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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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.
Page 2 of 104 Quality Audit of Diesel Loco POH Workshop
Quality of Subassembly repairs (important items)
a. Expressor/Compressor b. Air Brake Section c. Bogie section d. Rotating Machines Section e. Turbo section f. Engine Block, Crankshaft and Main bearings g. Cylinder Head , Piston and Valve section h. Radiator section. i. FIP/Injector Section j. Governor Section k. Electrical Control Section l. Battery Section m. Under-frame, side buffers, cow catcher,
couplers, superstructure/Upper-frame, roof, driver cabin, hand rails, fuel tank, loco painting/marking/stencilling etc.
a. Further details of check sheet covered in Annexure 1. b. -do- c. Further details of check sheet covered in Annexure 2. d. Further details of check sheet covered in Annexure 3. e. Further details of check sheet covered in Annexure 4. f. -do- g. h. -do- i. -do- j. Further details of check sheet covered in Annexure 5. k. -do- l. -do- m. Further details of check sheet covered in Annexure 6.
Implementation of modifications
As per modification sheets/Instruction Bulletin’s issued by RDSO/DLW/HQ.
Material
Availability of critical items
Procurement from unapproved sources, if any.
Any other item As decided by the auditing authority
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 Observations
1. 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
Page 4 of 104 Quality Audit of Diesel Loco POH Workshop
(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
Page 5 of 104 Quality Audit of Diesel Loco POH Workshop
Annexure-2
CHECK SHEET FOR
CONDUCTING TECHNICAL AUDIT OF BOGIE AT POH WORKSHOP (ALCO LOCOMOTIVE)
SN Activity
Loco Type Reference Details Observations
1. Overhauling/Inspection Alco Series RDSO report Misc. No. Misc-164, MP.MI-71/78 and SK.DL-3370 to be followed
Cleaning of bogie frame
Alignment of bogie frame (including tramming)
a) Wheel base spacing b) Transverse pedestal spacing c) Longitudinal pedestal spacing d) Pedestal bottom alignment e) Motor nose suspension lug
Page 7 of 104 Quality Audit of Diesel Loco POH Workshop
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 bogie Maintain all running gear clearance as per the MI’s Maintain the Lateral clearances between Axle Box and Pedestals (Ensure attention to wheel and axle assembly as per S.N. 8)
Page 8 of 104 Quality Audit of Diesel Loco POH Workshop
12. Availability of Tools And Test Stands WDM2, WDM3A,WDG3A, &
WDM3D/E/F
Over head Crane
Hydraulic Jacks
Cleaning vat
Bogie frame manipulator
Crack reclamation facility like gouging, grinding & welding facility etc.
Stress relieving furnace
DPT, MPT & UT testing facilities
Surface table for measurement
Spring load-deflection testing machine
Hydraulic damper testing machine
Torque wrench, Go/No Go Gauges
Height gauges
Inside and Outside Calliper, Vernier Caliper, Height Gauge, Cleaning Tank,
Painting facilities
Wheel 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 dimensions
Training of staff including qualification of welders
Maintenance manual and check sheets
Record keeping of tools and measuring
instruments
Calibration of measuring instruments
14.
Record Keeping For Traceability
Page 9 of 104 Quality Audit of Diesel Loco POH Workshop
Annexure-3
CHECK SHEET FOR
QUALITY AUDIT OF TRACTION MOTOR PINION & GEAR ASSLY. AT POH WORKSHOPS
During the audit, activities should be checked with regard to the Clause/Para/Item of the reference documents. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded:
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
Over 7 teeth 220.800MM
Permissible Backlsh With New Set
0.266 - 0.664MM
Condemning Limit On Basis Of Backlash
1.04MM
Crack detection MPMI or Zyglo test
Page 10 of 104 Quality Audit of Diesel Loco POH Workshop
1.2 TRACTION GEAR & PINION
WDG3A
Traction 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
Over 3 teeth 80.366MM
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 fan 1387.25/1387mm
Bore diameter of TA stator 1392mm
Bore diameter of TA fan 600.00 / 600.03mm
Diameter of fan seating area on barrel.
600.03 / 600.06mm
Width of fan seating at bore 9+1 mm
Depth of counter sunk bolts hole 4.5 - 5.5 mm
Bolt head width 12.3mm
6.4 Bolt head height above fan plate after final assembly should not be more than
6.5 6- 7mm
Circumferentially Fan gap on TA 2.50 – 2.75mm
Tightening torque and wire locking process
28 – 30Kg-m
Page 11 of 104 Quality Audit of Diesel Loco POH Workshop
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 bolts
M20 & 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
6.6 Proper alignment of TA fan should be checked by inserting filler gauge circumferentially
6.7 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 43T
PTU PINION - 43T
0.60mm to 1.40mm 0.05mm to 0.12mm
on shaft
Page 12 of 104 Quality Audit of Diesel Loco POH Workshop
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 STANDS All 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 Callipers
2.2 Disc Mike
2.3 Filler Gauge
4 INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.4Record keeping of tools and measuring instruments
5 TRACEABILITY
6 MATERIAL AVAILABILITY
5.1 Vital Spare -NA
5.2 Must change items -NA
Page 13 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
QUALITY AUDIT OF TRACTION MOTORS 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:
SN REQUIREMENTS LOCO TYPE MAKE OF SUB-ASSEMBLY
REFERENCE DETAILS
CLAUSE/ PARA/
ITEM DETAILS
OBSERVATION
1 MEASUREMENT
Alco Locos
Traction Motors of Alco Loco
MP.MI-2, MP.MI-6 &
Maintenance manual issued by OEMs viz. BHEL / CGL.
1.1 PRE-INSPECTION
i) Record IR of
a) Armature (Shall be > 10 MΩ)
b) Inter Pole (Shall be > 10 MΩ )
c) Main Pole (Shall be > 10 MΩ)
ii) Record ovality of commutator (Limit – 0.001”)
1.2 AFTER DIS-MANTLING
i) Pinion to be sent for Magna flux test / Zyglo test
ii) Visual examination of Armature banding. If found beyond repair, rewind it.
iii) Check commutator dia. for condemning size. Replace commutator, if condemning size reached. If commutator is retained, then check millivolt drop to ensure health of tig welding/bar to bar shortening. If required, repair it.
iv) Check commutator surface roughness. If found > 0.05 mm or any cut mark is observed, commutator to be grind on machine.
v) Ensure that there is no damage on armature seating area & armature shaft. If any damaged is noticed, re-metalize it to reqd. size.
vi) Ensure cleaning of magnet frame with cleaning solvent to RDSO spec. MP.0.8000.01 Rev.02 Oct.’2007.
Page 14 of 104 Quality Audit of Diesel Loco POH Workshop
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)
Page 15 of 104 Quality Audit of Diesel Loco POH Workshop
xxi) Ensure the replacement of PTFE sleeve of brush arm.
xxii) Ensure painting of support arm with red becktol varnish.
xxiii) Conduct high potential test as per OEM’s manual
1.3 ASSEMBLY
i) Motor assembly as per OEM’s manual
ii) Measure the final Insulation Resistance = 10 Mega ohm
a) Armature (Shall be > 100 MΩ)
b) Inter Pole (Shall be > 100 MΩ )
c) Main Pole (Shall be > 100 MΩ)
iii) Measure the end float (Lt. = 0.006” to 0.012”)
iv) Check the nose plate condition. If found damaged or wear out, shall be replaced.
v) Conduct the light run test at low, medium & 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.
Page 16 of 104 Quality Audit of Diesel Loco POH Workshop
2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 1000V Megger
2.2 Filler gauge
2.3 HV tester
2.4 Dial gauge
2.5 Tachometer / Speedometer
2.6 Pyrometer
2.7 Inside & Outside micrometer /calliper
3 INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.3 Record keeping of tools & measuring instruments
4 TRACEABILITY
5 MATERIAL AVAILABILITY & STORAGE (AC/non-AC)
5.1 Vital Spares
5.2 Must change items
Page 17 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
QUALITY AUDIT OF TRACTION ALTERNATOR 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:
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’s Maintenance 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 GEAR Spring pressure- 1.36 to 2.2 kgs (adjustable) to be adjusted to 1.8 kgs.
Minimum length of brush at which brush become inoperative – 35mm.
Clearance between brush holder & slip ring- 2 to 3 mm. c)SLIP RING Diameter (New) – 520 mm
Minimum worn out dia – 510 mm
Slip ring run our (max) – 0.1 mm Slip ring ovality (max) – 0.1 mm
Page 18 of 104 Quality Audit of Diesel Loco POH Workshop
d)ROTOR
Diameter- 1003 mm
Air gap at pole center – 6 mm Rotor bearing - NU330 EM/C4/D150mm x65 mm x 320mm O/D
Bearing housing dimension – 320-0.005 mm.
where outer race sites - - 0.025 mm Radial clearance of free bearing when new – 0.165 to 0.215 mm Fit between outer race & bearing housing- 0.035 mm clearance, 0.025 mm interference Shaft bearing seating dia – 150 + 0.055 mm + 0.035 mm Fit between inner race & shaft – 0.035 to 0.08 mm interference Diametrical slackness of free bearing – 0.15 to 0.18 mm Min. permissible racial clearance when assembled - 0.03 to 0.13 mm Min. diametrical clearance when assembled in the machine – 0.051 mm Bull gear wheel I/D – 149.098 + 0.025 mm + 0.0 mm Shaft bull gear seating dia–149.098 + 0.162 mm + 0.152 mm Gear box oil capacity – 2.6 litres approx. Lubricant type – SAE 40 or equivalent
Page 19 of 104 Quality Audit of Diesel Loco POH Workshop
e)TIGHTENING TORQUE KG.M
Exciter to gear box – 15 Aux-gen to gear box – 15 PTU to gear box – 15 Gear box to end shield – 15 (write locked) Gear box to end shield – 1 (at pads) Fan to rotor shaft – 25/27 (write locked) Rotor shaft extension to barrel – 25 Rotor pole bolts – 170/190 Slip ring to shaft extn. – 15
f) RESISTANCE AT 25°C- Stator- 0.002156 ohm (Line to Line) Rotor- 0.312 ohm (at slip ring) g) IR TESTS Stator (check with 1000V magger) : 2M Ohms Rotor(check with 1000V magger) : 2M Ohms
2 AVAILABILITY OF TOOLS AND TEST STANDS
a. Bearing retaining ring b. Clamping ring c. Shaft adaptor d. Guide sleeve e. Frame lifting fixture f. Extractor for bull gear g. Lifting tackle h. Forcing screws i. Guiding studs j. Spacers k. S.K.F. Oil Pump
Page 20 of 104 Quality Audit of Diesel Loco POH Workshop
l. Studs m. protection sleeves n. Extractor for bearing inner race o. Extractor foe bearing outer race from
bearing housing
3 INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.4Record keeping of tools & measuring instruments
4 TRACEBILITY
5 MATERIAL AVAILABILITY
5.1 Vital Spare
5.2 Must change items
Page 21 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
QUALITY AUDIT OF TRACTION MOTOR BEARING & ASSLY. COMPONENTS 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
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 mm Commutator End 0.065 mm 0.20 mm
b) In addition to above, max. service radial clearance
NU 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
Page 22 of 104 Quality Audit of Diesel Loco POH Workshop
Hub Outer dia. 177.040 to 177.090 mm
Outer dia. on 2
nd Groove 210.610 to 210.670 mm
Groove width 8.00 to 8.05 mm Total width 44.4 to 44.6 mm
e) End shield - PE Bore dia. 319.975 to 319.995 mm
f) End shield - CE Bore dia. 214.980 to 215.00 mm
g) Seat diameter on armature shaft For brg.-PE, Bore dia. 150.035 to 150.055 mm For brg.-CE, Bore dia. 100.025 to 100.040 mm For retaining collar PE 146.130 to 146.150 mm For bearing sleeve PE 153.220 to 153.240 mm For inner brg. wiper CE 101.600 to 101.620 mm
h) End Float on Traction motor (TM 4907) CE Limit – 0.50 mm Aim – 0.42 mm
1.5 Fits & Clearances (BG TM)
i) Pinion end bearing Interferences (Diametrical) Clearances (Diametrical Brg. 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
-------------- --------------
Page 23 of 104 Quality Audit of Diesel Loco POH Workshop
ii) Commutator end bearing
Interferences (Diametrical) Clearances (Diametrical Brg. 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. components
Item Heating temp.
Bearing inner race PE 100 - 110 ºC
Bearing inner race CE 100 -110 ºC
Sleeve (PE) 100 -130 ºC
Sleeve (CE) 100 -130 ºC
Flinger (PE) 100 -120 ºC
End shield (PE) 120 -130 ºC
End shield (CE) 120 -130 ºC
Retaining collar (wiper) 120 -130 ºC
2 AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Dial gauge
3 INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.3Record keeping of tools and measuring instruments
4 TRACEABILITY
5 MATERIAL AVAILABILITY
5.1 Vital Spare - NA
5.2 Must change items - NA
Page 24 of 104 Quality Audit of Diesel Loco POH Workshop
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, 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
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 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
Page 25 of 104 Quality Audit of Diesel Loco POH Workshop
1.11 Floating bush ID (CE) 40.011-40.05 mm
Para 5.2.4.13 & details in 5.4.2.5
Floating bush OD (CE) 53.80-53.86 mm
1.12 Floating bush OD (TE) 64.82-64.84 mm
1.13 Floating bush ID (TE) 51.022-51.07 mm
1.14 Thrust bearing width 10.39-10.50 mm
Para 5.2.4.13 & details 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 machine
2.2 Zyglo testing machine
2.3 Casing hydraulic test stand
2.4 Bearing puller (CE & TE)
2.5 Torque wrench up to 250 psi
2.6 micrometer 2”-3” & 0-4”
2.7 Go-NoGo gauge for checking fix nozzle ring
3
Availability of instructions etc.
3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
Page 26 of 104 Quality Audit of Diesel Loco POH Workshop
4 Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
5.2 Must change items
1
Measurements etc
1.1 Nozzle ring and gas inlet casing 0.022-0.032” DiaClearance (Cl)
Alco
Alco 720
Instruction Manual ALCO
ALCo MI 11126
1.2 Turbine blade and gas inlet casing 0.060-0.092”Dia CI
1.3 Nozzle ring and turbine disc 0.124” cold CI
1.4 Intermediate casing and impeller 0.017-0.065” longitudinal Clearance (long Cl)
1.5 Impeller and Blower inlet 0.035-0.075” long CI
1.6 Blower casing end blower inlet measure with bolt loose. Scatting with back of diffuser at lease to 80%(This is only in case when we apply a new diffuser) 0.005-0.020” Long CI (Gap)
1.7 Turbine disc and intermediate casing 0.008-0.016” Long CI
1.8 Bearing and thrust collar (Blower end) with surface by approx 0.003 less when oil. 0.007-0.018” Thrust CI
1.9 Inducer and blower casing 0.091-0.101”Dia CI
1.10 Thurst collar and oil seal Blower End 0.014-0.036”Dia CI
1.11 Interference between bearing and intermediate casing (blower & Turbine end ) 0.0005-0.0015” DiaCl
1.12 Rotor shaft and oil seal (turbine end) 0.006-0.008” Dia CI
1.13 Gas inlet casing and intermediate casing inside measurement 0.090-0.098” Dia CI
1.14 Impeller and intermediate casing 0.125-0.127” Dia CI
1.15 Max allowable clearance between Gas inlet casing & Nozzle ring 0.005” clearance
Page 27 of 104 Quality Audit of Diesel Loco POH Workshop
2
Availability of tools, Test Stands etc.
Alco
Alco 720
Instruction Manual ALCO
2.1 Balancing machine
2.2 Zyglo machine
2.3 Casing hydraulic test stand
2.4 Oil gallery flushing test stand
2.5 Bearing puller (CE & TE)
2.6 Sand blast machine for rotor cleaning
2.7 Torque wrench up to 250 psi
2.8 micrometer 2”-3” & 0-4”
2.9 Go-NoGo gauge for checking fix nozzle ring
3
Availability of instructions etc .
3.1 Display Chart
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
Page 28 of 104 Quality Audit of Diesel Loco POH Workshop
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
Loco Type
Make/class Of
Subassembly
Reference Details
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”.
Page 29 of 104 Quality Audit of Diesel Loco POH Workshop
Torque values for Cylinder head stud 100-120 ft pound.
4.
Availability of tools and test a) Plate, lifting b) Compound, gasket c) Turning plate, free end & gen. end. d) Fixture for checking distortion of Cyl,
block and cyl. liner to Cyl. block seat e) Sleeve tool, upper and lower. f) Mandrel g) Magnaflux h) Feeler gauge i) Vernier caliper j) Torque wrench
5.
Availability of instruction a) Display chart. b) Training of staff c) Maintenance manual and check
sheets. d) Record keeping of tools and
measuring instruments.
6. Record keeping traceability
.
7. Material availability (i). Vital spares. (ii). Must change item
Page 30 of 104 Quality Audit of Diesel Loco POH Workshop
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.
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”
Page 31 of 104 Quality Audit of Diesel Loco POH Workshop
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 &
11067C
4.
Availability of tools and test a) Lifting block b) Lapping tool c) Deflection guage. d) Feeler gauge e) Soft hammer f) Torque wrench
5.
Availability of instruction a) Display chart. b) Training of staff c) Maintenance manual and
check sheets. d) Record keeping of tools and
measuring instruments.
6. Record keeping traceability.
7. Material availability (i). Vital spares. (ii). Must change item
Page 32 of 104 Quality Audit of Diesel Loco POH Workshop
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. Workshop/Rly: Audited by: Date of audit:
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
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. Workshop/Rly: Audited by: Date of audit:
1.2 Inspect visually piston skirt and body for scoring or scuffing
1.3 Inspect piston crack using Magnaflux
1.4 Zyglo test for checking surface crack
1.5 (a) Groove width top ring, 2nd ring and 3rd ring 0.1902”- 0.1950”(conventional)
(b) Groove width top ring & 2nd ring 0.1900”-0.195”(3RV)
1.6 (a) Side clearance in above rings 0.0052” -0.012” (conventional)
(b) Side clearance in above rings 0.0054” -0.012” (3RV)
1.7 (a) Groove width of oil scraper ring 0.3140” – 0.3165” (conventional)
(b)Groove width of oil scraper ring 0.2377” – 0.0.241” (3RV)
1.8 (a) Side clearance in oil ring 0.002”- 0.006” (conventional)
(b) Side clearance in oil ring 0.002”- 0.0064” (3RV)
1.9 Piston pin to bushing clearance running 0.003” – 0.0075”
1.10 Piston pin to snap ring total clearance 0.076” – 0.118”
Page 34 of 104 Quality Audit of Diesel Loco POH Workshop
2.
Availability of tools , Test Stands etc.
2.1 Feeler gauge
2.2 Zyglo testing machine
2.3 Magna flux
2.4 Vernier caliper
2.6 Piston ring groove gauge
3
Availability of instructions 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
Page 35 of 104 Quality Audit of Diesel Loco POH Workshop
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:
Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco Type Make of Subassembly
Reference Details
Clause/Para/Item details
Observations
1
Measurements etc:
Alco --
Alco Instruction Manual (MI-
11020G)
Chapter on
Cylinder
Heads
1.1 Stem dia. of valves 0.6205-0.6195 (New).
1.2 Groove fillet radii 0.025-0.031R.
1.3 Valve disk thickness: for C and F type valve of 450: (a) 0.1562” (new) and (b) 0.0625” (condemning Limit).
1.4 Valve disk thickness (for E type valve 300) 0.1750” (new). And, 0.0937” (condemning Limit).
2
Availability of tools, test stands etc:
2.1 Depressor, Spring etc
2.2 Grinder
3
Availability of instructions etc:
3.1 Display Chart etc.
3.2 Training of Staff
3.3 Record keeping of tools and measuring instruments
4 Record keeping for traceability:
5
Material Availability:
5.1 Vital Spare
5.2 Must change items
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
Alco
Conventional
Alco MI
Chapter on Maintenance, Radiators.
2 Reconditioning of Radiator Chapter on LOCOMOTIVE INSPECTION,
MAINTENANCE AND LUBRICATION
MI 17003 A
2.1 Dismantling 2.2 Cleaning of the core 2.3 Changing of gaskets 2.4 Assembly 2.5 Testing
Chapter on Maintenance, Radiators.
3 Cleaning etc
Alco
Conventional
Alco 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 stand
4.4 Fin combing tool
4.5 Radiator immersion tank for cleaning
Page 37 of 104 Quality Audit of Diesel Loco POH Workshop
5
Availability of instructions etc.
5.1 Display board etc
5.2 Training of staff
5.3 maintenance manual and check sheets
5.4 Calibration facility for tools and measuring instruments
6 Record Keeping for Traceability
7.
Material Availability:
5.1 Vital spares
5.2 Must change Item
Page 38 of 104 Quality Audit of Diesel Loco POH Workshop
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
Page 39 of 104 Quality Audit of Diesel Loco POH Workshop
3. Availability of instructions etc.
3.1 Display of charts etc 3.2 Training of staff. 3.3 Maintenance manual and check sheet etc 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
Page 40 of 104 Quality Audit of Diesel Loco POH Workshop
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. Workshop/Rly: Audited by: Date of audit:
SN Requirements Loco type
Make /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-assembly Para on Inspection of Parts Para on Inspection of Parts Para on Assembly Para on Assembly Para on Assembly
1.1 Dis-assembly 1.2 Inspection of parts 1.3 Replace Intermediate disc if found cracked or
if indentation at the nozzle seating end exceeds 0.125 mm.
1.4 Opening pressure – 3700 to 3800 psi ( 260-270 kgf/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 test
2. Availability of Tools, Test Stands etc: List on Service Tools for Injector
Page 41 of 104 Quality Audit of Diesel Loco POH Workshop
3. Availability of instructions etc:
3.1 Display of chart 3.2 Training of staff 3.3 Maintenance manual and check sheet 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
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:
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
Page 43 of 104 Quality Audit of Diesel Loco POH Workshop
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 Type
Make 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.
ALCo
Contract 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 Commissioning Test schedule (Electrical equipment)
BHEL docs: TNE -2/2105/97/DELCTS Date
Page 44 of 104 Quality Audit of Diesel Loco POH Workshop
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 as ECS 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,
As per OEM manual
Page 45 of 104 Quality Audit of Diesel Loco POH Workshop
DISPLAYCHART & FLOW CHART
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)
Medha
1. Operational manual for drivers Doc.No.IM-38 Rev 3.0 July 07 2. Maintenance Instruction manual Doc. No.IM-53 Rev 0.0 Sept’2008 3. System Manual Doc. No. IM-08 Rev.3.0 March 2008 4. Troubleshooting Manual Doc.No. IM-51 Rev.2.0 Oct.2008 5. WDG3A Control wiring Drg. no.ED 1035 6. WDG3A Power. ED 1037 7. WDG3A Schematics Drg. no.ED Wiring Drg. no 1034 8. WDG3A TB wiring Drg. no.ED 1036 9. WDM3D Control wiring Drg. no.ED 1031 10. WDM3D Power Wiring Drg. no.ED 1033 11. WDM3D Schematics Drg. no.ED 1030 12. WDM3D TB wiring Drg. no.ED 1032
Siemens
1. KM DIREKT scheme no. DRG. No. 3FZE-00961
2. 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
Page 46 of 104 Quality Audit of Diesel Loco POH Workshop
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 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. Measurement
1.1 Control voltage 72+1 VDC All Diesel Electric Locomo tives (ALCo)
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.
IEC 60571
as per clause 10.2.9
Page 47 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
(iv) Contacts of interlocks (v) Interlocks and coil shorted together and main
contacts shorted together (vi) shorted main contacts and shorted interlocks, coil
and earth
2.0 Availability of tools and stands
2.1 Multimeter with proper calibration
2.2 Vernier calipers with valid calibration
2.3 Go- No gauge suiting to different cantactors
2.4 Dial gauge of different scale and resolution as suited to respective contactor
2.5 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.6 Variac
2.7 Meggar
2.8 Oscilloscope
2.9 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.1 Display Chart
3.2 Flow Chart
3.3 Training of staff
3.4 Proper Display of Do’s and Don’t
3.5 Maintenance manual and check sheets
3.6 Record keeping of tools and measuring instruments
3.7 Instruction Bulletin issued by RDSO
3.8 Maintenance Manual of Manufacturer
3.9 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability
4.1 Proper Register is maintained for Contactors with details of Manufacturer’s Brand Name, Date of
Page 48 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
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 in Sl. No.1 prior to Fitment to Loco after overhauling/maintenance with date and remarks, if any.
7. Material Availability
7.1 Vital Spares
7.2 Must change items
7.3 Consumables
8. Disposal
8.1 Segregation of Workable and Non-Workable equipments and proper house keeping
8.2 Proper Disposal of Materials including recycling following relevant environmental norms
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 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. Measurement
1.1 Short time control voltage -72+1v dc, All Diesel Electric Locomo tives (ALCo)
Drawing No. EL/PT/0641/
Altr R3 Part
No 121410510
Technical details given in the
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,
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, coil
and earth
as per IEC 60571
clause 10.2.9
2.0 Availability of tools and stands
2.10 Multimeter with proper calibration
2.11 Vernier calipers with valid calibration
2.12 Go- No gauge suiting to different contactors
2.13 Dial gauge of different scale and resolution as suited to respective contactor
2.14 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.15 Variac
2.16 Megger
2.17 Oscilloscope
2.18 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.10 Display Chart
3.11 Flow Chart
3.12 Training of staff
3.13 Proper Display of Do’s and Don’t
3.14 Maintenance manual and check sheets
3.15 Record keeping of tools and measuring instruments
3.16 Instruction Bulletin issued by RDSO
3.17 Maintenance Manual of Manufacturer
3.18 Specification
Page 51 of 104 Quality Audit of Diesel Loco POH Workshop
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 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.
4.4 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 Availability
7.4 Vital Spares
7.5 Must change items
7.6 Consumables
8. Disposal
8.3 Segregation of Workable and Non-Workable equipments and proper house keeping
8.4 Proper Disposal of Materials including recycling following relevant environmental norms
Page 52 of 104 Quality Audit of Diesel Loco POH Workshop
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 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.
Measurement
1.1 Short time control voltage 72+1 v dc, All Diesel Electric Locomo tives (ALCo)
Drawing No. EL/PT/0639/
Altr R3 Part
No 12141100
Technical details given 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
Page 53 of 104 Quality Audit of Diesel Loco POH Workshop
2.0 Availability of tools and stands
2.19 Multimeter with proper calibration
2.20 Vernier calipers with valid calibration
2.21 Go- No gauge suiting to different contactors
2.22 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 Variac
2.25 Megger
2.26 Oscilloscope
2.27 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.19 Display Chart
3.20 Flow Chart
3.21 Training of staff
3.22 Proper Display of Do’s and Don’t
3.23 Maintenance manual and check sheets
3.24 Record keeping of tools and measuring instruments
3.25 Instruction Bulletin issued by RDSO
3.26 Maintenance Manual of Manufacturer
3.27 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
Page 54 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.5 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.
4.6 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 Availability
7.7 Vital Spares
7.8 Must change items
7.9 Consumables
8. Disposal
8.5 Segregation of Workable and Non-Workable equipments and proper house keeping
8.6 Proper Disposal of Materials including recycling following relevant environmental norms
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 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. Measurement
1.1 Max pick up volt 48v All Diesel Electric Locomo tives (ALCo)
Drawing No. EL/PT/0629/
Altr R3 Part
No 12141033
Technical details given in the
drawing
1.2 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 IEC 60571 between
(i)Main contacts of contactor
(ii) Coil and magnet frame
IEC 60571
as per clause 10.2.9
2.0 Availability of tools and stands
2.28 Multimeter with proper calibration
2.29 Vernier calipers with valid calibration
2.30 Go- No gauge suiting to different cantactors
Page 56 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
2.31 Dial gauge of different scale and resolution as suited to respective contactor
2.32 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.33 Variac
2.34 Meggar
2.35 Oscilloscope
2.36 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.28 Display Chart
3.29 Flow Chart
3.30 Training of staff
3.31 Proper Display of Do’s and Don’t
3.32 Maintenance manual and check sheets
3.33 Record keeping of tools and measuring instruments
3.34 Instruction Bulletin issued by RDSO
3.35 Maintenance Manual of Manufacturer
3.36 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 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 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.
Page 57 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
7.
Material Availability
7.10 Vital Spares
7.11 Must change items
7.12 Consumables
8. Disposal
8.7 Segregation of Workable and Non-Workable equipments and proper house keeping
8.8 Proper Disposal of Materials including recycling following relevant environmental norms
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 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. Measurement
1.1 control voltage 72+1v dc, 1.2 Max pick up volt 48 v
All Diesel Electric Locomo tives (ALCo)
Radiator Fan contactor
Drawing No. EL/PT/0638/
Altr R3 Part
No 12140235
Technical details given in the
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 12140235
1.5 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
2.0 Availability of tools and stands
2.37 Multimeter with proper calibration
2.38 Vernier calipers with valid calibration
2.39 Go- No gauge suiting to different cantactors
Page 59 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
2.40 Dial gauge of different scale and resolution as suited to respective contactor
2.41 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.42 Variac
2.43 Meggar
2.44 Oscilloscope
2.45 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.37 Display Chart
3.38 Flow Chart
3.39 Training of staff
3.40 Proper Display of Do’s and Don’t
3.41 Maintenance manual and check sheets
3.42 Record keeping of tools and measuring instruments
3.43 Instruction Bulletin issued by RDSO
3.44 Maintenance Manual of Manufacturer
3.45 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability
4.9 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 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.
Page 60 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
7.
Material Availability
7.13 Vital Spares
7.14 Must change items
7.15 Consumables
8. Disposal
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
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 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. Measurement
1.1 Control voltage 72+1v dc, All Diesel Electric Locomo tives (ALCo)
1.7 operating coil resistance at 20 deg c 104 -116 ohms,
1.8 interlock (GPRelay type- 9-41n, 3no+3nc) contact gap 9.5-10.5
1.9 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
as per IEC 60571
clause 10.2.9
Page 62 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
contacts shorted together (vi) shorted main contacts and shorted interlocks, coil
and earth
2.0 Availability of tools and stands
2.46 Multimeter with proper calibration
2.47 Vernier calipers with valid calibration
2.48 Go- No gauge suiting to different cantactors
2.49 Dial gauge of different scale and resolution as suited to respective contactor
2.50 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.51 Variac
2.52 Meggar
2.53 Oscilloscope
2.54 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.46 Display Chart
3.47 Flow Chart
3.48 Training of staff
3.49 Proper Display of Do’s and Don’t
3.50 Maintenance manual and check sheets
3.51 Record keeping of tools and measuring instruments
3.52 Instruction Bulletin issued by RDSO
3.53 Maintenance Manual of Manufacturer
3.54 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
Page 63 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.11 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.
4.12 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 Availability
7.16 Vital Spares
7.17 Must change items
7.18 Consumables
8. Disposal
8.11 Segregation of Workable and Non-Workable equipments and proper house keeping
8.12 Proper Disposal of Materials including recycling following relevant environmental norms
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 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. Measurement ALCo Drawing No. EL/PT/0630/
Altr R4 Part
No 12141008
Technical details given in the
drawing
1.1 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,
1.9 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
Page 65 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
2.0 Availability of tools and stands
2.55 Multimeter with proper calibration
2.56 Vernier calipers with valid calibration
2.57 Go- No gauge suiting to different cantactors
2.58 Dial gauge of different scale and resolution as suited to respective contactor
2.59 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.60 Variac
2.61 Lever of 122.5 mm for measuring initial and final pressure.
2.62 Compresor with air reservoir
2.63 Megger
2.64 Oscilloscope
2.65 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.55 Display Chart
3.56 Flow Chart
3.57 Training of staff
3.58 Proper Display of Do’s and Don’t
3.59 Maintenance manual and check sheets
3.60 Record keeping of tools and measuring instruments
3.61 Instruction Bulletin issued by RDSO
3.62 Maintenance Manual of Manufacturer
3.63 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
Page 66 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.13 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.
4.14 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 Availability
7.19 Vital Spares
7.20 Must change items
7.21 Consumables
8. Disposal
8.13 Segregation of Workable and Non-Workable equipments and proper house keeping
8.14 Proper Disposal of Materials including recycling following relevant environmental norms
Page 67 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
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 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:
1.11 ROTEX TYPE: 3118AV1-3 coil resistance at 20degC-526 to 594 Ohms.
1.12 Contact impression (should be min 80%) Spec No.
MP.0.04.00.08
(Rev-
01),May’10
3.10.e
Page 68 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item 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
2.0 Availability of tools and stands
2.66 Multimeter with proper calibration
2.67 Vernier calipers with valid calibration
2.68 Go- No gauge suiting to different cantactors
2.69 Dial gauge of different scale and resolution as suited to respective contactor
2.70 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.71 Variac
2.72 Lever of 122.5 mm for measuring initial and final pressure.
2.73 Compresor with air reservoir
2.74 Megger
2.75 Oscilloscope
2.76 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.64 Display Chart
3.65 Flow Chart
3.66 Training of staff
3.67 Proper Display of Do’s and Don’t
3.68 Maintenance manual and check sheets
3.69 Record keeping of tools and measuring instruments
3.70 Instruction Bulletin issued by RDSO
Page 69 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
3.71 Maintenance Manual of Manufacturer
3.72 Specification Spec No.
MP.0.04.00.08
(Rev-
01),May’10
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability
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.
7.
Material Availability
7.22 Vital Spares
7.23 Must change items
7.24 Consumables
8. Disposal
8.15 Segregation of Workable and Non-Workable equipments and proper house keeping
8.16 Proper Disposal of Materials including recycling following relevant environmental norms
Page 70 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
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 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. Measurement
1.1 Auxiliary contacts 4 change over type, All Diesel Electric Locomo tives (ALCo)
Drawing No. EL/PT/0648/
Altr R5 Part No
12310300
Technical details given in the
drawing
1.2 Control voltage 72+1 V DC, 1.3 operating air pressure 4.9 kg/cm2,
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 Ohms
1.13 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
as per clause 10.2.9
Page 71 of 104 Quality Audit of Diesel Loco POH Workshop
2.0 Availability of tools and stands
2.77 Multimeter with proper calibration
2.78 Vernier calipers with valid calibration
2.79 Go- No gauge suiting to different cantactors
2.80 Dial gauge of different scale and resolution as suited to respective contactor
2.81 Source which can provide minimum current at respective voltage (24 V – 72 V DC)
2.82 Variac
2.83 Lever of 122.5 mm for measuring initial and final pressure.
2.84 Compresor with air reservoir
2.85 Meggar
2.86 Oscilloscope
2.87 Screw Driver, Plier, Spanner Set, etc.
3. Availability Of Instructions etc.
3.73 Display Chart
3.74 Flow Chart
3.75 Training of staff
3.76 Proper Display of Do’s and Don’t
3.77 Maintenance manual and check sheets
3.78 Record keeping of tools and measuring instruments
3.79 Instruction Bulletin issued by RDSO
3.80 Maintenance Manual of Manufacturer
3.81 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
Page 72 of 104 Quality Audit of Diesel Loco POH Workshop
6 Record Keeping For Traceability
4.17 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.
4.18 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 Availability
7.25 Vital Spares
7.26 Must change items
7.27 Consumables
8. Disposal
8.17 Segregation of Workable and Non-Workable equipments and proper house keeping
8.18 Proper Disposal of Materials including recycling following relevant environmental norms
Page 73 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
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 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.
Measurement
1.10 Nominal operating voltage (50-80 V) All Diesel Electric Locomo tives (ALCo)
BHEL, AAL and IEI
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 V
1.14 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 0.1
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 components
Clause16.1.9.2
1.20 IR Value between 1.20.1 Open contacts 1.20.2 Contacts and metal parts 1.20.3 Adjacent contacts 1.20.4 Coil and earth
as per IEC 60571
Clause 10.2.9
2.0 Availability of tools and stands
2.88 Multimeter with proper calibration
2.89 Vernier calipers with valid calibration
2.90 Go- No gauge
2.91 Dial gauge
Page 74 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
2.92 Source which can provide minimum current at respective 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 by manufacturer
3. Availability Of Instructions etc.
3.82 Display Chart
3.83 Flow Chart
3.84 Training of staff
3.85 Proper Display of Do’s and Don’t
3.86 Maintenance manual and check sheets
3.87 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 Bulletin
5. Follow of Maintenance Manual of Manufacturer
6 Record Keeping For Traceability
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.
Page 75 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
7.
Material Availability
7.28 Vital Spares
7.29 Must change items
8. Disposal
8.19 Segregation of Workable and Non-Workable equipments and proper house keeping
8.20 Proper Disposal of Materials including recycling following relevant environmental norms
Page 76 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
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 not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded. Work shop/Rly: Audited by: Date of audit:
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
1. Measurement :
2.1 Visual Inspection – check finish , material , sound quality of workman ship etc
Page 77 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item 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. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
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.,
Page 78 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
Date of Attending, Repair/Overhauling activity details, 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 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
7.30 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.
Page 79 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
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 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. Measurement :
2.1 Visual Inspection – check finish , material , sound quality of workman ship , water tightness etc
Page 80 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
3.1 Voltmeter with Valid Calibration
3.2 Ammeter with Valid Calibration
3.3 Lux Meter with proper Calibration
3.4 Test stand for measurement and testing.
3.5 Stop Watch
3.6 Screw Driver, Plier, etc.
3.7 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.1 Display Chart
3.2 Flow Chart
3.3 Training of staff
3.4 Proper Display of Do’s and Don’t
3.5 Maintenance manual and check sheets
3.6 Record keeping of tools and measuring instruments
3.7 Instruction Bulletin issued by RDSO
3.8 Maintenance Manual of Manufacturer
3.9 Specification RDSO specification No.
ELRS/SPEC/LFL/0017 Rev 1 Sept 04
Page 81 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
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 LED Flasher Light
4.3 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.
Material Availability
7.1 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 following
relevant environmental norms.
Page 82 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
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 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. Measurement :
2.7 Visual Inspection – check finish , material , sound quality of workman ship , water tightness etc.
2.9 Lux Value- for all input voltage range 45 V-90 V
Lamp Lux level at 1
Meter
Lux level at 3
Meters
RED 75 LUX 7 LUX
WHITE 75 LUX 7 LUX
RDSO specification No. ELRS/Spec/PR/
0022 (REV-1 Oct -2004)
Clause No. 2.4.3
2.
Availability Of Tools And Test Stands
3.8 Multimeter with Valid Calibration ALCo
3.9 Lux Meter with proper Calibration
3.10 Test stand for measurement and testing.
Page 83 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
3.11 Screw Driver, Plier, etc.
3.12 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.10 Display Chart
3.11 Flow Chart
3.12 Training of staff
3.13 Proper Display of Do’s and Don’t
3.14 Maintenance manual and check sheets
3.15 Record keeping of tools and measuring instruments
3.16 Instruction Bulletin issued by RDSO
3.17 Maintenance Manual of Manufacturer
3.18 Specification
4. Compliance of Instruction Bulletin
5. Follow of Maintenance Manual of Manufacturer
6. Record Keeping For Traceability
4.4 Proper Register is maintained for LED Marker Light with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.
Page 84 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
4.5 Proper record should be maintained for each LED Marker Light
4.6 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.
Material Availability
7.4 Vital Spares
7.5 Must change items
7.6 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 following relevant environmental norms.
Page 85 of 104 Quality Audit of Diesel Loco POH Workshop
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
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 Type
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 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
Page 86 of 104 Quality Audit of Diesel Loco POH Workshop
2.
Availability Of Tools And Test Stands
ALCo
M/s BHEL,
Asian Plastic, M/s Kaysons
(AMC/R2) Make
3.13 Voltmeter with Valid Calibration
3.14 Venier Caliper with Valid Calibration
3.15 Megger with Valid Calibration
3.16 Digital Multimeter with Valid Calibration
3.17 Potentiometer with Valid Calibration
3.18 Height gauge with Valid Calibration
3.19 High Voltage Tester with Valid Calibration
3.20 Bore Dial gauge with Valid Calibration
3.21 Ammeter with Valid Calibration
3.22 GO and NO GO Gauge
3.23 Screw Driver, Plier, Required spanner set etc.
3.24 Test stand for measurement and testing.
3.25 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.19 Display Chart
3.20 Flow Chart
3.21 Throttle sequence chart
3.22 Mechanical interlocking Chart
3.23 Training of staff
3.24 Proper Display of Do’s and Don’t
3.25 Maintenance manual and check sheets
3.26 Record keeping of tools and measuring instruments
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’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 each
4.9 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.
Material Availability
7.7 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
Page 88 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
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 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. Measurement :
2.10 Visual Inspection – check finish , material , sound quality of workman ship etc
ALCo
RDSO specification No. ELRS/SPEC/PR/0024 ( Rev-1,
Sept 2004)
Clause No.6.3.1
2.11 Functional Check –ON/OFF properly
2.12 Type of Bulbs used – H4 P45 T(IR), Twin Filament IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06
Clause No. 4.A.1
2.13 Model of Bulbs –Halonix and AutoPal Only IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06
Clause No. 4.A.2
2.14 Voltage Rating -24 V IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06
Clause No. 4.A.3
2.15 Wattage Rating of Bulbs -100/90 W, Bright/Dim filament at 24 V
IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06
Clause No. 4.A.4
Page 89 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
2.16 Lumen Out put -2600/1770 ± 15 % Lumen of Bright/Dim Filament at 24 V
IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06
Clause No. 4.A.5
2.17 Lux output with Twin Beam Head Light for 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
2.18 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
2.19 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 Stands
3.26 Voltmeter with Valid Calibration
3.27 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
3.28 Focusing Stand IB NO. MP.IB.EC. 01.08.06 DATE: 27-12-06
3.29 Screw Driver, Plier, etc.
Page 90 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
3.30 Test stand for measurement and testing.
3.31 Fire Extinguisher of proper class
3
Availability Of Instructions etc.
3.30 Display Chart
3.31 Flow Chart
3.32 Training of staff
3.33 Proper Display of Do’s and Don’t
3.34 Maintenance manual and check sheets
3.35 Record keeping of tools and measuring instruments
Page 91 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details
Clause/Para/Item Details
Observations
4.10 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.
4.11 Proper record should be maintained for each Twin Beam Head Light
4.12 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.
Material Availability
7.10 Vital Spares
7.11 Must change items
7.12 Consumables like bulbs , Reflector
8.
Disposal
8.1 Segregation of Working and Non-Working equipment and Proper House Keeping
8.2 Safe Disposal of Bulbs/reflector including recycling following relevant environmental norms.
Page 92 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF BATTERY SECTON LEAD ACID BATTERY CHECK SHEET FOR 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 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:
3.32 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.
3.33 Electrolyte mixing tank-Motorized type preferred
3.34 Voltmeter with Valid Calibration
3.35 Thermometer with Valid Calibration
Page 93 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
3.36 Hydrometer with Valid Calibration
3.37 Ammeter with Valid Calibration
3.38 Multi meter with Valid Calibration
3.39 Clamp Meter
3.40 Rubber syringe
3.41 Battery Charger(Preferred Constant Current Chargers)
3.43 Required Lab for testing of Acid and DM water
3.44 Screw Driver, Plier, Spanner Set etc.
3.45 Test stand for measurement and testing (Concrete Platform covered with Acid Resistant FRP sheets/coating for keeping batteries –charge /Discharge.)
3.46 D.M.Water Plant
3.47 Proper earthing facility for switch gear and Battery charging Panel.
3.48 Fire Extinguisher of proper class
3.49 Fork Lift
3.50 Hand trolley
3.51 Battery lifting crane on test bench
3.52 Plastic Pallet for storing Battery
3.53 Rubber Apron
3.54 Rubber Gloves
3.55 Goggles
3 Availability Of Instructions etc.
Page 94 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
3.39 Display Chart
3.40 Flow Chart
3.41 Training of staff
3.42 Proper Display of Do’s and Don’t
3.43 Maintenance manual and check sheets
3.44 Record keeping of tools and measuring instruments
4.13 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.
4.14 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
Page 95 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
7.
Material Availability
7.13 Vital Spares
7.14 Must change items
7.15 Consumables like Distilled Water,
Sulphuric Acid (for Lead Acid Battery), Lugs, Rubber Mat etc.
8.
Disposal
8.1 Segregation of Working and Non-Working equipment and Proper House Keeping
8.2 Safe Disposal of Battery including recycling following relevant environmental norms.
Page 96 of 104 Quality Audit of Diesel Loco POH Workshop
CHECK SHEET FOR
TECHNICAL AUDIT OF GOVERNOR SECTON (ALCo LOCO) FOR 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 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. Dis Assembly and Assembly ALCo
Maintenance manual of Woodward
Section 5 of Maintenance
Manual
2. Measurement :
2.29 Physical Examination
ALCo
Wood Ward Governor Test
Record Format No. TSP/F8572-828
and Maintenance manual 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 direction
2.33 Needle Valve setting
2.34 Speed Setting
2.35 Normal Shut Down
2.36 Pressure Requirement
2.37 Speed Setting timing
2.38 Lube Oil Shutdown
2.39 Air Box Pressure Fuel Limiting
2.40 Load Control
2.41 Vane Servo Timing
2.42 Excitation Resistor
2.43 General
2.44 Verification with Cover Installed
3.
Availability Of Tools And Test Stands ALCo
3.56 Test Stand for Wood Ward Governor
3.57 Multimeter with valid Calibration
3.58 Screw Driver, Plier, Allen Key, Spanner,
Page 97 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
etc.
3.59 Fire Extinguisher of proper class
4.
Availability Of Instructions etc.
3.48 Display Chart
3.49 Flow Chart
3.50 Training of staff
3.51 Proper Display of Do’s and Don’t
3.52 Display of Trouble Shooting Chart Maintenance Manual
Section 4
3.53 Maintenance manual and check sheets
3.54 Record keeping of tools and measuring instruments
3.55 Instruction Bulletin issued by RDSO NA
3.56 Maintenance Manual of Manufacturer
3.57 Specification NA
5. Compliance of Instruction Bulletin NA
6. Follow of Maintenance Manual of Manufacturer
7. Record Keeping For Traceability
4.15 Proper Register is maintained for Governor testing with details of Manufacturer’s Brand Name, Date of Manufacture, Type, Sl. No., Date of Attending, Repair/Overhauling activity details, Loco No. to which fitted.
Page 98 of 104 Quality Audit of Diesel Loco POH Workshop
SN Requirements
Loco Type
Make Of Subassembly
Reference Details Clause/Para/Item Details
Observations
4.16 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.
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-Working equipment and Proper House Keeping
9.2 Safe Disposal of scrap and waste including recycling following relevant environmental norms.
Page 99 of 104 Quality Audit of Diesel Loco POH Workshop
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.N
o.
Activity Clause/ Reference Observations
Underframe
01 Underframe to be kept on trestle at lifting lugs.
02 Proper cleaning & washing of U/F with detergents & water,.
03 Use of manipulator for carrying out repair work by down hand welding.
04 i. Visual inspection of buffer beam, striker block for any crack or damage, accordingly repair/weld properly
ii. Check the buffer base bolt holes for size, centers & ovality. Remove the ovality by welding and redrill if necessary
05 i. Check the cattle guard/rail guard by visual inspection, if any crack/ damage found then it should be repaired/replaced accordingly
ii. Ensure minimum clearance of cattle guard from R/L to be 178 mm iii. Ensure minimum clearance of rail guard from R/L. to be 115 mm iv. Modify/ change cattle guard and its support arrangements to plate type on
WDM3A locomotive
RDSO’s Drg. No.
SK.DL-4533/4535 and
DMW’s Drg. No.
2DMW/SK-938
06 Visual inspection of welding of gussets/ stiffeners in back of buffer beam
transferring buffing force from buffers to maintain longitudinal box section. If any
crack /damage is found, it shall be repaired accordingly.
Page 100 of 104 Quality Audit of Diesel Loco POH Workshop
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 out iii. If any leakage is found, shall be repaired accordingly.
Page 101 of 104 Quality Audit of Diesel Loco POH Workshop
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 tighten iv. Wooden spacer properly placed between the battery v. All hinges, locks should be in working
vi. Cover assly. properly secured & locked with battery box.
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 tighten v. Fuel gauge should not be broken and in working condition
vi. Fuel gauge mounting bracket, filler cap, vent pipe should be in good condition
RDSO’S Investigation
Report No.
MP-473/83 February, 1983
16 Visual inspection of underframe box section and side sill welding. If there is any
crack or damage, weld it properly with low hydrogen welding electrode.
RDSO’S Investigation
Report No.
MP.INV-8
December, 1995
17 i. Carefully examine the welding around the both center pivots for crack and also check the surface with magnaflux or die-penetrant method to identify cracks, if any, which is not visible to naked eyes.
ii. If any crack is found, weld it properly with down hand welding.
RDSO’Drg. No.
SK.DL-2069
18 i. Carefully examine the welding around side load bearers for crack and also check the surface with magnaflux or die penetrant method to 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
Page 102 of 104 Quality Audit of Diesel Loco POH Workshop
19 Loco painting, marking, stenciling;
Apply epoxy primer and PU paint before stenciling
As per extent colour
scheme
20 Center buffer coupler & Draft Gear
Check compliance of RDSO instructions for inspection and maintenance
Modify uncoupling arrangement to make it top operated
G-80
MP.MOD.LD.05.10.11
dated 18.07.2011
21 Side Buffers
Check compliance of RDSO instructions for inspection and maintenance
MP.MI-116/82, Rev.02
22 Loco Cab
Railway Board’s letter
No.2000/M(L)/466/9 dated
05.01.2005
23.
1
Driver/Pilot seat
i. Base mounting nut/ bolt and other fasteners should be properly tighten ii. Motion and its adjuster/locking arrangement/ Ver. & rotational motion
should be in functioning iii. Cushion & upholstery should be in good condition
23.
2
Side sash / window
i. Sliding glass should freely slide and not cracked ii. Locking arrangement properly in fuction
iii. Guide rail, weather rubber & glazing rubber should be in good condition iv. Rear view mirror if applied properly secured with frame and its rotational
movement checked. Mirror should be in good condition
Page 103 of 104 Quality Audit of Diesel Loco POH Workshop
23.
3
Cab door
i. Lock, hinges should be in function ii. Glass, weather strip should be in good condition and door properly sealed in
closed condition iii. Assistant seat properly secured and in good working condition iv. Wiper motors should be in working
23.
4
Cab floor
i. Flooring mat & trim should be in good condition ii. Steel structure/ panel sheet of cab should not be corroded or broken
23.
5
Cont. Comp door, short hood door & Cab inner trim
i. Lock, hinge and weather sealings should be in working condition ii. Perforated aluminium sheet , insulating material, fasteners should be in
good condition
23.
6
Cab light and fan
i. Switches, regulators and connections are properly in function
23.
7
Fire Extinguisher
i. Mounting bracket should be in good condition and refilling facilities should be available
23.
8
Air condition (if applied)
i. Switches, regulator and water drainage properly in function
23.
9
Token pick up arrangement
i. Token pickup rod properly joint with cab and should be in function (closing & opening)
ii. Cushion pad frame properly welded with cab and cushion mat condition should be 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
Page 104 of 104 Quality Audit of Diesel Loco POH Workshop
24 Superstructure
i. Check the condition of sheets and repair if possible otherwise change ii. Check hinges and door locks for proper working and repair if possible
otherwise change iii. Check for water leakage at various joints and renew weather stripes/ceilings iv. Door panel-sheet should not bend and properly close
25 Radiator compartment & Expansion tank
i. Gauge, vent, vacuum valve, low water alarm should function ii. Expansion tank plate should not be corroded
iii. Funnel grating, foot step, hand- rail, inspection door properly secured with rad. Comp. Structure.