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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

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INSPECTION CHECK LIST FOR TAMPING EXPRESS
MACHINE (09-3X)

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Report No.TM - 106
(Revision-1of 2014)

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December-2014

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RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW- 226 011
 INSPECTION OF TAMPING EXPRESS MACHINE (09-3x)
Name & Designation of Inspecting
Official :

Date of Inspection :

Machine No. :

Base Station /division :

Working between station :From-------------------To----------------

Location :From------------------To-----------------

Block hours :

Progress :

1.General :
S. No Items Remarks given by
inspecting officer
I. Name of supervisor
II. Machine make
III. Year of manufacturing
IV. First POH of Machine done on
V. Last IOH of M/C done on
VI. Next IOH of M/C due on
VII. Last POH of M/C done on
VIII. Next POH of M/C due on
IX. Last POH of camping coach done on
X. Next POH of camping coach due on
XI. All log book filled properly
XII. Pending Maintenance Schedule and reasons
Schedule I,II,III,IV,V,VI,VII

History of Machine:----------------------------------------------------------------------------------------
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Page 1 of 20
2. Preliminary work & Mode of Working:
S. Items Prevailing Condition
No.
I. Pre Tamping Operations being Done Yes No

II. Post Tamping Operations being Done Yes No

III. Depth of Clean Cushion under Sleeper Ok Less

(min. 150 mm)
IV. Condition of ballast Caked Clean

V. Lining Working Method 3 point 4point

VI. Mode of Lining smoothening Design

VII. Mode of Lifting Proportional Design

(smoothing )
VIII. Working method (input data feeding) Manual Measuring run

IX. Mode of work drive Automatic Semi

automatic
X. Cleanliness of Machine Satisfactory Need attention

XI. Tamping tools Condition Ok Worn out

(20% worn out allowed) (no. of tools-----)
XII. Depth of tamping tool(clearance Normal=15 mm Actual=------mm
between the bottom edge of the sleeper
and top of tamping tool blade)

Remarks
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 3. Oil/water/level in tank/container :

S. No. Items Agent / Description Prevailing Condition

I. Hydraulic oil Servo System HLP68N OK Need top up

or equivalent*
II. Radiator (2nos.) Water with coolant OK Need top up
III. ZF Gear Box 15W40 CF-4 OK Need top up
IV. Diesel Oil HSD OK Need top up

V. Intermediate Gear Box SAE-90 OK Need top up

VI. Reduction Gear Box SAE-90 OK Need top up

VII. Engine Lube oil 15W40 CF-4 OK Need top up

VIII. Changed Engine Lube oil 15W40 CF-4 Yes No
on due date
(After every 300hrs)
IX. Funk Gear Box 15W40 CF-4 OK Need top up
X. Driving Axle Gear Box I SAE-90 OK Need top up

XI. Driving Axle Gear Box II SAE-90 OK Need top up

XII. Satellite Axle Gear BoxI SAE-90 OK Need top up

XIII. Satellite Axle Gear BoxII SAE-90 OK Need top up

XIV. Compressor lube oil 15W40 CF-4 OK Need top up
(if used)
XV. Tamping unit oil tank Servo System HLP68N OK Need top up
LHS,Front or equivalent*
XVI. Tamping unit oil tank Servo System HLP68N OK Need top up
LHS,Rear or equivalent*
XVII. Tamping unit oil tank Servo System HLP68N OK Need top up
RHS, Front or equivalent*
XVIII. Tamping unit oil tank Servo System HLP68N OK Need top up
RHS, Rear or equivalent*

*equivalent of servo system HLP68N list issued by RDSO vide l.n.TM/HM/Oils

dated dt.26/07/2012
Remarks
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Page 3 of 20
 4. Filters:
S. No. Items Prevailing Condition
I. Change of ZF gear box filter (1no) Done Not done
( after every 250hrs or on choke indication)
II. Change of Servo valve filter (2nos) Done Not done
( after every 250hrs or on choke indication)
III. Change of Servo valve button filter (6nos) Done Not done
( after every 250hrs or on choke indication)
IV. Change of proportional valve filter (2no) Done Not done
( after every 250hrs or on choke indication)
V. Change of return filter (2nos) Done Not done
( after every 250hrs or on choke indication)
VI. Change of suction filter (6nos) Done Not done
(after every 500hrs or on choke indication)
VII. Change of variable pump suction filter (1nos) Done Not done
(after every 250hrs or on choke indication)
VIII. Change of air dyer filter (2nos) Done Not done
(after every 500hrs or at least once year)
IX. Change of squeezing filters (2nos) Done Not done
(To be done after every 250 hrs)
X. Cleaning of Air Cleaners filter outer, KTA –1150 Done Not done
(after every 50hrs or on dirt indication and change
after 500hrs)
XI. Cleaning of Air Cleaners filter outer, NTA –855 Done Not done
(after every 50hrs or on dirt indication and change
after 500hrs)
XII. Change of Air Cleaners filter inner, KTA –1150 Done Not done
( after every 500hrs)
XIII. Change of Air Cleaners filter inner, NTA –855 Done Not done
( after every 500hrs)
XIV. Change of engine oil , KTA –1150 Done Not done
(to be done after every 300hrsbut 1st time 100hrs)
XV. Change of engine oil ,NTA –855 Done Not done
(to be done after every 300hrsbut 1st time 100hrs)
XVI. Change of engine oil filters , KTA –1150 Done Not done
( after every 300hrs but 1st time 100hrs)
XVII. Change of engine oil filters , NTA –855 Done Not done
( after every 300hrs but 1st time 100hrs)
XVIII. Change of diesel filters, KTA –1150 Done Not done
(to be done after every 300 hrs)
XIX. Change of diesel filters , NTA –855 Done Not done
(to be done after every 300 hrs)

Remarks-------------------------------------------------------------------------------------------------
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5.Lubrication (Oiling & Greasing as per maintenance schedule):
S.No. Item Agent / Description Prevailing Condition

5.1Tamping units
I. Tamping unit guide Grease shell alvania RL2 Done Not done
column (Four bank)
II. Tamping arm Bolt Servo System HLP68N or Done Not done
(55mm) equivalent*
Big arm-8 nos. Servo System HLP68N or Done Not done
equivalent*
Small arm- 8 nos. Servo System HLP68N or Done Not done
equivalent*
III. Vibration shaft main Grease shell alvania RL2 Done Not done
bearing
IV. Connecting rod bolt / Grease shell alvania RL2 Done Not done
(35mm pin)
V. All balls and socket Lube oil Done Not done
joints
Note- if machine is equipped with auto greasing unit for some part/section working of it should be
ensured time to time
5.2 Satellite
I. Satellite slide rollers Grease shell alvania RL2 Done Not done

II. Satellite support roller Grease shell alvania RL2 Done Not done

III. Satellite sliding plate Grease shell alvania RL2 Done Not done
(lateral)
IV. Satellite sliding roller Grease shell alvania RL2 Done Not done
(horizontal)
5.3 Lifting and lining units
I. Clamp Pivot Grease shell alvania RL2 Done Not done

II. Lifting Unit Guide Grease shell alvania RL2 Done Not done
Column
III. Lining rollers Grease shell alvania RL2 Done Not done

IV. Clamp Housing Grease shell alvania RL2 Done Not done

V. Lining cylinder pivots . Lube oil Done Not done

VI. Lifting roller clamp Grease shell alvania RL2 Done Not done

VII. Lifting unit locking Grease shell alvania RL2 Done Not done

*equivalent of servo system HLP68N list issued by RDSO vide l.n.TM/HM/Oils

dated dt.26/07/2012

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Page 5 of 20
 S.No. Item Agent / Description Prevailing Condition

5.4 Cardon shaft

I. Engine to ZF Gear Box Grease shell alvania RL2 Done Not done

II. ZF to Distributor Gear Grease shell alvania RL2 Done Not done
Box
III. Engine to funk Gear Grease shell alvania RL2 Done Not done
Box
IV. Engine to pump Grease shell alvania RL2 Done Not done
distributor gear box
V. Distributor Gear Box to Grease shell alvania RL2 Done Not done
axle I
VI. Distributor Gear Box to Grease shell alvania RL2 Done Not done
intermediate shaft
VII. Intermediate shaft to Grease shell alvania RL2 Done Not done
axle II
VIII. Working drive reduction Grease shell alvania RL2 Done Not done
gear box to ZF gear box
5.5 Miscellaneous
I. Middle feeler rod bush Grease shell alvania RL2 Done Not done

II. Torque arm pivot Grease shell alvania RL2 Done Not done

III. Driving bogie Brake Grease shell alvania RL2 Done Not done
linkage
IV. Running bogie Brake Grease shell alvania RL2 Done Not done
linkage
V. pivot joint & bush of Grease shell alvania RL2 Done Not done
Front Trolley
VI. pivot joint & bush of Grease shell alvania RL2 Done Not done
Rear Trolley
VII. pivot joint & bush of Grease shell alvania RL2 Done Not done
Middle feeler Trolley
VIII. pivot joint & bush of Grease shell alvania RL2 Done Not done
Lining Trolley
IX. Axle gear box flange Grease shell alvania RL2 Done Not done
cover
X. Hand brake gear Grease shell alvania RL2 Done Not done

Remarks-

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Page 6 of 20
Sr.no. Items Prevailing Conditions Prevailing Conditions

6. Engine: Engine model Engine model

KTA –1150L NTA-855
i. Engine hours on date ------- ERH --------ERH
ii. Over-hauling of the Engine Ok Not Ok Not
as per maintenance satisfactory satisfactory
schedule of OEM
iii. Starting problem Yes No Yes No

iv. Condition of smoke White Black White Black

Normal Normal
v. Safety circuit for Engine Ok Need Ok Need
attention attention
vi. Leakage in Head gasket Yes No Yes No
(Head no.) (Head no.)

vii. Belt condition and tension Ok To be Ok To be

tightened tightened
viii. Leakage from water pump, Yes No Yes No
seal, hose and radiator
ix. Condition of battery Ok To be Ok To be
terminals tightened tightened
x. Condition of alternators. Ok Not Ok Not
satisfactory satisfactory
xi. Condition of self starter. Ok Not Ok Not
satisfactory satisfactory
xii. Calibration of fuel injection Ok Not Ok Not
pump(to be done after satisfactory satisfactory
every 1500hrs)
xiii. RPM of the Engine Actual-------- Actual--------
(rated 2100)
xiv. Engine oil pressure Actual-------- Actual--------

xv. a) 1.5 Kg/cm² at idle ----- -----

speed
b) 2.5 Kg/ cm² on load
after 2 hours working
xvi. Engine temperature after
two hrs. Working °C °C
(optimum range750c to
850c for both)

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Page 7 of 20
 Sr.no. Items Prevailing Conditions Prevailing Conditions
KTA –1150 NTA-855
xvii. condition of batteries Ok Not Ok Not
satisfactory satisfactory

xviii. Electrolyte level in batteries Ok Need Ok Need

(Plates should be Top up Top up
embedded in electrolyte
xix. Specific gravity of Ok Less Ok Less
electrolyte (min 1.24)

xx. calibration of Fuel Injectors Ok Not Ok Not

(to be done after every satisfactory satisfactory
1500hrs)
xxi. Whether working gauges are in order or not
a)R.P.M Yes No Yes No
i) In working cabin

ii) In front cabin Yes No Yes No

b) Oil Pressure Yes No Yes No

In working cabin
c) Temperature Yes No Yes No
In working cabin
d) Battery charging In Yes No Yes No
working cabin
e) Speedometer/ Yes No Yes No
Tachometer
i) in front cabin
ii) Working cabin Yes No Yes No

xxii. Any abnormal sound Yes No Yes No

xxiii. Overall condition of engine Ok Not Ok Not

satisfactory satisfactory

Remarks
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Page 8 of 20
Sr.no. Items Prevailing Conditions
7. General condition of Machine:
I. Requirement of PCB if any Part no.
II. Condition of tamping bank Noisy Smooth

III. Requirement of any relay/ics etc Part no.

IV. Requirement of any transducer / sensor. Part no.
V. Condition of tamping tools Ok To be
replaced

VI. No. of tamping arms developed play

VII. Infringement of tamping tools with one another Yes No

VIII. Actual no. of tools with which machine is Nos.

working
IX. Lights (head light & back light etc.) Working To be
attended

X. Condition of machine working tools (Spanner set Satisfactory To be

etc.) replaced

XI. Play in torque arm pivots Ok To be

attended
XII. Change of ZF gear box oil Done Not done
(To be done after every 500hrs or on choke
indication)

Remarks
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Page 9 of 20
8. Electrical and Electronics:
S.no Items Prevailing Condition
I. Condition of Depth transducer (4nos) Ok Need attention

II. Condition of lining transducer (2nos) Ok Need attention

III. Condition of Height transducer (2nos) Ok Need attention

IV. Condition of Satellite transducer (1nos) Ok Need attention

V. Working of lining galvanometer Ok Need attention

VI. Working of X- Level galvanometer (2nos) Ok Need attention

VII. Working of Lifting indication voltmeter LHS Ok Need attention

VIII. Working of Lifting indication voltmeter RHS Ok Need attention

IX. Working of Electric Horn Ok Need attention

X. Working of Head light Ok Need attention

XI. Safety circuit for Driving Ok Need attention

9. Gauges and meters working status

I. ZF oil pressure gauge Ok Need
attention
II. ZF oil temperature gauge Ok Need
attention
III. Battery voltage meter Ok Need
attention
IV. Hydraulic driving pressure gauge Ok Need
attention
V. Satellite brake pressure gauge Ok Need
attention
VI. Pneumatic pressure gauge Ok Need
attention
VII. Hydraulic oil pressure gauge Ok Need
attention
Remarks
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 10. Pneumatic.
I. Air Oiler working properly Yes Need attention

II. Water separator working properly Yes Need attention

III. Condition of brake shoes Ok Need replacement

IV. Clearance between brake shoes and Ok Need replacement

wheel
V. Working of brake application Satisfactory Need attention

VI. Working of unloader valve Satisfactory Need attention

VII. Working of satellite brake application Satisfactory Need attention

VIII. Working of booster Satisfactory Need attention

IX. Locking system of LHS lifting/lining Satisfactory Need attention

units
X. Locking system of RHS lifting/lining Satisfactory Need attention
units
XI. Locking system of LHS tamping Satisfactory Need attention
units(2NOS.)
XII. Locking system of RHS tamping Satisfactory Need attention
units(2NOS.)
XIII. Condition of meggy spring Satisfactory Need attention

XIV. Locking system of lining trolley Satisfactory Need attention

XV. Locking system of middle feeler Satisfactory Need attention

trolley
XVI. Locking system of front feeler trolley Satisfactory Need attention

XVII. Locking system of measuring feeler Satisfactory Need attention

trolley
XVIII. Locking system of satellite Satisfactory Need attention

Remarks
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Page 11 of 20
11.Hydraulic pressure and operation
Sl no. Items Prevailing Condition
Recommended Actual value
value
I. System Pressure 130-140 bar

II. High Pressure System for squeezing 150 bar

III. Counter Pressure for small squeezing 50 bar

cylinder
IV. Squeezing Pressure for concrete sleepers 110 -120 bar

V. ZF Oil Pressure 10 - 15 bar

VI. Boost/Charging Pressure 30 bar

VII. Accumulator pressure for

a) High pressure 100 bar (Max)

b) Working pressure 85 bar (Max.)

VIII. Vibration pressure LHS 150 bar

IX. Vibration pressure RHS 150 bar

X. Driving pressure 210 bar

XI. Satellite Booster pressure 40-60 bar

XII. Squeezing time 0.4 - 0.6 second

XIII. Air Pressure 6 – 7 bar

XIV. Preload pneumatic pressure 3.5 bar

XV. Condition of Oil Coolers Clean Clogged

XVI. Condition of ZF oil coolers(one no.) Clean Clogged

XVII. Function of satellite axle support cylinder Satisfactory Leaking

(2 nos)

Remarks
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Page 12 of 20
12. Miscellaneous:
Sl no. Items Prevailing Condition
I. Adjustment of track lifting roller height Ok To be
LHS adjusted
II. Adjustment of track lifting roller height Ok To be
RHS adjusted
III. Performance of Lining Satisfactory To be
adjusted

IV. Performance of Tamping unit up/down Satisfactory To be

adjusted

V. Performance of Lifting &Levelling Satisfactory To be

adjusted

VI. Performance of satellite Satisfactory To be

adjusted

VII. Leakage from Hydraulic circuit No Yes

(Location------ )
VIII. Leakage from Pneumatic circuit No Yes

(Location------ )
IX. Overall condition of the Machine working. Excellent Very good

Good Average
13. Staff:
I. Strength of staff Full Deficient

II. Group Performance Excellent V. Good

Good Average

III. Safety awareness Excellent V. Good

Good Average

IV. Staff due for Medical Yes No

Remarks
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Page 13 of 20
14.Safety Items:
Sl no. Items Prevailing Condition
I. Safety equipment as per Annexure-II Available deficient

II. Working of safety Emergency Braking Ok Defective

System of the machine
III. Fire extinguisher Ok Defective

IV. Visual and Physical inspection of wheel Done Not done

shall be done at a frequency of once in a
year or after every 1000 engine running
hours whichever is earlier
V. Ultrasonic testing of axles of machine shall Done Not done
be done between 40,000 to 45,000 kms of
running engine hours or three years,
whichever is earlier.

Remarks
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Signature of inspecting authority

Revision-1 of Inspection check list of T-Exp(09-3x), Dec. 2014,

Page 14 of 20
 Annexure – I

LIST OF SPARES TO BE KEPT IN MACHINE’S STORE

S. No. DESCRIPTION PART No. QUANTITY

1. Seal kit HZS.DS.401 02 Nos

2. Screw M16x35 04 Nos
3. Washer 16MM 04 Nos
4. Piston 2E35.303 01 No
5. Threaded pin M6x18 02 Nos
6. Grease nipple small 10 Nos
7. Piston Screw 2E36.48 02 Nos
8. Seal kit HZD 02.080.040 02 Nos
9. Seal kit HZ01.080 02 Nos
10. Hex bolt M16x50 04 Nos
11. Washer 16MM 04 Nos
12. Cylinder pin 20M6x4 02 Nos
13. Hex socket head cap screw M16x110 04 Nos
14. Spring washer 16MM 10 Nos
15. Hex nut 16MM 05 Nos
16. Screw M16x35 06 Nos
17. Hex socket head cap screw M8x25 02 Nos
18. Nut UD65.1177 01 No
19. Tamping tools 01 Set
20. Seal kit UD50.100DS 01 No
21. Seal kit UD50.2200DS 01 No
22. Hex socket head cap screw M16x35 04 Nos
23. Diesel filters One set
24. Lube oil filter One set
25. Hydraulic filters One set
26. Air filter One set
27. Lube oil API 15W40 CF4 50 lit.
28. Gear oil SAE 90 20 lit.
29. Hydraulic oil One barrel
30. Lining Fork ELT 67.00 01 No
31. Spring ELT 1041.12 01 No
32. Pneumatic Valve 90344 02 Nos
33. Proximity Switch ELT 1422K 02 Nos
34. Chord wire ELT 1.35 10mtr
35. Brake shoe WN146.730-k4 04 Nos.
36. Engage disengage rod WN70.1168 01 No

Revision-1 of Inspection check list of T-Exp(09-3x), Dec. 2014,

Page 15 of 20
 Annexure – II

List of Safety Equipments

S.No. Description Quantity

1. Detonators in a tin case 1 box

2. H.S. flag red 2 nos.
3. H.S. flag green 1 nos.
4. H.S. Tri colour lamps 2 nos.
5. Chain & Padlock 1 set
6. Clamp with Padlock 2 nos.
7. 20 t jack 1 no.
8. Crow bars 2nos.
9. Wooden blocks off sizes 8 nos.
10. Gauge cum level 1 no.
11. Rail thermometer (dial type) 1 no.
12. Banner flag 2 nos.
13. Walky talky 2 nos.
14. First Aid Box 1 no
15. Skids 4 nos.
16. Working time table of section where 1 copy
machine working
17. G&SR book with up to date 1 copy
amendment slips
18. 4 cell flasher light/ LED torch,6watt 1 no.
19. LED Petromax 1 no.
20. Safety helmets Machine staff
21. Protective clothing, safety shoes and Machine staff
safety gloves
22. Track Machine Manual 1 no.
23. Accident Manual 1 no.
24. Fire extinguisher 1 no.
25. Hooter (Manual/ Remote) 2 nos.
26. Hydraulic Hand Pump 1 no.
27. Emergency pneumatic/Hydraulic hose 1 no.
of sizes suiting to different
machines(complete with end fittings)

Revision-1 of Inspection check list of T-Exp(09-3x), Dec. 2014,

Page 16 of 20
 Annexure-III
Track Parameters measured
Km Curve/ Before tamping After tamping After DTS
post/ Straight
Sleeper
no.
XL Twist Align- XL Twist Alignm XL Twist Alignm
-ment -ent at -ent at
at ___ ___ ___

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Page 17 of 20
 Annexure-IV
ANY OTHER OBSERVATIONS/REMARKS:

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Page 18 of 20
 Annexure-V

Signature of Inspecting Officer

Name Designation Signature

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Page 19 of 20
 ACKNOWLEDGEMENT

Following officers and staff have made their valuable contributions in finalization
of revision -1 of Inspection Check List for Tamping Express Machine (09-3X).

RAILWAYS

1 S/SRI Dhanprakash SSE/TM/KOTA

RDSO

1. S/Shri Muslim Ahmad ARE/TM

2. S/Shri D.G.Sharma SSE/TM

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