technical / quality audit of diesel shed ref: check...

of 60 Quality Audit of Diesel Shed

Technical / Quality Audit of Diesel Shed

Ref: Letter No 2012/M(W)/814/5 dated 07.08.12 from Rly Bd.

CHECK SHEET

Item Description Reference Documents, Annexures, Further details on checksheet etc

General

Compliance of Schedule Maintenance Schedule of standard examinations: MP-Misc-140/141 (for Alco locos). Schedule of standard examinations: MP-Misc-285 [for HHP (EMD) locos]

Quality of major schedules:

M24

M48

-do-

Load Test/Load Box Test records:

HP

SFC

EGT

Peak Firing Pressure

Load Test MI No MP.MI-10 (Rev 0.02), Aug 2003. (for Alco locos). Document No. Misc-195 on Test procedure for EMD diesel engine, 16 cyl. Vee model 710G3B (4000/4500HP) issued by DLW.

Methodology and analysis of failure investigation.

Display of work instructions on shop floor

Training of staff

Status of record keeping

Calibration of gauges/ instruments

Safety items

a. Speed recorder/Indicator Section b. Wheel (Wear adapted profile) profile & other

defects. c. Brake adjustment, release & and application

timings. d. Headlight focus adjustment e. Horn maintenance f. Undergear safety brackets g. Gauging of Couplers h. Vertical offset between Side bearer and centre

pivot

a. OEM’s maintenance manual. b. Drg No SKDL-2561 Alt 8. c. Standard test scheme as per MP.TP-029/87 (Rev 02) Oct 2008 for Air

Brake, and, as per MP.TP-019/81 (Rev 02) Nov 08 for dual brake locos. d. IB No MP.IB.EC.01.08.06 (Rev 0) December 06.

f. MI No MP.IB.BD.02.16.01 (Rev 01) December 09. g. CBC Manual No G 76 Sept 87. h. MI No MP.IB.VL.02.11.10 (Rev 00) February 10.


---

Quality of Subassembly repairs (important items)

a. Expressor/Compressor b. Air Brake Section c. Bogie section d. Rotating Machines Section e. Turbo section f. Cylinder Head , Piston and Valve section g. Radiator section. h. FIP/Injector Section i. Governor Section j. Electrical Control Section k. Battery Section

a. Further details of check sheet covered in Annexure 1. b. -do- c. Further details of check sheet covered in Annexure 2. d. Further details of check sheet covered in Annexure 3. e. Further details of check sheet covered in Annexure 4. f. -do- g. -do- h. -do- i. Further details of check sheet covered in Annexure 5. j. -do- k. -do-

DM Plant and Spectrograph

General working condition MP Guide-6 (Rev 2) May 07 issued by RDSO in reference to spectrograph.

Material

Availability of critical items

Procurement from unapproved sources, if any.

Any other item

As decided by the auditing authority


Check List for quality audit of diesel loco sheds (Brake Items)

S.No. Item Parameter Observations

1. Whether all the prescribed schedules are being followed for brake equipment, compressor & air dryer or not

As per Schedule of standard examinations (No. MP.Misc.-140 & 141, Rev-01, September’2006)

Trip Sch.

M-2

M-4

M-12

M-24

M-48

M-72

POH

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.

2. Functioning of VCD Whether functioning of VCD is being checked in every trip 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 etc.

2. Whether, testing is done on above test benches. 3. Calibration of test benches and rigs is being done periodically

or not.

4. Test on compressor Testing for checking capacity of compressors as per MP.TP-41, 2010.

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 (i) Metrology lab (j) Store (k) Tool room (l) Fire extinguishers (m)Material handling facilities for movement of material and

components.


6. Storage of material Whether dust/damp proof environment 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.

7. Availability of Material Any Chromic shortage of material for maintenance

8. Human Resource development

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

9. Any other observation


CHECK SHEET FOR

TECHNICAL AUDIT OF BOGIE (ALCO LOCOMOTIVE)

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. Shed/Rly: Audited by: Date of audit:

SN Requirements

Loco Type Make Of Subassembly

Reference Details Clause/Para/Item Details

Observations

1. Measurement / Activity

Bogie frame & Bolster (if applicable)

Alco Series

WDM2, WDM3A,

WDG3A,WDP3A

& WDM3D/E/F

Maintenance Instruction no M&C Report MC – 44 & MC - 29

Cleaning of bogie frame

Crack detection and repair

Welding of Manganese Steel Liners at axle boxes and pedestal liners

Complete Bogie MP.MISC – 141 Item No. 165

Longitudinal and lateral pedestal clearances Wheel & Axle Assembly Wheel wear management

Instruction Bulletin no.MP.IB.BD.0216.01 (Rev-1) & MP MI71/78 MP.MISC – 141

Clause 4.3.8 Item No. 110, 161, 198,

Wheel wear measurement i.e. Root wear, Tread wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spaling etc. as per MP.MI 71/78 in every trip.

Wheel gauge (1596+3/-0.5 mm)

Deference in tread diameter of


wheels on same axle, same bogie & same loco

Ultrasonic testing of axles (interval of 06 months for passenger locos & 12 months for goods loco)

RDSO procedure MC-71

Brake rigging

WDM2, WDM3A

MP.IB.VL-03.11.01

MP.MISC – 141

Item No. 295

Piston travel

Wear of Brake shoe

Wear of Pins & Bushes Axle box & journal bearings

MP.MISC – 141

Item No. 47, 197

Inspection bearing components

Grease condition

Radial clearance

Distance over liners (face and lateral)

Dimensional measurement of bearing components

Centre Pivot & Loading Pads

MP.MISC – 141 MP.IB.VL-02.11.10

Item No. 274 & 278,

Centre pivot castings and loading pads, liners Load Pad to Centre Pivot Height Difference, Suspension Spring ( As per MI )

Free height of spring As per relevant drawings

working height of spring

Grouping / colour code of spring MP.IB.VL- 04.19.01 (Rev.01)

Friction Snubber Assembly WDM2, WDM3A MP.MISC – 141 Item No. 116

Height measurement Equaliser Beams MP.MISC – 141,

M&C MC - 43 Item No. 52

Free roller movement, Wear of hard face zone

Equaliser Spring Seat SK.DL-3889

Side Bearer (Rubber spring) WDG3A, MP.IB.VL. 04.30.08 (Rev.01)


Free Height of rubber spring WDM3D

Working height of rubber spring

Permanent set of rubber spring

Rubber crack length/ de-bonding

Hydraulic damper

Capacity / Rating of dampers As per relevant drawings

Damper overhauling MP.IB.VL. 05.39.10 (Rev.00)

2.

Availability of Tools And Test Stands

Surface table of measurement of springs

Height gauge for springs

Spring load-deflection testing machine

Hydraulic damper testing machine

Torque wrench, Go/No Go Gauges

Inside and Outside Calliper, Vernier Caliper, Height Gauge, Cleaning Tank,

Wheel wear measuring gauge SK.DL-3592

3

Availability Of Instructions Etc

3.1 Display Chart

3.2 Training of staff

3.3 Maintenance manual and check sheets

3.4 Record keeping of tools and measuring instruments

4 Record Keeping For Traceability

5

Material Availability

Vital Spares

Must Change items


CHECK SHEET FOR

TECHNICAL AUDIT OF HHP LOCOMOTIVE BOGIE


SN Requirements

Loco Type Make Of Subassembly


Observations

1. Measurements / Activities

General Maintenance HHP loco Maintenance Instruction no MI 1517 (Rev. A)

Para 2.1

Cleaning of bogie frame under locomotive

Tank immersion

Lubrication

Wheel and axle Inspection

Journal Bearings

Dampers

Rubber secondary spring

Brake rigging

Slack adjusters, adjustment

Hand brake


Wheel & Axle Assembly

Minimum wheel diameter after last truing operation.

Maximum diameter mismatch of two wheels on a common axle.

Maximum diameter mismatch between wheels on one axle compared to those of any other axle. These include wheels on the same bogie.

Minimum rim thickness.

Axle longitudinal limits.

Circumferential defects on or below the axle surface.

Axle Run-out.

Wheel wear measurement i.e. Root wear, Tread wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spaling etc.

Wheel gauge (1596+3/-0.5 mm)

Deference in tread diameter of wheels on same axle, same bogie & same loco

Ultrasonic testing of axles (interval of 06 months for passenger locos & 12 months for goods loco)

HHP loco

Maintenance Instruction no MI 1517 (Rev. A) As per latest Railway Board’s Instruction

Para 2.3

Journal bearings

Checking of running temperature of outside face of the adopter with a temperature indicating crayon/ direct pyrometer

Sign of overhearing (Temperature should not exceed more than 560C above ambient).

Excessive lubricant leakage from the

HHP loco Maintenance Instruction no MI 1517 (Rev. A)

Para 2.4


grease seals.

Broken, loose or missing parts (such as loose cap screws, etc.)

Loose or defective seals.

Cracked or broken cups, end caps or adapters, etc.

Dampers

Check for leaking fluid. Make certain that oil has not been deposited from some other source and check damper per Manual Qualification Procedures before condemning.

Perform manual qualification tests to detect gross loss of control.

Inspect bushing integrity. Bushings should not permit uncontrolled vertical or lateral movements of the damper.

If a failed vertical primary damper is detected, inspect journal springs, lateral thrust pads and wear plates at each journal bearing location as well.

If a failed yaw damper is detected, check the items noted in the above step as well as all traction rods and bushings, carbody pivot and rod assembly and bushings, and secondary springs (rubber pads).

steps to qualify vertical / yaw dampers (Refer instructions given in para 2.5)


Para 2.5

Rubber Secondary Springs

Free Height of rubber spring

Working height of rubber spring


Para 2.6


Permanent set of rubber spring

Rubber crack length/ de-bonding

Note: Do not wash the spring in paraffin de-greasing agents (such as trichloro-ethylene), caustic soda, or diesel fuel oil.

As per relevant drawings

MP.IB.VL-01.08.11 (Rev.0)

Para 5.6.4

Suspension Spring

Inspect the coils for breaks or surface cracks. Springs with any indication of surface cracks should be scrapped. Deep sharp surface nicks can cause failure of a spring, and their presence is cause for rejection.

Hand wash or shot blast the coil to remove surface rust. “Pickling” the spring is to be avoided. If the cleaning operation removes all indications of surface rust, and does not reveal corrosion pits, the spring is acceptable for qualification. If corrosion pits are visible after the cleaning operation, scrap the affected coil.

Smooth worn spots on a coil caused by rubbing - do not condemn the coil. However, it must still pass the other qualification criteria.

For spring identification and qualification, refer to M.I. 1512.

Maintenance Instruction no MI 1517 (Rev. A)

Para 3.2.6

Brake block guide (See instruction in relevant para)


Para 2.7


Slack adjusters

This procedure must be conducted with the locomotive parked on tangent track. If conducted with the locomotive in a curve, error in setting the piston travel will result.

It is recommended that a periodic visual inspection should be performed to find out if there is any damage, e.g. loose or missing lock pins or a bent or damaged assembly. Replace or repair the adjuster as required.


Para 2.8.2 & 2.8.3

Hand brake

The hand brake, chain, and lever should be inspected on a periodic basis, to check for unusual wear. The hand brake chain should not rub against the wheel or bogie during operation. The HTSC-B1 bogie has a special spring pre-tensioning arrangement to prevent rubbing. Quarterly checked:

Check that all fasteners (nuts & bolts), clamps, and brackets are secure.

Verify condition of chain, shackles, and pins for corrosion, wear and damage. Replace as required.

Check that the pulley on the brake handle assembly is in good condition and properly secured. Replace if required.

Chain and other components should be lightly oiled to prevent


Para 2.9.2 Para 2.9.4.1


corrosion.

Bogie removal

Inspections before bogie removal

Yaw Dampers

Primary Suspension

Secondary Suspension Springs

Carbody pivot pin clearance

Brake rigging

Wheel condition, Wheels, Axles, Axle Gears and Pinions

Axle lateral clearances

Vertical stop clearances

MI 1517 (Rev. A) M.I. 1518 and 1519

Para 2.5

Para 3.2.6 Para 2.6 Para 3.2.4 Para 3.2.2

Para 5.5.2 Para 5.5.2

BOGIE ASSEMBLY REMOVAL It is required without exception that all appropriate discharge procedures be performed prior to commencing work on the trucks or related components (For figures refer relevant pages and para).

MI 1517 (Rev. A)

Para 2.12.2

Bogie installation

Jacks are used to raise the locomotive, ensure that all jacks are raised simultaneously in equal amounts. Failure to keep the locomotive level may result in excessive stress on the underframe and carbody structure, or in a failure of the jacks.

Great care must be taken during this portion of the application process to prevent damage to the carbody pivot assembly and secondary suspension springs. The

MI 1517 (Rev. A)

Para 2.13.1


pivot pin and alignment dowels should slide into place easily. If this is not the case, slight movement of the bogie will be required to aid in assembly.

Vertical Stop Clearance

to be ensured 16 mm +/- 3.2 mm

MI 1517 (Rev. A) Para 2.13.2

Final Installation MI 1517 (Rev. A) Para 2.13.3

Bogie Overhaul While the overhaul procedures are similar for the two types of bogies, it is imperative that the correct assembly drawing be used to ensure correct dimensions are achieved. Detail instructions and guide lines for overhaul of bogie to be followed as per the para 3.0 to 3.5 of MI 1517 (Rev. A)

MI 1517 (Rev. A) Para 3.0 to 3.5

Maintenance and wear limits MI 1517 (Rev. A)

Para 5.5.1 and Para 5.5.2

2.

Availability of Tools, Test Stands and special procedures

MI 1517 (Rev. A) Work sketch 41089

Para 4.1

Lock bolt/ huck bolt installation machine

Wall mounted fixture to dampers

Surface table of measurement of springs

Height gauge for springs

Spring load-deflection testing machine

Hydraulic damper testing machine

Torque wrench, Go/No Go Gauges

Inside and Outside Calliper, Vernier Caliper, Height Gauge, Cleaning Tank,

Wheel wear measuring gauge SK.DL-3592

3 Availability, service data, special torque values and Instructions Etc

MI 1517 (Rev. A) Para 5.1.1 and Para 5.3


3.1 Display Chart





5

Material Availability and parts catalogues

HHP (MAC) HHP (PAC)

E26 E35

Vital Spares

Must Change items


CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTOR PINION & GEAR ASSLY.

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)

Traction Motor Pinion & Gear Assly. of Alco

Loco

MP-IB.EM.10.31.08

dated 24.10.2008

MP-MI 129/86 July 1986

MP-MI 5

1.1 TRACTION GEAR & PINION

Gear Ratio 18 : 65

Pinion Drg. No. 18 teeth, SKDP3624

Pinion Bedding In Cold Condition

Not less than 95 %

Pinion Advance 2.25 TO 2.45MM

Heating Temperature 190ºC + AMB TEP.

Span Size On New Pinion Over 3 teeth 88.595 /88.722MM

Condmning Limit On Basis Of Span Size Of Pinion

Over 3 teeth 86.995MM

Gear Drg. No. 65 teeth SKDP3623 & SKDP3775

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

Condmning Limit On Basis Of Span Size Of Gear


Permissible Backlsh With New Set

0.266 - 0.664MM

Condemning Limit On Basis Of Backlash

1.04MM

Crack detection MPMI or Zyglo test

1.2 TRACTION GEAR & PINION

Gear Ratio 18 : 74


Pinion Drg. No. 18 teeth, SKDP3443

WDG3A

All ALCo locos

MP-IB.EM.01.02.10 dated 11.01.2010.

Pinion Bedding In Cold Condition

Not less than 95 %

Pinion Advance 2.30 TO 2.45MM

Heating Temperature 185ºC + AMB TEP.

Span Size On New Pinion Over 3 teeth 81.976 /82.093MM

Condmning Limit On Basis Of Span Size Of Pinion


Gear Drg. No. 65 teeth SKDP3444 & SKDP3546

Span Size On New Gear Over 8 teeth 231.36/231.177

Condmning Limit On Basis Of Span Size Of Gear

Over 8 teeth 228.140

Permissible Backlsh With New Set

0.243 - 0.608MM

Condemning Limit On Basis Of Backlash

1.00MM

Crack detection MPMI or Zyglo test

1.3 TA FAN ASSEMBLY

Outer diameter of TA fan 1387.25/1387mm

Bore diameter of TA stator 1392mm

Bore diameter of TA fan 600.00 / 600.03mm

Diameter of fan seating area on barrel.

600.03 / 600.06mm

Width of fan seating at bore 9+1 mm

Depth of counter sunk bolts hole 4.5 - 5.5 mm

Bolt head width 12.3mm

6.4 Bolt head height above fan plate after final assembly should not be more than

6.5 6- 7mm

Circumferentially Fan gap on TA 2.50 – 2.75mm

Tightening torque and wire locking process

28 – 30Kg-m

Tightening torque of M30 (coupling bolt)

170 – 180 kg-m.

Oil catcher thickness (at bottom side)

53.90 to 54.10mm

Bolts strength properties grade R8.8.


Sunk type M20 bolts can be used in place of fully threaded M20 bolts

EMD locos (WDP4 & WDG4)

Traction Motor Gear Case of EMD Locos

MP.IB.EM.02.12.00dated 10-4-2000.

MP.IB.EM.03.12.10 dated 05-3-2010.

M20 & M30 bolts should be replaced

After 4 – 5 years service of TA

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

150 to 170 °С

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

GO & NO GO thread ring or plug gauge

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

Visual inspection is required

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

In place of (bolts) press fit.

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

As shown in photo

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

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

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

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

TA Gear train assembly Backlash at Steel plate

TA GEAR 102T AG/EG PINION 43T

PTU PINION - 43T

0.60mm to 1.40mm 0.05mm to 0.12mm

on shaft

1.4 Traction Motor Gear Case of EMD Locos

Following items must be checked before fitment/ assembly of top and bottom half gear case

The Heli -coil insert should be checked for looseness. If loose, an oversized insert should be used or the same insert should be used with Loctite / araldite.

The gear case must be cleaned thoroughly specially the mating surfaces.

The same set i.e. the same top and bottom portions must be re-assembled together.

Inter changeability of the two halves is not permitted.


The 6mm hole must be kept clean.

As above

The breather valve must be kept clean

The bolts must be tightened with the required torque of 35 ft and 990ft pound

The tightening sequence as described in the report must be followed.

The pinion inspection hole must be properly plugged by welding

Oil level should be checked as per Dip stick given in Annexure B of IB.

OEM recommended sealants DOW Corning DC-3-0100 and (RTV) GE Sealmate TRV-1473 should be used. Expairy date should also be checked befor use & Dow corning sealant can be procured from M/s Dow Corning India Pvt Ltd. Mumbai.

2 AVAILABILITY OF TOOLS AND TEST STANDS

2.1 Vernier Callipers

2.2 Disc Mike

2.3 Filler Gauge

3 INSTRUCTION

3.1 Display Chart

3.2 Training of Staff

3.4Record keeping of tools and measuring instruments

4 TRACEABILITY

5 MATERIAL AVAILABILITY

5.1 Vital Spare -NA

5.2 Must change items -NA


CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTORS



SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCE DETAILS

CLAUSE/ PARA/ ITEM

DETAILS

OBSERVATION

1 MEASUREMENT

Alco

Traction Motors of Alco Loco

MP.MI-2 & MP.MI-6

Maintenance manual issued by OEMs viz. BHEL/CGL.

1.1 Insulation Resistance = 10 Mega ohm

1.2 Carbon brushes for condemning sizes

1.3 Clearance between commutator and brush holder

1.4 Tension of brush holders springs.


2.1 1000V Megger

2.2 Filler gauge

3 INSTRUCTION

3.1 Display Chart



4 TRACEABILITY


5.1 Vital Spare

5.2 Must change items


CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS



S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCE DETAILS

CLAUSE/ PARA/ ITEM

DETAILS

OBSERVATION

1 MEASUREMENT

All ALCo locos

Traction Motor Bearing & Assly. Components of

MP-IB.EM.14.50.08

dated 20.02.2009

1.1 Verticality of Outer race

1.2 Verticality of Inner race

1.3 Max. deviations allowed in above cases:

Side Inner race Outer race

Pinion End 0.075 mm 0.25 mm

Commutator End 0.065 mm 0.20 mm

1.4 Radial Clearances of bearings

a) For New Bearings

Bearing Radial clearance before mounting

(mm)

Radial clearance after mounting (mm)

NU 330 0.165 - 0.215 mm 0.100 – 0.170 mm

NH 320 0.105 – 0.140 mm 0.060 – 0.100 mm

b) In addition to above, max. service radial clearance

NU 330 0.300 max. 0.250 max.

NH 320 0.190 max. 0.150 max.


C) Flinger - PE

Alco Loco

Bore Dia. 153.130 to 153.155

Total Width 12.65 to 12.70

d) Retaining collar - PE

Bore Dia. 146.015 to 146.040 mm

Total Width 12.65 to 12.70 mm

Outer Dia. 253.225 to 253.290 mm

Hub Outer dia. 177.040 to 177.090 mm

Outer dia. on 2nd

Groove 210.610 to 210.670 mm

Groove width 8.00 to 8.05 mm

Total width 44.4 to 44.6 mm

e) End shield - PE

Bore dia. 319.975 to 319.995 mm

f) End shield - CE

Bore dia. 214.980 to 215.00 mm

g) Seat diameter on armature shaft

For brg.-PE, Bore dia. 150.035 to 150.055 mm

For brg.-CE, Bore dia. 100.025 to 100.040 mm

For retaining collar PE 146.130 to 146.150 mm

For bearing sleeve PE 153.220 to 153.240 mm

For inner brg wiper CE 101.600 to 101.620 mm

h) End Float on Traction motor (TM 4907) CE

Limit – 0.50 mm Aim – 0.42 mm

1.5 Fits & Clearances (BG TM)

i) Pinion end bearing

Interferences (Diametrical) Clearances (Diametrical

Brg. 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 shaft

0.035 to 0.080 mm

--------------- --------------

Retaining collar to shaft

0.090 to 0.135 mm

-------------- --------------

ii) Commutator end bearing

Interferences (Diametrical) Clearances (Diametrical

Brg. 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

-------------- --------------

1.6 Heating temp. of brg. & assly. components

Item Heating temp.

Bearing inner race PE 100 -110 ºC

Bearing inner race CE 100 -110 ºC

Sleeve (PE) 100 -130 ºC

Sleeve (CE) 100 -130 ºC

Flinger (PE) 100 -120 ºC

End shield (PE) 120 -130 ºC

End shield (CE) 120 -130 ºC

Retaining collar (wiper) 120 -130 ºC


2.1 Dial gauge

3 INSTRUCTION

3.1 Display Chart



4 TRACEABILITY


5.1 Vital Spare -NA

5.2 Must change items -NA


CHECK SHEET FOR

QUALITY AUDIT OF TRACTION ALTERNATOR



SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCE DETAILS

CLAUSE/ PARA/ ITEM

DETAILS

OBSERVATION

1 MEASUREMENT

EMD locos (WDP4 & WDG4)

Traction Alternator

of EMD loco

Maintenance Instruction for

Traction Alternator of

EMD loco

MI-3317-1 and MI-3317-2

1.1 (a) Check tightness of all mechanical and electrical connections. Check for open fuses (indicating pins protruding). Check collector rings and brushes for sparking. (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, and the trailing edge of the brush holder(s) are set at .125”-140” from the surface of the slip ring. (d) Check that large brush spring pressure is 1.5 kg (3.3 lbs) and small spring pressure is 0.68 kg(1.5 lbs.) (e) Minimum length of bush = 3.81 cm. (1.5 in.) on the longest vertical side.

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

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 resistence values (@75°F/23°C) = 0.000195 + - 0.000010 ohm (d) All diodes in any paralleled group must be of the same polarity (ceramic cases or shrink tubing must be the same color), and the diodes must be applied to the proper heat-sink bus. (e) All diodes in any paralleled group should be of the same type (same impressed type


number and same type color band at the lower crimp).


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 Low Ohm Resistance Tester Kit, (Range 0 to 1.999 miliohms)

3.3

3 INSTRUCTION

3.1 Display Chart



3.4Record keeping of tools & measuring instruments

4 TRACEBILITY


5.1 Vital Spare



CHECK SHEET FOR QUALITY AUDIT OF TURBO SECTION

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. Shed/Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make Of Subassembly

Reference Details

Clause/Para/Item Details

Observations

1.

Balancing, measurements etc

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

5.6 5.6.2.5 5.6.2.5

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

Para 5.2.4.13 & details in 5.4.2.1

1.4 Bearing position OD B 50.987--51.000 mm

1.5 Bearing position OD C 56.10-56.20 mm

1.6 Piston ring recess S 2.58-2.85 mm

Wheel Bush 1.7 Compressor wheel set OD A 56.10 -56.20 mm

Para 5.2.4.13 & details in 5.4.2.2

1.8 Piston ring recess S 2.58-2.85 mm

1.9 Plain bearing (CE) ID A 54.00-54.06 mm Para 5.2.4.13 & details in 5.4.2.3

1.10 Bearing housing bore ID A 65.00-65.07 mm Para 5.2.4.13 & details in 5.4.2.4

1.11 Floating bush ID (CE) 40.011-40.05 mm Para 5.2.4.13 & details in 5.4.2.5

Floating bush OD (CE) 53.80-53.86 mm

1.12 Floating bush OD (TE) 64.82-64.84 mm

1.13 Floating bush ID (TE) 51.022-51.07 mm

1.14 Thrust bearing width 10.39-10.50 mm Para 5.2.4.13


& details in 5.4.2.6

1.15 Axial bearing width 16.76-16.88 mm Para 5.2.4.13 & details in 5.4.2.7

1.16 Piston ring width 2.00 -2.49 mm Para 5.2.4.13 & details in 5.4.2.8

1.17 Thrust bearing press fit measure (K) 170.5 -170.63 Para 5.2.4.13 & details in 5.4.2.9

1.18 Axial clearance A 0.11-0.32 mm Para 5.2.4.13 & details in 5.7

1.19 Radial clearance B 0.47-0.93 mm

2.

Availability of Tools, Test Stands etc.

Alco

do do

2.1 Balancing machine

2.2 Zyglo testing machine

2.3 Casing hydraulic test stand

2.4 Bearing puller (CE & TE)

2.5 Torque wrench up to 250 psi

2.6 micrometer 2”-3” & 0-4”

2.7 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc.

3.1 Display Chart





5


5.1 Vital Spares


Measurements etc


1

1.1 Nozzle ring and gas inlet casing 0.022-0.032” Dia Clearance (Cl)

Alco

Alco 720

Instruction Manual ALCO

ALCo MI 11126

1.2 Turbine blade and gas inlet casing 0.060-0.092”Dia CI

1.3 Nozzle ring and turbine disc 0.124” cold CI

1.4 Intermediate casing and impeller 0.017-0.065” longitudinal Clearance (long Cl)

1.5 Impeller and Blower inlet 0.035-0.075” long CI

1.6 Blower casing end blower inlet measure with bolt loose. Scatting with back of diffuser at lease to 80% (This is only in case when we apply a new diffuser) 0.005-0.020” Long CI (Gap)

1.7 Turbine disc and intermediate casing 0.008-0.016” Long CI

1.8 Bearing and thrust collar (Blower end) with surface by approx 0.003 less when oil. 0.007-0.018” Thrust CI

1.9 Inducer and blower casing 0.091-0.101”Dia CI

1.10 Thurst collar and oil seal Blower End 0.014-0.036” Dia CI

1.11 Interference between bearing and intermediate casing (blower & Turbine end ) 0.0005-0.0015” Dia Cl

1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008” Dia CI

1.13 Gas inlet casing and intermediate casing inside measurement 0.090-0.098” Dia CI

1.14 Impeller and intermediate casing 0.125-0.127” Dia CI

1.15 Max allowable clearance between Gas inlet casing & Nozzle ring 0.005” clearance

2

Availability of tools, Test Stands etc.

Alco

Alco 720

Instruction

2.1 Balancing machine

2.2 Zyglo machine

2.3 Casing hydraulic test stand

2.4 Oil gallery flushing test stand

2.5 Bearing puller (CE & TE)

2.6 Sand blast machine for rotor cleaning

2.7 Torque wrench up to 250 psi


2.8 micrometer 2”-3” & 0-4” Manual ALCO

2.9 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc .

3.1 Display Chart





5


5.1 Vital Spares



CHECK SHEET FOR TECHNICAL AUDIT OF CYLINDER HEAD SECTION

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. Shed/Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make Of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

1

Cleaning, measurements etc.

1.1 Cleaning of cylinder head

ALCo --

DLW Maintenance

Instruction Manual

Chapter on cylinder head

1.2 Cy head leak test at 70 PSI with hot water

1.3 Inspect head for cracks using Magnaflux

1.4 Valve guide to head int 0.002” -0.0005”

1.5 yoke to guide int 0.002” -0.0005”

1.6 Yoke guide ( press in dim) 3.210” -3.272”

1.7 Valve guide ( press in dim) 2.25”

1.8 Valve to guide cl 0.003 – 0.0045”

1.9 Cy head nuts torquing value 550ft/lbs

2

Availability of tools , Test Stands etc.

2.1 Valve seat reconditioning machine

2.2 Hydraulic test stand

2.3 Feeler gauge

2.4 Magna flux

3


3.1 Display Chart





5


5.1 Vital Spares



1

Cleaning, measurements etc.

1.1 Cleaning of cylinder head

EMD

--

EMD Engine Maintenance

Manual

Chapter on cylinder head

1.2 Cy head leak test at 85 to 95 PSI air pressure

1.3 Inspect head for cracks using Magnaflux

1.4 Cy head valve seat angle 30º -30 º 15’

1.5 Valve seat width 0.093” -0.125”

1.6 Dia at top of valve seat 2.375”-2.437”

1.5 Valve seat runout TIR max 0.008”

1.6 Valve guide inside dia max 0.633”

1.7 Valve stem to guide clearance max 0.020”

2

Availability of tools ,Test Stands etc.

2.1 Valve seat reconditioning machine

2.2 Hydraulic test stand

2.3 Feeler gauge

2.4 Magna flux arrangement

3

Availability of instructions etc

3.1 Display Chart





5


5.1 Vital Spares



CHECK SHEET FOR TECHNICAL AUDIT OF PISTON SECTION

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.

SN Requirements

Loco Type

Make Of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

1

Cleaning, inspection, measurements etc.

1.1 cleaning of piston

ALCo

--

DLW Maintenance

Instruction Manual

Chapter on piston and con rod

1.2 Inspect visually piston skirt and body for scoring or scuffing

1.3 Inspect piston crack using Magnaflux

1.4 Zyglo test for checking surface crack

1.5 Groove width top ring, 2nd ring and 3rd ring 0.1902”- 0.1950”

1.6 Side clearance in above rings 0.0052” -0.012”

1.7 Groove width of oil scrapper ring 0.3140” – 0.3165”

1.8 Side clearance in oil ring 0.002”- 0.006”

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”

2.

Availability of tools , Test Stands etc.

2.1 Feeler gauge


2.3 Magna flux

2.4 Vernier caliper

2.6 Piston ring groove gauge

3

Availability of instructions etc

3.1 Display Chart






5


5.1 Vital Spares


1.

Cleaning, inspection, measurements etc.

1.1 Inspect visually cylinder wall and top of piston for any scoring mark and water leak indication etc.

EMD

-- EMD Engine

Maintenance Manual

Chapter on piston

1.2 Measure side clearance of no 1 compression ring.

1.3 Inspect piston skirt for scoring or scuffing

1.4 cleaning of piston

1.5 Inspect piston crack using Magnaflux

1.6 Piston skirt diameter min 9.0485”

1.7 Out of round max 0.005”

1.8 Piston to carrier pilot cl max 0.011”

1.9 Piston platform to bottom of snap ring groove 6.626” -6.639”

1.10 No 1 compression ring groove width max 0.201”

1.11 Piston to Cy head cl 0.020”- 0.068”

1.12 Compression ring to land clearance No 1 groove Max 0.012”

1.13 Compression ring to land clearance No 2 & 3 groove Max 0.015”

1.14 Compression ring to land clearance No 4 groove Max 0.015”

1.15 Oil ring groove width 0.251- 0.254

1.16 Oil ring to land clearance 0.002- 0.006”

2.


2.1 Feeler gauge


2.3 Magna flux

2.4 Vernier caliper

2.5 Lead wire

2.6 Piston ring groove gauge

3


3.1 Display Chart






5

Material Availability 5.1 Vital Spares



CHECK SHEET FOR QUALITY AUDIT OF AIR & EXHAUST VALVE MAINTENANCE

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:

SN Requirements Loco Type Make of Subassembly

Reference Details

Clause/Para/Item details

Observations

1

Measurements etc:

Alco

--

Alco Instruction Manual (MI-

11020G)

Chapter on

Cylinder

Heads

1.1 Stem dia of valves 0.6205-0.6195 (New).

1.2 Groove fillet radii 0.025-0.031R.

1.3 Valve disk thickness: for C and F type valve of 450: (a) 0.1562” (new) and (b) 0.0625”(condemning Limit).

1.4 Valve disk thickness (for E type valve 300) 0.1750”(new). And, 0.0937”(condemning Limit).

2

Availability of tools, test stands etc:

2.1 Depressor, Spring etc

2.2 Grinder

3

Availability of instructions etc:

3.1 Display Chart etc



4 Record keeping for traceability:

5

Material Availability:

5.1 Vital Spare


1

Measurements etc:

1.1 Stem diameter-measured within 12.7 mm (1/2”) of weld and 12.7 mm (1/2”) below P/N stencil on stem- Min. – 15.761mm (0.6205”).

1.2 Valve face angle 30000’-29045’’.

1.3 Valve seat runout-Max-0.06mm(0.0025’’).

1.4 Valve rim thickness (measured at O.D.)-


Min.- 2.77mm (0.109”); Valve face width-Max- 8.71mm(0.343”).

EMD

--

EMD Engine Maintenance

Manual

Chapter on

cylinder

heads and

accessories

1.5 Surface finish of valve stem roughened not beyond 0.635µmm(25µin)

2

Availability of tools, test stands etc.

2.1 Single valve compressor (Part No 8033783)/Multiple valve spring compressor (Part No 9546582)

2.2 115V grinder for Grinding Valves

3


3.1 Display Chart etc


3.3 Record keeping of tools and measuring instruments.

4 Record keeping for traceability.

5


5.1 Vital Spares



CHECK SHEET FOR TECHNICAL AUDIT OF RADIATOR SECTION

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.

Shed/Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make/class Of Subassembly

Reference Details

Clause/Para/ Item/Chapter

Details

Observations

1

Cleaning etc

Alco

Conventional

Alco MI

Chapter on

Maintenance,

Radiators.

1.1 cleaning details

2


2.1 Torque wrench up to 140 ft-lb.

2.2 Hydraulic testing machine 0-10 Kg/Cm2

2.3 Radiator stand

2.4 Fin combing tool

2.5 Radiator immersion tank for cleaning

3


3.1 Display board etc


3.3 maintenance manual and check sheets

3.4 Calibration facility for tools and measuring instruments

4 Record Keeping for Traceability

5.


5.1 Vital spares

5.2 Must change Item


1. Cleaning etc

EMD

Mechanical Bonded Radiator (MBRs)

EMD MI

Chapter on

Maintenance,

Radiators.

Cleaning details

2.

Availability of Tools, Test Stands etc

2.1 Torque wrench up to 140 Ft-lbs

2.2 Hydraulic testing machine 0-10 Kg/Cm2

2.3 Radiator stand

2.4 Fin combing tool

2.5 Radiator immersion tank

3.

Availability of Instructions etc

3.1 Display board – Cleaning and test procedure of the MBRs


3.3 All maintenance manual and check sheets

3.4 Calibration facility for tools and measuring instruments

4. Record Keeping for Traceability

5.


5.1 Vital spares – Gaskets and Radiator core panel

5.2 Must change Item – Gaskets during overhauling


CHECK SHEET FOR QUALITY AUDIT OF FUEL INJECTION PUMP (FIP) MAINTENANCE

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. Shed/Rly: Audited by: Date of audit:

SN Requirements Loco type Make of subassembly

Reference details

Clause/Para/Item details Observation

1. Measurements etc

Alco

Bosch 17 mm

Bosch manual

on repair and

testing

Para on Assembly Para on Calibration Values Para on Inspection of Parts

Para on Inspection of Parts

1.1 Range control rack bush dia - 18.25 mm (0.7185”) - 18.27 mm (0.7192”).

1.2 BDC Dimension ‘a’ – 6.5 ± 0.05 mm. 1.3 Clearance between control rack and

bushing – within 0.05 mm (0.020”). 1.4 Control rack movement – within 0.38

mm (0.015”).

2. Availability of Tools ,Test Stands etc.

1.1 Depth gauge for checking of BDC dimension ‘a’ on test bench.

1.2 Nut torque wrench , 450 lbs – 500 lbs. 1.3 Bush reamer. 1.4 Micrometer, 16 – 20 mm. 1.5 Assembly and dis-assembly fixture 1.6 Pump calibration test stand 1.7 Calibration oil – Servo Calib-5

3. Availability of instructions etc.

3.1 Display of charts etc 3.2 Training of staff. 3.3 Maintenance manual and check sheet etc 3.4 Record keeping of tools and measuring instruments.

4. Record keeping for traceability:

5. Material availability: 5.1 Vital Spares 5.2 Must change items


CHECK SHEET FOR

QUALITY AUDIT OF INJECTOR MAINTENANCE

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. Measurements etc

Alco

Bosch

Bosch repair and testing manual

Para on Assembly

1.1 Opening pressure - 3900 to 4050 psi (New nozzle )

1.2 Opening pressure - 3700 to 3800 psi (Overhauled nozzle )

1.3 Nozzle cap nut tightening torque 130-150 Nm (13-15 kgf.m or 94-109 lbs-ft)

1.4 Repetition (chatter) and spray pattern test (for new nozzle)

2. Availability of Tools, Test Stands etc: List on Service Tools for Injector

2.1 Nozzle needle lift gauge 2.2 Feeler gauge 2.3 Dial gauge 2.4 Nozzle centering sleeve 2.5 True running gauge 2.6 Nozzle tester 2.7 Fixture for injector 2.8 Socket wrench 2.9 Test oil

3. Availability of instructions etc:

3.1 Display of chart 3.2 Training of staff 3.3 Maintenance manual and check sheet 3.4 Record keeping of tools and measuring instruments



5. Material availability: 5.1 Vital Spares 5.2 Must change items

1.

Cleaning, checking etc

EMD

Ecotip Superstack Mechanical Unit Injector

(MUI)

Ecotip Superstack Injector Maintenance Instructions of Interstate McBee USA

Relevant para on

cleaning etc.

1.1 Cleaning of injector components 1.2 Checking of injector parts 1.3 lapping

2.


Chapter on Tools and Fixture

requirements

2.1 EMD timing gauge 2.2 Vise with adapter 2.3 Calibration/Comparator Injector test stand. 2.4 Control rack set length blocks 2.5 Pop and Leak test stand 2.6 Torque wrench 2.7 Optical flat 2.8 Monochromatic light source 2.9 Soft wire buffng wheel 2.10 12 mm dia. Soft wire brush 2.11 Injector nut reamer 2.12 Wrench for injector nut

3.


3.1 Display chart 3.2 Training of staff 3.3 Maintenance manual and check sheet 3.4 Record keeping of tools and measuring instruments


5.

Material availability: 5.1 Vital Spares 5.2 Must change items


CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL ROOM

(Item: MBCS + MCBG +E type control)


SN Requirements

Loco Type

Make Of Subassem

bly


Obs

List of measuring equipments

Calibration status

Test bench set up facility

Segregation of tested equipments

Check List of safety and critical items identified

ECS operation check GR operation check Eng. Stop button check OST open check MUSD stop switch check LWS check GFOLR operation check (E type loco) Governor dry run check Flasher light Head light Classification light Horn Sanders and direction

ALCo and EMD

Schedule inspection


Cab light and exterior lights Alerter, lamp, alarm and reset Flasher lights switch panel GR, DB cut out and B/B cut out seals Indication panels Attendant call bell Cab fan and air brake fan

Eng Temp switch setting at 68ºC, 74ºC, 90ºC, 95ºC

Proper closing of all covers and gaskets are intact in ECC1, ECC2 and ECC3

Practice for Handling of the electronic cards and storing

ALCo Doc No. :IM 53 for MBCS Medha

Availability of crimping tool & connector pin details

ALCo Doc No. :IM 53 for MBCS Medha

Load Box testing facility ALCo MP MI -10 (Rev.0.02) August, 2003 for ‘E’ type and MBCS

Micro Controller Based Governor (MCBG) MEG 601

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

1. Measurement

Test procedure for MBCS loco 8th notch power curve

TA Volts

TA Amps.

ALCo IM-59, MP MI -10 (Rev.0.02) August, 2003 for ‘E’ type and MBCS


a. Amb. Temp.

b. Corrected THP

c. Fuel rack in mm

d. NLV (Specified 1130VDC)

e. 8th notch power curve

f. Notch separation test

Idle to full HP time (specified 40 sec)

1st notch current limit (specified 32- 33.5mA)

2. Availability Of Tools And Test Stands

Alco

3


3.1 Display Chart





5


5.1 Vital Spares


7 Availability of Tools And Test Stands

8


8.1 Display Chart





10 Material Availability


CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERATING FIELD CONTACTOR CONTACTOR CONTACTORS (ALCo LOCO) During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded. Shed/Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make Of Subassembly


Observations

1. Measurement

1.1 Control voltage 72+1 vdc, All Diesel Electric Locomo tives (ALCo)

Drawing No. EL/PT/0640/ Altr

R3 Part

No 12145439

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

(Rev-01),May’10

3.10.e

1.11 IR Value between (i) Main contacts (ii) Coil and magnet frame (iii) Interlocks and coil shorted together and earth.

IEC 60571

as per clause 10.2.9


SN Requirements

Loco Type

Make Of Subassembly


Observations

(iv) Contacts of interlocks (v) Interlocks and coil shorted together and main

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

and earth

2.0 Availability of tools and stands

2.1 Multimeter with proper calibration

2.2 Vernier calipers with valid calibration

2.3 Go- No gauge suiting to different cantactors

2.4 Dial gauge of different scale and resolution as suited to respective contactor

2.5 Source which can provide minimum current at respective voltage (24 V – 72 V DC)

2.6 Variac

2.7 Meggar

2.8 Oscilloscope

2.9 Screw Driver, Plier, Spanner Set, etc.

3. Availability Of Instructions etc.

3.1 Display Chart

3.2 Flow Chart


3.4 Proper Display of Do’s and Don’t



3.7 Instruction Bulletin issued by RDSO

3.8 Maintenance Manual of Manufacturer

3.9 Specification

4. Compliance of Instruction Bulletin

5. Follow of Maintenance Manual of Manufacturer


6.1 Proper Register is maintained for Contactors with


SN Requirements

Loco Type

Make Of Subassembly


Observations

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 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 Availability

7.1 Vital Spares


7.3 Consumables

8. Disposal

8.1 Segregation of Workable and Non-Workable equipments and proper house keeping

8.2 Proper Disposal of Materials including recycling following relevant environmental norms


CHECK SHEET FOR

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


SN Requirements

Loco Type

Make Of Subassembly


Observations

1. Measurement

1.1 Auxiliary contacts 4, change over type, ALCo Drawing No. EL/PT/0649/ Altr

R5 Part

No 12310372


1.2 Control voltage 72+1 V DC,

1.3 Operating air pressure 4.9 kg/cm2,

1.4 Min operating air pressure 3.85 kg/cm2,

1.5 Main contact gap19.05+1.6mm,

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

1.7 Contact impression (should be min 80%)

1.8 Auxiliary contact pressure 0.68-2.0kgf,

1.9 Auxiliary contact gap 31.75mm (min), ,

1.10 Magnet valve coil resistance at 20degC 615+5% ohm.for BHELTYPE: 5027MV2

1.11 ROTEX TYPE: 3118AV1-3 coil resistance at 20degC-526 to 594 Ohms.

1.12 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08

(Rev-01),May’10

3.10.e


SN Requirements

Loco Type

Make Of Subassembly


Observations

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








2.15 Variac

2.16 Lever of 122.5 mm for measuring initial and final pressure.

2.17 Compresor with air reservoir

2.18 Meggar

2.19 Oscilloscope



3.10 Display Chart

3.11 Flow Chart






SN Requirements

Loco Type

Make Of Subassembly


Observations



3.18 Specification Spec No.

MP.0.04.00.08

(Rev-01),May’10




6.3 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.

6.4 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.


7.4 Vital Spares


7.6 Consumables

8. Disposal




CHECK SHEET FOR

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


SN Requirements

Loco Type

Make Of Subassembly


Observations

1. Measurement

1.1 Auxiliary contacts 4 change over type, All Diesel Electric Locomo tives (ALCo)

Drawing No. EL/PT/0648/ Altr

R5 Part No 12310300


1.2 Control voltage 72+1 V DC, 1.3 operating air pressure 4.9 kg/cm2,

1.4 Min operating air pressure 3.85 kg/cm2 ,

1.5 Main contact gap19.05+1.6mm,

1.6 Main contact - outside pressure (with lever) 1.7 4.0-4.5kgf, inside pressure 5.8-6.5kgf,

1.8 Auxiliary contact pressure 0.68-2.0 kgf,

1.9 Auxiliary contact gap 31.75mm (min),

1.10 Magnet valve coil resistance at 20degC 1.11 615+5% ohm. for BHELTYPE : M5027MV2

1.12 ROTEX TYPE: 3118AV1-3 coil resistance at 20degC 526 to 594 Ohms

1.13 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08

(Rev-01),May’10

3.10.e

1.14 IR value between (i) Main contacts and frame (ii) Frame and all live parts connected together

(wth main cxontacts closed)

IEC 60571

a.



(iii) Terminals of both side, terminals shorted together on each side (Main contacts open)

(iv) All control and Aux. circuit







2.26 Variac

2.27 Lever of 122.5 mm for measuring initial and final pressure.

2.28 Compresor with air reservoir

2.29 Meggar

2.30 Oscilloscope



3.19 Display Chart

3.20 Flow Chart







3.27 Specification




6.5 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.

6.6 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.


7.7 Vital Spares


7.9 Consumables

8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF GOVERNOR SECTON(ALCo/EMD LOCO)


SN Requirements

Loco Type

Make Of Subassembly


Observations

1. Dis Assembly and Assembly ALCo/EMD

Maintenance manual of

WoodWard

Section 5 of Maintenance Manual

2. Measurement :

2.1 Physical Examination

ALCo/EMD

Wood Ward Governor Test

Record Format No. TSP/F8572-828

and Maintenance manual of

WoodWard

Section 6 of Maintenance Manual

2.2 Barometer Reading

2.3 Pressure Test

2.4 Hydraulic Seals, needle valve seat and buffer piston bypass in both direction

2.5 Needle Valve setting

2.6 Speed Setting

2.7 Normal Shut Down

2.8 Pressure Requirement

2.9 Speed Setting timing

2.10 Lube Oil Shutdown

2.11 Air Box Pressure Fuel Limiting

2.12 Load Control

2.13 Vane Servo Timing

2.14 Excitation Resistor

2.15 General

2.16 Verification with Cover Installed

3.

Availability Of Tools And Test Stands ALCo/EMD

3.1 Test Stand for Wood Ward Governor

3.2 Multimeter with valid Calibration


SN Requirements

Loco Type

Make Of Subassembly


Observations

3.3 Screw Driver, Plier, Allen Key, Spanner, etc.

3.4 Fire Extinguisher of proper class

4.

Availability Of Instructions etc.

3.28 Display Chart

3.29 Flow Chart



3.32 Display of Trouble Shooting Chart Maintenance Manual

Section 4



3.35 Instruction Bulletin issued by RDSO NA


3.37 Specification NA

5. Compliance of Instruction Bulletin NA


7. Record Keeping For Traceability

6.7 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.


SN Requirements

Loco Type

Make Of Subassembly


Observations

6.8 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.


7.10 Vital Spares


7.12 Consumables like Lub Oil, Cotton wool,

etc.

9. Disposal

9.1 Segregation of Working and Non-Working

equipment and Proper House Keeping

9.2 Safe Disposal of scrap and waste including

recycling following relevant environmental norms.