GOVERNMENT OF INDIA MINISTRY OF RAILWAYS, (RAILWAY BOARD) No.2001/M(L)/466/5 New Delhi, dated 10" October 2013 Chief Mechanical Engineers, Central Railway, Mumbai Eastern Railway, Kolkata Northern Railway, New Delhi, North Western Railway, Jaipur Southern Railway, Chennai South Eastern Railway, Kolkata Sub: Modifications to be implemented on ALCO locos during POH Ref: Discussions during ALCO BIM held on 19.7.2013 at DMW/Patiala In the last BIM, it was mentioned by Zonal Railways that the modifications advised by RDSO are not being done by POH shops. On the instructions of the Board, RDSO has compiled a list of modifications to be done and maintenance practices to be followed by POH shops (copy enclosed). Kindly ensure implementation of these within the next three months i.e. by 31.12.2013. A confirmation regarding the same should be sent to the undersigned on 1.1.2014. An officer should also be made responsible for ensuring that each locomotive is turned out with all these modifications after that date. Encl: As above a Cus {0-013 (Vivek Kumar) Exec Dir.Mech.Engg (Tr) Railway Board Copy to: All Chief Mechanical Engineers (except CR, ER, NR, NWR, SR & SER). They may monitor the implementation of these modifications on off POH locomotives and report discrepancies to Board and the POH undertaking Railway. Sr. EDS(MP}/RDSO/Lucknow for information.& alta Tole :+91 (522) 246 5733 (PBX) Wars - 226 011 Goverment of India Ministry of Raiways Research Designs & Standards Organisation LUCKNOW- 226 011 ‘7WTTelegram :RAILMANAK,, Lucknow ‘ereFAx +91 (622) 245 3016 (RDSO) $28! E-mal ID: jdmpengine@gmait.com No. SD.EN4 Mise Date: 19.09.2013 EDME/ Traction Rallway Board Rail Bhawan, New Delhi. Sub: List of modifications to be implemented on Alco Diesel Locos during POH. Ref: Discussions during ALCo BIM held on 19.07.13 at DMW/Patiala, Modifications to be implemented on Alco diesel locomotives have been issued through Mod Sheets, IBs etc from. time to time. These modifications pertaining to POH have been compiled and summarized position is attached herewith for kind information. DA: Asabove. . oe ef J0/Eng/ MP DteList of Modifications to be done during POH on Alco locos: Annexure Detail of Modification ‘Assiy/Sub-assly 7 System etc. RDSO MOD Sheet /i8 No [| Modifications of EP/EM Contactors and GM BKT]| Contactor and Relay | MP.MOD.EC.04 23.08 reverser | | (Rev.0.00),dt.31-08-09 2. | Modification of wiring of 4€/4V & 44 wires on WOM2C Electrical | MP-MOD-£C-05-33-00 | diesel electric locomotive. ‘Switch/wiring/ Dt. 25.09.00 3. [Provision of an emergency over riding switch on cable MP-18-€C-01- 0805 electronic low water level indicator/(ELWI/ELWS) used (Rev.0.00) dt. 04-02-09 fon ALCO type diesel electric locomotives of indian Rsiheoyet eamemmemans E L [% [Provision of MU jumper cable safety deat on AICO] MPI EC16-B0.09 locomotive. | (Rev. 0.00) dt. 25.11.09 5, [Low ile modification on WOG2 locomotive with GE, 'MP.MOD.£C.01.06.09 | Governor. Governor (Rev. 0.00}, dt.27.09.99 inteligent low idle (il) modification on non | MP-IB-£C-08-15-09 (Rev microprocessor locomotives fitted with Wood Ward (0.00) et. 27.02.08, Governor | 17] Dispensing of fuel oi booster air pressure transducers | MP-IBECA2-65.058 from D. E. locomotives fitted with Medha make | dt. 15.09.09 microprocessor based control system MEPG6O, VER-3.0 | and MCBG, Implementation of intelligent low idle (IL!) equipment MP-1B-EC-05-22-10 |” Jon woss locomotives fitted with WOOD WARD | at. 30.08.10 Governor, | 3, | Instruction bulletin for calibration of fuel oll tank with | FuelSensor | MPBECO20840 ak uitrasonic fuel level sensor for alco diesel electric | 25.02.10 locomotives (applicable for fuel sensor fitted MEP66O, VER-3 locos). 7 10. | Use of twin beam headlight with 24V DC-DC converter. | Head/flasher /LED | MP-1B-EC-02-04-00 __| So markeriight = | at. 32.02.00 1, | Modification in existing HLPR of WOP? Tacos to provide MP-MOD-EC-02-05.03 independent supply to each filament of 24V twin beam t.07.02.01 halogen bulb headlight. _ FD. | Guidelines for: procurement of Halogen bulbs for Twin P-B-ECOT-O-06 beam headight for D. E locomotives purchased from at. 27.42.06 | different sources. Procedure for beam alignment of twin beam headlight. = oo | T3. | Procedure for checking of LED marker ight used on MPB-ECA8 51-08 diesel electric locomotives. aoe _ _ (Rev. 0.00) dt. 30.12.09 14. | implementation of electronic load meter fitted on the. Load Meter MP-1B-EC-03-10-08 (Rev. control stand of diesel locomotives, for measurement 01) ¢t. 14.09.10 |__| ofthe curtent ofthe traction motor. 35. | Modification to prevent loosening of operating handle | Master controller | MP-1-EC-06-23-00 of stick type master controller for diesel electric loco bt. 26.07.00 application “Zé. | Modification of stick type master controller used on | MPMOD.ECO75270 | Alco locomotives to improve reliability. | (Rev. 0.00), dt.13.05.10 | 7. [ Development of tractive effort limiting equipment for | MBCS(Microprocess | MP-MOD-£C-01-01-05 WDG3A and WDM3B locomotives or Based control | (Rev. 01) dt. 11.05.06 18. | Automatic emergency brake system (AEBS) on diesel system) | MP-IB-EC-01-02-08 locomotives for operation in steeper ghat sections. Dt 08.01.08 Page 1/69. Modifications to Improve reliability of microprocessor | based control system of M/s Medha make (MEP-660) for diesel electric locomotives. | MP-MOD-EC-01-06-09 (Rev. 0.00) dt. 03.03.09 20, Removal of wheel slip buzzer from microprocessor based control system and wheel slip led drive change lover from SANDR relay to MEP660 output drive in diesel electric locomotives (ALCO) fitted with VER.2 & VER.3 MEPG6O systems. MP-IB-EC-11-64-09 at. 17.09.09 2. “Modification to remove electronic water level indicator by providing protection to the engine through development of suitable algorithm in MBCS for Improving reliability of diesel electric locomotives with microprocessor based control system of M/s Medha make (MEP-660) 2 Provision of flexible conduits for shielding of traction motor speed sensor cables along with tie rod and cable fixing clamp in the under frame for improving reliability of locomotives fitted with microprocessor based control system of M/s. Medha make (MEP-660) Modification sheet for using CPR diodesi2 FMR 140 in | place of CPR Diodes 12 FMR 100 for micro processor | based diesel electric locomotives (ALCO). ‘Modification sheet for fault management of MEP66O of | ‘MP-MOD-EC-07-31-09 (Rev. 0.00) dt. 21.10.09 dt. 30.10.09 MP-MOD-EC-02-12-10 (Rev. 0.00) dt. 29.01.10 ‘MP-MOD-EC-05-27-10 ‘multi diameter technology in Alco locomotive (type WDM3D, WOG3A, and WDM3A) fitted with roof 2a. |” | m/s. medha make applicable for microprocessor based (Rev. 0.00) dt. 26.03.10 |__| controt diese electric locomotives (ALCO). a |25[mounting/relocating of water pressure sensor on ‘wP-iB-EC-03-19-10 MEDHA make microprocessor based control diesel ot. 23.08.10 electriclocomotive (ALCO). | 26. | Revised algorithm for the protection of engine by [e-moo-ec-08-58-11 taking inputs of outlet pressure of WP, rate of rise of (Rev. 01} dt. 18.02.11 EOT and working of sensors (EWTI EOT) applicable for diesel electric locomotives (ALCO). 27. [Improvements in MEP660 of Medha make ‘MP-MOD-EC0206-12 | microprocessor based control system for implementing, at. 17.06.12 | improved features and functionality 28. | Configuration of MU 27 Pins on EMD/ALCO diesel| MUcoupler | MP-MOD-EC-03-25-10 electric locomotives. dt. 31.03.10 29. | Provision of inspection hale on the cam gear cover for | Speed Sensor | MP-MOD-€C-i0-61-10 | checking the improper gap between cam gear teeth (Rev. 0.00) dt. 31.05.10 and engine speed sensor tip applicable for mbcs diesel | electric locomotives (ALCO) —_ | 30. | To implement the use of Constant Pressure Brush | Brush Holder | MP.MOD.EM.04.05.11 Holder on Traction motor type TM4907 on Broad (Rev 00) dt.26-0011 | Gauge Diesel Electric Locomotives. _ | 31._ | Switch-over to E-beam irradiated cables. Cable MP.IB.EM, 02.08.08 dt. 24.01.08 _ +32. | Switch-over to Fluoro-elastomeric/Fluonlex cables for ‘MP.IB.EM. 03.04.08 traction motor main lead and brush gear | t.24.01.08 interconnectors during POH /IOH/Rewinding of motors. | | 33. | Provision of grease nipple in TM 4907 and C1001 for| _DCMotor | MP-MOD-EM.04.1809, greasingthe P.E.Bearing | | dt. 30.06.2009 ‘34, | Use of EDMP based cable & pipe sealing system with DBR Grid | MP-MOD-€M.07.32.10 | dt. 06.04.2010 Page 2/6mounted dynamic grid to avoid water ingress in DBR chamber/ short hood. 7 35, | Provision of Mica insulation based horlrontal type DBR MPMODEM, 03.13.03 | gridonatcotocomotives |__| (Rev. 0.01), ct. 30.06.20 36. | Use of DC Fuel Pump motor in place of AC motor for | Fuel Pump Motor | MP.MOD.EM.02.08.08, pre lubrication system of ALCO type Diesel electric at. 08.05.09 | locomotives provided with pre lubrication system. - 37. | Use of AC Cyclonic Fier motors inverter as a stand by MP MODEM OL. inverter for AC Fuel Pump motor, __| at 17.02.11 38. | Improvement measures for 3 phase AC smal motor MP.MOD.EM.02.02.41 (Rev 00), dt.21-04-11 39, | Introduction of improved gear case seal made of PU | Gear Case | MP-MOD-EM.02-02-99 (Blended Thermo Plastic Poly Urethane) in traction | (Rev.03) dt. 29.04.09 motor gear case of BG diesel electric locomotives | (Alco). 40. | Modification sheet for switch over to 9 kg. oll capacity MP-WOD-EM.03-14-10 gear case. (Rev.00) dt. 29.01.10 “Gi. | Provision of Fibre glass sheet on RC circuit of M/s Hind | ~ Rectifier (AMR) | MP.MOD.EM. 09.34.10 make Alternator Mounted Rectifiers to prevent the at, 06.04.2010 chances of flashover on rectifiers . @. | Provision of cil seal in place of existing felt seal in] SealforAG | MP.MOD.EM. 01.08.08 Auxiliary Generator/ Exciter type AG 3101 of BG diesel dt. 02.04.09, electric locomotives @. [Conversion of locomotives plain type suspension | TM Roller | MP-MOD-EM01.03-10 bearing arrangement (TM 156M / 4906) to roller | Suspension Brg. | (REV.00) dt. 08.01.20 suspension bearing arrangement (TM 4907). Arrangement 44, | Modification in pneumatic and electric circuit of air | Air Dryer Governor | MP.MOD.BK.05.27.00. dryer and electro pneumatic governor (EPG) of (EPG) Rev.0.00.dt.30.08.00 compressor of diese locomotives Jair Dryer 5. | Provision of by pass arrangement for air dryers in diesel MPI BKOLOLAL locos. at, 04.03.11 46. | Replacement of O-i auto drain valve AirValve | MP.1B.BK.05.19.08 at. 29.12.08. [a7 | Operation of locos Fitted with C2N & FT-I Feed Valves MP.16.8K.0732.09 | intrail or dead condition. dt.27.05.09. 8. | Standardisation of air brake ciruit and equipments on | Brake Circuit | MP.MOD.BK.01.04.01 aloMus. (Rev.0.0) dt. 27.02.01 45. | Maintenance instruction for break in two protection MP.1B.8K 02.14.01 feature provided on pure vacuum and dual brake diesel 4.300701, and electric locos. 50. | Modification to drawing and specication of fier. Brake Fiter | MP-MOD.BK06.06.08 _ (Rev.00) dt.11.09.08 ‘51. | Retrofitment of ‘Release-Run’ magnet valve and R-6 Brake Panel ‘MP.MOD.BK.03.11.02 (Rev | relay valve on existing IRAB-1 pneumatic panels fitted 0.00) at. 14.08.02 ‘on diesel locomotives. 52. | Indication of iv & “Out” port on panel for NA reducing | Mp s6.6K 02.12.02 | [valve at. 21.08.02. 353. | Conversion of various types of dual brake systern to MP.1B.BK.05.15.07 compact Triplate panel along with replacement of September 2007 Expressor by air compressor. : 54. | Deletion of 2°Vacuum pipe and hose pipe romnew | Brake Pipes | MPIB.BK0203.09 built and rebut locos for diesel and electric locos. dt, 06.01.09 '55. | Modification in air flow measuring valve circuit and | Brake Valve MP.MOD.BK-01.05.99 provision of R-6/SDW-1 relay valve to provide adequate Rev.0.00 dt: 13.10.99 Page 3/6| indication to driver in case of alarm chain pulling/train | parting. ee —— ‘Maintenance Instructions for VAAB control valve. | | MiP.@. 8K 08.10.00 L_ | 15.03.00. "57.7 Provision of additional cut out cocks for brake pipe of | MP.MOD.BK.03.13.00 Heal ace ceone pe novatzaose 58. | Use of magnet valvein place of D-Ipilot valve. | ‘MP.MOD.BK.02.08.01 _ | {Rev.0.00) dt. 15.03.01 |"58-) Garification for provision of Smm choke on C2W relay ‘MP.I8.BK.01.0801 | |__| valve meant for supplying air to brake cylinder of locos. | | dt. 26.03.01. 60. | Removal of N-1 reducing valve (limiting valve) provided MP.MOD.BK.03.14.01 in vacuum brake circuit of dual brake diesel locomotive. | (Rev.0.00 Jat. 27.08.01 [SE [edcton of 8 presur on dete and elec loco | MP.IB.BK.02.06.05 from 3.5Kg/em2 to 3.0 Kg/cm? during independent | dt. 05.12.05. |__| brake application through sSA9. 62. | Provision of additional mounting plate for 4 valves ie. [wp.mon8K.06.21.10 | Cow clay vave, add. C2W rely valve, MU2B vale & | | (Revonot.18.03.10 4 selector valve of M/s SIL make Tr-plate panel. 3. | Changes in layout of 6CD3UC/KE-6 expressor piping. MP. MOD.BK.01.05.02 Compressor/ | (Rev. 0.00) dt 17.04.02 64. | Instructions for removal and instalation of KAP face| — Expressor | MP.IBBKO1.1102 type oil seal assembly of expressor. dt. 27.06.02, 5. [Implementation of upgraded air suction filter and MP.MOD.BK.02.01.08 discharge valve assly in existing air compressor/ (Rev.0.00) dt. 24.03.08 expressor. | 66. [Use of upgraded critical spares of ‘MP 1B.BK.08.37.09(Rev.01) Compressors/Expressors in ALCO type locos for at. 25.03.2010 improving reliability, maintainability and performance. | | 67. | Modification from conventional hand brake to modified | Hand Brake | MP.MOD.BK 03.23.09 hand brake (Gear type) arrangement diesel locomotives } (Rev.00) dt. 30.09.09 application, _ 8. | Provision of sealing arrangement for COC provided in | Vigilance Contral | MP.IB.BK 03.09.17 VCO cru of diesel locomotives to isolate VCD penaty | Device | dt. 3011.1 application magnet valve. | | 69. | Changing the warning cycle time of VCD on diesel MP.MOD.BK.01.01.12 locomotives. | (Rev.00) dt. 05.01.12 70. | Modification to the design of tie bar (brake beam) of MP.MOD.VI-03.09.01 |__| tecomotives fitted with Co-Co Trimount Bogies. (Rev.00) at. 29.03.01 71, | Modified design of top slack adjusters fitted on | ‘MP.MODVL-07.13.01 locomotive with Co-Co Trimount Bogies. (Rev.00) dt. 08.08.01 72. | Modification for fitment of side bearer to RDSO MP.MOD.VL-05.11. | drawing no. SK.VL-133 on WOG3A locomotives. (Rev.00)} dt. 27.09.01 73. | Provision of spring pads (Happy pads) in 8G diesel & ‘MP.MOD.VL-02.04.05, || electric locomotives fted with three axle Trimount | (Rev.00) at. 25.08.05 | | Bogies to enhance the reliability of helical springs and Bogie _| achieve reduction in incidences of bogie frame cracks. _ | | 74. [Provision of spring pads (Happy pads) in diesel & ‘MP.MOD.MI-O1.01.07 electric locomotives to enhance the reliability of helical | (Rev.00) dt. 24.08.07 col springs. 75. | Conversion af WOMD locornotive bogie with equaliser [1mPiMo0.vL-04.08.08 beam arrangement into loco without equaliser beam (Rev.00) t. 19.12.08, —}strangement.___________t hae mopwcosaoe3 ——] 76._| Modification for preventing failures of Centre Pwvot| [MP:MOD.i-03.10.09 Page 4/6i ] Block and Ts components fitted in WDG3A/WDMBD | | locomotives. T (Rev.00) dt. 28.04.09 \ 77. | Modification in bogie of WOPi locomotive to improve ‘MP.MOD.VL-07.42.09 their reliability. (Rev.00) dt. 31.12.09 78. | Provision of eye type damper in lieu of stem type | MP.MOD.VL-09.85.10 dampers on high adhesion bogies of WOG3A & WDM3D (Rev.00) dt. 11.08.10 (with Equaliser & Compensating — Mechanism) locomotives. oe ee = 78. | Conversion of WOG3A locomotive bogie with Equalizer MP.MODML-02.07.12 Beam arrangement into without Equalizer Beam (Rev.00) dt. 31.12.12 arrangement. 80. | Replacement of cam bush of out board housing without | Cam shaft/gear | MP.IB.EN-07.39.08 dt. taking down the main alternator and corrective 04.03.09 ‘measures for loosening/breakage of out board housing. L Bi. | Introduction of oll passage in push rod lifter (Air & MP.MOD.EN.09.86.10 Exhaust) fitted with con/FE camshaft for lubrication of (Rev 0.0) dt. 30.07.10 cam roller. @2.| Spray nozzle dimension modification for cam gear MP.MODEN-07.63.20 lubrication _ a (Rev 0.0) at. 04.06.10 3. | Complete switch over to Stiffer Unit Camshaft GUCS) MP.MOD.EN - 08.36.08 on 3100 hp locomotives and use of modified | dated: 07.01.10 __| components in SUCS to increase the reliability 4, | Run out measurement process for conventional and FE | MP.IB.EN.04.15.10 Camshaft of ALCo locomotives. 85. | To identify the cam segment, manufactured with nose MP.MOD.EN. 03.31.10 angle 108.6" (RHS) /77.5*(LHS) and 105.3°(RHS) / 74.25°(UHS) of stiffer unit camshaft for setting of injection timing. 86._| Oil throwing from crank case exhauster. ‘rank case | MP.IB.EN-09.45.08 exhauster 87. | Practices tobe adopted for avoiding damageto. | Crankshaft/Main | MP.IB.EN-05.26.00 crankshaft thrust collar. bearing 38. | Modification of the material specication for main MP.MOD.EN.04.16.00, bearing stud of ALCO class of locomotives. Dt. 25.08.00 89. | Maintenance of crankshafts and main bearings. (MP.IB.EN.03.05.02 ‘90. | Inspection method to verify crankshaft run out, | MP.IB.EN-05.15.02 eccentricity and flange squareness of used crankshafts 03.12.02 of 16 cylinder DLW engine (ALCo Type). 94. [ Change of design from Flat bottom type lube oil fier | tube /fuel oll iter | MP.1B.EN.07.52.09. assembly to Dish bottom type lube ol fiter assembly. | bt. 18.08.09 _ 92. | Title - Modification of secondary filter casing of engine ‘MP IB.EN.03.22.08. air filtration system to adopt bag type fiter to RDSO |_| bre sk DP 3505 in place of Deep Design filter to RDSO | | Drg SKDP-3673 Pane! fter. a |'53. J Development of low mean pore size fiters for Alto | | MaP.MiSC.224 (Rev.00), | locomotives. Riys. were advised to immediate switch | | ec.2008. over to low mean pore size fuel fiters, vide letter No. | | |__| so.Fis dated 02.01.2009. ‘34. | Modification of Engine air fitration system to adopt MP.MOD.EN.02.13.10. | | bag type secondary filter to ROSO Drg. No. SKDP 3505 | in place of Six Panels type glass fibre secondary filter to ole DSO Drg. No. SKDP-3476. Page 5/6 Lae Prosi oF casing wih Bulla owes and deposable | car body fiters in place of impingement type wire mesh car body filters on ALCo Locomotives, along with Drg. No. SKDP-4109 (Alt.-1), SKDP-4110 (Alt.-1), SKDP- 4111(Alt.-1), & SKDP- 4112 (Alt.-1) issued to Rlys vide letter no. 8 FiL# dated 23.05.2012. ‘MP.MOD.EN.05.20.08 (Rev.01) July = 2011. 96. ‘Non Destructive Testing of connecting rods ‘Connecting Rod 97. ‘Alignment tolerances for ALCO engine block main and ‘cam bearing bore. Engine block MP.IBEN.04.25.01, dt. 19.12.01 ‘MP.IB-EN ~01.05.00 Use of Fibre Reinforced Plastic (FRP) cover in place of ‘MP.MOD.EN - 06.24.09 from bottom operated to top operated on locomotives fitted with E-type couplers. Page 6/6 Aluminum cast for FIP support for Alco engines. dated: 31.08.09 99. | Implementation of fre (accident) prevention measures Mise ‘MP.IB.EN.01.03.11, |__| on Diesel Locomotives of R. dt. 26.09. 100. | Modifications done in the handle trip lever shaft| OST TripHandle | MP.MOD.EN. 01.02.09 ‘mechanical OST assembly used in ALCo Diesel Engine. | (fev.0.00), dated 23.01.09 101, | introduction of Piston Ring Pack (FE type with Moly | Pistonring | MP.IB.EN.09.38.10 Coated Top Ring) in ALCo locomotives on Indian Dt. 16.07.10 Railways. _ 102, | Introduction of 3RV power assemblies for 16 cylinder MP.IB.EN.08.32.10 (Rev- Alco diesel engines of IR. 01) dt: 13.09.12 703. | Provision of rubber seal and damp between air inlet TSC ‘MP.MOD-EN-O1.01.02 ducting and turbocharger. (Rev.03) | 104. | Grinding of 30° air inlet valves on Sioux 2075 valve | Airinlet Valve/Push | MP.\B.EN.04 10.02 | grinding Machine. rod Assembly | Dt. 05.07.02 405. | Modifications done in push rod assembly & Change in ‘MP.IB.EN.04.23.08, material specification of valve springs used in Alco dated 22.08.08 diesel engine, 7 106. | implementation of the water pump shaft of stainless | Watercooling | MP MOD.ES.01.18.11 steel with taper sleeve arrangement in 16 cylinders system | dt.03.04.12 Aico diesel locomotives (8G) of I. 1107. | Conversion of CBC coupler uncoupling arrangement | CBC coupler MP.MOD —_D.05.10.11 Rev.00 dt. 18.07.11