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Better Use of small track machine,Suggestion &missing Links

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Why small track machine?

The perennial problems of vacancies of Gang Men and their continuously increasing age profile is leading to reduction in efficiency of manual maintenance of track. The track structure has become heavier. The deployment of small rack machines has become inevitable.Now there is no other way except introducing small track machine in day to day maintenance.

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Why small track machine?OUTPUT:- More than the manually achieved work?Time saver ;- in the modern scenario if we save Time then it will increase wagon turnaround (if you earn time ,you earn money),more time for traffic hence earning of railway is also increasedQuality & perfection :- Using the small track machine we can achieve best quality of work . Track can be maintained to closer tolerance as required.Suitable for concrete sleeper & CWR track.(modern track)Economy-Use Of STM is always Economical

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Introduction of small track machine

Due to revolutionary changes in socio economic structure gross root level workers are also hesitating to follow the old conventional method of maintenance. By introducing concrete sleeper and higher section 60Kg rail modern track structure became three times heavier than the conventional track of old age.Now the time has come to introduce the small track machine as stated in para no203/1 & Para no1408 of IRPWM

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Type of Small Track Machine

For Transporting material Like rail Dolly .Attachment to Rail Dolly ,material Trolley&Powered material trolleyFor ballast:- Portable ballast cleaner,& Shoulder ballast CompactorFor Rail;- Rail cutting saw type&Abrasive Disc Type Machine,Hole drilling machine, Chamfering Kit,Rail profile weld grinder,Mech & Hydraulic Rail tensor,Hydraulic jim Crow,Rail joint ETC.

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Type of small track machine

For Fitting :- Toe Load measuring device,ERC Extractor & Applicator, Hydraulic ERC Extractor for jammed ERC For Packing Work:- Mechanical & Hydraulic track Jack, Hydraulic Sleeper spacer, track lifting cum slewing Device Hand held off track tempers.Misc Work:- DC Welding generator for reconditioning works Contd.

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Type of small track machine

Misc Work :- Rail Hauling Systems,self propelled light weight weight trolley , Rail cum road vehicle , welding set for thermit welding

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Abrasive type rail cutting machineAbrasive rail cutting machine is a light weight state-of-art, fast cutting equipment which cuts the rail by abrasion and not by sawing.The cutter is very useful where cutting time is important. The average time taken for cutting 90 UTS rails of 60 kg section is within 5 minutes whereas 52 kg sections are cut within 3 minutes Thus we can save at least 20 minutes time when we cut rails By Disc Cutter in Place of Saw type cutting machine,

Abrasive track Machine

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Abrasive Disc cutterAbrasive Disc Cutter

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Needs for better functioning

For better functioning and introducing small track machine in day to day track maintenance the following area requires proper attention.User Awareness & Willingness – first of all users should be made aware regarding use & Benefits of using small track machine as most of all users hesitates to leave old practice &adapt modern maintenance practices.

AMC

Spare part

ROH

POH

Transportation

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Needs for better functioning1.Care to be taken during Procurement

(procurement to be made only from RDSO Approved manufacturer& specification)

2.Care to be taken at commissioning level(if machine fails on RDSO specification it must be rejected immediately)

3.Training of operator4.Competency certificate to be issued for each

type of machine5.Preparation of History book/Logbook6.Inspection at regular Interval,By Service

Engineer, ADEN & SSE who is custodian of machine

7. Transportation arrangement for machine from store to work Site.

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Needs for better functioning8.Ensuring Easy availability of consumable

Like ,Petrol,Diesel,Gears oil,Engine oil,Grease etc.

9.Ensuring availability of spare parts,with least delay,Each Manufacture should be asked to ensure availability of spares ,even after expiry of warranty period.

10. Based on MMU II criteria under each ADEN a base depot with all repairing facility under supervision of a SSE(P.way) Spl must be established.(As mentioned in small track machine manual)Along with well trained Skilled mechanic with helpers

11. Jhola chap road mechanic who are not aware should not allowed to Open the head of Engine.

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Prourement of S. T/machineAt the time of placement of P.O.Correct specifications should be mentioned and small track machine should be procured only from the Approved from RDSOWarranty period for at least Two years and three to four free service engineer visit may also be arranged by manufacturer mentioned in the P.O.( In the case of engine Fixed engine Like 400 hours must be included in the warranty)Whichever is later)List of each part of machine with cost & DRG. should be supplied by Supplier and he should bound to supply the required Part in case of damage even also expiry of warranty period.

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An Imported Tree cutting machine

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Inspection From the date of commissioning /Supply up to regular use All small track machines should be regularly Inspected By ADEN once in six month and by SSE( P,way) Once in a fortnight Inspection should be meaningful purposeful & fruitful These inspection should not be done with the aim of completing schedule.But the results of inspection must be recorded in the History Sheet/Log Book Of small track machines.If any machines found out of order then action taken to rectify the defect or referring the matter to higher authority For repairing must be recorded in the history Book/log Book

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Training of Two types(First By railway) In ETC General training

General training:- all small track machine operators should be trained for at least a period of 21 days.this training shold include(I) Different part of a Two stroke Engine & four stroke engine and their function.(II)Function of carburetor,Choke and its use,Refilling of Engine oil,Gear oil , Filter after prescrbed period in maintenance manual (III) Principal of Hydraulic machine,repairing of leakage,replacement of O ring ETC.

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Training of Two types(IV)Removal of Air from vent Screw for proper functioning(V) Study of some mechanical machine Like Mech Jack,Rail Dolly,(VI)Common trouble shooting Problems for various Small track machine and method of rectifications Like rectification of spark Plug, Cleaning of filter,overflow in carburetor.(VII)Filling of Logbooks preparation of B/Down report, Transportation & Storage Maintenance.

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Training of Two types(IV)Removal of Air from vent Screw for proper functioning(V) Study of some mechanical machine Like Mech Jack,Rail Dolly,(VI)Common trouble shooting Problems for various Small track machine and method of rectifications Like rectification of spark Plug, Cleaning of filter,overflow in carburetor.(VII)Filling of Logbooks preparation of B/Down report, Transportation & Storage Maintenance.

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Training of Two types(2nd Type)By Service engineer of ManufacturerSpl Training for Each Small Track

machine-Adequate training in operation and maintenance of the machine shall be imparted to Railway operators at the rate of one operator per machine . In case of complicated machine Like D.C.welding generator at least three days training must be arranged from end of suppliers /manufacturer.

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DocumentationHistory sheet/book of each machine must be prepared separately.Break/Down of machine should be immediately reported to Purchaser through proper channelConsumable materials ,output of machine and spares consumed for repairing must invariably recorded in the machine.Progress /output of machine regularly recorded By machine operator in log Book.

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Updating the design of machine

We should review the use of some machine and redesign , For example In place of conventional Rail dolly,Rail dolly for Carrying PSC sleeper we can redesign and make it Insulated Rail dolly for avoiding signal failure.Creating awareness regarding multiple using of several machine.Like we can use a rail tensor for (1)distressing of LWR at lower temperature(2)maintaining the Gaps in SEJ(particularly at The approaches of girder bridge(3) For holding the Welding gap when rail temperature is in decreasing trend

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Maintenance Schedule

All maintenance schedule as Laid down inUsers manual must be strictly Followed1.Daily Maintenance2. Periodical Maintenance(P.O.H.)Like

Changing of Engine oil,Gear oil,Filter replacement Etc,Done by users)

3.Intensive Overhauling(It should always be done in the presence of trained mechanic either in Base Depot or Preferably in manufacturer Workshop)

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Shadow ZoneSome Area Still Left Uncovered in small track machine Like:-Storage Maintenance:- When some Generator or Four Stroke Engine require to be KEPT Unused for long time what precautions should be taken to Store it or what extra maintenance needed to make the machine operative like Charging of battery,Starting the engine regularly after ten to fifteen days etc .or charging the battery of an electronic toe load measuring device at regular interval Should also be mentioned/Counseled to Each small track machine operator

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Shadow Zone

Safety Aspects/Rules of safety:- All machine Operators should be insisted to Wear safety goggles, ear phone Apron,Safety Shoe,Helmet As prescribed in Machine Users manual .It must be procured along with machine during first procurement.( Specially in the case of Abrasive disc cutter & Rail profile weld grinder)

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ConclusionAs per human tendency In railway in comparison of On-TrackMachine small track machine is always being ignored .But We should always remember as our ancestorPoet Rahim Says “ rahiman dekh Baren ko laghu na diseaye dor “ “ Jahan Kam ave sui Kahan kare Tarwar “

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