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INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 57

Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 220 of 303

S.No.

Description

Check for

VCD

Working

Loco Brakes

Effectiveness (by observing movement on 1

Notch)

Dynamic Brakes

Working

Conjunction Brakes

Working

Parking Brakes of DEMUs and
DHMUs

Availability and Working

TBUs of WDP1

Working

Hand Brake

Functioning

Flasher Light

Working and Automatic Switching ON

Headlight

Working and focusing, availability of spare
bulb

Classification Lamp

Working (both red and white)

Window Wipers

Working

Horns

Working

Speedometer

Working (both)

Fire Extinguisher

Availability and Inspection

Wooden Wedges

Availability and Condition

Annexure- 9.2

LIST OF SAFETY PRECAUTIONS TO BE TAKEN DURING MAINTENANCE OF THE

LOCOS

ELECTRICAL:

Description

Ensure ECC connection wires junction box cover to be intact with no oil inside.

Ensure headlight connections are free from dirt and oil

TA/TG room should always be kept dry.

Ensure no oil leakages on electrical cables.

TG/TA gear case oil should be filled duly using funnel and also avoid over filling.
Filling cap to be tightened properly.

Ensure TA/TG pit drains are free from obstructions.

Check regularly for IR values of power, control and power to control circuits and
ensure minimum prescribed values are maintained.

Ensure no loose cable / wire joints and perished/damaged insulation of cables is there.

Wires/ cables of correct rating to be used.

Ensure good condition / fitment of Arc chutes.

Ensure calibration of safety relays, MCBs and safety valves as per prescribed norms.

Avoid overcharging of batteries and blockage of vent plug holes.

Ensure no oil, dirt/waste papers are allowed in the control compartment and also in the

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Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 221 of 303

Description

control panel, i.e., under the BKT and REV switches.

Ensure electrical junction boxes are oil tight.

Ensure that all traction motor and generator / alternator cables under the floor are
properly secured in cleats and are thoroughly cleaned of all dirt, oil and grease. In no
case, cables should be tied up with wires / ropes / cloth, etc.

MECHANICAL:

Description

Complete engine room should be kept dry.

Check for tappet cover, sump and explosion door gasket joints for oil leakages.

Ensure availability of Braided/Rubber hose as cover over Fuel oil cross over Pipe.

Ensure no cracks on primary and secondary fuel oil filter housings.

Check for rubbing of hoses and metallic pipes with other parts. If so, these should be

properly clamped.

Check exhaust manifold for signs of any exhaust gas leakages from bellow

joints/manifold.

In every schedule lube oil drain pipe dummy should be removed and should be

properly fitted back after draining oil.

Ensure radiator room is completely dry. Leakages, if any, should be arrested. Check

lube oil pipe dressor couplings and flange joints for leakages. Lube oil drum cover
should be properly tightened. Ensure legs and cover bolts of filter housing are not
broken.

4 Nos. of fire extinguishers fit in all respects are to be always available in the Drivers

cab. They should be properly secured and located within easy reach of the loco pilot.

10. Ensure compressor high pressure discharge pipe lines are covered with thermal

insulating material. No oil should drip on insulation. If necessary, piping and joints
should be suitably relocated.

11. Ensure compressor pit is dry with no accumulation of oil and water. The drain pipe

under floor should be of adequate length at bottom to avoid falling of drained oil / fuel
on truck / TM or other under gear items.

12. Ensure cleaning of oil, grease and muck, etc., in loco to avoid catching of fire.

13. In every schedule brake cylinder piston travel and brake adjustment should be done in

sequence correctly.

14. Ensure that proper caps are secured on gear cases / suspension bearing oil sump, etc.

In no case openings should be allowed to be covered with cloth.

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Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 222 of 303

Annexure- 9.3.1

SAFETY PRECAUTIONS FOR CRANE OPERATION

1. Ensure free movement of crane in longitudinal and transverse directions, functioning of

controls and limit switches before starting the crane.

2. Do not keep loose objects in the crane to avoid accidental falling from crane.

3. Crane should never be over loaded beyond the safe working load capacity which should be

prominently marked on the machine.

4. Brakes should be checked when a near capacity load is being lifted by actually lifting the

load a few inches and switching off the controls.

5. If the brakes do not apply and the load comes down it should be repaired/set/adjusted first

before lifting the load again.

6. The hook block should never be lowered below the point where,

i) Less than two full wraps of rope remain on the hoisting drum or

ii) It is about to touch the floor.

Ensure the lower limit is adjusted accordingly.

7. The cranes should be centered over the load such that the hoisting ropes are vertical. It

should not be used for angular lifting or pulling a load.

8. Before shifting the load it should be lifted high enough to clear all obstructions on the floor.

9. Know and obey the signals from supervisor/slinger while operating the EOT crane.

10. Controls should be operated smoothly to avoid abrupt, jerky movements.

11. Personnel in the immediate area should be cleared off when the load is being lifted and

moved.

12. Look out in the direction of movement of moving loads to avoid accidents.

13. The bell provided should be operated to alert the staff about crane movement.

14. “STOP” the crane operation when in “DOUBT” about the health of the crane.

15. A suspended load should never be left un-attended.

16. Station the crane near the ladder.

17. “DO NOT” walk along the crane rails

18. SWITCH OFF the crane before leaving the crane.

19. SWITCH OFF main power supply when the crane is not in use.

20. Do not open fuse boxes and electrical controls for repairs without proper authority.

21. The crane should be electrically isolated and the main switch should be locked or tagged

and fuses removed before inspection, repairing, cleaning/lubricating etc., where an
accidental start of the Crane may result in a severe accident. (Refer to electrical isolation
and tagging)

22. When two EOT cranes available on one line, gantry or rail safety devices functioning should

be ensured which sounds a warning or cuts off the electricity supply to crane movement so
that collision between the two cranes can be avoided.

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Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 223 of 303

23. Check whether any maintenance schedule of crane is overdue. If so, immediately inform the

concerned supervisor.

24. Always keep the crane clean and tidy.

Annexure- 9.3.2

SAFETY PRECAUTIONS FOR USE AND EXAMINATION OF ESSENTIAL LIFTING

ACCESSORIES

1. Ensure that load being lifted is within the limit of safe working load of respective lifting

machine or tackle, wire rope

2. Ensure that lifting chains, ropes being used are not overdue testing and are free from any

visible defect.

3. Ensure lifting tackle is free from any visible defect.

4. Wear Protective Clothing, Helmets and shoes compulsorily while working with lifting

machines

5. The crane should be centered over the load such that the hoisting ropes are vertical. It

should not be used for angular lifting or pulling a load.

6. Ensure that loco lifting by jacks is done at prescribed place

7. Before use, ensure that locking device of loco lifting jacks is in working order

8. Ensure that loco lifting jacks are placed at the prescribed location.

9. Ensure that loco lifting jacks are placed firmly on floor

10. Ensure that lifting arm of loco lifting jack is free from visible defect

Annexure- 9.3.3

SAFETY PRECAUTIONS FOR ELECTRIC ARC WELDING

Wear protective cloth during welding operation.

Use nose mask for protection against welding fumes.

Avoid contact with any metallic element which carries voltage without proper
insulation.

Properly earth the negative terminal nearer to the work place. Do not resort to loose
connection on the earth terminal.

When not working, remove the electrode from holder and switch off the machine.

Holder should be kept in such a way that it does not make any contact with persons or
conducting objects.

Ensure holder is fully insulated and electrical connections are tight.

Keep welding cables, holders and other accessories neat and dry.

Wear helmets or head screens, goggles, safety shoes and protective clothing for all
welding operations.

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