rdso.indianrailways.gov.in · Web viewQuality Audit of Diesel Loco POH Workshops CHECK SHEET Item Description Reference Documents, Annexures, Further details on check sheet etc. General

Quality Audit of Diesel Loco POH Workshops CHECK SHEET

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

General

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

Quality of POH: -do-Load Test records:

HP SFC EGT Peak Firing Pressure

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

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

Display of work instructions on shop floor Training of staff Status of record keeping Calibration of gauges/ instruments

Safety items

a. Speed recorder/Indicator Sectionb. Wheel (Wear adapted profile) profile & other defects. c. Brake adjustment, release & and application timings.d. Headlight focus adjustmente. Horn maintenancef. Undergear safety bracketsg. Gauging of Couplersh. 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.

Page 1 of 105 Quality Audit of Diesel Loco POH Workshop

Quality of Subassembly repairs (important items)

a. Expressor/Compressorb. Air Brake Sectionc. Bogie sectiond. Rotating Machines Sectione. Turbo sectionf. Engine Block, Crankshaft and Main bearingsg. Cylinder Head , Piston and Valve sectionh. Radiator section.i. FIP/Injector Sectionj. Governor Sectionk. Electrical Control Sectionl. Battery Sectionm. Under-frame, side buffers, cow catcher,

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

a. Further details of check sheet covered in Annexure 1.b. -do-c. Further details of check sheet covered in Annexure 2.d. Further details of check sheet covered in Annexure 3.e. Further details of check sheet covered in Annexure 4.f. -do-g.h. -do-i. -do-j. Further details of check sheet covered in Annexure 5.k. -do-l. -do-m. Further details of check sheet covered in Annexure 6.

Implementation of modifications

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

Material Availability of critical items Procurement from unapproved sources, if

any.

Any other item As decided by the auditing authority


Annexure-1

CHECK LIST FOR TECHNICAL AUDIT AT POH WORKSHOPS (BRAKE ITEMS)

S.No. Item Parameter Observations1. Whether all the items

prescribed in the schedule is being followed for brake equipment, compressor /Expressor & air dryer or not

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

`

1. Whether maintenance is done as per RDSO MIs or manufacturers MI mentioned in MP.Misc.-140 & 141.

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

every POH schedule. 3. Test benches and rigs 1. Whether the required test bench and rigs are

available or not viz. AB test rack for brake valves, air dryer test bench, compressor/ Expressor test bench etc.

2. Whether, testing is done on above test benches.

3. Calibration of test benches and rigs is being done periodically or not.

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

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

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

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

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


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

movement of material and components.6. Storage of material Whether dust/damp proof environment with

controlled temperature is available for storage of brake equipment and rubber components. Whether rubber components are being stored as per guidelines mentioned in this office letter no. SD.DEV.RBC dated 28.02/07.03.2007 circulated to all Zonal Railways.

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

8. Human Resource development

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

9. Any other observation


Annexure-2CHECK SHEET FOR

CONDUCTING TECHNICAL AUDIT OF BOGIE AT POH WORKSHOP (ALCO LOCOMOTIVE)SN Activity Loco Type Reference Details Observations

1. Overhauling/Inspection Alco Series

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

Cleaning of bogie frame Alignment of bogie frame (including

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

squareness & spacing Crack detection, repair & heat

treatment (Stress relieving) Replacement of manganese liners and

brake rigging bushes

WDM2, WDM3A, WDG3A, & WDM3D/E/F

2. Axle box & journal bearings Cleaning of Axle box & bearings Inspection bearing components Overhauling as per the referred MP.MI

MP.MI-04.004

3. Suspension Springs ( As per MI ) Cleaning of springs Free height of springs Working height of springs Grouping / colour code of springs 100% replace of spring pads ( Happy

Pads)

WDM2, WDM3A, WDG3A, & WDM3D/E/F

As per relevant drawing, MP.IB.VL- 04.19.01 (Rev.01), MP.IB.VL- 04.19.01 (Rev.01) for WDG3A & MP.MI-31 for WDM3D/E/F

4. Friction Snubber Assembly Disassemble snubber (See SK.DL- 1505

for instructions) Check the inside diameter of the friction

sleeve with a “No Go” gauge Figure SK.DL- 3127

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

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

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


Re-assembly of snubber Height measurement and checking for

damping characteristics5. Hydraulic damper

Check the Capacity / Rating of dampers Damper overhauling Testing

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

6. Side Bearer (Rubber spring) Free Height of rubber spring Working height of rubber spring Permanent set of rubber spring Rubber crack length/ de-bonding

WDG3A, & WDM3D/E/F As per drawings No. SK.Vl-127 & 133 &

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

7. Equaliser Beams Checking for cracks Reclamation of hard face as per MC-43

and 92

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

8. Wheel & Axle Assembly Wheel wear measurement i.e. Root

wear, Tread wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spaling etc. ,wheel reprofiling.

Wheel gauge (1596+3/-0.5 mm) Deference in tread diameter of wheels

on same axle, same bogie & same loco

Ultrasonic testing of axles

WDM2, WDM3A,WDG3A, & WDM3D/E/F

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

RDSO procedure MC-71


9. Brake rigging Abnormal wear of brake hangers Replacement of Brake blocks, Pins &

Bushes Replace brake head, tie rod, brake

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

MP.MISC – 141

1. Centre Pivot & Loading Pads Load Pad to Centre Pivot Height

Difference to be maintained.2. Floating type Pivot assembly:

Dismantle complete assembly Clean of the metal component except

rubber bush Inspect for wear, tear and cracks Reassemble pivot block assembly with

change centre pivot bush. In case non-metallic pivot block, 100%

replacement may be carried out.

WDM2, WDM3A

WDG3A, & WDM3D/E/F

MP.IB.VL.02.11.10

SK.VL-128

SK.VL-501, RDSO Modification sheet no. 03.10.09

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

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

11. Re-assembly of bogieMaintain all running gear clearance as per the MI’sMaintain the Lateral clearances between Axle Box and Pedestals

(Ensure attention to wheel and axle assembly 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/F

Over head CraneHydraulic JacksCleaning vatBogie frame manipulatorCrack reclamation facility like gouging, grinding & welding facility etc.Stress relieving furnaceDPT, MPT & UT testing facilitiesSurface table for measurement Spring load-deflection testing machineHydraulic damper testing machineTorque wrench, Go/No Go GaugesHeight gaugesInside 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 critical dimensionsTraining of staff including qualification of weldersMaintenance manual and check sheetsRecord keeping of tools and measuring instruments

Calibration of measuring instruments

14. Record Keeping For Traceability

Annexure-3Page 8 of 105 Quality Audit of Diesel Loco POH Workshop

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

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

S.N REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY

REFERENCE DETAILS

CLAUSE/PARA/ITEM

DETAILS

OBSERVATION

1 MEASUREMENT

Alco (WDM2, WDM3A, WDM3D)

MP-IB.EM.10.31.08

dated 24.10.2008

1.1 TRACTION GEAR & PINIONGear Ratio 18 : 65

Pinion Drg. No. 18 teeth, SKDP3624

Pinion Bedding In Cold Condition

Not less than 95 %

Pinion Advance 2.25 TO 2.45MM

Heating Temperature 190ºC + AMB TEMP.

Span Size On New Pinion Over 3 teeth 88.595 /88.722MM

Condmning Limit On Basis Of Span Size Of Pinion

Over 3 teeth 86.995MM

Gear Drg. No. 65 teeth SKDP3623 & SKDP3775

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

Condmning Limit On Basis Of Span Size Of Gear


Permissible Backlsh With New Set

0.266 - 0.664MM

Condemning Limit On Basis Of Backlash

1.04MM

Crack detection MPMI or Zyglo test


1.2 TRACTION GEAR & PINION

WDG3ATraction Motor Pinion & Gear Assly. of Alco

Loco

MP-MI 129/86 July ‘1986

MP-MI 5

Gear Ratio 18 : 74

Pinion Drg. No. 18 teeth, SKDP3443

Pinion Bedding In Cold Condition

Not less than 95 %

Pinion Advance 2.30 TO 2.45MM

Heating Temperature 185ºC + AMB TEP.

Span Size On New Pinion Over 3 teeth 81.976 /82.093MM

Condmning Limit On Basis Of Span Size Of Pinion


Gear Drg. No. 65 teeth SKDP3444 & SKDP3546

Span Size On New Gear Over 8 teeth 231.36/231.177

Condmning Limit On Basis Of Span Size Of Gear

Over 8 teeth 228.140

Permissible Backlsh With New Set

0.243 - 0.608MM

Condemning Limit On Basis Of Backlash

1.00MM

Crack detection MPMI or Zyglo test

1.3 TA FAN ASSEMBLY

All ALCo locos

MP-IB.EM.01.02.10 dated 11.01.2010.

Outer diameter of TA fan1387.25/1387mm

Bore diameter of TA stator 1392mmBore diameter of TA fan 600.00 / 600.03mmDiameter of fan seating area on barrel.

600.03 / 600.06mm

Width of fan seating at bore 9+1 mmDepth of counter sunk bolts hole 4.5 - 5.5 mmBolt head width 12.3mmBolt head height above fan plate after final assembly should not be more than

6- 7mm

Circumferentially Fan gap on TA 2.50 – 2.75mmTightening torque and wire locking process

28 – 30Kg-m


Tightening torque of M30 (coupling bolt)

170 – 180 kg-m.

Oil catcher thickness (at bottom side)

53.90 to 54.10mm

Bolts strength properties grade R8.8.Sunk type M20 bolts can be used in place of fully

threaded M20 boltsM20 & M30 bolts should be replaced

After 4 – 5 years service of TA

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

150 to 170 °С

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

GO & NO GO thread ring or plug gauge

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

Visual inspection is required

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

In place of (bolts) press fit.

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

As shown in photo

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

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

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

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

TA Gear train assembly Backlash at Steel plate

All ALCo locos

MP.IB.EM.02.12.00dated 10-4-2000.TA GEAR 102T

AG/EG PINION 43TPTU PINION - 43T

0.60mm to 1.40mm0.05mm to 0.12mm

on shaft


2 Carbody cables and Traction Motor cables

All ALCo locos MP.IB.EM.02.03.08,

dated 24-01-2008

And

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

Ensure the following:

Control cables should be replaced fully irrespective of the condition after every 8 years. Power cables should be replaced on condition basis. During POH power cables, which are exposed to oil should be critically examined and replaced if any symptoms of bulging, softening or perishing of insulation at the cable terminals are noticed.

3 AVAILABILITY OF TOOLS AND TEST STANDSAll ALCo locos

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

And

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

2.1 Vernier Callipers2.2 Disc Mike2.3 Filler Gauge

4 INSTRUCTION3.1 Display Chart3.2 Training of Staff3.4Record keeping of tools and measuring

instruments5 TRACEABILITY6 MATERIAL AVAILABILITY

5.1 Vital Spare -NA5.2 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

OBSERVATION

1 MEASUREMENT

Alco LocosTraction Motors

of Alco Loco

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

Maintenance manual issued by OEMs viz. BHEL / CGL.

1.1 PRE-INSPECTIONi) 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 testii) Visual examination of Armature banding. If found

beyond repair, rewind it.iii) Check commutator dia. for condemning size.

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

xxiii) Conduct high potential test as per OEM’s manual1.3 ASSEMBLYi) Motor assembly as per OEM’s manualii) Measure the final Insulation Resistance = 10

Mega ohma) Armature (Shall be > 100 MΩ)b) Inter Pole (Shall be > 100 MΩ )c) Main Pole (Shall be > 100 MΩ)

iii) Measure the end float (Lt. = 0.006” to 0.012”)iv) Check the nose plate condition. If found damaged

or wear out, shall be replaced. v) Conduct the light run test at low, medium & high

rpms on assembled motor & observe for unusual sound using listening rod.

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

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

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

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

x) Apply a coat of paint on motor.


2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 1000V Megger2.2 Filler gauge2.3 HV tester2.4 Dial gauge2.5 Tachometer / Speedometer2.6 Pyrometer2.7 Inside & Outside micrometer /calliper

3 INSTRUCTION3.1 Display Chart3.2 Training of Staff3.3 Record keeping of tools & measuring instruments4 TRACEABILITY5 MATERIAL AVAILABILITY & STORAGE (AC/non-

AC)5.1 Vital Spares5.2 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

OBSERVATION

1 MEASUREMENT

ALCO locos Traction Alternator

of Alco loco

BHEL’sMaintenance Manual for Electrical

Equipment of ALCO loco (Volume-II)

a)Check tightness of all mechanical and electrical connections. Check slip rings and brushes for sparking.

b)BRUSH GEARSpring 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 RINGDiameter (New) – 520 mmMinimum worn out dia – 510 mmSlip ring run our (max) – 0.1 mmSlip ring ovality (max) – 0.1 mm


d)ROTORDiameter- 1003 mmAir gap at pole center – 6 mmRotor bearing - NU330 EM/C4/D150mm x65 mm x 320mm O/DBearing housing dimension – 320-0.005 mm.where outer race sites - - 0.025 mmRadial 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 interferenceShaft bearing seating dia – 150 + 0.055 mm + 0.035 mmFit between inner race & shaft – 0.035 to 0.08 mm interferenceDiametrical slackness of free bearing – 0.15 to 0.18 mmMin. permissible racial clearance when assembled - 0.03 to 0.13 mmMin. diametrical clearance when assembled in the machine – 0.051 mmBull gear wheel I/D – 149.098 + 0.025 mm + 0.0 mmShaft 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 – 170/190Slip 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 TESTSStator (check with 1000V magger) : 2M OhmsRotor(check with 1000V magger) : 2M Ohms

2 AVAILABILITY OF TOOLS AND TEST STANDSa. Bearing retaining ringb. Clamping ringc. Shaft adaptord. Guide sleevee. Frame lifting fixturef. Extractor for bull gearg. Lifting tackleh. Forcing screwsi. Guiding studsj. Spacersk. S.K.F. Oil Pump


l. Studs m. protection sleevesn. Extractor for bearing inner raceo. Extractor foe bearing outer race from

bearing housing

3 INSTRUCTION3.1 Display Chart3.2 Training of Staff3.4Record keeping of tools & measuring

instruments4 TRACEBILITY5 MATERIAL AVAILABILITY

5.1 Vital Spare5.2 Must change items


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 ALCo locos fitted

with TM 4907/C1001

Traction Motor Bearing & Assly. Components of

Alco Loco

MP-IB.EM.14.50.08

dated 20.02.2009

1.1 Verticality of Outer race

1.2 Verticality of Inner race

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

Pinion End 0.075 mm 0.25 mmCommutator End 0.065 mm 0.20 mm

1.4 Radial Clearances of bearings

a) For New BearingsBearing Radial clearance

before mounting (mm)

Radial clearance after mounting (mm)

NU 330 0.165 - 0.215 0.100 – 0.170

NH 320 0.105 – 0.140 0.060 – 0.100

b) In addition to above, max. service radial clearanceNU 330 0.300 mm max. 0.250 mm max.

NH 320 0.190 mm max. 0.150 mm max.

c) Flinger - PE

Bore Dia. 153.130 to 153.155 mm

Total Width 12.65 to 12.70 mm

d) Retaining collar - PE

Bore Dia. 146.015 to 146.040 mm

Total Width 12.65 to 12.70 mm

Outer Dia. 253.225 to 253.290 mm

Hub Outer dia. 177.040 to 177.090 mm


Outer dia. on 2nd 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 - PEBore dia. 319.975 to 319.995 mm

f) End shield - CEBore dia. 214.980 to 215.00 mm

g) Seat diameter on armature shaftFor 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) CELimit – 0.50 mm Aim – 0.42 mm

1.5 Fits & Clearances (BG TM)i) Pinion end bearing

Interferences (Diametrical) Clearances (DiametricalBrg. Sleeve to shaft

0.020 to 0.065 mm

Brg. Sleeve to inner brg. cap

0.635 to 0.750 mm

Flinger to shaft

0.065 to 0.110 mm

Retaining collar to outer brg. cap

0.25 mm (min.)

Inner race to shaft

0.035 to 0.080 mm

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

Retaining collar to shaft

0.090 to 0.135 mm

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


ii) Commutator end bearingInterferences (Diametrical) Clearances (DiametricalBrg. Sleeve to shaft

0.020 to 0.065 mm

Inner brg. Cap to sleeve

0.635 to 0.750 mm

Flinger to shaft

0.065 to 0.110 mm

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

Inner brg. Race to shaft

0.025 to 0.060 mm

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

1.6 Heating temp. of brg. & assly. componentsItem Heating temp.Bearing inner race PE 100 - 110 ºCBearing inner race CE 100 -110 ºCSleeve (PE) 100 -130 ºCSleeve (CE) 100 -130 ºCFlinger (PE) 100 -120 ºCEnd shield (PE) 120 -130 ºCEnd shield (CE) 120 -130 ºCRetaining collar (wiper) 120 -130 ºC

2 AVAILABILITY OF TOOLS AND TEST STANDS2.1 Dial gauge

3 INSTRUCTION3.1 Display Chart3.2 Training of Staff3.3Record keeping of tools and measuring

instruments4 TRACEABILITY5 MATERIAL AVAILABILITY

5.1 Vital Spare - NA5.2 Must change items - NA


Annexure-4

CHECK SHEET FOR QUALITY AUDITOF TURBO SECTION (POH)

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

Workshop/Rly: Audited by: Date of audit:

SN Requirements Loco Type Make Of Subassembly

Reference Details

Clause/Para/Item Details

Observations

1.

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

5.65.6.2.55.6.2.5

Rotor Shaft Dimensions:1.3 Bearing position OD A 39.98 – 40.00 mm

Alco ABB VTC 304 Turbocharger

ABB-Exhaust Gas

Turbocharger VTC 304 A

Comprehensive Manual for Indian Railways issued by M/s ABB

Para 5.2.4.13 &details in 5.4.2.1

1.4 Bearing position OD B 50.987--51.000 mm1.5 Bearing position OD C 56.10-56.20 mm1.6 Piston ring recess S 2.58-2.85 mmWheel Bush1.7 Compressor wheel set OD A 56.10 -56.20 mm

Para 5.2.4.13 &details in 5.4.2.2

1.8 Piston ring recess S 2.58-2.85 mm

1.9 Plain bearing (CE) ID A 54.00-54.06 mm Para 5.2.4.13 &details in 5.4.2.3

1.10 Bearing housing bore ID A 65.00-65.07 mm Para 5.2.4.13 &details in 5.4.2.4


1.11 Floating bush ID (CE) 40.011-40.05 mm Para 5.2.4.13 &details in 5.4.2.5

Floating bush OD (CE) 53.80-53.86 mm1.12 Floating bush OD (TE) 64.82-64.84 mm1.13 Floating bush ID (TE) 51.022-51.07 mm1.14 Thrust bearing width 10.39-10.50 mm Para 5.2.4.13

&details in 5.4.2.6

1.15 Axial bearing width 16.76-16.88 mm Para 5.2.4.13 &details in 5.4.2.7

1.16 Piston ring width 2.00-2.49 mm Para 5.2.4.13 &details in 5.4.2.8

1.17 Thrust bearing press fit measure(K) 170.5-170.63 Para 5.2.4.13 &details in 5.4.2.9

1.18 Axial clearance A 0.11-0.32 mm Para 5.2.4.13 &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 machine2.2 Zyglo testing machine2.3 Casing hydraulic test stand 2.4 Bearing puller (CE & TE)2.5 Torque wrench up to 250 psi2.6 micrometer 2”-3” & 0-4”2.7 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc.3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments


4 Record Keeping For Traceability

5

Material Availability5.1 Vital Spares5.2 Must change items

1

Measurements etc1.1 Nozzle ring and gas inlet casing 0.022-0.032” DiaClearance (Cl)

Alco Alco 720Instruction

ManualALCO

ALCo MI 11126

1.2 Turbine blade and gas inlet casing 0.060-0.092”Dia CI1.3 Nozzle ring and turbine disc 0.124” cold CI1.4 Intermediate casing and impeller 0.017-0.065” longitudinal Clearance (long Cl)1.5 Impeller and Blower inlet 0.035-0.075” long CI1.6 Blower casing end blower inlet measure with bolt loose. Scatting with back of diffuser at lease to 80%(This is only in case when we apply a new diffuser) 0.005-0.020” Long CI (Gap)1.7 Turbine disc and intermediate casing 0.008-0.016” Long CI1.8 Bearing and thrust collar (Blower end) with surface by approx 0.003 less when oil. 0.007-0.018” Thrust CI1.9 Inducer and blower casing 0.091-0.101”Dia CI1.10 Thurst collar and oil seal Blower End 0.014-0.036”Dia CI1.11 Interference between bearing and intermediate casing (blower & Turbine end ) 0.0005-0.0015” DiaCl1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008” Dia CI1.13 Gas inlet casing and intermediate casing inside measurement 0.090-0.098” Dia CI1.14 Impeller and intermediate casing 0.125-0.127” Dia CI1.15 Max allowable clearance between Gas inlet casing & Nozzle ring 0.005” clearance


2

Availability of tools, Test Stands etc.

Alco Alco 720 Instruction Manual

ALCO

2.1 Balancing machine2.2 Zyglo machine2.3 Casing hydraulic test stand 2.4 Oil gallery flushing test stand2.5 Bearing puller (CE & TE)2.6 Sand blast machine for rotor cleaning2.7 Torque wrench up to 250 psi2.8 micrometer 2”-3” & 0-4”2.9 Go-NoGo gauge for checking fix nozzle ring

3

Availability of instructions etc .3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments


5Material Availability5.1 Vital Spares5.2 Must change items


CHECK SHEET FOR TECHNICAL AUDIT OF ENGINE BLOCK, MAIN BEARING (POH)



SN Requirements Loco Type

Make/class Of

Subassembly

Reference Details

Clause/Para/Item/Chapter Details

Observations

1 Removal of Cyl Blocka) 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 InspectionDPT 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 testa) Plate, liftingb) Compound, gasketc) 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) Mandrelg) Magnafluxh) Feeler gaugei) Vernier caliperj) Torque wrench

5.

Availability of instructiona) Display chart.b) Training of staffc) Maintenance manual and check

sheets.d) Record keeping of tools and

measuring instruments.

6. Record keeping traceability.

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


TECHNICAL AUDIT OF CRANK SHAFT (POH)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.



Make/class Of

Subassembly

Reference Details


Observations

1 Removal of Crank Shafta) Removal of Oil

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

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

c) Apply grease and wrap journals and crankpins. Alco

Conventional

ALCO MI 11069 E

Chapter on Maintenance, Instruction of Cylinder Block

.2 Maintenance and Inspection a) Cleaningb) 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” maxd) MB Journal eccentricity limit 0.001” d) Crank pin dia 5.998”- 6.000”e) Crank pin out of roundness limit 0.002”


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

ALCO MI 11067 C

ALCO MI 11069 E &

11067C4.

Availability of tools and testa) Lifting blockb) Lapping toolc) Deflection guage.d) Feeler gaugee) Soft hammerf) Torque wrench

5.

Availability of instructiona) Display chart.b) Training of staffc) 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 FORTECHNICAL 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 water1.3 Inspect head for cracks using Magnaflux1.4 Valve guide to head int 0.002” -0.0005”1.5 yoke to guide int 0.002” -0.0005”1.6 Yoke guide ( press in dim) 3.210” -3.272”1.7 Valve guide ( press in dim) 2.25”1.8 Valve to guide 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 machine2.2 Hydraulic test stand2.3 Nozzle hole sleeve tube expander(Bottom & Top)2.4 Nozzle sleeve extractor2.5 Nozzle sleeve holder2.6 Feeler gauge2.7 Magna flux

3





CHECK SHEET FORTECHNICAL 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 Magnaflux1.4 Zyglo test for checking surface crack1.5 (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 gauge2.2 Zyglo testing machine2.3 Magna flux2.4 Vernier caliper2.6 Piston ring groove gauge

3

Availability of instructions etc3.1 Display Chart3.2 Training of staff3.3 Maintenance manual and check sheets3.4 Record keeping of tools and measuring instruments




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).

2Availability of tools, test stands etc:2.1 Depressor, Spring etc2.2 Grinder

3

Availability of instructions etc:3.1 Display Chart etc.3.2 Training of Staff3.3 Record keeping of tools and measuring

instruments4 Record keeping for traceability:

5Material Availability:5.1 Vital Spare5.2 Must change items


CHECK SHEET FOR TECHNICAL AUDIT OF RADIATOR SECTION (POH)




Make/class Of

Subassembly

Reference Details


Observations

1 Leakage testing

Alco Conventional Alco MI

Chapter on Maintenance, Radiators.

2 Reconditioning of Radiator Chapter on LOCOMOTIVE INSPECTION,

MAINTENANCE AND LUBRICATIONMI 17003 A

2.1 Dismantling 2.2 Cleaning of the core 2.3 Changing of gaskets2.4 Assembly2.5 Testing


3 Cleaning etc

Alco ConventionalAlco MI


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/Cm24.3 Radiator stand 4.4 Fin combing tool 4.5 Radiator immersion tank for cleaning


5

Availability of instructions etc.5.1 Display board etc5.2 Training of staff5.3 maintenance manual and check sheets5.4 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 FORQUALITY 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-assemblyPara on Inspection of partsPara on Inspection of parts

Para on Inspection of parts

Para on Inspection of parts

Para on assembly

Para on Calibration values

1.1 Dis-assembly1.2 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 fixture1.6 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 etc3.4 Record keeping of tools and measuring

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

5.1 Vital Spares5.2 Must change items


CHECK SHEET FORQUALITY AUDIT OF INJECTOR (POH)

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

Workshop/Rly: Audited by: Date of audit:SN Requirements Loco

typeMake /Class/Name of subassembly

Reference details

Clause/Para/Item details Observations

1. Dis-assembly /Measurement/Assembly etc:

Alco Bosch 17 mm Bosch repair

and testing manual

Para on Dis-assemblyPara on Inspection of PartsPara on Inspection of Parts

Para on Assembly

Para on Assembly

Para on Assembly

1.1 Dis-assembly1.2 Inspection of parts1.3 Replace Intermediate disc if found cracked or

if indentation at the nozzle seating end exceeds 0.125 mm.

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

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

1.6 Repetition (chatter) and spray pattern test2. Availability of Tools, Test Stands etc:

List on Service Tools for Injector

2.1 Nozzle needle lift gauge2.2 Feeler gauge2.3 Dial gauge2.4 Nozzle cleaning sleeve2.5 True running gauge2.6 Nozzle tester2.7 Fixture for injector2.8 Socket wrench 2.9 Test oil


3. Availability of instructions etc:3.1 Display of chart3.2 Training of staff3.3 Maintenance manual and check sheet3.4 Record keeping of tools and measuring instruments

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

5.1 Vital spares5.2 Must change items


CHECK SHEET FORTECHNICAL AUDIT OF PTLOC SECTION (POH)




Make Of Subassembly

Reference Details Clause/Para/Item/chapter

Details

Observations

1

Dis-assembly /Measurement/Assembly/Test etc.1.1 Overhauling procedure

1.2 Plate Pack Length1.3 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

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

3





Annexure-5

CHECK SHEET FOR TECHNICAL AUDIT OF POH WORKSHOP

Item: Electrical control MBCS + MCBG + E type

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

Workshop/Rly: Audited by: Date of audit:SN Requirements Loco

TypeMake Of

Sub assembly

Reference Details Clause/Para/ Item Details

Observation

1. No. of Trained personnel with experience

MBCS trained personnel

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

Shed doc

3. Practices for Handling of the electronic cards and storing

ALCo Doc No:IM 53 for MBCS Medha

4. Availability of crimping tool & connector pin details

ALCo Doc No. :IM 53 for MBCS Medha

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

DLW/Alco/AMC (micro)/01

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

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

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

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. Measurement11.1 Standards for load box examination of

D E locomotivesMP MI -10 (Rev.0.02)August, 2003

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

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


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

Sept 1997

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

ALCo IM-59

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

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

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

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

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

11.7 Check ground circuit leakage current -do-11.8 Check mv drop test of WSR (E type)12 Availability Of Tools And Test Stands For MBCS locos- Test stands

are not provided by MBCS supplier. Items are covered under AMC.

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

13.1 Display of DOS and DONTS, TROUBLE SHOOTING Chart, DISPLAYCHART & FLOW CHART

As per OEM manual


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

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

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

Medha1. Operational manual for drivers Doc.No.IM-38 Rev 3.0 July 072. Maintenance Instruction manual Doc. No.IM-53 Rev 0.0 Sept’20083. 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 1032Siemens1. KM DIREKT scheme no. DRG. No. 3FZE-009612. SIM CONTROL scheme no. DRG. No. 4SIM-2005093. SIMCONTROL Operator’s Instructions &Guidelines user manual ver.2.00 dated 10.12.094. 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)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Control voltage 72+1 VDC All Diesel

Electric Locomo tives (ALCo)

Drawing No. EL/PT/0640/

Altr R3Part

No 12145439

Technical details given in the

drawing

1.2 Max pick up volt 48v , 1.3 Main contact gap12-14.5mm, 1.4 Wipe 8-10 mm, 1.5 Contact pressure( kgf) initial 1.82-2.95,final 5.45-

7.25, 1.6 Operating coil resistance at 20 deg c 104 -116

ohm, (approx.),1.7 Interlock (gpr type : 9-41n, 3no+3nc) 1.8 Contact gap 9.5-10.5 mm, 1.9 Interlock contact pressure 220-300g.

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

(Rev-01),May’10

3.10.e

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

contacts shorted together

IEC 60571

as per clause 10.2.9



Make Of Subassembly

Reference Details


Observations

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

2.0 Availability of tools and stands2.1 Multimeter with proper calibration2.2 Vernier calipers with valid calibration2.3 Go- No gauge suiting to different cantactors2.4 Dial gauge of different scale and resolution as

suited to respective contactor2.5 Source which can provide minimum current at

respective voltage (24 V – 72 V DC)2.6 Variac2.7 Meggar2.8 Oscilloscope

2.9 Screw Driver, Plier, Spanner Set, etc.3. Availability Of Instructions etc.

3.1 Display Chart3.2 Flow Chart 3.3 Training of staff3.4 Proper Display of Do’s and Don’t3.5 Maintenance manual and check sheets3.6 Record keeping of tools and measuring

instruments 3.7 Instruction Bulletin issued by RDSO3.8 Maintenance Manual of Manufacturer3.9 Specification

4. Compliance of Instruction Bulletin 5. Follow of Maintenance Manual of Manufacturer6 Record Keeping For Traceability

4.1 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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



Make Of Subassembly

Reference Details


Observations

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

7. Material Availability7.1 Vital Spares

7.2 Must change items7.3 Consumables

8. Disposal8.1 Segregation of Workable and Non-Workable

equipments and proper house keeping8.2 Proper Disposal of Materials including recycling

following relevant environmental norms


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




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Short time control voltage -72+1v dc, All Diesel

Electric Locomotives (ALCo)


Altr R3 Part

No 121410510


drawing

1.2 Control voltage -24vdc,1.3 Max pick up volt 24v 1.4 Main contact gap12-14.5 mm, 1.5 Wipe 8-10 mm,, 1.6 Contact pressure( kgf) initial 1.82-2.95, final 5.45-

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

20.5ohm,1.8 Interlock (gpr type : 9-41n, 3no+3nc) 1.9 Contact gap 9.5-10.5 mm, 1.10 Interlock contact pressure 220-300 gm , 1.11 .)1.12 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08 (Rev-

01),May’10

3.10.e


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

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

and earth

as per IEC 60571

clause 10.2.9

2.0 Availability of tools and stands2.10 Multimeter with proper calibration2.11 Vernier calipers with valid calibration2.12 Go- No gauge suiting to different contactors2.13 Dial gauge of different scale and resolution as


respective voltage (24 V – 72 V DC)2.15 Variac2.16 Megger2.17 Oscilloscope







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

7. Material Availability7.4 Vital Spares7.5 Must change items7.6 Consumables





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




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Short time control voltage 72+1 v dc, All Diesel



Altr R3Part

No 12141100


drawing

1.2 Control voltage 24vdc,1.3 Max pick up volt 24 v1.4 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), 1.8 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08 (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 stands2.19 Multimeter with proper calibration2.20 Vernier calipers with valid calibration2.21 Go- No gauge suiting to different contactors2.22 Dial gauge of different scale and resolution as

suited to respective contactor

2.23 Source which can provide minimum current at respective voltage (24 V – 72 V DC)

2.24 Variac2.25 Megger

2.26 Oscilloscope

2.27 Screw Driver, Plier, Spanner Set, etc.

3. Availability Of Instructions etc.3.19 Display Chart3.20 Flow Chart 3.21 Training of staff3.22 Proper Display of Do’s and Don’t3.23 Maintenance manual and check sheets3.24 Record keeping of tools and measuring

instruments

3.25 Instruction Bulletin issued by RDSO3.26 Maintenance Manual of Manufacturer3.27 Specification

4. Compliance of Instruction Bulletin 5. Follow of Maintenance Manual of Manufacturer


6 Record Keeping For Traceability4.5 Proper Register is maintained for Contactors with

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







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




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Max pick up volt 48v All Diesel



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 ,


(Rev-01),May’10

3.10.e

1.7 IR Value as per clause 10.2.9 of IEC 60571 between(i)Main contacts of contactor(ii) Coil and magnet frame

IEC 60571




respective voltage (24 V – 72 V DC)



Make Of Subassembly

Reference Details


Observations

2.33 Variac2.34 Meggar2.35 Oscilloscope









equipments and proper house keeping



Make Of Subassembly

Reference Details


Observations

8.8 Proper Disposal of Materials including recycling following relevant environmental norms


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




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 control voltage 72+1v dc,1.2 Max pick up volt 48 v

All Diesel Electric Locomotives (ALCo)

Radiator Fan contactor


Altr R3Part

No 12140235


drawing

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

t 1.4 Wipe 0.8-1.6 mm, No 121402351.5 Contact pressure( gmf) initial 80-150, final 180.-

280, Altr R3

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

Drawing No. EL/PT/0638/Par

t 1.7 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


suited to respective contactor



Make Of Subassembly

Reference Details


Observations

2.41 Source which can provide minimum current at respective voltage (24 V – 72 V DC)

2.42 Variac2.43 Meggar2.44 Oscilloscope








8. DisposalPage 59 of 105 Quality Audit of Diesel Loco POH Workshop


Make Of Subassembly

Reference Details


Observations

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

8.10 Proper Disposal of Materials including recycling following relevant environmental norms


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




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Control voltage 72+1v dc, All

Diesel Electric Locomotives (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) initial 1.6 1.82-2.95,final 5.45-7.25,1.7 operating coil resistance at 20 deg c 104 -116

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

gap 9.5-10.51.9 Interlock contact mm pressure -220-300gm.,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.(iv) Contacts of interlocks(v) Interlocks and coil shorted together and main

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

and earth

as per IEC 60571

clause 10.2.9



Make Of Subassembly

Reference Details


Observations



respective voltage (24 V – 72 V DC)2.51 Variac2.52 Meggar2.53 Oscilloscope














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




Make Of Subassembly

Reference Details


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 contacts b) interlocks and MV c) interlocks and MV shorted together and earth d) contacts and interlocks e) Interlocks and MV shorted together and main

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

shorted with MV and interlocks.

IEC 60571 as per clause 10.2.9

2.0 Availability of tools and stands2.55 Multimeter with proper calibration



Make Of Subassembly

Reference Details


Observations

2.56 Vernier calipers with valid calibration2.57 Go- No gauge suiting to different cantactors2.58 Dial gauge of different scale and resolution as


respective voltage (24 V – 72 V DC)2.60 Variac2.61 Lever of 122.5 mm for measuring initial and final

pressure.2.62 Compresor with air reservoir2.63 Megger2.64 Oscilloscope














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




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Auxiliary contacts 4, change over type, ALCo Drawing No.

EL/PT/0649/ Altr R5

Part 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 at

20degC-526 to 594 Ohms.


(Rev-01),May’10

3.10.e



Make Of Subassembly

Reference Details


Observations

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

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

together on each side (Main contacts open)

(iv) All control and Aux. circuit

IEC 60571 as per clause 10.2.9




pressure.2.73 Compresor with air reservoir2.74 Megger2.75 Oscilloscope



instruments 3.70 Instruction Bulletin issued by RDSO3.71 Maintenance Manual of Manufacturer3.72 Specification Spec No.



Make Of Subassembly

Reference Details


Observations

MP.0.04.00.08 (Rev-

01),May’10


4.15 Proper Register is maintained for 6 M Reverser with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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






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




Make Of Subassembly

Reference Details


Observations

1. Measurement1.1 Auxiliary contacts 4 change over type, All

Diesel Electric Locomotives (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 20degC 1.11 615+5% ohm. for BHELTYPE : M5027MV2 1.12 ROTEX TYPE: 3118AV1-3 coil resistance at

20degC 526 to 594 Ohms1.13 Contact impression (should be min 80%) Spec No.

MP.0.04.00.08 (Rev-01), May’10

3.10.e

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

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

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

IEC 60571


2.0 Availability of tools and stands2.77 Multimeter with proper calibration2.78 Vernier calipers with valid calibration


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



pressure.2.84 Compresor with air reservoir2.85 Meggar2.86 Oscilloscope




4. Compliance of Instruction Bulletin

5. Follow of Maintenance Manual of Manufacturer





7. Material Availability7.25 Vital Spares

7.26 Must change items7.27 Consumables





CHECK SHEET FORTECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERAL PURPOSE RELAY (ALCo LOCO)




Make Of Subassembly

Reference Details


Observations

1. Measurement1.10 Nominal operating voltage (50-80 V) All Diesel


BHEL, AAL and IEI

Spec No. MP.0.400.03

(Rev-01) Nov’08

Clause 3.1.11.11 Pick up voltage (Must Operate), max 48V Clause 3.2 (ii)1.12 Drop out Voltage Min 7.5 V1.13 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 in

position 0.0 to 0.1Clause 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 IEC 60571

Clause 10.2.9

2.0 Availability of tools and stands2.88 Multimeter with proper calibration2.89 Vernier calipers with valid calibration2.90 Go- No gauge

2.91 Dial gauge

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



Make Of Subassembly

Reference Details


Observations

2.93 Variac2.94 Meggar2.95 Screw Driver, Plier, Spanner Set, etc.2.96 Sufficient set of tool and gauges provided by

manufacturer3. Availability Of Instructions etc.


instruments 3.88 Instruction Bulletin issued by RDSO3.89 Maintenance Manual of Manufacturer3.90 Specification Spec No.

MP.0.400.03 (Rev-01) Nov’08


4.19 Proper Register is maintained for GP Relay with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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

7. Material Availability7.28 Vital Spares7.29 Must change items




Make Of Subassembly

Reference Details


Observations




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

Reference Details


Observations

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

quality of workman ship etc

ALCo

RDSO specification No. ELRS/SPEC/DC

-DC Converter

/0021 ,Rev.01 Sept 2004

Clause No.6.3.1

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

-DC Converter

/0021 ,Rev.01 Sept 2004

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

RDSO specification No. ELRS/SPEC/DC

-DC Converter

/0021 ,Rev.01 Sept 2004

Clause No. 2.2 and 2.3

2. Availability Of Tools And Test Stands ALCo 3.1 Multimeter with Valid Calibration



Make Of Subassembly

Reference Details


Observations

3.2 Test stand for measurement and testing.

3.3 Screw Driver, Plier, etc.

3.4 Fire Extinguisher of proper class

3

Availability Of Instructions etc.

3.91 Display Chart

3.92 Flow Chart

3.93 Training of staff

3.94 Proper Display of Do’s and Don’t

3.95 Maintenance manual and check sheets

3.96 Record keeping of tools and measuring instruments

3.97 Instruction Bulletin issued by RDSO NA

3.98 Maintenance Manual of Manufacturer

3.99 Specification




4.21 Proper Register is maintained for DC-DC Converter (500 W) with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.



Make Of Subassembly

Reference Details


Observations

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

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

7.

Material Availability7.30 Vital Spares

7.31 Must change items

7.32 Consumables

8. Disposal

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

8.2 Safe Disposal including recycling following relevant environmental norms.


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


Workshop /Rly: Audited by: Date of audit:


Make Of Subassembly

Reference Details Clause/Para/Item Details

Observations


quality of workman ship , water tightness etc

ALCo

RDSO specification No.

ELRS/SPEC/LFL/0017 Rev 1 Sept 04

Clause No.6.3.

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


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

RDSO specification No.


Clause No. 2.3.3

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


Clause No. 2.4.1

1.5 Output regulated Voltage RDSO specification No.


Clause No. 2.4.5

1.6 Check Repeater indication properly RDSO specification No.


Clause No.2.4.3.1

2. Availability Of Tools And Test Stands ALCo 2.1 Voltmeter with Valid Calibration2.2 Ammeter with Valid Calibration



Make Of Subassembly


Observations

2.3 Lux Meter with proper Calibration


2.5 Stop Watch



3


3.1 Display Chart

3.2 Flow Chart





3.7 Instruction Bulletin issued by RDSO


3.9 Specification RDSO specification No.






Make Of Subassembly


Observations


6.1 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.

6.2 Proper record should be maintained for each LED Flasher Light

6.3 LED Flasher Light with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.

7.



7.3 Consumables such as fuses , toggle switches etc

8. Disposal




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




Make Of Subassembly

Reference Details


Observations


quality of workman ship , water tightness etc.ALCo RDSO

specification No. ELRS/Spec/PR/

0022 (REV-1 Oct -2004)

Clause No.6.3.

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

0022 (REV-1 Oct -2004)



Make Of Subassembly

Reference Details


Observations

2.6 Lux Value- for all input voltage range 45

V-90 V

RDSO specification No. ELRS/Spec/PR/

0022 (REV-1 Oct -2004)

Clause No. 2.4.3

2.

Availability Of Tools And Test Stands3.5 Multimeter with Valid Calibration ALCo3.6 Lux Meter with proper Calibration




3 Availability Of Instructions etc.

3.100 Display Chart

3.101 Flow Chart




Lamp Lux level at 1 Meter

Lux level at 3 Meters

RED 75 LUX 7 LUX

WHITE 75 LUX 7 LUX


Make Of Subassembly

Reference Details


Observations





3.108 Specification




4.24 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.

4.25 Proper record should be maintained for each LED Marker Light

4.26 LED Marker with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.

7.



7.35 Consumables such as fuses , toggle switches etc

8. Disposal



Make Of Subassembly

Reference Details


Observations




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

FOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES




Make Of Subassembly

Reference Details Clause/Para/Item

Details

Observations

A. Stick Type / Improved Stick type Master controller1. Measurement:

1.1 Visual checkingALCo

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

(AMC/R2) Make

BHEL Test programme document no. 865476 dt

Clause 1.1

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

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

Clause 1.2

1.3 Contact pressure, 1.4 Cam sequence and 1.5 Mechanical interlocking 1.6 Working of Throttle handle Clause 1.3

2. Test :

2.1 Insulation Resistance test: BHEL Test programme

document no. 865476

Clause 5.0

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


2.

Availability Of Tools And Test Stands

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

(AMC/R2) Make

3.10 Voltmeter with Valid Calibration3.11 Venier Caliper with Valid Calibration3.12 Megger with Valid Calibration3.13 Digital Multimeter with Valid Calibration3.14 Potentiometer with Valid Calibration3.15 Height gauge with Valid Calibration3.16 High Voltage Tester with Valid Calibration3.17 Bore Dial gauge with Valid Calibration3.18 Ammeter with Valid Calibration3.19 GO and NO GO Gauge3.20 Screw Driver, Plier, Required spanner set etc.3.21 Test stand for measurement and testing.3.22 Fire Extinguisher of proper class

3


3.109 Display Chart

3.110 Flow Chart

3.111 Throttle sequence chart

3.112 Mechanical interlocking Chart








3.119 Specification




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

4.28 Proper record should be maintained for each

4.29 EMD Master Controller with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.

7.



7.38 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)




Make Of Subassembly

Reference Details


Observations


quality of workman ship etcALCo RDSO

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

Sept 2004)

Clause No.6.3.1

2.8 Functional Check –ON/OFF properly

2.9 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

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

Clause No. 4.A.2

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

Clause No. 4.A.3

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

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

Clause No. 4.A.4

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

IB NO. MP.IB.EC.

Clause No. 4.A.5



Make Of Subassembly

Reference Details


Observations

01.08.06 DATE: 27-12-06

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

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

Clause No. 4.A.6

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

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

Clause No. 4 B

2.16 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 Stands3.23 Voltmeter with Valid Calibration3.24 1.A standard portable lux measuring

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

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







Make Of Subassembly

Reference Details


Observations

3.120 Display Chart

3.121 Flow Chart





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


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

Sept 2004)4. Compliance of Instruction Bulletin



4.30 Proper Register is maintained for Twin Beam Head Light with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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



Make Of Subassembly

Reference Details


Observations

4.32 Twin Beam Head Light /Bulbs with the measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.

7.



7.41 Consumables like bulbs , Reflector

8.

Disposal


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


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

WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVESDuring the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.



Make Of Subassembly


Details

Observations

1. Measurement :2.17 Physical Examination

ALCo

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

Clause 8.5

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

Clause 8.6

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

Clause 8.7

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

Clause 8.7

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

Clause 8.8

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

Clause 8.9

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

Clause 6

2.25 Polarity and absence of Short Circuit2. Availability Of Tools And Test Stands ALCo

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

3.30 Electrolyte mixing tank-Motorized type preferred3.31 Voltmeter with Valid Calibration3.32 Thermometer with Valid Calibration3.33 Hydrometer with Valid Calibration3.34 Ammeter with Valid Calibration



Make Of Subassembly


Details

Observations

3.35 Multi meter with Valid Calibration3.36 Clamp Meter3.37 Rubber syringe 3.38 Battery Charger(Preferred Constant Current

Chargers)3.39 Battery Discharger (Preferred Electronic type)3.40 Required Lab for testing of Acid and DM water3.41 Screw Driver, Plier, Spanner Set etc.3.42 Test stand for measurement and testing (Concrete

Platform covered with Acid Resistant FRP sheets/coating for keeping batteries –charge /Discharge.)

3.43 D.M.Water Plant

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


3.46 Fork Lift

3.47 Hand trolley

3.48 Battery lifting crane on test bench

3.49 Plastic Pallet for storing Battery

3.50 Rubber Apron

3.51 Rubber Gloves

3.52 Goggles


3.129 Display Chart



Make Of Subassembly


Details

Observations

3.130 Flow Chart





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


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



6.

Record Keeping For Traceability

4.33 Proper Register is maintained for Battery checking with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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

7.Material Availability

7.42 Vital Spares7.43 Must change items



Make Of Subassembly


Details

Observations

7.44 Consumables like Distilled Water, Sulphuric Acid (for Lead Acid Battery), Lugs, Rubber Mat etc.

8.

Disposal8.1 Segregation of Working and Non-Working

equipment and Proper House Keeping8.2 Safe Disposal of Battery including recycling

following relevant environmental norms.


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

IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES




Make Of Subassembly


Observations

1. Dis Assembly and Assembly ALCo Maintenance manual of Woodward

Section 5 of Maintenance

Manual2. Measurement :

2.26 Physical Examination

ALCo

Wood Ward Governor Test

Record Format No. TSP/F8572-828

and Maintenance manual of Woodward

Section 6 of Maintenance

Manual

2.27 Barometer Reading2.28 Pressure Test2.29 Hydraulic Seals, needle valve seat and buffer

piston bypass in both direction2.30 Needle Valve setting2.31 Speed Setting2.32 Normal Shut Down2.33 Pressure Requirement2.34 Speed Setting timing2.35 Lube Oil Shutdown2.36 Air Box Pressure Fuel Limiting2.37 Load Control2.38 Vane Servo Timing2.39 Excitation Resistor2.40 General

2.41 Verification with Cover Installed

3.

Availability Of Tools And Test StandsALCo3.53 Test Stand for Wood Ward Governor

3.54 Multimeter with valid Calibration3.55 Screw Driver, Plier, Allen Key, Spanner,

etc.3.56 Fire Extinguisher of proper class



Make Of Subassembly


Observations

4.

Availability Of Instructions etc.3.138Display Chart3.139Flow Chart 3.140Training of staff3.141Proper Display of Do’s and Don’t

3.142Display of Trouble Shooting Chart Maintenance Manual

Section 4

3.143Maintenance manual and check sheets

3.144Record keeping of tools and measuring instruments

3.145Instruction Bulletin issued by RDSO NA

3.146Maintenance Manual of Manufacturer

3.147Specification NA

5. Compliance of Instruction Bulletin NA



4.35 Proper Register is maintained for Governor testing with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.

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

Material Availability



Make Of Subassembly


Observations

8.7.45 Vital Spares

7.46 Must change items7.47 Consumables like Lub Oil, Cotton wool,

etc.

9.

Disposal


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


Annexure-6

Check sheet for Quality Audit of Railway Workshop

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

Sl.No.

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 mmiii. Ensure minimum clearance of rail guard from R/L. to be 115 mmiv. Modify/ change cattle guard and its support arrangements to plate type on

WDM3A locomotive

RDSO’s Drg. No.

SK.DL-4533/4535 and DMW’s Drg. No. 2DMW/SK-938

06 Visual inspection of welding of gussets/ stiffeners in back of buffer beam transferring buffing force from buffers to maintain longitudinal box section. If any crack /damage is found, it shall be repaired accordingly.


07 Visual inspection of Footstep for welding crack/damage and shall be repaired by welding properly or replaced.

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

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

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

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

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

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

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

MP.MOD.LD.01.02.11 dated 09.03.2011

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

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

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

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


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

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

iii. Mounting block, nut & bolt should be properly secured and tighteniv. Wooden spacer properly placed between the batteryv. All hinges, locks should be in working

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

RDSO’s letter No.SD.DMG.32 Dated 30.07.1996 and SK.DL-4436

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

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

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

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

RDSO’S Investigation Report No.

MP-473/83 February, 1983

16 Visual inspection of underframe box section and side sill welding. If there is any crack or damage, weld it properly with low hydrogen welding electrode.

RDSO’S Investigation Report No.

MP.INV-8

December, 1995

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

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

RDSO’Drg. No.

SK.DL-2069

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

ii. side load bearer shall be repaired

RDSO’s spec. No. MP.MI- 140/88, Sep’1988 and

RDSO’Drg. No.

SK.DL-2069


19 Loco painting, marking, stenciling;

Apply epoxy primer and PU paint before stenciling

As per extent colour scheme

20 Center buffer coupler & Draft Gear

Check compliance of RDSO instructions for inspection and maintenance

Modify uncoupling arrangement to make it top operated

G-80

MP.MOD.LD.05.10.11 dated 18.07.2011

21 Side Buffers

Check compliance of RDSO instructions for inspection and maintenance

MP.MI-116/82, Rev.02

22 Loco Cab Railway Board’s letter No.2000/M(L)/466/9 dated 05.01.2005

23.1 Driver/Pilot seat

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

should be in functioningiii. Cushion & upholstery should be in good condition

23.2 Side sash / window

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

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

movement checked. Mirror should be in good condition


23.3 Cab door

i. Lock, hinges should be in functionii. Glass, weather strip should be in good condition and door properly sealed in

closed condition iii. Assistant seat properly secured and in good working conditioniv. 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 conditionii. Perforated aluminium sheet , insulating material, fasteners should be in

good condition23.6 Cab light and fan

i. Switches, regulators and connections are properly in function23.7 Fire Extinguisher

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

23.8 Air condition (if applied)

i. Switches, regulator and water drainage properly in function23.9 Token pick up arrangement

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

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

23.10

Front look out 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 changeii. Check hinges and door locks for proper working and repair if possible

otherwise changeiii. Check for water leakage at various joints and renew weather stripes/ceilingsiv. Door panel-sheet should not bend and properly close

25 Radiator compartment & Expansion tank

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

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