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MAINTENANCE INSTRUCTION FOR CTRB CLASS ‘F’ AND CLASS ‘K’ BEARING FOR HHP LOCOMOTIVES

MP.MI. – 35 (Rev. 00), JAN-17 Page 1 of 35

INTRODUCTION Initially WDG4 and WDP4 locomotives were fitted with CTRB class F bearing of M/s Timken and M/s Brenco make. Subsequently, the locomotives are also fitted with of M/s SKF and M/s FAG make bearings. Maintenance Instruction No M.I. 1553 for grease lubricated cartridge type journal bearing is provided by M/s EMD for maintenance and overhauling of these CTRB class F bearing for HHP locomotives. However, some areas like grease oozing out, unusual sound and inspection of worn bearing adapter were not covered in this maintenance instruction. On the basis of issues raised by Zonal Railway, instruction bulletins were issued by this office from time to time and circulated to Zonal Railways on problem of grease oozing, unusual sound in bearing and inspection of worn bearing adapter. However, a need has arisen to make a comprehensive maintenance instruction covering both day to day maintenance and overhauling requirements of bearing adapter with journal bearing assembly. This maintenance instruction shall be read along with the reference documents as under: 1. EMD Maintenance Instruction no. M.I. 1553 for grease lubricated cartridge type journal bearing. 2. Instruction Bulletin Nos. MP.IB.VL- 08.30.09 (Rev 00) dated 28.04.2009 for maintenance and

inspection of CTRB Class ‘F’ axle journal bearings. 3. Instruction Bulletin Nos. MP.IB.VL- 02.08.12 (Rev.00) dated 14.01.2013 for Instructions on grease

oozing out in CTRB Class F Bearings. 4. Instruction Bulletin Nos. MP.IB.VL- 02.06.14 (Rev 00) dated 18.12.2014 for inspection of Bearing

Adapter Assembly of CTRB Class ‘F’ bearings. 5. OEM’s overhauling manual for condemning dimensions of CTRB’s components.

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CONTENTS

S. No. DESCRIPTION PAGE No.

1. TERMINOLOGY 3

2. GENERAL CONSTRUCTION 4

3. PERIODICITY OF MAINTENANCE 5

4. ROUTINE INSPECTION & MAINTENANCE 5

5. OVERHAULING OF CTRBs 10

6. PACKING & STORAGE OF BEARINGS 23

7. CHECKING OF AXLE JOURNALS 24

8. MOUNTING OF CTRBs ON AXLE 26

9. INTER-CHANGEABILITY OF BEARING COMPONENTS 30

10. BEARING MARKING ON OVERHAULED BEARING 30

11. TYPICAL LAYOUT OF OVERHAULING SHOPS 31

12. HANDLING OF MOUNTED WHEELSETS 31

13. COMMON BEARING DEFECTS 32

14. INSPECTION OF BEARING ADAPTER 32

ANNEXURE – A CRITICAL INFRASTRUCTURE / TOOLING REQUIRED FOR CTRB’s MAINTENANCE

34

ANNEXURE – B IMPORTANT PARAMETERS TO BE CHECKED DURING MAINTENANCE OF CTRBs

35



1. TERMINOLOGY

Terminology Description

Journal Bearing

Backing ring Collar between bearing and journal fillet, Axle collar, Dust guard ring, Enclosure collar

Cage Retainer; Separator

Cap screws End cap fasteners

End cap Cap at end of journal, Axle end cap, Locking cup, End cover

Inner ring Cone or inner race

Locking plate Cap screw locking device

No Field Lubricating (NFL) Bearings which are not designed to be lubricated in the field and do not have a lubricant fitting, or pipe plug

Outer ring Cup or outer ring

Raceways Surfaces of outer and inner ring on which rollers operate

Roller assembly Rollers with inner ring and cage, inseparable

Rollers Tapered rollers

Seal Seal proper, including inner case, if used

Seal wear ring Ring on which seal rides or makes contact

Spacer Spacer, spacer ring; Cone spacer

Bearing Adapter

Bearing Adapter A casting that fits between a CTRBs and the bogie frame to transfer the load from the bogie frame to the journal bearing.



2. GENERAL CONSTRUCTION The journal bearings are self-contained, pre-assembled, pre-adjusted, pre-lubricated and completely sealed unit. The bearings are applied to the axle and removed from the axle without exposing the bearing elements, seals or lubricant to contamination or damage. The bearing assembly is pressed on the axle journal as a completely sealed unit. It is retained on the axle journal by one end cap which is secured to the axle by three cap screws and locking plate. The Cartridge Tapered Roller Bearing (CTRB) has two inner races along with rollers and cage (cone assemblies), separated by a spacer, a single case-hardened outer race (Cup), a grease seal and a seal-wear ring at each end, a backing ring at the rear, axle end cap, 3 cap-screws, and locking plate as shown in Fig. 1 & 2. The cup also acts as the bearing housing and is fitted in the bogie frame with a suitable bearing adapter.

Fig. 1: Section view of Cartridge Tapered Roller Bearing

Fig. 2: Cartridge Tapered Roller Bearing (Exploded view)



3. PERIODICITY OF MAINTENANCE CTRB class F & K are complete sealed bearings. Therefore, No Field Lubrication’ (NFL) is required. These bearings require no maintenance between overhauling. However, following periodic attention to be given during maintenance of CTRB class F & K bearings:

Items to be checked Trip / Out of course /Monthly

90 / 180 days

Yearly (During UST)

Six yearly/ Bearing removed

Running Temperature (Permitted up to 560 C above ambient) Grease Oozing Out (Not more than 10% of the initial filled grease quantity)

Abnormal Sound Visual Inspection (Loose, missing, cracked, damaged) Axle Cap Screws Torque (420 ft. lbs) Overhauling / Remanufacturing Bearing Adapter for wear

4. ROUTINE INSPECTION & MAINTENANCE Whenever loco comes to shed for routine inspection, its Journal bearings should be given a visual inspection for overheating, excessive lubricant leakage, broken, loose or missing parts such as loose cap screws, loose or defective seals, cracked or broken end caps or adapters. The following are the recommended practices for long life and trouble-free operation of Cartridge tapered Roller bearings:

4.1 Bearing Running Temperature: Running temperature up to 560 C (1330 F) above ambient is expected under normal operating conditions. For further details, EMD’s maintenance instruction no. M.I.1553 may be referred.

4.2 Grease Oozing Out: In service, a centrifugal force acts on the grease due to bearing rotation, which moves some grease towards the seals of the bearing. When the space between the cone and seal is full of grease, this action may cause leakage of grease from the seals. As per AAR Section-H, M-959, the leakage of grease around the seals shall not be more than 10% of the initial filled grease quantity.

MP.MI.

4.3

4.4

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5. OVERHAULING OF CTRBs: The overhaul includes the removal, cleaning, inspection, repair or replacement, assembly of all parts and installation. The bearing must be overhauled after Six years or whenever bearing is dismounted from the axle journal for any reason. Overhauling of CTRBs i.e. dismounting of bearing from axle journal, disassembly of bearing, cleaning, inspection and reassembly of all the bearing components shall only be carried out by workshops / sheds, which have requisite infrastructure & tools/ gauges, as elaborated in subsequent para. Major repairs like re-machining / re-manufacturing of the track raceway of cone/cup, cage changing etc. is to be done only by the bearing manufacturers.

5.1 Removal of Bearing from Axle: CTRBs removing agency must have pusher and puller tool with required capacity as shown in Fig. 11. For removal of bearing from Axle Journal following procedure shall be followed:

Fig. 11: Photograph of pusher and puller tool

(i) Clean the outside surface of bearing. Open the cap screws from the end cap and remove locking plate and end cap as shown in Fig. 12.

Fig. 12



(ii) Attach pilot sleeve to the axle end or press ram where press is used as shown in Fig. 13.

Fig. 13

(iii) Select the pulling shoe adapter insert for the size of the bearing to be removed and fasten it to the pulling shoe.

(iv) Apply pulling shoe behind the backing ring as shown in Fig. 14.

Fig. 14

(v) Hold it in position until the pressure is applied. Go on increasing the pressure to pull off the bearing up to the axle end as shown in Fig. 15. The pressure may exceed 5 tons to the fitment pressure.

Fig. 15



(vi) Removed bearings should be kept in a clean and dry place in a covered room. Under no circumstances, a bearing should be left in open to avoid ingress of moisture/water causing severe rusting of the bearing.

(vii) The bearings should be very carefully handled. While loading/unloading of bearings for transportation from one place to another or otherwise, care should be taken to ensure that the bearings are not thrown one over the other. The bearings should be carefully stacked as even a small impact is enough to cause damage to the bearing. Every bearing is precious – SO HANDLE IT CAREFULLY.

5.2 Dismantling of Bearing: The bearing assembly after taken out from the axle journal by the puller tool is now ready for dismantling on the workbench. Remove the backing ring; seal wear rings and seals from both sides with the help of dismounting fixtures as shown in Fig. 16. Remove the cone assemblies and Spacer from the double cup. CTRBs overhauling agency must have dismounting fixtures as shown in photographs as under -

Fig. 16

5.3 Cleaning of CTRBs Components: CTRB class F bearing is also fitted with polyamide cage. During cleaning of cone assembly by centrifugal cleaning machine, rollers may come out from cage pocket of polyamide cage. Hence, agitator machine is preferred for cleaning of all the bearing components. Initial cleaning of all the CTRBs components: After the dismantling of bearing components, following procedure shall be followed: i) Remove the residual grease as much as possible from all the bearing components. ii) Dip separates components of CTRBs in separate clean containers containing MTO for 20-

30 minutes at room temperature for loosening the hard grease. After that, initial cleaning of the components to be carried out in same container.

iii) White spirit, MTO or other suitable solvent shall be used for initial clearing. Washing medium should be filtered before reuse, at least once in a day.

MP.MI. – 35 (Rev. 00

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MAINTENANC

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Final cleaning of all the CTRBs components: After initial clearing of bearing components, following procedure shall be followed: i) Wash these components in hot water (750C ~ 800C) mixed with caustic soda in shacking

tank no. 1 for one hour and again in shacking tank no. 2 for one hour. ii) Wash these components in plain hot water (750C ~ 800C)

Fig. 20: Cleaning machine

iii) Dry all the components in atmosphere and apply rust preventive oil (RUSTOP-275 or equivalent) to protect from corrosion.

5.4 Inspection of Bearing Components: Check each component carefully. Measure the dimension of components based on limits specified by manufacturers. OEM’s manual may referred for each and every wear limit.

5.4.1 End Cap Inspect for cracks, breakage, distortion and excessive wear. Defect if any observed, axle end cap should be scraped.

5.4.2 Cone Inspection (Inner Rings with Roller Cage Assemblies) Inspect the cone raceways and contact area of each roller for defects i.e. staining, corrosion, pitting, heat discoloration, false-brinelling, spalling, indentation, electrical burns, crack and embedded contamination etc. (See Clause 13 for details). Refer OEM’s reconditioning manual for condemning dimensions. The inner ring with roller and cage assembly should be placed on an inspection stand. Sufficient light should be made available. Probe of feeler gauge stock or surface roughness tester is inserted between the roller and cage adjacent to both the large and small ribs. The inner ring is rotated on the inspection stand as shown in Fig. 21 and 22. Surface defects noted visually or roughness felt through the feeler gauge probe, cone assembly shall be scraped. Probes of feeler gauge must be checked and replaced as the tips wear to avoid loss of sensitivity.



Fig. 21: Inspection stand (typical)

Fig. 22: Inspection inner ring for defects

Place the inner ring with the roller and cage assembly with back face (large diameter face) down on a horizontal support. Measure the bore diameter at both ends 9 to 13 mm from each face (Refer Fig. 23 & 24). The average bore diameter shall not be more than the specified limit at three locations (See ‘d’ in Fig. 24). The out of roundness should not exceed the specified limit. Average out of roundness = (d Max - d Min)/2 < specified limit Measure the gap between the small flange diameter of the inner ring and bore of cage flange in two diametrically opposite location. If the total of the two sets of feeler gauges is within specified limit or more, the roller assembly should not be returned to service. (See dim. B1 & B2 in Fig. 24) i.e. B1 + B2 < Specified limit. Measure the gap 'A' in Fig. 24 between the roller and the cage. The assembly should be rejected in case feeler gauge to the condemning dimensions can be inserted as given below.

MP.MI. – 35 (Rev. 00

Cracks of an& roller assecan be done

Cone face wlimit, to be s

MAINTENANC

0), JAN-17

ny size on theembly shall bee by the bear

Fig. 23

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CE INSTRUCTION

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5.4.3 Double Cup (Outer Ring) Inspection Cup counter bore is for seal fitting, hence measure the cup counter bores D1 and their out of roundness at both ends using the bore gauge as shown in Fig 26, 27 & 28. Measure the outside diameter D and their out of roundness at the points where the bearing adapter has been in contact with the cup using a micrometer as shown in Fig. 26 & 29. The cup counter bore diameter, outer diameter and their out of roundness should be within the specified limit. For these specified limits, OEM’s reconditioning manual shall be referred.

Fig. 26: Double Cup (Outer Ring)

Fig. 27: Checking seal fit counter bore with dial bore gauge (recommended method)

Fig. 28: Master setting ring to set dial bore gauge

MP.MI.

5.4.4

5.4.5

– 35 (Rev. 00

Inspect rollinspalling, sm30). Defect i

Seals Seals shall Spacers Width of Spfor cracks, diameter andand their colimit, refer O

MAINTENANC

0), JAN-17

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5.4.6 Seal Wear Rings Seal wear rings must be visually inspected for nicks, cracks, or scratches on the outside surface. The seal lip contact path must be smooth and free from any defects that might damage the seal lip. Measure the seal lip contact path depth, width and bore diameter of seal wear ring, if found beyond limit, it should be scraped (See Fig. 32). The wear ring and backing ring must fit tightly together. For specified limit, refer OEMs reconditioning manual.

Fig. 32: Checking Seal wear ring

5.4.7 Backing Ring Check backing ring break out diameter d in Fig. 33, which shall not exceed the specified limit. Check backing ring for excessive corrosion. Scrap backing ring with break-out diameter exceeding specified limits. Scrap distorted, cracked or heavily pitted backing rings also. The counter bore must provide a tight fit for seal wear ring. For specified limit, refer OEMs reconditioning manual.

Fig. 33

5.4.8 Cap Screw Check cap screws wear on threads and for elongation. Reject and replace if any defect is found. Cap screws which cannot be tightened to the recommended torque must be scrapped. The new cap screws shall be procured as per size “1-1/8 7UNC” having Hexagonal head and material shall be IS: 1367 (Part-3) Class P 8.8. The cap screw threads should be properly cleaned and lubricated before fitment. Cap screws having rusted threads should be used only after proper cleaning and lubricating. Mating threads on axle end holes should also be checked, cleaned and lubricated.



With clean and lubricated threads, major portion of the applied torque is used for tension of the cap screw. Higher the amount of tension developed in the cap screw, higher is the end cap deflection and better is the clamping of the bearing on the axle i.e. better retention. A deflected end cap acts like a lock washer. SO ‘DON’T FORGET TO CLEAN & LUBRICATE CAP SCREW THREADS AND AXLE END HOLES' However, during overhaul, the cap screws shall be replaced with new.

5.4.9 Locking Plate & Cap Screw Seal Rings Locking plate should never be reused. Whenever locking plates are removed, it should be replaced with new locking plates.

5.5 Accident Involved Bearings Extra precaution should be taken during inspection of accident involved bearings in the shop for brinelling, denting, cracks etc. on rollers and raceways (Refer Clause 5.4).

5.6 Assembly of Bearing After proper inspection of all the bearing components, bearing shall be assembled. Care should be taken that these parts do not get contaminated during assembly. Make sure that all components, tools and work benches are thoroughly cleaned. Cover the parts with waxed paper, polythene sheet or similar material whenever reassembly work is discontinued or delayed due to some reasons. Never use cotton waste.

5.6.1 Bench Lateral Improved rolling contact fatigue is the 'BENEFIT' of proper 'Bench Lateral'. Check the un- mounted bench play of the bearing assembly to make sure that the spacer has the correct width. Use radial indicator mounted to a cam actuated hand operated device (Fig. 34) for checking the bench lateral. The bench lateral must be within the limit as specified below:

Bench Lateral if Measured by

With Hand Operated Device With Power Operated Device

0.51 - 0.66 mm (0.020 to 0.026 in.)

0.58 - 0.74 mm (0.023 to 0.029 in.)

Fig. 34: Fixture for checking Bench lateral (recommended method)



5.6.2 Lubrication Grease to be used should be clean and free from all kind of contamination. The grease container should always remain closed. The grease recommended for use on CTRB class F bearing shall be AAR approved in accordance with M-942 of AAR MSRP Section H or RDSO approved in accordance with maintenance Instruction No MP.MI-15. Before applying the grease, clean all the equipment to be used for lubrication. Total amount of grease and their distribution in each roller assembly and spacer for Class ‘F’ bearing shall be as per AAR. However, latest OEM instructions regarding quantity of grease shall be followed. An automatic grease filling system shall be used to ensure correct amount by weight of grease filled and must be verified by measuring two samples per day. Quantity of grease excess than the specified should not be applied, as excess quantity of grease causes higher operating temperatures and also results in purging at the seal, thus giving false indication of seal wear or seal damage. The recommended automatic grease filling machine is shown in Fig. 35.

Fig. 35: Automatic Grease filling machine

5.6.3 Fitment of seal wear ring and Seals: Seal of CTRB class F bearing is critical; hence, fitment of seal wear ring in the seal shall be properly carried out for better performance of the CTRBs. Place the seal on the fixture and seal wear ring by aligning with the seal bore and then press by using the press machine and appropriate fixtures as shown in Fig. 36.



Fig. 36: Special designed fixtures for fitment of seal wear ring and seal

5.6.4 Fitment of seals and seal wear ring assembly on bearing: Place the grease filled bearing containing double cup, both the cones assemblies and spacer between them on the work bench of seal pressing machine as shown in Fig. 37. Then keep the seal assembly in position and press into the cup counter bore with the help of seal adapter ring attached with the press ram. The shoulder of the seal must be flush with or below the bearing outer ring face. Turn the bearing upside down and keep it on the work bench again and press the other seal as shown in Fig. 37.

Fig. 37: Seal and seal wear ring assembly pressing machine

5.6.5 Fitment of Backing Ring: Place the bearing fitted with seal wear ring assemblies on the work bench of backing ring pressing machine. Place and align the backing ring in their respective position and then press it by the pressing machine as shown in Fig. 38.



Fig. 38: Fitment of Backing Ring

6. PACKING & STORAGE OF BEARINGS: If the overhauled bearing is not immediately applied on axle journal, special attention must be given to proper packing and storage of CTRB. All outer surfaces should be coated with rust preventer (RUSTOP-275 or equivalent). After overhauling, a triangular card board should be inserted in the bore to avoid displacement of the spacer and to prevent lubrication loss as shown in Fig. 39.

Fig. 39

The complete bearing should then be wrapped in polythene of size of minimum 535 mm width and 890 mm length. The thickness of polythene should be 0.127 mm minimum. Complete bearing unit and components should be stored in a clean area with good protection from moisture. Periodic inspection of the storage area should be made. The storage time of CTRB from manufacture to placing in service is limited by self-life of grease. Therefore, if the CTRBs are stored beyond the specified period, bearing must be inspected for separation of oil from grease and the defect if any observed, bearing shall be overhauled before reuse. Regarding storage, OEM’s instructions shall be followed. Hence, bearing unit should be used in the order in which they were stored, i.e., first in, first out (FIFO). The packages of new bearing should be opened only before mounting. If they are opened for inspection etc. ensure that they are carefully sealed again.

MP.MI.

7.

7.1

7.2

– 35 (Rev. 00

The bearingthey are to CHECKING Before moulightened areFig. 40 is as

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AXLE ALLO

For Old AxlMeasure the1200 apart) aat each indiwithin the to

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Fig. 40: M

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ave the servhin the same OURNALS: TRBs, the jouf measuring j

ethod of mea

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Fig. 41

wo bearing sein cross hatchbe averaged e 7.1. DO NOT


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nal diameter

B & C (see Fch point A, B verage must for points B &GS.

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eat locations hed area (Figto obtain theT AVERAGE


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Fig. 41). Tak & C. The thr be within the

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OR HHP LOCOMO

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Fig. 42

Axle Journal

Dimensions (in mm)

A B C D

Class F (6 1/2” X 12”) 75 145 179 264

Class K (6 1/2” X 9”) 46 117 127 211

NOTE: There should be no abrupt changes or steps over the length of the journal for both NEW & OLD axles.

7.2.1 Journal Grooving From Inboard Seal Wear Ring Groove in axle not over 0.05 mm (0.002") deep can be repaired by polishing with abrasive cloth (80 grit or finer). No abrupt changes or sharp edges are permissible (Fig. 43). For dimension ‘A’, refer above table.

Fig. 43 Fig. 44

7.2.2 Measuring for Upset Journal Ends Measure the journal diameter in the cross hatched area of Fig. 44, for dimension ‘D’, refer above table. Take three readings at 1200 apart around the journal. Journal must never exceed 0.075 mm (0.003") above maximum diameter in this area, but may be below the minimum diameter in this area. Upset ends over 0.075 mm (0.003") may be corrected by files, provided surface roughness meets the specification.

7.2.3 Check fillet radius for proper seating of backing ring with template (See Fig. 45). If feeler gauge can be inserted more than 10 mm (3/8") around the journal periphery, the fillet must be corrected.

MP.MI.

8.

– 35 (Rev. 00

MOUNTINGThe bearingheating. A tFig. 11. Moui) To fac

Pilot sthe ceOEM’ssleeve

ii) Coat trust proil (SA

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G OF CTRBs Og unit shouldtypical hydrauunting procedcilitate mountisleeve must bentre of the ms manual fore.

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ON AXLE: be cold mo

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Fig. 45

ounted, i.e. mounting cum Bs on axle joure pilot sleeve

n such a way ve and squar

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n Fig. 47 & 48


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to the axleequipment iser:

xle journal as t the ram presce of the sea

pilot sleeve a

hub and the fn the journal w8.

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Fig. 47

Fig. 48

iii) Place the bearing unit on the pilot sleeve and slide it up against the journal as far as it will go without using force as shown in Fig. 49.

Fig. 49

iv) Now put mounting sleeve on the free end of pilot sleeve in position by moving the hydraulic pusher. Check that axle journal and pilot end are square in all planes with the face of the ram (See Fig. 50).

Fig. 50



v) Apply pressure from the press ram. The pressure will reach between 10 to 16 tons just before the backing ring along with the bearing butts against the dust guard fillet. To ensure that the backing ring along with the bearing is firmly seated against the fillet, allow the pressure to build up to the final gauge readings of 50±5 tons & hold for 5 seconds to fully seat the bearing (See Fig. 51).

Fig. 51

vi) When the final pressure has been reached, remove mounting tools and wipe the end of the axle using a clean lint free cloth (No cotton waste is to be used).

vii) Assemble the end cap and cap screws with locking plate to the end of the axle. Torque wrench should be used to tighten the axle cap screws (See Fig. 52). The torque wrenches should be calibrated at least once in a month. The recommended torque value is 420ft.lb. The torque wrenches to be set to one fix value i.e.420 ft.lb. Torque wrenches must be accurate within +4%.

Fig. 52

viii) Lock the locking plate as shown in Fig. 53. Locking plate once opened must be replaced.



Fig. 53

8.1 Mounted Lateral Mounted lateral is CRITICAL to bearing performance. Less mounted lateral will result in more rollers sharing the load. Though, the peak load on individual rollers will be less but, the friction will increase causing heat generation & may result in to bearing seizure (Fig. 54). Excessive mounted lateral will result in fewer rollers sharing the load & may cause high peak load on rollers (Fig. 55) & will reduce FATIGUE LIFE.

Hence, Mounted lateral should be optimized to within limits.

Fig. 54 Fig. 55

8.2 Check the mounted lateral play with a magnetic base dial indicator (See Fig. 56). Start by pushing the bearing laterally towards the wheel hub and zero the indicator. Then pull the bearing laterally away from the wheel hub to obtain the lateral reading. The lateral play should be between 0.03 mm to 0.38 mm (0.001" to 0.015"). If lateral play is somewhat less than 0.03 mm but greater than 0.00 and the bearing can be rotated freely by hand, the application is still satisfactory for service. However, if the clearances are observed not within limits, dismount the bearing for further inspection.

Outer Race Rollers

Inner Race

Axle Journal

Axle Journal

Outer Race

Rollers Inner Race

Roller Load Distribution for Zero Mounted Lateral Roller Load Distribution for More Mounted Lateral



Fig. 56: Checking residual lateral play after mounting

9. INTER-CHANGEABILITY OF BEARING COMPONENTS: As per AAR, components of AAR approved CTRBs i.e. backing ring, seal wear ring, spacer, end cap, locking plate and cap screws are interchangeable except cup and cone assembly. However, being a critical safety item, for better performance of CTRBs after overhauling, the interchangeability of components of one make with the others is not desirable as it may be difficult to have traceability of CTRBs components and therefore, will affect the reliability of bearing.

10. BEARING MARKING ON OVERHAULED BEARING: Bearings that have been overhauled during 6 yearly schedule or otherwise due to dismounting from journal for any reason, 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. 57 & 58 and also on the back face of backing ring. Caution must be used to avoid nicking or damage to the raceway surface. For marking use a suitable scribing tool. Electric etching or steel stamping is not permitted. The marking will include the date i.e. month and year and servicing workshop code/company's initial. Example: - If the bearing has been previously overhauled in Rayanapadu workshop in April, 2012 the marking will be 4-12- RYPS and presently overhauled in Dahod workshop in May, 2016, the marking will be 5-16-DHD.

Fig. 57



Fig. 58

11. TYPICAL LAYOUT OF OVERHAULING SHOPS: For proper maintenance, the work place dedicated for inspection & assembly should be well lit, spacious & weather controlled. The work place, tools, benches should be clean as even minute particle entering the bearing during assembly would render the most efficient sealing arrangement ineffective and cause premature failure. A typical layout of the overhauling shop is shown in Fig. 59.

Fig. 59: Typical Layout of overhauling shop

Workshop/ Sheds doing the overhauling work of CTRBs must have the requisite infrastructure, tooling/ gauging, fixtures etc as elaborated in ANNX –A.

12. HANDLING OF MOUNTED WHEEL SETS: Handling of wheel sets after mounting of CTRBs is to be done carefully. Special attention is required during handling, transportation from workshop to Shed or Shed to workshop. The cup and seals can be damaged due to:- a) Hitting of flange to bearing cup (See Fig. 60) b) Slinging more than one wheel set while lifting



c) Loading in wagon without proper wedging. d) Slinging the wheel set over the bearings. Following steps should be taken to ensure that no damage occurs to the bearing - i) Wheel sets should be handled with a lifting tackle arrangement and instructions regarding

this should strictly be followed. ii) Wheel sets with mounted bearings may be kept on single storage track overlapped as

shown in Fig. 61 to save space. With this arrangement the flanges of the wheels will not contact either the roller bearing assemblies or axle bodies of adjacent wheel sets.

Fig. 60

Fig. 61

13. COMMON BEARING DEFECTS: Some of the most common defects observed in cartridge tapered roller bearing at the time of inspection during overhauling / remanufacturing are elaborated in detail in EMD’s maintenance instruction no. M.I.1553, hence, may be referred.

14. INSPECTION OF BEARING ADAPTER: Bearing adapter assembly provides the proper distribution of load, which comes from the bogie frame and goes on to the bearing cup exterior. One unique feature of the adapter is that it allows the cup to “creep”. Due to track irregularities, the load between bearing cup and bearing adapter may appear and disappear because of system dynamics. This will allow the cup to turn in the bearing adapter a little bit called “creep”. Over the bearing’s life, it may make several complete revolutions in the adapter. This allows the fatigue wear to be spread over the entire cup instead of being isolated to one particular area.



Fig. 62: View of Bearing Adapter Assembly with Journal Bearing Assembly

Due to the above important function, bearing adapter get worn and it is very essential that adapters must be thoroughly inspected using specified gauge as shown in Fig. 63 before putting back to service as per Instruction Bulletin Nos. MP.IB.VL- 02.06.14 (Rev 00) dated 18.12.2014.

Fig. 63: Drawing of Adapter Wear Gauge

14.1 Inspection of Bearing Adapter bore (Bearing Seat Area): Check the entire surface of the bearing seating area of adapter by moving the gauge over it and verify bore diameter to original specification using the chordal gauge (AM-45092). Diameter must not be greater than 0.010 inch over the maximum specification value. Refer AAR Section-H [M-924], Appendix B, Clause 2.2.2.1 and see Fig. 64.

Fig 64: Bearing Adapter bore checking



ANNEXURE- A Critical Infrastructure / Tooling Required for CTRB’s maintenance:

S. No.

Activity Machine / Tooling / Fixture required

Reference para

Reference Figure

For mounting and dismounting of CTRB: 1. Removal of CTRBs from

axle Hydraulic pusher and puller tool, pilot sleeve and pulling shoe, mounting sleeve and torque wrench etc.

5.1 11, 13 & 14

2. Mounting of CTRBs on axle 8 46, 50 & 52

3. Mounted Lateral Magnetic base dial indicator 8.2 56 Dismantling and cleaning of bearing components: 4. Dismantling Dismantling fixture 5.2 16 5. Polishing or rust removal

from cup OD Polishing machine 5.3 19

6. Final cleaning Automatic cleaning machine 5.3 20 Inspection of Axle Journal and Bearing Components and marking on Cup: 7. Cone Inspection stand, feeler gauge

stock and dial bore gauge 5.4.2 21, 22 & 23

8. Double Cup Dial bore gauge and out side micrometer

5.4.3 27, 28 & 29

9. Seal Wear Ring Groove depth gauge 5.4.6 32 10. Backing Ring Dial bore gauge 5.4.7 33 11. Journal diameter and fillet

checking Snap gauge and axle fillet gauge 7 & 7.2.3 40, 45

12. Marking on Cup Scribing tool 10 58 Assembly of CTRBs : 13. Checking of bench lateral Fixture for checking bench lateral 5.6.1 34 14. Lubrication Automatic grease filling machine 5.6.2 35 15. Fitment of seal and seal

wear ring Pressing machine with specialy designed fixtures for fitment of seal wear ring and seal, seal in bearing and backing ring

5.6.3 36

16. Fitment of seal in bearing 5.6.4 37 17. Fitment of backing ring 5.6.5 38

Inspection of Bearing Adapter: 18. Bearing Adapter Adapter wear gauge and chordal

gauge 14, 14.1 63 & 64



ANNEXURE-B Important parameters to be checked during maintenance of CTRBs:

S. No. Activity Parameters to be checked Relevant para

Relevant Figure

1. Cone inspection Bore diameter, out of roundness, cage flange clearance, gap between roller and cage, cone face wear depth

5.4.2 24 & 25

2. Double cup inspection Cup counter bore, out side diameter, out of roundness

5.4.3 26

3. Seal wear ring inspection

Groove depth, width and bore diameter

5.4.6 --

4. Backing ring inspection Brake out diameter 5.4.7 33

5. Bench lateral Recommended value 5.6.1 --

6. Lubrication Recommended brand and quantity of grease

5.6.2 --

7. New axle journal checking

Diameter 7.1 41

8. Old axle journal checking

Diameter, journal grooving, upset journal ends and fillet radius

7.2 42, 43, 44 & 45

9. Mounting of CTRBs Mounting and final seating pressure, recommended torque and mounted lateral

8 (v, vii), 8.2

51, 52 & 56

10. Marking on cup Recommended marking details 10 57

11. Bearing adapter inspection

Shoulder and recess wear, bearing seating diameter

14, 14.1 63, 64

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