quality audit for diesel loco poh workshop(1)
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7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
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Page 1 of 104 Quality Audit of Diesel Loco POH Workshop
Quality Audit of Diesel Loco POH WorkshopsCHECK SHEET
Item Description Reference Documents, Annexures, Further details on check sheet
etc.
General
Compliance of POH Schedule: Schedule of standard examinations: MP-Misc-140/141 (for Alco
locos).Quality of POH: -do-
Load Test records:
HP
SFC
EGT
Peak Firing Pressure
Load Test MI No MP.MI-10 (Rev 0.02), Aug 2003. (for Alco locos).
Methodology of collection of failures on locos turned out by shops,
failure investigation, analysis and preventive action.
Display of work instructions on shop floor
Training of staff Status of record keeping
Calibration of gauges/ instruments
Safety items
a. Speed recorder/Indicator Section
b. Wheel (Wear adapted profile) profile & other defects.
c. Brake adjustment, release & and application timings.
d. Headlight focus adjustment
e. Horn maintenance
f. Undergear safety brackets
g. Gauging of Couplers
h. Vertical offset between Side bearer and centre pivot
a. OEM’s maintenance manual.
b. Drg No SKDL-2561 Alt 8.
c. Standard test scheme as per MP.TP-029/87 (Rev 02) Oct
2008 for Air Brake, and, as per MP.TP-019/81 (Rev 02) Nov
08 for dual brake locos.
d. IB No MP.IB.EC.01.08.06 (Rev 0) December 06.
f. MI No MP.IB.BD.02.16.01 (Rev 01) December 09.g. CBC Manual No G 76 Sept 87.
h. MI No MP.IB.VL.02.11.10 (Rev 00) February 10.
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Quality of
Subassembly
repairs
(important
items)
a. Expressor/Compressor
b. Air Brake Section
c. Bogie section
d. Rotating Machines Section
e. Turbo section
f. Engine Block, Crankshaft and Main bearings
g. Cylinder Head , Piston and Valve section
h. Radiator section.
i. FIP/Injector Section
j. Governor Section
k. Electrical Control Section
l. Battery Section
m. Under-frame, side buffers, cow catcher,
couplers, superstructure/Upper-frame, roof,
driver cabin, hand rails, fuel tank, loco
painting/marking/stencilling etc.
a. Further details of check sheet covered in Annexure 1.
b. -do-
c. Further details of check sheet covered in Annexure 2.
d. Further details of check sheet covered in Annexure 3.
e. Further details of check sheet covered in Annexure 4.
f. -do-
g.
h. -do-
i. -do-
j. Further details of check sheet covered in Annexure 5.
k. -do-
l. -do-
m. Further details of check sheet covered in Annexure 6.
Implementation
of modifications
As per modification sheets/Instruction Bulletin’s issued by RDSO/DLW/HQ.
Material Availability of critical items
Procurement from unapproved sources, if any.
Any other itemAs decided by the auditing authority
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Page 3 of 104 Quality Audit of Diesel Loco POH Workshop
Annexure-1
CHECK LIST FOR
TECHNICAL AUDIT AT POH WORKSHOPS (BRAKE ITEMS)
S.No. Item Parameter Observ ations
1. Whether all the items
prescribed in the schedule isbeing followed for brakeequipment, compressor /Expressor & air dryer or not
As per Schedule of standard examinations
(No. MP.Misc.-140 & 141, Rev-01,September’2006)
`
1. Whether maintenance is done as per RDSOMIs or manufacturers MI mentioned inMP.Misc.-140 & 141.
2. Maintenance facilities are available or not.2. Functioning of VCD Whether functioning of VCD is being checked in
every POH schedule.
3. Test benches and rigs 1. Whether the required test bench and rigs areavailable or not viz. AB test rack for brakevalves, air dryer test bench, compressor/
Expressor test bench etc.2. Whether, testing is done on above test
benches.3. Calibration of test benches and rigs is being
done periodically or not.
4. Test on Loco after POH Whether brake system check is done on loco asper test programme no. MP.TP-029 (for air brakeloco) & MP.TP-019 (For dual brake loco).
5. Infrastructure facilities (a) Whether dust proof and controlledtemperature environment for maintenance,assembly and testing of brake valves is
available.(b) Availability of compressed air (in test
benches.(c) Availability of compressor in air lines.(d) Whether air dryer provided in test benches/
air lines.(e) Reservoir pressure is being checked or not(f) Washing facilities
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Page 4 of 104 Quality Audit of Diesel Loco POH Workshop
(g) Painting facilities(h) Technical Cell(i) Metrology lab(j) Store(k) Tool room(l) Fire extinguishers(m)Material handling facilities for movement of
material and components.
6. Storage of material Whether dust/damp proof environment withcontrolled temperature is available for storage of brake equipment and rubber components.Whether rubber components are being stored asper guidelines mentioned in this office letter no.SD.DEV.RBC dated 28.02/07.03.2007 circulatedto all Zonal Railways.
7. Availability of Material Any Chromic shortage of material for maintenance
8. Human Resourcedevelopment
Whether periodic training is being imparted tomaintenance staff to make them conversant withthe maintenance practices.
9. Any other observation
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Page 5 of 104 Quality Audit of Diesel Loco POH Workshop
Annexure-2
CHECK SHEET FOR
CONDUCTING TECHNICAL AUDIT OF BOGIE AT POH WORKSHOP (ALCO LOCOMOTIVE)
SN Activity Loco Type Reference Details Observations
1. Overhauling/Inspection Alco Series
RDSO report Misc. No. Misc-164,MP.MI-71/78 and SK.DL-3370 to befollowed
Cleaning of bogie frame
Alignment of bogie frame (includingtramming)
a) Wheel base spacingb) Transverse pedestal spacingc) Longitudinal pedestal spacingd) Pedestal bottom alignmente) Motor nose suspension lug
squareness & spacing
Crack detection, repair & heattreatment (Stress relieving)
Replacement of manganese liners andbrake rigging bushes
WDM2, WDM3A, WDG3A, &
WDM3D/E/F
2. Axle box & journal bearings
Cleaning of Axle box & bearings
Inspection bearing components
Overhauling as per the referred MP.MI
MP.MI-04.004
3. Suspension Springs ( As per MI )
Cleaning of springs
Free height of springs
Working height of springs
Grouping / colour code of springs
100% replace of spring pads ( HappyPads)
WDM2, WDM3A, WDG3A, &
WDM3D/E/F
As per relevant drawing,MP.IB.VL- 04.19.01 (Rev.01),
MP.IB.VL- 04.19.01 (Rev.01) for
WDG3A & MP.MI-31 for
WDM3D/E/F
4. Friction Snubber Assembly
Disassemble snubber (See SK.DL- 1505for instructions)
Check the inside diameter of the frictionsleeve with a “No Go” gauge FigureSK.DL- 3127
Details as per Drawing SK.DL-2089A, SK.DL- 1505, SK.DL- 3127,SK.DL-3126, SK.DL- 1512 , SK.DL-1513
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Page 6 of 104 Quality Audit of Diesel Loco POH Workshop
Check the dimensions of the shoes asindicated in figure SK.DL-3126
Replace worn or broken parts. For assembly refer SK.DL- 1512 &1513
Re-assembly of snubber
Height measurement and checking for damping characteristics
5. Hydraulic damper
Check the Capacity / Rating of dampers Damper overhauling
Testing
As per drawings No. SK.VL-295,
SK.VL-328 and SK.VL-387 &overhauling as per MP.IB.VL. 05.39.10 (Rev.00)
6. Side Bearer (Rubber spring)
Free Height of rubber spring
Working height of rubber spring
Permanent set of rubber spring
Rubber crack length/ de-bonding
WDG3A, & WDM3D/E/F As per drawings No. SK.Vl-127 &
133 &
MP.IB.VL. 04.30.08 (Rev.01)
7. Equaliser Beams
Checking for cracks
Reclamation of hard face as per MC-43
and 92
WDM2, WDM3A, M&C document no. MC – 43 & MC-92
8. Wheel & Axle Assembly
Wheel wear measurement i.e. Rootwear, Tread wear, Flange wear, wheelflat, visual inspection for any defectlike crack, wheel flat, shelling, spalingetc. ,wheel reprofiling.
Wheel gauge (1596+3/-0.5 mm)
Deference in tread diameter of wheelson same axle, same bogie & sameloco
Ultrasonic testing of axles
WDM2, WDM3A,WDG3A, &
WDM3D/E/F
Wheel wear managementInstruction Bulletinno.MP.IB.BD.0216.01 (Rev-1) & MPMI71/78 & MP.MI-31
RDSO procedure MC-71
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Page 7 of 104 Quality Audit of Diesel Loco POH Workshop
9. Brake rigging
Abnormal wear of brake hangers
Replacement of Brake blocks, Pins &Bushes
Replace brake head, tie rod, brakeshoe key, top & bottom slack adjusters
(condition basis) and friction armspring, if found damaged.
MP.MISC – 141
1. Centre Pivot & Loading Pads
Load Pad to Centre Pivot HeightDifference to be maintained.
2. Floating type Pivot assembly:Dismantle complete assembly
Clean of the metal component exceptrubber bush
Inspect for wear, tear and cracks
Reassemble pivot block assembly withchange centre pivot bush.
In case non-metallic pivot block, 100%replacement may be carried out.
WDM2, WDM3A
WDG3A, & WDM3D/E/F
MP.IB.VL.02.11.10
SK.VL-128
SK.VL-501, RDSO Modification
sheet no. 03.10.09
10. Lateral Stopper, lifting chain and other fasteners and brackets are to be 100%replaced.
WDG3A, & WDM3D/E/F SK.VL-134
11. Re-assembly of bogieMaintain all running gear clearance as per the MI’s Maintain the Lateral clearances between
Axle Box and Pedestals
(Ensure attention to wheel and axleassembly as per S.N. 8)
WDM2, WDM3AWDG3A, & WDM3D/E/F
MP.MI-71/78, VL.Mi-02/96 &MP.MI-31
MP.IB.VL.03.04.06 (WDM2 &
WDM3A)
MP.IB.VL.01.02.06 (WDG3A)
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Page 8 of 104 Quality Audit of Diesel Loco POH Workshop
12. Availability of Tools And Test Stands WDM2, WDM3A,WDG3A, &
WDM3D/E/FOver head Crane
Hydraulic Jacks
Cleaning vat
Bogie frame manipulator
Crack reclamation facility like gouging,
grinding & welding facility etc.Stress relieving furnace
DPT, MPT & UT testing facilities
Surface table for measurement
Spring load-deflection testing machine
Hydraulic damper testing machine
Torque wrench, Go/No Go Gauges
Height gauges
Inside and Outside Calliper, Vernier Caliper, Height Gauge, Cleaning Tank,
Painting facilitiesWheel wear measuring gauge SK.DL-3592
Elecrode heating oven
Facility to measure pre-heat temperature
13. Availability Of Instructions Etc
Availability of WI including criticaldimensions
Training of staff including qualification of welders
Maintenance manual and check sheets
Record keeping of tools and measuringinstruments
Calibration of measuring instruments
14. Record Keeping For Traceability
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Page 9 of 104 Quality Audit of Diesel Loco POH Workshop
Annexure-3
CHECK SHEET FOR
QUALITY AUDIT OF TRACTION MOTOR PINION & GEAR ASSLY. AT POH WORKSHOPS
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are
not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCEDETAILS
CLAUSE/PARA/
ITEM
DETAILS
OBSERVATION
1 MEASUREMENT
Alco (WDM2,
WDM3A,WDM3D)
MP-IB.EM.10.31.08dated
24.10.2008
1.1 TRACTION GEAR & PINION
Gear Ratio 18 : 65
Pinion Drg. No. 18 teeth, SKDP3624
Pinion Bedding In ColdCondition
Not less than 95 %
Pinion Advance 2.25 TO 2.45MM
Heating Temperature 190ºC + AMB TEMP.
Span Size On New Pinion Over 3 teeth88.595 /88.722MM
Condmning Limit On Basis Of Span Size Of Pinion
Over 3 teeth86.995MM
Gear Drg. No. 65 teeth SKDP3623& SKDP3775
Span Size On New Gear Over 7 teeth223.989/223.798MM
Condmning Limit On Basis Of Span Size Of Gear Over 7 teeth220.800MMPermissible Backlsh With NewSet
0.266 - 0.664MM
Condemning Limit On BasisOf Backlash
1.04MM
Crack detection MPMI or Zyglo test
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Page 10 of 104 Quality Audit of Diesel Loco POH Workshop
1.2 TRACTION GEAR & PINION
WDG3ATraction Motor Pinion & Gear Assly. of Alco
Loco
MP-MI 129/86July ‘1986
MP-MI 5
Gear Ratio 18 : 74
Pinion Drg. No. 18 teeth, SKDP3443
Pinion Bedding In ColdCondition
Not less than 95 %
Pinion Advance 2.30 TO 2.45MM
Heating Temperature 185ºC + AMB TEP.Span Size On New Pinion Over 3 teeth 81.976
/82.093MMCondmning Limit On Basis Of Span Size Of Pinion
Over 3 teeth80.366MM
Gear Drg. No. 65 teeth SKDP3444 &SKDP3546
Span Size On New Gear Over 8 teeth231.36/231.177
Condmning Limit On Basis Of Span Size Of Gear
Over 8 teeth 228.140
Permissible Backlsh With NewSet
0.243 - 0.608MM
Condemning Limit On BasisOf Backlash
1.00MM
Crack detection MPMI or Zyglo test
1.3 TA FAN ASSEMBLY
All ALColocos
MP-IB.EM.01.02.10dated 11.01.2010.
Outer diameter of TA fan
1387.25/1387mm
Bore diameter of TA stator 1392mm
Bore diameter of TA fan 600.00 / 600.03mm
Diameter of fan seating area onbarrel.
600.03 / 600.06mm
Width of fan seating at bore 9+1 mmDepth of counter sunk bolts hole 4.5 - 5.5 mm
Bolt head width 12.3mm
Bolt head height above fan plateafter final assembly should not bemore than
6- 7mm
Circumferentially Fan gap on TA 2.50 – 2.75mm
Tightening torque and wire lockingprocess
28 – 30Kg-m
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Page 11 of 104 Quality Audit of Diesel Loco POH Workshop
Tightening torque of M30(coupling bolt)
170 – 180 kg-m.
Oil catcher thickness (at bottomside)
53.90 to 54.10mm
Bolts strength properties grade R8.8.
Sunk type M20 bolts can be used in place of fullythreaded M20 bolts
M20 & M30 bolts should be
replaced
After 4 – 5 years
service of TAFan bore area should be heated(for shrink fit).
150 to 170 °С
Re-used or old bolts and barrelthread condition should bechecked by
GO & NO GO threadring or plug gauge
Threaded portion of barrel & boltsshould be free from varnish or paint or dust deposits.
Visual inspection isrequired
TA fan should be mounted on thebarrel by “shrink fit “
In place of (bolts)press fit.
TA fan bolts locking wire endsshould not be come out of the bolthead(projected)
As shown in photo
Proper alignment of TA fan shouldbe checked by inserting filler gauge circumferentially
Clearance betweenthe fan (back side)and barrel of TA (asshown in attachedphoto)No clearance isallowed.
After Final assembly of TA fan,visual inspection is required on
Tightening torque,wire locking & fanback clearance withbarrel(by filler gauge(circumferentially)
TA Gear train assembly Backlash at Steelplate
All ALColocos
MP.IB.EM.02.12.0
0dated 10-4-2000.TA GEAR 102T AG/EG PINION 43T
PTU PINION - 43T
0.60mm to 1.40mm0.05mm to 0.12mm
on shaft
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2 Carbody cables and Traction Motor cables
All ALColocos
MP.IB.EM.02.03.08,dated 24-01-2008
And
MP.IB.EM.03.04.08,dated 24-01-2008
Ensure the following:
Control cables should be replaced fully irrespective of
the condition after every 8 years. Power cables
should be replaced on condition basis. During POH
power cables, which are exposed to oil should be
critically examined and replaced if any symptoms of
bulging, softening or perishing of insulation at the
cable terminals are noticed.
3 AVAILABILITY OF TOOLS AND TEST STANDSAll ALColocos
MP.IB.EM.02.03.08,dated 24-01-2008
And
MP.IB.EM.03.04.08,
dated 24-01-2008
2.1 Vernier Callipers
2.2 Disc Mike
2.3 Filler Gauge
4 INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.4Record keeping of tools and measuring
instruments
5 TRACEABILITY
6 MATERIAL AVAILABILITY
5.1 Vital Spare -NA
5.2 Must change items -NA
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CHECK SHEET FOR
QUALITY AUDIT OF TRACTION MOTORS AT POH WORKSHOPS
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are
not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-
ASSEMBLY
REFERENCE
DETAILS
CLAUSE/
PARA/
ITEM DETAILS
OBSERVATI
ON
1 MEASUREMENT
Alco Locos
Traction Motors
of Alco Loco
MP.MI-2,
MP.MI-6 &
Maintenance
manual issued
by OEMs viz.
BHEL / CGL.
1.1 PRE-INSPECTION
i) Record IR of
a) Armature (Shall be > 10 MΩ)
b) Inter Pole (Shall be > 10 MΩ )
c) Main Pole (Shall be > 10 MΩ)
ii) Record ovality of commutator (Limit – 0.001”)
1.2 AFTER DIS-MANTLING
i) Pinion to be sent for Magna flux test / Zyglo test
ii) Visual examination of Armature banding. If found
beyond repair, rewind it.
iii) Check commutator dia. for condemning size.
Replace commutator, if condemning size reached.
If commutator is retained, then check millivolt
drop to ensure health of tig welding/bar to bar
shortening. If required, repair it.
iv) Check commutator surface roughness. If found >
0.05 mm or any cut mark is observed,
commutator to be grind on machine.
v) Ensure that there is no damage on armature
seating area & armature shaft. If any damaged is
noticed, re-metalize it to reqd. size.
vi) Ensure cleaning of magnet frame with cleaning
solvent to RDSO spec. MP.0.8000.01 Rev.02
Oct.’2007.
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vii) Bake the magnet frame in oven at 120 + 10 °C &
record it.
viii) Apply insulation varnish as per RDSO MP.MI
153/92 (latest revision)
ix) Check IR after renewal of glass epoxy laminate,
GMGS & Nomex insulation for inter poles & main
poles (Shall be > 100 MΩ )
x) Ensure tightening of pole bolts during assembly of
magnet frame and maintain IP & MP bores as per
OEM manual.
xi) Joints may be brazed & insulated, if required with
RDSO approved Silicon elastomer tape.
xii) Check IR of main pole & inter pole assemblies &
record it. (Shall be > 100 MΩ )
xiii) High potential test of inter pole & main pole at
1.3 KV for 15 sec. shall pass the test.
xiv) Ensure spray cleaning of armature with cleaning
solvent to RDSO spec. MP.0.8000.01 Rev.02
Oct.’2007.
xv) Bake the armature in oven at 120 + 10 °C &
record it.
xvi) Spray varnish paint protecting the shaft &
commutator & cure it.
xvii) Ensure mica cutting. & chamfering as per OEM’s
manual
xviii) Ensure cleaning & baking of brush arms as perOEM’s manual.
xix) Measure IR of brush arm (Shall be > 100 MΩ). If
less, replace the brush arm
xx) Ensure the spring tension. (Lt. 4.5 Kg to 5.5 Kg)
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xxi) Ensure the replacement of PTFE sleeve of brush
arm.
xxii) Ensure painting of support arm with red becktol
varnish.
xxiii) Conduct high potential test as per OEM’s manual
1.3 ASSEMBLY
i) Motor assembly as per OEM’s manual
ii) Measure the final Insulation Resistance = 10
Mega ohm
a) Armature (Shall be > 100 MΩ)
b) Inter Pole (Shall be > 100 MΩ )
c) Main Pole (Shall be > 100 MΩ)
iii) Measure the end float (Lt. = 0.006” to 0.012”)
iv) Check the nose plate condition. If found damaged
or wear out, shall be replaced.
v) Conduct the light run test at low, medium & highrpms on assembled motor & observe for unusual
sound using listening rod.
vi) Check the bearing temperature after stabilisation
during light un test. (Shall not be > 60 °C)
vii) Apply brush seater on the commutator to seat
the carbon brushes on the commutator properly.
viii) Ensure tag welding / welding of stays on main
pole & compole fixing bolts.
ix) Apply recommended sealant to avoid ingress of
water etc.x) Apply a coat of paint on motor.
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2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 1000V Megger
2.2 Filler gauge
2.3 HV tester
2.4 Dial gauge
2.5 Tachometer / Speedometer2.6 Pyrometer
2.7 Inside & Outside micrometer /calliper
3 INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.3 Record keeping of tools & measuring instruments
4 TRACEABILITY
5 MATERIAL AVAILABILITY & STORAGE (AC/non-
AC)
5.1 Vital Spares
5.2 Must change items
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CHECK SHEET FOR
QUALITY AUDIT OF TRACTION ALTERNATOR AT POH WORKSHOPS
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are
not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-
ASSEMBLY
REFERENCE
DETAILS
CLAUSE/
PARA/ITEM
DETAILS
OBSERVATIO
N
1 MEASUREMENT
ALCO locos TractionAlternator
of Alco loco
BHEL’s
Maintenance
Manual forElectrical
Equipment of
ALCO loco
(Volume-II)
a)Check tightness of all mechanical and
electrical connections. Check slip rings and
brushes for sparking.
b)BRUSH GEAR
Spring pressure- 1.36 to 2.2 kgs (adjustable) to
be adjusted to 1.8 kgs.Minimum length of brush at which brush
become inoperative – 35mm.
Clearance between brush holder & slip ring- 2
to 3 mm.
c)SLIP RING
Diameter (New) – 520 mm
Minimum worn out dia – 510 mm
Slip ring run our (max) – 0.1 mm
Slip ring ovality (max) – 0.1 mm
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d)ROTOR
Diameter- 1003 mm
Air gap at pole center – 6 mm
Rotor bearing - NU330 EM/C4/D150mm x65
mm x 320mm O/D
Bearing housing dimension – 320-0.005 mm.where outer race sites - - 0.025 mm
Radial clearance of free bearing when new –
0.165 to 0.215 mm
Fit between outer race & bearing housing-
0.035 mm clearance, 0.025 mm interference
Shaft bearing seating dia – 150 + 0.055 mm
+ 0.035 mm
Fit between inner race & shaft – 0.035 to 0.08
mm interferenceDiametrical slackness of free bearing – 0.15 to
0.18 mm
Min. permissible racial clearance when
assembled - 0.03 to 0.13 mm
Min. diametrical clearance when assembled in
the machine – 0.051 mm
Bull gear wheel I/D – 149.098 + 0.025 mm
+ 0.0 mm
Shaft bull gear seating dia –149.098 + 0.162 mm
+ 0.152 mmGear box oil capacity – 2.6 litres approx.
Lubricant type – SAE 40 or equivalent
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e)TIGHTENING TORQUE KG.M
Exciter to gear box – 15
Aux-gen to gear box – 15
PTU to gear box – 15
Gear box to end shield – 15
(write locked)Gear box to end shield – 1
(at pads)
Fan to rotor shaft – 25/27
(write locked)
Rotor shaft extension to barrel – 25
Rotor pole bolts – 170/190
Slip ring to shaft extn. – 15
f) RESISTANCE AT 25°C-
Stator- 0.002156 ohm (Line to Line)
Rotor- 0.312 ohm (at slip ring)
g) IR TESTS
Stator (check with 1000V magger) : 2M Ohms
Rotor(check with 1000V magger) : 2M Ohms
2 AVAILABILITY OF TOOLS AND TEST STANDS
a. Bearing retaining ring
b. Clamping ring
c. Shaft adaptor
d. Guide sleevee. Frame lifting fixture
f. Extractor for bull gear
g. Lifting tackle
h. Forcing screws
i. Guiding studs
j. Spacers
k. S.K.F. Oil Pump
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Page 20 of 104 Quality Audit of Diesel Loco POH Workshop
l. Studs
m. protection sleeves
n. Extractor for bearing inner race
o. Extractor foe bearing outer race from
bearing housing
3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff
3.4Record keeping of tools & measuring
instruments
4 TRACEBILITY
5 MATERIAL AVAILABILITY
5.1 Vital Spare
5.2 Must change items
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Page 21 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
QUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS AT POH WORKSHOPS
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are
not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-
ASSEMBLY
REFERENCE
DETAILS
CLAUSE/
PARA/ITEM
DETAILS
OBSERVATION
1 MEASUREMENT
All ALColocos fitted
with TM4907/C1001
Traction Motor Bearing & Assly.Components of
Alco Loco
MP-IB.EM.14.50.08
dated20.02.2009
1.1 Verticality of Outer race
1.2 Verticality of Inner race
1.3 Max. deviations allowed in above cases:
Side Inner race Outer race
Pinion End 0.075 mm 0.25 mm
Commutator End 0.065 mm 0.20 mm
1.4 Radial Clearances of bearings
a) For New Bearings
Bearing Radial clearancebefore mounting
(mm)
Radial clearanceafter mounting (mm)
NU 330 0.165 - 0.215 0.100 – 0.170
NH 320 0.105 – 0.140 0.060 – 0.100
b) In addition to above, max. service radialclearance
NU 330 0.300 mm max. 0.250 mm max.
NH 320 0.190 mm max. 0.150 mm max.
c) Flinger - PEBore Dia. 153.130 to 153.155 mm
Total Width 12.65 to 12.70 mm
d) Retaining collar - PE
Bore Dia. 146.015 to 146.040 mm
Total Width 12.65 to 12.70 mm
Outer Dia. 253.225 to 253.290 mm
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Page 22 of 104 Quality Audit of Diesel Loco POH Workshop
Hub Outer dia. 177.040 to 177.090 mm
Outer dia. on 2n
Groove 210.610 to 210.670 mm
Groove width 8.00 to 8.05 mm
Total width 44.4 to 44.6 mm
e) End shield - PE
Bore dia. 319.975 to 319.995 mm
f) End shield - CE
Bore dia. 214.980 to 215.00 mmg) Seat diameter on armature shaft
For brg.-PE, Bore dia. 150.035 to 150.055 mm
For brg.-CE, Bore dia. 100.025 to 100.040 mm
For retaining collar PE 146.130 to 146.150 mm
For bearing sleeve PE 153.220 to 153.240 mm
For inner brg. wiper CE 101.600 to 101.620 mm
h) End Float on Traction motor (TM 4907) CE
Limit – 0.50 mm Aim – 0.42 mm
1.5 Fits & Clearances (BG TM)
i) Pinion end bearing
Interferences (Diametrical) Clearances (Diametrical
Brg. Sleeveto shaft
0.020 to0.065 mm
Brg.Sleeve toinner brg.cap
0.635 to0.750 mm
Flinger toshaft
0.065 to0.110 mm
Retainingcollar toouter brg.cap
0.25 mm(min.)
Inner race toshaft
0.035 to0.080 mm
--------------- --------------
Retainingcollar to shaft
0.090 to0.135 mm
-------------- --------------
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Page 23 of 104 Quality Audit of Diesel Loco POH Workshop
ii) Commutator end bearing
Interferences (Diametrical) Clearances (Diametrical
Brg. Sleeveto shaft
0.020 to0.065 mm
Inner brg.Cap tosleeve
0.635 to0.750 mm
Flinger toshaft
0.065 to0.110 mm
--------------- --------------
Inner brg.
Race to shaft
0.025 to
0.060 mm
-------------- --------------
1.6 Heating temp. of brg. & assly. components
Item Heating temp.
Bearing inner race PE 100 - 110 ºC
Bearing inner race CE 100 -110 ºC
Sleeve (PE) 100 -130 ºC
Sleeve (CE) 100 -130 ºC
Flinger (PE) 100 -120 ºC
End shield (PE) 120 -130 ºC
End shield (CE) 120 -130 ºC
Retaining collar (wiper) 120 -130 ºC
2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Dial gauge3 INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.3Record keeping of tools and measuring
instruments
4 TRACEABILITY
5 MATERIAL AVAILABILITY
5.1 Vital Spare - NA
5.2 Must change items - NA
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Page 24 of 104 Quality Audit of Diesel Loco POH Workshop
Annexure-4
CHECK SHEET FOR
QUALITY AUDITOF TURBO SECTION (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco Type Make Of
Subassembly
Reference
Details
Clause/Para/It
em Details
Observations
1.
Balancing, measurementsetc
Balancing:
1.1 Bladed shaft, range 31-257 gmm.
1.2 Rotor, range 157-470 gmm.
5.6
5.6.2.5
5.6.2.5
Rotor Shaft Dimensions:
1.3 Bearing position OD A 39.98 – 40.00 mm
Alco ABB VTC 304
Turbocharger
ABB-Exhaust
Gas
Turbocharge
r VTC 304 A
Comprehensi
ve Manual
for Indian
Railways
issued by
M/s ABB
Para 5.2.4.13
&
details in5.4.2.1
1.4 Bearing position OD B 50.987--51.000 mm
1.5 Bearing position OD C 56.10-56.20 mm
1.6 Piston ring recess S 2.58-2.85 mm
Wheel Bush
1.7 Compressor wheel set OD A 56.10 -56.20 mm
Para 5.2.4.13
&
details in
5.4.2.2
1.8 Piston ring recess S 2.58-2.85 mm
1.9 Plain bearing (CE) ID A 54.00-54.06 mm Para 5.2.4.13
&
details in
5.4.2.3
1.10 Bearing housing bore ID A 65.00-65.07 mm Para 5.2.4.13
&
details in
5.4.2.4
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Page 25 of 104 Quality Audit of Diesel Loco POH Workshop
1.11 Floating bush ID (CE) 40.011-40.05 mm Para 5.2.4.13
&
details in
5.4.2.5
Floating bush OD (CE) 53.80-53.86 mm
1.12 Floating bush OD (TE) 64.82-64.84 mm
1.13 Floating bush ID (TE) 51.022-51.07 mm
1.14 Thrust bearing width 10.39-10.50 mm Para 5.2.4.13
&
details in5.4.2.6
1.15 Axial bearing width 16.76-16.88 mm Para 5.2.4.13
&
details in
5.4.2.7
1.16 Piston ring width 2.00-2.49 mm Para 5.2.4.13
&
details in
5.4.2.8
1.17 Thrust bearing press fit measure(K) 170.5-170.63 Para 5.2.4.13
&details in
5.4.2.9
1.18 Axial clearance A 0.11-0.32 mm Para 5.2.4.13
&
details in 5.7
1.19 Radial clearance B 0.47-0.93 mm
2.
Availability of Tools, Test Stands etc.
Alco do do
2.1 Balancing machine
2.2 Zyglo testing machine
2.3 Casing hydraulic test stand
2.4 Bearing puller (CE & TE)
2.5 Torque wrench up to 250 psi
2.6 micrometer 2”-3” & 0-4”
2.7 Go-NoGo gauge for checking fix nozzle ring
3
Availability of instructions etc.
3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
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Page 26 of 104 Quality Audit of Diesel Loco POH Workshop
4 Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
5.2 Must change items
1
Measurements etc
1.1 Nozzle ring and gas inlet casing 0.022-0.032”DiaClearance (Cl)
Alco Alco 720
Instruction
Manual
ALCO
ALCo MI
11126
1.2 Turbine blade and gas inlet casing 0.060-0.092”Dia CI
1.3 Nozzle ring and turbine disc 0.124” cold CI
1.4 Intermediate casing and impeller 0.017-0.065”
longitudinal Clearance (long Cl)
1.5 Impeller and Blower inlet 0.035-0.075” long CI
1.6 Blower casing end blower inlet measure with bolt
loose. Scatting with back of diffuser at lease to 80%(This
is only in case when we apply a new diffuser) 0.005-
0.020” Long CI (Gap)
1.7 Turbine disc and intermediate casing 0.008-0.016”Long CI
1.8 Bearing and thrust collar (Blower end) with surface
by approx 0.003 less when oil. 0.007-0.018” Thrust CI
1.9 Inducer and blower casing 0.091-0.101”Dia CI
1.10 Thurst collar and oil seal Blower End 0.014-
0.036”Dia CI
1.11 Interference between bearing and intermediate
casing (blower & Turbine end ) 0.0005-0.0015” DiaCl
1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008”
Dia CI
1.13 Gas inlet casing and intermediate casing insidemeasurement 0.090-0.098” Dia CI
1.14 Impeller and intermediate casing 0.125-0.127” Dia
CI
1.15 Max allowable clearance between Gas inlet casing
& Nozzle ring 0.005” clearance
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Page 27 of 104 Quality Audit of Diesel Loco POH Workshop
2
Availability of tools, Test Stands etc.
AlcoAlco 720 Instruction
Manual
ALCO
2.1 Balancing machine
2.2 Zyglo machine
2.3 Casing hydraulic test stand
2.4 Oil gallery flushing test stand
2.5 Bearing puller (CE & TE)
2.6 Sand blast machine for rotor cleaning2.7 Torque wrench up to 250 psi
2.8 micrometer 2”-3” & 0-4”
2.9 Go-NoGo gauge for checking fix nozzle ring
3
Availability of instructions etc .
3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
5.2 Must change items
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Page 28 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF ENGINE BLOCK, MAIN BEARING (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make/classOf
Subassembly
ReferenceDetails
Clause/Para/Item/Chapter Details
Observations
1 Removal of Cyl Block
a) Removal of Cylinder liner.
b) Removal of cylinder liner sleeve.
Alco
Conventional
ALCO MI
11079 D
Chapter on Maintenance,
Instruction of Cylinder Block
.
2 Maintenance and Inspection
DPT for cracks/signs of leaks/ other
damage,
2.1 Check sizes of Main Brg. Bore.
a) New MB bore dia. 9.0355" -9.0370"
b) Worn MB bore dia. 9.0350" -
9.0385"
c) Cyl. Liner bore.
2.2 a)Out of roundness checking at planes
A,B,C,D, E & F (max. 0.0035”).
b) Check taper
i) At vertical planes A and D (0.001”).
ii) At 45° from vertical between
planes B & F and C & E (0.003”).
a) Horizontal misalignment limit – (i) Two adjacent bores – 0.002”
(ii) Two non-adjacent bores 0.004”
b) Vertical misalignment limit –
(i) Three adjacent bores-0.0015”
(ii) Two non-adjacent bores-
0.003”.
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Page 29 of 104 Quality Audit of Diesel Loco POH Workshop
Torque values for Cylinder head stud 100-
120 ft pound.
4.
Availability of tools and test
a) Plate, lifting
b) Compound, gasket
c) Turning plate, free end & gen. end.
d) Fixture for checking distortion of Cyl,
block and cyl. liner to Cyl. block seat
e) Sleeve tool, upper and lower.f) Mandrel
g) Magnaflux
h) Feeler gauge
i) Vernier caliper
j) Torque wrench
5.
Availability of instruction
a) Display chart.
b) Training of staff
c) Maintenance manual and check
sheets.
d) Record keeping of tools andmeasuring instruments.
6.Record keeping traceability
.
7.
Material availability
(i). Vital spares.
(ii). Must change item
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Page 30 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF CRANK SHAFT (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco
Type
Make/class
Of
Subassembly
Reference
Details
Clause/Para/
Item/Chapter Details
Observations
1 Removal of Crank Shaft
a) Removal of Oil
catcher/pipes/engine parts/main
brgs caps/shells & split gears.
b) Checked Crank shaft thrust
(i) Using Main brg shell 0.010”-
0.017”
(ii) Using Thrust collar 0.012”-
0.021”
c) Apply grease and wrap journals
and crankpins. Alco
Conventional
ALCO MI
11069 E
Chapter on Maintenance,
Instruction of Cylinder Block.2 Maintenance and Inspection
a) Cleaning
b) Magnaflux test for
cracks/other damage,
c) Roughness and burrs (limit 25
RMS max).
d) Check M/Brgs saddle bore
2.1 Check Crank shaft.
a) MB Journal dia. 8.498" – 8.500"
b) Out of roundness limit 0.002”
c) Run out for 16 cyl-0.008” max
d) MB Journal eccentricity limit
0.001”
d) Crank pin dia 5.998”- 6.000”
e) Crank pin out of roundness limit
0.002”
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Page 31 of 104 Quality Audit of Diesel Loco POH Workshop
2.2 Split Gear
a) Removal of gears.
b) Inspect gear teeth (ALCo MI 11030).
2.3 Check Split gear
a) Key Interference fit- 0.0000”-0.0005”
b) Gear side clearance-0.007”-0.023”
c) Split line clearance limit- 0.0015”
d) Torque for gear cap screw in ft-lbs –
i) Preliminary torque- 50 ft-lbsii) Final torque – 300 ft-lbs.
ALCO MI
11067 C
ALCO MI
11069 E &
11067C4.
Availability of tools and test
a) Lifting block
b) Lapping tool
c) Deflection guage.
d) Feeler gauge
e) Soft hammer
f) Torque wrench
5.
Availability of instruction
a) Display chart.
b) Training of staff c) Maintenance manual and
check sheets.
d) Record keeping of tools and
measuring instruments.
6. Record keeping traceability.
7.
Material availability
(i). Vital spares.
(ii). Must change item
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Page 32 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CYLINDER HEAD SECTION (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
1
Cleaning, measurements etc.
1.1 Cleaning of cylinder head
ALCo --
DLW
Maintenance
Instruction
Manual
Chapter on cylinder
head
1.2 Cy head leak test at 70 PSI with hot water
1.3 Inspect head for cracks using Magnaflux
1.4 Valve guide to head int 0.002” -0.0005”
1.5 yoke to guide int 0.002” -0.0005”
1.6 Yoke guide ( press in dim) 3.210” -3.272”
1.7 Valve guide ( press in dim) 2.25”
1.8 Valve to guide cl 0.003 – 0.0045”
1.9 Cy head nuts torquing value 550ft/lbs
2
Availability of tools , Test Stands etc.
2.1 Valve seat reconditioning machine
2.2 Hydraulic test stand
2.3 Nozzle hole sleeve tube expander(Bottom & Top)
2.4 Nozzle sleeve extractor
2.5 Nozzle sleeve holder
2.6 Feeler gauge
2.7 Magna flux
3
Availability of instructions etc.
3.1 Display Chart3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5Material Availability
5.1 Vital Spares
5.2 Must change items
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Page 33 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF PISTON SECTION (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
1
Cleaning, inspection, measurements etc.
1.1 cleaning of piston
ALCo--
DLW
Maintenance
Instruction
Manual
Chapter on piston and
con rod
1.2 Inspect visually piston skirt and body for scoring or
scuffing
1.3 Inspect piston crack using Magnaflux
1.4 Zyglo test for checking surface crack
1.5 (a) Groove width top ring, 2nd
ring and 3rd
ring
0.1902”- 0.1950”(conventional)
(b) Groove width top ring & 2nd
ring 0.1900”-0.195”(3RV)
1.6 (a) Side clearance in above rings 0.0052” -0.012”
(conventional)
(b) Side clearance in above rings 0.0054” -0.012”
(3RV)
1.7 (a) Groove width of oil scraper ring 0.3140” –
0.3165” (conventional)
(b)Groove width of oil scraper ring 0.2377” – 0.0.241”
(3RV)
1.8 (a) Side clearance in oil ring 0.002”- 0.006”
(conventional)
(b) Side clearance in oil ring 0.002”- 0.0064” (3RV)
1.9 Piston pin to bushing clearance running 0.003” –
0.0075”
1.10 Piston pin to snap ring total clearance 0.076” –
0.118”
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Page 34 of 104 Quality Audit of Diesel Loco POH Workshop
2.
Availability of tools , Test Stands etc.
2.1 Feeler gauge
2.2 Zyglo testing machine
2.3 Magna flux
2.4 Vernier caliper
2.6 Piston ring groove gauge
3
Availability of instructions etc3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
5.2 Must change items
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Page 35 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
QUALITY AUDIT OF AIR & EXHAUST VALVE MAINTENANCE (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference documents. Wherever the activities are not
performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco Type Make of
Subassembly
Reference
Details
Clause/Para/
Item details
Observations
1
Measurements etc:
Alco--
Alco Instruction
Manual (MI-
11020G)
Chapter on
Cylinder
Heads
1.1 Stem dia. of valves 0.6205-0.6195 (New).
1.2 Groove fillet radii 0.025-0.031R.
1.3 Valve disk thickness: for C and F type valve
of 450:
(a) 0.1562” (new) and (b) 0.0625”
(condemning Limit).
1.4 Valve disk thickness (for E type valve 300)
0.1750” (new). And, 0.0937” (condemning
Limit).
2
Availability of tools, test stands etc:
2.1 Depressor, Spring etc
2.2 Grinder
3
Availability of instructions etc:
3.1 Display Chart etc.
3.2 Training of Staff
3.3 Record keeping of tools and measuring
instruments
4 Record keeping for traceability:
5
Material Availability:
5.1 Vital Spare
5.2 Must change items
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Page 36 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF RADIATOR SECTION (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco
Type
Make/class
Of
Subassembly
Reference
Details
Clause/Para/
Item/Chapter Details
Observations
1 Leakage testing
AlcoConventional
Alco MI
Chapter on Maintenance,
Radiators.
2 Reconditioning of Radiator Chapter on LOCOMOTIVE
INSPECTION,
MAINTENANCE AND
LUBRICATION
MI 17003 A
2.1 Dismantling2.2 Cleaning of the core
2.3 Changing of gaskets
2.4 Assembly
2.5 Testing
Chapter on Maintenance,Radiators.
3 Cleaning etc
Alco ConventionalAlco MI
Chapter on Maintenance,
Radiators.
3.1 cleaning details
4
Availability of tools, Test Stands etc.
4.1 Torque wrench up to 140 ft-lb.
4.2 Hydraulic testing machine 0-10 Kg/Cm2
4.3 Radiator stand4.4 Fin combing tool
4.5 Radiator immersion tank for cleaning
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Page 37 of 104 Quality Audit of Diesel Loco POH Workshop
5
Availability of instructions etc.
5.1 Display board etc
5.2 Training of staff
5.3 maintenance manual and check sheets
5.4 Calibration facility for tools and measuring
instruments
6 Record Keeping for Traceability
7.
Material Availability:
5.1 Vital spares
5.2 Must change Item
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Page 38 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
QUALITY AUDIT OF FUEL INJECTION PUMP (POH)
During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed
correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco type Make of
subassembly
Reference
details
Clause/Para/Item details Observation
1. Dis-assembly /Measurement/Assembly etc
Alco Bosch 17 mm Bosch repair
and testing
manual
Para on Dis-assembly
Para on Inspection of parts
Para on Inspection of parts
Para on Inspection of parts
Para on Inspection of parts
Para on assembly
Para on Calibration values
1.1 Dis-assembly
1.2 Inspection of parts
1.3 Replace plunger guide cup if the indentation
on the Plunger and tappet seating surface is
more than 0.125 mm (0.005”)
1.4 Clearance between control rack and bushing
within 0.5 mm (0.020”)
1.5 Control rack movement – within 0.38 mm
(0.015”).
1.6 Range control bush dia – 18.25 mm (0.7185”)
– 18.27 mm (0.7192”)
1.7 BDC Dimension ‘a’ – 6.5 ± 0.05 mm.
2. Availability of Tools ,Test Stands etc.
1.1 Depth gauge for checking of BDC dimension
‘a’ on test bench.
1.2 Nut torque wrench, 450 lbs – 500 lbs.
1.3 Bush reamer.
1.4 Micrometer, 16 – 20 mm.
1.5 Assembly and dis-assembly fixture
1.6 Pump calibration test stand
1.7 Calibration oil – Servo Calib-5
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Page 39 of 104 Quality Audit of Diesel Loco POH Workshop
3. Availability of instructions etc.
3.1 Display of charts etc
3.2 Training of staff.
3.3 Maintenance manual and check sheet etc
3.4 Record keeping of tools and measuring
instruments.
4. Record keeping for traceability: 5. Material availability :
5.1 Vital Spares
5.2 Must change items
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Page 40 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
QUALITY AUDIT OF INJECTOR (POH)
During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed
correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Locotype Make/Class/Name
of
subassembly
Referencedetails Clause/Para/Item details Observations
1. Dis-assembly /Measurement/Assembly etc:
Alco Bosch 17 mm Bosch repair
and testing
manual
Para on Dis-assembly
Para on Inspection of Parts
Para on Inspection of Parts
Para on Assembly
Para on Assembly
Para on Assembly
1.1 Dis-assembly
1.2 Inspection of parts
1.3 Replace Intermediate disc if found cracked or
if indentation at the nozzle seating end exceeds
0.125 mm.
1.4 Opening pressure – 3700 to 3800 psi ( 260-270
kgf/cm
2
) for Overhauled nozzle1.5 Nozzle cap nut tightening torque 130-150 Nm
(13-15 kgf.m or 94-109 lbs-ft)
1.6 Repetition (chatter) and spray pattern test
2. Availability of Tools, Test Stands etc:
List on Service Tools for
Injector
2.1 Nozzle needle lift gauge
2.2 Feeler gauge
2.3 Dial gauge
2.4 Nozzle cleaning sleeve
2.5 True running gauge
2.6 Nozzle tester
2.7 Fixture for injector2.8 Socket wrench
2.9 Test oil
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Page 41 of 104 Quality Audit of Diesel Loco POH Workshop
3. Availability of instructions etc:
3.1 Display of chart
3.2 Training of staff
3.3 Maintenance manual and check sheet
3.4 Record keeping of tools and measuring
instruments
4. Record keeping for traceability: 5. Material availability:
5.1 Vital spares
5.2 Must change items
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Page 42 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF PTLOC SECTION (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco
Type
Make Of
Subassembly
Reference Details Clause/Para/Ite
m/chapter
Details
Observations
1
Dis-assembly /Measurement/Assembly/Test etc.
1.1 Overhauling procedure
1.2 Plate Pack Length
1.3 Hydraulic Test
Plate Type Lube
Oil Cooler
(PTLOC)
MPMI-24, Nov. 2004
& MP.IB.ES.01.07.08
DLW Drawing No.
TPL-8515, DLW Part
No. 11457260
Para on
Overhaul
procedure
Outline – Lube
Oil Cooler
2 Availability of tools , Test Stands etc.2.1 Ratchet spanner
3
Availability of instructions etc.
3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
5.2 Must change items
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Annexure-5
CHECK SHEET FOR
TECHNICAL AUDIT OF POH WORKSHOP
Item: Electrical control MBCS + MCBG + E type
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever theactivities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Sub
assembly
Reference Details Clause/Para/Item Details
Observation
1. No. of Trained personnel withexperience
MBCS trained personnel
2. Record keeping practices after thetests in relay control room for E typecontrol
Shed doc
3. Practices for Handling of the electronic
cards and storing
ALCo Doc No:IM 53 for MBCS
Medha4. Availability of crimping tool & connector
pin details ALCo Doc No. :IM 53 for MBCS
Medha
5. Maintenance practices of MicroProcessor Based Control System MEP660
DLW/Alco/AMC (micro)/01
6. Maintenance practices of MicroController Based Governor (MCBG)MEG 601
ALCo Doc No:IM-11 Rev. 0.0Date Jan 2009 of Medha
7. Practices followed for Fault dataanalysis for identifying the faulty
components and failure.
ALCoContract agreement no.DLW/ALCO/MCBG/Medha
8. Standard (OEM recommended) list of spares, consumable & tools ALCo
Contract agreement no.DLW/ALCO/MCBG/Medha
9. Measurement
11.1 Standards for load box examination of D E locomotives
MP MI -10 (Rev.0.02) August, 2003
11.2 Practices as per BHEL CommissioningTest schedule (Electrical equipment)
BHEL docs: TNE -2/2105/97/DELCTS Date
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for 3100/2750 HP BG DE loco for ‘E’type control
Sept 1997
11.3 Test procedure for MBCS loco controlsystem MEP660 for retrofitted D E loco
ALCo IM-59
11.4 Preventive maintenance schedule DLW/Alco/AMC (micro)/01Inspection and test report of MPreventive Maintenance schedSF-1405 (0)
11.5 Check working of safety and critical
items identified asECS operation check, GR operationcheck, Eng. Stop button check, OSTopen check, MUSD stop switch check,LWS check, GFOLR operation check(E type), Governor dry run check,Flasher light lights, Alerter, lamp, alarmand reset, Flasher lights switch panelGR, GRCO1/2, Indication panels,
Attendant call bell, Head light,Classification light, Horn, Sanders ,Directional check, Cab light andexterior lights,
ALCo Schedule inspection of shed
and items covered under DLW/Alco/AMC (micro)/01 for MBCS locos
11.6 Check set value of engine rpm,transition speed, LOPS, Engine water Temp., 1st notch current, DBparameters (field and armaturecurrent), loco over speed through user settable parameters,
User settable parameters asper RDSO MBCSspec.MP.0.2400.26
11.7 Check ground circuit leakage current -do-
11.8 Check mv drop test of WSR (E type)
12 Availability Of Tools And Test Stands For MBCS locos- Test standsare not provided by MBCS
supplier. Items are coveredunder AMC.
13 Display Chart Important instruction for trouble shooting like action tobe taken during wheel slip etcto be available on the cab
13.1 Display of DOS and DONTS,TROUBLE SHOOTING Chart,
As per OEM manual
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DISPLAYCHART & FLOW CHART
14 Maintenance manual and check sheets As provided by the MBCSmanufacturer*
15 Instruction Bulletin / Modification sheet/Hand book/ Trouble shooting charts asprovided by RDSO/ CAMTECH andimplementation by MBCS vendor
MBCS spec.MP.0.2400.26,Modification sheetNo.MP.MOD.EC.05.27.10(Rev. 00) Date 26.03.2010,Instruction Bulletinno.MP.IB.EC.04.21.10 Date
30.04.2010.CAMTECH/2010/M/MPBCS/1.0 March 2010 (IntroductionHand book on MBCS MP660fitted on diesel locomotives).CAMTECH/2000/DSL/1.0(Trouble shooting charts for drivers of WDM2 locomotive)
Medha
1. Operational manual for drivers Doc.No.IM-38 Rev 3.0 July 072. Maintenance Instruction manual Doc. No.IM-53 Rev 0.0 Sept’2008
3. System Manual Doc. No. IM-08 Rev.3.0 March 20084. Troubleshooting Manual Doc.No. IM-51 Rev.2.0 Oct.20085. WDG3A Control wiring Drg. no.ED 10356. WDG3A Power. ED 10377. WDG3A Schematics Drg. no.ED Wiring Drg. no 10348. WDG3A TB wiring Drg. no.ED 10369. WDM3D Control wiring Drg. no.ED 103110. WDM3D Power Wiring Drg. no.ED 103311. WDM3D Schematics Drg. no.ED 103012. WDM3D TB wiring Drg. no.ED 1032
Siemens
1. KM DIREKT scheme no. DRG. No. 3FZE-009612. SIM CONTROL scheme no. DRG. No. 4SIM-200509
3. SIMCONTROL Operator’s Instructions &Guidelines user manual ver.2.00 dated 10.12.09
4. Trouble shooting manual of Siemens WDG3A and fault category of Siemens
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Page 46 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERATOR FIELD CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Control voltage 72+1 VDC All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0640/
Altr R3Part
No 12145439
Technical detailsgiven in the
drawing
1.2 Max pick up volt 48v ,1.3 Main contact gap12-14.5mm,
1.4 Wipe 8-10 mm,
1.5 Contact pressure( kgf) initial 1.82-2.95,final 5.45-7.25,
1.6 Operating coil resistance at 20 deg c 104 -116ohm, (approx.),
1.7 Interlock (gpr type : 9-41n, 3no+3nc)1.8 Contact gap 9.5-10.5 mm,
1.9 Interlock contact pressure 220-300g.
1.10 Contact impression (should be min 80%) Spec No.MP.0.04.00.08
(Rev-01),May’10
3.10.e
1.11 IR Value between(i) Main contacts(ii) Coil and magnet frame(iii) Interlocks and coil shorted together and earth.
IEC60571
as per clause10.2.9
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SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
(iv) Contacts of interlocks(v) Interlocks and coil shorted together and main
contacts shorted together (vi) shorted main contacts and shorted interlocks, coil
and earth2.0 Availability of tools and stands
2.1 Multimeter with proper calibration2.2 Vernier calipers with valid calibration
2.3 Go- No gauge suiting to different cantactors
2.4 Dial gauge of different scale and resolution assuited to respective contactor
2.5 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.6 Variac
2.7 Meggar
2.8 Oscilloscope
2.9 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.3.1 Display Chart
3.2 Flow Chart3.3 Training of staff
3.4 Proper Display of Do’s and Don’t 3.5 Maintenance manual and check sheets3.6 Record keeping of tools and measuring
instruments
3.7 Instruction Bulletin issued by RDSO3.8 Maintenance Manual of Manufacturer
3.9 Specification4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer 6 Record Keeping For Traceability
4.1 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of
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SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.2 Proper record should be maintained for eachcontactor with the measurement of Parameters as
in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.1 Vital Spares
7.2 Must change items
7.3 Consumables8. Disposal
8.1 Segregation of Workable and Non-Workable equipments and proper house keeping
8.2 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
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Page 49 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR CRANKING CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Short time control voltage -72+1v dc, All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0641/
Altr R3Part
No 121410510
Technical detailsgiven in the
drawing
1.2 Control voltage -24vdc,1.3 Max pick up volt 24v
1.4 Main contact gap12-14.5 mm,
1.5 Wipe 8-10 mm,,1.6 Contact pressure( kgf) initial 1.82-2.95, final 5.45-
7.25,1.7 Operating coil resistance at 20 deg c 18.5-
20.5ohm,1.8 Interlock (gpr type : 9-41n, 3no+3nc)
1.9 Contact gap 9.5-10.5 mm,1.10 Interlock contact pressure 220-300 gm ,1.11 .)
1.12 Contact impression (should be min 80%) Spec No.MP.0.04.00.08
(Rev-01),May’10
3.10.e
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1.13 IR Value between(i) mMain contacts(ii) Coil and magnet frame(iii) Interlocks and coil shorted together and earth.(iv) Contacts of interlocks(v) Interlocks and coil shorted together and main
contacts shorted together (vi) Shorted main contacts and shorted interlocks, coiland earth
as per IEC60571
clause 10.2.9
2.0 Availability of tools and stands2.10 Multimeter with proper calibration
2.11 Vernier calipers with valid calibration2.12 Go- No gauge suiting to different contactors
2.13 Dial gauge of different scale and resolution assuited to respective contactor
2.14 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.15 Variac
2.16 Megger
2.17 Oscilloscope
2.18 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.3.10 Display Chart
3.11 Flow Chart3.12 Training of staff
3.13 Proper Display of Do’s and Don’t
3.14 Maintenance manual and check sheets3.15 Record keeping of tools and measuring
instruments
3.16 Instruction Bulletin issued by RDSO3.17 Maintenance Manual of Manufacturer
3.18 Specification
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4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer 6 Record Keeping For Traceability
4.3 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,
Repair/Overhauling activity details, Loco No. towhich fitted.
4.4 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.4 Vital Spares7.5 Must change items
7.6 Consumables8. Disposal
8.3 Segregation of Workable and Non-Workable equipments and proper house keeping
8.4 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
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Page 52 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR CRANKING CONTROL CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Short time control voltage 72+1 v dc, All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0639/
Altr R3Part
No 12141100
Technical detailsgiven in the
drawing
1.2 Control voltage 24vdc,1.3 Max pick up volt 24 v
1.4 Main contact gap 6-7.5mm,1.5 Wipe 0.8-1.6 mm,1.6 Contact pressure(gmf) initial 80-150, final 180.-
280,1.7 Operating coil resistance at 20 deg c 55+5%
ohm(52 to 58 ohms),
1.8 Contact impression (should be min 80%) Spec No.MP.0.04.00.08
(Rev-01),May’10
3.10.e
1.9 IR Value between(i) fixed contact to movable Contacts(ii) coil to frame
IEC 60571 clause 10.2.9
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2.0 Availability of tools and stands
2.19 Multimeter with proper calibration
2.20 Vernier calipers with valid calibration
2.21 Go- No gauge suiting to different contactors
2.22 Dial gauge of different scale and resolution assuited to respective contactor
2.23 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.24 Variac
2.25 Megger
2.26 Oscilloscope
2.27 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.
3.19 Display Chart3.20 Flow Chart
3.21 Training of staff
3.22 Proper Display of Do’s and Don’t
3.23 Maintenance manual and check sheets
3.24 Record keeping of tools and measuringinstruments
3.25 Instruction Bulletin issued by RDSO
3.26 Maintenance Manual of Manufacturer
3.27 Specification4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
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6 Record Keeping For Traceability
4.5 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.6 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.7 Vital Spares7.8 Must change items
7.9 Consumables8. Disposal
8.5 Segregation of Workable and Non-Workable equipments and proper house keeping
8.6 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
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Page 55 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FUEL PUMP CONTACTORS (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Max pick up volt 48v All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0629/
Altr R3Part
No 12141033
Technical detailsgiven in the
drawing1.2 Main contact gap 11-13 mm,1.3 Wipe 3.5-4.7mm,
1.4 contact pressure( kgf) initial 0.68-0.9kgf, final 0.9-1.4kgf.,
1.5 operating coil resistance at 20 deg c 169-195 ohm ,
1.6 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08
(Rev-
01),May’10
3.10.e
1.7 IR Value as per clause 10.2.9 of IEC60571 between
(i)Main contacts of contactor
(ii) Coil and magnet frame
IEC60571
as per clause10.2.9
2.0 Availability of tools and stands2.28 Multimeter with proper calibration
2.29 Vernier calipers with valid calibration2.30 Go- No gauge suiting to different cantactors
SN R i t L M k Of R f Cl /P /It Ob ti
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SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
2.31 Dial gauge of different scale and resolution assuited to respective contactor
2.32 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.33 Variac
2.34 Meggar
2.35 Oscilloscope
2.36 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.
3.28 Display Chart3.29 Flow Chart
3.30 Training of staff 3.31 Proper Display of Do’s and Don’t
3.32 Maintenance manual and check sheets3.33 Record keeping of tools and measuring
instruments3.34 Instruction Bulletin issued by RDSO
3.35 Maintenance Manual of Manufacturer 3.36 Specification
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.7 Proper Register is maintained for Contactors with
details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. to
which fitted.
4.8 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
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SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
7. Material Availability7.10 Vital Spares
7.11 Must change items7.12 Consumables
8. Disposal8.7 Segregation of Workable and Non-
Workable equipments and proper house keeping8.8 Proper Disposal of Materials including recycling
following relevant environmental norms
CHECK SHEET FOR
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CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR RADIATOR FAN CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 control voltage 72+1v dc,1.2 Max pick up volt 48 v
All DieselElectricLocomotives(ALCo)
Radiator Fancontactor
Drawing No.EL/PT/0638/
Altr R3Part
No 12140235
Technical detailsgiven in the
drawing
1.3 Main contact gap 6-7.5mm, Drawing No.EL/PT/0638/Par
t1.4 Wipe 0.8-1.6 mm, No 12140235
1.5 Contact pressure( gmf) initial 80-150, final 180.-280,
Altr R3
1.6 Operating coil resistance at 20 deg c -388ohm±5% (368 to 408 ohms),
Drawing No.EL/PT/0638/Par
t1.7 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08(Rev-
01),May’10
3.10.e
1.8 IR Value between(i) fixed contact to movable Contact(ii) coil to frame
IEC 60571 clause 10.2.9
2.0 Availability of tools and stands
2.37 Multimeter with proper calibration2.38 Vernier calipers with valid calibration
2.39 Go- No gauge suiting to different cantactors
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
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SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
2.40 Dial gauge of different scale and resolution assuited to respective contactor
2.41 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.42 Variac
2.43 Meggar
2.44 Oscilloscope
2.45 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.
3.37 Display Chart3.38 Flow Chart
3.39 Training of staff 3.40 Proper Display of Do’s and Don’t
3.41 Maintenance manual and check sheets3.42 Record keeping of tools and measuring
instruments3.43 Instruction Bulletin issued by RDSO
3.44 Maintenance Manual of Manufacturer 3.45 Specification
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.9 Proper Register is maintained for Contactors with
details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. to
which fitted.
4.10 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
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Page 60 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
7. Material Availability7.13 Vital Spares
7.14 Must change items7.15 Consumables
8. Disposal8.9 Segregation of Workable and Non-
Workable equipments and proper house keeping8.10 Proper Disposal of Materials including recycling
following relevant environmental norms
CHECK SHEET FOR
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Page 61 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FIELD SHUNTING CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Control voltage 72+1v dc, AllDieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0614/
Altr R4Part
No 12140491
Technical detailsgiven in the
drawing
1.2 max pick up volt 48v,1.3 Main contact gap12-14.5mm,
1.4 wipe 8-10 mm,1.5 contact pressure( kgf) initial1.6 1.82-2.95,final 5.45-7.25,
1.7 operating coil resistance at 20 deg c 104 -116ohms,
1.8 interlock (GPRelay type- 9-41n, 3no+3nc) contactgap 9.5-10.5
1.9 Interlock contact mm pressure -220-300gm.,
1.10 Contact impression (should be min 80%) Spec No.MP.0.04.00.08
(Rev-01),May’10
3.10.e
1.11 IR Value between(i) Main contacts(ii) Coil and magnet frame(iii) Interlocks and coil shorted together and earth.(iv) Contacts of interlocks(v) Interlocks and coil shorted together and main
as per IEC60571
clause 10.2.9
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
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Page 62 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
contacts shorted together (vi) shorted main contacts and shorted interlocks, coil
and earth2.0 Availability of tools and stands
2.46 Multimeter with proper calibration2.47 Vernier calipers with valid calibration
2.48 Go- No gauge suiting to different cantactors2.49 Dial gauge of different scale and resolution as
suited to respective contactor 2.50 Source which can provide minimum current at
respective voltage (24 V – 72 V DC)
2.51 Variac
2.52 Meggar
2.53 Oscilloscope
2.54 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.3.46 Display Chart3.47 Flow Chart
3.48 Training of staff 3.49 Proper Display of Do’s and Don’t
3.50 Maintenance manual and check sheets3.51 Record keeping of tools and measuring
instruments3.52 Instruction Bulletin issued by RDSO3.53 Maintenance Manual of Manufacturer
3.54 Specification
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
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Page 63 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.11 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.12 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.16 Vital Spares7.17 Must change items
7.18 Consumables8. Disposal
8.11 Segregation of Workable and Non-Workable equipments and proper house keeping
8.12 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
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Page 64 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR EP CONTACTORS (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement ALCo Drawing No.EL/PT/0630/
Altr R4Part
No 12141008
Technical detailsgiven in the
drawing1.1 Contact gap 15-17 mm
1.2 Wipe 25.4-28.6 mm
1.3 Knuckling spring pressure(without lever) initial 4.5-6.3 kgf, final 12.2-18.2 kgf,
1.4 Normal air pressure 4.9 kg/cm2
1.5 Interlock gap 2.5-3.95mm,1.6 Interlock pressure 500-900g.
1.7 Interlock rated current 10 A,1.8 Magnet valve coil resistance at 20degC 615+5%
ohm.for BHELTYPE: M5027MV21.9 ROTEX TYPE: 3118AV1-3 coil resistance at
20degC 526 to 594 Ohms,1.10 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08
(Rev-01),
May’10
3.10.e
1.11 IR Value between
a) main contactsb) interlocks and MVc) interlocks and MV shorted together and earthd) contacts and interlockse) Interlocks and MV shorted together and main
contacts shorted together.f) Main contacts shorted together and earth
shorted with MV and interlocks.
IEC 60571 as per clause
10.2.9
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
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Page 65 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
2.0 Availability of tools and stands2.55 Multimeter with proper calibration
2.56 Vernier calipers with valid calibration2.57 Go- No gauge suiting to different cantactors
2.58 Dial gauge of different scale and resolution assuited to respective contactor
2.59 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.60 Variac
2.61 Lever of 122.5 mm for measuring initial and finalpressure.
2.62 Compresor with air reservoir
2.63 Megger
2.64 Oscilloscope
2.65 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.3.55 Display Chart3.56 Flow Chart
3.57 Training of staff 3.58 Proper Display of Do’s and Don’t
3.59 Maintenance manual and check sheets3.60 Record keeping of tools and measuring
instruments
3.61 Instruction Bulletin issued by RDSO3.62 Maintenance Manual of Manufacturer
3.63 Specification
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
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Page 66 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.13 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.14 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.19 Vital Spares7.20 Must change items
7.21 Consumables8. Disposal
8.13 Segregation of Workable and Non-Workable equipments and proper house keeping
8.14 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
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Page 67 of 104 Quality Audit of Diesel Loco POH Workshop
C C S O
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6M REVERSER (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement
1.1 Auxiliary contacts 4, change over type, ALCo Drawing No.EL/PT/0649/
Altr R5Part
No 12310372
Technical detailsgiven in the
drawing1.2 Control voltage 72+1 V DC,1.3 Operating air pressure 4.9 kg/cm2,
1.4 Min operating air pressure 3.85 kg/cm2,
1.5 Main contact gap19.05+1.6mm,
1.6 Main contact outside pressure (with lever) 4.0-4.5kgf, inside pressure 5.8-6.5kgf,
1.7 Contact impression (should be min 80%)
1.8 Auxiliary contact pressure 0.68-2.0kgf,
1.9 Auxiliary contact gap 31.75mm (min), ,1.10 Magnet valve coil resistance at 20degC 615+5%
ohm.for BHEL type: 5027MV2
1.11 ROTEX TYPE: 3118AV1-3 coil resistance at20degC-526 to 594 Ohms.
1.12 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08
(Rev-
01),May’10
3.10.e
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
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Page 68 of 104 Quality Audit of Diesel Loco POH Workshop
qType Subassembly Details Details
1.13 IR Value between(i) Main contacts and frame(ii) Frame and all live parts connected
together (wth main cxontacts closed)(iii) Terminals of both side, terminals shorted
together on each side (Main contacts
open)(iv) All control and Aux. circuit
IEC 60571 as per clause10.2.9
2.0 Availability of tools and stands2.66 Multimeter with proper calibration
2.67 Vernier calipers with valid calibration2.68 Go- No gauge suiting to different cantactors
2.69 Dial gauge of different scale and resolution assuited to respective contactor
2.70 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.71 Variac2.72 Lever of 122.5 mm for measuring initial and final
pressure.
2.73 Compresor with air reservoir
2.74 Megger
2.75 Oscilloscope
2.76 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.3.64 Display Chart
3.65 Flow Chart3.66 Training of staff 3.67 Proper Display of Do’s and Don’t
3.68 Maintenance manual and check sheets3.69 Record keeping of tools and measuring
instruments
3.70 Instruction Bulletin issued by RDSO
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
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Page 69 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
3.71 Maintenance Manual of Manufacturer 3.72 Specification Spec No.
MP.0.04.00.08
(Rev-
01),May’10
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.15 Proper Register is maintained for 6 M Reverser
with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.16 Proper record should be maintained for each 6 MReverser with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability7.22 Vital Spares7.23 Must change items
7.24 Consumables8. Disposal
8.15 Segregation of Workable and Non-Workable equipments and proper house keeping
8.16 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
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Page 70 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6 M BKT CONTACTORS (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement
1.1 Auxiliary contacts 4 change over type, AllDieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0648/
Altr R5Part No
12310300
Technical detailsgiven in the
drawing1.2 Control voltage 72+1 V DC,1.3 operating air pressure 4.9 kg/cm2,1.4 Min operating air pressure 3.85 kg/cm2 ,
1.5 Main contact gap19.05+1.6mm,1.6 Main contact - outside pressure (with lever)1.7 4.0-4.5kgf, inside pressure 5.8-6.5kgf,
1.8 Auxiliary contact pressure 0.68-2.0 kgf,
1.9 Auxiliary contact gap 31.75mm (min),1.10 Magnet valve coil resistance at 20degC1.11 615+5% ohm. for BHELTYPE : M5027MV2
1.12 ROTEX TYPE: 3118AV1-3 coil resistance at20degC 526 to 594 Ohms
1.13 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08
(Rev-01),
May’10
3.10.e
1.14 IR value between(i) Main contacts and frame(ii) Frame and all live parts connected together
(wth main cxontacts closed)(iii) Terminals of both side, terminals shorted
together on each side (Main contacts open)(iv) All control and Aux. circuit
IEC60571
as per clause10.2.9
2.0 Availabili ty of tools and stands
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Page 71 of 104 Quality Audit of Diesel Loco POH Workshop
2.77 Multimeter with proper calibration2.78 Vernier calipers with valid calibration
2.79 Go- No gauge suiting to different cantactors2.80 Dial gauge of different scale and resolution as
suited to respective contactor
2.81 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.82 Variac2.83 Lever of 122.5 mm for measuring initial and final
pressure.
2.84 Compresor with air reservoir
2.85 Meggar
2.86 Oscilloscope
2.87 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.3.73 Display Chart
3.74 Flow Chart3.75 Training of staff
3.76 Proper Display of Do’s and Don’t 3.77 Maintenance manual and check sheets
3.78 Record keeping of tools and measuringinstruments
3.79 Instruction Bulletin issued by RDSO
3.80 Maintenance Manual of Manufacturer 3.81 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
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Page 72 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.17 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.18 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.25 Vital Spares
7.26 Must change items
7.27 Consumables
8. Disposal8.17 Segregation of Workable and Non-
Workable equipments and proper house keeping
8.18 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
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Page 73 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERAL PURPOSE RELAY (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement
1.10 Nominal operating voltage (50-80 V) All DieselElectricLocomotives(ALCo)
BHEL, AAL andIEI
Spec No.MP.0.400.03
(Rev-01) Nov’08
Clause 3.1.1
1.11 Pick up voltage (Must Operate), max 48V Clause 3.2 (ii) 1.12 Drop out Voltage Min 7.5 V
1.13 Auxiliary make rating 7.5 A at 72 V1.14 Resistance of the coil at 20 deg C 445±5%, Clause 3.2 (v) 1.15 Contact Pressure 100-250 g Clause 3.2 (vi)
1.16 Over travel (1.6 mm) with over travel gauge inposition 0.0 to 0.1
Clause 3.2 (vii)
1.17 Min contact gap 2.7 mm Clause 3.2 (viii) 1.18 Armature gap 4.7 to 6.6 Clause 3.2 (ix) 1.19 Ensure that no distortion or corrosion of any
componentsClause16.1.9.2
1.20 IR Value between1.20.1 Open contacts1.20.2 Contacts and metal parts1.20.3 Adjacent contacts1.20.4 Coil and earth
as per IEC60571
Clause 10.2.9
2.0 Availability of tools and stands
2.88 Multimeter with proper calibration2.89 Vernier calipers with valid calibration2.90 Go- No gauge
2.91 Dial gauge
SN Requirements LocoT
Make Of S b bl
ReferenceD t il
Clause/Para/ItemD t il
Observations
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Page 74 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
2.92 Source which can provide minimum current atrespective voltage (72 V DC)
2.93 Variac
2.94 Meggar
2.95 Screw Driver, Plier, Spanner Set, etc.
2.96 Sufficient set of tool and gauges provided bymanufacturer
3. Availabili ty Of Instructions etc.
3.82 Display Chart3.83 Flow Chart
3.84 Training of staff 3.85 Proper Display of Do’s and Don’t
3.86 Maintenance manual and check sheets3.87 Record keeping of tools and measuring
instruments
3.88 Instruction Bulletin issued by RDSO
3.89 Maintenance Manual of Manufacturer 3.90 Specification Spec No.
MP.0.400.03(Rev-01) Nov’08
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.19 Proper Register is maintained for GP Relay with
details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.20 Proper record should be maintained for GP Relaywith the measurement of Parameters as in Sl. No.1prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
SN Requirements LocoT pe
Make Of S bassembl
ReferenceDetails
Clause/Para/ItemDetails
Observations
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Page 75 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
7. Material Availability7.28 Vital Spares
7.29 Must change items8. Disposal
8.19 Segregation of Workable and Non-Workableequipments and proper house keeping
8.20 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
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Page 76 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF POH WORKSHOP OF ELECTRICAL CONTROL FOR DC-DC CONVERTER (500 W)-TWIN BEAM HEAD LIGHT(ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Work shop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement :2.1 Visual Inspection – check finish , material , sound
quality of workman ship etc
ALCo
RDSOspecification No.ELRS/SPEC/DC-DC Converter /0021 ,Rev.01
Sept 2004
Clause No.6.3.1
2.2 Functional Check –ON/OFF properly RDSOspecification No.ELRS/SPEC/DC-DC Converter /0021 ,Rev.01
Sept 2004
2.3 Available output regulated Voltage 25.5 ± .1% VDC with the variation of input voltage 50-85 V DC
RDSOspecification No.ELRS/SPEC/DC-DC Converter
/0021 ,Rev.01Sept 2004
Clause No. 2.2and 2.3
2.Availability Of Tools And Test Stands ALCo
3.1 Multimeter with Valid Calibration
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
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Page 77 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
3.2 Test stand for measurement and testing.
3.3 Screw Driver, Plier, etc.
3.4 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.91 Display Chart
3.92 Flow Chart
3.93 Training of staff
3.94 Proper Display of Do’s and Don’t
3.95 Maintenance manual and check sheets
3.96 Record keeping of tools and measuringinstruments
3.97 Instruction Bulletin issued by RDSO NA
3.98 Maintenance Manual of Manufacturer
3.99 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
4.21 Proper Register is maintained for DC-DCConverter (500 W) with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
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Page 78 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.
4.22 Proper record should be maintained for each DC-DC Converter
4.23 500 W DC-DC Converter with themeasurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenancewith date and remarks, if any.
7.
Material Availability7.30 Vital Spares
7.31 Must change items
7.32 Consumables
8. Disposal
8.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
8.2 Safe Disposal including recycling followingrelevant environmental norms.
CHECK SHEET FOR
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Page 79 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED FLASHER LIGHT (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop /Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Measurement :2.1 Visual Inspection – check finish , material , sound
quality of workman ship , water tightness etc
ALCo
RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
ClauseNo.6.3.
2.2 Functional Check –ON/OFF properly RDSO specificationNo.
ELRS/SPEC/LFL/0
017 Rev 1 Sept 042.3 Lux Value- The lux measured in axial directionshall not be less than 500 lux at 1 meter and 55lux at 3 meters for amber clour LED of 120 Nos
RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
Clause No.2.3.3
2.4 Flashes per Minute (40±5) RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
Clause No.2.4.1
2.5 Output regulated Voltage RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
Clause No.2.4.5
2.6 Check Repeater indication properly RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
ClauseNo.2.4.3.1
2. Availability Of Tools And Test Stands ALCo
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
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Type Subassembly em Details
3.1 Voltmeter with Valid Calibration3.2 Ammeter with Valid Calibration
3.3 Lux Meter with proper Calibration
3.4 Test stand for measurement and testing.
3.5 Stop Watch
3.6 Screw Driver, Plier, etc.
3.7 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.1 Display Chart
3.2 Flow Chart
3.3 Training of staff
3.4 Proper Display of Do’s and Don’t
3.5 Maintenance manual and check sheets
3.6 Record keeping of tools and measuringinstruments
3.7 Instruction Bulletin issued by RDSO
3.8 Maintenance Manual of Manufacturer
3.9 Specification RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
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Type Subassembly em Details
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
4.1 Proper Register is maintained for LED Flasher Light with details of Manufacturer’s Brand Name,Date of Manufacture, Type, Sl. No., Date of
Attending, Repair/Overhauling activity details,Loco No. to which fitted.
4.2 Proper record should be maintained for each LEDFlasher Light
4.3 LED Flasher Light with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.
7.
Material Availability7.1 Vital Spares
7.2 Must change items
7.3 Consumables such as fuses , toggle switches etc
8. Disposal
8.1 Segregation of Working and Non-Working
equipment and Proper House Keeping
8.2 Safe Disposal including recycling followingrelevant environmental norms.
CHECK SHEET FOR
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TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED MARKER LIGHT (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop /Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement :2.7 Visual Inspection – check finish , material , sound
quality of workman ship , water tightness etc.
ALCo
RDSOspecification No.ELRS/Spec/PR/
0022 (REV-1Oct -2004)
Clause No.6.3.
2.8 Functional Check –ON/OFF properly RDSO
specification No.ELRS/Spec/PR/0022 (REV-1Oct -2004)
2.9 Lux Value- for all input voltage range 45V-90 V
Lamp Lux level at 1
Meter
Lux level at 3
Meters
RED 75 LUX 7 LUX
WHITE 75 LUX 7 LUX
RDSOspecification No.ELRS/Spec/PR/
0022 (REV-1Oct -2004)
Clause No. 2.4.3
2.
Availability Of Tools And Test Stands3.8 Multimeter with Valid Calibration ALCo3.9 Lux Meter with proper Calibration
3.10 Test stand for measurement and testing.
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
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Type Subassembly Details Details
3.11 Screw Driver, Plier, etc.
3.12 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.10 Display Chart
3.11 Flow Chart
3.12 Training of staff
3.13 Proper Display of Do’s and Don’t
3.14 Maintenance manual and check sheets
3.15 Record keeping of tools and measuring
instruments3.16 Instruction Bulletin issued by RDSO
3.17 Maintenance Manual of Manufacturer
3.18 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
4.4 Proper Register is maintained for LED Marker Light with details of Manufacturer’s Brand Name,Date of Manufacture, Type, Sl. No., Date of
Attending, Repair/Overhauling activity details,Loco No. to which fitted.
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
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yp y
4.5 Proper record should be maintained for each LEDMarker Light
4.6 LED Marker with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.
7.
Material Availability
7.4 Vital Spares
7.5 Must change items
7.6 Consumables such as fuses , toggle switches etc
8. Disposal
8.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
8.2 Safe Disposal including recycling followingrelevant environmental norms.
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR STICK TYPE / IMPROVED STICK TYPE MASTER CONTROLLER
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TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR STICK TYPE / IMPROVED STICK TYPE MASTER CONTROLLERFOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
A. Stick Type / Improved Stick type Master controller
1. Measurement:
1.1 Visual checking ALCo
M/s BHEL, Asian Plastic,M/s Kaysons
(AMC/R2)Make
BHEL Testprogrammedocument no. 865476dt
Clause 1.1
Drawing of Improved
stick type Master Controller EL-PT-0633-R3 dt.29.12.2007.
1.2 Contact gap, BHEL Testprogrammedocument no. 865476dt 24.04.99 and
Clause 1.2
1.3 Contact pressure,
1.4 Cam sequence and1.5 Mechanical interlocking
1.6 Working of Throttle handle Clause 1.3
2. Test :
2.1 Insulation Resistance test: BHEL Testprogramme
document no. 865476
Clause 5.0
2.2 Continuity Test DLW Drg. No.35900030031Rev. 04
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2.
Availability Of Tools And Test Stands
ALCoM/s BHEL,
Asian Plastic,
M/s Kaysons(AMC/R2)
Make
3.13 Voltmeter with Valid Calibration3.14 Venier Caliper with Valid Calibration3.15 Megger with Valid Calibration
3.16 Digital Multimeter with Valid Calibration3.17 Potentiometer with Valid Calibration
3.18 Height gauge with Valid Calibration3.19 High Voltage Tester with Valid Calibration
3.20 Bore Dial gauge with Valid Calibration3.21 Ammeter with Valid Calibration
3.22 GO and NO GO Gauge3.23 Screw Driver, Plier, Required spanner set etc.
3.24 Test stand for measurement and testing.
3.25 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.19 Display Chart
3.20 Flow Chart
3.21 Throttle sequence chart
3.22 Mechanical interlocking Chart
3.23 Training of staff
3.24 Proper Display of Do’s and Don’t
3.25 Maintenance manual and check sheets
3.26 Record keeping of tools and measuringinstruments
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3.27 Instruction Bulletin issued by RDSO
3.28 Maintenance Manual of Manufacturer
3.29 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
4.7 Proper Register is maintained for EMD Master Controller checking with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.
4.8 Proper record should be maintained for each
4.9 EMD Master Controller with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.
7.
Material Availability7.7 Vital Spares
7.8 Must change items
7.9 Consumables like OTTO Switches, Reverser Handle), Terminal Lugs, 28-Pin Coupler, M/s.Radiant make cables. etc.
8. Segregation of Working and Non-Working equipment and
Proper House Keeping
CHECK SHEET FOR
TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR TWIN BEAM HEAD LIGHT (ALCo LOCO)
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TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR TWIN BEAM HEAD LIGHT (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop /Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement :2.10 Visual Inspection – check finish , material , sound
quality of workman ship etc
ALCo
RDSOspecification No.ELRS/SPEC/PR/0024 ( Rev-1,
Sept 2004)
Clause No.6.3.1
2.11 Functional Check –ON/OFF properly
2.12 Type of Bulbs used – H4 P45 T(IR), Twin Filament IB NO.
MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4.A.1
2.13 Model of Bulbs –Halonix and AutoPal Only IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4.A.2
2.14 Voltage Rating -24 V IB NO.MP.IB.EC.
01.08.06 DATE:27-12-06
Clause No. 4.A.3
2.15 Wattage Rating of Bulbs -100/90 W, Bright/Dimfilament at 24 V
IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4.A.4
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
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2.16 Lumen Out put -2600/1770 ± 15 % Lumen of Bright/Dim Filament at 24 V
IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4.A.5
2.17 Lux output with Twin Beam Head Light for eachreflector minimum 2400 Lux at a distance of 8 Mtand 24.5± 0.1 V DC terminal Voltage at LampHolder
IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4.A.6
2.18 Procedure to check correctness of bulb’s f ilamentin test room
IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4 B
2.19 Checking illumination intensity of head light
assembly when both bulbs are working
IB NO.
MP.IB.EC.01.08.06 DATE:27-12-06
Clause No.6
2.
Availability Of Tools And Test Stands3.26 Voltmeter with Valid Calibration
3.27 1.A standard portable lux measuringequipment ‘Lux meter’ like T.E.S. model TES –1330 shall be used. Lux Meter should be of range0-20000 lux with least count of 0.01 Lux with validcalibration
3.28 Focusing Stand IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
3.29 Screw Driver, Plier, etc.
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
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3.30 Test stand for measurement and testing.
3.31 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.30 Display Chart
3.31 Flow Chart
3.32 Training of staff
3.33 Proper Display of Do’s and Don’t
3.34 Maintenance manual and check sheets
3.35 Record keeping of tools and measuringinstruments
3.36 Instruction Bulletin issued by RDSO IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
3.37 Maintenance Manual of Manufacturer
3.38 Specification RDSOspecification No.ELRS/SPEC/PR/0024 ( Rev-1,
Sept 2004)
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
4 10 P R i i i i d f T i
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4.10 Proper Register is maintained for TwinBeam Head Light with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.
4.11 Proper record should be maintained for
each Twin Beam Head Light4.12 Twin Beam Head Light /Bulbs with the
measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenancewith date and remarks, if any.
7.
Material Availability7.10 Vital Spares
7.11 Must change items
7.12 Consumables like bulbs , Reflector
8.
Disposal
8.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
8.2 Safe Disposal of Bulbs/reflector includingrecycling following relevant environmental norms.
CHECK SHEET FOR
TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR POH
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TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR POHWORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Measurement :2.20 Physical Examination
ALCo
2.21 Air Pressure Spec. No.DEL/SPN/193 July’98
Clause 8.5
2.22 Ampere Hour Capacity Spec. No.DEL/SPN/193 July’98
Clause 8.6
2.23 Watt Hour Efficiency Spec. No.DEL/SPN/193 July’98
Clause 8.7
2.24 Ampere Hour Efficiency Spec. No.DEL/SPN/193 July’98
Clause 8.7
2.25 Internal Resistance Spec. No.DEL/SPN/193 July’98
Clause 8.8
2.26 Initial Cranking Current Spec. No.DEL/SPN/193 July’98
Clause 8.9
2.27 Electrolyte Level Spec. No.DEL/SPN/193 July’98
Clause 6
2.28 Polarity and absence of Short Circuit
2.
Availability Of Tools And Test Stands
ALCo
3.32 Battery Room Suitable size with sufficient area for movement of forklift, Storing of Acid Mixing tank,and Suitable battery test benches with sufficientExhaust fans.
3.33 Electrolyte mixing tank-Motorized type preferred3.34 Voltmeter with Valid Calibration
3.35 Thermometer with Valid Calibration
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
3 36 H d t ith V lid C lib ti
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3.36 Hydrometer with Valid Calibration3.37 Ammeter with Valid Calibration
3.38 Multi meter with Valid Calibration3.39 Clamp Meter
3.40 Rubber syringe3.41 Battery Charger(Preferred Constant Current
Chargers)3.42 Battery Discharger (Preferred Electronic type)
3.43 Required Lab for testing of Acid and DM water 3.44 Screw Driver, Plier, Spanner Set etc.
3.45 Test stand for measurement and testing (ConcretePlatform covered with Acid Resistant FRPsheets/coating for keeping batteries –charge/Discharge.)
3.46 D.M.Water Plant
3.47 Proper earthing facility for switch gear and Battery
charging Panel.3.48 Fire Extinguisher of proper class
3.49 Fork Lift
3.50 Hand trolley
3.51 Battery lifting crane on test bench
3.52 Plastic Pallet for storing Battery
3.53 Rubber Apron
3.54 Rubber Gloves
3.55 Goggles
3 Availability Of Instructions etc.
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
3 39 Displa Chart
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3.39 Display Chart
3.40 Flow Chart
3.41 Training of staff
3.42 Proper Display of Do’s and Don’t
3.43 Maintenance manual and check sheets
3.44 Record keeping of tools and measuringinstruments
3.45 Instruction Bulletin issued by RDSO MP. IB. EC.01.02.05(Rev.01), Dec. 2008
3.46 Maintenance Manual of Manufacturer
3.47 Specification Spec. No.DEL/SPN/193 July’98
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6.
Record Keeping For Traceability
4.13 Proper Register is maintained for Battery checkingwith details of Manufacturer’s Brand Name, Dateof Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.14 Proper record should be maintained for eachbattery with the measurement of Parameters as inSl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
MaterialAvailability
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7.
Material Availability7.13 Vital Spares
7.14 Must change items
7.15 Consumables like Distilled Water,
Sulphuric Acid (for Lead Acid Battery), Lugs,Rubber Mat etc.
8.
Disposal
8.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
8.2 Safe Disposal of Battery including recyclingfollowing relevant environmental norms.
CHECK SHEET FOR
TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo LOCO) FOR POH WORKSHOPS
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TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo LOCO) FOR POH WORKSHOPSIN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Dis Assembly and Assembly ALCo Maintenancemanual of Woodward
Section 5 of Maintenance
Manual 2. Measurement :
2.29 Physical Examination
ALCo
Wood WardGovernor Test
Record Format No.TSP/F8572-828
and Maintenancemanual of Woodward
Section 6 of Maintenance
Manual
2.30 Barometer Reading
2.31 Pressure Test
2.32 Hydraulic Seals, needle valve seat and buffer piston bypass in both direction2.33 Needle Valve setting
2.34 Speed Setting2.35 Normal Shut Down
2.36 Pressure Requirement2.37 Speed Setting timing
2.38 Lube Oil Shutdown2.39 Air Box Pressure Fuel Limiting
2.40 Load Control2.41 Vane Servo Timing
2.42 Excitation Resistor 2.43 General
2.44 Verification with Cover Installed
3.
Availability Of Tools And Test Stands ALCo3.56 Test Stand for Wood Ward Governor
3.57 Multimeter with valid Calibration3.58 Screw Driver, Plier, Allen Key, Spanner,
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
etc
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etc.3.59 Fire Extinguisher of proper class
4.
Availability Of Instructions etc.3.48 Display Chart
3.49 Flow Chart3.50 Training of staff
3.51 Proper Display of Do’s and Don’t
3.52 Display of Trouble Shooting Chart MaintenanceManual
Section 4
3.53 Maintenance manual and check sheets
3.54 Record keeping of tools and measuringinstruments
3.55 Instruction Bulletin issued by RDSO NA
3.56 Maintenance Manual of Manufacturer
3.57 Specification NA
5. Compliance of Instruction Bulletin NA
6. Follow of Maintenance Manual of Manufacturer
7. Record Keeping For Traceability
4.15 Proper Register is maintained for Governor testing with details of Manufacturer’s
Brand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
4 16 Proper record should be maintained for
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4.16 Proper record should be maintained for each Governor with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.
8.
Material Availability
7.16 Vital Spares
7.17 Must change items
7.18 Consumables like Lub Oil, Cotton wool,etc.
9.
Disposal
9.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
9.2 Safe Disposal of scrap and waste including
recycling following relevant environmental norms.
Annexure-6
Check sheet for Quality Audit of Railway Workshop
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Check sheet for Quality Audit of Railway Workshop
(Underframe/cattle guard/ fuel tank/ loco painting/ cab/ battery box/ superstructure/ CBC/ side buffers)
Sl.N
o.
Activity Clause/ Reference Observations
Underframe
01 Underframe to be kept on trestle at lifting lugs.
02 Proper cleaning & washing of U/F with detergents & water,.
03 Use of manipulator for carrying out repair work by down hand welding.
04 i. Visual inspection of buffer beam, striker block for any crack or damage,
accordingly repair/weld properly
ii. Check the buffer base bolt holes for size, centers & ovality. Remove the
ovality by welding and redrill if necessary
05 i. Check the cattle guard/rail guard by visual inspection, if any crack/ damage
found then it should be repaired/replaced accordingly
ii. Ensure minimum clearance of cattle guard from R/L to be 178 mm
iii. Ensure minimum clearance of rail guard from R/L. to be 115 mm
iv. Modify/ change cattle guard and its support arrangements to plate type on
WDM3A locomotive
RDSO’s Drg. No.
SK.DL-4533/4535 and
DMW’s Drg. No.
2DMW/SK-938
06 Visual inspection of welding of gussets/ stiffeners in back of buffer beam
transferring buffing force from buffers to maintain longitudinal box section. If any
crack /damage is found, it shall be repaired accordingly.
07 Visual inspection of Footstep for welding crack/damage and shall be repaired by
welding properly or replaced.
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08 i. Visual inspection of welding of Hand rails to underframe. If there is any
crack or damage in weld then reweld it properly.
ii. All fasteners are used for securing hand rail, clamp, hand rail support should
be properly tighten
09 The coupler pocket shall be examined closely for welding cracks/damage in ribs andinspection of welding with underframe. If any crack or wear is found, shall be
repaired or replaced properly.
10 Visual inspection of welding of ECC mounting stool. If there is any welding
crack/damage then it should be rewelded or replaced properly.
11 i. If abnormal vibration noted modify compressor mounting area of WDM3D
locomotive under frame
ii. Visual inspection of welding of expressor/ compressor mounting stool. If
there is any welding crack/damage then it should be rewelded or replaced
properlyiii. Clean the threads of mounting block on stool by tapping it properly.
MP.MOD.LD.01.02.11
dated 09.03.2011
12 i. Visual inspection of welding of engine mounting block. If there is any weld
defect carryout required welding or replace it
ii. Check/Clean the threads of mounting block by tapping.
13 i. Inspection of air duct gallery for all traction motors cutout for any leakage
or cracks
ii. Filling water/hydraulic test in the gallery carried out
iii. If any leakage is found, shall be repaired accordingly.
14 i. Visual inspection of battery box below side sill/bottom plate for corrosion &
welding cracks in wear plate, end plates & support plate. If there is any crack
or corrosion then it should be rewelded or replaced it
RDSO’s letter
No.SD.DMG.32 Dated
30 07 1996 and SK DL 4436
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p
ii. End plate of battery box with fuel tank end shall be modified as per RDSO
Drg. no. SK.DL-4436.
iii. Mounting block, nut & bolt should be properly secured and tighten
iv. Wooden spacer properly placed between the battery
v. All hinges, locks should be in working
vi. Cover assly. properly secured & locked with battery box.
30.07.1996 and SK.DL-4436
15 i. Ensure proper cleaning & washing of fuel tank to remove dirt, sludge
deposited inside the tank.
ii. Inspection of fuel tank for any leakage or cracks.
iii. Inspection of drain valve, glow rod and for any crack repair by welding or
replace if found beyond repair.
iv. Mounting block, nut & bolt should be properly secured and tighten
v. Fuel gauge should not be broken and in working condition
vi. Fuel gauge mounting bracket, filler cap, vent pipe should be in good
condition
RDSO’S Investigation
Report No.
MP-473/83 February, 1983
16 Visual inspection of underframe box section and side sill welding. If there is any
crack or damage, weld it properly with low hydrogen welding electrode.
RDSO’S Investigation
Report No.
MP.INV-8
December, 1995
17 i. Carefully examine the welding around the both center pivots for crack and
also check the surface with magnaflux or die-penetrant method to identify
cracks, if any, which is not visible to naked eyes.
ii. If any crack is found, weld it properly with down hand welding.
RDSO’Drg. No.
SK.DL-2069
18 i. Carefully examine the welding around side load bearers for crack and also
check the surface with magnaflux or die penetrant method to identifycracks, if any, which is not visible to naked eyes.
ii. side load bearer shall be repaired
RDSO’s spec. No. MP.MI-
140/88, Sep’1988 and
RDSO’Drg. No.
SK.DL-2069
19 Loco painting, marking, stenciling;
Apply epoxy primer and PU paint before stenciling
As per extent colour
scheme
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20 Center buffer coupler & Draft Gear
Check compliance of RDSO instructions for inspection and maintenance
Modify uncoupling arrangement to make it top operated
G-80
MP.MOD.LD.05.10.11
dated 18.07.2011
21 Side Buffers
Check compliance of RDSO instructions for inspection and maintenance
MP.MI-116/82, Rev.02
22 Loco Cab Railway Board’s letter
No.2000/M(L)/466/9 dated
05.01.2005
23.
1
Driver/Pilot seat
i. Base mounting nut/ bolt and other fasteners should be properly tighten
ii. Motion and its adjuster/locking arrangement/ Ver. & rotational motion
should be in functioning
iii. Cushion & upholstery should be in good condition
23.
2
Side sash / window
i. Sliding glass should freely slide and not cracked
ii. Locking arrangement properly in fuction
iii. Guide rail, weather rubber & glazing rubber should be in good condition
iv. Rear view mirror if applied properly secured with frame and its rotational
movement checked. Mirror should be in good condition
23.
3
Cab door
i. Lock, hinges should be in function
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ii. Glass, weather strip should be in good condition and door properly sealed in
closed condition
iii. Assistant seat properly secured and in good working condition
iv. Wiper motors should be in working
23.
4
Cab floor
i. Flooring mat & trim should be in good conditionii. Steel structure/ panel sheet of cab should not be corroded or broken
23.
5
Cont. Comp door, short hood door & Cab inner trim
i. Lock, hinge and weather sealings should be in working condition
ii. Perforated aluminium sheet , insulating material, fasteners should be in
good condition
23.
6
Cab light and fan
i. Switches, regulators and connections are properly in function
23.
7
Fire Extinguisher
i. Mounting bracket should be in good condition and refilling facilities should
be available
23.
8
Air condition (if applied)
i. Switches, regulator and water drainage properly in function
23.
9
Token pick up arrangement
i. Token pickup rod properly joint with cab and should be in function (closing
& opening)
ii. Cushion pad frame properly welded with cab and cushion mat condition
should be good23.
10
Front look out glass
i. Glass & weather strip should be scratches free and properly sealed with
front structure
ii. Covering grill glass properly cover with hinged grill
24 Superstructure
i. Check the condition of sheets and repair if possible otherwise change
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ii. Check hinges and door locks for proper working and repair if possible
otherwise change
iii. Check for water leakage at various joints and renew weather stripes/ceilings
iv. Door panel-sheet should not bend and properly close
25 Radiator compartment & Expansion tank
i.
Gauge, vent, vacuum valve, low water alarm should function
ii. Expansion tank plate should not be corroded
iii. Funnel grating, foot step, hand- rail, inspection door properly secured with
rad. Comp. Structure.
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