GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

INSPECTION CHECKLIST
OF
BALLAST REGULATING MACHINE

REPORT NO. TM- 96

February– 2006

RESEARCH DESIGNS & STANDARDS ORGANISATION

LUCKNOW-226011
Name of Inspecting Officer:

Designation :

Date of Inspection :

Machine No. & Make :

Base Station :

Items To Be Checked

S. Item Description Condition

No.
1. Oil/Coolant Levels
i) Hydraulic oil in tank HLP-68 or equivalent Ok / Less
ii) Diesel tank HSD Ok / Less
iii) Axle gear box SAE-90 or equivalent Ok / Less
iv) Transmission gear box SAE-90 or equivalent Ok / Less
v) Engine lube oil API CF4 15W40 or Ok / Less
equivalent
vi) Funk gear box SAE-90 or equivalent Ok / Less
vii) Water/ Coolant level in radiator Coolant Ok / Less

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S.No. Item Condition

2. Engine: (As per maintenance schedule)

Engine Model & No:

Engine hours:
i) Starting problem Yes / No
ii) Condition of smoke White/black/normal/grey
iii) Maximum Engine temperature after two hours working °C
iv) Leakage in Head gasket No/ Yes (Head no.)
v) Electrolyte level in batteries Ok / Less
vi) Specific gravity of electrolyte Ok / Less
vii) Belt tension Ok / To be tightened
viii) Condition of Engine Hoses Ok / To be replaced
ix) RPM of the Engine
x) Battery charging circuit Working/Not working
xi) Whether working gauges are in order:
a) RPM Yes / No
b) Oil pressure Yes / No
c) Temperature Yes / No
d) Battery charging Yes / No
xii) Engine oil pressure
Idle speed : 1.5 kg/sq. cm
Rated speed : 2.5 kg/sq. cm
xiii) Any abnormal sound from engine Yes/No
xiv) Engine safety Circuit Working / Not working
xv) Last change of air cleaner done on Dated
Engine hrs
xvi) Last change of engine oil done on Dated
Engine hrs
xvii) Last change of engine oil filters done on Dated
Engine hrs
xviii) Last change of diesel filters done on Dated
Engine hrs
xix) Last charging / change of batteries done on Dated
Engine hrs
xx) Last change / repair of
a) Self starter done on Dated.
Engine hrs
b) Alternator done on Dated.
Engine hrs
xxi) Last over-hauling of the Engine done on Dated
Engine hrs
xxii) Last calibration of fuel injection pump done on Dated
Engine hrs
xxiii) Last calibration of fuel injectors done on Dated.
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 Engine hrs
S.No. Item Condition

3. Power Transmission:
i) Oil leakage in gear boxes Yes / No
ii) Universal joints Ok / To be attended
iii) Clutch adjustment Ok / To be adjusted
iv) Abnormality in cardan shaft No/ To be attended
v) Greasing of all cardan shafts Ok / To be done
vi) Tightness of engine mounting bolts Ok / To be tightened
vii) Condition of shock absorber Ok / To be attended
4. Broom Unit:
i) Condition of Broom chain Ok / Not Ok
ii) Greasing of broom reel bearing Ok / To be done
iii) Tightness of sweeping elements. Ok / To be tightened
iv) Tightness of broom3 chain Ok / To be tightened
v) Condition of broom clamp bolts Ok / To be replaced
vi) Condition of broom bearing Ok / To be replaced
vii) Greasing of broom bearing Done/ Not done

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S.No. Item Agent C o n d i t io n

5. Wing Unit
i) Greasing of ballast wing Grease Done / Not done
ii) Greasing of wing Pivot Grease Done / Not done.
iii) Greasing of wing lift frame Grease Done / Not done.

6. Hydraulic and Hydraulic Hoses:

i) Any rubbing in hydraulic hoses No/ Yes (Location)
ii) System pressure for rated settings Ok / Not ok
iii) Charge flow filter element (10 micron) Cleaned / Clogged
iv) Leakage of oil from hydraulic circuit. No/ To be attended
v) General condition of hoses Ok / To be attended
vi) Hoses required to be changed Indicate numbers and
sizes
7. Electrical
i) Working of Emergency back up pump Working / Not working
ii) Battery charging system Working / Not working
iii) Electrical gauges Working / Not working
iv) Cooling system Working / Not working
v) All electrical lights Working / Not working

8. General:
i) General cleanliness of the machine Ok / To be cleaned
ii) Spares availability on the machine Sufficient/Deficient
(as per Annexure-I)
iii) All the safety item are present Yes / No
(as per Annexure-II)
iv) Log books & Schedule registers are filled Yes/No
properly
v) Locking devices Working / Not working
vi) Condition of broom swear element Ok / not ok
vii) Condition and clearance of brake shoes Ok/ To be attended
viii) Condition of machine working tools Satisfactory / To be
( spanner set etc. ) replaced
ix) Competency certificate of operator Current / Expired

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S.No. Item C o n d i t io n

9. During Block Working:

i) Location of working
ii) Post ballast profile Satisfactory / Not
satisfactory
iii) Duration of block
iv) Output of work
v) Machine protection is being done by PWI / machine Yes/No

10. Staff:
i) Strength of staff Full / Deficient
ii) Group performance Excellent / V. good /
Good / Average
iii) Cost awareness amongst staff Yes / No
iv) Safety awareness amongst staff Yes / No
v) Staff due for medical
vi) General condition of the machine Excellent / Very good /
Good
vii) Control Chart of Output Upward /Normal /
Downward
viii) Pending maintenance schedules & reasons
ix) Any other remarks by Inspecting Officer

Signature of Inspecting Officer

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 Annexure-I

LIST OF SPARES

S. No. Description Part no. Quantity

1. Fuel filter 3166555 2 Nos.
2. Lube Oil Filter 3166554 1 No.
3. Lube Oil Bypass filter 3873576 1 No.
4. Air cleaner element outer 4055280 1 No.
5. Air cleaner element inner 4055279 1 No.
6. Injector pipe in let 1 No.
7. Injector pipe outlet 1 No.
8. Injector copper washer 12 Nos.
9. Injector fuel feed connection pipe 6 Nos.
10. Cable for engine accelerator 1 No.
11. Charge flow filter (Hydraulic) 714374 1 No.
12. Return filter 10 Micron (Hyd.) 733692 2 Nos.
13. Broom element 230016 10 Nos.
14. Brake shoe 732166 4 Nos.
15. Hydraulic pressure pipe 1509/4 10 Meter
16. Hydraulic pressure pipe with 1509/16 1100 mm 1 No.
end connections
17. Hydraulic pressure pipe with 1509/20 1900 mm 2 Nos.
end connections
18. Hydraulic pressure pipe with 2755/20 2000 mm 1 No.
end connections
19. Hydraulic pressure pipe with 1509/10 2000 mm 1 No.
end connections
20. Broom driving chain 1” with chain 210011 1 No.
lock
21. Broom drive shaft bush and bearing 211222, 211620, 1 each
161099
22. V-belt for engine B-43, 41, 37 1 set
23. Seal set for hydraulic cylinders 1 set
24. Self starter 1 No.
25. Stock of hoses with the machine
26. Stock of hose fittings

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 Annexure-II
LIST OF TOOLS AND PLANTS

S. No. Description Part no. Quantity

1. Jack 5 t with foot lifting arrangement 1 No.
2. Socket ¾ inch square drive 106763 1 No.
3. Chain wrench 5/8”-4,1/2” 106766 1 No.
4 Open end wrench 1 –11/16” 773878 1 No.
5. Handle T-bar 031097 1 No.
6. Adopter T-bar 031010 1 No.
7. Socket ¾” square drive 040891 1 No.
8. 12 PT 2, ¼ , ¾ ''drive 106298 1 No.
9. Pipe wrench 18” 106760 1 No.
10. Socket 3,1/2 size, 6 PT 108321 1 No.
11. Grease gun having needle type nozzle 300010 1 No.
with 18" flexible connection
12. Pliers Allo joint combination 6” 300152 1 No.
13. Screw driver 4” 300256 1 No.
14. Screw driver 6” 300258 1 No.
15. Wrench ADJ 6” 300406 1 No.
16. Socket set 17 PCs ½” drive 300502 1 No.
17. Wrench ADJ 12” 300406 1 No.
18. Wrench 2-3/8 open end 301050 2 Nos.
19. Wrench set 9 PCs open end 301060 1 No.
20. Wrench set Hex Key 301061 1 No.
21. Wrench combination 1,1/2” 106057 1 No.
22. Diesel driven Porta-filter (10  ) 1 No.
having 7.5 HP engine.
23. Emergency back up system. 1 No.
24. Torque wrench 1 No.
25. Wire Brush 1 No.
26. Pneumatic air gun for pressurized air 1 No.
(with pressure gauge)
27. Lamp arrangement for inspection 1 No.
28. Calipers off sizes 1 No.
29. Pressure gauge (Digital) 1 No.
30. Litmus paper 1 No.
31. Bench grinder 1 No.
32. Multimeter 1 No.
33. Bearing puller 1 No.
34. Steel scale 1 No.
35. Taper gauge upto 1" 1 No.
36. Feeler gauge 1 No.
37. Cell Tester and battery charger 1 No.

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 Annexure-III

LIST OF SAFETY TOOLS

S.No. Description Quantity

1 Detonators 1 Box

2. Hand Signal Flag Red 2 Nos

3. Hand Signal Flag Green 1 Nos

4. Hand Signal Lamp 2 Nos.

5. Chain and Pad Lock 02 Set

6. Terfor (2 tonne capacity) 1 No.

7. 20t Jack with traverser 2 Nos.

8. Crow bars 2 Nos.

9. Wooden blocks off sizes 8 Nos.

10. Field Telephone 1 No.

11. Skids 4 Nos.

12. Working Time Table 1 No.

13. G&SR Book 1 No.

14. Banner Flag 2 Nos.

15. Warning hooter 1 Nos.

16. LV board/ Tail Lamp 1 No. Each
17. First Aid Box 1 No.

...........
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 ACKNOWLEDGEMENT

Following officers and staff have made their valuable contributions in finalization
of the Inspection Check List for Ballast Regulating Machine(BRM).

RAILWAYS

1. S/SRI. Trilok Raj SE/NR

2. “ Anees Khan JE-I/NR

3. “ Ranjjt Kumar JE-I/NR

RDSO

1. S/Shri A.K. Pandey DTM-V

2. ‘’ Neerendra Prasad ARE/TM
3. ‘’ M.N.Siddiqui SE/Engg/TM
4. ‘’ A.N. Shrivastava JRE-I/TM
5. ‘’ Prem Kumar JRE-I/TM

.............

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