quality audit for diesel loco poh workshop(1)

7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)

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of 104 Quality Audit of Diesel Loco POH Workshop

Quality Audit of Diesel Loco POH WorkshopsCHECK SHEET

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

etc.

General

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

locos).Quality of POH: -do-

Load Test records:

HP

SFC

EGT

Peak Firing Pressure

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

Methodology of collection of failures on locos turned out by shops,

failure investigation, analysis and preventive action.

Display of work instructions on shop floor

Training of staff Status of record keeping

Calibration of gauges/ instruments

Safety items

a. Speed recorder/Indicator Section

b. Wheel (Wear adapted profile) profile & other defects.

c. Brake adjustment, release & and application timings.

d. Headlight focus adjustment

e. Horn maintenance

f. Undergear safety brackets

g. Gauging of Couplers

h. Vertical offset between Side bearer and centre pivot

a. OEM’s maintenance manual.

b. Drg No SKDL-2561 Alt 8.

c. Standard test scheme as per MP.TP-029/87 (Rev 02) Oct

2008 for Air Brake, and, as per MP.TP-019/81 (Rev 02) Nov

08 for dual brake locos.

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

f. MI No MP.IB.BD.02.16.01 (Rev 01) December 09.g. CBC Manual No G 76 Sept 87.

h. MI No MP.IB.VL.02.11.10 (Rev 00) February 10.




Quality of

Subassembly

repairs

(important

items)

a. Expressor/Compressor

b. Air Brake Section

c. Bogie section

d. Rotating Machines Section

e. Turbo section

f. Engine Block, Crankshaft and Main bearings

g. Cylinder Head , Piston and Valve section

h. Radiator section.

i. FIP/Injector Section

j. Governor Section

k. Electrical Control Section

l. Battery Section

m. Under-frame, side buffers, cow catcher,

couplers, superstructure/Upper-frame, roof,

driver cabin, hand rails, fuel tank, loco

painting/marking/stencilling etc.

a. Further details of check sheet covered in Annexure 1.

b. -do-

c. Further details of check sheet covered in Annexure 2.

d. Further details of check sheet covered in Annexure 3.

e. Further details of check sheet covered in Annexure 4.

f. -do-

g.

h. -do-

i. -do-

j. Further details of check sheet covered in Annexure 5.

k. -do-

l. -do-

m. Further details of check sheet covered in Annexure 6.

Implementation

of modifications

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

Material Availability of critical items

Procurement from unapproved sources, if any.

Any other itemAs decided by the auditing authority




Annexure-1

CHECK LIST FOR

TECHNICAL AUDIT AT POH WORKSHOPS (BRAKE ITEMS)

S.No. Item Parameter Observ ations

1. Whether all the items

prescribed in the schedule isbeing followed for brakeequipment, compressor /Expressor & air dryer or not

As per Schedule of standard examinations

(No. MP.Misc.-140 & 141, Rev-01,September’2006)

`

1. Whether maintenance is done as per RDSOMIs or manufacturers MI mentioned inMP.Misc.-140 & 141.

2. Maintenance facilities are available or not.2. Functioning of VCD Whether functioning of VCD is being checked in

every POH schedule.

3. Test benches and rigs 1. Whether the required test bench and rigs areavailable or not viz. AB test rack for brakevalves, air dryer test bench, compressor/

Expressor test bench etc.2. Whether, testing is done on above test

benches.3. Calibration of test benches and rigs is being

done periodically or not.

4. Test on Loco after POH Whether brake system check is done on loco asper test programme no. MP.TP-029 (for air brakeloco) & MP.TP-019 (For dual brake loco).

5. Infrastructure facilities (a) Whether dust proof and controlledtemperature environment for maintenance,assembly and testing of brake valves is

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

benches.(c) Availability of compressor in air lines.(d) Whether air dryer provided in test benches/

air lines.(e) Reservoir pressure is being checked or not(f) Washing facilities




(g) Painting facilities(h) Technical Cell(i) Metrology lab(j) Store(k) Tool room(l) Fire extinguishers(m)Material handling facilities for movement of

material and components.

6. Storage of material Whether dust/damp proof environment withcontrolled temperature is available for storage of brake equipment and rubber components.Whether rubber components are being stored asper guidelines mentioned in this office letter no.SD.DEV.RBC dated 28.02/07.03.2007 circulatedto all Zonal Railways.

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

8. Human Resourcedevelopment

Whether periodic training is being imparted tomaintenance staff to make them conversant withthe maintenance practices.

9. Any other observation




Annexure-2

CHECK SHEET FOR

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

SN Activity Loco Type Reference Details Observations

1. Overhauling/Inspection Alco Series

RDSO report Misc. No. Misc-164,MP.MI-71/78 and SK.DL-3370 to befollowed

Cleaning of bogie frame

Alignment of bogie frame (includingtramming)

a) Wheel base spacingb) Transverse pedestal spacingc) Longitudinal pedestal spacingd) Pedestal bottom alignmente) Motor nose suspension lug

squareness & spacing

Crack detection, repair & heattreatment (Stress relieving)

Replacement of manganese liners andbrake rigging bushes

WDM2, WDM3A, WDG3A, &

WDM3D/E/F

2. Axle box & journal bearings

Cleaning of Axle box & bearings

Inspection bearing components

Overhauling as per the referred MP.MI

MP.MI-04.004

3. Suspension Springs ( As per MI )

Cleaning of springs

Free height of springs

Working height of springs

Grouping / colour code of springs

100% replace of spring pads ( HappyPads)

WDM2, WDM3A, WDG3A, &

WDM3D/E/F

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

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

WDG3A & MP.MI-31 for

WDM3D/E/F

4. Friction Snubber Assembly

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

Check the inside diameter of the frictionsleeve with a “No Go” gauge FigureSK.DL- 3127

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




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

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

Re-assembly of snubber

Height measurement and checking for damping characteristics

5. Hydraulic damper

Check the Capacity / Rating of dampers Damper overhauling

Testing

As per drawings No. SK.VL-295,

SK.VL-328 and SK.VL-387 &overhauling as per MP.IB.VL. 05.39.10 (Rev.00)

6. Side Bearer (Rubber spring)

Free Height of rubber spring

Working height of rubber spring

Permanent set of rubber spring

Rubber crack length/ de-bonding

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

133 &

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

7. Equaliser Beams

Checking for cracks

Reclamation of hard face as per MC-43

and 92

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

8. Wheel & Axle Assembly

Wheel wear measurement i.e. Rootwear, Tread wear, Flange wear, wheelflat, visual inspection for any defectlike crack, wheel flat, shelling, spalingetc. ,wheel reprofiling.

Wheel gauge (1596+3/-0.5 mm)

Deference in tread diameter of wheelson same axle, same bogie & sameloco

Ultrasonic testing of axles

WDM2, WDM3A,WDG3A, &

WDM3D/E/F

Wheel wear managementInstruction Bulletinno.MP.IB.BD.0216.01 (Rev-1) & MPMI71/78 & MP.MI-31

RDSO procedure MC-71




9. Brake rigging

Abnormal wear of brake hangers

Replacement of Brake blocks, Pins &Bushes

Replace brake head, tie rod, brakeshoe key, top & bottom slack adjusters

(condition basis) and friction armspring, if found damaged.

MP.MISC – 141

1. Centre Pivot & Loading Pads

Load Pad to Centre Pivot HeightDifference to be maintained.

2. Floating type Pivot assembly:Dismantle complete assembly

Clean of the metal component exceptrubber bush

Inspect for wear, tear and cracks

Reassemble pivot block assembly withchange centre pivot bush.

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

WDM2, WDM3A

WDG3A, & WDM3D/E/F

MP.IB.VL.02.11.10

SK.VL-128

SK.VL-501, RDSO Modification

sheet no. 03.10.09

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

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

11. Re-assembly of bogieMaintain all running gear clearance as per the MI’s Maintain the Lateral clearances between

Axle Box and Pedestals

(Ensure attention to wheel and axleassembly as per S.N. 8)

WDM2, WDM3AWDG3A, & WDM3D/E/F

MP.MI-71/78, VL.Mi-02/96 &MP.MI-31

MP.IB.VL.03.04.06 (WDM2 &

WDM3A)

MP.IB.VL.01.02.06 (WDG3A)




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

WDM3D/E/FOver head Crane

Hydraulic Jacks

Cleaning vat

Bogie frame manipulator

Crack reclamation facility like gouging,

grinding & welding facility etc.Stress relieving furnace

DPT, MPT & UT testing facilities

Surface table for measurement

Spring load-deflection testing machine

Hydraulic damper testing machine

Torque wrench, Go/No Go Gauges

Height gauges

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

Painting facilitiesWheel wear measuring gauge SK.DL-3592

Elecrode heating oven

Facility to measure pre-heat temperature

13. Availability Of Instructions Etc

Availability of WI including criticaldimensions

Training of staff including qualification of welders

Maintenance manual and check sheets

Record keeping of tools and measuringinstruments

Calibration of measuring instruments

14. Record Keeping For Traceability




Annexure-3

CHECK SHEET FOR

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

During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are

not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:

S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCEDETAILS

CLAUSE/PARA/

ITEM

DETAILS

OBSERVATION

1 MEASUREMENT

Alco (WDM2,

WDM3A,WDM3D)

MP-IB.EM.10.31.08dated

24.10.2008

1.1 TRACTION GEAR & PINION

Gear Ratio 18 : 65

Pinion Drg. No. 18 teeth, SKDP3624

Pinion Bedding In ColdCondition

Not less than 95 %

Pinion Advance 2.25 TO 2.45MM

Heating Temperature 190ºC + AMB TEMP.

Span Size On New Pinion Over 3 teeth88.595 /88.722MM

Condmning Limit On Basis Of Span Size Of Pinion

Over 3 teeth86.995MM

Gear Drg. No. 65 teeth SKDP3623& SKDP3775

Span Size On New Gear Over 7 teeth223.989/223.798MM

Condmning Limit On Basis Of Span Size Of Gear Over 7 teeth220.800MMPermissible Backlsh With NewSet

0.266 - 0.664MM

Condemning Limit On BasisOf Backlash

1.04MM

Crack detection MPMI or Zyglo test




1.2 TRACTION GEAR & PINION

WDG3ATraction Motor Pinion & Gear Assly. of Alco

Loco

MP-MI 129/86July ‘1986

MP-MI 5

Gear Ratio 18 : 74

Pinion Drg. No. 18 teeth, SKDP3443

Pinion Bedding In ColdCondition

Not less than 95 %

Pinion Advance 2.30 TO 2.45MM

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

/82.093MMCondmning Limit On Basis Of Span Size Of Pinion

Over 3 teeth80.366MM

Gear Drg. No. 65 teeth SKDP3444 &SKDP3546

Span Size On New Gear Over 8 teeth231.36/231.177

Condmning Limit On Basis Of Span Size Of Gear

Over 8 teeth 228.140

Permissible Backlsh With NewSet

0.243 - 0.608MM

Condemning Limit On BasisOf Backlash

1.00MM

Crack detection MPMI or Zyglo test

1.3 TA FAN ASSEMBLY

All ALColocos

MP-IB.EM.01.02.10dated 11.01.2010.

Outer diameter of TA fan

1387.25/1387mm

Bore diameter of TA stator 1392mm

Bore diameter of TA fan 600.00 / 600.03mm

Diameter of fan seating area onbarrel.

600.03 / 600.06mm

Width of fan seating at bore 9+1 mmDepth of counter sunk bolts hole 4.5 - 5.5 mm

Bolt head width 12.3mm

Bolt head height above fan plateafter final assembly should not bemore than

6- 7mm

Circumferentially Fan gap on TA 2.50 – 2.75mm

Tightening torque and wire lockingprocess

28 – 30Kg-m




Tightening torque of M30(coupling bolt)

170 – 180 kg-m.

Oil catcher thickness (at bottomside)

53.90 to 54.10mm

Bolts strength properties grade R8.8.

Sunk type M20 bolts can be used in place of fullythreaded M20 bolts

M20 & M30 bolts should be

replaced

After 4 – 5 years

service of TAFan bore area should be heated(for shrink fit).

150 to 170 °С

Re-used or old bolts and barrelthread condition should bechecked by

GO & NO GO threadring or plug gauge

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

Visual inspection isrequired

TA fan should be mounted on thebarrel by “shrink fit “

In place of (bolts)press fit.

TA fan bolts locking wire endsshould not be come out of the bolthead(projected)

As shown in photo

Proper alignment of TA fan shouldbe checked by inserting filler gauge circumferentially

Clearance betweenthe fan (back side)and barrel of TA (asshown in attachedphoto)No clearance isallowed.

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

Tightening torque,wire locking & fanback clearance withbarrel(by filler gauge(circumferentially)

TA Gear train assembly Backlash at Steelplate

All ALColocos

MP.IB.EM.02.12.0

0dated 10-4-2000.TA GEAR 102T AG/EG PINION 43T

PTU PINION - 43T

0.60mm to 1.40mm0.05mm to 0.12mm

on shaft




2 Carbody cables and Traction Motor cables

All ALColocos

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

And

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

Ensure the following:

Control cables should be replaced fully irrespective of

the condition after every 8 years. Power cables

should be replaced on condition basis. During POH

power cables, which are exposed to oil should be

critically examined and replaced if any symptoms of

bulging, softening or perishing of insulation at the

cable terminals are noticed.

3 AVAILABILITY OF TOOLS AND TEST STANDSAll ALColocos

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

And

MP.IB.EM.03.04.08,

dated 24-01-2008

2.1 Vernier Callipers

2.2 Disc Mike

2.3 Filler Gauge

4 INSTRUCTION

3.1 Display Chart

3.2 Training of Staff

3.4Record keeping of tools and measuring

instruments

5 TRACEABILITY

6 MATERIAL AVAILABILITY

5.1 Vital Spare -NA

5.2 Must change items -NA




CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTORS AT POH WORKSHOPS



SN REQUIREMENTS LOCO TYPE MAKE OF SUB-

ASSEMBLY

REFERENCE

DETAILS

CLAUSE/

PARA/

ITEM DETAILS

OBSERVATI

ON

1 MEASUREMENT

Alco Locos

Traction Motors

of Alco Loco

MP.MI-2,

MP.MI-6 &

Maintenance

manual issued

by OEMs viz.

BHEL / CGL.

1.1 PRE-INSPECTION

i) Record IR of

a) Armature (Shall be > 10 MΩ)

b) Inter Pole (Shall be > 10 MΩ )

c) Main Pole (Shall be > 10 MΩ)

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

1.2 AFTER DIS-MANTLING

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

ii) Visual examination of Armature banding. If found

beyond repair, rewind it.

iii) Check commutator dia. for condemning size.

Replace commutator, if condemning size reached.

If commutator is retained, then check millivolt

drop to ensure health of tig welding/bar to bar

shortening. If required, repair it.

iv) Check commutator surface roughness. If found >

0.05 mm or any cut mark is observed,

commutator to be grind on machine.

v) Ensure that there is no damage on armature

seating area & armature shaft. If any damaged is

noticed, re-metalize it to reqd. size.

vi) Ensure cleaning of magnet frame with cleaning

solvent to RDSO spec. MP.0.8000.01 Rev.02

Oct.’2007.




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

record it.

viii) Apply insulation varnish as per RDSO MP.MI

153/92 (latest revision)

ix) Check IR after renewal of glass epoxy laminate,

GMGS & Nomex insulation for inter poles & main

poles (Shall be > 100 MΩ )

x) Ensure tightening of pole bolts during assembly of

magnet frame and maintain IP & MP bores as per

OEM manual.

xi) Joints may be brazed & insulated, if required with

RDSO approved Silicon elastomer tape.

xii) Check IR of main pole & inter pole assemblies &

record it. (Shall be > 100 MΩ )

xiii) High potential test of inter pole & main pole at

1.3 KV for 15 sec. shall pass the test.

xiv) Ensure spray cleaning of armature with cleaning

solvent to RDSO spec. MP.0.8000.01 Rev.02

Oct.’2007.

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

record it.

xvi) Spray varnish paint protecting the shaft &

commutator & cure it.

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

manual

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

xix) Measure IR of brush arm (Shall be > 100 MΩ). If

less, replace the brush arm

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




xxi) Ensure the replacement of PTFE sleeve of brush

arm.

xxii) Ensure painting of support arm with red becktol

varnish.

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

1.3 ASSEMBLY

i) Motor assembly as per OEM’s manual

ii) Measure the final Insulation Resistance = 10

Mega ohm

a) Armature (Shall be > 100 MΩ)

b) Inter Pole (Shall be > 100 MΩ )

c) Main Pole (Shall be > 100 MΩ)

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

iv) Check the nose plate condition. If found damaged

or wear out, shall be replaced.

v) Conduct the light run test at low, medium & highrpms on assembled motor & observe for unusual

sound using listening rod.

vi) Check the bearing temperature after stabilisation

during light un test. (Shall not be > 60 °C)

vii) Apply brush seater on the commutator to seat

the carbon brushes on the commutator properly.

viii) Ensure tag welding / welding of stays on main

pole & compole fixing bolts.

ix) Apply recommended sealant to avoid ingress of

water etc.x) Apply a coat of paint on motor.




2 AVAILABILITY OF TOOLS AND TEST STANDS

2.1 1000V Megger

2.2 Filler gauge

2.3 HV tester

2.4 Dial gauge

2.5 Tachometer / Speedometer2.6 Pyrometer

2.7 Inside & Outside micrometer /calliper

3 INSTRUCTION

3.1 Display Chart


3.3 Record keeping of tools & measuring instruments

4 TRACEABILITY

5 MATERIAL AVAILABILITY & STORAGE (AC/non-

AC)

5.1 Vital Spares

5.2 Must change items




CHECK SHEET FOR

QUALITY AUDIT OF TRACTION ALTERNATOR AT POH WORKSHOPS



SN REQUIREMENTS LOCO TYPE MAKE OF SUB-

ASSEMBLY

REFERENCE

DETAILS

CLAUSE/

PARA/ITEM

DETAILS

OBSERVATIO

N

1 MEASUREMENT

ALCO locos TractionAlternator

of Alco loco

BHEL’s

Maintenance

Manual forElectrical

Equipment of

ALCO loco

(Volume-II)

a)Check tightness of all mechanical and

electrical connections. Check slip rings and

brushes for sparking.

b)BRUSH GEAR

Spring pressure- 1.36 to 2.2 kgs (adjustable) to

be adjusted to 1.8 kgs.Minimum length of brush at which brush

become inoperative – 35mm.

Clearance between brush holder & slip ring- 2

to 3 mm.

c)SLIP RING

Diameter (New) – 520 mm

Minimum worn out dia – 510 mm

Slip ring run our (max) – 0.1 mm

Slip ring ovality (max) – 0.1 mm




d)ROTOR

Diameter- 1003 mm

Air gap at pole center – 6 mm

Rotor bearing - NU330 EM/C4/D150mm x65

mm x 320mm O/D

Bearing housing dimension – 320-0.005 mm.where outer race sites - - 0.025 mm

Radial clearance of free bearing when new –

0.165 to 0.215 mm

Fit between outer race & bearing housing-

0.035 mm clearance, 0.025 mm interference

Shaft bearing seating dia – 150 + 0.055 mm

+ 0.035 mm

Fit between inner race & shaft – 0.035 to 0.08

mm interferenceDiametrical slackness of free bearing – 0.15 to

0.18 mm

Min. permissible racial clearance when

assembled - 0.03 to 0.13 mm

Min. diametrical clearance when assembled in

the machine – 0.051 mm

Bull gear wheel I/D – 149.098 + 0.025 mm

+ 0.0 mm

Shaft bull gear seating dia –149.098 + 0.162 mm

+ 0.152 mmGear box oil capacity – 2.6 litres approx.

Lubricant type – SAE 40 or equivalent




e)TIGHTENING TORQUE KG.M

Exciter to gear box – 15

Aux-gen to gear box – 15

PTU to gear box – 15

Gear box to end shield – 15

(write locked)Gear box to end shield – 1

(at pads)

Fan to rotor shaft – 25/27

(write locked)

Rotor shaft extension to barrel – 25

Rotor pole bolts – 170/190

Slip ring to shaft extn. – 15

f) RESISTANCE AT 25°C-

Stator- 0.002156 ohm (Line to Line)

Rotor- 0.312 ohm (at slip ring)

g) IR TESTS

Stator (check with 1000V magger) : 2M Ohms

Rotor(check with 1000V magger) : 2M Ohms


a. Bearing retaining ring

b. Clamping ring

c. Shaft adaptor

d. Guide sleevee. Frame lifting fixture

f. Extractor for bull gear

g. Lifting tackle

h. Forcing screws

i. Guiding studs

j. Spacers

k. S.K.F. Oil Pump




l. Studs

m. protection sleeves

n. Extractor for bearing inner race

o. Extractor foe bearing outer race from

bearing housing

3 INSTRUCTION

3.1 Display Chart3.2 Training of Staff

3.4Record keeping of tools & measuring

instruments

4 TRACEBILITY


5.1 Vital Spare





CHECK SHEET FOR

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



S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-

ASSEMBLY

REFERENCE

DETAILS

CLAUSE/

PARA/ITEM

DETAILS

OBSERVATION

1 MEASUREMENT

All ALColocos fitted

with TM4907/C1001

Traction Motor Bearing & Assly.Components of

Alco Loco

MP-IB.EM.14.50.08

dated20.02.2009

1.1 Verticality of Outer race

1.2 Verticality of Inner race

1.3 Max. deviations allowed in above cases:

Side Inner race Outer race

Pinion End 0.075 mm 0.25 mm

Commutator End 0.065 mm 0.20 mm

1.4 Radial Clearances of bearings

a) For New Bearings

Bearing Radial clearancebefore mounting

(mm)

Radial clearanceafter mounting (mm)

NU 330 0.165 - 0.215 0.100 – 0.170

NH 320 0.105 – 0.140 0.060 – 0.100

b) In addition to above, max. service radialclearance

NU 330 0.300 mm max. 0.250 mm max.

NH 320 0.190 mm max. 0.150 mm max.

c) Flinger - PEBore Dia. 153.130 to 153.155 mm

Total Width 12.65 to 12.70 mm

d) Retaining collar - PE

Bore Dia. 146.015 to 146.040 mm

Total Width 12.65 to 12.70 mm

Outer Dia. 253.225 to 253.290 mm




Hub Outer dia. 177.040 to 177.090 mm

Outer dia. on 2n

Groove 210.610 to 210.670 mm

Groove width 8.00 to 8.05 mm

Total width 44.4 to 44.6 mm

e) End shield - PE

Bore dia. 319.975 to 319.995 mm

f) End shield - CE

Bore dia. 214.980 to 215.00 mmg) Seat diameter on armature shaft

For brg.-PE, Bore dia. 150.035 to 150.055 mm

For brg.-CE, Bore dia. 100.025 to 100.040 mm

For retaining collar PE 146.130 to 146.150 mm

For bearing sleeve PE 153.220 to 153.240 mm

For inner brg. wiper CE 101.600 to 101.620 mm

h) End Float on Traction motor (TM 4907) CE

Limit – 0.50 mm Aim – 0.42 mm

1.5 Fits & Clearances (BG TM)

i) Pinion end bearing

Interferences (Diametrical) Clearances (Diametrical

Brg. Sleeveto shaft

0.020 to0.065 mm

Brg.Sleeve toinner brg.cap

0.635 to0.750 mm

Flinger toshaft

0.065 to0.110 mm

Retainingcollar toouter brg.cap

0.25 mm(min.)

Inner race toshaft

0.035 to0.080 mm

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

Retainingcollar to shaft

0.090 to0.135 mm

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




ii) Commutator end bearing

Interferences (Diametrical) Clearances (Diametrical

Brg. Sleeveto shaft

0.020 to0.065 mm

Inner brg.Cap tosleeve

0.635 to0.750 mm

Flinger toshaft

0.065 to0.110 mm

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

Inner brg.

Race to shaft

0.025 to

0.060 mm

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

1.6 Heating temp. of brg. & assly. components

Item Heating temp.

Bearing inner race PE 100 - 110 ºC

Bearing inner race CE 100 -110 ºC

Sleeve (PE) 100 -130 ºC

Sleeve (CE) 100 -130 ºC

Flinger (PE) 100 -120 ºC

End shield (PE) 120 -130 ºC

End shield (CE) 120 -130 ºC

Retaining collar (wiper) 120 -130 ºC


2.1 Dial gauge3 INSTRUCTION

3.1 Display Chart


3.3Record keeping of tools and measuring

instruments

4 TRACEABILITY


5.1 Vital Spare - NA

5.2 Must change items - NA




Annexure-4

CHECK SHEET FOR

QUALITY AUDITOF TURBO SECTION (POH)

During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the

activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.

Workshop/Rly: Audited by: Date of audit:

SN Requirements Loco Type Make Of

Subassembly

Reference

Details

Clause/Para/It

em Details

Observations

1.

Balancing, measurementsetc

Balancing:

1.1 Bladed shaft, range 31-257 gmm.

1.2 Rotor, range 157-470 gmm.

5.6

5.6.2.5

5.6.2.5

Rotor Shaft Dimensions:

1.3 Bearing position OD A 39.98 – 40.00 mm

Alco ABB VTC 304

Turbocharger

ABB-Exhaust

Gas

Turbocharge

r VTC 304 A

Comprehensi

ve Manual

for Indian

Railways

issued by

M/s ABB

Para 5.2.4.13

&

details in5.4.2.1

1.4 Bearing position OD B 50.987--51.000 mm

1.5 Bearing position OD C 56.10-56.20 mm

1.6 Piston ring recess S 2.58-2.85 mm

Wheel Bush

1.7 Compressor wheel set OD A 56.10 -56.20 mm

Para 5.2.4.13

&

details in

5.4.2.2

1.8 Piston ring recess S 2.58-2.85 mm

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

&

details in

5.4.2.3

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

&

details in

5.4.2.4




1.11 Floating bush ID (CE) 40.011-40.05 mm Para 5.2.4.13

&

details in

5.4.2.5

Floating bush OD (CE) 53.80-53.86 mm

1.12 Floating bush OD (TE) 64.82-64.84 mm

1.13 Floating bush ID (TE) 51.022-51.07 mm

1.14 Thrust bearing width 10.39-10.50 mm Para 5.2.4.13

&

details in5.4.2.6

1.15 Axial bearing width 16.76-16.88 mm Para 5.2.4.13

&

details in

5.4.2.7

1.16 Piston ring width 2.00-2.49 mm Para 5.2.4.13

&

details in

5.4.2.8

1.17 Thrust bearing press fit measure(K) 170.5-170.63 Para 5.2.4.13

&details in

5.4.2.9

1.18 Axial clearance A 0.11-0.32 mm Para 5.2.4.13

&

details in 5.7

1.19 Radial clearance B 0.47-0.93 mm

2.

Availability of Tools, Test Stands etc.

Alco do do

2.1 Balancing machine

2.2 Zyglo testing machine

2.3 Casing hydraulic test stand

2.4 Bearing puller (CE & TE)

2.5 Torque wrench up to 250 psi

2.6 micrometer 2”-3” & 0-4”

2.7 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc.

3.1 Display Chart

3.2 Training of staff

3.3 Maintenance manual and check sheets

3.4 Record keeping of tools and measuring instruments




4 Record Keeping For Traceability

5

Material Availability

5.1 Vital Spares


1

Measurements etc

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

Alco Alco 720

Instruction

Manual

ALCO

ALCo MI

11126

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

1.3 Nozzle ring and turbine disc 0.124” cold CI

1.4 Intermediate casing and impeller 0.017-0.065”

longitudinal Clearance (long Cl)

1.5 Impeller and Blower inlet 0.035-0.075” long CI

1.6 Blower casing end blower inlet measure with bolt

loose. Scatting with back of diffuser at lease to 80%(This

is only in case when we apply a new diffuser) 0.005-

0.020” Long CI (Gap)

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

1.8 Bearing and thrust collar (Blower end) with surface

by approx 0.003 less when oil. 0.007-0.018” Thrust CI

1.9 Inducer and blower casing 0.091-0.101”Dia CI

1.10 Thurst collar and oil seal Blower End 0.014-

0.036”Dia CI

1.11 Interference between bearing and intermediate

casing (blower & Turbine end ) 0.0005-0.0015” DiaCl

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

Dia CI

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

1.14 Impeller and intermediate casing 0.125-0.127” Dia

CI

1.15 Max allowable clearance between Gas inlet casing

& Nozzle ring 0.005” clearance




2

Availability of tools, Test Stands etc.

AlcoAlco 720 Instruction

Manual

ALCO

2.1 Balancing machine

2.2 Zyglo machine

2.3 Casing hydraulic test stand

2.4 Oil gallery flushing test stand

2.5 Bearing puller (CE & TE)

2.6 Sand blast machine for rotor cleaning2.7 Torque wrench up to 250 psi

2.8 micrometer 2”-3” & 0-4”

2.9 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc .

3.1 Display Chart





5


5.1 Vital Spares





CHECK SHEET FOR

TECHNICAL AUDIT OF ENGINE BLOCK, MAIN BEARING (POH)




SN Requirements LocoType

Make/classOf

Subassembly

ReferenceDetails

Clause/Para/Item/Chapter Details

Observations

1 Removal of Cyl Block

a) Removal of Cylinder liner.

b) Removal of cylinder liner sleeve.

Alco

Conventional

ALCO MI

11079 D

Chapter on Maintenance,

Instruction of Cylinder Block

.

2 Maintenance and Inspection

DPT for cracks/signs of leaks/ other

damage,

2.1 Check sizes of Main Brg. Bore.

a) New MB bore dia. 9.0355" -9.0370"

b) Worn MB bore dia. 9.0350" -

9.0385"

c) Cyl. Liner bore.

2.2 a)Out of roundness checking at planes

A,B,C,D, E & F (max. 0.0035”).

b) Check taper

i) At vertical planes A and D (0.001”).

ii) At 45° from vertical between

planes B & F and C & E (0.003”).

a) Horizontal misalignment limit – (i) Two adjacent bores – 0.002”

(ii) Two non-adjacent bores 0.004”

b) Vertical misalignment limit –

(i) Three adjacent bores-0.0015”

(ii) Two non-adjacent bores-

0.003”.




Torque values for Cylinder head stud 100-

120 ft pound.

4.

Availability of tools and test

a) Plate, lifting

b) Compound, gasket

c) Turning plate, free end & gen. end.

d) Fixture for checking distortion of Cyl,

block and cyl. liner to Cyl. block seat

e) Sleeve tool, upper and lower.f) Mandrel

g) Magnaflux

h) Feeler gauge

i) Vernier caliper

j) Torque wrench

5.

Availability of instruction

a) Display chart.

b) Training of staff

c) Maintenance manual and check

sheets.

d) Record keeping of tools andmeasuring instruments.

6.Record keeping traceability

.

7.

Material availability

(i). Vital spares.

(ii). Must change item




TECHNICAL AUDIT OF CRANK SHAFT (POH)




SN Requirements Loco

Type

Make/class

Of

Subassembly

Reference

Details

Clause/Para/

Item/Chapter Details

Observations

1 Removal of Crank Shaft

a) Removal of Oil

catcher/pipes/engine parts/main

brgs caps/shells & split gears.

b) Checked Crank shaft thrust

(i) Using Main brg shell 0.010”-

0.017”

(ii) Using Thrust collar 0.012”-

0.021”

c) Apply grease and wrap journals

and crankpins. Alco

Conventional

ALCO MI

11069 E


Instruction of Cylinder Block.2 Maintenance and Inspection

a) Cleaning

b) Magnaflux test for

cracks/other damage,

c) Roughness and burrs (limit 25

RMS max).

d) Check M/Brgs saddle bore

2.1 Check Crank shaft.

a) MB Journal dia. 8.498" – 8.500"

b) Out of roundness limit 0.002”

c) Run out for 16 cyl-0.008” max

d) MB Journal eccentricity limit

0.001”

d) Crank pin dia 5.998”- 6.000”

e) Crank pin out of roundness limit

0.002”




2.2 Split Gear

a) Removal of gears.

b) Inspect gear teeth (ALCo MI 11030).

2.3 Check Split gear

a) Key Interference fit- 0.0000”-0.0005”

b) Gear side clearance-0.007”-0.023”

c) Split line clearance limit- 0.0015”

d) Torque for gear cap screw in ft-lbs –

i) Preliminary torque- 50 ft-lbsii) Final torque – 300 ft-lbs.

ALCO MI

11067 C

ALCO MI

11069 E &

11067C4.

Availability of tools and test

a) Lifting block

b) Lapping tool

c) Deflection guage.

d) Feeler gauge

e) Soft hammer

f) Torque wrench

5.

Availability of instruction

a) Display chart.

b) Training of staff c) Maintenance manual and

check sheets.

d) Record keeping of tools and

measuring instruments.

6. Record keeping traceability.

7.

Material availability

(i). Vital spares.

(ii). Must change item




CHECK SHEET FOR

TECHNICAL AUDIT OF CYLINDER HEAD SECTION (POH)





Make Of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

1

Cleaning, measurements etc.

1.1 Cleaning of cylinder head

ALCo --

DLW

Maintenance

Instruction

Manual

Chapter on cylinder

head

1.2 Cy head leak test at 70 PSI with hot water

1.3 Inspect head for cracks using Magnaflux

1.4 Valve guide to head int 0.002” -0.0005”

1.5 yoke to guide int 0.002” -0.0005”

1.6 Yoke guide ( press in dim) 3.210” -3.272”

1.7 Valve guide ( press in dim) 2.25”

1.8 Valve to guide cl 0.003 – 0.0045”

1.9 Cy head nuts torquing value 550ft/lbs

2

Availability of tools , Test Stands etc.

2.1 Valve seat reconditioning machine

2.2 Hydraulic test stand

2.3 Nozzle hole sleeve tube expander(Bottom & Top)

2.4 Nozzle sleeve extractor

2.5 Nozzle sleeve holder

2.6 Feeler gauge

2.7 Magna flux

3


3.1 Display Chart3.2 Training of staff




5Material Availability

5.1 Vital Spares





CHECK SHEET FOR

TECHNICAL AUDIT OF PISTON SECTION (POH)





Make Of Subassembly

Reference Details Clause/Para/Item/chapter Details

Observations

1

Cleaning, inspection, measurements etc.

1.1 cleaning of piston

ALCo--

DLW

Maintenance

Instruction

Manual

Chapter on piston and

con rod

1.2 Inspect visually piston skirt and body for scoring or

scuffing

1.3 Inspect piston crack using Magnaflux

1.4 Zyglo test for checking surface crack

1.5 (a) Groove width top ring, 2nd

ring and 3rd

ring

0.1902”- 0.1950”(conventional)

(b) Groove width top ring & 2nd

ring 0.1900”-0.195”(3RV)

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

(conventional)

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

(3RV)

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

0.3165” (conventional)

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

(3RV)

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

(conventional)

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

1.9 Piston pin to bushing clearance running 0.003” –

0.0075”

1.10 Piston pin to snap ring total clearance 0.076” –

0.118”




2.

Availability of tools , Test Stands etc.

2.1 Feeler gauge

2.2 Zyglo testing machine

2.3 Magna flux

2.4 Vernier caliper

2.6 Piston ring groove gauge

3

Availability of instructions etc3.1 Display Chart





5


5.1 Vital Spares





CHECK SHEET FOR

QUALITY AUDIT OF AIR & EXHAUST VALVE MAINTENANCE (POH)

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

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


SN Requirements Loco Type Make of

Subassembly

Reference

Details

Clause/Para/

Item details

Observations

1

Measurements etc:

Alco--

Alco Instruction

Manual (MI-

11020G)

Chapter on

Cylinder

Heads

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

1.2 Groove fillet radii 0.025-0.031R.

1.3 Valve disk thickness: for C and F type valve

of 450:

(a) 0.1562” (new) and (b) 0.0625”

(condemning Limit).

1.4 Valve disk thickness (for E type valve 300)

0.1750” (new). And, 0.0937” (condemning

Limit).

2

Availability of tools, test stands etc:

2.1 Depressor, Spring etc

2.2 Grinder

3

Availability of instructions etc:

3.1 Display Chart etc.


3.3 Record keeping of tools and measuring

instruments

4 Record keeping for traceability:

5

Material Availability:

5.1 Vital Spare





CHECK SHEET FOR

TECHNICAL AUDIT OF RADIATOR SECTION (POH)





Type

Make/class

Of

Subassembly

Reference

Details

Clause/Para/

Item/Chapter Details

Observations

1 Leakage testing

AlcoConventional

Alco MI


Radiators.

2 Reconditioning of Radiator Chapter on LOCOMOTIVE

INSPECTION,

MAINTENANCE AND

LUBRICATION

MI 17003 A

2.1 Dismantling2.2 Cleaning of the core

2.3 Changing of gaskets

2.4 Assembly

2.5 Testing

Chapter on Maintenance,Radiators.

3 Cleaning etc

Alco ConventionalAlco MI


Radiators.

3.1 cleaning details

4

Availability of tools, Test Stands etc.

4.1 Torque wrench up to 140 ft-lb.

4.2 Hydraulic testing machine 0-10 Kg/Cm2

4.3 Radiator stand4.4 Fin combing tool

4.5 Radiator immersion tank for cleaning




5


5.1 Display board etc


5.3 maintenance manual and check sheets

5.4 Calibration facility for tools and measuring

instruments

6 Record Keeping for Traceability

7.

Material Availability:

5.1 Vital spares

5.2 Must change Item




CHECK SHEET FOR

QUALITY AUDIT OF FUEL INJECTION PUMP (POH)

During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed

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


SN Requirements Loco type Make of

subassembly

Reference

details

Clause/Para/Item details Observation

1. Dis-assembly /Measurement/Assembly etc

Alco Bosch 17 mm Bosch repair

and testing

manual

Para on Dis-assembly

Para on Inspection of parts




Para on assembly

Para on Calibration values

1.1 Dis-assembly

1.2 Inspection of parts

1.3 Replace plunger guide cup if the indentation

on the Plunger and tappet seating surface is

more than 0.125 mm (0.005”)

1.4 Clearance between control rack and bushing

within 0.5 mm (0.020”)

1.5 Control rack movement – within 0.38 mm

(0.015”).

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

– 18.27 mm (0.7192”)

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

2. Availability of Tools ,Test Stands etc.

1.1 Depth gauge for checking of BDC dimension

‘a’ on test bench.

1.2 Nut torque wrench, 450 lbs – 500 lbs.

1.3 Bush reamer.

1.4 Micrometer, 16 – 20 mm.

1.5 Assembly and dis-assembly fixture

1.6 Pump calibration test stand

1.7 Calibration oil – Servo Calib-5




3. Availability of instructions etc.

3.1 Display of charts etc

3.2 Training of staff.

3.3 Maintenance manual and check sheet etc


instruments.

4. Record keeping for traceability: 5. Material availability :

5.1 Vital Spares





CHECK SHEET FOR

QUALITY AUDIT OF INJECTOR (POH)

During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed

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


SN Requirements Locotype Make/Class/Name

of

subassembly

Referencedetails Clause/Para/Item details Observations

1. Dis-assembly /Measurement/Assembly etc:

Alco Bosch 17 mm Bosch repair

and testing

manual

Para on Dis-assembly

Para on Inspection of Parts

Para on Inspection of Parts

Para on Assembly

Para on Assembly

Para on Assembly

1.1 Dis-assembly

1.2 Inspection of parts

1.3 Replace Intermediate disc if found cracked or

if indentation at the nozzle seating end exceeds

0.125 mm.

1.4 Opening pressure – 3700 to 3800 psi ( 260-270

kgf/cm

2

) for Overhauled nozzle1.5 Nozzle cap nut tightening torque 130-150 Nm

(13-15 kgf.m or 94-109 lbs-ft)

1.6 Repetition (chatter) and spray pattern test

2. Availability of Tools, Test Stands etc:

List on Service Tools for

Injector

2.1 Nozzle needle lift gauge

2.2 Feeler gauge

2.3 Dial gauge

2.4 Nozzle cleaning sleeve

2.5 True running gauge

2.6 Nozzle tester

2.7 Fixture for injector2.8 Socket wrench

2.9 Test oil




3. Availability of instructions etc:

3.1 Display of chart


3.3 Maintenance manual and check sheet


instruments

4. Record keeping for traceability: 5. Material availability:

5.1 Vital spares





CHECK SHEET FOR

TECHNICAL AUDIT OF PTLOC SECTION (POH)





Type

Make Of

Subassembly

Reference Details Clause/Para/Ite

m/chapter

Details

Observations

1

Dis-assembly /Measurement/Assembly/Test etc.

1.1 Overhauling procedure

1.2 Plate Pack Length

1.3 Hydraulic Test

Plate Type Lube

Oil Cooler

(PTLOC)

MPMI-24, Nov. 2004

& MP.IB.ES.01.07.08

DLW Drawing No.

TPL-8515, DLW Part

No. 11457260

Para on

Overhaul

procedure

Outline – Lube

Oil Cooler

2 Availability of tools , Test Stands etc.2.1 Ratchet spanner

3


3.1 Display Chart





5


5.1 Vital Spares





Annexure-5

CHECK SHEET FOR

TECHNICAL AUDIT OF POH WORKSHOP

Item: Electrical control MBCS + MCBG + E type

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



Make Of Sub

assembly

Reference Details Clause/Para/Item Details

Observation

1. No. of Trained personnel withexperience

MBCS trained personnel

2. Record keeping practices after thetests in relay control room for E typecontrol

Shed doc

3. Practices for Handling of the electronic

cards and storing

ALCo Doc No:IM 53 for MBCS

Medha4. Availability of crimping tool & connector

pin details ALCo Doc No. :IM 53 for MBCS

Medha

5. Maintenance practices of MicroProcessor Based Control System MEP660

DLW/Alco/AMC (micro)/01

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

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

7. Practices followed for Fault dataanalysis for identifying the faulty

components and failure.

ALCoContract agreement no.DLW/ALCO/MCBG/Medha

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

Contract agreement no.DLW/ALCO/MCBG/Medha

9. Measurement

11.1 Standards for load box examination of D E locomotives

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

11.2 Practices as per BHEL CommissioningTest schedule (Electrical equipment)

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




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

Sept 1997

11.3 Test procedure for MBCS loco controlsystem MEP660 for retrofitted D E loco

ALCo IM-59

11.4 Preventive maintenance schedule DLW/Alco/AMC (micro)/01Inspection and test report of MPreventive Maintenance schedSF-1405 (0)

11.5 Check working of safety and critical

items identified asECS operation check, GR operationcheck, Eng. Stop button check, OSTopen check, MUSD stop switch check,LWS check, GFOLR operation check(E type), Governor dry run check,Flasher light lights, Alerter, lamp, alarmand reset, Flasher lights switch panelGR, GRCO1/2, Indication panels,

Attendant call bell, Head light,Classification light, Horn, Sanders ,Directional check, Cab light andexterior lights,

ALCo Schedule inspection of shed

and items covered under DLW/Alco/AMC (micro)/01 for MBCS locos

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

User settable parameters asper RDSO MBCSspec.MP.0.2400.26

11.7 Check ground circuit leakage current -do-

11.8 Check mv drop test of WSR (E type)

12 Availability Of Tools And Test Stands For MBCS locos- Test standsare not provided by MBCS

supplier. Items are coveredunder AMC.

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

13.1 Display of DOS and DONTS,TROUBLE SHOOTING Chart,

As per OEM manual




DISPLAYCHART & FLOW CHART

14 Maintenance manual and check sheets As provided by the MBCSmanufacturer*

15 Instruction Bulletin / Modification sheet/Hand book/ Trouble shooting charts asprovided by RDSO/ CAMTECH andimplementation by MBCS vendor

MBCS spec.MP.0.2400.26,Modification sheetNo.MP.MOD.EC.05.27.10(Rev. 00) Date 26.03.2010,Instruction Bulletinno.MP.IB.EC.04.21.10 Date

30.04.2010.CAMTECH/2010/M/MPBCS/1.0 March 2010 (IntroductionHand book on MBCS MP660fitted on diesel locomotives).CAMTECH/2000/DSL/1.0(Trouble shooting charts for drivers of WDM2 locomotive)

Medha

1. Operational manual for drivers Doc.No.IM-38 Rev 3.0 July 072. Maintenance Instruction manual Doc. No.IM-53 Rev 0.0 Sept’2008

3. System Manual Doc. No. IM-08 Rev.3.0 March 20084. Troubleshooting Manual Doc.No. IM-51 Rev.2.0 Oct.20085. WDG3A Control wiring Drg. no.ED 10356. WDG3A Power. ED 10377. WDG3A Schematics Drg. no.ED Wiring Drg. no 10348. WDG3A TB wiring Drg. no.ED 10369. WDM3D Control wiring Drg. no.ED 103110. WDM3D Power Wiring Drg. no.ED 103311. WDM3D Schematics Drg. no.ED 103012. WDM3D TB wiring Drg. no.ED 1032

Siemens

1. KM DIREKT scheme no. DRG. No. 3FZE-009612. SIM CONTROL scheme no. DRG. No. 4SIM-200509

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

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




CHECK SHEET FOR

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

During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.



Make Of Subassembly

ReferenceDetails

Clause/Para/ItemDetails

Observations

1. Measurement

1.1 Control voltage 72+1 VDC All DieselElectricLocomotives(ALCo)

Drawing No.EL/PT/0640/

Altr R3Part

No 12145439

Technical detailsgiven 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 -116ohm, (approx.),

1.7 Interlock (gpr type : 9-41n, 3no+3nc)1.8 Contact gap 9.5-10.5 mm,

1.9 Interlock contact pressure 220-300g.

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

(Rev-01),May’10

3.10.e

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

IEC60571

as per clause10.2.9





Make Of Subassembly

ReferenceDetails


Observations

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

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

and earth2.0 Availability of tools and stands

2.1 Multimeter with proper calibration2.2 Vernier calipers with valid calibration

2.3 Go- No gauge suiting to different cantactors

2.4 Dial gauge of different scale and resolution assuited to respective contactor

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

2.6 Variac

2.7 Meggar

2.8 Oscilloscope

2.9 Screw Driver, Plier, Spanner Set, etc.

3. Availabili ty Of Instructions etc.3.1 Display Chart

3.2 Flow Chart3.3 Training of staff

3.4 Proper Display of Do’s and Don’t 3.5 Maintenance manual and check sheets3.6 Record keeping of tools and measuring

instruments

3.7 Instruction Bulletin issued by RDSO3.8 Maintenance Manual of Manufacturer

3.9 Specification4. Compliance of Instruction Bulletin

5. Follow of Maintenance Manual of Manufacturer 6 Record Keeping For Traceability

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





Make Of Subassembly

ReferenceDetails


Observations

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

4.2 Proper record should be maintained for eachcontactor with the measurement of Parameters as

in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.

7. Material Availability

7.1 Vital Spares


7.3 Consumables8. Disposal

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

8.2 Proper Disposal of Materials including recyclingfollowing relevant environmental norms




CHECK SHEET FOR

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




Make Of Subassembly

ReferenceDetails


Observations

1. Measurement

1.1 Short time control voltage -72+1v dc, All DieselElectricLocomotives(ALCo)


Altr R3Part

No 121410510


drawing

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

1.4 Main contact gap12-14.5 mm,

1.5 Wipe 8-10 mm,,1.6 Contact pressure( kgf) initial 1.82-2.95, final 5.45-

7.25,1.7 Operating coil resistance at 20 deg c 18.5-

20.5ohm,1.8 Interlock (gpr type : 9-41n, 3no+3nc)

1.9 Contact gap 9.5-10.5 mm,1.10 Interlock contact pressure 220-300 gm ,1.11 .)


(Rev-01),May’10

3.10.e




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

contacts shorted together (vi) Shorted main contacts and shorted interlocks, coiland earth

as per IEC60571

clause 10.2.9

2.0 Availability of tools and stands2.10 Multimeter with proper calibration

2.11 Vernier calipers with valid calibration2.12 Go- No gauge suiting to different contactors



2.15 Variac

2.16 Megger

2.17 Oscilloscope




3.13 Proper Display of Do’s and Don’t

3.14 Maintenance manual and check sheets3.15 Record keeping of tools and measuring

instruments


3.18 Specification




4. Compliance of Instruction Bulletin

5. Follow of Maintenance Manual of Manufacturer 6 Record Keeping For Traceability

4.3 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,

Repair/Overhauling activity details, Loco No. towhich fitted.

4.4 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.


7.4 Vital Spares7.5 Must change items







CHECK SHEET FOR

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




Make Of Subassembly

ReferenceDetails


Observations

1. Measurement

1.1 Short time control voltage 72+1 v dc, All DieselElectricLocomotives(ALCo)


Altr R3Part

No 12141100


drawing

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

1.4 Main contact gap 6-7.5mm,1.5 Wipe 0.8-1.6 mm,1.6 Contact pressure(gmf) initial 80-150, final 180.-

280,1.7 Operating coil resistance at 20 deg c 55+5%

ohm(52 to 58 ohms),


(Rev-01),May’10

3.10.e

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

IEC 60571 clause 10.2.9




2.0 Availability of tools and stands

2.19 Multimeter with proper calibration

2.20 Vernier calipers with valid calibration

2.21 Go- No gauge suiting to different contactors



2.24 Variac

2.25 Megger

2.26 Oscilloscope


3. Availabili ty Of Instructions etc.

3.19 Display Chart3.20 Flow Chart




3.24 Record keeping of tools and measuringinstruments

3.25 Instruction Bulletin issued by RDSO

3.26 Maintenance Manual of Manufacturer

3.27 Specification4. Compliance of Instruction Bulletin

5. Follow of Maintenance Manual of Manufacturer





4.5 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.







CHECK SHEET FOR




CHECK SHEET FOR

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




Make Of Subassembly

ReferenceDetails


Observations

1. Measurement

1.1 Max pick up volt 48v All DieselElectricLocomotives(ALCo)


Altr R3Part

No 12141033


drawing1.2 Main contact gap 11-13 mm,1.3 Wipe 3.5-4.7mm,

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

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

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

MP.0.04.00.08

(Rev-

01),May’10

3.10.e

1.7 IR Value as per clause 10.2.9 of IEC60571 between

(i)Main contacts of contactor

(ii) Coil and magnet frame

IEC60571

as per clause10.2.9


2.29 Vernier calipers with valid calibration2.30 Go- No gauge suiting to different cantactors

SN R i t L M k Of R f Cl /P /It Ob ti





Make Of Subassembly

ReferenceDetails


Observations



2.33 Variac

2.34 Meggar

2.35 Oscilloscope




3.30 Training of staff 3.31 Proper Display of Do’s and Don’t


instruments3.34 Instruction Bulletin issued by RDSO

3.35 Maintenance Manual of Manufacturer 3.36 Specification

4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer

6 Record Keeping For Traceability4.7 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.


SN Requirements Loco Make Of Reference Clause/Para/Item Observations





Make Of Subassembly

ReferenceDetails


Observations

7. Material Availability7.10 Vital Spares

7.11 Must change items7.12 Consumables

8. Disposal8.7 Segregation of Workable and Non-

Workable equipments and proper house keeping8.8 Proper Disposal of Materials including recycling

following relevant environmental norms

CHECK SHEET FOR




CHECK SHEET FOR

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




Make Of Subassembly

ReferenceDetails


Observations

1. Measurement

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

All DieselElectricLocomotives(ALCo)

Radiator Fancontactor


Altr R3Part

No 12140235


drawing

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

t1.4 Wipe 0.8-1.6 mm, No 12140235

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

Altr R3

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

Drawing No.EL/PT/0638/Par

t1.7 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08(Rev-

01),May’10

3.10.e

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

IEC 60571 clause 10.2.9



2.39 Go- No gauge suiting to different cantactors






Make Of Subassembly

ReferenceDetails


Observations



2.42 Variac

2.43 Meggar

2.44 Oscilloscope









6 Record Keeping For Traceability4.9 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.







Make Of Subassembly

ReferenceDetails


Observations


7.14 Must change items7.15 Consumables


Workable equipments and proper house keeping8.10 Proper Disposal of Materials including recycling

following relevant environmental norms

CHECK SHEET FOR




CHECK SHEET FOR

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




Make Of Subassembly

ReferenceDetails


Observations

1. Measurement

1.1 Control voltage 72+1v dc, AllDieselElectricLocomotives(ALCo)


Altr R4Part

No 12140491


drawing

1.2 max pick up volt 48v,1.3 Main contact gap12-14.5mm,

1.4 wipe 8-10 mm,1.5 contact pressure( kgf) initial1.6 1.82-2.95,final 5.45-7.25,

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

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

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


(Rev-01),May’10

3.10.e

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

as per IEC60571

clause 10.2.9






Make Of Subassembly

ReferenceDetails


Observations

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

and earth2.0 Availability of tools and stands


2.48 Go- No gauge suiting to different cantactors2.49 Dial gauge of different scale and resolution as

suited to respective contactor 2.50 Source which can provide minimum current at

respective voltage (24 V – 72 V DC)

2.51 Variac

2.52 Meggar

2.53 Oscilloscope


3. Availabili ty Of Instructions etc.3.46 Display Chart3.47 Flow Chart



instruments3.52 Instruction Bulletin issued by RDSO3.53 Maintenance Manual of Manufacturer

3.54 Specification













CHECK SHEET FOR




CHECK SHEET FOR

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



SN Requirements LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations

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

Altr R4Part

No 12141008


drawing1.1 Contact gap 15-17 mm

1.2 Wipe 25.4-28.6 mm

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

1.4 Normal air pressure 4.9 kg/cm2

1.5 Interlock gap 2.5-3.95mm,1.6 Interlock pressure 500-900g.

1.7 Interlock rated current 10 A,1.8 Magnet valve coil resistance at 20degC 615+5%

ohm.for BHELTYPE: M5027MV21.9 ROTEX TYPE: 3118AV1-3 coil resistance at

20degC 526 to 594 Ohms,1.10 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08

(Rev-01),

May’10

3.10.e

1.11 IR Value between

a) main contactsb) interlocks and MVc) interlocks and MV shorted together and earthd) contacts and interlockse) Interlocks and MV shorted together and main

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

shorted with MV and interlocks.

IEC 60571 as per clause

10.2.9






Make Of Subassembly

ReferenceDetails


Observations





2.60 Variac

2.61 Lever of 122.5 mm for measuring initial and finalpressure.

2.62 Compresor with air reservoir

2.63 Megger

2.64 Oscilloscope


3. Availabili ty Of Instructions etc.3.55 Display Chart3.56 Flow Chart



instruments


3.63 Specification













CHECK SHEET FOR




C C S O

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




1. Measurement

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

Altr R5Part

No 12310372


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%

ohm.for BHEL type: 5027MV2

1.11 ROTEX TYPE: 3118AV1-3 coil resistance at20degC-526 to 594 Ohms.


MP.0.04.00.08

(Rev-

01),May’10

3.10.e





qType Subassembly Details Details

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 clause10.2.9





2.71 Variac2.72 Lever of 122.5 mm for measuring initial and final

pressure.


2.74 Megger

2.75 Oscilloscope



3.65 Flow Chart3.66 Training of staff 3.67 Proper Display of Do’s and Don’t


instruments






Type Subassembly Details Details

3.71 Maintenance Manual of Manufacturer 3.72 Specification Spec No.

MP.0.04.00.08

(Rev-

01),May’10


6 Record Keeping For Traceability4.15 Proper Register is maintained for 6 M Reverser

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

4.16 Proper record should be maintained for each 6 MReverser with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.

7. Material Availability7.22 Vital Spares7.23 Must change items




CHECK SHEET FOR




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




1. Measurement

1.1 Auxiliary contacts 4 change over type, AllDieselElectricLocomotives(ALCo)


Altr R5Part No

12310300


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 20degC1.11 615+5% ohm. for BHELTYPE : M5027MV2

1.12 ROTEX TYPE: 3118AV1-3 coil resistance at20degC 526 to 594 Ohms


MP.0.04.00.08

(Rev-01),

May’10

3.10.e

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

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

together on each side (Main contacts open)(iv) All control and Aux. circuit

IEC60571

as per clause10.2.9

2.0 Availabili ty of tools and stands





2.79 Go- No gauge suiting to different cantactors2.80 Dial gauge of different scale and resolution as

suited to respective contactor


2.82 Variac2.83 Lever of 122.5 mm for measuring initial and final

pressure.


2.85 Meggar

2.86 Oscilloscope




3.76 Proper Display of Do’s and Don’t 3.77 Maintenance manual and check sheets













7.25 Vital Spares


7.27 Consumables


Workable equipments and proper house keeping


CHECK SHEET FOR




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




1. Measurement

1.10 Nominal operating voltage (50-80 V) All DieselElectricLocomotives(ALCo)

BHEL, AAL andIEI

Spec No.MP.0.400.03

(Rev-01) Nov’08

Clause 3.1.1

1.11 Pick up voltage (Must Operate), max 48V Clause 3.2 (ii) 1.12 Drop out Voltage Min 7.5 V

1.13 Auxiliary make rating 7.5 A at 72 V1.14 Resistance of the coil at 20 deg C 445±5%, Clause 3.2 (v) 1.15 Contact Pressure 100-250 g Clause 3.2 (vi)

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

Clause 3.2 (vii)

1.17 Min contact gap 2.7 mm Clause 3.2 (viii) 1.18 Armature gap 4.7 to 6.6 Clause 3.2 (ix) 1.19 Ensure that no distortion or corrosion of any

componentsClause16.1.9.2

1.20 IR Value between1.20.1 Open contacts1.20.2 Contacts and metal parts1.20.3 Adjacent contacts1.20.4 Coil and earth

as per IEC60571

Clause 10.2.9


2.88 Multimeter with proper calibration2.89 Vernier calipers with valid calibration2.90 Go- No gauge

2.91 Dial gauge

SN Requirements LocoT

Make Of S b bl

ReferenceD t il

Clause/Para/ItemD t il

Observations





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

2.93 Variac

2.94 Meggar


2.96 Sufficient set of tool and gauges provided bymanufacturer





instruments


3.89 Maintenance Manual of Manufacturer 3.90 Specification Spec No.

MP.0.400.03(Rev-01) Nov’08


6 Record Keeping For Traceability4.19 Proper Register is maintained for GP Relay with

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

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

SN Requirements LocoT pe

Make Of S bassembl

ReferenceDetails


Observations






7.29 Must change items8. Disposal

8.19 Segregation of Workable and Non-Workableequipments and proper house keeping


CHECK SHEET FOR




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


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


Make Of Subassembly

ReferenceDetails


Observations

1. Measurement :2.1 Visual Inspection – check finish , material , sound

quality of workman ship etc

ALCo

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

Sept 2004

Clause No.6.3.1

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

Sept 2004

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

RDSOspecification No.ELRS/SPEC/DC-DC Converter

/0021 ,Rev.01Sept 2004

Clause No. 2.2and 2.3

2.Availability Of Tools And Test Stands ALCo

3.1 Multimeter with Valid Calibration


Make Of Subassembly

ReferenceDetails


Observations





3.2 Test stand for measurement and testing.

3.3 Screw Driver, Plier, etc.

3.4 Fire Extinguisher of proper class

3

Availability Of Instructions etc.

3.91 Display Chart

3.92 Flow Chart





3.97 Instruction Bulletin issued by RDSO NA


3.99 Specification




4.21 Proper Register is maintained for DC-DCConverter (500 W) with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,


Make Of Subassembly

ReferenceDetails


Observations





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

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

4.23 500 W DC-DC Converter with themeasurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenancewith date and remarks, if any.

7.

Material Availability7.30 Vital Spares


7.32 Consumables

8. Disposal

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

8.2 Safe Disposal including recycling followingrelevant environmental norms.

CHECK SHEET FOR




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


Workshop /Rly: Audited by: Date of audit:


Make Of Subassembly


Observations


quality of workman ship , water tightness etc

ALCo

RDSO specificationNo.

ELRS/SPEC/LFL/0017 Rev 1 Sept 04

ClauseNo.6.3.

2.2 Functional Check –ON/OFF properly RDSO specificationNo.

ELRS/SPEC/LFL/0

017 Rev 1 Sept 042.3 Lux Value- The lux measured in axial directionshall not be less than 500 lux at 1 meter and 55lux at 3 meters for amber clour LED of 120 Nos

RDSO specificationNo.


Clause No.2.3.3

2.4 Flashes per Minute (40±5) RDSO specificationNo.


Clause No.2.4.1

2.5 Output regulated Voltage RDSO specificationNo.


Clause No.2.4.5

2.6 Check Repeater indication properly RDSO specificationNo.


ClauseNo.2.4.3.1

2. Availability Of Tools And Test Stands ALCo


Make Of Subassembly


Observations




Type Subassembly em Details

3.1 Voltmeter with Valid Calibration3.2 Ammeter with Valid Calibration

3.3 Lux Meter with proper Calibration


3.5 Stop Watch



3


3.1 Display Chart

3.2 Flow Chart







3.9 Specification RDSO specificationNo.



Make Of Subassembly


Observations




Type Subassembly em Details




4.1 Proper Register is maintained for LED Flasher Light with details of Manufacturer’s Brand Name,Date of Manufacture, Type, Sl. No., Date of

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

4.2 Proper record should be maintained for each LEDFlasher Light

4.3 LED Flasher Light with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.

7.



7.3 Consumables such as fuses , toggle switches etc

8. Disposal

8.1 Segregation of Working and Non-Working

equipment and Proper House Keeping


CHECK SHEET FOR




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




Make Of Subassembly

ReferenceDetails


Observations


quality of workman ship , water tightness etc.

ALCo

RDSOspecification No.ELRS/Spec/PR/

0022 (REV-1Oct -2004)

Clause No.6.3.

2.8 Functional Check –ON/OFF properly RDSO

specification No.ELRS/Spec/PR/0022 (REV-1Oct -2004)

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

Lamp Lux level at 1

Meter

Lux level at 3

Meters

RED 75 LUX 7 LUX

WHITE 75 LUX 7 LUX

RDSOspecification No.ELRS/Spec/PR/

0022 (REV-1Oct -2004)

Clause No. 2.4.3

2.

Availability Of Tools And Test Stands3.8 Multimeter with Valid Calibration ALCo3.9 Lux Meter with proper Calibration



Make Of Subassembly

ReferenceDetails


Observations







3


3.10 Display Chart

3.11 Flow Chart







3.18 Specification




4.4 Proper Register is maintained for LED Marker Light with details of Manufacturer’s Brand Name,Date of Manufacture, Type, Sl. No., Date of

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


Make Of Subassembly

ReferenceDetails


Observations




yp y

4.5 Proper record should be maintained for each LEDMarker Light

4.6 LED Marker with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.

7.


7.4 Vital Spares


7.6 Consumables such as fuses , toggle switches etc

8. Disposal



CHECK SHEET FOR

TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR STICK TYPE / IMPROVED STICK TYPE MASTER CONTROLLER




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




Make Of Subassembly


Observations

A. Stick Type / Improved Stick type Master controller

1. Measurement:

1.1 Visual checking ALCo

M/s BHEL, Asian Plastic,M/s Kaysons

(AMC/R2)Make

BHEL Testprogrammedocument no. 865476dt

Clause 1.1

Drawing of Improved

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

1.2 Contact gap, BHEL Testprogrammedocument no. 865476dt 24.04.99 and

Clause 1.2

1.3 Contact pressure,

1.4 Cam sequence and1.5 Mechanical interlocking

1.6 Working of Throttle handle Clause 1.3

2. Test :

2.1 Insulation Resistance test: BHEL Testprogramme

document no. 865476

Clause 5.0

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




2.

Availability Of Tools And Test Stands

ALCoM/s BHEL,

Asian Plastic,

M/s Kaysons(AMC/R2)

Make

3.13 Voltmeter with Valid Calibration3.14 Venier Caliper with Valid Calibration3.15 Megger with Valid Calibration

3.16 Digital Multimeter with Valid Calibration3.17 Potentiometer with Valid Calibration

3.18 Height gauge with Valid Calibration3.19 High Voltage Tester with Valid Calibration

3.20 Bore Dial gauge with Valid Calibration3.21 Ammeter with Valid Calibration

3.22 GO and NO GO Gauge3.23 Screw Driver, Plier, Required spanner set etc.



3


3.19 Display Chart

3.20 Flow Chart

3.21 Throttle sequence chart

3.22 Mechanical interlocking Chart










3.29 Specification




4.7 Proper Register is maintained for EMD Master Controller checking with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.

4.8 Proper record should be maintained for each

4.9 EMD Master Controller with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.

7.



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

8. Segregation of Working and Non-Working equipment and

Proper House Keeping

CHECK SHEET FOR

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




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




Make Of Subassembly

ReferenceDetails


Observations


quality of workman ship etc

ALCo

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

Sept 2004)

Clause No.6.3.1

2.11 Functional Check –ON/OFF properly

2.12 Type of Bulbs used – H4 P45 T(IR), Twin Filament IB NO.

MP.IB.EC.01.08.06 DATE:27-12-06

Clause No. 4.A.1

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

Clause No. 4.A.2

2.14 Voltage Rating -24 V IB NO.MP.IB.EC.

01.08.06 DATE:27-12-06

Clause No. 4.A.3

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

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

Clause No. 4.A.4


Make Of Subassembly

ReferenceDetails


Observations




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

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

Clause No. 4.A.5

2.17 Lux output with Twin Beam Head Light for eachreflector minimum 2400 Lux at a distance of 8 Mtand 24.5± 0.1 V DC terminal Voltage at LampHolder

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

Clause No. 4.A.6

2.18 Procedure to check correctness of bulb’s f ilamentin test room

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

Clause No. 4 B

2.19 Checking illumination intensity of head light

assembly when both bulbs are working

IB NO.

MP.IB.EC.01.08.06 DATE:27-12-06

Clause No.6

2.

Availability Of Tools And Test Stands3.26 Voltmeter with Valid Calibration

3.27 1.A standard portable lux measuringequipment ‘Lux meter’ like T.E.S. model TES –1330 shall be used. Lux Meter should be of range0-20000 lux with least count of 0.01 Lux with validcalibration

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



Make Of Subassembly

ReferenceDetails


Observations






3


3.30 Display Chart

3.31 Flow Chart





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


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

Sept 2004)





Make Of Subassembly

ReferenceDetails


Observations

4 10 P R i i i i d f T i




4.10 Proper Register is maintained for TwinBeam Head Light with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.

4.11 Proper record should be maintained for

each Twin Beam Head Light4.12 Twin Beam Head Light /Bulbs with the

measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenancewith date and remarks, if any.

7.



7.12 Consumables like bulbs , Reflector

8.

Disposal


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

CHECK SHEET FOR

TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR POH




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




Make Of Subassembly


Observations

1. Measurement :2.20 Physical Examination

ALCo

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

Clause 8.5

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

Clause 8.6

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

Clause 8.7

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

Clause 8.7

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

Clause 8.8

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

Clause 8.9

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

Clause 6

2.28 Polarity and absence of Short Circuit

2.

Availability Of Tools And Test Stands

ALCo

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

3.33 Electrolyte mixing tank-Motorized type preferred3.34 Voltmeter with Valid Calibration

3.35 Thermometer with Valid Calibration


Make Of Subassembly


Observations

3 36 H d t ith V lid C lib ti




3.36 Hydrometer with Valid Calibration3.37 Ammeter with Valid Calibration

3.38 Multi meter with Valid Calibration3.39 Clamp Meter

3.40 Rubber syringe3.41 Battery Charger(Preferred Constant Current

Chargers)3.42 Battery Discharger (Preferred Electronic type)

3.43 Required Lab for testing of Acid and DM water 3.44 Screw Driver, Plier, Spanner Set etc.

3.45 Test stand for measurement and testing (ConcretePlatform covered with Acid Resistant FRPsheets/coating for keeping batteries –charge/Discharge.)

3.46 D.M.Water Plant

3.47 Proper earthing facility for switch gear and Battery

charging Panel.3.48 Fire Extinguisher of proper class

3.49 Fork Lift

3.50 Hand trolley

3.51 Battery lifting crane on test bench

3.52 Plastic Pallet for storing Battery

3.53 Rubber Apron

3.54 Rubber Gloves

3.55 Goggles

3 Availability Of Instructions etc.


Make Of Subassembly


Observations

3 39 Displa Chart




3.39 Display Chart

3.40 Flow Chart





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


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



6.

Record Keeping For Traceability

4.13 Proper Register is maintained for Battery checkingwith details of Manufacturer’s Brand Name, Dateof Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.

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


Make Of Subassembly


Observations

MaterialAvailability




7.



7.15 Consumables like Distilled Water,

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

8.

Disposal


8.2 Safe Disposal of Battery including recyclingfollowing relevant environmental norms.

CHECK SHEET FOR

TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo LOCO) FOR POH WORKSHOPS




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




Make Of Subassembly


Observations

1. Dis Assembly and Assembly ALCo Maintenancemanual of Woodward

Section 5 of Maintenance

Manual 2. Measurement :

2.29 Physical Examination

ALCo

Wood WardGovernor Test

Record Format No.TSP/F8572-828

and Maintenancemanual of Woodward

Section 6 of Maintenance

Manual

2.30 Barometer Reading

2.31 Pressure Test

2.32 Hydraulic Seals, needle valve seat and buffer piston bypass in both direction2.33 Needle Valve setting

2.34 Speed Setting2.35 Normal Shut Down

2.36 Pressure Requirement2.37 Speed Setting timing

2.38 Lube Oil Shutdown2.39 Air Box Pressure Fuel Limiting

2.40 Load Control2.41 Vane Servo Timing

2.42 Excitation Resistor 2.43 General

2.44 Verification with Cover Installed

3.

Availability Of Tools And Test Stands ALCo3.56 Test Stand for Wood Ward Governor

3.57 Multimeter with valid Calibration3.58 Screw Driver, Plier, Allen Key, Spanner,


Make Of Subassembly


Observations

etc




etc.3.59 Fire Extinguisher of proper class

4.

Availability Of Instructions etc.3.48 Display Chart



3.52 Display of Trouble Shooting Chart MaintenanceManual

Section 4



3.55 Instruction Bulletin issued by RDSO NA


3.57 Specification NA

5. Compliance of Instruction Bulletin NA



4.15 Proper Register is maintained for Governor testing with details of Manufacturer’s

Brand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.


Make Of Subassembly


Observations

4 16 Proper record should be maintained for




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

8.


7.16 Vital Spares


7.18 Consumables like Lub Oil, Cotton wool,etc.

9.

Disposal


9.2 Safe Disposal of scrap and waste including

recycling following relevant environmental norms.

Annexure-6

Check sheet for Quality Audit of Railway Workshop




Check sheet for Quality Audit of Railway Workshop

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

Sl.N

o.

Activity Clause/ Reference Observations

Underframe

01 Underframe to be kept on trestle at lifting lugs.

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

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

04 i. Visual inspection of buffer beam, striker block for any crack or damage,

accordingly repair/weld properly

ii. Check the buffer base bolt holes for size, centers & ovality. Remove the

ovality by welding and redrill if necessary

05 i. Check the cattle guard/rail guard by visual inspection, if any crack/ damage

found then it should be repaired/replaced accordingly

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

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

iv. Modify/ change cattle guard and its support arrangements to plate type on

WDM3A locomotive

RDSO’s Drg. No.

SK.DL-4533/4535 and

DMW’s Drg. No.

2DMW/SK-938

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

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

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

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

welding properly or replaced.




08 i. Visual inspection of welding of Hand rails to underframe. If there is any

crack or damage in weld then reweld it properly.

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

be properly tighten

09 The coupler pocket shall be examined closely for welding cracks/damage in ribs andinspection of welding with underframe. If any crack or wear is found, shall be

repaired or replaced properly.

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

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

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

locomotive under frame

ii. Visual inspection of welding of expressor/ compressor mounting stool. If

there is any welding crack/damage then it should be rewelded or replaced

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

MP.MOD.LD.01.02.11

dated 09.03.2011

12 i. Visual inspection of welding of engine mounting block. If there is any weld

defect carryout required welding or replace it

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

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

or cracks

ii. Filling water/hydraulic test in the gallery carried out

iii. If any leakage is found, shall be repaired accordingly.

14 i. Visual inspection of battery box below side sill/bottom plate for corrosion &

welding cracks in wear plate, end plates & support plate. If there is any crack

or corrosion then it should be rewelded or replaced it

RDSO’s letter

No.SD.DMG.32 Dated

30 07 1996 and SK DL 4436




p

ii. End plate of battery box with fuel tank end shall be modified as per RDSO

Drg. no. SK.DL-4436.

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

iv. Wooden spacer properly placed between the battery

v. All hinges, locks should be in working

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

30.07.1996 and SK.DL-4436

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

deposited inside the tank.

ii. Inspection of fuel tank for any leakage or cracks.

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

replace if found beyond repair.

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

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

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

condition

RDSO’S Investigation

Report No.

MP-473/83 February, 1983

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

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

RDSO’S Investigation

Report No.

MP.INV-8

December, 1995

17 i. Carefully examine the welding around the both center pivots for crack and

also check the surface with magnaflux or die-penetrant method to identify

cracks, if any, which is not visible to naked eyes.

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

RDSO’Drg. No.

SK.DL-2069

18 i. Carefully examine the welding around side load bearers for crack and also

check the surface with magnaflux or die penetrant method to identifycracks, if any, which is not visible to naked eyes.

ii. side load bearer shall be repaired

RDSO’s spec. No. MP.MI-

140/88, Sep’1988 and

RDSO’Drg. No.

SK.DL-2069

19 Loco painting, marking, stenciling;

Apply epoxy primer and PU paint before stenciling

As per extent colour

scheme




20 Center buffer coupler & Draft Gear

Check compliance of RDSO instructions for inspection and maintenance

Modify uncoupling arrangement to make it top operated

G-80

MP.MOD.LD.05.10.11

dated 18.07.2011

21 Side Buffers

Check compliance of RDSO instructions for inspection and maintenance

MP.MI-116/82, Rev.02

22 Loco Cab Railway Board’s letter

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

05.01.2005

23.

1

Driver/Pilot seat

i. Base mounting nut/ bolt and other fasteners should be properly tighten

ii. Motion and its adjuster/locking arrangement/ Ver. & rotational motion

should be in functioning

iii. Cushion & upholstery should be in good condition

23.

2

Side sash / window

i. Sliding glass should freely slide and not cracked

ii. Locking arrangement properly in fuction

iii. Guide rail, weather rubber & glazing rubber should be in good condition

iv. Rear view mirror if applied properly secured with frame and its rotational

movement checked. Mirror should be in good condition

23.

3

Cab door

i. Lock, hinges should be in function




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

closed condition

iii. Assistant seat properly secured and in good working condition

iv. Wiper motors should be in working

23.

4

Cab floor

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

23.

5

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

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

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

good condition

23.

6

Cab light and fan

i. Switches, regulators and connections are properly in function

23.

7

Fire Extinguisher

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

be available

23.

8

Air condition (if applied)

i. Switches, regulator and water drainage properly in function

23.

9

Token pick up arrangement

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

& opening)

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

should be good23.

10

Front look out glass

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

front structure

ii. Covering grill glass properly cover with hinged grill

24 Superstructure

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



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

otherwise change

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

iv. Door panel-sheet should not bend and properly close

25 Radiator compartment & Expansion tank

i.

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

ii. Expansion tank plate should not be corroded

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

rad. Comp. Structure.