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INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 3

Document No:

Chapter –I Organization

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 4 of 303

1.4 Modus Operandi- While no one plan will fulfill the requirement of every railway, the

following system will provide a suitable frame work which can form the basis of a
management procedure which will spell out the Corporate Objectives, Monitor progress,
Evaluate developments and Reshape Policies, as required. The Management of diesel
motive power maintenance and operation is best done through a system of periodical
reviews ranging from daily position sheets to quarterly meetings between concerned
officials of the railways.

1.4.1

General Manager of the Railway will conduct a quarterly review with the CME and
COM which should discuss –

1.4.1.1 Changes of locos ownership type wise & shed wise, which has been planned for

the intermediate and long term future. The programme of such changes should
be indicated.

1.4.1.2 A broad time bound schedule for development of facilities, location, training and

deployment of men for maintenance and operation.

1.4.1.3 Review of pending proposals of HQ and field units with finance, personnel and

other departments.

1.4.1.4 An evaluation of the progress in meeting such objectives over the past period.

1.4.2

The CME will conduct a quarterly review with principal HQrs engineers in-charge
of maintenance covering the following areas.

1.4.2.1 Personnel

1.4.2.1.1

Availability of trained supervisors, recruitment and conversion
programme, refresher courses, promotional courses.

1.4.2.1.2

Availability of trained maintainers, recruitment and conversion
programme, refresher courses, promotional courses.

1.4.2.2 Maintenance-Maintenance costs, an ABC analysis thereof, cost control measures.

1.4.2.3 Review of important items such as – ultrasonic examination of axles, testing of

pressure vessels, progress of loco alterations, status of power units in regard to
wheel profiling, wheel renewals, provision of fire extinguishers in motive power
units etc.

1.4.2.4 Progress in development of new facilities, acquisition / commissioning of plant and

machinery

1.4.3

The CME will conduct a monthly review with the CWE comprising of:-

1.4.3.1 POH overdues, programme and quality control.

1.4.3.2 Selected statistics of vital repair and return items from shops typically, electrical

rotating equipments, trucks, wheels, etc. Such lists will be drawn by the railway
to meet their own special requirements.

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Document No:

Chapter –I Organization

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 5 of 303

1.4.3.3 Special repairs of locos such as: re-power packing, rewiring, rebuilding of

accident damaged units.

1.4.4

The CME will conduct a monthly review with the principal HQ engineers in charge
of maintenance covering:-

1.4.4.1 Availability of units

1.4.4.2 Compliance of schedules covering time taken, analysis of unscheduled repairs,

preventive measures.

1.4.4.3 Casualties of units in traffic, preventive measures.

1.4.4.4 Status of waiting material and heavy repair locos, assistance required from Board,

Production units, other Railways and Shops.

1.4.4.5 Availability of spares.

1.4.4.6 Punctuality of diesel hauled passenger services.

1.4.4.7 Consumption of lubricants.

1.4.4.8 Special developments in maintenance techniques for achieving better quality of

service and reduction in downtime.

1.4.4.9 Scrutiny of the various outstanding issues listed in the monthly D.O. to be

addressed by the engineer in charge of the maintenance sheds to the CME
covering the topics listed above.

1.4.5

The meeting described above should include every quarter the Field Executives in
charge of the maintenance sheds and back shops covering all the topics listed in the
foregoing.

1.4.6

The CME will conduct a review with the Headquarter Engineers in charge of
Operations, Fuel and Maintenance covering the following aspects:-

1.4.6.1 Casualties of units in traffic involving crews, progress in monitoring of crews,

refresher courses, preventive measures

1.4.6.2 Trends in consumption of Fuels and lubricants – conservation measures.

1.4.6.3 Review performance of fueling points in regards to cleanliness in dispensation of

fuels and lubricants, safety and security measures.

1.5 Inspection: The CME will have a programme of inspection of diesel motive power unit

maintenance facilities and backshops so as to cover all the sheds and backshops in the
system atleast once in a year. Similar inspections will be carried out by CMPE/D
Dy.CME(D) HQ at a frequency of once in three months. Such inspections should include.

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Document No:

Chapter –I Organization

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 6 of 303

1.5.1

An appreciation of maintenance facilities, plant, equipment and personnel vis-à-vis
present, intermediate future and long term requirements - progress of work.

1.5.2

Evaluation of the progress of the maintenance shed in achieving targets of
availability, reduction in downtime, implementation of corrective measures

1.5.3

Review of casualties of diesel units and preventive measures.

1.5.4

Progress of locos alterations

1.5.5

Spot check of quality of work particularly selected from areas where difficulties
have been experienced.

1.5.6

Availability of unit exchange spares in good condition.

1.5.7

Lubricant conservation measures.

1.5.8

Inspection of shed premises to see if facilities, plant and equipment, trackage,
inspection pits, lighting are maintained functional, clean and ensuring safety.

1.5.9

Functioning of the staff grievance redressal system.

1.5.10

Measures for safety of rolling stock and at workplace, Random checks on vital
items such as records of bogie maintenance, wheel profiles, testing of fire
extinguishers, etc.

1.5.11

Inspection of locos selected at random to monitor implementation of a particular
casualty prevention measure, vital items such as: Speedometer, VCD, brakes etc. or
lubricant conservation measures.

1.5.12

Records of load test of units so as to ensure that repairs have been satisfactory.

1.5.13

Inspection of heavy repair/accident damaged units so as to monitor progress.

1.5.14

Review of status of repair of major assemblies and equipment such as power packs,
compressors, rotating electrical equipment, major auxiliaries, trucks, etc.

1.5.15

Availability of spares, storage conditions in stock rooms.

1.5.16

Selected shed statistics such as late starts, locos returning late for schedules, loco
wise defects register, lube oil change register, spectrograph reports etc

1.5.17

Random checks on quality of repairs such as on reconditioning of cylinder heads,
parts cleaning, etc.

1.5.18

Review status of outsourcing activities, maintenance of records related to execution
of contracts, timely initiation of new contracts, etc.

1.5.19

Progress of RSP, M&P and Works items

1.5.20

Compliance of various statutory acts laid down by Government of India

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Document No:

Chapter –I Organization

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 7 of 303

1.6 Diesel Officers Organization at HQ: Under overall charge of CME, the diesel

organization at HQ, depending on holding of diesel units (including multiple units,
counting each Power car as one unit), will be as under:

*Holding of
Diesel Units

SAG

JAG

≤200

CMPE/D

Dy.CME/D

**P-STC

Dy.CME(O) EME/D

EME/O

>200

≤400

CMPE/D CME/O

Dy.CME/D

**P-STC

2- EME/D

2-EME/O

1-AEME/

> 400

CMPE/D CME/O

Dy.CME/D

**P-STC

2- EME/D 2-EME/O

2-AEME/

AEME/O

* For the purpose of deciding organization of Mechanical Officers dealing with operations (O),

holding of diesel units higher of two: territorial and based on that Railway, will be
considered.

**P-STC- Principal System Training Centre (explained in Ch-6 of this manual)

1.6.1

CMPE/D & CME(O)/Dy.CME(O) along-with their Dy.CMEs/EMEs/AEMEs in
their respective fields will be responsible for the effective discharge of the
nominated functions and will report directly to the CME.

1.6.1.1 The CMPE/D with Dy.CME(Diesel) with their officers in-charge of maintenance

of units.

1.6.1.2 The CME/O/Dy.CME(O) with their officers in-charge of operation of diesel

motive power units, fuel and related matters

1.7 Functions of CMPE/D/Dy.CME(Diesel)-Intensive utilization of costly diesel motive

power units – a prime factor in obtaining the economics inherent in diesel traction, is
necessarily based on high standards of maintenance. To achieve this objective, CMPE/D
with Dy.CME/D/HQ will on behalf of the CME:

1.7.1

Plan the necessary maintenance facilities in coordination with the planning
department of the CME’s office to meet the operational needs.

1.7.2

Assist the CME to select, train and deploy experienced engineers to man the diesel
maintenance facilities.

1.7.3

Assess requirements of supervisors for the railway system, plan their recruitment,
training and deployment between different maintenance sheds.

1.7.4

Assess requirements of artisans and suitably monitor their availability and training.

1.7.5

Coordinate and review the annual requirements of bulk indent items and placement
of demands by COS for both stock and non-stock items. As per present policy such
requirements are bulked for ALCO designs of locos at DLMW/PTA and for HHP

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