R.D.S.

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR AXLE BOX ASSEMBLIES

WITH AXLE JOURNAL BEARINGS FOR LOCOMOTIVES

Specification No. MP.0.3600.01

(Revision - 01)

November 2020

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RESEARCH DESIGNS & STANDARDS ORGANISATION
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 CONTENTS

S.No. Description Page No.

1. SCOPE 1

2. MINIMUM GENERAL REQUIREMENTS OF THE FIRM 1

3. OPERATIONAL ENVIRONMENTAL & FUNCTIONAL CONDITIONS 1

4. APPLICABLE DOCUMENTS 1-2

5. VENDOR‟S SPECIAL RESPONSIBILITIES 2-3

6. TECHNICAL REQUIREMENTS 3-4

7. DESIGN REQUIREMENTS 4-7

8. QUALITY ASSURANCE 7-8

9. INSPECTION PLAN FOR AXLE JOURNAL BEARINGS, AXLE BOX 7-14

ASSEMBLY AND THEIR COMPONENTS
INSPECTION SCHEDULE FOR AXLE JOURNAL BEARINGS, AXLE BOX
10. 14-15
ASSEMBLY AND THEIR COMPONENTS
11. FIELD TRIAL 15

12. ACCEPTANCE CRITERIA 15

13. PREFERENCE TO MAKE IN INDIA 15

14. DATE OF ENFORCEMENT 15

15. Annexure – A i to x
CHECK SHEET FOR INSPECTION OF AXLE JOURNAL BEARINGS,
AXLE BOX HOUSING AND AXLE BOX ASSEMBLY COMPONENTS
16. Annexure – B xi
FORMAT FOR PERFORMANCE FEEDBACK OF AXLE BOX
ASSEMBLY WITH CYLINDRICAL ROLLER BEARINGS ON
LOCOMOTIVES
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

SPECIFICATION FOR AXLE BOX ASSEMBLIES WITH AXLE JOURNAL BEARINGS

FOR LOCOMOTIVES

1. SCOPE
1.1 This specification covers technical requirement for manufacture, supply, installation and inspection of
axle box assemblies with axle journal bearings for locomotives.
1.2 Terminology: As given in IS: 2399-1988 “Roller Bearings – Vocabulary”
2. MINIMUM GENERAL REQUIREMENTS OF THE FIRM
The firm shall be met minimum testing & manufacturing infrastructure to RDSO STR No. MP.STR.BD-
01.02.03 (Rev. -01 or Latest).
3. OPERATIONAL ENVIRONMENTAL & FUNCTIONAL REQUIREMENTS:
The bearings shall be able to meet the following general conditions –
3.1 Transfer of all vertical, lateral and longitudinal forces from the bogie to wheel and from wheel to bogie
through axle box housing.
3.2 All types of services, i.e. passenger, goods, mixed and shunting.
3.3 Heavy impacts, vibrations emanating and shock loads from all types of Indian Railway track conditions
(i.e. either continuously welded or jointed).
3.4 Varying loads and speeds, both in direction and magnitude with top speed close to limiting speed for
grease lubrication.
3.5 Limitation on maintenance during operation - hence long running period before inspection and re-
lubrication.
3.6 Limitation on maintenance during operation - hence long running period before inspection and re-
lubrication.
3.7 Direct exposure to sun, rain and moisture.
3.8 Exposure to oil, grease, degreaser, fuel and dust or dirt etc.
3.9 High reliability in performance.

4. APPLICABLE DOCUMENTS
4.1 Relevant drawing(s) of RDSO for the governing dimensions, axle-load, speeds, wheel diameter,
unsprung weight and dynamic-augment, etc.
4.2 Specifications and Standards:
The issues of following specifications and standards, in effect on date of invitation of bids or request
for proposal, shall form part of this specification to the extent specified herein:
S.No. Standards Description
1. IS : 1030 Carbon steel casting for general engineering purposes
2. IS : 1586 Method for Rockwell Hardness Test (B & C Scales) for Steel.
3. IS : 2399 / ISO: Roller Bearings – Vocabulary
5593- 1984

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

4. IS : 3073 Assessment of Surface Roughness.

5. IS : 3823 / ISO: Methods of Evaluating Static Load Ratings of Rolling Bearings.
76 - 1987
6. IS : 3824 /ISO: Methods of Evaluating Dynamic Load Ratings of Rolling Bearings.
281 - 1990
7. IS : 4163 Method for determination of inclusion content in steel by microscopic
method.
8. IS : 4397 Cold Rolled Carbon Steel Strips for Ball and Roller Bearing Cages.
9. IS : 4398 Specification for Carbon Chromium Steel for the manufacture of balls,
rollers and bearing races.
10. IS : 4897 Deviations on un-toleranced dimension and mass of steel casting
11. IS : 5669 General Plan of Boundary Dimensions for Radial Rolling Bearings.
12. IS : 5692 Tolerances for Radial Rolling Bearings.
13. IS : 5935 Radial Internal Clearances in Unloaded Radial Rolling Bearings.
14. IS : 6453 Technical Supply Conditions for Rolling Bearings.
15. IS : 7460 Tolerances for Tapered Roller Bearings.
16. IS : 7461 General Plan of Boundary Dimensions for Tapered Roller Bearing.
17. IS : 9202 Cylindrical rollers
18. IRS M2 Indian Railway Standard Specification for Steel Casting.
19. UIC 515-5 Powered and trailing stock bogies – Running gear “Tests for axle –
boxes
20. AAR M-934, Freight Cars Journal Roller Bearings
Section – H
21. EN 12080:1998 Railway applications-Axle boxes-Rolling Bearings
5. VENDOR’S SPECIAL RESPONSIBILITIES
5.1 The Vendor shall be completely responsible for the satisfactory and efficient performance of the Axle
Journal Bearings in service, notwithstanding any approval which the RDSO or the Inspecting Agency
may have given to:
5.1.1 The drawings of the Axle Journal Bearings and axle box assembly, incorporating all the design
features, prepared by the firm.
5.1.2 Assemblies, sub-assemblies and components during the course of manufacture at the Vendor‟s / Sub-
Vendor‟s Works;
5.1.3 The sub-Vendors for any material or fittings;
5.1.4 Other parts of the work involved in the contract;
5.1.5 The tests carried out either by the Vendor, RDSO or the Inspecting Officer.
5.2 Basic key Design Drawings provided by RDSO are only for guidance and may be modified to suit the
requirements, as subsequently directed by the RDSO. It shall be the responsibility of the Vendor to
ensure that the working drawings prepared by him are free from such discrepancies as are likely to
affect the satisfactory performance/maintenance of the Axle Journal Bearings. No modifications to the
Vendor Drawings or any other approved Drawings shall be made except with the prior approval of the
RDSO.
5.3 The Vendor shall further, notwithstanding any exercise by the Inspecting Officer of the power of
superintendence, be responsible for the sufficiency of packing, marking etc., of all the parts of work to
ensure their delivery without damage. The Vendor shall comply with the instructions of the Inspecting

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

Officer, if in his opinion, further precautions than those taken by the Vendor are necessary for the
proper execution and safe delivery of all the parts of the work.
5.4 The Vendor shall at his expense replace any part of the roller bearings and axle boxes failing or
proving unsatisfactory in service and attributed to defective/faulty design, defective material or bad
workmanship, within a period of 36 months or 3,60,000 kms from the date of its commissioning into
service. The period of warranty shall stand extended by the duration for which the roller bearings
remain inoperative under exercise of this clause. Further, should any design modification be made in
any part of the device as a result of any defect/fault/lacunae/shortcoming in the original design
features, the period of 36 months would commence from the date the modified part is commissioned
into service. The sole judge in this regard will be the RDSO.
5.5 In the event of the Vendor failing to carry out any work for which he is liable under the above clause
within a reasonable time, or if in the opinion of the RDSO the urgency of the case demands it, the
Purchaser, without prejudice to his other rights under the Contract, may carry out the work himself at
the expense of the Vendor.
5.6 The Vendor shall submit a list of components and equipment that is included in his scope of supply.
5.7 The Vendor shall supply a list of materials with quantities and facilities that would be needed from the
Purchaser for installation and satisfactory operation of his equipment.
6. TECHNICAL REQUIREMENTS
6.1 Supply of drawings and Maintenance Manual :
6.1.1 The vendor shall prepare, from the basic design requirements of RDSO, complete working drawing in
metric units giving assembly and component details of roller bearings and axle-box, at his own cost,
which shall be submitted to RDSO. Manufacture of bearing shall be done only after approval of basic
design features of the bearings, as submitted by the vendor. But this approval shall not be construed
as any kind of authorization/approval of the vendor for getting any purchase order.
6.1.2 While submitting the drawing of a particular detail, other details depending on it shall be shown in
juxtaposition and sufficient drawings of surrounding details shall be submitted to enable the design to
be judged. All drawings shall be fully dimensioned. The requisite tolerances shall be shown on each
dimension of the detailed drawings and the condemning sizes of wearing parts shall also be shown
against the relevant dimensions. (Reference standard for tolerance shall be mentioned in drawing)
6.1.3 Material specification for each component shall be indicated on the relevant drawings. If these are
other than the IS or IRS, then copies of such specifications, in English, should the original be in a
foreign language, shall be supplied to RDSO in duplicate.
6.1.4 Full calculations in support of the design capacity (load rating) and life expectancy of the Roller
Bearings shall be submitted.
6.1.5 The vendor shall indicate the details of durability test including the standard, to which the offered
bearing has been subjected. The vendor shall also submit results of such tests. Any validation done by
agency like UIC, AAR etc shall be indicated by the vendor.
6.1.6 A copy of the proposed Maintenance Manual of the bearing shall be supplied incorporating the
following information:
a) Description of the bearings.
b) Procedure for initial mounting and lubrication of the bearings indicating quantity of lubricant per
box.

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

c) Maintenance checks in service such as grease topping, bearing examination, seal change and
grease change, etc. between major examinations.
d) Procedure of bearing extraction, examination and assembly, special tools, if any, for this purpose.
e) Initial and condemning limits of the components.
f) The types/brands of suitable grease/lubricants (also refer to clause 6.15).
7. DESIGN REQUIREMENTS
The roller bearings shall generally conform to the technical supply conditions for roller bearings as per
IS: 6453.
7.1 Materials
7.1.1 Roller and bearing races shall be manufactured from suitable material conforming to IS: 4398 or
equivalent. Test report of material shall be furnished by the manufacturers. If the vendor wants to use
any other material, sufficient information about the alternative material shall be furnished and RDSO‟s
approval shall be obtained for the same before using.
7.1.2 Rolling elements of bearings shall conform to IS: 9202 (Cylindrical rollers) or equivalent.
7.1.3 The metal employed for roller bearings shall be free from defects, such as pipes, seams, laminations,
excessive inclusions of non-metallic impurities and such other internal defects as would render the
material unsuitable for the purpose for which it is intended. On microscopic examination, it shall show
fine grain size and shall be free from signs of overheating.
7.1.4 The inclusion rating of the bearing steel shall be declared by the manufacturer and in accordance with
IS: 4398 or equivalent and shall be determined in accordance with IS: 4163.
7.1.5 Bearings shall be fitted with cages made of suitable material which can withstand high durability and
provide service life. Vendor shall declare the specification of the material for the cage in the drawing at
the time of approval. Cold rolled carbon steel strip cages shall conform to IS: 4397. The Vendor may
use non-alloy steel or copper alloys or any other material for the cages, with the approval of the
RDSO.
7.1.6 The materials for the axle box housing and end cover etc. shall conform to the specification no. IRS
M2-65 or IS: 1030 or relevant RDSO drawings.
7.1.7 Axle box assembly fittings, such as thrower, distance rings, thrust rings and clamping plates etc. shall
conform to vendor‟s drawings as approved by RDSO.
7.1.8 For conical rubber thrust pad:
This shall conform to the specification no. IRS R-63-76 and RDSO drawing nos. SK.DL-2308 and
SK.DL-2309 latest version.
7.2 Dimensions and Tolerances
7.2.1 For Roller Bearings: The dimensions, tolerances and internal clearances shall conform to IS:5669,
IS:5692, IS:5935, IS:7460 & IS:7461 or any other published internal standards. The specific series or
groups adopted in the design shall be shown in the Vendor‟s drawings.
7.2.2 Axle box housings, end covers and axle box assembly components shall conform to the RDSO
drawings or approved vendor‟s drawings. Unless otherwise stated, the casting and machining
dimensions of these components shall be as per IS: 4897 (deviations on un-toleranced dimension and
mass of steel casting) and IS: 2102 (Medium) respectively.

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

7.3 Radial internal clearance for cylindrical roller bearing shall conform to IS: 5935 (Radial internal
clearance in unloaded radial rolling bearings). Value of radial internal clearance of bearing for new
condition, service and safety limit shall be declared by the vendor and same shall be approved by
RDSO.
7.4 Fitting tolerance grade for axle journal and bearings, axle box housing and bearing shall be provided
by the firm.
7.5 Surface Finish: The outer rings, the inner rings and the sides of the roller bearings shall have the
maximum values of surface finish as specified in IS:6453, when measured in accordance with
IS:3073.The functional surfaces shall have the required surface finish to ensure the performance of
the bearing.
The surface finish of functional surface of axle box housings, end covers and axle box assembly
components etc. shall be as per RDSO drawings or approved vendor‟s drawings.
7.6 Hardness: The rings and the rollers shall have the Rock Well C Hardness (HRC) of from 57 to 66
HRC and shall be measured in accordance with IS:1586
Caution: There shall be no impression of the test cone on the load bearing surfaces / raceways.
7.6.1 Rings/Races: There shall be no more than 3 HRC difference between the values measured on all the
rings of one roller bearing.
7.6.2 Rollers: There shall be no more than 3 HRC difference between the values measured on all the rolling
elements in one roller bearing.
7.7 Load Ratings:
7.7.1 The load rating and L10 life of the bearing shall be computed in accordance with IS: 3823- 1988
„Method of evaluating static load rating of rolling bearings and IS: 3824- 2002 „Method of evaluating
dynamic load ratings of rolling Bearings and a copy of the calculations shall be submitted by the
vendor.
7.7.2 The minimum L10 life rating of the roller bearing shall not be less than the value as given below :

S.No. Type of locos Travelled by locomotive wheels

1. BG Mixed Traffic loco 4.50 x 106 kms

2. BG Goods loco 2.56 x 106 kms

3. MG Mixed Traffic loco 2.56 x 106 kms

4. MG Goods loco 1.61 x 106 kms

7.8 Running Noise: The level of the running noise of the roller bearings shall be as agreed to between
the Vendor and the Purchaser. Vendor shall furnish the acoustic data i.e. NVH analysis for prototype
bearing to RDSO.
7.9 Interchangeability: The components of the bearings i.e., inner races and outer race assembly shall
be fully interchangeable with the same make, without exceeding (on either side) the specified limits of
radial clearance of the bearing.
7.10 Soundness of manufactured bearings:

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

7.10.1 The rolling elements shall be free from defects of workmanship, which may affect their serviceability.
The surfaces for the bore, outside diameter, sides and load carrying areas shall be smooth and shall
not show any damaged areas due to corrosion.
7.10.2 Rings and rolling elements: Rings and rolling elements shall be free of any defects, especially on
working surfaces that may be harmful to their function (such as burrs, scratches, rust stains, nicks and
dents).
7.10.3 Cages: Roller bearing cages shall exhibit no defects that might affect their function (such as burrs,
scratches, rust). To avoid crack initiation, the connection between the cage bars and annular body
shall be smooth and properly rounded off as per EN 12080:1998 or IS: 4397-1998.
7.10.4 Soundness of rings and rolling elements: Rings and rolling elements shall have no internal defects,
nor any form of surface defect that may be harmful to their function. The soundness shall be inspected
(ultrasonic inspection for inner race and outer race, MPI for ring surfaces, and Eddy current inspection
for roller raceways) by the manufacturer as per EN 12080:1998. Any alternative methods to be used,
which give equivalent results, shall have to be documented in the QAP, and approved by RDSO. The
bearing can be through hardened or case hardened .In case of case hardening, the case depth shall
be as per EN 12080:1998. There shall be no grinding burns during the different grinding operation.
This test shall be applicable for prototype approval of new design of bearing for higher speed (more
than 200 kmph) application.
7.11 Retouching/Rework: No retouching/rework is allowed without prior permission of RDSO. Any
retouching/rework with the purpose of concealing a defect is not permitted.
7.12 Marking: Each bearing i.e. inner race, outer race assembly shall be visibly and indelibly marked for
easy identification, with following description.
 Vendor‟s trade-mark;
 Complete designation of the bearing, defining type; dimensions, radial internal clearances etc.;
 Year of manufacture with batch number.
7.13 Protection against corrosion: The type of protection against corrosion shall be decided by the
Vendor depending on the packing material used. Under proper storage conditions, the anti-corrosive
treatment shall be effective for at least 12 months in order to ensure a satisfactory functioning of the
rolling bearings.
7.14 Packing and labeling:
7.14.1 The bearings shall be suitably packed to prevent damage during transit and handling. The packages
shall also carry the markings as given in para 7.12.
7.14.2 In case non-interchangeable components of a bearing are packaged in different boxes, the latter shall
be tied together so that they cannot be separated before the bearing is used. Additionally, the boxes
shall carry any reference marks necessary to enable re-assembly of the bearing
7.14.3 The packed containers shall be marked with the following:
 Vendor‟s trade-mark;
 Complete designation of the bearing;
 Batch number, month and year of Manufacturing;
 Quantity.

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

7.15 Lubrication:
7.15.1 The lubricant recommended for use shall be normally available in India.
7.15.2 The bearing shall be capable of working for a minimum period of three years without any examination
or grease change.
7.15.3 No attention (including grease topping) shall be required between two examinations. If this
requirement cannot be met by the Vendor, he shall submit specific recommendations regarding
minimum period for (i) grease topping, (ii) bearing examination, (iii) seal change and (iv) grease
change to the RDSO for acceptance.
7.15.4 The Vendor shall be responsible for correct mounting, locking and initial lubrication of the roller
bearings.
8. QUALITY ASSURANCE
8.1 The whole of the material or fittings used in the construction of the work shall be subject to inspection
by the Inspecting Officer and shall be as per relevant specification.
8.2 The Inspecting Officer shall have the power to:
8.2.1 Adopt any means he may consider necessary to satisfy himself that all the materials or fittings
specified are actually used throughout the construction;
8.2.2 Visit in working hours without previous notice, either Vendor‟s Works or his Sub-Vendor‟s Works to
inspect the manufacture and quality of the work at any stage;
8.2.3 Reject any material or fittings that do not conform to the relevant standard specifications or have not
been manufactured in accordance with approved practices. The rejected materials or fittings shall be
marked in a distinguishable manner and shall be disposed off in such a manner as the Inspecting
Officer may instruct.
8.3 Tests of materials and fittings shall, as far as possible, be carried out at firm‟s premises. The Vendor
shall provide, free of cost, such materials or fittings as may be required for testing, or arrange for test
pieces of forgings and castings used in bearing assembly.
8.4 The Vendor shall provide, free of cost, labour and appliances required by the Inspecting Officer for
inspecting and testing of the whole of the work under the Contract, whether inspected at his own or his
Sub-Vendor‟s premises, and shall make provisions in his orders to his sub-Vendor‟s for the inspection
and testing of materials or fittings at their works, unless permission is given by the Inspecting Officer
for the same to be inspected after delivery at the Vendor‟s Works.
8.5 All materials and fittings required for tests and analysis shall be selected by the Inspecting Officer, and
these tests shall be carried out in his presence. No test piece shall be cut from any material or fittings
until it has been stamped with such identifying marks as the Inspecting Officer may require.
9. INSPECTION PLAN FOR AXLE JOURNAL BEARINGS, AXLE BOX ASSEMBLY AND THEIR
COMPONENTS
9.1 General Aspects
On completion of manufacture, the bearings, which are ready for use, shall be presented for
inspection. Bearings shall normally be offered in un-lubricated condition. However, according to
previous agreement between Purchaser and Vendor, bearings may be presented in lubricated or un-
lubricated, packaged or unpackaged.

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

Bearings with the same designation, belonging to the same manufacturing batch and presented at the
same time, shall constitute a lot.
9.1.1 Internal inspection report of the complete lot shall be produced to the inspecting authority before
inspection of material.
9.1.2 Place of inspection: Inspection of the bearings shall be carried out at the Vendor‟s premises, except
for the examination of inclusions and chemical analysis, which, unless otherwise specified, shall be
carried out in the Purchaser‟s Laboratory.
9.1.3 Appearance of lot: All essential portions of the roller bearings shall be clean and free from defects
such as porosity, burrs, hardening cracks, grinding marks, indentations, rust marks etc. The
examination shall be carried out visually.
9.1.4 Surfaces other than those portions of the roller faces which are not in contact with the ring ribs, the
roller chamfers, and the reliefs at the ends of the outer and inner ring raceways shall be smooth.
9.1.5 Temperature of the area where measurements are done: Measurements shall be carried out at the
ambient temperature. The measurement room shall have controlled environment. The gauges and
measuring instruments and the parts to be inspected shall be stabilized at this temperature before any
test is carried out.
9.1.6 Gauges: All the measuring instruments and gauges to be used for inspection shall be calibrated, and
they shall not be due for calibration. Calibration details of all the measuring equipment‟s shall be
submitted by the firm.
9.2 Sampling:
The Purchaser or the inspecting agency shall select at random from each lot presented, the bearings
intended for the sampling inspection described below. The number of sample bearings is indicated in
the table below:
Table – Number of samples

No. of bearings in the lot No. of bearings to be selected for tests

Upto 100 2*

From 101 to 250 3

Over 250 4

* The number of samples for a lot equal to or less than 50 bearings will be 2 no. or as specified
otherwise as per agreement between Purchaser and Vendor.
For developmental order the sample size shall be twice of the normal sample size or as specified by
the contract.
The bearings selected for sampling inspection shall be degreased, if necessary.
9.3 Dimensional Inspection of Axle Journal Bearing
The dimensions and tolerances of the bearings shall be as stated on the drawings furnished by the
vendor (refer clause 7.2). Dimensional tests shall be carried out on the selected samples as
mentioned below. If there is any other superior well established method in vogue, the same shall be
brought to notice by the vendor, and get the same approved.

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

9.3.1 Bore diameter d (cylindrical bore) and outside diameter D of bearing:

For these measurements the bearing shall preferably be placed on a substantially horizontal plane
surface (see fig. 1 and 2).

The measurements shall be made in two planes parallel to the sides and at a distance of 2r from the
adjacent side (r = nominal ring chamfer dimension).
For both dimensions d and D, the smallest single diameter (dmin and Dmin.) and the largest single
diameter (dmax and Dmax) found in either of the two planes are determined, using a measuring
instrument with two points of contact. The mean diameter (dm and Dm) of a ring is the arithmetical
mean value of the smallest and the largest single diameter.
d min  d max
dm 
2
D min  D max
Dm 
2
9.3.2 Inner ring width and outer ring width: (Except for tapered roller bearings where the bearing
width is measured).
For both the rings, the distance between the side faces shall be checked using a measuring
instrument with two points of contact. At every point the distance shall be within the stipulated limits.
9.3.3 Inner ring and outer ring width variation: The variation is placed on three equal-distance supports

which are in contact only with the inner rings or outer rings (see fig. 3)
9.3.4 Radial run-out of inner and outer rings in the assembled bearing:
Cylindrical roller and self-aligning roller bearings Tapered roller bearings.
The bearing is mounted without clearance or The bearing is mounted without clearance or
deformation on a tapered * mandrel set horizontally deformation on a tapered* mandrel set
between centres (see fig. 4) vertically between centres (see fig. 5).

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

* Taper of about 0.03 mm on diameter per 100 mm length. If the bore is slightly tapered, its taper shall
be positioned in the same direction as that of the mandrel. Beforehand, the radial runout of the
mandrel shall be measured and located, and the readings of the dial gauge corrected, if necessary.
A dial gauge is placed in contact with the outer ring outside surface in the plane containing the middle
of the raceway.
On cylindrical roller bearings without ribs, tapered roller bearings and self-aligning roller bearings, the
outer ring shall be guided laterally.
(a) Radial runout of inner ring (all bearing types): The radial runout is equal to the differences
between the maximum and the minimum reading of the dial gauge in contact with the outer ring,
when rotating the mandrel and the inner ring through one revolution, the outer ring being
stationary.
(b) Radial runout of the outer ring (all bearing types): The radial run out is equal to the difference
between the maximum and the minimum reading of the dial gauge in contact with the outer ring,
when rotating this ring through one revolution the inner ring being stationary.
For tapered roller bearings other equivalent methods may be used for this inspection.
9.3.5 Radial runout of inner and outer ring raceways :
The ring is placed on an inclined plane surface and is guided in its bore at two points situated in a
plane parallel to the supporting surface and containing the middle of the roller raceway. A dial gauge
is applied to the outside surface of the ring in line with one of the internal guides (see fig. 6).

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

The radial runout is equal to the difference between the maximum and the minimum reading of the dial
gauge when rotating the ring through one revolution
9.3.6 Radial internal clearance: (except for tapered roller bearings).
With the bearing standing on a reasonably horizontal plane surface, the clearance in the upper part of
the bearing, between the two rollers adjacent to the vertical plane and either the outer ring or the inner
ring as applicable shall be measured with feeler gauges of known thickness (see fig. 7).
Three measurements shall be carried out, the outer ring being rotated through 1200 between
measurements while the inner ring is kept stationary.
The bearing clearance is the arithmetical mean value of the clearances measured.

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

For double row roller bearings, these measurements are made on both rows.

9.3.7 Interchangeability of inner ring of cylindrical roller bearings:

In a given complete bearing the inner ring is changed and the radial internal clearance measured
according to clause 7.9.
9.4 Destructive Tests of Axle Journal Bearing
Destructive tests shall be on disassembled Axle Journal Bearing for following tests
9.4.1 Surface finish: The outer rings, the inner rings and the sides of the roller bearings shall have the
maximum values of surface finish as specified in IS:6453, when measured in accordance with IS:3073.
9.4.2 Soundness tests of both rings and rollers of each bearing: Soundness tests of both rings and
rollers of each bearing shall be done as per clause 7.10.4. The rings and rollers shall not show any
signs of cracks or harmful defects. This test shall be applicable for prototype approval of new design
of bearing for higher speed application (more than 200 kmph).
9.4.3 Hardness testing: The test shall be carried out according to the Rockwell hardness test (B&C scales)
for steel (IS: 1586), as per provisions in clause 7.6.
9.4.3.1 Rings: The test shall be done on both rings of each bearing. The Rockwell hardness shall be
measured on one of the side faces of the ring at both ends of two diameters perpendicular to each
other. The hardness values measured on one ring shall not differ by more than 3 HRC units.
9.4.3.2 Rollers: The test shall be done on three rollers of each bearing. The Rockwell Hardness shall be
measured at one point on the surface of one end of the roller. The hardness values measured on
three rollers of one bearing should not differ by more than 3 HRC units
9.4.4 Expansion testing of inner rings: The test shall involve the expansion of the bore of the ring by
means of a tapered mandrel. The expansion shall be such that the bore diameter increase is 0.0015
times the bore diameter. The expansion shall be rapid. The use of an eccentric press is considered
suitable and it is recommended that necessary precautions be taken during the test, since ejected
fragments, if fracture occurs may be dangerous. An equivalent method may also be used.
After completion of the test, the ring shall show no signs of failure, as may be detected by any of the
method as specified in clause 7.10.4.
Expansion testing of inner rings is not required in case of case-hardened and bainite hardened rings.
9.4.5 Examination of structure and carburization: The examination shall be done on both rings and three
rollers of one bearing out of 1000 bearings inspected. The ring or the roller shall be fractured by a
method chosen by the manufacturer and accepted by RDSO during the qualifying procedure to show

Motive Power Directorate (VDG), RDSO, Lucknow No. MP.0.3600.01 (Rev.01) November’ 2020 Page 12 of 15
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

the structure of a brittle fracture. A regent may be used to permit accurate measurement of the
thickness of the carburized layer.
The fractured sections shall not show any discontinuity, laminations, flaws, shrinkage cavities or other
material defects. When case-hardening is one of the manufacturing operations, the thickness of the
carburized layer shall be in accordance with the specifications.
The structure shall be examined visually (without magnification).
9.4.6 Chemical analysis: The chemical analysis shall be performed as follows:
1. Ladle analysis micro structure and inclusion rating of steel for each heat. This shall correspond to
the stipulations in the approved drawings
2. Actual chemical composition of cage material for each heat out of which cages on bearings in lot
offered have been manufactured, by spectroscope or wet method. This shall correspond to the
stipulations in the approved drawings.
3. Inspector may order retest on rings, rollers and cage of one bearing out of every 1000 bearings
inspected.”
9.5 Inspection Plan for Axle Box Housings and Axle Box Assembly Components
9.5.1 Material: The material shall conform to clause 7.1.6, 7.1.7 & 7.1.8 of this specification. The casting
shall be free from defects like sponginess, blow and pin holes and sand inclusions, etc.
9.5.2 Dimensional and Squareness Checks, etc. of axle-boxes:
9.5.3 The dimensions of the axle box shall conform to relevant approved drawings.
9.5.4 The following main aspects of the axle box shall be checked meticulously:
a) Axle Box Housing wall thickness – At a number of locations.
b) Axle Box Housing Bore – Size, taper, ovality and surface finish of bore.
c) Bearing Seating Face – Distance from end face for ensuring central location of the bearing to
journal i.e. main bore depth.
d) Suspension seating area – Size, height and centrality of suspension seat from the journal Centre.
e) Face Liners – Over liners distance, parallelism and squareness of the faces to the suspension
seating area.
f) Side Liners – Lateral location (distance from the box front face to the liner face), parallelism and
squareness of side liners to the face liner.
g) Thrower End Cover – Sizes for adequate clearance from thrower after assembly.
9.5.5 Dimensional checks for axle box assembly components:
Thrower, end cover, distance rings, thrust rings locking plates, etc. shall conform to dimensions of
relevant approved drawings of vendor.
9.6 TESTING OF ASSEMBLED AXLE BOXES
Tests as mentioned in this clause may be exempted, if the offered bearing is already approved by UIC,
AAR or equivalent, and has successfully given field service for two years in at least 50 numbers of
locomotives. Approval certificate shall be submitted by the vendor.
These tests shall be applicable for new design of bearing during prototype approval of the item.

Motive Power Directorate (VDG), RDSO, Lucknow No. MP.0.3600.01 (Rev.01) November’ 2020 Page 13 of 15
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

9.6.1 General tests

9.6.1.1 Clearance between the thrower and thrower end cover of the box shall be adequate as per the
approved drawing.
9.6.1.2 Centrality and parallelism of the horn faces to the axle of the journal.
9.6.2 Water tightness/ seal test
After successful completion of above tests, one or two complete axle box assemblies shall be tested
for water tightness/ seal test as per UIC Code 515-5 for cylindrical roller bearing.
9.6.3 Endurance / Durability Test
After water tightness or seal test, the bearing shall be subjected to endurance test as per UIC Code
515-5.
10. INSPECTION SCHEDULE FOR AXLE JOURNAL BEARINGS, AXLE BOX ASSEMBLY AND THEIR
COMPONENTS
Check sheet for Prototype and Regular inspection of Axle Journal Bearings, Axle Box Housing and
Axle Box Assembly Components is given at Annexure „A‟. Inspection schedule shall be followed as
given bellow:
S. Parameter Reference Prototype Routine
No. para

1 Dimensional Inspection of Axle Journal 9.3 -- --

Bearing

Bore diameter d (cylindrical bore) and outside 9.3.1  

diameter D of bearing:

Inner ring width and outer ring width: (Except 9.3.2  

for tapered roller bearings where the bearing
width is measured)

Inner ring and outer ring width variation 9.3.3  

Radial run-out of inner and outer rings in the 9.3.4  
assembled bearing:

Radial runout of inner and outer ring raceways 9.3.5  

Radial internal clearance: (except for tapered 9.3.6  
roller bearings)

Interchangeability of inner ring of cylindrical 9.3.7  

roller bearings

2 Destructive Tests of Axle Journal Bearing 9.4 -- --

Surface finish 9.4.1  

Soundness tests of both rings and rollers of 9.4.2  
each bearing

Motive Power Directorate (VDG), RDSO, Lucknow No. MP.0.3600.01 (Rev.01) November’ 2020 Page 14 of 15
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

Hardness testing 9.4.3  

Expansion testing of inner rings 9.4.4  
Examination of structure and carburization 9.4.5  
Chemical analysis 9.4.6  
3. Inspection Plan for Axle Box Housings and Axle 9.5  
Box Assembly Components
4. Marking 7.12  
5 Protection against corrosion 7.13  
6 Packing and labeling 7.14  
7 Lubrication 7.15  
8 TESTING OF ASSEMBLED AXLE BOXES 9.6 -- --
General tests 9.6.1  
Water tightness/ seal test 9.6.2  
Endurance / Durability Test 9.6.3  
11. FIELD TRIAL
11.1 Field performance shall be monitored as per format at Annexure-B.
11.2 After successful completion of field trial approval may be considered.
12. ACCEPTANCE CRITERIA
12.1 The Vendor shall not withdraw the material offered for inspection during the course of inspection. Any
move by the firm in any way to withdraw the material or interfere/ hinder the inspection, shall render
rejection of the entire quantity of material offered for inspection.
12.2 If any sample fails in one or more criteria of inspection, double the sample size shall be drawn and
tested against the criteria in which the sample had failed. If all the samples of double sampling pass
the criteria, the entire quantity shall be accepted.
12.3 Failure of any sample of the double samples will, however, result in rejection of the entire offered
quantity.
12.4 In the event of rejection, the entire quantity offered for inspection shall be made unusable for Railway
application in presence of the Inspecting Official either by gas cutting or cross marking on one of the
rejected sample do not get mixed up with the other subjected items/ passed items at any stage.
13. PREFERENCE TO MAKE IN INDIA
The Government of India policy on `Make in India` shall apply.
14. DATE OF ENFORCEMENT
For all the firms, the time frame for implementation of revised requirement/ facilities in the Specification
shall be with effect from 01.01.2021.

Motive Power Directorate (VDG), RDSO, Lucknow No. MP.0.3600.01 (Rev.01) November’ 2020 Page 15 of 15
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for Locomotives

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Motive Power Directorate (VDG), RDSO, Lucknow No. MP.0.3600.01 (Rev.01) November’ 2020 Page 16 of 15
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Annexure - A
CHECK SHEET FOR INSPECTION OF AXLE JOURNAL BEARINGS, AXLE BOX HOUSING AND AXLE BOX ASSEMBLY COMPONENTS
1. Common parameters for all type of Axle Journal Bearings:
1. P.O. No., D.P. detail
2. Reference Axle Box Assembly Drawing No. as per P.O.
3. Detail of lot with nos.
4. Date of inspection
5. Place of inspection
6. Internal Inspection report of raw material of complete lot
7. Inspection of appearance of lot
8. Temperature of Inspection Place
9. Condition of Gauges with calibration details to be used for
inspection
10. Surface finish test
11. Soundness test of inner and outer rings and rollers
12. Hardness testing of inner rings, outer rings, angle ring and three
rollers of one bearing
13. Expansion test of inner rings test
14. Examination of structure and carburization test
15. Chemical analysis test for Bearing Materials
16. Type of grease, if supplied by firm with bearing
17. Endurance / durability test (applicable for prototype Ins.)

pg. i
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

2. Checking of Axle Journal Roller Bearing (Cylindrical Roller Bearing) as per RDSO approved vendor drawing no …………………….. :
Sl. Details of tests for Cylindrical Roller Recommended Value Bearing Sample No.
Bearing (in mm) __ __ __ __
1. Bore diameter of inner ring
Outside diameter of outer ring
Bore diameter of angle ring
Outer diameter of angle ring
Inner diameter of angle of angle ring
2. Width of outer ring
Width of inner ring
Total width of angle ring
Width of angle
Small width of angle ring
3. Inner ring width variation
Outer ring width variation
Angle ring width variation
4. Radial run out of Rotating inner ring
assembled bearing
Rotating outer ring
5. Radial internal clearance
6. Interchangeability test with inner races
7. Weight of bearing

pg. ii
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

3. Checking of Axle Journal Roller Bearing (CRU) as per RDSO approved vendor drawing no ……………………..:
Sl. Details of tests for CRU Bearing Recommended Value Bearing Sample No.
(in mm) __ __ __ __
1. Bore diameter of plain inner ring
Bore diameter of Lipped inner ring
Bore diameter of angle ring
Outside diameter of outer ring
Outer diameter of angle ring
Inner ring shoulder diameter
Inner diameter of inside seal (During proto)
Inner diameter of outside seal (During proto)
2. Width from lipped inner ring to angle ring
Small width from seal to seal face
Large width from seal to seal faces
3. Lipped Inner ring width variation
Plain Inner ring width variation
Angle ring width variation
Outer ring width variation
4. Radial run out of Rotating inner ring
assembled bearing Rotating outer ring
5. Radial internal clearance
6. Interchangeability test with inner races
7. Weight of CRU bearing (in Kg.)
8. Weight of grease (in Kg.)

pg. iii
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

4. Checking of Axle box housing as per RDSO drawing or RDSO approved vendor drawing no ……………………..:

Sl. Details of tests for Axle box housing Recommended Housing sample Nos.
value (in mm)
__ __ __ __
1. Material of axle box
Location 1at top
Wall Location 2 at bottom
2.
thickness Location 3 at left
Location 4 at right
Bearing Seat Diameter
Bore Diameter
3. Bore Taper
Ovality
Surface finish
Overall width of Box
Bearing Distance from end face of axle box to bearing
4.
seating face seating face
Bearing seating width
Vertical distance from axle box bore centre to
suspension seating centre
Longitudinal distance of suspension seating
Suspension centre to axle box bore centre
5.
seating area
Lateral distance of suspension seating centre
to axle box bore centre
Suspension seating dimensions

pg. iv
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Distance over liners

Longitudinal location
6. Face liners
Squareness
Parallelism
Distance between liners
Lateral location
7. Side liners
Squareness from face liner
Parallelism
Inner bore diameter
Labyrinth width from bearing seating face
Thrower End Over all width from bearing seating face
8.
Cover Under cut depth from outside face of box
Under cut inner diameter
Under cut outer diameter
5. Checking of Axle box Assembly components as per RDSO drawing or RDSO approved vendor drawing:

Sl. Details of tests for Axle box Assembly Recommended Assembly component sample no.
components value (in mm)
__ __ __ __
1. Thrower End Cover Material Copy of material T.C. to be attached.
(in case of CRU bearing) Outer Seating dia.
(Drg.no.------------------)
Over all width
Outer seating width
Inner bore dia.

pg. v
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Width
Labyrinth width
Under cut depth
Under cut inner dia.
Under cut outer dia.
Drilled hole dia./PCD
2. Finish Thrower Material Copy of material T.C. to be attached
(Drg.no.------------------) Seating dia
Seating width
Seating Radius
Over hang dia
Over hang width
Over all width
Depth dimension
Depth dimension
Outer dia.
Under cut outer dia
Under cut inner dia.
Seal groove width
Seal groove dia
1. 3. Journal Distance Ring Material Copy of material T.C. to be attached
(Drg.no.------------------) Width
Bore dia

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Outer dia.
Groove detail
2. 4. Housing Distance Ring Material Copy of material T.C. to be attached
(Drg.no.------------------) Width
Bore dia
Outer dia.
Groove detail
Greasing hole
3. 5. Outer Thrust Collar Material Copy of material T.C. to be attached
(Drg.no.------------------) Overall Width
Outside Dia.
Inside Dia.
Depth for Thrust Pad
Dia for Thrust Pad
Angle for Thrust Pad
Depth for Collar
Dia over Collar
4. 6. Inner Thrust Collar Material Copy of material T.C. to be attached
(Drg.no.-------------------) Overall Width
Outside Dia.
Inside Dia.
Dia for Thrust Pad
Depth for Thrust Pad

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Angle for Thrust Pad

Depth for Bolt Head
Dia for Bolt Head
No. of Holes/Holes
Dia / PCD
5. 7. Inner Thrust Collar Material Copy of material T.C. to be attached.
Distance Piece
Overall Width
(Plain to Drg. no.----------)
Outside Dia.
(Hasler to drg. no. --------)
Centre Hole Dia.
OD for Inner Thrust
Collar
Depth for Collar
Outer Dia for Axle
Depth for Axle
Tapped Hole/PCD
No. of Holes/Holes
Dia / PCD

6. 8. Outer Spacing Piece Material Copy of material T.C. to be attached.

(Drg No.--------------------) Overall width
Inside Dia
Outside Dia
Groove Depth
Groove Width at
Bottom

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Undercut OD
Undercut ID
7. 9. Clamping Plate Material Copy of material T.C. to be attached.
(Drg.no.----------------------) Overall Width
Width over Axle area
Outside Dia
Centre Hole Dia
Outer Dia for Axle
Inner Dia for Axle
No. of Holes/Holes
Dia / PCD
8. 10. Conical Rubber Thrust Material Copy of material T. C. attached.
Pad (Drg.no.---------------)
ID Small
OD Small
ID Large
OD Large
Width Large

9. 11. End Cover Material Copy of material T.C. attached

(Plain to Drg.no. -----------) OD for Axle Box
(Hasler to Drg.no. ---------)
Seating Width
(Alternator to Drg.no. -----)
Flange Thickness at
Bolt
Overall Depth

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 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Holes Dia / PCD / No.

of Holes
Center Hole Dia.
Tapped Holes / PCD /
No. of Holes
Center Hole Dia.
Tapped Hole / PCD /
No. of Holes

pg. x
 Specification for Axle Boxes Assemblies with Axle Journal Bearings for locomotives

Annexure - B
FORMAT FOR PERFORMANCE FEEDBACK OF AXLE BOX ASSEMBLY WITH CYLINDRICAL ROLLER BEARINGS ON LOCOMOTIVES
Based shed: ______________________ Loco type and their holding: ____________________________ Period: from _________ to ___________
Sl. Loco Location Date Brief description Make of Name of W/S Date of last Result of General remarks of the shed
No. of type and of of of failure (inner bearing or overhaul of any local about the condition of the grease
failure no. journal failure race cracked or manufacturing bearing and investigation found when axle box cover is
slackened etc.) unit where place of the failure opened during lubrication
bearing was overhauling for all locos
fitted and date

pg. xi