Master Copy for IRTMTCALD by IRICEN 08 275

Master Copy for IRTMTC/ALD by IRICEN

08 -275 UNIMAT-3 S was introduced on Indian Railway in year 1993 -94 In Indian Railway Machine Series no 8261 & above is 08 -275 UNIMAT-3 S

Main Features • All four axles are powered. • The tamping units can be rotated 8. 5 degrees on both sides. • 3 rd rail lifting arranged. • Lining and lifting: - By servo valve • Squeezing: - proportional valve • Intercom in all cabins • Central lubrication system(automatic greasing for tamping unit) • Maximum output one Turn Out/hour.

Technical Data OVER ALL LENGTH WIDTH WHEEL DIA L. CHORD LENGTH LEVELING CHORD WEIGHT = 22305 MM = 3550 MM = 730 MM = 22. 60 M = 15. 58 M = 64 TONNES

Main Assembly 1. Engine: Cummins or MWM with turbocharger and after cooler. Tamping unit – similar to 08 -275 UNIMAT. 2. Lifting & lining unit- similar to 08 -275 UNIMAT. 3. All the gear boxes same as 08 -275 UNIMAT 4. Work drive and Run drive system same as 08 -275 UNIMAT

Additional lifting Unit It is used for 3 rd rail lifting 1. Additional lifting device extension arm 2. Limit switch for extension arm in locked position 3. Lifting rope additional lifting device 4. Bracket for lifting rope fixation (transport position) 5. Additional lifting device

Hydraulic System This machine have 4 hydraulic pumps PUMPS - 3 Double & 1 single pumps are provided 1. Double pump (38× 17) GPM combined for the system pressure. 120 - 140 bar. 2. Double pump – (25 × 25)GPM 25 GPM = vibration (one side) pressure 150 bar 25 GPM = vibration (another side) pressure 150 bar 3. Double pump (20× 14) GPM 20 GPM = 2 Hydraulic oil cooler 150 bar. 14 GPM = ZF Cooler and Engine radiator 4. 20 LPM (Liter per minute) - For Squeezing, rail clamp and Tool tilting ( In new 08 -275 UNIMAT-3 S this pump is not provided) Note: In new 08 -275 UNIMAT-3 S, three triple pumps are used

Hydraulic System MOTOR: - 9 Motors are used on this machine. Vibration motor Driving motor Hydraulic oil cooler ZF cooler motor Water cooler motor - 2 nos 3 nos 2 nos 1 no 1 no.

Power Transmission of 08 Working Principle same as 08 -275 UNIMAT Engine ZF gear box Reduction gear box Axle Cardan Shaft Axle gear box Distributer gear box Hydraulic motor

PCBs and their functions Sl. No. PCB Part No. Function Quantity 1. EK 813 SV 00 DC to DC Convertor 24 V 15 V and 10 V 2. EK 812 SV 00 DC to DC Convertor 24 V +24 V and + 12 V 1 No. B 20 3. EK 2072 LV 00 Front input 1 No. B 4 4. EK 2173 LV 00 Lining Inputs control 1 No. B 10 5. EK 2140 LV 00 Lining Output& Over Slew control 1 No. B 10 6. EK 2041 LV 00 Track lifting 2 Nos. B 6 7. EK 2042 LV 00 Pendulum control 1 No. B 6 8. EK 120 V 00 Hook Control 1 No B 6 4 Nos Location Panel Box No B 4, B 6, B 10 1 2 1

PCBs and their functions Sl. No. PCB Part No. Function Quantity Location Panel Box No 9. EK 140 A 00 1 No. B 6 10. EK 132 V 02 2 Nos. B 6 11. EK 28 V 02 Proportional squeezing Tamping Unit UP/DN control Multiplexer 1 No. B 6 12. EK 502 P 00 1 No. B 20 13. EK 552 P 00 Programmer PCB Time Delay 1 No. B 20 14. EK 553 P 00 13 Nos. B 20 15. EK 554 P 00 Programmer Input/output QL-relay 5 Nos. B 10 16. EL-T 631. 00 Inter com. 1 No. B 40

Electrical System 1. Battery: - 12 V/ 180 AH, 4 Nos (12 V/180 AH-2 nos, 12 V/72 AH- 2 nos) 2. Alternator: - 28 V/55 A 2 Nos ( bosch make) 3. Self starter: 1 No. 4. Pendulum: 2 Nos 5. Height transducer: 2 Nos 6. Versine transducer: 2 Nos 7. Tamping depth transducer: 2 Nos 8. Rear Lining chord follow up compensation transducer - 1 no

Limitations of 08 -275 UNIMAT-3 S Though 08 -275 UNIMAT-3 S has solved the problem of turnout side to avoid damage to sleepers and also to avoid manual lifting of side, but turnout side need to be packed by bringing the machine on turnout track, thus this leave a gap in tamping of straight as well as deflecting track. This drawback has been removed in the further improved models of UNIMAT-4 S.

UNIMAT COMPACT or MPT (Multi Purpose Tamper) Old series Old Series (MPT-2000 to 2008 ) was introduced on Indian Railway in year 1999

UNIMAT SH MFI or MPT (Multi Purpose Tamper) New series . New Series (MPT-2009 to 2012) was introduced on Indian Railway in year 2012

Main Features • Tamping of plain track. • Tamping of Turnouts. • It can carry 4 -rails of 6. 5 m length taken to site. • It can carry 12 Track Men with their tools. • Track material like X-ing, SEJ, Glued joint and sleeper can be carried to site. • Welding site DG set and all other small machine can also be taken to site.

Main Features: • Old series MPT (UNIMAT COMPACT) in Indian railways is MPT-2000 to 2008. • New Series MPT (UNIMAT SH MFI ) UNIMAT Slit Head Multi Functioning for India is 2009 to 2016. • Both Series can tamp plain track as well as point and crossing. • Old series has a small 1 tone capacity crane for loading and unloading Rail pieces of about 6. 5 meter long. • New Series MPT has a small 2 tone capacity crane for loading and unloading Rail pieces of about 6. 5 meter long. • Old series MPT has tool tilt able taming unit while new series MPT has split head tamping unit.

Main Features: • Old series MPT has 8. 5 degree axial movement in taming unit while new series MPT has not axial movement facility. • Both Series can carry 12 workers to site of work with their tools. • Old Series has no roller clamps while new series has roller clamps. • In old series MPT working direction is reverse while In New Series MPT working direction is forward. • Old series MPT has no ALC while new Series MPT has ALC.

Technical Data LENGTH : 20. 270 M WIDTH : 3. 100 M HEIGHT : 3. 700 M DISTANCE BETWEEN BOGIE PIVOTS : 12. 000 M WHEEL DIA : 0. 730 M WEIGHT : 46 TONNES ENGINE CUMMINS : KT 855 SPEED POTENTIAL : 80 KMPH

WORKING PRINCPLE DRIVING: RUN DRIVE: - BY HYDRODYNAMICS (ZF) IV SPEED GEAR BOX. WORK DRIVE: - BY HYDRAULICS MOTOR WITH CONSTANT SPEED. NORMALLY TWO MOTORS ARE WORKING BUT ON GRADIENT THIRD MOTOR IS APPLIED LINING: SINGLE CHORD LINING SYSTEM WITH PNEUMATIC FOLLOW UP SYSTEM LEFT OVER ERROR IS VERY LESS (FR = FD/7. 6) LEVELLING: - DOUBLE CHORD FIXED TYPE SYSTEM THIRD RAIL LIFTING ARRANGEMENT IS GIVEN WHICH CAN LIFT ADJACENT RAIL AND PACKED MANUALLY

Power Transmission P 3 Reduction Gear Box ZF GEAR BOX ENGINE P 4 P 1 M P 2 PTO Distribution Gear Box M M Running Bogie Driving Bogie

Difference between UNIMAT and MPT: UNIMAT Especially for turn outs tamping. It has three cabins. It has no jib crane It has third rail lifting and tamping arrangement. All UNIMAT working direction is reverse. It can not carry 12 workers to site of work with their tools. For working two operators are required. MPT It is used for spot tamping i. e. both turn out and plain track. It has only two cabins. It has jib crane 1 ton/2 ton capacity. It has no third rail lifting and tamping arrangement. Old MPT working direction is same as UNIMAT while New MPT working direction is forward. It can carry 12 workers to site of work with their tools. For working only one operators is required.

PCBs and their functions Sl. No. PCB Part No. Function 1. Tamping unit control PCB EK 176 V-00 2. Leveling circuit control PCB EK 2041 LV 00 3. Pendulum Control PCB EK 2042 LV-00 a 4. Front input EK 3049 LV-002 a 5. Lining control EK 1. 1/17 LV-00 6. Over slew lining PCB EK 2140 LV-00 7. Hook control EK 120 V-00 8. Drive control EK 3045 LV-00 9. Speed control card EK-197 V-00

Electrical System 1. Battery: - 12 V/ 180 AH, 2 Nos 2. Alternator: - 28 V/55 A 2 Nos ( Bosch make) 3. Self starter: 1 No. 4. Pendulum: 2 Nos 5. Height transducer: 2 Nos 6. Versine transducer: 2 Nos 7. Tamping depth transducer: 2 Nos 8. Rear Lining chord follow up compensation transducer - 1 no

08 - 475 UNIMAT- 4 S 08 -475 UNIMAT- 4 S was introduced on Indian Railway in year 2009

Salient Features other than 08 -275 UNIMAT and 08 -275 UNIMAT-3 S • 2 bogies of 2 -2 Axles & one idle axle. • Fully automatic tamping cycle (plain track). • (Adjustment automatic system) SJA systems. • ALC system. • Toeing speed 100 km/hrs as per OEM. • 4 -rail tamping in addition to 3 -rail lifting. • Out put two turn out/hr. • CMS ( Computer Measurement System) • Universal Tamping Unit • 4 working pedal • SPS Diagnosis system (PC Diagnosis Programme) • Four tamping units working independently. • Telescopic jibs to extend the outer tamping units. • Tamping units can be adjusted to slanting sleepers from the operator’s seat

Main Assembly Engine – 2 Nos. (1) Cummins KTA-1150 L 350 W, 2100 RPM (2) Additional Engine Kirloskar 6. 8 KW Fuel Tank Capacity – 3000 ltr. + 1 additional tank of 900 ltr. Capacity Tamping Unit – In 4 parts & each contains 4 tilt able tools. Lining & Lifting Unit- Same as 08 -275 UNIMAT and 08 -275 UNIMAT-3 S

Additional Engine Make- Hatz diesel engine Type- DA 16 1 B 40 Output-6. 8 Kw @ 3000 rpm Cooling-Air-cooled Stroke-Four-stroke Cylinder-1 cylinder It is used for emergency back up during failure of main engine and also machine can be worked drive i. e. by this working line can be cleared i. e. no requirement of loco engine.

Universal Tamping Unit Vertical locking Tensioning bolt, tamping unit frame Outer Tamping unit RHS Outer Tamping unit frame locking unit device, front & rear RHS

Universal Tamping Unit • The machine is equipped with universal tamping units capable of working on S & C’s and on plain track. These tamping units combine the advantages of the tilting tamping tools as necessary for switch tamping with those of the tool pairs used on plain track. • Tamping Unit in 4 parts & each contains 4 tilt able tamping tools. The two outer tamping unit parts can be slewed laterally 200 mm to the inside & 1500 mm to the outer side. • The two tamping unit parts can be slewed on guide columns 200 mm to inside & 640 mm to the outside of the machine. • Each tamping unit parts can tilt 8½ 0. in either side. • Each tamping tool can tilt 150 inside & 850 out side.

Additional three-point lifting unit This device serves to execute an automatic additional lift for a S & C without support onthe ballast bed. Depending on the direction of work of the tamping machine, the liftingdevice may be used on the left or right side of the machine next to the combined lifting andlining unit

Driving Run Drive – By Hydrodynamics (ZF) IV Speed Gear Box. Work Drive – Three Hydraulic Motors are provided. Machine work in constant speed. Working principle- Same as 08 -275 UNIMAT and 08275 UNIMAT-3 S

Power Transmission Engine ZF gear box Axle Distributer & Reduction gear box Hyd motor Hydraulic motor Axle gear box

HYDRAULIC SYSTEM HYDRAULIC PUMPS 1. Hydraulic Pumps 2. Hydraulic Pumps 3. Hydraulic Pumps 4. Gear Pumps 24 x 14 – 1 No. 38 x 22 x 14 – 1 No. 20 x 14 – 1 No. 24 LPM – 1 No. ( Connected to additional engine for back up) HYDRAULIC MOTORS: 1. For Driving – 3 Nos. 2. For Vibration – 4 Nos. 3. For AC = 2 Nos. 4. Engine Radiator – 1 No. 5. For two alternators – 1 No. ( 120 A + 55 A) 6. 01 hyd. Cooler + 01 ZF Cooler = 02 Nos

HYDRAULIC SYSTEM Suction filters Hys-501 -460 -150 H – 3 Nos. Return flow filter Hys-501 -330 -10 A/H – 1 Nos. Filter Elements Hyd-501 -32 -10 ES – 2 Nos. Filter Hyr-508 -05 -01 – 3 Nos. Filter DL-40 -60 E – 2 Nos. Filter Hyd-501 -225 -25 – 1 No. Filter (Diesel) Hyd-506 -10 -30 – 1 No. ACCUMULATOR: 1. 85 bar 32 ltr capacity – 2 Nos. 1. 85 bar 20 ltr capacity – 1 No. SPECIAL VALVE: Servo Valve 3 Nos. Proportional Valve – 4 Nos. HYDRAULIC PRESSURE Vibration Pressure – 185 bar Squeezing Pressure – 130 -140 bar Big Squeezing – 150 bar AC - 10 bar Cardon Shaft – 5 Nos.

PNEUMATIC SYSTEM Two cylinder compressor Use: (i) For Brake System (ii) Lifting & Lowering of Trolleys (iii) For locking & unlocking of trolleys (iv) For warming device. (v) For horn (vi)For locking & unlocking of Tamping (vii) For Datum

ELECTRICAL SYSTEM 1. Battery: - 4 nos (12 V/220 AH-2 nos, 12 V/72 AH-2 nos) 2. Alternator: - 28 V/55 A 2 nos 28 V/120 A 1 no. 3. Self starter: 1 no. 4. Pendulum: 3 nos 5. Height transducer: 2 nos 6. Versine transducer: 2 nos 7. Tamping depth transducer: 4 nos 8. Front and rear Lining chord follow up compensation transducer - 2 no

Works required Before, During and After deployment of Points & Crossing Tamping Machine Pre-Requisites: • A minimum cushion of 150 mm of clean ballast. • Planning and execution of deep screening of ballast, as well as training out of ballast should be done well in advance. • Sanction of CRS for the working of new type UNIMAT Machine. • Traffic blocks of adequate duration shall be planned. • The sleepers shall be uniformly spaced.

Pre-Tamping Operations • Tamping of turnouts shall be planned to cover sufficient length of approach track. In case of the turnout leading to loop line, the turn in-curve shall also be tamped. • Layout including spacing of sleepers as per relevant drawings shall be ensured. The nose of the crossing may get battered or worn or the sleepers below it may get warped or bent. In such cases, the crossing should be reconditioned or replaced and sleepers below the crossing should be attended. • High points on the turn out and approaches should be determined and general lift should be decided. • Minimum general lift 10 mm must be given.

Operations During Tamping: • For packing turnout, main line is to be tamped first. While tamping mainline, the additional lifting arrangement lifts the turnout side rail also. The lifted end of sleepers should be adequately supported on wooden wedges till it is packed/tamped. • The machine carries out correction of alignment and levels on main line portion. On the turnout side, only tamping without lifting and lining shall be done. • The squeezing pressure to be applied is as follows: (a) ST sleepers/wooden sleepers: 110 -115 bar ( b) PSC sleepers: 135 -140 bar • In case there is hindrance to achieve adequate penetration of tool, penetration assistance system should be used to facilitate insertion of tools in ballast and to accelerate lowering of tamping units. • During and before tamping, S&T and Electrical staff should also be associated to complete their portion of work

Post Tamping Operations • Checking and tightening of loose fittings. • Replacement of broken fittings. • The ballast shall be dressed neatly. Proper consolidation of ballast between the sleepers shall be done. • Final track parameters should be recorded with the help of recorders provided in the tamping machine. If the recorder is not available, then track parameter of at least four stretches of 25 sleepers each per kilometre of tamped track should be recorded. In addition, the versines and super-elevation of curves shall be recorded for at least ten stations at a specified cord length. • The fixtures like check rails removed during pre-tamping operation should be restored. • All S&T/Electrical connections removed before tamping shall be restored back.

Points to checked by Track Machine Officers during Inspection of UNIMAT Machine Engine: • Lube Oil Pressure : (i) 1 to 2 bar at idle speed (ii) 3 to 7 bar at full RPM • Max. engine temperature during working. • General condition of engine • Observance of maintenance schedules and their quality. Hydraulic system: • Hydraulic pressure in various units and leakages: System Pressure- 120 to 140 bar Squeezing pressure- 135 to 140 bar for PSC Sleepers Vibration Pressure- 150 bar in UNIMAT- 2 S/3 S 185 bar in UNIMAT-4 S • Max. hydraulic temperature during working. • Whether hydraulic filters have been changed/cleaned as per schedule or not. • Condition of various types of hoses and their assemblies.

Points to checked by Track Machine Officers during Inspection of UNIMAT Machine Pneumatic System: • Air pressure and leakage. • Functioning of brakes. • Locking and Unlocking of various system. • Functioning of horns. Electrical system: • Condition of batteries and charging system. • Condition Cord wires of various types transducers. • Condition of Lining and levelling cord. General points: • General condition of the machine. • Functioning of all safety devices. • Functioning control unit and measuring units. • General cleanliness of the machine. • Tightness of the nuts and bolts of all moving and vibrating items.

Points to checked by Track Machine Officers during Inspection of UNIMAT Machine • Condition of Tamping tools, lifting roller clamps and lifting hooks. • Track parameters and output of machine. • Quality of pre and post attention in track for machine working. • Safety aspects (Rules of Protections, Safety equipments, knowledge of safety rules). • Maintenance register pertaining to the machine. • Inspection of machine store. • Welfare aspects for the staff accommodation and other facilities. • Adequate safety of staff working in block section against danger of incoming trains on adjacent lines. • Competency certificate of machine operator.

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