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1. 09- Series Machines Working Over Indian Railways

2. 09- Series Machines Working Over Indian Railways CSM 09-3X 09-3X-Dynamic Express

3. Main Function Of UNIMAT Machine LIFTING- Correction of longitudinal and cross levels. LINING - Correction of alignment. TAMPING- Packing of ballast under the sleepers.

4. Tamping Unit Control System

5. How the Tamping is Performed Tamping Cycle, Squeezing Time & Target Depth

6. Tamping Unit Control PCB T/U Up Down Cylinder T/U depth selector PLC Foot Pedel Squeezing Timer Sqeezing Valves Sqeezing Cylinders Lining Control PCB Lifting control PCB Proportional Valve Display T/U depth Transducer Simulation of Auto tamping

7. How the Target Depth is achieved Tamping PCB

8. HISTORY OF 09-32 CSM In 1981  Plasser & Theurer developed a new idea for more economical track maintenance: The Continuous Action Tamping 09-Series Machines . At the beginning of 1982 first trials were carried out with a prototype and in the year 1983 the first continuous action leveling, lining and tamping machine 09-32-CSM was used in a regular maintenance operation on Indian Railways .

9. HISTORY OF 09-32 CSM The success of the 09-Series is based on the notion of separating the main frame from the work unit frame called Satellite . This means that the main frame can move forward continuously during work, while Satellite moves in the essentially cyclic action equipped with all the working unit like lifting, lining and tamping units. Outcome of Changeover of 08-Series to 09-series Machines:- Excellent quality of work: There was a technological switchover from 08-Series to 09-Series machines, due to upgraded technology, incorporated in operations, lifting, lining and tamping which resulted excellent quality of work.

10. HISTORY OF 09-32 CSM 2.Higher working speed: Main frame of machine moves continuously only satellite unit stops for tamping, Due to light weight of satellite unit, the controlling of satellite movement becomes easier. It increase the 50% output as compare to 08–Series machine i.e. Duomatic . Even short time block can be availed effectively and cost-efficiently . 3.Highest working comfort : Due to the separation of main frame and sub-frame(Satellite), the vibrations of the work units and jurks are not transmitted to the cabins. Working comfort is considerably improved, operator can work for longer period without feeling exertions and without loosing efficiency .

11. 09-32-CSM ( Continous Tamping Machine)

12. MAIN FEATURES ( Old Series CSM-901 to 953) Machine have two parts i.e. MAIN FRAME & SATELLITE FRAME Driving from both cabin. Programmable Logic Control (PLC-P500) Machine. Fully auto cycle. Servo valve for Lifting & Lining .

13. MAIN FEATURES ( Old Series CSM-901 to 953) Multi-check system. It has 32 tamping tools and packs two sleepers at a time. It moves continuous during working. Output:- 2200 to 2400 Sleeper / Hr. Laser lining System (optional). Geometric Value Assesment (GVA) – Computer (Optional)

14. MAIN FEATURES ( New Series CSM 955 to 984) Machine have two parts i.e. MAIN FRAME & SATELLITE FRAME Main Gear Box— ZF Hydrodynamic - (4 speed gear box). Driving from both cabin. Fully auto cycle. Servo valve for Lifting & Lining . It has 32 tamping tools and packs two sleepers at a time. It moves continuous during working. Output:- 2200 to 2400 Sleeper / Hr.

15. MAIN FEATURES ( New Series CSM 955 to 984) Multi-check system. Programmable Logic Control (PLC-P600) Machine. SPS- Diagnostic System( Trouble Shooting Software for P600 installed in ALC Automatic Guiding Computer (ALC) Computer Measuring System (CMS) Computer Working System (CWS) :- CSM-966 Onwords

16. S. No. Parameter Value 1. Length over buffers 20670 mm 2. Height over top of rail 3600 mm 3. Width 3040 mm 4. Wheel diameter 730 mm 5. Gauge 1676 mm GENERAL TECHNICAL DATA (Old CSM-901 to 953)

17. S. No. Parameter Value 1. Overall Length 20670 mm 2. Overall Height 3895 mm 3. Overall Width 3140 mm 4. Wheel Diameter 730 mm GENERAL TECHNICAL DATA (New CSM-955 to 964)

18. S. No. Description Old CSM New CSM 1. Programmer System P500 P600 2. SPS diagnosis -NA- Available 3. A LC -NA- Available 4. CMS/CWS -NA- Available 5. Programmer Battery 12V/70AH -NA- Available 6. Satellite lateral movement Limit Switch control PCB control GENERAL TECHNICAL DATA (Old CSM-955 to 964)

19. S. No. Description Old CSM New CSM 7. Over all height 3600 mm 3895 mm 8. Overall width 3040 mm 3140 mm 9. Engine KTA-1150-L / MWM TBD 232V12 KTA-19-L 10. Alternator type 28V/55A - 02 Nos. 28V/55A - 02 Nos. , 28V/120A - 01 No. DIFFERENCE BETWEEN OLD AND NEW CSM

20. S. No. Description Old CSM New CSM 11. Electrically operated Emergency Pump -NA- Available 12 Hyd. Pumps 05 Nos. 04 Nos. 13. Hyd. Motors 08 Nos. 09 Nos. 14. System Accumulator 01No. 02 Nos. GENERAL TECHNICAL DATA (Old CSM-955 to 964)

21. Different Units of CSM CSM machine has been made in two parts. 1. Main Frame Unit . 2. Satellite Unit .

22. Different Units of CSM

23. Different Units of CSM CSM machine has been made in two parts. 1. Main frame :- It is made of rolled profiles and steel sheets, produced using the most up-to-date welding methods. These designs give stability and precision even on heavy types of permanent way. It consists of two cabins (driving and working) All control panels are fitted in these cabins. Driving and working is carried out from these cabins

24. Different Units of CSM CSM machine has been made in two parts. 1. Main frame :- The prime mover of machine, Engine is fitted on the main frame unit. Hydraulic tank and fuel tank . Three trolleys are attached in the main frame such as front, measuring and rear trolleys. Three gear boxes are mounted on this frame i.e. ZF gear box, Reduction gear box and Distribution gear box . It has four axles i.e. Two driving axles, two running axles. Two 2-axled bogies ensure smooth running of vehicle This unit moves continuous during working.

25. Different Units of CSM 2. Satellite Unit:- It carries all work units and measuring systems that use the cyclic work sequence like the lifting and lining units and the two tamping units. At the front, it is supported on the main frame via a longitudinal roller guide. The satellite frame axle, powered by hydraulics during working travel, hydraulic cylinders and a pneumatic brake ensure the cyclic work sequence. One gear box such as satellite axle gear box is mounted on this frame. During working it moves sleeper to sleeper. It has one axle called satellite axle. During travelling it moves in synchronization with the main frame. Satellite Unit

26. Main Units:- Engine Tamping unit Lifting and lining unit Z.F Hydrodynamic gear /box Distribution gear box Reduction gear box Pump gear box (Funk Gear box)

27. Main units:   Engine:- It is the prime mover of the machine which provides power during working or travelling to the machine.It has one diesel Engine. Some machine have MWM engine and some have Cummins engine which needs diesel as its fuel for working and mobil oil for its internal part lubrication. The grade of mobil oil is different for different models of engine as per recommendation of OEM. These are water cooled engines. MWM Model no. - TBD -232 –V12 @473BHP OR CUMMINS Model no. - KTA 1150L @473BHP

28. Main units:   Engine: - MWM Model no. - TBD -232 –V12 @473BHP Provided in Old Series CSM MWM – Motoren Werke Mannhem T -Turbocharged B -After cooled D - Diesel Engine 232 - Series V - V- Type 12 - Twelve Cylinders

29. Main units:   Engine: - CUMMINS Model no. - KTA 1150L @473BHP Provided in New Series CSM K – Engine Family T – Turbocharged A – After cooled 1150 – Displacement in Cubic Inches L – Locomotive.

30. Main units:   Tamping unit :- It has two tamping units one for left side track and other for right side track which is fitted on satellite unit of machine. It has 32 tamping tools and packs two sleeper at a time. Its tamping unit is similar to Duomatic type tamping unit. To get the proper quality of packing tool should be complete without any missing tool in tamping unit. The two high pressure tamping units work according to the non-synchronous uniform pressure tamping principle.

31. Main units:   Tamping unit :- Force equilibrium between the tamping tools, directional vibration in the squeeze direction and the ideal vibration frequency of 33-35 Hz gives completely uniform tamping. For work in curves, the unit can be centred automatically over each rail. During each cycle, two sleepers can be tamped with the help of 32 tamping tools The size of tool blade is 70mm×140mm whereas the size of Cut tool is 70mm×110mm or 70mm×90mm according to their positions.

32.  Tamping unit :Different Parts

33.  Tamping Unit :Different Parameters:- 1.Squeezing Pressure:- S.No . Type of Track and Sleeper Squeezing Pressure 1. Plain Track (CST9) 90-100 Kg/ Sqcm 2. Plain Track (ST & Wooden) 100-110 Kg/ Sqcm 3. Plain Track (PSC) 110-120 Kg/ Sqcm 4. P & C (ST/Wooden) 110-115 Kg/ Sqcm 5. P &C(PSC) 125-135 Kg/ Sqcm

34.  Tamping Unit :Different Parameters:- 2.Tamping Depth:- S.No . Type of Sleeper Desirable gap between top edge of the tamping tool blade and bottom edge of Sleeper 1. Flat Bottom Sleeper 15-20mm 2. Metal sleeper 22-25mm

35.  Tamping Unit :Different Parameters:- 3.Tamping Tool Vibration, Amplitude & Frequency, Vibration Pressure and Squeezing Time:- S.No . Parameter Value 1. Rate of Rotation of Vibration Shaft 2000 to 2100 RPM(approx.) 2. Vibration frequency of Tamping Tool 33 to 35 Hz.(approx.) 3. Amplitude of Oscillation 3 – 5 mm 4. Vibration Pressure 150 Bar to 210 Bar 5. Squeezing Time 0.8 Sec to 1.2 Bar

36. Lifting and lining Unit:- In CSM machine, One set (1Left and 1 right) lifting and lining unit is fitted for maintaining the cross level and alignment of track with the help of hydraulic cylinders. For lifting of track 4 no. disc clamp rollers are fitted on each side of unit. For alignment of track, 2 nos. of lining rollers are provided each side. Track lifting and lining is operated by servo valve. Disc clamp roller hold the track with the help of hydraulic rail clamp cylinder. The two lifting units consist of two pairs of lifting roller clamps on each side which lift and line the track in each cycle. Lifting and lining is carried out only when the unit is at standstill which results in precise lifting & lining. Main Units: Contd..

37. Lifting and lining Unit:- Main Units: Contd..

38. Z.F Hydrodynamic gear /box:-   This is a new era gearbox, which works on the principle of fluid coupling . It has a hydraulic clutch system, which can be engaged / disengaged electro-hydraulically. It provides eight speeds (four forward & four reverse) on machine. Without it, it is very troublesome to drive machine from both cabins. It replaced the cumbersome mechanical arrangement for mechanical driving and made driving a pleasure. It holds three hydraulic pumps. It is main gear box of the machine which is electrically controlled. It gets power input direct from the engine and send it to driving axles through distribution gear box during travelling. In working mode, it gets power input from the engine and gives drive to the hydraulic pumps which generate the hydraulic power. During working, machine and satellite movement is carried out by hydraulic power.

39. Distribution Gear Box:- This gear box is used for the purpose of power transmission. With the help of this distributor gear box, power is taken from ZF gear box and distributed to different axles by cordon shafts.

40. Reduction Gear Box:- It gets power from hydraulic motor. It reduces the output rpm and transfer power to distribution gear box though cardon shaft connected with it. Its use in work drives system. To give continuous drive to the machine. This gear box is used in the working mode, when the machine works during sleeper to sleeper movement. A driving motor is mounted on this gear box, which got supply from variable pump. Higher rpms of driving motor are reduced through this gear box and drive transferred to distributor gear box via ZF gear box. There is a power take off assembly on ZF gear box, which connects/disconnects this gear box from ZF gear box. During running, this gear box must be disconnected from ZF gear box.

41. Pump gear box (Funk Gear box):- This is a mechanical gear box used for the purpose of power transmission . It is directly getting power from engine through a cardon shaft. It gives drive to two hydraulic pump during working. There is a set of three gears in this gear box which gives the output of same direction. The function of this gear box is during working of machine. .

42. SATELLITE AXLE GEAR BOX: Since CSM is a continuous action machine so it moves continuously during working but it is quite impossible to tamp with a moving machine ,therefore an extra unit has to introduced for tamping, lining and levelling i.e. Satellite. It moves and stops in each cycle within main frame of machine. For smooth and stable running of this unit, a satellite axle along with a gear box is provided. For this purpose, tamping and lifting lining unit have been provided on Satellite frame which moves with a synchronising speed with machine movement.

43. SATELLITE AXLE GEAR BOX: This gear box consists of a spur gear, planetary gear box and hydraulic motor and engage/disengage lever. The spur gear is mounted on the satellite axle, which is attached to the planetary gear box through an engage/disengage mechanism. The engaging and disengaging is carried out lever, which is pneumatically operated. Normally, it is in disengaging condition while travelling i.e. idle position. As working is on, a pneumatic pressure is applied on lever and this engages the planetary gear box to the crown gear and thus, the hydraulic power is transmitted to satellite axle. When the pneumatic pressure is< 2.5 bar, pinion is partially engaged with crown gear and it leads to premature failure of satellite gearbox.

44. 9. Axles:- Axle gear box consists of a crown gear and tail pinion. The crown gear is mounted on the driving axle while the tail pinion is attached to the cordon shaft from the distributor gear box and gives drive to crown gear. It gives movement to the machine. There are five axles in CSM machine.   1. Driving axle –02 Nos.:- It consists of bevel gear and tail pinion fitted in main frame. It is the power axle during travelling mode and during working power axle for main frame drive. 2. Running axle –02 Nos.:- It is idle axle fitted in main frame. 3. Satellite axle –01 No:- It consists of spur gear. It helps in sleeper to sleeper movement of satellite unit during working. The power is given to satellite axle by hydraulic motor.

45. 9. Axles:- Cotd .. From the distributor gear box, two cordon shafts which rotate in the opposite directions to each other are taken out for two axle gear boxes. In one driving axle, the cordon shaft is attached to the left side of the crown gear while in the second one; the cordon shaft is fixed in the opposite side of the crown gear. Both have the same gear ratio. Therefore the speed and directions of movement of both the axles are same.

46. 10. Centralized Automatic Gearing System:- This system is provided for the greasing of both side tamping unit. Due to this system, machine can work continuously during the block period. Earlier in manual greasing after ever 1-1/2 hour continuous working tamping unit is needs re-grease which in turn to stop the machine for manual greasing. This system also reduces maintenance time as well as labour cost. In this system, the amount of grease is supplied according to the system requirement. Hence, wastage of grease is totally vanish. This system is electronically/mechanically controlled which gives indication during the failure of the greasing system. It needs special grease i.e. ALVANIA R L 2 or equivalent

47.   HYDRAULIC SYSTEM:- The working of machine is hydraulically controlled. This machine has a very sophisticated hydraulic system which consists of pumps, motors and various valve and cylinders. Description of pump and motors are as under:-  

48.   HYDRAULIC SYSTEM:- Contd …  

49.   HYDRAULIC SYSTEM:- Contd …  

50.   HYDRAULIC SYSTEM:- Contd …  

51.   HYDRAULIC SYSTEM:- Contd …  

52.   Pneumatic System :- The pneumatic system are used for brake system, horn, locking/unlocking of units, up-down of sensing bogies and chord wire tensioning, datum and vertical pre-load. Important parts of pneumatic system are as follows:  

53. Power Transmission System of 09-32-CSM   DRIVING SYSTEM: - WORK DRIVE : During work machine is driven by variable pump with variable speed 0 to 2 kmph. but satellite drive is proportional drive. the speed of satellite varies with the main frame speed. RUN DRIVE : Hydro dynamics gear box (zf) is provided on the machine.  

54. POWER TRANSMISSION SYSTEM Schematic Diagram

55. POWER TRANSMISSION SYSTEM Line Diagram

56. POWER TRANSMISSION Driving Mode ENGINE P1 P2 P3 M Driving Bogie Distribution Gear Box Reduction Gear Box PTO Running Bogie Satellite Bogie M Funk Gear Box P4 P5 ZF GEAR BOX      

57. POWER TRANSMISSION Working Mode ENGINE P1 P2 P3 M Driving Bogie Distribution Gear Box Reduction Gear Box PTO Running Bogie Satellite Bogie M Funk Gear Box P4 P5 ZF GEAR BOX            

58. What you have learnt? It moves continuous during working. All the working assemblies are fitted in satellite unit It packs two sleeper at a time It has 32 tamping tools. Output of this machine is 2200-2400 sleeper/hr. It has hydrodynamic gear box in power transmission system. It has five axles. Maximum permissible speed- 60kmph Servo valve for lifting & lining During working main frame & satellite units moves in synchronization.

59. 09-3X Tamping Express

60. INTRODUCTION TO 09-3X -TAMPING EXPRESS After the successful working of 09-32 CSM, M/S Plasser and Theurer developed a new category of Tamping machines i.e. High Output Tampers (HOT).The first machine of this category of tamping machines was called 09-3X Tamping Express introduced in India in the year 2000 .

61. Salient Features of 09-3X Tamping Express * High output: The output of this machine increased by 30 to 40% compared to CSM. It consists of 04 Nos. Tamping Units. It Consists of 48 Nos. Tamping Tools. It can tamp 3- sleepers at a time . Max. Working Speed 3Kmph . Max. output of 3500 sleepers in an hour . Average output of 2700 sleepers in hour. This proves to be the best cost efficient utilisation even in short duration of block .

62. Salient Features of 09-3X Tamping Express State of Art Gadgets. First time Automatic Guiding Computer (ALC) introduced in this machine in India. Which can work in Geometry Mode and Measuring Run mode.ALC eliminated manual versine calculations and manual feeding of correction values through potentiometers. LASER Lining System provided for Straight Track Only.(Optional)

63. LINING SYSTEM OF TAMPING EXPRESS The machine is equipped with the single cord 3- point & 4- point lining system. The lining chord is stretched between front and rear tightening trolleys. The versine is measured electronically by two transducers fitted on lining and measuring trolleys.The measuring transmitter of the single chord lining system is connected to a servo mechanism Through an electronic system which automatically monitors the lining process. The measured value is displayed on an analog instrument. Lining system 3-Point Lining Precision Method Laser System ALC Method Fixed Geometry Method Geometry + Front offset Method Measuring run & Compensation Method 4-Point Lining

64. Automatic Guiding Computor (ALC ) for lining as well as longitudinal level correction : In this system, lining and lifting of the machine is controlled by a computer programme Win ALC of Plasser&Theurer . In ALC, there are three options such as Fixed Geometry, Front Offset and Measuring run methods .

65. Automatic Guiding Computor (ALC ) for lining as well as longitudinal level correction: (a.) Geometry method: In this method, the track parameters of curve portion to be fed to ALC computer before work. Slew for correction of versines to be fed by computer during working of machine. This system is suitable for construction lines where no obligatory points and no limitation of slews. (b.) Front Offset method: Design Mode In this system, the slew required for correction of versines are to be pre-calculated and feed to the computer every 5metres before working of machine.

66. (c.) Measuring Run Method: The measuring Run method is used where the track data is not known. The data for the track is obtained via a measuring run at a speed of 10 KMPH using the machine measuring system, prior to the working. After the computation of curve is done by using any known.e.g fixed points, cant, radius,etc . Then machine is set to work with the ALC automatically entering the computed lift and slew values.

67. For correction of long misalignment, the laser lining system is preferably used. In this system a laser gun is placed at a good point at a distance of 250-300 metres . A laser receiver fitted in front of the machine controls the versine correction by the machine. Laser gun to be shifted every 250 - 300 meters and setting to be done during the working This will require a long duration of block. Hence another method of laser system called Laser-KHR can be adopted. Laser lining system for straight lines:

68. LASER SYSTEM OF 09-3X TAMPING EXPRESS - LINING

69. Laser – KHR system: In this system, the slews are recorded by the KHR at a speed of 10KMPH by shifting laser gun at every 250-300 metres . This values are stored in computer Win ALC and work can be done any time after getting sufficient block.

70. Salient Features of 09-3X Tamping Express State of Art Gadgets. Upgraded version of Programmer Unit(P600). Small CCTVs with Cameras provided in working cabins to have views of lifting and lining Units, clamps from outside. Upgraded Electronic Circuits Provided. Working Cabins were equipped with Hydraulic driven Air Conditioners.

71. Salient Features of 09-3X Tamping Express Other Features:- Can Tamp- Single insertion(1X), Double insertion(2X), Triple insertion(3X) It can tamp 01-Sleeper at a time i.e can work in UNO Mode also.. Measuring Run speed 10Kmph. Max . Permissible Speed 60 KMPH (BY RDSO) .

72. Salient Features of 09-3X Tamping Express Other Features:- Upgraded model of ZF- Gear Box. First time 02 Engines fitted in a Tamping Machines. ENGINES OF CUMMINS NT 855 & KTA 1150. 3 BOGIES OF 2 – 2 AXLES (INCLUDING SATELLITE BOGIE), Total 06-Axles AUTOMATIC CENTRALISE GREASING SYSTEM.

73. TECHNICAL DATA OF TAMPING EXPRESS 1.Overall length : 22940 mm 2. Height : 4090 mm 3. Width : 2900 mm 4. Distance between bogie pivots : 15700 mm 5. Wheel base on bogie : 1800 mm 6. Wheel diameter : 730 mm 7. Gauge : 1676 mm

74. TECHNICAL DATA OF TAMPING EXPRESS 8 . Diesel tank capacity : 1900 Lts . Approx. 9. Hydraulic tank capacity : 1900 Lts . Approx. 10. Total weight : 83 Tons Approx. 11. Front axle bogie load : 38 Tons Approx. 12. Rear axle bogie load : 28 Tons Approx. 13. Satellite axle bogie load : 17 Tons Approx. 14. Maximum travelling speed : 100 KMPH 15. Permissible travelling speed : 60 KMPH

75. MAIN UNITS:- Engine . Tamping Unit . Centralized Automatic Greasing System . Lifting and Lining unit . ZF Hydrodynamic Gear box . Pump Drive Gear Box . Distribution Gear Box . Reduction Gear Box . Axles .

76. MAIN UNITS Engine: - 09-3X machine is equipped with 2 Engines of CUMMINS make Model no. NT 855 L- 320 BHP & KTA 1150 L- 473 BHP . Engine NT 855 L gives drive to pump drive gear box which gives power to 4 nos. hydraulic pump. It is required only during working of machine. Engine KTA 1150 L is required for both working as well as for travelling.    

77. ENGINE DETAILS OF TAMPING EXPRESS ENGINE No.1 ENGINE No.2 Make CUMMINS CUMMINS Type KTA 1150 NT 855 L Horse Power 473 BHP 360 BHP Maximum RPM 2100 2100 Firing Order 153624 153624 Bore x Stroke (mm) 159x159 mm 140x152 mm Valve clearance Intake 0.36, Intake 0.33, Exhaust 0.69 Exhaust 0.63 8. Oil pan capacity 38 Litres 27 Litres 9. Engine oil recommended SAE 15W40 CF4 SAE 15W40 CF4

78. MAIN UNITS: Tamping Unit:- The tamping unit provided for tamping three sleepers at a time.There are four tamping unit in this machine. This machine packs three sleeper at a time. During the failure of any packing unit that tamping unit pair may stop for working and by using single pair of tamping unit machine operator can complete the work. By using single pair of tamping unit it packs single sleeper at a time of working of machine is called UNO MODE.

79. It is able to tamp three sleepers per tamping cycle. The tamping unit is divided into sections so that it is possible to switch over to single sleeper tamping at any time. 09-3x (three-sleeper) Tamping Unit Three-sleeper Tamping Single-sleeper Tamping

80. Tamping Unit:- Contd.. Total 48nos. Of Tamping tools are required in 09-3X machine. In 09-3X tamping unit, parallel shank type tamping tools are used. The size of tool blade is 70mm×140mm. In this unit, small arm cut type tools are used. Wear of tamping tool blade is permitted only up to 20%. More than 20% wear out tools need replacement for proper quality of packing of ballast under sleeper.

81. Tamping unit:- Contd.. In machine two types of tamping tools are used Forged steel tool with hardness of 280 BHN Tungsten Carbide tip tool (TCTT) Forged steel tamping tools wear and tear at blade portion becomes more and it reduces the blade size. It needs re-welding to maintain the proper size of blade after 10-15km working. TCTT type tamping tools are very long life tool. It gives approx. 250km life without any maintenance. In these tools, at the location of squeezing face Tungsten carbide tips are welded.

82. 3.Centralized Automatic greasing system:- Due to four tamping unit no. of greasing points is approx. 96 nos. so to reduce the maintenance time and man power of machine centralized automatic greasing system is compulsory. In manual greasing, it takes more time in maintenance. The automatic greasing system is similar to CSM machine.

83. Centralized Automatic greasing system:-Contd.. Automatic centralized grease lubrication is provided for all lubrication points of tamping units. The process of lubrication takes place as soon as the vibration of tamping units started and greasing timing and interval can be adjusted as per your requirement. This prevents the over greasing and wastage of grease during manual greasing in addition to reduce the labour for greasing.

84. 4.Lifting and lining unit:- In 09-3X machine, One set (1 for Left and 1for right) lifting and lining unit is fitted for maintaining the cross level and alignment of track with the help of hydraulic cylinders. For lifting of track 4 no. disc clamp rollers are fitted on each side of unit. For alignment of track, 2 nos. of lining rollers are provided each side. Track lifting and lining is operated by servo valve. Disc clamp roller hold the track with the help of hydraulic rail clamp cylinder.

85. 5.Z.F Hydrodynamic Gear /box:- There was too much failure in main gear box and so many assemblies were provided to give drive to hydraulic pumps and separate six speed gear box, forward-reverse gear box and clutch assembles were provided for the travelling of the machine. To overcome this complex design and to provide drive from both end, four speed hydrodynamic gear box is introduce. It gets power input direct from the engine and send it to required position. In working mode, it gets power input from the engine and gives drive to the hydraulic pumps which generate the hydraulic power.

86. 6.Pump Drive Gear Box. Pump Drive Gear box is mounted on engine NT 855 L of machine. It gets one input and gives drive to 4 nos. hydraulic pumps. The function of this gear box is required at the time of working. During travelling this pump is not required.  

87. 7.Axles:- Due to 4 nos. of packing units the weight of satellite unit increases and to overcome the problem, this machine is provided with 6 axles. 2 Driving Axles 2 Running Axles 2 Satellite axles Wheel diameter in axles is 730mm & the condemning limit is 680mm.During travelling pneumatic brakes are provided & during working hydraulic brakes are provided.

88. 8.Distribution gear box:- It distributes the power by getting one input and giving two outputs. It transfers power to the driving axle from Z.F gear box. It gives two output in opposite direction. 9.Reduction gear box:- It gets power from hydraulic motor. It reduces the output rpm and transfer power to distribution gear box though cardon shaft connected with it. Its use in work drives system. To give continuous drive to the machine.

89. HYDRAULIC SYSTEM:- HYDRAULIC PUMPS:- 09-3X machine has 6 DOUBLE PUMP AND ONE VARIABLE PUMP. HYDRAULIC MOTORS:-   This machine consists of 13 hydraulic motor for its operations.  

90. ZF GEAR BOX ENGINE I CUMMINS KTA-1150 35 17 35 17 38 25 SYSTEM PUMP 38X25 RH HYD. PUMP 35X17 LH HYD. PUMP 35X17 LH 32L 32L VIBRATION 210 bar RH T/U FRONT VIBRATION 210 bar RH T/U REAR HIGH PRESSURE 150 bar (Big.Sq. ) ACCUMULATOR 85 bar 32Lts.Cap. ACCUMULATOR 85 bar 32Lts.Cap SYSTEM PRESSURE II 130 bar RADIATOR FAN MOTOR ENGINE I ZF OIL COOLER MOTOR DESCRIPTION OF HYDRAULIC PUMPS – ENGINE I

91. DESCRIPTION OF HYDRAULIC PUMPS – ENGINE II PUMP DRIVE GEAR BOX ENGINE II CUMMINS NT-855L 38 25 35 17 125L 32L 3 II I 35 17 VIBRATION 210 bar LH T/U REAR VIBRATION 210 bar LH T/U FRONT SYSTEM PRESSURE I 130 bar ACCUMULATOR 85 bar 32Lts.Cap. VARIABLE PUMP 125LPM MACHINE WORKING DRIVE 210 bar HYD.COOLER MOTOR 3 RADIATOR FAN MOTOR ENGINE II HYD.COOLER MOTORS 1&2 SMALL SQUEEZING COUNTER PRESSURE 35 bar 65bar HYD. PUMP 38X25 RH HYD. PUMP 35X17 RH HYD. PUMP 35X17 LH

92. DETAILS OF VARIOUS HYDRAULIC PRESSURES USED ON TAMPING EXPRESS System Pressure : 130 bar High pressure ( Squeezing ) : 150 bar Squeezing Counter Pressure : 65 / 35 bar Vibration Pressure : 210 bar Working Drive Pressure : 240 bar Small Squeezing Pressure : 115 bar Big Squeezing Pressure : 80 bar Safety Braking Pressure : 30 bar Satellite Support Cyl . Pressure : 15 bar System/High Accumulator pressure : 85 bar M/C Support Accumulator Pressure : 120 bar Small Sq. Counter Accu . Pressure : 20 bar

93. ELECTRICAL SYSTEM   BATTERY: FOUR BATTERIES ARE PROVIDED TWO BATTERIES OF 12V/200AH TWO BATTERIES OF 12V/70AH FOR ALC AND PROGRAMMER   ALTERNATOR: THREE ALTERNATORS TWO ALTERNATORS ARE MOUNTED ON ENGINE I. CURRENT RATING 120A, BOSCH MAKE ONE ALTERNATOR IS MOUNTED ON ENGINE II. CURRENT RATING 40A, LUCAS MAKE   SELF STARTER: TWO SELF STARTERS ARE PROVIDED ONE ON EACH   DEPTH TRANSDUCER: FOUR NUMBERS   HEIGHT TRANSDUCER: TWO NUMBERS   LINING TRANSDUCER: TWO NUMBERS   PENDULUM: THREE NUMBERS

94. POWER TRANSMISSION ENGINE CUMMINS KTA 1150L P1 P2 P3 M Driving Bogie Distribution Gear Box Reduction Gear Box PTO Running Bogie Satellite Bogie M M ZF GEAR BOX ENGINE CUMMINS NT 855 L Pump Gear box   P4   P5   P6   P7

95. POWER TRANSMISSION ENGINE CUMMINS KTA 1150L P1 P2 P3 M Driving Bogie Distribution Gear Box Reduction Gear Box PTO Running Bogie Satellite Bogie M M ZF GEAR BOX ENGINE CUMMINS NT 855 L Pump Gear box   P4   P5   P6   P7 Driving Mode

96. WORKING MODE ENGINE CUMMINS KTA 1150L P1 P2 P3 M Driving Bogie Distribution Gear Box Reduction Gear Box PTO Running Bogie Satellite Bogie M M ZF GEAR BOX ENGINE CUMMINS NT 855 L Pump Gear box   P4   P5   P7   P6 POWER TRANSMISSION

97. Sr. No Parameters CSM 09-3X 1 Over all length 27640 22940 2 Height 3600 4090 3 Width 3040 2900 4 Weight 64 Tonnes 83 Tonnes 5 Engine 1 2 6 Tamping Unit 2 4 Diffrence between CSM and 09-3X

98. Sr. No Detail CSM 09-3X 7. Axle 5 6 8. Tamping Tools 32nos. 48 Nos. 9. Packing 2 Sleeper at a time 3 sleeper at a time 10. Uno Mode No Yes 11. Vibration Pressure 150 bar 210 bar 12. Output 2200-2400 Sleeper/Hr. 2700-3500 Sleeper/ Hr Diffrence between CSM and 09-3X

99. What you have learnt? It moves continuous during working. All the working assemblies are fitted in satellite unit It packs three sleeper at a time It has 48 tamping tools. Output of this machine is 2700-3500 sleeper/hr. It can work in Uno mode. It has hydrodynamic gear box in power transmission system. It has 6 axles. Maximum permissible speed- 60kmph Servo valve for lifting & lining During working main frame & satellite units moves separately.

100. 09-3X DYNAMIC TAMPING EXPRESS

101. QUALITIES OF DTEX Excellent quality of work Higher working speed Reduction of running costs Highest working comfort Ideal incorporation of the work processes Recording and processing of Track parameters Makes the system Person Independent

102. ADVANTAGES Minimum site occupation Better utilization of the track possessions Further relief to Operating department Lower operational costs Can tamp single sleeper in emergency Can work in duomatic mode Less staff required

103. TECHNICAL DATA S. No. Parameter Value 1. Length over buffers 34040 mm 2. Height over top of rail 4130 mm 3. Width 2900 mm 4. Number of wheel sets 8 5. Weight 134120 kg 6. Main engine type Caterpillar C18 7. Rated Power 447 kW@ 2100 rpm 8. DTS engine type Caterpillar C9 9. Rated Power 205 kW@ 2100 rpm 10. Fuel Tank capacity 4000 Ltr

104. TECHNICAL DATA S. No. Parameter Value LINING SYSTEM (AD= 21.00 m) 1 Front Trolley -Lining Trolley 11.175 m 2 Lining Trolley - Measuring Trolley 5.475 m 3 Measuring Trolley - Rear Trolley 4.350 m LEVELLING SYSTEM (RF= 15.090 m) 1 Front feeler – Middle feeler 10.455 m 2 Middle feeler- Rear feeler 4.635 m RECORDING SYSTEM (RF= 10.000 m) 1 Front feeler – Middle feeler 6.000 m 2 Middle feeler- Rear feeler 4.000 m

105. SOPHISTICATED TECHNOLOGIS PROVIDED ON DTEX Engine Control Module (ECM) Computer Measuring System (CMS) Computer Working System (CWS) Programmable Logic Controller diagnosis (SPS Diag ) Automatic Guide Computer (ALC) Data Recording Processor (DRP)

106. Engine Control Module (ECM)

107. Computer Measuring System (CMS)

108. SYSTEMS OF CMS

109. Computer Working System (CWS) Current working speed (Input - distance measuring wheel)       Average working speed Press the “service" key to shift to the detailed display. The button shows yellow when detailed view is active.   Additional engine speed   Tamping depth (Manual input) % of the selected accelerator Main Engine Speed Input Driving enabling   Forward / backward driving 1. Driving mode symbol (working mode drive)

110. SYSTEMS OF CWS

111. Programmable Logic Controller diagnosis (SPS Diag ) Speicher Programmierbare Steuerung

112. Automatic Guide computer (ALC) :Geometry Mode

113. Measuring Run Mode

114. Data Recording Processor

115. SALIENT FEATURES OF DRP Designed as a system for recording track parameters By comparing the measurement values against predefined limits for the individual parameters, it is possible to evaluate and classify the measurement results The DRP can be used to perform measurements which can be displayed graphically online on a screen monitor, and can be printed out on a standard printer in A4 format

116. Contd … Standard deviations are calculated for the D1 profiles for alignment and level which assist in the assessment of the track geometry. Reports allow the evaluation of limits that have been exceeded and also provide information about the track quality. The stored measurement data can be transferred via a USB stick to other computers for further analysis

117. CONFIGURATION OF WORKING

118. DATA MEASURING TROLLEY OF DRP

119. PARAMETERS CAN BE MEASURED UNDER CONFIGURATION -1 Cant. Twist. Lining versine (in mm) L.H./R.H. Longitudinal level (in mm) of L.H. rail. Longitudinal level (in mm) of R.H. rail. Longitudinal level D1 (in mm) of L.H. rail. Longitudinal level D1 (in mm) of R.H. rail. Track gauge error (optional).

120. PARAMETERS CAN BE MEASURED UNDER CONFIGURATION -2 Cant. Twist. Squeezing time. Tamping depth. Lifting value (in mm) of L.H rail. Lifting value (in mm) of R.H rail. Track gauge error (optional).

121. STANDARD DEVIATION DISPLAY

122. THANKS