quality audit of diesel loco poh workshops check sheet · page 6 of 104 quality audit of diesel...

of 104 Quality Audit of Diesel Loco POH Workshop

Quality Audit of Diesel Loco POH Workshops CHECK SHEET

Item Description Reference Documents, Annexures, Further details on check sheet etc.

General

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

Quality of POH: -do-

Load Test records:

HP

SFC

EGT

Peak Firing Pressure

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

Methodology of collection of failures on locos turned out by shops, failure investigation, analysis and preventive action.

Display of work instructions on shop floor

Training of staff

Status of record keeping

Calibration of gauges/ instruments

Safety items

a. Speed recorder/Indicator Section b. Wheel (Wear adapted profile) profile & other defects. c. Brake adjustment, release & and application timings. d. Headlight focus adjustment e. Horn maintenance f. Undergear safety brackets g. Gauging of Couplers h. Vertical offset between Side bearer and centre pivot

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. 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/Compressor b. Air Brake Section c. Bogie section d. Rotating Machines Section e. Turbo section f. Engine Block, Crankshaft and Main bearings g. Cylinder Head , Piston and Valve section h. Radiator section. i. FIP/Injector Section j. Governor Section k. Electrical Control Section l. Battery Section m. Under-frame, side buffers, cow catcher,

couplers, superstructure/Upper-frame, roof, driver cabin, hand rails, fuel tank, loco painting/marking/stencilling etc.

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. h. -do- i. -do- j. Further details of check sheet covered in Annexure 5. k. -do- l. -do- m. Further details of check sheet covered in Annexure 6.

Implementation of modifications

As per modification sheets/Instruction Bulletin’s issued by RDSO/DLW/HQ.

Material

Availability of critical items

Procurement from unapproved sources, if any.

Any other item As decided by the auditing authority


Annexure-1

CHECK LIST FOR

TECHNICAL AUDIT AT POH WORKSHOPS (BRAKE ITEMS)

S.No. Item Parameter Observations

1. Whether all the items prescribed in the schedule is being followed for brake equipment, compressor /Expressor & air dryer or not

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

`

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.

2. Functioning of VCD Whether functioning of VCD is being checked in every POH 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/ Expressor test bench 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 on Loco after POH Whether brake system check is done on loco as per test programme no. MP.TP-029 (for air brake loco) & MP.TP-019 (For dual brake loco).

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.

(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.

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.

7. Availability of Material Any Chromic shortage of material for maintenance

8. Human Resource development

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

9. Any other observation


Annexure-2

CHECK SHEET FOR

CONDUCTING TECHNICAL AUDIT OF BOGIE AT POH WORKSHOP (ALCO LOCOMOTIVE)

SN Activity

Loco Type Reference Details Observations

1. Overhauling/Inspection Alco Series RDSO report Misc. No. Misc-164, MP.MI-71/78 and SK.DL-3370 to be followed

Cleaning of bogie frame

Alignment of bogie frame (including tramming)

a) Wheel base spacing b) Transverse pedestal spacing c) Longitudinal pedestal spacing d) Pedestal bottom alignment e) Motor nose suspension lug

squareness & spacing

Crack detection, repair & heat treatment (Stress relieving)

Replacement of manganese liners and brake rigging bushes

WDM2, WDM3A, WDG3A, &

WDM3D/E/F

2. Axle box & journal bearings

Cleaning of Axle box & bearings

Inspection bearing components

Overhauling as per the referred MP.MI

MP.MI-04.004

3. Suspension Springs ( As per MI )

Cleaning of springs

Free height of springs

Working height of springs

Grouping / colour code of springs

100% replace of spring pads ( Happy Pads)

WDM2, WDM3A, WDG3A, &

WDM3D/E/F

As per relevant drawing, MP.IB.VL- 04.19.01 (Rev.01),

MP.IB.VL- 04.19.01 (Rev.01) for

WDG3A & MP.MI-31 for

WDM3D/E/F

4. Friction Snubber Assembly

Disassemble snubber (See SK.DL- 1505 for instructions)

Check the inside diameter of the friction sleeve with a “No Go” gauge Figure SK.DL- 3127

Details as per Drawing SK.DL-2089A, SK.DL- 1505, SK.DL- 3127, SK.DL-3126, SK.DL- 1512 , SK.DL- 1513


Check the dimensions of the shoes as indicated in figure SK.DL-3126

Replace worn or broken parts. For assembly refer SK.DL- 1512 &1513

Re-assembly of snubber

Height measurement and checking for damping characteristics

5. Hydraulic damper

Check the Capacity / Rating of dampers

Damper overhauling

Testing

As per drawings No. SK.VL-295, SK.VL-328 and SK.VL-387 & overhauling as per MP.IB.VL. 05.39.10 (Rev.00)

6. Side Bearer (Rubber spring)

Free Height of rubber spring

Working height of rubber spring

Permanent set of rubber spring

Rubber crack length/ de-bonding

WDG3A, & WDM3D/E/F As per drawings No. SK.Vl-127 &

133 &

MP.IB.VL. 04.30.08 (Rev.01)

7. Equaliser Beams

Checking for cracks

Reclamation of hard face as per MC-43 and 92

WDM2, WDM3A, M&C document no. MC – 43 & MC-92

8. Wheel & Axle Assembly

Wheel wear measurement i.e. Root wear, Tread wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spaling etc. ,wheel reprofiling.

Wheel gauge (1596+3/-0.5 mm)

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

Ultrasonic testing of axles

WDM2, WDM3A,WDG3A, &

WDM3D/E/F

Wheel wear management Instruction Bulletin no.MP.IB.BD.0216.01 (Rev-1) & MP MI71/78 & MP.MI-31

RDSO procedure MC-71


9. Brake rigging

Abnormal wear of brake hangers

Replacement of Brake blocks, Pins & Bushes

Replace brake head, tie rod, brake shoe key, top & bottom slack adjusters (condition basis) and friction arm spring, if found damaged.

MP.MISC – 141

1. Centre Pivot & Loading Pads

Load Pad to Centre Pivot Height Difference to be maintained.

2. Floating type Pivot assembly: Dismantle complete assembly

Clean of the metal component except rubber bush

Inspect for wear, tear and cracks

Reassemble pivot block assembly with change centre pivot bush.

In case non-metallic pivot block, 100% replacement may be carried out.

WDM2, WDM3A

WDG3A, & WDM3D/E/F

MP.IB.VL.02.11.10

SK.VL-128

SK.VL-501, RDSO Modification

sheet no. 03.10.09

10.

Lateral Stopper, lifting chain and other fasteners and brackets are to be 100% replaced.

WDG3A, & WDM3D/E/F SK.VL-134

11.

Re-assembly of bogie Maintain all running gear clearance as per the MI’s Maintain the Lateral clearances between Axle Box and Pedestals (Ensure attention to wheel and axle assembly as per S.N. 8)

WDM2, WDM3A WDG3A, & WDM3D/E/F

MP.MI-71/78, VL.Mi-02/96 & MP.MI-31 MP.IB.VL.03.04.06 (WDM2 & WDM3A) MP.IB.VL.01.02.06 (WDG3A)


12. Availability of Tools And Test Stands WDM2, WDM3A,WDG3A, &

WDM3D/E/F

Over head Crane

Hydraulic Jacks

Cleaning vat

Bogie frame manipulator

Crack reclamation facility like gouging, grinding & welding facility etc.

Stress relieving furnace

DPT, MPT & UT testing facilities

Surface table for measurement

Spring load-deflection testing machine

Hydraulic damper testing machine

Torque wrench, Go/No Go Gauges

Height gauges

Inside and Outside Calliper, Vernier Caliper, Height Gauge, Cleaning Tank,

Painting facilities

Wheel wear measuring gauge SK.DL-3592

Elecrode heating oven

Facility to measure pre-heat temperature

13. Availability Of Instructions Etc

Availability of WI including critical dimensions

Training of staff including qualification of welders

Maintenance manual and check sheets

Record keeping of tools and measuring

instruments

Calibration of measuring instruments

14.

Record Keeping For Traceability


Annexure-3

CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTOR PINION & GEAR ASSLY. AT POH WORKSHOPS

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)

MP-IB.EM.10.31.08

dated 24.10.2008

1.1 TRACTION GEAR & PINION Gear Ratio 18 : 65 Pinion Drg. No. 18 teeth, SKDP3624 Pinion Bedding In Cold Condition

Not less than 95 %

Pinion Advance 2.25 TO 2.45MM Heating Temperature 190ºC + AMB TEMP. Span Size On New Pinion Over 3 teeth

88.595 /88.722MM

Condmning Limit On Basis Of Span Size Of Pinion

Over 3 teeth 86.995MM

Gear Drg. No. 65 teeth SKDP3623 & SKDP3775

Span Size On New Gear Over 7 teeth 223.989/223.798MM

Condmning Limit On Basis Of Span Size Of Gear


Permissible Backlsh With New Set

0.266 - 0.664MM

Condemning Limit On Basis Of Backlash

1.04MM

Crack detection MPMI or Zyglo test


1.2 TRACTION GEAR & PINION

WDG3A

Traction Motor Pinion & Gear Assly. of Alco

Loco

MP-MI 129/86

July ‘1986

MP-MI 5

Gear Ratio 18 : 74 Pinion Drg. No. 18 teeth, SKDP3443 Pinion Bedding In Cold Condition

Not less than 95 %

Pinion Advance 2.30 TO 2.45MM Heating Temperature 185ºC + AMB TEP. Span Size On New Pinion Over 3 teeth 81.976

/82.093MM

Condmning Limit On Basis Of Span Size Of Pinion


Gear Drg. No. 65 teeth SKDP3444 & SKDP3546

Span Size On New Gear Over 8 teeth 231.36/231.177

Condmning Limit On Basis Of Span Size Of Gear

Over 8 teeth 228.140

Permissible Backlsh With New Set

0.243 - 0.608MM

Condemning Limit On Basis Of Backlash

1.00MM

Crack detection MPMI or Zyglo test

1.3 TA FAN ASSEMBLY

All ALCo locos

MP-IB.EM.01.02.10 dated 11.01.2010.

Outer diameter of TA fan 1387.25/1387mm

Bore diameter of TA stator 1392mm

Bore diameter of TA fan 600.00 / 600.03mm

Diameter of fan seating area on barrel.

600.03 / 600.06mm

Width of fan seating at bore 9+1 mm

Depth of counter sunk bolts hole 4.5 - 5.5 mm

Bolt head width 12.3mm

6.4 Bolt head height above fan plate after final assembly should not be more than

6.5 6- 7mm

Circumferentially Fan gap on TA 2.50 – 2.75mm

Tightening torque and wire locking process

28 – 30Kg-m


Tightening torque of M30 (coupling bolt)

170 – 180 kg-m.

Oil catcher thickness (at bottom side)

53.90 to 54.10mm

Bolts strength properties grade R8.8.

Sunk type M20 bolts can be used in place of fully threaded M20 bolts

M20 & M30 bolts should be replaced

After 4 – 5 years service of TA

Fan bore area should be heated (for shrink fit).

150 to 170 °С

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

GO & NO GO thread ring or plug gauge

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

Visual inspection is required

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

In place of (bolts) press fit.

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

As shown in photo

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

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

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

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

TA Gear train assembly Backlash at Steel plate

All ALCo locos

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

TA GEAR 102T AG/EG PINION 43T

PTU PINION - 43T

0.60mm to 1.40mm 0.05mm to 0.12mm

on shaft


2 Carbody cables and Traction Motor cables All ALCo locos

MP.IB.EM.02.03.08, dated 24-01-2008

And

MP.IB.EM.03.04.08, dated 24-01-2008

Ensure the following:

Control cables should be replaced fully irrespective of

the condition after every 8 years. Power cables

should be replaced on condition basis. During POH

power cables, which are exposed to oil should be

critically examined and replaced if any symptoms of

bulging, softening or perishing of insulation at the

cable terminals are noticed.

3 AVAILABILITY OF TOOLS AND TEST STANDS All ALCo locos

MP.IB.EM.02.03.08, dated 24-01-2008

And

MP.IB.EM.03.04.08, dated 24-01-2008

2.1 Vernier Callipers

2.2 Disc Mike

2.3 Filler Gauge

4 INSTRUCTION

3.1 Display Chart

3.2 Training of Staff

3.4Record keeping of tools and measuring instruments

5 TRACEABILITY

6 MATERIAL AVAILABILITY

5.1 Vital Spare -NA

5.2 Must change items -NA


CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTORS AT POH WORKSHOPS

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:

SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCE DETAILS

CLAUSE/ PARA/

ITEM DETAILS

OBSERVATION

1 MEASUREMENT

Alco Locos

Traction Motors of Alco Loco

MP.MI-2, MP.MI-6 &

Maintenance manual issued by OEMs viz. BHEL / CGL.

1.1 PRE-INSPECTION

i) Record IR of

a) Armature (Shall be > 10 MΩ)

b) Inter Pole (Shall be > 10 MΩ )

c) Main Pole (Shall be > 10 MΩ)

ii) Record ovality of commutator (Limit – 0.001”)

1.2 AFTER DIS-MANTLING

i) Pinion to be sent for Magna flux test / Zyglo test

ii) Visual examination of Armature banding. If found beyond repair, rewind it.

iii) Check commutator dia. for condemning size. Replace commutator, if condemning size reached. If commutator is retained, then check millivolt drop to ensure health of tig welding/bar to bar shortening. If required, repair it.

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

v) Ensure that there is no damage on armature seating area & armature shaft. If any damaged is noticed, re-metalize it to reqd. size.

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


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

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

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

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

xi) Joints may be brazed & insulated, if required with RDSO approved Silicon elastomer tape.

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

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

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

xv) Bake the armature in oven at 120 + 10 °C & record it.

xvi) Spray varnish paint protecting the shaft & commutator & cure it.

xvii) Ensure mica cutting. & chamfering as per OEM’s manual

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

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

xx) Ensure the spring tension. (Lt. 4.5 Kg to 5.5 Kg)


xxi) Ensure the replacement of PTFE sleeve of brush arm.

xxii) Ensure painting of support arm with red becktol varnish.

xxiii) Conduct high potential test as per OEM’s manual

1.3 ASSEMBLY

i) Motor assembly as per OEM’s manual

ii) Measure the final Insulation Resistance = 10 Mega ohm

a) Armature (Shall be > 100 MΩ)

b) Inter Pole (Shall be > 100 MΩ )

c) Main Pole (Shall be > 100 MΩ)

iii) Measure the end float (Lt. = 0.006” to 0.012”)

iv) Check the nose plate condition. If found damaged or wear out, shall be replaced.

v) Conduct the light run test at low, medium & high rpms on assembled motor & observe for unusual sound using listening rod.

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

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

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

ix) Apply recommended sealant to avoid ingress of water etc.

x) Apply a coat of paint on motor.


2 AVAILABILITY OF TOOLS AND TEST STANDS

2.1 1000V Megger

2.2 Filler gauge

2.3 HV tester

2.4 Dial gauge

2.5 Tachometer / Speedometer

2.6 Pyrometer

2.7 Inside & Outside micrometer /calliper

3 INSTRUCTION

3.1 Display Chart


3.3 Record keeping of tools & measuring instruments

4 TRACEABILITY

5 MATERIAL AVAILABILITY & STORAGE (AC/non-AC)

5.1 Vital Spares

5.2 Must change items


CHECK SHEET FOR

QUALITY AUDIT OF TRACTION ALTERNATOR AT POH WORKSHOPS

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:

SN REQUIREMENTS

LOCO TYPE MAKE OF SUB-

ASSEMBLY REFERENCE

DETAILS CLAUSE/ PARA/ ITEM

DETAILS

OBSERVATION

1 MEASUREMENT

ALCO locos

Traction Alternator

of Alco loco

BHEL’s Maintenance Manual for Electrical

Equipment of ALCO loco (Volume-II)

a)Check tightness of all mechanical and electrical connections. Check slip rings and brushes for sparking. b)BRUSH GEAR Spring pressure- 1.36 to 2.2 kgs (adjustable) to be adjusted to 1.8 kgs.

Minimum length of brush at which brush become inoperative – 35mm.

Clearance between brush holder & slip ring- 2 to 3 mm. c)SLIP RING Diameter (New) – 520 mm

Minimum worn out dia – 510 mm

Slip ring run our (max) – 0.1 mm Slip ring ovality (max) – 0.1 mm


d)ROTOR

Diameter- 1003 mm

Air gap at pole center – 6 mm Rotor bearing - NU330 EM/C4/D150mm x65 mm x 320mm O/D

Bearing housing dimension – 320-0.005 mm.

where outer race sites - - 0.025 mm Radial clearance of free bearing when new – 0.165 to 0.215 mm Fit between outer race & bearing housing- 0.035 mm clearance, 0.025 mm interference Shaft bearing seating dia – 150 + 0.055 mm + 0.035 mm Fit between inner race & shaft – 0.035 to 0.08 mm interference Diametrical slackness of free bearing – 0.15 to 0.18 mm Min. permissible racial clearance when assembled - 0.03 to 0.13 mm Min. diametrical clearance when assembled in the machine – 0.051 mm Bull gear wheel I/D – 149.098 + 0.025 mm + 0.0 mm Shaft bull gear seating dia–149.098 + 0.162 mm + 0.152 mm Gear box oil capacity – 2.6 litres approx. Lubricant type – SAE 40 or equivalent


e)TIGHTENING TORQUE KG.M

Exciter to gear box – 15 Aux-gen to gear box – 15 PTU to gear box – 15 Gear box to end shield – 15 (write locked) Gear box to end shield – 1 (at pads) Fan to rotor shaft – 25/27 (write locked) Rotor shaft extension to barrel – 25 Rotor pole bolts – 170/190 Slip ring to shaft extn. – 15

f) RESISTANCE AT 25°C- Stator- 0.002156 ohm (Line to Line) Rotor- 0.312 ohm (at slip ring) g) IR TESTS Stator (check with 1000V magger) : 2M Ohms Rotor(check with 1000V magger) : 2M Ohms


a. Bearing retaining ring b. Clamping ring c. Shaft adaptor d. Guide sleeve e. Frame lifting fixture f. Extractor for bull gear g. Lifting tackle h. Forcing screws i. Guiding studs j. Spacers k. S.K.F. Oil Pump


l. Studs m. protection sleeves n. Extractor for bearing inner race o. Extractor foe bearing outer race from

bearing housing

3 INSTRUCTION

3.1 Display Chart


3.4Record keeping of tools & measuring instruments

4 TRACEBILITY


5.1 Vital Spare



CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS AT POH WORKSHOPS

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

All ALCo locos fitted

with TM 4907/C1001

Traction Motor Bearing & Assly. Components of

Alco Loco

MP-IB.EM.14.50.08

dated 20.02.2009

1.1 Verticality of Outer race

1.2 Verticality of Inner race

1.3 Max. deviations allowed in above cases: Side Inner race Outer race

Pinion End 0.075 mm 0.25 mm Commutator End 0.065 mm 0.20 mm

1.4 Radial Clearances of bearings

a) For New Bearings Bearing Radial clearance

before mounting (mm)

Radial clearance after mounting (mm)

NU 330 0.165 - 0.215 0.100 – 0.170 NH 320 0.105 – 0.140 0.060 – 0.100

b) In addition to above, max. service radial clearance

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

c) Flinger - PE Bore Dia. 153.130 to 153.155 mm Total Width 12.65 to 12.70 mm

d) Retaining collar - PE Bore Dia. 146.015 to 146.040 mm Total Width 12.65 to 12.70 mm Outer Dia. 253.225 to 253.290 mm


Hub Outer dia. 177.040 to 177.090 mm

Outer dia. on 2

nd Groove 210.610 to 210.670 mm

Groove width 8.00 to 8.05 mm Total width 44.4 to 44.6 mm

e) End shield - PE Bore dia. 319.975 to 319.995 mm

f) End shield - CE Bore dia. 214.980 to 215.00 mm

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

h) End Float on Traction motor (TM 4907) CE Limit – 0.50 mm Aim – 0.42 mm

1.5 Fits & Clearances (BG TM)

i) Pinion end bearing Interferences (Diametrical) Clearances (Diametrical Brg. 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

Retaining collar to outer brg. cap

0.25 mm (min.)

Inner race to shaft

0.035 to 0.080 mm

--------------- --------------

Retaining collar to shaft

0.090 to 0.135 mm

-------------- --------------


ii) Commutator end bearing

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

-------------- --------------

1.6 Heating temp. of brg. & assly. components

Item Heating temp.

Bearing inner race PE 100 - 110 ºC

Bearing inner race CE 100 -110 ºC

Sleeve (PE) 100 -130 ºC

Sleeve (CE) 100 -130 ºC

Flinger (PE) 100 -120 ºC

End shield (PE) 120 -130 ºC

End shield (CE) 120 -130 ºC

Retaining collar (wiper) 120 -130 ºC


2.1 Dial gauge

3 INSTRUCTION

3.1 Display Chart


3.3Record keeping of tools and measuring instruments

4 TRACEABILITY


5.1 Vital Spare - NA

5.2 Must change items - NA


Annexure-4

CHECK SHEET FOR

QUALITY AUDITOF TURBO SECTION (POH)

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. Workshop/Rly: Audited by: Date of audit:

SN Requirements

Loco Type Make Of Subassembly

Reference Details

Clause/Para/Item Details

Observations

1.

Balancing, measurementsetc

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

5.6 5.6.2.5 5.6.2.5

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 mm

1.5 Bearing position OD C 56.10-56.20 mm

1.6 Piston ring recess S 2.58-2.85 mm

Wheel Bush 1.7 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 & 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 mm

1.12 Floating bush OD (TE) 64.82-64.84 mm

1.13 Floating bush ID (TE) 51.022-51.07 mm

1.14 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.

Availability of Tools, Test Stands etc.

Alco

do do

2.1 Balancing machine

2.2 Zyglo testing machine

2.3 Casing hydraulic test stand

2.4 Bearing puller (CE & TE)

2.5 Torque wrench up to 250 psi

2.6 micrometer 2”-3” & 0-4”

2.7 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc.

3.1 Display Chart

3.2 Training of staff

3.3 Maintenance manual and check sheets

3.4 Record keeping of tools and measuring instruments


4 Record Keeping For Traceability

5

Material Availability

5.1 Vital Spares


1

Measurements etc

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

Alco

Alco 720

Instruction Manual ALCO

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 CI

1.4 Intermediate casing and impeller 0.017-0.065” longitudinal Clearance (long Cl)

1.5 Impeller and Blower inlet 0.035-0.075” long CI

1.6 Blower casing end blower inlet measure with bolt loose. Scatting with back of diffuser at lease to 80%(This is only in case when we apply a new diffuser) 0.005-0.020” Long CI (Gap)

1.7 Turbine disc and intermediate casing 0.008-0.016” Long CI

1.8 Bearing and thrust collar (Blower end) with surface by approx 0.003 less when oil. 0.007-0.018” Thrust CI

1.9 Inducer and blower casing 0.091-0.101”Dia CI

1.10 Thurst collar and oil seal Blower End 0.014-0.036”Dia CI

1.11 Interference between bearing and intermediate casing (blower & Turbine end ) 0.0005-0.0015” DiaCl

1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008” Dia CI

1.13 Gas inlet casing and intermediate casing inside measurement 0.090-0.098” Dia CI

1.14 Impeller and intermediate casing 0.125-0.127” Dia CI

1.15 Max allowable clearance between Gas inlet casing & Nozzle ring 0.005” clearance


2

Availability of tools, Test Stands etc.

Alco

Alco 720

Instruction Manual ALCO

2.1 Balancing machine

2.2 Zyglo machine

2.3 Casing hydraulic test stand

2.4 Oil gallery flushing test stand

2.5 Bearing puller (CE & TE)

2.6 Sand blast machine for rotor cleaning

2.7 Torque wrench up to 250 psi

2.8 micrometer 2”-3” & 0-4”

2.9 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc .

3.1 Display Chart





5


5.1 Vital Spares



CHECK SHEET FOR

TECHNICAL AUDIT OF ENGINE BLOCK, MAIN BEARING (POH)

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.

Workshop/Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make/class Of

Subassembly

Reference Details

Clause/Para/ Item/Chapter Details

Observations

1 Removal of Cyl Block a) Removal of Cylinder liner. b) Removal of cylinder liner sleeve.

Alco

Conventional

ALCO MI 11079 D

Chapter on Maintenance, Instruction of Cylinder Block

.

2

Maintenance and Inspection DPT for cracks/signs of leaks/ other damage,

2.1 Check sizes of Main Brg. Bore. a) New MB bore dia. 9.0355" -

9.0370" b) Worn MB bore dia. 9.0350" -

9.0385" c) Cyl. Liner bore.

2.2 a)Out of roundness checking at planes A,B,C,D, E & F (max. 0.0035”).

b) Check taper i) At vertical planes A and D (0.001”). ii) At 45° from vertical between

planes B & F and C & E (0.003”). a) Horizontal misalignment limit –

(i) Two adjacent bores – 0.002” (ii) Two non-adjacent bores 0.004”

b) Vertical misalignment limit – (i) Three adjacent bores-0.0015” (ii) Two non-adjacent bores-

0.003”.


Torque values for Cylinder head stud 100-120 ft pound.

4.

Availability of tools and test a) Plate, lifting b) Compound, gasket c) Turning plate, free end & gen. end. d) Fixture for checking distortion of Cyl,

block and cyl. liner to Cyl. block seat e) Sleeve tool, upper and lower. f) Mandrel g) Magnaflux h) Feeler gauge i) Vernier caliper j) Torque wrench

5.

Availability of instruction a) Display chart. b) Training of staff c) Maintenance manual and check

sheets. d) Record keeping of tools and

measuring instruments.

6. Record keeping traceability

.

7. Material availability (i). Vital spares. (ii). Must change item


TECHNICAL AUDIT OF CRANK SHAFT (POH)



SN Requirements

Loco Type

Make/class Of

Subassembly

Reference Details


Observations

1 Removal of Crank Shaft a) Removal of Oil

catcher/pipes/engine parts/main brgs caps/shells & split gears.

b) Checked Crank shaft thrust (i) Using Main brg shell 0.010”-0.017” (ii) Using Thrust collar 0.012”-0.021”

c) Apply grease and wrap journals and crankpins.

Alco

Conventional

ALCO MI 11069 E

Chapter on Maintenance, Instruction of Cylinder Block

.

2

Maintenance and Inspection a) Cleaning b) Magnaflux test for

cracks/other damage, c) Roughness and burrs (limit 25

RMS max). d) Check M/Brgs saddle bore

2.1 Check Crank shaft. a) MB Journal dia. 8.498" – 8.500" b) Out of roundness limit 0.002” c) Run out for 16 cyl-0.008” max d) MB Journal eccentricity limit 0.001” d) Crank pin dia 5.998”- 6.000” e) Crank pin out of roundness limit 0.002”


2.2 Split Gear a) Removal of gears. b) Inspect gear teeth (ALCo MI 11030). 2.3 Check Split gear a) Key Interference fit- 0.0000”-0.0005” b) Gear side clearance-0.007”-0.023” c) Split line clearance limit- 0.0015” d) Torque for gear cap screw in ft-lbs – i) Preliminary torque- 50 ft-lbs ii) Final torque – 300 ft-lbs.

ALCO MI

11067 C

ALCO MI

11069 E &

11067C

4.

Availability of tools and test a) Lifting block b) Lapping tool c) Deflection guage. d) Feeler gauge e) Soft hammer f) Torque wrench

5.

Availability of instruction a) Display chart. b) Training of staff c) Maintenance manual and

check sheets. d) Record keeping of tools and

measuring instruments.

6. Record keeping traceability.

7. Material availability (i). Vital spares. (ii). Must change item


CHECK SHEET FOR

TECHNICAL AUDIT OF CYLINDER HEAD SECTION (POH)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

1

Cleaning, measurements etc.

1.1 Cleaning of cylinder head

ALCo --

DLW Maintenance

Instruction Manual

Chapter on cylinder head

1.2 Cy head leak test at 70 PSI with hot water

1.3 Inspect head for cracks using Magnaflux

1.4 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 cl 0.003 – 0.0045”

1.9 Cy head nuts torquing value 550ft/lbs

2

Availability of tools , Test Stands etc.

2.1 Valve seat reconditioning machine

2.2 Hydraulic test stand

2.3 Nozzle hole sleeve tube expander(Bottom & Top)

2.4 Nozzle sleeve extractor

2.5 Nozzle sleeve holder

2.6 Feeler gauge

2.7 Magna flux

3


3.1 Display Chart





5 Material Availability

5.1 Vital Spares



CHECK SHEET FOR

TECHNICAL AUDIT OF PISTON SECTION (POH)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

1

Cleaning, inspection, measurements etc.

1.1 cleaning of piston

ALCo

--

DLW Maintenance

Instruction Manual

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 crack

1.5 (a) Groove width top ring, 2nd ring and 3rd ring 0.1902”- 0.1950”(conventional)

(b) Groove width top ring & 2nd ring 0.1900”-0.195”(3RV)

1.6 (a) Side clearance in above rings 0.0052” -0.012” (conventional)

(b) Side clearance in above rings 0.0054” -0.012” (3RV)

1.7 (a) Groove width of oil scraper ring 0.3140” – 0.3165” (conventional)

(b)Groove width of oil scraper ring 0.2377” – 0.0.241” (3RV)

1.8 (a) Side clearance in oil ring 0.002”- 0.006” (conventional)

(b) Side clearance in oil ring 0.002”- 0.0064” (3RV)

1.9 Piston pin to bushing clearance running 0.003” – 0.0075”

1.10 Piston pin to snap ring total clearance 0.076” – 0.118”


2.

Availability of tools , Test Stands etc.

2.1 Feeler gauge

2.2 Zyglo testing machine

2.3 Magna flux

2.4 Vernier caliper

2.6 Piston ring groove gauge

3

Availability of instructions etc

3.1 Display Chart





5


5.1 Vital Spares



CHECK SHEET FOR

QUALITY AUDIT OF AIR & EXHAUST VALVE MAINTENANCE (POH)

During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference documents. Wherever the activities are not

performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:


SN Requirements Loco Type Make of Subassembly

Reference Details

Clause/Para/Item details

Observations

1

Measurements etc:

Alco --

Alco Instruction Manual (MI-

11020G)

Chapter on

Cylinder

Heads

1.1 Stem dia. of valves 0.6205-0.6195 (New).

1.2 Groove fillet radii 0.025-0.031R.

1.3 Valve disk thickness: for C and F type valve of 450: (a) 0.1562” (new) and (b) 0.0625” (condemning Limit).

1.4 Valve disk thickness (for E type valve 300) 0.1750” (new). And, 0.0937” (condemning Limit).

2

Availability of tools, test stands etc:

2.1 Depressor, Spring etc

2.2 Grinder

3

Availability of instructions etc:

3.1 Display Chart etc.



4 Record keeping for traceability:

5

Material Availability:

5.1 Vital Spare



CHECK SHEET FOR

TECHNICAL AUDIT OF RADIATOR SECTION (POH)



SN Requirements

Loco Type

Make/class Of

Subassembly

Reference Details


Observations

1 Leakage testing

Alco

Conventional

Alco MI

Chapter on Maintenance, Radiators.

2 Reconditioning of Radiator Chapter on LOCOMOTIVE INSPECTION,

MAINTENANCE AND LUBRICATION

MI 17003 A

2.1 Dismantling 2.2 Cleaning of the core 2.3 Changing of gaskets 2.4 Assembly 2.5 Testing

Chapter on Maintenance, Radiators.

3 Cleaning etc

Alco

Conventional

Alco MI

Chapter on Maintenance,

Radiators.

3.1 cleaning details

4

Availability of tools, Test Stands etc.

4.1 Torque wrench up to 140 ft-lb.

4.2 Hydraulic testing machine 0-10 Kg/Cm2

4.3 Radiator stand

4.4 Fin combing tool

4.5 Radiator immersion tank for cleaning


5


5.1 Display board etc


5.3 maintenance manual and check sheets

5.4 Calibration facility for tools and measuring instruments

6 Record Keeping for Traceability

7.

Material Availability:

5.1 Vital spares

5.2 Must change Item


CHECK SHEET FOR

QUALITY AUDIT OF FUEL INJECTION PUMP (POH)

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 of subassembly

Reference details

Clause/Para/Item details Observation

1. Dis-assembly /Measurement/Assembly etc

Alco

Bosch 17 mm

Bosch repair and testing

manual

Para on Dis-assembly Para on Inspection of parts Para on Inspection of parts Para on Inspection of parts Para on Inspection of parts

Para on assembly Para on Calibration values

1.1 Dis-assembly 1.2 Inspection of parts 1.3 Replace plunger guide cup if the indentation

on the Plunger and tappet seating surface is more than 0.125 mm (0.005”)

1.4 Clearance between control rack and bushing within 0.5 mm (0.020”)

1.5 Control rack movement – within 0.38 mm (0.015”).

1.6 Range control bush dia – 18.25 mm (0.7185”) – 18.27 mm (0.7192”)

1.7 BDC Dimension ‘a’ – 6.5 ± 0.05 mm.

2. Availability of Tools ,Test Stands etc.

1.1 Depth gauge for checking of BDC dimension ‘a’ on test bench.

1.2 Nut torque wrench, 450 lbs – 500 lbs. 1.3 Bush reamer. 1.4 Micrometer, 16 – 20 mm. 1.5 Assembly and dis-assembly fixture 1.6 Pump calibration test stand 1.7 Calibration oil – Servo Calib-5


3. Availability of instructions etc.

3.1 Display of charts etc 3.2 Training of staff. 3.3 Maintenance manual and check sheet etc 3.4 Record keeping of tools and measuring

instruments.

4. Record keeping for traceability:

5. Material availability: 5.1 Vital Spares 5.2 Must change items


CHECK SHEET FOR

QUALITY AUDIT OF INJECTOR (POH)

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. Workshop/Rly: Audited by: Date of audit:

SN Requirements Loco type

Make /Class/Name of subassembly

Reference details

Clause/Para/Item details Observations

1. Dis-assembly /Measurement/Assembly etc:

Alco

Bosch 17 mm

Bosch repair and testing

manual

Para on Dis-assembly Para on Inspection of Parts Para on Inspection of Parts Para on Assembly Para on Assembly Para on Assembly

1.1 Dis-assembly 1.2 Inspection of parts 1.3 Replace Intermediate disc if found cracked or

if indentation at the nozzle seating end exceeds 0.125 mm.

1.4 Opening pressure – 3700 to 3800 psi ( 260-270 kgf/cm2) for Overhauled nozzle

1.5 Nozzle cap nut tightening torque 130-150 Nm (13-15 kgf.m or 94-109 lbs-ft)

1.6 Repetition (chatter) and spray pattern test

2. Availability of Tools, Test Stands etc: List on Service Tools for Injector

2.1 Nozzle needle lift gauge 2.2 Feeler gauge 2.3 Dial gauge 2.4 Nozzle cleaning sleeve 2.5 True running gauge 2.6 Nozzle tester 2.7 Fixture for injector 2.8 Socket wrench 2.9 Test oil


3. Availability of instructions etc:

3.1 Display of chart 3.2 Training of staff 3.3 Maintenance manual and check sheet 3.4 Record keeping of tools and measuring instruments

4. Record keeping for traceability:

5. Material availability: 5.1 Vital spares 5.2 Must change items


CHECK SHEET FOR

TECHNICAL AUDIT OF PTLOC SECTION (POH)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details Clause/Para/Item/chapter

Details

Observations

1

Dis-assembly /Measurement/Assembly/Test etc.

1.1 Overhauling procedure

1.2 Plate Pack Length 1.3 Hydraulic Test

Plate Type Lube Oil Cooler (PTLOC)

MPMI-24, Nov. 2004 & MP.IB.ES.01.07.08 DLW Drawing No. TPL-8515, DLW Part No. 11457260

Para on Overhaul procedure Outline – Lube

Oil Cooler

2 Availability of tools , Test Stands etc.

2.1 Ratchet spanner

3


3.1 Display Chart





5 Material Availability

5.1 Vital Spares 5.2 Must change items


Annexure-5

CHECK SHEET FOR

TECHNICAL AUDIT OF POH WORKSHOP

Item: Electrical control MBCS + MCBG + E type

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.


SN Requirements

Loco Type

Make Of Sub

assembly

Reference Details Clause/Para/ Item Details

Observation

1. No. of Trained personnel with experience

MBCS trained personnel

2. Record keeping practices after the tests in relay control room for E type control

Shed doc

3. Practices for Handling of the electronic cards and storing

ALCo Doc No:IM 53 for MBCS Medha

4. Availability of crimping tool & connector pin details

ALCo Doc No. :IM 53 for MBCS Medha

5. Maintenance practices of Micro Processor Based Control System MEP 660

DLW/Alco/AMC (micro)/01

6. Maintenance practices of Micro Controller Based Governor (MCBG) MEG 601

ALCo Doc No:IM-11 Rev. 0.0 Date Jan 2009 of Medha

7. Practices followed for Fault data analysis for identifying the faulty components and failure.

ALCo

Contract agreement no. DLW/ALCO/MCBG/Medha

8. Standard (OEM recommended) list of spares, consumable & tools

ALCo

Contract agreement no. DLW/ALCO/MCBG/Medha

9. Measurement

11.1 Standards for load box examination of D E locomotives

MP MI -10 (Rev.0.02) August, 2003

11.2 Practices as per BHEL Commissioning Test schedule (Electrical equipment)

BHEL docs: TNE -2/2105/97/DELCTS Date


for 3100/2750 HP BG DE loco for ‘E’ type control

Sept 1997

11.3 Test procedure for MBCS loco control system MEP660 for retrofitted D E loco

ALCo IM-59

11.4 Preventive maintenance schedule

DLW/Alco/AMC (micro)/01 Inspection and test report of MEP Preventive Maintenance schedule SF-1405 (0)

11.5 Check working of safety and critical items identified as ECS operation check, GR operation check, Eng. Stop button check, OST open check, MUSD stop switch check, LWS check, GFOLR operation check (E type), Governor dry run check, Flasher light lights, Alerter, lamp, alarm and reset, Flasher lights switch panel GR, GRCO1/2, Indication panels, Attendant call bell, Head light, Classification light, Horn, Sanders , Directional check, Cab light and exterior lights,

ALCo Schedule inspection of shed and items covered under DLW/Alco/AMC (micro)/01 for MBCS locos

11.6 Check set value of engine rpm, transition speed, LOPS, Engine water Temp., 1st notch current, DB parameters (field and armature current), loco over speed through user settable parameters,

User settable parameters as per RDSO MBCS spec.MP.0.2400.26

11.7 Check ground circuit leakage current -do-

11.8 Check mv drop test of WSR (E type)

12 Availability Of Tools And Test Stands For MBCS locos- Test stands are not provided by MBCS supplier. Items are covered under AMC.

13 Display Chart Important instruction for trouble shooting like action to be taken during wheel slip etc to be available on the cab

13.1 Display of DOS and DONTS, TROUBLE SHOOTING Chart,

As per OEM manual


DISPLAYCHART & FLOW CHART

14 Maintenance manual and check sheets As provided by the MBCS manufacturer*

15 Instruction Bulletin / Modification sheet /Hand book/ Trouble shooting charts as provided by RDSO/ CAMTECH and implementation by MBCS vendor

MBCS spec.MP.0.2400.26, Modification sheet No.MP.MOD.EC.05.27.10 (Rev. 00) Date 26.03.2010, Instruction Bulletin no.MP.IB.EC.04.21.10 Date 30.04.2010. CAMTECH/2010/M/MPBCS/1.0 March 2010 (Introduction Hand book on MBCS MP660 fitted on diesel locomotives). CAMTECH/2000/DSL/1.0 (Trouble shooting charts for drivers of WDM2 locomotive)

Medha

1. Operational manual for drivers Doc.No.IM-38 Rev 3.0 July 07 2. Maintenance Instruction manual Doc. No.IM-53 Rev 0.0 Sept’2008 3. System Manual Doc. No. IM-08 Rev.3.0 March 2008 4. Troubleshooting Manual Doc.No. IM-51 Rev.2.0 Oct.2008 5. WDG3A Control wiring Drg. no.ED 1035 6. WDG3A Power. ED 1037 7. WDG3A Schematics Drg. no.ED Wiring Drg. no 1034 8. WDG3A TB wiring Drg. no.ED 1036 9. WDM3D Control wiring Drg. no.ED 1031 10. WDM3D Power Wiring Drg. no.ED 1033 11. WDM3D Schematics Drg. no.ED 1030 12. WDM3D TB wiring Drg. no.ED 1032

Siemens

1. KM DIREKT scheme no. DRG. No. 3FZE-00961

2. SIM CONTROL scheme no. DRG. No. 4SIM-200509

3. SIMCONTROL Operator’s Instructions &Guidelines user manual ver.2.00 dated 10.12.09

4. Trouble shooting manual of Siemens WDG3A and fault category of Siemens


CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERATOR FIELD CONTACTOR (ALCo)

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. Workshop/Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement

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

Drawing No. EL/PT/0640/

Altr R3 Part

No 12145439

Technical details given in the

drawing

1.2 Max pick up volt 48v ,

1.3 Main contact gap12-14.5mm,

1.4 Wipe 8-10 mm,

1.5 Contact pressure( kgf) initial 1.82-2.95,final 5.45-7.25,

1.6 Operating coil resistance at 20 deg c 104 -116 ohm, (approx.),

1.7 Interlock (gpr type : 9-41n, 3no+3nc)

1.8 Contact gap 9.5-10.5 mm,

1.9 Interlock contact pressure 220-300g.

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

(Rev-01),May’10

3.10.e

1.11 IR Value between (i) Main contacts (ii) Coil and magnet frame (iii) Interlocks and coil shorted together and earth.

IEC 60571

as per clause 10.2.9


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

(iv) Contacts of interlocks (v) Interlocks and coil shorted together and main

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

and earth

2.0 Availability of tools and stands

2.1 Multimeter with proper calibration

2.2 Vernier calipers with valid calibration

2.3 Go- No gauge suiting to different cantactors

2.4 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 Variac

2.7 Meggar

2.8 Oscilloscope

2.9 Screw Driver, Plier, Spanner Set, etc.

3. Availability Of Instructions etc.

3.1 Display Chart

3.2 Flow Chart


3.4 Proper Display of Do’s and Don’t



3.7 Instruction Bulletin issued by RDSO

3.8 Maintenance Manual of Manufacturer

3.9 Specification

4. Compliance of Instruction Bulletin

5. Follow of Maintenance Manual of Manufacturer


4.1 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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

7. Material Availability

7.1 Vital Spares


7.3 Consumables

8. Disposal

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 CRANKING CONTACTOR (ALCo)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement

1.1 Short time control voltage -72+1v dc, All Diesel Electric Locomo tives (ALCo)


Altr R3 Part

No 121410510


drawing

1.2 Control voltage -24vdc,

1.3 Max pick up volt 24v

1.4 Main contact gap12-14.5 mm,

1.5 Wipe 8-10 mm,,

1.6 Contact pressure( kgf) initial 1.82-2.95, final 5.45-7.25,

1.7 Operating coil resistance at 20 deg c 18.5-20.5ohm,

1.8 Interlock (gpr type : 9-41n, 3no+3nc)

1.9 Contact gap 9.5-10.5 mm,

1.10 Interlock contact pressure 220-300 gm , 1.11 .)

1.12 Contact impression (should be min 80%)

Spec No. MP.0.04.00.08

(Rev-01),May’10

3.10.e


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

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

and earth

as per IEC 60571

clause 10.2.9




2.12 Go- No gauge suiting to different contactors



2.15 Variac

2.16 Megger

2.17 Oscilloscope



3.10 Display Chart

3.11 Flow Chart







3.18 Specification





4.3 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.


7.


7.4 Vital Spares


7.6 Consumables

8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR CRANKING CONTROL CONTACTOR (ALCo)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1.

Measurement

1.1 Short time control voltage 72+1 v dc, All Diesel Electric Locomo tives (ALCo)


Altr R3 Part

No 12141100


drawing

1.2 Control voltage 24vdc, 1.3 Max pick up volt 24 v

1.4 Main contact gap 6-7.5mm,

1.5 Wipe 0.8-1.6 mm,

1.6 Contact pressure(gmf) initial 80-150, final 180.-280,

1.7 Operating coil resistance at 20 deg c 55+5% ohm(52 to 58 ohms),


(Rev-01),May’10

3.10.e

1.9 IR Value between (i) fixed contact to movable Contacts (ii) coil to frame

IEC 60571 clause 10.2.9





2.21 Go- No gauge suiting to different contactors



2.24 Variac

2.25 Megger

2.26 Oscilloscope



3.19 Display Chart

3.20 Flow Chart







3.27 Specification







7.


7.7 Vital Spares


7.9 Consumables

8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FUEL PUMP CONTACTORS (ALCo LOCO)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement

1.1 Max pick up volt 48v All Diesel Electric Locomo tives (ALCo)


Altr R3 Part

No 12141033


drawing

1.2 Main contact gap 11-13 mm,

1.3 Wipe 3.5-4.7mm,

1.4 contact pressure( kgf) initial 0.68-0.9kgf, final 0.9-1.4kgf.,

1.5 operating coil resistance at 20 deg c 169-195 ohm ,

1.6 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08

(Rev-

01),May’10

3.10.e

1.7 IR Value as per clause 10.2.9 of IEC 60571 between

(i)Main contacts of contactor

(ii) Coil and magnet frame

IEC 60571







SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations



2.33 Variac

2.34 Meggar

2.35 Oscilloscope



3.28 Display Chart

3.29 Flow Chart







3.36 Specification







SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

7.


7.10 Vital Spares


7.12 Consumables

8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR RADIATOR FAN CONTACTOR (ALCo)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement

1.1 control voltage 72+1v dc, 1.2 Max pick up volt 48 v

All Diesel Electric Locomo tives (ALCo)

Radiator Fan contactor


Altr R3 Part

No 12140235


drawing

1.3 Main contact gap 6-7.5mm, Drawing No. EL/PT/0638/Par

t

1.4 Wipe 0.8-1.6 mm, No 12140235

1.5 Contact pressure( gmf) initial 80-150, final 180.-280,

Altr R3

1.6 Operating coil resistance at 20 deg c -388 ohm±5% (368 to 408 ohms),

Drawing No. EL/PT/0638/Par

t


(Rev-01),May’10

3.10.e

1.8 IR Value between (i) fixed contact to movable Contact (ii) coil to frame

IEC 60571 clause 10.2.9






SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations



2.42 Variac

2.43 Meggar

2.44 Oscilloscope



3.37 Display Chart

3.38 Flow Chart







3.45 Specification







SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

7.


7.13 Vital Spares


7.15 Consumables

8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FIELD SHUNTING CONTACTOR (ALCo)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement

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


Altr R4 Part

No 12140491


drawing

1.2 max pick up volt 48v,

1.3 Main contact gap12-14.5mm,

1.4 wipe 8-10 mm,

1.5 contact pressure( kgf) initial 1.6 1.82-2.95,final 5.45-7.25,

1.7 operating coil resistance at 20 deg c 104 -116 ohms,

1.8 interlock (GPRelay type- 9-41n, 3no+3nc) contact gap 9.5-10.5

1.9 Interlock contact mm pressure -220-300gm.,


(Rev-01),May’10

3.10.e

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

as per IEC 60571

clause 10.2.9


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

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

and earth







2.51 Variac

2.52 Meggar

2.53 Oscilloscope



3.46 Display Chart

3.47 Flow Chart







3.54 Specification







7.


7.16 Vital Spares


7.18 Consumables

8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR EP CONTACTORS (ALCo)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement ALCo Drawing No. EL/PT/0630/

Altr R4 Part

No 12141008


drawing

1.1 Contact gap 15-17 mm

1.2 Wipe 25.4-28.6 mm

1.3 Knuckling spring pressure(without lever) initial 4.5-6.3 kgf, final 12.2-18.2 kgf,

1.4 Normal air pressure 4.9 kg/cm2

1.5 Interlock gap 2.5-3.95mm,

1.6 Interlock pressure 500-900g.

1.7 Interlock rated current 10 A,

1.8 Magnet valve coil resistance at 20degC 615+5% ohm.for BHELTYPE: M5027MV2

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


MP.0.04.00.08

(Rev-01),

May’10

3.10.e

1.11 IR Value between a) main contacts b) interlocks and MV c) interlocks and MV shorted together and earth d) contacts and interlocks e) Interlocks and MV shorted together and main

contacts shorted together. f) Main contacts shorted together and earth

shorted with MV and interlocks.

IEC 60571

as per clause

10.2.9


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations







2.60 Variac

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

2.62 Compresor with air reservoir

2.63 Megger

2.64 Oscilloscope



3.55 Display Chart

3.56 Flow Chart







3.63 Specification







7.


7.19 Vital Spares


7.21 Consumables

8. Disposal




CHECK SHEET FOR

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


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement

1.1 Auxiliary contacts 4, change over type, ALCo Drawing No. EL/PT/0649/

Altr R5 Part

No 12310372


drawing

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,

1.7 Contact impression (should be min 80%)

1.8 Auxiliary contact pressure 0.68-2.0kgf,

1.9 Auxiliary contact gap 31.75mm (min), ,

1.10 Magnet valve coil resistance at 20degC 615+5% ohm.for BHEL type: 5027MV2

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


MP.0.04.00.08

(Rev-

01),May’10

3.10.e


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

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

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

together on each side (Main contacts open)

(iv) All control and Aux. circuit

IEC 60571








2.71 Variac



2.74 Megger

2.75 Oscilloscope



3.64 Display Chart

3.65 Flow Chart







SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations


3.72 Specification Spec No.

MP.0.04.00.08

(Rev-

01),May’10




4.15 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.

4.16 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.


7.22 Vital Spares


7.24 Consumables

8. Disposal




CHECK SHEET FOR

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


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement

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


Altr R5 Part No

12310300


drawing

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 BHELTYPE : M5027MV2

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


MP.0.04.00.08

(Rev-01),

May’10

3.10.e

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









2.82 Variac



2.85 Meggar

2.86 Oscilloscope



3.73 Display Chart

3.74 Flow Chart







3.81 Specification







7. Material Availability

7.25 Vital Spares


7.27 Consumables

8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERAL PURPOSE RELAY (ALCo LOCO)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1.

Measurement

1.10 Nominal operating voltage (50-80 V) All Diesel Electric Locomo tives (ALCo)

BHEL, AAL and IEI

Spec No. MP.0.400.03

(Rev-01) Nov’08

Clause 3.1.1

1.11 Pick up voltage (Must Operate), max 48V Clause 3.2 (ii)

1.12 Drop out Voltage Min 7.5 V

1.13 Auxiliary make rating 7.5 A at 72 V

1.14 Resistance of the coil at 20 deg C 445±5%, Clause 3.2 (v)

1.15 Contact Pressure 100-250 g Clause 3.2 (vi)

1.16 Over travel (1.6 mm) with over travel gauge in position 0.0 to 0.1

Clause 3.2 (vii)

1.17 Min contact gap 2.7 mm Clause 3.2 (viii)

1.18 Armature gap 4.7 to 6.6 Clause 3.2 (ix)

1.19 Ensure that no distortion or corrosion of any components

Clause16.1.9.2

1.20 IR Value between 1.20.1 Open contacts 1.20.2 Contacts and metal parts 1.20.3 Adjacent contacts 1.20.4 Coil and earth

as per IEC 60571

Clause 10.2.9




2.90 Go- No gauge

2.91 Dial gauge


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

2.92 Source which can provide minimum current at respective voltage (72 V DC)

2.93 Variac

2.94 Meggar


2.96 Sufficient set of tool and gauges provided by manufacturer


3.82 Display Chart

3.83 Flow Chart







3.90 Specification Spec No. MP.0.400.03

(Rev-01) Nov’08




4.19 Proper Register is maintained for GP Relay 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.

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


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

7.


7.28 Vital Spares


8. Disposal




CHECK SHEET FOR

TECHNICAL AUDIT OF POH WORKSHOP OF ELECTRICAL CONTROL FOR DC-DC CONVERTER (500 W)- TWIN BEAM HEAD LIGHT(ALCo LOCO)

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. Work shop/Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement :

2.1 Visual Inspection – check finish , material , sound quality of workman ship etc

ALCo

RDSO specification No. ELRS/SPEC/DC-DC Converter /0021 ,Rev.01

Sept 2004

Clause No.6.3.1

2.2 Functional Check –ON/OFF properly RDSO specification No. ELRS/SPEC/DC-DC Converter /0021 ,Rev.01

Sept 2004

2.3 Available output regulated Voltage 25.5 ± .1% V DC with the variation of input voltage 50-85 V DC

RDSO specification No. ELRS/SPEC/DC-DC Converter /0021 ,Rev.01

Sept 2004

Clause No. 2.2 and 2.3

2. Availability Of Tools And Test Stands ALCo

3.1 Multimeter with Valid Calibration


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

3.2 Test stand for measurement and testing.

3.3 Screw Driver, Plier, etc.

3.4 Fire Extinguisher of proper class

3

Availability Of Instructions etc.

3.91 Display Chart

3.92 Flow Chart





3.97 Instruction Bulletin issued by RDSO NA


3.99 Specification



6. Record Keeping For Traceability

4.21 Proper Register is maintained for DC-DC

Converter (500 W) with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No.,


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

4.22 Proper record should be maintained for each DC-DC Converter

4.23 500 W DC-DC Converter 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.


7.30 Vital Spares


7.32 Consumables

8. Disposal

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

8.2 Safe Disposal including recycling following relevant environmental norms.


CHECK SHEET FOR

TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED FLASHER LIGHT (ALCo LOCO)

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. Workshop /Rly: Audited by: Date of audit:

SN Requirements

Loco Type

Make Of Subassembly

Reference Details Clause/Para/Item Details

Observations

1. Measurement :

2.1 Visual Inspection – check finish , material , sound quality of workman ship , water tightness etc

ALCo

RDSO specification No.

ELRS/SPEC/LFL/0017 Rev 1 Sept 04

Clause No.6.3.

2.2 Functional Check –ON/OFF properly RDSO specification No.


2.3 Lux Value- The lux measured in axial direction shall not be less than 500 lux at 1 meter and 55 lux at 3 meters for amber clour LED of 120 Nos

RDSO specification No.


Clause No. 2.3.3

2.4 Flashes per Minute (40±5) RDSO specification No.


Clause No. 2.4.1

2.5 Output regulated Voltage RDSO specification No.


Clause No. 2.4.5

2.6 Check Repeater indication properly RDSO specification No.


Clause No.2.4.3.1

2. Availability Of Tools And Test Stands ALCo


SN Requirements

Loco Type

Make Of Subassembly


Observations

3.1 Voltmeter with Valid Calibration

3.2 Ammeter with Valid Calibration

3.3 Lux Meter with proper Calibration


3.5 Stop Watch



3


3.1 Display Chart

3.2 Flow Chart







3.9 Specification RDSO specification No.



SN Requirements

Loco Type

Make Of Subassembly


Observations




4.1 Proper Register is maintained for LED Flasher Light 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.

4.2 Proper record should be maintained for each LED Flasher Light

4.3 LED Flasher Light 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.


7.1 Vital Spares


7.3 Consumables such as fuses , toggle switches etc

8. Disposal

8.1 Segregation of Working and Non-Working

equipment and Proper House Keeping

8.2 Safe Disposal including recycling following

relevant environmental norms.


CHECK SHEET FOR

TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED MARKER LIGHT (ALCo LOCO)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement :

2.7 Visual Inspection – check finish , material , sound quality of workman ship , water tightness etc.

ALCo

RDSO specification No. ELRS/Spec/PR/

0022 (REV-1 Oct -2004)

Clause No.6.3.

2.8 Functional Check –ON/OFF properly RDSO specification No. ELRS/Spec/PR/

0022 (REV-1 Oct -2004)

2.9 Lux Value- for all input voltage range 45 V-90 V

Lamp Lux level at 1

Meter

Lux level at 3

Meters

RED 75 LUX 7 LUX

WHITE 75 LUX 7 LUX

RDSO specification No. ELRS/Spec/PR/

0022 (REV-1 Oct -2004)

Clause No. 2.4.3

2.

Availability Of Tools And Test Stands

3.8 Multimeter with Valid Calibration ALCo

3.9 Lux Meter with proper Calibration



SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations



3


3.10 Display Chart

3.11 Flow Chart







3.18 Specification




4.4 Proper Register is maintained for LED Marker Light 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.


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

4.5 Proper record should be maintained for each LED Marker Light

4.6 LED Marker 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.


7.4 Vital Spares


7.6 Consumables such as fuses , toggle switches etc

8. Disposal


8.2 Safe Disposal including recycling following relevant environmental norms.


CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR STICK TYPE / IMPROVED STICK TYPE MASTER CONTROLLER FOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES


SN Requirements

Loco Type

Make Of Subassembly


Observations

A. Stick Type / Improved Stick type Master controller

1. Measurement:

1.1 Visual checking ALCo

M/s BHEL,

Asian Plastic, M/s Kaysons

(AMC/R2) Make

BHEL Test programme document no. 865476 dt

Clause 1.1

Drawing of Improved stick type Master Controller EL-PT-0633-R3 dt. 29.12.2007.

1.2 Contact gap, BHEL Test programme document no. 865476 dt 24.04.99 and

Clause 1.2

1.3 Contact pressure,

1.4 Cam sequence and

1.5 Mechanical interlocking

1.6 Working of Throttle handle Clause 1.3

2. Test :

2.1 Insulation Resistance test: BHEL Test programme

document no. 865476

Clause 5.0

2.2 Continuity Test DLW Drg. No. 35900030031Rev. 04


2.


ALCo

M/s BHEL,

Asian Plastic, M/s Kaysons

(AMC/R2) Make


3.14 Venier Caliper with Valid Calibration

3.15 Megger with Valid Calibration

3.16 Digital Multimeter with Valid Calibration

3.17 Potentiometer with Valid Calibration

3.18 Height gauge with Valid Calibration

3.19 High Voltage Tester with Valid Calibration

3.20 Bore Dial gauge with Valid Calibration


3.22 GO and NO GO Gauge

3.23 Screw Driver, Plier, Required spanner set etc.



3


3.19 Display Chart

3.20 Flow Chart

3.21 Throttle sequence chart

3.22 Mechanical interlocking Chart








3.29 Specification




4.7 Proper Register is maintained for EMD Master Controller checking 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.

4.8 Proper record should be maintained for each

4.9 EMD Master Controller 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.


7.7 Vital Spares


7.9 Consumables like OTTO Switches, Reverser Handle), Terminal Lugs, 28-Pin Coupler, M/s. Radiant make cables. etc.

8. Segregation of Working and Non-Working equipment and

Proper House Keeping


CHECK SHEET FOR

TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR TWIN BEAM HEAD LIGHT (ALCo LOCO)


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

1. Measurement :

2.10 Visual Inspection – check finish , material , sound quality of workman ship etc

ALCo

RDSO specification No. ELRS/SPEC/PR/0024 ( Rev-1,

Sept 2004)

Clause No.6.3.1

2.11 Functional Check –ON/OFF properly

2.12 Type of Bulbs used – H4 P45 T(IR), Twin Filament IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No. 4.A.1

2.13 Model of Bulbs –Halonix and AutoPal Only IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No. 4.A.2

2.14 Voltage Rating -24 V IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No. 4.A.3

2.15 Wattage Rating of Bulbs -100/90 W, Bright/Dim filament at 24 V

IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No. 4.A.4


SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

2.16 Lumen Out put -2600/1770 ± 15 % Lumen of Bright/Dim Filament at 24 V

IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No. 4.A.5

2.17 Lux output with Twin Beam Head Light for each reflector minimum 2400 Lux at a distance of 8 Mt and 24.5± 0.1 V DC terminal Voltage at Lamp Holder

IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No. 4.A.6

2.18 Procedure to check correctness of bulb’s filament in test room

IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No. 4 B

2.19 Checking illumination intensity of head light assembly when both bulbs are working

IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06

Clause No.6

2.



3.27 1.A standard portable lux measuring equipment ‘Lux meter’ like T.E.S. model TES –1330 shall be used. Lux Meter should be of range 0-20000 lux with least count of 0.01 Lux with valid calibration

3.28 Focusing Stand IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06



SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations



3


3.30 Display Chart

3.31 Flow Chart





3.36 Instruction Bulletin issued by RDSO IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06


3.38 Specification RDSO specification No. ELRS/SPEC/PR/0024 ( Rev-1,

Sept 2004)





SN Requirements

Loco Type

Make Of Subassembly

Reference Details


Observations

4.10 Proper Register is maintained for Twin Beam Head Light 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.

4.11 Proper record should be maintained for each Twin Beam Head Light

4.12 Twin Beam Head Light /Bulbs 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.


7.10 Vital Spares


7.12 Consumables like bulbs , Reflector

8.

Disposal


8.2 Safe Disposal of Bulbs/reflector including recycling following relevant environmental norms.


CHECK SHEET FOR

TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES


SN Requirements

Loco Type

Make Of Subassembly


Observations

1. Measurement :

2.20 Physical Examination

ALCo

2.21 Air Pressure Spec. No. DEL/SPN/193 July’98

Clause 8.5

2.22 Ampere Hour Capacity Spec. No. DEL/SPN/193 July’98

Clause 8.6

2.23 Watt Hour Efficiency Spec. No. DEL/SPN/193 July’98

Clause 8.7

2.24 Ampere Hour Efficiency Spec. No. DEL/SPN/193 July’98

Clause 8.7

2.25 Internal Resistance Spec. No. DEL/SPN/193 July’98

Clause 8.8

2.26 Initial Cranking Current Spec. No. DEL/SPN/193 July’98

Clause 8.9

2.27 Electrolyte Level Spec. No. DEL/SPN/193 July’98

Clause 6

2.28 Polarity and absence of Short Circuit

2.


ALCo

3.32 Battery Room Suitable size with sufficient area for movement of forklift, Storing of Acid Mixing tank, and Suitable battery test benches with sufficient Exhaust fans.

3.33 Electrolyte mixing tank-Motorized type preferred


3.35 Thermometer with Valid Calibration


SN Requirements

Loco Type

Make Of Subassembly


Observations

3.36 Hydrometer with Valid Calibration


3.38 Multi meter with Valid Calibration

3.39 Clamp Meter

3.40 Rubber syringe

3.41 Battery Charger(Preferred Constant Current Chargers)

3.42 Battery Discharger (Preferred Electronic type)

3.43 Required Lab for testing of Acid and DM water

3.44 Screw Driver, Plier, Spanner Set etc.

3.45 Test stand for measurement and testing (Concrete Platform covered with Acid Resistant FRP sheets/coating for keeping batteries –charge /Discharge.)

3.46 D.M.Water Plant

3.47 Proper earthing facility for switch gear and Battery charging Panel.


3.49 Fork Lift

3.50 Hand trolley

3.51 Battery lifting crane on test bench

3.52 Plastic Pallet for storing Battery

3.53 Rubber Apron

3.54 Rubber Gloves

3.55 Goggles

3 Availability Of Instructions etc.


SN Requirements

Loco Type

Make Of Subassembly


Observations

3.39 Display Chart

3.40 Flow Chart





3.45 Instruction Bulletin issued by RDSO MP. IB. EC.01.02.05 (Rev.01), Dec. 2008


3.47 Specification Spec. No. DEL/SPN/193 July’98



6.

Record Keeping For Traceability

4.13 Proper Register is maintained for Battery checking 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.

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


SN Requirements

Loco Type

Make Of Subassembly


Observations

7.


7.13 Vital Spares


7.15 Consumables like Distilled Water,

Sulphuric Acid (for Lead Acid Battery), Lugs, Rubber Mat etc.

8.

Disposal


8.2 Safe Disposal of Battery including recycling following relevant environmental norms.


CHECK SHEET FOR

TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo LOCO) FOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES


SN Requirements

Loco Type

Make Of Subassembly


Observations

1. Dis Assembly and Assembly ALCo

Maintenance manual of Woodward

Section 5 of Maintenance

Manual

2. Measurement :

2.29 Physical Examination

ALCo

Wood Ward Governor Test

Record Format No. TSP/F8572-828

and Maintenance manual of Woodward

Section 6 of Maintenance

Manual

2.30 Barometer Reading

2.31 Pressure Test

2.32 Hydraulic Seals, needle valve seat and buffer piston bypass in both direction

2.33 Needle Valve setting

2.34 Speed Setting

2.35 Normal Shut Down

2.36 Pressure Requirement

2.37 Speed Setting timing

2.38 Lube Oil Shutdown

2.39 Air Box Pressure Fuel Limiting

2.40 Load Control

2.41 Vane Servo Timing

2.42 Excitation Resistor

2.43 General

2.44 Verification with Cover Installed

3.

Availability Of Tools And Test Stands ALCo

3.56 Test Stand for Wood Ward Governor

3.57 Multimeter with valid Calibration

3.58 Screw Driver, Plier, Allen Key, Spanner,


SN Requirements

Loco Type

Make Of Subassembly


Observations

etc.


4.


3.48 Display Chart

3.49 Flow Chart



3.52 Display of Trouble Shooting Chart Maintenance Manual

Section 4



3.55 Instruction Bulletin issued by RDSO NA


3.57 Specification NA

5. Compliance of Instruction Bulletin NA



4.15 Proper Register is maintained for Governor 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.


SN Requirements

Loco Type

Make Of Subassembly


Observations

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

8.


7.16 Vital Spares


7.18 Consumables like Lub Oil, Cotton wool, etc.

9.

Disposal


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


Annexure-6

Check sheet for Quality Audit of Railway Workshop

(Underframe/cattle guard/ fuel tank/ loco painting/ cab/ battery box/ superstructure/ CBC/ side buffers)

Sl.N

o.

Activity Clause/ Reference Observations

Underframe

01 Underframe to be kept on trestle at lifting lugs.

02 Proper cleaning & washing of U/F with detergents & water,.

03 Use of manipulator for carrying out repair work by down hand welding.

04 i. Visual inspection of buffer beam, striker block for any crack or damage, accordingly repair/weld properly

ii. Check the buffer base bolt holes for size, centers & ovality. Remove the ovality by welding and redrill if necessary

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

ii. Ensure minimum clearance of cattle guard from R/L to be 178 mm iii. Ensure minimum clearance of rail guard from R/L. to be 115 mm iv. Modify/ change cattle guard and its support arrangements to plate type on

WDM3A locomotive

RDSO’s Drg. No.

SK.DL-4533/4535 and

DMW’s Drg. No.

2DMW/SK-938

06 Visual inspection of welding of gussets/ stiffeners in back of buffer beam

transferring buffing force from buffers to maintain longitudinal box section. If any

crack /damage is found, it shall be repaired accordingly.


07 Visual inspection of Footstep for welding crack/damage and shall be repaired by

welding properly or replaced.

08 i. Visual inspection of welding of Hand rails to underframe. If there is any crack or damage in weld then reweld it properly.

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

09 The coupler pocket shall be examined closely for welding cracks/damage in ribs and

inspection of welding with underframe. If any crack or wear is found, shall be

repaired or replaced properly.

10 Visual inspection of welding of ECC mounting stool. If there is any welding

crack/damage then it should be rewelded or replaced properly.

11 i. If abnormal vibration noted modify compressor mounting area of WDM3D locomotive under frame

ii. Visual inspection of welding of expressor/ compressor mounting stool. If there is any welding crack/damage then it should be rewelded or replaced properly

iii. Clean the threads of mounting block on stool by tapping it properly.

MP.MOD.LD.01.02.11

dated 09.03.2011

12 i. Visual inspection of welding of engine mounting block. If there is any weld defect carryout required welding or replace it

ii. Check/Clean the threads of mounting block by tapping.

13 i. Inspection of air duct gallery for all traction motors cutout for any leakage or cracks

ii. Filling water/hydraulic test in the gallery carried out iii. If any leakage is found, shall be repaired accordingly.


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

ii. End plate of battery box with fuel tank end shall be modified as per RDSO Drg. no. SK.DL-4436.

iii. Mounting block, nut & bolt should be properly secured and tighten iv. Wooden spacer properly placed between the battery v. All hinges, locks should be in working

vi. Cover assly. properly secured & locked with battery box.

RDSO’s letter

No.SD.DMG.32 Dated

30.07.1996 and SK.DL-4436

15 i. Ensure proper cleaning & washing of fuel tank to remove dirt, sludge deposited inside the tank.

ii. Inspection of fuel tank for any leakage or cracks. iii. Inspection of drain valve, glow rod and for any crack repair by welding or

replace if found beyond repair. iv. Mounting block, nut & bolt should be properly secured and tighten v. Fuel gauge should not be broken and in working condition

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

RDSO’S Investigation

Report No.

MP-473/83 February, 1983

16 Visual inspection of underframe box section and side sill welding. If there is any

crack or damage, weld it properly with low hydrogen welding electrode.

RDSO’S Investigation

Report No.

MP.INV-8

December, 1995

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

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

RDSO’Drg. No.

SK.DL-2069

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

ii. side load bearer shall be repaired

RDSO’s spec. No. MP.MI-

140/88, Sep’1988 and

RDSO’Drg. No.

SK.DL-2069


19 Loco painting, marking, stenciling;

Apply epoxy primer and PU paint before stenciling

As per extent colour

scheme

20 Center buffer coupler & Draft Gear

Check compliance of RDSO instructions for inspection and maintenance

Modify uncoupling arrangement to make it top operated

G-80

MP.MOD.LD.05.10.11

dated 18.07.2011

21 Side Buffers

Check compliance of RDSO instructions for inspection and maintenance

MP.MI-116/82, Rev.02

22 Loco Cab

Railway Board’s letter

No.2000/M(L)/466/9 dated

05.01.2005

23.

1

Driver/Pilot seat

i. Base mounting nut/ bolt and other fasteners should be properly tighten ii. Motion and its adjuster/locking arrangement/ Ver. & rotational motion

should be in functioning iii. Cushion & upholstery should be in good condition

23.

2

Side sash / window

i. Sliding glass should freely slide and not cracked ii. Locking arrangement properly in fuction

iii. Guide rail, weather rubber & glazing rubber should be in good condition iv. Rear view mirror if applied properly secured with frame and its rotational

movement checked. Mirror should be in good condition


23.

3

Cab door

i. 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

23.

4

Cab floor

i. Flooring mat & trim should be in good condition ii. Steel structure/ panel sheet of cab should not be corroded or broken

23.

5

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

i. Lock, hinge and weather sealings should be in working condition ii. Perforated aluminium sheet , insulating material, fasteners should be in

good condition

23.

6

Cab light and fan

i. Switches, regulators and connections are properly in function

23.

7

Fire Extinguisher

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

23.

8

Air condition (if applied)

i. Switches, regulator and water drainage properly in function

23.

9

Token pick up arrangement

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

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

23.

10

Front look out glass

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

ii. Covering grill glass properly cover with hinged grill


24 Superstructure

i. Check the condition of sheets and repair if possible otherwise change ii. Check hinges and door locks for proper working and repair if possible

otherwise change iii. Check for water leakage at various joints and renew weather stripes/ceilings iv. Door panel-sheet should not bend and properly close

25 Radiator compartment & Expansion tank

i. Gauge, vent, vacuum valve, low water alarm should function ii. Expansion tank plate should not be corroded

iii. Funnel grating, foot step, hand- rail, inspection door properly secured with rad. Comp. Structure.