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Technical / Quality Audit of Diesel Shed
CHECK SHEETDescription Reference Documents, Annexures, Further details on check sheet etc
General
Compliance of Schedule Maintenance Schedule of standard examinations: MP-Misc-140/141 (for Alco locos).
Schedule of standard examinations: MP-Misc-285 [for HHP (EMD) locos] Quality of major schedules:
M24 M48
-do-
Load Test/Load Box Test records: HP SFC EGT Peak Firing Pressure
Load Test MI No MP.MI-10 (Rev 0.02), Aug 2003. (for Alco locos).
Document No. Misc-195 on Test procedure for EMD diesel engine, 16 cyl. Vee model 710G3B (4000/4500HP) issued by DLW.
Methodology and analysis of failure investigation. Display of work instructions on shop floor Training of staff Status of record keeping Calibration of gauges/ instruments
Safety items
a. Speed recorder/Indicator Sectionb. Wheel (Wear adapted profile) profile & other
defects. c. Brake adjustment, release & and application
timings.d. Headlight focus adjustmente. Horn maintenancef. Under gear safety brackets
a. OEM’s maintenance manual.b. Drg No SKDL-2561 Alt 8.
c. Standard test scheme as per MP.TP-029/87 (Rev 02) Oct 2008 for Air Brake, and, as per MP.TP-019/81 (Rev 02) Nov 08 for dual brake locos.
d. IB No MP.IB.EC.01.08.06 (Rev 0) December 06.
f. MI No MP.IB.BD.02.16.01 (Rev 01) December 09.
Page 1 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
g. Gauging of Couplersh. Vertical offset between Side bearer and centre
pivot
g. CBC Manual No G 76 Sept 87. h. MI No MP.IB.VL.02.11.10 (Rev 00) February 10.
Quality of Subassembly repairs (important items)
a. Expressor/Compressorb. Air Brake Sectionc. Bogie sectiond. Rotating Machines Sectione. Turbo sectionf. Cylinder Head, Piston and Valve sectiong. Radiator section.h. FIP/Injector Sectioni. Governor Sectionj. Electrical Control Sectionk. Battery Section
a. Further details of check sheet covered in Annexure 1.b. -do-c. Further details of check sheet covered in Annexure 2.d. Further details of check sheet covered in Annexure 3.e. Further details of check sheet covered in Annexure 4.f. -do-g. -do-h. -do-i. Further details of check sheet covered in Annexure 5.j. -do-k. -do-
DM Plant and Spectrograph
General working condition MP Guide-6 (Rev 2) May 07 issued by RDSO in reference to spectrograph.
Material Availability of critical items Procurement from unapproved sources, if any.
Any other item
As decided by the auditing authority
Page 2 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Annexure-ICheck List for quality audit of diesel loco sheds (Brake Items)
S. No. Item Parameter Ref document Observations1. Whether all the
prescribed schedules are being followed for brake equipment, compressor & air dryer or not
As per Schedule of standard examinations(No. MP.Misc.-140 & 141, Rev-01, September’2006)Trip Sch.
M-2
M-4
M-12
M-24
M-48
M-72
POH
1. Whether maintenance is done as per RDSO MIs or manufacturers MI mentioned in MP.Misc.-140 & 141. 2. Maintenance facilities are available or not.
1. Schedule of standard examinations: MP-Misc-285 [for HHP (EMD) locos] to be added.2. For GD make compressor maintenance instruction, M/s GD maintenance manual and IB no.MP.IB.BK.01.05.12, Rev-0, dated 24.07.2012. For ELGI make compressor, M/s ELGI maintenance manual and RDSO IB No.MP.18.8K.01.09.18 (Rev.00) October 2018 to be followed.
Page 3 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
S. No. Item Parameter Ref document Observations3. CCB systems: CCB 1.5 as per ETI-991, CCB 2 IR as per NYT 1794-C.4. For IRAB-1 brake system, MP.TP.29 and for 28LAV-1, MP.TP.019 to be followed.5.OEM maintenance manual and MP.MI-18 for air dryer,
2. Functioning of VCD Whether functioning of VCD is being checked in every trip schedule. 3. Test benches and rigs 1. Whether the required test bench and rigs are available or not viz.
AB test rack for brake valves, air dryer test bench, compressor test bench, pressure switch, magnet / solenoid valve, Auto drain valve etc.
2. Whether, testing is done on above test benches.3. Calibration of test benches and rigs is being done periodically or
not.4. Test bench for air pressure gauge 5. CCB Simulator and Test bench for CCB
4. Test on compressor Testing for checking capacity of compressors as per MP.TP-41, 2010.5. Infrastructure facilities (a) Whether dust proof and controlled temperature environment
for maintenance, assembly and testing of brake valves is available.
(b) Availability of compressed air ( in test benches.
Page 4 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
S. No. Item Parameter Ref document Observations(c) Availability of compressor in air lines.(d) Whether air dryer provided in test benches/ air lines.(e) Reservoir pressure is being checked or not(f) Washing facilities(g) Painting facilities(h) Technical Cell(i) Metrology lab(j) Store(k) Tool room(l) Fire extinguishers(m) Material handling facilities for movement of material and
components.(n) Facilities for filtering the sand.
6. Storage of material Whether dust/damp proof environment with controlled temperature is available for storage of brake equipment and rubber components. Whether rubber components are being stored as per guidelines mentioned in this office letter no. SD.DEV.RBC dated 28.02/07.03.2007 circulated to all Zonal Railways.For storage of Sand: Storage space should be shaded, dry and dust free in the shed.
7. Availability of Material Any Chronic shortage of material for maintenance8. Human Resource
developmentWhether periodic training is being imparted to maintenance staff to make them conversant with the maintenance practices.
9. Air Reservoirs All air reservoirs are to be tested and certified periodically by a qualified Boiler Inspector. The period is to be specified by CME office.
10. Any other observation
Page 5 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Annexure-IITechnical / Quality Audit of Diesel Shed
CHECK SHEET FORTECHNICAL AUDIT OF CYLINDER HEAD SECTION
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
1
Cleaning, measurements etc.1.1 Cleaning of cylinder head ALCo -- DLW Maintenance
Instruction Manual
(MI-ENG-020)
Chapter on cylinder head1.2 Cy head leak test at 70 PSI with hot water
1.3 Inspect head for cracks using Magnaflux1.4 Valve guide to head int 0.002” -0.0005”1.5 yoke to guide int 0.002” -0.0005”1.6 Yoke guide ( press in dim) 3.210” -3.272”1.7 Valve guide ( press in dim) 2.25”1.8 Valve to guide clearance Top- 0.003 – 0.0045” Bottom- 0.005 – 0.0065’’1.9 Cy head nuts torquing value 550ft/lbs as per sequence described in Manual
2Availability of tools , Test Stands etc.2.1 Valve seat reconditioning machine2.2 Hydraulic test stand
Page 6 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
2.3 Feeler gauge2.4 Magna flux
3
Availability of instructions etc.3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5Material Availability5.1 Vital Spares5.2 Must change items
1
Cleaning, measurements etc. EMD -- EMD Engine Maintenance
Manual
Chapter on cylinder head1.1 Cleaning of cylinder head
1.2 Cy head leak test at 85 to 95 PSI air pressure with temp 150°F + 5°F1.3 Inspect head for cracks using Magnaflux1.4 Cy head valve seat angle 30°00’-30° 15’1.5 Valve seat width 0.093” -0.125”1.6 Dia at top of valve seat 2.375”-2.437”1.5 Valve seat runout TIR max 0.008”1.6 Valve guide inside dia max 0.633” 1.7 Valve stem to guide clearance max 0.010”
2Availability of tools ,Test Stands etc.2.1 Valve seat reconditioning machine2.2 Hydraulic test stand2.3 Feeler gauge2.4 Magna flux arrangement
Page 7 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
3
Availability of instructions etc 3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5Material Availability5.1 Vital Spares5.2 Must change items
Page 8 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FORTECHNICAL AUDIT OF PISTON SECTION
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
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 (MI-ENG-015)
Chapter on piston and con rod1.2 Inspect visually piston skirt and body for scoring or
scuffing 1.3 Inspect piston crack using Magnaflux1.4 Zyglo test for checking surface crack1.5 Groove width top ring, 2nd ring and 3rd ring New –(0.1902”- 0.1921”) Limit - 0.1950’’1.6 Side clearance in above rings New - ( 0.0052” -0.0088’’) Limit- 0.012”1.7 Groove width of oil scrapper ring New - (0.3140” – 0.3150’’) Limit - 0.3165”1.8 Side clearance in oil ring New - ( 0.002”-0.0040’’) Limit- 0.006”1.9 Piston pin to bushing clearance running New – (0.003”- 0.0070’’) Limit – 0.0075”1.10 Piston pin to snap ring total clearance 0.076” – 0.118”
2. Availability of tools , Test Stands etc.2.1 Feeler gauge
Page 9 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
2.2 Zyglo testing machine2.3 Magna flux2.4 Vernier caliper2.6 Piston ring groove gauge
3
Availability of instructions etc3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5Material Availability5.1 Vital Spares5.2 Must change items
1. Cleaning, inspection, measurements etc.Cleaning1. Immerse the piston in an alkaline solvent solution
and allow carbon deposits are loosened.2. Wash the piston using steam or hot water 3. Blow dry using compressed air.4. Remove any carbon deposits from the compression
ring grooves. 5. Using 3/32" and 5/32" drills in the respective holes,
clean the oil passages in the oil ring grooves.6. Remove under crown deposits.1.1 Inspect visually cylinder wall and top of piston for any scoring mark and water leak indication etc.
EMD -- EMD Engine Maintenance
Manual
Chapter on piston
1.2 Measure side clearance of no 1 compression ring.
Page 10 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
1.3 Inspect piston skirt for scoring or scuffing 1.4 cleaning of piston 1.5 Inspect piston crack using Magnaflux Check piston ring groove wear step. Check tin plated surface of the piston skirt should
be satisfactory condition (0.0007”-0.0015”)1.6 Piston skirt diameter min 9.0485”1.7 Out of round max 0.005”1.8 Piston to carrier pilot cl max 0.011”1.9 Piston platform to bottom of snap ring groove 6.626” -6.639”1.10 No 1 compression ring groove width max 0.201”1.11 Piston to Cy head cl 0.020”- 0.068”1.12 Compression ring to land clearance No 1 groove Max 0.012”1.13 Compression ring to land clearance No 2 & 3 groove Max 0.015”1.14 Compression ring to land clearance No 4 groove Max 0.015”1.15 Oil ring groove width 0.251- 0.2541.16 Oil ring to land clearance 0.002- 0.006”
2. Availability of tools, Test Stands etc.2.1 Feeler gauge2.2 Zyglo testing machine2.3 Magna flux2.4 Vernier caliper2.5 Lead wire
Page 11 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item/chapter Details
Observations
2.6 Piston ring groove gauge
3
Availability of instructions etc.3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5
Material Availability5.1 Vital Spares5.2 Must change items
Page 12 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR QUALITY AUDIT OFAIR & EXHAUST VALVE MAINTENANCE
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference documents. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
SN Requirements Loco Type Make of Subassembly
Reference Details
Clause/Para/Item details
Observations
1
Measurements etc:
Alco --
Alco Instruction Manual (MI-
11020G)
Chapter on Cylinder Heads
1.1 Stem dia of valves 0.6205-0.6195 (New).1.2 Groove fillet radii 0.025-0.031R.1.3 Valve disk thickness: for C and F type valve of 450: (a) 0.1562” (new) and (b) 0.0625”(condemning Limit).1.4 Valve disk thickness (for E type valve 300) 0.1750”(new). And, 0.0937”(condemning Limit).1.5 Blue matching of valve with VSI1.6 Zyglo testing for crack detection1.7 Grit blasting for removal of carbon deposition
2Availability of tools, test stands etc:2.1 Depressor, Spring etc2.2 Grinder
3 Availability of instructions etc:3.1 Display Chart etc3.2 Training of Staff3.3 Record keeping of tools and measuring instruments
Page 13 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type Make of Subassembly
Reference Details
Clause/Para/Item details
Observations
4 Record keeping for traceability:
5Material Availability:5.1 Vital Spare5.2 Must change items
1
Measurements etc:
EMD
--
EMD Engine Maintenance
Manual
Chapter on cylinder
heads and accessories
1.1 Stem diameter-measured within 12.7 mm (1/2”) of weld and 12.7 mm (1/2”) below P/N stencil on stem- Min. – 15.761mm (0.6205”).1.2 Valve face angle 30000’-29045’’.1.3 Valve seat runout-Max-0.06mm(0.0025’’). 1.4 Valve rim thickness (measured at O.D.)- Min.- 2.77mm (0.109”); Valve face width-Max- 8.71mm(0.343”).1.5 Surface finish of valve stem roughened not beyond 0.635µmm(25µin)1.6 Blue matching of valve with VSI1.7 Zyglo testing for crack detection1.8 Grit blasting for removal of carbon deposition
2
Availability of tools, test stands etc.2.1 Single valve compressor (Part No 8033783)/Multiple valve spring compressor (Part No 9546582) 2.2 115V grinder for Grinding Valves
3 Availability of instructions etc.3.1 Display Chart etc
Page 14 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type Make of Subassembly
Reference Details
Clause/Para/Item details
Observations
3.2 Training of Staff3.3 Record keeping of tools and measuring instruments.
4 Record keeping for traceability.
5Material Availability5.1 Vital Spares5.2 Must change items
Page 15 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Annexure-IIICHECK SHEET FOR
QUALITY AUDIT OF TURBO SECTION During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
1. Balancing, measurements etcBalancing:1.1 Bladed shaft, range 31-257 gmm.1.2 Rotor, range 157-470 gmm.
5.65.6.2.55.6.2.5
Rotor Shaft Dimensions:1.3 Bearing position OD A 39.98 – 40.00 mm
Alco ABB VTC 304 Turbocharger
ABB-Exhaust Gas
Turbocharger VTC 304 A
Comprehensive Manual for Indian Railways issued by M/s ABB
Para 5.2.4.13 &details in 5.4.2.1
1.4 Bearing position OD B 50.987--51.000 mm1.5 Bearing position OD C 56.10-56.20 mm1.6 Piston ring recess S 2.58-2.85 mmWheel Bush1.7 Compressor wheel set OD A 56.10 -56.20 mm
Para 5.2.4.13 &details in 5.4.2.2
1.8 Piston ring recess S 2.58-2.85 mm
1.9 Plain bearing (CE) ID A 54.00-54.06 mm Para 5.2.4.13 &
Page 16 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
details in 5.4.2.3
1.10 Bearing housing bore ID A 65.00-65.07 mm Para 5.2.4.13 &details in 5.4.2.4
1.11 Floating bush ID (CE) 40.011-40.05 mm Para 5.2.4.13 &details in 5.4.2.5
Floating bush OD (CE) 53.80-53.86 mm1.12 Floating bush OD (TE) 64.82-64.84 mm1.13 Floating bush ID (TE) 51.022-51.07 mm1.14 Thrust bearing width 10.39-10.50 mm Para 5.2.4.13
&details in 5.4.2.6
1.15 Axial bearing width 16.76-16.88 mm Para 5.2.4.13 &details in 5.4.2.7
1.16 Piston ring width 2.00 -2.49 mm Para 5.2.4.13 &details in 5.4.2.8
1.17 Thrust bearing press fit measure (K) 170.5 -170.63 Para 5.2.4.13 &details in 5.4.2.9
1.18 Axial clearance A 0.11-0.32 mm Para 5.2.4.13
Page 17 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
&details in 5.7
1.19 Radial clearance B 0.47-0.93 mm
2.
Availability of Tools, Test Stands etc.
Alcodo do
2.1 Balancing machine2.2 Zyglo testing machine2.3 Casing hydraulic test stand 2.4 Bearing puller (CE & TE)2.5 Torque wrench up to 250 psi2.6 micrometer 2”-3” & 0-4”2.7 Go-NoGo gauge for checking fix nozzle ring
3
Availability of instructions etc.3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5
Material Availability5.1 Vital Spares5.2 Must change items
1
Measurements etc1.1 Nozzle ring and gas inlet casing 0.022-0.032” Dia Clearance (Cl)
Alco Alco 720 Instruction Manual
ALCo MI 11126
1.2 Turbine blade and gas inlet casing 0.060-0.092”Dia CI1.3 Nozzle ring and turbine disc 0.124” cold CI1.4 Intermediate casing and impeller 0.017-0.065”
Page 18 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
longitudinal Clearance (long Cl)
ALCO
1.5 Impeller and Blower inlet 0.035-0.075” long CI1.6 Blower casing end blower inlet measure with bolt loose. Scatting with back of diffuser at lease to 80% (This is only in case when we apply a new diffuser) 0.005-0.020” Long CI (Gap)1.7 Turbine disc and intermediate casing 0.008-0.016” Long CI1.8 Bearing and thrust collar (Blower end) with surface by approx 0.003 less when oil. 0.007-0.018” Thrust CI1.9 Inducer and blower casing 0.091-0.101”Dia CI1.10 Thurst collar and oil seal Blower End 0.014-0.036” Dia CI1.11 Interference between bearing and intermediate casing (blower & Turbine end ) 0.0005-0.0015” Dia Cl1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008” Dia CI1.13 Gas inlet casing and intermediate casing inside measurement 0.090-0.098” Dia CI1.14 Impeller and intermediate casing 0.125-0.127” Dia CI1.15 Max allowable clearance between Gas inlet casing & Nozzle ring 0.005” clearance
2Availability of tools, Test Stands etc.2.1 Balancing machine2.2 Zyglo machine2.3 Casing hydraulic test stand
Page 19 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
AlcoAlco 720 Instruction
ManualALCO
2.4 Oil gallery flushing test stand2.5 Bearing puller (CE & TE)2.6 Sand blast machine for rotor cleaning2.7 Torque wrench up to 250 psi2.8 micrometer 2”-3” & 0-4”2.9 Go-NoGo gauge for checking fix nozzle ring
3
Availability of instructions etc .3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5Material Availability5.1 Vital Spares5.2 Must change items
Page 20 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FORQUALITY AUDIT OF HHP TURBO FITMENT & MATCHING PROCEDURE.
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded. DLW /BSB issued Design Bulletin No. DB/01/2015/26,dt.11/05/15 for defining the procedure of fitment and matching of turbocharger on HHP
locos a diesel sheds to arrest the failure of HHP turbocharger.
Shed/Rly: Audited by: Date of audit:
Sn. Loco No.
Schedule
Date 1st notch TSC LOP at
comp. bearing support.(not less than 12
psi)
8st notch TSC LOP at comp. bearing support
HHP Turbocharger clearance HHP Turbo Impeller Eye clearance Remark
TSC inlet(TSC
filter)A
TSC outlet at (support Comp.
bearing)B
LOP dropA-
B(Should not
exceed 34 psi)
Turbine shaft thrust6-24 thou
Backlash-TSC drive
gear & TSC idler gear 6-18
thou
Backlash-Auxi . drive gear 10-22 thou
Auxi. Drive gear
thrust 133-162
thou
At 12 O’clock24-48 thou
At 3 O’clock16-39thou
At 6 O’clock12-25thou
At 9O’clock16-39 thou
1
Page 21 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Page 22 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR TECHNICAL AUDIT OF RADIATOR SECTION
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:SN Requirements Loco
TypeMake/class Of Subassembly
Reference Details
Clause/Para/Item/Chapter
Details
Observations
1
Cleaning etc
AlcoConventional
Alco MI -15 Rev.10, Feb-
2018, Page-12
Chapter on Maintenance,
Radiators.Cleaning of
Radiator
1.1 cleaning details
2
Availability of tools, Test Stands etc. 2.1 Torque wrench up to 140 ft-lb.2.2 Hydraulic testing machine 0-10 Kg/Cm22.3 Radiator stand 2.4 Fin combing tool 2.5 Radiator immersion tank for cleaning
3
Availability of instructions etc.3.1 Display board etc3.2 Training of staff3.3 maintenance manual and check sheets3.4 Calibration facility for tools and measuring instruments
4Record Keeping for Traceability
5. Material Availability:
Page 23 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make/class Of Subassembly
Reference Details
Clause/Para/Item/Chapter
Details
Observations
5.1 Vital spares 5.2 Must change Item
1.Cleaning etc
EMDMechanical
Bonded Radiator (MBRs)
EMD MI-549, Rev-B, for Tube
leak repair & service data
Chapter on Maintenance,
Radiators.
Cleaning details
2.
Availability of Tools, Test Stands etc2.1 Torque wrench up to 140 Ft-lbs2.2 Hydraulic testing machine 0-10 Kg/Cm22.3 Radiator stand 2.4 Fin combing tool 2.5 Radiator immersion tank
3.
Availability of Instructions etc3.1 Display board – Cleaning and test procedure of the MBRs3.2 Training of staff3.3 All maintenance manual and check sheets3.4 Calibration facility for tools and measuring instruments
4.Record Keeping for Traceability
5.Material Availability:5.1 Vital spares – Gaskets and Radiator core panel 5.2 Must change Item – Gaskets during overhauling
CHECK SHEET FOR
Page 24 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
QUALITY AUDIT OF ALCO LOCO FUEL INJECTION PUMP (FIP) & INJECTOR MAINTENANCE
During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco type
Make /Class/Name of subassembly
Reference details
Clause/Para/Item details
Observations
1 Availability of tools/Equipment for maintenance Alco
Bosch 17 mm / 18 mm
Bosch repair and testing manual
Para on AssemblyPara on Calibration ValuesPara on Inspection of PartsPara on Inspection of Parts
1) Torque wrench:O-250 ft.lbs& 0-500 ft.lbs2) Ring spanner-1 3/8"3) Ring spanner-31/4"4) BWS DE-325) Single end 2 3/4"ring spanner6) 0-0.025"lift guage7) Feeler gauge8) Depth gauge for checking of BDC dimension ‘a’ on
test bench.9) Bush reamer.10) Micrometer, 16 – 20 mm. 11) Assembly and dis-assembly fixture12) Nozzle needle lift gauge13) Calibration oil – Servo Calib-514) Dial gauge15) Nozzle centering sleeve16) True running gauge17) Nozzle tester
Page 25 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco type
Make /Class/Name of subassembly
Reference details
Clause/Para/Item details
Observations
18) Fixture for injector19) Socket wrench20) Test oil
2
Availability of test benches and other related equipments:
1) Calibration test stand( Make and date of commissioning)
2) Injector test stand ( Make and date of commissioning)
3 Availability of instructions1) Display charts related to reconditioning Training of staff2) Display charts related to testing 3) Maintenance manual and check sheet including calibration and functional test procedure
4) Record keeping of tools and measuring instruments 4 Availability O/H/Renew kit 5 Schedule for maintenance 6 Record keeping for traceability 7 1) Storage of FIP/ Injectors-
a) Store in proper Handling Rack b) Cover with plastic 2) Stored for longer time but <1 year a) Injectors are filled with calibrating oil b) Tight fitting plastic caps used for covering the filter caps , spray tip end and on the theraded injector stud
Page 26 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco type
Make /Class/Name of subassembly
Reference details
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Observations
3) Stored for more than one year a) After one year, to be filled with clean fuel/ calibrating oil again
b) Slowly pop a few times prior to installation 8 Audit of Reconditioning
8.1 Dismantling of injector components 8.2 Cleaning & Inspection of injector components
1) Cleaning of injector components 2) Check the condition of shims, guide bush,
intermediate disc.3) Lapping of intermediate disc & Injector body
8.3 Must change items for reconditioning of FIP/Injector 8.4 Measurements etc.
FIP testing1) FIP range control rack bush dia -18.25
mm(0.7185”) -18.27 mm (0.7192”)2) BDC Dimension ‘a’- 6.5 +/- 0.05 mm3) Clearance between control rack and bushing-
within 0.05 mm (0.020”)4) Control rack movement- within 0.38 mm (0.015”)
8.5 Injector Testing1) Opening pressure – 3900 to 4050 psi ( New nozzle)2) Opening pressure – 3700 to 3800 psi ( Overhauled
nozzle)3) Nozzle cap nut tightening torque 130-150 Nm (13-
15 kgf.m or 94-109 lbs-ft)
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4) Chattering test5) Valve seat tightness test6) Fuel leak test7) Spray pattern test
8.6 Nozzle Test 1) Check the condition of nozzle2) Clean the nozzle assembly by Multi cleaner"3) Ultrasonic cleaning of nozzles4) check the nozzle lift 0.016"to 0.025"
8.7 Fuel Injection Pump1) Check the pump phasing2) Check the Interface between guide cup &
crosshead3) Chech the gap between HP tube and snuber valve4) Chech the alignment of HP tube5) Chech the torquing of delivery valve6) Chech the torque valve of HP tube fitment
fasteners at cylinder head7) Chech the alignment of banjo bolt8) Chech the alignment of fuel jumper bolt9) Chech the free movement of banjo bolt
9 Misc1) Chech the fuel booster pump pressure2) Chech the current taken by fuel pump3) Chech the relief and regulating valve opening
pressure
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4) Chech the air drawal at suction side of FPM5) Annealing of copper pipes
6) Copper pipe line joint for fuel leakingConduct the bleed test
10 M & P1) FIP calibration test stand 2) Fuel pump motor efficiency checking test bench 3) Profile gauge for checking of HP line 4) Injector test stand
11 Injector output and Slide Adjustment Injector Output data: Test oil……. Viscor 1487 AW2 or equivalent Test oil temperature………35 *C to 40 *C Test oil pressure………..35 psi (241.3 kpa) Test stand RPM………………. 500 RPM
CHECK SHEET FORQUALITY AUDIT OF HHP LOCO MECHANICAL UNIT INJECTOR (MUI) MAINTENANCE
Page 29 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco type
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1 Availability of tools/Equipment for maintenance Ecotip Superstack Mechanical Unit Injector
(MUI)
Ecotip Superstack Injector Maintenance Instructions of Interstate McBee USA
1) EMD timing gauge 2) Vise with adapter 3) Control rack set length blocks 4) Pop and Leak test stand 5) Torque wrench 6) Optical flat 7) Monochromatic light source 8) Soft wire buffing wheel 9) 12 mm dia. Soft wire brush 10) Injector nut reamer 11) Wrench for injector nut
2 Availability of test benches and other related equipment’s: EMD
1) Calibration test stand( Make and date of commissioning) 2) Injector test stand ( Make and date of commissioning) 3) Master Injector Kit (Part No. 4992244.) This kit contains Low Master Injector P/N 4991173 and High Master Injector P/N 4991174
3 Availability of instructions1) Display charts related to reconditioning
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Training of staff2) Display charts related to testing 3) Maintenance manual and check sheet including calibration and functional test procedure
4) Record keeping of tools and measuring instruments 4 Availability of 3 Yearly OVH kit 5 Schedule for maintenance of MUIs 6 Record keeping for traceability 7 1) Storage of Mechanical Unit Injectors-
a) Store in proper Handling Rack b) Cover with plastic 2) Stored for longer time but <1 year a) Injectors are filled with calibrating oil b) Tight fitting plastic caps used for covering the filter caps , spray tip end and on the threaded injector stud
3) Stored for more than one year a) After one year, to be filled with clean fuel/ calibrating oil again b) Slowly pop a few times prior to installation
8 Audit of Reconditioning8.1 Dismantling of injector components
a) Clamp the injector in vise (equipped with an injector holding adapter) in a follower up position. Excessive clamp force may cause component damage.
b) Dismantled parts of each injector should be kept in separate pan to avoid inter mixing of injector parts and care must be taken not to damage any of the parts.
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c) Remove the fuel filter caps. Remove and discard gasket and filter elements.
d) Disengage the plunger from the follower and remove the follower spring.
e) To remove the follower spring, insert a small rod between coils of spring and push “stop pin” in to release the follower and carefully lift the follower and plunger from the injector.
f) Invert the injector in the vise. By using socket wrench lose injector nut and then remove the nut by hand.
g) After the nut is removed the exposed stacked parts can be removed.
h) Remove the spill deflector and bushing straightly. i) Remove and discard the body to nut seal ring. J) Release the injector body from the vise and holding free hand at bottom, invert the body to remove the gear retainer and gear. After the gear is removed, the injector rack can be withdrawn from the body.
8.2 Cleaning & Inspection of injector components Cleaning of injector components a) Bodies-To clean entire body by using brush (1” diameter china
bristle) and fuel passage by using dry compress air. b) Injector nut-Clean external surface of the nut by buffing on
the soft wire buffing wheel. Wash Injector nut inside and outside using brush and solvent. Blow off nut with dry compressed air.
c) Injector rack-Clean rack teeth by using soft brush. Wash the rack in cleaning solution and blow off with dry compressed air.
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d) Injector gear- Clean gear teeth and outside surface by brushing. Clean inside using 12 mm diameter soft metal brush mounted in a motor driven chuck and wash gear in cleaning solution.
e) Plunger and bushing (P&B) -The plunger and bushing (P&B) are precisely matched components and should be kept together in a non-metallic container during the cleaning, inspection and assembly of other parts .
f) Plunger- To remove oil and carbon deposits, lightly buff only the upper half of the plunger where the gear slides and do not buff the lapped lower portion of the plunger.
g) Bushing- By using soft bristle brush and solvent, wash bushing bore and external surface. Blow off with dry compressed air.
If this lower portion of the plunger and Bushing is scored, scratched or galled the entire P&B should be rejected and replaced with a new P&B .
h) Spill deflector-Using brush and cleaning solution wash entire part. Blow off with dry compressed air.
i) Gear retainer-Buff external surface of gear retainer on soft wire buffing wheel and use the cleaning solution, wash the retainer and blow off with dry compressed air.
8.3 Must change items for reconditioning of injector : These parts cannot be reconditioned to deliver proper
performance and should never be re-used. These must be completely replaced as part of an Ecotip Super stack Kit.
8.4 List of Must change items in Ecotip Super stack Kit -
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(i)Spray tip (ii) spring cage (iii) spacer (iv) spring seat (v) valve spring (vi) check valve cage (vii) filter (viii) copper gasket.
8.5 Remaining injector parts- Clean some of the parts listed below by washing (buff on soft
wire wheel if necessary) and inspect:
a) Follower assembly- Removes retainer, stop pin and spring. Regrind follower face to
remove pitting and wear. Gage from face to bottom of slot; acceptable length specification 2.644-2.650 inches.
b) Filter Caps- No nicks, cracks, brinneling in the flare seat and gasket areas.
Threads must be free from nicks or other damage.
c) Follower (Plunger) Spring- Demagnetize and load test; discard if not within the following
Specification: 51.0-57.0 pounds at 2.750 inches load length.
d) Filter Springs- Replace if broken or damaged; no load test required. e) Copper Gaskets- Copper gaskets must be discarded after use and replaced with
new.
f) Injector Nut Seal Ring- Must be discarded and only new OEM diamond shaped seal
rings must be used in order correctly seal the nut to the body.
8.6 Inspection of injector components a) Bodies- Should be carefully inspected for any burrs, metal
slivers or bad threads. The body and all drilled passages should be
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clean. b) Plunger and Bushing- Defects on plunger surface such as scores, scratches or galling on
the lapped surface and chipping or eroding on helices may be seen with a good magnifying glass or microscope. Defects are found on P&B then the P&B should be rejected and replaced with a new unit .
c) Injector nuts - i) Inspect the outside of the nut for pits around the spray
tip end. The spray tip in a reconditioned injector should never protrude more than 0.05 inch (1.27 mm) from the fire face of the nut.
ii) The seat inside the nut should be inspected for the presence of hard carbon deposits or pitted burned metal.
iii) The injector nut cone must be free of pitting and nicks. if necessary, refinish the cone area by reducing the diameter of the cone by a maximum of 0.02 inch (0.5 mm)
d) Control Rack and Gear - To move freely, Control Rack and Gear should be free from burrs
and rough spots. The rack must be straight.
8.7 Assembly of Injector- Collect the clean and inspected parts Blow off with dry compressed air, and place them in a clean dry parts pan or on clean paper. Each injector part is dipped in clean calibrating oil (Viscor 1487AW2 or equivalent) and do not blow off.
The assembly sequence is as follows:
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1) Insert two new fuel filters in the body fuel ports. Then apply filter springs and filter caps, using new copper filter cap gaskets. Torque filter caps to 75 ft-lbs (102 NM) with torque wrench.
2) Insert the injector rack into the body. Position the rack so that the two marked teeth are centrally located in the body bore as viewed from the thread end (bottom) of the body.
3) Apply rack gear to mesh with the rack so timing mark on the one gear tooth is between the marked teeth of the rack.
4) Apply gear retainer on top of the gear 5) Position the bushing on the body so locating pin enters the slot in the body and place spill deflector over the bushing.
6) Remove the cap from the ECOTIP Superstack kit and carefully place the stack onto the bottom of the bushing.
7) Place the injector nut carefully over the stacked parts Screw nut down by hand, then finally tighten to 140 ft- lbs (190 Nm) when using injector nut wrench T-1404 and torque wrench. If using a deep socket and torque wrench to tighten the nut then torque to 150 ft-lbs (203 Nm).
8) Invert the injector in the vise, nut end down and re-clamp in the vise.
9) Install stop pin, spring, and retainer in the follower. 10) Apply follower spring in place on injector body. 11) Position the rack so that the flat in the ID of the gear is known relative to the injector body.
12) Slide the plunger into the cutout at the bottom of the follower. Position the flat side of the plunger so that it aligns with
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the flat on the gear in the body, the follower stop pin and with the stop pin slot in the body.13) Place the follower and plunger assembly into the body. 14) Depress the stop pin and press down on to of the follower. If necessary, move rack slightly in or out until plunger engages with rack gear.
15) Continue pressing on follower until stop pin enters slot. 16) On injectors equipped with calibrating slides, assemble the slide so that the end of the slide is flush with the face of the injector body.
17) Apply plastic caps over the filter caps after injector testing or immediately after build if the injectors will be stored prior to testing to prevent dirt from entering the injector and a cap over the stud threads to prevent handling damage.
9 INJECTOR TESTING Testing of injector
a) Qualifying the Test stand – 1) Install the test block in place of an injector in the stand and pump up pressure to 2000 psi (138 Bar), as indicated by the gauge.
2) After five minutes, the pressure should not have dropped below 1975 psi (136 Bar).
3) Release the block and recheck at 500 and 1000 psi (34 and 69 Bar). These pressures should hold one minute with no apparent gauge drop.
4) Make these tests with the pressure shutoff valve open all the
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way. If the tests are satisfactory, all injector tests may be made without using the shutoff valve.5) If the preceding tests indicate leakage in the stand, repeat the tests, closing the shutoff valve before timing the leak off rates.
6) If the tests are satisfactory with the shutoff valve closed, it will be necessary to use the shutoff valve when making the injector holding pressure test.
b) General Information : 1) When operating the pump, use a rate of approximately 40 smooth strokes per minute. This provides a calibrating oil rate to operate the check valve smoothly and to circulate oil within the injector.
2) When using the popping lever, do not use such force as to damage either the injector or the test stand. Do not permit the lever to fly up freely.
3) In making holding tests, do not pump the stand above 2500 psi (172 Bar).
4) Test stands regularly in use should be checked daily for leaks, using the test blocks.
5) Calibrating oil used for testing should not be reused. c) Spray pattern and Valve chatter test 1) Remove the protective plastic caps from the filter caps and stud.
2) Install the injector in the test stand. 3) Fill the injector with calibrating oil, but do not connect the fuel line from pump to injector at this time.
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4) Set the injector rack at maximum fuel output position (minimum rack length).
5) “Pop” the injector with the popping lever, using approximately 40 smooth even strokes per minute. A finely atomized spray should show at each of the holes in the tip. Rapid closing of the needle valve should produce a sharp “chatter”.
6) If the injector plunger does not move down smoothly, stop. Do not force the plunger downward or component damage may occur.
d) Holding Pressure& leak Test: 1) Tighten to 40 in lbs (4.5 Nm) Apply 2000 psi (138 Bar) pressure to the injector. No leakage is permitted at the nut to body seal, filter cap gasket, body plugs, or between spray tip and injector nut.
2) For reconditioned injector, conduct Holding test by timing the interval for a drop in pressure from 2000 psi to 1500 psi (138 to 103 Bar). If this interval is less than 30 seconds, repeat the test but close the pressure shut off on the test stand immediately after establishing 2000 psi pressure. If the timed interval for the pressure drop from 2000 psi to 1500 psi (138 to 103 bar) is still less than 30 seconds, the injector should be rejected.
e) Rack freeness test: The rack must fall in and out through full travel, by its own weight, when injector is held horizontally and rotated about its axis. A binding rack may cause sluggish or erratic speed changes and over speed trip action.
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f) Binding Plunger test A binding or stuck plunger can be caused by improperly inserting the plunger into the bushing during assembly. The plunger must be well lubricated with calibrated oil/diesel fuel and inserted into the bushing gently and without any rocking or wiggling motion.
10 QUALIFYING THE CALIBRATION STAND a) Calibration stand should 1) Maintain a constant clamp force on the injector body to insure a good cone seal and to prevent body movement.
2) Maintain calibrating fluid temperature between 95 to 105◦ F (35 to 40◦ C).
3) Maintain a minimum calibrating fluid pressure of 35 psi (241 kPa) during test.
4) Maintain a constant set speed of 900 RPM within + or – 2 rpm during test.
5) Maintain contact of the calibration blocks to the body face during test.
b) Sheds is to use Master Injectors to qualify the stands. The Master Injector Kit for Indian Railway 710 engines is Part Number 4992244. This kit contains Low Master Injector P/N 4991173 and High Master Injector P/N 4991174.
c) Temperature gauges and pressure gages should be calibrated with master gages every six months.
d) RPM readout should be verified with a certified tachometer every six months.
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e) Injector stroke length should be verified yearly in order to detect cam/follower wear.
f) Rack set length blocks are high wear gages and should have the 0.875 +/- 0.001 inch (22.23 +/- 0.025mm) rack length dimension verified monthly. These blocks snap over the ball on the rack and must be held against the body face of the injector during the calibration test.
g) Verify that the mechanical and fluid systems are operating properly (consistent fluid supply, drive system set up properly and well lubricated)
h) Run the low master injector three (3) times, calculating the average low output limit for this 710 injector on your calibrator.
i) Run the high master injector three (3) times, calculating the average high output limit for this 710 injector on your calibrator.
j) Run production injectors within the high and low limits calculated in steps h and i above.
k) Two newly reconditioned injectors should be set to the calculated high and low limits established in steps h and i above and used daily to verify calibration of your test stands. Master Injectors should be stored in their original case and used only for periodic checks or if problems arise.
11 a) CALIBRATING INJECTOR OUTPUT Install the injector in the calibration stand and let the injector run in the calibration stand for a period sufficient to stabilize the injector temperature (Body of the injector should be 40◦ C or greater) Run a test cycle to check the output. If the output is not
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within the range established by the High and Low master injectors, adjust the calibrating slide.b) INJECTOR OUTPUT AND SLIDE ADJUSTMENT INJECTOR OUTPUT DATA: Test oil …………………………Viscor 1487AW2 or equivalent Test oil temperature ……………………………… 35° C to 40° C Test oil pressure ………………………………..35 psi (241.3 kPa Test stand speed ……………………………….. 900 RPM c) 710 ECOTIP Injector (NEW P/N 40083540,DLW- P/N 16241186 UTEX P/N 40079007) Output :
ECOTIP Low Master Injector……………….277 cc/300 strokes ECOTIP High Master Injector………………283 cc/300 strokes
Annexure-IVCHECK SHEET FOR
QUALITY AUDIT OF TRACTION MOTOR PINION & GEAR ASSLY.
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
1 MEASUREMENT1.1 Pinion Drg. No. 18 teeth, SKDP36241.2 Pinion Bedding In Cold Not less than 95 %
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CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
Condition
Alco (WDM2, WDM3A, WDM3D)
WDG3A
Traction Motor Pinion & Gear
Assly. of Alco Loco
MP-IB.EM.10.31.08
dated 24.10.2008
MP-MI 129/86 July 1986
MP-MI 5
1.3 Pinion Advance 2.25 TO 2.45MM1.4 Heating Temperature 190ºC + AMB TEP.1.5 Span Size on New Pinion Over 3 teeth
88.595 /88.722MM1.6 Condemning Limit on
Basis of Span Size of Pinion
Over 3 teeth 86.995MM
1.7 Gear Drg. No. 65 teeth SKDP3623 & SKDP3775
1.8 Span Size on New Gear Over 7 teeth 223.989/223.798MM
1.9 Condemning Limit on Basis Of Span Size of Gear
Over 7 teeth 220.800MM
1.10 Permissible Backlash With New Set
0.266 - 0.664MM
1.11 Condemning Limit on Basis of Backlash
1.04MM
1.12 Crack detection MPMI or Zyglo test 2 TRACTION GEAR & PINION
2.1 Gear Ratio 18 : 742.2 Pinion Drg. No. 18 teeth, SKDP34432.3 Pinion Bedding In Cold
Condition Not less than 95 %
2.4 Pinion Advance 2.30 TO 2.45MM
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S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
HHPWDG4
Traction Motor Pinion & Gear
Assly. of HHP LocoMP-
IB.EM.01.04.14 dated
21.08.2014
2.5 Heating Temperature 185ºC + AMB TEP.2.6 Span Size on New Pinion Over 3 teeth 81.976
/82.093MM2.7 Condemning Limit on
Basis of Span Size of Pinion
Over 3 teeth 80.366MM
2.8 Gear Drg. No. 65 teeth SKDP3444 & SKDP3546
2.9 Span Size on New Gear Over 8 teeth 231.36/231.177
2.10 Condemning Limit on Basis of Span Size of Gear
Over 8 teeth 228.140
2.11 Permissible Backlash With New Set
0.243 - 0.608MM
2.12 Condemning Limit on Basis of Backlash
1.00MM
2.13 Crack detection MPMI or Zyglo test3 MEASUREMENT
3.1 TRACTION GEAR & PINION
WDG4
3.2 Gear Ratio 17 : 903.3 Maximum limit of
Backlash23 (In Thou)0.58 (in MM)
3.4 Minimum limit of Backlash
10 (In Thou)0.254 (in MM)
3.5 Condemning limit of 37 (In Thou)
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CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
Backlash 0.94 (in MM)
HHPWDP4
3.6 SPAN size (“K”) for Traction Pinion service wear limit
Over 3 Teeth 67.40 / 67.45 mm
3.7 SPAN size (“K”) for Traction Pinion Condemning wear limit
Over 3 Teeth 65.80 / 68.85 mm
3.8 SPAN size (“K”) for Traction Bull Gear service wear limit
Over 13 Teeth 328.70 / 328.75 mm
3.9 SPAN size (“K”) for Traction Bull Gear Condemning wear limit
Over 13 Teeth 325.50 / 325.55 mm
3.10 Condemning Teeth Profile wear limit of Traction Pinion
18 (In Thou)0.45 (in MM)
3.11 Condemning Teeth Profile wear limit of Traction Bull Gear
30 (In Thou)0.77 (in MM)
4 MEASUREMENT4.1 TRACTION GEAR &
PINION WDP4
4.2 Gear Ratio 17 : 774.3 Maximum limit of
Backlash24 (in Thou)0.61 (in MM)
4.4 Minimum limit of 11 (in Thou)
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S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
Backlash 0.280 (in MM)
All Alco locosMP-IB.EM.01.02.10 dated 11.01.2010.
4.5 Condemning limit of Backlash
39 (in Thou)1.00 (in MM)
4.6 SPAN size (“K”) for Traction Pinion service wear limit
Over 3 Teeth 77.00 / 77.05 mm
4.7 SPAN size (“K”) for Traction Pinion Condemning wear limit
Over 3 Teeth 75.35 / 75.40 mm
4.8 SPAN size (“K”) for Traction Bull Gear service wear limit
Over 11 Teeth 314.40 / 314.45 mm
4.9 SPAN size (“K”) for Traction Bull Gear Condemning wear limit
Over 11 Teeth 311.20 / 311.25 mm
4.10 Condemning Teeth Profile wear limit of Traction Pinion
18.5 (In Thou)0.47 (in MM)
4.11 Condemning Teeth Profile wear limit of Traction Bull Gear
31.5 (In Thou)0.80 (in MM)
5 TA FAN ASSEMBLY 5.1 Outer diameter of TA fan 1387.25/1387mm5.2 Bore diameter of TA
stator1392mm
5.3 Bore diameter of TA fan 600.00 / 600.03mm
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REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
EMD locos
(WDP4 & WDG4)
Traction Motor Gear Case of EMD
Locos
MP.IB.EM.02.12.00dated 10-4-2000.
MP.IB.EM.03.12.
10 (Rev 01) 20.6.2017
5.4 Diameter of fan seating area on barrel.
600.03 / 600.06mm
5.5 Width of fan seating at bore
9+1 mm
5.6 Depth of counter sunk bolts hole
4.5 - 5.5 mm
5.7 Bolt head width 12.3mm5.8 Bolt head height above
fan plate after final assembly should not be more than
6- 7mm
5.9 Circumferentially Fan gap on TA
2.50 – 2.75mm
5.10 Tightening torque and wire locking process
28 – 30Kg-m
5.11 Tightening torque of M30 (coupling bolt)
170 – 180 kg-m.
5.12 Oil catcher thickness (at bottom side)
53.90 to 54.10mm
5.13 Bolts strength properties grade
R8.8.
5.14 Sunk type M20 bolts can be used
in place of fully threaded M20 bolts
5.15 M20 & M30 bolts should be replaced
After 4 – 5 years’ service of TA
5.16 Fan bore area should be 150 to 170 °С
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OBSERVATION
heated (for shrink fit).
As above
5.17 Re-used or old bolts and barrel thread condition should be checked by
GO & NO GO thread ring or plug gauge
5.18 Threaded portion of barrel & bolts should be free from varnish or paint or dust deposits.
Visual inspection is required
5.19 TA fan should be mounted on the barrel by “shrink fit “
In place of (bolts) press fit.
5.20 TA fan bolts locking wire ends should not be come out of the bolt head(projected)
As shown in photo
5.21 Proper alignment of TA fan should be checked by inserting filler gauge circumferentially
Clearance between the fan (back side) and barrel of TA (as shown in attached photo)No clearance is allowed.
5.22 After Final assembly of TA fan, visual inspection is required on
Tightening torque, wire locking & fan back clearance with barrel(by filler gauge (circumferentially)
5.23 TA Gear train assembly Backlash at Steel plate
Page 48 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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ITEM DETAILS
OBSERVATION
5.24 TA GEAR 102TAG/EG PINION 43TPTU PINION - 43T
0.60mm to 1.40mm0.05mm to 0.12mm on shaft
6 Traction Motor Gear Case of EMD Locos6.1 Following items must be checked before fitment/
assembly of top and bottom half gear case6.2 The Heli -coil insert should be checked for looseness.
If loose, an oversized insert should be used or the same insert should be used with Loctite / araldite.
6.3 The gear case must be cleaned thoroughly specially the mating surfaces.
6.4 The same set i.e. the same top and bottom portions must be re-assembled together.
6.5 Inter changeability of the two halves is not permitted.
6.7 The 6mm hole must be kept clean.6.8 The breather valve must be kept clean6.9 The bolts must be tightened with the required
torque of 35 ft. and 990ft pound6.10 The tightening sequence as described in the report
must be followed.6.11 The pinion inspection hole must be properly plugged
by welding6.12 Oil level should be checked as per Dip stick given in
Annexure B of IB.6.13 OEM recommended sealants DOW Corning DC-3-
Page 49 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
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ITEM DETAILS
OBSERVATION
0100 and (RTV) GE Seal mate TRV-1473 should be used. Expiry date should also be checked before use & Dow corning sealant can be procured from M/s Dow Corning India Pvt. Ltd. Mumbai.
7 AVAILABILITY OF TOOLS AND TEST STANDS7.1 Vernier Callipers7.2 Disc Mike7.3 Filler Gauge8 INSTRUCTION
8.1 Display Chart8.2 Training of Staff8.3 Record keeping of tools and measuring instruments9 TRACEABILITY
10 MATERIAL AVAILABILITY10.1 Vital Spare -NA10.2 Must change items -NA
CHECK SHEET FOR QUALITY AUDIT OF TRACTION MOTORS
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
Page 50 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
AlcoTraction Motors of
Alco Loco
MP.MI-2 &MP.MI-6
Maintenance manual issued by OEMs viz. BHEL/CGL.
1.1 PRE-INSPECTION1.2 Record IR of
a) Armature (Shall be > 10 MΩ)b) Inter Pole (Shall be > 10 MΩ )c) Main Pole (Shall be > 10 MΩ)
1.3 Record ovality of commutator (Limit – 0.001”)1.4 Check Carbon Brushes
a) Condemning sizeb) Clearance between commutator and brush
holderc) Tension of brush holder’s spring
2 AFTER DIS-MANTLING2.1 Pinion to be sent for Magna flux test / Zyglo test2.2 Visual examination of Armature banding. If required,
repair it.2.3 Check commutator dia. for condemning size. Replace
commutator, if condemning size reached. If commutator is retained, then check millivolt drop to ensure health of bar to bar shortening. If required, repair it.
2.4 Check commutator surface roughness. If found > 0.05 mm or any cut mark is observed, commutator to be grind on machine.
2.5 Ensure that there is no damage on armature seating area & armature shaft. If any damaged is noticed, repair it to reqd. size.
Page 51 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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2.6 Ensure cleaning of magnet frame with cleaning solvent to RDSO spec. MP.0.8000.01 Rev.02 Oct.’2007.
2.7 Bake the magnet frame in oven at 120 + 10 °C & record it.
2.8 Apply insulation varnish as per RDSO MP.MI 153/92 (latest revision)
2.9 Check IR after renewal of glass epoxy laminate, GMGS & Nomex insulation for inter poles & main poles (Shall be > 100 MΩ) condition basis.
2.10 Ensure tightening of pole bolts during assembly of magnet frame and maintain IP & MP bores as per OEM manual.
2.11 Check IR of main pole & inter pole assemblies & record it. (Shall be > 100 MΩ )
2.12 High potential test of inter pole & main pole at 1.3 KV for 15 sec. shall pass the test.
2.13 Ensure spray cleaning of armature with cleaning solvent to RDSO spec. MP.0.8000.01 Rev.02 Oct.’2007.
2.14 Bake the armature in oven at 120 + 10 °C& record it.2.15 Spray varnish paint protecting the shaft &
commutator & cure it.2.16 Ensure mica cutting. & chamfering as per OEM’s
manual2.17 Ensure cleaning & baking of brush arms as per
Page 52 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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OBSERVATION
OEM’s manual.2.18 Measure IR of brush arm (Shall be > 100 MΩ). If less,
replace the brush arm2.19 Ensure the spring tension. (Lt. 4.5 Kg to 5.5 Kg) 2.20 Ensure the replacement of PTFE sleeve of brush arm.2.21 Ensure painting of support arm with red becktol
varnish.2.22 Conduct high potential test as per OEM’s manual2.23 Tan Delta Test on Armature as per OEM’s manual
3 ASSEMBLY3.1 Motor assembly as per OEM’s manual3.2 Measure the final Insulation Resistance = 10 Mega
ohma) Armature (Shall be > 100 MΩ)b) Inter Pole (Shall be > 100 MΩ )c) Main Pole (Shall be > 100 MΩ)
3.3 Measure the end float (Lt. = 0.006” to 0.012”)3.4 Check the nose plate condition. If found damaged or
wear out, shall be replaced. 3.5 Conduct the light run test at low, medium & high
rpms on assembled motor & observe for unusual sound using listening rod.
3.6 Check the bearing temperature after stabilisation during light un test. (Shall not be > 60 °C)
3.7 Apply brush seater on the commutator to seat the carbon brushes on the commutator properly.
Page 53 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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OBSERVATION
3.8 Ensure tag welding / welding of stays on main pole & compole fixing bolts.
3.9 Apply recommended sealant to avoid ingress of water etc.
3.10 Apply a coat of paint on motor.4 AVAILABILITY OF TOOLS AND TEST STANDS
4.1 1000V Megger4.2 Filler gauge4.3 HV tester4.4 Dial gauge4.5 Tachometer / Speedometer4.6 Pyrometer4.7 Inside & Outside micrometre /calliper4.8 High Potential Testing Machine4.9 Tan Delta Machine5 INSTRUCTION
5.1 Display Chart5.2 Training of Staff5.3 Record keeping of tools and measuring instruments6 TRACEABILITY7 MATERIAL AVAILABILITY& STORAGE (AC/Non-AC)
7.1 Vital Spare7.2 Must change items
Page 54 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Page 55 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR QUALITY AUDIT OF TRACTION MOTORS- HHP LOCOMOTIVES
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
HHP locos (WDP4, WDP4B, WDP4D,
WDG4D & WDG4)
Traction Motors of HHP locos
(WDP4, WDP4B, WDP4D, WDG4D
& WDG4)
Refer MI 1517ARefer tractionmotor operatinginstructionA1A25110E/01.2001/Version 1.
1.1 Insulation Resistance = 10 Mega ohm 1.2 Inspect all cables (Power, sensor and earthing) for
insulation damage or cut marks.
1.3 Inspect all cable cleats for broken studs, excessive tightness and rubber cleat damage.
1.4 Inspect all sensor (Speed &Temp) plugs for correct locking.
1.5 Inspect all air ducts (TM Bellows) and fixing bolts for damage.
1.6 Inspect all motors for any hit marks, physical damage and presence of all end shield cover bolts.
1.7 Inspect cable junction plates and umbrella boots for signs of damage or overheating.
1.8 Ensure all cables are routed properly and there is no excess/short cable over hangs.
1.9 Apply insulation/spacers at all locations where cables are rubbing each other and with locomotive body.
1.10 Blow all the traction motors with dry compressed air1.11 Gear case mounting:
Check Gear Case oil level by dip stick as per
Page 56 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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OBSERVATION
MP.IB.EM.03.12.10), March’ 2010). Add if required.Traction Motor Cables and Cleats:
Check for any signs of damage/rubbing on the TM cables and cleats
1.12 Open inspection covers, inspect windings for any damage and presence of foreign material and blow with light compressed air
1.13 Open motor and car body connection umbrella boots and inspect cable lugs for signs of overheating.
1.14 Oil consumption record of each Traction Motor should be recorded. It should not be more than 0.5 to 1.0 Litre/Month.
1.15 Gear Case oil level should be checked by dip stick (MP.IB.EM.03.12.10), March’ 2010).
1.16 Provide all car body and junction plates.1.17 Record IR and winding resistance of all TMs.1.18 Replace defective items if necessary (like heat shrinks,
colour code, lugs, cleats etc.)1.19 Reconnect all the TM cables.1.20 Check terminal connections of TM for overheating and
loosening.1.21 Check that car body cable and TM cable is properly
secured.1.22 Gear Case oil should be checked (MP.IB.EM.03.12.10),
March’ 2010.1.23 Aluminium cover oil path should be cleaned before
Page 57 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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OBSERVATION
filling fresh oil (MPMOD.EM.01.05.16 (Aug’ 2016).1.24 Backlash & wear on teeth should be checked by
recommended gauge (MP.IB.EM.01.04.14) Aug’ 2014.2 CABLE ROUTING
2.1 Check all TM sensors (speed & temperature) and locking plugs.
2.2 Check all TM cables for any excessive hanging and improper routing.
2.3 Check Sensor cables and earthing cables2.4 Provide cable cleats and spacers wherever necessary.2.5 Secure cables with cable ties.3 BELLOW ATTENTION
3.1 Check and ensure the condition of TM bellows.3.2 Check all the bottom side fixing bolts for proper
tighten and missing of bolts provide if necessary.3.3 Renew the bellow if necessary.3.4 Record all bellow Sl. No. and make.4 TM INSPECTION
4.1 Open all the TM inspection covers and ensure no foreign body present inside the TM.
4.2 Blow with dry compressed air (4.5-5 kg/cm sq.) from inspection window and gear case end opening.
4.3 With a hand lamp, check the motor winding for any foreign body entry and broken/burnt winding insulation etc.
4.4 Check all TMs for any hit marks and external damage.
Page 58 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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4.5 Check all TMs for any gear case oil entry or grease oozing.
4.6 Provide back all the inspection covers.5 TORQUING AND CLEANING
5.1 Check and torque NDE end shield cover bolts (18mm) with a value 70 Nm.
5.2 Check and torque both DE and NDE side bolts (36mm) with a value of 680 Nm.
5.3 Scrap all motors with wire brush.5.4 Clean all the power cables, sensor cables and earth
cables by surf water.5.5 Record all TM serial Nos. and make.6 AVAILABILITY OF TOOLS AND TEST STANDS
6.1 5000V Megger6.2 Filler gauge7 INSTRUCTION
7.1 Display Chart7.2 Training of Staff7.3 Record keeping of tools and measuring instruments8 TRACEABILITY9 MATERIAL AVAILABILITY
9.1 Vital Spare9.2 Must change items
Page 59 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR QUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS
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
Traction Motor Bearing & Assly. Components of
Alco Loco
MP-IB.EM.14.50.0
8dated 20.02.2009
1.1 Verticality of Outer race1.2 Verticality of Inner race1.3 Max. deviations allowed in above cases:
Side Inner race Outer racePinion End 0.075 mm 0.25 mmCommutator End 0.065 mm 0.20 mm
1.4 Radial Clearances of bearings:For New BearingsBearing Radial clearance
before mounting (mm)
Radial clearance after mounting
(mm)NU 330 0.165 - 0.215 mm 0.100 – 0.170 mmNH 320 0.105 – 0.140 mm 0.060 – 0.100 mm
1.5 In addition to above, max. service radial clearance:NU 330 0.300 max. 0.250 max.NH 320 0.190 max. 0.150 max.
1.6 Flinger - PEBore Dia. 153.130 to 153.155
Page 60 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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OBSERVATION
Total Width 12.65 to 12.701.7 Retaining collar - PE
Bore Dia. 146.015 to 146.040 mmTotal Width 12.65 to 12.70 mmOuter Dia. 253.225 to 253.290 mmHub Outer dia. 177.040 to 177.090 mmOuter dia. on 2nd Groove 210.610 to 210.670 mmGroove width 8.00 to 8.05 mmTotal width 44.4 to 44.6 mm
1.8 End shield - PEBore dia. 319.975 to 319.995 mm
1.9 End shield - CEBore dia. 214.980 to 215.00 mm
1.10 Seat diameter on armature shaftFor brg.-PE, Bore dia. 150.035 to 150.055 mmFor brg.-CE, Bore dia. 100.025 to 100.040 mmFor retaining collar PE 146.130 to 146.150 mmFor bearing sleeve PE 153.220 to 153.240 mmFor inner brg wiper CE 101.600 to 101.620 mm
1.11 End Float on Traction motor (TM 4907) CELimit – 0.50 mm Aim – 0.42 mm
1.12 Fits & Clearances (BG TM)1.12.1 Pinion end bearing:
Interferences (Diametrical) Clearances (Diametrical
Brg. Sleeve 0.020 to Brg. 0.635 to
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OBSERVATION
to shaft 0.065 mm Sleeve to inner brg. cap
0.750 mm
Flinger to shaft
0.065 to 0.110 mm
Retaining collar to outer brg. cap
0.25 mm (min.)
Inner race to shaft
0.035 to 0.080 mm
--- ---
Retaining collar to shaft
0.090 to 0.135 mm
--- ---
1.12.2 Commutator end bearing:Interferences (Diametrical) Clearances
(DiametricalBrg. Sleeve to shaft
0.020 to 0.065 mm
Inner brg. Cap to sleeve
0.635 to 0.750 mm
Flinger to shaft
0.065 to 0.110 mm
-- --
Inner brg. Race to shaft
0.025 to 0.060 mm
--- --
1.13 Heating temp. of brg. & assly. componentsItem Heating temp.
Bearing inner race PE 100 -110 ºCBearing inner race CE 100 -110 ºC
Page 62 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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OBSERVATION
Sleeve (PE) 100 -130 ºCSleeve (CE) 100 -130 ºCFlinger (PE) 100 -120 ºCEnd shield (PE) 120 -130 ºCEnd shield (CE) 120 -130 ºCRetaining collar (wiper) 120 -130 ºC
2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 Dial gauge3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare -NA5.2 Must change items -NA
Page 63 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR QUALITY AUDIT OF MOTOR SUSPENSION UNIT WITH BEARINGs & ASSLY. COMPONENTS
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/WORK TO BE DONE
Alco Locos MSU with BRGMP.IB.
EM.01.22.09 (Rev.01), Sep.’18
1.1 Check bearing temperature just after the operation of locomotive, if found abnormal temperature, change out its suspension tube.
1.2 Check securing of bolt to ensure their tightness using torque wrench to a correct revised torque value.
1.3 Check positioning of adjustment washer.1.4 Check and refit the missing or damaged grease
nipples.1.5 Check and replace earthing brushes if missing /
damaged.1.6 Carefully inspect the suspension bearing housing for
cracks and if found, bearing housing must be replaced.
1.7 Check for loose/out position or cracked enclosure. If found then replace.
1.8 Replenish grease of gear wheel side and road side wheel bearings.
1.9 Check bearing abnormal noise or roller ticking noise by rotating the tube assembly.
1.10 Check end play as per the procedure given in
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OBSERVATION
manual.1.11 In order to arrest loosening /dropping /breakage of
bolt of suspension tube, tightening torques is revised as under:
Actual size of bolt/screws
Torque in Kg.cm.
M 10x30 (Property Class
12.9)
245 to 295 400 to 600
M 12x90(Property Class
12.9)
418 to 503 800 to 1000
M 36x110(Property Class
12.9)
12100 to 14500
14500
1.12 It is useful to ensure correctness of the threads of the bolts/screws by standard GO-NOT GO thread ring gauges and correction of relevant threaded hole by GO-NOT GO thread plug gauges.
1.13 Loctite 243 & 2760, MY-T-Loc-3330R, Anabond-131 or equivalent thread locker should be used on all the bolts/screws given in the table above to ensure that bolts do not become loose due to vibrations etc.
Recommended size of screws
Recommended Loctite
M 10 to M 16 Loctite 243, MY-T-Loc-
Page 65 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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OBSERVATION
3330 & Anabond-131M 20 to M 36 Loctite 2760
1.14 For M36 bolts, spring lock washers/disc lock washers must be used.
1.15 Ensure proper tightening of all bolts as per the table at Para 6.2 above with torque wrench & maintain revised torque value.
1.16 A final check for loose/missing bolts, washers, cap screws must be done during the assembly.
2 INSTRUCTION2.1 Display Chart2.2 Training of Staff2.3 Record keeping of tools & measuring instruments3 TRACEBILITY4 MATERIAL AVAILABILITY
4.1 Vital Spare4.2 Must change items
Page 66 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FORQUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS AT DIESEL SHED
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 DURING MOTOR ASSEMBLILY
All EMD/HHP locos
Traction Motor Bearing & Assly. Components of
HHP Loco
OEM’s/Manufacture
s drawings
1.1 Cylindrical Roller Bearing (Drive end)Bearing ID (Inner race) 159.945 to 159.970 mmBearing OD (Outer race) 339.960 to 340.000 mmBearing Width 67.75 to 68.00 mm
1.2 Deep Groove Ball Bearing (Non drive end)Bearing ID (Inner race) 129.975 to 130.000 mmBearing OD (Outer race) 279.965 to 280.000 mmBearing Width 57.75 to 58.00 mm
1.3 Rotor ShaftBearing seating area DE (without pinion)
159.910 to 159.940 mm
Bearing seating area NDE 130.027 to 130.045 mm1.4 End Shield bore DE:
Bearing seating area339.910 to 339.950 mm
1.5 Bearing Housing NDE: Bearing seating area
279.948 to 280.000 mm
1.6 Radial Clearance of DE bearing before pinion fitment
SKF & FARO make: 0.340 to 0.370 mm.
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OBSERVATION
FAG (Schaeffler) make:0.115 to 0.165 mm
1.7 Radial Clearance of DE bearing after pinion fitment
SKF & FARO make: ---------- mm.FAG (Schaeffler) make:----------- mm
2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 Dial gauge3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare 5.2 Must change items
CHECK SHEET FOR
Page 68 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
QUALITY AUDIT OF TRACTION ALTERNATOR-RECTIFIERDuring the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
1 MEASUREMENT
HHP locos (WDP4, WDP4B,
WDP4D, WDG4D &
WDG4)
Traction Alternatorof HHP loco
Maintenance Instruction for
Traction Alternator of
HHP loco
MI-3317-1and MI-3317-2HOR latest revision
1.1 (a) Check tightness of all mechanical and electrical connections. Check for open fuses (indicating pins protruding). Check collector rings surface and brushes for marks of sparking pitting, blackening.
(b) Collector Rings: -Maximum Ring Eccentricity = 0.15 mm (0.006"), -Maximum Lateral Ring Runout = 0.8 mm
(1/32"), -Condemning Limit on Ring Outside Diameter =
260 mm (10-3/4") -Minimum spiral groove depth = 0.635 mm
(0.025 inches). -Maximum lateral run-out = 0.8 mm (1/32").
(c) Check that the slip ring 1 and 2 brush holders applied are centred on the slip ring width, with a minimum 1.6 mm (1/16”) distance to the edge of the slip ring. For vertical positioning of single box brush holder, clearance between the brush holder(s) trailing edge to Slip Ring
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OBSERVATION
surface are set at.125”-140”. For vertical positioning of dual box brush holder, ensure that the tips of each brush holder are the same distance to the slip ring on each side.
(d) Ensure that CA side Brush holder assembly has been modified as per MP.MOD.EM. 01.03.18 Rev.-00 July 2018 which calls for replacement of small size brush holders with large size single pocket brush holders as that used on TA side. Check that large brush spring pressure is 1.5 kg (3.3 lbs)
Ensure free sliding of spring clip in Brush Holder Pocket and free rotation of spring clip about hinge Stucking of Spring clip shall not be allowed.
(e) Minimum length of bush = 3.81 cm. (1.5 in.) on the longest vertical side.
(f) Ensure polarity reversal of excitation supply at every 6 months.
(g) Ensure provision of rubber grommets at both ends of pipe conduit carrying rotor cables for TA rotor and CA rotor, ensure proper cable lug
MP.MOD.EM. 01.03.18 Rev.-00 July 2018
dlw.m.65.262
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connections.(h) Ensure proper gap maintained between CA
covers and fly wheel coupling bolts as per DLW Design bulletin to avoid rubbing or damage to CA covers.
(i) Ensure proper alignment of TA with Engine by ensuring uniform air gap of TA around the stator peripheral to overcome the problem of ‘DC Link Over Current’ and Load meter response ZERO in EMD locos.
(j) Visually inspect and ensure that all the components of AIR BOX (such as diodes, fuses, lead connections, Slip ring guard, cables, cleat, terminal board etc.) are free from black deposits of Smog, soot and Muck. If found so, proceed to check the condition of: fins of TM Blower for black deposits, Exhaust manifold in engine room.
Because leakage of smoke from exhaust manifold in engine room get suctioned by the TM blower via AG. (Even the partition wall provided on AG could not check this black smoke) and same is blown forcibly to the AIR BOX and may further get deposited on stator and rotor winding of TA, CA & TM. Prolonged service of loco in such condition may lead to:
dtd. 27.07.16
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OBSERVATION
Flashing in Rectifier panel. Low IR of stator and rotor windings of TA,
CA, AG & TMs. Winding burnt cases of TA, CA, AG & TMs.
ETI – 897
ETI – 904
1.2 COLD RESISTANCE LIMITS (in Ohms at 75°C):For Main Alternator:- Rotor Collector Ring to Collector Ring =
1.384(Nominal), 1.439(Max), 1.328(Min).- Stator Line-to-Neutral (Per 5 Phase Group) =
0.00300(Nominal), 0.00306(Max), 0.00294(Min).
- Stator Line-to-Line (Per 5 Phase Group) = 0.00568(Nominal), 0.00579(Max), 0.00557(Min)
For Companion Alternator:- Rotor Collector Ring to Collector Ring =
1.51(Nominal), 1.54(Max), 1.48(Min).- Stator Line-to-Line (Per 5 Phase Group) =
0.00435(Nominal), 0.00445(Max), 0.00428(Min)
CT Resistance: 11.8±10% Ohms at 25°C.1.3 (a) ROLLER BEARINGS:
- Outer diameter = 259.999 mm (+ 0.00 mm/ - 0.036 mm),
- Bearing Bore = 1200.00 mm (+ 0.00 mm/ - 0.020 mm),
Page 72 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
- Width = 85.99 mm (+ 0.00 mm/ - 0.13 mm),- Internal Clearance (before assembly) = 0.104
mm to 0.150 mm,- Internal Clearance (after assembly) = 0.063
mm Min,- Bearing Housing Bore Inside Diameter =
260.1152 mm (+0.102 mm/ -0.00 mm)
(b) Lubrication Capacity:- Bearing Cap = 284 g (10 oz),- Outer Bearing Cover = 284 g (10 oz),- Bearing = 369 g (13 oz),
MP.IB.EM. 02.04.18 Rev.00 July 2018
1.4 RECTIFIER:(a) Checked for any loose connections, flash
damage or damage caused by shorting to ground
(b) Continuity tester readings: 10 to 20 ohms in one direction and above 30,000 ohms when leads are reversed (for good diodes).
(c) Current limiting fuse resistance values (@75°F/23°C) = 0.000195 + - 0.000010 ohm
(d) All diodes in any paralleled group must be of the same polarity (ceramic cases or shrink tubing or colour band at the lower crimpmust be the same colour), and of same type (same
Page 73 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
type number impressed). The diodes must be applied to the proper heat-sink bus.
(e) Replace defective diodes with good diodes of identical polarity, and voltage class (or
Higher voltage class). Apply a thin coating of compound 8346481 to the base of the
Diode hex to cover the surface. Do not apply on threads.
(f) With special diode socket and 0 – 50 ft.-lbs. Torque wrench, torque diodes to 45 to 47 Nm (33 to 35 ft.-lbs.). Make certain that the wrench is properly seated when torquing.
(g) Torque diode terminal lug bolts to between 15 to 18 Nm (11 to 13 ft.-lbs).
(h) Some sheds are incorporating FRP sheets between +Ve and –Ve Bus Bar, to overcome cases of flash over in EMD design rectifiers.
Note: BHEL make TAs are fitted with rectifier of their own design having flat square base diodes. Ensure implementation of protective cap on bolts heads of Heat sink mounting bolts and epoxy red gel paint on bolt heads of rectifier mounting bolts as per MP.IB.EM. 02.04.18 Rev.00 July 2018 to avoid cases of flashover.
2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 - Induction Heater
Page 74 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
- Stone (1" x 1-1/2" x 5")- Collector Ring Grinder- Collector Ring Grinder Adapter,- Hydraulic Pump,- Collector Ring, Seals, and Bearing, -Puller
Assembly2.2 - Torque Wrench 0 – 50 ft/lbs. – 1/2” Drive,
- Multimeter,- Megger, Insulation Resistance Test Set (500,
1000, 2500, 5000 volt),- Digital Micro Ohm Resistance Tester Kit,
(Range 0 to 1.999 miliohms) 3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools & measuring instruments4 TRACEBILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 75 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR SMALL MOTOR OF ALCO LOCOMOTIVEQUALITY AUDIT OF SMALL MOTOR
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 Small Motor of Alco Loco
MP.MISC-141 (Rev-01),
September 2006
.
1.1 Check brush pig-tail screws for tightness1.2 Check the Cleanness of the commutator string band
and cable connections. 1.3 Check brushes for condition & size1.4 Check varnished surfaces of the armature and field
coils for cracks, flaking. 1.5 Check covers terminal connections etc.2 AVAILABILITY OF TOOLS AND TEST STANDS
2.13 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 76 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR STARTER MOTOR OF HHP LOCOMOTIVEQUALITY AUDIT OF STARTER MOTORS
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
HHP
Starter Motor of HHP Loco
MP.MISC-285 (Rev-00),
August 2012&
MP-IB-EM 02.07.14 (Rev.-
00), January 2015
1.1 Measure IR of motor > 1 M ohm1.2 Measure Hold-in coil resistance (4.7-5.8 ohms)
between battery to ground terminal of solenoid,1.3 Measure Pull-in coil resistance (0.7 to 1.1 ohm)
between battery to switch terminal of solenoid1.4 Check for proper engagement of starter motor
pinions with ring gear and measure clearance between pinion tooth and ring gear slot (3 to 4 mm).
1.5 Check cables for any insulation damage & intactness of cable tags.
1.6 Measure the distance between pinion face & inside Machined face of nose housing after movement of pinion. It should be between 8.3 mm to 9.9 mm.
1.7 Check for intactness of cables, routing and tightness of mounting bolts
1.8 Check intactness of drive gears & ring gear.2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Digital multimeter 2.2 Magger 3 INSTRUCTION
Page 77 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/PARA/
ITEM DETAILS
OBSERVATION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 78 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR RADIATOR FAN OF HHP LOCOMOTIVEQUALITY AUDIT OF RADIATOR FAN
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
HHP Radiator Fan of HHP Loco
MP.MISC-285 (Rev-00),
August 2012&
MP.0.24.00.55 (Rev-01),
October 2009
.
1.1 Measure IR of motor > 1 M ohm1.2 Check clearance between the longest blade and fan
shroud1.3 Check RTV sealant on rotor to stator mounting bolts1.4 Check for any unusual sounds from motor and
intactness of cables.1.5 Check cables for any insulation damage & intactness
of cable tags.1.6 Locked rotor current< 5 Amps.2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Digital multimeter 2.2 Magger 3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 79 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR FPM OF HHP LOCOMOTIVEQUALITY AUDIT OF FUEL PUMP MOTORS
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
HHP Fuel Pump Motor of HHP Loco
MP.MISC-285 (Rev-00),
August 2012
.
1.1 Measure FPM current < 20.16 Amp.1.2 Horizontal FPM is polarity dependant i.e. +ve and –
ve supply, cables should be connected +ve and –ve terminals on motor.
1.3 Ensure the intactness of terminal box & cable conduct.
1.4 Check for any slackness of foundation bolts.1.5 Check inverter and clean heat sinks.1.6 Check for any unusual sounds from motors2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Digital multimeter 3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 80 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR FPM OF ALCO LOCOMOTIVEQUALITY AUDIT OF FUEL PUMP MOTORS
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 Fuel Pump Motor of Alco Loco
MP.MISC-141 (Rev-01),
September 2006
.
1.1 Measure FPM current < 15.54 Amp.1.2 horizontal FPM is polarity dependant i.e. +ve and –
ve supply, cables should be connected +ve and –ve terminals on motor.
1.3 Ensure the intactness of terminal box & cable conduct.
1.4 Check for any slackness of foundation bolts.1.5 Check inverter and clean heat sinks.1.6 Check for any unusual sounds from motors2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Digital multimeter3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 81 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR RTTM BLOWER OF ALCO LOCOMOTIVEQUALITY AUDIT OF RTTM BLOWER
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 RTTM Blower of Alco Loco
MP.MISC-141 (Rev-01),
September 2006
1.1 Check the alignment of pulleys1.2 Check the blower bearing with grease and ensure
that old grease does not fall in blower casing.1.3 Check adaptor nut for tightness and ensure that tub
washer is in position and locked1.4 Check the belts for condition and tension.1.5 Check blower impeller for shifting2 AVAILABILITY OF TOOLS AND TEST STANDS3 INSTRUCTION
3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools and measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 82 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR AUXILLIARY GENERATOR OF HHP LOCOMOTIVEQUALITY AUDIT OF AUXILLIARY GENERATOR
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
HHP
AG of HHP Loco
MP.MISC-285 (Rev-00),
AUGUST 2012
.
1.1 Inspect diode plate and check cleanness 1.2 Check aux. Gen o/p cables and exciter field cables
for any insulation damage.1.3 Check for intactness of covers with bolts.1.4 Check for any unusual sound & rubbing marks
1.5 Check covers terminal connections etc.2 AVAILABILITY OF TOOLS AND TEST STANDS
3 INSTRUCTION3.1 Display Chart
Training of Staff3.3Record keeping of tools and measuring instruments
4 TRACEABILITY5 MATERIAL AVAILABILITY
5.1 Vital Spare5.2 Must change items
Page 83 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Annexure-VCHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL ROOM(Item: MBCS + MCBG +E type control)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:SN Requirements Loco Type Make Of
SubassemblyReference Details Clause/
Para/Item Details
OBSERVATION
List of measuring equipment Calibration status Test bench set up facility Segregation of tested equipments
Check List of safety and critical items identified ECS operation check GR operation check Eng. Stop button check OST open check MUSD stop switch check LWS check GFOLR operation check (E type loco) Governor dry run check Flasher light Head light Classification light Horn
ALCo andHHP
Schedule inspection
Page 84 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type Make Of Subassembly
Reference Details Clause/Para/Item
Details
OBSERVATION
Sanders and direction Cab light and exterior lights Alerter, lamp, alarm and reset Flasher lights switch panel GR, DB cut out and B/B cut out seals Indication panels Attendant call bell Cab fan and air brake fan
Eng Temp switch setting at 68ºC, 74ºC, 90ºC, 95ºC( not applicable in MBCS Loco)Proper closing of all covers and gaskets are intact in TCC, ECC1, ECC2, ECC3 and ECC4(Dual Cab)Practice for Handling of the electronic cards and storing
ALCo Doc No. :IM 53 for MBCS Medha
Availability of crimping tool & connector pin details ALCo Doc No. :IM 53 for MBCS Medha
Load Box testing facility ALCo MP MI -10 (Rev.0.02)August, 2003 for ‘E’ type and MBCS
Micro Controller Based Governor (MCBG) MEG 601 ALCo Doc No:IM-11 Rev. 0.0 Date Jan 2009 of Medha
1. Measurement
Page 85 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type Make Of Subassembly
Reference Details Clause/Para/Item
Details
OBSERVATION
Test procedure for MBCS loco 8th notch power curve
ALCo IM-59, MP MI -10 (Rev.0.02)August, 2003 for ‘E’ type and MBCS
2. Availability Of Tools And Test Stands
Alco3
Availability Of Instructions Etc3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
Page 86 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
TA Volts
TA Amps.a. Amb. Temp.b. Corrected THP c. Fuel rack in mmd. NLV (Specified 1130VDC)e. 8th notch power curve f. Notch separation testIdle to full HP time (specified 40 sec)1st notch current limit (specified 32- 33.5mA)
SN Requirements Loco Type Make Of Subassembly
Reference Details Clause/Para/Item
Details
OBSERVATION
5.2 Must change items
7 Availability of Tools And Test Stands
8
Availability Of Instructions Etc8.1 Display Chart8.2 Training of staff8.3 Maintenance manual and check sheets8.4 Record keeping of tools and measuring instruments
9 Record Keeping For Traceability 10 Material Availability
Page 87 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERATING FIELD CONTACTOR CONTACTORS (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.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Measurement1.1 Control voltage 72+1 vdc, All Diesel
Electric Locomo tives (ALCo)
Drawing No. EL/PT/0640/ Altr
R3Part
No 12145439
RDSO Drg No.4141
Technical details given in the drawing
1.2 Max pick up volt 48v , 1.3 Main contact gap12-14.5mm, 1.4 Wipe 8-10 mm, 1.5 Contact pressure( kgf) initial 1.82-2.95,final 5.45-
7.25, 1.6 Operating coil resistance at 20 deg c 104 -116
ohm, (approx.),1.7 Interlock (gpr type : 9-41n, 3no+3nc) 1.8 Contact gap 9.5-10.5 mm, 1.9 Interlock contact pressure 220-300g.
Page 88 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1.10 Contact impression (should be min 80%) Spec No. MP.0.04.00.08
(Rev-02), Aug’18
Pg 21,Clause 4.1.4
1.11 IR Value between(i) Main contacts(ii) Coil and magnet frame(iii) Interlocks and coil shorted together and earth.(iv) Contacts of interlocks(v) Interlocks and coil shorted together and main
contacts shorted together(vi) shorted main contacts and shorted interlocks, coil
and earth
IEC 60571
as per clause 10.2.9
2.0 Availability of tools and stands2.1 Multimeter with proper calibration2.2 Vernier calipers with valid calibration2.3 Go- No gauge suiting to different cantactors2.4 Dial gauge of different scale and resolution as
suited to respective contactor2.5 Source which can provide minimum current at
respective voltage (24 V – 72 V DC)2.6 Variac2.7 Meggar
2.8 Oscilloscope
Page 89 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
2.9 Screw Driver, Plier, Spanner Set, etc.3. Availability Of Instructions etc.
3.1 Display Chart3.2 Flow Chart 3.3 Training of staff3.4 Proper Display of Do’s and Don’t3.5 Maintenance manual and check sheets3.6 Record keeping of tools and measuring
instruments 3.7 Instruction Bulletin/ Mod sheet issued by RDSO3.8 Maintenance Manual of Manufacturer3.9 Specification
4. Compliance of Instruction Bulletin 5. Follow of Maintenance Manual of Manufacturer6 Record Keeping For Traceability
6.1 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.
6.2 Proper record should be maintained for each contactor with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
Page 90 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
7.1 Vital Spares
7.2 Must change items7.3 Consumables
8. Disposal8.1 Segregation of Workable and Non-Workable
equipments and proper house keeping8.2 Proper Disposal of Materials including recycling
following relevant environmental norms
Page 91 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6 M REVERSER (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.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Measurement1.1 Auxiliary contacts 4, change over type, ALCo Ref:-DLW
Drawing No. EL/PT/0649/ Altr
R5Part
No 12310372
RDSO Drg. No SKDP 4136
Technical details given in the drawing1.2 Control voltage 72+1 V DC,
1.3 Operating air pressure 4.9 kg/cm2,1.4 Min operating air pressure 3.85 kg/cm2,1.5 Main contact gap19.05+1.6mm,
1.6 Main contact outside pressure (with lever) 4.0-4.5kgf, inside pressure 5.8-6.5kgf,
1.7 Contact impression (should be min 80%)
1.8 Auxiliary contact pressure 0.68-2.0kgf, 1.9 Auxiliary contact gap 31.75mm (min), , 1.10 Magnet valve coil resistance at 20degC 615+5%
Page 92 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
ohm.for BHELTYPE: 5027MV2 1.11 ROTEX TYPE: 3118AV1-3 coil resistance at
20degC-526 to 594 Ohms.
1.12 Contact impression (should be min 80%) Spec No. MP.0.04.00.08
(Rev 02), Aug’18Pg 14,Clause 6.5
1.13 IR Value between(i) Main contacts and frame (ii) Frame and all live parts connected
together (wth main cxontacts closed)(iii) Terminals of both side, terminals shorted
together on each side (Main contacts open)
(iv) All control and Aux. circuit
IEC 60571 as per clause 10.2.9
2.0 Availability of tools and stands2.10 Multimeter with proper calibration2.11 Vernier calipers with valid calibration2.12 Go- No gauge suiting to different cantactors2.13 Dial gauge of different scale and resolution as
suited to respective contactor2.14 Source which can provide minimum current at
respective voltage (24 V – 72 V DC)2.15 Variac2.16 Lever of 122.5 mm for measuring initial and final
pressure.2.17 Compresor with air reservoir
Page 93 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
2.18 Meggar
2.19 Oscilloscope
2.20 Screw Driver, Plier, Spanner Set, etc.3. Availability Of Instructions etc.
3.10 Display Chart3.11 Flow Chart 3.12 Training of staff3.13 Proper Display of Do’s and Don’t3.14 Maintenance manual and check sheets3.15 Record keeping of tools and measuring
instruments 3.16 Instruction Bulletin/ Mod sheet issued by RDSO3.17 Maintenance Manual of Manufacturer3.18 Specification Spec No.
MP.0.04.00.08 (Rev- 02), Aug’18
4. Compliance of Instruction Bulletin/ Mod Sheet issued by RDSO
5. Follow of Maintenance Manual of Manufacturer6 Record Keeping For Traceability
6.3 Proper Register is maintained for 6 M Reverser with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.
Page 94 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
6.4 Proper record should be maintained for each 6 M Reverser with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability7.4 Vital Spares
7.5 Must change items7.6 Consumables
8. Disposal8.3 Segregation of Workable and Non-Workable
equipments and proper house keeping8.4 Proper Disposal of Materials including recycling
following relevant environmental norms
Page 95 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6 M BKT CONTACTORS (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.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Measurement1.1 Auxiliary contacts 4 change over type, All
Diesel Electric Locomotives (ALCo)
Ref:DLW Drawing No.
EL/PT/0648/ Altr R5
Part No 12310300
RDSO Drg. No SKDP 4137
Technical details given in the drawing1.2 Control voltage 72+1 V DC,
1.3 operating air pressure 4.9 kg/cm2, 1.4 Min operating air pressure 3.85 kg/cm2 , 1.5 Main contact gap19.05+1.6mm,, 1.6 Main contact - outside pressure (with lever) 1.7 4.0-4.5kgf, inside pressure 5.8-6.5kgf, 1.8 Auxiliary contact pressure 0.68-2.0 kgf, 1.9 Auxiliary contact gap 31.75mm (min), 1.10 Magnet valve coil resistance at 20degC 1.11 615+5% ohm. for BHEL TYPE : M5027MV21.12 ROTEX TYPE: 3118AV1-3 coil resistance at 20degC
526 to 594 Ohms
1.13 Contact impression (should be min 80%) Spec No. MP.0.04.00.08
(Rev- 02), Aug’18Pg 14,Clause 6.5
Page 96 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1.14 IR value between(i) Main contacts and frame(ii) Frame and all live parts connected
together (wth main cxontacts closed)(iii) Terminals of both side, terminals shorted
together on each side (Main contacts open)
(iv) All control and Aux. circuit
IEC 60571
as per clause 10.2.9
2.0 Availability of tools and stands2.21 Multimeter with proper calibration2.22 Vernier calipers with valid calibration2.23 Go- No gauge suiting to different cantactors2.24 Dial gauge of different scale and resolution as
suited to respective contactor2.25 Source which can provide minimum current at
respective voltage (24 V – 72 V DC)2.26 Variac2.27 Lever of 122.5 mm for measuring initial and final
pressure.2.28 Compresor with air reservoir2.29 Meggar
2.30 Oscilloscope
2.31 Screw Driver, Plier, Spanner Set, etc.3. Availability Of Instructions etc.
3.19 Display Chart3.20 Flow Chart
Page 97 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
3.21 Training of staff3.22 Proper Display of Do’s and Don’t3.23 Maintenance manual and check sheets3.24 Record keeping of tools and measuring
instruments 3.25 Instruction Bulletin/Mod sheet issued by RDSO3.26 Maintenance Manual of Manufacturer3.27 Specification
4. Compliance of Instruction Bulletin / Mod Sheet issued by RDSO
5. Follow of Maintenance Manual of Manufacturer6 Record Keeping For Traceability
6.5 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.
6.6 Proper record should be maintained for each contactor with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability7.7 Vital Spares7.8 Must change items7.9 Consumables
8. Disposal
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Observations
8.5 Segregation of Workable and Non-Workable equipments and proper house keeping
8.6 Proper Disposal of Materials including recycling following relevant environmental norms
Page 99 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo/ HHP 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.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Dis Assembly and Assembly ALCo/ HHP
Maintenance manual of
Wood Ward
Section 5 of Maintenance Manual
2. Measurement :2.1 Physical Examination ALCo/
HHPWood Ward
Governor Test Record Format No. TSP/F8572-
828 and Maintenance
manual of WoodWard
Section 6 of Maintenance Manual2.2 Barometer Reading
2.3 Pressure Test2.4 Hydraulic Seals, needle valve seat and buffer
piston bypass in both direction2.5 Needle Valve setting2.6 Speed Setting2.7 Normal Shut Down2.8 Pressure Requirement2.9 Speed Setting timing2.10 Lube Oil Shutdown2.11 Air Box Pressure Fuel Limiting2.12 Load Control2.13 Vane Servo Timing2.14 Excitation Resistor2.15 General
Page 100 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
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Observations
2.16 Verification with Cover Installed
3.
Availability Of Tools And Test StandsALCo/ HHP
3.1 Test Stand for Wood Ward Governor3.2 Multimeter with valid Calibration3.3 Screw Driver, Plier, Allen Key, Spanner, etc.3.4 Fire Extinguisher of proper class
4.
Availability Of Instructions etc.3.28 Display Chart3.29 Flow Chart 3.30 Training of staff3.31 Proper Display of Do’s and Don’t3.32 Display of Trouble Shooting Chart Maintenance
ManualSection 4
3.33 Maintenance manual and check sheets3.34 Record keeping of tools and measuring
instruments 3.35 Instruction Bulletin /Mod sheet issued by RDSO NA3.36 Maintenance Manual of Manufacturer
3.37 Specification NA
5.Compliance of Instruction Bulletin/Mod sheet issued by RDSO
NA
6.Follow of Maintenance Manual of Manufacturer
7.Record Keeping For Traceability
6.7 Proper Register is maintained for Governor
Page 101 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
SN Requirements Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
testing with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.
6.8 Proper record should be maintained for each Governor with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
8.
Material Availability
7.10 Vital Spares
7.11 Must change items7.12 Consumables like Lub Oil, Cotton wool, etc.
9. Disposal
9.1 Segregation of Working and Non-Working equipment and Proper House Keeping
9.2 Safe Disposal of scrap and waste including recycling following relevant environmental norms.
Page 102 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Annexure-VICheck sheet for Quality Audit of Diesel Loco Sheds (Loco Design Group Items)
(Under frame/cattle guard/ fuel tank/ / painting/cab/ battery box/ superstructure/ CBC/ side buffers)During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:
Sl. No. Activity Reference/ Clause ObservationsUnder frame
01 Under frame to be kept on trestle at lifting lugs.02 Proper cleaning & washing of U/F with detergents & water.04 i. Visual inspection of buffer beam, striker block for any
crack or damage, accordingly repair/weld properlyii. Check the buffer base bolt holes for size, centers &
ovality. Remove the ovality by welding and re- drill if necessary
05 i. Check the Cattle guard/Rail guard by visual inspection, if any crack/ damage found then it should be repaired/replaced accordingly
ii. Ensure minimum clearance of cattle guard from R/L to be 178 mm
iii. Ensure minimum clearance of rail guard from R/L. to be 115 mm
DLW Drg. No. TPL-3373(for Alco locos) DLW Drg. No. 10630723(for EMD locos)
06 Visual inspection of welding of gussets/ stiffeners in back of buffer beam transferring buffing force from buffers to maintain longitudinal box section. If any crack /damage is found, it shall be repaired accordingly.
Page 103 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Sl. No. Activity Reference/ Clause Observations07 Visual Inspection of Footstep for welding crack/damage and
shall be repaired by welding properly or replaced.08 i. Visual inspection of welding of Hand rails to under
frame. If there is any crack or damage in weld then reweld it properly.
ii. All fasteners are used for securing hand rail, clamp, hand rail support should be properly tighten
09 The coupler pocket shall be examined closely for welding cracks/damage in ribs and inspection of welding with under frame. If any crack or wear is found, shall be repaired properly.
14 i. Visual inspection of Battery box below side sill/bottom plate for corrosion & welding cracks in wear plate, end plates & support plate. If there is any crack or corrosion then it should be rewelded or replaced it
ii. Mounting block, nut & bolt should be properly secured and tighten
iii. Wooden spacer properly placed between the batteryiv. All hinges, locks should be in workingv. Cover assly. properly secured & locked with battery box.
Page 104 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Sl. No. Activity Reference/ Clause Observations15 i. Ensure proper cleaning & washing of Fuel tank to
remove dirt, sludge deposited inside/ outside the tank.ii. Inspection of fuel tank for any leakage or cracks.
iii. Inspection of drain valve, glow rod and for any crack repair by welding or replace if found beyond repair.
iv. Mounting block, nut & bolt should be properly secured and tighten
v. Fuel gauge should not be broken and in working condition
vi. Fuel gauge mounting bracket, filler cap, vent pipe should be in good condition
1. RDSO Investigation Report no. 473/83, February’1983(for WDM2/3A loco)2. MP.IB.LD.01.01.14 (Rev.00) dated 03.01.2014(for EMD type)3. MP.IB.LD.01.01.19 (Rev.01) dated 04.04.2019
16 Visual inspection of Under frame box section and side sill welding. If there is any crack or damage, weld it properly with low hydrogen welding electrode.
RDSO’s MP.INV-8 December’1995
17 i. Carefully examine the welding around the both Center Pivots for crack and also check the surface with magnaflux or die-penetrant method to identify cracks, if any, which is not visible to naked eyes.
ii. If any crack is found, weld it properly with down hand welding.
RDSO Drg. No.SK.DL-2069(for WDM2/3A locomotive)
18 i. Carefully examine the welding around Side load bearers for crack and also check the surface with magnaflux or die penetrant method to identify cracks, if any, which is not visible to naked eyes.
ii. side load bearer shall be repaired
1. RDSO MP.MI- 140/88, Sep’19882. MP.IB.LD.01.08.07 (Rev.00)dated 21.08.20173. RDSO Drg. No.SK.DL-2069(for WDM2/3A Loco)
19 Loco painting, marking, stencilling;Apply epoxy primer and PU paint before stencilling
As per extent colour scheme
Page 105 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Sl. No. Activity Reference/ Clause Observations20 Center buffer coupler & Draft Gear
Check compliance of RDSO instructions for inspection and maintenanceModify uncoupling arrangement to make it top operated
1. G-802. MP.MOD.LD.05.10.11 (Rev 01)dated 08.02.2016(for Alco Loco)
21 Side BuffersCheck compliance of RDSO instructions for inspection and maintenance
MP.MI-116/82, Rev.02
23.1 Driver/Pilot seati. Base mounting nut/ bolt and other fasteners should be
properly tightenii. Motion and its adjuster/locking arrangement/ Ver. &
rotational motion should be in functioningiii. Cushion & upholstery should be in good condition
DLW Drg. No. 11811717 ( for all diesel loco)
23.2 Side sash / windowi. Sliding glass should freely slide and not cracked
ii. Locking arrangement properly in functioniii. Guide rail, weather rubber & glazing rubber should be in
good conditioniv. Rear view mirror if applied properly secured with frame
and its rotational movement checked. Mirror should be in good condition
23.3 Cab doori. Lock, hinges should be in function
ii. Glass, weather strip should be in good condition and door properly sealed in closed condition
iii. Assistant seat properly secured and in good working condition
iv. Wiper motors should be in working
Page 106 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Sl. No. Activity Reference/ Clause Observations23.4 Cab floor
i. Flooring mat & trim should be in good conditionii. Steel structure/ panel sheet of cab should not be
corroded or broken23.5 Cont. Comp door, short hood door & Cab inner trim
i. Lock, hinge and weather sealing should be in working condition
ii. Perforated aluminium sheet , insulating material, fasteners should be in good condition
23.6 Cab light and fani. Switches, regulators and connections are properly in
function23.7 Fire Extinguisher
i. Mounting bracket should be in good condition and refilling facilities should be available
23.8 Air condition (if applied)i. Switches, regulator and water drainage properly in
function23.9 Token pick up arrangement
i. Token pickup rod properly joint with cab and should be in function (closing & opening)
ii. Cushion pad frame properly welded with cab and cushion mat condition should be good
23.10 Front look out glassi. Glass & weather strip should be scratches free and
properly sealed with front structureii. Covering grill glass properly cover with hinged grill
Page 107 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Sl. No. Activity Reference/ Clause Observations24 Superstructure
i. Check the condition of sheets and repair if possible otherwise change
ii. Check hinges and door locks for proper working and repair if possible otherwise change
iii. Check for water leakage at various joints and renew weather stripes/ceilings
iv. Door panel-sheet should not bend and properly close25 Radiator compartment & Expansion tank
i. Gauge, vent, vacuum valve, low water alarm should function
ii. Expansion tank plate should not be corrodediii. Funnel grating, foot step, hand- rail, inspection door
properly secured with rad. Comp. Structure.
Page 108 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
Annexure-VII
CHECK SHEET FOR TECHNICAL AUDIT OF BOGIE (ALCO LOCOMOTIVE)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:SN Requirements Loco Type Make Of
SubassemblyReference Details Clause/
Para/Item Details
Observations
1. Measurement / Activityi) Bogie frameii) Bolster (if applicable)
Alco SeriesWDM2, WDM3A, WDG3A,WDP3A,WDP3AM & WDM3D/E/F
Maintenance Instruction no.M&C Report MP.MI-71/78VL.MI.-02/96VL.MI.-04/98MP.MI-31MC – 44 & MC - 29
Cleaning of bogie frame / Bolster Crack detection and repair Welding of Manganese Steel Liners at axle
boxes and pedestal liners
2. Complete BogieMP.MISC – 141 Item No. 165 Longitudinal and lateral pedestal clearances
3. Wheel & Axle Assembly Wheel wear management Instruction Bulletin no.MP.IB.BD.0216.01 (Rev-1) &MP MI71/78MP. MISC – 141
Clause 4.3.8Item No. 110, 161, 198,
Wheel wear measurement i.e. Root wear, Tread wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spalling etc. as per MP.MI 71/78 in every trip.
Wheel gauge (1596+3/-0.5 mm)
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Observations
Deference in tread diameter of wheels on same axle, same bogie & same loco
Ultrasonic testing of axles (interval of 06 months for passenger locos & 12 months for goods loco)
RDSO procedure MC-714. Brake rigging WDM2, WDM3A
MP.IB.VL-03.11.01MP.MISC – 141
Item No. 295 Piston travel Wear of Brake shoe Wear of Pins & Bushes
5. Axle box & journal bearings Inspection bearing components Grease condition Radial clearance Distance over liners (face and lateral) Dimensional measurement of bearing
components
MP.MISC – 141 Item No. 47, 197
6. Centre Pivot & Loading PadsMP. MISC – 141
MP.IB.VL-02.11.10
Item No. 274 & 278,Centre pivot castings and loading pads, liners
Load Pad to Centre Pivot Height Difference,7. Suspension Spring ( As per MI )
WDM2, WDM3A, WDG3A,WDM3D
Free height of spring As per relevant drawingsworking height of springGrouping / colour code of spring MP.IB.VL- 04.19.01
(Rev.01), MP.IB.VL-
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Details
Observations
01.06.02 (Rev.00),MP MI-31
8. Friction Snubber Assembly WDM2, WDM3A MP.MISC – 141 Item No. 116Height measurement
9. Equaliser Beams MP. MISC – 141,M&C document no. MC –
43 & MC-92
Item No. 52Free roller movement, Wear of hard face zone
10. Side Bearer (Rubber spring) WDG3A, WDM3D
SK.VL-127, SK.VL-608, MP.IB.VL. 04.30.08
(Rev.01)
Para 6Free Height of rubber springWorking height of rubber springPermanent set of rubber springRubber crack length/ de-bonding
11. Hydraulic damper
Para 6Capacity / Rating of dampers As per relevant drawingsDamper overhauling MP.IB.VL. 05.39.10
(Rev.01)Availability of Tools And Test Stands
Para 2 of Annexure-IPara 7
Surface table of measurement of springsHeight gauge for springs Spring load-deflection testing machine Spec. No. MP.0.4900.12
(Rev.04) Hydraulic damper testing machine MP.IB.VL. 05.39.10
(Rev.01)Torque wrench, Go/No Go GaugesInside and Outside Caliper, Vernier Caliper,
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Details
Observations
Height Gauge, Cleaning Tank,Wheel wear measuring gauge SK.DL-3592
13. Availability Of Instructions etc.3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
14. Record Keeping For Traceability15. Material Availability
Vital SparesMust Change items
Page 112 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019
CHECK SHEET FOR TECHNICAL AUDIT OF HHP LOCOMOTIVE BOGIE
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Shed/Rly: Audited by: Date of audit:
SN Requirements Loco Type Make Of Subassembly
Reference Details Clause/Para/Item
Details
Observations
1. Measurements / ActivitiesGeneral Maintenance HHP loco Maintenance Instruction no.
MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
MP. Misc-285 (Rev.00)
Para 2.0
Para 2.0
Item Nos. 19, 46
Cleaning of bogie frame under locomotive Trucks (Visual Examination) Tank immersion Lubrication Wheel and axle Inspection Journal Bearings Dampers Rubber secondary spring Brake rigging Slack adjusters, adjustment Hand brake
2. Wheel & Axle Assembly Minimum wheel diameter after last truing
operation. Maximum diameter mismatch of two wheels on a
common axle.
HHP Loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5
Para 2.3
Para 2.9
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Observations
Maximum diameter mismatch between wheels on one axle compared to those of any other axle. These include wheels on the same bogie.
Minimum rim thickness. Axle longitudinal limits. Circumferential defects on or below the axle
surface. Axle Run-out. Wheel wear measurement i.e. Root wear, Tread
wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spalling etc.
Wheel gauge (1596+3/-0.5 mm) Deference in tread diameter of wheels on same
axle, same bogie & same loco Ultrasonic testing of axles (interval of 06 months
for passenger locos & 12 months for goods loco)
Locomotive.
MP. Misc-285 (Rev.00)
Wheel wear management IB no. MP.IB.BD.02.16.01 (Rev-01) & MP.MI-71/78
Para 4.3.8
3. Journal bearings Checking of running temperature of outside face
of the adopter with a temperature indicating crayon/ direct pyrometer
Sign of overhearing (Temperature should not exceed more than 560C above ambient).
Excessive lubricant leakage from the grease seals. Broken, loose or missing parts (such as loose cap
screws, etc.)
HHP Loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
MP. Misc-285 (Rev.00)
Para 2.4
Para 2.3
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Observations
Loose or defective seals. Cracked or broken cups, end caps or adapters, etc.
4. Dampers Check for leaking fluid. Make certain that oil has
not been deposited from some other source and check damper per Manual Qualification Procedures before condemning.
Perform manual qualification tests to detect gross loss of control.
Inspect bushing integrity. Bushings should not permit uncontrolled vertical or lateral movements of the damper.
If a failed vertical primary damper is detected, inspect journal springs, lateral thrust pads and wear plates at each journal bearing location as well.
If a failed yaw damper is detected, check the items noted in the above step as well as all traction rods and bushings, carbody pivot and rod assembly and bushings, and secondary springs (rubber pads).
Steps to qualify vertical / yaw dampers (Refer instructions given in Para 2.5)Capacity/Rating of DamperOverhauling of damper
HHP Loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
MP. Misc-285 (Rev.00)
As per relevant drawingsMP.IB.VL-05.39.10 (Rev.1)
Para 2.5
Para 2.4
Para 6
5. Rubber Secondary Springs Free Height of rubber spring
HHP loco Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 &
Para 2.6
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Details
Observations
Working height of rubber spring Permanent set of rubber spring Rubber crack length/ de-bondingNote: Do not wash the spring in paraffin de-greasing agents (such as trichloro-ethylene), caustic soda, or diesel fuel oil.
WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.As per relevant drawings MP.IB.VL-01.08.11 (Rev.0) MP.Misc-285 (Rev.00)
Para 5.6.4
Para No. 2.5
Para 6
6. All type of Bushings Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.MP.Misc-285 (Rev.00)
Para 3.4.1.1
Item no. 987. Lateral Thrust Pads Maintenance Instruction no.
MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
MP.Misc-285 (Rev.00)
Para 3.4.1.2
Para no. 6.5.2.2, 6.5.2.3 and 6.5.2.4Item no. 98
8. Happy pads MP. Misc-285 (Rev.00)Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
Item no. 98Para no.2.7
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Observations
9. Suspension Spring Inspect the coils for breaks or surface cracks.
Springs with any indication of surface cracks should be scrapped. Deep sharp surface nicks can cause failure of a spring, and their presence is cause for rejection.
Hand wash or shot blast the coil to remove surface rust. “Pickling” the spring is to be avoided. If the cleaning operation removes all indications of surface rust, and does not reveal corrosion pits, the spring is acceptable for qualification. If corrosion pits are visible after the cleaning operation, scrap the affected coil.
Smooth worn spots on a coil caused by rubbing - do not condemn the coil. However, it must still pass the other qualification criteria.
For spring identification and qualification, refer to M.I. 1512.
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
MP.Misc-285 (Rev.00)
Para 3.2.6
Para 2.6
10. Brake block guide (See instruction in relevant para) Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
Para 2.7
M/s Knorr Bremse Tread brake unit PEC-7
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Observations
MP.Misc-285 (Rev.00)
manual (B-B000.25) Rev-12Item Nos. 19, 46
11. Slack adjusters This procedure must be conducted with the
locomotive parked on tangent track. If conducted with the locomotive in a curve, error in setting the piston travel will result.
It is recommended that a periodic visual inspection should be performed to find out if there is any damage, e.g. loose or missing lock pins or a bent or damaged assembly. Replace or repair the adjuster as required.
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.
MP.Misc-285 (Rev.00)
Para 2.8.2 & 2.8.3
12. Hand brake The hand brake, chain, and lever should be
inspected on a periodic basis, to check for unusual wear. The hand brake chain should not rub against the wheel or bogie during operation. The HTSC-B1 bogie has a special spring pre-tensioning arrangement to prevent rubbing.
Quarterly check: Check that all fasteners (nuts & bolts), clamps, and
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.
MP.Misc-285 (Rev.00)
Para 2.9.2
Item Nos. 19, 46
Para 2.9.4.1
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Observations
brackets are secure. Verify condition of chain, shackles, and pins for
corrosion, wear and damage. Replace as required. Check that the pulley on the brake handle
assembly is in good condition and properly secured. Replace if required.
Chain and other components should be lightly oiled to prevent corrosion.
13. Bogie removal:Inspections before bogie removal
Yaw Dampers Primary Suspension Secondary Suspension Springs Carbody pivot pin clearance Brake rigging Wheel condition, Wheels, Axles, Axle Gears
and Pinions Axle lateral clearances Vertical stop clearances
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives(Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.)
M.I. 1518 and 1519
MP.Misc-285 (Rev.00)
Para 2.12
Para 3.0
Para 5.5.2Para 5.5.2Item No. 98
14. BOGIE ASSEMBLY REMOVAL It is required without exception that all appropriate discharge procedures be performed prior to commencing work on the trucks or related components (For figures refer relevant pages and para).
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
Para 2.12.2
Para 3.0
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Observations
MP.Misc-285 (Rev.00) Item No. 9815. Bogie installation
Jacks are used to raise the locomotive, ensure that all jacks are raised simultaneously in equal amounts. Failure to keep the locomotive level may result in excessive stress on the underframe and carbody structure, or in a failure of the jacks.
Great care must be taken during this portion of the application process to prevent damage to the carbody pivot assembly and secondary suspension springs. The pivot pin and alignment dowels should slide into place easily. If this is not the case, slight movement of the bogie will be required to aid in assembly.
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.MP.Misc-285 (Rev.00)
Para 2.13.1
Para 3.0
16. Vertical Stop Clearance to be ensured 16 mm +/- 3.2 mm
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
Para 2.13.2
Para 6.5.2.6
17. Final Installation Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.
Para 2.13.3
18. Bogie Overhaul While the overhaul procedures are similar for the two types of bogies, it is imperative that the correct
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.
Para 3.0
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Observations
assembly drawing be used to ensure correct dimensions are achieved.Detail instructions and guide lines for overhaul of bogie to be followed as per the para 3.0 of MI 1517 (Rev. A)
Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.MP.Misc-285 (Rev.00)
Para 3.0
Item Nos. 98 & 113
19. Maintenance and wear limits Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.Maintenance Instruction no.MP.MI-33 (Rev. -00) for WDG5 Locomotive.
Para 5.5
Para 6.5
20. Availability of Tools, Test Stands and special procedures
Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 & WDG4 Series of Locomotives.
Work sketch 41089
Para 4.1
Lock bolt/ huck bolt installation machineWall mounted fixture to dampersSurface table of measurement of springsHeight gauge for springs Spring load-deflection testing machineHydraulic damper testing machine Torque wrench, Go/No Go GaugesInside and Outside Caliper, Vernier Caliper, Height Gauge, Cleaning Tank,Wheel wear measuring gauge SK.DL-3592
21. Availability, service data, special torque values and Instructions etc.
. Maintenance Instruction no.MI 1517 (Rev. A) for WDP4 &
Para 5.1.1 and Para
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SN Requirements Loco Type Make Of Subassembly
Reference Details Clause/Para/Item
Details
Observations
WDG4 Series of Locomotives. 5.33.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments
22. Record Keeping For Traceability23. Material Availability and parts catalogues HHP (MAC)
HHP (PAC)E26E35Vital Spares
Must Change items
Page 122 of 122 Quality Audit of Diesel Shed (Rev.-01), Date: 23.07.2019