8 WHEELER DIESEL ELECRIC TOWER CAR WITH UNDERSLUNG TRANSMISSION. OPERATING & MAINTENANCE MANUAL (2019) - page 5

CONTROL GEAR EQUIPMENT

• Re-varnish insulation surfaces, other than porcelain.

• Clean metal support frames and covers, repaint if necessary

• Check resistance values to figures given "Data for Control Apparatus".

MAINTENANCE MANUAL FOR DETC-US

CONTROL GEAR EQUIPMENT

NOTES

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MAINTENANCE MANUAL FOR DETC-US

CHAPTER XI

DRIVING INSTRUCTION

Maintenance Manual

DIESEL ELECTRIC TOWER CAR | UNDER SLUNG TRANSMISSION

DRIVING INSTRUCTIONS

CHAPTER XI

DRIVING INSTRUCTIONS

OPERATING INSTRUCTIONS FOR DRIVER

Preparation of Vehicle for Service

The driver should be provided with a master controller key and driver's control key. Before taking

a train into service, the driver must check the following points.

1.1

Check that all sealed switches are in OFF position.

1.2

Insert driver's control switch (DCS) key in Driver's Control Switch box (BL box) and turn in ON

& OFF.

1.3

Insert the master controller key and operate FORWARD & REVERSE and keep it in the OFF

position.

1.4

Switch on 24-Volt DC Battery isolating switch in the engine room.

1.5

Switch on 110 Volt DC battery isolating fuse switch behind driver's seat.

1.6

Switch on both battery voltmeter switches and check for

i) Starting battery voltage reads 24V

ii) Control battery voltage reads above 88V

1.7

Switch on all MCBs (control and auxiliary) except rectifier blower motor MCB

i) Switch on 110 V MCB and 24 V MCB in the engine control panel

ii) Throw the local/remote selector switch in the engine control panel to remote side.

1.8

Insert DCS key in the BL box & turn it ON.

1.9

Switch ON control switch in the BL box.

MAINTENANCE MANUAL FOR DETC-US

DRIVING INSTRUCTIONS

Control ON indication will come on LED indication panel.

1.10

Press lamp test switch and see that all LED indications are glowing.

1.11

Keep Engine Control Switch (ECS) in "IDLE" position.

1.12

Press "Engine ON" switch.

“Engine ON” indication will come and “Engine TRIP” indication will go OFF.

1.13

Once Engine is ON, auxiliary alternator rectifier set will generate supply and auxiliary alternator

failure indication will go off.

1.14

Switch ON rectifier blower motor MCB. Rectifier blower motor will start functioning now.

Rectifier cooling fan failure indication will go off.

1.15

Keep the test sequence switch in OFF condition and ECS continue to be in "IDLE" position.

1.16

Allow the engine to run in IDLE position till feed pipe pressure reaches 7 Kg/cm sq. For fast

build up of the pressure engine can be notched up accordingly.

Note: Alternator Excitation ON switch on BL box should necessarily be in OFF condition.

Instructions for driving

2.1

Ensure that parking brake is released. If not, release the parking brake switch.

2.2

If feed pipe pressure is built up to 7 Kg/cm sq. and guard's key is inserted, driver's interlock relay

(DIR) will operate thereby drive function released indication will come. It is now possible to take

traction.

2.3

Put ECS switch in "RUN" position

2.4

Switch on Excitation ON switch in BL box. Alternator Excitation ON indication will come.

MAINTENANCE MANUAL FOR DETC-US

DRIVING INSTRUCTIONS

2.5

Ensure that brake pipe pressure is 5 Kg/cm sq.

2.6

Move the master controller key in clockwise direction by 90° & set the reverse handle of master

controller to the FORWARD position.

2.7

Depress deadman's handle and move it in the Notch-1 position.

2.8

Now, the master controller can be moved to next notch.

Instructions for shutting off the vehicle

3.1

Bring the master controller handle to OFF position & release the deadman's knob.

3.2

Switch OFF the excitation.

3.3

Apply parking brake

3.4

Put ECS switch in "IDLE" position. Switch off engine by pressing Engine OFF switches.

3.5

Switch off the Control Switch in BL box.

3.6

Bring DCS key in off position and remove it from DCS box.

3.7

Switch off control battery and starting battery-isolating switches.

3.8

Close all the doors and windows of the driving cab.

MAINTENANCE MANUAL FOR DETC-US

DRIVING INSTRUCTIONS

NOTES

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MAINTENANCE MANUAL FOR DETC-US

CHAPTER XII

DETC DRAWINGS

1. Power Pack and accessories

2. Wiring Schematics

3. General Arrangement Drawings

Maintenance Manual

DIESEL ELECTRIC TOWER CAR | UNDER SLUNG TRANSMISSION

DETC DRAWINGS

CHAPTER XII

DETC DRAWINGS

A. Power Pack and accessories

S. No.

Description

Drawing No.

Power Pack Arrangement

45812450

Power pack Assembly

45812440

Air Cleaner Arrangement

45831110 S1,S2

Exhaust Pipe Mounting Arrangement

45820420

Radiator Mounting Arrangement

45820470

Radiator Water Piping Arrangement

45820510 S1,S2

Schematic Diagram of Hydraulic Circuit

45825260

Fuel Line Piping Arrangement

45825270

B. Wiring Schematics

S. No.

Description

Drawing No.

Power Schematic

30104007

Control Schematic Cab - 1

30104005

Control Schematic Cab - 2

30104006

Auxiliary Schematic

30104008

Power pack schematic 1 & 2

30104009

C. General Arrangement Drawings

S. No.

Description

Drawing No.

Traction Alternator

CGA/101004

Traction Motor

11290003

Power Rectifier - OGA

1216-02-1807

Power Rectifier - IGA

1216-03-1807

Auxiliary Alternator

19A 3086

Rectifier Regulator Unit

4A 3089

Driver’s Desk

31610140

Control Cubicle Cab 1 - OGA

31610142

Control Cubicle Cab 1 - IGA

31610143

Control Cubicle Cab 2

31610138

Motor Switch Group Cubicle - OGA

31610144

Motor Switch Group Cubicle - IGA

31610145

Resistor Panel

31610139

CARDAN SHAFT

Annexure 1

Cardan Shaft

A1.1 Introduction

1. Exploded view

2. Specifications

3. Installation, Maintenance and servicing

MAINTENANCE MANUAL FOR DETC-US

CARDAN SHAFT

A1.2 Key to typical exploded view:

1. Flange yoke

2. snap ring

3. Bearing cups

U.J. kit

4. Journal

5. Lubricator

6. Sleeve yoke with sleeve yoke plug

7. Cork washer

8. Steel washer

9. Dust cap

10. Slip stub shaft

11. Tube

12. Stud ball yoke

13. Lubricator

A1.3 Installation, Maintenance and Servicing

A1.3.1 Transport and storage

Care should be taken on the following points:

1. The shafts should be transported in horizontal position. For vertical transportation an

additional protection must be provided in order to avoid the shaft coming apart. The sleeve

yoke plug and the dust cap of the spline seal must not be loaded by the weight of the

propeller shaft.

2. Shocks and bumps must be avoided during transport.

3. The shafts should be stored side by side on wooden frames and the flange yokes should be

supported loosely, as shown

MAINTENANCE MANUAL FOR DETC-US

CARDAN SHAFT

4. Balance weight strips wherever fitted on the shaft tube should not be removed. Removal will

create unbalance which will cause uneven running and premature wear of the propeller shaft

joints and the bearings of the connected units.

A1.3.2 Installation

For satisfactory operation, the driving shaft and the driven shaft should be coplanar and the

propeller shaft should be installed either as per arrangement 1 or 2 shown below:

The flanges of the propeller shaft and that of companion flange (propeller shaft mating part

fitted on the driving/driven shaft) should be free of dirt, grease, paint, anti-rust compound, burrs,

etc., This is important as torque is transmitted through friction between flanges. For the same

reason only the bolts and nuts recommended, same to be torque tightened.

The spigot bore/dia of companion flange should be concentric with driving/driven shaft on

which it is fitted and its flange face should be square to driving/driven shaft to ensure true

running of propeller shaft.

The mounting bold should be steadily tightened with a torque wrench in a crosswise pattern to

torque values indicated.

While using fixed length propeller shaft and universal joint (types J & L) at least one of the

units to be connected should be capable of axial movement and subsequent bolting down as the

propeller shaft/universal joint has to be fitted over the flange spigot dia/bore.

MAINTENANCE MANUAL FOR DETC-US

CARDAN SHAFT

Important: The propeller shaft/universal joint is to be is to be greased at points 1,2 and 3 before

installation.

A1.3.3 Maintenance

Maintenance should be carried out at regular intervals and it is advisable to do-ordinate this with

the maintenance work of the other items of machinery/installation. The maintenance intervals

mentioned herein are only for guidance. The actual frequency will depend on working

conditions.

1. Noise testing: continuously, any deviation from normal working noise should be located

and corrected immediately.

2. Checking of Flange bolts: periodically the bolts should be checked for tightness and

tightened whenever necessary.

3. Lubrication: propeller shafts should be periodically greased with lithium based grease only.

This should be acid and soap free, as the former causes corrosion and the latter clogs the

passages. Recommended grease are given in separate table. The propeller shaft should be

greased at three points, where the grease nipples are provided. Greasing of joints to be done

till the grease comes out through the seals, and for sleeve yoke till the grease flows out

through the vent holes on the sleeve yoke plug.

Joints

Sliding splines

Application

Earth moving equipment

5000 kms

2500 kms

Trucks, Lorries, Busses

10000 kms

5000 kms

Locomotives,

Railcars,

30 days/500 hrs.

Rolling

mills

Cranes,

MAINTENANCE MANUAL FOR DETC-US

CARDAN SHAFT

Marine applications &

general machinery

A1.3.4 Servicing

A1.3.4.1 Dis-assembly of propeller shaft

Remove the dust cap, pull back the cork washer & steel washer and pull off the sliding joint

from the shaft. (Flange yoke to sleeve yoke)

Disassembly of the universal joint

(Snap ring type : 0400 to 1510 series)

1. Clean enamel / paint from snap rings and top of bearing cups. Remove snap rings by pinching

their ears together with a pair of pliers and rising with a screw driver. If ring does not snap out of

the groove readily, tap end of bearing race lightly to relieve the pressure against the ring. Support

sleeve yoke lug on a wooden block and tap yoke ears with a soft hammer.

1. Now the bearing cup should begin to emerge. Turn the joint and finally remove the bearing

cup with fingers. Care should be taken to avoid any of needle rollers being dropped.

2. Similarly remove the opposite bearing cup also. If necessary tap bearing cup from inside

with a small dia bar, taking care not to damage the bearing cups / journal.

3. Now the sleeve yoke can be removed, rest the two exposed trunnions on wooden blocks to

avoid damage. By tapping the yoke ears lightly with a soft hammer and following the above

procedure, remove the other two bearing cups.

4. On the same lines dis-assemble the fixed joint (stub ball yoke side) also.

A1.3.4.1.1 Examination and check for wear

The parts most likely to show signs of wear after long usage are bearing cups and journals. Should

looseness in the fit of these parts, load markings or distortion be observed they should be renewed

complete as a unit, because worn needle bearings used with a new journal, or new needle bearings

used with a worn journal, will wear more rapidly, making another replacement necessary in a short

time.

MAINTENANCE MANUAL FOR DETC-US

CARDAN SHAFT

It is essential that bearing cups are a light drive fit in the yoke trunion

In the rare event of wear having taken place in the yoke cross holes, the holes will most certainly be

oval and the yokes must be replaced.

In the case of wear of the cross holes in stub ball yoke, which is welded onto tube, only in cases of

emergency should this stub ball yoke be replaced. Normally stub ball yoke along with tube and slip

stub shaft should be replaced as one unit.

The other parts likely to show signs of wear are the splined sleeve yoke, or slip stub shaft. a total of

0.004” (0.1mm) circumferential movement, measure on the outside diameter of the spline, should

not be exceeded. Should the slip stub shaft require renewing, this must be dealt with in the same

way as the stub ball yoke.

A1.3.4.2 Re-assembly

Assemble needle rollers in the bearing cups. Should any difficulty be encountered while

assembling needle rollers in the bearing cup, smear the wall of the cup with grease. It is

advisable to install new gaskets and gasket retainers on the journal or spider assembly. It is

also useful to have snap rings available as replacements in the even of damaging a ring

whilst dis-assembling the joint.

See that all drilled holes in journals are cleaned out and filled with grease, with the rollers in

position fill the races about one-third full with grease.

Insert journal in yoke holes and using a soft round drift with flat face about 1/32” (0.8mm)

smaller in diameter than the hole in the yoke, tap the bearing cup into position. Repeat this

operation for the other three bearing cups. Fit snap rings or bearing caps, bearing cap

screws, locking plate etc., with the bearing cap type make sure that bearing cups are placed

with the slot in the top of the cup in line with bearing cap screw holes, so that they are

prevented from rotating by the key in the bearing cap. If joint appears to bind, tap lightly

with a wooden mallet, which will relieve any pressure of the bearings on the end of the

journal. When refitting a sliding joint on shaft, be sure that trunnions in sliding and fixed

yoke are in line. Observing that arrows marked on splined sleeve yoke and slip stub/tube are

in line can check this.

MAINTENANCE MANUAL FOR DETC-US

CARDAN SHAFT

Annexure 2

Trouble shooting - Power pack

Sl. No.

IN CASE OF

CAUSE

REMEDY

Drained battery

Check & charge battery

Engine does

not crank

Check the battery connections

Incorrect /loosen battery connections

and rectify

No fuel in tank

Add sufficient fuel

Fuel filter clogged

Clean the fuel filter

Engine cranks

but doesn’t

Identify any loose connections

Improper Fuel connections at pump

starts

and rectify

Restriction in air inlet / exhaust

Check piping and rectify if any

restriction exists

Air entering in the fuel system

Check all the fuel connections,

tighten if found loose

Starts but does

Fuel suction line restricted

Inspect fuel line for any blockage

not throttle

Inspect fuel sample / verify by

Fuel contaminated

connecting a temporary fuel tank

Remove and clean the filter

Air inlet filter clogged

element

Excessive

exhaust smoke

Contaminated fuel

Check the fuel sample &

replenish with new fuel

Restriction in air inlet / exhaust

Check piping and rectify if any

restriction exists

Low engine

out put power

Check the lube oil level in sump

Excessive lubricating oil

with dipstick provided and reduce

if it is high

MAINTENANCE MANUAL FOR DETC-US

CARDAN SHAFT

Improper / leakage in fuel flow to fuel

Check any leakage / restriction at

pump

connections, rectify if any

Malfunction of throttle solenoid valves

Check and rectify if any

Malfunction of tachometer

Test and rectify

Low engine

Fuel line restricted

Check and rectify

speed at full

throttle

Excessive traction load on the power

Reduce the vehicle load

pack

Release the brake on desk and

Vehicle brakes applied

bring brake handle to ‘Release &

running’

Vehicle does

Check & select master controller

not moves

Controls not engaged in Forward /

direction selector to required

when engine

Reverse

position, if not selected

throttled

Release the parking brake with

Parking brakes applied

operating switch provided on

desk

Check and open the isolating cock

at air inlet side and Check for

System Pressure not developed

proper functioning of Limiting

valve and non return valve

Check water availability at pipe

No water

Insufficient suction head / inlet restricted

outlet / inspect for any block in

outlet from

the pipe

water rising

apparatus

Isolating valve at outlet is closed

Check and open the valve

Check for proper connections /

Hose / pipe joints leaking or disconnected

routing with respect to drawing

MAINTENANCE MANUAL FOR DETC-US

TIGHTENING TORQUE

Annexure 3

TIGHTENING TORQUE IN N-m FOR THREADED COMPONENTS.

MATERIAL PROPERTY CLASS AS PER IS:1367

8.8

10.9

MIN.YIELDSTRESS N/mm2

640

900

SIZE

SCREW

BOLT

SCREW

BOLT

2.5

1.5

M8x1.0

M10

M10X1.0

M12

107

M12X1.5

130

M14

117

165

126

M14X1.5

137

121

193

170

M16

176

139

248

195

M16X1.5

196

156

275

220

M18

245

186

344

261

MAINTENANCE MANUAL FOR DETC-US

TIGHTENING TORQUE

M18X1.5

264

220

372

310

M20

328

264

461

372

M20X1.5

343

294

482

413

M20X2.0

333

284

468

399

M22

421

343

592

482

M22X1.5

441

392

620

551

M22X2.0

431

362

606

510

M24

549

411

772

579

M24X1.5

578

441

813

620

M24X2.0

568

431

799

606

M27

921

539

1296

758

M27X1.5

1078

637

1516

896

M27X2.0

1029

607

1447

854

M30

1264

725

1778

1020

M30X1.5

1539

921

2164

1296

M30X2.0

1470

882

2068

1241

M33

1735

2440

M33X1.5

2059

2895

M33X2.0

1980

2785

M36

2216

3116

MAINTENANCE MANUAL FOR DETC-US

TIGHTENING TORQUE

M36X1.5

2706

3805

M36X2.0

2608

3668

M36X3.0

2402

3378

The above values apply to bolts of lengths in excess of 5 times the thread diameter. For

smaller lengths the valves are to be reduced by 10%.

To get lb-ft multiply the above values by 0.737

To get lb-inch multiply the above values by 8.85

To get kg-m multiply the above values by 0.102

MAINTENANCE MANUAL FOR DETC-US

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