This document provides information about a tamping machine called the WST. Some key points: - It is a modified version of an old Duomatic machine that moves from sleeper to sleeper during work. - It has a ZF hydrodynamic gearbox instead of the old configuration with multiple gearboxes. - It has 32 tamping tools and packs two sleepers at a time. The progress is relatively faster at 1800 sleepers per hour. - It is driven from both cabins and has a more powerful Cummins engine than the previous model. - The main units include the engine, tamping unit, gearbox, lifting/lining unit, and it has four axles

1. TAMPING MACHINE

2. SESSION- 4

3. WST (Work Site Tamper)

4. MAIN FEATURES:-
It is modified version of old Duomatic machine. It moves sleeper to
sleeper during working.
 ZF HYDRODYNAMIC GEAR BOX IS PROVIDED INSTEAD OF MAIN
GEAR BOX, DRIVE CLUTCH, REVERSING GEAR BOX, 6-SPEED GEAR
BOX, PTO ASSEMBLY.
 TWO TRIPLE HYDRAULIC PUMP & ONE DOUBLE PUMP PROVIDED.
 ONE EMERGENCY PUMP PROVIDED FOR BACK-UP SYSTEM.
 TWO HYDRAULIC MOTORS ARE PROVIDED FOR WORK DRIVE.
 CENTRAL LUBRICATION SYSTEM IS PROVIDED.
 SERVO VALVES ARE PROVIDED FOR LINING & LIFTING
 THE PROGRESS IS RELATIVELY MORE 1800 SLEEPER/Hr.
 DRIVING FROM BOTH CABINS.
 CUMMINS ENGINE NTA855-L 380HP (280 KW) IS PROVIDED INSTEAD
OF NT-743C IN OLD MODEL.
 IT PACKS TWO SLEEPERS AT A TIME AND HAS 32 TAMPING TOOLS.

5. Driving Axle
Running Axle
Tamping Unit

6. GENERAL DATA:
1. OVERAL LENGTH = 18940MM
2. GAUGE = 1676 MM
3. HEIGHT FROM RAIL LEVEL = 3350MM
4. WIDTH = 2900MM
5. WHEEL DIA (NEW) = 730MM
6. WHEEL DIA (WORNOUT) = 680MM
7. MAXIMUM PERMISSIBLE SPEED (OWN POWER)
= 75 KMPH (TRAIN FORMATION)
= 80 KMPH AS PER OEM

7. MAIN UNITS:
1. Engine
2. Tamping unit
3. ZF Hydrodynamic Gear Box
4. Lifting & lining unit
5. Distribution Gear Box
6. Reduction Gear Box
7. 4 axle – 2 Driving axle & 2 Running axle
8. Centralized Automatic Gearing System

8. 1. Engine:-
WST machine consist of one diesel engine of CUMMINS make model
no. NTA 855L 380 HP @ 2100 RPM. It is mounted on frame of the
machine. This engine is water cooled engine.
2. Tamping Unit:-
It has two tamping units one left and one right which is fitted on the
machine. It has 32 tamping tools and packs two sleepers at a time.Its
tamping unit is non-synchronous type. To get the proper quality of
packing tool should be complete without any missing tool in tamping
unit. In double sleeper packing unit the small arm are close enough
which causes the chance of tamping tools infringement. To avoid the
infringement of tools, the center line of small arm tool bore is shifted.
Due to this change in center line of small arms, tool position is also
shifted which causes the squeezing action not in a straight line. To
keep the squeezing action in straight line, Cut tamping tool are used in
small arms. In WST tamping unit, taper shank type tamping tools are
provided. The size of tool blade is 70mm×140mm whereas the size of
Cut tool is 70mm×110mm or 70mm×90mm according to their
positions.

9. 3. ZF Hydrodynamic Gear Box:-
There was too much failure in main gear box and so many
assemblies were provided to give drive to hydraulic pumps and
separate six speed gear box, forward-reverse gear box and clutch
assembles were provided for the travelling of the machine. To
overcome this complex design and to provide drive from both
end, four speed hydrodynamic gear box is provided in CSM
machine. It holds three hydraulic pumps. It is main gear box of
the machine which is electrically controlled.
It gets power input direct from the engine and sends it to driving
axles through distribution gear box during travelling.
In working mode, it gets power input from the engine and gives
drive to the hydraulic pumps which generate the hydraulic
power. During working, machine movement is carried out by
hydraulic power through reduction gear box.

10. 4. Lifting and lining unit:-
In WST machine, one set (1Left and 1 right) lifting and lining unit is
fitted for maintaining the cross level and alignment of track with the
help of hydraulic cylinders. For lifting of track 4 no. disc clamp rollers
are fitted on each side of unit. For alignment of track, 2 nos. of lining
rollers are provided each side. Track lifting and lining is operated by
servo valve.
Disc clamp roller holds the track with the help of hydraulic rail clamp
cylinder.
5. Distribution gear box:-
It distributes the power by getting one input and giving two outputs. It
transfers power to the driving axle from Z.F gear box. It gives two
outputs in opposite direction.
6. Reduction gear box:-
It gets power from hydraulic motor. It reduces the output rpm and
transfer power to distribution gear box though cardon shaft connected
with it. Its use is in work drives system to give continuous drive to the
machine.

11. 7. Axles:-
It gives movement to the machine. There are four axles in WST
machine.
I. 2 driving axle – It have bevel gear and tail pinion fitted in main
frame. It is the power axle during travelling mode and during
working power axle for main frame drive.
II. 2 running axle – It is idle axle fitted in main frame. And in one
axle hydraulic motor is fitted which gives power during working
for sleeper to sleeper movement. Due to this motor on axle
increases the pickup and increases the efficiency of machine.
In driving and running axle during travelling pneumatic brake
system are provided and during working hydraulic brake are
provided.

12. 8. Centralized Automatic Gearing System:-
This system is provided for the greasing of both side tamping unit.
Due to this system, machine can work continuously during the block
period. Earlier in manual greasing after ever
11/2hourcontinuousworking,tamping unit needs re-grease which in
turn to stop the machine for manual greasing. This system also
reduces maintenance time as well as manpower cost. In this system,
the amount of grease is supplied according to the system
requirement. Hence, wastage of grease is totally vanish.
This system is electronically/mechanically controlled which gives
indication during the failure of the greasing system. It needs special
grease i.e. ALVANIA R L 2 or equivalent

13.  HYDRAULIC SYSTEM:-
WST machine consist of three hydraulic pumps.
 HYDRAULIC MOTOR:-
This machine has 7 nos. of hydraulic motor.

14. WORKING PRINCIPLE
Driving System:
RUN DRIVE: By hydrodynamics ZF 4 speed gear box.
WORK DRIVE: Two hydraulic motors are provided. machine work
in constant speed.
LINING: Single chord lining system.
LEVELLING : Double chord fixed type system for cross-level
TAMPING UNIT : Duomatic type (32 tools) provided on the
machine.

15. POWER TRANSMISSION
ENGINE
P1
P2
P3
M
M
Driving Bogie
Running Bogie
Distribution
Gear Box
Reduction
Gear Box
PTO
ZF GEAR
BOX

16. POWER TRANSMISSION
Driving Mode
ENGINE
P1
P2
P3
M
M
Driving
Bogie
Running Bogie
Distribution
Gear Box
Reduction
Gear Box
PTO
ZF GEAR
BOX

17. WORKING MODE
POWER TRANSMISSION
ENGINE
P1
P2
P3
M
M
Driving Bogie
Running Bogie
Distribution
Gear Box
Reduction
Gear Box
PTO
ZF GEAR
BOX

18. Parameter to be check for the quality of Track
1. The tamping (Squeezing) pressure should be according to the
type of sleeper as under:
i. CST-9 sleeper : 90 - 100 kg/sq.cm
ii. ST or wooden sleeper : 100 - 110 kg/sq.cm
iii. PSC sleeper : 110 - 120 kg/ sq.cm
2. System Pressure should be 120-140 kg/ sq.cm
3. Vibration Pressure should be 150 kg/ sq.cm
4. Tool must be present in tamping unit. Missing tool not
permitted.
5. More than 20% wear out tool to be replace.
6. Tool depth – Sleeper Height + Rubber Pad + Rail Height
10 to 12 mm

19. 7. Minimum ballast cushion of 150mm
8. Fitting and fastening should be remove during tamping
operation.
9. Squeezing time 0.4-0.6 sec.
10. All the track parameter after machine work.
11. General lift should be given in the ratio of 1 : 1000

20. What you learnt?
1. Main Gear Box ZF Hydrodynamic
2. Driving From both cabin.
3. It packs two sleeper at a time
4. It has 32 tamping tools.
5. Output of this machine is 1800 sleeper/hr.
6. It has 4 axles.
7. Maximum permissible speed- 60kmph
8. Servo valve for lifting & lining
9. Two work drive Hydraulic motor.
10. Three powered axles.

21. RUSSIAN DUOMATIC (Model VPR-02M)

22. Main features.
• It has two packing unit. It tamp 2000 sleeper/eff. Hr. In
this machine there is mechanical cum drive gear box.
• Maximum lifting & slewing - 150mm.
• In tamping arm center pin bearing is used in place of
bush, bearing.
• There is no. multi-check & programmer system.
• Only two hydraulic cooler is provided.
• Max. measuring speed is 5 km/hr.
• 3 Point lining system only.
• Hydrodynamic gear box for power transmission.

23. • General Data:-
• Length (buffer to buffer) (mm) - 17740±100
• Height (mm) - 3780±50
• Width (mm) - 2970±30
• Weight of machine -51tonnes
• Rated Power Output of Diesel Engine(kW) - 268
• Engine - Cummins QSM11-C360 360 HP
• Number of breaking axles -
With pneumatic drive - 4
With hydraulic drive - 4
With mechanical drive - 2

24. Main Unit:
 Engine
 Tamping unit
 Raising and lifting unit
 Power unit
 Two cabins: 1- Front cabin, 2- Working cum rear
cabin
 ALC (Automatic guiding computer)
 Axles
 Battery and Alternator

25. 1. Engine:-
VPR has one diesel engine of Cummins make, model no.
QSM11-C360 360 HP. It is water cooled engine.
2. Tamping unit:-
One left and one right tamping unit is provided in this
machine.it packs two sleepers at a time in this type of
unit at centre pin location bearing are provided in place
of bronze bush. The frequency is same as in Plasser
tamping units. But there is difference in amplitude.
Its tamping unit is non-synchronous & similar to
Duomatic type tamping unit. To get the proper quality of
packing tool should be complete without any missing tool
in tamping unit.

26. Tamping Unit:-
In double sleeper packing unit the small arm are close enough which
causes the chance of tamping tools infringement. To avoid the
infringement of tools, the centre line of small arm tool bore is shifted.
Due to this change in center line of small arms, tool position is also
shifted which causes the squeezing action not in a straight line. To
keep the squeezing action in straight line, cut tamping tool is used. In
this tamping unit, taper shank type tamping tools are provided. The
size of tool blade is 70mm×140mm whereas the size of Cut tool is
70mm×110mm or 70mm×90mm according to their positions.
3. Raising and lifting unit:-
It is similar to WST machine. It has 4nos. disc clamp roller to hold the
track for lifting in each side and 2 nos. lining roller for slewing of track
in each side. Disc clamp rollers hold the rail with the help of hydraulic
rail clamp cylinder.

27. 4. Power unit:-
In Power unit there is one hydrodynamic gearbox. It gets power from
engine and gives power to reduction gear box and driving axles
through intermediate support. On reduction gearbox four hydraulic
pumps are provided. It reduces the RPM and gives drive to all four
hydraulic pumps.
5. Two cabins:-
I. Front cabin: From this cabin driving of machine is carried out in
front direction. During working some data is also feed in front cabin.
II. Working-cum-Rear cabin: From this cabin machine working as well
as Driving in rear direction is carried out .
6. ALC (Automatic Guiding Computer):-
This is a computer in which there is facility to measure track
parameters in Run-mode and data can be feed in machine by this
computer during work.

28. 7. Axles:-
There are four axles in this machine- Two driving and Two running.
Driving axles gets power from hydrodynamic gearbox through cardon
shafts. There are three powered axle and one idle axle. During working
in sleeper to sleeper drivehydraulic power is given in three axles with
help of hydraulic motor.
8. Battery and Alternator:-
Battery is used for starting of the engine.
Alternator is used to charge the battery and supply power to all the
systems.

29. POWER TRANSMISSION
ENGINE
P1
Feed Pump
P2
M
Driving Bogie
Running Bogie
Intermediate
support
Reduction
Gear Box
Hy.
Dynami
c Gear
box
P3
P5
P4
M

30. POWER TRANSMISSION
Driving Mode
ENGINE
P1
Feed Pump
P2
M
Driving Bogie
Running Bogie
Intermediate
support
Reduction
Gear Box
Hy.
Dynami
c Gear
box
P3
P5
P4
M

31. POWER TRANSMISSION
Working Mode
ENGINE
P1
Feed Pump
P2
M
Driving Bogie
Running Bogie
Intermediate
support
Reduction
Gear Box
Hy.
Dynam
ic Gear
box
P3
P5
P4
M

32. Parameter to be check for the quality of Track
1. The tamping (Squeezing) pressure should be according to the
type of sleeper as under:
i. CST-9 sleeper : 90 - 100 kg/sq.cm
ii. ST or wooden sleeper : 100 - 110 kg/sq.cm
iii. PSC sleeper : 110 - 120 kg/ sq.cm
2. System Pressure should be 120-140 kg/ sq.cm
3. Vibration Pressure should be 150 kg/ sq.cm
4. Tool must be present in tamping unit. Missing tool not
permitted.
5. More than 20% wear out tool to be replace.
6. Tool depth – Sleeper Height + Rubber Pad + Rail Height
10 to 12 mm

33. 7. Minimum ballast cushion of 150mm
8. Fitting and fastening should be remove during tamping
operation.
9. Squeezing time 0.4-0.6 sec.
10. All the track parameter after machine work.
11. General lift should be given in the ratio of 1 : 1000

34. What you learnt?
1. Main Gear Box Hydrodynamic
2. Driving From both cabin.
3. It packs two sleeper at a time
4. It has 32 tamping tools.
5. Output of this machine is 2000 sleeper/hr.
6. It has 4 axles.
7. Maximum permissible speed- 60kmph
8. Servo valve for lifting & lining
9. Two work drive Hydraulic motor.
10. All powered axles.
11. Bearing in Centre arm pin of Tamping unit
12. Grease lubrication in Centre Arm pin
13. Only 3 point Lining System
14. ALC system is provided.

35. Difference between New Duomatic, Imported Duomatic and
Russian Duomatic.
Sr. No Indian Duomatic Imported Duomatic Russian Duomatic
1 Length – 18940 mm. Length – 16400 mm Length-17740
2 Height – 3350 mm. Height – 3724 mm Height-3780
3 Width – 2900 mm Width – 3000 mm Width-2970
4 ALC is provided only in
(8060-8064)
ALC is not provided. ALC is provided
5 Two triple pump and one
double pump provided
Three triple pump is provided 5 Pumps are provided.
6 Two accumulators is
provided.
Three accumulators is provided. One Accumulator is provided.
7 Automatic greasing only
provided
Automatic as well as manual
greasing is provided.
No Automatic Greasing
8 Progress is 1800 sleeper per
hour
Progress is 1800 sleeper per hour Progress is 2000 Sleeper/hour

36. 09-32-CSM

37. HISTORY OF 09-32 CSM
• In 1981 Plasser & Theurer developed a new idea for more economical
track maintenance: the continuous action tamping machine. At the
beginning of 1982 first trials were carried out with a prototype. And in
the year 1989 the first continuous action leveling, lining and tamping
machine was used in a regular maintenance operation on Indian
Railways within a mechanized maintenance system.
• The success of the 09 series is based on the notion of separating the
main frame from the work unit frame. This means that the main
frame can move forward continuously during work, when the
essentially cyclic action of the working unit for lifting, lining and
tamping is limited to the sub-frame.
This brings:-
1. Excellent quality of work
2. Higher working speed
3. Highest working comfort
4. Easy combination with other operations

38. MAIN FEATURES:
• Machine have two parts i.e. MAIN FRAME & SATELLITE FRAME
• Main Gear Box— ZF Hydrodynamic - (4 speed gear box).
• Driving from both cabin.
• Programmable Logic Control (PLC) Machine.
• Fully auto cycle.
• Data Recorder (after work) 3- channels.
• Twist correction.
• Servo valve for lining and lifting.
• Multi-check system.
• It has 32 tamping tools and packs two sleepers at a time.
• It moves continuous during working.
• CMS Equipped.
• SPS Diagnosis system.
• Laser lining (optional).
• Auto greasing.
• Output:- 2200 to 2400 Sleeper / Hr.

39. GENERAL DATA:
 Overall length -- 27640 mm
 Height above rail level -- 3600 mm
 Width -- 3040 mm
 Wheel dia -- 730 mm
 Total weight -- 64 tons
 Minimum Radius working -- 100 m

40. CSM machine has been made in two parts.
1. Satellite Unit:-
All the working assemblies like tamping unit, lifting unit, auto
greasing and other hydraulic components are fitted on satellite
frame. During working it moves sleeper to sleeper. It has one axle
called satellite axle. During travelling it moves with the main
frame.
2. Main frame Unit :-
Main frame unit have two cabin i.e Working cabin / Main cabin
and Front cabin. All control panels are fitted in these cabins.
Driving and working is carried out from these cabins. It has four
axles i.e. Two driving axles, two running axles. This unit moves
continuous during working. The prime mover of machine, Engine
is fitted on the main frame unit.

41. Main Units:-
 Engine
 Tamping unit
 Lifting and lining unit
 Z.F Hydrodynamic gear /box
 Distribution gear box
 Reduction gear box
 Pump gear box (Funk Gear box)
 Axles
 Centralized Automatic greasing System

42. Main units:
1. Engine:-
It is the prime mover of the machine which provides power during
working or travelling to the machine.It has one diesel Engine. Some
machine have MWM engine and some have Cummins engine which needs
diesel as its fuel for working and mobil oil for its internal part lubrication.
The grade of mobil oil is different for different models of engine as per
recommendation of OEM. These are water cooled engines.
MWM Model no. - TBD -232 –V12 @473BHP
OR
CUMMINS Model no. - KTA 1150L @473BHP
2. Tamping unit :-
It has two tamping units one left and one right which is fitted on satellite
unit of machine. It has 32 tamping tools and packs two sleeper at a time.
Its tamping unit is non-synchronous &similar to Duomatic type tamping
unit. To get the proper quality of packing tool should be complete without
any missing tool in tamping unit. In double sleeper packing unit the small
arm are close enough which causes the chance of tamping tools
infringement.

43. Position of Tamping tools

44. Tamping Unit:-
To avoid the infringement of tools, the centre line of small arm tool
bore is shifted. Due to this change in center line of small arms, tool
position is also shifted which causes the squeezing action not in a
straight line. To keep the squeezing action in straight line, Cut tamping
tool is used. In CSM tamping unit, taper shank type tamping tools are
provided. The size of tool blade is 70mm×140mm whereas the size of
Cut tool is 70mm×110mm or 70mm×90mm according to their
positions.
3. Lifting and lining unit:-
In CSM machine, One set (1Left and 1 right) lifting and lining unit is
fitted for maintaining the cross level and alignment of track with the
help of hydraulic cylinders. For lifting of track 4 no. disc clamp rollers
are fitted on each side of unit. For alignment of track, 2 nos. of lining
rollers are provided each side.Track lifting and lining is operated by
servo valve.
Disc clamp roller hold the track with the help of hydraulic rail clamp
cylinder.

45. 4. Z.F Hydrodynamic gear /box:-
There was too much failure in main gear box and so many assemblies
were provided to give drive to hydraulic pumps and separate six speed
gear box, forward-reverse gear box and clutch assembles were
provided for the travelling of the machine. To overcome this complex
design and to provide drive from both end, four speed hydrodynamic
gear box is provided in CSM machine. It holds three hydraulic pumps. It
is main gear box of the machine which is electrically controlled.
It gets power input direct from the engine and send it to driving axles
through distribution gear box during travelling.
In working mode, it gets power input from the engine and gives drive
to the hydraulic pumps which generate the hydraulic power. During
working, machine and satellite movement is carried out by hydraulic
power.

46. 5. Distribution gear box:-
It distributes the power by getting one input and giving two outputs. It
transfers power to the driving axle from Z.F gear box. It gives two
output in opposite direction.
6. Reduction gear box:-
It gets power from hydraulic motor. It reduces the output rpm and
transfer power to distribution gear box though cardon shaft connected
with it. Its use in work drives system. To give continuous drive to the
machine.
7. Pump gear box (Funk Gear box):-
It is directly getting power from engine through a cardon shaft. It gives
drive to two hydraulic pump during working. The output capacity of
both pump is same hence to keep less stock and to use same type of
both pump. There is a set of three gears in this gear box which gives
the output of same direction. The function of this gear box is during
working of machine.

47. 8. Axles:-
It gives movement to the machine. There are five axles in CSM machine.
• 2 driving axle – It have bevel gear and tail pinion fitted in main frame. It is
the power axle during travelling mode and during working power axle for
main frame drive.
• 2 running axle – It is idle axle fitted in main frame.
• 1 satellite axle – It has spur gear. It helps in sleeper to sleeper movement
of satellite unit during working. The power is given to satellite axle by
hydraulic motor.
9. Centralized Automatic Gearing System:-
This system is provided for the greasing of both side tamping unit. Due to this
system, machine can work continuously during the block period. Earlier in
manual greasing after ever 11/2hour continuous working tamping unit is needs
re-grease which in turn to stop the machine for manual greasing. This system
also reduces maintenance time as well as labour cost. In this system, the
amount of grease is supplied according to the system requirement. Hence,
wastage of grease is totally vanish.
This system is electronically/mechanically controlled which gives indication
during the failure of the greasing system. It needs special grease i.e. ALVANIA
R L 2 or equivalent

48. Front Trolley
Main Frame
Satellite Frame
Driving Axle
Tamping Unit
Runnig Axle

49.  HYDRAULIC SYSTEM:-
This machine consist of 5 Pump (4 Double pumps + 1 variable pump)
for the working of the system
 HYDRAULIC MOTORS:-
Total 8 nos. of hydraulic Motors are used in CSM machine to give drive
to the different unit.

50. WORKING PRINCPLE OF 09-32-CSM
DRIVING SYSTEM: -
WORK DRIVE : During work machine is driven by variable pump with
variable speed 0 to 2 kmph. but satellite drive is proportional drive. the
speed of satellite varies with the main frame speed.
RUN DRIVE : Hydro dynamics gear box (zf) is provided on the machine.
LINING : Single chord lining system is provided on CSM .on few
machine (only 5 machines) laser lining systems are provided.
LEVELING : On this machine fixed chord double chord leveling system
is provided. This machine is designed for the twist correction for that
rear pendulum is given.
RECORDER : 3 channel recorders are provided on each machine to
record the parameters i.e. versine, cross level and lift value after work.

51. POWER TRANSMISSION
ENGINE
P1
P2
P3
M
Driving Bogie
Distribution Gear
Box
Reduction
Gear Box
PTO
Running Bogie Satellite Bogie
M
Funk
Gear Box
P4
P5
ZF GEAR
BOX

52. POWER TRANSMISSION
Driving Mode
ENGINE
P1
P2
P3
M
Driving Bogie
Distribution Gear
Box
Reduction
Gear Box
PTO
Running Bogie Satellite Bogie
M
Funk
Gear
Box
P4
P5
ZF GEAR
BOX

53. POWER TRANSMISSION
Working Mode
ENGINE
P1
P2
P3
M
Driving Bogie
Distribution Gear
Box
Reduction
Gear Box
PTO
Running Bogie Satellite Bogie
M
Funk
Gear
Box
P4
P5
ZF GEAR
BOX

54. Pre-Requisites For Introduction of
Tamping Machines

55. 1. A minimum cushion of 150 mm of clean ballast is
recommended for the proper functioning of the
machine.
2. Adequate ballast should be available in shoulders and
cribs to allow for required lift ( about 20 mm in each
tamping operation) and retention of packing after
tamping.
3. For this purpose, planning and execution of deep
screening of ballast, as well as training out of ballast
should be done well in advance.
4. Traffic blocks of adequate duration shall be planned.
5. The sleepers shall be uniformly spaced.
Pre-Requisites

56. FOR PLAIN TRACKS DUO/CSM
Pre-Tamping Operations
The following preparatory works shall be completed before
undertaking tamping of track:-
1. Field survey should be carried out to determine existing profile of
track and to decide the general lift. In case of design mode working ,
the survey should be done as per guidelines.
2. The beginning and the end of curve/transition curves should be
marked on sleepers. Super elevation and slew should be marked on
alternate sleeper to act as guide for the operator.
3. Ballast shall be heaped up in the tamping zone to ensure effective
packing. However, sleeper top should be visible to the operator and
the ballast should not obstruct the lifting rollers.
4. Hogged, battered and low joints shall be attended.
5. Low cess should l be made up.
6. Track drainage should be improved for better retentively of packing,
Pumping locations should be attended. Rounded ballast should be
replaced with clean and angular ballast.

57. 7. Deficient fittings and fastenings should be made good and all
fittings and fastenings like fish bolts, keys, cotters, loose jaws,
elastic rail clips, pads etc should be properly tightened. Worn out
fittings should be replaced.
8. Broken and damaged sleepers shall be replaced.
9. Sleepers should be squared, correctly spaced and gauge
corrected.
10. Destressing of rails, adjustment of creep, expansion gaps in joints,
buffer rails and SEJs etc.,if necessary shall be carried out.
11. Guards rails at the approach of bridges and check rail shall be
removed temporarily.
12. All obstructions such as rail lubricators, signal rods, cable pipes,
which are likely to obstruct the tamping tools should be clearly
marked and made known to the operator before the start of the
work.
13. Wooden blocks and joggled fishplates shall be removed
temporally ahead of tamping.
14. In electrified sections, the earthing; bond should either be
removed or properly adjusted for tamping.

58. 10 to 12 mm
Operations During Tamping
• The following points should be observed by the machine
operator and the Section Engineer (P Way):-.
1. The gap between top edge of the tamping blade and
the bottom edge of the sleeper in closed position of the
tamping tool should be adjusted depending upon the
type of rail and sleepers. The gap for different types of
sleepers will be as under:
 Metal sleeper : 22-25mm
 Flat bottom sleeper : 10-12mm

59. 2. The tamping (Squeezing) pressure should be adjusted according
to the type of sleeper as under:
 CST-9 sleeper : 90 - 100 kg/sq.cm
 ST or wooden sleeper : 100 - 110 kg/sq.cm
 PSC sleeper : 110 - 120 kg/ sq.cm
3. Care should be taken to ensure that tamping tools are inserted
centrally between the sleepers into the ballast to avoid damage
to sleepers. The number of insertions of the tamping tool per
sleeper varies with the type of sleeper and the amount of track
lift to be given. While tamping, following guidelines should be
adopted:-
 CST-9 sleepers and steel trough sleepers may require double
insertion before passing on to the next sleeper.
 Wooden sleepers, require one insertion up to 20 mm lift and two
insertions for lifts above 20mm.
 One additional insertion for joint sleepers will also be required.
 Concrete sleepers require one insertion upto 30 mm lift. Two
insertions may be required for lifts above 30mm.

60. 4. For maintenance packing, squeezing time of 0.4 second to 0.6
seconds should normally be adequate. Higher squeezing time
may be required for track with caked up ballast.
5. The machine should have full complement of tamping tools. The
tamping tools should not be loose or worn out. The wear on the
tool blade should not be more than 20% of its sectional area.
6. A ramp of 1 in 1000 shall be given before dosing the day's work
and obligatory point. The next day's work shall begin from the
point of commencement of previous day's ramp.
7. If work is to be done during night, sufficient lighting at work site
should be ensured.
8. Care shall be taken to provide for Slew and lift compensation as
necessary. Heavy slewing or lifting should normally be done in
steps of not more than 50 mm. For LWR/CWR track, the relevant
provisions of. LWR manual shall be adhered to.
9. During tamping, the parameters of tamped track should be
checked immediately after tamping for cross level and alignment
and necessary corrective action should be taken.

61. The Section Engineer (P. Way) shall pay attention to the
following items:-
1. Checking and tightening of loose fittings.
2. Replacement of broken fittings.
3. The ballast shall be dressed neatly. Proper consolidation of
ballast between the sleepers shall be done.
4. Final track parameters should be recorded with the help of
recorders provided in the tamping machine. A copy of this
record should be kept with the Section Engineer (P. Way) and
the recorded values should not exceed the following limits:
Post Tamping Operations
Parameter Not more than 10 peaks per
km to exceed this value
Any peak exceeding this
value
Alignment ± 4 mm ± 6 mm
Cross level ± 6mm -
Unevenness 6mm 10 mm

62. 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.
5. While working in LWR territory, the provision of Manual of
Instructions on Long Welded Rail - 1996 should be
followed.
6. The fixtures like check rails removed during pre-tamping
operation should be restored.

63. Parameter to be check for the quality of Track
1. The tamping (Squeezing) pressure should be according to the
type of sleeper as under:
i. CST-9 sleeper : 90 - 100 kg/sq.cm
ii. ST or wooden sleeper : 100 - 110 kg/sq.cm
iii. PSC sleeper : 110 - 120 kg/ sq.cm
2. System Pressure should be 120-140 kg/ sq.cm
3. Vibration Pressure should be 150 kg/ sq.cm
4. All tamping tool must be present in tamping unit. Missing tool
not permitted.
5. More than 20% worn out tool to be replace (Tool blade size
70mm×140mm)
6. Tool depth – Sleeper Height + Rubber Pad + Rail Height
10 to 12 mm

64. 7. Minimum ballast cushion of 150mm
8. Fitting and fastening should be remove during tamping
operation.
9. Squeezing time 0.4-0.6 sec.
10. All the track parameter after machine work.
11. General lift should be given in the ratio of 1 : 1000

65. What you learnt?
1. It moves continuous during working.
2. All the working assemblies are fitted in satellite unit
3. It packs two sleeper at a time
4. It has 32 tamping tools.
5. Output of this machine is 2200-2400 sleeper/hr.
6. It has hydrodynamic gear box in power transmission
system.
7. It has five axles.
8. Maximum permissible speed- 60kmph
9. Servo valve for lifting & lining
10. During working main frame & satellite units moves
separately.

66. 09-3X Tamping Express

67. MAIN FEATURES:
 LATEST VERSION OF CSM
 PROGRAMMABLE LOGIC CONTROL (PLC) MECHANISM.
 COMPUTER
 ALC: - FOR AUTOMATIC DATA FEEDING
 3 BOGIES OF 2 – 2 AXLES (INCLUDING SATELLITE BOGIE)
 2 – ENGINES OF CUMMINS NT 855 & KTA 1150
 MAXIMUM PERMISSIBLE SPEED 60 KMPH (BY RDSO)
 OUTPUT 2700 to 3500 SLEEPPER/HOUR
 4 TAMPING UNIT / MACHINE
 IT PACKS 3 SLEEPERS AT A TIME
 IT CAN WORK IS UNO MODE
 IT HAS 48 TAMPING TOOLS
 MACHINE IS IN TWO PARTS
1. SATELLITE FRAME
2. MAIN FRAME
 AUTOMATIC CENTRALISE GREASING SYSTEM

68. GENERAL DATA:
 OVERALL LENGTH -- 22940 MM
 HEIGHT -- 4090 MM
 WIDTH -- 2900 MM
 DISTANCE BETWEEN BOGIE PIVOTS -- 15700 MM
 WHEEL DIA -- 730 MM
 TOTAL WEIGHT -- 83 TONNES

69. MAIN UNITS:-
 Engine:-
 Tamping Unit:-
 Pump Drive Gear Box.
 Axles:-
 Centralized Automatic greasing system:-
 ZF Hydrodynamic Gear box:-
 Distribution Gear Box:-
 Reduction Gear Box:-
 Lifting and lining unit:-

70. MAIN UNITS:
1. Engine:-
In 09-3X machine 2 engines of CUMMINS make Model no. NT 855 L-
320 BHP & KTA 1150 L- 473 BHP are provided. Engine NT 855 L gives
drive to pump drive gear box which gives power to the 4 nos. hydraulic
pump. It is required only during working of machine. Engine KTA 1150
L is required for both working as well as for travelling.
2. Tamping Unit:-
There are four tamping unit in this machine. This machine packs three
sleeper at a time. During the failure of any packing unit that tamping
unit pair may stop for working and by using single pair of tamping unit
machine operator can complete the work. By using single pair of
tamping unit it packs single sleeper at a time of working of machine is
called UNO MODE.

71. Tamping unit:-
• In 09-3X tamping unit, parallel shank type tamping tools are used.
The size of tool blade is 70mm×140mm. In this unit, small arm cut
type tools are used.
• Wear of tamping tool blade is permitted only up to 20%. More than
20% wear out tools need replacement for proper quality of packing
of ballast under sleeper.
• In machine two types of tamping tools are used
I. Forged steel tool with hardness of 280 BHN
II. Tungsten Carbide tip tool (TCTT)
• Forged steel tamping tools wear and tear at blade portion becomes
more and it reduces the blade size. It needs re-welding to maintain
the proper size of blade after 10-15km working.
• TCTT type tamping tools are very long life tool. It gives approx.
250km life without any maintenance. In these tools, at the location
of squeezing face Tungsten carbide tips are welded.
• Total 48nos. of tools are required in this 09-3X machine.

72. 3. Pump Drive Gear Box.
Pump Drive gear box is mounted on engine NT 855 L of machine. It
gets one input and gives drive to 4 nos. hydraulic pumps. The function
of this gear box is required at the time of working. During travelling
this pump is not required.
4. Axles:-
Due to 4 nos. of packing units the weight of satellite unit increases and
to overcome the problem, this machine is provided with 6 axles.
I. 2 Driving Axles
II. 2 Running Axles
III. 2 Satellite axles
Wheel diameter in axles is 730mm & the condemning limit is
680mm.During travelling pneumatic brakes are provided & during
working hydraulic brakes are provided.

73. 5. Centralized Automatic greasing system:-
Due to four tamping unit no. of greasing points is approx. 96 nos.
so to reduce the maintenance time and man power of machine
centralized automatic greasing system is compulsory. In manual
greasing, it takes more time in maintenance. The automatic
greasing system is similar to CSM machine.
6. Z.F Hydrodynamic gear /box:-
There was too much failure in main gear box and so many
assemblies were provided to give drive to hydraulic pumps and
separate six speed gear box, forward-reverse gear box and clutch
assembles were provided for the travelling of the machine. To
overcome this complex design and to provide drive from both
end, four speed hydrodynamic gear box is introduce.
It gets power input direct from the engine and send it to
required position. In working mode, it gets power input from
the engine and gives drive to the hydraulic pumps which
generate the hydraulic power.

74. 7. Distribution gear box:-
It distributes the power by getting one input and giving two outputs. It
transfers power to the driving axle from Z.F gear box. It gives two output in
opposite direction.
8. Reduction gear box:-
It gets power from hydraulic motor. It reduces the output rpm and transfer
power to distribution gear box though cardon shaft connected with it. Its use
in work drives system. To give continuous drive to the machine.
9. Lifting and lining unit:-
In CSM machine, One set (1Left and 1 right) lifting and lining unit is fitted for
maintaining the cross level and alignment of track with the help of hydraulic
cylinders. For lifting of track 4 no. disc clamp rollers are fitted on each side of
unit. For alignment of track, 2 nos. of lining rollers are provided each side.
Track lifting and lining is operated by servo valve.
Disc clamp roller hold the track with the help of hydraulic rail clamp cylinder.

75.  HYDRAULIC SYSTEM:-
09-3X machine has 6 DOUBLE PUMP AND ONE VARIABLE PUMP.
 HYDRAULIC MOTOR:-
This machine consists of 13 hydraulic motor for its operations.

76. WORKING PRINCPLE 09-3X TAMPING EXPRESS
DRIVING SYSTEM: -
WORK DRIVE : During work machine is driven by variable pump with
variable speed 0 to 2 kmph. but satellite drive is proportional drive. the
speed of satellite varies with the main frame speed.
RUN DRIVE : -Hydro dynamics gear box (ZF) is provided on the machine.
LINING : - Single chord lining system is provided on 3x. ALC is provided
on this machine for measuring run and automatic data feeding .
LEVELING : - On this machine double chord fixed type leveling system is
provided. This m/c is designed for the twist correction for that rear
pendulum is given.
RECORDER: - ALC is provided for recording the data’s during the
measuring run mode.

77. POWER TRANSMISSION
ENGINE
CUMMINS
KTA 1150L
P1
P2
P3
M
Driving Bogie
Distribution
Gear Box
Reduction
Gear Box
PTO
Running Bogie Satellite Bogie
M
M
ZF GEAR
BOX
ENGINE
CUMMINS
NT 855 L Pump
Gear box
P4
P5
P6
P7

78. POWER TRANSMISSION
ENGINE
CUMMINS
KTA 1150L
P1
P2
P3
M
Driving Bogie
Distribution
Gear Box
Reductio
n Gear
Box
PTO
Running Bogie Satellite Bogie
M
M
ZF GEAR
BOX
ENGINE
CUMMINS
NT 855 L
Pump
Gear
box
P4
P5
P6
P7
Driving Mode

79. WORKING MODE
ENGINE
CUMMINS
KTA 1150L
P1
P2
P3
M
Driving Bogie
Distribution
Gear Box
Reduction
Gear Box
PTO
Running Bogie Satellite Bogie
M
M
ZF GEAR
BOX
ENGINE
CUMMINS
NT 855 L
Pump
Gear
box
P4
P5
P7
P6
POWER TRANSMISSION

80. Parameter to be check for the quality of Track
1. The tamping (Squeezing) pressure should be according to the
type of sleeper as under:
i. CST-9 sleeper : 90 - 100 kg/sq.cm
ii. ST or wooden sleeper : 100 - 110 kg/sq.cm
iii. PSC sleeper : 110 - 120 kg/ sq.cm
2. System Pressure should be 120-140 kg/ sq.cm
3. Vibration Pressure should be 150 kg/ sq.cm
4. Tool must be present in tamping unit. Missing tool not
permitted.
5. More than 20% wear out tool to be replace.
6. Tool depth – Sleeper Height + Rubber Pad + Rail Height
10 to 12 mm

81. 7. Minimum ballast cushion of 150mm
8. Fitting and fastening should be remove during tamping
operation.
9. Squeezing time 0.8-1.2 sec.
10. All the track parameter after machine work.
11. General lift should be given in the ratio of 1 : 1000

82. What you learnt?
1. It moves continuous during working.
2. All the working assemblies are fitted in satellite unit
3. It packs three sleeper at a time
4. It has 48 tamping tools.
5. Output of this machine is 2700-3500 sleeper/hr.
6. It can work in Uno mode.
7. It has hydrodynamic gear box in power transmission system.
8. It has 6 axles.
9. Maximum permissible speed- 60kmph
10. Servo valve for lifting & lining
11. During working main frame & satellite units moves separately.

83. Sr.
No
Detail CSM 09-3X
1 Over all length 27640 22940
2 Height 3600 4090
3 Width 3040 2900
4 Weight 64 Tonnes 83 Tonnes
5 Engine 1 2
6 Tamping Unit 2 4
7 Axle 5 6
8 Packing 2 Sleeper at a time 3 sleeper at a time
9 Uno Mode No Yes
10 Vibration Pressure 150 bar 210 bar
11 Output 2200-2400 Sleeper/Hr. 2700-3500 Sleeper/Hr
Diffrence between CSM and 09-3X