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Engineering Standard Rolling Stock

ESR 0200

SPECIFICATION FOR THE RESTORATION OF 48 CLASS

LOCOMOTIVES

Version 1.0

Issued June 2010

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

Owner: Chief Engineer Rolling Stock

Approved by:

Stephen White, Technical Specialist Rolling Stock Performance Standards

Authorised by:

Michael Uhlig, Manager, Rolling Stock Access Integrity

UNCONTROLLED WHEN PRINTED of 25

RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200

© Rail Corporation of 25 Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0

Document control

Revision Date Summary of change (RSS 0200) 1.0 August 2007 1.1 May 2008 RRS references amended (ESR 0200) 1.0 June 2010 Reformatted and renumbered

Summary of changes from previous version

Summary of change Section NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’ to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the ‘Document control’ page carries over to a second page separate pages must be used for ‘Contents’ and ‘Document control’



Contents

1 Purpose ..............................................................................................................................................5 2 Scope..................................................................................................................................................5

2.1 General procedures, dimensions & clearances ........................................................................5 3 Mandatory work.................................................................................................................................5

3.1 Strip down .................................................................................................................................5 3.2 Structure....................................................................................................................................5 3.3 Engine room..............................................................................................................................6 3.4 Pipe work ..................................................................................................................................6 3.5 Body ..........................................................................................................................................6

3.5.1 General.........................................................................................................................6 3.5.2 Engine compartment ....................................................................................................6 3.5.3 Pilot area ......................................................................................................................6

3.6 Drawgear...................................................................................................................................7 3.7 Engine, generator and auxiliary components............................................................................7

3.7.1 Overhauled engine to be supplied by RailCorp ...........................................................7 3.7.2 Overhauled engine not supplied by RailCorp ..............................................................7

3.8 Cooling system..........................................................................................................................8 3.9 Compressor...............................................................................................................................8 3.10 Electrical....................................................................................................................................8

3.10.1 Electrical control equipment .........................................................................................9 3.10.2 Low tension rewire .......................................................................................................9 3.10.3 Terminal boards ...........................................................................................................9 3.10.4 Circuit breaker replacement .......................................................................................10 3.10.5 Control stands 1 & 2...................................................................................................10 3.10.6 Low tension cable rewire............................................................................................10 3.10.7 Testing........................................................................................................................11 3.10.8 Electrical compartment...............................................................................................11

3.11 Alignment ................................................................................................................................11 3.11.1 Engine to compressor ................................................................................................11 3.11.2 Compressor to radiator fan drive................................................................................11

3.12 Fast’s coupling ........................................................................................................................11 3.13 Holset coupling........................................................................................................................11 3.14 Auxiliary drive belts .................................................................................................................11 3.15 Traction motors & blowers ......................................................................................................11 3.16 Electrical jumper junction boxes .............................................................................................12 3.17 Battery bbox ............................................................................................................................12 3.18 Bogies .....................................................................................................................................12 3.19 Brakes .....................................................................................................................................12

3.19.1 Brake equipment system blow out Procedure ...........................................................13 3.19.2 Handbrake..................................................................................................................14 3.19.3 New equipment ..........................................................................................................14 3.19.4 Modifications ..............................................................................................................14 3.19.5 Brake & vigilance control system tests.......................................................................14



3.20 Main reservoirs........................................................................................................................14 3.21 Cab..........................................................................................................................................15

3.21.1 Train radio ..................................................................................................................15 3.22 Fuel tank .................................................................................................................................15 3.23 Filters.......................................................................................................................................16 3.24 Sandboxes ..............................................................................................................................16 3.25 Vigilance control box ...............................................................................................................16 3.26 Horn assembly ........................................................................................................................16 3.27 Guards.....................................................................................................................................16 3.28 Steps and handrails ................................................................................................................17 3.29 Painting ...................................................................................................................................17 3.30 Other equipment .....................................................................................................................17

4 After inspection work......................................................................................................................17 4.1 Inspection................................................................................................................................17

5 Load testing .....................................................................................................................................17 5.1 Test report ...............................................................................................................................18

6 Road trial ..........................................................................................................................................18 7 Standard variations.........................................................................................................................19

7.1 Air conditioning........................................................................................................................20 7.2 Catalytic converter ..................................................................................................................20

8 Equipment to be supplied by RailCorp .........................................................................................20 8.1 Engine .....................................................................................................................................20 8.2 Catalytic converter ..................................................................................................................20 8.3 AEI tags...................................................................................................................................20 8.4 Train radios .............................................................................................................................20

9 Referenced standards.....................................................................................................................20 9.1 RailCorp standards .................................................................................................................20 9.2 TRS instructions......................................................................................................................24 9.3 Drawings .................................................................................................................................24 9.4 Australian standards ...............................................................................................................24 9.5 Other standards ......................................................................................................................24



1 Purpose The purpose of this standard is to describe RailCorp’s minimum requirements for the restoration (overhaul) of 48 class locomotives.

2 Scope This document outlines the minimum requirements with respect to the restoration and overhaul of the locomotive to perform reliably until its next major component change out. Also included are equipment cleaning, repair, testing and other requirements as stated.

2.1 General procedures, dimensions & clearances Unless otherwise stated all work will be carried out as per procedures in A E Goodwin Ltd Instruction Manual for the 48 class locomotives. TPI 871, ALCO Maintenance Information Bulletins and relevant ESR instructions. If one standard contradicts another then Superintendent will make a determination as to the standard that will apply.

3 Mandatory work

3.1 Strip down Remove all rubbish from the locomotive.

Remove the engine and all equipment that is to be overhauled.

Thoroughly clean the underframe, body and all other equipment.

3.2 Structure The locomotive frame is to be examined to ensure there is no major structural damage or corrosion. Any damage must be reported to RailCorp. Particular attention shall be made in examining load bearing surfaces.

Inspect the centre castings. All welds shall be die penetrate and/or magnetic particle tested in accordance with ESR 0300.

Inspect the centre casting wear plates for excessive wear in the oil lubricating grooves.

Inspect the elephant’s feet. All welds shall be die penetrate and/or magnetic particle tested in accordance with ESR 0300.

Inspect the elephant’s feet wear plates for excessive wear in the oil lubricating groove.

The engine well and fan room must be thoroughly examined to ensure there are no cracks (especially around the mounting points for the engine, compressor and eddy current clutch).

With the engine removed examine the tundish for fractures or damage, particularly in the area of the waste drain pipe. Reinforce weld around waste drain pipe.

Examine the shelf on the engine room side of the electrical cabinet for fractures. Repair as required.

Report any cracks, damage or wear to RailCorp.



3.3 Engine room Engine room walls, engine well, radiator fan room and short end hood/nose (inside) to be thoroughly cleaned and all loose debris removed and painted in alpine green.

All foot plate walk ways and locomotive access steps are to be painted with a suitable non-slip paint.

3.4 Pipe work All pipework shall receive the following attention:

• Oil & water pipework shall be thoroughly cleaned both internally and externally.

• All gaskets & seals to be renewed. All flexmaster coupling clamps are to satisfy the requirements of ESR 0254.

• Correctly secured with all U-bolts, bracket bolts and other clamps fitted.

• All flexible hoses to be replaced with new hoses (including all head stock hoses).

• Replace #3 & #4 pipes behind the headstock ensuring pipe is cut back past any corrosion (use Loctite 567 pipe sealant or similar). .

• All pipes, hoses are to be free from rubbing. Any pipes, which show signs of abrasion damage, are to be replaced.

Note: Ensure restricting orifice is fitted in turbo oil line for steel capped pistons (refer to Alco EB-11176 Subject #1F p2).

3.5 Body

3.5.1 General Repair all corrosion damage.

Replace broken or missing windows.

Replace missing or faulty headlights.

Replace missing number lights and number boards.

Repair corrosion damage to bodyside filter housings.

3.5.2 Engine compartment Engine canopies to be examined for fractures, damaged doors or hinges, excessive corrosion etc. to be repaired as required to provide a presentable appearance. Canopies doors and hinges are to function correctly and are not to have excessive wear/play.

Engine canopy body cover strap seals to be renewed.

All engine and radiator room doors must be in good working condition with all screws, hinges, handles, clips etc. fitted (door seals to be renewed).

3.5.3 Pilot area Check condition, security and clearance from rail of the pilot and correct if necessary. A minimum clearance of 100mm from the top of the rail to the lowest point on the bottom of the pilot.



Check condition and security of the automatic coupling release handle and correct if necessary.

Check condition and security of air hose dummy couplings and repair or replace as necessary.

All through cocks, main reservoir (MR), brake pipe (BP), 3 & 4 pipe to be overhauled or replaced. All cocks are to be of self venting type.

Replace air brake coupling hoses.

3.6 Drawgear Overhaul the couplers and draftgear in accordance with ESR 0520 Overhaul of locomotive drawgear.

Drawgear pocket to examine for wear and fracture, damage to be repaired to ESR 0520.

To be magnetic particle tested for cracks to ESR 0300 and any defects repaired.

Coupling height to be checked and adjusted to be 880 to 890 mm from the centre of the auto jaw to the to top of the rail head.

Yokes are to be inspected for type. A written report on yoke type is to be forwarded to the Superintendent.

3.7 Engine, generator and auxiliary components

3.7.1 Overhauled engine to be supplied by RailCorp RailCorp shall provide one (1) overhauled engine.

The engine shall be fitted and any additional equipment not supplied by RailCorp is to be overhauled and fitted as per Clause 3.7.2.

3.7.2 Overhauled engine not supplied by RailCorp The equipment to be overhauled is not limited to the following:

• Engines complete with turbo and auxiliary generator & exciter.

• All magnet valves for sanding and compressor governor application.

• Fuel transfer pump and motor.

• Low water alarm float switch.

• Temperature switch - 1 x T1 (68°C).

• Temperature switch - 1 x ETS (91°C).

• Temperature switch - 1 x T2 (74°C).

The supplier is then to assemble the engine with overhauled equipment and equipment supplied by RailCorp.

The engine and equipment is to be overhauled in accordance with

• ESR 0255 Napier & Brown Bovari turbocharger

• ESR 0300 Non destructive testing



• ESR 0550 Overhaul of engine assembly

• ESR 0551 Overhaul of power assembly

• ESR 0552 Overhaul of 320F turbocharger

• ESR 0553 Overhaul of engine crankshaft and free end drive assembly

• ESR 0554 Overhaul of engine camshaft assembly

• ESR 0555 Overhaul of engine lubrication oil system

• ESR 0556 Overhaul of Alco fuel injector pump & nozzle

• ESR 0557 Overhaul of eddy clutch and gear box

• ESR 0558 Overhaul of fuel system

• ESR 0559 Overhaul of engine block and pan

• ESR 0560 Overhaul of NA155 Napier turbocharger overhaul spec

• ESR 0561 Overhaul of engine exhaust manifold

• ESR 0575 Overhaul of air coolers

• ESR 0602 Overhaul of traction generator

• ESR 0603 Overhaul of auxiliary generator

• ESR 0606 Overhaul of fuel pump motor

• ESR 0619 Inspection, service & testing of crankshaft exhaust motors

• ESR 0620 Overhaul of traction alternators

3.8 Cooling system The cooling system is to be overhauled in accordance with ESR 0573 Overhaul of cooling water system. This specification also refers to the following specifications.

• ESR 0270 Setting of engine temperature switches

• ESR 0570 Overhaul of DE locomotives radiator overhaul

• ESR 0571 Overhaul of radiator fan drive overhaul spec

• ESR 0572 Overhaul of water pump overhaul spec

• ESR 0574 Overhaul of aftercooler overhaul spec

Radiator fan shaft bearings are to be renewed.

The Supplier is to replace the radiator cores. Supplier to source Mesabi Radiator from L & M Radiators Cnr Kew & Mars Street, Welshpool WA 6106

3.9 Compressor The air compressor is to be overhauled in accordance with ESR 0511 Overhaul of 3-CDC air compressor

3.10 Electrical The following electrical equipment is to be overhauled:

• ESR 0600 Overhaul of electrical compartment

• ESR 0604 Overhaul of AG32 exciter



• ESR 0605 Overhaul of arc chute

• ESR 0607 Overhaul of motor contactor

• ESR 0608 Overhaul of cranking contactor

• ESR 0609 Overhaul of generator field & fuel pump contactor

• ESR 0610 Overhaul of field shunting contactor

• ESR 0611 Overhaul of reverser

• ESR 0612 Overhaul of auxiliary contacts

• ESR 0613 Overhaul of control relay

• ESR 0614 Overhaul of ground relay

• ESR 0615 Overhaul of AEI master controller type 38MC

• ESR 0616 Overhaul of AEI “on” type magnet valve

• ESR 0617 Overhaul of field shunting control & transition relay

All electrical conduits are to be examined and any defects repaired. If the movement between body sections has caused the defect, suitable flexible joints are to be fitted.

View all high tension cabling looking for deterioration, cracks or oil impregnation. Report to the Superintendent if repairs are considered necessary.

3.10.1 Electrical control equipment The following electrical item components are to be removed, overhauled and refitted:

• All control relays.

• Cranking contactors. ESR 0608

• Field shunting contactors. ESR 0610

• Generator field & fuel pump contactor. ESR 0609

• Ground relay ESR 0614

• Master controller. ESR 0615

• Motor contactors. ESR 0607

• Reverser. ESR 0611

• Transition Panel. ESR 0617

3.10.2 Low tension rewire The locomotives entire low tension wiring & conduits are to be removed. Rigid conduit is to be cleaned & examined for condition & security (repair as required, variation).

3.10.3 Terminal boards Terminal boards are to be removed & replaced with Wago type at the following locations:

• Main terminal board in the electrical compartment.

• Engine room terminal board located near temperature switches.

• #1 & #2 end control jumper connection boxes.

• #1 & #2 control stands.



3.10.4 Circuit breaker replacement The following circuit breakers are to be replaced with identical rating circuit breakers:

Control compartment:

• Auxiliary generator 15 Amp

• Lighting 30 Amp

• Fuel pump 30 Amp

• Headlight 30 Amp

• Heater 30 Amp

• Air conditioning 50 Amp

• Battery 200 Amp

A suitable circuit breaker panel must be designed & manufactured by the Supplier to accommodate the new type circuit breakers into the control compartment.

3.10.5 Control stands 1 & 2. Flexible conduit replacement.

All flexible conduit must be renewed to standard ESR 0421.

All flex conduits must be suitably terminated at all connecting points & through walls.

All flex conduits to be suitably secured (saddled) to protect against rubbing & potential damage from in service operation or maintenance work of the locomotive.

All non-metallic flexible conduits must be completed to the requirements of ESR 0273.

3.10.6 Low tension cable rewire Rewire of low tension wiring must be completed to the requirements & relevant standards specified in ESR 0421.

Cable size & type used for rewire must satisfy standard ESR 0421 & current ratings stated on the supplied schematic diagrams. Where there is a conflict of information on the drawings or standards, a RailCorp representative will make a determination as to the standard that will apply.

All wiring is to be neatly loomed & secured to minimise rubbing & potential to rub through to locomotive frame & body work.

All wiring loom rails are to be suitably re-insulated

All wiring that passes through walls must be in conduit where required or securely fastened grommets, conduits where required must be suitably terminated to pass through wall.

All wiring must be clearly labelled as stated in the supplied drawings at all connection points. Labels must be able to with stand heat, oil & solvents.

Crimp lugs must be used to connect to electrical components & to be completed to the requirements of standard ESR 0421 item 13.



3.10.7 Testing On completion of rewire, all components & systems of the low tension system must be checked for correct operation.

Circuit breaker trip function to be tested.

All electrical system & components to be tested in conjunction with load testing of loco & road trial of loco.

3.10.8 Electrical compartment Must be thoroughly cleaned (Use only solvent specified in ESR 0214).

All wiring must be free from rubbing and all hot lugs and damaged wire must be replaced.

Resistor panels and resistors to be cleaned and checked for condition of insulation and repaired or replaced as necessary.

Resistor mountings are to be checked for cracks or fatigue and repaired as required.

All covers and doors must be in place and in good working condition with all screws, hinges, handles, clips etc. fitted (door seals to be renewed).

3.11 Alignment

3.11.1 Engine to compressor Engine to compressor alignment is to be carried out to Alco Instruction Manual MI-1052 (Fast's Coupling - Air Compressor Drive Installation and Alignment).

3.11.2 Compressor to radiator fan drive Compressor to radiator fan drive alignment is to be carried out to Alco Instruction Manual MI-16005B and MI-16006 (Reassemble and Alignment).

3.12 Fast’s coupling As per Alco Instruction Manual MI-1052.

Must be filled with 900 grams of Caltex Ultra Duty Grease.

3.13 Holset coupling All rubber blocks and bronze bushing must be replaced with new items.

Alignment.

3.14 Auxiliary drive belts The auxiliary drive belts are to be replaced with a complete set of new matched belts.

3.15 Traction motors & blowers Traction motors must be overhauled in accordance with the requirements of ESR 0601.

The traction motor blowers must be overhauled in accordance with ESR 0618.



The traction motor cooling air ducts shall be cleaned and serviced/repaired as required.

3.16 Electrical jumper junction boxes All electrical jumper junction boxes must be in good structural condition.

Remove covers. Rewire.

Drill drain hole in bottom of the junction box and fit split pin to prevent hole from blocking.

Renew cover seals and ensure water tight seal.

3.17 Battery bbox Corrosion damage must be repaired and all timbers must be in good condition. Refer drawing 106-236.

The battery box must be thoroughly cleaned and then painted with epoxy modified bituminous black paint or Isonol 300 Red or equivalent product.

Four fibreglass trays must be manufactured and installed (two batteries per tray) into the battery box the dimensions for these trays are 5mm thick × 700mm long × 82mm deep × 420mm wide. The trays are to have four (two per battery) raised portions approximately 4mm high to keep the battery off the bottom of the inside of the tray. They will be inserted into the fibreglass (when the tray is manufactured) and be 140mm × 20mm. Refer drawing 207-791.

The Supplier is to supply new batteries.

3.18 Bogies The bogies are to overhauled in accordance with the requirements of:

• ESR 0540 Overhaul of 48 Class bogie.

• ESR 0240 Axlebox overhaul longitudinal clearances

Missing brake cylinders will have to be supplied. Brake piping, where missing, will need to be supplied.

Hasler speed unit to be provided.

Fit new wheels.

3.19 Brakes The following air brake equipment is to be removed overhauled in accordance to ESR 0220 Brake system component changeout and then refitted:

• equalising reservoir control valve (x2).

• 5lb pressure switch.

• independent brake valve (x2).

• dead engine device.

• distributing valve.

• independent release valve.

• automatic brake valve handle.



• independent brake valve handle.

• automatic brake valve (x2).

• 55lb safety valve.

• 95lb control air safety valve.

• 130lb main reservoir safety valve (x2).

• flow meter (x2).

• isolating cock (x2).

• 60lb safety valve.

• M3 feed valve.

• vigilance control unit.

• BC double check valve.p

• 19B double check valve.

• 1/2" air strainers (x3).

3.19.1 Brake equipment system blow out Procedure NOTE: - When installing air gear, the system is to be blown out with compressed air working from main reservoirs to each item of equipment being installed as listed below:

• First blow out reservoir with shop air

• Replace 2 X 130LB safety valves Blow out system from reservoir connection again.

• Replace 2 isolating valves Blow out system from reservoir connection again.

• Replace 2 feed valves Blow out system from reservoir connection again.

• Replace 2 automatic brake valves Blow out system from reservoir connection again.

• Replace 2 independent brake valves Blow out system from reservoir connection again.

• Replace feed valve (control air) Blow out system from reservoir connection again.

• Replace 2 flowmeter Blow out system from reservoir connection again.

• Replace distributing valve Blow out system from reservoir connection again.

• Replace dead engine device Blow out system from reservoir connection again.

• Replace 1 independent release valve Blow out system from reservoir connection again.

• Replace 2 equalising reservoir control valve Blow out system from reservoir connection again.

• Replace control governor 250-350kp Blow out system from reservoir connection again.



• Replace all gauges Blow out system from reservoir connection again.

• Replace compressor governor 750-850kp Blow out system from reservoir connection again.

• Replace 1 magnet valve (compressor governor) D75 Blow out system from reservoir connection again.

• Replace all sander magnet valves D75 Blow out system from reservoir connection again.

3.19.2 Handbrake The handbrake, chain and linkages must be removed and overhauled. Any worn parts to be replaced.:

3.19.3 New equipment The Supplier is to replace the following equipment with new equipment:

• All air line strainer elements

• Air compressor oil drain pipe to be fitted with plugged John valve.

3.19.4 Modifications The Supplier shall provide a quotation for the following additional work:

• Convert the brake equipment from A7-EL to B7-EL standard.

• Remove the AA vigilance control equipment and fit EH or later vigilance control system. Refer to ESR 0223 Vigilance Control Systems.

3.19.5 Brake & vigilance control system tests Brakes and vigilance control are to be operating correctly.

• Brakes to be tested to ESR 0221 A7/B7 locomotive brake test.

• Vigilance control to be tested to ESR 0220 Testing of vigilance control system.

All slack adjusters are to be adjusted correctly to ESR 0224

Ensure the settings of the following pressure switches are correct - adjust as necessary:

• power knock out switch (350-250 kPa).

• compressor governor (750-850 kPa). See Alco MI-1053 for setting procedure.

• brake cylinder pressure switch (20-50 kPa).

3.20 Main reservoirs Main reservoirs are to be inspected by an accredited boiler inspector. Repairs to be undertaken as required. Main reservoirs must be certified safe for use before refitting to locomotive. Certification documentation to be forwarded to the Superintendent. Ensure Main Reservoirs are clear and operating correctly. Replace cocks and/or hose if damaged.



3.21 Cab All cab & short end equipment and accessories are to be clean and in good working order including the following (any defective equipment to be repaired or replaced with new or overhauled equipment):

• Hasler speed recording equipment.

• All gauges must be calibrated.

• Mirrors, windows, doors and door seals.

• All lights and lamps, heaters, cab fans, blinds and windscreen wiper units.

• Seats (Bremshy type and must also be free from damage). Part no. FA416/48

• Locomotive numbers must be readable.

• Control stand and master controller (must be clean inside and outside).

– Remove control stand covers and check the following:

o replace all hot lugs and damaged wiring on control stand and master controller.

o operation and mechanical interlock of selector, throttle and reverser handles. Lightly lubricate mechanical rollers.

o check all cams and contacts for condition and movement.

o check all connections for tightness and condition of wiring

o check all gauge lights, alarms and switches.

o examine all alarm light fittings.

o examine loadmeters for obvious defects.

• All screws, latches, hinges, brackets, etc. must be fitted and in good condition to ensure that covers/equipment will not rattle. Note:- Worn hinges are to be renewed.

• Remove the toilet and seal all holes.

• Repair or replace hotplate.

The cab floor must also be in a safe, clean condition (any defective sections must be repaired).

The cab and short end must be clean and painted, colour requirements according to ESR 0212.

The Drivers cab is to be painted in accordance with ESR 0212.

3.21.1 Train radio Train Radio handsets are to be supplied by RailCorp and fitted by the contractor.

3.22 Fuel tank The fuel tank is to be removed and cleaned.

Fuel tanks shall be inspected and repaired in accordance with TRS 1067 if this work has not previously been completed.

Fuel tank is to be checked for fractures. Repair as required.

All fuel tank gaskets to be renewed.



Fuel tank plastic drains to renew using heavy duty plastic hose suitably held, leading drainage into the 4 ft.

Inspect fuel lift pipe. Replace if necessary.

3.23 Filters The following filters are to be replaced with new items:

• Lubricating oil.

• Fuel oil: primary.

secondary.

• Air filtration - Fibreglass bodyside.

Turbocharger air intake filters

Dynacell filter service indicator.

3.24 Sandboxes All sand boxes must be in good structural condition and free from rust/corrosion.

All sand boxes must have covers fitted and in good condition.

Renew sand box cover seals.

Renew sand box hoses.

Refit all sand pipes.

Sand flow rate must be 0.5 - 0.7 kg (1 - 1½ lbs) per minute. For adjustment procedure, refer to ESR 0210.

3.25 Vigilance control box Check wire harness connection to vigilance box. Replace if required.

Ensure internal wiring is neat and tidy replacing any non standard wiring back to standard.

3.26 Horn assembly The condition, security and operation of air horn assemblies is to be checked and any faults corrected as necessary.

The condition of the “whistle cord” is to be checked and replace/repair as required. If replaced, use plastic coated cord of 10 mm diameter.

Replace horns if missing.

3.27 Guards All guards are to be fitted and in good order including but not limited to, the following guards:

• ECC drive shaft



• radiator fan

• radiator

• fast's coupling

• auxiliary generator

• exciter

• AC drive belts.

3.28 Steps and handrails Replace damaged or missing steps and handrails.

3.29 Painting Locomotive 4801 is to be painted in original 48 class locomotive colour scheme.

Locomotive 4805 is to be painted in RailCorp colour scheme.

Refer to the Work Train Operations Unit for details of the RailCorp colour scheme.

There shall be contrasting colours on the ends of the locomotives for high visibility.

The cab is to be painted in accordance with ESR 0212 Cab interior painting

Engine room walls, engine well, radiator fan room and short end hood/nose (inside) to be thoroughly cleaned and all loose debris removed and painted in alpine green.

All foot plate walk ways and locomotive access steps are to be painted with a suitable non-slip paint.

All handrails, coupler uncoupling handle, bogie brake cut-out cocks and air brake coupling cocks are to be painted white.

3.30 Other equipment The following additional equipment shall be fitted:

• AEI tags as supplied by RailCorp.

• Reflective delineators in accordance with RSU 330.

4 After inspection work

4.1 Inspection Following completion of the restoration the locomotives shall be inspected in accordance with the following standards:

• ESR 0202 Electrical commissioning of 48 class locomotives following CCO.

• ESR 0203 Mechanical commissioning of 48 class locomotives following CCO.

5 Load testing The locomotive is to be free from any leaks (fuel oil, lubricating oil, cooling, booster, exhaust and air systems).



Battery charging circuit is to be operating correctly.

Temperature switches are to be operating at the correct temperatures:

• T1 - 68°C.

• T2 - 74°C.

• ETS - 91°C.

The temperature switches are to be set using a thermometer which has been calibrated within the past 12 months. At this time the readings taken on the calibrated thermometer are to be compared with the readings taken on the locomotive thermometer in the range 40°C-80°C at no greater than 10°C intervals. If the locomotive thermometer varies by more than ±2°C at any point it is to be replaced with a new thermometer.

Compressor and radiator fan is to be operating correctly.

All fuel and lubricating oil valves, both relief and regulating are to be operating at the correct pressures when the locomotive has reached operating temperature. See ESR 0250 for correct pressures.

The locomotive is to operate at 900 horsepower + 50, - 0 in 8th throttle notch.

For testing procedure see ESR 0256.

After shutting down final test run, the following operations should be done:

• Take sample of lubricating oil from crankcase for analysis then change all lubricating oil filters.

• The oil sample should be labelled “Post CCO Sample” with the following information stated:

– Locomotive number

– Date sampled

– Sender information.

• The sample is then to be sent for analysis.

Note any remarks or unusual running characteristics of engine.

The locomotive is to be free from any leaks (fuel oil, lubricating oil, cooling water, booster air, exhaust and air systems).

5.1 Test report The copy of test readings duly signed and certified should be forwarded to the Superintendent, along with all additional data and measurements, as required by this specification, before service trials are commenced.

A copy of the Quality Control Engine Performance Test Report shall be forwarded to the Superintendent at the completion of trials and prior to hand over of each locomotive.

A copy of the results from the testing of the oil samples are to be supplied to the Superintendent.

6 Road trial Locomotive is to be road trialled to ensure it is powering correctly. This includes ensuring correct operation of transition and field shunting.



Air brake equipment is to operate correctly when travelling in either direction.

All vigilance control functions are to operate correctly.

Locomotive to be returned to Supplier after trial for final clean up and attention to trial bookings. A Lube oil sample is to be taken immediately prior to release of locomotive and sent to an approved laboratory for analysis. Sample should be labelled “Post CCO Sample” with the following information stated:

• Locomotive number

• Date sampled

• Sender information.

The Supplier is to provide the analysis results to the Superintendent within 14 days from delivery of locomotive.

7 Standard variations The following variations are to be carried out if they have not previously been implemented, as directed by the Superintendent:

• Fuel Tank Strengthening to TRS 1067.

• Bodyside filters housing frames to be fitted with fixed louvers. Note: some sizes will need to be changed to suit individual doors.

• Fitting of John cocks to all oil and water drainage pipes.

• Battery box drains to be enlarged with PVC drainage piping to prevent blocking.

• Remove external oil pressure switch OPS3 if fitted. Refer to TRS 1490.

• Windscreens to be replaced if condition requires. Ref drawing 305-781.

• Fuel Sight Indicator to TRS 1292.

• All fluid drains to lead to the 4ft:

– Tundish

– The four breather hoses from the Banlaw Breathers on the fuel tank

– The main reservoir condensate drains as per M95-055.01

• All fluid drains to lead to the 6 ft:

– Locomotive lubricating oil drain (must be fitted with screw on cap).

– Locomotive water coolant drain (must be fitted with screw on cap).

– Locomotive waste sump drain (must be fitted with screw on cap) as per M96-059.01.

Note: On the locomotive waste sump a plug to access the drain pipe must be fitted to access the drain pipe from the 4 ft.

• Long fuel sight glass level indicators to be replaced with Weka magnetic indicators supplied by control component part No. 969124/01.

• Short fuel sight glass level to be removed and blanking plates to be fitted.

• Provide 100mm square hole over waterproof screened cover over engine governor to allow application of lifting appliance.

• Relocate low water alarm cut out switch to protect it against heat and fire damage.



• Relocate conduit and switch to the other side of the steel mounting plate.

• Manufacture and fit where necessary, engine air intake housing to accept Dynacell air filters.

• Brake pipe and main reservoir end cocks TRS 1059

• Electrical compartment door strengthening TRS 1290

• Modification to main reservoir drains TRS 1777

7.1 Air conditioning Air conditioning shall be supplied and fitted.

7.2 Catalytic converter Fit catalytic converter to one locomotive (4805) as supplied by RailCorp.

8 Equipment to be supplied by RailCorp

8.1 Engine One overhauled engine.

8.2 Catalytic converter One catalytic converter.

8.3 AEI tags Four programmed AEI tags.

8.4 Train radios Two sets of train radio equipment.

9 Referenced standards

9.1 RailCorp standards ESR 0202 Electrical commissioning of 48 class locomotives following CCO.

ESR 0203 Mechanical commissioning of 48 class locomotives following CCO.

ESR 0210 Adjustment of sandtraps

ESR 0211 Measurement of sand flow rates

ESR 0212 Cab interior painting

ESR 0213 Painting of locomotive bogies and components

ESR 0214 Cleaning using solvents

ESR 0220 Brake system component changeout



ESR 0221 A7/B7 locomotive brake equipment test

ESR 0222 Testing of vigilance control system

ESR 0223 Vigilance control equipment

ESR 0224 Adjustment of brake piston travels

ESR 0225 Calibration of pressure gauges

ESR 0230 Inspection of locomotive gear and pinions

ESR 0231 Process for ECMD on gear wheels

ESR 0232 Reclamation of gear bore by metal spraying

ESR 0240 Axlebox overhaul longitudinal clearances

ESR 0241 Installation & removal of bogie from locomotive

ESR 0242 Installation of traction motors onto wheelsets

ESR 0243 Inspection & restoration of traction motor caps

ESR 0244 Greasing of 48 class locomotive axle bearings

ESR 0245 Inspection & installation of suspension bearing wick & oil

ESR 0246 Traction motor gearcase lubricant levels

ESR 0247 Maintenance of oil drains on traction motor gearcases

ESR 0250 Alco oil regulating and relief valves

ESR 0251 Fuel pump rack adjustment

ESR 0252 Cleaning oil contaminated water coolant system

ESR 0253 Testing locomotive coolant water

ESR 0254 Maintenance of flexmaster couplings

ESR 0255 Napier & Brown Bovari turbochargers

ESR 0256 48 class locomotive load box procedure

ESR 0257 48 class locomotive load control regulator

ESR 0270 Engine temperature switches

ESR 0271 Fitting of high tensile bolts to traction motor connections

ESR 0272 Brush bedding and commutator dressing

ESR 0273 Use of non-metallic flexible conduit in locomotives

ESR 0274 Alco fuel pump motor reverse interpole test

ESR 0275 Application of electrical warning labels

ESR 0300 Application of non destructive testing

ESR 0400 Specification for journal bearing & multipurpose grease



ESR 0401 Specification for suspension bearing oil

ESR 0402 Specification for traction motor gear lubricant

ESR 0403 Specification for material for arc chutes

ESR 0404 Specification for general purpose grease

ESR 0405 Specification for rubber hose

ESR 0406 Specification for lubricants, cleaning fluids for air brake equipment

ESR 0407 Specification for the selection of non-asbestos gasket material

ESR 0410 Specification for journal bearings

ESR 0411 Specification for coil springs

ESR 0412 Specification for wrought steel wheels

ESR 0413 Specification for case hardened gear wheels

ESR 0414 Specification for steel wear plates

ESR 0415 Specification for surface finish on traction motor suspension bearings

ESR 0420 Electrical circuits &Y equipment for rolling stock

ESR 0421 Construction & installation of electrical equipment

ESR 0422 General specification for electronic equipment

ESR 0423 Specification for moulded insulation

ESR 0424 Specification for single core elastomer insulated flexible cords

ESR 0500 Overhaul of Hasler axlebox remote drive

ESR 0510 Maintenance, repair & overhaul of air brake equipment

ESR 0511. Air compressor 3-CDC overhaul spec

ESR 0512 Overhaul of A7/B7 brake control equipment

ESR 0513 Overhaul of A7/B7 brake valves

ESR 0514 Overhaul of AF2 locomotive brake cylinders

ESR 0515 Overhaul of Westinghouse AF brake cylinders

ESR 0520 Locomotive drawgear overhaul spec

ESR 0530 Overhaul of locomotive axles

ESR 0540 Overhaul of 48 Class bogie.

ESR 0541 Overhaul of loco axleboxes.

ESR 0542 Overhaul of Symington Type S snubbers.

ESR 0543 Requalification of traction motor nose assembly.

ESR 0544 Requalification of traction motor suspension bearing.



ESR 0550 Overhaul of engine assembly

ESR 0551 Overhaul of power assembly

ESR 0552 Overhaul of 320F turbocharger

ESR 0553 Overhaul of engine crankshaft and free end drive assembly

ESR 0554 Overhaul of engine camshaft assembly

ESR 0555 Overhaul of engine lubrication oil system

ESR 0556 Overhaul of Alco fuel injector pump & nozzle

ESR 0557 Overhaul of eddy clutch and gear box

ESR 0558 Overhaul of fuel system

ESR 0559 Overhaul of engine block and pan

ESR 0560 Overhaul of Napier NA 155 turbocharger

ESR 0561 Overhaul of engine exhaust manifold

ESR 0570 Overhaul of locomotive radiator

ESR 0571 Overhaul of radiator fan drive

ESR 0572 Overhaul of water pump

ESR 0573 Overhaul of cooling water system

ESR 0574 Overhaul of aftercooler

ESR 0575 Overhaul of air coolers

ESR 0600 Overhaul of electrical compartment

ESR 0601 Overhaul of traction motor

ESR 0602 Overhaul of traction generator

ESR 0603 Overhaul of auxiliary generator

ESR 0604 Overhaul of AG32 exciter

ESR 0605 Overhaul of arc chute

ESR 0606 Overhaul of fuel pump motor

ESR 0607 Overhaul of motor contactor

ESR 0608 Overhaul of cranking contactor

ESR 0609 Overhaul of generator field & fuel pump contactor

ESR 0610 Overhaul of field shunting contactor

ESR 0611 Overhaul of reverser

ESR 0612 Overhaul of auxiliary contacts

ESR 0613 Overhaul of control relay



ESR 0614 Overhaul of ground relay

ESR 0615 Overhaul of AEI master controller type 38MC

ESR 0616 Overhaul of AEI “on” type magnet valve overhaul spec

ESR 0617 Overhaul of field shunting control & transition relay overhaul spec

ESR 0618 Overhaul of traction motor blower overhaul spec.

ESR 0619 Overhaul of crankshaft exhaust motors

ESR 0620 Overhaul of GMG158 exciter auxiliary generator set

9.2 TRS instructions TRS 1059 BP & MR end cocks

TRS 1067 Fuel tank strengthening – 48 class

TRS 1290 Electrical compartment door strengthening

TRS 1292. Fuel system sight flow indicator

TRS 1490. Removal of external oil pressure switch OPS3

TRS 1499 48 class inspection schedule (Level 3) ??

TRS 1777 Modification of MR drains

9.3 Drawings 106-236 Battery box arrangement

207-791 Battery box drip tray details

305-781 Locomotive windows & blinds driver fixes window glass

9.4 Australian standards AS 1171 Methods for magnetic particle testing of ferromagnetic products and compounds

AS 1210 Unfired pressure valves

9.5 Other standards A E Goodwin Ltd Instruction Manual for the 48 class locomotives. TPI 871

Alco EB-11176 Subject #1F p2

Alco Instruction Manual MI-1052 (Fast's Coupling - Air Compressor Drive Installation And Alignment).

Alco MI-1053 for setting procedure.

Alco Instruction Manual MI-16005B and MI-16006 (Reassemble and Alignment).

The main reservoir condensate drains as per M95-055.01



Locomotive Waste Sump drain (must be fitted with screw on cap) as per M96-059.01

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