Tools/plants & spare parts to be kept with the track machines

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)

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 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.



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



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



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



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



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



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



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



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-



10

B - Spares for emergency on CSM.


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-



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-



-do- -do-



-do- -do-



-do- -do-



-do- -do-



-do- -do-



-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-



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



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.



14

C - Spares for emergency on Express Tamper.


Engine

1. Fuel pre-filter (breather) 1 To be

taken in

block



4. Lube. Oil filter 2 -do-

5. Air cleaner filter 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-


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-



15

12. Roof clamp 4 -do-

13. Clapper cylinder 1

14. Clapper bracket 2

15. Clapper cylinder pin (12 mm,

16mm, 20mm)

2 sets


cylinder seals

1 set


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-


2781-6

-do- -do-


2781-8

-do- -do-


2781-10

-do- -do-

11. Hydraulic hoses 2781-12 (Crimped

fittings)

-do- -do-



16

12. Hydraulic hoses 2755-16

(Crimped fittings)

-do- -do-


(Crimped fittings)

-do- -do-


(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



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



18

CHAPTER – 4

Point and Crossing Tamping Machine (UNIMAT)

A - Tools


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.



19

B - Spares for emergency


Engine

1. Fuel pre-filter (breather) 1 To be taken

in block



4. Lub oil filter 2 -do-

5. Air cleaner filter 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-


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-


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



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


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-



21







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-



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



23

CHAPTER – 5

Ballast Regulating Machine (BRM)

A- Tools


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



24

B - Spares for emergency


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-



2 -do-



1 -do-



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-



25

19. Charge flow filter (Hydraulic)

(714374)

1 -do-


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


***

Go to index



26

CHAPTER – 6

Ballast/Shoulder Cleaning Machine (FRM & BCM)

A - Tools for FRM & BCM


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



27

19. Hoisting device (over head)

(800 KG.)

1

20. Lead (DNZ-400 BAR) 1

21. Gas cutting equipment 1 set



28

B - Spares for emergency on BCM


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-



20 -do-



20 -do-



20 -do-



20 -do-



5 -do-



20 -do-

17. Cutter bar 1 -do-



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



45. Corner roller assembly

(64.08.500021)

2



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.



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.



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-


(5 mtrs.)

1 no. -do-



33


(5 mtrs.)

1 no. -do-

24. Hand control valve 1 no. -do-



34

C - Spares for emergency on FRM


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.


14. Air cleaner (outer) (C.3085012) 2

15. Air cleaner (inner) (CF.1600) 2

16. Set of copper washers 1 set




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


(HYS.501.160.P19)

3


(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



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



37

CHAPTER – 7

Dynamic Track Stabiliser (DGS)

A- Spares for emergency


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-



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


(Hyd.501-460-150)

1


(Hyd.501-160-10)

2

30. Hydraulic Return filter

(Hyd.501-330-10ES)

1


(Hyd.501-160-P10ES)

2

32. Hydraulic Filter Driving

(Hyd.501-32-10ES)

2



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



40

NOTES

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Go to index



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

Tools/plants & spare parts to be kept with the track machines

Documents

Transcript of Tools/plants & spare parts to be kept with the track machines