Engineering Standard Engineering Standard Rolling Stock ESR 0200 SPECIFICATION FOR THE RESTORATION OF 48 CLASS LOCOMOTIVES Version 1.0 Issued June 2010 Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp. Owner: Chief Engineer Rolling Stock Approved by: Stephen White, Technical Specialist Rolling Stock Performance Standards Authorised by: Michael Uhlig, Manager, Rolling Stock Access Integrity UNCONTROLLED WHEN PRINTED Page 1 of 25
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Transcript
Engi
neer
ing
Stan
dard
Engineering Standard Rolling Stock
ESR 0200
SPECIFICATION FOR THE RESTORATION OF 48 CLASS
LOCOMOTIVES
Version 1.0
Issued June 2010
Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.
Owner: Chief Engineer Rolling Stock
Approved by:
Stephen White, Technical Specialist Rolling Stock Performance Standards
Authorised by:
Michael Uhlig, Manager, Rolling Stock Access Integrity
UNCONTROLLED WHEN PRINTED Page 1 of 25
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
Revision Date Summary of change (RSS 0200) 1.0 August 2007 1.1 May 2008 RRS references amended (ESR 0200) 1.0 June 2010 Reformatted and renumbered
Summary of changes from previous version
Summary of change Section NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’ to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the ‘Document control’ page carries over to a second page separate pages must be used for ‘Contents’ and ‘Document control’
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
2.1 General procedures, dimensions & clearances ........................................................................5 3 Mandatory work.................................................................................................................................5
3.1 Strip down .................................................................................................................................5 3.2 Structure....................................................................................................................................5 3.3 Engine room..............................................................................................................................6 3.4 Pipe work ..................................................................................................................................6 3.5 Body ..........................................................................................................................................6
3.5.1 General.........................................................................................................................6 3.5.2 Engine compartment ....................................................................................................6 3.5.3 Pilot area ......................................................................................................................6
3.6 Drawgear...................................................................................................................................7 3.7 Engine, generator and auxiliary components............................................................................7
3.7.1 Overhauled engine to be supplied by RailCorp ...........................................................7 3.7.2 Overhauled engine not supplied by RailCorp ..............................................................7
3.11 Alignment ................................................................................................................................11 3.11.1 Engine to compressor ................................................................................................11 3.11.2 Compressor to radiator fan drive................................................................................11
3.19.1 Brake equipment system blow out Procedure ...........................................................13 3.19.2 Handbrake..................................................................................................................14 3.19.3 New equipment ..........................................................................................................14 3.19.4 Modifications ..............................................................................................................14 3.19.5 Brake & vigilance control system tests.......................................................................14
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
3.20 Main reservoirs........................................................................................................................14 3.21 Cab..........................................................................................................................................15
3.21.1 Train radio ..................................................................................................................15 3.22 Fuel tank .................................................................................................................................15 3.23 Filters.......................................................................................................................................16 3.24 Sandboxes ..............................................................................................................................16 3.25 Vigilance control box ...............................................................................................................16 3.26 Horn assembly ........................................................................................................................16 3.27 Guards.....................................................................................................................................16 3.28 Steps and handrails ................................................................................................................17 3.29 Painting ...................................................................................................................................17 3.30 Other equipment .....................................................................................................................17
4 After inspection work......................................................................................................................17 4.1 Inspection................................................................................................................................17
5 Load testing .....................................................................................................................................17 5.1 Test report ...............................................................................................................................18
6 Road trial ..........................................................................................................................................18 7 Standard variations.........................................................................................................................19
7.1 Air conditioning........................................................................................................................20 7.2 Catalytic converter ..................................................................................................................20
8 Equipment to be supplied by RailCorp .........................................................................................20 8.1 Engine .....................................................................................................................................20 8.2 Catalytic converter ..................................................................................................................20 8.3 AEI tags...................................................................................................................................20 8.4 Train radios .............................................................................................................................20
1 Purpose The purpose of this standard is to describe RailCorp’s minimum requirements for the restoration (overhaul) of 48 class locomotives.
2 Scope This document outlines the minimum requirements with respect to the restoration and overhaul of the locomotive to perform reliably until its next major component change out. Also included are equipment cleaning, repair, testing and other requirements as stated.
2.1 General procedures, dimensions & clearances Unless otherwise stated all work will be carried out as per procedures in A E Goodwin Ltd Instruction Manual for the 48 class locomotives. TPI 871, ALCO Maintenance Information Bulletins and relevant ESR instructions. If one standard contradicts another then Superintendent will make a determination as to the standard that will apply.
3 Mandatory work
3.1 Strip down Remove all rubbish from the locomotive.
Remove the engine and all equipment that is to be overhauled.
Thoroughly clean the underframe, body and all other equipment.
3.2 Structure The locomotive frame is to be examined to ensure there is no major structural damage or corrosion. Any damage must be reported to RailCorp. Particular attention shall be made in examining load bearing surfaces.
Inspect the centre castings. All welds shall be die penetrate and/or magnetic particle tested in accordance with ESR 0300.
Inspect the centre casting wear plates for excessive wear in the oil lubricating grooves.
Inspect the elephant’s feet. All welds shall be die penetrate and/or magnetic particle tested in accordance with ESR 0300.
Inspect the elephant’s feet wear plates for excessive wear in the oil lubricating groove.
The engine well and fan room must be thoroughly examined to ensure there are no cracks (especially around the mounting points for the engine, compressor and eddy current clutch).
With the engine removed examine the tundish for fractures or damage, particularly in the area of the waste drain pipe. Reinforce weld around waste drain pipe.
Examine the shelf on the engine room side of the electrical cabinet for fractures. Repair as required.
Report any cracks, damage or wear to RailCorp.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
3.3 Engine room Engine room walls, engine well, radiator fan room and short end hood/nose (inside) to be thoroughly cleaned and all loose debris removed and painted in alpine green.
All foot plate walk ways and locomotive access steps are to be painted with a suitable non-slip paint.
3.4 Pipe work All pipework shall receive the following attention:
• Oil & water pipework shall be thoroughly cleaned both internally and externally.
• All gaskets & seals to be renewed. All flexmaster coupling clamps are to satisfy the requirements of ESR 0254.
• Correctly secured with all U-bolts, bracket bolts and other clamps fitted.
• All flexible hoses to be replaced with new hoses (including all head stock hoses).
• Replace #3 & #4 pipes behind the headstock ensuring pipe is cut back past any corrosion (use Loctite 567 pipe sealant or similar). .
• All pipes, hoses are to be free from rubbing. Any pipes, which show signs of abrasion damage, are to be replaced.
Note: Ensure restricting orifice is fitted in turbo oil line for steel capped pistons (refer to Alco EB-11176 Subject #1F p2).
3.5 Body
3.5.1 General Repair all corrosion damage.
Replace broken or missing windows.
Replace missing or faulty headlights.
Replace missing number lights and number boards.
Repair corrosion damage to bodyside filter housings.
3.5.2 Engine compartment Engine canopies to be examined for fractures, damaged doors or hinges, excessive corrosion etc. to be repaired as required to provide a presentable appearance. Canopies doors and hinges are to function correctly and are not to have excessive wear/play.
Engine canopy body cover strap seals to be renewed.
All engine and radiator room doors must be in good working condition with all screws, hinges, handles, clips etc. fitted (door seals to be renewed).
3.5.3 Pilot area Check condition, security and clearance from rail of the pilot and correct if necessary. A minimum clearance of 100mm from the top of the rail to the lowest point on the bottom of the pilot.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
• ESR 0560 Overhaul of NA155 Napier turbocharger overhaul spec
• ESR 0561 Overhaul of engine exhaust manifold
• ESR 0575 Overhaul of air coolers
• ESR 0602 Overhaul of traction generator
• ESR 0603 Overhaul of auxiliary generator
• ESR 0606 Overhaul of fuel pump motor
• ESR 0619 Inspection, service & testing of crankshaft exhaust motors
• ESR 0620 Overhaul of traction alternators
3.8 Cooling system The cooling system is to be overhauled in accordance with ESR 0573 Overhaul of cooling water system. This specification also refers to the following specifications.
• ESR 0270 Setting of engine temperature switches
• ESR 0570 Overhaul of DE locomotives radiator overhaul
• ESR 0571 Overhaul of radiator fan drive overhaul spec
• ESR 0572 Overhaul of water pump overhaul spec
• ESR 0574 Overhaul of aftercooler overhaul spec
Radiator fan shaft bearings are to be renewed.
The Supplier is to replace the radiator cores. Supplier to source Mesabi Radiator from L & M Radiators Cnr Kew & Mars Street, Welshpool WA 6106
3.9 Compressor The air compressor is to be overhauled in accordance with ESR 0511 Overhaul of 3-CDC air compressor
3.10 Electrical The following electrical equipment is to be overhauled:
• ESR 0600 Overhaul of electrical compartment
• ESR 0604 Overhaul of AG32 exciter
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
• ESR 0609 Overhaul of generator field & fuel pump contactor
• ESR 0610 Overhaul of field shunting contactor
• ESR 0611 Overhaul of reverser
• ESR 0612 Overhaul of auxiliary contacts
• ESR 0613 Overhaul of control relay
• ESR 0614 Overhaul of ground relay
• ESR 0615 Overhaul of AEI master controller type 38MC
• ESR 0616 Overhaul of AEI “on” type magnet valve
• ESR 0617 Overhaul of field shunting control & transition relay
All electrical conduits are to be examined and any defects repaired. If the movement between body sections has caused the defect, suitable flexible joints are to be fitted.
View all high tension cabling looking for deterioration, cracks or oil impregnation. Report to the Superintendent if repairs are considered necessary.
3.10.1 Electrical control equipment The following electrical item components are to be removed, overhauled and refitted:
• All control relays.
• Cranking contactors. ESR 0608
• Field shunting contactors. ESR 0610
• Generator field & fuel pump contactor. ESR 0609
• Ground relay ESR 0614
• Master controller. ESR 0615
• Motor contactors. ESR 0607
• Reverser. ESR 0611
• Transition Panel. ESR 0617
3.10.2 Low tension rewire The locomotives entire low tension wiring & conduits are to be removed. Rigid conduit is to be cleaned & examined for condition & security (repair as required, variation).
3.10.3 Terminal boards Terminal boards are to be removed & replaced with Wago type at the following locations:
• Main terminal board in the electrical compartment.
• Engine room terminal board located near temperature switches.
• #1 & #2 end control jumper connection boxes.
• #1 & #2 control stands.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
3.10.4 Circuit breaker replacement The following circuit breakers are to be replaced with identical rating circuit breakers:
Control compartment:
• Auxiliary generator 15 Amp
• Lighting 30 Amp
• Fuel pump 30 Amp
• Headlight 30 Amp
• Heater 30 Amp
• Air conditioning 50 Amp
• Battery 200 Amp
A suitable circuit breaker panel must be designed & manufactured by the Supplier to accommodate the new type circuit breakers into the control compartment.
3.10.5 Control stands 1 & 2. Flexible conduit replacement.
All flexible conduit must be renewed to standard ESR 0421.
All flex conduits must be suitably terminated at all connecting points & through walls.
All flex conduits to be suitably secured (saddled) to protect against rubbing & potential damage from in service operation or maintenance work of the locomotive.
All non-metallic flexible conduits must be completed to the requirements of ESR 0273.
3.10.6 Low tension cable rewire Rewire of low tension wiring must be completed to the requirements & relevant standards specified in ESR 0421.
Cable size & type used for rewire must satisfy standard ESR 0421 & current ratings stated on the supplied schematic diagrams. Where there is a conflict of information on the drawings or standards, a RailCorp representative will make a determination as to the standard that will apply.
All wiring is to be neatly loomed & secured to minimise rubbing & potential to rub through to locomotive frame & body work.
All wiring loom rails are to be suitably re-insulated
All wiring that passes through walls must be in conduit where required or securely fastened grommets, conduits where required must be suitably terminated to pass through wall.
All wiring must be clearly labelled as stated in the supplied drawings at all connection points. Labels must be able to with stand heat, oil & solvents.
Crimp lugs must be used to connect to electrical components & to be completed to the requirements of standard ESR 0421 item 13.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
3.10.7 Testing On completion of rewire, all components & systems of the low tension system must be checked for correct operation.
Circuit breaker trip function to be tested.
All electrical system & components to be tested in conjunction with load testing of loco & road trial of loco.
3.10.8 Electrical compartment Must be thoroughly cleaned (Use only solvent specified in ESR 0214).
All wiring must be free from rubbing and all hot lugs and damaged wire must be replaced.
Resistor panels and resistors to be cleaned and checked for condition of insulation and repaired or replaced as necessary.
Resistor mountings are to be checked for cracks or fatigue and repaired as required.
All covers and doors must be in place and in good working condition with all screws, hinges, handles, clips etc. fitted (door seals to be renewed).
3.11 Alignment
3.11.1 Engine to compressor Engine to compressor alignment is to be carried out to Alco Instruction Manual MI-1052 (Fast's Coupling - Air Compressor Drive Installation and Alignment).
3.11.2 Compressor to radiator fan drive Compressor to radiator fan drive alignment is to be carried out to Alco Instruction Manual MI-16005B and MI-16006 (Reassemble and Alignment).
3.12 Fast’s coupling As per Alco Instruction Manual MI-1052.
Must be filled with 900 grams of Caltex Ultra Duty Grease.
3.13 Holset coupling All rubber blocks and bronze bushing must be replaced with new items.
Alignment.
3.14 Auxiliary drive belts The auxiliary drive belts are to be replaced with a complete set of new matched belts.
3.15 Traction motors & blowers Traction motors must be overhauled in accordance with the requirements of ESR 0601.
The traction motor blowers must be overhauled in accordance with ESR 0618.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
The traction motor cooling air ducts shall be cleaned and serviced/repaired as required.
3.16 Electrical jumper junction boxes All electrical jumper junction boxes must be in good structural condition.
Remove covers. Rewire.
Drill drain hole in bottom of the junction box and fit split pin to prevent hole from blocking.
Renew cover seals and ensure water tight seal.
3.17 Battery bbox Corrosion damage must be repaired and all timbers must be in good condition. Refer drawing 106-236.
The battery box must be thoroughly cleaned and then painted with epoxy modified bituminous black paint or Isonol 300 Red or equivalent product.
Four fibreglass trays must be manufactured and installed (two batteries per tray) into the battery box the dimensions for these trays are 5mm thick × 700mm long × 82mm deep × 420mm wide. The trays are to have four (two per battery) raised portions approximately 4mm high to keep the battery off the bottom of the inside of the tray. They will be inserted into the fibreglass (when the tray is manufactured) and be 140mm × 20mm. Refer drawing 207-791.
The Supplier is to supply new batteries.
3.18 Bogies The bogies are to overhauled in accordance with the requirements of:
Missing brake cylinders will have to be supplied. Brake piping, where missing, will need to be supplied.
Hasler speed unit to be provided.
Fit new wheels.
3.19 Brakes The following air brake equipment is to be removed overhauled in accordance to ESR 0220 Brake system component changeout and then refitted:
• equalising reservoir control valve (x2).
• 5lb pressure switch.
• independent brake valve (x2).
• dead engine device.
• distributing valve.
• independent release valve.
• automatic brake valve handle.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
3.19.1 Brake equipment system blow out Procedure NOTE: - When installing air gear, the system is to be blown out with compressed air working from main reservoirs to each item of equipment being installed as listed below:
• First blow out reservoir with shop air
• Replace 2 X 130LB safety valves Blow out system from reservoir connection again.
• Replace 2 isolating valves Blow out system from reservoir connection again.
• Replace 2 feed valves Blow out system from reservoir connection again.
• Replace 2 automatic brake valves Blow out system from reservoir connection again.
• Replace 2 independent brake valves Blow out system from reservoir connection again.
• Replace feed valve (control air) Blow out system from reservoir connection again.
• Replace 2 flowmeter Blow out system from reservoir connection again.
• Replace distributing valve Blow out system from reservoir connection again.
• Replace dead engine device Blow out system from reservoir connection again.
• Replace 1 independent release valve Blow out system from reservoir connection again.
• Replace 2 equalising reservoir control valve Blow out system from reservoir connection again.
• Replace control governor 250-350kp Blow out system from reservoir connection again.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
• Replace all gauges Blow out system from reservoir connection again.
• Replace compressor governor 750-850kp Blow out system from reservoir connection again.
• Replace 1 magnet valve (compressor governor) D75 Blow out system from reservoir connection again.
• Replace all sander magnet valves D75 Blow out system from reservoir connection again.
3.19.2 Handbrake The handbrake, chain and linkages must be removed and overhauled. Any worn parts to be replaced.:
3.19.3 New equipment The Supplier is to replace the following equipment with new equipment:
• All air line strainer elements
• Air compressor oil drain pipe to be fitted with plugged John valve.
3.19.4 Modifications The Supplier shall provide a quotation for the following additional work:
• Convert the brake equipment from A7-EL to B7-EL standard.
• Remove the AA vigilance control equipment and fit EH or later vigilance control system. Refer to ESR 0223 Vigilance Control Systems.
3.19.5 Brake & vigilance control system tests Brakes and vigilance control are to be operating correctly.
• Brakes to be tested to ESR 0221 A7/B7 locomotive brake test.
• Vigilance control to be tested to ESR 0220 Testing of vigilance control system.
All slack adjusters are to be adjusted correctly to ESR 0224
Ensure the settings of the following pressure switches are correct - adjust as necessary:
• power knock out switch (350-250 kPa).
• compressor governor (750-850 kPa). See Alco MI-1053 for setting procedure.
• brake cylinder pressure switch (20-50 kPa).
3.20 Main reservoirs Main reservoirs are to be inspected by an accredited boiler inspector. Repairs to be undertaken as required. Main reservoirs must be certified safe for use before refitting to locomotive. Certification documentation to be forwarded to the Superintendent. Ensure Main Reservoirs are clear and operating correctly. Replace cocks and/or hose if damaged.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
3.21 Cab All cab & short end equipment and accessories are to be clean and in good working order including the following (any defective equipment to be repaired or replaced with new or overhauled equipment):
• Hasler speed recording equipment.
• All gauges must be calibrated.
• Mirrors, windows, doors and door seals.
• All lights and lamps, heaters, cab fans, blinds and windscreen wiper units.
• Seats (Bremshy type and must also be free from damage). Part no. FA416/48
• Locomotive numbers must be readable.
• Control stand and master controller (must be clean inside and outside).
– Remove control stand covers and check the following:
o replace all hot lugs and damaged wiring on control stand and master controller.
o operation and mechanical interlock of selector, throttle and reverser handles. Lightly lubricate mechanical rollers.
o check all cams and contacts for condition and movement.
o check all connections for tightness and condition of wiring
o check all gauge lights, alarms and switches.
o examine all alarm light fittings.
o examine loadmeters for obvious defects.
• All screws, latches, hinges, brackets, etc. must be fitted and in good condition to ensure that covers/equipment will not rattle. Note:- Worn hinges are to be renewed.
• Remove the toilet and seal all holes.
• Repair or replace hotplate.
The cab floor must also be in a safe, clean condition (any defective sections must be repaired).
The cab and short end must be clean and painted, colour requirements according to ESR 0212.
The Drivers cab is to be painted in accordance with ESR 0212.
3.21.1 Train radio Train Radio handsets are to be supplied by RailCorp and fitted by the contractor.
3.22 Fuel tank The fuel tank is to be removed and cleaned.
Fuel tanks shall be inspected and repaired in accordance with TRS 1067 if this work has not previously been completed.
Fuel tank is to be checked for fractures. Repair as required.
All fuel tank gaskets to be renewed.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
3.28 Steps and handrails Replace damaged or missing steps and handrails.
3.29 Painting Locomotive 4801 is to be painted in original 48 class locomotive colour scheme.
Locomotive 4805 is to be painted in RailCorp colour scheme.
Refer to the Work Train Operations Unit for details of the RailCorp colour scheme.
There shall be contrasting colours on the ends of the locomotives for high visibility.
The cab is to be painted in accordance with ESR 0212 Cab interior painting
Engine room walls, engine well, radiator fan room and short end hood/nose (inside) to be thoroughly cleaned and all loose debris removed and painted in alpine green.
All foot plate walk ways and locomotive access steps are to be painted with a suitable non-slip paint.
All handrails, coupler uncoupling handle, bogie brake cut-out cocks and air brake coupling cocks are to be painted white.
3.30 Other equipment The following additional equipment shall be fitted:
• AEI tags as supplied by RailCorp.
• Reflective delineators in accordance with RSU 330.
4 After inspection work
4.1 Inspection Following completion of the restoration the locomotives shall be inspected in accordance with the following standards:
• ESR 0202 Electrical commissioning of 48 class locomotives following CCO.
• ESR 0203 Mechanical commissioning of 48 class locomotives following CCO.
5 Load testing The locomotive is to be free from any leaks (fuel oil, lubricating oil, cooling, booster, exhaust and air systems).
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
Battery charging circuit is to be operating correctly.
Temperature switches are to be operating at the correct temperatures:
• T1 - 68°C.
• T2 - 74°C.
• ETS - 91°C.
The temperature switches are to be set using a thermometer which has been calibrated within the past 12 months. At this time the readings taken on the calibrated thermometer are to be compared with the readings taken on the locomotive thermometer in the range 40°C-80°C at no greater than 10°C intervals. If the locomotive thermometer varies by more than ±2°C at any point it is to be replaced with a new thermometer.
Compressor and radiator fan is to be operating correctly.
All fuel and lubricating oil valves, both relief and regulating are to be operating at the correct pressures when the locomotive has reached operating temperature. See ESR 0250 for correct pressures.
The locomotive is to operate at 900 horsepower + 50, - 0 in 8th throttle notch.
For testing procedure see ESR 0256.
After shutting down final test run, the following operations should be done:
• Take sample of lubricating oil from crankcase for analysis then change all lubricating oil filters.
• The oil sample should be labelled “Post CCO Sample” with the following information stated:
– Locomotive number
– Date sampled
– Sender information.
• The sample is then to be sent for analysis.
Note any remarks or unusual running characteristics of engine.
The locomotive is to be free from any leaks (fuel oil, lubricating oil, cooling water, booster air, exhaust and air systems).
5.1 Test report The copy of test readings duly signed and certified should be forwarded to the Superintendent, along with all additional data and measurements, as required by this specification, before service trials are commenced.
A copy of the Quality Control Engine Performance Test Report shall be forwarded to the Superintendent at the completion of trials and prior to hand over of each locomotive.
A copy of the results from the testing of the oil samples are to be supplied to the Superintendent.
6 Road trial Locomotive is to be road trialled to ensure it is powering correctly. This includes ensuring correct operation of transition and field shunting.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200
Air brake equipment is to operate correctly when travelling in either direction.
All vigilance control functions are to operate correctly.
Locomotive to be returned to Supplier after trial for final clean up and attention to trial bookings. A Lube oil sample is to be taken immediately prior to release of locomotive and sent to an approved laboratory for analysis. Sample should be labelled “Post CCO Sample” with the following information stated:
• Locomotive number
• Date sampled
• Sender information.
The Supplier is to provide the analysis results to the Superintendent within 14 days from delivery of locomotive.
7 Standard variations The following variations are to be carried out if they have not previously been implemented, as directed by the Superintendent:
• Fuel Tank Strengthening to TRS 1067.
• Bodyside filters housing frames to be fitted with fixed louvers. Note: some sizes will need to be changed to suit individual doors.
• Fitting of John cocks to all oil and water drainage pipes.
• Battery box drains to be enlarged with PVC drainage piping to prevent blocking.
• Remove external oil pressure switch OPS3 if fitted. Refer to TRS 1490.
• Windscreens to be replaced if condition requires. Ref drawing 305-781.
• Fuel Sight Indicator to TRS 1292.
• All fluid drains to lead to the 4ft:
– Tundish
– The four breather hoses from the Banlaw Breathers on the fuel tank
– The main reservoir condensate drains as per M95-055.01
• All fluid drains to lead to the 6 ft:
– Locomotive lubricating oil drain (must be fitted with screw on cap).
– Locomotive water coolant drain (must be fitted with screw on cap).
– Locomotive waste sump drain (must be fitted with screw on cap) as per M96-059.01.
Note: On the locomotive waste sump a plug to access the drain pipe must be fitted to access the drain pipe from the 4 ft.
• Long fuel sight glass level indicators to be replaced with Weka magnetic indicators supplied by control component part No. 969124/01.
• Short fuel sight glass level to be removed and blanking plates to be fitted.
• Provide 100mm square hole over waterproof screened cover over engine governor to allow application of lifting appliance.
• Relocate low water alarm cut out switch to protect it against heat and fire damage.
RailCorp Engineering Standard — Rolling Stock Specification for the restoration of 48 class locomotives ESR 0200