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1. GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 69 2 3 2 Torque Value Torque values for fastener tightening when threads are not lubricated while fitting if lubricated use values lower by 20 S Description Approx N Torque M Kg 1 M 12 X 1 75 x Screw Socket 12 35 Head 2 M14x2 Bolt Hex hd 14 3 M16x2x50 Screw Hex hd 21 4 M20x2 Bolt Hex Fitted 41 5 M20x 1 5 x 140 Bolt Hex hd 46 6 M24x15x170 46 7 M24x3 x 330 71 8 M24x3x 270 71 9 MI10x2x 60 21 10 M14x2x 35 14 2 3 3 Recommended Oils for the Axle Drive S N Name of Petroleum Co Grade of Oil 1 Hindustan Petroleum HP Gear Oil EP 90 2 Bharat Petroleum Bharat Spirol 90 EP 3 Indrol Hypod C 80 W 90 4 Indial Oil Servo gear HP 90 Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 70 3 3 1 3 2 CONTROL EQUIPMENT amp INSTRUMENTS In the Tower Car there are two cabins and two control desks The operator can drive the car from any one cabin in whichever direction he desires to travel Adequate controls including gauges instruments and safety devices are provided for safe and satisfactory operation of the car The equipment is so arranged on the driver s desk and it is within easy reach Controls monaogs Engine
2. should be checked and cleaned regularly and as frequently as necessary depending upon the operating conditions A badly corroded or plugged breather restricts proper breathing causing oil leaks Control Linkage Adjustment Manual shift linkage must be adjusted so that the operator s control is positioned to exactly match the detent position of the selector valve on the transmission Adjust the linkage so that it can be freely connected without moving either the valve or the operator s control Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 23 Then operate the range selector lever the directional selector lever and the output disconnect if applicable through each position Make minor adjustments if necessary to insure that each of the selector levers seats in each position of the operator s control Then inspect the control linkage for binding wear or breaks 4 3 TROUBLE SHOOTING OF HM HYDRAULIC TRANSMISSION Causes Remedy A LOW CLUTCH APPLY PRESSURE 1 Low oil level Add oil to correct level 2 Clogged oil strainer Clean strainer 3 Clogged oil filter Replace filter element 4 Inching control Check adjust linkage adjustment not fully retracted 5 Air leak at intake side of Check pump mounting oil pump bolts 6 External oil leakage Tighten bolts or replace gaskets 7 Brake hyd
3. 27 4 6 Maintenance of KPC Hydraulic Transmission 29 4 7 K P C Axle drive Maintenance Schedule 34 BRAKE SYSTEM 37 5 1 Air Pressure System 37 5 2 Maintenance of the Valves 44 TXR CHECKING 46 ELECTRICAL MAINTENANCE 47 7 1 Trip Schedule 47 7 2 Fortnightly Schedule 48 7 3 Monthly Schedule 48 7 4 Quarterly Schedule 49 7 5 Half Yearly Schedule 49 7 6 Yearly Schedule 49 Chapter Contents Page No No 8 MAINTENANCE OF BATTERY 50 8 1 Hydrometer reading and battery condition 51 9 IMPORTANT OPERATING AND MAINTENANCE INSTRUCTIONS FOR DRIVERS OF OHE CAR 52 9 1 Description and operating principle 52 9 2 Stationary Condition 56 9 3 Running Condition 59 9 4 Change of Cabin 59 10 DO S and DON TS 60 10 1 Do s 60 10 2 Don ts 61 10 3 Suggestion for achieving zero Failure 62 10 4 Maintenance Step for Engine 63 Annexure A Techanical Specification of Tower Wagon 64 Annexure B Oil Change 73 REFERENCE 76 oh ooo KE GO BACK TO CONTENT ISSUE OF CORRECTION SLIPS The correction slips to be issued in future for this handbook will be numbered as follows CAMTECH 2001 E CL TW XX date Where XX is the serial number of the concerned correction slip starting from 01 onwards CORRECTION SLIPS ISSUED Date of issue Page no and Item no modified Remarks GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 CHAPTER 1 INTRODUCTION Tower wagon has a key role in the maintenance of OHE and for attending of bre
4. 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 57 e Press the button pink for oil indication and simultaneously press the starter green push button release the button once the engine starts e Ensure F R forward Reverse switch is in Neutral position e Move the engine throttle to higher notch for fast charging of the MR BP e Pressure build up time Check that MR pressure is build up from 0 to 7 5 kg cm in 10 minutes e Ensure MR pressure between 7 to 8kg cm e Check brake pipe pressure to 5 kg cm e Observe the brake cylinder pressure to be zero If not pull the manual release valve of the distributor valve for a short while e Apply leak hole test In this test mild steel plate of 8mm dia hole is to be provided at the end of BP pipe and ensure that pressure drop of BP is not more than 0 5 40 1 kg cm in 5 minutes and pressure drop in MR is not more than 0 7kg cm in 5 minutes FIGURE 9 1 CHECKING BELT TENSION Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 58 e Check proper belt tension manually e Check the working of horn wipers before moving the car e Once the system is charged then apply emergency brake application and observe BC pressure to be 3 8 kg 0 1 kg cm2 and BP 0 kg cm2 e Release the brake and recharge the system e Ensure that brake app
5. 5 minutes before shutting it off after a full load operation This allows adequate cool down of pistons cylinder liners bearing amp turbocharger components e Do not idle the engine for excessively long periods e If the engine coolant temperature becomes too low 60 C raw fuel will wash the lubricating oil off the cylinder walls and dilute the crankcase oil All the moving parts of the engine will not receive correct amount of lubrication e Operate engine only on electrical mode amp ensure all safety controls are functioning e Do not over load the engine e Do not remove radiator cap when engine is in operation or immediately after stopping the engine e Perform periodic maintenance as per recommendations e Ensure trained person carries out the schedule maintenance e Ensure periodic health checks by experts e Ensure quality of lubricants and fuel as per standards e Correct problems when they are minor e Use proper tools Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 63 e Use only CF4 grade lube oil for engine lubrication e Do not operate the engine without thermostat e Do not crank the engine for more than 5 7 seconds e Use only genuine parts while repairs maintenance 10 4 MAINTENANCE STEPS FOR ENGINE e keep dirt out of engine e Maintain a lubricating film on all bearing surfaces e Regulate the engi
6. Clean dustpan and pre cleaner of dry type air cleaner Use clean engine oil Check air line connections for leaks Correct as required Remove and clean air compressor breather if equipped Fill with clean oil upto the mark Drain air receiver tank at the beginning of every day and then close the drain cock Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 8 gt Maintenance Steps Remarks No P 10 Clean crankcase Discard paper type breather element if clogged Check oil level in Check for leaks Use 11 hydraulic governor if engine oil for topping up provided ie shown in a 3 1 FIGURE 3 1 CHECKING OF OIL LEVEL S Maintenance Remarks No Steps 12 Start the engine If there is a change in oil and note the oil pressure both at idling and maximum speed pressure from that recorded in the log book on earlier occasion then stop engine and check through trouble shooting technique the cause for oil pressure change and correct if necessary for assistance in diagnosing the change in oil pressure call your service representative if necessary Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 end of the day S Mainten
7. During this over haul the transmission is stripped as far as necessary Bearing labyrinth rings shaft seats etc are inspected and damaged parts are replaced MAINTENANCE OF HINDUSTAN MOTOR HYDRAULIC TRANSMISSION Control Linkage Check the transmission shift control linkage and the directional linkage to ensure that the linkages are free and that the selector levers are properly positioned The Shift levers should engage in all shift tower positions freely Inspect the linkages for binding wear cracks breaks or defective cotter pins Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 21 4 2 2 4 2 3 4 2 4 Cold Oil Level Check The cold check engine not running is made to determine if there is sufficient oil to safely start the engine especially if the vehicle has been idle The oil level should be at or near the full level check plug Some transmissions have one plug others have two plugs an ADD and a FULL plug Hot Level Check Oil level must be checked with the engine running at 1000 rpm transmission in neutral and with the transmission at normal operating temperature 82 3 C 93 4 C The upper check plug if there are two plugs indicates the full oil level while the lower plug is the add level The oil must be maintained at the FULL level If there is only one check plug the oil level must be maintained at this l
8. and 85 C Discard p and fit new thermostat if operation is not satisfactory 3 Check fan hub and Check mounting bolts and drive bearing end play 4 Check impeller water Correct if necessary pump for play 5 Check for turbocharger Correct as required oil leaks 6 Tighten turbocharger Tighten to the specified f torque Do not tighten mounting nuts ae when engine is hot re Check after cleaning dry Check ilei air PE air cleaner element If a restriction in excess of restriction 63 5cm water a new element must be fitted B Clean oil bath air Ronove comple assembly and clean cleaner l inclusive of fixed screens Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 Mainten ance Steps Remarks Clean and tighten all electrical connections 10 Check generator brushes and commutators Replace and clean as required 11 Clean entire engine High pressure and soap water mixture preferred after spraying engine with cleanser taking care of protecting electrical system 12 Tighten all mounting bolts and nuts Tighten as required Over tightening may result in distortion or damage 13 Clean aneroid air breather Replace breather if necessary 14 Check engine blowby Readings in excess of recommended limits Corrective action
9. been also provided in the Driver s cabin to show the Brake cylinder pressure when brake is applied Another two nos gauge have been provided for control system one in each Dr s cabin One no of pressure gauge has been provided on control box Which will show the actual pressure receiving by the control system There is one air pressure oiler fitted with service pipe line to control box to facilitate the lubrication of pneumatic valves and equipment fitted in control board Condemned water from the system can be removed by means of drainage valve provided in air supply tanks There are 4 nos of brake cylinders one for each wheel to facilitate perfect brake on the tread of wheels from both sides There are two spring brake actuators provided specially for parking brake It can park the Tower car where there is no air in the system In the normal running condition due to air pressure brake are in the released condition It will function as emergency brakes when the air pressure drops below the spring brake hold off pressure the spring pushes the piston and the push rod out to apply the brakes Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 39 5 1 2 Important valves and their functions 5 1 2 1 C3W distributor valve The C3W distributor valve consists of the following major parts i Main valve li Quiere service valve iii In
10. centered air actuator The rod of the cylinder is connected to the lever of selector valve of transmission When operated the rod shifts the lever as per direction selection and hence the respective clutch is engaged Solenoid valve SOV 5 Its function is to start and run the engine The coil of valve is energized by 24 volt DC supply It can also be operated manually by tightening the screw provided on it Solenoid Valves Sov 1 to 4 These are also operated by 24 volts DC supply and used for speed control of engine with the help of CS3 Solenoid Valve SOV 6 3 2 way solenoid operated valve is used for supplying air to stand still detector when energised by 24 volt DC supply Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 55 9 1 11 Solenoid valve SOV 7 amp 8 A 5 3 way solenoid operated valve is used for supplying air to the desired port of clutch actuating cylinder by energizing the corresponding solenoid This in turn controls the movement of selector valve lever 9 1 12 Flow control valves Flow control valve FC1 FC2 amp FC3 are used as time delay valves in pneumatic circuit 9 1 13 Pressure switches Pressure switches PS2 amp PS3 are for forward reverse clutch pressure for the safety of transmission If the clutch pressure is below the set value 10Kg cm2 on a pressure switch it will not allow the operatio
11. for earthing e Check the condition and ensure proper working of all relays pressure and tumbler switches rectifiers and contactors etc Adjust if required e Clean and inspect contacts of engine starting press keys 7 3 MONTHLY SCHEDULE 7 3 1 Condition Diesel engine stopped e Open cabinet doors of pneumatic and electrical control and blow out with clean and dry compressed air Ensure that the equipment is dry sand clean Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 49 7 4 7 4 1 TAD pee 7 5 1 7 6 7 6 1 e Check starter motor alternator and engine tachometer Blow off dirt with compressed air Inspect carbon brushes holders and commutators Check brush pigtail QUARTERLY SCHEDULE Condition Diesel engine running e Check and adjust alternator e Check engine tachometer with a master tachometer for correct and accurate operation Condition Diesel Stopped e Check the complete circuit and wiring and rectify as required e The alternator and self starter may be removed and inspected connections checked and their working may also be checked HALF YEARLY SCHEDULE Condition Diesel engine stopped Remove and repair alternator if condition warrants YEARLY SCHEDULE Condition Diesel engine stopped 7 6 1 1 Remove and overhaul the following electrical machines e Self starter e Alternator e Engine
12. oil level g Foamed oil g Check for air leak in suction line No oil a Faulty pressure a Replace pressure pressure gauge gauge b Low oil level b Check or emply sump gasekets seals for leakage Replace parts causing leakage Maintain correct oil level c Fully clogged c Remove amp clean it oil strainer d Damaged oil d Replace oil pump pump Poor a Low oil a Add oil to performance pressure maintain oil level b Use recommended b Improper oil oil Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 34 4 7 Handbook on General Maintenance Schedule for Symptom Cause Remedy c Clutch slipping c Disassemble clutch assemblies check clutch plates and replace worn out or damaged plates Excessive a Air leak in a Check and tighten Noise suction line of all joints Replace the sump damaged end fittings hoses pipes b Bearing failure b Disassemble transmission Replace damaged bearings Neutral a clutch plates a Replace clutch warped plates KPC AXLE DRIVE MAINTENANCE SCHEDULE 1 Periodic maintenance Daily Check oil level daily It should be at the upper mark Refill the oil if the level has dropped below the minimum mark Be sure to use the same oil brand 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK T
13. start amp stop Engine throtle control Forward reverse Speed changer Horn Provision for air brake and parking brake Instruments amp Gauges rd mo ao p Engine RPM meter Engine Hour meter Engine oil pressure gauge Engine oil temp gauge Engine cooling water temp gauge Ammeter Transmission temperature gauge Transmission pressure gauge Air pressure gauges Speedometer Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 71 3 3 Indication amp warning lights Engine on indication Battery charge indication Air on indication Forward reverse neutral cum speed indication Bose 3 4 Safety devices Water temperature too high Transmission oil temperature too high Low lubricating oil pressure Engine speed too high Low radiator water level 0 m o TH 3 5 Electrical Equipment a 24V Electrical system complete with batteries alternator rectifier and starter motor provided b Switch for light provided 3 6 Storage Batteries 24V Lead acid batteries one set is provided KKK KK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 72 ANNEXURE B OIL CHART Description Capacit Hindustan Indian Caster Bharat y Petroleum Oil Oil Petroleu Corpn m Corpn Ltd Diesel 300 High
14. tachometer generator KKKKK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 50 CHAPTER 8 MAINTENANCE OF BATTERY The following simple instructions will if observed have to obtain long life built into battery Keep Clamps and terminals clean Corrosion product has high resistance cause power loss and prevent full charging back Smear Terminals with Vaseline Vaseline film prevents corrosion grease may contain metal soaps which attack lead and should not be used Top Up Regularly Water is lost during charging as gas or by evaporation Low level of electrolyte will damage dry top of plates make acid stronger and more destructive to plates Keep Vent plug tight To prevent electrolyte evaporation or splash Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 51 Keep battery top clean and dry Dirt and moisture cause surface current leaks between top metal resulting in battery running down Use distilled or deionised water only Ensure water will cause self discharge or attack plates due to the impurities present in it Keep cable connection tight Because loose connections cause power loss Keep hold downs firmly secured To prevent bouncing container abrasion and damage 8 1 HYDROMETER READING
15. the spherical roller bearings The input pinion is meshed with out put gear which is key mounted on the out put shaft The out put flange is key mounted on out put shaft The out put shaft runs on spherical roller bearings The gears and bearing are lubricated through pipe by means of a Hypo pump mounted on the output shaft Oil seals are provided at input and out put end to prevent the oil oozing through the end covers Maintenance 1 Daily oil level to be checked through the level plug indicator if necessary top up the oil 2 Daily check the oil leakage through input out put oil seals through the end cover s and through housing joints etc if so rectify the oil leakage by changing the new oil seals or by tightening the respective bolts and nuts Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 27 4 5 3 Once in a week take out the magnetic drain plug from the gear boxes and check for any wear out particles or debris if heavier particles found the gear box has to be opened and checked 4 For the new gears first oil changing period is one month Then once in three months the specified oil to be changed Note Before changing the equivalent oil clean the gearbox with kerosene or diesel Then pour the equivalent oil and drain out 1 2 to 1 litre of the same oil through the drain plug Then put the oil little above the level pl
16. 1 1 BODY STRUCTURE The body of the tower wagon is built up by iron sheets supported on the large frame work erected on the under frame Tower wagon s inside is divided into two driving cabs with seating arrangement for driver and supervisor and central portion The central portion is having various racks and pigeon holes on one side and lattice enclosure on the other side A space is left at the centre for the staff to work All the enclosures are used for preserving the materials and tools for attending OHE maintenance and breakdowns The roof of the tower wagon is mounted with iron corrugated sheet and strengthen for staff to work on the top It is also mounted with lifting and swiveling platform at one end while the other end is having pantograph TR KK KK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 3 CHAPTER 2 LIFTING AND SWIVELING PLATFORM AND PANTOGRAPH Lifting and swiveling platform measuring with in the permissible limits is mounted on the one end of the roof for raising its height and rotating it by 360 The arrangement is such that when the maintenance staff has to work near the structure the platform can be rotated so that it reaches the structure and facilitates the working of the staff Similarly height of the plat form can be adjusted to suit the working spot on overhead equipment This has got the chain pull
17. AND BATTERY CONDITION Hydrometer reading Battery Condition Correct at 27 C 1 250 0 005 Fully Charged 1 170 0 005 75 Charged 1 120 0 005 50 charged 1 100 or below must be recharged Keep return record of daily and monthly inspection The monthly inspection included gravity and voltage readings of all shells flushing down the battery checking connectors and compartment vents Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 52 CHAPTER 9 IMPORTANT OPERATING AND MAINTENANCE INSTRUCTIONS FOR DRIVERS OF O H E CAR 9 1 DESCRIPTION AND OPERATING PRINCIPLE The following components are used in electro pneumatic system 9 1 1 Station Selection Key Switch CSI A station selection switch is provided in both the drivers cabin which is key operated Only one key is to be used for both the cabins so that the control system can be operated from only one cabin at a time 9 1 2 MCB CSO A 15 ampere capacity Miniature Circuit Breaker MCB is provided in control system as a MAINS if due to any fault current in the control system exceeds than 15 ampere it will trip the control circuit automatically Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 53 9 1 3 9 1 4 Engine Operation Mode Selection Sw
18. High High High Engine Ltrs Speed Speed Speed Speed Fuel Lube 32 Ltrs Diesel diesel Diesel Diesel Oil Hy Lube servo Deus OL Bharat Extra super 20 W Actuma 20W 40 20W 40 20 W 40 40 CRT 42 Ltrs Power Servo 5633 Glide C Transm Transmissi 3 ission on C 310 on C4 C 330 SAE 30 DROP 10 Ltrs EP 140 SERVO Bharat GEAR GR OIL GEAR Spiral BOX HP 140 EP 140 Axle drive 40 Ltrs EP 140 Servo Bharat gear box for each GR oil Gear spiral 140 gear box HP EP 140 Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 73 REFERENCE 1 Operating and maintenance manual bulletin 3243773 02 Cummmins India Ltd 2 Instruction and Maintenance Manual By Kirloskar Pneumatic Co Ltd i Electro Pneumatic control of 4 wheeler OHE Car ii Hydraulic Transmission KTC 100 20 iii Axle Drive V 1719 3 Operating and Maintenance Manual of VENTRA Locomotive Ltd 4 Allison Transmission CRT 5633 By Hindustan Motors 5 Papers presented during the seminar at CAMTECH on maintenance of Tower Wagon KKK OK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT
19. Kg cm2 3 0 Kg cm2 minimum 2 2 2 Operating temperature 80 C to 110 C 2 2 3 Oil change interval Replace every 1000 hours of operation or 3 months whichever is earlier 2 2 4 Main filter element change First change after 60 Hrs interval of operation Thereafter every 1000 Hrs of operation 2 2 5 Suction strainer cleaning Every 10 15 Hrs operation initially and once a week thereafter 2 2 6 Recommended oils amp Grease Oils a Hindustan petroleum ENKLO NX 32 b Indian Oil Corp Servo Torque 10 Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 68 Grease a Hindustan petroleum Multipurpose Grease H b Bharat Bharat MP Grease2 c Veedol Veedol AP Grease Recommended torque tightening values for bolts screws Thread Torque in M Kg Lubricated threads M10 4 2 M12 7 0 M14 10 8 M16 16 2 All bolts must be tightened to its specified torque value Use appropriate torque wrench for it 2 3 TECHNICAL DATA OF KPC AXLE DRIVE Dry weight of axle drive exclusive of axle shaft 670 kg Oil capacity 12 Lit Max oil level below axle centre line 145 mm Min oil level below axle centre line 155 mm Normal axle load capacity 18 T Max 2 3 1 Gear ratio Total reduction Ratio 4 289 1 Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III
20. O CONTENT CAMTECH 2002 E TW 1 0 35 Check the bolts and screws and re tighten if necessary Inspect the torque reaction rod assembly and its mounting to base frame 2 Every 375 000 Kms Subject all parts to an intermediate inspection Check the bearing pattern on the bevel gear drive Check the taper roller bearings for proper axial clearances 3 Every 750 000 Kms Subject all components to a major inspection and replace if necessary 4 Oil Change After a new axle drive has been in use for 50 Hrs the oil must be changed Further oil change must be made after every 6000 Hours of operation Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT D CAMTECH 2002 E TW 1 0 36 Remove the oil drain plug to drain the oil from the drive If excessive metal particle are detected on the magnetic plug or in the oil it shows that some components have rubbed each other Open the axle drive and inspect Remove the plunger type pump and clean pump strainer Clean the housing from oil sludge Replace the drain plug Fill with new filtered oil through the filler neck 5 Axial clearance check Tapered Roller Bearings Proceed in accordance with the guidelines and instructions The bearing clearance must be maintained 6 Check of Bearing Pattern Bevel Gear Drive To enable this inspection the axle drive must be opened Lightly coat three or four teeth on beve
21. akdown restoration of damaged OHE equipment and erection of small length catenary and contact wires It is also used for inspection patrolling and maintenance of overhead equipment The satisfactory up keep of tower wagon is therefore of utmost importance It is the direct responsibility of tower wagon incharge to ensure that the tower wagon is maintained satisfactorily and is available always for attending OHE maintenance and for use in the event of OHE breakdown This handbook deals with details of schedule maintenance to be carried out by OHE depots POH facilities are not available in OHE depots and therefore POH of complete tower wagon including engine running gear arrangement brake rigging wheel and axle roller bearing pneumatic valves lifting and swiveling platform hydraulic transmission axle drive bogie electrical equipment and all under frame equipment shall be carried out at an interval of three years in an EMU shop Electric Loco shed Electric Loco workshop as decided by CEE This handbook does not include details of work to be carried during POH of tower wagon in EMU shop Electric Loco shed Electric Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark IlI GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 2 Loco workshop Similarly work to be carried out by TXR during monthly examination is not included in this handbook as this handbook is intended for the staff of OHE depots only
22. ance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 25 Causes Remedy F VEHICLE LACKS POWER AND ACCELERATION AT LOW SPEED 1 Low clutch apply Refer to A pressure 2 Low converter out Refer to A pressure 3 Engine malfunction Check engine refer to engine service manual 4 Aerated oil Refer to C G CLUTCH CUTOFF VALVE INEFFECTIVE 1 Valve or plug sticking Rebuild control valve body assembly 2 Brake apply hydraulic Check pressure at control pressure incorrect valve min max limit 9 15 kg cm 140 7 kg cm 3 Brake apply air Check air cylinder 15 85 pressure not reaching kg force required to air cylinder stroke valve 4 Plunger sticking in air Check operation of air cylinder cylinder 5 Air entering at valve Check operation of air air actuated cylinder seals Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 26 4 4 MAINTENANCE OF VENTRA DROP GEAR BOX General Ventra drop gearbox is a single stage gearbox all the bearing and gear s are adequately rated to give a longer life This gearbox transmits the power from converter transmission to the rear axle drive gearbox through carden shaft of adequate design Description The input flange is key mounted on the input pinion shaft which runs on
23. ance Steps Remarks No 13 Record oil pressure Refer operation and maintenance manual for lub oil pressure limits 14 Fill fuel tank at the Use clean fuel and a strainer Also clean the cap and surrounding area before opening the filler cap Fill fuel at end of the day allowing diesel to settle Drain sediment from fuel filter water separator bowl 3 2 B CHECK EVERY 300 HOURS or 6 MONTHS WHICH EVER IS EARLIER Maintenance Steps Remarks 1 Repeat all maintenance steps of A check 2 Change engine oil When lub oil is examined through lub oil analysis in a laboratory oil change period may be extended In such cases refer to your service representative 3 Fit new lubricating oil Inspect the changed filter full flow filter element element and check for metal particles and oil sludging oxidation Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 Maintenance Steps Remarks Remove clean and inspect dry type air cleaner element Remove and clean dustpan Inspect element for holes and tears Check gaskets rings and O damage for FIG 3 3 ELEMENT CHECKING WITH ELECTRIC FIG 3 2 AIR CLEANER Blow out dust with compressed air in the opposite direction of the normal air flow If very dirty wash in solution of warm wate
24. ce Schedules Maintenance interval Work to be performed 20 000 km Check oil level 300 000 km Oil change inspection of control parts replacement of filter replacement of disposable filter 900 000 km Major overhaul 4 1 1 1 Maintenance after 20 000 km Check the oil level 4 1 1 2 Maintenance after 300 000 km a Oil change Under normal operating conditions the oil filling lasts for a distance of approx 300 000km This period can be extended if the oil sample is still with in the tolerance of the specification for new oil For changing the oil drain it from valve while it is at operating temperature and drain the oil cooler too If oil of a different approved brand is to be filled in flush the transmission and cooling system with half the quantity of the new oil needed for a complete fill Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 20 b Replace all filters For this purpose drain off the oil first then remove the filters take off the caps and remove filter elements c Check control parts such as governor standstill detector valve operating cylinder and main control valve for proper operation leakage and wear 4 1 1 3 Major Overhaul 4 2 4 2 1 A major over haul of the transmission is recommended after approx 900 000 km of operation depending on operating conditions and duty
25. clean diesel oil All foreign particles must be removed from the strainer before refitting it Ensure air tightness after replacing plug on housing strainer Thread sealing compound may be used to avoid leakage of air in to the circuit h Remove the breather assembly every 1000 Hrs of operation Flush the oil breather assembly 4 6 1 2 Inspection Daily a Check oil level Add if necessary b Check all pipelines end connections for leakages Replace damaged parts to stop leakages c Check all pressure temperature gauges for proper functioning Replace damaged gauge immediately Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 31 d Check oil leakage from oil seal bolted joints Replace damaged oil seals Tighten loose bolts screw to stop leakages from joints 4 6 1 3 Inspection Weekly a Check strainer and clean b Check filters element and clean if necessary c Check and tighten oe A all bolted joints including mounting bolts 4 6 1 4 Inspection After Each 1000hrs Of Operation a Change oil in the sump and fill new recommended oil b Clean selector valve c Check all gauges for their correctness 4 6 1 5 Periodic Overhaul A complete over haul of the transmission should be done simultaneously with overhauling of engine The period is aproximately4000Hrs of operation or 18 month whicheve
26. down gradient short application and release of air brakes is recommended to maintain the specified speed and brake power e Spare sub assemblies Should be made available in the OHE car for unit exchange basis in case of an emergency This include BP hose angle cock Distributor Valve relay valve etc e Independent emergency brake valve is provided in the cab both ends facilitate the guard to initiate an emergency brake in case of emergency 9 4 CHANGE OF CABIN Apply emergency application and then remove the driver s brake valve handle by bringing it quickly to isolating position Switch off the ignition key Change the cabin and repeat all the checks given under heading 9 2 KKK OK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 60 CHAPTER 10 DO S AND DON TS 10 1 DO s Do keep the engine clean Do pay particular attention to lubrication Do use only approved grades of lubricating oil Do keep all bolts and nuts tight oF a eS Do eliminate all air from the fuel system and keep all fuel oil unions air tight 6 Do examine engine oil level in sump daily and replace if necessary 7 Do completely change engine oil in accordance with periodical attentions 8 Do renew element in lubricating oil filter in accordance with periodical attention 9 Do keep a check on the temperature of the cooling water 10 Do at
27. e Ltd VENTRA Hyderabad Hydraulic transmission offered by M S KPC is of their own design and that of M s Ventra is of Hindustan Motors However five numbers 4 wheeler tower wagons were provided with Voith transmission system A common power pack is used for both the two designs A Kirloskar Cummins Ltd model N 743 L naturally aspirated diesel engine developing 210 horsepower at 2100 rpm has been used The transmission of both powers from diesel engine to wheels is by means of hydrodynamic system incorporating torque converter and gears The final power transmission in both designs is through carden shaft and axle drives In the KPC design the transmission output is directly connected to the axle drive on the rear axle by means of a long cardan shaft using axle drives of two different overall gear ratios This transmission also incorporates reversing arrangements with the use of plate clutch unit In the VENTRA design the transmission output is connected to the axle drive through an intermediate gearbox of a differential gear unit and a hydrodynamic torque converter incorporating speed change provision The final drive from diesel engine is through a slip clutch assembly properly aligned with in the engine fly wheel housing Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 19 4 1 MAINTENANCE OF VOITH HYDRAULIC TRANSMISSION 4 1 1 Maintenan
28. e and a vent valve which is actuated only when the brake valve handle is placed in Emergency position for the purpose of venting brake pipe pressure at an emergency rate Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 43 5 1 2 7 Double check valve Function To charge a central line in a selected manner from two independent sources Operation When a pressure differential exists between the two end ports the higher air pressure forces the check valve over to seal against its seat on the low pressure side This closes the passage between the low pressure port and the common port in the body Air then flows from the high pressure port through the common port to the device under control 5 1 2 8 Al Check valve Check valves are used in pneumatic brake system to allow compressed air to flow in one direction only The Al check valve is metal seated check valve and is used in compressor delivery line When compressed air flows in the right direction the valve of the check valve lifts by the upward air force acting underneath the valve and allows air to pass through the outlet connection In case of reverse flow the valve is pressed on its seat tightly due to air pressure acting on top face of the valve 5 1 2 9 J1 Safety Valve The J1 safety valve is installed vertically in the main reservoir system vents pressure at a pre determine se
29. evel Add oil if necessary to bring the level to the FULL mark Oil Filter Change The oil should be changed every 1000 hours of operation or sooner depending upon operating conditions Also the oil must be changed whenever there are traces of dirt or evidence of high temperature indicated by discoloration or strong odor The filter screen in the sump should be removed and cleaned with mineral spirits at each oil change The filter elements should be replaced at each oil change and at 200 hour intervals between oil changes Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 22 4 2 5 4 2 6 4 2 7 4 2 8 The filter shells should be cleaned New gaskets and seal rings must be used when replacing filter elements After installation check the filter for oil leakage while the vehicle engine is running Keeping oil clean It is absolutely necessary that the oil put in the transmission be clean Oil must be handled in clean containers filler etc to prevent foreign material from entering the system Filling Transmission At temperature above 23 3 C pour hydraulic transmission fluid type C 2 into filler opening At temperature below 23 3 C an auxiliary preheat is required to raise the temperature in the sump Use only C 2 fluids from approved manufacturers Care of Breather The breather should be kept clean at all times It
30. ey and gear system and having its operating arrangement on the top by means of a handle The platform is surrounded from all the three sides other than panto side with collapsible railing of pipe These railings can be lifted up as and when the staff works on the roof otherwise these are normally kept lowered on the platform and thus the moving dimensions are maintained Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 4 2 1 PANTO GRAPH Pantograph is similar to that used for AC loco but having spring control only The required pressure of panto is adjusted by means of control springs at the bottom It is mounted on the centre line along the roof of the tower wagon at the other end The height of the panto is adjusted suitably to meet the requirement of overhead equipment On panto pan the marking of stagger is done Similarly the height gauge is also fitted to the pantograph This facilitates recording of the stagger and height of the contact wire respectively FIGURE 2 1 PANTOGRAPH LOWERED CONDITION Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 5 FIGURE 2 2 PANTOGRAPH RAISED CONDITION Details of figure 2 1 and 2 2 S Details S Details 1 Base 10 Joint of upper tube 2 Horizontal Spindle 11 Spring Box 3 Lower Arm 12 Positioning L
31. fuser and impeller and check end float 5 Check turbocharger Only end float on semi bearing clearances floating bearing if in excess of limits replace 1t 6 Check crankshaft end If in excess of float recommended limits corrective action is indicated 7 Clean injector inlet Must be done only if a screens performance deterioration is evident Some of the indications for performance deterioration are 1 Black smoke Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 S Maintenance Steps Remarks 2a Change in fuel manifold pressure 3 Loss of power 4 Malfunction of aneroid 5 Clean and calibrate all injectors 6 Check fuel pump calibration 7 Replace aneroid bellows and calibrate 8 Replace fuel pump filter screen and magnet 9 Steam clean engine If steam is not available then use clean soap water solution as outlined in C check item 11 3 5 E CHECK Overhauling Of Engine After Two D Check KKK KKK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 18 CHAPTER 4 TRANSMISSION The transmission and control equipment were supplied by two firms viz M s Kirloskar Pneumatic Co Ltd Pune and M s Venkateswara transmission privat
32. ink 4 Yoke 13 Lifting Spring 5 Tube 14 Servo Motor 6 Upper Tube 15 Tie rod insulator horn 7 Thrust Rod 16 Collector 8 Pivot point 17 Insulated Horn 9 Transverse Tube 18 Support Insulator se oR KK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 6 CHAPTER 3 MAINTENANCE OF ENGINE 3 1 A CHECK EVERY DAY No Maintenance Steps Remarks 1 cies premous aay Correct as required engine log book Drain water and 2 sediment from fuel Before starting the filter through drain engine cock Check engine oil level 3 and top up if dip stick when engine is necessary stopped and has stood for 20 minutes or more must be measured after all oil is drained back into oil pan Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 Maintenance Steps Remarks Check for fuel oil water and exhaust leaks Correct if leaking Fill radiator surge tank with treated water chromate concentration PPM 3500 Radiator cap must be firmly tightened back into the radiator surge tank neck Engine must not be operated without the aeration and overheating of the coolant Check engine radiator water level Check air cleaner oil level and change oil if required If oil bath type
33. itch Cs2 The engine mode selection switch is provided to select the engine mode of operation i e 1 Test 2 off 3 run The engine can be started only in test mode and clutch selection is possible only in run mode Direction selection switch CS4 The direction switch is provided to select the desired direction by engaging correspondence clutch The switch has three positions i e Forward Neutral Reverse The direction selection from neutral is possible only when the engine is operating in run mode Speed selector switch CS5 Engine speed selector switch with 8 positions is provided to select the speed of engine This can be rotated through 320 from position 0 to 7 in clockwise direction To decrease the speed rotate it anticlock wise No attempt should be made to rotate the switch from position 7 to 0 in clockwise direction Stand still detector SSD The stand still detector mounted on axle drive is provided to detect the stand still condition of OHE CAR The clutch cannot be engaged in either direction unless OHE CAR is stationary Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 54 9 1 7 9 1 10 Clutch actuating cylinder CAC The clutch actuating cylinder mounted on transmission is provided for shifting the lever of selector valve to forward neutral and reverse position This is a pivot mounted double acting and spring
34. l aware to correct maintenance and maintenance techniques adopted in field It is clarified that this handbook does not supersede any provisions laid down by RDSO or Railway Board I am sincerely thankful to Director TD RDSO LKO for his valuable suggestions and comments I am also thankful to all field personnel who helped us in preparing this handbook Technological upgradation and learning is a continuous process Hence feel free to write to us for any addition modification in this handbook We shall highly appreciate your contribution in this direction CAMTECH GWALIOR RANDHAWA SUHAG DATE 17 01 02 DIRECTOR ELECT GO BACK TO CONTENT CONTENTS Chapter Contents Page No No FOREWORD v PREFACE vii CONTENTS ix CORRECTION SLIP XV 1 INTRODUCTION 01 1 1 Body Structure 02 2 LIFTING SWIVELING PLATFORM AND PANTOGRAPH 03 2 1 Pantograph 04 3 MAINTENANCE OF ENGINE 06 3 1 A Check Every Day 06 3 2 B Check Every 300 Hours or 6 months which ever is earlier 09 3 3 C Check Every 1500 Hours or 6 months which ever is earlier 13 3 4 D Check Every 6000 Hours or 2 years which ever is earlier 16 3 5 E Check 17 v Chapter No Contents Page No TRANSMISSION 18 4 1 Maintenance of VOITH Hydraulic Transmission 19 4 2 Maintenance of Hindustan Motor Hydraulic Transmission 20 4 3 Trouble Shooting of H M Hydraulic Transimission 23 4 4 Maintenance of VENTRA Drop Gear Box 26 4 5 VENTRA Axle Drive Maintenance Schedule
35. l pinion with blue colouring Rotate the driven gear by hand Check the bearing pattern on the contact surfaces The bearing pattern should be centered on the working surface or pointing a little toward the minor diameter If the bearing pattern falls short of this requirement readjust KKK KK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 37 CHAPTER 5 BRAKE SYSTEM 5 1 AIR PRESSURE SYSTEM 5 1 1 Introduction Air pressure system in the Tower car mark III carried out the following operations i Operation of the brake cylinders ii Control system ili Signal Horns iv Parking brake When the power pack of tower car works the entire air pressure system is charged by the integrated diesel engine air compressor The main reservoir pressure is kept between 7 to 8 kg cm2 with the help of governor time relay auto drain valve fitted with main reservoir and unloader There is one another Safety valve set at 9 5 kg cm2 which can save the air pressure system in the worst case when the usual safety valve unloader and auto drain valve with time relay fails Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 38 Duplex pressure gauges have been provided in both the Dr cabins which will show the M R and B P of the air pressure system Two nos gauges have
36. lication time is 6 to 9 sec and brake releasing time is 10 to 15 sec e Check graduated application and release of brakes for proper lapping and number of steps Minimum 6 Nos e All the BC Isolating cock should be open and outer most angle cock of wagons amp OHE car should be kept closed e Every time driver should ensure charging of BP by seeing the pressure gauge readings as well handle position After BP is charged he should wait for 5 minutes for complete charging of brake system including CR pressure and AR pressure etc e Driver must confirm availability of service brakes before moving the car e Isolating valve handle of R Charger must be in down ward position otherwise charging of distributor valve will not take place e Whenever quick release valve is operated for manual release of brake driver should wait for recharging of brake system and confirm the availability of brakes again by bringing the handle to application position Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 59 9 3 RUNNING CONDITION e During the run if brake application is required to reduce the speed the handle of the Driver s brake valve should be brought to Ist notch in the application range Driver should reduce the BP to minimum value as reduction of BP by 1 4 kg cm2 will give full brake cylinder pressure of 3 8 kg cm2 e To operate the car on
37. must be taken through analysis with the help of trouble shooting chart 15 Clean radiator Blow air through the radiator core in opposite direction to the normal flow of air if working under dusty dirty condition Reverse flushing operation Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 S Mainten Remarks No ance Steps 16 Check air compressor Check shaft and clearance Adjust injectors and Clean fuel inlet connection valves screens Final adjustments must be carried out with 17 engine hot and with correct torque as specified Refer O amp M manual Change hydraulic Ss 18 governor _ail aneroid Use engine lubricating oil oil Check wobble and eccentricity alignment 19 Check vibration marks on rubber type damper Discard damper if misalignment is more than 0 16 cm Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 3 4 D CHECK EVERY 6000 HOURS or 2 YEARS WHICH EVER IS EARLIER S Maintenance Steps Remarks No 1 Repeat all maintenance steps of checks A B amp C 2 Check exhaust and inlet manifold nuts and capscrews 3 Tighten all mounting bolts and nuts 4 Clean turbocharger dif
38. n aneroid control If equipped Use same oil as used in oil pan Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 k Maintenance Steps Remarks Tighten belt tension use ST 1293 a E Check and adjust belts New belts will stretch 12 ee A within one hour of use a They must be readjusted AP A M FIG 3 4 CHECK BELT TENSION Tighten foundation bolts 13 and flexible coupling bolts of engine and alternator Check all air cleaner 14 connections for cracks Correct as required chafing etc Tighten all air intake connections Use special tool no ST 845 or ST 893 for 15 Check fan hub and drive dighignme dhe Tan hub nut Clean change air Chane ipa to naturally aspirated 16 compressor breather f engine Clean screen for element turbo engine 17 Check throttle linkage Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 13 3 3 C CHECK EVERY 1500 HOURS or 1 YEAR WHICH EVER IS EARLIER S Mainten Damak No ance Steps ao 1 Repeat all maintenance steps of checks A amp B 2 It should start opening and open fully within range 73 9 C and 79 5 C or Check thermostat 76 6 C
39. n of engine speed control switch even if speed is selected after clutch engagement Pressure switch PS1 is pneumatically operated by 3 2 way solenoid valve through SSD It is used for avoiding the clutch engagement without achieving the stand still condition of OHE car 9 1 14 Lubricating oil pressure switch It is mounted on engine It will stop the engine if the engine lubricating oil pressure is below 0 842 kg cm Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 56 9 1 15 Water temperature switch 9 2 It is also mounted on engine and will bring down the engine RPM to idle from high if the engine cooling water temperature reaches above set value 204 F on it STATIONARY CONDITION On entering the Driver s Cab the Driver should check and observe the following e Check visually all equipment for any visible defects as leakage in water fuel luboil TC oil line or pneumatic pipe lines loose joints FIGURE 9 1 CONTROL PANEL etc and rectify Clean Driver s cave inside and wind shields e Ensure that the handle of the Driver s brake Valve of the rear cabin is in ISOLATING POSITION e Handle of the Driver s Brake valve of the Driving Cabin should be in release and running position e Start the engine as follows e Switch on the ignition key Handbook on General Maintenance Schedule for January 2002
40. nd One brake cylinder works on each wheel When C3W valve BC lines operates the air pressure rush into the cylinder and compress the spring and ultimately push out the piston and apply the brake on wheels treads from both sides with the help of mechanical levers and brakes shoes If the driver release the brake with the help of auto brake valve A9 the pressure is released by C3W valve as well as through shut off vent type Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 42 5 1 2 6 Auto Brake Valve A 9 Automatic Valve It is valve by which drivers can apply the brake to the tower car as well as release the brake to run the vehicle Tower car Description The A 9 Automatic Brake Valve is a compact self lapping pressure maintaining brake valve which is capable of graduating in application or release of tower wagon brakes The A 9 Automatic Brake valve has five positions Release minimum Reduction Full service Over reduction and emergency The full service application position is preceded by a zone in which brake pipe air is supplied or exhausted in proportion to brake valve handle movement through this zone thus providing the graduation of an automatic application or release of the tower wagon brakes The A 9 Automatic Brake Valve consists of a self lapping regulating portion which supplies or exhausts the brake pipe pressur
41. ne fuel e Control operating temperatures e Guard against corrosion e Let the engine breath e Prevent over speeding e Know your engines condition e Correct troubles while they are simple e Schedule and control your maintenance KKK KK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 ANNEXURE TECHNICAL SPECIFICATION OF TOWER WAGON Model Type Track Gauge Axle classification No of axles Nominal axle load Tractive Effort vs Speed Curve No Adhesion factor Maximum speed Wheel dia Fuel tank capacity OHE Tower Car Mark HI Diesel Hydraulic 1676 mm O B O Driven carrying Two One One 16t max VT G 490 0 3 70 kmph 904 5 Half worn 300 litres 64 A 1 POWER PACK 1 1 Diesel Engine Make Model Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III Installed Power Governed speed Operating cycles No of cylinders Bore amp Stroke Formation Engine breathing Kirloskar Cummins Limited N 743 212 HP 2100 rpm 2100 rpm four Six 130 x 152 In line Naturally aspirated January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 65 2 TRANSMISSION 21 TECHNICAL DATA OF VENTRA TOWER WAGON 2 1 1 HYDRAULIC TRANSMISSION Make Hindustan Motors Limited Model Allison CRT 5633 Type Torque converter three speed forward amp reverse power shift tran
42. ode Sees sT g For Official Use Only aia aaa HRA Xb GOVERNMENT OF INDIA at Haley MINISTRY OF RAILWAYS Handbook on General Maintenance Schedule for OHE Tower Wagon Mark III CAMTECH 2002 E TW 1 0 January 2002 Centre ra for Fo 4 Advanced KOI KK ke Maintenance Execellence in Maintenance TEC Hnology Maharajpur GWALIOR 474 005 FOREWORD Indian Railways uses large number of Tower wagons for maintenance of overhead equipment in electrified section The proper maintenance of tower wagon is vital to ensure its availability and reliability CAMTECH has prepared this hand book to cover all essential aspects of tower wagon maintenance This handbook describes various maintenance schedules trouble shooting instructions and do s and don ts It also covers operating and maintenance instructions for OHE car driver I am sure the book will prove to be very useful to our field personnel to carry out their work more effectively and efficiently CAMTECH GWALIOR M L GUPTA DATE 17 01 02 EXECUTIVE DIRECTOR GO BACK TO CONTENT PREFACE Tower Wagon is an important vehicle for regular inspection and attending breakdown of O H E Therefore proper maintenance of tower wagon is necessary to ensure the reliability and availability of tower wagon in emergency and for regular maintenance of OHE This handbook on Maintenance of Tower Wagon has been prepared by CAMTECH with the objective of making our maintenance personne
43. quivalent oil and drain out 1 2 to 1 litre oil again Close the drain Fill the sump with specified quality Period of changing oil every three months Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 29 4 6 MAINTENANCE OF KPC HYDRAULIC TRANSMISSION 4 6 1 Maintenance 4 6 1 1 Hydraulic system a The oil capacity of transmission is 20 litres b Oil level should be checked daily through the oil level gauge in transmission Oil level should be checked at idling engine speed it should be between high amp low marks c Oil must be changed after 1000 Hrs of operation d Drain valve is provided for draining the oil without loss Connect hose to the drain valve and then open the valve e Fill the oil in transmission through breather cap hole Run the engine and check the oil level Replace the breather cap or alternatively remove plug provided on cover top amp fill oil Refit plug after oil filling Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 30 f Replace filter element as per recommendations Remove the filter cover and replace filter element Use new gasket if necessary for the filter cover g Suction strainer Unscrew plug on top of strainer housing for strainer removal Clean strainer throughly by flushing in
44. r 48 9 C 60 C and non sludging detergent Allow it to dry first then use compressed air Replace if washed two times Caution Excess air pressure will damage paper Air nozzle must be kept at least 8 from the element Must not be used if even one pin hole exists Discard element if punctured and also change gasket along with element Clean oil bath cleaner tray screen air Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 _ GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 Maintenance Steps Remarks Change lubricating oil by pass filter element and gasket if provided Record oil pressure Clean float tank and or main fuel tank breather Check coolant PH value concentration of DCA chromate concentration 3500 PPM Change corrosion resistor element if PH calue is below normal range 8 5 10 5 Check chromate concentration at 3500 PPM Check magnesium plate in assembly corrosion resistor Change water filter element Check magnesium plate for pitting or being eaten away Change if more than 50 of area is lost Use DCA service element or chromate element bags AR 95679 if concentration is low 10 Change fuel filter element washer and O ring on mounting bolt Clean shell fuel filter Change element when restriction exceeds vacuum 20 32cm of mercury 11 Check oil i
45. r is earlier Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT i CAMTECH 2002 E TW 1 0 4 6 2 32 TROUBLE SHOOTING OF KPC HYDRAULIC TRANSMISSION Symptom Cause Remedy Overheating a Insufficient a Install heat heat exchanger exchanger of capacity sufficient capacity b Insufficient b Check pipe lines cooling water and heat exchanger flow for clogging Check correctness of pipe size used c Clutch slipping c Low clutch oil pressure see low oil pressure d Oil level too d Correct oil level high e Improper oil e Use only recommended oils f Clutch plates f Replace clutch warped plates Low oil a Clogged a Remove amp clean pressure strainer strainer b Stuck pressure b Remove selector regulation valve assembly piston in and clean piston selector valve assembly c Broken piston c Disassemble rings in clutches and clutches replace piston rings Handbook on General Maintenance Schedule for 4 Wheeler OHE Tower Wagon Mark III January 2002 GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 33 Symptom Cause Remedy d Damaged or d Remove oil pump worn oil pump Replace damaged assly worn assly e Clogged or e Remove orifice plugged orifice plate and clean plate in selector valve assembly f Lowoillevel f Add oil to maintain proper
46. raulic or air Check brake residual pressure applying clutch pressure brakes cutoff valve released check brakes for full release 8 Internal failure Overhaul transmission or repair subassembly B OVERHEATING 1 High oil Restore proper oil level 2 Clutch failed Rebuild transmission Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 24 Causes Remedy 3 Vehicle overloaded Reduce load 4 Low clutch apply Refer to A pressure 5 Engine water overheated Correct engine overheating 6 Cooler oil water line Clean or replace line kinked or clogged C AERATED foaming OIL 1 Incorrect type oil used Change oil use proper type 2 High oil level Restore proper oil level 3 Low oil level Restore proper oil level 4 Air entering suction side Check oil pump bolts of oil pump and gasket 5 Air entering at clutch Check plug seal and cutoff valve air seal ring of valve actuated D VEHICLE WILL NOT TRAVEL 1 Low clutch apply pressure Refer at A 2 Selector linkage broken or Repair or connect disconnected linkage 3 Internal mechanical Overhaul failure transmission E VEHICLE TRAVELS IN NEUTRAL WHEN ENGINE IS ACCELERATED 1 Selector linkage out of Adjust linkage adjustment 2 Clutch failed won t Overhaul release transmission Handbook on General Mainten
47. s to the lap position Everytime B P pressure is increased in steps this phenomenon repeats There is on lever provided in C3W valve by pulling it the brakes can be released manually The passenger freight change over device helps to achieve required brake application and release timings depending on the type of service either frieght on passenger 5 1 2 3 Spring brake actuator Function To produce braking forces at the wheel for parking brake Operation In the normal running condition the chamber air is pressurized and the piston compresses the spring and the brakes are in released condition Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 41 5 1 2 4 Spring brake application Parking brake When the air pressure in the Chamber is depleted the spring pushes the piston and thereby the push rod out and applies the brakes through the slack adjuster 5 1 2 5 Emergency brake When the system air pressure drops below the spring brake hold off pressure the spring pushes the piston and the push rod out to apply the brakes through the slack adjuster Mechanical Release To release the brake temporarily for towing the vehicle the wind off nut is unscrewed after loosening the lock nut thus retracting the push rod Brake Cylinder In tower car 4 nos of brake cylinders have been used which have been fitted at rear end and front e
48. sary e Replace all parts that are cracked broken worn excessively damaged or in such a condition as would result in unsatisfactory operation e The spring may be wire brushed to assist in the removal of rust and scale After cleaning blow all metal parts with a low pressure jet of clean and dry air e Promptly blow the parts dry with low pressure jet of clean and dry air e Discard the filter unit and replace with a new one e Inspect all other parts Reject and replace any part that is cracked cut damaged worn excessively or is in such a condition that would result in unsatisfactorily operation e The spring must be replaced if it is rusted distorted or has taken a permanent set e Frequency of overhauling of valves is to be decided by depots depending upon the utilization of tower wagon However overhauling is to be carried out at least once in year NOTE All the gauges and meters are to be caliberated once a year Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 46 CHAPTER 6 TXR CHECKING A general inspection of brake control wheel and axle and suspension should be done by depot s staff before going on trip A monthly inspection of running gear soundness and conditions of wheels and axle underframe undergear fittings buffer height brake rigging roller bearing axle box laminated springs horn check gap and
49. shot valve iv Cut off valve v Double release valve vi Auxiliary reservoir check valve vii Freight to passenger change over device or lock viii Application and release chokes 5 1 2 2 Operation The compressed air from brake pipe charges into CR control reservoir of the C3W valve and auxiliary reservoir AR through cut off valves when the BP pressure is reduced by the Driver s brake valve due to differential pressure across the main valve diaphragm the hollow stem lefts and allow AR pressure into B C brake cylinder through inshot valve The B C pressure also acts on top of the upper diaphragm bringing the main diaphragm assembly down wards and finally to cap position In this position B C pressure is held against permissible leaks Every time B P pressure is reduced in steps this phenomenon repeats Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 40 The quick service valve helps in quick propagation of B P Brake pressure reduction through the length of the train also When the B P Brake pipe pressure is increased by Driver s brake valve the hollow stem of main valve is brought to normal position by neutralizing the pressure differential across the main valve diaphragm and the B C pressure is released through the hollow stem to the atmosphere As in the application the upper diaphragm balance against upward force and come
50. smission with drop gear box Ratio Forward I speed 3 95 1 II speed 1 96 1 II speed 0 99 1 Reverse I speed 4 11 1 II speed 2 04 1 IMI speed 1 04 1 2 1 1 1 Drop gear Box Make VENTRA Model GBM 0081 Ratio 2 41 1 2 1 1 2 Axle drive gear box Make f VENTRA Model GBM 0063 Ratio 1 71 1 2 1 1 3 Carden shafts a Make Twindisc USA Model J 230 TS Between transmission amp drop gear box output and axle drive gear box input Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 66 2 1 1 4 Compressor Make Kirloskar Cummins Model Single cylinder Engine Engine mounted 13 2 cfm 100 PSD 2 2 TECHNICAL DATA OF KPC HYDRAULIC TRANSMISSION Model KTC 100 20 Specifications Spec Number 780 430 Converter 8 1600 M S Value 330 RatioF R f 1 333 1 Housing Suitable for SAE 1 Flyweel housing Dry weight 500 Kg Approximately Sump capacity 20 Litres excluding pipe lines heat exchanger Pump capacity 52 Litres min at engine speed of 1400 rpm Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 67 2 2 1 Operating pressure at 2100 rpm engine speed a Converter base pressure 2 0 to 4 5 kg cm2 b Clutch engagement pr 13 0 to 16 0 Kg cm2 12 0Kg cm2 minimum c Clutch neutral pressure 4 5
51. tend immediately to fuel and lubricating oil leaks 11 Do keep essential spare in store 12 Do drain radiator if engine is being left idle in frosty weather 13 Do remove pressurized radiator filter cap where fitted before draining the coolant system Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 61 10 2 DON Ts Do not neglect the routine maintenance Do not race the engine in neutral 3 Do not run the engine unless the gauge shows oil pressure Do not unnecessarily interfere with any adjustments 5 Do not continue to run the engine if the cooling water boils Do not forget to keep the fan belt adjusted 7 Do not continue to run the engine if black smoke is coming from the exhaust 8 Do not omit to wipe the engine occasionally with a clean rag 9 Do not use cotton waste or any fluffy cloth when cleaning 10 Do not use unapproved brands of lubricating oil 11 Do not store fuel oil in a galvanised container 12 Do not subject the engine or vehicle to continuous overloading 13 Do not load the vehicle beyond the stipulated payload 14 Do not coast when travelling down hill Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 62 10 3 SUGGESTION FOR ACHIEVING ZERO FAILURES e Engine should run idle for 3 to
52. tting to atmosphere in order to prevent excessive main reservoir pressure build up Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 44 5 1 2 10 Automatic Drain Valve The automatic drain valve automatically discharges precipitated moisture from a reservoir with each operating cycle of the control device 5 1 2 11 J air filter The J air filter function to assist in preventing the passage of dirt and moisture which may be mixed with the air flowing from the main reservoir into the air brake equipment 5 2 MAINTENANACE OF THE VALVES 5 2 1 Cleaning Inspecting andRepairing e With the brake valve completely disassembled all parts must be cleaned and inspected e All the parts excepting rubber parts must be washed in a suitable solvent that will dissolve oil or grease and permit all the parts to be thoroughly cleaned without abrasion The exterior of the body must be thoroughly cleaned by means of a cloth or rag saturated with a suitable solvent e All Gasket Diaphragms and O rings must be replaced e All Packing rings should be replaced Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 45 e Clean all springs using a wire brush and suitable solvent and inspect for pitted marks distortion or permanent set Replace where neces
53. ug indicator 5 Breather must be cleaned thoroughly once in three months VENTRA AXLE DRIVE MAINTENANCE SCHEDULE The final drive to the tower wagon is affected by the axle mounted right angle drive gear box The input and intermediate shaft run spherical roller bearing The axle also run on spherical roller bearing the gear box housings have been provided with oil pockets and gears and bearings get abundant lubrication The bottom housing serves as the oil sump Level drain plug and inspection door have been provided for regular maintenance Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 28 1 Daily oil level to be checked through the level plug and if necessary top up with the same oil please refer oil chart for quantity grade 2 Check for oil leakage through oil seals and housing joints Seal are to be replaces or housings are to be tightened according to the prescribed tightened torque if necessary 3 Once in a fortnightly take out the magnetic drain plug from the gear box and check for any wear particles or debris if heavier particles are found the gear box has to be inspected by opening the cover at the top Note For Changing Oil For a new gear box first oil change shall be done after one month During changing clean the gear box with kerosene or diesel after draining out the sump Pour the recommended e
54. wheel line gauge should be done by the TXR as per the relevant drawings issued by Jamalpur workshop of Eastern Railway KOKK OK OK Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 47 CHAPTER 7 ELECTRICAL MAINTENANCE ELECTRICAL ITEMS OTHER THAN BATTERIES 7 1 TRIP SCHEDULE 7 1 1 Condition Diesel engine running General examination a Check for high temperature unusual sound and odour of the following e Alternator e Lube oil pump e Engine tachometer e Starting equipment b Ensure the working of hour meter and battery charging 7 1 2 Condition Diesel engine stopped General examination Make visual examination of junction boxes distributors electrical control equipment and instruction for dirt flashover overheating loose covers and screws leads and wiring connections for tightness presence of moisture and incipient damage due to rubbing and other defects Handbook on General Maintenance Schedule for January 2002 4 Wheeler OHE Tower Wagon Mark III GO BACK TO CONTENT CAMTECH 2002 E TW 1 0 48 Lights Check operation of Head and buffer lights Cab lights Gauge lights Warning and indicating lights Inspection lights Dimmer lights Flasher lights wmonoge 7 2 FORTNIGHTLY SCHEDULE 7 2 1 Condition Diesel engine stopped e Check insulation resistance of reversible protected type plugs and ensure

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