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INDIAN RAILWAY

SPECIFICATIONS FOR POINTS & CROSSINGS CHANGING MACHINE

FOR BROAD GAUGE (1676 mm)
(Specification No. TM/HM/PCCM/370 rev. 01 of 2016)

S. No. Month & Year of Revision/Amendment Reason for Amendment

approval
1. July-2009 Nil First Issue
2. July-2018 Rev.-01 Technical Review

Issued By:

Track Machine & Monitoring Directorate

Research Designs and Standards Organization
Manak Nagar, Lucknow-226011
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SPECIFICATIONS FOR POINTS & CROSSINGS CHANGING MACHINE

FOR BROAD GAUGE (1676 mm)
(Specification No. TM/HM/PCCM/370 rev. 01 of 2016)

1.0 GENERAL

1.1 These specifications have been framed for a robust and sturdy machines, which shall
take out the old turnouts and replace them by newly assembled turnouts expeditiously
and with desirable degree of accuracy. It shall also perform other related functions as
detailed in the following clauses.

1.2 The technical specifications have been drafted to reflect the performance and quality
requirement of the machine in a neutral manner without bias to any specific
manufacturer. Bidders are requested to study the specifications carefully and assure that
their machine fully comply therewith. If a bidder feels that his machine can substantially
meet the performance and quality requirements of the specifications, but does not fully
satisfy a particular specification, he should mention the same in the statement of
deviation from the specifications, giving the details how the functional requirements are
going to be met with.

1.3 The bidder shall specify the make/model offered and furnish a detailed technical
description of the machine. The machine may consist of more than one units and the
complete set of units required for performing the functions desired in the specifications
shall be treated as one machine. Systems/subsystems of the working mechanism of the
machine, as per Para 3 in particular and all items of the specifications in general, shall
be described in detail in the “Technical Description” along with sketches to show the
manner in which the requirements of the specifications are accomplished by the
machine (model) offered.

1.4 Photographs of the type of machine offered in working mode shall be enclosed with the
offer. This shall also show close-ups of various working assemblies/systems and the full
machine. The tenderer shall also furnish a compact disc (computer enabled) or DVD or
USB showing the working of machine in real time under field conditions. Tenderer shall
also submit the names of countries & Railways where the offered machines are working
and where their working at site can be visited by Indian Railway officials.

2.0 DIMENSIONAL AND OPERATING REQUIREMENTS

2.1 The machine shall be diesel powered which shall be robust, reliable and suitable for
working on straight, transition and curved tracks (upto 10 degree) on broad gauge (1676
mm) of Indian Railways. The design and dimensions of the machine and its components
shall be to metric standards and shall comply with provision of Indian Railways Schedule
of Dimensions-1676mm gauge(BG), revised, 2004 with latest corrigendum and upto date
correction slips issued. Quality assurance during manufacturing of the machine shall be
according to ISO-9001.The welding standard followed for manufacturing of machine
should conform to ISO: 3834, EN: 15085 or any other equivalent standard for welding
railway vehicle and components. The manufacturer should specify the standard followed
and certify that it meets the welding standard mentioned above.

2.2 The profile of the machine (including its units) longitudinally and in cross-section shall be
within the provision of Indian Railways Schedule of Dimensions–1676 mm gauge (BG)
revised, 2004 with latest corrigendum and up to date correction slips issued during
transfer as self-propelled vehicle on track or loaded on railway wagons. The minimum

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and maximum moving dimensions are enclosed at ANNEXUREI/I. Floor height of

standard railway wagon of BWT/B, in empty condition may be taken 1070 mm from Rail
level (Annexure-I/V) to determine the profile of machine as loaded on Indian Railway
BWT/B type wagon. Floor height may be reduced beyond 1070 mm in loaded condition.

2.3 Adequate clearance shall be allowed so that no component of any unit of machine shall
infringe the minimum clearance of 102 mm from rail level while travelling on track up to
condemnation limit.

2.4 Wherever applicable, Axle load of machine units shall be lesser than 20.32T with
minimum axle spacing of 1.5 m while moving on track with or without Turnout. Load per
meter shall not exceed 7.67 T.

2.5 It shall be desirable to have rail wheel diameter of 915 mm, however, lesser diameter
can also be considered.

2.6 Machine units shall be capable of negotiating curves up to 100 curvature (175 m radius),
super elevation up to 185mm and gradients up to 3% in travel mode.

2.7 It shall be capable of continuous operation during the varying atmospheric and climatic
conditions occurring throughout the year in India. The range of climatic conditions is as
follows:

Ambient Temperature : -50 C to 550 C

Altitude – Sea Level : 1750 m above mean sea level.
Humidity : Upto 100%
Max. rail temperature : 700 C.

All the system components on the machine, which are vulnerable to moisture ingress
and adversely affected during rains, should be covered by roof or suitable arrangement
so that the machine is able to work continuously even during rains.

2.8 During transfer from one station to another, the machine units should be equipped with
suitable arrangements to fasten & secure it properly on the Railway wagon, so as to
permit the movement of loaded Railways wagon at a speed of 75 kmph.

2.9 It shall be capable of working and travelling without requiring power block in electrified
sections.2x25KV AC power supply is used for traction through an overhead wire at 5500
mm above rail level on Indian Railways. The height is restricted to 4800 mm on bridges
and tunnels.

3.0 WORKING MECHANISM

3.1 The machine shall be required to handle 1 in 8 ½ or 1 in 12 or 1 in 16 or 1 in 20 turnouts

with Straight or curved switches or thick web switches and built up/cast manganese steel
/ welded crossing on concrete sleepers. The details regarding length and weights of 1 in
8 ½, 1 in 12 and 1 in 16 turnout on concrete sleepers is at Annexure I/II. Total weight of
60 kg 1 in 12 fan shaped concrete turnout is 54.936 tonnes and that of 1 in 16 is about
67.40 tonnes as mentioned at Annexure I/II. Out of this, while lifting the assembled
turnout more weight comes on the machine due to lifting the crossing side. Total weight
of assembly may increase even further with introduction of thick web switches and wider
sleepers for 25 t axle load. Considering these factors, lifting capacity of the machine

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shall not be less than 72 metric tonnes while lifting and transporting the assembled
turnout. If two or more than two units are used for the job, individual capacity of each unit
shall be equal and total capacity of these units acting as machine shall not be less than
72 metric tonnes. The machine should also be capable of handling Diamond turnout on
Concrete sleepers and Trap switches on concrete sleepers. Dimensional detail of
Diamond and Trap switch is enclosed at Annexure I/II.

3.2 Total number of lifting points (Left rail and Right rail lifting together at one location is one
point) in machine (all units involved in lifting at a time put together) should not be less
than 6 to avoid excess sag in assembled turnout on concrete sleepers when lifted by
machine. The load carrying capacity of each hook/chain/Jaw should be sufficient to lift
the complete assembled turnouts according to number of lifting points.

3.3 It shall be possible to change the entire turnout as one piece. However, if required by the
Purchaser, it shall also be possible to change the turnout in segments. The machine
shall however be so designed that it could be modified and /or augmented to handle
longer turnouts of 1 in 16 and 1 in 20 which shall be 55 m and 65 m long respectively.

3.4 The machine shall be capable of completing the following operations in a single traffic
block(refer sketch at Annexure -I/III)

a) Machine approaching the old turnout (G) from the side position near (A) or longitudinally
from position near (D) or from some parking position in the yard by Lateral shifting and
by moving on track.

b) Picking up of the complete assembly of old turnout (G) and its transportation and
deposition at Position near (A) or (B) depending on site conditions. It may be noted that
position near (A) may not necessarily be right opposite the old turnout and therefore the
old turnout may be required to be moved both longitudinally and laterally or else it may
have to be steered to Position near (A) or (B) at an angle other than right angle to the
track.

c) Transfer of machines to the new turnout assembled at position near (A) or (B) and its
lifting and transportation to the site of laying.

d) Laying of new turnout in place of old turnout.

e) Clearing of the site by the machines to position near (A) or (B) or some other position in
the yard after laying of Points and crossing.

3.5 The machine (with its units) should have following capability (Refer sketch at Annexure-
1/III) to perform the above function.

a) The machine and its units can be unloaded from Railway wagon in suitable siding line in
Railway Yard and can be self-propelled to position C and D with trolley without requiring
any assistance of another power/Locomotive. This movement of machine should
preferably be on Rail wheel on track so as not to infringe train movement on adjacent
track and negotiating from one track to another over turnout which may be required for
reaching position C and D is also comfortable.

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b) It should be capable of shifting itself with all necessary units from track (C) & (D) to the
position on ground at say position (A) and (B) which may be required for clearing
occupied track or to shift itself on the fabricated panel placed at position A and B. The
shifting facility and procedure should be simple and each set of unit being shifted should
be stable by itself not requiring additional assistance of any auxiliary unit.

c) It should be capable of laterally shifting fabricated assembly from position on ground at

say A or B to the nearby location for either directly laying the prefabricated panel or to
load it over trolley placed on track there for shifting on track to some other position of
laying .

d) It should be able to carry prefabricated turnout assembly over trolleys.

e) It should have arrangement for carrying the fabricated assembly longitudinally on crawler
on prepared bed for final laying and adjustment.

f) The machine should have the capability to self-load and unload itself with its units from
the Indian Railways wagon as per para 3.17.

The manufacturer should clearly state how the above capability has to be provided.

3.6 The supplier shall quote as part of the machine the following as applicable to his system.

a) Prime mover for longitudinal transfer of the old or new turnout assembly on track and on
ground.

b) Facilities for lifting, loading and unloading on and from trolley & laying of old or new
turnout assembly during the process of renewal.

c) Facilities of loading and unloading of machine and its unit on Indian Railway wagon for
transit from one station to other (Ref. clause 3.17) .The BWT/B wagons used on IR are
detailed in Annexure I/V, and total requirements of such wagons should not be more
than two.

d) Any other unit required for performing the operations mentioned in clause 3.4 and for
having capability mentioned at Clause 3.5.

3.7 As mentioned in para 3.5 above, the facilities for transfer of old or new turnout shall be
provided in the shape of trolleys. There should be minimum four numbers of trolleys to
avoid sag in assembled turnout. The powering arrangement for movement of trolleys
should be clearly stated. The trolleys should be motorized so that they are capable of
lifting the assembled turnout by at least 30 cm and at same time they should also be
capable of slewing the lifted turnout by at least 30 cm in either direction (left or right).

3.8 Various types of units comprising the system shall be quoted and described individually
and the total number of each type of units in the system shall be clearly stated. The
machine shall permit unrestricted movement of trains on the adjoining up tracks while
replacing a turnout, in situations mentioned at clause 3.4.

3.9 The machine shall also have the capability to change turnout on a Platform line (low and
rail level).

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3.10 The workers at site shall not be required to work under a lifted turnout at any stage of the
turnout changing operation.

3.11 Portal type unit of machine shall have preferably four legs or a Crawler with rail wheel
arrangement for movement on track for ensuring stability and safety. Crawlers shall
move on continuous steel chains provided in machine units for movement on ground.
Crawler chains should be covered with rubberized shoe plates to avoid any damage to
the rails, sleepers and other track fittings. It is desirable that the rubber soles are made /
fitted in such a manner that the replacement / recoupment are possible during the
service life of machine. Further during the service life of machine, replacements of
rubber soles should be treated as a spare part for which the supplier has to ensure
availability of rubber sole and its fitment on the steel chains (read with para12, as well).

3.12 Machine may require to pass an OHE mast, a signal post or a wagon standing on
another line, etc. during longitudinal transfer of the turnout on track. The cycle of by-
passing such an obstacle by laterally shifting the turnout by 1 m, then moving 50 m in
forward direction and again reverting back to the original position by lateral shift shall not
take more than 6 minutes.

3.13 While working on platform lines, if the platform is to be used for machine working, the
maximum pressure applied on platform surface by machine and its units supporting the
prefabricated panel shall not exceed 3 kg /cm2.

3.14 The operations of travelling, lifting / lowering or lateral shifting shall not be sudden or
jerky to avoid distortion of the turnout. During transport of the linked turnout, rails,
sleepers and other track components are subjected to handling stresses so it is
desirable that the mechanism of picking up and handling is smooth.

3.15 Operations of gripping / releasing of turnouts and lifting /lowering, travelling & braking
shall preferably be done from one operating panel for the purpose of better
synchronization and reduced stresses on the turnout. In any case, if more than two
operators and corresponding number of units have to perform travelling/ braking/ lifting /
lowering / shifting operations, simultaneously, the machine shall have in-built system of
synchronization of the motion of all units. Provision should exist for either synchronized
working or the independent working of the machines by operation of switch inside the
working cabins wherever applicable.

3.16 There shall be adequate safety arrangement to ensure proper locking of the lifted turnout
to avoid any chance of falling of the same. It is desirable to maintain the lifted turnout in
one horizontal plane. Suitable arrangement and control systems may be provided on the
machines for this purpose.

3.17 The machine units which are not self-propelled for transfer from one station to another
and are required to be loaded on Railway wagons for transfer, the same shall be self-
loading / unloading type or else a crane or suitable equipment or arrangement required
for loading/unloading of the machine units shall form the part of the machine and be
quoted by the tenderer accordingly. The loading/unloading equipment or arrangement of
self-loading / unloading on Railway wagons shall be transported along with the
machines. The wagon floor height may be taken same as in Clause 2.2. Also, the loaded
profile should not infringe the minimum and maximum moving dimensions enclosed at
ANNEXURE I/I.

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3.18 Sag in the turnout in lifted position during transit or during laying shall not be more than
20cm at any point for 52 / 60 kg rails turnouts on concrete sleepers. Calculation may be
submitted in support. The lifting location and number of transportation trolleys may be
increased if required to achieve the sag within the specified limits.

3.19 There shall be provision for longitudinal and lateral adjustments of the lifted turnout
assembly for at least 20 cm in the assembly lifting unit of machine for accurate
positioning at the time of final laying for proper butting of Stock Rail Joint and Back Leg
of Crossing.

3.20 In the case of machines provided with sliding beams and tubes, there should be
provision of lubrication/rollers on the metallic surfaces in contact with each other. The
beam should be made to slide inside the tube with wear plates surrounding the beam in
such a manner that, the beam's surfaces do not rub directly on the tubes insides. This
will ensure that neither the tube nor the beam is damaged in case of wear due to metallic
friction and wear is borne by the especially designed wear plates. The wear plates
should be fixed on the beam in such a manner that they can be replaced with ease.

3.21 The complete break-up of the cycle time inlaying of one prefabricated assembly of 1 in
12 turnout and clearing the site by machine for train operation over newly laid turnout in
the situations given in Annexure 1/VI shall be given by the tenderer in his description of
the working of the machine. This will include steps involved in shifting of machine to
position of fabricated panel, positioning itself for clamping, lifting, laterally shifting,
longitudinal shifting, transportation, lowering, butting of Stock Rail Joint and releasing of
the turnout and clearing the relayed point. The maximum lateral and longitudinal stroke
assumed for the purpose shall also be specified.

3.22 Speed of longitudinal transfer of the machine while carrying a 1 in 12 concrete sleeper
turnout shall be furnished.

3.23 The supplier should get acquainted himself with normal Indian Railway yard layouts and
the types of terrain available in the Indian Railway yards. The machine should be able to
work successfully in all the yards and the timings mentioned in para 3.21& 3.22 above
should take into account the realistic yard conditions.

3.24 The offer shall also be submitted separately including a complete scheme of operations
with timings to cover all the operations like machine approaching the old turnout,
removing the old turnout, shifting the same to the location specified, placing it on ground,
machine approaching the new turnout, picking it up, bringing of the new turnout to the
site of laying, laying of new turnout and clearing of the site by the machines.

3.25 The holding and lifting (which is normally by clamping on rail) of turnout assembly by
machine during lateral shifting, longitudinal shifting, transportation & final laying should
be rigid enough so as not to normally take reaction from sleeper at any time which may
disturb the original position of sleeper on assembled turnout. All units involved in the
process should also be synchronized.

3.26 The machine should be equipped with GPS, GSM/GPRS based remote monitoring
capabilities for monitoring the location of machine on real time basis. The data transfer
unit of this equipment should be compatible with the Track Management System (TMS)
of IR.

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4.0 DIESEL ENGINE

4.1 The machine and its unit shall be powered by diesel engine preferably indigenous, with
proven record of service in tropical countries; robust construction and low maintenance
cost are of particular importance. Adequate allowance shall be made for de-rating of
diesel engine under the most adverse climatic conditions mentioned in this specification
elsewhere.

4.2 The supplier shall furnish the details of diesel engine and its controls to assess its
conformity with the engines already operating on track machines on Indian Railways.
The engine should be one of such designs/brand which is being manufactured
indigenously and/or such designs, whose after sales servicing facilities are available in
India.

4.3 High-speed diesel oil to Indian Standard Specification shall be normally used. Minimum
fuel tank capacity sufficient for continuous operation of each unit of machine for 8 hrs will
be desirable.

4.4 Sight glass type fuel measuring gauge preferably of full height shall be provided on the
fuel tank.

4.5 For starting the engine, storage batteries of well-known make shall be provided for
starting the engine. The engine shall normally be push/pull button start type or key type.

4.6 Since the engine has to work outdoor under extreme dusty conditions, the air intake
system shall be designed suitably so as not to allow dust through air intake system.

4.7 There is a likelihood of dust deposition over the engine body and surrounding area over
the lubricants spill over. These should be easy to access for daily cleaning and routine
maintenance. In case, air cooled engines are proposed by the supplier, maintenance
equipment for cleaning and maintenance of the air cooling fins shall be provided by the
supplier along with the machine.

4.8 The engine parameter monitoring gauges like temperature, rpm, and lubricant Oil
pressure shall be direct reading type mounted on the engine backed up by
electrical/mechanical gauges in the operator's cabin showing the absolute readings
along with safe limits suitably coloured. There shall be audio visual warning (safety
mechanism) to the operators in case of any of the parameters exceeding the safe limit,
engine shut down automatically.
4.9 Suitable and rugged mechanism should be provided to start the prime mover at no
load/minimum load and gradual loading after the start of the prime mover.

4.10 The engine power take off shall be coupled to the main gear box through a flexible
coupling. The engine shall be mounted on suitable Anti Vibration Mountings.

4.11 The tenderer should furnish the information regarding make and model of the engine
proposed to be used and details of agency which will provide after sales service support
and availability of spares in India, details of diesel engine and its controls to assess its
conformity with the engines already operating on track machines on Indian railways. If
the machine design incorporates an engine, not already operating with the purchaser,
the model of the engine is liable for change as per the technical requirements and the
maintenance logistics with the purchaser after technical negotiations with the supplier.
Nothing extra shall be payable on this account.

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4.12 In order to adhere to pollution control norms, the diesel engine should be electronically
controlled emmissionized engine with minimum compliance of tier 2 stage.

4.13 The engine should be enclosed in a weather protective, sound and dust resistant
enclosure to minimise engine noise and to prevent oozing out of oil spills etc. from
engine area to the adjacent machine components, hoses, electrical cables fittings as a
protection against fire. All doors on the enclosure shall be strategically located in areas
as to allow ease of maintenance of the engine and allow good access to and visibility of
instruments, controls, engine gauges, etc. Sufficient louvers shall be provided to allow
the total engine cooling air requirements used in this application.

5.0 COOLING SYSTEM

5.1 The cooling system shall be efficient and designed for a maximum ambient temperature
of 55°C. Supplier may note that the machine shall be working under extreme dusty
conditions and the cooling mechanism should be maintainable under these conditions.
Adequate heat transfer arrangement shall be provided so that under extreme heat
conditions as mentioned in Para 2.7 above, the system oil temperature does not go
beyond specified range of the engine.

6.0 BRAKES
6.1 Hydraulic/pneumatic brakes shall be provided. The brakes provided for the different
operations shall be protected from ingress of water, grease, oil or other substances
which may have an adverse effect on the brake. The brake lining shall be suitable for
high ambient temperature of 550C. The force required for operating the brakes shall not
exceed 10 kg at the handle while applying by hand and 20 kg on the pedal when applied
by foot.

7.0 HORN, HOOTER AND SAFETY SWITCHES

7.1 The machine units capable of independent movement shall be provided with
electric/pneumatic horns at suitable location. The horns shall be distinctly audible from a
distance of at-least 200 m from the machine unit. The horns shall be operated by means
of push buttons provided in the operating panel and also outside the machine body at
appropriate locations. Wherever feasible adequate numbers of safety stop switches
should be provided in the body of machine unit so that in case of any danger to worker
during working, the working can be stopped immediately.
7.2 Machine shall be provided with emergency backup system to wind up the machine in the
event of failure of prime mover or power transmission system of the machine.

7.3 One Pneumatically/electrically operated hooter capable of producing intensity of sound

between 105-110 db at a distance of 5 meter (when measured in still air in a closed
room) and with variation in intensity of sound not be more than 5 dB shall be provided as
a unit with the machine. The hooter shall be fixed in one of the main unit facing outwards
at suitable locations, operated by means of push buttons provided in the operating panel
to warn the staff working on/around the machine about approaching train on adjoining
track. Additional switches for such hooter shall be provided outside on the main machine
unit frame so that it can be operated by staff present at work site near the machine unit.
The hooter shall also be operatable from remote point at a distance of at least 300 m
from the hooter.

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8.0 ELECTRIC EQUIPMENT AND LIGHTING

8.1 The electrical equipment to be provided shall conform to relevant standard specifications
and shall be suitable for Indian climatic conditions. The machine units capable of
independent movement shall be equipped with head light at each end and with two front
and rear parking lights, which can be switched on to red or white according to the
direction of the travel. Powerful swivelling floodlights shall also be provided in main
working units to illuminate the working area sufficiently bright for efficient working during
night.

9.0 STRUCTURAL FRAME

9.1 The body framework shall be of standard welded steel sections and of steel sheets, so
as to permit transportation of the machine properly secured on a wagon.

10.0 CABINS

10.1 Wherever operators’ panel are provided in cabins, the cabin of that machine unit shall be
fully enclosed with safety glass windows. In view of the high ambient temperature
prevailing in India, special attention should be paid to free circulation of air and
ventilation in the cabin. It shall be possible to have a clear view of the track ahead while
driving/working the machine.

10.2 The gauges, instruments and controls shall be suitably located in the operator’s panel so
that they can be observed without undue fatigue to the operator. One screen wiper shall
be provided preferably operated by compressed air/Electrically on the front window of
cabin where ever applicable.

10.3 Suitable no. of fire extinguisher shall be provided in the cabin. The chemicals used for
extinguishing fire by such fire extinguishers shall not chemically react with electronic
equipments/components, PCBs, cables etc.

10.4 The machine shall be provided with adequate space for keeping the tools and spares
required for on-site repair of the machine to attend the breakdowns and other working
requirements.

11.0 TOOLS & INSTRUCTION MANUALS

11.1 Each machine shall be supplied with a complete kit of tools required by the operator in
emergency and for normal working of the machine. The list of tools to be provided shall
include all tools necessary for maintenance and repair of the entire machine including
specialized equipment. All special tools shall be listed and catalogued illustrating the
method of application. The tenderer shall along with his offer submit the list of tools to be
supplied along with each machine. The list can be modified to suit the purchaser’s
requirement, while examining the offer.

11.2 Detailed operating manual, maintenance and service manual, service and repair
instructions shall be specially prepared in English language and four hard copies & soft
copies of each of the same shall be supplied with each machine.

11.3 The manufacturer shall also supply circuit diagrams of electrical, hydraulic, pneumatic
and electronic circuits used on the machine and its unit. Trouble shooting diagram/table
shall also be supplied. In addition, the tenderer shall provide dimension and drawings

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with material description of items like rubber seals, washers, springs, bushes, metallic
pins, etc. Main features such as type, rpm & discharge etc. of items like hydraulic
pumps, motors and such other bought out components/assemblies shall be furnished by
the tenderer. These shall be specially prepared in English language and four copies of
these shall be provided with each machine.

11.4 While offering the machine for first inspection, the supplier shall submit one copy of
complete technical literature in English language including operation, service and
maintenance manual/instructions and complete electrical, electronic hydraulic &
pneumatic circuit diagrams, troubleshooting charts, component drawings/description and
other relevant technical details as reference document for the inspecting officer.

11.5 A draft copy of all documents to be supplied with the machine should be sent 3 months
in advance of inspection of the first machine to RDSO for their review regarding
adequacy and manner of detailing. Necessary modifications and further detailing as per
RDSO’s comments should be carried out and compliance should be reported to RDSO
as well as the Inspecting officer of the first machine.

11.6 One set of all the manuals and diagrams should also be sent to the Principal/IRTMTC,
Allahabad, one set to ED/TMM, RDSO, Lucknow, one set to DTK (MC)/Railway Board
and one set to Director/IRICEN/Pune along with supply of first machine of similar group.
In case, there is any subsequent amendment in above documents based on field
performance, the amendment/amended documents should also be sent to above
mentioned authorities.

11.7 One portable diesel operated D.C. welding plant (with the provision of auxiliary output of
minimum 2.5 KW, 230 V AC for lighting) of reputed make (preferably made in India) with
a minimum 5 KVA capacity capable of welding upto 5 mm electrode (dia) at 60% duty
cycle shall be supplied. Sufficient cable or lead shall be provided with the welding plant
for day to day repairing of machine and its wearing parts. The diesel tank capacity shall
be not less than 10 liters.

12.0 SPARE PARTS

12.1 The tenderer should quote, apart from main equipment, separately for the mandatory
spares as well as for recommended spares required for two years of operation along
with description, part number, quantity, cost, whether imported or indigenous. The
expected life of the components/spare parts should be advised along with their
condemning limits. The manufacturer shall be responsible for the subsequent availability
of spare parts to ensure trouble free service for the life of the machine (20 years). For
indigenous parts, and bought out components and assemblies the source (original
equipment manufacturers reference and part number) and other technical details shall
be supplied while offering the first machine for inspection.

13.0 MAKER'S TEST CERTIFICATE

13.1 Copies of Maker’s certificate, guaranteeing the performance of the machines shall be
supplied in duplicate along with the delivery of each machine.

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14.0 OPERATORS

14.1 The number of operators and allied staff for working of the machines under normal
condition shall be indicated, specifying their duties and minimum qualifications.

15.0 OPTIONAL EQUIPMENT

15.1 Tenderer is expected to quote for optional equipment separately for each item giving the
advantages/functions of such optional equipment. Tenderer shall also indicate whether
such equipments are already in use on machines elsewhere indicating the user Railway
system.

16.0 WARRANTY

16.1 In addition to the special conditions of contract dealing with warranty, the following will
apply.
The machine shall be warranted for 1200 effective working hours or 18 months from
date of commissioning and proving test of equipment or 24 months from date of delivery
at ultimate destination in India whichever shall be earlier. Effective working hours for this
purpose will be traffic block time during which machine is deployed for work. If any
design modification is to be made in any part of the equipment offered, the warranty
period of 18 months would commence from the commissioning and proving test of
equipment for the purpose of that part and those parts which may get damaged due to
defects in the new replaced part. The cost of such modification should be borne by the
supplier.

17.0 INSPECTION OF THE MACHINE

17.1 While inspecting the machine before dispatch from the supplier's premises, the
inspecting officer shall verify the conformity of the machine with respect to individual
specification as above. The machine's conformity/non-conformity with respect to each
item shall be jointly recorded before issue of the inspection certificate and approval for
dispatch of the machine as per Annexure-IV enclosed.

17.2 Following arrangements shall be made by the supplier/Manufacturer at the inspection

premises for carrying out inspection of the machine by inspecting officials:

 Machine units are to be stabled on straight & level BG track. The length of the
track should be at least 10 m more than buffer to buffer length of machine.
 In order to check Maximum Moving dimensions in cross section, a Sturdy frame of
IR Max Moving Dimensions shall be provided by the manufacturer and passed
over the machine units (loaded on wagon or raised to the floor height of wagon)
holding it perpendicular to track, centre aligned with track centre. Adequate
arrangements shall be made to the satisfaction of inspecting official

17.3 The following documents shall be provided to the Inspecting Officer at least 4 weeks in
advance of the date of inspection.

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i) One copy of complete technical literature mentioned in clause 11, in English language,
including operation, service and field maintenance manuals/instructions and complete
electrical, hydraulic and pneumatic circuit diagrams, trouble shooting charts, component
drawings/ description and other relevant technical details as a reference documents for
the inspecting officer.
ii) Cross section of the machine units (both on track and loaded on wagon) super imposed
on IR maximum moving dimensions envelope shall be provided to IO in advance.
iii) Clause by clause comments of the manufacturer to be sent to Inspecting Officer (IO) in
advance for his review. Comments should state manufacturer’s conformity of compliance
of each of the requirement stated in each clause, elaborating where necessary the
details/manner in which the requirement has been complied. The proforma for the
clause-wise comments is given below:
Clause Clause no. Comments of Comments of Inspecting Officer
Supplier/manufacturer

iv) Manufacturer’s Internal Quality Inspection Report of the machine.

v) Manufacturer’s quality certificate and/or test reports for bought out assemblies/sub-
assemblies to be provided to IO, containing serial number wherever applicable.
vi) Draft Inspection Report to be prepared by the manufacturer, containing all annexure
mentioned at para 17.4
vii) Details of arrangements made for checking Maximum Moving Dimensions for his
approval.

Supplier will incorporate amendments/further clarification in the above documents to the

satisfaction of the Inspecting Officer keeping in view the Inspecting Officer’s comments, if
any.
List of documents to be annexed in the draft Inspection Report should include:
i. Maker’s Test Certificate.
ii. Manufacturer’s Internal Quality Inspection Report
iii. Quality Certificates of Bought out assemblies/sub-assemblies.
iv. Cross section of the machine units when on track and when loaded on wagon super
imposed on the IRMMD.
v. List of spare parts to be dispatched along with the machine.
vi. List of tools to be dispatched along with the machine.
vii. List of Manuals, Drawings, Spare Parts Catalogues, etc. to be dispatched along with the
machine, duly indicating the number of sets of each.

These above documents shall be part of final inspection report.

18.0 ACCEPTANCE TESTS

In addition to verification of the various items of specifications covered earlier, the

following tests shall be carried out in India at the Purchaser’s premises by the
Purchaser’s nominee at the time of commissioning of the machine.

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18.1 Dimensional check of loading gauge i.e. maximum moving dimensions, clearance with
machine units on track and on wagons wherever applicable etc.

18.2 Testing for negotiability of machine units capable of moving on track of 10 0 curve and
on1 in 8 ½ turnout where ever applicable, on the first machine.

18.3 Stability test of machine loaded on Indian Railway wagon being pulled by power. Any
arrangement to be made on first wagon for fixing the machine properly is to be done by
the supplier. The details of wagon shall be as per para 2.2.

18.4 Construction and engineering of the machine and its ability to perform all the functions
as laid down in the specifications above.

18.5 Actual output and performance quality test

These tests shall consist of the use of machine under field conditions in India. The
machine shall be operated by the trained personnel of the purchaser or the operators
provided by the supplier. The following operations will be conducted. (Refer sketch at
Annexure 1/III).

a) The time taken in laying pre-assembled assembly from position (A) by lateral
shifting to position (G) with proper alignment and butting of stock rail joint and back
leg of crossing, taking initial position when machine units are in complete readiness
with fabricated assembly should not be more than one and half hour. The laying is
to be done primarily by lateral shifting without using transportation trolley to
beforehand prepared bed at G. The above requires lateral shifting of minimum 6m
and longitudinal shifting minimum 2 m. The time of one and half hour to include
clearing of laid assembly by machine units for permitting movement of train over the
laid assembly.

b) The time taken in laying pre-fabricated assembly (B) by shifting the assembly on
trolley to Position (G) with proper alignment and butting of stock rail joint and Back
leg of crossing taking initial position when machine units are in complete readiness
with fabricated assembly for loading on trolley placed in the siding line should not be
more than one and half hour. The laying would primarily be by longitudinally shifting
the assembly to the beforehand prepared bed at (G). The above requires
longitudinal movement up to 700 m. The time of one and half hour to include
clearing laid assembly by machine units for permitting movement of train over the
laid assembly.

c) Test of machine capability as per Item 3.5.

d) Self-loading/unloading of machine on wagons or loading by other equipment in

accordance with Para 3.17 including self-loading of the equipment itself.

19.0 Should any modifications found necessary as a result of the tests, these shall be carried
out by the supplier at his own expenses.

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20.0 TRAINING AND SERVICE ENGINEERS

20.1 The supplier shall provide at his own expense the services of competent engineers
during the warrantee period for warrantee related issues. The service engineers shall
be available for the commissioning of the machine for regular service. E-Learning
courses module should be arranged for imparting training to railway operators. In
addition the service engineer shall provide hands on training to railway staff in
calibration, operation, repairing and maintenance of the machine in field to make them
fully conversant with the machine. The engineers shall also advise the Railways on
appropriate maintenance, testing, operating, repair and staff training facilities that are
necessary for the efficient performance of the machines.

21.0 MARKING & COLOUR OF MACHINE

21.1 The machine body shall be painted in golden yellow colour of Indian Standard Colour
code of 356 as per IS:5. The exterior painting shall be polyurethane binder based
conforming to RDSO Specification No. M&C/PCN/100/2013 (Specification for Epoxy
cum Polyurethane Painting System–Two packs for the Exterior Painting of Railway
Coaches, Diesel and Electric Locomotives and other Industrial Applications) or ISO
12944.
21.2 Following should be written in black on the machine at appropriate location in English &
Hindi as per direction of Indian Railway official

i. Indian Railways logo of suitable height in different machine units at prominent

locations.
ii. “INDIAN RAILWAYS” is to be written in Bold and in Black colour of appropriate
size for clear visibility at prominent location on different units of machine.
iii. Manufacturers Name and Machine model and manufacturing Year should be
written in black colour and in letter of size less than the size in which Indian
Railways is written and at suitable locations.

******

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Annexure-I/I

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Annexure-I/III

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Annexure-I/IV
INSPECTION CERTIFICATE

CERTIFICATE OF INSPECTION OF TRACK MACHINE ( ) BY INSPECTING OFFICIAL AND

APPROVAL FOR DISPATCH OF MACHINES. (STRIKE OUT WHICHEVER NOT
APPLICABLE)

This is to certify that I have inspected the machine

type)_______________________________bearing Sl.No._________________ from(date)
____________to _____________at (Place) ________________ for its conformity/non-
conformity with respect to the laid down Technical Specifications in contract Agreement
No.________________________________dated_______________________between
President of India through Director Track Machines and M/s. (Name of Supplier)
__________________________
_____________________________________.

The detailed Inspection note regarding its conformity/non-conformity to the laid specifications is
to be enclosed along with this certificate. It is observed that (strike out whichever is not
applicable):-
The Machine conforms to all the laid down specifications. The machine conforms to all the laid
down specifications except those at Sl.No.________________________. The above deviations
are minor/major affecting/not affecting the performance of the equipment in substantial way. The
following T and P/manuals/drawings are to be supplied along with the machine:
__________________________
__________________________
__________________________

Based on the above, the Machine is certified/not certified to be conforming to the specifications:
The machine is approved/not approved for dispatch to
_____________________________(Consignee) Indian Railways.

SIGNATURE AND DATE

For M/s.__________________ INSPECTING OFFICIAL
___________________ (NAME AND DESIGNATION)
For and behalf of President of India

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Annexure-I/V

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Annexure-I/VI

TIME TAKEN IN LAYING 1 in 12 POINTS AND CROSSING

The complete break-up of the cycle time in laying of one prefabricated assembly
of 1 in 12 Turn out and clearing the site by machine for train operation over newly laid
T/O in the below two situation is to be given (reference Annexure 1/III) :

Case –I: Machine (including all units) is at C and newly prefabricated T/O assembly is at
A. Existing laid assembly G is to be shifted to cess close to A and then new assembly at
A is to be laid in its place. The prefabricated panel is at a distance of around 6m or more
from the siding line on which machine is positioned initially. Also the new assembly at A
is not in the complete lateral alignment of existing T/O G and is required to be shifted by
not less than 2 m towards Stock Rail Joint for laying at required position.

The breakup of time is to be given activity wise as given below which may be further split
into sub activities involved wherever felt necessary.

 Shifting of machine from C to the existing T/O assembly at G and removal of T/O
assemble to cess.
 Further shifting of machine to new fabricated T/O at A.
 Shifting and Laying of the new T/O assembly at the position G by lateral shifting without
use of trolley including longitudinal adjustment of minimum 2 m required.
 Clearing of site by machine back to position C by lateral shifting or by movement on
track as comfortable taking minimum time.

Brief on how these activities will be performed should also be given

Case-II: Machine (including all units) is at Don siding line and prefabricated T/O
assembly is at B close to the siding line. Laying is to be done at G where existing points
and crossing is dismantled and bed is prepared beforehand. The net longitudinal
movement is 700 m.

The breakup of time is to be given activity wise as given below which may be further split
into sub activities involved wherever felt necessary.

 Shifting of machine from C to over assembled T/O at B and shifting the assembly on
trolley on siding line.
 Time in transit of the assembled T/O on trolley to the site of laying.
 Time in activities involved in actual laying and correct placement of new T/o.
 Time in clearing the site by machine to position C by lateral shifting or by movement on
track as comfortable taking minimum time.

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