Technical/ Quality Audit of Diesel Shed CHECK SHEET

Page 1 of 121 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019

Technical / Quality Audit of Diesel Shed

CHECK SHEET

Description 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:

M24M48

-do-

Load Test/Load Box Test records:

HPSFCEGT

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 staffStatus 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.

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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

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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 befollowed.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

1.1 Cleaning of cylinder head ALCo -- DLW MaintenanceInstruction

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

22.1 Valve seat reconditioning machine2.2 Hydraulic test stand

Cleaning, measurements etc.

Availability of tools , Test Stands etc.



Make Of Subassembly


Observations

2.3 Feeler gauge

2.4 Magna flux

33.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets

3.4 Record keeping of tools and measuring instruments 4

5 5.1 Vital Spares

5.2 Must change items

1

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°F

1.3 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”

22.1 Valve seat reconditioning machine2.2 Hydraulic test stand

2.3 Feeler gauge

Availability of instructions etc.

Record Keeping For Traceability Material Availability

Cleaning, measurements etc.

Availability of tools ,Test Stands etc.



Make Of Subassembly


Observations

2.4 Magna flux arrangement

33.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments

4

5 5.1 Vital Spares5.2 Must change items

Availability of instructions etc



CHECK SHEET FORTECHNICAL AUDIT OF PISTON SECTION



Make Of Subassembly


Observations

1

1.1 cleaning of piston

ALCo--

DLW Maintenance

Instruction Manual

(MI-ENG-015)

Chapter on piston and con rod

1.2 Inspect visually piston skirt and body for scoring or scuffing 1.3 Inspect piston crack using Magnaflux

1.4 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”

2.2.1 Feeler gauge

Cleaning, inspection, measurements etc.

Availability of tools , Test Stands etc.



Make Of Subassembly


Observations

2.2 Zyglo testing machine

2.3 Magna flux2.4 Vernier caliper2.6 Piston ring groove gauge

3

3.1 Display Chart

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

4


1.

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

ManualChapter on piston

1.2 Measure side clearance of no 1 compression ring.

Availability of instructions etc

Record Keeping For Traceability

Material Availability

Cleaning, inspection, measurements etc.



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- 0.254

1.16 Oil ring to land clearance 0.002- 0.006”

2.2.1 Feeler gauge2.2 Zyglo testing machine

2.3 Magna flux2.4 Vernier caliper

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Availability of tools, Test Stands etc.



Make Of Subassembly


Observations

2.5 Lead wire

2.6 Piston ring groove gauge

3

3.1 Display Chart3.2 Training of staff

3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments

4

55.1 Vital Spares5.2 Must change items


Record Keeping For TraceabilityMaterial Availability


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

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

2 2.1 Depressor, Spring etc2.2 Grinder

33.1 Display Chart etc3.2 Training of Staff3.3 Record keeping of tools and measuring instruments

4

Measurements etc:

Availability of tools, test stands etc:

Availability of instructions etc:

Record keeping for traceability:



Reference Details


Observations

5 5.1 Vital Spare5.2 Must change items

1

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

22.1 Single valve compressor (Part No 8033783)/Multiple valve spring compressor (Part No 9546582) 2.2 115V grinder for Grinding Valves

33.1 Display Chart etc3.2 Training of Staff

3.3 Record keeping of tools and measuring

Material Availability:

Measurements etc:

Availability of tools, test stands etc.




Reference Details


Observations

instruments.

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Record keeping for traceability.Material Availability


Annexure-IIICHECK SHEET FOR

QUALITY AUDIT OF TURBO SECTIONDuring 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: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 mm

1.6 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 &details in 5.4.2.3

1.10 Bearing housing bore ID A 65.00-65.07 mm Para 5.2.4.13

Balancing, measurements etc



Make Of Subassembly

Reference Details


Observations

&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 mm

1.13 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 &details in 5.7

1.19 Radial clearance B 0.47-0.93 mm

2. do doAvailability of Tools, Test Stands etc.



Make Of Subassembly

Reference Details


Observations

2.1 Balancing machine

Alco2.2 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



4

5 5.1 Vital Spares


1

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

Alco Alco 720Instruction

ManualALCO

ALCo MI 11126

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

1.3 Nozzle ring and turbine disc 0.124” cold CI1.4 Intermediate casing and impeller 0.017-0.065” longitudinal Clearance (long Cl)1.5 Impeller and Blower inlet 0.035-0.075” long CI1.6 Blower casing end blower inlet measure with bolt


Record Keeping For TraceabilityMaterial Availability

Measurements etc



Make Of Subassembly

Reference Details


Observations

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

2

Alco

2.1 Balancing machine

2.2 Zyglo machine2.3 Casing hydraulic test stand 2.4 Oil gallery flushing test stand2.5 Bearing puller (CE & TE)

2.6 Sand blast machine for rotor cleaning




Make Of Subassembly

Reference Details


Observations

2.7 Torque wrench up to 250 psi Alco 720 Instruction ManualALCO

2.8 micrometer 2”-3” & 0-4”2.9 Go-NoGo gauge for checking fix nozzle ring



4


Availability of instructions etc .



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


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

Ø


CHECK SHEET FORTECHNICAL 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

AlcoConventional

Alco MI -15 Rev.10, Feb-

2018, Page-12

Chapter on Maintenance,

Radiators.Cleaning of

Radiator

1.1 cleaning details

2

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

3.1 Display board etc3.2 Training of staff

3.3 maintenance manual and check sheets3.4 Calibration facility for tools and measuring instruments

4

5.

Cleaning etc



Record Keeping for Traceability




Make/class Of Subassembly

Reference Details

Clause/Para/Item/Chapter

Details

Observations

5.1 Vital spares 5.2 Must change Item

1.

EMDMechanical

Bonded Radiator (MBRs)

EMD MI-549, Rev-B, for Tube

leak repair & service data

Chapter on Maintenance,

Radiators.

Cleaning details

2.

2.1 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.

3.1 Display board – Cleaning and test procedure of the MBRs3.2 Training of staff

3.3 All maintenance manual and check sheets3.4 Calibration facility for tools and measuring instruments

4.

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

Cleaning etc

Availability of Tools, Test Stands etc

Availability of Instructions etc

Record Keeping for Traceability


CHECK SHEET FOR


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

1 Availability of tools/Equipment for maintenance Alco Bosch 17 mm / 18 mm

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

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) Ring spanner-31/4"4) BWS DE-32

5) 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-5

14) Dial gauge15) Nozzle centering sleeve16) True running gauge

3/8"




Reference details


Observations

17) Nozzle tester18) Fixture for injector19) Socket wrench20) Test oil

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

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

Display charts related to reconditioning

Display charts related to testingMaintenance manual and check sheet including

calibration and functional test procedure

Record keeping of tools and measuring instruments

Store in proper Handling RackCover with plastic

Injectors are filled with calibrating oil

2

Availability of test benches and other related equipments:

3 Availability of instructions1) Training of staff2) 3)

4) 4 Availability O/H/Renew kit5 Schedule for maintenance 6 Record keeping for traceability

7 1) Storage of FIP/ Injectors-a) b) 2) Stored for longer time but <1 year

a)




Reference details


Observations

Tight fitting plastic caps used for covering the filter caps , spray tip end and on the theraded injector stud

After one year, to be filled with clean fuel/ calibrating oil again

Slowly pop a few times prior to installation

1) Cleaning of injector components

2) Check the condition of shims, guide bush, intermediate disc.

3) Lapping of intermediate disc & Injector body

1) 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”)

1) Opening pressure – 3900 to 4050 psi ( New nozzle)2) Opening pressure – 3700 to 3800 psi ( Overhauled

b)

3) Stored for more than one year a)

b) 8 Audit of Reconditioning

8.1 Dismantling of injector components8.2 Cleaning & Inspection of injector components

8.3 Must change items for reconditioning of FIP/Injector8.4 Measurements etc.

FIP testing

8.5 Injector Testing




Reference details


Observations

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

15 kgf.m or 94-109 lbs-ft)4) Chattering test5) Valve seat tightness test

6) Fuel leak test7) Spray pattern test

Check the condition of nozzleClean the nozzle assembly by Multi cleaner"

3) Ultrasonic cleaning of nozzles4) check the nozzle lift 0.016"to 0.025"

1) Check the pump phasing

2) Check the Interface between guide cup & crosshead

3) Chech the gap between HP tube and snuber valve4) Chech the alignment of HP tube5) Chech the torquing of delivery valve

6) Chech the torque valve of HP tube fitment fasteners at cylinder head

7) Chech the alignment of banjo bolt

8) Chech the alignment of fuel jumper bolt9) Chech the free movement of banjo bolt

8.6 Nozzle Test 1)2)

8.7 Fuel Injection Pump

9 Misc




Reference details


Observations

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

pressure4) Chech the air drawal at suction side of FPM

5) Annealing of copper pipes

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

2) Fuel pump motor efficiency checking test bench

4) Injector test stand

Injector Output data:

Test oil temperature………35 *C to 40 *C

Test stand RPM………………. 500 RPM

10 M & P1) FIP calibration test stand

3) Profile gauge for checking of HP line

11 Injector output and Slide Adjustment

Test oil……. Viscor 1487 AW2 or equivalent

Test oil pressure………..35 psi (241.3 kpa)


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

1 Availability of tools/Equipment for maintenance

1)

2) 3) 4)

5) 6) 7) 8)

9) 10) 11)

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

1) 2)

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

Ecotip Superstack Mechanical

Unit Injector (MUI)

Ecotip Superstack Injector Maintenance Instructions of Interstate McBee USA

EMD timing gauge

Vise with adapterControl rack set length blocksPop and Leak test stand

Torque wrenchOptical flatMonochromatic light sourceSoft wire buffing wheel

12 mm dia. Soft wire brushInjector nut reamerWrench for injector nut

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




Reference details


Observations

Master Injector Kit (Part No. 4992244.) This kit contains Low Master Injector P/N 4991173 and High Master Injector P/N 4991174

Display charts related to reconditioning

Display charts related to testingMaintenance manual and check sheet including calibration

and functional test procedureRecord keeping of tools and measuring instruments

Availability of 3 Yearly OVH kitSchedule for maintenance of MUIsRecord keeping for traceability

Store in proper Handling Rack

Cover with plastic

Injectors are filled with calibrating oilTight fitting plastic caps used for covering the filter caps ,

spray tip end and on the threaded injector stud

After one year, to be filled with clean fuel/ calibrating oil again Slowly pop a few times prior to installation

3)

3 Availability of instructions1)

Training of staff2) 3)

4)

4567 1) Storage of Mechanical Unit Injectors-

a)

b) 2) Stored for longer time but <1 yeara) b)

3) Stored for more than one year a) b)

8 Audit of Reconditioning

8.1 Dismantling of injector components




Reference details


Observations

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

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.

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

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

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.

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

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

Remove the spill deflector and bushing straightly.Remove and discard the body to nut seal ring.

) 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.

a)

b)

c)

d)

e)

f)

g)

h) i) J

8.2 Cleaning & Inspection of injector componentsCleaning of injector components




Reference details


Observations

-To clean entire body by using brush (1” diameter china bristle) and fuel passage by using dry compress air.

-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.

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

- 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.

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

- 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.

- 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 .

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

a) Bodies

b) Injector nut

c) Injector rack

d) Injector gear

e) Plunger and bushing (P&B)

f) Plunger

g) Bushing

h) Spill deflector




Reference details


Observations

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.

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.

-

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

-

Clean some of the parts listed below by washing (buff on soft wire wheel if necessary) and inspect:

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.

-No nicks, cracks, brinneling in the flare seat and gasket areas.

Threads must be free from nicks or other damage.

Demagnetize and load test; discard if not within the following Specification: 51.0-57.0 pounds at 2.750 inches load length.

Replace if broken or damaged; no load test required.

i) Gear retainer-

8.3 Must change items for reconditioning of injector :

8.4 List of Must change items in Ecotip Super stack Kit

8.5 Remaining injector parts

a) Follower assembly-

b) Filter Caps

c) Follower (Plunger) Spring-

d) Filter Springs-




Reference details


Observations

-Copper gaskets must be discarded after use and replaced with new.

- Must be discarded and only new OEM diamond shaped seal rings must be used in order correctly seal the nut to the body.

Should be carefully inspected for any burrs, metal slivers or bad threads. The body and all drilled passages should be clean.

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 .

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.

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

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)

e) Copper Gaskets

f) Injector Nut Seal Ring

8.6 Inspection of injector components

a) Bodies-

b) Plunger and Bushing-

c) Injector nuts -

i)

ii)

iii)




Reference details


Observations

To move freely, Control Rack and Gear should be free from burrs and rough spots. The rack must be straight.

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:

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.

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.

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

Apply gear retainer on top of the gearPosition the bushing on the body so locating pin enters the

slot in the body and place spill deflector over the bushing. Remove the cap from the ECOTIP Superstack kit and

carefully place the stack onto the bottom of the bushing.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

d) Control Rack and Gear -

8.7 Assembly of Injector-

1)

2)

3)

4) 5)

6)

7)




Reference details


Observations

torque to 150 ft-lbs (203 Nm).

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

Install stop pin, spring, and retainer in the follower.

Apply follower spring in place on injector body.Position the rack so that the flat in the ID of the gear is

known relative to the injector body.Slide the plunger into the cutout at the bottom of the

follower. Position the flat side of the plunger so that it aligns with the flat on the gear in the body, the follower stop pin and with the stop pin slot in the body.

Place the follower and plunger assembly into the body.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.Continue pressing on follower until stop pin enters slot.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.

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.

8)

9)

10) 11)

12)

13) 14)

15) 16)

17)

9 INJECTOR TESTINGTesting of injector




Reference details


Observations

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.

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

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.

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

If the preceding tests indicate leakage in the stand, repeat the tests, closing the shutoff valve before timing the leak off rates.

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.

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.

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.

In making holding tests, do not pump the stand above 2500

a) Qualifying the Test stand –1)

2)

3)

4)

5)

6)

b) General Information :1)

2)

3)




Reference details


Observations

psi (172 Bar). Test stands regularly in use should be checked daily for leaks,

using the test blocks. Calibrating oil used for testing should not be reused.

Remove the protective plastic caps from the filter caps and stud.

Install the injector in the test stand. Fill the injector with calibrating oil, but do not connect the fuel

line from pump to injector at this time.

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

“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”.

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

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.

4)

5) c) Spray pattern and Valve chatter test

1)

2) 3)

4)

5)

6)

d) Holding Pressure& leak Test:1)




Reference details


Observations

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.

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.

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.

Maintain a constant clamp force on the injector body to insure a good cone seal and to prevent body movement.

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

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

2)

e) Rack freeness test:

f) Binding Plunger test

10 QUALIFYING THE CALIBRATION STANDa) Calibration stand should1)

2)

3)




Reference details


Observations

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

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

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.

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

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

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

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.

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

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

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

4)

5)

b)

c)

d)

e)

f)

g)

h)

i)




Reference details


Observations

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

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.

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

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

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

j)

k)

11 a) CALIBRATING INJECTOR OUTPUT

b) INJECTOR OUTPUT AND SLIDE ADJUSTMENTINJECTOR OUTPUT DATA:

c) 710 ECOTIP Injector (NEW P/N 40083540,DLW- P/N 16241186 UTEX P/N 40079007) Output :


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 MEASUREMENT

Alco (WDM2, WDM3A, WDM3D)

Traction Motor Pinion & Gear

Assly. of Alco Loco

MP-IB.EM.10.31.08

dated 24.10.2008

MP-MI 129/86 July 1986

MP-MI 5

1.1 Pinion Drg. No. 18 teeth, SKDP36241.2 Pinion Bedding In Cold

Condition Not less than 95 %

1.3 Pinion Advance 2.25 TO 2.45MM

1.4 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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

2 TRACTION GEAR & PINION

1.11 Condemning Limit on Basis of Backlash

1.04MM

WDG3A

HHPWDG4

Traction Motor Pinion & Gear

Assly. of HHP LocoMP-

IB.EM.01.04.14 dated

21.08.2014

1.12 Crack detection MPMI or Zyglo test

2.1 Gear Ratio 18 : 74

2.2 Pinion Drg. No. 18 teeth, SKDP34432.3 Pinion Bedding In Cold

Condition Not less than 95 %

2.4 Pinion Advance 2.30 TO 2.45MM2.5 Heating Temperature 185ºC + AMB TEP.

2.6 Span Size on New Pinion Over 3 teeth 81.976 /82.093MM

2.7 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 test



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

3 MEASUREMENT

HHPWDP4

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 Backlash


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 30 (In Thou)



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

4 MEASUREMENT

Profile wear limit of Traction Bull Gear

0.77 (in MM)

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

4.1 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 Backlash

11 (in Thou)0.280 (in MM)

4.5 Condemning limit of Backlash

39 (in Thou)1.00 (in MM)

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

18.5 (In Thou)0.47 (in MM)



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

5 TA FAN ASSEMBLY

Traction Pinion

EMD locos

Traction Motor Gear Case of EMD

Locos

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

4.11 Condemning Teeth Profile wear limit of Traction Bull Gear

31.5 (In Thou)0.80 (in MM)

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 / 600.03mm5.4 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.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

5.12 Oil catcher thickness (at bottom side)

53.90 to 54.10mm

(WDP4 & WDG4)

MP.IB.EM.03.12.

10 (Rev 01) 20.6.2017

As above

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 heated (for shrink fit).

150 to 170 °?

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

Clearance between the fan (back side) and



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

6 Traction Motor Gear Case of EMD Locos

inserting filler gauge circumferentially

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 plate5.24 TA GEAR 102T

AG/EG PINION 43TPTU PINION - 43T

0.60mm to 1.40mm0.05mm to 0.12mm onshaft

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

6.2 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 clean



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

7 AVAILABILITY OF TOOLS AND TEST STANDS

8 INSTRUCTION

9 TRACEABILITY10 MATERIAL AVAILABILITY

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

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

6.11 The pinion inspection hole must be properly plugged by welding

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

6.13 OEM recommended sealants DOW Corning DC-3-0100 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.

7.1 Vernier Callipers7.2 Disc Mike

7.3 Filler Gauge

8.1 Display Chart8.2 Training of Staff

8.3 Record keeping of tools and measuring instruments

10.1 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 MEASUREMENTPRE-INSPECTION

2 AFTER DIS-MANTLING

AlcoTraction Motors of

Alco Loco

MP.MI-2 &MP.MI-6

Maintenance manual issued by OEMs viz. BHEL/CGL.

1.1

1.2 Record IR ofa) Armature (Shall be > 10 MO)b) Inter Pole (Shall be > 10 MO )

c) Main Pole (Shall be > 10 MO)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

2.1 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.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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.

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 MO) 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 MO )

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.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

ASSEMBLY

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

manual

2.17 Ensure cleaning & baking of brush arms as per OEM’s manual.

2.18 Measure IR of brush arm (Shall be > 100 MO). If less, replace the brush arm

2.19 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

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

ohma) Armature (Shall be > 100 MO)

b) Inter Pole (Shall be > 100 MO )c) Main Pole (Shall be > 100 MO)

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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION


5 INSTRUCTION

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.

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.

4.1 1000V Megger4.2 Filler gauge4.3 HV tester

4.4 Dial gauge4.5 Tachometer / Speedometer4.6 Pyrometer4.7 Inside & Outside micrometre /calliper4.8 High Potential Testing Machine

4.9 Tan Delta Machine

5.1 Display Chart5.2 Training of Staff5.3 Record keeping of tools and measuring instruments



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

6 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

Gear case mounting:

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

Check Gear Case oil level by dip stick as per



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

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

2 CABLE ROUTING

3 BELLOW ATTENTION

4 TM INSPECTION

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.

2.1 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.

3.1 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.

4.1 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

5 TORQUING AND CLEANING


7 INSTRUCTION

8 TRACEABILITY

9 MATERIAL AVAILABILITY

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

4.6 Provide back all the inspection covers.

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.

6.1 5000V Megger6.2 Filler gauge




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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Max. deviations allowed in above cases:

Radial Clearances of bearings:

In addition to above, max. service radial clearance:

Flinger - PE

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 race

1.3Side Inner race Outer race

Pinion End 0.075 mm 0.25 mmCommutator End 0.065 mm 0.20 mm

1.4For 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

1.5NU 330 0.300 max. 0.250 max.NH 320 0.190 max. 0.150 max.

1.6Bore Dia. 153.130 to 153.155



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1.7 Retaining collar - PE

1.8 End shield - PE

1.9 End shield - CE

1.10 Seat diameter on armature shaft

1.11 End Float on Traction motor (TM 4907) CE

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

Total Width 12.65 to 12.70

Bore Dia. 146.015 to 146.040 mmTotal Width 12.65 to 12.70 mmOuter Dia. 253.225 to 253.290 mm

Hub Outer dia. 177.040 to 177.090 mmOuter dia. on 2nd

Groove210.610 to 210.670 mm

Groove width 8.00 to 8.05 mmTotal width 44.4 to 44.6 mm

Bore dia. 319.975 to 319.995 mm

Bore dia. 214.980 to 215.00 mm

For 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 mm

For inner brg wiper CE 101.600 to 101.620 mm

Limit – 0.50 mm Aim – 0.42 mm

Interferences (Diametrical) Clearances



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1.12.2 Commutator end bearing:

1.13 Heating temp. of brg. & assly. components

(DiametricalBrg. Sleeve to shaft

0.020 to 0.065 mm

Brg. Sleeve to inner brg. cap

0.635 to 0.750 mm

Flinger to shaft

0.065 to 0.110 mm

Retainingcollar 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

--- ---

Interferences (Diametrical) Clearances (Diametrical

Brg. Sleeve to shaft

0.020 to 0.065 mm

Inner brg. Cap to sleeve

0.635 to 0.750 mm

Flinger to shaft

0.065 to 0.110 mm

-- --

Inner brg. Race to shaft

0.025 to 0.060 mm

--- --

Item Heating temp.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION


3 INSTRUCTION


Bearing inner race PE 100 -110 ºCBearing inner race CE 100 -110 ºCSleeve (PE) 100 -130 ºCSleeve (CE) 100 -130 ºCFlinger (PE) 100 -120 ºC

End shield (PE) 120 -130 ºCEnd shield (CE) 120 -130 ºCRetaining collar (wiper) 120 -130 ºC

2.1 Dial gauge


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

2 INSTRUCTION

3 TRACEBILITY4 MATERIAL AVAILABILITY

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.

2.1 Display Chart2.2 Training of Staff2.3 Record keeping of tools & measuring instruments



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

Cylindrical Roller Bearing (Drive end)

Deep Groove Ball Bearing (Non drive end)

Rotor Shaft

All EMD/HHP locos

Traction Motor Bearing & Assly. Components of

HHP Loco

OEM’s/Manufacture

s drawings

1.1Bearing ID (Inner race) 159.945 to 159.970 mm

Bearing OD (Outer race) 339.960 to 340.000 mmBearing Width 67.75 to 68.00 mm

1.2Bearing ID (Inner race) 129.975 to 130.000 mm

Bearing OD (Outer race) 279.965 to 280.000 mmBearing Width 57.75 to 58.00 mm

1.3Bearing 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

SKF & FARO make: 0.340 to 0.370 mm.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION


3 INSTRUCTION

TRACEABILITY

MATERIAL AVAILABILITY

fitment 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

2.1 Dial gauge

3.1 Display Chart

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

55.1 Vital Spare 5.2 Must change items


CHECK SHEET FOR QUALITY AUDIT OF TRACTION ALTERNATOR-RECTIFIER



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT1.1

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

(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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

the brush holder(s) trailing edge to Slip Ring surface are set at.125”-140”. For vertical positioning of dual box brush holder, ensurethat 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

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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

partition wall provided on AG

TA rotor and CA rotor, ensure proper cable lug connections.

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

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

dlw.m.65.262 dtd. 27.07.16

•

•



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

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

For Companion Alternator:

CT Resistance1.3 (a) ROLLER BEARINGS:

service of loco in such condition may lead to: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

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)

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)

: 11.8±10% Ohms at 25°C.

Outer diameter = 259.999 mm (+ 0.00 mm/ -0.036 mm),Bearing Bore = 1200.00 mm (+ 0.00 mm/ -

•

•

•

-

-

-

-

-

-

-



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

(b) Lubrication Capacity:

1.4 RECTIFIER:

0.020 mm),Width = 85.99 mm (+ 0.00 mm/ - 0.13 mm),Internal Clearance (before assembly) = 0.104 mm to 0.150 mm,Internal Clearance (after assembly) = 0.063 mm Min,Bearing Housing Bore Inside Diameter = 260.1152 mm (+0.102 mm/ -0.00 mm)

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

(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

--

-

-

---



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

Note:


be the same colour), and of same type (same type number impressed). The diodes must be applied to the proper heat-sink bus.

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

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

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

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

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

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

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.



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

2.1

2.2

3 INSTRUCTION

4 TRACEBILITY5 MATERIAL AVAILABILITY

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

Assembly- 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)


3.3 Record keeping of tools & measuring instruments



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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT


3 INSTRUCTION

4 TRACEABILITY


Alco Small Motor of Alco Loco

MP.MISC-141 (Rev-01),

September 2006

.

1.1 Check brush pig-tail screws for tightness

1.2 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.

2.1




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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT


3 INSTRUCTION

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 ohm

1.2 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 solenoid

1.4 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.

2.1 Digital multimeter 2.2 Magger



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


3 INSTRUCTION


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 ohm

1.2 Check clearance between the longest blade and fan shroud

1.3 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.

2.1 Digital multimeter 2.2 Magger

3.1 Display Chart

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

5.1 Vital Spare



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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT


3 INSTRUCTION


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 motors

2.1 Digital multimeter





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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT


3 INSTRUCTION


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 motors

2.1 Digital multimeter





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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

2 AVAILABILITY OF TOOLS AND TEST STANDS3 INSTRUCTION


Alco RTTM Blower of Alco Loco


September 2006

1.1 Check the alignment of pulleys

1.2 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 locked

1.4 Check the belts for condition and tension.1.5 Check blower impeller for shifting

3.1 Display Chart

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



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



REFERENCE DETAILS

CLAUSE/PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT


3 INSTRUCTION

4 TRACEABILITY


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.

3.1 Display ChartTraining of Staff3.3Record keeping of tools and measuring instruments



Annexure-VCHECK SHEET FOR

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

SN Requirements Loco Type Make Of Subassembly

Reference Details Clause/Para/Item Details

OBSERVATION

ALCo andHHP

Schedule inspection

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.


List of measuring equipment Calibration status

Test bench set up facilitySegregation of tested equipments

Check List of safety and critical items identifiedECS operation checkGR operation checkEng. Stop button checkOST open checkMUSD stop switch checkLWS checkGFOLR operation check (E type loco)Governor dry run checkFlasher lightHead lightClassification lightHornSanders and direction

•

•

•

•

üüüüüüüüüüüüü




OBSERVATION

1. Measurement

üüüüüüü

Cab light and exterior lightsAlerter, lamp, alarm and resetFlasher lights switch panelGR, DB cut out and B/B cut out sealsIndication panelsAttendant call bellCab 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

Test procedure for MBCS loco 8th notch power curve

TA Volts

TA Amps.

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




OBSERVATION

2. Availability Of Tools And Test Stands

3

Availability Of Instructions Etc

4 Record Keeping For Traceability

5


7 Availability of Tools And Test Stands

8

Availability Of Instructions Etc

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)

Alco


5.1 Vital Spares



8.3 Maintenance manual and check sheets8.4 Record keeping of tools and measuring




OBSERVATION

9 Record Keeping For Traceability 10 Material Availability

instruments


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


Make Of Subassembly


Observations

1. MeasurementDrawing No.

EL/PT/0640/ Altr R3

Part No 12145439

RDSO Drg No.4141

Technical details given in the drawing



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

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

Spec No. MP.0.04.00.08

(Rev-02), Aug’18

Pg 21,Clause 4.1.4

IEC 60571

as per clause 10.2.9

2.0

2.4

1.10 Contact impression (should be min 80%)

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 earthAvailability of tools and stands2.1 Multimeter with proper calibration

2.2 Vernier calipers with valid calibration2.3 Go- No gauge suiting to different cantactors

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

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

2.6 Variac2.7 Meggar

2.8 Oscilloscope



Make Of Subassembly


Observations

3. Availability Of Instructions etc.

4. Compliance of Instruction Bulletin

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

7. Material Availability

2.9 Screw Driver, Plier, Spanner Set, 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

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.



Make Of Subassembly


Observations

8. Disposal

7.1 Vital Spares

7.2 Must change items7.3 Consumables

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

8.2 Proper Disposal of Materials including recycling following relevant environmental norms


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


Make Of Subassembly


Observations

1. Measurement1.1 Ref:-DLW

Drawing No. EL/PT/0649/ Altr

R5Part

No 12310372

RDSO Drg. No SKDP 4136




Auxiliary contacts 4, change over type, ALCo

1.2 Control voltage 72+1 V DC,

1.3 Operating air pressure 4.9 kg/cm2,

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

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


1.8 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

Spec No. MP.0.04.00.08

(Rev 02), Aug’18Pg 14,Clause 6.5

(iv)2.0

2.13

ohm.for BHELTYPE: 5027MV2

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


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)All control and Aux. circuit

IEC 60571 as per clause 10.2.9

Availability of tools and stands2.10 Multimeter with proper calibration2.11 Vernier calipers with valid calibration

2.12 Go- No gauge suiting to different cantactorsDial gauge of different scale and resolution as suited to respective contactor


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


Mod sheet

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 Manufacturer


2.18 Meggar

2.19 Oscilloscope


3.10 Display Chart

3.11 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/ issued by RDSO3.17 Maintenance Manual of Manufacturer3.18 Specification

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


8. Disposal

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

7.4 Vital Spares

7.5 Must change items7.6 Consumables




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


Make Of Subassembly


Observations

1. MeasurementRef:DLW Drawing

No. EL/PT/0648/ Altr

R5Part No 12310300

RDSO Drg. No SKDP 4137


Spec No. MP.0.04.00.08

(Rev- 02), Aug’18Pg 14,Clause 6.5



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

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

1.4 Min operating air pressure 3.85 kg/cm2 , 1.5 Main contact gap19.05+1.6mm,, 1.6 Main contact - outside pressure (with lever) 1.7 4.0-4.5kgf, inside pressure 5.8-6.5kgf, 1.8 Auxiliary contact pressure 0.68-2.0 kgf,

1.9 Auxiliary contact gap 31.75mm (min), 1.10 Magnet valve coil resistance at 20degC 1.11 615+5% ohm. for BHEL TYPE : M5027MV21.12 ROTEX TYPE: 3118AV1-3 coil resistance at 20degC

526 to 594 Ohms




Make Of Subassembly


Observations

2.0

2.24


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

Availability of tools and stands2.21 Multimeter with proper calibration2.22 Vernier calipers with valid calibration2.23 Go- No gauge suiting to different cantactors

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


2.26 Variac

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

2.28 Compresor with air reservoir

2.29 Meggar

2.30 Oscilloscope


3.19 Display Chart3.20 Flow Chart



Make Of Subassembly


Observations

4. Compliance of Instruction Bulletin

5. Follow of Maintenance Manual of Manufacturer



8. Disposal

3.21 Training of staff

3.22 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 RDSO

3.26 Maintenance Manual of Manufacturer3.27 Specification

/ Mod Sheet issued by RDSO

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

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

7.7 Vital Spares7.8 Must change items7.9 Consumables



Make Of Subassembly


Observations




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


Make Of Subassembly


Observations

1. Dis Assembly and Assembly

2. Measurement :



ALCo/ HHP

Maintenance manual of

Wood Ward

Section 5 of Maintenance Manual

2.1 Physical Examination

ALCo/HHP

Wood Ward Governor Test Record Format No. TSP/F8572-

828 and Maintenance

manual of WoodWard

Section 6 of Maintenance Manual

2.2 Barometer Reading2.3 Pressure Test2.4 Hydraulic Seals, needle valve seat and buffer

piston bypass in both direction2.5 Needle Valve setting

2.6 Speed Setting2.7 Normal Shut Down2.8 Pressure Requirement2.9 Speed Setting timing2.10 Lube Oil Shutdown

2.11 Air Box Pressure Fuel Limiting2.12 Load Control2.13 Vane Servo Timing2.14 Excitation Resistor

2.15 General



Make Of Subassembly


Observations

3.

Availability Of Tools And Test Stands

4.

Availability Of Instructions etc.

Compliance of Instruction Bulletin

Follow of Maintenance Manual of Manufacturer

7.Record Keeping For Traceability

2.16 Verification with Cover Installed

ALCo/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

3.28 Display Chart3.29 Flow Chart 3.30 Training of staff

3.31 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./Mod sheet issued by

RDSONA

6.

6.7 Proper Register is maintained for Governor



Make Of Subassembly


Observations

8.


9.

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.

7.10 Vital Spares

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

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)

Sl. No. Activity Reference/ Clause ObservationsUnder frame

buffer beam, striker block

Cattle guard/Rail guard

gussets/ stiffeners in back of buffer beam

(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.


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 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 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 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 ObservationsFootstep

Hand rails

coupler pocket

Battery box

07 Visual Inspection of for welding crack/damage and shall be repaired by welding properly or replaced.

08 i. Visual inspection of welding of 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 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 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 ObservationsFuel tank

Under frame box section

Center Pivots

Side load bearers

Loco painting, marking, stencilling;

15 i. Ensure proper cleaning & washing of 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 tightenv. Fuel gauge should not be broken and in working

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

be in good condition

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

16 Visual inspection of 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 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 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)

19Apply epoxy primer and PU paint before stencilling

As per extent colour scheme


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

Side Buffers

Driver/Pilot seat

Side sash / window

Cab door

20Check 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)

21Check compliance of RDSO instructions for inspection and maintenance

MP.MI-116/82, Rev.02

23.1i. 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)

23.2i. 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

23.3i. 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 ObservationsCab floor

Cont. Comp door, short hood door & Cab inner trim

Cab light and fan

Fire Extinguisher

Air condition (if applied)

Token pick up arrangement

Front look out glass

23.4i. Flooring mat & trim should be in good condition

ii. Steel structure/ panel sheet of cab should not be corroded or broken

23.5i. Lock, hinge and weather sealing should be in working

conditionii. Perforated aluminium sheet , insulating material,

fasteners should be in good condition

23.6i. Switches, regulators and connections are properly in

function23.7

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

23.8i. Switches, regulator and water drainage properly in

function

23.9i. 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

i. Glass & weather strip should be scratches free and properly sealed with front structure

ii. Covering grill glass properly cover with hinged grill


Sl. No. Activity Reference/ Clause ObservationsSuperstructure

iv.Radiator compartment & Expansion tank

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

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

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

weather stripes/ceilingsDoor panel-sheet should not bend and properly close

25i. Gauge, vent, vacuum valve, low water alarm should

functionii. 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)



Observations

1. Measurement / ActivityAlco Series

2. Complete Bogie

3. Wheel & Axle Assembly



i) Bogie frameii) Bolster (if applicable) WDM2, 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 repairWelding of Manganese Steel Liners at axle boxes and pedestal liners

MP.MISC – 141 Item No. 165Longitudinal and lateral pedestal clearances

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)

Deference in tread diameter of wheels on

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Observations

4. Brake rigging

5. Axle box & journal bearings

6. Centre Pivot & Loading Pads

7. Suspension Spring

same axle, same bogie & same locoUltrasonic testing of axles (interval of 06 months for passenger locos & 12 months for goods loco)

RDSO procedure MC-71WDM2, WDM3A

MP.IB.VL-03.11.01MP.MISC – 141

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

Inspection bearing components

Grease conditionRadial clearanceDistance over liners (face and lateral)

Dimensional measurement of bearing components

MP.MISC – 141 Item No. 47, 197

MP. MISC – 141 MP.IB.VL-02.11.10

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

Load Pad to Centre Pivot Height Difference,( As per MI )

WDM2, WDM3A, WDG3A,WDM3D

Free height of spring As per relevant drawingsworking height of spring

Grouping / colour code of spring MP.IB.VL- 04.19.01 (Rev.01), MP.IB.VL-01.06.02 (Rev.00),

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Observations

8. Friction Snubber Assembly

9. Equaliser Beams

10. Side Bearer (Rubber spring)

11. Hydraulic damper

12.Availability of Tools And Test Stands

MP MI-31

WDM2, WDM3A MP.MISC – 141 Item No. 116Height measurement

MP. MISC – 141,M&C document no. MC –

43 & MC-92

Item No. 52

Free roller movement, Wear of hard face zone

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 spring

Rubber crack length/ de-bonding

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

(Rev.01)

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, Height Gauge, Cleaning Tank,




Observations


14. Record Keeping For Traceability15. Material Availability

Wheel wear measuring gauge SK.DL-3592


Vital Spares

Must Change items


CHECK SHEET FOR TECHNICAL AUDIT OF HHP LOCOMOTIVE BOGIE


Reference Details Clause/Para/Item

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

LubricationWheel and axle InspectionJournal Bearings

Dampers Rubber secondary spring Brake rigging

Slack adjusters, adjustmentHand brake

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Details

Observations

2. Wheel & Axle Assembly HHP Loco

3. Journal bearings HHP Loco

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Minimum wheel diameter after last truing operation. Maximum diameter mismatch of two wheels on a common axle. Maximum diameter mismatch between wheels on one axle compared to those of any other axle. These include wheels on the same bogie.

Minimum rim thickness. Axle longitudinal limits. Circumferential defects on or below the axle surface. Axle Run-out.

Wheel wear measurement i.e. Root wear, Treadwear, 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 locoUltrasonic testing of axles (interval of 06 months for passenger locos & 12 months for goods loco)



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

Para 2.3

Para 2.9

Para 4.3.8

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

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

Para 2.4




Details

Observations

4. Dampers

Steps to qualify vertical / yaw dampers

HHP Loco

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

MP.MI-33 (Rev. -00) for WDG5 Locomotive.


Para 2.3

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).



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

Para 2.5

Para 2.4

Para 6




Details

Observations

5. Rubber Secondary Springs

Note

HHP loco

6. All type of Bushings

7. Lateral Thrust Pads

(Refer instructions given in Para 2.5)Capacity/Rating of DamperOverhauling of damper

Free Height of rubber spring

Working height of rubber springPermanent set of rubber springRubber crack length/ de-bonding

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

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 drawings MP.IB.VL-01.08.11 (Rev.0)MP.Misc-285 (Rev.00)

Para 2.6

Para 5.6.4

Para No. 2.5

Para 6

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. 98Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.

Para 3.4.1.2

Para no. 6.5.2.2, 6.5.2.3 and 6.5.2.4

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Details

Observations

8. Happy pads

9. Suspension Spring

10. Brake block guide

MP.Misc-285 (Rev.00) Item no. 98

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

Item no. 98Para no.2.7

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.


MP.Misc-285 (Rev.00)

Para 3.2.6

Para 2.6

(See instruction in relevant para) Maintenance Instruction no. Para 2.7

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Details

Observations

11. Slack adjusters

12. Hand brake

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


M/s Knorr Bremse Tread brake unit PEC-7 manual (B-B000.25) Rev-12Item Nos. 19, 46

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

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


Para 2.9.2

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Details

Observations

Quarterly check:

13. Bogie removal:Inspections before bogie removal

bogie has a special spring pre-tensioning arrangement to prevent rubbing.

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

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

Check that the pulley on the brake handle assembly is in good condition and properly secured. Replace if required. Chain and other components should be lightly oiled to prevent corrosion.

MP.Misc-285 (Rev.00) Item Nos. 19, 46

Para 2.9.4.1

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

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Details

Observations

14. BOGIE ASSEMBLY REMOVAL

15. Bogie installation

16. Vertical Stop Clearance

It is required 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

Item No. 98

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.


Para 2.13.1

Para 3.0

to be ensured 16 mm +/- 3.2 mm


Para 2.13.2

Para 6.5.2.6

without exception

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Details

Observations

17. Final Installation

18. Bogie Overhaul

19. Maintenance and wear limits

20. Availability of Tools, Test Stands and special procedures


Para 2.13.3

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


Para 3.0

Para 3.0

Item Nos. 98 & 113


Para 5.5

Para 6.5


Work sketch 41089

Para 4.1

Lock bolt/ huck bolt installation machineWall mounted fixture to dampers

Surface table of measurement of springsHeight gauge for springs Spring load-deflection testing machineHydraulic damper testing machine




Details

Observations

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

22. Record Keeping For Traceability23. Material Availability and parts catalogues

Torque wrench, Go/No Go GaugesInside and Outside Caliper, Vernier Caliper, Height Gauge, Cleaning Tank,Wheel wear measuring gauge SK.DL-3592

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

Para 5.1.1 and Para 5.33.1 Display Chart

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

HHP (MAC)HHP (PAC)

E26E35Vital Spares

Must Change items