Master Copy for IRTMTCALD by IRICEN Utility Track

Master Copy for IRTMTC/ALD by IRICEN

Utility Track Vehicle (UTV) Machines General – It is a self-propelled 4 -wheeler vehicle with crane used for loading and unloading and transportation of P. way materials like rail, sleeper and other heavy materials. It has the capability to attach and haul one BFR or similar railway wagon for holding the material

Utility Track Vehicle (UTV) Machines Models of UTVs – Presently 9 models of UTV‘s of different manufacturers are working over Indian Railways. 1 -UTV-502 with mobile cranes by Tamper Corporation, USA. 2 -UTV with fixed crane (11. 25 tm capacity) by Phooltas Tamper, India. 3 -UTV with mobile crane (11. 25 tm capacity) by Phooltas Tamper, India. 4 -UTV with fixed crane (15 tm capacity) by Phooltas Harsco, India. 5 -UTV by BEML India. 6 -UTV by BHEL India. 7 -UTV by OEPL India. 8 -UTV by Trident Engineering (11. 25 tm). 9 -UTV by SAN Engineering (11. 25 tm).

Main Assemblies of UTV and their Functions Cabin – Cabin is provided on one side only. The cabin has seating arrangement for staff. Platform – Platform is the flat portion of the UTV, where material can be stacked. Loading and unloading of materials can be done either on the platform or on railway flat wagon attached with UTV. Crane – There are different models of UTVs. Some of the earlier models of UTV had mobile crane (crane with tyred wheels mounted on flat wagon) of capacity of 1. 5 t at 7. 5 m radius. Current models have fixed type of crane. It is installed on platform, having multi stage extension. Crane has its own power pack for its operation. The crane capacities of some machines are 1. 5 t at 7. 5 m radius i. e. 11. 25 tm while of others is 2 t at 7. 5 m radius. It is further planned to increase the crane capacity for handling a set of stock and tongue rail (3 t at 7. 5 m i. e. 22. 5 tm). Engine – The vehicle has one diesel-operated prime mover with watercooled engine for the driving the vehicle and also for crane operation.

Power Transmission of UTV Power Transmission – Hydrodynamic power transmission system provided for transit driving and for working in the section. Both axles of vehicle are powered. Brake System – Following brake system is provided on UTV Machine: Direct Brake (service brake) – This brake is applied directly by hand operated valve (SA 9) to all brake cylinders of both the axles through pneumatic relay (C 2 W) when machine is running. Indirect Brake for Coupled Coach/Wagon – Indirect brake (A 9) is applied on both machine and coupled coaches/wagon in new machine. In old machine, this brake is applied separately for camping coach/wagon, in addition to machine brake. Parking Brake – Two spring loaded separate cylinders are mounted on both the wheels of one axle of the machine. This brake is applied automatically when air of these cylinders released or when air system pressure drops below 3. 5 bar. Emergency Brake – This is applied directly on the machine in the case of emergency for immediate stopping. Vacuum Brake – A separate power pack with own circuit is provided and applied when camping coach/wagon is having vacuum brake system.

Working Principle of UTV • The UTV shall be self-propelled, bi-directional, 2 -axle, fully rail borne vehicle for picking up of P. Way material from midsection, and for transportation of men, material and equipment. • There should be a loading platform on the UTV machine itself so that it is possible to carry at least two numbers 6. 5 meter long rails and one number CMS crossing along with fracture repair equipments loaded on the UTV machine itself. This requirement is important as in some cases UTV may be required to move in the block section alone, without any attached wagon, in that case it shall be possible to carry necessary equipment’s and materials loaded on the UTV machine itself. The crane fixed on the machine (UTV) should be capable of efficiently handling the equipment’s and

DESCRIPTION • The loading platform should be provided allaround with a sidewall/Railing of about 45 to 60 centimeters height to protect the men and materials from falling. • The UTV shall be provided with adequate space on loading platform with proper lock and key arrangement for keeping the tools, equipments and spares required for on-site repair of the machine and other working requirements.

CRANE • The UTV shall have a fixed crane mounted on it. The crane shall be capable of lifting 3. 0 t load over front at such a minimum radius so as the lifting hook to be 7. 5 Mts. away from the end buffer of UTV on one side (non cabin side). • The crane operation should be such that there is no infringement to over head electric equipment during crane maneuvering/extension/shortening and there is no infringement to the Indian Railways Schedule of Dimensions– 1676 mm gauge(BG), revised, 2004 with latest corrigendum and up to date correction slips issued, on the adjacent track at 4265 mm track centers. In case there is a possibility of boom getting lifted to infringe the overhead electric equipment, suitable safety device, to prevent such an eventuality, should be provided.

Rail Borne Maintenance Vehicle(RBMV) General – Indian Railway RBMV manufactured by Phooltas. This is an 8 wheelers vehicle designed for running at maximum speed of 105 kmph. This is designed to carry men, material and tools and plant to worksite for attention of track

Main Features of RBMV • It has payload capacity of 15 t. • It has space for carrying 2 rails of 13 m length of 60 kg or two sets of switch and stock rail assembly along with fittings. • One cabin to hold small track machines, tools and equipment, P. Way materials as listed for Mobile Maintenance Unit (MMU). • Seating arrangement (12) for officials accompanying RBMV in the other cabin. • Fitted with hydraulic crane for material handling with 1 t at 8 m lifting capacity. • Has diesel operated Portable generator of 5 KVA for general lighting, welding & other works.

Main Assemblies of RBMV and their Functions • Drive Cabin – One driving cabin each is provided at both ends of the vehicle for driving ineither direction. • Cabin for Men and Material – Two additional cabins are provided, one for keeping P. Way materials, tools and plant and other for crane operating cabin with staff seating arrangement. 12 Nos. of staff can be accommodated in the staff cabin. • Crane – One hydraulic pillar jib crane is installed on this vehicle in the middle of flat platform, having multi-stage extension. Crane has its own power pack for operation. Loading and unloading of materials is done on own platform as no BFR can be attached with RBMV. • Engine – The vehicle has two diesel engines, which are in under slung position; Cummins model No. NTA 855 R. Each engine drives one bogie through independent power transmission.

Power Transmission of RBMV • Power Transmission – RBMV has two hydrodynamic power transmission systems provided for driving as well as working in the section. These transmission systems are powered by independent prime movers giving power to each transmission gearbox. • Brake System – Following brake system are provided on RBMV Machine: – Direct Brake (service brake) – This brake is applied by control lever SA 9 on the both bogies of the machine through pneumatic relay C 2 W while running. – Indirect Brake – This is indirect brake is applied on machine with coupled camping coach /wagon automatically through pneumatic relay C 2 W when air pressure of BP line releases through valve A 9 or drops. – Parking Brake – Two springs loaded separate cylinders are mounted on each bogie of machine. This brake is applied automatically when air of these cylinders released or when air system pressure drops below 3. 5 bar. – Emergency Brake – This is applied directly on the machine in the case of emergency for immediate stopping.

Works required Before, During and After Deployment of UTVs and RBMVs – P. Way materials to be handled should be collected and stacked at locations within the reach of crane boom in advance. – Availability of material handling slings and other such attachments should be checked and ensured before going for the block. – Support posts in flat wagons with UTV’s /foldable side wall in RBMV’s which infringe in loading of material shall be lowered before starting material handling at site. – Centre line of rail piece to be handled shall be marked.

Works required Before, During and After Deployment of UTVs and RBMVs – Longer rails shall be cut to pieces of less than 13 m length. – It should be ensured that the vehicle is stabilised and parking brakes are ON before operation of the crane. – The crane should not be used in strong wind blowing at more than 50 kmph. – The operator should have a clear view of the work area and ensure that no one is there within the operating radius of the crane.

Works required Before, During and After Deployment of UTVs and RBMVs – The stability of the crane vehicle should be constantly checked during the manoeuvres. – The operator should check the details of load to be lifted and the radius of operation as per the load distance diagram. – The operator should be careful while working near electric power cables. – The operator should never leave the machine unattended when boom is extended and the load is lifted from the groun If it becomes unavoidable, he must manoeuvre the load to ground and turn-off the vehicle.

Works required Before, During and After Deployment of UTVs and RBMVs – Loading/unloading and material handling should preferably be done to/from cess side of track. In case of handling material in between two tracks or beyond on adjacent running track side, proper track protection on adjacent track should be done. – Crane movement to infringing side shall be locked during working. – The single point slinging should be avoided to avoid risk of bending and damage to rail surface. The overhang should not be more than one half the distances between two lifting points. – Loading of rails and sleepers on BFR in UTV’s & on RBMV’s should normally be limited to 4 and 3 layers respectively. – The rails should be kept horizontal and straight while lifting/moving.

Works required Before, During and After Deployment of UTVs and RBMVs – Support posts/foldable side wall if any shall be lifted up or rails shall be tied up with chain to secure rails after completion of loading, before movement. – Loading should be uniformly distributed and eccentric loading should be avoided. – Crane shall be handled carefully in the electrified territory and station yards. – The staff should not stand below the suspended load for their safety. – The staff should wear protective gloves and industrial shoes to minimise the risk of injury.

Items Specifice to UTV • SSE/JE(P. Way) should work as guard on the machine. The guard along with the machine staff should be deputed on the BRN for safety when the machine moves towards the crane side with an attached BRN. • The flat wagon should have a valid BPC for the movement. • BRN should be provided with detachable hand brake operating lever.

Items Specific to RBMV • . • All tools and plants as prescribed for Mobile Maintenance Unit (MMU) should be available in working order. • Pay Load should not be more than 15 t. The staff should wear distinctive colour helmets and clothing for easy identification by crane and machine drivers to avoid accidents.

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