Maintainability of

Diesel Loco
Engine System
Complicated design of Engine
Water pump and lube oil pump changing very difficult

Right hand side Lub oil Aux. Header union and nut –
Very difficult to attend

Fuel inlet pipe and water inlet elbow – lot of skill

involved

Leakages from push rod grommet and aluminium

spacer – requires head changing

Lube oil from cylinder head exhaust elbow

Contd..
Suggestions for Improvement
Complicated design of Engine
Changing of camshaft – very difficult

Backlash checking of water pump and lube oil pump –

not possible in-situ.

Problem with out-board bearing – clearance checking

of out board bearing and camshaft, Oil leakage,
requires removal of alternator to attend out-board
bearing.

Opening of cam gear – some times snap ring comes

out, gear requires to cut out.

Erratic behavior of Mechanical OST – requires routine

maintenance and adjustment.
Suggestions for Improvement
Complicated piping and pipe joints

Lube oil cooler water outlet (bottom)

Victaulic joint.

Contd.
Complicated piping and pipe joints
Lube oil strainer outlet Armour joint.
Lube oil pipe Armour joint to regulating valve.

Contd.
Complicated piping and pipe joints

Lube oil Filter tank drain pipe dresser joint (3/4”)

under RTTM blower

Contd.
Complicated piping and pipe joints

Lube oil filter and strainer drain pipe jointing “T”

joint.

Contd.
Complicated piping and pipe joints
Lube main junction box to right side auxiliary
header union.

Suggestions for Improvement

 Cooling water System
Water pump - inside and outside bolts uncoupling and
fitting is very difficult
Water loss through pressurization cap and joints etc.
 Cooling water System
Problematic Radiator & Radiator drive
Problems with induced draft
Problematic drive of Radiator fan
through long shaft, ECC, Slip rings and
carbon brushes
Failure of radiator fan due to external
reasons
Excess power consumption
Requirement for greasing of universal
shaft and checking of gear box oil level
Suggestions for Improvement
 Cooling water System

Leakages through pressurization cap

Evaporation of water due to less

pressurized water system.

Suggestions for Improvement

 Vehicle and
Super structure
 Compressor/ Expressor
Carbon deposit requiring frequent attention of
valves.
Wear out of liner and piston ring requiring
replacement.
Oil throwing
High consumption of lub oil-Consumable sump
capacity very less
Piston ring seizure
Failure of Pistons/Liners
Heat Exchangers-Tube failures
Failure of the engine side oil seal in expressor
Valve adjustment by trial & error method
Suggestions for Improvement
 RTTM Blower
Problematic belt driven RTTM Blower
Six Belts to match
Tension of the belts
Alignments of pulleys
Variation of Belt tensions during service
No Clear cut guideline for checking Pulley grooves
Compressor alignment, and variation in alignment
during service
Frequent requirement of greasing of RTTM blower
bearing.
High ambient temperature in the vicinity of RTTM
blower.
Suggestions for Improvement
 Brake system
Too many valves requiring
maintenance
Complicated piping and their failure
proneness
Poor design of EMD type wind shied
wipers
Dusty and moist air in braking
system.
Efficiency of air dryer.
Suggestions for improvement
Weak areas for maintenance

No specific location for storage of

sand, provided on line.
Sand particles
get scattered in
the nose
compartment as
well as cab
room.
Results
malfunctioning
of valves and
contactors.
Weak areas for maintenance

Congested radiator Compartment.

Difficult for
inspection of
RTTM Blower.

Every chance to
damage to
radiators while
attending L.O.
filter.
Electrical System
Geared Traction transmission
system
Addition of cardium compound in
every schedule
Attention to gear box
Ingress of cardium to suspension
bearing.
Hardening of cardium compound
Auxiliary Motors
D.C. motors
Wear out of carbon brushes.
Failure of carbon brush holder and spring
AC Motors
Individual inverter for individual motors
Un-necessary space occupation, failure
multiplication, problem in fault diagnosis and
more maintenance work.
Oil and dust
Maintenance of other components becomes
difficult because of space occupied by inverters
Suggestions for Improvement
 Under slung battery box
Problem in maintenance
Battery changing difficult during pit
maintenance.
Safety aspect
 Control system
Too many contactors and interlocks
EMC = 15; EPC = 11 to be checked in
every schedule. (Power contactor design in
MEP locos may be changed)
Too many circuit breakers (18 nos or so) &
relays (non MEP = 23 Nos, MEP = 13 Nos)
Regular checking required
Location of some power contactors and
reverser (S31 & P31, Rev) – Insp. Difficult.
 Other Difficulties

Alternator Mounted Rectifier loco -

Checking of CCEM and governor
difficult
Conventional dynamic grid – requires
more maintenance
Vertical foundation of cyclonic blower
motor – difficult to maintain
Weak areas for maintenance

Sanding system
Ingress of water into the sand box.
Chocking of sand nozzles and sand
traps
Suggestions for Improvement
Separate drive for Water pump and lube oil
pump

Pipelines layout to be reviewed for a better

design. EMD type pipe joints.

Microprocessor based or electrically

controlled Integrated fuel injection system

Stiffer unit camshaft in all locos

Electronic OST in place of Mechanical OST

Complicated design of Engine
Suggestions for Improvement
Radiator drive may be converted to motor driven
to eliminate horizontal shaft, ECC.
Lighter radiator fan.
forced draft in place of induced draft for radiator
cooling.

Air cooled Lube oil cooler.

Pressurization level of water may raised upto 2.0

Kg/ cm2

Better and compact design of heat exchangers

Cooling water System
Suggestions for Improvement

Water cooled air compressor like

ELGI 66101W or equivalent may be
installed.
Indication for A/C lube oil pressure
and safety device.
OEM spares.
Improved design of A/C.

Compressor/ Expressor
Suggestions for Improvement

Problematic belt driven RTTM Blower

Motor driven in place of belt driven

RTTM Blower
Suggestions for improvement

Complicated brake system

Microprocessor controlled brake system
as in GM locos.

Brake system
Suggestions for Improvement

One single inverter in place of

multiple inverters.
One stand by arrangement may be
provided.

Auxiliary Motors
Spares of Proven Quality

Rubber Hoses
Gaskets
Equaliser lubricating pin
Thank you