MAINTENANCE SCHEDULE MANUAL

FOR
BALLAT REGULATING MACHINE
(PBR-400R)

REPORT NO. TM-153

DECEMBER-2010
 PREFACE

Maintenance of On-Track Machines is a challenging task. Maintenance of these

machines is being done by zonal railways with the assistance of local trade available,
zonal track machine workshops, CPOH / Allahabad and RDSO / Lucknow. With
experience over the years, the railway engineers have developed adequate expertise
in the maintenance of these machines. However, in absence of approved
maintenance instructions, different maintenance practices have come into vogue.
Therefore, it has become imperative to have a uniform maintenance standard
throughout the Indian Railways. Maintenance schedule manuals of CSM (09-32),
BCM (RM-80), FRM-80, Unimat, Duomatic machine (DUO), Unomatic machine
(UNO), Ballast Regulating Machine (BRM 66-4), Tamping Express (09-3X), Dynamic
Track Stabilizer (DGS 62N), Multi purpose track tamping machine (Unimat Compact--
M), Plasser’s Quick Relaying System (PQRS), T-28, Track Relaying Train (TRT),
Phooltas make UTV, FRM-85F, Worksite Tamping Machine (Plasser make) and
Worksite Tamping Machine (Metex make) have been issued by RDSO.
Maintenance schedule manual of Ballast Regulating Machine (PBR-400R) have
been prepared on the basis of experience and suggestions received from Zonal
Railways.

It is hoped that this manual will be quite useful for the staff maintaining the machines
in field.

While every care has been taken to make the maintenance schedules quite
exhaustive, there is always scope for further improvement. Suggestions from the
Railways in this regard will be welcome and may be sent to the undersigned.

(A.K.Pandey)

Executive Director/Track Machine

RDSO/Lucknow-226011.

December -2010

(i)
 EXPLANATORY NOTES

While preparing text of Maintenance Schedules Manual for Ballast Regulating

Machine (PBR-400R), the terms used and their meanings are explained below:

CHECK - Ensure a specific condition does (or does not) exist.

INSPECT - Look for damage and defects including breakage, distortion cracks,
corrosion and wear, check for leaks, security and that all items are
completed.

CHANGE - Remove old parts by substituting a new or overhauled

reconditioned part. Fit new or overhauled / reconditioned part in
place of missing part.

OVERHAUL - Dismantle, examine, recondition or renew parts as necessary

against given specifications, reassemble, inspect and test.

(ii)
 INDEX

S. CONTENT DESCRIPTION PAGE

NO. NO.
1. Schedule I To Be Done Daily 1
2. Schedule II To Be Done After 50 Hours 2
3. Schedule III To Be Done After 100 Hours 3
4. Schedule IV To Be Done After 200,400,600 And 800 4
Hours
5. Schedule V To Be Done After 1000,3000,5000 Hours 5
6. Schedule VI To Be Done After 2000 And 4000 Hours 6
(IOH)
7. Schedule VII To Be Done After 6000 Hours 7-8
8. Annexure-I List Of Safety Equipments 9
9. Annexure-II Safety 10-11
10. Annexure-III First Aid 12
11. Annexure-IV Fire Protection 13
12. Annexure-V Hazard 14
13. Annexure-VI Protective Equipment 15
14. Annexure-VII Instructions For Use Of Starter Batteries 16
15. Annexure-VII Engine Oil Change 17
16. Annexure-IX Cleaning Of Machine 18
17. Annexure-X Lubrication 19
18. Annexure-XI Original Filling Of Working Stock 20
19. Annexure-XII Testing Of Hydraulic Oil 21
20. Annexure-XII Brake 22
21. Annexure-XIV V-Belt Tension 23
22. Acknowledgement 24

(iii)
 SCHEDULE -- I
(TO BE DONE DAILY)
DURATION- ONE HOUR

1. ENGINE

i) Check engine oil level.

ii) Check level of engine cooling agent.
iii) Check the fuel reserves for the diesel engine and do the needful.
iv) Drain all the air receiver.
v) Drain the water separator of the engine.
vi) Check the function of charging ammeter.
vii) Check engine oil pressure at

a) Idle RPM
b) On load after two hrs. working
viii) Check the water temperature of engine after two hrs. working.
ix) Check the condition of the engine smoke and do needful.
x) Check the condition of V-belts.

2. MACHINE GENERAL

i) It is necessary to clean the machine before starting the work.

ii) Check level of Hydraulic oil in tank.
iii) Check all the choking indicator of hydraulic suction filters.
iv) Check the leakage from hydraulic hoses and do the needful.
v) Check the hydraulic oil temperature after two hrs. working.
vi) Check the pneumatic brake pressure.
vii) Check the brake application.
viii)Check the charge pressure.
ix) Check the working of all gauges.
x) Check the working of all lights.
xi) Check the condition of shoulder plough for wear and do the needful.
xii) Check the condition of front plough for wear and do the needful.
xiii) Check the condition of brush sweeping unit and do the needful.

Page 1 of 24
 SCHEDULE II
(TO BE DONE AFTER 50 HOURS OF ENGINE RUNNING)
DURATION- TWO HOURS

1. ENGINE:

i) Check the V-belt tension.

ii) Drain all drip cups.
iii) Clean the outer air cleaner element.
iv) Check any unusual sound from engine.

2. MACHINE GENERAL:

i) Lubricate all dirt repelling agents of axle gearbox.

ii) Visually check and lubricate the cylinder pin of shoulder plough.
iii) Visually check and lubricate the arm pin of shoulder plough.
iv) Visually check and lubricate the guide of shoulder and front plough.
v) Adjust the height of brush assembly through adjusting screw as required.
vi) Visually check and lubricate the brush shaft bearings.
vii) Visually check and lubricate the guide columns of brush assembly.
viii) Check oil level of pneumatic lubricator.
ix) Lubricate the motor bearing of conveyor with grease.
x) Check the foundation bolts of front plough sliding cylinder.
xi) Ensure proper engaging of axle gear box physically.
xii) Check the oil level of pump gear box.
xiii) Check the oil level of axle gear boxes.
xiv) Check the leakage of all gear boxes.

NOTE: While doing this schedule all works of schedule (I) have also to be carried out.

Page 2 of 24
 SCHEDULE III
(TO BE DONE AFTER 100 HOURS OF ENGINE RUNNING)
DURATION- ONE DAY

1. ENGINE:

i) Check the electrolyte level of the battery.

ii) Check the safety circuit of engine.
iii) Check the condition of engine hoses.
iv) Check the leakage from head gasket.

2. MACHINE GENERAL:

i) Lubricate all the movable parts such as, cylinder fastenings, guide bushes,
spindles, slide faces etc. with oil/grease.
ii) Check all hydraulic and pneumatic universal joints visually and lubricate with
oil.
iii) Check the brake linings and brake block play.
iv) Clean the pneumatic lubricator.
v) Check the rubbing of hydraulic hoses with one another.
vi) Lubricate axle engage/disengage cylinder guide rod.
vii) Lubricate the brush assembly guide column with oil.
viii) Lubricate the sliding surface of front plough guide.
ix) Check the functioning of emergency back up system.

NOTE: While doing this schedule all works of schedule (I) and (II) have also to be
carried out.
Page 3 of 24
 SCHEDULE IV
(TO BE DONE AFTER 200,400,600 AND 800 HOURS OF ENGINE RUNNING)
DURATION-TWO DAYS

1. ENGINE:

i) Check the specific gravity of electrolyte of battery.

ii) Check the condition of battery terminal and connection.
iii) Replace the engine oil.
iv) Replace the fuel filter.
v) Replace the lube oil filter.
vi) Replace the coolant filter.
vii) Check the concentration (PH-value) of radiator coolant/water.
viii)Change filter / granulate cartridge of air drier.
ix) Change both the air cleaner.

REMARK: A. Item no. (iv) to (viii) will be done after 300 engine hrs.
B. Item no. (x) to (xi) will be done after 500 engine hrs.

2. MACHINE GENERAL:

i) Change the suction filter (Part no.HY-S501.160.P10).

ii) Check the brake linkage and lubricate.
iii) Check the condition of sweeper element and replace as required.
iv) Check the V-belt of air conditioner.
v) Visually check lifting cylinder and lubricate the hinges.
vi) Visually check the front plough guide and lubricate.
vii) Change the oil of pump drive gear box.
viii) Change the oil axle gearbox
ix) Replace the suction filter (Part no.HY-S501.460.150).
x) Replace the return filter.
xi) Change trabold filter.

REMARK: A. Item no. (i) will be done after 250 engine hrs.
B. Item no. (xii) to (xvi) will be done after 500 engine hrs.

NOTE: While doing this schedule all works of schedule (I), (II) and (III) have also
to be carried out.

Page 4 of 24
 SCHEDULE-V
(IOH)

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

DURATION- 7 DAYS
1. ENGINE:

i) Clean the diesel tank.

ii) Overhaul the self starter on condition basis.
iii) Overhaul the alternator on condition basis.
iv) Calibrate the fuel pump.
v) Calibrate the fuel injector.
vi) Clean the radiator.
vii) Change all engine hoses on condition basis.
viii) Replace the battery on condition basis.
ix) Overhaul the compressor on condition basis.
x) Overhaul the air unloader.

2. MACHINE GENERAL:

i) Check the hydraulic oil for viscosity, maximum water content, purity and, acid
content.
ii) Check grease filling in hand brake gear.
iii) Clean the underside of machine, however, at least once a year.
iv) Lubricate the axle bearing with grease.
v) Clean the hydraulic tank.
vi) Check the wheel tread for wheel burn, flat tyre etc.
vii) Clean the hydraulic oil cooler.
viii) Replace the brake shoes.
ix) Lubricate the bogie pivot with grease.
x) Check all hydraulic pressures and adjust if needed.
xi) Check the leakage from hydraulic valves and do needful.
xii) Replace all sweeper elements.
xiii) Do the strengthening of the machine by welding, where crack detected.
xiv) Do the patch work painting.
xv) Reconditioning/ replace hinges of plough unit as required.
xvi) Recondition/ replace the yoke of all hydraulic cylinders, as required.
xvii) Replace the seal kit of all hydraulic cylinders on condition basis.
xviii) Replace/Overhaul the pneumatic cylinder on condition basis.
xix) Tighten all the following screws
- working mode drive
- power divider
- suspensions
- gear boxes

NOTE: While doing this schedule all works of schedule (I), (II), (III) and (IV) have
also to be carried out.
Page 5 of 24
 SCHEDULE VI

(IOH)

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

DURATION-45 DAYS

1. ENGINE

i) Top overhaul the engine, if required.

ii) Overhaul the radiator.
iii) Clean the crank case breather.
iv) Rewire the engine wiring with temperature proof wires on condition basis.
v) Change anti vibration mounting pads of the engine.

2. MACHINE GENERAL

i) Check all gearboxes and overhaul, if required.

ii) Replace old Pn. hoses along with clamps on condition basis.
iii) Clean the hydraulic oil tank. Paint the surface of tank with approved quality of
paint and fill new oil.
iv) Thoroughly clean all panel boxes.
v) Replace defective switches Replace defective indicative instruments.
vi) Replace defective pneumatic cylinders.
vii) Replace damaged hydraulic hoses.
viii) Replace pneumatic valves, if required.
ix) Overhaul broom reel bearing and bushes.
x) Change all clamps for rubber elements if found defective.
xi) Change worn out rubber sheet provided at broom.
xii) Repair/ replace missing and defective hand tools.
xiii) Check function of all assemblies after IOH.

NOTE: While doing this schedule all works of schedule (I), (II), (III), (IV) and (V)
have also to be carried out.

Page 6 of 24
 SCHEDULE VII

(POH)
(TO BE DONE AFTER 6000 HOURS OF ENGINE RUNNING)
DURATION-90 DAYS

1. ENGINE

i) Overhaul/Replace the engine on condition basis.

ii) Overhaul the air compressor.
iii) Overhaul the self-starter and alternator.
iv) Change anti-vibration mounting pads of the engine.
v) Clean diesel tank.
vi) Change all the high-pressure fuel pipes, pipe clamp, flexible fuel hoses and
rubber hoses.
vii) Overhaul the turbo charger.
viii) Change the shut down valve on condition basis.
ix) Change all engine filters along with lube oil.
x) Replace air unloader, if required.
xi) Change air inlet hoses.

2. MACHINE GENERAL

i) Strengthen the machine frame where cracks have developed.

ii) Check the wheels for any tyre defects. Re-profile or change if required.
iii) Check the axle bearing and grease them. Change, if required.
iv) Change mounting pads of all gearboxes.
v) Overhaul all the gearboxes.
vi) Replace all the hydraulic hoses along with fittings.
vii) Replace all hydraulic pumps and motors.
viii) Check all hydraulic cylinders. Change, if required.
ix) Clean hydraulic tank, inside surface is to be painted with approved type of paints.
x) Replace the hydraulic oil.
xi) Check all the pressure control valves and change, if required.
xii) Check all the stopcocks and flow control valves and change, if required.
xiii) Flush complete hydraulic system.
xiv) Test air tank for rated pressure.
xv) Check all pneumatic valves and change, if required.

Page 7 of 24
xvi) Check all the pneumatic cylinders and do the needful.
xvii) Change the seal of brake cylinder.
xviii) Change all the brake shoes.
xix) Check calibration of all the indicative instruments.
xx) Arrange insulation test of main cables and replace the defective ones.
xxi) Change all the defective switches and lights.
xxii) Change sensors, if required.
xxiii) Change worn out sweeping element.
xxiv) Change bearing of the broom unit.
xxv) Replace wear plates and strips.
xxvi) Paint complete machine with approved paint.
xxvii) Test the machine working for one week near POH Workshop, before it is put for
actual working in the section on regular basis.

NOTE: While doing this schedule all works of schedule (I), (II), (III), (IV), (V) and
(VI) have also to be carried out.

Page 8 of 24
 Annexure-I

List of Safety Equipments

S. No. Description Quantity

1. Detonators 01 box
2. H.S. flag red 02 nos.
3. H.S. flag green 01 nos.
4. Banner flag 02 nos.
5. H.S. Tri color lamps 02 nos.
6. Chain & Pad lock 01 set
7. Terfor ( 2 t capacity ) 01 no.
8. 25 t jack with traverser 02 no.
9. Petromax 01 no.
10. Wooden blocks off sizes 08 nos.
11. Portable Control Phone 01 no
12. Skids 04 nos.
13 Walkie Talkie Set 01 no
14. Switch clamp 02 nos.
15. G&SR book 01 no.
16. Track machine Manual 01 no.
17. Fire extinguisher 01 no.
18. Remote controlled Hooter 01 no.
19. Flasher lights 02 nos.
20. First Aid Kit 01 no
21. Safety Helmet 10 nos
22 Leather safety boots and shoes 10 nos
23 Leather and cotton gloves 10 nos
24 High visibility warning clothes 10 nos

Note:

i) While doing the maintenance, official should wear the safety items 21 to 24.
ii) All the working units should be properly locked and a tag should be attached to
the unit showing the name of person who has locked the unit.

Page 9 of 24
 Annexure-II
SAFETY
 Maintenance works in principle have to be carried out when the vehicle is
stationary and secured against breaking away.
 It is strictly prohibited to climb on the vehicle roof under centenary. Before
beginning of repair and maintenance works it must be ensured that the centenary
is switched off and earthed. These safety measures have to be carried out and
supervised by the machine in- charge.
 Always pay attention to trains passing on adjacent tracks.
 Use skid-pans when parking the vehicle on gradients.
 If a check of certain structural elements might cause danger, these elements may
be checked only when the machine is stationary or after work.
 Never change the settings of safety valves.
 Before disassembling hydraulic system elements make sure that the equipment
is unpressurized. Hydraulic oil coming out under pressure may penetrate skin
and cause serious injuries.
 When draining engine oil or hydraulic oil at working temperature you might scald
yourself.
 Always ensure that on or in the vehicle nobody works with naked flames.
 Do not smoke when refueling the vehicle or checking the acid level of the
batteries.
 Never check the acid level of the battery or the fuel level in the tank with a naked
flame.
 Before beginning welding works (electric arc welding) particularly make sure that
the machine has been secured against breaking away (parking brake, skid-pans
etc.); the engine has been switched off; the main switch has been switched
"OFF“; the program control switch has been switched "OFF, if existing; the
battery sets have been entirely disconnected, the earth electrode fastened at the
vehicle has been connected as close to the weld as possible.
 The earth electrode must never be mounted on the rail.
 Never connect the earth electrode to cylinder piston rods, hydraulic
accumulators, hydraulic pumps, batteries, earth cable, loose connections, or to
hydraulic oil or fuel tanks.
 Do not direct any high-pressure cleaning and lubricating devices to man or
animal.
 Do not use any easily flammable fluids or caustic cleansing agents to clean the
machine.

Page 10 of 24
 Before carrying out any repair work on the machine the following safety
instructions must be observed:
 Deactivate hydraulic pressure
 Deactivate the air system
 Protect the machine from breaking away (parking brake, skid-pans etc.)
 Turn off the engine
 Turn off the working-mode main switch and protect it from unauthorized
operation
 Turn off the battery main switch and protect it from unauthorized operation
 If repair works are carried out in closed workshops the batteries have to be
disconnected
 The battery terminals have to be secured accordingly.
 Furthermore, the machine crew and all persons having access to the machine
must be informed of the intended repair work.
 Furthermore, the machine crew has to be informed of the repair work completed
before the operating mode of the machine is restored.
 Only professionally competent and trained persons are allowed to restore the
working mode of the machine.

Page 11 of 24
 ANNEXURE-III

FIRST AID
Always ensure that the first aid kit is in a proper, complete and neat condition.
Immediately refill the used up material.

 Procedure for first aid measures

 In the case of burning

 Extinguish the burning person with water, fire extinguisher, blankets or

through rolling.

 In the case of eye contact with hazardous materials

 Rinse out several times with spray bottle or beverage and subsequently
consult a doctor.

 In the case of skin contact with hazardous materials

 Thoroughly wash with soap under running water and subsequently consult
a doctor.

 When inhaling hazardous materials

 When inhaling higher concentration, take person into the fresh air and
subsequently consult a doctor.

 After ingesting

 Do not induce vomiting and immediately consult a doctor.

 After intensive contact with clothing

 Immediately change saturated clothing, shower and subsequently consult

a doctor.

Page 12 of 24
 ANNEXURE-IV

FIRE PROTECTION
 Everybody is responsible to refrain from everything that may result in a fire or
favor the spreading of a fire. In addition to this, all measures to prevent the
development or spreading of fires must be taken in individual cases.
 Oily or greasy rags saturated in solvent must be kept in a fire-protected place
since they could cause fires through self-ignition.
 In order to avoid the development of fires, the following parts, must be kept free
of deposits.

 Drives
 Heaters
 Belts
 Gears
 Control cabinets
 Power distribution boards etc.

 The fire extinguishers must always be ready for operation, freely accessible,
periodically tested and equipped with test plaques.
 The date of expiry must be checked by the responsible fire protection
representative.
 The in charge of the machine will immediately made the arrangement for the
filling of all used fire extinguishers and in the meantime he will also inform the
concern controlling officer for the replacement of fire extinguishers.
 The use of open flames and easily flammable agents on the vehicle and in
immediate vicinity is strictly prohibited.
 The diesel fuel tanks may only be filled with the engine switched off and cooled
off.
 Smoking is strictly prohibited in the vicinity of the machine.

Page 13 of 24
 ANNEXURE-V

HAZARD
Service life and the operational safety is increased by virtue of carefully performed
maintenance, which will be reflected in a clear reduction of working accidents and
resultant damage to persons.

 GENERAL

 The instructions of the machine in charge must be followed under any

circumstances.
 Entering the machine is only permitted by way of the steps provided for this
purpose, which should be kept free of grease, oil, fuel, dirt, snow and ice.
 Climbing onto machine parts during loading, unloading and repair operations
located in the hazard area of the overhead line is always prohibited unless the
overhead line has been switched off.
 Crossing underneath the machine during operation or working is strictly
prohibited.
 When present in the vicinity of the machine the use of ear protection is
absolutely essential.
 If problems are encountered while work in progress, activate the emergency
engine stop as required. Based on the type of the fault it must be decided how it
should be rectified most effectively. Instinctive reactions for rectifying the fault
during working operation may result in serious injury to body and even death.
 Touching the exhaust system may result in burns.

Page 14 of 24
 ANNEXURE-VI

PROTECTIVE EQUIPMENT

In order to keep hazards and their consequences to health as low as possible it is

imperative to ensure suitable protective equipment.

 Head protection………. Hard hat or helmet

 Ear protection………….Ear muffs, earplugs
 Hand protection………. Gloves
 Foot protection………. Steel cap shoes
 Warning clothing…… Clothing in signal colors with reflecting
stripes
 Breathing protection… Dust mask

Page 15 of 24
 ANNEXURE - VII

INSTRUCTIONS FOR USE OF STARTER BATTERIES

 INSTALLATION IN THE VEHICLE
 Before removing and installing the battery, switch off the engine and all power
consumers.
 Avoid short-circuits through tools.
 When removing the battery, first disconnect the negative terminal (-), then the
positive terminal (+).
 Prior to installing the battery, clean the standing area in the vehicle.
 Clean battery terminals and terminal clamps and lightly grease with acid-free
grease.
 On installation, first connect positive terminal (+), then negative terminal (-).
Ensure terminal clamps are tightened securely.

 MAINTENANCE
 In order to achieve a long service life for the battery, the following instructions
should be observed.

 Keep the surface of the battery clean and dry.

 Regularly check the acid level and, if necessary, replenish with
Desalinated or distilled water. Never add acid.
 If the acid density is below 1.21 kg/l (or 1.18 kg/l recharge the battery.
 Check the fluid level, it should be at least 2-3 mm and maximum 10 mm
above the top of the battery plate; if necessary, add distilled water.
 Measure the acid number of the individual cells with a battery tester.

Page 16 of 24
 ANNEXURE-VIII
ENGINE OIL CHANGE
 PROCEDURE OF OIL CHANGE

 Heat up the engine at approx. 80°C.

 Ensure horizontal vehicle position.
 Turn off the engine.
 Clean the surrounding area of the oil drain plug.
 Open the oil drain plug and collect the oil.
 Do not let oil get into the soil.
 Beware the danger of scalding yourself by the used oil.
 Insert the oil drain plug with a new sealing ring, tighten it.
 Fill the engine crank case with new oil as per the capacity of the engine.
 Wait for 5 minutes, then check the oil level ; if it is correct, close the oil drain plug,
 Make sure that the washer of drain plug is correctly seated.
 Replace the filter cartridge whenever changing oil.
 After replacing the filter cartridge, again check the oil level. If it is beyond the limits
then do as required.

Page 17 of 24
 ANNEXURE-IX

CLEANING OF MACHINE

 If the machine is soiled to such an extent that maintenance works would be

impeded, it is necessary to clean the machine before starting the working.
 Cleaning is the best opportunity to check an element visually.
 Additionally, periodical cleaning is prescribed for certain structural elements.
 It is of particular importance to clean the coolers in time.
 Do not direct any high-pressure cleaning devices against thin covers.
 Do not use any easily flammable or caustic cleansing agents.
 Clean underside at least once a year.

Page 18 of 24
 ANNEXURE-X

LUBRICATION

 For greasing and oiling remove any dirt, gummy grease and oil and lubricate the
respective part.
 All measuring and tensioning trolleys have to be lubricated / greased at intervals
according to the maintenance schedules.
 Furthermore, all hydraulic and pneumatic cylinder bearings (even if not listed in
the maintenance instruction) have to be checked visually every 50 hours of
operation and, if necessary, must be lubricated.
 All movable parts not mentioned in the maintenance instruction, such as piston
rods, cylinder fastenings, guide bushes, spindles, slide faces etc., have to be
lubricated every 50 hours of operation with oil / grease.
 For lubrication never use a grease gun generating pressure of more than 15 bar.
 Grease and grease gun must be free of dirt and foreign bodies.
 Clean the lubricating nipples of the bearings before and after lubricating them.
 Continue to lubricate until evenly distributed fresh (clean) grease will come out
the bearings. Then remove excess quantities of grease.

Page 19 of 24
 ANNEXURE-XI

ORIGINAL FILLING OF WORKING STOCK

SL. WORKING STOCK LUBRICANTS QUANTITY

NO.
1. Engine Lube oil API CF-4 15W40 25 Litres
2. Axle Gear Box Gear oil SAE 90 6.5 Litres
3. Pump Drive Gear Box Gear oil SAE 90 4.0 Litres
4. Hydraulic Oil Tank Shell Tellus Oil 68 or equivalent 450 Litres
5. Pneumatic Lubricators Shell Tellus Oil 68 or equivalent 0.25 Litres
6. Radiator Water with coolant with ratio 8:1 60 Litres
7. Grease Shell Alvania Grease RL2 or ----
equivalent

 During warranty period use the lubricants as specified by the OEM for claim
of warranty.
 At low temperatures the fuel pipe system may get clogged because of
paraffin precipitation which may lead to operational failures.
 At outside temperatures below 0°C winter fuel has to be used (up to –20°C).
Below –20°C petroleum has to be added.

Page 20 of 24
 ANNEXURE -XII

TESTING OF HYDRAULIC OIL

First filling of hydraulic oil will be done only after the testing of the oil for its
recommended values of parameters as given below.

 After that every 500 working hrs.

 At least one oil test per year.

 RECOMMENDED VALUES OF TEST PARAMETERS.

 VISCOSITY:
The admissible decrease in Viscosity is ( – 10%) of the original value

 MAXIMUM WATER CONTENT:

The water content has to be as low as possible. The maximum admissible

concentration of water in the hydraulic oil is 1000 ppm. This corresponds
to 0.10% by volume.

 PURITY:

The purity of the oil should be maintained as per NAS 1638 : 7-8 , ISO
4406 : 19/16/13-20/17/14

 ACID CONTENT:

The TAN (Total acid Number) of fresh oil amounts 0.05 mg KOH/g. The
values for used oil to be between 0.05 to 1 mg / KoH/g.

Page 21 of 24
 ANNEXURE-XIII

BRAKE

 During the cycle of service of a brake block its play has to be re-adjusted for at
least one time.
 Usually the brake block play has to be re-adjusted, when:

 The break block play is not between 5-7 mm.

 The brake blocks are replaced.
 The brake blocks are worn out on one side.
 The wheel profile had been re-worked

 PROCEDURE FOR BRACK ADJUSTMENT

 Secure the machine against breaking away by skid-pans.

 Release the parking brake.
 Release the brake cylinders (ZERO brake pressure).
 Turned off the engine.
 When assembling new brake blocks, first shift the turnbuckles so that there is
enough room for new one’s.
 Adjust the brake play by using the turnbuckles.
 Secure the turnbuckles with counter nuts.
 Do not change all brake blocks at once (e.g. in two stages).

Page 22 of 24
 ANNEXURE-XIV

V-BELT TENSION
 Check visually the V-belts over its entire dimension.
 Replace defective V-belts.
 Check new V-belts after a working time of 15 minutes.
 Check V-belt tension by finger test as below,
 Put the flat steel scale onto the V-belt between two pulleys.
 Press the V-belt at the centre and measure the depth of shifting
 It should not be more than 15mm. If so, then re-adjust the tension.

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 ACKNOWLEDGEMENT

The following officers and staff have made their valuable contributions in preparation of
Maintenance Schedule Manual of Ballast Regulating Machine (PBR-400R):

Zonal Railways

1. S/Shri P.K. Sharma, SSE/TM/SECR.

2. ‘’ ‘’ Mukhvinder Singh SSE/TM/NR.

3. ‘’ ‘’ S.K.Patel SE/TM/SECR

RDSO
S/SRI

1. T.K. Pandey Director/TM

2. Mahavir Prasad ARE/TM

3. M.N.Siddiqui, SE/TM

4. A.N.Srivastava SRE/TM

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