M.I.

1738

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
5. Procedures listed in M.I. 1705 or 1707 will be
where average load factors and average climatic
followed for new locomotives and newly installed
conditions are encountered. It is intended to serve as a
replacement assemblies.
guide when establishing maintenance schedules 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 reference
conditions: publications that contain information related to
maintenance. The following examples are provided to
1. Fuel oil used will meet the specifications of aid in understanding the abbreviations used.
Maintenance Instruction 1750.
LSM means Locomotive Service Manual
2. Lubricating oil used will meet the specifications of
the applicable Maintenance Instructions, and will EMM means Engine Maintenance Manual
be changed at the intervals specified in this M.I.
M.I. means Maintenance Instruction
3. Engine coolant used will meet the specifications in
Maintenance Instruction 1748.

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

DE-L July 1978

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M.I. 1738

ONE WEEK OR 3500 MILES

LUBE OIL FILTERS

Check lube oil filter tank pressure. LSM. Checks can be made weekly or oftener at fueling or
turnaround points. Replace filter elements 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.

ONE MONTH OR 15,000 MILES

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.

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.

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M.I. 1738
ONE MONTH OR 15,000 MILES (CONT'D)

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

TWO MONTHS OR 30,000 MILES

LUBE OIL FILTER

Change filter elements. LSM

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

THREE MONTHS OR 45,000 MILES

FUEL FILTERS

Clean or replace suction strainer element. LSM

Change engine mounted filter elements. EMM. Use only elements equalto original equipment.

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

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M.I. 1738

THREE MONTHS OR 45,000 MILES (CONT'D)

COOLING SYSTEM

Check inhibitor concentration. M.l. 1748

FUEL TANK

Drain condensate. LSM. More frequently during periods of high humidity or rapid
temperature change.

TRACTION MOTORS

Replace brushes (in sets only). M.l. 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 lubri- Clean and replace as necessary.
cators for dirt plugging of the wick and
for excessive wear.

INERTIAL FILTER BLOWER MOTOR

Check operation.

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.

LOW VOLTAGE ELECTRICAL SYSTEM

Check for grounds. LSM

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M.I. 1738
THREE MONTHS OR 45,000 MILES (CONT'D)

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 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

SIX MONTHS OR 90,000 MILES 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.

Clean oil pan.

Clean filter housing.

ENGINE

Check exhaust manifold base flange bolts

for proper tightness.

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M.I. 1738
SIX MONTHS OR 90,000 MILES (CONT'D)

RADIATORS

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

MAIN GENERATOR AR10/D14

Inspect collector rings and brushes. M.I. 3317-2 Reverse polarity of collector rings.

D32/D14

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

HANDBRAKE

Check operation and lubricate. M.I. 1577

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M.I. 1738
ONE YEAR 180,000 MILES

ENGINE BOLT AND NUT RETORQUING

Cylinder head crab nuts. Loosen, and then torque to value specified in 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.

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 EMM harmonic balancer while engine is being barred
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

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M.I. 1738

ONE YEAR OR 180,000 MILES (CONT'D

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

Visually inspect tips of all power
contactors, reversers, and brake transfer switches.
Replace as required.

Check timing of time delay devices.

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.

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M.I. 1738
ONE YEAR OR 180,000 MILES (CONT'D)

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.

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

Replace or recondition shutter magnet valves.

RADIATORS

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

DYNAMIC BRAKE GRIDS (Where Used)

Inspect and blow clean with dry air.

DYNAMIC BRAKE BLOWER

MOTOR (Where Used)

Inspect in place; renew brushes as necessary.

(Replace brushes in sets.)

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M.I. 1738

ONE YEAR OR 180,000 MILES (CONT'D)

MAIN GENERATOR

AR10/D14

Replace collector ring brushes.

D32/D14

Replace collector ring and commutator 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. 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.

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M.I. 1738

TWO YEARS OR 360,000 MILES

LUBE OIL COOLER

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

HOT OIL DETECTOR

Remove and check for operation at proper LSM temperature.

GOVERNOR

Renew diaphragm. EMM

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

Replace. M.I. 259 or M.I. 260. Qualify on test stand after renewing
springs, "O" rings, and diaphragms.

ELECTRICAL CONTROL CIRCUITS

Check settings and operation of non-modular LSM

protective and regulating devices and circuits.

On module equipped locomotives, qualify mod- LSM

ules and related circuits.

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M.I. 1738

THREE YEARS OR 540,000 MILES

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

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--AR10

Remove rectifier assemblies from air box. Re- 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.

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M.I. 1738

FOUR YEARS OR 720,000 MILES

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. M.l. 4101, M.1. 4110

AUXILIARY GENERATOR

Replace. M.1. 1753. Replacement should be EMD Unit Exchange or

equivalent.

Replace drive couplings. M.1. 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.

SIX YEARS OR 1,080,000 MILES

AIR COMPRESSOR

Recondition. M.l. 1144

Recondition drive coupling. M.l. 1753

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M.I. 1738

SIX YEARS OR 1,080,000 MILES (CONT'D)

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.

TWELVE YEARS OR 2,160,000 MILES

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. However, shop efficiency may
require this operation at time of engine and generator exchange.

LOW VOLTAGE WIRING

Renew. Same remark as immediately above.

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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 M.I. 1518

removed.

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.

• • • • A Service Department Publication * * * *

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

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