PUBLIC TRANSPORT CORPORATION ENG-TE-SPE-6603 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE STANDARD INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS Issued by | Track Engineering Department L4, 689 Collins Street, Melbourne, Vic. 3001 Tel: (03) 9619 4496 or Fax: (03) 9619 4440 Prepared by | A. Sowinski, Senior Technical Officer y Checked by _|P. Leombruni, Track Materials Engineer Approved by __|B. Held, Department Manager LLA ‘Authorised by _| D. Patterson, Group Manager Signature ‘© Copyright Public Transport Corporation, Engineering Services Division, 1998 Tack Engng Page aroPUBLIC TRANSPORT CORPORATION ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group ENG-TE-SPE-6603 VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS RECORD OF AMENDMENTICHANGE ‘The amendments noted in the undermentioned amendment list have been incorporated in this copy of the publication: AMENDMENT | VERSION | VERSION ‘SUMMARY OF CHANGE DOCUMENT UST NO. DATE AUTHORITY ‘IRE | rial issoe os TOT. gr Track Eng, z tT ‘AINE | Renumbered, Refornatied, Cover & Armendment aheete added. | Bee 3 7 3 é 7 @ o Track Engineering ~~ Page 2 of 10PUBLIC TRANSPORT CORPORATION ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group ENG-TE-SPE-6603 VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS ‘TABLE OF CONTENTS CLAUSE 1 GENERAL. 1.1 PURPOSE. 1.2 SCOPE 1.3 REFERENCE DOCUMENTS 13.1 132 Track Maintenance.... ‘S&C Maintenance: 1.4 DEFINITIONS. 1.5 RESPONSIBILITIES... 1.6 RECORDS... 2 INSTRUCTIONS... 3 PRECAUTIONS. 3.1. SAFEWORKING. 3.2 WORK PRACTICES. PAGE DQanasasraaae Track Engineering Page 3 of 10ate ENGINEERING SERVICES DIVISION C PUBLIC TRANSPORT CORPORATION ENG-TE-SPE-6603 Infrastructure Engineering Services Group VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS 1 1A 12 13 GENERAL PURPOSE This instruction provides direction for the inspection and maintenance of Type 29, 30, 39 and 40 ‘Australian National Dual Gauge tuouts. Implementation of the recommendations will improve ‘operational integrity, increase service life and reduce major maintenance/renewal requirements, SCOPE ‘The instruction covers Type 29, 30, 39 and 40 Australian National Dual Gauge turnouts only. ‘Specification ENG-TE-SPE-6602 "Inspection and Maintenance of Points & Crossings” provides {general inspection information and details maintenance tolerances which should be complied with, unless otherwise specified in this document. Inspection and maintenance requirements for materials which are common with open track, e.g. sleepers, aluminothermic rail welds, insulated joints, fishplated joints, standard rail base piates and fastenings are detailed in other specifications and circulars, Inspection and maintenance requirements for point machines, interlocking and detection equipment ‘and points operation adjustment are set out in Signals and Communications service and maintenance instructions. REFERENCE DOCUMENTS 13.4 Track Maintenance ‘Sketch TM174 Revision A Dual Gauge T/Os, Track gauging & tolerances - maintenance ‘Sketch TM182 Grinding of new toe profile on worn switches Standard Plan F598 Revision 8 Track formation and ballast Circular CEC 3/87 Laying, welding, destressing & maintenance of welded track Circular CEC 2/96 Lubrication of point slide chairs Circular CEC 4/95 Inspection and maintenance of insulated rail joints ‘Specification ENG-TE-SPE-6802 _ Inspection and Maintenance of Points & Crossings 13.2 ‘S&C Maintenance: ‘The following S&C documents detail maintenance frequencies and requirements for signalling ‘equipment. However, local conditions may dictate a change in maintenance frequencies, Service Schedules: SS SC 0303-16 ‘Amended to include Dual Gauge Points SS SC 0303-17 ‘Amended to include Dual Gauge Points SS SC 0303-18 ‘Amended to include Dual Gauge Points SS SC 0303 -29 ‘Amended to include Dual Gauge Points SS SC 0303 - 30 ‘Amended to include Dual Gauge Points Maintenance Instructions (Referenced in Service Schedules) MISC 0303-01 Mi SC 0303 - 02 - MISC 0303 ~ 04 MISC 0303 - 18 ‘Amended to include Dual Gauge Points Track Engineering “Page 4 of 10> PUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6603 ag te ENGINEERING SERVICES DIVISION S Infrastructure Engineering Services Group VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS: 14 18 18 MISC 0303 - 19 MISC 0303 - 20, ‘MISC 0303 - 22 MISC 0303 - 23 MI SC 0303 - 24 MI SC 0303 - 27 MISC 0303 - 28 MISC 0303 - 33 MISC 0303 - 34 MISC 0303 - 36 Dual Gauge Points Mi SC 0303 - 37 MISC 0303 - 43, MISC 0303 - 44 ‘MISC 0602-01 DEFINITIONS Public Transport Corporation: _In the context of this instruction, Public Transport Corporation (PTC) shall include the successors to the Public Transport Corporation. Maintenance Manager: ‘Track Maintenance Manager, District Engineer or other Engineer responsible for track maintenance, Technical Definitions: Refer ENG-TE-STD-2201 RESPONSIBILITIES This instruction applies to all Maintenance Managers, Track Supervising Officers, Signal Supervising Officers, Gangers (Special and Track), and Track Inspectors. It also provides information for the guidance of S&C Officers, S&C Technicians and Operations Staff involved in the ‘operation, inspection and maintenance of points. Itis the responsibilly of the Maintenance Manager to specify the frequency of inspection and to assign ‘the responsibility for regular inspection of the turnouts and subsequent maintenance, if required. It is the responsibilty of the assigned officers to ensure that the inspection of the tumouts and subsequent maintenance is performed in accordance with this instruction. {All personnel involved in inspection and maintenance ofthe turnouts shall be qualified in Track Safeworking and suitably trained to carry out the duties in accordance with ths instruction. In general terms, inspection and maintenance of hand operated points is the responsibilty of tack maintenance staff Inspection of points which incorporate signalling equipment is a combined responsibilty of signals and communications technicians and also track maintenance staft Maintenance of the various operating aspects of points which incorporate signalling equipment is defined in relevant instructions for signals and communications staff RECORDS Records of dual gauge turnout inspection and maintenance should be kept. The format of records shall be approved by the relevant Maintenance Manager Track Engineering Page 5 af 10‘ PUBLIC TRANSPORT CORPORATION ENG-TE-SPE-6603 aye ENGINEERING SERVICES DIVISION C Infrastructure Engineering Services Group VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS: 2___ INSTRUCTIONS MAINLINE INSPECTION AND MAINTENANCE TABLE TEMS LOCATION INSPECTION [REMEDIAL ACTION METHODIS Railtoimber fastenings | Tumout _| Visual = Tighten loose fastenings including spanner + Replace broken /damaged fastenings Mk R screws & spring washers, dogspikes Rail fastenings (bolts, Huck |Tumout | Visual + Tighten loose fastenings bolts, washers, spit pins, spanner _|+ Replace broken damaged fastenings ‘Supertock nut locking clips) + Ensure Superlock nut locking clips & split, at pins are fitted correctly chairs supports heel spreader brackets spreaders angle plates joints Point switches Points Visual ~ Inspect gap between switch and stock (toe to intersection of Jimeasurement | _rail- if more than 1 mm at the toe, heads) feeler arrange for S&C adjustment Inspect gap between switch and stock rail beyond the toe tothe Intersection of Heads - if more than 3 mm at any point, * check for:- * binding (dit or lack of lubrication) * switch damage * rollover or lifing of switches * ifrequired, arrange for * thorough cleaning lubrication * checking/adjustment by S&C of - switch connecting rods - spreader bolts (bracketspreader) - spreader (insulation) joints * detailed inspection Grind toe to profile in accordance with skeich TM182 if worn or damaged + Grind metal flow at toe f more than 2 mm + If switch sits more than 2 mm above base plate at toe, adjust timber support by tamping &/or arrange for adjustment of operating mechanism by S&C + Top of switch toe must be more than 14 mm below top of stock rail - for a worn stock rai, the allowance should be increased - arrange for detailed inspection if required Track Engineering Page 6 of 10PUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6603 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS MAINLINE INSPECTION AND MAINTENANCE TABLE. ITEMS. LOCATION INSPECTION METHODS: REMEDIAL ACTION Toe throw Points, Visual Imeasurement > Inspect toe throw of common, SG & BG ‘switches to ensure conformance with sketch TM174 - arrange for S&C adjustment if not complying Ensure back of BG switch, when in open position, is within 2 mm of contacting the back of SG stock rail for full length to 1200 mm from flared end of stock rail - arrange for S&C adjustment if not complying Connecting rod - BG to SG switch extension pieces BG ESC ‘switch extension pieces Visual under traffic Inspect for clearance of connecting rod through oval hole in web of SG stock rail enlarge by machining if required Visual + Check connecting rod & nuts, if bent, broken or damaged - arrange for S&C to replace & adjust Ensure nuts are tight against switch extension pieces Ensure connecting rod is removed, inspected for fractures or other damage, replaced & adjusted by S&C - after any abnormal incident or ~ at six (6) monthly intervals [Connecting rods - special switch tug to BG switch BG switch - clearance through stock’ Visual under traffic Inspect for clearance of connecting rods through oval holes in web of BG stock rai = enlarge by machining if required BG switch - attachment to spreader bar Visual * Check connecting rods & nuts, if bent, broken or damaged - arrange for S&C to replace & adjust + Ensure nuts are tight against angle plate and switch + Ensure connecting rod is removed, inspected for fractures or other damage, replaced & adjusted by S&C ~ after any abnormal incident or - at six (6) monthly intervals Point stops: Points: \Visualfeeler + Rectighten ifloose + Replace if bent, broken of missing + Adjust or replace if fit against switch web exceeds 3 mm + Ensure split pins are fitted correctly "Track Engineering Page 7 of 10wh PUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6603 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS MAINLINE INSPECTION AND MAINTENANCE TABLE ITEMS LOCATION INSPECTION METHOD/S REMEDIAL ACTION Point heels Points, \Visualfeeler Inspect fasteners for looseness and adjust or replace if required + Ensure Supertock nut locking clips & spit pins are fitted correctly + Inspect heel block fit at switch fishing faces - replace blocks if gap is more than 2 mm (take note of switch flogging under traffic) + Inspect for rail end batter and wear - arrange for detailed inspection if more than 2 mm (take note of switch lif at toe under traffic) + Ensure freedom from binding and ease of operation -if required, arrange for S&C to lubricate with graphite spray lubricant or point ol - ensure side surfaces of chairs &| support plate are not fouled by these lubricants Visual under traffic “inspect for flogging and adjust timber ‘support by tamping i required (take note of switch if at toe) ‘Spreader bars Points Visualfeeler > Ensure straightness and clearance under support plate and rails + Arrange lubrication of any slide surfaces if ‘scraping or rust is evident Points operation Points Visual ~ Inspect for ballast fouling the operation of spreaders, lock rods, detection equipment ‘etc. and clear as required + Inspect for ballast clearance under support plate to ensure drainage and that ballast cannot protrude through drain holes + Inspect for dirt between switch blade and ‘stock rail especially on dual rail side and clean out at two (2) weekly intervals or more frequently if required - utilise’ vacuum or compressed air + Arrange lubrication of side chairs and slide surfaces of support plate (after thorough cleaning) in accordance with CEC 2/96 at ‘wo (2) weekiy intervals or more frequently if required Track Engineering Page 8 of 10,wh PUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6603 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS MAINLINE INSPECTION AND MAINTENANCE TABLE ITEMS LOCATION INSPECTION [REMEDIAL ACTION METHODIS (Crossing rails Crossings - | Visual + Inspect fasteners for looseness and adjust K straightedge | oF feplace if required and + Inspect for damage or abnormal wear - Double V ‘arrange for building up by welding before| wear exceeds 6 mm or arrange for detailed inspection Refer ENG-TE-SPE-6602 Guard rails & flangeways |Guardrails | Visual ~ Inspect fasteners for looseness and adjust Imeasurement | of replace if required + Inspect for damage or abnormal wear - arrange for detailed inspection if required Rails - general Tumout | Visual ~ Inspect for damage or abnormal wear ~ -Tumout including Points (but including arrange for detailed inspection if required excluding switches) _and| Points + Inspect for metal flow and grind to profile if] Crossings {excluding greater than 3 mm. switches) Ensure that vertical running faces of stock and rails are not ground Crossings Joints ‘Mechanical | Visual + Inspect fasteners for looseness and adjust and Glued or replace if required insulation + Inspect for rail end batter and wear -| joints arrange for detailed inspection if more than 2mm + Inspect for metal flow across insulation gap and grind out and maintain in accordance with CEC 4/95 if required [Visual under |» inspect for flogging and adjust timber traffic support by tamping ifrequired Fabricated platework Chairs, ral_| Visual ~ Inspect for damage and repair or replace supports if required + Monitor individual plates with cracked welds - Repair or replace plates if plate contains a crack of aggregate length more than 75 mm or two or more plates contain cracks (Gauge of track Tumout | Track gauge _|~ Check track gauge for conformance with (Gauge of points measurement } sketch TM174 and adjust or replace [Gauge of crossings components if required Gauge of guard rails Track alignment and top |Turnout | Visual > Check for conformance with TM26 and string line adjust & tamp if required Rail creep Points Visual ~ Monitor rail creep on a three (3) monthly string tine basis and install additional anchors after adjustment if required or arrange for detailed inspection - note relative movement of each rail at points Track Engeeing Page 9 of 10.aye PUBLIC TRANSPORT CORPORATION ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group ENG-TE-SPE-6603 VERSION 1.1 INSPECTION AND MAINTENANCE OF A.N. DUAL GAUGE TURNOUTS MAINLINE INSPECTION AND MAINTENANCE TABLE ITEMS: LOCATION INSPECTION /METHOD/S: REMEDIAL ACTION Ballast formation Timbers Visual ~ Ensure that ballast formation (width and height) from the timber in front of the toe to the timber beyond the V crossing conforms to CEC 3/87, Section A 22 (i) (refer Appendix 'D' & Standard Plan F598) and that width of ballast at each ‘end of timbers on each side of operating spreaders is 800 mm. Rail end bolt holes: Rail ends including heels Visual Tspect for cracks in rails, fishplates and blocks after any abnormal incident Ultrasonic + Test for fractures within two weeks after any abnormal incident or inspect visually + Three (3) monthly tests until defect/ailure pattems have been established Point switch Points Replacement ~ When repacing a switch ensure that- Relative heights between switch and stock rail are maintained, especially at the toe - refer to Point switches (toe to intersection of heads) section * Slide surfaces are clean and suitably lubricated + Clean underside of foot and lubricate with Rocol Switch Plate Lubricant 3__ PRECAUTIONS Protection for trains must be provided whenever an out of specification condition is detected and 3.4. SAFEWORKING ‘Track safeworking requirements shall be complied with the track is rendered unsafe for movements at normal speed. 3.2. WORK PRACTICES Work practices, including the use of the relevant safety equipment, suitable work clothing, equipment and materials shall comply with occupational health and safety guidelines. “Track Engineering Page 10 of 10