1414666049508-TI MI 0044 Rev 0

1 OF 80 Issued On 15.11.2012 Maintenance Instruction No. TI/MI/0044 Rev.
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
SPECIAL MAINTENANCE INSTRUCTION

for
4-WHEELER TOWER CAR
(November, 2012)
ISSUED BY:
TRACTION INSTALLATION DIRECTORATE

RESEARCH, DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR,
LUCKNOW - 226 011.
2 OF 80 Issued On 15.11.2012 Maintenance Instruction No. TI/MI/0044 Rev. 0

for
4-WHEELER TOWER CAR
Amendment Date of Amendment Total Pages including Amendment/Revision

Number Aneexure
New 15.11.2012 80 -
PREPARED BY CHECKED BY APPROVED BY

SIGNATURE
DATE
DESIGNATION SSE(TW) DDTI (TW & COND) EDTI
COPY N0.
ISSUED BY …………………………. SIGNATURE …............................ DATE…………………….
ISSUED TO ……………………………………………………………………………………………
……………………………………………………………………………………………
NOTE: This maintenance Instruction is property of RDSO. No reproduction shall be done without
permission from DG(TI).

for
4-WHEELER TOWER CAR
INDEX
Sl.No. DESCRIPTION PAGE No.

1 Monthly Schedule of Electrical System 4
2 Three Monthly Schedule of Electrical System 5
3 Half Yearly Schedule of Electrical System 7
4 Overhaul During IOH/POH 9
5 Maintenance of engine 10
6 Maintenance of transmission 18
7 Maintenance of Brake System 29
8 Maintenance of carriage and under frame 34
9 Maintenance of suspension, wheels & Axles 41
10 List of reference Drawings 54
11 Formats for schedule examination 57
12 Spares 70-80
SPECIAL MAINTENANCE INSTRUCTION FOR

4-WHEELER TOWER CARS
1.0 Objective: For upkeep of tower wagons and all time availability of
tower Cars in working conditions.
2.0 Back Ground: Tower Cars are used for maintenance and attending to
break downs of overhead equipment (OHE) for quick restoration of
power supply to OHE. This Special Maintenance Instruction (SMI) has
been prepared to maintain tower Cars so that its availability can be
ensured all the time.
Following maintenance instructions are to be followed for maintenance

of various items of Tower Cars.
3.0 Monthly Schedule (With engine stopped).
3.1 Contactor and relays: (i) Inspect visually.

(ii) Manually operate contactor to check
operation.
(iii) Check interlock and contactors.
(iv) Check operations and contactors.
(v) Clean the interlock of contactor & relays.
3.2 Resistor & blocking diode: Check values and function of all resistors
and diode and record it.
3.3 High and low voltage circuit: Check ground record insulation
resistance of power circuit
3.3 Batteries: (i) Clean dirt or any oil on top of battery.

(ii) Keep oil terminal tight, clean and apply vaseline
petroleum jelly.
(iii) Ensure that vent plugs are clean.
(iv) Check specific gravity of electrolyte
(v) Top up the distilled water as per the requirement i.e.
twice in summer season and once in winter season in
a month.
3.4 Traction Motor: (i) Brush off loose dust or dirt before removing
commutator cover.
(ii) Clean the commutator veering. Remove any

copper beads from the commutator surface
with fine caborandum cloth.
(iii) Deposit from dirt or greasy hands should be
removed from solvent.
(iv) Examine the brush gear and clean the
insulation of the brush arm.
(v) Check that the brush ring sits correctly on the
carbons and that the springs are in good
condition.
(vi) Check carbon brushes for wear. Fit new
brushes in place of worn out carbon brusher or
any one which are unlikely to last until the
next inspection. See data for minimum length
and brush grade.
(vii) Check carbon brushes for freedom in the brush
holder and if striking cleans both the brush and
inside of the brush holder.
(viii) Do not shake the carbon, as solvent will
eventually ooze out affecting the commutator
and causing the brush to jam in the brush
holder. If the brush appears to be excessively
slack in the brush holder, check the brush size
and discard the brush holder as the case may
be.
(ix) Top up suspension bearing lubrication oil and
cardium compound of traction motors,
gearbox.
3.5 Traction Alternator: (i) Brush off loose dust or dirt before removing
cover.
(ii) Check tightness of connections.
(iii) Check for any loose hardware especially on the
rotating rectifier assembly.
4.0 Three Monthly Schedule (with engine stopped)

4.1 Repeat all checks followed in monthly check.
4.2 Contactor and relays: (i) Inspect visually.
(ii) Manually operate contactor to check
operation.
(iii) Check interlock and contactors.
(iv) Check contactors contact tips for pitting.
4.3 Resistor and blocking diode: Check values and function of all resistors
and diode.
4.4 High and low voltage: Check for ground , record insulation circuits
Resistance of power circuit and control circuit.
4.5 Batteries: (i) Clean dirt or any oil on top of battery.

(ii) Keep all terminals tight clean and apply
Vaseline petroleum jelly.
(iii) Ensure that vent plugs are clean.
(iv) Check specific gravity of electrolyte.
(v) Check the specific gravity & cell to cell
voltage of each Cell of battery. If specific
gravity is found below the requirement
limit, maintain it to its required value.
4.6 Traction Motor: Repeat the monthly service with following additional
schedules.
(i) Blow out machine using clean dry compressed air. Take
particular care to direct air under the commutator in order to
remove dirt lodged in the armature core ducts.
(ii) Check tightness of all brush gear bolts.
(iii) Check tightness of bolts securing axle caps and gear case
(iv) Check air inlet bellows for cracking, tearing or collapsing.
(v) Check for the leakage from the gear case and suspension
bearings Ensure the lids of the axle suspension bearing oil
wells fit correctly.
(vi) Check all external leads for chaffing.
(vii) Measure insulation resistance, it should not be less than one
mega ohm.
4.7 Traction Alternator: Monthly Service plus.
(i)Wipe off loose dirt on the outside surface of the alternator

with a clean filter free cloth.
(ii) Remove stubborn accumulation of dirt using xylene
(iii) Clean all ventilating parts with filtered and compressed air
at pressure of 1.75 to 2.8 kg/cm2.
(iv) Clean inside of alternator using dry compressed air of a
pressure of 1.75 to 2.8kg/cm2.
4.8 Cable Connections: Check for loosening adjoins on terminal board &
Equipments. Check for insulation damage also.
5.0 HALF YEARLY SCHEDULE (WITH ENGINE STOPPED)
5.1 Master controller Clean and inspect contact, fingers. Check

mechanical Interlock
Control equipments Check condition and flexibility; replace worn
shunts. frayed broken or corroded braided shunt.
Control equipments Check terminal connectors and tighten if
required.
Control Equipment (i) Clean contactors
(ii) Replace contact tips if worn or pitted.
Safety devices
(i) Cooling water(i) Remove and check on test bench and adjust
temperature switch if required.
(ii) Engine over speed (ii) Remove and check on test bench and adjust
switch if required.
Engine RUN/STOP switch Check and clean contact
Battery Remove boxes from tower wagon. Clean and
repaint.
Load Ammeters Check calibration
Traction Motor suspension (i) Change oil.
bearing (ii) Change wick lubricator if damaged.
(iii) Check bearing cap bolts for tightness.
(iv) Check bearing cap bolts for tightness.
(v) Check wear on motor suspension and
nose suspension.
(vi) Check suspension bearing suspension.
Traction Motor Repeat three monthly service including
following additional schedules:-
(i) Clean the grease escape drain from P.E.
outer bearing cap and P.E. end shield.
(ii) Clean all pinion and gear wheels check for
tooth wear.
(iii) Clean lubricant from each gear case to
ensure that it is not cracked and the seals
are in good condition.
(iv) Replace felt seals if necessary.
6.0 MAINTENANCE OF TRACTION MOTOR
Overhaul: An overhaul is required after three to five years service.

Following schedules are to be ensured
(i) Remove as much dirt as possible particularly around the

commutator covers the axle-cap filler pipes and the armature

bearing caps.
(ii) Check the lateral and diametrical clearances of the axle
suspension bearings; fit new bearings if the existing bearings
are worn beyond the limits recommended (see data as given in
the manual).
(iii) Remove the motor from the bogie and using the oil-injection
equipment, remove the pinion.
(iv) Before dismantling the motor, give it a light run at 1500-2000
rev/min to check that the bearings are not noisy and that the
vibration is not excessive.
(v) Dismantle the motor (see under dismantling & reassembling).
Clean the armature thoroughly, also the interior of the frame.
Bake each at 90oC to remove moisture. (See Workshop Manual).
After drying, check the insulation resistance while the machine is
still hot. This should be at least one Meg. Ohm, if it is, apply a
high voltage test. (See under HIGH VOLTAGE TESTS). Apply a
commutator bar to bar comparison test to check for open or
short circuited coils.
(vi) Remove and clean the brush holders. Examine each brush
holder for brush clearance, for brush spring pressure, for
damaged insulators, for spring-hub wear, for loose or defective
support pin insulator and burnt spots. Recondition as
necessary. Fit new brushes if necessary.
(vii) Check the wear plates on the nose suspension for wear, check
also axle ways and the axle caps for wear, distortion and
cracks. Examine all cables, fit a new cable in place of any that
is chafed or otherwise damaged.
(viii) If the field coils and the connections are tight, dry and are in
good condition, repaint the whole of the interior with silicone
gray finishing paint.
(ix) If field coils have to be removed, recondition them individually,
and on reassembly, refill the counter bores around the top pole
studs with Tar Compound, class IV (Supplied by M/s Shalimar
India) to exclude moisture.
(x) Inspect all other motor components for wear, distortion or for
any other defects. Fit new bearings if necessary.
(xi) Inspect the shaft for damage to threads, bearing and whether
pinion fits and ensure that the shaft is straight. Further
inspect the armature for loose bands, solder throwing or other
defects. Recondition the armature as necessary.
(xii) Treat the reconditioned or repaired armature with solventless
polyester (GE 702 or equivalent) insulating varnish. (For
procedure, see Workshop Manual). The number of such
treatments will depend upon the condition of the armature, but

normally, twice will be sufficient.
7.0 OVERHAUL DURING IOH/POH
During the overhaul the pantograph must be removed from the Tower
Wagon.
Bearings: After dismantling, check all ball bearings for wear of cage ball
etc. and replace if necessary
Mechanical parts: The upper and lower articulation tubes must be

dismantled and repaired if bent. The middle articulation shaft triangular
bracket and equalizer arm etc. should be checked thoroughly for damages.
Throttle valve: Dismantle and over haul throttle valve.
Self starter: Self starter motor for Mark-II, Mark-III tower wagon to be
overhauled in every IOH/POH & replaced in second POH.
Alternator: Engine driven alternator to be overhauled in every IOH/POH

and replaced in second POH.
Painting: Scratch the old paint. Clean the surface and apply paint.
8.0 MAINTENANCE OF RECTIFIER
Except for blower, the rectifier unit as such is a static equipment with no
moving parts, hence little maintenance is required. However, regular
inspection is necessary if trouble free operation is required.
(i) The unit must be periodically cleaned with air blast. For inspection
the front door can be opened easily by opening the locks and
doors can be kept aside according to convenience.
(ii) Checkup various contacts and terminal connections in the initial
stage of operation and later once in six months.
9.0 MAINTENANCE OF ENGINE:

Daily check A-Check
SN Maintenance steps Remarks

1 Check previous days engine log Correct as required.
book
2 Drain Water and sedimentation Before starting the engine.
from fuel filter through drain
cock.
3 Check engine oil level and top up Must be slightly less than or
if necessary equal to ‘H’ mark on dip stick
when engine is stopped and
has stood for 20 minutes or
more (must be measured after
all oil is drained back into oil
pan)
4 Check for fuel, oil, water and Correct if leaking.
exhaust leaks
5 Fill radiator/surge tank with Radiator cap must be firmly
treated water (Chromate tightened back into the
concentration 3500 PPM) radiator/surge tank neck.
Engine must not be operated
without the aeration and
overhauling of the coolant
check, engine radiator water
level.
6 Check air cleaner, oil level and Use clean engine oil
change oil, if required( if oil bath
type) clean dust pan
7 Check airline connection for leaks Correct as required.
8 Remove and clean air compressor Fill with clean oil upto the
breather, if equipped. mark.
9 Drain air receiver tank at the -
beginning of every day and close
the drain cock.
10 Clean crank case breather. Discard paper type element if
clogged.
11 Check oil level in hydraulic Check for leaks. Use engine oil
governor, if provided. for topping up (as shown in fig
3.1)
12 Start the engine and note the oil If there is a change in oil
pressure both at idling and pressure from that recorded in
maximum speed. the log book on earlier occasion
then stop engine and check

through trouble shooting
technique the cause for oil
pressure change and correct if
necessary.
13 Record oil pressure Refere operation and
maintenance manual for lube
oil pressure limits
14 Fill fuel tank at the end of the day Use clean fuel and a strainer.
Also clean the cap and
surrounding area before
opening the filler cap. Fill fuel
at the end of the day allowing
diesel to settle. Drain sediment
from fuel filter water separator
bowl.
3.2 Check Every 300 Hrs or 6 Months whichever is earlier B -Check
S.No Maintenance Steps Remarks

1. Repeat all --
maintenance steps
of ‘A’check
2. Change engine oil. When lub oil is examined through lub oil
analysis in a laboratory, oil change period
may be extended. In such cases, refer to
your service representative.
3. Fit new lubricating Inspect the changed filter element and check
oil full flow filter for metal particles and oil sludging/oxidation.
element.
S. No Maintenance Steps Remarks

4.
Remove, clean Blow out dust with compressed air in the
and inspect dry opposite direction of the normal air flow. If
type air cleaner very dirty , wash in solution of warm water.
element. Remove (48.9°C-60°C) and non sludging detergent.
and clean dustpan. Allow it to dry first then use compressed air.
Inspect element Replace if washed two times.
for holes and Caution : Excess air pressure will damage
tears. Check paper. Air nozzle must be kept at least 8”
gaskets and ‘O’ from the element. Must not be used if even
rings for damage. one pin hole exists. Discard element if
punctured and also change gasket along with
element.
Clean oil bath air
5. cleaner tray -----
screen.
Change lubricating
oil by-pass filter
6. Record oil pressure
element and
gasket if provided.
Clean float tank
7. and/or main fuel -----
tank breather.
8. Check coolant PH
value/concentratio
Change corrosion resistor element if PH calue
n of
is below normal range 8.5 – 10.5. Check
DCA/chromate
chromate concentration at 3500 PPM.
concentration
(3500 PPM).
9. Check magnesium Check magnesium plate for pitting or being
plate in assembly eaten away. Change if more than 50% of area
corrosion resistor. is lost. Use DCA service element or chromate
Change water element bags AR 95679 if concentration is
filter element. low.
10. Change fuel filter Clean shell fuel filter. Change element when
element washer restriction exceeds vacuum 20.32cm of
and ‘O’ ring on mercury.
mounting bolt.
11. Check oil in Use same oil as used in oil pan.
aneroid control, If
equipped.
S.N
Maintenance Steps Remarks
o
Tighten belt tension (use ST –
1293)
Check and adjust belts. New belts

12. will stretch within one hour of use.
They must be readjusted.
Tighten foundation bolts and

13. flexible coupling bolts of engine -----
and alternator.
Check all air cleaner connections

Correct as required.
14. for cracks-chafing etc. Tighten all
air intake connections.
Use special tool no. ST 845 or ST

15. Check fan hub and drive. 893 for tightening the fan hub
nut.
Change element for naturally

Clean/change air compressor
16. aspirated engine. Clean screen for
breather element.
turbo engine.
17. Check throttle linkage. -----
EVERY 1500 HOURS OR 1 YEAR WHICH EVER IS EARLIER C - Check
1 Repeat all maintenance steps of Checks `A’ & ‘B’
2 Check thermostat operation It should start opening

3 Check fan hub and drive Check mounting bolts & bearing
end play
4 Check impeller water pump for Correct if necessary
play
5 Check for turbocharger oil leaks Correct as required
6 Tighten turbocharger mounting Tighten to the specified torque.
nuts Do not tighten when engine is
hot condition.
7 Check inlet air restriction Check after cleaning dry type air
cleaner element. If restriction is
in excess of 25” water, a new
element must be fitted.
8 Clean oil bath air cleaner Remove complete assembly and
clean inclusive of fixed screens.
9 Clean and tighten all electrical -
connections.
10 Check generator brushes and Replace and clean as required
commutators
11 Clean entire engine High pressure and soap water
mixture preferred after spraying
engine with cleanser taking care
of protecting electrical system.
12 Tighten all mounting bolts and Tighten as required. Over
nuts tightening may result in
distortion or damage.
13 Clean aneroid air breather. If Replace breather if necessary.
provided
14 Check engine blowby. Reading in excess of
recommended limits. Corrective
action must be taken through
analysis with the help of trouble
shooting chart.
15 Clean radiator Blow air through the radiator
core in opposite direction to the
normal flow of air, if working
under dusty/dirty condition.(
Reserve flushing operation)
16 Check air compressure Check shaft and clearance.
17 Adjust injectors and valves Clean fuel inlet connection
screens. Final adjustments must
be carried out with engine hot
and with correct torque as
specified (refer O & M manual)
18 Change hydraulic governor oil/ Use engine lubricating oil
aneroid oil
19 Check vibration damper If steam is not available, then
use clean soap water solution as
outlined in ‘C’ check it.
20 Fuel & lube oil filters Replace fuel & lube oil filter
elements with sealing rings and
clean the filter housing.
EVERY 6000 HOURS OR 3 YEARS WHICHEVER IS EARLIER. D-Check
SN Maintenance Steps Remarks

1 Repeat all maintenance steps of
check A, B & C
2 Check exhaust and inlet manifold
and nuts.
3 Tighten all mounting bolts and
nuts.
4 Clean Turbocharger diffuser and
impeller and check end float.
5 Check turbo charger bearing Only end float on semi floating
clearances bearing if in excess of limits,
replace it.
6 Check crank shaft end float If in excess of recommended
limits, corrective action is
indicated
7 Clean injector inlet screens Must be done only if performance
deterioration is evident. Some of
the indications for performance
deterioration are.
1. Black smoke
2. Change in fuel manifold
pressure
3. Loss of power
4. Malfunction of aneroid.
5. Clean and calibrate all
injector.
6. Check fuel pump calibration.
7. Replace aneroid bellows &
calibrate.
8 Replace fuel pump filter screen
and magnet.
9 Steam clean engine. If steam is not available, then
use clean soap water.
10.0 MAINTENANCE OF TRANSMISSION
(i) Maintenance steps: Check the transmission oil level and top up, if
necessary. It must be equal to H mark on the dip stick. When
engine is stopped and has stood for 20 minutes or more (must be
measured after oil, get back into the transmission housing)
(ii) Clean the transmission and check the transmission oil leakage.
Rectify the same if leakage observed.
(iii) The oil should be changed every 1000 hours of operation or sooner,
depending upon operating conditions. Also, the oil must be changed
whenever there are traces of dirt or evidence of high temperature
indicated by discoloration or strong odour. The filter screen in the
sump should be removed and cleaned with mineral sprits at each oil
change.
(iv) The filter element should be replaced at each oil change and at
200-hour intervals between oil changes. The filter shells should be
cleaned. New gaskets and seal rings must be used when replacing
filter elements. After installation, check the filter for oil leakage
while the vehicle engine is running.
11.0 MAINTENANCE OF AXLE DRIVE
1 Three years or Remove the final drives from the car &
(approx 3,00,000 disassemble the gears, shaft & sub-assembly.
kms which ever is Inspect the gears and bearing. The defective
earlier. components must be replaced before re –
assembly.
2
12.0 MAINTENANCE OF LIFTING AND SWIVELLING PLATFORM.
1 Replace suction Yearly

strainer.
2 Replace return line Yearly
filter element.
3 Drain oil tank, clean Yearly
it and change oil.
4 Replace seals of Two yearly
hydraulic cylinder
5 Replace guiding pads Two yearly
between telescopic
structures.
6 Major over haul At 72 months Replacing guide pads between
telescopic structures and replacing seals of

hydraulic cylinder constitute a part of major
over haul.
13.0 Requirement of spares for maintenance during various schedules.
The items of maintenance spares required to be stocked alongwith the

list of must change items in respect of carriage, diesel engine,
transmission system including traction motor spares are enclosed as
annexure-V.
14.0 4-wheeler tower Cars shall have twin beam head light and LED type
flasher light. Earlier tower wagons, which are not provided with twin
beam headlight & LED type flasher light, shall be provided with twin
beam headlight & LED type flasher light during major overhaul with
modification in the shell.
15.0 OVERHAUL DURING IOH/POH
(i) During the overhaul the pantograph must be removed from the
Tower car.
(ii) All the electrical equipments like traction motor to be overhauled
as per the guidelines explained in the proceeding para.
(iii) After dismantling, check all ball bearings for wear of cage ball etc.
and replace, if any.
(iv) The upper and lower articulation tubes must be dismantled and
repaired, if bent. The middle articulation shaft triangular bracket
and equalizer arm etc. should be checked thoroughly for damage.
(v) Dismantle and overhaul throttle valve
(vi) All mechanical parts, brake equipments, transmission system etc.
to be thoroughly checked and accordingly carryout all repair
/replacement for safety and smooth functioning as suggested in this
document/Maintenance Manual of the equipment/ supplier.
(vii) Scratch the old paint. Clean the surface and apply paint as per
colour scheme.
TRANSMISSION
16 The transmission and control equipment were supplied by two firms viz.
M/s Kirloskar Pneumatic Co. Ltd., Pune and M/s Venkateswara
transmission private Ltd. (VENTRA) Hyderabad. Hydraulic transmission
offered by M/S KPC is of their own design and that of M/s Ventra is of
Hindustan Motors. However five numbers 4 wheeler tower wagons were
provided with Voith transmission system.
A common power pack is used for both the two designs. A Kirloskar
Cummins Ltd. model N-743-L naturally aspirated diesel engine
developing 210 horsepower at 2100 rpm has been used. The
transmission of both powers from diesel engine to wheels is by means of
hydrodynamic system incorporating torque converter and gears.
The final power transmission in both designs is through cardan shaft

and axle drives. In the KPC design the transmission output is directly
connected to the axle drive on the rear axle by means of a long cardan
shaft using axle drives of two different overall gear ratios. This
transmission also incorporates reversing arrangements with the use of
plate clutch unit.
In the VENTRA design the transmission output is connected to the

axle drive through an intermediate gearbox of a differential gear unit
and a hydrodynamic torque converter incorporating speed change
provision. The final drive from diesel engine is through a slip- clutch
assembly properly aligned with in the engine flywheel housing.
16.1 MAINTENANCE OF VOITH HYDRAULIC TRANSMISSION.

16.2 Maintenance Schedules
Maintenance interval Work to be performed

20,000 km Check oil level
300,000 km Oil change, inspection of control parts,
replacement of filter, replacement of
disposable filter.
900,000 km Major overhaul
16.3 Maintenance after 20,000 km

Check the oil level.
16.4 Maintenance after 300,000 km
a) Oil change
Under normal operating conditions, the oil filling lasts for a
distance of approx. 300,000km . This period can be extended if
the oil sample is still within the tolerance of the specification for
new oil.
For changing the oil, drain it from valve while it is at operating

temperature and drain the oil cooler too. If oil of a different
approved brand is to be filled in, flush the transmission and
cooling system with half the quantity of the new oil needed for a
complete fill.
b) Replace all filters. For this purpose, drain off the oil first, then
remove the filters, take off the caps and remove filter elements.
c) Check control parts such as governor, standstill detector valve,

operating cylinder, and main control valve for proper operation,
leakage and wear.
16.5 Major Overhaul

A major over haul of the transmission is recommended after
approx. 900,000 km of operation, depending on operating
conditions and duty. During this over haul, the transmission is
stripped as far as necessary. Bearing labyrinth rings, shaft seats
etc. are inspected and damaged parts are replaced.
17.0 MAINTENANCE OF HINDUSTAN MOTOR HYDRAULIC TRANSMISSION
17.1 Control Linkage
Check the transmission shift control linkage and the directional linkage
to ensure that the linkages are free and that the selector levers are
properly positioned. The Shift levers should engage in all shift tower
positions freely. Inspect the linkages for binding, wear, cracks, breaks
or defective cotter pins.
17.2 Cold Oil Level Check
The cold check (engine not running) is made to determine if there is

sufficient oil to safely start the engine - especially if the vehicle has
been idle. The oil level should be at or near the full-level check plug.
Some transmissions have one plug, others have two plugs, an ADD
and a FULL plug.
17.3 Hot Level Check

Oil level must be checked with the engine running at 1000 rpm,
transmission in neutral and with the transmission at normal operating
temperature (82.3°C - 93.4°C). The upper check plug (if there are two
plugs) indicates the full oil level while the lower plug is the add level.
The oil must be maintained at the FULL level. If there is only one
check plug, the oil level must be maintained at this level. Add oil if
necessary to bring the level to the FULL mark.
17.4 Oil, Filter Change
The oil should be changed every 1000 hours of operation or sooner,

depending upon operating conditions. Also, the oil must be changed
whenever there are traces of dirt or evidence of high temperature
indicated by discoloration or strong odor. The filter screen in the sump
should be removed and cleaned with mineral spirits at each oil change.
The filter elements should be replaced at each oil change and at

200 hour intervals between oil changes. The filter shells should be
cleaned. New gaskets and seal rings must be used when replacing
filter elements. After installation, check the filter for oil leakage while
the vehicle engine is running.
17.5 Keeping oil clean
It is absolutely necessary that the oil put in the transmission be clean.

Oil must be handled in clean containers, filler etc., to prevent foreign
material from entering the system.
17.6 Filling of Transmission Oil
At temperature above -23.3°C, pour hydraulic transmission fluid

type C-2 into filler opening. At temperature below -23.3°C, an
auxiliary preheat is required to raise the temperature in the sump. Use
only C-2 fluids from approved manufacturers.
17.7 Care of Breather
The breather should be kept clean at all times. It should be checked

and cleaned regularly and as frequently as necessary, depending upon
the operating conditions. A badly corroded or plugged breather
restricts proper breathing, causing oil leaks.
17.8 Control Linkage Adjustment
Manual shift linkage must be adjusted so that the operator's control is

positioned to exactly match the detent position of the selector valve on
the transmission. Adjust the linkage so that it can be freely connected
without moving either the valve or the operator's control. Then

operate the range selector lever, the directional selector lever and the
output disconnect (if applicable) through each position. Make minor
adjustments, if necessary, to insure that each of the selector levers
seats in each position of the operator's control. Then inspect the
control linkage for binding wear or breaks.
17.9 TROUBLE SHOOTING OF HM HYDRAULIC TRANSMISSION
Causes Remedy
A. LOW CLUTCH APPLY PRESSURE
1. Low oil level Add oil to correct level
2. Clogged oil Clean strainer
strainer
3. Clogged oil filter Replace filter element
4. Inching control Check, adjust linkage
adjustment not
fully retracted
5. Air leak at intake Check pump mounting bolts.
side of oil pump
6. External oil Tighten bolts or replace gaskets
leakage
7. Brake hydraulic (or Check brake residual pressure (brakes
air) pressure released); check brakes for full release.
applying clutch
cutoff valve
8. Internal failure Overhaul transmission, or repair
subassembly
B. OVERHEATING
1. High oil Restore proper oil level
2. Clutch failed Rebuild transmission
Causes Remedy
3. Vehicle overloaded Reduce load
4. Low clutch apply pressure Refer to A.
5. Engine water overheated Correct engine overheating
6. Cooler oil water line kinked Clean or replace line
or clogged
C. AERATED (foaming) OIL
1. Incorrect type oil Change oil; use proper type
used
2. High oil level Restore proper oil level
3. Low oil level Restore proper oil level
4. Air entering suction Check oil pump bolts and gasket

side of oil pump
5. Air entering at Check plug seal and seal ring of valve.
clutch cutoff valve
(air actuated)
D. VEHICLE WILL NOT TRAVEL
1. Low clutch apply Refer at A
pressure
2. Selector linkage Repair or connect linkage
broken or
disconnected
3. Internal mechanical Overhaul transmission
failure
E. VEHICLE TRAVELS IN NEUTRAL WHEN ENGINE IS ACCELERATED
1. Selector linkage out Adjust linkage

of adjustment
2. Clutch failed (won't Overhaul transmission
release)
Causes Remedy
F. VEHICLE LACKS POWER AND ACCELERATION AT LOW SPEED
1. Low clutch apply Refer to A

pressure
2. Low converter Refer to A
out pressure
3. Engine Check engine; refer to engine service manual
malfunction
4. Aerated oil Refer to C
G. CLUTCH CUT-OFF VALVE INEFFECTIVE
1. Valve or plug Rebuild control valve body assembly
sticking
2. Brake apply Check pressure at control valve (min-max limit
hydraulic pressure - 9.15 kg/cm2 -140.7 kg/cm2)
incorrect
3. Brake apply air
pressure not Check air cylinder (15.85 kg force required to
reaching air stroke valve)
cylinder
4. Plunger sticking
Check operation of air cylinder
in air cylinder
5. Air entering at
valve (air Check operation of air cylinder (seals)
actuated)
18.0 MAINTENANCE OF VENTRA DROP GEAR BOX
General
Ventra drop gearbox is a single stage gearbox, all the bearing
and gear s are adequately rated to give a longer life. This gearbox
transmits the power from converter/ transmission to the rear axle
drive gearbox through cardan shaft of adequate design.
Description
The input flange is key mounted on the input pinion shaft, which
runs on the spherical roller bearings. The input pinion is meshed
without put gear, which is key mounted on the output shaft. The
output flange is key mounted on output shaft. The output shaft runs
on spherical roller bearings. The gears and bearing are lubricated
through pipe by means of a Hypo pump mounted on the output shaft.
Oil seals are provided at input and output end to prevent the oil oozing
through the end covers
18.1 Maintenance
1. Daily oil level to be checked through the level plug /indicator, if

necessary, top up the oil.
2. Daily check the oil leakage through input, out put oil seals, through
the end cover s and through housing joints etc. if so, rectify the oil
leakage by changing the new oil seals or by tightening the
respective bolts and nuts.
3. Once in a week take out the magnetic drain plug from the gear
boxes and check for any wear out particles or debris, if heavier
particles found, the gear box has to be opened and checked.
4. For the new gears, first oil changing period is one month Then once
in three months, the specified oil to be changed
Note: Before changing the equivalent oil, clean the gearbox with
kerosene or diesel. Then pour the equivalent oil and drain out 1/2
to 1 litre of the same oil through the drain plug. Then put the oil
little above the level plug / indicator
5. Breather must be cleaned thoroughly once in three months.
18.2 Ventra Axle Drive Maintenance Schedule
The final drive to the tower wagon is affected by the axle

mounted right angle drive gear box. The input and intermediate shaft
run spherical roller bearing. The axle also run on spherical roller
bearing the gear box housings have been provided with oil pockets
and gears and bearings get abundant lubrication. The bottom housing
serves as the oil sump. Level, drain plug and inspection door have
been provided for regular maintenance.
1. Daily oil level to be checked through the level plug and if

necessary top up with the same oil (please refer oil chart for
quantity/grade).
2. Check for oil leakage through oil seals and housing joints. Seal
are to be replaces or housings are to be tightened according to
the prescribed tightened torque, if necessary.
3. Once in a fortnightly take out the magnetic drain plug from the
gear box and check for any wear particles or debris; if heavier
particles are found the gear box has to be inspected by opening
the cover at the top.
Note for Change of Oil
For a new gear box, first oil change shall be done after one
month. During changing, clean the gear box with kerosene or diesel
after draining out the sump. Pour the recommended/equivalent oil and
drain out 1/2 to 1 litre oil again. Close the drain. Fill the sump with
specified quality.
Periodicity for change of oil - every three months.
18.3 Maintenance of KPC HYDRAULIC transmission

18.3.1 Maintenance
18.3.2 Hydraulic system
a. The oil capacity of transmission is 20 litres.
b. Oil level should be checked daily through the oil level gauge in
transmission. Oil level should be checked at idling engine speed, it
should be between high & low marks.
c. Oil must be changed after 1000 Hrs. of operation.

d. Drain valve is provided for draining the oil without loss. Connect hose
to the drain valve and then open the valve.
e. Fill the oil in transmission through breather cap hole. Run the engine
and check the oil level. Replace the breather cap or alternatively,
remove plug provided on cover top & fill oil. Refit plug after oil filling.
f. Replace filter element as per recommendations. Remove the filter
cover and replace filter element. Use new gasket, if necessary, for
the filter cover.
g. Suction strainer: Unscrew plug on top of strainer housing for
strainer removal. Clean strainer throughly by flushing in clean diesel
oil. All foreign particles must be removed from the strainer before
refitting it. Ensure air tightness after replacing plug on housing
strainer. Thread sealing compound may be used to avoid leakage of
air in to the circuit.
h. Remove the breather assembly every 1000 Hrs. of operation. Flush
the oil breather assembly.
18.3.3 Inspection - Daily
a. Check oil level. Add if necessary.

b. Check all pipelines, end connections for leakages. Replace damaged
parts to stop leakages.
c. Check all pressure/ temperature gauges for proper functioning.
Replace damaged gauge immediately.
d. Check oil leakage from oil seal bolted joints. Replace damaged oil
seals. Tighten loose bolts/ screw to stop leakages from joints.
18.3.4 Inspection – Weekly

a Check strainer and clean.
b Check filters element and clean if necessary.
c Check and tighten all bolted joints including mounting bolts.
18.3.5 Inspection After Each 1000hrs Of Operation
a Change oil in the sump and fill new recommended oil

b Clean selector valve.
c Check all gauges for their correctness.
18.3.6 Periodic Overhaul
A complete over haul of the transmission should be done

simultaneously with overhauling of engine. The period is
approximately 4000 Hrs of operation or 18 month whichever is earlier.
19.0 TROUBLE SHOOTING OF KPC HYDRAULIC TRANSMISSION
Symptom Cause Remedy

Over a. Insufficient heat a) Install heat exchanger of
heating exchanger capacity. sufficient capacity.
b. Insufficient cooling b) Check pipe lines and heat
water flow. exchanger for clogging. Check
correctness of pipe size used.
c. Clutch slipping. c) Low clutch oil pressure (see
low oil pressure).
d. Oil level too high. d) Correct oil level.
e. Improper oil. e) Use only recommended oils.
f. Clutch plates warped f) Replace clutch plates.
Low oil a) Clogged strainer. a) Remove & clean strainer .
pressure b) Stuck pressure b) Remove selector valve
regulation piston in assembly and clean piston.
selector valve
assembly.
c) Broken piston rings in c) Disassemble clutches and
clutches. replace piston rings.
d) Damaged or worn oil d) Remove oil pump. Replace
pump assly. damaged /worn assly.
e) Clogged or plugged e) Remove orifice plate and clean
orifice plate in selector
valve assembly.
f) Low oil level. f) Add. oil to maintain proper oil
level.
g) Foamed oil. g) Check for air leak in suction
line.
No oil a) Faulty pressure gauge a) Replace pressure gauge .
pressure
b) Low oil level or empty b) Check gaskets, seals for
sump . leakage. Replace parts causing
leakage. Maintain correct oil
level.
c) Fully clogged oil c) Remove & clean it.
strainer.
d) Damaged oil pump. d) Replace oil pump.
Poor a) Low oil pressure. a) Add oil to maintain oil level.
performa b) Improper oil. b) Use recommended oil .
nce c) Clutch slipping c) Disassemble clutch
assemblies.check clutch plates
and replace worn-out or

damaged plates.
Excessive a) Air leak in suction a) Check and tighten all joints.

Noise line of the sump. Replace damaged end
fittings/hoses /pipes.
b) Disassemble transmission.
b) Bearing failure Replace damaged bearings.
Neutral a) clutch plates warped. a) Replace clutch plates.
20.0 KPC Axle Drive Maintenance Schedule

1. Periodic maintenance
Daily - Check oil level daily. It should be at the upper mark. Refill
the oil, if the level has dropped below the minimum mark. Be sure
to use the same oil brand.
Check the bolts and screws and re-tighten if necessary.
Inspect the torque reaction rod assembly and its mounting to base
frame.
2. Every 375,000 Kms
Subject all parts to an intermediate inspection. Check the bearing
pattern on the bevel gear drive. Check the taper roller bearings for
proper axial clearances.
3. Every 750,000 Kms.
Subject all components to a major inspection and replace if
necessary.
4. Oil Change
After a new axle drive has been in use for 50 Hrs., the oil must be
changed. Further oil change must be made after every 6000 Hours
of operation.
Remove the oil drain plug to drain the oil from the drive. If
excessive metal particle are detected on the magnetic plug or in the
oil, it shows that some components have rubbed each other. Open
the axle drive and inspect, Remove the plunger type pump and
clean pump strainer.
Clean the housing from oil sludge. Replace the drain plug. Fill
with new filtered oil through the filler neck.
5. Axial clearance check, Tapered Roller Bearings:
Proceed in accordance with the guidelines and instructions. The
bearing clearance must be maintained.
6. Check of Bearing Pattern, Bevel Gear Drive:
To enable this inspection the axle drive must be opened. Lightly

coat three or four teeth on bevel pinion with blue coloring. Rotate the
driven gear by hand. Check the bearing pattern on the contact
surfaces. The bearing pattern should be centered on the working
surface or pointing a little toward the minor diameter. If the bearing
pattern falls short of this requirement, readjust.
BRAKE SYSTEM
21.0 Air Pressure System
21.1 Introduction
Air pressure system in the Tower car mark III carry out the
following operations -
i) Operation of the brake cylinders
ii) Control system
iii) Signal Horns
iv) Parking brake
When the power pack of tower car works, the entire air pressure
system is charged by the integrated diesel engine air compressor. The
main reservoir pressure is kept between 7 to 8 kg/cm2 with the help
of governor, time relay auto drain valve (fitted with main reservoir)
and unloader. There is one another Safety valve set at 9.5 kg/cm2
which can save the air pressure system in the worst case, when the
usual safety valve (unloader and auto drain valve with time relay)
fails.
Duplex pressure gauges have been provided in both the Driver’s
cabins which will show the M.R. and B.P. of the air pressure system.
Two nos. gauges have been also provided in the Driver's cabin to show
the Brake cylinder pressure when brake is applied. Another two nos.
gauge have been provided for control system (one in each Driver’s.’s
cabin) One no. of pressure gauge has been provided on control box
which will show the actual pressure receiving by the control system.
There is one air pressure oiler fitted with service pipe line to control
box to facilitate the lubrication of pneumatic valves and equipment
fitted in control board.
Condemned water from the system can be removed by means of

drainage valve provided in air supply tanks. There are 4 nos. of brake
cylinders (one for each wheel) to facilitate perfect brake on the tread
of wheels from both sides.
There are two spring brake actuators provided specially for

parking brake. It can park the Tower car when there is no air in the
system. In the normal running condition due to air pressure, brakes
are in the released condition.
It will function as emergency brakes when the air pressure drops

below the spring break hold off pressure, the spring pushes the piston
and the push rod out to apply the brakes.
21.2 Important valves and their functions.

21.2.1 C3W distributor valve
The C3W distributor valve consists of the following major parts.

i) Main valve
ii) Quiere service valve
iii) Inshot valve
iv) Cut off valve
v) Double release valve
vi) Auxiliary reservoir check valve
vii) Freight to passenger change over device or lock.
viii) Application and release chokes
21.2.2 Operation
The compressed air from brake pipe charges into (CR) control
reservoir of the C3W valve and auxiliary reservoir (AR) through cut off
valves. When the BP pressure is reduced by the Driver's brake valve
due to differential pressure across the main valve diaphragm, the
hollow stem lefts and allow AR pressure into B.C (brake cylinder)
through inshot valve. The B.C pressure also acts on top of the upper
diaphragm bringing the main diaphragm assembly down wards and
finally to cap position. In this position B.C pressure is held against
permissible leaks. Every time B.P. pressure is reduced in steps this
phenomenon repeats.
The quick service valve helps in quick propagation of B.P (Brake
pressure) reduction through the length of the train also. When the B.P.
(Brake pipe pressure) is increased by Driver's brake valve, the hollow
stem of main valve is brought to normal position by neutralizing the
pressure differential across the main valve diaphragm and the B.C.
pressure is released through the hollow stem to the atmosphere. As in
the application, the upper diaphragm balance against upward force
and comes to the lap position. Every time B.P. pressure is increased in
steps, this phenomenon repeats.
There is on lever provided in C3W valve, by pulling it, the brakes
can be released manually. The passenger freight change over device
helps to achieve required brake application and release timings
depending on the type of service either freight on passenger.
22 Spring brake actuator

Function
To produce braking forces at the wheel for parking brake
Operation
In the normal running condition the chamber air is pressurized
and the piston compresses the spring and the brakes are in released
condition.
23 Spring brake application (Parking brake)

When the air pressure in the Chamber is depleted, the spring pushes
the piston and thereby the push rod out and applies the brakes
through the slack adjuster.
24 Emergency brake
When the system air pressure drops below the spring brake hold off
pressure, the spring pushes the piston and the push rod out to apply
the brakes through the slack adjuster.
Mechanical Release
To release the brake temporarily for towing the vehicle, the wind off
nut is unscrewed after loosening the lock nut, thus retracting the push
rod.
Brake Cylinder
In tower car 4 nos. of brake cylinders have been used which have
been fitted at rear end and front end. One brake cylinder works on
each wheel.
When C3W valve BC lines operates, the air pressure rush into
the cylinder and compress the spring and ultimately push out the
piston and apply the brake on wheels treads from both sides with the
help of mechanical levers and brakes shoes. If the driver release the
brake with the help of auto brake valve A9,the pressure is released by
C3W valve as well as through shut off vent type.
25 Auto Brake Valve (A-9 Automatic Valve)
It is valve by which drivers can apply the brake to the tower car
as well as release the brake to run the vehicle (Tower car)
Description
The A-9 Automatic Brake Valve is a compact self-lapping,
pressure maintaining brake valve which is capable of graduating in
application or release of tower wagon brakes. The A-9 Automatic
Brake valve has five positions: Release, minimum Reduction, Full
service, over - reduction and emergency. The full service application
position is preceded by a zone in which brake pipe air is supplied or
exhausted in proportion to brake valve handle movement through this
zone, thus providing the graduation of an automatic application or

release of the tower wagon brakes.
The A-9 Automatic Brake Valve consists of a self-lapping
regulating portion, which supplies or exhausts the brake pipe pressure
and a vent valve which is actuated only when the brake valve handle
is placed in Emergency position for the purpose of venting brake pipe
pressure at an emergency rate.
26 Double check valve

Function
To charge central line in a selected manner from two
independent sources.
Operation
When a pressure differential exists between the two end ports, the
higher air pressure forces the check valve over to seal against its seat
on the low-pressure side. This closes the passage between the low
pressure port and the common port in the body. Air then flows from
the high-pressure port through the common port to the device under
control.
27 A1 Check valve
Check valves are used in pneumatic brake system to allow -

compressed air to flow in one direction only. The A1 check valve is
metal seated check valve and is used in compressor delivery line.
When compressed air flows in the right direction, the valve of the
check valve lifts by the upward air force acting underneath the valve
and allows air to pass through the outlet connection. In case of
reverse flow, the valve is pressed on its seat tightly due to air
pressure acting on top face of the valve.
28 Safety Valve
The J1 safety valve is installed vertically in the main reservoir system,

vents pressure at a pre determine setting to atmosphere in order to
prevent excessive main reservoir pressure build up.
29 Automatic Drain Valve

The automatic drain valve automatically discharges precipitated
moisture from a reservoir with each operating cycle of the control
device.
30 J air filter
The J-air filter function to assist in preventing the passage of dirt and
moisture which may be mixed with the air flowing from the main
reservoir into the air brake equipment.
31 MAINTENANACE OF THE VALVES
Cleaning, Inspecting and Repairing
 With the brake valve completely disassembled, all parts must be cleaned
and inspected.
 All the parts (excepting rubber parts) must be washed in a suitable
solvent that will dissolve oil or grease and permit all the parts to be
thoroughly cleaned without abrasion. The exterior of the body must be
thoroughly cleaned by means of a cloth or rag saturated with a suitable
solvent.
 All Gasket, Diaphragms, and "O" rings must be replaced.
 All Packing rings should be replaced.
 Clean all springs using a wire brush and suitable solvent and inspect for
pitted marks distortion, or permanent set. Replace where necessary.
 Replace all parts that are cracked, broken, worn excessively, damaged or
in such a condition as would result in unsatisfactory operation.
 The spring may be wire brushed to assist in the removal of rust and
scale. After cleaning, blow all metal parts with a low pressure jet of clean
and dry air.
 Promptly blow the parts dry with low pressure jet of clean and dry air.
 Discard the filter unit and replace with a new one.
 Inspect all other parts. Reject and replace any part that is cracked, cut
damaged, worn excessively or is in such a condition that would result in
unsatisfactorily operation.
 The spring must be replaced if it is rusted, distorted or has taken a
permanent set.
 Frequency of overhauling of valves is to be decided by depots depending
upon the utilization of tower wagon. However overhauling is to be carried
out at least once in year.
NOTE : All the gauges and meters are to be calibrated once a year.
MAINTANANCE GUIDELINES AND SCHEDULE (CARRIAGE PART)

OF
4 -WHEELER TOWER CAR
1.0 BODY REPAIRS
(i) Inspection and repair of body members are done after the Tower
Car body is lifted off the wheels and axles are placed on trestles.
(ii) All furnishing and other components from coach shell, which are
stripped, are to be sent to the respective sections for maintenance.
(iii) For major repairing work all the equipments (under slung, onboard
and roof mounted) shall be removed from the Tower Car.
2.0 INSPECTION OF UNDERFRAME
(i) The underframe members should be thoroughly inspected for

locating cracked/bent/corroded members. Corrosion is indicated
by flaking of paint of metal, pitting and scale formation.
Components like sole bar and trough floor which are not visible
from both sides should be examined by tapping with a spiked
hammer , Proper illumination will be required to carry out the
check. A component will require repair / replacement if it has lost
more than 20% of its thickness.
(ii) The underframe and shell members are categorized as vulnerable
and not so vulnerable areas for corrosion.
(iii) Particular attention should be paid to the vulnerable members and
locations listed below: -
 Sole bar, body pillars, and trough floor.
 Sole bars, body pillars above lifting pads.
 Sole bars and pillars behind the door pockets.
 Sole bars and pillars at the door corners.
 Head Stock
 Sole bars and pillar.
(iv) Procedure for inspection of underframe members for corrosion
attention is laid down in RDSO technical pamphlet No C-7602.
2.1 SOLE BAR, BODY PILLAR
(i) Examine visually supplemented by tapping with a spiked hammer

sole bars, body pillars in the bays under after removing the
accumulated dirt and cleaning the surface.
(ii) If incidence of corrosion is noticed in the bottom half of the sole bar,
the trough floor should be cut to a width of 300 mm and requisite
length for examination of inside top half.

(iii) If heavy corrosion is noticed, the sidewall should be cut to a height of
500mm from the bottom of covering sufficient length and all the
exposed parts, after scraping and cleaning should be examined to
determine the extent of corrosion.
2.2 SOLE BAR AND PILLAR ABOVE THE LIFTING PADS
(i) Examine the above members in the same manner as described in

clause 2.1 above.
(ii) If signs of corrosion are noticed, the sidewall sheet above the lifting
pads should be cut to a height of 500mm. above and to a length of
half meter, on either side of lifting pads. Scrape the structural
members, clean and examine minutely to ascertain the extent of
corrosion.
2.3 SOLE BAR AND PILLAR AT THE DOOR CORNERS
Examine the above locations visually. If corrosion is noticed, cut to a

width of half meter from the door corner. Remove accumulated dust.
Structural members should be thoroughly scraped, cleaned and
examined to assess the extent of corrosion.
2.4 SOLE BAR & BODY PILLAR AT LOCATIONS OTHER THAN DESCRIBED
ABOVE
(i) Examine visible portion of sole bar through the end from above of the
underframe.
(ii) Remove the accumulated dust and scrape structural members to the
extent possible. If corrosion is noticed, sidewall sheet in the area of
corrosion should be cut to a height of 450mm from the bottom of
covering for sufficient length for thorough examination.
2.5 HEAD STOCK
(i) Examine visually inner headstock, outer headstock, stiffening

immediately behind the buffers and the junction of the sole bar at the
headstock for incidence of corrosion.
(ii) Examine carefully the base of buffer assembly as corrosion has been
primarily noticed at this location.
(iii) Examine carefully the buffer base of headstock by chalk test or sound
test for cracks and dents. Buffers fixing holes should not be
elongated and no minor cracks to be allowed. Replace headstock if
the wear is more than 4 mm i.e. when the thickness is below 4mm.
2.6 TROUGH FLOOR
(i) Examine the trough floor in the bays adjoining the wash basin and
from below for signs of corrosion, supplemented by tapping with a
spiked hammer.
(ii) If signs of corrosion are noticed in the above examination, the part
should be thoroughly cleaned by scraping and an intensive inspection
should be carried out to detect the extent of corrosion in the trough
floor.
2.7 CORROSION REPAIRS TO UNDERFRAME MEMBERS
(i) Corrosion repairs shall be carried out as per instruction laid down in
RDSO technical pamphlet nos. C-7602
(ii) It is essential to use corrosion resistant steel sheets for corrosion
repairs of tower cars. Welding electrodes and paints should be of the
prescribed quality conforming to the relevant IS/IRS specifications.
 Corrosion resistant steel sheet for trough floor, pillars, sidewall and
roof should conform to IRS M-41.
 Electrode: IRS class A3/B2 of approved brands.
 Paints: Red oxide zinc chromate primer – IS 2074-92. Black
synthetic enamel paint to IS:8662.
(iii) Where the corrosion noticed is of a very minor nature and has just
started, there is no need to renew the parts. In those areas, the
paint and the rust should be thoroughly cleaned to reach the bare
metal and the surface treated with two coats of red oxide zinc
chromate primer to IS:2074-92 to a DFT of 50 microns followed by
two coats of black synthetic enamel paint to IS:8662 to a DFT of 40
microns
(iv) Where the corrosion repairs are carried out on the underframe or its
paint coat is damaged, the underframe should be painted with two
coats of red oxide zinc chromate primer to IS:2074-92 to a DFT of 50
microns followed by two coats of black synthetic enamel paint to
IS:8662 to a DFT of 40 microns.
(v) For carrying out corrosion repairs to underframe members, the Tower
Car body should be lifted off the Wheels & axles and kept on trestles.
For repairs to sidewall and end wall, no lifting is required.
2.8 Head stock

For replacement of headstock, the following parts need to be stripped
first:
 Side buffers
 Compreg board and Aluminum chequered sheet flooring
 End partition and electrical wiring
 Draw gear assembly
 End portion of BP/FP
Before the corroded portion is cut off, the auxiliary headstock and the
two sole bar ends should be firmly supported on trestles. The corroded
headstock is then replaced as per annexure-v of RDSO technical
pamphlet No. C-7602. Only corrosion resistant steel (IRS M-41 or
IS:2062 Fe 410 Cu WC) should be used for head stock repairs.
2.9 SOLE BAR
For carrying out repairs to sole bar, it is necessary to strip first the
interior fittings, laminate paneling and window frames. Before cutting
off the corroded portion of sole bar, both the adjacent ends should be
supported on trestles. The new sole bar piece should be welded from
outside and inside. To facilitate welding from inside, the Tower Car
body should be lifted and kept on trestles.
2.10 CORROSION REPAIR OF SOLE BAR
Repairs to sole bar for replacement of corroded portions at the

locations mentioned below should be carried out as per Annexure-II of
RDSO technical pamphlet No. C-7602
2.11 SIDE WALL MEMBERS
For repairs to side wall sheets, the interior fittings, laminate paneling
and window frames should be stripped first. Corrosion repair of side
wall sheets and body pillars should be done as per annexure-III of
RDSO technical pamphlet No. C-7602.
2.12 TROUGH FLOOR

For replacement of trough floor, first Compreg board and Aluminum
chequered sheet flooring needs to be stripped. Corrosion repairs to
trough floor should be done as per the annexure-IV of RDSO technical
pamphlet No. C-7602.
2.13 ROOF
a) Roof repairs
Tower car, roof should be checked for corrosion. Special
attention should be paid at location where gutter mouldings are
welded and ventilators bolted. Corroded roof should be repaired

according to the instructions given in annexure VII of RDSO
technical pamphlet no. C-7602.
b) TRA type roof ventilators repairs
(i) Examine the roof ventilator for damage or corrosion or

leakage. If no corrosion is observed then seal the joints
and crevices with waterproof sealing agent as per IS/IRS
Specification. Ventilators found beyond repairs should be
replaced as per RDSO technical pamphlet no. C-7602,
Annexure-VII.
(ii) After repairs and refitting, ventilators should be tested for
water leakage at their base joints at the time roof testing.
c) Roof testing
Tower car after POH repairs should be tested under water spray
for roof leakage before they are finally turned out from the
workshop. For this purpose, a fixture designed to simulate
monsoon conditions should be provided in the workshop.
2.14 REPAIRS TO DOOR HANDLES

Examine the door handle for breakage, damages. If the fixing bolts
are loose or missing, tighten the bolts. Replace the door handles,
which are found beyond repairs.
2.15 REPAIRS OF BODY SIDE DOOR

The body side doors shall be repaired as per annexure VIII of RDSO
technical pamphlet no. C-7602
2.16 REPAIRS TO DOOR PIVOTS

Examine the door pivots for corrosion, breakage or wear by cutting
the bottom portion of outer panel. Cut the corroded portion of the
door pillar (Z molding) and weld new piece joining the door pivot
pin. If the female socket is worn or damaged beyond repairs then
replace it. Replace the bush provided in the socket.
2.17 REPAIRS TO PARTITION WALL PILLAR/MOUNTING PLATE

Examine pillar/mounting plate for corrosion or breakage, etc. at
bottom ends. If found corroded, repair the same as per RDSO
technical pamphlet no. C-7602
2.18 REPAIRS TO DRAW AND BUFFING GEAR SUPPORT STRUCTURE

(i) Examine the draw gear support structure for corrosion,

breakage, etc. If the corrosion is light, scrap off the rust to
bare metal, clean well and re-paint. If the corrosion is heavy,
replace the corroded angle or gusset plate with new support
angle.
(ii) Similarly examine the buffing gear support structure for
corrosion, breakage, etc. if the corrosion is light, scrap off the
rust to bare metal, clean well and re-paint. If the corrosion is
heavy, replace the corroded angle or stiffeners.
(iii) Examine the body bolster for corrosion, breakage, wear, etc.
If the corrosion is light, scrap off the rust to bare metal, clean
well and re-paint. If the corrosion, breakage or wear are
beyond repair, replace the body bolster. Check the area
surrounding centre pivot pin mounting holes for cracks.
2.19 WATER TANK SUPPORT STRUCTURE

Examine the water tank support structure for corrosion, breakage,
wear, etc. if the corrosion is light, scrap off the rust to bare metal,
clean well and re-paint. If the corrosion, breakages are beyond
repair, replace the corroded angle with new angle of suitable size as
per the requirement. Replace the rubber/wooden packing if perished
or damaged.
2.20 REPAIRS TO THE FLOOR CHANNEL

Examine the floor channel for corrosion, breakage, wear, etc. by
cutting open the Compreg board and Aluminum chequered sheet
flooring where the corrosion is suspected. If the corrosion is light,
scrap off the rust to bare metal, clean well and re-paint. If the
corrosion, breakages are beyond repair, replace the corroded
channels with new channel of suitable size as per the requirement.
2.21 GENERAL
(i) All repairs of cracks should be carried out by gouging and

welding by suitable electrodes.
(ii) CAUTION: No electric welding on the Tower Car should be
carried out without proper earthing from near the portion
being welded. And in no case the earthing through Axle
box/wheels and rails shall be permitted. In the absence of
such earthing, the return current passes through axle roller
bearings causing pitting of rollers and bearing failure in
service.
(iii) Distorted and bent parts should be heated and straightened.
(iv) The parts used for repairs should be given proper surface
treatment and applied with protective paint. Relatively thick
sections such as sole bars, cross bearers, etc. should
preferably be grit blasted and immediately thereafter given a
protective coat of red oxide zinc chromate primer paint.
(v) Welder’s Qualification: Welders deputed to carry out welding
work on coaches and coach components should be only those
tested and certified as adequately skilled for welding work on
coaches and coach components.
2.22 LIST OF TOOLS AND PLANTS
Lifting shop Corrosion repair shop

1. EOT cranes 1. EOT cranes
2. Trestles for Tower Car 2. Trestles for Tower Car body
body
3. Inspection torches 3. Gas cutting plants
4. Spiked hammers 4. Multi-operator welding plants
5. Ball peen hammers 5. CO2 welding plant
6. Goggles for inspection 6. Electrical angle grinders
staff
7. Measuring tape 7. Pneumatic hand grinders
8. Measuring scale 8. Component painting equipment
9. Safe guard for safety of 9. Phosphating plant
heads of inspecting staff.
2.23 Examination and repair practice in maintenance depot shall be as per

Annexure – IV.
Annexure -II
SUSPENSION, WHEEL & AXLES
1.0 BRIEF DESCRIPTION OF SUSPENSION
Suspension arrangement for 4-W Tower car (Except Mark-III) consists of

helical springs working in parallel with hydraulic shock absorbers. Axles
with their self-aligning spherical roller bearings mounted inside cast steel
axle boxes are guided by axle guide assemblies.
Following are leading particulars of the 4-Wheeler Tower car:-
Particulars 4-Wheeler Tower car

BEML/PHOOLTAS/ BHEL JAMALPUR
VENTRA Mark-III Mark-IV
Rigid Wheel Base 6100 mm 6100 6100 6100 mm 6100 mm
mm mm
Diameter of 915 mm. 915 mm. 952 952 mm 915 mm.
wheel on Tread. mm
Axle Load 16 t 16 t 16 t 16 t 16 t
2.0 FEATURES WHICH CONTRIBUTES TO IMPROVED RIDING COMFORTS

(Except Mark III)
Axles mounted on self-aligning spherical/cylindrical roller bearings, with

helical springs working in parallel with shock absorbers of specified
characteristics have all contributed to superior riding comforts. It is
therefore, essential to ensure that these features are well maintained in
service so as to obtain the desired performance throughout the life of the
4W-Tower Car.
Riding comfort offered by the 4W-Tower car depends exclusively on above

design features and unless they are properly maintained and attended
during periodical maintenance schedules & overhauls, riding deteriorates
leading to subsequent heavier and costly maintenance.
3.0 OVERHAULING (Except Mark III)
TOWER Car suspensions are designed for good riding comforts with the help
of self aligning spherical roller bearings, hydraulic shock absorber, helical
springs for suspensions. Proper handling and maintenance of these will
result in longer life and satisfactory service performance.
Tower Car requires to be given thorough periodical over haul (POH). The
intermediate overhaul (IOH) as per the details given in Annexure-IV.
While carrying out the overhauls instructions as given in the following
paragraphs should be strictly followed.
3.1 LIFTING THE BODY OFF THE SUSPENSION (For all OHE Car)
Tower car body can be lifted off the suspension by either:

(i) Two electric cranes of minimum 10t capacity each with suitably
designed swings and cradles, or
(ii) Four Hydraulic/electrical lifting jacks of 10t capacity each
simultaneously operated by single control switch. The 4-W
Tower Car should not be lifted from any other point but from
lifting pads.
Note: Under no circumstances a lifting jack or sling should be

applied on at any other location except on lifting pads in
the workshops.
(iii) Cranes or jacks used for lifting should be operated uniformly
and simultaneously without jerks, before lifting the 4-W Tower
car, following components should be disconnected.
(a) Propeller shaft (For Diesel Hydraulic) coupling connecting

axle drive
(b) Standstill detector connected on axle drive
(c) Speedometer cable connection on axle drive
(d) Disengage all axle box safety straps
(e) Torque arm assembly connecting axle drive and
underframe
(f) Shock absorbers connecting axle box and underframe
(g) Brake tie members and brake block hanger bracket
(h) Safety chain link connection axle drive with underframe
(i) Motor connections (For Diesel Electric Tower Car)
Note: Before finally lifting 4-Wheeler Tower car body, the axle drive should
be supported by steel/wooden blocks of requisite thickness, so as to
avoid the axle drive from overturning in case of hydraulic
transmission.
Tower Car should never be lifted from one end only as the axle guides
and lower spring seats are likely to suffer damage and dents may
occur on body panel. The 4-Wheeler Tower car may be lifted by
means of a crane or screw jacks as mentioned above till all the 8 guide
bushes disengage from the lower springs seats and wheels are rolled
out.
3.2 ATTENTION TO SUSPENSION COIL COMPONENTS (Except Mark III)
Following attention should be paid to 4-W Tower car suspension

components during POH before assembling them.
(i) After through cleaning check for any possible cracks,

particularly at places where axle guide flanges and safety strap
bracket are welded. Circlip groove should also be checked for
damages. Normally squareness and alignment of axle guide
does not require checking. If biased wheel flange wear or wear
in the rear cover of the roller bearing axle box have been
observed, the squareness of guides and their alignment should
be checked thoroughly with the help of alignment gauges. In
the event of misalignment of axle guides or damaged guides,
which require replacement, following procedure may be
adopted.
(a) Whenever a axle guide is damaged it is to be replaced.
(b) Where the measurements of guides shows a deviation from the
dimension given in fig.1 (Applicable for BEML 4 Wheeler Tower
Car only .For other make of tower cars their Trammeling
Drawing can be obtained from their respective manufacturer).
The concerned pair of guides should be cut and re-welded in
position. Guide should always be cut in pairs, as the adjacent
guide distance has to be maintained. In case of BEML it is
630+1 mm .
(c) While cutting out guides, care should be taken that only weld
metal is cut and guide flange or underframe is not damaged.
(d) Guides which are cutout, need not be scrapped but the flange
periphery should be built up by welding wherever spoiled or
pitted by gas cutting and ground to shape, care should be
taken not to damage the circlip groove of the guide cap.
(e) For re-welding of axle guide:-
 Locate new guide with the aid of setting gauges with
reference to other guides. Two gauges, one giving the
longitudinal and other diagonal location in relation to other
guides are sufficient to locate it. However, a third gauge be
used as a counter-check. Tack weld the guide to
underframe.
 Remove the gauge and complete the welding.
 Allow the frame to cool off.
 Check the dimension of the guide in relation to others with
the aid of master gauges.

 Check also the height of the guide in relation to other
guides with a straight edge.
 Use low hydrogen electrodes of approved brand for welding
(Electrodes under IRS Class A3/A4 may be used).
 Important dimensions to be checked after rectification.
 The crown clearance between the rubber pad and the axle
box shall be as per following table.
BEML VENTRA BHEL PHOOLTAS

JAMALPUR
Mark-III Mark-IV
125 +0/- 130 +0/- 50 +0/- 92 ± 5mm NA 110 +0/-
5mm. 5mm 5mm 5mm
The rubber pad is to be adjusted every time the timber packing are
inserted between the lower spring seat and the lower rubber washer
to compensate tyre wear, so as to obtain the prescribed clearance
between axle box crown and the rubber pad.
3.3 WHEELS AND AXLES (For all Tower Cars)
(i) The leading dimensions of powered wheels and axles set should
be checked as per respective drawings of different
manufacturers as mentioned in Annexure III These wheels are
clearly marked with their axle capacity and should not be
interchanged with other wheels under any circumstances
(ii) The wheel profile should be checked to RDSO SK. No.91146
Alt.3 profile Fig. 2 If the profile is found worn out, it should be
re turned.
(iii) Variation in the tread diameter of the wheel on the same axle
should not exceed 0.5mm. Large variation in wheel diameter
will lead to biased flange wear. The variation in wheel diameter
between one pair of wheels and the other should not exceed
13mm.
(iv) Wheel gauge should be within the tolerance of +/-1mm.
(v) Under no circumstances, wheels, which have reached the
condemning, limit, as indicated by grooves on the wheel
rim/tyre should be used.
(vi) In case any wheel is de-wheeled and repressed on, the pressing
on pressure and the wheel gauge tolerance shown in as per
respective drawings of different manufacturers as mentioned in
Annexure III should be strictly adhered to and a record of wheel
pressing on pressure maintained.
3.4 ROLLER BEARINGS (For all 4 W Tower Cars)
Axle boxes are fitted with roller bearing as per Drawing mentioned in
Annexure III.
(a) LUBRICATION OF ROLLER BEARINGS
The quantity of grease required to be filled in axle box during

renewal is given below:
SKF bearing – 2 kg
FAG bearing – 1.5 kg
The list of approved brands of grease is given below:-
Supplier Type of bearing

SKF FAG
IOCL Servogem 3 Servogem 3
HPCL - Lithon 3
BPCL - Polypak 3
Different types of grease should not be mixed together.
(b) INSPECTION OF ROLLER BEARING (For all 4 W Tower Cars)
(i) Thoroughly clean the exterior of axle box and then remove the
front cover from the body casting.
(ii) Examine the grease, if it is discoloured fully, bearing should be
dismounted and thoroughly inspected. If the grease is in good
condition, bearing need not be dismounted, but be washed and
cleaned in position with petrol or white spirit.
(iii) When dismounted, scoop out all accessible grease by the
hand and by using a rubber scraper take out all grease.
Wash the bearing with spirit or petrol.
Ensure that tracks, rollers and cages of bearing are free from
damage. Measure the bearing clearance using a feeler, if the
roller and tracks are not pitted or flaked and cage is not worn,
In case of Spherical roller Bearing check that rollers do not fall
out when the outer ring is swiveled at an angle, bearing is in
good condition. The following bearing clearances for new as
well as in service self-aligned spherical roller bearing for BG
Tower Cars may be followed:-
Bearing Make Radial Clearance in un- Radial Clearance in mounted

mounted condition condition (mm)
(mm)
New In service New Bearings In service
Bearings bearings bearings
FAG/NORMA 0.145 - 0.270 0.080 - 0.160 0.220 Max
0.190 Max.
NEI/NBC 0.145 ~ 0.295 0.080 ~ 0.160 0.245 Max
0.190 Max.
(c) DISMANTLING
Roller bearing can be dismounted as described below:
(i) Straighten the folded tabs of the triangular locking plate, unscrew the
hexagon and screws holding the securing cup. Remove the securing
cup. Then push the injector adapter ring on the journal against the
bearing and clamp it firmly against the bearing inner ring. Connect
the oil injection pump capable of developing a minimum pressure of
740kg/sq.cm to the adaptor ring and pump in thick cylinder oil, so that
a film of oil is formed between the bearing and the axle journal.
Remove the adapter ring as soon as the oil firm is formed. Fit the
withdrawal tool over the bearing outer ring, then push the locking ring
forward, so that the claws of the sleeve engage the inside face of the
bearing outer ring. Due to oil film between the journal and inner ring
the bearing can be easily dismounted by turning the withdrawal screw.
(ii) After removing the bearing, remove the rear cover and the sealing
ring.
(iii) Wash and examine the bearing and other components.
(d) FELT SEALING RING

The felt sealing ring should be examined and if found damaged,
replace it. However, it is advisable that every alternate POH, the felt
ring is renewed.
(e) MOUNTING OF ROLLER BEARING AND AXLE BOX
(i) Soak felt ring in cylinder oil to IS:1589-60 Type-I Gr-3 heated to
40oC - 50 oC for 30 minutes and fit in the groove in rear cover.
(ii) Clean and examine journal and ensure that threaded holes for locking
screw are perfect.
(iii) The collar may be shrunk fitted on axle journal after heating the
collar in a neutral oil bath or by an Induction heater, with the help of
a mounting sleeve. Make sure that the collar firmly butts against
journal shoulder.
(iv) Fit the rear cover with four bolts alongwith rubber ‘O’ ring and felt
sealing ring in position. Fill in the ‘V’ grooves and the cavity in the
rear cover upto the face of the ring with approved brand of grease.
(v) Heat the roller bearing in a hot oil bath or an Induction heater and
slide it over the journal carefully with the help of a mounting tool.
Push the bearing forward till it firmly butts against the ring. The
stamped face of the bearing should be kept outwards while fitting the
bearing so that the stamping can be seen during inspection. After
the bearing cools off, pack the bearing with grease.
(vi) Assemble the required securing cup and lock plate with hexagon
screw The securing screw is locked by bending over the tabs provided
in the locking plate against flat of bolt heads.
(vii) Liberally, smear inside of axle box with grease and fit it over the
bearing. Put the required front cover with sealing rings and tighten
up bolts and lock the nuts with split pins.
(viii) Check if the axle box can be rotated freely by hand.
The working space for mounting and dismounting of roller bearing
must be absolutely clean and the table on which roller bearings are
cleaned must be free from iron filings, dust, etc. Kerosene oil may
be used for cleaning the roller bearing and journals. The cleaning
bath should be changed every time to keep it free from dust and
foreign matter. Steel trays with lids should be used for cleaning
roller bearing.
3.5 AXLE BOX HOUSING
Roller bearings are housed in accurately machined cast steel axle

boxes. The axle boxes are also provided with cast iron Front cover
and light alloy back covers secured by four bolts. Axle boxes and
covers should be thoroughly cleaned and checked for cracks
particularly at the bolt holes of the covers, which have shown
proneness to failures. The bolts should be examined for worn threads,
straightness etc. before reuse and should be well tightened and
locked by spring washers and split pins to ensure that the covers and
the axle box housing form a water-tight assembly and protect bearing
from dust and moisture.
3.6 AXLE BOX SPRINGS (Except Mark –III)
Axle box springs are as per respective drawings of different

manufacturers as mentioned in Annexure III manufactured as per RDSO
spec. WD-01-HLS-Latest Revision/Amendment. It is necessary to check
these springs for cracks and measure their free height to ensure that
they meet the design requirements.
All the springs shall be grouped in categories and used on bogies as per
instructions detailed in RDSO technical pamphlet no.C-8419 (latest
revision/amendment).
Top and bottom faces of these springs should be ground parallel if

necessary as both ends bear against flat surfaces and the inclination in
vertical axis corrected to fall within the tolerances specified on their
respective drawings
3.7 LOWER SPRING SEAT (Except Mark –III)
Lower spring seat on axle box wing in which guide bush moves up and
down does not normally wear in service. If the surface is worn more
than 0.4mm in diameter or if the surface is scored or other wise
damaged, the lower spring seat should be replaced. The lower spring
seats should be carefully checked for cracks before reuse. During POH
clean the inner surface of lower spring seat and smear all-round the
honed face with Axle box roller bearing grease.
3.8 AXLE GUIDE ASSEMBLIES (Except Mark –III)
Axle box set guides are accurately machined and welded to the
underframe to ensure that the wheel set are guided in parallel, these
guides are fitted with bushes at the lower end to guide the wheel set
both in lateral and longitudinal direction.
Following components which form the axle guide assembly should be

thoroughly examined and renewed as indicated:
1. Guide Circlip groove is damaged.

2. Upper spring Damaged, dented or seat or protective tube cracked
3. Dust shield Distorted or broken spring or otherwise defective
4. Dust shield Examine at every POH change if required
5. Guide ring Cracked broken or worn
6. Circlip Replace if bent or worn-out
7. Guide bush Worn out more than 1.2mm in diameter
8. Lower rubber Distorted or damaged
9. Upper rubber Distorted or damaged washer
In case of the total diametric clearance is more than 1.6mm between

the guide and the lower spring seat based on maximum bore diameter
and minimum bush diameter the component worn out should be

replaced.
l) SHOCK ABSORBERS (Except Mark –III)
Hydraulic shock absorbers are set to offer resistance as per following

table. Shock absorbers are fitted to work in parallel with axle springs.
These shock absorbers normally give trouble-free service and require no
attention in between two POHs
BEML VENTRA BHEL PHOOLTAS

JAMALPUR
Mark- Mark-IV
III
250 kg / 275 Kg/ 475 kg 250 kg NA 250kg/10cm/sec
10cm/sec 10cm/se /10cm/sec /10cm/sec
c
However, a shock absorber, which is found either leaking or physically

damaged, should be renewed. As the resistance of these shock
absorbers is likely to deteriorate in service, it is necessary to attend to
them. The shock absorbers can be got overhauled from their respective
manufacturers, tested and renewed as and when required.
3.10 ACTION TO BE TAKEN BEFORE REASSEMBLING THE SUSPENSION

(Except Mark III)
After attending to the various components as detailed above the

suspension may be reassembled taking into consideration the following
aspects.
(i) The two wheel and axle sets selected for the 4-Wheeler Tower car
should not have variation of more than 13mm on tread diameter
(ii) The two pairs of axle box springs selected for each axle should
not vary in their tare height by more than +/-3 mm and their
load deflection characteristics should be as per RDSO specification
WD-01-HLS (Latest revision/Amendment).
(iii) Packing rings of requisite thickness to be selected for use on
lower spring seat for taking up the wheel wear.
(iv) Top and bottom rubber pads on the axle box spring should not be
used again if they are not in good condition.
3.11 SEQUENCE OF REASSEMBLING THE SUSPENSION (Except Mark –III)
(i) Assemble the roller bearing and axle boxes and ensure that the
bearing is effectively secured.
(ii) Smear the honed surface of lower spring seat with roller
bearing grease. Place the lower rubber washer on axle box
wing and insert the helical spring on the lower springs seats
with rubber ring and compensating ring. Wooden packing to be
added if required to compensate for wheel wear.
(iii) Insert upper rubber washer, top spring seat, dust shield spring,
dust shield, guide ring and guide bush on the axle box guide
and lock the bush in the position with circlip.
(iv) Lower the 4-W Tower car body on the wheel and axle sets
taking care to ensure that all the 8 guide bushes engage lower
spring seat and the body is set evenly on the 4 axle boxes.
(v) Assemble propeller shaft coupling connecting with axle drive.
(vi) Assemble torque arm connecting axle drive with underframe.
(vii) Connect speedometer cable and standstill detector.
(viii) Engage all axle box straps.
(ix) Shock absorbers connecting axle box and underframe to be
bolted.
(x) Connect brake tie members and brake block hanger bracket
with pins.
(xi) Touch up the paint on the suspension with one coat of anti-
corrosive black paint.
(xii) Connect TM cable in case of Diesel Electric Tower Cars.
4.0 RUNNING CLEARANCES (Except Mark –III)
After assembling suspension and lowering 4-W Tower car body, the
clearances between the 3.2) above & to be maintained accordingly.
Suitable packing shall be used to maintain dimension when wooden
packing is given on axle box to compensate for wheel wear.
5.0 ATTENTION REQUIRED FOR SUSPENSIONS ON OPEN LINES AT

DEPOTS.
(i) Lifting the body off the suspension, instruction contained in para
3.1 above should be strictly adhered to while lifting the body off
the suspension.
(ii) Sick lines should not try to weld a damaged axle box guide or
replace the same. The 4-Wheeler Tower car should be sent to
workshops for welding the guide and checking the alignment of
guides.
(iii) The instructions contained in Conference Rules, Part IV for the

examination of wheel profile, axle should be strictly adhered to.
Wheel sets showing biased flange wear, i.e. one flange wearing
faster than the other should be with drawn from service and sent
to shops for examination and rectification. 4-W Tower car have
been provided with 16 tonnes wheel and axle sets, which are
marked clearly on the wheels. It is important that these wheels
are not mixed up with the 13 tonnes axle wheel assembly, which
is used on other stocks.
Note: Max. permissible flat on wheels of these coaches should be

limited to 50mm.
(iv) Roller bearing should not be attended to in sicklines. All that
would be necessary in service is to feel the axle boxes at train
examining stations for any tendencies on their part to get
overheated. If any axle box shows a tendency to run hot, the 4-
Wheeler Tower car should be sent to shops for attention.
(v) Four bolts securing the rear and front cover of the axle box shall
be examined to ensure correct assembly with spring washer and
split pins.
(vi) Whenever a spring is to be replaced, it should be ensured that the
variation in the height of the spring with respect to the other
springs forming the suspension already on the 4-W Tower car
should not be more than 6 mm. Difference upto 6mm should be
made by insertion of suitable steel packing.
(vii) For this purpose, it is necessary that the sicklines should have an
imprest of axle box springs duly tested and certified to conform to
the instructions contained in para 3.10).
(viii) If hydraulic shock absorbers used on suspension show any sign of
oil leakage or other damages, the same should be replaced with a
shock absorber completely overhauled. For this purpose, the
sicklines should maintain ‘imprest’ for use as unit change
assemblies. Leaking shock absorbers should be sent to the
workshop for overhauling. The shock absorbers should be checked
to ensure that the bolts securing it are properly tight and locked.
(ix) The brake blocks should be replaced when worn out to a
thickness of 20mm For BEML.
(x) Straps for the axle boxes, should be checked for proper securing
arrangement and for adequate running clearances.
(xi) If hard wooden packing are required to be used on lower spring
seats for taking up the wheel wear, the packing of proper
thickness should be used.
(xii) Under no circumstances wheels, which have reached the
condemning limit, indicated by the grooves on the wheel
rims/tyres should be used.

(xiii) Tower car should not be allowed to run in service with a broken
axle guide or broken spring. 4-W Tower car should be
immediately sent to shops for replacing the broken axle guides
or broken springs.
6.0 MAINTENANCE OF GUIDE LINES FOR SUSPENSION OF 4 WHEELER

Tower CAR (Mark III)
(a) As Mark III Tower Car is fitted with laminated bearing spring
unlike other tower cars. Therefore, the inspection and
maintenance of the suspension system should be done as per
following procedure.
S.No. Description of item Inspection criteria
1 Shackle Visually examine the shackle, check
the dimension for inner gap
357x62, wear limit is 1 mm for both
sides.
2 Horn cheek Visually examine the horn cheek.
Check the horn gap (285mm). The
wear limit of rubbing surface is
1mm.
3 Shackle pin Visually examine the shackle pin,
check the dia. of pin (Ø 35mm),
wear limit is 0.5mm.
4 Suspension arrangement The axle box housing clearance
from axle guard horn is 10mm at
either sides and lateral clearance is
20mm (either side)
b. LEAF SPRING REPAIR
Following procedure should be adopted for leaf spring repair of Mark -

III Tower car.
(i) Physically examine whether any spring plate/buckle and spring

clip are broken. The springs are tested by scragging.
(ii) Check camber and free camber whether it is within limits or not.
(iii) If any plate spring clip and buckle is found broken the same is to
be replaced.
(iv) If Camber and free camber are not within limits it is to corrected.
(v) The spring is debuckled and is checked by scragging. Then
spring is to be buckled. After clipping the spring is to be riveted.
(vi) Load test is to be done.
(vii) The Free camber is 146 +6 mm.
7.0 BRAKE GEAR
(i) Maximum radial clearance of 1mm between the brake gear pins and
bushes is permitted. If the clearance is more, the worn out part
should be replaced and the standard clearance maintained
(ii) Brake block should be replaced when they wear out to the specified
thickness. For BEML the thickness is of 20mm.
(iii) An adjusting palm pull rod with holes at regular intervals is provided
in the brake rigging to take up slack in the rigging due to wheel
wear. Adjustment should be done by relocating the pin in different
holes on the palm pull rod.
8.0 WIND SCREEN WIPER
(i) Windscreen wipers should be checked for its operation only on the
wet windscreen. If wiping is not proper the wiper blade has to be
replaced.
(ii) The wiper arm and blade assembly shall be to RDSO Specification
No, C-K306 (Latest revision).
Annexure III
LIST OF THE REFERENCE DRAWINGS
Following are the lists of the drawing for 4-wheeler tower Car
manufactured by different vendors.
1 Drawing no. of M/s BEML’s 4 Wheeler Tower Car.
SN Description Drawing no.

(i) Powered wheel and axle BEML drg. No.907-81009
(ii) Non-powered wheel and axle BEML drg. No.907-81010
(iii) Axle box springs BEML drg. No. 907-81105
(iv) Guide 907-81002
(v) Upper spring 907-81007
(vi) Dust shield 903-81110
(vii) Dust shield 411-81114
(viii) Guide ring 903-81156
(ix) Circlip 411-81160
(x) Guide bush 411-81161
(xi) Lower rubber 903-81139-P.2
(xii) Upper rubber 903-81140
(xiii) Bearing SKF no.22328C/C3
(xiv) Felt ICF/M/D/SPEC-001
2 Drawing no. of M/s Phooltas Harsco Rail Solution Wheeler Tower Car.

(i) Power pack Arrangement OHE-4 0200/00 Rev 02
(ii) Axle Drive Gear Box OHE-4 01 03/00 Rev.01
(iii) Torque Arm Assembly OHE-4 02-05/00 Rev.01
(iv) Layout of Tower Car OHE-4 00 02/00 Rev.02
(v) Axle (Powered) OHE-4 01 00/02 Rev.01
(vi) Axle (Non Powered) OHE-4 01 00/01 Rev. 0
(vii) Helical Coil Spring OHE-4 03 01/00 Rev.0
(viii) Brake Rigging Diagram OHE-4 07 00/00 Rev.0
(ix) Wheel & Axle OHE-4 01 01/00 Rev.0
(x) Suspension Arrangement OHE-4 03 00/00 Rev.01
(xi) Axle Box Guide Arrangement OHE-4 04 00/00 Rev.01
3.0 Drawing no. of M/s Ventra Locomotives Ltd., 4 Wheeler Tower Car

(i) Axle box assembly drawing no. ABS 0076
(ii) Suspension cum axle box guide SGM 0090
arrangement
(iii) Lower spring seat and Guide SGP 0532 & 0533
(iv) Coil spring SGP 0482
(v) Brake rigging arrangement BGM 0132
(vi) Wheel and axles Powered WAS 0103
(vii) Non-powered WAS 0104
4.0 Drawing no. of Jamalpur Workshop’s 4-Wheeler Tower Car Mark III

(i) Suspension arrangement SKETCH –89068
(ii) Wheel and axle JMP drg. No. OHE/M3/RG-02
(iii) Axle box bearing No.4000/22 (item 9)
(iv) Axle box Arrangement 4000/22,4000/23,4000/24
(v) Laminated bearing spring SKETCH-89069
5.0 Drawing no. of Jamalpur Workshop’s 4-Wheeler OHE Car Mark-IV

(i) Details of running gear K1016
arrangement
(ii) Running gear arrangement RDSO/SK-K0042
(iii) Helical spring SK-K1016 (item 1)
(iv) Lower rubber washer EMU/M-0-1-008
(v) Guide bush ICF/SK-0-1-182 (item 2)
(vi) Circlip ICF/SK-0-1-182 (item 3)
(vii) Dust shield T-0-1-619
(viii) Dust shield spring T-0-1-667
(ix) Upper rubber washer EMU-0-1-005
(x) Wheel and axle set powered SK-K1017 (item 1&2)
(xi) Wheel and axle set non-powered SK-K1017 (item 1&3)
6.0 Drawing no. of BHEL’s 4 Wheeler Tower Car

(i) Wheel and axle 1 720 11 03 000
(ii) Wheel Ø 952 EMU/M-0-1-027
(iii) Cartridge bearing 0 718 88 01 000
(iv) Axle box guide arrangement 1 72016 03 001
(v) Roller bearing 1 720 16 03 002
(vi) Lower rubber washer EMU/M-0-1-008
(vii) Guide bush EMU/M-0-1-023
(viii) Helical spring 2 720 15 03 001
(ix) Dust shield 3 720 16 03 002
(x) Dust shield spring T-0-1-012
(xi) Guide ring T-0-1-640
(xii) Rubber packing ring T-0-1-632
(xiii) Circlip 115x4N IS: 3075-86 Part-I
Annexure-IV
FORMAT FOR SCHEDULE OF STANDARD EXAMINATION OF

4-WHEELER OHE CAR
(Daily Check)
4-WHEELER Tower CAR: Cumulative km.:
Date :
No. Details of work to be Condition/Action Sign. Remarks

carried out
1.0 4 WHEELER TOWER CAR
1.1 Drain condensate from
automatic drain valves
of brake system.
1.2 Drain the moisture
manually on daily
basis.
1.3 Check the leakage of
air pressure, if any,
rectify the same.
1.4 Check the brake
application and
relieving before leaving
the depot.
1.5 Check the working of
horns during starting.
1.6 Check the oil level of
axle drive, if found
less, add upto
maximum mark.
1.7 Check the
Transmission oil level
in the oil tank , if
found less, add upto
maximum mark.
1.8 Ensure correct level of
radiator water, lube oil
in ADGB & fuel in tanks
SCHEDULE OF STANDARD EXAMINATION OF 4 WHEELER TOWER CAR
(Car body, Under frame, Brake Rigging etc.)
Weekly Schedule
4-WHEELER Tower Car No. Cumulative km.:
Date :
No. Details of work to be carried Condition Sign. Remarks

out /Action
1.0 4 WHEELER TOWER CAR
1.1 Repeat all Daily checks
2.0 Car Body

2.1 Car body should be washed
both from outside and inside.
3.0 Shell
3.1 Visually check body panels/
walls for damages.
3.2 Visually inspect window bars
for damage/missing.
3.3 Examine body side doors for
proper working/damages.
3.4 Inspect door handles for
damages/missing.
4.0 Under frame
4.1 Check condition of head
stock/sole bar/cross
members.
4.2 Inspect brake hanger
brackets for damages.
4.3 Inspect safety brackets for
brake hanger pins.
5.0 Suspension
5.1 Examine rubber stopper/stop
screw of axle box crown for
damage/ missing/ looseness.
5.2 Inspect axle box safety
straps/loops for
damage/breakage/missing.
5.3 Visually examine axle box

springs for breakage/damage.
5.4 Visually examine dashpot oil
filling special screw for
deficiency.
5.5 Check oil leakages in dashpot
through defective seals/vent
screws.
5.6 Visually examine axle box
clearance.
5.7 Examine vertical shock
absorbers for damages.
6.0 Brake rigging
6.1 Check brake-rigging
arrangement for any
defects/deficiencies.
6.2 Examine brake beams
breakages/ damages.
6.3 Check and attend brake beam
safety wire ropes/safety
straps.
6.4 Check and attend brake shoe
head and key and replace if
necessary.
6.5 Check and replace worn brake
blocks.
6.6 Visually inspect brake
hangers, brake gear pins and
cotters/split pins and replace
if necessary.
6.7 Visually inspect damaged/
missing brake gear bushes
and replace if necessary.
6.8 Examine lever hanger pins.
7.0 Draw gear
7.1 Check and replace damaged/
missing split pins/cotter/
rivets.
7.2 Examine draw hook, draw
bars and rubber pads for
damages.
7.3 Check conditions of the screw
coupling and its components
and replace if required.

7.4 Check condition of draw beam
and locating pins on it.
7.5 Examine visually draft key
locking pins.
8.0 Buffing gear
8.1 Visually examine buffer plungers
for damage/drooping/stroke
length.
8.2 Examine buffer mounting
bolts and attend if necessary.
8.3 Examine visually buffer casing
for cracks/damages.
9.0 Running gear
9.1 Examine visually axle box for
grease oozing out, warm axle
box if any.
9.2 Visually examine wheel tyre
profile and thickness of tyre
and check with tyre profile
gauge if they appear to be
near condemning limit.
9.3 Visually inspect axle box
covers.
9.4 Inspect wheel tread for
shattered rim, spread rim,
shelled tread, thermal cracks,
heat checks.
9.5 Check the oil level of axle
drive, if found less, add upto
maximum mark.
10.0 Seats
10.1 Examine the holding/securing
brackets for seats and attend
if necessary.
10.2 Examine and repair damaged
upholstery cushions
10.4 Seats and frames should be
cleaned.
10.5 Cushion should be cleaned
with duster. Oil or head stain
and dirty spots if any should
be cleaned with mild soap
solutions and wipe dry.

11.0 Doors
11.1 Examine doors for proper
functioning and securing with
hinge pivots. Doors should
not graze with floor or doorsill
plates.
11.2 Examine door locks, latches
firmly secured with correct
sized screws and properly/
smoothly engaging in their
slot. The tongue of gravity
type latch should be in proper
alignment with its slot plate.
11.3 Visually examine window
shutters for smooth working and
proper locking.
12.0 Windows
12.1 Check window-balancing
mechanism for proper
functioning.
12.2 Examine window safety
catches for proper
engagement in their slots.
12.3 Window bars should be
provided and fixed in
prescribed manner and
replaced if damaged.
13.0 Interior fittings
13.1 Examine laminated panels
and mouldings for
damage/cracks.
13.2 Examine tower bolts of
backrests for proper working.
13.3 Examine ventilation grills for
damages.
14.0 Wash Basin fittings
14.1 Examine push cock for proper
function
14.2 Check and attend leakage in
pipe, pipe fittings.
14.3 Clean drain grills and drain

holes of wash basin if found
chocked
14.4 Check and replace damaged/
missing mirrors / shelves /
soap dishes

(Car body, Under frame, Brake Rigging etc.)
MONTHLY SCHEDULE
4-Wheeler Tower Car No. Cumulative km.:
Date :
S Details of work to be carried out Condition/ Sign. Remarks

No. Action
1.0 Repeat all items of Weekly Schedule
2.1 Suspension
2.1. Add specified grade of oil in
1 dashpot.
3.0 Brake System
Externally clean the brake system
pneumatic pipes and check for
leakages. If required tighten the
end fittings.
3.1
Check the mounting fasteners of
Air reservoir/ Distributor valve/
relay valve magnet valve and
other brake system equipments
Check and attend brake block
3.2
adjuster.
3.3 Examine and attend brake levers.
Examine and attend brake
3.4
hanger lever brackets.
SCHEDULE OF STANDARD EXAMINATION OF4 WHEELER TOWER CAR

(Coach body, Under frame, Brake Rigging etc.)
QUARTERLY SCHEDULE
4 WHEELER TOWER Car No. Cumulative km.:
Date :
S Details of work to be carried out Condition/ Sign Remarks

No. Action .
Repeat all items of Monthly
1.0
Schedule
2.0 Intensive cleaning of Tower Car
3.0 Under frame
Examine trough floor and other
3.1 under frame members from
underneath for corrosion.
4.0 Secondary Suspension
Check Axle Box Crown
4.1
clearance.

(Coach body, Under frame, Brake Rigging etc.)
Six Monthly Schedule
4-WHEELER TOWER Car no. Cumulative km.:
Date :
No. Details of work to be carried out

Condition/ Sign. Remarks
Action
1.0 Repeat all items of Quarterly Schedule
2.0 Shell
2.1 Thoroughly clean and remove
dust, rust accumulated at
underframe and pillars with coir
brush and compressed air.
2.2 Examine for corrosion of sole bar
and other under frame members
with torch light or inspection
lamp.
2.3 Touch up damaged paint both
inside and outside.
2.4 Check roof ventilator for
damages.
3.0 Suspension
3.1 Check and attend axle guide
assembly if necessary.
3.1. Check axle box clearance with
1 gauge.
4.0 Draw gear
4.1 Ensure that wear on screw
coupling shackle pins, trunion
pins, shackle/link holes and draw
hook holes should not exceed
3mm.
4.2 Ensure that wear at any section
on draw hook should not exceed
10mm.
5.0 Buffing gear
5.1 Ensure the length is within 584-
635mm.
No. Details of work to be carried out Condition/ Sign. Remarks

Action
5.2 Inspect buffer plunger false plate
for wear and profile.
6.0 Running gear
6.1 Check with wheel distance gauge
for loose or tight wheel.
7.0 Flooring
7.1 Inspect and attend
damaged/cracked flooring.
7.2 Examine and attend opened
joints.
7.3 Examine Drain holes in trough
floor for accumulation of water
due to clogging if noticed. Inspect
affected area for corrosion.
(Coach body, Underframe, Brake rigging etc.)
Yearly Schedule
4 WHEELER TOWER Car no.
Cumulative km.:
Date :
No. Details of work to be carried out Condition/ Sign Remarks

Action .
1.0 Repeat all items of Six-monthly
Schedule
2.0 Thorough flushing of water tanks
Overhaul all brake equipments,
3.0
except brake cylinder.
Replace rubber kits during yearly
4.0
repairing of pneumatic valves.
(Coach body, Under frame, Brake rigging etc.)
Twenty Four Months
Cumulative km.:
Date :

Action .
1.0 Repeat all items of Yearly
Schedule
2.1 Run out the Wheels/Axles and
attend all the items as mentioned
in Annexure-II
Thirty six Months
Cumulative km.:
Date :

Action .
1.0 Repeat all items of yearly
Schedule
2.0 Brake
2.1 Overhaul the safety switch.
2.2 Clean the chokes, exhaust plugs,

mesh filters in the distributor
valves and check proper
functioning of all sub-
assemblies.
2.3 Overhaul the drivers brake valve.
Replace all the rubber items,
clean filters.
2.4 Check for proper functioning of
relay valves and replace the
damaged/ worn out items.
2.5 Replace rubber-sealing washer of
air brake hose coupling.
2.6 Check all the hose assemblies of
brake system for damage or over
ageing replace if required.
2.7 Remove the brake cylinder and
over haul 100% rubber parts
replacement.
2.8 Overhaul all valve magnets,
speed cylinders, direction
cylinders and gear cylinders by
replacing 100% rubber parts.
Periodical Overhaul (seventy two months)
Cumulative km.:
Date:
SN Details of work to be carried out Condition/ Sign. Remarks

Action
1. The following sequence of work
should be generally followed
during POH of Tower Car
2. Verification of deficiencies.
3. Pre-inspection and Lifting of
Tower Car body
4. Stripping
5. Body repair.
6. Fitting of Water Tank, Plumbing
& Leakage testing
7. Repair of internal panels
8. Fitment of shutters
9. Fitment of doors
10. Fitment of seats
11. Repair, maintenance & fitment of
screw coupling.
12. Painting and finishing
13. Repair and maintenance of Axle
Box Guide Arrangement as per
Annexure II.
14. Repair and maintenance of brake
system including overhauling of
Distributor valve.
15. Repair and maintenance of
rolling gear
16 Lowering of Tower Car body on
Wheels/ Axles.
17. Brake Testing
SN Details of work to be carried out Condition/ Sign. Remarks

Action
18. Testing of branch wiring
19. Testing of electrical equipment
20 Final Inspection & Dispatch
21. Ultrasonic Testing of wheel set
22. Maggering and continuity check
of electrical equipment to be
carried out. Same should also be
tested on test bench.
ANNEXURE-V
(A) Spares for Carriage
Must change items (with dash pot type of guide arrangement) during POH
SN Description Qty
1 Roller bearing grease 1.52 to 2.0 kg/ bearing
when opened
2 Locking plat 4 nos (when opened)
3 Rubber sealing ring of axle front & rear cover 4 front, 4 rear (when
opened)
4 Rubber packing arrangement 8 nos
5 Guide ring (Acetal) 8 nos
6 Guide bush (Acetal) 8 nos
7 Circlip for dash pot guide bush 8 nos
8 Dash pot oil 2 lts approx./dash pot
9 Brake gear bush (as a set) All
10 Brake shoe key 8 nos
11 Shoe adjuster assembly & nut and bolt with 8 nos
split pin
12 Brake beam bush collored 8 nos
13 All bulb type cotters All when opened
14 Sealing washer for air vent screw 8 nos
15 Rubber stopper and crown bolt 4 nos
16 Air brake house pipes 2 nos
17 Dirt collector filters All
18 Felt sealing ring (for axle box) 4 nos
19 Wiper blades 4 nos
20 Lower and upper rubber washers (IRSR- 8 lower & 8 upper
64/98)
Spares to be kept in the inventory at POH shop/shed.
SN Description Qty
1 Shock absorbers 2 nos
2 Suspension springs 2 nos
3 Brake blocks 16 nos
4 Brake head shoe key 4 nos
5 Brake gear pins & bushes 1 complete set for 1-
tower car
6 Brake beams 2 nos
7 Felt sealing rings 4 nos
8 Locking plats 4 nos

9 Wipers arm and blade assembly & wiper 2 assemblies
motor
10 Horns 2 nos
11 Upper & lower spring seat 2 nos each
12 Flexible hose connection for brake cylinder 4 nos
13 Air brake hose assembly 2 nos
14 Roller bearing grease 5 kg approx.
15 Rubber sealing rings of axle box front and 4 nos
rear cover
16 Rubber packing rings 8 nos
17 Guide ring (Acetal) 4 nos
18 Guide bush (Acetal) 4 nos
19 Circlip for dash pot guide bush 4 nos
20 Dash pot oil 50 lt approx.
21 Shoe adjuster assembly 4 nos
22 Split pins & cottors Sufficient
23 Sealing washers for air vent screw 8 nos
24 Rubber stopper and crown bolts 4 nos
25 Dirt collector filters 1 no. each
26 Buffer bolts 8 nos
27 Glass wind screen 2 nos
28 Suspension safety straps 4 nos
29 Brake beam safety strap/loop 4 nos
30 Glass shutters with equalizing device 2 assemblies
31 Louver shutters 2 assemblies
32 Air brake hose pipe assembly 2 nos
33 Isolating and cut off cocks 1 no. of each type
34 Fans 2 nos
35 Brake cylinders (with its spares like piston 2 nos
packing ring, dust excluders etc)
36 Brake gear levers 1 complete set for a
Tower car
37 Lower & upper rubber washer (IRSR-64/98) 4 lower & 4 upper
38 Driving axle alongwith axle drive with torque 1No
arm for each type of tower Car.
39 Non-driving axle for each type of tower Car. 1No
40 Valve Magnet –for speed gear and direction. 04 Nos
41 A-9 Valve, distributor valve, C3W valve, C2W 1 each
relay valve
(B) Transmission System

Must change parts for transmission for CRT-5633 ( Avtec)
SN PART NO DESCRIPTION Qty

Mandatory Changes
1 80000561 Element ( every 250 hours 2
Transmission Oil C4 SAE 30 Transmission Oil ( Every 1000 r App 55 Litres
2
hours)
Overhaul Parts list ( App 8000 Hours )
1 6884505 SEAL & GASKET KIT 1
2 9409058 BOLT 12
3 23041915 BEARING ROLLER 2
4 6838403 EXT SNAP RING 1
5 6774184 INT SNAP RING 1
6 6703059 RING,EXT SNAP 1
7 6774708 NUT LOCK 1
8 6758485 WASHER THRUST 1
9 6773088 CUP 24
10 6770302 Roller needle 12
11 6769276 Spring 12
12 6770574 Roller needle 12
13 6774710 Plate Stator backing 1
14 6770578 Retainer 2
15 23047054 Sleeve Converter ground 1
16 23048010 Bearing 1
17 6769319 Snap ring 1
18 23048012 Bearing 1
19 6882657 Hose Assy 1
20 23047967 Bearing 1
21 6753304 Snap ring 1
22 6750025 Snap ring 1
23 6768469 Thrust Washer 1
24 23047964 Bearing 1
25 6756042 Belleville Spring 1
26 6756041 Snap Ring 1
27 6884212 Washer Thrust 1
28 6880157 Hose lube feed 1
29 23045626 Tube Jumper 1
30 6754835 Snap ring 1
31 6769721 Ring Compression 1
32 23018736 Hub 1
33 23047970 Bearing 2
34 6756338 Spacer 1
35 6753487 Snap ring 1

36 23041450 Bearing 1
37 8892840 Snap ring 1

38 23018418 Pump Assy 1
39 6776451 Screen Assy 1
Recommended spares for each transmission CRT 5633 transmission for

2 years.
SN Description Qty
1. FILTER ELEMENT 10
2. SEAL AND GASKET KIT 2
3. GASKET 5
4. GASKET 5
5. HOSE ASSEMBLY 2
6. Ring external snap 1
7. Turbine 1
8. Nut. Lock 1
9. Washer Thurst 1
10. Race 1
11. Stator 1
12. Cup 24
13. Roller, Needle 12
14. Spring, Needle Roller 12
15. Roller, Stator Freewheel 12
16. Plate, Stator Backing 1
17. Bolt 12
18. Strip, Locking 6
19. Pump, Torque TC 580 1
20. Bearing, Ball 1
21. Gear, Accessory Drive Inp. 1
22. Washer 36
23. Bolt 36
24. Ground Sleeve 1
25. Bolt 5
(C) Engine:
Must change items for engine NTA-855 of Cummins India Ltd, Pune
SN Parts Qty
1. SHELL,MAIN BEARING 1
2. RING,LINER SEAL 6
3. LINER,CYLINDER 6
4. SEAL,OIL 1
5. SEAL,OIL 1
6. PICKUP,MAGNETIC 1
7. PISTON & CONN ROD 6
8. VALVE,SOLENDID 1
9. SEAL,O RING 1
10. RING,RETAINING 1
11. VIBRATION DAMPER 1
12. GASKET,CAM FOL HOUSING 3
15. ROD,PUSH 12
16. ROD,PUSH 6
17. CAP,FILLER 1
18. THERMOSTAT 1
19. COOLER LUB OIL 1
20. NOZZLE,PISTON COOLING 6
21. BREATHER,CRANKCASE 1
22. MANIFOLD,EXHAUST 1
25. MTG EXHAUST MANIFOLD 1
26. SHIELD,HEAT 1
27. HOSE OIL SUPPY 1
28. INTERCOOLER AIR 1
29. V-BELT 1
30. PICKUP MAGNETIC 1
31. FILTER,LUB OIL 1
32. FILTER,FUEL 1
33. FILTER,OIL BYPASS 1
34. HOSE,FLEXIBLE 1
35. HOSE,FLEXIBLE 1
36. BUSHING 1
37. CLIP 3
38. BLANKET,TURBOCHARGER HEAT 1
39. CONTROL,SAFETY 1
40. SWITCH,PRESSURE 1
41. BUSHING 1
42. SWITCH,PRESSURE 1
43. HOSE,FLEXIBLE 1
44. SENSOR,TEMPERATURE 2
45. SENSOR,PRESSURE 1
46. V-BELT, RIBBED 2
47. SWITCH,OVERSPEED 1
48. HOSE,FLEXIBLE 2
49. HOSE,FLEXIBLE 1
50. HOSE,FLEXIBLE 1
51. HOSE,FLEXIBLE 1
52. HOSE,FLEXIBLE 2
53. KIT,VENT HOSES 1
54. INHIBITOR,CORROSION 1
55. SWITCH,RELAY 6
56. THERMATIC,VALVE 1
57. KIT, WASHER SEALING 1
58. KIT, WASHER SEALING 1
59. CLAMP,TUBE 12
60. CLAMP,TUBE 3
61. CLAMP,TUBE 2
62. SCREW,HEXAGON HEAD CAP 24
63. WASHER,LOCK 56
68. WASHER,LOCK 80
69. HOSE,FLEXIBLE 2
71. WASHER,LOCK 8
73. WASHER,LOCK 4
75. WASHER,LOCK 40
76. SEAL,O RING 14
77. SEAL,O RING 10
78. SEAL,O RING 16
79. SEAL,O RING 6
80. WASHER,LOCK 40
81. INDICATOR,RESTRICTION 1
82. HOSE,ELBOW 1
83. CLAMP,T BOLT 1
84. HOSE,ELBOW 7
85. HOSE,ELBOW 1
86. CLAMP,T BOLT 13
87. CLAMP,T BOLT 6
88. CLAMP,T BOLT 2
89. HOSE,HUMP 1
Recommended spare of engine for six months
SN Description Qty
1. Seal oil Acc Drive 1
2. Oil seal 1
3. Heat shield cover 1
4. Valve solenoid 1
5. Switch pressure 1
6. Switch temperature 1
7. Thermostat 1
8. Gauge oil level 1
9. Cap filter 1
10. Hose oil supply 1
11. Clip 2
12. Switch magnetic 1
13. Switch pressure 1
14. Wiring harness 2
15. Hose assembly 1
16. Sender 2
17. Transducer pressure 2
18. Hose flexible 1
19. Probe 1
20. Ammeter 1
21. Gauge water 1
22. Gauge lub. Oil 2
23. LO pressure gauge 2
24. Techno meter 1
25. Gauge Lub. Oil 1
26. Gauge water 1
27. Hose flexible 2
28. Hose assy 1
29. Hose assy. 1
30. Elbow 12
31. Hose assy. 1
32. Vaccum indicator 1
33. Elbow 1
34. Hose Air Cleaner 2
35. Elbow Hose 1
36. Clamp T.bolt 1
37. Clamp T.bolt 2
38. Hose hump 2
39. Clamp T.bolt 2
40. Hose Elbow 2
41. Clamp T.bolt 4
42. Clamp T.bolt 1
43. Kit Hyd.Filter & hoses 1
44. Ket Hyd. Hoses 1
45. B Check ket (AR3238018) 10
46. Assy. Rotor screen 2
47. Gasket Rkr Hsg 3
48. O Ring Injector body 6
49. O Ring Injector body 12

50. Gasket breather cover 4
51. Element inner 3
52. Element outer 3
53. Belt WTR Pump 1
54. Belt alt. Fan (178473) 1
55. Coil assy.(3054610) 1
56. Total
Requirement of oil and lubricant for tower Car.
SN Description Qty
1 Lube oil 3 Litrs
2 Hydraulic drive for radiator 54 Litrs
3 Transmission CRT-5633 (V) 40 Litrs
4 Axle drive gear box 25 Ltrs
5 Axle box 2 Kg.
6 Cardan shaft 100 gms
7 Brake rigging As required
(D) Recommended spares for 3-years normal maintenance for Traction Motor
SN Description Qty
1 Axle BRG lubricator assembly 4
2 Half wiper of felt ASSY.COM 4
3 Brush holder complete (RH) 6
4 Brush holder complete (LH) 6
5 Cable bush PE side 4
6 Cable bush PE side CE side 4
7 Bellows 2
8 Rubber sandwitch unit 2
9 Carbon brush 64
10 Control gear equipment 72V 01
11 Magnet valve complete with coil 01
12 Contact for EP contactor 01
13 ARC box for EP contactor 01
14 Fixed contactor for master controller 09
(E) Recommended spares for 3-years normal maintenance for lighting circuit
1 Twin beam Sealed assembly 01

2 Lamp holder for cab and hood light 05
3 Push button with element 02
4 Hood light switches 10
5 Head light switch 01
6 LED type flasher lamps 01
7 LED type marker lamps 01
(F) Recommended spares for 3-years normal maintenance of traction alternator
SN DESCRIPTION PART NO UNIT

1 Wound stator frame T9501 1 No
2 Wound main rotor T9502 1 No
3 Wound exciter armature T9503 1No
4 Wound exciter field T9504 1No
5 Machined shaft with keys T9505 1No
6 Aluminum fan T9506 1No
7 Coupling hub T9507 1No
8 Balancing disc T9508 1No
9 Diode disc assembly T9509 1No
10 Rotating diode 130A, 1600V (F) T9510 3Nos
11 Rotating diode 130 A, 1600V (R) T9511 3Nos
12 MOV (250V/14) T9512 1No
13 NDE bracket T9513 1No
14 DE bracket T9514 1No
15 Bearing hub T9515 1No
16 Outer bearing cap T9516 1No
17 Inner bearing cap T9517 1No
18 Stationary ring (grease) T9518 1No
19 Mobile ring (grease) T9519 1No
20 CGS plate T9520 2No
21 Side cover with filter T9521 2No
22 Top cover with filter T9522 1No
23 Front cover T9523 1No
24 Rear cover T9524 1No
25 NDE cover T9525 1No
26 DE cover with grid T9526 1No
27 Tinned copper busbar (N) T9527 1No
28 Tinned copper busbar (U) T9528 1No
29 Tinned copper busbar (V) T9529 1No
30 Tinned copper busbar (W) T9530 1No
31 Deep groove ball bearing (6317/C3) T9531 1No
32 Molded Insulator (10/36) T9532 17No
33 Supporting clamp T9533 2No
34 Flex plate 1.2mm Thick (SAE 0) T9534 6No

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1 OF 80 Issued On 15.11.2012 Maintenance Instruction No. TI/MI/0044 Rev.

SPECIAL MAINTENANCE INSTRUCTION

TRACTION INSTALLATION DIRECTORATE

SPECIAL MAINTENANCE INSTRUCTION

Amendment Date of Amendment Total Pages including Amendment/Revision

PREPARED BY CHECKED BY APPROVED BY

ISSUED BY …………………………. SIGNATURE …............................ DATE…………………….

SPECIAL MAINTENANCE INSTRUCTION

Sl.No. DESCRIPTION PAGE No.

SPECIAL MAINTENANCE INSTRUCTION FOR

Following maintenance instructions are to be followed for maintenance

3.0 Monthly Schedule (With engine stopped).

3.1 Contactor and relays: (i) Inspect visually.

3.3 Batteries: (i) Clean dirt or any oil on top of battery.

(ii) Clean the commutator veering. Remove any

4.0 Three Monthly Schedule (with engine stopped)

4.5 Batteries: (i) Clean dirt or any oil on top of battery.

4.7 Traction Alternator: Monthly Service plus.

(i)Wipe off loose dirt on the outside surface of the alternator

5.0 HALF YEARLY SCHEDULE (WITH ENGINE STOPPED)

5.1 Master controller Clean and inspect contact, fingers. Check

6.0 MAINTENANCE OF TRACTION MOTOR

Overhaul: An overhaul is required after three to five years service.

(i) Remove as much dirt as possible particularly around the

commutator covers the axle-cap filler pipes and the armature

treatments will depend upon the condition of the armature, but

7.0 OVERHAUL DURING IOH/POH

Mechanical parts: The upper and lower articulation tubes must be

Throttle valve: Dismantle and over haul throttle valve.

Alternator: Engine driven alternator to be overhauled in every IOH/POH

8.0 MAINTENANCE OF RECTIFIER

9.0 MAINTENANCE OF ENGINE:

SN Maintenance steps Remarks

then stop engine and check

3.2 Check Every 300 Hrs or 6 Months whichever is earlier B -Check

S.No Maintenance Steps Remarks

S. No Maintenance Steps Remarks

Check and adjust belts. New belts

Tighten foundation bolts and

Check all air cleaner connections

Use special tool no. ST 845 or ST

Change element for naturally

17. Check throttle linkage. -----

EVERY 1500 HOURS OR 1 YEAR WHICH EVER IS EARLIER C - Check

1 Repeat all maintenance steps of Checks `A’ & ‘B’

2 Check thermostat operation It should start opening

clean the filter housing.

EVERY 6000 HOURS OR 3 YEARS WHICHEVER IS EARLIER. D-Check

SN Maintenance Steps Remarks

10.0 MAINTENANCE OF TRANSMISSION

11.0 MAINTENANCE OF AXLE DRIVE

12.0 MAINTENANCE OF LIFTING AND SWIVELLING PLATFORM.

1 Replace suction Yearly

telescopic structures and replacing seals of

13.0 Requirement of spares for maintenance during various schedules.

The items of maintenance spares required to be stocked alongwith the

15.0 OVERHAUL DURING IOH/POH

The final power transmission in both designs is through cardan shaft

In the VENTRA design the transmission output is connected to the

16.1 MAINTENANCE OF VOITH HYDRAULIC TRANSMISSION.