GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

TROUBLE SHOOTING MANUAL OF CONTINUOUS TAMPING MACHINE (09-32 CSM)  OCTOBER, 1999

RESEARCH DESIGNS & STANDARDS ORGANISATION MANAKNAGAR, LUCKNOW-226011

I_N_D_E_X

I.	Engine
II.	ZF Gear Box
III.	Tamping Unit
IV.	Hydraulic
	- Pump
	- Relief Valve
	Unloader Valve
	Motor
	P_R_E_F_A_C_E
	ACKNOWLEDGEMENT

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

TROUBLE SHOOTING MANUAL

OF

CONTINUOUS TAMPING MACHINE

(09-32 CSM)

 OCTOBER, 1999

RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAKNAGAR, LUCKNOW-226011

P_R_E_F_A_C_E

Presently, about 300 On-track Machines are working on Indian Railways covering different works related to track maintenance and renewals. Both preventive maintenance and break-down maintenance of the machines is the responsibility of zonal railways. While efforts should be made to keep the break-downs to minimum, it is also important to identify the defect and repair the machine in shortest possible time when break-down occurs. In this context, need was felt to develop trouble shooting manuals for different On-Track Machines and Railway Board vide their letter no.96/Track-III/TK/44dated 01-4-99 constituted a committee of Sr. Professor/Track Machines, IRICEN/Pune, Deputy Chief Engineer/CPOH, Northern Railway, Allahabad, Deputy Chief Engineer/ Track Machines, Central Railway, Jhansi, and Director/Track Machines, RDSO, for preparing the manuals. To make beginning, the manual for Continuous Tamping Machine (CSM 09-32) has been prepared by the committee.

It is hoped that this manual will be quite useful for the staff attending break-down of the machines in field. Suggestions for further improvement in the manual should be sent to the undersigned.

Executive Director/TM,

RDSO, Lucknow-226011.

Dated:29-10-99.

I. ENGINE

S. No.	Faults	Probable Causes	Remedial Actions
1.	Engine does not start.	1. Emergency stop switch 2. No fuel in the tank.	1. Emergency stop switch should be in release position. 2. Fill fuel in the tank. Bleed air from fuel system in the following steps: i) Loosen the bleed plug on the fuel filter and operate the priming pump until the fuel emerges free of bubbles. Tighten the bleed plug. ii) Then loosen banjo plug on injec- tion pump and operate priming pump until fuel emerges free of bubbles. Tighten the banjo plug.
		3. Shut down mechanism stuck.	3. Release the shut down mechanism and check – i) Lift rods of the shutdown solenoid and the speed setting together with the moving parts. Grease lift rods if necessary. ii) Move the manual shutdown mechanism into the stop position and release. The lever must return automatically to its starting position. iii. Check electrical shut down circuit for proper functioning.
		4. Air in fuel system.	4. Bleed air from fuel system as explained in s..no.1, item 2 above.
		5. Governor is stuck.	5. Replace the governor and send the released for repair in workshop.
		6. Misconnection of starting switch.	6. Check starting switch and if any misconnection is noticed, rectify it.
		7. Faulty valve clearance.	7. To check valve clearances, follow these steps : i. Unscrew bolts and remove cylinder cover. ii. Crank engine until the inlet valve is closed. Then turn approx. ½ turn further. iii. The feeler gauge should pass between the valve cone end and the rocker lever with suction. iv. If the valve clearances need resetting, loosen the lock nut and readjust by means of the set screw. v. Tighten lock nut and recheck valve clearances. vi. Renew gasket, sealing ring and fit cylinder head cover.
		8. Weak batteries.	8. Check electrolyte level in the batteries. Terminals should be clean and the charging system should be working. Over-aged batteries should be replaced.
		9. Injectors not properly functioning.	9. Remove faulty injectors and get it overhauled/calibrated or alterna-tively replace it with new one.
		10. Valves not seating properly. 11.Too much fuel in engine or flooded engine.	10. i) Check the valves spring and replace the broken spring if any. ii) Tap the valves. iii) Lap the valve seat, if required. 11. Clean fuel return pipe.
2.	Engine stops	1. No fuel.	1. Fill fuel in the tank and follow steps as in s. no. 1, item no.2.
		2. Air in the fuel system.	2. Bleed air from fuel system as explained in s. no.1, item no.2.
		3. Valve clearances are not proper.	3. Adjust valve clearances. See s.no.1, item no.7 above.
		4. Governor is stuck.	4. Governor needs repairs/ overhauling in workshop.
		5.Overheating of Engine	5. Take remedial action as in s.no.5 below.
		6.Check down circuit fails.	6. Recheck and repair the faulty circuit.
3.	Engine misfiring	1. Dirty fuel filter.	1. Check fuel filters and if necessary- i. Renew fuel change filter. ii. Change fuel filter elements. iii. Clean the inlet filter.
		2. No / less fuel in tank.	2. Fill fuel in the tank and follow step in s. no.1, item no.2.
		3. Air in fuel system.	3. Bleed air from the system. Same as s. no.1, item no.2.
		4. Faulty Injector.	4. Remove the faulty injector and get it overhauled / calibrated. Alternatively, replace the faulty injector with new one.
		5. Faulty valve clearance.	5. Adjust valve clearances as in s. no.1, item no.7.
		6. Fuel injection timing not proper.	6. Correct the timings or call the service engineer.
4.	Excessive engine smoking .	1. Engine oil level too high.	1. Check oil level. For this purpose, draw dipstick and clean with lint-free cloth. Return dipstick, wait a little until the oil has wetted the dipstick. Then remove dipstick again and check oil level.
		2. Faulty injector	2 Same as s.no.1, item no.9.
		3. Faulty valve clearance.	3. Same as s. no.1, item no.7.
		4. Air in fuel system.	4. Same as s. no.1, item no.2.
		5. Clogged air cleaner.	5. Clean element and change oil.
		6. Excessive carbon on cylinder head and piston.	6. De-carbonise the engine.
		7. Engine overloaded.	7. Check and reduce the load.
5.	Engine running too hot.	1. Coolant level too low.	1. Check coolant level and top up with coolant upto the mark in the filler neck.
		2. Faulty thermostat.	2. Check thermostat as in the following steps: i. Drain cooling water and catch it for reuse. ii. Loosen hose clamps, pull back hoses and then remove thermostat. iii. Heat water in container to approx. 85^o C and place thermostat in it. Maintain temperature of water by agitating. iv. By short circuit and radiator opening, check whether the thermostat opens fully. If not, call in the Service Engineer to fit new thermostat. Or Alternatively check tempera-ture of coolant in radiator for functioning of thermostat.
		3. Faulty water pump.	3. Call in the service engineer to check/repair water pump.
		4. V-belt for water pump needs adjustment.	3. Remove V-belt guard and check V-belt tension. To adjust, release take-up pulley mount or generator and regulate tension in the belt. Then tighten the take-up pulley. If warranted, replace the V-belt.
		5. Oil cooler properly not working.	5. Call service engineer for repair/ replacement of Oil Cooler.
		6. Faulty valve clearances.	6. Adjust valve clearance as explained in s. no.1, item no.7.
		7. Air filter is choked.	7. Clean air filter.
		8. RPM of coolant fan is too low.	8. Adjust RPM of the motor. Check hydraulic system and change pump and motor if necessary.
		9. Water radiator choked.	9. Get the radiator cleaned in work-shop.
		10.Radiator cap worn out or missing.	10.Replace with new cap.
		11.Water Hose too old.	11.Replace water hose.
6.	Engine knocking	1. Incorrect Injector setting.	1. Remove the faulty injector and get it reset or alternatively replace it with new one.
		2. Mechanical damage to piston/cylinder.	2. Call in the service engineer.