General Loco Inspection After Manufacturing

CMM machine AMC staff did not turn up in the morning. Terminal box connection process was inspected in the Shop # 23 today.

Loco 30049 WAP5 in the test and trial line was inspected, one of the operating rod was not working , same was reported to Dy.CME(ELF) .

Despite reminding in PPM there are movements without movement slips in from Shop #17 and 18.

Reports from shed:- Sr.DEE BRC informed that one of the 3 phase locos he received recently, valve set of traction converter has become defective, and same is being sought to be replaced with help of GZB shed.

Locos scheduled to be dispatched were inspected in the trial line .

Screws were not provided in the cab window fame which was reported to the production staff.

Due to some railnfall , there was water leakage in the mid-machine room. It was also shown to the production staff.

Report received from BRCY shed ( enclosed herewith) was discussed in the shop today alongwith inspection supervisors.

In addition to warranty failure, one problem reported was that of not locking of the gear case oil guage cover.

All gear cases were having cover on the oil guage.

Recently one gear case of KMRI was M-13ed by WM , hence some gearcases available in the shop were inspected from oil leakage point of view.

Making of Traction Motor

Machining of three phase TM shaft was inspected today in the shop.

Two items are received in TM shop from steel foundry as small foundry. Both of these are among

70 off loaded to trade.

Machining of commutator spider was inspected. It was seen there were lot of surface defects in the spider hub.

Hitachi Commutator Manufacturing

Audit of TM Shop #23 Work Instructions was started. Following WIs were audited :-

Stacking of Hitachi Commutator ( W23.027):-

Points noticed:-

• Triclorothylene solvent which is used to clean copper segments was checked for expiry date ( Mfd in 2008).

• 
  Jigs INJ-33 , INJ-34, INJ -106 were being sent for calibration.

• Instruction no 3.8 was not being followed ( use of the triangular block and 0.5 mm guage).

Static Pressing of Hitachi Commutator After Stacking (W23.028)
Points noticed:-

• Pressing Jig HITA/COM/6 was being sent for calibration.
• No of heating –cooling cycles and its duration (6hrs) could not be maintained as per instruction no 3.1
• 
  Alkyd varnish WI-294 was checked for expiry date.

• Production staff was made conversant with the steps to be followed in this WI.
• Gauges used for checking inner dia were sent for calibration.

Inner Dia was checked in the recently made commutator C8446 was found to be 276 mm ( within limit).

Traction Motor Commutator

Audit of WIs in TM Shop report:-

Assembly of Stacked Commutatort on Steel Parts( W23.030):-

Points noticed:-

• Cleaning of machined commutator should not be done with Trichloroethylene in place of Methyl Alcohol. Cut jars should not be  used for cleaning in place of Proper Containers.
• Varnish WSY-195 R used on 8 degree face was being checked for expiry date.
• Application this varnish up to bottom should be done.
• Varnish TVA 1410 applied on exposed steel parts  should not be of expiry date.
• No make was written/embossed on the front and back Micanite Cone.(These are RDSSO controlled items but inspection mark CLW-4 was written over them)
• For commutator vee ring, make SHESS was written but same should be in approved in master list.
• While assembly, elastomer should be applied per instruction 3.4.1.

• 
  Jigs INJ-040,038 and HITA/COM/05 were being sent for calibration.

• Only 2 cycles of Claming Heating and Cooling should not be done in place of 3. For trade commutators, dielectric strength was being tested at 6.5 KV only against prescribed 8.01 KV.

• Measurement of 22 mm diemsion should be   taken as prescribed in instruction no 3.6

Profile Turning and Deburring ( W23.001):-

points noticed:-

• 
  
  Spanner used for fixing driver dog should be  no. 24/27.

• 
  Dial Guage With limit 0.015 should be calibrated

• Depth guage should be calibrated.
• Armature shaft sleeves have become very old and probably deformed in profile.
• Deburring tool should be available.
• Impulse and IR test was being conducted after heating only. WI says heating ( that too 12 hrs) should be done only if IR comes < 100 MOhms.