WHEEL DEFECTS CMIK003
GUIDELINES FOR INTERPRETATION OF WHEEL DEFECTS IN SOLID/ TYRED
COACHING/ EMU IN OPEN LINE AND WORKSHOPS
SHATTERED RIM
SPREAD RIM
1) SHELLED TREAD
THERMAL CRACKS
2) HEAT CRACKS
Wheels received with these defects are cleaned thoroughly and inspected carefully. Wheel
sets require machining the visual defects subjected to thorough inspection including rim UST
to ensure complete removal of defects.
__________________________
Biased wear
Wheel flange burr
Wheel flange sharp
Less radius at root
Sharp flange
Thin flange
Hollow tyre.
Other wheel defects
Flange cut mark
Loose tyre
Tyre grooved
Skidded wheel
Thin tyre
Axle pulley defect.
BIASED WEAR;
A good wheel (assembled in good bogie) on as straight track will maintain equal
clearance between flange and rails, which leads to equal wear. Inadequacies in wheel and or
bogie can lead to one wheel remaining in contact with rail leaving other wheel having more
clearance between flange and rail. Consequently the disc in constant contact wear more than
the other disc. This difference in wear between the two discs in same axle is called biased
wear.
Reasons for biased wear
1. Wheel not pressed equidistant from the axle center.
2. Dash pot guide misalignment
3. Hardness variation due to work hardening.
Wheel center line gauge & comb gauge are used vide TSO 10 / 97 to measure the biased
wear the difference in reading indicates the center line variation and the amount of disc offset
is half of this distance.
Average coach wheel disc life – 10 years.
Dashpot guide misalignment attributes to biased wear. Reasons for dashpot guide
misalignment are as follows
(a) One clearly established reason that some coaches de-rail in yard is due to poor attention
given to sick lines
(b) Bend occurs due to one side lifting of coach in sick line when repairs are carried out
especially wheel changing.
(c) Proper attention not given during attention in workshops
COMPARISON OF FORGED WHEEL DISCS AND CAST WHEEL DISC.
Forged wheel discs have ‘ s ‘ shaped contour whereas cast wheel have parabolic plate
contours and are rough machined.
Cast wheel have marking of raiser pads and sprues on the plate surface and are supplied UN-
machined and ready for use condition
ADAPTION OF WORN WHEEL PROFILE. LETTER M/CW/87/B/IV DATED 10.03. 93 CME /
MAS.
COACH disc thickness 127 to 131 mm
STD Sketch 91146
Flange thk. @ 13 mm – 29.4
Flange radius - 14.5R
Radius @ 44 - 14 R
Radius @ 65.5.5 - 100 R
Radius @ 91 - 330R
Inter mediate – 25 thk. Sketch 92082
Flange thk. @ 13 mm – 25
Flange radius - 11.5 R
Radius @ 38.5 - 14 R
Radius @ 65.5.5 - 100 R
Radius @ 91 - 330 R
Inter mediate – 22 thk. Sketch 92082
Flange thk. @ 13 mm – 22
Flange radius - 10 R
Radius @ 35.5 - 14 R
Radius @ 65.5.5 - 100 R
Radius @ 91 - 330 R
Inter mediate – 20 thk.
Flange thk. @ 13 mm – 20
Flange radius - 9R
Radius @ 35.5 - 14 R
Radius @ 65.5.5 - 100 R
Radius @ 91 - 330 R
TSO 4 / 2000
The following details are to recorded in the inspection register
Coach No / code.
Last POH attention given with shop code and date
Type of axle 16.25 T / 13 T and UT particulars.
Wheel diameter at the time of attention to bearings
Type of roller bearing and make
SL. No. of bearing
Year of manufacture of bearing. Initial date put in service and age.
Shop / depot, month year when bearing last attended.
Type of attention. In-situ of dismounting.
New felt rings are soaked in warm cylinder oil IS: 1589 type I Gr. 3
STAMPING PARTICULARS OF DISC COACH
ASSEMBLY
Workshop code, Month and year of assembly, pressing in pressure in tones.
SPECIFICATION
Coach Disc – IRS R 19/93 part II.
Forged wheel 241 BHN to 277 BHN difference 36 BHN
Cast wheel 255 BHN to 320 BHN difference is 65 BHN
AXLE BOX – IS 1030 gr. 2
AL rear cover – IS 617 – 76
CI - IS 210 – Gr. 2
IRS R 65 – 78 - Steel liners
IS 4398 - general specification for roller bearing.
Heat treatment of wheel disc: -
Heating either min of full wheel for sufficient time to bring uniform temperature at least
to 825 degree C, subsequently quenching in suitable bath followed by tempering of about 500
degree C. wheel is left to cool in air.
Axles are guaranteed for four years. Grain size should not be coarser than 5 (ASTM-5 < Grain
size)
Disc Branding – coach disc
Maker code - 3 digits
Year of manufacture - 2 digits
Individual SL No. - 5 digits
Contract No. - Short form
IR - for Rly initial
Drg No. -
‘R’ or ‘Q’ - Rim or full quenching
Insp. app - Stamp
UT - for UT check
COST
Type Cost for the year 2001 - 2002
POH cum corrosion repair of BG coach 2.55 lakhs
POH DEMU - TC 2.55 lakhs
DTC 3.80 lakhs
DPC 15.68 lakhs
AC/ POH 39.38 lakhs
AC/ POH cum RC 61.34 lakhs
WAP4 385.86 lakhs
WAG7 405.63 lakhs
WDM2C 399.63 lakhs
WDG2 400.69 lakhs
COACH BG GS 38.81 lakhs
BG SCN 41.14 lakhs
WGFAC 86.45 lakhs
WCBAC 81.49 lakhs
WGSCWAC 101.72 lakhs
DMU DTC 48.74 lakhs
DMU TC 41.7 lakhs
DMU DPC 173.86 lakhs
GEAR 62 TEETH 0.77 lakhs
AXLE FOR WAM4 & WDM2 0.45 lakhs
DISC ,, ,,, ,, 0.27 lakhs
AXLE COACH 19253
DISC ,, ,, 19388
DM BEARING 9624
SUSP TUBE 27450
SPL ROLLER BEARING 10055
HORN FACE LINER 150
[Link] COVER FOR 561
[Link] COVER FOR 565
COACH AXLE BOX HOUSING 4632
AXLE BOX FOR WAM4 6136
Loco gear ratio
Sl. No. Loco Ratio Value
1. WAG7 16:65 0.2462
2. WAG5HA 18:64 0.2813
3. WAP4 23:58 0.3966
4. WAM4-ORD 15:62 0.2419
5. WAM4-HS 21:58 0.3621
6. WAG - H. Tor 17:77 0.2208
7. WDM2, WDM2 - HS 18:65 0.2769
8. WDS6 18:74 0.2432
9. WDG2 18:74 0.2432
10. WDP2 22:61 0.3607
11. DEMU / MC 20:91 0.2198
Axle end steel high tensile cap screws
Spec. No. IS 1367 (I) AB/RB 39-2002, (II) AB/RB 32 rev.3, (III) AB/RB 25-85
Vendor list QA – 1 / 0001. – validity 01.07.04 to 31.12.04 page 36 of 231.
Part – I
1. GKW fasteners division, 97 Andal road, Howrah - 711103 GKW
2. Precision fasteners ltd., 15. MICD industrial area, Thana belaspur road, Kalwa, PFL
Tane – 400601
3. Sundaram fasteners ltd., Padi, Chennai – 600050 TVS
Part – II
1. Bolt master (India) Pvt ltd., Kashmir – Bhayander road, Post Mira distt, Thane – BML
401104
2. Pooja forge ltd. 1/43, DLF industrial estate, Faridabad – 121003 Pooja forge
3. Laksmi precision screws ltd., Hisar road, Rothak, Haryana – 124001 LPS
4. D.N. Sircar S.K. Das Pvt ltd, Hisar road, 36/2 ‘W’ Road, Howrah – 711105 SKD
General maintenance & Inspection – FAG Manual
Motor Suspension tube – AC / DSL Loco
Sl.
Checks P
No.
Check temperature of suspension tube and bearings by hand. If the
tube is very hot and touching is not possible, then measure
1. W
temperature. If found above 80º C, investigate cause of increase in
temperature thoroughly by dismounting the tube
Bearing noise to be checked by rotating the assembly. Any abnormal
2. P
sound is cause of concern
Inspect the tube thoroughly for any crack. If a crack is noticed, the
3. Every th
tube is to be replaced immediately
4. Inspect and tighten bolts Every th
Check for missing bolts, nuts, washers and grease nipples and
5. W
replace immediately if found missing
For yearly replenishment of grease, the amount should be GS – 250
6. Y
gms, NGS – 150 gms
7. End play of bearings must be checked and adjusted as per method Y
COMMON DEFECTS OBSERVED IN MOTOR SUSPENSION TUBE ASSEMBLY
SL. Defect Possible cause Remedial measure
No.
(a) Scoring of outer periphery Gear case rubbing against periphery of Renew enclosure.
of enclosure enclosure
(b) Slackening & shearing of (a) Sudden impact of load. Gear to be pressed out
fastening cap screws of (b) Entry of cadmium compound and pressed in.
enclosure to the bull gear between tube and enclosure Dismantling of tube and
Gear case preventing free rotation of re- fitting.
enclosure.
(c) Adjustment washer Fastening screw slackening and falls Dismantling of tube and
dropping off down refitting with long bolt &
self locking nut
(d) Seizure of taper roller a) Lack of lubrication Dismantling of tube and
bearing b) Cadium compound seeping into refitting. Sometimes re-
gear side bearing housing axling.
preventing free rotation of rollers.
c) Broken motor suspension tube
(e) Elongation of locating / Improper mounting of motor Tube renewal
fastening holes of
suspension bearing motor
(f) Rib crack on the tube Improper mounting of motor Tube renewal
(g) Scoring of axle body Entry of foreign body like loose bolts, Dismantling of tube and
small screws and washers etc., re- assemble of complete
suspension unit.
(h) Gear side bearing cone Gear side end cover rubbing against Renewal of bearing
(inner race) face wearinginner race because of excessive end
play say more than 2.5 mm.
(i) Suspension tube breaking Porosity, crack present in neck portion. Removal of porosity and
at neck portion crack by gouging and
welding.
(j) Increase in lateral play Gap present between abutment piece Press- in the non- gear
and non- gear disc hub. side disc to reduce the gap
if present and Increase the
adjustment washer
thickness.
(k) Suspension tube labyrinth Excessive lateral play causing grease Renewal of tube
wearing leakage and allows seepage of cadium
compound in to GS bearing.
COMMON DEFECTS OBSERVED IN MOTOR SUSPENSION TUBE ASSEMBLY
SL.
No. Defect Possible causes
Scoring of outer periphery of Gear case rubbing against periphery of enclosure due to
1.
enclosure wearing of wick pad.
a) Sudden impact of load due to sudden braking & brake
Slackening & shearing of binding etc.
2. socket head cap screws of b) Entry of cadmium compound between tube and
enclosure to the bull gear enclosure
Gear case preventing free rotation of enclosure.
3. Adjustment washer dropping off Fastening screw slackening and falls down
a) Lack of lubrication
b) Cadium compound seeping into gear side bearing
4. Seizure of taper roller bearing
housing preventing free rotation of rollers.
c) Broken motor suspension tube
Elongation of locating /
5. fastening holes of suspension Improper mounting of motor
bearing motor
6. Rib crack on the tube Improper mounting of motor
Entry of foreign body like loose bolts, small screws and
7. Scoring of axle body
washers etc.,
Gear side bearing cone (inner Gear side end cover rubbing against inner race because
8.
race) face wearing of excessive end play say more than 2.5 mm.
Suspension tube breaking at Porosity, crack present in neck portion which
9.
neck portion Develops in service condition.
Gap present between abutment piece and non- gear disc
10. Increase in lateral play
hub.
Suspension tube labyrinth Excessive lateral play causing grease leakage and allows
11.
wearing seepage of cadium compound in to GS bearing.
Components and its general defects :
Enclosure: Scoring on outer periphery due to gear case rubbing on outer periphery consequentially breaking enclosure socket
head cap screws.
End cover: Rubbing with GS taper roller bearing cone due to excessive endplay (if end play is more than 2.5 mm approx).
Scoring bottom face due to broken enclosure socket head cap screws.
Taper roller bearing: Gear side Cone inner race face wearing due to gear side end cover rubbing against cone due to excessive
endplay and other common bearing defects.
Tube: locating hole elongation, threaded hole damage, broken rib, dim ‘A’ less, Porosity, crack at neck & labyrinth portion,
labyrinth worn out, GS bearing seat worn out.
Maintenance sheds should take extra care in attention of MSU in the following areas
1. Periodical greasing to be done
2. Endplay to be checked periodically an the adjustment washer to be changed to ensure that the play is within permissible
limit
3. Entry of cadmium compound to be checked and arrested. If excessive heat and abnormal sound is noticed wheel should be
isolated and to be subjected to thorough inspection
Damages of suspension tube bearings (Some typical damages)
1. Corrosion due to moisture
Causes
Pitting and corrosion for moisture and ingress of water in to the bearing.
Remedies
Care should be taken to avoid ingress of moisture at the time of grease filling. There should not be any
entry for ware to go inside the bearing.
2. fluting
Causes
Constant passage of alternating or direct current.
Remedies
Prevent current flowing through the bearings by proper grounding or insulation .
3 False brinelling
Causes
Static over load, sever impact caused by dropping of striking at bearing rings.
Remedies
Use appropriate care in handling bearings and use right mounting tools.
..2
(1)
4 Surface damage due to attack of aggressive media (like gear compound etc.)
Causes
Ingress of gear compound due to sealing failure and unsuitable lubricant.
Remedies
Check sealings. Use lubricant recommended by the bearing manufacturers.
5 Fatigue damage in the outer ring (cup) race way of tapered roller bearing.
Causes
Due to indention from had particles like foundry sand, grinding agent, coal dust etc.
Remedies
Cleanliness and caution during mounting, improved sealing.
6 Excessive preload.
Causes
Excessive loading of the bearing due negative endplay. If the bearing is left with no or negative end play at
the time of mounting, deformation of the roller and race ways result in premature failure.
Remedies
The bearings are to be mounted with correct endplays as recommended in the manual so that preloading
does not occur during running.
..3
(2)
7 Excessive endplay.
Causes
Incorrect settings with excessive axial play results in bearing running without desired loading and causes
undesirable heavy contact between cage pockets. Consequently, the cage pockets get deformed in a short
time leading to pre- mature bearing failure.
Remedies
Assemble the bearings with right bench endplay. Check endplay at the time of POH.
(3)
Coach, DEMU MC Direct Mount bearing
A. Dismounted Clearance
New bearing 0.145 – 0.190 mm
Maximum permissible clearance for bearings in service
SKF 0.33 mm
FAG/ Norma 0.27mm
NBC 0.295mm
B. Mounted Clearance ( ref. Letter No. MC/RB/Genl dated 10.7.98)
SKF 0.15 – 0.296 mm
FAG/ Norma 0.08 – 0.295 mm
NBC 0.080 – 0.295 mm
Torque M16 bolts – 11 to 12 KGM
Torque M20 bolts – 15 to 16 KGM
Lubrication
Coach SKF – 2.00KG
Other makes – 1.75 KG
DEMU MC - 2.25 KG
Felt ring soaking in cylinder oil IS: 1589 – 60 type I Gr 3 heated to 40 to 50 degree centigrade for 30 minutes.
Induction heating of bearing in such a way that it takes 5 to 7 minutes to attain 120 degree centigrade (max)
Warranty period of DM bearing is 36 months from date of delivery of 4 lakhs KM from the date of commissioning
whichever is later.
Coach axle box must change items.
When opened
A. Roller bearing grease.
B. Locking plates [Link]. T-0-2-637
C. Rubber sealing ring of axle box front & rear cover. Drg. No. T-0-2-625 .
Coach 16.25tons Axle, Disc, Axle box roller bearing & its accessories
Sl. Description Drg. No. Matl Spec. PL No. Class
No
.
1 Collar for DM brg. T-0-2-628 IS:1875, Cl 2 30020724 X
2 Rear cover for axle box T-0-2-603 Al. IS:617-75 4600-m 30020451 X
3 Felt ring for RB T-0-2-005 ICF/M/D/spec f.001 30020116 Z
Bolt & nut for coach axle X
4 T-0-2-608 IS:2062 30020452
box, M20x295,
5 DM ring T-0-2-629 IS: 1875-71 Cl.2 30020736 X
6 Direct mount bearing 22326 C / C3 RDS0- C8527 85131167 Z
7 Axle box housing T-0-2-602 IS:1030 30020414 X
Front cover for coach axle X
8 T-0-2-633 Al. IS:617-75 4600-m 30020130
box
Sealing ring for Coach axle M
9 T-0-2-625 IS:2073, Hor rubber 30020670
box
10 Retaining ring DM brg T-0-2-621 IS:1875 cl-2 30027044 X
Locking plate Coach 1.6 T-0-2-637 alt M
11 IS:1079 30027068
thk. ‘C’
T-0-2-619 alt Z
12 Hex. Head screw Coach RDSO - C9307 30027317
L
ICF/SK/9-0- X
13 Axle pulley assy IS:210-78 Gr 25 45990580
491