GOVERNMENT OF INDIA MINISTRY OF RAILWAYS RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW - 226 011 No. SV.IB Dt: 25.03.2010 INSTRUCTION BULLETIN No. 3. 4. TITLE Movement of EMD & WDP3A locomotives with three axle and WDP1 with two axle bogies as light engine with one defective/iocked axle using wheel set trolley. 2. BACKGROUND There may be instances when axle of locomotives gets locked/ defective on the mid section thus blocking the Railway traffic movement on the effected section. ‘The causes for such an eventuality may one or more of the following i. Axle roller bearing seizure. il. Traction motor suspension bearing seizure. ii, Traction motor roller bearing seizure. iv. Heavy skidding of wheels. Under such an eventuality, it becomes the top priory to move the affected locomotive tothe nearest Station! loco shed! loco workshop and restore the trafic. To facilitate such a movement, a detelod Brocedure has been prepared for movement of Cape gauge locomotives as light engine with one defective axle using wheel set trolley, 3. OBJECT To prepare an instruction bulletin to lay down the procedure for the movement of EMD, WOP3A and WOPI locomotives as light engine with one defectivocked ave using wheel set toll, 4. DETAILS OF STUDY/ EXPERIMENTATION DONE Bogie designs of EMD, WOP3A and WDP1 locomotives have been studied for floating the defective axle {o Place wheel set trolley under i. Study also included the provision of a common whee! set trolley for EMD, WDP3A and WOP1 locomotives having different type of bogies. 5. APPLICATION TO CLASS OF LOCOMOTIVES EMD, WOPSA and WDP1 locomotives 8. INSTRUCTION CONTENTS -1 Instructions of EMD, WOP3A and WOP1 locomotives A. Basic Requirements for placing wheel set trolley under lockedidefective axle The following items should be available at site, before ling the lockedidefective ave: |. Two hydraulic jacks having minimum capacity of 25 tonnes each for iting the locked defective axle ii The distance pieces i.e. ‘wooden blocs" to fil up the gap between axle box and hydrauic ja0ks, if required, ili, Whee! Set Trolley to RDSO Drawing Nos. SK.VL- 215 to 218,iv. v. vi. ‘Two numbers of stee! plates of size 300mm x 300mm x 30mm, which may be required for making the foundation firm and leveled for placement of jacks. Wooden wedges (at least 6 nos.) for application at the wheels for preventing rolling of locomotive while applying jacks, Toolbox with appropriate tools, nuts, bolts, washers and wrenches / spanners. Precautions & Procedure for “PLACING WHEELSET TROLLEY” under locked/defective axle +1. Precautions while floating lockedi/defective axle we i. Dismantle the sand box pipes. Remove footsteps, if required. ji. Apply wooden wedges at wheels of the affected locomotive to prevent roling, ili, Release all the brakes of the affected bogie, which requires lifting. Make the brake rigging of affected axie ineffective. . Isolate the particular traction motor traction motor group of the affected bogie. V. Dismantle the brake rigging slack adjuster. vi. Clamp or remove the vertical brake hanger levers at the location of affected axle at appropriate place with bogie frame to prevent fouling of these levers with the wheel set trolley during movement. Before the application of jacks for iting, ensure that the ground below the lifting jacks 's fm and leveled. Due care must be taken to avoid jacks slipping off. Procedure for lifting locked/defective axle (end & middle) for placing wheel set trolley under it Dismantle the sand box pipes. Remove footsteps, if required. ii, Dismantie the axle box stay plates during liting the locked axle wheel to avoid the hitting with compensating & equalizer beam. ii, _Dismantle the slack adjuster of the locked wheel. Clamp or remove the vertical brake hanger levers of locked axle at appropriate place with the bogie frame to prevent fouling ofthese levers with the wheel set trolley during movement. iv. Remove the primary vertical dampers between the bogie frame and axle boxes of locked axle of the affected bogie. v. Raise the spindle of the hydraulic jacks placed on two sides of the affected axle simuitaneously in upward direction til the spindle just lifts the bearing adopter/axle ‘box & check for stability of the arrangement. vi. Now, ifthe affected axle by 55 to 60 mm by simultaneously applying two jacks of minimum 25t capacity each below the bearing adopter at both sides of the affected axle = vi vii, Assemble the wheel set trolley below the affected axle over the track as elaborated below in such a way that the wheels of this axle rest over the supporting rollers of the trolley. Procedure for assembly of Wheel Set Trolley: a. The locked wheel set has to be lifted up approximately by 65 mm to 60 mm. 'b. Push both the Inner Longitudinal Frames (Item No. 1 of Drg. No. SK.VL-215) of the trolley under the locomotive. Place both the Steel Tubes (Item no. 32 of Drg. No. SK.VL-218) in position. Lift up the frame along with the steel tubes, push in and fasten the tunning wheel arrangements (Item no.3 of Drg. No. SK.VL-215), supporting roller arrangements (Item No. 4 of Drg. No. SK.VL-215) with keys and bolts, 2e. Push the outer longitudinal frames (item No. 2 of Drg. No. SK.VL-215) of the trolley Under the locomotive; lift the frame, push in outer steel tubes / sleeves (Item no, 33 of Drg. No, SK.VL-218) and fasten the frames with keys and nuts, f. To facilitate easy assembly of wheel set trolley, suitable markings as shown in the drawing must be provided to identify the. matching parts, 9. Lower the locked wheel set ofthe locomotive gradually onthe supporting rollers. It is essential to ensure that the wheel flanges of the lifted wheel set are ‘sufficiently clear from the rails, to avold hitting / infringement during movement of the locomotive, especially on curves & turn outs. hh. Sketch no. 2010 - 32 to 39 of Annexure Ill (A) to (G) shows the locations for application of jacks for ling and arrangement of wheel set troley under the affected axle of EMD, WOP3A & WDPY locomotive bogies. i. Release the jacks simultaneously, on both sides of the affected axle ensuring thatthe locomotive wheels of the locked axle rest properly on the rollers of the wheel set trolley. : j, Remove the wooden wedges placed at wheels of the locomotive. . Locomotive with effected wheel set placed on the wheel set trolley can now be moved al arestricted speed, as given in subsequent Para. C, Precautions & Procedure for “MOVEMENT” of locomotive with one lockedidefective axle floated using wheel set trolley -1_ Precautions during movement of locomotive with floated locked/defective axle i. Relevant traction motoritraction motor group of the affected bogie is isolated. |i, Movement of only one locomotive having defective axle in floated condition is Permitted at a time as light engine. ii, If the locomotive having defective axle in floated condition is intended to negotiate ghat sections and grades thereof, the local train operation instructions like speed restrictions etc. should be followed, if they are more restrictive, in addition to the other technical instructions contained in tis IB, iv. In case, the floated axle happens to be a leading axle and turnouts / points have to be negotiated, the locomotive shall be brought to a stop before the tumout and escorting staff should detrain & monitor the passage of locomotive over the turnout. v. Movement of locomotive with a defective axle in floated condition shall be avoided during extreme winter conditions when temperatures below 8°C are reported, especially during night time, Vi. In case operation on track structure consisting of rail 52kg, M+7, 250mm ballast Cushion or superior as well as in case of SOR rail, M+4 sleeper density and 200 mm ballast cushion, movement with WHEEL SET TROLLEY can be considered up to speed 20kmph in straight track and 1Skmph on curves irrespective of degree of Curve to clear the blocked section or to move the affected locomotive to the nearest station/loco shed/loco workshop and restore the trafic. A close watch is necessary while passing over curves and tumouts. The locomotive should be escorted by Permanent way/ competent locomotive shed / workshop staff. Requirement of permanent way staff escort is optional. However, in such case permanent way staff should be intimated about such $ movement vil. The additional instructions regarding movement of such locomotives are enclosed at Annexure I viii, Any other special instructions issued by Railway Board in this context. ix. Such crippled locomotive shall be operated up to speed 20kmph in straight track and ‘15kmph on curves irrespective of degree of curve.7 .2 Procedure for movement of locomotive a In case of axle roller bearing seizure, traction motor suspension bearing seizure and heavy skidding of wheels In such cases: i, Float the concerned axle as per the procedure elaborated above. ji. Isolate the particular traction motor / traction motor group of the affected bogie. i. Work the locomotive as a light engine on its own power with the maximum speed restricted to 20 kmph on straight track and 15 kmph on curved track irrespective of degree of curve to clear the blocked section or to move the affected locomotive to the nearest station/Ioco shed/loco workshop and restore the trafic. A close watch is necessary while passing over curves and tumouts. The locomotive should be escorted by Permanent way/ competent locomotive shed / workshop staff. Requirement of permanent way staff escort is optional. However, in such case permanent way staff should be intimated about such s movement. »._In case of traction motor roller bearing seizure In such cases: i. Remove the pinion of affected traction motor. ji. Isolate the affected traction motor / traction motor group of the affected bogie. ii, Work the locomotive as a light engine on its own power. In this case, the lifting of affected axle, the restriction on speed, single locomotive operation as well as escorting by Permanent way! locomotive shed / workshop staff is not necessary, However, the local train operation instructions like temporary / permanent speed restrictions etc. should be followed, if they are more restrictive. iv. Provision of wheel set trolley as above in such cases is not required. In case of traction motor roller bearing seizure and when removal of its pinion is not possible | such case, the procedure for floating the relevant affected axle and locomotive Movement procedure as in case of axle roller bearing seizure, traction motor ‘suspension bearing seizure and heavy skidding of wheels elaborated here, may be followed. MATERIALS REQUIRED AND SOURCES OF SUPPLY Wheel set trolley as per drawing no. SKVL - 215 to SKVL - 218 along with other accessories as per this 1B Zonal Railways approved sources for similar items. ADDITIONAL INFORMATION (SPECIAL BENEFITS, FINANCIAL IMPLICATIONS. etc) Following IB's may be referred for movement of other diesel locomotives having one axle defective. ‘SNo. [18. NO | DISCRIPTION ‘APPLICABLE FOR Loco 1. | MP.IB.VL-04.05.07(Rev.00) | Movement of locomotive as | WOG3A locomotives with light engine with one high adhesion bogies defective! locked axle floated 2, MP.IB.VL-01.02.07(Rev.00) | Movement of locomotive as | locomotives with timount light engine with one bogies. defective! locked axle floated1. AGENCY AND SCHEDULE OF IMPLEMENTATION 1 AllZonal Railway Head Quarters. .2 Workshops undertaking POH of EMD, WOP3A & WDP1 Locomotives. 3 All Diese! Locomotive Maintenance Sheds with EMD, WDP3A & WDP1 holding, ). DISTRIBUTION All Zonal Railway Head Quarters for circulation to all con Diesel Loco Maintenance Sheds, REFERENCE Nil cerned Locomotive POH Workshops & oe (NARE: R) Director Stds./ MP-(VDG) For Director General / MPMalling List ‘A. EDME/ Traction, Railway Board, Rail Bhavan - 110001 B. Director / CAMTECH / Indian Railways / Maharajpur, Gwalior (MP) ~ 474 020 ©. Director /IRIMEE, Jamalpur, Distt Munger, Bihar~811 214 D. Chief Mechanical Engineer 1. Central Railway CST Mumbai - 400 001 2. Eastem Railway Fale Pace, Kolkata - 700 004 3. Wester Railway Churchgate, Mumbai - 400 020 4, Northern Railway Baroda House, New Delhi - 110 001 5. Southem Railway NGO Annexes, Park Town, Chennai - 600 003 6. North Eastem Railway Gorakhpur - 273 004 7. North Central Railway Allahabad (UP) - 211 004 8. North Westem Railway Jaipur (Rajasthan) - 302 006 9. Northeast Frontier Railway — Maligaon, Guwahati - 781 014 40. East Central Railway Hajpur (Bihar) - 844 101 11. East Coast Railway Rail Vihar, B-2 Chandrasekharpur Bhubaneshwar - 751 023 12. South Eastem Railway Garden Reach, Kolkata - 700 043 43. South Central Railway Rail Nilayam, Secunderabad - 500 071 14, South West Railway Hubli (Karanataka) - 580 023 15. South East Central Railway Bilaspur (CG) - 495 004 16. West Central Railway Jabalpur (MP) - 482 001 47. CLW Chittaranjan ~ 713 331 48. DLW Varanasi~ 221 004 49. DMW Patiala ~ 147 001 20. Rail Wheel Factory Yelahanka, Bangalore - 560 064 E. Chief Works Manager 1. Central Railway Workshop, Parel, Mumbai 2. Eastern Railway Workshop, Jamalpur— 811 214 3. Western Railway © & W Workshop - Dahod, Gujrat 4. Northem Railway Loco Workshop, Charbagh, Lucknow - 226 005 5. Southern Railway Workshop, Golden Rock, Tiruchirapali- 620 004 6. South Eastern Railway Workshop, Kharagpur - 721 304 7. North Westem Railway Workshop, Ajmer - 305 001F. Sr. Divi Central Railway Central Railway Central Raiiway Central Railway Central Railway Central Railway Central Railway Central Railway Eastern Railway |. Eastem Railway Eastem Railway . Eastern Raltway ._Eastem Ralway . Eastern Railway 5. Eastem Railway . Eastern Railway ~ Northem Railway 5; Northem Railway Norther Railway Northem Railway |. Northem Railway . Northem Railway }. Northern Railway. . Northeast Frontier Railway 5. Northeast Frontier Ralway . Northeast Frontier Railway "Northeast Frontier Railway . North Eastern Railway North Eastem Railway Southem Railway "Southern Railway Southem Railway . Southem Raitway ‘Southem Railway 35. South Central Railway . South Central Railway South Central Railway ; South Central Railway South Central Railway ‘South Central Railway |. South Eastern Raiiway South Eastem Raitway South Easter Ralway . South Easter Railway 5. South Eastem Railway . South Eastem Railway . Westem Railway ; Westem Railway Wester Railway Wester Railway. . Wester Railway . Westem Railway . Westem Railway J. Westem Railway 5. North East Railway . East Central Railway 1al Mechanical Engineer (Dsl,) / Div. Mech. Engineer (Dsl.), Diesel Loco Shed: itarsi - 461 115 New Katni Jn. - 463 501 dhansi - 284 001 Pune - 411 103 Kalyan -421 304 ‘Agra Cantt- 282 001 Kurla, Mumbai - 400 024 Gwalior - 474 0041 Andal -713 324 ‘Burdwan - 713 304 Bamangachi, Howrah - 711 106 Beliaghata, Sealdah - 700 014 Howrah 711 101 Jamalpur - 814 214 Patratu - 829 120 Mughalsarai - 232 101 Tughlakabad, New Delhi- 110.044 Mughalsarai- 232 101 Bhagat - ki kothi, Jodhpur - 342 004 ‘Alambagh, Lucknow - 226 011 Ludhiana - 144 001 Shakurbast, Delhi- 110 034 Kalka - 133 302 Sligur Jn.-734 403 Malda Town ~732 102 ‘Narangi, New Guwahati - 781021 Lumding -782.447 Gonda - 271 002 lzatnagar, Distt, Bareilly - 243 122 Golden Rock, Ponmalai, Tiuchchirapalli-620 004 Erode - 638 602 Emakulam Jn. - 682 011 Krishna Rejapuram, Bangalore - 560 036 Tondiarpet, Chennai - 600 081 Guntakal -522 004 Kazipet - 500 803 Gooty - 515 401 Vijaywada -520 001 Mauta Ali - 600 040 EMD Diesel Shed, Hubli, Kamataka Vishakhapatnam - 530 008 Bondamunda - 770 032 Kharagpur - 721 301 Raipur (M.P.) Angul, Orissa. Bokaro Steel City ~ 827 010 Ratlam - 457 00' ‘Abu Road - 307 026 Vatva, Ahmedabad - 382 445 ‘Sabarmati, Ahemdabad - 380 019 Gandhidham, Kutch - 370 201 Phulera (Rajasthan) Bandra, Mumbai - 400 060 Pratapniagar - 390004 Samastipur (Bihar) 848 101 Narkatia Ganj, West Champaran (Bihar) - 845 455ANNEXURE | ADDITIONAL INSTRUCTIONS REGARDING MOVEMENT OF LOCOMOTIVES WITH TRIMOUNT BOGIES & HAVING ONE LOCKED / DEFECTIVE AXLE FLOATED 1. General: i. The defective locomotive with one axle floated shall be escorted by competent permanent way / locomotive shed / workshop staff. Requirement of permanent way staff is optional. ii, Whenever a locomotive with one axle in floated condition is required to be moved, the diesel Power controller! traction locomotive controller shall advise engineering control of the division about the intended movement. Competent staff shall be arranged to escort the defective locomotive within a reasonable time as mentioned above, li, Appropriate mechanism shall be set up in the control office for movement of such locomotives in accordance with the instructions as above. 2. In.case of movement of locomotives with Cape gauge bogies as light engine with one defective ale floated using Whee! Set Trolley: i. The first tran to traverse the stretches in the sections, after movement of locomotive with wheel in floated condition, shall be restricted to work at not more than 20 kmph speed on straight track and 15 kmph on curved track imespective of degree of curve. In the event of report of any unusual problem, adequate precautions by way of speed restrictions ete. may be prescribed for subsequent trains. ji. In the event of ‘No Abnormality Report” on the movement of firs train after the whee! floated locomotive, all subsequent trains shall move at normal speed, subject to all other restrictions in force. ii, Since the axle load of affected axle is bome by the wheel set trolley (with 04 miniature wheels), there is no possibilty of redistribution ofthis axle load to the remaining two axles of the affected bogie. Hence, there is no requirement of inspection of the track in the stretch traversed by locomotive with floated wheel to be done by USFD (Ultrasonic flow detective) team‘ANNEXURE I = B&S Directorate No CBS/HHDL Datedz¢11-2008 ‘Sub: Movement of locomotive with one defective axle as light engine. Ref: Motive Power Directorate’s note no. SV. TOW.Eqpt. dated 07-11-2008. In ref.to above it is stated that the instruction for movement of locomotive with one defective axle as light engine is being vetted from bridge point of view with the following conditions - (a) The clearance refers to bridges with standard design of girders slabs, pipe culverts. piers and abutments etc. issued by RDSO for BGML, RBG and MBG-1987 standard loadings. However,the bearings of span 78.8 m (effective) designed for BGML standard loading as per RDSO's drawing No. BA-11154 should be strengthened by providing two additional anchor bolts. (b) Superstructures & bearings of non-standard spans including Arches and sub-structures of all bridges are to be examined under the directions of the Chief Bridge Engineer concern and certified safe by him in terms of current IRS Bridge Rules, Steel Bridge Code, Concrete Bridge Code, Arch Bridge Code, Bridge Sub-Structures and Foundations Code etc. read with up to-date correction slips (c) Zonal Railways to certify adequacy of existing bridges for permitting rolling stock based on physical condition of bridges by keeping them under observations considered necessary by the Chief Bridge Engineer of Railway (d) Location of bridges on which speed restrictions are imposed shall be notified by the Railways and incorporated in the working timetable. One copy of the above Instruction Bulletins may please be sent to this directorate when issued. 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