Action Plan ALCO LOCO

Top 10 Assembly wise Reported cases

2017-18

2018-19

2019-20
(up to
June)
Assly Code Assly name

27 Water Cooling Sys. 21 12 07

32-38 Air Brake System 22 15 04
24 Fuel Oil System 14 14 01
64 Cable & Lug 13 13 01
56 Relays & Contactors 10 14 02
25 Injection System 09 16 00
26 Lube Oil System 11 11 01
62 Traction Motor 08 05 04
15 Cam shaft/Crank shaft 05 01 02
31 Compressor/Expressor 04 01 00

 To improve quality and reliability of loco maintenance, action

plan for major failure areas is as under -
Water Cooling System
 Action Plan – Water Cooling System
Year Nos.
2017-18 21
2018-19 12
2019-20 (up to June) 07

Action Plan
Cause 17-18 18-19 19-20 Action taken
Water Pump 02 00 01 All gear failed due to breakage of teeth of water pump.
Gear Teeth Reports of all failures sent to DMW/PTA for further
Broken analysis. DPT of gear is being done before fitment.
 Hardness of gear teeth being checked before fitment.
 Backlash of Water Pump Gear being checked at
supervisor level.
 Gear sound being checked in every schedule &
corrective action taken, if required.
Additional lubrication connection for water pump gear
train provided.
Water pump 01 01 00 Run out of mating ring & shaft is being checked and water
seal Failure pump tested on test stand before giving on locomotive.
Water pump 01 00 00 Letter sent to POH/CB regarding improper fitment of
shaft key worn impeller on shaft with key.
out
 Action Plan
Cause 17-18 18-19 19-20 Action taken
Water pump 01 00 01 Letter sent to firm for bad quality of the material.
bearing failure
Radiator core 02 02 00  Internal tube cleaning of radiator by specified cleaning
tube puncture agent & hydraulic testing is being done at 2.5 Kg/cm2
press. & 90oC Temp.
 Proper checking of radiator fan’s jaali (Top & bottom)
along with all clamps is being done in every sch. and
condition of jaali is being ensured during fitment of
radiator fan.
Radiator fan 02 00 00  DPT of radiator fan blade is being done before fitment
blade broken on loco.
 Play in Radiator fan bearing is being checked in every
schedule.
 Action Plan
Cause 17-18 18-19 19-20 Action taken
Armoured joint, Pipe 08 05 03  Shelf life of gaskets, pipeline alignment & proper
line Gasket Joint , clamping being ensured.
Water jumper ‘O’  Ensuring clamping at both ends of armoured joint
Ring, Water header  A test stand has been made to train staff for armoured
pipe, Water riser joint fitment.
crack, Bubble  Cleaning & annealing of copper pipes being done
collector/ copper before fitment.
pipe broken/Flexible  Shelf life of water riser i.e. 08 years being maintained
Pipe burst during M24 & above schedules.
 Shelf life of flexible pipes also being ensured during
fitment on loco.
 Proper cleaning , checking & DPT testing of water risers
is being done before fitment during major sch.
Expansion tank 04 02 01  Water leakage/ seepage from expansion tank is
crack/Pressurisation checked in every schedule by striking with the rubber
cap defective hammer.
 During M24 schedule expansion tank bottom plate is
checked for corrosion by cutting on roof & corrective
action taken .
Misc. 00 02 01
----------------------------------------------------------
Air Brake System
 Action Plan – Air Brake System
Year Nos.
2017-18 22
2018-19 15
2019-20 (up to June) 04

Action Plan
Cause 17-18 18-19 19-20 Action taken
Air pipe, 05 04 01  Proper clamping of pipe line being ensured in every schedule.
Horn  Leakages of pipeline, flange, threads & horn etc being checked &
leakage/c attended in every schedule.
rack/  BP/ FP protection plate fitted in every loco & checked in every
Broken/A schedule to prevent the breakage of angle cock.
ngle cock  Proper clamping being done near dresser joint of air flow measuring
valve outlet pipe.
 Counseling of all staff regarding brake pipe dresser joint in control
stand is to be changed in M48 Sch. & to ensure tightness & any
leakage in every sch.
Valves 04 06 01  Staff counseled for proper cleaning before overhauling the valves.
Stick up/  Valves being checked in every schedule.
Defective  Staff counseled for proper fitment and alignment of valves and their
respective gaskets.
  Action Plan – Air Brake System
Cause 17-18 18-19 19-20 Action taken
Air dryer purge 01 02 01  Additional grill fitted above the purge valve to prevent the
valve/Auto ingress of desiccant particles.
drain valve  Air dryer bypass arrangement provided to prevent line
defective failure.
C3W Distributor 03 00 00  C3W distributor valve being properly cleaned & overhauling
valve mal- being done with new kit only.
functioning  Over due C3W distributor valve monitoring being done &
changed on priority basis.
 Letter sent for counseling of loco pilot regarding “do not
tempered the valves during running”.
BP Gage 01 00 00  BP gauge reading is being matched with DID panel reading in
defective every Sch.
 In M12 & above Sch. all gages being calibrated on calibration
test stand.
CCB failure/Air 03 01 00  Air leakage from CCB panel & valves are being checked in
leakage from every sch.
CCB Panel/stick  6 Yearly sch. of CCB 1.5 of loco no. 16521 competed in
up of CCB Dec’18 at IZN/Shed
valves
Misc. & CRO 05 02 01 --------------------------------------------------------------------
Fuel Oil System
  Action Plan – Fuel Oil System
Year Nos.
2017-18 14
2018-19 14
2019-20 (up to June) 01

Action Plan
Cause 17-18 18-19 19-20 Action Plan
Breakage of Fuel 01 02 01  FP inlet screw torquing schedule has been reduced
Pump Inlet & being done during M2 schedule.
mounting  Projection of gasket over FP inlet being ensured.
screw/gasket Fuel jumper bolts are replaced during M12 and
above schedule.
failure & leakage
from banjo bolt
Filter Choking 03 02 00  HSD Tank cleaning during M24 Schedule is being
and Housing ensured.
crack Monitoring of O/Due filter is being done.
DPT of S/Filter housing being done during sch.
 Letter sent to concerned RDI regarding bad fueling
(Water contamination)
 Action Plan – Fuel Oil System
Cause 17- 18- 19- Action taken
18 19 20
Leakage from 03 02 00  Sleeves on pipes being provided to prevent rubbing.
Pipe Line/HSD  Pipes renewed during major schedules.
Glow rod  Fuel cross over pipes removed & hydraulic testing done during M4 sch.
gauge/HSD  Counseling of technicians is done regarding proper fitment &
tank alignment of HSD glow rod.
 HSD tank inspection cover gkt. Is being changed during M24 &
onward.
Fuel Header 02 00 00  Tightness of fuel header mounting bolt checked in every sch.
Adaptor  Thread condition of fuel header and adopter being ensured before
Leakage/Break fitting.
age  Cleaning of fuel header being done during M24 Sch. & ensuring no
foreign particle inside the header at supervisor level.
Rel. /Reg. 03 03 00  Test cock pressure & delivery being checked in M2 sch. for monitoring
Valve defective of performance of the valves.
 In case of any pressure difference, cause identified and corrective
action taken.
Fuel buster 02 00 00  Letter sent to firm (DEC-PUNE) for bad quality of the material &
pump warranty replacement as failed within 02 months.
defective.

Misc. 00 02 00 Letter sent to Sr.DME/O&F Northern Railway regarding

mismanagement by crew during fuelling.
Cable & Lug
  Action Plan of Cable & Lug

Year Power Cable Control Cable Total

2017-18 03 10 13
2018-19 08 05 13
2019-20 (up to June) 00 01 01
  Action Plan-Cable & Lug

To reduce the failures on account of cables and lugs following

measures have been taken:-

 Condition of power and control circuit cables & wires with wire lug
terminals being checked during M-4 and above schedules.
 Proper securing of power and control cables being done during M-4
and above schedules.
 Critical location lugs, terminal board connections and wire lug
terminal tightness being ensured during M-12 and above
schedules.
 Checking and securing of AF-1 & AF-2 cables of TA being ensured
during M-4 and above schedule.
 Proper securing of power and control circuit harness with the help
of insulating tape & ties being ensured with renewal of critical
location wire lug terminals on condition basis during M-24 and
above schedules.
Relay & Contactors
  Action Plan – Relay & Contactors
Year Nos.
2017-18 10
2018-19 14
2019-20 (up to June) 02
Action Plan
Cause 17-18 18-19 19-20 Action taken
Master 02 00 00  Master controller finger interlock contact
Controller pressure being checked during M2 & above Sch.
Defective.  Stick type master controller being overhauled
during M4 & above Sch.
 Collar of accelerating shaft cleaning & checking
of cam profile being done during M2 & above
Sch.
Operating coil 00 00 00  Operating coil condition checked during M24 &
burnt & open above Sch. & renewed on condition basis.
circuit  FPC Coil value measurement is being done
during M4 & above. Sch.
  Action Plan – Relay & Contactors
Action Plan
Cause 17-18 18-19 19-20 Action taken
Reverser, BKT & 04 12 00  A test bench for checking contact pressure of
GF, Cranking electromagnetic contactor developed.
Contactor, Aux.  Ensuring cleaning of reverser & contactors
contactor, FPC during M2 and above sch.
Defective & Gov. Ensuring wiping action of electro magnetic
control unit contactors during M-2 and above schedules.
 During A/E after POH, CK1, CK2 & CK3
contactors being checked on test stand.
 Proper working of governor control unit &
reverser contactor is checked in every sch.
Malfunctioning 04 01 02  Proper attention being given during Sch. Work
of Relays & for preventing ingress of foreign material like
Contactors, washer, bolt, nut etc. between contacts.
Master  Roof sealing is being done on drive basis to
controller etc prevent the water ingress during rainy weather.
Misc 00 01 00 Nothing found abnormal in data downloading.
Injection System
 Action Plan – Injection System
Year Nos.
2017-18 09
2018-19 16
2019-20 (up to June) 00
Action Plan
Cause 17-18 18-19 19-20 Action taken
OSTA Plunger 03 09 00  OSTA plunger being Zyglo tested.
broken /Check nut  RPM of OSTA plunger being adjusted on test bench only and OSTA
work out/OST RPM being checked M2 sch. onwards.
tripping/Stud broken
Control Shaft Jam 03 02 00  OSTA dog gap being maintained in order to ensure full & free rack
movement.
 Play in between pin and shaft, dog & its key etc being checked
during every sch. and corrected if found.
 Free movement of control shaft being checked in every sch. &
ensured at supervisor level.
FIP holder /Bottom 01 00 00  Over-tightness of HP tube bottom nut prohibited.
collar/ foundation  New snubber valve being fitted during M24 & condition checked
bolt broken during M12 sch.
 FIP foundation bolt’s depth in FIP support is being checked for
uniform size before fitment on loco during M24 & above sch.
HP Tube broken/ 02 05 00  Counseling of staff done regarding over-tightness of nut & proper
Bottom nut crack care taken for alignment during fitment of the HP tube.
 HP tubes are properly overhauled & tested in OVH sec.
Lube Oil System
 Action Plan – Lube Oil System
Year Nos.
2017-18 11
2018-19 11
2019-20 (up to June) 01

Action Plan
Cause 17-18 18-19 19-20 Action taken
Armoured/Dresser 01 04 00  Shelf life of gaskets, pipeline alignment & proper
/ Victaulic joint clamping being ensured.
leakage/Regulating  Ensuring clamping at both ends of armoured joint
& relief valve.  A test stand has been made to train staff for
armoured joint fitment.
 Correct gap and alignment being ensured in lube oil
strainer outlet armoured joint in M-24 Schedule.
Rigid pipe / 06 01 00 • DPT done after welding of pipe lines before fitting in
Copper pipe joint Loco.
leakage/ crack • Lube oil outlet ‘Z’ pipe is being changed with new one
during M24 sch. & above.
• Proper annealing of copper pipes is being done
before fitment.
Lube oil leakage 00 00 01 • Letter sent to DMW/PTA to improve quality of
from delivery joint. material.
  Action Plan – Lube Oil System
Cause 17-18 18-19 19-20 Action taken
Leakage 01 02 00 Counselling of BG major mechanical staff done regarding proper
from pipe fitment of pipe line and it’s connector/cone.
line
Leakage 00 02 00  In every sch. leakage is being checked at higher temp.
from self  Foundation bolt tightness of self centrifuge & its bracket being
centrifuge checked in every sch.
& PTLOC  Lube oil leakage from PTLOC plate & gasket is to be ensured in
every sch.
Lube oil 00 01 00  Staff counselled for proper cleaning of engine sump during
pump M24/M48 Schedule and strictly prohibited use of any wooden
defective/ patches during fitment of LO pump.
Gear teeth
broken
Lube oil 01 01 00  Counselled all staff for lube oil filter drum ‘O’ ring groove
filter drum checking regarding depth, width & any sharp edge and proper
‘O’ ring tightness and torquing of fly nuts
leakage
Misc. 02 00 00
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Traction Motor
 Action Plan – Traction Motor
Year Nos.
2017-18 08
2018-19 06
2019-20 (up to June) 04

Action Plan
Cause 17-18 18-19 19-20 Action taken
Brg. seizure & 00 02 00  PE end bearing NU-330 being changed during M48 Sch.
retaining  Shock pulse meter and vibration meter being used during M24 & above Sch.
collar out. for bearing condition detection.
 Retaining collar position being checked during M12 & above Sch.
Carbon brush 3 01 01 Special attentions are being given and counseling done for proper carbon
holder brush fitment, pig tail securing, ensuring proper sleeve, condition of brushes &
failure/epoxy epoxy glass sheet etc.
glass sheet Carbon brush holder and its insulating stud condition being checked during
damaged. M4 and above sch.

Armature 04 03 03  Ovality correction of the TM armature being done during M-24 schedule
failure/ and complete overhauling during M-48 schedule.
Interpole IR  Hi-potential test, Millivolt drop test, resurfacing of the commutator being
done in M48 Sch.
less.
 TM light run test is being done during M-24 and out of course changing.
 Complete bogie light run test and ovality correction is being done in out of
course changing.
Misc. 01 00 00 During checking nothing found, precautionary TM changed.
Cam shaft/Crank shaft
 Action Plan – Cam shaft/Crank shaft
Year Nos.
2017-18 05
2018-19 01
2019-20 (up to June) 02

Action Plan
Cause 17-18 18-19 19-20 Action taken
Cam gear/Split 03 00 00 •Cam gear temp. measured in every Sch. & necessary action
gear teeth taken if required.
broken • Backlash of cam gear checked at supervisor level.
• Molycot powder used between teeth of gear train during
fitment.
• Spray nozzle cleaning done in M4 & above Sch.
• Cam gear removed during M24 Sch. and fitted after DPT.
• Letter sent to DMW/PTA to improve quality of material.
Cam 02 00 00 •Letter sent to DMW/PTA & RDSO LKO to improve quality of
shaft/Crank material.
shaft broken. • Warranty claim of power pack logged on DMW/PTA as new
power pack was received on 04/2017
Cam shaft 00 01 02 • Counselling of staff for proper tightening of cam shaft
flange joint flange joint bolts were done.
bolt broken
Compressor / Expressor
 Action Plan – Compressor / Expressor
Year Nos.
2017-18 04
2018-19 01
2019-20 (up to June) 00

Action Plan
Cause 17-18 18-19 19-20 Action taken
Improper 03 00 00 • To ensure proper checking and cleaning of compressor
cleaning of drain sump during M4 sch. & onward.
passage during • To ensure proper checking of ‘S’ Pipe cones and
sump sch. & annealing of ‘S’ Pipe during M-12 schedule & onward.
checking oil level • Proper cleaning & checking of oil level indicator is to be
indicator ensured during sump sch. & oil filling.
Fast coupling 01 01 00 • Proper alignment of compressor is to be ensured during
gear teeth & M24 & onward.
inter cooler fan • Cardium compound filling in fast coupling is to be
blade breakage ensured.
• Proper cleaning & DPT of inter cooler fan is to be
ensured before fitment during M24 sch. and onward.