TRACTION MOTOR TYPE TM 4907BZ

IB-571- 1
 TRACTION MOTOR TYPE TM 4907BZ
CONTENTS

DESCRIPTION PAGE NO.

INTRODUCTION 03

DESCRIPTION 03

CONSTRUCTION 03

DATA 05

MAINTENANCE SCHEDULE 11

PUTTING INTO SERVICE 11

ROUTINE MAITENANCE 12

RECONDITIONING AND REPAIRS 16

MAINTENANCE TOOLS 20

DISMANTLING & REASSEMBLING 49

REMOVING AND REFITTING ARMATURE SHAFT 61

GEAR AND GEARCASE 74

GEAR CASE 74

GEAR WHEEL 74

REMOVING AND FITTING PINIONS 81

BEARINGS 90

BRUSH GEAR 94

MOTOR SUSPENSION UNIT 97

IB-571- 2
 DESCRIPTION AND OPERATION 97

FAULT FINDING 100

MAINTENANCE PRACTICES 101

REMOVAL/INSTALLATION 101

SERVICING 101

ADJUSTING/CHECKING 102

OVERHAUL PROCEDURES 103

DISASSEMBLY 103

CLEANING 105

CHECKING 105

REASSEMBLING 107

IB-571- 3
 TACTION MOTOR-TYPE TM4907BZ

INTRODUCTION

DESCRIPTION
The Traction motor is a D.C. series wound, four pole, forced ventilated
machine arranged for axle mounting on roller bearings, and supported on
the opposite side by resilient suspension unit. Transverse movement is limited
by the flanges of the axle suspension bearings.

CONSTRUCTION
The armature core is built up from electrical quality varnished sheet steel
laminations assembled on the shaft with interference fit and consolidated
under pressure.

The armature is lap wound with 100% equalization. The armature coils
are Kapton covered. The armature and equalizer coil leads are TIG welded to
commutator risers. The armature coil are held down in the core slots by
Epoxy glass wedges, and the end windings are secured by Resi-I-glass
bands. The wound armature is finally Vacuum Pressure Impregnated with
insulation varnish.

There are four brush holders per motor, each carrying three split carbon
brushes, each brush holder is carried on two insulated support pins. Correct
brush pressure is provided by coil spring.

The armature is supported on grease lubricated roller bearings. Bearing

assemblies are sealed type, thereby necessitating lubrication in about 2/3 years.
The armature is located axially by the commutator end bearings. The pinion
end bearing applies no axial restraints and thus permits the differential
expansion between armature and frame.

The axle suspension tube is made from cast steel, of one integral part, and
at the both ends tapered bearing housing are formed. The upper and lower
flanges of suspension tube are mounted to the magnet frame with bolts.
There TIMKEN make tapered roller bearings are used at both sides of tube,
and they are lubricated with grease.

The pinion which is shrunk on the armature shaft, drives the loco axle

IB-571- 4
through a spur gearwheel which is pressed onto the axle. The gearcase is of
welded sheet steel construction and is in two halves, which are bolted
together. The complete gearcase is supported on the motor frame. The joints
between the gearcase halves are baffled and grooved to carry felt sealing
rings so as to prevent ingress of dust and any other foreign material and escape of
the gear lubricant.

The motor is forced ventilated. Air enters the motor through a duct
system connected to an opening on the motor frame at the commutator
end. The cooling air then flows in two parallel paths, one under the
commutator through the armature core ducts, and the other along the
outside of the armature and between the field coils, and is discharged through
the openings provided at the pinion end of the frame.

IB-571- 5
 MAINTENANCE DATA
RATING (continuous) at 45 Deg. C ambient

Volts Amps Rpm KW Insulation Class

325 1000 430 280 Class 200

WEIGHTS (Approximate)
Machine complete with gears & 3664 Kg
gearcase
Armature 1165.5 kg
Gearcase 126 Kg
Pinion (18:74) 24 Kg

RESISTANCE VALUES (Average at 25 deg. C)

Armature winding 0.0096
Armature (across 38 micas) 0.0307
Series field winding 0.0053
Commutating field winding 0.0044

ARMATURE
Core diameter 489 mm

Core Length 394 mm

Distance between bearing to bearing 933.45 mm
Overall length of armature 1276.35 mm

ARMATURE TEMPORARY BANDING

Material 1.6mm diameter tinned steel
wire
Turns 45 on each winding
100 on core
Banding tension 140 Kg

ARMATURE PERMANENT BANDING-RESI-I-GLASS

Material 0.33 tk X 19 wide 2F Hi-
Temp Resi-I-glass Tape
Turns on PE Endwinding 110

Turns on CE Endwinding 110

Banding tension 220-230 Kg

IB-571- 6
COMMUTATOR
Length of working face 187 mm

Diameter-New 423/424 mm

Diameter-min. permissible 390 mm

Mica thickness 1.6 mm

Depth of Mica undercut 0.75 to 1.25 mm

BRUSHGEAR
No of brush arms 4
Brush holders per arm 1
Brush per holder 3
Max. permissible brush to brush 0.5 mm box clearance
Clearance between brush-holder & 2.0 to 3.0 mm
commutator

CARBON BRUSH

Total No. of brushes 12

Length 52 mm

Width 57.15 mm

Thickness over two halves 19.0 0 mm

Min. permissible length 28 mm

Pressure on new brush 5.0 to 5.5 Kg

Brush grade EG14D Morgan or EG6754

(Le Carbon) or E88 (S & E)

POLE BORES – Average

Mainpoles 498.6 mm
IB-571- 7
Compoles 498.95 mm

LINER AT BACK OF POLES

Mainpole One no 2 mm tk hot rolled
carbon steel sheet
Compole One no 2..5 mm tk. half hard
brass to IS:410 Gr. Cu Zn
37.

ARMATURE BEARINGS

PINION END COMMUTATOR

END
TYPE NU330EM/C4- NH320M/C4-roller
roller
Radial clearance of free 0.165 to 0.215 mm 0.105 to 0.140 mm
bearing when new.
Fit between inner race 0.035 to 0.08 mm 0.025 to 0.06 mm
and shaft interference interference
Fit between outer race 0.025 mm 0.020 mm
and housing interference to interference to
0.035 mm 0.030 mm
clearance clearance
Min Permissible radial 0.03 to 0.13 mm 0.03 to 0.10 mm
clearance when
assembled

LUBRICATION
Quantities indicated for lubricants are approximate and for general guidance
only. The actual quantity of the lubricant and the interval between re-lubrication
should be determined from experience and duty. Relevant dipsticks should
invariably be used for checking levels of lubricants in the gearcase.

ARMATURE BEARINGS
Recommended Grease ESSO Andok B R or HP LITHON 3

Pinion End Commutator End

Quantity for first fill 1000 gms 385 gms
IB-571- 8
Replenishment period 3 Yrs. 3 Yrs

AXLE SUSPENSION BEARINGS

Roller bearing details Gearwheel end Road wheel end

Manufacturer TIMKEN TIMKEN

Type of bearing Taper Roller Taper Roller Cone

Cone M249747 M349547 Cup
Cup M249710 M349510

Lubrication Shell Alvania grease No.3

Change of lubricant (total 600 gr. 1250 gr.

value).

GEARS
Recommended Lubricant
Quantity of Lubricant in grease
Caltex Crater No.2 or Bharat
camex Compound FOR HP
Gear Tak 2.
5 Kgs at Max. Level 3 Kgs at
Min. Level

TORQUE SPANNER SETTINGS

The values specified are for bolts with lubricated threads.

Suspension tube bolts M36. 121-145 Kg.m.

Gearcase mounting bolts. M36 140 Kg.m

Gearcase joints bolts. M20 24-25 Kg.m

Mainpole bolts 53-55 Kg.m

Compole bolts 53-55 Kg.m

Commutator bolts during Hot 33.5 Kg.m Cold 27.5 Kg.m

seasoning
Endshield bolts PE & CE.M24 40-42 Kg.m
Bearing Locking Plate CE, M20 24-25 Kg.m
IB-571- 9
Outer bearing cap CE, & PE, 15-16 Kg.m
M16
Brush holder to Mag. Frame M24 22-24 Kg.m

HIGH VOLTAGE TESTS

A proper judgment is required to be exercised in selecting test voltage
bearing in mind that the insulation deteriorates gradually with the period
of service.

The following rms voltage values are at 50 Hz AC.

ON NEW MACHINE OR WHEN RE-WINDING COMPLETELY WITH

NEW INSULATION:

Between commutator bars before 500 V flash

winding
All commutator bars to earth 5500 V for 15 sec.
before winding
Armature winding before final 5000 V for 15 sec.
banding to earth
Complete machine (hot) to earth 3200 V for 60 Sec

ON OLD INSULATION TO EARTH

At overhaul after cleaning 1300 V for 15 sec.

armature and field
Before partial repair of armature 1600 V for 15 sec
or field
After repair and re-varnishing of 1450 V for 15 sec.
armature or field
Brush holder support bars 3000 V for 60 sec.

IB-571- 10
 MAINTENANCE SCHEDULE
The efficient performance of electrical machines depends very largely on
periodical inspections during which incipient defects can be rectified.
Such attention reduces the cost of repairs and lengthens life of the
equipment.

The most suitable intervals between service maintenance occasions can

only be determined by actual service experience. Initially the intervals
should be as specified until it becomes possible to change them as
experience is gained.

In the case of Lubricants, the quantities and frequency of lubrications

specified should similarly be treated as guide only. The actual interval
between re-lubrication and quantity of lubricant should be determined
from experience and individual duties of each machine.

A complete history of each machine, detailing the maintenance effected,

the lubricant consumption, a list of renewals, replacements etc, is
therefore the utmost importance, and a card similar system containing
such information is advised.

PUTTING INTO SERVICE

After putting new or reconditioned machines into service for the first time,
the following checks should be carried out, during or at the end of first
week of operation.

Check that after the motor has been mounted backlash exists between
pinion and gear wheel. New gears are manufactured to have a nominal
backlash of 0.25 to 0.76 mm, as measured on the outer i.e. non relieved
end of the pinions.

Check tightness of all bolts, particularly suspension tube, gearcase and

brushgear bolts; apply the torque as detailed in data.

Examine commutators and brushgear and check that skin on the

commutator is being formed and carbon brushes are bedded correctly.

Check that after a load run, temperatures of axle suspension bearing are
not excessive.

ROUTINE MAINTENANCE

MONTHLY:

Before removing commutator covers, brush off loose dust or dirt. Examine
the commutator and clean the outer vee-ring and the insulation over the
IB-571- 11
risers. The commutator should be of uniform colour, have a well -
polished surface and be free from bar marking or bar edge burning. For
commutator faults and their rectification see WORKSHOP
INSTRUCTION.
Remove any copper beads from the commutator surface with fine
carborundum cloth. Deposits from dirty or greasy hands should be
removed by a solvent.

Examine the brushgear and clean the support pin insulators.

Check that the brush springs sit correctly on the brushes and that the
springs are in good condition.

Check carbon brushes for wear/Fit new brushes in place of any which are
unlikely to last until the next inspection. See DATA for minimum length
and brush grade. Bed all new brushes to the curvature of the commutator.

Check carbon brushes for mechanical damage, breakage of flexible, etc.

Fit new brush if necessary.

Check that the flexible are firmly secured to the brush-holder.

Check brushes for freedom in the brush-holder and if sticking, clean both
the brush and the brush way in the holder. Do not soak the brush as the
solvent will eventually ooze out affecting the commutator and causing the
brush to jam in the holder.

If the brush appears to be excessively slack in the brush-holder check the

brush size and discard the brush or the holder as the case may be.

If brush-holder have to be removed from the machine, slip thin, clean

pressboard between each brush-holder and the commutator to avoid
damaging the commutator surface.

On replacing brush-holders check the clearance between the underside

of the brush-holder and the commutator. See DATA

Look carefully for any signs of flashover, overheating, loose connection or

damaged insulation.

Top up gearcase to the level of gear filler until. See DATA for Grade of
lubricant.

THREE MONTHLY

MONTHLY SERVICE PLUS:-

Blow out machines using clean, dry compressed air.

IB-571- 12
Take particular care to direct air under the commutator in order to remove
dirt lodged in the armature core ducts.

Check tightness of all brushgear bolts. Apply torque see DATA.

Check tightness of bolts securing axle suspension tube and gearcase. For
torque values with lubrication of the threads refer MACHINE DATA.

Check external leads for chafing.

Check air inlet bellows for cracking, tearing or collapsing. Renew if

necessary.

Check for leakage from the gearcase.

SIX MONTHLY

THREE MONTHLY SERVICE PLUS:-

Clean outlet provided on PE /End shield in bottoms.

Check the Gearcase mounting bolt hole on magnet frame and replace the
bushes if wornout.

ANNUALLY

SIX MONTHLY SERVICE PLUS:-

When motors are removed from bogies for wheel turning etc. clean pinion
and gearwheel and check for tooth wear.

Before fitting the gear cases, clean out old lubricant to avoid the
possibility of gears running subsequently in contaminated lubricant.

OVERHAUL - THREE YEARLY

Remove traction motors from the bogies and overhaul.

Dismantle the motor and clean the armature and field system. Dry out to
remove any detrimental moisture. After drying out, check the hot
insulation resistance of the armature and field and if greater that 1
Megohm apply a high voltage test as detailed under HIGH VOLTAGE
TEST.
Check the armature for open and short circuits by a commutator bar-to-
bar test. For method see WORKSHOP INSTRUCTION.

Remove the brush-holder from the machine. Clean and inspect for brush
clearance in the holder-spring pressure and damage. Recondition as

IB-571- 13
necessary.

If the field coils and connections are in good condition and dry, paint the
interior of machine with suitable insulating varnish. If the field coils require
repair, remove and recondition individually, check the armature bearings
and bearing details of damage renewing as necessary.

Inspect the shaft for damage to pinion and bearing seatings and ensure
that it is straight.
Inspect the armature for loose bands, solder throwing etc. recondition as
required. If the commutatoris worn or damaged, skim the commutator and
undercut the micas.

Varnish impregnate the repaired or re-conditioned armature. For details

refer to WORKSHOP INSTRUCTION.

Check the gear case mounting hole on magnet frame and replace the
metallic bushes if worn out.

Dynamically balance the armature, reassemble the machine and paint the
exterior of the machine. Run the machine on no load at about 1100 RPM
to ensure correct operation of the bearings. When installing the motor in
the bogie ensure that all bolts are tightened to the specified torque
values. Fill the gearcase with the correct lubricant to the maximum level
use dipsticks for Gear cases to be filled up to the filler unit level.

IB-571- 14
 RECONDTIONING AND REPAIRS
Note: Refer also to WORKSHOP INSTRUCTION for reconditioning
and repair procedures.

ARMATURE
After removing the armature from the magnet frame, blow off loose dust
and dirt with clean, dry compressed air, if the armature is very dirty, clean
it.

Visually inspect the condition of the armature coils and bands. Check the
pinion and commutator end bands for looseness by tapping the band light
hammer and feeling for vibration.

Check the armature for open and short circuits by carrying out a
commutator bar-to-bar test.

Dry out the armature and check the hot insulation resistance. If this is
greater than 1 megohm apply a high voltage test, as detailed under HIGH
VOLTAGE TESTS in MACHINE DATA.

If necessary after drying out treat the armture in insulating varnish.

Wash and inspect the armature bearings. Inspect the bearing details for
damage. renewing as necessary. Inspect the shaft for damage to bearing
and pinion seatings. Ensure that the shaft is straight.

COMMUTATOR
If the commutator is damaged, grooved or shows flats and high bars,
resurface in a lathe. Turn the armature on its bearing seatings and
remove as little metal as possible. After turning undercut the micas to the
dimensions given in DATA, bevel the bar edges and clean out undercuts.
Do not resurface a commutator whose surface has a good polish and
colour and is free from grooving, signs of flats, high bars and bar marking.

FITTING NEW PTFE SLEEVES

Clean the surface of the support pins and remove any surface
irregularities with fine glass paper. Check the support pin insulation
resistance. If this is lower than 40 megohms, dry out the insulation by
baking at 90 deg. Celsius. Apply a high voltage test of 2,000V, 50 c/s for
60 sec. between the support pin and the brush-holder. Pins failing this
test should be discarded.

Heat the sleeve to about 150 deg. Celsius in an oven having proper
exhaust ventilation and press it over the support pin. Ensure that it is
IB-571- 15
pushed solidly against the brush holder castings.

NOTE:-

Extreme care should be taken when heating PTFE sleeves since at

temperatures of 200 deg. Celsius and above it release colourless and
odourless decomposition products which are poisonous. Precautions
should be taken to protect personnel in areas where PTFE dust may be
produced by grinding or machining operations. Do not burn scrap PTFE
sleeves or pieces.

AXLE SUSPENSION BEARINGS

Wash and inspect the axle suspension bearings. Inspect the axle
suspension bearing details for damage. Renewing as necessary. Inspect
the suspension tube and axle for damage to bearing.

MAGNET FRAMES
Clean and inspect the armature bores/faces. Check for any crack, dent,
damage repair them if required.

Check that the gear case mounting holes are not enlarged/oblong replace
the bushes if required.

Check the end shield mounting tapped holes on PE & CE side repair
them if required. Check the axle bore and face for dents, damages and
repair if required.

MAINTENANCE OF FLAME RINGS

Traction motor has been provided with a flame ring which is supported on
the CE end shield with the help of 6 Nos. screws. The purpose of the
flame ring is to provide an arcing gap direct to earth & to protect the
commutator in the event of flashover.

The following aspects while replacing/refitting the flame ring assembly.

- Maintenance of arcing gap between flame ring and commutator.

- Proper fitment of flame ring to end shield and its locking
arrangement.

PROCEDURE:

For replacement of flame ring as and when required.

IB-571- 16
 -Chip off the welding from flame ring screw heads

-Replace all the existing 6 screws with M12 x 40 mm hex. screws.

-Fully tighten the screws on to the flame ring after ensuring the
arcing gap to 25+2 /+0 mm between commutator and Flame ring
as shown in the Fig.o1. Steel washers may be used for maintaining
the arcing gap if required.

Lock the flame ring screw heads by tack welding at two places with CE
end shield as shown in Fig.01.

IB-571- 17
IB-571- 18
 MAINTENANCE TOOLS
The following List gives the Maintenance Tools for traction Motor Type
TM4907BZ.

TOOLS
1. Spirit level, wooden blocks, wooden “V” blocks, chisel, light
hammer, Copper drift, oven, Screw Press.
2.
Spanners: Nos. 10,13,17,19,24,30,36,47 & 55.

NOTE:- Box Spanners with ratchet may be used to the extent possible.

Allen keys: SIZE (A/F) 3 & 5.

3. Set of Torque Spanners with Suitable adaptors. Refer Machine

Data for torque values.

SPECIAL TOOLS TOOL NOS.

Gearcase Dipstick 1405374

Fibre Guide Bush for CE of Shaft 1405375

Extractor for CE Inner wiper and Inner 1405376

Bearing Race

Lifting Cap & protection Sleeve CE Bearing 1405377

Extractor for PE Flinger 1405378

Pinion Ejection safety Plate 1405379

Extractor for Bearing Sleeve PE 1405380

Retaining Ring & Lifting Plate 1405381

Extractor for Bearing Retaining collar PE & inner 1405382

bearing Race PE

IB-571- 19
Extractor for PE outer Bearing Race 1405383

Protection Sleeve & Special Retaining Plate 1405384

Armature Clamping Tackle 1405385

Pinion Position Gauge 1405387

Puller for abutment piece from axle 1405573

Withdrawal of suspension tube 1405574

Removing bearing cone at gear wheel end 1405575

Pulling out of bearing cut(Gear wheel end) 1405576

Removing bearing housing 1405577

Removing of bearing cup (Road wheel end) 1405578

Forcing screws-It.11 & 19 (3 each) 1405975

Guide Stud -it4(3nos.) 1405976

Lifting Shackle -it8-(1no) 1405977

Eye Bolt - it 20 (2 no.): it 24 & 30 one each 1405978

Spacer 1405979

Studs 1405982

IB-571- 20
IB-571- 21
IB-571- 22
IB-571- 23
IB-571- 24
IB-571- 25
IB-571- 26
IB-571- 27
IB-571- 28
IB-571- 29
IB-571- 30
IB-571- 31
IB-571- 32
IB-571- 33
IB-571- 34
IB-571- 35
IB-571- 36
IB-571- 37
IB-571- 38
IB-571- 39
IB-571- 40
IB-571- 41
IB-571- 42
IB-571- 43
IB-571- 44
IB-571- 45
IB-571- 46
IB-571- 47
 DISMATLING & REASSEMBLING

DISMANTLING
The following list shows the tools which are required for dismantling
the traction motor. (See under MAINTENANCE TOOLS)

TOOLS
Spanners 13, 17, 19, 24, 30, 36, 46, 55.
Eyebolts M20, M24
Allen Keys 3 A/F, 5 A/F
Chisel, Spirit level, Wooden blocks, Screw press.

SPECIAL TOOLS BHEL TOOL NOS.

Extractor for CE bearing inner race 1405376

and bearing sleeve
Protection sleeve for CE 1405377
bearing and lifting cap
Extractor for Flinger PE & Inner Brg. Cap PE 1405378
Extractor for bearing sleeve PE 1405380
Retaining ring & Lifting plate 1405381
Extractor for PE bearing inner race 1405382
and bearing collar
Extractor for PE bearing outer race 1405383
Protection sleeve for PE bearing 1405384
Forcing screws for CE bearing 405975 It.11
outer cap and PE bearing outer 4 Nos.
Forcing screws for CE and PE endshield 1405975 It.19

Guide studs for PE endshield 1405976 It. 04

Lifting shackles 1405977 It. 08

IB-571- 48
IB-571- 49
 Before dismantling the motor refer to the section “Ball and Roller Bearings”
in the WORKSHOP INSTRUCTION for the precautions to be taken, to
avoid damage to the bearings. Also refer to the section “Hydraulic Tools” for
the correct use of such tools specified.

1. END SHIELD CE 24 GEAR CASE

2. INNER BEARING CAP CE 25 GEAR CASE

3. CE BEARING CAP BOLT 26 GEAR CASE FELT

(MOTOR SIDE)

4. OUTER BEARING CAP CE 27 GEAR WHEEL

5. ARMATURE SHAFT 28 ARMATURE BEARING

PE

6. BEARING LOCKING PLATE 29 GEARCASE FELT

(AXLE SIDE)

7. CE BEARING LOCKING 30 FLINGER PE

PLATE BOLT
8. INNER BEAR WIPER CE 31 BEARING SLEEVE PE

9. CE BEARING LIP 32 MAINPOLE BOLT

(AXLE SIDE)

10. ARMATURE BEARING CE 33 BRUSH GEAR

11. MAIN FIELD COIL 34 TAPERED ROLLER

BEARING ASSY

12. MAIN POLE 35 END COVER GEAR

WHEEL SIDE

13. MAIN POLE BOLT 36 SOLAT HD CAP

SCREW

14. COMPOLE BOLT 37 ENCLOSURE

15. COMPOLE 38 GREASE NIPPLE

16. COMPOLE COIL 39 TUBE

17. PE END SHIELD BOLT 40 ADJUSTMENT

WASHER

IB-571- 50
18. END SHIELD PE 41 BEARING HOUSING

19. PE OUTER BEARING CAP 42 END COVER (CE

SCREW SIDE)

20. OUTER BEARING CAP PE 43 ABUTMENT

21. BEARING RETAINING 44 TAPERED ROLLER

COLLAR PE
22. PINION 45 AXLE

23. PINION RETAINING PLATE

IB-571- 51
REMOVING THE ARMATURE AND ARMATURE BEARINGS
1. Clean the motor externally.

2. Remove the pinion 22 see PINIONS.

3. Remove the bolts 3 insert three forcing screws 1405975 item

11 and force the CE. outer bearing cap 4 out of its fit. Remove the
bolts 7 withdraw the CE. Bearing locking plate 6. Remove
Bearing Lip 9.

4. Remove screws 19 insert three forcing screws 1405975 item

11 and force the PE. Bearing outer cap 20 out of its fit. Assemble
the retaining ring 1405381 over the shaft and apply the bolts.
Tighten the bolts uniformly and with just sufficient force to take up
any slackness between the ring and the endshield.

No harm will be done if the armature moves forward and

pushes the CE bearing outer race just for enough out of the
endshield 1, to allow the retaining ring to butt up to the PE bearing
retaining collar 21. Apply the lifting plate 1405381 to PE of shaft and
tighten down on to the retaining ring.

5. Remove two of the P.E. endshield bolts 17 and insert two M24
eyebolts Using these eyebolts and lifting shackles 1405977 item
8 up-end the motor CE down onto wooden blocks. Using a spirit
level, set the machine axis truly vertical.

6. Remove all carbon brushes.

7. Check the retaining ring bolts for tightness and take up any
slackness which may have developed due to the armature
moving forward.

8. Remove the remaining endshield bolts 17 and the eyebolts.

Insert two guiding studs 1405976 item 4 diametrically opposite
in the magnet frame. Insert three forcing screws 1405975 item 11
in the PE. endshield and force it out of its fit in the magnet frame.
Lift the armature out of the magnet frame by means of the lifting
cap on the shaft.

IB-571- 52
 Fit the protecting sleeve 1405377 in the CE of the shaft. The
protecting sleeve permits trestle mounting of the armature,
provides a shaft extension for lowering the armature,
accommodates a lifting cap and protects the bearing inner race.
Lower the armature into a horizontal position on a wooden V-
block.

9. If the CE. bearing inner race is damaged or the commutator is to

be resurfaced remove the bearing inner race and CE Inner
Bearing Wiper 8 with the extractor 1405376 and inner bearing
cap 2.

10. Remove the lifting cap and retaining ring. Using the extractor
1405382 remove the P.E. bearing retaining collar 21 Remove
screws 19 and insert three forcing screw 1405975 item 11 in the
bearing cap P.E. 20 and force it out of its fit. Insert eyebolt 1405979
item 4 into a forcing screw hole in the P.E. endshield 18 apply a
lifting sling and remove the endshield complete with the P.E.
bearing outer race.

Remove the P.E. bearing outer race from the endshield with
extractor 1405383. Clean and oil the inner bearing cap 30 inner
Race. flinger 29 and inner bearing sleeve 31.

Fit the protecting sleeve 1405384. If the bearing inner Race, flinger,
PE inner bearing cap. Inner bearing sleeve are damaged and are
to be replaced, remove inner bearing race P.E using 1405382.
Remove inner bearing cap and flinger using extractor 1404378.
Remove inner bearing sleeve P.E using extractor 1405378.

11. Using two M24 eyebolts screwed into the magnet frame at
P.E. endshield. Securing bolt holes turn the frame into a
horizontal position. Using three forcing screws 1405975
item 19 remove the C.E. endshield. Using a screw pressto
with draw the C.E bearing outer race from the endshield.

IB-571- 53
REMOVING THE FIELD COILS
1. Remove the insulation from the connection and unbraze these
using brazing tongs or a gas torch. If a gas torch is used, adjacent
insulation must be protected with wet asbestos paper.

2. After removal of the pole bolts, remove the pole and coil assembly.
If a main pole assembly is to be removed, the adjacent
compoles must be first removed.

3. Lift the coil and pole and coil assembly and recondition, if
necessary. The insulation and mechanical protection applied to
the coils are shown in the figure. After repair, treat the field
coils in silicone varnish and paint with insulating varnish.

REASSEMBLINGTHENEW/RECONDITIONED MAINFIELDCOIL&POLE
ASSEMBLY

1. On to the cleaned pole fit the main pole spring with the crests of the
corrugations adjacent to the pole tip. The open end of the spring
should, when the pole is finally assembled into the machine, be at
the pinion end of the machine.

2. Slide the new or reconditioned coil onto the pole.

3. Mount the pole and coil assembly in the frame, and fit new locking
washers on the pole bolts of the nose side , top & bottom poles,
The axle side pole is fitted with the reduced head bolts, which are
locked by tack welding the ends of the square steel bar, laid long
one of the bolts head flats to the Magnet frame. New main field coil
and pole assembly to be used where existing main field coil and
pole assembly is found in heavy damaged condition or magger
value is zero.

Tighten the bolts in accordance with the torque spanner settings

given in DATA. For reconditioned main field coil and pole
assembly rotate the same number of lines behind that main pole
number was originally found in the motor. For new field coil and
main pole assembly to be fitted in the frame, use stand liners of
the back of main pole to mature the original main pole bore of the
machine.

IB-571- 54
REASSEMBLING THE COMPOLE COILS
1. Clean the pole and check that the liner specified in DATA is fitted
to the back of the compole.

2. Mount the pole and coil assembly in the frame after

reconditioning.

3. Using new locking washers under the pole bolt heads, mount the
frame and pull down the bolts.

RECONNECTING
Reconnect the coil as shown in fig. 03. All connections are made with
silver phos bearing alloy 0.25 mm thick using one piece only between
terminals and connections strips or brush gear leads. Flux is not required with
this alloy. It is strongly recommended that, if available, a brazing machine with a
pair of carbon brazing jaws to be used for brazing operations. Soak asbestos
paper in water and use it to protect the insulation adjacent to each
connection. Braze the connections using a current of approximately 2000
amperes.

If a brazing machine is not available a gas torch may be used, precautions

being taken to protect insulation from the flame as follow:

Soak asbestos paper in water and pack it around the connection to be

brazed and around adjacent field coils to a thickness of about 25 mm.
Ensure that all insulation is covered.

Slip a piece of Silver phos bearing alloy, between the terminals and
clamp the connection with a screw clamp or vice grip pliers.

With the torch set to give a neutral flame, braze the connection
adding extra brazing alloy to fill the joints. Remove the clamps and
asbestos and blow out the inside of the frame with dry compressed air.

INSULATING STAPLES
Insulate the staples with two half lapped layers of 0.15 mm thick
varnished seamless Bias cut terylene tape, followed by one layer of 0.18
mm thick woven glass tape, wet treated in insulating enamel.

IB-571- 55
IB-571- 56
INSULATION OF BRAZED CONNECTIONS

a. BRAZING OF JOINTS
Existing and proposed method of placing the connection leads are
shown at fig. A & B.
b. INSULATION OF BRAZED JOINTS
The following insulation materials are used in brazed joints of field
connections for traction motor:-

Items Operation Description Qty.

INSULATE THE STAPPLES

1. TAPE ONE LAYER 1/2 SILICONE 1.5M

LAPPED ELASTOMER
GLASS TAPE (BIAS
CUT) 0.15TKx25
2. TAPE TWO LAYERS 1/2 POLYESTER 2.0M
LAPPED TAPED.13TKx20

3. TAPE ONE LAYER 1/2 WOVEN GLASS 1.5M

LAPPED TAPE .23TKx25

4. INSULATE BRAZED
JOINTS

5. APPLY PUTTY ARROUND SILICONE 1 KG

THE BRAZED JOINTS. ASBESTOS
PUTTY.

FOR JOINTS WITH CABLE A,AA & BRUSH GEAR LEAD WITH
COMPOLE COIL S1

6. PUT GLASS MICA GLASS GLASS MICA GLASS 6NOS.

PIECE ON EACH SIDE OF 0.38 TK x 65 x 115
JOINT

7. WRAP JOINTS TWO SILICONE 20 M

LAYERS 1/2 LAPPED ELASTOMER
GLASS TAPE (BIAS
CUT) 0.15TKx25
8. PUT NOMEX PIECES ON NOMEX GR.410 6NOS.
EITHER SIDE OF JOINTS 0.13TKx30x75

IB-571- 57
 9. FINAL TAPE ONE LAYER WOVEN GLASS 10 M.
1/2 LAPPED TAPE 25TKx25

FOR OTHER JOINTS

10. WRAP JOINTS 2 LAYERS SILICONE 80 M

1/2 LAPPED ELASTOMER
GLASS TAPE (BIAS
CUT) 0.15TKx25
11. FINAL TAPE ONE LAYER WOVEN GLASS 40 M
1/2 LAPPED TAPE .25TKx25

TIE UP BRUSH GEAR LEAD WITH

CONNECTOR

12. TAPE BRUSH GEAR LEAD WOVEN GLASS 9M

TOGETHER WITH TAPE .23TKx25
CONNECTING STRAP 1
LAYER 1/2 LAPPED.
NOTE:-TAPPING TO BE DONE WHOLE LENGTH OF BRUSH
GEAR LEAD.

13. TAPE BRUSH GEAR LEAD WOVEN GLASS 12 M

TOGETHER WITH TAPE .23TKx25
CONNECTING STRAP 1
LAYER 1/2 LAPPED

14. SPRAY OVER JOINTS ANTI TRACKING 2.5KG

AND INTERIOR OF THE RED INSULATING
FRAME PAINT

IB-571- 58
IB-571- 59
INSULATION OF THE CABLE TERMINAL PLATE JOINT OF
POSITIVE BRUSH HOLDER LEAD

On the motors, flash over marks are observed on positive brush holder (3
‘O’ clock ) cable connector. Presently the terminal plate of the connector
is bare. Flashover, takes place between the +ve brush holder terminal
and the -ve terminal or between +ve terminal and ground. The flashover
cause erosion of the +ve bare terminal & amage to field coils.

MATERIALS:
a) Elastomer tape - 0.5 tk x 25 x 2.0 M

b) Woven glass tape - 0.25 tk x 25 x 1.0 M

c) Red anti-tracking paint RE004 R5A.

PROCEDURE:

1. Dismantle the armature from the magnet frame.

2. Disconnect the positive brush holder lead from the brush holder (3
‘O’ clock).

3. Insulate the brush gear lead +ve terminal plate using the material
given at item 2.0 as follows :

a) Apply 2 layer 1/2 lap elastomer tape

b) Apply 1 layer 1/2 lap woven glass tape.

c) Apply red anti tracking paint RE004 R5A.

4. Reassemble the brush gear lead along with the terminal to

the brush holder.

REMOVING AND REFITTING THE ARMATURE SHAFT

The following list shows the tools which are required for removing and
refitting the armature shaft (See under MAINTENANCE TOOLS).

IB-571- 60
TOOLS
Eye bolts M20, M24

SPECIAL TOOLS BHEL TOOLS

Extractor for CE bearing inner race & sleeve 1405376

Extractor for flinger and Inner bearing Cap PE 1405378

Extractor for Bearing Sleeve PE 1405380

Extractor for PEbearing inner race 1405382

Armature clamping tackle 1405385

REMOVING
1. Remove the pinion and bearing inner race using extractor 1405382
remove flinger 29 and inner Bearing Cap PE 30 using extractor
1405378 & remove inner bearing sleeve PE 31 using extractor
1405380 using extractor 1405376 remove CE, and sleeve and
bearing inner race. Remove inner bearing cap CE.2.

2. Assemble the armature clamping tackle on the armature as shown in

1405385. Fully tighten the clamping stud bolts.

3. Mount the armature in a press, arrange to push the shaft from the
commutator end to pinion end. Between 200 to 350 tones will be
required to move the shaft. Immediately pressure is applied, check the
clamping stud nuts for tightness and retighten uniformly.

4. Complete the shaft removal.

IB-571- 61
REFITTING
1. The armature core and commutator are located on the shaft by
means of keys. During the refitting operation, the keys, unless held
axially in the shaft keyways, could possibly cause difficulty by
riding up the run-outs of the keyways. To prevent this, fit the keys to
the shaft and, at about 25 mm from the commutator end of the
keys, drill through both keys in to the shaft to a depth of 15 to 17
mm from the top of the keys. Ream the holes 6 mm diameter
and fit 6 mm diameter steel pegs into the holes such that the top
of the pegs are flush or slightly below the top of the keys.

2. Heat the clamped up armature for two hours at 150 Deg.C

During the heating period examine the new shaft for damage
caused by handling. Smear the shaft along the portions which
finally fit in the core and commutator hub with mercurial
ointment.

3. Press the new shaft in to the preheated armature. Take care to

start squarely and use a copper or brass between the press arm
and the pinion end face of the shaft. Press the shaft from pinion
end to commutator end. A pressure of 150 to 250 tones will be
required to push the shaft into the final position.

4. Dismantle the clamping tackle.

IB-571- 62
 REASSEMBLING
The following list shows the tools which are required to reassemble the
traction motor. (See under MAINTENANCE TOOLS).

TOOLS
Spanners; 19,24,30, 36, 46, 55, Eyebolts; M20, M24, & Allen Keys;
3A/F, 5 A/F; light hammer, Copper drift, Oven, Spirit level, Wooden blocks,
Screw Press, Dial gauge, Feeler gauges.

SPECIAL TOOLS BHEL TOOLS

P.E. Spacer 1405979

Retaining ring 1405381

Lifting cap & Protection Sleeve CE bearing 1405377

Guide studs for CE & PE end shields 2-off 1405976 Item 4.

each

Lifting shackles 1405977 Item 8.

Fibre guide bush 1405375

Please refer “CE & PE Bearing grease Distribution” for the quantity of
grease to be filled in the armature bearings. See fig. 04 & 05.

1. Smear grease in the labyrinth of CE, bearing inner cap3 as

shown in fig.05 and slide onto the shaft. Thoroughly clean and fit
the CE bearing sleeve by shrinking on at 90 to 100 Deg. Celsius
above ambient temperature. When cold, tap the sleeve to ensure
that it is solidly up to the shaft face.

Shrink the CE bearing inner race onto the shaft at 100 to 110
Deg. Celsius actual temperature. Fill the CE bearing cap inner 2
with grease as shown in fig.05.

IB-571- 63
PE BEARING GREASE DISTRIBUTION FOR
TM4907AZ FIG.-4

IB-571- 64
CE BEARING GREASE DISTRIBUTION FOR
TM4907AZ FIG.-5

IB-571- 65
2. With the identification marks facing towards the outside of
the machine, using screw press, press the CE bearing outer
race into the CE endshield. Force grease into the spaces
between the rollers, Roller faces, cage and out race track
at the back of the bearing position as shown.

Stick the gasket between the CE Bearing inner cap 2 and the
endshield with jointing compound. Insert two guiding studs
1405976 it.4 diametrically opposite in the magnet frame at
endshield securing bolt holes and assemble the endshield to the
magnet frame. Tighten bolts at specified torque.

3. Fit the PE bearing sleeve 31 by shrinking at 90 to 100 deg.

Celsius Smear grease in labyrinths of inner bearing cap 30
as shown and fit inner bearing cap 30, shrink fit flinger 29
by heating at 90 to 100 deg. Celsius Shrink the PE bearing
inner race onto the shaft at 100 to 110 deg. Celsius actual
temperature. The PE bearing inner and outer race MUST be
assembled with the identification marks on the races facing
towards the outside of the machine because a bearing
having a cambered inner is used. If the bearing is incorrectly
assembled VERY RAPID FAILURE of the bearing will occur.
Fill the inner bearing cap 30 with grease as shown in the
sketch.

Force grease into the spaces between the rollers, Roller faces, &
cage and outer race track at the back of PE. bearing as shown in
Fig.04 Arrange the bearing such that the identification marks
face towards the outside of the machine and press the bearing outer
race into the endshield by a screw press.

4. Insert a M24 eyebolt into the tapped hole in the PE endshield

and assemble over the shaft end on to the inner race. Take
care, not to damage the bearing. Due care is to be taken to
align the bottom grease outlet with the outlet of inner
bearing cap 30.

IB-571- 66
 Force grease into the spaces between the rollers, Roller face, & cage
and outer race at the front of the PE bearing positions as shown in
Fig.04 (Fill grease in the outer bearing cap PE 20 as shown. Do not
assemble at this stage.)

5. Thoroughly clean the PE spacer 1405979 and slide onto the shaft
butting up against the PE bearing inner race. The PE spacer is used in
place of the PE bearing collar 21 to enable run out and diametrical
clearance checks to be made on the bearing after assembly of the
armature in the magnet frame.

6. Assemble the rotating ring and lifting plate 1405381 and apply the bolts
and screw up tightly to the retaining ring. Tighten the retaining ring
bolts.

7. Using two M24 eyebolts to the magnet frame at the tapped holes used
for the PE endshield, turn the frame on end, CE down. Set up on
blocks high enough to give access later to guide the shaft though the
CE bearing. Using a spirit level, set the machine axis truly vertical.
Screw two guiding studs 1405976 it. 4 into the frame to guide the PE
endshield during assembly.

8. Assemble the guide bush 1405375 to the commutator end of the shaft.
By means of the lifting cap on the Pinion End of the shaft, lift the
armature and lower into the magnet frame. Take care not to damage
the bearings. Insert and uniformly tighten the PE endshield bolts 17.

9. Using one of the lifting eyes cast on the motor frame and two M24
eyebolts in the tapped holes for the PE endshield bolts, turns the frame
into a horizontal position resting the PE on a wooden block
approximately 100 mm high.

10. Remove the lifting cap, retaining ring and PE spacer.

11. Remove the guide bush at the CE of shaft.

12. Measuring the bearing run-out and radial clearances as follows, taking
care to prevent dirt getting into the grease and bearings.

(a) Attach a dial gauge with a magnetic base to the end of the armature
shaft. Arrange the spindle to bear against the bearing outer race-as
near the centre as possible but avoiding all identification marks.

(b) Rotate the armature slowly and read the run-out of the bearing outer
IB-571- 67
 race making sure that the armature is kept forward (using the wooden
block under PE) so as to eliminate any end play.

The maximum permissible run-outs are:

CE 0.08 mm, PE 0.10 mm.

If the run-out exceeds the above limits, check for burrs, dirt under the
fits of the endshield and magnet frame.

(c) Attach the dial indicator to the bearing outer race or a flat
portion of the endshield and arrange the spindle to bear
against the bearing inner race as near to the centre as
possible but avoiding all identification marks.

CE 0.013 mm PE 0.013 mm

(d) Check the diametaral clearance between each roller and

inner race at the bearing. Place the edge of the feeler gauge
against the roller and the inner race where they make contact
with each other.

Turn the shaft just sufficiently to roll the top roller on the feeler gauge.
Insert different feeler gauges until the clearance is established. Repeat
this for all rollers.

The minimum clearance for the bearings are:

CE 0.04 mm. PE 0.05 mm.

13. Assemble outer bearing cap PE 20 onto the endshield taking due care
to align the bottom grease outlet with the endshield outlet. Fit the
bearing retaining collar 21 by shrinking on at 90 to 100 deg. Celsius
above ambient temperature. When cold, tap the bearing collar with the
light hammer and copper drift to ensure that it is solidly butting against
the bearing inner race. Slowly tighten the bearing cap screw 19. check
and maintain a radial gap 0.25 mm minimum between collar and outer
bearing cap 20. Tighten screws at specified torques.

1 4 . Force grease into the spaces between the roller, roller faces, cage and
bearing outer race at the front of the CE bearing as shown in greasing
schedule.

Fit the CE bearing separate lip 9 and assemble the CE bearing locking
IB-571- 68
 plate 6. Using a new locking washer under the 7 bolts. Tighten bolts at
specified torques. Lock the CE bearing locking plate bolts 7.

15. Smear the mating faces with suitable jointing compound and fit the CE
bearing outer cap 4 without putting grease inside it and tighten the
bolts 3 uniformly.

16. Refit the pinion-See under PINIONS.

17. Replace the carbon brushes and check that they are properly bedded.

18. Test the motor under light load conditions as follows:

(a) Run the motor at a speed of 1100 rev/min. After the motor has been
running for a few minutes, check for noise. Run motor for at least one
hour for a correctly assembled bearing, the peak temperature rise
should not exceed 35 to 40 deg. Celsius during this run.

(b) Increase the speed to 1,700 rev/min. and run until the temperature of
the bearings has passed a peak value of 45 to 50 deg. Celsius above
ambient temperature and has fallen to a steady state of between 35 to
40 deg. Celsius above ambient temperature.

(c) Increase the speed to 2,231rev/min. for a short period to check for
bearing noise and vibration. In this case the peak temperature rise
above ambient should not exceed 60 deg. Celsius and the steady
temperature should be between 35 to 40 deg. Celsius above ambient
temperature.

It is unadvisable to run bearings at high speed under light load

conditions for long periods because of the possibility of roller skid,
which may cause scuffling of the track and roller surfaces.

19. Dismantle outer bearing cap CE 4 and fill the grease as shown in
greasing schedule reassemble the outer bearing cap CE 4, tighten the
bolts 3 at specified torque.

ASSEMBLING THE GEARCASE

Remove all the old lubricant and dirt from used gearcase with a steam
lance or a caustic solution. Do not burn gear compound in the gearcase as
warping will result. Rinse the gearcase thoroughly in boiling water to remove
all traces of caustic solution. Dry, straighten and repaint the gearcase.
Renew all felt seals.
IB-571- 69
 Check that the two halves of the gearcase fit together, that is the groove
in top half fits over the groove of the bottom half and that the semi-circles of
each opening are in reasonable alignment. If the two halves do not fit
together properly it may be because they were not originally assembled and
machined together. Each half of gearcase is stamped with the same
number. Check these numbers (the number will be found at the pinion end
of the gearcase on the road wheel side, near the horizontal joint).

To prevent damage to the felt seals on reassembly, the following

procedure is recommended.

1. Lift the bottom half gearcase up around the gearwheel until the
felt seals around the motor shaft opening and the axle openings
rest on the bearing cap and gearwheel hub respectively.

2. Insert the two M36 mm mounting bolts, fitted with new lock
washers, and screw down to support the gear case, but do not
tighten.

3. Heat about 2.5 kgs. of gear lubricant to, about 85 deg. Celsius
and pour it over the pinion and gearwheel or alternatively paint
this lubricant onto the teeth.

4. Lower the top half gearcase over the gears until the felt seal rests
on the bearing cap as in note 1, above and insert and screw
down the M36 mm mounting bolt. Do not tighten bolt.

5. Fit Four M20 mm joint bolts and nuts, using new lock-washers,
and tighten. torque value, 20-22 Kg .M. In case one bolt of M30
is used tighten the bolt at 30 Kg M.

6. Tighten the three M36 mm mounting bolts at specified torque.

SEE MACHINE DATA.

7. Top up gearcase with heated lubricant-use dipstick Tool

No.1405374 or maintain the level up to the oil filling cap level.

PROVISION OF REPLACEABLE COLLAR BUSHES IN GEAR

CASE LUGS OF MAGNET FRAME
On investigation it was observed that plain bush in gearcase lug was
used. It was also felt that sometimes it is difficult to weld the bush properly to
the lug and weld metal may project on I/D, damaging the surface.

IB-571- 70
MATERIAL REQUIRED:-
1. Dia 80x60 mm long forged bars to IS2004 class 4, machined as per the
FIG.06.

2. 3.5 mm dia Supratherme electrode of M/s D&H Secheron Ltd. Indore.

PROCEDURE:

1. Remove the tack weld of the plain bush with the help of
chisel and remove the bush from the holes at two locations.

2. Clean the holes for welding deposit etc. and deburr the holes.

3. Press fit the bush fig.06 in the hole item 001 at top and item 002
at bottom maintaining the alignment of machined collar with the
frame step.

4. Tack weld the bush at 4 places on the collar using electrodes as

mentioned in material required sl.No. 2 above. Care to be taken
that weld should not project above the collar.

IB-571- 71
IB-571- 72
 TRACTION MOTOR GEARS AND GEARCASE

GEARCASE
For the correct method of assembling, the gearcase and for the initial
application of lubricants to the gears. See ASSEMBLING THE GEARCASE
under MACHINE DISMANTLING AND REASSEMBLING.

See DATA for approved lubricants and quantities. The lubricant should
be heated to about 85 deg. Celsius to enable it to be poured. The gearcase
filler unit is in the bottom half of the gearcase and is accessible from the axle-side
of the motor.

During the first few weeks in service, check the level of lubricant every week
on several vehicles and, look generally for any sign of leakage. All checks
should be carried out with the gearcase warm after a run, but after allowing a
short period to settle the lubricant. Continue these weekly checks until the
lubricant level has fallen to the minimum permissible as batch of vehicles may
be used as a basis for the lubrication schedule, after allowing a safety margin to
ensure that the lubricant must last until the next examination. Thus, if the shortest
time interval two months specify topping up at months i n t e r v a l s .

EXAMINATION OF GEAR WHEEL

Whenever a gearcase is removed from a motor, examine the gears
carefully. They should be coated uniformly with lubricant which should show no
sign of being contaminated with dirt or water.

If the gears are to re-enter service immediately clean thoroughly using xylol
or a similar solvent applied with a brush. Wipe with a cloth after wares. If the
gearwheel is likely to stand for a time, clean only ten to twelve teeth spaced
equally round the periphery, leaving lubricant on the remainder of the
gearwheel as protection. After examination, if the condition of these cleaned
teeth is satisfactory, recoat them with lubricant.

The teeth should be free from cracks and the flanks should have a
uniform, unscored polished appearance. The tooth profile should be
substantially the same as that of a new gear. If a gearwheel has chipped
broken or badly worn teeth, discard it and fit a new gearwheel.

Ensure that, as far as possible gearwheels are returned to service with the
pinions with which they were meshed originally.
IB-571- 73
 Do not over fill the gear case which may flood the PE armature bearing
and cause premature bearing failure. Ensure that the gear case compound
is filled to the level of compound filling unit. Which is the maximum level.
Ensure also on no account, lubricant level goes below the minimum level.
Use dipstick 1405374 for maintaining minimum level.

Gear and pinion to be critically examined as below before allowing them

further for service.

PRECAUTIONS
Whenever a gear or pinion wears significantly there is “step” created near
the root of the tooth where the tip of the mating tooth runs out of engagement. If
the gear centre distance is exactly correct, this step will occur at the lowest point of
contact between the mating tooth. However the gear Centre distance cannot
be controlled exactly in service, due to axle bearing lining wear. As the gear centre
distance spreads, the teeth become further out of engagement this forms
“step” at varying depths.

If the same gearings are used there will be very severe tip leading of the tooth
and very poor profile at the root end of the tooth. This can cause severe noise,
vibration , and premature failure.

The step is to be dressed up with the help of small hand grinder,. Care
should be taken during the grinding operation not to under cut the tooth. Step
should be removed before checking the profile of the tooth by profile gauge
otherwise faulty readings will occur.

GEAR TOOTH WEAR

Gear tooth wear is measured by scaling the width of the land or tip of the
tooth.

The gear wheel and pinion should be removed from service when
width at tooth tip or maximum wear per flank measures less or more
respectively than the following limits.

GEAR WHEEL PINION

Min Tip Max. Wear per Min. Tip Max. wear per
width flank width flank

3.2 mm 3.2 mm 1.6 mm 1.6 mm

IB-571- 74
 Dimension “K” shown in Fig No.08 is to be checked at the specified
number of teeth on 8 different sets of teeth. In case the coverage dimension is
found less than the service limit indicated in fig.08 gear or pinion should not
be used.

PROFILE DEVIATION LIMIT

The maximum profile error on any worn gear wheel when checked by
a profile checking gauge should be within 0.2 mm to 0.4 mm.
Gears/Pinions having more deviation in profile than above should not be
used.

Feeler gauges of 0.05, 0.1, 0.15, 0.2, 0.25, 0.3 & 0.4 mm thickness
may be required for this purpose.

Profile checking gauges can be made as per the instructions given

below:(see fig. 07)

Instruction For Making Gear Teeth Profile Gauge.

(Using) A New gear as a pattern.

1. Be sure that the gear used as pattern is new. The gauge can only be as
accurate as the gear from which it is made. The gear should be thoroughly
cleaned before using as a pattern.
2. Make a “partial” mould as shown in Fig.07. The gear itself will complete the
mould.

3. Wax all surfaces which will receive the moulding compound with
silicone wax CP mould release. This material is made by the Chemical
Development Corporation, 54 Encicott St. Danvers, Mass U.S.A.

4. Lay the pinion or gear on a flat smooth waxed surface with the bore
vertical. If a table is not available, make a flat plate and clamp it to the side
of the gear or pinion.

NOTE:-

The pinions are made with tapered teeth-that is, the tooth is thicker
at the outboared (small bore) end than at the inboared (large bore) end.
Then pinion should be laid on the flat surface, with the outboared (small
bore) and face down. Thus the gauge will be moulded to fit the thicker
end of the tooth.
IB-571- 75
5. Place the partial mould in position against the tips of the teeth as
shown in sketch. Make sure that all surfaces that will contact the
moulding compound have been coated with wax as described
under sl.No.3 of the above. The partial mould and the pinion
should be clamped in position with “C” clamps to prevent anything
from disturbing their position during the hardening process.

IB-571- 76
IB-571- 77
LOCO PINION/ NO.OF NO. OF Dimension ‘K’ Service
GEAR TEETH TEETH
ON K

TM4939 PINION 18 3 82.093 MM MAX 80.366 MM

WAM4A 81.966 MM MIN
WCG-2

TM4906AZ GEAR 74 8 231.370 MM 227.87 MM

WDS-6 MAX 230.870
TM4907AZ MM MIN
WDG-2
165M PINION 18 3 88.722 MM MAX 86.995 MM
&TM4906AZ 88.595 MM MIN

WDM2, WDM2-C GEAR 65 7 224.030 MM 220.80 MM

WDP1, WDS-8 MAX 223.800
MM MIN

SERVICE

NOTE: MEASURE DIMENSION 'K' OVER THE SPECIFIED NO. OF

TEETH, AND NOTE THE AVERAGE VALUE OF 8 DIFFERENT
MEASUREMENTS BY A PLATE MICROMETER OF SUITABLE
SIZE.

MEASUREMENT OF WEAR ON GEAR TEETH

FIG. -08
IB-571- 78
6. Mix eleven (II) Parts of Ren Die Surface Coat RP-3260-B with one (I)
part of Ren Die surface Coat Hardner RP-3260-B by weight. These
materials can be obtained from Ren Plastic Inc. P.O. Box. 1256, Lansing
4 Michigan U.S.A. This is a modified epoxy resin which has a ‘pot life’ of
about 30 minutes at room temperature after the hardener is added.
Observe the precautions started on the can, especially avoiding any
contact with the skin.

7. Pour the thoroughly mixed resin into the mould until full. Allow the mould
to set for several hours, preferably 12 hours or more.

8. Remove the parts of the mould the pattern pinion or gear the partial
mould, and the plate. If one was used. Care should be taken to slide the
plastic off the end of the gear teeth, so as not to disturb the profile surface of
the newly moulded gauge.

9. Trim the rough moulded gauge to dimensions indicated by the dotted

lines shown in fig.07 The most critical surface and dimension “A”. To
the lowest point of contact on the gauge are shown. The trimmed
gauge can then be scribed as shown in fig.07 with pinion or gear
catalog number and number of teeth. The dimension “A” for the gear is
14.02 mm and for the pinion 19.33 mm.

IB-571- 79
 REMOVING AND FITTING PINIONS

REMOVING THE PINIONS

A groove is machined around the armature shaft extension within the
pinion seating and is connected by drilled holes tapped 1/4" B.S.P. in the
end face of shaft. These are provided for the removal of the pinion by oil
injection, oil under high pressure being supplied by the SKF oil pump.

The tapped hole in the shaft is sealed with a screwed plug to prevent
gear lubricant from entering and blocking the oil ways thus rendering the oil
injection difficult.

The tools required for removing the pinion are:-

Screw driver (large)
Pinion injection safety plate 1405379

Pinion positioning gauge 1405387

Using a solvent such as white spirit, remove all traces of gear lubricant
from the pinion, the shaft end, and the oil injection plug. Remove the plug
sealing the oil injection hole, using a large screw driver.

Remove any gear lubricant which may have found its way past the
plug.

Mount the pinion ejection safety plate 1405379 (item 1) onto the shaft,
allowing a gap of about 5 mm, for the removal of the pinion.

Assemble the S.K.F. pump and injector attachment tool no.1405981 fit
the high pressure pipe and fill the pump reservoir with clean oil. Fit the
reservoir to the pump. Do not fit the pump handle at this stage.

Open the pump relief valve and using the fingers, operate the pump
rapidly until air bubbles cease to be expelled with the oil. Close the relief
valve and again operate the pump handle socket with the fingers until the
system is full of oil and resistance to pumping is felt. Fit the pump handle
and continue pumping, raising the pressure gradually and pausing after
each stroke to let the pressure build up at the pinion seating. It will be
obvious when the pinion has ejected as a sharp crack will be heard as the
pinion hits the safety plate.
IB-571- 80
NOTE:-

The use of excessive pressure will cause the pinion to be ejected violently, it
may then rebound back of the special nut and reseat itself on the shaft, it
could also cause permanent distortion of the pinion bore. As the pressure is
built up and oil forces its way between the mating surfaces of the shaft and
pinion point is reached as at which oil will begin to seep out at the ends.
Should the pinion not have been released by the time this pressure has
been reached and maintained for approximately five minutes, release the
pressure and leave for 10-15 minutes before repeating the attempt. Repeat
the pumping up to pressure pausing releasing and waiting at least five times
and if the pinion still refuses to move. It is permissible to change the oil in the
pump for one of a grade heavier, before following the above.
Refit the plug in the oil injection hole immediately after removal of the
pinion to prevent the ingress of foreign matter. Protect the pinion bore and
shaft tapered end from damage and corrosion.

FITTING THE PINION

Examine the shaft taper and pinion bore for burrs or other superficial
damage. Trim any such defects with a fine oil stone and finish with very fine
emery cloth. Especially ensure that rectification extends to the position that
will be finally occupied by the pinion. Wipe clean the pinion and shaft taper.
Apply a thin even film of marking compound to the pinion bore. Pass
the pinion over the shaft to within 25.0 mm of its forward position and then
push it smartly home without the use of excessive forces. When the pinion is
withdrawn, evidence of bedding should be apparent over not less than 80%
of the area of the pinion seating.
If satisfactory marking is not obtained, the shaft or pinion should be
dressed with a fine stone to ease any high spots indicated by the marking
compound. Care should be taken that the dressing is applied only to the
defective surface. Clean the pinion bore and shaft extension and repeat the
bedding check.

If after repeating the bedding check several times, and light stoning still
fails to produce a satisfactory seating the shaft and pinion may be lightly
lapped using very fine emery paste.

Lapping, which shall be avoided wherever possible, is intended to

remove only small irregularities. Excessive lapping will produce steps
corresponding with the end faces of the pinion and the oil groove around the
IB-571- 81
shaft. These steps will cause incorrect seating when the pinion is advanced
to its final position.

Thoroughly clean the surface of the shaft including oil injection hole and
pinion using a solvent with degreasing properties such as white Spirit Wipe
dry using a clean dry cloth.

To establish the “cold” pinion position, pass the pinion onto the shaft,
and push it home without using excessive force. The desirable amount of
force, is such that the pinion seated thus, has sufficient Adhesion to allow it
to be used to rotate the armature. Mark a corresponding radial line on the
pinion and shaft end faces with chalk and measure with a depth micrometer
or vernier gauge the position of the pinion face in relation to the shaft end at
the chalk line and record this distance. The chalk line will facilitate the return
of the pinion to its original position, circumferentially in relation to the shaft.

IB-571- 82
APPLICATION OF R.C. COMPOUND:-
MATERIAL:

Special compound : For application on the shaft and pinion bore.

SOURCE OF SUPPLY:-

R C COMPOUND:

I. M/S NALCO CHEMICAL CO. Export Group, 1, Nalco centre, Naper

Ville 1160566-024, U.S.A.

INDIAN REPRESENTATIVE :

M/S NALCO CHEMICAL INDIA, C/O IEL Ltd., P.O.No. 107

Hamilton House, New Delhi 110 001.

II. M/S ALLCHEM Ltd., 1055, Trumen Street, P.B. 5002 L7 R3 Y9

Burlington, ONTARIO, CANADA.

III. BHEL, BHOPAL.

The special compound has short shelf life of 3 months and starts to gel. It
is, therefore, recommended that the date of manufacture/expiry may be
checked before use of the special compound.

PROCEDURE :
Clean and degrease the Pinion bore and shaft taper. It is necessary to
check that 90 percent bedding is achieved between pinion and shaft before
application of special compound. Also ensure that bedding on the shaft portions
up to 15 mm length at both ends of the taper (major and minor dia) is 90
percent. This will also avoid oil leakage problem during extraction of the pinion.
See Fig. 09.

After checking pinion bedding on the shaft as above and marking of pinion
on shaft in cold condition as explained in Maintenance Manual, apply special
compound on the shaft and pinion bore as detailed below.

Clean the shaft and pinion bore with dry cloth. Stir the compound
thoroughly.

IB-571- 83
IB-571- 84
 Apply a coat of compound with brush on the shaft and pinion bore.

Wipe clean the shaft and pinion bore with a dry lintless cloth or blotting
paper before the compound dries of its own to leave only a thin film on the
surface. Do not touch or allow any contamination of the treated surface.

Heat the pinion in an oven or induction heater and follow the pinion fitment
procedure as given in Maintenance Manual.

RECOMMENDATION :
Mount the pinion positioning gauge 1405387ontothe pinion, taking care
that there is 5.0 mm of clearance between the back of the setting tackle and the
pinion end bearing cap to allow for the advance of the pinion without fouling.
Adjust the setting screw, placing a gauge of the correct thickness between the
point of the screw and the shaft end.

Do not over tighten the setting screw against the gauge as this will give a
false position and the desired advance may not be achieved. Lock the setting
screw in position. Mark the position of Pinion on the shaft. Remove the pinion.

Heat the pinion (still with positioning tackle attached) in an oven providing
uniform heating. The oven should operate at a temperature approximately 20
deg. Celsius higher than that required for the pinion and must be constructed so
that the pinion is not in direct contact with the source of heat. Under no
circumstances must be oven temperature exceed 190 deg. Celsius.

Heat the pinion to a temperature such that the temperature difference

between shaft and pinion is 125 deg. Celsius. The time required to heat the
pinion to the required temperature depends upon the mass of the pinion and
the working temperature of the oven, but a heating time of 2 hours is
generally sufficient.

When the pinion and positioning tackle have reached the required
temperature, quickly transfer them to a position conveniently near to the shaft,
and carefully wipe the mating surfaces on the shaft and pinion with a clean dry
cloth. Place the pinion over the shaft end 25 mm from its final position, with the
chalk marks coincidental. Quickly press the pinion as far onto the shaft as the
setting screw on the positioning gauge will allow. Hold the pinion in position until it
cools sufficiently to grip the shaft, and then remove the positioning tackle.

Check the advance of the pinion at the marked position using a depth
micrometer or vernier gauge. The advance must be between the limits

IB-571- 85
specified i.e. 2.25 to 2.45 mm. If the advance is not within these values,
remove the pinion by oil injection verifying the temperature to obtain the
correct, advance. If the advance is correct, allow the pinion to cool. After cooling
again check and record the final pinion advance which should remain within
the specified range.

If a suitable oven is not available, the pinion may be heated in an oil bath, but all
traces of oil must be removed from the pinion before fitting. In such case, R.C.
compound should not be applied on the shaft & pinion bore. This may effect
the bonding quality of the compound.

Alternatively Pinion may be heated on induction heaters such that the

temperature at pinion bore does not increase more than 170 deg. Celsius
above ambient. The time required for heating the pinion will depend upon the
mass of pinion, generally 11 to 13 minutes may be required.

METHOD FOR REMOVAL OF TRACTION MOTOR PINION:

In some cases, difficulties are faced in removing the traction motor
pinion from shaft due to leakage of oil during extraction of pinion by oil
injection method.

MATERIAL & EQUIPMENT REQUIRED:

i) ‘M’ seal putty : for sealing the oil leakage.

ii) Hot Oil : for heating the pinion

iii) Oil injection Equipment (details given in Workshop Manual)

iv) Hydraulic Ram (details given in Workshop Manual)

PROCEDURE:- By Applying ‘M’ Seal Putty:

• Clean the face of the pinion & shaft with petrol or suitable cleaning
solvent.

• Wipe clean the pinion faces & shaft with dry cloth.

• Apply thick layer of ‘M’ seal putty on both side faces of the pinion
at the mating points of pinion bore periphery and shaft, to seal the
same.

• Allow the putty to cure at room temperature for 12 hours.

IB-571- 86
 • After the putty gets cured, heat the pinion slightly with the gas
torch.

• Extract the pinion with oil injection method which is explained in

Maintenance Manual.

• If oil still leaks out through ‘M’ seal putty, repeat the process as
per clauses 1 to 6.

BY HEATING THE PINION

1. Clean the faces of the pinion & shaft with petrol or suitable
cleaning solvent.

2. Apply Hydraulic Ram for pulling out the pinion.

3. While applying extraction force, pour hot oil (200 deg. Celsius
approx), over the pinion.
4. If the pinion is not getting extracted, apply oil pressure
simultaneously by using Oil Injection. For this purpose, a small
metallic spacer may be used in between shaft end and ram of the
puller so as to enable fitting of oil injection plug into the shaft.

RECOMMENDATIONS:
The procedure of pulling and heating the pinion may be resorted to only
after oil injection with ‘M’ seal fails repeatedly.

TRACTION MOTOR BEARINGS

ARMATURE BEARINGS

Both CE and PE armature bearing arrangement incorporate sealed

assemblies to prevent contamination of bearing grease from impurities,
there by necessitating lubrication during OVERHAULS only.
WORKSHOP MANUAL is give details of maintenance aspects on
armature bearings.
NOTE :- Care to be taken to record and store the bearings grouped as
per their identification. Specially CE side bearing lip is to be
stored along with corresponding Inner Race and Outer
Race, to avoid incorrect assembly.

IB-571- 87
PROCEDURE FOR ASSEMBLING OF DROP ROLLER CAGE
TYPE BEARING

INTRODUCTION :
Drop roller cage type bearings have also been successfully used on traction
motors. These bearing offer the following advantages:
- Larger shoulder diameter of the outer ring for easy mounting.
- Easier application of grease.
- Facilitating cleaning during inspections.
- Accurate examination of outer ring raceway possible.
It is pertinent to mention that these bearing have a cage which permits
the rollers to drop down towards the centre of the bearing. So, it is
necessary to use the bearing rollers guide to spread and guide the rollers up
over the inner race during the assembly of endshield on the shaft.
Considering the advantages of drop roller cage bearings, these have
been used o n a trial basis on traction motors like TM4907BZ.

PROCEDURE FOR BEARING ASSEMBLY:

Refer enclosed sketches:
.i Fig.10 For bearing roller guides.
ii. Fig.11 for CE & PE bearing assembly.

IB-571- 88
IB-571- 89
IB-571- 90
PINION END :

Shrinkfit bearing sleeve (item 2) tight against the end plate at the
temperature of 115 degree Celsius (+20/-0 degree Celsius), if it has
been removed earlier. Shrink fit flinger (29) by heating at 90 to 100 Deg.
Celsius actual temperature.
Heat the bearing inner race (item 3) at the temperature of 110 degree
Celsius, and shrink it on to the shaft tight against the flinger.
Fill the pocket of endshield with 600 gms. of grease and smear 15 gms.
of grease on labyrinth of endshield, bearing sleeve & bearing inner race.
Fit inner bearing cap (30)and fill pocket of IBC with 600 gms. Grease.
Grease outer race track with 20 gms. of grease, assembly rollers in
outer race. Press the bearing outer race and rollers (item 5) tight against the
housing of endshield (item 4).
Force 50 gms. of grease into the spaces between the rollers, cage &
outer race track at the back of the bearing.
Now, install the bearing roller guide (fig. 10 item 1) on to the shaft as
shown in the sketch to facilitate assembly of drop roller bearing.
Slide the endshield with the bearing in position on the shaft through the
bearing roller guide.
Remove the bearing roller guide from shaft.
Fill 300 gms. of grease in outer bearing cap & smear 30 gms. of grease
on labyrinth of outer bearing cap.
Assemble outer bearing cap on the endshield.
Fit the bearing retaining collar (item 7) on to the shaft by shrinking at
the temperature of 115 deg. Celsius (+20/-0 degree Celsius). When cold,
tap the bearing collar with light hammer & copper drift to ensure that it is
solidly butted against the bearing inner race.
After assembly of outer bearing cap to the endshield, secure them with
suitable bolts & lock washers (item 8).
Tighten the bolts at specified torque.
COMMUTATOR END:
Locking typeroller bearing is used on commutator end.

IB-571- 91
 BRUSHGEAR

Removing brushgear from traction motor

To remove the brushgear from the traction motor, proceed as follows:

1. Lift the brushes and insert clean presspaper between the brush-
holders and commutator.

2. Disconnect the brush flexible and remove the brushes.

3. Remove the clamp bolt and clamp plate securing the brush
holder to the frame. On the top brush holder the clamp bolt is
accessible through the top commutator opening on the axle side
brush-holder it is accessible through the bottom axle side
inspection opening and on the bottom and nose side brush-
holders the bolts accessible through the bottom nose side
inspection opening.

4. Working through the inspection opening push the brush-holder

as far as it will go towards the commutator endshield in order to
obtain better access to the bolts securing the cable to the holders.
Direct access to the bolts on the bottom holder can be obtained
through the bottom axle side inspection opening. Remove the
bolts and withdraw the top brush-holder through the top
commutator opening. Withdraw the nose side and bottom
holders through the bottom nose side inspection opening and
withdraw the axle side holder through the bottom axle side
inspection opening.

BRUSH HOLDERS:
1. Remove the brush holders from the magnet frame and
thoroughly clean them.

2. Inspect each brush holder for damage and recondition it as

necessary. Check the condition of the springs and check the
spring tension.

3. Check the clearance between a new carbon brush and the brush
box. If the clearance is excessive discard the brush holder. If the
brushes are sticking recondition as necessary.

IB-571- 92
PTFE INSPECTION.
1. Brush holder support pins have been covered with PTFE
(polytertra fluoroethylene) insulators to facilitate periodic cleaning.
Clean the PTFE surface by wiping a clean dry cloth. Do not
paint the insulators or wash in water.

2. For fitting new insulator remove the defective insulator and clean the
surface to the support pin with fine glass paper to remove any
carbon deposits and surface i r r e g u l a r i t i e s .

3. Check the support pin insulator resistance. If this is lower than 40

megohms dry out the insulation by baking at 90 deg. Celsius
apply a high voltage test see DATA. Discard he pin w hic h fails
this test.

4. Heat the insulator to about 150 deg. Celsius in an oven having

proper exhaust ventilation and then press it over the support pin.

NOTE:
Extreme care should be taken when heating PTFE, since at about 200
deg. Celsius PTFE starts to release colourless and odourless gases which
are poisonous. Do not burn scrap PTFE insulator or pieces. Take
precaution to protect personnel in areas where PTFE dust may be
produced by grinding or machining operations.

ELIMINATION/REMOVAL OF COPPER SHUNT FROM

BRUSH HOLDER SPRING ASSEMBLY
The copper shunt fixing screws from brush holder are fitting loose
falling in service. As the use of rubber top carbon brushes have been
regularized , copper shunt along with the spring is no more required.

PROCEDURE:
As and when the motor comes to Diesel loco shed for POH or for
repair.

- All the brush holders are to be removed from the motor.

IB-571- 93
 - Lift the spring and rest it onto the resting pin.

- Remove hexagonal screws M8 size from brush holder fitted to

the copper shunt.

- Cut the other end of copper shunt with scissors knife keeping its
terminal rivetted with the spring.

- Replace the spring on to its position.

PRECAUTION

Cut the copper shunt near the terminal.

Copper shunt is not required in case the spring is replaced by new one.

IB-571- 94
 MOTOR SUSPENSION UNIT

DESCRIPTION AND OPERATION (REFER FIGS.12 & 13)

FOR TM4907BZ TRACTION MOTOR
- The axle suspension tube (traction motor suspension bearing) (7) is
made from cast steel, of one integral part, and at the both ends
tapered roller bearing housings are formed.
- At the opening side of the U-type section of the suspension tube (7),
there is a machined flange which serves as the mounting surface
to the magnet frame. (Refer fig.12)
- The upper flange of suspension tube (7) is mounted to the
magnet frame with 4 hex, head bolts (14)
- The lower flange of suspension tube is mounted in a slot provided
in the magnet frame, is secured with 4 hex. head bolts (14)
- The hex. head bolts (14) are tightened with spring washers (15),
and the heads of the bolts (14) are locked with wire.
- Tapered roller bearings (TIMKEN) (5) & (8) are used at both sides
of tube.
- The outer race of gear side bearing (8) is fitted directly into the bearing
housing or suspension tube, whereas the outer race of the opposite-
side bearing (5) is fitted into a separate cartridge bearing housing (3) for
adjusting the axle distance.
- The inner races of both gear and opposite-side bearings are f i t t e d
to the axle.
- Adjustment of axial distance is accomplished by varying the
thickness of split-type adjustment washer (4).
- The split-type adjustment washer (4) are locked between the flange
of suspension tube and bearing housing (3).
- The suspension bearings(5)& (8) are lubricated with grease.
- Grease is supplied through a grease nipple (6) fitted to the suspension
tube (7) by a grease pump.

IB-571- 95
IB-571- 96
IB-571- 97
- BEARING INFORMATION
Axle suspension tube:-
Roller bearings: Non-gear wheel side Gear wheel side
Manufacturer: TIMKEN TIMKEN

Tapered roller Cone Tapered roller

Type: M349547 Cup Cone M249747
M349510 Cup M249710

FAULT FINDING

1 CRACKED SUSPENSION BEARING HOUSING

a. During wheel changes, suspension bearing housing should be

carefully checked visually for cracks and found replaced.

2 LOOSE SECURING BOLTS

a Securing bolts should be checked to ensure that their tightness

conforms to the required torque value as per table. (Page
No.IB-572-83).

3 FAILURE OF BEARINGS (SEIZED)

a It is not possible to check bearings in condition of assembly.

b Touch the hand to outside of suspension tube, and check

temperature of bearing, just behind operating the locomotive. If
found abnormal temperature, change out it’s suspension unit.

IB-571- 98
 MOTOR SUSPENSION UNIT FOR TM4907BZ
(SEE FIG. 12 & 13)
ITEM DESCRIPTION
1. ABUTMENT PIECE.
2. END COVER (ROAD WHEEL END).
3. BEARING HOUSING.
4. ADJUSTMENT WASHER.
5. TAPERED ROLLER BEARING ASSEMBLY.
6. GREASE NIPPLE.
7. TUBE.
8. TAPERED ROLLER BEARING ASSEMBLY.
9. ENCLOSURE.
10. END COVER (GEAR WHEEL END).
11. SOCKET HD.CAP SCREW M10x30LG.
12. SOCKET HD.CAP SCREW M12x90 LG.
13. SOCKET HD.CAP SCREW M12x70 LG.
14. BOLT.
15. SPRING WASHER.

MAINTENANCE PRACTICES

1 REMOVAL / INSTALLATION.

a. Removal / Installation of suspension bearing unit can only be

undertaken during dismantling/assembling of wheel pairs.

2 SERVICING

a. Lubrication information for axle suspension bearings.

IB-571- 99
 Non-gear wheel side Gear wheel side

First fill lubricant: Shell Alvania No.3 Shell Al.no.3

Manufacturer: Shell Oil Co. Shell Oil co.
Quantity used for 600 gr. 1250 gr.
first fill:
Replenishment period: Annual Annual
Replenishment qty.: 150 gr. 250 gr.

3 ADJUSTMENT/CHECKING

a. In the maintenance checking of suspension bearings and

unit, listen for any abnormal noise from the unit.

b. Check the bearing temperature, in accordance to touch

the outside of bearing housing of suspension tube.

c. Also check for loose securing bolts to prevent unnecessary

problems.

- The suspension unit is secured to the magnet frame with

bolts. The bolts may slacken from time to time. Regularly
retighten these bolts.

d. Perform the following checks.

- Check the tightness of the suspension tube mounting

bolts with using the torque wrench. If found loose,
retighten to correct torque value.(See torque value table)

- Check suspension tube for cracks.

- Check the condition of bolts, wire locking and washers, replace

the damaged bolts and washers.

Check the tightness of all socket head screw on the axle

suspension unit.

e. The following table is to be worked to for the correct torque

values:

IB-571- 100
 TORQUE VALUE TABLE
Insulating Torque value in kg-cm
Bolt size Standard Maximum

M36 12100 14500

M12 418 503

M10 245 295

OVERHAUL PROCEDURES

1. DISASSEMBLY

Axle suspension bearings are disassembled after dismantle the

Non-gear wheel of non gearside. Disassembly procedures are as
follows:

a. Withdrawal of abutment piece

b. Removal of cover (Non-gear wheel end)

c. Removal of adjusting washers

d. Removal all securing bolts

e. Dismantling the suspension tube

f. Removal of gear wheel end bearing cone.

2 WITHDRAWAL OF ABUTMENT PIECE

- To withdrawal the abutment piece (1), use the special Tools No.
1405573.

- Remove the abutment piece (1), by special tool.

3 REMOVAL OF COVER (Non-gear wheel end)

- Remove all securing bolt (13) and cover (2) from end of
suspension tube (7).

IB-571- 101
 4 Removal of Adjusting Washer (4)

- Remove the sealant on the outer surface of suspension tube

and cover, and two joints of adjusting washer could be found
out.

- Insert the chisel into clearances of joints and draw out the
adjusting washers (4).

5 Removal All Securing Bolts

- Remove all securing bolts (12) of cover (10)

6 Dismantling the Suspension Tube.

- Withdraw the suspension tube (7) from axle by withdrawal

equipment as shown in Tool No.1405574.

Road wheel end bearing inner race (cone) can be pulled out
with the suspension tube (7).

CAUTION: THE ADJUSTING WASHERS (4) SHOULD BE REMOVED

FROM SUSPENSION TUBE (7). BEFORE WITHDRAWAL
OF SUSPENSION TUBE

IF THE SUSPENSION TUBE (7) WAS WITHDRAWN AS

ASSEMBLING THE ADJUSTING WASHER (4), THE
BEARING WILL MAKE ANY DAMAGES.

7 Removal of Gear Wheel End Bearing Cone

- Remove the bearing cone (8) by bearing puller. Tool

No.1405575.

8 Pull out the bearing cup (8) from the suspension tube (7) by
bearing puller as shown in Tool No. 1405576.

9 Dismantle the bearing housing (3) from the suspension tube (7)
as a shown in Tool No. 1405577.

10 Pull out the bearing cup (5) from the bearing housing (3) as
shown in Tool No. 1405578

IB-571- 102
CLEANING:

- CLEANING AXLE SUSPENSION BEARINGS

When cleaning the axle suspension bearings, put them into a

container with Orion 77 heated up to about 60 deg. Celsius,
without degreasing, and leave them for more than 10 minutes to
remove excess grease. Then, blow away sticking grease with
compressed air. Repeat this procedure a few times, after which
the bearings are finally washed with clean Orion 77 at normal
temperature.

Dry with compressed air. When handling the bearing after the final
washing, make sure hands are cleaned with such degreasing
agent as ethyl alcohol to prevent the bearing from getting rusty.

- CLEANING OF OTHER PARTS

Soak the dismantled parts such as the suspension tube, covers

and bearing housing in Orion 77 for more than 30 minutes to
remove grease. Wash out remaining grease by brushing in it.
Then, take these parts from the Orion 77 container and blow away
Orion 77 with compressed air.

- WIPING.

Wipe insulating bolts and insulating washers with waste cloth

Orion 77 soaked.

CHECKING:
- Inspect visually appearances of the axle suspension tube, the
covers and so on for damages or rust or cracks.

- Check the axle suspension tube by liquid penetrate checking for

cracks.

- Measurement of dimensions

- Axle suspension tube

IB-571- 103
a. Inner diameter of installation portions for bearing

Non-gear end: Min. 375.000 / Max. 375.057 mm

Gear end: Min. 358.775 / Max. 358.825 mm

b. Bearing housing (ZC141003) of non-gear end

Outer diameter: Min. 375.004 / Max. 375.040 mm

I n n e r d i a m e t e r : Min. 342.850 / Max. 342.900 mm

c. Tapered roller bearings (Timken type bearing)

- NON-GEAR END BEARING

Inner diameter of cone (Cone No. M349547):

Min. 255.6002/ Max. 255.6256mm

Outer diameter of cup (Cup No. M349510):

Min. 342.9000/ Max. 342.9508 mm

Inner race/Cone bearing width: 63.5 mm

- GEAR END BEARING

Inner diameter of cone (cone No.M249747):

Min. dia. 257.175mm/Max.dia.257.2004mm.

Outer diameter of cone (cup No.M249710):

Min dia. 358.775 mm/Max.dia.358.8258mm.

Inner race (cone) width : 76.2mm.

d. Abutment piece

Inner diameter : 253.957 mm (Min.)

: 254.000 mm (Max.)

Width: 47.8 mm (min.) : 48.2 mm (Max.)

IB-571- 104
e. Dimensions of mounting flanges of axle suspension tube Fig.
14.

SYMBOL DIMENSION

A = 282+ 0.052mm + 0.020mm

H = 35 + 0.1 mm + 0 mm

REASSEMBLING
1. GENERAL INFORMATION

(a) HEATING BEARINGS AND COMPONENTS FOR ASSEMBLY

Electric ovens or electrically heated oil baths can be used but

these should have thermostatic control. Where oil is heated in a
pan or metal container over an open flame, there should be a
screen on which the bearings will rest which is raised 25 mm or
so from the bottom of the pan. The bearings should not rest on
the bottom of the pan as the heat will be transferred directly
from the flame through the pan to the bearing. This temperature
will be very high and will draw the bearing.

If an induction heater is used, care should be exercised to

prevent residual magnetism affecting the bearing material.

IB-571- 105
(b) ASSEMBLY METHODS

Drivers and sleeves will assure easier assembly and prevent

damage to bearing components.

If drivers are not available, mild steel bars can be used. Use
only mild steel, not hardened drifts or brass bars. The
hardened bars will damage the bearing and brass will chip
easily. On no account should a copper or brass-faced hammer
be used during assembly of bearing parts.

(c) STORAGE

Completed wheel sets must be protected against the entry of

water or foreign matter into the bearing housings.

For short-term storage the wheel sets should be kept in a

covered building. Machined surfaces should be coated with a
suitable rust preventative.

If the wheel sets are stored outside, the tube should be turned
so that the open portion is on the lower side and wedged in
position. The assembly should be covered with waterproof
sheets for further protection and again, the machined surfaces
should be coated with a suitable rust preventative.

2. ASSEMBLING PROCEDURE OF MOTOR SUSPENSION UNIT:

(a) Fit the gear wheel in the correct position on the axle.

(b) Check that the face of the gear wheel is square to the axle
within 0.05 mm on the face adjacent to the gear wheel end
bearing. This can be done by putting the axle in a lathe
between centre and checking run-out with a dial indicator. If the
face runs out more than the prescribed 0.05 mm, correct this
by machining. FIG.-15.

After fitting the gear wheel, check the dimension of part of dia
320 +0.113/+0.051 and correct with specified tolerance by
machining. Fig.-15

(c) The axle should now be placed in a vertical position with the
gear wheel at the bottom with the enclosure (Item 9) in position
making sure that all enclosure grooves are free from dirt and
swarf. FIG.-16.
IB-571- 106
 (d) Clean thoroughly the suspension tube (7), making sure that
all holes are free from dirt and swarf and tighten the bolt (Item 11) to
the gear wheel. Apply “THREE BOND screw lock super No.1303” or
loctite ‘270’ to bolt (IT.11). It numbers referred to in Fig.-12 & 13.

(e) Clean thoroughly covers (IT.2&10) abutment piece (IT.1).

Space washer (IT.4) cup holder Bearing housing (IT.3). Unwrap one
bearing M249747-M249710 and one bearing M349547-
M349510.(Fig.-25)

(f) Place the two bearing cone assemblies in a tank of oil or dry
oven heated to 120 deg. Celsius (See General
information Section )

NOTE : Cone assembly M249747 will be required first for

assembly and should be suitably positioned in the
hearting tank or oven. The minimum heating time is ten
minutes and during this time operations g, h and i can be
carried out.

(g) Stand the tube on end, gear wheel end uppermost and fit
the gear wheel and cup M249710 into the tube Item 7.
The cup is a tight fit in the tube (7) and should be fitted
IB-571- 107
 as follows:

* Coat the tube cup bore with a light mineral oil.

* Place the bearing cup in the tube, (Fig.17) back-face (broad-

face) down.

IB-571- 108
 FTG. - 18

FIG. - 19
* that the bearing cup in fitted squarely, top the cup driver near to
the cover edge and around its circumference units the bearing
cup is correctly seated against the abutment shoulder.

* Check that the cup is fully seated against its abutment shoulder

IB-571- 109
 using a feeler gauge of 0.05 mm thickness. The gauge must
not enter between the faces of the cup and abutment of the
tube (fig 18).

(h) Fit cup M349510 into the Bearing Housing (It.3) in a similar
manner.

(i) Thread the end cover(It.10) over the axle and place in position.

NOTE: Ensure that the cover is correctly positioned to form the

labyrinth seals.

(j) Remove cone assembly M249747 from the heater and enter
squarely over the axle and into position against the gearwheel face.
Oil bath temperature of 120 deg. Celsius must be strictly
maintained.
NOTE : Ensure that the back-face (broad-face) of the cone is
against the gearwheel bearing face. Use a clean assembly sleeve
to tap down the cone as it cools, ensuring that the cone is properly
seated. Remove the sleeve when the cone is fully cooled fig.-20.

Check that the cone assembly is a abutted against the gear wheel.
Then apply grease by hand and press that grease to fill the inner
spaces within the cage of bearing, and ensure adequate grease to
bottom roller ends, take into consideration that total amount of
grease in filling tube and pump up in 1250 grammes into gear
wheel end bearing on completion of total assembly.

Dimensions of a suitable sleeve are indicated on TIMKEN (Fig. 25).

FIG. - 20
IB-571- 110
(k) With suitable lifting tackle, thread the suspension tube (Gear wheel
and leading) over the axle and position on the cone assembly
engaging the cover,(IT.10) on the tube FIG.- 21.
(l) Fit the eight cover bolts (IT.12) and torque to 418 Kg. Cm. Rotate
the tube to ensure that bearing rollers are correctly seated against
the cone thrust rib and also to ensure that there is no fouling of the
cover (It.10) and gear wheel.
(m) Fit the bearing Housing (IT.3) with cup M349510 fitted, into the
tube and fit the split master spacer.(It. 10).
(n) Remove bearing cone assembly M349547 from the heater and fit in
the correct position on the axle. Follow immediately with the
assembly sleeve (FIG.-21) as used previously. Do not tap down,
but rotate the tube as the cone cools, allow to fully cool and remove
the assembly sleeve.
Then apply grease by hand and press the grease to fill the inner
space within the cage of bearing and around the thrust face (i.e.
top ends) of the rollers. Take into the consideration that total
amount of grease in filling tube and pump up to 600 grms in to non
gear wheel end bearing on completion of total assembly.

FIG. - 21

(o) Fit the cover (Item 2) and cover bolts (Item 13) and tighten to clamp
the cup holder master spacer, and cover and tube together. Check
that no gap exists between the faces by use of a 0.05 mm gauge.

(p) Place the abutment piece (IT.1) into position against the back face
IB-571- 111
 of cone assembly.

(q) Remove cover bolts (it.13) and with draw the two halves of the split
master spacer.

If necessary use two M10 x 50 mm jacking off screws in holes

provided in the tube to loosen the spacer by applying thrust on cup
holder flange remove jacking off screws.

(r) Fit non gear wheel on to the axle. The inner face of the wheel must
contact the outer face of the abutment piece (it.1). Any inward
movement of the abutment piece due to fitting the wheel should be
restricted to a maximum of 3mm. If movement exceeds this, the
wheel should be removed. The bearing cone and abutment piece
should be withdrawn and refitted according to the assembly
procedure (K to P inclusive).

FIG. - 22

IB-571- 112
FIG. - 23

(s) It is expected that the normal 12mm spacer will be reduced by a

small amount when the wheel is fitted (Ref.’r’). To assist the
measurement of the final end play in the assembly it is
recommended that two split secondary master spacers are
produced, one 11mm ±0.025 and one 10mm ±0.025 thick. The
actual thickness of the secondary master spacer to be marked on
each half.

After the wheel fitted, position thickest possible secondary master

spacer into the gap, refit the end of coller and screws and tighten
sufficiently to clamp all pieces together. Check that no gap exists
between the faces by use of a 0.05mm gauge.

(t) Check the lateral play in the assembly according to the instructions
given under Reference ‘u’. If the measured end play is above 0.25,
then a thicker adjustment washer will be required.

EXAMPLE:
End play required 0.15 to 0.25 Aim 0.2
IB-571- 113
Master spacer thickness 11.000 mm
Measured end play 0.275 mm
Required end play (Aim) 0.2 mm
Actual thickness end play is less than 0.05 then a thinner adjustment
washer is required.
EXAMPLE:
Master spacer thickness 11.00 mm
Measured end play 0.02 mm
Required end play (Aim) 0.2 mm
Actual thickness of adjustment washer - 11 + (0.02 - 0.2) = 10.82

After determining the correct adjustment washer size, manufacture

a washer to the correct size and tolerance. Remove the secondary
master spacer from the assembly and fit actual adjustment washer
required. Complete the assembly according to Reference ‘u’.

u) The end play in the final assembly must be checked before the
wheel set is released for service. Fix a Dial Indicator on to the tube
with the stem contacting the wheel. Using levers, apply even loads
to move the tube in one direction and then the opposite direction.
Note the readings from the dial indicator which should be between
0.15 mm and 0.25 mm. Any measurement outside this tolerance
must be corrected by applying a narrower or wide adjustment
washer as required.

FIG. - 24

IB-571- 114
v) Grease nipples (Item 6) may be fitted if standard push-on grease
connectors are used for lubrication, but it is easier for the initial
filling to be by an adaptor screwed into the tapped holes with the
grease nipples fitted afterwards.

w) Pump grease into the Non-gear wheel end bearing housing until a
witness of grease is visible around the enclosure (approximately
600g).
x) Fill the gearwheel end bearing housing with approximately 1.25 kg
of grease.
The tube should be oscillated whilst filling with grease to ensure an
even distribution around the bearing.
The lubricant used should be a approved No. 3 consistency lithium
soap based grease.
The assembly procedure for the motor suspension unit is now
complete.
The final operation to complete the wheel set assembly is to fit the
gear end non gear wheel (Fig.-23) to gauge.
(y) Disassembly and withdrawal procedure
Item numbers referred are those on as per fig.12. Unless otherwise
stated.

(z) NON-GEAR WHEEL END BEARING REMOVAL

* Remove the journal axle box from the non-gear wheel end of
the axle.
* Remove the non-gear wheel from the axle at the non-gear
wheel end.
* Remove all cover bolts (Item 12 and 13) from each end of the
tube.
* Remove non-gear wheel end cover (Item 2).
* Remove split adjustment spacer (Item 4).
* To withdraw the abutment piece (Item1) and the non-gear
wheel end bearing, fit withdrawal blocks and rods to the flange
of the tube and cross block. Fit the axle end protector and apply
pressure through the hydraulic ram as shown in Tool No.
1405574.
* Should the gearwheel end bearing cone (inner race) required
IB-571- 115
removing, it may be achieved by removing the gearwheel. This
bearing can then be pushed off using the axle Tool Nos.
1405573, 1405574, 1405575, 1405576, 1405577, 1405578.

IB-571- 116
IB-571- 117