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OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

DEFINITION OF TERMS

1. EXAMINE: Look for damage and defects including breakage, cracks, corrosion
and wear. Look for leakage, looseness and check completeness etc.
Particular aspects are emphasised where necessary.

2. CHECK Ensure a specific condition does (or does not) exist.

3. TAMPING
CHECK OPERATION MACHINE
Operate in normal manner (possibly as part of a procedure
specified) to ensure correct function.

4. RENEW Remove old part and substitute a new, overhauled or re-


conditioned part. Fit new, overhauled or re-conditioned part in
place of missing part.

5. OVERHAUL Dismantle, examine, re-condition and renew parts as necessary or


against given specifications. Re-assemble, test and inspect.
OPERATORS SERVICING SCHEDULE
6. TEST Carry out a procedure to determine performance against specific
criteria.

PLASSER 07 275 P&C


GENERAL REQUIREMENTS

1.
TAMPER07-275
Responsibility
Machine operators are responsible for undertaking the periodic servicing (i.e.
cleaning,
SERIES V-VII
examination, checking and lubrication) of the appliances as covered in this Servicing
Schedule. All defects arising must be bought to the notice of the machine supervisor
or
operator in charge and the maintenance department for the necessary attention.
Operators must enter in the machine log book details of servicing undertaken, together
with
details of defects found and action taken. Full information regarding repairs and spares
fitted,
and deficiencies in the tool kit and emergency spares kit must also be recorded, enabling
an Railway Support Services
The importance of this Montpellier
routine
accurate history to be compiled. House,
maintenance cannot be over-emphasised. If difficulty
is Montpellier Drive,
experienced in obtaining access to lubrication points, e.g. Cardan shafts, this must
Cheltenham,
be GL50 1TY
reported immediately so that appropriate action can be taken.

2. Cleaning
Cleanliness is and essentialTel:contribution
0870 803towards
4651 efficient and trouble-fee running of
the Fax: 0870 803 4652
machine. The machine must be kept clean and tidy at all times and inflammable
materials
www.railwaysupportservices.co.uk
must not be kept inside the cabs. To avoid any detrimental effect on moving parts, only
approved cleaning info@railwaysupportservices.co.uk
agents are to be used.
All rags etc., used for cleaning purposes must be stored in approved containers.
Lubricants
and fuels must not be allowed to become contaminated by dirt or water. Different grades
of OUT OF OFFICE HOURS
oil must not bePlease
mixed. contact Paul Fuller
If dirt is allowed on with
to mix 07794 480410
oil or grease it can form an abrasive
paste
causing rapid wear of lubricated parts. Dirt or water in fuel systems can have serious
consequences causing prolonged delays.
Railway Support Services Page 2
1 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Schedule275
3. Operation
The machine must be operated in accordance with the appropriate Operating
Instructions.
During operation of the machine, listen for noises which may indicate bearing failure or
wear.
Be observant of leaks and loose or worn parts.

Lubrication
4. The machine must be lubricated in accordance with this Servicing Schedule and only
the
specified lubricants used. Do not use contaminated lubricants nor mixed grades of oil.
Oil levels must be checked and levels corrected with the machine standing on level track.
When greasing use only the types of grease-gun supplied with the machine as this type
will fit
correctly and deliver the correct amount of grease each stroke. Before using the grease-
gun
make sure it contains the correct grease and is operating correctly. Grease nipples must be
wiped clean before greasing commences and surplus grease removed afterwards.

Log Books and Communication with Maintenance Staff


5. Entries in the log books must be made every time the machine is used. All servicing, oil
changes and defects must be recorded and entries signed by the machine operators.
Maintenance staff (fitters etc.) will sign the log book when repairs have been completed.
It is
the responsibility of the senior members of the operating team to ensure that all relevant
details are recorded.

The log book must not be removed from the machine without special authorisation and
must
be available for inspection when required.
The machine supervisor (or other senior member of the team) must communicate with the
maintenance department staff directly when immediate attention to the machine is
required.
The details must be entered in the log book.

6. Missing Parts
If during operation or servicing of the machine, parts are found to be missing,
replacements
must be fitted and/or the condition reported to the supervisor or operator in charge and
maintenance staff.

Railway Support Services Page 3 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE:
PLASSER 07-275 SERIES VII TAMPING MACHINE

WORK DESCRIPTIONS AND STANDARDS

Contents

1: Engine

2: Hydraulic System

3: Pneumatic System

4: Brake System

5: Emergency Equipment

6: Axles and Bogies

7: Transmission

8: Electrical System

9: General Examination

10: Levelling and Lining System

11: Tamping Banks

12: Track Lifting and Lining Unit

13: Fire Detection and Extinguishing System

Railway Support Services Page 4 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 1: ENGINE

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

1.1 Sump oil Level X X X

1.2 Fuel Tank Level X X X

1.3 Radiator Coolant Level X X X

1.4 Hour meter X X X

1.5 Turbocharger Bearing Oil Level X X X

1.6 Water Separator X X

1.7 Throttle Control Linkage X

Railway Support Services Page 5 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 2: HYDRAULIC SYSTEM

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

2.1 Hydraulic Tank Level X X X

2.2 Pump Drive Bearing X X

2.3 Cylinder and Ram X X

2.4 Pipes and Hoses X X

Railway Support Services Page 6 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 3: PNEUMATIC SYSTEM

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

3.1 Air Oil Level X X X

3.2 Antifreeze Device X X X

3.3 Compressor Oil Level X X X

3.4 Horns X X X

3.5 Windscreen Wipers X X X

3.6 Air Receiver X X X

3.7 Cylinder and Ram X X

Railway Support Services Page 7 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 4: BRAKE SYSTEM

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

4.1 Brake Operation X X X

4.2 Water Drain Tap X X X

4.3 Train Brake System Pressure X X X

4.4 Brake Linkage X

4.5 Main Brake Arm Pivot X

4.6 Brake Pivot Pins, Brake Shoe Pins and Return Spring X

4.7 Passenger/Goods Changeover Mechanism and X


On/Off Mechanism

4.8 Handbrake Linkage Pivot Pins X

4.9 Hydraulic Brake Cylinder Anchor Pivot X

Railway Support Services Page 8 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 5: EMERGENCY EQUIPMENT

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

5.1 Track Circuit Clip X X X

5.2 Detonators and Flags X X X

5.3 Fire Extinguishers X X X

5.4 Third Rail Emergency Equipment X X X

Railway Support Services Page 9 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 6: AXLES AND BOGIES

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

6.1 Support Plate Oil Cup Oil Level X X X

6.2 Link Rod X X

6.3 Axle Gearbox Oil Level X X

6.4 Axle Gearbox Flange Cover X X

6.5 Shock Absorber Pin X X

6.6 Intermediate Support Bearing on Power Axle 2 Oil X X


Level

6.7 Torque Arm Pivot X

6.8 Bogie Centre Pivot X

Railway Support Services Page 10 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 7: TRANSMISSION

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

7.1 Twindisc Gearbox Oil Level X X X

7.2 Engine (front) / Triple Pump Cardan Shaft X X

7.3 Engine / Twindisc Gearbox Cardan Shaft X X

7.4 Twindisc Gearbox / Hydraulic Pump Cardan Shaft X X

7.5 Differential Distributor Gearbox Oil Level X X

7.6 Reduction Gearbox Hydraulic Working Drive Oil X X


Level

7.7 Differential Gearbox / Power Axle 2 Cardan Shaft X

7.8 Differential Gearbox / Intermediate Support Bearing X


on Power Axle 2 Cardan Shaft

7.9 Intermediate Bearing / Power Axle Cardan Shaft X

7.10 Hydraulic Drive Reduction Box / Twindisc Gearbox X


Cardan Shaft

7.11 Twindisc Gearbox / Differential Distributor Gearbox X


Cardan Shaft

7.12 Hydraulic Working Drive Clutch Linkage X

7.13 Twindisc Disengaging Clutch Linkage X

Railway Support Services Page 11 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 8: ELECTRICAL SYSTEM

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

8.1 Cab, Working, Step and Headlights X X X

8.2 Engine Stop Button X X X

8.3 Horn X X X

8.4 Intercom X X X

8.5 Sirens and Wander Leads X X X

8.6 Proximity Switch X X X

8.7 Speedometer X X X

8.8 Windscreen Washers X X X

8.9 Windscreen Wipers X X X

8.10 Batteries X X

Railway Support Services Page 12 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 9: GENERAL EXAMINATION

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

9.1 Cab Doorway Safety Chains and Clasps X X X

9.2 Windows X X X

9.3 Machine Functional Checks X X X

9.4 General Checks X X X

9.5 Doors and Locks X X

9.6 Tool Kit X X

9.7 Warning Notices X X

9.8 Cleaning X X

9.9 Emergency Spares Kit X X

9.10 Frame Supporting Cylinder X X

9.11 Frame Supporting Cylinder Upper Pivot X X

9.12 Wheel Support Cylinders X X

9.13 Cab Lockout Cylinders X X

9.14 General Examination X X

9.15 Frame Supporting Adjusting Stops X

9.16 Engine Compartment Door Chain X

9.17 Engine Compartment Door Sprocket X

9.18 Engine Compartment Door Winding Handle X

Railway Support Services Page 13 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 10: LEVELLING AND LINING SYSTEM

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

10.1 Levelling and Lining Wires X X X

10.2 Rear Tightening Bogie Adjustment Spindle X X X

10.3 Front Feeler Rod and Guide Bush X X

10.4 Front Feeler Rod Thrust Plate X X

10.5 Front Bogie Locking Device Pivot X X

10.6 Front Tightening Bogie Wire Adjuster and Anchor X X

10.7 Front Tightening Bogie Pulley & Winch X X

10.8 Levelling Wire Adjusting Spindles (Front Cab) X X

10.9 Levelling Wire Tensioning Cylinder Pivots and X X


Pulleys (Rear Cab)

10.10 Measuring Bogie Locking Device Pivot X X

10.11 Middle Feeler Rod and Guide Bush X X

10.12 Middle Feeler Rod Guide Column X X

10.13 Middle Feeler Rod Thrust Plate X X

10.14 Rear Feeler Rods and Guide Bush X X

10.15 Rear Feeler Rod Thrust Plate X X

10.16 Rear Tightening Bogie Locking Device X X

10.17 Rear Tightening Bogie Preload Air Cylinder X X

10.18 Rear Tightening Bogie Preload Pivot X X

10.19 Rear Tightening Bogie Pull Rod X X

10.20 Centre Bogie Lift/Lower and Preload Air Cylinder X


Pivot

10.21 Front Tightening Bogie Lift/Lower and Preload Air X


Cylinder

10.22 Front Tightening Bogie Anchor Pivot X

10.23 Measuring Bogie Lift/Lower and Preload Air Cylinder X

10.24 Measuring Bogie Anchor Pivot

Railway Support Services Page 14 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 11: TAMPING BANKS

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

11.1 Connecting Rod Bearing (Centre) X X X

11.2 Connecting Rod Bearing (Forked) X X X

11.3 Connecting Rod Pin X X X

11.4 Guide Column Bush X X X

11.5 Tamping Arm Pivot Bush Oil Level X X X

11.6 Tamping Tools X X X

11.7 Vibration Shaft Main Bearing Oil Level X X X

11.8 Tamping Tool Pivot Pin X X X

11.9 Tamping Tool Swivel Cylinder Pivots X X X

11.10 Extra Width Cylinder Pivot X X

11.11 Adjusting Frame Cylinder Spherical Joint and Anchor X X

11.12 Tamping Frame Slide Bush X X

11.13 Lifting Cylinder Pivot X X

11.14 Opening/Closing Squeeze Cylinder X X

11.15 Guide Column X

11.16 Tamping Tool Extraction Equipment X

Railway Support Services Page 15 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 12: TRACK LIFTING AND LINING UNIT

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

12.1 Lifting Clamp Pivot Pin X X

12.2 Link Rod Bearing Pin X X

12.3 Lining Roller Pin X X

12.4 Lining Cylinder Pivot Pin X X

12.5 Roller Clamp Housing Oil Level X X

12.6 Roller Clamp Pivot Pin X X

12.7 Derailing Protector X X

12.8 Hook Adjusting Cylinder Pivot X X

12.9 Hook Lifting Cylinder Pivot X X

12.10 Track Lifting Cylinder Pivot Pins X X

12.11 Link Cylinder Bearing X X

12.12 Link Cylinder Piston Rod Pivot X X

12.13 Lifting Bar Pivot X X

12.14 Lifting Hook Sliding Frame Guide Bushes X X

12.15 Lifting Hook Swivel Cylinder Pivot X X

12.16 Lifting Cylinder Pivot X X

12.17 Lifting Hook Adjusting Cylinder Pivot X X

12.18 Lifting Hook Sliding Frame X X

Railway Support Services Page 16 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
SECTION 13: FIRE DETECTION AND EXTINGUISHING SYSTEM

ITEM EXAMINATION
NO. ITEM Shift WeeklyMonthly

13.1 B.C.F. Cylinders X X X

13.2 Fire Alarm Test X X X

13.3 Portable Fire Extinguishers X X X

Railway Support Services Page 17 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

1 ENGINE

1.1 Sump Oil Level Shift Check Top mark on dipstick Top up using good quality 15w/40
engine oil

1.2 Fuel Tank Level Shift Check Full Tank Top up using clean fuel oil

1.3 Radiator Coolant Level Shift Check Top up using Antifreeze mixture (50:50
mix)

1.4 Hour Meter Shift Check reading at end of shift and enter
in log book

1.5 Turbo Charger Bearing Oil Shift Check if engine has not been run for 1 Top up using good quality 15w/40 oil
Level month

1.6 Water Separator Weekly Check. Drain fluid until clean fluid
appears

1.7 Throttle Control Linkage Monthly Lubricate pivots using 15w/40 oil

Railway Support Services Page 18 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

2 HYDRAULIC SYSTEM

2.1 Hydraulic Tank Level Shift Check Full Tank Top up using Panolin HLP46

2.2 Pump Drive Bearing Weekly Lubricate using correct grade grease 1 Nipple on each bearing given 2 shits
Top up using clean fuel oil
of grease

2.3 Cylinders and Rams Weekly Check. Lubricate piston rods with good
quality 15w/40 oil

2.4 Pipes and Hoses Weekly Check with systems pressurised No leaks or chaffing. Report defects to Maintenance
Department

Railway Support Services Page 19 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

3 PNEUMATIC SYSTEM

3.1 Air Oiler Level Shift Check Top up using appropriate grade oil

3.2 Antifreeze Device Shift Check Top up using clean methylated spririt

3.3 Compressor Oil Level Shift Check Top mark on dipstick Top up using good quality 15w/40 oil

3.4 Horns Shift Check operation Horns must sound when button is Machine must not travel is unless hors
pressed are working correctly

3.5 Windscreen Wipers Shift Check Operation Do not operate on dry screen

3.6 Air Receiver Shift Drain at end of each shift

3.7 Cylinders and Rams Weekly Check. Lubricate piston rods using
good quality 15w/40 oil

Railway Support Services Page 20 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

4 BRAKES

4.1 Brake Operation Shift Test in accordance with Plant Plant Instruction 15 Report any defects to Maintenance
Instruction 15 Department

4.2 Water Drain Trap Shift Drain at the end of each shift

4.3 Train Brake System Pressure Shift Drain pressure from Train Brake
System and the end of each shift

4.4 Brake Linkage Monthly Lubricate using appropriate grease 7 nipples per bogie require 2 shots of
grease

4.5 Main Brake Arm Pivot Monthly Lubricate using appropriate grease 1 nipple per pivot requires 1 shot of
grease

4.6 Brake Pivot Pins Monthly Lubricate using good grade 15w/40 oil
Brake Shoe Pins and Return
Springs

4.7 Passenger/Goods ChangeoverMonthly Lubricate using good grade 15w/40 oil


Mechanism and On/Off
Mechanism

4.8 Handbrake Linkage Pivot PinsMonthly Lubricate using good grade 15w/40 oil

4.9 Hydraulic Brake Cylinder Monthly Lubricate using appropriate grease 1 nipple per cylinder requires 1 shot of
Anchor Pivot grease

Railway Support Services Page 21 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

5 EMERGENCY EQUIPMENT

5.1 Track Circuit Clips Shift Check clips are on the machine 1 set per cab

5.2 Detonators and Flags Shift Check contents Case must be sealed Renew defective or missing items

5.3 Fire Extinguishers Shift Check cleanliness. The machine must not work or travelReport damage or defects.
Check seal or visual indicator is intact.
or otherwise be operated without theClean or remove nozzle obstructions.
Check nozzle is not obstructed. correct number of serviceable Remove access obstructions.
Check date. extinguishers fitted
Check operating instructions are
legible.
Check portable fire extinguishers are
accessible.
(Also referenced under section 13)

5.4 Third Rail Emergency Shift Check Only applicable for machines
Equipment rd
travelling/operating on 3 rail
electrified track only. Equipment to be
carried in accordance with local
instructions

Railway Support Services Page 22 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

6 AXLES AND BOGIES

6.1 Support Plate Oil Cup Shift Check Full bottle Top up using appropriate oil

6.2 Link Rod Weekly Lubricate using appropriate grease 4 nipples on each bogie requires 2
shots of grease

6.3 Axle Gearbox Oil Level Weekly Check Correct level MAX mark Top up using appropriate oil

6.4 Axle Gearbox Flange Cover Weekly Lubricate using appropriate grease 2 nipples per axle requires 4 shots of
grease

6.5 Shock Absorber Pin Weekly Lubricate using good quality 15/40 oil

6.6 Intermediate Support BearingWeekly Check Bottom of level plug. Top up using appropriate oil
on Power Axle 2 Oil Level Allow surplus to drain

6.7 Torque Arm Pivot Monthly Lubricate using appropriate grease 1 nipples per torque arm requires 2
shots of grease

6.8 Bogie Centre Pivot Monthly Lubricate using appropriate grease 1 nipple per centre pivot requires 40
shots of grease

Railway Support Services Page 23 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

7 TRANSMISSION

7.1 Twindisc Gearbox Oil Level Shift Check Correct level top of sight glass with Top up using Shell Donax TM oil.
engine stopped. Between marks on
sightglass with engine running at 900
o
rev/min and oil temperature 65 C.

7.2

7.3 Engine (Front) Triple Pump Weekly Lubricate using appropriate grease 2 nipples 3 shots of grease each
Cardan Shaft (where fitted)

7.4 Engine/Twindisc Weekly Lubricate using appropriate grease 3 nipples 3 shots of grease each
Gearbox/Cardan Shaft

7.5 Twindisc Gearbox/Hydraulic Weekly Lubricate using appropriate grease 2 nipples 3 shots of grease each
Pump Cardan Shaft

7.6 Differential Distributor Weekly Check Bottom of level plug allow surplus to
Gearbox drain

7.7 Reduction Gearbox Hydraulic Weekly Check Mark on sight glass


Working Drive Oil Level

7.8 Differential Distributor Monthly Lubricate using appropriate grease 3 nipples 3 shots of grease each
Gearbox / Power Axle 2
Cardan Shaft

7.9 Differential Distributor / Monthly Lubricate using appropriate grease 3 nipples 3 shots of grease each
Intermediate Bearing on
Power Axle 2 Cardan Shaft

7.10 Intermediate Bearing / Power Monthly Lubricate using appropriate grease 3 nipples 3 shots of grease each
Axle 1 Cardan Shaft

Railway Support Services Page 24 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
7.11 Hydraulic Drive Reduction Box
Monthly Lubricate using appropriate grease 3 nipples 3 shots of grease each
/ Twindisc Gearbox Cardan
Shaft

7.12 Twindisc Gearbox / Monthly Lubricate using appropriate grease 3 nipples 3 shots of grease each
Differential Distributor
Gearbox Cardan Shaft

7.13 Hydraulic Working Drive Monthly Lubricate using good quality 15/40 oil
Clutch Linkage

7.14 Twindisc Disengaging Clutch Monthly Lubricate using good quality 15/40 oil
Linkage

Railway Support Services Page 25 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

8 ELECTRICAL SYSTEM

8.1 Cab, Working, Step and Shift Check Operation All lights must illuminate Replace any defective lamps
Headlights

8.2 Engine Stop Button Shift Check operation of each button Engine must stop without keeping Report any defects to Maintenance
button depressed Department

8.3 Horn Shift Check operation Horns must sound when each button Machine
is must not work unless horns
depressed are operating correctly

8.4 Intercom Shift Check operation Speech must be clear Report defects to Maintenance
Department

8.5 Sirens and Wander Leads Shift Check operation. Check condition of Sirens must sound when each buttonMachine must not work unless sirens
wander lead cable is depressed. Buttons must be are operating correctly
illuminated

8.6 Proximity Switch Shift Check operation. Remove any metal


particles from sensing head

8.7 Speedometer Shift Check operation during transit Max error 5%. Refer to Plant Report any defects to Maintenance
Instruction No.51 Department

8.8 Windscreen Washers Shift Check operation Top up with water and screen mix

8.9 Windscreen Wipers Shift Check operation Do not operate on dry screen

8.10 Batteries Weekly Check electrolyte level. Wipe top of Correct level is 10-15mm (0.4 - 0.6 in)
Top up with distilled or deionised
battery clean. Check terminal clampsabove top of plates water. Secure loose clamps. Lightly
are secure and smeared lightly with smear with petroleum jelly
petroleum jelly

Railway Support Services Page 26 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

9 GENERAL EXAMINATION

9.1 Cab Doorway Safety Chains Shift Check


and Clasps

9.2 Windows Shift Check cleanliness Clean windows

9.3 Machine Functional Check Shift Ensure engine is stopped and BIS
closed. Select position 1 on ignition
switch. Check oil pressure lamps on
each driving desk is illuminated.

Check: engine oil pressure and charge


warning lamps on fault panel
are illuminated.

Start engine.

Check: warning lamps on driving desks


and fault panel go out.

Check: ammeter indicates a charge. Ammeter must indicate charge with


engine running.
Check: engine oil pressure. 2
Min. pressure 21.kg/cm (30psi) at
900rpm.
Check: idling working and maximum Idling speed 750rpm. Working speed
speed of engine. 1650/1700rpm. Max speed 2100rpm.

Allow air system to pressurise. Correct pressure 7.2 bar

Check Main Air reservoir pressure.

Turn on hydraulic working controls.

Railway Support Services Page 27 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
9.3 Check Hydraulic pressures. Position 1 system pressure: 130 bar.
cont. Position 2 L.H. Vibration Drive
pressure: 60-80 bar.
Position 3 R.H. Vibration Drive
pressure: 60-80 bar.
Position 4 Lifting Cylinder Counter
pressure: 10-20 bar.
Position 5 L.H. Tamping pressure: 90-
110 bar.
Position 6 R.H. Tamping pressure: 90-
110 bar.
Position 7 Tamping Cylinder High
pressure: 180 bar
Hydraulic Brake pressure: 45-60 bar

Check: Return Flow Filter indicator Light must not be illuminated with
light. system pressurised.

Check: Twindisc gearbox pressure. Normal pressure: 15-18.7 bar

o
Check: Twindisc gearbox temperature.
Normal temperature 82-90 C

Check: all gauges, warning lamps and Report any defects found during this
tachometer show normal function to the Maintenance
readings. Department

9.4 General Check Shift Check for unusual noises from moving Report defects to Maintenance
parts whilst the machine is working. Department
Check for leaks with systems
pressurised.

9.5 Doors and Locks Weekly Check and lubricate pivots and rollers Clean guides
with good quality 15w/40 oil

9.6 Tool Kit Weekly Check Replace any missing tools

9.7 Warning Notices Weekly Check Report any defects to Maintenance


Department

Railway Support Services Page 28 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
9.8 Cleaning Weekly Clean machine internally and
externally

9.9 Emergency Spares Kit Weekly Check Replace used items

9.10 Frame Supporting Cylinder Weekly Lubricate with good quality 15w/40 oil
Lower Pivot

9.11 Frame Supporting Cylinder Weekly Lubricate with appropriate grease 1 nipple per cylinder requires 2 shots
Upper Pivot of grease each

9.12 Wheel Support Cylinder Weekly Check operation

9.13 Cab Lockout Cylinders Weekly Check operation

9.14 General Examination Weekly Examine machine for loose or All bolts and screws must be tight Tighten loose bolts. Report worn or
damaged parts in particular locking damaged parts to Maintenance
and retaining devices. Department

9.15 Frame Support Adjusting Monthly Check Stops must not be worn or missing Report to Maintenance Department is
Stops stops are worn or missing

9.16 Engine Compartment Door Monthly Lubricate with good quality 15w/40 oil
Chains

9.17 Engine Compartment Door Monthly Lubricate with appropriate grease 1 nipple per sprocket requires 1 shot
Sprocket of grease each

9.18 Engine Door Winding Handle Monthly Lubricate with good quality 15w/40 oil

Railway Support Services Page 29 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

10 LEVELLING AND LINING


SYSTEM

10.1 Levelling and Lining Wires Shift Check Wires must not be frayed or kinked Repair or replace damaged wires

10.2 Rear Tightening Bogie Shift Lubricate with good quality 15w/40 oil
Adjusting Spindle

10.3 Front Feeler Rod and Guide Weekly Lubricate with good quality 15w/40 oil
Bush

10.4 Front Feeler Rod Thrust Plate Weekly Lubricate with appropriate grease

10.5 Front Bogie Locking Device Weekly Lubricate with good quality 15w/40 oil
Pivot

10.6 Front Tightening Bogie Wire Weekly Lubricate adjusting spindle screw and
Adjuster and Anchor guide rods, cord anchor guide rod and
pulley with good quality 15w/40 oil

10.7 Front Tightening Bogie Pulley Weekly Lubricate with good quality 15w/40 oil
and Winch

10.8 Levelling Wire Adjusting Weekly Lubricate spindles and columns using
Spindle (Front Cab) good quality 15w/40 oil

10.9 Levelling Wire Tensioning Weekly Lubricate with good quality 15w/40 oil
Cylinder Pivots and Pulleys
(Rear Cab)

10.10 Measuring Bogie Locking Weekly Lubricate with good quality 15w/40 oil
Device Pivot

10.11 Middle Feeler Rod Guide BushWeekly Lubricate with good quality 15w/40 oil

Railway Support Services Page 30 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
10.12 Middle Feeler Rod Guide Weekly Wipe clean and lubricate with good
Column quality 15w/40 oil

10.13 Middle Feeler Rod Thrust Weekly Wipe clean and lubricate with
Plate appropriate grease

10.14 Rear Feeler Rods and Guide Weekly Clean feeler rods and lubricate with
Bush good quality 15w/40 oil

10.15 Rear Feeler Rod Thrust Plate Weekly Wipe clean and lubricate with
appropriate grease

10.16 Rear Tightening Bogie Locking


Weekly Lubricate pivots using good quality
Device 15w/40 oil

10.17 Rear Tightening Bogie PreloadWeekly Lubricate with appropriate grease 1 nipple per piston rod joint end
Air Cylinders requires 1 shot of grease each

10.18 Rear Tightening Bogie PreloadWeekly Lubricate with good quality 15w/40 oil
Pivot

10.19 Rear Tightening Bogie Pull Rod


Weekly Clean and lubricate with 15w/40 oil

10.20 Centre Bogie Lift/Lower and Monthly Lubricate piston rod joint ends using 1 nipple per piston rod joint end
Preload Air Cylinder Pivot appropriate grease. Lubricate pivots requires 1 shot of grease each
using good quality 15w/40 oil

10.21 Front Tightening Bogie Monthly Lubricate piston rod joint ends using 1 nipple per piston rod join end
Lift/Lower and Preload Air appropriate grease. Lubricate pivots required 1 shot of grease each
Cylinder using good quality 15w/40 oil

10.22 Front Tightening Bogie AnchorMonthly Lubricate using appropriate grease. 1 nipple requires 2 shots of grease
Pivot (Series V only)

10.23 Measuring Bogie Lift/Lower Monthly Lubricate using appropriate grease. 1 nipple requires 2 shots of grease
and Preload Air Cylinder Lubricate pivots with 15w/40 oil

10.24 Measuring Bogie Anchor PivotMonthly Lubricate with good quality 15w/40 oil
1 nipple per piston rod join end
required 1 shot of grease each

Railway Support Services Page 31 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

11 TAMPING BANKS

11.1 Connecting Rod Bearing Shift Lubricate using appropriate grease 2 nipples per bank require 6 shots of
(Centre) grease each

11.2 Connecting Rod Bearing Shift Lubricate using appropriate grease 4 nipples per bank require 3 shots of
(Forked) grease each

11.3 Connecting Rod Pin Shift Lubricate using appropriate grease 4 nipples per bank
until clean grease appears.
NOTE: This item should be repeated
every 2-3 hours

11.4 Guide Column Bush Shift Lubricate using appropriate grease 2 nipples per bank require 8 shots of
until clean grease appears. grease each
NOTE: This item should be repeated
every 4 hours

11.5 Tamping Arm Pivot Bush Oil Shift Check. Check for oil leaks. Mark on indicator bottle. Use only Top up using appropriate grade of
Level NOTE: Repeat 20 minutes after fresh oil and clean utensils. No leaks Hydraulic Oil. Report any leaks to
commencing work and then every 4 present Maintenance Department
hours

11.6 Tamping Tool Shift Check wear with approved gauge. Tool head must be within the limits ofReplace worn tools. Check tightness of
Ensure that securing bolt and lock nut
the gauge. Guide columns must be replacement tools after 20 minutes
is tight protected when removing and
replacing tools.

11.7 Vibration Shaft Main Bearing Shift Check. Check for oil leaks. Mark on indicator bottle. Use only Top us using appropriate grade of
Oil Level NOTE: Repeat 20 minutes after fresh oil and clean utensils. No leaks Hydraulic Oil. Report any leaks to
commencing work and then every 4 present Maintenance Department
hours

Railway Support Services Page 32 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
11.8 Tamping Tool Pivot Pins Shift Lubricate using appropriate grease 4 nipples per bank require 2 shots of
grease each

11.9 Tamping Tool Swivel Cylinder Shift Lubricate using appropriate grease 8 nipples per bank require 1 shot of
Pivots grease each

11.10 Extra Width Cylinder Pivot Weekly Lubricate using appropriate grease 8 nipples per bank require 2 shot of
grease each

11.11 Adjusting Frame Cylinder Weekly Lubricate with good quality 15w/40 oil
Spherical Joint and Anchor

11.12 Tamping Frame Slide Bush Weekly Lubricate bushed using appropriate 2 nipples per bank require 2 shots of
grease. Clean slides and lubricate using
grease each
good quality 15w/40 oil

11.13 Lifting Cylinder Pivot Weekly Lubricate with good quality 15w/40 oil

11.14 Opening/Closing Squeeze Weekly Check hoses and connections No leaks or chaffing limit Report defects to Maintenance
Cylinder Department

11.15 Guide Columns Monthly Clean. Examine for scoring flaking No scoring flaking chrome or Report to Maintenance Department.
chrome and indentations. Check indentations Tighten clamp bolts
tightness of clamp bolts

11.16 Tamping Tool Extraction Monthly Examine. Check safety chains are No leaks from hoses, cylinder, pump Report
or defects to Maintenance
Equipment correctly fitted connections Department

Railway Support Services Page 33 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

12 TRACK LIFITNG AND LINING


UNIT

12.1 Lifting Clamp Pivot Pin (SeriesWeekly Lubricate using appropriate grease 1 nipple per pivot; 1 shot of grease
V Standard Machines only)

12.2 Link Rod Bearing Pin (Series VWeekly Lubricate using appropriate grease 1 nipple per pin; 1 shot of grease
Standard Machines only)

12.3 Lining Roller Pin Weekly Lubricate using appropriate grease 1 nipple per roller; 2 shots of grease

12.4 Lining Cylinder Pivot Pin Weekly Lubricate using appropriate grease 1 nipple per roller; 2 shots of grease

12.5 Roller Clamp Housing Oil Level


Weekly Check Correct level: bottom of filter plug hole
Top up using good quality 15w/40 oil
(Series V Standard Machines
only)

12.6 Roller Clamp Pivot Pins (Series


Weekly Lubricate using appropriate grease 2 nipples per pivot; 1 shot of grease
V Standard Machines only)

12.7 Derailing Protector (Series V Weekly Lubricate with good quality 15w/40 oil
Machines only)

12.8 Hook Adjusting Cylinder PivotWeekly Lubricate using appropriate grease 1 nipple per pivot; 1 shot of grease

12.9 Hook Lifting Cylinder Pivot Weekly Lubricate with good quality 15w/40 oil

12.10 Track Lifting Cylinder Pivot Weekly Lubricate with good quality 15w/40 oil
Pins

12.11 Link Cylinder Bearing (Series Weekly


V Lubricate using appropriate grease 1 nipple per cylinder
rd
3 Rail and Series VI & VII
Machines only)

Railway Support Services Page 34 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
12.12 Link Cylinder Piston Rod PivotWeekly Lubricate with good quality 15w/40 oil
rd
(Series V 3 Rail and Series VI
& VII Machines only)
12.13 Lifting Bar Pivot (Series V Weekly Lubricate using appropriate grease 1 nipple per pivot; 2 shots of grease
Standard Machines only)

12.14 Lifting Hook Sliding Frame Weekly Lubricate using appropriate grease 1 nipple per bush; 1 shots of grease
Guide Bushes (Series V
Standard Machines only)

12.15 Lifting Hook Swivel Cylinder Weekly Lubricate using appropriate grease 1 nipple per pivot; 1 shots of grease
Pivot (Series V Standard
Machines only)

12.16 Lifting Cylinder Pivot (Series VWeekly Lubricate using appropriate grease 1 nipple per pivot; 1 shots of grease
Standard Machines only)

12.17 Lifting Hook Adjusting Weekly Lubricate with good quality 15w/40 oil
Cylinder Pivot (Series V
Standard Machines only)

12.18 Lifting Hook Sliding Frame Weekly Lubricate using appropriate grease
rd
(Series V 3 Rail and Series VI
& VII Machines only)

Railway Support Services Page 35 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
OPERATORS SERVICING SCHEDULE: PLASSER 07-275 SERIES VII TAMPING MACHINE

ITEM ITEM EXAM WORK REQUIRED STANDARD REQUIRED WORK AS NECESSARY


NO.

13 FIRE DETECTION AND


EXTINGUISHING SYSTEM

13.1 B.C.F. Cylinders Shift Check cylinders are connected and not
Cylinders must be connected and notReport defects to Supervisor /
discharged discharged, i.e. indicator pin must not
Maintenance Supervisor
protrude

13.2 Fire Alarm Test Shift Depress test button and check that All bells must sound. All alarm lights Renew defective lamps. Report defects
alarm bell in each cab sounds. Checkmust illuminate. to Supervisor / Maintenance
alarm light at each operating and The engine must not be started until Department
driving position illuminates the test is satisfactory.

13.3 Portable Fire Extinguishers Shift Check cleanliness.


Check seal or visual indicator is intact.
Check nozzle is not obstructed.
Check date.
Check operating instructions are
legible.
Check accessibility.
(Also referenced under Section 5)

Railway Support Services Page 36 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 37 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 38 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 39 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 40 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 41 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 42 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 43 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 44 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 45 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 46 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 47 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 48 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 49 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 50 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 51 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule
Railway Support Services Page 52 Plasser 07-275 Series VII P&C Tamper: Servicing Schedule