UNIMAT-8253 POH REPAIRS AND WORKS TO BE ATTENDED

Date:o ')OJ./ l-D.2-2,

@GTL

From

SSE/TM/UNI MAT 8253

GTL DIV

TO

SSE/TM/CPOH/RYP

COPY TO: SSE/TM/GTL

ADEN/TM/GTL

Respected sir,

SUB: Works to be attended for Uni-8253 m/c during POH - regarding

The following are details of works to be done during POH of Uni8253/GTI. at RYP

Machine : UNIMAT-8253

Div: GTL

Year of commissioning: 1992 (built 1990) ( O °1 r .3"0l- 1 r 11 C\ 2..)

Last POH attended on: 09/06/2019@ EH:0035

Present E.Hrs : .-:,;;_: •--5512 as on 5/ o1-) ':)..oJ...3

1.ENGINE

MODEL:: NTA 855 L BC (overhauled)

S.No: 25421999

DATE OF FITMENT: 16-02-2022

WORKED SO FAR : I q S-1 i.,_.,.-

SPARES REQUIRED REMARKS

S.No WORKS TO BE PERFORMED
DESCRIPTION QTY --
Existing overhauled engine so far worked abo ut hrs, need NTA 855L BC 01 no
1
replacement
Engine silencer and exhaust bellows to be checked 11nd replace if 01 each
2
necessary
3 Replace all AVM rubber pads of engine
4 PT pump & injectors to be calibrated
Alternators need to be replaced 02
5
6 Twin cyl air
Air compressor to be checked and replace if necessary 01
compressor
7 Radiator to be overhauled
8 All water hoses , lub oil and fuel hoses to be replaced on cond ition
basis
9 Radiator fan is in bent condition, hence fan shaft and bracket to be
replaced
10 Alternator holding brackets th be replaced

2. TAMPING BANK

The existing tamping banks were fitted on 08/04/2021@ 2819.0 hrs (TP-.E.N.D 8'\<'r-b) r-llAt<t)
So far tamping banks progress is I I 2-Lf- poin-l;s -t 0 · 01-\c..""' L!::::- 13 2.-lf.- f
0
', "' bj OY'l 3 1/ 0
1)1-o 2.3

All arms have developed heavy play. Hence required replacement of tamping banks

3. LIFTING UNIT

1 Lifting unit needs complete overhauling since it is wornout and

developed play in its bushes and pivot pins
2 Lining rollers (flat) need to be replaced along with guide pin and OPJ \3,, tVDD ~:U.'I. 2
its bushes
3 Cone rollers need to be replaced and its bushes needs to be VD 313 - 1t'l2-- 2
replaced
V1>313.• 130 S- 2 +2 ILUIS-, • !p.t>.f'
4 Roller clamp housing need to be replaced (both male and
U.l> 31:r \'306 C.\JISD' tp.oC
fema le)
s, Roller clamp cylinders to be replaced »;1c6i~ ·063 ·0.36 ·0/00· / 4
6 Roller clamp holding brackets frequently worked out from
parent body, hence need proper welding of holding brackets
7 Preload cylinders to be replaced LJj) , 3 \;3, · q64 2
8 Hooks on both sides to be replaced UD 313.1304 2
9 Hook lateral movement cylinder to be replaced on both sides 2
10 Hook up & down cylinder to be replaced on lhs side CU 311.3007 LI 1
11 Hook up & down cylinder to be replaced on rhs side CU 311.3007 RE 1
12 Lifting unit cylinders to be replaced HZGB.125.050.0365.1 .001 2
13 Logic valves to be replaced on both sides HY 151.171 2
14 Hook lateral movement cylind2r holding brackets to be
overhauled
15 Vertical bushes for both hook guide pieces to be replaced (U3\l· 302-0 2+2
16 Horizontal bushes for both hook guide pieces to be replaced C.,U 31\ • 3.0I°\ 4+4
17 Required overhauling of hook transducers holding brackets
 lJJJ /118 ·/oo· o4-S" -oS(J o •l.· ov 2
18 Lining cylinders to be replaced
19 Lining cylinder holding bushes to be checked and re placed
20 Rocker bearings to be provided for every holding brackets on
lifting unit
21 Lifting unit lock hooks to be checked and overhauled
22 Hook up n down cylinder dummy hitting-to lateral cylinder yoke.
To be checked for alignment
23 Provide rocker bearings for all holding joints of lifting unit
24 All pins to be checked and replaced on condition basis
25 Proper placement of hook transducer to be arranged. Threads
wornout regularly
26 Overhauling of cone roller pin body required

4. TRANSMISSION

1 Torque arm supporting rod with clevis needs to be replaced

UD 61.2635-2 02
Torque rod
UD 61.101G 02
Torque rod clevis
2 Torque arm rubber elements to be replaced
741444 mittel 06
Torque arm rubber disc
Torque arm r,late bolts needs to be replaced M16x50 DIN
3
931-8
UD 72.4224 01
4 Cardon shaft between ZF and engine to be changed
5 Bolts and nuts of cardon shafts getting loosen after working about
two hours between distribution gear box and axle gear box. Hence
distribution gearbox to be checked for condition and attend repairs
6 Leakage in distribution gearbox. Body to be checked
7 All rubber mountings of distribution gearbox to be replaced
8 Zf gearbox mountings to be replaced
9 Zf gerbox pump mountings ca;rier/ drive shaft and bearings to be
checked and replace if necessary
10 Final drive and Pump engage disengage levers to be overhauled {not
disengaging sometimes) -
11 Distribution gear box flange to be checked and replace if necessary
12 Third axle engage disengage guide rods to be checked
13• ZF gearbox metal pipes leakage at ferrules. Required replacement of
metal pipes
14* Cardon shaft between ZF and distribution g/b to be replaced KGW 01
180.1170.110.02
i,:: LJI(..'.) /.5'0 • /ouo · 0 I
/lo •oo
S.MECHANICAL

1 HSD oil tank cleaning to be done

2 Hyd tank cleaning to be done
3 Rubber packing of tamping unit up down cyl inders worn out. Need
replacement to avoid shaking of cylinder
4 T/U Lateral movement frame guide bushes and guide cones worn out.
Need to be replaced
5 All under carriage of the machine and break linkages to be checked for
condition and necessary repairs to be attended
6 Bogie pivot bolt of front cabin to be attended. Frequently loosening and
..ould not be tightened. Suspecting worn out of threads. Need attention

7 Brake lever pivot body and bush under front cabin to be checked and
replaced

8 Brake rods to be replaced on both front and rear cabins

9 Brake pivot pin holes ablonged. Needs reconditioning and brake pivot
pin needs to be fabricated and brass bushes needs to be provided
10 Profiling of all axles required and ultrasonic testing to be done
11 All datum wheels worn out. Reconditioning required
12 Bearings in all datum wheels to be replaced on condition basis

13 Lining bogie feeler rods got worr;i out. Required replacement or

reconditioning

14 All brass guide bushes of all feeler rods to be replaced

15 Meggie springs damaged, need replacement 732073- 16 nos
MG670-S6
16 Brackets for hyd hoses on both tamping unit frames to be welded

17 Springs of locking/unlocking of all bogies needs to be replaced, since

became weak
18* All panels locking to be rectified
19* Working area Pendulum base rod is in bent position. To be rectified
20* Coupling hook on rear cabin side got bent. Need to be rectified or
replace
21• Bll panel door hinge to be replaced ELT-4003.00 01 no
LI/RE
22• Lining bogie feeler rod is worn out. Need to be replaced
23* Front and rear cabin tops are leaking during rain . Hence to be checked
and modification works to be done
24* Lining transducer fitting plate body threads worked out. To be overhaul
25* Front trolley i-bolt with nut to be changed as inner threads got wornout GAR 25UK 01 no
6.HYDRAYLIC SYSTEM

Hyd stop cocks for vibration pressures have leakage. HY 152.07 02

1
Require replacement
2 All HYD pumps, motors and actuators to be checked and
replaced
3 All accumulators to be checked for condition and refilling
to be done
All axle support cylinders to be replaced UD 50.100 06 no
4
HZMB 02 nos
5 Front bogie tension hyd cylinders to be replaced
080.036.0210.2.024

6 HYD & ZF oil cooler fins to be checked and replace if

necessary
7 All HYD DC valves & pressure control valves to be
checked and replaced
UD 216.450b 02 nos
8 Both HYD brake cylinder with yoke to be replaced
03 nos
9 Gasket of Hyd Suction filter housing damaged . Need
replacement
02nos
10 LH and RH side proportional valves to be replaced
HY 10 RSJ 02nos
11 LH and RH tamping bank lateral movement valves to be
replaced
HYV 10 RSEET 02 nos
12 LH and RH hook lateral movement valves to be replaced
R4 V03 530 10Al 01 no
13 Check valve leaking. Need replacement
HY 55R 02 nos
14 Sq .. pressure reducing valves need to be replaced
l-lY6 RSJ 04 nos
15 Valve for Tool tlting cyl to be replaced
HY 6 RSD 02 nos
16 Valve for front axle support need to be replaced
17 All Hyd hoses to be replaced
02 nos
18 Hyd brake valves on both cabins to be replaced, since not HY lORSD
working properly and pressure regulator to be replaced
19 Tamping bank lateral movement cyl holding brackets to
be checked
03 nos
20 Suction filter housing to be chi!cked and replaced
HZGB 050.025.0580.1.001 02 nos
21 Hook lateral movement cylinders to be replaced
HZGB.080.040.0710.1.001 02 nos
22 Tamping bank up down cylinders to be replaced
HZGB.063.036.0100.1.001 04 nos
23 All roller clamp cylinders to be replaced
HZ60.01 2 02 nos
24 Clevis to be replaced
GE35DO 02 nos
25 Tamping unit sliding cyl pivot bearing to be replaced
26* Hyd temperature circuit is not in working condition. To
be checked and rectify
27* Seamless metal pipes are required for hyd hoses running
beside center cabin
28* Center cabin base bearings to be replaced •
HZGB.080.045.0530.1 02 nos
29 T/U Lateral movement cyl to be replaced
CU 311.3007 .RE 01 no
30 Hook UP DOWN cyl rhs to be replaced
CU 311.3007.LI 01 no
31 Hook UP DOWN cyl lhs to be replaced

'?\J((ly' S,
~"f 8 oC, 7-- 2-o · \ ";\,-- Li
tl'( 8 06 X 3 ?> · 7..-2-
r\"f go6 'X ,2..0 • 2-2... L..
7. PNEUMATIC

1 Accelerating Pn.valve of front cabin to be replaced WN 607-81 01

2 Engine accelerating valve needs to be changed WN 388D 01 no
3 Air tank 1 & 2 drain plugs to be replaced 90157 02 nos
4 KE valve to be repaired and indirect braking not working 01
5 Pn brake valves leaking, to be replaced in both cabin s 90364 02 nos
6 All pneumatic cylinders and valves to be replaced on
condition basis
7 Require plasser make pressure regulators for brake system 90189 06 nos
8 Pn safety valve 9 bar & water separator to be replaced 90204 & 90356 01 no
9 Measuring bogie lock unlock cylinders to be replaced PN2Z-35/12/50 02 nos
10 Measuring bogie up down cylinders to be replaced PN2Z-70/20/300 02nos
11 All pneumatic pipes to be replaced
12 Cooling coil to be replaced DL 90.37 01 no
13 Pneumatic horns on front cabin side to be replaced PZ 204 01 no
14 All metal pipes to be replaced due to over aging
15

8.ELECTRICAL

1 Batteries to be replaced 12V 180AH 02 nos

2 PCB jack base thimbles and its wiring damaged in panel
box Bl0 & B20 to be replaced
3 In B5,B13,B22,B23,B24 panel boxes, bases for wire
connector damaged, play in connector base, screw head
worn out, No labeling and wires damaged. Resulting in
frequent failures . Need replacement .
4 In B23 panel resistors and diode panels are rusted and
base damaged & soldering hardened, need replacement
5 Pedal switches in working cabin worn out. Need to be
changed I
6 Intercom pcb box damaged. Its place to be changed
7 In B13 panel box, whole wiring to be replaced and
terminal numbers to be providecJ
8 All external wiring for solenoil valves, transducers, limit
switches & lights etc to be replaced since become hard
and failing frequently
9 All transducers, pendulums to be checked and replaced tL.T-,~•oo = o t,-No-~
/recond itioned tLT - {,o9•~ 02..- N,l,.!,.-
10 All existing switches to be replaced on condition basis
11 All head light and ta il light push button switches in both
cabins to be replaced since short circuiting frequently
12 All limit switches to be restored
13 Cable path in all panel boxes to be closed with rubber
sockets
Ir
~14

15
Lining and leveling calibration needs to be done In both
3pt and 4pt
Head light circuit to be checked, since frequent short
circuit and failing of headlights occurring
16 There are several number of unwanted wires In open'
condition in all panel boxes, to be removed or secured
17 All gauges to be in working order in 85 panel
18 ZF pressure gauge not workinf ( circuit to be checked) EL-T 1001.00 01 no
19* Additional lifting joysticks required in 823 panel 02 nos
20• Electrical wires near reduction gear box have cuts. Hence
replacement of all 2 core wires is required
21• ZF transmission cable got hardened. Require to be
replaced
22• Working area pendulum inner wiring and socket to be
replaced

B10

1 EK 554 pcb to be replaced (transistor type) EK 554 02 nos

2 Base wires of all load pcbs to be checked

811

1 Toggle switches, cant switch, selector switch for versine

,slew.general lift &SE and its wiring needs to be changed
since over aged and failing freque'n tly
2 Labeling for the wires needs to be done
3 All ground connector buses to be replaced

B13

1 Wires connecting base strip needs to be replaced, since

existing base screw rounded and play in strip
2 Labeling for the wires and wire base need to be done
3 Damaged diodes and relays to be replaced
4 Panel box locking to be rectified

B22

1 Wires connecting base strips in damaged condition. Need to

I
be replaced
2 Ground buses to be replaced
3 Some of the connections in hanging position and excess wires
to be removed
r

B23

1 Wire trays and wires connecting base strip is in damaged

condition. Need to be replaced with new one
Potentiometers at position f6 and f7 hook sliding to be ELT 496.02 02 nos
2
replaced since not working
3 Auto cycle switch,X25,X26 switches damaged. Need to be
replaced
4 All illuminated lock unlock switches to be replaced with good
quality switches

B24

1 Tamping counter reading electrical connection to be checked. Not

working at certain times
2 24 core wire related to roller clamp circuit to be replaced since
damaged
3 Wire connecting base strip is in damaged condition. Needs to be
replaced and labeling required
4• Cable number 144 is completely damaged (24 core). Required
replacement of cable.