MA.

1 7 4 0
*Rev. J

SCHEDULED MAINTENANCE PROGRAM

TURBOCHARGED F, GP, &SD MODEL
LOCOMOTIVES (645E3 THRU 645E3C ENGINES)
4 . Lubricating oil filters will be of a quality equal
INTRODUCTION to original equipment and will be changed at the
intervals specified in this M.I.
This Maintenance Instruction provides average
recommendations which should ensure satisfactory
locomotive operation and economical maintenance 5. Procedures listed in M.I. 1705 or 1707 will be
cost where average load factors and average climatic followed for new locomotives and newly
conditions are encountered. It is intended to serve installed replacement assemblies.
as a guide when establishing maintenance schedules
that will meet the particular requirements of
individual operations and planned economic life of INSTRUCTION REFERENCES
the locomotive.

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

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

1 Areas of change are indicated by vertical bars.

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 M.I. 1740

I
LUBE OIL FILTERS
Check lube oil filter tank pressure. LSM. Checks can be made weekly or more often at
fueling or turnaround points. Replace filter
elements if tank pressure so indicates.

FUEL FILTER

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

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

(Where Used)
Check drain valve operation. M.I. 582

I
LUBE OIL

Take sample for analysis. The services of a competent laboratory may help to
monitor the suitability of the oil for continued use
according to M.I. 1752.

ANNUNCIATOR MODULE (Where Used)

/Monitor annunciator and record lighted LSM, ETG

indicators.

Perform checks or maintenance indicated by

lights.

Set annunciator switch to test position and

observe that all annunciator lamps are lighted.

I Place annunciator switch in reset position.

ENGINE PROTECTOR

Check operation. EMM, LSM, MI. 259 or MI. 260

AIR BOX DRAINS

I Check operation and clean, if necessary. EMM

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 M.I. 1740

I
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 are
required. removed, clean the inspection windows, and inspect
collector rings and brushes.

SOAK BACK PUMP AND MOTOR

Check operation. With the engine shut down and soak back pump
motor running, remove left rear handhole cover and
check oil flow through gear train.

Observe camshaft bearings. If lube oil flows from

camshaft bearings with soak back pump running
and engine shut down, inspect turbo filter outlet
check valve for proper operation.

JOURNAL BOX (CYLINDRICAL ROLLERS)

Maintain to fill plug level. M.I. 1756, M.I. 1552. Oil level maintenance is
dependent on type of service and may be required
before the 45 day inspection. I

LUBE OIL FILTER-SEVEN ELEMENTS

Change filter elements. LSM. Oil filter changeout is dictated by filter

pressure readings and may be required before the
45 day inspection.

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

I
TURBOCHARGER AND SOAK BACK
OIL FILTERS
Replace elements. Filter elements must be of a quality equal to original
equipment. The interval of change for turbocharger
and soak back filter elements is influenced by load
factor, kind of lubricating oil, type of operation,
climatic conditions, and maintenance of main lube
oil filters.

Where these factors are favorable, it may be possible

to extend the period to 3 months, but do not exceed
this interval due to a possible loss of filter structural
integrity.
I

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 M.I. 1740

GENERATOR PIT DRAIN ASPIRATOR

I Inspect and clean, if needed. LSM

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 filter(s). LSM. Use only pleated cotton-paper elements.

COOLING SYSTEM
Check inhibitor concentration. M.I. 1748

Check for proper cooling system drain operation

(Where Used).

FUEL TANK

Drain condensate. LSM. More frequently during periods of high

humidity or rapid temperature change.

I
MAIN GENERATOR

Inspect rectifier banks. Clean as necessary to minimize dirt accumulation.

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

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.

INTERIAL FILTER BLOWER MOTOR

Check operation.

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

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 M.I. 1740

ENGINE AIR FILTERS - PAPER

Take manometer readings. Replace elements if LSM
necessary.

ENGINE AIR FILTERS - FIBERGLASS

Replace elements.

TURBOCHARGER EXHAUST DIFFUSER

Visually inspect for evidence of warpage or

damage.

EDUCTOR TUBE

Inspect for carbon deposits and clean, if EMM

necessary.

BATTERY

Wash cell tops and apply petroleum jelly to

terminals.

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

LOW VOLTAGE ELECTRICAL SYSTEM

Check for grounds. LSM

ENGINE

Inspect air box. EMM

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 EMM

for 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.

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 M.I. 1740

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OIL SYSTEM

Change engine oil. LSM, EMM. Evaluation of engine and oil condition
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.

ENGINE

Check pressure drop across aftercoolers, oil bath LSM. Clean air passages if necessary.
filter equipped engines only.

Check exhaust manifold base flange bolts for

proper tightness.

EXHAUST SYSTEM

Remove manifold adapter and screen assembly. EMM

Check for cracks, clean screen and trap box. If
foreign objects are found in trap, inspect turbine
I vanes and power assemblies.

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

Inspect collector rings and brushes. M.I. 3317-2

Reverse polarity of collect rings.

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, ETG

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 M.I. 1740

VOLTAGE REGULATOR (Where Used)

Check auxiliary generator output voltage. LSM, ETG

Check auxiliary generator reference voltage.

VR MODULE (Where Used)

Check auxiliary generator output voltage. LSM, ETG

TH MODULE (Where Used)

Check output voltage of VRR section. LSM

GROUND RELAY
Check ground relay action. LSM

HANDBRAKE
Check operation and lubricate. MI. 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. (All except those equipped with plate type
crabs.)

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

Head frame to crankcase bolts. EMM

Turbocharger to air duct bolts, aftercooler to air EMM

duct bolts, and air duct to crankcase bolts, and
turbine inlet link bolts.

ENGINE
Replace top deck cover seals and check latches. EMM

Qualify injectors. EMM. Perform “Pop” test.

Set injector timing and injector rack length. EMM

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 M.I. 1740

ENGINE (CONT’D)
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

Check pressure drop across aftercooler; paper LSM, EMM. Clean air passages if necessary.
and fiberglass filter equipped engines only.

Inspect crankshaft damping device. EMM

Remove, clean, and inspect; replace if necessary. EMM

Soak back check valve in the turbo filter inlet.

Soak back oil pressure relief valve in the soak

back filter head.

Soak back filter bypass valve in the soak back

filter head.

Turbo oil filter check valve in the turbo filter

head.

1 Inspect oil pan. Clean if prime painted surface is not visible.

EXHAUST SYSTEM
Inspect manifold sections for possible cracked leg
baffles or expansion joints and replace, if
necessary.

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

AIR FILTERS
Carbody (Inertial) LSM

Measure pressure drop. Clean if necessary.

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 M.I. 1740

MAGNET VALVES

Clean and replace seats. MI. 4707

ELECTRICAL CABINETS

I P ressure Taps

Check hoses and taps for leaks or obstructions.

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.

I AUXILIARY
TYPE
GENERATOR-COMMUTATOR

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

DYNAMIC BRAKE RHEOSTAT(Where Used)

Blow out with dry air. Inspect contact brush and M.I. 4334
replace if necessary.

LOAD REGULATOR - LINEAR-TYPE

RHEOSTAT

Blow out with dry air and clean windings, if M.I. 4506
necessary.

Check rheostat operation and replace if necessary.

FUEL PUMP MOTOR

Inspect and clean with dry air. MI. 4101

I Inspect brushes. Replace if ne’cessary.

STARTING MOTORS
Blow out with dry air. EMM

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M.I. 1740

CAB HEAT BLOWER MOTOR

Replace brushes.

AIR CONDITIONER (Where Used)

Inspect compressor motor brushes and replace if M.I. 4122
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 and applicable M.I.

Replace or recondition shutter magnet valves. M.I. 4707

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.)

SOAK BACK PUMP MOTOR

Inspect and clean with dry air. M.I. 4101

Replace brushes.

MAIN GENERATOR

Replace collector ring brushes. M.I. 33 17-2

TRACTION MOTOR

Check air duct bellows for alignment and

leakage. Inspect wear plates and arm.

HEAD END GEAR BOX (Where Used)

.
Change oil. M.I. 1252

Clean oil fill/ breather assembly.

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 M.I. 1740

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.

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

OIL SYSTEM
Clean filter housing. Clean if prime painted surface is not visible.
I
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

(Where Used)
Recondition automatic drain valve. M.I. 582

LUBE OIL COOLER

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

I
LUBE OIL FILTER

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

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M.I. 1740

SOAK BACK PUMP

Replace coupling spider.

COOLING SYSTEM PRESSURE CAP

Replace cap. LSM

Inspect filler neck for damage. Replace if

damage.

ENGINE PROTECTOR
Replace or recondition and requalify. MI. 259 or M.I. 260. Qualify on test stand after
renewing springs, “0” rings, and diaphragms.
Replacement can be EMD Unit Exchange.

HOT OIL DETECTOR

Remove and check for operation at proper LSM
temperature.

FUEL PUMP AND MOTOR

Replace coupling spider.

STARTING MOTORS

Disassemble, clean, and lubricate. EMM

Inspect brushes and replace if necessary. EMM

AIR COMPRESSOR (Gear Type Oil Pump)

Replace oil filter. M.I. 1144

FUEL OIL PREHEATER (Where Used)

Renew thermostatic valve element.

ENGINE

I Recalibrate injectors and check lash adjusters. EMM

ELECTRICAL CONTROL CIRCUITS

Check settings and operation of non-modular LSM
protective and regulating devices and circuits.

On module equipped locomotives, qualify ETG

modules and related circuits.

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 M.I. 1740

ENGINE

Replace cylinder assemblies. EMM

Replace injectors. EMM. Replacement should be EMD Unit

Exchange or equivalent.

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.

I Q uahfy
. lash adjusters and valve bridges. EMM

Check exhaust valve timing. EMM

Replace water pump seals and all worn parts. EMM

Inspect lower liner inserts and replace if EMM

necessary.

AIR COMPRESSOR

Recondition valves. M.I. 1144, LSM

TRACTION MOTORS
Replace. Replacement motors should be EMD Unit
Exchange or equivalent. Refer to non-scheduled
maintenance portion of this M.I.

MAIN GENERATOR
Remove rectifier assemblies from air box. MI. 3317-2.
Remove 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.

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 M.I. 1740

DYNAMIC BRAKE BLOWER

Replace. Replacement should be EMD Unit Exchange or

equivalent.

TURBOCHARGER
Unit Exchange. EMM. Average individual operating conditions will
determine frequency.

TURBOCHARGER-TO-FILTER AIR DUCT

(Where Used)
Replace.

GOVERNOR ’
Replace. Replacement should be EMD Unit Exchange or
equivalent.

FUEL PUMP AND MOTOR

Recondition. M.I. 4101, MI. 4110

SOAK BACK PUMP AND MOTOR

Recondition. M.I. 4101, MI. 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.

I
AIR COMPRESSOR

Recondition. MI. 1144

Recondition drive coupling. M.I. 1753

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 MI. 1740

HEAD END GEAR BOX (Where Used)

Recondition. M.I. 1252

Recondition drive coupling. M.I. 1753

ENGINE

Replace or recondition oil pumps. EMM. Replacement can be EMD Unit Exchange.

Remove oil pressure relief valve; clean, inspect, EMM

and test.

Replace lower liner inserts. EMM

Inspect injector control linkage. Replace links, EMM

seals, and bearings if required.

MAIN GENERATOR
(Large bearing) Remove bearing cover and M.I. 3317-1
inspect for grease contamination, excessive wear,
and overheating. Apply new grease.

(Small bearing) Replace bearing and bearing M.I. 3317-1

housing.

MAIN RESERVOIR SYSTEM

Clean system and recondition valves.

I
ENGINE
Replace crankshaft viscous damper (Where EMM. Replace with gear type damper.
Used).

Remove crankshaft gear type damper (Where EMM. Inspect, qualify, &recondition, if necessary.
Used).
I
I

ENGINE
Replace. Replacement should be EMD Unit Exchange or
equivalent.

MAIN GENERATOR

Replace. Replacement should be EMD Unit Exchange or

equivalent.

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M.I. 1740

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 maximum 1500 RPM. 1

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 (cylindrical rollers). M.I. 1552

Remove and requalify (tapered rollers). M.I. 1553

TRUCK ASSEMBLIES

Inspect, test, and repair or replace the following M.I.‘s 1501, 1504, or 1506
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 l l 0 l

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

- 16- Litho in U.S.A.