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Date: 21,.1L2017

The Chief Motive power Engineer/Diesel1. CMPE, NR, HQ. Office, Baroda House, New Delhi.2. CMPE, SCR, HQ. Office, Rail Nilayam, Secunderbad.3. CMPE, WR, HQ. Office, Churchgate, Mumbai-2O4. Central Railway, M umbai CST-15. Eastern Railway, Fairlie place, Kolkata6. North Eastern Railway, Gorakhpur-2730017. N.F. Railway, Maligaon, Guwahati-791011B. North Western Railway, Jaipur9. Southern Railway, park Town, Chennai-310. S.E. Railway, Garden Reach, Kolkata-4311. East Central Railway, Hajipur (Bihar)12. North Central Railway, Allahabad (U.p)13. South Western Railway, Hubli, Karnataka14. South East Central Railway, Bilaspur.15. CDE (Mech.), tCF, Chennai16. CDE (Elec.), lCF, Chennai17 , Dir (Mech.), CAMTECH, Gwalior (M.p.)

sub: schedule of standard Examination of 1600 hp AC-AC BG DEMU.Ref: lcF's letter no. MD/DSS/AC-AC DEM u/r6s dated 23.02.2016.

In reference to the letter cited above, 'schedule of Standard Examination of 1600hpAC-AC BG DEMU no. MP.M|SC.328 (Rev-00) Nov'2017 has been prepared by RDSO (Mp) anduploaded on RDSo' website for comments from concern.

The subject schedule can be accessed using path'www.rdso.indionroilways.gov.in/Motive Power/ Schedute of Standard Examination of1600hp AC-AC BG DEMIJ no. MP.M\SC.I28 (Rev-00) Nov'20I7'. The comments can also besent through email at and [email protected] forearly finalisation of schedule. It+-A,..u..J

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Dy. Director/MP (EM & Hyd.)for Director General (Mp)

Copy to:

L M/s Cummins lndia Limited, Cummins India Office Campus, Tower A, Znd Floor,Survey no.21, Balewadi, pune - 41,tO4SM/s GMMCO Limited, 6, G.S.T. Road, St. Thomas Mount, Chennai - 600 016 (T.N.)

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

Schedule of Standard Examination

of

1600 HP ACAC BG DEMU

Report no. MPMISC.328 (Rev. 00)

November’2017

Issued by-

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW – 226011

RDSO (MP) RDSO Report no. Rev. Month & Year

Report no. MPMISC.328

(Rev. 00) November’ 2017

ScheduleofStandardExaminationof1600HPAC-ACBGDEMU Page2

C O N T E N T S

SN DESCRIPTION Page no.

1. Preface 3

2. General Description

4

3. Part I: Schedule for Engine, Air Brake, Compressor, etc.

13

4. Part – II: Schedule for Electrical transmission & Control 30

5. Part – III: Schedule for Coach body, Underframe, Bogie,

Brake rigging etc.

39

6. Part – IV: Schedule for Carriage Electrical

46

7. Annexure – I: Maintenance of Toilets 50





Preface

1600HP ACAC DEMUs are powered by EFI (Electronic Fuel Injection) & EU StageIII A diesel

engines supplied by two different OEMs i.e. M/s Cummins India Limited, Pune (Model QSK 50) & M/s

Caterpillar, Hosur (CAT 3512C). On the request of ICF and ZR, ‘A draft Schedule of Standard

Examination of 1600HP ACAC BG DEMU’ was prepared on pattern similar to Schedule for 1400HP

DEMUs and uploaded on RDSO’s website for comments from ICF, Zonal Railways, M/s Cummins &

M/s GMMCO (Authorized Dealer of M/s Caterpillar).

Earlier, the trip schedules of ‘Traction Engine, Compressor, Electrical Transmission &

Control’ pertaining to 1400hp BG DEMUs were being carried out after 7 days. On the directives of

Railway Board vide letter no. 2016/M(L)/101/2 (BG)/Pt. D dated 21.03.2017, trials were conducted on

1400 hp BG DEMUs based at JUC / NR and BZA / SCR to study the possibility of extension of existing

trip schedule from 7 days to 10 days. Based on the satisfactory feedback, trip schedule for 1400 hp

DEMUs has been increased from 7 days to 10 days. Accordingly, the trip schedule of 1600HP DEMU

has been initially fixed as 10 days on the basis of 12 hours daily working.

Also, there is a difference between schedules of engine as recommended by respective OEMs

i.e. M/s Cummins & M/s Caterpillar. To sort out the maintenance issues, a meeting was held at RDSO

(MP Dte.) on 13th Sep.’2017 & was attended by both OEMs. Both OEMs i.e. M/s Cummins & M/s

Caterpillar submitted their comments on the draft schedule proposed by RDSO.

The proposed schedule is based on the following assumptions:

� Daily working : 12 hours

� Interval of trip schedule : 10 days

� Interval of POH of DPC : 18 months

In order to synchronize the schedules of all major components/equipments/assemblies/sub

assemblies, trip schedule ideology similar to diesel locos has been adopted. This will not only match

with the schedules prescribed by OEMs of diesel engines but also be cost effective. Based on the

above assumptions each trip schedule has been numbered as T1, T2, T3.......T54 upto 18 months.

The monthwise schedules have been marked as ‘M’ alongwith it’s interval. e.g. 3 months have been

marked as ‘3M’. Similarly, yearwise schedules too have been marked as ‘Y’ alongwith its interval. e.g.

4 Year has been marked as ‘4Y’.





SCHEDULE OF STANDARD EXAMINATION OF 1600 HP ACAC BG DEMU

General Description 1. Introduction:

1.1 The Schedule of Standard Examination for maintenance of 1600 HP ACAC BG Diesel Electric

Multiple Unit (HHPDEMU) has been prepared on the similar pattern of 1400hp DEMU

schedule.

1.2 The service periods of 1600 HP ACAC BG DEMU specified in this schedule for maintenance

attention are the maximum allowable periods between successive examinations.Variations in

operating conditions in different regions may make it necessary to carry out examination

more frequently, or to introduce examinations not scheduled herein. In such cases, the

matter should be brought to the notice of the appropriate Sr. DME/DME, who alone is

authorized to introduce any change in the standard examination detailed herein. The

Sr.DME/DME in all such cases will bring to the notice of the Motive Power Directorate of

RDSO, for any modification to the schedules, giving full details with appropriate justification.

2. References:

The following documents are also required to be referred for further information.

i) Cummins Operation and Maintenance Manual, Bulletin No. 4397530 of 2017

ii) Caterpillar Operation & Maintenance Manual, Bulletin No. SEBU844002, April’2013.

iii) Propulsion Equipments for BG DEMUs: Manuals of M/s Medha & M/s CGL.

iv) Operating Instruction and Maintenance Manual for ELGI make electric motor driven

Air Compressor Assembly model: TRC – 15070

v) INDIAN RAILWAYS: Maintenance Manual for BG Coaches, December (1995) issued by

IRCAMTECH, Gwalior.

vi) Maintenance Manual for AC/DC EMU & MEMU Bogie and Undergear Manual No.

CMIK001 (April’2000) issued by RDSO.

3. Scope of Maintenance Schedule:

This booklet covers maintenance schedule for different assemblies & components under

different heads, as under:

PART I : Engine, Air Brake, Compressor, etc.

PART II : Electrical transmission & controls.

PART III : Coach body, Under frame, Bogie.

PART IV : Carriage Electrical

3.1 General Schedules / Check sheets for Engine, Engine systems, Brake, Compressor, Air dryer

etc. have been mentioned in individual schedules of PartI.

3.2 At the end of each schedule of PartI, the schedules attention for particular equipment fitted

with 1600hp DEMUDPCs, as recommended by OEMs, have been given.

4. Periodicity of maintenance of Engine, Air Brakes, Compressor, Electrical Transmission &

Controls (for PartI & II) (assuming average running of HHP DEMU trains as 12 hrs. per day):

Periodicity of diesel engines has been mentioned in hours as recommended by OEMs as well

as in months/years as per Indian Railway’s practices so far. However, maintenance of EFI &

EUStage III diesel engines shall be carried out on the basis of periodicity occurring earlier.

S. Type of Periodicity of Periodicity of diesel engine





no. schedule Brakes,

Compressor,

Electrical

Transmission &

Controls

For Cummins engine

model QSK50

For Caterpillar engine

model CAT3512C

i. Trip Schedule Yes At end of each trip (max.

10 days)

At end of each trip

(max.10 days)

ii. Monthly Yes 1 M ± 3 days

(Also repeat trip sch.)

1 M ± 3 days (500hrs)

(Also repeat trip sch.)

iii. Quarterly Yes 3 M ± 7 days.

(Also repeat trip &

monthly sch.)

3 M ± 7 days (1000 hrs)

(Also repeat trip &

monthly sch.)

iv. Halfyearly Yes 6 M ± 10 days

(Also repeat trip,

monthly & quarterly sch.)

6 M ± 10 days (2000hrs)

(Also repeat trip, monthly

& quarterly sch.)

v. 9monthly Repeat trip,

monthly &

quarterly sch.

Repeat trip, monthly &

quarterly sch.

9 M (3000hrs)

Also repeat trip, monthly

& quarterly sch.

vi. 12monthly Repeat trip,

quarterly & half

yearly schedule

Repeat trip, quarterly &

halfyearly schedule 12 M (4000hrs)

Also repeat trip, monthly,

quartly. & half yearly sch.

vii. 18monthly 18 M

(for Compressor &

Air dryer)

Also repeat trip,

quarterly & half

yearly schedule

18 M

(Also repeat trip,

quarterly, halfyearly and

Nine monthly schedule)

18 M (6000hrs)

(Also repeat trip,


Nine monthly schedule)

viii. 24monthly /

2Y

Repeat trip,

quarterly & half

yearly schedule

Repeat trip, quarterly &

halfyearly schedule 24 M / 2Y (9000hrs)

(Also repeat trip,


yearly schedule)

ix. 54monthly Repeat the above

schedules

(Repeat the above

schedules)

Only injector to be replaced

at

20,000 hrs / 54M

(Engine schedule Matching

with

3rd

POH of DPC)

Repeat the above

schedule upto 18,000 hrs

/ 54M or 4.5Y

(1st

Top end overhaul)

(Engine schedule

Matching with

3rd

POH of DPC)

Remarks Repeat the above

schedules up to 40,000

hrs

/ 108 M or 9Y

(Matching with 6th

POH

of DPC)

� 2nd

Engine POH at

36000 hrs / 96 M or 8Y

(Matching with

6th

POH of DPC)

� 3rd Engine POH at

54000 hrs/144M or 12Y

(Matching with

8th POH of DPC

� 4th

Engine POH at

72000 hrs/192M or 16Y

(Matching with

11th

POH of DPC)





5. Type and periodicity of schedules of Coach body, Under frame, Bogie assembly, Brake

rigging (for PartIII):

i) Primary : After 3500 km or 10 days, whichever is earlier (for bothDEMU with

toilet / DEMU without toilet). Maintenance of toilets to be done

during various schedules as per AnnexureI, enclosed at the end of

this schedule. ii) Schedule ‘A’ : 1 month ± 3 days

iii) Schedule ‘B’ : 3 months ± 7 days.

iv) IOH : 9 months ± 15 days.

6. Type and periodicity of schedules of Carriage Electrical (for PartIV)

i) Primary : After 3500km or10 days (for DEMU with toilets / without toilets) ii) Monthly : 1 month ± 3 days

iii) Quarterly : 3 months ± 7 days.

iv) IOH : 9 months ± 15 days.

7. Schedules of Periodical Overhauling(POH) of Major Items :

i) Injector for CIL engine : To be replaced every 20,000 Hrs./54M

ii) Engine for CIL engine : To be carried out every 40,000 Hrs./108M/ 9Y

iii) Engine for CAT engine : To be carried out every 18,000 Hrs./54M

iv) Traction motors : 18 months (to coincide with POH of DPC).

v) Traction Alternators : 36 months (to coincide with alternate POH of DPC).

vi) Compressor : 18 months (to coincide with POH of DPC).

vii) EP /air brake system : 18 months (to coincide with POH of DPC).

viii) Air dryer : 36 month (to coincide with alternate POH of DPC). (As per RDSO MP.MI.18 (Rev02) April’2008) ix) Roller bearing : 18 months (to coincide with POH of DPC).

x) Ebeam cables: All conventional cables (Control & Power) should be

replaced by Ebeam cables as per RDSO’s Instruction

Bulletin no. MP.IB.EM.07.14.08 dated 25.04.08 during

POH of DPC.

7.1 Miscellaneous Schedules of Compressor:

S.N Type of Schedule

Interval Items to be checked

i. 18 months schedule

18M Motor bearing regrease.

ii. 36 months schedule

3Y /

Matching with

2nd

POH of

DPC

i. Replace filter element

ii. Replace the piston rings

iii. Replace the valves

iv. Replace the Oil seal and all gaskets

v. Replace the breather valves

vi. Check the cylinder and replace if required.

iii. 48 months

schedule

4Y / Matching

with 3rd

POH

ofDPC

i. Replace Aluminium piston.

ii. Replace the Cylinder.

iii. Replace the Aluminium Cooler.

iv. 72 months

schedule

6Y/4th POH of DPC

Replace the Crankshaft assembly in 72 month.

8. Based on the recommendations of OEMs, the periodicity of change of filters and oil in various

systems of 1600HP ACAC DEMU, their specification and source of supply are summarized

below for information:





8.1 Periodicity of Filters & Oil change of Engine systems, as recommended by OEM:

The periodicity of Filters & Oil change of engine systems, as recommended by OEMs, is as follows:

S.No Description Periodicity (for CIL engine ) Periodicity (for CAT engine)

1. Lube oil system

a. Engine lube

oilfilter

NA 500 hrs. subjected to differential

pressure, it should not be more

than 15 psi.

b. Engine Lube oil 1000 hrs or every quarter,

whichever is earlier.

500 hrs subjected to differential

pressure, it should not be more

than 15psi. Can be extended as

per Schedule of sampling (SOS)

report.

c. Eliminator &

Centrifuge

1000 hrs or every quarter

whichever is earlier

NA

2. Fuel system

a. Fuel filter 750 hrs or bimonthly,


500 hrs subject to differential

pressure, should not be more than

15 psi.

3. Cooling system

a. Coolant filter 750 hrs or bimonthly,


NA

4. Air intake system

a. Air filter 1500 hrs. or at every 4 months,


1000 hrs or 3 months,

whichever earlier

5. Hydraulic System

a. Hydraulic Oil Filter

change

Every bimonthly After every 3000 hrs or 6 months

b. Hydraulic Oil

change

After every 9 months After every 5000 hrs or Yearly

8.2 Periodicity of Filters & Oil change for CIL engine (according to Trip):

Trip (CIL) Engine

Lube oil

Filter

Engine

Lube oil

Eliminator

&

Centrifuge

Fuel

Filter

Coolant

Filter

Air

Filter

Hydraulic

Oil filter

Hydraulic

Oil

T1 NA

T2 NA

T3 NA

T4 NA

T5 NA

T6 NA √ √ √

T7 NA

T8 NA

T9 NA √ √

T10 NA

T11 NA

T12 NA √ √ √ √

T13 NA

T14 NA





Trip (CIL) Engine

Lube oil

Filter

Engine

Lube oil

Eliminator

&

Centrifuge

Fuel

Filter

Coolant

Filter

Air

Filter

Hydraulic

Oil filter

Hydraulic

Oil

T15 NA

T16 NA

T17 NA

T18 NA √ √ √ √ √

T19 NA

T20 NA

T21 NA

T22 NA

T23 NA

T24 NA √ √ √

T25 NA

T26 NA

T27 NA √ √ √ √

T28 NA

T29 NA

T30 NA √ √ √

T31 NA

T32 NA

T33 NA

T34 NA

T35 NA

T36 NA √ √ √ √ √

T37 NA

T38 NA

T39 NA √

T40 NA

T41 NA

T42 NA √ √ √

T43 NA

T44 NA

T45 NA √ √

T46 NA

T47 NA

T48 NA √ √ √

T49 NA

T50 NA

T51 NA

T52 NA

T53 NA

T54 NA √ √ √ √ √ √ √





8.3 Periodicity of Filters & Oil change for CAT engine (according to Trip)

Trip

(Caterpillar)

Engine

Lube

Oil

Filter

Engine

Lube oil

Eliminator

&

Centrifuge

Fuel

Filter

Coolant

Filter

Air

Filter

Hyd.

Oil

Filter

Hyd.

Oil

Water

sep.

filt.

T1 NA NA

T2 - NA NA -

T3 - NA NA -

T4 √ √ NA √ NA √ T5 - NA NA -

T6 - NA NA -

T7 - NA NA -

T8 √ √ NA √ NA √ T9 - NA NA √ -

T10 - NA NA -

T11 - NA NA -

T12 √ √ NA √ NA √ T13 - NA NA -

T14 - NA NA -

T15 - NA NA -

T16 √ √ NA √ NA √ T17 - NA NA -

T18 - NA NA √ √ -

T19 - NA NA -

T20 √ √ NA √ NA √ T21 - NA NA -

T22 - NA NA -

T23 - NA NA -

T24 √ √ NA √ NA √ T25 - NA NA -

T26 - NA NA -

T27 - NA NA √ -

T28 √ √ NA √ NA √ T29 - NA NA -

T30 - NA NA -

T31 - NA NA -

T32 √ √ NA √ NA √ T33 - NA NA -

T34 - NA NA -

T35 - NA NA -

T36 √- √ NA √ NA √ √ √ √- T37 - NA NA -

T38 - NA NA -

T39 - NA NA -

T40 √ √ NA √ NA √ T41 - NA NA -

T42 - NA NA -

T43 - NA NA -

T44 √- √ NA √ NA √-





Trip

(Caterpillar)

Engine

Lube

Oil

Filter

Engine

Lube oil

Eliminator

&

Centrifuge

Fuel

Filter

Coolant

Filter

Air

Filter

Hyd.

Oil

Filter

Hyd.

Oil

Water

sep.

filt.

T45 - NA NA √ -

T46 - NA NA -

T47 - NA NA -

T48 √ √ NA √ NA √ T49 - NA NA -

T50 - NA NA -

T51 - NA NA -

T52 - NA NA -

T53 - NA NA -

T54 √ √ NA √ NA √ √ √

8.4 Periodicity of Filters & Oil change of Compressor:

S. no. Description Half yearly 18 monthly

1. Filter change � * **

2. Oil change �

* If condition warrants.

** Filter element shall be replaced in 18 months on condition basis. First time oil change of

new compressor shall be carried out in 01 month time.

8.4 Recommended Lubricants for Engine lube oil:

S.No. Name of Manufacturer Grade of oil

(for CIL QSK 50L engine)

Brand name

(for CAT 3512C engine)

i. Indian Oil Corporation 15W40,CI4+Equivalent

ii. Hindustan Petroleum

Corporation

15W40,CI4+Equivalent

iii. Bharat Petroleum Corporation 15W40,CI4+Equivalent

iv. Valvoline Cummins Limited Valvoline Premium

Blue 15W40,CI4+

v. M/s Caterpillar Cat DEO 15W40 CI4 or

CH4

8.4 Recommended Coolant for engine.

S.No Name of Manufacturer Brand name

( for CIL QSK50L engine)

Brand name

( for CAT3512C engine)

i. M/s Cummins India Ltd. Compleat EG 50:50

PREMIX

ii. M/s Caterpillar Cat ELC 50/50 Premix

8.5 Recommended Hydraulic oil for cooling system of engine.

S.No Name of Manufacturer Brand name

( for Cummins QSK50L

engine)

Brand name

( for Caterpillar Cat

3512C engine)





i. Indian Oil Corporation Servo System68

ii. Hindustan Petroleum

Corporation

Enklo68

iii. Bharat Petroleum

Corporation

Hydrol68

iv. M/s Caterpillar Cat HYDO Advanced 20

8.6 Cleaning of Hydraulic oil :

The hydraulic oil is required to be periodically cleaned by Centrifuge Cleaning arrangement.

During oil change and also during topup, oil should be added through Centrifuge Cleaning

arrangement so that cleanliness of oil is maintained.

8.7 High speed Diesel:

The high speed diesel oil shall be to IS 1460: 1995 read with Amendment 2 (February’1999).

9. Recommended oils for coaches of DPC&TC :

9.1 Dashpot & side bearer oil

Supplier Brand Name

IOC Servoline 100

BPC Bharat Univol 100

HPC Yantrol 100

10. General Instructions :

10.1 The intensive utilisation of the HHPDEMUs necessitates properly laid down maintenance

schedules to be followed. A well organized inspection is essential to ensure reliability and

freedom from failure in service.

10.2 There are certain fundamental requirements that are important to any successful

maintenance programme. These are:

10.2.1 Adequate provision of well trained supervisors and skilled workmen.

10.2.2 Adequate provision of proper maintenance facilities and tools.

10.2.3 Adequate time for scheduled maintenance work to be completed properly before a

HHPDEMU is released for its next trip.

10.2.4 Provision of lubricating oil, water treatment etc. required to ensure satisfactory engine

performance.

10.2.5 A well scheduled maintenance programme including an adequate system of maintenance of

records.

10.2.6 While carrying out the work of the schedule, all missing nuts, bolts, setscrews, cotters, split

pins etc. must be REPLACED, as and when found defective. Split pins and cotters once

removed should not be used again and new ones must be fitted. All loose nuts, set screws

etc. must be tightened. Wherever cotters or split pins are fitted, they must be of the correct

size and so fitted that they bear against the nut or washer properly. Examine and ensure that

all locking devices, wherever provided, are properly secured.





10.2.7 All measuring devices such as torque wrenches, electric meters, lubricant dispensers etc.

which require calibration should be checked one yearor sooner, if required, for accuracy.

10.2.8 All tools and parts should be accounted for and removed from the HHPDEMU after any

maintenance work has been performed.

10.2.9 All work done including methods and tools used must be in accordance with the

manufacturers instructions, maintenance manual or any technical orders issued.

10.2.10 Do not mix different brands of engine oil, hydraulic oil, and gear oil. Excessive lubrication is

as harmful as inadequate lubrication.

10.2.11 Use of waste cotton on HHPDEMU is PROHIBITED. Use lint less rags or wiping towels. Exterior

of HHPDEMU is to be washed after each trip. The underframe and top surface of fuel tanks

should be cleaned to remove dirt and oil. Spraying of water directly on electrical equipment

should be avoided. Interior of cab, all windows, head/light and warning light lenses and

interior of the passenger compartment etc., must be thoroughly cleaned.

10.2.12 The fire extinguishers should be refilled and maintained as per the schedule. Under no

circumstances should any HHPDEMU be allowed to leave the shed without requisite number

of fire extinguishers in working order.

10.2.13 DURING ANY SCHEDULE EXAMINATION, ALL THE ITEMS OF THE LOWER SCHEDULES SHOULD

ALSO BE CARRIED OUT.

10.2.14 Columns of Condition/Action, Signature and Remarks to be added against each item so the

schedules given ahead in this report. Also, Name and Signature of Technicians & Supervisors

should be added at the end of the each schedule form.





Part – I

Schedule for Engine, Air Brake, Compressor etc.

Trip Schedule (10 days) DPC/TC/TCV No: Cumulative km.

Date : Cumulative hrs.

S. No Details of work to be carried out

A. CONDITION: DIESEL ENGINE STOPPED

1. Oil & Water filling Check and topup if necessary: a) Lube oil b) Fuel oil c) Coolant d) Hydraulic oil e) Compressor oil

2. Drain residue from : a) Air reservoirs. b) Intercooler of compressor. c) After cooler of pneumatic circuit.

3. Engine fuel system Drain sediments from water separator.

4. Check and clean fuel tank level gauge.

5. VBelts Check the belts provided for Hydraulic ventilation fan pump drive for correct tension and serviceability.

6. Engine air intake system a) Remove and clean dust pan. b) Check for complete red band on vacuum indicator. Clean outer element only with dry

compressed air from inside to outside. Note: Replace outer element after 4/5 cleanings or as soon as red band appears immediately even after cleaning.

7. Clean the following items with dry compressed air. a) Panel filter (engine room). b) Outer body of engine air intake filters.

8. Check and ensure proper fitment of hose securing clamp and hose end fittings.

B. CONDITION : DIESEL ENGINE RUNNING

9. Mechanical (General examination) a) General visual checking to be made to detect loose, defective, missing or leaky parts in

the following systems: i) Cooling water ii) Lube oil iii) Fuel oil iv) Air intake & exhaust v) Hydraulic vi) Pneumatic

b) Ensure proper working of all gauges. (DPC)

10. Check and ensure that hydraulic valve is fully open.

11. Check radiator fan Hydraulic oil pressure & temperature For CIL enginePressure : 150 170 bar

Temperature : Not more than 70°C

12. Check operation of compressor to ensure that there is no noise and vibration.

13. Check and record: Idle 1800 rpm

Engine lube oil pressure: Permissible values; *12 kg/ cm.2 *37 kg/ cm.2






*Lube oil temp: Should lie between 75°C 105°C *Cooling water temp : Not more than 95°C

14. Pneumatic system (DPC ) a) Time for charging the main air reservoir from 0 to 8

kg/cm2 with engine at idle notch

:

10 min. max.

b) Compressor governor setting i) Closed at

ii) Open at

:

:

8 kg/cm2 7.4 kg/cm2

c) Safety valve i) Blowing pressure

ii) Closing pressure

:

:

8.5 ± 0.1 kg/cm2

7.5 to 7.8 kg/cm2

d) Setting of Safety valve brake circuit i) DPC ii) TC

:

:

1.8 kg/cm2

3.8 4.0 kg/cm2

e) Setting of pressure limiting valve i) DPC ii) TC

:

:

1.6 kg/cm2

3.8 kg/cm2

f) Duplex check valve to charge horn reservoir opens at : 5.0 kg/cm2

g) Control circuit governor i) Closes at ii) Opens at

:

:

4.2 kg/cm2

3.4 kg/cm2

h) Equipment governor i) Closes at ii) Opens at

:

:

4.2 kg/cm2

3.4 kg/cm2

15. Check and record the following : a) Brake Cylinder Pressure.

i) DPC – : 1.6 ± 0.1 kg/cm2

ii) TC – : 3.8 ± 0.1 kg/cm2 b) Brake Pipe pressure : 5.0 ± 0.1 kg/cm2 c) Feed .Pipe Pressure : 7.4 ± 0.1 kg/cm2 d) Parking Brake pressure : 5.0 ± 0.1 kg/cm2

16. Full EP application: a) B.C. Pressure : 1.4 Kg/cm² (DPC) b) B.C. Pressure : 3.6 Kg/cm² (TC) c) Time for BC pressure built up : 3 to 5 secs (DPC/ TC)

17.1. Auto application time : 2.7 to 3.5 secs

17.2. Emergency application time : 1 to 2 secs

17.3. Full EP release: a) B.C. Pressure to drop to 0.2 Kg/cm² (DPC) in 5.5 to 6.5 Secs& final pressure 0 Kg/cm². b) B.C. Pressure to drop to 0.4 Kg/cm² (TC) in 5.5 to 6.5 Secs& final pressure 0 Kg/cm².

17.4. Auto release time : 5.5 to 7.0 secs

17. Leakage tests: a) Main Reservoir system with EP Brake

application 1.2 Kg/cm²/Hour from 8Kg/cm²

Observation 0.4 Kg/cm² in 20 min. b) Brake pipe system Handle at Lap/R.R.

with Br. control isolating cock closed 1Kg/cm²/Hour from 5Kg/cm²

Observation 0.4Kg/cm² in 24 min. c) Brake Cylinder (Handle Emergency, EP

switch off) 1 Kg/cm²/Hour from 3.6 Kg/cm²

Observation 0.4 Kg/cm² in 24 min.

18. Functional Test: (DPC & TC) a) A9 valve Apply & Release b) SA9 valve Apply & Release c) EP brake Apply & Release d) Auto brake Apply & Release

:Satisfactory : do : do : do






e) Emergency brake Apply & Release f) Guard’s valve Apply & Release g) Deadman’s device Apply & Release h) Brake application by opening Br. Pipe angle cock at one end – Apply &

release i) Manual release of Brake cylinder pressure after emergency application

(EP off) release of brake block j) Brake Indication lamp k) Function of foot operated horn valve l) Function of hand operated horn valve m) Function of Horn isolation n) Function of Wiper operation system/switches o) Function of Unloader valve p) Function of Auto drain valve q) Function of manual drain cock r) Function of isolating cock with vent s) Function of end angle cocks

: do : do : do : do : do : Effective

:Satisfactory : do : do : do : do : do : do : do : do

Trip schedules for individual make and model of engines fitted with 1600hp DEMUDPCs:

CONDITION: DIESEL ENGINE STOPPED

S. no. Details of work to be carried out Condition /Action Remarks

For Caterpillar CAT3512C engine (every 250hrs. Service)

1. Check & collect coolant sample

2. Check & collect lube oil sample

3. Inspect & clean air filter outer element only

4. Check water separator & drain water from fuel system

5. Check tightness of belts

6. Check tightness of mounting system

For Cummins QSK50 engine

1. Crankcase Breather TubeCheck

2. FuelWater SeparatorDrain

3. Lubricating Oil level Check

4. Air Cleaner PrecleanerClean

5. Air Intake PipingCheck

6. Air Cleaner RestrictionCheck

7. Air tank and ReservoirsDrain

8. Drive BeltsCheck

9. Fuel Filter, Remote Mounted2Drain

10. Fuel Filter, Remote Mounted2Check

11. Hydraulic tank provided with Cummins QSK50 engine:

Check filter clogging sensor for 75% clogging indication

on return line filter on hydraulic tank. If 75% found,

change the filter.





Air Dryer:

Maintenance schedule of air dryer shall be done in the following schedule (Ref. Doc. RDSO MP.MI18

Rev. 02, April2008):

S.N Items to be checked Condition/action Remarks

TRIP SCHEDULE

1. Open drain cock of final filter to drain off any accumulated water content

2. Check the colour of humidity indicator

It indicates condition of air after passing through air dryer. Indication of various colourare as under. Blue colour Dryer is performing correctly Lavender Dryer is suspect Verify dryer is cycling. If dryer is cycling correctly and auto drain valve of main reservoir No.1 is operating correctly, release the DEMU for service White Possible damaged dryer Verify dryer is cycling. Remove humidity indicators and look for desiccant dust or residue on inside of manifold and humidity indicators. If desiccant dust or residue is seen– Remove dryer for attention. If no desiccant dust or residue is seen on inside of manifold Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly Release DEMU for service. Yellow or Brown colour Damaged dryer It indicates that desiccant has been contaminated with oil. Replacement of coalescing element and desiccant is required.

3. Check auto drain of main

reservoir No.1

It should function properly.

4. Check electrical connection of air dryer and their tightness.





Part – I


Monthly Schedule

DPC/TC/TCV No.: Cumulative km.

Date: Cumulative hrs.

S.

No Details of work to be carried out

A. CONDITION: DIESEL ENGINE STOPPED

1. General check : Check tightness of foundation/ mounting bolts of the following :

a) Engine, b) Radiators, c) Compressor d) Radiator &Ventilation fan. e) Inlet & Exhaust manifolds.

2. Fuel inlet connection screens : Check and clean magnetic filter screens in fuel system.

3. Clean and inspect. Replace, if damaged. a) Crank case breather, b) Compressor breather, c) Fuel Tank breather, d) Hydraulic Tank breather.

4. Hydraulic oil: Hydraulic oil to be checked for water contamination by draining sample from the bottom plug and see if cloudiness is observed in the oil.

5. Compressors (TRC 15070) a) Remove and cleansuction filter thoroughly. b) Check for any abnormal noise in compressor (Every month).

Note: i. Check oil level and Topup if required (Every 02 month).

ii. Visible check for wire rope isolator (AVM) (Every 02 month). 6. Check air piping. Visually inspect hoses, pipes for damages/cracks and clamps for looseness.

7. Test and refill the fire extinguishers if necessary.


8. Cooling water system Check that vent pipes in the system are open.

9. Check working of radiator fan: Radiator fan RPM should be measured by inserting tachometer at fan shaft. Side mounted Min. : 750 Radiator Max. : 1600 Vent Fan Max. : 1200

10. Check safety valve operation of compressor. (9.0 kg/cm2)

Monthly schedules for individual make and model of engines fitted with 1600hp DEMUDPCs:

CONDITION: DIESEL ENGINE STOPPED

S. no. Details of work to be carried out Condition /Action Remarks

For Caterpillar CAT3512C engine (Every 500 hrs. service)

1. Repeat trip schedule

2. Replace fuel filter –subject to differential

pressure

Differential pressure

should not be more

than 15psi (1.054604

kg/cm2). (1psi =

0.070307 kg/cm2)

3. Replace lube oil & filter–subject to

differential pressure

do





4. Inspect / replace water separator filter

subject to diesel quality

Filters can be used up

to1000hrs.

5. Check battery electrolyte level & connections

6. Change lube oil15W40CH4 subject to SOS Use only 15W40 CH4

Grade Lube oil.

Change period can be

extended as per SOS

report.

7. Replace seal lube oil filter Change

8. Replace seal fuel filter Change


1. Engine oil sample – Obtain, Inspect. Inspection bi

monthly

Oil Analysis

2. Hydraulic Oil sample, Inspect. Inspection bi

monthly

Oil Analysis

3. Air filter – Inner & Outer Element Replace every 4

months

4. Change the following filters as per mentioned schedule :

a) Engine fuel filter – i. Stage 0 ii. Stage 1 iii. Stage 2

b) Coolant filter c) Hydraulic filter

At every 02 months, replace

5. Coolant:

a) Check coolant with Complete EG Test Strip

b) Complete EG connection level to be maintained between 0.3 to 1.3 units/liter

c) The coolant water should be changed at 6000hrs or when hardness total and total chloride content exceeds the following limits:

d) Total hardness : 170 ppm as CaCO3 e) Cholrides : 40 ppm as NaCl f) PH : < 7

Air Dryer:




Monthly Schedule

1. Repeat all the items of Trip schedule.

2. Check cyclic operation of air dryer.

While the dryer is cycling, there should be a slight and continuous exhaust from the relevant purge valve. After predetermined cyclic time, exhaust from the purge valve stops and that of the second tower starts exhausting. This cycle should be reversed after cycle time. The cycle timings of various makes of air dryer are as under:





FTIL air dryer 1 minute drying and 1minute regeneration Stone India Ltd. air dryer do KnorrBremse air dryer 2 minute drying and 2 minute regeneration

3. Check Memory Feature When compressor gets unloaded purging of air should stop and when compressor again gets loaded purging should continue.

4. Examine the drain valve on the sump of pre coalesce

With the dryer operation, the drain valve must expel a short burst of air once a minute (each cycle).





Part – I


Quarterly Schedule DPC/TC/TCV No.: Cumulative km.


Repeat all checks of Monthly Schedule

S.


A. CONDITION : DIESEL ENGINE STOPPED

1. Compressors

i. Remove and clean air filter elements.

ii. Clean breather valve.

2. A9 & SA9 brake valves for DPC & TC

Lubricate brake valve cams.

3. Pneumatic System :

a. Clean aftercooler externally by blowing compressed air.

b. Blow down air reservoirs with compressed air and clean.

B. CONDITION: DIESEL ENGINE RUNNING

4. Check for leakages in all the systems.

Quarterly schedules for individual make and model of engines fitted with 1600hp DEMUDPCs:

CONDITION: Diesel Engine Stopped

S.

no.

Details of work to be carried out Condition /Action Remarks

For Caterpillar CAT3512C engine (Every

1000hrs service / every 3 months, whichever

is earlier.)

1. Repeat 500 hrs. service

2. Check & inspect engine protective

device.

3. Replace water separator Max. life of water separator

4. Clean crankcase breather

5. Replace air cleaner element outer Outer element can be cleaned

max. 6 times with carefully &

differential pressure should not

be more than 6.2 kPa

(0.063222kg/cm2). (1kPa =

0.010197 kg/cm2)

6. Replace air cleaner element inner Inner element need to change

every 3 cleaning of outer

element.


1. LubricatingoilChange Replace

2. Fan ,Cooling Check Check

3. Supplemental Coolant Additive check Check

4. Engine Support Bracket,FrontCheck Check

5. Engine Mountscheck Check

6. Water Pump Weep Hole Filtercheck Check





7. Fleet guard Weep Hole FilterCheck Clean

8. Replace air cleaner inner & outer filter

elements

Change after 1500 Hrs. or 4

month

Air Dryer:




Quarterly

1. Repeat all the items of Monthly schedules.

2. Charge the system from zero pressure and check the dryer does not cycle immediately. Note the pressure when the dryer starts cycling.

Pressure settings of start of cyclic operation are as under: FTIL air dryer 7.0 kg/cm2 SIL air dryer 7.0 kg/cm2 KnorrBremse air dryer 4.6 kg/cm2





Part – I


HalfYearly Schedule DPC/TC/TCV No.: Cumulative km.


Repeat all checks of Quarterly Schedule

S.


A. CONDITION : DIESEL ENGINE STOPPED

1. Hydraulic system

a. Check return line filter element.

b. Clean and check strainer for external damage. Change if necessary.

2. Compressor:

a. i. Clean filter element.

ii. Crank case oil to be changed.

b. Crankcase oil to be changed.


3. Check for leakoffs from pumps in the hydraulic systems. Remove leakoff hose and collect oil in

measuring jar for one minute.

4. Check for leakages in the system.

HalfYearly schedules for individual make and model of engines fitted with 1600hp DEMUDPCs:


S. no. Details of work to be carried out Condition

/Action

Remarks

For Caterpillar CAT3512C engine (Every 2000hrs service / 6

months, whichever is earlier)

1. Repeat 1000hrs/ quarterly schedule

2. Engine cleaning

3. Check vibration damper

4. Clean radiator with compressed air

5. Engine mounts inspection

6. Driven equipment check


1. Fleet guard centrifuge & Eliminatorclean Clean

2. Coolant heater (J&K DEMU Only) Check

3. Battery Check

4. Battery cablescheck Check

Air Dryer:




Half Yearly Schedule

1. Repeat all the items of Monthly schedules.





2. Charge the system from zero pressure and check the dryer does not cycle immediately. Note the pressure when the dryer starts cycling.

Pressure settings of start of cyclic operation are as under: FTIL air dryer 7.0 kg/cm2 SIL air dryer 7.0 kg/cm2 KnorrBremse air dryer 4.6 kg/cm2





Part – I


Nine Monthly Schedule (9 monthly) DPC/TC/TCV No.: Cumulative km.


Repeat all checks of Trip, Monthly& Quarterly Schedule

Applicable for Only Cummins QSK50 engine

S.


C. CONDITION : DIESEL ENGINE STOPPED

Hydraulic system

Change Hydraulic Oil

3rd

Quarterly or 3000 Hrs. Engine Service

(Applicable for Caterpillar CAT3512C engine only)

Every 3000 Hrs Service/ 9 monthly Condition /Action Remarks

1. Repeat 1000 hrs Service

2. Hoses & Clamps Inspect/ Replace

3. Change Coolant if used Diesel Engine Aid Cooled(DEAC )

4. Add Coolant If used Extended Life Coolant (ELC)

5. checked hydraulic lines & coolant joints

6. Replace Hydraulic Filter and check hydraulic oil/Replace





Part – I

Schedule for Engine, Brake Power, Compressor etc.

Yearly Schedule (12 monthly schedule) DPC/TC/TCV No.: Cumulative km.


Repeat all checks of Trip, Monthly, Quarterly Schedule, Half yearly.

4th

Quarterly or 4000 hrs Engine Service

(Applicable for Caterpillar CAT3512C engine only)

Every 4000 hrs service/Every Year whichever is earlier Condition /Action Remarks

1. Repeat 2000 hrs service

2. Engine Valve lash Check and adjust ( Tappet Seal)

3. Speed sensor Clean/ Inspect

4. Prelube Pump check & Inspect If fitted

5. Starting Motor Check & Inspect

6. Fuel Injectors Inspect & Adjust

7. Change Hydraulic oil





Part – I


EighteenMonthly Schedule (18 months)

DPC/TC/TVC No.: Cumulative km.


Repeat all checks of Trip, Monthly, Quarterly& Halfyearly Schedule.

S.No Details of work to be carried out Condition/action Remarks

Air Intake & Exhaust System

1. Turbocharger

i) Check oil leakages through intake & exhaust

seals.

ii) Check turbocharger shaft end clearance with a

dial depth gauge.

iii) Repair the turbo with repair kit.

Inspect & reuse

2. Check for leakage in air intake system, if any,

rectify the same with necessary parts.

Check

3. Replace air cleaner inner & outer filter elements Check

4. Check vacuum indicators for functioning of

reset button & external damages and replace if

necessary

Check

5. Check for leakage from exhaust system, if any,

rectify the same with necessary parts.

Check

6. Check & replace hoses & clamps of air intake

pipings on condition basis.

Check

7. Check air intake and exhaust piping supports.

Take corrective action accordingly.

Check

8. Clean the engine room panel filters by dry

compressed air and replace if necessary.

Check

Fuel System

1. Water separator assembly. Replace For CIL engine only:

Stage 0, 1 &2 2. Replace fuel filter element. Replace

3. Replace all fuel line hoses. Check

4 Check fuel lines & connections for leakage. Check

5 Clean thoroughly fuel tank with steam and

detergents and dry the tank with air blast.

Clean

Lubricating Oil System

1. Replace engine oil.

Replace

2. Replace all oil line hoses & clamps. Check

4. Check external oil leakage from head

gasket/rocker housing gasket, seals, etc. If

necessary, replace the same.

Cooling System





1. Flush cooling water tank. Replenish with CAC and

water.

For CIL engine:Flush cooling water tank. Fill up

with premix Compleat EG 50:50.

Replace Coolant filter.

2. Replace water pump drive belts. NA for CIL engine

3. Replace all hoses, clamps & coupling ORings of

cooling system pipe lines and radiator assembly.

Check & replace

4. Remove radiator assembly (SMR) from the

mounting & clean the radiator assembly.

Clean

5. Check all radiator Anti Vibration Mountings and

replace if necessary.

Check for physical

damage

Hydraulic System

1. Replace hydraulic oil. Ensure that oil cleanliness

level is of NAS1638 Class 9 or better

Replace every 9

months

2. Replace hydraulic oil return line filter. Replace

6. Externally clean & check leakoffs from main

hydraulic & ventilation pump at rated speed.

Check

Externally clean & check leakoffs from main

hydraulic & ventilation motor at rated speed.

Check

7. Externally clean & check radiator fan operation Check

8. Externally clean & check vent fan operation Check

9. Hoses:

i) Replace all hydraulic pressure line

hoses.

ii) Replace all hydraulic leakoff &

return line hoses on condition basis.

Check

10. Clean hydraulic oil cooler externally. Clean

11. Check & set hydraulic system pressure at 170 bar Check

12. Check Vibration damper, replace if necessary. Check

13. Carry out repairs advised by Shed in Pre

Shopping report.

CONDITION : DIESEL ENGINE RUNNING

14. Carry out the load box test to check the

performance of engine.

15. Check for the leakages in various systems.

18Monthly schedules for individual make and model of engines fitted with 1600hp DEMUDPCs:


S.

no.


For Caterpillar CAT3512C engine (Every 6000hrs service/ half

yearly schedule)

1. Repeat 2000hrs service

2. Change Extended Life Coolant (ELC)

3. Coolant temperature regulator replace (920C)

4. After cooler line temperature regulator (470C)

5. Speed sensor alongwith all other sensors, clean & inspect.


1. Replace Coolant Replace





2. Water Pumpcheck Check

3. Turbocharger, Inspect Check

Compressor:


18 months schedule:

Motor bearing regrease.

Note: For other schedules, after 18 monthly schedules, pl. see para no. 7.1 of General Description of this schedule.

Air Dryer:




Eighteen Monthly Schedule

1. Repeat all the items of Quarterly/ Half Yearly schedules

2. Replace consumables as per respective manufacturer’s recommended replacement kit

Please see AnnexureIII of Ref. Doc. RDSO MP.MI18 Rev. 02, April2008 for list of items to be replaced.

3. Clean external muffler connected with purge valves.

Follow the instructions given in maintenance manual of respective manufacturers.

4. Check condition of each pipe assembly and their tightness.

Note –

(a) Overhaul the complete air dryer and change desiccant during alternate Eighteen Monthly Schedule

For overhauling follow the instructions given in maintenance manual of respective manufacturers.

(b) Replace consumables as perrespective manufacturer’s recommended replacement kit in every alternate Eighteen Monthly Schedule

Please see AnnexureIII of Ref. Doc. RDSO MP.MI18 Rev. 02, April2008 for list of items to be replaced.

(c) Test each air dryer before putting it back in to service during alternate Eighteen Monthly Schedule

Schematic diagram of test bench is given in AnnexureIV of Ref. Doc. RDSO MP.MI18 Rev. 02, April2008 List of tests to be conducted and format of record to be maintained is given in Annexure V of Ref. Doc. RDSO MP.MI18 Rev. 02, April2008 For further details, specification No. MP.0.01.00.06may be referred.





Part – I


Two Yearly Schedule (24 months)

DPC/TC/TVC No.: Cumulative km.


Repeat all checks of Yearly Schedule.


S.

no.


For Caterpillar CAT3512C engine (Every 8000hrs service/ Every

2yearly schedule, whichever is earlier)

1. Repeat 4000hrs service/ yearly service

2. Charging alternator check and inspect

3. Turbocharger check, clean & inspect

4. Water pump check & inspect





Part – II

Schedule of Electrical Transmission & Controls

Trip Schedule (10 days) DPC No. Cumulative kms

Dated Cumulative hours

S. No Items to be checked

1. Check Driver Log Book for any repair / problem booked by Driver.

2. Check following items for unusual sound, high temperature and odour when DPC is ON.

a) Traction motor TM1, TM2, TM3, TM4.

b) Traction alternator

c) 110V Aux. Alternator

d) Rectifier blower motor

e) 24 Volt Battery Charging Alternator

3. Open all Control Panels, Control Desk doors and all electrical components when DPC is

in "OFF", and blow with dry compressed air at 3kg/cm 2.

4. Check the following items working :

a) Flasher lights, Headlight, tail light & marker light, emergency headlights.

b) Horns

c) Wipers

d) Proper working of Fans, Normal lights, Emergency lights in Driver Cab and Coaches

e) Check the Emergency Bell ring and PAS indication on every Passenger Alarm Chain pull in DPC & TC.

f) Deadman Handle release.

g) Working of DCS.

h) Working of GCS.

i) LED Indication Panel

j) Signal bell

k) Emergency bell

l) Ensure ERS switch is in OFF and sealed condition.

m) EP brake supply

n) Excitation switches FB.

o) WTB Communication between Lead and Remote DPC's.

p) Proper securing of A,B, D Couplers

q) All switches, Push – buttons, MCBs ( Control Panel & Control Desk)

r) Check working of Indication Lights on Control Desk/ Driver Desk by indication test switch.

s) RCD TB, RCD panel for burning marks.

t) Replace Fused/Deficient Lamps/Tube Lights.

5. Check V belts for correct tension and serviceability.

Auxiliaryalternator (110 volts).

Auxiliaryalternator (24 volts).

6. 24V Battery Checking:

a) Select the pilot cell/ battery in a set, which will represent the characteristics of other cells, Rotate the pilot cell monthly so that all the cell will be covered in a year.

b) Check the firmness of vent plug.

c) Check the condition of vent plug. Replace if it is broken.

d) Check for any broken container / cover. Remove and replace with good one, as it will damage the battery box.

d) Check for any dust accumulation on cell cover, vent plug and any corroded connectors. Take immediate action.

e) Check voltage setting on board and proper functioning of ammeter and voltmeter.

f) Electrolyte should be maintained up to green mark of level indicator fitted on each cell.







a) Check for Bypassing of failed cellsIf by passed cells are found replace these failed immediately with the healthy cell.

b) Dust accumulation – if observed, clean with dry cotton cloth.

c) Cell cover / container cracked or burst – if noted replace the cell with a healthy cell immediately.

d) In case of battery terminal / cables over heating sign. Check for loose connection at the cell terminal post/ cable end if required replace the cable immediately.

e) Charge the batteries with external source if Train detention for long time.

f) Do not charge the cells for more than 12hrs.

8. 24V Alternator Checking:

a) Check Carbon Brushes/ Pig Tail.

b) Check Brush Holder.

c) Check and Clean Commutator.

d) Record details of Commutator for any flash marks.

9. Ensure all Covers are with Gaskets, Intact & properly closed:

a) Control Panel (CP).

b) Control Desk (CD).

10. Check the electronic governor in each notch (engine)

a) Raise the notch from 1st

to 8th

and check the indication on HMI panel

b) Check RPM of engine from the RPM indicator in the cab.

1st notch – 750, 2nd notch – 1000

3rd

notch – 1200, 4th

notch – 1300

5th

notch – 1400, 6th

notch – 1500

7th

notch – 1650, 8th

notch –1800

11. Check charging rate and voltage of auxiliary generator in each notch.

Charging voltage should be above 110 Volt

12. Record voltage of 24 volt alternator in each notch

Voltage of 24 volt alternator should be Min – 25 V and Max 27 V.

13. Check electrolyte level of batteries.

Electrolyte level should be maintained up to green mark of level indicator fitted on each

cell.

14. Clean rectifier box with dry compressed air at 3 kg/cm2.

15. Check Traction Motor and Cables

a) Inspect all cable cleats for broken studs, excessive tightness and rubber cleat damage

b) Inspect TM1, TM2, TM3, TM4 Speed & Temperature sensor plugs for correct locking.

c) Inspect TM1, TM2, TM3, TM4 air duct (Bellows) and fixing bolts for damage.

d) Ensure TM1, TM2, TM3, TM4 cables are routed properly and there is no excess/short

cable over hangs.

e) The electric connecting cables should be verified for external damage.

f) Apply insulation/spacers at all locations where cables are rubbing each other and with

locomotive body.

g) Visually inspect the traction motor for external damage.

h) Repair or change the damaged mounting parts and suspension elements

i) Replace parts if any corrosion observed.

j) External screws must be checked for tightness.

k) Check traction motor electric supply connections and ensure that contact is secure.

l) Clean the Gear Box Oil Level Indicator and Oil Filling Plug.

m) Check the Oil level; if necessary add oil upto maximum level.

16. Check roller suspension bearing – on Traction motors.

a) Non contact type laser gun.






b) Check for loose or missing bolts

c) Check for missing or damaged grease nipple

17. Check proper securing of train line couplers

18. Conduct the following SELF Test:

a) ENGINE OVER SPEED TRIP TEST.

b) ENGINE ACTUATOR TEST.

c) CONTACTORS AND RELAY TEST.

d) EXCITATION TEST.

19. Check the following Functionality:

a) Operation of Self Engine Start & Stop from Display.

b) Driver and Guard Control Switch.

c) WTB Communication between Lead and Remote DPC's.

20. Check working of Load Meter in both directions at 1st

notch in both DPC's and note down the readings.

L E A D

Parameter

FOR Direction

REV Direction

Parameter

FOR Direction

REV Direction

Parameter

FOR Direction

REV Direction

NOTCH DCLI TI1UPI Eng Rpm BATV110 TI1VPI DCLV Trq Ref1 TI1WPI EXFI Trq Trq Ref2 TI2UPI AAIS Trq Trq Fbk1 TI2VPI KW ref Trq Fbk2 TI2WPI KW fbk THP

R E M O T

E

Parameter

FOR Direction

REV Direction

Parameter

FOR Direction

REV Direction

Parameter

FOR Direction

REV Direction

NOTCH DCLI TI1UPI Eng Rpm BATV110 TI1VPI

DCLV Trq Ref1 TI1WPI EXFI Trq Trq Ref2 TI2UPI AAIS Trq Trq Fbk1 TI2VPI KW ref Trq Fbk2 TI2WPI KW fbk THP

21. Perform the DEMU run test and ensure all TM RPM's are equal.

• DPC1

TM1 RPM TM2 RPM TM3 RPM TM4 RPM FOR REV FOR REV FOR REV FOR REV

5. • DPC2 TM1 RPM TM3 RPM TM3 RPM TM4 RPM FOR REV FOR REV FOR REV FOR REV

22. Critical fault information if observed and action taken, while DEMU RUN check.

FAULT REMARK





Part – II


Monthly Schedule (One month) DPC No. Cumulative kms


S. No. Items to be checked

1. Carry out all Trip Schedule activities.

2. Conduct IR test as per IR test procedure.

3. Clean MPU surface.

4. Visually check for any physical damages and burning symptoms on the following

components and ensure for all the connectors proper locking / tightness, also clean if

necessary:

a) Magnetic Pick Up unit – MPU

b) RCD panel, RCD TB.

c) Check male and female pins for bent and damage, Ensure for proper locking while putting

back.

� Harting connectors in CP and CD

� WTB Harting connectors

� CPC1, CPC2, CPC3, CPC4 – Control Panel and Control Desk / Driver Desk

� Master Controller connector

d) Relays:

� AOR Alternator ON Relay

� CR Compressor Relay

� DFR Driver Function Relay

� EOR Engine ON Relay

� ACOR Another Cab Occupied Relay

� UFR Unit Fail Relay

� WFR WTB Fail Relay

� Relay Extended Interlock

e) Contactors:

� AAPC Auxiliary Alternator Protection Contactor

� EC Excitation Contactor

� ECC Engine Crank Contactor

� ESC Engine Stop Contactor

� GAPC Governor Actuator protection Contactor

� EPBC Electro Pneumatic Brake Contactor

� NBC No Bypass Contactor

f) Jet Pump Convertor Unit

g) Flasher Light Control Unit FLUC

h) Wiper Motor1, Wiper Motor2 – Convertor Units

i) Wiper Motor1, Wiper Motor2

j) Marker Light and Tail Light Unit

k) Head Light Convertor

5. Remove the TM1, TM2, TM3, TM4 inlet Air Filters and clean the filters by blowing with

dry compressed air at 3kg/cm 2.

6. Auxiliary Alternator Checking:

a) Blow out Auxiliary Alternator with dry compressed air at 3kg/cm 2.

b) Open the Terminal Box and clean

c) Check for any slackness

7. Rectifier Regulator Unit (RRU):





S. No. Items to be checked

a) Open the Rectifier Box Cover and clean the rectifier with compressed air of 3kg/cm2 and look for any abnormality like flash marks.

8. 24V Alternator checking:

a) Check 24V Alternator Output voltage which should be min 25V DC to Max 27V DC. If varies attend and overhaul if necessary.


a) Record Open circuit voltage for pilot cell/battery

Verify state of charge with pilot cell/battery voltage reading. Take remedial action.

10. Perform No LOAD VOLTAGE TEST and note down the DC link Voltage in Below Table:

Sl No.

Notch Eng RPM DC LV (For Reference)

DC LV (Observed Reading)

Remark

1 1 750+/10 750+/10V

2 2 1000+/10 1000+/10V

3 3 1200+/10 1200+/10V

4 4 1300+/10 1300+/10V

5 5 1400+/10 1400+/10V

6 6 1500+/10 1500+/10V

7 7 1650+/10 1650+/10V

8 8 1800+/10 1800+/10V

11. Check the connections and working of the following devices:

a) LWLS Low Water Level Switch

b) LHOLS Low Hydraulic Oil Level Switch

c) HOFFS Hydraulic Oil Level Flow Fault Switch

d) EWTS Engine Water Temperature Sensor

e) FOPS Fuel Oil Pressure Sensor

f) LOPS Lube Oil Pressure Sensor

g) FSD Fuel Shut Down valve

h) GAC Governor Actuator Coil





Part – II


Quarterly Schedule (3 months) DPC No. Cumulative kms


S.

No. Item to be checked

Remarks

1. Repeat all items of Trip& Monthly schedules.

2. Check tightness of main and aux. alternator foundation bolts. If found loose,

tighten.

3. Control Panel, Control Desk / Driver Desk, Engine Electrical:

a) Check for any Loose or Overheated marks on below mentioned items:

� Wago Terminal Boards

� Instrument Panel

� 24V Alternator

� Terminal Box for Exciter

b) Check all the Switches, Circuit Breakers for Loose connections and should

operate properly.

c) Provide missed screws, nut & bolts wherever applicable.

d) Renew faulty or damaged Switches and Circuit Breakers.

e) Check for Wipers movement and damage.

4. Visually check for any physical damages/Connections/ burning symptoms on

the following devices:

� BIVS 110.

� EFR1 and EFR2 Exciter Field Resistors.

� CGR Control Ground Resistor.

� PGR Power Ground Resistor.

� CPR1, CPR2, CPR3, CPR4 Diode Panel.

� Dead Man Valve.

� Load Resistor Panel.

� All Relays and Contactors.

� IPTB_ Instrument Panel Terminal Block.

� ESM1 & ESM2 – Engine Starting Motors.

� MSR1 and MSR2 – Magnetic Switch Relays.

� HOFF – Hydraulic Oil Flow Fault Switch.

� LCWLS – Low Coolant Water Level Switch.

� LHOLS – Low Hydraulic Oil Level Switch.

� EWT – Engine Water Temperature.

� FOPS – Fuel Oil Pressure Sensor.

� LOPS Lube Oil Pressure Sensor.

5. Check male and female pins for bent and damage, ensure proper locking

while putting back for below mentioned connectors:

� Harting Connectors.

� WTB Connectors.

� CPC1, CPC2, CPC3, CPC4 Control Panel and Control Desk / Driver Desk.

6. 110V Batteries Checking: (physical checks shall be made)

a) Confirm the tightness of terminal bolt with torque wrench (10Nm).

b) Terminal post corrosion if observed remove the cable and clean the

terminal post and cable lug with brass brush or fine emery paper and apply

petroleum jelly.





c) Check Battery Bank Voltage (Open circuit voltage)

7. Magnetic Pick Up Unit (MPU):

Check MPU Resistance: It should be 800 To 1600 Ohms.

8. Miscellaneous Checking:

a) Check 24V Battery Knife Switch connections for Slackness.

b) Check for any Loose or Overheated connections in RRU Unit.

c) Inspect Traction Motor and Traction Inverter air ducts and fixing bolts for

damage.

d) Apply insulation/spacers at all locations where cables are rubbing each other

and with DPC Body.


a) Thoroughly clean and Inspect TM1,TM2,TM3,TM4 Cable (Power & Sensor)

for insulation damage or cut marks.

b) Inspect all cable cleats for broken studs, excessive tightness and rubber cleat

damage

c) Inspect TM1,TM2,TM3,TM4 Speed & Temperature sensor plugs for correct

locking.

d) Inspect TM1,TM2,TM3,TM4 air duct (Bellows) and fixing bolts for damage.

e) Inspect TM1,TM2,TM3,TM4 for any hit marks, Physical damage and presence

of all end shield cover bolts.

f) Inspect cable junction boxes for signs of overheating or damage.

g) Ensure TM1,TM2,TM3,TM4 cables are routed properly and there is no

excess/short cable over hangs.

h) Apply insulation/spacers at all locations where cables are rubbing each other

and with locomotive body.

i) Open Inspection Covers, inspect windings and blow with compressed air at

3kg/cm2

j) Open motor and car body connection and inspect cable lugs for signs of

overheating or damage.

k) Clean the Gear Box Oil Level Indicator and Oil Filling Plug.

l) Check the Oil level, if necessary add oil upto maximum level.





Part – II


Half Yearly Schedule (6 months) DPC No. Cumulative kms


S.


1. Repeat all items of trip, monthly & quarterly schedules.

2. Check in situ

(a) HWT Safety control

(b) Signal/Alarm bell


(a) Check the cables for proper connection.

(b) Check the level of electrolyte, add if necessary

(c) Record the quantity of topped up DM water.

4. Remove and overhaul the following

(a) Starter

(b) 24 V Alternator

(c) Oil safety control (OPS)

(d) Rectifier blower and blower motor

5. Master Controller :

(a) Open the cover and clean the Master Controller.

(b) Check and ensure proper operation of the Contactors and Interlocks.

(c) Clean the cam switch and Contactors.

(d) Check visual connections for tightness.

(e) Check and ensure none of the Cam switches get damaged and cracked.

6. Traction Alternator: (Refer Traction Generator Operating Manual TSA004950/0/EN chapter

6.3).

(a) Visual Inspection of ventilation apertures

(b) Checking of external damages

(c) Inspection of the mechanical connection elements

(d) Inspection of generator cable connection.


a) Thoroughly clean and Inspect TM1, TM2, TM3, TM4 Cable (Power & Sensor) for insulation

damage or cut marks.

b) Inspect all cable cleats for broken studs, excessive tightness and rubber cleat damage

c) Inspect TM1, TM2, TM3,TM4 Speed & Temperature sensor plugs for correct locking.

d) Inspect TM1,TM2,TM3,TM4 air duct (Bellows) and fixing bolts for damage.

e) Inspect TM1,TM2,TM3,TM4 for any hit marks, Physical damage and presence of all end

shield cover bolts.

f) Inspect cable junction boxes for signs of overheating or damage.

g) Ensure TM1,TM2,TM3,TM4 cables are routed properly and there is no excess/short cable

over hangs.

h) Apply insulation/spacers at all locations where cables are rubbing each other and with

locomotive body.

i) Open Inspection Covers, inspect windings and blow with compressed air at 3kg/cm2

j) Open motor and car body connection and inspect cable lugs for signs of overheating or

damage.

k) Clean the Gear Box Oil Level Indicator and Oil Filling Plug.

l) Check the Oil level; if necessary add oil upto maximum level.

m) Remove the Traction Motor air grid and blow with compressed air at 3kg/cm2.





S.


8. Conduct Load Box test **

a) On 8th

notch, input to the alternator (excluding auxiliaries) should be 1450 HP. At least three

different readings corresponding to Max. Voltage limit, Max. Current limit and constant HP

curve should be recorded. Voltage and current values should be verified with VI curve of

Alternator**

b) VCC, TCC characteristics **

Check VCC & TCC characteristics ***

Note: Half yearly Schedule be conducted after six months and repeated again after twelve months of

commissioning / POH.

** For MEDHA Electrics refer MEDHA manual: Maintenance manual for Broad Gauge 1600 HP

Diesel Electric Multiple Units (Electrical Equipment).

** For CGL Electrics refer CGL manual: Operation & Maintenance manual of Electrical Equipment

for 1600 HP Diesel Electric Multiple Units (AC/AC System).

*** For electrics other than MEDHA and CGL make, refer respective manufacturer’s maintenance

manuals.





Part – III

Schedule of Coach body, Under frame, Bogie, Brake rigging etc.

Primary Examination (on rake) after 3500km or 10 days DPC/TC/TCV No.: Cumulative km:

Date : Cumulative hrs:

S. No. Details of work to be carried out

1. Coach

1.1. Coach should be washed both from outside and inside.

2. Shell

2.1. Visually check body panels/end walls for damages.

2.2. Visually inspect destination boards brackets.

2.3. Visually inspect window bars for damage/missing.

2.4. Examine body side doors for working/damages.

2.5. Inspect door handles for damages/missing.

2.6. Inspect vestibule and its Rubber fittings for damages/missing, repair if necessary.

2.7. Visually check vestibule fall plate, mounting brackets, pins and lock lever for ease of

operation, damages/deficiency.

3. Under frame

3.1. Visually examine centre pivot mounting bolts and attend if needed.

3.2. Check condition of head stock/sole bar.

3.3. Visually inspect centre pivot cover.

4. Bogie

4.1 Bogie frame

4.1.1 Examine visually the condition of bogie side frame, transom, longitudinal, bolster etc. at

all welded locations.

4.1.2 Examine rubber stopper/stop screw of axle box crown for damage/missing/loose.

4.1.3 Inspect axle box safety straps/loops for damage/broken/missing.

4.1.4 Brake hanger brackets for damages.

4.1.5 Inspect safety brackets for brake hanger pins.

4.1.6 Examine visually anchor link bracket of TC.

4.2 Primary Suspension

4.2.1 Visually examine axle box springs for breakage.

4.2.2 Visually examine dashpot oil filling special screw for deficiency.

4.2.3 Check oil leakages in dashpot through defective seals/vent screws.

4.2.4 Visually examine axle box clearance.

4.3 Secondary Air Suspension

4.3.1 Visually check general condition of air spring for external damages, air leakage and

infringement of any fitting etc.

4.3.2 Drain 150liter air reservoir of air spring.

4.3.3 Drain 20liter air reservoir of air spring.

4.3.4 Visually check anchor links of TC.

4.3.5 Visually examine the anchor link securing bolts and attend if needed of TC.

4.3.6 Visually examine connecting stay.

4.3.7 Examine vertical/lateral shock absorbers for damages.

4.4 Brake rigging

4.4.1 Check brake gear and adjust so that the piston stroke is within the limit.

4.4.2 Examine brake beams breakages/damages.

4.4.3 Check and attend brake beam safety wire ropes/safety straps.

4.4.4 Check and attend brake shoe head and key and replace if necessary.

4.4.5 Check and replace worn brake blocks.






4.4.6 Visually inspect brake hangers, brake gear pins and cotters/split pins and replace if

necessary.

4.4.7 Visually inspect damaged/missing brake gear bushes and replace if necessary.

4.4.8 Examine lever hanger pins.

5. Brake System

5.1 Air brake system

5.1.1 Conduct brake test as per rake test and attend leakages and defective components if

any.

5.1.2 Visually inspect for damage on brake pipe, feed pipe and hose coupling.

5.1.3 Visually inspect suspension bracket for air brake equipment and antipilferage device for

any defect and rectify.

5.1.4 Check passenger alarm by pulling the chain with spring balance with 6.4kg to 10kg force.

5.1.5 Carry out manual brake release test to ensure proper function of release lever.

5.1.6 Check and adjust brake gear to achieve correct piston stroke.

5.1.7 Service application & release test of every coach of the rake to ensure full brake power.

5.1.8 Carry out guard van valve test to ensure proper functioning of guard van valve.

5.2 EP brake system

5.2.1 Conduct brake test as per rake test and attend leakages and defective components if

any.

5.2.2 Visually inspect for damage on brake pipe, feed pipe and hose coupling.

5.2.3 Visually inspect suspension bracket for air brake equipment and antipilferage device for

any defect and rectify.

5.2.4 Check passenger alarm by pulling the chain with spring balance with 6.4kg to 10kg force.

5.2.5 Carry out manual brake release test to ensure proper function of release lever.

5.2.6 Check and adjust brake gear to achieve correct piston stroke.

5.2.7 Check service application & release of brakes under EP, auto & emergency mode through

brake controller.

5.2.8 Carry out guard van valve test to ensure proper functioning of guard van valve.

5.3 Parking Brake System (Please also see AnnexureII)

5.3.1 Check that the parking brakes are applied & released properly.

5.3.2 Check the functions of indicators for parking brakes.

6. Schaku Coupler

4.1. Check for physical damage/missing components.

4.2. Examine rubber pads for damages.

4.3. Check for slackness between two coupled couplers, which should not be more than 4mm

or 2mm in case of individual coupler and to be checked with coupler play inspection

gauge.

7. Buffing Gear

5.1. Visually examine buffer plungers for damage/drooping/stroke length.

5.2. Examine buffer mounting bolts and attend if necessary.

5.3. Examine visually buffer casing for cracks/damages.

8. Running gear

8.1 Examine visually axle box for grease oozing out, warm box if any.

8.2 Visually examine wheel tyre profile and thickness of tyre and check with tyre profile

gauge if they appear to be near condemning limit.

8.3 Visually inspect axle box covers.

8.4 Inspect wheel tread for shattered rim, spread rim, shelled tread, thermal cracks and heat

checks.

9. Seats

9.1 Oil or head stain and dirty spots if any should be cleaned with mild soap solutions and






wipe dry.

9.2 Seats and frames should be cleaned.

10. Doors

10.1 Examine doors for proper functioning and securing with hinge pivots. Doors should not

graze with floor or door sill plates.

10.2 Examine door locks, latches firmly secured with correct sized screws and

properly/smoothly engaging in their slot. The tongue of gravity type latch should be in

proper alignment with its slot plate.

10.3 Visually examine window shutters for smooth working and proper locking.

10.4 Examine visually rolling shutters/sliding doors of vestibule for smooth working.

10.5 Examine visually operation of sliding door for smooth operation.

11. Windows

11.1 Check windowbalancing mechanism for proper function.

11.2 Examine window safety catches for proper engagement in their slots.

11.3 Window bars should be provided and fixed in prescribed manner and replaced if

damaged.

11.4 Check the availability of emergency exits in coaches. Examine and attend if necessary.

12. Interior fittings

12.1 Examine laminated panels and mouldings for damage/cracks.

12.2 Visually inspect amenity fittings, replace if found damaged/deficient.

12.3 Examine ventilation grills for damages.

12.4 Examine luggage racks/bunks for breakage.

13. Inspect for sign of overheating of roller bearing of axle boxes

14. Check proper fitting of cattle guards of DPC and TC





Part – III


ScheduleA: Monthly

(On rake at nominated primary depot. ) DPC/TC/TCV No.: Cumulative km.


S No. Details of work to be carried out

1. Repeat all items of Primary Schedule

2. Coach

2.1. Disinfect and spray insecticide at corner and crevices of coaches after washing all

coaches.

2.2. Intensive cleaning of coach

3. Bogie

3.1. Bogie frame

3.1.1. Examine oil level in side bearer oilbath and oilfilling cap replenish oil if needed.

3.2. Primary Suspension

3.2.1. Add specified grade of oil in dashpot.

3.3. Secondary Air Suspension

3.3.1. Checking of installation lever with inflated air spring for normal function, tightening of

installation lever nuts, protection screen nuts, tightening of brackets of all flexible hoses.

3.3.2. Cleaning of air filter of 150 liter reservoir.

3.3.3. Cleaning of leveling valve filter.

3.4. Brake rigging

3.4.1. Check and attend brake block adjuster.

3.4.2. Examine and attend brake levers.

3.4.3. Examine and attend floating lever suspension brackets.

4. Air Drier

4.1. Check fortnightly the condition of air drier fuse & humidity indicators.

4.2. Check for proper purging, cycling, automatic draining, external leakage and proper

functioning of pressure switch.

4.3. Knorr Bremse FTIL SIL

a) Drain valve opens at 4.5 kg/cm2 or above 55.8 kg/cm2 _____kg/cm2

b) Drain valve closes at Less than 4.5 kg/cm2 3.44.2 kg/cm

2 _____kg/cm

2

c) Tower change over frequency 120 ± 5 Secs 60 ± 5Secs 60 ± 5 Secs

d) Indication Gauge pin Indication light

e) Humidity indication Blue Blue

f) Memory function

5. Seats

5.1. Disinfect the seats and frames.





Part – III


ScheduleB: Quarterly (3 months)

(On rake at nominated primary depot. ) DPC/TC/TCV No.: Cumulative km.


S No. Details of work to be carried out

1. Repeat all items of Monthly Schedule

2. Under frame

2.1. Examine trough floor, turn under and other under frame members from underneath for

corrosion.

3. Secondary Air Suspension

3.1. Checking of air spring, bulging of bellow, air leakage.

3.2. Checking of air suspension pipe leakage by using soap water.

3.3. Removing dust, mud & oil deposit if any, on air spring & control equipment.

3.4. Thorough checking of lower spring beam for any crack and deformation.

3.5. Tightening of air spring bottom plate bolts and nuts.

3.6. Measurement of bogie clearances related to air springs.

3.7.

Air spring leak test:

a) Under frame air spring pipe layout : 0.2 Kg/sq. cm. in 10 mins

b) Air spring

i) D1 : 0.2 kg/sq. cm in 2 hrs

ii) D2 : 0.2 kg/sq. cm in 2 hrs

iii) D3 : 0.2 kg/sq. cm in 2 hrs

iv) D4 : 0.2 kg/sq. cm in 2 hrs

c) Duplex check valve opening pressure

i) I : 1.5 ±0.1 Kg/sq. cm.

ii) II : 1.5 ±0.1 Kg/sq. cm.

d) 4 point suspension

Special remarks if any

4. Bogie:

4.1.

Measure and record following clearances

a) Axle box crown clearance

b) Bogie bolster clearance

c) Body bolster to bogie frame clearance

d) Bolster stopper clearance

5. Brake cylinders

5.1. Check the piston strokes of brake cylinders under applied & released condition

a) Brake cylinder piston stroke 40mm (DPC)

b) Brake cylinder piston stroke 32 ± 1mm (TC/TCV)





Part – III


IOH (NineMonthly Schedule)

DPC/TC/TCV No. Cumulative km. :

Date : Cumulative km. :


1. Repeat all items of Quarterly Schedule.

2. Clean dust: Thoroughly clean and remove dust, rust accumulated at pillars through turn under

holes with coir brush and compress air.

3. Sole bar: Examine for corrosion of sole bar and other under frame members with torch light or

inspection lamp. Pocket between sole bars and turn unders should be thoroughly cleaned through

the inspection opening of the sole bars and inspected with the help of torch light or inspection

lamps.

4. Bogie to be run out (for all: DPC/TC/TCV)

4.1. Thorough repairs of running gear to be done.

4.2. Bogie frame

4.2.1. Check for damage, cracks or deformation on bogie frames.

4.2.2. Examine condition of wearing piece and wearing plate.

4.3. Examine and replace all the brake gear components found deficient/worn out.

4.4. Primary Suspension

4.4.1. Examine and replace primary and secondary suspension components as required.

4.4.2. Free height of the springs should be checked and springs should be fitted after pairing.

4.4.3. Check and attend axle guide assembly if necessary.

4.4.4. Check axle box clearance with gauge.

4.5. Wheel & axles:

4.5.1. The wheels & axles should be subjected to ultrasonic flaw detection for detecting internal flaws.

In case any grease is found discolored or any abnormality in bearing is noticed, replace complete

wheel sets with wheel sets received from work shop.

4.5.2. Before, wheel changing / turning, the data like kms. earned / no. of months shall also be

considered.

4.5.3. Check with wheel distance gauge for loose or tight wheel.

4.6. Thorough checking of slack adjuster for control dimension and functioning.(DPC/TC). Defective

ones to be sent to the base workshops for repairs, testing and return.

5. Buffing gear

5.1. Ensure the length is within 584635mm.

5.2. Inspect buffer plunger false plate for wear and profile.

5.3. Buffer and Coupler height adjustment to be done. Check wheel diameter and provide packing

below the axle box springs to maintain buffer and coupler height if necessary.

6. Brake System (Conventional & EP)

6.1. Clean, repair and test to ensure operation in a safe and suitable condition of service of the

following:

DPC

i) SA 9 Independent brake valve

ii) A 9 Automatic brake valve

iii) E3 Emergency application valve

iv) 24A Double check valve

v) Magnet valves

vi) Safety valves

vii) 3way cut out cock

DPC/TC






i) C3W distributor valve

ii) N1 reducing valve

iii) Brake cylinders

DPC/TCV

i) C3W distributor valve

ii) N1 reducing valve

iii) Brake cylinders

6.2. Air leakage test(5 mints) for DPC & TC a) Brake Pipe with DV isolated 0.1 kg/cm2 b) General leakage with DV including FP & BP 0.15 kg/cm2

i) DPC

ii) TC

iii) TCV

6.3. Single car testing of the coach to be done, after assembly

6.4. Air drier

6.4.1. Clean mufflers

6.4.2. The following to be checked: Regenerative orifice operation, condition of Precoalescing, Desiccant and Final filter (replace if contaminated), clean purge valve, clean auto drain valve, replace mufflers and proper functioning of Timer Circuit Board.

7. Windows, doors, Seat, * Toilets, ventilators etc.:

7.1. Thorough checking and full repairs of all roof ventilators, window shutters, doors, seat &

cushions, safety catches, safety latches, staples and hasps of compartment, lavatory, body side

and vestibule doors for ease of operations.

8. Flooring

8.1. Inspect and attend torn/damaged/cracked flooring.

8.2. Examine and attend opened joints.

8.3. Examine Drain holes in trough floor for accumulation of water due to clogging if noticed, inspect

affected area for corrosion.

8.4. Clean sliding door guide rail pocket.

9. Painting:

9.1. Touching up damaged paint of coaches on outside as well as inside.

9.2. Polishing of the polished surfaces.

*Note: Maintenance of toilets to be done during various schedules as enclosed at AnnexureI





Part – IV

Schedule of Carriage Electrical

Trip Schedule (After 3500km or 10 days for DEMU with toilet/ without toilet) DPC/TC/TCV No. Cumulative km. :


S.


1. Check fuse/deficient lamps/ tube lights and replace, if necessary

2. Check switches and replace defective switches, if necessary

3. Check proper working of fans and replace, if necessary.

4. Provide switch/ tube light covers and fuse covers promptly, if they are missing

5. Replace broken acrylic covers/grill of tube lights

6. Earth Checking

7. Check earth test by using a double test lamp as explained in the RDSO Code of practice of 110

V coaches.

8. Check MCB/fuse controlling the fan circuits for correct rating. If found defective MCB to be

replaced. Never replace a blown fuse by a higher gauge fuse

9. Check MCBs for light & fan circuit in junction box for proper operation and replace defective

MCBs

10. Loose and exposed/hanging wires should be taped and to be properly secured.





Part – IV


Monthly Schedule (One month) DPC/TC/TCV No. Cumulative km. :


S.


1. Carry out all trip schedule items

2. Junction Box: Open Front Door

a) Clean the junction box A, B,C, D & E in both MCB & Non –MCB end walls of DPC/TC.

b) Blow with clean dry compressed air of 3 kg/cm2

c) Check all connections in MCBcumfuse panel for tightness/ heating sign on

connections/joints, etc.

d) Check availability of terminal lugs for all cables in junction box and replace ( if necessary) by

terminal lugs of correct size.

e) Close front door and secure properly by the locking key. If found defective, the same may be

attended/replaced.

3. Wiring & Accessories

a) Wiring shall be tested separately for IR value by keeping negative MCB/fuse in open

condition & all controlling MCBs for all circuits in off condition. All other MCBs/fuses shall

remain in circuit. Insulation resistance shall be measured with all fittings and equipment

connected to be tested.

b) The IR value should be minimum 2 MegaOhm in fair weather condition and min. 1 Mega

Ohm under adverse weather condition. Availability of inspection cover of junction box

should ensure.

c) Check at MCB &NonMCB end wall with isolation of A, B, C, D & E cables from junction box.

d) Check Terminal connections for loose connection on both nonMCB and & MCB end walls

4. Fans

a) Studs used for fixing the fan to coach body, shall be checked and tightened, wherever

necessary. Availability of all the three fixing studs should be ensured.

b) All fans shall be checked for its smooth operation and correct working and replaced, where

necessary.

c) Fan blades shall be replaced if found bent, or if there is no proper air discharge.

5. Tumble/Toggle Switches

Check each toggle switch of lights and fans for proper fixing and operation. Replace defective

toggle switches. Toggle switches should be provided in the locations intended for them and

provided with covers with their knobs exposed for operation by passengers.





Part – IV


Quarterly Schedule (3 months) DPC/TC/TCV No. Cumulative km. :


S.


1. Carry out all Monthly & Trip schedule items

2. Fans:

a) The fan body, guards and blade shall be thoroughly cleaned with cloth.

b) All fans shall be opened and condition of commutator, brushes and brush gear shall be

thoroughly checked. (not applicable for BLDC fans)

3. Carriage Lighting:

a) Open each fitting with the grill/cover key and remove the dust off the fitting both from

inside and outside. Ensure free operation of locking mechanism and replace defective

fitting. Clean cover/grill first with wet cloth and then with a clean dry cloth.

b) Replace rusted fittings and fittings with damaged surface.

c) Check up wattage of lamps and replace with that of correct wattage.

d) Check up all lighting circuit MCBs/fuses in each coach for correct sizesand replace if

necessary. Stencil the size of MCBs/fuses near the locations, if not already done.





Part – IV


IOH Schedule (9 months) DPC/TC/TCV No. Cumulative km. :


S.


1. Carry out all Monthly & Trip schedule items

Measure insulation values as follows:

2. SUPER STRUCTURE:

2.1 a) Short all the outgoing positive terminals from MCB cum fuse panel.

b) Measure and record the following insulation values:

i) Between the bunched outgoing terminals and earth.

ii) Between bunched outgoing positive terminal and main negative out going terminal.

iii) Between the main negative outgoing and earth

c) Remove the coach electrical coupler from end wall and check the condition of male pin

and female sockets.

2.3 Note: Insulation resistance under fair weather conditions shall be minimum 2 mega ohm.

However, under adverse (highly / wet) weather conditions, the minimum insulation upto 1

mega ohm is acceptable. In case the insulation resistance is found less than the values

mentioned above, individual subcircuits at junction box for super structure wiring shall be

meggered separately. The sub circuit having insulation lower than that prescribed above shall

be taken up for wiring. If the nature of repairs is heavy the coach shall be booked for shops for

attention. Do not resort to patch in wiring with temporary joints.

Proceed further as follows:

a) Use crimped socket of appropriate size in all cable ends to avoid loose connections and

consequent overheating.

b) Coach wiring should be terminated in two way connectors which shall be of tough non

ignitable molding materials of rigid PVC from which connection to the fitting shall be

provided by flexible single core cable for the following:

i). Fan

ii). Tube light fitting

iii). Emergency light fitting





Annexure – I

Schedule for Lavatory and Lavatory fittings

S.

no.

Particulars Schedule

Primary ‘A’ ‘B’ ‘IOH’

Frequency of

Examinations

After 3500

or 7 days

1 month ± 3

days

3 month ± 7

days

9 month ± 15

days

Maintenance to be

done at

On rake On rake at

nominated

primary depot

On rake at

nominated

primary depot

Sick line at

nominated

primary depot

1. *Check lavatory hinge

door for proper

function.

2. Examine lavatory door

latches/ tower bolts

for proper function.

3. Examine push cock,

flush valve for proper

functioning.

4. Check and attend

leakage in pipes,

fittings and shower

roses in lavatory.

5. Clean drain grills and

drain holes in bath

room and wash basin

if found chocked.

6. Check and replace

damaged / missing

mirrors / shelves /

soap dishes.

7. Examine squatting

pans and foot rest for

damages.

8. Intensive cleaning of

lavatory pans and

commode with

cleaning agent.

9. Thorough flushing of

water tanks.

*Note: Daily water filling & cleaning system.

Documents

Office, SCR, Office, - rdso.indianrailways.gov.inrdso.indianrailways.gov.in/works/uploads/File/Schedule of Standard... · i) Cummins Operation and Maintenance Manual, Bulletin No