rdso.indianrailways.gov.in · Web viewCheck List for quality audit of diesel loco sheds (Brake Items) S. No. Item Parameter Ref document Observations Whether all the prescribed schedules

Technical / Quality Audit of Diesel Shed

CHECK SHEETDescription Reference Documents, Annexures, Further details on check sheet etc

General

Compliance of Schedule Maintenance Schedule of standard examinations: MP-Misc-140/141 (for Alco locos).

Schedule of standard examinations: MP-Misc-285 [for HHP (EMD) locos] Quality of major schedules:

M24 M48

-do-

Load Test/Load Box Test records: HP SFC EGT Peak Firing Pressure

Load Test MI No MP.MI-10 (Rev 0.02), Aug 2003. (for Alco locos).

Document No. Misc-195 on Test procedure for EMD diesel engine, 16 cyl. Vee model 710G3B (4000/4500HP) issued by DLW.

Methodology and analysis of failure investigation. Display of work instructions on shop floor Training of staff Status of record keeping Calibration of gauges/ instruments

Safety items

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

defects. c. Brake adjustment, release & and application

timings.d. Headlight focus adjustmente. Horn maintenancef. Under gear safety brackets

a. OEM’s maintenance manual.b. Drg No SKDL-2561 Alt 8.

c. Standard test scheme as per MP.TP-029/87 (Rev 02) Oct 2008 for Air Brake, and, as per MP.TP-019/81 (Rev 02) Nov 08 for dual brake locos.

d. IB No MP.IB.EC.01.08.06 (Rev 0) December 06.

f. MI No MP.IB.BD.02.16.01 (Rev 01) December 09.

Page 1 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019

g. Gauging of Couplersh. Vertical offset between Side bearer and centre

pivot

g. CBC Manual No G 76 Sept 87. h. MI No MP.IB.VL.02.11.10 (Rev 00) February 10.

Quality of Subassembly repairs (important items)

a. Expressor/Compressorb. Air Brake Sectionc. Bogie sectiond. Rotating Machines Sectione. Turbo sectionf. Cylinder Head, Piston and Valve sectiong. Radiator section.h. FIP/Injector Sectioni. Governor Sectionj. Electrical Control Sectionk. Battery Section

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

DM Plant and Spectrograph

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

Material Availability of critical items Procurement from unapproved sources, if any.

Any other item

As decided by the auditing authority


Annexure-ICheck List for quality audit of diesel loco sheds (Brake Items)

S. No. Item Parameter Ref document Observations1. Whether all the

prescribed schedules are being followed for brake equipment, compressor & air dryer or not

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

M-2

M-4

M-12

M-24

M-48

M-72

POH

1. Whether maintenance is done as per RDSO MIs or manufacturers MI mentioned in MP.Misc.-140 & 141. 2. Maintenance facilities are available or not.

1. Schedule of standard examinations: MP-Misc-285 [for HHP (EMD) locos] to be added.2. For GD make compressor maintenance instruction, M/s GD maintenance manual and IB no.MP.IB.BK.01.05.12, Rev-0, dated 24.07.2012. For ELGI make compressor, M/s ELGI maintenance manual and RDSO IB No.MP.18.8K.01.09.18 (Rev.00) October 2018 to be followed.


S. No. Item Parameter Ref document Observations3. CCB systems: CCB 1.5 as per ETI-991, CCB 2 IR as per NYT 1794-C.4. For IRAB-1 brake system, MP.TP.29 and for 28LAV-1, MP.TP.019 to be followed.5.OEM maintenance manual and MP.MI-18 for air dryer,

2. Functioning of VCD Whether functioning of VCD is being checked in every trip schedule. 3. Test benches and rigs 1. Whether the required test bench and rigs are available or not viz.

AB test rack for brake valves, air dryer test bench, compressor test bench, pressure switch, magnet / solenoid valve, Auto drain valve etc.

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

not.4. Test bench for air pressure gauge 5. CCB Simulator and Test bench for CCB

4. Test on compressor Testing for checking capacity of compressors as per MP.TP-41, 2010.5. Infrastructure facilities (a) Whether dust proof and controlled temperature environment

for maintenance, assembly and testing of brake valves is available.

(b) Availability of compressed air ( in test benches.


S. No. Item Parameter Ref document Observations(c) Availability of compressor in air lines.(d) Whether air dryer provided in test benches/ air lines.(e) Reservoir pressure is being checked or not(f) Washing facilities(g) Painting facilities(h) Technical Cell(i) Metrology lab(j) Store(k) Tool room(l) Fire extinguishers(m) Material handling facilities for movement of material and

components.(n) Facilities for filtering the sand.

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

7. Availability of Material Any Chronic shortage of material for maintenance8. Human Resource

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

9. Air Reservoirs All air reservoirs are to be tested and certified periodically by a qualified Boiler Inspector. The period is to be specified by CME office.

10. Any other observation


Annexure-IITechnical / Quality Audit of Diesel Shed

CHECK SHEET FORTECHNICAL AUDIT OF CYLINDER HEAD SECTION

During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.

Shed/Rly: Audited by: Date of audit:

SN Requirements Loco Type

Make Of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

1

Cleaning, measurements etc.1.1 Cleaning of cylinder head ALCo -- DLW Maintenance

Instruction Manual

(MI-ENG-020)

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

1.3 Inspect head for cracks using Magnaflux1.4 Valve guide to head int 0.002” -0.0005”1.5 yoke to guide int 0.002” -0.0005”1.6 Yoke guide ( press in dim) 3.210” -3.272”1.7 Valve guide ( press in dim) 2.25”1.8 Valve to guide clearance Top- 0.003 – 0.0045” Bottom- 0.005 – 0.0065’’1.9 Cy head nuts torquing value 550ft/lbs as per sequence described in Manual

2Availability of tools , Test Stands etc.2.1 Valve seat reconditioning machine2.2 Hydraulic test stand



Make Of Subassembly


Observations

2.3 Feeler gauge2.4 Magna flux

3

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

4 Record Keeping For Traceability

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

1

Cleaning, measurements etc. EMD -- EMD Engine Maintenance

Manual

Chapter on cylinder head1.1 Cleaning of cylinder head

1.2 Cy head leak test at 85 to 95 PSI air pressure with temp 150°F + 5°F1.3 Inspect head for cracks using Magnaflux1.4 Cy head valve seat angle 30°00’-30° 15’1.5 Valve seat width 0.093” -0.125”1.6 Dia at top of valve seat 2.375”-2.437”1.5 Valve seat runout TIR max 0.008”1.6 Valve guide inside dia max 0.633” 1.7 Valve stem to guide clearance max 0.010”

2Availability of tools ,Test Stands etc.2.1 Valve seat reconditioning machine2.2 Hydraulic test stand2.3 Feeler gauge2.4 Magna flux arrangement



Make Of Subassembly


Observations

3

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




CHECK SHEET FORTECHNICAL AUDIT OF PISTON SECTION



Make Of Subassembly


Observations

1

Cleaning, inspection, measurements etc.1.1 cleaning of piston ALCo -- DLW

Maintenance Instruction

Manual (MI-ENG-015)

Chapter on piston and con rod1.2 Inspect visually piston skirt and body for scoring or

scuffing 1.3 Inspect piston crack using Magnaflux1.4 Zyglo test for checking surface crack1.5 Groove width top ring, 2nd ring and 3rd ring New –(0.1902”- 0.1921”) Limit - 0.1950’’1.6 Side clearance in above rings New - ( 0.0052” -0.0088’’) Limit- 0.012”1.7 Groove width of oil scrapper ring New - (0.3140” – 0.3150’’) Limit - 0.3165”1.8 Side clearance in oil ring New - ( 0.002”-0.0040’’) Limit- 0.006”1.9 Piston pin to bushing clearance running New – (0.003”- 0.0070’’) Limit – 0.0075”1.10 Piston pin to snap ring total clearance 0.076” – 0.118”

2. Availability of tools , Test Stands etc.2.1 Feeler gauge



Make Of Subassembly


Observations

2.2 Zyglo testing machine2.3 Magna flux2.4 Vernier caliper2.6 Piston ring groove gauge

3

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



1. Cleaning, inspection, measurements etc.Cleaning1. Immerse the piston in an alkaline solvent solution

and allow carbon deposits are loosened.2. Wash the piston using steam or hot water 3. Blow dry using compressed air.4. Remove any carbon deposits from the compression

ring grooves. 5. Using 3/32" and 5/32" drills in the respective holes,

clean the oil passages in the oil ring grooves.6. Remove under crown deposits.1.1 Inspect visually cylinder wall and top of piston for any scoring mark and water leak indication etc.

EMD -- EMD Engine Maintenance

Manual

Chapter on piston

1.2 Measure side clearance of no 1 compression ring.



Make Of Subassembly


Observations

1.3 Inspect piston skirt for scoring or scuffing 1.4 cleaning of piston 1.5 Inspect piston crack using Magnaflux Check piston ring groove wear step. Check tin plated surface of the piston skirt should

be satisfactory condition (0.0007”-0.0015”)1.6 Piston skirt diameter min 9.0485”1.7 Out of round max 0.005”1.8 Piston to carrier pilot cl max 0.011”1.9 Piston platform to bottom of snap ring groove 6.626” -6.639”1.10 No 1 compression ring groove width max 0.201”1.11 Piston to Cy head cl 0.020”- 0.068”1.12 Compression ring to land clearance No 1 groove Max 0.012”1.13 Compression ring to land clearance No 2 & 3 groove Max 0.015”1.14 Compression ring to land clearance No 4 groove Max 0.015”1.15 Oil ring groove width 0.251- 0.2541.16 Oil ring to land clearance 0.002- 0.006”

2. Availability of tools, Test Stands etc.2.1 Feeler gauge2.2 Zyglo testing machine2.3 Magna flux2.4 Vernier caliper2.5 Lead wire



Make Of Subassembly


Observations

2.6 Piston ring groove gauge

3



5

Material Availability5.1 Vital Spares5.2 Must change items


CHECK SHEET FOR QUALITY AUDIT OFAIR & EXHAUST VALVE MAINTENANCE

During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference documents. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:

SN Requirements Loco Type Make of Subassembly

Reference Details

Clause/Para/Item details

Observations

1

Measurements etc:

Alco --

Alco Instruction Manual (MI-

11020G)

Chapter on Cylinder Heads

1.1 Stem dia of valves 0.6205-0.6195 (New).1.2 Groove fillet radii 0.025-0.031R.1.3 Valve disk thickness: for C and F type valve of 450: (a) 0.1562” (new) and (b) 0.0625”(condemning Limit).1.4 Valve disk thickness (for E type valve 300) 0.1750”(new). And, 0.0937”(condemning Limit).1.5 Blue matching of valve with VSI1.6 Zyglo testing for crack detection1.7 Grit blasting for removal of carbon deposition

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

3 Availability of instructions etc:3.1 Display Chart etc3.2 Training of Staff3.3 Record keeping of tools and measuring instruments



Reference Details


Observations

4 Record keeping for traceability:

5Material Availability:5.1 Vital Spare5.2 Must change items

1

Measurements etc:

EMD

--

EMD Engine Maintenance

Manual

Chapter on cylinder

heads and accessories

1.1 Stem diameter-measured within 12.7 mm (1/2”) of weld and 12.7 mm (1/2”) below P/N stencil on stem- Min. – 15.761mm (0.6205”).1.2 Valve face angle 30000’-29045’’.1.3 Valve seat runout-Max-0.06mm(0.0025’’). 1.4 Valve rim thickness (measured at O.D.)- Min.- 2.77mm (0.109”); Valve face width-Max- 8.71mm(0.343”).1.5 Surface finish of valve stem roughened not beyond 0.635µmm(25µin)1.6 Blue matching of valve with VSI1.7 Zyglo testing for crack detection1.8 Grit blasting for removal of carbon deposition

2

Availability of tools, test stands etc.2.1 Single valve compressor (Part No 8033783)/Multiple valve spring compressor (Part No 9546582) 2.2 115V grinder for Grinding Valves

3 Availability of instructions etc.3.1 Display Chart etc



Reference Details


Observations

3.2 Training of Staff3.3 Record keeping of tools and measuring instruments.

4 Record keeping for traceability.



Annexure-IIICHECK SHEET FOR

QUALITY AUDIT OF TURBO SECTION During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.



Make Of Subassembly

Reference Details

Clause/Para/Item Details

Observations

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

5.65.6.2.55.6.2.5

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

Alco ABB VTC 304 Turbocharger

ABB-Exhaust Gas

Turbocharger VTC 304 A

Comprehensive Manual for Indian Railways issued by M/s ABB

Para 5.2.4.13 &details in 5.4.2.1

1.4 Bearing position OD B 50.987--51.000 mm1.5 Bearing position OD C 56.10-56.20 mm1.6 Piston ring recess S 2.58-2.85 mmWheel Bush1.7 Compressor wheel set OD A 56.10 -56.20 mm

Para 5.2.4.13 &details in 5.4.2.2

1.8 Piston ring recess S 2.58-2.85 mm

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



Make Of Subassembly

Reference Details


Observations

details in 5.4.2.3

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

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

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

&details in 5.4.2.6

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

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

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

1.18 Axial clearance A 0.11-0.32 mm Para 5.2.4.13



Make Of Subassembly

Reference Details


Observations

&details in 5.7

1.19 Radial clearance B 0.47-0.93 mm

2.

Availability of Tools, Test Stands etc.

Alcodo do

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

3



5

Material Availability5.1 Vital Spares5.2 Must change items

1

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

Alco Alco 720 Instruction Manual

ALCo MI 11126

1.2 Turbine blade and gas inlet casing 0.060-0.092”Dia CI1.3 Nozzle ring and turbine disc 0.124” cold CI1.4 Intermediate casing and impeller 0.017-0.065”



Make Of Subassembly

Reference Details


Observations

longitudinal Clearance (long Cl)

ALCO

1.5 Impeller and Blower inlet 0.035-0.075” long CI1.6 Blower casing end blower inlet measure with bolt loose. Scatting with back of diffuser at lease to 80% (This is only in case when we apply a new diffuser) 0.005-0.020” Long CI (Gap)1.7 Turbine disc and intermediate casing 0.008-0.016” Long CI1.8 Bearing and thrust collar (Blower end) with surface by approx 0.003 less when oil. 0.007-0.018” Thrust CI1.9 Inducer and blower casing 0.091-0.101”Dia CI1.10 Thurst collar and oil seal Blower End 0.014-0.036” Dia CI1.11 Interference between bearing and intermediate casing (blower & Turbine end ) 0.0005-0.0015” Dia Cl1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008” Dia CI1.13 Gas inlet casing and intermediate casing inside measurement 0.090-0.098” Dia CI1.14 Impeller and intermediate casing 0.125-0.127” Dia CI1.15 Max allowable clearance between Gas inlet casing & Nozzle ring 0.005” clearance

2Availability of tools, Test Stands etc.2.1 Balancing machine2.2 Zyglo machine2.3 Casing hydraulic test stand



Make Of Subassembly

Reference Details


Observations

AlcoAlco 720 Instruction

ManualALCO

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

3

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




CHECK SHEET FORQUALITY AUDIT OF HHP TURBO FITMENT & MATCHING PROCEDURE.

During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded. DLW /BSB issued Design Bulletin No. DB/01/2015/26,dt.11/05/15 for defining the procedure of fitment and matching of turbocharger on HHP

locos a diesel sheds to arrest the failure of HHP turbocharger.


Sn. Loco No.

Schedule

Date 1st notch TSC LOP at

comp. bearing support.(not less than 12

psi)

8st notch TSC LOP at comp. bearing support

HHP Turbocharger clearance HHP Turbo Impeller Eye clearance Remark

TSC inlet(TSC

filter)A

TSC outlet at (support Comp.

bearing)B

LOP dropA-

B(Should not

exceed 34 psi)

Turbine shaft thrust6-24 thou

Backlash-TSC drive

gear & TSC idler gear 6-18

thou

Backlash-Auxi . drive gear 10-22 thou

Auxi. Drive gear

thrust 133-162

thou

At 12 O’clock24-48 thou

At 3 O’clock16-39thou

At 6 O’clock12-25thou

At 9O’clock16-39 thou

1



CHECK SHEET FOR TECHNICAL AUDIT OF RADIATOR SECTION


Shed/Rly: Audited by: Date of audit:SN Requirements Loco

TypeMake/class Of Subassembly

Reference Details

Clause/Para/Item/Chapter

Details

Observations

1

Cleaning etc

AlcoConventional

Alco MI -15 Rev.10, Feb-

2018, Page-12

Chapter on Maintenance,

Radiators.Cleaning of

Radiator

1.1 cleaning details

2

Availability of tools, Test Stands etc. 2.1 Torque wrench up to 140 ft-lb.2.2 Hydraulic testing machine 0-10 Kg/Cm22.3 Radiator stand 2.4 Fin combing tool 2.5 Radiator immersion tank for cleaning

3

Availability of instructions etc.3.1 Display board etc3.2 Training of staff3.3 maintenance manual and check sheets3.4 Calibration facility for tools and measuring instruments

4Record Keeping for Traceability

5. Material Availability:



Make/class Of Subassembly

Reference Details

Clause/Para/Item/Chapter

Details

Observations

5.1 Vital spares 5.2 Must change Item

1.Cleaning etc

EMDMechanical

Bonded Radiator (MBRs)

EMD MI-549, Rev-B, for Tube

leak repair & service data

Chapter on Maintenance,

Radiators.

Cleaning details

2.

Availability of Tools, Test Stands etc2.1 Torque wrench up to 140 Ft-lbs2.2 Hydraulic testing machine 0-10 Kg/Cm22.3 Radiator stand 2.4 Fin combing tool 2.5 Radiator immersion tank

3.

Availability of Instructions etc3.1 Display board – Cleaning and test procedure of the MBRs3.2 Training of staff3.3 All maintenance manual and check sheets3.4 Calibration facility for tools and measuring instruments

4.Record Keeping for Traceability

5.Material Availability:5.1 Vital spares – Gaskets and Radiator core panel 5.2 Must change Item – Gaskets during overhauling

CHECK SHEET FOR


QUALITY AUDIT OF ALCO LOCO FUEL INJECTION PUMP (FIP) & INJECTOR MAINTENANCE

During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.


SN Requirements Loco type

Make /Class/Name of subassembly

Reference details


Observations

1 Availability of tools/Equipment for maintenance Alco

Bosch 17 mm / 18 mm

Bosch repair and testing manual

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

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

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




Reference details


Observations

18) Fixture for injector19) Socket wrench20) Test oil

2

Availability of test benches and other related equipments:

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

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

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

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

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




Reference details


Observations

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

b) Slowly pop a few times prior to installation 8 Audit of Reconditioning

8.1 Dismantling of injector components 8.2 Cleaning & Inspection of injector components

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

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

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

FIP testing1) FIP range control rack bush dia -18.25

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

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

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

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

15 kgf.m or 94-109 lbs-ft)




Reference details


Observations

4) Chattering test5) Valve seat tightness test6) Fuel leak test7) Spray pattern test

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

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

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

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

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

pressure




Reference details


Observations

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

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

10 M & P1) FIP calibration test stand 2) Fuel pump motor efficiency checking test bench 3) Profile gauge for checking of HP line 4) Injector test stand

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

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


During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.




Reference details


Observations

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

(MUI)

Ecotip Superstack Injector Maintenance Instructions of Interstate McBee USA

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

2 Availability of test benches and other related equipment’s: EMD

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

3 Availability of instructions1) Display charts related to reconditioning




Reference details


Observations

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

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

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

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

8 Audit of Reconditioning8.1 Dismantling of injector components

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

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




Reference details


Observations

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

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

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

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

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

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

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

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

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

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




Reference details


Observations

d) Injector gear- Clean gear teeth and outside surface by brushing. Clean inside using 12 mm diameter soft metal brush mounted in a motor driven chuck and wash gear in cleaning solution.

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

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

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

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

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

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

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

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

8.4 List of Must change items in Ecotip Super stack Kit -




Reference details


Observations

(i)Spray tip (ii) spring cage (iii) spacer (iv) spring seat (v) valve spring (vi) check valve cage (vii) filter (viii) copper gasket.

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

wire wheel if necessary) and inspect:

a) Follower assembly- Removes retainer, stop pin and spring. Regrind follower face to

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

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

Threads must be free from nicks or other damage.

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

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

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

new.

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

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

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

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




Reference details


Observations

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

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

c) Injector nuts - i) Inspect the outside of the nut for pits around the spray

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

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

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

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

and rough spots. The rack must be straight.

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

The assembly sequence is as follows:




Reference details


Observations

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

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

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

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

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

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

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

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

12) Slide the plunger into the cutout at the bottom of the follower. Position the flat side of the plunger so that it aligns with




Reference details


Observations

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

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

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

9 INJECTOR TESTING Testing of injector

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

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

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

4) Make these tests with the pressure shutoff valve open all the




Reference details


Observations

way. If the tests are satisfactory, all injector tests may be made without using the shutoff valve.5) If the preceding tests indicate leakage in the stand, repeat the tests, closing the shutoff valve before timing the leak off rates.

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

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

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

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

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

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

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




Reference details


Observations

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

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

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

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

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

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




Reference details


Observations

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

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

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

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

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

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

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

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

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




Reference details


Observations

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

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

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

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

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

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

k) Two newly reconditioned injectors should be set to the calculated high and low limits established in steps h and i above and used daily to verify calibration of your test stands. Master Injectors should be stored in their original case and used only for periodic checks or if problems arise.

11 a) CALIBRATING INJECTOR OUTPUT Install the injector in the calibration stand and let the injector run in the calibration stand for a period sufficient to stabilize the injector temperature (Body of the injector should be 40◦ C or greater) Run a test cycle to check the output. If the output is not




Reference details


Observations

within the range established by the High and Low master injectors, adjust the calibrating slide.b) INJECTOR OUTPUT AND SLIDE ADJUSTMENT INJECTOR OUTPUT DATA: Test oil …………………………Viscor 1487AW2 or equivalent Test oil temperature ……………………………… 35° C to 40° C Test oil pressure ………………………………..35 psi (241.3 kPa Test stand speed ……………………………….. 900 RPM c) 710 ECOTIP Injector (NEW P/N 40083540,DLW- P/N 16241186 UTEX P/N 40079007) Output :

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

Annexure-IVCHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTOR PINION & GEAR ASSLY.

During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:

S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT1.1 Pinion Drg. No. 18 teeth, SKDP36241.2 Pinion Bedding In Cold Not less than 95 %



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

Condition

Alco (WDM2, WDM3A, WDM3D)

WDG3A

Traction Motor Pinion & Gear

Assly. of Alco Loco

MP-IB.EM.10.31.08

dated 24.10.2008

MP-MI 129/86 July 1986

MP-MI 5

1.3 Pinion Advance 2.25 TO 2.45MM1.4 Heating Temperature 190ºC + AMB TEP.1.5 Span Size on New Pinion Over 3 teeth

88.595 /88.722MM1.6 Condemning Limit on

Basis of Span Size of Pinion

Over 3 teeth 86.995MM

1.7 Gear Drg. No. 65 teeth SKDP3623 & SKDP3775

1.8 Span Size on New Gear Over 7 teeth 223.989/223.798MM

1.9 Condemning Limit on Basis Of Span Size of Gear


1.10 Permissible Backlash With New Set

0.266 - 0.664MM

1.11 Condemning Limit on Basis of Backlash

1.04MM

1.12 Crack detection MPMI or Zyglo test 2 TRACTION GEAR & PINION

2.1 Gear Ratio 18 : 742.2 Pinion Drg. No. 18 teeth, SKDP34432.3 Pinion Bedding In Cold

Condition Not less than 95 %

2.4 Pinion Advance 2.30 TO 2.45MM



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

HHPWDG4

Traction Motor Pinion & Gear

Assly. of HHP LocoMP-

IB.EM.01.04.14 dated

21.08.2014

2.5 Heating Temperature 185ºC + AMB TEP.2.6 Span Size on New Pinion Over 3 teeth 81.976

/82.093MM2.7 Condemning Limit on

Basis of Span Size of Pinion


2.8 Gear Drg. No. 65 teeth SKDP3444 & SKDP3546

2.9 Span Size on New Gear Over 8 teeth 231.36/231.177

2.10 Condemning Limit on Basis of Span Size of Gear

Over 8 teeth 228.140

2.11 Permissible Backlash With New Set

0.243 - 0.608MM

2.12 Condemning Limit on Basis of Backlash

1.00MM

2.13 Crack detection MPMI or Zyglo test3 MEASUREMENT

3.1 TRACTION GEAR & PINION

WDG4

3.2 Gear Ratio 17 : 903.3 Maximum limit of

Backlash23 (In Thou)0.58 (in MM)

3.4 Minimum limit of Backlash

10 (In Thou)0.254 (in MM)

3.5 Condemning limit of 37 (In Thou)



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

Backlash 0.94 (in MM)

HHPWDP4

3.6 SPAN size (“K”) for Traction Pinion service wear limit

Over 3 Teeth 67.40 / 67.45 mm

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

Over 3 Teeth 65.80 / 68.85 mm

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

Over 13 Teeth 328.70 / 328.75 mm

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

Over 13 Teeth 325.50 / 325.55 mm

3.10 Condemning Teeth Profile wear limit of Traction Pinion


3.11 Condemning Teeth Profile wear limit of Traction Bull Gear


4 MEASUREMENT4.1 TRACTION GEAR &

PINION WDP4

4.2 Gear Ratio 17 : 774.3 Maximum limit of

Backlash24 (in Thou)0.61 (in MM)

4.4 Minimum limit of 11 (in Thou)



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

Backlash 0.280 (in MM)

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

4.5 Condemning limit of Backlash

39 (in Thou)1.00 (in MM)

4.6 SPAN size (“K”) for Traction Pinion service wear limit

Over 3 Teeth 77.00 / 77.05 mm

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

Over 3 Teeth 75.35 / 75.40 mm

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

Over 11 Teeth 314.40 / 314.45 mm

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

Over 11 Teeth 311.20 / 311.25 mm

4.10 Condemning Teeth Profile wear limit of Traction Pinion

18.5 (In Thou)0.47 (in MM)

4.11 Condemning Teeth Profile wear limit of Traction Bull Gear

31.5 (In Thou)0.80 (in MM)

5 TA FAN ASSEMBLY 5.1 Outer diameter of TA fan 1387.25/1387mm5.2 Bore diameter of TA

stator1392mm

5.3 Bore diameter of TA fan 600.00 / 600.03mm



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

EMD locos

(WDP4 & WDG4)

Traction Motor Gear Case of EMD

Locos

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

MP.IB.EM.03.12.

10 (Rev 01) 20.6.2017

5.4 Diameter of fan seating area on barrel.

600.03 / 600.06mm

5.5 Width of fan seating at bore

9+1 mm

5.6 Depth of counter sunk bolts hole

4.5 - 5.5 mm

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

fan plate after final assembly should not be more than

6- 7mm

5.9 Circumferentially Fan gap on TA

2.50 – 2.75mm

5.10 Tightening torque and wire locking process

28 – 30Kg-m

5.11 Tightening torque of M30 (coupling bolt)

170 – 180 kg-m.

5.12 Oil catcher thickness (at bottom side)

53.90 to 54.10mm

5.13 Bolts strength properties grade

R8.8.

5.14 Sunk type M20 bolts can be used

in place of fully threaded M20 bolts

5.15 M20 & M30 bolts should be replaced

After 4 – 5 years’ service of TA

5.16 Fan bore area should be 150 to 170 °С



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

heated (for shrink fit).

As above

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

GO & NO GO thread ring or plug gauge

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

Visual inspection is required

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

In place of (bolts) press fit.

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

As shown in photo

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

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

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

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

5.23 TA Gear train assembly Backlash at Steel plate



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

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

6 Traction Motor Gear Case of EMD Locos6.1 Following items must be checked before fitment/

assembly of top and bottom half gear case6.2 The Heli -coil insert should be checked for looseness.

If loose, an oversized insert should be used or the same insert should be used with Loctite / araldite.

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

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

6.5 Inter changeability of the two halves is not permitted.

6.7 The 6mm hole must be kept clean.6.8 The breather valve must be kept clean6.9 The bolts must be tightened with the required

torque of 35 ft. and 990ft pound6.10 The tightening sequence as described in the report

must be followed.6.11 The pinion inspection hole must be properly plugged

by welding6.12 Oil level should be checked as per Dip stick given in

Annexure B of IB.6.13 OEM recommended sealants DOW Corning DC-3-



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

0100 and (RTV) GE Seal mate TRV-1473 should be used. Expiry date should also be checked before use & Dow corning sealant can be procured from M/s Dow Corning India Pvt. Ltd. Mumbai.

7 AVAILABILITY OF TOOLS AND TEST STANDS7.1 Vernier Callipers7.2 Disc Mike7.3 Filler Gauge8 INSTRUCTION

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

10 MATERIAL AVAILABILITY10.1 Vital Spare -NA10.2 Must change items -NA

CHECK SHEET FOR QUALITY AUDIT OF TRACTION MOTORS


SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

AlcoTraction Motors of

Alco Loco

MP.MI-2 &MP.MI-6

Maintenance manual issued by OEMs viz. BHEL/CGL.

1.1 PRE-INSPECTION1.2 Record IR of

a) Armature (Shall be > 10 MΩ)b) Inter Pole (Shall be > 10 MΩ )c) Main Pole (Shall be > 10 MΩ)

1.3 Record ovality of commutator (Limit – 0.001”)1.4 Check Carbon Brushes

a) Condemning sizeb) Clearance between commutator and brush

holderc) Tension of brush holder’s spring

2 AFTER DIS-MANTLING2.1 Pinion to be sent for Magna flux test / Zyglo test2.2 Visual examination of Armature banding. If required,

repair it.2.3 Check commutator dia. for condemning size. Replace

commutator, if condemning size reached. If commutator is retained, then check millivolt drop to ensure health of bar to bar shortening. If required, repair it.

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

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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

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

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

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

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

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

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

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

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

commutator & cure it.2.16 Ensure mica cutting. & chamfering as per OEM’s

manual2.17 Ensure cleaning & baking of brush arms as per



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

OEM’s manual.2.18 Measure IR of brush arm (Shall be > 100 MΩ). If less,

replace the brush arm2.19 Ensure the spring tension. (Lt. 4.5 Kg to 5.5 Kg) 2.20 Ensure the replacement of PTFE sleeve of brush arm.2.21 Ensure painting of support arm with red becktol

varnish.2.22 Conduct high potential test as per OEM’s manual2.23 Tan Delta Test on Armature as per OEM’s manual

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

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

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

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

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

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

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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

3.9 Apply recommended sealant to avoid ingress of water etc.

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

4.1 1000V Megger4.2 Filler gauge4.3 HV tester4.4 Dial gauge4.5 Tachometer / Speedometer4.6 Pyrometer4.7 Inside & Outside micrometre /calliper4.8 High Potential Testing Machine4.9 Tan Delta Machine5 INSTRUCTION

5.1 Display Chart5.2 Training of Staff5.3 Record keeping of tools and measuring instruments6 TRACEABILITY7 MATERIAL AVAILABILITY& STORAGE (AC/Non-AC)

7.1 Vital Spare7.2 Must change items



CHECK SHEET FOR QUALITY AUDIT OF TRACTION MOTORS- HHP LOCOMOTIVES



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP locos (WDP4, WDP4B, WDP4D,

WDG4D & WDG4)

Traction Motors of HHP locos

(WDP4, WDP4B, WDP4D, WDG4D

& WDG4)

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

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

insulation damage or cut marks.

1.3 Inspect all cable cleats for broken studs, excessive tightness and rubber cleat damage.

1.4 Inspect all sensor (Speed &Temp) plugs for correct locking.

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

1.6 Inspect all motors for any hit marks, physical damage and presence of all end shield cover bolts.

1.7 Inspect cable junction plates and umbrella boots for signs of damage or overheating.

1.8 Ensure all cables are routed properly and there is no excess/short cable over hangs.

1.9 Apply insulation/spacers at all locations where cables are rubbing each other and with locomotive body.

1.10 Blow all the traction motors with dry compressed air1.11 Gear case mounting:

Check Gear Case oil level by dip stick as per



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

MP.IB.EM.03.12.10), March’ 2010). Add if required.Traction Motor Cables and Cleats:

Check for any signs of damage/rubbing on the TM cables and cleats

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

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

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

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

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

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

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

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

March’ 2010.1.23 Aluminium cover oil path should be cleaned before



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

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

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

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

2.3 Check Sensor cables and earthing cables2.4 Provide cable cleats and spacers wherever necessary.2.5 Secure cables with cable ties.3 BELLOW ATTENTION

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

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

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

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

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

4.4 Check all TMs for any hit marks and external damage.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

4.5 Check all TMs for any gear case oil entry or grease oozing.

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

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

5.2 Check and torque both DE and NDE side bolts (36mm) with a value of 680 Nm.

5.3 Scrap all motors with wire brush.5.4 Clean all the power cables, sensor cables and earth

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

6.1 5000V Megger6.2 Filler gauge7 INSTRUCTION

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



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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

All Alco locos

Traction Motor Bearing & Assly. Components of

Alco Loco

MP-IB.EM.14.50.0

8dated 20.02.2009

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

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

1.4 Radial Clearances of bearings:For New BearingsBearing Radial clearance

before mounting (mm)

Radial clearance after mounting

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

1.5 In addition to above, max. service radial clearance:NU 330 0.300 max. 0.250 max.NH 320 0.190 max. 0.150 max.

1.6 Flinger - PEBore Dia. 153.130 to 153.155



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

Total Width 12.65 to 12.701.7 Retaining collar - PE

Bore Dia. 146.015 to 146.040 mmTotal Width 12.65 to 12.70 mmOuter Dia. 253.225 to 253.290 mmHub Outer dia. 177.040 to 177.090 mmOuter dia. on 2nd Groove 210.610 to 210.670 mmGroove width 8.00 to 8.05 mmTotal width 44.4 to 44.6 mm

1.8 End shield - PEBore dia. 319.975 to 319.995 mm

1.9 End shield - CEBore dia. 214.980 to 215.00 mm

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

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

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

Interferences (Diametrical) Clearances (Diametrical

Brg. Sleeve 0.020 to Brg. 0.635 to



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

to shaft 0.065 mm Sleeve to inner brg. cap

0.750 mm

Flinger to shaft

0.065 to 0.110 mm

Retaining collar to outer brg. cap

0.25 mm (min.)

Inner race to shaft

0.035 to 0.080 mm

--- ---

Retaining collar to shaft

0.090 to 0.135 mm

--- ---

1.12.2 Commutator end bearing:Interferences (Diametrical) Clearances

(DiametricalBrg. Sleeve to shaft

0.020 to 0.065 mm

Inner brg. Cap to sleeve

0.635 to 0.750 mm

Flinger to shaft

0.065 to 0.110 mm

-- --

Inner brg. Race to shaft

0.025 to 0.060 mm

--- --

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

Bearing inner race PE 100 -110 ºCBearing inner race CE 100 -110 ºC



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

Sleeve (PE) 100 -130 ºCSleeve (CE) 100 -130 ºCFlinger (PE) 100 -120 ºCEnd shield (PE) 120 -130 ºCEnd shield (CE) 120 -130 ºCRetaining collar (wiper) 120 -130 ºC

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


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


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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT/WORK TO BE DONE

Alco Locos MSU with BRGMP.IB.

EM.01.22.09 (Rev.01), Sep.’18

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

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

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

nipples.1.5 Check and replace earthing brushes if missing /

damaged.1.6 Carefully inspect the suspension bearing housing for

cracks and if found, bearing housing must be replaced.

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

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

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

1.10 Check end play as per the procedure given in



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

manual.1.11 In order to arrest loosening /dropping /breakage of

bolt of suspension tube, tightening torques is revised as under:

Actual size of bolt/screws

Torque in Kg.cm.

M 10x30 (Property Class

12.9)

245 to 295 400 to 600

M 12x90(Property Class

12.9)

418 to 503 800 to 1000

M 36x110(Property Class

12.9)

12100 to 14500

14500

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

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

Recommended size of screws

Recommended Loctite

M 10 to M 16 Loctite 243, MY-T-Loc-



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

3330 & Anabond-131M 20 to M 36 Loctite 2760

1.14 For M36 bolts, spring lock washers/disc lock washers must be used.

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

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

2 INSTRUCTION2.1 Display Chart2.2 Training of Staff2.3 Record keeping of tools & measuring instruments3 TRACEBILITY4 MATERIAL AVAILABILITY



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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT DURING MOTOR ASSEMBLILY

All EMD/HHP locos

Traction Motor Bearing & Assly. Components of

HHP Loco

OEM’s/Manufacture

s drawings

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

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

1.3 Rotor ShaftBearing seating area DE (without pinion)

159.910 to 159.940 mm

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

Bearing seating area339.910 to 339.950 mm

1.5 Bearing Housing NDE: Bearing seating area

279.948 to 280.000 mm

1.6 Radial Clearance of DE bearing before pinion fitment

SKF & FARO make: 0.340 to 0.370 mm.



REFERENCE DETAILS

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ITEM DETAILS

OBSERVATION

FAG (Schaeffler) make:0.115 to 0.165 mm

1.7 Radial Clearance of DE bearing after pinion fitment

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

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


5.1 Vital Spare 5.2 Must change items

CHECK SHEET FOR


QUALITY AUDIT OF TRACTION ALTERNATOR-RECTIFIERDuring the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:


REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP locos (WDP4, WDP4B,

WDP4D, WDG4D &

WDG4)

Traction Alternatorof HHP loco

Maintenance Instruction for

Traction Alternator of

HHP loco

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

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

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

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

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

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

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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

surface are set at.125”-140”. For vertical positioning of dual box brush holder, ensure that the tips of each brush holder are the same distance to the slip ring on each side.

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

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

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

(f) Ensure polarity reversal of excitation supply at every 6 months.

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

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

dlw.m.65.262



REFERENCE DETAILS

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OBSERVATION

connections.(h) Ensure proper gap maintained between CA

covers and fly wheel coupling bolts as per DLW Design bulletin to avoid rubbing or damage to CA covers.

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

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

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

dtd. 27.07.16



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

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

ETI – 897

ETI – 904

1.2 COLD RESISTANCE LIMITS (in Ohms at 75°C):For Main Alternator:- Rotor Collector Ring to Collector Ring =

1.384(Nominal), 1.439(Max), 1.328(Min).- Stator Line-to-Neutral (Per 5 Phase Group) =

0.00300(Nominal), 0.00306(Max), 0.00294(Min).

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

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

1.51(Nominal), 1.54(Max), 1.48(Min).- Stator Line-to-Line (Per 5 Phase Group) =

0.00435(Nominal), 0.00445(Max), 0.00428(Min)

CT Resistance: 11.8±10% Ohms at 25°C.1.3 (a) ROLLER BEARINGS:

- Outer diameter = 259.999 mm (+ 0.00 mm/ - 0.036 mm),

- Bearing Bore = 1200.00 mm (+ 0.00 mm/ - 0.020 mm),



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

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

mm Min,- Bearing Housing Bore Inside Diameter =

260.1152 mm (+0.102 mm/ -0.00 mm)

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

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

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

damage or damage caused by shorting to ground

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

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

(d) All diodes in any paralleled group must be of the same polarity (ceramic cases or shrink tubing or colour band at the lower crimpmust be the same colour), and of same type (same



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

type number impressed). The diodes must be applied to the proper heat-sink bus.

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

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

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

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

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

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

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

2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 - Induction Heater



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

Assembly2.2 - Torque Wrench 0 – 50 ft/lbs. – 1/2” Drive,

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

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

(Range 0 to 1.999 miliohms) 3 INSTRUCTION

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



CHECK SHEET FOR SMALL MOTOR OF ALCO LOCOMOTIVEQUALITY AUDIT OF SMALL MOTOR



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco Small Motor of Alco Loco

MP.MISC-141 (Rev-01),

September 2006

.

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

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

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

2.13 INSTRUCTION




CHECK SHEET FOR STARTER MOTOR OF HHP LOCOMOTIVEQUALITY AUDIT OF STARTER MOTORS



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP

Starter Motor of HHP Loco


August 2012&

MP-IB-EM 02.07.14 (Rev.-

00), January 2015

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

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

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

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

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

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

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

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

2.1 Digital multimeter 2.2 Magger 3 INSTRUCTION



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION




CHECK SHEET FOR RADIATOR FAN OF HHP LOCOMOTIVEQUALITY AUDIT OF RADIATOR FAN



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP Radiator Fan of HHP Loco


August 2012&

MP.0.24.00.55 (Rev-01),

October 2009

.

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

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

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

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

2.1 Digital multimeter 2.2 Magger 3 INSTRUCTION




CHECK SHEET FOR FPM OF HHP LOCOMOTIVEQUALITY AUDIT OF FUEL PUMP MOTORS



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP Fuel Pump Motor of HHP Loco


August 2012

.

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

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

1.3 Ensure the intactness of terminal box & cable conduct.

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

2.1 Digital multimeter 3 INSTRUCTION




CHECK SHEET FOR FPM OF ALCO LOCOMOTIVEQUALITY AUDIT OF FUEL PUMP MOTORS



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco Fuel Pump Motor of Alco Loco


September 2006

.

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

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

1.3 Ensure the intactness of terminal box & cable conduct.

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

2.1 Digital multimeter3 INSTRUCTION




CHECK SHEET FOR RTTM BLOWER OF ALCO LOCOMOTIVEQUALITY AUDIT OF RTTM BLOWER



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco RTTM Blower of Alco Loco


September 2006

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

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

washer is in position and locked1.4 Check the belts for condition and tension.1.5 Check blower impeller for shifting2 AVAILABILITY OF TOOLS AND TEST STANDS3 INSTRUCTION




CHECK SHEET FOR AUXILLIARY GENERATOR OF HHP LOCOMOTIVEQUALITY AUDIT OF AUXILLIARY GENERATOR



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

HHP

AG of HHP Loco


AUGUST 2012

.

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

for any insulation damage.1.3 Check for intactness of covers with bolts.1.4 Check for any unusual sound & rubbing marks

1.5 Check covers terminal connections etc.2 AVAILABILITY OF TOOLS AND TEST STANDS

3 INSTRUCTION3.1 Display Chart

Training of Staff3.3Record keeping of tools and measuring instruments

4 TRACEABILITY5 MATERIAL AVAILABILITY



Annexure-VCHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL ROOM(Item: MBCS + MCBG +E type control)

During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.

Shed/Rly: Audited by: Date of audit:SN Requirements Loco Type Make Of

SubassemblyReference Details Clause/

Para/Item Details

OBSERVATION

List of measuring equipment Calibration status Test bench set up facility Segregation of tested equipments

Check List of safety and critical items identified ECS operation check GR operation check Eng. Stop button check OST open check MUSD stop switch check LWS check GFOLR operation check (E type loco) Governor dry run check Flasher light Head light Classification light Horn

ALCo andHHP

Schedule inspection


SN Requirements Loco Type Make Of Subassembly

Reference Details Clause/Para/Item

Details

OBSERVATION

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

Eng Temp switch setting at 68ºC, 74ºC, 90ºC, 95ºC( not applicable in MBCS Loco)Proper closing of all covers and gaskets are intact in TCC, ECC1, ECC2, ECC3 and ECC4(Dual Cab)Practice for Handling of the electronic cards and storing

ALCo Doc No. :IM 53 for MBCS Medha

Availability of crimping tool & connector pin details ALCo Doc No. :IM 53 for MBCS Medha

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

Micro Controller Based Governor (MCBG) MEG 601 ALCo Doc No:IM-11 Rev. 0.0 Date Jan 2009 of Medha

1. Measurement




Details

OBSERVATION

Test procedure for MBCS loco 8th notch power curve

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

2. Availability Of Tools And Test Stands

Alco3

Availability Of Instructions Etc3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments


5

Material Availability

5.1 Vital Spares


TA Volts

TA Amps.a. Amb. Temp.b. Corrected THP c. Fuel rack in mmd. NLV (Specified 1130VDC)e. 8th notch power curve f. Notch separation testIdle to full HP time (specified 40 sec)1st notch current limit (specified 32- 33.5mA)



Details

OBSERVATION

5.2 Must change items

7 Availability of Tools And Test Stands

8

Availability Of Instructions Etc8.1 Display Chart8.2 Training of staff8.3 Maintenance manual and check sheets8.4 Record keeping of tools and measuring instruments

9 Record Keeping For Traceability 10 Material Availability


CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERATING FIELD CONTACTOR CONTACTORS (ALCo LOCO)




Make Of Subassembly

Reference Details Clause/Para/Item Details

Observations

1. Measurement1.1 Control voltage 72+1 vdc, All Diesel

Electric Locomo tives (ALCo)

Drawing No. EL/PT/0640/ Altr

R3Part

No 12145439

RDSO Drg No.4141

Technical details given in the drawing

1.2 Max pick up volt 48v , 1.3 Main contact gap12-14.5mm, 1.4 Wipe 8-10 mm, 1.5 Contact pressure( kgf) initial 1.82-2.95,final 5.45-

7.25, 1.6 Operating coil resistance at 20 deg c 104 -116

ohm, (approx.),1.7 Interlock (gpr type : 9-41n, 3no+3nc) 1.8 Contact gap 9.5-10.5 mm, 1.9 Interlock contact pressure 220-300g.



Make Of Subassembly


Observations

1.10 Contact impression (should be min 80%) Spec No. MP.0.04.00.08

(Rev-02), Aug’18

Pg 21,Clause 4.1.4

1.11 IR Value between(i) Main contacts(ii) Coil and magnet frame(iii) Interlocks and coil shorted together and earth.(iv) Contacts of interlocks(v) Interlocks and coil shorted together and main

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

and earth

IEC 60571

as per clause 10.2.9

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

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

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

2.8 Oscilloscope



Make Of Subassembly


Observations

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

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

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

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

6.1 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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

7. Material Availability



Make Of Subassembly


Observations

7.1 Vital Spares

7.2 Must change items7.3 Consumables

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

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

following relevant environmental norms


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




Make Of Subassembly


Observations

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

Drawing No. EL/PT/0649/ Altr

R5Part

No 12310372

RDSO Drg. No SKDP 4136

Technical details given in the drawing1.2 Control voltage 72+1 V DC,

1.3 Operating air pressure 4.9 kg/cm2,1.4 Min operating air pressure 3.85 kg/cm2,1.5 Main contact gap19.05+1.6mm,

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

1.7 Contact impression (should be min 80%)

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



Make Of Subassembly


Observations

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

20degC-526 to 594 Ohms.


(Rev 02), Aug’18Pg 14,Clause 6.5

1.13 IR Value between(i) Main contacts and frame (ii) Frame and all live parts connected

together (wth main cxontacts closed)(iii) Terminals of both side, terminals shorted

together on each side (Main contacts open)

(iv) All control and Aux. circuit

IEC 60571 as per clause 10.2.9



respective voltage (24 V – 72 V DC)2.15 Variac2.16 Lever of 122.5 mm for measuring initial and final

pressure.2.17 Compresor with air reservoir



Make Of Subassembly


Observations

2.18 Meggar

2.19 Oscilloscope


3.10 Display Chart3.11 Flow Chart 3.12 Training of staff3.13 Proper Display of Do’s and Don’t3.14 Maintenance manual and check sheets3.15 Record keeping of tools and measuring

instruments 3.16 Instruction Bulletin/ Mod sheet issued by RDSO3.17 Maintenance Manual of Manufacturer3.18 Specification Spec No.

MP.0.04.00.08 (Rev- 02), Aug’18

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

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

6.3 Proper Register is maintained for 6 M Reverser with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.



Make Of Subassembly


Observations

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

7. Material Availability7.4 Vital Spares

7.5 Must change items7.6 Consumables

8. Disposal8.3 Segregation of Workable and Non-Workable

equipments and proper house keeping8.4 Proper Disposal of Materials including recycling

following relevant environmental norms


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




Make Of Subassembly


Observations

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

Diesel Electric Locomotives (ALCo)

Ref:DLW Drawing No.

EL/PT/0648/ Altr R5

Part No 12310300

RDSO Drg. No SKDP 4137

Technical details given in the drawing1.2 Control voltage 72+1 V DC,

1.3 operating air pressure 4.9 kg/cm2, 1.4 Min operating air pressure 3.85 kg/cm2 , 1.5 Main contact gap19.05+1.6mm,, 1.6 Main contact - outside pressure (with lever) 1.7 4.0-4.5kgf, inside pressure 5.8-6.5kgf, 1.8 Auxiliary contact pressure 0.68-2.0 kgf, 1.9 Auxiliary contact gap 31.75mm (min), 1.10 Magnet valve coil resistance at 20degC 1.11 615+5% ohm. for BHEL TYPE : M5027MV21.12 ROTEX TYPE: 3118AV1-3 coil resistance at 20degC

526 to 594 Ohms


(Rev- 02), Aug’18Pg 14,Clause 6.5



Make Of Subassembly


Observations

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

together (wth main cxontacts closed)(iii) Terminals of both side, terminals shorted

together on each side (Main contacts open)

(iv) All control and Aux. circuit

IEC 60571

as per clause 10.2.9



respective voltage (24 V – 72 V DC)2.26 Variac2.27 Lever of 122.5 mm for measuring initial and final

pressure.2.28 Compresor with air reservoir2.29 Meggar

2.30 Oscilloscope


3.19 Display Chart3.20 Flow Chart



Make Of Subassembly


Observations

3.21 Training of staff3.22 Proper Display of Do’s and Don’t3.23 Maintenance manual and check sheets3.24 Record keeping of tools and measuring

instruments 3.25 Instruction Bulletin/Mod sheet issued by RDSO3.26 Maintenance Manual of Manufacturer3.27 Specification

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

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

6.5 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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

7. Material Availability7.7 Vital Spares7.8 Must change items7.9 Consumables

8. Disposal



Make Of Subassembly


Observations

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

8.6 Proper Disposal of Materials including recycling following relevant environmental norms


CHECK SHEET FOR TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo/ HHP LOCO)




Make Of Subassembly


Observations

1. Dis Assembly and Assembly ALCo/ HHP

Maintenance manual of

Wood Ward

Section 5 of Maintenance Manual

2. Measurement :2.1 Physical Examination ALCo/

HHPWood Ward

Governor Test Record Format No. TSP/F8572-

828 and Maintenance

manual of WoodWard

Section 6 of Maintenance Manual2.2 Barometer Reading

2.3 Pressure Test2.4 Hydraulic Seals, needle valve seat and buffer

piston bypass in both direction2.5 Needle Valve setting2.6 Speed Setting2.7 Normal Shut Down2.8 Pressure Requirement2.9 Speed Setting timing2.10 Lube Oil Shutdown2.11 Air Box Pressure Fuel Limiting2.12 Load Control2.13 Vane Servo Timing2.14 Excitation Resistor2.15 General



Make Of Subassembly


Observations

2.16 Verification with Cover Installed

3.

Availability Of Tools And Test StandsALCo/ HHP

3.1 Test Stand for Wood Ward Governor3.2 Multimeter with valid Calibration3.3 Screw Driver, Plier, Allen Key, Spanner, etc.3.4 Fire Extinguisher of proper class

4.

Availability Of Instructions etc.3.28 Display Chart3.29 Flow Chart 3.30 Training of staff3.31 Proper Display of Do’s and Don’t3.32 Display of Trouble Shooting Chart Maintenance

ManualSection 4

3.33 Maintenance manual and check sheets3.34 Record keeping of tools and measuring

instruments 3.35 Instruction Bulletin /Mod sheet issued by RDSO NA3.36 Maintenance Manual of Manufacturer

3.37 Specification NA

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

NA

6.Follow of Maintenance Manual of Manufacturer

7.Record Keeping For Traceability

6.7 Proper Register is maintained for Governor



Make Of Subassembly


Observations

testing with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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

8.

Material Availability

7.10 Vital Spares

7.11 Must change items7.12 Consumables like Lub Oil, Cotton wool, etc.

9. Disposal

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

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


Annexure-VICheck sheet for Quality Audit of Diesel Loco Sheds (Loco Design Group Items)

(Under frame/cattle guard/ fuel tank/ / painting/cab/ battery box/ superstructure/ CBC/ side buffers)During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.


Sl. No. Activity Reference/ Clause ObservationsUnder frame

01 Under frame to be kept on trestle at lifting lugs.02 Proper cleaning & washing of U/F with detergents & water.04 i. Visual inspection of buffer beam, striker block for any

crack or damage, accordingly repair/weld properlyii. Check the buffer base bolt holes for size, centers &

ovality. Remove the ovality by welding and re- drill if necessary

05 i. Check the Cattle guard/Rail guard by visual inspection, if any crack/ damage found then it should be repaired/replaced accordingly

ii. Ensure minimum clearance of cattle guard from R/L to be 178 mm

iii. Ensure minimum clearance of rail guard from R/L. to be 115 mm

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

06 Visual inspection of welding of gussets/ stiffeners in back of buffer beam transferring buffing force from buffers to maintain longitudinal box section. If any crack /damage is found, it shall be repaired accordingly.


Sl. No. Activity Reference/ Clause Observations07 Visual Inspection of Footstep for welding crack/damage and

shall be repaired by welding properly or replaced.08 i. Visual inspection of welding of Hand rails to under

frame. If there is any crack or damage in weld then reweld it properly.

ii. All fasteners are used for securing hand rail, clamp, hand rail support should be properly tighten

09 The coupler pocket shall be examined closely for welding cracks/damage in ribs and inspection of welding with under frame. If any crack or wear is found, shall be repaired properly.

14 i. Visual inspection of Battery box below side sill/bottom plate for corrosion & welding cracks in wear plate, end plates & support plate. If there is any crack or corrosion then it should be rewelded or replaced it

ii. Mounting block, nut & bolt should be properly secured and tighten

iii. Wooden spacer properly placed between the batteryiv. All hinges, locks should be in workingv. Cover assly. properly secured & locked with battery box.


Sl. No. Activity Reference/ Clause Observations15 i. Ensure proper cleaning & washing of Fuel tank to

remove dirt, sludge deposited inside/ outside the tank.ii. Inspection of fuel tank for any leakage or cracks.

iii. Inspection of drain valve, glow rod and for any crack repair by welding or replace if found beyond repair.

iv. Mounting block, nut & bolt should be properly secured and tighten

v. Fuel gauge should not be broken and in working condition

vi. Fuel gauge mounting bracket, filler cap, vent pipe should be in good condition

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

16 Visual inspection of Under frame box section and side sill welding. If there is any crack or damage, weld it properly with low hydrogen welding electrode.

RDSO’s MP.INV-8 December’1995

17 i. Carefully examine the welding around the both Center Pivots for crack and also check the surface with magnaflux or die-penetrant method to identify cracks, if any, which is not visible to naked eyes.

ii. If any crack is found, weld it properly with down hand welding.

RDSO Drg. No.SK.DL-2069(for WDM2/3A locomotive)

18 i. Carefully examine the welding around Side load bearers for crack and also check the surface with magnaflux or die penetrant method to identify cracks, if any, which is not visible to naked eyes.

ii. side load bearer shall be repaired

1. RDSO MP.MI- 140/88, Sep’19882. MP.IB.LD.01.08.07 (Rev.00)dated 21.08.20173. RDSO Drg. No.SK.DL-2069(for WDM2/3A Loco)

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

As per extent colour scheme


Sl. No. Activity Reference/ Clause Observations20 Center buffer coupler & Draft Gear

Check compliance of RDSO instructions for inspection and maintenanceModify uncoupling arrangement to make it top operated

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

21 Side BuffersCheck compliance of RDSO instructions for inspection and maintenance

MP.MI-116/82, Rev.02

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

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

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

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

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

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

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

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

23.3 Cab doori. Lock, hinges should be in function

ii. Glass, weather strip should be in good condition and door properly sealed in closed condition

iii. Assistant seat properly secured and in good working condition

iv. Wiper motors should be in working


Sl. No. Activity Reference/ Clause Observations23.4 Cab floor

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

corroded or broken23.5 Cont. Comp door, short hood door & Cab inner trim

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

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

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

function23.7 Fire Extinguisher

i. Mounting bracket should be in good condition and refilling facilities should be available

23.8 Air condition (if applied)i. Switches, regulator and water drainage properly in

function23.9 Token pick up arrangement

i. Token pickup rod properly joint with cab and should be in function (closing & opening)

ii. Cushion pad frame properly welded with cab and cushion mat condition should be good

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

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


Sl. No. Activity Reference/ Clause Observations24 Superstructure

i. Check the condition of sheets and repair if possible otherwise change

ii. Check hinges and door locks for proper working and repair if possible otherwise change

iii. Check for water leakage at various joints and renew weather stripes/ceilings

iv. Door panel-sheet should not bend and properly close25 Radiator compartment & Expansion tank

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

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

properly secured with rad. Comp. Structure.


Annexure-VII

CHECK SHEET FOR TECHNICAL AUDIT OF BOGIE (ALCO LOCOMOTIVE)


Shed/Rly: Audited by: Date of audit:SN Requirements Loco Type Make Of

SubassemblyReference Details Clause/

Para/Item Details

Observations

1. Measurement / Activityi) Bogie frameii) Bolster (if applicable)

Alco SeriesWDM2, WDM3A, WDG3A,WDP3A,WDP3AM & WDM3D/E/F

Maintenance Instruction no.M&C Report MP.MI-71/78VL.MI.-02/96VL.MI.-04/98MP.MI-31MC – 44 & MC - 29

Cleaning of bogie frame / Bolster Crack detection and repair Welding of Manganese Steel Liners at axle

boxes and pedestal liners

2. Complete BogieMP.MISC – 141 Item No. 165 Longitudinal and lateral pedestal clearances

3. Wheel & Axle Assembly Wheel wear management Instruction Bulletin no.MP.IB.BD.0216.01 (Rev-1) &MP MI71/78MP. MISC – 141

Clause 4.3.8Item No. 110, 161, 198,

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

Wheel gauge (1596+3/-0.5 mm)




Details

Observations

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

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

RDSO procedure MC-714. Brake rigging WDM2, WDM3A

MP.IB.VL-03.11.01MP.MISC – 141

Item No. 295 Piston travel Wear of Brake shoe Wear of Pins & Bushes

5. Axle box & journal bearings Inspection bearing components Grease condition Radial clearance Distance over liners (face and lateral) Dimensional measurement of bearing

components

MP.MISC – 141 Item No. 47, 197

6. Centre Pivot & Loading PadsMP. MISC – 141

MP.IB.VL-02.11.10

Item No. 274 & 278,Centre pivot castings and loading pads, liners

Load Pad to Centre Pivot Height Difference,7. Suspension Spring ( As per MI )

WDM2, WDM3A, WDG3A,WDM3D

Free height of spring As per relevant drawingsworking height of springGrouping / colour code of spring MP.IB.VL- 04.19.01

(Rev.01), MP.IB.VL-




Details

Observations

01.06.02 (Rev.00),MP MI-31

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

9. Equaliser Beams MP. MISC – 141,M&C document no. MC –

43 & MC-92

Item No. 52Free roller movement, Wear of hard face zone

10. Side Bearer (Rubber spring) WDG3A, WDM3D

SK.VL-127, SK.VL-608, MP.IB.VL. 04.30.08

(Rev.01)

Para 6Free Height of rubber springWorking height of rubber springPermanent set of rubber springRubber crack length/ de-bonding

11. Hydraulic damper

Para 6Capacity / Rating of dampers As per relevant drawingsDamper overhauling MP.IB.VL. 05.39.10

(Rev.01)Availability of Tools And Test Stands

Para 2 of Annexure-IPara 7

Surface table of measurement of springsHeight gauge for springs Spring load-deflection testing machine Spec. No. MP.0.4900.12

(Rev.04) Hydraulic damper testing machine MP.IB.VL. 05.39.10

(Rev.01)Torque wrench, Go/No Go GaugesInside and Outside Caliper, Vernier Caliper,




Details

Observations

Height Gauge, Cleaning Tank,Wheel wear measuring gauge SK.DL-3592

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

14. Record Keeping For Traceability15. Material Availability

Vital SparesMust Change items


CHECK SHEET FOR TECHNICAL AUDIT OF HHP LOCOMOTIVE BOGIE





Details

Observations

1. Measurements / ActivitiesGeneral Maintenance HHP loco Maintenance Instruction no.

MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.

MP. Misc-285 (Rev.00)

Para 2.0

Para 2.0

Item Nos. 19, 46

Cleaning of bogie frame under locomotive Trucks (Visual Examination) Tank immersion Lubrication Wheel and axle Inspection Journal Bearings Dampers Rubber secondary spring Brake rigging Slack adjusters, adjustment Hand brake

2. Wheel & Axle Assembly Minimum wheel diameter after last truing

operation. Maximum diameter mismatch of two wheels on a

common axle.

HHP Loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5

Para 2.3

Para 2.9




Details

Observations

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

Minimum rim thickness. Axle longitudinal limits. Circumferential defects on or below the axle

surface. Axle Run-out. Wheel wear measurement i.e. Root wear, Tread

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

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

axle, same bogie & same loco Ultrasonic testing of axles (interval of 06 months

for passenger locos & 12 months for goods loco)

Locomotive.


Wheel wear management IB no. MP.IB.BD.02.16.01 (Rev-01) & MP.MI-71/78

Para 4.3.8

3. Journal bearings Checking of running temperature of outside face

of the adopter with a temperature indicating crayon/ direct pyrometer

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

Excessive lubricant leakage from the grease seals. Broken, loose or missing parts (such as loose cap

screws, etc.)

HHP Loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.


Para 2.4

Para 2.3




Details

Observations

Loose or defective seals. Cracked or broken cups, end caps or adapters, etc.

4. Dampers Check for leaking fluid. Make certain that oil has

not been deposited from some other source and check damper per Manual Qualification Procedures before condemning.

Perform manual qualification tests to detect gross loss of control.

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

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

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

Steps to qualify vertical / yaw dampers (Refer instructions given in Para 2.5)Capacity/Rating of DamperOverhauling of damper

HHP Loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.


As per relevant drawingsMP.IB.VL-05.39.10 (Rev.1)

Para 2.5

Para 2.4

Para 6

5. Rubber Secondary Springs Free Height of rubber spring

HHP loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 &

Para 2.6




Details

Observations

Working height of rubber spring Permanent set of rubber spring Rubber crack length/ de-bondingNote: Do not wash the spring in paraffin de-greasing agents (such as trichloro-ethylene), caustic soda, or diesel fuel oil.

WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.As per relevant drawings MP.IB.VL-01.08.11 (Rev.0) MP.Misc-285 (Rev.00)

Para 5.6.4

Para No. 2.5

Para 6

6. All type of Bushings Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.MP.Misc-285 (Rev.00)

Para 3.4.1.1

Item no. 987. Lateral Thrust Pads Maintenance Instruction no.

MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.

MP.Misc-285 (Rev.00)

Para 3.4.1.2

Para no. 6.5.2.2, 6.5.2.3 and 6.5.2.4Item no. 98

8. Happy pads MP. Misc-285 (Rev.00)Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.

Item no. 98Para no.2.7




Details

Observations

9. Suspension Spring Inspect the coils for breaks or surface cracks.

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

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

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

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

Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.


Para 3.2.6

Para 2.6

10. Brake block guide (See instruction in relevant para) Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.

Para 2.7

M/s Knorr Bremse Tread brake unit PEC-7




Details

Observations


manual (B-B000.25) Rev-12Item Nos. 19, 46

11. Slack adjusters This procedure must be conducted with the

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

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

Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.


Para 2.8.2 & 2.8.3

12. Hand brake The hand brake, chain, and lever should be

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

Quarterly check: Check that all fasteners (nuts & bolts), clamps, and



Para 2.9.2

Item Nos. 19, 46

Para 2.9.4.1




Details

Observations

brackets are secure. Verify condition of chain, shackles, and pins for

corrosion, wear and damage. Replace as required. Check that the pulley on the brake handle

assembly is in good condition and properly secured. Replace if required.

Chain and other components should be lightly oiled to prevent corrosion.

13. Bogie removal:Inspections before bogie removal

Yaw Dampers Primary Suspension Secondary Suspension Springs Carbody pivot pin clearance Brake rigging Wheel condition, Wheels, Axles, Axle Gears

and Pinions Axle lateral clearances Vertical stop clearances

Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives(Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.)

M.I. 1518 and 1519


Para 2.12

Para 3.0

Para 5.5.2Para 5.5.2Item No. 98

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


Para 2.12.2

Para 3.0




Details

Observations

MP.Misc-285 (Rev.00) Item No. 9815. Bogie installation

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

Great care must be taken during this portion of the application process to prevent damage to the carbody pivot assembly and secondary suspension springs. The pivot pin and alignment dowels should slide into place easily. If this is not the case, slight movement of the bogie will be required to aid in assembly.

Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.MP.Misc-285 (Rev.00)

Para 2.13.1

Para 3.0

16. Vertical Stop Clearance to be ensured 16 mm +/- 3.2 mm


Para 2.13.2

Para 6.5.2.6

17. Final Installation Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.

Para 2.13.3

18. Bogie Overhaul While the overhaul procedures are similar for the two types of bogies, it is imperative that the correct


Para 3.0




Details

Observations

assembly drawing be used to ensure correct dimensions are achieved.Detail instructions and guide lines for overhaul of bogie to be followed as per the para 3.0 of MI 1517 (Rev. A)

Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.MP.Misc-285 (Rev.00)

Para 3.0

Item Nos. 98 & 113

19. Maintenance and wear limits Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.

Para 5.5

Para 6.5

20. Availability of Tools, Test Stands and special procedures


Work sketch 41089

Para 4.1

Lock bolt/ huck bolt installation machineWall mounted fixture to dampersSurface table of measurement of springsHeight gauge for springs Spring load-deflection testing machineHydraulic damper testing machine Torque wrench, Go/No Go GaugesInside and Outside Caliper, Vernier Caliper, Height Gauge, Cleaning Tank,Wheel wear measuring gauge SK.DL-3592

21. Availability, service data, special torque values and Instructions etc.

. Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 &

Para 5.1.1 and Para




Details

Observations

WDG4 Series of Locomotives. 5.33.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments

22. Record Keeping For Traceability23. Material Availability and parts catalogues HHP (MAC)

HHP (PAC)E26E35Vital Spares

Must Change items
