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SMALL TRACK MACHINES

SMALL TRACK MACHINES. By Anil Choudhary Sr Prof/IRICEN. MECHANISATION. Mechanized maintenance of track was introduced in early sixties . Track machines are of two categories: Heavy track machines Small track machines.

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SMALL TRACK MACHINES

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  1. SMALL TRACK MACHINES By Anil Choudhary Sr Prof/IRICEN

  2. MECHANISATION • Mechanized maintenance of track was introduced in early sixties. • Track machines are of two categories: • Heavy track machines • Small track machines. • For Heavy track machines, Track Machine Manual was first published in March, 2000. • For Small track machines (STM), Manual was first published in July, 2005.

  3. VARIOUS SMALL TRACK ACHINES • Machines For Operations on RAIL • Machines For Operations on Sleeper • Machines For WELDING OPERATIONS • Machines For Operation on Fittings • Machines For Lifting and Slewing of track • Machines For TRANSPORTATION/ HANDLING of Men/Material • Machines For Track Ballast

  4. Yardstick Of STM (Minimum)(Annexure-1, modified vide ACS-01 & 05) • Minimum yardstick of availability of STMs as per Annexure-1 • In the list, only min requirement is specified & all machines are not part of list. • Additional requirement of other STMs wherever required shall be worked out based on requirement of individual Division/Zonal Railways (As per list of STM approved by Railway board and as per local conditions) • Additional spare machines may be kept at Divisional/Sub divisional depot, to be decided by Zonal Railways based on actual need to be used in emergencies. • Such spare machines shall be frequently used so that they remain in good condition.

  5. Yardstick Of STM (Minimum)(Annexure-1, modified vide ACS-05)

  6. Items Covered under Minimum requirement but not in IRSTM manual • Hacksaw Blade for cutting Rail • Box type Guage cum level(BG & MG) along with Spirit Level • Magnetic Base Type Thermometer • Continuous Rail Thermometer • Gang/Worksite Remote Control Hooter

  7. Other Items not in STM (Loaded at RDSO Web site) rdso.indianrailways.gov.in

  8. SMALL TRACK MACHINE-SETUP At HQ level - • Under the overall charge of CTE or CE/TM • Assisted by one Dy. Chief engineer/Sr. Engineer for small track machines. At Divisional level – • Sectional Sr.DEN/DEN – procurement, maintenance • Sectional ADEN & SSE/JE/Pway – maintenance One SSE (P-Way) to be in charge of STM Depot in Sub-division.

  9. Procurement 1.4 (a) 1. The officers of Engg. Deptt., dealing with small track machines shall have the same powers to procure small track machines/tools and their spares, consumables and small tools to meet the requirements as available to that of officers of Stores Deptt. In corresponding post i.e. PCE - COS, CE/TMC - CMM, Dy CE - Dy COS and SEN/MC - SSO.

  10. Procurement contd.. 2. The rules and procedure as laid down for procurement by the Stores Deptt. should be followed by Engg. Deptt. while exercising above referred power. 3. Small track machines should be charged to proper sanctioned estimates under Demand No. 16 or Revenue Budget(Demand no 4- P-Way works), Track renewal estimates and construction estimates as per requirements.

  11. Procurement Contd.. 4.The tender committee wherever necessary to be constituted with Engineering Officers of appropriate level as a convener and the other members from Finance and Stores departments as per the schedule of powers delegated on zonal Railways. 5. Before procurement of any machine, it should be ensured that similar machine/tools available on division are effectively utilized.

  12. Procurement 6.The SMT/tools shall be procured only from manufacturers/suppliers approved by RDSO/RB as per specifications and drawings approved by RDSO/RB. 7. STM/tools shall be accepted only after firm arranges one field Demonstration cum training at Railway premises. 8. All STM and tools to be purchased under 1 year manufacturer’s warranty. (ACS-1) 9. It is desirable to have AMC of 5years along with procurement to ensure satisfactory performance.(ACS-1) Note: Items 6,7,8 and 9 will form part of tender conditions. GUIDELINES FOR VENDERS

  13. Powers Of Emergency Repairs And Purchase Of Spares Incidental To Such Repairs The following powers have been delegated:

  14. Powers Of Emergency Repairs And Purchase Of Spares Incidental To Such Repairs Note: • The overall annual ceiling limit for purchase/repairs for each Zonal Railway is 5 lakhs/- • Cases exceeding 25,000/- will require AGM’s sanction • All other conditions laid down in para ii), iii) and iv) of Board’s letter no. 96/Track-III/TK/28 dated 09.09.98 should be followed.

  15. Sub Divisional Depot (1.4.1) • Each sub division should have a Nucleus Depot(Base workshop), preferably at the sub divisional HQ. The existing workshop etc may be used. • The base workshop in each sub division will be modernized for repairs of all SMT/T&P and will be under control of AEN and SE (In-charge). • Required cash imprest and AMC shall be available to SE(Incharge) and AMC for all machines shall be arranged covering entire division. • At least 1 SE(SMT), 1 fitter with minimum 2 khalasisshall be posted for sub divisional depot within the existing manpower.

  16. New Para Added Vide ACS-01 Para 1.4.2- Divisional Depot: For major repairs, machine to be sent to Divisional Maintenance Centre for track machine which will have necessary supervisory, skilled and unskilled staff. For day to day and minor repairs, Sub Divisional Maintenance Depot may be set up at Sub Divisional HQ. Para 1.4.3- Scheduled maintenance and minor repairs to STMs will be carried out by staff responsible for operation. Adequate imprest for spares and consumables should be provided with In-charge AEN of the section.

  17. Inspection As per ACS-02: • AEN : Should inspect all STM once in 6 months. • SE : Should inspect all the machines and tools once in 3 months.

  18. Inspection 1. Sr.DEN/DEN/AENs shall pay special attention to repairs, maintenance and effective use of SMT during their inspections. 2. They will scrutinize the register of small track machine. 3. Sr.DEN/DEN shall monitor the availability, use and performance of each type of machine under the control of each AEN. 4. The report should be submitted to the HQ regarding performance in monthly PCDO.

  19. Inspection • The problematic aspects of STM as brought out in PCDO shall be inspected by an officer nominated by Zonal HQ. • The report about problems and suggested solutions shall be endorsed to Sr.DEN(CO) and CTE who will endeavor to communicate the solution to the users.

  20. Para 1.5.2 added as per ACS no.3

  21. Training • Sr.DEN(CO) shall organize for training of staff for operation, maintenance of STM/tools through the machines/tools manufacturers. • It will also be ensured that adequate training facilities are made available in DTC and ZTC. • Centralized training for operation, maintenance and repairs of STM/tools shall be organized at Zonal Railway Training Centers/Divisional Training Centers.

  22. Operation and Routine Maintenance-CS-4 • Maintenance shall be carried by Track Maintainers • Track Maintainers shall be trained in operation and maintenance of STM in a programmed manner. • Necessary facilities and equipment for training of STM shall be provided at the divisional training centre and Divisional Small Track Machines Maintenance Centre.

  23. REQUIREMENT OF MANPOWER • Indicative manpower requirement is given in the manual.(Only for machines in STM) • However, the actual requirement will depend on the nature of Track maintenance operations/activities to be carried out in various sections. • Grouping of machines and local conditions to be considered as all the machines will not be required to work every day on each section. • Leave reserves have not been included in the manpower requirement. • Actual requirement for individual section to be worked out by Division.

  24. Aspects Covered in ‘‘Small Track Machine Manual’’ (July 2005) • Description and use of different small track machines, • Guidelines for using, handling, transporting and storing machines, safely and efficiently, • Maintenance schedules and type of maintenance in each schedule, • Requirement of manpower, • Requirement of consumables, • Type of power pack to be used.

  25. VARIOUS SMALL TRACK ACHINES • Machines For Operations on RAIL • Machines For Operations on Sleeper • Machines For WELDING OPERATIONS • Machines For Operation on Fittings • Machines For Lifting And Slewing of track • Machines For TRANSPORTATION/ HANDLING of Men/Material • Machines For Track & Ballast

  26. MACHINES FOR OPERATIONS ON RAIL 1. Abrasive rail cutter. 2. Rail cutting machine (Saw type) 3. Rail drilling machine. • Chamfering kit. • Hydraulic rail tensor (Non-infringing type), 70t capacity. • Hydraulic rail bender ( Jim crow), heavy duty.

  27. Abrasive Rail Cutter

  28. ABRASIVE RAIL CUTTER Salient features: • Prime mover - A petrol engine of about 7 HP at 7000 RPM . • Fuel Tank Capacity - At least 1 litre, which shall be sufficient for at least 5 cuts in 52 kg, 90 UTS rails. • Overall weight - Maximum 35 kg. • Tolerance - + 1 mm both for vertical and lateral faces of railhead.

  29. ABRASIVE RAIL CUTTER Contd… • No. of cuts per disc- Minimum 7 cuts on 52 Kg, 90 UTS • Cutting time - (i) 60 Kg/m, 110 UTS -- 5 min (ii) 60 Kg/m, 90 UTS -- 4 min (iii) 52 Kg/m, 90 UTS & other rails -- 3 min (iv) 52 Kg/m, 72 UTS & other rails – 2 min • Man Power- 1 skilled person --- To operate the machine. 1 unskilled person --- To carry it.

  30. Rail Cutting Machine (Saw type)

  31. Rail Cutting Machine (Saw type) Salient Features: • Prime mover— Petrol start, kerosene/petrol run engine 2.0 to 3.0 HP capacity at 3000-4000 rpm. • Fuel tank capacity-- Sufficient for making 4 to 5 rail cuts. • Overall weight of the machine including wheel arrangement shall not exceed -- 70 Kg • Cutting time for each cut-- Maximum time is 30 minutes.

  32. Rail Cutting Machine (Saw type) • Tolerance of squareness both vertical and lateral -- +1.0 mm • Fuel consumption -- Minimum two cuts for 1 litre fuel. • Man Power -- Skilled --- 01 -- Unskilled --- 01 • The high speed steel of hacksaw blade should confirm to XT 87 W 6 Mo 5 Cr 4 V2 as per IS: 7291-1981. • The blades should be of ‘All hard (Type A) conforming to IS:2594:77 (Specifications for hacksaw blades).

  33. Rail Cutting Machine (Saw type) Cutting performance:

  34. RAIL DRILLING MACHINE

  35. RAIL DRILLING MACHINE Salient Features: • Overall weight -- 65 Kg ( Approx.) • Drilling time -- 3 to 4 minutes • Fixing time -- 2 minutes • Prime Mover (Engine) -Petrol start , kerosene/petrol run 3 HP engine at 3000 to 4000 rpm. • Fuel tank capacity -- 2.0 Litres ( Approx)

  36. RAIL DRILLING MACHINE • Fuel consumption - Minimum 10 holes in 60Kg/90UTS rails with 1 liter of fuel. • No. of holes in a day - 60 holes (Approx.) • Tolerance for diameter and position of the hole - + 0.7 mm • Drill bit - As per I.S : 5103- 1969 and shall last for 100 fish bolt holes in 60 Kg/90 UTS rails. • Man Power - Skilled - 01 Unskilled - 01

  37. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type)

  38. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) Use: Hydraulic tensor is used for de-stressing of LWR track and for maintaining specified gap at rail joints. Man Power: Skilled : 01 Unskilled : 03

  39. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) The main components of the machine :- (i) Rail gripping heads or yokes, (ii) Lever arm assembly, Right & Left hand (iii) Cylinders, (iv) Connecting rods, (v) Pins, (vi) Pump with tank.

  40. Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) Salient features : • Maximum total weight including hand pump -- 375 Kg. • Maximum weight of any individual part -- 115 Kg • Maximum pulling force -- 70 t • Maximum pushing force -- 30 t • Hydraulic ram stroke -- 300 mm ( min.) • Rail section to be handled (To pull up to 150 mm) -- 90 R/52 Kg /60 Kg.

  41. Chamfering kit Use :Chamfering kit is a tool used for chamfering and work hardening the sharp edges of the periphery of the fish bolt hole to eliminate chances of developing crack at the sharp edges of the drilled holes. Man Power: Skilled : 01, Unskilled : 01

  42. Chamfering kit

  43. Chamfering kit -manual Description Of Items: 1. H.T. Bolt, 2. H.T. Nut, 3. Chamfering Bit, 4. Packing Piece, 5. Torque Wrench. Note: The dimensions and assembling of different parts should be as per drawing no. TM/0512.

  44. Hydraulic Rail Bender (Jim Crow), Heavy duty Use:It Is used for bending/de-kinking of all types flat bottom rails in horizontal plane.

  45. Hydraulic Rail Bender ( Jim Crow), Heavy Duty Salient features : • Bending force : 60 tonnes • Maximum piston stroke : Not less than 40 mm, • Weight : Maximum 115 Kg, • Holding span for bending : 725-900 mm, • Time for operation : 10 minutes (Approx.) • Time for fixing : 2 minutes (Approx.) • Man Power : Skilled : 01 Unskilled : 01

  46. Machines For Operations On Sleeper Hydraulic sleeper spacer,

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