Quality Audit of Diesel Loco POH Workshops
CHECK SHEET
Item
Description
Reference Documents, Annexures, Further details on check sheet
etc.
Compliance of POH Schedule:
General
Safety items
Schedule of standard examinations: MP-Misc-140/141 (for Alco
locos).
-doLoad Test MI No MP.MI-10 (Rev 0.02), Aug 2003. (for Alco locos).
Quality of POH:
Load Test records:
 HP
 SFC
 EGT
 Peak Firing Pressure
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
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 1 of 104
Quality Audit of Diesel Loco POH Workshop
Quality
of
Subassembly
repairs
(important
items)
Implementation
of modifications
Material
Any other item
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.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
Further details of check sheet covered in Annexure 1.
-doFurther details of check sheet covered in Annexure 2.
Further details of check sheet covered in Annexure 3.
Further details of check sheet covered in Annexure 4.
-do-do-doFurther details of check sheet covered in Annexure 5.
-do-doFurther details of check sheet covered in Annexure 6.
As per modification sheets/Instruction Bulletin’s issued by RDSO/DLW/HQ.
 Availability of critical items
 Procurement from unapproved sources, if any.
As decided by the auditing authority
Page 2 of 104
Quality Audit of Diesel Loco POH Workshop
Annexure-1
CHECK LIST FOR
TECHNICAL AUDIT AT POH WORKSHOPS (BRAKE ITEMS)
S.No.
Item
1. Whether
all
the
items
prescribed in the schedule is
being followed
for brake
equipment,
compressor
/Expressor & air dryer or not
2.
Functioning of VCD
3.
Test benches and rigs
4.
Test on Loco after POH
5.
Infrastructure facilities
Parameter
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.
Whether functioning of VCD is being checked in
every POH schedule.
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.
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).
(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 3 of 104
Quality Audit of Diesel Loco POH Workshop
Observations
6.
Storage of material
7.
Availability of Material
8.
Human Resource
development
9.
Any other observation
(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.
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.
Any Chromic shortage of material for
maintenance
Whether periodic training is being imparted to
maintenance staff to make them conversant with
the maintenance practices.
Page 4 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
1.
Overhauling/Inspection
Alco Series
 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
squareness & spacing
 Crack detection, repair & heat
treatment (Stress relieving)
 Replacement of manganese liners and
brake rigging bushes
Axle box & journal bearings
 Cleaning of Axle box & bearings
 Inspection bearing components
 Overhauling as per the referred MP.MI
Suspension Springs ( As per MI )
 Cleaning of springs
 Free height of springs
 Working height of springs
 Grouping / colour code of springs
 100% replace of spring pads ( Happy
Pads)
Friction Snubber Assembly
 Disassemble snubber (See SK.DL- 1505
for instructions)
 Check the inside diameter of the friction
sleeve with a “No Go” gauge Figure
SK.DL- 3127
WDM2, WDM3A, WDG3A, &
WDM3D/E/F
2.
3.
4.
Loco Type
Reference Details
RDSO report Misc. No. Misc-164,
MP.MI-71/78 and SK.DL-3370 to be
followed
MP.MI-04.004
WDM2, WDM3A, WDG3A, &
WDM3D/E/F
Page 5 of 104
As per relevant drawing,
MP.IB.VL- 04.19.01 (Rev.01),
MP.IB.VL- 04.19.01 (Rev.01) for
WDG3A
&
MP.MI-31
for
WDM3D/E/F
Details as per Drawing SK.DL2089A, SK.DL- 1505, SK.DL- 3127,
SK.DL-3126, SK.DL- 1512 , SK.DL1513
Quality Audit of Diesel Loco POH Workshop
Observations
5.
6.
7.
8.
 Check the dimensions of the shoes as
indicated in figure SK.DL-3126
 Replace worn or broken parts. For
assembly refer SK.DL- 1512 &1513
 Re-assembly of snubber
 Height measurement and checking for
damping characteristics
Hydraulic damper
 Check the Capacity / Rating of dampers
 Damper overhauling
 Testing
Side Bearer (Rubber spring)
WDG3A, & WDM3D/E/F
 Free Height of rubber spring
 Working height of rubber spring
 Permanent set of rubber spring
 Rubber crack length/ de-bonding
Equaliser Beams
WDM2, WDM3A,
 Checking for cracks
 Reclamation of hard face as per MC-43
and 92
WDM2, WDM3A,WDG3A, &
Wheel & Axle Assembly
 Wheel wear measurement i.e. Root WDM3D/E/F
wear, Tread wear, Flange wear, wheel
flat, visual inspection for any defect
like crack, wheel flat, shelling, spaling
etc. ,wheel reprofiling.
 Wheel gauge (1596+3/-0.5 mm)
 Deference in tread diameter of wheels
on same axle, same bogie & same
loco
 Ultrasonic testing of axles
Page 6 of 104
As per drawings No. SK.VL-295,
SK.VL-328 and
SK.VL-387 &
overhauling as per
MP.IB.VL. 05.39.10 (Rev.00)
As per drawings No. SK.Vl-127 &
133 &
MP.IB.VL. 04.30.08 (Rev.01)
M&C document no. MC – 43 & MC92
Wheel
wear
management
Instruction
Bulletin
no.MP.IB.BD.0216.01 (Rev-1) & MP
MI71/78 & MP.MI-31
RDSO procedure MC-71
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.
1. Centre Pivot & Loading Pads
WDM2, WDM3A
 Load Pad to Centre Pivot Height
Difference to be maintained.
WDG3A, & WDM3D/E/F
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.
MP.MISC – 141
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
WDM2, WDM3A
WDG3A, & WDM3D/E/F
MP.MI-71/78, VL.Mi-02/96 &
MP.MI-31
MP.IB.VL.03.04.06 (WDM2 &
WDM3A)
(Ensure attention to wheel and axle
assembly as per S.N. 8)
MP.IB.VL.01.02.06 (WDG3A)
Page 7 of 104
Quality Audit of Diesel Loco POH Workshop
12.
Availability of Tools And Test Stands
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
Elecrode heating oven
WDM2, WDM3A,WDG3A, &
WDM3D/E/F
SK.DL-3592
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 8 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:
S.N
REQUIREMENTS
1
MEASUREMENT
1.1
LOCO TYPE
MAKE OF SUBASSEMBLY
REFERENCE
DETAILS
TRACTION GEAR & PINION
Gear Ratio
18 : 65
Pinion Drg. No.
Pinion
Bedding
Condition
Pinion Advance
18 teeth, SKDP3624
In
Cold
Not less than 95 %
2.25 TO 2.45MM
Heating Temperature
190ºC + AMB TEMP.
Span Size On New Pinion
Over
3
teeth
88.595 /88.722MM
Over
3
teeth
86.995MM
65 teeth SKDP3623
& SKDP3775
Over 7 teeth
223.989/223.798MM
Over
7
teeth
220.800MM
0.266 - 0.664MM
Condmning Limit On
Span Size Of Pinion
Gear Drg. No.
Basis Of
Span Size On New Gear
Condmning Limit On Basis Of
Span Size Of Gear
Permissible Backlsh With New
Set
Condemning Limit On
Basis
Of Backlash
Crack detection
Alco (WDM2,
WDM3A,
WDM3D)
1.04MM
MPMI or Zyglo test
Page 9 of 104
Quality Audit of Diesel Loco POH Workshop
MPIB.EM.10.31.08
dated
24.10.2008
CLAUSE/
PARA/
ITEM
DETAILS
OBSERVATION
1.2
TRACTION GEAR & PINION
Gear Ratio
18 : 74
Pinion Drg. No.
Pinion
Bedding
Condition
Pinion Advance
18 teeth, SKDP3443
In
Cold
Not less than 95 %
2.30 TO 2.45MM
Heating Temperature
185ºC + AMB TEP.
Span Size On New Pinion
Over 3 teeth 81.976
/82.093MM
Over
3
teeth
80.366MM
65 teeth SKDP3444 &
SKDP3546
Over 8 teeth
231.36/231.177
Over 8 teeth 228.140
Condmning Limit On
Span Size Of Pinion
Gear Drg. No.
Basis Of
Span Size On New Gear
Condmning Limit On Basis Of
Span Size Of Gear
Permissible Backlsh With New
Set
Condemning Limit On
Basis
Of Backlash
Crack detection
1.3
MP-MI 129/86
July ‘1986
Traction Motor
Pinion & Gear
Assly. of Alco
Loco
MP-MI 5
0.243 - 0.608MM
1.00MM
MPMI or Zyglo test
TA FAN ASSEMBLY
Outer diameter of TA fan
6.4
WDG3A
Bore diameter of TA stator
Bore diameter of TA fan
Diameter of fan seating area on
barrel.
Width of fan seating at bore
Depth of counter sunk bolts hole
Bolt head width
Bolt head height above fan plate
6.5
after final assembly should not be
more than
Circumferentially Fan gap on TA
Tightening torque and wire locking
process
1387.25/1387mm
1392mm
600.00 / 600.03mm
600.03 / 600.06mm
All ALCo
locos
MPIB.EM.01.02.10
dated 11.01.2010.
9+1 mm
4.5 - 5.5 mm
12.3mm
6- 7mm
2.50 – 2.75mm
28 – 30Kg-m
Page 10 of 104
Quality Audit of Diesel Loco POH Workshop
Tightening
torque
of
M30
(coupling bolt)
Oil catcher thickness (at bottom
side)
Bolts strength properties grade
Sunk type M20 bolts can be used
6.6
M20 & M30 bolts should be
replaced
Fan bore area should be heated
(for shrink fit).
Re-used or old bolts and barrel
thread condition should be
checked by
Threaded portion of barrel & bolts
should be free from varnish or
paint or dust deposits.
TA fan should be mounted on the
barrel by “shrink fit “
TA fan bolts locking wire ends
should not be come out of the bolt
head(projected)
Proper alignment of TA fan should
6.7
be checked by inserting
filler
gauge circumferentially
After Final assembly of TA fan,
visual inspection is required on
TA Gear train assembly
TA GEAR 102T
AG/EG PINION 43T
PTU PINION - 43T
170 – 180 kg-m.
53.90 to 54.10mm
R8.8.
in place of fully
threaded M20 bolts
After 4 – 5 years
service of TA
150 to 170 °С
GO & NO GO thread
ring or plug gauge
Visual inspection is
required
In place of (bolts)
press fit.
As shown in photo
Clearance between
the fan (back side)
and barrel of TA (as
shown in attached
photo)
No
clearance
is
allowed.
Tightening
torque,
wire locking & fan
back clearance with
barrel(by filler gauge
(circumferentially)
Backlash at Steel
plate
0.60mm to 1.40mm
0.05mm to 0.12mm
on shaft
Page 11 of 104
All ALCo
locos
MP.IB.EM.02.12.0
0dated 10-4-2000.
Quality Audit of Diesel Loco POH Workshop
2
Carbody cables and Traction Motor cables
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
4
5
6
AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Vernier Callipers
2.2 Disc Mike
2.3 Filler Gauge
INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.4Record keeping of tools and measuring
instruments
TRACEABILITY
MATERIAL AVAILABILITY
5.1 Vital Spare
-NA
5.2 Must change items
-NA
Page 12 of 104
All ALCo
locos
MP.IB.EM.02.03.08,
dated 24-01-2008
And
MP.IB.EM.03.04.08,
dated 24-01-2008
All ALCo
locos
MP.IB.EM.02.03.08,
dated 24-01-2008
And
MP.IB.EM.03.04.08,
dated 24-01-2008
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
1
1.1
i)
MEASUREMENT
PRE-INSPECTION
Record IR of
a) Armature (Shall be > 10 MΩ)
b) Inter Pole (Shall be > 10 MΩ )
c) Main Pole (Shall be > 10 MΩ)
Record ovality of commutator (Limit – 0.001”)
AFTER DIS-MANTLING
Pinion to be sent for Magna flux test / Zyglo test
Visual examination of Armature banding. If found
beyond repair, rewind it.
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.
Check commutator surface roughness. If found >
0.05 mm or any cut mark is observed,
commutator to be grind on machine.
Ensure that there is no damage on armature
seating area & armature shaft. If any damaged is
noticed, re-metalize it to reqd. size.
Ensure cleaning of magnet frame with cleaning
solvent to RDSO spec. MP.0.8000.01 Rev.02
Oct.’2007.
ii)
1.2
i)
ii)
iii)
iv)
v)
vi)
LOCO TYPE
Page 13 of 104
Alco Locos
MAKE OF SUBASSEMBLY
Traction Motors
of Alco Loco
Quality Audit of Diesel Loco POH Workshop
REFERENCE
DETAILS
MP.MI-2,
MP.MI-6 &
Maintenance
manual issued
by OEMs viz.
BHEL / CGL.
CLAUSE/
PARA/
ITEM DETAILS
OBSERVATI
ON
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
xix)
xx)
Bake the magnet frame in oven at 120 + 10 °C &
record it.
Apply insulation varnish as per RDSO MP.MI
153/92 (latest revision)
Check IR after renewal of glass epoxy laminate,
GMGS & Nomex insulation for inter poles & main
poles (Shall be > 100 MΩ )
Ensure tightening of pole bolts during assembly of
magnet frame and maintain IP & MP bores as per
OEM manual.
Joints may be brazed & insulated, if required with
RDSO approved Silicon elastomer tape.
Check IR of main pole & inter pole assemblies &
record it. (Shall be > 100 MΩ )
High potential test of inter pole & main pole at
1.3 KV for 15 sec. shall pass the test.
Ensure spray cleaning of armature with cleaning
solvent to RDSO spec. MP.0.8000.01 Rev.02
Oct.’2007.
Bake the armature in oven at 120 + 10 °C &
record it.
Spray varnish paint protecting the shaft &
commutator & cure it.
Ensure mica cutting. & chamfering as per OEM’s
manual
Ensure cleaning & baking of brush arms as per
OEM’s manual.
Measure IR of brush arm (Shall be > 100 MΩ). If
less, replace the brush arm
Ensure the spring tension. (Lt. 4.5 Kg to 5.5 Kg)
Page 14 of 104
Quality Audit of Diesel Loco POH Workshop
xxi)
xxii)
xxiii)
1.3
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
Ensure the replacement of PTFE sleeve of brush
arm.
Ensure painting of support arm with red becktol
varnish.
Conduct high potential test as per OEM’s manual
ASSEMBLY
Motor assembly as per OEM’s manual
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)
Measure the end float (Lt. = 0.006” to 0.012”)
Check the nose plate condition. If found damaged
or wear out, shall be replaced.
Conduct the light run test at low, medium & high
rpms on assembled motor & observe for unusual
sound using listening rod.
Check the bearing temperature after stabilisation
during light un test. (Shall not be > 60 °C)
Apply brush seater on the commutator to seat
the carbon brushes on the commutator properly.
Ensure tag welding / welding of stays on main
pole & compole fixing bolts.
Apply recommended sealant to avoid ingress of
water etc.
Apply a coat of paint on motor.
Page 15 of 104
Quality Audit of Diesel Loco POH Workshop
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
AVAILABILITY OF TOOLS AND TEST STANDS
1000V Megger
Filler gauge
HV tester
Dial gauge
Tachometer / Speedometer
Pyrometer
Inside & Outside micrometer /calliper
3
3.1
3.2
3.3
4
5
INSTRUCTION
Display Chart
Training of Staff
Record keeping of tools & measuring instruments
TRACEABILITY
MATERIAL AVAILABILITY & STORAGE (AC/nonAC)
Vital Spares
Must change items
5.1
5.2
Page 16 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
1
REQUIREMENTS
LOCO TYPE
MAKE OF SUBASSEMBLY
REFERENCE
DETAILS
Traction
Alternator
of Alco loco
BHEL’s
Maintenance
Manual for
Electrical
Equipment of
ALCO loco
(Volume-II)
MEASUREMENT
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.
ALCO locos
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 17 of 104
Quality Audit of Diesel Loco POH Workshop
CLAUSE/
PARA/
ITEM
DETAILS
OBSERVATIO
N
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 housing0.035 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 18 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°CStator- 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 19 of 104
Quality Audit of Diesel Loco POH Workshop
l.
m.
n.
o.
3
4
5
Studs
protection sleeves
Extractor for bearing inner race
Extractor foe bearing outer race from
bearing housing
INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.4Record keeping of tools & measuring
instruments
TRACEBILITY
MATERIAL AVAILABILITY
5.1 Vital Spare
5.2 Must change items
Page 20 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
1
MEASUREMENT
1.1
1.2
1.3
c)
d)
REFERENCE
DETAILS
Verticality of Inner race
Max. deviations allowed in above cases:
Inner race
Outer race
Pinion End
0.075 mm
0.25 mm
Commutator End
0.065 mm
0.20 mm
Radial Clearances of bearings
For New Bearings
Bearing
b)
MAKE OF SUBASSEMBLY
Verticality of Outer race
Side
1.4
a)
LOCO TYPE
NU 330
Radial clearance
before mounting
(mm)
0.165 - 0.215
0.100 – 0.170
NH 320
0.105 – 0.140
0.060 – 0.100
In addition
clearance
to
above,
Radial clearance
after mounting (mm)
max.
service
radial
NU 330
0.300 mm max.
0.250 mm max.
NH 320
0.190 mm max.
0.150 mm max.
Flinger - PE
Bore Dia.
153.130 to 153.155 mm
Total Width
12.65 to 12.70 mm
All ALCo
locos fitted
with TM
4907/C1001
MPIB.EM.14.50.08
dated
20.02.2009
Traction Motor
Bearing & Assly.
Components of
Alco Loco
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 21 of 104
Quality Audit of Diesel Loco POH Workshop
CLAUSE/
PARA/
ITEM
DETAILS
OBSERVATION
e)
Hub Outer dia.
177.040 to 177.090 mm
Outer dia. on 2nd Groove
210.610 to 210.670 mm
Groove width
8.00 to 8.05 mm
Total width
44.4 to 44.6 mm
End shield - PE
Bore dia.
f)
319.975 to 319.995 mm
End shield - CE
Bore dia.
g)
h)
214.980 to 215.00 mm
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
End Float on Traction motor (TM 4907) CE
Limit – 0.50 mm
1.5
i)
Aim – 0.42 mm
Fits & Clearances (BG TM)
Pinion end bearing
Interferences (Diametrical)
Brg. Sleeve 0.020
to
to shaft
0.065 mm
Flinger
shaft
to
0.065
to
0.110 mm
Inner race to
shaft
Retaining
collar to shaft
0.035
to
0.080 mm
0.090
to
0.135 mm
Clearances (Diametrical
Brg.
0.635
to
Sleeve to 0.750 mm
inner brg.
cap
Retaining
0.25 mm
collar to (min.)
outer brg.
cap
--------------- ---------------------------
--------------
Page 22 of 104
Quality Audit of Diesel Loco POH Workshop
ii)
Commutator end bearing
Interferences (Diametrical)
Brg. Sleeve 0.020
to
to shaft
0.065 mm
Flinger
to
shaft
Inner
brg.
Race to shaft
1.6
2
3
4
5
0.065
to
0.110 mm
0.025
to
0.060 mm
Clearances (Diametrical
Inner brg. 0.635
to
Cap
to 0.750 mm
sleeve
--------------- ---------------------------
--------------
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
AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Dial gauge
INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.3Record keeping of tools and measuring
instruments
TRACEABILITY
MATERIAL AVAILABILITY
5.1 Vital Spare
- NA
5.2 Must change items
- NA
Page 23 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:
SN
1.
Audited by:
Requirements
Loco Type
Balancing, measurementsetc
Balancing:
1.1 Bladed shaft, range 31-257 gmm.
1.2 Rotor, range 157-470 gmm.
Rotor Shaft Dimensions:
1.3 Bearing position OD A 39.98 – 40.00 mm
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
1.8 Piston ring recess
S 2.58-2.85 mm
1.9 Plain bearing (CE)
1.10 Bearing housing bore
ID A 54.00-54.06 mm
ID A 65.00-65.07 mm
Page 24 of 104
Alco
Date of audit:
Make Of
Subassembly
ABB VTC 304
Turbocharger
Reference
Details
ABB-Exhaust
Gas
Turbocharge
r VTC 304 A
Comprehensi
ve Manual
for Indian
Railways
issued by
M/s ABB
Quality Audit of Diesel Loco POH Workshop
Clause/Para/It
em Details
5.6
5.6.2.5
5.6.2.5
Para 5.2.4.13
&
details in
5.4.2.1
Para 5.2.4.13
&
details in
5.4.2.2
Para 5.2.4.13
&
details in
5.4.2.3
Para 5.2.4.13
&
details in
5.4.2.4
Observations
1.11 Floating bush ID (CE) 40.011-40.05 mm
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
5.4.2.5
Para 5.2.4.13
&
details in
5.4.2.6
Para 5.2.4.13
&
details in
5.4.2.7
Para 5.2.4.13
&
details in
5.4.2.8
Para 5.2.4.13
&
details in
5.4.2.9
Para 5.2.4.13
&
details in 5.7
1.15 Axial bearing width 16.76-16.88 mm
1.16 Piston ring width
2.00-2.49 mm
1.17 Thrust bearing press fit measure(K) 170.5-170.63
1.18 Axial clearance
1.19 Radial clearance
2.
3
A 0.11-0.32 mm
B 0.47-0.93 mm
Availability of Tools, Test Stands etc.
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
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 25 of 104
Alco
do
Quality Audit of Diesel Loco POH Workshop
do
4
5
1
Record Keeping For Traceability
Material Availability
5.1 Vital Spares
5.2 Must change items
Measurements etc
1.1 Nozzle ring and gas inlet casing 0.022-0.032”
DiaClearance (Cl)
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) 0.0050.020” 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 0.0140.036”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 26 of 104
Alco
Alco 720
Instruction
Manual
ALCO
Quality Audit of Diesel Loco POH Workshop
ALCo MI
11126
2
3
4
5
Availability of tools, Test Stands etc.
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
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
Record Keeping For Traceability
Material Availability
5.1 Vital Spares
5.2 Must change items
Page 27 of 104
Alco
Alco 720
Instruction
Manual
ALCO
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:
SN
1
2
Requirements
Audited by:
Loco
Type
Make/class
Of
Subassembly
Date of audit:
Reference
Details
Clause/Para/
Item/Chapter Details
Removal of Cyl Block
a) Removal of Cylinder liner.
b) Removal of cylinder liner sleeve.
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 bores0.003”.
ALCO MI
11079 D
Alco
Chapter on Maintenance,
Instruction of Cylinder Block
.
Conventional
Page 28 of 104
Quality Audit of Diesel Loco POH Workshop
Observations
4.
5.
6.
7.
Torque values for Cylinder head stud 100120 ft pound.
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
Availability of instruction
a) Display chart.
b) Training of staff
c) Maintenance manual and check
sheets.
d) Record keeping of tools and
measuring instruments.
Record keeping traceability
.
Material availability
(i). Vital spares.
(ii). Must change item
Page 29 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.
Workshop/Rly:
SN Requirements
1
2
Removal of Crank Shaft
a) Removal
of
Oil
catcher/pipes/engine parts/main
brgs caps/shells & split gears.
b) Checked Crank shaft thrust
(i) Using Main brg shell 0.010”0.017”
(ii) Using Thrust collar 0.012”0.021”
c) Apply grease and wrap journals
and crankpins.
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”
Audited by:
Loco
Type
Make/class
Of
Subassembly
Date of audit:
Reference
Details
ALCO MI
11069 E
Alco
Clause/Para/
Item/Chapter Details
Chapter on Maintenance,
Instruction of Cylinder Block
.
Conventional
Page 30 of 104
Quality Audit of Diesel Loco POH Workshop
Observations
4.
5.
6.
7.
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.
Availability of tools and test
a) Lifting block
b) Lapping tool
c) Deflection guage.
d) Feeler gauge
e) Soft hammer
f) Torque wrench
Availability of instruction
a) Display chart.
b) Training of staff
c) Maintenance manual and
check sheets.
d) Record keeping of tools and
measuring instruments.
Record keeping traceability.
Material availability
(i). Vital spares.
(ii). Must change item
ALCO MI
11067 C
ALCO MI
11069 E &
11067C
Page 31 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:
SN
Audited by:
Requirements
1
2
3
4
5
Loco
Type
Cleaning, measurements etc.
1.1 Cleaning of cylinder head
1.2 Cy head leak test at 70 PSI with hot water
1.3 Inspect head for cracks using Magnaflux
1.4 Valve guide to head int 0.002” -0.0005”
1.5 yoke to guide
int 0.002” -0.0005”
1.6 Yoke guide ( press in dim) 3.210” -3.272”
1.7 Valve guide ( press in dim) 2.25”
1.8 Valve to guide cl
0.003 – 0.0045”
1.9 Cy head nuts torquing value 550ft/lbs
Availability of tools , Test Stands etc.
2.1 Valve seat reconditioning machine
2.2 Hydraulic test stand
2.3 Nozzle hole sleeve tube expander(Bottom & Top)
2.4 Nozzle sleeve extractor
2.5 Nozzle sleeve holder
2.6 Feeler gauge
2.7 Magna flux
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
Record Keeping For Traceability
Material Availability
5.1 Vital Spares
5.2 Must change items
Page 32 of 104
ALCo
Date of audit:
Make Of
Subassembly
--
Reference Details
DLW
Maintenance
Instruction
Manual
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item/cha
pter Details
Chapter on cylinder
head
Observations
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:
SN
Requirements
Loco
Type
1
Cleaning, inspection, measurements etc.
1.1 cleaning of piston
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 33 of 104
ALCo
Date of audit:
Make Of
Subassembly
--
Reference Details
DLW
Maintenance
Instruction
Manual
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item/cha
pter Details
Chapter on piston and
con rod
Observations
4
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
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
Record Keeping For Traceability
5
Material Availability
5.1 Vital Spares
5.2 Must change items
2.
3
Page 34 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:
SN
1
2
3
4
5
Audited by:
Requirements
Loco Type
Measurements etc:
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).
Availability of tools, test stands etc:
2.1 Depressor, Spring etc
2.2 Grinder
Availability of instructions etc:
3.1 Display Chart etc.
3.2 Training of Staff
3.3 Record keeping of tools and measuring
instruments
Record keeping for traceability:
Material Availability:
5.1 Vital Spare
5.2 Must change items
Alco
Page 35 of 104
Date of audit:
Make
of Reference
Subassembly Details
--
Alco Instruction
Manual (MI11020G)
Clause/Para/
Item details
Chapter on
Cylinder
Heads
Quality Audit of Diesel Loco POH Workshop
Observations
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:
SN
Requirements
1
Leakage testing
2
Reconditioning of Radiator
Audited by:
Loco
Type
Alco
3
4
Make/class
Of
Subassembly
Conventional
Date of audit:
Reference
Details
Clause/Para/
Item/Chapter Details
Alco MI
Chapter on Maintenance,
Radiators.
Chapter on LOCOMOTIVE
INSPECTION,
MAINTENANCE AND
LUBRICATION
MI 17003 A
Chapter on Maintenance,
Radiators.
Alco MI
Chapter on Maintenance,
Radiators.
2.1 Dismantling
2.2 Cleaning of the core
2.3 Changing of gaskets
2.4 Assembly
2.5 Testing
Cleaning etc
3.1 cleaning details
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
Alco
Page 36 of 104
Conventional
Quality Audit of Diesel Loco POH Workshop
Observations
5
6
7.
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
Record Keeping for Traceability
Material Availability:
5.1 Vital spares
5.2 Must change Item
Page 37 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:
SN
Requirements
1.
Dis-assembly /Measurement/Assembly etc
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.
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
2.
Loco type
Make of
subassembly
Date of audit:
Reference
details
Clause/Para/Item details
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
Alco
Page 38 of 104
Bosch 17 mm
Bosch repair
and testing
manual
Quality Audit of Diesel Loco POH Workshop
Observation
3.
4.
5.
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.
Record keeping for traceability:
Material availability:
5.1 Vital Spares
5.2 Must change items
Page 39 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:
SN Requirements
1.
2.
Audited by:
Loco Make
type /Class/Name
of
subassembly
Dis-assembly /Measurement/Assembly etc:
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
Availability of Tools, Test Stands etc:
2.1 Nozzle needle lift gauge
2.2 Feeler gauge
2.3 Dial gauge
2.4 Nozzle cleaning sleeve
2.5 True running gauge
2.6 Nozzle tester
2.7 Fixture for injector
2.8 Socket wrench
2.9 Test oil
Reference
details
Date of audit:
Clause/Para/Item details
Observations
Para on Dis-assembly
Para on Inspection of Parts
Para on Inspection of Parts
Para on Assembly
Para on Assembly
Para on Assembly
Alco
Page 40 of 104
Bosch 17 mm
Bosch repair
and testing
manual
List on Service Tools for
Injector
Quality Audit of Diesel Loco POH Workshop
3.
4.
5.
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
Record keeping for traceability:
Material availability:
5.1 Vital spares
5.2 Must change items
Page 41 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:
SN
Audited by:
Requirements
Loco
Type
Dis-assembly /Measurement/Assembly/Test etc.
1.1 Overhauling procedure
1
1.2 Plate Pack Length
1.3 Hydraulic Test
2
3
4
5
Date of audit:
Make Of
Subassembly
Reference Details
Plate Type Lube
Oil Cooler
(PTLOC)
MPMI-24, Nov. 2004
& MP.IB.ES.01.07.08
DLW Drawing No.
TPL-8515, DLW Part
No. 11457260
Availability of tools , Test Stands etc.
2.1 Ratchet spanner
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
Record Keeping For Traceability
Material Availability
5.1 Vital Spares
5.2 Must change items
Page 42 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Ite
m/chapter
Details
Para on
Overhaul
procedure
Outline – Lube
Oil Cooler
Observations
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:
SN
1.
2.
3.
4.
5.
6.
7.
8.
9.
11.1
11.2
Requirements
Loco
Type
No. of Trained personnel with
experience
Record keeping practices after the
tests in relay control room for E type
control
Practices for Handling of the electronic
cards and storing
Availability of crimping tool & connector
pin details
Maintenance practices of Micro
Processor Based Control System MEP
660
Maintenance practices of Micro
Controller Based Governor (MCBG)
MEG 601
Practices followed for Fault data
analysis for identifying the faulty
components and failure.
Standard (OEM recommended) list of
spares, consumable & tools
Audited by:
Make Of
Reference Details
Sub
assembly
MBCS trained personnel
Shed doc
ALCo
ALCo
ALCo
Doc No:IM 53 for MBCS
Medha
Doc No. :IM 53 for MBCS
Medha
DLW/Alco/AMC (micro)/01
Doc No:IM-11 Rev. 0.0
Date Jan 2009 of Medha
ALCo
Contract agreement no.
DLW/ALCO/MCBG/Medha
ALCo
Contract agreement no.
DLW/ALCO/MCBG/Medha
Measurement
Standards for load box examination of
D E locomotives
Practices as per BHEL Commissioning
Test schedule (Electrical equipment)
Page 43 of 104
MP MI -10 (Rev.0.02)
August, 2003
BHEL docs: TNE 2/2105/97/DELCTS Date
Quality Audit of Diesel Loco POH Workshop
Date of audit:
Clause/Para/
Item Details
Observation
11.3
11.4
11.5
11.6
11.7
11.8
12
for 3100/2750 HP BG DE loco for ‘E’
type control
Test procedure for MBCS loco control ALCo
system MEP660 for retrofitted D E loco
Preventive maintenance schedule
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,
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,
Check ground circuit leakage current
Check mv drop test of WSR (E type)
Availability Of Tools And Test Stands
13
Display Chart
13.1
Display of
TROUBLE
DOS and
SHOOTING
ALCo
DONTS,
Chart,
Page 44 of 104
Sept 1997
IM-59
DLW/Alco/AMC (micro)/01
Inspection and test report of MEP
Preventive Maintenance schedule
SF-1405 (0)
Schedule inspection of shed
and items covered under
DLW/Alco/AMC (micro)/01 for
MBCS locos
User settable parameters as
per RDSO MBCS
spec.MP.0.2400.26
-doFor MBCS locos- Test stands
are not provided by MBCS
supplier. Items are covered
under AMC.
Important instruction for
trouble shooting like action to
be taken during wheel slip etc
to be available on the cab
As per OEM manual
Quality Audit of Diesel Loco POH Workshop
14
15
DISPLAYCHART & FLOW CHART
Maintenance manual and check sheets
Instruction Bulletin / Modification sheet
/Hand book/ Trouble shooting charts as
provided by RDSO/ CAMTECH and
implementation by MBCS vendor
As provided by the MBCS
manufacturer*
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 45 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:
SN
Requirements
1.
Measurement
1.1
Control voltage 72+1 VDC
1.2
1.3
1.4
1.5
Audited by:
Loco
Type
Make Of
Subassembly
All Diesel
Electric
Locomo
tives
(ALCo)
1.7
1.8
1.9
Max pick up volt 48v ,
Main contact gap12-14.5mm,
Wipe 8-10 mm,
Contact pressure( kgf) initial 1.82-2.95,final 5.457.25,
Operating coil resistance at 20 deg c 104 -116
ohm, (approx.),
Interlock (gpr type : 9-41n, 3no+3nc)
Contact gap 9.5-10.5 mm,
Interlock contact pressure 220-300g.
1.10
Contact impression (should be min 80%)
1.11
(i)
(ii)
(iii)
IR Value between
Main contacts
Coil and magnet frame
Interlocks and coil shorted together and earth.
1.6
Date of audit:
Page 46 of 104
Reference
Details
Clause/Para/Item
Details
Drawing No.
EL/PT/0640/
Altr R3
Part
No 12145439
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev01),May’10
IEC
60571
3.10.e
Quality Audit of Diesel Loco POH Workshop
as per clause
10.2.9
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference
Details
(iv)
(v)
2.0
Contacts of interlocks
Interlocks and coil shorted together and main
contacts shorted together
(vi)
shorted main contacts and shorted interlocks, coil
and earth
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
3.
4.
5.
6
Oscilloscope
2.9
Screw Driver, Plier, Spanner Set, etc.
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
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
Record Keeping For Traceability
4.1
Proper Register is maintained for Contactors with
details of Manufacturer’s Brand Name, Date of
Page 47 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference
Details
Manufacture, Type, Sl. No., Date of Attending,
Repair/Overhauling activity details, Loco No. to
which fitted.
4.2
7.
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.
Material Availability
7.1
Vital Spares
7.2
Must change items
7.3
Consumables
Disposal
8.1
Segregation of Workable and NonWorkable equipments and proper house keeping
8.2
Proper Disposal of Materials including recycling
following relevant environmental norms
Page 48 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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:
SN
Requirements
1.
Measurement
1.1
Short time control voltage -72+1v dc,
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
Audited by:
Date of audit:
Loco
Type
Make Of
Subassembly
All Diesel
Electric
Locomo
tives
(ALCo)
Control voltage -24vdc,
Max pick up volt 24v
Main contact gap12-14.5 mm,
Wipe 8-10 mm,,
Contact pressure( kgf) initial 1.82-2.95, final 5.457.25,
Operating coil resistance at 20 deg c 18.520.5ohm,
Interlock (gpr type : 9-41n, 3no+3nc)
Contact gap 9.5-10.5 mm,
Interlock contact pressure 220-300 gm ,
.)
Contact impression (should be min 80%)
Page 49 of 104
Reference
Details
Clause/Para/Item
Details
Drawing No.
EL/PT/0641/
Altr R3
Part
No 121410510
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev01),May’10
3.10.e
Quality Audit of Diesel Loco POH Workshop
Observations
1.13
(i)
(ii)
(iii)
(iv)
(v)
2.0
IR Value between
mMain contacts
Coil and magnet frame
Interlocks and coil shorted together and earth.
Contacts of interlocks
Interlocks and coil shorted together and main
contacts shorted together
(vi)
Shorted main contacts and shorted interlocks, coil
and earth
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
3.
as per IEC
60571
Oscilloscope
2.18 Screw Driver, Plier, Spanner Set, etc.
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 50 of 104
Quality Audit of Diesel Loco POH Workshop
clause 10.2.9
4.
5.
6
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
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
7.
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.
Material Availability
7.4
Vital Spares
7.5
Must change items
7.6
Consumables
Disposal
8.3
Segregation of Workable and NonWorkable equipments and proper house keeping
8.4
Proper Disposal of Materials including recycling
following relevant environmental norms
Page 51 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:
SN
Requirements
1.
Measurement
1.1
Short time control voltage 72+1 v dc,
1.2
1.3
1.4
1.5
1.6
Audited by:
Loco
Type
Make Of
Subassembly
All Diesel
Electric
Locomo
tives
(ALCo)
1.8
Control voltage 24vdc,
Max pick up volt 24 v
Main contact gap 6-7.5mm,
Wipe 0.8-1.6 mm,
Contact pressure(gmf) initial 80-150, final 180.280,
Operating coil resistance at 20 deg c 55+5%
ohm(52 to 58 ohms),
Contact impression (should be min 80%)
1.9
(i)
(ii)
IR Value between
fixed contact to movable Contacts
coil to frame
1.7
Date of audit:
Page 52 of 104
Reference
Details
Clause/Para/Item
Details
Drawing No.
EL/PT/0639/
Altr R3
Part
No 12141100
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev01),May’10
IEC 60571
3.10.e
Quality Audit of Diesel Loco POH Workshop
clause 10.2.9
Observations
2.0
3.
4.
5.
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.
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
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
Page 53 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
7.
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.
Material Availability
7.7
Vital Spares
7.8
Must change items
7.9
Consumables
Disposal
8.5
Segregation of Workable and NonWorkable equipments and proper house keeping
8.6
Proper Disposal of Materials including recycling
following relevant environmental norms
Page 54 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:
SN
Requirements
1.
Measurement
1.1 Max pick up volt 48v
1.2
1.3
1.4
Audited by:
Date of audit:
Loco
Type
1.5
Main contact gap 11-13 mm,
Wipe 3.5-4.7mm,
contact pressure( kgf) initial 0.68-0.9kgf, final 0.91.4kgf.,
operating coil resistance at 20 deg c 169-195 ohm ,
1.6
Contact impression (should be min 80%)
1.7
IR Value as per clause 10.2.9 of IEC
60571 between
Make Of
Subassembly
All Diesel
Electric
Locomo
tives
(ALCo)
Reference
Details
Clause/Para/Item
Details
Drawing No.
EL/PT/0629/
Altr R3
Part
No 12141033
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev01),May’10
3.10.e
IEC
60571
(i)Main contacts of contactor
(ii) Coil and magnet frame
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 55 of 104
Quality Audit of Diesel Loco POH Workshop
as per clause
10.2.9
Observations
SN
Requirements
2.31
2.33
2.34
Dial gauge of different scale and resolution as
suited to respective contactor
Source which can provide minimum current at
respective voltage (24 V – 72 V DC)
Variac
Meggar
2.35
Oscilloscope
2.32
3.
4.
5.
6
Loco
Type
Make Of
Subassembly
Reference
Details
2.36 Screw Driver, Plier, Spanner Set, etc.
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
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
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 56 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
SN
Requirements
7.
Material Availability
7.10 Vital Spares
7.11 Must change items
7.12
Consumables
Disposal
8.7
Segregation of Workable and NonWorkable equipments and proper house keeping
8.8
Proper Disposal of Materials including recycling
following relevant environmental norms
8.
Loco
Type
Page 57 of 104
Make Of
Subassembly
Reference
Details
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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:
SN
Requirements
1.
Measurement
1.1
control voltage 72+1v dc,
1.2
Max pick up volt 48 v
Audited by:
1.3
Main contact gap 6-7.5mm,
1.4
1.5
Wipe 0.8-1.6 mm,
Contact pressure( gmf) initial 80-150, final 180.280,
Operating coil resistance at 20 deg c -388
ohm±5% (368 to 408 ohms),
1.6
1.7
Contact impression (should be min 80%)
1.8
2.0
IR Value between
(i) fixed contact to movable Contact
(ii) coil to frame
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 58 of 104
Date of audit:
Loco
Type
Make Of
Subassembly
Reference
Details
Clause/Para/Item
Details
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
Drawing No.
EL/PT/0638/Par
t
No 12140235
Altr R3
Drawing No.
EL/PT/0638/Par
t
Spec No.
MP.0.04.00.08
(Rev01),May’10
IEC 60571
Quality Audit of Diesel Loco POH Workshop
3.10.e
clause 10.2.9
Observations
SN
Requirements
2.40
2.42
2.43
Dial gauge of different scale and resolution as
suited to respective contactor
Source which can provide minimum current at
respective voltage (24 V – 72 V DC)
Variac
Meggar
2.44
Oscilloscope
2.41
3.
4.
5.
6
Loco
Type
Make Of
Subassembly
Reference
Details
2.45 Screw Driver, Plier, Spanner Set, etc.
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
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
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 59 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
SN
Requirements
7.
Material Availability
7.13 Vital Spares
7.14 Must change items
7.15
Consumables
Disposal
8.9
Segregation of Workable and NonWorkable equipments and proper house keeping
8.10 Proper Disposal of Materials including recycling
following relevant environmental norms
8.
Loco
Type
Page 60 of 104
Make Of
Subassembly
Reference
Details
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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:
SN
Requirements
1.
Measurement
1.1
Control voltage 72+1v dc,
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
Audited by:
Date of audit:
Loco
Type
Make Of
Subassembly
All
Diesel
Electric
Locomo
tives
(ALCo)
max pick up volt 48v,
Main contact gap12-14.5mm,
wipe 8-10 mm,
contact pressure( kgf) initial
1.82-2.95,final 5.45-7.25,
operating coil resistance at 20 deg c 104 -116
ohms,
interlock (GPRelay type- 9-41n, 3no+3nc) contact
gap 9.5-10.5
Interlock contact mm pressure -220-300gm.,
Contact impression (should be min 80%)
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
Page 61 of 104
Reference
Details
Clause/Para/Item
Details
Drawing No.
EL/PT/0614/
Altr R4
Part
No 12140491
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev01),May’10
as per IEC
60571
3.10.e
Quality Audit of Diesel Loco POH Workshop
clause 10.2.9
Observations
SN
2.0
Requirements
4.
5.
Make Of
Subassembly
Reference
Details
contacts shorted together
(vi) shorted main contacts and shorted interlocks, coil
and earth
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
3.
Loco
Type
Oscilloscope
2.54 Screw Driver, Plier, Spanner Set, etc.
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
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
Page 62 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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
7.
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.
Material Availability
7.16 Vital Spares
7.17 Must change items
7.18
Consumables
Disposal
8.11
Segregation of Workable and NonWorkable equipments and proper house keeping
8.12 Proper Disposal of Materials including recycling
following relevant environmental norms
Page 63 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:
SN
1.
Audited by:
Requirements
Measurement
1.1 Contact gap 15-17 mm
1.2 Wipe 25.4-28.6 mm
1.3 Knuckling spring pressure(without lever) initial 4.56.3 kgf, final 12.2-18.2 kgf,
1.4 Normal air pressure 4.9 kg/cm2
1.5 Interlock gap 2.5-3.95mm,
1.6 Interlock pressure 500-900g.
1.7 Interlock rated current 10 A,
1.8 Magnet valve coil resistance at 20degC 615+5%
ohm.for BHELTYPE: M5027MV2
1.9 ROTEX TYPE: 3118AV1-3 coil resistance at
20degC 526 to 594 Ohms,
1.10 Contact impression (should be min 80%)
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.
Page 64 of 104
Date of audit:
Loco
Type
ALCo
Make Of
Subassembly
Reference
Details
Drawing No.
EL/PT/0630/
Altr R4
Part
No 12141008
Clause/Para/Item
Details
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev-01),
May’10
IEC 60571
3.10.e
Quality Audit of Diesel Loco POH Workshop
as per clause
10.2.9
Observations
SN
2.0
Requirements
4.
5.
Make Of
Subassembly
Reference
Details
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
3.
Loco
Type
Oscilloscope
2.65 Screw Driver, Plier, Spanner Set, etc.
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
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
Page 65 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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
7.
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.
Material Availability
7.19 Vital Spares
7.20 Must change items
7.21
Consumables
Disposal
8.13
Segregation of Workable and NonWorkable equipments and proper house keeping
8.14 Proper Disposal of Materials including recycling
following relevant environmental norms
Page 66 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:
SN
1.
Audited by:
Requirements
Loco
Type
Measurement
1.1
Auxiliary contacts 4, change over type,
1.2
Control voltage 72+1 V DC,
1.3
Operating air pressure 4.9 kg/cm2,
1.4
Min operating air pressure 3.85 kg/cm2,
1.5
Main contact gap19.05+1.6mm,
1.6
Main contact outside pressure (with lever) 4.04.5kgf, inside pressure 5.8-6.5kgf,
1.7
Contact impression (should be min 80%)
1.8
1.9
1.10
Auxiliary contact pressure 0.68-2.0kgf,
Auxiliary contact gap 31.75mm (min), ,
Magnet valve coil resistance at 20degC 615+5%
ohm.for BHEL type: 5027MV2
ROTEX TYPE: 3118AV1-3 coil resistance at
20degC-526 to 594 Ohms.
1.11
1.12
Date of audit:
Contact impression (should be min 80%)
Page 67 of 104
ALCo
Make Of
Subassembly
Reference
Details
Clause/Para/Item
Details
Drawing No.
EL/PT/0649/
Altr R5
Part
No 12310372
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev01),May’10
3.10.e
Quality Audit of Diesel Loco POH Workshop
Observations
SN
Requirements
1.13
2.0
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
Make Of
Subassembly
Reference
Details
IEC 60571
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
3.
Loco
Type
Oscilloscope
2.76 Screw Driver, Plier, Spanner Set, etc.
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 68 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
as per clause
10.2.9
Observations
SN
Requirements
3.71
3.72
4.
5.
6
Loco
Type
Maintenance Manual of Manufacturer
Specification
Make Of
Subassembly
Reference
Details
Spec No.
MP.0.04.00.08
(Rev01),May’10
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
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
7.
8.
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.
Material Availability
7.22 Vital Spares
7.23 Must change items
7.24
Consumables
Disposal
8.15
Segregation of Workable and NonWorkable equipments and proper house keeping
8.16 Proper Disposal of Materials including recycling
following relevant environmental norms
Page 69 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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:
SN
Requirements
1.
Measurement
1.1 Auxiliary contacts 4 change over type,
1.2 Control voltage 72+1 V DC,
1.3 operating air pressure 4.9 kg/cm2,
1.4 Min operating air pressure 3.85 kg/cm2 ,
1.5 Main contact gap19.05+1.6mm,
1.6 Main contact - outside pressure (with lever)
1.7 4.0-4.5kgf, inside pressure 5.8-6.5kgf,
1.8 Auxiliary contact pressure 0.68-2.0 kgf,
1.9 Auxiliary contact gap 31.75mm (min),
1.10 Magnet valve coil resistance at 20degC
1.11 615+5% ohm. for BHELTYPE : M5027MV2
1.12 ROTEX TYPE: 3118AV1-3 coil resistance at
20degC 526 to 594 Ohms
1.13 Contact impression (should be min 80%)
1.14
Date of audit:
Loco
Type
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
Page 70 of 104
Make Of
Subassembly
All
Diesel
Electric
Locomo
tives
(ALCo)
Reference
Details
Clause/Para/Item
Details
Drawing No.
EL/PT/0648/
Altr R5
Part No
12310300
Technical details
given in the
drawing
Spec No.
MP.0.04.00.08
(Rev-01),
May’10
IEC
60571
3.10.e
Quality Audit of Diesel Loco POH Workshop
as per clause
10.2.9
Observations
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
4.
2.87 Screw Driver, Plier, Spanner Set, etc.
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
Compliance of Instruction Bulletin
5.
Follow of Maintenance Manual of Manufacturer
3.
Page 71 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
7.
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.
Material Availability
7.25 Vital Spares
7.26 Must change items
7.27
Consumables
Disposal
8.17
Segregation of Workable and NonWorkable equipments and proper house keeping
8.18 Proper Disposal of Materials including recycling
following relevant environmental norms
Page 72 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:
SN
Requirements
1.
Measurement
1.10 Nominal operating voltage (50-80 V)
1.11 Pick up voltage (Must Operate), max 48V
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%,
1.15 Contact Pressure 100-250 g
1.16 Over travel (1.6 mm) with over travel gauge in
position 0.0 to 0.1
1.17 Min contact gap 2.7 mm
1.18 Armature gap 4.7 to 6.6
1.19
Ensure that no distortion or corrosion of any
components
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
Availability of tools and stands
2.88 Multimeter with proper calibration
2.89 Vernier calipers with valid calibration
2.90 Go- No gauge
2.0
2.91
Date of audit:
Loco
Type
Make Of
Subassembly
Reference
Details
Clause/Para/Item
Details
All Diesel
Electric
Locomo
tives
(ALCo)
BHEL, AAL and
IEI
Spec No.
MP.0.400.03
(Rev-01) Nov’08
Clause 3.1.1
Clause 3.2 (ii)
Clause 3.2 (v)
Clause 3.2 (vi)
Clause 3.2 (vii)
Clause 3.2 (viii)
Clause 3.2 (ix)
Clause16.1.9.2
as per IEC
60571
Dial gauge
Page 73 of 104
Quality Audit of Diesel Loco POH Workshop
Clause 10.2.9
Observations
SN
Requirements
2.92
2.93
2.94
Loco
Type
Make Of
Subassembly
Reference
Details
Source which can provide minimum current at
respective voltage (72 V DC)
Variac
Meggar
2.95
2.96
3.
4.
5.
6
Screw Driver, Plier, Spanner Set, etc.
Sufficient set of tool and gauges provided by
manufacturer
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
Compliance of Instruction Bulletin
Follow of Maintenance Manual of Manufacturer
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 74 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
SN
Requirements
7.
Material Availability
7.28 Vital Spares
7.29 Must change items
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
8.
Loco
Type
Page 75 of 104
Make Of
Subassembly
Reference
Details
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
CHECK SHEET FOR
TECHNICAL AUDIT OF POH WORKSHOP OF ELECTRICAL CONTROL FOR DC-DC CONVERTER (500 W)TWIN BEAM HEAD LIGHT(ALCo LOCO)
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:
SN
Requirements
Loco
Type
1.
Measurement :
2.1 Visual Inspection – check finish , material , sound
quality of workman ship etc
2.2 Functional Check –ON/OFF properly
ALCo
2.3 Available output regulated Voltage 25.5 ± .1% V
DC with the variation of input voltage 50-85 V DC
2.
Availability Of Tools And Test Stands
3.1 Multimeter with Valid Calibration
Make Of
Subassembly
Date of audit:
Reference
Details
RDSO
Clause No.6.3.1
specification No.
ELRS/SPEC/DC
-DC Converter
/0021 ,Rev.01
Sept 2004
RDSO
specification No.
ELRS/SPEC/DC
-DC Converter
/0021 ,Rev.01
Sept 2004
RDSO
Clause No. 2.2
specification No. and 2.3
ELRS/SPEC/DC
-DC Converter
/0021 ,Rev.01
Sept 2004
ALCo
Page 76 of 104
Clause/Para/Item
Details
Quality Audit of Diesel Loco POH Workshop
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference
Details
3.2 Test stand for measurement and testing.
3.3 Screw Driver, Plier, etc.
3.4 Fire Extinguisher of proper class
Availability Of Instructions etc.
3
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
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
NA
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 77 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference
Details
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.
Material Availability
7.30
Vital Spares
7.
8.
7.31
Must change items
7.32
Consumables
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 78 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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:
SN
Requirements
Loco
Type
1.
Measurement :
2.1 Visual Inspection – check finish , material , sound
quality of workman ship , water tightness etc
2.2 Functional Check –ON/OFF properly
2.3 Lux Value- The lux measured in axial direction
shall not be less than 500 lux at 1 meter and 55
lux at 3 meters for amber clour LED of 120 Nos
ALCo
2.4 Flashes per Minute (40±5)
2.5 Output regulated Voltage
2.6 Check Repeater indication properly
2.
Availability Of Tools And Test Stands
Make Of
Subassembly
Date of audit:
Reference Details
Clause/Para/It
em Details
RDSO specification
No.
ELRS/SPEC/LFL/0
017 Rev 1 Sept 04
RDSO specification
No.
ELRS/SPEC/LFL/0
017 Rev 1 Sept 04
RDSO specification
No.
ELRS/SPEC/LFL/0
017 Rev 1 Sept 04
RDSO specification
No.
ELRS/SPEC/LFL/0
017 Rev 1 Sept 04
RDSO specification
No.
ELRS/SPEC/LFL/0
017 Rev 1 Sept 04
RDSO specification
No.
ELRS/SPEC/LFL/0
017 Rev 1 Sept 04
Clause
No.6.3.
ALCo
Page 79 of 104
Quality Audit of Diesel Loco POH Workshop
Clause No.
2.3.3
Clause No.
2.4.1
Clause No.
2.4.5
Clause
No.2.4.3.1
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference Details
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
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
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/0
017 Rev 1 Sept 04
Page 80 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/It
em Details
Observations
SN
Requirements
Loco
Type
4.
Compliance of Instruction Bulletin
5.
Follow of Maintenance Manual of Manufacturer
6.
Record Keeping For Traceability
Make Of
Subassembly
Reference Details
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.
Material Availability
7.1 Vital Spares
7.
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 81 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/It
em Details
Observations
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:
SN
Requirements
Loco
Type
1.
Measurement :
2.7 Visual Inspection – check finish , material , sound
quality of workman ship , water tightness etc.
2.8 Functional Check –ON/OFF properly
ALCo
2.9 Lux Value- for all input voltage range 45
V-90 V
2.
Lamp
Lux level at 1 Lux level
Meter
Meters
RED
75 LUX
7 LUX
WHITE
75 LUX
7 LUX
at
3.10
Reference
Details
RDSO
specification No.
ELRS/Spec/PR/
0022 (REV-1
Oct -2004)
RDSO
specification No.
ELRS/Spec/PR/
0022 (REV-1
Oct -2004)
RDSO
specification No.
ELRS/Spec/PR/
0022 (REV-1
Oct -2004)
ALCo
Test stand for measurement and testing.
Page 82 of 104
Clause/Para/Item
Details
Clause No.6.3.
Clause No. 2.4.3
3
Availability Of Tools And Test Stands
3.8 Multimeter with Valid Calibration
3.9 Lux Meter with proper Calibration
Make Of
Subassembly
Date of audit:
Quality Audit of Diesel Loco POH Workshop
Observations
SN
Requirements
Loco
Type
3.11
Screw Driver, Plier, etc.
3.12
Fire Extinguisher of proper class
Make Of
Subassembly
Reference
Details
Availability Of Instructions etc.
3
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 83 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference
Details
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.
Material Availability
7.4 Vital Spares
7.
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 84 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
CHECK SHEET FOR
TECHNICAL AUDIT OF CONTROL GEAR SECTION FOR STICK TYPE / IMPROVED STICK TYPE MASTER CONTROLLER
FOR POH WORKSHOPS IN REFERENCE TO POH OF ALCo DIESEL LOCOMOTIVES
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:
SN
A.
1.
Audited by:
Requirements
Loco
Type
Make Of
Subassembly
Stick Type / Improved Stick type Master controller
Measurement:
1.1 Visual checking
ALCo
M/s BHEL,
Asian Plastic,
M/s Kaysons
(AMC/R2)
Make
1.2 Contact gap,
2.
1.3 Contact pressure,
1.4 Cam sequence and
1.5 Mechanical interlocking
1.6 Working of Throttle handle
Test :
Date of audit:
Reference Details
Clause/Para/
Item Details
BHEL Test
Clause 1.1
programme
document no. 865476
dt
Drawing of Improved
stick type Master
Controller EL-PT0633-R3 dt.
29.12.2007.
BHEL Test
Clause 1.2
programme
document no. 865476
dt 24.04.99 and
Clause 1.3
2.1 Insulation Resistance test:
BHEL Test
Clause 5.0
programme
document no. 865476
DLW Drg. No.
35900030031Rev. 04
2.2 Continuity Test
Page 85 of 104
Quality Audit of Diesel Loco POH Workshop
Observations
2.
Availability Of Tools And Test Stands
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
ALCo
M/s BHEL,
Asian Plastic,
M/s Kaysons
(AMC/R2)
Make
Availability Of Instructions etc.
3
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 86 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.
Material Availability
7.7 Vital Spares
7.
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 87 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:
SN
1.
Audited by:
Requirements
Loco
Type
Measurement :
2.10 Visual Inspection – check finish , material , sound
quality of workman ship etc
2.11 Functional Check –ON/OFF properly
Make Of
Subassembly
Date of audit:
Reference
Details
Clause/Para/Item
Details
RDSO
Clause No.6.3.1
specification No.
ELRS/SPEC/PR
/0024 ( Rev-1,
Sept 2004)
IB NO.
Clause No. 4.A.1
MP.IB.EC.
01.08.06 DATE:
27-12-06
2.12 Type of Bulbs used – H4 P45 T(IR), Twin Filament
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
ALCo
Page 88 of 104
Quality Audit of Diesel Loco POH Workshop
Observations
SN
2.
Requirements
Loco
Type
Make Of
Subassembly
Reference
Details
Clause/Para/Item
Details
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
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
3.29
IB NO.
MP.IB.EC.
01.08.06 DATE:
27-12-06
Screw Driver, Plier, etc.
Page 89 of 104
Quality Audit of Diesel Loco POH Workshop
Observations
SN
Requirements
Loco
Type
3.30
Test stand for measurement and testing.
3.31
Fire Extinguisher of proper class
Make Of
Subassembly
Reference
Details
Availability Of Instructions etc.
3
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
3.36
Instruction Bulletin issued by RDSO
3.37
Maintenance Manual of Manufacturer
3.38
Specification
IB NO.
MP.IB.EC.
01.08.06 DATE:
27-12-06
RDSO
specification No.
ELRS/SPEC/PR
/0024 ( Rev-1,
Sept 2004)
4.
Compliance of Instruction Bulletin
5.
Follow of Maintenance Manual of Manufacturer
6.
Record Keeping For Traceability
Page 90 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference
Details
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.
Material Availability
7.10
Vital Spares
7.
7.11
Must change items
7.12
Consumables like bulbs , Reflector
Disposal
8.
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 91 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/Item
Details
Observations
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:
SN
1.
Audited by:
Requirements
Loco
Type
Measurement :
2.20
Physical Examination
2.21
Air Pressure
2.
2.22
Ampere Hour Capacity
2.23
Watt Hour Efficiency
2.24
Ampere Hour Efficiency
2.25
Internal Resistance
2.26
Initial Cranking Current
2.27
Electrolyte Level
ALCo
2.28
Polarity and absence of Short Circuit
Availability Of Tools And Test Stands
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 92 of 104
Date of audit:
Make Of
Subassembly
Reference Details
Spec. No.
DEL/SPN/193 July’98
Spec. No.
DEL/SPN/193 July’98
Spec. No.
DEL/SPN/193 July’98
Spec. No.
DEL/SPN/193 July’98
Spec. No.
DEL/SPN/193 July’98
Spec. No.
DEL/SPN/193 July’98
Spec. No.
DEL/SPN/193 July’98
ALCo
Quality Audit of Diesel Loco POH Workshop
Clause/Para/
Item Details
Clause 8.5
Clause 8.6
Clause 8.7
Clause 8.7
Clause 8.8
Clause 8.9
Clause 6
Observations
SN
Requirements
3.36
3.37
3.38
3.39
3.40
3.41
3.42
3.43
3.44
3.45
3.46
Loco
Type
Make Of
Subassembly
Reference Details
Hydrometer with Valid Calibration
Ammeter with Valid Calibration
Multi meter with Valid Calibration
Clamp Meter
Rubber syringe
Battery Charger(Preferred Constant Current
Chargers)
Battery Discharger (Preferred Electronic type)
Required Lab for testing of Acid and DM water
Screw Driver, Plier, Spanner Set etc.
Test stand for measurement and testing (Concrete
Platform covered with Acid Resistant FRP
sheets/coating for keeping batteries –charge
/Discharge.)
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 93 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/
Item Details
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference Details
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
3.45 Instruction Bulletin issued by RDSO
MP. IB. EC.01.02.05
(Rev.01), Dec. 2008
3.46 Maintenance Manual of Manufacturer
3.47 Specification
Spec. No.
DEL/SPN/193 July’98
4.
Compliance of Instruction Bulletin
5.
Follow of Maintenance Manual of Manufacturer
Record Keeping For Traceability
6.
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 94 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/
Item Details
Observations
SN
7.
8.
Requirements
Loco
Type
Make Of
Subassembly
Reference Details
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.
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 95 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/
Item Details
Observations
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:
SN
Audited by:
Requirements
Loco
Type
ALCo
1.
Dis Assembly and Assembly
2.
Measurement :
2.29 Physical Examination
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
Availability Of Tools And Test Stands
3.56
Test Stand for Wood Ward Governor
3.57
Multimeter with valid Calibration
3.58
Screw Driver, Plier, Allen Key, Spanner,
3.
Page 96 of 104
ALCo
Date of audit:
Make Of
Subassembly
Reference Details
Maintenance
manual of
Woodward
Wood Ward
Governor Test
Record Format No.
TSP/F8572-828
and Maintenance
manual of
Woodward
ALCo
Quality Audit of Diesel Loco POH Workshop
Clause/Para/It
em Details
Section 5 of
Maintenance
Manual
Section 6 of
Maintenance
Manual
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference Details
Clause/Para/It
em Details
Maintenance
Manual
Section 4
etc.
3.59
Fire Extinguisher of proper class
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
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 97 of 104
Quality Audit of Diesel Loco POH Workshop
Observations
SN
Requirements
Loco
Type
Make Of
Subassembly
Reference Details
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.
Material Availability
8.
7.16
7.17
7.18
etc.
Disposal
9.
Vital Spares
Must change items
Consumables like Lub Oil, Cotton wool,
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 98 of 104
Quality Audit of Diesel Loco POH Workshop
Clause/Para/It
em Details
Observations
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
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.
ii.
05
06
Visual inspection of buffer beam, striker block for any crack or damage,
accordingly repair/weld properly
Check the buffer base bolt holes for size, centers & ovality. Remove the
ovality by welding and redrill if necessary
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
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 99 of 104
RDSO’s Drg. No.
SK.DL-4533/4535 and
DMW’s Drg. No.
2DMW/SK-938
Quality Audit of Diesel Loco POH Workshop
Observations
07
08
Visual inspection of Footstep for welding crack/damage and shall be repaired by
welding properly or replaced.
i.
ii.
Visual inspection of welding of Hand rails to underframe. If there is any
crack or damage in weld then reweld it properly.
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.
ii.
12
iii.
i.
ii.
13
i.
ii.
iii.
If abnormal vibration noted modify compressor mounting area of WDM3D
locomotive under frame
Visual inspection of welding of expressor/ compressor mounting stool. If
there is any welding crack/damage then it should be rewelded or replaced
properly
Clean the threads of mounting block on stool by tapping it properly.
Visual inspection of welding of engine mounting block. If there is any weld
defect carryout required welding or replace it
Check/Clean the threads of mounting block by tapping.
MP.MOD.LD.01.02.11
dated 09.03.2011
Inspection of air duct gallery for all traction motors cutout for any leakage
or cracks
Filling water/hydraulic test in the gallery carried out
If any leakage is found, shall be repaired accordingly.
Page 100 of 104
Quality Audit of Diesel Loco POH Workshop
14
i.
ii.
iii.
iv.
v.
vi.
15
16
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
End plate of battery box with fuel tank end shall be modified as per RDSO
Drg. no. SK.DL-4436.
Mounting block, nut & bolt should be properly secured and tighten
Wooden spacer properly placed between the battery
All hinges, locks should be in working
Cover assly. properly secured & locked with battery box.
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
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 letter
No.SD.DMG.32 Dated
30.07.1996 and SK.DL-4436
RDSO’S Investigation
Report No.
MP-473/83 February, 1983
RDSO’S Investigation
Report No.
MP.INV-8
December, 1995
17
18
i.
ii.
i.
ii.
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.
If any crack is found, weld it properly with down hand welding.
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.
side load bearer shall be repaired
RDSO’Drg. No.
SK.DL-2069
RDSO’s spec. No. MP.MI140/88, Sep’1988 and
RDSO’Drg. No.
SK.DL-2069
Page 101 of 104
Quality Audit of Diesel Loco POH Workshop
19
As per extent colour
scheme
Loco painting, marking, stenciling;
Apply epoxy primer and PU paint before stenciling
20
21
Center buffer coupler & Draft Gear
Check compliance of RDSO instructions for inspection and maintenance
G-80
Modify uncoupling arrangement to make it top operated
MP.MOD.LD.05.10.11
dated 18.07.2011
Side Buffers
MP.MI-116/82, Rev.02
Check compliance of RDSO instructions for inspection and maintenance
22
Loco Cab
23.
1
Driver/Pilot seat
23.
2
Railway Board’s letter
No.2000/M(L)/466/9 dated
05.01.2005
i.
ii.
Base mounting nut/ bolt and other fasteners should be properly tighten
Motion and its adjuster/locking arrangement/ Ver. & rotational motion
should be in functioning
iii.
Cushion & upholstery should be in good condition
Side sash / window
i.
ii.
iii.
iv.
Sliding glass should freely slide and not cracked
Locking arrangement properly in fuction
Guide rail, weather rubber & glazing rubber should be in good condition
Rear view mirror if applied properly secured with frame and its rotational
movement checked. Mirror should be in good condition
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Quality Audit of Diesel Loco POH Workshop
23.
3
23.
4
23.
5
23.
6
23.
7
23.
8
23.
9
23.
10
Cab door
i.
ii.
Lock, hinges should be in function
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
Cab floor
i.
Flooring mat & trim should be in good condition
ii.
Steel structure/ panel sheet of cab should not be corroded or broken
Cont. Comp door, short hood door & Cab inner trim
i.
ii.
Lock, hinge and weather sealings should be in working condition
Perforated aluminium sheet , insulating material, fasteners should be in
good condition
Cab light and fan
i.
Switches, regulators and connections are properly in function
Fire Extinguisher
i.
Mounting bracket should be in good condition and refilling facilities should
be available
Air condition (if applied)
i.
Switches, regulator and water drainage properly in function
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
Front look out glass
i.
ii.
Glass & weather strip should be scratches free and properly sealed with
front structure
Covering grill glass properly cover with hinged grill
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Quality Audit of Diesel Loco POH Workshop
24
Superstructure
i.
ii.
25
Check the condition of sheets and repair if possible otherwise change
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
Radiator compartment & Expansion tank
i.
ii.
iii.
Gauge, vent, vacuum valve, low water alarm should function
Expansion tank plate should not be corroded
Funnel grating, foot step, hand- rail, inspection door properly secured with
rad. Comp. Structure.
Page 104 of 104
Quality Audit of Diesel Loco POH Workshop