Content .. 48 49 50 51 ..

INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 50

Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 192 of 303

8.34.2.3 Mixed – Base Grease: This term is usually applied to a grease with a mixed

sodium lime base. This is less fibrous than the straight sodium greases and is
particularly suitable for the lubrication of ball and roller bearings. It also has an
excellent temperature range, giving good lubrication from -40

c to 120

C or

higher. The proportion of lime soap is normally very low, so that the
characteristics are substantially those of a soda grease.

8.34.2.4 Brick Grease: This grease is a sodium base grease made by a different process

from that used for the normal sodium greases and resembles hard soap in
general appearance. It is used for heavy duty applications where oil lubrication
is difficult or impossible, such as the driving journals of steam locos. Normally
a bar or brick of grease is placed in contact with the journal and kept under
pressure so that a steady supply of lubricant is maintained.

8.34.2.5 Lithium Base Grease: Lithium base greases, made with suitable natural

petroleum and /or synthetic oils, may be used over a range of temperature from
around – 70

C to 150

C. They are smooth and buttery in texture and do not

harden or soften unduly over their temperature range. Lithium base grease is
fairly water resistant. Its service life is usually long comparable with that of a
good soda grease. It is suitable for antifriction bearing lubrication.

8.34.2.6 Aluminum Base Grease: This is like petroleum jelly in appearance. It is very

adhesive to metals and is employed for automobile chassis lubrication and on
cams, chains and oscillating surfaces to which other greases will not cling. It
does not bleed readily and is not recommended for anti-friction bearing use.

8.34.2.7 Barium Base Grease: Resembles in appearance and characteristics a sodium or

sodium calcium mixed base grease, except that the grease has no dropping point
in the normal sense, remaining semi-solid until it fails due to high-temperature
break-down or oxidation of the oil incorporated. It is very adhesive to metals,
has good water resistance and can be used, with natural petroleum oil
constituents at temperatures upto about 175

C. It is suitable for anti-friction

bearing use.

8.35 Characteristics of Lubricating Greases

8.35.1

Cone Penetration of lubricating greases

Grease consistency correlates to the firmness of the grease. Depending on the
applications they're designed for, greases can range from semi fluid consistencies to
almost solid. Care must be taken to select the correct consistency for the
application. If the grease is too hard, it may not adequately flow to the areas in need
of lubrication. If it is too soft, it may leak away from the desired area. Since
consistency directly correlates to pump ability, equipment greased through a
dispensing system may require grease representing a compromise between what is
required for lubrication and what can be adequately pumped.

8.35.2

Drop point

Drop point is the temperature at which grease turns from semi-solid to liquid state.
It is significant only in that an operating temperature above the dropping point may

Home

Ch-8

Draft

Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 193 of 303

cause permanent thickener separation or alteration of grease properties. It is not
necessarily a measure of the upper temperature limit of the grease

8.35.3

Oxidation stability

This is the ability of greases to resist a chemical reaction with oxygen. The reaction
of grease with oxygen produces insoluble gum, sludge & deposits that cause
sluggish operation, increased wear, and reduction of clearances. Prolong high
temperature exposure accelerates oxidation of grease. Oxidation stability is
expressed in terms of pressure drop over a given time period

8.35.4

Shear / Mechanical stability

Grease consistency may change as it is mechanically worked or sheared between
wearing surfaces. Grease’s ability to maintain its consistency when worked is its
shear stability or mechanical stability. Unstable greases whose characteristics
changes drastically in service can result in poor lubrication or other operational
problems.

8.35.5

Load -Carrying capacity of Lubricating grease (Four ball method)

This method is used for specification purposes, differentiates between lubricating
greases having low, medium, and high level of extreme pressure properties. The
results do not necessarily correlate with results from service.

8.35.6

Rust preventive characteristics of lubricating greases (Emcor method)

This test method is used to assess the ability of grease to prevent corrosion in
rolling bearings operated in the presence of distill water, sodium chloride, or
synthetic sea water. It is used for development and specification purposes.

8.35.7

Oil separation from lubricating grease during storage
When lubricating grease separates oil, the remaining composition increases in
consistency. This can affect the ability of the product to function as designed. This
test method is not intended to predict oil separation tendencies of the grease under
dynamic conditions.

8.35.8

Detection of Copper Corrosion from lubricating grease

This method measures the tendency of lubricating grease to corrode copper under
specific static conditions. It may be of some value in predicting possible chemical
attack on lubricated parts, such as bearings that contain copper or copper alloys.
However, no correlations with actual field service, most of which are under
dynamic conditions.

8.36 Storage, Handling and Dispensing of Lubricants in Running Sheds :

8.36.1

General: Even slight dirt and contamination will impair the lubricating quality of
an oil or grease which will result in excessive wear, loss of power and early
breakdown. The benefits to be derived by use of expensive oil or grease brands can
be easily off-set by indifferent and incorrect storage or handling of lubricants.

Home

Ch-8

Draft

Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 194 of 303

Utmost care has to be exercised in handling and dispensing of lubricants which are
the very life of diesel engines and loco components.

8.36.2

Storage and distribution of lube oil through Bulk Installations: Now-a-days
most of the diesel loco sheds has got bulk lube Oil Installations, which remain
under custody of Stores. Following procedure, broadly, may be followed for
accountal of lube oil in such installations.

8.36.2.1 Main Tanks (horizontal/vertical) of suitably capacity, to hold at least two months

requirement, shall be installed in the diesel loco shed.

8.36.2.2 These tanks shall be connected by a common receipt pipe line, with isolating

valve for each tank.

8.36.2.3 These tanks shall have in-built level gauges to check lube oil balance or provision

of measurement by dip rod.

8.36.2.4 These main tanks will be under the custody of stores.

8.36.2.5 After receipt of the Road tanker, quantity in the tanker shall be verified with the

help of a calibrated dip rod, after placing the tanker on a level platform, before
decanting.

8.36.2.6 The receipt quantity will be recorded in terms of gauge level/dip rod reading of

the storage tank before and after decanting of road tanker. Further, any leftover
quantity in the road tanker will also be collected and measured.

8.36.2.7 For the purpose of the acknowledging receipt, the quantity recorded in the tanker

with the help of calibrated dip rod of the tanker will be treated as final.
However, in case of abnormal difference between the reading by calibrated dip
rod and in-built level gauge/dip rod of the main storage tanks, the matter will be
investigated and accordingly corrective action taken.

8.36.2.8 A suitable capacity ancillary tank (sufficient for holding one week requirement)

will be provided in the shed in which lube oil from main storage tank will be
transferred, on placing a demand by the consignee. This tank will have
provision for measurement of the quantity received with the help of a dip rod or
through an in-built level gauge. This tank will remain under the custody of
SSE/General of the shed.

8.36.2.9 The delivery side pipe line from the main storage tank shall be provided with a

flowmeter for measurement of the issued quantity. A daily issue register shall
be maintained recording the quantity issued and balance by the reading of level
gauge, converted into quantity. A ledger card shall be maintained in the stores
for stock balance i.e. (Opening balance, Receipt, Issues and Closing Balance).

8.36.2.10 The reading of flowmeter of main storage tanks will be considered final for the

purpose of receipt in the ancillary tank by the SSE/General. However, in case of
abnormal difference in the quantities shown by flowmeter reading of the main
storage tank and dip rod/level gauge reading of the ancillary tank, the matter
will be investigated and accordingly corrective action taken.

Home

Ch-8

Draft

Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 195 of 303

8.36.2.11 Issues to the loco will be done from the ancillary tank through a flowmeter. The

balance in the ancillary tank shall be recorded by dip rod/level gauge. The
quantities issues to locos will be maintained in a register date-wise with
signature of the shift in-charge, i.e. (Opening balance, Receipt, Issues and
Closing Balance).

8.36.3

Storage of oils received in Drums:

8.36.3.1 The drums should be stored preferably under proper cover.

8.36.3.2 If storage in the open is unavoidable, the following precautions should be taken:

a. Drums should be stored on their sides or bilges

b. Wooden dunnage should be used to keep them clear of the ground and to

prevent rusting of the underside.

c. Drums should never be stacked directly on a surface containing clinker as

this is particularly corrosive to metal.

d. The drums at each end of the stack must be securely wedged to prevent

movement.

e. Drums can be stored either in a single layer or in tiers with wooden battens

between the layers, but three layers is the maximum.

f. Drums of different brands of oils should be stored at separate places marked

for each brand.

8.36.4

Storage of Smaller Packages :

8.36.4.1 Smaller packages of oils and greases are less resistant than large drums to the

effect of weathering. These should never be left in the open and should be
stored in a well covered place.

8.36.4.2 Package of different brands of lubricants should be stored separately at places

marked for each brand.

8.36.5

Dimensioning of Lubricating Oils:

8.36.5.1 Out of the various oils used in a diesel loco, engine lubricating oil has the

maximum and a sizeable consumption. This oil is issued for the following two
purposes:

a. For renewing engine lubricating oil, which requires comparatively large

quantities at a time.

b. For topping up, requiring a few litres each time.

8.36.5.2 Renewing the Engine lubricating oil for large consumptions : In sheds where

locos in excess of 20% of one type are homed and where the consumption of a

Home

Ch-8

Draft

Content .. 48 49 50 51 ..