Instruction Bulletin no. MP.IB.EM.08.70.

09

Government of India,
Ministry of Railways
Research Designs & Standard Organisation
Manak Nagar, Lucknow 226 011
Instruction Bulletin no.MP.IB.EM.08.70.09

Dated 29.10.2009

1.0 TITLE:
Instructions for arresting loosening/ breakage of screws fitted in roller
suspension bearing unit and gear case of Alco locomotives.
2.0

BACKGROUND:
The fitment procedure and maintenance of the suspension bearing
arrangement on ALCO locos was standardized through MP.MISC.- 141
(Rev.01), September 2006 (Schedule of standard examinations of 3100 HP
and 3300 HP Diesel Electric Locomotives fitted with Roller Suspension
Bearings), MP.MI-20 of Nov. 2001, MP.MI-22 of March2002 and
MP.IB.EM.01.22.09.

2.1

In view of continued complaints by Diesel sheds regarding loosening of cap

screws, some of the maintenance practices advised in MP.IB.EM.01.22.09
have been studied afresh and this additional instruction bulletin is being
issued.

3.0

OBJECT:
The object of this IB is to lay down guidelines to prevent loosening of screws
of suspension tube and gear case during locomotive run.

4.0 DETAILS OF STUDY/ EXPERIMENTATION DONE:

Study has been carried out in diesel sheds regarding problem of loosening of
screws fitted at the locations. These screws become loose due to vibrations
generated on locomotive at run. The torque value of the screws has been
revised upward along with instruction to use thread locker vide IB no.
MP.IB.EM.01.22.09. In order to arrest cases of loosening of these screws a
new design of washer known as Disc-Lock washer has been developed for
application at these locations and demonstrated in Itarsi and AMV Diesel
Sheds. This washer has been found to be effective in preventing loosening
of these screws.
5.0

APPLICATION TO CLASS OF LOCOMOTIVES:

All Alco design of locomotives with MSU arrangement.

6.0

INSTRUCTION CONTENT:
In order to arrest loosening/ dropping/ breakage of screws of suspension
tube components following instructions are being issued;
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Instruction Bulletin no. MP.IB.EM.08.70.09

i)

This IB shall give an option to the sheds etc. to switch over to Disc Lock
washer in case they are unable to arrest the loosening by application of
thread locker/ use of higher torque. In case the Disc lock washers are
used, revised torque values shall have to be used as given in table-I.

ii) Provision of disc lock washers shall be done on all M-12 and M-36 bolts
fitted on wheel/ gear end of MSU components and gear case as per table
below:
Table- I
S.
No.

3
4

Size of Screw/
Location
/Qty.

Part no./
Order

Torque with
Disc Lock
Washer
(Kg.cm)
418 to 503

Torque with
Conventional
Washer
(Kg.cm)
800 to 1000

M12 x L70 at RWE

of MSU
Qty. = 8 nos.
M12 x L90 at GWE
of MSU
Qty. = 8 nos.
M36 of MSU
Qty. = 8 nos.
M36 of gear case,
qty. for;
TM4907 & TM5002
= 2 nos. each.
TM4906 = 3 nos.

105-01

418 to 503

800 to 1000

117-01

12100 to 14500

14500

117-01

20700 to
24400 (Dry
condition)

20700 to 24400
(Dry condition)

No. *

* (CB)
105-01

* (CB)

* Order no. as per M/s V.M.R.Engineering Services Pvt. Ltd. Instructions

Solves the problem of fastener failure.

* (CB) Counter Bore.

Procedure of fitment:
a) Place a pair of Disc-lock washer at M-12 cap screws and M-36 bolts on
MSU and M-36 bolts on gear case.
b)

Both the disc lock washers should be applied such that the sides with
cams are mated together as shown under;

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Instruction Bulletin no. MP.IB.EM.08.70.09

c) Location of bolts on suspension tube and gear case

Suspension Tube Indicating Location of Mounting Bolts

& Disc-Lock Washer
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Instruction Bulletin no. MP.IB.EM.08.70.09

Traction Motor (TM4907) Gear case Indicating Location of Mounting

Bolts & Disc-Lock Washer

Precautions while using disc lock washers:

i.

Disc lock washers should be applied such that the sides with cams are
mated together

ii.

Washers of sizes matching with the fastener should only be used as given in
table-I.

iii. The threads should be properly cleaned and recommended torque values to
be used for tightening the fasteners.
iv. The disc lock washers are re-usable based upon its condition and
soundness. As in case of conventional fasteners before re-use, disc lock
washers should be carefully examined. If deep scoring on the cam surfaces
or the seizing ridges getting worn/ flattened, the washers must not be reused.
v. Sometimes, bolts/ screws are used to push/ jack an assembly into place.
This practice should not be followed where disc lock washers are used. They
must not be used to push/ jack an assembly into place. Disc lock washers
must be installed when the assembly is in place and ready for tightening.
7.0 MATERIAL REQUIRED AND SOURCES OF SUPPLY:
Material-

As given at Table- I.

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Instruction Bulletin no. MP.IB.EM.08.70.09

Sources:
M/s VMR Engineering Services Pvt. Ltd., 20, Paras Majestic, E-8, Area
Colony, Bhopal- 462 039, Tel: 07480-231056, Fax: 0755-2560483,
Mobile: 09300811757 (Contact person: Mr. Manish Vichitra).
Note: Alternately, similar material is also available from M/s Fair Field
Equipment Pvt. Limited, 40, Strand Road, 2nd Floor, Room No. 14,
Kolkata for Nord Lock Washers. Small orders may be placed on
this firm also, its efficacy evaluated and reported to RDSO.

8.0 ADDITIONAL INFORMATION:

-

Nil -

9.0 AGENCIES AND SCHEDULE OF IMPLEMENTATION:

All Zonal Railways
DLW, Varanasi
DCW, Patiala
10.0 DISTRIBUTION: As per enclosed list.
11.0 REFERENCE:
i) Sr.D.M.E, N.E Railway, Gonda letter no. M/Dsl/CS/Misc/02/783, Dated
11.08.2009 indicating problem of loosening of cap bolts fitted on
suspension tube.
ii) MP.IB.EM.01.22.09 Instructions for arresting loosening/ breakage of bolts/
cap screws fitted on MSU in Alco locomotives.

(Vivek Khare)
for Director General/MP

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