Technical / Quality Audit of Diesel Shed

Ref: Letter No 2012/M(W)/814/5 dated 07.08.12 from Rly Bd.

CHECK SHEET

Item / Description / Reference Documents, Annexures, Further details on checksheet etc
General / Compliance of Schedule Maintenance / Schedule of standard examinations: MP-Misc-140/141 (for Alco locos).
Schedule of standard examinations: MP-Misc-285 [for HHP (EMD) locos]
Quality of major schedules:
  • M24
  • M48
/ -do-
Load Test/Load Box Test records:
  • HP
  • SFC
  • EGT
  • Peak Firing Pressure
/ Load Test MI No MP.MI-10 (Rev 0.02), Aug 2003. (for Alco locos).
Document No. Misc-195 on Test procedure for EMD diesel engine, 16 cyl. Vee model 710G3B (4000/4500HP) issued by DLW.
Methodology and analysis of failure investigation.
  • Display of work instructions on shop floor
  • Training of staff
  • Status of record keeping
  • Calibration of gauges/ instruments

Safety items /
  1. Speed recorder/Indicator Section
  2. Wheel (Wear adapted profile) profile & other defects.
  3. Brake adjustment, release & and application timings.
  4. Headlight focus adjustment
  5. Horn maintenance
  6. Undergear safety brackets
  7. Gauging of Couplers
  8. Vertical offset between Side bearer and centre pivot
/
  1. OEM’s maintenance manual.
  2. Drg No SKDL-2561 Alt 8.
  1. 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.
  2. IB No MP.IB.EC.01.08.06 (Rev 0) December 06.
  1. MI No MP.IB.BD.02.16.01 (Rev 01) December 09.
  2. CBC Manual No G 76 Sept 87.
  3. MI No MP.IB.VL.02.11.10 (Rev 00) February 10.

Quality of Subassembly repairs (important items) /
  1. Expressor/Compressor
  2. Air Brake Section
  3. Bogie section
  4. Rotating Machines Section
  5. Turbo section
  6. Cylinder Head , Piston and Valve section
  7. Radiator section.
  8. FIP/Injector Section
  9. Governor Section
  10. Electrical Control Section
  11. Battery Section
/
  1. Further details of check sheet covered in Annexure 1.
  2. -do-
  3. Further details of check sheet covered in Annexure 2.
  4. Further details of check sheet covered in Annexure 3.
  5. Further details of check sheet covered in Annexure 4.
  6. -do-
  7. -do-
  8. -do-
  9. Further details of check sheet covered in Annexure 5.
  10. -do-
  11. -do-

DM Plant and Spectrograph / General working condition / MP Guide-6 (Rev 2) May 07 issued by RDSO in reference to spectrograph.
Material /
  • Availability of critical items
  • Procurement from unapproved sources, if any.

Any other item / As decided by the auditing authority

---

Check List for quality audit of diesel loco sheds (Brake Items)

S.No. / Item / Parameter / Observations
Whether all the prescribed schedules are being followed for brake equipment, compressor & air dryer or not / As per Schedule of standard examinations
(No. MP.Misc.-140 & 141, Rev-01, September’2006)
Trip Sch. / M-2 / M-4 / M-12 / M-24 / M-48 / M-72 / POH
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.
Functioning of VCD / Whether functioning of VCD is being checked in every trip schedule.
Test benches and rigs /
  1. Whether the required test bench and rigs are available or not viz. AB test rack for brake valves, air dryer test bench, compressor 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.

Test on compressor / Testing for checking capacity of compressors as per MP.TP-41, 2010.
Infrastructure facilities / (a)Whether dust proof and controlled temperature environment for maintenance, assembly and testing of brake valves is available.
(b)Availability of compressed air ( in test benches.
(c)Availability of compressor in air lines.
(d)Whether air dryer provided in test benches/ air lines.
(e)Reservoir pressure is being checked or not
(f)Washing facilities
(g)Painting facilities
(h)Technical Cell
(i)Metrology lab
(j)Store
(k)Tool room
(l)Fire extinguishers
(m)Material handling facilities for movement of material and components.
Storage of material / Whether dust/damp proof environment with controlled temperature is available for storage of brake equipment and rubber components.
Whether rubber components are being stored as per guidelines mentioned in this office letter no. SD.DEV.RBC dated 28.02/07.03.2007 circulated to all Zonal Railways.
Availability of Material / Any Chromic shortage of material for maintenance
Human Resource development / Whether periodic training is being imparted to maintenance staff to make them conversant with the maintenance practices.
Any other observation

CHECK SHEET FOR

TECHNICAL AUDIT OF BOGIE (ALCO LOCOMOTIVE)

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.

Shed/Rly: Audited by: Date of audit:

SN / Requirements / Loco Type / Make Of Subassembly / Reference Details / Clause/Para/Item Details / Observations
1. / Measurement / Activity
Bogie frame & Bolster
(if applicable) / Alco Series
WDM2, WDM3A, WDG3A,WDP3A & WDM3D/E/F / Maintenance Instruction no
M&C Report
MC – 44 & MC - 29
  • Cleaning of bogie frame
  • Crack detection and repair
  • Welding of Manganese Steel Liners at axle boxes and pedestal liners

Complete Bogie / MP.MISC – 141 / Item No. 165
Longitudinal and lateral pedestal clearances
Wheel & Axle Assembly / Wheel wear management Instruction Bulletin no.MP.IB.BD.0216.01 (Rev-1) &
MP MI71/78
MP.MISC – 141
RDSO procedure MC-71 / Clause 4.3.8
Item No. 110, 161, 198,
  • Wheel wear measurement i.e. Root wear, Tread wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spaling etc. as per MP.MI 71/78 in every trip.
  • Wheel gauge (1596+3/-0.5 mm)
  • Deference in tread diameter of wheels on same axle, same bogie & same loco
Ultrasonic testing of axles (interval of 06 months for passenger locos & 12 months for goods loco)
Brake rigging / WDM2, WDM3A / MP.IB.VL-03.11.01
MP.MISC – 141 / Item No. 295
  • Piston travel
  • Wear of Brake shoe
  • Wear of Pins & Bushes

Axle box & journal bearings / MP.MISC – 141 / Item No. 47, 197
  • Inspection bearing components
  • Grease condition
  • Radial clearance
  • Distance over liners (face and lateral)
  • Dimensional measurement of bearing components

Centre Pivot & Loading Pads / MP.MISC – 141
MP.IB.VL-02.11.10 / Item No. 274 & 278,
Centre pivot castings and loading pads, liners
Load Pad to Centre Pivot Height Difference,
Suspension Spring ( As per MI )
Free height of spring / As per relevant drawings
working height of spring
Grouping / colour code of spring / MP.IB.VL- 04.19.01 (Rev.01)
Friction Snubber Assembly / WDM2, WDM3A / MP.MISC – 141 / Item No. 116
Height measurement
Equaliser Beams / MP.MISC – 141,
M&C MC - 43 / Item No. 52
Free roller movement, Wear of hard face zone
Equaliser Spring Seat / SK.DL-3889
Side Bearer (Rubber spring) / WDG3A, WDM3D / MP.IB.VL. 04.30.08 (Rev.01)
Free Height of rubber spring
Working height of rubber spring
Permanent set of rubber spring
Rubber crack length/ de-bonding
Hydraulic damper
Capacity / Rating of dampers / As per relevant drawings
Damper overhauling / MP.IB.VL. 05.39.10 (Rev.00)
2. / Availability of Tools And Test Stands
Surface table of measurement of springs
Height gauge for springs
Spring load-deflection testing machine
Hydraulic damper testing machine
Torque wrench, Go/No Go Gauges
Inside and Outside Calliper, Vernier Caliper, Height Gauge, Cleaning Tank,
Wheel wear measuring gauge / SK.DL-3592
3 / Availability Of Instructions Etc
3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
4 / Record Keeping For Traceability
5 / Material Availability
Vital Spares
Must Change items

CHECK SHEET FOR

TECHNICAL AUDIT OF HHP LOCOMOTIVE BOGIE

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.

Shed/Rly: Audited by: Date of audit:

SN / Requirements / Loco Type / Make Of Subassembly / Reference Details / Clause/Para/Item Details / Observations
1. / Measurements / Activities
General Maintenance / HHP loco / Maintenance Instruction no
MI 1517 (Rev. A) / Para 2.1
  • Cleaning of bogie frame under locomotive
  • Tank immersion
  • Lubrication
  • Wheel and axle Inspection
  • Journal Bearings
  • Dampers
  • Rubber secondary spring
  • Brake rigging
  • Slack adjusters, adjustment
  • Hand brake

Wheel & Axle Assembly
  • Minimum wheel diameter after last truing operation.
  • Maximum diameter mismatch of two wheels on a common axle.
  • Maximum diameter mismatch between wheels on one axle compared to those of any other axle. These include wheels on the same bogie.
  • Minimum rim thickness.
  • Axle longitudinal limits.
  • Circumferential defects on or below the axle surface.
  • Axle Run-out.
  • Wheel wear measurement i.e. Root wear, Tread wear, Flange wear, wheel flat, visual inspection for any defect like crack, wheel flat, shelling, spaling etc.
  • Wheel gauge (1596+3/-0.5 mm)
  • Deference in tread diameter of wheels on same axle, same bogie & same loco
Ultrasonic testing of axles (interval of 06 months for passenger locos & 12 months for goods loco) / HHP loco / Maintenance Instruction no
MI 1517 (Rev. A)
As per latest Railway Board’s Instruction / Para 2.3
Journal bearings
  • Checking of running temperature of outside face of the adopter with a temperature indicating crayon/ direct pyrometer
  • Sign of overhearing (Temperature should not exceed more than 560C above ambient).
  • Excessive lubricant leakage from the grease seals.
  • Broken, loose or missing parts (such as loose cap screws, etc.)
  • Loose or defective seals.
  • Cracked or broken cups, end caps or adapters, etc.
/ HHP loco / Maintenance Instruction no
MI 1517 (Rev. A) / Para 2.4
Dampers
  • Check for leaking fluid. Make certain that oil has not been deposited from some other source and check damper per Manual Qualification Procedures before condemning.
  • Perform manual qualification tests to detect gross loss of control.
  • Inspect bushing integrity. Bushings should not permit uncontrolled vertical or lateral movements of the damper.
  • If a failed vertical primary damper is detected, inspect journal springs, lateral thrust pads and wear plates at each journal bearing location as well.
  • If a failed yaw damper is detected, check the items noted in the above step as well as all traction rods and bushings, carbody pivot and rod assembly and bushings, and secondary springs (rubber pads).
steps to qualify vertical / yaw dampers (Refer instructions given in para 2.5) / HHP loco / Maintenance Instruction no
MI 1517 (Rev. A) / Para 2.5
Rubber Secondary Springs
  • Free Height of rubber spring
  • Working height of rubber spring
  • Permanent set of rubber spring
  • Rubber crack length/ de-bonding
Note: Do not wash the spring in paraffin de-greasing agents (such as trichloro-ethylene), caustic soda, or diesel fuel oil. / HHP loco / Maintenance Instruction no
MI 1517 (Rev. A)
As per relevant drawings
MP.IB.VL-01.08.11 (Rev.0) / Para 2.6
Para 5.6.4
Suspension Spring
  • Inspect the coils for breaks or surface cracks. Springs with any indication of surface cracks should be scrapped. Deep sharp surface nicks can cause failure of a spring, and their presence is cause for rejection.
  • Hand wash or shot blast the coil to remove surface rust. “Pickling” the spring is to be avoided. If the cleaning operation removes all indications of surface rust, and does not reveal corrosion pits, the spring is acceptable for qualification. If corrosion pits are visible after the cleaning operation, scrap the affected coil.
  • Smooth worn spots on a coil caused by rubbing - do not condemn the coil. However, it must still pass the other qualification criteria.
  • For spring identification and qualification, refer to M.I. 1512.
/ Maintenance Instruction no
MI 1517 (Rev. A) / Para 3.2.6
Brake block guide (See instruction in relevant para) / Maintenance Instruction no
MI 1517 (Rev. A) / Para 2.7
Slack adjusters
  • This procedure must be conducted with the locomotive parked on tangent track. If conducted with the locomotive in a curve, error in setting the piston travel will result.
  • It is recommended that a periodic visual inspection should be performed to find out if there is any damage, e.g. loose or missing lock pins or a bent or damaged assembly. Replace or repair the adjuster as required.
/ Maintenance Instruction no
MI 1517 (Rev. A) / Para 2.8.2 & 2.8.3
  • Hand brake
  • The hand brake, chain, and lever should be inspected on a periodic basis, to check for unusual wear. The hand brake chain should not rub against the wheel or bogie during operation. The HTSC-B1 bogie has a special spring pre-tensioning arrangement to prevent rubbing.
Quarterly checked:
  • Check that all fasteners (nuts & bolts), clamps, and brackets are secure.
  • Verify condition of chain, shackles, and pins for corrosion, wear and damage. Replace as required.
  • Check that the pulley on the brake handle assembly is in good condition and properly secured. Replace if required.
  • Chain and other components should be lightly oiled to prevent corrosion.
/ Maintenance Instruction no
MI 1517 (Rev. A) / Para 2.9.2
Para 2.9.4.1
Bogie removal
  • Inspections before bogie removal
  • Yaw Dampers
  • Primary Suspension
  • Secondary Suspension Springs
  • Carbody pivot pin clearance
  • Brake rigging
  • Wheel condition, Wheels, Axles, Axle Gears and Pinions
  • Axle lateral clearances
  • Vertical stop clearances
/ MI 1517 (Rev. A)
M.I. 1518 and 1519 / Para 2.5
Para 3.2.6
Para 2.6
Para 3.2.4
Para 3.2.2
Para 5.5.2
Para 5.5.2
BOGIE ASSEMBLY REMOVAL
It is required without exception that all appropriate discharge procedures be performed prior to commencing work on the trucks or related components (For figures refer relevant pages and para). / MI 1517 (Rev. A) / Para 2.12.2
Bogie installation
  • Jacks are used to raise the locomotive, ensure that all jacks are raised simultaneously in equal amounts. Failure to keep the locomotive level may result in excessive stress on the underframe and carbody structure, or in a failure of the jacks.
  • Great care must be taken during this portion of the application process to prevent damage to the carbody pivot assembly and secondary suspension springs. The pivot pin and alignment dowels should slide into place easily. If this is not the case, slight movement of the bogie will be required to aid in assembly.
/ MI 1517 (Rev. A) / Para 2.13.1
Vertical Stop Clearance
  • to be ensured 16 mm +/- 3.2 mm
/ MI 1517 (Rev. A) / Para 2.13.2
Final Installation / MI 1517 (Rev. A) / Para 2.13.3
Bogie Overhaul
While the overhaul procedures are similar for the two types of bogies, it is imperative that the correct assembly drawing be used to ensure correct dimensions are achieved.
Detail instructions and guide lines for overhaul of bogie to be followed as per the para 3.0 to 3.5 of MI 1517 (Rev. A) / MI 1517 (Rev. A) / Para 3.0 to 3.5
Maintenance and wear limits / MI 1517 (Rev. A) / Para 5.5.1 and Para 5.5.2
2. / Availability of Tools, Test Stands and special procedures / MI 1517 (Rev. A)
Work sketch 41089 / Para 4.1
Lock bolt/ huck bolt installation machine
Wall mounted fixture to dampers
Surface table of measurement of springs
Height gauge for springs
Spring load-deflection testing machine
Hydraulic damper testing machine
Torque wrench, Go/No Go Gauges
Inside and Outside Calliper, Vernier Caliper, Height Gauge, Cleaning Tank,
Wheel wear measuring gauge / SK.DL-3592
3 / Availability, service data, special torque values and Instructions Etc / MI 1517 (Rev. A) / Para 5.1.1 and Para 5.3
3.1 Display Chart
3.2 Training of staff
3.3 Maintenance manual and check sheets
3.4 Record keeping of tools and measuring instruments
4 / Record Keeping For Traceability
5 / Material Availability and parts catalogues / HHP (MAC)
HHP (PAC) / E26
E35
Vital Spares
Must Change items

CHECK SHEET FOR

QUALITY AUDIT OF TRACTION MOTOR PINION & GEAR ASSLY.

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

S.N / REQUIREMENTS / LOCO TYPE / MAKE OF SUB-ASSEMBLY / REFERENCE DETAILS / CLAUSE/
PARA/
ITEM DETAILS / OBSERVATION
1 / MEASUREMENT / Alco (WDM2, WDM3A, WDM3D)
WDG3A
All ALCo locos
EMD locos (WDP4 & WDG4) / Traction Motor Pinion & Gear Assly. of Alco Loco
Traction Motor Gear Case of EMD Locos / MP-IB.EM.10.31.08 dated 24.10.2008
MP-MI 129/86 July 1986
MP-MI 5
MP-IB.EM.01.02.10 dated 11.01.2010.
MP.IB.EM.02.12.00dated 10-4-2000.
MP.IB.EM.03.12.10 dated 05-3-2010.
As above
1.1 / TRACTION GEAR & PINION
Gear Ratio / 18 : 65
Pinion Drg. No. / 18 teeth, SKDP3624
Pinion Bedding In Cold Condition / Not less than 95 %
Pinion Advance / 2.25 TO 2.45MM
Heating Temperature / 190ºC + AMB TEP.
Span Size On New Pinion / Over 3 teeth 88.595 /88.722MM
Condmning Limit On Basis Of Span Size Of Pinion / Over 3 teeth 86.995MM
Gear Drg. No. / 65 teeth SKDP3623 & SKDP3775
Span Size On New Gear / Over 7 teeth 223.989/223.798MM
Condmning Limit On Basis Of Span Size Of Gear / Over 7 teeth 220.800MM
Permissible Backlsh With New Set / 0.266 - 0.664MM
Condemning Limit On Basis Of Backlash / 1.04MM
Crack detection / MPMI or Zyglo test
1.2 / TRACTION GEAR & PINION
Gear Ratio / 18 : 74
Pinion Drg. No. / 18 teeth, SKDP3443
Pinion Bedding In Cold Condition / Not less than 95 %
Pinion Advance / 2.30 TO 2.45MM
Heating Temperature / 185ºC + AMB TEP.
Span Size On New Pinion / Over 3 teeth 81.976 /82.093MM
Condmning Limit On Basis Of Span Size Of Pinion / Over 3 teeth 80.366MM
Gear Drg. No. / 65 teeth SKDP3444 & SKDP3546
Span Size On New Gear / Over 8 teeth 231.36/231.177
Condmning Limit On Basis Of Span Size Of Gear / Over 8 teeth 228.140
Permissible Backlsh With New Set / 0.243 - 0.608MM
Condemning Limit On Basis Of Backlash / 1.00MM
Crack detection / MPMI or Zyglo test
1.3 / TA FAN ASSEMBLY
Outer diameter of TA fan / 1387.25/1387mm
Bore diameter of TA stator / 1392mm
Bore diameter of TA fan / 600.00 / 600.03mm
Diameter of fan seating area on barrel. / 600.03 / 600.06mm
Width of fan seating at bore / 9+1 mm
Depth of counter sunk bolts hole / 4.5 - 5.5 mm
Bolt head width / 12.3mm
6.4Bolt head height above fan plate after final assembly should not be more than / 6.56- 7mm
Circumferentially Fan gap on TA / 2.50 – 2.75mm
Tightening torque and wire locking process / 28 – 30Kg-m
Tightening torque of M30 (coupling bolt) / 170 – 180 kg-m.
Oil catcher thickness (at bottom side) / 53.90 to 54.10mm
Bolts strength properties grade / R8.8.
Sunk type M20 bolts can be used / in place of fully threaded M20 bolts
M20 & M30 bolts should be replaced / After 4 – 5 years service of TA
Fan bore area should be heated (for shrink fit). / 150 to 170 °С
Re-used or old bolts and barrel thread condition should be checked by / GO & NO GO thread ring or plug gauge
Threaded portion of barrel & bolts should be free from varnish or paint or dust deposits. / Visual inspection is required
TA fan should be mounted on the barrel by “shrink fit “ / In place of (bolts) press fit.
TA fan bolts locking wire ends should not be come out of the bolt head(projected) / As shown in photo
6.6Proper alignment of TA fan should be checked by inserting filler gauge circumferentially / 6.7Clearance between the fan (back side) and barrel of TA (as shown in attached photo)
No clearance is allowed.
After Final assembly of TA fan, visual inspection is required on / Tightening torque, wire locking & fan back clearance with barrel(by filler gauge (circumferentially)
TA Gear train assembly / Backlash at Steel plate
TA GEAR 102T
AG/EG PINION 43T
PTU PINION - 43T / 0.60mm to 1.40mm
0.05mm to 0.12mm on shaft
1.4 / Traction Motor Gear Case of EMD Locos
Following items must be checked before fitment/ assembly of top and bottom half gear case
The Heli -coil insert should be checked for looseness. If loose, an oversized insert should be used or the same insert should be used with Loctite / araldite.
The gear case must be cleaned thoroughly specially the mating surfaces.
The same set i.e. the same top and bottom portions must be re-assembled together.
Inter changeability of the two halves is not permitted.
The 6mm hole must be kept clean.
The breather valve must be kept clean
The bolts must be tightened with the required torque of 35 ft and 990ft pound
The tightening sequence as described in the report must be followed.
The pinion inspection hole must be properly plugged by welding
Oil level should be checked as per Dip stick given in Annexure B of IB.
OEM recommended sealants DOW Corning DC-3-0100 and (RTV) GE Sealmate TRV-1473 should be used. Expairy date should also be checked befor use & Dow corning sealant can be procured from M/s Dow Corning India Pvt Ltd. Mumbai.
2 / AVAILABILITY OF TOOLS AND TEST STANDS
2.1 Vernier Callipers
2.2 Disc Mike
2.3 Filler Gauge
3 / INSTRUCTION
3.1 Display Chart
3.2 Training of Staff
3.4Record keeping of tools and measuring instruments
4 / TRACEABILITY
5 / MATERIAL AVAILABILITY
5.1 Vital Spare -NA
5.2 Must change items -NA

CHECK SHEET FOR