Hkkjr ljdkj & jsy ea=ky; Government of India - Ministry of Railways

vuqla/kku vfHkdYi vkSj ekud laxBu Research, Designs & Standards Organization,
y[kuÅ & 226011 LUCKNOW – 226011
e-mail : [email protected] Telex: 0535-2424 RDSO-IN
Telephone : 0522-2465739 Fax: 91-0522-2452581
lR;eso t;rs

No. EL/3.6.1 Dated: 20.10.2021

Secretary (Electrical),
Railway Board,
New Delhi-110 001
(Kind Attn.: Shri Kishore Vaibhav, DEE/RS/RB)

Sub: Review of periodicity of Maintenance Schedules of Electric Locomotives.

Ref.: (i) Railway Board letter no. 92/Elect. (TRS)/138/5 Pt. dated 06.10.2020
(ii) RDSO letter of even no dated 13.10.2020 & 25.06.2021.

Vide letter under reference above, Railway Board besides communicating the acceptance of
recommendations of committee on Review of periodicity of Maintenance Schedules of Electric Locomotives has also
advised RDSO to send the comments on additional issues identified on subject matter. Accordingly, RDSO has
asked Zonal Railways to furnish comments on same vide letter under reference (ii) above. Based upon the
comments received from Zonal Railways & further examination of same by RDSO, point wise comments on
additional issues are as under:
SN Issue Comments
i. Must change items of Must change items list have been reviewed & enclosed as
TOH/IOH/POH to be reviewed in Annexure-A.
line with the aforesaid revised
schedules.
ii. Conventional coaching locomotives The conventional coaching locos should not be sent for last POH,
may not be sent for the last POH if if their residual life is less than 6 years. The locomotive should be
residual life is less than 6 years. maintained by sheds for its residual life as per respective
iii. WAG-7, WAG-5H and WAG-5 existing/revised TOH/IOH schedules. The Shed shall ensure
TAOCHI locomotives may not be fitness of the locomotives i.e. The various additional POH activities
sent for last POH if residual life is like replacement of TM/axle box/MSU tube/auxiliary motor bearing,
less than 9 years. Primary/Secondary suspension spring/dampers/TM rubber
sandwich assembly, overhauling of VCB/tap changer /Pantograph
using prescribed IOH/POH kits, replacement of equalizer/
compensating beam/CBC/rusted or corroded pneumatic pipe line
/flexible metallic braided pipe line / rubber pipe line /repair of centre
pivot and other equipments to be done by sheds on condition
basis, if required for reliable & safe working of locomotive on line.
Shed should ensure the fitness of the loco for service for service
viz. condition of camber tolerances and body corrosion is within the
safe limit.
Similarly, conventional freight locomotives should not be sent to
shop for POH if their residual life is less than 9 years.
iv. Scheme, modalities and Facility for on line transferring of loco parameters already exists on
development of condition monitoring locomotive in form of Remote Diagnostic System(RDS) for 3-phase
based assessment system for bogie, electric loco , Remote Monitoring and Analysis for Electric
wheel and Traction motor in trip Locomotive (REMAN_EL) for tap-changer based loco with MPCS
sheds for remote monitoring of
electric locomotives. Ver -3 and Remote monitoring system as Train Tracer Centralized

Page 1 of 21
 Fleet Maintenance Application In WAG12B Locomotive. By Use of
sensor data (vibration, temperature etc.) and AI based software to
be made part of RDS, MPCS Ver 3 and Train Tracer Centralized
Fleet Maintenance Application to facilitate remote monitoring
/predictive maintenance of loco. The RDS, MPCS Ver 3 and Train
Tracer Centralized Fleet Maintenance Application may be
interfaced with the Real Time Train Information System (RTIS),
presently installed on locomotives OR active RFID tags may also
be used for transferring the locomotive health data to remote
server, accessible by all the stake holders.
v. Guidelines for periodicity of UST The periodicity for UST of locomotive axles to be followed as per
may be reviewed as per EKM. RDSO Technical Circular no. ELRS/TC/0047(2000)(Rev-02) are as
under:
Axle of locomotive Speed Frequency of
on (kmph) UST
Goods <120 12 month
Passenger <120 12 month
Passenger >= 120 6 month
In addition to above, all axles of locomotive passing through wheel
shop for any repair (like re-discing, MSU repair etc.) shall be tested
for flaw detection irrespective of last date of testing.
Since, at present, there is no effective mechanism available for
monitoring of EKM; hence the existing practice of duration based
UST schedule to be followed as per RDSO Technical Circular no.
ELRS/TC/0047(2000)(Rev-02) & continued till effective
mechanism for monitoring of EKM is developed.
At present, 2700 Electric locomotives have been provided with
Real Time Train Information System (RTIS) in Phase-1 and
balance locomotives will be provided with RTIS in Phase -2. In
order to switch over to EKM based periodicity of UST, it requires
that EKM figure of loco to be interfaced with RTIS or alternatively,
LP may use the facility of sending contextual message for EKM at
the time of taking the charge of locomotive till the interfacing of
EKM with RTIS is implemented & the maintenance schedules
(Minor/Major) of electric locomotives including UST schedules is
revised on EKM basis suitably.
Hence, duration based UST schedule as per RDSO Technical
Circular no. ELRS/TC/0047(2000)(Rev-02) should be followed
during ( Minor/Major) schedules of electric locomotives.
The above duration based UST schedule shall be strictly followed
under suitable minor /major schedules of respective locos in such
a way that in any case, the above prescribed UST may not get
violated.
vi. Periodicity of replacement of items The must change items have been reviewed accordingly.
should be in line of Major schedules
and uniformity of replacement
should also be maintained over
codal life.
Page 2 of 21
 vii. All schedules activities of must The must change items have been reviewed accordingly.
change of equipments/assembly
which require lifting of locomotives
should be aligned with IOH schedule
of locomotive so that TOH schedule
of locomotive should be made non
lifting maintenance schedule.
viii. Suitable ± grace period may be With the implementation of RTIS & available communication tools,
included in each Major/Minor it’s possible to locate the loco & may be called back to shed from
Schedule. line as per due schedule of loco. The running of overdue
maintenance loco to be avoided for safe working of loco/train. The
various schedules have already been increased over the time &
grace periods (+) will further increase the probability of running of
overdue schedule locos which is not desirable. It’s only a matter of
planning & coordination to pull back the loco. The pulling back of
maintenance due loco may be planned in advance within the due
date of schedule maintenance i.e. the grace period should be
considered included in the periodicity of maintenance schedule &
may be suitably followed for the purpose. This will also avoid the
running of overdue schedule locos which is a major concern as it
has lead to serious failure of locomotives in past as well as in
recent times. Accordingly, following grace period may be adopted
uniformly for all class of electric locomotives:
Trip schedule: No Grace Period
Minor Schedule(IA, IB, IC): -10/+0 days
Major Schedule(TOH,IOH, POH): -1/+0 Month

Board is requested to consider the aforesaid clarification to enable RDSO in issuing the guidelines to Zonal
Railways accordingly.
This issues with approval of PEDSE.

SANJAY Digitally by SANJAY

signed

KUMAR KUMAR TIWARI

(Sanjay Kumar Tiwari)
Encl.: As above Date:
for Director General Std. 2021.10.20
/Electrical
TIWARI 13:11:05 +05'30'

Page 3 of 21
 Annexure-A
1. MUST CHANGE ITEMS OF WAP5, WAP7, WAG9 AND WAG9H LOCOMOTIVES
SN DESCRIPTION TOH IOH POH Remarks
A LOCO BODY
1 PU painting of locomotive. X √ √
2 Roof Hatch Gaskets:
The pantograph and converter roof hatch gaskets. X √ √
3 Roof hatch rubber seals:
The rubber seals around the pantograph and converter roof
X √ √
hatches and the roof beam.
4 Body Structure
Fibre body above buffer and CBC coupler (WAP5 & WAP7 only). X X √
Decals (stickers). X √ √
5 Exterior
Seals involved in fitment of side body and roof filters. X X √
6 Draft gear & couplers:
Complete CBC assembly including Draft gear. X X √
Transition coupling (WAP7) X X √
Transition coupling (WAG9/9H) X IOH2/IOH4 X
Knuckle, clevis, clevis pin and yoke pin. X √ √
Striker block wear plate. X √ √
7 Buffers:
Buffers along with fasteners. X X √
All rubber rings. X √ √
8 Cattle guard:
Cattle guard along with its hardware. X X √
9 Doors and steps
Door seals. X √ √
10 Washer and Wipers:
Wiper motor driver shaft seal, wiper arm, pneumatic end
X √ √
water hoses, wiper blade and idler shaft assembly.
11 Wind screen and windows:
Front lookout glass and side glass (WAP7) X X √
Front lookout glass and side glass(WAG9/9H) X IOH2/IOH4 X
Seals of cab windows, sliding window, splashed shield,
windscreen shield and rubber flap on the cab side window X X √
drainage channel outlet.
B1 Under frame:
1 Sanding equipments:
Sand in all sand boxes. √ √ √
Sander hosepipe and seal in the sand box lids. √ √ √
2 Battery Box:
All fasteners of battery boxes. X X √
Page 4 of 21
 Battery box ventilation hose. X X √
B2 Bogie and Running Gear:
1 Secondary Suspension
All Secondary Suspension springs. X X √
Dampers. X X √
The lateral bump stops. X X √
Insulating bases of secondary suspension (WAP5 only). X X √
2 Primary Suspension
All Primary Suspension springs. X X √
Provision of Happy pads on top and bottom of secondary X √ √
suspension springs
Dampers. X X √
3 Traction link
Traction link assembly with housing. X X √
Safety sling, pins and R- clips. X √ √
Aclathan / Vulkollan Rings and tab washers. X √ √ While revising the
IOH schedule, the
EKM has either been
kept same (WAP7)
or has been
proportionately
reduced with respect
to increase in
periodicity duration
(WAG9). Since, the
wear & tear of item
mainly depends
upon utilization of
loco, the activity can
be taken in IOH
schedule.

All fasteners of Aclathan / Vulkollan ring retaining plate. X √ √

All Nylock Nuts opened for lifting of locos at: In case of steel lock
A. Secondary Dampers (Yaw, Vertical, horizontal) nuts in place of
B. Primary Dampers top side. √ √ √ Nylock, the steel lock
C. Traction link nuts may be
D. Gear Case Support arm. replaced in IOH &
POH and not in
TOH.
4 Bogie Frame and brake Gear:
All pins and pads of brake rigging. √ √ √
All bushes of brake rigging X √ √
All rubber components, hoses and fasteners on the bogie. X √ √
The hoses between – a) the bogie frame connection and the brake
cylinders and b) the locomotive under frame and bogie. X √ √

Overhauling kit of brake caliper. X X √

Replacement of Brake hanger of WAP7/WAG9 X √ √
Page 5 of 21
 Replacement of safety sling of brake hanger of
WAP7/WAG9 √ √ √
5 Wheel set & Axle Box:
Taper Roller bearing unit (CRU 150/SKF, BC2-0067A) for
X X √
WAP7, WAG9 & WAG9H.
Axle Box Racers (WAG9/9H)
TOH2/TOH5 X √
Taper Roller bearing Unit (SKF 1639457A) for WAP5. X √ √
Fasteners of brake discs. X X √
Axle box “O‟ ring and cover bolts. √ √ √
6 Gear case/ Transmission
Gear case oil. √ √ √
Gear case bearing along with associate components (for
X X √
WAP5 only).
Gearbox oil seal / “O‟ rings. X √ √
All gear case fasteners and TM fixing bolts. X X √
Drain plug washer and oil filling plug washer. √ √ √
Gauge glass oil seal. √ √ √
TM support arm, Gear case support arm (for WAP5 only) & Axle
X X √
guide rod.
7 Crown Gear Coupling (WAP5)
The membrane and the oil of Crown Gear coupling. √ √ √
8 Spheriblocs
The Spheriblocs of the axle guide rod (WAP5)
X √ √
The Spheriblocs of the gear case support arm ,TM & TM
√ √ √
support arm (WAP5)
The Spheriblocs of the axle guide rod (WAP7/WAG9/9H).
X √ √
The Spheriblocs of the TM support arm (WAP7/WAG9/9H).
√ √ √
Spheriblocs of all types of dampers X √ √
C Power supply System
1 Pantograph
Low Speed Pantograph type AM12, IR01, PAN01 & EL-01 for freight locomotives
1.1
As per TC No. RDSO/2007/EL/TC/0094(Rev‟0‟) √ √ √
1.2 High Speed Pantograph for M/E locomotives
Type AM92 and IR03H as per SMI No. 2016/EL/SMI/0292,Rev. ‘ √ √ √
0’ dated 27.06.2016
Type WBL-85 As per OEM’s maintenance manual
1.3 High Reach Pantograph for all Electric locomotives
As per OEM’s maintenance manual √ √ √
2 Primary voltage Transformer:
The rubber cable conduit between transducer & terminal box and
X √ √
the roof cable duct.
3 High voltage bushing insulator:
The seal on the high voltage bushing & cork gasket. X √ √ Bushing to be
Page 6 of 21
 replaced if tan delta
& capacitance value
is more (Refer
RDSO’s letter no.
EL/3.2.21/1 dated
10.12.2010)
4 Main circuit breaker (VCB):
All items specified in latest version of RDSO‟s Special
√ √ √
maintenance instruction no. ELRS/SMI/0236
5 Harmonic Filter Resistor:
The cable glands & seal of the filter resistor junction box on the
X √ √
converter roof hatch.
Replacement of the seal of the filter resistor. X √ √
Harmonic Filter Capacitor X X √ To be replaced in
POH on condition
basis as per
maintenance manual
Harmonic Filter resister. All insulators to be replaced X X √
6 Main transformer:
The silica gel in breather assembly. √ √ √
All sealing gaskets including tank cover gasket of TFP(WAP7) X X √
All sealing gaskets including tank cover gasket of TFP(WAG9/9H) X IOH2/IOH4 X
All rubberised cork sheets. X √ √
All TFP bushings rubber seals( As per TC 0076 latest version). X √ √
All transformer foundation bolts & bushing lock nuts X X √
Transformer Oil(WAP7) X X √
Transformer Oil(WAG9/9H) X IOH2/IOH4 X
Main transformer drain oil cock rubber parts X X √
Transformer conservator gauge glass gasket, rubber parts(WAP7) X X √
Transformer conservator gauge glass gasket, rubber X IOH2/IOH4 X
parts(WAG9/9H)
Oil hose( vent tube) from main transformer to conservator, √ √ √ To be replaced on
equalizing pipe along with accessories condition basis.
Oil Cooling Radiator Complete(WAP7) X X √
Oil Cooling Radiator Complete(WAG9/9H) X IOH2/IOH4 X
TFP Pressure Sensor & Temperature Sensor X X √
TFP Pressure Sensor & Temperature Sensor X IOH2/IOH4 X
D. Propulsion System
1 Traction Converter:

The rubber parts of servo motor of pre-charging & main

contactor. X √ √

Page 7 of 21
The rubber parts of main cylinder of pre-charging & main X √ √
contactor.
The air cooling hoses, seals on the traction converter doors
X √ √
(WAP5/WAP7/WAG9/9H).
Silica gel in breather assembly. √ √ √
Converter Oil(WAP7) X X √
Converter Oil(WAG9/9H) X IOH2/IOH4 X
Contact tips of Electro-pneumatic and Electro-magnetic
X X √
contactors(WAP7)
Contact tips of Electro-pneumatic and Electro-magnetic X IOH2/IOH4 X
contactors(WAG9/9H)
Traction converter oil flexible pipe line(WAP7)
X X √
Traction converter oil flexible pipe line(WAG9/9H) X IOH2/IOH4 X

Stoochi Coupling rubber parts(WAP7)

X X √
Stoochi Coupling rubber parts(WAG9/9H) X IOH2/IOH4 X

DC link capacitor & resonance circuit capacitor(WAP7)

X X √ 1. Dry type to be
replaced in POH
on condition basis
as per
maintenance
manual.
2. Oil filled to be
replaced with dry
type.
DC link capacitor & resonance circuit capacitor(WAG9/9H) X IOH2/IOH4 X
1. Dry type to be
replaced in
IOH2/IOH4 on
condition basis as
per maintenance
manual.
2. Oil filled to be
replaced with dry
type.
Traction converter gauge glass rubber parts(WAP7)
X X √
Traction converter gauge glass rubber parts(WAG9/9H) X IOH2/IOH4 X

As per RDSO guidelines modified heat sinks to be provided

X X √ To be done in POH,
on SR rack(WAP7)
if not modified.

Page 8 of 21
 As per RDSO guidelines modified heat sinks to be provided X IOH2/IOH4 X
To be done in
on SR rack(Wag9/9H)
IOH2/4, if not
modified.
Internal Cooling fan complete(WAP7) X X √

Internal Cooling fan complete(WAG9/9H) X IOH2/IOH4 X

SR Pressure Sensor & Temperature Sensor(WAP7) X X √

SR Pressure Sensor & Temperature Sensor(WAG9/9H) X IOH2/IOH4 X

2 Traction Motor:
Traction motor bearing (DE + NDE) along with Outer/inner
X √ √ In any case, the
labyrinth pins and accessories.
bearings should be
replaced after 12
lakh km.

Suspension tube bearing X X √

Bull gear (WAG9/WAG9H/WAP7) X X √
TM pinion (WAG9/WAG9H) X √ √ The EKM of 8 lakh
during IOH with
periodicity of 6 years
is equivalent to 4
years of pre-revised
IOH periodicity & 12
lakh km. Since, the
wear & tear of item
mainly depends
upon utilization of
loco. Further, there
is reduction in pinion
failures. The activity
may be taken in IOH
schedule.
.
TM pinion (WAP7). X √ √
End plate “O”Rings & the gaskets on the terminal box of TM. X √ √
TM bellows. X √ √
Gasket of temperature sensor cover. √ √ √
The helical inserts of Junction box of TM. X X √
Holder fixing bolts X X √
Power cable of TM X X √
Temperature sensor complete assembly including cable X X √
All plastic conduit pipes X X √
All hardware of TM body X X √
TM holder plate for suspension 12R(WAP7) X X √
TM holder plate for suspension 12R(WAG9/9H) X IOH2/IOH X
4
Bellow plate of TM side X X √
TM Speed Sensor(WAP7) X X √
Page 9 of 21
 Temperature Sensor(WAP7) X X √
TM Terminal board assembly(WAP7) X X √
Speed probe housing(WAP7) X X √
TM Speed Sensor(WAG9/9H) X IOH2/IOH X
4
Temperature Sensor(WAG9/9H) X IOH2/IOH X
4
TM Terminal board assembly(WAG9/9H) X IOH2/IOH X
4
Speed probe housing(WAG9/9H) X IOH2/IOH X
4
VCU bus station and Electronics of Power Converter & Auxiliary Converter:
3
Back up batteries in VCU bus station diagnostic &
X √ √
communication computers, DIA, DDA1 & 2.
The seals in the UIC socket. X X √
All Fibre-optic cable of Power Converter, including spares. X X √
Rehabilitation of cards as per RDSO guidelines No. X X X
To be rehabilitated
EL/G/2008/01 Rev.1 with latest amendment.
every 6 years

Instrument cooling fans. X √ √

E. Auxiliary System

1 Auxiliary converter:
Gasket of DC link capacitor bank. X √ √
Gasket of WRE, GG and battery charger modules. X X √
Bearing of internal cooling fan X √ √
Seals on the Aux. Converter cabinets & equipment modules. X √ √
Contact tips of EMC. X X √
Contact tips of contactors in the BUR 1, 2 & 3. X √ √
Set of rotary switch X X √
All DC link bank capacitors X X √ 1. Modified DC link
capacitor bank to
be provided.
2. To be replaced in
POH on condition
basis as per
Maintenance
manual
Male & female contact of GG & WRE module X X √
2 Battery Set
Battery(WAP7) X X √
Battery(WAG9/9H) X IOH2/IOH X
4
Battery Box X X √ To be replaced on
condition basis.
3 Lights

Page 10 of 21
 The head light gasket, head light seals (between headlight
retaining ring & head light housing), Marker Light rubber gasket X √ √
and its “O” rings and the flasher light gasket (Between flasher &
loco roof).
Head light lamp. √ √ √
4 Oil Cooling Piping:
The “O” rings in the main transformer & main converter oil
X √ √
cooling piping joints.
5 Oil Cooling Pumps:
The bearings & “O” rings. √ √ √
6 Oil Cooler Blower / Motor:
The bearings of oil cooler blower motor and associate
√ √ √
component.
Impeller of oil cooler blower X √ √
7 Oil Cooler Blower Seals:
The seals between the oil cooler blower & the filter duct, between
the oil cooler blower filter & the pantograph roof hatch on the oil
cooler blower unit, between the oil cooler blower & machine room X √ √
floor, on the oil cooler blower filter & ducting and on the oil cooler
blower inspection door
(WAP5/WAP7).
The seals between the oil cooler blower & the filter duct, between May be done in TOH
the oil cooler blower filter & the pantograph roof hatch on the oil considering the shelf
cooler blower unit, between the oil cooler blower & machine room √ √ √ life of rubberized
floor, on the oil cooler blower filter & ducting and on the oil blower material & to meet
inspection door (WAG9/WAG9H). the exact cycle of
revised
maintenance.
8 Machine Room Blower Motor:
The drive & non drive end bearings along with associated
√ √ √
components.
9 Machine Room Blower Seals:
The seals of machine room blower filter plenum & duct,
inspection door, blower filter & ducting and between the machine
room blower and machine room floor, between the machine room X √ √
blower filter and filter duct and the machine room blower filter
duct seal and wear plate (WAP5/WAP7)
The seals of machine room blower filter plenum & duct, May be done in TOH
inspection door, blower filter & ducting and between the machine √ √ √ considering the shelf
room blower and machine room floor, between the machine room life of rubberized
blower filter and filter duct and the machine room blower filter material & to meet
duct seal and wear plate (WAG9/ WAG9H). the exact cycle of
revised
maintenance.
10 Traction Motor Blower Seals:
The traction motor blower filter, plenum, wear plate and duct seals
X √ √
(WAP5/WAP7).
The traction motor blower filter, plenum, wear plate and duct seals May be done in TOH
(WAG9/ WAG9H). √ √ √ considering the shelf

Page 11 of 21
 life of rubberized
material & to meet
the exact cycle of
revised
maintenance.
The seals on the TM blower filter & ducting (WAP5/WAP7) X √ √
The seals on the TM blower filter & ducting (WAG9/ May be done in TOH
WAG9H). √ √ √ considering the shelf
life of rubberized
material & to meet
the exact cycle of
revised
maintenance.
The seals between the TM blower & machine room floor and
between the plenum box and body side panel X √ √
(WAP5/WAP7).
The seals between the TM blower & machine room floor and May be done in TOH
between the plenum box and body side panel √ √ √ considering the shelf
(WAG9/ WAG9H). life of rubberized
material & to meet
the exact cycle of
revised
maintenance.
The seals on the TM blower inspection cover (WAP5/WAP7) X √ √
The seals on the TM blower inspection cover (WAG9/ May be done in TOH
WAG9H). √ √ √ considering the shelf
life of rubberized
material & to meet
the exact cycle of
revised
maintenance.
Traction Motor Blower Motor:
11
The drive & non drive end bearings along with associated
√ √ √
components.
12 TM & Oil cooler Blower Scavenger:
The hoses at the oil cooler blower filter scavenger boxes
X √ √
(WAP5/WAP7).
The hoses at the oil cooler blower filter scavenger boxes
X √ √ The activity may be
(WAG9/ WAG9H).
taken in IOH
schedule.
The equaliser hoses between the TM & oil cooler blower
X √ √
scavenger & the filter (WAP5/WAP7).
The equaliser hoses between the TM & oil cooler blower
X √ √ The activity may be
scavenger & the filter (WAG9/ WAG9H).
taken in IOH
schedule.
The seal at the oil cooler blower scavenger duct slip joint
X √ √
(WAP5/WAP7).
The seal at the oil cooler blower scavenger duct slip joint
√ √ √ May be done in TOH
(WAG9/ WAG9H).
Page 12 of 21
 The seals and gaskets on the TM and oil cooler blower
X √ √
scavenger ducting (WAP5/WAP7).
The seals and gaskets on the TM and oil cooler blower
√ √ √ May be done in TOH
scavenger ducting (WAG9/ WAG9H).
Rubber hoses. X √ √
13 TM & Oil cooler Blower Scavenger Motor:
The driving & non-driving end bearings along with
√ √ √
associated components.
14 Machine Room Blower Scavenger Motor:
The driving & non-driving end bearings along with
√ √ √
associated components.
15 Machine Room Blower Scavenger:
The flexible duct between the machine room blower scavenger X √ √ The activity may be
motor and filter. taken in IOH
schedule.
Rubber hoses. X √ √
The equaliser hoses between the machine room blower
X √ √
scavenger motor and the filter (WAP5/WAP7).
The equaliser hoses between the machine room blower X √ √ The activity may be
scavenger motor and the filter (WAG9/ WAG9H). taken in IOH
schedule.
The seals and gaskets on the machine room blower scavenger
X √ √
ducting (WAP5/WAP7).
The seals and gaskets on the machine room blower scavenger X √ √ The activity may be
ducting (WAG9/ WAG9H). taken in IOH
schedule.
16 Main Compressor Motor:
The main compressor drive motor bearings along with
√ √ √
associated components.
17 Cab heater/Blower motor and crew fan motor:
Bearing of cab heater Blower motor and crew fan motor. X √ √
18 Cubicles:
The rubber parts of servo motor of EP Contactors in cubicles.
X √ √

The rubber parts of main cylinder of EP Contactors in

cubicles. X √ √

Contact tips of EP contactors(WAP7) X X √

Contact tips of EP contactors(WAG9/9H) X IOH2 X
/IOH
4
Filter of fire detection unit. √ √ √
F Air Supply and Pneumatic System:
1 Main Compressor:
The main element & the safety element of the air intake filter &
X √ √
other parts as prescribed in manual.
Suction air filter element. √ √ √
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 Compressor oil. √ √ √
Secondary oil filter. √ √ √
Gaskets of concentric valves. √ √ √
The main compressor resilient mountings & mounting pads. √ √ √
CP delivery pipe. √ √ √
HP & LP cylinder, HP & LP concentric valves all make. X √ √
Concentric valve kit. X √ √
The delivery hose from the main compressor. √ √ √
Inter cooler after cooler assembly X X √
Copper Interconnecting pipes between intercooler and after
X √ √
cooler (WAP5/WAP7).
Copper Interconnecting pipes between intercooler and after
X √ √ .
cooler (WAG9/WAG9H).
Overhaul kit of Inter cooler after cooler assembly (WAP5 & X X √
WAP7).
Overhaul kit of Inter cooler after cooler assembly (WAG9 & X IOH2 X
WAG9H). /IOH
4
Overhaul kit of Main Compressor-Oil free (Faiveley/Elgi / Knorr X √ √
Bremse)
Overhaul kit of Main Compressor-Oil lubricated √ √ √
(D&M/SWIL( Faiveley) /Elgi) (WAP5/ WAP7)
Overhaul kit of Main Compressor-Oil lubricated (D&M / SWIL
√ √ √ The activity may be
(Faiveley)/Elgi) (WAG9/ WAG9H)
taken in TOH
schedule.
Replacement of HP,
LP valves, air filter,
coupling tyre
element, piston ring
set (LP & HP) & soft
& hard mount (AVM
assembly) to be
done during every
IC2 schedule of TOH
periodicity. This is
required to meet the
revised schedule. As
per existing TOH
schedule of 24
months, above
activities are falling
under IB3, but due to
limited maintenance
time under IB
schedule, these
activities may not be
carried out. As such,
have been taken in
IC2 schedule.
2 Auxiliary Compressor:

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 The delivery hose between the auxiliary compressor and
√ √ √
brake frame & overhauling kit.
Compressor oil. √ √ √
3 Pneumatic Valves, Cocks and Filters:
All rubber components (WAP5/WAP7). X √ √
All rubber components (WAG9/ WAG9H). X √ √
4 Horn:
Horn gasket and other rubber parts of Horn. √ √ √
5 Brake Pneumatics:
Overhauling kit of Complete E-70 / CCB brake system.
Overhauling kit of driver brake controller and automatic As per OEM‟s instructions
brake controller.
TBU and PBU kit (WAP7). X √ √
TBU and PBU kit (WAG9/ WAG9H). X √ √ Since firm is giving
warranty period for 5
years, the activity
may be taken in IOH
schedule.
Brake activating mechanism (main cylinder & parking brake
X √ √
cylinder)
Complete Conventional Brake rigging alongwith pins, bushes &
X X √
fasteners (WAP7)
Complete Conventional Brake rigging alongwith pins, bushes &
X IOH2/IO X
fasteners (WAG9/9H)
H4
6 Air dryer
Overhauling kit of air dryer( As per OEMs manual , make wise) √ √ √
Body connector male & female X X √
G Interior
1 Cab Door and Machine Room Door:
The door seals, door window seals. X √ √
2 Driver’s Seat:
The seat cover and cushion of driver seat. √ √ X
Driver seat. X X √
3 Cab Interior
Antiskid flooring in cab. √ √ √
4 Cab Equipment:
Vigilance, Sanders, PVEF pedal switches. X √ √
All switches BPFA, BLPR, ZPRD, BLDJ, ZPT, BPVR, BPVG etc. X √ √
Cab activation switch. X √ √
Cab heater flexible duct. √ √ √ The activity may be
taken in TOH
schedule.
H Overhaul the EM and EP Contactors in different Modules The rubber parts (180 deg May be overhauled
C class) of servomotor in IOH Schedules
should be changed in
alternate TOH. Depending
upon the experience in
future, the periodicity may

Page 15 of 21
 be increased gradually up to
IOH.

I. ADDITIONAL ITEMS :
REPLACEMENT
SN DESCRIPTION OF ITEM /SUB ASSEMBLIES
DURING POH
1. TEST ROOMS ITEMS
i) Pre Charging contactor, Main Contactor EPC of SR, FB Panel Copper contact to be
To be replaced
replaced.
ii) 80 Amp Contactor To be replaced
iii) 150 amp contactor (07 nos) to be replaced with contactors
To be replaced
along with Snubber Circuit & auxiliary switches.
iv) Replace 100% FB Panel EP Contactor Insulating base C Type.
To be replaced
v) FB Panel Air Supply Pipe Line Set to be replaced by new one. To be replaced
vi) All Driver Desk Switches To be replaced
vii) All pneumatic panel solenoid valves to be replaced by modified ones. To be done in POH ,if
not done earlier
viii) All auxiliary switches of precharging and EPC contactor To be replaced
ix) Angle transmitter To be replaced
2. ITEMS OF RELAY SECTION
i) Indication Lamps To be replaced
ii) All gauges To be replaced
iii) 63 Amp MCB of OBC and TMB 59.1/1 and 59.1/2,53.1/1 and 53.1/2 To be replaced
iv) 40 Amp MCB of CP 47.1/1 and 47.1/2 To be replaced
v) MRB contactor 54.2/1 and54.2/2 with timer To be replaced
vi) Contactor 136.3, 126.5, 136.4, 126.7/1, 130.1, 211, 126.6, 126.7/2
To be replaced

vii) BPVG push button switch To be replaced

viii) Marker Light To be replaced
ix) All Programme Switches To be replaced
x) All desk meters, Push button switches To be replaced
xi) All types of push button switches To be replaced
xii) Flasher Unit & Lamp Unit To be replaced
xiii) All tube lights & CFL lamps with fittings To be replaced
xiv) DC-DC Converter To be replaced
3. ITEMS OF INSPECTION SECTION
i) All side filters & roof filters(MRB,TMB,OCB) To be replaced
ii) All door locks To be replaced

Note:
(i)The lubricants shall be used wherever applicable as per RDSO’s technical circular No. ELRS/TC/0034(Rev.4) dated 21-7-
2008 or latest.

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(ii)The must change items for WAP7 locomotives fitted with conventional type brake rigging shall be as per RDSO
Modification sheet No. RDSO/2009/EL/MS/0381 dated 7-9-09 and RDSO letter EL/3.1.35/2 (3 phase) dated 20-10-11.

2. MUST CHANGE ITEMS OF CONVENTIONAL ELECTRIC LOCOMOTIVES DURING IOH & TOH SCHEDULES
No Change is proposed in existing Technical Circular No. ELRS/TC/0029(Rev ‘01’) - 2002 and ELRS/TC/0031 (Rev’ 01’)
- 2002 for must change items during IOH & TOH schedule respectively.

3. MUST CHANGE ITEMS OF CONVENTIONAL ELECTRIC LOCOMOTIVES DURING POH SCHEDULES

Replacement during Replacement during
S.N. Item and its sub-assemblies
first POH Second POH
01 Traction Motor
Gear case- passenger loco To be replaced
i)
- goods loco To be replaced
Suspension bearing (plain sleeve) along with Remetalling/
ii)
lubricating pad assly. Replacement
Oil pump for suspension bearing Only pinion to be
iii)
replaced.
iv) Traction Motor bellow To be replaced
v) Traction Motor pinion To be replaced
vi) Sandwich mounting assembly To be replaced
vii) Gear in two halves for suspension bearing oil pump To be replaced
viii) Hitachi TM suspension tube bolt To be replaced
ix) PE end bearing To be replaced
x) CE end bearing To be replaced
xi) Brush holder assembly of TM To be replaced
All carbon brushes liners, gaskets, needle roller To be replaced
xii)
bearings of TM
xiii) Teflon ring of armature To be replaced
xiv) Insulating rod, 5565/675 & 5565/740 To be replaced
02 Auxiliary Machines
i) Auxiliary motor bearing To be replaced
ii) Auxiliary Compressor To be replaced
iii) MVMT Impeller with duct To be replaced
iv) HP & LP valves, crank shaft of compressor To be replaced
v) MPH To be replaced
vi) MVMT & MVRH impeller To be replaced
vii) Main compressor To be replaced
viii) Axial fan for SIV Motor To be replaced
ix) DC & AC MVRF To be replaced
x) MVSI, MVSL& MVRF To be replaced
xi) All churning fans of SIV To be replaced
xii) All door and panel rubber gaskets of SIV To be replaced
xiii) All end shields of auxiliary motors To be replaced

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 All auxiliary motors *Rewinding after 12
years
xiv) *Replacement of Aux
motors after 18 years

03 Pantograph
i) Bow assembly with plunger To be replaced
ii) Upper Arm assembly To be replaced
Other items as per TC-94 for freight locos and as per To be replaced.
iii)
OEMs manuals for passenger locos
04 All Damping panels
i) VCB Damping panel To be replaced
ii) TFP damping panel To be replaced
iii) Capacitors of RC network To be replaced
iv) Other Damping panels To be replaced
05 Roof
Twin beam Headlight Reflector with holder, gaskets & To be replaced
i)
bulbs
25 KV condenser bushing To be replaced with To be replaced
ii) vertical take-off CHT
assembly
06 VCB/DJ
i) Air dryer sieve To be replaced
Other items/components To be replaced as per
RDSO’s latest version of
SMI No. ELRS / SMI/0223
ii)
& 236 for kits of single
and double bottle VCBs

DJ To be replaced with single

iii)
bottle VCB
Double bottle VCB To be replaced with
iv)
single bottle VCB
07 Transformer
i) Transformer oil To be replaced.
Tap changer N-32 (including SMGR) RDSO’s TC No.0102
ii) (latest revision) to be
followed
08 Cab
i) BL Box complete with switches To be replaced
ii) Rubber mat To be replaced
iii) All relay covers To be replaced
iv) Bakelite separators of TK panel To be replaced

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v) A9 valve To be replaced
vi) BL box of driving desk To be replaced
vii) Cab fans To be replaced
viii) Cab heaters To be replaced
ix) Cab window assembly complete To be replaced
x) All gauges, meters, indication panel & light fittings To be replaced
Wiper servo motor assembly complete with To be replaced
xi)
arms/blades/control valves
xii) Master Controller (Cam switches) & rollers To be replaced
xiii) DC-DC Converter To be replaced
xiv) Flasher light unit & Lamp box. To be replaced
xv) Marker Light To be replaced
xvi) All Push buttons To be replaced
xvii) All PC8 Relay Contacts & springs To be replaced
xviii) RU of all voltmeters To be replaced
Analog NR To be replaced with digital
xix)
NR
xx) Indication panel To be replaced
FDCS All PCB Cards to be
xxi)
rehabilitated
VCD Foot switch and push
xxii)
button to be replaced.
xxiii) Driver and Asstt. Driver seat To be replaced
xxiv) Front look out glass and corridors glasses To be replaced
09 Corridor
Pressure switches and air flow relays-micro switch To be replaced
i) and diaphragm
ii) All NR valves, NC4, NC7 valves To be replaced
iii) Body filters To be replaced
iv) SMGR-PR valve To be replaced
v) All gauges To be replaced
vi) Electro-magnetic contactor To be replaced
vii) Micro switch of relays To be replaced
viii) Time delay relay timer To be replaced
ix) Shunt for QF relay & traction ammeter To be replaced
x) RC network To be replaced
xi) TM cable cleats To be replaced
All programme switches including HOM switch, To be replaced
xii)
selector switch, SPDP toggle switch & D type fuses
xiii) All gauges and meters To be replaced
Auxiliary contactors for EP contactors with power To be replaced
xiv) contact tips, all insulators and hardware’s including
square head bolt.

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 Rehabilitation of Safety relays by OEM To be Rehabilitated as
xv) per guidelines of
Railway Board.
Tri-plate panel All valves rubber components, all To be replaced
valves base gasket, O ring between plates,NC-4&NC-
xvi)
7 valves and pressure switches

EPC, C-145,shunting contactors To be replaced

a) Servomotor Piston Bucket, Gasket Piston Bucket To be replaced
xvii) & Felt Ring To be replaced
b) Fixed & Mobile Contacts To be replaced
c) Complete shunt Assembly To be replaced
d) Aux Switch with Cam.
Reverser
a) Fork & all Dowel Pins To be replaced
b) Servomotor Piston Bucket, Gasket Piston Bucket To be replaced
xviii) & Felt Ring To be replaced
c) Finger & Drum Contacts with brass ball. To be replaced
d) Aux Switches
e) Notching Lever Complete To be replaced
xix) HOM AIR Valve To be replaced
xx) RSI Block PTFE Cable To be replaced
xxi) Hinges of all doors To be replaced
10 Under frame
i) Battery lead acid with battery box To be replaced
ii) Replacement of Vertical/horizontal dampers To be replaced
iii) Side buffer assembly along with fixing bolts. To be replaced
iv) Complete CBC assembly To be replaced
v) EMU type inter and after cooler To be replaced
vi) Set of cover for SL To be replaced
vii) Cattle guard with rail guard To be replaced
Air Dryer Overhauling Kit to be
viii) replaced in POH as per
instructions of RDSO
11 Bogie
i) Springs To be replaced
ii) Spring seat & equalizer of tri-mount bogie To be replaced
Replacement of equalizer & compensating beam, pin, To be replaced
bushes, modified centre block, side bearer, D-
iii)
shackle (high adhesion bogie), tie rod for equalizer,
snubbers, split cotters
Complete brake rigging along with pins, bushes & To be replaced
iv)
fasteners
All spring seats, wearing plate, all synthetic To be replaced
v) liners/pads, oil seal felts, pins, bushes, high tensile
fasteners, safety clamps of bogie & axle box etc.

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 vi) Foot step assembly To be replaced
vii) Maintenance kits of brake cylinder To be replaced
Sander pipe arrangement including rubber hose for To be replaced
viii)
sanders
WAP-4 bogies items: outer & inner straps, Conical To be replaced
ix) thrust pad, Hanger pin, bush, Brake head spring,
brake hanger, happy pad
Wheel items: Axle box bearing, MSU & its bearings,
x) (DE& NDE side)MSU bolts, Axle box complete To be replaced
12 General
All perishable items like rubber gaskets, rubber To be replaced
i) grommets, felts, rubber pipes, hoses rubberized cork
sheets, oil seals etc.
Brake block, carbon brushes, silica gel, grease To be replaced
ii)
nipple, metalized carbon strip for pantograph etc.
iii) All oil and greases To be replaced
Replacement of filters, pipelines, ceramic filters in DJ To be replaced
iv)
& SMGR
v) MU coupler jumper pins To be replaced
vi) All type of washers, spring washers etc. To be replaced
Various ball type isolating cocks, check valve, To be replaced
vii)
pressure cut out switch etc.
viii) diaphragm for horns with horn valve To be replaced
ix) All flexible shunts To be replaced
x) Auxiliary Switches (SMGR, MP, CTF, J, C-118 To be replaced
A9 & SA9 pipe line To be replaced with
xi) stainless steel pipe line
13 Electrical items
i) DBR grids To be replaced
ii) Shunts SHA/SHF To be replaced
C-118 with R-118 To be replaced on condition
iii)
basis
iv) All capacitors other than in damping panels To be replaced (including
Oil type to be replaced
with dry type)
14 Loco Body
i) PU painting of locomotive To be incorporated as per
standard procedure
already advised vide
Report No.
ELRS/IR/0115(Rev’0’) of
Sept’06.

=======

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