English - Rdso - Ministry Of Railways

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(For official use only) GOVERNMENT OF INDIA MINISTRY OF RAILWAYS Tools/plants & spare parts to be kept with the track machines (a) At base station (b) During block CAMTECH/2004/C/TL-PL/1.0 MARCH - 2004 Centre for Advanced Maintenance Excellence in Maintenance TECHnology Maharajpur, GWALIOR - 474 020 Tools/plants & spare parts to be kept with the track machines (a) At base station (b) During block Foreword Track machines play an important role in track maintenance. Certain tools/plants & spare parts are desirable to be kept with the machines for proper and optimum output of the machines. This handbook mainly focuses on the list of spares, tools/plants to be kept at base station and during block with machine for its proper maintenance and repairing for achieving maximum output from machines. Civil Engineering branch of CAMTECH has made excellent effort to bring out this handbook. I am sure that this handbook would be useful as reference book for track machine officials of engineering branch for proper upkeep of track machines. CAMTECH/Gwalior Date : 16 .03.2004 C.B.Middha Executive Director Preface These days, with ever-increasing reliance on on-track machines for track maintenance, it is essential to obtain maximum output with high standard from these costly & sophisticated machines for proper utilisation. The objective of this handbook is to provide desirable list of tools/equipment & spare parts to be kept with the machines at base station and during blocks with the aim to attend the minor repairs & break downs during block in least possible time, to ensure proper utilization of machines and to avoid traffic block bursting. This handbook is for general guidance for track machine staff and does not supersede any existing instructions from Railway Board, RDSO, Zonal Railways & Track Machine Manual on the subject. This handbook is not statutory & contents are for the purpose of guidance only. I am grateful for the assistance given by Shri Neeraj Shrivastava, STA/Civil/CAMTECH, who went through the complete text, collected information, data etc. Nice data entry & formatting has done by Shri Ramesh Bhojwani, Console Operator, CAMTECH. We welcome valuable suggestions from our readers for further improvements. CAMTECH/Gwalior Date : 15.03.2004 Manoj Agarwal Director/Civil CONTENTS Sr. No. Description/Topic Page Nos. Foreword i Preface ii Content iii Correction Slip iv 1.0 Introduction 01 2.0 Desired equipment and tools with all machines. 03 3.0 Track tamping machines (CSM & Express tamper) 09 4.0 Point & crossing tamping machine (UNIMAT) 18 5.0 Ballast regulating machine (BRM) 23 6.0 Ballast/Shoulder cleaning machines (FRM & BCM) 26 7.0 Dynamic track stabiliser (DGS) 37 Notes 40 *** ISSUE OF CORRECTION SLIPS The correction slips to be issued in future for this handbook will be numbered as follows: CAMTECH/2004/C/TL-PL/1.0/CS. # XX date …… Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards). CORRECTION SLIPS ISSUED Sr. No. of C.Slip Date of issue Page no. and Item No. modified Remarks CAMTECH/C/2004/TL&PL/1.0 1 CHAPTER - 1 Introduction In present scenario, with ever increasing traffic density with higher speed and axle load, the track structure has been upgraded by using PSC sleepers, higher poundage rails & LWR track etc. These days due to heavy track structure, temperature restriction due to LWR and ever reducing time availability for maintenance, manual attention of track has become practically difficult. Therefore, to maintain the track to fine track tolerances for a smooth and safe riding, a mechanised track maintenance system has been introduced gradually on all-important routes. Under mechanised maintenance main inputs to the track is given by heavy duty on track machines, such as tamping machines, ballast-regulating machines, ballast cleaning machines and dynamic stabilising/consolidating machines. These track machines are very costly and sophisticated; therefore to obtain optimal output both qualitative and quantitatively, it is essential to keep the breakdown time of machines to bare minimum. Accordingly a periodic & daily maintenance schedule has been laid down for the various machines. However, to attend the minor repairs at base station under daily maintenance schedule and the break down during blocks, availability of certain tools/equipment and spare parts is desirable with the machines. Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 2 In the subsequent chapters the details of such tools/equipment and the spare parts, which are desirable, to be kept with the various machines at the base station and on the machine during blocks has been given. In the enclosed list the necessary details of part number have been provided, however the machine staff shall ensure that the spare parts kept on the machine conforms to original equipment manufacturer’s specification. *** Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 3 CHAPTER - 2 Desired equipment & tools with all machines AS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. At base station. Description DG set (5 KVA) Welding plant Bench grinder Bench vice and a work table Drill machine (230 V AC with stand) Portable filter plant Hot air blowers Digital multi-meter Accumulator pressure checking and filling device PC-250 complete Torque wrench Pendulum calibration pads Versine measuring chord with complete instrument Go-No-Go gauge for tamping gauge Tamping tool profile bore gauge Steel scale 1' to 6 " Taper gauge upto 1" Feeler gauge Thread gauge Cell tester (battery voltage) Battery charger (oil bath type) Digital calliper Tool/plants & spare parts to be kept with the machine Qty. 1 1 1 1 1 1 1 1 1 set 1 set 1 set 1 set 1 2 1 set 1 1 1 1 1 1 March - 2004 CAMTECH/C/2004/TL&PL/1.0 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. Hydrometer Chain pulley (3 t capacity) Pipe cutting machine (disc cutter) Jerry cane (20 litres capacity) Oil filling pump Funnel for oil filling Grease pump Distance pieces of various sizes Tyre defect gauge Tamping tool measuring gauge Steel tray Bearing puller Lamp arrangement for inspection Litmus paper Tool/plants & spare parts to be kept with the machine 4 1 1 1 1 1 1 1 1 set 1 1 2 1 1 1 March - 2004 CAMTECH/C/2004/TL&PL/1.0 B– S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 20. 5 During block. Description Safety items Red hand signal flags. Green hand signal flag Tri-colour hand signal lamps Chains with padlocks. Clamps with padlocks Fog signals (detonators) in a tin case A copy of the working time table of the section where the machine is working. G&SR book with up to date amendment slips. 4 cell flasher light. Portable field telephone Walkie-talkie Banner flags First aid box. Skids Petromax/LPG lamps Safety helmets for machine staff Protective clothing, safety shoes with face mask and safety gloves. Track machine manual Accident manual. Rail thermometer Gauge-cum-level Fire extinguisher Tool/plants & spare parts to be kept with the machine Qty. 2 1 2 2 2 10 1 1 1 1 1 set 2 1 2 2 1 1 1 1 1 March - 2004 CAMTECH/C/2004/TL&PL/1.0 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. Hooter (manual) Equipment & tools Jack 50 t with traversing system Jack 5 t Wooden blocks Crow bars Trefor (3t) Hydraulic hand pump (for emergency back up) Emergency pneumatic/hydraulic hose of sizes suiting to different machines (complete with end fittings) Wire rope with close loops at both ends 2 metres & 9 metres (12 to 16 mm dia.) Machine drawing and catalogue D-Spanner set Ring spanner set Allen key set Pipe wrench Nose plier Combination plier Circlip plier (outer & inner) Monkey plier Chain adjusting plier Punch (drift pin) Files of different sizes (half round, flat, round) Needle file Drill bit Trap set of different sizes Seal puller Tool/plants & spare parts to be kept with the machine 6 2 2 1 8 4 4 1 1 1 each 1 1 set 1 set 1 set 1 set 1 1 1 each 1 1 1 set 1 set 1 1 1 set 1 March - 2004 CAMTECH/C/2004/TL&PL/1.0 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. Box spanner Screw driver of different sizes (star head & plain) Tommy bar of different sizes Hacksaw Hammer of different sizes (metal & plastic) Pad locks Grease gun Measuring tape (3 metre) Set of chisel Diode tester Key of different sizes for shaft Key Extractor Torch Soldering iron (24 V DC) Tool box De-soldering gun Soldering wire one role Flux PCB extension chord Puller Wire stripper Extension lead Flat Spanner Set Pump Plier Extension pipes of different sizes Oiler Scrapper (flat & triangular) Tool bag for MWM/Cummins engine Adjustable screw wrench (up to 12") Tool/plants & spare parts to be kept with the machine 7 1 set 1 set 1 set 1 set 1 set 3 1 1 1 set 1 1 set 1 1 1 1 1 1 1 1 1 2 1 1 set 1 1 set 1 1 each 1 1 March - 2004 CAMTECH/C/2004/TL&PL/1.0 75. 76. 77. 78. 79. 8 Single end spanner off set (55 mm to 212 mm) Steel bucket Dummy & adopters of all sizes O-Rings of sizes Fuses (4A, 2A, 1A) 1 set 1 1 set 1 set 2 each *** Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 9 CHAPTER – 3 Track Tamping Machines (CSM and Express tamper) AS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Tools for CSM and Express Tamper Description Hook spanner Aluminium protection 125 mm Copper rod 20 X 200 mm Piston ring press 2 X 1/8” to 5” Ring for piston ring (Sq. Big) 2E 130.01 Qty. 1 2 1 1 1 Side cutter 6” Puller complete E130.150a Extractor (pin) E130.151 Ring for piston ring (Sq. Small) 2E 130.02 Piston ring plier 1 1 1 Set 1 To be taken in block -do-do-do-do- 1 -do- Tool/plants & spare parts to be kept with the machine Remarks March - 2004 CAMTECH/C/2004/TL&PL/1.0 BS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 10 Spares for emergency on CSM. Description Seal set for small squeezing cylinder Qty. 4 sets Big squeezing cylinder seal sets Tamping unit Up & Dn hydraulic cylinder seal sets 35 mm pin Satellite pin 25 mm dia (U-61104) Piston rod assembly for big and small squeezing cylinder Tamping tools Tamping tools bolt Tamping tool cap Locating screw Clamp roller Tamping depth transducer chord Versine transducer chord Chord wire (2 mm) Carrier T/depth transducer Versine transducer carrier Seal set for all hydraulic cylinder Fuel pre-filter Primary fuel filter Secondary fuel filter Lube. oil filter 2 sets 2 sets Remarks To be taken in block -do-do- 2 1 -do-do- 1 set -do- 1 sets 8 8 8 2 7m 7m 30 m 2 2 1 set each 1 1 1 2 -do-do-do-do-do-do-do-do-do-do-do-do-do-do-do- Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. Fuel pressure hoses (injector pipes) Radiator hoses Set of copper washer High pressure hydraulic hose with spare fittings (2781-4) High pressure hydraulic hose with spare fittings (2781-6) High pressure hydraulic hose with spare fittings (2781-8) High pressure hydraulic hose with spare fittings (2781-10) High pressure hydraulic hose with spare fittings (2781-12) High pressure hydraulic hose with spare fittings (2781-16) High pressure hydraulic hose with spare fittings (2781-20) (503-24) With spare fittings Pneumatic hose ¼" Pneumatic hose ½" Relay ELT – 663 Relay 7002/S4 Relay ELT 277 PCB EK 813, EK16, EK24, EK347,EK 349 Head light and working light bulb Tool/plants & spare parts to be kept with the machine 11 1 set -do- 1 set 1 packet Max. length provided on m/c. -do- -do-do-do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do5m 5m 2 2 2 1 each -do-do-do-do-do-do-do- 2 nos. each -do- -do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. Satellite transducer spring ELT-1041-12 Pin bolt, 32 ½ mm dia Damping ring (GR-100) V-Belt Break shoe Battery terminals Thimbles of sizes Distilled water Suction filter Proportional filter Servo valve filter ZF in line filter Return line hydraulic filter Air cleaner filter element (outer & inner) Grease hose assembly Teflon washer PG bush Potentiometer EL-T500, EL-T595A Variable pump suction filter Pin 55 mm Cardon shaft Engine to ZF gear box Engine to funk gear box Distributor gear box to axle gear box Tool/plants & spare parts to be kept with the machine 12 1 -do- 1 1 1 set 2 4 20 10 litres 4 1 2 1 2 2 set -do-do-do-do- 1 set 16 16 1 each 2 2 1 1 1 March - 2004 CAMTECH/C/2004/TL&PL/1.0 63. ZF to distributor gear box 64. Engine oil API – CF4-15W40 65. Gear oil SAE –90 66. ZF oil ultra 10W or equivalent * Ten litres to be carried in block. Tool/plants & spare parts to be kept with the machine 13 1 To be taken in block 50 lts. 50 lts.* 60 lts. March - 2004 CAMTECH/C/2004/TL&PL/1.0 CS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 14 Spares for emergency on Express Tamper. Description Engine Fuel pre-filter (breather) Qty. Remarks 1 Primary fuel filter Secondary fuel filter Lube. Oil filter Air cleaner filter Radiator hoses Injector pipes ‘V’ belts Fuel flexible hoses Tamping unit Piston rod assembly Tamping tool (WN 300 NI Z 70.500-1 FRI) Tamping tool (WN300 NI Z70.500-1 FRW) Tamping tool bolts Tamping tool cap Tamping tool bolt (G 30, 42) Tamping depth transducer chord Carrier tamping depth transducer. 35 mm & 40 mm pin steel bush, nut & washer. Gear ring for vibration coupler. Tamping tool key 1 1 2 1 set 1 set 1 set 1 set 1 set To be taken in block -do-do-do-do-do-do-do-do- 1 set 8 -do-do- 4 -do- 4 4 2 7 mtrs. 1 1 each -do-do-do-do-do-do- 1 6 -do-do- Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 12. 13. 14. 15. 15 Roof clamp Clapper cylinder Clapper bracket Clapper cylinder pin (12 mm, 16mm, 20mm) Tamping unit Up & Dn hydraulic cylinder seals Tamping unit Up & Dn hydraulic cylinder piston rod (complete) Hydraulic Proportional filters Servo filters ZF In-line filter Hydraulic suction filter Hydraulic return filters Seat set for all hydraulic cylinders 4 1 2 2 sets 7. Hydraulic hoses with spare fitting 2781-4 8. Hydraulic hoses with spare fitting 2781-6 Hydraulic hoses with spare fitting 2781-8 Hydraulic hoses with spare fitting 2781-10 Hydraulic hoses 2781-12 (Crimped fittings) Max. length provided on m/c. -do- 16. 17. 1. 2. 3. 4. 5. 6. 9. 10. 11. Tool/plants & spare parts to be kept with the machine -do- 1 set 1 set 2 2 1 1 set 1 set 1 set To be taken in block -do- -do- -do- -do- -do- -do- -do- -do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 12. 13. 14. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 3. 4. 5. 6. 7. Hydraulic hoses 2755-16 (Crimped fittings) Hydraulic hoses 1781-20 (Crimped fittings) Hydraulic hoses 1503-24 (Crimped fittings) Electrical PCB EK-816,429,429DV,430DV, 813 DV PCB EK-1AP7 Relay El-T 7064/24 Relay El-T 7054/24 Fuses Head light & working light bulbs Versine transducer carrier Versine transducer chord 0.80 mm Longitudinal transducer chord 1.33 mm Miscellaneous Track lifting roller Chord wire 2 mm Pneumatic hose ¼" & Hose ½" Cardon shaft engine to ZF gear box Cardon shaft ZF gear box to distribution gear box Cardon shaft distribution gear box to axle gear box Brake shoe Tool/plants & spare parts to be kept with the machine 16 -do- -do- -do- -do- -do- -do- 1 each -do- 1 2 2 4 2 each 1 7 mtrs. 7 mtrs. -do-do-do-do-do- 1 30 meters 5 meters 1 1 1 2 March - 2004 CAMTECH/C/2004/TL&PL/1.0 8. 17 1 set 9. Satellite support roller complete assembly Tamping depth transducer 10. Proximity switch ELT 1482 K 1 no. 1 To be taken in block -do- *** Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 18 CHAPTER – 4 Point and Crossing Tamping Machine (UNIMAT) AS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Tools Description Hook spanner Qty. 01 Nos. Piston ring plier Ring for piston ring (Squeezing) 2E130.02 A Side cutter (cutting plier) 6" Extension piece DL 131-02 Flushing plate DL 40-579 Mechanical puller E 130-150a Extractor (Pin) E 130-151 Piston ring press 2 X 1/8 " to 5" 01 Nos. 01 Set Tool/plants & spare parts to be kept with the machine 01 Nos 01 Nos. 03 Nos. 01 Nos. 01 Set 01 Nos. Remarks To be taken in block -do-do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 BS. No. 1. 19 Spares for emergency Description Engine Fuel pre-filter (breather) 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Primary fuel filter Secondary fuel filter Lub oil filter Air cleaner filter Radiator hoses Injector pipes ‘V’ Belts Fuel flexible hoses Gear oil SAE-90 Engine oil API-CF4 15W40 ZF oil ultra 10W or equivalent Tamping unit 1. Piston rod assembly complete 2. Tamping unit Up & Dn hydraulic cylinder seals 3. Tamping tool (2 W.81.418) 4. Tamping tool (W.37.1320) 5. Tamping tool bolts 6. Tamping tool cap 7. Tamping tool bolt (G30.42) 8. Tamping depth transducer chord 9. Carrier tamping depth transducer * Ten litres to be taken in block Tool/plants & spare parts to be kept with the machine Qty. Remarks 1 To be taken in block -do-do-do-do-do-do-do-do- 1 1 2 1 set 1 set 1 set 1 set 1 set 50 lts.* -do60 lts. 1 2 set -do-do- 4 4 4 4 2 7 mtrs. 2 -do-do-do-do-do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 10. 1. 2. 3. 4. 5. 6. 7. 35 mm pin with steel bush, nut & washer Gear ring for vibration coupler (GR 63) Tamping tool key Tool tilting cylinder Pin bolt (W.31.133A) Pin bolt (CU.37.632) Rubber ring (W.33.83) Round hard lock nut Pin 60 mm size (W371410) Spacer (W371440) Radial seal (DL1222) Pressure disc 2 E 3441 Part clutch Tamping arm Tamping unit Up & Dn hydraulic cylinder piston rod (complete) Hydraulic Proportional filters Servo filters ZF in-line filter Hydraulic suction filter Hydraulic return filters Squeezing filter Hydraulic hoses 2781-4 8. Hydraulic hoses 2781-6 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Tool/plants & spare parts to be kept with the machine 20 1 -do- 1 -do- 6 1 2 2 6 1 1 set 1 set 1 1 1 1 1 -do-do-do-do-do-do- 2 2 1 4 1 set 2 Max. length provided on m/c. -do- To be taken in block -do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 9. 10. 11. 12. 13. 14. 15. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 1. 2. 3. 4. 5. Hydraulic hoses 2781-8 Hydraulic hoses 2781-10 Hydraulic hoses 2781-12 Hydraulic hoses 2755-16 Hydraulic hoses 2781-20 Hydraulic hoses 1503-24 Seal set for all hydraulic cylinders Electrical Contact block Battery terminal Distilled water Thimble of different sizes Alternator Self starter Relay 7002/S4 Relay ELT.663,277,7045,7010 Head light & working light bulbs Versine transducer carrier Versine transducer chord PCB EK 813 PCB EK 132 Miscellaneous Track lifting roller Chord wire 2 mm Pneumatic hose ¼" Pneumatic hose ½" Cardon shaft engine to ZF gear box Tool/plants & spare parts to be kept with the machine 21 -do-do-do-do-do-do1 sets -do-do-do-do-do-do-do- 2 4 10 litres 20 1 1 2 2 each 2 each 1 7 metres 1 1 To be taken in block -do-do-do-do-do-do-do- 1 30 metres 5 metres 5 metres 1 -do-do-do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 6. 7. 8. 9. 10. 22 ZF gear box to distribution gear box Distribution gear box to axle gear box Brake shoes Brake cylinder seal Reduction gear box to ZF 1 -do- 1 1 1 4 *** Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 23 CHAPTER – 5 Ballast Regulating Machine (BRM) AS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Tools Description Socket 3, ½ size, 6 PT Socket ¼ inch square drive Chain wrench 5/8 " 4.1/2" Open end wrench 1 – 11/16" Handle T-bar Adopter T-bar Socket ¼" square drive 12 PT 2. ¼", ¾" drive Socket set 17 PCs ½" drive Wrench 2-3/8 open end Wrench set 9 PCS open end Wrench set Hex key Wrench combination 1. ½" Diesel driven porta- filter (10) having 7.5 HP engine Tool/plants & spare parts to be kept with the machine Qty. 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Remarks To be taken in block -do-do-do-do-do-do-do-do-do-do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 BS. No. 24 Spares for emergency Description Qty. Remarks 1. Fuel filter (3166555) 2 2. 3. 4. Lube. Oil filter (3166554) Lube. oil bypass filter (v) Screen filter for PT fuel pump (200743) Screen filter for PT fuel pump (149767) Injector pipe in let Injector pipe outlet Injector in-line filter Injector fuel feed connection pipe Hydraulic pressure pipe (1509/4) Hydraulic pressure pipe with end connections (1509/16 1100 mm) Hydraulic pressure pipe with end connections (1509/20 1900 mm) Hydraulic pressure pipe with end connections (2755/20 2000 mm) Hydraulic pressure pipe with end connections (1509/10 2000 mm) V-belt for engine (B-43,41,37) Self starter Cable for propeller shaft Cable for engine accelerator 1 1 1 To be taken in block -do-do-do- 1 -do- 1 1 6 6 10 meter 1 -do-do-do-do-do-do- 2 -do- 1 -do- 1 -do- 1 set 1 1 1 -do-do-do-do- 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 25 Charge flow filter (Hydraulic) (714374) Gear oil SAE-90 Engine oil API CF4 15W 40 Return filter 10 Micron (Hydraulic) (733692) Broom element (230016) Diaphragm for brake cylinder Brake shoe (732166) Broom driving chain 1” with chain lock (210011) Broom drive shaft bush and bearing 211222, 211620, 161099) Hydraulic return filter element (176521) Seal set for hydraulic cylinders Air cleaner filter element outer (4055280) Air cleaner filter element inner (4055279) Injector copper washer 1 -do- 50 lts.* -do2 10 1 4 1 no. 1 each 1 1 set 1 1 12 * Ten litres to be taken in block *** Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 26 CHAPTER – 6 Ballast/Shoulder Cleaning Machine (FRM & BCM) AS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Tools for FRM & BCM Description Brass rod (200 x 20 mm) Locking pin (3000-08-138/US) Open spanner set (6-5) Rod (G.130.32) Rod (G.130.33) Rod (G.130.34) Face mask Head phone (MT72H7A-15) Emergency pump handle (35 X 1000 MM) Flat (Green) Heavy duty ratchet spanner (cutter bar tightening) Hook spanner for rail clamp roller sleeve Cutter bar lifting bracket Cutting plier (1122) Flexible pipe (1") Filter element (C-30850/2) Filter element (CF-1600) Aluminium protection bracket Tool/plants & spare parts to be kept with the machine Qty. 1 set 4 1 1 1 1 3 1 1 Remarks To be taken in block -do-do-do-do-do-do-do-do- 1 2 nos. -do-do- 1 no. -do- 2 nos. 1 6 mtrs. 2 2 2 -do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 19. 20. 21. Hoisting device (over head) (800 KG.) Lead (DNZ-400 BAR) Gas cutting equipment Tool/plants & spare parts to be kept with the machine 27 1 1 1 set March - 2004 CAMTECH/C/2004/TL&PL/1.0 BS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 28 Spares for emergency on BCM Description General Screw (T. bolt with D. nut and Spring Washer) Chain bolt (61.04.212 GEN) Fixing pin (8:40DIN 1481) Lock washer (64.08.2035) Wear arch (62.08.8032) Wear arch (64.08.1333) Strip (64.08.1330) Strip (64.08.1329) U clamp with spare nut Counter shunk screw with nut and spring washer (12 X 60 MM) Counter shunk screw with nut and spring washer (12 X 50 MM) Counter shunk screw with nut and spring washer (16 X 65 MM) Counter shunk screw with nut and spring washer (20 X 50 MM) Counter shunk screw with nut and spring washer (20 X 65 MM) Counter shunk screw with nut and spring washer (20 X 90 MM) Counter shunk screw with nut and spring washer (16 X 50 MM) Cutter bar Tool/plants & spare parts to be kept with the machine Qty. Remarks 100 nos. 50 nos. 100 nos. 100 nos. 1 7 1 2 20 20 To be taken in block -do-do-do-do-do-do-do-do-do- 20 -do- 20 -do- 20 -do- 20 -do- 5 -do- 20 -do- 1 -doMarch - 2004 CAMTECH/C/2004/TL&PL/1.0 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. Cardon shaft (engine to main gear box) U.J.kit for above cardon shaft Guide cone Allen cap screw (4X20, 12X60, 10X50, 16X60) Round shaft chisel (64.08.2034 GEN) Wear plate (64.08.1469) Wear plate (64.08.1449) Wear plate (64.08.1461) Wear plate (64.08.1209) Wear plate (62.08.1217) Wear plate (62.08.1217) Wear plate (64.08.1450) Wear plate (64.08.1328) Wear plate (64.08.1620) Wear plate (64.08.1623) Wear plate (64.08.1624) Strip (62.08.1300) Strip (64.08.1299) Strip (64.08.1451) Strip (62.08.1301) Wear plate (62.08.1212) Strip (64.08.1455 Wear plate (62.08.1032) Wear plate (62.08.1213) Screen mesh (25 MM) Screen mesh (50 MM) Screen mesh (80 MM) Corner roller assembly (64.08.500021) Tool/plants & spare parts to be kept with the machine 29 1 set -do- 1 set 1 no. 10 nos. each 100 nos. 3 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 3 1 6 6 6 2 -do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 1. 2. 3. 4. 5. 6. 7. 8. 9. Conveyer rear scrapping pad (distributing) Conveyer rear scrapping pad (main waste) Main scooper with intermediate link and sub components Dredger drum spoket HTS bolts with nuts (24 X 130 MM) Roller (62.11.7000.09) Roller (62.11.7000.10) Roller (62.11.7000.23) Roller (62.11.7000.24) Roller (62.11.7000.11) Roller (62.11.7000.25) H.T.S. hex. Bolts (6X20, 8X5, 8X50, 8X75, 10X25, 10X40, 10X65, 10X80, 12X50, 12X60, 12X90, 16X50, 16X60, 16X90, 16X120, 20X50, 20X90) Electrical Self starter (Bosch type) Battery cable Pilot lamps Working light & head light bulbs Time relay for engine 8 pin relay Thimbles of sizes Distilled water Petroleum jelly Tool/plants & spare parts to be kept with the machine 30 2 1 6 sets 1 2 2 1 2 2 2 1 25 nos. each 1 no. 2 nos. 5 nos. 5 sets 2 sets 2 nos. 10 each 1 lit. 1 kg. -do-do-do-do-do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 10. 11. Battery (+ve connector terminal) Battery (-ve connector terminal) Engine 1. Fuel filter (paper) 2. Fuel filter (cloth) 3. Lube. Oil filter (4006104000) 4. High pressure fuel pipes 5. V-Belt (KHD2421916) 6. Rubber hoses for air passage 7. Flexible fuel pipes 8. Brake fluid (white) 9. O-ring for centrifugal filter inner bowl. (117*125*4) 10. Power PCB EK-8135V00 11. O-ring for centrifugal filter inner bowl. (186*174*6) 12. Engine oil APICF4 15W40 13. Gear oil SAE-90 14. Air filter cartridge (dry type) (KHD2165059) 15. Fuel filter flat rings and copper washers 16. Cooling coil Hydraulic 1. Filter element (62, 05, 1000, 113) 2. Filter element (62, 05, 1000, 256) 3. Filter element (v) 4. Main gear box flange oil seal 5. Dredge drum gear box shaft seal * Ten litres to be taken in block. Tool/plants & spare parts to be kept with the machine 31 2 nos. 2 nos. 6 nos. 6 nos. 4 nos. 1 set 2 sets 1 set 1 set 1 lit. 2 nos. -do-do-do-do-do-do-do-do-do- 1 no. 2 nos. -do-do- 50 lts. 50 lts. * 2 nos. 4 sets 1 no. 4 nos. 2 nos. 1 no. 1 set 1 no. March - 2004 CAMTECH/C/2004/TL&PL/1.0 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Buffer valve for extra lifting Difference Pressure Filter element (62, 05, 1000, 293) Return Filter element (62, 05, 1000, 270) Return Filter element (62, 05, 1000, 273) Filter element (64, 08, 4000, 247, 08) Seal set for all hydraulic cylinders Driving motor shaft seal (827 SK 60-80-7GOETZE) Bush (axle gear box) (64, 02, 2107, 00) Piston ring (axle gear box) (64, 02, 2000, 87) Driving directional valve Pressure switch for driving. Hose no. 16 h.p. in driving circuit Hose no. 20 in excavating circuit Hose no. 24 return hose excavation system. Hose no. 16 screen vibration circuit. Hose no. 8 h.p. with end fittings (5 mtrs.) Hose no. 6 h.p. with end fittings (5 mtrs.) Tool/plants & spare parts to be kept with the machine 32 1 no. 1 no. 1 no. 1 no. 1 no. 1 set 2 nos. 4 nos. 12 nos. 1 no. 1 no. 1 no. 1 no. 1 no. To be taken in block -do-do-do-do- 1 no. -do- 1 no. -do- 1 no. -do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 23. 24. Hose no. 4 h.p. with end fittings (5 mtrs.) Hand control valve Tool/plants & spare parts to be kept with the machine 33 1 no. -do- 1 no. -do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 CS. No. 1. 34 Spares for emergency on FRM Description Qty. Remarks Engine Fuel filter 1 litre capacity paper type 2 To be taken in block -do-do-do-do-do-do- 2. 3. 4. 5. 6. 7. Fuel filter 1 litre capacity cloth type Fuel filter 1 litre capacity paper type Lube. Oil filter (6054.297.0039) Set of fuel injection pipes Set of water radiator hoses Set of fuel hoses (I) 6.234.939.045.4.L = 700 mm (II) 6.234.939.048.4.L = 300 mm (III) 6.234.939.040.4.L = 700 mm 8. V-belts – A.61.A.52.A.45 9. Banjo bolts 10. Fuel filter – O-ring for 1 litre & 5 litre capacity filter 11. Self starter (065.000.1417058) 12. Engine oil APICF4 15W40 13. Gear oil SAE-90 14. Air cleaner (outer) (C.3085012) 15. Air cleaner (inner) (CF.1600) 16. Set of copper washers * Ten litres to be taken in block Tool/plants & spare parts to be kept with the machine 2 2 1 1 set 1 set 1 1 1 2 4 2 each 1 50 lts. 50 lts.* 2 2 1 set -do-do-do-do- March - 2004 CAMTECH/C/2004/TL&PL/1.0 3. Hydraulic Hydraulic Hoses with end connection (length 5 mtrs. Each) (4.6.8.10.16.20) Hydraulic Return hoses with end connection (5 mtrs. Length) dia 24 Pneumatic hose ¼" dia 4. Pneumatic hose ½" dia 5. 6. Pneumatic hose clamp ¼" & ½" dia Hose connection (compressor to cooling coil) (90291) Brake cylinder hose (90286) Hydraulic Suction filter (HYS.501.360.150) Hydraulic Suction filter (HYS.501.160.P19) Hydraulic Suction filter (HYS.501.460.150) Hydraulic Return filter (HYR.501.330.104) Clutch filter (62.05.1000.113) Clutch filter (62.05.1000.293) Piston ring for clutch shaft (A.302943) Modified piston ring for clutch shaft 1. 2. 7. 3. 4. 5. 6. 7. 8. 9. 10. 35 1 -do- 1 -do- 10 mtrs. 10 mtrs. 6 each 1 -do- 1 1 -do- -do-do-do- 3 4 2 1 4 3 3 (if modified) 11. Bush for clutch shaft (64.02.2107.00) Tool/plants & spare parts to be kept with the machine 2 March - 2004 CAMTECH/C/2004/TL&PL/1.0 12. 13. 14. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1. 2. 3. 4. 5. 6. 7. 8. 36 Seal set for Hydraulic cylinder (for each cylinder) Brake cylinder seal Brake shoe Electrical Head light bulbs Working light bulbs Tail lamp bulbs Micro fuse 4 Amps. Limit switch complete Limit switch cartridge Battery terminals Thimbles off sizes Power supply chord (EK.8135V002) 4 way toggle switch for waste conveyor and cutter unit operation Mechanical and general Hex bolt with nylon nut 12 x 65 mm Rivets with washer Cutter chain shovels Bolt for cutting chain (6560801050) Cutter bar bolt M-24 x 20 mm Roller (SU127.21.4.1.5) Bush Clamping bushing (656.080.1040) 1 set 1 4 2 4 4 6 2 2 4 1 1 1 -do-do-do-do-do-do-do-do-do-do- 100 50 4 2 4 4 4 2 -do-do-do-do-do- *** Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 37 CHAPTER – 7 Dynamic Track Stabiliser (DGS) AS. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Spares for emergency Description Hydraulic Pipe (SAE 100 R2A: 04) Hydraulic Pipe (SAE 100 R2A:06) Hydraulic Pipe (SAE 100 R2A:08) Hydraulic Pipe (SAE 100 R2A:10) Hydraulic Pipe (SAE 100 R2A:16) Hydraulic Pipe (SAE 100 R2A:20) Hydraulic Pipe (SAE R5-24) Power supply circuit (EK:812:SV00) Cardon shaft (KGW:180:1250:11D:00) Cardon shaft (LZ:400:LA50/587:30/ FL:D:180) Cardon shaft (KGV:150:0900:110:00) Qty. Max. length provided on m/c -do- Remarks To be taken in block -do- -do- -do- -do- -do- -do- -do- -do- -do- -do1 -do-do- 1 -do- 1 -do- 1 -do- Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. Relay (EL-T7002/S4) Relay (ELT-663) Head light bulbs Working light bulbs Self starter (a) V-Belt (B-95) (b) V-Belt (A-52) (c) V-Belt (A-60) HSD oil filter (25 38234) Lube. Oil filter (15 8139) Bypass filter for Mobil oil (38 73576) Mobile oil (API-CF4) 15 W 40 Gear oil SAE-90 Radiator hose Grease Petroleum jelly Emery paper fine ZF filter (Hyd.501-22525ES) Hydraulic Suction filter (Hyd.501-460-150) Hydraulic Suction filter (Hyd.501-160-10) Hydraulic Return filter (Hyd.501-330-10ES) Hydraulic Suction filter (Hyd.501-160-P10ES) Hydraulic Filter Driving (Hyd.501-32-10ES) 38 2 2 4 6 1 3 1 1 2 2 1 -do-do-do-do-do-do- 60 lts. -do- 30 litrs. 1 set 10 kgs. 250 gms. 2 1 -do-do-do- Tool/plants & spare parts to be kept with the machine -do-do-do- 1 2 1 2 2 March - 2004 CAMTECH/C/2004/TL&PL/1.0 33. 34. 35. 36. 39 Air cleaner (a) Outer element (22 37953) (b) Inner element (32 26019) Distilled water for battery ZF gear box oil Hydraulic Oil shell Telus – 68 or equivalent. 2 2 2 bottles 50 ltrs. 210 ltrs. *** Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0  40 NOTES  1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Go to index Tool/plants & spare parts to be kept with the machine March - 2004 CAMTECH/C/2004/TL&PL/1.0 41 OUR OBJECTIVE To upgrade Maintenance Technologies and Methodologies and achieve improvement in productivity and performance of all Railway assets and manpower which inter-alia would cover Reliability, Availability, and Utilisation. If you have any suggestion & comments, please write to us : Contact person: Director (Civil) Postal Address : Centre for Advanced Maintenance Technology, Maharajpur, Gwalior (M.P.) Pin code – 474 020 Phone : (0751) - 2470869, 2470803 Fax : (0751) - 2470841 Tool/plants & spare parts to be kept with the machine March - 2004