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WS 4519

U 08 475 / 4S
MAINTENANCE INSTRUCTION

WS 4519

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

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WS 4519

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.

WS 4519

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

WS 4519

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.

WS 4519

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
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.
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!

-----Bharat spiral EP %

Actuma Super Ultra 10W

Bharat wheel bearing


Grease Special
----------------

Automatic transmition

Bearing Grease
------Grease
Engine oil
Lubrication oil

Bharat Petroleum
-----Servo gear H.P.90
(Servo Ultra 10W)Servo Pride CF4
15W40
Servo grease WB
---------------------

Indian Oil Corporation

EQUIVALENT CHART

Hydraulic oil
Gear oil

Type

PLASSER INDIA
PRIVATE LIMITED

WS 4519

Tellus oil-68 or Tellus oil T-68


80 W 90
(Rotella JX oil 10 W) Remula super
15W40
Alvania E.P. Grease 2
Rettina LX2
Alvania grease RL2 or Alvania grease R2
Volvoline 20W40
Tellus oil 100 or Tellus oil T68

Shell

FOR PLASSER MAKE


MACHINES

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WS 4519

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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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WS 4519

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 coordination 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!

WS 4519

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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WS 4519

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.

WS 4519

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:
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.

WS 4519

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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6.3.3 Valvoline 15W40


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.

WS 4519

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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6.3.4 SHELL TELLUS S100


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.

WS 4519

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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WS 4519

6.3.5 SHELL ALVANIA GREASE RL2


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:
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.
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.

WS 4519

Exposure Controls / Personal Protection


Respiratory protection:
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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WS 4519

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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WS 4519

Jump-starting
Because of the sensitive electronics in the vehicle, always use a starting booster for jumpstarting.
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 jumpstarting 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).
1

Batteries of
the donor
vehicle
2 x 12V

+
-

+
-

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

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.

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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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WS 4519

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.

WS 4519

29

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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WS 4519

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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31

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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33

9.5 CHANGING WORKING STOCK


filter:

engine:

gear box:

oil filter
(whenever changing oil)

after 250 working hours.

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.

oil filter

after 500 working hours.

hy- oil tank: suction filter

replace depending on the


contamination indication of the vacuummeter; 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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37

12. MAINTENANCE SCHEDULE SURVEY


interval

KIND OF WORK

after 10 hours of
operation or daily

PLAIN VISUAL CHECK


16.1
CHECK OF WORKING STOCK:
16.2
- 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
POWER SHIFT GEAR - OIL LEVEL CHECK
17
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

after 50 hours of
operation or weekly

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

chapter

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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 semiannually

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

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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.

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13. GENERAL SURVEY

5
5
6

1)
2)
3)
4)
5)
6)

Front sensing device and tensioning trolley


Additional lifting assembly
Lifting and lining unit
Tamping bank
Diesel fuel tank
Generator set

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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

Tellus Oil T 68 (Shell)

1200 litres

1/8 cooling agent / water (up to 25 C)

85 litres

hydraulic oil
engine cooling agent

centralized lubrication system

Shell Alvania Grease RL2

grease

Shell Alvania Grease RL2

pneumatic lubricators
tine arm bearing

Tellus Oil T 68 (Shell)

0,2 litres

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

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.

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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

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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

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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

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WS 4519

10h or daily

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!

10h or daily

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.

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WS 4519

10h or daily

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

10h or daily

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.

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WS 4519

10h or daily

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

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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

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WS 4519

50h or weekly

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

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50h or weekly

50h or weekly

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

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50h or weekly

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)

50h or weekly

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.

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50h or weekly

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

1
3

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.

50h or weekly

COMBINED LIFTING AND LINING DEVICE


SURVEY
1.
2.
3.
4.

lining rollers
clamp bolts
horizontal hook guide
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

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50h or weekly

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

50h or weekly

TAMPING BANK - SURVEY


1) Tamping arm bearings
2) Tamping tool tine slewing cylinder bearings
3) 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

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50h or weekly

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

50h or weekly

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).

WS 4519

65

66

WS 4519

50h or weekly

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

50h or weekly

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

WS 4519

67

68

WS 4519

50h or weekly

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

50h or weekly

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

WS 4519

69

70

WS 4519

50h or weekly

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!

50h or weekly

WS 4519

71

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

78

WS 4519

250h or. Semi-annually

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

250h or. semi-annually

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

WS 4519

79

80

WS 4519

250h or. Semi-annually

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

250h or. semi-annually

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

WS 4519

81

82

WS 4519

250h or. Semi-annually

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

250h or. semi-annually

Frame slewing cylinder:


(2 nipples)

- visual check
- lubrication - Shell Alvania Grease RL2

SUPPORT ROLLERS
(AXLE 3 / 4)

- visual check
- lubrication Shell Alvania Grease RL2

WS 4519

83

84

WS 4519

250h or. Semi-annually

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.

250h or. semi-annually

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.

WS 4519

85

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

88

WS 4519

500h or semi-annually

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

500h or semi-annually

WS 4519

FUEL FILTER REPLACEMENT


engine furel supply tank:
1)
2)
3)

Diesel fuel filter/water separator


Diesel fuel stop cock
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).

89

90

WS 4519

500h or semi-annually

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.

500h or semi-annually

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.

WS 4519

91

92

WS 4519

500h or semi-annually

CARDAN SHAFT POWER DIVIDER


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

500h or semi-annually

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

WS 4519

93

94

WS 4519

500h or semi-annually

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

500h or semi-annually

TRABOLD FILTER (1) - change


3 pcs.

Order no.: HY-R508.05.01 ES


The filter cartridge has to be replaced every
500 engine hours.

WS 4519

95

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

1000h or annually

WS 4519

97

98

WS 4519

1000h or annually

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

1000h or annually

WS 4519

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:
M14
M16
M18

120 Nm
190 Nm
295 Nm
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

99

100

WS 4519

1000h or annually

ANNEX

Operating and Servicing Instructions


Intermediate Clutch
BR 152 0300

B01

Part. No.

Type

Part. No.

Type

Part. No

Type

WN 220.01 A
WN 220.04 A
WN 220.07
WN 220.10
WN 220.13
WN 220.17
WN 220.20
WN 220.23 A
WN 220.27
WN 220.32
WN 220.36
WN 220.39
WN 220.44
WN 220.47
WN 220.51
WN 220.55
WN 220.58

045
050
055
040
040
040
045
045
030
030
030
040
040
050
045
040
040

WN 220.02
WN 220.05
WN 220.08
WN 220.11
WN 220.14
WN 220.18
WN 220.21 A
WN 220.25
WN 220.28
WN 220.34 A
WN 220.37
WN 220.40
WN 220.45
WN 220.49
WN 220.53
WN 220.56

045
030
050
030
040
030
040
030
050
030
060
055
050
040
055
045

WN 220.03 A
WN 220.06
WN 220.09
WN 220.12 A
WN 220.15 A
WN 220.19 A
WN 220.22
WN 220.26
WN 220.31
WN 220.35
WN 220.38
WN 220.41
WN 220.46
WN 220.50
WN 220.54
WN 220.57

045
040
050
040
045
045
050
030
055
030
040
030
050
030
040
035

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.

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.

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.

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 one!
The corresponding part numbers and designations can be taken from the parts lists.
To avoid wrong deliveries, it is adviseable also to state the production no. stamped on the
main body of the clutch!
Threshold values of wear for friction disc and friction ring
above which it is recommended to exchange these components
Type
005
Thickness 3
Permissible 0,3
wear

010
3
0,3

020
3
0,3

030
4
04,

035
4
0,4

040
4
0,4

045
4
0,4

050
5
0,5

055
5
0,5

060
6
0,6

065
6
0,6

070
6
0,6

075
7
0,7

080
7
0,7

085
8
0,8

090
8
0,8

CAUTION:
All intermediate clutches are balanced with a balance quality of G = 6,3 as per. DIN ISO
1940!
If running is not smooth after a repair, re-balancing is needed according to the threshold
values given in the assembly drawing.

Fig. 7

HYDRAULIC SUCTION FILTER


REPLACEMENT

Before starting to replace the suction


filter, some principal requirements have
to be met:
Under no circumstances handle open
fire on the machine.
HAZARD OF FIRE!!!!

The machine must be secured from


BREAKING AWAY (activated parking
brake, activated safety brake, skid-pans
etc.).
Furthermore, the machine engine has to be
turned off and protected against
unauthorized starting.

The hydraulic system must be


depressurized and secured against
unauthorized operation.

It is necessary to cool down the hydraulic oil


to ambient temperature (the machine has to
be out of operation for several hours).
OTHERWISE HAZARD OF BURNS!

replace the suction filter in accordance with


the service intervals and/or the degree of
contamination (see symbolic photograph).

Fig. 3943 ws 10

clean the suction filter case by using a


suitable cleansing agent. DO NOT USE
inflammable cleansing agents.

Fig. 1

When having cleaned the outer case of the


suction filter unit thoroughly from dust,
grease and other dirt, you may start to
replace the suction filter itself.

Fig. 1

For replacing the filter an open-end wrench


(opening 36) or a ring wrench (opening 36)
and a suitable receptacle for the old filter
are required.

Fig. 2

Press the above mentioned open-end


wrench, or, optionally, the ring wrench
tightly onto the hexagon on the suction filter
cover. The wrench must fit tightly.

Fig. 4

Put the receptacle for the old suction filter


and the oil running out underneath the
suction filter case.
Turn off the cover for 25 mm, a slight
pressure exerted by the return valve has to
be felt. As the return valve is proportional to
the thread of the filter case cover, after 25
mm the return valve has to be closed.

Fig. 3

It is advisable to screw off the joint of the


mini-measuring line (see arrow). This
procedure makes it possible to test the
function of the return valve.

Fig. 5

Provided that it is operated and used as


directed the return valve incorporated in the
suction filter case ensures that no hydraulic
oil escapes from the hydraulic oil tank.

Fig. 6

If due functioning of the return valve is


ensured, completely screw out the cover
and remove it carefully, duly collect the oil
remaining in the filter case. After about of
a litre to 1 litre no more oil must come out.

Fig. 7

Remove the suction filter from its case and


put it into the receptacle.

Fig. 8

The hydraulic filter together with the


hydraulic oil coming out have, of course, to
be deposited duly.

Fig. 9

Caution: avoid damage to the O-ring on


the suction filter case.

Fig. 10

Seal the screwed connection of the minimeasuring line again, screw it into the filter
case unit the connection will fit tightly, but
make sure not to screw it in too far, as
otherwise the return valve would not
function !!!!!!

The new suction filter (item number see


spare parts catalogue, hydraulic system
scheme) has to be put into the case in
accordance with the required mounting
position!

Fig. 11

To ensure the operational safety of the


hydraulic system, only original spare parts
must be used.

Check the tight fit and the due condition of


the O-ring.
When the O-ring is safe for operation,
lubricate it slightly with hydraulic oil so that it
will more easily adapt to the surface.

Fig. 10

Screw in the case cover using the wrench


36 and tighten it. The O-ring must neither
come out nor get damaged !

Fig. 4

Now the hydraulic system again is ready for


operation.

Check the tightness of the suction filter


case.

It is recommendable to check the viscosity


of the hydraulic oil by an authorized institute
when replacing the suction filter. In case of
relevant deviations of the acid number or an
increased degree of contamination change
the hydraulic oil (as required according to
the service instruction). Observe the
respective safety instructions for handling
hydraulic oil.

S 19 02b

Symbolfoto

ASSEMBLY AND
DISASSEMBLY FOR TAMPING TINES
WITH CONICAL MOUNTING SHAFT

S 19 02b

TINE ASSEMBLY
Before inserting new tines, clean cone in the tyne arm and tyne. Check for damages
(dents, fins notches etc.).
Repair damages properly.

Important!
Do not use tines with damaged or deformed cones, since a fast fit is
not ensured and subsequently will create ovality in the tine arm cone
and finally cracks will occur.
Oval tines or tine arms have to be changed.

(used) cones with shaft and measurements

S 19 02b
Before mounting tines clean cones of tines and tine-arms.
Apply a thin oil film on the tamping tine shaft by using an oilimpregnated clean cloth (use oil15W/40).

Attention :
Hard face tamping tines must not be hit with a hammer or any other striking tool.
Splitering fragment are dangerous and can cause insury. Further on the hard face
tamping tines must not hit rail fastenings or any other iron objects during work to
prevent damage to the tamping tine.

PLEASE NOTE:
After working 100 to 200 m the bolts A, B, E, H (see description) have to
Be retighten.
Check tamping tines and bolts for proper condition regularly.

S 19 02b

Tamping Tine Type according to drawing


Insert points and crossing tines right
reading, with force into the tine arm and
tighten with 250 Nm bolt "A" (before
inserting the bolt use Loctite Anti Seize
and secure it by the corresponding nut
(1).

Tamping Tine Type with feather


Insert feather "F" on the proper side and
put in the tamping tines with force
according to the tamping tine
arrangement drawing.
Insert tine according tine arrangement
into tine arm. Put disc "C" on top of tine
and fasten with screw "B" dimension
M20x1,5 10.9 (before inserting the bolt
grease slightly with Loctite Anti Seize).
Use locking washer VS 20 and tighten
the screw with 600 Nm.

S 19 02b

Tamping Tine Type with Fitting screw


Insert fitting screw "E" into the tine arm
and tighten it properly. The bolt must
not get in contact with the tine face.
Insert tine according tine-arrangement.
Put disc "C" on top of tine and fasten
with screw "B" dimension M20x1,5 10.9
(before inserting the bolt grease slightly
with Loctite Anti Seize). Use locking
washer VS 20 and tighten the screw
with 600 Nm.

S 19 02b

Tamping Tine Type with Fitting screw


Clean screw thread by using a dapping
drill.
Insert fitting screw with the lock washer
and tighten properly. The screw "E"
must not touch the tine face.
Put in the tamping tine with force
according
to
the
tamping
tine
arrangement drawing.
Before inserting the screw "H" put little
Loctite Anti Seize on it. Tighten the
screw "H" with the nut "G" on the bolt
head with 250 Nm (nut "G" is used as a
burst protection). Then the nut "G" can
be removed. Put the lock washer "K" to
the screw and tighten the cap nut with
250 Nm.

PLEASE NOTE:
After working 100 to 200 m the bolts A, B, E, H (see description) have to
be retighten.
Check tamping tines and bolts for proper condition regularly.

S 19 02b
DISASSEMBLY OF TINE
Tamping Tine Type according to drawing

Loosen screw "A".


Insert wedge "3" with the rounded side
upwards and remove the tine.

Attention:
Falling out tamping tines can cause injury.
The tamping tine shaft could be damaged.

S 19 02b

Tamping Tine Type with feather and


Fitting screw

Loosen screw "B" and disc "C". Put in


thrust piece "D", insert wedge "3" with the
rounded side upwards and remove the tine.

Attention:
For driving out the tamping tines
different tools (tool kit) can be used.

Attention:
Falling out tamping tines can cause injury.
The tamping tine shaft could be damaged.

SERVICE INFORMATION
LUFTTROCKNER 90187
Zur Vermeidung von Schden an der Druckluftanlage ist der Lufttrockner periodisch zu
berprfen.
Der Filtereinsatz (Bestell-Nr. 90187-ES) ist
alle 500 Motor-Betriebsstunden, mindestens
aber einmal jhrlich, zu erneuern.
Die Granulateinstze (Bestell-Nr. 432 406
920 2) sind alle 500 Betriebsstunden zu
erneuern.
Die Tropfbecher der Druckluftversorgung
sind tglich zu entleeren.

S-37

AIR DRYER 90187


To avoid damages to the pneumatic system
periodically checks of the air dryer are
necessary.
The filter cartridge (Part-No. 90187-ES) has
to be renewed every 500 engine operation
hours, but at least once a year.
The granulate cartridges (Part-No. 432 406
920 2) are to be renewed every 500 hours of
operation.
The drip cups in the pressure supply circuit
are to be daily drained.

030969

GRANULATEINSATZ
Granulate cartridge

Filter cartridge

SERVICE INFORMATION

S-43b
(0104)

GENERALINSPEKTION VON
ANTRIEBSKOMPONENTEN
an Bahnbaumaschinen
und Oberbaufahrzeugen
NACH 6 JAHREN AB INBETRIEBNAHME,
aber sptestens nach 8000 Betriebsstunden.

GENERAL INSPECTION OF
DRIVE COMPONENTS
on Track Maintenance Machines
and Permanent Way Vehicles
6 YEARS AFTER THE FIRST START-UP,
but latest after 8000 operating hours.

Neben den vorgeschriebenen regulren Wartungsund Revisionsintervallen sind nach 6 Jahren ab


der ersten Inbetriebnahme, sptestens aber nach
8000 Betriebsstunden, folgende Untersuchungen
und Prventivmanahmen durchzufhren:

In addition to the compulsory regular maintenance


and overhaul intervals following inspection and
preventive measures are to be carried out 6 years
after the first start-up, but latest after 8000
operating hours:

Allgemein
Kraftstoffanlage
Leitungen
Filter
Keilriemen
Keilriemenscheiben
Khlsystem
Luftpresser
Alternatoren
Starter
Abgasanlage
Aufstellung
Dmpfungselemente
Befestigungsschrauben
Rahmen und Sttzen
Kupplung
Nebenantriebe

Zustand u. Prventive
Reparatur Erneuerung

Assembly

X
X
X
X
X

X
X
X
X
X
X
X
X
X
X
X
X

*)
*)

Radreifenprofil
X
Verschlei prfen und ggf. reprofilieren.
ACHTUNG !
1. Alle Radstze mssen gleichen LaufkreisDurchmesser haben.
2. Die Verschleigrenze (Marke) darf nicht
berschritten werden.
3. Bei nachgedrehten Radstzen ist unter
Bercksichtigung der Einfederung folgendes
unbedingt zu beachten:
a) Berhrungsfreiheit zu anderen Bauteilen.
b) Einhaltung des Fahrzeugprofiles.
c) Unbehinderte Wirkung der Bremsen.
d) Freier Wirkungshub der Stodmpfer.
e) Bei Triebachsen: Lage des Achsgetriebes,
Lage der Drehmomentsttze,
Beugungswinkel und Lngenausgleich
der Gelenkwellen.

ENGINE

Bauteil

Component

Condition Preventive
and Repair Renewal

General
Fuel system
Pipes
Filters
V-Belts
V-Belt pulleys
Cooling system
Air compressor
Alternators
Starter
Exhaust system
Attachment
Damping elements
Fixing bolts
Frame and supports
Clutch
Auxiliary drives

X
X
X

Wheel profile

X
X
X
X
X
X
X
X
X
X
X
X
X
X

*)
*)

Wear check, if necessary re-profiling.


ATTENTION !

1.
2.
3.

WHEEL SETS

RADSTZE

MOTOR

Baugruppe

All wheel-sets are to be on equal rim diameter.


The wear limit (marking) must not be exceeded.
When using re-profiled wheel sets, the spring
deflection must be considered and following care
must be unconditionally taken to:a) Clearance to other components.
b) Observance of the vehicle gauge.
c) Unhindered action and efficiency of the
brakes.
d) Free action of the shock absorbers.
e) On powered axles: Position of the axle gear box.
Position of the torque arm.
Diffraction angle and expansion
compensation of the cardan shafts.

SERVICE INFORMATION

S-43b
(0104)

Baugruppe

Bauteil
Achslagergehuse

Zustand u. Prventive
Reparatur Erneuerung

Assembly

X
X
X

Achsgetriebe
Zahnrder
Lager
Antriebswellen
Kupplungsteile
Dichtungen
Schmierpumpe
Gelenkwellenflansch

X
X
X
X
X
X
X
X

X
X
X
X
X
X
X

WHEEL SET
SUSPENSION

*)

ACHTUNG !
1. Bei Kegelradgetrieben sind Tellerrad und
Triebling gepaart. Bei fehlerhaften Teilen ist das
Achsgetriebe, bzw. der Radsatz zu erneuern.
2. Bei formschlssigen Antrieb mehrerer Achsen
mssen alle Radstze unbedingt den gleichen
Laufkreisdurchmesser haben. Dazu entweder
alle Radstze zu erneuern oder auf den
gleichen Durchmesser zu drehen.
X
Alle Gelenkwellen
*)
ACHTUNG !
Es drfen nur die vorgeschriebenen Schrauben,
Sicherungsscheiben und Muttern verwendet werden.
Die erforderlichen Anzugsmomente mssen
eingehalten werden. Nach sptestens 25
Betriebsstunden sind die Gelenkwellen und deren
Verschraubungen zu berprfen; in der weiteren
Folge alle 200 Betriebsstunden.

AXLE DRIVES

Drehzapfen
Drehzapfenlager
Drehpfanne
Fettfllung
Seitenfederung (Gummi)
Seitenfedern (Spiralfed.)
Gleitplatten
Stodmpfer
Drehgestellrahmen
Achslagerfhrungen

BOGIES

Alle Achslager
X
Fettfllung
X
Alle Gummifedern
X
*)
X
Spiralfedern
Federn auf Ermdung berprfen, ggf. sind die
Federn aller Radstze zu erneuern.
X
Federhalterungen
Federfhrungen und Sttzplatten berprfen, bei
Verschleierscheinungen sind alle Fhrungen und
Sttzplatten eines Radsatzes zu erneuern.
X
Alle Stodmpfer
*)

CARDAN SHAFTS

GELENKWELLEN

ACHSANTRIEBE

DREHGESTELLE

RADSATZAUFHNGUNG

Zerlegen und Lagersitze prfen. Bei Verschleispuren sind die Lagergehuse zu erneuern.

Component

Condition Preventive
and Repair Renewal

X
Axle bearing housings
Dismantle and check of the bearing seats. In case of
worn seat surfaces the axle bearing housings are to
be renewed.
All axle bearings
X
Lubricant
X
All rubber springs
X
*)
X
Spiral springs
Fatigue check of the springs, if necessary the springs
of all wheel sets are to be renewed.
X
Spring attachment
Check of spring guides and support plates. In case of
wear signs all guides and supports of the wheel set
are to be renewed.
All shock absorbers
X
*)

King pin
King pin bearing
Swivel ring
Lubricant
Lateral springs (rubber)
Lateral springs (spiral)
Support plates
Shock absorbers
Bogie frame
Axle bearing guide plates

X
X
X
X
X
X
X
X
X

*)

Axle gear box


X
Gears
X
Bearings
X
Drive shafts
X
Clutch components
X
Seal rings
X
Lubrication pump
X
Cardan shaft flange
X
ATTENTION !
1. On bevel type gear boxes the crown gear and
the pinion are paired. In case of wear signs the
axle gear box, respectively the wheel set must
be renewed.
2. All wheels of form-closure connected drive axles
must have unconditionally the same rim
diameter. For that, all concerned wheel sets
either to be renewed or to be turned to equal
diameter.
All cardan shafts

*)

ATTENTION !
Only the appropriate types of bolts, retaining washers
and nuts must be used and the required tightening
torque must be observed. Latest after 25 operating
hours the cardan shafts and their bolts are to be
checked for proper condition, subsequently after
every 200 operating hours.

SERVICE INFORMATION

GETRIEBE

ANTRIEBSFLANSCHE

Alle Kraftbertragungen

Zustand u. Prventive
Reparatur Erneuerung

Component
All power transmissions

Befestigungen, Lager, Dichtungen, Keilprofile und


Flanschbohrungen auf Verschlei berprfen und
schadhafte Teile erneuern.

Alle Getriebe

Assembly

DRIVE
FLANGES

Bauteil

Generalinspektion und Erneuerung aller verschlissenen, bzw. defekten Bauteile.

HINWEIS:
Alle Inspektions- und Reparaturmanahmen drfen nur von
autorisierten Fachdiensten durchgefhrt werden.

(0104)

Condition Preventive
and Repair Renewal
X

Bolts, bearings, seal rings, spline profile and flange


bores to be checked for wear. Worn parts are to be
renewed.

All gear boxes

GEAR
BOXES

Baugruppe

S-43b

General inspection and renewal of all worn or


defective components.

Es sollen nur Original-Ersatzteile verwendet werden.

NOTE:
All inspection and repair measures are to be carried out only by
authorised workshops.
Only original spare parts are to be used.

*) nderungen gegenber S-43a:

*) Amendments toS-43a:

Anstelle von Prventive Erneuerung sind die betroffenen


Bauteile auf ihren Zustand zu berprfen und deren Eignung fr
eine weitere Verwendung durch geeignete Manahmen sicher zu
stellen.

Instead of Preventive Renewal the corresponding components


are to be checked for proper condition and their suitability for a
further usage has to be assured by appropriate means.

Plasser & Theurer


Service Center

(U. Peters)

SERVICE INFORMATION

SI-0300-01

GENERAL DESCRIPTION FOR THE OPERATION, MAINTENANCE, PERIODICAL CHECKING


AND TRACK WORTHINESS OF PLASSER & THEURER TRACK MAINTENANCE MACHINERY.
On track Heavy Plant Machinery, Measuring Cars and Inspection Vehicles are subject to certain
operation and periodical maintenance procedures to maintain the correct standard and ensure they
meet the safety requirements.

The end user is responsible to follow the instructions of the manufacturer to keep the
vehicles in correct operational and working condition. For this purpose we the
manufacturer hereby supply the following instructions that should be strictly adhered to:
1) SAFETY REQUIREMENT:
Our Direction; General Operation and Safety Requirements for Plasser & Theurer Track Maintenance
Machines, BS-02.00-* This instruction is a part of the documentation originally delivered with the
machine. The instruction should be carefully read and followed, it contains instructions for operating,
how to reduce danger and risks, and other useful information.

2) TRACK WORTHINESS:
The End User is responsible for ensuring that all necessary requirements related to vehicle safety on
track have been fulfilled.

3) INTENDED USE, OPERATION AND LIABILITY:


a) The delivered vehicle should only be used for the purpose that it is designed for, and should only be
operated and maintained by qualified personnel.
b) In case the machine is not operated and maintained by qualified persons, or repairs are carried out
without following the service instruction, or the use of non original spare parts, the manufacturer can
not be held responsible for any damage.

4) OPERATING CONDITION AND MAINTENANCE:


Before putting the vehicle into operation the end user must ensure that the delivered product is fully
operational:
a) All necessary instructions and maintenance intervals as stipulated in the Service Instructions must
be followed by the machine personnel.
b) Only those materials described in the relevant instructions should be used for cleaning and
maintenance.

5) INSPECTION AND REPAIR:


In addition to the recommended periodical inspection of Track Maintenance Equipment, and with
reference to requirements for Heavy Plant Machinery, it is necessary to carry out frequent checks on;
Undercarriage, Drive Control, Brake System Components, Frame, General Working Functions,
Measuring Systems and Safety Controls. Any problem identified should be immediately reported and
dealt with.
a) The machine must always be repaired in a suitable workshop by qualified personnel using only
approved components.
b) In general a service network for technical assistance has been set up by Plasser & Theurer.
c) The End User (customer) in case of failure can contact the appropriate Plasser & Theurer Service
Branch.
d) The Service Branch is available for providing Technical Assistance for the checking and
commissioning of the machine, in both a practical and technical capacity.
e) To ensure an accurate and reliable performance of the equipment it is strongly recommended that
only original spare parts should be used. During the warranty period it is a condition of the warranty
that original spare parts from Plasser & Theurer have to be used.
f) Modifications, additional installations and using the equipment for purposes other than which it was
designed for, can seriously affect the safety requirements of the equipment, and therefore can only
be carried out with the prior approval of the manufacturer.
Plasser & Theurer
Export von Bahnbaumaschinen
Gesellschaft m.b.H.