No. EL/3.1.35/2 Date: 13.02.

2006

Chief Electrical Engineers,

1. Central Railway, Chhatrapati Shivaji Terminus, Mumbai-400001.
2. Eastern Railway, Fairlie Place, Kolkata-700001.
3. Northern Railway, Baroda House, New Delhi-110001.
4. Southern Railway, Park Town, Chennai-600003.
5. South Central Railway, Rail Nilayam, Secunderabad-500071.
6. South Eastern Railway, Garden Reach, Kolkata-700043.
7. Western Railway, Churchgate, Mumbai-400020.
8. East Coast Railway, Chandrashekharpur, Bhubaneshwar-751023
9. North Central Railway, Hasting Road, Allahabad-211001.
10. East Central Railway, Hajipur-844101.
11. South Western Railway, Hubli-580023.
12. West Central Railway, Jabalpur-482001.
13. South East Central Railway, Bilaspur-495004.

Technical Circular No. ELRS/TC/0090 (Rev.’0’).

Sub: Procedure for movement of WAG9 / WAP7 and WAP5 locomotives for clearing blocked
section by floating / lifting the locked axle in the event of axle getting locked on line.

There are instances when locomotive axle gets locked in the mid section thus blocking
the Railway traffic movement on the affected section. Under such eventuality, it becomes the
top priority to move the locomotive to the nearest station and restore the traffic.
This technical circular states the procedure for movement of WAG9 / WAP7 and WAP5
locomotives in the event of axle getting locked for clearing the blocked section while observing
the extant norms / instructions in vogue from Railway Board vide letter no.
2001/M(L)/466/2305 dated 22.08.2003 and various concerned departments to maintain safe
movement of the locomotive.
For lifting the end axles of WAG9 / WAP7 and any axle of WAP5, Wheel Set Trolley as
per RDSO Drawing Nos. SK.VL-215 to 218 will be required. Earlier, RDSO drg. Nos. SKVL
129 - 132 were issued for use on WAP5 only. Whereas RDSO Drawing Nos. SK.VL-215 to
218 are suitable for WAG9 / WAP7 as well as WAP5.
Annexure “A” describes the procedure for WAG9/WAP7 locomotive. Annexure “B”
describes the procedure for WAP5 locomotive

Encl: Annexure “A” with 05 sketches

Annexure “B” with 02 sketches

(N.K.Sinha)
For Director General (Elect.)
Copy to:-
Secretary/Elect.Engg.(RS), Railway Board, Rail Bhawan, New Delhi-110 001

(N.K.Sinha)
For Director General (Elect.)
 ANNEXURE “A”

Procedure for Movement of WAG9 / WAP7 Locomotives by Lifting / Floating the Locked
Axle in the Event of Axle Getting Locked on Line.

The schematic Arrangement of bogie of WAG9 / WAP7 locomotive is shown in Sketch

1. An axle of the locomotive may get locked under the following circumstances:
• Traction Motor Roller Bearing seizure.
• Traction Motor Suspension Bearing seizure.
• Axle Box Roller Bearing seizure.
While it may be possible to free the Traction Motor from the axle in case of Traction
motor bearing seizure, the other cases require floating / lifting of the affected wheel for move-
ment of the locomotive. Floating / lifting of the affected wheel may become necessary in case
of wheel flats & heavy skidding of wheels also.

1.0 Procedure when Traction Motor Roller Bearing gets Seized

In case of traction motor roller bearing seizure, the pinion of the affected
motor should be removed and all the traction motors of the affected bogie
should be electrically isolated. The locomotive should be worked as light
engine on its own power to the nearest Electric Locomotive Shed for atten-
tion.

However, where removal of the pinion is not possible due to any reason,
the locked axle should be floated following the procedure given at Para 2.0
below for clearing the section.

2.0 Procedure for Floating / Lifting the Locked Axle:

In case when Axle gets locked due to Axle Roller Bearing Seizure, Traction Motor
Suspension Bearing Seizure, Wheel Flat or Heavy Skidding of Wheels, the affected
axle should be floated/lifted (depending on the axle number) after electrically isolating
all the motors of affected bogie. The locomotive should be worked as a light engine on
its own power with a maximum restricted speed of 25 km/h under escort by mainte-
nance staff. In such case, a close watch is necessary while passing over curves and
turnouts.

2.1 Items required for Lifting of Axle

The following items are required for lifting the locked axle:
i. Two hydraulic jacks having minimum capacity of 15 tonnes each.
ii. The distance pieces i.e. “wooden blocks” to raise the hydraulic jacks, if required, to
compensate the gap between the jack & axle box / bogie frame.
iii. Two numbers of steel plates of size 300mm x 300mm x 30mm, which may be re-
quired for making the foundation firm and leveled for jacks.
iv. Wooden wedges (at least 6 nos.) for application at the wheels for preventing rolling
of locomotive while applying jacks.
v. Resilient Block of thermoplastic polyurethane elastomer material (04 Nos.) as per
the material, dimension and design conforming to Sketch 2.
vi. Wheel Set Trolley to RDSO Drawing Nos. SK.VL-215 to 218 (When end axle i.e.
Axle No. 1, 3, 4 or 6 is locked)
 vii. Short link as per the material, dimension and design conforming to Sketch 3 (02
Nos. each) (When Middle Axle i.e. Axle No. 2 or 5 is locked).
viii. Toolbox with appropriate tools, Nuts, Bolts, Washers and Wrenches / Spanners.

2.2 Precautions to be taken

Before attempting the lifting of locked axle of the locomotive, the steps given below should strictly be followed to avoid
damage to equipment or any mishap:
i. Apply wooden wedges at wheels to prevent rolling of locomotive.
ii. Release all TBUs (brakes) of the affected bogie, which requires lifting.
iii. Before application of jacks for lifting, ensure that the ground below the lifting jacks
is firm and leveled. Due care must be taken to avoid slipping of the jacks.
iv. Isolate all the traction motors of the affected bogie.
v. Remove all primary vertical dampers of the affected bogie to avoid their damage.
vi. Remove links between axle box and bogie frame from middle axle of the affected
bogie.

2.3 When One of the End Axles (i.e Axle Nos. 1, 3, 4 or 6) gets Locked

i. Dismantle the slack adjuster of the locked end axle wheels.

ii. Clamp the vertical brake hanger levers of locked axle at appropriate place with the
bogie frame to prevent fouling of these levers with the wheel set trolley during
movement.
iii. Dismantle the sand box pipes. Remove footsteps, if required.
iv. Remove the vertical dampers between the bogie frame and axle boxes of locked
end axle of the affected bogie.
v. Lift frame of the affected bogie from the end at the other side of the locked axle (eg.
from the end near Axle No. 3 if Axle No.1 is locked) to obtain a clearance of 75 to
80 mm between axle box top and bottom of the bogie frame at both sides by simul-
taneously applying two jacks of minimum 15t capacity each below the axle guide
bracket / bogie end beam.
vi. Place the Resilient Block between axle box top and bottom of the bogie frame at
both the sides and release the jacks.
vii. Now lift the locked end axle of the affected bogie simultaneously from both sides by
applying two jacks of minimum 15t capacity each under the bogie end beam / axle
guide bracket. The bogie frame should be lifted to obtain sufficient clearance be-
tween axle box top and bottom of the bogie frame at middle axle.
viii. Place the Resilient Block between axle box top and bottom of the bogie frame at
both the sides at middle axle location and release the jacks.
ix. While releasing the jacks, it must be ensured that the springs are properly seated.
x. Now, lift the locked end axle by 55 to 60 mm by simultaneously applying two jacks
of minimum 15t capacity each below the axle box housings at both sides.
xi. Assemble the wheel set trolley below the locked end axle over the track in such a
way that the wheels of locked axle rest over the supporting rollers. Refer Procedure
given below for Assembly of Wheel Set Trolley.
xii. Sketch 4 shows the locations of the application of jacks for lifting and arrangement
of wheel set trolley under the affected end axle.
 xiii. Release the jacks from both sides of the locked end axle ensuring that the locomo-
tive wheels of the locked axle rest properly on the rollers of the wheel set trolley.
xiv. Remove the wooden wedges placed at wheels of the locomotive.
xv. Locomotive with effected wheel set placed on the wheel set trolley can now be
moved dead at a restricted speed not exceeding 25 km/h to clear the blocked sec-
tion.

2.3.1 Procedure For Assembly Of Wheel Set Trolley

i. The locked wheel set has to be lifted up approximately by 55 mm to 60 mm.

ii. Push both the Inner Longitudinal Frames (Item No. 1 of Drg. No. SK.VL-215) of trol-
ley under the locomotive.
iii. Place both the Steel Tubes (Item no. 32 of Drg. No. SK.VL-218) in position.
iv. Lift up the frame along with the steel tubes, push in and fasten the running 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.
v. Push the outer Longitudinal Frames (Item No. 2 of Drg. No. SK.VL-215) of the trol-
ley 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.
vi. To facilitate easy assembly of wheel set trolley, suitable markings as shown in the
drawing must be provided to identify the matching parts.
vii. Lower the locked wheel set of the locomotive gradually on the supporting rollers.
viii. After lowering the wheels on trolley, it is essential to ensure that the wheel flanges
of the lifted wheel set are sufficiently clear from the rails, to avoid hitting / infringe-
ment during movement of the locomotive.

2.4 When Middle Axle (i.e. Axle No. 2 or 5) gets Locked

i. Lift the bogie frame of the affected bogie from one end by applying two jacks of
minimum 15t capacity each simultaneously at both sides (RHS & LHS) below the
axle guide bracket / bogie end beam to obtain a clearance of 105 to 110 mm be-
tween axle box top and bottom of the bogie frame.
ii. Place the Resilient Block at the top of axle box in centre position at both the sides
(RHS & LHS) of this end axle and release the jacks gradually till the bogie frame
rests on the resilient blocks. While releasing the jacks it must be ensured that the
springs are properly seated.
iii. Now lift the bogie frame of the affected bogie from the other end axle from both the
sides (RHS & LHS) simultaneously by applying two jacks of minimum 15t capacity
each under the bogie end beam / axle guide bracket to obtain a clearance of 105 to
110 mm between axle box top and bottom of the bogie frame at this end.
iv. Place the Resilient Block at the top of axle box in centre position at both the sides
(RHS & LHS) of this end axle and release the jacks gradually till the bogie frame
rests on the resilient blocks. While releasing the jacks it must be ensured that the
springs are properly seated.
v. Now, lift the locked middle axle simultaneously by applying two jacks of minimum
15t capacity each below the axle box housings at both sides (RHS & LHS).
vi. Mount short links between axle box cover and bogie frame at both sides (RHS &
LHS) as shown in Sketch 5 using existing pins of middle axle links.
vii. It can be seen that the wheel flanges of the affected axle are lifted approximately by
40 to 45 mm from rail level.
viii. Remove wooden wedges placed at wheels of the locomotive.
ix. The locomotive with effected wheel set lifted can now be moved on its own power
at a restricted speed not exceeding 25 km/h to clear the blocked section after iso-
lating all the motors of the affected bogie.

*****
 UNDER FRAME BOGIE FRAME

AXLE DAMPER
LINK

AXLE BOX

RAIL LEVEL

END AXLE MIDDLE AXLE END AXLE

(AXLE 1 OR 6) (AXLE 2 OR 5) (AXLE 3 OR 4)

Sketch 1

Schematic Bogie Arrangement

 Sketch 2

Resilient Block
 Material Specification to IS:2062

Sketch 3
Short Link
 AXLE - 3 AXLE - 2 AXLE - 1

Sketch 4

Locations For Application of Lifting Jacks

and
Arrangement of Wheel Set Trolley for Lifting of End Axle in WAG9/WAP7 Locomo-
tives
 UNDER FRAME BOGIE FRAME

RESILIENT BLOCK

RESILIENT BLOCK
A SHORT LINK

PROVIDE WASHER(S)
IF REQUIRED
40 MIN.

ENLARGED VIEW `A'

RAIL LEVEL

END AXLE MIDDLE AXLE END AXLE AXLE GUIDE BRACKET

(AXLE 1 OR 6) (AXLE 2 OR 5) (AXLE 3 OR 4)

Sketch 5

Locations For Application of Lifting Jacks

and
Arrangement for Lifting of Middle Axle using short links in WAG9/WAP7 Locomotives
 ANNEXURE “B”

Procedure for Movement of WAP5 Locomotives by Lifting the Locked Axle

in the Event of Axle Getting Locked on Line

The Schematic Arrangement of WAP5 locomotive bogie is shown in Sketch 1. An

axle of the locomotive may get locked under the following circumstances:
• Traction Motor Roller Bearing seizure.
• Axle Box Roller Bearing seizure.
While it may be possible to free the Traction Motor from the axle in case of Traction
motor bearing seizure, the other case requires lifting of the affected wheel for movement of
the locomotive. Lifting of the affected wheel may become necessary in case of wheel flats
& heavy skidding of wheels also.

1.0 Procedure when Traction Motor Roller Bearing gets Seized

In case of traction motor roller bearing seizure, the Hurth coupling connection
of the affected traction motor should be removed / uncoupled and both the
traction motors of the affected bogie should be electrically isolated. The lo-
comotive should be worked as light engine on its own power to the nearest
Electric Locomotive Shed for attention.

However, where removal of Hurth coupling connection is not possible due to

any reason, the locked axle should be floated following the procedure given
at Para 1.2 below for clearing the section.

2.0 Procedure for Lifting the Locked Axle

In case when Axle gets locked due to Axle Roller Bearing Seizure or there is Wheel
Flat or Heavy Skidding of Wheels, the affected axle should be lifted after electrically
isolating both the motors of affected bogie. The locomotive should be worked as a
light engine on its own power with a maximum restricted speed of 25 km/h under es-
cort by maintenance staff. In such case, a close watch is necessary while passing
over curves and turnouts.
2.1 Items required for Lifting of Axle

The following items are required for lifting the locked axle:
ix. Two hydraulic jacks having minimum capacity of 15 tonnes each.
x. The distance pieces i.e. “wooden blocks” to raise the hydraulic jacks, if required,
to compensate the gap between the jack & axle box.
xi. Two numbers of steel plates of size 300mm x 300mm x 30mm, which may be
required for making the foundation firm and leveled for jacks.
xii. Wooden wedges (at least 4 nos.) for application at the wheels for preventing roll-
ing of locomotive while applying jacks.
xiii. Wheel Set Trolley to RDSO Drawing Nos. SK.VL-215 to 218.
xiv. Toolbox with appropriate tools, Nuts, Bolts, Washers and Wrenches / Spanners.

2.2 Precautions to be taken

Before attempting the lifting of locked axle of the locomotive, the steps given below should strictly be followed to
avoid damage to equipment or any mishap:
vii. Apply wooden wedges at wheels to prevent rolling of locomotive.
viii. Release all brakes of the affected bogie, which requires lifting.
 ix. Before application of jacks for lifting, ensure that the ground below the lifting
jacks is firm and leveled. Due care must be taken to avoid slipping of the jacks.
x. Isolate both the traction motors of the affected bogie.
xi. Remove all primary vertical dampers of the affected bogie to avoid their dam-
age.

2.3 Procedure for lifting of Axle when it gets locked

xvi. Dismantle the sand box pipes. Remove footsteps, if required.
xvii. Remove the vertical dampers between the bogie frame and axle boxes of
locked axle of the affected bogie.
xviii. Now, lift the locked axle by 55 to 60 mm by simultaneously applying two
jacks of minimum 15t capacity each below the axle box housings at both sides.
xix. Assemble the wheel set trolley below the locked axle over the track in such a
way that the wheels of locked axle rest over the supporting rollers. Refer Proce-
dure given below for Assembly of Wheel Set Trolley.
xx. Sketch-2 shows the locations for application of jacks for lifting and arrangement
of wheel set trolley under the affected axle.
xxi. Release the jacks from both sides of the locked axle ensuring that the locomo-
tive wheels of the locked axle rest properly on the rollers of the wheel set trolley.
xxii. Remove the wooden wedges placed at wheels of the locomotive.
xxiii. Locomotive with effected wheel set placed on the wheel set trolley can now
be moved dead at a restricted speed not exceeding 25 km/h to clear the blocked
section.

2.3.1 Procedure For Assembly of Wheel Set Trolley

ix. The locked wheel set has to be lifted up approximately by 55 mm to 60 mm.

x. Push both the Inner Longitudinal Frames (Item No. 1 of Drg. No. SK.VL-215) of
trolley under the locomotive.
xi. Place both the Steel Tubes (Item no. 32 of Drg. No. SK.VL-218) in position.
xii. Lift up the frame along with the steel tubes, push in and fasten the running
Wheel Arrangements (Item no.3 of Drg. No. SK.VL-215), Supporting Roller Ar-
rangements (Item No. 4 of Drg. No. SK.VL-215) with keys and bolts.
xiii. 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.
xiv. To facilitate easy assembly of wheel set trolley, suitable markings as shown in
the drawing must be provided to identify the matching parts.
xv. Lower the locked wheel set of the locomotive gradually on the supporting rollers.
xvi. After lowering the wheels on trolley, it is essential to ensure that the wheel
flanges of the lifted wheel set are sufficiently clear from the rails, to avoid hitting /
infringement during movement of the locomotive.
……..
AXLE - 1 AXLE - 2

Sketch 1

Schematic Bogie Arrangement of WAP5 Locomo-

 AXLE - 1 AXLE - 2

Sketch 2

Locations for Application of Lifting Jacks

and
Arrangement of Wheel Set Trolley for Lifting of Locked Axle in WAP5 Locomotives