Maintenance Instruction

WS 4519 1

U 08 475 / 4S

MAINTENANCE INSTRUCTION

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TABLE OF CONTENTS 1. INTRODUCTION 3 2. PURPOSE 4 3. SAFETY 5 4. FIRST AID 8 5. FIRE PROTECTION 9 6. HAZARD ANALYSIS 11 6.1 GENERAL 11 6.2 HAZARD INFORMATION 12 6.3 EXTRACTS FROM THE SAFETY DATA SHEETS 13 7. INSTRUCTIONS FOR USE OF STARTER BATTERIES 24 8. MAINTENANCE 27 9. MAINTENANCE WORKS 28 9.1 CLEANING 28 9.2 VISUAL CHECK 29 9.3 TOPPING UP WORKING STOCK 31 9.4 LUBRICATION 32 9.5 CHANGING WORKING STOCK 33 10. PICTOGRAPHS 34 11. INTERVALS 36 12. MAINTENANCE SCHEDULE SURVEY 37 13. GENERAL SURVEY 40 14. ORIGINAL FILLING OF WORKING STOCK 42 15. IN BETWEEN PERIODICALLY 44 15.1 SAFETY CONTRIVANCES 44 15.2 BRAKE 45 15.3 COOLER 45 16. AFTER 10 HOURS OF OPERATION OR DAILY 46 16.1 PLAIN VISUAL CHECK 48 16.2 CHECKING WORKING STOCK 48 17. AFTER 50 HOURS OF OPERATION OR WEEKLY 53 18. AFTER 100 HOURS OF OPERATION OR MONTHLY 72 19. AFTER 250 HOURS OF OPERATION OR SEMI-ANNUALLY 76 20. AFTER 500 HOURS OF OPERATION OR SEMI-ANNUALLY 86 21. AFTER 1000 HOURS OF OPERATION OR ANNUALLY 96

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1. INTRODUCTION Maintenance of this machine over its entire service life has to be performed according to the Maintenance Instructions (prENV 14033-1 / enclosure "J"). The owner respectively the operating organization is responsible for maintenance of this machine! At regular intervals of at least 2 years all machines will be inspected by the railway infrastructure organization, on whose tracks the machine is deployed. The railway infrastructure organization must be notified of any derailment, collision, rupture of running gear as well as any anormal heating of the wheelset bearings, which will lead to special inspection by qualified personnel of the railway infrastructure organization. Machine parts and components influencing driving safety must not be modified without prior consent of the authorized approval body. Any modification entails the necessity of obtaining a new transport approval. Any works at the machine frame, the bogie frames, brake system, wheelsets, wheels, wheelset bearings, speedometers, equipment for repeating and recording of signal indications and indications at the drivers desks may only be carried out by workshops holding the respective admission of the authorized approval body. Current maintenance works will be carried out by the machine operating organization at its own responsibility. The general operating and safety instructions BS-02.00 (refer to auxiliary documentation) are to keep.

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2. PURPOSE

The machine operating organization bears the responsibility for maintenance.

Maintenance comprises all machine components that do not influence driving safety see above.

According to the present maintenance instruction this machine over its entire service life is subject to regular maintenance.

Professional maintenance will be decisive for the term of service life of the machine and its permanent readiness for service.

Essential maintenance criteria are:

- qualification of the maintenance staff

- quality of maintenance works

- observance of the time intervals prescribed

- use of the working stock prescribed

- use of original spare parts

Maintenance has to be carried out in stages, i. e., any time interval automatically includes all preceding intervals. EXAMPLE: At dates set for monthly maintenance there have to be carried out also all

works listed for weekly and daily maintenance.

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3. SAFETY Maintenance works in principle have to be carried out when the vehicle is stationary and secured against breaking away. It is strictly prohibited to climb on the vehicle roof under catenary. Before beginning repair and maintenance works it must be ensured that the catenary is switched off and earthed. These safety measures have to be carried out and supervised by the responsible safety officers! Always pay attention to trains passing on adjacent tracks. Use skid-pans when parking the vehicle on gradients. If a check of certain structural elements might entail danger, these elements may be checked only when the machine is stationary or after work. Before starting maintenance works the parking brake has to be applied (with few exceptions), the engine has to be turned off and the main switch must be switched off. Never change the settings of safety valves. Before disassembling hydraulic system elements make sure that the equipment is unpressurized. Hydraulic oil coming out under pressure may penetrate skin and cause serious injuries. When draining engine oil or hydraulic oil at working temperature you might scald yourself. Always ensure that on or in the vehicle nobody works with naked flames. Do not smoke when refuelling the vehicle or checking the acid level of the batteries. Never check the acid level of the battery or the fuel level in the tank with a naked flame. continued on next page

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continued: safety Before beginning welding works (electric arc welding) particularly make sure that: the machine has been secured against breaking away (parking brake, skid-pans etc.); the engine has been switched off; the main switched has been switched "OFF; the program control switch has been switched "OFF, if existing; the battery sets have been entirely disconnected. the earth electrode fastened at the vehicle has been connected as close to the weld as possible. The earth electrode must never be mounted on the rail. Never connect the earth electrode to cylinder piston rods, hydraulic accumulators, hydraulic pumps, batteries, earth cable, loose connections, such as bearings or similar, or to hydraulic oil or fuel tanks. Do not direct any high-pressure cleaning and lubricating devices to man or animal. Do not use any easily flammable fluids or caustic cleansing agents to clean the machine.

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Safety Guide Lines to prepare any Repair Work on the Machine Entering the danger areas on the machine in working mode is strictly prohibited. Repair work on the machine must be carried out only by specialized and trained personnel. The adjacent track in train service must not be entered. Please follow the local railway regulations. Before carrying out any repair work on the machine the following safety hints have to be kept:

The Hydraulic system has to be switched off!

The Pneumatic system has to be switched off!

The machine has to be secured from rolling off!

The working main switch has to be turned off and be protected from misuse and accidental operation.

The battery main switch has to be turned off and be protected from misuse and

accidental operation.

All operators and people involved with the machine operation have to be notified about the kind of repair work on the machine.

A competent person has to be chosen to supervise and carry out the repair work

and oversee the work in regard of safety matters.

Before the machine is put back into operation all people involved with the machine operation have to be notified about the repair and the machine may only be put back in operation by qualified personnel.

In working mode the danger areas are again prohibited areas on the machine.

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4. FIRST AID Always ensure that the first aid kit is in a proper, complete and neat condition. For the purpose of first aid measures and suitable equipment consult the first aid service or doctor of your responsible department.

Immediately replenish used up material!

Note Medicines, tranquillisers or other medications can result in drowsiness or impair for instance the reactivity. Procedure for first aid measures

1. HELPING

2. REPORTING

3. SECURING

4. WARNING

For Helping refer to first aid measures in the extracts of the safety data sheets. In the case of burning Extinguish the burning person with water, fire extinguisher, blankets or through rolling. In the case of eye contact with hazardous materials Rinse out several times with spray bottle or beverage and subsequently consult a doctor. In the case of skin contact with hazardous materials Thoroughly wash with soap under running water and subsequently consult a doctor. When inhaling hazardous materials When inhaling higher concentration, take person into the fresh air and subsequently consult a doctor. After ingesting Do not induce vomiting and immediately consult a doctor After intensive contact with clothing Immediately change saturated clothing, shower and subsequently consult a doctor.

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5. FIRE PROTECTION

First aid procedures Rescuing people Alarming the fire brigade Attempting to extinguish fire Everybody is obligated as far as possible and acceptable to refrain from everything that may result in a fire or favour the spreading of a fire. In addition to this, all measures to prevent the development or spreading of fires must be taken in individual cases.

Oily or greasy rags saturated in solvent must be kept in a fire-protected place since they could cause fires through self-ignition.

In order to avoid the development of fires, the following parts, especially equipment subject to the development of heat, must be kept free of deposits.

Drives Heaters Belts Gears Control cabinets Power distribution boards etc. For this reason, timely familiarise yourself with the operational fire protection regulations and the proper use of the existing extinguishing agents. For this purpose consult the fire protection representative of your department! The fire extinguishers must always be ready for operation, freely accessible, periodically tested and equipped with test plaques. The date of expiry must be checked by the responsible fire protection representative! Following the use of a fire extinguisher this must be immediately brought to the attention of the fire protection representative who is responsible for the operation. The representative will immediately arrange for the filling of all used fire extinguishers and he is obligated to provide replacement fire extinguishers in the meantime!

NOTE!

The use of open flames and easily flammable agents on the vehicle and in immediate vicinity is strictly prohibited!

The diesel fuel tanks may only be filled with the engine switched off and cooled off.

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6. HAZARD ANAYSIS Carefully performed preventive maintenance to maximise the service life and increase the operational safety, which will be reflected in a clear reduction of working accidents and resultant damage to persons.

6.1 GENERAL The instructions of the operations manager or machine operator must be followed under any circumstances.

Entering the machine is only permitted by way of the steps provided for this purpose, which should be kept free of grease, oil, fuel, dirt, snow and ice.

Climbing onto machine parts during loading, unloading and repair operations located in the hazard area of the overhead line is always prohibited unless the overhead line has been switched off, in which case the safety regulations issued by the respective rail operators will have to be followed.

Crossing underneath the machine during operation or working is prohibited. Danger! When present in the vicinity of the machine the use of ear protection is absolutely

essential.

If problems are encountered while work in progress, activate the emergency or engine stop. Based on the type of the fault it must be decided how it should be rectified most effectively.

Instinctive reactions for rectifying the fault during working operation may result in serious injury to body and even death.

The removal of covers and safety instructions is strictly prohibited. Touching the exhaust system may result in burns. In addition to this the safety regulations of the responsible railway administration or more stringent regulations of other competent authorities as amended will apply.

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6.2 HAZARD INFORMATION

Hazards Mainly impact, drawing-in, pinching, squeezing and squashing hazards and the danger of skin burns exist at the mentioned hazard locations as a result of which only instructed personnel may be assigned to work with and on the machine. When climbing onto the machine there is the additional danger of electric shock. Information with regard to endangering third parties falls under the area of responsibility of the local construction management (co-ordination). Instruction sheets and sketches are submitted to the respective principal who will be responsible for further distribution.

6.2.1 Responsibilities for implementation

Distributor.. Announces the hazards Operator. Technical issues Local construction supervision Specific construction site issues and the co-

ordination of all issues with the individual persons The handling of hazardous service products without any danger must be clearly established for the following working materials by means of regulations that must be imparted to the employees in training courses. (References in the extracts of the safety data sheets)

Flammable and/or explosive materials (diesel, etc.) Working materials hazardous to health (oils, greases, etc.) Other hazardous materials (adhesives, cleaners, etc.) 6.2.2 Protective equipment

In order to keep hazards and their consequences to health as low as possible it is imperative to ensure suitable protective equipment.

Head protection. Hard hat Ear protection. Ear muffs, earplugs Hand protection. Gloves Foot protection.. Steel cap shoes Warning clothing Clothing in signal colours with reflecting stripes Breathing protection. Dust mask NOTE: It is imperative to observe the signs, covers, safety guards, earthing cables, etc., attached to the machine for the protection of the health of persons and the equipment as well as the environment!

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6.3 EXTRACTS FROM THE SAFETY DATA SHEETS Gearbox oil 15 W 40 CF4 Hydraulic oil SHELL TELLUS T 68 Engine oil Valvoline 15W40 Lubricating oil SHELL TELLUS S100 93 / 112 / EC to material 35891 Lubricating grease SHELL ALVANIA GREASE RL2 93 / 112 / EC to material 75202 The safety data sheets contain additional information on the following.

Material, preparation and company designation Composition / details concerning ingredients Possible hazards Fire-fighting measures Measures if inadvertently liberated Handling and storage Physical and chemical properties Stability and reactivity Toxicological details Ecological details Disposal instructions Transport details Regulations Other information

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6.3.1 15 W 40 CF4 Possible hazards Hazard designation:

Extended or repeated skin contact may lead to dermatitis. No special health hazard if used as intended.

Safety risks: Avoid the formation of oil mist.

Environmental hazards: Do not allow the product to contaminate the environment in an uncontrolled manner. Not entirely biodegradable.

First aid measures General instructions: After inhalation:

Take the person concerned into the fresh air and rest quietly. Obtain medical advice. Following skin contact:

Remove contaminated clothing and wash the skin areas concerned with soap and water. Should product under high pressure get underneath the skin immediately consult a doc.

Following eye contact: Thoroughly rinse out immediately for 15 minutes with spread eyelids under running water and consult a doctor.

Following ingestion: Do not induce vomiting. Obtain medical advice.

Instructions for the doctor: Symptomatic treatment.

Fire fighting measures Suitable extinguishing agents:

Foam, powder, carbon dioxide, sand or soil Extinguishing agents which are unsuitable for safety reasons:

Do not use concentrated water jets. Special hazard through the material or combustion products:

Complex gas-aerosol mixtures which may contain carbon monoxide, nitric oxides, soot, sulphuric dioxide and organic compounds are generated under the conditions of an uncontrolled fire.

Special fire-fighting protection equipment: None.

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Exposure Controls / Personal Protection Respiratory protection:

Not normally required. If oil mist cannot be controlled, a respirator fitted with an organic vapour cartridge combined with a particulate pre-filter should be used.

Hand protection: PVC or nitril rubber gloves if splashes are likely to occur and if applicable.

Eye protection: Safety spectacles

Body protection: Minimise all forms of skin contact.

Hygiene measures: Dont keep oily rags in your pockets. Wash hands before eating and drinking.

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6.3.2 SHELL TELLUS T68 Possible hazards Hazard designation:















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6.3.3 Valvoline 15W40 Possible hazards Hazard designation:















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6.3.4 SHELL TELLUS S100 Possible hazards Hazard designation:















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6.3.5 SHELL ALVANIA GREASE RL2 Possible hazards Hazard designation:




First aid measures General instructions: Following inhalation:

The inhalation of parts of this product is improbable and does not constitute an acute hazard. Take the person concerned into the fresh air and rest quietly.

Following skin contact: Remove contaminated clothing and wash the skin areas concerned with soap and water. Should product under high pressure get underneath the skin immediately consult a doc.









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Not normally required. Hand protection:

PVC or nitril rubber gloves if splashes are likely to occur and if applicable. Eye protection:

Safety spectacles Body protection:

Minimise all forms of skin contact. Hygiene measures: Dont keep oily rags in your pockets. Wash hands before eating and drinking.

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7. INSTRUCTIONS FOR USE OF STARTER BATTERIES Storage and transport Starter batteries require no maintenance prior to being filled. Store in a dry and cool place (no frost).

Recharge filled starter batteries not later than at an acid density below 1.21 kg/l (1.18 kg/l with filling acid 1.23 kg/l). Transport and store filled batteries in the upright position to prevent acid spillage. When transporting, secure the battery to prevent toppling over. Commissioning Empty charged starter batteries are ready for operating after having been filled with battery acid without separate charging.The temperature of the battery and the acid should be at least 10C when filling. Remove battery caps.Fill the individual cells of the battery with sulphuric acid according to VDE 0510 of density 1.28 kg/l (for tropical countries 1.23 kg/l) up to the maximum acid level mark or 15 mm above the upper edge of the plates. Leave battery to stand for 15 minutes, slightly tilt several times and replenish acid if required.Firmly screw in or press in the filler caps. Wipe off any spilled acid. Batteries supplied in the filled state are ready for operation. Note: If a battery produces insufficient starting capacity due to low temperature or unfavourable storage, recharge the battery. Installation in the vehicle Before removing and installing the battery, switch off the engine and all power consumers. Avoid short-circuits through tools.

When removing the battery, first disconnect the negative terminal ( - ), then the positive terminal ( + ). Prior to installing the battery, clean the standing area in the vehicle. Firmly secure the battery. Clean battery terminals and terminal clamps and lightly grease with acid-free grease.

On installation, first connect positive terminal ( + ), then negative terminal ( - ). Ensure terminal clamps are tightened securely.

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Charging outside the vehicle Before charging, check the electrolyte level and, if required, add desalinated or distilled water up to the maximum acid level mark or 15 mm above the upper edge of the plates. Remove the battery for recharging to avoid damage to the vehicle. Note : Observe the vehicle manufacturers instructions when disconnecting the battery.

Batteries may only be charged with direct current. Connect positive terminal ( + ) of the battery with the ( + ) of the charger and the negative terminal ( - ) with the negative terminal ( - ) of the charger. Switch on the charger only once the battery has been connected. At the end of the charge, switch off the charger first. A tenth of the capacity is recommended as charge current. (For instance: 44 Ah : 10 = 4.4 A charge current)

The acid temperature may not exceed 55 C during charging. Interrupt the charging process if the temperature is exceeded. The charging process is completed when the current is almost 0 or no longer reduces or the automatic charger has switched off. Ensure sound ventilation during the charging process.

Caution : Highly explosive oxyhydrogen is generated during charging! Fire, sparks,

naked light and smoking prohibited! Maintenance In order to achieve a long service life for the battery, the following instructions should be observed. Keep the surface of the battery clean and dry. Regularly check the acid level and, if necessary, replenish with desalinated or distilled water. Never add acid. If there is a major loss of water, have the regulator voltage checked by a specialist. Do not use any so-called conditioning agents. The charge condition can be determined by measuring the acid density. If the acid density is below 1.21 kg/l (or 1.18 kg/l with filling acid 1.23 kg/l), recharge the battery. At that acid density the battery is protected against freezing up to - 15 C (at 1.28 kg/l up to -70 C ).

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Jump-starting Because of the sensitive electronics in the vehicle, always use a starting booster for jump-starting. Jump-starting the car may lead to voltage peaks when disconnecting and damage or even destroy the electronics of the vehicle. For this reason follow the following instructions when using jumpstarting leads! When jump-starting with jump-starting leads it is advisable to use standardised jump-starting leads (for instance according to DIN 72 553). Follow the instructions for use of the jump-starting leads. Connect only batteries of the same rated voltage. Connecting: Both vehicle engines off! First connect the two positive terminals 1 and 2, then the negative terminal of the donor vehicle 3 with a metallically bright point on the vehicle requiring assistance 4 away from the battery (pay attention to the vehicle manufacturers instructions). Start the incapacitated vehicle for a maximum of 15 seconds, do not start the donor vehicle during this time. Disconnection: Disconnect cables in reverse order. Taking the battery out of service Charge the battery and store in a cool place. If the battery remains in the vehicle, disconnect the negative terminal. Regularly check the charge condition.

Batteries of the donor vehicle 2 x 12V

Battery of the vehicle to be jump-started 2 x 12V

++

- -

1 2

3 4

- -

++

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8. MAINTENANCE Machine maintenance is divided into activities (maintenance works) chapter 9, and intervals chapter 11. Only if both criteria are observed, the correct activity will be carried out at the correct moment as shown in the maintenance schedule survey chapter 12. Maintenance works are divided as follows: - cleaning - chapter 9.1 - visual check - chapter 9.2 - topping up of working stock - chapter 9.3 - lubrication - chapter 9.4 - changing working stock - chapter 9.5 If during maintenance works carried out at machine components that influence driving safety there are discovered defects, the status automatically changes from maintenance to inspection and, if necessary, on to repair. EXAMPLE: During an extended visual check there are discovered wheel fissures.

As this irregularity has been discovered at a machine component which influences driving safety, status changes from maintenance to inspection.

An inspection may be carried out only by those workshops that are admitted for such kind of works by the authorized approval body!

If during inspection it is found out that the number and dimensions of fissures exceed the admissible values, the respective part has to be replaced.

Status automatically changes to repair! A workshop of the above mentioned type will carry out repair works. Maintenance works have to be recorded in the operators logbook. These records should document any type of maintenance carried out (who, when, what, where and why). In case it is intended to park the machine for a period longer than 6 months, preservation measures as usual in practise have to be provided.

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9. MAINTENANCE WORKS

9.1 CLEANING

If the machine is soiled to such an extent that maintenance works would be impeded and of no use, it is necessary to clean the machine before starting working.

Additionally, periodical cleaning is prescribed for certain structural elements. Cleaning is the best opportunity to check an element visually. It is of particular importance to clean the coolers in time! Do not direct any high-pressure cleaning devices against thin covers. Do not use any easily flammable or caustic cleansing agents.

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9.2 VISUAL CHECK plain visual check chapter 9.2.1 extended visual check chapter 9.2.2 immediate visual check chapter 9.2.3

Fundamental requirements for a visual check

Machines, working units etc. that move, drive, work, are subject to wear and tear. If wear is not taken into account, sooner or later it will lead to serious damage to the machine that may entail unnecessary (avoidable) high costs and long down times.

Visual checks are usually underestimated as maintenance factors. The purpose of a visual check is to find out as soon as possible dangerous changes, as well as wear and obvious irregularities in order to initiate suitable measures. To carry out visual checks successfully, a certain degree of experience and responsibilty is required.

Dangerous changes are, e. g.: (the list is not intended to be complete) - massive and/or unevenly distributed wear - deformations by force - chafe marks with material shrinkage - porosity - leaks - fissures - notches in critical places - rupture of structural elements - corrosion - loose fit of screwed connections - loose securing elements - lost parts - discolouration as a consequence of high temperatures - bad general condition (dirty coolers, fluid levels below minimum etc) NOTE: It is assumed to be obvious and compelling that as a result of visual checks it

may be necessary to take measures!

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9.2.1 Plain visual check A plain visual check usually will be carried out before putting the machine into operation and after its deployment. Before starting the first operation of the day or after longer breaks it is recommended to check the machine visually for its general condition and any obvious irregularities when approaching towards the machine from a greater distance. EXAMPLE: broken windows, bent machine parts etc. indicate to the use of force and make

a more detailed investigation necessary. Depending on their nature structural elements have to be investigated visually for dangerous changes, such as fissures, deformation, ruptures, corrosion, discolouration by temperature, leaks, as well as for the general condition and the fit of securing elements. Plain visual check is identical with extended visual check, is, however, restricted to areas visible from outside.

9.2.2 Extended visual check An extended visual check is carried out in monthly intervals from an assembly pit. An extended visual check will be necessary before start-up, if:

the operating condition is not known, the machine had been parked over a longer period, a new or untrained crew will put the machine into operation.

9.2.3 Immediate visual check Irregularities during operation (anormal noises, smoke, fire, suddenly running out operating stock, discolouration by heat, smell of elements running hot etc.) require an immediate visual check. Lost structural elements are a serious indication of a dangerous change and require a careful and immedate investigation of the reasons.

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9.3 TOPPING UP WORKING STOCK Checks of working stock levels have to be carried out when the vehicle stands on a level surface (without super-elevation or inclination). Before dismantling hydraulic elements make sure that the system is unpressurized. Hydraulic oil coming out under pressure may penetrate skin and cause serious injuries. When draining engine oil or hydraulic oil at working temperature you might scald yourself. Always ensure that on or in the vehicle nobody works with naked flames.

Do not smoke when refuelling the vehicle or checking the acid level of the batteries. Never check the acid level of the battery or the fuel level in the tank with a naked flame. When changing working stock (hydraulic oil, engine oil etc.) collect them and duly dispose them. Do not let working stock get into the soil.

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9.4 LUBRICATION For greasing and oiling remove any dirt and gummy grease and oil and lubricate the respective part anew. All measuring and tensioning trolleys have to be lubricated / greased at intervals according to the maintenance schedule. Furthermore, all hydraulic and pneumatic cylinder bearings (even if not listed in the maintenance instruction) have to be checked visually every 50 hours of operation and, if necessary, must be lubricated. All movable parts not mentioned in the maintenance instruction, such as piston rods, cylinder fastenings, guide bushes, spindles, slide faces etc., have to be lubricated every 50 hours of operation with oil / grease (Shell Alvania Grease RL2). For lubrication never use a grease gun generating pressure of more than 15 bar!! Grease and grease gun must be free of dirt and foreign bodies. Clean the lubricating nipples of the bearings before and after lubricating them. Continue to lubricate until evenly distributed fresh (clean) grease will come out the bearings. Then remove excess quantities of grease.

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9.5 CHANGING WORKING STOCK filter: engine: oil filter after 250 working hours. (whenever changing oil) fuel filter after 500 working hours.

(when using poor quality diesel fuel: increase intervals of change)

air cleaner clean filter cartridge every 250 hours, renew at least annually. After 5

maintenance operations, no later than after 2 years replace the safety cartridge.

gear box: oil filter after 500 working hours. hy- oil tank: suction filter replace depending on the

contamination indication of the vacuum-meter; however, at least every 500 engine hours

return filter the filter cartridge has to be replaced every 500 engine hours compressed air: air dryer the filter cartridge has to be replaced every 500 engine hours, at least, however, once a year. filter: First change of all fuel filters, proportional- and servo filters after max. 100 hours of operation, afterwards in accordance with maintenance instuction. oils: First change of all engine and gearbox oils after max. 100 hours of operation, afterwards in accordance with maintenance instuction. brake blocks: Please pay attention to the decreased braking effect after replacing the brake blocks, if these are unworked or not run in. Therefore do not change all brake blocks at once (e.g. in two stages).

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10. PICTOGRAPHS

visual check

topping up of fluids (cooling agents etc.)

unscrewing / tightening of screws

topping up of machine oil

refuelling

greasing / lubricating

cleaning

lubricating (oil)

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11. INTERVALS The following intervals are applied for maintenance:

- after 10 hours of operation or daily chapter 16

- after 50 hours of operation or weekly chapter 17

- after 100 hours of operation or monthly chapter 18

- inbetween, periodically chapter 15

- after 250 hours of operation or semi-annually chapter 19

- after 500 hours of operation or semi-annually chapter 20

- after 1000 hours of operation or annually chapter 21

Maintenance has to be carried out in stages, i. e., any time interval automatically includes all previous intervals. EXAMPLE: When performing monthly maintenance works all works listed for weekly and

daily maintenance have to be done as well.

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12. MAINTENANCE SCHEDULE SURVEY

interval KIND OF WORK chapter

after 10 hours of operation or daily

PLAIN VISUAL CHECK CHECK OF WORKING STOCK:

- deutz engine check oil level - engine cooling agent - check level - hatz engine check oil level - diesel engine fuel reserves - hydraulic oil level check, check filter - drain air receiver - tamping bank - oil level in tine bearings - centralized lubrication unit - anti freeze device

16.1 16.2

after 50 hours of operation or weekly

POWER SHIFT GEAR - OIL LEVEL CHECK INTERMEDIATE DRIVE SHAFT - OIL LEVEL CHECK AXLE GEARBOX - OIL LEVEL CHECK AXLE GEARBOX - LUBRICATE (DIRT REPELLING AGENT) CARDAN SHAFT POWER DIVIDER - OIL LEVEL CHECK PNEUMATIC LUBRICATOR - OIL LEVEL CHECK V-BELT TENSION DRAIN DRIP CUP SEPAR DIESEL FUEL FILTER / DRAIN WATER SEPARAT. COMBINED LIFTING AND LINING DEVICE Lining rollers - visual check and lubrication Clamp bolts - visual check and lubrication Horizontal hook guide - visual check and lubrication Vertikal hook guide - visual check and lubrication Longitudinal guide - visual check and lubrication TAMPING BANK

Tamping tool tine slewing cylinder bearings - visual check, lubricat.Drag bearings of outside tamping unit - visual check, lubrication Guide plate and deflection pulley - visual check, clean, lubrication Sliding element - visual check and lubrication Swivel axle for tamping tine fixing - check

ADDITIONAL LIFTING ASSEMBLY

Guide plate visual check, clean if necessary, lubricatrion SUSPENSION visual check and lubricatrion SENSING DEVICES AND TENSIONING TROLLEYS: (FRONT / CENTRAL / REAR)

visual check, clean if necessary, lubrication (oil, grease) ENGINE - AIR CLEANER visual check and clean

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interval KIND OF WORK chapter

after 100 hours of operation or monthly

EXTENDED VISUAL CHECK TORQUE CONVERTER BEARING CHECK CARDAN SHAFT - LUBRICATION BRAKE LINING CHECKS

18

in between periodically

SAFETY CONTRIVANCES BRAKE COOLER

15

after 250 hours of operation or semi-annually

CUMMINS ENGINE - OIL CHANGE HATZ ENGINE OIL CHANGE BRAKE LEVER BEARING. BRAKE RODS check, lubrication COMBINIED LIFTING AND LINING DEVICE

Link joint - visual check and lubrication Guide plate - visual check and lubrication

TAMPING BANK Lateral shifting cylinder - visual check and lubrication Adjustment cylinder - visual check and lubrication Lifting cylinder - visual check and lubrication Frame slewing cylinder - visual check and lubrication

SUPPORTING ROLLERS - visual check and lubrication ADDITIONAL LIFTING ASSEMBLY

Lifting clamp - visual check and lubrication Swivelling pin - visual check and lubrication

CONDITION OF THE BATTERY AND CABLE CONNECTIONS PROPORTIONAL FILTER - REPLACEMENT SERVOFILTER REPLACEMENT

19

after 500 hours of operation or annually

INTERMEDIATE DRIVE SHAFT - OIL CHANGE FUEL FILTER REPLACEMENT POWER SHIFT GEAR - OIL CHANGE AIR DRIER - CHANGE OF FILTER / GRANULE CARTRIDGE CARDAN SHAFT POWER DIVIDER - OIL CHANGE AXLE GEARBOX - OIL CHANGE TRABOLD FILTER - CHANGE

20

after 1000 hours of operation or yearly

CHECK HYDRAULIC OIL VISCOSITY HAND BRAKE GEAR - CHANGE GREASE FILLING DRAW GEAR COUPLING - visual check and lubrication AXLE BEARING COUPLING BOLT RETIGHTEN SCREWS FIRE EXTINGUISHER FIRST AID KIT

21

annex INTERMEDIATE CLUTCH BR 152 0300 SERVICE INFORMATION / CHANGE HY. SUCTION FILTER ASSEMBLY AND DISASSEMBLY OF TAMPING TINES S 19-02B SERVICE INFORMATION S-37 / AIR DRIER SERVICE INFORMATION S-43B / GENERAL INSPECTION SERVICE INFORMATION SI-0300-01 / GENERAL RULES

.

WS 4519 39

Daily:

After 10 hours of operation at the latest, or daily before starting operation, depending on which of these events occurs first. Weekly:

After 50 hours of operation at the latest, or weekly before starting operation, depending on which of these events occurs first. Monthly:

After 100 hours of operation at the latest, or monthly before starting operation, depending on which of these events occurs first. In between - periodically:

Depending on working or environmental conditions, so to speak, on operational criteria. Semi-annually:

After 250 respectively 500 hours of operation, or semi-annually before starting operation (for exact instructions refer to the respective maintenance chapter semi-annually), depending on which of these events occurs first. Annually:

After 1000 hours of operation at the latest or yearly before starting operation, depending on which of these events occurs first.

.

40 WS 4519

13. GENERAL SURVEY

1) Front sensing device and tensioning trolley 2) Additional lifting assembly 3) Lifting and lining unit 4) Tamping bank 5) Diesel fuel tank 6) Generator set

21 4 3

6

5

5

.

WS 4519 41

.

42 WS 4519

14. ORIGINAL FILLING OF WORKING STOCK Cummins engine oil Vivoline 15 W-40 (Shell) 35 litres power shift gear Servo 15 W-40 (Shell) 62 litres axle gearbox, axle 1 Servo G80W90 (Shell) 12,5 litres axle gearbox, axle 2 Servo G80W90 (Shell) 12,5 litres axle gearbox, axle 3 Servo G80W90 (Shell) 12,5 litres axle gearbox, axle 4 Servo G80W90 (Shell) 12,5 litres cardan shaft power divider Servo G80W90 (Shell) 12 litres intermediate drive shaft Servo G80W90 (Shell) 0,35 litres hydraulic oil Tellus Oil T 68 (Shell) 1200 litres engine cooling agent 1/8 cooling agent / water (up to 25 C) 85 litres centralized lubrication system Shell Alvania Grease RL2 grease Shell Alvania Grease RL2 pneumatic lubricators Tellus Oil T 68 (Shell) 0,2 litres tine arm bearing Tellus Oil S 100 (Shell) 1,2 litres The above working stock filling quantities are original fillings by the manufacturer. In any case, the oil-level gauge, the inspection glass, the oil-level glass or the level plug mark will be decisive. Important note: The oil brands are valid only at the moment of delivery of the machine.

Manufacturers of lubricants use to change the designations of their products in rapid succession! Besides, identical products have different names in different countries.

If the above listed lubricants are not (or no longer) available, ensure compatibility when changing the oil brand; obtain the respective confirmation by the supplier. We point out particularly that blending lubricants may lead to incompatibility and, consequently, to damage. Especially the change from undoped to doped oil may cause leakage.

If these oil brands are not available in the operating organizations country or if the client wishes to use other oil brands, the above mentioned notes apply, too.

Service departments of the lubricant suppliers provide professional information! During warranty period lubricants as specified in this chapter (original fillings) have to be used! Otherwise no warranty may be claimed!

.

WS 4519 43

FUEL QUALITY Use commercial diesel fuels with a sulphur content below 0,5%. If fuel with a higher sulphur content is used, reduce the oil change intervals. The following fuel specifications / standards are admitted: CEN EN 590 or DIN/EN 590 (draft) DIN 51 601 (February, 1986) BS 2869 (1988): A1 and A2 ASTM D975-88: 1-D and 2-D NATO Codes F-54 and F-75 Exhaust emission values determined during homologation always refer to the reference fuel prescribed by the authority for homologation. At low temperatures the fuel pipe system may get clogged because of paraffine precipitation which may lead to operational failures. At outside temperatures below 0C wnter fuel has to be used (up to 15C); (usually petrol stations offer it in time before the beginning of the cold season). Frequently doped fuel with an operative temperature up to approximately 20C (super diesel fuel) is offered. Below 15C / 20C petroleum has to be added.

.

44 WS 4519

15. IN BETWEEN PERIODICALLY Depends on external conditions or operational criteria.

15.1 SAFETY CONTRIVANCES Safety contrivances must be checked at regular intervals for operativeness. If their operativeness is not ensured, the machine is no longer ready for service!! Immediate repair is required. The inspection and its result must be recorded in the operators logbook. Safety contrivances are, e. g.:

- direct-acting brake - indirect-acting brake - emergency brake - emergency switch - emergency stop buttons - dead mans handle - electronic data recorder TEL 1000 - audible warning systems (high and low frequency signals) - optical warning systems

.

WS 4519 45

15.2 BRAKE During service life of a brake block the brake play has to be readjusted for at least one time. The brake play (distance between brake block bottom and wheel tread) is normally about 5 mm.

In principle, the brake block play has to be re-adjusted, if: - the warning lamps of the brake block wear indicator light up

- brake blocks are replaced

- the wheel profile had been re-worked

How to adjust the brake block play: secure the machine against breaking away (skid-pans) RELEASE the parking brake release the brake cylinders (ZERO brake pressure)

When assembling new brake blocks, first shift the turnbuckles so that the brake blocks will move backwards and make room for the new ones.

Adjust the brake play by using for this purpose the turnbuckles. Secure the turnbuckles from unintended shifting.

NOTE: there is no need to disassemble the truss bar head and the brake levers!!

brake blocks: Please pay attention to the decreased braking effect after replacing the brake blocks, if these are unworked or not run in. Therefore do not change all brake blocks at once (e.g. in two stages).

15.3 COOLER Timely cleaning

.

46 WS 4519 10h or daily

16. AFTER 10 HOURS OF OPERATION OR DAILY

PLAIN VISUAL CHECK

CHECKING OF WORKING STOCK: - cummins engine check oil level - engine cooling agent check level - hatz engine check oil level - fuel reserves for the diesel engine - hydraulic oil level check - drain air receiver - tamping bank - check tine arm bearing oil level - centralized lubrication unit - anti freeze device

.

10h or daily WS 4519 47

.


16.1 PLAIN VISUAL CHECK

Refer to chapter 9.2 visual check

Before starting the first operation of the day or after longer breaks it is recommended to check the machine visually for its general condition and any obvious irregularities when approaching towards the machine from a greater distance. Check all areas that can be seen from outside. A plain visual check is usually carried out before start-up and after work.

16.2 CHECKING WORKING STOCK

CUMMINS ENGINE CHECK OIL LEVEL - oil level may in principle be checked only when the vehicle stands on a level track (without superelevation and gradient); - cold engine: pull out the oil-level indicator, wipe it clean with a clean cloth, put it in again up to the limit stop, pull it out and check the oil level. If necessary, top up to maximum level.

- hot engine: turn the engine off, wait for 5 minutes and then check oil level as described above.

If the oil level is only just above the minimum marker, top up. Oil level must never be below the minimum marker. PLEASE SEE ENGINE OPERATING INSTUCTION!

.


ENGINE COOLING AGENT Check the cooling water level at regular intervals, top up if necessary. - unscrew the radiator cap to drop pressure - ensure sufficient quantity of antifreeze. Original filling by the manufacturer: 85 litres 8/1 water/antifreeze LED for cooling agent indication: at the drivers desk

HATZ ENGINE CHECK OIL LEVEL - oil level may in principle be checked only

when the vehicle stands on a level track (without superelevation and gradient);

If the oil level is only just above the minimum marker, top up. Oil level must never be below the minimum marker. PLEASE SEE ENGINE OPERATING INSTRUCTION! FUEL RESERVES FOR THE DIESEL ENGINE As far as possible ensure that the diesel fuel tank is filled to avoid water condensation. LED for filling level indication: at the drivers desk.

.


HYDRAULIC OIL LEVEL hydraulic oil tank: original filling: approx. 1200 l of Tellus Oil T 68 (Shell) The upper marker at the inspection glass shows the maximum level! Before replacing hydraulic system elements make sure that the system is unpressurized. When changing hydraulic oil, the sealing cap together with its filter has to be changed under all circumstances! (problems of deaeration of the hydraulic oil tanks!) Suction filter: (order no:) HY-S501.460.150 ES HY-S501.360.150 ES If the dirt indicator (vacuum-meter) points to the caution zone, immediately replace the cartridge, however, at least every 500 engine hours. Return filter: (order no:) HY-R501.330.10A ES The filter cartridge has to be replaced every 500 engine hours

.


Hydac Filter: 1 pcs: If the gauge indication is within the red range, the filter element has to be changed (HY-501.03.05 ES) Note: Replace the filter element only when the device is switched off. The filter cup must show "0 bar". Otherwise pressure has to be blown off by opening the vent screw in the cover.

DRAIN THE AIR RECEIVER Before start-up of the machine pull the strap to drain condensation water that possibly may have assembled.

.


TAMPING BANK - OIL LEVEL IN THE TINE ARM BEARINGS (4 PCS.) Oil reservoir: approx. 1,2 l hydraulic oil Shell Tellus Oil S100 Check the oil level in the inspection glass and top up, if necessary.

CENTRALIZED LUBRICATION UNIT UD 320.1600 A operating time: 4 min break period: 30 min emergency operation: in case of manual lubrication the device has to be filled with about 25 cm of grease so that any of the lubrication points will get at least 0,2 cm.

.

50h or weekly WS 4519 53

17. AFTER 50 HOURS OF OPERATION OR WEEKLY POWER SHIFT GEAR - OIL LEVEL CHECK

INTERMEDIATE DRIVE SHAFT - OIL LEVEL CHECK

AXLE GEARBOX - OIL LEVEL CHECK AXLE GEARBOX - LUBRICATION (DIRT REPELLING AGENT)

CARDAN SHAFT POWER DIVIDER - OIL LEVEL CHECK

PNEUMATIC LUBRICATOR - OIL LEVEL CHECK

V-BELT TENSION

DRAIN DRIP CUP

SEPAR DIESEL FUEL FILTER / DRAIN WATER SEPARATOR

COMBINED LIFTING AND LINING DEVICE Lining rollers - visual check and lubrication Clamp bolts - visual check and lubrication Horizontal hook guide - visual check and lubrication Vertikal hook guide - visual check and lubrication Longitudinal guide - visual check and lubrication

TAMPING BANK Tamping tool tine slewing cylinder bearings - visual check and lubrication Drag bearings of outside tamping unit - visual check and lubrication Guide plate and deflection pulley - visual check, clean if necessary and lubrication Sliding element - visual check and lubrication Swivel axle for tamping tine fixing - check

ADDITIONAL LIFTING ASSEMBLY Guide plate visual check, clean if necessary and lubricatrion

SUSPENSION visual check and lubricatrion

SENSING DEVICES AND TENSIONING TROLLEYS: (FRONT / CENTRAL / REAR) visual check, clean if necessary, lubrication (oil, grease)

ENGINE - AIR CLEANER visual check and clean

.

54 WS 4519 50h or weekly

.


POWER SHIFT GEAR - OIL LEVEL CHECK Oil level check by oil level indicator: - oil levels may in principle be checked only

when the vehicle stands on a level track (without super-elevation, without gradient) and with the engine idling at approx. 1000 min-1

- screw off the oil level indicator by turning it counterclockwise, pull it out and wipe it clean with a clean cloth free oft fluff, put it in up to the limit stop and pull it out again (at least 2x).

- optimum oil level is in the middle between the marks.

- oil level at 80 C is decisive. NOTE

- for temperatures of about 40C the lower mark "COLD applies and serves as a standard value for the starting procedure only.

- for temperatures of about 80C the upper mark "HOT applies which should not be exceeded.

- put the oil level indicator in again and screw it down by turning it clockwise. Oil level check by inspection glass: - the optimum oil level is between the markings

of the inspections glass. INTERMEDIATE DRIVE SHAFT OIL LEVEL CHECK - check and top up if necessary,

approx. 0.35l Shell Servo G80 W90

.


.


AXLE GEARBOX OIL LEVEL CHHECK, AXLE GEARBOX LUBRICATION (DIRT REPELLER) Power Bogie (axle 1 + axle 2): - oil level checks may in principle be carried out

only at the vehicle standing on level track (no super-elevation, no gradient).

- clean the inspection glass. - the optimum oil level is in between the

markings of the inspections glass.

- in case oil level is below the minimum mark, top up immediately.

Power Bogie (axle 3 + axle 4): - optimum oil level is in the middle of the oil

inspection eye dirt repeller: (axle 1/2/3) - visual check - lubrication - Shell Alvania Grease RL2

.


CARDAN SHAFT POWER DIVIDER OIL LEVEL CHECK - Optimum oil level is in the middle of the oil

inspection eye.

PNEUMATIC LUBRICATOR CHECK OIL LEVEL (with water separator - drain) Top up if necessary. (Shell Tellus Oil T 68)

.


V-BELT TENSION Visual check for damage of the V-belt over its entire dimension. Replace defective V-belts. Check new V-belts after a working time of 15 minutes. Check V-belt tension by finger test, maximum depth of impression 15mm, or use a V-belt tension measuring device. - submerge the indicator arm in the measuring

device - put the guiding device onto the V-belt

between two pulleys, the limit stop should fit laterally.

- press the button evenly at right angles to the V-belt until the spring is released audibly or visibly; carefully lift the measuring device without changing the indicator arm position

- read the measured value at the intersection of scale and indicator arm.

- if necessary,. re-adjust tension and repeat measurement.

DRAIN DRIP CUPS These must be drained at regular intervals to protect the air drier from contamination.

.


DIESEL FUEL FILTER / DRAIN WATER SEPARATOR engine furel supply tank: 1) Diesel fuel filter/water separator 2) Diesel fuel stop cock 3) Diesel fuel drain cock

Drain the Diesel fuel filter / water separator weekly. - before carrying out maintenance works at the

diesel fuel filter, turn off the engine. - close the fuel stop cock - open the drain cock "3 and drain water /

diesel fuel emulsion, close drain cock again. - after having topped up clean fuel deaerate

fuel pipe system to avoid that air gets in or that the injection system runs dry.

By the above mentioned procedure the filter cartridge will be washed in reverse direction and regenerated, which ensures a longer service life of the filter cartridge.

3

2

1

.


COMBINED LIFTING AND LINING DEVICE SURVEY

1. lining rollers 2. clamp bolts 3. horizontal hook guide 4. vertical hook guide

- visual check - lubrication - Shell Alvania Grease RL2 Linkage and guide plate: Refer to maintenance interval: "after 250 hours of operation or semi-annually" lining rollers: horizontal hook guide: vertical hook guide: clamp bolts: - visual check - lubrication - Shell Alvania Grease RL2

clamp bolts: - visual check - lubrication - Shell Alvania Grease RL2

.


Longitudinal guide: - visual check - lubrication - Shell Alvania Grease RL2

.


TAMPING BANK - SURVEY 1) Tamping arm bearings 2) Tamping tool tine slewing cylinder bearings3) Drag bearings of outside tamping unit 4) Lifting cylinder 5) Lateral adjusting cylinder 6) Adjustment cylinder Pos. 1) Tamping arm bearings: Refer to maintenance interval: "after 10 hours of operation or daily" Pos. 4), 5) and 6) Lifting- lateral adjusting and displacement cylinder: Refer to maintenance interval: "after 250 hours of operation or semi-annually". Tamping tool tine slewing cylinder bearings: Drag bearing of outside tamping unit: - visual check - lubrication - Shell Alvania Grease RL2

.


Guide plate and deflection pulley: - visual check - lubrication Shell Tellus S 100 - clean if necessary

Sliding element: (3 nipples) - visual check - lubrication - Shell Alvania Grease RL2

.


Swivel axle for tamping tine fixing The swivel axis guide play has to be checked every 50 hours of operation or weekly and to be re-adjusted if necessary. Also make sure that the swivel tine bearing is well greased. Swivel bearing adjustment: The swivel bearing play has to be adjusted in such a way (item 1 castellated nut), as to ensure the swivelling movement of the tamping tines without guide play of the swivel tine bearing. (The swivel bearing never must turn too softly!) CAUTION: A guide play of the swivel axis will lead to increased wear and consequently to diminished service life. When the swivel axis can no longer be adjusted to fulfil its function, the distance rings must be replaced (item 2).

.


ADDITIONAL LIFTING ASSEMBLY item 1) guide plate: - visual check - clean if necessary - lubricate - Shell Alvania Grease RL2 item 2) lifting clamp: item 3) swivelling pin: Refer to maintenance interval: "after 250 hours of operation or semi-annually" SUSPENSION (axle 5 and 6) - visual check - lubricate - Shell Alvania Grease RL2

.


FRONT SENSING DEVICE AND TENSIONING TROLLEY Sensing rods: Guide bushes: Chord displacement asssy.: Preload cylinder: Lifting cylinder: - visual check - clean if necessary - lubricate (oil) - Shell Tellus S 100 Guide bushes: - visual check - lubricate (oil) - Shell Tellus S 100

.


CENTRAL SENSING DEVICE AND LINING TROLLEY Guide rods:

- visual check - clean if necessary - lubricate: Shell Tellus S 100

Lateral guide plate:

- visual check - lubrication - Shell Alvania Grease RL2

Guide play:

- check - if required, re-tension the adjusting

screws

.


REAR SENSING DEVICE Sensing rods: Guide bushes: Preload cylinder: Lifting cylilnder: - visual check - lubricate (oil) - Shell Tellus S 100

Guide bushes: Deflection pulley: - visual check - lubricate (oil) - Shell Tellus S 100

REAR TENSIONING TROLLEY Chord displacement asssy.: - visual check - clean if necessary - lubricate (oil) - Shell Tellus S 100

.


ENGINE - AIR CLEANER (1) CLEAN, CHECK Open and clean dust reservoir (2) every 50 hrs. Clean filter cartridge (3) every 250 hours and replace it at the latest after one year of operation. After 5 filter services, however, at the latest, after 2 years the spare cartridge (4) has to be replaced. Note! Do not clean filter cartridge with benzine or any hot fluids!

.


.

72 WS 4519 100h or monthly

18. AFTER 100 HOURS OF OPERATION OR MONTHLY EXTENDED VISUAL CHECK

CHECK OF CONVERTER TORQUE BEARING

CARDAN SHAFT - LUBRICATION

CHECK OF BRAKE LININGS

.

100h or monthly WS 4519 73

.

74 WS 4519 100h or monthly

EXTENDED VISUAL CHECK Refer to chapter "9.2 visual check

Extended visual checks are performed monthly from the inspection pit. Extended visual checks have to be carried out before start-up, if:

- the operating condition is unknown - the machine had been parked over a longer period of time - a new or untrained crew will put the machine into operation

CONVERTER TORQUE BEARING Check lubrication points and lubricate, if necessary. Visual check: general condition of the rubber elements sharp-edged notches obvious deformation fit of screwed connections

CARDAN SHAFT - LUBRICATION Under normal working conditions the cardan shaft has to be lubricated semi-annually, under harder working conditions, as well as under harder environmental conditions lubricate monthly. For this purpose: Never use a grease gun generating pressure higher than 15 bar!! Grease and grease gun must be free of dirt and foreign bodies. The lubrication nipples have to be cleaned before and after lubrication. Lubrication has to be continued until fresh (clean) grease will come out of the lubrication points. Afterwards remove excess grease. one lubrication point per joint

.

100h or monthly WS 4519 75

CHECK OF BRAKE LININGS AND BRAKE BLOCK PLAY Brake Linings: Brake linings have to be changed at the latest, when their thickness of 35mm (new) has diminished to 5mm (worn). Grooves in the brake linings are indicators of brake lining thickness. If the grooves are no longer visible, the remaining thickness of the brake lining is below 10 mm. It will soon become necessary to change the brake linings. The thickness of the brake linings must in no place be below 5 mm. Bremsspiel: In der Brake play: During the cycle of service of a brake block its play has to be re-adjusted for at least one time. Usually the brake play (distance between the brake block bottom and the wheel tread) is approximately 5 mm. In principle, the brake block play has to be re-adjusted, when: the warning lamp indicating brake block wear lights up the brake blocks are replaced the wheel profile had been re-worked How to adjust the brake block play: Secure the machine against breaking away (skid-pans) RELEASE the parking brake Release the brake cylinders (ZERO brake pressure) When assembling new brake blocks, first shift the turnbuckles so that the brake blocks will move backwards and make room for the new ones. Adjust the brake play by using for this purpose the turnbuckles. Secure the turnbuckles from unintended shifting. NOTE: there is no need to disassemble the truss bar head and the brake levers!!

.

76 WS 4519 250h or. Semi-annually

19. AFTER 250 HOURS OF OPERATION OR SEMI-ANNUALLY CUMMINS ENGINE - OIL CHANGE

HATZ ENGINE OIL CHANGE

BRAKE LEVER BEARING AND BRAKE RODS - CHECK AND LUBRICATION

COMBINIED LIFTING AND LINING DEVICE Link joint - visual check and lubrication Guide plate - visual check and lubrication

TAMPING BANK Lateral shifting cylinder - visual check and lubrication Adjustment cylinder - visual check and lubrication Lifting cylinder - visual check and lubrication Frame slewing cylinder - visual check and lubrication

SUPPORTING ROLLERS - visual check and lubrication

ADDITIONAL LIFTING ASSEMBLY Lifting clamp - visual check and lubrication Swivelling pin - visual check and lubrication

CONDITION OF THE BATTERY AND CABLE CONNECTIONS PROPORTIONAL FILTER - REPLACEMENT SERVOFILTER REPLACEMENT

.

250h or. semi-annually WS 4519 77

.


Cummins ENGINE - OIL CHANGE Approx. 35 l of Valvoline 15W-40. First oil change after 100 hours of operation. Any further oil change after 250 hours of operation, however, at least once a year: Procedure: - Heat up the engine - Ensure horizontal vehicle position Lubrication oil temperature : approx. 80 C - turn off the engine - clean the surrounding area of the oil drain plug - open the oil drain plug and collect the oil

running out in a cup - beware the danger of scalding yourself by

the used oil - insert the oil drain plug with a new sealing

ring, tighten it. - fill in oil as described above and check the oil

level - duly deposit the drained waste oil. Replace the filter cartridge whenever changing oil: - loosen and unscrew the lubrication oil filter

with the help of usual tools. - collect possibly running out oil - clean the sealing surface of the filter support

from dirt - slightly lubricate the rubber seal of the new

lubrication oil filter cartridge - screw down the cartridge manually until the

seal will fit - perform another half-revolution to screw down

the filter cartridge - check the oil level - check the oil pressure - check the seals of the lubrication oil filter

cartridge for tightness

.


HATZ ENGINE - OIL CHANGE Approx. 1,5 l Oilquality:

CCMC D4 D5 PD2 or API CD CE CF CG or SHPD

First oil change after 100 hours of operation. Any further oil change after 250 hours of operation, however, at least once a year: procedure - see above: engine - oil change

.


CHECK BRAKE LEVER BEARING AND BRAKE RODS Clean and check brake lever bearing and brake rods every 250 hours, lubricate if necessary. Visual check:

general condition fastenings damaged bellows contamination tightness of pneumatic connections thickness and condition of the brake block

.


COMBINED LIFTING AND LINING DEVICE Link joint: Guide plate: - visual check - lubrication - Shell Alvania Grease RL2

Guide plate: - visual check - lubrication - Shell Alvania Grease RL2

.


TAMPING BANK Lateral shifting cylinder: - visual check - lubrication - Shell Alvania Grease RL2

Adjustment cylinder: (2 pcs.) - visual check - lubrication - Shell Alvania Grease RL2

Lifting cylinder: (4 pcs.) - visual check - lubrication - Shell Alvania Grease RL2

.


Frame slewing cylinder: (2 nipples) - visual check - lubrication - Shell Alvania Grease RL2

SUPPORT ROLLERS (AXLE 3 / 4) - visual check - lubrication Shell Alvania Grease RL2

.


ADDITIONAL LIFTING ASSEMBLY Item 2) lifting clamp: Item 3) swivelling pin: - visual check - lubricate - Shell Alvania Grease RL2 Item 1) guide plate: Refer to maintenance interval: "after 50 hours of operation or weekly" CONDITON OF THE BATTERY AND THE CABLE CONNECTIONS - keep the battery clean and dry - loosen contaminated connecting terminals - clean battery poles (+ / -) and terminals and

lubricate with acid-free and acid-resistant grease

- when assembling, ensure tight contact of the terminal connections and finger-tight fastening of the terminal screws

- check acid level, the fluid level should be at least 2-3 mm and maximum 10 mm above the top of the battery plate; if necessary, add distilled water.

- measure the acid number of the individual cells with a battery tester.

.


item 1) PROPORTIONAL FILTER item 2) SERVO FILTER item 1) replacing the proportional filter (HY-D 501.32.10 ES) Replacing the proportional filter every 250 hours of working or when the pilot lamp of the dirt indication lights up (driving desk), change the proportional filter immediately. item 2) replacing the servo filter (DL 40.60E ES) Replacing the servo filter every 250 hours of working or when the pilot lamp of the dirt indication lights up (driving desk), change the servo filter immediately.

.

86 WS 4519 500h or semi-annually

20. AFTER 500 HOURS OF OPERATION OR SEMI-ANNUALLY INTERMEDIATE DRIVE SHAFT - OIL CHANGE FUEL FILTER REPLACEMENT POWER SHIFT GEAR - OIL CHANGE AIR DRIER - CHANGE OF FILTER / GRANULE CARTRIDGE CARDAN SHAFT POWER DIVIDER - OIL CHANGE AXLE GEARBOX - OIL CHANGE TRABOLD FILTER - CHANGE

.

500h or semi-annually WS 4519 87

.


INTERMEDIATE DRIVE SHAFT OIL CHANGE - approx 0.35l Shell Servo G80 W90 If possible drain the gear oil at working temperature. - clean the surroundings of the oil drain plug - open the oil drain plug and collect the oil


the used oil - investigate the drained oil for rubbed off

metal particles (finger test) rubbed of metal indicates

damage to the bearings or the gearbox - insert the oil drain plug with a new sealing

ring, tighten it - top up hot oil up to the mark,

when filling the oil, let it pass through a 200 M filter.

- duly deposit the drained oil - wait for 5 minutes, then check the oil level again; if it is correct, close the oil drain plug, make sure that the washer is correctly seated

.


FUEL FILTER REPLACEMENT engine furel supply tank: 1) Diesel fuel filter/water separator 2) Diesel fuel stop cock 3) Diesel fuel drain cock

Replace every 500 hours of operation OR, in case of decreasing engine power, check for contamination and replace, if necessary.

Changing the filter cartridge: - turn off the engine - unscrew the cover screws - remove the cover - take out the spring box - take out the filter cartridge by the clip - insert new filter element - place the spring box on the element - check the tight fit of the cover seal in the cover, check for damage

(replace, if necessary) - screw down the cover with the help of the screws (crosswise) - check tight fit and tightness of the cover - refill the fuel system, deaerate it (pump with the help of the hand pump until diesel fuel

will come out without bubbling).

1

.


POWER SHIFT GEAR - OIL CHANGE 62l engine oil: 15W-40 CF 4 First oil change after 100 hours of operation. Further oil changes after every 500 hours of operation, at the least, however, once a year: oil changes in principle may be carried out only when the vehicle stands on level track (no super-elevation, no gradient) and with the gearbox at working temperature. - open the oil drain plug and the sealing surface - drain used oil and collect the oil running out in

a cup - duly deposit the waste oil - beware the danger of scalding yourself by the

waste oil - investigate the drained oil for rubbed metal

particles (finger test) rubbed off metal particles indicate defective bearings or gearbox

- clean the oil drain plug and the sealing face on the case, re-assemble with a new sealing ring.

- fill in oil, ensure absolute cleanliness of oil and filter!

- the mark of the oil-level indicator is decisive in any case!

- start the engine, idle-running speed - gearbox in neutral position N - top up oil to the upper mark of the "COLD

area - fully apply the brake - switch the accelerator to all positions - check oil level again, if necessary, to up - the oil level at 80C is decisive

NOTE: For temperatures of about 80C there applies the upper mark HOT of the oil-level indicator, this should not be exceeded. For temperatures of about 40C the lower mark of the oil-level indicator applies, it serves as a standard value for starting only.

-pull out the oil-level indicator, wipe it clean with a clean cloth free of fluff, insert it up to the limit stop and pull it out again.

ATTENTION At every oil chang, the suction filter "pos. 1" must be cleaned.

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Whenever changing oil, replace the filter cartridge (pos. 2). (order no.: HY-D 501.225.25 ES) When replacing the filter cartridge make sure that no dirt or oil sediments may get into the circuit. Under all circumstances avoid to insert the filter by force. Slightly lubricate the seal with oil, screw in the filter until contact with the sealing face is ensured, then tighten it by turning it manually for about 1/3 to 1/2 revolution. AIR DRIER - CHANGING OF THE FILTER AND GRANULE CARTRIDGE To avoid damage to the pneumatic equipment the air drier has to be checked periodically. The filter cartridges (order no.90187-ES) and the granule cartridges (order no 432 406 920 2) have to be replaced every 500 hours of operation, at the least, however, once a year.

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CARDAN SHAFT POWER DIVIDER OIL CHANGE 12 litres of Shell Servo G80 W90, procedure - see above: intermediate drive shaft - oil change

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AXLE GEARBOX - OIL CHANGE Power bogie: axle 1: 12,5 litres - Shell Servo G80 W90 axle 2: 12,5 litres - Shell Servo G80 W90 If possible drain the gear oil at working temperature. - clean the surroundings of the oil drain plug - open the oil drain plug and collect the oil


the used oil - investigate the drained oil for rubbed off

metal particles (finger test) rubbed of metal indicates

damage to the bearings or the gearbox - insert the oil drain plug with a new sealing

ring, tighten it - top up hot oil up to the mark,

when filling the oil, let it pass through a 200 M filter.

- duly deposit the drained oil - wait for 5 minutes, then check the oil level

again; if it is correct, close the oil drain plug, make sure that the washer is correctly seated

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Power bogie: axle 3: 12,5 litres - Shell Servo G80 W90 axle 4: 12,5 litres - Shell Servo G80 W90 procedure: refer to axle gearbox; oil change

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TRABOLD FILTER (1) - change 3 pcs. Order no.: HY-R508.05.01 ES The filter cartridge has to be replaced every 500 engine hours.

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96 WS 4519 1000h or annually

21. AFTER 1000 HOURS OF OPERATION OR ANNUALLY

CHECK HYDRAULIC OIL VISCOSITY

HAND BRAKE GEAR - CHANGE OF GREASE FILLING

DRAW GEAR COUPLING CHECK AND LUBRICATION

AXLE BEARING

COUPLING BOLT - check

RETIGHTEN SCREWS

FIRE EXTINGUISHER

FIRST AID KIT

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1000h or annually WS 4519 97

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CHECK OF THE HYDRAULIC OIL VISCOSITY Send 1 litre of hydraulic oil to an authorized testing institute; in case of deviations from the acid number or increased stage of contamination change the oil. When changing hydraulic oil, the sealing cap together with its filter has to be changed under all circumstances! (problems of deaeration of the hydraulic oil tanks!) As the recipes of the individual hydraulic oil manufacturers may differ greatly and as this might lead to possible undesired chemical reactions, it is strongly recommended not to mix different brands. This could lead to increased occurrence of mud and consequently to filter problems. Furthermore even the performance could change in an uncontrollable way. HAND BRAKE GEAR change of grease filling - Shell Alvania Grease RL2

DRAW GEAR COUPLING - visual check - clean if necessary - lubrication - Shell Alvania Grease RL2

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1000h or annually WS 4519 99

AXLE BEARING Refer to Service Instruction axle bearing! COUPLING BOLT - Thorough inspection and examination

of axial plays - Freemovement control - Clean if necessary - Examine all screws for tightness

RETIGHTENING OF THE SCREWS The following screws have to be retightened annually: - all screws of the cardan shafts with a tightening moment as listed below, which are not

secured by retaining pins or washers M12: 120 Nm M14 190 Nm M16 295 Nm M18 450 Nm

- Tighten all the following screws if they are not secured by retaining pins or washers: - working mode drive - power divider - suspensions - gearboxes

FIRE EXTINGUISHER:

- date of expiry FIRST AID KIT: date of expiry

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ANNEX

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Operating and Servicing Instructions

Intermediate Clutch

BR 152 0300

B01 Part. No. Type Part. No. Type Part. No Type WN 220.01 A 045 WN 220.02 045 WN 220.03 A 045 WN 220.04 A 050 WN 220.05 030 WN 220.06 040 WN 220.07 055 WN 220.08 050 WN 220.09 050 WN 220.10 040 WN 220.11 030 WN 220.12 A 040 WN 220.13 040 WN 220.14 040 WN 220.15 A 045 WN 220.17 040 WN 220.18 030 WN 220.19 A 045 WN 220.20 045 WN 220.21 A 040 WN 220.22 050 WN 220.23 A 045 WN 220.25 030 WN 220.26 030 WN 220.27 030 WN 220.28 050 WN 220.31 055 WN 220.32 030 WN 220.34 A 030 WN 220.35 030 WN 220.36 030 WN 220.37 060 WN 220.38 040 WN 220.39 040 WN 220.40 055 WN 220.41 030 WN 220.44 040 WN 220.45 050 WN 220.46 050 WN 220.47 050 WN 220.49 040 WN 220.50 030 WN 220.51 045 WN 220.53 055 WN 220.54 040 WN 220.55 040 WN 220.56 045 WN 220.57 035 WN 220.58 040

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Installation and Servicing Regulation

Intermediate Clutch BR 152 0300

Dismantling and stripping the intermediate clutch For checking, or for exchanging the clutch element (Pos. 3) the cardan shaft screwed to the intermediate clutch is released and removed. After this, the flywheel connecting bolts are released and the clutch can be lifted out completely. After releasing the out bolts (Pos. 7) and the inner bolts (Pos. ), the clutch can be dismantled into its separate parts. Cleaning and checking the clutch parts Before assembly all parts should be cleaned. No gasoline, petroleum or oil should be used on rubber parts.

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In case of slight soiling, i.e. dry, powdery dust, the clutch parts should be cleaned only with a hand brush. Take care not to change the smoothly worn running faces of the close-fitting steel parts for friction disc (Pos. 3). It is not possible to re-work these surfaces due to the precision of the surfaces. In the case of heavy soiling, i.e. sticky, smeared rubber residue as occurring when the clutch turns through, the steel parts of the clutch can be washed in a cold cleaning fluid (e.g. Inwac K 2000 form Inwac GmbH Dortmund). If the element (Pos. 3) broke in operation, the clutch had turned through. In that case the friction disc (Pos. 4) and the friction ring (Pos. 5) should generally be exchanged. During checks not in connection with damage, the friction disc and friction ring should be checked for wear. The threshold values for wear can be taken from the general checking and servicing guidelines.

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Installation and servicing regulation Intermediate clutch BR 152 0300

Assembly and installation instruction When assembling the clutch the bolt tightening moments must be observed (see drawing). Assembly begins with the insertion of the friction ring (Pos. 5) and the friction disc (Pos. 4) into the flange mantel (Pos. 1). If re-using the friction disc (Pos. 4) the faces should be lightly coated with mineral oil. The friction ring (Pos. 5) should be inserted in dry condition. After this, the hub (Pos. 2) is pushed in and the rubber element (Pos. 3) inserted. The clutch is bolted together firmly using the inner and the outer fastening bolts (Pos. 6 and 7). The cardan shaft can now be mounted and bolted. Balancing All intermediate clutches are balanced with a balancing quality of G = 6,3 as per. DIN ISO 1940! New parts manufactured in our factory are well within the permissible threshold values. The wearing parts to be renewed in the case of repair are rotation symmetrical and in our experience do not lead to any impermissible or disruptive imbalance. If any irregularity in running should occur, it is necessary to make a balancing check. The permissible imbalance data can then be taken from the assembly drawing.

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Checking and Service general Dismantling of the clutch is performed according to the appropriate dismantling guidelines. When the clutch has been dismantled, the friction disc and friction ring can be measured. See table for permissible wear. The clutch element can be investigated for possible loose parts and cracks by pulling it apart axially under a press. The pulling distance should not exceed a maximum of 1/3 of the overall height of the clutch element. Loose parts and cracks become visible in extended state, in which case the element must be exchanged. Cleaning and assembly should be carried out according to the appropriate cleaning and assembly guidelines.. It is recommended to keep a stock of the listed clutch components as spare parts. The parts should be exchanged at the following indications: Clutch element - if damage has occurred Friction disc and friction ring - if wear threshold values in the table are exceeded NOTE: If the rubber element is exchanged, the friction ring and friction disc must also be renewed at all events to ensure that the properties of the clutch comply with those of a new o

Maintenance Instruction

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