critical spares part list for

CRITICAL SPARES PART LIST FOR

MULTI PURPOSE TAMPING MACHINE UNIMAT-SPLIT HEAD MFI

March -2017

RESEARCH DESIGNS & STANDARDS ORGANISATION

LUCKNOW- 226 011

PREFACE

For maintenance of any Track Machine, timely availability of spare parts/units and consumables play an

important role. Thus, to keep the machine in sound condition, first and foremost prerequisite is availability of spares and

consumables. As there are thousands of items/spares which are required for maintenance of machine, it is very much

required to identify critical spares which are vital and in turn, to ensure availability of such spares well within the

scheduled time.

Critical spares for UNIMAT-SPLIT HEAD MFI is prepared. It may be noted that this is the list of spares required for the

normal maintenance of UNIMAT-SPLIT HEAD MFI for one year only and does not include the spares required for IOH ,

POH and other special maintenance work. Railways are advised to check the part list of own machine before any

execution of work as parts list may vary from machine to machine. Maintenance requirement for such scheduled

maintenance (IOH/POH) and emergency maintenance/attention may be assessed separately on need basis by zonal

railways itself.

March 2017 (ANIL CHOUDHARY) Director Track Machine-III

INDEX

Category Page Nos

1. ENGINE 1 2. HYDRAULICS 2- 5

3. MECHANICAL 6-7

4. ELECTRICAL & ELECTRONICS 8-9 5. PNEUMATIC 10-11

SITE - At machine STMD - Satellite depot ZTMD - Zonal depot

Critical spares parts list of UNIMAT MFI, March 2017 Page 1 of 11

UNIMAT MFI ENGINE

S.No Brief description Part no. Nos per M/C

Estt. life

cycle in year

Requirement per m/c

SITE STMD ZTMD

A. .ENGINE MODEL NO- KTA 1150 L CUMMINS WATER COOLED OUT PUT: 350KW,RPM 2100

1. Lube Oil 15W40 CF4 40 lts 0.25 210 lts 105 lts 105 lts

2. Lube oil filter element 31665554 1 0.25 2 1 2

3. Air cleaner(outer) 4055280 2 0.5 2 2 2

4. Air cleaner(inner) 4055279 2 0.5 2 2 2

5. V-belt A-52 1 1 3 1 1

6. V-belt A-56 3 1 1 0 1

7. V-belt A-48 1 1 1 0 1

8. Lub. Oil Pressure gauge 500109 1 5 0 0 0.2*

9. Temperature Switch 323.803/002/002 1 3 0 0 0.3*

10. Temperature sensor 500108-R 1 5 0 1 0.2*

11. Lube oil Bypass filter 3873576 1 0.2 2 1 1

12. Fuel filter 4084133 2 0.2 4 1 1

13. Hose pipe (by pass KTA 1150) AS 0603500SS 1 1 1 0 1

14. Self-starter SM-90 make Lucas. 1 3 0 0 0.3*

15. Alternator BOSCH make (28V/120A) A-60/1554LD 1 3 0 0 0.3*

16. Alternator BOSCH make (28V/55A) A-1867 LP/A/65 1 3 0 0 0.3*

*minimum quantity 1


UNIMAT-MFI HYDRAULICS


Estt. life cycle

in year

Requirement per m/c SITE STMD ZTMD

A.VALVE 1. Servo valve(for lining &lifting) EL-T76.00.MO 3 6 0 0 0.5*

2. Proportional Control Valve

(for tamping unit up/down)

HYA16-RPE2-150.DSO728 1 6 0 0 0.2*

3. Reducing Valve(for squeezing) HY55R-B 2 6 0 0 0.3*

4. Reducing Valve

(for track lifting pre load)

HY511.65-P/50 2 6 0 0 0.3*

5. Pressure Relief valve

(for vibration unit)

HY511.06 2 6 0 0 0.2*

6. Sq. Cylinder piston rod complete HZS.K201.134 1 6 0 0 0.2*

7. Safety valve

(for squeezing counter pressure)

HY511.08 1 6 0 0 0.2*

8. Valve for lining unit HY10RSX-B 2 6 0 0 0.3*

9. Valve for lining unit HY10RSD-B 2 6 0 0 0.3*

10. Valve for lifting unit HY151.199 2 6 0 0 0.3*

11. Valve for lifting unit HY10RSG-B 2 6 0 0 0.3*

12. Pressure Relief valve HY511.15 2 6 0 0 0.3*

13. Safety valve for accumulator HY511.64/330 3 6 0 0 0.5*

14. Safety valve HY56R 3 6 0 0 0.5*

15. Safety valve HY151.215 3 6 0 0 0.5*

16. Safety valve HY511.50/350 3 6 0 0 0.5*

17. Non return valve HY151.15 3 6 0 0 0.5*



20. Non return valve HY151.33/5bar16 3 6 0 0 0.5*

21. Non return valve HY151.33/0,5bar12 3 6 0 0 0.5*

22. Non return valve HY151.33/0,5bar06 3 6 0 0 0.5*

23. Solenoid valve HY157.44- 3 6 0 0 0.5*

24. Solenoid valve HY157.44-A 3 6 0 0 0.5*

25. Safety valve(for unloader ) HY511.11 3 6 0 0 0.5*

26. Safety valve(for unloader) HY511.12 3 6 0 0 0.5*

*minimum quantity 1




Estt. life cycle

in year


27. Flow control valve HY100.03 3 6 0 0 0.5*

28. Flow control valve HY157.106/270 3 6 0 0 0.5*

29. Double shock valve(for work drive) HY157.27-160bar 3 6 0 0 0.5*

30. Shuttle valve(for work drive) HY157.50(RS417) 3 6 0 0 0.5*

31. Radiator safety valve HY151.188/5 3 6 0 0 0.5*


B. PUMP

1. Tripple pump(crane+accumulator) HY-832X38.22.03LI 1 6 0 0 0.2*

2. Tripple pump(vibration+oil cooler) HY-842X31.31.12RE 1 6 0 0 0.2*

3. Tripple pump

(accumulator+generator+ZF)

radiator+airconditioning )

HY-832X20.17.06 LI 1 6 0 0 0.2*

C. MOTOR

1. Hydraulic Motor (for work drive) HY916N800 2 6 0 0 0.3*

2. Hydraulic Motor air-conditioning HY935.N10 1 6 0 0 0.2*

3. Hydraulic Motor(ZF fan blade

motor)

HY90.N52 1 6 0 0 0.2*

4. Hydraulic Motor

(for hydraulic oil cooler)

HY90.N43 2 6 0 0 0.3*

5. Hydraulic Motor for vibration(LHS) HY701x14LI 2 6 0 0 0.3*

6. Hydraulic Motor for vibration(RHS) HY701x14RE 2 6 0 0 0.3*

D. FILTER ELEMENT

1. Servo filter DL40.60E 2 0.25 4 2 2

2. Suction Filter HY-S501.460.150 ES 3 0.25 4 2 2

3. Return Filter HY-R501.330.10A/H/ES 63 2 0.25 4 2 2

Proportional filter HY-D501.32.10ES 1 0.25 4 2 2

4. ZF filter HY-D501.225.25 1 0.25 4 2 2

E. CYLINDER

1. Hyd. Cylinder (hook lifting and

lowering LHS)

UD313.3305LI/RE 2 6 0 0 0.3*

*minimum quantity 1




Estt. life cycle

in year


2. Hyd. Cylinder (hook on/off) HZDGB.125.050.0365.1-004 2 6 0 0 0.3*

3. Hyd. Cylinder(hook lifting and

lowering RHS)

NZGB.100.045.0580.2 8 6 0 0 1

4. Hyd. Cylinder for tamping unit

vibration

HZDGB.063036.0765.1.010 6 6 0 0 1


vibration

NZGB063.036.0800.1 4 6 0 0 1


vibration

HZS-A.201.134/HZS-

G.201.135

4 6 0 0 1

7. Hyd. Cylinder for vibration (R) HZDGB.063.036.0100.1 4 6 0 0 1

8. Hyd. Cylinder for vibration (LE) HZPK.063.040.0320.1 4 6 0 0 1

9. Hyd. Cylinder for grips of Lifting

&Lining)

HZDGB.063.036.0765.1.010 4 6 0 0 1

10. Hyd. Cylinder for Lining NZGB.063.036.0800.1 2 6 0 0 0.3*

F. SEAL KIT & O’ RING

1. Seal Kit for tamping unit UP/DN

cylinder

HY55R/DS 2 1 1 1 2

2. Seal Kit for UP/DN cylinder HY152.01DS 2 1 1 1 2

3. Seal for lining cylinder HY155.19DS 4 1 2 1 2

4. Seal kit for accumulator HY-S501.460.150/DS 4 1 2 1 2

5. Seal kit for ZF gear box HY-D501.225.25DS 4 1 2 1 2

*minimum quantity 1




Estt. life cycle

in year


G. HOSE

1. HOSE with fitting 100R2-4x4000 1 6 1 0 0.2*






7. HOSE with fitting R02-4x1000 2 6 1 0 0.4*

8. HOSE with fitting R02-6X800 2 6 1 0 0.4*







15. HOSE with fitting R02-6X1500 6 6 2 0 1


H.OTHERS

1. Hydraulic accumulator 20L HY156-03 1 6 1 0 0.2*

2. Hydraulic accumulator 32L HY156.09 1 6 1 0 0.2*

3. Liquid indicator FSK254-2.4/W/-/12 1 6 1 0 0.2*

4. Pressure gauge HY154.03 1 6 0 0 0.2*

5. Hydraulic Oil TellusT-68 1100 lts. 1** 210 210 1100 lts

*minimum quantity 1

**First check quality of hydraulic oil after that change oil if required.


UNIMAT-MFI MECHANICAL


Estt. life cycle

in year

Requirement per mc

SITE STMT ZTMD

A. Shaft (vibration+ cardon)

1. Cardan shaft(Engine to

ZFgear box)

KGW180.1300.110.80 1 6 0 0 0.2*

2. Cardan shaf( ZF to gear box) KGV180.0950.110.80 1 6 0 0 0.2*

3. Cardan shaft( distribution gear

box to Intermediate gear box)

KGW180.0665.110.00 1 6 0 0 0.2*

4. Cardan shaft(Intermediate

gear box to Axle II)

KGW180.900.110.00 1 6 0 0 0.2*

5. Vibration shaft Cu.20.301

B. BEARING

1. Vibration Shaft Bearing U20.220P 8 6 0 0 0.6*

2. Vibration Shaft Bearing V20.221P 8 6 0 0 0.6*

3. Vibration Shaft Bearing V20.223P 8 6 0 0 0.6*

4. Cylindrical Roller Bearing for

Vibration drive

NUP2313EN1AC 16 6 0 0 1

5. Tamping arm Bearing CU21.3110STKL 4 2 0 0 2

6. Intermediate bearing for

Cardan shaft

UD61.5451 2 2 0 0 1

7. Slanted ball Bearing for

Cardan shaft

7212BGJ 1 2 0 0 0.5*


Cardan shaft

NU2212EM133 2 2 0 0 1


axle gear box

NJ310E/C3 4 2 0 0 1

10. Tapered roller bearing for axle

gear box

WN70.1217/H67C 4 2 0 0 1

*minimum quantity 1


UNIMAT-MFI MECHANICAL


Estt. life cycle

in year

Requirement per mc

SITE STMT ZTMD

11. Plane bearing bush for locking

device

PN3530DX 2 2 0 0 1

12. Plane Bearing bush for

tamping cylinder

MB5040DX 2 6 0 0 0.3*

13. Plane Bearing bush for flap

cylinder

MB1625BU 4 6 0 0 0.3*

14. Deep groove ball Bearing for

fan drive

6209/2RS 1 6 0 0 0.2*

C. OTHERS

1. Grease pipe 8.4x2.1 1 6 1 0 0.2*

2. Track lifting roller UD311.505 1 6 0 0 0.3*

*minimum quantity 1


UNIMAT-MFI ELECTRICAL / ELECTRONICS


Estt. life cycle

in year

Requirement per mc

SITE STMT ZTMD

A. Printed circuit board (PCB)

1. Microprocessor ELB-EPO-00 1 6 0 0 0.2*

2. Microcontroller subroutine ELB-EMO-02 1 6 0 0 0.2*

3. Micro controller Timer ELB-EMO-01 1 6 0 0 0.2*

4. Power output Ek-664-P-00B(02B) 6 6 0 0 1

5. Power supply(24>5v) EK-805SV-00 1 6 0 0 0.2*

6. Power supply(24>±15v>±10v) EK-819SV-00 4 6 0 0 0.5

7. Front Input EK-2310LV-00 1 6 0 0 0.2*

8. Lining control EK-KRO-04 1 6 0 0 0.2*

9. Lining output control EK-2140 LV-00 1 6 0 0 0.2*

10. Leveling control EK-3069 LV-00 2 6 0 0 0.5

11. Pendulum control &settlement

compensation

EK-2351 LV-00 1 6 0 0 0.2*

12. Super elevation controller EK-637MC-00b/244 1 6 0 0 0.2*

13. Tamping unit up/dn control ELB-KVO-00 4 6 0 0 0.5

14. Hook clamp control EK-120V-00(02) 1 6 0 0 0.2*

15. Multi check EK-207V-00B(02) 1 6 0 0 0.2*

16. Input/output EK 653P/s-00A 20 6 0 0 4

17. Relay PCB EK 602 E-002 1 6 0 0 0.2*

B. Relays & Sensor

1. Relay EL-T 7045 24 2 0 0 12

2. Relay EL-T 7064 24 2 0 0 12

3. Relay EL-T 7002/S4 24 2 0 0 12

4. Relay EL-T 1218 S 8 2 0 0 4

5. Power Pack EL-T 7050/500 5 2 0 0 2

6. Proximity Switch EL-T 1422 KU 15 2 4 0 8

7. Encoder EL-T 7055/700 1 2 0 1 1

8. Filter Chocking indicator 6 bar WO/WE 3 2 0 0 1

*minimum quantity 1


UNIMAT-MFI ELECTRICAL / ELECTRONICS


Estt. life cycle

in year

Requirement per mc

SITE STMT ZTMD

9. Potentiometer EL-T 500 HQD 1 6 1 0 0.2*

10. Potentiometer EL-T 1044 5 6 1 0 0.2*

11. Potentiometer EL-T 2044 2 6 1 0 0.2*

12. Galvanometer EL-T 7097 4 2 0 0 2

C. OTHERS

1. Fuse socket 031.5001 1 6 1 0 0.2*

2. Fine- wire fuse 5X20/1AFLINK 1 6 1 0 0.2*

3. Voltmeter EL-T7100.00E/A 1 6 1 0 0.2*

4. Ignition lock 0342311007 1 6 1 0 0.2*

5. Pressure gauge 0-5 bar/24V EL-T7138.00B 1 6 1 0 0.2*

6. Chord wire ELT.576.1.35 4 1 2 1 0

7. Spring tension ELT.750.15 4 1 2 1 0

8. Carrier ELT.67.00C 4 1 2 1 0

*minimum quantity 1


UNIMAT-MFI PNEUMATICS


Estt. life cycle

in year

Requirement per mc

SITE STMT ZTMD

A. Cylinders

1. Trolley up/dn front lining &

measuring

PN2ZG-100/25/300 (52114-12) 6 6 0 0 1

2. Datum cylinder except lining PN2ZG-70/20/400 (52113-16) 4 6 0 0 1

3. Trolleys lock/unlock PN1ZG-35/12/50 (52111-2SP) 7 6 0 0 1

4. Lining datum PN4Z-70/20x230x230 1 6 0 0 0.2*

5. Rear trolley up/dn PN2ZG-70/20/300 (52113-12) 2 6 0 0 0.3*

6. Rear trolley datum PN2ZG-70/20/200 (52113-8) 2 6 0 0 0.3*

7. Chord follow up cylinder PN2ZG-50/16/100 (52112-4) 1 6 0 0 0.2*

8. Lining unit unlock cylinder PN2ZG-50/16/150 (52112-6) 2 6 0 0 0.2*

9. Brake cylinder 8” CA215.3723 2 6 0 0 0.3*

10. Brake cylinder 6” 90217/370 1 6 0 0 0.2*

11. Tamping unit lock/unlock

cylinder

PN1ZG-35/12/50 (52111-2) 4 6 0 0 0.3*

12. Rear chord follow up cylinder PNZ02/50/900 1 6 0 0 0.2*

13. Level chord tension cylinder PNZ02/50/16/200(52112-8) 2 6 0 0 0.3*

14. Wiper cylinder PNZ02/35/12/50 (52112-8) 2 6 0 0 0.2*

15. Flapper cylinder JT 30.150B 8 6 0 0 1

16. ZF engage/disengage cylinder PNZ2KF/50/18/70 1 6 0 0 0.3*

17. Power axle

engage/disengage cylinder

PNIZ-ML-50/12/63-1 1 6 0 0 0.3*

B. Valves

1. Electric pneumatic valve 90344 25 6 5 0 5

2. Safety valve 90204 2 6 1 0 0

3. Unloader valve 90201 2 6 1 0 0

4. Valve pneumatic “ON” 90346 2 6 1 0 0

5. Over flow valve 90247-A 3 6 0 0 0.5*

6. Non return valve 90382 3 6 0 0 0.5*

7. Throttle Control Valve WN388-UIC2B.730.K4 1 6 0 0 0.2*

*minimum quantity 1


UNIMAT-MFI PNEUMATICS


Estt. life cycle

in year

Requirement per mc

SITE STMT ZTMD

8. Two way valve 90252 2 6 0 0 0.3*

9. Stop cock 90259 8 6 0 0 1

10. Two way cock 90375 8 6 0 0 1

11. Break valve(direct) 90366 2 6 0 0 0.3*

12. Break valve(M/C) 90370 2 6 0 0 0.3*

C. Seal Kit

1. Seal kit for tamping arm bearing

DL12.22 4 1 2 1 0

2. Seal kit for tamping cylinder 2E34.150DS 4 1 2 1 0

3. Seal kit for tamping cylinder HZS-DS.75 4 1 2 1 0

4. Seal kit for tamping unit lifting cylinder

HZ01.063 4 1 2 1 0

5. Seal kit for flap cylinder 2E34.150DS 4 1 2 1 0

6. Seal kit for unit locking device PN2Z-35DS 4 1 2 1 0

7. \ Seal kit for support cylinder UD50.550DS 4 1 2 1 0

8. Seal kit for ZF gearbox 90201DS 4 1 2 1 0

9. Seal kit for brake system 90356DS 4 1 2 1 0



12. Seal kit for brake system 90346/DS 4 1 2 1 0

D. Others Spares

1. Pressure regulator 90189-A 7 1 2 1 0

2. Pressure regulator 90190-A 5 1 2 1 0

3. Pressure switch 64.07.1000.54 6 1 2 1 0

4. Horn 162502 2 1 2 1 0

5. Air dryer 90187 1 6 0 0 0.2*

6. Cooling coil DL90.37 1 6 0 0 0.2*

7. Air oiler 90180-A 1 6 0 0 0.2*

8. Water separator 90181-A 1 6 0 0 0.2*

9. Double pressure gauge 90283 4 1 2 1 0

10. Single pressure gauge 90284 2 1 2 1 0

*minimum quantity 1

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