Pre-commissioning checks for Diesel Locos

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These are the checks to be undertaken before commissioning a diesel locomotive for active service, after receipt from Diesel Loco Works, Varanasi.

Mechanical checks

  1. Remove valve lever mechanism and examine valve lever sents and push rods.
  2. Remove water inlet jumpers with signs of leakage and replace with proper gaskets and set screws.
  3. Remove sump covers, and examine con.rods, con.rod bolt, split pins and sump cover screws.
  4. Remove and overhaul test the plunger in Zyglo before fitment.
  5. Examine Glacier bearings No. 2 and 7 main bearings and refit.
  6. Examine the radiators fins and tubes and attend damaged portion if any.
  7. Remove one radiator to facilitate welding of angles at the base of the RTTM blower and ensure water entry into traction motor ducts, Prevented.
  8. Remove fuel pump supports examine push rod lifter sents etc. and refit.
  9. Remove the lube oil pump and remake the front cover and flange joints.
  10. Align all lube oil pipe lines and ensure no leakage.
  11. Ensure bypass line anchoring brackets are secured properly and weld.
  12. Align properly RTTM blower.
  13. Remove lube oil relief and regulating valve. Check the settings and test before fitment.
  14. Examine the universal shafts in position and grease.
  15. Check for proper operation of LWS float.
  16. Remove all the Fuel injection pumps, check calibration.
  17. Remove fuel injection nozzles and test f or proper functioning.
  18. Replace brass adopters of cross over pipe by steel adopters.
  19. Examine needle bearing in Fuel pump linkage and renew if necessary.
  20. Examine the Governor output shaft for bend etc. renew if necessary.
  21. Remove turbo, overhaul and examine the condition of bearings.
  22. Drain the fuel oil completely; flush the tank to remove sludge and foreign material.
  23. Remove fuel booster pump. Overhaul, test and fit.
  24. Remove fuel relief and regulating valves test and fit.
  25. Remove copper pipes in fuel system, examine, anneal and fit.
  26. Secure fuel-filling strainers properly and weld in position with suitable adopter for fuelling.
  27. Open all the brake cylinders and examine piston cups for proper greasing.
  28. Check and modify the brake block keys fitted at DLW if necessary.
  29. Examine axle journals in position. Remove suspension bearings in case of flaking of bearing metal. Ensure proper sealing of wick pads.
  30. Examine the roller bearings in position and grease.
  31. Modify the compensating beam bolt.
  32. Remove VAIB, 28 VB, A9, SA9, C2 relay HD5. H5A overhaul and refit.
  33. Remove windshields wiper assembly and vigilance valves, overhaul and refit.
  34. Check Ni reducing valve and renew if necessary.
  35. Remove acceleration control device overhaul and refit. Renew diaphragms if necessary.
  36. Test and match the air brake system gauges.
  37. Examine the expresser sump, chain, counterweight etc.
  38. Check expresser valves and ensure for its proper condition.
  39. Re-grease fast couplings.
  40. Ensure ladders, cab fittings and door locks are welded in position.
  41. Check mechanical speedometer drive and speedometer condition.

Electrical checks

  1. Attention to Traction Motors. Check Traction Motor cables connections for correct shoe crimping, proper layout, checkbrush gear and the tie pigtails, blow out and attend. Check banding.
  2. Traction Generator: Check all connections and banding, check correct staggering. Apply Araldite to V-Ring band. Blow out. Clean and attend air cure.
  3. Unload Aux. Gen. and Ex. Gen. for brush gear modification and load back.
  4. Check up grids, Blower motor and ECC.
  5. Unload Governor. Test in test stand and refit.
  6. Remove Governor Pump, modify, test and refit.
  7. Check Governor hosepipe, Amp. plug, oil filling up.
  8. Unload CCB-Motor, FPM, TG, Ax. Alt., overhaul, test in test stand and fit back.
  9. Unload batteries, correct electrical levels and specific gravity.
  10. Give batteries a booster charge and re-load.
  11. Strip out from loco power contactor, magnetic contactors, relays, panels, meters, overhaul, test, calibrate and refit to loco.
  12. Modify interlock fingers by applying araldite to springs.
  13. Test 'E' type cards in testing panel.
  14. Remove Master control and provide stopper pin for master control.
  15. Strip out power contactors, air engine and clean the rusty surface.
  16. Clean ultrasonically all rusted interlocks, shuts etc.
  17. Check for proper crimping of all control and power cables.
  18. Shift stops to control compartment.
  19. Modify Gauge lights to 75V.
  20. Relocate load ammeter resistance.
  21. Testing: Take IR value. Sequence checking, cranking, testing and adjusting to be carried in order.
  22. Test in Load box before and after pre-commissioning check.
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