INSTRUCTION BULLETIN MP.IB.EN.04.15.10

1. TITLE Run out measurement process for conventional and FE Cam-shaft of ALCo locomotives. 2. INTRODUCTION/BACKGROUND

Cases of breakage of cam and split gears and breakage of L9/R9 cam block in engine block have been reported frequently. A lot of measures were undertaken in the design improvement of cam/split gears and L9/R9 cam blocks. Excessive run out of cam shaft is considered to be playing some part in these failures. Accordingly in 40th DMG, the maximum value of TIR of cam shaft was recommended 0.002”( individual segment) and 0.004” (in assembly condition). Since SUCS have nos of joints as it is assembled with 17 pieces ( 8 segment +7 spacers +2 Gen. end/Free end shafts) in one bank, it is therefore, not practicable to achieve the run out of assembly to the extent of 0.002 thou. So SUCS has been kept away from this exercise.

3. REFERENCE

Reported high rate of rejection of Cam-shafts by zonal railway

4. SCOPE It will help in increasing the reliability and reducing rate of rejection for Conventional and FE camshaft

5. TECHNICAL CONTENT

The cam-shaft should be of manufactured with concentric/same diameters at bearing surface so that it during rotating no surface of the journal diameter should have a metallic contact with bushing surface. In case of excessive run out, it will not only damage to cam blocks but contact of split gear and cam gear shall shift beyond PCD to either direction or leading to gear breakage. To avoid the said problem, run out of camshaft should be controlled and maintained to prescribe limits.

(a) Devices required:- i. Matched ‘V’-block/s. Or V blocks with rollers (DLW Drawing

No.MT.05AL0095) enclosed as Annexure I source are given in Annexure II. ii. Dial Gauge

iii. Surface table ( EXCELLO make or similar with key way, Which could accommodate full length of assembled camshaft)

(b) Method:-

i. If ‘V’ blocks with rollers are used, the rollers are inspected for the wear otherwise it shall give erratic readings during TIR checking. In case of wear, it should be replaced.

ii. Surface table is trued with the help of sprit level.

iii. The V-blocks are fitted in the sIot of the Ievelled surface table. iv. The cam-sbafts are assembled and each bearing journal is placed on a Y

block. v. The dial-gauge 9tylus is made to touch on the bearing surface of cam-shaft- . The cam-shaft is rotated about its artis wirh the stylus touching its bearing

surface. (c) 0bsewation:-

i. If the cam-shaft bearing surface is perfectly round then the pointer of the dial of dial gauge will be stationary at every point on the periphery of journal [mostly at 'O'(zero)].

i. If there is any discrepancy then there will dflection of dial-gauge pointer. iii. This deflection of pointer for F'E and Conventional cam-shafts is

O.O02"(max. permissible) iv. If deflwtion of pointer is more than the above permissible limits the cam-

shaft/~ /are zejected far fitment on loco. v. The Values of TIR should be recorded in following table

NOTE:- The above method of run-out checking has been prescribed keeping in View that the threaded fasteners have been tightened to the proper torque value. (90 ft. lb~].

Location

Emended Shaft ta

(6) AGENCDB FOR IMPLEMENTATION-

Run Out Measurement in Thou 0" ( 90" / 180" 1 270"

(1) DLW Cz) QMJw (3) FOB Workshops

(7) Distribution CIOPMW, CDEJDLW, All CWMs, CMPEs and Sr. DMEs (As pm enclosed List )

(Ad Kumar) Director (3)

For Director General/ RDSO

Annexure-I

Annexure-II

Vender for MTO5AL0095

1. WELL MECH CORPORATION 12/1 ‘Z’ROAD SHAUPUR (SOUTH) DASNAGAR, HOWRAH- 711105

2. J.D.ENGINEERING Pvt. Ltd 39, KALI KRISHNA TEGORE STREET 4th Floor, room No. 411 KOLKATA-700007

3 ELECTRO MECH VILL. & POST- RAGHUDEVBATI VIA FORT GLOSTER SANK RAIL HOWRAH- 7111310

1. CIO, Diesel Modernisation Works, Patiala 2. Cheif Design Engineer, Diesel Locomotive Works, Varanasi.

The Chief Works Manager,

1. Northern Railway Loco Workshop,Charbagh,Lucknow - 226 005. 2. Southern Railway Workshop, Golden Rock, Tiruchirapalli - 620 004(TN) 3. Central Railway Workshop, Parel, Mumbai. 4. South Eastern Railway Workshop, Kharagpur. - 721 304 5. Western Railway Workshop, Ajmer.- 305 001 6. Eastern Railway Workshop,Jamalpur, Distt.Munger-811214 (Bihar)

The Chief Motive Power Engineer (Dsl) 1 Central Railway CST Mumbai – 400 001. 2 Eastern Railway Fairlie Place, Kolkata – 700 001. 3 Northern Railway Baroda House, New Delhi – 110 001. 4 North Eastern Railway HQrs. Office, Gorakhpur – 273 001. 5 Northeast Frontier Railway Maligaon, Guwahati – 781 011. 6 Southern Railway NGO Annexe, Park Town, Chennai – 600 003. 7 South Eastern Railway Garden Reach, Kolkata – 700 043. 8 South Central Railway Rail Nilayam, Secunderabad – 500 371. 9 Western Railway Churchgate, Mumbai – 400 020. 10 East Central Railway HQrs. Office, Hajipur – 844101. (Bihar) 11 East Coast Railway HQrs. Office, Rail Vihar, B-2 Chandrasekharpur,

Bhubaneshwar-571 023 12 North Central Railway HQrs. Office, Allahabad – 211 001. 13 North Western Railway HQrs. Office, Jaipur – 302 006. (Rajasthan) 14 South East Central Railway HQrs. Office, Bilaspur. (CG) 15 South Western Railway HQrs. Office, Hubli (Karnataka). 16 West Central Railway HQrs. Office, Jabalpur (MP). The Sr. Div. Mech. Engineer(Diesel)/ Div. Mech. Engineer(Diesel), Diesel Loco Shed:

1 Central Rly. Diesel Loco Shed Pune - 411103 2 Diesel Loco Shed Kalyan - 421304 3 Eastern Rly. Diesel Loco Shed Andal, Distt. Burdwan - 713 321(WB) 4 Diesel Loco Shed Burdwan, Distt. Burdwan- 713 101 (WB), 5 Diesel Loco Shed Jamalpur, Distt.Munger- 811214(Bihar), 6 Diesel Loco Shed Bamangachi, P.O. Salkia, Howrah – 711106

(W.B.) 7 Northern Rly. Diesel Loco Shed Tughlakabad, New Delhi - 110 044 8 Diesel Loco Shed Alambagh, Lucknow - 226 011 9 Diesel Loco Shed Ludhiana – 141 001 10 North Eastern Rly. Diesel Loco Shed Gonda – 271 002(UP) 11 Northeast Frontier Rly. Diesel Loco Shed Siliguri Jn.- 734 403 12 Diesel Loco Shed Malda Town – 732 102 13 Diesel Loco Shed New Gauhati 14 Southern Rly. Diesel Loco Shed Golden Rock, Ponmalai, Tiruchchirapalli -

620 004 15 Diesel Loco Shed Erode – 638 002(TN) 16 Diesel Loco Shed Ernakulam Jn. - 682 011(Kerela) 17 Diesel Loco Shed, Tondiarpet - 600081(TN) 18 South Central Rly.

Diesel Loco Shed Guntakal, Anantpur (AP) – 515801

19 Diesel Loco Shed Kazipet, Distt.-Warangal (AP) – 560 003

20 Diesel Loco Shed Gooty, Anantpur Distt (AP) - 515 402 21 Diesel Loco Shed Maula Ali, Hyderabad(AP) - 500 147 22 Diesel Loco Shed Vijaywada, Khuddus Naga, Krishna Distt.

Vijaywada(AP) – 520 001 23 South Eastern Rly. Diesel Loco Shed Bondamunda, Sundar Nagar, Orissa– 770 032 24 Diesel Loco Shed Kharagpur, Distt. Midnapure(WB) - 721 301 25 Diesel Loco Shed Bokaro Steel City – 827 010 26 Diesel Loco Shed, Angul, Distt.- Angul, Orissa 27 Western Rly. Diesel Loco Shed, Ratlam – 413701 (MP) 28 Diesel Loco Shed Vatva , Ahmedabad – 382 445 (Gujrat) 29 Diesel Loco Shed Sabarmati , Ahemdabad - 380 019 (Gujarat) 30 Diesel Loco Shed Gandhidham, - North Gujrat-370021 31 Diesel Loco Shed Gandhidham, Kutch-370 011 32 Diesel Loco Shed, Pratap Nagar, Baroda (Gujrat) -390 004 33 Diesel Loco Shed, Bandra, Maharashtra – 400 051 34 East Central Rly.

Diesel Loco Shed Mughalsarai, distt. Chandauli- 232 101(UP)

35 Diesel Loco Shed, Samastipur, Bihar. 36 Diesel Loco Shed Patratu, Distt. Hazaribagh - 829120

(Jharkhand) 37 East Coast Rly. Diesel Loco Shed Vishakhapatnam, P.O. Kanchrapalam(AP)-

530 008 38 North Central Rly. Diesel Loco Shed Jhansi - 284001 39 North Western Rly. Diesel Loco Shed Bhagat - ki -kothi, Jodhpur - 342 001 40 Diesel Loco Shed,Abu Road Sirohi – 307 026 41 Diesel Loco Shed Phulera-303338 (Rajasthan) 42 South East Central Rly. Diesel Loco Shed Raipur, Chhattisgarh-492005 43 South Western Rly. Diesel Loco Shed Krishna Rajapuram , Bangalore - 560 036 44 Diesel Loco Shed, Hubli, near Rly Jn. Gadag Road, Shazrwal

Distt., Karnataka – 580 020 45 West Central Rly. Diesel Loco Shed Itarsi - 461115 46 Diesel Loco Shed New Katni Jn. - 463 501