INSPECTION CHECK LIST

FOR
( UNIMAT 4S)

REPORT NO TM- 169

May -2012
 PREFACE
Any Machine can only be kept in good condition by regular Inspection of
its various assemblies at different levels of inspections. To ensure that the
components of On-Track machines are properly working & being
maintained and the documentation of the same is being done properly,
multi tiered Inspection of On-Track machines is also required. For the
purpose IRTMM-2000 includes the duties of different inspecting authorities
from Dy. CE/TMC to SSE/TMC with the objective to monitor the health of
machines and to ensure that the officials concerned are carrying out their
duties satisfactorily. For the guidance of the inspecting authorities, RDSO
is dealing with the preparation and issuing the list of items to be inspected
for a particular type of machine.
In this context, the check list for Inspection of CSM (09-32), BCM (RM-80),
FRM-80, Unimat, Duomatic machine (DUO), Unomatic machine (UNO),
Ballast Regulating Machine (BRM 66-4), Tamping Express (09-3X),
Dynamic Track Stabilizer (DGS 62N), Multi purpose track tamping
machine (Unimat Compact--M), Plasser’s Quick Relaying System (PQRS),
Turn out changing machine (T-28), Track Relaying Train (P811S),
Phooltas make UTV, FRM-85F, Worksite Tamping Machine (Plasser
make), Worksite Tamping Machine (Metex make) ,BRM (PBR-400R) and
Track Laying Equipment (Simplex) have been issued by RDSO till date.
The suggestion and feedback from Zonal Railways has been taken &
incorporated in provisional Inspection Check list of Unimat 4S for
inspection purpose.
While every care has been taken to make the Inspection Check List quite
exhaustive, there will always be scope for further improvement.
Suggestions from the railways in this regard will be welcome and may be
sent to the undersigned for future improvement.

(A.K.Pandey)

Executive Director/Track Machine

RDSO/Lucknow-226011.
May-2012
Check List for Inspection of P&C Tamping Machine (UNIMAT 4S)

Name & designation of Inspecting :

Official :
Date of inspection :
Machine no. :
Base station/division :

S. No. Item Prevailing Conditions. No.

1 General
i) Name of supervisors
ii) Machine make
iii) Year of manufacturing
iv) Last IOH of M/C done on
v) Next IOH of M/C due on
vi) Last POH of M/C done on
vii) Next POH of M/C due on
viii) Last POH of camping coach done on
ix) Next POH of camping coach due on
2 Engine:
i) Engine model: KTA1150L (S.L No -----) Engine Hours:
ii) Last overhauling of engine, if done Dated
iii) Last top overhauling of the Engine if done Dated
iv) Engine temperature on load after two hours Normal /within limit
working. Range 75ºc to 95ºc
0
v) Engine temperature during working C
vi) Starting problem /No/ requires attention
vii) Condition of smoke White/Black/Normal
viii) Leakage in Head-gasket No /Yes (Head No.---------)
ix) Condition of battery terminal OK/ to be attended
x) Electrolyte level in batteries Ok/ to be recouped
xi) Specific gravity of electrolyte (min.1.24) Ok/Less
xii) Working of Self starter Satisfactory/need attention
xiii) Compressor working Satisfactory/ need attention
xiv) Belt condition and tension Ok/ need attention
xv) Leakage in water pump seal& radiator No/requires attention
xvi) R.P.M. of the Engine (rated 2100 rpm) Actual ---------

Page 1 of 13
S. No. Item Prevailing Conditions . No.
xvii) Engine Oil Pressure
a) pressure at rated RPM Actual ………
3 to 7 kg/cm2 & 2.4 to 3.1kg/cm2 for DFC
b) pressure at idle RPM
1 to2 kg/cm2 & 0.7(min) for DFC Actual …………….
xviii) Change of Air Cleaner filters Done/Not done
( after 300hrs)
xix) Change of Engine oil Done/Not done
( after 300hrs but Ist time 100hrs)
xx) Change of Engine oil filters Done/Not done
(after 300hrs but Ist time 100hrs)
xxi) change of Diesel filters Done/Not done
(after 300hrs)
xxii) Change of by pass filters Done/Not done
(after 300hrs but Ist time 100hrs)
xxiii) Condition of Radiator Clean/ requires attention
xxiv) Calibration of fuel injector pump &valve Done/Not done
clearance (after 1500hrs)
xxv) Calibration of Fuel Injectors if requires Done/Not done
(after1500hrs) Engine hrs.........................
xxvi) Whether Working Gauges are in order
a) R.P.M. Yes/ no requires attention
b) Oil pressure Yes/ no requires attention
c) Engine temperature Yes/ no requires attention
d) Ammeter Yes/ no requires attention
xxvii) Any abnormal sound No/ Yes requires attention
xxviii) Function of engine safety circuit
a) Low lub oil pressure cut off switch Ok / Defective
b) High temperature cut off switch Ok / Defective
xxix) Working of emergency back up engine Working/To be attended
xxx) Battery charging system Ok/ not satisfactory
xxxi) Condition of batteries Ok/ need replacement

xxxii) Last attention given by Service Engineer to Dated

Engine Engine hrs

Page 2 of 13
S.No. Item Agent/Description Prevailing
conditions
3 Oil/Coolant Level :
i) Hydraulic oil Shell tellu68/equivalent Ok/Less
ii) Radiator Coolant Ok/Less
iii) ZF gear box 15W-40 CF4 Ok/Less
iv) Fuel HSD oil Ok/Less
v) Power divider gear box SAE90 Ok/Less
vi) Intermediate drive shaft SAE90 Ok/Less
Housing
vii) Engine lube oil I15W-40 CF4 Ok/Less
viii) All Axle gear boxes SAE90 Ok/Less
ix) Tamping arm bearing Servo system-100 or Done / Not done
equivalent
Note : Checks of working stock levels have to be carried out when the vehicle stands on the level surface
(without super-elevation or inclination).
4 Lubrication (As per maintenance schedules)
4.1 Tamping Bank
i) Tamping unit guiding plate and Shell Alvania grease RL2 Done / Not done
deflection pulley /equivalent
ii) Vibration shaft main bearing Shell Alvania grease RL2 / Done / Not done
equivalent
iii) Tamping unit guide column Shell Alvania grease RL2 Done / Not done
/equivalent
iv) Telescopic extension of tamping Grease/Oil Done / Not done
unit
v) Connecting rod bearing of Grease/ Shell Alvania Done / Not done
squeezing cylinder, lateral grease RL2/ equivalent
shifting cylinder, adjusting
cylinder, lifting cylinder, frame
slewing cylinder and slewing pin
4.2 Lifting/Lining Unit:
i) Additional lifting assembly Grease Shell Alvania RL2 Done / Not done
Guide plate & deflection pulley /equivalent
ii) Lifting cylinder pivot Oil Servo system- 100 or Done / Not done
equivalent
iii) Clamp bolt &Clamp Grease Shell Alvania RL2 Done / Not done
/equivalent
iv) Locking device of lifting/ lining Oil Servo system- 100 or Done / Not done
unit equivalent
v) Swiveling frame Grease Shell Alvania RL2 Done / Not done
/equivalent
vi) Sliding plate Grease Shell Alvania Done / Not done
grease RL2 /equivalent
vii) Lining roller Grease Shell Alvania RL2 Done / Not done
/equivalent
Page 3 of 13
S.No Item Agent/Description Prevailing
conditions
viii) Vertical/longitudinal hook guide Grease Shell Alvania RL2 Done / Not done
/equivalent
4.3 Cardan shaft
i) Engine to ZF gear box Grease Shell Alvania RL2 Done / Not done
/equivalent
ii) ZF to power divider gear box Grease Shell Alvania Done / Not done
grease RL2 /equivalent
iii) power divider gear box to driving Grease Shell Alvania RL2 Done / Not done
axle-I /equivalent
iv) power divider gear box to Grease Shell Alvania RL2 Done / Not done
Intermediate shaft drive /equivalent

v) Intermediate shaft drive to Grease Shell Alvania RL2 Done / Not done
Driving axle-II /equivalent &Oil SS-100
4.4 Others units
i) Sensing rod , guide bush and Oil Servo system- 100 or Done / Not done
deflection pulley of Measuring equivalent
bogie
ii) Torque arm pivot Grease Shell Alvania RL2 Done / Not done
/equivalent
iii) King pin pivot Grease Shell Alvania RL2 Done/not done
/equivalent
iv) Gear box flange cover of driving Grease Shell Alvania RL2 Done/not done
and idle bogies /equivalent
v) All balls and socket pivot point Oil by Servo system- 100 Done/not done
or equivalent
vi) Sensing feeler rod, tensioning Grease Shell Alvania RL2 Done/not done
trolley, guide bush and chord /equivalent
displacement assembly of Front
tension bogie.
vii) Brake linkage, brake lever Grease Shell Alvania Done/not done
bearing & Brake rod RL2 /equivalent
viii) Guide rod & lateral plate of Oil Servo system- 100 or Done/not done
measuring trolley equivalent
ix) Lateral guide & guide rod of Grease Shell Alvania Done/not done
lining trolley RL2 /equivalent
x) Suspension of machine bogie Grease Shell Alvania Done/not done
RL2 /equivalent
Note: Auto greasing provided for some locations, but it should be checked manually also.

Page 4 of 13
S. Item Prevailing conditions
No
5. Hydraulic circuit
i) Leakage in hydraulic system No/Yes (location)
ii) Tamping unit main pin bearing leakage Yes/ no No. if any-------------
iii) Hoses required to be changed Ok/Leaking (location)
(no. & sizes)
iv) Clamping of hoses Proper / Improper
v) Stock of hoses with the machine as per Adequate/Less
annexure- II
vi) Stock of hose fitting as per annexure-ii Adequate/Less
vii) Hydraulic pressure (bars) Rated Actual
a) System pressure 130-140 ---------
b) High pressure 150 ----------
c) Squeezing pressure
i) Wooden sleeper 100-110 ---------
ii) Concrete sleeper 135-140 ---------
d) Accumulator pressure
i) High pressure 85 (max) ----------
ii) System pressure 85(max) -----------
e) Vibration pressures 185 bars ---------
f) Tamping unit interlocking 80 bar -----------
Pressure
g) emergency pump pressure 130 bar -------------
h) air condition pressure 210 bar ----------
i) hyd. brake pressure 30 to 70 bar ------------
j) Air pressure 6-7 Kg/cm2
k) ZF oil pressure 12-14 bar
viii) ZF oil temperature (80°c - 110oC) ------------
ix) Hyd. oil temperature (after 2 hr. Working 0C
x) Quality of hydraulic oil as per visual Ok/need testing
Inspection
xi) Condition of oil coolers Clean/Clogged
xii)
xiii) Overall condition of hydraulic system satisfactory/not satisfactory

xiv) Change of ZF gear box oil Done/not done

(Av. Life 500hrs but first time 100hrs)
xv) Change of ZF gear box filter Done/not done
(Av. Life 500hrs but first time 100hrs)
xvi) Change of servo valve filters Done/not done
(Av. Life 250hrs)
xvii) Change of proportional, squeezing valve Done/not done
filters (Av. Life 250hrs)
Page 5 of 13
S. Item Prevailing conditions
No
xviii) Change of hydraulic suction filters Done/not done
(Av. Life 500hrs)
xix) Change of hydraulic return filters Done/not done
(Av. Life 500hrs)
xx) Change of Servo valve button filters Done/not done
(Av. Life 250hrs)
xxi) Change of Trabold filters Done/not done
(Av. Life 500hrs)
6 Tamping Units
i) Condition of tamping bank Satisfactory / Noisy
ii) Tilting of Tamping Tools Ok/ Unsatisfactory
iii) Condition of Tamping Tools blade (max. Ok/ To be replaced (Nos)
20% of wear on area basis is allowed).
iv) No. of tamping arms developed play ……………
(Identification nos.)
v) Actual number of tools with which the ……………Nos
machine is working
vi) Leakage from tamping bank No/yes location ………….
7 Miscellaneous
i) Air Oiler working properly Yes/No
ii) Water separator working properly Yes/No
iii) Air dryer cartridges changed
(Avg 500hrs but at least in 1 yr)
iv) Braking System Satisfactory/Unsatisfactory
v) Condition of brake shoes Satisfactory/ to be replaced
vi) Clearance between Brake shoe and Within limit/to be adjusted
wheel at the centre (min 3 - 5 mm
permissible)
vii) Thickness of brake shoe (minimum 13 Ok/Less value………..
mm at any point)
viii) Brake pressure (3.8bars) Actual.
ix) Adjustment of track lifting roller height: Ok/to be adjusted
x) Play in torque arm pivot Ok/to be attended
xi) Condition of Machine working tools Satisfactory/to be changed
(spanner set etc.)
xii) All log books filled properly Yes/No
8. PCB & ELECTRICAL
i) Defective/ Released PCB available with Part no.
the machine
ii) PCBs for tamp. unit up/down working Yes/no PCB no………..
properly
iii) PCBs for lining system working properly Yes/no PCB no………..
iv) PCBs for lifting system working properly Yes/no PCB no………..
Page 6 of 13
S. Item Prevailing conditions
No
v) PCBs for driving system working Yes/no PCB no………..
properly
vi) Condition of Lights (head light & back Ok/ to be attended
light)
vii) Requirement of other PCB if any Part no.
9.Safety unit of machine
i) Safety equipment as per annexure-I Available/Deficient
ii) Functioning of locking devices of all units Yes/No
as tamping unit locking indicator, safety
limit switches, lifting unit locking indicator,
working properly etc.
iii) Expiry date of fire extinguisher Ok/Expired
(one unit per cabin)
iv) Expiry date of detonators Ok/Expired
v) Expiry date of first aid box Ok/Expired
10. Inspection During Block Working:
i) Location of the block working Km/TP
ii) Duration of block (hrs/minutes)
iii) Depth of tamping tool ( 10-12 mm blade adequate /inadequate
top edge below sleeper bottom)
iv) Condition of ballast Clean / Caked
v) Depth of clean cushion under sleeper Sufficient / Less
(required min. is 150 mm)
vi) Track readings mainly cross level & Satisfactory/not satisfactory
alignment after tamping
vii) Pre & post tamping operations being Yes/No
done
viii) Output of work Turn out /Sleepers
11.Staff
i) Competency certificate of the Operator Current/Expired
ii) Strength of Staff as per IRTMM Full/Deficient
iii) Group performance Excellent /V. good/Good/
Average
iv) Cost awareness Excellent /V. good/Good/
Average
v) Safety awareness Exce/V. good/Good/Av.
vi) Staff due for medical
vii) Staff due for training
12. General condition of the machine Excellent /V. good/Good/
Average
13. Availability of spares as per annexure-II Full/Deficient
Page 7 of 13
14. Condition of camping coach Satisfactory/poor
15. Condition of machine base stabling Satisfactory/poor
siding
16. Staff availing rest on due date Yes /no
17. Condition of rest house at stabling station Satisfactory/poor
18. Staff amenities as per up to date IRTMM Satisfactory/poor
19 Any other remark by the Inspecting
Official

(Signature of Inspecting Official)

Name:
Designation:
Date:

Page 8 of 13
 Annexure-I

List Of Safety Tools

Sl. Description Qty

No.
1. Hand Signal flags (red) 02 Nos
2. Hand Signal flags (green) 01 Nos
3. Tri colour lamps hand signals 2 Nos
4. Chain & pad lock 1 set
5. Clamps with pad locks 02 nos
6. Fog signals (Detonators) in tin case 12 nos
7. G& SR book with upto date amendment slip 1 No
8. Flasher light ( 4 cell) 1 no.
9. Portable control phone 1 No
10. Banner flag with stand 02nos
11. First aid kit with Stretcher 1 No
12. Skids 2 No
13. Patromex /Emergency electric lamp 01 no.
14. Protective Equipments as per Annexure-III 1 set each staff
15. Track Machine manual 1 no.
16. Accident Manual 01 no.
17. Fire extinguisher 03 nos
18. Wooden blocks of different sizes 4 Nos
19. Walkie –Talkie 1 No
20. Remote Control Hooter 2 Nos
21. Fire Extinguisher 03 Nos.

Page 9 of 13
 Annexure-II

List of Spares for Emergency

Sl. No. Description Qty

Engine: 1
1. Fuel filter 1 Set
2. Lube oil filter 1 Set
3. Air cleaner filter 2 Set
4. Radiator hoses 1 Set
5. Injector pipes 1 Set
6. `V’ belts 1 Set
7. Fuel flexible hoses 1 Set
Tamping Unit:
1. Piston for squeezing cylinder 1 Set
2. Gland bush for squeezing cylinder 1 Set
3. Piston Locking Screw 1 No
4. Tamping unit Up / Dn cylinder seals 1 No
5. Tamping unit Up / Dn cylinder piston rod 1 No
6. Tamping tool cu30.6220-BE 8 Nos
7. Tamping tool cu30.6820-BE 8 Nos
8. Tamping tool bolts cu30.406 8 Nos
9. Tamping tool lock bolt (WN119-M20.100-1) 16Nos
10. Tamping depth transducer ( EL-T750.00/ZS) 02 Nos
11. 35 mm pin with steel bush, nut & washer 1 No
12. Squeezing cylinder piston rod 1 No
13. Tool tilting cylinder 1 No
14. Bolt ( W.31.133A ) 2 Nos
15. Bolt (CU.37.632) 2 Nos
Hydraulic:
1 Squeezing filter element 4nos
2 Seal set for all hydraulic cylinders 1 set each
3 Proportional filters 2 No
4 Servo filters 2 Nos
5 ZF in-line filter 1 No
6. Hydraulic suction filter 1 Set
7 Hydraulic return filters 1 Set
8 Hydraulic hoses R02-4 25 mtrs

Page 10 of 13
Sl. No. Description Qty
9. Hydraulic hoses R02-6 10 mtrs
10. Hydraulic hoses- R02-8 10 mtrs
11. Hydraulic hoses R02-10 10 mtrs
12 Hydraulic hoses R02-12 10 mtrs
13. Hydraulic hoses R02-16 10 mtrs
14 Hydraulic hoses R02-20 10 mtrs
15. Hydraulic hoses R05/R06 -24 10 mtrs
16. Hydraulic hoses R05/R06 -32 10 mtrs
17 Hydraulic hose fitting of different sizes 2 each
18 HT bolts of different sizes 5 each
19 O ring of different sizes 1 each
20 Grease nipple 10 Nos
Electrical:
1. PCB EK819 1 No
2. PCB EK816 1 no
3. EK IAP13.02a 01 no.
4. Relay ELT- 7002/S4 2 Nos
5 All type of Fuses 2 Nos each
6 Head light , tail light & working light bulbs 2 Each
7 Versine transducer carrier 1 No
8. Versine transducer chord 1mm 16 mtrs
9 Chord wire 2mmx80mts 80mts
10. Battery lug 4 Nos
Miscellaneous:
1 Track lifting roller 1 No
2. Pneumatic hose 6.3 mm 15 mtrs
3 Pneumatic hose 12.5 mm 05 mtrs
4 Brake shoes 8 Nos
5 Brake cylinder seal 1set
6. Cardan shaft nut and bolt 10 each

Page 11 of 13
 ANNEXURE-III

PROTECTIVE EQUIPMENT
In order to keep hazards and their consequences to health as low as
possible it is imperative to ensure suitable protective equipment as listed
below

 Head protection……….Safety helmet

 Hand protection……….Leather and cotton gloves
 Foot protection………. Leather safety boots and shoes
 Warning clothing…… High visibility warning cloth.
 Breathing protection… Dust mask
Note: Inspecting official should wear the protective equipment when
doing the inspection.

Page 12 of 13
 ACKNOWLEDGEMENT

Following officers and staff have made their valuable contributions in finalization of
the Inspection Check List for P&C Tamping Machine (UNIMAT 4S)

RAILWAYS

1. S/SRI ’ L.N. Mishra SSE/TM/ ECR

2. ‘’ ‘’ Ashish Maurya JE/TM/ NER

3. ‘’ ‘’ Vijay Paswan JE/TM/ ECR

RDSO
1. S/SRI Anil Choudhary DTM-III

2. ‘’ ‘’ Muslim Ahmad ARE/TM

3. ‘’ ‘’ A.N.Srivastava, SSRE/TM

Page 13 of 13