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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW 226 011
No. SV.IB

Dated: 22.07.2010
INSTRUCTION BULLETIN No. MP.IB.VL.04.33.10 (Rev.01)

1.

TITLE
Instructions for replacement cage to a modified design on CRU bearing of M/s National
Engineering Industries Ltd. fitted in Axle Box Assembly for WDG3A and WDM3D locomotives.

2.

BACKGROUND
Subsequent to this office Instruction Bulletin no. MP.IB.VL.02.26.08 (Rev.00) for mounting,
dismounting and maintenance of Axle Box Assembly with CRU Bearings from M/s National
Engineering Industries Ltd. for WDG3A and WDM3D locomotives was issued on 29.09.2008, some
failures of these CRUs have been reported by Zonal Railways. A failure investigation report no.
No.MP. INV. 49, Revision - 00, Feb.10 has been prepared by this office. Causes and reasons of
failures and their corrective actions have been detailed in this investigation report.

3.

OBJECT
The object of this Instruction Bulletin is to apprise the present status with regard to action taken to
arrest failure of inner races and address the problem of cage breakage in CRU bearings and
ensure further action.

4.

DETAILS OF STUDY / EXPERIMENTATION DONE


Failure of inner races and cages of CRU bearings were studied jointly with DLW and M/s NEI.

5.

APPLICATION TO CLASS OF LOCOMOTIVES


WDG3A and WDM3D locomotives

6.

INSTRUCTION CONTENTS
This IB should be read along with the Maintenance Instructions (MI) of the CRU bearing
manufacture, Instruction Bulletin no. MP.IB.VL.02.26.08 (Rev.00) for mounting, dismounting and
maintenance of Axle Box Assembly with CRU Bearings and failure investigation report no. No.MP.
INV. 49, Revision - 00, Feb.10.
i. Failure of CRUs due to Inner races crack:
In the investigation it has been observed that the failure of CRU bearing due to inner races
crack on account of following reasons:
a) Inadequate quantity of grease: Initially CRU bearings were filled with 440 gms of
grease. Looking in to grease purging and starvation during running in service, it has
been felt that the grease quantity is inadequate. This inadequate quantity of grease has
resulted in to breakage/ cracking of inner races, bearing seizure.
b) Loosening of end cap bolts: Loosening of end cap bolts had also been experienced.
Investigation into this revealed presence of metal chips in axle tapped holes and
inadequate torquing of bolts. Improper bending of locking plate was also found to be
contributory factor in loosening of end cap bolts.
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Corrective action:
a) Quantity of grease in CRUs has been increased from 440 gms to 740 gms by M/s NEI
and subsequently approved by this office. The CRU bearings fitted on WDG3A &
WDM3D should be re-greased as per the frequency and schedule mentioned in
instruction bulletin no. MP.IB.VL- 02.26.08.
b) DLW and Zonal Railways assembling/ maintaining CRU bearings should follow special
instructions for assembly of CRUs on locomotives as per instruction bulletin no.
MP.IB.VL- 02.26.08 in addition to OEMs (NEIs) maintenance instructions.
c) For re-greasing of CRUs and re-torquing of axle end cap bolts a one time special drive
was undertaken by M/s NEI in association with different sheds, and all CRU fitted locos
have been covered.
ii.

Cage breakage/ Worn out:


The rollers in side the bearing are held together with the help of a cage. In this type of
failures, the cage gets broken/ worn-out and rollers gets dislodged from their location. This
type of failure leads to bearing seizure. Excessive cage wear also results in to increased Fe
& Cu contents in the grease, which may cause damage to the rollers and grease starvation.
In the investigation it has been observed that the failure of CRU bearing due to cage
breakage / worn out on account of the following reasons:
a) The cases of cage breakage are being experienced on CRUs, which were initially filled
with 440 gms of grease and topped up to 740 gms grease. Primary cause for these
failures indicated by M/s NEI was inadequate design of cage.
b) Also, excessive Fe & Cu contents have been reported by Zonal Railways in grease,
which indicates inadequacy of cage material.
Corrective action:
a) Material of the cage has been revised with HBsC1 for better wear resistance and design
of the cage has also been revised for its strengthening by M/s NEI and subsequently
approved by this office. This has been implemented since April 2009 with bearing S. No.
B-601.
b) M/s NEI have agreed to replace cages of all CRU bearings having unmodified cages
with the CRUs having modified cages (i. e. HBsC1 material with better strengthened
design), in stead of waiting for failure. It is therefore advised that sheds should get this
replacement due during M-12 schedule of locomotives. For this M/s NEI should be
intimated tentative dates so that the work can be executed with least detention of
locomotives in shed.
c) In case, the CRU with unmodified cage is replaced with by CRU with modified cage, with
greasing hole, a hole needs to be drilled in axle box housing also, so that greasing of the
bearing can be done through the greasing hole of axle box housing. The hole in the axle
box housing shall be as per NEI drawing no. X-198, and M/s NEI should be involved in
making the hole in the axle box. It must be ensured that only the CRU with greasing
hole should be fitted in axle box housing with greasing hole i.e. if the axle box
housing is having a greasing hole, CRU also must have greasing hole, or else there is a
possibility of confusion during maintenance, as the lubrication done through the greasing
hole of axle box housing will not lubricate the CRU bearing and may cause lack of
lubrication and failure of the bearing.
d) If there is no greasing hole in the axle box housing, greasing shall be done in the CRU
bearing front side by opening the axle box front cover, with the help of grease gun.
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7.

MATERIAL REQUIRED AND SOURCE OF SUPPLY


M/s National Engineering Industries Ltd., Khatipura Road, Jaipur 302 006 (Manufacturers Code:
NBC) will supply and fit CRU bearings with modified cages in place of CRU bearings with
unmodified cages.

8.

ADDITIONAL INFORMATION
NIL

9.

AGENCY AND SCHEDULE FOR IMPLEMENTATION


i. Diesel Locomotive Sheds, during M-12 schedule.
ii. Loco Maintenance Workshops, during POH.

10.

DISTRIBUTION
As per mailing list.

11.

REFERENCE
Nil
(N. K. BARNAWAL)
Director / MP (Vehicle)
For Director General / MP

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