SIN No.

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62, 73 & 74 CLASS LOCOMOTIVE E - SERVICE
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Job MMS Time Workers

Measurement Start End Date Initiais
Code M ins takeil No.
1.0 INCOMING INSPECTION 30

1.1 Carry out preliminary incoming inspection (visual, running and functional tests). Record all faults reported
in the travelling log book on to the Examination sheet
8.0 QUICK - ACTING AIR SHUT-OFF FLAP:
See MTU Maintenance Manual Section 2.12.3.3.
8.1 Test the equipment for correct operation in accordance with the MTU instruction 2.12.3.3. 5

8.2 Report any defects to the supervisor and record on Examination sheet. 5

9.0 WHEELS AND TYRES:

9.1 Hammer test all wheels to check for loose tyres. 15

9.2 Examine each tyre for flats or other tread damage. 20

9.3.1 Use the profile gauge to check the profile of each tyre and record the amount of hollow on the Crack 60
detection & Tyre Measurement Report Form - 003
The maximum wear on tread must not exceed 6.50mm
When the wear reaches arrangements must be made for tyre turning at the next 'C' service.
Report any unusual flange or tread wear or any wheel defects immediately to the supervisor.
Note: If wheels have to be changed, the exle drives and gears must be checked at the same time. See
Henschel Manual for drive shaft end- play limits.
9.3.2 Check all axles for cracks and record measurements on FORM - 003 above 180

9.4 AXLE BOXES:

9.4.1 Inspect each axle box guide bracket (stay) and axle box liners for damage. Report any damage to the 15

9.4.2 Check all nuts and bolts for tightness. 15

9.4.3 Repack the axleboxes with fresh grease. 60

Note: Roller bearing type axleboxes should be filled with grease only to three quarters of their capacity.

Check vertical distance between frame opening and axlebox case. This should be 30 mm. 15

9.5 AXLE BOX LINERS:

9.5.1 Check 'play' between axlebox and axlebox guide. If the play between the axlebox liners exceeds: 20
2.00mm. In the longitudinal direction, or 6.00mm. In the cross direction, the liners on the axle-box quide
must be renewed.
Note: High manganese steel, or plain carnon steel, type liners can be separated and welded into place
again after interposition of shims. In order to avoid distortion by welded heat, avoid welding on the axle
boxes. If absolutely necessary, place the axle box in a water bath. Proceed with care. After re-assembly,
the play must be as follows: 0.60 - 1.50mm. in the longitudinal direction, and 1.40 - 3.00mm. in the cross
direction. Whenever any work has to be done on the axle box liners, the centre distances, the parallelism
of the axles and their angularity with the underfame have to be checked.

10 DIESEL ENGINE AND AUXILIARIES:

10.1 Clean the outside of the engine. Remove all traces of oil so that leakage may be detected when the 30
engine is running.
10.2 Take a sample of lubricating oil for analysis. Label the sample bottle correctly and dispatch to the 5
labaratory for analysis.
10.3 If instructed to do so, drain the sump, renew the engine oil Main filter and by-pass filter cartridges (see 30
sections 10.5 and 10.6)
10.3.1 Refill with new lubricating oil. Use Total RUBIA TIR XLD oil or an approved equivalent. 30

10.3.2 Record the quantity and type of oil used on the examination sheet. 5

#REF! Note: If an oil change is to be carried out, this must be done when the engine is at operating
10.5 ENGINE oil main filter (See MTU manual section 2.9.1)
10.5.1 Drain the oil sludge from the filter housing and examine the sludge for residue. 10

10.5.2 Report any sign of metallic particles to the supervisor and record on examination sheet. 5

10.5.3 Clean the filter housing. Remove filter inserts and fit four new inserts. 20

10.6 By-pass filter (Lube Oil): [Centrifugal filter for class 73**]
10.6.1 Change the filter elements only if the engine oil is changed. 15

10.6.2 Remove and clean parts. Replace and ensure the connections are tight. 10

Centrifugal Filter (MTU Mtce Manual Sect G 16.391)

10.6.3 Remove and clean all parts. Renew the filter sleeve. 10

10.7 Fuel Filter: (Dual Type) - MTU Maintenance Manual Section 2.11.2.
10.7.1 Drain off the fuel oil from engine filter housing. 5

10.7.2 Replace the paper inserts, or clean the felt tube inserts. (According to the type of insert in use). 10

10.8 Fuel pre-filter: -MTU Maintenance Manual Section 2.11.1

10.8.1 Remove and clean all parts. 10

10.8.2 Replace and tighten connections. 5

10.9 PANEL TYPE AIR FILTERS:

10.9.1 Clean and moisten with fresh oil. 30

10.1 ENGINE AIR INTAKE FILTERS:

10.10.1 Remove and clean the first stage filters (Pre-cleaner) panels with compressed air through back and front 60
of the cyclnoic separator tubes and dust bin.
10.10.2 Withdrawn the second stage filters (the farr Pamic paper cartridge) and replace the new cartridges. 30

10.11 ENGINE HOUSING EXHAUSTER:

MTU Maintenance Manual Section 2.2.1
10.11.1 Remove the cover and withdraw insert. 20

10.11.2 Wash thoroughly and allow to dry. 20

10.11.3 Refit the insert and cover. 5

10.11.4 Ensure that the cover seal is in good condition - Replace if necessary. 5

10.12 ENGINE SUSPENSION : - MTU Maintenance Manual Section 2.13.1

10.12.1 Check the rubber elements for cracks. If the protective lacquer coating needs renewing report this to the 5
Supervisor and record on examination sheet.
10.12.2 Check that the catcher bolts have a minimum clearance of 5.0mm. between the underside of the bolt 10
head and the upper supporting rail.
10.12.3 Check that all the other engine mounting bolts are tight. 10

10.13 Engine Protection Equipment - MTU Maintenance Manual

10.13.1 Check the following for correct operation:- Cooling water temperature control switch, (See MTU Manual 45
Section 2,10, page 3), low oil pressure safety shut down, oil pressure control switch (MTU Manual 2,16),
lube oil pressure gauge and remote speed transmitter. (MTU Manual Section 2.16)
10.13.2 Report any defects to the supervisor and record on Examination sheet. 5

10.14 FUEL INJECTOR NOZZLES: - MTU Maintenance Manual Section 2.7.2

10.14.1 Remove cylinder head covers and disconnect the high pressure fuel line to the nozzle holder of each 30
cylinder head.
10.14.2 Unscrew the cap nut. Remove the inner leak -off fuel line and the leak-off connecting line. 15

10.14.3 Unscew the thrust screw a few turns with the aid of the extracting fixture. Release the nozzle holder with 45
the extracting fixture, Unscrew the thrust screw completely. Withdraw the nozzle holder with the nozzle.

10.14.4 Remove the supporting rings and the CE-ring from the cylinder by means of a wire hook, - (See GA 05 5
154, Page 2, Section 2.7.2).
10.14.5 Clean the injector nozle externally. Remove carbon residue from the end face of the nozzle bocy, using a 15

10.14.6 Test each nozzle, together with its own holder, with the test unit in accordance with the instructions given 30
in the MTU Maintenanace Manual, Section 2.7.2, Pages 3 and 4
10.14.7 Defective nozzles must be replaced by new or re-conditioned nozzles. Any defective nozzles shall be 30
taken for re-conditioning.
10.14.8 Re-fit injector nozzles in accordance with the instructions given in the MTU Maintenance Manual, Section 30
2.7.2, Page 9. Note: When tightening the thrust screw, do not exceed a torque of 78NM (8KgM). Do not
replace the cylinder head covers at this stage.

11 ENGINE AIR INTAKE DUCTING, EXHAUST MANIFOLS AND EXHAUST NOZZLE RAIN FLAP:
11.1 Ensure that all joints are tight and that the fastenings are secure. Adjust or rectify as necessary. 20

11.2 Check the exhaust nozzle rain flaps must be easy to move. 5

11.3 Report any damage to the supervisor and record on the examination sheet. 5

12 ENGINE COOLING SYSTEM

12.1 Check the engine cooling water inhibitor. (Pn value 8.5 to 9.5). Top-up as necessary, use Total 20
LACTUATE LT2 or an improved equivalent at a dilution of 1% of the cooling system volume. (This is
approximately 2.5 litres for the initial filling, and the same proportion should be used for toppin gup.)
Note: Before topping - up check that all lines and vents are clear.

12.2 If there is an abnormal loss of cooling water, examine the system for leaks. If no leaks can be found, 30
check for water in the cylinders and the lubricating oil. (See MTU Manual Section 2.10 page 4)
12.3 Check the cooling water level control switch for correct operation and rectify as necessary. 10

13 Spare section - not yet used

14 VALVE CONTROL GEAR: (See the MTU Maintenance Manual Section 2.6, Page 3.)
14.1 Measure the valve clearance with Feeler Gauges while the engine is cold and the piston is set to the 90
firing Top Dead center position. Adjust, if necessary, to obtain the following settings:- Inlet valve
clearance o.3mm. And exhaust valve clearance 0.45mm.
14.2 Visually inspect all components of each cylinder head. 30

14.2.1 Report any defects to the supervisor and record on Examination sheet. 5

15 REGULATING LINKAGE:
15.1 Check for free movement and grease lightly. 5

15.1.1 Check for clevis pins for wear and replace if necessary. 15

16 HOSES AND RUBBER CONNECTIONS:

16.1 Examine all hoses, flexible pipes and rubber sleeves for damage, swelling or mechanical distortion. 30

16.1.1 Report any defects to the supervisor and record on Examination sheet. 5

17 RADIATOR GROUP:
17.1 Clean the exterior of the radiator cooling elements by applying a jet of compressed air from inside of the 45
engine compartment.
17.2 Check the water pipes for tightness of joints and fastenings. 15

17.3 Inspect the fan, fan pump, fan motor and radiators 15

17.3.1 Report any defects to the supervisor and record on Examination sheet. 5

18 HYDRAULIC TURBO TRANSMISSION: (See Voith Operating instructions).

18.1 Check the level of the hydraulic turbo transmission oil and top up as necessary with Total AZOLLA VT 32 5
oil or its approved equivalent.
18.1.1 Record the type of oil, and the amount used, on the examination sheet. 5

18.2 Remove and clean the metallic Turbo Transmissio Oil Filter Insert. Report any accumulation of metallic 30
swarf on the Magnetic Disc to the Supervisor.
18.3 Clean and Rod Restrictor Inserts and the Strainer which protects the labyrinth restrictor. 5

18.4 Ensure that the 10 fixing bolts which secure the cover for the operating cylinder (Forward & Reverse) are 5
in place and secure.
18.5 DRAIN oil from the transmission sump and heat exchanger. Renew the filter cartridge in the micro filter. 30
Clean strainers protecting the scavenger pumps.
18.6 Fill with Total AZOLLA VT 32 oil. Record the type of oil, and amount used, on the examination sheet. See 30
Voith operating instructions page 23.
19 AIR COMPRESSOR:
62 class locomotives type VV 450-10 and 73 class locomotives type 243 VC 60 refer to the
Manufacturers recommended schedules.
Remove, overhaul and install air compressor 3060

20 HYDROSTATIC FAN UNIT:

20.2 Remove and Clean the magnetic filter in the oil reservoir of the hydrostatic fan unit. 20

20.3 DRAIN hydraulic oil from the Fan Reservoir and REFILL with TOTAL RUBIA TIR XLD. Record the type, and 20
the amount of oil used on the examination sheet.
21 AXLE DRIVE GEAR BOX UNITS: Nos. 1,2,3 & 4
21.1 Examine each gearbox for external damage and report any damage to the supervisor. 15
21.2 Check all nuts and bolts for tightness. Ther must be no leakage of oil at all. 15
21.3.1 Check the level of oil in each sump 10

21.3.2 Top up as necessary with Total EP85W-90 or its approved equivalent oil. 10

21.4 DRAIN oil from each sump and re-fill with Total EP85W - 90 oil. Record the type of oil, and the amount 60
used, on the examination sheet.
21.5 Report any deposits of metallic swarf on the Dip sticks to the Supervisor and record on examination 5
sheet.
23 VULCAN Elastic coupling:
See MTU Maintenance Manual Section 2.14.1 class locomtives type Vulkan EZ 121/2S, 62 class
locomotives type Vulkan EZ 80/2S, 73 class locomotives type EZ 80/2S and 73 class locomotives type EZ
135/2S.
23.1 Inspect the coupling carefully, especially the condition of the resilient members and the protective 10
coating. Report any defect to the supervisor.
23.2 Lubricate the coupling using hand grease gun. Do not over lubricate. 20

24 GREASE:
Grease the following units using a hand grease gun only. Note: After greasing the splines of the cardan
shafts, the grease nipples must be removed to release any excess grease. Replace the grease nipples to
24.1 Cardan shaft between engine and turbo transmission unit, -6 nipples at 3 greasing points. 20
24.2 Cardan shaft between engine and compressor drive, -6 nipples at 3 greasing points. 10
24.3 Fuel pump Operating lever, - 1 grease nipple. 5
24.4 Cardan shafts from final drive to Axle gearboxes, 12 grease points. 30
24.5 Four torque supports, -4 grease points 10
24.6 Brake rod cross members, -16 grease points 10

24.7 Brake cylinder - remove the rubber cover and grease the piston rods and slack adjusters. 60

24.8 Hand brake spindle, Nut and Chain. 15

24.9 Any movable joints, such as door hinges, not fitted with grease nipples 10

24.1O Quick acting air shut-off valve. 5

25 BOGIE PIVOT CENTERS:

25.2 Drain oil from bogie centers. REFILL with TOTAL RUBIA TIR XLD, or equivalent. Record the type of oil and 20
the amount used on the examination sheet.
26 OVERALL GENERAL CHECKS:

26.1 Clean the insert of the Air filter on the air control pipe. Replace the insert if damaged. 10

26.2 Check the correct operation of the Hand brake and adjust if necessary. Brake blocks less than 18mm 60
thick must be replaced.
26.3 Check all suspension springs and Axle boxes and report any that are broken, jammed or defective to the 15
supervisor.
26.4 Check the condition of the front and rear Drawgear and repair as necessary. 5

26.4.1 Check the condition of the support bracket and ensure that the Dragbox Bolts are tight. 15

26.4.2 Report any Drawgear defects to the supervisor and record on examination sheet. 5

26.5 Check the tightness of the Torque Support Securing Nuts. 20

26.6 Check the locomotive of any loose nuts, bolts, damage and for signs of leakage of oil from the engine, 5
Transmission and Axle drive gear boxes rectify as necessary.
26.6.1 Report any damage to the supervisor and record on the examination sheet. 60

26.7 Check the play in the joints and moving sleeves of the Cardan Shafts. Check the bearing cover bolts of 15
universal joints and flange clamps for tightness and that the locking plates are satisfactory. Warning:
Cardan Shafts must not be turned with Crow bars .
26.8 Check the mountings of the Engine, Hydraulic Transmission Unit, Auxiliary Equipment and Compressor 5
and tighten if necessary.
26.8.1 Report any cracks, defects or damage to the supervisor and record on examination sheet. 30

26.9 Check all Air Hoses. Replace damaged hoses. Rectify any air leaks. 5

26.1O Check that the Control Air pressure is between 5.5 bars and 5.7 bars (with the engine stopped and the 5
power control lever in the 'max' position.)
26.11 Check again the oil level in the Diesel Engine Sump. 10
26.12 Grease the hand brake chain. 10
26.13 Check the vigilance unit and the over-speed control unit are properly sealed. 10
26.14 Rubber Parts
26.14.1 Check all visible seals, hoses, dighragms, etc for leakage. 60
26.14.2 Check all silent - blocs, springs and pads for ageing, distortion and subsidence. 30
27 ENGINE RUNNING CHECKS
27.1 Listen carefully for any unusual noise or uneven running of the engine and auxiliaries. Report anything 20
unusual to the supervisor and Record on examination sheet.
27.2 Operate the throttle lever to vary engine speed and check for any signs of uneven firing. Report any 15
black smoke from the exhaust to the supervisor and record on examination sheet.

27.3 Check the cylinder head and Exhaust Manifold for blows. 5
27.4 Check the Air, Lube Oil, Fuel and Water systems for leaks. 20
27.5 Check that the Engine idling speed and the Engine Lubricating oil pressure is NOT LESS THAN 1.4 5
kg/cm^2 (21 p.s.i.)
27.6 Test and adjust air pressure at the Driver's Brake Valve and Automatic Air Brake. The Auto air brake 5
pressure must be 5kg/cm2 (70 p.s.i.)
27.7 Check the front and rear brake hose pipes for damage and leakages. Secure the hoses to the dummy 5
couplings.
27.8 Check that the Horns and Windscreen Wipers operate correctly. 5
27.9 Test the Delivery efficiency of the Air compressor. 15
Note: The Compressor should cut in at 6.6 kg/cm2 (96 p.s.i.). The compressor should cut out
7.8kg/cm2
27.1O Check the Main Air Reservor filling time at Engine iding speed. A pressure of 7.8 kg/cm.^2. Must be 15
obtained in a time LESS THAN 10 minutes.
27.11 Test the setting of the air compressor Safety Valve by closing the isolating cock. The safety Valve MUST 5
discharge at a pressure of 8.5 kg/cm.^2. (123 p.s.i.)
27.12 Check the Hydrostatic Fan Drive oil system for leaks. All leaks must be rectified. 30
27.13 Check that the fan starts to operate when the Engine Cooling Water Temperature reaches 78c.(1730 F) 15
The engine cooling water temperature must not exceed 84C. (1850F) when the fan is running

27.14 Check the operation of the Brakes using the Automatic Brake Valve. 5
27.15 Check the operation of the Brakes using the Independent Air Brake Valve. 5
27.16 Check the oil flow to the Engine Valve Gear in accordance with the MTU Maintenace Manual. All cylinder 5
head covers must be carefully replaced and there must be no oil leaks from the joints.

27.17 Refill the windscreen Washer reservoir with clean water. 5

27.18 Check Turbo charger boost pressure. (See MTU Maintennace Manual, Section 2.12.1, page 3)

27.18.1 (i) Connect air pressure gauge to the charge air piping at the connection point. 5
 27.18.2 (ii) Measure the charge air pressure and compare with the value obtained when tests were first made at 5
site.
27.18.3 (iii) If the charge air pressure is more than 100mm. HG (or0.14 Kg/cm^2) below the original value, the 5
cause must be determined and rectified.
27.18.4 Report to the Mechanical supervisor and record on job card. Note: A fouled exhaust gas turbo-charger 5
must be removed from the engine.
29.O TURBO-CHARGER
29.1 Shut down the engine and listen to the Turbo-chrger running down. 5
29.1.1 Report any unusual noises to the supervisor and record on examination sheet. 5
30.O ENGINE STOPPED TESTS:
With the Engine stopped and the Main Air Reservoir charged to 7.8kg./cm.^2 (110 p.s.i) carry out the
following work:-
30.1 Check for air leakage by observing the drop in Main Reservoir Air Pressure. The pressure drop must not 10
exceed 0.30 kg/cm^2 (5 p.s.i.) in 5 minutes. If a greater drop is observed the cause must be found and
rectified.
30.2 Check that the Automatic Drain Valves work correctly. 60
30.3 Report any defects to the supervisor and record on Examination sheet. 5
30.4 Remove and Clean the magnetic filter in the oil tank of the Hydrostatic fan drive. Replace after cleaning. 30

30.5 Check the condition of the Fan, Fan Pump, Fan Motor and Radiators. Clean as necessary. 30
30.6 Report any defects to the supervisor and record on Examination sheet. 5
30.7 Wash loco exterior, underframe, bogies and engne room. 240
31.O RESTART the Engine and carry out the foolowing checks:-
31.1 Check the Hydrostatic Fan Drive oil system pipework for leaks. Rectify as necessary to satisfy all leaks. 20

31.2 Check that the Fan starts to operate when the Engine Cooling Water Temperature reaches 78c.(1730 F) 15
31.2.1 Check that the Engine cooling water temperature does not exceed 840C (185oc) when the fan is running. 5

31.3 Check the operation of the brakes, using the Automatic Air Brake Valve and the Independent air Valve 10
individually.

TOTAL 6000
70 ADDITIONAL WORK TO BE DONE

Supervisor: ---------------·- Production Engineer: ------------- PP&C Engineer: --------------

Date: Date: Date:

Doc. No.:RC - LOCO - 05 - 02

Date of ssue: 02.12.2002