S 15 – 02d engl.

SERVICE and MAINTENANCE

INSTRUCTION
for AXLE BEARINGS
with
STUB AXLE Ø = 120 mm
 Copyright © Plasser & Theurer
All rights reserved, particularly the right to produce copies, to distribute these copies, as
well to translate the work. Without written consent of Plasser & Theurer no part of this work
may be reproduced in any form (photocopy, microfilm or other methods) or stored,
processed, copied or distributed with the help of electronic systems.
 S 15 – 02d 1

SERVICE INSTRUCTIONS FOR WHEELSET AXLE BEARINGS

This instruction replaces the Service Instruction S 15-01.

The new service instruction S 15-02 contains a changed time interval of bearing
replacement.

Safeguarding of operational security is he top priority for any support vehicles

maintenance measures.

After any operating accident (e. g. after derailment, collision, etc.) the
corresponding checks and measures are MANDATORY. Due to the special tasks
and often extreme operating conditions and high stress of permanent-way
machinery the manufacturer prescribes servicing and service intervals that may
differ from the usual railway rules for on-rail vehicles. In case the respective railway
administrations apply stricter rules, these must be followed and observed.

Any assembly, service and repair works of wheelsets may be carried out only in
specialized workshops with the necessary equipment and only by trained and
authorized personnel.

PERIODICAL SERVICE WORKS:

DAILY:
For safety reasons the due condition of the machine has to be checked
before each travel.
Check the working temperature of bearings at the axle bearing housings.
In case the temperature of one of the axle bearings is considerably higher
than the others, find out the reason. A visible change in colour of the axle
bearing bodies or grease running out are distinct signs of a bearing run
hot!
The respective measures have to be taken immediately.
2 S 15 – 02d

MONTHLY:
Visual check for wear, damage, deformation, breakage, cracks etc.

¾ tynes
¾ axle bearing guides
¾ springs
¾ spring pins
¾ shackles
¾ brakes
¾ torque converter bearing
¾ axle gearbox drive clutch
¾ cardan shafts
¾ axle support

Lubrication:

¾ clean and grease axle bearing guides

¾ lubricate spring pins (of coil springs)
¾ lubricate dirt scraper of axle gearboxes
¾ check oil level of axle gearboxes
¾ clutches and cardan shafts

All other service works have to be carried out in accordance with the machine
service instruction.
 S 15 – 02d 3

ANNUALLY

Check the bearings:

For this check it is necessary to dismantle the axle bearings.
Afterwards the following checks have to be carried out:

¾ Condition of the grease filling:

Burnt grease and / or metal particles are a certain sign of a defective
bearing.

¾ Condition of the internal bearing race:

The raceways must be smooth (without grooves, pressure marks,
notches, fissures etc.)

¾ Seat of the internal bearing races:

The internal bearing races must fit tightly on the axle journal. The
internal wearing ring and the intermediary ring must not move, as well.

¾ Condition of the external parts of the roller bearings:

The roller surfaces must be smooth, without flats, notches or other
defects, they must not show any marks of overheating (dark colour).
The roller cages must not have any cracks, broken off parts or loose
rivets.

Note:
In case bearing elements show rust marks it may be supposed that water
or aggressive cleansing agents got in or unsuitable lubricants were used.

Whenever such kinds of damage are discovered, the

bearings and probably other defective parts of the axle
bearings have to be replaced immediately.
Both roller bearings of an axle bearing box must be replaced
by new ones.
4 S 15 – 02d

Before checking the axle bearings, the machine has to be secured in accordance
with the strictest safety standard.
¾ To check the bearing unscrew the
screws of the bearing cover.

FAG 05

¾ Remove the bearing cover carefully.

FAG 06
 S 15 – 02d 5

¾ The photograph shows the removed

bearing cover.

FAG 08

¾ Open the screw retention device (safety

plate).

FAG 12

¾ Unscrew the screws.

FAG 13
6 S 15 – 02d

¾ Dismantle the safety plate.

FAG 14

¾ Now remove the axle bearing box and

check it.

FAG 21

FAG 22

Note:
At the time the illustrations were compiled, DEA CARON 2 was still in use, the FUCHS
WHEELSET ROLLER BEARING GREASE DPFV currently used for new greasing is of
dark brown colour, as opposed to the DEA Caron 2 (refer to technical data sheet FUCHS
WHEELSET ROLLER BEARING GREASE GPFV)
 S 15 – 02d 7

¾ Now you can see the internal bearing

races.

FAG 20

¾ After a due check and cleaning of all accessories by an authorized specialized

workshop the bearings and bearing boxes have to be re-assembled.

¾ Note: to secure the screws (observe the necessary tightening moment of the screws,
refer to page 13) a new safety plate must be used.

¾ When re-assembling the axle bearing boxes make sure that their pairing corresponds
with the original pairing. Assembling the bearings in reverse pairs (interior and external
races) may lead to damage!

¾ Before assembling the bearings, remove any metal chips, dirt and grease residues
from centering locations and thread bores of the axle journals.

¾ If necessary, demagnetize the axle before assembling the bearings.

¾ When the bearings and their accessories

are in faultless condition and have been
cleaned duly, fill the specified grease
“FUCHS Radsatzrollenlagerfett GPFV”
into the bearing and the bearing housing
(grease quantity and specification – refer
to page 13).

FAG 16
8 S 15 – 02d

¾ The bearing must be duly greased.

FAG 18

The following components must also be checked:

™ Check the efficiency of the shock absorbers.

™ Full floating axles: check the condition and smooth running of the
pendulum suspension.

™ Bogie pivot pin: check the condition and the smooth running of the bogie
pivot pin and the center bearing.

™ Springs: check the condition and efficiency of all springs and supports.
 S 15 – 02d 9

REPLACING THE AXLE BEARINGS

The axle bearings mentioned here are to be replaced in intervals of 6

years at the latest. Difficult operating conditions as well as higher work
output and high mileage might be the reason for shorter intervals. If,
however, the local railway infrastructure organization prescribes
stricter directives, these, of course, have to be observed.

The following criteria have to be applied:

¾ Immediate measures in case of overheating or accidents.

¾ Results of checks carried out according to this instruction.

¾ Rules and measures of the respective railway administration or the

authorizing board.

When replacing bearings, pay attention to the following:

After having removed both bearing races, check the stub:

¾ If it is in good condition, new bearings may be mounted.

¾ If it shows stripes or is shrunk at the seat, the axle must be replaced as

well.

¾ Measure the seats of the bearings with the help of a micrometer gauge
to check their diameter and to find out possible defects of form. If they
are oversized, they must be dressed, if undersized, this axle must NOT
be used any longer.
Note: micrometer screws, gauge blocks and axles must have the same
ambient temperature.

¾ After having dismantled the axle bearing box and the bearings, the
axles and wheels have to be checked for thruth of running. A deformed
axle may lead to oscillating movements because of radial deviations,
the irregular load distribution resulting from it may cause premature
bearing damage.
10 S 15 – 02d

IMPORTANT INFORMATION!

The face of the axle journal may show a marking on the slackness of the roller
bearings (C3 or C4). If so, consider the following:

Never
¾ mount C3 roller bearings on a C4 axle,
¾ mount C4 roller bearings on a C3 axle,
¾ mount C4 roller bearings on an unmarked axle.

NOTE: USE ORIGINAL ROLLER BEARINGS ONLY!

 S 15 – 02d 11

How to assemble an axle bearing with stub axle diameter Ø 120 mm

Components of the axle bearing:

1 = axle
2 = bearing box
3 = intermediate ring
4 = interior cylindrical roller bearing
5 = external cylinder roller bearing
6 = wear ring of the bearing, item 5
7 = screws
8 = safety plate
9 = disk
10 = bearing cover
11 = screws and lock washers
12 = back-up ring
13 = felt strip
14 = labyrinth seal

The item numbers and order numbers are given in the spare parts catalogue.
12 S 15 – 02d

Assembly of bearings Ø120 mm:

Note: the bearings must be marked

¾ At all events protect the bearings from dirt and humidity. The assembly
place must be dry and free from dirt. The assembly place must not be
close to grinding machines. Avoid the use of compressed air. The axle
stub as well as the bearing box must be clean.

¾ Carry the back-up ring (item 12), the internal race of item 4, the
intermediate ring, item 3, and the external race of item 5 to a
temperature of max. 120 C (e. g.: oil bath, mineral oil with a viscosity
of V50 = 8 – 10 E and a flashing point of more than 250 ºC, but under
no circumstances a flame). Note: before assembling the heated up
bearing elements let them drop. Oil must be wiped off all fitting
surfaces. Use appropriate gloves!

¾ Fit the heated up back-up ring (item 12) in accordance with the drawing
tightly onto the axle stub by using an assembly bush. Remove the
assembly bush after the back-up ring, item 12, has cooled down.

¾ Fit the heated interior race of item 4 with hoop with the correct surface
forward on the axle journal.

¾ The next move is to push the heated intermediate ring (item 3) onto the
axle journal.

¾ Fit the heated external race, item 5, on the axle journal, so that the
bevelled surfaced will fit together. (Note: push the interior races onto
the axle journal by exerting a screwing movement).

¾ Strike the interior race with the help of a suitable striking tool.

¾ Soak the felt strip (item 13) with oil (oil temperature – max. 40ºC) and
insert it in the labyrinth seal (item 14). When inserting the felt strip
make sure that the fibres are directed radially.
 S 15 – 02d 13

¾ Insert the labyrinth seal in the bearing box with the correct surface
forward.

¾ Insert the outer race with roller ring of the inner cylindrical roller
bearing, item 4, in the bearing box. Make sure that the mark of the
outer race points to the labyrinth seal.

¾ Insert the outer race with roller ring of the outer cylindrical roller
bearing, item 5, in the bearing box. Make sure that the mark of the
outer race now points outward.

¾ Fill the free spaces between rolling elements and the bearing cages up
to 80% with grease. Fill the space between rear bearing and labyrinth
seal up to about 1/3 with grease. As a whole the bearing has to be
greased with about 250 g of FUCHS Radsatzrollenlagerfett GPFV
wheel set roller bearing grease.

¾ Push the bearing box on to the axle journal with the labyrinth seal in
the bearing box pointing to the back-up ring on the journal.

¾ Degrease the front surface of the inner race of the outer cylindrical
roller bearing, item 5.

¾ Fit the heated wear ring (item 6) on the axle journal. The mark must
remain visible.

FINAL ASSEMBLY OF THE BEARINGS

¾ Put the safety plate (item 8) on the box and tighten the screws M16
with 160 Nm.

FAG 13
14 S 15 – 02d

¾ Secure the screws (item 7) with the help of the safety plate (item
8).

FAG 25

¾ Apply grease on the bearing cover (9).

FAG 08

¾ Remove excess grease

¾ Note: there must be space in the bearing cover to hold the grease coming
out of the bearings.
 S 15 – 02d 15

FAG 26 FAG 05

¾ Re-assemble the bearing cover and drive it home (with a torque of 75-
80 Nm).

¾ Clean the bearing cover from grease that may have remained after the
bearing assembly!
16 S 15 – 02d

SERVICE INSTRUCTION

The manufacturer prescribes the following brand of grease for axle bearings:

FUCHS Radsatzrollenlagerfett GPFV

¾ For topping up or replacing the grease filling use the prescribed

grease only!

Mixing different sorts of grease may reduce the lubricity und thus lead to serious
damage. It is therefore forbidden!
If you have any questions concerning the grease to be used, please contact the
manufacturer of the respective grease.
 S 15 – 02d 17

Cleaning

Make absolutely sure that no water may get into the bearing. Water in the bearing destroys
the lubricating properties of the grease which will lead to a breakdown of the bearing.
When washing the bogie, do not direct high-pressure cleaning devices directly on seals.

Be particularly careful when using high-pressure cleaning devices to

avoid damage to seals.

Cleaning by sandblasting or similar techniques:

Sandblasting or similar techniques destroy the seals and the phosphate layer on the inner
and outer seals and the external races. When using these cleaning methods, the box, the
bearing and the seal have to be covered, e. g., by a shield, in order to avoid damage.

Electric Welding

Whenever it is necessary to carry out welding on the machine, the

welding current must under no circumstances be lead via the bearings.
Never install the counterpole of the welding electrode on the rail or at
wheelset elements, but as near as possible to the weld.
18 S 15 – 02d

PRODUCT INFORMATION

Wheelset Roller Bearing Grease GPFV

Description

The GPFV wheelset roller bearing grease is a dark brown, oxidation-stable grease on the
basis of a lithium-12-hydroxy stearate soap.

Field of application

The GPFV wheelset roller bearing grease proves its excellent lubricating effect in the
cylindrical roller bearing wheelsets of the Deutsche Bahn AG: more than 700,000 km
without regreasing.

Advantages

¾ Good resistance to water

¾ Good corrosion protection
¾ High stability of the worked grease
¾ A highly efficient combination of additives guarantees reliable lubrication of roller and
slide bearings.

Releases

Deutsche Bahn AG Mat.-No. 106225, ETG 1219 N

Physical Characteristics

Properties Unit Data Tested according to

Designation -- KP 2 N-30 DIN 51 502
ISO-L-X-CDEB 2 ISO 6743-9
Colour -- dark brown --
Thickening agent -- lithium-12- --
hydroxystearate
Drop point °C >180 IP 396
Worked penetration (Pw60) 0.1 mm 265 – 295 DIN ISO 2137
Deutsche Bahn AG Stirring test at -20°C stirrable DB-TL 91810
Corrosion protective properties corr. degree 0–0 DIN 51 802
(Emcor test)
Timken test, ok load Ibs 50 ASTM D 2509
Resistance to water at 90°C Assessment 1 - 90 DIN 51807-T1
stage
SKF test run (R2F) 1 – 120 In-house method of the
DB AG
Oil separation at 7d / 40°C % <3 DIN 51 817
Basic oil viscosity 40°C mm2/s 180 DIN 51 562
Working temperature °C -30 to +140 DIN 51 825
 S 15 – 02d 19

SAFETY DATA SHEET

1. Identification of substance

2. Hazards identification

3. Composition / information on ingredients

4. Firstaidmeasures

5. Fire fighting measures

6. Accidental release measures

7. Handling and storage

8. Exposure controls and personal protection

9.Physikal and chemical properties

10. Stability and reactivity

11. Toxicological information

12. Ecological information

13. Disposal considerations

14. Transport information

15. Regulatory information

16. Other Informations

20 S 15 – 02d

SAFETY DATA SHEET

1. Identification of substance

-Product details:

-Trade name: RADSATZROLLENLAGERFETT GPFV 180K#

-Application of the substance / the preparation: Lubricating grease

-Manufacturer / Supplier:
FUCHS EUROPE SCHMIERSTOFFE GMBH
Friesenheimer Str. 15
D- 68169 Mannheim
Tel: ++49 (0)621/3701-0 (Switch Board)
Fax: ++49 (0) 621/3701-570

-Informing department:
Product safety department Tel: ++49 (0)621/3701-333
-Emergency information:
Tel: ++49 (0)621//3701-333 or ++49 (0)621/3701-01 (Switch Board)

2. Hazards identification

-Hazard designation:
By handling of mineral oil products and chemical products no particular hazard is known when normal
precautions (item 7) and personal protective equipment (item 8) are kept.
-Information pertaining to particular dangers for man and environment this product is water polluting, see
item 12.
R 52/53 Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic environment.
-Classification system
The classification is in line with current EC lists. It is expanded, however, by information from technical
literature and by information furnished by supplier companies.
The classification results from the Conventional Method of the Directive 1999/45/EC concerning specific data
of compounds.

3. Composition / information on ingredients

-Chemical characterization
-Description:
Lubricating grease: Thickener system and additives in solvent refined mineral oil.

Dangerous components: R-phrases

Lead compounds 0.1-1%
T, N, R 61-62-20/22-33-50/53

-Additional information
The content of lead counted as element amounts to smaller 0,5%.
For the wording of the listed risk phrases refer to section 16.
 S 15 – 02d 21

4. First aid measures

-General information
Change clothes and shoes contaminated or soaked by the product.
Never put rags contaminated by the product into cloth-pockets.
-After inhalation seek medical treatment in case of complaints.
-After skin contact
Instantly wash with water and soap and rise thoroughly.
-After eye contact
Rinse opened eye for several minutes under running water.
-After swallowing seek medical treatment.

5. Fire fighting measures

-Suitable extinguishing agents

CO2, extinguishing powder or water jet. Fight larger fires with water jet or alcohol-resistant foam.
-For safety reasons unsuitable extinguishing agents
Water with a full water jet.
-Protective equipment:
In case of fire fighting: wear self containing breathing apparatus

6. Accidental release measures

-Person –related safety precautions: Not required.

-Environmental protection measures:
Do not allow to enter drainage system, surface or ground water.
-Measures for cleaning / collecting:
Collect mechanically.
Dispose of the material collected according to regulations.
-Additional information: No dangerous materials are released.

7. Handling and storage

-Handling
-Information for safe handling: No special measures required.
-Information about protection against explosion and fires:
No special measures required.

-Storage
-Requirements to be met by storerooms and containers:
No special requirements.
Information about storage in one common storage facility:
Store away from foodstuffs.

-Further information about storage condition:

Local regulations concerning handling and storage of waterpolluting products have to be followed.
22 S 15 – 02d

8. Exposure controls and personal protection

Additional information about design of technical systems: No further data; see item 7.

-Components with critical values that require monitoring at the workplace:

The product does not contain any relevant quantities of materials with critical values that have to be
monitored at the workplace.
-Additional information:
The lists that were valid during the compilation were used as basis.

-Personal protective equipment

-General protective and hygienic measures
The usual precautionary measures should be adhered to in handling the chemicals and the mineral oil
products.
Wash hands during breaks and at the end of the work.
Avoid close or long term contact with the skin.
Use skin protection cream for preventive skin protection.
Do not carry cleaning cloths impregnated with the product in trouser pockets.
-Breathing equipment: Not required.
-Protection of hands: Protective gloves and protective skin cream.
-Material of gloves
The selection of the suitable gloves does not only depend on the material, but also on further marks of
quality and varies from manufacturer to manufacturer. As the product is a preparation of several substance,
the resistance of the glove material can not be calculated in advance and has therefore to be checked prior
to the application.
-Penetration time of glove material
The exact break trough time has to be found out by the manufacturer of the protective gloves and has to be
observed.
-For the permanent contact gloves made of the following materials are suitable:
Nitrile rubber, NBR
Neoprene gloves
-Not suitable are gloves made of the following materials:
Butyl rubber, BR
Natural rubber, NR
-Eye protection: Not required.
-Body protection: Protective work clothing.

9.Physikal and chemical properties

-General Information

-Form: Pasty
-Colour: Dark brown
-Smell: Characteristik
-Value / Range Unit Method
-Change in condition
-Melting point / Melting range: Not determined
-Boilting point / Boilting range: not applicable or not determined

Flash point: Not applicable

-Self – inflammability: Produkt is not selfigniting.

-Danger of explosion: Product is not explosive.

-Density at 25° C ca. 0.96 g/cm3 DIN 51 757

-Solubility in / Miscibility with
-Water: Insoluble
-Viscosity or Consistency-Class NLGI 2
 S 15 – 02d 23

10. Stability and reactivity

-Thermal decomposition / conditions to be avoided: No decomposition if used according to specifications.

-Dangerous reactions: No dangerous reaction known
-Dangerous products of decomposition: No dangerous decomposition products known

11. Toxicological information

-Acute toxicity:
-Primary irritant effect:
-on the skin: No irritant effect known.
-on the eye: No irritant effect known.
-Sensitization: No sensitizing effects known.
-Additional toxicological information:
When used and handled according to specifications, the product does not have any harmful effects
according to our actual informations.

12. Ecological information

-Behavior in environmental systems:

-Mobility and bioaccumulation potential: No data available
-Ecotoxical effects:
-Remark: Harmful to fish
-Behaviour in sewage processing plants:
The product swims on the water surface.
-General notes:
German water Endangering Class 2 (Self-assessment): hazardous for water.
Do not allow product to reach ground water, water bodies or sewage system.
Danger to drinking water if even small quantities leak into soil.
Harmful to aquatic organisms.

13. Disposal considerations

-Product:
-recommendation
Smaller quantities have to be disposed in line with local legislation.
When storing used mineral oil products, ensure that the categories for waste oil and mixing instructions are
observed.
Delivery of waste oil only to officially authorized collectors.
-European waste catalogue 12 01 12: spent waxes and fats

-Uncleaned packaging:
-Recommendation:
Empty contaminated packaging thoroughly. They can be recycled after thorough and proper cleaning. Small
one-way packaging have to be disposed according to the local regulations.
24 S 15 – 02d

14. Transport information

-Land transport ADR/RID and GGVS/GGVE (cross-border/domestic)

-ADR/RID-GGVS/E Class:

-Maritime transport IMDG/GGVSea:

-IMDG/GGVSea Class : -
-Marine pollutant: no

-Air transport ICAO-TI and IATA-DGR:

-ICAO/IATA Class:
-Transport/Additional information:
No dangerous good acc. To dangerous goods/transport directions.

15. Regulatory information

-Designation according to EU guidelines:

Observe the normal safety regulations when handling chemicals or mineral oil products.
The product has been classified and labelled in accordance with EC Directives until 2004/73/EC (29. ATP)

-Risk phrases:
52/53 Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic environment.

-Safety phrases:
61 Avoid release to the environment. Refer to special instructions/safety data sheets.

-National regulations

-German Water Hazard Class:

Water Endangering Class 2 (Self-assessment): hazardous for water.

16. Other Informations

All ingredients are listed in the European Inventories. These data are based on our present knowledge.
However, they shall not constitute a guaranty for any specific product features and shall not establish a
legally valid contractual relationship. This data sheet is a safety data sheet according to 91/155/EU. For
products which are not subject to classification according to EU lists this data sheet is made on a voluntary
base.
-Relevant R-phrases for the hazardous components in item 3
20/22 Harmful by inhalation and if swallowed.
33 Danger of cumulative effects.
50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment.
61 May cause harm to the unborn child.
62 Possible risk of impaired fertility.
 S 15 – 02d 25

Department issuing data specification sheet:

FUCHS EUROPE SCHMIERSTOFFE GMBH Export Division
Product Safety Departement
-Contact:
Product Safety Departement:
Tel: ++49 (0) 621/3701-333 Mrs. Manuwald/ -955 Mrs. Dr. Kukuckova
-Validity:
With this latest edition of this MSDS all former editions are not valid any longer.

Changed items are marked with “*”*