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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

COMMISSIONING SCHEDULE
OF
4000 HP /4500 HP MICROPROCESSOR CONTROLLED EMD TYPE DIESEL ELECTRIC
LOCOMOTIVES

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APRIL – 2010
MP-MISC.- 255, Revision – 00)
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RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226 011
 Commissioning Checks for WDG4 and WDP4 EMD locomotives
General:
Check whether all modifications as per attach annexure have been implemented. If no, carryout the same and make a reference of non-compliance to DLW and
RDSO.
M-MECHANICAL, E- Electrical
No. Item Work to be done Remarks
1 M Engine i. Torque crab nuts & Exhaust manifold, Connecting-rod basket, Equipment rack foundation, cooler air
duct mounting & chimney bolts.
ii. Remove and inspect of Valve lever asm, clean and refit fuel Injectors, torquing nuts Head to liner, OSTA
trip pawl, camshaft studs, cam bearing cap fasteners.
iii. Adjust exhaust Valve & Injector timing and adjust all fuel racks
iv. If OST is tripping then provide sleeves to OSTA nuts & adjust spring tension.
v. Check Piston cooling pipe alignment and crack/pin holes near brazing joint. Replace if defective and
torque the fasteners.
vi. Check Governor oil test report. Flush if required.
vii. Check all the pipe flexible couplings for leakages, tighten if necessary.
viii. Check Fuel Suction 'L' Pipe for infringement with strainer and ensure proper clamping.
ix. Check piston-cooling pipe for any leakage during the pre lube.
x. Align aux drive shaft to 0.5mm TIR.
xi. Conduct FRC, load test & record all readings.

2 M Compressor i. Torque Compressor foundations bolts & drive flex-coupling bolts on Engine & Compressor end.
ii. Check compressor oil to test report and Flush and fill fresh oil if required.
iii. Grease un-loaders, Check proper loading and unloading.
3 M Radiator Check for any leakage/damages in Radiators and proper seating and condition of Rubber packing.
4 M Air Brake i. Check CCB Electrical connectors for tightness/intactness.
ii. Conduct Air Brake self-test & blended brake from both control stands.
iii. Check proper working of Air dryer & condition of Humidity indicators.
iv. Check MR2 check-valve for proper functioning & MR safety valves setting.
v. Tighten panel valves and pipe lines (Front and Driver cab side).
vi. Remove & clean both Emergency valves, clean the BP pipe after removing hose.

5 M Air System Check Radial clearance between engine air filter housing Inlet Manifold to partition plate.
6 M Cooling water i. Change water pumps if fitted Non modified.
system ii. Obtain Cooling water/coolant test report from Laboratory.
iii. Check for any leakages in the cooling system.
iv. Provide thread sealant in all the threaded joints of the pipelines
7 M Lube oil i. Check Engine Oil Test report and CHANGE OIL if required.
system ii. Check intactness strainer element and Change lube oil filters.
iii. Check for metal chips etc. in the sump and strainers. If found then drain and clean the sump and fill
with fresh oil.
iv. Provide thread sealant in all the threaded joints of the pipelines where leakages have been found.
v. Check and tighten the mounting of soak back motor.

1
No. Item Work to be done Remarks
vi. Check Lube oil dip-stick markings/graduations and mark if required.
8 M Bogie i. Check the side clearance of latral stop at primary secondary.
ii. Check condition brake rigging and loose bolts
9 M Miscellaneous i. Record Make and Sl. No of Engine block, water inlet tubes to cylinder liners, air compressor, radiators,
after coolers, engine air filter Housing, window sash assembly and wiper motors etc and Becc, Dyn.
Controller control stand, ECC 1,2 & 3, TCC 1 & 2 cabinet, IPR's and blower motor, Traction/ companion
Alternator, Grid blower Motor, AG, Dust bin/ TCC blower motor, Radiator Fans, FP, TLPM and GBC
Motors, Batteries, Traction Motors etc. other newly developed items.
ii. Paste instruction sheet Airbrake self test, change of control stands etc, AB operational Instruction.
10 E Dynamic Check & attend dynamic controllers for over travel, mal-operation. Unload and check for loose connections.
Controller
11 E Control Check all connections for tightnes And operations of horn, H/L, sanders switches, toggle switches,
Console indication panels.
12 E ECC 1,2&3 i. Check all EM 2000, Panel Mounted, Power Chassis modules & Plugs for slackness.
ii. Check all breakers and connection in breaker panel. Check test panel connections.
iii. Check all relays, resistors, contactors, diodes, capacitors and plug type connection for loose & wrong
connections. Ensure plug all connectors are locked.
iv. Check all Motor connections, DCL link connections for Loose bolted.
v. Check signs of Connections, overheating due to Bad Crimping etc.
vi. Check radiator fan connections on Bus bars, contactors etc for over heating.
vii. Contact surfaces; check all inter lock, coil connections for loose/wrong connection.
viii. Check battery knife switch connections including shunt connections.
ix. Check all cable joints are having proper heat shrink sleeve over them.
x. Check H/L resistance and adjust accordingly.
xi. Check for sealing of cab, ECC 3 front as well as back, welding of Bus bar support plate.
xii. Check for modifications of auto flasher wiring, AEB/TEL wiring, , DVR wiring, and EFS/FVS isolation.
xiii. Check all Sensors and Cables (clearance of EPU and TPU over respective gear teeth).
xiv. Check all Element Filters and their covers.
xv. Torque of ECC#2 mounting bolts. Ensure DCL reactor to rear wall clearance above 5 mm.

13 E DBR Check for mounting and cable connection tightness, condition of ribbon resistor brazing & record IR value of
the grid paths
14 E TCC # 1, TCC # i. Check all terminal connections.
2 ii. Check all “X “plugs for proper connections, check for clamp inside the plugs.
iii. Check ASG for any loose card / locking Bar.
iv. Check all other connections on Terminal Board and Bus bar.
v. Check proper fitment of Dynacell filters and verify gasket condition.
vi. Check IPR for Bus bar clearance modification.

15 E Alternator i. Check condition of slip rings, brushes, and brush holder springs, fuses, diodes, suppression capacitors
& resistors.
ii. Check all connection on terminal board and on Bus bar and condition of cables/ routing for TA & CA.

2
 No. Item Work to be done Remarks
16 E Grid Blower i. Check condition of brushes, connections, brush holder spring, supply connections, insulated bush /
Motors connectors.
ii. Rotate and check condition of bearing, fan for any rubbing, wobble.
iii. Check bolts tightness of frame assembly.
17 E Auxiliary i. Modified diode plate or not record.
Generator ii. Check conditions of Aux. Gen. shaft and couplings.
iii. Check Aux Gen base bolts for slackness and torque to - 278 Nm.
iv. Check condition of diode plate for overheating, open connections etc.
v. Check all cable condition and insulate properly from earthing.
vi. Check all cable condition and insulate properly from earthing.
18 E Radiator Fan i. Check for wobbling, unusual sound etc.
ii. Check the fan assembly torquing and torque frame.
19 E TCC, Dust Bin i. Check condition of all blowers for any unusual sound and proper connections.
& electronic ii. Check condition of cyclonic filters, TCC 1 & TCC 2 hose pipes and filter hose pipes.
blower iii.
20 E Fuel Pump/ Check condition of motor connections on terminal board and insulate properly, condition of love - joy
Turbo Lube coupling, brushes and foundation bolt tightness.
Pump / GBC
Motors
21 E Batteries i. Check condition of batteries for any damage, overheating etc., inter cell and terminal connections,
clamping of cables, specific gravity, electrolyte level and cell voltage.
ii. Ensure proper packing to avoid vibration Check battery box covers and latches for proper fitment and
torque mounting bolts.
22 E Traction i. Check conditions of all cables, routing and tightness of cleats, for correct phase to phase connections,
Motors correct colour coding of power & sensor cables.
ii. Check conditions of sensor plugs & pins, proper locking of plugs. proper fitment of sensors.
iii. Check end shield bolts for slackness, torque to 70 Nm for 18mm bolts and 680 Nm for 1 1/8" bolts.
Check for TM end shield stone entry guard application.
iv. Check for foreign material oil entry in traction motors by removing bottom inspection covers.
v. Check ECC 2 hosepipe for fitment and any damage.
vi. Check radar angle and fitment of guard.
vii. Ensure correct cable sag between cleats.
23 E Miscellaneous i. Apply RTV sealant to cab roof and verify for any leakages.
ii. Apply RTV sealant to cab windshield glass from within and outside.
iii. Ensure no water seepage inside locomotive body through welding blow-holes below ECC1, TCC
cabinets and cyclonic filters.
iv. Apply RTV sealant to all the light entry points inside clean air chamber.
v. Apply RTV sealant for all the insulators split cabinet at the back of ECC1 top side.
vi. Drill holes for long hood classification light cabinets at the bottom for water draining.

ATTACHED - ANNEXURE-I

3
 Annexure - I
RECENT RDSO PUBLICATIONS ON EMD LOCOMOTIVE
(2008 onward)
Publication Number Subject of the Document
1. MP.Misc-241 Sept.’09 Modified lower damper bracket design of EMD locos: comparative
Fatigue Analysis
2. MP.MI-15 Rev.4 Aug’ 09 Recommended lubricants, coolant and cleaning compounds for diesel
locomotives.
3. MP.INV-48 March Report on investigation of EMD locomotive pinions.
4. MP.IB.VL.03.28.08 Tolerances on Lateral Clearances between bearing adapter and lateral
thrust pad in WDG4 & WDP4 locomotives.
5. MP.IB.VL.05.33.08 Instructions regarding material, tests and inspection of Rubber Spring
(Rev.01) Assembly used on WDG4 & WDP4 locomotive bogies.
6. MP.IB.BK.03.04.09 Deletion of D-24B Feed valve from WDG4/WDP4 Locos.
7. MP.IB.EN.02.06.09 Recommendation for anti-seize paste, anti-friction coatings, specialty
greases mounting paste, RTV sealant/compounds for use on
equipment/components of diesel-electric locomotives (ALCo & EMD).
8. MP.IB.VL.03.19.09 Design modification of lower bracket for primary damper of WDG4 &
WDP4 locomotive to prevent their failure.
9. MP.IB.VL.07.29.09 Optimisation of suspension system of WDP4B passenger ver. of EMD
locomotive bogies while rationalizing the metal to rubber bonded
components for all EMD loco.
10. MP.IB.EC.06.34.09 Instruction bulletin for improving reliability of M/s KEPCO make Dynamic
controller used on EMD Locomotive.
11. MP.IB.VL.16.60.09 Procedure for ensuring alignment of yaw dampers fitted in EMD
locomotives.
12. MP.IB.EM.07.69.09 Isolation of defective speed sensor on EMD traction motors
13. MP.IB.EC.13.72.09 IB for enhanced rating of ‘MCB1’ and ‘MCB2’ (radiator fan blower motor
breakers) in ECC3 due to failure of EMD locomotives
14. MP.IB.EC.14.75.09 Activation of Low Idle feature in EMD locomotives type WDG4/ WDP4
diesel Electric locomotives.
15. MP.IB.EC.15.77.09 Removal of Power Supply Buffer - High frequency filter/buffer G129 card
from SIBAS TCC panel of M/s. Siemens make in EMD locomotives type
WDG4/ WDP4 diesel Electric locomotives.
16. MP.IB.VL.18.82.09 Instructions for preventing loosening/ failures of fasteners provided in
EMD loco bogie.
17. MP.IB.EM.12.83.09 Provision of filter circuit to prevent superimposition of electromagnetic
noise interference on speed sensor signals.
18. MP.IB.EM.13.84.09 Instruction bulletin for provision of improved slip-ring foundation bolts in
EMD traction alternators (TA17 – CA6) of WDG-4/WDP-4/WDP-4B EMD
Locomotives.
19. MP.IB.EC.17.89.09 IB for improvements in Siemens make TCC for EMD locomotives.
20. MP.IB.LD.03.93.09 IB for Clevis Pin in transition type Tight Lock Coupler.
21. MP.IB.EM.03.12.10 Prevention of Oil Leakage on the EMD locomotive gear case
22. MP.IB.VL- 03.14.10 Movement of EMD & WDP3A Locomotives with three axle and WDP1
with two axle bogies as light engine with one defective / locked axle
using wheel set trolley.
23. MP.MOD.ES.02.19.09 Provision of additional clamp for holding the tube (EMD part No.
9544979), supplies lub oil manifold to governor in frame & Latch
assembly-RB used on EMD locomotives.
24. MP.MOD.EM.05.32.09 Modification sheet for provision of traction motor speed sensor isolation
switch in WDP4/WDP4B EMD Locomotives.
25. MP.MOD.EM.08.40.09 Use of modified capacitors in the transient voltage suppression system
(surge capacitors) in WDG4/WDP4/WDP4B locomotives.
26. MP.MOD.BK.05.34.09 Modification of CCB software for reduction in BC pressure on WDG4/
WDP4 Locomotives from 4.4 Kg/cm2 to 1.8 Kg/cm2 during Automatic
brake application.
27. MP.MOD.EM.07.39.09 Provision of upgraded cables for Radiator cooling fan assembly of EMD
locomotives.
28. MP.MOD.BK.01.02.10 Up-gradation of Nipples provided in dead engine circuit of CCB system
in diesel electric locomotives.
29. MP.MOD.BK.02.04.10 Modification of MREQ. pipe connection for supply dry air on diesel
electric locomotives.
30. MP.MOD.BK.03.05.10 Modification of non memory air dryer of Faiveley make, fitted on
WDG4/WDP4 Locomotives
 Publication Number Subject of the Document
31. MP.MOD.ES.02.07.10 Change of gasket material of Chamber to crankcase (EMD part No.
40055466) from existing one to Copper for EMD locomotives
32. MP.MOD.ES.05.20.10 Use of Teflon (P.T.F.E) flexible radiator vent hose ID ½”dia. X 15” length
(outer SS304 steel wire braided) to DLW part list No.- 17320872, with
both ends female swivel Nuts 7/8” -14 UNF for EMD locomotives.
33. MP.MOD.BK.08.24.10 Modifications in CRU cover to provide transparent Plexi glass window
for viewing fault display code of CCBs
34. MP.MOD.EC.03.25.10 Standardization of 27 pins MU configuration on EMD/ALCo Locomotives
35. MP.MOD.VL- 03.29.10 Unification of suspension components in EMD locomotives
36. MP.MOD.EM.08.33.10 Removal of RC circuits (snubber circuits) in existing Traction Alternators
fitted in 4000/4500 HP EMD locomotives.
37. MP.0.01.00.26 (Rev.00) Specification for auto drain valve for its use in brake system fitted on
March’ 2010 diesel and electric locomotives.
38. MP.0.0400.11 (Rev.00) Specification for the development of 1 kw DC/DC converter for
June’2009 application of EMD type headlight on diesel electric locomotive
(ALCo/EMD).
39. MP.0.2400.64 (Rev.00) Automatic control of Engine Stop with Auxiliary Power unit – ACES with
November’2009 APU for EMD Locomotives.
40. MP.0.2600.26 (Rev.00) Specification for 10”x30’ Long Life Lube oil and Fuel oil Filter Elements
September’2009 (Two Piece) for EMD Locomotive.