WESTERN RAILWAY

No. W641/TMC/DGS-401/24-25 Office of Senior Section Engineer

Track Machine Organisation,
Vatva
Date:17.06.2024
To,
SSE/ZMC/VTA

Sub.: Works to be done along with POH of machine DGS-401 Machine

In connection to the above subject following work are required to be done along with POH of
DGS-401 machine (The machine has run for 16846.0 hours and the first & second POH has
not been done ) .For this reason details of repair has been prepared based on 2nd POH
condition of machine is too poor.

Engine details

Overhauled engine (S.R. No.25361225 was fitted on date: 22.05.2018 at E/H 9339.0. Present
E/H is 16846.0hours on dated 17.06.2024 .Total Engine runs E/H 7507.Hence ‘D’ check to
be done.

Engine

1. Overhaul or replace the engine on condition basis.

2. Overhaul/ replace the fuel injection/PT pump.
3. Overhaul the fuel injector
4. Overhaul the air compressor.
5. Overhaul the self-starter.
6. Overhaul the alternators.
7. Change anti-vibration mounting pad/rubber hoses of the engine.
8. Clean diesel tank.
9. Overhaul turbo charger.
10. Change all the high pressure fuel pipes, pipe clamps, flexible fuel hoses and rubber
hoses.
11. Change the shutdown valve.
12. Check engine safety system and do the needful.
13. Change all engine filters along with lube oil.
14. Clean cooling coil and unloader valve.

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 15. Replace water separator on condition basis.
16. Test air tank for rated pressure.
17. Change radiator.

POWER TRANSMISSION AND GEAR BOX

1. Check and top up oil of axle gear box, Drive intermediate shaft, ZF gear box, distribution
gear box and vibration gear box.
2. Lubricate both axle guides/Stabilizing unit rollers with grease.
3. Grease the vibration motor to vibration units couplings
4. Clean and oiling of work drive axle motor.
5. Check the axle bearing and grease them, change if required
6. Change mounting pad of all gear boxes.
7. Overhaul all the gear boxes except ZF-gear box.
8. Replace the cardon shaft or these may be overhauled with complete nut bolt
9. Replace the shaft coupling and holding lock nuts & bolts on condition basis
10. Overhaul the driving and idle bogies. Replace the defective parts.
11. Check the temperature of ZF gear box.

HYDRAULIC

1. Replace all the hydraulic hoses along with clamps.

2. Check all hydraulic pumps and motors on the test bench for rated output, replace if
required.
3. Check all hydraulic cylinders change if necessary.
4. Fill new oil after replacing all the hydraulic filters.
5. Clean hydraulic oil cooler.
6. Check all the direct acting and pilot operated direction valves and change if necessary
7. Check all the pressure control valves and change if necessary.
8. Check all the stop cocks and flow control valves and change if required.
9. Flush the complete system

PNEUMATIC

1. Change/overhaul all pneumatic valves.

2. Check all the pneumatic cylinders and change on condition basis.
3. Change all pneumatic hoses.
4. Replace air dryer assembly.
5. Change/overhaul Emergency brake system.
6. Check all Pneumatic pressure.

MECHANICAL

1. Change all the brake shoes.

2. Check brake cylinder bore for corrosion. If corroded, the inner bore should be chrome-
plated and ground to standard size
3. Strengthen the machine frame where cracks have developed
4. Check the wheels for any tyre defects. Reprofile or change if required.
5. Check tightness of the frame of stabilizing unit
6. Change stabilizing unit roller.
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 7. Check stabilizing unit guide column. Change if required
8. Change clamp pivot pins
9. Change link rods with their bearings.
10. Overhaul derailment protection mechanism.
11. Check chassis side members, cross frames, buffer beams and welded joints etc. If
damaged, it should be repaired.
12. Check bogie side frame, springs, shock absorbers, wheel’s torque supports, shackles,
brakes and rod linkage. If any damage is noticed, it should be changed
13. Replace all meggy springs.
14. Replace/overhaul all suspension mechanism (because m/c is taking jerk during driving
above 40 kmph )

ELECTRICAL

1. Overhaul/replaceand calibration of the pendulums and transducers .

2. Overhaul the panel boxes and provide thimbles as required.
3. Renew the complete wiring of the machine if existing wiring found more than 40%
damaged otherwise replace only the damaged circuits.
4. Check and replace the defective LED’s of solenoids if required
5. Replace the defective PCBs
6. Check the calibration of all the indicative instruments
7. Arrange insulation test of main cables and replace the defective ones.
8. Check all electrical and emergency switches and do the needful
9. Change all the defective switches and lights
10. Check the LED of all solenoids and replace if required
11. Replace all the limit switches
12. Restoration of safety brake system.
13. Replace gauge and display if required.

Running Gear and Wheels

1. Check the wheels for any tyre defects. Re-profile or change if required
2. Check the axle bearing and grease them. Change, if required.
3. Change mounting pads of all gearboxes
4. Overhaul all the gearboxes

GENERAL

1. Attend complete painting of the machine.

2. A glass of window need to change
3. AC is not working in working condition need to attend .

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Remaining work to be done as per Circular number REPORT NO. TM --90 of RDSO.

Note- All work has to be done as per RDSO list

Must change item replace as per must change list (Attached)

During POH, Machine Supervisor and POH Inspecting Authority jointly inspect the
Machine. Any part of Machine is to be repaired or replaced ,this final decision is to be
taken by POH Inspecting authority

****

Must Change Items during POH for DGS M/c (62 N)

Sr. No. Description Part No Qty. 2nd

POH
I Bearings
1 Bearing N2315 2 Change
2 Bearing 31312 8 Change

3 Bearing 31313 4 Change

4 Bearing 31315 8 Change

5 Bearing 32009 12 Change

6 Bearing 6209 2RSR 2 Change

7 Bearing 7212 2 Change

8 Bearing NU 2212 1 Change

9 Bearing NJ 2224 8 Change

10 Bearing NJP 2224 8 Change

11 Rocker bearing GE25DO 8 Change

12 Bearing NA6913 4 Change

13 Bush PM9090DX 16 Change

II Engine

1 New/Overhauled Cummins KTA- 1 Change

1150 L
2 Silencer (Muffler) - 1 Change

3 Set of Hoses with clamp for set 1 Change

Radiator

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 4 Elbow rubber 90 3873738(KCL) 2 Change

5 Elbow rubber 90 3030514(KCL) 1 Change

6 Air cleaner Outer & Inner 4055280 & 1 Change

Element 4055279
S.No. Description Part No Qty. 2nd
POH
III ELECTRICAL

1 Intercom speaker DR 4.29 2 Change

2 QL Relay ELT 7002/S4 15 Change

3 Micro fuse ELT 272/4A 25 Change

4 Proximity switch ELT 1422K 4 Change

5 Derailment sensor ELT 1151 Q 10 Change

6 All limit switches LL1/LL2 12 Change

7 All working lights - 12 Change

8 All Tail Lights - 4 Change

9 All head lights 24 VDC/70-75 W 6 Change

10 Electric horn - 2 Change

11 Cabin tube light - 4 Change

12 Drive shaft EL-T 1004.26-800 1 Change

13 NC/NO Cartridge - 40 Change

14 Indication bulbs - 20 Change

15 Transducer socket 90° - 2 Change

16 Pendulum socket EL-T7056S-6POL 02 Change

SUBSTITUTE EL-
T7056S
17 Chord wire 2 mm 50 Change

18 Encoder EL-T7055/7AF 1 Change

19 All cables Mtr. Change

20 self starter Lucas 1 Change

26024422,SM-
130-PE model
21 Alternator Bosch pt 2 Change
no.12069643

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 22 Batteries 12V/200AH 2 Change

23 Solenoid coupler 30 Change

ELT7078/7079
24 Speedometer sensor 2 Change
EL-T1263.00/120/B
25 Temperature Sensor 2 Change
232.011/017/017
S.No. Description Part No Qty. 2nd
POH
26 Pressure gauge Sensor 0-10 Bar 1 Change

27 Pressure gauge Sensor 0-25 Bar 1 Change

28 Tachometer EL T1263.00/120 2 Change

IV Hydraulics

A Pumps

1 System Pump HY 830-14-10 R e 1 Change

2 Drive Pump HY 704X90L/EL/A175 1 Change

3 Vibration Pump HY 704X71L/ 1 Change

EP4/A350
B Hyd Motors

1 Motor HY 916N 800 1 Change

2 Motor HY 916N 500 2 Change

3 Motor HY925N32 2 Change

4 Motor HY90N42 1 Change

5 Motor HY701N17Re 1 Change

6 Motor HY910x56 1 Change

C Hyd Cylinders
1 Seal sets set 1 Change

2 All pressure gauges to be replace 5

(i) Working System Pressure Gauge HY154.21 01

(ii) Hyd. oil temp. Gauge EL-T1200/0-100/B 01
Change
(iii) Pre Load Pressure gauge HY154.23 02
(iv) Charging Pressure gauge HY154.22 02
(v) Drive Pressure Gauge HY154.21 01
D Hyd. Filters
1 Hyd Filters HYS 501.360.150ES 1 Change
2 Hyd Filters HYR 501.330.10ES 1 Change

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 3 Hyd Filters HYD 501.225.25ES 1 Change

4 Hyd Filters HYS 501.160.P10ES 2 Change

5 Screw mesh filter FSB 25 M 3 Change

E Hyd Valves

1 All unloader/ relief / safety HY 511-22 1 Change

2 All unloader/ relief / safety HY 511-12 1 Change

S.No. Description Part No Qty 2nd

POH

F Hoses

1 All Hydraulic hoses - 1 Change

2 All Pneumatic hoses 6.3mm & 1 Change

12.5mm(set)
V General
1 Shock Absorbers WN 63.01 ZD 5.7KN 8 Change

2 Brake block WN 146.730.K3 8 Change

3 Cone bearing 571801313-50SH 8 Change

4 Torque arm plate UD 63.1051 2 Change

5 Bush MB 9060 DU 16 Change

6 Brake reversal spring MSW 100.1101.31 8 Change

7 Oil seal 85-105-13 2 Change

8 Oil seal 7 1/2 ZX8 1/2ZX 8 Change

3/4Z
9 Oil seal 195-220-13 8 Change

10 Oil seal 75-95-10 2 Change

11 Oil seal 100-115-9 8 Change

12 Wiper double arm assy. - 2 Change

13 Axle GLF311.804/GLF3 8 Change
11.847
14 Disc spring UD61.605.55SHORE 12 Change

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 15 Slide Plate UD61.402.PAS-LX 4 Change

16 Spring UD311.307 16 Change

17 Clamp Roller GLF311.810 4 Change

18 Meggie flex washer 741444 6 Change

S.No. Description Part No Qty 2nd

POH
19 Meggie flex washer 741401 4 Change

20 Damping disc E34.143AS 4 Change

21 Damping block GE15.76 4 Change

22 Silicon oil AK12500 Change

23 Rubber Gasket 15x6x6 8 Change

24 Nitrogen Gas - Change

25 Rubber Spring UD311.307 25 Change

26 Galze Bush MB4030DV 2 Change

27 Brake lever pin WN110.40h9.101 2 Change

M30X1
28 Damper Rubber 60x40M121/1- 4 Change
60SHORE
29 Meggie spring 732073.S6 16 Change

VI Pneumatic

1 Pn Cylinder PN 2ZK-F 50-18- 2 Change

70
2 Working Cylinder 90233 1 Change

3 ACC Cylinder WM 388 1 Change

4 ACC Valve WM 607 2 Change

5 Brake Cylinder seal 12(BGS 12"DS) 2 Change

6 Pn Regulator 90188 4 Change

7 4 Way valve 90254 2 Change

8 Air Oiler 90180 1 Change

9 Air Drier 90187/09 1 Change

10 Air Drier cartridge 434069202 Change

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 11 Water separator 90181 1 Change

12 Pn horn 162502 2 Change

13 Pn Valve 90362 1 Change

14 Pn Valve 90204 1 Change

S.No. Description Part No Qty 2nd

POH
15 Pn. valve 90344 12 Change

16 Pn. valve 90419 3 Change

17 Over flow valve 90247 2 Change

18 Air unloader valve 90201 1 Change

19 Pressure gauge 90283 2 Change

20 Pressure gauge 90284 2 Change

21 Cooling coil DL 90-37 1 Change

22 Seals of All Pn. cylinders tobe set 1 Change

replaced
23 Driver Brake Valve 90366 2 Change

24 Brake Valve 90370 2 Change

25 Clutch Cylinder 90233 1 Change

SSE/TMC/VTA

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