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Quality Audit of Diesel Loco POH Workshops Annexure-I

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 Sectionb. Wheel (Wear adapted profile) profile & other defects. c. Brake adjustment, release & and application timings.d. Headlight focus adjustmente. Horn maintenancef. Undergear safety bracketsg. Gauging of Couplersh. 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.

Quality of a. Expresser/Compressor a. Further details of check sheet covered in Annexure 1.

of 165 Quality Audit of Diesel Loco POH Workshop (Rev.-01), Date: 23.07.2019

Subassembly repairs (important items)

b. Air Brake Sectionc. Bogie sectiond. Rotating Machines Sectione. Turbo sectionf. Engine Block, Crankshaft and Main bearingsg. Cylinder Head, Piston and Valve sectionh. Radiator section.i. FIP/Injector Sectionj. Governor Sectionk. Electrical Control Sectionl. Battery Sectionm. Under-frame, side buffers, cow catcher,

couplers, superstructure/Upper-frame, roof, driver cabin, hand rails, fuel tank, loco painting/marking/stencilling etc.

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 item

As decided by the auditing authority


Annexure-IICHECK LIST FOR

TECHNICAL AUDIT AT POH WORKSHOPS (BRAKE ITEMS)S.No. Item Parameter Reference document Observations

1. Whether all the items prescribed in the schedule is being followed for brake equipment, 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 RDSO MIs or manufacturers MI mentioned in MP.Misc.-140 & 141.

2. Maintenance facilities are available or not.

1. Schedule of standard examinations: MP-Misc-285 [for HHP (EMD) locos] to be added.2. For GD make compressor maintenance instruction, M/s GD maintenance manual and IB no. MP.IB.BK.01.05.12, Rev-0, dated 24.07.2012 For ELGI make compressor, M/s ELGI maintenance manual and RDSO IB No. MP.18.8K.01.09.18 (Rev.00) October 2018 to be followed. 3. CCB systems: CCB 1.5 as per ETI-991, CCB 2 IR as per NYT 1794-C.4. For IRAB-1 brake system, MP.TP.29 and for 28LAV-1, MP.TP.019 to be followed.5.OEM maintenance


S.No. Item Parameter Reference document Observationsmanual and MP.MI-18 for air dryer

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 are available or not viz. AB test rack for brake valves, air dryer test bench, compressor test bench pressure switch, magnet / solenoid valve, Auto drain valve 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 bench for air pressure gauge 5. CCB Simulator and Test bench for CCB

4. Test on Loco after POH Whether brake system check is done on loco as per test programme no. MP.TP-029 (for air brake IRAB-1 brake system fitted loco) & MP.TP-019 (For dual brake 28 LAV-1 brake system fitted loco).For HHP Loco fitted with CCB system, whether testing is being done as per following procedures:CCB(II)NYT-1794-C and CCB(1.5): ETI-0991

5. Infrastructure facilities (a) Whether dust proof and controlled temperature 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(g) Painting facilities(h) Technical Cell


S.No. Item Parameter Reference document Observations(i) Metrology lab(j) Store(k) Tool room(l) Fire extinguishers(m) Material handling facilities for movement of

material and components.(n) Facilities for filtering the sand.

6. Storage of material Whether dust/damp proof environment with controlled temperature is available for storage of brake equipment and rubber components. Whether rubber components are being stored as per guidelines mentioned in this office letter no. SD.DEV.RBC dated 28.02/07.03.2007 circulated to all Zonal Railways.For storage of Sand: Storage space should be shaded, dry and dust free in the shed.

7. Availability of Material Any Chronic shortage of material for maintenance8. Air Reservoirs All air reservoirs are to be tested and certified periodically

by a qualified Boiler Inspector. The period is to be specified by CME office.

9. Human Resource development Whether periodic training is being imparted to maintenance staff to make them conversant with the maintenance practices.

10. Any other observation


Annexure-IIICHECK 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 Loco Type

Make/class of

Subassembly

Reference Details

Clause/Para/Item/Chapter Details

Observations

1 Removal of Cyl Blocka) 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 InspectionDPT for cracks/signs of leaks/ other damage, Hydrostatic test for leakage

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.



Make/class of

Subassembly

Reference Details


Observations

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”.

Torque values for Cylinder head stud 100-120 ft pound.



Make/class of

Subassembly

Reference Details


Observations

4.

Availability of tools and testa) Plate, liftingb) Compound, gasketc) 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) Mandrelg) Magnafluxh) Feeler gaugei) Vernier caliperj) Torque wrench

5.

Availability of instructiona) Display chart.b) Training of staffc) 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


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.




Make/class of

Subassembly

Reference Details


Observations

1 Removal of Crank Shafta) 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) Cleaningb) 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” maxd) MB Journal eccentricity limit 0.001” d) Crank pin dia 5.998”- 6.000”e) Crank pin out of roundness limit 0.002”



Make/class of

Subassembly

Reference Details


Observations

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-lbs ii) Final torque – 300 ft-lbs.

ALCO MI 11067 C

ALCO MI 11069 E &

11067C

4.

Availability of tools and testa) Lifting blockb) Lapping toolc) Deflection guage.d) Feeler gaugee) Soft hammerf) Torque wrench

5.

Availability of instructiona) Display chart.b) Training of staffc) 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


CHECK SHEET FORTECHNICAL AUDIT OF CYLINDER HEAD SECTION (POH)




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 (MI-ENG-020)

Chapter on cylinder head1.2 Cy head leak test at 70 PSI with hot water

1.3 Inspect head for cracks using Magnaflux1.4 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 clearance Top 0.003 – 0.0045” Bottom- 0.005 – 0.0065’’1.9 Cy head nuts torquing value 550ft/lbs as per sequence as described in manual.

2

Availability of tools , Test Stands etc.2.1 Valve seat reconditioning machine2.2 Hydraulic test stand2.3 Nozzle hole sleeve tube expander(Bottom & Top)2.4 Nozzle sleeve extractor2.5 Nozzle sleeve holder2.6 Feeler gauge2.7 Magna flux

3 Availability of instructions etc.3.1 Display Chart



Make of Subassembly


Details

Observations

3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments

4 Record Keeping For Traceability

5Material Availability5.1 Vital Spares5.2 Must change items


CHECK SHEET FORTECHNICAL AUDIT OF PISTON SECTION (POH)




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

(MI-ENG-015)

Chapter on piston and con rod

1.2 Inspect visually piston skirt and body for scoring or scuffing

1.3 Inspect piston crack using Magnaflux1.4 Zyglo test for checking surface crack1.5 (a) Groove width top ring, 2nd ring and 3rd ring New

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”



Make of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

2.

Availability of tools , Test Stands etc.2.1 Feeler gauge2.2 Zyglo testing machine2.3 Magna flux2.4 Vernier caliper2.6 Piston ring groove gauge

3

Availability of instructions etc3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments




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:


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).

1.5 Blue matching of valve with VSI1.6 Zyglo testing for crack detection1.7 grid blasting for removal of carbon deposition

2Availability of tools, test stands etc:2.1 Depressor, Spring etc2.2 Grinder

3

Availability of instructions etc:3.1 Display Chart etc.3.2 Training of Staff3.3 Record keeping of tools and measuring

instruments4 Record keeping for traceability:5 Material Availability:


5.1 Vital Spare5.2 Must change items

Annexure-IV

CHECK SHEET FOR QUALITY AUDIT OF TURBO SECTION (POH)


Shed/Rly: Audited by: Date of audit:


Make of Subassembly

Reference Details

Clause/Para/Item Details

Observations

1. Balancing, measurements etcBalancing:1.1 Bladed shaft, range 31-257 gmm.1.2 Rotor, range 157-470 gmm.

5.65.6.2.55.6.2.5

Rotor Shaft Dimensions:1.3 Bearing position OD A 39.98 – 40.00 mm

Alco ABB VTC 304 Turbocharger

ABB-Exhaust Gas

Turbocharger VTC 304 A

Comprehensive Manual for Indian Railways issued by M/s ABB

Para 5.2.4.13 &details in 5.4.2.1

1.4 Bearing position OD B 50.987--51.000 mm1.5 Bearing position OD C 56.10-56.20 mm1.6 Piston ring recess S 2.58-2.85 mmWheel Bush1.7 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 mm1.9 Plain bearing (CE) ID A 54.00-54.06 mm Para 5.2.4.13 &

details in 5.4.2.31.10 Bearing housing bore ID A 65.00-65.07 mm Para 5.2.4.13 &

details in 5.4.2.41.11 Floating bush ID (CE) 40.011-40.05 mm Para 5.2.4.13 &



Make of Subassembly

Reference Details


Observations

details in 5.4.2.5 Floating bush OD (CE) 53.80-53.86 mm1.12 Floating bush OD (TE) 64.82-64.84 mm1.13 Floating bush ID (TE) 51.022-51.07 mm1.14 Thrust bearing width 10.39-10.50 mm Para 5.2.4.13 &

details in 5.4.2.61.15 Axial bearing width 16.76-16.88 mm Para 5.2.4.13 &

details in 5.4.2.71.16 Piston ring width 2.00 -2.49 mm Para 5.2.4.13 &

details in 5.4.2.81.17 Thrust bearing press fit measure (K) 170.5 -170.63 Para 5.2.4.13 &

details in 5.4.2.91.18 Axial clearance A 0.11-0.32 mm Para 5.2.4.13 &

details in 5.71.19 Radial clearance B 0.47-0.93 mm

2.

Availability of Tools, Test Stands etc.

Alcodo do

2.1 Balancing machine2.2 Zyglo testing machine2.3 Casing hydraulic test stand 2.4 Bearing puller (CE & TE)2.5 Torque wrench up to 250 psi2.6 micrometer 2”-3” & 0-4”2.7 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc.3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments





Make of Subassembly

Reference Details


Observations

1

Measurements etc1.1 Nozzle ring and gas inlet casing 0.022-0.032” Dia Clearance (Cl)

Alco Alco 720Instruction

ManualALCO

ALCo MI 11126

1.2 Turbine blade and gas inlet casing 0.060-0.092”Dia CI1.3 Nozzle ring and turbine disc 0.124” cold CI1.4 Intermediate casing and impeller 0.017-0.065” longitudinal Clearance (long Cl)1.5 Impeller and Blower inlet 0.035-0.075” long CI1.6 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 CI1.8 Bearing and thrust collar (Blower end) with surface by approx 0.003 less when oil. 0.007-0.018” Thrust CI1.9 Inducer and blower casing 0.091-0.101”Dia CI1.10 Thurst collar and oil seal Blower End 0.014-0.036” Dia CI1.11 Interference between bearing and intermediate casing (blower & Turbine end ) 0.0005-0.0015” Dia Cl1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008” Dia CI1.13 Gas inlet casing and intermediate casing inside measurement 0.090-0.098” Dia CI1.14 Impeller and intermediate casing 0.125-0.127” Dia CI1.15 Max allowable clearance between Gas inlet casing & Nozzle ring 0.005” clearanceAvailability of tools, Test Stands etc.



Make of Subassembly

Reference Details


Observations

2

AlcoAlco 720

Instruction ManualALCO

2.1 Balancing machine2.2 Zyglo machine2.3 Casing hydraulic test stand 2.4 Oil gallery flushing test stand2.5 Bearing puller (CE & TE)2.6 Sand blast machine for rotor cleaning2.7 Torque wrench up to 250 psi2.8 micrometer 2”-3” & 0-4”2.9 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc .3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments




CHECK SHEET FORQUALITY AUDIT OF HHP TURBO FITMENT & MATCHING PROCEDURE(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. DLW /BSB issued Design Bulletin No. DB/01/2015/26,dt.11/05/15 for defining the procedure of fitment and matching of turbocharger on HHP locos

a diesel sheds to arrest the failure of HHP turbocharger.


Sn. Loco No.

Schedule

Date 1st notch TSC LOP at

comp. bearing support.(not less than 12

psi)

8st notch TSC LOP at comp. bearing support

HHP Turbocharger clearance HHP Turbo Impeller Eye clearance Remark

TSC inlet(TSC

filter)A

TSC outlet

at(support Comp. bearing)

B

LOP dropA-

B(Should not

exceed 34 psi)

Turbine shaft

thrust6-24 thou

Backlash-TSC drive

gear & TSC idler gear 6-18

thou

Backlash-Auxi . drive gear 10-22 thou

Auxi. Drive gear

thrust 133-162

thou

At 12 O’clock24-48 thou

At 3 O’clock16-39thou

At 6 O’clock12-25thou

At 9O’clock16-39 thou

1

2

3


CHECK SHEET FOR TECHNICAL AUDIT OF RADIATOR SECTION (POH)




Make/class of

Subassembly

Reference Details


Observations

1 Leakage testing

Alco Conventional Alco MI

Chapter on Maintenance, Radiators. As RDSO Technical

Specification No.-MP.0.0500.01 (Rev. 03),MAY

– 2009,para 10.12 Reconditioning of Radiator

2.1 Dismantling 2.2 Cleaning of the core 2.3 Changing of gaskets2.4 Assembly2.5 Testing

Chapter on LOCOMOTIVE As per item no 313 M of

MaintenanceSchedule MP.Misc.141

(Rev.01) May 2006 for ALCo Locomotives,

Chapter on Maintenance, Radiators.

3 Cleaning etc

AlcoConventional

Alco 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



Make/class of

Subassembly

Reference Details


Observations

4.3 Radiator stand 4.4 Fin combing tool 4.5 Radiator immersion tank for cleaning

5

Availability of instructions etc.5.1 Display board etc5.2 Training of staff5.3 maintenance manual and check sheets5.4 Calibration facility for tools and measuring

instruments Record Keeping for Traceability Material Availability:5.1 Vital spares 5.2 Must change Item


CHECK SHEET FORQUALITY AUDIT OF ALCO LOCO FUEL INJECTION PUMP (FIP) & 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.


SN Requirements Loco type

Make /Class/Name of subassembly

Reference details

Clause/Para/Item details

Observations

1 Availability of tools/Equipment for maintenance Alco

Bosch 17 mm / 18 mm

Bosch repair and testing manual

Para on AssemblyPara on Calibration ValuesPara on Inspection of PartsPara on Inspection of Parts

1) Torque wrench:O-250 ft.lbs& 0-500 ft.lbs2) Ring spanner-1 3/8"3) Ring spanner-31/4"4) BWS DE-325) Single end 2 3/4"ring spanner6) 0-0.025"lift guage7) Feeler gauge8) Depth gauge for checking of BDC dimension ‘a’ on

test bench.9) Bush reamer.10) Micrometer, 16 – 20 mm. 11) Assembly and dis-assembly fixture12) Nozzle needle lift gauge13) Calibration oil – Servo Calib-514) Dial gauge15) Nozzle centering sleeve16) True running gauge17) Nozzle tester




Reference details


Observations

18) Fixture for injector19) Socket wrench20) Test oil

2

Availability of test benches and other related equipments:

1) Calibration test stand( Make and date of commissioning)

2) Injector test stand ( Make and date of commissioning)

3 Availability of instructions1) Display charts related to reconditioning Training of staff2) Display charts related to testing 3) Maintenance manual and check sheet including calibration and functional test procedure

4) Record keeping of tools and measuring instruments 4 Availability OVH/Renew kit 5 Schedule for maintenance 6 Record keeping for traceability 7 1) Storage of FIP/ Injectors-

a) Store in proper Handling Rack b) Cover with plastic 2) Stored for longer time but <1 year a) Injectors are filled with calibrating oil b) Tight fitting plastic caps used for covering the filter

caps , spray tip end and on the theraded injector stud

3) Stored for more than one year a) After one year, to be filled with clean fuel/




Reference details


Observations

calibrating oil again b) Slowly pop a few times prior to installation

8 Audit of Reconditioning8.1 Dismantling of injector components 8.2 Cleaning & Inspection of injector components

1) Cleaning of injector components 2) Check the condition of shims, guide bush,

intermediate disc.3) Lapping of intermediate disc & Injector body

8.3 Must change items for reconditioning of FIP/Injector 8.4 Measurements etc.

FIP testing1) FIP range control rack bush dia -18.25

mm(0.7185”) -18.27 mm (0.7192”)2) BDC Dimension ‘a’- 6.5 +/- 0.05 mm3) Clearance between control rack and bushing-

within 0.05 mm (0.020”)4) Control rack movement- within 0.38 mm (0.015”)

8.5 Injector Testing1) Opening pressure – 3900 to 4050 psi ( New nozzle)2) Opening pressure – 3700 to 3800 psi ( Overhauled

nozzle)3) Nozzle cap nut tightening torque 130-150 Nm (13-

15 kgf.m or 94-109 lbs-ft)4) Chattering test5) Valve seat tightness test6) Fuel leak test7) Spray pattern test

8.6 Nozzle Test




Reference details


Observations

1) Check the condition of nozzle2) Clean the nozzle assembly by Multi cleaner"3) Ultrasonic cleaning of nozzles4) check the nozzle lift 0.016"to 0.025"

8.7 Fuel Injection Pump1) Check the pump phasing2) Check the Interface between guide cup &

crosshead3) Chech the gap between HP tube and snuber valve4) Chech the alignment of HP tube5) Chech the torquing of delivery valve6) Chech the torque valve of HP tube fitment

fasteners at cylinder head7) Chech the alignment of banjo bolt8) Chech the alignment of fuel jumper bolt9) Chech the free movement of banjo bolt

9 Misc1) Chech the fuel booster pump pressure2) Chech the current taken by fuel pump3) Chech the relief and regulating valve opening

pressure4) Chech the air drawal at suction side of FPM5) Annealing of copper pipes

6) Copper pipe line joint for fuel leakingConduct the bleed test

10 M & P1) FIP calibration test stand 2) Fuel pump motor efficiency checking test bench




Reference details


Observations

3) Profile gauge for checking of HP line 4) Injector test stand

11 Injector output and Slide Adjustment Injector Output data: Test oil……. Viscor 1487 AW2 or equivalent Test oil temperature………35 *C to 40 *C Test oil pressure………..35 psi (241.3 kpa) Test stand RPM………………. 500 RPM


CHECK SHEET FORQUALITY AUDIT OF HHP LOCO MECHANICAL UNIT INJECTOR (MUI) (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.



Make /Class /Name

of subassembly

Reference details

Clause/Para/Item

details

Observations

1 Availability of tools/Equipment for maintenance Ecotip Superstack Mechanical Unit Injector

(MUI)

Ecotip Superstack Injector Maintenance Instructions of Interstate McBee USA

1) EMD timing gauge 2) Vise with adapter 3) Control rack set length blocks 4) Pop and Leak test stand 5) Torque wrench 6) Optical flat 7) Monochromatic light source 8) Soft wire buffing wheel 9) 12 mm dia. Soft wire brush 10) Injector nut reamer 11) Wrench for injector nut

2 Availability of test benches and other related equipments: EMD

1) Calibration test stand( Make and date of commissioning)2) Injector test stand ( Make and date of commissioning)3) Master Injector Kit ( Part No. 4992244.) This kit contains Low Master Injector P/N 4991173 and High Master Injector P/N 4991174



Make /Class /Name

of subassembly

Reference details

Clause/Para/Item

details

Observations

3 Availability of instructions1) Display charts related to reconditioning Training of staff2) Display charts related to testing 3) Maintenance manual and check sheet including calibration and functional test procedure

4) Record keeping of tools and measuring instruments 4 Availability of 3 Yearly OVH kit 5 Schedule for maintenance of MUIs 6 Record keeping for traceability 7 1) Storage of Mechanical Unit Injectors-

a) Store in proper Handling Rack b) Cover with plastic 2) Stored for longer time but <1 year a) Injectors are filled with calibrating oil b) Tight fitting plastic caps used for covering the filter caps , spray tip end and on the theraded injector stud

3) Stored for more than one year a) After one year, to be filled with clean fuel/ calibrating oil again b) Slowly pop a few times prior to installation

8 Audit of Reconditioning8.1 Dismantling of injector components

a) Clamp the injector in vise (equipped with an injector holding adapter) in a follower up position. Excessive clamp force may cause component damage.

b) Dismantled parts of each injector should be kept in separate pan to avoid inter mixing of injector parts and care must be taken not to damage any of the parts.



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Observations

c) Remove the fuel filter caps. Remove and discard gasket and filter elements.

d) Disengage the plunger from the follower and remove the follower spring.

e) To remove the follower spring, insert a small rod between coils of spring and push “stop pin” in to release the follower and carefully lift the follower and plunger from the injector.

f) Invert the injector in the vise. By using socket wrench lose injector nut and then remove the nut by hand.

g) After the nut is removed the exposed stacked parts can be removed.

h) Remove the spill deflector and bushing straightly. i) Remove and discard the body to nut seal ring. J) Release the injector body from the vise and holding free hand at bottom, invert the body to remove the gear retainer and gear. After the gear is removed, the injector rack can be withdrawn from the body.

8.2 Cleaning & Inspection of injector components Cleaning of injector components a) Bodies-To clean entire body by using brush (1” diameter china

bristle) and fuel passage by using dry compress air. b) Injector nut-Clean external surface of the nut by buffing on

the soft wire buffing wheel. Wash Injectornut inside and outside using brush and solvent. Blow off nut with dry compressed air.

c) Injector rack-Clean rack teeth by using soft brush. Wash the rack in cleaning solution and blow off with dry compressed air.

d) Injector gear- Clean gear teeth and outside surface by brushing. Clean inside using 12 mm diameter soft metal brush



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Observations

mounted in a motor driven chuck and wash gear in cleaning solution.

e) Plunger and bushing (P&B) -The plunger and bushing (P&B) are precisely matched components and should be kept together in a non-metallic container during the cleaning, inspection and assembly of other parts .

f) Plunger- To remove oil and carbon deposits, lightly buff only the upper half of the plunger where the gear slides and do not buff the lapped lower portion of the plunger.

g) Bushing- By using soft bristle brush and solvent, wash bushing bore and external surface. Blow off with dry compressed air.

If this lower portion of the plunger and Bushing is scored, scratched or galled the entire P&B should be rejected and replaced with a new P&B .

h) Spill deflector-Using brush and cleaning solution wash entire part. Blow off with dry compressed air.

i) Gear retainer-Buff external surface of gear retainer on soft wire buffing wheel and use the cleaning solution, wash the retainer and blow off with dry compressed air.

8.3 Must change items for reconditioning of injector : These parts cannot be reconditioned to deliver proper

performance and should never be re-used. These must be completely replaced as part of an Ecotip Super stack Kit.

8.4 List of Must change items in Ecotip Super stack Kit - (i)Spray tip (ii) spring cage (iii) spacer (iv) spring seat (v) valve

spring (vi) check valve cage (vii) filter (viii) copper gasket.

8.5 Remaining injector parts- Clean some of the parts listed below by washing (buff on soft



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details

Observations

wire wheel if necessary) and inspect: a)Follower assembly- Removes retainer, stop pin and spring. Regrind follower face to

remove pitting and wear. Gage from face to bottom of slot; acceptable length specification 2.644-2.650 inches.

b)Filter Caps- No nicks, cracks, brinneling in the flare seat and gasket areas.

Threads must be free from nicks or other damage.

c) Follower (Plunger) Spring- Demagnetize and load test; discard if not within the following

Specification: 51.0-57.0 pounds at 2.750 inches load length.

d) Filter Springs- Replace if broken or damaged; no load test required. e) Copper Gaskets- Copper gaskets must be discarded after use and replaced with

new.

f) Injector Nut Seal Ring- Must be discarded and only new OEM diamond shaped seal rings

must be used in order correctly seal the nut to the body.

8.6 Inspection of injector components a) Bodies- Should be carefully inspected for any burrs, metal

slivers or bad threads. The body and all drilled passages should be clean.

b) Plunger and Bushing- Defects on plunger surface such as scores, scratches or galling on

the lapped surface and chipping or eroding on helices may be seen with a good magnifying glass or microscope. Defects are found on P&B then the P&B should be rejected and replaced with



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details

Observations

a new unit . c) Injector nuts - i) Inspect the outside of the nut for pits around the spray

tip end. The spray tip in a reconditioned injector should never protrude more than 0.05 inch (1.27 mm) from the fire face of the nut.

ii) The seat inside the nut should be inspected for the presence of hard carbon deposits or pitted burned metal.

iii) The injector nut cone must be free of pitting and nicks. if necessary, refinish the cone area by reducing the diameter of the cone by a maximum of 0.02 inch (0.5 mm)

d) Control Rack and Gear - To move freely, Control Rack and Gear should be free from burrs

and rough spots. The rack must be straight.

8.7 Assembly of Injector- Collect the clean and inspected parts Blow off with dry compressed air, and place them in a clean dry parts pan or on clean paper. Each injector part is dipped in clean calibrating oil (Viscor 1487AW2 or equivalent) and do not blow off.

The assembly sequence is as follows: 1) Insert two new fuel filters in the body fuel ports. Then apply filter springs and filter caps, using new copper filter cap gaskets. Torque filter caps to 75 ft-lbs (102 NM) with torque wrench.

2) Insert the injector rack into the body. Position the rack so that the two marked teeth are centrally located in the body bore as viewed from the thread end (bottom) of the body.

3) Apply rack gear to mesh with the rack so timing mark on the one gear tooth is between the marked teeth of the rack.



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Observations

4) Apply gear retainer on top of the gear 5) Position the bushing on the body so locating pin enters the slot in the body and place spill deflector over the bushing.

6) Remove the cap from the ECOTIP Superstack kit and carefully place the stack onto the bottom of the bushing.

7) Place the injector nut carefully over the stacked parts Screw nut down by hand, then finally tighten to 140 ft- lbs (190 Nm) when using injector nut wrench T-1404 and torque wrench. If using a deep socket and torque wrench to tighten the nut then torque to 150 ft-lbs (203 Nm).

8) Invert the injector in the vise, nut end down and re-clamp in the vise.

9) Install stop pin, spring, and retainer in the follower. 10) Apply follower spring in place on injector body. 11) Position the rack so that the flat in the ID of the gear is known relative to the injector body.

12) Slide the plunger into the cutout at the bottom of the follower. Position the flat side of the plunger so that it aligns with the flat on the gear in the body, the follower stop pin and with the stop pin slot in the body.

13) Place the follower and plunger assembly into the body. 14) Depress the stop pin and press down on to of the follower. If necessary, move rack slightly in or out until plunger engages with rack gear.

15) Continue pressing on follower until stop pin enters slot. 16) On injectors equipped with calibrating slides, assemble the slide so that the end of the slide is flush with the face of the injector body.



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details

Observations

17) Apply plastic caps over the filter caps after injector testing or immediately after build if the injectors will be stored prior to testing to prevent dirt from entering the injector and a cap over the stud threads to prevent handling damage.

9 INJECTOR TESTING Testing of injector

a) Qualifying the Test stand – 1) Install the test block in place of an injector in the stand and pump up pressure to 2000 psi (138 Bar), as indicated by the gauge.

2) After five minutes, the pressure should not have dropped below 1975 psi (136 Bar).

3) Release the block and recheck at 500 and 1000 psi (34 and 69 Bar). These pressures should hold one minute with no apparent gauge drop.

4) Make these tests with the pressure shutoff valve open all the way. If the tests are satisfactory, all injector tests may be made without using the shutoff valve.

5) If the preceding tests indicate leakage in the stand, repeat the tests, closing the shutoff valve before timing the leakoff rates.

6) If the tests are satisfactory with the shutoff valve closed, it will be necessary to use the shutoff valve when making the injector holding pressure test.

b) General Information : 1) When operating the pump, use a rate of approximately 40 smooth strokes per minute. This provides a calibrating oil rate to operate the check valve smoothly and to circulate oil within the injector.



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details

Observations

2) When using the popping lever, do not use such force as to damage either the injector or the test stand. Do not permit the lever to fly up freely.

3) In making holding tests, do not pump the stand above 2500 psi (172 Bar).

4) Test stands regularly in use should be checked daily for leaks, using the test blocks.

5) Calibrating oil used for testing should not be reused. c) Spray pattern and Valve chatter test 1) Remove the protective plastic caps from the filter caps and stud.

2) Install the injector in the test stand. 3) Fill the injector with calibrating oil, but do not connect the fuel line from pump to injector at this time.

4) Set the injector rack at maximum fuel output position (minimum rack length).

5) “Pop” the injector with the popping lever, using approximately 40 smooth even strokes per minute. A finely atomized spray should show at each of the holes in the tip. Rapid closing of the needle valve should produce a sharp “chatter”.

6) If the injector plunger does not move down smoothly, stop. Do not force the plunger downward or component damage may occur.

d) Holding Pressure& leak Test: 1) Tighten to 40 in lbs (4.5 Nm) Apply 2000 psi (138 Bar) pressure to the injector. No leakage is permitted at the nut to body seal, filter cap gasket, body plugs, or between spray tip and injector nut.



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Clause/Para/Item

details

Observations

2) For reconditioned injector, conduct Holding test by timing the interval for a drop in pressure from 2000 psi to 1500 psi (138 to 103 Bar). If this interval is less than 30 seconds, repeat the test but close the pressure shut off on the test stand immediately after establishing 2000 psi pressure. If the timed interval for the pressure drop from 2000 psi to 1500 psi (138 to 103 bar) is still less than 30 seconds, the injector should be rejected.

e) Rack freeness test: The rack must fall in and out through full travel, by its own weight, when injector is held horizontally and rotated about its axis. A binding rack may cause sluggish or erratic speed changes and over speed trip action.

f) Binding Plunger test A binding or stuck plunger can be caused by improperly inserting the plunger into the bushing during assembly. The plunger must be well lubricated with calibrated oil/diesel fuel and inserted into the bushing gently and without any rocking or wiggling motion.

10 QUALIFYING THE CALIBRATION STAND a) Calibration stand should 1) Maintain a constant clamp force on the injector body to insure a good cone seal and to prevent body movement.

2) Maintain calibrating fluid temperature between 95 to 105◦ F (35 to 40◦ C).

3) Maintain a minimum calibrating fluid pressure of 35 psi (241 kPa) during test.

4) Maintain a constant set speed of 900 RPM within + or – 2 rpm during test.



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Observations

5) Maintain contact of the calibration blocks to the body face during test.

b) Sheds is to use Master Injectors to qualify the stands. The Master Injector Kit for Indian Railway 710 engines is Part Number 4992244. This kit contains Low Master Injector P/N 4991173 and High Master Injector P/N 4991174.

c) Temperature gauges and pressure gages should be calibrated with master gages every six months.

d) RPM readout should be verified with a certified tachometer every six months.

e) Injector stroke length should be verified yearly in order to detect cam/follower wear.

f) Rack set length blocks are high wear gages and should have the 0.875 +/- 0.001 inch (22.23 +/- 0.025mm) rack length dimension verified monthly. These blocks snap over the ball on the rack and must be held against the body face of the injector during the calibration test.

g) Verify that the mechanical and fluid systems are operating properly (consistent fluid supply, drive system set up properly and well lubricated)

h) Run the low master injector three (3) times, calculating the average low output limit for this 710 injector on your calibrator.

i) Run the high master injector three (3) times, calculating the average high output limit for this 710 injector on your calibrator.

j) Run production injectors within the high and low limits calculated in steps h and i above.

k) Two newly reconditioned injectors should be set to the calculated high and low limits established in steps h and i above



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Clause/Para/Item

details

Observations

and used daily to verify calibration of your test stands. Master Injectors should be stored in their original case and used only for periodic checks or if problems arise.

11 a) CALIBRATING INJECTOR OUTPUT Install the injector in the calibration stand and let the injector run in the calibration stand for a period sufficient to stabilize the injector temperature (Body of the injector should be 40◦ C or greater) Run a test cycle to check the output. If the output is not within the range established by the High and Low master injectors, adjust the calibrating slide.

b) INJECTOR OUTPUT AND SLIDE ADJUSTMENT INJECTOR OUTPUT DATA: Test oil …………………………Viscor 1487AW2 or equivalent Test oil temperature ……………………………… 35° C to 40° C Test oil pressure ………………………………..35 psi (241.3 kPa Test stand speed ……………………………….. 900 RPM c) 710 ECOTIP Injector (NEW P/N 40083540,DLW- P/N 16241186 UTEX P/N 40079007) Output :

ECOTIP Low Master Injector……………….277 cc/300 strokes ECOTIP High Master Injector………………283 cc/300 strokes


CHECK SHEET FORTECHNICAL AUDIT OF PTLOC SECTION (POH)




Make Of Subassembly


Details

Observations

1

Dis-assembly /Measurement/Assembly/Test etc.1.1 Overhauling procedure

1.2 Plate Pack Length1.3 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

2Availability of tools , Test Stands etc.2.1 Ratchet spanner

3

Availability of instructions etc.3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments




Annexure-VCHECK 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

REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco (WDM2, WDM3A, WDM3D)

Pinion & Gear Assly.

MP-IB.EM.10.31.08

dated 24.10.2008

1.1 TRACTION GEAR & PINION1.2 Gear Ratio 18 : 651.3 Pinion Drg. No. 18 teeth, SKDP36241.4 Pinion Bedding In Cold

Condition Not less than 95 %

1.5 Pinion Advance 2.25 TO 2.45MM1.6 Heating Temperature 190ºC + AMB TEMP.1.7 Span Size On New Pinion Over 3 teeth

88.595 /88.722MM1.8 Condemning Limit On Basis

Of Span Size Of PinionOver 3 teeth 86.995MM

1.9 Gear Drg. No. 65 teeth SKDP-3623 & SKDP-3775

1.10 Span Size On New Gear Over 7 teeth 223.989/223.798MM

1.11 Condemning Limit On Basis Of Span Size Of Gear

Over 7 teeth 220.800MM

1.12 Permissible Backlash With New Set

0.266 - 0.664MM

1.13 Condemning Limit On Basis Of Backlash

1.04MM

1.14 Crack detection MPMI or Zyglo test



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

2 TRACTION GEAR & PINION

WDG3A

HHPWDG4

Traction Motor Pinion & Gear Assly. of Alco

Loco

Traction Motor Pinion & Gear Assly. of HHP

Loco

MP-MI 129/86 July ‘1986

MP-MI 5

MP.IB.EM.01.04.14

Dt. 21.08.2014

2.1 Gear Ratio 18 : 742.1 Pinion Drg. No. 18 teeth, SKDP-34432.2 Pinion Bedding In Cold

Condition Not less than 95 %

2.3 Pinion Advance 2.30 TO 2.45MM2.4 Heating Temperature 185ºC + AMB TEP.2.5 Span Size On New Pinion Over 3 teeth 81.976

/82.093MM2.6 Condemning Limit On Basis

Of Span Size Of PinionOver 3 teeth 80.366MM

2.7 Gear Drg. No. 65 teeth SKDP3444 & SKDP3546

2.8 Span Size On New Gear Over 8 teeth 231.36/231.177

2.9 Condemning Limit On Basis Of Span Size Of Gear

Over 8 teeth 228.140

2.10 Permissible Backlash With New Set

0.243 - 0.608MM

2.11 Condemning Limit On Basis Of Backlash

1.00MM

2.12 Crack detection MPMI or Zyglo test3 MEASUREMENT

3.1 TRACTION GEAR & PINION WDG43.2 Gear Ratio 17 : 90 3.3 Maximum limit of Backlash 23 (In Thou)

0.58 (in MM)3.4 Minimum limit of Backlash 10 (In Thou)



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

0.254 (in MM)3.5 Condemning limit of Backlash 37 (In Thou)

0.94 (in MM)3.6 SPAN size (“K”) for Traction

Pinion service wear limitOver 3 Teeth 67.40 / 67.45 mm

3.7 SPAN size (“K”) for Traction Pinion Condemning wear limit

Over 3 Teeth 65.80 / 68.85 mm

3.8 SPAN size (“K”) for Traction Bull Gear service wear limit

Over 13 Teeth 328.70 / 328.75 mm

3.9 SPAN size (“K”) for Traction Bull Gear Condemning wear limit

Over 13 Teeth 325.50 / 325.55 mm

3.10 Condemning Teeth Profile wear limit of Traction Pinion

18 (In Thou)0.45 (in MM)

3.11 Condemning Teeth Profile wear limit of Traction Bull Gear

30 (In Thou)0.77 (in MM)

4 MEASUREMENT4.1 TRACTION GEAR & PINION WDP4 Loco4.2 Gear Ratio 17 : 77 4.3 Maximum limit of Backlash 24 (in Thou)

0.61 (in MM)4.4 Minimum limit of Backlash 11 (in Thou)

0.280 (in MM)4.5 Condemning limit of Backlash 39 (in Thou)

1.00 (in MM)4.6 SPAN size (“K”) for Traction

Pinion service wear limitOver 3 Teeth 77.00 / 77.05 mm

4.7 SPAN size (“K”) for Traction Pinion Condemning wear limit

Over 3 Teeth 75.35 / 75.40 mm

4.8 SPAN size (“K”) for Traction Bull Over 11 Teeth



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

Gear service wear limit 314.40 / 314.45 mm4.9 SPAN size (“K”) for Traction Bull

Gear Condemning wear limitOver 11 Teeth 311.20 / 311.25 mm

4.10 Condemning Teeth Profile wear limit of Traction Pinion

18.5 (In Thou)0.47 (in MM)

4.11 Condemning Teeth Profile wear limit of Traction Bull Gear

31.5 (In Thou)0.80 (in MM)

5 TA FAN ASSEMBLY

All ALCo locosMP-IB.EM.01.02.10 dated 11.01.2010.

5.1 Outer diameter of TA fan 1387.25/1387mm5.2 Bore diameter of TA stator 1392mm5.3 Bore diameter of TA fan 600.00 / 600.03mm5.4 Diameter of fan seating area on

barrel.600.03 / 600.06mm

5.5 Width of fan seating at bore 9+1 mm5.6 Depth of counter sunk bolts

hole4.5 - 5.5 mm

5.7 Bolt head width 12.3mm5.8 Bolt head height above fan

plate after final assembly should not be more than

6- 7mm

5.9 Circumferentially Fan gap on TA

2.50 – 2.75mm

5.10 Tightening torque and wire locking process

28 – 30Kg-m

5.11 Tightening torque of M30 (coupling bolt)

170 – 180 kg-m.

5.12 Oil catcher thickness (at bottom side)

53.90 to 54.10mm

5.13 Bolts strength properties grade R8.8.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

5.14 Sunk type M20 bolts can be used

in place of fully threaded M20 bolts

5.15 M20 & M30 bolts should be replaced

After 4 – 5 years service of TA

5.16 Fan bore area should be heated (for shrink fit).

150 to 170 °С

5.17 Re-used or old bolts and barrel thread condition should be checked by

GO & NO GO thread ring or plug gauge

5.18 Threaded portion of barrel & bolts should be free from varnish or paint or dust deposits.

Visual inspection is required

5.19 TA fan should be mounted on the barrel by “shrink fit “

In place of (bolts) press fit.

5.20 TA fan bolts locking wire ends should not be come out of the bolt head(projected)

As shown in photo

5.21 Proper alignment of TA fan should be checked by inserting filler gauge circumferentially

Clearance between the fan (back side) and barrel of TA (as shown in attached photo)No clearance is allowed.

5.22 After Final assembly of TA fan, visual inspection is required on

Tightening torque, wire locking & fan back clearance with barrel(by filler gauge



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

(circumferentially)5.23 TA Gear train assembly Backlash at Steel

plate All ALCo locos MP.IB.EM.02.12.00dated 10-4-2000.

MP.IB.EM.02.03.08, dated 24-

01-2008

And

MP.IB.EM.03.04.08, dated 24-

01-2008

5.24 TA GEAR 102TAG/EG PINION 43TPTU PINION - 43T

0.60mm to 1.40mm0.05mm to 0.12mm on shaft

6 Carbody cables and Traction Motor cables

All ALCo locos6.1 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.

7 AVAILABILITY OF TOOLS AND TEST STANDSAll ALCo locos7.1 Vernier Callipers

7.2 Disc Mike7.3 Filler Gauge8 INSTRUCTION

8.1 Display Chart8.2 Training of Staff8.3 Record keeping of tools and measuring instruments9 TRACEABILITY

10 MATERIAL AVAILABILITY10.1 Vital Spare -NA



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

10.2 Must change items -NA


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

OBSERVATION

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 Record IR ofa) Armature (Shall be > 10 MΩ)b) Inter Pole (Shall be > 10 MΩ )c) Main Pole (Shall be > 10 MΩ)

1.2 Record ovality of commutator (Limit – 0.001”)2 AFTER DIS-MANTLING

2.1 Pinion to be sent for Magna flux test / Zyglo test2.2 Visual examination of Armature banding. If found

beyond repair, rewind it.2.3 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.

2.4 Check commutator surface roughness. If found > 0.05 mm or any cut mark is observed, commutator to be grind on machine.

2.5 Ensure that there is no damage on armature seating area & armature shaft. If any damaged is noticed, re-metalize it to reqd. size.

2.6 Ensure cleaning of magnet frame with cleaning solvent to RDSO spec. MP.0.8000.01 Rev.02 Oct.’2007.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

2.7 Bake the magnet frame in oven at 120 + 10 °C &record it.

2.8 Apply insulation varnish as per RDSO MP.MI 153/92 (latest revision)

2.9 Check IR after renewal of glass epoxy laminate, GMGS & Nomex insulation for inter poles & main poles (Shall be > 100 MΩ )

2.10 Ensure tightening of pole bolts during assembly of magnet frame and maintain IP & MP bores as per OEM manual.

2.11 Joints may be brazed & insulated, if required with RDSO approved Silicon elastomer tape.

2.12 Check IR of main pole & inter pole assemblies & record it. (Shall be > 100 MΩ )

2.13 High potential test of inter pole & main pole at 1.3 KV for 15 sec. shall pass the test.

2.14 Ensure spray cleaning of armature with cleaning solvent to RDSO spec. MP.0.8000.01 Rev.02 Oct.’2007.

2.15 Bake the armature in oven at 120 + 10 °C & record it.2.16 Spray varnish paint protecting the shaft &

commutator & cure it.2.17 Ensure mica cutting. & chamfering as per OEM’s

manual2.18 Ensure cleaning & baking of brush arms as per OEM’s

manual.2.19 Measure IR of brush arm (Shall be > 100 MΩ). If less,

replace the brush arm2.20 Ensure the spring tension. (Lt. 4.5 Kg to 5.5 Kg)2.21 Ensure the replacement of PTFE sleeve of brush arm.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

2.22 Ensure painting of support arm with red becktol varnish.

2.23 Conduct high potential test as per OEM’s manual2.24 Tan Delta Test on Armature as per OEM’s manual

3 ASSEMBLY3.1 Motor assembly as per OEM’s manual3.2 Measure the final Insulation Resistance = 10 Mega

ohma) Armature (Shall be > 100 MΩ)b) Inter Pole (Shall be > 100 MΩ )c) Main Pole (Shall be > 100 MΩ)

3.3 Measure the end float (Lt. = 0.006” to 0.012”)3.4 Check the nose plate condition. If found damaged or

wear out, shall be replaced. 3.5 Conduct the light run test at low, medium & high rpms

on assembled motor & observe for unusual sound using listening rod.

3.6 Check the bearing temperature after stabilization during light un test. (Shall not be > 60 °C)

3.7 Apply brush seater on the commutator to seat the carbon brushes on the commutator properly.

3.8 Ensure tag welding / welding of stays on main pole & compole fixing bolts.

3.9 Apply recommended sealant to avoid ingress of water etc.

3.10 Apply a coat of paint on motor.4 AVAILABILITY OF TOOLS AND TEST STANDS

4.1 1000V Megger4.2 Filler gauge



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

4.3 HV tester4.4 Dial gauge4.5 Tachometer / Speedometer4.6 Pyrometer4.7 Inside & Outside micrometer /calliper

4.8 High Potential Testing Machine

4.9 Tan Delta Machine

3 INSTRUCTION3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools & measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY & STORAGE (AC/non-AC)

5.1 Vital Spares5.2 Must change items


CHECK SHEET FOR QUALITY AUDIT OF TRACTION MOTORS- HHP LOCOMOTIVES



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP locos (WDP4, WDP4B, WDP4D,

WDG4D & WDG4)

Traction Motors of HHP locos

(WDP4, WDP4B, WDP4D, WDG4D

& WDG4)

Refer MI 1517ARefer tractionmotor operatinginstructionA1A25110E/01.2001/Version 1.

1.1 Insulation Resistance = 10 Mega ohm 1.2 Inspect all cables (Power, sensor and earthing) for

insulation damage or cut marks.1.3 Inspect all cable cleats for broken studs, excessive

tightness and rubber cleat damage.1.4 Inspect all sensor (Speed &Temp) plugs for correct

locking.1.5 Inspect all air ducts (TM Bellows) and fixing bolts for

damage.1.6 Inspect all motors for any hit marks, physical damage

and presence of all end shield cover bolts.1.7 Inspect cable junction plates and umbrella boots for

signs of damage or overheating.1.8 Ensure all cables are routed properly and there is no

excess/short cable over hangs.1.9 Apply insulation/spacers at all locations where cables

are rubbing each other and with locomotive body.1.10 Blow all the traction motors with dry compressed air

1.11 Gear case mounting: Check Gear Case oil level by dip stick as per MP.IB.EM.03.12.10), March’ 2010). Add if required.



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Traction Motor Cables and Cleats: Check for any signs of damage/rubbing on the TM cables and cleats

1.12 Open inspection covers, inspect windings for any damage and presence of foreign material and blow with light compressed air

1.13 Open motor and car body connection umbrella boots and inspect cable lugs for signs of overheating.

1.14 Oil consumption record of each Traction Motor should be recorded. It should not be more than 0.5 to 1.0 Liter/Month.

1.15 Gear Case oil level should be checked by dip stick (MP.IB.EM.03.12.10), March’ 2010).

1.16 Provide all car body and junction plates.1.17 Record IR and winding resistance of all TMs.1.18 Replace defective items if necessary (like heat shrinks,

colour code, lugs, cleats etc.)1.19 Reconnect all the TM cables.1.20 Check terminal connections of TM for overheating and

loosening.1.21 Check that car body cable and TM cable is properly

secured.1.22 Gear Case oil should be checked (MP.IB.EM.03.12.10),

March’ 2010.1.23 Aluminium cover oil path should be cleaned before

filling fresh oil (MPMOD.EM.01.05.16 (Aug’ 2016).1.24 Backlash & wear on teeth should be checked by

recommended gauge (MP.IB.EM.01.04.14) Aug’ 2014.2 CABLE ROUTING



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2.1 Check all TM sensors (speed & temperature) and locking plugs.

2.2 Check all TM cables for any excessive hanging and improper routing.

2.3 Check Sensor cables and earthing cables.2.4 Provide cable cleats and spacers wherever necessary2.5 Secure cables with cable ties.3 BELLOW ATTENTION

3.1 Check and ensure the condition of TM bellows.3.2 Check all the bottom side fixing bolts for proper

tighten and missing of bolts provide if necessary.3.3 Renew the bellow if necessary.3.4 Record all bellow Sl. No. and make.4 TM INSPECTION

4.1 Open all the TM inspection covers and ensure no foreign body present inside the TM.

4.2 Blow with dry compressed air (4.5-5 kg/cm sq.) from inspection window and gear case end opening.

4.3 With a hand lamp, check the motor winding for any foreign body entry and broken/burnt winding insulation etc.

4.4 Check all TMs for any hit marks and external damage.4.5 Check all TMs for any gear case oil entry or grease

oozing.4.6 Provide back all the inspection covers.5 TORQUING AND CLEANING

5.1 Check and torque NDE end shield cover bolts (18mm) with a value 70 Nm.

5.2 Check and torque both DE and NDE side bolts (36mm)



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with a value of 680 Nm.5.3 Scrap all motors with wire brush.5.4 Clean all the power cables, sensor cables and earth

cables by surf water.5.5 Record all TM serial Nos. and make.6 AVAILABILITY OF TOOLS AND TEST STANDS

6.1 5000V Megger6.2 Filler gauge7 INSTRUCTION

7.1 Display Chart7.2 Training of Staff7.3 Record keeping of tools and measuring instruments8 TRACEABILITY9 MATERIAL AVAILABILITY



CHECK SHEET FOR QUALITY AUDIT OF TRACTION ALTERNATOR AT POH WORKSHOPS



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ITEM DETAILS

OBSERVATION

1 MEASUREMENT

ALCO locos Traction Alternatorof Alco loco

BHEL’sMaintenance Manual for Electrical

Equipment of ALCO loco (Volume-II)

1.1 Check tightness of all mechanical and electrical connections. Check slip rings and brushes for sparking.

2 BRUSH GEAR2.1 Spring pressure- 1.36 to 2.2 kgs (adjustable) to be

adjusted to 1.8 kgs.2.2 Minimum length of brush at which brush become

inoperative – 35mm.2.3 Clearance between brush holder & slip ring- 2 to 3

mm.3 SLIP RING

3.1 Diameter (New) – 520 mm3.2 Minimum worn out dia – 510 mm3.3 Slip ring run our (max) – 0.1 mm3.4 Slip ring ovality (max) – 0.1 mm 4 ROTOR

4.1 Diameter- 1003 mm4.2 Air gap at pole center – 6 mm4.3 Rotor bearing - NU330 EM/C4/D150mm x65 mm x

320mm O/D4.4 Bearing housing dimension – 320- 0.005 mm.



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where outer race sites - - 0.025 mm

All ALCo locosMP.IB.EM.02.12.00dated 10-4-2000Misc Report No. MP.Misc.254 (Rev.-01) March 2016

4.5 Radial clearance of free bearing when new – 0.165 to 0.215 mm

4.6 Fit between outer race & bearing housing- 0.035 mm clearance, 0.025 mm interference

4.7 Shaft bearing seating dia – 150 + 0.055 mm + 0.035 mmFit between inner race & shaft – 0.035 to 0.08 mm interference

4.8 Diametrical slackness of free bearing – 0.15 to 0.18 mm

4.9 Min. permissible racial clearance when assembled - 0.03 to 0.13 mm

4.10 Min. diametrical clearance when assembled in the machine – 0.051 mm

4.11 Bull gear wheel I/D – 149.098 + 0.025 mm + 0.000 mm

4.12 Shaft bull gear seating dia–149.098 + 0.162 mm + 0.152 mm

4.13 Gear box oil capacity – 2.6 litres approx.4.14 Lubricant type – SAE 40 or equivalent.

5 TIGHTENING TORQUE KG.M5.1 Exciter to gear box – 155.2 Aux-gen to gear box – 155.3 PTU to gear box – 155.4 Gear box to end shield – 15

(write locked)5.5 Gear box to end shield – 1

(at pads)



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5.6 Fan to rotor shaft – 25/27(write locked)

5.7 Rotor shaft extension to barrel – 25 5.8 Rotor pole bolts – 170/1905.9 Slip ring to shaft extn. – 156 RESISTANCE AT 25°C-

6.1 Stator- 0.002156 ohm (Line to Line)Rotor- 0.312 ohm (at slip ring)

7 IR TESTS7.1 Stator (check with 1000V magger) : 2M Ohms7.2 Rotor(check with 1000V magger) : 2M Ohms8 TA FAN ASSEMBLY

8.1 Outer diameter of TA fan 1387.25/1387mm8.2 Bore diameter of TA stator 1392mm8.3 Bore diameter of TA fan 600.00 / 600.03mm8.4 Diameter of fan seating area

on barrel. 600.03 / 600.06mm

8.5 Width of fan seating at bore 9+1 mm8.6 Depth of counter sunk bolts

hole4.5 - 5.5 mm

8.7 Bolt head width 12.3mm8.8 Bolt head height above fan

plate after final assembly should not be more than

6- 7mm

8.9 Circumferentially Fan gap on TA

2.50 – 2.75mm

8.10 Tightening torque and wire locking process

28 – 30Kg-m

8.11 Tightening torque of M30 170 – 180 kg-m.



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(coupling bolt) 8.12 Oil catcher thickness (at

bottom side) 53.90 to 54.10mm

8.13 Bolts strength properties grade

R8.8.

8.14 Sunk type M20 bolts can be used

in place of fully threaded M20 bolts

8.15 M20 & M30 bolts should be replaced

After 4 – 5 years service of TA

8.16 Fan bore area should be heated (for shrink fit).

150 to 170 °С

8.17 Re-used or old bolts and barrel thread condition should be checked by

GO & NO GO thread ring or plug gauge

8.18 Threaded portion of barrel & bolts should be free from varnish or paint or dust deposits.

Visual inspection is required

8.19 TA fan should be mounted on the barrel by “shrink fit “

In place of (bolts) press fit.

8.20 TA fan bolts locking wire ends should not be come out of the bolt head(projected)

As shown in photo

8.216.10 Proper alignment of TA fan should be checked by inserting filler gauge circumferentially

6.11 Clearance between the fan (back side) and barrel of TA (as shown in attached photo)No clearance is



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allowed.8.22 After Final assembly of TA

fan, visual inspection is required on

Tightening torque, wire locking & fan back clearance with barrel(by filler gauge (circumferentially)

8.23 TA Gear train assembly Backlash at Steel plate

8.24 TA GEAR 102TAG/EG PINION 43TPTU PINION - 43T

0.60mm to 1.40mm0.05mm to 0.12mm on shaft

9 AVAILABILITY OF TOOLS AND TEST STANDS9.1 Bearing retaining ring9.2 Clamping ring9.3 Shaft adaptor9.4 Guide sleeve9.5 Frame lifting fixture9.6 Extractor for bull gear9.7 Lifting tackle9.8 Forcing screws9.9 Guiding studs

9.10 Spacers9.11 S.K.F. Oil Pump9.12 Studs 9.13 protection sleeves9.14 Extractor for bearing inner race9.15 Extractor foe bearing outer race from bearing

housing10 INSTRUCTION



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10.1 Display Chart10.2 Training of Staff10.3 Record keeping of tools & measuring instruments11 TRACEBILITY12 MATERIAL AVAILABILITY



CHECK SHEET FOR QUALITY AUDIT OF ALTERNATOR MOUNTED RECTIFIER AT POH WORKSHOPS



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1 VISUAL INSPECTIONS

ALCO locos Alternator

Mounted Rectifier of Alco loco

MP.MI.29 (Rev.-00) December

2007

1.1 Remove the rectifier cover and blow clean compressed air at approximate 2 kg/cm² to remove dust, dirt and soot deposition.

1.2 Check that the flag of the micro switches on all the fuses is in closed condition. Check the functionality of micro switch on indication panel and replace if faulty.

1.3 Check the diodes, fuse for marks of Overheating, cracks or any other abnormalities on the devices. Check the condition of resistors and capacitors.

2 MEASUREMENT2.1 Check the heat sink to bus bar connections for

looseness. Check the tightness of diode with heat sink at 2 Nm to 3 Nm.

2.2 Check healthiness of diodes by conducting forward bias test, reverse bias test and leakage current test.

2.3 Replacement of diode or refitting (if found OK) may be done as follows: Apply thin layer of heat sink compound such as Dow corning make DC340R or equivalent, smear it out with clean cotton then



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place diode on heat sink. Place the clamp, insert Allen screws (M8) then tight it by torque wrench diagonally setting torque at 12.5 NM. Ensure healthiness of fuse, snubber capacitor and snubber resistor.

3 INSTRUCTION

3.1 Display Chart

3.2 Training of Staff

3.3 Record keeping of tools & measuring instruments

4 Traceability 5 Material Availability

5.1 Vital spares

5.2 Must change item


CHECK SHEET FOR QUALITY AUDIT OF TRACTION ALTERNATOR-RECTIFIER



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OBSERVATION

1 MEASUREMENT

HHP locos (WDP4, WDP4B,

WDP4D, WDG4D &

WDG4)

Traction Alternatorof HHP loco

Maintenance Instruction for

Traction Alternator of

HHP loco

MI-3317-1 Jand MI-3317-2HOR latest revision

1.1 (a) Check tightness of all mechanical and electrical connections. Check for open fuses (indicating pins protruding). Check collector rings surface and brushes for marks of sparking, pitting, blackening.

(b) Collector Rings:- Maximum Ring Eccentricity = 0.15 mm (0.006")- Maximum Lateral Ring Runout = 0.8 mm

(1/32")- Condemning Limit on Ring Outside Diameter =

260 mm (10-3/4")- Minimum spiral groove depth = 0.635 mm

(0.025 inches). - Maximum lateral run-out = 0.8 mm (1/32").

(c) Check that the slip ring 1 and 2 brush holders applied are centered on the slip ring width, with a minimum 1.6 mm (1/16”) distance to the edge of the slip ring. For vertical positioning of single box brush holder,



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OBSERVATION

clearance between the brush holder(s) trailing edge to Slip Ring surface are set at .125”-140”. For vertical positioning of dual box brush holder, ensure that the tips of each brush holder are the same distance to the slip ring on each side.

(d) Ensure that CA side Brush holder assembly has been modified as per MP.MOD.EM. 01.03.18 Rev.-00 July 2018 which calls for replacement of small size brush holders with large size single pocket brush holders as that used on TA side. Check that large brush spring pressure is 1.5 kg (3.3 lbs).

(e) Ensure free sliding of spring clip in Brush Holder Pocket and free rotation of spring clip about hinge Stucking of Spring clip shall not be allowed.

(f) Minimum length of bush = 3.81 cm. (1.5 in.) on the longest vertical side.

(g) Ensure polarity reversal of excitation supply at every 6 month.

(h) Ensure provision of rubber grommets at both ends of pipe conduit carrying rotor cables for TA rotor and CA rotor, ensure proper cable lug connections.

MP.MOD.EM. 01.03.18 Rev.-00 July 2018

dlw.m.65.262 dtd. 27.07.16



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(i) Ensure proper gap maintained between CA covers and fly wheel coupling bolts as per DLW Design bulletin to avoid rubbing or damage to CA covers.

(j) Ensure proper alignment of TA with Engine by ensuring uniform air gap of TA around the stator peripheral to overcome the problem of ‘DC Link Over Current’ and Load meter response ZERO in EMD locos.

(k) Visually inspectand ensure that all the components of AIR BOX (such as diodes, fuses, lead connections, Slip ring guard, cables, cleat, terminal board etc.) are free from black deposits of Smog, soot and Muck. If found so, proceed to check the condition of : fins of TM Blower for black deposits, Exhaust manifold in engine room.

Because leakage of smoke from exhaust manifold in engine room get suctioned by the TM blower via AG. (Even the partition wall provided on AG could not check this black smoke) and same is blown forcibly to the AIR BOX and may further get deposited on stator and rotor winding of TA, CA & TM. Prolonged service of loco in such condition may lead to:



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OBSERVATION

Flashing in Rectifier panel Low IR of stator and rotor windings of TA CA,

AG & TMs. Winding burnt cases of TA, CA, AG & TMs.

ETI – 897

ETI – 904

1.2 COLD RESISTANCE LIMITS (in Ohms at 75°C):

For Main Alternator:

- Rotor Collector Ring to Collector Ring = 1.384(Nominal), 1.439(Max), 1.328(Min).

- Stator Line-to-Neutral (Per 5 Phase Group) = 0.00300(Nominal), 0.00306(Max), 0.00294(Min).

- Stator Line-to-Line (Per 5 Phase Group) = 0.00568(Nominal), 0.00579(Max), 0.00557(Min)

For Companion Alternator:- Rotor Collector Ring to Collector Ring =

1.51(Nominal), 1.54(Max), 1.48(Min).

- Stator Line-to-Line (Per 5 Phase Group) = 0.00435(Nominal), 0.00445(Max), 0.00428(Min)



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CT Resistance: 11.8±10% Ohms at 25°C

1.3 (a) ROLLER BEARINGS:- Outer diameter = 259.999 mm (+ 0.00 mm/ -

0.036 mm),- Bearing Bore = 1200.00 mm (+ 0.00 mm/ -

0.020 mm),- Width = 85.99 mm (+ 0.00 mm/ - 0.13 mm),- Internal Clearance (before assembly) = 0.104

mm to 0.150 mm,- Internal Clearance (after assembly) = 0.063

mm Min,- Bearing Housing Bore Inside Diameter =

260.1152 mm (+0.102 mm/ -0.00 mm)

(b) Lubrication Capacity:- Bearing Cap = 284 g (10 oz),- Outer Bearing Cover = 284 g (10 oz),- Bearing = 369 g (13 oz),

1.4 RECTIFIER:(a) Checked for any loose connections, flash

damage or damage caused by shorting to ground.

(b) Continuity tester readings: 10 to 20 ohms in one direction and above 30,000 ohms when leads are reversed (for good diodes).

(c) Current limiting fuse resistance values (@75°F/23°C) = 0.000195 + - 0.000010 ohm



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(d) All diodes in any paralleled group must be of the same polarity (ceramic cases or shrink tubing or color band at the lower crimp must be of same color) and of same type (same type number impressed). The diodes must be applied to the proper heat-sink bus.

(e) Replace defective diodes with good diodes of identical polarity, and voltage class (or

higher voltage class). Apply a thin coating of compound 8346481 to the base of the

diode hex to cover the surface. Do not apply on threads.

(f) With special diode socket and 0 – 50 ft.-lbs. Torque wrench, torque diodes to 45 to 47 Nm (33 to 35 ft.-lbs.). Make certain that the wrench is properly seated when torquing.

(g) Torque diode terminal lug bolts to between 15 to 18 Nm (11 to 13 ft.-lbs).

(h) Some sheds are incorporating FRP sheets between +Ve and –Ve Bus Bar, to overcome cases of flash over in EMD design rectifiers.

Note: BHEL make TAs are fitted with rectifier of their own design having flat square base diodes. Ensure implementation of protective cap on bolts heads of Heat sink mounting bolts and epoxy red gel paint on bolt heads of rectifier mounting bolts as per MP.IB.EM. 02.04.18 Rev.00 July 2018 to avoid cases of flashover.

2 AVAILABILITY OF TOOLS AND TEST STANDS



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OBSERVATION

MP.IB.EM. 02.04.18 Rev.00 July 2018

2.1 - Induction Heater,- Stone (1" x 1-1/2" x 5"),- Collector Ring Grinder,- Collector Ring Grinder Adapter,- Hydraulic Pump,- Collector Ring, Seals, and Bearing, -Puller

Assembly,2.2 - Torque Wrench 0 – 50 ft/lbs. – 1/2” Drive,

- Multimeter,- Megger, Insulation Resistance Test Set (500,

1000, 2500, 5000 volt),- Digital Micro Ohm Resistance Tester Kit, (Range 0

to 1.999 miliohms) 3 INSTRUCTION

3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools & measuring instruments4 TRACEBILITY5 MATERIAL AVAILABILITY



CHECK SHEET FOR QUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS AT POH WORKSHOPS



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OBSERVATION

1 MEASUREMENT

All ALCo locos fitted with TM 4907/C1001

Traction Motor Bearing & Assly. Components of

Alco Loco

MP-IB.EM.14.50.08

dated 20.02.2009

1.1 Verticality of Outer race1.2 Verticality of Inner race1.3 Max. deviations allowed in above cases:

Side Inner race Outer racePinion End 0.075 mm 0.25 mmCommutator End 0.065 mm 0.20 mm

1.4 Radial Clearances of bearingsFor New BearingsBearing Radial clearance

before mounting (mm)

Radial clearance after mounting

(mm)NU 330 0.165 - 0.215 0.100 – 0.170 NH 320 0.105 – 0.140 0.060 – 0.100

1.5 In addition to above, max. service radial clearanceNU 330 0.300 mm max. 0.250 mm max.NH 320 0.190 mm max. 0.150 mm max.

1.6 Flinger - PEBore Dia. 153.130 to 153.155 mmTotal Width 12.65 to 12.70 mm

1.7 Retaining collar - PEBore Dia. 146.015 to 146.040 mmTotal Width 12.65 to 12.70 mm



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OBSERVATION

Outer Dia. 253.225 to 253.290 mmHub Outer dia. 177.040 to 177.090 mmOuter dia. on 2nd Groove 210.610 to 210.670 mmGroove width 8.00 to 8.05 mmTotal width 44.4 to 44.6 mm

1.8 End shield - PEBore dia. 319.975 to 319.995 mm

1.9 End shield - CEBore dia. 214.980 to 215.00 mm

1.10 Seat diameter on armature shaftFor brg.-PE, Bore dia. 150.035 to 150.055 mmFor brg.-CE, Bore dia. 100.025 to 100.040 mmFor retaining collar PE 146.130 to 146.150 mmFor bearing sleeve PE 153.220 to 153.240 mmFor inner brg. wiper CE 101.600 to 101.620 mm

1.11 End Float on Traction motor (TM 4907) CELimit – 0.50 mm Aim – 0.42 mm

1.12 Fits & Clearances (BG TM)1.12.1 Pinion end bearing

Interferences (Diametrical)

Clearances (Diametrical

Brg. Sleeve to shaft

0.020 to 0.065 mm

Brg. Sleeve to inner brg. cap

0.635 to 0.750 mm

Flinger to shaft

0.065 to 0.110 mm

Retaining collar to outer brg. cap

0.25 mm (min.)

Inner race to 0.035 to ---- ----



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OBSERVATION

shaft 0.080 mm

Retaining collar to shaft

0.090 to 0.135 mm

---- ----

1.12.2 Commutator end bearingInterferences (Diametrical) Clearances

(DiametricalBrg. Sleeve to shaft

0.020 to 0.065 mm

Inner brg. Cap to sleeve

0.635 to 0.750 mm

Flinger to shaft

0.065 to 0.110 mm

---- ----

Inner brg. Race to shaft

0.025 to 0.060 mm

---- ----

1.13 Heating temp. of brg. & assly. componentsItem Heating temp.

Bearing inner race PE 100 - 110 ºCBearing inner race CE 100 -110 ºCSleeve (PE) 100 -130 ºCSleeve (CE) 100 -130 ºCFlinger (PE) 100 -120 ºCEnd shield (PE) 120 -130 ºCEnd shield (CE) 120 -130 ºCRetaining collar (wiper) 120 -130 ºC

2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 Dial gauge



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OBSERVATION

3 INSTRUCTION3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY

5.1 Vital Spare - NA5.2 Must change items - NA


CHECK SHEET FOR QUALITY AUDIT OF MOTOR SUSPENSION UNIT WITH BEARINGs & ASSLY. COMPONENTS



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OBSERVATION

1 MEASUREMENT/WORK TO BE DONE

Alco locos MSU with BRGAssly. Components

MP.IB. EM.01.22.09

(Rev.01), Sep.’18

1.1 Check bearing temperature just after the operation of locomotive, if found abnormal temperature, change out its suspension tube.

1.2 Check securing of bolt to ensure their tightness using torque wrench to a correct revised torque value.

1.3 Check positioning of adjustment washer.1.4 Check and refit the missing or damaged grease

nipples.1.5 Check and replace earthing brushes if missing /

damaged.1.6 Carefully inspect the suspension bearing housing for

cracks and if found, bearing housing must be replaced.

1.7 Check for loose/out position or cracked enclosure. If found then replace.

1.8 Replenish grease of gear wheel side and road side wheel bearings

1.9 Check bearing abnormal noise or roller ticking noise by rotating the tube assembly.

1.10 Check end play as per the procedure given in manual.



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1.11 In order to arrest loosening /dropping /breakage of bolt of suspension tube, tightening torques is revised as under:

Actual size of bolt/screws

Torque in Kg.cm.

M 10x30 (Property Class

12.9)

245 to 295 400 to 600

M 12x90(Property Class

12.9)

418 to 503 800 to 1000

M 36x110(Property Class

12.9)

12100 to 14500

14500

1.12 It is useful to ensure correctness of the threads of the bolts/screws by standard GO-NOT GO thread ring gauges and correction of relevant threaded hole by GO-NOT GO thread plug gauges.

1.13 Loctite 243 & 2760, MY-T-Loc-3330R, Anabond-131 or equivalent thread locker should be used on all the bolts/screws given in the table above to ensure that bolts do not become loose due to vibrations etc.Recommended size of

screwsRecommended Loctite

M 10 to M 16 Loctite 243, MY-T-Loc-3330 & Anabond-131

M 20 to M 36 Loctite 27601.14 For M36 bolts, spring lock washers/disc lock washers

must be used.



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OBSERVATION

1.15 Ensure proper tightening of all bolts as per the table at Para 6.2 above with torque wrench & maintain revised torque value.

1.16 A final check for loose/missing bolts, washers, cap screws must be done during the assembly.

2 INSTRUCTION2.1 Display Chart2.2 Training of Staff2.3 Record keeping of tools & measuring instruments4 TRACEBILITY5 MATERIAL AVAILABILITY



CHECK SHEET FORQUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS AT DIESEL SHED



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OBSERVATION

1 MEASUREMENT DURING MOTOR ASSEMBLILY

All EMD/HHP locos

Traction Motor Bearing & Assly. Components of

HHP Loco

OEM’s/Manufactures

drawings

1.1 Cylindrical Roller Bearing (Drive end)Bearing ID (Inner race) 159.945 to 159.970 mmBearing OD (Outer race) 339.960 to 340.000 mmBearing Width 67.75 to 68.00 mm

1.2 Deep Groove Ball Bearing (Non drive end)Bearing ID (Inner race) 129.975 to 130.000 mmBearing OD (Outer race) 279.965 to 280.000 mmBearing Width 57.75 to 58.00 mm

1.3 Rotor ShaftBearing seating area DE (without pinion)

159.910 to 159.940 mm

Bearing seating area NDE 130.027 to 130.045 mm1.4 End Shield bore DE:

Bearing seating area339.910 to 339.950 mm

1.5 Bearing Housing NDE: Bearing seating area

279.948 to 280.000 mm

1.6 Radial Clearance of DE bearing before pinion fitment

SKF & FARO make: 0.340 to 0.370 mm.FAG (Schaeffler) make:0.115 to 0.165 mm



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OBSERVATION

1.7 Radial Clearance of DE bearing after pinion fitment

SKF & FARO make: ---------- mm.FAG (Schaeffler) make:----------- mm

2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 Dial gauge3 INSTRUCTION


5.1 Vital Spare 5.2 Must change items


CHECK SHEET FOR

QUALITY AUDITOF MOTOR SUSPENSION UNIT WITH TAPER ROLLER SUSPENSION BEARINGS (POH)



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OBSERVATION

1 IN COMING INSPECTION:

All HHP Locos MSU Assembly with Taper roller

suspension bearings.

MP.MISC-325 (Rev.00)

May”2017

1.1 Lateral play < 0.8 mm1.2 Condition of adjustment shim No damage/step

formed1.3 Condition of DE Bearing- No seizure1.4 Condition of NDGE Bearing No seizure1.5 Condition of cap axle screws DE No damages1.6 Condition of cap axle screws

NDENo damages

1.7 Grease condition of DE bearing No oozing1.8 Grease condition of NDE end

bearing No oozing

2 IINSPECTION DURING OVERHAULING:2.1 Axle diameter at roller bearing

seating area.a. Gear side (DE)

b. Non gear side (NDE)

8.712” +0.001 - 0.000”

8.692” ”+0.001 - 0.000”

2.2 MSU tube bore dia. as per drawing number 40075563- NDE

12.371” +0.002” -0.000”

2.3 Bearing outer race outer diameter as per NBC drawing

12.375” +0.002”



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

number PESD-5069 and part No:17400053- NDE

-0.000”

2.4 Interference- NDE 0.002” to 0.006”2.5 Thickness of NDE bearing outer

race collar drawing no: PESD 5068 and part No:17400030 NDE

0.375”

2.6 The step size of the cap axle bearing NDE

0.367” +0.001” -0.000”

2.7 MSU tube bore dia. as per drawing number 40075563- DE

12.371” +0.002” -0.000”

2.8 Bearing outer race outer diameter as per NEI drawing number PESD-5069 and part No:17400030 DE

12.375” +0.002” -0.000”

2.9 Interference DE 0.002” to 0.006”2.10 The step size of cap axle DE

bearing as per drawing No:40076795

0.560” +0.000” -0.002”

2.11 Short allen screw to EMD drg. No:138293

2.50”

2.12 Long allen screw to EMD drg. No:138299

3.50”

3 USE OF RECOMMENDED GREASE QUANTITY:3.1 Bearing location DE 1250 gms3.2 Bearing location NDE 900 gms3.3 Heating temp of bull gear 93 °C above ambient

temp3.4 Position of bull gear from centre 483.39 mm



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

of the axle 3.5 Heating temp of gear seal 93 °C above ambient

temp3.6 Amount of grease application on

gear seal198.5 gms

3.7 Heating temp of DE bearing cone

93 °C above ambient temp

3.8 DE bearing cup- shrinking temp -32 °C3.9 NDE bearing cup-shrinking temp -32 °C

3.10 DE allen screw head torque 136N-m3.11 NDE bearing cone-heating temp 93 °C above ambient

temp3.12 NDE Spacer heating temp

(abutment piece)93 °C above ambient

temp3.13 NDE allen screw head torque 136N-m

4 FINAL INSPECTION:4.1 DE allen head screw torque

( 8 nos.)136N-m

4.2 NDE allen head screw torque (09 nos. )

136N-m

4.3 Axial/Lateral play of suspension tube assembly

0.025 mm to 0.13 mm

5 AVAILABILITY OF INSTRUCTION:5.1 Display Chart5.2 Training of staff5.3 Maintenance manual and check sheets5.4 Record keeping of tools and measuring instruments

6 RECORD KEEPING FOR TRACEABILITY:7 MATERIAL AVAILABILITY:



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

7.1 Vital Spares7.2 Must change items

8. AXIAL PLAY RECORDING FORMAT:

Axle no Name of Shed Date last overhauledLateral play at the time of

last overhauledDate of present

overhaulingIncoming lateral

playRemarks

9. WHEEL ASSEMBLY WISE MSU MATERIAL RECORDING FORMAT:

Sl noAxle

unique no

DE bearing no, Make & DOC

NDE bearing

no Make & DOC

Suspension Tube No , Make &

DOC

Bull gear makeNew

/serviceable

Seal gear makeNew

/serviceable

Cap axle GE

New/ serviceabl

e

Cap axle NGENew/

serviceable

AbutmentpieceNew/

serviceable

Steel ringNew/

serviceable

Steel tubeNew/

serviceable

CHECK SHEET FOR


QUALITY AUDIT OF SMALL MOTOR OF ALCO LOCOMOTIVE



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco Small Motor of Alco Loco

MP.MISC-141 (Rev-01),

September 2006

.

1.1 Check brush pig-tail screws for tightness1.2 Check the Cleanness of the commutator string band

and cable connections. 1.3 Check brushes for condition & size1.4 Check varnished surfaces of the armature and field

coils for cracks, flaking. 1.5 Check covers terminal connections etc.2 AVAILABILITY OF TOOLS AND TEST STANDS

2.13 INSTRUCTION




CHECK SHEET FOR QUALITY AUDIT OF STARTER MOTORS OF HHP LOCOMOTIVE



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP Starter Motor of HHP Loco

MP.MISC-285 (Rev-00), August

2012&

MP-IB-EM 02.07.14 (Rev.-

00), January 2015

.

1.1 Measure IR of motor > 1 M ohm1.2 Measure Hold-in coil resistance (4.7-5.8 ohms)

between battery to ground terminal of solenoid,1.3 Measure Pull-in coil resistance (0.7 to 1.1 ohm)

between battery to switch terminal of solenoid1.4 Check for proper engagement of starter motor

pinions with ring gear and measure clearance between pinion tooth and ring gear slot (3 to 4 mm).

1.5 Check cables for any insulation damage & intactness of cable tags.

1.6 Measure the distance between pinion face & inside Machined face of nose housing after movement of pinion. It should be between 8.3 mm to 9.9 mm.

1.7 Check for intactness of cables, routing and tightness of mounting bolts

1.8 Check intactness of drive gears & ring gear.2 AVAILABILITY OF TOOLS AND TEST STANDS

2.1 Digital multimeter 2.2 Magger 3 INSTRUCTION

3.1 Display Chart



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY



CHECK SHEET FOR QUALITY AUDIT OF RADIATOR FAN OF HHP LOCOMOTIVE



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP Radiator Fan of HHP Loco


August 2012&

MP.0.24.00.55 (Rev-01),

October 2009

.

1.1 Measure IR of motor > 1 M ohm1.2 Check clearance between the longest blade and fan

shroud1.3 Check RTV sealant on rotor to stator mounting bolts1.4 Check for any unusual sounds from motor and

intactness of cables.1.5 Check cables for any insulation damage & intactness

of cable tags.1.6 Locked rotor current< 5 Amps.2 AVAILABILITY OF TOOLS AND TEST STANDS

2.1 Digital multimeter 2.2 Magger 3 INSTRUCTION




CHECK SHEET FOR QUALITY AUDIT OF FUEL PUMP MOTORS OF HHP LOCOMOTIVE



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP Fuel Pump Motor of HHP Loco


August 2012

.

1.1 Measure FPM current < 20.16 Amp.1.2 Horizontal FPM is polarity dependant i.e. +ve and –

ve supply, cables should be connected +ve and –ve terminals on motor.

1.3 Ensure the intactness of terminal box & cable conduct.

1.4 Check for any slackness of foundation bolts.1.5 Check inverter and clean heat sinks.1.6 Check for any unusual sounds from motors2 AVAILABILITY OF TOOLS AND TEST STANDS

2.1 Digital multimeter 3 INSTRUCTION




CHECK SHEET FOR QUALITY AUDIT OF FUEL PUMP MOTORS OF ALCO LOCOMOTIVE



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco Fuel Pump Motor of Alco Loco


September 2006

.

1.1 Measure FPM current < 15.54 Amp.1.2 Horizontal FPM is polarity dependant i.e. +ve and –

ve supply, cables should be connected +ve and –ve terminals on motor.

1.3 Ensure the intactness of terminal box & cable conduct.

1.4 Check for any slackness of foundation bolts.1.5 Check inverter and clean heat sinks.1.6 Check for any unusual sounds from motors2 AVAILABILITY OF TOOLS AND TEST STANDS

2.1 Digital multimeter3 INSTRUCTION




CHECK SHEET FOR QUALITY AUDIT OF RTTM BLOWER OF ALCO LOCOMOTIVE



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco RTTM Blower of Alco Loco


September 2006

.

1.1 Check the alignment of pulleys1.2 Check the blower bearing with grease and ensure

that old grease does not fall in blower casing.1.3 Check adaptor nut for tightness and ensure that tub

washer is in position and locked1.4 Check the belts for condition and tension.1.5 Check blower impeller for shifting2 AVAILABILITY OF TOOLS AND TEST STANDS

2.13 INSTRUCTION




CHECK SHEET FOR

QUALITY AUDIT OF AUXILLIARY GENERATOR OF HHP LOCOMOTIVE



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP AG of HHP Loco MP.MISC-285 (Rev-00),

AUGUST 2012

.

1.1 Inspect diode plate and check cleanness 1.2 Check aux. Gen o/p cables and exciter field cables

for any insulation damage. 1.3 Check for intactness of covers with bolts.1.4 Check for any unusual sound & rubbing marks.1.5 Check covers terminal connections etc.2 AVAILABILITY OF TOOLS AND TEST STANDS

2.13 INSTRUCTION




Annexure-VI

CHECK SHEET FOR TECHNICAL AUDIT OF POH WORKSHOP

Item: Electrical control MBCS + MCBG + E typeDuring the audit, activities should be checked with regard to the Clause/Para/Item 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

Sub assembly

Reference Details Clause/Para/ Item Details

Observation

1. No. of Trained personnel with experience MBCS trained personnel 2. Record keeping practices after the tests in

relay control room for E type controlShed doc

3. Practices for Handling of the electronic cards and storing

ALCo Doc No:IM 53 for MBCS Medha

4. Availability of crimping tool & connector pin details

ALCo Doc No. :IM 53 for MBCS Medha

5. Maintenance practices of Micro Processor Based Control System MEP 660

DLW/Alco/AMC (micro)/01

6. Maintenance practices of Micro Controller Based Governor (MCBG) MEG 601

ALCo Doc No:IM-11 Rev. 0.0 Date Jan 2009 of Medha

7. Practices followed for Fault data analysis 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. Measurement11.1 Standards for load box examination of D E

locomotivesALCo MP MI -10 (Rev.0.02)

August, 2003


SN Requirements Loco Type Make Of Sub

assembly


Observation

11.2 Practices as per BHEL Commissioning Test schedule (Electrical equipment) for 3100/2750 HP BG DE loco for ‘E’ type control

ALCo BHEL docs: TNE -2/2105/97/DELCTS Date Sept 1997

11.3 Test procedure for MBCS loco control system MEP660 for retrofitted D E loco

ALCo IM-59

11.4 Preventive maintenance schedule ALCo DLW/Alco/AMC (micro)/01 Inspection and test report of MEP Preventive Maintenance schedule SF-1405 (0)

11.5 Check working of safety and critical items identified asECS operation check, GR operation check, Eng. Stop button check, OST open check, MUSD stop switch check, LWS check, GFOLR operation check (E type), Governor dry run check, Flasher light lights, Alerter, lamp, alarm and reset, Flasher lights switch panel GR, GRCO1/2, Indication panels, Attendant call bell, Head light, Classification light, Horn, Sanders , Directional check, Cab light and exterior 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, DB parameters (field and armature current), loco over speed through user settable parameters,

User settable parameters as per RDSO MBCS spec.MP.0.2400.26(Rev. 07),Feb’2018

11.7 Check ground circuit leakage current -do-


SN Requirements Loco Type Make Of Sub

assembly


Observation

11.8 Check mv drop test of WSR (E type)12 Availability Of Tools And Test Stands For MBCS locos- Test stands are

not provided by MBCS supplier. Items are covered under AMC.

13 Display Chart Important instruction for trouble shooting like action to be taken during wheel slip etc to be available on the cab

13.1 Display of DOS and DONTS, TROUBLE SHOOTING Chart, DISPLAYCHART & FLOW CHART

As per OEM manual

14 Maintenance manual and check sheets As provided by the MBCS manufacturer*

15 Instruction Bulletin / Modification sheet /Hand book/ Trouble shooting charts as provided by RDSO/ CAMTECH and implementation by MBCS vendor

MBCS spec.MP.0.2400.26, (Rev. 07),Feb’2018 Modification sheet No.MP.MOD.EC.05.27.10 (Rev. 00) Date 26.03.2010, Instruction Bulletin no.MP.IB.EC.04.21.10 Date 30.04.2010.CAMTECH/2010/M/MPBCS/1.0 March 2010 (Introduction Hand book on MBCS MP660 fitted on diesel locomotives).CAMTECH/2000/DSL/1.0 (Trouble shooting charts for drivers of WDM2 locomotive)

Medha1. Operational manual for drivers Doc.No.IM-38 Rev 3.0 July 07


2. Maintenance Instruction manual Doc. No.IM-53 Rev 0.0 Sept’20083. System Manual Doc. No. IM-08 Rev.3.0 March 2008/System Manual IM-78 Rev 3.0,June 20144. Troubleshooting Manual Doc.No. IM-51 Rev.2.0 Oct.2008/IM-84,Rev 1.0,July 20105. 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/WDG3D Schematics Drg. no.ED 103012. WDM3D TB wiring Drg. no.ED 1032

Siemens1. KM DIREKT scheme no. DRG. No. 3FZE-009612. SIM CONTROL scheme no. DRG. No. 4SIM-2005093. SIMCONTROL Operator’s Instructions &Guidelines user manual ver.2.00 dated 10.12.094. Trouble shooting manual of Siemens WDG3A and fault category of Siemens


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 not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.



Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Control voltage 72+1 VDC All Diesel

Electric Locomo tives (ALCo)

DLW Drawing No.

EL/PT/0640/ Altr R3

Part No 12145439

RDSO Drg No.4141

Technical details given 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 -116

ohm, (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

Pg 21,Clause 4.1.4



Make Of Subassembly

Reference Details


Observations

(Rev-02),Aug’181.11 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

contacts shorted together(vi) shorted main contacts and shorted interlocks, coil

and earth

IEC 60571

as per clause 10.2.9

2.0 Availability of tools and stands2.1 Multimeter with proper calibration2.2 Vernier calipers with valid calibration2.3 Go- No gauge suiting to different cantactors2.4 Dial gauge of different scale and resolution as

suited to respective contactor2.5 Source which can provide minimum current at

respective voltage (24 V – 72 V DC)2.6 Variac2.7 Meggar

2.8 Oscilloscope

2.9 Screw Driver, Plier, Spanner Set, etc.3. Availability Of Instructions etc.

3.1 Display Chart3.2 Flow Chart 3.3 Training of staff3.4 Proper Display of Do’s and Don’t3.5 Maintenance manual and check sheets3.6 Record keeping of tools and measuring



Make Of Subassembly

Reference Details


Observations

instruments 3.7 Instruction Bulletin/Mod sheet issued by RDSO3.8 Maintenance Manual of Manufacturer3.9 Specification

4. Compliance of Instruction Bulletin 5. Follow of Maintenance Manual of Manufacturer6 Record Keeping For Traceability

4.1 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.

4.2 Proper record should be maintained for each contactor 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 Availability7.1 Vital Spares

7.2 Must change items7.3 Consumables

8. Disposal8.1 Segregation of Workable and Non-Workable

equipments and proper house keeping8.2 Proper Disposal of Materials including recycling

following relevant environmental norms


CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR CRANKING CONTACTOR (ALCo)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Short time control voltage -72+1v dc, All Diesel

Electric Locomotives (ALCo)

Ref:-DLW Drawing No. EL/PT/0641/

Altr R3 Part

No 121410510

RDSO Drg. No SKDP 4142


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. Pg 21,Clause



Make Of Subassembly

Reference Details


Observations

MP.0.04.00.08 (Rev- 02), Aug’

18

4.1.4

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, coil

and earth

as per IEC 60571

clause 10.2.9

2.0 Availability of tools and stands2.10 Multimeter with proper calibration2.11 Vernier calipers with valid calibration2.12 Go- No gauge suiting to different contactors2.13 Dial gauge of different scale and resolution as


respective voltage (24 V – 72 V DC)2.15 Variac2.16 Megger

2.17 Oscilloscope


3.10 Display Chart3.11 Flow Chart 3.12 Training of staff3.13 Proper Display of Do’s and Don’t



Make Of Subassembly

Reference Details


Observations

3.14 Maintenance manual and check sheets3.15 Record keeping of tools and measuring


4. Compliance of Instruction Bulletin/Mod sheet issued by RDSO

5. Follow of Maintenance Manual of Manufacturer6 Record Keeping For Traceability



7. Material Availability7.4 Vital Spares7.5 Must change items7.6 Consumables





CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR CRANKING CONTROL CONTACTOR (ALCo)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Short time control voltage 72+1 v dc, All Diesel


Ref DLW Drawing No. EL/PT/0639/

Altr R3Part

No 12141100



drawing

1.2 Control voltage 24vdc,1.3 Max pick up volt 24 v1.4 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-

Pg.No 23Clause No. 3.1.4



Make Of Subassembly

Reference Details


Observations

02),Aug’181.9 IR Value between (i) fixed contact to movable Contacts(ii) coil to frame

IEC 60571 clause 10.2.9

2.0 Availability of tools and stands2.19 Multimeter with proper calibration2.20 Vernier calipers with valid calibration2.21 Go- No gauge suiting to different contactors2.22 Dial gauge of different scale and resolution as


respective voltage (24 V – 72 V DC)

2.24 Variac

2.25 Megger

2.26 Oscilloscope

2.27 Screw Driver, Plier, Spanner Set, etc.

3. Availability Of Instructions etc.3.19 Display Chart3.20 Flow Chart 3.21 Training of staff3.22 Proper Display of Do’s and Don’t3.23 Maintenance manual and check sheets3.24 Record keeping of tools and measuring


4. Compliance of Instruction Bulletin/Mod sheet issued by



Make Of Subassembly

Reference Details


Observations

RDSO5. Follow of Maintenance Manual of Manufacturer6 Record Keeping For Traceability








CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FUEL PUMP CONTACTORS (ALCo LOCO)



SN Requirements Loco Type Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Max pick up volt 48v All Diesel


Ref : DLW Drawing No. EL/PT/0629/

Altr R3Part

No 12141033



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

,


(Rev- 02),Aug’18

Pg 17,Clause 3.1.4

1.7 IR Value as per clause 10.2.9 of IEC 60571 between(i)Main contacts of contactor(ii) Coil and magnet frame

IEC 60571


2.0 Availability of tools and stands2.28 Multimeter with proper calibration



Reference Details


Observations

2.29 Vernier calipers with valid calibration2.30 Go- No gauge suiting to different cantactors2.31 Dial gauge of different scale and resolution as



2.35 Oscilloscope



instruments 3.34 Instruction Bulletin/Mod sheetissued by RDSO3.35 Maintenance Manual of Manufacturer3.36 Specification



4.7 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



Reference Details


Observations

which fitted.







CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR RADIATOR FAN CONTACTOR (ALCo)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 control voltage 72+1v dc,1.2 Max pick up volt 48 v

All Diesel Electric Locomotives (ALCo)

Radiator Fan contactor

Ref:-DLW Drawing No. EL/PT/0638/

Altr R3Part

No 12140235

RDSO Drg.No: SKDP 4139


drawing

1.3 Main contact gap 6-7.5mm, 1.4 Wipe 0.8-1.6 mm, 1.5 Contact pressure( gmf) initial 80-150, final 180.-

280, 1.6 Operating coil resistance at 20 deg c -388

ohm±5% (368 to 408 ohms), 1.7 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08 (Rev-

02),Aug’18

Pg 23,Clause 3.1.4

1.8 IR Value between(i) fixed contact to movable Contact(ii) coil to frame

IEC 60571 clause 10.2.9



Make Of Subassembly

Reference Details


Observations




2.44 Oscilloscope



instruments 3.43 Instruction Bulletin/ Mod sheetissued by RDSO3.44 Maintenance Manual of Manufacturer3.45 Specification



4.9 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of



Make Of Subassembly

Reference Details


Observations

Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.







CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FIELD SHUNTING CONTACTOR (ALCo)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Control voltage 72+1v dc, All

Diesel Electric Locomotives (ALCo)

Ref:-DLW Drawing No. EL/PT/0614 /

Altr R4Part

No 12140491RDSO Drg. No

SKDP 4140


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 1.6 1.82-2.95,final 5.45-7.25,1.7 operating coil resistance at 20 deg c 104 -116

ohms, 1.8 interlock (GPRelay type- 9-41n, 3no+3nc) contact

gap 9.5-10.51.9 Interlock contact mm pressure -220-300gm.,1.10 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08 (Rev-02),Aug’18

Pg 23,Clause 3.1.4

1.11 IR Value between as per IEC clause 10.2.9



Make Of Subassembly

Reference Details


Observations

(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

contacts shorted together(vi) shorted main contacts and shorted interlocks, coil

and earth

60571




2.53 Oscilloscope



instruments 3.52 Instruction Bulletin/ Mod sheetissued by RDSO



Make Of Subassembly

Reference Details


Observations

3.53 Maintenance Manual of Manufacturer3.54 Specification

4. Compliance of Instruction Bulletin/ Mod sheet issued by RDSO









CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR EP CONTACTORS (ALCo)




Make Of Subassembly

Reference Details


Observations

1. Measurement ALCo Ref:-DLW Drawing No. EL/PT/0630/

Altr R4Part

No 12141008



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 20 degC

526 to 594 Ohms,1.10 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08 (Rev-

02),Aug’18

Pg 11,Clause 3.3

1.11 IR Value between a) main contacts b) interlocks and MV c) interlocks and MV shorted together and earth d) contacts and interlocks e) Interlocks and MV shorted together and main

IEC 60571 as per clause 10.2.9



Make Of Subassembly

Reference Details


Observations

contacts shorted together. f) Main contacts shorted together and earth

shorted with MV and interlocks.2.0 Availability of tools and stands

2.55 Multimeter with proper calibration2.56 Vernier calipers with valid calibration2.57 Go- No gauge suiting to different cantactors2.58 Dial gauge of different scale and resolution as


respective voltage (24 V – 72 V DC)2.60 Variac2.61 Lever of 122.5 mm for measuring initial and final

pressure.2.62 Compresor with air reservoir2.63 Megger

2.64 Oscilloscope



instruments 3.61 Instruction Bulletin Mod sheetssued by RDSO3.62 Maintenance Manual of Manufacturer3.63 Specification



Make Of Subassembly

Reference Details


Observations










CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6M REVERSER (ALCo)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Auxiliary contacts 4, change over type, ALCo Ref:-DLW

Drawing No. EL/PT/0649/

Altr R5Part

No 12310372



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 gap 19.05+1.6mm,

1.6 Main contact outside pressure (with lever) 4.0-4.5 kgf, inside pressure 5.8 - 6.5kgf,

1.7 Contact impression (should be min 80%)

1.8 Auxiliary contact pressure 0.68-2.0 kgf, 1.9 Auxiliary contact gap 31.75 mm (min), , 1.10 Magnet valve coil resistance at 20 degC 615+5%

ohm.for BHEL type: 5027MV2 1.11 ROTEX TYPE: 3118AV1-3 coil resistance at 20

degC-526 to 594 Ohms.




Make Of Subassembly

Reference Details


Observations

(Rev- 02), Aug’18

Pg 14,Clause 6.5

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 clause 10.2.9




pressure.2.73 Compresor with air reservoir2.74 Megger

2.75 Oscilloscope


3.64 Display Chart3.65 Flow Chart 3.66 Training of staff



Make Of Subassembly

Reference Details


Observations

3.67 Proper Display of Do’s and Don’t3.68 Maintenance manual and check sheets3.69 Record keeping of tools and measuring

instruments 3.70 Instruction Bulletin/ Mod sheetissued by RDSO3.71 Maintenance Manual of Manufacturer3.72 Specification Spec No.

MP.0.04.00.08 Rev-02), Aug’18



4.15 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. to which fitted.

4.16 Proper record should be maintained for each 6 M Reverser with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.



equipments and proper house keeping



Make Of Subassembly

Reference Details


Observations

8.16 Proper Disposal of Materials including recycling following relevant environmental norms


CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6 M BKT CONTACTORS (ALCo LOCO)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Auxiliary contacts 4 change over type, All

Diesel Electric Locomotives (ALCo)

Ref:DLW Drawing No. EL/PT/0648/

Altr R5Part No

12310300



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 4.0-4.5 kgf, inside pressure 5.8-6.5 kgf, 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 20 degC 1.11 615+5% ohm. for BHEL TYPE : M5027MV2 1.12 ROTEX TYPE: 3118AV1-3 coil resistance at 20 degC

526 to 594 Ohms1.13 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08 (Rev-02),Aug’18

Pg 14,Clause 6.5

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

IEC 60571




Make Of Subassembly

Reference Details


Observations

together on each side (Main contacts open)

(iv) All control and Aux. circuit2.0 Availability of tools and stands

2.77 Multimeter with proper calibration2.78 Vernier calipers with valid calibration2.79 Go- No gauge suiting to different cantactors2.80 Dial gauge of different scale and resolution as



pressure.2.84 Compresor with air reservoir2.85 Meggar

2.86 Oscilloscope






Make Of Subassembly

Reference Details


Observations


5. Follow of Maintenance Manual of Manufacturer

6 Record Keeping For Traceability4.17 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.


7. Material Availability7.25 Vital Spares

7.26 Must change items7.27 Consumables





CHECK SHEET FORTECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERAL PURPOSE RELAY (ALCo LOCO)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.10 Nominal operating voltage (50-80 V) All Diesel


BHEL, AAL and IEI

Spec No. MP.0.400.03

(Rev-01) Nov’08

Clause3.1.11.11 Pick up voltage (Must Operate), max 48V Clause 3.2 (ii)1.12 Drop out Voltage Min 7.5 V1.13 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 in

position 0.0 to 0.1Clause 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 IEC 60571

Clause 10.2.9

2.0 Availability of tools and stands2.88 Multimeter with proper calibration2.89 Vernier calipers with valid calibration2.90 Go- No gauge



Make Of Subassembly

Reference Details


Observations

2.91 Dial gauge

2.92 Source which can provide minimum current at respective voltage (72 V DC)

2.93 Variac2.94 Meggar

2.95 Screw Driver, Plier, Spanner Set, etc.2.96 Sufficient set of tool and gauges provided by

manufacturer3. Availability Of Instructions etc.


instruments 3.88 Instruction BulletinMod sheet issued by RDSO3.89 Maintenance Manual of Manufacturer3.90 Specification Spec No.

MP.0.400.03 (Rev-01) Nov’08



4.19 Proper Register is maintained for GP Relay with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,



Make Of Subassembly

Reference Details


Observations

Repair/Overhauling activity details, Loco No. to which fitted.

4.20 Proper record should be maintained for GP Relay 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 Availability7.28 Vital Spares7.29 Must change items





CHECK SHEET FOR TECHNICAL AUDIT OF POH WORKSHOP OF ELECTRICAL CONTROL FOR DC-DC CONVERTER (500 W)-

TWIN BEAM HEAD LIGHT (ALCo LOCO)


Work shop/Rly: Audited by: Date of audit:


Make Of Subassembly

Reference Details


Observations

1. Measurement :2.1 Visual Inspection – check finish , material ,

sound quality of workman ship etcALCo RDSO

specification No.

ELRS/SPEC/DC-DC Converter /0021 ,Rev.01

Sept 2004

Clause No.6.3.1

2.2 Functional Check –ON/OFF properly RDSO specification

No. ELRS/SPEC/DC-DC Converter /0021 ,Rev.01

Sept 20042.3 Available output regulated Voltage 25.5 ± .1% V

DC with the variation of input voltage 50-85 V DC

RDSO specification

No. ELRS/SPEC/DC-DC Converter

Clause No. 2.2 and 2.3



Make Of Subassembly

Reference Details


Observations

/0021 ,Rev.01 Sept 2004

2.

Availability Of Tools And Test Stands ALCo 3.1 Multimeter with Valid Calibration

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 staff3.94 Proper Display of Do’s and Don’t3.95 Maintenance manual and check sheets3.96 Record keeping of tools and measuring

instruments 3.97 Instruction Bulletin/ Mod sheet issued by

RDSONA

3.98 Maintenance Manual of Manufacturer

3.99 Specification

4.Compliance of Instruction Bulletin/ Mod sheet issued by RDSO


6. Record Keeping For Traceability

4.21 Proper Register is maintained for DC-DC Converter (500 W) with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,



Make Of Subassembly

Reference Details


Observations

Repair/Overhauling activity details, 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 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 Availability7.30 Vital Spares

7.31 Must change items

7.32 Consumables

8. Disposal

8.1 Segregation of Working and Non-Working equipment and Proper House Keeping

8.2 Safe Disposal including recycling following relevant environmental norms.


CHECK SHEET FOR TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED FLASHER LIGHT (ALCo LOCO)


Workshop /Rly: Audited by: Date of audit:


Make Of Subassembly

Reference Details Clause/Para/Item Details

Observations


sound quality of workman ship , water tightness etc

ALCo RDSO specification No.

ELRS/SPEC/LFL/0017 Rev 1 Sept 04

Clause No.6.3.

1.2 Functional Check –ON/OFF properly RDSO specification No.


1.3 Lux Value- The lux measured in axial direction shall not be less than 500 lux at 1 meter and 55 lux at 3 meters for amber clour LED of 120 Nos

RDSO specification No.


Clause No. 2.3.3

1.4 Flashes per Minute (40±5) RDSO specification No.


Clause No. 2.4.5

1.5 Output regulated Voltage RDSO specification No.


Clause No. 2.4.1

1.6 Check Repeater indication properly RDSO specification Clause



Make Of Subassembly


Observations

No. ELRS/SPEC/LFL/001

7 Rev 1 Sept 04

No.2.4.3.1

2.

Availability Of Tools And Test Stands ALCo 2.1 Voltmeter with Valid Calibration2.2 Ammeter with Valid Calibration2.3 Lux Meter with proper Calibration2.4 Test stand for measurement and testing.2.5 Stop Watch2.6 Screw Driver, Plier, etc.

2.7 Fire Extinguisher of proper class

3


3.1 Display Chart

3.2 Flow Chart 3.3 Training of staff3.4 Proper Display of Do’s and Don’t3.5 Maintenance manual and check sheets3.6 Record keeping of tools and measuring instruments 3.7 Instruction Bulletin/Mod sheet issued by RDSO3.8 Maintenance Manual of Manufacturer

3.9 Specification RDSO specification No.


4.Compliance of Instruction Bulletin/Mod sheet issued by RDSO



Make Of Subassembly


Observations



6.1 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.

6.2 Proper record should be maintained for each LED Flasher Light

6.3 LED Flasher Light 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.



7.3 Consumables such as fuses , toggle switches etc

8. Disposal




CHECK SHEET FOR TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED MARKER LIGHT (ALCo LOCO)




Make Of Subassembly

Reference Details


Observations


sound quality of workman ship , water tightness etc.

ALCo

RDSO specification

No. ELRS/Spec/PR/0022 (REV-1 Oct -

2004)

Clause No.6.3.

2.5 Functional Check –ON/OFF properly RDSO specification


2004)2.6 Lux Value- for all input voltage range 45 V-90 V

RDSO specification


2004)

Clause No. 2.4.3

2. Availability Of Tools And Test Stands


Lamp Lux level at 1 Meter

Lux level at 3 Meters

RED 75 LUX 7 LUX

WHITE 75 LUX 7 LUX


Make Of Subassembly

Reference Details


Observations

3.5 Multimeter with Valid Calibration ALCo3.6 Lux Meter with proper Calibration3.7 Test stand for measurement and testing.3.8 Screw Driver, Plier, etc.3.9 Fire Extinguisher of proper class

3


3.100 Display Chart


instruments 3.106 Instruction Bulletin/Mod sheet issued by RDSO3.107 Maintenance Manual of Manufacturer

3.108 Specification




4.24 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.



Make Of Subassembly

Reference Details


Observations

4.25 Proper record should be maintained for each LED Marker Light

4.26 LED Marker 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.



7.35 Consumables such as fuses , toggle switches etc

8. Disposal




CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR STICK TYPE / IMPROVED STICK TYPE MASTER CONTROLLER

FOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES




Make Of Subassembly

Reference Details Clause/Para/Item

Details

Observations

A. Stick Type / Improved Stick type Master controller1. Measurement:

1.1 Visual checkingALCo

M/s BHEL,Asian Plastic,M/s Kaysons

(AMC/R2) Make

BHEL Test programme document no. 865476 dt

Clause 1.1

Drawing of Improved stick type Master Controller EL-PT-0633-R3 dt. 29.12.2007.

1.2 Contact gap, BHEL Test programme document no. 865476 dt 24.04.99 and

Clause 1.2

1.3 Contact pressure, 1.4 Cam sequence and 1.5 Mechanical interlocking 1.6 Working of Throttle handle Clause 1.3

2. Test :2.1 Insulation Resistance test: BHEL Test

programme Clause 5.0



Make Of Subassembly


Details

Observations

document no. 865476

2.2 Continuity Test DLW Drg. No. 35900030031Rev. 04

2.

Availability Of Tools And Test Stands

ALCoM/s BHEL,

Asian Plastic,M/s Kaysons

(AMC/R2) Make

3.10 Voltmeter with Valid Calibration3.11 Venier Caliper with Valid Calibration3.12 Megger with Valid Calibration3.13 Digital Multimeter with Valid Calibration3.14 Potentiometer with Valid Calibration3.15 Height gauge with Valid Calibration3.16 High Voltage Tester with Valid Calibration3.17 Bore Dial gauge with Valid Calibration3.18 Ammeter with Valid Calibration3.19 GO and NO GO Gauge3.20 Screw Driver, Plier, Required spanner set etc.3.21 Test stand for measurement and testing.3.22 Fire Extinguisher of proper class

3


3.109 Display Chart

3.110 Flow Chart

3.111 Throttle sequence chart3.112 Mechanical interlocking Chart3.113 Training of staff3.114 Proper Display of Do’s and Don’t3.115 Maintenance manual and check sheets3.116 Record keeping of tools and measuring

instruments


3.117 Instruction Bulletin/Mod sheet issued by RDSO3.118 Maintenance Manual of Manufacturer

3.119 Specification



6. Record Keeping For Traceability4.27 Proper Register is maintained for EMD Master

Controller checking 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.

4.28 Proper record should be maintained for each

4.29 HHP Master Controller 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.



7.38 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)




Make Of Subassembly

Reference Details


Observations


sound quality of workman ship etcALCo RDSO

specification No.

ELRS/SPEC/PR/0024 ( Rev-1, Sept 2004)

Clause No.6.3.1

2.8 Functional Check –ON/OFF properly

2.9 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

2.10 Model of Bulbs –Halonix and AutoPal Only IB NO. MP.IB.EC.01.08.06 DATE: 27-12-06

Clause No. 4.A.2

2.11 Voltage Rating -24 V IB NO. MP.IB.EC.01.08.06 DATE: 27-12-06

Clause No. 4.A.3



Make Of Subassembly

Reference Details


Observations

2.12 Wattage Rating of Bulbs -100/90 W, Bright/Dim filament at 24 V

IB NO. MP.IB.EC.01.08.06 DATE: 27-12-06

Clause No. 4.A.4

2.13 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

2.14 Lux output with Twin Beam Head Light for each reflector minimum 2400 Lux at a distance of 8 Mt and 24.5± 0.1 V DC terminal Voltage at Lamp Holder

IB NO. MP.IB.EC.01.08.06 DATE: 27-12-06

Clause No. 4.A.6

2.15 Procedure to check correctness of bulb’s filament in test room

IB NO. MP.IB.EC.01.08.06 DATE: 27-12-06

Clause No. 4 B

2.16 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 Stands3.23 Voltmeter with Valid Calibration3.24 1.A standard portable lux measuring equipment

‘Lux meter’ like T.E.S. model TES –1330 shall be



Make Of Subassembly

Reference Details


Observations

used. Lux Meter should be of range 0-20000 lux with least count of 0.01 Lux with valid calibration

3.25 Focusing Stand IB NO. MP.IB.EC.01.08.06 DATE: 27-12-06

3.26 Screw Driver, Plier, etc.

3.27 Test stand for measurement and testing.3.28 Fire Extinguisher of proper class

3 Availability Of Instructions etc.

3.120 Display Chart


instruments 3.126 Instruction Bulletin/ Mod sheetissued by RDSO IB NO.

MP.IB.EC.01.08.06 DATE:

27-12-063.127 Maintenance Manual of Manufacturer

3.128 Specification RDSO specification

No. ELRS/SPEC/PR/0



Make Of Subassembly

Reference Details


Observations

024 ( Rev-1, Sept 2004)




4.30 Proper Register is maintained for Twin Beam Head 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.

4.31 Proper record should be maintained for each Twin Beam Head Light

4.32 Twin Beam Head Light /Bulbs 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.



7.41 Consumables like bulbs , Reflector

8.

Disposal


8.2 Safe Disposal of Bulbs/reflector including



Make Of Subassembly

Reference Details


Observations

recycling following relevant environmental norms.


CHECK SHEET FOR TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR POH

WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVESDuring the audit, activities should be checked with regard to the Clause/Para/Item 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.



Make Of Subassembly


Details

Observations

1. Measurement :2.17 Physical Examination

ALCo

2.18 Air Pressure Spec. No. DEL/SPN/193 July’98

Clause 8.5

2.19 Ampere Hour Capacity Spec. No. DEL/SPN/193 July’98

Clause 8.6

2.20 Watt Hour Efficiency Spec. No. DEL/SPN/193 July’98

Clause 8.7

2.21 Ampere Hour Efficiency Spec. No. DEL/SPN/193 July’98

Clause 8.7

2.22 Internal Resistance Spec. No. DEL/SPN/193 July’98

Clause 8.8

2.23 Initial Cranking Current Spec. No. DEL/SPN/193 July’98

Clause 8.9

2.24 Electrolyte Level Spec. No. DEL/SPN/193 July’98

Clause 6

2.25 Polarity and absence of Short Circuit2. Availability Of Tools And Test Stands ALCo

3.29 Battery Room Suitable size with sufficient area for movement of forklift, Storing of Acid Mixing tank, and Suitable battery test benches with



Make Of Subassembly


Details

Observations

sufficient Exhaust fans.3.30 Electrolyte mixing tank-Motorized type preferred3.31 Voltmeter with Valid Calibration3.32 Thermometer with Valid Calibration3.33 Hydrometer with Valid Calibration3.34 Ammeter with Valid Calibration3.35 Multi meter with Valid Calibration3.36 Clamp Meter3.37 Rubber syringe 3.38 Battery Charger(Preferred Constant Current

Chargers)3.39 Battery Discharger (Preferred Electronic type)3.40 Required Lab for testing of Acid and DM water3.41 Screw Driver, Plier, Spanner Set etc.3.42 Test stand for measurement and testing

(Concrete Platform covered with Acid Resistant FRP sheets/coating for keeping batteries –charge /Discharge.)

3.43 D.M.Water Plant3.44 Proper earthing facility for switch gear and

Battery charging Panel.3.45 Fire Extinguisher of proper class3.46 Fork Lift3.47 Hand trolley3.48 Battery lifting crane on test bench3.49 Plastic Pallet for storing Battery3.50 Rubber Apron3.51 Rubber Gloves3.52 Goggles



Make Of Subassembly


Details

Observations

3

Availability Of Instructions etc.3.129 Display Chart3.130 Flow Chart 3.131 Training of staff3.132 Proper Display of Do’s and Don’t3.133 Maintenance manual and check sheets3.134 Record keeping of tools and measuring

instruments 3.135 Instruction Bulletin / Mod sheetissued by RDSO MP. IB. EC.01.02.05

(Rev.01), Dec. 20083.136 Maintenance Manual of Manufacturer3.137 Specification Spec. No.

DEL/SPN/193 July’98


5.Follow of Maintenance Manual of Manufacturer


4.33 Proper Register is maintained for Battery checking 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.

4.34 Proper record should be maintained for each battery with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and



Make Of Subassembly


Details

Observations

remarks, if any

7.Material Availability7.42 Vital Spares7.43 Must change items7.44 Consumables like Distilled Water, Sulphuric

Acid (for Lead Acid Battery), Lugs, Rubber Mat etc.

8.

Disposal8.1 Segregation of Working and Non-Working

equipment and Proper House Keeping8.2 Safe Disposal of Battery including recycling

following relevant environmental norms.


CHECK SHEET FOR TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo LOCO) FOR POH WORKSHOPS

IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES




Make Of Subassembly


Observations

1. Dis Assembly and Assembly ALCo Maintenance manual of Woodward

Section 5 of Maintenance

Manual2. Measurement :

2.26 Physical Examination

ALCo

Wood Ward Governor Test

Record Format No. TSP/F8572-828 and

Maintenance manual of Woodward

Section 6 of Maintenance

Manual

2.27 Barometer Reading2.28 Pressure Test2.29 Hydraulic Seals, needle valve seat and buffer

piston bypass in both direction2.30 Needle Valve setting2.31 Speed Setting2.32 Normal Shut Down2.33 Pressure Requirement2.34 Speed Setting timing2.35 Lube Oil Shutdown2.36 Air Box Pressure Fuel Limiting2.37 Load Control2.38 Vane Servo Timing2.39 Excitation Resistor2.40 General2.41 Verification with Cover Installed



Make Of Subassembly


Observations

3.

Availability Of Tools And Test StandsALCo3.53 Test Stand for Wood Ward Governor

3.54 Multimeter with valid Calibration3.55 Screw Driver, Plier, Allen Key, Spanner, etc.3.56 Fire Extinguisher of proper class

4.

Availability Of Instructions etc.3.138 Display Chart3.139 Flow Chart 3.140 Training of staff3.141 Proper Display of Do’s and Don’t3.142 Display of Trouble Shooting Chart Maintenance

ManualSection 4

3.143 Maintenance manual and check sheets3.144 Record keeping of tools and measuring

instruments 3.145 Instruction Bulletin/ Mod sheet issued by RDSO NA3.146 Maintenance Manual of Manufacturer

3.147Specification NA


NA

6.Follow of Maintenance Manual of Manufacturer

7.Record Keeping For Traceability

4.35 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 activity details, Loco No. to which fitted.



Make Of Subassembly


Observations

4.36 Proper record should be maintained for each Governor with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.

8.

Material Availability

7.45 Vital Spares

7.46 Must change items7.47 Consumables like Lub Oil, Cotton wool, etc.

9.

Disposal


9.2 Safe Disposal of scrap and waste including recycling following relevant environmental norms.


Annexure-VII Check sheet for Quality Audit of Railway Workshop (Loco Design Group Items)

(Under frame/cattle guard/ fuel tank/ loco painting/ cab/ battery box/ superstructure/ CBC/ side buffers)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 not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.


Sl. No. Activity Reference/ Clause ObservationsUnder frame

01 Under frame 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.Railway Board letter no.2001/M(L)/466/2713 dated 24.09.2003

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 re- drill 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

DLW Drg. No. TPL-3373(for Alco locos) DLW Drg. No. 10630723(for EMD locos)


Sl. No. Activity Reference/ Clause Observations06 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.

08 i. Visual inspection of welding of Hand rails to under frame. 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 and inspection of welding with under frame. 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 properly

iii. Clean the threads of mounting block on stool by tapping it properly.

MP.MOD.LD.01.02.11 dated 09.03.2011(for vibration in WDM3D locomotive)

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.

As per diesel engine mounting asm DLW Part No. 11030070. (ALCO Loco)


Sl. No. Activity Reference/ Clause Observations13 i. Inspection of air duct gallery for all traction motors cut-

out for any leakage or cracksii. 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

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 batteryv. All hinges, locks should be in working

vi. Cover assly. properly secured & locked with battery box.

RDSO’s letter No.SD.DMG.32 Dated 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 of fuel tank should be

properly secured and tightenv. Fuel gauge should not be broken and in working

conditionvi. Fuel gauge mounting bracket, filler cap, vent pipe should

be in good condition

1. RDSO Investigation Report no. 473/83, February’1983(for WDM2/3A loco)2. MP.IB.LD.01.01.14 (Rev.00) dated 03.01.2014(for EMD type)3. MP.IB.LD.01.01.19 (Rev.01) dated 04.04.2019


Sl. No. Activity Reference/ Clause Observations16 Visual inspection of under frame box section and side sill

welding. If there is any crack or damage, weld it properly with low hydrogen welding electrode.Measurement of Camber of under frame

RDSO’s MP.INV-8 December’1995(for WDM2/3A Locomotives)

RDSO Drg. No. 4475(for recording camber measurement)

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(for WDM2/3A locomotive)

18 i. Carefully examine the welding around side load bearers 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. side load bearer shall be repaired iii. Applicable for WDM2/3A Loco

1. RDSO MP.MI- 140/88, Sep’19882. MP.IB.LD.01.08.07 (Rev.00)dated 21.08.20173. RDSO Drg. No.SK.DL-2069

19 Loco painting, marking, stencilling;Apply epoxy primer and PU paint before stencilling

As per extent colour schemeMP.MOD.LD.02.04.13 ( for all diesel loco)

20 Center buffer coupler & Draft GearCheck compliance of RDSO instructions for inspection and maintenanceModify uncoupling arrangement to make it top operated

1. G-802. MP.MOD.LD.05.10.11 (Rev 01)dated 08.02.2016(for Alco Loco)

21 Side BuffersCheck compliance of RDSO instructions for inspection and maintenance

MP.MI-116/82, Rev.02


Sl. No. Activity Reference/ Clause Observations22 Loco Cab Railway Board’s letter

No.2000/M(L)/466/9 dated 05.01.2005

23.1 Driver/Pilot seati. Base mounting nut/ bolt and other fasteners should be

properly tightenii. Motion and its adjuster/locking arrangement/ Ver. &

rotational motion should be in functioningiii. Cushion & upholstery should be in good condition

DLW Drg. No. 11811717 ( for all diesel loco)

23.2 Side sash / windowi. Sliding glass should freely slide and not cracked

ii. Locking arrangement properly in functioniii. Guide rail, weather rubber & glazing rubber should be in

good conditioniv. Rear view mirror if applied properly secured with frame

and its rotational movement checked. Mirror should be in good condition

23.3 Cab doori. Lock, hinges should be in function

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 working23.4 Cab floor

i. Flooring mat & trim should be in good conditionii. Steel structure/ panel sheet of cab should not be

corroded or broken


Sl. No. Activity Reference/ Clause Observations23.5 Cont. Comp door, short hood door & Cab inner trim

i. Lock, hinge and weather sealing should be in working condition

ii. Perforated aluminium sheet , insulating material, fasteners should be in good condition

23.6 Cab light and fani. Switches, regulators and connections are properly in

function23.7 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

function23.9 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 good

23.10 Front look out glassi. Glass & weather strip should be scratches free and

properly sealed with front structureii. Covering grill glass properly cover with hinged grill

24 Superstructurei. Check the condition of sheets and repair if possible

otherwise changeii. Check hinges and door locks for proper working and

repair if possible otherwise changeiii. Check for water leakage at various joints and renew

weather stripes/ceilingsiv. Door panel-sheet should not bend and properly close


Sl. No. Activity Reference/ Clause Observations25 Radiator compartment & Expansion tank

i. Gauge, vent, vacuum valve, low water alarm should function

ii. Expansion tank plate should not be corrodediii. Funnel grating, foot step, hand- rail, inspection door

properly secured with rad. Comp. Structure.

RDSO Mod sheet no.MP.MOD.LD.07.79.10(Rev 00) dated 02.07.2010(for expansion tank of WDM2/3A loco)

Annexure-VIIICHECK SHEET FOR

CONDUCTING TECHNICAL AUDIT OF BOGIE AT POH WORKSHOP (ALCO LOCOMOTIVE)SN Activity Loco Type Reference Details Observations1. Overhauling/Inspection Alco Series

RDSO report No. MP. Misc-164 and MP.MI-71/78SK. DL-3370, SK.VL-296,

Cleaning of bogie frame & crack detection / repair.

Tramming of Bogie frame Replacement of manganese liners and brake 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


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


SN Activity Loco Type Reference Details Observations 100% replace of spring pads ( Happy Pads)

4. Friction Snubber Assembly Disassemble snubber (See SK. DL- 1505 for instructions) Check the inside diameter of the friction sleeve with a

“No Go” gauge Figure SK. DL- 3127 Check the dimensions of the shoes as indicated 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

Details as per Drawing SK.DL-2089A, SK.DL- 1505, SK.DL- 3127, SK.DL-3126, SK.DL- 1512 , SK.DL- 1513

5. Hydraulic damper Check the Capacity / Rating of dampers Damper overhauling Testing

As per relevant drawings overhauling as per MP.IB.VL. 05.39.10 (Rev. 01)

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 & 608MP.IB.VL. 04.30.08 (Rev.01)

7. Equaliser Beams Checking for cracks Reclamation of hard face

WDM2, WDM3A M&C document no. MC – 43 & MC-92

8. Wheel & Axle Assembly Wheel wear measurement i.e. Root wear, Tread wear,

Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spalling etc., wheel reprofiling.

Wheel gauge (1596+3/-0.5 mm) Deference in tread diameter of wheels on same axle,


Wheel wear management Instruction Bulletin no.MP.IB.BD.0216.01 (Rev-1) & MP MI71/78 & MP.MI-31

RDSO procedure MC-71


SN Activity Loco Type Reference Details Observationssame bogie & same loco

Ultrasonic testing of axles9. Brake rigging

Abnormal wear of brake hangers Replacement of Brake blocks, Pins & Bushes Replace brake head, tie rod, brake shoe key, top &

bottom slack adjusters (condition basis) and friction arm spring, if found damaged.

MP.MISC – 141

1. Centre Pivot & Loading Pads Load Pad to Centre Pivot Height Difference to be

maintained.2. Floating type Pivot assembly:

Dismantle complete assembly Clean of the metal component except rubber bush Inspect for wear, tear and cracks Reassemble pivot block assembly with change 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-128SK.VL-611SK.VL-501 & RDSO Modification sheet no. 03.10.09 (Rev-01).

10. Lateral Stopper, lifting chain and fasteners are to be 100% replaced.

WDG3A, & WDM3D/E/F SK.VL-134SK. DL-4195 & 4196SK.VL-225

11. Re-assembly of bogieMaintain all running gear clearance as per the MI’sMaintain the Lateral clearances between Axle Box and Pedestals(Ensure attention to wheel and axle assembly as per S.N. 8)

WDM2, WDM3AWDG3A, & WDM3D/E/F

MP.MI-71/78, VL.MI-02/96 & MP.MI-31MP. MISC – 141, Item no. 165MP.IB.VL.01.02.06 (WDG3A)

12. Availability of Tools And Test Stands WDM2, WDM3A, WDG3A, & WDM3D/E/FOverhead Crane

Hydraulic JacksCleaning vat


SN Activity Loco Type Reference Details ObservationsBogie frame manipulatorCrack reclamation facility like gouging, grinding & welding facility etc.Stress relieving furnaceDPT, MPT & UT testing facilitiesSurface table for measurement Spring load-deflection testing machineHydraulic damper testing machineTorque wrench, Go/No Go GaugesHeight gaugesInside and Outside Calliper, Vernier Calliper, Height Gauge, Cleaning Tank,Painting facilitiesWheel wear measuring gauge SK.DL-3592 Electrode heating ovenFacility to measure pre-heat temperature

13. Availability Of Instructions Etc Availability of WI including critical dimensionsTraining of staff including qualification of weldersMaintenance manual and check sheetsRecord keeping of tools and measuring instruments Calibration of measuring instruments

