Trouble with Tamping Units and it's remedial action fault 11

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

11) Fault :-  Automatic lifting system not functioning.

Probable causes and Remidial action.

A) No system pressure. 

 Ensure system pressure. 
B)  No servo current on Galvanometer 18G2 (position 1 for LH & 2 for RH). 
i) Servo plug loose, Correct it. 
ii) Check power supply 24V & 12V on program panel.  If OK, check output voltage + 15V & +10V of PCB EK813 SV (6U4).  If no output, replace PCB EK 813 SV(6U4).  
iii) Check signal Q06 – X06 for LHS and Q07 – X07 for RHS.  If no signal, then follow the steps as below- 
*  Front bogie is lowered and limit switch is operated, check limit switch. Replace if defective. 
*   Rear bogie is lowered and limit switch is operated, check limit switch. Replace if defective. 
* Sensor X24 for LHS and X25 for RHS of lifting unit is defective or not properly positioned over rail.  If defective, replace sensor or bye-pass, using switch on operating panel. 
* Automatic levelling switch X2E in “ON” position but signal X2E is not coming. It means switch X2E is defective.  Replace it. 

* If Over-lifting limitation signal X32 & X33 is coming.  Reset ON/OFF switch on EK347.
C)  Defective PCB EK- 347. 
Signal Q06 – X06 & Q07-X07 is OK, still no lift - 
    PCB EK347 is defective and to be replaced. 
D)  Servo current available, bye-pass operated and tamping unit below middle position, still no lifting. 
 Servo valve is defective, replace it. 

Trouble with Tamping Units and it's remedial action fault 10

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

10) Fault :- Lifting and lowering unit not lifting up by manual operation.

Probable causes and Remidial action.

A) No system pressure. 

 Ensure system pressure.
B) No 24V supply on program panel.  
 Ensure 24V supply on program panel. 
C) Up position switch defective. 
 By   operation  of Up position switch, indication Q1C for LHS & QID for RHS should come.  
* Q16 & Q17 indicating down position should not come. 
Check relay Re3 for up position and Re4 for down position of PCB EK347. 
Blocking valve indication. 
* QL34 when LHS unit is not going up. 
* QL35 when RHS unit is not going up. 
D) No supply to bye-pass valve 
Check signal QL2E for LHS and QL2F for RHS. 
E) Servo valve defective 
If servo current is showing on galvanometer 18G2 for respective sides and bypass indication is coming and still the unit is not lifted up, servo valve is defective.  Replace servo valve. 

Trouble with Tamping Units and it's remedial action fault 9

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

9) Fault :-  Lining automatic not working.

Probable causes and Remidial action.

A)  No system pressure. 
Ensure system pressure. 
B) No servo current indication on Galvanometer 18G2 (at position-3) even if lining indicator is showing deflection. 
1. Check servo valve plug for loose connection. 
2. Check power supply 24V and 12V on program panel.  If OK, check +15V and + 10V on PCB EK813 (10U4).  If defective, replace PCB EK813.  If + 15V and +10V is not available, lining indicator will not show deflection.  
3. Check signal Q05 on program   panel - 
* If Q05 is not coming, check Q0B- X0B is coming or tamping unit attained below middle position. 
* For Q0B-X0B, X15 & X16 input signal should come. 
* X15 and X16 will come when relay Re.3 of EK16 of LHS & RHS is operated. (Tamping unit below middle position).  If X15 and X16 is not indicated, check relay Re3. Replace defective relay Re3. 

 If Q05 is not coming- 
 Check signal Q0A.  If not, check switch for auto-lining is either not operated or defective.  Replace defective switch. 
   Signal for sensor lifting/ lining circuit X24 (LHS), X25 (RHS) not coming- 
   Sensor out of position or defective.   

   Replace defective sensor or bye- pass switch.  If bye-passed, X2F should indicate. 

 If Q05 is OK and still no servo current, PCB EK349 or EK290 is defective.  Replace defective PCB. 
C) No lining indication. 
Check power supply 24V and 12V.  If OK, check PCB EK813 for +15 V and + 10V  
If PCB 813 (10U4) is OK, check output from lining transducer, measuring transducer and digital potentiometer. 
D) No supply to bye-pass valve. 
If servo current is showing on program panel and no supply for bye-pass valve, check relay Re7 (EL.T.7002 S4) on PCB EK349.  Replace defective relay.

Trouble with Tamping Units and it's remedial action fault 8

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

8) Fault :-  Manual lining  not functioning. .

Probable causes and Remidial action.

A)  No system pressure 

Ensure system pressure. 
B) Bye pass valve is inoperative. 
Check relay Re7 (EL.T.7002.S4) of PCB EK 349. Replace defective relay. 
C) No servo current – no deflection on galvanometer 18G2 (at position-3).  
Operate switch for manual lining.  Either X3B or X3C should come on programme panel.  
   If still no current, check Re5 for left side and Re6 for right side movement on PCB EK349.  If defective, replace relays. 

Trouble with Tamping Units and it's remedial action fault 7

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

7) Fault :-  Satellite movement reverse failed.

Probable causes and Remidial action.

A) No  proportional current. 

1. Check output QL.36  
If signal is OK check relay QL.36 (ELT.7002.S4 of B7 Panel). 
    Replace defective relay. 
2.  If no signal at QL36 –  
Check input signal X34 for satellite reverse by joystick. 
3. Signal 0B should not come.  If signal 0B comes, check position of tamping unit middle or upper position. 

Trouble with Tamping Units and it's remedial action fault 6

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

6) Fault :-  Satellite forward movement failed.

Probable causes and Remidial action.

A)  No system pressure.

Check system pump, unloader valve and safety valve for proper functioning.  Replace defective ones. 
B) Proportional valve defective. 
Operate proportional valve manually. Feel the outlet pipe. If surge is not felt, valve is defective. 
C) Satellite motor defective.
If proportional valve is OK,  remove satellite drive motor from reduction gearbox, operate proportional valve manually.  If motor rotates, motor is Ok.  If not, replace satellite motor. 
D) Defective planetary gearbox. 
Replace the planetary gearbox. 
E) Defective bye-pass valve 
Replace the defective bye-pass valve. 
F) Satellite drive axle not engaged properly. 
Ensure satellite drive axle is engaged properly. 
G) Satellite gearbox pinion, gear or shaft damaged.
Replace pinion, shaft or gear of satellite gearbox as required.
H) No supply on satellite drive proportional valve. 
i) Check   deflection   on   galvanometer 18G3  (at position-3). 
* If no  deflection, check power supply 24V and 12 V and ensure proper power supply. 
* If power supply is proper, check output +15V and +10V on PCB EK813 SV (10U5)  
ii) If output is correct, check signal Q61 – X61 
    If output is not correct – 
* Check input signal X12 by joy stick for forward movement or X11 by pedal drive.  If either of the signal comes, X0F should come. 
 * Signal 6F should not come.  If 6F signal is coming, check whether tamping units are in middle or in upper position.
iii)  If Q61 – X61 is OK – 
 Check relays Re1, Re2, Re5 and Re6 (ELT.663) of PCB EK24.  Replace defective relays. 
iv) If all the above conditions are OK and still no supply to proportional valve, replace PCB EK24.  

Trouble with Tamping Units and it's remedial action fault 5

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

5) Fault :-  Machine not moving in reverese direction.

Probable causes and Remidial action.

A) No deflection on galvanometer 18G2 of programme panel switch on position-4.

Check signal Q09 - X 09. If no signal.

• Check X37 or X 38  switch and signal X37 or X38 on programme panel.
• Check input signal X23 for reverse joystick.

• Check input signal X13 and X14 indicating tamping unit is in middle or Up position. 

• Output signal Q83, indicates that machine moving in reverse direction.  

• No signal X30 indicates, auto  working switch is off.  

• Check out put signal Q42.  If Q42 is OK, check relay 18U1(C)   (EL.T.277). Replace defective relay. 
• Check relay QL37 (EL.T.7002.S4) behind B7 panel.  Replace defective relay. 

If all the above conditions are OK, replace PCB EK319. 

Trouble with Tamping Units and it's remedial action fault 4

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

4) Fault :-  Machine not moving forward in working drive.

Probable causes and Remidial action.

A)  No charge pressure.
Charge pressure should be 30 bar.
B) Suction filter clogged.
Replace suction filter.
C) Charge pump  shaft may be broken.
Replace charge pump.
D) Adjustment of relief valve wrong.
Adjust relief valve. Replace relief valve, if required.
E) No working drive pressure. (Working pedal pressed).
Ensure charge pressure.
F) Defective variable output pump.
Replace variable output pump.
G) Excessive leakage through working drive motor.
Repair or replace working drive motor.
H) Reduction grearbox shaft broken and motor running freely.
Replace broken gearbox shaft.
I) Axial pistorn pump proportional valve defective.
If any of the above problems does not exist, operate the proportional valve of axial piston pump. if pressure is shown, proportional valve and pump is OK. If no pressure is shown, replace axial piston pump. If proportional valve is OK, check supply on proportional valve with working pedal presed.
J)  No supply on proportional valve with drive pedal pressed.
Check output from galvanometer 18G2 on program panel at position 4. If no deflection, check powersupply 24V and 12V and ensure they are proper. If 24V and 12V supply is OK, check output voltage +15V and +10V of PCB EK 813 SV (6U7). If not OK, replace PCB EK 813. If output from PCB EK813 is OK, check output from PCB VT3005, (terminal 6 - 8 for forward and terminal 6 - 7 for reverse). If no output, PCB VT3005 is defective. Replace PCB VT 3005.
K) No deflection on galvanometer.
If there is no deflection on galvanometer, check signal Q04 - X04.
a) If signal is not coming
* Check X37 or X38
( Continuous drive X38, step by step X37)
*check Input signal Q63 - X63 i.e. tamping units are in middle or up position.
* Satellite in rear position - limit switch X22 defective. Input signal X22 should not come.
b) If Q04 - X04 is OK, still no galvanometer current-
* Check replay 18U1(B) (Relay EL.T.277).
Replace defective relay.
* Check relay QL.137 (ELT.7002.S4) behind panel B7. Replace defective relay.
L) PCB EK319 may be defective.
Replace PCB EK319.
M) Longitudinal transducer may be defective.
Longitudinal transducer to be repaired for defective potentiometer, gear slipped broken spring or chord wire broken.
N) Satellite zero position is not adjusted.
Zero position of satellite (satellite locked in front position) should be adjustment at +8V on terminal 6d of PCB EK24.

Trouble with Tamping Units and it's remedial action fault 3

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

3) Fault :-  Tamping unit is not going up during tamping operation (Tamping unit remains in down position).

Probable causes and Remidial action.

A) No system pressure.
Check system pressure. If system pressure is not there, check 38X22 system pump, unloader valve, non-return valve and relief valve. Replace  defective ones.
B) Piston rod or piston broken (Tamping unit UP & DN).
Replace piston rod assembly or complete cylinder.
C) Defective proportional valve.
Operate proportional valve manually. If the unit is not lifting up, proportional valve is defective and replace it. If proportional valve is OK, check supply on proportional valve.
D) No supply on proportional valve.
Check deflection on galvanometer 18G3 at position 1 for LH and position 2 for RH. If no deflection :-
i) Check and  ensure supply voltage 24V & 12V on program panel.
ii) If supply voltage is OK, check output voltage of PCB EK813SV (10U5) for +15V and +10V. If not proper, replace PCB EK813.
iii) Check output signal Q10 for LH and Q11 for RH. These should not come.
iv) If Q10  and Q11 appears, check-
 a) Signal Q0D-X0D. This should come.
b) If Q0D - X0D is not coming, check input signal X27 or X28 (X27 for continuous working mode and X28 for step by step working mode).
c) Check Q01 - X01. This should come, indicating that squeezing has been completed. If Q01 - X01 is not coming, check-
*Input signal X17 for LH & X18 for RH. If no input signal, check depth transducer for slipped forkk, broken chord or defective potentiometer.
* Check signal Q69 - X69, If no signal, setting of squeezing time is defective or timer chord defective. Adjust timer chord or replace chord.
d) If all the above points are OK but still Q10 or Q11 is not coming, PCB EK16 is defective. Preplace PCB EK16.

Trouble with Tamping Units and it's remedial action fault 2

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

2) Fault :-  Tamping unit not going Up for unlockng.

Probable causes and Remidial action.

A) No system pressure.
If no system pressure, check 38X22 system pump, unloader valve, non-return valve and safety valve. Replace defective ones.
B) Tamping unit Up & Dn movement hydraulic cylnder or pistorn defective or piston rod broken.
Replace broken piston rod assembly or replace cylinder.
C) Defective proportional valve.
Operate proportional valve manually. If unit is not lifted up, proportional valve is ddefective. Replace proportional valve. If proportional valve is OK, check for supply on proportional valve.
D) No supply on proportional valve.
Check switch X19 in Up position (Input signal X19 should come on programme panel).

Trouble with Tamping Units and it's remedial action fault 1

Trouble with Tamping units.

You are on n4net and this is indian railway track machine trouble shooting with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Tamping Unit"

1) Fault :-  Tamping unit not going down.

Probable causes and Remidial action.

A) Tamping unit lock not open.
Ensure that the lock is properly open.
B) Un-locking indication limit switch not functioning properly.
For proper functioning of limit switch input indication X5A for LH and X5B or RH should not appears on programme panel. If input is indicated, Limit switch is defective and should be replaced.

C) No system pressure.

If no system pressure, Check delivery from 38X22 hydraulic pump. If delivery is ok, Check non-return Valve, unloader valve and safety valve. Replace the defective one.
D) Defective propotional valve.
Ensure propotional valve ok. Follow these steps:-
a) Check the supply on propotional valve coupler with tamping pedal pressed. If it is found there and still, unit doesn't operate, propotional valve is defective. Replace defective propotional valve.
b) Operate propotional valve mannualy. If unit operates, the propotional valve is ok, and the problem is insolenoid coil. Replace the coil or complete propotional valve.
E) No  supply on propotional valve when tamping pedal is pressed.
a) Visualy examine the lock, limit switch, transducer fork and cord wire of the transducer. If no defect is noticed follow these steps :-
         Check deflaction on galvanometer 18G3 of programe panel with switch on position 1 for LH and position 2 for RH and do as follow:-
  i) If there is no deflection, Check supply of 24V and 12V on programme panel. Ensure of 24V and 12V.
  ii) If supply voltages ok, Check output voltage of +15V and +10V of PCB  EK813SV (10U5). If output is not proper, Replace the PCB EK813SV.
  iii)  If output voltage is ok, Check for output signal Q10 for LH and Q11 for RH. If output signal is ok , Check relay Re1,Re2,and Re5 respectivly of PCB EK16. Replace defective relay. Check for fuse os EK16 and replace it if defective.
iv) If  output signal Q10 and Q11 is not OK, check the following:
# Check switch for tamping system X19 in 'ON' position (Input signal X19 should come on programme panel).
# Tamping switch X10 should be in 'ON' position (Input signal X10 should come on programme panel).
# Check input signal X13 and X14.
   If no input signal, check tamping depth transducer for slipped fork, broken chord wire or defective potentiometer.
v) Output signal from depth transducer or both tamping unit is not synchronizing (difference more). If defference is more than 100 mm, either X13 or X14 will not come).  To operate both, the difference should be less than 100mm.
vi) Check switch X3E, tamping without lining should not be pressed (Input X3E should not come).
vii) If all the above conditions are fulfilled and still Q10 and Q11 is not coming, replace PCB EK16.