INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 1

Document No:

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

PREFACE

Indian Railways Maintenance Manual for Diesel Loco, popularly known as “White Manual”, was

published in the year 1978. However, since then a number of technological advancements such as:
MBCS, MCBG, PTLOC, Moatti filters, Centrifuges, Air dryers, RSB, Mechanically bonded radiator
cores, AC motors, Bag type air intake filters, upgraded compressors, Stiffer Unit Camshafts, 251 +
cylinder heads, Steel cap single bolt 11.75 CR pistons, high efficiency Turbochargers, etc, have been
incorporated in the diesel loco design.

New variants on WDM2 platform viz: WDM3A, WDG3A, WDM3D, WDM3F have been introduced

in the last 15 years. High horse power locos viz: WDG4/4D WDP4/4B/4D, etc., based on advanced
technology (AC-AC traction, Computer Controller Brakes, Microprocessor Control System) have been
inducted in large numbers. One prototype WDG5 loco, upgraded version of WDG4, has also been
manufactured. These HHP locos are going to be the main workhorse of Indian Railways.

Maintenance requirement of these technologically advanced locos is different from old traditional

ones. At the same time number of diesel locos homed in diesel sheds has gone up manifold which
requires different organization set up.

Introduction of such advanced technology diesel locos on Indian Railways over a period of time has

necessitated a paradigm shift in maintenance philosophy, retaining the essence of matured knowledge
gained over years.

This new look ‘White Manual’ shall supplement the long felt need of Transport Engineers of not only

having a documented set of guidelines and instructions in consonance with the present scenario, but
would also act as a harbinger in their pursuit of knowledge.

Railway Board had nominated a committee of six officers for review of “White Manual” and laid

down broad objectives. The revision and updation of this manual has been done accordingly.

Though a large number of officers and staff have contributed in revision of this Manual, we would

like to express our special thanks to: Shri R. Vishnoi, Sr.EDS/MP, Shri P.C. Gajbhiye, CME/SCR, Shri
Anil Sharma, CME/NER, Shri S.K. Luthra, CME/NFR, Shri A.K. Tewari, DRM/ADI/WR, Shri
Shubranshu, CME/IROAF, Shri Vivek Kumar, EDME/Tr. & Shri Anirudh Gautam, ED/ED(CNG) for
their guidance and support in the revision of this manual.

We would also like to acknowledge the contribution of Shri Sachin Sharma, ex. DME/Tr., Shri Alok

Mishra, DME/Tr. Shri S. Srinivas, Sr. DME(D)/GY/SCR, Shri G.V. Durgaprasad, Dy.CME/D/SCR, Shri
T.S.N. Murthy, Dy.CME(R&L)/SCR, Shri T. Dilip, DME/D/BZA/SCR, Shri Adarsh Khare,
Dy.CME/D/NER, Shri D.Saibaba, Dy.CME/D/NFR, Shri K. P. Yadav, Jt.Director/Mech/CAMTECH &
Shri Sanjeev Kumar, Sr. CTA/Mech/CAMTECH in revision of this Manual.

Draft

Document No:

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

iii

NOTE

1. The various stipulations, yardsticks, criteria, etc. given in this Manual are of

General Nature. Changes in these may be required depending on the local
conditions.

2. Various references of Railway Board’s and RDSO’s letters given in this

manual will stand modified, as and when original issuing authorities of such
letters revise them.

3. Introduction of new types of locos, modifications/upgradation in existing

locos in future may require addition/deletion in this Manual. This may be
done through periodic amendments/revisions, as need be.

4. In case of any contradiction in the instructions contained in this manual and

those issued by Board, RDSO, contained in Code, etc, the later will prevail,
till such time necessary amendment in these instructions is done.

5. This Manual should necessarily be revised after 10 years from the year of

issue.

6. A separate compendium of instructions, issued till date on various subjects

related to diesel loco maintenance, operation, fuelling, ARTs, etc. is being
separately issued by CAMTECH. This compendium will need to be revised
every six months by CAMTECH. For ensuring that CAMTECH receive the
latest instructions, RDSO, Railway Board and PUs will mark copies of
letters related to diesel loco maintenance, operation and related subjects to
CAMTECH on regular basis.

Draft