CE Nstruction: Lectro Otive

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M.I.

1738
*Rev. E
E L E C T R O -M OTIVE

CE
NSTRUCTION

SCHEDULED MAINTENANCE PROGRAM


BLOWER-TYPE GP & SD MODEL
LOCOMOTIVES (645 ENGINES)
INTRODUCTION 4. Lubricating oil filters will be of a quality equal
to original equipment and will be changed at the
This Maintenance Instruction provides average intervals specified in this M.I.
recommendations which should ensure satisfactory
locomotive operation and economical maintenance
cost where average load factors and average climatic 5. Procedures listed in M.I. 1705 or 1707 will be
conditions are encountered. It is intended to serve as followed for new locomotives and newly
a guide when establishing maintenance schedules installed replacement assemblies.
that will meet the particular requirements of
individual operations, and planned economic life of
the locomotive. INSTRUCTION REFERENCES
These recommendations are based on the following Abbreviations are used in this instruction to
conditions: reference publications that contain information
related to maintenance. The following examples are
1. Fuel oil used will meet the specifications of provided to aid in understanding the abbreviations
Maintenance Instruction 1750. used.

2 . Lubricating oil used will meet the specifications


of the applicable Maintenance Instructions,
and will be changed at the intervals specified in LSM means Locomotive Service Manual
this M.I.
EMM means Engine Maintenance Manual
3 . Engine coolant used will meet the specifications
in Maintenance Instruction 1748. M.I. means Maintenance Instruction

*This bulletin is revised and supersedes previous issues of this number.

DE-L December 1980


M.I. 1738

LUBE OIL FILTERS

Check lube oil filter tank pressure. LSM. Checks can be made weekly or oftener at
fueling or turnaround points. Replace filter ele-
ments if tank pressure so indicates.

FUEL FILTER

Check pressure differential at rack mounted LSM. Same note as immediately above.
filter gauge. Use only pleated cotton-paper element.

TRACTION MOTOR SUPPORT BEARINGS

Check lubricant level. Fill to overflow. M.I. 1756.

TRACTION MOTOR GEAR CASE

Maintain lubricant at sufficient level to provide M.I. 1756


full gear tooth dip into grease.

AUTOMATIC COOLING SYSTEM DRAIN


(If Equipped)

Check drain valve operation. M.I. 582

LUBE OIL

Take sample for analysis.. The services of a competent laboratory may help
to monitor the suitability of the oil for continued
use.

ENGINE PROTECTOR

Check operation. EMM, LSM, M.I. 259 or M.I. 260

GENERATOR PIT DRAIN ASPIRATOR

Inspect and clean, if needed. LSM

AIR BOX DRAINS

Check operation and clean, if necessary. EMM

BATTERY

Check electrolyte level.

Check specific gravity.


Wash out battery boxes.

MAIN GENERATOR

Inspect diode fuses, replace diodes and fuses as M.I. 3317-2. Whenever generator air box panels
required (Where Used). are removed, clean the inspection windows, and
inspect collector rings and brushes.
-2-
M.1. 1738

ENGINE AIR FILTER-PANEL TYPE


OIL BATH (Where Used)

Check oil level. LSM

ENGINE AIR FILTER-CYCOIL TYPE


(Where Used)

Check oil level. LSM

ENGINE AIR FILTER-PAPER OR


FIBERGLASS TYPE (Where Used)

Check indicator. If tripped, take manometer LSM


readings, and replace elements if necessary.

ANNUNCIATOR MODULE (Where Used)

Monitor annunciator and record lighted LSM


indicators.
Perform checks or maintenance indicated by
lights.

Set annunciator switch to test position and


observe that all annunciator lamps are lighted.
Set annunciator switch to reset position.

JOURNAL BOX

Maintain lubricant to fill plug level. M.I. 1756, M.I. 1552

LUBE OIL FILTER

Change filter elements. LSM


Clean lube oil strainer. EMM. Fill strainer housing with oil before starting
engine.

FUEL FILTERS

Clean or replace suction strainer element. LSM


Change engine mounted filter elements. EMM. Use only elements equal to original
equipment.

Change rack mounted primary filter. LSM. Use only pleated cotton-paper element.

-3-
M.I. 1738

COOLING SYSTEM

Check inhibitor concentration. M.I. 1748

Check for proper automatic cooling system drain


operation (If Equipped).

FUEL TANK

Drain condensate. LSM. More frequently during periods of high


humidity or rapid temperature change.

TRACTION MOTORS

Replace brushes (in sets only). M.I. 3900. Depending upon type of service and
operating conditions, brush life will range from 3
to 6 months.

Clean creepage areas and blow out with clean


dry air.

Visually inspect support bearing wick lubricators Clean and replace as necessary.
for dirt plugging of the wick and for excessive
wear.
INERTIAL FILTER BLOWER MOTOR

Check operation. M.I. 3614

ELECTRICAL CABINET PRESSURE TAPS

Check hoses and taps for leaks or obstructions.

ENGINE AIR FILTERS-CYCOIL

Change oil. Drain and fill only. LSM

ENGINE AIR FILTER-PANEL


TYPE OIL BATH

Change oil. Drain and fill only. LSM

ENGINE AIR FILTERS-PAPER

Take manometer readings. Replace elements if LSM


necessary.
ENGINE AIR FILTERS-FIBERGLASS

Replace elements.

BATTERY

Wash cell tops and apply petroleum jelly to


terminals.

Inspect battery boxes for damage or rust. Repair and paint if necessary.

-4-
M.I. 1738

LOW VOLTAGE ELECTRICAL SYSTEM

Check for grounds. LSM

ENGINE

Inspect air box. EI\IM

Inspect crankcase. EMM

Inspect crankshaft and connecting rods. EMM

Inspect pistons and piston rings. EMM

Inspect cylinder liners. EMM

Inspect cylinder head mechanism with engine EMM


idling and at operating temperature.
Inspect engine fuel lines and connections for EMM
leaks.

Inspect engine water system for leaks. EMM, LSM

SPEED RECORDER AND DRIVE CABLE

Lubricate. This item is not required for grease lubricated


recorders. Refer to speed recorder manufacturer’s
bulletins.
DOOR HARDWARE

Lubricate hinges, latches, and linkage. M.I. 1756

OIL SYSTEM

Change engine oil. LSM, EMM. Evaluation of engine and oil condi-
tion should dictate the frequency of this item.
Type of service, type of oil, quality of filter
elements, and condition of engine will influence
the frequency of oil change.

Clean oil suction screens. EMM

Clean scavenging oil screens. EMM. Fill strainer housing with oil before starting
engine.

Clean oil pan.

Clean filter housing.

ENGINE

Check exhaust manifold base flange bolts for EMM


proper tightness.
-5-
M.I. 1738

RADIATORS

Clean air passages. LSM and M.I. 549. Operation in certain sections of
the country and during certain seasons will require
more frequent cleaning due to airborne seeds and
leaves.

MAIN GENERATOR

ARlO/D14

Inspect collector rings and brushes. M.I. 3317-1

Reverse polarity of collector rings.

D32/D14

Inspect collector rings and brushes. M.I. 3302 or M.I. 3304

Reverse polarity of collector rings.


Inspect commutator brushes.

Blow out with air and clean creepage


surfaces.

MAIN RESERVOIR

Replace air filter element. LSM

Check operation of automatic drain valves. LSM

IDAC (Where Used)

Check operation. LSM

MODULE TESTING (Where Used)

Perform self-test on modules. LSM

VOLTAGE REGULATOR (Where Used) LSM, M.I. 4522

Check auxiliary generator output voltage.

Check auxiliary generator reference voltage.

VR MODULE (Where Used) LSM

Check auxiliary generator output voltage.

TH MODULE (Where Used) LSM

Check output voltage of VRR section.

GROUND RELAY LSM

Check ground relay action.

-6-
M.I. 1738

HANDBRAKE

Check operation and lubricate. M.I. 1577

CAB SEATS

Lubricate cab seat posts and guide rails. Lubriplate 630-2 or equivalent.

ENGINE BOLT AND NUT RETORQUING

Cylinder head crab nuts. Follow torquing procedures as outlined in the


EMM.
Main lube oil and piston cooling oil pump EMM
shaft nut.

Head frame to crankcase bolts. EMM

ENGINE

Replace top deck cover seals and check latches.


Qualify injectors. EMM

Set injector timing and injector rack length. EMM

Check engine speed. EMM

Check overspeed trip. EMM


Check governor pilot valve setting. EMM. If engine speed is changed, reset on governor
stand.

Remove and clean oil separator element. EMM

Remove oil pan handhole cover and inspect Follow inspection procedures as outlined in the
harmonic balancer while engine is being barred EMM.
over.

EXHAUST SYSTEM

Clean spark retention trap.

Tighten bands connecting manifold sections.

AIR COMPRESSOR

Clean air intake screen. (Where Used). LSM


Clean air filter housing and replace air filter LSM
elements. Do not attempt to clean elements.

Change oil, M.I. 1756

-7-
M.I. 1738

AIR FILTERS

Carbody (Inertial) LSM

Measure pressure drop. Clean if necessary.

Engine (Cycoil) LSM

Change oil and clean sump.

Check operation of variflow valves.


Check condition of hoses.

Engine (Panel Type Oil Bath)

Change oil. Clean sump and filter media. LSM

LUBE OIL FILTER

Remove oil filter bypass valve; clean, inspect M.I. 926


and test.

MAGNET VALVES

Clean and replace seats. M.I. 4707

ELECTRICAL CABINETS

Air Filter LSM

Change filter element.

Door Seals
Check for damage and leakage. Replace if
necessary. Adjust lock keeper, if required.

Contact Tips LSM and applicable M.I.

Visually inspect tips of all power contactors,


reversers, and brake transfer switches. Replace
as required.

Check timing of time delay devices. LSM and applicable settings chart drawing.

AUXILIARY GENERATOR

Inspect and replace brushes when required. Normal auxiliary generator brush life is between
Replace in sets. 21 and 24 months.

DYNAMIC BRAKE RHEOSTAT (Where Used)

Blow out with dry air.


Inspect contact brush and replace if necessary. M.I. 4334

-8-
M.I. 1738

LOAD REGULATOR-PLATE TYPE

Blow out with dry air.

Inspect contact brush and replace if necessary. M.I. 4505

FUEL PUMP MOTOR

Inspect and clean with dry air.

Replace brushes. M.I. 4101

STARTING MOTORS (Where Used)

Blow out with dry air. EMM

CAB HEATER BLOWER MOTOR

Replace brushes.

AIR CONDITIONER (Where Used)

Inspect compressor motor brushes and replace M.I. 4122


if necessary.
Inspect blower motor brushes and replace if
necessary.

Clean evaporator return air filter.


Clean condenser coils.

COOLING FANS AND ENGINE


TEMPERATURE SWITCHES

Check for proper operation and setting. LSM. M.I. 5511 or 5524.
Replace or recondition shutter magnet valves. M.I. 4707

RADIATORS

Clean or renew header screens after first year M.I. 549 and 550. The presence of metal chips at
of operation. Condition of screen at this inspection first cleaning or after engine parts have been renewed
can provide a basis for future cleaning. is not an abnormal condition.
DYNAMIC BRAKE GRIDS (Where Used)

Inspect and blow clean with dry air. M.I. 1601

DYNAMIC BRAKE BLOWER


MOTOR (Where Used)

Inspect in place; renew brushes as necessary. M.I. 4104


(Replace brushes in sets.)

-9-
M.I. 1738

MAIN GENERATOR

ARlO/D14

Replace collector ring brushes. M.I. 3317-1


D32/D14

Replace collector ring and commutator M.I. 3302 or M.I. 3304


brushes.

TRACTION MOTOR

Check air duct bellows for alignment and


leakage. Inspect wear plates and arm.

Replace support bearing wick lubricators. M.I. 3900

ALIGNMENT CONTROL COUPLER


(Where Used)

Check for wear and alignment control M.I. 2703


engagement.

COOLING SYSTEM

Inspect and perform pressure test. LSM


Replace pressure cap if defective.

GOVERNOR

Change oil. EMM, M.I. 1764

BRAKE SLACK ADJUSTER SCREWS

Coat threads, using graphite grease.

TRUCK CENTER BEARING

Add two quarts of oil. LSM

AUTOMATIC MAIN RESERVOIR


DRAIN VALVES

Clean and repair.

AUTOMATIC COOLING SYSTEM DRAIN


(If Equipped)

Recondition automatic drain valve. M.I. 582

- IO-
M.I. 1738

LUBE OIL COOLER

Check temperature differential between lube LSM. M.I. 928. Clean cooler, if necessary, M.I. 927.
oil and cooling water into engine.

HOT OIL DETECTOR

Remove and check for operation at proper LSM


temperature.

FUEL PUMP AND MOTOR

Replace coupling spider.

STARTING MOTORS (Where Used)

Disassemble, clean and lubricate. EMM

Inspect brushes and replace if necessary. EMM

AIR COMPRESSOR (Gear Type Oil Pump)

Replace oil filter. M.I. 1144

COOLING SYSTEM PRESSURE CAP

Replace cap. LSM

Inspect filler neck for damage. Replace if


damaged.

ENGINE PROTECTOR

Recondition and qualify. M.I. 259 or M.I. 260. Qualify on test stand after
renewing springs, “0” rings, and diaphragms.

ELECTRICAL CONTROL CIRCUITS

Check settings and operation of non-modular LSM and applicable settings chart drawing.
prQt.&.ve amd regulating devices and circuits.

On module equipped locomotives, qualify mod- LSM


ules and related circuits.

FUEL OIL PREHEATER (If Equipped)

Renew thermostatic valve element.

-II-
M.I. 1738

ENGINE

Replace cylinder assemblies. EMM

Replace injectors. EMM

Inspect and qualify connecting rod bearings. EMM

Inspect and qualify piston cooling tubes. EMM

Install new thrust collars. EMM

Install new lower main bearings. EMM

Check rocker arms, rocker arm bushings, and EMM


cam followers.

Check lash adjusters. EMM

Check exhaust valve timing. EMM

Replace water pump seals and all worn parts. EMM

Inspect lower liner inserts. Renew if necessary. EMM

AIR COMPRESSOR

Recondition valves. M.I. 1144, LSM

TRACTION MOTORS

Replace. Replacement motors should be EMD Unit Ex-


change -or equivalent. Refer to non-scheduled
maintenance portion of this M.I.

MAIN GENERATOR-AR1 0

Remove rectifier assemblies from air box. M.I. 3317-2


move fuses and thoroughly wash heat sink and
diodes.

CAUTION
Never use a caustic solution.

COOLING SYSTEM

Replace flexible coupling seals.

BATTERY BOXES

Clean and paint.

SHUTTER AIR CYLINDERS

Replace piston, piston rod, and cylinder seals. Air test cylinder after seal replacement.

- 12-
M.I. 1738

DYNAMIC BRAKE BLOWER

Replace. Replacement should be EMD Unit Exchange or


equivalent.

ENGINE BLOWERS

Replace. Replacement should be EMD Unit Exchange or


equivalent.

BLOWER-TO-FILTER AIR
DUCT (Where Used)

Replace.

GOVERNOR

Replace. Replacement should be EMD Unit Exchange or


equivalent.

FUEL PUMP AND MOTOR

Recondition and qualify. M.I. 4101, M.I. 4110

AUXILIARY GENERATOR

Replace. M.I. 1753. Replacement should be EMD Unit


Exchange or equivalent.

Replace drive couplings. M.I. 1753

INERTIAL AIR FILTER MOTOR

Replace. Replacement should be EMD Unit Exchange or


equivalent.

COOLING FANS

Replace. Replacement should be EMD Unit Exchange or


equivalent.

AIR COMPRESSOR

Recondition. M.I. 1144

Recondition drive coupling. M.I. 1753

- 13-
M.I. 1738

ENGINE

Replace crankshaft harmonic balancer. (Where Recondition and requalify.


Used)
Replace oil pumps.

Remove oil pressure relief valve; clean, inspect EMM


and test.
Replace lower liner inserts.

Inspect injector control linkage. Replace links,


seals, and bearings, if required.

MAIN GENERATOR

AR10 OR D32 WITH LARGE BEARING

Remove bearing cover and inspect for grease M.I. 3317-1


contamination, excessive wear and over-
heating. Apply new grease.

AR10 WITH SMALL BEARING

Replace bearing and bearing housing. M.I. 3317-1

MAIN RESERVOIR SYSTEM

Clean system and recondition valves.

ENGINE

Replace. Replacement should be EMD Unit Exchange or


equivalent.

MAIN GENERATOR

Replace. Replacement should be EMD Unit Exchange or


equivalent.

HIGH VOLTAGE CABLING

Renew. It is recognized that this work may not be


required at this particular time or mileage. How-
ever, shop efficiency may require this operation
at time of engine and generator exchange.

LOW VOLTAGE WIRING

Renew. Same remark as immediately above.

- 14-
M.I. 1738

NON-SCHEDULED MAINTENANCE

A definite time or mileage schedule for items listed below cannot be established due to variations in wear and
component life related to operating conditions.

The following work is to be performed at wheel change time or when truck is removed for reconditioning.

PINION

Check for involute profile wear.

Magnaflux. M.I. 1518

AXLE GEAR

Check for involute profile wear.

Magnaflux. M.I. 1518

AXLE

Magnaflux with wheels and inner races removed. M.I. 1518

TRACTION MOTOR

Check bearings using heat and noise test. M.I. 3900. Whenever truck assembly is removed
from locomotive, check traction motors for
unusual bearing noise or heat at not less than
1500 RPM.

Jigstone commutator and clean slots. M.I. 3900. Restore smooth and concentric surface
when inspection indicates need.

CAUTION
Do not stone commutator by hand.

JOURNAL BOXES/JOURNAL BEARINGS

Clean and recondition. M.I. 1552

TRUCK ASSEMBLIES

Inspect, test, and repair or replace the follow- M.I.‘s 1501, 1504, or 1506
ing items as necessary; frame, bolster, wear
plates, liners, springs, spring seats, snubbers,
brake rigging, rubber bolster springs, shock
absorbers, and sander guides.

0 0 0 0 A Service Department Publication o l l l


Electra-Motive Division Of General Motors La Grange, Illinois 60525

Litho in U.S.A. - 15-

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