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INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 29

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 108 of 303

4. Knowledge of fuel system, lube oil system, cooling water system, air brake system,

trouble shooting and maintenance.

5. Knowledge of functioning and maintenance of air brake system, including vigilance

control device and Automatic Emergency Brakes.

6. Knowledge of functioning and maintenance of compressors.

7. Knowledge of inspection and attention to under truck and loco chassis.

8. Knowledge of working and attention of Wood Ward Governors.

9. Knowledge of periodic tests carried out in the Diesel laboratory on lube oil, fuel oil,

cooling water and control over their quality.

10. Knowledge of overhauling and testing of fuel injection equipment.

11. Knowledge of load testing and remedial measures to be taken based on observation.

12. Knowledge of Multiple Unit operations and their testing.

13. Knowledge of various safety items and safety devices located in the locos.

B. Syllabus for the Written Test for the Post of Junior Engineer (Electrical)

1. Types of Diesel locos in use and their general working principles.
2. Principles of different types of excitation systems and principles of governing engine

in Alco and HHP locos.

3. Knowledge of Micro Processor Controller Based governor and its function.
4. Application of semi-conductors to Diesel Electrical Locos Comparative advantage –

principles of working transistor circuits.

5.  Sound knowledge of safety devices and their function.
6.  Trouble shooting-ability to locate defects and rectify.
7.  Dynamic braking principles – calibration and re-calibration of circuits.
8.  Load testing, objective of load testing and remedial measures to be taken based on

observation.

9. Knowledge of Indian Electrical Act and rules.
10. Knowledge of various warning systems
11. Knowledge of various electrical circuits in the ALCO and HHP locos.
12. Knowledge of Microprocessor Based Excitation Control System Schedule attentions

as per extant versions.

Schedule forecast Register for ALCO Locos

ANNEXURE 4.5

Initial Arrival Particulars

Page No.

Arrived from DLW

Loco No.

Arrived from DLMW
Date of Comm.:

Type

POH/RB Particulars:

Shed Left

Shop Arrival Shop Left

Shed Arrival

T1 Schedule Dates

RB Particulars

POH Particulars

T2 Schedule Dates

Home

Ch-4

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 109 of 303

Major Sch. Particulars (M24/48/72)

M2 Schedule Dates

S.No.

Type of Sch.

Date

Stopped

Date

Released

Medium Schedule Particulars

(M4, M8, M12, M16, M20)

General Check (NS) Dates

S.No.

Type of Sch.

Date

Stopped

Date

Released

-------------RAILWAY

ANNEXURE 4.6

Engine Repair Book

LP Name __ T. No.__ Train no.___ Loco no. ___
ALP Name__ T. No.__ From_____ To____
LP home shed__ Load as per Guard’s journal __
Type of schedule attended at home shed
/Satellite shed date
Actual Dep. Time ____ Date _____
Actual Arr. Time _____ Date _____
Type of Schedule ____ due and date
Kilometers earned during the trip ____
Fuel oil consumption ____ Litres

(Items to be handed over and taken over by drivers.)

1.  M.U. Jumper cable
2.  V.R.R. Spare fuse (for E type locos).
3.  Ground relay cut-out switch seal.
4.  Fire extinguisher
5.  RTTM blower bolts.
6.  Emergency telephone key and seal
7.  One spare transition screw coupling.
8.  Spare BP & FP hose

LP bookings ____
Shift JE/outstation Technician remarks.

Signature of LP          Signature of LP
Handing over             taken over
Name                    Name
Designation                Designation
Home shed                    Name shed
Date                         Date

Signature of Shift JE/outstation Technician

Levels to be measured

1.  Lube oil sump level ---- added -----  litres
2.  Compressor sump level --- added ---  litres
3.  Generator gear case level ----added -----

litres

4.  Governor oil level -----------added ------- litres.
5.  Expansion tank water level -----added --- litres.
6.  Air maze oil bath filter level -----added ----- ltrs.

REGARDING : To be recorded every half an hours.

1.  Time
2.  Booster pressure
3.  Fuel oil pressure.
4.  Lube oil pressure
5.  Load ammeter readings
6.  Battery charging ammeter reading.

7.  Water temperature
8.  Compressor oil pressure
9.  Speed
10.  Gradient.
11.  Notch
12.  Position of Dynamic Brake selector handle.
13.  Motoring (M) or Dyn. Braking (B)

------------ RAILWAY

ANNEXURE 4.7

DIESEL SHED ------------- LOCO TYPE ------------

REPEATED BOOKING REGISTER ----------- NUMBER ------ MONTH-------

Dates 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Remarks
1 Throttle not responding

2 Loadmeter not responding

3 Engine hunting

4 Low booster pressure

5 Compressor throwing oil

6 Power ground

Home

Ch-4

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 110 of 303

Dates 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Remarks
7 Power brakes not re-leasing

8 Power contactor fluttering during transition.

9 Low lube oil pressure

10 Fuel oil pressure dropping on higher notches

11 Vent pipe leaking or cracking

12 Battery charging rate on high side beyond 20 amps.

13 Wheels slip indication

14 Fuel Pump circuit breaker tripping

15 Experiencing jerks while handling

16 Transition not picking up properly

17 OSTA tripping and unable to recrank

18 Fuel Pump Motor not Working

19 Experiencing wheel slip and unable to haul the load

20 HP Tube breakages

21 Fuel banjo bolt leaking fuel oil.

22 Water level reducing

23 Water leaking through fuel leak off

24 Oil carrying

25 Cam roller splitting

26 Engine side buffers crack

27 Engine side buffers disc rotating

28 Fuel jumper bolt breakages

29 Horizontal shaft wobbling

30 Radiator core tubes leaking water

31 Water leaking from water pump tell tale pipe

32 Unusual sound from RTTM blower

------------- RAILWAY

ANNEXURE 4.8

O. K. REGISTER

Date

Loco

Train

Shed

dep

VCD

condition

VCD COC

HB-5

COC

H-5

COC

Brake

cyl-

COC

28VB

COC

Condition

of CCB

Fire Ex.

MR QA

Sanders

Wipers

Cab

Cut in

Cut out

Speedometer

Check sealing of Gear no. case bolt &

suspension on bearing

Driver’s name

Signature

Recorder

Roll

Indicator

& clock

Cap

Bolts

Hand
brake

working

order

Fire

extinguishers

condition &

Nos. available

VCD

working

order

Phone
Sl.No.

Dynamic

brake in

conjunction

of Loco

brakes

Spare

BP/FP

Pipe

available

or not

No. of
Wheel

skids

Classification

lamps

working

order

Flasher

lights

working

order

Head

lights

working

order

Sign. of

shift

JE/Elec.
& Mech

Home

Ch-4

Draft

Document No:

Chapter –5 Management Information System

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 111 of 303

INDEX

Chapter 5

Management Information System

Para No.

Description

Page No.

5.1

Introduction

113

5.2

Overall objectives

113

5.3

IT Architecture

114

5.4

Authentication

116

5.5

Model for MIS data management and
presentation

116

5.6

Broad Features of MIS of Diesel Operation &
Maintenance

120

5.7

Centralized Organization for handling of MIS of
Diesel O & M:

120

Draft

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