2O24/Track.

|ll/TK/17

l/310988s/20?4 GOVERNMET{T OF INDIA ( qr{ilT(iir()

MINISTRY OF RAILWAYS (tc{Trd{)
(RATLWAY BOARD) (ts+ff)
No.20241-rack-lfi fiKl 17 New Delhi, dated 20.11,2024.

Principal drief Engineerc,

All Zonal Railways.

Sub: Summary of Service Instructions for Track Machines.

Keeping track machines in good fettle is an important aspect to maintain track

parameters and to ensure their proper utilization in maintenance of back. Westem
Railway has circulated service instructions on maintenance/ check up of different
assemblies/ suFassemblies/ systems/ parts of track machines.

Copy of the said Service lnstructions for Track Machines is enclosed herewith for
ready reference and adoption on Railways.

Action taken in this regard may be apprised to the Board's office.

DA: as above.

(VI'AY
q GH)
rP7t1

Ex. DIRECTOR TRACK (M & MC)

RAILWAY BOARD
Tele: No.011- 47845531
Email ID : vijay.singh.2017@gov.in
Room to. 150, First Floor, Rail Bhawan,
Raisina Road, ew Delhi - 110 O01.
 ft*rt alc,,hl{ 6 il/ p qL{
s u m m a ry o f S e rV I c e I n s t r u c t o n S Issued
Sr. No.

1
Service
!nstruction No.
w64t/t/1.6
Date

3t/01./20t9 Ch e ck I tl c o
f\h e e p ro f I e
Description
I

2 w64r/7/L6 27/08/20L9 Opening of Assurance re gister

3 w641./1./s2 7 /r012020 Co nl p a rl c e o f n s t
U ct o n VC n n G & SR tor s h U n t o ration
4 0t/2020 28/Lo/2020 T o e n s U r e a p b etwe e n T m p un t to m os t osition and lock
5 w64r/!!s2 8/12/2020 Co m p I i a n c e of sa I ety I n 5 t u cti o n I n c o n str U ct i o n p roj ect
6 02/2020 30/12/2020 Battery cha ing system.
l 0t/2021, 7t/t/2021 Working of MDU
8 02/2027 s/2/2027 Ch ec k o f L m e r e n c Ba ck u S ys t e rIt
9 03/2021 23/03/202r Rad Ia to I cl eani n c a n d A i I d c I o t k co n d t on
10 04/2027 ls/04/202L Summer precaution
11 0s/2021 26/04/2021. M a I n t e n a n c e of a x e e a bo x o f UTV
1.2 06/2021 1/6/2027 Maintenance of UW machine
13 07 /2027 t7 /07 /202r WorkinB of PQRS machinJ
14 08/2027 s/8/2021 Ch a in s v st e m o f b a tte r e 5 t o I a t a ck m a ch I n e
15 09/2021 30/0e/2021. f
Sa e t ys t nl o f a I t c k trl .l c h I n C
16 t0/2022 4/1/2022 n a s 5 o f Fa il U r e o f x e e a I bo x
I
I

l7 71/2022 7 /1/2022 S h u n t n I o p e I .l t o n a n d m o VE rn
e n t o f T Ia c k m a ch n e I
18 72/2022 L5/03/2022 Manual Greasi n ( c o u p e I o f ta IT] p n8 U n
t of D T E m a ch n ES I
19 1.3/2022 28/03/2022 5 e c e n s t tl cti o n s t o r F R M a n d B C M
M ach n c S
20 14/2022 ls106/2022 Se c U I n Ce n t e P o U h & s h o u d e I p
c I
o u h of F R M M a c t) n e 5 I
21_ 7s/2022 15 /09 /2022 Stablin of Machine
22 L612022 3/12/2022 F R M con e r b e I t nt a nt e n a n ce
23 17 /2023 6/3/2023 R a r d n a T r al c k tn a ch i n es
I

24 t812023 23/03/2023 UW En e disengage asssembl

25 1.912023 18/07 /2023 T L U P D o n cy d e r p i st o n r
o d tl ( o ke n
26 20/2023 22/08/2023 a te t SC a at o { of DT F R M et c
27 21/2023 23/08/2023 MFI Emergen cy Backu p tem
28 22/2023 79/70/2023 Air entra ment of PETM
29 23/2024 30/07/2024 To Prevent SPAD
30 2412024 s/2/2024 Tampin on SEJ
 tlflin' rrl thr,
r rl.rr t.tt t, t,i ll!., ('1: [t,
t l'i\l('l
Trrlnl ihlrtutrlrr l r.nlr'ti
'lirrrk iltrrhhr (I qlrrlulhrn.
l'rrlull.

No, W(r'l l/l/16 I t.r,t.l0l"

Ssli l'l'lu('t lll.. ltll(:. |tr'jtt.liBt, lLn'

Suh: llsptrlar uhrcking ol'shr,r:l pnrlilcs ol'rnrcl rnnclrirrrs.

Iu rcllrtnsu lrt alnrr'. dtriug trtttlittt itltrr-lirrtr rrl'lllVJllJll ntirr;ltilt'rrl llll('ltiri',irru.

rllitrI llflngr h:rs lrtcrr rx'littrl irr lhc rrltr:lr rrhich i\ rl;lrrr'rrr \ nr il ttritl rsrrh itr lrrl,.rr l ufiiL'
lxrs,'itrE ,rn tr.rr.rt nrrl : rirl Larl trr rlsraihrr*rrl ol rrt;rr:hirr,', llltSlt rirls ilr larl','rt r',, li\l-l,( l'l
Jrrll -lltl-' lr;n gircn lr,tnlnrr lrt't'iwti tw ylt\it't i,t\yq..7i,,t tl vlal,y't ul iattrt,l n,nl
urltim* /.\11'.lll. hti, ;rlxr issncrl onu l lrc l)t'lr:t t i;rrtlr ard rxts l tri|(l \ur l ;lrl!( tr t r'lt
J)ll(. r\rt:rrrrlirull. it i.;instrrrctrtl tocat11 ru clrr'L rl ulrr:ck ol'lll lnl:L rrrrlrirrrs;rr ;rr ;{r,r c
tcrrlt $lrl;(itrll! lirr thir, xnil slxtlp l}rrrps vr l};t rrtrr rlclirt cnn lr rhNcl(l| r xlt('tth!l litttr'l!.

I hir ir lirr r rur inlirnnliim ntrrl N/A pL:nc.

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(-'l:
lr!'. I l rl( ,lll.

('/- Il:.\ I lt(', Al,l. l( ltU

I
At:;r- t I \lr', lll.. llll(l -lir
,\l'\ (ltll', lll. urrrrru:rttrl *-nrl tcPrll

oudr il rEu wlu r \-,illIIOca

;
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lall t.4n t.l,t /)/.'.a ! | t tt! t Al
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Ofiice 'rf l"c,

lrv CL ('fttlC) lll'
. tr.trr, \.t;\ 'lt n a l' !$ $ n I c n t n c c C cnl ct'
'f rzck frlachinc Orglnhtllon"
Y alttd.
No. W(r4tll/l(r 2t.08.20t9
$sE (t)MC) UL, tlttc, tl,r.tvr, stil, tLrT

!irb: Oporing of Assurorrc llegistcrr.

n s pcr inslruclions of cl: (l'MC) ccG. Assurance Rcaistcrs an lo bc.rrr$cd b}, cach ssgDMCr
rutd nll thc rafcly rclotcd instrucriong, circulors. Jpo.g. concction slips of c & sR, ctc ro bc
pnstcd ontl circukrtcd to all TMC staff from SSE to ltclpr lwcl including ncrvly rccruilat staff.
Signaturcs of nll stnffmust hc lakcn in thcsc Assumncc Rcgisters as ro?.cn of rcknorvledgmcnt of
llrc inslructkrrrs, 'l'his cxr:rcisc ntusl hc complcted rvithin a ncek time.

This is'Ior your informotion and nccLssary action.

A
Dy. CE ".'BL

Scanned with CamSca

 ()fficc of thr.
Dy. CE ('l'l\'lCl lll,
rtli,tt,,| ).-rt) 7-onll Mnirrlcnntttc Ccltlcr.
'l ruck [\lrtthinc I )t gr trir{l hrri,
Vlhnd.

No. W( l/l/5? t)1. 07.10.20211

ssE (DMC) lrl-. BRC. lu'll. Slll. R rr

AEN/XEN (TMC) ItL, Bltc. RTM, ADl. IUT

Sub: Conrpliorrce of iushtctions Bivcn in C & SR.

Ref: SR no 5.14 (?) of G & Slt

lnslruclions gircn h the G& SR rcguling Shunting of tr ns or vehiclca as per SR m' 5'14 (3)
nre reitcmtcd bclorv:

Ikfttt.c *nunctrcitry! shutrlitrl oleroliot;rl on Gtmtb shel onl Tra,,sshiltttrcttl .rlrr/ JdrE.r ."'rtrc"
litu:s n'lrcre lrthourer.t otrtorkhtp the ruilla.l' xcrwrnt in-chorgq of shunting olxrolions rill
stttisfi' hirnsell tlntt all looiing ad trnlooding :l,.ork hos hcen stopped, and lhut oll lulx'm'erx
ttt"
lrut'e hecn ttuncl.
lu of ot4. shtr ingonor trl(r tlre poinls lca.ling lo Erch lincs. the ruiltt<4: senutt in'thuryc
ct,|.te

r 'shutrtittg, operalil,Lt tflusl et:rstfc llrd tlrc points lculing to g/frjh liues unt scl t[rr/ /rrcter/ rrgtirtrl
th{]c lines.

ln vierv ol ahrve it is inslructed to ensuae comPtiance of th€sc inslirlctioos durin8 rrorking

ot'
prius arc clarnped ind
Trach Machines in block spciolly UNIMAT mchinc by cmuring that
locketl before rtxrvetncrl of machinc on lhc Poillt. Tlrcsc iltsu'ttctiom
ue lo be notq! in tlr
Assure[cc Registcrs of ccch Track Machirrs aml ltc samc 1o bc notcrl lor conrpliunte by all
r.Bistcrs lur strict
nrrchine op..rit.rs i.c. JEs & SSE' I TMC of nll Divisions in assuranct
conrplinnce.

rvithin ot issu'ttr'
Cnrrrpliunce ol'tltcsc instrucl,i0ns is to bc suhnlilted t$ thc urdcrsigncd
this lc(lct invariablY. )tlrrls
IJ ,rYl".I
Dr' cil$'rucruu

DUar ll leu wltl I t",dl I loua

 ;-

,4aF-S

OIIice of lhe'
Dy. CE GMC) BL
ErlEtrfi td"\ Zonal Maintenance Ccnter,
Track Machine 0rganisation,
Valsad.

SERVICE TNSTRUCTION (TRACK TvTACHINE) W.R. I/2020 Dt. 28. 10.2020

Recently in tanrping machine, '[anrping Unit Lifting/Lowering cylindcr piston rod thread slipped or their
nut loosened inside cover plate due to rvhich tarnping rvork could not be done behind deep screencd track
and caulion order was imposed, also. some trains rvcre detained.

Follorving service instructions are bcing issucd for preventing such failure
l) The gap bclrvee[ tamping unit aI top ntost position and Lock rnust bc kept upto 3mm.Whenever
lock nut loosen inside cover plate ,length of rod asscmbly incrcascs due to rvhich above gap
rcduccs and trouble is noticed in tampilg unit locking rvhich is the indication of looseness of
locking Nut. This checking must be added in 50 Hrs schedule.
2) on expericnce in another checking lorvcr rhc rampi.g unit and check for lateral play of the
piston rod. rhere shourd ool b€ any pray. rf ploy is noticed it indicarcs looseness
of bc[-nut.
3) Also. ensurc chcrking of l<rknur and rocker bearing ofthe lamping unit liftiog /rowering cyrinder
i, 200 Hrs. Scrrdure nrairrtcnancc by opcning thc cover prstc and lrso ehcck fo. fr* ,ior"menr
of rocker bearing. odc of the reasors for brtakilg of ramping unit lifting/lorvering
pisron rod is
jamrning of the rocker beoring insirie the cowr plate.

Approval o[Cornpntent Authority i.e. CUTMC lras been obtained-

t-L
?.et
ry/
(Mukesh SFri vastava)
AEN(Zh,rc)BL
For XEN C[MC) BL

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 WESTERN RAILWAY Office of the,
oy. cE (TMc) 8t
zonal Maintenance center,
Track Machine Organisation,
Valsad.
No,w641/1/1/s2 08.72.2020

SSE(DMC)Bt,BRC,RTM<ADI, RJT
AEN/XEN(TMC)BL,BRgRTM,ADI,RJT

Subi Compliance of safety instruction

whenever any machine is deployed in construction project, Machine incharge must ensure
that points are clamped and locked before movement of machine on the point. These
instructions are to be noted in the assurance register ofeach track machine and the same to
be noted for compliance by all machine operators i.e..lEs & ssEs
/TMC of all Divisions in
assurance registers for strict compliance.
compliance of these instructions is to be submitted to the undersigned within 07 days of
issue of this letter invariably

,r,r""rn#&
xEN(ZMCIBL

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 VAIBHAV SAKLECHA, Offrce of Dy. CE (TMC) BL
Dy. CE (TMC) Zonal Maintenance Center,
Valsad Track Machine Organisation,
Valsad.
qI-otri >ffa

SERVICE INSTRUCTIONS (TRACK MACHINE) W.R. ZtzoZO itrted 3GLZ-202O

l) On date 25-12-2020, block for Unimat 8429 was given for tamping of newl1, laid crossover l l5-
I 16 in Karchha yard of Indore-Ujlain section from 14:30 to 15:30 hrs. At 15:20 hrs front axle of
machine derailed in the crossover Pt.ll6 laid on zl-12-2ozo by construction Dept. It came into
notice that newly laid track was not having cross level within limit and there u.as misalignment.
Compliance of para 602 of IRTMM was not ensured before deploymort of machine which resulted
into derailment of machine.

All units are hereby instruded to strioly foaow the para 602 of IRTMM belore dqtoynunt of
ruachhe b ConstruAion/RWl projea.

2) On date 23/24-12-2020. at about 22:15 hrs, during maintenance of Unimat 45 8401, engine
suddenll' stopped. During checking by machine stalI it was found tha altemators of the machine
were not charging the battedes and both baneries were discharged. During investigation, indication
of failure (altemators were not charging the batteries at ideal RpM during previous days) was
overlooked by machine stalf when new altemators and batteries fitted in the machine, new
altemator was also not charging fte batteries and on further investigation, it was found that in new
such type of machines, altemators run by dre help ofhy'draulic motor and hydraulic pump. Finally it
was lound that hydraulic pump was not delivering the required flow for motor to run the altemalor
and therefore altemators were not able to charge the batteries. Finally, hydraulic pump rvas replaced
and machrne got put right. In this failure machine was idle for trvo davs.

In daily mainlcnancefollowlng should be qsured;

i) The charglng ststem of bdfrqies shmld be checked daily and fatlare of any indicAton
should be taken serbas$ and to be checked thwoughly.

3) On 29130-12-2020, engineering block wa allorved from 22:55 hrs to 0l:55 lor BCM group
machne worliing, between DRD-VGN on up line. At 00:50 hrs, LHS tamping unit transducer of
Duomatic-8056, was failed, same $as replaced by spare one available on machine at 0l:20 hrs, but
that one also failed. On investigating the failure it came into notice that helical spring of transducer
was broken. The spare transducer was nol checked b1, SSE and after fixing the spare transducer it
came into notice thal transducer was not working as chord rire came out of pulley. Ttus shows
negligence of machine staff.
Alt rhe spores anilable on machine shoald be checked whethet they orefrt rclional or nol

In daily nulnlenance following should be ensured;

i) Chord wtre of tu rtpirrg unit to be checked daily for any breohage

ii) Chord wire of transdacer n be aligaed vertica! when tied with tomping unit bracket'
iii) Do nol tie lhe chord wire i.e. do not profide knol in the chord wire Use rupe clamp
for cltmplng chord wlre ln tamping unlt brackeL

VAIBHAV ffi.i'X,'iTfl:I^
SAKLECHATff!':,"'#
Dy CE TMC BL

C/. CE TMC CCG- For kind information please-

 ^

VAIBHAV SAKLECHA, Office of qv. CE (TMC) BL

Dy. CE (TMC) Zonal Maintenance Center,
Valsad Track Machine Organisalion,
Valsad.
trfetrg )trt

SERVICE INSTRUCTIONS (TRACK MACHINE) W.R. tt202t dateit tr-ot-20l21

MDUS are meant for disposal of muck generaled / collected during screening of ballast by
BCM,/FRM on platform line and./or in yards having multiple tracks.

2. Capacity of single MDU is 65 cu.m. ln ideal condition BCM is screening about 500 cum. of
ballast with disposal of around 2o to 25o/o of screened ballast i.e. 100 to 125 cum. of muck. In this
condition for disposal of muck disposed by the BCM after deep screening of track in 3 hours of
traffic block i.e. 2 hours of effective working,4 units of MDU are required for collecting the muck
from the BCM for further disposal.

3. MDUs are not self-propelled. Hence, sepamte loco is required for BCM working in platform
lines, in suburban and in yards having multiple lines. oEM has suggested that BCM can haul the
MDU unit single or multiple in working mode. Further oEM has suggested that BCM/IRM cannol
haul empty or loaded single or multiple MDUs in dnving mode.
4. In view of the constraint explained in Para 3 above, exclusive loco is required for deep screening
/ shallow screening work with BCM/FRM respectively. Marshalling of Loco, MDU and other track
machines should be in following sequence.
lst-Loco then special flat BFR wagon for resting of Waste Conveyor of MDU, MDUs, BCM/FRM,
Tamper and DTS.

5. Working w'ith MDU will following mumer:

be in
a- On allowing traffic block, Loco attached rvi$ MDU through special purpose BFR, MDUs, BCM
and other machines will move to deep screening site independentl-v.

b. On reaching at site Loco will attach the MDUs with BCM and then loco will be detached and
u,ill be stabled at safe distance from deep screening site during block.
c. waste conveyor of BCM nill be directed towards attached MDU and direction of waste
conveyor of all MDUs will also be directd towards afiached next MDU in sequence. waste
conveyor oflast MDU will rest on special flat BFR wagon if required.
d. During block muck will be disposed by Waste Convq.or of BCM in the MDU attached with
BCM.
e. During block longitudinal bottom conveyor belt at the floor of the machine and waste conveyor
belt except o[ the last MDU rvill be operated to transfer and load the muck in sequential manner
from MDU at the exreme end to the MDU attached with BCM. As soon as the level of muck
reaches at level marked for maximum permissible capacilv, tongitudinal conve,yor belt at the floor
 of the extreme MDU and waste conveyor of adjacent MDU will be stopped. Similar operations will
be done till loading of all MDUs upto maximum permissible limit.
f Then loco power will be brought to the site and MDU will be attached to loco power through
special purpose BFR.
g. Then last MDU will be detached from the BCM.
h. tnco power with loaded MDU will be moved keeping sufficient distance to enable clearmce ol
site by BCM. Tamper and DTS.
i. All track machines at site will clear tre block as per G & SR.
j. Btock will have to be cleared in the direction of operating loco aUached with loaded BFR.

6. After block hours loco power will take the loaded MDUs to unload /discharge lhe muck on either
side of track beyond cess or into Railway wagon or along the track by the side of the Railwary
line
by operating inclined swiveling conveyor belt located at the front end ofthe first MDU attached
to
power. For discharge of the muck inclined swiveling conveyor belt and longitudinal bottom belt at
the floor of all the MDU have to be operated simultaneowly till fully discharge of MDUs .

Following additionat Precautions art to be taken during wor*ing:

i. Itwas reported that during discharglng of muck in the curve by MDU in centre Railway' Waste
line.
conveyor Belt swing towards inner rail by Weight and hit the goods trai n going on adjacent
There are locks providcd on both side of waste conyEmr Beb to slop lhe laleral novement
For
beh
discharging much on c{,Js, in lhe direcTioa in which lderal movement of coweyor
is

requbed, side lock ofthal side only should be opened.

lYhen MDIJs are placed on a4iacent line afiached with Power oad are used to coued
ttutch
iL
has or, Indicotion
from BCM working on aaother line, precotttion to be taken thot every MDU
vtasle co"velot
fot mtximum trovet span of w$tu oonvqor of BCM .It has to "tale sure lha'
of BCM shouw not exceed the tndicated limit on MDII to a'oid hining oJ wosle conveyor of
BCM wtth MDII as height ol MDU increoses toi,ards uraste convEzor of MDU. For
which
pilor olrd
reosonable novemer,t of MDU srafi accordhrg to wtrkhg speed of BCM. Also Loco
Guard should be figitantfor mowntent of MDIL according to ntovement of BCM.
'o*ing
itl During transfening of mtck from one MDIJ to another MDII, precautlon should be taken
that mack colledlon should not exceed above the sale tevet (Indicoted on MDll). othenoise
thefe is possibiliy of snck up of main convq,or beh of MDlt and also chancq of damage ot
hydraulic motor.
VAIBHAV ?@I"ti*:T
SAKLECHAmi#'Hl#
Dy CE TMC BL

C/- CE TMC CCG- For kind information please.

All SSE DMCs- For necessary action
 VAIBHAV SAKLECHA. Offrce of qv. CE (TMC) BL
Dy. CE (TMC) Zonal Maintenance Center,
Valsad Track Machine Organisation,
Valsad.
qffa* >ern

SER!'ICE INSTRUCTIONS MACHINf, ) W.R. 21 2O2l dated 0+02-202 I

Emergenry backup system is provided on machine to work at the ttme of any failure in the
machine. Emergencl, backup system be checked in 50 hours schedule of machines.
Emergency backup system is to be operated checked about its working in the schedule. Item of
emergenct backup sl.stem should be rn the schedule of 50 houn and details shall be
entered in the machine maintenance register Also entnes in the assurance register to be
done by the machine staffabout the knowledge of working of Emergency Backup System.

VAIBHAV bvorslt ty sqnd

VAIEHAV
SAKLECH sin:Gre
- [hE.2o2].02.05
A Du cE TM0BH",
(
C/- CE TMC CCG- For kind information
AII SSE DMCs- For necessary action
 OfEce of Dv. CE (TMC) BL
VAIBHAV SAKLECHA, Zonal Maintenance Center'
Dy. CE (TMC) Track Machine Organisation,
Valsad Valsad.
qfitTa lEra

sERvIcEINSTRUCTIoNS(TRACKMACIIINE)w.R.3/202ldgted2}03.2021
:
l. Radiator cleaninq and use of Coolsnt
during block or during
it has been seen that three numbers.gf tfi1lrs leaked badlv
RecentlY
iJ""tf- Uf resulting idling of machine Also
dailv mainrenanc" -a .*mnJitiJ b"fo'" its f"tlut" consequently premature
to identify conolii"*oi tiaiutoi""k/^shifting
.ruri faiteo be adopted to avoid such tvpe
of failuresl
reptacemenr has be"n aon". roifii'i'n;r#;;#
the air in the opposite
air for removing loose debris Direct
i) Clean radrator with Pressurized
nozzle approximarely 6 mm Away
from the fins'
direction of the ai' no* noiJtt't movement will
nozat i' ii'"t'i* that is parallel with the tubes This
ii) Slowl5' move the air
"
tubes'
remove debris deposited bet*-een
cleaning ,-r n,crino.,fnrbes and corrosion
iii) Pressurized water may also be used for corrosi
*aiator' this will prevent rusting of tubes
iv) Use OEM specified t*r'* i""f''
of tubes by rupture'
which will further prevent failure
v) Coolant must be used in l: 16 ratio'

2. Failure of Air comoressor

either by
of the compressor in various division faited which were attended
Recartly some pressure (due to
;;;;'il; farlure it was observed that back
repairing or by replacing'
of air compressor head
occuned resulting into failure
restriction of air flow) on ,r'.i.rr-..r.r
g^t.i-a tnto*ing of oil with air (Specially in BCM)'
to avoid such type of failuresl
Following procedure must be adopted
and. also replace cartridge T !:t
iltt specified
Always keep the air dr-ver functional to avoid
recurren*ii *;i rJt**. Also clean the cooling coil and drip cup
schedule to avoid
pressure on compressor'
restricted flow of air and back

VA|BHAV ?#l,'mg^
sAKLECHAri.l"l"i#
Dy. CE (TMC)BL

please
C/- CE TMC CCG- For kind information
please'
All SSE DMCs- For necessary action
 Offrce of D"v. CE (TMC) BL
VAIBHAV SAKLECHA,
Zonal Maintenance Center.
Dy. CE (TMC)
Track Machine Organisalion,
Valsad
Valsad.
L.foilrr : {d

SERVICEINSTRUCTIONS(TRACKMACHINE)W'RS/202ldated?jl'04'2o2t

failures of breakage of bearing of pinion

In one of the UTV of BCT division there were repetitive
shaftofAxlegealbxhaveoccurred.DetailedFailurearralysishasbeerrdone'uryrd.'
recurrence of such type failures following
annexure "A" for better appreciationTo avoid
instructi ons are being issued.
repairing of pinion shaft assembly'
I ) Proper Bearings and spacers shall be ensued during
between Gear and pinion must be
zi orrlng assembling of gear box Back-lash (Play) -
gasket shims
maintained by providing metallic shims and paper
gearbox assemblies as both &e Axles are
3) Difference oi wheet Diimeter mav carse failure of
Powereda,xlearrddnvenbySingleCommonGearbox,Diameterdiffererrceofwheelsshall
be checked to avoid such failures'

DA-As mentioned above

VATBHAV ,TA[,'AHfl^
SAKLECHAT:;1'x,';9
Dv.CE/TMC/BL

to: CUTMCICCG for kind information please

Cop-"-
All SSE DMCs- For necessary action please'
 1

Annexurt A

FAILT]RE R E PORT OF t;Tv 039 H

1. FAILURE DETAIL: UTV-039 H has failed on 26127 -03-202 t in Mumbai division due ro the Breakage
of Pinion and the Gear Assembly olthe Front Axle Gearbox.

2. HISTORY: Failure of Gearbox Bearing was occurred four times in the past, (on 14-03-2019 Bt
Chinchpad4 M'07-2O20 at Dondaicha, 25126-@-2020 at Dahanu Road and lasfly on t6/17-o3-2021 at
Palghar). These failures were attended by machine staff by repairing the pinion shaft (bl,replacement
of
bearing). Smell of buming or smoke from the axle gearbox was noticed in the previous failures.
In the previous three failures, the bearing of the pinion shaft (3 numbers) have been replaced by
purchasing the same from the local market. It came into notice tha! Perfect fitm€nt
could not be
ascertained due to crushing or badly damaged bearing and spacer. During repairing after failure, One
bearing has been fitted wrongly once i.e. fitment of22l5 instead ofNJ 215.

Photographs of damaged parts are as under:

\ I
t\
'! \
\
\ \
/
N

\ \
ii r.. i
3 7
a .t L \':
llt t
I 1) r (
*
I

REOMI I{OTE 8
,a
AI QUAD CAUERA
$

Broken Pinion eeth

Figurc No, I
 oa
oc
=
I

I
f
,/
7
r/
\ 7= \

I
I ,/
( q
)
I
1 I
I \ a
,/
\
%^ \

Broken Crown Gear Teeth

Figure No. 2

Due to the recurrence of similar type of failure. a detailed analysis

of fatlure
3. FAILURE ANALySIS:
was done. Bearing NJ-215 (01 Nos) utd 32216- (02 Nos) have damaged
in the recent fallwe of 26127 -
(play) between gear and pinion
O3-ZO2:.It was also observed during the assembly of gearbox, backlash
movement. Diameters of wheels were
was not available which is essential during forward and reverse
the wheel of front and rear axle
measured and it was found that there was difference of 02 mm between
of the machine.
Difference in u'heel
As both the Axtes are powered a.rle and driven b.v Single Common Gearbox,
diameter might be caused the failue of gearbox assemblies'

4. ACTIONTAKEN:
(01 Nos) utd 32216- (02
i) Front axle gearbox has been assembled with new bearing NJ-215
Numbers).

ii) MaalticshimsaswellasGasketpapershimsofChampionJointinghasbeenprovided'also
proper back-lash to the gear-pinion assembly have been maintained'

iii) Tyretumingofallthewheelshavebeendone@PrrWHEELSectionofElectricLocoShed
Valsad to match the wheel diameters.
Existing Wheel diameters

Axle Lel t side Risht side

1"'A''de 9l( .2mm 910.8 mm
2nd A\le 908 .5 mm 909.0 mm

After tumrng 1o the proper Profile and Size. Wheel diameters available are as follows:

Axle Left side Right side

1"'Axle 905.6 mm 905 7 mm
2od Axle 905.5 rrun 905 2 mm
 VAIBHAV SAKLECHA Offrce of r/r*'. CE (TMC) BL
D_v. CE (TMC) Zonal Maintenance Center,
Valsad Track Machine Organisation,
Valsad.
qfrk-}dr.

SERVTCE INSTRUCTIONS (TRACK MACHINE)W.R. 06/202 I DATED 0 1.06.202 I

Analysis of rec€nt failure in one of the UTV has been done. After clearing the block when
gear
machine was required to be shifted in loop line, the machine incharge reponed &at rhe
got
could no1 be engaged. On checking it was found thal Locknut of the shifter assembll'
loosen due to which gear could not be engaged and the macline could not be shifted to loop
line. This has affected the movement of trains on main line. To avoid reclrrence of such type
of failure following instructions are being issued regarding UTV machines.

I ) Pneumatic cylinder, both shifter assembly and Forward/Reverse drive assembly along with
connected special type pneumatic pipes should be checked regularly Sell lock nut
should

be provided instead of a simple lock nut and this nut should be checked for ils looseness.

2) It has come into notice that there is no mechanism provided by oEM for disurgaging of
Hydraulic pump of crane working. Hence rhis pump always nms during crane working as
well as in driving. In case an)' pipe ofhydraulic circuit busts, then even driving could not
be possible and there will be chmces of damage of pump due to dry run For avoiding
Machine'
such type of failure sufficient numbers ofhydraulic hose pipes must be kept on

alea
3) Ensure Blocvcaution order on the adjacent line rvhile lifting of Rail/sleeper from the
between the tracks. while lifting the long rails, rail ma-r-' rotate and infringe the
adjacent

line which could not be controlled by operator therefore blocvcaution order shall be taken
for adj acent line also.

4) Torque support rod with mittal disc and nut attached with Axle gearbox for preventtng
twisting of gearbox. Looseness of lock nut and./or any damage of mittal disc must be
checked regularl-v to avoidjerk in cardan shaft. Jerk in cardan shaft may cause breakage
of
type of
engine sump as there is very less gap betueen cordon shafl and engine sump This
got
failure happened in the past in t'hich due to jelk in cardan shaft engine sump damaged'
 \ 1

\.-

/
/
, >
-
,/

t'7 F

ruL I
,/
V
I t

Fig. - Torque support rod with mrttal disc and nut

5) Direct brake is provided for appl-ving brake through SA-9 valve and C2W pneumatic rela1,
w'hen the machine is in running condition. Indirect braking system (A-9) is also provided
to apply brake simultaneously on the machine and on coupled wagon for prevenEng
rolling of coupled wagon. Parking brake is also provided in machine for application rvhen
the machine is stabled. All this braliing system should be kept in rvorking condition.

vAtBHAV trxi'jl,'gr*^
*5!'8HffiiuTii-

C/- CE TMC CCG- For kind informatron please.

All SSE DMCs- For necessary action please.
 O{fice of D. CE (TMC) BL
VAIBHAV SAKLECHA,
(TMC) Zonal Maintenance CenEq
-r't'. CE Track Machine Organisation,
Valsad
Valsad.
iJfri.a >.{a

SERVICE INSTRUCTIONS FOR PQRS MACHINES WORKING(TRACK

MACHINE) W'R 07/2021 DATED l7'O7'2f.D1

Recently there were failures occurred inPQRS machines during block' Failures rvere
recurrence of failures:
analysi and following instructions are hereby being issued to aroid
clamping' driving of one portal
1) During the block, all systems inclucling liftinflorvering'
one portal- Due to which planned
become slorved down, therefore uork was done with
BRN by replacing Batteries from other
f.orr"r. t*u, hampered. The portal rvas loaded on
Ponal.
On anall'sis of failure, Batteries n€re found discharged due
to fauls Alternator' It is
instructed that the chsrging system be checked properly
on display system for
or not There are chances of
voltage/current and also LED to Le checked whether it is off
fast discharge of Batteries while working in the night
2)lnanotherBlock,therewasanelectricalfailureinlateralmovementandclampingsystem'
instructions are being issued and
Due to which planned progress was hampered' Following
shall be followed strictly;
tested and ensure thst emergency
a) Before entering into the block section it must be
also rll the functions ofthe
brckup system of Machine equipment is in working order'
machine should be checked.
and alt 4 duplex chains should have
b) The duplex and simpler chain should be made fit
have equal tension' if tension in
equal tension, similarly all 'l simpler chains should
s;e set of chains is different than same should be corrected by turnbuckle'
should be check thorougtly for any
c) Before going into block sprocket and all chains
breekage.
precautions should be taken to svoid
d) When working in the cun'es, while moving
taken during the loading
hitting of the portal with BFR and also precautions should be
ard unloading of Portals.
bolts to be checked for looseness' ii)
e) In additioi to ihe above, i) Synchronizing shaft
cievir of bridp Lifting/Lowering Cylioder to be check
for proper fitmert' iii) One setof
Synchronizing shrft bolts
all types of spare Chains with S-ufiicient number of locks and
must be kept with Machine for the emergent situation'

VAIBHAV
sArdlEAf\tliffs[

C/- CE TMC CCG- For kind information Plece'

All SSE DMCs- For necessary action please'
 VAIBTIAV SAKLECHA, Office of ry'. CE (TMC) VTA
Dy. CE (rMC) Zonal Maintenance Centgr,
Vatva Track Machine Organisation.
Vatva.
qEE . l-r.'!

SERVICE INSTRUCTIONS REGARDING CHARGING SYSTEM OF BAI-TERIES

FOR ALL TRACK MACHINES W.R OB/202I DATED 05.0t.2021

A-nalysis of Frequent failures of Battery charging system of UNI 4s-g401 has been carried
out, in which both gpes of Alternaton (120 AH and 55 AH) *ere failed several times either
due to buming or due to failure of the regulator. Details of failure of both types Altemators
are as under;
l) Five Failuresof 55AH Alternator has happened on dates 23.02.2021, 28.03.2021,
31.3.0201, 17.06.2021 arLd 29.06.2021
2) Three Failures of 120 AH Alternators has happened on darcs 08.06.2021,21.06.2021 ad
29.06.2021

Indication before failure: After st rting the engine, the initial charging current went up ro
80A for 3-4 mrnutes and then came down to zero Ampere.

Activiti$ which have been done to rectify the Failure: sSE track machine and Elecricat
expert have tried to recti! the problem but tlrey could not find the cause of failure.
Thereafter Plasser service Engineer has attended the machine. He has done following
works to recti$ the problem;
(i) Replaced old Battery cables along with terminal with New cables of both Alternarors (120
AH & 55 AH).
(ii) Replaced low capacity strip fuse of 100 A & 35 A in place of original rating strip fuse of
125 A & 80 A for avoiding drawing of large current.
(iii) Tightening ofconnections of Engine circuit 6nd cable lugs.
(iv) Even after doing the above exercise, On starting the engine of Machrne, the initial
charging current went up to 80A for 3-4 minutes and then came dorm to zero Ampere.
The engine was stopped and batery voltage was checked which was more than 24V.
(v) Batteries rxere replaced by another charged batteries and Engine was staied. It was
observed that the initial charghg current went up to 25 A for 30-40 sec and then reduced
to Zero Ampere. The machine was checked on fult load during night block, no any
problem came and battery Voltage was up b 2ry.

Conclusion:
l)
On this machine, New Exide (Factory charged) make 12Y27 plates batteries were
provided on 24.12.2020 which shows that batteries were within their stipulated life.
2) Both batteries n'ere sent for the technical check to the supplier. It was found that one
cell ofone battery was damaged from the bottom side due to breakage of the body of
batEry. This has happened due to mishandling of battery. Electolyte leakage in that
ce[[ has happened due to which alternator was drawing more current causing buming
 VAIBHAV SAKLECHA, Office of Dy. CE (TMC) VTA
qv. CE (rMC) Zonal Maintenance Centgr,
Vatl-a Track Machine Organization,
Vatva.
t.f+trz ldra

SERVICE INSTRUCTIONS REGARDING SAFETY SYSTEM OF ALL MACHINES

(IRACK MACEINE) W.R 0e/2021 DATED 30.0e.2021

A. Following are the obsenrtions from the derailment of CMS-9S0 -

On 10.09.2021, CSM 950 and DGS 406 were granted block up to 14:50 hrs and machine
completed the worli at 14:40 hrs. While entering into common loop line tlrough 103/104
point jerk and unusual sound was observed. Machine was stopped and on checking it was
found that both wheels of axle number 3 were derailed and one feeler rod of left hand side
measuring trolley was lying on the track. The rod was found bent at one end. On
investigation, marks of hitting and rubbing on left hand side measuring wheel was found,
while right hand side measuring wheel found in lock position and also there were no any sign
ofrubbing and hitting found on right hand side wheel of measuring rolley.

It shows LHS side measuring wheel was not locked and it was running with Machine wheel.
While travelling in switch portion, due to sudden braking there might be jerk felt on
measuring wheel due to w'hich feeler rod came out and infringe movement of very next
wheel. Next rvheel which is running just behind the wheel of measuring trolley hit be feeler
rod and got derailed.

Sequence of failure-

l. Due to improper locking of measuring trolley on left side, left side wheel came down
rvhile machine was in motement to clear the block.
2. It was found that Frame of measuring trolley got disturbed and on left side it came
near to front wheel of rear bogie. This might be happened due to hitting of lell side
wheel of measuring trolley b), any obstruction like distance block etc. Feeler rod of
teft side wheel of measuring trolley came out due to hitting of left side wheel by
obstruction. Feeler rod obstructed movement of wheel of front axle of rear bogie due
to which wheel got derailed.
3. Speed of machine might be more than stipulued.
4. On analyzing, safety of locking system was found bypassed.

Precautions to be taken to avoid such failure-

l. All safety systems of machines should be kept in working condition.

2. Locking of all the trolleys, tamping banks etc. should also be checked visually
before starting fie driving ofmachine.

B. On 18.09.2021, during block rvorking of FRM-56403, while passing OHE Masr no.
201/14, excavating aough hit and bend the OHE mast. Following are dre observations-
 of alternators. Regular chec* of speifrc gruvrty of the elec'trollte (Recommend
Specific grovity - 1.180 to 1.260for charyetl Baderbs) shdl be done
3) AIso, it came into notice thal machine staffs were recouping the electrollte lvithout
finding tlre rcason for loss of electmllte so frequentll'. Il there is fteqaent loss of
electollte then the root cause of the same shalt be found oul to avoid furthet
failure.
4) Sen'ice Instruction 2/2020 Sr. Number 2 reiterated below must be elsurcd for battery
charging system:
"On date Xn4J2-2020, at about 22:15 hrs, during nuintetance of llnimd 45 8401' the
engine suddenly sroPpetl. Dwing chec*ing by machine stafJ !'as found that aL!!a|$
ii*" ^*t ini *oi'not chergiig rte boaer'us and borh baderies was dbcharged During-
ite hvestigaion, indicaion iffiilure lalternators h,ere not charging the batteties at ideal,
RPM duing previous days) wis overlooked by machine s,qiltr When new allernators and
laneries wii in rtL machine, new altemator teas ako nol charging the baneries and
Jiued
onfunher iniestigation, it ,hat in new such type of machina, alternalots run
was found
nih th" h.lp o7 *jdroulic notor and hydraulic puno. fiaily, A wos Iound that -hy.dtaulb
pirrp not io; acnudag the requirel'flow for- mior n run the abefio'ot and therefore
rephced md
altemators were not able to chatge th"iottii"* Finally, hydraulic pump was
nachine got pat right- In rtis failure machine was klb for n'o dals' "

Sst b
Damage to batter)' due
I mishandling

VAIBHAV ilif.I"ffi,.?*
SAKLECHAffifx"#
B.CE (tMC) Vatva

C/- CE TMC CCG- For kind information please'

please'
AU ADEN DMCs. ADEN ZMC, SSE DMCs- For necessq action
 VAIB}IAV SAKLECHA, OIfice of qv. CE CIMC) VTA
Dy. CE (TMC) Zonal Maintenance Center,
Vawa Track Machine Organization,
Vatva.
r rtetr.| lcro

Sf,RVICE INSTRUCTIONS FOR ALL ON TRACK MACHINES (TRACK

MACHINE) W.R. 10/2022 DATED 04.01.2022

Analysis of recent failure of 4th Axle gearbox flange (Part No: UD 64.76) of DGS-354
machine has been done. On 2l/06DO20, After Block. machine was shifted from pDp to AN,
rvhile shifting flange teeth were broken, after repairing machine was given put right. On
09106/2021, during shifting from WA to TBV, flarge teeth were again broken. On
12/0712A21, after block during shifting
from TISI to NDB, flange teeth rvere broken same
were repaired. On 10ll212021, dtnng shifting from SCH to CHM, flange teeth were broken.

Failure Description:

Due io recurrence of similar type of failure, Machine was taken in ZMC/BL and cardon shalt,
complete 46 axle gearborq its torque support plarc has been dismantled. Alter dismantling it
was found that:

i) Pinion shaft thread and thread of its nut was badly wom-out. (Fig I . I & I .2)
iD Flange, flange cover and seal offlange have been damaged. @ig 1.3)
iiD Mittal Disc and its rod was also wom out. (Fig 1.4)
iv) Torque support plate holes were found oblong. (Fig 1.5)
v) Cardan shaft flange holes were found oblong.

After analysis it was found tha! due to elfect ofall the above, gearbox flange spline @art No
UD 64.76) was being broken regularly.

rl
Ir E
I
fF-.-Y -
\.
*
a

Fig 1.1 Pinion Shaft

 l. Side chain trough anti collision device was not opened'
and
2. Misunderstanding in exchanging hand signal betrveen machine operator
Machine assistance available near chain trough due to which there was

misjudpent of clearance between mast and trough'

Precautions to be taken to avoid such failure-

s-vstem including anti cotlision device to be kept
in wodiing condition and
l. AII safetf
to be used during working.
be lifted and taken near
2. While passing obstruction like OHE Mast chain trough must
machine frame-

VAIBHAV ?l1r"'I"'fl1fl3*

'ffi['ffim#ir
C/- CE TMC CCG- For kind infonmation please'
please
All ADEN DMCs, ADEN ZMCs, SSE DMCs- For necessary action
 VAIBHAV SAKLECHA, O(fice of Dy. CE (TMC) VTA
Dy. CE (TMC) Zonal Maintenance Center,
Vatva Trrck Machine Organization,
Vatva.
.:lfOlrJr l..r&

SERVICE INSTRUCTIONS REGARDING SHUNTING OPf,RATION AND

MOVEMET{T OF TRACK MACHINES (TRACK MACHINE) W.R 1I/2022 DATED
47.o1.2022

on the basis of rcc€nt incidents of spAD and other unusual occurrences while
shunting/driring of rrack machines, Paragraphs of G & SR are being reiterated below for
saG movement of track machines, these instuctions are to be followed strictly;

(A) During shunting

(l) No Track machine shall be brought on a running line from the siding/stabling line without
written permission of the on duty station master issued in the form of a shunting order T-
806.
2) while receiving the written memo from offrciar In-charge/machine in-charge (in
case of
shifting from one station to another), on duty station master shall advice section
controller
regarding shunting of machine on control phone. wilh the permission of section
controller
shunting movement will be taken up by the station master.
3) No shunting movement of heav-v on track machine shall be canied out on
any verbal
instruction of SSE/Prvay or any other authorized person deputed for the same.
4\ on duty station master shalr ensure shunting of each mrchine is being done separatery
i.e.
signal shall be taken offor frst machine for shunting. Afier the machine is received on
frst
required line, then only the signar shall be taken offor the second and subsequenr
machine
and so on. Each machine is to be treated as separute tain.
5) The offrcial in charge of heav-v on track machine/machines shall be responsible
for
completion of shunting ofeach machine as well as second and subsequent machine
does not
move till concerned goveming signal is not taken off for that machins.
6) In no case, machine shall be coupled during shunting.
7) It will be sole responsibility of each machine operalor to observe the aspect
of the signal
before starting his machine. No vcrbal inrtnrctions oftrarfic stafi chould
be followed.
8) Machine in-charge will be solery responsibre for shunting speed ma.inained
during shunting, rvhich should not be morc than l5 KMpH and should not be more
\'
machine
than l0
KMPH on tumouts.
shunting in non interlock yard- tralfic staff will be solely responsible for point and routs
ar€ correctly set and locked during shunting movement of machines and route
should not be
changed till movement of machine is complete over those points. points man/Traflic
sta{f
should accompany with each machine in shunting movement in case of non-interlock
movement in section yard.
l) Shunting stalf will confirm the correct setting and locking of points/point and Rout€
supported by private no. to on duty station master.
 iv) New torque support plate has been fitted.
v) New cardan shaft has been fitted.

Conclusion

Initially Mi6al disc plates got damaged which has caused play in torque plab holes and
pad which
cardan shdt flange holes. Further mittal disc has been replaced by simple rubber
further
resulted into increase in play and caused damage to pinion shalt thread and nut which
damaged flange spline (Part No UD 64.76)

Recommendttion:
failures
l. Delay in atlention to Mittal Disc Plate aggmvated the problem and frequent
have prevented these t-vpes
ocourred to flange. Timely replacement of Miual Disc plate would
provided with the
of failures. In most of the Plasser make machines, Mittal disc plates are
plates for any
orque plate of driving arle geartox assembly. Ensure checking of these discs
damage and replace Bre faultY one
permissible limit i e'
2. Ensure Difference in Wheel diamet€r on same axle should be *'ithin
0.5 mm.

3. Ensure that there should not be excessive play in gear box and
connected assemblies'

VAIBHAV ilffi,ffi^
sa(rtr$ets:ffffifr
t

C/- CE TMC CCG- For kind infonnation please'

please'
All ADEN DMCs, ADEN ZMCs, SSE DMCs- For nccessary action
 I
7t 4

il ili
7T: t
,t

,.

{i

Fig l.{ Mittal Disc Rod

fr

t*,

Fig 1.5 Torque support plate

Action Txken:

i) New thread formed on pinion shaft and accordingly nut has

been made.
i0 Flange and its cover along with seal has been replaced.
iiD Mittal disc and its rod has been replaced.
 I

S'

h-l L

Fig 1.2 Pirion sbaft nut

-l
Lr"/'
I r!

I^i
t {hl;,t
'
ED
?.

tq .+1
,;o
a
a
I
I I
l' I
Fig 1.3 Geerbor Flange

-
2) Each machine operator, start his machine on receiving written memo for shunting with
date and time and after ensuring proceed hand signal is being displayed by shunting staff.
3) Shunting operation of each machine will be supen'ised b1, offrcial in charge of machine
along *'ith raffrc staff.
4) Machine in-charge will be solely responsible for shunting speed maintained by machine
during shunting, which should not be more than 15 KMPH and should not be more than 10
KMPH on tumouts.

(B)During movement for working

l) During working maximum five track machine may be allowed on one authority to proc€ed
for workrng within block section and proceed to next station and come back. Leading
machine shall enter il
block s@tion on proper authority to proceed, other healy on track
machine shall follor*' the leading healy on track machrne keeping a safe distance from
leading machine. No separate authonty is required for the machines following the leading
machine.
2) After entering of all the machines in block section safely then oficial in<harge will
inform on duty station master duly supported by private number that all Eack machines have
cleared the last set ofpoint.
3) It should be ensured while movement for wor*ing via urong line, facing points have been
clamped and locked, wrifien authority T-5ll issued and piloting by competent railway
servant till last point.
4) It should be ensure while receiving of machine after working on non signalled line, facing
points has been claoped, written authority T-510 issued and piloting is being done by
competent railway servant till station.
5) Do not use Mobile phone during movemen! and rvorliing of machine.

VA|BHAV,,H,ffiP.
SAIICESHffiffiA

C/- CE TMC CCG- For kind information please.

All ADEN DMCs, ADEN ZMCs, SSE DMCs- For necessary' rction please
 VAIBHAV SAKLECHA, Offrce of D-v. CE CIMC) VTA
qv cE (rMc) Zonal Maintonance Center,
Vatva Track Machine Organization,
Vawa.
.rr*r.l .--rA

SERYICE INSTRUCTIONS REGARDING MANUAL GREASING OF SLEEVES

(COUPLER) OF TAMPING UNIT OF DTE MACHINES (TRACK MACHI]\'E) W.R.
I 2 I 2022 D LT ED 1 5.03.2022

Recent failure of Tamping Unit Vibration Shaft's Coupler (Sleeve Part No: UD25.l130 &
Sleeve Part No: UD25.1l3l & Sliding Sleeve Part No: UD25.l132) of DTE-3X 56844 has
been analyzed and following are the details offarlure;

Failure Description:

There was continuous abnormal noise coming fmm LHS front Tamping Unit. Machine was
under warranty, Plasser Semce Engineer was called to attend the problem. After dismantling
it was found that there was play in sleeves and sleeves ucre found rvom out.

Analyris:

After complete dismantling of the LHS front tamping bank, it was found that there is
mechanism to transmit vibration &om motor side half vibration shaft to outer half vibration
shaft. These two shafts are coupled with each other by two sleeves and one sliding sleeve. For
smooth functioning of these mechanisms, grease lubrication is to be done at 250 hls of
working of tmping unit as per lvl/s Plasser's maintenmce instruction (Ref: WS 56367'n
Page No 107).

one Grease nipple is provided on outer periphery of sliding sleeve. To enable greasing at this
location, flIxheel of tamping unit is required to be rotated until lubrication nipple of sliding
sleeve will point downward and visible tl[ough recess provided at the bottom of tamping unit
frame, Greasing is to be done until fresh grease comes out from either side of sleeves

In this case, there rlas insufficient greaslng due to which ptay developed betu'oen sleeves and
sliding sleeve causing abnormat noise from tamping unit and also sleeves were found wom
out.

Similar Bpe of failure was also occurred in LHS Tamping unit ofDTE-3X 9007'
 Recess to acc€ss
the lresse niPple 8t
the bottom of
tsmping Unit

J
G
7

Recommendation i

Looking to the gravity of this failure, it is recommended to do the manual geasing of sleeves
(coupler) of tamping units al every 50 hn of worting in DTE machines. This item should be
included in 50 hn schedule in the schedule maintenance register.
Oigit ly slgrEd b,
VAIBHAV vaBl{av SlfittcH^
t\.re: 2022-03.15
sA8+6tlr+ Nr€?r/srlrA

C/- CE TMC CCG- For kind infornation please.

All ADEN DMCs. ADEN ZMCs, SSE DMCs- For necessary action please.
 VAIBHAV SAKLECHA, OfEce of Dy. CE (TMC) VTA
Dy. CE GvIC)
Vatva
t
E
Zonal Marntenance Center,
Track Machine Organization.
Vatva"
qEra>(fd

SERVICE INSTRUCTIONS FOR FRM & BCM MACHINES (TRACK MACHINE) W.R. 13/2022
DATED 28,03.2022

Failure Analvsis of FRM 85F 1900-56403

Description of failurc:

Date of brealidown: 17 -03-2022

During machine shifting from KKRD (departure 1 I : lshrs) to VYA, Machine driving s_v-stem fatled
at I 1:30 hrs in the section.
) Machine driving enabled after interchanging Input/output PCB.

Initiat Analysis (Probeble Cause):

Interchanged PCBs rvere again fitted at their original location. Same were Checked and found that there
** no d.iuing problem occurred. There are 8 numbers of hl draulic clutch pressure switches
(part.no.64.07. 1000.54) system, it seems that one of the clutch pn$surie switches had
in driving
malfunctioned which might have caused the stopping of the driving of the machine.

Final Analysis:

On date 21.03.2022 same driving problem occurod at the same location between WA-KKRD on UP
Line. To reset the systenL engine was made off, battery key removd machine rolled back for up to 10
meter. Engine was started again and found *rat machine driving system started functioning properly and
cleared the section.

Other conditions such as clutch pressure, indication from pressure switches on driving panel, proportional
current for driving pumps were available bur hydraulic driving pumps werc not creating pressure causing
stopping of &iving system

After further analysis by chechng Logic Conditions (Refer Fig.l), it is found that srrbloutine Q05 for
forward driving direction & Q06 for reverse &iving direction was available due to which proportional
cur.r.ent was displayed in the gauge. Furher it is noticed thar Hydrautic driving pump enable/permission
condition FQ I-1 for pump-l and FQ l5 for purnp-ll may not have fulftlled

PAGE 1. OF 3
 00/. LATCH z.GEAB ON F01 4 PERMISSION FOfl PUMP I

ern:
2
t {2{^E^2t )Y (25^36^t)l^?3^00^X
+1l3 {05v05)^d

En en, t(2{^bh(2$2-Ot^03 28u

x04 (Rel )
Q0s LATCH ORIVE FORWARD F0 r5 PEFMISSION FOR PUMP II

ein, ( (29D^2ilF^0t{^il^mt rt2t^Zl (05105)^{5v0A} l^T

- ^F[&{tBr,tz6^3?qry{'^08))
{16 en, ( t, Zr^F
++ t

25rE-^F2t {
^E&^S^00 I 28ut4
x05 2g^Fn^66^fi (Rel)
^6^fi^6-^tr t, I t t
005 LATCH ORIVE BEVERSSE FQ15 INDIC.ORIVE FOAWAfIDS
?i n ( (25^AC^F^0|^0J^FI^00},

2 ^Ff,Boor,r26 33
t

ftr&a))
?t^2E
6 =05
m r ren, (r 25.It^Ei7ifr^07-1r^00t, r l+6 30F )( ?7
x06 rfr26slf r r t ZOr!r[^-25rfir0C r t r9Fx20

Fie.l

Input signal X3C, which is common for bolh the driving pumps, may have caused lhe problem.

This input sipal X3C which comes from pnerrnatic pressure switch (Parr \o: 9o{51 R0/2) fittsd in brake
circuit of machine (Refer Fig.2). On further tracing il is formd that the cables connectod with this brake
pressure switch were removed and two connectors of this cable werc short circuiting wittr each other.
(Refer Fig.3)

.DRIVINGSTOT
2ru{
F
I
J A
{e SIGNAT

rus SIGN.

{o CBASH PHOT.COII\/.CHIIN
FX 3 B
I 1 .a

5u2/A
{e
d PRESURESWIICH
BRAKE

ENGINE RUNNING SIGNAL

1FX 3

5F)( 3 0
t I
rl
.l
L 4t'

l
(READY FoR SIARING)
Pressure

FX 3 E Switch

{d
p" WATCH.DOG OK 4FX 3 F
.-t?r
Cable
Fie.2 Fis.J

PAGE 2 OT 3
Recommendation:

This Pneumatic pressue swilch (P,rrt lo: 90{51R0/2) (Rcfer Fig.4) is operated at preumatic pressure of
I bar applied in the bralie rylinder, *irich causes input xJC semding sigral to program to cut off hydraulic
pressure from both the driving pump, thus unloading these pumps when brakes are applied. This is safety
features provided on all the FRM and BCM amchinos should always be in working condition. Bypassirtg
of this pt.essutr switch will cause loading of hydraulic ddving pumps even when brakes al.e applied
and machine in standstill condition. which may cause failurc of these pumps and bumting of
h;.-draulic hoses in driving system,

In case of malfrnctioning of this pressue snitch, in emergency if cable are required to be removed for
bypassing switch, wires should be properly isolated from each other by providing PVC tape'

I L
rL,

Fip.4 Pneumatic oressure slritch

VA|BHAV 911f.L1111,fl^
SAKLECHAff#T*l,?
I}v CE TMC VTA

Copy to:

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PAGE 3 OT 3
 VAIBHAV SAKLECHA, Office CE CIMC) VTA
of ry.
Dy. CE (TMC) Zonal Maintenance C€nter,
F Track Mchine Oryanisation.
VaNa
Vatla.
t.fr}ttr t.ri

SERVICE INSTRUCTIONS REGARDING SECURING CENTRE PLOUGH &

SHOI.]LDER PLOUGH OF FRM MACHINE (TRACK MACIIINE)W.R 1.I/2022
DATED I5.OG2O22

Recently deraitnant of FRM machine happened in SWR, Probable cause seems to be

entanglement of centre plough flap with the rail rvhile negotiating dte cross over during
ravelhng mode & resulting in lifting of rear bogie & tilting of complete machine.

..:.: :
This Entanglement might have caused due to less clearanc€ available betwccn plough Ihp
and rail head in locked condition.

lBo
..-n-

:
Centrt Plough
entangled

A) This avaitable clearance might get rcduced in due course of working due to following
rcasons:
l) Flap pins getting bent due to obstrustions like boulder rail piece etc. on the track
2) Proper locking of unit has not been ensured.
 t --.-

Centre Plough Flap Pin

B) If FRM is rvorking with BRM mode onll', there is probability of hitting of shoulder plough
with the obstruction prssent in the shoulder ballast. In &at case less clearance will be
available betwe€n plough & rail top, even u'hen unit will bc locked.
-2
--.-a

J
! ... tl
G .a
EE '!I
Ccntrc Plough Lock T !
I I
ffiI
I
I Centre Plough
\
\ Additional Lock
;t
I

In view of the ebove followirg itrstructions rre b€ing issued for strict compliance:
l) Ensure proper locking of shoulder plough uni! centne plough & broom unit before
movement of machine.
2) Additional security of these units with slings/ chains etc. should be done.
3) Ensure tftat no component should infringe the minimum vertical clearance of 102 mm
from rail level while travelling.
4) Attend pins of flap if any deformation observed. VATBHAV iltff",f*fi.

'^S"8&ffi8wio
C/- CE TMC CCG- For kind information please.
All ADEN TMC, ADEN ZMC & SSE DMCs- For necessary action please.
 VAIBHAV SAKLECHA, Office of D,'. CE (TMC) VTA
Dr'. CE (TMC) Zonal Maintenance Cenbr,
Vatva Track Machine Orgonisation,
Vatva.
st&,l l.ra

SERVICE INSTRUCTIONS REGARDING STABLING OF TRACK MACHINE AND

C0ACHES (TRACK MACHINE) W.R. 15/2022 DATED 05-09-2022

There were incidences of rolling of track machine, coaches or BRN coupled with track
machines in stabling siding. There are instuctions in IRTMM-2019 Para 705 (1) & Para (6)
of correction slip no. 4l of G & SR regarding stabling of machine & precautions to be taken'
Instruotions are being reircrated for strict compliance;

l) Track machine staff should put skids on either side ofmrchine wheel during stabling.
2) It must be ensured that mechanical hand brakes provided on machines are working
effrciently.
3) lt should be ensured that machine is secured with the chain and pad locks during
stabling.
4) It shoukl also be ensured that pneumatic parking brake (appliod when ZF key switch
is made off) is working.
5) There should not be excessive wear ofbrake shoes
6) Condition of brake chain, cable pulleys should be sound.
7) Additional Two skids to be kept when camping coach is accompanied with the

machine
g) when the heav-v on-track machine is stabled, th<: operators shall ensure thst it is
berthed clear offouling marts anrl traps and withot d obstructing the adjacent lines.
He

shall apply the hand brates and secure by wooden r"vedges to prevent moveEenl'
9) Entry should be done in load stabling register available with the station master'
l0) Ensur€ prking brakes are in functibnal in UTVs

fifT,'ff#*
VAIBHAV
SAKITCHAMf
Dy. CE(IVIC)WA

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All ADEN TMC, ADEN ZMC & SSE DMCs- For necessary actin please
 VAIBHAV SAKLECHA, Offrceof Dy. CE (TMC) VTA
Dy. CE (TMC) Zonal Maintenance Center,
Vatva Track Machine Organ isat ion,
Vatva.
qEraHr

SERVICE INSTRUCTIONS REGARDING FAILURE OF EXCAVATING

coN!'EyOR BELTS rN FRM MACHINES (TRACK MACHINE) W.R. 1612022
DATED 0112-2022

Description of failure: Plasser make FRM machines are equrpped wrth two numbers of
excavating conveyor belts to carry the exca ted shoulder ballast towards screen unit.
It has been noticed that these belts tear out frequeftly and required to be replaced. In some
cases due to insertion of ballast, supporting rods ofthese belts also get bent.

E
5
rrr,1ll.l_L
\
a i-
I

Damaged Belt B€nt Supporting Rod

Analysis: After analysis of failures, it was for+d that the metallic plates clamping the scrapper
rubber fitted over tlis excavation belts were touching and rubbing with the belts and due to
friction belts were berng damaged.

.J_.
a

Worn out metallic clamping plate

Action to be taken: Following instruction should be followed for maintenance of excavating

bels and other belt units ofFRM machines;

(i) All belts are to be driven first before operating Excavation cutting chain for avoiding
jamming of ballast.

(ii) As per OEIv[ mainain gap of I mm between excavating belt and scrapper rubber.
(iii) After bloclq check and adjust scrapper rubber as per para (ii) above.

(iv) Lubrication of side chain of o<cavating belt to be done in wery block to prorent failure of
sidc drain.

(v) During working excavation belt become loose due to elongation of side chain of excavation
belt which requires tightening and aligning with the help of bolt given with lower roller
assembly.

(vi) It is seen that supports are being bent either by tapping of ballast under upper driving
roller of orcavating bclt or by running of cxcavating bclt in loose condition. To prcvcnt damagc
of supportp, tightening and aligning with the help of bolt given with lower roller assembly
should be done and cleaning and maintaining of scrapper rubber should be done.

(vii) It is seen that base metal plates of scrapper rubbers (100 mm width) become loose due to
vibration or during maintenance of scrapper rubber and come down and start touching with
excavating belt. For which o<tra care must be taken. These plates should not touch conve,yor
belts.

(viii) Top cover plates are required for tightening scrapper rubber in specified positioq for
which welding dots are provided under side. In due course of time these welding dots wom out
and scrapper rubbers become loose. Due to this, chances of uplift of scrapper rubber indeases
and entering of ballast inside of excavating belt increases which further cause tearing out of
belts.

t--
'F. Efi r-€7: rY -/
L
t

,_' "

I
(ix) Top cover plate of side guide rubber having thickness of 5mm. in drr course of time it
wears out. It is required to repair or replace during maintenaace-

(x) To prevent entering of ballast inside excavating belt additional arrangement as mentioned
in photo below can be done.
f

's YrL--=*--'
).ar
r.
i,i-fi
ti

- ri.- I

o.t.: 202212.03
1a:4,r:11 +o5'3o

Cf,/TMC/V'TA

C/- CE TMC CCG- For kind information please.

All ADEN TMC, ADEN ZMC & SSE DMCs- For necessary aclion please.
 VAIBHAV SAKLECHA, Ollice of Dy. CE (TMC) VTA
Dy. CE (nvlc) Zonal Maint€nmce Center,
Vatva Track Machine Organisatiolt"
Vdva
qfi*rrr :.3ra

SERVICE INSTRUCTIONS REGARDING TRACK MACHINE WORKING W.R

l712023 DATED 06-03-2023

It is seen that on some TrackMachines, some functions are raely us€d. All these
frmctions are hy&aulic operated and eloctrically contolled througb solenoid coils. The list
is

enumerat€d as blolYi

l) Screen Tilting ir BCM and FRM- usod on curves only.

2) Flep over dirtributor behs in BCM and FRM' To distribute the ballast over
distributor belts /towards cente plough.
3) Coverirg Hood UP/DN in BCM and FRM- Operated only when complet€
excavation of ballast is to be done.
4)Be||rstHopperconveyorinUSP.ToStoretheexc€ssballastandtodistributeover
deficient portlon of Track.
5) Crane in MFI- When P way materials need to be loaded or unloaded
6) MDU rnd T-2t- MDU machines are only used wi$ BCMs working in yrd or in
cutting rea and T-28 is used only while lsying turnouts or doing layout correction'

Due to long irtling of &ese futrctiondmachines, failurcc litro stuokitg of sgicnoid

spools, short circuiting of solenoid coilq rusting sooka termhals may occur'

Action to be taken-
and
A. Check functions (Sr. No. I to 5) in every 50 hrs / weekly whichever is earlier
rectify the finction iffound defective.
B.AllfunctionsofMDUandT-28machinesshouldbecheckedatleastonceina
week.

Entries of checking of functions shoutd be done in maintenance register

h' Drr.2023.03-6
| 7a927 +053d

C/- CE TMC CCG- For kind irformation please.

All ADEN TMC, ADEN ZMC & SSE DMCs- For necessary rction please'
VAIBHAV SAKLECHA, Offrce of D-v. CE (TMC) VTA
a* cE (rMc) Zonal Maintenance Center,
Vatva Track Machrne Organization.
Vatva.
qfotrrr }--rt

SERVICE INSTRUCTIONS REGARDING ENGAGE-DISENGAGE ASSEMBLY OF

SINGLE SPEED DROP BOX OF UTV MACHINE W.R. 18/2023 DATED 2}05.2023

Descrlodon of Fallare: Ury-029H was under shifting irom RJT to VADAL on date 19.05.2023
but suddenly unusual noise was heard by machine staff and machine driving gol stopped.

An@z The transmission s)'slem of the UTV machine consist of an engine, transmission
gearbox (CRT-5633) follolved by single speed drop box and arle gearbox through a cardan shaft.
There is an Engage-Disengage assembly provided in singl+speed drop box used during towing
olthe machrne. Normally it is in engaged position. We need to disengage the single speed drop
box during toring ofthe machine.

There are trro bolts provided in the engage-drsengage assemblv namely, the
& the , as shorm in the figure belor', to facilitate tow-ing of the machine

f'-qY3:@
,l
I kxking bolt
r----ir I

I
E-!
c
l
I' I
Li (. I
D,

t, I ri \r
t llngage4isengage

'r
[1, boh

I I ,*l
Engagedisengage bolt is used to engage & disengage the final drive bl rotating the bolt
clocl<wise and antialoclcw i.re respectively. The Locking bolt is used for keeping the shifter in
engaged position and to absorb the shock/vibrations ifany.

In case of Ury-029H machrne, this locking bolt got loosened due to vibrations causing
disengage ofthe shifter assembly rvhich further stopped the driving of the machine.

Redificdion Adon: The shifter assembly in single.speed drop box is provided in a splined
shaft. After disorgagement of the shifter assembly, it is necessary to engage the shifter with
helical pinion by rotating the input shaft and matching /aligrring with the teeth so that it is
perfectlv aligned/ matched.

Acdon to be taken: There should be permanent markings with paint on the engage.disengage
bolt with reference to its semi-circular body regarding whether the shifter assembly is engaged or
drsengaged and frequent monitoring of its position and tightening of the locking bolt in the
engaged position of the engage-disengage bolt.

It is hereby instructed to daily checking the position of the engagedisengage bolt & tighten the
locking bolt and intermittently check during long shifting of machine.

Addltional check: There are M pneumatic cytinders of FESTO rnake provided in the
transmission Gearbox in which 02 pneumatic cylinders are used for selecting lhe forward/reverse
direction of machine and 02 pneumatic cylinders are used lor selecting firsVsecond/third gear of
the machine. Also. there are 04 solenoid valves corresponding to these 04 pneumatic c.vlinders- It
should be ensured that all these solenoid valves and pneumatic cy'linden are in worhng
condition without any lealiage.

Drslt fy Can db,

VAAHAV SAXIICHA
D.te 2023.0523

Dy

Copy to:

C/- CE TMC CCG- For kind information please.

All ADEN TMC, ADEN ZMC & SSE DMCs- For necessary aaion please.
VAIBHAV SAKLECHA, Oflice of D.v. CE (TMC) VTA
Dy. CE (Tlv{C) Zonal Maintenance Cente(
Vatva Track Machine Organization,
Vatva-
r rf?-.ra >ciA

SER\'ICE INSTRUCTIONS REGARDING PRECAUTIONS TO BE TAKEN TO AVOID

BREAKAGE OF TAMPING T]'NIT UP/DOWN CYLINDER PISTON ROD OF
TAMPING MACHINE W.R. I9/2OI} DATED IE47-2O23

There have been many instances of breaking of tamping unit up down rylinder piston rods in the
tampen from the end $,here it is attached with Tamping Unit.

After detailed analysis, most probable rcasm was found to be:-

This piston rod is attached with tarping unit with provision of two pivot bearings (one at top
(GE35AX) of the hex nut and other at the lower side (GE20AX) ofhex nut. These are basically
thrust bearing which allows rocking movement ofpiston rod during up/down movement of T. U.
Top bearing is covered on top with thick cover plate with 6 Allen bolls, which ultimately couples
the piston rod and tamping unit frame.
In due course, ingress of grit, dust causes jamming of these pivot bearings and stop6 the rocking
movement causing the brealiing ofpiston rod oftamping up/down cylinder.

4 h:-
I
9l
t
a I
I
B a
H
I c
I \
!
-r; ra TL
,:

, 7\
(This contact surface should be lubricated)
Plain Thrust Bering GE3sAX
Jammed ftrust bearing
 I It

-
\ \r
F- ,/
iq
Pattem of breaLing ofPiston Rod Pattern of breaking of Piston Rod

Earlier service Instruciton No.0l/2020 dt. 2E.10.2020, has been issued

for checking and
following care
cleming/ lubricating of thrust bearings in 200 hrs sch. maintenance. In additional
to be taken r*trile fitrnent of piston rod witr fte tamping unit frame'

bearing top poruon'

l. Proper size of shim to be provided between top cover plate and thrust
is pe'rformed'
such that there is no excessive gap between them and proper rocker action
/ cover to be ensured between cover plate md piston rod to prevent ingress of
ballast
2. Seal
gril dust etc. which causes jamming of bearing.
Machines in which rubber support is provided betrveen Emping u/dorvn
3. cylinder and
proper location'
tamping unit frame, it should be ensured that it is intact and at
4. Piston rod locking ntrt properly tightened and locked'
not be any
5. Lower the tamping unit and check for lateral play of piston rod, there should
play. Laeral play indicates looseness of lock nut'
Digii.lt egned bY
VAIBHAV SAXIECHA
o.re:202107.18
'. Soricrheh
!,y*. CE TMC VTA

Copy to:
CBTMC/CCG - for kind information please.
AII ADEN TMC, ADEN ZMC & SSE DMCs- For necessary action please
 VAIBHAV SAKLECHA, Oflice of D-v CE (TMC) VTA
D_v. CE (TMC)
Zonal Maintenance Center,
Vatva Track Machine O rganizatron
Vatva"
t.rfftTri >.rr)

SERVICE INSTRUCTIONS R.EGARDING WATER SEPARATOR ASSEMBLY FITTED

IN DTf,'FRM &USp MACHINES W.R 20 /2023 DATED 22.U.2023

There was sudden engine shut down in DTE-5708? u.orking in MMCT division on date
10111.08.2023 during working between BoR-vGN DN line. Earlier Similar incidenr was
reported from DTE-568.14 machine also. The reason of shutdown of engine was air entrapped in
the fuel system. Air entered through the crack developed in the cover plate of diesel water
separator assembly fiued in suction line.
To prevent air entrainment in the fuel system and avoid sudden engine shutdowns like the
incidents mentioned above, it's important to take proper precautions during the replacemenl of
the filter cartridge GIY-D506.10.3085) of the diesel water separalor assembly in lhe mactrines in
rvhich this is fitted (DTE,FRM & USP). Here are the necessary precautions that should be
fotlowed during the 500-hour scheduled maintenance:

I ) After replacement of filter cartridge, it is to be ensured that rubber sealing ring is properly
fitted in the groove ofcover plate.

cr.ck
&vclop!d
due to
7
ll d #
Rubber sealing exceiilvc
tithtcnlng
in the groove

-
Fig. I
l

li Lrhhcr sculrnr:
!tl-* .l
Fig.2 Crack developed in the cover plate

2) While tightening the bolts of cover plate, equal tightening of all four bolts to be ensued.
,\i., t Lc'i,' irr'. iirrc'c to be applied on these bolts.
3) There is c,r/ betwe€n the cover plate and the body aboL$ 3 to 4 mm in ideal condition as
sho$n in fig.3 and to be maintained equalll' all around the periphery of the filter
assembly during tightening of the cover plate bolts.
 3to4mmGaP

) I
I
Fig3 Shorving Gap betwean cover ud body
Digitally 5l9n dbY
VAIBHAV

l7oOO4 +05'30'

C/- CE TMC CCG- For kind information please.

All ADEN DMCs, ADEN ZMC, SSE DMCs- For necessar_v action please.
 VAIBHAV SAKLECHA, Office of Dv. CE (TMC) VTA
Dy. CE (TMC) Zonal Maintenance Cenler.
E
Vatva Track Machine Organization
Vatva-
qfg>r,r >.it

SER!'ICE INSTRUCTIONS RDGARDING EFFECTIVE USE OF EMERGENCY

BACKUP SYSTf,M FOR MFI MACHINES (TRACK MACHINE) W.R. 21/2023 DATEI)
23.08.2023

To ensure the effrcient operation and safety of MFI machrnes, it is crucial that all machine in-
ciarges are well-versed in various meftods of locking of the machines in cases of failure. This
will help in early locking of the machine and also block bunnng can be avoided.

To remain aware of all type of system of locking of machine in all cases of failure it is very
much essential to praclice them in a routine manner.

Hence machine in-charges ofall MFI machines are instructed to check the emergency back up as
per the follow'ing cmergsncy baekup plan;

Emersenq backuo olan lor MFI machine lockinq

Sr. Cases of failule System for locking of machine Approx.

No. Engine Programmer CMS Tamping unit Lifting unit time
Supply taken

Push& lock Tum on "emergenc-v 05 mins

mushroom (cut-off) stowage" in CMS push
valve. Push spool of spool of DC valve of
I On Fail On
proportional valve both side lifting
for up movement. cylinder
simultaneously
Push & lock Ifsolenoid valve get 05 mins
mushroom (cut-oft) stuck-up, one a line
valve. Push spool of having pressure of
proportional l alve other hydraulic valve
for up mol'emant. catr be connected to lift
the lifting unit.
2 On Fail ofr OR OR OR
Push & lock Use hydraulic hand l0 mins
mushroom (cut-off) pump.
valve. Push spool of
proportional valve
for up movement.
 Tum on electrical motor operaled backup l0 mins
3 ofl On On system and lock units by using proper
switches provided for up/down movement
Tum on electrical Tum on "emergency l0 mins
motor operated stowage" in CMS Push
backup system. spool of DC valve of
Push &lock both side lifting
4 olf Fail On
mushroom (cut-off) cylinder
vaIve. Push spool of simultaneousll'.
proportional valve
for up movement,
Tum on electrical Use hydraulic hand l5 mins
motor operated pump.
backup system.
Push & lock
5 ofr Fail Fail
mushroom (cut-off)
valve. Push spool of
proportional valve
for up movem€nt.
Ok. but Use pulley block / Use pulley block Ailith 20 130
piston With the help of the help of Jack and mins
6 On ok screw Jack and rvooden wooden block.
broken block.

In case of failirre of electrical molor operated back systenr, hydraglic hand pranp shall be used
for locking of all utits.

In case of slipping or breaking of piston rod, with the help of chain pulley or with the help of
Jack and wooden block tamping unit shall be locked.

AII fiese items shall be operated and checked for their working in 50 hours schedule. Details of
drecking ofabove items should be entered in the machine schedule maintenance regster.

Digitally 5iqmd by
VAIBHAV SAKfCHA
Date:208.0423
I 5r48il3 +0530
Dr. CE TMC VTA

Copy To-
CE TMC CCG- For kind information please.
All ADEN/TMC, AEN/ZMC and SSE/DMCs- For necessary action Please
 VAIBHAV SAKLECHA, O{fice of Dy. CE CIMC) VTA
ry,. cE (rMc) Zonal Maintenance Center.
Vatva Track Machine Organizati on,
Valva-
qfoE-,'ada

SERVICE INSTRUCTIONS REGARDING PREVENTION OT AIR ENTRAPMENT IN

FUEL LINE IN CDC-I6W & XCD-T6W PCTM MACHINES (TRACK MAC}IINE) W.R.
22t2023 D ATED 19.10.2023

There have been instances of air entrapment in the fuel line and shutdown of engine of PCTM
machines. There are two filters (on the diesel tank) in the suction line before the electric fuel
pump, this line is susceptible to air entrapment if contrnuitv is broken due to loose fitment. To
avoid such failures in PCTM machines, follouing instruction should be followed;

A. Transparcnt plastic hody filter-

0,r rn
\
f r I
I
I
[' b
E
r ;tL

rEf

\ I r,,lil

Transpfient plastic bodl filter Metal filter with manual feed pumP

i) Diesel pipes to be dlecked for any loose fitmenl.

ii) Check plastic filter body cover for any crack.
iii) Check tighhess of filter body cover and ensure drarn screrv is tight.
iv) Each time during filter cartridge replacemenl or cleaning, apply teflon tape to body cover
thread and tight it properly by hand onl-v. No belt spanner should be used (to prevent crack in
body due to over tightening).
v) Clean filter body and cartridge if dirt or foreigrr particles are observed.
B. Metal lilter with manud feed pump
i) Check input connection for any loose fitting.
ii) Check tighfiress of filter daily.
iii) Check water drain plug for tighuress, each time when water is drained ensure plug is
tightened properly.
iv) Never opan drain plug when electric fuel pump is running, otherwise air will get trapped in
fuel line.

Other Prtcautions

i) All tlree electric fuel pumps are nmning or not to be checked daily. Replace fuel pump if
fourd faulty.
ii) Apply cable tie on ball valve to avoid closing of ball valves accidentally.
iii) If the engine starting is getting delayed from normal than there are chances that air is
entrapped in ttre fuel line, in this case check fuel line continuity immediately.

& i
a- !_ x

l'-,
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't

Digitalt signed by
VAIEHAV

r0.19
l5:1116.r053O'

Copy to!

C/- CE TMC CCG- For kind information please.

All ADEN TMC. ADEN ZMC & SSE DMCs- For necessary action please.
ANUJ KULHARI O{Ice of Dy. CE (TMC) VTA
Dy. cE (TMC)
Vawa
f =
Zonal Maintenance Center,
Track Machine Organ ization.
Vatva.
rrfdtr&H

SERVICE INSTRUCTION REGARDING PREVENTION OF SPAD (TRACK

MACHINE). W.R. 2312024 DATED :3ol0ll2o24

Recently in the past some of SPAD cases in track machines has been occured on western
railway.
Following instructions arc being issued for proper working of track machines and to avoid SPAD
cases.
1. No operator to be deputed for work whose LRD, Competency. Training and PME are
due.
2. Nominated CLI of the division must visit regularly on the machine and counsel
operators regarding safe working to avoid probable SPAD.
3. Usc of mobile should be prohibited specially during driving/shunting/Block.
4. Proper authoritaes to be ensured by machine in charge as prescribd fot HOTM as per
G&SR. Before driving of machine, operator should carefully strdy the standard
tbnns/authorities given by station master and ensure whether they are p,roper or not as per
requirement.
5. Do not indulge in any t)?e of conversation amongst thc stafl present in driving cabin,
which can divert concentration of operator during driving/shunting. As tir as possible.
minimum staffshould be available in driving cabin.
6. Discussion of block working with PWl during shunting/driving should be avoided. PWI
should give work planning well in advance during daily maintenance period/Previous day
after work.
7. Staff should not be under rest. (Machine should be placed in siding just aller roster
period). And staff should be available on time as per duty roster period to avoid
unnecessary hurriedness for giving machine ready.
' 8. During inspection of SDI and ADENAMC of thc respective division, knowlcdge of
operator for wotking should be checked. lf station mast€r is avoiding to issue proper
authorities for HOTM working, dren it should be highlighted through CLI to higher
authorit ies,
9. During shifting, Aspect of the signals should be observed carefully and repeated loudly
by other operator/senior most technician. Signal should be observed till passing it.
10. Machinc in charge should ensure for brrke power during daily maintenance. Machine
should not be over speeding as prescribed in correction slip no- 4l of G&SR.
 (50/40 kmph & l0 kmph on P&C). Control the speed of machine as per aspect of signal/
caution order.
"OVERCONFIDENCE MUST BE AVOIDED" (b) "THE BEST
ll.(a) SAFETY
DEVICE Is VIGILANT MAN' (c) "ALwAYs ALERT - ACCIDENT AvERTs"
must be followed by all operators.

ANUJ MM"
KULHARI Hiffiii?
D)'. CE(TMC)VTA

COPY TO: CE/TMC - For kind ilformation plc2se-

: ALL .ADEN TMC, ADEN ZMC & SSE DMCs - For necessrry rctiotr plersc'
 ,ANUJ KULHARI.
Dy. CE (TMC)
Ollice of Dy. CE ('IMC) \rt A
Zonal Maintenance Center, t
t
Vatva
Track Machine Otganization,
Vawa.

L
S[,RVICE INSTRIICTION
L
SERVICE INSTRUCTIOT{ REGARDING PRECAUTIOI{ TO BE TAIGN DURI'{G TAMPII{G OF SE BY TAMPING
MACHTNE W,R. 2al2024 DATED 0s.O2,ZO2l

On it was reponed by P.WAY staff that CSM-980 *'hile working on DN line between VApI-
-09/10.01'2024
K-EB' has creatcd dent nrark on the outer flange ofSEI rail. After detailed investiladon
following ohservations
are recorded.

In normal plain track no dent marf,:s are observed. The rcason is that rhe rail flange wirlth in normal track
structure is 150 mm, whereas at location of SEJ flange width is 175 mm and 165 mm-in
two types at sEJ type
No. 6902 Gap and sEJ rype No. 6922 ooubte cap respectively mat ing p-uLiiiry'oi Lnt
.Single
Horvever itwas not the tamping tool hitting mark. raDptng iool liwet airrpng
.r*.
id
brraoy arm lin o
side) on RHS tamping unit is touching rvith the rait nange at SU. "intot
Thcre are two probrble rrrsons for this:

l) On the approach ofSEI wider slceper having height of230 mm at rail sear. Tamping depth is
kept 412
mm as Per requirement of track structure.However, ar SEJ location of slecpcr ki;ht is 200 mm. At
tamping depth seuing of412 mm there is tikely hood ofrouching ofhex bolt with tiriflange.

Solutioa:To reduce the depth to 3E3 mm while temping SEJ tocation.

2) Tamping unit'slateral auto position may malfi.:ncdon. lt was checked for is zero calibration and tbund
colrect.

Osnt mark on
rell f,ango of
ll 7'S
r Hex Bolt
of
SEJ
Tamping

) Hence instruction issued to reduce the trmping toot depth to 3&l mm while terping SE,I sleepers
b!, CSM, DUO, DTE in the trarh structure of wider stecpers rld whcre modified trmping arms
ere fitted.
ANUJ ii',fllliflf "
KULHART ffi,fl"',#;l:
Dy.CE/TMCA/TA
C/- CE TMC CCG- For kind intbrmation please.
All ADEN DMCs, ADEN ZMCs, SSE DMCs- For ne€essary action and acknowledganent for all Tamping
machine incharges.