Duo, CSM ,VPR & 09-3X Machines.pptx

track machine

1. TAMPING MACHINE

2. SESSION- 4

3. WST ( W ork Site Tamper)

4. MAIN FEATURES :-  It is modified version of old D uomatic machine. It moves sleeper to sleeper during working. ZF HYDRODYNAMIC GEAR BOX IS PROVIDED INSTEAD OF MAIN GEAR BOX, DRIVE CLUTCH, REVERSING GEAR BOX, 6-SPEED GEAR BOX, PTO ASSEMBLY. TWO TRIPLE HYDRAULIC PUMP & ONE DOUBLE PUMP PROVIDED. ONE EMERGENCY PUMP PROVIDED FOR BACK-UP SYSTEM. TWO HYDRAULIC MOTORS ARE PROVIDED FOR WORK DRIVE. CENTRAL LUBRICATION SYSTEM IS PROVIDED. SERVO VALVES ARE PROVIDED FOR LINING & LIFTING THE PROGRESS IS RELATIVELY MORE 1800 SLEEPER/Hr . DRIVING FROM BOTH CABINS. CUMMINS ENGINE NTA855-L 380HP (280 KW) IS PROVIDED INSTEAD OF NT-743C IN OLD MODEL .   IT PACKS TWO SLEEPERS AT A TIME AND HAS 32 TAMPING TOOLS .

5. Driving Axle Running Axle Tamping Unit

6. GENERAL DATA:   OVERAL LENGTH = 18940MM GAUGE = 1676 MM HEIGHT FROM RAIL LEVEL = 3350MM WIDTH = 2900MM WHEEL DIA (NEW ) = 730MM WHEEL DIA (WORNOUT) = 680MM MAXIMUM PERMISSIBLE SPEED (OWN POWER) = 75 KMPH (TRAIN FORMATION ) = 80 KMPH AS PER OEM

7. MAIN UNITS : Engine Tamping unit ZF Hydrodynamic Gear Box Lifting & lining unit Distribution Gear Box Reduction Gear Box 4 axle – 2 Driving axle & 2 Running axle Centralized Automatic Gearing System

8. Engine :- WST machine consist of one diesel engine of CUMMINS make model no. NTA 855L 380 HP @ 2100 RPM. It is mounted on frame of the machine. This engine is water cooled engine. Tamping Unit :- It has two tamping units one left and one right which is fitted on the machine. It has 32 tamping tools and packs two sleepers at a time.Its tamping unit is non-synchronous type. To get the proper quality of packing tool should be complete without any missing tool in tamping unit. In double sleeper packing unit the small arm are close enough which causes the chance of tamping tools infringement. To avoid the infringement of tools, the center line of small arm tool bore is shifted. Due to this change in center line of small arms, tool position is also shifted which causes the squeezing action not in a straight line. To keep the squeezing action in straight line, Cut tamping tool are used in small arms. In WST tamping unit, taper shank type tamping tools are provided. The size of tool blade is 70mm×140mm whereas the size of Cut tool is 70mm×110mm or 70mm×90mm according to their positions .

9. ZF 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 provided in CSM machine. 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 sends 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 movement is carried out by hydraulic power through reduction gear box.  

10. Lifting and lining unit:- In WST 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 holds the track with the help of hydraulic rail clamp cylinder.   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 outputs in opposite direction.   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 is in work drives system to give continuous drive to the machine.

11. Axles:- It gives movement to the machine. There are four axles in WST machine. 2 driving axle – It have 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 – It is idle axle fitted in main frame. And in one axle hydraulic motor is fitted which gives power during working for sleeper to sleeper movement. Due to this motor on axle increases the pickup and increases the efficiency of machine.   In driving and running axle during travelling pneumatic brake system are provided and during working hydraulic brake are provided.

12. 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 11/2hourcontinuousworking,tamping unit needs re-grease which in turn to stop the machine for manual greasing. This system also reduces maintenance time as well as manpower 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

13. HYDRAULIC SYSTEM:-   WST machine consist of three hydraulic pumps. HYDRAULIC MOTOR:- This machine has 7 nos. of hydraulic motor.

14. WORKING PRINCIPLE Driving System:   RUN DRIVE : By hydrodynamics ZF 4 speed gear box.   WORK DRIVE : Two hydraulic motors are provided. machine work in constant speed.   LINING: Single chord lining system.   LEVELLING : Double chord fixed type system for cross-level   TAMPING UNIT : Duomatic type (32 tools) provided on the machine .

15. POWER TRANSMISSION ENGINE P1 P2 P3 M M Driving Bogie Running Bogie Distribution Gear Box Reduction Gear Box PTO ZF GEAR BOX

16. POWER TRANSMISSION Driving Mode ENGINE P1 P2 P3 M M Driving Bogie Running Bogie Distribution Gear Box Reduction Gear Box PTO ZF GEAR BOX

17. WORKING MODE POWER TRANSMISSION ENGINE P1 P2 P3 M M Driving Bogie Running Bogie Distribution Gear Box Reduction Gear Box PTO ZF GEAR BOX

18. Parameter to be check for the quality of Track The tamping (Squeezing) pressure should be according to the type of sleeper as under: CST-9 sleeper : 90 - 100 kg/sq.cm ST or wooden sleeper : 100 - 110 kg/sq.cm PSC sleeper : 110 - 120 kg/ sq.cm System Pressure should be 120-140 kg / sq.cm Vibration Pressure should be 150 kg/ sq.cm Tool must be present in tamping unit. Missing tool not permitted. More than 20% wear out tool to be replace. Tool depth – Sleeper Height + Rubber Pad + Rail Height 10 to 12 mm

19. Minimum ballast cushion of 150mm Fitting and fastening should be remove during tamping operation. Squeezing time 0.4-0.6 sec. All the track parameter after machine work. General lift should be given in the ratio of 1 : 1000

20. What you learnt? Main Gear Box ZF Hydrodynamic Driving From both cabin. It packs two sleeper at a time It has 32 tamping tools. Output of this machine is 1800 sleeper/hr. It has 4 axles. Maximum permissible speed- 60kmph Servo valve for lifting & lining Two work drive Hydraulic motor. Three powered axles.

21. RUSSIAN DUOMATIC (Model VPR-02M)

22. Main features . It has two packing unit. It tamp 2000 sleeper/eff. Hr. In this machine there is mechanical cum drive gear box. Maximum lifting & slewing - 150mm. In tamping arm center pin bearing is used in place of bush, bearing. There is no. multi-check & programmer system. Only two hydraulic cooler is provided. Max. measuring speed is 5 km/hr. 3 Point lining system only. Hydrodynamic gear box for power transmission .

23. General Data:- Length (buffer to buffer) (mm ) - 17740±100 Height (mm) - 3780±50 Width (mm) - 2970±30 Weight of machine -51tonnes Rated Power Output of Diesel Engine(kW ) - 268 Engine - Cummins QSM11-C360 360 HP Number of breaking axles - With pneumatic drive - 4 With hydraulic drive - 4 With mechanical drive - 2

24. Main Unit : Engine Tamping unit Raising and lifting unit Power unit Two cabins: 1- Front cabin, 2- Working cum rear cabin ALC (Automatic guiding computer ) Axles Battery and Alternator

25. Engine :- VPR has one diesel engine of Cummins make, model no. QSM11-C360 360 HP. It is water cooled engine .   Tamping unit :- One left and one right tamping unit is provided in this machine.it packs two sleepers at a time in this type of unit at centre pin location bearing are provided in place of bronze bush. The frequency is same as in Plasser tamping units. But there is difference in amplitude. I ts tamping unit is non-synchronous & similar to Duomatic type tamping unit. To get the proper quality of packing tool should be complete without any missing tool in tamping unit.

26. Tamping Unit:- In double sleeper packing unit the small arm are close enough which causes the chance of tamping tools infringement. To avoid the infringement of tools, the centre line of small arm tool bore is shifted. Due to this change in center line of small arms, tool position is also shifted which causes the squeezing action not in a straight line. To keep the squeezing action in straight line, cut tamping tool is used. In this tamping unit, taper shank type tamping tools are provided. The size of tool blade is 70mm×140mm whereas the size of Cut tool is 70mm×110mm or 70mm×90mm according to their positions. Raising and lifting unit :- It is similar to WST machine. It has 4nos. disc clamp roller to hold the track for lifting in each side and 2 nos. lining roller for slewing of track in each side. Disc clamp rollers hold the rail with the help of hydraulic rail clamp cylinder.

27. Power unit:- In Power unit there is one hydrodynamic gearbox. It gets power from engine and gives power to reduction gear box and driving axles through intermediate support. On reduction gearbox four hydraulic pumps are provided. It reduces the RPM and gives drive to all four hydraulic pumps.   Two cabins:- Front cabin: From this cabin driving of machine is carried out in front direction. During working some data is also feed in front cabin. Working-cum-Rear cabin: From this cabin machine working as well as Driving in rear direction is carried out . ALC (Automatic Guiding Computer):- This is a computer in which there is facility to measure track parameters in Run-mode and data can be feed in machine by this computer during work.

28. Axles :- There are four axles in this machine- Two driving and Two running. Driving axles gets power from hydrodynamic gearbox through cardon shafts. There are three powered axle and one idle axle. During working in sleeper to sleeper drivehydraulic power is given in three axles with help of hydraulic motor. Battery and Alternator:- Battery is used for starting of the engine. Alternator is used to charge the battery and supply power to all the systems.

29. POWER TRANSMISSION ENGINE P1 Feed Pump P2 M Driving Bogie Running Bogie Intermediate support Reduction Gear Box Hy . Dynamic Gear box P3 P5 P4 M

30. POWER TRANSMISSION Driving Mode ENGINE P1 Feed Pump P2 M Driving Bogie Running Bogie Intermediate support Reduction Gear Box Hy . Dynamic Gear box P3 P5 P4 M          

31. POWER TRANSMISSION Working M ode ENGINE P1 Feed Pump P2 M Driving Bogie Running Bogie Intermediate support Reduction Gear Box Hy . Dynamic Gear box P3 P5 P4 M

32. Parameter to be check for the quality of Track The tamping (Squeezing) pressure should be according to the type of sleeper as under: CST-9 sleeper : 90 - 100 kg/sq.cm ST or wooden sleeper : 100 - 110 kg/sq.cm PSC sleeper : 110 - 120 kg/ sq.cm System Pressure should be 120-140 kg / sq.cm Vibration Pressure should be 150 kg/ sq.cm Tool must be present in tamping unit. Missing tool not permitted. More than 20% wear out tool to be replace. Tool depth – Sleeper Height + Rubber Pad + Rail Height 10 to 12 mm

33. Minimum ballast cushion of 150mm Fitting and fastening should be remove during tamping operation. Squeezing time 0.4-0.6 sec. All the track parameter after machine work. General lift should be given in the ratio of 1 : 1000

34. What you learnt? Main Gear Box Hydrodynamic Driving From both cabin. It packs two sleeper at a time It has 32 tamping tools. Output of this machine is 2000 sleeper/hr. It has 4 axles. Maximum permissible speed- 60kmph Servo valve for lifting & lining Two work drive Hydraulic motor. All powered axles. Bearing in Centre arm pin of Tamping unit Grease lubrication in Centre Arm pin Only 3 point Lining System ALC system is provided.

35. Difference between New Duomatic , Imported Duomatic and Russian Duomatic . Sr. No Indian Duomatic Imported Duomatic Russian Duomatic 1 Length – 18940 mm. Length – 16400 mm Length-17740 2 Height – 3350 mm. Height – 3724 mm Height-3780 3 Width – 2900 mm Width – 3000 mm Width-2970 4 ALC is provided only in (8060-8064) ALC is not provided. ALC is provided 5 Two triple pump and one double pump provided Three triple pump is provided 5 Pumps are provided. 6 Two accumulators is provided. Three accumulators is provided. One Accumulator is provided. 7 Automatic greasing only provided Automatic as well as manual greasing is provided. No Automatic Greasing 8 Progress is 1800 sleeper per hour Progress is 1800 sleeper per hour Progress is 2000 Sleeper/hour

36. 09-32-CSM

37. HISTORY OF 09-32 CSM In 1981  Plasser & Theurer developed a new idea for more economical track maintenance: the continuous action tamping machine. At the beginning of 1982 first trials were carried out with a prototype. And in the year 1989 the first continuous action leveling, lining and tamping machine was used in a regular maintenance operation on Indian Railways within a mechanized maintenance system. The success of the 09 series is based on the notion of separating the main frame from the work unit frame. This means that the main frame can move forward continuously during work, when the essentially cyclic action of the working unit for lifting, lining and tamping is limited to the sub-frame . This brings:- Excellent quality of work Higher working speed Highest working comfort Easy combination with other operations

38. MAIN FEATURES: Machine have two parts i.e. MAIN FRAME & SATELLITE FRAME Main Gear Box— ZF Hydrodynamic - (4 speed gear box ). Driving from both cabin . Programmable Logic Control (PLC) Machine . Fully auto cycle . Data Recorder (after work) 3- channels. Twist correction. Servo valve for lining and lifting. Multi-check system. It has 32 tamping tools and packs two sleepers at a time. It moves continuous during working. CMS Equipped. SPS Diagnosis system. Laser lining (optional). Auto greasing. Output:- 2200 to 2400 Sleeper / Hr.

39. GENERAL DATA:   Overall length -- 27640 mm Height above rail level -- 3600 mm Width -- 3040 mm Wheel dia -- 730 mm Total weight -- 64 tons Minimum Radius working -- 100 m

40. CSM machine has been made in two parts . Satellite Unit :- All the working assemblies like tamping unit, lifting unit, auto greasing and other hydraulic components are fitted on satellite frame. During working it moves sleeper to sleeper. It has one axle called satellite axle. During travelling it moves with the main frame . Main frame Unit :- Main frame unit have two cabin i.e Working cabin / Main cabin and Front cabin. All control panels are fitted in these cabins. Driving and working is carried out from these cabins. It has four axles i.e. Two driving axles, two running axles. This unit moves continuous during working. The prime mover of machine, Engine is fitted on the main frame unit.

41. 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 ) Axles Centralized Automatic greas ing System

42. 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 Tamping unit :- It has two tamping units one left and one right which is fitted on satellite unit of machine. It has 32 tamping tools and packs two sleeper at a time. Its tamping unit is non-synchronous &similar to Duomatic type tamping unit. To get the proper quality of packing tool should be complete without any missing tool in tamping unit. In double sleeper packing unit the small arm are close enough which causes the chance of tamping tools infringement.

43. Position of Tamping tools

44. Tamping Unit:- To avoid the infringement of tools, the centre line of small arm tool bore is shifted. Due to this change in center line of small arms, tool position is also shifted which causes the squeezing action not in a straight line. To keep the squeezing action in straight line, Cut tamping tool is used. In CSM tamping unit, taper shank type tamping tools are provided. The size of tool blade is 70mm×140mm whereas the size of Cut tool is 70mm×110mm or 70mm×90mm according to their positions. 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.

45. 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 provided in CSM machine. 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.  

46. 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. 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 . Pump gear box (Funk Gear box ):- It is directly getting power from engine through a cardon shaft. It gives drive to two hydraulic pump during working. The output capacity of both pump is same hence to keep less stock and to use same type of both pump. 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.

47. Axles:- It gives movement to the machine. There are five axles in CSM machine.   2 driving axle – It have 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 – It is idle axle fitted in main frame. 1 satellite axle – It has spur gear. It helps in sleeper to sleeper movement of satellite unit during working. The power is given to satellite axle by hydraulic motor . 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

48. Front Trolley Main Frame Satellite Frame Driving Axle Tamping Unit Runnig Axle

49.   HYDRAULIC SYSTEM:-   This machine consist of ­ 5 Pump (4 Double pumps + 1 variable pump) for the working of the system   HYDRAULIC MOTORS: - Total 8 nos . of hydraulic Motors are used in CSM machine to give drive to the different unit.  

50. WORKING PRINCPLE 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.   LINING : Single chord lining system is provided on CSM .on few machine (only 5 machines) laser lining systems are provided.   LEVELING : On this machine fixed chord double chord leveling system is provided. This machine is designed for the twist correction for that rear pendulum is given. RECORDER : 3 channel recorders are provided on each machine to record the parameters i.e. versine , cross level and lift value after work.

51. POWER TRANSMISSION 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

52. 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      

53. 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            

54. Pre-Requisites For Introduction of Tamping Machines

55. A minimum cushion of 150 mm of clean ballast is recommended for the proper functioning of the machine. Adequate ballast should be available in shoulders and cribs to allow for required lift ( about 20 mm in each tamping operation) and retention of packing after tamping. For this purpose, planning and execution of deep screening of ballast, as well as training out of ballast should be done well in advance. Traffic blocks of adequate duration shall be planned. The sleepers shall be uniformly spaced. Pre-Requisites

56. FOR PLAIN TRACKS DUO/CSM Pre-Tamping Operations The following preparatory works shall be completed before undertaking tamping of track:- Field survey should be carried out to determine existing profile of track and to decide the general lift. In case of design mode working , the survey should be done as per guidelines. The beginning and the end of curve/transition curves should be marked on sleepers. Super elevation and slew should be marked on alternate sleeper to act as guide for the operator. Ballast shall be heaped up in the tamping zone to ensure effective packing. However, sleeper top should be visible to the operator and the ballast should not obstruct the lifting rollers. Hogged , battered and low joints shall be attended. Low cess should l be made up. Track drainage should be improved for better retentively of packing, Pumping locations should be attended. Rounded ballast should be replaced with clean and angular ballast.

57. Deficient fittings and fastenings should be made good and all fittings and fastenings like fish bolts , keys, cotters, loose jaws, elastic rail clips, pads etc should be properly tightened. Worn out fittings should be replaced . Broken and damaged sleepers shall be replaced. Sleepers should be squared, correctly spaced and gauge corrected. Destressing of rails, adjustment of creep, expansion gaps in joints, buffer rails and SEJs etc., if necessary shall be carried out. Guards rails at the approach of bridges and check rail shall be removed temporarily. All obstructions such as rail lubricators, signal rods, cable pipes, which are likely to obstruct the tamping tools should be clearly marked and made known to the operator before the start of the work. Wooden blocks and joggled fishplates shall be removed temporally ahead of tamping. In electrified sections, the earthing ; bond should either be removed or properly adjusted for tamping .

58. 10 to 12 mm Operations During Tamping The following points should be observed by the machine operator and the Section Engineer ( P Way):-. The gap between top edge of the tamping blade and the bottom edge of the sleeper in closed position of the tamping tool should be adjusted depending upon the type of rail and sleepers. The gap for different types of sleepers will be as under: Metal sleeper : 22-25mm Flat bottom sleeper : 10-12mm

59. The tamping (Squeezing) pressure should be adjusted according to the type of sleeper as under: CST-9 sleeper : 90 - 100 kg/sq.cm ST or wooden sleeper : 100 - 110 kg/sq.cm PSC sleeper : 110 - 120 kg/ sq.cm Care should be taken to ensure that tamping tools are inserted centrally between the sleepers into the ballast to avoid damage to sleepers. The number of insertions of the tamping tool per sleeper varies with the type of sleeper and the amount of track lift to be given. While tamping, following guidelines should be adopted :- CST-9 sleepers and steel trough sleepers may require double insertion before passing on to the next sleeper. Wooden sleepers, require one insertion up to 20 mm lift and two insertions for lifts above 20mm. One additional insertion for joint sleepers will also be required. Concrete sleepers require one insertion upto 30 mm lift. Two insertions may be required for lifts above 30mm.

60. For maintenance packing, squeezing time of 0.4 second to 0.6 seconds should normally be adequate . Higher squeezing time may be required for track with caked up ballast . The machine should have full complement of tamping tools. The tamping tools should not be loose or worn out. The wear on the tool blade should not be more than 20% of its sectional area. A ramp of 1 in 1000 shall be given before dosing the day's work and obligatory point. The next day's work shall begin from the point of commencement of previous day's ramp. If work is to be done during night, sufficient lighting at work site should be ensured. Care shall be taken to provide for Slew and lift compensation as necessary. Heavy slewing or lifting should normally be done in steps of not more than 50 mm. For LWR/CWR track, the relevant provisions of. LWR manual shall be adhered to. During tamping, the parameters of tamped track should be checked immediately after tamping for cross level and alignment and necessary corrective action should be taken.

61. The Section Engineer (P. Way) shall pay attention to the following items:- Checking and tightening of loose fittings. Replacement of broken fittings . The ballast shall be dressed neatly. Proper consolidation of ballast between the sleepers shall be done. Final track parameters should be recorded with the help of recorders provided in the tamping machine . A copy of this record should be kept with the Section Engineer (P. Way) and the recorded values should not exceed the following limits : Post Tamping Operations Parameter Not more than 10 peaks per km to exceed this value Any peak exceeding this value Alignment ± 4 mm ± 6 mm Cross level ± 6mm - Unevenness 6mm 10 mm

62. If the recorder is not available, then track parameter of at least four stretches of 25 sleepers each per kilometre of tamped track should be recorded. In addition, the versines and super-elevation of curves shall be recorded for at least ten stations at a specified cord length . While working in LWR territory, the provision of Manual of Instructions on Long Welded Rail - 1996 should be followed. The fixtures like check rails removed during pre-tamping operation should be restored.

63. Parameter to be check for the quality of Track The tamping (Squeezing) pressure should be according to the type of sleeper as under: CST-9 sleeper : 90 - 100 kg/sq.cm ST or wooden sleeper : 100 - 110 kg/sq.cm PSC sleeper : 110 - 120 kg/ sq.cm System Pressure should be 120-140 kg / sq.cm Vibration Pressure should be 150 kg/ sq.cm All tamping tool must be present in tamping unit. Missing tool not permitted. More than 20% worn out tool to be replace (Tool blade size 70mm×140mm) Tool depth – Sleeper Height + Rubber Pad + Rail Height 10 to 12 mm

64. Minimum ballast cushion of 150mm Fitting and fastening should be remove during tamping operation. Squeezing time 0.4-0.6 sec. All the track parameter after machine work. General lift should be given in the ratio of 1 : 1000

65. What you 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 separately.

66. 09-3X Tamping Express

67.   MAIN FEATURES:   LATEST VERSION OF CSM PROGRAMMABLE LOGIC CONTROL (PLC) MECHANISM. COMPUTER ALC : - FOR AUTOMATIC DATA FEEDING 3 BOGIES OF 2 – 2 AXLES (INCLUDING SATELLITE BOGIE) 2 – ENGINES OF CUMMINS NT 855 & KTA 1150 MAXIMUM PERMISSIBLE SPEED 60 KMPH (BY RDSO) OUTPUT 2700 to 3500 SLEEPPER/HOUR 4 TAMPING UNIT / MACHINE IT PACKS 3 SLEEPERS AT A TIME IT CAN WORK IS UNO MODE IT HAS 48 TAMPING TOOLS MACHINE IS IN TWO PARTS SATELLITE FRAME MAIN FRAME AUTOMATIC CENTRALISE GREASING SYSTEM

68. GENERAL DATA:   OVERALL LENGTH -- 22940 MM HEIGHT -- 4090 MM WIDTH -- 2900 MM DISTANCE BETWEEN BOGIE PIVOTS -- 15700 MM WHEEL DIA -- 730 MM TOTAL WEIGHT -- 83 TONNES

69. MAIN UNITS:- Engine:- Tamping Unit:- Pump Drive Gear Box . Axles:- Centralized Automatic greasing system :-   ZF Hydrodynamic Gear box:- Distribution Gear Box:- Reduction Gear Box:- Lifting and lining unit:-

70. MAIN UNITS: Engine :- In 09-3X machine 2 engines of CUMMINS make Model no. NT 855 L- 320 BHP & KTA 1150 L- 473 BHP are provided. Engine NT 855 L gives drive to pump drive gear box which gives power to the 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.     Tamping Unit :- 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.

71. Tamping unit:- 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. 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. Total 48nos. of tools are required in this 09-3X machine.

72. 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.   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.

73. 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 . 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.

74. 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. 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 . 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.

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

76. WORKING PRINCPLE 09-3X TAMPING EXPRESS    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 . LINING : - Single chord lining system is provided on 3x. ALC is provided on this machine for measuring run and automatic data feeding . LEVELING : - On this machine double chord fixed type leveling system is provided. This m/c is designed for the twist correction for that rear pendulum is given . RECORDER: - ALC is provided for recording the data’s during the measuring run mode.

77. 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

78. 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

79. 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

80. Parameter to be check for the quality of Track The tamping (Squeezing) pressure should be according to the type of sleeper as under: CST-9 sleeper : 90 - 100 kg/sq.cm ST or wooden sleeper : 100 - 110 kg/sq.cm PSC sleeper : 110 - 120 kg/ sq.cm System Pressure should be 120-140 kg / sq.cm Vibration Pressure should be 150 kg/ sq.cm Tool must be present in tamping unit. Missing tool not permitted. More than 20% wear out tool to be replace. Tool depth – Sleeper Height + Rubber Pad + Rail Height 10 to 12 mm

81. Minimum ballast cushion of 150mm Fitting and fastening should be remove during tamping operation. Squeezing time 0.8-1.2 sec. All the track parameter after machine work. General lift should be given in the ratio of 1 : 1000

82. What you 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.

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

84. Thank you