperature and

tempered. These chains are marked with figure ‘63’ at every 1meter intervals or
at every 20th link.
2. Repairs.
i) Material for replace link.

Alloy steel similar to the parent material (Material specified in IS 6217-71).
ii) Methode of repair.
Electric flash butt welding of replace link is an acceptable method of repair.
Forge welding or below pipe welding is totally unsuitable for alloy steel
chain repair.
3. Heat treatment.
Chain and sings to the specification are carefully heat treated during manufacture
to produce the necessary mechanical properties and special equipment which may not be
readily available may be required. Haphazard or improvised heat treatment should not
be applied for chains. Any heat treatment to chains and components, after service,
should be done only on the advice of the experts and under their care and supervision.
4. Proof testing.
After repairs, the chain should be proof tested as per clause 6 and Table 2 IS 6217-71.
INFORMATION TO BE SUPPLIED DURING ENQUIRY OR ORDER

ENQUIRY ORDER
CHAINS
Capacity of chain Capacity of chain
Length Length(s) of chain
*Specifications *Specifications
Calibrated (for use with pulley blocks) Calibrated (for use with pulley
or uncalibrated for use with chain slings. blocks) or uncalibrated for use with
chain slings. Grade of the chain,
size of the chain IS/BS specification
to which it should conform.
Inspecting Authority.
CHAIN SLINGS
Capacity (capacity of each leg should Capacity (capacity of each legs
preferably be specified). For two- legged should preferably be specified). For
slings, capacity of the sling when the two- legged slings, capacity of the
legs are at an angle of 90° in each other sling when the legs are at an angle
can also be specified. of 90° in each other can also be
specified.
No.of legs. No. of legs.
Overall length of the slings. Overall length of the slings.
The type of suspension link required i.e. The type of suspension link required
whether the top most link should be an i.e. whether the top most link should
oblong link or a ring. This is to be be an oblong link or a ring. This is
decided based on the crane hook with to be decided based on the crane

which the chain sling is proposed to be hook with which the chain sling is
used so that the sling can go on to the proposed to be used so that the
hook. sling can go on to the hook.
IS/BS specification / which the
chains and the other components
will conform.
HOOKS
Type of hook required i.e. (i) Crane Type of hook required i.e. (i) Crane
hook or ramshorn** hook, (ii) Shank hook or ramshorn** hook, (ii)
hook (for use as hook on cranes) or Eye Shank hook (for use as hook on
hooks (for use with chain slings). cranes) or Eye hooks (for use with
chain slings).
Cross section trapezoidal or circular- Cross section trapezoidal or
Trapezoidal section should be preferred. circular-Trapezoidal section should
be preferred.
Rated working load. Rated working load.
Material Material
Specification to which the hook should Specification to which the hook
conform. should conform.
Details of screw threads in case of shank Details of screw threads in case of
hook. shank hook.
Type of Eye required in case of Eye Type of Eye required in case of Eye
hooks i.e. whether for joining links hooks i.e. whether for joining links
shackle or wire rope thimbles. shackle or wire rope thimbles.
In case of ramshorn hook whether a In case of ramshorn hook whether a
central shackle is required for light central shackle is required for light
loads. loads.
Whether load stop is required Whether load stop is required
*Any particular IS or BS specification **Ramshorn hooks are normally
should be stipulated only if the chain is order when the capacity of hooks is
to to be of a particular grade so that it over 40 Tons.
can be used for have already been
decided(see para 5.1 ) otherwise, the
various see paras 1.2 and 7. Normally it
is a good practice to ensure that any
sling can be attached to a crane hook
whose capacity is 5 times that of the
sling.

CERTIFICATE OF TEST AND EXAMINATION ( CHAINS)

( Extracts from IS-2429)
We hereby warrant that the chain (s) supplied described hereunder, conforming
in all respects to IS: 2429-1967 “Specification for electric butt welded steel chain, short
link and pitched or calibrated, Grade30 , for listing purposes.”
Quantity of Length……………………………………………………..
Description:
Short link chain:

Unpolished.
Pitched or calibrated chain:
Polished:
Unpolished:
The actual result(s) of the tensile test (s) made on a length of one meter(or
equivalent ) of the chain(s) supplied is (are) as follows:
IDENTIFICATION SIZE OF PROOF LOAD ON EQUIVALENT ENERGY
MARK (S) ON CHAIN LOAD TEST EXTENSION ON ABSORPTION
END LINKS SIMPLE 1m FACTOR
TEST SAMPLE
1 2 3 4 5 6
mm kgf kgf mm kgf.m
Particulars of the heat treatment to which the chains has been subjected in
manufacture as follows:
We hereby certify that the whole of the above chain has been subjected to the
appropriate proof by a competent person.
Note: For normal conditions of use, the same working load shall not exceed one-half the
proof load.
Manufacturer…………………………………
Signature………………………………………..
Date of Test……………………………………

CERTIFICATE OF TEST AND EXAMIONATION (HOOK)

(Extracts from IS:3822)
Distinguishing Description Material Number Proof Load applied in the Safe

Mark of hook tested load Destruction test on working
applied the test sample. load
1 2 3 4 5 6 7
kgf kgf
Particulars of the heat treatment to which the hooks have been subjected, stating
temperatures and methods of cooling, are as follows: manufacture as follows:
…………………………………………………………………….
…………………………………………………………………….
We hereby certify that the hooks described above, comply in all respects with
IS: 3822-1966 and that they were subjected to the proof load and
subsequently examined and passed by a competent person.
Signature……………………………………..
Date of Test…………………………………

CERTIFICATE OF TEST AND EXAMIONATION (CHAIN SLING)

(Extracts from BS:2902)
Distinguishing Description Number tested Proof load applied Safe working load
Mark Tons cwt.
1 2 3 4 5
The materials of which the components of the sling (other than the common links) are
made, comply with the following En series of BS:970;
……………………………………………………………………………………………
……………………………................……………………………………………………
…………………………………………………………………….................……………
……………………………………………………………………………………………
………………...............................................
Particulars of the heat treatment to which the common links and slings components
have been subjected setting temperatures and methods of cooling:
…………………………………………………………………….
We hereby certify that the slings or sling component described above comply
in all respects with IS: 2902 and that they were subjected to the proof load
and subsequently examined by a competent person.
Note: For normal conditions of use, the maximum permissible loaded (same
working load) of any component shall not exceed one half proof load.
Signature………………………………………..
Date of Test……………………………………
*State type, Size, and length of sling, or type and size of component.

SAFETY RECOMMENDATIONS FOR THE USE, CRANE AND

MAINTENANCE AND STORAGE OF CHAIN AND SLINGS
1. Excessively pitted, nicked, corroded, deeply scratched or worn chain should not
be used.
2. A chain in which the links are locked or stretched, or are without free movement
should not be used.
3. Overloading chains or chain sling must be avoided.
4. It should be remembered that the safe working a multiple leg sling decreases as
the angle between the leg increases. Also that with a 3 or 4 leg slings, two of the
legs may be taking the greater part or even whole of the load.
5. Avoid lifting with a kink, knot or twist in chains.
6. A suitable pad should be used to prevent gouging or bending of the chain links as
well as possible scarring of the load.
7. Hammering a chain to strengthen a link or to force a link or hook into position
should be avoided.
8. Insertion bolt/ or spikes to shorten chains should not be resorted to.
9. Insertion of the tip of a hook into a chain link should not be resorted to.
10. The load should not be carried on the point or tip of the hook.
11. A unbalanced load should not be carried.
12. Special care should be taken to avoid snatch or sudden loads.
13. Precautions always to be strictly observed.
a) Do not take chances if a chain does not look safer get it repaired or
passed by the instructor.
b) Do not assume a chain safe because it is new chain can be ruined by a
single overload.
c) Do not cross, twist, kink or knot any chain sling.
d) Do not drag a chain or sling from under a load.
e) Do not drop a chain or sling from a height.
f) Do not let a load rest on a chain.
g) Do not allow load to fall on a chain.
h) Do not roll loads over with a chain or sling.
i) Use of chain or sling over sharp corner or allow severe bending of the
links should be avoided.
j) Do not use an excessively worn chain by reducing the safe working load,
when wear is excessive, the chain should be discarded.
k) Do not forget to keep record on all chain and call for regular periodical
inspection no matter how good your chain looks to you.
14. Special precaution must be taken and a larger size chain or sling used when-
a) The exact load is in doubt.
b) There is a liability to shock.
c) The conditions are abnormal or severe.
d) There is exceptional hazard to life and limb.

Remember that -
15. Chains are important equipment and should be treated as such.

17. Wrought iron chain slings and component must be periodically annealed.
18. Periodical heat treatment any link necessary for wrought iron chain is not
required and unnecessary for steel chains including alloy steel chains.
19. Higher tensile load or alloy steel slings carefully heat treated during manufacture
to produce the necessary mechanical properties and special equipment, which
may not be readily available, is required. Do not to tempted to apply haphazard
or improvised heat treatment as if this is carried out wrongly will weaken the
steel. No Heat treatment of steel chains and component should be applied after
service except on the advice of expert and under their care and supervision, send
the slings to the makers or to a repairers establishment, competent to do the
work.
20. Fire –Welding or blow pipe welding is totally unsuitable for higher tensile steel
chains and slings. Repairers should be made or joining fitting attached by the
approved methods.
Storage
21. Chains should never be stored in damp dirty places or in places crossed to the
weather.
22. Chains which are to be placed in storage for any length of time should receive a
coating of oil. Hang than a clean dry place.
23. L Frames provide an excellent method of taking care of chain when not actually
in service. The chain should be hung from pipe at the top of the L frame and loop
free of the floor.
RECOMMENDATIONS FOR THE USE OF RAMSHORN HOOKS
1. The Ramshorn hooks covered by this standard should not be upgraded for
use with slings is included angles less than 90°, as the capacity of the hook is
also governed by the permissible stress is the shank. (Advantage cannot
therefore, be taken of the increased body strength when the included sling
angles are less than 90°.
2. Ramshorn hooks should not be used with sling legs at excessive angles, since
the stress in the body of the hook will increase at greater rate than that in the
sling leg. (Tables of angular loading on slings will not therefore be equally
applicable to the loading on the ramhorn hook.
3. For heavy and bulky loads. It is preferable to use a lifting been suspended
from the hook by two pairs of links at fixed centres, the centres of the link

pins on the base being slightly greater than the canters of the bed diameters
of the hook.
4. Appropriate included angles between the link plates would be of the order of
30°. With so small an included angle the stress reduction fe.. for the hook
body is less than one-half.
5. To avoid the danger of overloading individual link plates and their associated
link, pins, due to the possible tilting of the beam end the consequent out of
balance effect, link plate assemblies should be designed with an angle margin
of safety.
6. When using lifting beams, their length can be arranged to take varying
centres of slings to suit the loads, and ensure true balancing. True balancing
is essential in order that the hook may rotate freely under load when required.
7. When lifting bulky loads where the centre of gravity is not central between
the points of slinging, it is desirable to adjust the length of the slings so that
the centre of gravity of the load is immediately below the centre line of the
hook.
8. In order to reduce the effort required to rotate the hook when loaded, it is
recommended that the hook be carried on a ball or roller thrust bearing.
9. When sling angles approach the limiting included angle for which the hook is
designed, it is necessary to take are that neither of the two horns is subjected
to a load exceeding one-half of the safe working load of the hook, since the
stress reduction factor would then be nearly unity, and any out of balance
affect could overload one of the horns. When lifting loads just within the
opacity of the hook, extreme care is needed in this respect.
____

Maintain and Operate 140T Cranes, ARTs & ARMEs

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GOVERNMENT OF INDIA

MAINTENANCE AND OPERATION

Maharajpur, Gwalior – 474005 (INDIA)

This “Maintenance and Operational Manual for 140T Cranes, ARTs

The guidelines in the Manual will not supersede any standing

Indian Railway is a vast system comprising of nearly 64000 route kilometres

CHAPTER NO. 2 Operation of 140 T. Break Down Crane &

CHAPTER NO. 3 Deployment of Break Down Staff and

CHAPTER NO. 4 Important Rules for ARTs/ARMEs & SPARTS

CHAPTER NO. 5 Important Letters from Railway Board & RDSO

CHAPTER NO. 6 Record Keeping and Certification

CHAPTER NO. 7 Technical Description of GOTTWALD 140T.

CHAPTER NO. 8 DO’s and DON’Ts for COWANS SHELDON 140 T.

CHAPTER NO. 9 Operation of Hydraulic Re-railing Equipments

CHAPTER NO. 11 Dealing with LPG & Ammonia Gas

CHAPTER NO. 12 Drawings and Layouts for Composition of

CHAPTER NO. 13 Relief and Rescue Operation on Passenger Train

CHAPTER NO. 14 Infrastructural Facilities for Maintenance of 140

CHAPTER NO. 15 High Speed SPART

Appendix – I Chains & Chain Slings

Rules for the working of Cranes

II. Responsibility for correct carrying out of Rules 06

7. 140T Diesel Hydraulic Cranes 15

Code of Signals for controlling movement of Cranes 19 to 22

140 T Diesel Hydraulic Breakdown cranes ( Cowans sheldon) 32

Form Particulars Page

1.0 Designated use of the machine 03

Standard Lists for ART, ARME, SPARMV & SPART

Drawings and Layouts for Composition of ART/SPART/ARME on IR.

Chains & Chain Slings

TECHNICAL CONSIDERATIONS FOR PROCUREMENT INSPECTION, TESTING AND

Chapter I Specifications for Chains & Chain Slings 1-2

Chapter II Grades of Chains 3

Chapter III Technical Considerations for choosing slings 4-5

Chapter IV Procurement of chains, chain Slings and their 6-7

Chapter V Manufacture of Chain Slings in Railway Workshops 8-9

Chapter VI Working Loads 10-11

Chapter VIII Procedure for Identification, Repairs and Heat 15-19

Chapter IX Information to be supplied during enquiry or order 20-27

RULES FOR THE

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

RULES FOR THE WORKING OF CRANES

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

1. Preparation and implementation of Disaster Management plan is the responsibility

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

II. Classification of Cranes -

1. Cranes belonging to the Railway are divided into three classes :-

2. Main Line Traveling Cranes are further sub divided in to :-

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

III. Traveling Cranes. Hire and Haulage Charges :-

(i) Cost of Diesel/Lube oil etc.

SSE(Diesel)/SSE(C&W) of depots where Break down or other cranes are posted

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

I. Qualifications and Examination of Crane men :-

A crane may only be worked/Handled by a properly Trained/certified crane man.

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

"This is to certify that Mr.............................................No.........................................

Chief Mech. Engineer.

(Proforma of Competency Certificate )

Operation Manual for Working of ART\ARME\140 Te. Cranes\5

B. In general, cranes working on breakdown operations or where the balance

C. In Electrified sections, before commencing the operation, the crane supervisor/

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