NTPC LTD

Station ______________ M12 Half Yearly Sch Mechanical Page No.: 1/5
[WDM2 /WDG3A/ WDS6]

Loco No.: Class Date Taken Under Schedule

Upper Deck
Initial Testing (IT) Final Inspection
Date/ Shift
Name of
Technician
Signature
Customer Feed Back Bookings (Record repairs booked by driver)
Name of TCN / Remarks, if any &
SN Customer Feed Back Bookings Action Taken
Attended By Sign. of Super.

Engine FOP in Engine LOP in Kg/cm2 at Radiator Fan Engine BAP in Kg/cm2
Kg/cm2 operation Turbo type BAP
8th Notch Alco 350 C 1.0 – 1.3
Idle Alco 720 1.3 – 1.6
Idle 8 Notch
th
Std. Value 3.0 ± 0.5 [2.5 ± 0.2 5.5 ± 0.5 6.0 ± 0.5 ABB VTC 304 1.4 – 1.8
4.0± 0.5 3.5± 0.5
with LO cleaner] [WDS6/WDM2] [WDG3A] ABB VTC 304-13 1.6 – 2.2
GE 7S 1716 1.8 – 2.4
Driver Book
Final

Coolant Water Fuel Oil Lubricating Oil Radiator Air Maize Oil Level Cyclonic filter
Glow Sample Sample Sample Fan Rt. Rt. Lt. Lt.
Level Level Vacuum
Rod Report Report Report Operation Top Bot Top Bot
Std. Incoming Min. L.M & Between Add and 18” Water
Full Clear Suitable Suitable Suitable Outgoing High mark (max) Normal
Val. High Mark column (max)
IT
Final

Signature of Supervisor/ Engineer

 NTPC LTD
Station ______________ M12 Half Yearly Sch Mechanical Page No.: 2/5
[WDM2 /WDG3A/ WDS6]

Loco No.: Class Date Taken Under Schedule

TSC run down in sec LWS Function
Std. Alco 350C Alco 720 Napier ABB (both types) GE
Working
Value 80 – 120 90 – 180 30 – 70 65 – 200 20 (min)
IT
Final
Lube oil pressure drop Engine CC Vacuum OSTA RPM
(Engine not to be shut down) (inch of H2O column) WDG3A WDM2 WDS6
Std. 1.6 kg/cm2 2.0 kg/cm2 (min) [1.8 ± 0.2 kg/cm2 Min 0.5”
1200  20 1110–1160 1225 25
Value (min) at 93 oC with Lube oil cleaner] at 80 oC Idle 8th Notch
IT
Final
Traction Motor Blower
RTTM Blower FTTM
Belt Condition Belts Tension [Force/Deflection] From ECC side Blower
Installation: 18 mm deflection on 3 to 5 kg load (lower value load preferred)
Std. Values Normal In service: 20 mm deflection on 3 to 5 kg load (lower value load preferred) Normal
1 2 3 4 5 6
IT
Final
Tightness and wire sealing
Lube Oil Filter Lube Oil Strainer Water Drain MR Safety Valve Inter Cooler
Drain Cock Drain Cock Cock and Drain Cock Safety Valve
Std Values Tight and Sealed Tight and Sealed Tight and Sealed Tight and Sealed Tight and Sealed
IT
Final
Blow bye Test Readings [Standard Value Time for pressure 5 Kg/cm² to drop to Zero is 6 to 13 seconds or 4.5 to
1.2 kg/cm2 is maintained in the combustion chamber when inlet pressure is 5.0 kg/cm 2]
1 2 3 4 5 6 7 8
E/ Right
E/ Left

Miscellaneous/General
Check & attend during
Driver
Cleaning Monsoon season only Look out
Speedometer Fire Extinguisher Cabin
of loco Sander Sand Wiper Glass
Condition
Operation filling Operation
Std. Values Cleaned Working Full Working Clear Working Sealed Good
IT
Final
1. Check Working of Auto Flasher light
2. Check Working of Signal Overshoot device and corresponding Application of Brakes
SN Detail of Work/ Inspection Name of Technician Sign/ Remarks
I ENGINE BLOCK-I
1. Carry out Blow Bye Test and record.
2. Carry out CC Examination and fit overhauled explosion
covers.
3. Renew filter element & gasket of long life primary &

Signature of Supervisor/ Engineer

 NTPC LTD
Station ______________ M12 Half Yearly Sch Mechanical Page No.: 3/5
[WDM2 /WDG3A/ WDS6]

Loco No.: Class Date Taken Under Schedule

secondary fuel filter. Also get fuel tested from Laboratory
SN Detail of Work/ Inspection Name of Technician Sign/ Remarks
4. Renew filter element & gasket of fuel oil long life
filter (Primary & Secondary).
5. Remove fuel Cross-Over flexible pipe/Other fuel
flexible pipes and hydraulic hoses.
6. Clean LO Strainer Housing & it’s element and refit
7. Open & Pull Out all Injectors
8. Open CCE Motor joint & elbow
9. Change Carbody filters by cleaned filters
10. Open and remove Universal Shaft
11. Remove Engine over speed trip device (OSTA)
I. MAIN BEARING [Only WDG3A loco]
Inspect & renew Main Bearings No. 3 & 7 if necessary.
Reverse Elongation Make of Main Bearings
Location
Right Left Top Before Top After Bottom Before Bottom After
3
7
II. Replace CYCLONIC FILTER element
III. AIR MAIZE- I
1. Remove, clean all Air Maize Panels & change gaskets
2. Check Foundation & Mounting bolts for their tightness
IV. AIR MAIZE- II : Fit, tight and fill oil in all air maize panels.
Check Foundation and mounting bolts for tightness
V. Change Conventional After Cooler, its O-ring & gasket
VI. TURBO SUPER CHARGER
Remove & refit Alco 720 TSC in case WDM 2 loco & Alco 350 C
in case of WDS6 loco
VII. WATER PUMP
1. Remove water pump and send to QC PR
2. Collect & fit overhauled water pump.
VIII. WATER INLET ELBOW
Renew water inlet elbow water hoses
IX. ENGINE BLOCK-II
1 Check Valve Levers & Equalising Yokes
2 Check & adjust Tappet - Phasing
3 Fit overhauled Engine over speed trip device (OSTA)
4 Open and cleaned Cam Gear nozzle pipes and ensure
continuity of lube oil flow through them
5 Check wear of Torsion spring rack bar shaft & bearing assembly
6 Check & adjust Rack setting, Oil them
7 Clean all Injector seats, fit overhauled Injectors & Torque
them at 55 ft.lbs.
8 Fit CCE Motor joint & elbow
9 Carry out hot engine and note cooling time (max. 6
minute) from 85 - 65°C temperature drop on 4th Notch
Observed cooling time Minute

Signature of Supervisor/ Engineer

 NTPC LTD
Station ______________ M12 Half Yearly Sch Mechanical Page No.: 4/5
[WDM2 /WDG3A/ WDS6]

Loco No.: Class Date Taken Under Schedule

SN Detail of Work/ Inspection Name of Technician Sign/ Remarks

X. RTTM BLOWER
1. Check and adjust alignment of ‘V’ belts.
2. Check the condition and adjust alignment of belts. Measure
& record ‘V’ belts tension by belt tension gauge.
3. Change Right Angle Gear Box oil
XI. 1 Remove and fit overhauled Lube oil By-pass valve, Relief
and Regulating Valve
2 Fit overhauled Universal Shaft
3 Change Water Glow Rod
4 Centrifuge oil cleaner: Open filter bowls, remove dirt
deposits, clean with kerosene & re-assemble. Change ‘O’
rings & gasket of cut-off valve
5 Clean lube oil (LO) Filter Housing exterior, change paper
filters & filter ring, clean the sump, screen and replace sump
oil.
6 Fit tested/ new fuel Cross-Over flexible pipe/Other fuel
flexible pipes and hydraulic hoses

Write defects noticed and action taken against below in Non-Schedule repair table, Put () mark on the check box
(CB) against each item if the same has been checked.
SN Description CB
1 Loose, missing and broken component
2 Clamping condition and their welding
3 Colour of smoke TSC exhaust/ CCE Motor
4 Abnormal sound
5 Leakage in Exhaust Gas Passages
6 Overheated components
7 Condition and working of all pressure and vacuum gauges
8 Working of all brake valves
9 Leakage of air (MR)/ Vacuum
10 Condition of cyclonic filter indicator (if found red filters should be changed).
11 Working of Engine by
a) Checking firing of each injector
b) Hearing for rhythmic sound
12 Leakage of Fuel, Lube Oil, Water system
13 Gauges, securing of driver cabin
Date Remarks Name of Supervisor Sign

Signature of Supervisor/ Engineer

 NTPC LTD
Station ______________ M12 Half Yearly Sch Mechanical Page No.: 5/5
[WDM2 /WDG3A/ WDS6]

Loco No.: Class Date Taken Under Schedule

Record all Non-schedule repairs in the following table [If required add extra sheet(s)]
No. of sheet(s) added____
SN Work Done Name of TCN Work Balance Sup’s Sign

Engineer (Remarks if any & sign)

Note:
1. Checklist are common for WDM 2/ WDG3A/ WDS6 locos. Individual MGR workshop may prepare checklist for the loco
available with them on the basis of above checklist.
2. For standard values, refer enclosed data sheet of standard values (Mechanical) based on IR standards.

Signature of Supervisor/ Engineer