:- Failure of newly commissioned HHP loco  due to leakage in Lube oil system.

Diesel shed is experiencing problem of Lube oil leakages in various locations on newly commissioned HHP locos due to bad workmanship during manufacturing.

suitable suggestions against each item have been prepared as a corrective action for implementation at Shop floor level. These measures shall help in improving the reliability of HHP locos apart from saving precious lube oil.

The details of the lube oil leakage cases are discussed below.

1.0 1.1 1.2 1.3	Lube Oil Leakage from Turbo Housing (Right Side) No. of cases: 03 Nos.  Cause of Leakage : Improper sequence of torquing of Housing Bolt Corrective Action Required: At the time of fitment of Turbo Housing, sealing compound should be used properly and working sequence to be maintained.
2.0 2.1 2.2 2.3	Lube Oil Leakage from Scavenging Pump Header Plug  No. of case: 01  Cause of Leakage: Plug tightened, but without any compound Corrective Action Required: Use of Thread locker compound at the time of fitment
3.0 3.1 3.2 3.3	Lube Oil Leakage from OST Housing. No. of cases: 02   Causes of Leakage: Improper tightness sequence of OST Housing Bolt Corrective Action Required: Proper torquing sequence along with gasket and adhesive to be used.
4.0 4.1 4.2 4.3	Lube Oil Leakage from Turbo Housing (Left Side) No. of cases: 03  Cause of Leakage: Improper tightening sequence of Housing Bolt Corrective Action Required: Proper tightening sequence to be followed with use of thread locker compound.
5.0 5.1 5.2 5.3	Lube Oil Leakage from Hot Oil Detector Pipe Joint No. of cases: 04  Cause of Leakage: Improper alignment of steel pipe. Corrective Action Required: Proper alignment to be ensured by checking through a suitable template.
6.0 6.1 6.2 6.3	Lube Oil Leakage from TSC Plug No. of cases: 01  Cause of Leakage: Plug was not tightened properly and became loose Corrective Action Required:  Proper tightness of plugs to be ensured with use of thread locker compound.
7.0 7.1 7.2 7.3	Lube Oil Leakage from Top Deck Cover Gasket No. of cases : 01  Cause of Leakage : Improper tightness of  top deck cover back side clamp Corrective Action Required :  Back side clamp alignment and  tightness to be ensured.
8.0 8.1 8.2 8.3	Lube Oil Leakage from Lube Oil Strainer Steel Pipe thread joint  No. of cases: 01  Cause of Leakage: One end of Steel Pipe fitted to strainer housing got    loose Corrective Action Required:   Proper tightness with thread locker should be ensured.
9.0 9.1 9.2 9.3	Main Crank Case Lube Oil Drain pipe No. of cases : 7 Cause of failure- Improper Torquing of elbow, leading to leakage in majority of the locos. Corrective action required-  At the time of assembly at DLW, the elbow should be correctly torqued
10.0 10.1 10.2 10.3	Turbo soak back filter to turbo filter pipe line No. of cases: 2 Cause of Failure - Leakage from Flange to tube joint and soak back pipe gets punctured due to rubbing with either starter motor body or engine base. Corrective Action Required – Soak back pipe line should be realigned by passing it above the starter motor to avoid rubbing and facilitate easy checking and quality of Flange to Tube joint to be improved
11.0 11.1 11.2 11.3	L/oil leakage from L/oil filter drum gauge sight glass No. of cases: 1. Cause of cases: ‘O’ ring of sight glass leaks. Corrective action required-  At the time of manufacturing, the fitment   of Slight Glass should be proper and give leak-proof service of minimum three years.	gauge sight glass
12.0 12.1 12.2 12.3	Lube oil leakage from cylinder head cover frame gasket joint No. of cases: 1 Cause of failure – Improper application of gasket, sealant and incorrect torquing of hex head bolts.(EMD Pt- 454911). Leakage occurs after 2 – 3 months  of commissioning. Corrective action required-   ·      Proper application of gasket and sealant as per EMD manual. ·      Correct torquing of hex head bolts.(EMD Pt- 454911) at the time of assembly.	Leaky joints
13.0 13.1 13.2 13.3	Lube oil leakage from Armour joint. No. of cases: 9 Cause of failure – Lube oil leakage from scavenging pump to filter drum  armour joint due to misalignment during assembly. Corrective action required-  Proper alignment of mating pipelines to reduce extra stress  and dimensional accuracy of fittings should be ensured.
14.0 14.1 14.2 14.3	L/oil leakage from the sock back flange. No. of failures : 1 Cause of Failure - Leakage from Flange to tube joint due to misalignment. Corrective Action Required- Proper alignment of mating pipelines to reduce extra stress.
15.0 15.1 15.2 15.3	L/oil leakage from EMD gauge top and bottom joint . No. of cases: 2 Cause of Failure - Leakage from joint due to misalignment. Corrective Action Required- Proper alignment of mating pipelines to reduce extra  stress
16.0 16.1 16.2 16.3	Lube oil cooler adopter and elbow. No. of failures : 3 Cause of cases: Leakage from joint due to misalignment. Corrective Action Required- Proper alignment of mating pipelines to reduce extra stress.
17.0 17.1 17.2 17.3	Vent pipe at strainer to Main Lube oil Pump. No. of cases: 3 Cause of Failure - Leakage from joint due to misalignment. Corrective Action Required- Proper alignment of mating pipelines to reduce extra stress.
18.0 18.1 18.2 18.3	Lube oil leakage from filter drum pressure testing plug No. of cases: 5 Cause of Failure – Improper tightness. Corrective Action Required- Proper tightness at the time of installation and  use of thread locking compounds.