Sop Loco Engine Replacement

STANDARD OPERATING PROCEDURE
Form No.: EHSMSM/446/4013 Form Rev. No.:Effective date:

SOP No.: TSK/QMS/CMM/MEL/LOCO/SOP/33 Effective Date 10.11.2020 Revision No. 01
SOP Description: Loco Engine Replacement
Section Loco
Department: Loco & Mobile Equipment Page 1 of 14
Step Activity Associated Requirement/Impacts Responsibility Process / tools / PPEs (HOW) Remarks /
No. (WHAT) (WHO) Reference
Common site hazards and action to be taken

Sl No Hazard Mitigation
1. Maintain proper housekeeping at work area.
2. Follow designated pathway and staircase while going to and from Control Room for work permit issuance.
3. Always maintain 3 Point contact while using any staircase.
P
1 Slip trip and fall at the work area
4. Remain mindful of the debris accumulated in the staircase.
5.
1.
S O
Keep all required spares at a designated place at job site and barricade the working area.
Use of Dust Mask is Mandatory
2 Dust Hazard
2.
i d
Always start after positive isolation and after engine cooling.
l
3 Fire hazard due to hot work
V
1.
2.
a
If any hot work is required for the maintenance. Use ceramic cloth for spatter arresting.
Fire hydrant hose to be fixed at nearest location. Keep fire extinguisher at hot work area.
O P
d S
Name: Malay Kumar Si (JE)
Signature with Date:
PREPARED BY APPROVED BY
a l i
Name and Designation : Ravi Shankar, Sr Manager
Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 Printed on - 30-Nov-2021V Page 1
SOP Valid Till - 27-Nov-2022
Section Loco
Safety Safety Safety FR Jacket Safety Full Body Gas Welding Eye Welding Eye Shield CO detector Dust Mask
Helmet Shoe Goggles Gloves Hardness Glass
P
List Of PPE’s
S O
l i d
During Pre
V a
Start-up Job
activity.
× ×
During On Job
× ×
O P
d S
Name: Malay Kumar Si(JE)
a l i
Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 V

Printed on - 30-Nov-2021
Page 2
Section Loco
1. Preparing of SAFETY :  Take clearance from BF operation.

job ● Slip & trip hazard.  Isolate the energy source.
 Dirty floor &use hand railing.  Don’t handle components with oily or grease hands,
 Take use hand gloves
clearance Sr. Technician/
 Use correct size of tools & tackles.
from BF Technician/
operation.
● General
Contractor
O
Supervisor
P 


Clean the loco floor & hand railing properly.
Take care during ascending or descending from loco.
Hold compressed air hose pipe firmly while
Safety
instruction &
d S 
cleaning.
Proper compressed air line arrangement
precautions
related to work.
a l i PPEs –Must use Safety Shoes, Helmet, Safety Jacket, Safety

Goggles, Hand gloves, Dust Mask, Ear plug and Isolation lock
while executing any activity of the entire job.
V Other Accessories: Drinking Water, Dust bin.
O P
d S
a l i

Page 3
Section Loco
 Take the loco to workshop and park on level track

2. Placing the SAFETY :  Put track lock. Lock all sources of energy (electrical &
loco on  Loco may roll down mechanical). Do isolation. Keep equipment lock in
servicing  Dashing with other loco positive isolation box & put supervisor lock, personal
pit/place and  Injury of Person Sr. Technician/ lock on positive isolation box.
Inspection  Slippage of tackles Technician/  Clean work area. Any grease or oil or any other slippery
substances.
 Exposure to dust Contractor

ENVIRONMENT: NIL
Supervisor
O P 
Clean thoroughly the engine before carrying out
maintenance job.
Apply the parking brake and scotch block.
QUALITY:
d S  Give a round inspection around the loco for safety
purpose.
 Park the LOCO at marked place and

moving up and down in LOCO.
a
also put plate with hand rail for
l i 

Safe & flat place, luminous & well-ventilated area for
doing job. Correct place will help to do job faster
maintaining quality.
V 
Do not touch hot engine or hot pipes while engine
in operation
Check platform, base, Stair case & moving
machinery in surroundings.
O P
d S
a l i

Page 4
Section Loco
3. Work Permit , SAFETY:
Positive  Loco may roll down  Use PPE; Give a look to surroundings against potential
Isolation & Six  Dashing with other loco Sr. Technician/ hazards.
direction  Injury of Person Technician/  Put stopper at the wheels and lock with
hazard form Contractor equipment lock.
 Slippage of tools and tackles Supervisor  Put parking brake.
 Exposure to dust
 Do positive isolation to the starting battery supply switch
O P and put all the keys in isolation box. On that isolation

box put the lock and keep that key with the working
personals.
ENVIRONMENT: Nil
QUALITY:
d S 

Working area should be barricaded by safety tapes.
Fill six direction hazard forms.
 Approachable place ergonomic work
and condition of tools.
a
place. Ensure correct/slandered size
l i 

Insure that clearance form should be filled in loco
repair shop side.
Working area should be free from oil & slippery material.
V 


Put the personal lock in Isolation box.
Write personal lock no. on clearance form.
Check it that clearance form approved by
operation department.
 Put track lock and keep the inside the positive isolation
box.
O P
d S
a l i
Section Loco
 Blow out the engine compartment by compressed air before start the Before starting
job.
4. Disconnect SAFETY: job make sure
 At first inspect the all supply connections of engine as like as fuel
all  Unnoticed hazards around Sr. Technician/ system, air system & cooling system of engine. engine
accessories Technician/
from
work place  Before removing fuel line connection from engine at first close supply temperature
Contractor valve cock which was placed on main fuel reservoir. comes down to
engine. Supervisor  Remove the fuel hose pipe from fuel water separator by using 36-41 45⁰C.
mm D spanner.
O P  Loose the both jubilee clamp which was fitted on turbo charger
and air filter housing for removing of main suction pipe line by
using 12-13mm Ring/D-spanner.
d S  Remove both side main support stud of suction pipe line by

unbolting with the help of 16-17mm & 18-19mm Ring and D-
Spanner.
a l i Sr. Technician/


Remove both air filter from its housing by lose the wing nut
manually.
Remove pre-filter (Hood) by loose the jubilee clamp with the help
V Technician/
Contractor
Supervisor


of 12-13mm Ring/D-spanner.
Loose the jubilee clamp for removal of filter housing extension
pipe by using 16-17mm Ring & D-spanner.
Loose all bolts of air filter housing and remove it.
 Drain all coolant from radiator.
 Loose the coolant line hose pipe metal clamp & remove the hose

pipe by using 16-17mm Ring & D-spanner.
Remove water pump suction line hose pipe by unbolting 4 no’s of
bolt with the help of 14-15mm Ring & D-spanner.
O P


d S
Remove the vent line hose pipe by using 12-13 mm D spanner.
Remove the lube oil drain hose pipe by using 36-41mm D spanner.

a l i
Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 Printed on - 30-Nov-2021 V SOP Valid Till - 27-Nov-2022
Page 6
Section Loco
5. Disconnect all SAFETY : Sr. Technician/  Before remove any electrical connection tagging all properly.
electrical
 Unnoticed hazards around Technician/
 Both side starter motor power cable disconnect by using 18-
connection. Contractor
work place 19 & 20-22 mm Ring & D spanner.
Supervisor
 Disconnect all electrical instrumentation connection from
control Junction Box by using screwdriver set.
 Remove all power cable from output supply Junction Box of
main alternator by using 18-19 Ring & D spanner.
O P 

Remove the sensor cable from main alternator.
Remove the coolant level sensor connection from radiator top
tank.
d S  Remove the 24v charging alternator power supply cable by

using 10-11 mm & 12-13mm ring spanner.
6. Dismantle
SAFETY :
 Unnoticed hazards around
 Before removing the fan guard makes the match mark on
guard for future reference.
Radiator fan work place
V Technician/
Contractor
Supervisor


Remove the fan guard bolts (10 no’s bolts M10) by using14-
154mm D & ring spanner.
Remove the fan guard from the radiator shroud to outside of
the loco.
 Remove the Radiator fan bolt from its bearing housing (06 no’s
M12 bolts) by using of 18-19mm spanners.
 Slide the fan towards the fan shroud side.


Loose the belt adjuster pulley base bolts 03 no’s bolts by
using16-17mm ring spanner.
O P
S
Then loose the adjusting bolt by using 14-15mm ring spanner.
 After loose the belt properly remove the03 no’s (B-68) belt
PREPARED BY
from drive and driven pulley carefully.
APPROVED BY
l i d

a
Page 7
Section Loco
SAFETY :  Before start the dismantling job of exhaust pipe line at first
remove the patrician between the engine compartment & Air
7. Dismantle  Unnoticed hazards around Sr. Technician/
compressor compartment.
Exhaust Technician/
work place.
pipe line Contractor  Loose the both side jubilee clamp of exhaust bellow form turbo
,Carden  Finger injury Supervisor charger by using 12-13 mm ring spanner.
shaft&  Remove both side exhaust bellow coupling bolt by unbolting 06 no’s
Hood Roof ENVIRONMENT: NIL
bolt by using 16-17 mm ring spanner.
cover plate
 Then remove the exhaust pipeline guard/cover by unbolting 06 no’s
O P bolt by using 16-17 mm ring spanner & use the EOT Crane for
removing from loco.
d S  Then remove the silencer bend pipe by unbolting 06 no’s bolt by

using 16-17 mm ring spanner.
a l i 

Then remove the main silencer pipe line carefully from Loco.
Then remove the hood roof cover plate by unbolting the 06 no’s bolt
by using 16-17 mm ring spanner.
V 




Remove air compressor belt guard by using 18-19mm ring spanner.
Lose the compressor base bolts spanner (18-19mm) both side.
Loose the adjustable nut bolts by using (spanner 24mm).
Remove the compressor belts.
Remove carden shaft by unbolting 04 no’s bolts by using 18-19mm
ring &d spanner.
Sr. Technician/  Remove the engine base bolt 08 no’s (front & rear) by using 24-
P
Engine &Main SAFETY : Technician/ 27mm ring spanner.
8. Contractor
Traction  Unnoticed hazards around work  As like as engine remove the Main Traction alternator base bolt 04
Alternator Base
bolt removal

place
Finger injury
Supervisor

No’s (LHS & RHS) by using 30-32 mm ring spanner.
S
Keep the slot wedge between rotor and starter to prevent bearing
and coils damages.
O

i d
Then remove the engine & main alternator assembly from loco by
using EOT Crane carefully.
l
PREPARED BY
Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021
Signature with Date: SignaturePrinted
APPROVED BY
on - 30-Nov-2021
with Date: V
a Page 8

Section Loco
9. Dismantle the main SAFETY : Sr. Technician/  Place the engine &main alternator properly on floor on its
alternator from
stand.
engine Contractor
work place
Supervisor  Remove the guard plate of main alternator by using 8-
 Finger injury 9mm Ring & D spanner.
 Manually rotate the engine by using 32mm socket on Engine
front side and lose the coupling bolts one by one by using
P
socket and T handle (socket no24mm).
 Put packing(non-conductor) material under rotor & stator of
S O 

main alternator.
Remove the all bolts of flex plate.
Dismantle the main alternator from engine by using EOT
l id 
crane and siling.
Inspect main alternator, starter, rotor and its bearing condition
a
properly.
New Engine SAFETY : Sr. Technician/  Remove the all plastics from engine which was used for
10. lubrication &
Inspection work place
 Finger injury
V
Contractor
Supervisor


packing purpose.
Inspect the engine all accessories & components properly.
Check the engine oil level and make sure that it’s on ‘H’
mark.
 Lubricate the both LHS &RHS turbocharger by using lube oil
and rotate the impeller manually for checking the proper

clearance.
Re grease the water pump properly.
O P

S
Check all hosepipe connections tightness & condition
properly.
d
a l i
SignaturePrinted
with Date:
By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021
Printed on - 30-Nov-2021 V
Page 9
Section Loco
11. SAFETY :  Lift the main alternator and place it at the installation
Assembly of  Unnoticed hazards around Sr. Technician/ position.
new engine work place Technician/  Move the alternator towards the main engine.
with main Contractor
alternator  Finger injury Supervisor  Match all the bolts of main engine and main alternator as
well as main alternator foundation bolt.
 Alignment engine with main alternator properly.
 Tighten all the bolts are cross tightening way and keep
O P 
engine moving time to time.
After completion of job check for any foreign material in
maintenance area. Remove all the unwanted material from
Installation of main SAFETY :
d S the area.
 Then lift the engine & main alternator assembly to loco
12. engine ,Alternator &
other accessories on
Loco
 Unnoticed hazards around
work place
Technician/
Contractor

by using EOT Crane carefully.
Put down the engine on its base frame and match the
marking for fixing the base bolts.
V
Supervisor
 Fix the all fasteners as per required and gives the
appropriate torque.
 Fix the radiator fan belt 03 no’s(B-68) and adjust it
properly.
 Fix the radiator fan on its fan hub and fix all fasteners
which removed from it.



Check the clearance of fan from its shroud properly.
Fix the radiator fan guard appropriately.
O P
line and water manifold pipe line.
d S
Fix the 03 no’s coolant hose pipe on water pump suction

a l
i
Section Loco
SAFETY : Sr. Technician/  Fix the vent hosepipe line on thermostat housing properly.
 Then top up coolant 210 liters on radiator and if any leakage
work place Contractor
found arrest that immediately.
Supervisor
 Then fix the fuel suction hose pipe on fuel water separator by
using 36-41mm d spanner.
 On the fuel cutoff valve which was situated on main reservoir
tank & if any leakage found then arrest it immediately.
O P 

Fix the lube oil drain hose pipe by using 36-41mm D spanner.
Fix the exhaust bellow on turbocharger and tight the jubilee
clamp properly.
d S  Then fix the exhaust bend hose and exhaust silencer main
hose pipe properly.
a l i 


Fix the exhaust silencer hose pipe cover properly.
Lubricate the exhaust silencer pipe rain cap properly.
Fix the air filter housing assembly and attach inner and outer
V 
air filter.
Fix the suction air main hose pipe from turbo charger to air
filter housing and tightened the both front & rear jubilee
clamp.
 Fix the support stud of air suction line by using 16-17mm &
18-19mm ring spanner.
 Fix the carden shaft& it’s guard properly by tightening bolt
with the help of 18-19mm ring spanner.
O P
d S
a l i

Section Loco
SAFETY :  Fix the hood cover plate properly by tightening the bolt
13. Loco Hood &  Unnoticed hazards around Sr. Technician/ with the help of 16-17mm ring spanner.
Technician/
primary air filter work place  Both side suction air primary filter fixing by tightening the
fixing Contractor
jubilee clamp properly.
Supervisor
 Before fix any electrical connection follow by tagging.
P
14. Fixing of All SAFETY :
electrical harness  Unnoticed hazards around Sr. Technician/
 Both side starter motor power cable connect by using 18-19 &
connections work place
 Unnoticed start of engine
S O
Technician/
Contractor
Supervisor
20-22 mm Ring & D spanner.
 Connect all electrical instrumentation connection in control
Junction Box by using screwdriver set.
l i d  Fix all power cable from output supply Junction Box of main
alternator by using 18-19 Ring & D spanner.
V a 


Fix the sensor cable in main alternator.
Fix the coolant level sensor connection in radiator top tank.
Fix the 24v charging alternator power supply cable by using
10-11 mm & 12-13mm ring spanner.

O P
d S
a l i
Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 Printed on - 30-Nov-2021 V Page 12
Section Loco
15. Sr. Technician/  Start the engine for 5-10 minutes by pressing the ignition Don’t over
Starting of SAFETY : Technician/ switch and push button. speed the
Engine  Check all items removed from loco. Contractor
 Ensure the engine oil pressure is built up. engine just after
Supervisor start.
 Check for any oil leakage & seepage at any
equipment of loco.
 After checking all maintenance work done in loco
shut down the engine.
16.
Engine
Parameters
SAFETY :
 Check all items removed from loco.
O P Running Engine Inspection to be done in last:

 Check if any abnormal sound from engine or
turbocharger.
d S  Lube oil temp-85°C to 105°C.

 Lube oil PR. 3-7 Kg/cm²
a l i 


Water temp-75°C to 95°C.
Traction alternator winding temp <60°C.
V Engine RPM – Idle -750 & High RPM-1800
O P
d S
Name: Malay Kumar Si (JE)
a l i

Page 13
Section Loco
SAFETY :  Blow out with compressed air all compartments of Loco Use all PPE’s
17. Blowing  Unnoticed hazards around Sr. Technician/ properly after completing the all job. properly at the
Technician/ time of cleaning
&Cleaning of work place  Cleaning must be necessary after completing the weekly
Loco Contractor or blowing of
 Unnoticed start of engine Supervisor
checkup.
loco
Return work  Write the return
P
18. SAFETY: Check all tool & tackles items removed from loco and
permit and Sr. Technician/ also manpower removed from loco. time on the work
clearance form Technician/
S
Contractor
SupervisorO 


Return Clearance form to operation dept.
Open all isolations lock if applied.
permit.
d
Return key of loco.
a l i
V
O P
d S
a l i
Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 Printed on - 30-Nov-2021 V Page 14

Sop Loco Engine Replacement

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Sop Loco Engine Replacement

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STANDARD OPERATING PROCEDURE

Form No.: EHSMSM/446/4013 Form Rev. No.:Effective date:

Common site hazards and action to be taken

Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 V

1. Preparing of SAFETY :  Take clearance from BF operation.

a l i PPEs –Must use Safety Shoes, Helmet, Safety Jacket, Safety

V Other Accessories: Drinking Water, Dust bin.

Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 V

 Take the loco to workshop and park on level track

 Park the LOCO at marked place and

Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 V

O P and put all the keys in isolation box. On that isolation

d S  Remove both side main support stud of suction pipe line by

Name: Malay Kumar Si(JE)

d S  Remove the 24v charging alternator power supply cable by

Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 V

d S  Then remove the silencer bend pipe by unbolting 06 no’s bolt by

SOP No.: TSK/QMS/CMM/MEL/LOCO/SOP/44 Effective Date 10.11.2020 Revision No. 01

Installation of main SAFETY :

Name: Malay Kumar Si(JE)

SOP No.: TSK/QMS/CMM/MEL/LOCO/SOP/44 Effective Date 10.11.2020 Revision No. 01

 Before fix any electrical connection follow by tagging.

Name: Malay Kumar Si(JE)

O P Running Engine Inspection to be done in last:

d S  Lube oil temp-85°C to 105°C.

V Engine RPM – Idle -750 & High RPM-1800

Printed By -MALAY KUMAR SI(161298) Print valid till - 10-Dec-2021 V

Return work  Write the return

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