MAINTENANCE TOOLS CATALOGUE - Indian Railway · 2018-07-13 · Indian Railways MAINTENANCE TOOLS CATALOGUE FOR DIESEL – ELECTRIC LOCOMOTIVES DIESEL LOCOMOTIVE WORKS VARANASI-221004

Maintenance Tool Catalogue (HHP Locos.) June 2018

Indian Railways

MAINTENANCE TOOLS

CATALOGUE

FOR

DIESEL – ELECTRIC LOCOMOTIVES

DIESEL LOCOMOTIVE WORKS VARANASI-221004 INDIA

dLw


M O D E L E.M.D.

710G3B SERIES TURBOCHARGED

E N G I N E

T O O L S

DIESEL LOCOMOTIVE WORKS VARANASI-221004 (U.P.)

INDIA

dLw


PREFACE

The MAINTENANCE TOOLS CATALOGUE issued by D.L.W. For 710G3B series

engine & locomotive is an effort to list all the tools used in assembly and maintenance in one place. This catalogue has been issued in January 2009 for the first time and shall be continuously updated. The short comings in the catalogue will be corrected in subsequent revisions.

To continuously improve this manual, the feed back from users is essential. The feed back

& suggestions may be sent to SSE/P&T or A.P.E./Tooling or Dy.C.M.E./Tooling, D.L.W., Varanasi. The requirement of any new type of tool, making assembly or maintenance process simpler, is welcome.


INDEX

SECTION CATEGORY

A

CRANKCASE ASSLY.

B

POWER ASSEMBLY

C

CYLINDER HEADS

D

CARRIER PISTON

E

PISTONS

F

TURBO SUPERCHARGER

G

CYLINDER LINER

H

GOVERNOR

J CONNECTING ROD

K COOLING AND LUBRICATION

L FUEL INJECTION EQUIPMENT

N CHASSIS

P ELECTRICAL

Q MISCELLANEOUS


NUMERICAL INDEX OF PART NUMBERS

D.L.W. PART NO.

PAGE D.L.W. PART NO.

PAGE

15510670 C-1

15610202

B-2

15610019

A-4

15610214

A-10

15610020

A-5

15610226 A-11

15610032

A-5

15610238 A-12

15610044

A-6

15610240 A-13

15610056

A-6

15610251 A-12

15610068

A-7

15610263 A-14

15610070

A-7

15610275 A-11

15610081

A-2

15610287 A-15

15610093

A-1 15610299

A-9

15610100

A-1 15610317 A-16

15610111

A-3 15610329

H-1

15610123

A-3 15610330 A-17

15610135

A-2 15610342

A-10

15610147

F-1 15610354 A-21

15610159

A-4 15610366 A-18

15610160

A-8 15610378

F-1

15610172

A-9 15610391

D-1

15610184

B-1

15610196

B-2



D.L.W. PART NO.


PAGE

15610408

E-1 15610627

C-1

15610410

B-3 15610639

C-3

15610421

C-1 15610640

C-2

15610433

A-17 15610652

C-3

15610445

G-1 15610664

A-23

15610457 A-21 15610676

E-1

15610469 A-20 15610688

L-1

15610470

A-6 15610690

C-2

15610482 A-13 15610706

H-1

15610494 A-20 15610718

L-2

15610500 A-24 15610720

L-2

15610512 A-24 15610731

L-2

15610524 A-24 15610743

B-1

15610536 A-22 15610755

C-3

15610548 A-22 15610779

A-23

15610550 A-24 15610780

J-2

15610561

L-1 15610792

A-23

15610573

B-3 15610809

C-4

15610603

C-3 15610810

H-1

15610615

K-1



D.L.W. PART NO.


PAGE

15610822

K-1 15620013

P-1

15610834

G-1

15610846

Q-1 15630018

N-1

15630020

N-1

15610858

Q-1 15630031

N-2

15610860

J-1 15630043

N-2

15610871 C-4 15630055

N-3

15610883

C-2 15630067

N-4

15610895 J-2 15630079

N-4

15610901 E-1 15630080

N-5

15610913 Q-2 15630092

N-5

15610925 L-3

15630109 N-5

15610937

J-1 15630110 N-6

15610949

L-3 15630122

N-6


A C R A N K C A S E A S S E M B L Y


---- A-1 CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.

Tool Use DLW DRG. No.

1. 15610093 Alignment gauge (accessory end)

To check line up of oil pan & crank case on accessory end.

GP01GM0012

2. 15610100 Alignment gauge (camshaft drive end)

To check line up of oil pan & crank case on camshaft drive end.

GP01GM0013

Data subject to change without notice

dlw

×××

×××

× × ×

1

2


---- A-2 CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1. 15610081 Guide pin To line up oil pan to crankcase during assy.

MT01GM0136

2. 15610135 Gauge with dial indicator

To check overhang of oil pan to crankcase.

GP01GM0008


dlw


---- A-3 CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1. 15610111 Line up fixture(big length)

To line up crankcase during assembly with oil pan.

MT01GM0116

2. 15610123 Line up fixture (small length)

To line up crankcase during assembly with oil pan.

MT01GM0137


dlw

1

2


---- A-4 CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610159 Cranking tool For cranking the crank shaft MT01G40081

2 15610019 Lifting hook For lifting accessory drive housing.

MT01GM0044


dlw


A-5

CRANKCASE

REF. No. 01 REF. No. 02

Ref. No.

D.L.W. Part No.


1. 15610032 Jacking tool Mounted into splines of governor drive gear flange & use for lining accessory drive housing on engine assembly line.

MT01GM00111

2. 15610020 Jacking tool Mounted over the end of accessory drive shaft & use for adjusting & lining up accessory drive housing on engine assembly line.

MT01GM0138


dlw

1

2


A-6

CRANKCASE

REF. No. 01

REF. No. 03

Ref. No.

D.L.W. Part No.


1 15610044 Alignment gauge For accessory drive housing alignment use on L.H. water pump holes.

MT01GM0094

2 15610470 Alignment gauge For accessory drive housing alignment use on R.H. water pump holes.

MT01GM0147

3. 15610056 Alignment gauge For accessory drive housing alignment used in oil pump holes

GP01GM0017


dlw

1

1

2

3


A-7

CRANKCASE

REF. No. 02

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15610068 Distance gauge Distance gauge # 2 idler gear stub & L/S & R/S cam shaft.

GP01GM0009

2. 15610070 Master gauge Master for setting gauge no. GP01GM0009(distance gauge # 2 idler gear stub & L/S cam shaft).

GP01GM0238


dlw

2

1


A-8 CRANKCASE

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15610160 Gauge To set up of stubshaft from crankshaft & camshaft assly.

GP01GM0236


dlw


A-9

CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610172 Gauge To check backlash on starter gear & bracket assly.

GP01GM0244

2 *15610299

Reaming Fixture Reaming Fixture For Oil Pan with Starter Motor Bracket.

MS01G40241

* This tool is used by production unit for locos. production. This may not be required by sheds. Data subject to change without notice

dlw


A-10

CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610214 Lifter For lifting Aux. Gen. Assly. MT01GM0106

2. 15610342

C’ clamp For clamping auxiliary generator assly during backlash checking.

SK01GM0114


dlw


A-11

CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610226 Spanner bar Spanner bar to check flexing of accessory drive gear assly.

MT01GM0060

2. 15610275 Locater Locating pad for end crab cyl head at accessory end.

MT01GM0100


dlw

2


A-12

CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610238 Hook and clamp Hook and clamp for lifting lube oil stainer assly.

MT01GM0041

2. 15610251 Lifter For lifting turbo air duct assly.

MT01GM0046


dlw

2


A-13

CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610240

Bracket lifter.

For lifting camshaft drive housing assembly.

MT01GM0045

2. 15610482 Alignment gauge For alignment of camshaft drive housing.

GA01GM0014


dlw

1


A-14

CRANKCASE

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15610263 Timing gauge Timing gauge for end of injection at full rack

MT01G40083


dlw


A-15

CRANKCASE

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15610287

Lifting beam

For lifting engine assly. Without generator.

SK01GM0032


dlw


A-16

CRANKCASE

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15610317

Holding fixture. Holding fix for crankshaft with crank case.

MT01GM0151

Data subject to change without notice.

dlw


A-17 CRANKCASE


Ref. No.

D.L.W. Part No.


1 15610433 Lifter For lifting head frame MT01GM0149

2 15610330

Lifting fixture For lifting aftercooler assly during engine assly..

MT01GM0042


dlw

1


A-18 CRANKCASE

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15610366 Reaming fixture. Ream fix. And plug to be used to ream stub shaft to crank case plate.

MT01GM0153


dlw


A-19

CRANKCASE


REF. No. 03

Ref. No.

D.L.W. Part No.


1. *15610500 Pressing tool Tool for pressing ½” O.D. tube in main frame member of crank case.

MT01GM00145

2. 15610512 Cleaning tool. For cleaning water seal counterbore in liner.

MT05GM0152

3. 15610524 Lifter for bearing caps.

For lifting main bearing caps during assembly.

MT01GM0158

* This tool is used by production unit for locos. production. This may not be required by sheds. Data subject to change without notice.

dlw


A-20 CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610494 Clamp lifter For lifting idler gear stub shaft in horizontal position

MT01GM0141

2. 15610469 Alignment gauge Counterweight alignment at camshaft drive end.

GP01GM0243


dlw


A-21 CRANKCASE


Ref. No.

D.L.W. Part No.


1 15610354 Try square 12” (standard)

Counterweight alignment at accessory drive end..

MT01GM00142

2 15610457 Steel straight edge 36” long.

Counterweight alignment at accessory drive end..

MT01GM00143


dlw

1

2


A-22 CRANKCASE

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610536 Wire brush. For cleaning of piston cooling pipe.

EQ04G40052

2 15610548 Wire brush. For cleaning of c/case lube oil manifold.

EQ01G40083


dlw


A-23

CRANKCASE


REF. No. 03

Ref. No.

D.L.W. Part No.


1. 15610664 Tube (4 req. per cyl.)

To protect crab stud thread. MT01GM0173

2. 15610779 Upper main bearing shell remover.

To remove all upper main bearing shell, except Nos. 5 and 6 on 16-cyl. Engines.

MT01GM0182

3. 15610792 Head frame seal inserter.

For installing seal on square top inside head frame covers.

MT01GM0184

dlw


A-24

CRANKCASE

Insert pressing position Insert removing position REF. No. 01

Ref. No.

D.L.W. Part No.


1. 15610550 Insert pressing & removal tool

For pressing or removing insert in crank case assly.

MT01GM0150


dlw


B P O W E R

A S

S E M B L Y

-


B-1

POWER ASSEMBLY


Ref. No.

D.L.W. Part No.


1. 15610743 Clamp – Conn. Rod positioning.

For positioning connecting rod during assembly /removal in cyl. Liner.

MT01GM0178

2. 15610184 Power assly removing tool.

Clamp lifting piston, liner and cyl. Head assly

MT01GM0097


dlw


B-2

POWER ASSEMBLY

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610196 Piston holder Piston holder for power pack drop.

MT01GM0098

2. 15610202 Clamp For removing & installing cylinder head.

MT05GM0103


dlw


B-3

POWER ASSEMBLY

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610410 Test gauge To check leakage of power pack assly.

MT05GM0112

2. 15610573 Cradle for four power pack.

For assembly of power pack.

SK05GM0052


dlw


C C Y L I N D E R

H E

A D S


C-1

CYLINDER HEAD

REF. No. 01

REF. No. 02

REF. No. 03

Ref. No.

D.L.W. Part No.


1 15510670

Compressor For compressing valve spring (single).

MST/E/5170

2. 15610627 Valve bridge spring compressor.

For compressing spring during assly or disassembly of valve bridge.

MT05GM0169

3. 15610421

Mandrel For installing/ removing cyl. Head exhaust valve guide.

MT05GM0061


dlw


C-2

CYLINDER HEAD


REF. No. 03

Ref. No.

D.L.W. Part No.


1. 15610640 Installer – Hydraulic lash adjuster.

For installing new or qualified hydraulic lash adjuster assemblies in the valve bridge.

MT05GM0171

2. 15610690 Multiple puller for hydraulic lash adjuster.

To remove hydraulic lash adjuster assembly from valve bridge.

MT05G40085

3. 15610883 Reamer for Cylinder test valve seat.

For reaming cylinder test valve seat.

MT01GM0194


dlw


C-3

CYLINDER HEAD



Ref. No.

D.L.W. Part No.


1. 15610652 Trammel – valve height checking.

For checking valve height with a feeler gauge

MT05GM0172

2. 15610639 Lash adjuster minimum clearance gauge

To check minimum clearance between lash adjuster body & the end of valve stem.

MT01GM0170

3. 15610603

Wrench for cylinder test valve.

Used to open and close the cylinder test valve.

MT01GM0165

4. 15610755 Guide-valve bridge snap ring installing.

For installing valve bridge snap ring.

MT05GM0131


dlw


C-4

CYLINDER HEAD

REF. No. 01, 02

Ref. No.

D.L.W. Part No.


1. 15610809 Gauge block for lash adjuster test stand.

To check and adjust the tripping point of switches of lash adjuster test stand.

MT05GM0185

2. 15610871 Tool for oil loading . To charge the lash adjuster with oil and bleed off any air.

MT05GM0193


dlw


D C A R R I E R P I S T O N S


D-1

CARRIER

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15610391 Assembly fixture. Assly. Fix. For connecting rod ,carrier & piston pin.

MT05GM0101


dlw


P I S T O N S

E


E-1 PISTON

REF. No. 01


Ref. No.

D.L.W. Part No.


1 15610408 Guide For piston ring compressor. MT05GM0096

2. 15610676 Eye bolt for lifting piston.

For lifting piston. MT05GM0174

3. 15610901 Expander For HHP engine piston ring. MT05GM0196


dlw


T U R B O

S U P E R C F H A R G E

R


F-1 TURBOCHARGER

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610147 Lifter. Lifter for ‘G’ turbocharger. MT01GM0040

2 15610378 Eye bolt For lifting turbocharger. MT01GM0040/13 Data subject to change without notice

dlw

1

2


C Y L I N D E G R

L I N E R

S


G-1 CYLINDER LINER


Ref. No.

D.L.W. Part No.


1. 15610445 Cylinder liner lifter. (Style-I)

For lifting cyl. Liner assy. With stud.

MT05G40051

2. 15610834 Cylinder liner lifter. (Style-II).

For lifting cyl. Liner assy. With stud.

MT05GM0188


dlw


G O V E R N O R

H


H-1 GOVERNOR

REF. No. 01


Ref. No.

D.L.W. Part No.


1. 15610329

Jacking tool Jacking tool for governor injector link setting.

MT01GM0140

2. 15610706 Wrench

For adjusting shutdown nut – SI & PG governors.

MT02GM0175

3.

15610810 Box Socket Wrench – Half moon 5/8” x ¾”.

For removing two rear nuts retaining governor and water pump mounting bolts.

MT01GM0186


dlw


C J O N N E C T I N G

R O D


J-1 CONNECTING ROD

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15610937

Qualifying Gauge For qualifying connecting rod fork and connecting rod blade.

GI06GM0206

2 15610860 Wrench – basket bolt and nut

For tightening/removing the lower basket bolts and self-locking nuts.

MT01GM0190


dlw


J-2 CONNECTING ROD


Ref. No.

D.L.W. Part No.


1 15610895 Lead wire holder

To check piston to cyl. Head clearance.

MT01GM0195

2. 15610780 Rod for TDC checking.

For checking Top Dead Center.

MT01GM0183


dlw


C K O O L I N G A N L D U B R I C A T I O N


K-1

COOLING AND LUBRICATION

The impeller installer being used to assemble the impeller to the drive shaft in the support housing. The threaded bushing is screwed on pump shaft threads and then, by turning outer portion of installer tool, the impeller is pressed into position. Care must be taken to start the impeller straight on the shaft and to see that the key and key way are aligned.

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1. 15610615 Installer – Water pump impeller.

To assemble the impeller to the drive shaft in the support housing.

MT05GM0168

2. 15610822

Water pump disassembly tool.

For disassembly water pump. MT05GM0187


dlw


F L U E L I N J E C E T Q I U O I N P M E N T


L-1

FUEL INJECTION EQUIPMENT


Ref. No.

D.L.W. Part No.


1. 15610561 Gauge Injector rack setting.

To set the injector racks within the setting range marks on the gauge during engine assly.

GA01GM0015

2. 15610688 Gauge block – 1” To check the accuracy of the injector rack gauge by inserting the master block in the gauge body.

GA01GM0015


dlw


L-2


REF. No. 01


Ref. No.

D.L.W. Part No.


1. 15610720 Injector pry bar

To remove the injector from the cylinder head.

MT01GM0176

2. 15610731 Wrench – injector assembly

For loosening nut of injector assembly.

MT02GM0177

3. 15610718 Pin vise – Pin 0.0”-0.40” dia.

For holding cleaning wires. SP02GM0041


dlw


L-3


Ref. No.

D.L.W. Part No.


1. 15610925 Master injector Kit

Master Injector Kit is used for calibration of MUI test bench to authenticate their resuls.

SP02GM0059

2. 15610949 Test bench for Mechanical Unit Injector.

This test Bench was designed and constructed in order to properly calibrate Mechanical Unit Injector. It enables maintenance personnel to test the efficiency and adjust the calibration of used and overhauled MUI with greater accuracy.

SP02GM0061


dlw


C H A S S I S

N


N-1

CHASSIS

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15630018 Line up tool.

For line up engine to compressor applied to shaft.

MT21GM0002

2. 15630020 Fixture. For doweling generator. MT21GM0006


dlw


N-2

CHASSIS

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1 15630031

Alignment fixture For aligning water coupling (engine) to equipment rack.

MT21GM0031

2. 15630043

Lifter For lifting radiator assly.

MT21GM0124


dlw

2

1


N-3

CHASSIS

REF. No. 01

Ref. No.

D.L.W. Part No.


1 15630055

Lifter For lifting cooling fan assly.

MT21GM0130


dlw


N-4

CHASSIS


Ref. No.

D.L.W. Part No.


1 *15630067

Lifter For lifting long hood assly equip. #1 end (cab end).

MT21GM0134

2. *15630079

Lifter For lifting long hood assly equip. #2 end ( Radiator end)

MT21GM0135

* These lifting tools are used by production unit for locos. production. This may not be required by sheds. Data subject to change without notice

dlw

1

2


N-5

CHASSIS

REF. No. 01


Ref. No.

D.L.W. Part No.


1. 15630080

Alignment device. For alignment of alternator & engine during assly..

MT21GM0159

2. 15630092

Alignment device. For alignment of driving end of auxiliary generator (mounted on shaft dia.)

MT21GM0157

3. 15630109

Alignment device. For alignment of driving end of auxiliary generator (mounted on flange dia.)

MT21GM0156


dlw

XX X XXX

1


N-6

CHASSIS

REF. No. 01

REF. No. 02

Ref. No.

D.L.W. Part No.


1. 15630122

Hydraulic pinion pressing equipment.

For pressing pinion in traction motor shaft.

MT35GM0204

2. 15630110 Lock Bolting & collar cutter.

For bolting & collar cutting of lock bolts of HHP bogies.

SP23GM0055


dlw


E L E C T R I C A L P


P-1

ELECTRICAL

REF. No. 01

Ref. No.

D.L.W. Part No.

Tool Use DLW DRG. No.-

1. 15620013 Socket for diode removing.- For removing diode AR6, 7, 10, 11, 12, 15, 16, and 17.

MT21GM0191


dlw


M I S C E L L A N E O U S Q


Q-1

MISCELLANEOUS


Ref. No.

D.L.W. Part No.


1. 15610846

Crank over tool (manual operation).

To rotate EMD crankshafts on any engine with ring gear including heavy flywheel. Can be applied without removing starters.

SP02GM0043

2. 15610858

Air drive kit

For pneumatic operation of crank over tool SP02GM0043.

SP02GM0044


dlw


Q-2

MISCELLANEOUS

Basic hand tools set required for locomotive maintenance :- D.L.W. Part No.- 15610913 D.L.W. Drg. No.- MT01GM0197 Ref. No.

Tool Description Use

1. Open end wrench 5/16” x 3/8” General use






7. Open end wrench 7/8” x 1” General use

8. Open end wrench 1-1/8” x 1-1/4” General use

9. Socket 7/16”, 1/2” drive General use









18. Socket 1”, 1/2” drive General use

19. Socket 1-1/16”, 1/2” drive General use


dlw


Q-2

MISCELLANEOUS

Ref. No.


21. Ratchet 1/2” drive General use

22. Extension bar. 1/2” drive x 5” long. General use



25. Universal joint. 1/2” drive General use

26. Hinge handle 1/2” drive General use









35. Universal joint. 3/4” drive General use

36. Hinge handle 3/4” drive General use

37. Ratchet 3/4” drive General use

38. Box wrench 3/8” x 7/16” General use



dlw


Q-2

MISCELLANEOUS

Ref. No.


41. Box wrench 15/16” x 1” General use

42. Chisel 1/2” x 6” long. General use

43. Punch 1/4” x 5” long. General use

44. Screw driver Flat tip, round shank(Φ1/4”), 4” shank length.

General use

45. Screw driver Flat tip, round shank(Φ3/8”), 10” shank length.

General use

46. Pry bar 16” long General use

47. Hammer Ball peen type, 16 oz. General use

48. Wrench 8” adjustable General use

49. Diagonal cutting pliers Heavy duty. General use

50. Tool box Single box for Ref. 1 to 49. Data subject to change without notice.

dlw

Documents

MAINTENANCE TOOLS CATALOGUE - Indian Railway · 2018-07-13 · Indian Railways MAINTENANCE TOOLS CATALOGUE FOR DIESEL – ELECTRIC LOCOMOTIVES DIESEL LOCOMOTIVE WORKS VARANASI-221004