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INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 5

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 12 of 303

1.9.2.6 Give regular feedback to PUs and RDSO regarding performance of material

supplied by various vendors.

1.9.2.7 Keep record and follow up of warranty claims lodged by field units.

1.9.2.8 ABC analysis of costs and follow up on cost control measures.

1.9.2.9 Liaison with field units to frame the bulk indents of the railways.

1.9.2.10 Keep track of various technological developments in loco and assemblies design

and maintain proper record of the same.

1.9.2.11 Keep track of various modifications in loco issued by RDSO and PUs, compile

them, advised them to field units and monitor their compliance.

1.9.2.12 Process proposals for outsourcing, non-stock procurement, AMC/overhauling,

RSP, Miscellaneous, etc. received from sheds.

1.9.2.13 Any other work assigned by CMPE/D.

1.9.2.14 The organization of TSG/(Materials and Designs) will consist of SSEs/JEs and

technicians. The technicians will help supervisor in discharge of their duties
during visit to field units, for photocopying, binding, maintaining documents,
etc. SSE & JE will form a separate cadre, converted from existing drawing
cadre. Technicians will come from regular cadre and will go back to parent shed
after five years. The staff complement of the TSG, depending upon the holding
of diesel units (including multiple units, counting each Power car as one unit) in
a Zonal Railway, will be as under:-

Holding of Diesel Units

SSE

Technicians

≤200

>200

≤400

> 400

1.9.2.15 The (TSG)/(Material & Design) should be suitably equipped with advanced

computer work station having latest design and drawing software, computer
operated duplicating machines, photocopying machine, advanced diagnostic
tools like: Vibration measuring equipment, decibel meter, infrared
thermometers, thermal imaging camera, high definition digital camera, high
definition video camera, measurement equipments such as digital micrometers,
digital verniers, thread gauges, basic hand tools, filling cabinets and record
keeping equipments, drawing storage equipment ,etc.

1.9.3

A Quality Assurance Group (QAG) consisting of an experienced engineer in
JAG/SS suitably assisted by an experienced inspector assists the Administrative
officer to provide the backup support in the following fields:-

1.9.3.1 Maintain various performance statistics related to diesel units: Outage,

Ineffective, Reliability, Punctuality, Heavy Schedules, Lube Oil and Fuel Oil
consumption, Scrap disposal, etc.

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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 13 of 303

1.9.3.2 Analysis of casualties and follow up on casualty prevention procedures.

1.9.3.3 Co-ordination with field units for sending diesel units to shops for POH timely.

1.9.3.4 Co-ordination with Traction Directorate of Railway Board for submitting various

information related to Outage, Reliability, Punctuality, allotment/transfer of
locos, condemnation of locos, etc.

1.9.3.5 Carry out checking of diesel units in yard and online for assessing the safety and

reliability.

1.9.3.6 Carry out Quality Audit of one major assembly and two ready locos (turned out

after schedule) in each shed once in a month.

1.9.3.7 Monitor various drives: Summer, Monsoon, Winter, Special Safety and

Reliability Drives.

1.9.3.8 Follow up on modification advices with assistance of TSG (Materials & Designs)

1.9.3.9 Monitor follow up of safety, occupational and environmental management in field

units

1.9.3.10 Staffing of maintenance sheds – Planning & coordinating recruitment, training,

refresher courses.

1.9.3.11 Dissemination of maintenance instructions, manuals etc with the assistance of

TSG/ (Materials & Designs).

1.9.3.12 Any other work assigned by CMPE(D).

1.9.3.13 The organization of QAG will consist of SSEs and technicians. The technicians

will help supervisor in discharge of their duties. SSEs and Technicians will be
drafted from regular maintenance cadre of sheds and will be rotated after every
five years. The staff complement of the QAG, depending upon the holding of
diesel units (including multiple units, counting each Power car as one unit) in a
Zonal Railway, will be as under:-

Holding of Diesel Units

SSE

Technicians

≤200

>200

≤400

> 400

1.10 Field Organization:

1.10.1

The Field Organization on the Railways will consist of:-

1.10.1.1 The Diesel motive power maintenance sheds

1.10.1.2 The outstation fuelling and servicing/ trouble shooting points.

1.10.1.3 Operations of diesel units on the divisions

1.10.1.4 Backshops – not being covered in this manual at present.

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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 14 of 303

1.10.2

A typical Diesel Motive power maintenance shed holding 100 locos usually
maintains Rs. 1200 crores worth of assets, spends annually a maintenance and
lubricant budget of Rs. 16 crores and is closely linked with an annual fuel budget of
over Rs. 500 crores. Owing to the high level of investment and the high cost
repercussion of out of service coupled with the complexity of the equipment,
maintenance activities are no longer simple servicing and breakdown repairs. The
maintenance management organization in the shed has to provide a comprehensive,
well organized and administered engineering service. Various technical studies
undertaken by RDSO have established the need for a wider and larger engineering
service. Deployment of a larger number of trained engineers with the availability of
sophisticated cost and time saving diagnostic techniques is becoming a must.
Managerial organization of sheds will be as under:-

1.10.2.1 In view of a large variation in sizes, Diesel Sheds are place in three categories, as

under:-

•

Mega Sheds – Holding >175 to

≤250 locos

•

Major Sheds – Holding >100 to

≤175 locos

•

Minor Sheds – Holding

≤100 locos

1.10.2.2 Depending on the loco holding, the following orgainsation structure at diesel shed

level is proposed:-

Shed Category

Holding

JA grade officer SS officer JS officer

Total

Mega Shed

>175

≤250

1+*1

10+*1

Major Shed

>100

≤175

2+*1

7+*1

Minor Shed

≤100

2+*1

4+*1

*One Principal DTTC, as explained in Chapter 6 of this manual

1.10.2.3 Beside these officers, the following officers / subordinate staff are also required:-

Shed Type

Holding

Stores

M&C

Personnel Finance Engg.

Mega Shed

>175

≤250 SMM

CMT

DPO

SAO

DEN

Major Shed >100

≤175 SMM/AMM CMT/ACMT APO

AAO

AEN

Minor Shed

≤100

AMM

ACMT

OS (P)

Sup (W)

1.10.3

The diesel sheds will be independent units and will be under direct control of
CME/CMPE(D), like workshops are under CME/CWE.

1.10.4

The Engineer-in-Charge of the Diesel Motive Power maintenance shed will be
in overall charge of all technical and administrative matters in the shed
connected with the maintenance of the stock and facilities. His activities range
over “pure maintenance” with its attendant planning, operation of maintenance
facilities, supervision to alterations/ modifications, and commissioning new
designs and stock. The following list is illustrative:-

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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 15 of 303

1.10.4.1 Plan preventive maintenance of the stock with judicious use of regular scheduled

maintenance, judiciously executed planned re-placement, and as also breakdown
maintenance – replace when defective in accordance with various guidelines of
RDSO/ manufacturers and the railways experience.

1.10.4.2 Execute the above plan.

1.10.4.3 Design, operate and utilize a suitable management information system (Guide

lines are available in the chapter on MIS)

1.10.4.4 Frame a budget and operate within it.

1.10.4.5 Design and oversee a suitable documentation service so that the past guides the

future with the help of data on identification of areas and information on the
frequency of failures. Mean Time between failure (MTBF), data on rate of wear,
etc.

1.10.4.6 Oversees the planning and procurement of material for which he will be assisted

by a suitable stores organization under the charge of an officer, the administrative
control of the stores organization will rest with the Engineer –in-charge of the
shed.

1.10.5

While no single procedure of business can universally apply to all sheds and types
of motive power, the following will serve as a useful guideline which may be
modified by the Engineer-in-Charge as found necessary to suit local conditions.
Details of the documents, proforma etc. are available in the chapter on “MIS”.

1.10.5.1 Short term:-

a) The engineers and senior supervisors of the shed review the progress in the past

twenty four hours and plan the work in hand of the next twenty four hours with
the help of a ‘Daily Position Sheet’. This is made available at their residences by
06.00 hrs. and has the position current upto 04.00 hrs. This paper provides
information on: outage in the last 24 hrs, casualties, outturn of locos from the
various repair centers inclusive of the average time taken. For planning the days
work the Daily Position Sheet gives the disposition of locos at various repair
centers. The early scrutiny of this position sheet permits early planning to get
repairs off to a flying start.

b) A “Repair summary” of the locos that have come in the last 24 hrs with remark

regarding repairs done and test results is made available a little later in the day.
This permits a quick check on the efficacy of the repairs done and permits locos
to be recalled or corrective measures instituted on the basis of this data.

c) A “Repeated booking register” maintained loco-wise where dates that a particular

item has been booked are posted under the appropriate column is used to keep tab
on the general health of the fleet and Monitor a ‘no defect’ programme. Usually
20-25 selected items are nominated for this book. A few of the items are changed
from time to time as designs change or maintenance improves and attention is
shifted to another area. However, now with advancements in information

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