LIGHT REPAIR BAY

SCHEDULE OF STANDARD EXAMINATION

First standard schedule of examination for WDG2 locos was issued by

RDSO in the year 1981.
The examination schedules
1. T-15/T-30 schedule -15/30 days (Trip).
2. M-2 schedule – 60 days (Monthly).
3. M-4 schedule in 4 months (Quarterly).
4. M-12 schedule in 12 months (Half yearly).
5. M-24 schedule in 24 months (yearly), with 100 % cylinder liner
and piston ring change.
6. M-48 schedule in 48 months (2 yearly).
7. M-72 schedule shall be the same as M-24 (3 yearly)
8. POH at an interval of Eight years (M-96) or 1000000 KM earned
by the locomotive, whichever is earlier.
It may be noted that the service period of locomotives specified
in this schedule for maintenance attention are the maximum
allowable between the successive examinations.
 Maintenance schedule
It is recommended that the procedures listed in this maintenance
schedule be performed at least once during the specified time period
or more frequently is service conditions so indicate. Failure to
perform the procedures at the specified time period may result in
damage to equipment, which could possibly cause a malfunction that
may result in property damage and/or bodily injury. More frequent
maintenance intervals may be found necessary, depending on the
severity of user’s responsibility to more frequently schedules for
maintenance are required.

Trip schedule (m1):

 Loading and unloading the inlet & discharge valves.
 Cutting cut off 10 to 8 kgs and oil sample checking.
 Leakages and vibrations.
 Oil level checking in sump.
 Checking the oil pressure indicator valves.
 Check the crankcase vacuum is in 36 psig.
Monthly trip (m2):
 Same as trip schedule and air inlet filter cleaning.
 Change crankcase oil. Clean interior of using a natural sponge
and mineral spirits. After cleaning, dry the crankcase
completely.
Quarter schedule:
 Trip schedule.
 Discharge valve cleaning.
 Safety valve cleaning
 Breather valve overhauling on M16 onwards.
M8 schedule:
 Inlet valve cleaning
 Complete oil changing
 Relief valve changing and sump examination
 Lube oil strainer cleaning
 Air inlet filters cleaning
Half yearly schedule:
 Trip schedule
 M8 schedule + rings cleaning
 Cylinder heads overhauling
 Liner diameter checking
Annual schedule:
 Replace the oil indicator
 Replace aluminium pistons
 Replace cast iron piston
 Replace all the piston rings in low pressure cylinder and high
pressure cylinder
 Replace all the cylinders

Maintenance of diesel locomotive is one of the most important tasks

for its longer life. They are explained in brief below.
1. Yearly locos (heavy repair):
Heavy repair bays (yearly locos) works for M24, M48, M72, etc.,
services. Under this schedule, every pin to pin is checked
(removed & assembled except main alternator with
crankshaft), oil change, total loco repair, cleaning (washing),
incorrect shafts changed, etc., is performed.
 First of all, components are cleaned by brushing off the oil&
washing is done. Then they are inspected, repaired and
assembled.
2. Half yearly & quarterly locos (Medium Repair):
Medium repair bays (half yearly, quarterly locos) work for M6,
M12, etc. services. Here, aux. mechanical devices like pumps,
aux. electric devices except main general & compressor are
cleaned. Other devices are also checked.

3. Monthly & fortnight locos(Light Repair):

Locos sent from heavy repair bay (yearly locos) return to light
repair bay (15 days or monthly (30 days)) for filters change,
pads change, injectors cleaning, etc. M4, M8, M16, M20
services come under light repair where M4 means 4 months,
next M4 i.e., M8 (8 months).
Except 20/30/40 days trips (any shed), all the other schedules
are performed at home shed only.
Apart from these, trouble free locos are tested and send to
“express locos” to use them for like/express trains. For every 18
yearly, locos are modernised at diesel modernisation works
(DMW), Patiala.
 Schedule examination for ALCO
locomotives
South central railway
(Mechanical department)
Schedule: T-1 MECHANICAL
S.No. As per MISC components
141
1 General examination
Check and attain
Water jumper location
Fuel jumper location
2 25 M Cooling water system
radiators
3 Car body air intake filters
4 wheels
Work to be done
a. A general visual examination to be made of all
locomotives to detect loose, defective, missing or
leaking parts.
b. Cylinder heads, manifolds and joints for blow and
leaks.
c. Unusual noise from running engine other power/
cylinders, cam shafts, cam gears and power pack
components.
d. Unusual noise from RTTM blower.
e. Check lube oil pressure at idle, 4th , 8th notch and
record (min 2.5 kg/cm2)
f. Check fuel oil pressure at idle, 4th , 8th notch and
record (min 3.5 kg/cm2& 3.5 kg/cm2 at 8th
notch)
g. Check fuel injection pumps and pipes for leakage
at maximum engine speed.
h. Check safety brackets of bogies.
i. Any water jumper/ fuel jumper are leaking, do
not tighten the bolts. Remake the joint with new
gasket to correct torque value. Record water
jumpers/ fuel jumpers locations.
j. Visually examine the bogie frame for cracks.
Rectify, if any.
k. Check turbocharger smooth run down as engine
is stopped and record turbo run down time
l. Check oil level of centre pivot casting and side
loading pad oil pans. Top up , if necessary.
Blow with compressed air in the direction opposite to
normal airflow.
Car body air intake filters to be cleaned, oiled and fitted.
Visually examine for fractures, the tyre profile for wear,
flat and skidding marks.
5 38 M Hand brakes Check condition and operation. Lubricate, adjust as
necessary.
6 37 M extinguishers Check for broken or missing seals. If found investigate
reasons before replacing & replace with live FE.
7 23 M Send sample of engine coolant for testing. Replenish if
necessary. Check water and oil leakage at water pump
tell-tale hole. DO NOT PLUG THE HOLE. Top up with
treated water as requires. Do not add water unless
absolutely necessary. Account for leaks that may have
developed after making sure that water is not leaking
into the lube oil system. Add only treated water as
specified.
8 39 M Traction motor a. Check bearing temp. just after the operation of
suspension taper roller locomotive. If found abnormal temperature,
bearings change out its suspension tube.
b. Check securing of bolts to ensure their tightness
using torque wrench to a correct value.
c. Check positioning of adjustment washer.
d. Check and refit the missing or damaged grease
nipples.
e. Check and replace earthing bushes if
missing/damaged.
f. Check oil level with the gauge it should be at the
max. mark top up if necessary.
9 Roller bearing a. Visually examine the axle boxes for any damage
or for any unusual condition.
b. Check for missing or improperly locked cover
bolts.
c. Examine the leakage of lubricant from housing
joint.
d. Observe any sign of overheating on the axle box.
e. In case of unusual conditions, it may be
necessary to investigate further and take
appropriate action.
f. Look for any loose, cracked or missing wear
plates on axle boxes or pedestals.
10 45 M Hydraulic dampers, a. Check tightness of mounting bolts and nuts,
springs and safety condition of rubber bushes and for oil leakage,
brackets. take corrective action as required
b. Check the suspension springs for any cracks/
damage. If any spring in the nest of inner & outer
springs is found broken, both the inner & outer
springs (complete grout) should be replaced.
c. Cracked / damaged springs are not permitted to
remain in service under any circumstances.
11 H type coupler a. Check tell tale of coupler.
b. Visual check for external damage, condition wear
plate on shank.
c. Replace wear plate if necessary.
d. Also check side buffers, screw and transition
coupling.
12 49 M Centre buffer coupler E Examine in position for fractures, strain and wear. Also
type check side buffers, screw and transition couplers.
13 50 M Cattle guard Check supporting brackets and rail guards. Adjust rail
guard to attain 100mm gap between rail and rail guard.
14 47 M Brakes a. Check piston travel of brake cylinder.
b. Slake adjusters should be set to provide 3/8” or
10 shoe release.
c. Check nuts on brake head pins
15 48 M Main and control Check working of Auto-drain valve.
reservoirs
16 32 M Traction motor blower a. Top up blower bearing with grease and ensure
(belt driven) that does not fall in blower casing.
b. Check the belt for condition and tension.
c. Check adaptor nut for tightening and ensure that
tub washer is in position & locked.
d. Check blower impeller for shifting.
17 54 M Fuel tanks Check the intactness and visibility of fuel glow rod gauge.
Record fuel oil level before schedule and after schedule.
Fill as required & record quantity added.
18 24 M Engine lubricating oil a. Send lube oil sample for lab tests before topping
system. up.
b. Check oil level in the crank case of engine. Top
up if necessary and record quantity added.
19 55 M Wind shield wipers Check operation.
20 56 M Horns Check operation.
21 57 M Sanders Check operation.
Fill sand boxes, as necessary.
22 60 M Air-brake system Check operation of straight air brakes at service &
including distributor valve emergency positions. Carry out tests at driving positions
and ensure: -
a. Operation of independent locos brake and adjust
brake cylinder pressure to 3.5 kg/cm2.
b. Brake pipe and equalizing reservoir pressure is
adjusted to 5 kg/cm2 with adjusting knob of A-9
valve.
c. Pressure of main reservoir is maintained
between 8.0^0.1 to 10.0^0.1 kg/cm2. It should
cut in at 8.0 kg/cm2 and vu tot at 10.0^0.1
kg/cm2.
d. Brake cylinder pressure in emergency not less
than 1.8^0.1 kg/cm2. Control air pressure is
adjusted to 5 kg/cm2.
e. Check calibration of air flow measuring valve.
f. Check electrical connections
g. Check functioning of distributed valve.
h. Check setting of pressure switch.
i. Check operation of additional cut out cock
provided on brake pipe. Open additional COC, BP
should drop & BC should rise. Close additional
COC, BP should rise & BC should drop.
23 61 M Pressure switch PCS-1, For pcs-1 close at 6.5^0.1 and open at 7.5^0.1 kg/cm2.
 PCS-2 For pcs-2 close at 2.8 and open at 4.0 kg/cm2.
24 Traction motor Check oil level.
suspension bearings 1. Check temperature of bearing, tightening, washer
Plain 2. Taper roller damaged grease nipple, brushes.
25 40 M Motor gear case Lubricating level, case bolts.
26 22 M Cab and engine room Clean cab, windows, engine room & running gear.
27 Moatti filter Check for leakages, damage to copper pipes.
28 26 M Fuel filter (primary Collect sample.
housing)
29 27 M After cooler Check water leaks.
30 28 M Turbo charger vent pipe The safety clamps and brackets.
31 29 M Expresser Check oil level and top up as required
32 30 M Inter cooler Drain condensate.
33 31 M Dirt collector Remove collected dirt.
34 33 M Engine speed control Clean & lubricate external linkage & connections.
linkage
35 Bag type filters Check the condition of cyclones by lifting the door.
36 42 M Roller bearing Axle boxes a. Inspect overheating and see that bolts, nuts, pip
plugs and other parts.
b. Check for leakages of lubricant around gaskets at
covers.
c. Check for missing or loose pedestal lug line.
37 44 M Roller bearing Axle boxes Visually examine the axle boxes for any damages. Check
for missing or improperly locked cover studs/ bolts and
other parts.
Examine the leakage of lubricant from housing joints etc.
38 46 M J-filter Drain condensate.
39 52 M Equalizer beam In the normal condition the equalizer pin should be free.
40 53 M Side bearer Visually examine all side bearers (rubber springs) for
cracks or damage.
41 58 M Plate type lube oil coolers Leakage of water/ oil from the plat/ gaskets of the
PTLOC.
42 62 M Measuring against fire Ensure the following:
a. Compressor inlet cooler pipes are dry and oil
bath filter does not fall on the pipes (where
locomotives have been provided with oil bath
filters).
b. Thermo guard lagging is provided on compressor
delivery pipes.
c. No leakages of lube oil and fuel oil.
d. Fuel cross over pipes is properly secured and is
not rubbing with engine block.
43 CRU bearing a. Visual inspect the axle box housing, front cover,
rear cover and other parts for front cover.
b. Wherever the locomotive comes for routine
inspection, it is recommended to open the front
cover for checking any abnormal excessive
leakage of grease leakage could be normal and
comes from initial purging of grease and relieving
of internal pressures.
 TROUBLE SHOOTING
a. Reasons for fuel oil pressure dropping ever though fuel pump motor
working:
1. Less fuel oil in the tank.
2. Fuel trap may be dirty.
3. Primary and secondary filters may chock.
4. Suction pipes may be air drawing.
5. Relief & regulating valves may be struck up in open condition.
6. Love joy coupling may be slack.
7. Delivery pipes may be leaking.
8. Fuel booster pump may be defective.
9. Gauge pipe line may be damaged.
10. Fuel oil pressure gauge may be defective.
11. Water contaminated with fuel.
b. Reasons for lube oil pressure dropping:
1. Less lube oil in the sump.
2. Lube oil pump may be defective.
3. Relief & regulation valves may be struck up in open condition.
4. Delivery pipes may be leaking.
5. Filter drum filters may be chocked.
6. Filter drum ‘o’ ring may be damaged.
7. Filter drum & strainer casing drain cocks may be partially open.
8. Strainer may be dirty.
9. Lube oil gauge may be defective.
10. Gauge pipe line may be damaged.
c. Reasons for water temperature raising and hot engine alarm:
Due to LWS:
1. Malfunctioning of LWS.
2. 3 way COC may be closed.
3. Water level drops below one inch from the bottom of tank.

Due to ETS:
4. Water temperature above 90 *c.
 5. Radiators may be chocked.
6. Radiator from door may be open.
7. ECC may be defective.
8. Radiator fan not working.
9. Continuous load on engine.
10. Less water in expansion tank.
11. Atmospheric air temperature may be high.
12. Right angle gear box may be defective.
13. R-2 and R-2 contactors may be defective.
14. Right angle gear box may be defective.
15. R-1 and R-2 contactors may be defective.
16. TS-1, TS-2 & ETS may be defective or malfunctioning or setted
wrongly.
17. Water pump may be defective.
d. Reasons for turbo back pressure (surging).
1. Faulty injection system.
2. Improper nozzle ring gap.
3. After cooler blocked.
e. Reasons for MR pressure dropping.
1. MR1, MR2 drain cocks may be open.
2. Auto drain valve may be continuously blowing
3. BP, FP, MR, BC equalizing pipes may be opened to atmosphere
4. Expressor pipe line may be leaking very badly
5. Inter cooler tubes may be damaged
6. Inter cooler safety valves may be defective or dropped
7. AC governor may be malfunctioning
8. Compressor valves may be defective
9. MR gauge may be defective
10. Piston rings heavy blow-bye
f. Reasons for BP not charging:
1. Less MR pressure
2. A-9 may be in application
3. Both side control stand A 9 COC may be closed
4. MU2B in dead condition
5. 3/4” COC may be closed
6. Firemen emergency may be in open condition
7. Additional c-2 relay valve may be defective
 LOCOWASHING

SCOPE OF WORK
The scope of work in brief for cleaning of loco during
Light/Medium/Heavy schedule maintenance contains the
following activities.

1. Loco Exterior washing

1. The locos will be placed in washing bay for external washing of
locos.
2. Only specified / approved cleaning agent shall be used for this
purpose.
3. After placement of the loco, close the side doors of the loco on
both sides. Clean the Side doors, hood top doors and the front
portion of the loco by applying diesel/kerosene oil where ever
required and wipe it out cleanly with duster cloth such that it is free
from any oil/grease stains.
4. Apply high pressure water jet with lance on all the surfaces of
flap doors, hood top doors, driver cab doors, foot boards, loco
chassis sides etc.
5. Apply cleaning agent with brush over the wet surface of the
loco side doors, hood top doors driver cab doors, foot boards, chassis
etc.
6. Apply high pressure water jet and clean the surfaces. In case
the cleaning is not satisfactory/ the stains are not removed properly
apply cleaning agent again with more concentration and repeat the
same steps as above.
7. Clean the driver cab look out glass, head lights, marker lights on
both sides of the loco by applying cleaning agent and then wiping it
out with brush/duster cloth.
 8. Apply cleaning agent on the foot boards, chassis sides and
clean thoroughly with high pressure water jet hose.
9. Similarly clean the front & rear cattle guard areas.
10. Finally wipe the entire loco side doors driver cab doors, look
out glass, Head lights with wet/dry cloth and ensure proper
cleaning.
11. Clean the driver cab inside panels look out glasses from inside
with wet cloth followed by dry cloth. Apply cleaning agent if required
to clean hard stains.
12. Clean the cab PVC floor sheet with mop by applying cleaning
agent and finally cleaning it with wet mop seeder/cloth.
13. Maximum time allowed for exterior washing of loco is 40
minutes.

2. Steam and air blowing of radiators

2.1 The radiators have to be blown with air/steam at the nominated
place on arrival of the loco. Compressed air required for this purpose
will be supplied by railways. The cleaning staff should wear nose
mask and gloves.
2.2 Air blowing from outside to inside -On arrival of the loco connect the
flexible air hose to the compressed air supply line. Position the
Nozzle over the radiator core from top and move horizontally from
one end to the other end and later move vertically downwards.
Ensure that the entire surface of the radiator is covered. Repeat the
same for the other radiator. It is advisable that the radiator fan is
kept in working while blowing from outside to inside so that the dust
will be driven out by the radiator fan.
2.3 Air blowing from inside to outside—Repeat the same procedure from
inside radiator room, blowing air from inside to outside. Radiator fan
must be in off condition or loco shall be in shut down condition.
4.2.4 After the above repeat the same procedure with high pressure
steam jet.
 4.2.5 Maximum time allowed for air and steam blowing together is
40 minutes.

3. Loco interior cleaning

3.1 Interior cleaning of the loco shall be done while the schedule
attention is in progress or almost in finishing stage. This work has to
be completed in the period between Initial running check (IRC) and
final running check (FRC).
3.2 Clean the Engine Room - clean the oily areas on engine block surface
and clean the oil leakages from FIP covers, Cylinder heads, OSTA
body and tappet covers etc. and also clean the floor adjacent to the
engine block with duster cloth. All these areas shall be cleaned free
from oil/ muck.
3.3 Clean the areas of compressor room- clean the cardium/oil spillage on
outer surfaces of lube oil pump, water pump and their corresponding
pipe lines, compressor room floor, compressor pit & the pit side
walls, drain out the accumulated oil & water if any from the
compressor sump/pit. After cleaning the compressor pit, it should
look clean and dry.
3.4 Clean the loco side doors inside /outside with Kerosene oil so that the
oil/grease stains can be removed.
3.5 Clean the radiator room. Spray saw dust inside the radiator room and
allow it soak for few minutes. Then sweep/remove the soaked saw
dust and clean the floor with cloth. Clean the lube oil cooler and
lube oil filter drum with cloth.
3.6 Clean the foot boards in the same way as mentioned above.
3.7 Clean the drivers cab doors, Loco front and rear body with cloth.
Remove any oil/ grease stains with kerosene oil.
3.8 The muck/oil and waste accumulated in the engine room, compressor
room, foot boards, radiator room floor have to be scrubbed and
removed using wire brush/scrappers and cleaned dry with cloth.
3.9 Clean the alternator room floor, alternator and auxiliary machines
with cloth. Remove any oil/grease on the machines.
3.10 During the schedule attention of loco, if it necessitates any out of
course repair such as removal of water pump, lube oil pump, cam
shafts, cylinder head, pistons, liners etc., any the oil/water spillage
occurred during the course of removal/fitment shall be thoroughly
cleaned.

4 Cleaning of Under Truck

4.1 Cattle guard is to be cleaned and it should be free from, dust,
oil and muck. If the loco has been subjected cattle run over (CRO)
while on run, then all the muck & foreign particles if present over it
shall be thoroughly cleaned.
4.2 Rail guards are also to be cleaned such that they are free from any
dust & muck.
4.3 All dust accumulated over the surface of MR Tank shall be scrapped
off with wire brush and cleaned with dry cloth.
4.4 The outside surface area of fuel tank shall be cleaned with dry cloth
and shall not have
Any oil traces over it.
4.5 All the Traction Motor Gear Cases shall be cleaned by scrapping off the
dust, excess
Cardium spillage and any foreign particles attracted to it such as
cloth, papers, etc. shall be removed and cleaned thoroughly.
4.6 Dust and cardium flash present on all the pull rod safety brackets are
to be cleaned & any foreign particles such as cloth, papers, etc. if
attracted to it shall be removed and cleaned.
4.7 Wick pads and wick pad oil on traction motor surface shall be cleaned
with dry cloth.
4.8 All traction motor cables (car body cables) shall be cleaned.
4.9 All the drain pipes of compressor pit, alternator pit shall be blown
with air and scrap all dust accumulated over it’s the outer surface.
4.10 The chassis, bogie frames, wheel axle assemblies and side buffers of
the loco should be scrubbed by wire brush and cleaned with dry
cloth. After cleaning, cleaned items should be free from muck, grease
and oil traces.
 5.0 Cleaning of car body filters.
5.1 Removal of car body filters from the locos undergoing schedules (as
per the advice of representative of Sr.DME/DSL/KZJ) and soaking the
same for two hours in the wash tank provided for the purpose.
Cleaning the soaked filters with jet of water after removing from the
wash tank and finally a lubricant (will be given by the shed) is applied
on the filters. On an average 60 numbers of car body filters are to be
cleaned per day. (Due to conversion of car body filters to paper type
filters in ALCO type of locos, the average numbers of filters to be
cleaned per day is likely to reduce gradually). The Railway will
arrange required ingredients like TRI SODIUM PHOSPHATE, CASUTIC
SODA and SODA ASH as per the Lab memo for adding to the soaking
tank. The soaking tank must be thoroughly cleaned by the
Contractor’s staff whenever ingredients are accumulated after
draining out the used solution so that fresh dose of chemicals can be
charged. Cleaned car body filters shall be refitted on the loco
nominated by the representative of Sr.DME/DSL/KZJ.

5.2 The Contractor Staff should clean the components available in the
wash tank as mentioned above as per the advice of the concerned
Section In-charge/Representative of Sr.DME/DSL/KZJ in the sequence
prescribed for different components by the representative of
Sr.DME/DSL/KZJ.
5.3 The Contractor staff should be available during 8/17 hours for
component cleaning.

6. Additional cleaning activities which are specific to only heavy repair

schedule attention locos are mentioned below.

6.1 In the process of stripping of all components and all the oil /water
spilled over the areas such as radiator compartment, compressor
compartment including compressor pit and Engine Block shall be
sprayed with saw dust and then cleaned with cloth.
6.2 After completion stripping of all components, the loco shall be cleaned
thoroughly by steam blowing.
6.3 The stripped components also shall be thoroughly cleaned by steam
blowing.
6.4 The removed pipe lines shall be thoroughly cleaned in wash tank.
6.5 Cleaning of Engine block cam bush housings for DPT (Dye-Penetrant
test)
6.6 Cleaning of all welding joints with wire brush.
6.7 Cleaning of foot board with wire brush.
6.8 Cleaning of sump covers, water jumpers, tappet covers and FIP covers
in Wash tank.
6.9 Daily cleaning of all compartments along with hood doors till
completion of all components fitment on the loco.
6.10 The Loco shall be thoroughly cleaned before commencing the
painting work on entire loco as done in Yearly Special Repairs.

On completion of the cleaning work in the above mentioned areas

of the loco, a certificate for the proper cleaning should be obtained
from the concerned railway supervisor(s) doing the schedule
maintenance on that loco.
The contract is governed by the General conditions of contract
for engineering works of Indian Railways as amended from
time to time and the special conditions as given in the scope
of work.
 MATERIALS/CONSUMABLES TO BE
USED
To carry out the different activities as prescribed under Para 4.0,
the following materials are required as per specification
mentioned against each.

Sl. Activity Description Approx. Specifications

No. Qty./month
1. Loco 1. Cleaning 400 Kgs. As per Is Spec.
exterior agent IS.7532/1974-1
washing. or any other
brand/make with
prior approval by
Sr.DME/DSL/KZJ.
2. Cleaning 10 Nos. Any standard
brushes. Brand/ make
with the prior
approval of
Sr.DME/DSL/KZJ
or his
representative
2. Steam/air 1. Nose 12 Nos. -DO-
blowing mask.
of 2. Hand 12 pairs -DO-
radiators gloves
3. Loco 1. Duster 75 Meters. -DO-
interior Cloth
cleaning. 2. Oil/Agent 150 Liters. As per local
cleaning market
3. Scrubbing 12 Nos. Any standard
brushes. Brand / make
with the prior
approval of
Sr.DME/DSL/KZJ
or his
representative
The contractor shall arrange at his own cost, the
material/consumables, tools, machinery and plants required to
undertake the cleaning activities. The minimum requirements of
consumables/materials/tools and implements/ machines with
specification are specified above. Any excess quantities required
other than the minimum requirements the contractor has to
arrange at his cost.

All the consumable/materials shall be handed over to the

mechanical stores section of the diesel shed along with relevant
purchase documents where in all the items after receipt are
accounted in the separate Daily Material Transaction Register
(DMTR). Materials will be issued on daily or weekly basis as per
the written memo of the contractor supervisor. The railway
departmental stores clerk maintains the DMTR and issue
registers.

The materials /consumables may be inspected for the

quality/quantity by the representative of Sr.DME/DSL/KZJ as
and when required and if any items found to be inferior in
quality such materials will be rejected and shall not be allowed
to use. Immediate replacement has to be arranged for such
rejected quantity by the contractor at his cost. Decision of
Sr.DME/DSL/KZJ is the final in case of any ambiguity in
inspection of materials.

TOOLS AND IMPLEMENTS TO BE USED

1. The tools and implements required for the contract work are
furnished below. The contractor should utilize the
branded/reputed make tools and any breakage of the tools
and implements in the course of contract work, Railway is
not responsible. The contractor has to make immediate
arrangements for replacement of damaged/defective tools &
implements.
Sl. Activity Tools and machines specification
No. Description Approximate
Qty/year
1. Steam/Air Spray 04 Nos. Local make
blowing of Nozzles
Radiators.
2. Loco Iron 10 Nos. Local make
Component/ scrappers
Internal
Cleaning

MACHINERY & PLANT TO BE USED

1. The shed has already setup HP Jet system at loco working

shed. This HP jet system was supplied and commissioned by
“M/s. Magna Cleaning Systems Pvt. Ltd, Thane”. The HP jet
system in good working condition will be handed over to the
contractor before commencement of the work.
2.There after the contractor has to maintain the system and
use the same for loco washing. The necessary spares given
below also shall be ensured available by the contractor for
regular maintenance.

S. Description Specification
No
1 Ball valve 1” S.S.304 Industrial Ball valve size 1” BSP
with PTFE seat and seal suitable to work
on 80 Kg/Cm2 for main distribution
chamber of virgin Engineers/ Fairfield,
Asian Hydraulics make – 05Nos.
2 Ball Valve 3/8” S.S.304 Industrial Ball valve size 3/8”
BSP with PTFE seat and seal suitable to
work on 80 Kg/Cm2 for main distribution
chamber of virgin Engineers/ Fairfield,
Asian Hydraulics make – 08Nos.
3 Male QRC 3/8” Made of SS 304 with PTFE seal and seat,
working size 3/8” BSP of Orion make –
05 No.
4 Female QRC Made of SS 304 with PTFE seat and seat,
3/8” working pressure 100 bar.
Size 3/8” BSP of Orion / Fairfield / Asian
Hydraulic male – 06 Nos.
5 High pressure Wire braided reinforcement synthetic
Hose rubber cover against oil and weather
abrasion spec. SAE 100 R1 size ¼” ID,
length 15 meters. With end fittings1/4”
BSP suitable for working pressure of 100
bar of Dunlop/ Alfa Gama / Mark well
make – 02Nos.
6 Trigger gun Trigger operated spray gun lance and V-
with lance and Jet of P.A. – Italy or M.S. Hawks/ Arrow
V –Jet line – 02 Nos.

3. Repair and Maintenance of the above machinery has to be

attended by the contractor by engaging suitable agency.
Railway will not bear any charges on this account.
4. Failure/break down of the machines will not be allowed
during the work for more than three days.
5. The system should be handed over in good working
condition after completion of the contract period.
 CLEANING AREAS
Cleaning areas in external cleaning:

Man
S.No Cleaning activity
hours
1 Clean the Engine Room and oil 1:15hours
leakages from FIP covers, Cylinder
heads, OSTA body and tappet
covers etc. and also clean the floor
adjacent to the engine block
2 Clean the areas of compressor 40min.
room- clean the compressor pit and
the cardium/oil spillage on outer
surfaces of lube oil pump, water
pump and on their corresponding
pipe lines.
3 Clean the loco side doors from 30min.
inside & outside with Kerosene oil.

4 Clean the radiator room - Clean the 30min.

floor, lube oil cooler and lube oil
filter drum and its pipelines.
5 Clean the drivers cab doors, Loco 40min.
front and rear body with cloth.
Remove any oil/ grease stains with
kerosene oil.
6 Clean the alternator room –clean 45min.
the alternator pit and surfaces of
alternator & auxiliary machines with
cloth. Remove any oil/grease on the
machines
Total man hours 4:20hours
 Cleaning areas in internal cleaning:

S. Man
No Cleaning activity
hours
Cleaning of the loco Side doors, hood top doors, 30min.
drivers cab doors and the front & back surfaces of
1 the loco
20min.
Cleaning of the foot boards, loco chassis sides etc.
by applying cleaning agent on the foot boards,
chassis sides and clean thoroughly with high
2 pressure water jet hose.
Cleaning of the driver cab lookout glass, headlights, 30min.
flasher lights and marker lights on both sides of the
loco by applying cleaning agent and then wiping it
3 out with brush/duster cloth.
Cleaning of buffers, cattle guard and rail guard on 20min.
both ends of the loco using high pressure water jet
4 and apply cleaning agent if required.
Cleaning of Fuel tank and bogie frames using high 20min.
pressure water jet and apply cleaning agent if
5 required.
Cleaning of driver cab inside panels & all the lookout 15min.
6 glasses from inside.
Cleaning of the cab PVC floor sheet with mop by 15min.
applying cleaning agent and cleaning it with wet mop
7 seeder/cloth.
2:30ho
Total man house urs
Total super cleaning agent used 5liters
1.86uni
Total power consumption ts
 Cleaning area: radiators:

Man Power
S.No Cleaning activity hours consumption
1 Air blowing of radiators from 15min. 4.47units
outside to inside using (For 12min. of
compressed air. Position the motor work.)
Nozzle over the radiator core
from top and move horizontally
from one end to the other end
and later move vertically
downwards. Ensure that the
entire surface of the radiator is
covered
2 Air blowing of radiators from 15min. 4.47units
inside to outside in similar (For 12min. of
fashion. motor work.)

3 Steam blowing of radiators with 15min. 1unit

high pressure steam jet from
outside to inside in similar
fashion.
4 Steam blowing of radiators with 15min. 1unit
high pressure steam jet from
inside to outside in similar
fashion.
Total man hours 1hour
Total power consumption 10.94units
Fuel used by boiler per hour 35liters (diesel)
Cleaning area: under truck and car body filter

S.No Cleaning activity Man hours

1 Cattle guard is to be cleaned and it 30min.
should be free from, dust, oil and muck.
2 Rail guards are also to be cleaned. 40min.
3 All dust accumulated over the interior 30min.
surfaces of MR Tank shall be scrapped
off with wire brush and cleaned with dry
cloth.
4 The outside surface area of Fuel tank 40min.
and glow rod gauges shall be cleaned
with dry cloth and shall not have any oil
traces over it.
5 All the Traction Motor Gear Cases shall 40min.
be cleaned by scrapping off the dust
and excess cardium spillage.
6 Clean the Dust and cardium flash 30min
present on all the pull rod safety
brackets and on sand pipes.
7 All traction motor cables (car body 20min.
cables) shall be cleaned.
8 All the drain pipes of compressor pit, 30min.
alternator pit shall be blown with air
and scrap all dust accumulated over it’s
the outer surface.
9 Clean the chassis, bogie frames, wheel 2hours
axle assemblies and side buffers of the
loco.
10 Cleanliness of washed car body filters 4hours
(if applicable)
Total man hours 10:20hours
Loco washing:
 Assuming number of man power used is 1 per loco
 Number of shifts per day are 3.
 Water quantity per loco 560 liters.
 Power consumption per loco (both blowing and washing) is
8.94 units.
 2 types of brushes are user.
 Life time of one brush is for 8 locos.
 Scrapper is used for removing cadmium spillage.
 The quantity of super cleaning agent used per loco is 5 liters.
 The ratio of super cleaning agent and water is 1:2.
 Motor capacity :
* For Blowing 30HP
* For Washing 7.5HP

s.no. Type of cleaning Man hours

(in hours)
1 Blowing 1
2 External washing 2:30
3 Internal cleaning power Mechanical 3:40
pack electrical 45min.
3 Internal cleaning under Mechanical 5:20
truck electrical 1
4 Car body filter 4
Total man hours per loco 18:10
COST ANALYSIS
 According to the analysis, the total man hours per loco is
18:10hours.
 Man power required per 8 hours (shift) is 2.26.
 Daily wages of a labor is 448
 Daily wages paid for 2.26 labours is 1012.48 per loco.
Additional things that can be added to the cost analysis
of loco cleaning are:
 Power consumption for blowing, washing and internal
cleaning is 24units.
 Cost for one unit of power consumption is 6.42Rs.
 Fuel (diesel) used for steam generation is 17.5litres.
 Wages of labour are according to
F.No.1/13(2)/2017-LS-II date of 6/10/2017 and it
belongs to unskilled “B” area section.

s.no. cost (Rs.)

1 Labour wages 1012.48
2 Power consumption per loco 154.08
3 Super cleaning agent 37.50
Total cost for cleaning in DLS 1204.06
 SUGGESTIONS
Budget management for washing locomotive will be easy by
following this:

External washing:
 Water consumption can be reduced by usingproper jet and
also by using jet we can clean deeper parts in loco.
 Exact ratio (1:2) of super cleaning agent and water will give a
proper loco washing.
Blowing:
 The fuel used in steam boiler can also be included to the
account of contractor. Thus we can reduce burden on railway.
 One worker is enough for this operation.
Internal cleaning:
 Diesel oil is used for GM locos and wood dust is used for ALCO.
 Including kerosene or petroleum products can be used for easy
cleaning of loco.
 CONCLUSION

Diesel engine is one of the engines that changes the pace of

transportation. By using schedules of heavy/medium/light
repair it is possible to control the problems in locomotives
after its travel at most. Light repair bay will check the loco
health frequently in order to avoid hazards. Schedules are
telescopic in nature. I.e. lower schedules items gets covered in
higher schedule. This report will be useful to know what
operations are done in light repair schedule.
Loco cleaningis the combination of blowing, external cleaning
and internal cleaning (power pack and under truck). This report
will shows the budget modification details of loco washing. It is
clear from this report that we can reduce the cost of one loco
cleaning by maintaining time for individual cleaning areas.
No of schedules of ALCO locomotive for 2015-16 year: 2256
No of schedules of ALCO locomotive for 2016-17 year: 2141
Total schedules for two years: 4397
Man power per loco: 30 man hrs
Total man hrs for 2 years: 4397x30= 131910 hrs
Total mandays for 2 years: 131910/8= 16488.75
Wage per manday = Rs. 448
Cost of ALCO Mandays for two years = Rs. 7386960
(Man power required per day = 16488.75/730=22.58)

No of schedules of HHP locomotive for 2015-16 year: 3033

No of schedules of HHP locomotive for 2016-17 year: 2884
Total schedules for two years: 5917
Man power per loco: 15 man hrs
Total man hrs for 2 years: 5917x15= 88755 hrs
Total man days for 2 years: 131910/8= 11094.375
Wage per manday = Rs. 448
Cost of HHP Mandays for two years = Rs. 4970280
(Man power required per day = 11094.375/730=15.19)

Total labour cost = Rs.1, 23,57,240/-

Total material cost = Rs. /-
Total contract cost = Rs. /-