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mnbh

By Ronald Boyd,2014-01-20 02:15
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mnbh

    SCHEDULE I

    (TO BE DONE DAILY)

    DURATION -- ONE HOUR

1. ENGINE

     CUMMINS NTA-855, 2100 RPM

i) Check level of lube oil. Keep the level as possible as towards the highest

    mark.

    ii) Top up water in radiator.

    iii) Check the tension and condition of V-belts.( Sag at center should be

    within 15 mm).

    iv) Check and prevent leakage from fuel pump, injectors, fuel supply and

    return pipes.

    v) Check leakage of lube oil and prevent it if required.

    vi) Check the leakage from water hoses.

    vii) Check lube oil pressure. Rated Actual

    a) At idle RPM --- 1 to 2 kg/cm?

    b) At rated RPM--- 3 to 7 kg/cm?

    c) On load at rated RPM --- 4 kg/cm? viii) Check air brake pressure ( 3.8 bar on lock position of brake valve)

    ix) Check fuel level and fill up the tank as per requirements.

    x) Check the battery charging gauge.

    xi) Record the maximum engine temperature of the day.

    xii) Clean the engine and premises.

2. GENERAL

i) Check level of oil of ZF gear box at 1200 RPM. Top up if required.

    ii) Check oil level of axle gear boxes.

    iii) Check oil level of distribution gear box.

    iv) Check the tightness of cardan shaft bolts.

    v) If filter indicator of proportional and servo valves lights during work,

    change the cartridge immediately.

    vi) Replace cartridge of return line filter immediately, if filter indicators lights

    during work.

    vii) Top up the air oiler.

    viii) Check air brake application.

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ix) Record the maximum hydraulic temperature of the day’s work.

    x) Drain the air reservoirs after day’s work. xi) Check the complete machine for any unusual sound and rectify the

    problem before block working.

    xii) Check the tank for lubrication of vibration shaft main bearing and top up,

    if required.

    xiii) Check and top up hydraulic oil in tank for tamping unit arm bearing.

    xiv) Grease the pivot of tamping tool adjusting cylinder.

    xv) Check and top up oil level of tank for lubrication of guide columns.

    xvi) Grease tamping unit sliding bushes.

    xvii) Check the hyd. hoses and prevent the leakage, if observed.

    xviii) Change the worn out tamping tools.

    xix) Check all the circuit breakers.

    xx) Clean the tamping banks.

    xxI) Check all functions of the machine before block working.

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    SCHEDULE II

    (TO BE DONE AFTER 50 HOURS OF ENGINE RUNNING)

    DURATION -- TWO HOURS

1. ENGINE

    i) Check outer air cleaner and clean it as necessary with pressurized air. ii) Replace the oil of air oiler with hyd. oil if found dirty other wise top up. iii) Check water leakage from water hoses and water pump seal.

    iv) Drain water / sediments etc. from drain plug of HSD oil tank. v) Check battery terminal and connections.

    vi) Check electrolyte level and gravity of batteries.

2. GENERAL

i) Check oil of clutch and top up if required.

    ii) Check the oil level in pump drive gear box and top up if required. iii) Lubricate the bearing of rear feeler rollers by lube oil.

    iv) Lubricate the guide bushes of rear feeler rod by lube oil.

    v) Lubricate the guide pulley of front tightening trolley by lube oil. vi) Clean the chord displacement assembly and grease it.

    vii) Check the oil level of axle gear boxes and top up if required. viii) Check the oil level of drive intermediate shaft of powered bogie and top

    up if required. ix) Grease the axle gear box flange cover of powered bogie.

    x) Lubricate the fixing hinges of tamping cylinders with grease. xi) Clean and lubricate the guide plates of tamping cylinders with lube oil. xii) Lubricate the horizontal lifting hook guide of lifting and lining unit with

    grease. xiii) Lubricate the bearing of lining rollers of lifting and lining unit with grease. xiv) Lubricate the vertical lifting hook guide of lifting and lining unit with

    grease. xv) Lubricate the longitudinal guide of lifting and lining unit with grease. xvi) Lubricate the feelers of front feeler with lube oil.

    xvii) Lubricate the guide bushing of front and middle feeler with lube oil. xviii) Lubricate the feeler rollers of middle feeler with lube oil. xix) Clean and lubricate the guide rod of middle feeler with lube oil.

    42185254.doc Page 3 of 14

    SCHEDULE -- III

    (TO BE DONE AFTER 100 HOURS OF ENGINE RUNNING)

    Duration One Day

1. ENGINE

I) Check tension and condition of V-belts. (maximum play at center should

    be within 15 mm). ii) Check whether the safety circuit of engine is functioning properly or not. iii) Lubricate the battery terminal with grease.

    iv) Check the functioning of water separator.

    v) Check the functioning of air unloader.

2. GENERAL

i) Check the tension of leveling chord wire.

    ii) Check the condition of lining fork and replace if found damaged.

    iii) Check the condition of leveling and lining transducer chord wires and

    replace if found damaged. iv) Check the condition of brake shoes.

    v) Adjust the gap between wheel and brake shoes.

    vi) Check the operation of limit switch for brake shoes.

    vii) Check the solenoid socket connections.

    viii) Clean the complete machine.

    42185254.doc Page 4 of 14

    SCHEDULE IV

    (TO BE DONE AFTER 200 HOURS OF ENGINE RUNNING)

    Duration Two Days

    1. ENGINE

    i) Replace the engine oil.

    ii) Replace the lube oil filter.

    iii) Replace the pre filter element.

    iv) Clean the secondary filter element.

    v) Replace the micro filter.

    vi) Check and adjust the tappet clearance.

    vii) Clean radiator fins by blowing air from opposite side.

    viii) Check the radiator hoses and replace if found damaged.

2. GENERAL

i) Lubricate the clutch of cardan shaft from engine to ZF gear box with

    grease.

    ii) Lubricate the rocker bearing of preload cylinder of front tightening trolley

    with grease.

    iii) Lubricate the rocker bearing of lifting cylinder of front tightening trolley

    with grease.

    iv) Lubricate the rocker bearing of preload cylinder of rear tightening trolley

    with grease.

    v) Lubricate the clutch and cross bearing of cardan shaft between

    distributor and axle gear box with grease. vi) Replace the oil of axle gear boxes.

    vii) Replace the oil of drive intermediate shaft of powered bogie.

    viii) Lubricate the torque arm pivot of powered bogie with grease.

    ix) Lubricate the clutch and cross bearing of cardan shaft between axle 2

    axle 1 of powered bogie with grease. x) Lubricate the brake linkage of powered bogie with grease.

    xi) Lubricate the brake lever pivot with grease.

    xii) Lubricate the brake linkage of brake mechanism with lube oil.

    xiii) Replace the hyd. oil of tank for vibration shaft main bearing.

    xiv) Lubricate the rocker bearing of pre load and lifting cylinder of middle

    feeler rod.

    xv) Replace the filter element for servo valve.

    xvi) Replace the filter element for proportional valve.

    xvii) Check the filter indicator of return line filter and replace the filter on

    condition basis. xviii) Check the filter indicator of suction line filter and replace the filter on

    condition basis. xix) Check the calibration of X-level.

    xx) Check the calibration of lining.

    xxi) Check the calibration of tamping unit depth.

    xxii) Recondition the jaw of lifting unit hook

    42185254.doc Page 5 of 14

    SCHEDULE V

    (TO BE DONE AFTER 1000,3000 AND 5000 HOURS OF ENGINE RUNNING)

    DURATION SEVEN DAYS

1. ENGINE

i) Replace the worn out water hoses.

    ii) Overhaul the air compressor.

    iii) Clean the cooling coil.

    iv) Clean the crank case air breather.

    v) Overhaul the self starter.

    vi) Overhaul the alternator.

    vii) Check the bearing of shaft of radiator fan drive. viii) Check and adjust the engine timing.

    ix) Clean the HSD oil tank.

    x) Clean the radiator by pressurized air from opposite side.

2. GENERAL

    i) Replace the oil of clutch assembly of engine. ii) Replace the oil of pump drive gear box at engine. iii) Lubricate the king pin pivot of powered bogie with grease. iv) Replace the grease of hand brake gear.

    v) Perform chemical testing of hyd, oil.

    vi) Replace the return line filter.

    vii) Replace the suction filter element.

    viii) Check the bearing of all axles and grease them. ix) Check Maggie spring and replace if found damaged. x) Check bearing of trolley wheel and grease them. xi) Check and clean the air reservoir.

    xii) Inspect the chord wires of all transducers.

    xiii) Check the play in tamping unit arm bearing. If play found excessive then

    overhaul/replace the tamping unit.

    xiv) Recharge the batteries.

    xv) Clean the hydraulic oil through 10µ portable filter. xvi) Clean the hydraulic tank.

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    SCHEDULE VI

    IOH

    (TO BE DONE AFTER 2000 AND 4000 HOURS OF ENGINE RUNNING)

    DURATION 45 DAYS

1. ENGINE

    i) Overhaul the engine, if required, due to lack of compression or low lub

    oil pressure.

    Otherwise,

    ii) Decarbonise the engine.

    iii) Overhaul the injectors.

    iv) Overhaul the fuel injection pump.

    v) Overhaul the air compressor.

    vi) Overhaul the self starter.

    vii) Overhaul the alternator II & I.

    viii) Overhaul water pump.

    ix) Clean the engine radiator.

    x) Check the engine mounting pads.

    xi) Change water hoses.

    xii) Change bearing and shaft of radiator fan drive.

    xiii) Change engine air cleaner elements.

    xiv) Change all engine filters and lub oil.

    xv) Check engine damper for dynamic balance.

    xvi) Check the RPM of engine radiator fan.Take corrective measures if

    required.

    xvii) Clean diesel tank.

2. HYDRAULIC

i) Check the hydraulic pumps for rated delivery on the test bench and

    replace if it is less than the demand of circuit. ii) Check the hydraulic motors for rated torque and replace, if required. iii) Check the directional valves for leakage on the test bench, under rated

    pressure and replace, if required. iv) Replace the seals of all hydraulic cylinders along with gland bushes

    /piston and hone the cylinder barrel, if required. v) Replace all suction line, pressure line and return line filters.

    vi) Clean the hydraulic reservoir, paint with approved quality of paint and fill

    new oil.

    vii) Recharge the accumulators.

    viii) Overhaul all pressure controls and replace their kits, if required. ix) Clean the hydraulic oil cooler and repair, if required.

    x) Replace the hydraulic hoses on condition basis

    42185254.doc Page 7 of 14

2. PNEUMATIC

     i) Clean cooling coils.

    ii) Overhaul/ Replace air unloader.

    iii) Test air tanks. (Three times the working pressure.) iv) Overhaul water separator and air oiler.

    v) Change damaged and chocked pneumatic pipes if required. vi) Overhaul all pneumatic valves and change the unserviceable valves. vii) Change the seals of all pneumatic cylinders on condition basis. viii) Change the pneumatic clapper cylinders on condition basis. ix) Change the seals of pneumatic brake cylinders.

4. MECHANICAL

    i) Overhaul/ Replace the tamping units if required (AS POH) ii) Overhaul/Replace the lifting units.

    iii) Overhaul the trollies and wheels of all the feeler rollers. iv) Strengthen the machine frame, where cracks have developed. v) Check the wheels for tyre defects, reprofile or replace, if required. vi) Do axle greasing and replace the damaged bearings. vii) Check all gear boxes and repair, if required.

    viii) Check the X bearing of all the propeller shafts.

    ix) Replace the couplings of the propeller shafts.

    x) Grease the bogie pivots.

    xi) Replace the brake shoes.

    xii) Replace the meggie spring, if found damaged.

    xiii) Paint the roof of machine.

    xiv) Do patch painting where paint has pealed off or blistered and where

    welding work has been done.

5. ELECTRICAL

i) Thoroughly clean all panel boxes.

    ii) Provide missing thimbles.

    iii) Replace defective switches and potentiometers.

    iv) Replace defective indicative instruments.

    v) Replace the batteries.

    vi) Overhaul the pendulums

    vii) Overhaul all transducers and replace the chord wires. viii) Replace the missing or defective light.

    ix) Calibrate the machine for zero setting for leveling & alignment.

6. GENERAL

i) Check the function of all assemblies after IOH.

    ii) Calibrate the sensing equipments.

    iii) Test the machine for one week near the workshop, before it is put for

    work in regular section.

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    SCHEDULE VII

    POH

    ( TO BE DONE AFTER 6000 HOURS OF ENGINE RUNNING)

    DURATION 90 DAYS

1. ENGINE

    i) Overhaul /replace the engine on condition basis. If condition of engine is

    within limit of compression and lube oil pressure, carry out only the

    following. ii) De-carbonize the engine.

    iii) Overhaul the injectors.

    iv) Overhaul the fuel injection pump.

    v) Overhaul the air compressor.

    vi) Overhaul the self starter.

    vii) Overhaul the alternators.

    viii) Overhaul the radiator fan drive assembly.

    ix) Clean the engine radiator.

    x) Replace the engine mounting pads.

    xi) Replace the water hoses.

    xii) Overhaul the water pump.

    xiii) Replace the engine air cleaner element.

    xiv) Replace all engine filters.

    xv) Inspect the engine damper for dynamic balance.

    xvi) Check the RPM of engine radiator fan.

    xvii) Clean the diesel tank.

    xviii) Check the engine coupling pt. no.- WN2204A

    xix) Get clean the cooling coil.

2. HYDRAULIC

i) Replace all hydraulic pumps.

    ii) Replace all hydraulic motors.

    iii) Replace the hydraulic cylinders on condition basis.

    iv) Replace all hydraulic hoses.

    v) Replace all hydraulic filters.

    vi) Clean the hydraulic tank.

    vii) Replace the hydraulic oil in hydraulic tank.

    viii) Clean hydraulic oil cooler.

    ix) Check the hydraulic accumulator and recharge it.

    x) Replace the direct acting and pilot operated directional valve on

    condition basis. xi) Get the servo and proportional valve calibrated from manufacturer. xii) Replace all the pressure control valve on condition basis. xiii) Replace all the stop cock and flow control valves on condition basis. xiv) Flush the complete hydraulic system

    42185254.doc Page 9 of 14

3. PNEUMATIC

i) Clean the cooling coil.

    ii) Replace air unloader.

    iii) Test air tanks for rated pressure.

    iv) Replace water separator and air oiler.

    v) Change all pneumatic hoses.

    vi) Change all pneumatic valves.

    vii) Change all pneumatic cylinders on condition basis. viii) Overhaul the brake cylinders.

     ix) Change clapper cylinders.

     x) Change all the brake shoes.

4. MECHANICAL

i) Overhaul/Replace the tamping units.

    ii) Overhaul/ Replace the lifting units.

    iii) Overhaul the trolleys, wheels & feeler rollers.

    iv) Strengthen machine frame where cracks have developed. v) Check the wheels for tyre defects, reprofile or change the assembly, if

    required. vi) Check the axle bearings and grease them. .

    vii) Axles may be replaced if the bearings are loose on the journal. viii) Complete machine may be painted as per approved paint scheme.

     ix) Overhaul the driving and idling bogies and replace the defective parts.

5. ELECTRICAL

     i) Replace the defective PCBs.

     ii) Replace the defective limit switches.

     iii) Calibrate all the indicative instruments.

     iv) Overhaul the pendulums.

     v) Overhaul all the transducers.

    vi) Conduct insulation test of main cables and replace the defective ones. vii) Overhaul the panel boxes.

    viii) Defective switches and indicative lights may be replaced.

     ix) Check the LED of all the solenoids.

     x) Check the calibration of digital potentiometers and replace the defective

    ones. xi) Calibrate the machine for lifting and alignment on zero setting for

    leveling and alignment.

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