SMALL TRACK MACHINES Features Mechanized maintenance of track

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SMALL TRACK MACHINES

SMALL TRACK MACHINES

Features • Mechanized maintenance of track was introduced in early sixties. • Track machines

Features • 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.

SMALL TRACK MACHINE-SETUP At HQ level • Under the overall charge of CTE or

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.

Need for STM • To fill working gap between heavy track machines & manual

Need for STM • To fill working gap between heavy track machines & manual working. • Difficulty in maintenance of heavy track structure with conventional method. • To have compatible maintenance system between track machine maintenance. • To assist sectional gang with machines for travel, transport, handling of materials, lifting, levelling, lining & packing of track at isolated locations.

Need for STM • Due to heavy axle load & increase in traffic density,

Need for STM • Due to heavy axle load & increase in traffic density, frequent attention at isolated locations is needed in less available time & manpower. • Effective in restoration, accidents & unusuals. • Improves productivity, quality & safety of track operations. • Shortage of manpower/labour. Age factor of existing track men. • Change in attitude of working class towards hard manual labour.

VARIOUS SMALL TRACK ACHINES Machines For Operations on RAIL Machines For Operations on Sleeper

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 • • •

MACHINES FOR OPERATIONS ON RAIL 1. 2. 3. 4. 5. Abrasive rail cutter. Rail

MACHINES FOR OPERATIONS ON RAIL 1. 2. 3. 4. 5. Abrasive rail cutter. Rail cutting machine (Saw type). Rail drilling machine. Chamfering kit. Hydraulic rail tensor (Non-infringing type), 70 t capacity. 6. Hydraulic rail bender ( Jim crow), heavy duty.

Abrasive Rail Cutter

Abrasive Rail Cutter

Abrasive Rail Cutter Salient features: • Prime mover - A petrol engine of about

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.

Abrasive Rail Cutter • No. of cuts per disc- Minimum 7 cuts on 52

Abrasive Rail Cutter • 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.

Rail Cutting Machine (Saw type)

Rail Cutting Machine (Saw type)

Rail Cutting Machine (Saw type) Salient Features: • Prime mover— Petrol start, kerosene/petrol run

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 • Cutting time for each cut-- -- 70 Kg Maximum time is 30 minutes.

Rail Cutting Machine (Saw type) • Tolerance of squareness both vertical and lateral -+1.

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 V 2 as per IS: 7291 -1981. • The blades should be of ‘All hard (Type A) conforming to IS: 2594: 77 (Specifications for hacksaw blades).

Rail Cutting Machine (Saw type) Cutting performance: Size Number of cuts 300 x 25

Rail Cutting Machine (Saw type) Cutting performance: Size Number of cuts 300 x 25 x 1. 25 x 2. 5 (10 TPI) 12 (52 kg, 72 UTS) 300 x 25 x 1. 25 x 2. 5 (10 TPI) 15 07 (52 kg, 72 UTS) or (52 kg, 90 UTS) 300 x 32 x 1. 60 x 4. 0 (6 TPI) 08 (52 kg, 90 UTS)

Rail Drilling Machine

Rail Drilling Machine

Rail drilling machine Salient Features: • Overall weight -- 65 Kg ( Approx. )

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)

Rail drilling machine • Fuel consumption - Minimum 10 holes in 60 Kg/90 UTS

Rail drilling machine • Fuel consumption - Minimum 10 holes in 60 Kg/90 UTS 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

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

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

Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) Use: Hydraulic tensor is used for

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

Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) • The main components of the

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.

Hydraulic Rail Tensor, 70 t capacity (Non-infringing type) Salient features : • Maximum total

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.

Chamfering kit

Chamfering kit

Chamfering kit Description Of Items: 1. H. T. Bolt, 2. H. T. Nut, 3.

Chamfering kit 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.

Chamfering kit Use : Chamfering kit is a tool used for chamfering and work

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

Hydraulic Rail Bender (Jim Crow), Heavy duty Use: It Is used for bending/de-kinking of

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

Hydraulic Rail Bender ( Jim Crow), Heavy Duty Salient features : • Bending force

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

Machines For Operations On Sleeper 1. Hydraulic sleeper spacer, 2. Concrete sleeper breaker

Machines For Operations On Sleeper 1. Hydraulic sleeper spacer, 2. Concrete sleeper breaker

Hydraulic Sleeper Spacer Use: It is used for re-spacing/squaring of sleepers.

Hydraulic Sleeper Spacer Use: It is used for re-spacing/squaring of sleepers.

Hydraulic Sleeper Spacer Salient features : • • Weight (without operating lever and reaction

Hydraulic Sleeper Spacer Salient features : • • Weight (without operating lever and reaction rods) : 14 Kg ( maximum), Rated capacity : 8 tonnes, Length of hydraulic jack in closed position : 200 mm, Hydraulic lift : 125 mm, (Travel of ram), Screw extension : 75 mm (Minimum), Time for squaring the sleeper : 5 – 7 min. , including fixing and removal, Base size : 150 mm x 140 mm

Hydraulic Sleeper Spacer Components: 1. 2. 3. 4. Hydraulic Jack Back plate Saddle Cap,

Hydraulic Sleeper Spacer Components: 1. 2. 3. 4. Hydraulic Jack Back plate Saddle Cap, Reaction rods. Man Power : Of 8 t capacity, With tapered thickness, Skilled : 01 Unskilled : 01

Concrete sleeper breaker and angle grinder

Concrete sleeper breaker and angle grinder

Concrete Sleeper Breaker And Angle Grinder Use: 1. It is used primarily for breaking

Concrete Sleeper Breaker And Angle Grinder Use: 1. It is used primarily for breaking the concrete sleepers into pieces thereby facilitating quick removal of damaged concrete sleepers and restoration of Railway Track in case of accidents/derailments and other emergent situations. 2. It can also be used for breaking brick work, asphalt and rocks.

Concrete Sleeper Breaker And Angle Grinder Description: It is an electrically/ engine (Petrol or

Concrete Sleeper Breaker And Angle Grinder Description: It is an electrically/ engine (Petrol or diesel) driven breaking equipment which imparts vibrational impacts through a drill bit/chisel to break concrete sleepers/pavement/brickwork into pieces. Weight : 30 kg (Approx) Man Power : Skilled : 01 Unskilled : 01

MACHINES FOR WELDING OPERATIONS – Portable DC welding generator, – Double action weld trimmer

MACHINES FOR WELDING OPERATIONS – Portable DC welding generator, – Double action weld trimmer for AT welding (Power pack version), – Rail profile weld grinder.

Portable DC welding generator

Portable DC welding generator

Portable D. C. Welding Generator Use: 1. It is a portable generator for producing

Portable D. C. Welding Generator Use: 1. It is a portable generator for producing DC current for the operation of arc welding equipment for reconditioning of points and crossings at site. 2. It has also an auxiliary AC unit for producing alternating current required for miscellaneous applications i. e. Lighting at worksite, operation of electrically driven devices like rail profile grinder, rail drilling, cutting machine etc.

Portable D. C. Welding Generator Description: 1. 2. 3. 4. 5. I. C. Engine,

Portable D. C. Welding Generator Description: 1. 2. 3. 4. 5. I. C. Engine, An alternator, Control panel, Tubular frame with 4 nylon wheels, 2 double flanged wheels. Weight: Max 150 kg Man Power: (Excluding transportation arrangement) Skilled : 01 Unskilled : 01

Portable DC welding generator Salient features : • • • Engine : 15 h.

Portable DC welding generator Salient features : • • • Engine : 15 h. p. Petrol/Diesel/kerosene run engine. Range of welding current: 60 to 200 amp. Rated current : Maximum welding current shall not be less than 200 amp at 60% duty cycle. Current regulation : Current is regulated by regulating switch/device with graduation to show the magnitude of current range. Open circuit voltage : Max. 100 V. Auxiliary output : 2500 watts at 220 -240 v (A. C. ) at 50/60 Hz.

Double action weld trimmer for AT welding (power pack version)

Double action weld trimmer for AT welding (power pack version)

Double Action Weld Trimmer For AT Welding (Power Pack Version) Use: This machine is

Double Action Weld Trimmer For AT Welding (Power Pack Version) Use: This machine is used for trimming the extra weld metal from rail (Top and sides) of AT welded rail joint after the welding operation. Components: 1. Trimming Unit, 2. Power Pack- a) Hydraulic pump, b) An engine. Man Power: Skilled: 01 Unskilled: 01

Double Action Weld Trimmer For AT Welding (Power Pack Version) Salient features : •

Double Action Weld Trimmer For AT Welding (Power Pack Version) Salient features : • • Prime mover : Petrol start kerosene/petrol run engine of minimum rating 3 HP. Hydraulic stroke : 120 -150 mm Minimum shearing force : 18 tonnes Total weight : 175 Kg (Max. ) Life of shear blade : Trimming of minimum 200 joints The machine is also provided with emergency hand pump device which can be used in case of failure of power pack for retrieving the trimming unit. Tolerance before grinding : Top of rail head + 0. 5 mm to + 1. 5 mm Side width of rail head+ 1. 00 mm to + 2. 0 mm

Rail Profile Weld Grinder

Rail Profile Weld Grinder

Rail Profile Weld Grinder Use: It is used for grinding of A. T. welded

Rail Profile Weld Grinder Use: It is used for grinding of A. T. welded joints after weld trimming operation is complete. Components: 1. Grinding Unit, 2. An engine/electric motor, 3. Feed screw, 4. Frame. Man Power: Skilled : 01 Unskilled: 01

Rail profile weld grinder Salient features : Power pack : Generator or A. C.

Rail profile weld grinder Salient features : Power pack : Generator or A. C. supply. Weight including power pack: 80 Kg (Maximum) • Grinding tolerance : – 0. 5 mm on top of rail head, gauge and non gauge faces with 1 metre straight edge. – 0. 2 mm on top of rail head with 10 cm straight edge. – 0. 3 mm on gauge and non gauge faces of rail head with 10 cm straight edge • Grinding time : 15 minutes (max. ). • •

Machines For Operation On Fittings – Heavy duty hydraulic extractor for jammed ERCs, –

Machines For Operation On Fittings – Heavy duty hydraulic extractor for jammed ERCs, – Toe load measuring device (Mechanical), – Toe load measuring device (Electronic).

Heavy Duty Hydraulic Extractor For Jammed ERCs

Heavy Duty Hydraulic Extractor For Jammed ERCs

Heavy Duty Hydraulic Extractor For Jammed ERCs Use: It is used to remove jammed

Heavy Duty Hydraulic Extractor For Jammed ERCs Use: It is used to remove jammed ERCs from concrete sleepers without any damage to sleeper. Components: 1. Feed rod/pin. 2. Hydraulic ram, 3. Pump, 4. Heavy and strong frame. Man power: Skilled : 01 Unskilled : 01

Heavy Duty Hydraulic Extractor For Jammed ERCs • Salient Features: • Maximum weight :

Heavy Duty Hydraulic Extractor For Jammed ERCs • Salient Features: • Maximum weight : 40 Kg • Extraction force exerted on clip : 10 tonnes ( minimum) • Extraction stroke : 20 mm (min) • Time taken for removing jammed ERC including fixing & removing : 5 -10 min.

Toe Load Measuring Device Mechanical

Toe Load Measuring Device Mechanical

Toe Load Measuring Device Use: This machine is used to determine the toe load

Toe Load Measuring Device Use: This machine is used to determine the toe load of elastic rail clips during service in the field. Components: 1. Pre calibrated helical spring, 2. Steel pointer, 3. Link hanger, 4. Rotating hanger, Toe Load -- Displacement of the pointer x Spring constant.

Toe Load Measuring Device Salient Features: 1. Weight (Max. ) - 12 kg 2.

Toe Load Measuring Device Salient Features: 1. Weight (Max. ) - 12 kg 2. Capacity of the spring to measure the load - 1400 kg 3. Material of the main spring - Silico manganese spring steel conforming to Grade -55 of IS: 3195 -1992 Man Power : 1 skilled.

Electronic Toe Load Measuring Device

Electronic Toe Load Measuring Device

Electronic Toe Load Measuring Device Use: It is used to measure the toe load

Electronic Toe Load Measuring Device Use: It is used to measure the toe load of elastic rail clips in service. Components: 1. Load cell, 2. LCD panel, 3. Lever arrangement, 4. Rotating handle. Man Power: Skilled: 01

Electronic Toe Load Measuring Device Salient Features: 1. Load cell capacity : 2000 kg,

Electronic Toe Load Measuring Device Salient Features: 1. Load cell capacity : 2000 kg, 2. Operating temperature : -5 to + 70 degrees, 3. Measurement accuracy : + 0. 5% of rated capacity. 4. Display : 8 or 16 alphanumeric display, 5. Sensitivity : Fast return to zero, 6. Operating source : Rechargeable battery pack.

Machines For Lifting And Slewing – Mechanical Track Jack, – Hydraulic Track Jack, –

Machines For Lifting And Slewing – Mechanical Track Jack, – Hydraulic Track Jack, – Portable Track Lifting and Slewing Device (Tralis).

Mechanical Track Jack

Mechanical Track Jack

Mechanical Track Jack Use: It is used for lifting of track during track maintenance/construction

Mechanical Track Jack Use: It is used for lifting of track during track maintenance/construction work like spot attention, picking up slacks in isolated patches. Types : 1. Rack and pinion, 2. Rack and Pawl.

Mechanical Track Jack Components: 1. Rack And Pinion: a) Frame, b) Base plate, c)

Mechanical Track Jack Components: 1. Rack And Pinion: a) Frame, b) Base plate, c) Pinion through a gear train, d) External handle. 2. Rack And Pawl: a) Frame, b) Base plate, c) Pawl, d) Operating handle. Both the jacks are non-infringing type. Man Power: Skilled : 01 Unskilled : 01

Mechanical Track Jack Salient features: • • • Minimum lifting capacity Height of top

Mechanical Track Jack Salient features: • • • Minimum lifting capacity Height of top of jack in lowest position : 250 mm (maximum) Height of toe of jack in lowest position : 120 mm (maximum) Area of base plate : 155 mm. X 300 mm (Approx. ) Length & size of operating handle : – – • • : (a) With top – 8. 0 t (b) With toe - 7. 0 t 1250 mm long, 30 mm dia. (for rack and pawl model), 800 mm long, 20 mm dia. (for rack and pinion model) Lift Weight (Without handle) : 100 mm (minimum) : 20 Kg. (Max. )

Hydraulic Track Jack

Hydraulic Track Jack

Hydraulic Track Jack Use: The hydraulic Track Jack (Non-infringing type) is used for lifting

Hydraulic Track Jack Use: The hydraulic Track Jack (Non-infringing type) is used for lifting of track in track maintenance/construction work. Components: 1. 2. 3. 4. Man Power: Hydraulic lifting arm, Hydraulic hand pump, Release key, Pre set safety release valve. Skilled: 01

Hydraulic Track Jack Salient Features: Items 10 tones Jack 15 tones Jack Capacity 10

Hydraulic Track Jack Salient Features: Items 10 tones Jack 15 tones Jack Capacity 10 tones 15 tones Closed height 166+3 mm Maximum hydraulic lift 80+ 3 mm Weight (Without handle) 10. 5+ 0. 5 kg 13. 5+ 0. 5 kg Base area 300 sq cm (Approx) Length of operating handle 750 mm (Approx)

Portable Track Lifting And Slewing Device ( Tralis )

Portable Track Lifting And Slewing Device ( Tralis )

Portable Track Lifting And Slewing Device ( Tralis ) Use: TRALIS is a hydraulic

Portable Track Lifting And Slewing Device ( Tralis ) Use: TRALIS is a hydraulic device used for lifting and slewing of Railway track and turnouts for maintenance and laying purpose. Components: 1. A pair of lifting cum slewing device : Man Power : Each comprising of one horizontal and one vertical jack. 2. Hydraulic pump : One. 3. High pressure rubber : A pair. Skilled – 01 Unskilled -- 01

Portable Track Lifting And Slewing Device (Tralis) Salient features: • Reaction Support plate size

Portable Track Lifting And Slewing Device (Tralis) Salient features: • Reaction Support plate size • • • : Min 400 x 200 x 50 mm Reaction Trough size : 140 x 300 mm Close Height : 230 mm (a) Vertical jack : - (1)Capacity : 10 tonnes (2)Hydraulic lift : 80 mm (b) Horizontal jack : - (1) Capacity : 5 tonnes (2)Hydraulic stroke : 100 mm (50 mm both side) Overall weight : 60 Kg (maximum) Capable of lifting and slewing a track / turnout by a single man.

MACHINES FOR TRANSPORTATION/ HANDLING OF MEN/MATERIAL – Self-propelled light weight trolley, – Powered material

MACHINES FOR TRANSPORTATION/ HANDLING OF MEN/MATERIAL – Self-propelled light weight trolley, – Powered material trolley, – Light weight rail (mono) cum road trolley,

Self-Propelled Light Weight Trolley

Self-Propelled Light Weight Trolley

Self-Propelled Light Weight Trolley Use: It is used by Railway officials for track inspection

Self-Propelled Light Weight Trolley Use: It is used by Railway officials for track inspection and to reach accident/work site quickly. Components: 1. Light metallic tubular frame, 2. Two sets of axles, 3. An IC engine, 4. Seating arrangements in front and rear.

Self-Propelled Light Weight Trolley Man Power Requirement: 1. For lifting and lowering the trolley

Self-Propelled Light Weight Trolley Man Power Requirement: 1. For lifting and lowering the trolley on/from the track 2. Trolley men with a valid competency certificate to drive the trolley : 2 men, : 1

Self-Propelled Light Weight Trolley Salient Features: 1 Track Gauge (Nominal) 1676 mm(BG)/1000 mm(MG) 2

Self-Propelled Light Weight Trolley Salient Features: 1 Track Gauge (Nominal) 1676 mm(BG)/1000 mm(MG) 2 Pay load capacity 400 kg (Minimum) 3 Seating capacity 2 in front and 2 in rear 4 Self weight 90 -95 kg 5 Speed Maximum 20 kmph 6 Engine Petrol/diesel/kerosene driven of minimum 2 HP capacity. 7 Fuel tank capacity Adequate for a run of 60 km. 8 Insulation Wheels/Trolley are insulated. 9 Brakes Foot pedal operated brakes or mechanical hand brake. It has mechanical parking brakes also.

Powered Material Trolley

Powered Material Trolley

Use: Powered Material Trolley It is used by P-Way staff for carrying small track

Use: Powered Material Trolley It is used by P-Way staff for carrying small track machines and tools for day to day track maintenance works. Components: 1. Platform made of light steel , aluminum alloy structure and chequered plates, 2. 4 wheels, 3. Seats, 4. Braking arrangements fitted on wheels, 5. An air cooled engine to run the trolley. Man Power: 8 men including at least one trolleyman/supervisor.

Powered Material Trolley Salient Features: Track Gauge 1676 mm Pay load capacity 1 tone

Powered Material Trolley Salient Features: Track Gauge 1676 mm Pay load capacity 1 tone (Minimum) Design speed 30 kmph but for P&Cs, diamond crossings etc, it is 10 kmph. Reverse speed 5 kmph Self weight 350 kg Fuel tank Adequate capacity for a run of 100 km. Seating arrangements Seat for 3 persons in front and 3 more persons in the rear of front seat. Lighting arrangement Head and tail lamps shall be provided. Braking system operated by foot pedal or mechanical hand brake. Trolley also has parking brakes.

Light Weight Rail (Mono) Cum Road Trolley

Light Weight Rail (Mono) Cum Road Trolley

Light Weight Rail (Mono) Cum Road Trolley Use: It is manually driven trolley to

Light Weight Rail (Mono) Cum Road Trolley Use: It is manually driven trolley to carry small track machines and can be moved on single rail or on ground. Components: 1. 2. 3. 4. 5. Fabricated rectangular frame, A set of 2 double flanged wheels for use on rails, 4 nylon wheels for use on ground and road, 4 separate axles, A Tubular detachable pushing handle. Man Power: 1 -3 (1 person is required to move the trolley and 1 -2 are required to load/unload the material carried.

Light Weight Rail (Mono) Cum Road Trolley Salient Features: 1. Double flange wheel tread

Light Weight Rail (Mono) Cum Road Trolley Salient Features: 1. Double flange wheel tread : 85 mm (Approx) 2. Flange depth : 12 mm (Approx) 3. Flange thickness : 5 mm (Approx) 4. Trolley frame size : 650 x 400 mm(Approx) 5. Weight of trolley : 17 kg (Max) 6. Load carrying capacity : 100 kg 7. Diameter of nylon wheel : 150 mm (Approx)

Machines For Track & Ballast – Hand Held Off-Track Tamper,

Machines For Track & Ballast – Hand Held Off-Track Tamper,

Hand Held Off Track Tampers

Hand Held Off Track Tampers

Hand Held Off Track Tampers Use: These are used for tamping of track for

Hand Held Off Track Tampers Use: These are used for tamping of track for slack picking in concrete sleeper track as a means of intermediate attention in between the runs of on track tampers. Composition Of 1 set: 1. 4 hand held tampers, 2. 2 external/internal power source (Electrical/hydraulic/mechanical engine) Man Power: Skilled- 06

Hand Held Off Track Tampers Salient features • (i) Tamper : • Weight of

Hand Held Off Track Tampers Salient features • (i) Tamper : • Weight of hand tamper • Weight of tamping tool • Power input • Impact rate ( Blow/min) • (ii) Power source : • Capacity • • : 12 Kg ( Approx) : 2. 5 Kg ( Approx) : Upto 1600 watts : 900 to 2200 (Adjustable) : 3. 6 KW, minimum at 230 V, AC at 7300 RPM Current output : Upto 8. 5 Amp Fuel : As specified by manufacturer. Starting mechanism : Rope start/self start. Continuous operating time : Not less than 4 hours.

Hand Held Off Track Tampers Using: 1. Site selection, 2. Pre-tamping operations, 3. Tamping

Hand Held Off Track Tampers Using: 1. Site selection, 2. Pre-tamping operations, 3. Tamping works, 4. Post tamping works, 5. Precautions in operation.

SMALL TRACK MACHINE MANUAL (JULY 2005) • First small track machines Manual (IRSTM) was

SMALL TRACK MACHINE MANUAL (JULY 2005) • First small track machines Manual (IRSTM) was published in July, 2005. • Revised in July 2005 • CS issued - 3

Aspects Covered in ‘‘Small Track Machine Manual’’ (July 2005) – Description and use of

Aspects Covered in ‘‘Small Track Machine Manual’’ (July 2005) – Description and use of 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.

1. The officers of Engg. Deptt. , dealing with small track machines shall have

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 CE/TMC Dy CE SEN/MC - COS, - CMM, - Dy COS and - SSO.

Procurement 2. The rules and procedure as laid down for procurement by the Stores

Procurement 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.

Procurement 4. The tender committee wherever necessary to be constituted with Engineering Officers of

Procurement 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.

6. The SMT/tools shall be procured only from manufacturers/suppliers approved by RDSO/RB as per

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. 9. It is desirable to have AMC of 5 years along with procurement to ensure satisfactory performance. Note: Items 6, 7, 8 and 9 will form part of tender conditions. GUIDELINES FOR VENDERS

Powers Of Emergency Repairs And Purchase Of Spares Incidental To Such Repairs The following

Powers Of Emergency Repairs And Purchase Of Spares Incidental To Such Repairs The following powers have been delegated: 1. PHOD, DRM ADRM Rs 25, 000/- instead of Rs. 1 lakh per breakdown with finance concurrence. 2. Dy CE/TT Rs 5, 000/- per breakdown without finance concurrence with annual ceiling limit of Rs 1 lakh. 3. XEN/TT Rs 2, 500/- without finance concurrence with annual ceiling limit of Rs 50, 000/-.

Powers Of Emergency Repairs And Purchase Of Spares Incidental To Such Repairs Note: a)

Powers Of Emergency Repairs And Purchase Of Spares Incidental To Such Repairs Note: a) The overall annual ceiling limit for purchase/repairs for each Zonal Railway is 5 lakhs/b) Cases exceeding 25, 000/- will require AGM’s sanction c) All other conditions laid down in para ii), iii) and iv) of Board’s letter no. 96/Track-III/TK/28 dated 09. 98 should be followed.

Sub Divisional Depot 1. Each sub division should have a Nucleus Depot, preferably at

Sub Divisional Depot 1. Each sub division should have a Nucleus Depot, preferably at the sub divisional HQ. 2. 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). 3. Required cash imprest and AMC shall be available to SE(Incharge) and AMC for all machines shall be arranged covering entire division. 4. At least 1 SE(SMT), 1 fitter with minimum 2 khallasis shall be posted for sub divisional depot within the existing manpower.

New Para Added Vide ACS-01 Para 1. 4. 2 - Divisional Depot: For major

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.

As per ACS-02: 1. AEN : Should inspect all STM once in 6 months.

As per ACS-02: 1. AEN : Should inspect all STM once in 6 months. 2. SE : Should inspect all the machines and tools once in 3 months.

Inspection 1. Sr. DEN/AENs shall pay special attention to repairs, maintenance and effective use

Inspection 1. Sr. 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.

Inspection 5. The problematic aspects of STM as brought out in PCDO shall be

Inspection 5. The problematic aspects of STM as brought out in PCDO shall be inspected by an officer nominated by Zonal HQ. 6. 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.

Para 1. 5. 2 added as per CS no. 3

Para 1. 5. 2 added as per CS no. 3

 • Sr. DEN(CO) shall organize for training of staff for operation, maintenance of

• 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 DTS and ZTS. • Centralized training for operation, maintenance and repairs of STM/tools shall be organized at Zonal Railway Training Centers/Divisional Training Centers.

Yardstick Of STM (Minimum) (Annexure-1, modified vide ACS-01) • Minimum yardstick of availability of

Yardstick Of STM (Minimum) (Annexure-1, modified vide ACS-01) • 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. • Such spare machines shall be frequently used so that they remain in good condition. • 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.

Yardstick Of STM (Minimum) (Annexure-1, modified vide ACS-01) S. N. Type Of Machine Minimum

Yardstick Of STM (Minimum) (Annexure-1, modified vide ACS-01) S. N. Type Of Machine Minimum Quantity 1. ABRASIVE RAIL CUTTER 2. ABRASIVE RAIL CUTTING WHEEL RAIL CUTTING MACHINE (SAW TYPE) AS REQUIRED. HACKSAW BLADE FOR CUTTING RAILS RAIL DRILLING MACHINE AS REQUIRED. 3. 4. 5. 3 PER SE (SUBURBAN) 1 PER SE (Other than sub urban) 1 PER ART 2 NOS. PER SE (OTHER THAN SUBURBAN), 1 PER ART 2 PER SE (SUBURBAN), 1 PER SE (Other than suburban), 1 PER ART.

 6. CHAMFERING KIT 1 PER SE 7. HYDRAULIC RAIL TENSOR (NON -INFRINGING TYPE),

6. CHAMFERING KIT 1 PER SE 7. HYDRAULIC RAIL TENSOR (NON -INFRINGING TYPE), 70 T CAPACITY 2 PER SE 8. HYDRAULIC RAIL BENDER (JIM CROW), HEAVY DUTY 1 PER SE 9. 10. HYDRAULIC SLEEPER SPACER CONCRETE SLEEPER BREAKER WITH ANGLE GRINDER 2 PER SE 1 PER ART

11. PORTABLE DC WELDING GENERATOR 1 PER SE 12. DOUBLE ACTION WELD TRIMMER FOR

11. PORTABLE DC WELDING GENERATOR 1 PER SE 12. DOUBLE ACTION WELD TRIMMER FOR AT WELDING (POWER PACK VERSION) RAIL PROFILE WELD GRINDER 1 PER WELDING-UNIT HEAVY DUTY HYDRAULIC EXTRACTOR FOR JAMMED ERCS TOE LOAD MEASURING DEVICE (MECHANICAL) 1 PER SE 1 PER ART 16. ELECTRONIC TOE LOAD MEASURING DEVICE 1 PER SE 17. MECHANICAL TRACK JACK 2 PER GANG/UNIT 18. HYDRAULIC TRACK JACK 4 PER GANG/UNIT 13. 14. 15. 1 PER WELDING-UNIT 1 PER SE

19. PORTABLE TRACK LIFTING & SLEWING DEVICE (TRALIS) 2 PER SE 20. SELF PROPELLED

19. PORTABLE TRACK LIFTING & SLEWING DEVICE (TRALIS) 2 PER SE 20. SELF PROPELLED LIGHT WEIGHT TROLLEY POWERED MATERIAL TROLLEY 1 PER AEN 22. LIGHT WEIGHT RAIL (MONO) CUM ROAD TROLLEY 2 PER GANG 23. JIB CRANE ATTACHABLE TO BFRBRH FOR HANDLING CONCRETE SLEEPER AS REQUIRED 24. ATTACHMENT FOR RAIL DOLLY FOR PRC SLEEPER 4 PER SE 25. POWERED RAIL HAULING SYSTEM HAND HELD OFF TRACK TAMPER PORTABLE BALLAST CLEANER (SEMI-MECHANISED) 1 PER PQRS SITE PORTABLE SHOULDER BALLAST COMPACTOR 1 PER SE 21. 26. 27. 28. 1 PER SE 3 PER SE 1 PER GANG

REQUIREMENT OF MANPOWER • Indicative manpower requirement is given in the manual. • However,

REQUIREMENT OF MANPOWER • Indicative manpower requirement is given in the manual. • 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.

Creation Of Posts 1. The posts sought to be created for operation and maintenance

Creation Of Posts 1. The posts sought to be created for operation and maintenance of small track machines should be done by surrender of equivalent money value of live revenue charged posts of gangman/other category involved in the track maintenance. 2. The component of unskilled staff being created should be barest minimum. 3. The proportion of skilled personnel should form at least 75% of the total posts to be created. 4. No gazetted posts are to be created either at Divisional level or at HQ level.

THANKS

THANKS