Page 3 of 17 Issued on 16.05.2013 Technical …...viii) Hitachi TM suspension tube bolt To be replaced ix) PE end bearing To be replaced x) CE end bearing To be replaced xi) Brush

Page 3 of 17 Issued on 16.05.2013 Technical Circular No. RDSO/2013/EL/TC/0123,Rev‘0’

Annexure-I

List of “Must Change Items during POH” for Conventional Electric Locomotives

S.N. Item and its sub-assemblies Replacement during

first POH Replacement during

Second POH

01 Traction Motor

i) Gear case- passenger loco - goods loco

To be replaced

To be replaced

ii) Suspension bearing (plain sleeve) along with lubricating pad assly.

Remetalling/ Replacement

iii) Oil pump for suspension bearing Only pinion to be

replaced.

iv) Traction Motor bellow To be replaced

v) Traction Motor pinion To be replaced

vi) Sandwich mounting assembly To be replaced

vii) Gear in two halves for suspension bearing oil pump

To be replaced

viii) Hitachi TM suspension tube bolt To be replaced

ix) PE end bearing To be replaced

x) CE end bearing To be replaced

xi) Brush holder assembly of TM To be replaced

xii) All carbon brushes liners, gaskets, needle roller bearings of TM

To be replaced

xiii) Teflon ring of armature To be replaced

xiv) Insulating rod, 5565/675 & 5565/740 To be replaced

02 Auxiliary Machines

i) Auxiliary motor bearing To be replaced

ii) Auxiliary Compressor To be replaced

iii) MVMT Impeller with duct To be replaced

iv) HP & LP valves, crank shaft of compressor To be replaced

v) MPH To be replaced

vi) MVMT & MVRH impeller To be replaced

vii) Main compressor To be replaced

viii) Axial fan for SIV Motor To be replaced

ix) DC & AC MVRF To be replaced

x) MVSI, MVSL& MVRF To be replaced

xi) All churning fans of SIV To be replaced

xii) All door and panel rubber gaskets of SIV To be replaced

xiii) All end shields of auxiliary motors To be replaced

xiv)

All auxiliary motors *Rewinding after 12 years *Replacement of Aux motors after 18 years


03 Pantograph

i) Bow assembly with plunger To be replaced

ii) Other items as per TC-94 for freight locos and as per OEMs manuals for passenger locos

To be replaced.

04 All Damping panels

i) VCB Damping panel To be replaced

ii) TFP damping panel To be replaced

iii) Capacitors of RC network To be replaced

iv) Other Damping panels To be replaced

05 Roof

i) Twin beam Headlight Reflector with holder, gaskets & bulbs

To be replaced

ii) 25 KV condenser bushing To be replaced with

vertical take off CHT assembly

06 VCB/DJ

i) Air dryer sieve To be replaced

ii)

Other items/components To be replaced as per RDSO’s latest version of SMI No. ELRS / SMI/0223 & 236 for kits of single and double bottle VCBs

iii) DJ To be replaced with

single bottle VCB

iv) Double bottle VCB To be replaced with

single bottle VCB

07 Transformer

i) Transformer oil To be replaced.

ii) Tap changer N-32 (including SMGR) RDSO’s TC No.0102

to be followed

08 Cab

i) BL Box complete with switches To be replaced

ii) Rubber mat To be replaced

iii) All relay covers To be replaced

iv) Bakelite separators of TK panel To be replaced

v) A9 valve To be replaced

vi) BL box of driving desk To be replaced

vii) Cab fans To be replaced

viii) Cab heaters To be replaced

ix) Cab window assembly complete To be replaced

x) All gauges, meters, indication panel & light To be replaced


fittings

xi) Wiper servo motor assembly complete with arms/blades/control valves

To be replaced

xii) Master Controller (Cam switches) & rollers To be replaced

xiii) DC-DC Converter To be replaced

xiv) Flasher light unit & Lamp box. To be replaced

xv) Marker Light To be replaced

xvi) All Push buttons To be replaced

xvii) All PC8 Relay Contacts & springs To be replaced

xviii) RU of all voltmeters To be replaced

xix) Analog NR To be replaced with

digital NR

xx) Indication panel To be replaced

xxi) FDCS All PCB Cards to be

rehabilitated

xxii) VCD Foot switch and push

button to be replaced.

xxiii) Driver and Asstt. Driver seat To be replaced

xxiv) Front look out glass and corridors glasses To be replaced

09 Corridor

i) Pressure switches and air flow relays-micro switch and diaphragm

To be replaced

ii) All NR valves, NC4, NC7 valves To be replaced

iii) Body filters To be replaced

iv) SMGR-PR valve To be replaced

v) All gauges To be replaced

vi) Electro-magnetic contactor To be replaced

vii) Micro switch of relays To be replaced

viii) Time delay relay timer To be replaced

ix) Shunt for QF relay & traction ammeter To be replaced

x) RC network To be replaced

xi) TM cable cleats To be replaced

xii) All programme switches including HOM switch, selector switch, SPDP toggle switch & D type fuses

To be replaced

xiii) All gauges and meters To be replaced

xiv) Auxiliary contactors for EP contactors with power contact tips, all insulators and hardware’s including square head bolt.

To be replaced

xv) Rehabilitation of Safety relays by OEM To be Rehabilitated

per guidelines of Railway Board.

xvi)

Tri-plate panel All valves rubber components, all valves base gasket, O ring between plates,NC-4&NC-7 valves and pressure switches

To be replaced


xvii)

EPC, C-145,shunting contactors To be replaced

a) Servomotor Piston Bucket, Gasket Piston Bucket & Felt Ring

b) Fixed & Mobile Contacts c) Complete shunt Assembly d) Aux Switch with Cam.

To be replaced To be replaced To be replaced To be replaced

xviii)

Reverser a) Fork & all Dowel Pins b) Servomotor Piston Bucket, Gasket

Piston Bucket & Felt Ring c) Finger & Drum Contacts with brass ball. d) Aux Switches e) Notching Lever Complete

To be replaced To be replaced To be replaced To be replaced To be replaced

xix) HOM AIR Valve To be replaced

xx) RSI Block PTFE Cable To be replaced

xxi) Hinges of all doors To be replaced

10 Under frame

i) Battery lead acid with battery box To be replaced

ii) Replacement of Vertical/horizontal dampers To be replaced

iii) Side buffer assembly along with fixing bolts. To be replaced

iv) Complete CBC assembly To be replaced

v) EMU type inter and after cooler To be replaced

vi) Set of cover for SL To be replaced

vii) Cattle guard with rail guard To be replaced

viii)

Air Dryer

Overhauling Kit to be replaced in POH as per instructions of RDSO

11 Bogie

i) Springs To be replaced

ii) Spring seat & equalizer of trimount bogie To be replaced

iii)

Replacement of equalizer & compensating beam, pin, bushes, modified centre block, side bearer, D-shackle (high adhesion bogie), tie rod for equalizer, snubbers, split cotters

To be replaced

iv) Complete brake rigging along with pins, bushes & fasteners

To be replaced

v)

All spring seats, wearing plate, all synthetic liners/pads, oil seal felts, pins, bushes, high tensile fasteners, safety clamps of bogie & axle box etc.

To be replaced

vi) Foot step assembly To be replaced

vii) Maintenance kits of brake cylinder To be replaced

viii) Sander pipe arrangement including rubber hose for sanders

To be replaced


ix) WAP-4 bogies items: outer & inner straps, Conical thrust pad, Hanger pin, bush, Brake head spring, brake hanger, happy pad

To be replaced

x)

Wheel items: Axle box bearing, MSU & its bearings, (DE& NDE side)MSU bolts, Axle box complete

To be replaced

12 General

i)

All perishable items like rubber gaskets, rubber grommets, felts, rubber pipes, hoses rubberized cork sheets, oil seals etc.

To be replaced

ii) Brake block, carbon brushes, silica gel, grease nipple, metalized carbon strip for pantograph etc.

To be replaced

iii) All oil and greases To be replaced

iv) Replacement of filters, pipelines, ceramic filters in DJ & SMGR

To be replaced

v) MU coupler jumper pins To be replaced

vi) All type of washers, spring washers etc. To be replaced

vii) Various ball type isolating cocks, check valve, pressure cut out switch etc.

To be replaced

viii) diaphragm for horns with horn valve To be replaced

ix) All flexible shunts To be replaced

x) Auxiliary Switches (SMGR, MP, CTF, J, C-118

To be replaced

xi)

A9 & SA9 pipe line To be replaced with stainless steel pipe line

13 Electrical items

i) DBR grids To be replaced

ii) Shunts SHA/SHF To be replaced

iii) C-118 with R-118 To be replaced on

condition basis

iv) All capacitors other than in damping panels To be replaced (including Oil type to be replaced with dry type)

14 Loco Body

i) PU painting of locomotive To be incorporated as per standard procedure already advised vide Report No. ELRS/IR/0115(Rev’0’) of Sept’06.


Annexure-II

List of “MUST CHANGE ITEMS during POH” for three phase electric locomotives

SN DESCRIPTION OF ITEM/SUB-ASSEMBLIES REPLACEMENT

DURING POH

A LOCO BODY:

1 PU painting of locomotive To be done

2 Roof Hatch Gaskets

The pantograph and converter roof hatch gaskets. To be replaced

3 Roof hatch rubber seals

The rubber seals around the pantograph and converter roof hatches and the roof beam. To be replaced

4 Body Structure

i) Fiber body above buffer To be replaced

ii) CBC coupler (WAP5 & WAP7 only). To be replaced

iii) Decals (stickers). To be replaced

5 Exterior

Seals involved in fitment of side body and roof filters To be replaced

6 Draft gear & couplers

i) Complete CBC assembly including Draft gear. To be replaced

ii) Transition coupling. To be replaced

iii) Knuckle, clevis, clevis pin and yoke pin To be replaced

iv) Striker block wear plate. To be replaced

7 Buffers

i) Buffers along with fasteners. To be replaced

ii) All rubber rings. To be replaced

8 Cattle guard

i) Cattle guard along with its hardware. To be replaced

9 Doors and steps

i) Door seals. To be replaced

10 Washer and Wipers

i) Wiper motor driver shaft seal, wiper arm, pneumatic end water hoses, wiper blade and idler shaft assembly.

To be replaced

11 Wind screen and windows

i) Front lookout glass and side glass. To be replaced

ii) Seals of cab windows, sliding window, splashed shield, Wind screen shield and rubber flap on the cab side window drainage channel outlet.

To be replaced

B1 UNDERFRAME :

1 Sanding equipments


i) Sand in all sand boxes. To be replaced

ii) Sander hosepipe and seal in the sand box lids. To be replaced

2 Battery Box

i) All fasteners of battery boxes. To be replaced

ii) Battery box ventilation hose. To be replaced

B2 BOGIE AND RUNNING GEAR:

1 Secondary Suspension

i) All Secondary Suspension springs. To be replaced

ii) Dampers. To be replaced

iii) The lateral bump stops. To be replaced

iv) Insulating bases of secondary suspension (WAP5 only). To be replaced

2 Primary Suspension

i) All Primary Suspension springs. To be replaced

ii) Dampers. To be replaced

3 Traction link

i) Traction link assembly with housing. To be replaced

ii) Safety sling, pins and R- clips. To be replaced

iii) Aclathan / Vulkollan Rings and tab washers. To be replaced

iv) All fasteners of Aclathan /Vulkollan ring retaining plate. To be replaced

v) All Nylock Nuts opened for lifting of locos at: A. Secondary Dampers (Yaw, Vertical, horizontal) B. Primary Dampers top side. C. Traction link D. Gear Case Support arm.

To be replaced

4 Bogie Frame and brake Gear

i) All pins, bushes and pads of brake rigging To be replaced

ii) All rubber components, hoses and fasteners on the bogie To be replaced

iii) The hoses between – a) the bogie frame connection and the brake cylinders and b) the locomotive under frame and bogie.

To be replaced

iv) Overhauling kit of brake caliper. To be replaced

v) Replacement of Brake hanger of WAP7/WAG9 To be replaced

vi) Replacement of safety sling of brake hanger of WAP7/WAG9 To be replaced

5 Wheel set & Axle box

i) Taper Roller bearing unit (CRU150/SKF, BC2-0067A) for WAP7, WAG9 & WAG9H.

To be replaced

ii) Taper Roller bearing Unit (SKF 1639457A) for WAP5 To be replaced

iii) Fasteners of brake discs. To be replaced

iv) Axle box „O’ ring and cover bolts. To be replaced

6 Gear case/ Transmission

i) Gear case oil. To be replaced


ii) Gear case bearing along with associate components (for WAP5 only).

To be replaced

iii) Gearbox oil seal / ‘O’ rings. To be replaced

iv) All gear case fasteners and TM fixing bolts. To be replaced

v) Drain plug washer and oil filling plug washer. To be replaced

vi) Gauge glass oil seal. To be replaced

vii) TM support arm, Gear case support arm (for WAP5 only) & Axle guide rod.

To be replaced

7 Crown Gear Coupling (WAP5)

i) The membrane and the oil of Crown Gear coupling To be replaced

8 Spheriblock

i) The Spheriblocks of the axle guide rod, gear case support arm, TM & TM support arm (WAP5).

To be replaced

ii)

The Spheriblocks of the axle guide rod and TM support arm (WAP7/WAG9).

To be replaced

C POWER SUPPLY SYSTEM :

1 Pantograph

1.1

Pantograph type AM12, IR01 & PAN01 for freight locomotives

i) As per TC No. RDSO/2007/EL/TC/0094(Rev’0’)

To be replaced

1.2 Pantograph for M/E locomotives

i) As per OEM’’s maintenance manual Also as per instruction for conventional electric locomotives

2 Primary voltage Transformer

i)

The rubber cable conduit between transducer & terminal box and the roof cable duct.

To be replaced

3 High voltage bushing insulator

i) The seal on the high voltage bushing and cork gasket To be replaced ,Bushing to be replaced if tan delta and capacitance value more (refer RDSO’s letter no.EL/3.2.21/1 dt 10.12.2012)

4 Main circuit breaker (VCB)

i) All items specified in latest version of RDSO’s Special maintenance Instruction no. ELRS/SMI/0236

To be replaced

5 Harmonic Filter Resistor


i) The cable glands & seal of the filter resistor junction box on the converter roof hatch.

To be replaced

ii) Replacement of the seal of the filter resistor. To be replaced

iii) Harmonic Filter Capacitor To be replaced in POH on condition basis as per maintenance manual

iv) Harmonic Filter Resister All insulator to be replaced To be replaced in POH

6 Main transformer

i) The silica gel in breather assembly. To be replaced

ii) All sealing gaskets including tank cover gasket of TFP.(as per TC 0076)

To be replaced

iii) All rubberised cork sheets. To be replaced

iv) All TFP bushings rubber seals. (as per TC 0076 latest version) To be replaced

v) All transformer foundation bolts & bushing lock nuts To be replaced

vi) Transformer Oil. To be replaced

vii) Main Transformer Drain Oil Cock rubber Parts To be replaced

viii) Transformer conservator Gauge glass gasket, Rubber parts To be replaced

ix) Oil Hose (Vent Tube) from main transformer to conservator, Equalizing pipe along with its accessories.

To be replaced on condition basis

D PROPULSION SYSTEM :

1. Traction Converter

i) The rubber parts of servo motor of pre-charging & main contractor.

To be replaced

ii) The rubber parts of main cylinder of pre-charging & main contractor.

To be replaced

iii) The air cooling hoses, seals on the traction converter doors (WAG9/WAG9H).

To be replaced

iv) The air cooling hoses, seals on the traction converter doors (WAP5/WAP7).

To be replaced

v) Silica gel in breather assembly. To be replaced

vi) Converter Oil. To be replaced

vii)

Contact tips of Electro-pneumatic and Electro-magnetic contactors.

To be replaced

viii) Traction converter oil Flexible pipe line To be replaced in POH

ix) Stoochi coupling Rubber Parts To be replaced in POH

x) DC Link capacitor & Resonance circuit capacitor i) Dry type to be replaced in POH on condition basis as per maintenance manual

ii) Oil filled to be


replaced with dry type

xi) Traction Converter Gauge glass rubber Parts To be replaced

xii)

As Per RDSO Guide line Modified Heat sink to be provided on SR Rack

To be done in POH, if not modified

2 Traction Motor

i) Traction motor bearing (DE +NDE) To be replaced

ii) Suspension tube bearing. To be replaced

iii) Bull gear (WAG9/WAG9H/WAP7) To be replaced on condition basis during rediscing

iv) TM pinion (WAG9/WAG9H) To be replaced

v) TM pinion (WAP7). To be replaced

vi) End plate “O” Rings & the gaskets on the terminal box of TM To be replaced

vii) TM bellows. To be replaced

viii) Gasket of temperature sensor cover. To be replaced

ix) The helical inserts of Junction box of TM. To be replaced

x) Holder fixing bolt To be replaced

xi) Power cable of TM To be replaced

xii) Temperature sensor complete assembly including cable To be replaced

xiii) All plastic conduit pipes. To be replaced

xiv) All hardware of TM body. To be replaced

xv) TM holder plate for suspension 12R To be replaced

xvi) Bellow Plate of TM side. To be replaced

3 VCU bus station and Electronics of Power Converter & Auxiliary Converter

i) Back up batteries in VCU bus station diagnostic & communication computers, DIA, DD A1 & 2.

To be replaced

ii) The seals in the UIC socket. To be replaced

iii) All Fiber-optic cable of Power Converter, including spares. To be replaced

iv)

Rehabilitation of cards as per RDSO guidelines No. EL/G/2008/01 Rev.1 with latest amendment.

To be replaced

v) Instrument cooling fans. To be replaced

E. AUXILIARY SYSTEM :

1 Auxiliary Converter

i) Gasket of DC link capacitor bank. To be replaced

ii) Gasket of WRE, GG and battery charger modules To be replaced

iii) Bearing of internal cooling fan. To be replaced

iv) Seals on the Aux. Converter cabinets & equipment modules To be replaced

v) Contact tips of EMC. To be replaced

vi) Contact tips of contactors in the BUR 1, 2 & 3. To be replaced

vii) Set of Rotary switch To be replaced

viii) All DC Link Bank Capacitors i) Modified DC Link Capacitor Bank to be


provided ii) To be replaced in POH on condition basis as per maintenance manual

ix) Male & Female contact of GG & WRE Module To be replaced

2 Battery Set

i) Battery To be replaced

ii) Battery Box To be replaced

on condition basis

3 Lights

i) The head light gasket, head light seals (between headlight retaining ring & head light housing), Marker Light rubber gasket and its “O” rings and the flasher light gasket (between flasher & loco roof).

To be replaced

ii) Head light lamp. To be replaced

4 Oil Cooling Piping

i) The “O” rings in the main transformer & main converter To be replaced

ii) Oil cooling piping joints. To be replaced

5 Oil Cooling Pumps

i) The bearings & “O” rings. To be replaced

6 Oil Cooler Blower / Motor

i) The bearings of oil cooler blower motor and associate component.

To be replaced

ii) Impeller of oil cooler blower. To be replaced

7 Oil Cooler Blower Seals

i) The seals between the oil cooler blower & the filter duct, between the oil cooler blower filter & the pantograph roof hatch on the oil cooler blower unit, between the oil cooler blower & machine room floor, on the oil cooler blower filter & ducting and on the oil cooler blower inspection door (WAP5/WAP7).

To be replaced

ii) The seals between the oil cooler blower & the filter duct, between the oil cooler blower filter & the pantograph roof hatch on the oil cooler blower unit, between the oil cooler blower & machine room floor, on the oil cooler blower filter & ducting and on the oil blower inspection door (WAG9/WAG9H).

To be replaced

8 Machine Room Blower Motor

i)

The drive & non drive end bearings along with associated components.

To be replaced

9 Machine Room Blower Seals

i) The seals of machine room blower filter plenum & duct, inspection door, blower filter & ducting and between the machine room blower and machine room floor, between the machine room blower filter and filter duct and the machine room blower filter duct seal and wear plate (WAP5/WAP7)

To be replaced

ii) The seals of machine room blower filter plenum & duct, inspection door, blower filter & ducting and between the

To be replaced


machine room blower and machine room floor, between he machine room blower filter and filter duct and the machine room blower filter duct seal and wear plate (WAG9/ WAG9H).

10 Traction Motor Blower Seals

i) The traction motor blower filter, plenum, wear plate and duct seals (WAP5/WAP7).

To be replaced

ii) The traction motor blower filter, plenum, wear plate and duct seals (WAG9/ WAG9H).

To be replaced

iii) The seals on the TM blower filter & ducting (WAP5/WAP7) To be replaced

iv) The seals on the TM blower filter & ducting (WAG9/ WAG9H). To be replaced

v) The seals between the TM blower & machine room floor and between the plenum box and body side panel (WAP5/WAP7).

To be replaced

vi) The seals between the TM blower & machine room floor And between the plenum box and body side panel (WAG9/ WAG9H).

To be replaced

vii) The seals on the TM blower inspection cover (WAP5/WAP7) To be replaced

viii) The seals on the TM blower inspection cover (WAG9/ WAG9H).

To be replaced

11 Traction Motor Blower Motor

i) The drive & non drive end bearings along with associated components.

To be replaced

12 TM & Oil cooler Blower Scavenger

i) The hoses at the oil cooler blower filter scavenger boxes (WAP5/WAP7).

To be replaced

ii) The hoses at the oil cooler blower filter scavenger boxes (WAG9/ WAG9H).

To be replaced

iii) The equaliser hoses between the TM & oil cooler blower scavenger & the filter (WAP5/WAP7).

To be replaced

iv) The equaliser hoses between the TM & oil cooler blower scavenger & the filter (WAG9/ WAG9H).

To be replaced

v) The seal at the oil cooler blower scavenger duct slip joint (WAP5/WAP7).

To be replaced

vi) The seal at the oil cooler blower scavenger duct slip joint (WAG9/ WAG9H).

To be replaced

vii) The seals and gaskets on the TM and oil cooler blower scavenger ducting (WAP5/WAP7).

To be replaced

viii) The seals and gaskets on the TM and oil cooler blower scavenger ducting (WAG9/WAG9H).

To be replaced

ix) Rubber hoses. To be replaced

13 TM & Oil cooler Blower Scavenger Motor

i) The driving & non-driving end bearings along with associated components. .

To be replaced

14 Machine Room Blower Scavenger Motor

i) The driving & non-driving end bearings along with associated components.

To be replaced

15 Machine Room Blower Scavenger

i) The flexible duct between the machine room blower scavenger motor and filter.

To be replaced

ii) Rubber hoses. To be replaced


iii) The equaliser hoses between the machine room blower scavenger motor and the filter (WAP5/WAP7).

To be replaced

iv) The equaliser hoses between the machine room blower scavenger motor and the filter (WAG9/ WAG9H).

To be replaced

v) The seals and gaskets on the machine room blower scavenger ducting (WAP5/WAP7).

To be replaced

vi) The seals and gaskets on the machine room blower scavenger ducting (WAG9/ WAG9H).

To be replaced

16 Main Compressor Motor

i) The main compressor drive motor bearings along with associated components.

To be replaced

17 Cab heater/Blower motor and crew fan motor

i) Bearing of cab heater Blower motor and crew fan motor. To be replaced

18 Cubicles

i) The rubber parts of servo motor of EP Contactors in cubicles. To be replaced

ii) The rubber parts of main cylinder of EP Contactors in cubicles.

To be replaced

iii) Contact tips of EP contactors. Filter of fire detection unit. To be replaced

F AIR SUPPLY AND PNEUMATIC SYSTEM:

1 Main Compressor

i) The main element & the safety element of the air intake filter & other parts as prescribed in manual.

To be replaced

ii) Suction air filter element. To be replaced

iii) Compressor oil. To be replaced

iv) Secondary oil filter. To be replaced

v) Gaskets of concentric valves. To be replaced

vi) The main compressor resilient mountings & mounting pads. To be replaced

vii) CP delivery pipe. To be replaced

viii) HP & LP cylinder, HP & LP concentric valves all make. To be replaced

ix) Concentric valve kit. To be replaced

x) The delivery hose from the main compressor. To be replaced

xi) Inter cooler after cooler assembly To be replaced

xii) Copper Interconnecting pipes between intercooler and after cooler (WAP5/WAP7).

To be replaced

xiii) Copper Interconnecting pipes between intercooler and after cooler (WAG9/WAG9H).

To be replaced

xiv) Overhaul kit of Inter cooler after cooler assembly. To be replaced

xv) Overhaul kit of Main Compressor (Elgi / Knorr Bremse). To be replaced

xvi) Overhaul kit of Main Compressor (D&M / SWIL) (WAP5/ WAP7)

To be replaced

xvii) Overhaul kit of Main Compressor (D&M / SWIL) (WAG9/ WAG9H).

To be replaced

2 Auxiliary Compressor

i) The delivery hose between the auxiliary compressor and brake frame and overhauling kit.

To be replaced

ii) Compressor oil. To be replaced

3 Pneumatic Valves, Cocks and Filters To be replaced


i) All rubber components (WAP5/WAP7). To be replaced

ii) All rubber components (WAG9/WAG9H). To be replaced

4 Horn To be replaced

i) Horn gasket and other rubber parts of Horn.

To be replaced

5 Brake Pneumatics

i) Overhauling kit of Complete E- 70 / CCB brake system. As per OEM’s instructions

ii) Overhauling kit of driver brake controller and automatic brake controller.

As per OEM’s instructions

iii) TBU and PBU kit (WAP7). To be replaced

iv) TBU and PBU kit (WAG9/ WAG9H). To be replaced

v) Brake activating mechanism (main cylinder & parking brake cylinder)

To be replaced

6 Air dryer

i) Overhauling kit of air dryer. (As per OEM’s manual, makewise) To be replaced

ii) Body connector male & female To be replaced

G INTERIOR :

1 Cab Door and Machine Room Door

i) The door seals, door window seals. To be replaced

2 Drivers Seat

i) The seat cover and cushion of driver seat. To be replaced

ii) Driver seat. To be replaced

3 Cab Interior

i) Anti skid flooring in cab. To be replaced

4 Cab. Equipment

i) Vigilance, Sanders, PVEF pedal switches. To be replaced

ii) All switches BPFA, BLPR, ZPRD, BLDJ, ZPT, BPVR, BPVG etc.

To be replaced

iii) Cab activation switch. To be replaced

H . ADDITIONAL ITEMS :

SN DESCRIPTION OF ITEM /SUB ASSEMBLIES REPLACEMENT

DURING POH 1. TEST ROOMS ITEMS

i) Pre Charging contactor, Main Contactor EPC of SR, FB Panel Copper contact to be replaced.

To be replaced

ii) 80 Amp Contactor . To be replaced

iii) 150 amp contactor (07 nos) to be replaced with contactors along with Snubber Circuit & auxiliary switches.

To be replaced

iv) Replace 100% FB Panel EP Contactor Insulating base C Type.

To be replaced

v) FB Panel Air Supply Pipe Line Set to be replaced by new one. To be replaced

vi) All Driver Desk Switches . To be replaced


vii) All pneumatic panel solenoid valves to be replaced by modified ones.

To be done in POH ,if not done earlier

viii) All auxiliary switches of precharging and EPC contactor To be replaced

ix) Angle transmitter To be replaced

2. ITEMS OF RELAY SECTION

i) Indication Lamps To be replaced

ii) All gauges To be replaced

iii) 63 Amp MCB of OBC and TMB 59.1/1 and 59.1/2,53.1/1 and 53.1/2

To be replaced

iv) 40 Amp MCB of CP 47.1/1 and 47.1/2 To be replaced

v) MRB contactor 54.2/1 and54.2/2 with timer To be replaced

vi) Contactor 136.3, 126.5, 136.4, 126.7/1, 130.1, 211, 126.6, 126.7/2 To be replaced

vii) BPVG push button switch To be replaced

viii) Marker Light To be replaced

ix) All Programme Switches To be replaced

x) All desk meters, Push button switches To be replaced

xi) All types of push button switches To be replaced

xii) Flasher Unit & Lamp Unit To be replaced

xiii) All tube lights & CFL lamps with fittings To be replaced

xiv) DC-DC Converter To be replaced

3. ITEMS OF INSPECTION SECTION

i) All side filters & roof filters(MRB,TMB,OCB) To be replaced

ii) All door locks To be replaced

Note: 1. The lubricants shall be used wherever applicable as per RDSO‘s Technical

Circular No. ELRS/TC/0034 (Rev.4) dated 21-7-2008 or latest. 2. The must change items for WAP7 locomotives fitted with conventional type brake

rigging shall be as per RDSO Modification sheet No. RDSO/2009/EL/MS/0381 dated 7-9-09 and RDSO letter EL/3.1.35/2 (3 phase) dated 20-10-11.

3. Technical Circular No. RDSO/2013/EL/TC/0123, Rev.’0’ dated 16/05/2013 supersedes

LRS/TC/0021 (Rev’01)-2002, dated 16.04.02 may be considered as obsolete.

Documents

Page 3 of 17 Issued on 16.05.2013 Technical …...viii) Hitachi TM suspension tube bolt To be replaced ix) PE end bearing To be replaced x) CE end bearing To be replaced xi) Brush