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

vuql/a kku vfHkdYi vkSj ekud laxBu Research, Designs & Standards Organization,
y[kuÅ & 226011 LUCKNOW - 226011
Tele/Fax : 2465713 & 42224 (Rly)
lR;eso t;rs e-mail : [email protected]

No. EL/3.6.4/2 Dated: 09.01.2018

Chief Electrical Engineer, eq[; fo|qr vfÒ;ark,

1. Central Railway, Mumbai CST-400 001 e/; jsyos] eqEcbZ lh-,l-Vh & 400 001
2. East Central Railway, Hazipur, Bihar-844 101 iwoZ e/; jsyos] gkthiqj] fcgkj & 844 101-
3. East Coast Railway, Chandrashekharpur, iwoZ rVh; jsyos] paæ'¨[kjiqj] Hkqous”oj & 751 016-
Bhubaneswar-751 016
4. Eastern Railway, Fairlie Place, Kolkata-700 001 iwoZ jsyos] Qs;jyh Iysl] dskydkrk & 700 001
5. North Central Railway, Subedarganj, mRrj e/; jsyos] lqcns kjxt] bykgkckn & 211 033
Allahabad-211 033
6. Northern Railway, Baroda House, New Delhi- mRrj jsyos] cM+kSnk gkml] ubZ fnYyh & 110 001
110 001
7. North Western Railway, Jaipur-302 006 mRrj if”pe jsyos] t;iqj&302 006
8. South Central Railway, Rail Nilayam, nf{k.k e/; jsyos] jsy fuy;e] fldUnzkckn &
Secunderabad-500 071 500071-
9. South East Central Railway, Bilaspur- 495 004 nf{k.k iwoZ e/; jsyos] fcykliqj & 495 004
10. South Eastern Railway, Garden Reach, Kolkata- nf{k.k iwoZ jsyos] xkMZujhp] dskydkrk & 700 043-
700 043
11. Southern Railway, Park Town, Chennai-600 nf{k.k jsyos] ikdZ Vkmu] psUubZ & 600 003
003
12. South Western Railway, Hubli-580 024 nf{k.k if”pe jsyos] gqcyh&580024
13. West Central Railway, Jabalpur-482 001 if”Pke e/; jsyos] tcyiqj & 482 001-
14. Western Railway, Churchgate, Mumbai if”Pke jsyos] ppZxsV] eqEcbZ & 400 020-
15. Chittaranjan Locomotive Works, Chittaranjan fpRrjatu jsy batu dkj£kuk] fpRrjatu&713 331-

TECHNICAL CIRCULAR NO. RDSO/2017/EL/TC/0142(Rev. ‘0’),

Dated 09.01.2018

Sub: Reliability Action Plan (RAP) for Conventional & Three Phase Electric
Locomotives.
Ref: (i) 38th MSG meeting held at Secunderabad/South Central Railway on 28th &
29th July’2017- SN 1 of Other Important points discussed during MSG.
(ii) Railway Board’s letter no. 2017/Elect (TRS)/155/1 dated 14.11.2017.

Introduction:
In order to improve the reliability of Conventional & Three Phase Electric Locomotives, a
Reliability Action Plan based on nature of failures occurring frequently has been prepared
& issued in the form of Technical Circular. Zonal Railways are requested to implement
this Technical Circular to achieve the objective of perceptible improvement in the

Page 1 of 48
 reliability of Electric Locomotives. Further, the local RAPs of Railways must also be
continued & implemented to achieve the purpose.

1. Reliability Action Plan

for
Conventional Electric Locomotives

1.1 Electrical Equipments:

1.1.1 Traction Motor

SN Reliability Action Plan

1. Use of Bore Gauge for measurement of internal diameters of End Shield/
Racer during bearing fitment in traction motors for Electric Locomotives as per
SMI no. RDSO/2017/EL/SMI/0318 (Rev ‘0’) Dated 16.10.2017.
2. Use of Dial Snap Gauges for measurement of shaft diameter of traction motor
for Electric Locomotives as per SMI no. RDSO/2017/EL/SMI/0314 (Rev ‘0’)
Dated 29.9.2017.
3. Magnetic Particle Testing (MPT) of Traction motor (TM) nose stay in
conventional locomotives, TM suspension holder support and motor support in
WAG9/WAP7 locomotives and traction motor support arm in WAP5
locomotives as per SMI no. RDSO/2017/EL/SMI/0311 (Rev ‘0’) Dated
25.8.2017.
4. Implementation of Preventive measures to be taken for crack detection of
traction motor nose stay & lifting lugs to eliminate chances of falling of traction
motor during service in 25 KV AC conventional electric locomotives as per SMI
no. RDSO/2017/EL/SMI/0308 (Rev ‘0’) dated 28.6.2017.
5. Use of Induction Heater for heating of End Shields/End frames of traction
motors for bearing fitment as per SMI no. RDSO/2016/EL/SMI/ 0301 (Rev ‘0’)
Dated 8.11.2016.
6. Implementation of revised Q20 setting from 865/740V to 790/700V for
conventional locomotives to reduce the TM flashover cases as per SMI no.
RDSO/2015/EL/SMI/ 0284 (Rev ‘0’) Dated 11.9.2015.
7. Instructions for bonded rubber sandwich mounting for nose suspension of
traction motors issued as Special Maintenance Instruction No. ELRS/SMI/186
dated 15.05.1997 along with its amendment No. 2 dated 01.04.2014 to be
followed.
8. Instructions to maintain gap between traction motor bottom nose and bonded
rubber sandwich mounting unit issued as Technical Circular No.
RDSO/2014/EL/TC/0126, Rev.’0’ dated 25.03.2014 to be followed.
9. Specification No. RDSO/2014/EL/SPEC/0115 Rev.’0’ dated 22.08.2014 for
bonded rubber sandwich mounting for nose suspension of traction motor for
electric locomotives to be followed.
10. Instructions for replacement of sandwich mounting assembly in POH issued
vide Technical Circular No.

Page 2 of 48
 RDSO/2013/EL/ TC/0123, Rev’0’ dated 16.05.2013 along with its
amendment No. 2 dated 16.05.2016 to be followed.
11. Instructions for replacement of sandwich mounting assembly in IOH issued
vide Technical Circular No.
ELRS/TC/0029 Rev.1 dated 15.7.2002 to be followed.
12. Instructions for replacement of sandwich mounting assembly of WAP4
locomotives in every TOH schedule issued vide Technical Circular No.
ELRS/TC/0031 Rev.1 dated 15.7.2002 along with its amendment No. 1 dated
28.06.2017 to be followed.
13. Modification in the pinion end portion of armature shaft of Traction Motor type
HS 1050Er/HS15250A as per Modification sheet no. WAG5/0244 Amendment
2 dated 14.2.2014.
14. Measurement of dimensions of various assembly components and ensuring
adequate interferences as per modification sheet no. RDSO/2017/EL/MS/414
Rev 0 Amendment 1 dated 29.1.2013 during replacement of Hitachi TM
bearings.
15. Replacement of Hitachi Traction motor Brush holder spacers for HS15250A
Traction Motor made of brass with PTFE as per modification sheet no.
ELRS/MS/0329 (Rev 0) Amendment 1 dated 13.1.2012
16. Modification in traction motor nose suspension system for provision of
additional L clamps and split pins to prevent falling of vertical nose pin of
traction motor type HS 15250A/TAO 659 as per Modification Sheet No.
RDSO/2011/ELRS/ MS/0392, Rev.’0’ dated 11.02.2011.
17. Testing of brazed joints of interconnectors of field coils and compoles coils in
traction motors type HS 15250A and TAO 659 using high current injection test
as per SMI no. RDSO/2011/EL/SMI/ 0271 (Rev ‘0’) Dated 17.11.2011.
18. Use of Fixtures and Gauges for Brush holders and BHRR Assemblies of
Traction Motors type TAO-659 and HS-15250A of Electric Locomotives as per
SMI no. RDSO/2007/EL/SMI/ 0243 (Rev ‘0’) Dated 22.3.2007.
19. Adoption of modified Arcing stud & fixing bracket on BHRR assembly of
Traction Motor type HS-15250A as per Modification Sheet No. ELRS/
MS/0347, Rev.’0’ dated 31.07.2006 with drawing no. SKEL-4707 ALT. 1 dated
23.11.2010.
20. Preventive measures to arrest the failures due to breakage of M16 X 40L
Hexagonal head bolts of CE outer bearing stopper on HS 15250 A Traction
motors as per SMI no. ELRS/SMI/0220-2000 (Rev ‘1’) Dated 28.10.2004 to be
followed.
21. Use of fixture for checking of concentricity & parallelism of suspension tubes
of HITACHI TM as per SMI no. RDSO/ELRS/SMI/0226/2002 (Rev ‘0’) Dated
28.1.2002.
22. Maintenance practices for MSU of traction motor type HS 15250A/TAO - 659
as per SMI no. ELRS/SMI/0221-2000 (Rev ‘0’) Dated 4.8.2000 to be followed.
23. Procedure as per SMI no. ELRS/SMI/0218-2000 (Rev ‘0’) Dated 19.4.2000 to
be followed for improvement in the reliability of plain sleeve suspension
bearing of TAO659 TM by arresting the leakage of suspension bearing oil from

Page 3 of 48
 various locations.
24. Implementation of Remedial measures to arrest the failures of MSU of traction
motor type HS15250A/TAO-659 due to the dropping of its adjustment washer/
failure of its taper roller suspension bearing as per SMI no. ELRS/SMI/0217-
2000 (Rev ‘0’) dated 24.2.2000 and amendment-1 dated 7.4.2000.
25. Checking main dimension of suspension tube while mounting on magnet
frame of traction motor type HS15250A as per SMI no. ELRS.SLI/0207-1999
(Rev ‘0’).
26. Procedure for tightening of axle cap fixation bolts of Traction Motor type TAO-
659 as per SMI no. RDSO/ELRS/SMI/TM/0205-98 (REV. 0) dated 31.8.1998
to be followed.
27. Procedure for proper tightening of suspension tube fixation bolts fitted on the
Traction Motor type TAO-659 and HS-15250A as per SMI no.
RDSO/ELRS/183 Amendment -1 dated 19.3.1998 to be followed.
28. Neutral setting of brush holder revolving ring of Traction Motor by ‘KICK
METHOD’as per SMI no. ELRS/SMI/181 dated 30.5.1996.
29. Testing of armature shaft by ultrasonic testing during major overhaul as per
SMI no. RDSO/ELRS/SMI/150 dated 23.11.1992.
30. Tan delta (Dissipation factor) measurements on Traction Motor armature as
per SMI no. RDSO/ELRS/SMI/128 dated 19.6.1985.
31. Condition monitoring of bearings by SPM Meter as per SMI no. RDSO/EL-
RS/SMI/58 of July 1979.
32. Bar to bar conductor resistance and equaliser resistance test on Traction
Motors (Drop Test) of armature to be done during major overhaul as per SMI
no. RDSO/ELRS/SMI/51 dated 30.4.1979.
33. Under cutting & chamfering of traction motor Commutators as per SMI no.
RDSO/ELRS/SMI/31 dated 24.10.1978
34. Resurfacing of Commutators (by diamond tool) and measurement of ovality as
per SMI no. RDSO/ELRS/SMI/29 of August 1978, and RDSO/ELRS/SMI/6
dated 30.12.1977. In the sheds/POH Shops, Commutators require a finishing
cut, Diamond turning is best suited and finish of 0.3 to 0.8 micron can be
obtained. SMI No. 29 of August 1978 prescribes diamond turning by sheds
and POH shops. Carbide tools are most suited for coarse turning of the
Commutator. Coarse turning of Commutator with roughing cut is normally
required only during the initial turning of the Commutators in manufacturing
units. SMI No. 29 to be followed by the shed.
35. Ensure the inspection cover for Hitachi TM is as per MS-364.
36. Ensure top and bottom lug for Hitachi TM is as per MS-363.
37. Provision of modified earthing brush assembly on TM type HS15250A as per
Modification sheet no. ELRS/MS/0300-2000 (Rev 0) dated 30.10.2000.
38. Ensure the grease outlet i.e. drain hole in ‘CE’ outer bearing cap of TM type HS
15250 A and procedure for re-greasing of armature roller bearing (PE & CE) as
per Modification sheet no. WAG5/0280 dated 29.1.1996.
39. Storage of TM/MSU bearings in horizontal condition, away from wall/floor in a
stack of not more than 5 bearings and following First-In-First-Out (FIFO)

Page 4 of 48
 system for storage.
40. Ensuring 24 X 7 working of air conditioners provided in air conditioned
storage wards. Temperature and humidity indicators to be provided at the far
end of AC Storage ward.
41. Fridge/Deep freezer of adequate capacity needs to be used for storage of
varnishes which are to be stored at less than 10 degree C.
42. Implementation of Technical circular no. RDSO/2010/EL/TC/104 (Rev. 0)
dated 16.7.2010 for storage & handling of lubricant/greases used in Electric
locomotives. All barrels must be stored, preferably indoors; away from extreme
heat/cold, dust, acidic fumes and moist atmospheric conditions. Lubricating
oil barrels should be stored horizontally preferably on wooden rails dunnage to
avoid contact with ground. The barrel bungs should be in the clock position at
3 & 9. Grease barrels must be stored vertically preferably covered with
tarpaulin, if not stored indoors.
43. Use of induction heaters equipped with essential features like temperature
display, temperature hold, auto cut off & de-magnetization. Induction heating
should always be done in temperature mode as same/similar components of
different manufactures may have different properties. Temperature setting
should not be more than 1200C for bearing assembly components.
44. Use of grease guns equipped with Grease dispensing meter to provide
prescribed quantity of grease.
45. Bearings should be handled with protective industrial gloves. Lint free cloth
should be used for cleaning purpose.
46. To follow the prescribed replacement schedule for traction motor bearings.
Conventional traction motor bearing is must change item during POH.
47. Use of prescribed torque wrench for tightening of bolts etc.
48. Area for blowing and cleaning activities should be separate from TM assembly
area.
49. Becktol Red is E Class (120 degree C) Anti-tracking finishing varnish.
Prescribed anti-tracking finishing varnish for TAO-659 TM is F-93/RE-118
which is H Class (180 degree C). Prescribed finishing varnish for Hitachi TM is
TVA-1410 which is Class 200 degree C. Only TVA-1410 varnish to be used as
finishing varnish for Hitachi TMs and TAO-659/TM type 4601 rewound with
insulation scheme as per TC-125/ TC-127. TVA 1410 is having shelf life of
only 3 months when stored at less than 10 degree C. Proper storage facility to
store TVA1410 at less than 10 degree C is required. Staggered supply of
TVA1410 needs to be ensured so that it is used within shelf life.
50. Ensure securing of balance weights during overhauling.
51. Checking of resin glass band.
52. Provision of PTFE band on armature cone during major overhaul.
53. Deburing of Commutator during major overhaul to be done on machine only.
54. Covering of Commutator to avoid damage during handling.
55. Use of induction heater for heating pinion and racer of bearing during
mounting/dismounting process.
56. Measuring of K value of pinion during major overhaul.

Page 5 of 48
 57. RDPT of pinion during major overhaul.
58. Bearing seat and pinion seat of armature shaft in section to be kept covered
with very thin film of grease inside polythene bags to avoid damage and dust
deposition.
59. Ready pinions to be covered with thin film of grease and to be kept inside
polythene bags to avoid damage and dust deposition.
60. Pinion bedding to be ensured.
61. Interference between shaft and inner racer of bearing and dimension of the
bearing in the end shield to be recorded.
62. Must change items to be replaced during POH as per TC-0123.
63. Use of assembly components in kit form vide RDSO’s letter No. EL/3.2.172
dated 26.06.2007
64. Follow Compendium of Instructions on Traction Motor, MSU and Axle Box
Bearings given in document no. RDSO/2016/EL/PUB/0003 of DEC’2016.
65. Cleaning of Commutator by movement of loco during IC schedule.
66. To check cable socket and condition of ferrules during lifting & overhauling.
67. Cleaning of stator by high pressure jet of air during overhauling.
68. Terminal insulator cleaning with Orion-77 and checking tightness during
overhauling.
69. Cleaning of stator by Orion-77 during overhauling.
70. Blowing of TM Commutator chamber by dry compressed air before IC
inspection or as required

1.1.2 Transformer

SN Reliability Action Plan

1. DGA analysis to be done in every IC/TOH/IOH inspection.
2. SMI-80 all ‘L’ clamps to be replaced by palm clamps on a0-a1 bushing and
special clamp to be fitted on a3 bushings.
3. Shifting of sluice valve (MPH) 180 deg. To ensure the gap in between sluice
valve operating wheel and a33 palm clamp also ensure the connection of wire
No. EF-12 on a3 bushing. To be done during TOH/IOH.
4. SMI-193 Maintenance practices for improving reliability of cable head
termination system.
5. SMI-179 Check point during commissioning of TFP fitted with M/s BSES
bushing (A33).
6. Clamping of vent pipe to be checked during inspection, oil leakage from pipe
line joint should also to check at supervisor level.
7. Cleaning of radiator with water jet on condition basis during TOH.
8. SMI-163 for strengthening of tanks.
9. As per SMI-159, the level of inhibitor is to be ensured by periodic checks duly
ensuring necessary facilities.
10. Insulation resistance of transformer winding shall also be recorded during
filtration of oil during TOH/IOH as and when carried out.
11. As per SMI-138, BDV of oil to be checked and centrifuge the transformer oil if

Page 6 of 48
 required.
12. All the gaskets of the conservator and drain plugs shall be replaced during
IOH. Cork sheet gasket should be used in place of rubber (SMI-178,124) of
required thickness. Bushing cap 0-ring (45mm inner dia) should also be
replaced to avoid leakages.
13. Lengthy studs to be used on a0-a1, a7 & a8 bushings for better contact to the
palm clamp during IOH or during over hauling of TFP.
14. Graphite grease is to be applied during TOH/ IOH at the threaded portions of
palm clamps on TFP to avoid bad contact and overheating of clamps.
15. Only Fibreglass sleeves to be used for bushing leads (Modification No. 176).
16. Glass epoxy tubes to be used for core bolts. (Mod No. 176)
17. The size of the cleats opening should be such that the leads be held firmly.
(Mod No. 176).
18. Whenever the TFP is taken for repairs or in 1st IOH core bolts to be tightened
with 25 Kgm torque to avoid loosening in service/ breakage of bolts during
tightening. (SM1123 & 164). Core bolts to be replaced on condition basis.
19. Whenever TFP is taken for repairs, wrapping of tap leads to be carried out
(SM1-122) to overcome the problem of peeling off of the paper insulation and
formation of a powdery sludge in the neck portion.
20. During transformer repair wrap 3 layers of creep papers, half lap on bare bus
bars duly sealing with fevicol at either end. (Mod NO. 182).
21. Core rests on the bottom supports to be examined with empty tank before final
assembly
22. To avoid bulging of auto winding, parmali spacers are to be properly positioned
before tightening the bolts of the core and those of supporting plates for the
winding.
23. DGA plant, tan delta test equipment, acidity BDV and other test kits should be
calibrated periodically.
24. Whenever tank modification/ repairs are taken up, repainting of tank inside
should be carried out as per RDSO's instructions (SM1-125).
25. RTV compound is to be applied around the opening of the rubber enclosure of
turret surface to avoid ingress of moisture and dust into the apparatus
bushing (horizontal type CHT)
26. External earthing shunt of CHT is to be insulated with fiberglass
tape and 3M fusible silicon tape near the RGR area to avoid external flash
over.
27. In RGR (Lachhman make) additional base plate projection is to be cut to
increase the clearance between CHT earth cable and RGR.
28. Provision of 'Oil trap chamber' in drainpipe of conservator tank of TFP (modn.
No.324) to be provided on all locos. A suitable float with reflective paint will be
an added advantage for trapped oil level reading.
29. Radiator cleaning shall be done and replacement of gaskets shall be carried
out during 10H.
30. Temperature sensing strip provided on pipe line of MPH to detect the
temperature rise on line.

Page 7 of 48
 31. Transformer and GR oil level to be checked and kept at adequate level as per
seasons especially before summer & winter.

1.1.3 Tap-changer

SN Reliability Action Plan

1. Regular replacement of PHGR filters silica gel & rubber gaskets of breather
container assembly with cork grains.
2. Ensuring working of PHGRs in all locos.
3. Ensuring minimum BDV of 48KV when fresh oil is filled in GR and it should
be done directly from the centrifuging plant avoiding any handling equipment.
4. Ensuring minimum BDV of 40KV when measured for oil in service.
5. DGA to be done in every schedule inspection.
6. Replacement of worn out lantern gears.
7. Replacement of worn out coupling shaft
8. Ensuring replacement of parts during TOH & IOH as per kit prescribed by
RDSO.
9. No patch repair of GR contact plate and intermixing of GR parts.
10. Ensuring replacement of old copper washer with new ones every time PHGR is
refitted.
11. Testing of PHGR on test bench during TOH/IOH schedule and replacement of
rubber repair kit during every IOH schedule.
12. Replacement of top & bottom oil seals (Part No. 3897) during IOH schedule of
RDSO approved makes ( i.e. Fenner.) duly ensuring inner Dia of seal.
13. Sign of plate crack and leakage from any contact pins to be thoroughly
checked during GR opening.
14. Rehabilitation of N-32 tap changers in compliance of Railway Board directives
on a similar pattern.
15. All RDSO SMI Nos.82, 90,105,106, 113,117, 118,129.134.135 to be followed.
16. Proper contacts pressure in GR to be ensured by replacing the rollers during
TOH/IOH which are below 17.3mm dia.
17. Modified PHGRs only to be procured.
18. Roll pin of GR main shaft to be checked visually during IC schedule.
19. During major schedule roll pin of GR main shaft ovality should be checked by
measuring dia before and after changing of roll pin to avoid play.
20. CGR frame contact bolt (new design thicker neck) to be procured from
approved vendor & to provide the same. Make sure that these bolts have firm
name and Mfg embossed on head.
21. Visual checking of RPGR connecting link to be done during every inspection.

1.1.4 SMGR

SN Reliability Action Plan

1. Proper cleaning of Auxiliary contacts and maintenance of gaps to be ensured.
2. RDPT/magnaflux of crankshaft of SMGR during overhauling & replacem-e3f of

Page 8 of 48
 defective crankshafts.
3. Replacement of manual operating mechanism on condition basis.
4. B02 type filter are to be ensured during overhauling,
5. 0.5mm Gap to be ensured in between push rod with seal and push rod of
VE1/VE2 assembly.
Gap of 0.9mm to be ensured in between armature and setting screw of
VE1/VE2 assembly.
Chec-king of freewheeling diode of VE1/VE2 assembly.
6. Healthiness and tightness of SMGR foundation bolts to be checked during IC
inspection.
7. Clamping of reducing valve to be ensured to avoid passing of the vibrations to
the pipeline connecting 3-way valve
8. Complete testing of SMGR to be done after overhauling on SMGR test bench.
9. SMGR stand should be used for transportation of SMGR.
10. All RDSO SMI Nos. 18,21,22,46,47,48,49,105 & 129 to be followed.
11. Air filters and strainer in the SMGR circuit should be cleaned in schedule
inspection.
12. Pressure reducing valve to be overhauled in 2nd IC
inspection.
13. Seal with the push rods of control valves to be replaced during TOH.
14. Locktite to be applied after tightening the fixing bolts of the journal pin
TOH/IOH.
15. Spring between guide pin and toothed segment to be replaced during TOH.
16. Gap between control lever and intermediate gear wheel of SMGR should be
checked dining IC and adjusted between 0.4 to 0.7mm and whenever it is
found to be more than 0.7mm, it should be recorded as a defect and adjusted.
17. SMGR auxiliary switches (4 nos), which are maximum used, should be
replaced during TOH & auxiliary I/L of these switches to be cleaned during IC.
18. Universal coupling to be replaced during TOH.
19. Copper washers only to be used in SMGR copper pipeline joints
20. Checking of Q-53 & Q-54 (In AAL make SMGR) in IC.
21. Double roll pin with jaws procured from approved firms & to be provided.

1.1.5 RSI Block

SN Reliability Action Plan

1. To ensure proper tightness/ crimping of cable sockets during major schedule.
2. To record R & C values of AC & DC damping panels in major overhaul &
replacement of defective components & parts.
3. Testing of diodes to be carried out with recommended voltage in every_
overhaul (as per SMI No: 37, 70 & 71.)
4. To check micro switch for any breakage and malfunctioning in every schedule
except IA as per SMI No.67, 68, 70 & 71.
5. To check trip indicator fuse for proper functioning in every schedule except
IA/IB as per SMI No.67, 68, 70 & 71.

Page 9 of 48
 6. Checking the capacitance of the capacitors in ac damping, dc damping and
snubber circuits of silicon rectifiers used on electric locos (SMI-110)
7. Dusting of diodes during TOH/IOH/by forced air and with brush during IC to
avoid dust accumulation and flashes.
8. AC damping panels capacitance values to be checked during TOH/IOH and
whenever QOP problem/TMs arc horns flashing reported
9. Guideline of maintenance of Capacitor in Single Phase AC Electric Locomotive.
(SMI-230, Rev. 0))
10. Silicon rectifier damping capacitor failure. (MS-104)
11. Cleaning of heat sink with dry air during overhauling (TOH/IOH).
12. Protection covers of tail-tail fuse to be insured for proper fitment to avoid dust
on micro switch.
13. Application of silicon grease between diodes & heat sink.
14. Check all RSI insulator in IC/TOH/IOH & replaced with new if found any
defective/repaired.
15. Thermostat resistance measurement in RSI during TOH/IOH.
16. The wiring between BTSI and HVSI should be in conduit pipe .This should be
ensured.
17. One cycle drive of checking proper gap between tail-tail fuse cover/ its nut bolt
and its micro switch or current carrying part.

1.1.6 Vacuum Circuit Breaker(Double Bottle)

SN Reliability Action Plan

1. Checking contact pressure and crushing of auxiliary
contact with suitable pressure gauge during major schedule.
2. Ensuring proper setting of indfoss make pressure switch, on test bench in
every overhauling using calibrated pressure gauge. GEC 4/4.6, BHEL 4/4.6
AAL/BT 3.3/3.6 kg/cm2 pressure setting for open/Close respectively.
3. Check surge suppressors for current in range of 14 to 19mA by applying 110V
AC & replacing defective ones during overhauling to prevent CCDJ/CCPT
cases on line.
4. Replacing of components in magnet valve assembly in every overhauling.
5. SMI-136, SMI-137, SMI-161, SMI-162, SMI-208, Mod-209 and Mod.302 to be
followed.

1.1.7 Vacuum Circuit Breaker(Single Bottle)

SN Reliability Action Plan

1. Aux. contact assembly should be changed after every 5 years along with
related springs (as per OEM)
2. Filter cartridge of pressure control valve set be changed during every IOH
3. Dampers, shock absorbers plate and that joint gasket should be changed after
every 3 years (as per OEM).

Page 10 of 48
 4. Application of silicon sealant on the mouth of rubber protective sleeve and
other exposed joints of VCB on roof to avoid ingress of dust and moisture
during run.
5. Checking of VCB damping and HV leakage test of vacuum bottle to be ensured
during overhauling.
6. Replacement of auxiliary switch during POH
7. Paralleling of DJ closing interlock in VCB auxiliary switch during TOH/IOH.

1.1.8 Head Light

SN Reliability Action Plan

1. DC-DC converter unit should be tested on load.
2. Paralleling of BLPRF, BLPRD, and BLPRR limit switch interlocks in headlight
circuit during major schedules should be ensured.
3. Removal of RTPR from all locos.
4. Checking and focusing of H/L during every schedule.
5. Cables around the holder should be provided with fibreglass sleeves.
6. Modification of twin beam headlight with DC-DC converter as per MS-0325 to
be ensured.
7. Provision of cable (10 sq. mm) from DC-DC convertor to head light to improve
voltage (TOH/IOH) as per MS-453.
8. Replacement of reflector during TOH/IOH.
9. Millivolt drop/contact resistance measurement of two way toggle switch in
both input and output side during OH of DC-DC converter.
10. Checking of DC-DC converter toggle switch in IC schedule.
11. Terminal dust cover in DC-DC converter should be provided.
12. DC-DC converter toggle switch to be provided with loctite after tightness.

1.1.9 Flasher Light

SN Reliability Action Plan

1. Provision of LED type flasher light in all locomotives.
2. Ensuring proper marking on terminal connection of control units during every
schedule.
3. Ensuring that control unit is tested on load and then it is put in service.
4. Provision of automatic switching 'ON' flasher light during TOH/IOH.
5. Check flasher light working in every schedule for 10 Mins.
6. Terminal dust cover on Flasher light control unit should be provided.
7. F/L light unit (Hood) glass fuse holder contact tension to be checked during
every schedule.
8. Flasher light control box toggle switch and fuses to be provided with loctite
after tightness.

Page 11 of 48
1.1.10 Speedometer

SN Reliability Action Plan

1. To change PG rubber kit in TOH/IOH to avoid dust etc.
2. To ensure stiffener with JB to secure PG lead in every schedule.
3. To ensure proper securing of PG lead with help of clamp on bogie in every
schedule.
4. To provide wire braided sleeve similar to WAP5 design on PG lead during
IC/TOH/IOH.
5. Replacement of three-core SC cable with shielded cable from SC to JB to
avoid surges.
6. Provision of microprocessor based energy cum speed recording
system as per RDSO specification.
7. PG bearing should be changed from 6002 Z to double sealed bearing 6002
ZZ by sheds/shops. Manufacturers should provide only double sealed
bearing.
8. Bearing should be replaced during IOH/condition basis.
9. Oil seal to be changed during every overhaul.
10. Proper clamping of PG cables to be ensured by sheds/shops.
11. PG to be mounted on axle box such that cable entry is inclined 45°
downwards from center line and is towards center line of loco.
12. Cover gasket must be replaced whenever it is opened.
13. All un-modified type driving forks wherever in service to be replaced by
modified driving fork.
14. Rubber components to be purchased from OEMs.
15. ESMON timings to be calibrated during every shed visit with control office
watch.
16. PG to be checked during every IC schedule after its detachment.
17. ESMON data to be downloaded in every schedule and to ensure that all data
are getting recorded alongwith any unusual.
18. All PGs to be provided with double sensors.

1.1.11 Relays

SN Reliability Action Plan

Air Flow Relays
1. SMI-173 regarding measures to improve reliability of relays to be followed
2. Air flow relay having 25mm dia orifice as per modification
sheet No.WAG 5/10 be inducted in service while procuring new relays to
replace flap type relays and 8mmfl6mm dia. Switzer relays
3. Ensuring proper fixing clamp on mounting plate of micro switch for proper
securing of lead wire from micro switch to terminal BD of air flow relay
4. Diaphragm to be replaced in every TOH/IOH and to be procured from OEM.
5. Checking of micro switch with multimeter to ensure healthiness of its N/0,
N/C contacts during overhauling.

Page 12 of 48
6. Alignment & setting of various adjusting nuts & screws of moving plate to be
ensured during overhauling for proper functioning of micro switch.
7. Portable digital manometer for measurement of operating values of airflow
relays to be procured as advised by RDSO vide letter No. EL/3.2.39/4 dated
12/01/01.
8. Base gasket & cover gaskets be replaced 100% during
TOH/IOH.
9. Millivolt drop test in MTDJ circuit during 2nd IC schedule.
Time Lag & PC-8 Relays
1. Use of cleaning agent for cleaning contacts of various types of relays and micro
switch of Q48 relay & C-118 chronomatic relays to ensure its proper
functioning.
2. Check proper functioning of various N/O & N/C contacts of PC-8 relays during
every schedule.
3. Ensure proper functioning of timer unit of various types of relays on test
bench during every schedule.
4. Ensure proper wiring of timers, relays & base connections.
5. Ensure proper clamping on contact holders and all springs for proper
operation of contacts and contact holder.
6. During inspections, it should be ensured that freewheeling
diodes of QTD-105 is in working order and without open circuit fault.
7. Replacement of PCB in Q-118, Q-44, Q-119 relay during IOH.
8. 100% replacement of contact tips and contact tensioning spring in every IOH
schedule.
9. Coil resistance and contact pressure should be measured during every
overhauling.
English Electric Relays
1. Check & ensure contact pressure/crushing and healthiness of push rod
during every schedule.
2. Measure & record ohmic values of economy coil and economy resistance
during TOH/IOH.
3. Replace QV60, QV61, QV62, QV63, QV64 & Q51 English Electric Relays with
PC-8 type relays during TOH/IOH.
4. Ensure mechanical locking arrangement of QLM relay and its proper fitment of
locking spring in every schedule.
5. Small size connecting screws of English Electric relay should be replaced with
longer ones as has been provided in the relays of earlier version
Pressure Switches
1. Overhaul and test thoroughly pressure switches during major schedule as per
SMI No. 190.
2. Use proper tools for pneumatic connection and differential assembly.
3. Ensure differential locking to eliminate chances of getting loose during jerk /
vibration on line.
DI/DU, QD, Q20 Relays
1. Record testing data and physical healthiness during

Page 13 of 48
 TOH/IOH.
2. Check non-magnetic shunt for groove formation / wear in every overhaul.
3. QD relay has to be calibrated in IC0 and in TOH, IOH after overhaul.
4. Covers shall be provided on all the relays and availability of adequate quantity
of these should be ensured sources of supply of these covers have been
identified.
5. DI, DU relays after overhauling, shall be sealed before these are provided on
the locos.
6. DC coils of the relays are the part of the relays and they should be procure
only from OEMs to ensure reliability.
7. RTV silicon sealant is to be ensured to prevent dust entry at relay bottom base

1.1.12 Auxiliary Machines

SN Reliability Action Plan

1. Use of electric motor checker for measurement of resistance and inductance of
motors after overhauling.
2. To use induction heating for fitting bearing on the rotor shaft.
3. Use of mechanical puller for removing fan from MCP during overhauling.
4. To measure dia of end shield housing and rotor shaft by micro meter during
overhauling as per SMI No. 16.
5. To measure shaft dia. at impeller seat and cooling fan seat and the inner dia of
impeller / cooling fan during overhauling.
6. Bearing sound to be measured with the help of echo pulse meter during
overhauling and bearing replaced on condition basis in MPH & MVSL.
However, MVSI & MVSL bearings to be changed in TOH/IOH.
7. Use of thermocouple contact thermometer for checking the temperature of
bearings while using induction heater.
8. Use of mechanical puller for removing impeller from MVMT, MVRH, MVSL &
MVSI during overhauling.
9. Balancing of MVMT during overhauling.
10. To check impeller cracks by RDPT during IC/TOH/IOH.
11. To change impeller in case of blade crack/broken and do not resort to welding.
12. To check the tightness of the bolt of the duct chair of MVMT to avoid vibration,
during every schedule.
13. To check alignment of MVMT duct and motor while fitting on the chair of
locomotive.
14. To check winding lead lugs and crimping during every
schedule.
15. Cleaning ARNO overhang portion in IC schedule.
16. Balancing of MVMT in position in loco on every changing/replacement.
17. Covering of MVMT duct on removal of MVMT is to be ensured.
18. Capacitors across MCP should be provided.
19. Unloader valve with timer circuit to be implemented
20. Time delay starting to avoid overloading on ARNO

Page 14 of 48
 21. RDSO modifications regarding provision of 3 capacitors across ARNO
supply to be completed on priority and capacitance values to checked.
22. 3-phase EMCs to be overhauled during TOH. Main contacts and auxiliary
contacts should be checked during 2nd IC.
23. Contact bits of 3-phase contactors of compressor motor should be checked in
IOH and contact pressure measured.
24. Growler test to be done on the rotor bars of ARNOs to detect any internal-
cracks during TOH. It should be repeated by the supervisor on ARNOs, which
are more than 5 years old. ARNOs which are more than 5 years old should be
overhauled during 2nd IC.
25. Overhung of ARNOs should be cleaned during IC schedule because lot of
grease is getting accumulated in the top portion of the ARNO. As dust is
getting accumulated over the grease , heat dissipation is getting affected
leading to failures.
26. To ensure that the compressor motor starts on No load, the non-return valves
near the compressor delivery pipes must be provided between the compressor
delivery and the non-return valve as per the approved modification.
27. Proper functioning of the NRV can be certified by checking that continuous
leakage of air from the leak hole is not there once the compressor has started.
If the leakage is continuous, NRV needs to be attended.
28. Additional insulating sleeve should be provided over connection leads of stator
winding to avoid insulation damage.

1.1.13 Reverser/CTF

SN Reliability Action Plan

1. Ensure compliance of SMI-224 for operating coils (solenoids) in the equipment
like Reverses/CTFs contactors (EP/EM) & electro valves.
2. Ensure compliance of SMI-234 to arrest flashing/melting of silver tips of fixed
as well as moving segment breakage of other components of existing
reversers/CTF and its up gradation to 1500 Amps high capacity
CTFs/Reversers.
3. Implementation of MS-362 for modification in 1000 Amp reverser/CTF
servomotor to avoid breakage of fork, roller bush and shaft.
4. Milli volts drop of J/CTF to be ensured during TOH/IOH.
5. Crushing gap of 1.5 to 2 mm to be ensured for fixed contact by using of Go -
No Go gauge at the time of building up of contacts and in every overhaul.
6. Ensuring proper contact pressure in Reverser and CTF and application of
conductive jelly on the contacts to avoid air gap.
7. Defective top and bottom valve of NC4 valve to be weeded out and VITONE
type Top & Bottom valve to be used.
8. Fork material to be changed to forged steel.
9. Blowing of BA panel pipeline to be done during TOH/IOH.
10. J/CTF working to be checked for 100 operations on
automatic test bench after overhauling.

Page 15 of 48
 11. J1 + J2 handle to be checked during major schedule and to be replaced with
modified one in IOH.
12. Rubber gaskets/buckets must be changed during TOH/IOH (TC - 29 & 31
Rev. l).
13. Servomotor Epoxy bushes of Reverser, CTF must be replaced during
overhauling and quality of material must be ensured.
14. Replacement of shunt leads on condition basis during
overhauling
15. Broken/Cracked contact bits must be changed during all schedules and
alignment & contact pressure to be ensured.
16. To avoid breakage of 'U' fork/shaft, damping arrangement for servomotor is to
be implemented on all locomotives.
17. HV testing at 5.1KV, 50 Hz AC for one minute to be conducted to ensure
proper insulation resistance level.
i) Between main contacts & frame.
ii) Between open main contacts.
18. On CTF & Reverser contact bit number to be painted to enable to pack proper
bit while isolating TMs in case of earth fault in TM/Power circuit.
19. CTF/Reverser Ellen screws to be provided with ‘M’ seal after tightening, to
avoid loosening in service.
20. Silver contact cleaning should be done during IC, TOH/IOH schedules as per
the special instructions issued (SMI-30).
21. Date of -provision of new contact bits may be punched/
painted at side face and failures/replacement to be recorded for wear rate &
failure analysis.
22. Aux. I/L cover to be provided with insulating paper pasted inside to avoid
flashing/ earthing of cables/ I/L.
23. Setting of contact pressure and proper bedding
24. Checking of contact pressure of CTF/Reverser to be done during TOH/IOH.
25. Sintered Bronze roller to be replaced with Bronze to avoid breakage during
TOH/IOH.

1.1.14 EMC

SN Reliability Action Plan

1. Solenoids or coil are used in large number of electric rolling stock on EP/EM
contactors relays etc. (SMI-69)
2. Maintenance instruction for ensuring complete snap action of Siemens switch
type K-138 (16 Amp) for loco application. (SMI-74)
3. Condition monitoring of fuses. (SMI-76)
4. Provision of RC suppression circuit across C-118 contactor coil. (MS-226)
5. Provide N/C interlock of QCVAR in C-118 coil branch (for WAG-7 modular
loco). (MS-257) in MPCS locos only.
6. Adoption of improved version (High current carrying capacity) of EM
contactors for C105/C106 (MVMT) C101, 102, 103 (MCP) and C107 (MVRH)

Page 16 of 48
 applications. (MS-310, REV. 0)
7. Provision of N/C interlock of C-118 as a input on WAG-7 Locos as per
ELRS/MS/0256.
8. To ensure locking groove for fingers of contactors during overhauling.
9. To test operation of EMCs on automatic test bench for 30 minutes and also to
ensure proper bedding, during TOH/IOH.
10. C118 contacts with Tungsten copper nickel coated having thickness of 3 mm
duly inserted on the existing copper contact to be procured to try with.
11. Reliability improve measure for operative coils (solenoids) in the equipment
like air blast circuit breakers reverses/CTFs contactors (EP/EM) & electro
valves of Electric locomotive. (SMI 224)
12. EM coils to be checked for internal shorting during TOH with the help of Q-
meter.
13. Contact tips for mobile and fixed contacts with shunts must be changed items
during IOH (TC No. 29 rev-1).
14. Contact tips for mobile and fixed contacts must be changed items during TOH
(TC No. 31 rev-1).
15. In C-118 contactor mobile contact spring pressure to be ensured (5 - 6.5 Kg. /
Sq.cm) as per CLW Spec. CLW/ES/C-15/C.
16. Ensuring proper fitment of mobile bits and shunts leads in all schedules.
During OH defective shunts to be replaced
17. C-118 limit switches are to be replaced irrespective of the condition during
0/H. Old limit switches to be immediately disposed off by cutting into two
pieces
18. Araldite to be applied between the fixed contacts and nylon body of auxiliary
switch during IOH.
19. The spare N/o interlock to be used for paralleling in C-118 Aux. Switch.
20. EMC shunts should be examined critically and proper mouth profile on end
fittings have to be ensured. Thread locking compound on fasteners of
contactor on insulated bar during over haul is advised. Also proper flat/
spring washers have to be ensured.

1.1.15 EPC

SN Reliability Action Plan

1. Checking up to clearance between the interlock operator (inter lock arm) and
bottom fixing screw of the connector assembly of 22PC E-P contactor of
BHEL/AEI make SKEL-2795. (SMI-9)
2. Cleaning of interlock contact of E.P. Contact changeover switch reverser
master controller tap changer etc. (SMI-30)
3. Improved maintenance practices for CLW make EP contactors. (SMI-174)
4. Reliability improve measure for operative coils (solenoids) in the equipment
like air blast circuit breakers reverses/CTFs contactors (EP/EM) & electro
valves of Electric locomotive (SMI-224, Rev. 0)
5. Reliability improvement measures to arrest flashing/melting of silver tips of

Page 17 of 48
 fixed as well as moving segment breakage of other components of existing
reversers /CTF its up gradation and use of 1500 Amps high capacity
CTFs/Reversers. (SMI-234, Rev. 0)
6. Modification to traction motor EP line contactor (Type 3421-212M). (MS-46)
7. Design improvements/modifications to be carried out on CLW make Electro-
pneumatic line contactor. (MS-159)
8. Provision of additional silver tip contacts in parallel with existing main
contacts on CLW make EP line contactors. (MS-219)
9. Design improvements for CLW EP line contactors. (MS-231)
10. Modification in unmodified 1000 Amp reverser/CTF servomotor to avoid
breakage of fork, roller bush and shaft. (MS-362, Rev. 0)
11. To ensure that milli-volt drop across EPC contacts is within limit during
overhauling.
12. To weed out defective top and bottom valve of NC4 valve and to use VITONE
type Top & Bottom valve.
13. To change piston cup for EPC during TOH/IOH.
14. Rehabilitation/ conversion of all the 1000 A line contactors to 1500 A capacity,
in a phased manner.
15. To ensure that arc chute horns are firmly held in place by riveting, during
overhauling.
16. To test contactors on test bench for 100 operations after overhauling to ensure
proper bedding.
17. To ensure that contacts close at minimum specified pressure and there is no
air leakage perceptible to ear at working pressure, after overhauling.

1.1.16 Cab AC

SN Reliability Action Plan

1. Ensure maintenance of CAB AC unit as per SMI No.
RDSO/2016/EL/SMI/0293 Rev-0 dated 29.07.2016.
2. Modification for providing dummy plate in cab roof in place of Air Conditioning
unit as per MS RDSO/2017/EL/MS/0461 (Rev 0)

1.1.17 Smoothing Reactor/SJ

SN Reliability Action Plan

1. RDPT of the brazed joints of terminal cleat to be carried out whenever SL is
taken out.
2. Insulated bushes from TMs are to be replaced with Mica sleeve.
3. Surge test on "OFF POH" locos incorporated in IC0 schedule & TOH/IOH to be
carried out.
4. SMI-5/15 improvement measure for smoothing reactor type SL-42 &
SL-30 to be followed.
5. SMI-147 modification to connection cable cleat from 18mm thick to 23mm.
6. Inductive shunt base should be thoroughly checked for any cracks during

Page 18 of 48
 inspection
7. Surge Comparison testing of SL during IOH.
8. Measurement of mV drop at 1000A DC to calculate resistance.
9. Inductance measurement at 10V AC as per SMI 0304.
10. Polarity of SL to be checked during IC0 schedule (in OFF POH schedule locos)
and whenever SL is changed.
11. Matching of SL sleeve & cleat size.
12. Gap between SL coils to be checked during every IOH.

1.1.18 Cables (Control, Power & Auxiliary)

SN Reliability Action Plan

1. Ensuring proper cable bunching and phase segregation during every schedule.
2. Ensuring proper type crimping of power cables at TFP bushing, RSI block, TK
panel and TM cables during TOH/IOH.
3. Checking cable socket for overheating, loose crimping etc. at TFP bushing, RSI
block and TK panel during minor schedule.
4. Provision of rubber sheet/grommet at points where cable is in direct
contact/rubbing with metallic parts, during every schedule.
5. Loco recabling to be carried out after 18 years along with respective POH &
this is to be ensured duly coordinating with workshops.
6. Procurement of Elastomeric cables to be done as per RDSO specification No.
E14/01 (Rev.2) 1993.
7. Neoprene rubber insulated sheet to be used for the
protection of cables against mechanical damage.
8. In order to avoid failures of TM cables at ferrules, lay out of the cables to be
ensured without sharp bends. Cables of short lengths are to be replaced.
Ready stock of these cables to be maintained.
9. Whenever cable connections are made, size of ferrule to be checked before
making connection with the help of Go- `No-Go' gauge.
10. Whenever TM (TAO-659) is removed on account of burning/heavy flashing
etc., particular TM cables should be inspected thoroughly.
11. Ensure that the cable insulation is well gripped by the socket (TC - 4)
12. To ensure soundness of crimped joints procedure given in SMI-114 to be
followed, crimping tools should be checked periodically to ensure effective
crimping.
13. While tightening the connections of the control wire, it should be ensured that
the wire is held in one hand so that rotation of the lug is avoided.
14. Proper box spanner/Nut drivers should be used for
tightening of control cable connections. Torque wrenches should be provided
to avoid over/ under tightening.
15. Iron rods supporting the control cables should be first insulated with
one layer of PVC adhesive tape followed by second layer of black adhesive
cotton tape of Johnson make.
16. Cable to be tied up to an insulating rod fixed near the socket to-prevent flexing

Page 19 of 48
 of the wire (SMI-32)
17. Ensure that there is no relative vibration between the socket and the
insulated support rod. (SM1-32).
18. To minimize vibrations in the cables, various hinged boxes and panels need to
be properly attended in respect of hinges and fixing bolts.
19. 1.5 mm thick rubber sheet should be pasted on the metallic surface below the
control cables and above the supporting plates, channels, and angles.
20. Whenever control wires pass against angle frames 'U' type gaskets should be
provided on the frames and fixed by using araldite.
21. Isolated control wires such as those to E.P valves, E.M contactor etc., should
be properly secured with only adequate lengths to minimize shaking.
22. Provision of protection cover on MU couplers and their sealing to avoid water
entry should be ensured.
23. Negative bonding of the cables to be checked during trip inspections and areas
more prone to negative bonding should be specially attended to on priority,
Cab light holders, corridor light holders and battery boxes are some of the
vulnerable areas.
24. Crimping tool bits condition to be ensured to avoid bad crimping of cables.
25. Checking of any looseness and bad crimping of lug as one time drive during IC
and there after TOH/IOH.
26. Checking the junction of TM cables (lug & crimping) in major schedule /
unscheduled lifting.
27. Checking of overheating of terminals of cable/busbar/'C'
clamps/bushings/TM terminal during major overhaul by Thermal Imaging
Camera.
28. Ensure provision of fibre separator between terminal board (MVSI) and
metallic base plate.

1.1.19 Bronze Support & Busbar

SN Reliability Action Plan

1. Sharp bends to be avoided while making bus bars.
2. Bus bar to be provided with nylon insulators support where ever unsupported
length is more than 100 cm.

1.1.20 Battery

SN Reliability Action Plan

1. Condition of seamless pipe and it's clamping to be checked during every
schedule and fixed if required.
2. Provision of rubber grommet and Anabond at cable entry points to be made to
avoid damage to the cables from conduit edges, during every schedule.
3. Ensuring that there are no joints in the cable from BA box to SB inside the
locomotive, during TOH/IOH.
4. Provision of PTFE sheet under batteries to be done during every schedule.

Page 20 of 48
 5. Ensuring provision of wooden packing between batteries during every
schedule.
6. Batteries with life up to 4 years in locos to be maintained.
7. Proper crimping of cable sockets to be checked and heat shrinkable sleeve
provided during every schedule.
8. Checking of MCB of Battery with reference to its enclosure that it is
symmetrical and the connection are passed through insulated stuffing glands
such that they do not get bonded with the body.
9. Panel type doors to be provided in place of covers in battery boxes in locos.
10. Batteries to be provided with ceramic vent plugs.
11. PVC adhesivei.ape to be provided near the terminals of the inter connectors to
avoid acidic corrosion of the cable.
12. Inter connector leads and lifting ropes of the batteries to be replaced during
TOH/IOH/POH. Released inter connector leads to be checked for any damages
after removing the tape near the lug and serviceable ones utilized for
unscheduled replacements after re-taping. Length of the inter connector
should be such that these are not rubbing with the battery box cover.
13. During TOH, IOH, IC'0', the clamps of the battery box to be examined for any
cracks.
14. During TOH/IOH/POH the capacity test must be done on the batteries And
batteries having efficiency of less than 80% to be replaced with new ones.
15. 10sq.mm. Cable from HBA to HOBA middle point (in place of
3 sq.mm. cable) shall be provided. This should be checked
during IC’0' schedule as a preventive check for new/ off POH/off re-cabling
locos.
16. Provision of additional CCBA in the form of MCB / Fuse box near/ inside the
battery box to take care of any earth fault in the battery positive cable before
the CCBA. The location of the provision shall be so selected that the fuse does
not get damaged during cattle run over or external hitting.
17. Packing material and battery box shall be painted with anti-corrosive and acid
proof black paint during TOH/IOH/POH.
18. Necessary instruments and tools like voltmeters to read cell voltage, battery
voltages, hydrometers thermometers, gauge for measuring the electrolyte level
to be made available in good condition for the maintenance staff and should be
calibrated periodically.
19. It shall be ensured that anti-theft rod of battery box is not touching with
battery terminals.
20. Extra supporting clamps to be provided on battery box as per MS 351.
21. Only nylon nuts to be used for battery box tightness. All the nylon nuts to be
replaced whenever opened.

1.1.21 SIV

SN Reliability Action Plan

1. Provision of flange cum foot mounted blower motor in AAL make SIV as per

Page 21 of 48
 RDSO MS no RDSO/2016/EL/MS/0449 Rev 0 dated 30.03.2016.
2. Blowing with dry air, Vacuum cleaner and Cleaning of heat sinks and other
components by electro static brush in every IC schedule.
3. One cycle cleaning of SIVs as part of summer precautions as per RDSO letter
no EL/1.2.9.1 dated 20.02.2014
4. Measurement of capacitance value of DC link, sine wave filter and snubber
circuits, wherever possible during IOH schedule as per SMI no
RDSO/2016/EL/SMI/0291(Rev 0) dated 21.06.2016.
5. Downloading and analysis of recorded fault messages in every schedule for
taking the corrective action as per SMI no RDSO/2016/EL/SMI/0291(Rev 0)
dated 21.06.2016.
6. Checking of sealing gaskets in every IC schedule and replacement in every IOH
on condition basis.
7. The rotation movement of churning and cooling fan & the bearing are to be
verified during TOH, IOH schedule. But the replacement is to be done as per
schedule submitted by firm. This has already been mentioned in minutes of
meeting dated issued vide RDSO’s letter no. EL/1.2.9.1 dated 17.07.2017.
8. AMC of all makes of SIV as per SMI no. RDSO/2016/EL/SMI/0291(Rev 0)
dated 21.06.2016.
9. Checking of GDU card in AAL make SIV. As per the firm the main cause of
failures of GDU card is due to deterioration of capacitance value of
capacitors in GDU cards which leads to failures of pulse transformer and
IGBT. The replacement of capacitors and pulse transformer after a service
period of 06 years is to be done on the condition basis.
10. MCU Card – Provision of higher rating MCU card in M/s AAL make SIV.
11. Replacement of ABB make DCCT and Battery charger in AAL make SIV.
12. Replacements of ZCT of M/s Deesys of Korea by M/s. Broycee Control of
England in AAL make SIV.
13. Proper locking of input isolator / Removal of input Isolator in M/s SIEMENS
make SIV.
14. Modification of MC card and TDC_IF card in M/s Medha make SIV to be
implemented by firm.
15. In M/s Medha make SIV the dv/dt capacitors are to be replaced after
service period of 4 to 5 years. If capacitance value is less than 20% of
specified value then replacement is to be done by the firm.
16. Dust cover modification in M/s MEDHA make SIV to be carried out by the
firm.
17. Condition monitoring of snubber capacitors in Hind Rectifiers make SIV
during major schedule. Replacement of the same after a service of 06 years or
if the capacitance value detoriate.
18. Provision of implementation of QCON timer and EAU (Energy absorption
unit) in Hind Rectifiers make SIV to be done by the firm.
19. Provision of modified MVSI motor in place of Siemens make cooling fan in
Siemens make SIV.

Page 22 of 48
 20. Replacement of bearings of cooling fan of SIV in major schedule on proper
fixture with special tools.
21. Sound checking of cooling fan using Shock Pulse Meter (SPM) during schedule
inspection.
22. Check condition of MCB in Hirect make SIV during every major schedule,
replacement of MCB in IOH.
23. Snubber circuit capacitor values to be checked in Medha make SIV during
TOH.

1.1.22 MPCS

SN Reliability Action Plan

1. Replacement of sealing gasket during IOH schedule.
2. Downloading and analysis of recorded fault messages in every schedule for
taking the correction action.
3. Ensure proper earthing during welding works in locomotives & to ensure that
welding is carried out in Battery OFF condition.
4. To carryout AMC as per SMI No. RDSO/2016/EL/SMI/0288 (REV. '0')
5. Ensure the CPU battery voltage of RTC is in proper condition during TOH and
replace whenever required.
6. Ensure the maintenance of dynamic braking excitation contactor C145 as per
SMI no. RDSO/2012/EL/SMI/0276 Rev.’0’ dated 27.07.2012 in each
schedule.
7. Time matching of MPCS digital clock with control office clock during every
inspection /loco visit.
8. Real Time Clock of MPCS to be replaced as per OEM guideline.

1.2 Pneumatic Equipments:

1.2.1 Pneumatic Valves

SN Reliability Action Plan

1. Calibration of AFMV during A01-1/10H schedule as per RDSO Letter no.
SD/Dev.128 LAV, Dated 19.11.91.
2. C2W and C3W valves to be tested on test bench after overhauling.
3. Provision of 1/2" isolating cock without vent of Legris make identical to the
one being used on WAP5 locos during every schedule.
4. D24B to be replaced with Feed Valve (FT 1) during TOH/IOH.
5. Replacement of corroded pipeline coming from under frame to driver cut out
cocks to be done during TOH/IOH.
6. Master gauges used for testing of gauges should be calibrated periodically.
7. Overhauling and storage of critical pneumatic valves and their components to
be done in a dust free environment. Over hauled valves should be kept after
wrapping properly by polythene/bubble wraps. All precautions should be
taken for storage of rubber components.
8. Modification to prevent damage/breakage/falling the drain cock of after cooler

Page 23 of 48
 (EMU type) due to external hitting in all locos as per MS/308 in every
schedule.
9. EMU type after cooler inlet/outlet pipe line union joint to be supported by
suitable clamp provision in every schedule.
10. Provision of additional BP cock with vent and transposition of BP gauge intake
pipe line to avoid failure of loco in case of cattle run over and in case of
inadvertent operation as per MS 0349.
11. Cleaning of air strainers to be done in schedule inspections.
12. Overhauling of A9, C2 relay valves and duplex valves for horns to be done in
IC.
13. Cam fixing screw of A9 valve to be tightened during overhauling and thread
locking. Dog cams of A9 valve of SI/RPIL make to be ensured during overhaul.
Check nut to be provided on adjusting knob of A9 valve.
14. Teflon seating to be provided to horn operating valves in lieu of rubber valve
reinforced with brass. Horn diaphragm made out of Hylam sheet of 1 mm thick
in place of phosphorous bronze to be provided.
15. Non-return valve has to be provided with union nuts to facilitate their removal
for overhauling repairs. Non-return valves with Teflon seating to be provided.
16. Non-returning valve in DJ circuit to be cleaned during IC.
17. Auto drain valve to be overhauled in every major schedule and all rubber
components replaced.
18. During overhauling Duplex check valve, check valve stem to be tightened by
applying thread locking compound to avoid loosening.
19. Replacement of existing Nylon filter with Sintered bronze filter in ½” & 3/8” air
strainer in the pneumatic circuit of conventional electric locomotives as per
MS 0359.
20. Procedure to be followed for Dew point Depression temperature measurement
of compressed air passing through heat less regenerative twin tower type air
dryer being used in electric locomotives as per TC 0139.
21. To standardize the maintenance activities during various schedules of electric
locomotives for heat less regenerative twin tower type compressed Air Dryer,
the SIM No. RDSO/2017 /EL/ SMI/ 0305 /Rev’0’ dated 17.04.2017 to be
followed.
22. Provision of Trap chamber for collecting coal/dust particles coming from
BP pipe in A9-BP circuit in conventional electric locomotives to be ensured as
per MS-0463 dated 08.09.2017
23. Ascertaining the proper functioning including discharge rate of 1-1/4” NRV
used in the pneumatic circuit of Electric Locomotive the RDSO’s SMI-184
Rev’1’ to be followed.
24. Blowing of BP/FP pipelines by opening angle cocks on either ends after
building complete pressure to be carried out once in every schedule.
25. Replacement of D-1 auto drain valve in accordance to RDSO bulletin no.
MP.IB.BK.05.19.08 Rev. 00 dated 25.06.2008.
26. A9,SA9,C2 braking should be overhauled during IC.C2 charging ,VEPT-
1&2,Duplex valve of horn , MR & CPA safety valve ,SMGR PRV should be

Page 24 of 48
 overhauled during 2nd IC.
27. All non returning valves to be cleaned during IC.
28. Extended metallic portion of BP/FP pipe upto its angle cock centre to be
measured in every schedule.
29. BP/FP hose pipe length to be measured and its pressure test on 10kg/cm2
pressure to be done before fitment in locomotive.

1.2.2 Compressors & After Cooler Valves

SN Reliability Action Plan

1. Overhauling of Compressor should be followed as per OEM maintenance
manual
2. Provision of additional 1000 LPM compressor in WAP-4 class of Electric
locomotive with segregated pneumatic valves layout arrangement as per
modification RDSO/2010/EL/MS/0388/Rev’0’ dated 23.07.2010
3. Modification sheet for provision of 2 Nos. of oil free compressors of 1750 LPM
each onboard mounting in WAP-4 class of Electric Locomotives with modified
cab fed by 180 KVA SIV as per modification RDSO/2016/EL/MS/0451/Rev’0’
dated 25.04.2016
4. Provision of Disc type coupling in Main compressor of 1000 LPM capacity in
place of resilent coupling as per modification as per modification sheet no.
RDSO/2017/EL/MS/0462 Rev’0’
5. Provision of 2 Nos. of lubricated compressors of 1750 LPM each on-board
mounting in WAP-4 class of Electric Locomotives with modified cab fed by 180
KVA SIV during POH by Electric Loco Sheds as per modification no.
RDSO/2015/MS/0445 Rev’0’
6. Provision of safety sling in all under slung compressors in conventional
locomotives.
7. Safety valve in ELGI make compressor to be mounted upwards instead of
suspended position on inter-cooler.

1.2.3 Pantograph

SN Reliability Action Plan

1. Visual Inspection on critical components of pantograph (Intactness of split
pins & bolts and its tightness, Panto pan, Metallised carbon strips, Main
spring, Mechanism assembly & pantograph mounting insulator, top mounting
part A + B, cylinder support, support rod and steady link for its cleanliness
and crack or spark marks) and ensure proper levelling of the panto pan to be
done in every schedule. Proper lubrication must be done. Application of
lubrication should be carried out after proper cleaning.
2. Provision of rubber bush inside the open end of longitudinal tube of AM-12
type pantograph to avoid ingress of water in TOH/IOH during every overhaul
as per RDSO modification sheet No. RDSO/WAG-5/29(New No.

Page 25 of 48
 ELRS/MS/WAG5/242).
3. Servomotor piston packing ring changing during IOH and use only LIPLEX T2
Grease of M/s. Balmer Lawrie or Servogem 2 grease of M/s. IOCL so as to
avoid servomotor piston jamming. Do not intermix above greases. During pre-
winter precaution, the packing ring to be checked.
4. Cleaning of roof insulators in every schedule and application of silicon oil as
per RDSO special maintenance instruction No. RDSO/2012/EL/SMI/0274
Rev. ‘0’ dated 29.03.2012.
5. Rubber stopper should be provided to minimize jerks in the panto assembly
during lowering.
6. Brass bush part No. 00298/00299 of plunger box to be replaced by gun metal
to reduce wear & to enhance the life.
7. Items must be changed during Schedules as per RDSO technical circular No.
RDSO/2007/EL/TC/0094 for AM-12 type pantographs.
8. RDSO special maintenance instruction No. RDSO/2016/EL/SMI/0292 should
be followed maintenance of AM-92 or IR-03H type pantographs. Plunger
9. To reduce failures recommendation of RDSO Investigation Report No.
RDSO/2011/EL/IR/0147 Rev. ‘0’ should be followed.
10. Transverse Rigidity of the pantograph must be checked. It should be within
±30mm with 30kg transverse force. Procedure of Test: The pantograph shall
be extended to its upper operating position (2000mm for AM-12 type & AM-92
type conventional pantograph and 3400mm for High Reach pantograph).
When a force of 30kg is applied successively on each side of the part of the
frame which supports the collector head, then the displacement shall be less
or equal to 30 mm on each side. After each application force, there shall be no
permanent deformation. Measurement of upper operating position (height)
should be measured above metallised carbon strip, pantograph in locked down
position.

1.3 Mechanical Equipments:

1.3.1 Wheel Sets (TAO/HITACHI)

SN Reliability Action Plan

1. Implementation of RDSO/ELRS /SMIs during overhauling and wheel, axle
box, MSU & other bogie equalizer. SMI/183 (Tightness of suspension tube
fixation bolt), SMI/207 (Main dimension check of suspension tube of fixation
bolt), SMI/216 (Maint. Practice Sch., Do’s & don’ts to be followed for Axle box
assembly of WAP-1/4 & WAG-7, SMI/217 (Remedial measure to arrest failure
of MSU of Hitachi TM), SMI/221 (Maint. Practice during TOH sch. of MSU of
Hitachi TM)
2. The diameter of front & rear racers/racer seatsto be recorded in two
perpendicular directions before dispatching and after receipt of the wheel sets
to & from workshops, to identify any swelling during Rediscing.
3. Induction heater to be used for fitment/removal of racers.
4. All dimensions of axle boxes to be ensured and recorded as per RDSO (SMI

Page 26 of 48
 216).
5. Ultrasonic test of Axles to be done during axle overhauling & IC inspection. In
no case the time interval for ultrasonic testing of locomotives axles should be
more than 12 months.
6. Wheel gauge to be measured during every IC/TOH/IOH and during axle
changing.
7. RDPT of bull gear to be done in TOH/IOH.
8. Wheel gauge to be measured in every IC schedule as per RDSO/MP-MI-90/80-
1993
9. Locos whenever visited shed to be checked for wheel skidding.
10. Distance between axle collars of wheel to be ensured as 915 mm.
11. Ellen screws to be provided on split gear plain sleeve
Suspension bearings during TOH to avoid loosening on run.
12. Fixing of Gear case should be done in such a way that it touches TM collar
without any tension to avoid crack in TM collar/Gear case.
13. Non gear end cover bolts are to be replaced with bolt & nut arrangement to
avoid dropping of adjustment washer.
14. Pressure pipe line for greasing MSU/Axle box should have air dryer. Before
releasing the pressure, water should be drained out.
15. TM fixing bolt (M36 x 110) to be tightened with torque wrench at 140 kg M
torque & thread locking compound to be provided during TOH/IOH/
unscheduled lifting.
16. Measurement of Longitudinal and Lateral clearance after lowering of bogie to
be taken & corrected as per requirement.
17. Clearance of 0.2 to 0.5 mm to be confirmed in between outer thrust collar &
outer distance piece.
18. Welding of liner to be continuous type instead of tag welding with Mn.
Electrode.
19. Before fitment of TM, MSU to be rotated manually for free movement checking.
20. Checking of Allen screw tightness to be ensured during major schedule and
during axle changing.
21. Checking of bull gear after thorough cleaning during major schedule.
22. Either double check nut or loctite to be provided after adjustment of brake
cylinder piston to keep intactness of BC piston.
23. Final checking and adjustment of piston travel after loco movement to be
done.
24. ‘P’ & ‘K’ value of bull gear to be checked during changing of TM and
overhauling of wheel sets.
25. Welding work with proper earthing to be ensured strictly.
26. After Wheel Re-Profiling (WPR), checking of wheel profile with master gauge to
be done and record to be maintained.
27. Use of snap gauge for measurement of Racer journal dia and swell of journal.

Page 27 of 48
1.3.2 Loco Body & Bogie
SN Reliability Action Plan
1. Readjustment of sander pipe nozzle height fitted on WAG7 loco. (SMI-215)
2. Provision of stopper plate for preventing falling off of centre pivot assembly of
CO-CO high adhesion bogie. (MS-1)
3. Removal of side stops from existing 4 Nos per bogie to 2 Nos per bogie.
(MS-6)
4. Side stopper arrangement in lieu of tie bar arrangement for WAG-7, WCAM-3
& WCAG-1 class of locomotives. (MS-281)
5. Modification in the arm of friction piston device in cast steel bolster of
WAP1/WAP4 Electric Locomotives. (MS-354, Rev. 0)
6. Use & Maintenance/Fitment Practices of Equalizer & Compensating Beam
Pins, Bushes & Cotters in WAG-7 Locomotives. (SMI-264, Rev. 0)
7. Utilization of imported center pivot rubber bush in WAG-7 locomotives
provided with pivot pin having uniform dia of 246 mm.(MS-338)
8. Provision of sleeve on center pivot pin in WAG-7 locomotive. (MS-316)
9. Provision of modified equaliser compensating beam & links. (SMI-227)
10. Material for pins & bushes in the brake rigging.(TC-11)
11. Change in material of brake rigging components of flexi coil mark-1 bogies in
WAP-4. (TC-48 Rev '0')
12. Change in material of brake blocks for electric locomotives. (TC-49)
13. Critical geometry features of helical springs to be given special attention. (TC-
50)
14. Critical clearance in flexi coil mark-1 bogies in WAP-4. (TC-59)
15. Comprehensive guideline for improving wheel life. (TC-63)
16. Procedure for welding of centre pivot WAP4/7. (TC-74)
17. Instruction of colour coding of coil spring fitted on WAP-4 locomotive. (TC-75)
18. Electrode and welding procedure as recommended by RDSO to be followed (MC
— 44 dt. Aug. 01); CGS-680 x-upper electrode size 3.15 mm EAT make to be
used for Mn liner welding.
19. Washers to be provided on brake hangars of all WAP locomotives
during TOH/IOH.
20. A gap of 31.5 mm between outer brake pull rod & wheel and 21.5 mm between
inner brake pull rod & wheel to be maintained in all WAP locomotives.
21. Safety slings to be provided on outer brake hangers in WAP locomotives during
TOH/IOH.
22. Vertical play in WAP locomotives in between pin & bush of outer brake hanger
to be checked.
23. Modified guides as per RDSO latest Drg. No. SKEL-4559 ALT.'0' to be provided
along with nylon liners. MS-283.
24. Modified lightweight trunnion to be provided in WAP
locomotives (ELRS/MS/284 Rev. '0' 2000).
25. Sleeve to be used on inner brake hangars of WAP locomotives (ELRS/MS/285
Rev.'1' 2000).
26. Design of outer brake hanger and inner brake hanger have been modified as

Page 28 of 48
 per RDSO Modification No. ELRS /MS/0284, 0285 ,0286.
27. The vertical play of outer brake hanger to be checked during every scheduled
and it should not be more than 10 mm. in any case.
28. Adequate clearance to be maintained in connection strap (outer & inner) from
the wheel face to avoid its rubbing with wheels.
29. Manganese pins and bushes to be provided at outer brake hanger locations in
bogie & brake hanger as per RDSO recommendation.
30. Provision of modified slack adjuster upper.
31. Buffer length to be measured in IC/TOH/IOH to maintain a length of 615 to
635mm.
32. RDPT/Magnaflux of buffers to be done in every overhaul schedule.
33. Replacement of all welded bolsters in service, in a phased manner.
34. Repair of side bearer and center pivot showing crack/ breakage in the
weldments to be carried out by use of electrode and procedure as laid down by
RDSO (SMI 57).
35. RDPT of center pivot of WAP loco during TOH/IOH to be done.
36. Effective sealants (i.e. RTV or equivalent) for roof, elliptical glass, front glass
and round glass) to be used to prevent rainwater ingress inside loco.
37. All locos to be equipped with CBC operating handle during TOH/IOH and the
same to be checked for proper operation during any visit of the loco.
38. Ultimate vinyl to provide on WAP loco floor.
39. All WAP locos more than 10 years old to be surface refurbished,
in a phased manner.
40. DPT checking of knuckles and D shackles.
41. The alignment of brake hanger to be ensured.
42. All brake rigging must have locking plate on brake adjusting screw and to be
checked.
43. To avoid falling of liners, welding to be done on complete edge of liners with
manganese electrode.
44. Visual checking of bogie frame after cleaning to be done during Major
schedule.
45. RDPT and re-welding of Gear case breather to be done.
46. Clearance between bogie, loco body U-bracket and bolster to be ensured in
WAP4 locos during schedule inspection.
47. Bogie liners welding electrode to be preheated at 2500C-3000C temperature.

1.3.3 Loco Suspension

SN Reliability Action Plan

1. Spring seat and equalizer tiepin to be checked regularly and to be replaced if
found worn out beyond limits (SMI 194), during TOH/IOH.
2. Anti vibration pads on primary springs of WAP1 locomotives to arrest spring
failures, to be provided during TOH/IOH (RDSO letter No. S.V. WAP4 dt.
21.06.2000)
3. Thorough checking of PHS for tip thickness, surface

Page 29 of 48
 deformity and painting during TOH/IOH + new provision.
4. To reduce breakage of main shaft of SB oil pump, lightweight pinion machined
out of the existing pinion to be provided, during TOH/IOH.
(ELRS/MS/0313 )
5. Mating surfaces of magnet frame and SB head to be cleaned by
thinner/kerosene prior to application of adhesive, especially in those cases
where head has been dissembled after test run.
6. M12 bolt holes in axle caps to be got repaired from trade.
7. Replacement of oil pumps to be done on condition basis. Oil pumps are tested
for discharge in IC and overhauled in TOH/IOH.
8. The free rotational clearance between split gear and axle cap to be ensured in
every IC schedule to be 5 to 7 mm. SB to be changed if gap is less than 3mm
(SMI 7).
9. Tightening of axle cap bolts of TAO 659 TM to be done crosswise and with
torque value 121-145 kgm (SMI 205) during assembly.
10. Suspension tube bolts of TAO 659 and HS 15250A TMs to be tightened with a
torque wrench of 121 to 145 kgm (SMI 183) during assembly.
11. To make use of the lubricating oil for SB from the lowest available level in the
sump modified oil pump to be used (ELRS/MS/303 - 2000 Rev '0').
12. Matching of split gear & pinion to be ensured in IC.
13. All deformed magnet frames to be weeded out and got repaired through trade.
14. Procurement of fasteners should be of reliable make.
15. Measurement of backlash and ensuring it properly during OH and whole
TM/Wheel set changing

1.3.4 Other Mechanical

SN Reliability Action Plan

1. Only 60T screw couplings to be used. Testing & crack detection through RDPT
I Magnaflux in every TOH/IOH to be done.
2. Testing of loco brake power as per parameter given in RDSO SMI 197.
3. Measurement of backlash of traction motors. SMI-160
4. Main Dimensional Checks of suspension tube while mounting on magnet
frame of traction motor type HS. 15250A. SMI-207
5. Main Dimensional Checks of suspension tube while mounting on magnet
frame of traction motor type HS. 15250A. SMI-207
6. Tightness of enclosure ring fixed on main gear wheel of Hitachi Wheel Set.
SMI-229
7. Provision of stopper plate for preventing falling off of centre pivot assembly of
CO-CO high adhesive bogie. RDSO/WAG-7/11
8. Improvement in the performance of centre pivot rubber bush fitted in WAG-7
locos. RDSO/WAG-7/04
9. Apply Loctite 222 ANR 124 on the threaded portion of adjustment washer
fixation socket head cap screw 12X70. RDSO/WAM-4/167
10. Modification to gear case assembly of WAG7 Locomotive.MS/248

Page 30 of 48
11. Improvement in the performance of side bearer assembly fitted in WAG7
locomotives. MS/0277
12. Modification to the bottom plate of centre pivot pins on WAG-7 loco.MS/309
13. Fitment of lubricating pins for WAG7/ WCAM3/WCAG1 class of Electric
Locomotives as per MS-0331.
14. Utilization of imported center pivot rubber bush in WAG-7 locos provided with
pivot pin having uniform dia of 246mm as per MS 0338
15. Modification in TM suspension system for provision of additional L clamp &
split pin to prevent filing of vertical nose pin of TM type HS 15250A
RDSO/MS/0392
16. Screw couplings, which have long shackle above the nut surface to be weeded
out.
17. Checking of CBC operating handles in every visit of the locomotive as per
RDSO/ELRS/SMI/0213-99 Rev 0,
18. Checking of Knuckle nose wear in every IC as per
RDSO/ELRS/SMI/0213-99 Rev 0.
19. Working of CBC locking key to be ensured during every inspection schedule.
20. On gear case joint, through nut bolt system to be adopted instead of bolt.
21. Metallic felt to be provided in Hitachi gear case.
22. Modified sander bracket assembly to be provided to increase the height of
sander from rail level and to prevent it's falling on run, in all locos in every
schedule.
23. Sander bracket assembly along with sanding hose
connection to be intact. In case of all WAP loco the sander bracket should be
on double support.
24. Rubber sandwich of TMs to be replaced during TOH/IOH as per TC-29 Rev-1,
TC-31 Rev-1 Amendment-1, TC-123 Rev-0 amendment-2.
25. Maintenance of rubber sandwich unit to be done as per SMI 186.
26. All fasteners to be fitted at prescribed torque values (SMI 1).
27. To avoid theft cases of earthing assembly on HS 15250A TM, being non-
ferrous, modified earthing assembly to Drg. No. SKEL 4566 Rev. ‘1’ is provided
(ELRS/MS/300 Rev. ‘1’).
28. Ensure yoke pin support for any crack.
29. RDPT/Magna flux checking of D-shakles
30. Checking of TS coupling /CBC with RDSO specified set of Go-NO GO gauges.
31. Provision of top operated CBC operating handle in all locos as per RDSO MS
454.
32. Run testing of assembled TM to be done after adding cardium compound.
33. Monitoring of gear case oil level using dipstick while in and out of loco and
record maintenance to be done.

Page 31 of 48
 2. Reliability Action Plan
for
Three Phase Electric Locomotives

2.1 Electrical Equipments:

2.1.1 Traction Converter

SN Reliability Action Plan

1. Installation and implementation of testing set up of gate unit of Traction
Converter for 3-Phase electric locomotives. (RDSO/2010/EL/SMI/0263 ,
Rev.’0’ dtd.27.07.2010)
2. Replacement of ECSX make 24 MHz crystals by FOX make crystals in
electronic cards of three phase electric locomotives (MS no.
RDSO/2010/EL/MS/0391 (Rev.0), Dated 04.02.2011) PPA 988, PPB471 &
PPB622.
3. Installation and implementation test set up for SAP cards and sensors (SMI
260).
4. Checking of Gate Unit cards by measuring dBm level of QFBR-1478C
transmitter (component no.151). (RDSO/2009/EL/SMI/0257,dated 22.05.09)
5. Replacement of 1mW crystal of 24 MHz by Zauch make 0.5 mW in PPA988
cards and PPB622 cards (RDSO’s letter no. EL/11.5.5/5 dtd. 13.04.12).
6. Testing of URB512 D15 (Digital I/O Board Computer) and URB177 D15
(Digital I/O Board Computer) used in VCU & SR (SMI no.
RDSO/2013/El/SMI/0277, Rv. 0 Dated 02.01.14.
7. Improved Grounding of ALG rack in Traction Converter of 3phase electric
locomotives as per MS/365.
8. Checking of waveforms of gate unit of converter with the help of GUSET in
case of valve set failure / false alarm of GBC as per SMI-263.
9. Checking of gate unit GK cable, optic fibre cable losses, downloading of
software PPA 988 card in case of GTO failure.
10. Improvement of reliability of LWL cards (AFB635A01) and bus coupler cards
(UFB 660 A01 & UFB 701A01) of three phase locomotives by testing QFBR
1478 C and 2478C transmitter & receivers as per SMI/258.
11. Checking of valve set GTO values in MOH with multi-meter and in IOH
schedule with IC variable meter as per SMI-247.
12. The capacitance of combined DC link capacitor as well as combined resonant
capacitor should be measured in every TOH. In case of abnormal variance in
the combined capacitance value identify the faulty capacitor by measuring the
capacitance value of individual capacitor and change the capacitor accordingly
as per RDSO Letter No. EL/3.1.35/17 (BHEL) dt.16.12.16.
13. Draining of traction converter oil in GTO based loco and filtration of oil to be
done in TOH.
14. Calibration & Testing of Wandler module as per SMI 260.
15. (i) By PUs: Earthing of screening of TM temperature sensors to avoid

Page 32 of 48
 spurious message of “Error PS hardware” (MS-347)
(ii) By Shed: Earthing of temp sensor shielding with end-bell at both ends.
16. Dust removal from Machine Room by Industrial Vacuum Cleaner in each
schedule.
17. Repair and maintenance instructions of GTO valve sets as per RDSO Technical
report No. RDSO/2016/EL/IR/0176(Rev’0’), Oct’2016.
18. No valve set should be kept without oil either in the locomotive or as a spare
unit.
19. SR oil DGA, BDV checking in IA, IB, IC & major schedules as per SMI No.138,
158.
20. Modification in cooling circuit of M/s BHEL make IGBT based traction
converter to prevent air locking, spillage of coolant and fluctuating in coolant
level as per RDSO/MS 457 Rev'0' dt:12.01.17.
21. Working of churning fans of traction converter, Aux converter and VCU
electronics racks to be ensured in every schedule.

2.1.2 Auxiliary Converter

SN Reliability Action Plan

1. Shifting of MCB-100 from BUR-III to HB-2 panel.
(RDSO/2008/EL/MS/0367/Rev.‘0’ dated-29.08.08.
2. Knife contactor (female) position on its base plate in WRE module (1, 2, 3 & 4)
and (3, 4, 5 & 6) in GG modules to be ensured (RDSO RAP Rev’10 May’14).
3. Modification to address failures of Auxiliary converter cards. (MS no.
RDSO/2010/EL/MS/0389 (Rev.0), Dated 22.11.2010).Vide RDSO’s letter no.
EL/11.5.5/5 dtd. 12.04.12 the MS is to be read as RDSO/2010/EL/MS/0393
(Rev.0)
4. Replacement of 1mW crystal of 24 MHz by Jauch make 0.5 mW in PPB 471
cards having intermittent message (RDSO’s letter no. EL/11.5.5/5 dtd.
21.08.12).
5. Replacement of 1mW crystal of 24 MHz by Jauch make 0.5 mW in all PPB 471
cards having indigenized BAP ASIC during major schedule or whenever card is
taken out (RDSO’s letter no. EL/11.5.5/5 dtd. 26.03.13).
6. KUC153 card should be checked for leaky electrolytic capacitors after 5 years
of operational life and capacitors should be replaced if found leaky. 100%
replacement of electrolytic capacitor of BUR power supply card (KUC 153) after
completion of 6 years operational life.
7. Tightness of the tap connection in the transformer of battery charger in
Auxiliary Converter – 3 of GTO based locos in every IC schedule.
8. Interchanging of BUR2 GG and WRE modules with BUR1 and BUR3 to
enhance life of modules during major schedule.
9. Provision of CG71 grease to male and female contacts to enhance life of
contacts of WRE and GG modules of BURs.
10. Measuring the capacitance values of BUR DC link capacitors to detect
defective capacitors during IC/major schedules. (MOM of Aug’14 failure
meeting)
11. Repairing & testing of WRE module of BUR for 3-Phase electric locomotives as

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 per RDSO/2009/EL/SMI/0261 Rev. 0 dated 15.12.09.
12. Modification to address failures of DC link capacitors of 3x100 KVA, GTO
based auxiliary converter as per RDSO MS-436 Dt. 11.07.14.

13. Modification in Aux. converter of 3 Phase Electric locos to improve reliability as

per RDSO MS No. 372.
14. Pulse transformer has to be checked in the failed GG module.
15. Checking of waveform of WRE gate card of Aux converter as per RDSO SMI No.
256 dt 19.05.09.
16. Replacement of Knife contacts of BUR 2 GG module during IOH.

2.1.3 Sensors

SN Reliability Action Plan

1. Pre-testing of speed sensor as per SMI-252.
2. Pre-testing of temperature sensors, pressure sensor, current sensor and
Wandler module on interconnected bus station as per SMI-260.
3. Pre-testing of Master Controller as per TC-134.
4. Ensure proper crimping of temperature measurement cable with temperature
sensor resistance element cable inside Aluminium ferrule & its covering with
heat shrinkable sleeve during TOH/IOH or change of temperature sensor.
5. Ensuring proper shielding of TFP/SR/TM temperature sensors cables at SR
rack.

2.1.4 HOG

SN Reliability Action Plan

1. SMI for Operational, Maintenance and Trouble shooting of 2x500 kVA, IGBT
based hotel load converter (SMI No. RDSO/2016/EL/SMI/0297, Rev. ‘0’)
2. Technical Circular for ‘Trouble shooting of different make 2x500 kVA, IGBT
based Hotel Load Converter of WAP-7 locomotives (TC No.
RDSO/2017/EL/TC/0141, Rev. ‘0’).

2.1.5 Electronic Cards (Central Electronics)

SN Reliability Action Plan

1. Checking the tightness of screws of electronic cards in every schedule.

2. Check the condition of DC-DC Converter in suspected PPA988 Processor cards.
3. Fibre optic cable tip to be dipped in Acetone to remove the dust which scatters
the signal and may lead to communication failure. Alternatively a drop of
acetone may be added on lens cleaning paper which may be gently rubbed on
the connectors’ end of OFCs.
4. Checking of temperature sensor (thermostat) for Control electronics during IC0
and Calibration during major schedule.
5. Ensuring availability of earth shunt connection for all concerned equipment.
6. Ensuring proper shielding of TFP/SR/TM temperature sensors cables at SR
rack.

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 7. Use of 8 Amps rating reed relay as per RDSO letter no. EL/11.5.5/5 dtd.
28.12.12.
8. Avoiding low pressure zone above hood ventilator as per MS-304.
9. Measurement of dB level of output of fibre optic transmitters as per SMI-257.
10. Provision of cab redundancy in WAG9/9H and WAP7 as per MS/0429 and
MS/0435.
11. Provision of Modified cooling radiators for SR as per RDSO letter no.
EL/11.5.5/5 dt. 15.02.10.
12. Rehabilitation of PCB cards as per RDSO guideline no. ELG/2008/01, Rev. ‘1’
dated 13.08.09.
13. Availability of Loco Diagnostic System (LDS).
14. Dedicated computer system for storage of DDS and PCB database: All the
sheds holding 3-Phase locomotives to have dedicated computers for the storage
of DDS and PCB History with connectivity to Railnet.
15. Availability of setup of Interconnected Electronic Bus Stations as per TC/134.
16. Standardization of electronic labs infrastructure as per TC/135
17. Implementation of TC/091 to ensure the proper handling and upkeepment of
PCB cards.
18. Identification and replacement of PCB cards with the leaky capacitors.
19. Repeated failed card (3 or more than 3 times) to be removed from system and
should be planned for repair/rehabilitation. Bad history card should not be put
in service.
20. Ensuring proper cleaning of heat sinks of VCU, SR and BUR in MOH/IOH.
21. Checking of condition of churning fans in SR, BUR and VCU in every schedule.

2.1.6 Software & other measures

SN Reliability Action Plan

1. Removal of interlocks of control ckt contactor no.126 from MCPA ckt.
RDSO/2011/EL/MS/0399 Rev ‘0’ dated 9.8.11.
2. Modification for avoiding necessity of cab changing in case of failure of
processor cards of VCU of WAP7 (MS no. RDSO/2014/EL/MS/0435 Rev.0
dated 06.06.2014)
3. Blocking of leak holes in the machine room.
4. Provision of the rehabilitated URB 512 cards on critical circuits to take
advantage of the 2 NO interlocks on such cards.
5. Loco software downloading: The loco software, other than the minimum
software, should be downloaded only with the help of LDS instead of EPROM
writer.
6. During re-downloading of the software, apart from *.hex code of the concerned
processor *.chk/*.os file of concerned processor will also be downloaded in the
card through LDS. Downloading only of application software may not be
helpful.
7. Replacement of EPROM in the processor cards of CEL, BUR and SR racks of
three phase locomotives after 6 years of operational life as per ToT guidelines.
8. Checking the working of the churning fan of electronic racks during every
schedule inspection & unscheduled visit.

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 9. Checking the working of DC-DC (48V) converter during every equipment
temperature high case to ensure working of cooling fans.
10. Checking of crystal in processor cards in case of life sign missing messages.

2.1.7 Flasher Light, Head light & Marker Lights

SN Reliability Action Plan

1. Modification in control circuit of Flasher light & Headlight of 3-phase electric
locomotives.(RDSO/2008/EL/MS/0357 Rev 0 dated 20.02.08)
2. Modification to be carried out to ensure the working of marker lights even if BL
is in de-activated condition and Battery MCB (110) in off through battery
supply for dead engine movement.(Disconnection of 2095 wire i.e. incoming
feed to 310.7 MCB and provision of loop from 110 MCB (2021) to marker light
MCB.( RDSO/2006/EL/MS/0344 Rev-0 dt.28.04.2006)
3. Modification to avoid simultaneous switching ON/OFF white and red marker
light in 3-Phase locomotives. (RDSO/2012/EL/MS/0411 Rev.’0’ dtd.5.6.12
4. Modification sheet for improving illumination of Head Light in Dimmer mode in
3-Phase electric locomotives (MS no. RDSO/2013/EL/MS/0425, (Rev. '0')
dated 22.05.13)
5. Improvement in the illumination of head light in dimmer mode(47 ohms, 250
watts resistor to be changed with 10 ohms , 250 watts resistor)
6. Focusing of head light bulb.

2.1.8 Cab AC

SN Reliability Action Plan

1. Ensure maintenance of CAB AC unit as per SMI No.
RDSO/2016/EL/SMI/0293 Rev-0 dated 29.07.2016.
2. Modification for providing dummy plate in cab roof in place of Air Conditioning
unit as per MS RDSO/2017/EL/MS/0461 (Rev 0)

2.1.9 Traction Motor

SN Reliability Action Plan

1. Implementation of modification sheet no. RDSO/2017/EL/MS/466 (Rev 0)
dated 15.11.2017 for modification in drawing of Outer bearing cap DE to
achieve adequate lateral thrust in Traction motor (TM) assembly of 6FRA6068
TM in WAG9/WAP7 class of locomotives.
2. Use of Bore Gauge for measurement of internal diameters of End Shield/
Racer during bearing fitment in traction motors for Electric Locomotives as per
SMI no. RDSO/2017/EL/SMI/0318 (Rev ‘0’) Dated 16.10.2017.
3. Use of Dial Snap Gauges for measurement of shaft diameter of traction motor
for Electric Locomotives as per SMI no. RDSO/2017/EL/SMI/0314 (Rev ‘0’)
Dated 29.9.2017.
4. Magnetic Particle Testing (MPT) of Traction motor (TM) nose stay in

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 conventional locomotives, TM suspension holder support and motor support in
WAG9/WAP7 locomotives and traction motor support arm in WAP5
locomotives as per SMI no. RDSO/2017/EL/SMI/0311 (Rev ‘0’) Dated
25.8.2017 .
5. Implementation of Modification sheet No. RDSO/2017/EL/MS/460 (Rev 0)
dated 12.6.2017 for modification in drawing of bearing cap NDE to achieve
adequate lateral thrust in Traction motor (TM) assembly of 6FRA6068 TM in
WAG9/ WAP7 class of locomotives.
6. Implementation of SMI no. RDSO/2017/EL/SMI/0307 (Rev ‘0’) Dated
5.6.2017 for periodicity & quantity of re-greasing in minor schedule in every
alternate schedule (i.e. Ist IB, 2nd IA, 2nd IC ) for Traction Motor (TM) type
6FRA6068.
7. Measurement of dimensions of various assembly components and ensuring
adequate interferences as per modification sheet no. RDSO/2017/EL/MS/415
Rev 0 Amendment 2 dated 18.5.2017 during replacement of TM bearings.
8. Use of Induction Heater for heating of Bearing seating area of Suspension tube
instead of flame heating for fitment of MSU Bearings in WAG-9/WAP-7
locomotives as per SMI no. RDSO/2016/EL/SMI/ 0306 (Rev ‘0’) Dated
17.04.2017.
9. Implementation of Modification sheet No. RDSO/2017/EL/MS/ 0456 (Rev ‘0’)
dated 09.01.2017 for modification in drawing of supporting ring to achieve
adequate ‘C’ Clearance in MSU assembly of 6FRA-6068 TM in WAG9/ WAP7
class of locomotives.
10. Implementation of Modification sheet No. RDSO/2016/EL/MS/ 0439 (Rev ‘0’)
dated 23.11.2016 for modification in drawing of Outer Bearing Cap (DE) to
drain out ingressed gear case oil from TM type 6FRA6068.
11. Use of Induction Heater for heating of End Shields/End frames of traction
motors for bearing fitment as per SMI no. RDSO/2016/EL/SMI/ 0301 (Rev ‘0’)
Dated 8.11.2016.
12. Following the periodicity of overhauling of MSU of WAG9/WAG9H/WAP7
locomotives to prevent premature MSU failures as per SMI no.
RDSO/2016/EL/SMI/ 0300 (Rev ‘0’) Dated 2.11.2016.
13. Maintenance of TM mounting arrangement for 6FRA6068 type traction motor
as per SMI no. RDSO/2011/EL/SMI/269 Rev 1 dated 16.03.2016 .
14. Implementation of Modification sheet no. RDSO/2015/EL/MS/443 (Rev 0)
dated 17.9.2015 for improving the reliability of Motor Support in Locomotives
type WAP7/WAG9.
15. Ensuring adequate radial clearance between resistance ring and end ring in
Scheme-II design of rotors for traction motor type 6FRA6068 as per
Modification sheet No. RDSO/2015/EL/MS/438 (Rev 0) dated 27.8.2015.
16. Ensuring proper fitment of traction motor bearings in 6FRA6068 TM following
the procedure specified in SMI no. RDSO/2013/EL/SMI/0278, (Rev. 0) dated
24.12.2013. Colour matching, measurement of dimensions of matching
components, use of ring gauge and plug gauge, measurement of pinion travel
etc. to done as per SMI.

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17. Implementation of SMI no. RDSO/2011/EL/SMI/ 0273 (Rev ‘0’) Dated
23.12.2011 for detection of rotation of outer racer of bearing and assembly
components by checking metal content in grease sample 3 Phase traction
motors type 6FRA6068 and 6FXA7059.
18. Implementation of SMI no. RDSO/2011/EL/SMI/ 0272 (Rev ‘0’) Dated
2.12.2011 for use of extreme pressure lubricant paste for shafting of rotors of
traction motors type 6FRA6068 and 6FXA7059 to prevent damage to
stampings and scoring of shafts at the time of removal of shaft
19. Ensuring availability of Grease outlet channel at NDE side of TM type 6FRA
6068 used in WAG-9 and WAP-7 locomotives as per Modification Sheet No.
RDSO/2010/EL/MS/0387 dated 7.7.10
20. Implementation of Technical circular no. RDSO/2010/EL/TC/104 (Rev. 0)
dated 16.7.2010 for storage & handling of lubricant/greases used in Electric
locomotives. All barrels must be stored, preferably indoors; away from extreme
heat/cold, dust, acidic fumes and moist atmospheric conditions. Lubricating
oil barrels should be stored horizontally preferably on wooden rails dunnage to
avoid contact with ground. The barrel bungs should be in the clock position at
3 & 9. Grease barrels must be stored vertically preferably covered with
tarpaulin, if not stored indoors.
21. Detection of rotor bar crack & stator defect for traction motor type 6FRA6068
used on WAG9 / WAP7 locomotives as per SMI no. RDSO/2010/EL/SMI/262
(Rev 10) dated 10.06.2010 by measurement of inductance.
22. Implementation of Modification Sheet No. RDSO/2009/ELRS/MS/0373 Rev.
'1' Amendment 2 dt. 15.04.13 for Mounting Arrangement of Bellow for Traction
motor type 6FRA6068 of WAG9/WAP7 class of Electric Locomotives.
23. Implementation of Modification Sheet No. ELRS/MS/0355 Rev2 dated
18.11.2010 for provision of double support at connection end and single
support at non connection end of winding overhang.
24. Ensuring availability of proper size of TM cables in WAP-5 locos as per
Modification Sheet No. RDSO/2008/EL/MS/0370 dated 26.11.08.
25. Ensuring Modification in fixing arrangement of temperature sensor in TM type
6FRA6068 as per Modification Sheet No. RDSO/2007/EL/MS/350 Rev‘0’
dated 1.11.2007 to enable replacement of temperature sensor without lifting of
locomotive.
26. Modification of Drive End - Outer Labyrinth of WAG9/WAP7 Traction Motor
type 6FRA 6068 as per Modification Sheet No. ELRS/MS/314 dated
12.7.2002.
27. Condition monitoring of bearings by SPM Meter as per SMI no. RDSO/EL-
RS/SMI/58 of July 1979.
28. To follow the prescribed replacement schedule for traction motor bearings. 3-
phase traction motor bearing is must change item during IOH & POH.
29. Carrying out Growler test of rotor bars during overhauling to detect rotor bar
cracks .
30. Use of grease guns equipped with Grease dispensing meter to provide
prescribed quantity of grease.

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 31. Bearings should be handled with protective industrial gloves. Lint free cloth
should be used for cleaning purpose.
32. Use of induction heaters equipped with essential features like temperature
display, temperature hold, auto cut off & de-magnetization. Induction heating
should always be done in temperature mode as same/similar components of
different manufactures may have different properties. Temperature setting
should not be more than 1200C for bearing assembly components.
33. Storage of TM/MSU bearings in horizontal condition, away from wall/floor in a
stack of not more than 5 bearings and following First-In-First-Out (FIFO)
system for storage.
34. Ensuring 24 X 7 working of air conditioners provided in air conditioned
storage wards. Temperature and humidity indicators to be provided at the far
end of AC Storage ward.
35. Use of prescribed torque wrench for tightening of bolts etc.
36. Use of Cleaning agent Xylol-CHR (Chemically pure) cleaning agent as
prescribed in ABB manual (Volume D-2 Maintenance and Repair manual –
Indent No. 3EHW 411433 Page 7/60).
37. Area for blowing and cleaning activities should be separate from TM assembly
area.
38. Use of assembly components in kit form vide RDSO’s letter No. EL/3.2.172
dated 26.06.2007
39. Application of sealant in the terminal box of traction motor to avoid ingress of
dust

2.1.10 Control Circuit Cables

SN Reliability Action Plan

1. Cleaning of male and female contacts of blocking diode during every inspection
schedule.
2. Replacement of unapproved make of Fast-ON lugs used in paralleling of
auxiliary intact locks of EPCs in the past.
3. Re-routing of cables with Fast-ON lugs to avoid tension in the connection.
4. During testing, the working of non-tripping VCB after tripping the MCB112 is
being ensured.
5. Provision of insulating paper between electrical connections and cover of VCD
paddle switch.
6. Provision of HRC fuse in PT circuit of SB-2 panel.

2.1.11 HT/LT Cables/Contactors/Relays

SN Reliability Action Plan

1. Replacement of 10mm2cable of OCB with 16mm2
2. Replacement of 120mm2 cable of traction motor in WAP5 loco with 150mm2
cable.
3. Measurement of cable continuity for all four earthing brushes during every

Page 39 of 48
 schedule.
4. Paralleling of interlocks of EP contactors and relays to improve the reliability of
three phase locos (RDSO/2010/EL/MS/0390 Rev.0)
5. Modification in loco ckt for multiple unit operation for microprocessor based
control and fault diagnostic system of 25 KV AC electric locos.
RDSO/2010/EL/MS/0386 Rev ‘0’ dated 18.01.10.
6. Modification sheet for shifting the termination of 4GKW, 1.8kv, 70 Sq.mm.
RDSO/2011/EL/MS/0400 Rev ‘0’ dated 10.8.11
7. PT fuse modification as per RDSO/2009/EL/MS/0377 Rev ‘0’ dated 22.04.09
8. Modification sheet for shifting the termination of 4GKW, 1.8 kV, 70mm2 cables
and 2X2.5mm2 cables housed in lower portion of HB2 panel and provision of
SRBGF sheet (RDSO/2011/EL/MS/0400 Rev’0’ dtd.10.8.11.)
9. Standardisation of power selection switch position in flasher units provided in
three phase electric locomotives. (RDSO/2012/EL/MS/0407 Rev.’0’
dtd.29.02.2012)
10. Modification in blocking diode fixing arrangement as per MS-467 and one time
checking of blocking diode pins. Checking of blocking diode for any
slackness/looseness during every TOH.
11. Removal of shorting link provided at c-d terminal of over current relay (MS no.
RDSO/2014/EL/MS/0432 rev. 0 dated 12.03.2014)
12. Modification for relocation of each fault relays for Harmonic filter and Hotel
load along with its registers (MS no. RDSO/2014/EL/MS/0428 Rev. 0 dated
10.12.2013)
13. Maintenance of earthing system as per SMI/248.
14. Auto switching of machine room / corridor lights to avoid draining of batteries
in 3-phase electric locomotives (MS no. RDSO/2011/EL/MS/0403 Rev’0’ dtd.
30.11.11).
15. SMI for measurement of Millivolt drop of contactor no.218 & 126.SMI no.
RDSO/2012/EL/SMI/0275 Rev’0’ dtd 22.03.12.
16. Paralleling of auxiliary interlock of Filter Contactor 8.41 and Auxiliary
contactors (RDSO/2012/EL/MS/0413 Rev’0’dated 28.09.12)
17. Modification to provide rubber sealing gasket in master controller of 3-phase
locos. (MS no. RDSO/2012/EL/MS/0419 Rev.0 dated 20.12.12.
18. Modification Sheet to provide mechanical locking arrangement in Primary Over
Current relay. MS. No. RDSO/2013/EL/MS/0420, Rev.’0’ dated 23.01.13.

2.1.12 Auxiliary Motors

SN Reliability Action Plan

1. Replace MS impeller with Aluminum impeller. (Ref. CLW’s letter no
ELDD/3743/CRH dated 08/05/09. For OCB).
2. To provide water discharge outlet in TM Scavenge Blower on WAG9, WAP5 &
WAP7 class of locomotives.( Ref ELRS/MS/0328 Rev.’0’ dtd 29.10.03. For
SCTM).
3. Replacement of 10 mm2 cable type 4GKW-AX (cable no.1147,1148 & 1149) of

Page 40 of 48
 oil cooling unit with 16 mm2 cable type 4GKW-AX to improve the reliability of
three phase loco.(RDSO/2010/EL/MS/0395 Rev.0 dated 28.02.11)
4. Rewinding of all Aux. motors except MRB/SCMRB by Corona resistant wire
(ref. RDSO's letter no. EL/2.2.8/17 dated 14.08.08)
5. All new motors procurement except MRB/SCMRB for indigenous sources must
be with corona resistant wire only. (Ref. Amendment 32 spec no. E-10/3/09
(Motor)-Aug1997 issued vide EL/3.2.176/1 dated 28.01.2009.)
6. All new motors procurement except MRB/SCMRB for indigenous sources must
be with corona resistant wire only. (Ref. Amendment 32 spec no. E-10/3/09
(Motor)-Aug1997 issued vide EL/3.2.176/1 dated 28.01.2009.)
7. Measurement of current & bearing sound of machines during schedule
inspection.
8. RDPT of OCB impeller in 3-phase locomotives during TOH Schedule.

2.1.13 Transformer LOT 6500/7500kVA

SN Reliability Action Plan

1. Shifting of conservator from OCB dome to an independent stand provided
adjacent to OCB dome in 3-Ph drive locomotives as per RDSO Modification
Sheet No RDSO/2008/EL/MS/0360, Rev 1 , Jan,2011.
2. Replacement of phosphor bronze washers with spring steel conical M-30
Belleville washers in core coil clamping tie rod in 2019 series of BHEL make
transformer as per RDSO's letter no. EL/3.2.1/3-Phase dated 27.12.12.
3. Conduction of DGA on priority basis of AAW series (16 TFPs) and AAU series
(28 TFPs) and taking up the matter with ABB for their rectification as RDSO's
letter no. EL/3.2.1/3-Phase dated 18.01.2013.
4. Implementation of Minutes of Meeting (MOM) dated 11.06.2014 circulated vide
letter no. EL/3.2.1/3-Phase dated 27.06.2014 for preventing circulating
current in transformer.

2.1.14 VCB
SN Reliability Action Plan
1. Up-gradation/conversion/modification of single bottle VCB type BVAC 25.10
of M/s AAL. Railway Board’s letter No. 2007/Elect./ (TRS)/441/10 dt.
06.02.08.
2. Replacement of metallic corrugated steel pipe/outside steel braided flexible
pipe by flexible reinforced rubber pipe connected in between VCB and Air drier
and main air pipe line to Air drier. (ELRS/MS/0340(Rev.‘0’) dt. 29.06.05).
3. Modification in BT make VCBs supplied after Dec, 2007. RDSO’s letter No.
EL/3.2.61/BT dt. 30.07.2009.
4. “Up-gradation/modification of single bottle VCBs type BVAC 25.10(old version)
and BVAC 25.10 MO7 (old) of M/s BTIL to BVAC 25.10 MO7 (New) as per
Railway Board’s letter no. 2007/Elect (TRS)/441/10 dtd. 3.5.10.
5. Implementation of modification No. RDSO/2006/EL/MS/0345, Rev’0’ dt.
08.05.06 for interchangeability of VCBs between 3-phsae locos & conventional

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 locos.
6. Development of maintenance infrastructure in sheds/workshops (Letter No.
EL/3.2.61 dated 24.02.12)
7. Replacement of defective auxiliary switches and suspected CMDEs (with 12
terminals) by corrected auxiliary switches and modified CMDEs (with 14
terminals) (Letter No. EL/3.2.61/BT dated 30.12.11)

2.2 Pneumatic Equipments & Brake Systems

2.2.1 Air Dryer

SN Reliability Action Plan

1. Provision of 3 A MCB (128.1) in Air Dryer circuit of three phase locos as per
modification sheet no. RDSO/2009/EL/MS/0375 Rev ‘1’ dated 28.09.12 to be
followed.
2. Replacement of existing PCBs of air dryer to modified (opto coupler) PCBs in
M/s FTIL make air dryer to avoid failure as per RDSO letter no SD.DFM.A
4.7.1.3 dated 13.02.09
3. Procedure to be followed for Dew point Depression temperature measurement
of compressed air passing through heat less regenerative twin tower type air
dryer is being used in electric locomotives as per TC139.

2.2.2 Compressor

SN Reliability Action Plan

1. Changing the orientation of suction filter in ELGI compressor wherever
applicable in old design compressor. (RDSO/ ELRS / MS/0352 dtd 07.01.08).
2. Changing of CP delivery pipe in ELGI make type RR20100 by SAE-100 –R 1
pipe. (Ref: RAP circulated vide RDSO’s letter no. EL/3.1.35/10 dated
16.12.2011 at Serial no.12 page 16)
3. Maintenance Practices of Under slung Compressor mounted on WAP-5, WAP-7
& WAG-9 class of Electric Locomotive to avoid falling down of the compressor
unit on line. Standardization of safety sling arrangement of under slung
compressor mounted on WAP-5, WAP-7 & WAG-9 class of Electric Locomotive
as per RDSO SMI No. RDSO/2006/EL/SMI/0242 Rev. ‘1’ dated 03.5.2016.
4. Modification for MCP control circuit (MS no. RDSO/2014/EL/MS/0427 Rev. 0
dated 23.10.2013
5. Standardization of scheduled maintenance practices for 1750 lpm capacity
lubricated reciprocating compressors for Electric Locomotives. SMI NO.
RDSO/2016/EL/SMI/,0296 Rev.‘0’ Dated 02.09.2016.
6. Replacement of mounting bracket on compressor side of air compressor model
RR20100 CG (M) by M/s ELGI in under slung. (Vide RDSO’s letter no.
EL/3.2.15/3-Phase dated 11.08.2014)
7. Provision of clamp with rubber on copper pipe from HP head to after cooler in
compressor model RR20100 M under slung mounting in 3-phase electric
locomotives by M/s ELGI. (Vide RDSO’s letter no. EL/3.2.15/3-phase dated

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 19.06.2015.)

2.2.3 E-70 (FTRTIL)

SN Reliability Action Plan

1. Provision of imported potentiometer in place of Pankaj make potentiometer in
DBC (A9) to be followed.
2. Replacement of Teflon nut on isolator assembly on C3W manifold.
3. Changing of the stem of restricting valve assembly of E–70 control unit.
4. Imported sleeve/ Imported EP-Valve to be provided in all EP valve of E-70
brake system.
5. Replacement of Metal seated NRV by PU seated NRV provided after compressor
(Ref-RDSO’s letter no EL/3.2.19/3-Phase dated 11.09.2012)
6. Provision of isolating cock for unloader valves (12) in E-70 brake system as per
RDSO’s Modification Sheet No. RDSO/2012/EL/MS/0412 Rev. ‘0’ dated
22.08.2012
7. Replacement of existing PRVs of polycarbonate body by high flow pressure
limiting valve of metallic body in E-70 brake system during IOH & POH or
whenever defective PRV is to be replaced. (Ref. RDSO letter no. EL/3.2.19/3-
Phase dated 14.06.13.
8. Replacement of defective plunger of Driver’s Brake valve in M/s FTIL make.
9. Rehabilitation of those E-70 tri-plate panels which have completed 9 years and
not have been rehabilitated during POH of the locomotive.

2.2.4 CCB (Knorr)

SN Reliability Action Plan

1. One cycle replacement of Lead-trail function selector switch in all locomotives
having CCB version 1.5.
2. Provision of BP feed back during banking operation has been done through
ZBAN switch in all units.
3. Modification to protect water entry in EBV (A-9) (to be done with the help of
M/s KBIL).
4. Software modification to remove interlock of parking brake with BP reduction/
charging.
5. Installation of upgraded software in WAG9 locos with existing choke and in
WAP7 with choke size 6.5 mm to reduce the brake application time through
SA9. (RDSO letter no. EL/3.2.19/3-phase/CCB dated 20.06.2017)
6. Installation of upgraded software in WAP5 to reduce booting time from 40-
60sec to 20 seconds.
7. BPCP strainer provision to be done and cleaning of strainer to be ensured
during every schedule.
8. Provision of new type Unloader valves of KBIL to be ensured.
9. Provision of moisture drains arrangement of auxiliary reservoir using Cu pipe
and drain-cock from test point of panel.

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 10. Provision of Trap Chamber for collecting coal/dust particles coming from BP
Train Pipe during emergency brake application as per MS 0465.
Replacing KBIL make ‘NB-11 valve’ (size 01”) of CCB system with FTRTIL make
‘Emergency Exhaust valve’ (size 11/4”) of E-70 system or similar design
Emergency exhaust valve as per MS 0465.

2.2.5 E-70 Brake Electronics

SN Reliability Action Plan

1. Provision of spacer and insulation strip in indigenous cards/electronic rack
respectively to ensure interchangeability as per Report no 159 Annexure-12.
2. Change of Regulator L7805 with LM140 in VCD card.
3. Change of EC make electrolytic capacitors by Kemmet make in LPO card.
4. Change of EC make electrolytic capacitors by Kemmet make in Controller card.
5. Testing of electronic card on Test Rig as per SMI-298.
6. Refurbishment of electronic card as per SMI-298.

2.2.6 Brake System (E-70/CCB) & Pneumatics

SN Reliability Action Plan

1. Standard maintenance activities to be followed as per SMI-298.
2. Setting of MR pressure switch is being ensured to cut-in at 8.5 kg/cm2 and cut-
out at 10.5 kg/cm2.
3. Replacement of Metal seated NRV by Teflon seated NRV in compressor.
4. Overhauling of un-loader & NRV in every IC schedule.
5. Troubleshooting instructions for the loco pilots to be pasted in cabs of locos
equipped with CCB system.
6. Replacement of AFI gauge glass with 12mm thick polycarbonate.
7. Blowing of BP/FP pipelines by opening angle cocks on either ends after building
complete pressure once in every schedule as per MS-0465.
8. Overhauling of A9 in 3-phase locos during TOH/IOH/POH as per SMI-298
9. Replacement of old PVC pipe in the pneumatic gauges in those 3 –phase locos
which have completed more than 6 years in service.
10. Provision of Trap Chamber for collecting coal/dust particles coming from BP
Train Pipe during emergency brake application as per MS 0465
11. SMI-313 to be followed for pneumatic tube connection to electro pneumatic
contactor of harmonic filter/hotel load convertor of 3-phase locos.
12. To address the issue of S/R interlock loco brake , the BC pressure switch (IBS-
PS & both BC-PS) setting lower limit existing 0.2±0.1kg/cm2 to 0.30kg/cm2 to
be ensured. Now the standard setting will be from 0.30 kg/cm2 to 0.65kg/cm2.

2.3 Mechanical Equipments

2.3.1 Traction link, housing and related items

SN Reliability Action Plan

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 1. Provision of modified traction link flange & mounting bolts in WAG-9 & WAP-7
3-Phase loco. RDSO/2006/EL/SMI/241 dated 24.10.06 &
RDSO/2009/EL/SMI/0259 dated 09.12.09
2. One cycle DPT of traction bar (Letter No. EL/3.1.35/2 (3-phase) dated
17.09.12)
3. Modification sheet of Bogie isolation rotary switch (SCH.POS.154 Cutout
switch) MS no. RDSO/2013/EL/MS/0426, (Rev. '0') dated 18.07.13.
4. Provision of modified support as per MS -443.

2.3.2 Bogie

SN Reliability Action Plan

1. Zonal Railways/PUs have been advised vide letter no. EL/3.1.35/2 (3-phase)
dated 31.3.11 that in WAP-7 locomotives only imported hydraulic dampers
should be used. For WAG-9 locomotives indigenous/imported dampers will
continue to be used.
2. Modification of brake assembly of WAP7 Electric Locos, as per RDSO
Modification Sheet No. RDSO/2008/EL/MS/0369(Rev. ‘0’) dated: 04/11/2008

3. Fitment of Tie-Bars in WAP7 locomotives (Letter No. EL/3.1.35/2 (3-phase)

dated 10.01.12)
4. Modification in brake hanger mounting bracket (Holder & Support) of
WAP7/WAG9 locomotive (RDSO/2011/EL/MS/0396 Rev’0’ dated 17.10.11)
5. Use of all FS locknuts (Report RDSO/2011/EL/IR/0150 Rev’0’ of Aug’12)
6. Use of safety device as an emergency support to prevent falling of aluminum
gear case in WAP-5 class of electric locomotives, during run in the event of
breakage of its mounting lug (of aluminum gear case) due to sudden impulse
loading (MS no. RDSO/2013/EL/MS/0424 (Rev. 0) dated 21.03.13)
7. Ensure availability of safety slings for traction bar, traction motors, brake
hanger, TBU & PBU and Tie bars.
8. Check the bogie frame visually for any cracks particularly at under mentioned
locations during all schedules and by way of doing RDPT/MPT test during all
schedules.
 At Traction Link pivot post welding portion on both body side&
bogie side. On bogie side frame welding portion also to be tested.
 At axle guide fixing post.
 All brake hanger fixing brackets.
 Damper fixing Brackets welding portion.
 Torque arm supporting brackets MPT to be done.
9. Check for any cracks on TM supporting brackets & at curvatures portion by
way of doing MPT till the modification is completed.
10. Ensure quantity and schedule of greasing of axle box bearing for
WAP7/WAG9/WAG9H locos as per RDSO SMI No. 246 and grease samples to
be checked for metal content.
11. Checking of axle box rear ring for any loose/ breakage of bolts during every

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 IC/MOH schedules.
12. Measurement of radial clearance during major schedules or during Axle Box
changing.
13. To detect the inner racer crack UST to be done in mounted position
14. Ensure intactness of earth brush assembly on axle boxes 1, 6, 7&12 and
ensure healthiness of three nos. Carbon brushes and its proper spring
pressure on each axle box with earthing assembly during MOH/IOH.
Replacement of springs on condition basis during IOH.
15. Ensure Intactness and tightness of traction bar flange fixing bolts during all
schedules. Ensure availability of safety slings at either ends of the traction link
and also additional safety sling.
16. 2.0 mm or more shim plate to be provided as per requirement in between pivot
head and the retaining plate of alcathan ring to avoid breakage of retaining
plate fixing bolts.
17. Check for any cracks by way of RDPT/MPT on Housing flanges & Push pull
rod flanges
18. Check the Elastic ‘V’’ ring for any bulging and shifting down.
19. Replace Traction link flange bolts during every Major schedule along with
steel lock nuts. And tighten to the torque of273NM
20. Check the Elastic ‘V’’ ring for any bulging and shifting down..
21. Replace all inner& outer retaining ring fixing bolts M12x35 mm with new and
8.8 Property Clause. Replace all locking plates fixing bolts & tighten the bolts
to the torque of 80 NM
22. Ensure maintenance of brake hangers for WAG9/WAG9H locomotives as per
RDSO SMI No. 251 Rev. 1 or latest.
23. In WAP7 locos, Provision of Head type pins in place of Headless pins on hanger
no 5, 6, 19 & 20.and provision of É’ type clamps for Brake hangers top
mounting pins head locking arrangement. All are Head type pin provided.
24. Closely observing the spheri-block for any cracks in every schedule. Axle guide
spheri-blocks to be replaced if rubber crack is more than 270 degrees. Torque
arm sphere-blocks to be replaced if rubber crack is more than 180 degrees.
Replacement of spheriblocs in TOH/IOH/POH as per RDSO letter no.
EL/3.1.25/16 dated 28.3.2017.
25. Provision of M/s KONI make imported dampers or M/s Knorr- Bremse make
Modified dampers in all WAP-7 locos
26. Ensuring of lateral play of MSU with in 1.0mm.
27. Checking of temperature of MSU’s bearings during all trip schedules, minor
and major schedules and ensuring temperature rise below 25°c above ambient
temp.
28. Testing of grease samples of MSU’s bearings at NDE side by Re-greasing of
NDE side MSU bearing till grease comes out from outlet.
29. Proper testing of primary and secondary helical springs as recommended by
OEM during IOH. Grouping of springs on the basis of loaded height and giving
colour codes.
30. Provision of happy pads on top & bottom of Secondary Helical Spring. No

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 happy pad being provided in 3 ph loco.
31. To avoid PHS breakages in WAG 9 locos, Provision and ensuring of 6mm thick
liners under end Axle Box Primary Helical Springs and 2mm thick liners under
middle Axle Box Primary Helical Springs.

2.3.3 Axle Box/Hurth Coupling/Alkthan Ring

SN Reliability Action Plan

1. Greasing of axle box bearing in WAP7/WAG9locos by removing loose lip
instead of grease nipple as per RDSO SMI 246.
2. Hurth coupling membrane is being replaced in TOH/IOH schedule.
3. Training to all staff regarding correct procedure for checking of leveling of
Hurth coupling.
4. Replacement of Alkthan ring of three phase locos in every alternate major
schedule (i.e. every 4 years)
5. Fitment procedure/Replacement schedule of Elastic ring as per RDSO SMI no.
RDSO/2017/EL/SMI/316 Rev ‘0’
6. Assembly of Aluminium gear case/Hurth coupling as per RDSO SMI no.
RDSO/2017/EL/SMI/309 Rev ‘0’
7. Maintenance of Hurth coupling in WAP-5 locomotive as per RDSO SMI no.
RDSO/2017/EL/SMI/310 Rev ‘0’

2.3.4 Radiators/Filters/Machine room

SN Reliability Action Plan

1. Cleaning of radiators with recommended water jet nozzle as per SMI-288.
2. Cleaning of Filter (MRB, TMB & OCB) and replacement of gasket in case of air
leakage/gap, if any as per SMI/287.
3. Setting of wheel diameter in the loco to avoid the wheel calibration error as per
RDSO letter No. EL/11.5.5/5/1/IGBT dated 23.05.2017.
4. Availability of Industrial type vacuum cleaner to ensure the machine room
cleaning in every schedule.
5. Improvement measures to maintain pressure in the machine room and make it
dust free as per RDSO guideline circulated vide letter no. EL/3.1.35/10 dated
11.04.16.
6. Assuring air delivery: Implementation of SMI/255 for Measurement of air
delivery at specified location.
7. Provision of inspection window on the side of filter cubicle.
(RDSO/2008/EL/MS/0366 Rev ‘0’ dated 29.08.08)

2.4 Others
SN Reliability Action Plan
1. Partial blocking of opening duct of back side of auxiliary converter of three
phase electric locomotives. (MS no. RDSO/2009/EL/MS/ 0385 (Rev.0), Dated
15.12.2009)

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 2. Modification sheet (No. RDSO l2OL4lELlMS/0434'Rev-O dated 28.03.2014) to
create low pressure zor.e above hood ventilator in order to make machine room
pressurized and free from dust to avoid failure of electronic cards in three
phase locos.

2.3.5 Harmonic filter

SN Reliabtlity Action Plan
1. Replacement of FB cubicle pneumatic pipes with double ferrule.
2. Replacement of FB cubicle pneumatic pipe in locos more than 6 years old.
J. Measurement of the capacitance values of Harmonic filter capacitors to detect
defective capacitors during major schedules. (Fire prevention measure) as per
RDSO Letter No. ELl3.1.35/2 (Elect.) dated 29.01.13.

(P.K.Saraswat)
Encl: Nil for Director General Std. /Electrical

Copy to:

1. Secretary (Electric Traction), Railway Board, Rail Bhawan, New Delhi- 110 001
(Kind Attn.: DEE (RS)/Railway Board)
t+fus (fr-gd), H N, l-o rr+q, =r$ ffi-ro oor
F{ePm fr-gd (4d {+n) d tlrdTod"T tg)
2. As per Standard Mailing List No. EL-M-4.2.3-19 Latest Revision.

':T16
(P.K.Saraswat)
Encl: Nil for Director General Std. /Electrical

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