tools/plants & spare parts to be kept with the track machines
TRANSCRIPT
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
TECHnology
Excellence in Maintenance
Maharajpur, GWALIOR - 474 020
(For official use only)
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 C.B.Middha
Date : 16 .03.2004 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 Manoj Agarwal
Date : 15.03.2004 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
Tool/plants & spare parts to be kept with the machine March - 2004
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.
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
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
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
3
CHAPTER - 2
Desired equipment & tools with all machines
A - At base station.
S. No. Description Qty.
1. DG set (5 KVA) 1
2. Welding plant 1
3. Bench grinder 1
4. Bench vice and a work table 1
5. Drill machine (230 V AC with stand) 1
6. Portable filter plant 1
7. Hot air blowers 1
8. Digital multi-meter 1
9. Accumulator pressure checking and filling
device PC-250 complete
1 set
10. Torque wrench 1 set
11. Pendulum calibration pads 1 set
12. Versine measuring chord with complete
instrument
1 set
13. Go-No-Go gauge for tamping gauge 1
14. Tamping tool profile bore gauge 2
15. Steel scale 1' to 6 " 1 set
16. Taper gauge upto 1" 1
17. Feeler gauge 1
18. Thread gauge 1
19. Cell tester (battery voltage) 1
20. Battery charger (oil bath type) 1
21. Digital calliper 1
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
4
22. Hydrometer 1
23. Chain pulley (3 t capacity) 1
24. Pipe cutting machine (disc cutter) 1
25. Jerry cane (20 litres capacity) 1
26. Oil filling pump 1
27. Funnel for oil filling 1
28. Grease pump 1
29. Distance pieces of various sizes 1 set
30. Tyre defect gauge 1
31. Tamping tool measuring gauge 1
32. Steel tray 2
33. Bearing puller 1
34. Lamp arrangement for inspection 1
35. Litmus paper 1
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
5
B – During block.
S. No. Description Qty.
Safety items
1. Red hand signal flags. 2
2. Green hand signal flag 1
3. Tri-colour hand signal lamps 2
4. Chains with padlocks. 2
5. Clamps with padlocks 2
6. Fog signals (detonators) in a tin case 10
7. A copy of the working time table of the
section where the machine is working.
1
8. G&SR book with up to date amendment
slips.
1
9. 4 cell flasher light. 1
10. Portable field telephone 1
11. Walkie-talkie 1 set
12. Banner flags 2
13. First aid box. 1
14. Skids 2
15. Petromax/LPG lamps 2
16. Safety helmets for machine staff -
17. Protective clothing, safety shoes with face
mask and safety gloves.
-
18. Track machine manual 1
19. Accident manual. 1
20. Rail thermometer 1
21. Gauge-cum-level 1
20. Fire extinguisher 1
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
6
21. Hooter (manual) 2
Equipment & tools
22. Jack 50 t with traversing system 2
23. Jack 5 t 1
24. Wooden blocks 8
25. Crow bars 4
26. Trefor (3t) 4
27. Hydraulic hand pump (for emergency back
up)
1
28. Emergency pneumatic/hydraulic hose of
sizes suiting to different machines
(complete with end fittings)
1
29. Wire rope with close loops at both ends 2
metres & 9 metres (12 to 16 mm dia.)
1 each
30. Machine drawing and catalogue 1
31. D-Spanner set 1 set
32. Ring spanner set 1 set
33. Allen key set 1 set
34. Pipe wrench 1 set
35. Nose plier 1
36. Combination plier 1
37. Circlip plier (outer & inner) 1 each
38. Monkey plier 1
39. Chain adjusting plier 1
40. Punch (drift pin) 1 set
41. Files of different sizes (half round, flat,
round)
1 set
42. Needle file 1
43. Drill bit 1
44. Trap set of different sizes 1 set
45. Seal puller 1
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
7
46. Box spanner 1 set
47. Screw driver of different sizes (star head &
plain)
1 set
48. Tommy bar of different sizes 1 set
49. Hacksaw 1 set
50. Hammer of different sizes (metal &
plastic)
1 set
51. Pad locks 3
52. Grease gun 1
53. Measuring tape (3 metre) 1
54. Set of chisel 1 set
55. Diode tester 1
56. Key of different sizes for shaft 1 set
57. Key Extractor 1
58. Torch 1
59. Soldering iron (24 V DC) 1
60. Tool box 1
61. De-soldering gun 1
62. Soldering wire one role 1
63. Flux 1
64. PCB extension chord 1
65. Puller 1
66. Wire stripper 2
67. Extension lead 1
68. Flat Spanner Set 1 set
69. Pump Plier 1
70. Extension pipes of different sizes 1 set
71. Oiler 1
72. Scrapper (flat & triangular) 1 each
73. Tool bag for MWM/Cummins engine 1
74. Adjustable screw wrench (up to 12") 1
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
8
75. Single end spanner off set (55 mm to 212
mm)
1 set
76. Steel bucket 1
77. Dummy & adopters of all sizes 1 set
78. O-Rings of sizes 1 set
79. Fuses (4A, 2A, 1A) 2 each
***
Go to index
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
9
CHAPTER – 3
Track Tamping Machines (CSM and Express tamper)
A - Tools for CSM and Express Tamper
S. No. Description Qty. Remarks
1. Hook spanner 1
2. Aluminium protection 125 mm 2
3. Copper rod 20 X 200 mm 1
4. Piston ring press 2 X 1/8” to 5” 1
5. Ring for piston ring (Sq. Big) 2E
130.01
1 To be
taken in
block
6. Side cutter 6” 1 -do-
7. Puller complete E130.150a 1 -do-
8. Extractor (pin) E130.151 1 Set -do-
9. Ring for piston ring (Sq. Small)
2E 130.02
1 -do-
10. Piston ring plier 1 -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
10
B - Spares for emergency on CSM.
S. No. Description Qty. Remarks
1. Seal set for small squeezing
cylinder
4 sets To be
taken in
block
2. Big squeezing cylinder seal sets 2 sets -do-
3. Tamping unit Up & Dn hydraulic
cylinder seal sets
2 sets -do-
4. 35 mm pin 2 -do-
5. Satellite pin 25 mm dia (U-61-
104)
1 -do-
6. Piston rod assembly for big and
small squeezing cylinder
1 set -do-
7. Tamping tools 1 sets -do-
8. Tamping tools bolt 8 -do-
9. Tamping tool cap 8 -do-
10. Locating screw 8 -do-
11. Clamp roller 2 -do-
12. Tamping depth transducer chord 7 m -do-
13. Versine transducer chord 7 m -do-
14. Chord wire (2 mm) 30 m -do-
15. Carrier T/depth transducer 2 -do-
16. Versine transducer carrier 2 -do-
17. Seal set for all hydraulic cylinder 1 set each -do-
18. Fuel pre-filter 1 -do-
19. Primary fuel filter 1 -do-
20. Secondary fuel filter 1 -do-
21. Lube. oil filter 2 -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
11
22. Fuel pressure hoses
(injector pipes)
1 set -do-
23. Radiator hoses 1 set -do-
24. Set of copper washer 1 packet -do-
25. High pressure hydraulic hose with
spare fittings (2781-4)
Max.
length
provided
on m/c.
-do-
26. High pressure hydraulic hose with
spare fittings (2781-6)
-do- -do-
27. High pressure hydraulic hose with
spare fittings (2781-8)
-do- -do-
28. High pressure hydraulic hose with
spare fittings (2781-10)
-do- -do-
29. High pressure hydraulic hose with
spare fittings (2781-12)
-do- -do-
30. High pressure hydraulic hose with
spare fittings (2781-16)
-do- -do-
31. High pressure hydraulic hose with
spare fittings (2781-20)
-do- -do-
32. (503-24) With spare fittings -do- -do-
33. Pneumatic hose ¼" 5 m -do-
34. Pneumatic hose ½" 5 m -do-
35. Relay ELT – 663 2 -do-
36. Relay 7002/S4 2 -do-
37. Relay ELT 277 2 -do-
38. PCB EK 813, EK16, EK24,
EK347,EK 349
1 each -do-
39. Head light and working light bulb 2 nos.
each
-do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
12
40. Satellite transducer spring
ELT-1041-12
1 -do-
41. Pin bolt, 32 ½ mm dia 1 -do-
42. Damping ring (GR-100) 1 -do-
43. V-Belt 1 set -do-
44. Break shoe 2 -do-
45. Battery terminals 4
46. Thimbles of sizes 20
47. Distilled water 10 litres
48. Suction filter 4
49. Proportional filter 1
50. Servo valve filter 2
51. ZF in line filter 1
52. Return line hydraulic filter 2
53. Air cleaner filter element
(outer & inner)
2 set
54. Grease hose assembly 1 set
55. Teflon washer 16
56. PG bush 16
57. Potentiometer EL-T500,
EL-T595A
1 each
58. Variable pump suction filter 2
59. Pin 55 mm 2
Cardon shaft
60. Engine to ZF gear box 1
61. Engine to funk gear box 1
62. Distributor gear box to axle gear
box
1
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
13
63. ZF to distributor gear box 1 To be
taken in
block
64. Engine oil API – CF4-15W40 50 lts.
65. Gear oil SAE –90 50 lts.*
66. ZF oil ultra 10W or equivalent 60 lts.
* Ten litres to be carried in block.
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
14
C - Spares for emergency on Express Tamper.
S. No. Description Qty. Remarks
Engine
1. Fuel pre-filter (breather) 1 To be
taken in
block
2. Primary fuel filter 1 -do-
3. Secondary fuel filter 1 -do-
4. Lube. Oil filter 2 -do-
5. Air cleaner filter 1 set -do-
6. Radiator hoses 1 set -do-
7. Injector pipes 1 set -do-
8. ‘V’ belts 1 set -do-
9. Fuel flexible hoses 1 set -do-
Tamping unit
1. Piston rod assembly 1 set -do-
2. Tamping tool
(WN 300 NI Z 70.500-1 FRI)
8 -do-
3. Tamping tool
(WN300 NI Z70.500-1 FRW)
4 -do-
4. Tamping tool bolts 4 -do-
5. Tamping tool cap 4 -do-
6. Tamping tool bolt (G 30, 42) 2 -do-
7. Tamping depth transducer chord 7 mtrs. -do-
8. Carrier tamping depth transducer. 1 -do-
9. 35 mm & 40 mm pin steel bush, nut
& washer.
1 each -do-
10. Gear ring for vibration coupler. 1 -do-
11. Tamping tool key 6 -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
15
12. Roof clamp 4 -do-
13. Clapper cylinder 1
14. Clapper bracket 2
15. Clapper cylinder pin (12 mm,
16mm, 20mm)
2 sets
16. Tamping unit Up & Dn hydraulic
cylinder seals
1 set
17. Tamping unit Up & Dn hydraulic
cylinder piston rod (complete)
1 set
Hydraulic
1. Proportional filters 2
2. Servo filters 2
3. ZF In-line filter 1
4. Hydraulic suction filter 1 set
5. Hydraulic return filters 1 set
6. Seat set for all hydraulic cylinders 1 set To be
taken in
block
7. Hydraulic hoses with spare fitting
2781-4
Max.
length
provided
on m/c.
-do-
8. Hydraulic hoses with spare fitting
2781-6
-do- -do-
9. Hydraulic hoses with spare fitting
2781-8
-do- -do-
10. Hydraulic hoses with spare fitting
2781-10
-do- -do-
11. Hydraulic hoses 2781-12 (Crimped
fittings)
-do- -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
16
12. Hydraulic hoses 2755-16
(Crimped fittings)
-do- -do-
13. Hydraulic hoses 1781-20
(Crimped fittings)
-do- -do-
14. Hydraulic hoses 1503-24
(Crimped fittings)
-do- -do-
Electrical
1. PCB EK-816,429,429DV,430DV,
813 DV
1 each -do-
2. PCB EK-1AP7 1 -do-
3. Relay El-T 7064/24 2 -do-
4. Relay El-T 7054/24 2 -do-
5. Fuses 4 -do-
6. Head light & working light bulbs 2 each -do-
7. Versine transducer carrier 1
8. Versine transducer chord 0.80 mm 7 mtrs.
9. Longitudinal transducer chord 1.33
mm
7 mtrs.
Miscellaneous
1. Track lifting roller 1
2. Chord wire 2 mm 30
meters
3. Pneumatic hose ¼" & Hose ½" 5 meters
4. Cardon shaft engine to ZF gear box 1
5. Cardon shaft ZF gear box to
distribution gear box
1
6. Cardon shaft distribution gear box to
axle gear box
1
7. Brake shoe 2
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
17
8. Satellite support roller complete
assembly
1 set
9. Tamping depth transducer 1 To be
taken in
block
10. Proximity switch ELT 1482 K 1 no. -do-
***
Go to index
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
18
CHAPTER – 4
Point and Crossing Tamping Machine (UNIMAT)
A - Tools
S. No. Description Qty. Remarks
1. Hook spanner 01 Nos. To be
taken in
block
2. Piston ring plier 01 Nos. -do-
3. Ring for piston ring (Squeezing)
2E130.02 A
01 Set -do-
4. Side cutter (cutting plier) 6" 01 Nos -do-
5. Extension piece DL 131-02 01 Nos. -do-
6. Flushing plate DL 40-579 03 Nos.
7. Mechanical puller E 130-150a 01 Nos.
8. Extractor (Pin) E 130-151 01 Set
9. Piston ring press 2 X 1/8 " to 5" 01 Nos.
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
19
B - Spares for emergency
S. No. Description Qty. Remarks
Engine
1. Fuel pre-filter (breather) 1 To be taken
in block
2. Primary fuel filter 1 -do-
3. Secondary fuel filter 1 -do-
4. Lub oil filter 2 -do-
5. Air cleaner filter 1 set -do-
6. Radiator hoses 1 set -do-
7. Injector pipes 1 set -do-
8. ‘V’ Belts 1 set -do-
9. Fuel flexible hoses 1 set -do-
10. Gear oil SAE-90 50 lts.*
11. Engine oil API-CF4 15W40 -do-
12. ZF oil ultra 10W or equivalent 60 lts.
Tamping unit
1. Piston rod assembly complete 1 -do-
2. Tamping unit Up & Dn hydraulic
cylinder seals
2 set -do-
3. Tamping tool (2 W.81.418) 4 -do-
4. Tamping tool (W.37.1320) 4 -do-
5. Tamping tool bolts 4 -do-
6. Tamping tool cap 4 -do-
7. Tamping tool bolt (G30.42) 2 -do-
8. Tamping depth transducer chord 7 mtrs. -do-
9. Carrier tamping depth transducer 2 -do-
* Ten litres to be taken in block
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
20
10. 35 mm pin with steel bush, nut &
washer
1 -do-
11. Gear ring for vibration coupler
(GR 63)
1 -do-
12. Tamping tool key 6 -do-
13. Tool tilting cylinder 1 -do-
14. Pin bolt (W.31.133A) 2 -do-
15. Pin bolt (CU.37.632) 2 -do-
16. Rubber ring (W.33.83) 6 -do-
17. Round hard lock nut 1 -do-
18. Pin 60 mm size (W371410) 1 set
19. Spacer (W371440) 1 set
20. Radial seal (DL1222) 1
21. Pressure disc 2 E 3441 1
22. Part clutch 1
23. Tamping arm 1
24. Tamping unit Up & Dn hydraulic
cylinder piston rod (complete)
1
Hydraulic
1. Proportional filters 2
2. Servo filters 2
3. ZF in-line filter 1
4. Hydraulic suction filter 4
5. Hydraulic return filters 1 set
6. Squeezing filter 2
7. Hydraulic hoses 2781-4 Max.
length
provided
on m/c.
To be
taken in
block
8. Hydraulic hoses 2781-6 -do- -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
21
9. Hydraulic hoses 2781-8 -do- -do-
10. Hydraulic hoses 2781-10 -do- -do-
11. Hydraulic hoses 2781-12 -do- -do-
12. Hydraulic hoses 2755-16 -do- -do-
13. Hydraulic hoses 2781-20 -do- -do-
14. Hydraulic hoses 1503-24 -do- -do-
15. Seal set for all hydraulic cylinders 1 sets -do-
Electrical
1. Contact block 2
2. Battery terminal 4
3. Distilled water 10 litres
4. Thimble of different sizes 20
5. Alternator 1
6. Self starter 1 To be
taken in
block
7. Relay 7002/S4 2 -do-
8. Relay ELT.663,277,7045,7010 2 each -do-
9. Head light & working light bulbs 2 each -do-
10. Versine transducer carrier 1 -do-
11. Versine transducer chord 7 metres -do-
12. PCB EK 813 1 -do-
13. PCB EK 132 1 -do-
Miscellaneous
1. Track lifting roller 1 -do-
2. Chord wire 2 mm 30 metres -do-
3. Pneumatic hose ¼" 5 metres -do-
4. Pneumatic hose ½" 5 metres -do-
5. Cardon shaft engine to ZF gear
box
1 -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
22
6. ZF gear box to distribution gear
box
1 -do-
7. Distribution gear box to axle gear
box
1
8. Brake shoes 1
9. Brake cylinder seal 1
10. Reduction gear box to ZF 4
***
Go to index
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
23
CHAPTER – 5
Ballast Regulating Machine (BRM)
A- Tools
S. No. Description Qty. Remarks
1. Socket 3, ½ size, 6 PT 1 To be
taken in
block
2. Socket ¼ inch square drive 1 -do-
3. Chain wrench 5/8 " 4.1/2" 1 -do-
4. Open end wrench 1 – 11/16" 1 -do-
5. Handle T-bar 1 -do-
6. Adopter T-bar 1 -do-
7. Socket ¼" square drive 1 -do-
8. 12 PT 2. ¼", ¾" drive 1 -do-
9. Socket set 17 PCs ½" drive 1 -do-
10. Wrench 2-3/8 open end 2 -do-
11. Wrench set 9 PCS open end 1 -do-
12. Wrench set Hex key 1 -do-
13. Wrench combination 1. ½" 1 -do-
14. Diesel driven porta- filter (10)
having 7.5 HP engine
1
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
24
B - Spares for emergency
S. No. Description Qty. Remarks
1. Fuel filter (3166555) 2 To be
taken in
block
2. Lube. Oil filter (3166554) 1 -do-
3. Lube. oil bypass filter (v) 1 -do-
4. Screen filter for PT fuel pump
(200743)
1 -do-
5. Screen filter for PT fuel pump
(149767)
1 -do-
6. Injector pipe in let 1 -do-
7. Injector pipe outlet 1 -do-
8. Injector in-line filter 6 -do-
9. Injector fuel feed connection pipe 6 -do-
10. Hydraulic pressure pipe (1509/4) 10 meter -do-
11. Hydraulic pressure pipe with end
connections (1509/16 1100 mm)
1 -do-
12. Hydraulic pressure pipe with end
connections (1509/20 1900 mm)
2 -do-
13. Hydraulic pressure pipe with end
connections (2755/20 2000 mm)
1 -do-
14. Hydraulic pressure pipe with end
connections (1509/10 2000 mm)
1 -do-
15. V-belt for engine (B-43,41,37) 1 set -do-
16. Self starter 1 -do-
17. Cable for propeller shaft 1 -do-
18. Cable for engine accelerator 1 -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
25
19. Charge flow filter (Hydraulic)
(714374)
1 -do-
20. Gear oil SAE-90 50 lts.*
21. Engine oil API CF4 15W 40 -do-
22. Return filter 10 Micron (Hydraulic)
(733692)
2
23. Broom element (230016) 10
24. Diaphragm for brake cylinder 1
25. Brake shoe (732166) 4
26. Broom driving chain 1” with chain
lock (210011)
1 no.
27. Broom drive shaft bush and bearing
211222, 211620, 161099)
1 each
28. Hydraulic return filter element
(176521)
1
29. Seal set for hydraulic cylinders 1 set
30. Air cleaner filter element outer
(4055280)
1
31. Air cleaner filter element inner
(4055279)
1
32. Injector copper washer 12
* Ten litres to be taken in block
***
Go to index
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
26
CHAPTER – 6
Ballast/Shoulder Cleaning Machine (FRM & BCM)
A - Tools for FRM & BCM
S. No. Description Qty. Remarks
1. Brass rod (200 x 20 mm) 1 set To be taken
in block
2. Locking pin (3000-08-138/US) 4 -do-
3. Open spanner set (6-5) 1 -do-
4. Rod (G.130.32) 1 -do-
5. Rod (G.130.33) 1 -do-
6. Rod (G.130.34) 1 -do-
7. Face mask 3 -do-
8. Head phone (MT72H7A-15) 1 -do-
9. Emergency pump handle
(35 X 1000 MM)
1 -do-
10. Flat (Green) 1 -do-
11. Heavy duty ratchet spanner
(cutter bar tightening)
2 nos. -do-
12. Hook spanner for rail clamp roller
sleeve
1 no. -do-
13. Cutter bar lifting bracket 2 nos. -do-
14. Cutting plier (1122) 1 -do-
15. Flexible pipe (1") 6 mtrs. -do-
16. Filter element (C-30850/2) 2
17. Filter element (CF-1600) 2
18. Aluminium protection bracket 2
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
27
19. Hoisting device (over head)
(800 KG.)
1
20. Lead (DNZ-400 BAR) 1
21. Gas cutting equipment 1 set
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
28
B - Spares for emergency on BCM
S. No. Description Qty. Remarks
General
1. Screw (T. bolt with D. nut and
Spring Washer)
100 nos. To be
taken in
block
2. Chain bolt (61.04.212 GEN) 50 nos. -do-
3. Fixing pin (8:40DIN 1481) 100 nos. -do-
4. Lock washer (64.08.2035) 100 nos. -do-
5. Wear arch (62.08.8032) 1 -do-
6. Wear arch (64.08.1333) 7 -do-
7. Strip (64.08.1330) 1 -do-
8. Strip (64.08.1329) 2 -do-
9. U clamp with spare nut 20 -do-
10. Counter shunk screw with nut and
spring washer (12 X 60 MM)
20 -do-
11. Counter shunk screw with nut and
spring washer (12 X 50 MM)
20 -do-
12. Counter shunk screw with nut and
spring washer (16 X 65 MM)
20 -do-
13. Counter shunk screw with nut and
spring washer (20 X 50 MM)
20 -do-
14. Counter shunk screw with nut and
spring washer (20 X 65 MM)
20 -do-
15. Counter shunk screw with nut and
spring washer (20 X 90 MM)
5 -do-
16. Counter shunk screw with nut and
spring washer (16 X 50 MM)
20 -do-
17. Cutter bar 1 -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
29
18. Cardon shaft (engine to main gear
box)
1 set -do-
19. U.J.kit for above cardon shaft 1 set -do-
20. Guide cone 1 no. -do-
21. Allen cap screw (4X20, 12X60,
10X50, 16X60)
10 nos.
each
-do-
22. Round shaft chisel (64.08.2034 GEN) 100 nos.
23. Wear plate (64.08.1469) 3
24. Wear plate (64.08.1449) 1
25. Wear plate (64.08.1461) 2
26. Wear plate (64.08.1209) 1
27. Wear plate (62.08.1217) 1
28. Wear plate (62.08.1217) 1
29. Wear plate (64.08.1450) 1
30. Wear plate (64.08.1328) 1
31. Wear plate (64.08.1620) 1
32. Wear plate (64.08.1623) 1
33. Wear plate (64.08.1624) 1
34. Strip (62.08.1300) 2
35. Strip (64.08.1299) 1
36. Strip (64.08.1451) 1
37. Strip (62.08.1301) 1
38. Wear plate (62.08.1212) 1
39. Strip (64.08.1455 1
40. Wear plate (62.08.1032) 3
41. Wear plate (62.08.1213) 1
42. Screen mesh (25 MM) 6
43. Screen mesh (50 MM) 6
44. Screen mesh (80 MM) 6
45. Corner roller assembly
(64.08.500021)
2
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
30
46. Conveyer rear scrapping pad
(distributing)
2
47. Conveyer rear scrapping pad
(main waste)
1
48. Main scooper with intermediate
link and sub components
6 sets
49. Dredger drum spoket 1
50. HTS bolts with nuts (24 X 130
MM)
2
51. Roller (62.11.7000.09) 2
52. Roller (62.11.7000.10) 1
53. Roller (62.11.7000.23) 2
54. Roller (62.11.7000.24) 2
55. Roller (62.11.7000.11) 2
56. Roller (62.11.7000.25) 1
57. H.T.S. hex. Bolts (6X20, 8X5,
8X50, 8X75, 10X25, 10X40,
10X65, 10X80, 12X50, 12X60,
12X90, 16X50, 16X60, 16X90,
16X120, 20X50, 20X90)
25 nos.
each
Electrical
1. Self starter (Bosch type) 1 no. -do-
2. Battery cable 2 nos. -do-
3. Pilot lamps 5 nos. -do-
4. Working light & head light bulbs 5 sets -do-
5. Time relay for engine 2 sets -do-
6. 8 pin relay 2 nos. -do-
7. Thimbles of sizes 10 each -do-
8. Distilled water 1 lit.
9. Petroleum jelly 1 kg.
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
31
10. Battery (+ve connector terminal) 2 nos.
11. Battery (-ve connector terminal) 2 nos.
Engine
1. Fuel filter (paper) 6 nos. -do-
2. Fuel filter (cloth) 6 nos. -do-
3. Lube. Oil filter (4006104000) 4 nos. -do-
4. High pressure fuel pipes 1 set -do-
5. V-Belt (KHD2421916) 2 sets -do-
6. Rubber hoses for air passage 1 set -do-
7. Flexible fuel pipes 1 set -do-
8. Brake fluid (white) 1 lit. -do-
9. O-ring for centrifugal filter inner
bowl. (117*125*4)
2 nos. -do-
10. Power PCB EK-8135V00 1 no. -do-
11. O-ring for centrifugal filter inner
bowl. (186*174*6)
2 nos. -do-
12. Engine oil APICF4 15W40 50 lts.
13. Gear oil SAE-90 50 lts. *
14. Air filter cartridge (dry type)
(KHD2165059)
2 nos.
15. Fuel filter flat rings and copper
washers
4 sets
16. Cooling coil 1 no.
Hydraulic
1. Filter element (62, 05, 1000, 113) 4 nos.
2. Filter element (62, 05, 1000, 256) 2 nos.
3. Filter element (v) 1 no.
4. Main gear box flange oil seal 1 set
5. Dredge drum gear box shaft seal 1 no.
* Ten litres to be taken in block.
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
32
6. Buffer valve for extra lifting 1 no.
7. Difference Pressure Filter element
(62, 05, 1000, 293)
1 no.
8. Return Filter element
(62, 05, 1000, 270)
1 no.
9. Return Filter element
(62, 05, 1000, 273)
1 no.
10. Filter element
(64, 08, 4000, 247, 08)
1 no.
11. Seal set for all hydraulic cylinders 1 set
12. Driving motor shaft seal
(827 SK 60-80-7GOETZE)
2 nos.
13. Bush (axle gear box)
(64, 02, 2107, 00)
4 nos.
14. Piston ring (axle gear box)
(64, 02, 2000, 87)
12 nos.
15. Driving directional valve 1 no. To be
taken in
block
16. Pressure switch for driving. 1 no. -do-
17. Hose no. 16 h.p. in driving circuit 1 no. -do-
18. Hose no. 20 in excavating circuit 1 no. -do-
19. Hose no. 24 return hose
excavation system.
1 no. -do-
20. Hose no. 16 screen vibration
circuit.
1 no. -do-
21. Hose no. 8 h.p. with end fittings
(5 mtrs.)
1 no. -do-
22. Hose no. 6 h.p. with end fittings
(5 mtrs.)
1 no. -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
33
23. Hose no. 4 h.p. with end fittings
(5 mtrs.)
1 no. -do-
24. Hand control valve 1 no. -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
34
C - Spares for emergency on FRM
S. No. Description Qty. Remarks
Engine
1. Fuel filter 1 litre capacity paper type 2 To be
taken in
block
2. Fuel filter 1 litre capacity cloth type 2 -do-
3. Fuel filter 1 litre capacity paper type 2 -do-
4. Lube. Oil filter (6054.297.0039) 1 -do-
5. Set of fuel injection pipes 1 set -do-
6. Set of water radiator hoses 1 set -do-
7. 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
1
1
1
-do-
8. V-belts – A.61.A.52.A.45 2 -do-
9. Banjo bolts 4 -do-
10. Fuel filter – O-ring for 1 litre & 5
litre capacity filter
2 each -do-
11. Self starter (065.000.1417058) 1 -do-
12. Engine oil APICF4 15W40 50 lts.
13. Gear oil SAE-90 50 lts.*
14. Air cleaner (outer) (C.3085012) 2
15. Air cleaner (inner) (CF.1600) 2
16. Set of copper washers 1 set
* Ten litres to be taken in block
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
35
Hydraulic
1. Hydraulic Hoses with end
connection (length 5 mtrs. Each)
(4.6.8.10.16.20)
1 -do-
2. Hydraulic Return hoses with end
connection (5 mtrs. Length) dia 24
1 -do-
3. Pneumatic hose ¼" dia 10
mtrs.
-do-
4. Pneumatic hose ½" dia 10
mtrs.
-do-
5. Pneumatic hose clamp ¼" & ½" dia 6 each -do-
6. Hose connection (compressor to
cooling coil) (90291)
1 -do-
7. Brake cylinder hose (90286) 1 -do-
3. Hydraulic Suction filter
(HYS.501.360.150)
1
4. Hydraulic Suction filter
(HYS.501.160.P19)
3
5. Hydraulic Suction filter
(HYS.501.460.150)
4
6. Hydraulic Return filter
(HYR.501.330.104)
2
7. Clutch filter (62.05.1000.113) 1
8. Clutch filter (62.05.1000.293) 4
9. Piston ring for clutch shaft
(A.302943)
3
10. Modified piston ring for clutch shaft 3 (if
modified)
11. Bush for clutch shaft
(64.02.2107.00)
2
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
36
12. Seal set for Hydraulic cylinder (for
each cylinder)
1 set
13. Brake cylinder seal 1
14. Brake shoe 4
Electrical
1. Head light bulbs 2 -do-
2. Working light bulbs 4 -do-
3. Tail lamp bulbs 4 -do-
4. Micro fuse 4 Amps. 6 -do-
5. Limit switch complete 2 -do-
6. Limit switch cartridge 2 -do-
7. Battery terminals 4 -do-
8. Thimbles off sizes 1 -do-
9. Power supply chord (EK.8135V002) 1 -do-
10. 4 way toggle switch for waste
conveyor and cutter unit operation
1 -do-
Mechanical and general
1. Hex bolt with nylon nut 12 x 65 mm 100 -do-
2. Rivets with washer 50 -do-
3. Cutter chain shovels 4 -do-
4. Bolt for cutting chain (6560801050) 2 -do-
5. Cutter bar bolt M-24 x 20 mm 4 -do-
6. Roller (SU127.21.4.1.5) 4
7. Bush 4
8. Clamping bushing (656.080.1040) 2
***
Go to index
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
37
CHAPTER – 7
Dynamic Track Stabiliser (DGS)
A- Spares for emergency
S. No. Description Qty. Remarks
1. Hydraulic Pipe
(SAE 100 R2A: 04)
Max. length
provided on
m/c
To be
taken in
block
2. Hydraulic Pipe
(SAE 100 R2A:06)
-do- -do-
3. Hydraulic Pipe
(SAE 100 R2A:08)
-do- -do-
4. Hydraulic Pipe
(SAE 100 R2A:10)
-do- -do-
5. Hydraulic Pipe
(SAE 100 R2A:16)
-do- -do-
6. Hydraulic Pipe
(SAE 100 R2A:20)
-do- -do-
7. Hydraulic Pipe (SAE R5-24) -do- -do-
8. Power supply circuit
(EK:812:SV00)
1 -do-
9. Cardon shaft
(KGW:180:1250:11D:00)
1 -do-
10. Cardon shaft
(LZ:400:LA50/587:30/
FL:D:180)
1 -do-
11. Cardon shaft
(KGV:150:0900:110:00)
1 -do-
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
38
12. Relay (EL-T7002/S4) 2 -do-
13. Relay (ELT-663) 2 -do-
14. Head light bulbs 4 -do-
15. Working light bulbs 6 -do-
16. Self starter 1 -do-
17. (a) V-Belt (B-95)
(b) V-Belt (A-52)
(c) V-Belt (A-60)
3
1
1
-do-
18. HSD oil filter (25 38234) 2 -do-
19. Lube. Oil filter (15 8139) 2 -do-
20. Bypass filter for Mobil oil
(38 73576)
1 -do-
21. Mobile oil (API-CF4) 15 W
40
60 lts. -do-
22. Gear oil SAE-90 30 litrs. -do-
23. Radiator hose 1 set -do-
24. Grease 10 kgs. -do-
25. Petroleum jelly 250 gms.
26. Emery paper fine 2
27. ZF filter (Hyd.501-225-
25ES)
1
28. Hydraulic Suction filter
(Hyd.501-460-150)
1
29. Hydraulic Suction filter
(Hyd.501-160-10)
2
30. Hydraulic Return filter
(Hyd.501-330-10ES)
1
31. Hydraulic Suction filter
(Hyd.501-160-P10ES)
2
32. Hydraulic Filter Driving
(Hyd.501-32-10ES)
2
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
39
33. Air cleaner
(a) Outer element (22
37953)
(b) Inner element (32 26019)
2
2
34. Distilled water for battery 2 bottles
35. ZF gear box oil 50 ltrs.
36. Hydraulic Oil shell Telus –
68 or equivalent.
210 ltrs.
***
Go to index
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
40
NOTES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Go to index
CAMTECH/C/2004/TL&PL/1.0
Tool/plants & spare parts to be kept with the machine March - 2004
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