7/27/2019 Quality Audit for Diesel Loco POH Workshop(1) http://slidepdf.com/reader/full/quality-audit-for-diesel-loco-poh-workshop1 1/104 Page 1 of 104 Quality Audit of Diesel Loco POH Workshop 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 Section b.Wheel (Wear adapted profile) profile & other defects. c.Brake adjustment, release & and application timings. d.Headlight focus adjustment e.Horn maintenance f.Undergear safety brackets g.Gauging of Couplers h.Vertical offset between Side bearer and centre pivot a.OEM’s maintenance manual. b.Drg No SKDL-2561 Alt 8. c.Standard test scheme as per MP.TP-029/87 (Rev 02) Oct 2008 for Air Brake, and, as per MP.TP-019/81 (Rev 02) Nov 08 for dual brake locos. d.IB No MP.IB.EC.01.08.06 (Rev 0) December 06. f.MI No MP.IB.BD.02.16.01 (Rev 01) December 09. g.CBC Manual No G 76 Sept 87. h.MI No MP.IB.VL.02.11.10 (Rev 00) February 10.
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7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 3 of 104 Quality Audit of Diesel Loco POH Workshop
Annexure-1
CHECK LIST FOR
TECHNICAL AUDIT AT POH WORKSHOPS (BRAKE ITEMS)
S.No. Item Parameter Observ ations
1. Whether all the items
prescribed in the schedule isbeing followed for brakeequipment, compressor /Expressor & air dryer or not
As per Schedule of standard examinations
(No. MP.Misc.-140 & 141, Rev-01,September’2006)
`
1. Whether maintenance is done as per RDSOMIs or manufacturers MI mentioned inMP.Misc.-140 & 141.
2. Maintenance facilities are available or not.2. Functioning of VCD Whether functioning of VCD is being checked in
every POH schedule.
3. Test benches and rigs 1. Whether the required test bench and rigs areavailable or not viz. AB test rack for brakevalves, air dryer test bench, compressor/
Expressor test bench etc.2. Whether, testing is done on above test
benches.3. Calibration of test benches and rigs is being
done periodically or not.
4. Test on Loco after POH Whether brake system check is done on loco asper test programme no. MP.TP-029 (for air brakeloco) & MP.TP-019 (For dual brake loco).
5. Infrastructure facilities (a) Whether dust proof and controlledtemperature environment for maintenance,assembly and testing of brake valves is
available.(b) Availability of compressed air (in test
benches.(c) Availability of compressor in air lines.(d) Whether air dryer provided in test benches/
air lines.(e) Reservoir pressure is being checked or not(f) Washing facilities
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(g) Painting facilities(h) Technical Cell(i) Metrology lab(j) Store(k) Tool room(l) Fire extinguishers(m)Material handling facilities for movement of
material and components.
6. Storage of material Whether dust/damp proof environment withcontrolled temperature is available for storage of brake equipment and rubber components.Whether rubber components are being stored asper guidelines mentioned in this office letter no.SD.DEV.RBC dated 28.02/07.03.2007 circulatedto all Zonal Railways.
7. Availability of Material Any Chromic shortage of material for maintenance
8. Human Resourcedevelopment
Whether periodic training is being imparted tomaintenance staff to make them conversant withthe maintenance practices.
9. Any other observation
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Annexure-4
CHECK SHEET FOR
QUALITY AUDITOF TURBO SECTION (POH)
During the audit, activities should be checked with regard to the Clause/Para/Item/chapter of the reference document as per applicability. Wherever the
activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco Type Make Of
Subassembly
Reference
Details
Clause/Para/It
em Details
Observations
1.
Balancing, measurementsetc
Balancing:
1.1 Bladed shaft, range 31-257 gmm.
1.2 Rotor, range 157-470 gmm.
5.6
5.6.2.5
5.6.2.5
Rotor Shaft Dimensions:
1.3 Bearing position OD A 39.98 – 40.00 mm
Alco ABB VTC 304
Turbocharger
ABB-Exhaust
Gas
Turbocharge
r VTC 304 A
Comprehensi
ve Manual
for Indian
Railways
issued by
M/s ABB
Para 5.2.4.13
&
details in5.4.2.1
1.4 Bearing position OD B 50.987--51.000 mm
1.5 Bearing position OD C 56.10-56.20 mm
1.6 Piston ring recess S 2.58-2.85 mm
Wheel Bush
1.7 Compressor wheel set OD A 56.10 -56.20 mm
Para 5.2.4.13
&
details in
5.4.2.2
1.8 Piston ring recess S 2.58-2.85 mm
1.9 Plain bearing (CE) ID A 54.00-54.06 mm Para 5.2.4.13
&
details in
5.4.2.3
1.10 Bearing housing bore ID A 65.00-65.07 mm Para 5.2.4.13
&
details in
5.4.2.4
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CHECK SHEET FOR
TECHNICAL AUDIT OF ENGINE BLOCK, MAIN BEARING (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 LocoType
Make/classOf
Subassembly
ReferenceDetails
Clause/Para/Item/Chapter Details
Observations
1 Removal of Cyl Block
a) Removal of Cylinder liner.
b) Removal of cylinder liner sleeve.
Alco
Conventional
ALCO MI
11079 D
Chapter on Maintenance,
Instruction of Cylinder Block
.
2 Maintenance and Inspection
DPT for cracks/signs of leaks/ other
damage,
2.1 Check sizes of Main Brg. Bore.
a) New MB bore dia. 9.0355" -9.0370"
b) Worn MB bore dia. 9.0350" -
9.0385"
c) Cyl. Liner bore.
2.2 a)Out of roundness checking at planes
A,B,C,D, E & F (max. 0.0035”).
b) Check taper
i) At vertical planes A and D (0.001”).
ii) At 45° from vertical between
planes B & F and C & E (0.003”).
a) Horizontal misalignment limit – (i) Two adjacent bores – 0.002”
(ii) Two non-adjacent bores 0.004”
b) Vertical misalignment limit –
(i) Three adjacent bores-0.0015”
(ii) Two non-adjacent bores-
0.003”.
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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.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco
Type
Make/class
Of
Subassembly
Reference
Details
Clause/Para/
Item/Chapter Details
Observations
1 Removal of Crank Shaft
a) Removal of Oil
catcher/pipes/engine parts/main
brgs caps/shells & split gears.
b) Checked Crank shaft thrust
(i) Using Main brg shell 0.010”-
0.017”
(ii) Using Thrust collar 0.012”-
0.021”
c) Apply grease and wrap journals
and crankpins. Alco
Conventional
ALCO MI
11069 E
Chapter on Maintenance,
Instruction of Cylinder Block.2 Maintenance and Inspection
a) Cleaning
b) Magnaflux test for
cracks/other damage,
c) Roughness and burrs (limit 25
RMS max).
d) Check M/Brgs saddle bore
2.1 Check Crank shaft.
a) MB Journal dia. 8.498" – 8.500"
b) Out of roundness limit 0.002”
c) Run out for 16 cyl-0.008” max
d) MB Journal eccentricity limit
0.001”
d) Crank pin dia 5.998”- 6.000”
e) Crank pin out of roundness limit
0.002”
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CHECK SHEET FOR
TECHNICAL AUDIT OF CYLINDER HEAD 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.
Page 33 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF PISTON 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.
Page 36 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF RADIATOR 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/class
Of
Subassembly
Reference
Details
Clause/Para/
Item/Chapter Details
Observations
1 Leakage testing
AlcoConventional
Alco MI
Chapter on Maintenance,
Radiators.
2 Reconditioning of Radiator Chapter on LOCOMOTIVE
INSPECTION,
MAINTENANCE AND
LUBRICATION
MI 17003 A
2.1 Dismantling2.2 Cleaning of the core
2.3 Changing of gaskets
2.4 Assembly
2.5 Testing
Chapter on Maintenance,Radiators.
3 Cleaning etc
Alco ConventionalAlco MI
Chapter on Maintenance,
Radiators.
3.1 cleaning details
4
Availability of tools, Test Stands etc.
4.1 Torque wrench up to 140 ft-lb.
4.2 Hydraulic testing machine 0-10 Kg/Cm2
4.3 Radiator stand4.4 Fin combing tool
4.5 Radiator immersion tank for cleaning
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CHECK SHEET FOR
QUALITY AUDIT OF FUEL INJECTION PUMP (POH)
During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed
correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco type Make of
subassembly
Reference
details
Clause/Para/Item details Observation
1. Dis-assembly /Measurement/Assembly etc
Alco Bosch 17 mm Bosch repair
and testing
manual
Para on Dis-assembly
Para on Inspection of parts
Para on Inspection of parts
Para on Inspection of parts
Para on Inspection of parts
Para on assembly
Para on Calibration values
1.1 Dis-assembly
1.2 Inspection of parts
1.3 Replace plunger guide cup if the indentation
on the Plunger and tappet seating surface is
more than 0.125 mm (0.005”)
1.4 Clearance between control rack and bushing
within 0.5 mm (0.020”)
1.5 Control rack movement – within 0.38 mm
(0.015”).
1.6 Range control bush dia – 18.25 mm (0.7185”)
– 18.27 mm (0.7192”)
1.7 BDC Dimension ‘a’ – 6.5 ± 0.05 mm.
2. Availability of Tools ,Test Stands etc.
1.1 Depth gauge for checking of BDC dimension
‘a’ on test bench.
1.2 Nut torque wrench, 450 lbs – 500 lbs.
1.3 Bush reamer.
1.4 Micrometer, 16 – 20 mm.
1.5 Assembly and dis-assembly fixture
1.6 Pump calibration test stand
1.7 Calibration oil – Servo Calib-5
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CHECK SHEET FOR
QUALITY AUDIT OF INJECTOR (POH)
During the audit, activities should be checked with regard to the clause/Para/Item of the reference document. Wherever the activities are not performed
correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Page 42 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF PTLOC 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/Ite
m/chapter
Details
Observations
1
Dis-assembly /Measurement/Assembly/Test etc.
1.1 Overhauling procedure
1.2 Plate Pack Length
1.3 Hydraulic Test
Plate Type Lube
Oil Cooler
(PTLOC)
MPMI-24, Nov. 2004
& MP.IB.ES.01.07.08
DLW Drawing No.
TPL-8515, DLW Part
No. 11457260
Para on
Overhaul
procedure
Outline – Lube
Oil Cooler
2 Availability of tools , Test Stands etc.2.1 Ratchet spanner
3
Availability of instructions etc.
3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
4 Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
5.2 Must change items
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Annexure-5
CHECK SHEET FOR
TECHNICAL AUDIT OF POH WORKSHOP
Item: Electrical control MBCS + MCBG + E type
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever theactivities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Sub
assembly
Reference Details Clause/Para/Item Details
Observation
1. No. of Trained personnel withexperience
MBCS trained personnel
2. Record keeping practices after thetests in relay control room for E typecontrol
Shed doc
3. Practices for Handling of the electronic
cards and storing
ALCo Doc No:IM 53 for MBCS
Medha4. Availability of crimping tool & connector
pin details ALCo Doc No. :IM 53 for MBCS
Medha
5. Maintenance practices of MicroProcessor Based Control System MEP660
DLW/Alco/AMC (micro)/01
6. Maintenance practices of MicroController Based Governor (MCBG)MEG 601
ALCo Doc No:IM-11 Rev. 0.0Date Jan 2009 of Medha
7. Practices followed for Fault dataanalysis for identifying the faulty
components and failure.
ALCoContract agreement no.DLW/ALCO/MCBG/Medha
8. Standard (OEM recommended) list of spares, consumable & tools ALCo
Contract agreement no.DLW/ALCO/MCBG/Medha
9. Measurement
11.1 Standards for load box examination of D E locomotives
MP MI -10 (Rev.0.02) August, 2003
11.2 Practices as per BHEL CommissioningTest schedule (Electrical equipment)
BHEL docs: TNE -2/2105/97/DELCTS Date
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
and items covered under DLW/Alco/AMC (micro)/01 for MBCS locos
11.6 Check set value of engine rpm,transition speed, LOPS, Engine water Temp., 1st notch current, DBparameters (field and armaturecurrent), loco over speed through user settable parameters,
User settable parameters asper RDSO MBCSspec.MP.0.2400.26
11.7 Check ground circuit leakage current -do-
11.8 Check mv drop test of WSR (E type)
12 Availability Of Tools And Test Stands For MBCS locos- Test standsare not provided by MBCS
supplier. Items are coveredunder AMC.
13 Display Chart Important instruction for trouble shooting like action tobe taken during wheel slip etcto be available on the cab
13.1 Display of DOS and DONTS,TROUBLE SHOOTING Chart,
As per OEM manual
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DISPLAYCHART & FLOW CHART
14 Maintenance manual and check sheets As provided by the MBCSmanufacturer*
15 Instruction Bulletin / Modification sheet/Hand book/ Trouble shooting charts asprovided by RDSO/ CAMTECH andimplementation by MBCS vendor
MBCS spec.MP.0.2400.26,Modification sheetNo.MP.MOD.EC.05.27.10(Rev. 00) Date 26.03.2010,Instruction Bulletinno.MP.IB.EC.04.21.10 Date
30.04.2010.CAMTECH/2010/M/MPBCS/1.0 March 2010 (IntroductionHand book on MBCS MP660fitted on diesel locomotives).CAMTECH/2000/DSL/1.0(Trouble shooting charts for drivers of WDM2 locomotive)
Medha
1. Operational manual for drivers Doc.No.IM-38 Rev 3.0 July 072. Maintenance Instruction manual Doc. No.IM-53 Rev 0.0 Sept’2008
3. System Manual Doc. No. IM-08 Rev.3.0 March 20084. Troubleshooting Manual Doc.No. IM-51 Rev.2.0 Oct.20085. WDG3A Control wiring Drg. no.ED 10356. WDG3A Power. ED 10377. WDG3A Schematics Drg. no.ED Wiring Drg. no 10348. WDG3A TB wiring Drg. no.ED 10369. WDM3D Control wiring Drg. no.ED 103110. WDM3D Power Wiring Drg. no.ED 103311. WDM3D Schematics Drg. no.ED 103012. WDM3D TB wiring Drg. no.ED 1032
Siemens
1. KM DIREKT scheme no. DRG. No. 3FZE-009612. SIM CONTROL scheme no. DRG. No. 4SIM-200509
3. SIMCONTROL Operator’s Instructions &Guidelines user manual ver.2.00 dated 10.12.09
4. Trouble shooting manual of Siemens WDG3A and fault category of Siemens
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CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERATOR FIELD CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Control voltage 72+1 VDC All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0640/
Altr R3Part
No 12145439
Technical detailsgiven in the
drawing
1.2 Max pick up volt 48v ,1.3 Main contact gap12-14.5mm,
Page 49 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR CRANKING CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Short time control voltage -72+1v dc, All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0641/
Altr R3Part
No 121410510
Technical detailsgiven in the
drawing
1.2 Control voltage -24vdc,1.3 Max pick up volt 24v
Page 50 of 104 Quality Audit of Diesel Loco POH Workshop
1.13 IR Value between(i) mMain contacts(ii) Coil and magnet frame(iii) Interlocks and coil shorted together and earth.(iv) Contacts of interlocks(v) Interlocks and coil shorted together and main
contacts shorted together (vi) Shorted main contacts and shorted interlocks, coiland earth
as per IEC60571
clause 10.2.9
2.0 Availability of tools and stands2.10 Multimeter with proper calibration
2.11 Vernier calipers with valid calibration2.12 Go- No gauge suiting to different contactors
2.13 Dial gauge of different scale and resolution assuited to respective contactor
2.14 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.15 Variac
2.16 Megger
2.17 Oscilloscope
2.18 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.3.10 Display Chart
3.11 Flow Chart3.12 Training of staff
3.13 Proper Display of Do’s and Don’t
3.14 Maintenance manual and check sheets3.15 Record keeping of tools and measuring
instruments
3.16 Instruction Bulletin issued by RDSO3.17 Maintenance Manual of Manufacturer
3.18 Specification
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4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer 6 Record Keeping For Traceability
4.3 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,
Repair/Overhauling activity details, Loco No. towhich fitted.
4.4 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.4 Vital Spares7.5 Must change items
7.6 Consumables8. Disposal
8.3 Segregation of Workable and Non-Workable equipments and proper house keeping
8.4 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
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CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR CRANKING CONTROL CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Short time control voltage 72+1 v dc, All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0639/
Altr R3Part
No 12141100
Technical detailsgiven in the
drawing
1.2 Control voltage 24vdc,1.3 Max pick up volt 24 v
1.4 Main contact gap 6-7.5mm,1.5 Wipe 0.8-1.6 mm,1.6 Contact pressure(gmf) initial 80-150, final 180.-
280,1.7 Operating coil resistance at 20 deg c 55+5%
ohm(52 to 58 ohms),
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
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6 Record Keeping For Traceability
4.5 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.6 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.7 Vital Spares7.8 Must change items
7.9 Consumables8. Disposal
8.5 Segregation of Workable and Non-Workable equipments and proper house keeping
8.6 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 55 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FUEL PUMP CONTACTORS (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed 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 LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Max pick up volt 48v All DieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0629/
Altr R3Part
No 12141033
Technical detailsgiven in the
drawing1.2 Main contact gap 11-13 mm,1.3 Wipe 3.5-4.7mm,
1.4 contact pressure( kgf) initial 0.68-0.9kgf, final 0.9-1.4kgf.,
1.5 operating coil resistance at 20 deg c 169-195 ohm ,
1.6 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08
(Rev-
01),May’10
3.10.e
1.7 IR Value as per clause 10.2.9 of IEC60571 between
(i)Main contacts of contactor
(ii) Coil and magnet frame
IEC60571
as per clause10.2.9
2.0 Availability of tools and stands2.28 Multimeter with proper calibration
2.29 Vernier calipers with valid calibration2.30 Go- No gauge suiting to different cantactors
SN R i t L M k Of R f Cl /P /It Ob ti
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SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
2.31 Dial gauge of different scale and resolution assuited to respective contactor
2.32 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.33 Variac
2.34 Meggar
2.35 Oscilloscope
2.36 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.
3.28 Display Chart3.29 Flow Chart
3.30 Training of staff 3.31 Proper Display of Do’s and Don’t
3.32 Maintenance manual and check sheets3.33 Record keeping of tools and measuring
instruments3.34 Instruction Bulletin issued by RDSO
3.35 Maintenance Manual of Manufacturer 3.36 Specification
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.7 Proper Register is maintained for Contactors with
details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. to
which fitted.
4.8 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 58 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR RADIATOR FAN CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 control voltage 72+1v dc,1.2 Max pick up volt 48 v
All DieselElectricLocomotives(ALCo)
Radiator Fancontactor
Drawing No.EL/PT/0638/
Altr R3Part
No 12140235
Technical detailsgiven in the
drawing
1.3 Main contact gap 6-7.5mm, Drawing No.EL/PT/0638/Par
t1.4 Wipe 0.8-1.6 mm, No 12140235
1.5 Contact pressure( gmf) initial 80-150, final 180.-280,
Altr R3
1.6 Operating coil resistance at 20 deg c -388ohm±5% (368 to 408 ohms),
Drawing No.EL/PT/0638/Par
t1.7 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08(Rev-
01),May’10
3.10.e
1.8 IR Value between(i) fixed contact to movable Contact(ii) coil to frame
IEC 60571 clause 10.2.9
2.0 Availability of tools and stands
2.37 Multimeter with proper calibration2.38 Vernier calipers with valid calibration
2.39 Go- No gauge suiting to different cantactors
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 59 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
2.40 Dial gauge of different scale and resolution assuited to respective contactor
2.41 Source which can provide minimum current atrespective voltage (24 V – 72 V DC)
2.42 Variac
2.43 Meggar
2.44 Oscilloscope
2.45 Screw Driver, Plier, Spanner Set, etc.
3. Availabili ty Of Instructions etc.
3.37 Display Chart3.38 Flow Chart
3.39 Training of staff 3.40 Proper Display of Do’s and Don’t
3.41 Maintenance manual and check sheets3.42 Record keeping of tools and measuring
instruments3.43 Instruction Bulletin issued by RDSO
3.44 Maintenance Manual of Manufacturer 3.45 Specification
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.9 Proper Register is maintained for Contactors with
details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. to
which fitted.
4.10 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 61 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR FIELD SHUNTING CONTACTOR (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
1. Measurement
1.1 Control voltage 72+1v dc, AllDieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0614/
Altr R4Part
No 12140491
Technical detailsgiven in the
drawing
1.2 max pick up volt 48v,1.3 Main contact gap12-14.5mm,
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
as per IEC60571
clause 10.2.9
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 63 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.11 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.12 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.16 Vital Spares7.17 Must change items
7.18 Consumables8. Disposal
8.11 Segregation of Workable and Non-Workable equipments and proper house keeping
8.12 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 64 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR EP CONTACTORS (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement ALCo Drawing No.EL/PT/0630/
Altr R4Part
No 12141008
Technical detailsgiven in the
drawing1.1 Contact gap 15-17 mm
1.2 Wipe 25.4-28.6 mm
1.3 Knuckling spring pressure(without lever) initial 4.5-6.3 kgf, final 12.2-18.2 kgf,
1.4 Normal air pressure 4.9 kg/cm2
1.5 Interlock gap 2.5-3.95mm,1.6 Interlock pressure 500-900g.
1.7 Interlock rated current 10 A,1.8 Magnet valve coil resistance at 20degC 615+5%
ohm.for BHELTYPE: M5027MV21.9 ROTEX TYPE: 3118AV1-3 coil resistance at
20degC 526 to 594 Ohms,1.10 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08
(Rev-01),
May’10
3.10.e
1.11 IR Value between
a) main contactsb) interlocks and MVc) interlocks and MV shorted together and earthd) contacts and interlockse) Interlocks and MV shorted together and main
contacts shorted together.f) Main contacts shorted together and earth
shorted with MV and interlocks.
IEC 60571 as per clause
10.2.9
SN Requirements Loco Make Of Reference Clause/Para/Item Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 66 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.13 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.14 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.19 Vital Spares7.20 Must change items
7.21 Consumables8. Disposal
8.13 Segregation of Workable and Non-Workable equipments and proper house keeping
8.14 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 67 of 104 Quality Audit of Diesel Loco POH Workshop
C C S O
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6M REVERSER (ALCo)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement
1.1 Auxiliary contacts 4, change over type, ALCo Drawing No.EL/PT/0649/
Altr R5Part
No 12310372
Technical detailsgiven in the
drawing1.2 Control voltage 72+1 V DC,1.3 Operating air pressure 4.9 kg/cm2,
Page 69 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
3.71 Maintenance Manual of Manufacturer 3.72 Specification Spec No.
MP.0.04.00.08
(Rev-
01),May’10
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.15 Proper Register is maintained for 6 M Reverser
with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.16 Proper record should be maintained for each 6 MReverser with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability7.22 Vital Spares7.23 Must change items
7.24 Consumables8. Disposal
8.15 Segregation of Workable and Non-Workable equipments and proper house keeping
8.16 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 70 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR 6 M BKT CONTACTORS (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed 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 LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement
1.1 Auxiliary contacts 4 change over type, AllDieselElectricLocomotives(ALCo)
Drawing No.EL/PT/0648/
Altr R5Part No
12310300
Technical detailsgiven in the
drawing1.2 Control voltage 72+1 V DC,1.3 operating air pressure 4.9 kg/cm2,1.4 Min operating air pressure 3.85 kg/cm2 ,
1.5 Main contact gap19.05+1.6mm,1.6 Main contact - outside pressure (with lever)1.7 4.0-4.5kgf, inside pressure 5.8-6.5kgf,
1.8 Auxiliary contact pressure 0.68-2.0 kgf,
1.9 Auxiliary contact gap 31.75mm (min),1.10 Magnet valve coil resistance at 20degC1.11 615+5% ohm. for BHELTYPE : M5027MV2
Page 72 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.17 Proper Register is maintained for Contactors withdetails of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.18 Proper record should be maintained for eachcontactor with the measurement of Parameters asin Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.25 Vital Spares
7.26 Must change items
7.27 Consumables
8. Disposal8.17 Segregation of Workable and Non-
Workable equipments and proper house keeping
8.18 Proper Disposal of Materials including recyclingfollowing relevant environmental norms
CHECK SHEET FOR
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 73 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR GENERAL PURPOSE RELAY (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed 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 LocoType Make Of Subassembly ReferenceDetails Clause/Para/ItemDetails Observations
1. Measurement
1.10 Nominal operating voltage (50-80 V) All DieselElectricLocomotives(ALCo)
BHEL, AAL andIEI
Spec No.MP.0.400.03
(Rev-01) Nov’08
Clause 3.1.1
1.11 Pick up voltage (Must Operate), max 48V Clause 3.2 (ii) 1.12 Drop out Voltage Min 7.5 V
1.13 Auxiliary make rating 7.5 A at 72 V1.14 Resistance of the coil at 20 deg C 445±5%, Clause 3.2 (v) 1.15 Contact Pressure 100-250 g Clause 3.2 (vi)
1.16 Over travel (1.6 mm) with over travel gauge inposition 0.0 to 0.1
Clause 3.2 (vii)
1.17 Min contact gap 2.7 mm Clause 3.2 (viii) 1.18 Armature gap 4.7 to 6.6 Clause 3.2 (ix) 1.19 Ensure that no distortion or corrosion of any
componentsClause16.1.9.2
1.20 IR Value between1.20.1 Open contacts1.20.2 Contacts and metal parts1.20.3 Adjacent contacts1.20.4 Coil and earth
as per IEC60571
Clause 10.2.9
2.0 Availability of tools and stands
2.88 Multimeter with proper calibration2.89 Vernier calipers with valid calibration2.90 Go- No gauge
2.91 Dial gauge
SN Requirements LocoT
Make Of S b bl
ReferenceD t il
Clause/Para/ItemD t il
Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 74 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
2.92 Source which can provide minimum current atrespective voltage (72 V DC)
2.93 Variac
2.94 Meggar
2.95 Screw Driver, Plier, Spanner Set, etc.
2.96 Sufficient set of tool and gauges provided bymanufacturer
3. Availabili ty Of Instructions etc.
3.82 Display Chart3.83 Flow Chart
3.84 Training of staff 3.85 Proper Display of Do’s and Don’t
3.86 Maintenance manual and check sheets3.87 Record keeping of tools and measuring
instruments
3.88 Instruction Bulletin issued by RDSO
3.89 Maintenance Manual of Manufacturer 3.90 Specification Spec No.
MP.0.400.03(Rev-01) Nov’08
4. Compliance of Instruction Bulletin5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability4.19 Proper Register is maintained for GP Relay with
details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.20 Proper record should be maintained for GP Relaywith the measurement of Parameters as in Sl. No.1prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
SN Requirements LocoT pe
Make Of S bassembl
ReferenceDetails
Clause/Para/ItemDetails
Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 76 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF POH WORKSHOP OF ELECTRICAL CONTROL FOR DC-DC CONVERTER (500 W)-TWIN BEAM HEAD LIGHT(ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Page 78 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly Details Details
Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.
4.22 Proper record should be maintained for each DC-DC Converter
4.23 500 W DC-DC Converter with themeasurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenancewith date and remarks, if any.
7.
Material Availability7.30 Vital Spares
7.31 Must change items
7.32 Consumables
8. Disposal
8.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
8.2 Safe Disposal including recycling followingrelevant environmental norms.
CHECK SHEET FOR
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 79 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED FLASHER LIGHT (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
017 Rev 1 Sept 042.3 Lux Value- The lux measured in axial directionshall not be less than 500 lux at 1 meter and 55lux at 3 meters for amber clour LED of 120 Nos
RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
Clause No.2.3.3
2.4 Flashes per Minute (40±5) RDSO specificationNo.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
Clause No.2.4.1
2.5 Output regulated Voltage RDSO specificationNo.
Page 81 of 104 Quality Audit of Diesel Loco POH Workshop
Type Subassembly em Details
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
4.1 Proper Register is maintained for LED Flasher Light with details of Manufacturer’s Brand Name,Date of Manufacture, Type, Sl. No., Date of
Attending, Repair/Overhauling activity details,Loco No. to which fitted.
4.2 Proper record should be maintained for each LEDFlasher Light
4.3 LED Flasher Light with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.
7.
Material Availability7.1 Vital Spares
7.2 Must change items
7.3 Consumables such as fuses , toggle switches etc
8. Disposal
8.1 Segregation of Working and Non-Working
equipment and Proper House Keeping
8.2 Safe Disposal including recycling followingrelevant environmental norms.
CHECK SHEET FOR
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 82 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR LED MARKER LIGHT (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Page 85 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR STICK TYPE / IMPROVED STICK TYPE MASTER CONTROLLERFOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
A. Stick Type / Improved Stick type Master controller
1. Measurement:
1.1 Visual checking ALCo
M/s BHEL, Asian Plastic,M/s Kaysons
(AMC/R2)Make
BHEL Testprogrammedocument no. 865476dt
Clause 1.1
Drawing of Improved
stick type Master Controller EL-PT-0633-R3 dt.29.12.2007.
1.2 Contact gap, BHEL Testprogrammedocument no. 865476dt 24.04.99 and
Page 87 of 104 Quality Audit of Diesel Loco POH Workshop
3.27 Instruction Bulletin issued by RDSO
3.28 Maintenance Manual of Manufacturer
3.29 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
4.7 Proper Register is maintained for EMD Master Controller checking with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.
4.8 Proper record should be maintained for each
4.9 EMD Master Controller with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.
7.
Material Availability7.7 Vital Spares
7.8 Must change items
7.9 Consumables like OTTO Switches, Reverser Handle), Terminal Lugs, 28-Pin Coupler, M/s.Radiant make cables. etc.
8. Segregation of Working and Non-Working equipment and
Proper House Keeping
CHECK SHEET FOR
TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR TWIN BEAM HEAD LIGHT (ALCo LOCO)
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 88 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF POH WORKSHOP ELECTRICAL CONTROL FOR TWIN BEAM HEAD LIGHT (ALCo LOCO)
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Page 89 of 104 Quality Audit of Diesel Loco POH Workshop
2.16 Lumen Out put -2600/1770 ± 15 % Lumen of Bright/Dim Filament at 24 V
IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4.A.5
2.17 Lux output with Twin Beam Head Light for eachreflector minimum 2400 Lux at a distance of 8 Mtand 24.5± 0.1 V DC terminal Voltage at LampHolder
IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4.A.6
2.18 Procedure to check correctness of bulb’s f ilamentin test room
IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
Clause No. 4 B
2.19 Checking illumination intensity of head light
assembly when both bulbs are working
IB NO.
MP.IB.EC.01.08.06 DATE:27-12-06
Clause No.6
2.
Availability Of Tools And Test Stands3.26 Voltmeter with Valid Calibration
3.27 1.A standard portable lux measuringequipment ‘Lux meter’ like T.E.S. model TES –1330 shall be used. Lux Meter should be of range0-20000 lux with least count of 0.01 Lux with validcalibration
3.28 Focusing Stand IB NO.MP.IB.EC.01.08.06 DATE:27-12-06
3.29 Screw Driver, Plier, etc.
SN Requirements LocoType
Make Of Subassembly
ReferenceDetails
Clause/Para/ItemDetails
Observations
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 91 of 104 Quality Audit of Diesel Loco POH Workshop
4.10 Proper Register is maintained for TwinBeam Head Light with details of Manufacturer’sBrand Name, Date of Manufacture, Type, Sl. No.,Date of Attending, Repair/Overhauling activitydetails, Loco No. to which fitted.
4.11 Proper record should be maintained for
each Twin Beam Head Light4.12 Twin Beam Head Light /Bulbs with the
measurement of Parameters as in Sl. No.1 prior to Fitment to Loco after overhauling/maintenancewith date and remarks, if any.
7.
Material Availability7.10 Vital Spares
7.11 Must change items
7.12 Consumables like bulbs , Reflector
8.
Disposal
8.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
8.2 Safe Disposal of Bulbs/reflector includingrecycling following relevant environmental norms.
CHECK SHEET FOR
TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR POH
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 92 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR POHWORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
3.32 Battery Room Suitable size with sufficient area for movement of forklift, Storing of Acid Mixing tank,and Suitable battery test benches with sufficientExhaust fans.
3.33 Electrolyte mixing tank-Motorized type preferred3.34 Voltmeter with Valid Calibration
3.35 Thermometer with Valid Calibration
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
3 36 H d t ith V lid C lib ti
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
4.13 Proper Register is maintained for Battery checkingwith details of Manufacturer’s Brand Name, Dateof Manufacture, Type, Sl. No., Date of Attending,Repair/Overhauling activity details, Loco No. towhich fitted.
4.14 Proper record should be maintained for eachbattery with the measurement of Parameters as inSl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
MaterialAvailability
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 96 of 104 Quality Audit of Diesel Loco POH Workshop
TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo LOCO) FOR POH WORKSHOPSIN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference document as per applicability. Wherever the activities are notperformed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.
Workshop/Rly: Audited by: Date of audit:
SN Requirements LocoType
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
1. Dis Assembly and Assembly ALCo Maintenancemanual of Woodward
Section 5 of Maintenance
Manual 2. Measurement :
2.29 Physical Examination
ALCo
Wood WardGovernor Test
Record Format No.TSP/F8572-828
and Maintenancemanual of Woodward
Section 6 of Maintenance
Manual
2.30 Barometer Reading
2.31 Pressure Test
2.32 Hydraulic Seals, needle valve seat and buffer piston bypass in both direction2.33 Needle Valve setting
Page 98 of 104 Quality Audit of Diesel Loco POH Workshop
4.16 Proper record should be maintained for each Governor with the measurement of Parameters as in Sl. No.1 prior to Fitment to Locoafter overhauling/maintenance with date andremarks, if any.
8.
Material Availability
7.16 Vital Spares
7.17 Must change items
7.18 Consumables like Lub Oil, Cotton wool,etc.
9.
Disposal
9.1 Segregation of Working and Non-Workingequipment and Proper House Keeping
9.2 Safe Disposal of scrap and waste including
recycling following relevant environmental norms.
Annexure-6
Check sheet for Quality Audit of Railway Workshop
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)
Page 100 of 104 Quality Audit of Diesel Loco POH Workshop
08 i. Visual inspection of welding of Hand rails to underframe. If there is any
crack or damage in weld then reweld it properly.
ii. All fasteners are used for securing hand rail, clamp, hand rail support should
be properly tighten
09 The coupler pocket shall be examined closely for welding cracks/damage in ribs andinspection of welding with underframe. If any crack or wear is found, shall be
repaired or replaced properly.
10 Visual inspection of welding of ECC mounting stool. If there is any welding
crack/damage then it should be rewelded or replaced properly.
11 i. If abnormal vibration noted modify compressor mounting area of WDM3D
locomotive under frame
ii. Visual inspection of welding of expressor/ compressor mounting stool. If
there is any welding crack/damage then it should be rewelded or replaced
properlyiii. Clean the threads of mounting block on stool by tapping it properly.
MP.MOD.LD.01.02.11
dated 09.03.2011
12 i. Visual inspection of welding of engine mounting block. If there is any weld
defect carryout required welding or replace it
ii. Check/Clean the threads of mounting block by tapping.
13 i. Inspection of air duct gallery for all traction motors cutout for any leakage
or cracks
ii. Filling water/hydraulic test in the gallery carried out
iii. If any leakage is found, shall be repaired accordingly.
14 i. Visual inspection of battery box below side sill/bottom plate for corrosion &
welding cracks in wear plate, end plates & support plate. If there is any crack
or corrosion then it should be rewelded or replaced it
RDSO’s letter
No.SD.DMG.32 Dated
30 07 1996 and SK DL 4436
7/27/2019 Quality Audit for Diesel Loco POH Workshop(1)