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INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 24

Document No:

Chapter –4 System of Maintenance

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 88 of 303

4. S

YSTEM OF

AINTENANCE

4.1 Objective: Indian Railways (IR) follows the system of preventive maintenance for its

Rolling Stock so as to achieve the maximum possible availability and reliability in service.
The system of preventive maintenance envisages a schedule for maintenance attention at
regular specified intervals including replacement of components. It aims to replace the
components before they actually fail in service due to ageing, wear and tear, while also
endeavoring to obtain maximum life possible for the components. The system also aims at
synchronization of attention to all related components so that the manpower and engine-
days lost on account of the examination is minimized.

However, IR needs to introduce the concept of predictive maintenance to bring down both
cost and as well as down time for maintenance. To achieve this, it is necessary to lay down
a list of parameters which are required to be monitored remotely and also during the last
shed attention paid to arrive at the decision about next schedule to be given to the loco.
Remote monitoring is an essential requirement in achieving this objective. It is
recommended that, few locos should be put on trial on the system of predictive
maintenance.

4.2 Basis of Maintenance : The system of preventive maintenance has evolved on one of the

following criterion:

Time;

ii.

KM;

iii.

Engine hours

Time basis is used for scheduling the preventive maintenance of diesel locos due to its
simplicity. Time involved between schedules being adjusted according to the utilization of
the locos. However, for POH of Alco locos, both time and Km basis is presently specified
i.e. 10 lac Km or 8 years, whichever is earlier.

4.2.1 Frequency of Maintenance Schedule: Periodicity of various maintenance

schedules of Alco Locos have been enhanced substantially since the introduction of
WDM2 locos. The schedule and periodicity of various maintenance schedules of
Alco and HHP locos are presently prescribed in the following documents of
RDSO:-

4.2.1.1 MP-MISC.-140 (Rev.1) of Sept’06- Schedule of Standard Examinations of Alco

Locos of 2600 & 3100 HP with plain suspension bearings

4.2.1.2 MP-MISC.-141(Rev.1) of Sept’06- Schedule of Standard Examinations of Alco

Locos of 3100 & 3300 HP with roller suspension bearings

4.2.1.3 MP-MISC.-212 of May’08 and Railway Board’s letter dated 2003/M(L)/466/20

dated 27

June’08 for enhancing trip schedule periodicity of 3100 & 3300 HP

Alco locos to 30 days

Draft

Document No:

Chapter –4 System of Maintenance

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 89 of 303

4.2.1.4 MP-MISC.-236(Rev.0) of July’09 and Railway Board’s letter

2003/M(L)/466/20 dated 13

May’10 for enhancing trip schedule periodicity of

3100 & 3300 HP Alco locos to 40 days

4.2.1.5 MP-MISC.-285 of Aug’12- Schedule of Standard Examinations of HHP Locos

of 4000 & 4500 HP

4.2.1.6 MP-MISC.-285 of Aug’12- Schedule of Standard Examinations of HHP Locos

of 5500 HP

4.2.1.7 Apart from the above-mentioned Schedules of Standard Examination, RDSO

regularly issues Instruction Bulletins (IBs), Modification Sheets (MOD Sheets),
Investigation Reports (INV), Maintenance Guides (Guide), Diagram Books (D-
Book), Minutes of Diesel Maintenance Group (DMG) Meetings, Miscellaneous
Reports (MISC), Indian Railway Standard (IRS) Specifications of various
items, Specifications of various items (Spec), Project Reports (PROJ), Test
Procedures (TPs) and Drawings of items. All these are hosted on a website
called IR Diesel Power (www.irdieselpower.in) for online reference. These
should be regularly taken into cognizance by the sheds for the purpose of
maintenance and procurement of material and for building up infrastructure.

4.2.1.8 DLW also issues a periodical Technical Publication called “Soochna” which

contains latest developments made in manufacturing of locos, Design Bulletins,
Failure Investigations, Important Change Notices, Important Corrective and
Preventive Action (CAPA) and Trial Items fitment details. This technical
publication is available on official website of DLW
‘www.dlw.indianrailways.gov.in

’

. It should be referred regularly by the sheds

for making themselves aware of the latest developments and for purpose of
maintenance and monitoring performance of materials supplied by new
vendors/new design products.

4.2.1.9 Schedule periodicity of Alco locos is as under:-

No.

Schedules

Original

Periodicity

Current Schedules for Alco Locos

Name of Sch Periodicity

Trip or Weekly

Max. 7 days T1*

15, 20, 30 & 40 days

Fortnightly

15 days

T2*

15, 20, 30 & 40 days

Monthly

30 days

M-2

60 days

Quarterly

90 days

M-4

120 days

Half Yearly

180 days

M-12

12 Months

Yearly

1 year

M-24

24 Months

2 yearly

2 years

3 Yearly

3 years

M-48

48 Months

POH

6 years

M-96

96 Months

*Periodicity of:
-15 days for WDM2, WDM3A & WDG3A with plain suspension bearing. In these types
of locos T2(T-30) contains all items of T-15 + some additional items like fuel oil filter
change, compressor discharge valves cleaning, alternator/generator cleaning , rectifier
cleaning and suspension bearing examination.
-20 days for Roller Suspension Bearing locos including WDM3D locos. In these types of
locos T2(T-40) contains all items of T-20 + some additional items like compressor

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Document No:

Chapter –4 System of Maintenance

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 90 of 303

discharge valves cleaning, alternator cleaning , rectifier cleaning and roller suspension
bearing examination.
-30 days for Locos fitted with Microprocessor Based Control System (MBCS) and Pure
Air Brake (applicable to locos having 20 days trip schedule)
-40 days for locos fitted additionally with REMMLOT, Small Auxiliaries motors (CCE,
FPM, DEBM) in AC variant, MCBG & Upgraded Compressor (applicable to locos
having 30 days trip schedule). In these types of locos monthly will be done after 80 days,
Quarterly after 160 days and Half Yearly after 400 days

4.2.1.10 The schedule periodicity of HHP locos is as under (as given in RDSO report no.

MP.Misc-285 of Aug’12) :

S.No.

Schedules

Periodicity

Trip/Monthly

Trip/30 days

90/180 days

Yearly

1 year

2 yearly

2 years

3- Yearly

3 years

6-Yearly

6 years

POH

18 years

4.3 Maintenance Schedule: The schedule of attention to various items in the loco and the

frequency of attention shall be as indicated in the Schedule of Standard Examination, issued
by RDSO from time to time. The current schedules issued are mentioned in para 4.2.1.

Any changes warranted to the above schedules shall be authorized only by CME and such
changes shall be discussed in the ensuing DMG meeting for final adoption, if considered
necessary.

4.4 Maintenance Methods: Maintenance methods followed shall be in conformity with the

DMI(s) issued from RDSO or OEM’s instructions, if in case RDSO has not issued DMI(s)
on the subject. The number of copies of DMI(s) distributed to each Shed shall be adequate
to cater to all the officers and senior supervisors of the Shed. After attending to the
Schedule, the same shall be certified in the relevant cards/registers maintained for the
purpose. All DMI(s) and OEM’s instructions should also be available in soft copies on a
central server with each section which should have a dedicated computer through which
these DMI(s) and OEM’s instructions can be accessed. This system can also be used for
conveying important instructions issued by HQ, Sr.DME and various other information
relevant to maintenance, reliability, safety at work place, environment management, etc.

4.5 Use of Advance/Diagnostic Methods for increasing the effectiveness of Preventive

Maintenance:

4.5.1 Present practice of diesel loco maintenance is based upon preventive maintenance

schedules. Preventive maintenance schedules entails planned replacement /
checking of diesel loco components on pre-defined maintenance periodicity.
Currently diesel sheds are replacing most of the items during M24 / M48 and very
few items during M12 / M4 schedules. Though this system has served IR very
well, but sometimes components do not follow predefined maintenance frequency.
Certain components have a tendency to fail prematurely; before planned
replacement cycle.

Draft

Document No:

Chapter –4 System of Maintenance

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 91 of 303

4.5.2 Predictive maintenance technique tries to plug the loophole of preventive

maintenance by incorporating condition monitoring of component parameters.
These parameters are mostly temperature, vibration, Insulation Resistance, current,
run down time, energy consumed, rpm, drop in level, concentration, condition of
lube oil & fuel oil. etc.

4.5.3 At present, the only diagnostic method being used to carry out predictive

maintenance is testing of the lube oil in which presence of various elements is
ascertained and if found beyond a limit, the causes for the same are looked for.
Also, to some extent Fuel Oil Pressure (FOP), Lube Oil Pressure (LOP) and
Booster Air Pressure (BAP) readings recorded by Loco Pilots during running of the
locos are analyzed to see if there is any need to undertake investigation of a
particular assembly/area. However, now-a-days technology has become advanced
and there are many advanced diagnostic methods available for increasing
effectiveness of maintenance. Some of them are mentioned hereunder:

4.5.3.1 Trend analysis of loco parameters: Logging of various performance

parameters of Loco like current in individual traction motors, Insulation
Resistance, turbo run down time, logging of transient faults, FOP, LOP, BAP,
etc. By analysis of these parameters, it can be seen whether there is any trend
which indicates problem in a particular component or area and accordingly
timely preventive action can be taken. This can also be remotely monitored by
using REMMLOT and thus be quite effective in improving online reliability of
locos.

4.5.3.2 Vibration Measurement and Vibration Analysis: Use of vibration level of

loco and engine at various places to pinpoint deficiency in the fitment/defect in
a component. A single low cost hand held vibration meter or shock pulse meter
can give advance indication about the health of the loco components. Condition
of the component can be judged by either of the following two methods:

a) Rise in vibration reading from previous reading of same loco in identical

condition and location

b) Variation in vibration reading of same component from other locos. Reading

should be taken at identical locations. Any change in type and increase in
intensity of sound is a cause of alarm. Engineer’s stethoscope can also be
used for listening sound. However, it is a qualitative technique.

4.5.3.3 Ferrography: Use of ferrography to determine ferrous content in grease of

traction motors and axle box bearings gives an indication of signs of incipient
failures, which if taken care of in time, can prevent potential failures.

4.5.3.4 Thermography & Temperature measurement: It is a very simple technique.

Measurement is made by using a low cost laser based temperature gun. Properly
interpreting the data and observing the temperature rise trend, health of loco
components can be predicted. It is based on the premise that efficient/well
maintained assembly will consume least amount of energy and will have a
minimum heat loss. Higher heat loss indicates deterioration in performance and

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