MAINTENANCE SCHEDULE MANUAL FOR

TRACK LAYING EQUIPMENT (SIMPLEX)

REPORT NO. TM -159

JULY-2011

PREFACE

Maintenance of On-Track Machines is a challenging task. Maintenance of these machines is being done by zonal railways with the assistance of local trade available, zonal track machine workshops, CPOH / Allahabad and RDSO / Lucknow. With experience over the years, the railway engineers have developed adequate expertise in the maintenance of these machines. However, in absence of approved maintenance instructions, different maintenance practices have come into vogue. Therefore, it has become imperative to have a uniform maintenance standard throughout the Indian Railways. Final maintenance schedule manuals of CSM (09-32), BCM (RM-80), FRM-80, Unimat, Duomatic machine (DUO), Unomatic machine (UNO), Ballast Regulating Machine (BRM 66-4), Tamping Express (09-3X), Dynamic Track Stabilizer (DGS 62N), Multi purpose track tamping machine (Unimat Compact--M), Plasser’s Quick Relaying System (PQRS), T-28, Track Relaying Train (TRT), Phooltas make UTV, FRM-85F, Worksite Tamping Machine (Plasser make),Worksite Tamping Machine (Metex make) and BRM (PBR-400R) have been issued by RDSO.

These maintenance schedules for Track Laying Equipment (Simplex) have been prepared on the basis of experience and suggestions received from railways. Provisional maintenance schedule of TLE was issued vide letter TM/HM/TLE/Pt. IV dated 29-3-2011 as report no TM-157. The suggestion and feedback from field has been taken and incorporated in this these maintenance schedules. While every care has been taken to make the maintenance schedules quite exhaustive, there is always scope for further improvement. Suggestions from the railways in this regard will be welcome and may be sent to the undersigned for future improvement.

(A.K.Pandey)

Executive Director/Track Machine RDSO/Lucknow-226011.

JULY -2011

(i)

EXPLANATORY NOTES

While preparing text of Maintenance Schedules Manual for Track Laying

Equipment (Simplex), the terms used and their meanings are explained below:

CHECK - Ensure a specific condition does (or does not) exist.

INSPECT - Look for damage and defects including breakage, distortion cracks,

corrosion and wear, check for leaks, security and that all items are

completed.

CHANGE - Remove old parts by substituting a new or overhauled

reconditioned part. Fit new or overhauled / reconditioned part in

place of missing part.

OVERHAUL - Dismantle, examine, recondition or renew parts as necessary

against given specifications, reassemble, inspect and test.

(ii)

INDEX

S. NO.

CONTENT DESCRIPTION

PAGE NO.

1. Schedule I

To Be Done Daily 1

2. Schedule II

To Be Done After 50 Hours engine running

2

3. Schedule III To Be Done After 100 Hours engine running

3

4. Schedule IV

To Be Done After 200,400,600 And 800 Hours engine running

4

5. Schedule V

To Be Done After 1000,3000,5000 Hours engine running

5

6. Schedule VI

To Be Done After 2000 And 4000 Hours engine running (IOH)

6

7. Schedule VII

To Be Done After 6000 Hours engine running

7

8. Annexure-I Safety 8-9

9. Annexure-II First Aid 10

10. Annexure-III

Fire Protection 11

11. Annexure-IV

Hazard 12

12. Annexure-V

Protective Equipment 13

13. Annexure-VI

Instructions For Use Of Starter Batteries 14

14. Annexure-VII Engine Oil Change 15

15. Annexure-VIII

Cleaning Of Machine 16

16. Annexure-IX

Lubrication 17

17. Annexure-X

Original Filling Of Working Stock 18

18. Annexure-XI

Testing Of Hydraulic Oil 19

19. Annexure-XII Brake 20

20. Annexure-XIII V-Belt Tension 21

21. Acknowledgement 22

(iii)

Page 1 of 22

SCHEDULE -- I

(TO BE DONE DAILY) Duration-One hour

1. ENGINE ---

a) Check level of lube oil and top up if required b) Check the condition of all V-belts and do needful. c) Check and correct the tension of all V- belts, If required. d) Check fuel level and top up, if required. e) Check the engine temperature gauge pointer. It should always be in green

zone. f) Check for any leakage from fuel pump, injectors, filters and fuel pipes g) Check engine oil pressure

Rated Actual

Engine oil pressure in idle run- minimum 0.5 kg/cm2 Engine oil pressure in normal working (Engine worm) Min. 3.2 to 4.5 kg/cm2

h) Check all engine parameter monitoring gauges after starting the engine. i) Check working of flasher light. j) Clean the engine and its premises. k) Check the battery connection, tighten, if required.

2. MACHINE GENERAL.

a) Clean the machine before starting of work. b) Check the level of hydraulic oil in tank and recoup, if required. c) Check the condition of links of duplex chain and do needful. d) Check the condition of links of synchronizing chain and do needful. e) Check the condition of locks of duplex and synchronizing

chain by physical inspection f) Check the leakage in hydraulic circuit and rectify if required. g) Grease the following parts.

i) Pipe pulleys ii) Driving motors iii) Sprocket gears iv) Lateral movement trellises

h) Check the brake application. i) Check the chain tension and adjust if required. j) Adjust the tension of driving chain. k) Inspect the complete crane for any visual crack in main frame. l) Check all functions of portal in base depot. m) Grease or oil all moving parts and pins. n) Examine the whole machine for loose parts.

Page 2 of 22

SCHEDULE-II

(TO BE DONE AFTER 50 HOURS OF ENGINE RUNNING) DURATION-TWO HOURS

(TO BE DONE IN ADDITION TO SCHEDULE-I )

1. ENGINE-

a) Check the level of electrolyte of batteries. b) Check the specific gravity of battery electrolytes. c) Check and clean battery terminals and apply petroleum jelly or soft grease. d) Clean the outer air cleaner element and change on condition basis.

2. MACHINE GENERAL-

a) Check the condition of duplex chain and replace the defective length. b) Check the condition of synchronizing chain and replace the defective

length. c) Check the tension of duplex chain. d) Check the tension of synchronizing chain. e) Check the condition of eye bolts. f) Check the tightness of eye bolts. g) Check the oil cooler fan bearing. h) Check the tightness of top plate bolts. i) Check the tightness of bottom plate bolts. j) Check the tightness of bolts of synchronizing shaft. k) Brake pressure should be 30-50 bar. l) Clearance between brake blocks and running wheel should be within 3 to 5mm. m) Lubricate all the guide rollers with good quality wheel bearing grease. n) Grease the following parts after cleaning with diesel.

i. Synchronizing chain. ii. Duplex Chain. iii. Driving chain.

Page 3 of 22

SCHEDULE-III

(TO BE DONE AFTER 100 HOURS OF ENGINE RUNNING) DURATION- ONE DAY

(TO BE DONE IN ADDITION TO SCHEDULE- I AND II ) 1. ENGINE-

a) Change the engine oil. b) Change the engine oil filter. c) Change fuel filter. d) Check the engine and surroundings for any unusual occurrence. e) Check the condition of smoke, it should be colorless during running.

2. MACHINE GENERAL-

a) Inspect the effect of rollers on side frames and do the needful. b) Inspect the synchronizing shaft for any bend or crack and do the needful. c) Check the leakage from bridge lifting cylinders and change the seal on

condition basis. d) Check the hydraulic return filter and replace on condition basis.

Page 4 of 22

SCHEDULE-IV

(TO BE DONE AFTER 200 HRS. OF ENGINE RUNNING) DURATION-TWO DAYS

(TO BE DONE IN ADDITION TO SCHEDULE- I, II AND III)

1. ENGINE-

a) Clean diesel tank. b) Adjust the tappet clearance with the help of service representative of engine

OEM. c) Change the outer and inner air cleaner element.

2. MACHINE GENERAL-

a) Lubricate the wheel bearing with soft grease. b) Change the return line filter. c) Change the suction line filter. d) Check the teeth of adopter plate shaft. e) Check the entire limit switch. f) Clean the complete machine. g) Lubricate the turn table with grease. Note: Item no. (a) and (b) will be done at 500 hrs.

Page 5 of 22

SCHEDULE-V

(TO BE DONE AFTER 1000, 3000 and 5000 Hrs. OF ENGINE RUNNING) (IOH)

DURATION- 7 DAYS (TO BE DONE IN ADDITION TO SCHEDULE- I, II, III AND IV)

1. ENGINE- a) Overhaul the engine on condition basis b) Check the alternator for proper working, Get overhauled if required. c) Check the self starter for proper working, Get overhauled if required. d) Calibrate the fuel Injectors. e) Calibrate the fuel injection pump on condition basis. f) All V- belts must be renewed on condition basis. g) Replace the batteries, if it had work for 1000hrs otherwise on condition basis.

2. MACHINE GENERAL-

a) Clean the hydraulic tank. b) Test the hydraulic oil for recommended parameter given in annexure-XI. c) Fill the hydraulic oil, If found OK in testing. Otherwise refill new oil. d) Change the side rollers with bearings. e) Replace the duplex chain. f) Replace the synchronizing chain. g) All driving wheels to be reprofile on condition basis. h) Inspect thoroughly the complete crane for any damage. i) Inspect the gear drive mechanism and overhaul/replace, as required. j) Replace the wheel drive chains on condition basis. k) All minor electrical fittings, fuses, bulbs must be renewed. l) Check the critical weld joint by DP/MP test, when found OK apply just

preventives. m) Bearings of all wheels to be replaced. n) Replace the brake blocks. o) Change the bearing of synchronizing shaft

Page 6 of 22

SCHEDULE- VI (IOH)

(TO BE DONE AFTER 2000 and 4000 Hrs. OF ENGINE RUNNING) DURATION-45 DAYS

(TO BE DONE IN ADDITION TO SCHEDULE- I, II,III,IV AND V)

1. ENGINE- a) Change the engine mounting pads.

2. MACHINE GENERAL-

a) All the roller guides to be taken out and built up by welding the profile. b) All hydraulic hoses to be replaced on condition basis. c) Pumps to be checked and replace if required. d) Motors to be checked and replace if required. e) Panel wiring and external wiring should be changed.

Page 7 of 22

SCHEDULE-VII (POH)

(TO BE DONE AFTER 6000 Hrs. OF ENGINE RUNNING) DURATION - 60 DAYS

(TO BE DONE IN ADDITION TO SCHEDULE- I, II,III,IV,V AND VI) 1. ENGINE-

a) Overhaul or replace the engine on condition basis. b) Overhaul or replace the self starter. c) Overhaul or replace the alternator. d) Change the engine mounting pads. e) Change all V-belts. f) Clean the diesel tank.

2. MACHINE GENERAL- a) Replace seals of all hydraulic cylinders. b) Change all hydraulic pumps. c) Change all hydraulic motors. d) Replace all hydraulic hoses. e) Clean the hydraulic tank. f) Replace the hydraulic oil. g) Replace all hydraulic filters. h) Clean hydraulic oil cooler along with required repairs. i) Change all D.C. valves. j) Change all pilot operated valves. k) All rollers to be replaced. l) Contact surface of side frame with rollers should be checked. For any dips and

wear, welding should be done. m) Side frame should be attended for any cracks. n) Replace all defective lights. o) Check the condition of sleeper gripper and strengthen it if required. p) Change the cables and wires of electrical circuit on condition basis. q) Paint the complete crane. r) Check the proper functioning of portal in all respect. s) Replace/repair the lateral movement trolleys, as required. t) Replace/repair the top plate of side frame, as required. u) Replace the hydraulic cylinder on condition basis.

Page 8 of 22

Annexure-I

SAFETY Maintenance works in principle have to be carried out when the vehicle is

stationary. It is strictly prohibited to go on the machine’s bridge under OHE line during

maintenance and block working. Before beginning of repair and maintenance works it must be ensured that the OHE line is properly switched off and earthed. These safety measures have to be carried out and supervised by the machine in-charge.

Always pay attention to trains passing on adjacent tracks. Use skids when parking the vehicle on gradients. Never change the settings of safety valves. Before disassembling hydraulic system elements make sure that the equipment

is unpressurized. Hydraulic oil coming out under pressure may penetrate skin and cause serious injuries.

When draining engine oil or hydraulic oil at working temperature you might scald yourself. Necessary protection to be taken accordingly.

Always ensure that on or in the vehicle no body works with naked flames. Do not smoke when refueling the vehicle or checking the acid level of the

batteries. Never check the acid level of the battery or the fuel level in the tank with a naked

flame. Before beginning welding works (electric arc welding) particularly make sure that

the machine has been secured against rolling the engine has been switched off; the main switch has been switched "OFF“; the program control switch has been switched "OFF, if existing; the battery sets have been entirely disconnected, the earth electrode fastened at the vehicle has been connected as close to the weld as possible.

The earth electrode must never be mounted on the rail. Never connect the earth electrode to cylinder piston rods, hydraulic

accumulators, hydraulic pumps, batteries, earth cable, loose connections, or to hydraulic oil or fuel tanks.

Do not direct any high-pressure cleaning and lubricating devices to man or animal.

Do not use any easily flammable fluids or caustic cleansing agents to clean the machine.

Page 9 of 22

Before carrying out any repair work on the machine the following safety instructions must be observed: Turn off the engine.

Turn off the working-mode main switch and protect it from unauthorized

operation.

Turn off the battery main switch and protect it from unauthorized operation

If repair works are carried out in closed workshops the batteries have to

be disconnected.

The battery terminals have to be secured accordingly.

Deactivate hydraulic pressure.

Deactivate the air system.

Protect the machine from rolling away (Use skid-pans etc.)

Furthermore, the machine crew and all persons having access to the machine

must be informed of the intended repair work.

Furthermore, the machine crew has to be informed of the repair work completed

before the operating mode of the machine is restored.

Only professionally competent and trained persons are allowed to restore the

working mode of the machine.

Page 10 of 22

ANNEXURE-II

FIRST AID Always ensure that the first aid kit is in a proper, complete and neat condition. Immediately refill the used up material.

Procedure for first aid measures

In the case of burning Extinguish the burning person with water, fire extinguisher, blankets or

through rolling.

In the case of eye contact with hazardous materials Rinse out several times with spray bottle or beverage and subsequently

consult a doctor.

In the case of skin contact with hazardous materials Thoroughly wash with soap under running water and subsequently consult

a doctor.

When inhaling hazardous materials When inhaling higher concentration, take person into the fresh air and

subsequently consult a doctor.

After ingesting Do not induce vomiting and immediately consult a doctor.

After intensive contact with clothing

Immediately change saturated clothing, shower and subsequently consult

a doctor.

Page 11 of 22

ANNEXURE-III

FIRE PROTECTION

Everybody is responsible to refrain from everything that may result in a fire or favor the spreading of a fire. In addition to this, all measures to prevent the development or spreading of fires must be taken in individual cases.

Oily or greasy rags saturated in solvent must be kept in a fire-protected place since they could cause fires through self-ignition.

In order to avoid the development of fires, the following parts, must be kept free of deposits.

Drives Belts Gears Control cabinets Power distribution boards etc.

The fire extinguishers must always be ready for operation, freely accessible,

periodically tested and equipped with test plaques. The date of expiry must be checked by the responsible fire protection

representative. The in charge of the machine will immediately make the arrangement for the

filling of used fire extinguishers and in the mean time he will also inform the concern controlling officer for the replacement of fire extinguishers.

The use of open flames and easily flammable agents on the vehicle and in immediate vicinity is strictly prohibited.

The diesel fuel tanks may only be filled with the engine switched off and cooled off.

Smoking is strictly prohibited in the vicinity of the machine.

Page 12 of 22

ANNEXURE-IV

HAZARD Service life and the operational safety is increased by virtue of carefully performed maintenance, which will be reflected in a clear reduction of working accidents and

resultant damage to persons.

GENERAL

The instructions of the machine in charge must be followed under any

circumstances. Entering the machine is only permitted by way of the steps provided for this

purpose, which should be kept free of grease, oil, fuel, dirt, snow and ice. Climbing onto machine parts during loading, unloading and repair operations

located in the hazard area of the overhead line is always prohibited unless the overhead line has been switched off.

Crossing underneath the machine during operation or working is strictly prohibited.

If problems are encountered while work in progress, activate the emergency engine stop as required. Based on the type of the fault it must be decided how it should be rectified most effectively. Instinctive reactions for rectifying the fault during working operation may result in serious injury to body and even death.

Touching the exhaust system may result in burns.

Page 13 of 22

ANNEXURE-V

PROTECTIVE EQUIPMENT

In order to keep hazards and their consequences to health as low as possible it is imperative to ensure suitable protective equipment while doing maintenance and working.

Head protection……….Safety helmet Hand protection……….Leather and cotton gloves Foot protection………. Leather safety boots and shoes Warning clothing…… High visibility warning cloth.

Breathing protection… Dust mask

Page 14 of 22

ANNEXURE - VI

INSTRUCTIONS FOR USE OF STARTER BATTERIES

INSTALLATION IN THE VEHICLE

Before removing and installing the battery, switch off the engine and all power consumers.

Avoid short-circuits through tools. When removing the battery, first disconnect the negative terminal (-), then the

positive terminal (+). Prior to installing the battery, clean the standing area in the vehicle. Clean battery terminals and terminal clamps and lightly lubricate with acid-free

grease. On installation, first connect positive terminal (+), then negative terminal (-).

Ensure terminal clamps are tightened securely.

MAINTENANCE

In order to achieve a long service life for the battery, the following instructions should be observed. Keep the surface of the battery clean and dry. Regularly check the acid level and, if necessary, replenish with

desalinated or distilled water. Never add acid. If the acid density is below 1.21 kg/l (or 1.18 kg/l recharge the battery. Check the fluid level. It should be at least 2-3 mm and maximum 10 mm

above the top of the battery plate; if necessary, add distilled water. Measure the acid number of the individual cells with a battery tester.

Page 15 of 22

ANNEXURE-VII

ENGINE OIL CHANGE

PROCEDURE OF OIL CHANGE

Heat up the engine at approx. 80°C. Ensure level position of the vehicle. Turn off the engine. Clean the surrounding area of the oil drain plug. Open the oil drain plug and collect the oil. Do not let oil get into the soil. Beware the danger of scalding yourself by the used oil. Insert the oil drain plug with a new sealing ring, tighten it. Fill the engine crank case with new oil as per the capacity of the engine. Wait for 5 minutes, then check the oil level ; if it is correct, close the oil drain plug, Make sure that the washer of drain plug is correctly seated. Replace the filter cartridge whenever changing oil. After replacing the filter cartridge, again check the oil level. If it is beyond the limits

then do as required.

Page 16 of 22

ANNEXURE-VIII

CLEANING OF MACHINE

If the machine is soiled to such an extent that maintenance works would be impeded, it is necessary to clean the machine before starting the working.

Cleaning is the best opportunity to check an element visually. Additionally, periodical cleaning is prescribed for certain structural elements. It is of particular importance to clean the coolers in time. Do not direct any high-pressure cleaning devices against thin covers. Do not use any easily flammable or caustic cleansing agents. Clean underside at least once a year.

Page 17 of 22

ANNEXURE-IX

LUBRICATION

For greasing and oiling, remove any dirt or gummy grease and oil and lubricate

the respective part. Furthermore, all hydraulic cylinder bearings (even if not listed in the maintenance

instruction) have to be checked visually every 50 hours of operation and, if necessary, must be lubricated.

All movable parts not mentioned in the maintenance instruction, such as piston rods, cylinder fastenings, guide bushes, spindles, slide faces etc., have to be lubricated every 50 hours of operation with oil / grease.

For lubrication never use a grease gun generating pressure of more than 15 bar. Grease and grease gun must be free of dirt and foreign bodies. Clean the lubricating nipples of the bearings before and after lubricating them. Continue to lubricate until evenly distributed fresh (clean) grease will come out

the bearings. Then remove excess quantities of grease.

Page 18 of 22

ANNEXURE-X

ORIGINAL FILLING OF WORKING STOCK

SL. NO.

WORKING STOCK LUBRICANTS QUANTITY

1. Engine Equivalent to SAE 15 W40 15.5 Litres

2. Hydraulic Oil Tank Equivalent to SAE 68 500 Litres

3. Grease RR-3 or Equivalent ----

During warranty period use the lubricants as specified by the OEM for claim of warranty.

At low temperatures the fuel pipe system may get clogged because of paraffin precipitation which may lead to operational failures.

At outside temperatures below 0°C winter fuel has to be used (up to –20°C). Below –20°C petroleum has to be added.

Page 19 of 22

ANNEXURE -XI

TESTING OF HYDRAULIC OIL

RECOMMENDED VALUES OF TEST PARAMETERS.

VISCOSITY:

The admissible decrease in Viscosity is (–10%) of the original value

MAXIMUM WATER CONTENT:

The water content has to be as low as possible. The maximum admissible concentration of water in the hydraulic oil is 1000 ppm. This corresponds to 0.10% by volume.

PURITY:

The purity of the oil should be maintained as per NAS 1638 : 7-8 , ISO 4406 : 19/16/13-20/17/14

ACID CONTENT:

The TAN (Total acid Number) of fresh oil amounts 0.05 mg KOH/g. The values for used oil to be between 0.05 to 1 mg / KoH/g.

Page 20 of 22

ANNEXURE-XII

BRAKE

During the cycle of service of a brake block its play has to be re-adjusted for at

least one time.

Usually the brake block play has to be re-adjusted, when:

The brake block play is not between 5-7 mm. The brake blocks are replaced. The brake blocks are worn out on one side. The wheel profile had been re-worked.

PROCEDURE FOR BRAKE ADJUSTMENT

Secure the machine against braking away by skid-pans. Release the brake. (ZERO brake pressure). Turned off the engine. Adjust the brake play. Do not change all brake blocks at once (e.g. in two stages).

Page 21 of 22

ANNEXURE-XIII

V-BELT TENSION Check visually the V-belts over its entire dimension. Replace defective V-belts. Check new V-belts after a working time of 15 minutes. Check V-belt tension by finger test as below.

Put the flat steel scale onto the V-belt between two pulleys. Press the V-belt at the centre and measure the depth of shifting

It should not be more than 15mm.

Page 22 of 22

ACKNOWLEDGEMENT

Following officers and staff have made their valuable contributions in finalization of the Maintenance Schedule Manual for Track Laying Equipment (Simplex).

RAILWAYS 1. S/SRI K.P. Singh SSE/TM/ NCR 2. ‘’ ‘’ S.K.Khannagwal SSE/TM/ NCR 3. ‘’ ‘’ G.P.Tiwari SSE/TM/ ECR 4. ‘’ ‘’ I.K.Singh SSE/TM/ NR

RDSO 1. S/SRI Anil Choudhary DTM-III 2. ‘’ ‘’ Mahavir Prasad ARE/TM 3. ‘’ ‘’ M.N.Siddiqui, SSE/TM 4. ‘’ ‘’ A.N.Srivastava, SSE/TM