ctrb

Technical Pamphlet No.G-81 (SECOND RIVISION) (SUPERSEDES FIRST RIVISION) INSTRUCTIONS FOR INSPECTION & MAINTENANCE OF CARTRIDGE TAPER ROLLER BEARING FITTED ON CAST STEEL BOGIES (DRAFT) LIST OF AMENDMENTS S. No. 1. Amendment Date 06/02/2015 Version 1.0 Details First Issue ISSUED BY:RESEARCH DESIGNS & STANDARDS ORGANISATION (MINISTRY OF RAILWAYS) MANAK NAGAR, LUCKNOW-226011 1 Technical Pamphlet No. G-81 CONTENTS S.No. DESCRIPTION PAGE No. 1. TERMINOLOGY 3 2. GENERAL CONSTRUCTION 4 3. GREASE SEAL 4 4. LIFE EXPECTANCY 5 5. APPLICATION 5 6. PERIODICITY OF MAINTENANCE 6 7. SCHEDULE OF INSPECTION & MAINTENANCE 7 8. PROCEDURE FOR OVERHAUL 13 9. STORAGE & PACKING OF BEARINGS 28 10. MOUNTING OF TAPER BEARING ON AXLE 29 11. FITMENT OF AXLE UNDER THE BOGIE 36 12. MAINTENANCE SPECIFICATIONS 37 13. INTER-CHANGEABILITY OF BEARING COMPONENTS 38 14. BEARING MARKING 38 15. BEARING MAINTENANCE WORKSHOPS 41 16. HANDLING OF MOUNTED WHEELSETS 41 17. WELDING OF WAGONS/BOGIE FITTED WITH CTRB 42 18. BEARINNG DAMAGE - DESCRIPTION & LIMITS 43 19. ADAPTER 49 20. CHECK LIST AT A GLANCE 62 21. ANNEXURE I to XVIII 64 - 98 2 Technical Pamphlet No. G-81 1. TERMINOLOGY Terminology Description of Cartridge Bearing Parts Backing ring Collar between bearing and journal fillet; Axle collar; Dust guard ring; Enclosure collar Retainer; Separator. End cap fasteners. Cap at end of journal; Axle end cap; Locking cup; End cover. Backing ring with extension to provide press fit with suitable diameter axle dust guard seat. Cone or inner race. Cap screw locking device. Cage Cap screws End cap Fitted backing ring Inner ring Locking plate No Field Lubricating (NFL) bearing Outer ring Raceways Roller assembly Rollers Seal Seal wear ring Spacer Roller bearing adapter Bearings which are not designed to be lubricated in the field and do not have a lubricant fitting, or pipe plug. Cup or outer ring. Surfaces of outer and inner ring on which rollers operate. Rollers with inner ring and cage, inseparable Tapered rollers Seal proper, including inner case, if used. Ring on which seal rides or makes contact Spacer, spacer ring; Cone spacer Adapter Any single component that forms a safe, reliable and efficient interface between the roller bearing outer cup surface and the bogie. Fig. 1: Expanded View of Cartridge Tapered Roller Bearing Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 3 (b) Prevent the ingress of water and other contaminants in to the bearing.Technical Pamphlet No.WD92089-S-01 for Narrow Jaw adapter & WD. 3 cap-screws. and locking plate as shown in Fig. The weight of Class 'E' 6 X 11 CTRB is around 34.0 kg. The limiting dimensions of CTRB Class-E (6”X11”) Grease Seal (Indigenous) have been mentioned at Annexure – II Seals perform two important functions:(a) Retain a quantity of grease inside the bearing to provide adequate lubrication through the bearing service period. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 4 . separated by a spacer. The cup also acts as the bearing housing and is fitted in the bogie side frame with a suitable adapter (See General Arrangement of CTRB Drg. 2: Cartridge Tapered Roller Bearing Section view 3. a backing ring at the rear. GREASE SEAL The grease seal is made of special synthetic rubber of superior oil resistance quality.2. and wide jaw Adapter is around 23 kg. No. axle end cap. G-81 2.13042-S-01 for Wide Jaw adapter at Annexure-I A & I B respectively). Double lip seal element is bonded to the steel plate seal cover which is retained in the outer ring by a press-fit. a single case-hardened outer race (cup). weight of Narrow Jaw Adapter is around 12. The seal lips are moulded to provide bi-directional grease retention employing the elasto hydro-dynamic principle (Fig.3 kg.3). a grease seal and a seal-wear ring at each end. GENERAL CONSTRUCTION The Cartridge Type Taper Roller Bearing (CTRB) has two inner races (cones) alongwith rollers and cage. Fig. BOBRNHS.3 4. G-81 Fig. BCNAHS.1 Different Makes Cartridge Tapered Roller bearings Indian Railways have procured these bearings from five manufacturers viz: M/s NEI/Brenco. backing ring. BCN.USA. M/s FAG. No.Technical Pamphlet No. The general arrangement of their bearings is shown in their Drg. PESD-6086 for wide jaw adapter (Annexure-III A & III B). (a) M/s NEI/ BRENCO Bearings M/s NEI/ Jaipur initially procured complete sealed units from M/s Brenco. However. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 5 . BOBSN. No. WD-89025-S-02. cap screws and cap screw seal rings were indigenous. M/s Timken India Ltd. BLCA/BLCB etc. In 1990. M/s NEI have now indigenised the following critical components also: (i) Cup (ii) Cone (iii) Roller (iv)Cage (v) Seal Wear ring (vi) Spacer. 5. This bearing is suitable for Indian Railway standard Axle to drawing no. Initial design of CASNUB Bogie i. BOY. CASNUB 22 NL bogies with narrow jaw adapter was designed to reduce weight and from 1991-92 light weight 22 NLB bogie have been adopted as a standard bogie. adapter. M/s SKF & M/s KOYO.These bearings are being used on all BG wagons/Container fitted with CASNUB 22NL/22NLB/22HS /LCCF20(C) Bogies like BOXN. BTPN.e. BOXNHL. APPLICATION The Cartridge Bearings used on Indian Railways are of type Class 'E' 6“x11”. 22W & 22 WM was with wide jaw adapter. 5. axle end cap.. LIFE EXPECTANCY The 'L10 Life' is defined as that life at which no more than 10% of the bearings may have been replaced solely due to fatigue of metal. PESD-6085 for narrow jaw adapter and Drg. 85/M(W)/814/53 dated 19-3-86. 6. The cup. Other components were indigenous. IV). These bearings have been modified to suit journal length to SK. The bearings.2 of IRCA Part –III latest) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 6 .219/Policy/W dated . 5.5 (* Ref.4 mm of Axle to Drg.4.85/M(W)/814/53 dated 3-7-90. No.4. 8.5 3 3 6 4. of Cartridge Bearings as per their Drg. 69601 which is 247.A 11100 (Ann. The periodicity of first POH of BOXN Wagons has been laid down as six years by Railway Board vide letter No.No.99 & Para 2. Now the company has also indigenised the following components:(i) Cup (ii) Cone (iii) Rollers (iv) Cage (v) Seal Wear Ring (vi) Spacer (vii) Grease seal See general arrangement drawing no. should not be opened in the Sicklines/ ROH Depots.5 6 6 6 6 4 4 4.Technical Pamphlet No. The PCD of axle end holes of axle to SK. spacer. CP 200840. 4.5 4. therefore. TL/002/01/13. No. 6. WD89025/S-2. 7. BOXN CR BRN BOY BTPH BTPN BOBR & BOBRN BTPGLN BTALN *POH (Years) First Subsequent 6 4. cone.0 mm against 277. Other components were indigenous.5 6 6 6 4. G-81 M/s NEI have also supplied about 4300 Nos. 69601 is 90 mm as against 98. (c) M/s FAG Bearings M/s PBI. 9. No Stock/Wagons 1. seal wear rings.8 mm of Standard IR axle to Drg.A-G. BOXN. 3. These bearings require no maintenance between POH to POH. The periodicity of subsequent POH has been fixed as 4 1/2 years by Board vide their letter No. P.10. WD .No. seals were imported from FAG/Germany. (b) M/s TIL Bearings The first supply of M/s TIL was of complete imported sealed unit along with backing ring.05.89025/S-2. Vadodara have supplied Cartridge Taper Bearing to their Drg.: IRCA letter M. 2. This general arrangement of M/s NEI modified Cartridge Bearing is given in Annexure-III C. BLC BCN/BCNA. PERIODICITY OF MAINTENANCE The Cartridge Taper Roller Bearings used on Indian Railways are of 'No Field Lubrication’ (NFL) Type. POH interval of main wagons of air brake has been mentioned below: POH INTERVAL OF AIR BRAKE STOCK S . (iv) Displaced Adapter. Any wear of damage to the end cap or backing ring is an indicator that the adapter has been out of position. Outer cup. off centre loading. If two or more cap screws are found loose or missing. (ii) Running Temperature Detection of warm bearings on arrival of the train. torque tighten all the cap screws. Check for displaced adapter from its correct location on the bearing outer cup which can result from lack of care at the time of bogie assembly or from vehicle abuse during tippling. Check operating temperature of the bearing by touching the adapter or underside of the bearing cup with bare hands immediately after wagon/vehicle is halted. backing ring and end cap should be thoroughly examined and then the adapter should be properly seated. G-81 7.1. Apply a new locking plate and. SCHEDULE OF INSPECTION & MAINTENANCE The following are the recommended practices for long life and trouble-free operation of Cartridge tapered Roller bearings 7. A displaced adapter can cause mechanical damage.1 The bearings should be examined for (i) Abnormal Noise Check for any abnormal sound and/or grinding noise. If it is found impossible to hold the hand for a few seconds on the adapter or the Cup it means that the bearing is running hot. locking plate. the bearing should be removed from service for complete inspection and servicing before reuse. (iii) Visible Damage Inspect adapter. axle cap screws. accelerated fatigue damage and pre-mature bearing failure. If bearing temperature is more than 90 degree centigrade the wagon/vehicle should be removed from service. broken or distorted the wheel set must be removed from service. If any of these are found cracked.1 Recommended Practice during incoming examination in yards 7. Sometimes a displaced adapter can get automatically reseated in its correct position due to bogie action. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 7 .Technical Pamphlet No. the bogie should be lifted. Tighten the axle cap screw with torque wrench to a specified torque of 40 kg-m. If an adapter is found displaced. Cross check the bearing temperature with temperature sensing hand held pyrometers/sensors giving direct reading of the bearing. remove locking plate and fit a new one. If it is OK remove all the cap screws. outside of the cup and seal. Running temperature upto 380 C above ambient may be expected under normal operating conditions. Lock the cap screws by bending the tabs of locking plate. If locking plate tab are broken. If one cap screw is found loose or missing examine the bearing by rotating it. 562 mm (7. It will “set-up” and stop further leakage”. 5: Adapter properly located on bearing cup (v) Grease Leakage In case of grease purging or leaking out of the bearing. Grease leaking between the cup counter bore and the seal cage major diameter (Location B in Fig. This should not be wiped away.03") see clause 8. The break out diameter d1 of backing ring should not exceed 178. 6 (vi) Availability of adapter retaining nut and bolt in wide jaw bogie. in new mounted/installed bearing (either POHed CTRB or New CTRB) Leakage of grease upto 30 grams from seal and wear ring contact area is normal and comes from the purging of seal prelube and the reliving of internal bearing pressure. 2) may be an indication of a loose seal. 2) is an indicator of a loose backing ring and a loose bearing.9.5. Bearing with loose backing ring should be removed from service. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 8 . If a backing ring can be moved by hand on application of pressure it is considered to be loose. Fig.Technical Pamphlet No. check for visible damage to seals. Seal is loose if it can be moved by hand or is cocked out of position. 4: Adapter properly positioned in side-frame Fig. G-81 Fig. Grease leaking between backing ring on the axle dust guard (Location C in Fig. Please keep in mind. 2 In no case the bearing should be opened out in the Yards/Sicklines/ROH Depot. open out the axle end cap and replace it with a dummy cover. The torque specified is 40 kgm.1.2 Check for loose and/or missing cap screws. Also check axle end cap screw holes for any grit/swarf. The dummy cover can be made as per RDSO Drg. Area where bearings are opened for UST of axle must have controlled environment. 7: 2. Fig. Fig. and check the condition of bearing seals and adapter. (2) Before tyre turning.Technical Pamphlet No. Bearings giving unusual sound should be removed from service. Proper visual examination of bearings to be done.1 Overheating. (3) Mount the axle end cap and locking plate.1 above.2 Examination in Sicklines (1) When wagons pass through sicklines for some repair or tyre turning. such as discoloration or parts fused together. Bend the tabs of locking plate and finally rotate the bearing. Tighten the axle cap screws with torque wrench. In case if the bogie is lifted for any reason the bearing should be rotated by hand and checked for any unusual sound due to raceway damage. the bearing should be subjected to external examination as listed in Para 7. clean the axle end thoroughly.1. Some important aspects to be checked are as under: 2. 7. 2. 8: Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 9 . G-81 7. After tyre turning. WDIIA-8514/S-1(Annexure-V).3 Recommended Practices for ROH Depots: 1. 7. taking special care to see that no grit or swarf if left. No. 6 Check for cracked or broken outer rings (also called bearing cups).5 Examine the bearing for welding damage or exposure to extreme heat.3 2.9: Inspect for damage or wear to the end cap from a displaced adapter. Fig.10: 2. G-81 2. Fig.11: 2. Fig.4 Check that all tabs of the locking plate are properly bent up against the flats of the cap screw heads in the loosening direction. 12: Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 10 . Fig. such as from a cutting torch. Remove the bearing from service if you find any damage.Technical Pamphlet No. 15: 3.. If you can move or rotate the backing ring by hand. While carrying out wheel turning. The torque wrench must be maintained with an accuracy of +/. remove the bearing from service. the prescribed dummy/protective covers (as mentioned in clause 7. . If any screw movement persists after 5 passes check for any irregularity. Fig.2 (2) & shown in Drawing No. The specified torque should be maintained to 40 Kg–m (290 foot-pound).8 Inspect for a loose backing ring. Fig.4% (Maximum). WDIIA-8514/S-1) on bearing may be used 4.Technical Pamphlet No.9 Check whether the grease seal is displaced or cocked or has external damage Fig.7 2.13: Check the backing ring for damage or wear from a displaced adapter.14: 2. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 11 . Proper tightening of end cap screws with periodically (monthly) calibrated torque wrench at specified torque may be ensured on wheel sets. G-81 2. Minimum 2 passes and maximum 5 passes to be applied to ensure proper clamping. This is a normal condition that also causes wear to the adapter’s seat pads Fig. Alternatively the earthing can be done with a earthing wire/strip running parallel to the track instead of earthing with the rails. The earthing should be done very close to welding area and the earthing wire should be tightly secured at both ends. 9. such wheels must be sent to nominated workshop for overhauling. Fig. special attention should be paid so that electric current does not pass through the bearings. Most bearings will “creep” in service. the adapter must be thoroughly inspected for soundness and wear. In case bogie(s) are dismantled for any purpose.17: 8. Ensure the Adapter is properly placed on CTRB. as shown on the left side of the image below. A shiny edge at the extreme end of the outer ring. is an indication that the thrust shoulder is worn. 7. In case CTRBs fitted wheel are found to be overdue overhauling in course of ROH/Sick line examination to the wagon. creating two wear bands as pictured below.Technical Pamphlet No. The stamping of overhauling date on backing ring of CTRB has been advised to be done by workshops on each overhauled bearing to ensure traceability. indicate an excessively worn adapter seat. Handling of wheel sets to be done by using the prescribed lifting tackle and not wire ropes which can damage the grease seals. Whenever wagons or bogies fitted with CTRBs require welding in ROH Depots/Sicklines. Gauging must be done as specified clause 19. Replace the adapter if either of these conditions exist. If wagon is not properly earthed the current passing through the bearings will cause arcing in between the rollers and the raceways leading to failure. as shown on the right side of the image below. G-81 5.16: Wear bands that extend to the end of the outer ring. 6. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 12 . is to be done only by the bearing manufacturer. cleaning. assembly of all parts and installation.2. G-81 10. Lift sideframe and take out wheelset. inspection. For rectification of defective bearings in Railway workshop refer to clause 13.1 Clean the outside surface of bearing.1 Removal of wheel set from the side frame. The details of pilot sleeve are shown in Fig.Technical Pamphlet No. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 13 . PROCEDURE FOR OVERHAUL 8. Unscrew the axle cap screws from the end cap and remove locking plate and end cap.2.2 Removal of Bearing from Axle 8. The word 'Accident Involved' should be painted on the outside of the cup of such bearings before sending to workshop for detailed examination (Refer Para 8. (c) When Hot Box or Bearing failure has been reported on account of broken cup. 8.1 Remove side frame key bolt and the key. repair or replacement. 8. 18.0. Overhauling should be carried out at the time of POH of wagon and also at the following occasions:(a) Rediscing (b) When wagon has been submerged in flood.4 Overhauling of Taper Bearing 7.1. (d) Derailment: All the bearings of wagons involved in accident should be removed and sent for servicing/overhauling in the workshop. 8. 7.4.6). Checking of the mounted end lateral play may be ensured on each mounted CTRB. cage changing etc. Remove adapter retaining bolt and nut (only for wide jaw bogies) and take out adapter from the sideframe. The workshops will do the following work during POH of Cartridge Bearings:(a) Disassembly (b) Cleaning (c) Inspection (d) Reassembly Major repairs like remachining/ remanufacturing of the track raceway of cone/cup. etc. unusual sound etc. 8.1 The overhaul includes the removal.2 Attach pilot sleeve to the axle end or where press is used to the press ram. the guide tube is to be fastened to the end of the axle. Fig.2. 22.3 Apply pulling shoe behind the backing ring. 18 Fig. G-81 Fig.Technical Pamphlet No. 21: Select the pulling shoe adapter insert for the size of the bearing (6x11 Class “E”) to be removed and fasten it to the pulling shoe. Go on increasing the pressure to pull the bearing off the axle end. Fig. Hold it in position until the pressure has been applied. 8. A general arrangement for removal of bearing is shown in Fig. This adapter is retained by a springloaded ball and is not threaded. 19: When bearing Assembly is to be removed. 20: Insert the guide tube adapter in the threaded hole in the guide tube. The pressure may exceed 5 tons. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 14 . The bearing is now ready for dismantling on the workbench. 8.Technical Pamphlet No.3 Dismantling of Bearing After the assembly is taken out from the puller.5 The bearings should be very carefully handled.24: Position the bearing removal fixture on the bearing assembly to be removed by tilting the pulling frame. 25. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 15 .2.23: Place the forcing plug adapter in the ram head. care should be taken to ensure that the bearings are not thrown one over the other.4 Removed bearings should immediately be kept in a clean and dry place in a covered room. The bearings should be carefully stacked one over the other as even a small impact is enough to damage the bearing. 22 8. While loading / unloading the bearings for transportation from one place to another or otherwise. G-81 Fig. Fig. Under no circumstances a bearing should be left in open to avoid ingress of moisture/water causing severe rusting of the bearing. Remove seals from both sides with the help of seal dismounting jig. Fig. seal wear rings and excess grease.2. Every bearing is precious – SO HANDLE IT CAREFULLY. 8. The application of seal dismounting jig is shown in Fig. remove backing ring. V-C & V-D. 25 The parts of seal dismounting jig and its details are shown in the Annx. Alternatively seal may be removed with pry bar as shown in Fig. 26A. Remove the inner ring assembly and Spacer from the outer cup. Fig.Technical Pamphlet No. G-81 Fig. 26A Seal Removal Using a Pry Bar Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 16 . The details of pry bar given in Fig. 26B. 5. Axle end caps that are distorted. wear and distortion of machined surfaces. Overnight filtering is one of the solutions. 27 is critical as this comes in contact with the seal wear ring.Technical Pamphlet No. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 17 . G-81 Fig. 26B 8.5 Inspection of Bearing Components Check each component carefully. Ref: Annexure VI for these dimensions. agitator or spray system or by hand. breakage. 8. cracked or damaged should be scrapped. Surface marked C in Fig. Alternate cleaning method as shown in Annexure V-E can also be used. Washing medium should be filtered before reuse. Measure the dimension of components which have been laid down by the manufacturer.4 Cleaning of Components After the dismantling of components remove the residual grease as much as possible from the components before washing can be done by automatic cleaner.1 End Cap Inspect for cracks. at least once in a day. 8. White spirit or other suitable solvent should be used. Surface defects can be noted visually or by any roughness felt through the feeler gauge probe as shown in Fig.2 Cone Inspection (Inner Rings with Roller Cage Assemblies) Inspect the raceways for staining. Place the inner ring with the roller and cage assembly with back face (large diameter face) down on a horizontal support. Sufficient light should be made available at the inspection stand. A feeler gauge probe or surface roughness tester is inserted between the roller and cage at the large and small ends of roller in turn.5.D Min)/2 < 0. spalling.Technical Pamphlet No. heat discolouration.003") Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 18 .076 mm (0. 27. corrosion. Average out of roundness = (D Max . The inner ring is rotated on the inspection stand. Sufficient light should be made available at the inspection stand. The average bore dia shall not be more than 144.28 and 29. electrical burns. 27 8.488 mm (5. cracks and embedded contamination (See Clause 18).6885") at three locations (see 'd' in Fig. Measure the bore diameter at both ends 9 to 13 mm from each face. G-81 Fig. indentation. false brinelling. The inner ring with roller and cage assembly should be placed on an inspection stand. pitting. 30) out of roundness should not exceed 0.076 mm (0.003") as per Annexure VI. rotate inner ring. 28: Inspection inner ring for defects Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 19 . Measure the gap 'A' in Fig. NEI/ Brenco & SKF make bearings. 27 between the roller and the cage.08") Place feeer of surface roughness tester between the roller and cage adjacent to both the large and small ribs.0 mm (0.3 mm (0.090") or more. the roller assembly should not be returned to service. Fig.090"). If the total of the two sets of feeler gauges is 2. Any surface defects can be noted by roughness felt through the feeler gauge. NEI/BRENCO. The assembly should be rejected in case feeler gauge to the condemning dimensions given below can be inserted:Make TIL.06") 2. Measure the gap between the small flange of the inner ring and bore of cage flange in two diametrically opposite location.3 mm (0.e. (See dim. B1 + B2 < 2.Technical Pamphlet No. SKF KOYO Condemning Dimension 'A' 1.127 mm (0. 31. 27)i. This is to be measured only for Timken.5 mm (0.005”) as shown in Fig. B1 & B2 in Fig. FAG. G-81 Cone face wear depth shall not exceed 0. 29: Inspection stand (typical) Fig. the feeler gauge (as shown in Fig. Additionally while rotating the inner ring. the inner race can be visually inspected.Technical Pamphlet No. G-81 By rotating th inner ring and observing the light area between roolers. 30: Checking inner ring bore with dial bore gauge (recommended method) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 20 .28) can be used to inspect the raceway adjacent to both the large and small thrust shoulders. Fig. 677 mm (8. The out of roundness should not exceed 0.423 mm (8.4 Outer Ring (Cup) Inspection 8.5. G-81 Fig.255”) to 209. Measure the counter bores at both ends (see Fig 32). refer Annexure-VI].1 Counterbore Check inside dia of counter bores D1 in Fig. 28 for the seal fit which should be within 209.4. Fig.Technical Pamphlet No. smearing.253”).127 mm (0.5. 8. spalling. 31: Cone back face wear groove 8.5. (See clause 18).32: Checking seal fit counter bore Fig.33: Master setting ring to set dial with dial bore gauge (recommended bore gauge method) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 21 . indentation and corrosion etc.005").245”) [only for KOYO bearing maximum counter bore dia should be 209.626 mm (8.3 Rollers The contact area of each roller must be inspected for any damage or type of defects like brinelling. 35 B). The make wise limits of outside cup dia are reproduced below: Make Timken. The wear pattern on the outerside of the cup should be studied because it reveals excessive wear of adapter. smearing or peeling.3 Wear Pattern The maximum out of roundness should not exceed 0.4. 35A : Normal wear bands Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 22 . in Fig.2 Cup Outer Dia Measure the outside diameter using a micrometer at the points where the adapter has been in contact (See location 'A. If wear bands extend upto the ends of the cup it reveals excessive wear on the adapter (See location B in fig. 35 A) with the cup.663 (8.4. G-81 8. SKF.675) 220. spalling. FAG KOYO Condemning Cup outside dia mm (in.) 220.6875) Fig.36). Inspect cup for wear band due to an excessively worn adapter at the ends. Inspect for intensity of corrosion also.127 mm (0.5.Technical Pamphlet No. 34: 8.345 (8. The dia should not be less than that specified in the manufacturer's specification (Annexure VI). Fig.005") (See Annexure-VI). The adapter in such case should be rejected.5. NEI/BRENCO. Inspect rolling surface for any damage or type of defects like brinelling. fragment indentation or electric burns (See clause 18 & Fig. 6 Seals Seals must never be reused.5 Cage Check cage pocket clearance as given in the last two paragraphs of clause 8.36: 8. 35B: Abnormal wear of outer ring/Cup due to excessively worn adapter Fig.2. Cracks of any size on the cage specially at the corners of the roller pockets are cause for scrapping roller assembly.Technical Pamphlet No. 8. 27 & 37). G-81 Fig.5.025 mm (0. nicks and burrs. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 23 .5. All used seals must be replaced with new seals. The end faces of the spacer should be parallel within 0.7 Spacers Spacers must be visually inspected for cracks.5.5. Cracked spacer must be scrapped. Nicks and burrs on the end faces should be ground smooth. Cage changing can be done by the bearing manufacturer only and not by the workshops. 8.001") (See spacer in Fig. Cage once taken out cannot be re-used. they must be scrapped (See 'F' in Annexure -VI also).8 Seal Wear Rings Seal wear rings must be visually inspected for nicks.005") they should be replaced (See seal wear ring in Fig.562 mm (7. 27 & 38). The wear ring and backing ring must fit tightly together. G-81 Note : Widths of Spacer decides bearing Lateral Play Fig. cracked or heavily pitted rings also. Check backing ring for excessive corrosion.37: Radial and Lateral Clearance indication 8. Scrap backing ring with break-out dia which exceeds the specified limits.5. which shall not exceed 178.5.03").9 Backing Ring Check backing ring break out diameter d1 in Fig. If worn to the extent that there is no longer a tight fit.Technical Pamphlet No. 39. Seal wear rings with vent holes should be discarded if found during maintenance /reconditioning. Check Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 24 . 38: Checking Seal wear ring groove depth 8.13 mm (0. The seal lip contact path must be smooth and free from any defects that might damage the seal lip. Scrap distored. Fig. If seal lip contact path worn to a depth of more than 0. cracks. or scratches on the outside surface. Check seal wear ring for wear. 5.11 Locking Plate & Cap Screw Seal Rings Locking plate should never be reused.5. I in Annexure-VI also. See G. Reject and replace if any defect is found. In dry threads or rusted threads a major portion of the torque is used up to overcome the friction.e. Whenever locking plates are removed they should be replaced with new locking plates. The counterbore must provide a tight fit for seal wear ring. 39. The cap screw threads should be properly cleaned and lubricated before fitment. H.8. The new cap screws shall be procured as per size 1" Dia-8 UNC-2A X 2-1/4” Long having Hexagonal head and material shall be IS: 1367 (Part-3): 2002 Class P 8. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 25 . Backing rings with vent holes should be discarded if found during maintenance/overhauling. No. WD-87019/S1 (Annexure-VII). Mating threads on axle end holes should also be checked. With clean and lubricated threads the major portion of the applied torque is used for tension of the cap screw. A deflected end cap acts like a lock washer. and for stretching or elongation. SO 'DON’T FORGET TO CLEAN & LUBRICATE CAP SCREW THREADS AND AXLE END HOLES' 8. Fig. Locking plate shall be as per RDSO Drg. cleaned and lubricated. higher is the end cap deflection and better is the clamping of the bearing on the axle i. Cap screws which cannot be tightened to the recommended torque must be scrapped.10 Cap Screw Check cap screws wear on threads. Cap screws having rusted threads should be used only after proper cleaning and lubricating. G-81 seal wear ring counterbore diameter d2 in Fig. better retention. Higher the amount of tension developed in the cap screw. 39 8.Technical Pamphlet No. Use radial indicator mounted to a cam actuated hand operated device (Fig. The grease container should always remain closed. tools and work benches are thoroughly cleaned.0. Care should be taken that these parts do not get contaminated during assembly.023 to 0. Make sure that all components.2 Lubrication Grease to be used should be clean and free from all kind of contamination. polythene sheet or similar material whenever reassembly work is discontinued or delayed due to some reasons.74 mm (0.029") With Power Operated Device Fixture for checking Bench lateral (recommended method) Fig. The bench lateral must be within as specified below: 0.40) for checking the bench lateral. Never use cotton waste.58 . 40 8.66 mm (0. The grease recommended for use on CTRB of Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 26 . Cover the parts with waxed paper. Check the unmounted play of the bearing assembly to make sure that the spacer has the correct width.4.1 Bench Lateral Improved rolling contact fatigue is the 'BENEFIT' of proper 'Bench Lateral'.0.026”) With Hand Operated Device 0. 8. cracks etc. G-81 8.Technical Pamphlet No.7.1 d).7 Assembly of Bearing After proper inspection of all the components they can be assembled.7. So assembly should be done in a proper place. 8.020 to 0.6 Accident Involved Bearings Extra precaution should be taken during inspection of accident involved bearings in the shop for brinelling.51 . on rollers and raceways (Refer Clause 7. denting. in accordance with their specification No. Apply grease to each single assembly and between the roller and cage assemblies in the quantity as given below:Amount of Grease to be applied To single Roller Assembly (Each Cone assembly) 115 g Between Roller Assembly (Around spacer) 170 g Total + 30 gram 400 g Accurate lubrication system/device must be used to apply correct amount by weight of lubricant and must be verified by measuring two samples per day. 43).Technical Pamphlet No. 8. 41. Use seal mounting jig for assembly of cone and seals. (iii) Installing Plate . 42. 42 & 43 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 27 . clean all the equipment to be used for lubrication. Quantity of grease excess than the specified should not be applied. G-81 freight stock shall be AAR approved in accordance with M-942-2004 or latest of AAR MSRP Section H or Grease Approved by RDSO. as excess quantity of grease causes higher operating temperatures and also results in purging at the seal. IX & X. 41. FIG.transfers pressures directly to the seal base shoulder. if not prelubricated by supplier.may be required depending upon the type of press used.in which the outer ring stands to keep it in an upright position. Before applying the grease. WD-24MISC-2003.3 Mounting of Roller & Cage Assembly & Fitment of Seals. (ii) Adapter Ring . The recommended cone greasing fixture and its details are shown in the Annexure -VIII. thus giving false indication of seal wear or seal damage. The lips of the seal should also be lubricated with same grease. Recommended dimensions of these parts are given in (Fig. The three parts of Jig are:(i) Support Ring .7. 7. While mounting the seal wear ring.4 Fitment of Seal Wear Rings & Backing Ring Slowly force the seal wear ring in position so that lips of seal expand and do not get turned under. STORAGE & PACKING OF BEARINGS. 9. After servicing/ overhauling a triangular card board as shown in Annexure-XI should be inserted in the bore to avoid displacement of the spacer & to prevent lubrication loss. Then keep seal in position and press into the outer ring with the use of seal adapter ring as shown in Fig. The shoulder of the seal must be flush with or below the bearing outer ring face. 8.5. Put the backing ring and other seal wear ring in their respective places (See para 8. Turn the unit upside down and keep it on the support ring again.7. Fill the space between spacer and outer ring with grease as prescribed in Para 8. Keep the first cone assembly in the outer ring. 45 Keep the support ring on the work bench and place the outer ring (cup) in its recess.Technical Pamphlet No. Special attention must be given to proper packing and storage of CTRB. Insert spacer in position. The procedure for fitment of other outer ring is repeated as described above.2. 44 Fig. The complete bearing should then be wrapped in Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 28 . 44 & 45. make sure that they are assembled with the tapered end towards the bearings. All outer surfaces should be coated with rust preventive.8 & ‘F’ in Annexure. G-81 Fig.VI). Before mounting. the journal should be inspected in a clean and well-lit area. Periodic inspection of the storage area should be made. the bearing unit should be used in the order in which they were stored. The bearings should leave the servicing room only in properly packed condition even if they are to be used within the same premises/workshop. MOUNTING OF TAPER BEARING ON AXLE. B & C. or axle must be rejected.127 mm minimum.XII.Technical Pamphlet No. 46 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 29 . Take three readings. ensure that they are carefully sealed again.564 mm to 144.. Method of measuring journal dia for new and old axles is as under:10. Complete bearing unit and components should be stored in a clean area with good protection from moisture. i.e. first out (FIFO). If they are opened for inspection etc. Total nine readings have to be taken.6915 " to 5. equidistant (i. The three circumferential readings taken at ‘A’ must be averaged and the average must be within the tolerance shown below. B & C (see Fig. The same applies for points B & C. first in.144. 46). 1200 apart) around diameter at each point A.539 mm (5.1 For New Axles Measure the journal diameter at three points A. G-81 polythene bags of minimum 400 mm width and 600 mm length. The thickness of polythene should be 0.6905 ") Fig. As the self-life of grease is limited. The packages of new bearing should be opened only before mounting.e. DO NOT AVERAGE ALL NINE READINGS:AXLE ALLOWABLE DIA . The packed bearings should be kept in a container as shown in Annexure. 10. 48 A 10. G-81 10.1 above.2 For Old Axles Measure the journal diameter at the two bearing seat locations at three equidistant points (i. 47 : Method of measuring journal diameter by snap gauge NOTE: .1 Journal Grooving From Inboard Seal Wear Ring Groove in axle not over 0.There should be no abrupt changes or steps over the length of the journal for both NEW & OLD axles. which must be within the tolerance given in Clause 10. Fig.Technical Pamphlet No.e. No abrupt changes or sharp edges are permissible (Fig.05 mm (0. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 30 . DO NOT AVERAGE ALL THE SIX READINGS. 48 A). The three measurements at each individual bearing seat may be averaged to obtain the average size. 1200 apart) around the journal shown in cross hatched area (Fig. 48 B). Fig.2.002") deep can be repaired by polishing with abrasive cloth (80 grit or finer). Take three readings at 1200apart around the journal. Journal must never exceed 0. 48 B 10.Technical Pamphlet No. 49).003") above maximum diameter in this area.3 Check fillet radius for proper seating of backing ring with template (See Fig.075 mm (0. : 49 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 31 . but may be below the minimum diameter in this area. 48 C). If feeler gauge can be inserted more than 10 mm (3/8") around the journal periphery. Fig. 10.003") may be corrected by only files.075 mm (0. provided surface roughness meets the specification.2 Measuring for Upset Journal Ends Measure the journal dia in the cross hatched area (Fig.2. the fillet must be corrected. Upset ends over 0. G-81 Fig. 48 C Fig. Fig. Coat the journal fillet and portion of axle between wheel hub and the fillet with lead free rust preventive (Spec. i.e. 18 should be used for pressing bearing unit on to the journal. IS: 9862). Then coat the bearing seating on the journal with heavy mineral oil (SAE 30/SAE 40) or Castor oil. No. a pilot sleeve shown in Fig. However. 51 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 32 . 50. 53 respectively. 50 To facilitate mounting. it must be designed to ensure that the ram pressure is applied to the centre of the mounting sleeve and squarely to the face of the seal wear ring. The mounting sleeve can either be separate or attached to the press ram. pressed on to the journal without heating. 18 and Fig. The recommended dimensions of pilot sleeve and the mounting sleeve are given in Fig. Hydraulic mounting tool Fig. A hydraulic type of mounting equipment is shown in Fig.4 The bearing unit should be cold remounted. G-81 10.Technical Pamphlet No. 52 Bolt the pilot sleeve to the axle end. Now put mounting sleeve (See Fig. G-81 Fig.54 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 33 . The pressure will reach between 10 to 16 tons just before the backing ring alongwith the bearing butts against the dust guard fillet. 53) on the free end of pilot sleeve and roll the wheels and axle assembly into position in the press. 53 Fig. Fig. Apply pressure from the wheel press ram. Check that journal and pilot end are square in all planes with the face of the ram (See Fig. Place the bearing unit on the pilot sleeve and slide it up against the journal as far as it will go without using force.Technical Pamphlet No. To ensure that the backing ring alongwith the bearing is firmly seated against the fillet allow the pressure to built up to the final gauge readings of 50 + 5 tons held for 5 seconds to fully seat the bearing. 54). 61) as a result of fewer rollers sharing the load.2AX 2-1/4” Long’. The locking plates to be used shall be as per RDSO Drg. Torque wrench should be used to tighten the axle cap screws. The torque wrenches to be set to one fix value i.5 Mounted Lateral Mounted lateral is CRITICAL to bearing performance. 10. 56 Fig. This reduces FATIGUE LIFE. With correct mounted lateral more rollers share the load as a result peak load on individual rollers are less (Fig. No. WD-87019/S-1 (Annexure -VII). and locking plate to the end of the axle. The torque wrenches should be calibrated at least once in a month. The cap screws should be of High Tensile Steel to IS Specification 1367 (Part-3): 2002 Class P 8. The threads shall be to 1”dia 8 UNC . G-81 Fig. 60). 55 Fig. 57 When the final pressure has been reached. Assemble the end cap. 59 Fig. 40 Kg-m.e. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 34 . Locking plate once opened must be replaced. cap screws. remove mounting tools and wipe the end of the axle using a clean lint free cloth (No cotton waste is to be used). 58 Fig.Technical Pamphlet No. The recommended torque value is 40 kg-m (290 foot. Excessive mounted lateral causes high peak roller loads (Fig.8.pound). Torque wrenches must be accurate within + 4 %. 001" to 0. dismount the bearing for further inspection.00 and the bearing can be rotated freely by hand.03 mm but greater than 0. The lateral play should be between 0. Start by pushing the bearing laterally towards the wheel hub and zero the indicator.6 Check the mounted lateral play with a magnetic base dial indicator (See Fig.Technical Pamphlet No. Lock the cap screws by bending all the tabs of the locking plate flat against the side of the cap screw head.38 mm (0. G-81 Fig.03 mm to 0. Then pull the bearing laterally away from the wheel hub to obtain the lateral reading. Fig.015"). 60 Fig. 62). 61 10. Do not bend the tabs against the corner and do not break them (See Fig. the application is still satisfactory for service. If the clearances are not in the limits. If lateral play is somewhat less than 0. 62: Checking residual lateral play after mounting Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 35 . 63). This is to shift the loading zone and in turn increase the life of the bearing. 64 A). Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 36 . A in Fig. FITMENT OF AXLE UNDER THE BOGIE The axle after the mounting of bearings is ready for fitment under the bogie. Whenever adapter seating marks are found to be confined on a limited circumferential length on the outer cup. Place the adapter in between the sideframe of wide jaw bogies hold it firmly and tighten the adapter retaining nut and bolt. Lower the sideframe over wheelset. In narrow jaw bogies adapter retaining nut and bolt is not used. the bearing should be rotated so as to bring that portion of the cup under the adapter which does not have adapter seating marks. 63 11. G-81 Bending locking plate tabs with rib joint pliers Tabs bent against adjacent flats Tabs bent against alternate flats Preferred bending when one tab is centered on corner Fig. Hitting of retaining bolt head may cause breakage/denting of cup.Technical Pamphlet No. While lowering attention should be given to avoid adapter retaining bolt head hitting the cup of bearings due to less clearance (see Dim. Technical Pamphlet No. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 37 . 64 A Fig. MAINTENANCE SPECIFICATIONS The suppliers of Cartridge Bearings have recommended condemning dimensions of components. These are reproduced in Annexure-VI. 64 B 12. G-81 Fig. so as to clearly differentiate that the servicing has been done by some company. have to be permanently and legibly marked on the Cup/outer ring inner diameter on the straight portion in the centre between the raceways as shown in Fig. Note: .if the outer ring races of a bearing have been remanufactured by M/s NEI/JP in Jan. of any two make. G-81 13. (b) Marking of Remanufactured or Repaired Components. (i) Outer Ring/Cup Outer ring with reground race must be marked as indicated in Para (a) with the additional remanufacturing symbol encircled R i. Refer Annexure. (ii) Inner Ring Inner ring which have been remanufactured (cage removed for inspection and/or operating surfaces reground) must be marked on the end face following manufacturers identification in the manner illustrated in Fig. The marking will include the date i. No.XIII also. spacer. accident etc. are not interchangeable. Bearings that have been serviced during POH or otherwise because of rediscing. cone. cup.Technical Pamphlet No.Encircled ® should be marked only when operating surfaces have been reground Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 38 .. 1985 the marking will be 4-85. locking plates and Grease seals are common for all make of bearings.e. 66. 14. If the bearing has been serviced by any manufacturing company like M/s NEI/JP the manufacturers code has to be encircled. All other components viz.e. seal wear ring.If the bearing has been serviced in Liluah workshop in April. BEARING MARKING (a) Marking of Overhauled Bearings. hot box. month and year and servicing workshop code/company's initial. ®. 65.. 1990 and servicing has been done by M/s NEI/JP in Feb. INTER-CHANGEABILITY OF BEARING COMPONENTS The components like axle cap screws. In addition to above marking/Stamping shall also be done on Backing Ring as per Drg. WD-03034/S-1 (Annexure XIV). 90then the marking shall be 1-90 ® 2-90 (NBC). However cannibalization of parts of two defective bearings of the SAME MAKE is permitted. Precaution should be taken that components of one unit do not get mixed up with components of other unit of same make or of other make during servicing. Example: .LLH. end cap and backing ring etc. For example:. 65 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 39 .Technical Pamphlet No. G-81 Fig. Technical Pamphlet No. G-81 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 40 . Therefore. the work place should be well lit and sufficiently spacious. be carried out in a dust-free and dry environment. which are removed from axles for inspection for suspected damage must be marked as per Para (a) with additional marking of symbol 'N' following the repairing Workshop/Company's code marking. then marking will be (R) 10-12.Technical Pamphlet No. Note: . WD-II-A-8513/S2 should be followed (Annexure XVIII). BEARING MAINTENANCE WORKSHOPS For efficient maintenance. No. The whole room. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 41 .If cage has been removed for inspection and recaging done by Timken India in Oct. the marking will be 10-92.. All new bearing inspected and marked as per this rule will be considered new bearing. Example: . the following steps should be taken:(i) Wheel sets should be handled with a lifting tackle as per Sk. Special attention is required during handling.K. Handling of wheel sets after mounting cartridge bearings is to be done carefully. WD-II-A-8513/S-1 (Annexure XVII). To ensure that no damage occur to the bearing. No. 15. tools.If a new bearing with no service mileage has been opened for suspected damage and found O. 1992 without any regrinding of the races. The cup and seals can be damaged due to:(a) Hitting of flange (See Fig. by RAINAPADU workshop in Jan. 16. (c) New bearings. transportation from workshop to Division or Division to workshop. Maintenance should. (ii) The instructions given in SK. (iii) Spacer Space which have end faces remachined must have the date (month and year) and the remachining Workshop/Company's initials marked on the outside diameter as shown in Fig. 68) (b) Slinging more than one wheel set while lifting (c) Loading in wagon without proper wedging. Note: . benches and work places should be kept clean as even minute particle entering the bearing during mounting would render the most efficient sealing arrangement ineffective and cause premature failure. 1988 the marking will be 1-88 RYPS-N. with no service mileage.Outer ring raceways and Inner ring operating surfaces can be reground only once. 67. therefore.Around 20% of the failures are due to cup broken/crack. handle the bearing carefully. HANDLING OF MOUNTED WHEEL SETS. A general layout of the maintenance shop is appended as Annexure XV & XVI. (d) Slinging the wheel set over the bearings. If regrinding is also done. G-81 Example: . One of the proposed scheme of earthing Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 42 . 69 17. The earthing should be done very close to welding area and the earthing wire should be tightly secured at both ends.Technical Pamphlet No. WELDING OF WAGONS/BOGIES FITTED WITH CTRB Whenever wagons or bogies fitted with roller bearings require welding in Workshops/ROH Depots/Sicklines special attentions should be paid so that electric current may not pass through the bearings. 69 to save space. G-81 Wheel sets with mounted bearings may be kept on single storage track overlapped as shown in Fig. 68 Fig. With this arrangement the flanges of the wheels will not contact either the roller bearing assemblies or axle bodies of adjacent wheel sets. Fig. G-81 is given in Fig. lack of lubricant.Technical Pamphlet No. 18. Fig. impact load on the bearing etc. If a bearing has failed it is recommended that the reason for bearing failure should be investigated so that corrective actions may be taken. 18. There are so many reasons for flaking e. Alternatively the earthing can be done with aearthing wire/strip running parallel to the track instead of earthing with the rails. do not forget to earth the two bogie bolster ends of two bogies of the wagon prior to welding.1 Flaking / Spalling: Minute surface cracks are the first visible indication that flaking on the rolling surface has started. BEARING DAMAGES Following are some of the most common damages found in cartridge tapered roller bearing at the time of overhauling and inspection in bearing shop. It spreads up due to increase in stresses at edges of the spall. If wagon is not properly earthed the current passing through the bearings will cause arcing in between the rollers and the raceways leading to failure.g. grease contamination.71: Fatigue spall Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 43 . abnormal loading conditions. Metal fragments those separated from the spalled area are carried in lubricant and causing increase in size of the flaked area. metal fatigue. displaced adapters. 70. However. 5 mm (1/16” x 1/16”) or less in an equally large section. The maximum acceptable depth for spall is 3 mm (1/8”).Technical Pamphlet No. G-81 Flaked / Spalled Cone Assembly: If the raceway of cone or a roller surface is spalled.74: Large Spall (Rejectable) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 44 . However small pinhead size spalls on the cone raceway 2. except where the spalls can be run together within the maximum dimension if one spall 10 mm x 10 mm (3/8” x 3/8”). 72: Incipient spall acceptable after repair Not more than two spalls of maximum size 10 mm x 10 mm (3/8” x 3/8”) should be repaired in a 50 mm (2”) circumferential section of the raceway and not more than four spalls 1. If the spall size is more than 10 mm x 10 mm (3/8” x 3/8”) the cup must be rejected.5 mm x 1. Flaked / Spalled Cup: As specified in AAR Roller Bearing Manual.4 mm (3/32” x 3/32”) are acceptable as exception for further service.73: Incipient spall acceptable after repair I Fig. A bridge of 5 mm (3/16”) must be left between two spalls after grinding.4 mm x 2. It is recommended to use spall limit gauge to determine maximum repairable spall size. the complete cone assembly should be scrapped. Fig. Fig. incipient spalls on cup or cone can be repaired using pencil grinder and fine abrasive wheel to grind away loose material and to remove sharp edges of the spall. 76 A: Acceptable Brinelling Fig. G-81 18.75: showing brinelling mark Fig. It is recommended to use “Brinell width and Spall Limit Gauge “ to check width of the brinell mark. Also if the part has heavy brinell marks having length more than half raceway Width the ring must be rejected. Fig. 76 B: Acceptable Brinelling Fig.Technical Pamphlet No. Any number of brinell marks is permissible. If the length of the faint brinell mark is more than half the width of raceway and it’s width at widest point does not exceed 2. If the brinell mark exceed either of the limitations the cup must be rejected.4 mm (3/32”) the part is satisfactory for further service. 77: Acceptable Brinelling Fig.78: Brinelling not acceptable Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 45 . In other words. If the length of a faint brinell mark is less than half the width of raceway and if its width at the widest point does not exceed 4mm (5/32”)the part is acceptable for service.2 Brinelling: Brinelling are the surface indentation marks in raceways made by roller under impact load. when rollers are forced into surface of either raceway while the bearing was subjected to heavy impact loading beyond it’s capacity. Technical Pamphlet No. G-81 18.3 Smearing & Peeling: Smearing is transfer of metal from one surface to another as a result of galling. This may be due to sliding of rollers on raceways due to adverse lubricating condition. If the cup, cone or rollers has very shallow smearing less than 0.025 mm (0.001”) depth it may be returned to service after polishing. Fig.79: Smearing -Acceptable after Polishing Peeling is the condition caused by minute particles of metal peeling away from original metal surface. Cup, cone & rollers having very shallow peeling depth 0.025 mm (0.001”) or less on rolling surface may be returned to service. Fig.80: Peeling -Acceptable 18.4 Stain Discoloration, Corrosion Pitting & Rust The adjacent figure shows surface corrosion damage on raceways and rollers, of three different intensities. Stain discoloration are caused by etching due to moisture or acidity in the lubricant. Superficial stains & discoloration having no depth and which can be removed by 180 grit abrasive or finer or wire brush are acceptable after polishing. Care should be taken that metal is not removed from rolling surfaces. Corrosion pitting or rusting (black corrosion lines or pit marks) which has advanced to severe pitting must be repaired by polishing raceways and rollers. Slight pitting after polishing is acceptable. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 46 Technical Pamphlet No. G-81 The cup or cone assembly which cannot be repaired satisfactorily by polishing must be rejected. Fig. 81: Strain & discoloration having no depth 18.5 Fig. 82: Superficial water or acid etching Fig.83: Severe corrosion pitting Heat Discoloration Color from faint straw to dark blue may be indication of overheating of bearing (Heat discoloration should not be confused with lubricant stains or the dark coating used on certain parts by some manufacturers). Parts should be rejected only if there is other evidence of overheating. Overheating from an internal source generally originates in the roller inner ring rib contact area and will usually be indicated by visible inner ring rib and/or roller end face wear. Overheating from an external source would usually show indications on both the outside and inside. If there is evidence of overheating, parts must be rejected. Fig.84: Heat Discoloration 18.6 Fragment Indentations Fragment indentations in the bearing may be caused due to lubricant contamination e.g. dirt, dust and spalling debris passing over rolling surfaces. Bearing parts should not be rejected for indentation marks present on raceways unless the damage is Such that roughness can be detected when the bearing can be rotated by hand (See fig 43). Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 47 Technical Pamphlet No. G-81 Fig. 85: Fragment Indentations 18.7 Electric Burns Surface damage from passage of electric current causing localized craters, pits, fluting or corrugatations. Pitting, shown in Figs. 44A and 44B, is the result of electric current passing through the bearing, such as when the ground cable is clamped to the rail or wheel for arcwelding repairs on wagons/cars. Parts so affected must be rejected. Although only one pit is shown in the below photographs, pitting may occur at several points simultaneously on any or all bearings on the wagon/car when arc-welding is used for repair work, if the ground cable is not clamped to or near the part being welded as recommended (See Para 16).Welders must attach the ground cable so that the circuit formed will not allow current to flow through the roller bearings. Fluting or corrugations, as shown in Fig. 45, result from electric current passing through the rotating bearing. The parts of bearings so affected must be rejected. Fig.86 A Fig. 86 B Fig.86A, 48B: Pitting, resulting from electric current passing through bearing (Bearing parts affected must be rejected) Fig. 87: Fluting or corrugation, resulting from electric current passing through rotating bearing (Bearing parts affected must be rejected) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 48 ) Note: Adapter shall not be welded at any location. Casnub-22NLB.8 Nicks Nicks are surface damages caused due to rough handling of bearing parts. The inspection for wear shall include the application of gauges at locations detailed in para 19. Wide jaw Adapter for Casnub-22W Bogie without Elastomeric pad and Casnub-22W(M) Bogie with elastomeric pad. Repairing of adapters by welding/brazing is not permitted. Warped.2 to 19.7. 3. ADAPTER Earlier wide jaw adapter were used on Casnub 22W and Casnub22W (M) bogies.78527 (Latest Alt. Instruction for inspection of Adapter has been exhaustively mentioned in RDSO manual ‘Instructions for Inspection and maintenance of Casnub Bogie Technical Pamplet No. Casnub-22 HS Bogie. (Latest Alt.1 INSPECTION OF ADAPTERS When bogie are dismantled for any purpose adapter must be thoroughly inspected for soundness and wear.85053/S-1 pad retrofitted. 2. 19. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 49 . Narrow Jaw Adapter for Casnub-22NL. place the adapters on the bearing cup and it must seat firmly on the cup without rocking or pinching when hand pressure is applied. distorted or twisted adapters must be scrapped.) SK . G-81 18.However for ready reference the main points have been reproduced here.Technical Pamphlet No. G 95’. Wide jaw Adapter for LCCF – 20(C) bogie/BLC wagons WD-89067/S-9 (Latest Alt. 2.) Modified Adapter for Casnub-22W Bogie with Elastomeric WD . 18. To check distortions. provided part is repairable and functioning of part is not affected after repairing. Adapter Drawings 1. In order to reduce undamped mass of the bogie. 19. 1.9 Cracks & Fracture A crack of any length/size is found on any roller. 22 NL bogies were designed with narrow jaw adapters these are under manufacture since 1990-91. Broken or cracked adapters must be scrapped. any location in inner ring/cone or outer ring/cup or cage the component should be scrapped. Nicks present on component can be corrected by use of oil stone. 88 A Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 50 . Adapters must be checked for proper fit on the cup and in the pedestal before placing in the bogie/truck frame. G-81 3. 89C). the adapters must be scrapped (see Fig. 9. When such groove exceeds 0. Adapter machined relief must have 0. 6.Technical Pamphlet No. 8. 5. When adapters are worn to such an extent that ridges or grooves prevent proper seating in side frame on the adapter or proper seating on cup. adapters must be scrapped. 7.7 mm in depth at any point. When both sides’ shows wear more than 3 mm (1/8”) do not reuse the adapters. Thrust shoulders of the adapters may show wear due to contact with ends of the cup. but otherwise satisfactory must be reversed in direction when reapplied into the pedestal frame. If the crown portion of the adapters has fully worn (up to the crown relief groove) adapters must be replaced by new adapters (see Fig. 4. 88A & 88B). Adapters which are worn on one side between thrust lugs due to braking reaction. 92). Fig. 89D). Check full bearing seats of the adapter for wear by gauge (see Fig. Excessively worn out adapters must be scrapped.8 mm (1/32”) or greater depth (see Fig. Technical Pamphlet No. 88 B Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 51 . G-81 Fig. Technical Pamphlet No. G-81 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 52 . 89C & 91).7 mm at any location the adapter must be scrapped (See Fig.7 mm Fig.Technical Pamphlet No. G-81 Fig. 89E 19. When depth of such a groove exceed 0.2 Thrust shoulder Wear limit Gauge : Wide Jaw Narrow jaw 0. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 53 .90 The thrust shoulders of used adapter may show grooves due to contact with the ends of outer cup. 91 19.8 mm or greater depth. The gauge for checking machined relief thrust shoulder face and body wear is shown in Fig. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 54 .Technical Pamphlet No. 90 Adapter machined relief must have 0. 90 Fig. 90.8 mm Gauge : Wide Jaw Narrow jaw Fig. G-81 Fig.3 Adapter bore (bearing seat) Adapter machine relief depth > 0. 89D & 92). Check the entire surface of the bearing seating by moving the gauge over it (See Fig. 5 163.5 4 156 164 4 To determine the amount of wear in the adapter outer and inner lugs use the gauge shown in the figure 93/94. While using the gauge. The gauge should be moved for full length of crown surface to measure wear. With gauge in position as shown in figure 95. if a 5 mm thick shim can be inserted between the worn lug and the gauge on either side at any point. the Centre line of crown seat is to be marked taking the unworn surface of the crown lugs as datum.4 ADAPTER CROWN LUGS: WEAR LIMITS = 4 mm (either sides) Description Adapter Crown lugs (Narrow Jaw) Adapter Crown lugs (Wide Jaw) New (mm) Worn (mm) Wear Limit (mm) 155. 92 19. the adapter should be scrapped.Technical Pamphlet No. G-81 Fig. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 55 . the Centre line of the gauge and the marked Centre line of the crown seat should be kept in the same line. Before using the gauge. Technical Pamphlet No. G-81 Fig 93: Gauge applicable for Narrow jaw adapter Fig 94: Gauge applicable for Wide jaw adapter Fig 95: Adapter Crown lug Gauge application Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 56 . 5 45 25. it indicates the limit of wear and the adapter should be scrapped. 98. If a 4. 96/97.5 22 Wear Limit (mm) 3.5 ADAPTER CROWN SEAT: WEAR LIMITS = 3.5 3.Technical Pamphlet No. G-81 19. The gauge should be applied as shown in Fig.5 mm shim can be inserted between gauge 1 and gauge 2.5 mm Description Adapter bore seat to crown seat of Narrow jaw adapter Adapter bore seat to crown seat of Wide jaw adapter Adapter bore seat to crown seat of Modified wide jaw adapter New (mm) 26.5 3. Fig 96 : Adapter Crown seat Gauge applicable for Narrow jaw adapter Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 57 .2 Worn (mm) 22.7 48.5 To determine the amount of wear on the adapter crown seat by using the gauge shown in the Fig. Technical Pamphlet No. G-81 DIM A CASNUB-22W 22W(M) 76 RETROFITTED CASNUB-22W 53 Fig 97: Adapter Crown seat Gauge applicable for Wide jaw/Modified wide jaw adapter Fig 98: Adapter Crown seat Gauge application Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 58 . If a 4 mm thick shim can be inserted between worn surface of the lug and gauge at either sides at any point. While using the gauge.Technical Pamphlet No. the Centre line of gauge and the marked Centre line of the side of adapter should be kept in the same line. G-81 19. The gauge should be moved for full length of worn surface to measure wear. Fig 99: Adapter side lug Gauge applicable for Narrow jaw adapter Fig 100: Adapter side lug Gauge applicable for Wide jaw adapter Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 59 . Before using the gauge. vertical Centre line of each side is to be marked taking the unworn surface of the side lugs as datum.6 ADAPTER SIDE LUGS: Wear limits = 3 mm Description Adapter Side Lugs (Narrow jaw) Adapter Side Lugs (Wide jaw) New (mm) 97 Worn (mm) 103 Wear Limit (mm) 3 130 136 3 To determine the amount of wear on the adapter side lugs by using the gauge shown in the figure below: With the gauge in position as shown in figure below. the adapter should be scrapped. Two 3.102/103. With the gauge in position as shown in Fig.5 mm thick shims are required to be used simultaneously.Technical Pamphlet No. Before using the gauge. the centre line of the adapter side is to be marked on the adapter sides taking the unworn surface of their adapter as datum. The gauge centre line should be kept to fall on the marked centre line of adapter sides. the adapter should be scrapped. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 60 . 102/103.7 ADAPTER SIDES: Wear limit = 3 mm (either side) Description Adapter Sides (Narrow jaw adapter) Adapter Sides (Wide jaw adapter) New (mm) 181 Worn (mm) 175 Wear Limit (mm) 3 268 262 3 To determine the amount of wear on the adapter side by using the gauge shown in Fig. If a 3.5 mm thick shim can be inserted between the casting and the gauge at each end at any point. G-81 Fig 101: Adapter side Lug Gauge application 19. G-81 Fig 102: Adapter sides Gauge application on Narrow jaw adapter Fig 103: Adapter sides Gauge application on Wide jaw adapter Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 61 .Technical Pamphlet No. 66 0. Gap (A) between Cage Pocket & Fig. B1 + B2 (Max.5.677 8 (a) Maximum 209.2 Flange i. Cup Counter Bore D1 209.5. 3. 19.5.025 Max.) 14.076 8.5.03”) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 8. 5.127 8.4. FAG.9 62 .7.4. Seal Lip contact path has worn to a depth less than 0. 10.) 220. 27 8.) 0. Backing Ring Breakout Diameter Average I.) Inspect Cup for extended wear band. 12.) Fig. unless otherwise stated CTRB Cone Bore/ID (Max. Greasing of Seal Lips 0.663 Cup Outer Dia out of roundness (Max.7.) Fig. Dia.3 B in Fig.Technical Pamphlet No.1 Fig.4.7.423 Cup Counter Bore out of roundness 0. 6. 8 Roller 1. 7.488 8.2 8.2 Inspection of Cone Raceways by 8.e.4.2 9 8. Around 10 g to be applied. 9.2 feeler gauge probe. Gap between Inner ring & Cage 8.5.5.1 0.3 8.345 For TIMKEN.5. 4.51-0. 13.4.127 8.626 (for Koyo only) (b) Minimum 209.562 (7. 2.2 Cup Outside Diameter (Min.5 mm For TIMKEN.3 Bearing) 8.005”) 8.7.2 8. FAG & SKF For KOYO 220. 1. AT A GLANCE CHECK LIST OF MEASUREMENTS/PARAMETER CHECKS TO BE CARRIED OUT S. SKF For KOYO 2. 11.13 mm (0.58-0.2. 18.74 400 +30 gm Minimum two samples per day.No. G-81 20.2 Cone Bore out of roundness (Max.7 8. (Max.) 144.8 8.5.5.0 mm 8. BRENCO/NEI. 35B 0. 27 (Only for TIMKEN.5. if not prelubricated by supplier 17. NEI/BRENCO. BRENCO & SKF 2.5.D not to exceed 178.5. 15.1 (Max.5. Parallelity of End Faces of Spacer Wear limit for Seal Wear Ring O. Packing Polythene bags etc.5. Description Specified Relevant Dimensions/parameter in mm Clause.8 8. 8. Bench Lateral: With Hand Operated Device With Power Operated Device Amount of Grease to be Applied Verification of Quantity of Grease 16. Seal wear ring fitting into Backing Tight fit Ring Counter Bore. 1 10.7 (max.) Bearing Seats Heavy mineral oil (SAE 30/SAE 40) or Castor oil 33.) Fillet & Collar Dia.38 10.5 46. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 63 . Final Mounting Pressure 50 tons 10. Adapter sides 3.5. Adapter Machined Relief Depth 0.4 +5 34. Journal size Journal to Drg. Groove depth on Axle Journal 0.075 Max.6 47.9 8.) 19.10 & LG’ 10.6 40.5 & (apply hand pressure only) 0.5 19. depth of insertion). Adapter Crown Lugs 4. 10. Axle Fillet Radius 38. Journal Coating Anti-rust lead free compound 10.1&10. Cap Screw 1” DIA 8 UNC .4 (apply minimum 2 passes) 37. Adapter Crown Seats 3.3 (Max.4 38. Cap Screw Tightening Torque 40 kg-m 10. 10.2 43. Torque Wrench Accuracy Must be within + 4% 10.5. 10.05 Max. 27.1 28. Adapter Crown Wear 19. Mounting Pressure before abutment. Frequency of Calibration of Torque Once in a month 10. Cleaning & Lubricating Screws & Axle End Holes of Cap Backing rings with vent holes should be discarded - 8.0 19. mm) 41. Mounted Bearing Lateral play 10. Locking Plate Bent all tabs properly 10.2 29.8 (Min.03 – 0. Adapter Thrust Shoulder Wear 0.1.4 Wrenches Adapter (wear limit.5.2 27. Backing Ring with vent holes 21.7 Note :-(i) All gauges should be calibrated /checked with Master Gauge atleast once in a month. Axle Fillet Radius with Feeler Gauge 10 Max.3 44. WD-89025/S5 02 26.Technical Pamphlet No. 10 to 16 tons 10. 30.1 No wear No wear 8.5.) 19.2. G-81 20. Upset End of Axles 0.4 45.10 8. Machined Surface 'C' of End Cap in Fig.6 36.0 19.4 (a.4 39. 24. Journal Diameter of Axle 144.10 To be done 8. Adapter Side Lugs 3.10 Axle 25.5.3 31.539 10.5. Wear on threads of Cap Screws Wear on threads of Axle End Holes 22. No. Axle end Tapped hole Thread Size 1” – 8 UNC – 2B 5. 23.4 (Hold for 5 seconds for proper seating) 35. to IS: 9862 (b.2A X 2-1/4” 8.4 42.2.2 (Annex.1A) Bearing Mounting 32.0 19.564 to 144. Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies Technical Pamphlet No. G-81 ANNEXURE-IA (Refer clause-2) 64 . G-81 ANNEXURE.Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies Technical Pamphlet No.I B (Refer clause-2) 65 . Seal case clearance outline and limiting dimensions CTRB Class ’E’ Seal (6” X11”) M/s.II (Ref. 1.8 to 1.157.5 155. MP 701131100 G (mm) Technical Pamphlet No.4 0.3 0.2 (nom.4 + 0.82 ( with sealant) Max.4 1.3 0.) N (mm) 189.) P (mm) 156.3) 209. 0.83 (with sealant) 41.63 (max.8 1.9 (with sealant) H (mm) 0.4 1.3 209.10. clause .4 (min) E (mm) 0.15 Not mentioned Dust lip dia. (mm) Annexure .3 Fig.7 (min.31 to 157.8 - Max.14 .638 206.9 0.03 41.24 to 156.18 Min.2 205.157 to 12.2 0.2 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 66 .) Min.956 (with sealant) 209.8 to 1.7 156.7 (min. G-81 42 (max.63 J (mm) 205. Timken Seal part No.2 205.) C 450 +1 450 45 0 0.) A (mm) 13.9 0.92 to 190.9 1.4 (max) 10.4 0. 209.58 1. SKF Seal Drg.68 182. 0.4 0. .1 (min. 0.1 (min.41 Not mentioned Fluid Lip dia.9 209.04 190. (mm) 155.7 (min.8 (min) F (mm) D (mm) Max Min .) 157.) B (mm) 13.4 to 156.) 209. No. K -86861 13 13.4 value as per Specification M-959 AAR MSRP-H M/s.751 10.8 41.) K (mm) - 157.7 (max. G-81 ANNEXURE.Technical Pamphlet No.1 a) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 67 .5.III A (Refer clause . Technical Pamphlet No.III B (Refer clause . G-81 ANNEXURE.5.1 a) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 68 . G-81 ANNEXURE.5.Technical Pamphlet No.1 a) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 69 .IIIC (Refer clause . G-81 ANNEXURE.5.Technical Pamphlet No.IV (Refer clause .1 b) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 70 . G-81 ANNEXURE-V (Refer clause – 7.Technical Pamphlet No.2) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 71 . G-81 ANNEXURE.Technical Pamphlet No.3) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 72 .V ‘A’ (Refer clause – 7. 3) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 73 .V ‘B’ (Refer clause – 7.Technical Pamphlet No. G-81 ANNEXURE. V ‘C’ (Refer clause – 7. G-81 ANNEXURE.2) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 74 .Technical Pamphlet No. 076 (0. G-81 ANNEXURE-VI (Refer Clause – 8.6885) 144.562 (7.677 (8.003) ROLLERASSEMBLY MAX.127 (0.030) 178.6885) 144.675) 220.423 (8.562 (7.488 (5.076 (0.345 (8.076 (0.003) 0.005) 0.076 (0.6875) OUT OF ROUND mm (inch) 0. mm (inch) 209.005) 0. 60 APART Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies Technical Pamphlet No.127 (0.488 (5.D.677 (8.677 (8.003) 0.6885) 144.005) 0.626 (8. BORE mm (inch) 209. BORE mm (inch) 144.255) 209.663 (8.255) 209.030) 178.245) OUTER RING/CUP Diameters are averages 220.345 (8.030) ALL DIAMETERS ARE THE AVERAGE OF 3 MEASURRMENTS.FAG BRENCO TIMKEN 23 32 5A 1A NAME OF THE FIRM SKF 14 AAR Approval No. (as on April 2011) KOYO OUT OF ROUND mm (inch) 0.6885) 144.245) 209.345 (8.003) 0. -----) AROUN D SPECE R 170 (6) 170 (6) 225 (8) 225 (8) 225 (8) 400 (14) 400 (14) 455 (16) 455 (16) 455 (16) TOTAL QUANTITY + 30 g AMOUNT OF GREASE g (oz.423 (8.076 (0.255) 209.005) 0 BACKING RING MAXIMUM C.127 (0.423 (8.675) 220.488 (5.030) 178. BORE mm (inch) 178.423 (8.030) 178.345 (8.255) 209.677 (8.562 (7.488 (5.562 (7.245) 209.488 (5.127 (0.005) 0.5.675) 220.675) 220. BORE mm (inch) MINIIMUM C.003) 0.423 (8.127 (0.253) MAXIMUM C.245) 209.) EACH ROLLER ASSEMBLY 115 (4) 115 (4) 115 (4) 115 (4) 115 (4) 75 .245) 209.562 (7.6885) MINIMUM O. (A) IF THE ROLLER POCKET OF THE CAGE IS WORN TO THE EXTENT THAT A 1. (B) MESURE THIS CLEARANCE USING TWO SETS OF FELLER GAUGES.023” . Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 76 .08”).A SPACER MUST BE Power Driven Equipment mm(in. VENT FITTING: .06”) FEELER GAUGE CAN BE INSERTED BETWEEN THE ROLLER AND THECAGE BRIDGE. (L) SEAL:-SCRAP ALL USED SEALS AND REPLACE WITH NEW SEALS.74 (0.020” .66 (0. BREAKAGE.THE SEAL WEAR RING MUST HAVE A TIGHT FIT IN THE BACKING RING COUNTERBORE.13mm (0. WEAR OR DISTORTION. BACKING RING – FIT ON THE SEAL WEAR RING: . FACE) WHEN CHECKING CLEARANCES.0.IF THE OUT SIDE SURFACE OF THE SEAL WEAR RING IS CRACKED OR SCRATCHED OR IF THE LIP CONTACT HAS WORN TO A DEPTH OF 0.026”) Hand Operated Equipment mm(in. IF THE OUTER RING IS DISTORTED IN THEAREAOF THE COUNTER BORE A CLOSE VISUAL INSPECTION OF THE INSIDE AND OUTSIDE SURFACES IS REQUIRED.) SELECTED TO PROVIDE BENCH LATERAL AS SPECIFIED BELOW.e 0. BACKING RING – SIZE AND RADIUS (FITTED) :CHECK BRAKE OUT DIAMETER. TO BE MESURED IN ADAPTER PAD WEARS AREAS.0 mm (0. CHECK BORE RADIUS FOR EXCESSIVE CORROSION. SCRAP BACKING RING WHICH ARE BENT OR DISTORED.D.010”) ON DIA.005”) i. 0. OUTER RING THAT HAS HAIR LINE CRACKS MUST BE SCRAPPED. IF TOTAL OF THE TWOSETS OF FEELER GAUGES IS 2. (C) OUTER RING (CUP):-MINIMUM O.029”) IF THE BEARING BENCH LATERAL IS NOT WITHIN THE ABOVE LIMITS THE CONE SPACER SHOULD BE GROUND OR A NEW CONE SPACER SELECTED TO PROVIDE THE SPECIFIEDBEARING BENCH LATERAL.CAGE INSPECTION/CAGE WEAR :PLACE ROLLER ASSEMBLY ON BACK FACE (LARGE DIA.09”) OR MORE. FOR KOYO BEARING THE ACCEPTABLE DIMENSION IS 2.THE COUNTER BORE OF THE BACKING RING MUST HAVE A TIGHT FIT ON THE SEAL WEAR RING. G-81 SEAL WEAR RING LIMIT:. LIGHT PITTING AND RUSTING IS ACCEPTABLE. SEAL WEAR RING – FIT IN BACKING RING: .58 -0. (E) (F) (G) (H) (I) (J) Technical Pamphlet No.51. INSERT THE FEELER GAUGESBETWEEN THE SMALL RIB AND CAGE FLANGE AT TWO LOCATIONS DIAMETRICALLYOPPOSITE. (D) SPACER WIDTH-BENCH LATERAL: ..0.26 mm (0. (K) END CAP: -INSPECT FOR CRACKS.VENT FITTING SHOULD BE PLUGGED DURING SERVICING.) 0. THE SEAL WEAR RING SHOULD BE SCRAPPED.3mm (0.0. NEW BACKING RINGS ARE NOW WITHOUT VENT FITTING. THE ROLLER ASSEMBLY SHOULD NOT BE RETURNED TO SERVICE. THE ROLLER ASSEMBLY SHOULD NOT BE RETURNED TO SERVICE.5 mm (0. No.621 (1.488 (5.: AAA M-934 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 77 .525 (0.678) 157.) (in new condition) 144.Technical Pamphlet No. WD-89025-S-02) Value in mm (in. G-81 ANNEXURE.15 (6. Standard cross section of seal wear ring Bearing Class Nominal Journal Size Dimension Tolerance A B C D Maximum Nominal Nominal Minimum Class ’E’ (6”X11”) 6”X11” (Axle to Drg.6885) 42.187) 9.375) Ref.VI A Fig. G-81 Annexure-VII (Refer clause 8.11) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 78 .Technical Pamphlet No.5. 2) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 79 .7.VIII (Refer clause 8.Technical Pamphlet No. G-81 ANNEXURE. 2) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 80 .7.Technical Pamphlet No.IX (Refer clause 8. G-81 ANNEXURE. G-81 ANNEXURE.2) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 81 .X (Refer clause 8.Technical Pamphlet No.7. G-81 ANNEXURE.Technical Pamphlet No.XI (Refer clause 9) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 82 . G-81 ANNEXURE.Technical Pamphlet No.XII (Refer clause 9) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 83 . XIII (Refer Clause – 12 ???) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 84 . G-81 ANNEXURE.Technical Pamphlet No. Technical Pamphlet No. G-81 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 85 . Technical Pamphlet No. G-81 ANNEXURE.XIV (Refer Clause – 13 ????) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 86 . Technical Pamphlet No. G-81 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 87 . G-81 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 88 .Technical Pamphlet No. Technical Pamphlet No.XV (Refer clause 14) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 89 . G-81 ANNEXURE. G-81 ANNEXURE.Technical Pamphlet No.XVI (Refer clause 15) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 90 . G-81 ANNEXURE.Technical Pamphlet No.XVII (Refer clause 16) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 91 . G-81 ANNEXURE – XVIII (Refer clause 16) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 92 .Technical Pamphlet No. G-81 ANNEXURE. Description of Final Use of Gauge Gauge 1 Adapter Crown Lugs Gauge for CASNUB-22 NLB. 2 Adapter Crown Lugs Gauge for CASNUB-22 W RETROFITTED Bogie.XIX LIST OF GAUGES FOR CTRB AND ADAPTER Sr. HS Bogie.Technical Pamphlet No. Photo or Sketch of Gauges No. 3 Adapter Crown seat Gauge for Narrow jaw adapter 4 Adapter Crown seat Gauge for 22W Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 93 . Technical Pamphlet No. G-81 5 Adapter side lug Gauge for Narrow jaw adapter 6 Adapter side lug Gauge applicable for Wide jaw adapter 7 Adapter Gauge Narrow adapter 8 Adapter sides Gauge on Wide jaw adapter sides on jaw Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 94 Technical Pamphlet No. G-81 Annexure- XX 1. Dimension for Narrow Jaw Adapter (WD-89067-S/9) S Sample size No. 1 (a) Visual Inspection-10 % of lot, randomly selected, for casting quality ( like cracks, inclusions shrinks, porosity, application of rust preventive coating etc.) and marking. (b) Colour matching of the adapter with the CTRB’s outer cup: 10% of lot shall be checked-The adapter should be placed on the coloured CTRB outer ring & hand pressure applied on the top of adapter. Then the adapter is removed from outer cup and the adapter inner bore touching area with the CTRB outer cup to be inspected. At least 80% of the area must be coloured matched. 2 Gauging: Lot size Sample size 281-500 50 501-1200 80 1201-3200 125 3201-10000 200 3 Hardness- All hardness values to checked on1 % of lot received for inspection. S N o. Parameters Gauged/Checke d Acceptance Std. (mm unless specified otherwise) 1 Centrality Must be equal within 1.6 mm after bore is machined 2 Equal Thickness Within 0.5 mm after bore is machined 3 Bearing Thrust Shoulder Thickness 4 Bore Diameter 5 Concentricity & Taper (Use gauge on clear and unpainted surfaces) 6 Bearing Thrust Shoulder Depth 7 Bearing Thrust Shoulder Spacing and Relief Gauge No./gauge Suffix & Name(As per AAR M-924) Actual size Observation Machined Surfaces AM-45109-4 (Centrality gauge) AM-45117-4 (Equal thickness gauge) AM-45096-4 13.5+0.4/ - 2.0 (Bearing thrust shoulder thickness gauge) +0.015/ - 0.112 AM-45092-4 (Bore 110.5 R diameter-Chordal Gauge) The max reading AM-45094 - 4 & on any of the four (Concentricity indicators must taper gauge) not exceed 0.038 mm (Top center only). AM-45095 - 4 10.11+0.0/ - 0.914 (Bearing thrust shoulder depth gauge) +1.6 / - 0.0 AM-45097 - 4 166.7 (Bearing thrust shoulder spacing & relief gauge) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 95 Technical Pamphlet No. G-81 8 Bearing Thrust Shoulder Chamfer Angle 35˚±2˚ 9 Bearing Thrust Shoulder Chamfer Location 4.76 + 0.796/ - 0 10 Heat indicator hole 17.859 +0.25/-0.0 diameter and & 81.8 +1.2/-0.0 depth (When specified by the customer) 11 Snap Ring Groove 19.13 + 0.25/ - 0 12 Machined Surface 6.3 µm (N9) Finish 13 Overall Width 225.56+0.5/ -2.0 14 Body Width 181+2/ - 0 15 Outer Thrust Lug Spacing 97 +4 / - 0 16 Top Thrust Spacing Lug 155.5+ 2 / - 0 17 Outer Thrust Lug Height 21.0 +1.6/-0.7 18 Combined Crown Radius 1524R+0/ -508 R 19 Pedestal Fit 20 Marking AM-45104 (Bearing thrust shoulder chamfer angle gauge) AM-45105 - 4 (Bearing thrust shoulder chamfer location gauge) AM-45093 – 4 (Heat indicator hole diameter and depth gauge) AM-45101 (Snap ring gauge) groove Comparator or surface roughness measuring instruments UNMACHINED SURFACES AM-45084 - 4 (Overallwidthgauge) AM-45091 - 4 (Bodywidthgauge) AM-45085 - 4 (Outerthrustlugspaci ng gauge) AM-45086-4 (OuterThrustLugHei ght Gauge) AM-45110 – 4 (Combined crownradius gauge) AM – 45102 – 4 (Pedestal fit gauge) As per Drg. WD-89067 – S/9 Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 96 4 110. (mm unless specified otherwise) Gauge No. Dimension for Wide Jaw Adapter (SK-78527) S No. 1 2 3 S N o.All hardness values to checked on1 % of lot received for inspection.4 after bore is (Equal thickness machined Gauge) AM-45096 .6 mm after (Centrality gauge) bore is machined 1 Centrality 2 Equal Thickness 3 Bearing Shoulder Thickness 4 Bore Diameter 5 Concentricity & Taper (Use gauge on clear and unpainted surfaces) 6 Bearing Thrust Shoulder Depth Thrust Within 0.1. application of rust preventive coating etc.6 (Bearing thrust Shoulder thickness Gauge) +0. for casting quality ( like cracks.4 on any of the four (Concentricity & indicators must not taper gauge) exceed 0.) and marking.Technical Pamphlet No.4 (Bearing thrust shoulder depth gauge) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 97 .015/ . Gauging: Lot size Sample size 281-500 50 501-1200 80 1201-3200 125 3201-10000 200 Hardness./gauge Suffix & Name(As per AAR M-924) Observation Machined Surfaces Must be equal AM-45109 – 4 within 1.1+0. inclusions shrinks. porosity. Sample size Actual size (a) Visual Inspection-10 % of lot.4 mm AM-45117.5+0. 10.5 R (Bore diameterchordal Gauge) The max reading AM-45094 .0/ .905 AM-45095 . (b) Colour matching of the adapter with the CTRB’s outer cup: 10% of lot shall be checked-The adapter should be placed on the coloured CTRB outer ring & hand pressure applied on the top of adapter. Then the adapter is removed from outer cup and the adapter inner bore touching area with the CTRB outer cup to be inspected. At least 80% of the area must be coloured matched. Parameters Gauged/Checked Acceptance Std.0.112 AM-45092 .009/-0.4 13. G-81 2.038 mm (Top center only). randomly selected. 175 +3.175 / .425 15 Outer Thrust Lug Height 19 +1.75 / . 78527 AM-45084 .0 10 Machined Surface Finish 6. 1.0.0.0.: For details please see Adapter Inspection Plan (Check sheet) QM-C7. 8 Bearing Thrust Shoulder Chamfer Angle 35˚±2˚ 9 Bearing Thrust Shoulder Chamfer Location 4.5 mm – 5.796/ .4 (Bearing thrust shoulder chamfer location gauge) Comparator or surface roughness measuring instruments UNMACHINED SURFACES 11 Overall Width 306 12 Body Width 268+0.4 (OuterThrust Lug Spacing Gauge) AM-45086 – 4 (Outer thrust lug height gauge) AM – 45110 – 4 (Combined crown radius gauge) AM – 45102 – 4 (Pedestal fit gauge) SK- Location Hardness Crown 350.76 – 3.450 BHN.888 13 Outer Thrust Lug Spacing 130.1/CASTING/0001 of QA/Mech.Technical Pamphlet No. 0.2 16 Combined Crown Radius 1524R+ 0/ .0 14 Top Thrust Spacing 156+ 2. G-81 7 Bearing Thrust Shoulder Spacing and Relief 162 max.4 (OverallWidthGaug e) AM-45091 – 4 (BodyWidthGauge) AM-45085 .8 mm in depth Observed value (Ref.76+ 0.0 mm in depth Thrust Shoulders 350.3 µm (N9) AM-45097 .5/.450 BHN. Dte/RDSO) Instructions for Inspection & Maintenance of CTRB Fitted On Cast Steel Bogies 98 .508 R 17 Pedestal Fit 18 Marking 19 Surface Hardness: Lug As per Drg.4 (Bearing thrust shoulder spacing & relief gauge) AM-45104 (Bearing thrust shoulder chamfer angle gauge) AM-45105 .287/ -2.