Government of India Ministry of Railways

..

Instructions for Inspection and Maintenance of

•

Casnub Bogies

Te.chnical Pamphlet No} G·9S

(Revision·l) March 1997

00000J0581

Research Designs & Standards Orga~lisation

Manak Nagar, Lucknow-226oo1

Amendment slip No.5 (.June 2003) to the Instructions for inspection and Maintenance of CASNTB Bogie -Technical'

Pamphlet No. (;-95 (Rev.l of March 1997)

"Para 5.2.11 read in place of "new/renewed" as "New" only" "Para 5.2.12 read in place of "new/renewed" as "New" only" "Para 5.2.13 read in place of"new/renewed" as "New" only" "Para ),2.14 read in place of "new/renCVied"' as "New" only"

.'

~\ rnend111 t'llt Slip No.4. of (April-2002) to tht Inspectioll

'U,jntenance of CAS NUB -Bogie-Tcchnicall)amphlet 1\0.G·95

(Rev.) of March 1997

Fig. 16 Ada;:>ter Crc)\vn Seat Gauge revised and enclos~d

"Amendment OSlin :\0.3 ( .lanll:I\·":, ~\)n:! ) to the Insnection & '-bintenance of C\S:\\.'t3 Bo\!it~~ - ','echnkal P:lmllhlct :\0. G-'):;

(Hoc", I) of \I:II'\:h \1)<)7"'

" ""Iil th~ g:\llge in position as sho\\n in rig, 3-1 \a) iLl" "" :,;i\c:: in ,\:',:l,'~I~e o ,\!I~r redaiming il should be en,.:red Ih:ll Ihl! gauge aJmils in Ihe jaw op~~i:1;; Si"!t: !':':\Il\e p~ .. k;I:\1 opening verti;;:!1 proti\c check gauge 10 ROSO Org:\o \\'O-<1Slj:'2-S, I') 111.1\ be used for checking the contour",

"

5iM .... P ~MM lE-riERS,

190

~~~~~~nn~~~~' A II AUGE NO.\' t~

CASNUB-22 NI., 22 NL"B &' ,2~ liS BOGIE, ,_'".: ~" " g .

\

ICO

r-,....

t 50 \ ~--STAMP5f'.'t.1 LEiiERS - I

o:N '. ADAPTER CROWN GAUGE NO.2

C"SNUo-22!{L, 22 NLB & ESBOGI E 7

" NI _---L

Q - o I 200 \. \ U§J

I , ,

GAUGE-1 GAUGE-2

t NOTE SURFACE MARKED It THUS

~., l.I:: fJ' AMO DIMENSIONS UMDER j, . ..q;::: ~.y )-?5CORED ARE. If"iPOR'tANl

.7);'<'0,1./ ".'''-; / .F.i1MATERIAL - . -

\--~O~:""'r--ti'~\' . GAUGE TIP·\S:IS't? CL4 """--~'-T---,.-.J:-"""':""'" \ lL-H ~ROE. N £ D & G \l.O UN ~

\', fSQD'f IS: a:> 62 Fe 410 .,. ~ I

FIG. A ADAPTER CROWN SE.AT GAUGE.

CASNuB-~ NL,22 NLB & 22 HS EOGIES

. FIG.1 6 -----_.

Amendment Slip No.2 of February 2000 to the "Inspection and Maintenance ofCASNt."'B bogies-Technical Pamphlet G-95 (Revision I) of ¥arch 1997 (Printed July, 1998)'·.

1. Para 4.1.3 Shall be deletc(l and shall read follows·

4.1.3 The bogies shall be dismantled siuring ROH. The bogie clearances and tolerances should be checked and rectified. iffound necessary. The br:!ke beam safety support to RDSO drg.No. WD-87078-Sil shall be provided :or the bogies of all versions with spring planks which are already provided with holes for fi.xing brake beam suPPOrt .

., Para 4.1.9 Shall be deleted arid'shall rene! as follows:

4.1.9 During POH of wagon in shops, all we:uing surfuces of bogie shall be orought to "As new condition". I"he brake beam safety support to RDSO drg.No.WD-87078-S/1 shall be provided in the bogies of all versions. wherever .these brake beam satety support is not alre:ldy provided. In ~ holes are not provided in the spring plank. the same may be drilled in position by taking suitable precaution to avoid distortion.

3. Figure 44- ne dimension 170 shall be read as 175.

4. Figure 45 The dimension 64 shall be read as 59 in the elevation and side elevation.

Page 1 of 1. Checked by- sdI- Approved by- sdI-· CDAlBogie dt 141212000 ADE:BD dt 14/2'2000

"

Amendmentsiip No.1 of June, 1999 to Instruction and Maintenance . Of C:lSnub Bogies. Technical Pamphlet No.G-95 (Revision I)

OfMan:h, 1997 (Pr;nted July, 1998) .

The following para shall be added as para 5.8.1. 5.8.1.1, 5.8.l.2 after para 5.8

5.8.1 Important: The studies have indicated fuilures of centre pivot top are occurring on account of dimensional inaccuracies, therefore.

5.8.1.1 Inspect the bore of the top centre pivot (170 +0.5 rom -O.Omm

\VI) 85079-S/2 for W (M) NL. NLB. HS Bogies) which should ha>le a push fit with retainer ring ( outer dia 270+ 00 =) so that

··0.1 longirudi.nal 'forces are transmitted through ret:Uning ring and not through rivets

5.8.1.2 Before fument of new top centre pivots (for NL NLBIHS Bogies) Centre pivots sball be checked· by applying tire ga1.lges to Drg.No WD.99033-Sf3 and ensure rivet holes are as per drawing No WD-8S079-S/2.

@

~ -" o·

~ o Ul o . a:

" I

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS'

INSTRUCTIONS FOR INSPECTION AND MAINTENANCE OF

CASNUB BOGIES

TECHNICALPAMPHLET No. G-95 (Revision-I)

Printed JULY 1998

RESEARCH DESIGNS AND STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW-226 011

OOOOOOOj'/il

INDEX

S. No . Description Page No. •

I. Introduction

2.

, .'. ~.

4.1

~.2

4.2.1

~.2.2

4.2J

s. .il

5.1.5

.1.2

5.2.~

SA

i5

S.6

S.7

.1.8

S.9

S.\O

S.II

5.11.1

.'.12

.1.\3

7.

lIistory

S.,liC1l1 Features

l\1ainlenilncc of Bogie

Gener:ll .

Assembling ;1nd l1isassemhling of the Bogie.

Method or Di.<1I.,"emhling.

Method or Rc-assembling.

Nominal Clearances

Bogie Components .

Wheel Sct with Rcaring Units

Axle

Axle Rox/A,!;,,,tcr with Retainer Bolt

Adapter .

Sioe fr;lme with Friction WCf11' Phltes

B()I~ter

Spring Plank

La;,,1 Bearing Springs and Snubber Springs

Friction Shoe Wedge Rlack

Celltre Pivot

Side ReiHers

Etasl0111cr.ic Pads.

[hake Gear Maintenance.

Brake Bealll

Adjustment or CnC/Blifrer Height

Precautions to be taken while doing welding operation on Wagon or Bogie filled with Roller Bearings. . . . . . .

Procurement of Spare Pal1s .

'Failure Reporting

OOOOOOOJ'I5 (i )

I

1

2

2

2

2

2

2

3

3

3

3

4

6

8

9

9

9

10

11

11

11

11

12

13

13

13

INDEX OF FIGURES ·.-_ .... -----

No. I )('scr; I J[ i (J/ 1

\Vilccl Sc~ with C;lrlridgc Bc;\rin~

,). Nnlllin<-l1 C\c,'lrilllCCS

4. NOlllin;ll Ck;U,lllCCS

S. Assembly Pnlccliurc

6. Assembly Procedure

7. Assembly Pnlccdurc

X. Scr<l[l Lnl~;lti()Il,':; nC \VOr!1 Adilplcr

9. Ad;l[IICr Sitouldn & Bore We;ll" (j;ltIge

HI. ;\(Llptc:r Cro\""ll LlI!;!- (~,wgc

11. Ad,lptcr Crown SI~{!1 Ciilugc

12. Ad;l[ltcr Side Lug CJ(llll!C

U. Ad;lptcr Side (i;llI~C

14. Scrap LnUlliotls of \\lorn A(L-1ptL'r

1 S. Ad;1 pier C mW!1 J .lI&

16. Ad;l(1tcr Sidl' Lu),:! (~ilUt'C

17. Ad;lptcr CroWI\ Scat (i;lllg:C

IR. Ad;lptl"'r Side (i;Hlgl'

19. /·\xk Jlnx Cnj'\.'ll Lugs ("y1. Rolla BC<lfing).

20. Axle no:>.: Cro\v'l1 (J;lllgt

1l. AxIL T10x Side Lug (r(ll1g(~

22. A:,1c Bl):\ Side . .:; {J-augc

J' _.1.

24.

Rec ];.1111,\ 1 il)!1

Fril!l1e.

Reclamation Fril1llt.'.

r ,oc; 11 i () 11

Lllc(llion

at

,II

\Vom Side

\Vora Side

25. Friction PL-llC DeLlils ;llld Procedure for Arpiic;Jlion 10 Side Fraille.

26. Column (iallgl:'

27. Anti Rol:llion Lug Cialtge

lX. PCdCSlili R()of C]"(W,,'11 G:1LJgC

:?\l Pedestal Roof Cn)\"'!l (jilLlgC

~Il Pct!cs!,\l Silk 8:.. C !"Own Side (i;llJgC

."1\ Pede"';1'll Side 8.;. C("l)Wl1 Side (j-"llIgc

.12. Pcdc,-..;\,ll .I,n\-' (,illlgt:

.-n. RccbnHl1inl1 of \VortlOUI PcdcSl,i\ .1;1\\' by

\Vclding Spring S"lec! LinLT

OCQj~GJOJ70

ling;c l 11r'l'sion

NUl

\V. \V (M I. Nt. NI.B. LIS

W. \v(MI

Nl.. NUl. liS

All Vcrsi()n~

All Versions

All Versions

\v. IV (Rclro). \V (M)

w. IV (Rello). IV (M)

IV. IV (RClro), IV (M)

\V IV (Rein»). W (M)

IV. \V (Relro). W 1M)

\V \V (Relro), IV (M)

Nl.. NtB. lIS

Ii i)

NL. Nl.Il. liS

NI., NIB, liS

Nt. NUl. liS

NI. NLB. lIS

W (Cy!. R. B.)

w (ryi. R. B,)

W (Cyi. R. H.)

W (ryi. R. H.)

W. IV(M)

NI .. NIB: liS

All Versions

All Versinns

All Versions

\V \v(MI

Nt. NLB lIS

W. IV(M)

NI. NI.H. HS

\V IV(M)

W. \V (Re/ro). W (M)

Fig. No.

2

3

4

5

6

7

8

9

10

1l

12

13

13A

14

15

16

17

18

19

20 •

21

22

23

24

25

26

27

28

29

30

31

32

S. No. DeSf.-i-ipliol1

34. Peliesl,lI .Tn\\' (Shor!) C;Huge

35. Petiesl'll .l:iw (Long) GHuge

36. Side Bearer [)elails

37. Side Bearer [)elails 38. Procedure for checking Combined ·Wear of

Bolsler/Side Fnll11e Liners & Wedge.

39. Procedure for checking Combined Wear of Bolsler/Side Fr:llne Liners & Wedge.

40. RedamHliol1 ,lJHI Location of \Vorn Bolsler.

41. Bolslerland Surfaces & Atlli Rolalion SlOP lug Gauge.

42. Column Gih G(lllgC

43. Spring Group for Various Load Applica­lion lind Snubbing Armngemenl.

44. Spring GrollI' fm ViIt'iolls Load Applica-tion and Snubbing Arrangement

45. Friclion Shoe Wear Gauge

46. Cenlre Pivol G:JlIge

47. Cenlre Pivol Gauge

48. Cenlre Pivo!., and Cenlre Pivol Pins

49.· Brake Gear Arrangement·

50. Brake Beam & Shoe

51. Manual Adjusltllenl of flogie Brake Gear

52. Rech,malion of Brake End

/logie VeJwioll

NL. NlH. HS

Nt. NLH. HS

\V

NL. NlH. I-IS All Versions

All Versions

All Versions

All Versions

,'jAil Versions ."- . All Versions excepl liS

liS

All Versions

w. W (Relro)

W(M). NL, NLB. HS

All Versions

W

W. NL. NtB. HS

All Versions

NL_ NLH. I-IS

LIST OF ANNEXlJRES

[)ifferences among differenl versions of Casnub bogies.

Fig. No.

33

34

35

36 37

38

39

40

41

42

43

44

45

46

47

48

49

50

51, 52, 53, 54, 55 & 56

ANNEXURE-A

ANNEXURE-R [)rHwing index of differctll versions of ClSnub bogies-22W, 22 W (M), 22 NLB, 22 l-IS.

ANNEXVRE-C

ANNEXVRE-D

ANNEXURE-E

ANNEXURE-F

AiliNEXI1RE-G

Welding of slmetuml slecl 10 IS: 226 Fe 410 SJIS:. 2062 Fe 410 WA

Welding of caSI Slecl componenls.

Welding of siruciural steel to IS : 226 Fe 410 SlIS : 2062 Fe 410 WA to cast steel to IS : 1030 Gr. 280-520 W.

Welding of spring slcel Iin~rs 10 IS : 3885 Pari I Gr. IV on cast steel surface.

List of imporlant modificalions.

(iii) OOOQOOO~97

I. I:>ITROnUCTION: The ellst Sleel CASNUB 8ogiC':-; comprise or two c). __ t side-frames (wd (] floafing

holsler. The bolsler is supporled on Ihe side-frilllleS through two groups of spring. which (1}50 incorporfilc the load prnporlioll.lI friction dnll1ping. The side­rrfllllcs nrc connected hy (l f;lhricilled mild steel spring plank to m;:lintain the hogie sqUCll."C. The various bogie vcrsions dc"cb)ped :1I"C ,IS under:-

I. C ASNUB-22W

2. CASNUB-22W (Relrnfilled)

.1. CASNUfi-22\V{M)

4. CASNUB-12NI.

S. CASNIlB-22NI.B

(,. CASNUB-12HS

These hogie=, have been ntted under following w;]gons-BOXN. BeN. BeNA BRN. BTPN ;]nel BTPGLN.

All C<lsl1ub 12W hogies ,Ire 10 he converted to C;lSIlUh 21\V (retrofitled) hy the maintenilOcc depots and workshops.

2. IIISTORY: The CASNUB Bogie was first leSied in 1972 unciel' HOI W;]gon. and was fonnd safe 10 rlln <11

lest speecis '.11' 10 110 kill/h. Test resullS have heen published in RDS()'s Mceh;]nieal Engineering Report No. M-265.

In .l9X1. tri:lIs were <lgain lIllderl,lkcn on thi:;. hogie tinder 'RO XN' \Vngon on track l1lainl(ll,lCd to 1l1,1inlinc st;I1Hlards and its hch;rviour WilS well within safety limits ur' to lJO Km/h speed. This bogie W:1S lirst ri.1tcd under open BOXN wagons ,lnct was designated itS Casnub 21\V. This \V;'lS Illodiried ,IS Casnuh 22 \V(M). Ill" inly In '" ke en ro 0 [h igh wheel wea r rep0ried on earlier version. Suhscqllcnlly Castlub 22 NL (N<11TI)\"" j;l\v) and CasJluh 22 NLH (Narrow j~nv with li.sh helly bolslcr) \·ersions were introduced.

lnsnub 2, liS bogies lli,,'e been developed [or high speed operation with maximum permitted speed lIplO

100 km/h. This is presenlly al Iri"l ''''ge.

. 1. SALIENT FEATI!RES: The s;]lienl [eatllres of

the hogie are:

(,<luge: ]()76 111m

Axle LO;leI : lO .. )! 11nwevcr. all bogies cxccrt C,lsnuh :2:211S. cnl1 be upgraded upto :22.91.

Wheel Di;]llleler: 1000 mlll(New) 956 min (Nev.') for rctrotiHed cas­i\U b 12\V

Wheel Rase: }OOIl 111m

Type of Axle Be'Hing:

Casnuh-22W & 22W(M)

(a) Cylindrical roller bearing axle box in limited no. on C"snub 22W Bogies only.

(b) Siandard AAR Tapered car­tridge bearing class 'E' suilable for 152.4x276.4 111m (6"X II"') wide jaw.

Casnub-22NI, 22NLB & 22 liS. Standard AAR tapered Car­Iridge Bearing Class 'E' suitable for 152.4X276.4 mm (6'x II') narrow jaw.

Di.,lallee hetween 2260 mm jou rnal centres:

Distance between 1474 mm side heel rers :

Type of ,ide C.snub 22W hearers: Roller type (clearance type)

Rctrolitted C.snub 22W, Casnub 22W(M), 22NL. 22NLB

Constant eonlaet type (Metal honded rubber pad, housed inside side bearer housing).

C.snub 22I1S Spring loaded constant contact Iype side bearer.

Type of pivot: C.snub 22W IRS Type

Anti rot~ltion features:

Tvpe of brake hcam:

Top Pivot-ROsa Org. No. WI BE-60l.

Bottom Pivot-RDSO Drg. No. WIBE-602 or similar mating profile integrally cast with bolster.

. Casnub-22W(M), 22NL, 22NLB, UIIS Spherical type RDSO Drg. No . WO-85079-S/2.

Anti rota lion lugs have been provided helween bogie bolster and sidcframc.

Casnub-22W, 22NL, 22NLB and nils Unit type fabricated brake beam supported and guided in the bra ke beam pockets.

OOOOUJOJ~:j

Suspension details:

Elastomeric pads:

Casnuh-12W(,\1) Unit type Cilst Steel nrake heilm suspended by hangers from side frilme brackets.

Long travel helical springs.

011 All types of bogies except Casnub '12W Subsequently pro­vided in rctrofi.hncn1..

4. MAINTENANCE OF THE BOGIE

4.1 GENERAL

~.1.1 The CASNUB Bogie. as designed. is not expec­ted to call for breilk-down maintenance. However. to ohtain optimum life of the bogie. it is desirable to maintain the variolls clearances. within the recom­mended limits.

-t 1.2 Due to we;] r of the mating components, incrcClse in clearance takes place which should be moni­tored ..

4.1.3 The bogies should be dismantled during ROH only. The bogie cleHrances and tolerances should be checked and recti lied. if found necessary.

4.1.4 Whenever the weal' reaches the recommended limits. or it is felt thilt it will ctoss recommended wear limit before next' ROB. the repairs should be uncler­laken by either building up the wear on surfaces. or changing of their liners. as the case may be.

4.1.5 Fig. 37 indicales Ihe method of checking the combined wear in bolslerlsideframe liners and wedge. Ouc to wcarin bolstcrlsidcframc liners andwedgc sur­r.,ees. the wedge will move upwards. If the holes in holsler pockel Willi and wedge start crossing., repair shall he undertaken. Allernatively. gauge shown al Fig. .;:;: shall be llsed to determine the wear limit. to decide whether repair Sh;lll he undcria"kcn.

4.1.6 The "bove repairs should he e"rried alit by posilioning the job for down-hand welding and suit­ahlc manipulators ;-nrangco to ensure this.

~.1.7 After Ihe repairs. Ihe rep"ired surfaces should be checked with 'Ihe relevant gauge for correctness. Excess materiaL if a ny. should be removed by gl'i lrel i nglmach i 11 ing.

4; 1.8 The class of eleclrode. gauge of electrode. weld­ing current '''ld welding precautions to be wken while rcp"iring the surfaces by welding. should be followed as per Annexures C to F.

4.1.9 During POll of wagon in shops. all the wearing surfaces of bogie shall be brought to. "As new t.:ondilion",

4.2 ASSEMnLING AND DISASSEMBLING OF TIJE nOGlE

4.2.1 Method of Dis.Assembling

4.2.1.1 Dis·conneci nogie Brake Rigging attachments 10 underframe and underframe brake Gear and raise

. ooooobd099' 2

car body after removing shackle lock/castle nut etc. Run out the bogie.

4.2.1.2 Insert assembly pins (12 mm diaX250 mm long) to retain friction shoes.

4.2.1.3 Raise bolster to conWct top member of sideframe. 4.2.1.4 Remove outer. inner and snubber springs.

4.2.1.5 Remove assembly pins and lower wedge blocks to take them oul.

4.2.1.6 Lower bolster to rest on the spring plank. .

4.2.1.7 Slide the bolster to one side to take it oul.

4.2.1.8 Take out side frame key to release the wheelse!.

4.2.1.9 Take out the side frames and spring plank a.ssembly.

4.2.1.10 In case of bogie litted with cartridge type beming with wide jaw adapters. remove the adapter retainer bolt to release the adapter.

4.2.2 Method of Re-Asscmbling: Re-assemble the bogie by reversing the procedure, outlined in Para 4.2.1.

Also see Fig. 5, 6 and 7 "Assembly Procedure". IMPORTANT: Inspect all the load and snubber springs for proper seating after wagon body is on bogies.

For matching of load bearing springs. refer Para 5.6.2.

The centre Pivot of the bogie shall be lubricated with graphite flakes to IS : 495 at the time of assembly. No other mating surface in the bogie shall be lubricated.

4.2.3 Nomi .. 1 Clearances: The nominal clearances and the lolerances of the bogie assembly are shown in ligure 3 and 4. The main clearances are :-

Descrip rion Type of Casnub Bogies

22W 22W 22NL. 22HS 22W (M) NLB

(ReI,O)

l. Lateral clearance bet- 18mm ISmm lSmro 25mm 'ween sideframe & bolstc;r.

2. Lateral clearance bet· 25mm 25mm 16mm 16mm 'ween sideframe and axle box/adaptr:r.

3. Longitudinal clearance 2mm IOmm 9Ibin 9mm between sideframe & axle box/adapter.

4. Longitudinal c1eamnce 6rnm 6mm 6mm 6mrn befween sideframe and bolster.

5. Clearance between 4mm 4mm 4mm 4mm anti-rotation lug & bolster.

5. BOGIF. COM PO:-.lF.:-.ITS: The Cas nub hogle .;l~.scll1bly consists of lhe following componcnls-

(I) Wheel .'el wilh cyl indrical roller hearing or wheel set with cartridge hC<1ring.

(2) Axle hox/<ld"pl0r. relainer holl &. side frame key assembly.

(:l) Sideframe wilh friclinn wear plales.

(4) Bolsler wilh wear liners.

(5) Spring plnnk. filholls & rive".

(6) Load bearing springs and snubber springs.

(7) Friclion shoe wedges.

(8) Cenlre rivol arrangemenl comprising of cenlre pivot top. centre pivot holtom. centre pivot pin. centre pivot rcl(lillCr & locking clrr;1ngemcnt.

(9) Side bearers.

(10) Elaslomeric 1);"ls.

(11) Bogie hrake gear.

(12) Brake beam.

Delailecl deseriplion of each ilem and Ihe main­tenance requirement. is given in the following paragraphs.

5.1 WIIEEL SET WITH BEARINGS: The Iniliallot of Casnuh bogies werc filled wilh cylindrical roller bearing axle box and m,lIching wheel set. However standard AAR taper cartridge bearings have been sub~ ,c;cquent1y stand:-ndiscci for these bogies. Fig. 2 inciicrttcs these components.

5.1.1 Maintenance requirement of cnrtridge tnpcr roller bearings h",'c been issued under ··lnslruelions ror inspection and mtlintcnance of cartridge laper mller bearing fitled on cast slecl bogies" Technical pamphlet No. G-ln. lSI revision by RDSO:

5.1.2 Cylindrical Roller Bearing axle boxes filled on Ihe Casnub Bogies nrc supplied by M/s NEI Jaipur 10

Iheir Drg No. 92-4289A. The maintenance instruclions 10 be fonowed me indicaled in their Drg No. M 3.1128.

5.1.3 Wheel.profilc used had been slDndard 1 in 20 laper. afler the rool radius. eC'lrJier. However. currently a worn wheel profile has been prescribed to reduce wheel wear and increilse wheel life. The worn whed profile for new wheels is as per Ihe Drg. No. WD-88021. During reprofiling. wheels should be ttl·rned as per inlermcdiMc profitc~ having varying wheel flange Ihjckncssc.~. selecting the appropri<-1te flange thickness oul or the four O(]ngc thicknesses. so that. minimum. material is removed ;-11 the time of turning. These arc as per Drg. No. WD-89060-S/2.

5.1.4 Wheel diallleicr for new wheels is IOOOmlll. !-lowever. for Ca.,nub 22W (rclmfitled). maximum per­missihle wheel cli,,,"clcr is 956mm. Condemning wheel dia is 906mlll for all versio·ns. btll with suilable pnekings. as dcscrihcd in par<l 5.12.

.l

5. \.5 Axle

5.l.S.! A,lcs have 10 be subjected to ultrasonic testing during ROH/POB or whenever the wagons are sent to sltops. Wheel selS, whose axles have undergone ullrasonie teslitlg. shall he ·slampecl on the hub fillet as per RDSO's Drg. No. WD-SJ089-S/1.

5.1.5.2 Some axles on Casnuh bogies have been rcporled 10 have grazing on account of main pull rod. These can be reclaimed. in case depth of notches/ scratch/nicKs is less Ihan 5mm as per the instructions issued vide RDSO's leHer No. MW/WA/GENL dt. 20-12-91. The reclamation of the axles for the reasons ollter thanlltose indicated in the ahove quoted letter is nol permiHed.

5 .. \.5.3. Whenever axles are renewed. the workshop shall punch in 5mmlClters the following parliculars on I he axle end.

(i) Serial No.

(ii) Workshop code where pressing has been clone.

(iii) Date of pressing.

(iv) Journal Centre.

(v) Pressing on pressure in tonnes (Both ends).

5. L5.3h For Re-disced Wheels, the stamping shall be a' pc r R DSO D rg. No. WD-S70S0/S-1.

5.1.5.4 Axle cnd holes should be properly cleaned and lubricated before reuse. Thread should be checked wilh standard thread gauge. Reclamation of axles wilh defective cap screw holes shall he carried out as per the inslructions given in RDSO's letter MW/WA/GENL daled 8-5-92.

5.2 AXl.E BOX/ADAPTER WITH RETAINER BOLT

5.2.1 . C.snub 22W : Initial lot of wheel sets with cylin­drical roller bearing were provided with axle box on Casnuh 22W lype bogies. However. cartridge taper roller bearing was soon standardised which are pro­vided wilh adapter & adapter retainer holt Casnuh 22W hogies arc provided with wide jaw adapter as per RDSO sketch No. SK-78527 but without elastomeric pads wilh wheel set to Drg. No. WAfWL4902. SK-68512 and WD-89025-S/1 and retainer holt to Drg. No. SK-69594.

5.2.2 C.snllb 22W(I\1): Wheel sets with wide jaw adapler. cartridge roller hearing and adapter retainer boll. (WA/WL-4902/WD-89025-S/l for wheelsets).

5.2.3 Casnub 22NL. 22N.LB & 22BS bogies: Wheel scls wilh narrow jaw adapter and cartridge roller hear-ing. (WD-8902S-S/1 for wheclselS). .

C.snub 22W (Retrotitted) : Bogies arc provided wil h modified wide jaw adapters but these are nol

0000000600 .

intcn:h,lngc;lhlc nilh (',I~tluh :'.:'.\V "-:.. (',,:-;\1l1h 2.~\v(M !

:).2.4 Axle Rnx

Axle nox Crown Lug<; (Cylindric~11 [loller H,'.rings)

We:ll; limit 4111111

(i;l\lgc Fig !~

New/Rencwed

A:;1e Box Crmvll 1.11:;.'> I ~\) nllll

\\'01"n

167 llllll

Determine the ,11l1nunt or we;l!" in the ;\xie hnx crown

nuter and inner Iltg ... hy ll..;ing. the g,luge shown in Fig. I~.

To dctcrIllinc the wcarlHllhc oul~r ,111..1 illllerll.lgs. with ~;lUgC ill POSiill)l1 ::IS sho\\'11 ill Fig. (A). If;\ 5mm thick . ..:;him l',lll he inserlcti hL:I\ .... cen the worn lug and the g;!ugc Jll either sides. ;\t ;ln1' point. rcpnir should he made rollovv'ing the procedure gi\'en in Annexure-D.

NOTF. . J1crnre using !he g<!ug.c. the centre- line or the crown sc:lI is to be m;Hkcd t<lking the UI1-\,,'orn surC,lcc nfthc clo\vnlugs as datum. \Vhilc using. the g;ltlgc.the l~clltre line of the: g;'lIl!;!C and the lll;Hkcd centre line of the cnJ\\!1 seal should bl' kepi in the S,ltllC lille. TilL gil ugl' s h.)tJid he nv wcd 1"0 r 1 he filII kn g I h of c rOWJl sO r­f;lCC to mca,':'urc WC;l\".

The rc!';\ircd side lugs should be chcI:kcd \"'ilh lllc L!;lllgC tiS shown in Fig. IX (AI ~lnd (B). Fxces . .:;ivc !lIalcrial i, In he remove .. l hy grinding.

~.2..s Axlt~ nox Crown ~cat (Cylindrical Roller

Rl·aring) :

CiaHgc

Bearing housing tn Crown Seal

.~.S mill

Ncw/Rc Ill' \\'cd

.~6.s I11Ill

\Vorn

3l mill

Determine the amount of weal" on fhe <-Ixle box cro\vn selll hy using the g;lllgC sho\vn in Fig. 19.

To dcterminf the amount of we,ll" on the a.'de hox crown scat the g,1l1gc ShOldd bc applied ;IS shown in Fig. (A) of Fig. 19. If ,1 ~.s m111 lh ick sh im ca n be inscr-1ed betwecn gauge \ ,ItH! ~'HlgC 2. it would indicate the limit of we;]\'.

S.2.6 Axle Rnx Side Lug' (Cyliudrie.1 Roller

Rl'aring,} :

\Vear limit J mill

Gauge Fig. :20

New/Renewed \Vorn

. Axle Bux Side 1. lI rs

OOlJ00006U :.

rL:lcnninc (ht ;11';1011l1t of wear all the axle box side lltgs hy lIsing lhe g.'lUge shown in fig. 20.

To determine thc ;11110unl of wear on the side lugs with the gr1uge in position as shown in Fig. 20 (B). if a 4 mm thick :.:.hilll C,lil bc inserted hetween the worn surface of the lug ;Jnd gJlUge at either sides at any point. repair .should be m;lde following thc procedure at Anncxurc~ -rf.

NOTF.: l1efore u:;ing the gauge. the vertical centre line of e,leh side is to be marked laking the unWonl surf"ee of the side lugs as datum. While using the g~ll1ge. the centre linc of the g~lllge and the marked eenlre line oflhe side lugofthe axle box should be kept in lhe S,11l1e line. Thc Gauge should be moved for the full length of \\o"orn surface to measure wear.

4

TIll' reprlircd "ide lugs. should he checked with the

r'"'ge '" shown in Fig. 20 (A) and (11). Excessive ll1alcri,1i is 10 be removed by g.rinding.

S.2.7 Axle Rox Side, (Cylindrical Roller Rearing):

\VC:H limit Jmm

( inuge Fig. 21

Ncw/Rcnewcd \Vorn

Axle nox Sides 26S mIll 262 mm

Determinc the amountorWC(lfOn the axle hox sides by using the g~ugc shown in Fig. 21.

\Vilh g,lIJge in position as ShO\\,l1 in Fig. (A), if a shim or .~.5 mm thickness can he inscrled between the cast­illg and Ihe g:1tlge ,lt each end at any point. rcpair :.;hcllild be made rollowing the procedure indicated at .'\nncxun>D,

""OTE: Before using Ihe gouge the centre line of the ;IX!c box sides is 10 be l1l;:,rkcd on the axle hox sides l;lking tbe' un-worn surface of the ;:,xlc box as d'ltum.

The gouge cenlre line should he kept to fall in the same line of Ihe centre line of axle box sidcs. T\\!o, 3.5 mm 1hick shims are required to be used simultaneously.

~.2.8 Adal,!er: WIDE JAW/NARROW JAW ADAP­TERS TO BE USED WITH TAPERED CAR­TRIDGE ROLLER BEARING: REFER SK-78527 & WD-R509.1-S/I WIDE JAW & MODIFIED WIDE JAW ADAPTERS RESPECTIVELY &. WD-89067-S/9 (FOR NARROW JAW ADAPTER).

\Vhen bogies <Ire disJllantled for any purpose adapter must he thoroughly inspected for soundness and wear. The inspection for Wear shall include the application of gauges at IOc;:llions det;:,iled in Fig. 8 & 13A.

The follrming condilions sh,,11 render the adopter to be scr"J'pc:d and rcplaccl\ '.-

(:Ii Cr;leked or bmken a\ "n)' location .

(b) W<lrped or twisted or otherwise distore". To check the adapter for distortion. place the ad"pter on the bearing outer ring. It should sit firmly on tIle outer ring without rocking when hand pressure is applied on the top of the adaptcL

(c)- When uniform weal' band on the outer cup is not observed where the adapter sits and shining marks are scen on the wear band area. the aciapter should be scrapped. The shining.marks at the ends of the wear band corrcspo'nding to (A) in Fig. 13 & 17 should. not be the cause for rejection. Non~u nirorm wear band on the outer cup indicates th"t the aclapter bore does not match with the outer cup dia.

(d) Worn to the extent th"t lidges or grooves prevent the proper scaling of the adapter on the bearing.

(c) When the wear at the thrust shoulder. adapter hore. adapter crown lugs. <ldapter crown seat. adapter <ide lugs and adapter sides reaches the limits indica'tcd in subsequent paragr<lphs.

(I) Whenever visual marks of the adapter seating are found to be confined on a limited length circumferen­tially on the outer cup. the bearing should be rotated so as to bring that p011ion of the outer cup seating area underthe adapter which docs not have adapter scaling marks. This procedure will facilitale shifting of the loaded zone du ring the life of the bearings and thus increase Ihe life of the Cartridge Bearing which are worn in one side between lugs from brake reactions hut which are otherwise satisfactory for reuse should he reversed when reused. When both sides exceeds J mill weat'. do not I'euse adapter.

5.2.9 Thrust shoulders:

Wear limit ~ 0.7 mm

Gauge: Wide jaw } .-Nan"ow jaw

Fig. 9·

The thrust shoulder of the used adap1ers may show grooves due to contact wi1h the ends of roller bearing outer ring. The depth of such grooves shall be gauged hy using gauge at Fig. 9.

If. at any point OIi lhe periphery of adapter. the gauge touel;es i.e. the groove is n.7 nUll. the adapter shall be scrapped.

5.2.10 Adapter bore (bearing scat) :

Gauge = Fig. 9

Machined relicf has been provided by the side of the hearing seats at a ·different level. When measured. machined relief depth shall be 0.8 mm or more. The gauge shown at Fig. 9 B shall seat on the bealing seat without touching the machined relief. If the gauge touches the machined relief. the adnpter shall be scrapped.

rhe "dapter bearing seat III ust be checked over full arc hy Ihis g:lUge.

5

5.2.11 Adapter Crown Lugs:

Wear limit

Gauge Wide Jaw

Narrow Jaw

4 mm

Fig. 10

= Fig. 14

New/Renewed Worn

Adapter Crown Lugs 156 mm 164 mm (Wide Jaw)

Adapter Crown Lugs 155.5 mm 163.5 mm (Narrow.law)

To determine the amount of wear in the adapter outer and inner lugs use the gauge shown in Fig. 10/14.

With gange in position as shown in Fig. 10/14 (A), if a 5 mm thick shim can be inserted between the worn lug and the gauge on either side at any point, the adapter shou Id be scrapped.

Before using the gauge. the centre line of crown seat is to be marked taking the unworn surface of the crown lugs as datum. While using the gauge. the centre line of the gauge and Ihe marked tentre line of the crown seat should be kept in the same line. The gauge should be moved for full length of crown surface to measure wear.

5.2.12 Adapter Crown Seat:

Wear limit

Gauge Wide Jaw

Narrow Jaw

3.5 mm

Fig. 1\

Fig. 16

NewlRenewed Worn

Adapter bore seat to Crown Scat' Wide Jaw Adapter 48.5 mm

Modified Wide Jaw 25.5 mm Adapter

Narrow Jaw Adapter 26.2 mill

45 mm

22 mm

22.7 mm

Determine the amount of wear on the adapter crown seat by using the gauge shown in fig. 11/16. '

The gauge should be applied as shown in Fig. A of Fig. IlI16. If a 4.5 mm shim can be inserted between gauge I and gauge 2. it indicates the limit of wear and the adapter should be scrapped.

5.2.13. Adapter Side Lugs:

Wear limits

Gauge: Wide Jaw Adapter

Narrow Jaw Adapter

000000'0602

3 rom

Fig. 12

Fig. 15

Ad:tpler Side Lllgs

Wide .r"w

N;] rrow J;1\\/

Ncw/RcncWCl! \Vonl

1 30 111111 I 36 III In

97 mill 11)3 I11Ill

Determine the ,111101 1 n1 of wc;)(' on the fldflplcr side lugs hy using the g<lUgt.: shll\vn in Fig. 12/15.

\Vil h I he gauge in posi lion ;1.., shnwn in r- ig. 1 ::/i S (A}. : r a 4 mm thick shim em) be inserted helween worn jUf­

face or the lug and gauge <It either jidL'S at ~Iily poilll. the adapter s.hall he scrapped,

ileforc using the riwgC. v~r!ic~li L'('!ltre line .;i"C;il:h "idi..' . is to be marked tirL.:iJl(. !he 1I11,VUm surt;!ce of tile .'·;idt'

lugs as datum. \Vhi!c tJ~il;r Iht: e!~lUgC. Ihe ~cnjr.: linc or gauge ~md the lll,Hkcd Cl'ld('c line (Il!i:c side of(ld~lpl('r S.hOlild l")c Lcpt in !i'l' ."MllL linc. The :;;lUt.'c ..:hollid he moved for full knglh or worn surface to 111caSUrc

W('(1r.

5.2.14. ;\dapfl'r ~idt~:

\Vc(lr limit

Gauge: \Vidc j;l\\I

N a rJ'()',V .h w

Ad"pler Side.,

Wide Jaw Narrov,/ Jaw

J min

Fig. 1:1

Fig. 17

New/Renewed Worn

16X 111111

I X t' Illlll

2el2 mIll

175 lIlin

Determine Ihe amount of wear Oil the (Hiaplcr side hy lIsinr. the gauge shown in Fig, J 3/17,

\Vith ~p11lge in position a.' shOWJl in Fig, \3/17 (A). if:1 shim of :;.5 mill thickness can be inserted hel\I,'cen the Glstingand the gauge <11 (:;'I\.::h end at any point, adapter should be scrapped.

Refore using the gauge the centre line of the adilpicr .sides is tt') he: marked Oil the adaptn sides laking t1l1\\:orn surf;lcc of their adapter CIS datulll The f!<luge centre line sh)U\d he kept 10 rall on the marked ce1ltre line of adapter sides. Two: .).S mm thick shims ,He.:

l'cqtlired to ',1C llsed simultancoli.:.dy,

:;.3 SIDE FRAME WITH FRICTION WEAR

PLATES

5 . .1.1 Side Frame: The \\,e;.lring surfaces in the side frame ,He shown in Fig. 22123. Details of reclamation procedure for each loccltion (!rc given in the following p,uagnlphs',

:1.3.2 Side frame Colnmn Friction .Plate :

(Common for ill! versions)

\Vcar limil

Reference

4 llllll

Fig. 24.

Sidc Fr~l1l1e columns kl\'C been provided with 10 111m ;hick Silico Mang'lIlCSc. Slc,,1 well\' liners 10 IS: .'8S5 PI. L Gr. IV weldcd on lhe colulllns. Tile liners ;nay be pCl'miftcd in service lip to a thickness or 6 1111ll to he i:'tlSl/H.,d by suil;:lhlc g,lugC ct..:ntrally pl.Jecei. or

G "ij' 'l U'" i I 0·:' .!j .; U t.: OJ t..;'u .... 6

\\hcncver found broken. Usc friction plate as shown in Fig. 24.

Dress lhe surf"ce of column face.

The new [riclion plale is to be held light against Ihe column face during welding whieh should be done in clownhand position.

~i;ln welding at di,lgonal ends of the plate and work !<nvards the centre.

Refer Annexure 'F' for olher welding details.

No pilint or grcase. should be applied on fdcliol1 plate .

~.3.3 Side Frame Column Sides:

(Common for all vcrsions)

\VC,H limit

Gauge

5 mm

Fig. 25.

New/Renewed Worn

the

Column Sides 216 mm 206 mm

Thi:i gauge deknnincs the amount of wear on the out~ side and the inside of 5ide frame columns.

,Mark the centre line nn !.he friction plate or sleel C3St~ ing and place lhe gauge so lhat tite cenlre line of the g;lUgc fell.< in line wilh the cenlre line of the side frame column as shown in Fig. 25. If a 6 mIll shim can be inserkd hetween the ca~ting and gauge at each side, at ;lIlY point. !he surface should be dressed 10 enable "clding of suitably thick liners of Silico Manganese Slee} follo\\ing welding procedure as per Annexure 'F. Afler pUlling liners. admissibilily of Ihe gauge should be ensured.

NOTE: Two: 6 mm shims arc required $ i III U Ita neolls!y.

S.3.4 Side Frame Anti-Rotation l.ug:

(Camnltln for all \'ersions)

Wear limil

Gauge

3 mm

Fig. 26.

to be used

New/Renewed Worn

Anti-rotation lug 522 mOl 528 mm

This gauge determines the wear on the anti·rotation lug. Wilh gauge in position een trally placed, if a 4 mm shim can be inserted between the casting and the gi!UgC at Celch rotation stop. at any point Ihe surface should be dressed to enable welding of suilably thick liner of Si-Mn Sleci. following welding procedure given in <lllnched Annexure 'F' (Refer Fig. 26).

NOTE: Two: 4 111m shims are required to be used ~i III U Ita ncotls' y.

The gauge is designed 10 use wilh frielion plate applied to the side frame columns. If anti~.rotiltion lugs are

gauged without friction phlles two 10 mill thicK spacers (one at each side) shoulJ be positioned within the column and the gauge to simulate friction plates on tIre columns.

5.3.5 Pedestal Crown Roof:

Wear limit

Gauge

Key Seat td Pedestal

Crown Roof

22W

22W(M)

5 IUm

Fig. 27 & 28 (for22W. 22W Retrofit­ted, 22W(M) and other versions respectively).

New/Renewed Worn

273 mIU 278 mm

318 IUm 323 mm

22NL/NLR/HS 323 mm 328 mm

Determine the amount of wear on the side frame pedestal Crown Roof by using the relevant gauge shown in Fig. 27 & 28 as the case may be.

With the gauge in position. as shown in Fig. 27/28 (A), if a shim of 6 mm thickness can be inserted between the casting and the gauge at any point, the surface should be dressed to enahle weJding of suitably Chick liner of Si-Mn Steet fallowing welding procedure as ret Annexure 'F.

The repaired Crown Roof should be checked with the gauge for flatness excessive material is to be removed by grinding.

5.3.6 Pedestal Crown Sides and Sides of the Pedestal:

Wear limits Crown Sides 4mm

Pedestal Sides

Gauge Fig. 29 .for Casnub 22W, 22W (re­trofitted) & 22W(M)

Fig. 30 for Casnub 22NL 22NLB & 22HS Bogies.

Bogie New/Renewed Worn

All Bogies Crown Sides 152, mm

22W. 22W(M) Pedestal 105 mm Sides 22NLINLB/HS Bogies 81 mOl

144 mm

101mm

77 mm

Determine the a mount of wear on pedestal crown sides by gauge shown in Fig. 29 or 30 as the case may be.

Pedestal Crown Sides: With the gauge in position as shown in "A" of Fig. 29/30 it a shim of 5 mm thick can be inserted between the casting and the gaug~ at each end at any.point repair should be made by welding, following the instructions given in Annexure 'D'.

NOTE: Before using the gauge the centre li~e of the pedestal crown sides is to be~~:marked taking the

7

unworn surface as datum. The gauge centre line sholl ld be kept to fan in the same line of the centre of the pedestal crown sides. Two 5 mm thick shims are rcquired to be useel simultaneously. The gauge should be moved for the full length of worn surface to measure wear.

Pre-heat the area to be reclaimed up to a temperature of 250°C before undertaking the reclamation work.

After welding. the welded portion should be allowed to cool slowly by covering it with asbestos/sand.

Sides of the Pedestal: With the gauge in position as shown in "BOO of Fig. 29/30. if a shim of 3 mm thickness can be inserted between the casting and the gauge at each end at any point. repair should be made by weld­ing following the instructions given in Annexure 'D'.

NOTE: Before using the 'gauge the centre line of the sides of each jaw is to be marked taking the unworn surface as datum. The gauge centre line should be kept to faU in" the same line of the centre line of the ja"w. Two 3 mm shims are required to be used simulta­neously. The gauge should be moved for the full length of worn surface to measure wear.

Pre-heat is not necessary.

5.3.7 Pedestal Jaw for Casnub 22W, 22W (Retrofitted) & 22W (M) Bogies:

Wear limit

Gauge

Casnub 22W 22W (Retrofitted)

Casnub 22W(M)

4 mm

Fig. 31

New/Renewed Worn

270 mm 278mm

278 mm 286mm

Determine the adount of wear on the pedestal jaw (outer and inner) by using the gauge shown in Fig. 31.

With the gauge in position as shown in Fig. 31 (A), ifa shim of5 mm can be inserted between the casting and the gauge at each end at any point, repair should be made.

Casnub 22W Bogie (Cyt. RoUer Bearing) : Worn out sur­face shall be reclaimed by welding following the instructions given in Annexure 'D'.

Casnub ZlW Bogie (Cartridge bearing), Retrofitted Cas­nub Bogie and Casnub 22W(M) Bogie! Worn out sur­face shall be reclaimed as per instruction given in. Fig. 32.

NOTE: Before using the gauge .the centre line of the jaw opening (Le. distance between outer and inner jaws} is to be marked taking the un-worn surface ofthe jaws as datum. The gauge centre line should be kept to fall in the Same line of the centre line of the jaw

opening. Two 5 11111l thick shims are required to be used siniultaneously.

Pre-heat is not necessary.

5.3.8 Pedestal Jaw of Casnub 22NIJNLB/HS Bogies:

Pedestal Jaw (Short)

Distance between Pedestal Jaw (Outer and Inner)

Wear limit

Gauge

New/Renewed Worn

190 198

4 mm Fig. 33

Determine the amou nt of wear on Pedestal Jaws (outer and inner) by using gauge as shown in Fig. 33

With the gauge in position as shown in Fig. 33(A) if a shim of 5 mrn can be inserted between the casting and the gauge at each end at any point Pedestal jaw face should be dressed to enable welding of suitably thick silico manganese steel liners as shown in Fig. 33. Pro­cedure for welding shall be fonowed as per Annexure 'F'. After welding of liners it should be ensured that gauge admits between the jaws.

NOTE: Before using the gauge centre line of the jaw opening is to be marked taking the unworn surface of the jaw as datum. The gauge centre line should be kept to fall ill the centre line of the ja w opening for Pedestal .Taw long & short. Two S 111m thick shims are required to be used simultaneously.

Petlestal Jaw (Long) :

Wear limit 4 mm

Gau~e Fig. 34

New/~newed Worn

Distance between jaws 236 244

Determine tbe amount of wear on pedestal jaw (outer and inner) bX using the gauge shown in Fig. 34.

With the gauge in position as shown in Fig. 34 (A) if a shim of 5mm can he inserted between the casting and the gauge at each end at any point pedestal jaw face should be reclaimed and restored to original contour by welding and grinding <lS per the procedure given in Annexure-'D'. After reclaiming it should be ensured that gauge admits in the jaw opening.

, . Sideframe key with key bolt spring washer nut and split pin has been provided as per RDSO's Drg. No. SK-fi9594. Ad'lpter retainer bolt as per Drg. No. SK-69594 has been providecl 01\ Casnub 22W. 22W(Retrofitted) and Casnuh 22W(M) bogies but has been eliminated on Casnub 21NL. 22NLB. and 22HS.

'0000000605 8

5.3,9 The repaired sideframe should be checked for its wheel base (distance between centre lines of the jaw openings) and ensure whether the correct. button marking is left on the repaired sideframe. While pairing the sideframe for a bogie, it should be ens~red that there should not be any difference between the nU'mber of buttons on the two sideframes.

5.4 BOLSTER: The wearing surfaces in the Bolster are shown in Fig. 39. Details of reclamation procedures for each location are given in the following paragraphs:

5.4.1 Bolster Pocket 35± 10 Slope Surface NOJDinal

Liner Wear Limit: 5mm

Bolster pocket has been provided with 8mm thick Silico Manganese Steel Liner to IS : 3885 Pt I Gr. IV Welded with Pocket Slope. The liner may be permitted in service upto a thickness of 3mm.

Chip off the welded liner to prepare the surface for welding new liner.

For welding of liner procedure given in Annexure 'F' be followed.

No paint or grease should be applied on plate.

5.4.2 Bolster Land Surfaces and Rotation Stop Lugs (Common for all Casnub Bogies)

NOTE: Some bogie bolsters such as those of Cas nub-22NLB '& 22HS bogies have been provided with 5 mm thick wear liners on land surfaces & same are to be required to be replaced after 3mm wear.

Wear limit:

Bolster land surface/= 3mm wear liner

Rotation stop lug

Gauge

=3mm

= Fig. 40

New/Renewed Worn

Dim. over Bolster land surface/Wear Liner.

Dim. over rotation Stop lugs

444

518

438

512

Before repair is undertaken the exact wear is measured by using t,he gauge as shown in fig. 40. The Centre line of the gaage should fall in line with the marked centre line of the bolster as shown in Fig. 40.

With the gauge in position if a 4mm shim can be inser­ted between the casting/wear liners and the gauge at each land surface or rotation stop lug at any point, the wornout surfaces should be dressed/worn out liners, if provided. s40uld be chipped off & surfaces should be dressed smooth to enable welding of suitable thickness of Silica manganese steel liner following

welding procedure as givc\\ in Annexurc 'F'. The width over land surfaces and rotation stop lugs after the welding of liners should admit the gauge.

NOTE: Two shims of size 4 mm arc required to he used simultaneously. Preferably liners on land sur­races shou1d he welded aflcr rcd~liming: inner column gib by welding and hefore reclaiming outer gibs by liners.

5.4.3 RoIster Column Gihs :

Wear limit

Outer Gih Inner Gib

,. Outer Gib Inner Gib

New/Renewed Fig. 41 Worn

= 5m I1l

=5111111

Others Casnub Others Casnuh

234 136

nI-IS 22HS

241 136

244 146

251 146

This gauge determines the WC~lT on outer and inner column gibs.

With the gauge in posilions as shown in Fig. 41 if a shim of 6mm for outer and inner gib can be inserted hetween casting and the gilUgC al eetch end at any point outer gibs are 10 be reclaimed by welding Silico manganese 'lee1liners of suilable Ihickness as shown in Fig. 41. following Ihe welding procedure as per attached Annexure .F".

Inner Gihs are to he recblimed by welding procedure as per Annexure ·D·.

After reclaiming holh the Gibs. it should be ensured that widlh over the Gihs should admit the gauge.

NOTE: Two (, mm Shims arc required to he used simultaneously for each locations.

5.5 SPRING PLANK: Spring plank is a member made of mild steel (flanging quality).to IS: 5986 Gr. Fe .'GO.ltjoins two sideframes ofeasnuh bogie by eight 24 dia Iivets and four M24 ·fit' bolts to keep bogie fmme square.

Spring plank should he examined for defects like 100se'ling of rivets/cracks/bending. welding failure of ~prings spigot etc. Whenever. spring plank is renewed. the leading dimensions of the bogie as per Drg. No. SK-69599(W). WD-85054-S/6 (22WM). WD-90042-S/l (NLB). WD-92058-S7(HS) must be measured on the uxture. Special care is to be taken regarding the use of ·fit' bolts as well as quality of rivetting. Fitment of spr­ing plank with the side frames should he done on suit­able fixture.

5.6 LOAD BEARING SPRINGS AND SNUBBER SPRINGS: The bogies arc fitted with two groups of long travel helical springs nests. The spring group for bogie for various axle load applications ~re shown in Gg. 42 & 43. Spring detail., arc shown in WD-83069-S/l

9

(Common for all versions except Casnub-22HS Bugie). The spring details for Casnub-22HS bogies are shown in WD-92058-S/5

5.6.1 namping: The suspension is provided with load proportional friction damping arrangement with the help of a M n Steel Cast Wedge supported on the snubber springs. The details of the snubbing arrange­ment are shown in fig. 42 & 43.

5.6.2 Load and Snubher Springs: The spring groups for 'Casnuh' bogies are shown on the "Details of Snub­bing. Spring Group Arrangement Drawing Fig. 42 & 43 for different type of Axle Load.

The springs are condemned on the basis of free height. Springs should replaced if minimum spring height is at or less than shown below:

Bogie Springs

All versions Outer ('xc~~pt Cas nub Inner 22 HS Snubber

Cas nub 22 HS Outer

Bogies Inner

Snubber

Free height

nominal (mm)

260 262 294

260

243

293

Recommended free

condemning height (mm)

245 247 279

245

228

278

Grouping: Matching of both. load and snubber springs. is important. It is recommended that springs having not more than 3 mm free height variation should be assembled in the same group.

Mixing of new and old springs should be avoided.

The 'Cas nub' bogie springs are manufactured out of Silica Manganese Steel to IS: 3195 Gr. 60 Si 7, Gr. 60Cr4V2. IRS Specification R2 & RDSO Specification WD-Ol-l-ILS-94 (Rev. 1).

5.7 FRICTION SHOE WEDGE BLOCK (SK-77579 Common for all versions)

Wear limit

VertiCil I surface from centre line of spigot.

Vertical Surface

Slope Su rface

Gauge

NewlRenewed

61 mm

7 mm

3 mm

Fig. 44

Worn

54 mm

This gauge detennincs the wear on the friction shoe of the two wear surfaces.

5.7.1 Vertical Surface: With gauge (Fig. 44) in posi­tion if an 8mm shim can be inserted between the cast­ing (Vertical surface) and the gauge at any poinL repair

C00000060J

should be nVH1c. The ";\lorn surf,lce sball he reclaimed by welding.

:i7.2 Slope Surf:H'l': The wear on l11e slope surt',lce is 10 he measured with g;lltgC (Fig. -l4). \Vith the g;lUgC

ill posilion ira 41]1111 :,hil1l c<ln he ill.sCrlCd hel\vce!\ the casting and the giluge at cenlrc point (marked on the gauge). the wedge i,,, 10 he replaced by :1 new olle.

5.7.3 Reclamation of Friction \\ledge: Mcthnd-I (P:·c­ferahle dnring P()II)

Surface Preparation: The surfacr should he cleaned properly 10 rCIll(h\~ dllst. oil. (:r(lc~ . .,. sc;l1cs. dent m;'lrks

clc. prior to welding.

Electrode: 4111111 size eli;'1 ()r .111) of the rol1ov.'in~ elec­

lrodes approved lIndcr eLl" 112 '" per IRS M-2;;· J 97(, should be w:;ed. The br<llld Ilrtn'c of electrodes ;Irc :

I. "Gridu:~M·· l1lanUf;lcturel! hy ~vf/s General Flectrrdcs EquirnH>nh Ltd .. Bomhay.

") ··ManJ.!;1I1ic···-·m;lnllf"dcIIJrcd hy Mis Modi Arc.

ElcclIodcs eG .. Mndillagar.

3. ·'Philips MN·· manufaclured hy Mis Philips

lnrli". Lid .. Ramh"y

4. "~1:-mg:lnic India'·, m;:lnufaclurcd by Rock\l,;cld Illcli;]. M;Hba . .I.

Current CnndiHons: The power source as reC01l1men­ded hy tile m;lI1Ur[lCllHCr of Ihe elcctrodes sh,lIl he lIsed. 'I'll·: lowest t""l{).ssi hi C L'lI lTC III l' ;·1 pel h Ie () f [l r()(lu ci ng s;ltisfacfciry welding should he U"C(J. Over he,l[ing should he tlvoidcd.

5.7.4 \lidding Prllecdure:

I. Short nnrl stringellt welding bC:ld should he used.

2. Skip welding .";CqUCllCC shouid he: followed.

3. Short arc should ht' i11;Jlnt,lincti.

. 1. \Vc;lVing is not nxoll1!11cnded.

5. The suhscrjllcnt rlln~ life only to he g.iven ,Incr the preceding mns have heen cooled to "hand \~;1r11l".

6. The weld bCild sh(Juld he peened immccii;ltcty

iJfter welding.

7. The craler should he filled up by removinr the electrodcs slowly ,dter goin!;! b;'H.:kw:lrd.

X. Po~t weld Ill'at treatmcnt : I! .should he ensured that the weld ll1ct;11 is quiddy cooled.

5.7.5 Inspection: The \ ... ·L:ldcd surf~lc~ after being cooled should be ground properly 10 the required dimensions and then subjected to dyc-penc(r~lI1t tesl to ensure freedom of surface cracks. During grinding it should be ensured lhal ,";Jll;.tli arca is ground and im mediately cooled h y pOll ri nt~ \Va ter or a ppl yin g COJll­pressed air 10 avoid formation of surface cracks.

\10111011-11 (rnr ROil Depots): .

Rcd:lI11·"lion of Wedge Block by Welding a ~Iate.

(,,) Plale 10 be u.led has 10 be ahout 5mm .<horter in dimcnsions nil "round Ihe Wedge Block.

(h) A mang"nc.,e sleelliner of 120 mm X 140 mm X (, 1l1ln is required 10 be welded on the wedge face by using Class I12 eleclrodes as per IR Classific8lion.

S.H CENTRE PIVOT:

(a) Centre pivot arrangement for Ctlsnub 22W bogie is os pcr RDSO Drg. No. WIllE-flOI for lap cenlre pivot and W IllE·fi02 far bottom centre rivot (fOf sep;uate cast bottom pivot) or bOil om pivol integrally casl with bolsler (SK-775i8).

(h) For C<-lsl1llh Bogies of versions other then Cas· nuh 22W Iype eenlre pivot boltom and centre pivot lop are as per RDSO Drg. Na: WD-85079-S/2.

(e) Cenlre pivol pin for Casnuh 22W bogie is head­less pin \\lhilc for other versions is a special type of pin provided wilh c"stlc nut/shackle lock for locking. (Refer Fig. 47).

(d) Centre Pimt "augc : To be used for integral! scp;]rale Iype cenlre pivol ofCasnuh 22W & for spherical type bottom centre pivot of Casnub­lCW(MI. 22NL. 22NLB & 22]]S Ragies.

\VC:IJ' li!l1 i I Vert iell! Side 5.5 mm 4 mm

s\~ ,11 4 ml1l 4 mm

C;Juge Fig. 4) & 46

Deterllline the ~J!llOIl[lt of \·,tear on the scat and sides or centre pivot howl hy lIsing the gauge shown in Fig. 45/46 .

To determine lhe s(~i!1 wear, the gauge should be placed in po.,ilinl1 (IS ~ho\V1l in Fig. 45/46 (A). ffthe pivot SUf­

C;lCC st;lrls touching the surface markl.!d as'" on the t!-;luge at any point n:p;\ir should be made rollowing the \Vclding Procedure given at Annexure 'D'. The g,\uge should he moved on the complete worn surface to he mc;\sured. The surfaces aftcrreclnmation shaH he 10 [be original dimensions as per the respective d r,1 wi ng." for proper J1l:11ching of surfaces with top cen­Ire rivnL

To determine the \I.,TarOn vertical wan oflhe bowl with gauge in po,<;itinn ira Y mm (forCasnub 22'V) & 7 mm (for olher Bogies) Ihick shim can be inserted for the rldl depth hetween the worn surface and the gauge at (lilY point repair :-;hould be made as per prticcdure given in Annexure 'I)". The gauge should be moved on thL' complete WOrtl surface to be measured.

During ROB/POn the wear onthe vertical side of the howL seat of the bowl should be built up by welding.

Pre-heat the surface to be reclaimed upto a maJ.imum temperature of 250°C and after welding it ~h04]d be allowed to cool slowly by covering the welded portion with Asbestos/Sand. '

The repaired pivot should be checked with gauge in Figs. 45/46 applying two 4 mOl thick shims between the casting and the gauge surface marked as *.

The gauge should be moved around to eheck the pro­per fit up.

5.9 Stl)E BEARERS:

Casnub 22W Bogies: Bogies are fitted with roller type side bearers which are free to move in a cast steel hous­ing riveted on the bogie bolster. The detafls are shown in Fig. 35 ..

Casnub 22W (Retrofitted), Casnub 22W(M), 22NL, 22NLB Bogies: Bogies are fitted with constant con­tact type of side bearer rubber pads located in Cast Steel Housing which is riveted to the Bogie Bolster. The details are shown in Fig. 36 for Cas nub 22W(M), 22NL. 22NLB Drg. No. WD-89094 for Casnub 22W (Retrofitted).

Casnub 22118 Bogie: Bogies cue fitted with Helical , sIfring loaded constant contact type side bearers

rivetedlbolted on bogie bolster. The details are shown in WD-92058-S/9/WD-92093-S/l.

Condemnation criteria for side bearers are given in Para No. 5.10.1.

5.10 ELASTOMERIC PADS: EhlstOlneric pads are provided in all the versions of Casnub Bogie except Cas nub 22W., The main purpose oJ providing . elas­tomeric pads is to reduce wheel flange wear.

5.10.1 Elastomeric pads to WD-89067-S/IO & WD­n058-S/8(For HS) and side bearer rubber pads to WD-85076-S/l shan be con.lcmned on the following grounds and shall be replaced by new ones:

(a) If the top or the bottom plates or intermediate plate in case of side hearer pads show any crack in service.

(b) Ifanycrack of more than 50 mmis developed at any surface of rubber.

(c) Ifa bond failure givingw~ more than 40 mm in any direction is developed in service;

(d) When in free condition. the pad has taken a per­manent set of the order given below:-

Type of Pad Nominal Dimention

EJastomeric pad Side 'Bearer Rubber Pad

2-41 RDSO/Luck/97

Dimensions after penna­nent set

46 mm 114 l\un

42 mm I09inm

11

(e) If any sign of crushing of rubber is noticed.

s.li BRAKE GEAR MAINTENANCE: The general arrangement of brake gear are shown in Fig. 48, WD­RS054-S/4, WD-89067-S/5. Bogie Brake details are shown in SK-69597.

The brake gear consists of mainly : Brake Beams (with brake head and brake block assembly), Equalizing Levers, Push Rod, End Pull Rod, Brake Beam Hangers (in Casnub-22W(M) Bogie).

The bushes provided are either IRSM:4 Class IV or Class I case hardened (lS-2073 C-45 or C-14 case hardenedlIS 5517-45 C8) and pins are made from steel to IS : 226 Fe 410S/IS 2062 Fe 410 WA The maximum permissible wear on the pin diameter and bush inside diameter is limited to 1.5 mm.

In service as the tread dia. of wheel decreases due to wear, pins located in End pull rod with underframe are to be relocated as shown in Fig. 50.

The brake beam of Casnub 22 W is of a purely fab­ricated (structural steel members) design with inte­grallyfabricated brake head. In case of Casnub 22W(M) bogie it isof Cast Steel and Brake Head & Block Assembly isa separate assembly. This sub­assembly is attached at the circular ends of a Cast Steel Brake Beam by means of a pin.

In case of Casnub 22 NL/22NLBI22HS bogies the brake beam is fabricated one. Brake beam strut and End piece casting are of cast steel. Brake head is integral part of ' End Piece Casting'. S;;tme brake beam has now been specified for Casnub 22W also.

The standard brake shoe to Drg. No. WA/BG 6158 which is used on 'BOX' Wagon can be locked in posi­tion on the brake head by means of a key. The brake shoe should be replaced when worn 48 mm i.e. when 10 tnm' metal is Jeft from the base of the shoe.

5. tt.l BRAKE BEAM: Casnub 22W, 22NL, 22NLB & 22IISBogies : Bogies are fitted with Unit type fab­ricatd brake beams which slide in guide cavity pro­vided on side frames.

Cavities are provided with Silico Maganese Steel liners. The brake heads are integral parts of the brake beam. The details of standard versions of brake beam for all versions of Casnub bogies [except Casnub 22W(M)] are shown in Fig. 49. The details are shown in WD-89033-S/1. However, the brake block to WA/BG-6158 is common for all versions.

,CasDub-22W(M) Bogie: The bogie is fitted with Unit type suspended cast steel brake beams. The brake head is 11 separate sub-assembly which is fixed with brake beam circular ends by means of pin passing thorough brake beam end and brake shoe adjuster alongwith spring loaded brake head. Assembly provides rota­tional flexibility to brake head. Details are shown in Drg. No. WD-85084-S/1, WD-88012-S/l & WD-86034-S/1.

£000000008

RECLAMATION OF BRAKE BEAM ON ACCOUNT OF WORN OlJT BRAKE HEADS: Reclamation pro­cedure for different versions of Casnub bogie brake beams shall be as follows:

Casnub-22W Bogie :Brake heads are welded with brake beam channel. side rest and outer stiffner plate as shown in Drawing SK.69596. Repair procedure for worn out brake heads is as follows :-

Replacement:

(a) Remove worn out brake heads by gas cutting the welds indicated in drawing SK.69596 with as little damage to other members as possible. Other members. if damaged. should be built up by welding using electrodes and taking pre­cautions as per Annexure 'C' followed by pro­per cleaning and finishing operation.

(b) Weld new brake head at correct position with brake beam channeL outer stiffner plate and 'Side Rest' by fillet welds of Sizes indicated in drawing No. SK.69596. ..

Repair by Welding: Depending upon extent of wear on brake head it is optional for Repairing Shop~/Depots 10 either go for total replacement of worn out brake heads or to build up worn out portion by welding as per Annexure (C). followed by proper finishing operations.

Casnub 22W(M) Bogie: Brake Heads a're fitted on brake beam with the help of Brake Shoe Adjuster as shown in drawing No. WD-88012-S/1. They are further secured on brake beam ends by Washer and split pin. Procedure of replacing worn-out brake heads is as under ':-

(a) Remove split pin and washer from brake beam ends. Remove pin securing brake shoe adjuster with brake beam by relllOving split pin.

(b) Take brake heads out of brake beam alongwith brake shoe adjuster.

(c) Disengage brake shoe adjuster from brake hea'a. by removing bolt after disengaging split/i)'iti; nut, cover. spring and adjusting piece.

(d) Assemble new brake head with brake shoe adjuster by using items mentioned in Para (c) as shown in drawing No. WD-88012-S/l.

/ (e) Slide new brake heads; assembled with brake shoe adjuster on brake beam end and engage brake shoe adjuster with brake beam by using pin and split pin as shown in drawing No. WD-88012-S/1.

(1) Further secure brake heads oQ,brake beaUt end "''>

by putting washer and splif"in as shown in drawing No. WD-85054-S/4.

C000000609 12

Casnub-22NL, 22NLB & 2UIS Bugies: Brake head ~s integrally cast with End Piece Casting which is weld~d with structural steel brake beam channel and 'Truss Flat' at ends as shown in drawing No. WO-89033-SIl. Depending upon the extent of wear, worn out brake heads can either be built up by welding following pro­cedure as per attached Annexure-D or worn out brake heads can be replaced by new brake head as follows.

Removal of worn-out 'Brake Head' from 'End Piece Casting' :. Fig. 51, 52 and 53 are to be referred for this purpose. Gas cut material shown as cross Hatched' in Fig. 51 & 52. Gas cutting may be fOllowed by gt:;inding operations to achieve contour shown in fig. 5l

Fabrication of New 'Brake Head': New 'Brake Head' shall be manufactured as per details in Fig. (54), Alter­natively 'Brake Head' can be produced by modifying, Brake Head of brake beam to SK-69596 meant for Casnub-22W bogie. Only modifications to be carried out is provision of opening of size 4lX27 mm.

Fabrication of New Brake Head with Bralf.e Beam: Fig. (55) & (56) should be referred for thi~ purpose. New brake head shall be welded with the brake ~am as per welding details shown in above quoted figures and following welding procedure and type of Electrodes etc. as per Annexure 'E'.

5.12 ADJUSTMENT OF CBC/BUFFER HEIGHT: To maintain CBC/BufTer Height within permissible limits following packings shall be pro.vided as des­cribed below for different versions of Casnub Bogies:

Casnub 22W, Casnub 22W (Retrofitted with Elas­tomeric Pad/and Constant Contact Side Bearers) Cas­nub 22W(M), Casnub 22NU22NLB/22HS Bogies:

S. Type of Bogie Wheel Dia Drawing to be No. followed

12 mm thick packlng l. Casnub 22W

~'l Casnub 2lW_ (Retrotitted) 910 WD-86021-S/1 Casnub-22W(M) 954

2. Casllub-22NL 954 } Casnub·22NLB 954 WD-91074-S/1

Casnub-22HS 954

37mm thick special packing l. Casnub-22W 924} WD-88039-S/1

Casnub-22W(M) 930

2. Casnub-22NL ~30 } Casbub-22NLB 930 WD-91074-S/1

Casnub-22HS 930

NOTE: 37mm thick special packing is not required for Casnub-22W(Retrofitted) Bogie due to use of worn out wheel from initial stage.

\~ 1 I

5.13 PRECAUTIONS TO BE TAKEN WHILE DOING WELDING OPERATION ON WAGON OR BOGIE FITTED WITlI ROLLER BEARINGS: Whenever Wagon or Bogies filled with roller bearings require welding in Workshops/ROJ-! Depots Sick Lines. Special ;ll1ention should be paid so that electric current may not pass through the bearings. The return current lead for earthing purposes shou Id be fLXed very close to the welding area and the earthing wire should he tightly secured at both ends. If wagon is not pro­perlyearthed the current passing through the bearings \vill cause arclng in between 1he rol1ers and raceways. leading to failure.

6. PROClJREMENT OF SPARE PARTS: Certain spare parts. which arc con.siderecl important in the per­forD1ance of Cas nub bogie. are to be procured from approved Sources only. These itms are also to he CO(1]­

pulsorily inspected by Executive Director (I&L)I RDSO. or his represent<llive. List of such components is given below-

(3) Brake beam

(b) Spring plank

(c) Springs

(d) Silico Manganese steel liners of Castlub bogies.

(e) Adapters

(1) Elastomeric pad and side hearer rubber pad

(g) Ce!)tre pivot

(h) Wedge }

To be purchased from Class 'A' foundries only, as per list issued by RDSO.

The list of approved manufacturers is updated by I&L Dte .. RDSO from time to time. and are issued under MW/ILJVENDORAPPROVAL. nlIs IS REVISED HALF YEARLY.

7. FAILURE REPORTING: POl'jler failure re­porting (1nd analysis is an important activity for ensur­ing proper maintenance and quality check on components leading to improved perfon11ance. Feed­hilck is needed for making design improvement also.

All bilse ,Ierots should maintain performance statis­tics. which should cover defect wise wagon detach­ments and rep .. lirs analysis, components life statistics & vendor rating etc. These are general guidelines and mily be modified to suit specific requirements.

Premature failure of items in'peclCd by RDSO should he directly reported to Wagon Dte. and I&L Dte. of RDSO hy the concerned division.

Failure reports should have fonowing information­

I. Wagon No.

2. Dilte of fililure.

3. St:ltion of failure.

4. Stillion where failed component has been kept.

5. Location of failure with it sketch.

6. Year of manufacture.

7. Nilme of manufacturer.

8. Metallurgical investigation report. This is necessary to know the cause of failure and affix responsibility.

Year of manufacture and name of manufacturer are to he provided by manufacturers on following com­ponents-

130gie side frame. Bogie bolster, Springs. Elastomeric Pad, Side bearer pad, Centre pivot. Adapter, Wedge, Brake beam Spring plank. Any of these components without these particulars cast/embossed on them should not be fitted on wagons.

, Metallurgical investigation report can be sent later after condUcting the investigation.

C0000006.l0 13

DitTercnccs among different \'crsions of Casnuh Rogics

----------------------------------SI. J)cscril,linn of IIl'm :\In.

\Vl"ighl (A"llmx,)

Yr, !If Manufaclllrt'

rYPE I. Si(l('""rallll~

IFj\l~ Typl'S)

C! C)

= c..:.-:I c: C~ = C). f-.­f-

2. RoIstc:>r (Six Types)

Casnuh 22\\'

III \Vide Pedeslal jaw opening. rockl't fpr sliding llr brake twam. PrrJ\·ilied \\·ilh hole for ("('Ininer hill! in Oilier jHWS.

Mat.:rial :-

IS: lflJO Gr. 27·54.

Drg. Sf(. 69592.

T,pe (I) & (2) Two Type.'>

1. Integml IRS Bouom Pivot.

(Protile uf WIBE-ff(2) Sf(. 77578.

2. Separate IRS Bot· tom Pivot. (Drg. WIBE'('()2) rivet· ted on bolster to Drg. No. WD-81023-S/I Hanom of bolster is straight. It is to be fitted with 'Side hearer housing for rollers' (ltem·2 of Sf(. 69594)

Rc,ro(itlt'd Casnuh 21W

(I)

Si.:ll'frame 01 (·n.<;nllh

nw sh all be pro· vidl~ll with alHAhr-f hule for rdainer hult h('}nw l":'I.isting one :11

a disl;!n.:e of 32 mm as shu .... TJ in Drg. \\'D· X9tI94-S11

Same as in Casnub 21W Bogie.

Casnuh 22 W(I\1)

CI Wide jaw opr-ning. hr:'H.:k~'ls for hrake: h("llll SllS.pt~llsion.

pG,ks!:t! ptlJ1iuIlIllO.I­

ifit'.ito :h.YOIllIllOtl'I!c­·El;>.slolllt'ric PiIJ·. Pnwi.1cd ..... ;th hute for relainf'"r hull in oulC'r j:Jws.

Mall'rial

IS: 1030 Gr. .:!7·54.

Drg. No. '\.'n~RSf):i4·

S/3.

(3) Drg. Nu. WD-85()79-­Sf] Bolsler has heMl modified to suit Jit· ilwnt of spherical hut­tom pivot. (WI>-

85079-S/2 hem-l).

Material :-

IS: 1030 Gc. 27·54

Bottom of bolster is ... traight. It is to be fit· ted with side bearer housing for metal bonded rubber pads. (ltem-4 of SK 69594)

Caslluh 22 NL

5.51.

S9-9I1

(.\)

Narrow jaw o)wlling. po.:kct lor hmkl' bC;Llll sliding. rH'.Ics­tal suit.able fOl·,h..·..:om· llloJating Ill~ri{; P·d(l.

Material

EI:I .... 1O·

Initially it was IS' 10:;0 Cir. .:!J·54. Subsequently rr-vise.l fur Casnub 22NUl Drg. No. ' .... D·~91)(17· S/J. There is nu hok for retainer boll in outer jaws.

Dolster is s<tmc as in Casnu b 22W (M)

Bogie.

S.·II. \)0·91

C:1snuh 22 .\)1...,1'1

.'i.1.2SI.

n -------- ----- _.

(4)

Sam\.~ ;l.~ in Casnllh 22NL bogj~ ~x\.·t"pt

m:llcli,li.

M:l1erial

Sp~cial ..-\!luy \.:a~.1

Sled h;l"\:ing cUlHp':Jsi·

I ion as follows-

C ll.~ to n.~";.

Mil. D.6 tu I.U'.\;,

Si. 0.03 lu U.5% S O.l~ MllX. P 0.04 M;lX .

Drg. Nll. Wf}-X,/<lli7-S/3

(4)

11 is ~\lilablt· for fit· ment of spherical bot· tom pi\-·ot. (ltem·l 01 \VD·85079---S/2).lt has heen given shape of 'Fish Belley' Ht the centre and wall thick· ncsscs have been reduced. Consequen­tly weight has been reduced consider· ably.

Material :-

Same as for Sideframr, (Drg. No. WD-89067-S/4)

co:; ) Olher t"l'atur(:s '.allll' ;IS ill ('a.sIllih 22 NL/ ."!2NLII I':-::Cl'pt matl'· Ii .. l ...... hidl is Spt~ciill

.;::1 .... ' .s1r-l~J hadn},' fo! Ie ..... ; ng l:omp.lsi·

liun-

C·El lllivalt'llt -IU~5% (M'H .. )

S·{).tJ.5% (Ma.x.)

P'{1.05% (MiL'(.)

SIIpt'I"iOl· Illct .. lllur .... ,,'Y has cnnblt"d red tie· lion in ""nil Ihicknrs .... and weit'h!.

Org No. WD·S9t17(}-SJ 3.

(5) Other design feHtures are same as in thr bolster 01 Casnub .:!2NI .. B ('xccpt thOlt the material of construc­tion is same as i~ for sideframe and weight has been further reduced by reducing Wall Thicknesses. Drg No. WD-8907(),SI 4 .

,\;\INEXURE-A (SIIEET-I)

Ca<nuh-21 liS

5.41.

9.1

H) S~lIue :IS in Ca:.:lllih 22 NUl Bogil'.s.

Dll!. No. WI)·i.;90lI7· SJ3.

(6)

BoL'Her difTers from that for Casnub 22 NLR in rcsped of diamctt"fS for spring spigots and increased outer gib opening from 234+210

-0

241 + 2 -0

Drg. No. WD-92OS8-S/3.

ANNF:XlJRF.-A (SIIF.F.T -2)

-----_ ... _----------------------,-------------------SI. He-scription or Itrm Nn.

J. Ct~nln:' Pi\"l1ts

O\\'U types)

4. Centre pivClt pins (Four Types).

,. .

5. Side Bearers

o a o o C-) D a c. ".. .. -,'v

Casnub 22\\<"

1-"1 "1)'Pe

R(·trnfit't:'d ('.JIsntm 12W

I. IRS I}1W buthUll S;1Il1t';lS in Cmmllh pivOi. (Drg. 'VinE· 22W BI~i('.

,

(lO2) inlegmlly cast

or separately ri"'('I-Ii.~d and l4'Chieli.

IRS Tup Pivot. (Drg. W/BE WI') rivclled with linder-frame bolster.

Type (1)

Casnub 22 W(M) C ..... b 22 NIJ Cunuh 22 NLB

nnd TypC'

Splw';{:.'ll type bOl· Santi' .as tn \asllub SHl1H~ lll> ill Cason/) lUlU pivot. (lll'm-) or 2.:!W(M) 22\V(M) Drg. No. WD-85H7~-S!2) and Tup pivot. (helll-:! of WD-85079-S/2) "'ith rt"lllin{"1".

retaining ring. Washer and Dust Shield ete.

(2) (3) (4)

Plain whkh rests on the plalfonn In

bolster (Drg. \V/nI:-613).

Same as in Casnub Pin with provision uf Pin lo~ked by sha(:klc Same t}pe of pin as in .2.2 N L. t"x~ .. :ept rt>.Juced kn.glil.

Oearnnce type Rol­lers placed in side bearer housing.

(Item 2 & 3 of SIC. 69594)

.2.2W Rogie. locking at bOllUUl by luck. Pin he-ad dill.

Constant contact Side Bearers. Metal bon­ded rubber pads (Drg. No. WD-85076-SI1) are placed in housing.

Item 2 of SK. 69594 with packing piece

(ltem-9 of Drg. WD-89094-S/1)

C:;stlc nut Jlnd split 70 1Il1ll.

pin. I J in he.'1d is 8UQ

suitably modified for pTPyenting rotalion of pin at the lime of tightening castle nut. Subsequently design was modified for locking by Shackle lock Pin head dia. was made 70c) mm.

Same as in Retrofil1t"d Casnub 22W except housing which io;. as per Item 4 of 5K. 69594.

Same ao;. in Casnub 22W(M).

Same as in Casnub 22W(M).

Cnsnub 22 Nl1\1

S4I!UC' us in ('nsnuh

.2:!W(M)

Same us in 22 NUl.

Same as in Casnub 22W(M).

Casnob 22 us

~;Iltll~ ;1S in Cnsllllb

~.2W(M)

Silml~ as in 22 NUl.

Constant contact Side Bearer (spring load­ed).

Drg. WD-n05&-S/6.

'-'I. Ik<;rriplinll or IIl'HI '\.j~ I .

(, Iha!..,' ik;IIH

\1 "l1il l}1W) ,\

bnlkv hint:k.

c-' ~" . .) = ) ( ..... C . .­~-:> Q:. ~ .. VJ

7. Hcarill£.s wilh ,I xIt'box/a( la pfl' fS.

8. Ela~lorneric Pad

Rt"rntillt'll Cll"nllh 22\\'

~;i,ling l~[>l' fall- S,!lllC:I:> 1:1 (·a.,;nllh

I·i...:ah'd .... 1 fll..:l lind ~h','l ~~\\" HlIo'i," t:llll .... 1nl,:li,111 !l}!\'inl'

i:ll<'grill br;Ik<' head.

[J)rg. NlI. SK. (,l)596) lInd Br;lb' 1H1l,:k \II Dr;,!. W·\. H{i-r,].~:-'

whil·h :11\' ."Ylln',1

tllgl'lhn b~ II k,'y.

Initial Je-Sigll wa;; with cyl. miler r..t'u· ing insiJc ilxlebox but subsequently use of standar,i AA.R taper­C'd CclTtridgc hC'aring Class "E' (6"X 11") was !>lanJarJised along­with wide jaw adapter to Drg. SK. 77578.

Basic v.rithout Pad.

dtJiga is Ela.')10mf'ric

Swndanl AAR Cnl"­fridge ben ring Cla.~.s

'E' (b~Xll~) wilh modifie-d wide jaw ad<lpter to Drg. No. \VD .. 85053-S/ I. l-ieight of this ,ltlapkr has bet!11 rcciu..:cJ by 23 mIll frolll thai of standard adapter 77578.

wide jaw to SK.

Elastomeric Pad to Deg. No. WD-89U67-SIlO is tu be retrofit­ted bctween modiJlccl wide jaw adapter and side frame pedestal crown fOTminimising wheel flange wear.

IIHnri:lg tYPl' (';lSI

Sll'.'i Brak .. Hearn hI

Drg. Nil. WJ)-,'\:,\)X~­

S.'I. Brake he;ld ... and hnlki' hl.Kks an' st" •. :lll"l'd hy key :111.[

Ihe~ ;In' f\l11h~'r

a.-';-"~'Inhkd wilh hrakt' bC;l\ll lhr(l\l~h spring loaded hmb' .... 111"11' Ildjl1s\('r ,IS .~hllwn in Drl,'. \VI )-:";SOI2-S/ I.

11 i.~ (11I11wr n' .... llrl!· 1l1l'!Hkd 10 .~\lSp"l111

hr;\ke IWflms from strut [0 jHC\'ent lheir

dn1!)l'ing :lS ShU\\"ll ill Drg. WI)-XIJ!Ii.'i-S:"!

Slan.1ar,J AAR Car­rridgt' t->C'uin:; (,hiSS

'F (hWX II ") wilh wide

jaw adaplt'r 10 SK. 77578.

E. Pad to Drg. No. WD-76."!I-SJI (Re­numbered IlS WD-89067-S/IO) is fitted hetween adapler frame crown.

wide jaw and side­

pedestal

Sliding 1:<11" hmb' b,';]I\1 r"hri,:;]I<'1I <1111

,II' C;I. ... 1 :--In·1 :"lnl1 and 'Fnd Pil., .... I. .. C;lS'

ting.s ha\'i!lg illlq!r:t! hrake h'~llds wilh .-.;1 rlll"lil rill sll"~'1 Illl'lll· her.s;ls SllllWll ill Dr.!,' N.I. WD-:><4Un-Sil

This hrak{~ h('mll loS

inl(""rch1!n~:'<lbl<.· wilh

pllrd~' r;lhrll',lfl"'[

hr'lk~~ beam nf elIS­

nub nW to Drg. SK. 69590. nnd":l~ Block 10

Drg. No. WA/Ber­(I] :'ii'i.

Sl ,] lhi:-Hd . AAR' C fir­lridge' ht'aring Class 'E' (6"X II"") with narrow jaw adR.ptt'r to D.rg. No. \\'0-89067-S/9.

E. Pad to Drg. No. WD-89067-S/10 is being filted.

C:l~nllh 22 NUl

,\:"<:"L\URE-.\ (SII U.T-.I)

S;lIll<" ;1. ... ill Ca.'>lllih S;I111C a.~ III C:l ..... 11llb S:lllll' :1<; ill <";1"'1111\'

2~NI 22NI. 22NI.

Same as in Casnub 21 NI..

Same as in Casnub 22 NL Bogie.

Same as in Casllllh 2'::­NL

Same as in Casnub 22 NL bogie.

Same :!.~ in Casllub 22 NI..

Fitted with Elas­tomeric Pad 10 Dfl!'. No. WD-92058-S/8 which is 35% stiffer in lateral modt:: <uid has nil clearance with adapter in lon­gitudinal direction.

CJ CJ a c...::> o c <::) c, ~.~

.,..:~...,

SI. Description of Item No.

9. Wheel Dia

10. Brake Beam Safety Strap.

11. Safety strap for push Rod.

12. Spring Plank

-~. -, ............. _~~.'1 .... ..L_.'"'

Casnub 22W

1000 (New) 906 (Condemnirtg) Previously condemn­ing dia. was 925 mm.

Not provided~

In original design safety Strap was provided. Now it can be removed after modifying equalising levers and brake push rod to DIg. No. SI{. 695~.

Drg. No. SK. 69594 Item-I.

Material: Structural Steel to IS : 226 St. 42S which was later on changed to flanging quality Steel to IS: 3747-66.

..

Retrofitted Casnah 22W

956 mm (New) 906 mm (Condemn­ing).

Not provided.

Casnub 22 W(M)

1000 (New) 906 (Condemning) Previously condemn­ing dia. was 915 mm.

Casnub 22 NL

Same as for Casnub 22 W(M).

Loop type brake Not Provided. beam safety 'straps (blest design) to 1)rg. No. WD-88108-S/1 have not been titted and bogies are fitted with 'Brake Beam Support' to· Drg. No. WD-87017-S/1. Item I. These straps are to be removed at the time of fitment of • Mditional Brake Beam Hangers' to Drg. No. WO-89075-SIL

Safety strap to Drg. Same as for Casnub No. WD-87017-SII. 22 W(M). Item 2 has been removed and push rod and equalising lever design have been modified to Drg. No. SK-695~ to take care of this safety aspect.

One 130 mm dia. Both the longer opening is provided at openings (Measurilll the centre. Twelve 400 X 200) and aU holes for 12 q, rivets 12 q, rivet holes have are made for fo:tment been 'eliminated'. of 'Brake :Beam Sup- Other featutes are port' tiour out of same as in Casnub twelve holes (Meant 22W(M) bogie.

Casnah 22 NLB

Same as for Casnub 22 W(M).

Not Provided.

Same as for Casnub 22 W(M).

SaJDellS in Casnub 22 NL Bogie.

Casnllb 22 NLM

Same as for Casnub 22 W(M).

Not Provided.

Same as for Casnub 22 W(M).

Same as in Casnub 22 NL Bogie.

ANNEXURE-A

(SHEET-4) .

Casnnb 22 HS

Same as for Casnub 22 W(M).

Not Provided.

Same as for Casnub 22 W(M).

Drg. No. WD-92058-S/4 Item-I. Arrange­ment and dimensions of spigots for springs ha\Ye been changed. c:>ther details are same as in Casnub 22

/

-00

SI. Descriplion of Item Nc>.

c) C> o o C"..J o o O. .-..

Casnuh 22W

Heigbt: Initially 60 mm and ~ubsequently increased to 75 mm.

Provided with one 100 $ hole at the cent tre which was,' tater on. closed aM' two

longeropenintls measuring 400 mOl X 200 mm at 200nlm on either side of centre line~ It is provided with eight holes for 12 mm dia. rivets for fit­ment of safety strap for push rod and twelve holes for 24 $ rivets for filment with Side Frames.

Initially top of flange was not given any regular proffie, later on square/round baTS were welded with flanges all along its length. FinaUy top of flange was given re­gular ntdius of 6 mm.

RetroliUed Casnllh 22W

Ois/ltlb22 W(M)

for tillllcnt wilh side­frau"') art' macit;:' ~uil­able for M-14 'Fit Bolts'. Other design fealures are same as' tin ally in Casnub 22W bogie.

Casnuh 22 NL Casnuh 22 NLR

ANNEXIJRE-A

(SHEET-S) ._----'--_.-'-.-_. ~

Casnuh 22 NLM Casnuh 22 HS

NLB and 22 NLM Bog.ies.

S. Nn. DrawinR Nil,

I. SK·74513

2. SK-74512

.1. SK~6959~

4. SK·77578

~. SK·69594

6. SK·69595

7. SK·(i9596

R. SK·69597

9. SK-69599

III. SK-6Q600

II. SK·77579

12. SK"('9601

13. STR.No.·AB.'RB·fK,·77

14. SK·(ll)5~)4 (ITEM·))

15. SK·69WI

16. STR.NO.AIl·RII·I.1·~O

17. SK·69594 (ITEM·,,)

IN. SK·78517

19. SK·69594 (ITEM ~)

~O. SK"('8511

21. STR.NO. AIl/RB/I.1·RO

22. SK·69594 (lTFM·(,j

23. SK·78527

24. SK·('1.)594 (lTEM-H)

~S. SK-69594 (lTEM·9)

CASNlIB-22W BOGIE INOEX

nescription

INDEX

GENERAL ARRAI'lGEMENT.

CAST STEEL SIDE FRAME.

CAST STEEL BOLSTER (SPHERICAL PIVOT).

DOGIE DETAILS.

BOGIE BRAKE GEAR ARRAN(;EMENT.

IIRAKE BEAM.

DOGlE BRAKE GEAR DETAILS.

LEADING DIMENSIONS AND TOLERANCES.

ASSEMBLY PROCEDURE.

WEDGE

WHEEL AND AXLE

ANNEXURE-B (SHEET-I)

AXLE nox CYLINDRICAL R. n. APPLICATIo.N.

SIDE FRAME KEY OR WHEEL AND AXLE

MODIFIED CARTRIDGE R. n. ASSEMBLY

SIDE FRAME KEY

WIDE JAW ADAPTFR

RETAINER no.LT & NUf DR WHEEL & AXl.E

STD. A<lcR CLASS 'E' CARTRIDGE R. n. ASSEMBLY

SIDE FRAME KEY

WlDE JAW ADAPTER

RETAINER DDLT & NUf

KEY BOLT WITH SPRING WASHER. NuT & SPLIT PIN.

MODIFIED CARTRIDGE APPLICATIo.N.

STD. AAR CARTRIDGE R. B. APPLICATIDN.

APPLICABLE FDR ALL TYPE o.F BEARINGS.

Nll!L': Rcfl'" Drg. Nil. V\iD-X9094-S/I tilr Cmmub 22\y (RcII'OJitled) bogie.

CDOOOOOGiG 19

s, ~I),

I.

2.

J.

5.

,. 8.

9.

Ifi.

II.

11.

13.

i4.

IS.

16.

17.

18.

19.

2\.

:!4.

25.

~7.

J)rawin~ ;\'n,

WI)·R5()54-S/!

WD·X5(154-S/2

WD·S5(IS4-S/J

WD·~5()54·S:1

\\·D-8.~fIW-S/1

Wl)-S5fJ5..l·S/fl

\VD-:(\117 lj·SIJ

WJ)··.~902S·S/ I

STR. Nt"l. AIVRIl-\) 1.)11 STD. REV.·I

SK-7S)27

SK-69:i94 (lTEM·X)

SK·69594 nTEM-9)

WD·891)b7-S/IO

WI)·8SI112·SI1

WD-85!1;{4-Sn

WD-R5fl~'l)-S/'?'

WD-R5fl7 I J-S/1

WD·.\WJ4·SI1

WD·8W]H.SII

1-<-1 'D c::> o c:;) C'~)

o c:..' U

CAS:-.IUR-22W(M) ROGIE INDEX

INDEX

{;FNERAL ARRAN(iEMENT.

CAST STEEL SIDF FRAME.

BOld!'. DnA".S

l\()(;(F Hk.\,f:l (;EAR ARRAN(iEMENT.

CAST STITt. IlRAKE BFAM.

BUGIF BRAKE (;FAR DETAilS

SPR1N(r DFTA1LS C~1l JI AXLE LOAD).

WI:DGE

LEADING DIMI'NSIONS AND TOLERANCES.

ASSEMBLY PROCEDljRE.

CAST STEEL ROLSTI'R (FOR MODIFIED SEPARATE TYPE PIVOl)

W"HI & AXLE.

STD. 'AAR CLASS 'I" CARTRIJ)(;E ROLLER REARING ASSEMBLY

SIDE FRA~'JI' KEY

WI DE .TAW ADAPTFR.

RETAlNER HOlT A~D KEY

KEY BOLf WlTlI SPRING WASIIER. NJ;r & SI'UT PIN,

ANNEXURE-B (SIIEET-2)

METAL BONDEIl Rl:BBER PADS FOR SECONDARY SUSPENSION BOGIES WInI CAR· TRIDGE REARING.

IlRAXE Ill.0CK ASSFMRLY ANI) DETArLS.

IlRAKI' HEAD & Dt:TAlLS (FAIlRICAlTD).

CENTRE PIVOT ASSFMIlLY DETAlLS.

METAL RONDE I) RUBBER PAilS FOR SIDE BEARER.

DFTAII's OF SAITTY LOOP FOR BRAKE BEAM.

CENTRE PIVOT AND SIDE 1lL-\RER ARRANGEMENT,

BRAKE ilEAl) (CAST STEEL!.

MARKING SCIIEM E FOR CAST STHt SIDE FRAME & BOLSTER

20

S. Nel. llrawing No.

1. WD-9009r.S/l

2. WD-89073-S/1

3. WD-89067-S/3

4. SK-69594

5. WD-89067·S/l

6. WD-89033-S/I

7. SK-69597

8. WD-83069-S/l

9. SK-77579

10. WD-90042-S/I

II. WD-850l4-Sn

12. WD-89067-S/4

13. WD-8902;-SIl

14. STR. No. AB/RB 35·90

15. SK-69594 (Jlem-6)

16. WD-89067-S/9

17. SK-69594 (11<111-9)

18. WD-89067-S/IO

19. WD-85079-S/2

20. WD-8507(.SIl •.

2l. WD-85079-S/I

!2. WD-8900(.S/I

~. WD-8603I!-S/I

ANNEXURE-B

(SHEET-3)

CASNUIl-22NLB BOGIE INDEX

Description

INDEX

GENERAL ARRANGEMENT.

CAST STEEL SIDE FRAME.

BUGlE DETAILS.

BOGIE BRAKE GEAR ARRANGEMENT.

BRAKE BEAM.

BOGIE BRAKE GEAR DETAILS.

SPRING DETAILS (20. It.AXLE WAD).

WEDGE.

LEADING DIMENSIONS AND TOLERANCES.

ASSEMBLY PROCEDURE.

CAST STEEL BOLSTER (FOR MODIFIED SEPARATE TYPE PIVOT).

WHEEL & AXLE.

STD. AAR. CLASS 'E' CARTRIDGE ROLLER BEARING ASSEMBLY.

SIDE FRAME KEY.

NARROW JAW ADAPTER.

KEY BOLT NUf, SPRlNG WAStIER & SPLIT PIN.

METAl, BONDED RUBBER PADS FOR CARTRIDGE BEARINGS.

CENTRE PIVOT ASSEMBLY DF.TAILS,

METAL BONDED RUBBER PADS FOR SIDE BEARER.

CENTRE PIVOT AND SIDE BEARER ARRANGEMENT.

BG, MG & NG COIL SPRlNG DRAWING CODE.

MARKING SCHEME FOR CAST STEEL SIDE FRAMES AND BOLSTERS.

21

(0 --j

"Q Cl ,1:)

o C) (:::J G CJ

S, Nn.

I.

,

:;.

,. 5.

('.

7.

S.

" 10.

II.

I~.

1\.

14.

15.

16.

11.

IS.

[9.

~().

21.

22.

~.'.

INOEX-il. S. BOGIE

ANNEXURE-B (SHEET-4)

---.--~-----.---.-----------------------

Ilnmill~ :"Ju.

W D·()20);>!·S,'1

\Vj)-9~()5H-Si2

WD·S9067,S/J

WD·92U58,S/4

\\,D-~()U67-S!5

WD·H9IJJJ-Sfl

SK-(19597

WI)-')1!)5X-S/~.

S;""-775i9

Wj)·n1l5~-S;7

\'v'I)-~505...J-S;?

WJ)·92058-Si)

WI)·fJ9025-S/!

STR. No. ABfRA-3~·f90

\VD-9:W58-S/4 (1IClll-:!)

WI)·8'1'J67·S!9

WD-92f158-S/4 (ItCIll-4)

WIJ.92USR·SIR

WJ)·l:l5079-S/2

WD-9209J-S/I

WI)-92U5x-S/(1

\\.1)·89t)'1(; ... SI 1

\VD-86038·SII

,:~:t--.,

.-1 '.0 o '-::J c-J C-, Q C) C)

lk~cripfinn

INDEX

GE..'JERAL ARRAN(iEMEr\T.

c.~"r STEF L SIDE FRAM E

HOGI1: 11FTAJLS.

IiOi.,IE BRAKE GEAR ARRANGEMENT:

BRAKE nEAM.

nO(;II' BRAKE GEAR DI'TAILS.

SPRING DETAILS

WEDC'[

L[A!'ING DIMENSIONS AND TOLER,o\NCES.

A~SEMHLY PROCEDURE.

CAST STHL ROLST[R

WIIEI'L AND AXLE.

STIl. AAR. CLASS r CARTRIDGE R. O. ASSEMBLY.

SIDE I'R\ME KEY.

NARROW JAW ADAPTER.

KEY BOlT NUT, SPRING WASHER .I: SPLIT PIN.

METAl. BONDI'D RlmBER PAI)S FOR CARTRIDGE OEARlNGS.

CENTRE PIVOT ASSI'MHl.Y DETAILS.

SPRING LOADED SIDE BEARER ASSEMllLY ANI) DETAILS

CENTRr PIVOT AN I) SIDE BEARER ARRANGEMENT.

11<. •. MG ,~ NO COil SPRINe. DRAWING CODE.

MARKING SCIIEME FOR CAST STEEL SIDE FRAMES AND BOLSTERS.

22

ANNEXURE-C

W('Jdirlg or Slrnctllffl;J Src('f In IS: 226 .'e 410SnS: 2062 Fe 410 WA

l)'Pf flr Electrodes and olh('r prN'Rlilions tn he iRk('n ",hill' bulldillg lip ~'nrh nut bmkc heads of Casnllh-22W Bogil"s:

(I) El('clrodl!s confirming In ClilSS 82 of IRS M 28-66 are to be used.

en Welding must be done by properly trained welders under qualified supenision.

(3) Welding should be done under cover in wet weather and dry storagl' of eleCl,lOdes should be ensured.

ANNEXURE-D

Welding of Ca .... Steel CompolK'nt!'J

Comllnnrnts :

(I) Rr.lke hends for brake bl~:lt\l of Casnub-22NL 22NLR & 22BS Dogies.

(2) Centre pivots (Muledal 10 IS: 1030 Gr. 27-S4/1S: I03n Gr. lSO-520W).

(3) Sidcframe and Dolsler (Exl:epl Casnllb 22 NLM Bogie).

}:lfelrone

Low Hydrogen Electrodes approved by ROSa under both the Cluss C2 & 01 shall be used. Electrodes shall be prehealed i~ tin drying I)ven Rllempcrnture of ISO"-20Uo Cor flS per recommendations of InanufaClurcrs atirasl one hour before usc. The size of elee1rode ~hAll depend upon extenl of wenr.

Alternatively RDSO' approvcd. electrodes'under Class C & 0 may be used: Examples fHC. Supercord, Supercilo of MIS Advnni, SuperthemlC' & Indothermc of MIS General Electrodes. Indare felTOweld-2 of MIS Indian Ox)tgcn. These Electrodes are to be dried hefore use as recommrnded by manulHclUrcrs. Short arc is 10 be maintained. 4 or 5 mm electrodes are to be used.

IJro~durc

In) The womollt area !;hnll be cleaned [)t\~ferabi)' by grindill8 v.ilh pot1able glinder.

(b) The ground area shall he ('xamined \'isually for presence of Any crack.

(e) Each nm of weld metal shall be' deslagged thoroughly before further run is applied. pat1icularly at the junction I\·gion between the weld metal and lilSioll faces. Visible.dcfecl.~ SUdl as crncks, po rosilY. voids :lnd other depositing faults shall be removed before depositing further \\.'eld metal.

(d) Each bead shall 'be p,cened with a baU pen hammer immediately after dePosition. starting from the hot end and then proceeding backwards.

(e) The welding operation, once started. "hall be completed in one S1cetch mainlaining an interpass temperature between 250' - 300' C.

(f) All 'Welding shall be carried out preferably in down hAnd posi· tion with the help of manipulntor'whenever required. In case of necessity. welding can also be carried out in horizontal: or verti· cal up position.

(g) While u!'Iing low hydrogen electrode. it shall be ensured 10 main· lain .~hortest possible arc and minimum weaving of electrodes.

(h) The crater ends must be filled up by retracing back the dec. trodes 10 about 12lllm followed by withdrawal from weld pool:, When a new electrode is to be straled. this shall be struck a little Star1ed ahead of craler end of previous run. then travel back over the crater end and then forward again.

en No post weld heal·treatment is necessary.

U) The build up area shall be finished grinding up to the original dimensions aVOiding fonnations of &rinding Cracks.

(k) The reconditioned area shall be examined visually as well as by . magnetic particle Test/Dye penetrant Test to ensure freedom

from any defects!cracks, If any crack}defect is still evident! persists the same shOUld be removed and repaired and then rechecked by MPT/DPT.

Welder.;

All .welding shall be done by welders qualified as per IS: 7318 P1. I.

Wl"lding CDrrent-

A" recommended by Electrode ManufacturerS.

ANNEXURE-E

\\'dding nf S'r.dural S'..,I 'n [S: 226 Fe 4tnSnS: 2062 Fe 410WA '0 C." 5''''''0 [5: 1030 Gr, 27-S4nS: 1030 Gr, 281l-520W

Welding of new brake h~ad (SII1IC1urnl Steel to rs: 226 Fe 41OS/ (S: 2062 Fe 41OWA)wilh 'End Piece Casting' OS: 1030 Gr. 27-54I1S; 1030 Gr. 2SD-520W).

Electrodes to he woed

Any brnnd of Low Hydrogrl1 Electrodes approved by RO.S.O., <l~flin.~t Class C2 and DI of JRSM·28 shall be used.

Welding procedure;

(I) The Brake head shall be held in posilion v.ilh the help of suit­able clamps <Ind Ihen tAck welded on eilher side.

(2) The welchnmt area shlill bt- clenned properly to make it free from heavy se;lIe. nisI. paint. oil. grease etc. before welding.

(3) Welding shall bl" carried out in down hand position witlHhc help of !'Iuilablc clnmps.

23

(4) Each run shall be deslagged thoroughly before depositing subsequent nm.

(S) Sh0l1est possible arc and minimum weaving shall be main~ tained while using 'Low Hydrogen Electrodes' Stray arcing should be avoided.

(6) The crater end must be filed up properly by rctr~cing back slightly.

(7) Visible defects such as cracks. porosities., voids and other deposition faulls shall be removed bygouging before depos.it~ ing further weld metaL

Precaution :-Low HYl1rogen EleclIudes shall be preheated in 8n Electrode drying oven at a temperature of lSQ"·200" C or as per recommendations of Electrodes 'Manfifaciu~~ for at'least one hOUT before use.

COUQOUOG20

ANNEXURE-F Wl·I.IiIl~ IIf Spring SIl'd Lilll'r.. 10 IS: 3885 PArt-l Gr. IV un Cast Steel Surface (Except Crulnub 22 NLM)

F!l'C"rnrll'!i to be U'il'd

Allslenilic Stainless ')1l"('1 l:h~clrnd\' llll\'ing llominf1t compnsitilJn of

I~% Chromiulil. 8% Nickd and 5% manganese nnd approved by RDSO againsl Class M 1 of IRSM-2~ shall be used.

General Welding Prol:cdurc'

(1) llle liner shull be held in positio11 hy tf1ck welding al mid points of the \vlIglh sid",

en Welding shall h(~ dOllr in dl1\\'n hand po;:iliun.

(3) Fillt'! size shall hf" l1lainl,lined as stipulated in 1he Jr<1wing.

Pr('('flutinn'4 :

1.inifnlll1 b.'ad is 10 hI' dt~pu;dt{"lt. \Ve~\\'ing is nOl pt'rmiueo. Each weld is to be followed hy lighl pi~t'nillg. if any crack is n(lli{;t~d,

wdding shall be 11'II1O\"(,d hy Clllling electn .. ll1e and reweld.

\\>'t-IdillF; of S[lril1J! Sf('{'\ UUN In IS! 3~R5 Pari I Gr. IV "'ilh Casl SI('el Roister:

Electrude!! 10 be u~cd:-

Same as recommended ('arlier fur wehiing spring !Ht>elliners on Cast Steel Sll rfaces in )!elll'rni.

Wrlding Prll('cdurr : H~. 'C' i.'j In bc refcfTed.

111e liol"r shall ht: hl'ld ill position hy tack welding nn either side (Side AE & MR). Ta("k .... dding shall be done at the mid point (If,he lenghl side nn cilh!:r .<;idc i. l~. \tIP (AE) find hottom side (MR).

W~lding shall ne donr in dnwll hil!ld pusition prt"ferably as pt'r the . ~eqllence given in Fig. ·C,

nll~ ll~llgth of the ~rJing sled lin ..... ,' is "bou! 150 rum. Thi.~ kngth shall be diviJed in 10 four equal sizes and marked as 1. 2. 3 & 4 on nne side I11h1 5. 6. 7 lit. ~ lin till: upposite side.

SIal1 wddillg al (0 <lud weld lip 10 (9). StOll' again at (C) and ",~ld up 10 (1.)).

\

153

i!i A 3 B C

~I I I

Ix'

,

-L ~I , ~ M 1 N 5 P

T!tell start at (B) and weld up to (X) covering the COmer (A). Start at (I)) and weld up 10 (Y) covering the comer (E).

Thl' opposite side (Side MR) shall be welded in the manner as PeT seql1ence given on Fig. 'C'.

TIle width sides (Sides AM and EK) are not accessible for welding.

111e filiet size shall be maintained as stipulated in the drawing.

Welding is to be done in two passes firstly with 3.15 mm dis_ Elec~ trode and then with 4 or 5 mm dia.

PreC'Quljnns :

Same as mentioned for general application under same Annexure (E).

Welding of Spring Steel Liner to IS : 388S Part I Gr. l V on the side­frame Column (Except Casnub 22NLM).

Type of Elf"ctroctes to be used, their size and precautions to be taken shall be same as described for bolster lincr application. Down hand welding shall be used. Regarding welding Sequence refer Fig. 24.

\Velding Sequence :

$11111 from one comer and then weld opposite corner and so on till all four comerS are completed in the same pass.

Sequence of Welding Corner (A). (M), (L) and (N) :

Sequence of welding at each corner (e. g) Corner (A) .

l£g.(A). (e) & (D) ,

Log. (Al. (El & (Il) ,

1 2 0 4 E:>;

J ~l

~

'" 0

J " Q 8 d

'"

Start at (C) and weld outwards towards (A). Start again at (C) and weld outwards towards (B).

Start at (E) and weld towards (A). Start at (E) and weld towards (0).

(All dimensions are in mm not to scale)

C000000621 Fig. 'C' Bolster Li ncr showing welding sequence

24

LIST OF IMPORTANT MOUU1CA:nONS

S.:-.su. Tlem

I. To prevent the brllkl' OCIlIll t-'dlul'cs. the brnkc beam SK-69596 of 12W bogies 10 be' lIlodilied by boxing the channel as indicnled in SK-69596 All. 7.

, SHepglhening of pivot W/B E--60 I 8.: dele-ling greflsl' groO\~cs as per All. :..

~ TIle existing push rod SUppUl1 arrangement arc 10 he removed & repbh:ed by nrrang~.ll1ent shm\1l in SK-69597 All. 22 I,,, llW & WD-85tJ,4-S/4 All. 7 for 2ZW (MI bogies.

4.

h.

1.

9.

1U.

II.

12.

1.1.

14.

15.

If).

17.

IX.

19.

:!II.

Retrolitment of E. pad & C01\811\111 conlnct sidl> bearel'"S 011

12W bogies.

Filment of strengthened brake shoe adjuster 10 Drg. No. WD-88012-SI1 Item 4.

Fitmcnl of brak(' beam hunger & suspension hrnckct us per Drg. No. WD-89075-SIHl AU. 2 & l\'tlIuVIlI of 581'('1),

sirnp as per Drg. No. \VO-,-nn17-S/l All. 2.

Provision of extn1 roller type pull rod SlIl'Plll1S as per Drg. No. WD-9001(>-S/I All. 11. Fitment of hrake heam hangl'r & sU'\.lwnsion bra(:kel III

provide cellIral SUpp0l1 tll brake beam in Casnu'b 22\\0' (M) bogies.

Modification of cr:nlre pivot borlom all Cnsriub ll.W bogies 10 avoid jflnllUillg:.

ProVision of wear liner on weRling surfaces of Casnuh 12W(M) & NLB bogies.

Repia<''elllenl of Nylon bush h)' steel bushes 011

Casnu b bogies.

Rivclling of ~nl(\~ pivot lOp of BOXN/BCN wagons \I,;th Cnsnub bogies.

Conversion of lOP c!;'.ntl"e pivOI nrrangement from bolted to riveted df'sign on RCNAlBRN wagons.

Fitment of centre pivot lOp wjth body bolster by rivets in place of bolts in BTPN wagon.

Retrolitmenl of E. Pads nnd constant contaCt side bearer.~ in Casnub 22W hogics.

Fitmt"nt of strenglhelwd brake shoe adjusll'r in Casnuh 11W(M) bogie,.

Use of bulb cottf'rs in place of standard split cotters in Casnub bogies.

Modification 10 push rod snfelY 31rap.

TIle brake beam Wo.89033-S"ll Alt. 14 has been Slrenglhened by providing stiffn~r plate.

In centre pivot details WD-85079-S12 All. 15 assembled height wilh tolerances indicated & material of top pivo1 changed to AAR-20l Gr. C.

itLltlnlCliom for welding or bottom cenfre pivot with bolster hns been gi"'cn by wdding size and type of c.>1("l·lroc\e.

RUSO's R.f.

MW/ROXNIMAINT. ctt. 10111.9.90.

MW/ROXNIMAINT. dl. 10111. 9. 9U.

MW/BOXNIMAINT. dt. 10/11.9.9U.

MW/l'l.NG/CSNR dl. 15.1.90

MW/ROXNIMAINT. dl. 10/11.9.90.

MW/ROXN/MAINT. <11. 10111.9.90.

MW/PLNG/CSNRIM <il. 2n .5.91.

MW/PLNG/CSNBIM dl. 31.1.94.

MW/PLNG/CSNBIM dl. 28.11.93.

Sick Line

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

MW/NYLON BG/COMP dl. 18.5.94.

NO

MW/BOXNIMAINT dl. 18.6.9.1.

MW/PLNG/CSNB dl. 3.5.94.

MW/BTPN dt. 18.7.94.

MW/PLNG/CSNB dl. 15.1.9U.

MW/BOXNIMAINT dl. 10111.9.90.

MW/PLNG/CSNB dt. 14.9.94.

MW/PLNG/CSNB dl. 13.9.94. MW/PLNG/CSNIl dl. 9/17.11.95.

MW/CSNBIPLNG dt.1.4.96.

MW/CSNB/PLNG dl. 2.4.96.

NO

NO.

NO

NO.

NO

YES

NO.

NO

NO

NO

250000000"Jr .bc.. ,:;:

ANNEXURE-G

To be done in ROH

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

POH

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

~-----------------------------------------i

2000 (WH EEL B.4SE) •

~ SECIION-M I.

l\.~;+.J I

fD

H~~ I I .i (

)' J \ I) r-~I~~'-r--::-----; re: I.'!.:I. I _ ~ ~

G'::--' ~/(~. ~, ,- '- : I '-1:"' L'--::- r--

'= ~"b.\:i: -~~ i,~~&,",~: --L _

•

.i

I

I _L :J

t::;;::i - r'--j I':=l.

---=-~

--=

I

-

R.L

BOGIE GE~(8AI_ ARRANGEMENT

[ C.A,) ~Jl1f:l- 22 N LBJ

FIC.NO. -1

2260 CENTRES OF JOURNALS

_12'Z 1600!~ .I 27r-\ ,-/ "-

I 1 . II

.., - I

\

1

,.~

i ......., v-251<:+ \·5 1--------

WHEEL SET

/ •. f .

TAPERED ROLLER BEARING UNIT REFER G-81 FOR MAINTENANCE: DETAILS

3-41 RDSD/luck/97 .

~HEEL SET & ROLLER BEARING UNIT

(CARTRIDGE BEARING]

(CASNUb-2ZW .22\1.1 eM) 2.'2.NL a ~ 'Z. WlS .22 .. S

boGliS

.' . OOOOOOOci24

FIG.-2

(' j.r{~RI )GE itO LL ~R 3jA FIT r<i

, T . -E:~

~.\

+f \

, I ,

,

'I I I

,

, i i I, I , I

i

I ! I

I

I I I

i ,

i I I I I :

1 BoGIE

CASt,WB 22W

_Jt '! \J ~. :

.

)

r ? ,

!

\ , r / l ,

~ . I ,., I

i

I i \17~/ I ,

,

i ,

I I i

/ ,

5

ld ,

I ! I

-.- \ :"\ J- - , !

>~ , I ; t "

/' I I I ".~ I

\ I ''0 I

I . Jc5' ' " , .,

I

NOM INAL CLEARANCES CASNUB-22IJ,22IJ(M) BOGIES, I

FIG, 31 COUOOLJ062J

~ 2OOO±5 ~HHL BASE

BOGm CASNUB'22NlJNLB CASNUB·22.H3

DIM 'X' 9

12.5

I

i 1

. CARTRIDGE BEARING ADAPTER &; ELASTOMEF1C PAD

NOMINAL CLEARANCES (CASNU8 • 22 NL.NLB. HS

FIG.4

COOOOUOo2b --

(1) ASSEI£LE SPRING PLANK WITH TWO SIDEFR.&.MES BY RIVEtING &: FIT BOLTS.

(11) INSERT BOLSTER THROUGH THE CENTRAL OPENING IN ONE OF TtiS TWO SIDE:FRAMES.

ASSEMBLY PROCEDURE (SHEET -1)

CAS'i113-22W,22H(M), 22'fL, 2:J1LB &: 22 HS BOGIES.

FIG.-5

COUOOiJOo27

BOLSTER SHOWN FULLY INSERTED

SECT ION-A A

(111) RAISE BOLsrER TO THE MAlCIMUH POSSIBLE EXTENT

C1v) INSERT SNlBBER WEDGE INTO THE BOLsrER TAIL paCKEl' AND HOLD THEM BY PINS AS SHOWN.

(V) PLACE THE LOAD BEARING SPRINGS OVER THE LOWER SP IGOT S, LOWER THE BOLSTER TO SETTLE ON T HE SPRINGS AND REMOVE THE 'WEDliE PINS.

ASSEMBLY PROCEDURE (SHESl'-2)

CASNUB-22W,22W(M), 22NL, 22NLB& 22 AS BOGIES.

FIG,-6

COOOOU0628 ',' 'I

~ r 7! \ j'

I II t

\ ,I II l \11 I \ll ~I I ~ ~c ~

,. T" ~

~ ~

(VI) ASSEMBLE BRA~E BEAM WITH SIDEFRAMES AFTER FITTING THE BRAKE BEAM WEAR LINERS INTO THE CORROSPONDING INNER GUIDES ON THE FRAME (EXCEPTCASNUB 22W(M». FOR CASNUB 22W(M)­ASSEMBLE CAST STEEL BRAKE BEAM WITH BRAKE HEAD AND BLOCK ASSEMBLY (DRG.~D-88012-S/1) HANG BRAU BEAMS FROM BRAKETS THROUG~ . HANGERS AND PINS ETC.

\

I i

! ~

(VII)RAISE THE COHPLETE ASSEMBLY AND LOWER OVER THE AXLE BOXES/CTG.BEARING ADAPTERS AND

ELASTOHERIC PADS FITTED ON JOURNALS. (VIII) PLACE THE ~y THROUGH THE SLOT IN SIDEFRAME AND BOLT IT WITH SIDEFRAHE. (lX) ASSEMBLE" ADAPTER RETAINER BOLTS" WITH SIDEFRAHE (ONLY IN WIDE JAW BOGIES WITH CTG. BEARINGS BUT WlTHOUT 37mm PAC~ING.)

80TE: THOUGH SHAPES OF SIDEFRAHE AND BOLSTER (SHOWN HERE FOR CASNUB 22W) DIFFER IN VARIOUS VERSIONS, ASSEMBLY PROCEDURE IS BASICALLY SAHE. ASSEMBLY PROCEDURE (SHEET-3)

CASNUB-2Z'w',22\J(M),22N:",22N:"B,22HS BOGIES FIG.-7

COUOULJOG~9

CROWN AT

ADAPTER 51DES

, LOCAnONS WI-I~N SCRAPED I 1 .. ADAPTER BORE Wf.1.R.. , 2. ADAPTER SHOULDER WEAA.. i 3. ADAPTER SIDES. I 4-. ADAPTER CROWN LUGS.

I 5, ADAPTER CROWN SEAT. o 6. ADAPTER SIDE LUGS •.

~-CA5NUB UP'" I 22W

I 22W(M)

152.5

~b~P"tER Sl40UlOER.

~APTER. 8~

RE.1ROmTEO CAS)lUB-22 W

129.5

SCRAP LOCATIONS OF VORN ADAPTER I 1 r

i t

CASNUB-22W,22~' RETOOFI TTED) , 22 W( M)

.. FIG.S ~~-----~--------------------------------~~~~

COOOOlJOo~G

~ 1.2 t : ..

·V

'" ""

MO;I Xl

I

~

115 .... \ .,. 0-7 • • o. , ... !o ... t"

0

G IGO I

-'OAPTER WEAR GAUGE

o r- ..

I • I

.. _ .. ..l. ACCEPTABLE TO BE REJECTED

E-t3. A

ME.I110D Of GAUGING IHRU.5T 5\-\OULDE.R WE-A. R

---4-.ACCEPTABLE \

s:lG,B

METHOD' OF GAUGING SORE WEAR

NOTt: SHARP CORNER~ TO BE REMOVED: ALL GAUGING SURFACES TO 8E HARDE Wcl)& GROUND. . -MATERIAL-IS: 1875 CL-4

ADAPTE.R THRUST SHOULDER& BORE. WEAR GAUGE. (CA ~NUe,- 2Z·W. 22W(R(T ROF IT TW), 22W (M), 2.2NL .?22).lL~, 22 J.lLM,ZZHS

BOGIES) '2 . . FIG.9

0000000631':' ' i

100 ftMMPlATi

L SCRIBE < ~ OF GAUGE t' V'l ON CUI ~ N ,

• 0 STAMP SMM LETTERS iADAPTER CFOJri LUG G~E I')

~ CASf'lJS-~!.2.Wt22'w'(

I-." r !2i JrrtJ ;r- '7

_.

f' .. \ I

~ _J '-~ \

\ fri"r-l'-~ UI I~ -,... -I~.L.I -

FIG,.A ~QIE; SUBrACE MAR~E~ 'I' AN~ tllblEt:lSIQt:! Ut:I~EB S~QBm ARE IblPQRTANT,

MATEBIAL: II6UGE IlP-IS;lIlZ~ CL.~ HAR~Et:lEQ ANQ GBQUt:/Q BQQX-IS:2062 Fe 410WA

ADAPT ER CROWN LUG GAUGE CASNUB - 22W,22W(RETROFITIED),22W(M)

. FIG.10

GOOOOlJOt)32

STAMP 5MM LETTERS (' 190

L --- 6 - -'-

: L...ADAPl£,~ CROWN GMJG E NO, 1

• ('R>'lU13 21"!'~'{'A) 1/ 2ffl (Rt''IC) !!&.;'f;S

r - (J

SO 40 roo ~ .- ft :> ...

'" 1I!1

.----STAMP 5MM LETT~R5

,-ADAPTER CROWN GAUGE 00-2 CASNUB-22W BOGIE.

200

C,AUGE-I GAUGE-2

..

o If)

, ~I ..oj

j t' { , , , '-._ j(i. . ,. '-1 J .

NOTE SURFACE MARKED 'e THUS ANDDIMENSION5 UNDER SCORED ARE IMPORTANT.

MATERIAL -GAUGE TIP-IS: 1875 C LA HARDENED &.. GROUND BODY - 15:2062 F. 410 WA

ADAPTER CROWN SEAT GAUGE 1r-....---__ -,-__ -=;CASN.\.I..El - 22W,22W(RDROFITTEP), 22W( M)

Dlt CASNUB,H' RETROFITTED 22W(M) CP2NUB-22W

A 76 53 FIG,11

COUOCJOo33

10 N

~I

~ ,..

.

1"'"'

-,

~

u

5TAMP SMM UTTERS

200

'--_ AIW'TER SIDE LUG GAUGE CASNUB -22W _22W(t.ll

I

• rzw (RETRO) BOGIES

128

r~ 1'"

~ ,

i I

,

I L>'=

FIG.- A

MATERiAl: CAL!CE De IS·1875 eli HARDENED AND GRQUND BODY 15·2062 Ee 410WA

ADAPTER SIDE LUG GAUGE -CASNUB -22W,22W(RETROFITIED).22W(M)

COOOOtJ0634 I, "

'- . --

~

30

- STAMP 5 rnm LETTE.RS

, ADAPTER SIDE GAUGE. 0 CASNUB -2 2 W~2 W( RETOO)22 W(M If)

SCRIBE t OF GAUGE t"')

ON BOTH SIDES)" Il)

" • 269 30

~RFACE MARKED 'fl THUS AND DIMENSION

i UNDER SCORED ARE .,--------, ,. ", IMPORTANT

!~r-' \ MATERIAL: I . \ GAUGE TIP-IS:1875 C LA

II ;/;' .,r:~~''-'-l ~~~~:~~~ ~G:20UND I~ 1/ \' A Fe 4W WA

1 ~j \-- ' !. ~ _J:..L

FIG,-A

ADAPTER SIDES GAUGE CASNUB-22 W, 22 W( RETROFl TTIID), 22 W( Ml.

FIG.13 COOOGdOOJ J

C'") o o o c.­O 0: ~ 0-:'

CROWN LUGS

CROWNSEAT

-.. _._._._-_._._._._._._._._. -'-'-'-:,.;;._._._'_.- _.--0

ADAPTER SIDES

LOCATIONS WHEN SCRAPED 1. ADAPTER GROWN LUGS

2. ADAPTER CROWN SEAT 3. ADAPTER SHOULDER WEAR 4. ADAPTER BORE WEAR 5. ADAPTER SIDES

6. ADAPTER SIDE LUGS

SCRAP LOCATIONS OF WORN ADAPTER

CASNUB - 22NL,NLB,& HS

FIG.-13A

~ ,

6 MM PLATE

scm BE ~ OF GAUGE ON roTH 51 DFB. .

I . SNU B-22 NL, NL B,HS Be GI E

PTER COO'WN LUG GAUGE

I fIG-A

.. 1.

NOTE~

SU.RFACE MARKED. THUS AND DlMEN5tON UNDER LINlD ARE tMPO~ ANT

MATERIAL GAUGE TIP·IS: 1875 CL-4 HARDENED' TEMPERf.D &oOy~ IS: 2062 '.410 WA, ~.

ADAPT ER CROWN LUG GAUGE CASNUB-22 NL, 22 NLB & HS EQGI ES

FIG.14

~--------" ~~=~.----------------~

If) N

\0 N

STAMP SMM LETTERS 200

. ~ADAPTER SI[~ lUG GWGE

. '

• CASNUB-22 ,NL,NLB &

.. A ...... ':.4=. OF r..alr.F HS OOGir.8I,

195

.lJ

~ ON BOTH ,SIDES

NOTE :-I ,

, SURFACE MARKED·. THUS AND DIMENSION UNDER SCORED ARE IMPORTANT

MATERIAL:-GAUGE TIP· IS: 1875 CL4 HARDE.NED & GROUNO BODY· ISI3)62 Fe

410 WA

F1G. A

ADAPTER SIDE WG GAUGE .GASNU B-22 NL, 22 NLB & HS EO GI E'S

FIG.15 CDOOOUOb30

~TAMP 5MM LETTERS r' 190 .1 I I

LADAPTER CFlOWN GAUGE NO'\ CASNUB-22 NL, 22 NLB & 0 22 HS 80GI E

\I')

u

,..... I<)

o..n 50 40 .1 leo J

~ ,

I) '.-~ll

Il\ I')

1_"-

r---STAMP5M'vl LEnE~ o

~_ADAPTER CROWN GAUGE NO.2 CASNUB-22NL, 22 NLB & HS OOGIE

u 200 I ..

GAUGE-I GAUGE'2

NOTE

6

""""-. ~

SURFACE MARKED '0 THUS f) AND DIMENSIONS UNOE.R

.'-:;;=;:::;::~.Yn SCORED ARE. IMPORtANl

,1";' / /11MATERIAL' ~....J[r4.=.r'-Lt-li·A{ I GAUGE TIP·IS:1875 Cl.:±'.

lilt 'L_ HARDENED &. GROUND '---i+Ht--t-T"''---'-..... i \ 00 DY IS: 3:) 62 Fe 4J.0 ~; A

F\~. A

I I

ADAPTER CROWN SEAT GAUGE CASNUB-22 NL,22 NLB & 22 HS OOGl ES

FIG.16

GOUOOIjOo3~

-

-

.- SlAMP 5 "'''' LETTERS

0' ADAPTER ~.IOE GAUGE CASNUB-e2NQ 2NlB.22HS JOGlES. Wl 1

'" ~ t I/)

~ SCRIBE t OF GAUG!

~~ ON B01H 5<"5, ,H 30 tel Co

+2.0 @TE;: ~'81-0'O SUBEACE MABKEO 'I' ANQ

OVER ADAPTER SlOES IllblE~SIQI:l U!iIlEB SCQBEQ . , ARE IMPQBTANT, : , , i t, --- --~ I MATEBI8L: i

,.- . ~t~ h GAUGE IlE IS; 1 aZ:i t::~~ HARIlE!iEQ 6H1l GBQU~Q

! BQQY IS:2062 Fe 410WA ----I ~.'----r---~

. /' ~" (f) A . ' .~,

p,j. \J "---- .

FIG-A

ADAPTER SIDES GAUGE CASNUB- 22NL.,22NLB,22HS -BOGIES.

FIG.17

4-41 AOSO/Luck/97 GOODOUOOi)U··

6MM PlATE.

GAlXl".

I b--i---=:l L..,

inn n 11

f lG.ooti

COOOOIJOotil

OOTE:· SlJ<AfK:E. MARKJoe AND OIAMENSION UNDER SCORE. ARE. MPORTANT.

MATERIAL> GAUGE TIP-I5:IB75 CL.4 HARDE.NE.D &. GROuND BODY -15:2062 F~ 410 WI>.

AXLE BOX CROWN LUG GAUGE ~A5NUB-2 2W BOGIE.]

FIG.18

-~

GAUGE-I

STAMP SMM LETTERS

"AXLE BOX CROWN GAUGE 1'01 CASNUB 2.2W BOGIE.

• 50

7S

o '" 0';'

11)1

'1' -I r-...

o t')

175

50

""STAMP S~M LETTE.RS

'--AXLE BOX CROWN GAUGE NO.2 CASNUB 22W BOGIE

II) t')

1

F IGo. A.

• 200

NOTE: SURfACE MARKED 't, AND DIMENSION UNDER SCQRED ARE IMPORTANT.

MATERIAL:-GAUGE DP IS: 1875 Cl4 HARDENED AND GROUND BQDY-IS:2062 fe 410WA

AXLE BOX CROWN GAUGE ~ASNue'22W BOGIE]

FIG.19

COOOCUOb4~

100 100 SCRl&tOF~~ 6MM PLATE ON BOTH SIDES /

AX Lf. BOX LUG GAU< f.-CASN\ll£2W BOGIE 101 lQ /

22.5R~ It . • I\. 0

AXLE BO< i5IDEGALx;

98

128 - -

FIG-A

,,' I ) I J_·_·t, -I .. ~~ lfH I

. :--J r-. ! . ~7

w

~l t<)

NOTE SURFACE MARKED'. AND DIM:NSION UNDER ARE IMPORTANT

MATERIAL GAUGE TIP-IS:1675 CL4 HARDENED &. GROJND BODY -IS:2062 Fe 410 WA

A XLEBOX SlOE-lUG GAUGE kCAS/lUB-22W BOGIE]

FIG.20

CO[J;JCOOtl43

~STAMP5MM LETTERS 6MM PLATE \

, ~

... AXLE BOX 51 DES GAUGE 0 CASNUS- 22W BOGIE I/)

SCRIBE CENTRE-LINE OF GAUGE ON SOTH SIDES

• I 30 269 30

0 .

• U")

l N

• •

.

NOTE

n f\ SURFACE MARKEOte ANQ

(,~.- ~--' ,--1.~ DIME~IQ~ U~QER SCQRED

( .... ~ ~. ARE rpO TANT

MATERIAL h . J GAUGE TIP-IS:1875 CLA HARDENED &. GROUND

.. 1"[ . I

BODY - IS:2062 Fe 410 WA

if1 .. iJ ·'·f .~. ___ .-J U-.

FIG.-A ,

AXLEBOX SIDES GAUGE [CASNUB-22.W BOGIE J

FIG.21 COOOOUOG44

CJ C:) o CJ C"~ c:; a 0: .;;:>. c..;-~

WELD LINERS AS SHOWN IN FIG.24

RECLAIM COLUMN SIDES WITH LINERS TO m GAUGE TO FIG.25

RECLAIM CROWN SIDES &. PEDESTAL SIDE WITH WELD TO FlT GAUGE TO FIG.29

~ RECLAIM PEDESTAL JAW ,~-~-:----- RECLAIM PEDESTAL} WITH LINER TOFIrGAUGE

f=::;i/,~' ='-...,.,.:; 7 CROWt< ROOF WITH // E TO FIG.31 f-f-_._--/ LINER TO FIT GA'JG

~_..-/ TO FIG.27

L.oCATIO~~S TO BE RECL/\I!vlcI2 LRECLAi:Y1 A~HIROIATION STOP LUG 1. SIDE FRA~,,!E COLUMN SiDES. WITH ~INER TI" "'IT GAUGE TO FIG.26

2. ANTI-ROTATION LUGS. RECLAltvlATION LOCATIONS OF J. SIDE FRAME FRICTION LINERS. WORN SI DE FRAtv1 E 4. PEDESTAL CROWN ROOF. [CASNUB 22W,22W(M) B~J£SJ

SIDES & PEDESTAL SIDeS .5. PEDESTAL CROWN FI G, 22 6. PEDESTAL JAW.

a

LOCATIONS TO BE

RECLAIMED 1. SIDE FRAME COWMN SIDES.

2. AN TI- ROTATION LUGS.

3. SIDE FRAME FRICTION LINERS.

4. PEDESTAL. CROWN ROOF.

5. PEDE<r.TAL CROWN SIDES "8.­

PEO£STAL. SIDES.

~6. PEDf.STAL TAW.

WELD UNERS AS SHOWN IN FIG.24

CO!OMN SIDES WITH UNER TO FlT GAUGE TO FIG.25

REClAIM CROWN SIDE & . SIDE WITH WELD TO

GAUGE TO FlG.30

RECLAIM PEDESTAL JAW (LONG) BY WELDING TO FIT GAUGE TO FIG.34

REClAIM pn,r<:CTAI--'\' PEDESTAL JAW CROWN ROOF WITH '--"ByJt."WL-"E!ILOM'NG SUITABLE UNER TO -IT GAUGE LINER TO FIT GAUGE TO FIG.2B TO FIG.33

RECLAIM ANTIROTATION STOP LUG WITH LINER TO FIT GAUGE TO FIG.26

RECLAIMATION LOCATIONS OF WORN SIDE FRAME FIG 23

[CASNUB' 22NL.NLB. & 22HS BOGIE] .

r------·-----------"·--------:-~------,f .1.

- I

c c

WELD NOT TO EXI£ND BEYOND FACE OF SIDE FRAME7

/

SECTION-M

-• Cl O'>

GRAIN DIRECTION

I J

- t-

f>1 2.1.7 ~ ~ B.J -4

SECTION-BB ALTERNATIVE

WLARGED PETNL AT 'Y'

ARROWS INDICATE DIREC110N OF WELDING

, 1 8 (66)V 'A"-,'HL"ll/ 0 L-ni-{---; _ /1 ~ DITAILAT 'X'

~-.------..

FLAT MUST NOT BE WARPED MORE THAN 0_5 mm AND

" fl' ~I +2' f~I;~ 'j, " ""- '/' Iii, 450 - 0 '~-- ~.~t!. I M MATERIAL:- SPRING STEEL-IS:3885 Pt 1,Gr_ 1V

l ~'-_. J ~ I,)j "y l1 "- BHN (380 TO 420)

MUST BE FREE FROM SCAL;:

~ ~I -S(6C)v'; I \ 6i5)~ £RICTl 0 f'L.-P LATE DETAIL & PROCEDURE -~~-~ I _L_ .~_-1.=-_.;:; FOR APPLICATION TO SIDE FRAME '",--- --'-J =:;:-= '.-~·4~)fi"~~-t.JUR~2W~nYilliJ2l1iU~2NLB,22H5 BOGIES, FI G. 24 ,------_._--------- -.-------

%S 10

rl H "f

a

CLOUMN SIDES ARE TO 8E REClAIMED 8Y WELDING SUITABLE UNERS

GAUgE MUST BE TILTED WHEN APPLIED WITH FRICTION PlATE REMOVED

SC R1B_~ (E. NTR E. L NE. ~---! Ot-l e,OTK S\ DE s .. 5021850

~--~----~~--------~~~

NOTE

DIMENSIONS UNDE.R LINED AND SURFACE. MARKEO. ARE. IMPORTANT

MATERIAL-gAUGE Tap-IS: 1875. CL.4 HARDENED 8. GROUND,&ODY- IS:2062 Fe- 410 WA

DE.TAILS OF LINERS

MTL .:- 1$",3865 Pt. X 6 .... IY

COLUMN GAUGE CASNUB-22 W. 22 W(M). NL. NLB c!c HS FIG 25

BOGIES •

C000000840

C)'

o CJ C> a o o m +:;::.. ...0

ANTI ROTATIO\.l LUGs/~flE. TO BE. RHLAIMED B"{ 'W£LDlN(, LINE.R5 '-0 SUtT

/ . ANTI ROTATION LUG GAUGE / FOR CASNUB~BOGIES

~. --.--0 I 0\

~l

I ---,' ,

_' .---.J

5MM PLATE STAMP 5mm LEIlERs

SCRIBE. CENTRE . LINE. ON BOTH SIDES

/

. cr',

DE.TAiL OF' LINER MTL:- '~ •. 3B85 Pt t b\"N

su~~c£ MARKED!.' AND DIMENSION UNDE~ SCOR­E.D ARE. tMPORTAN'f:

. . MATERIAL - .

ij . GAUGE TlP-IS~I87SaA HARDENED &. GROUND L ..... _ !lODY - 1S:2062 F. 410 Wo\

'-_.-

~ I ANTI ROTATION LUG GAUGE CASNUB-22 w~ 22 W~M). Nt. NLB a: HS

BOGIES. FIG.26

.. - 2 Ii:: ~w

lQ/ ~§ 4. I,{l U w -~ I- z;t 6MM PLATE I- ~ 0,

w o~ .J erN

~ ~I')J ~t(l ..

10 10 Ifl~ N ~ W~

F(R' • 0 « 8 u N l- ll.. If)

~ '\L..:.·X' 25

130 50 BO

260

SURFACE'X'MUST SEAT

[-~--~-~ DIMENSION CASNUB 0 22W. CASNUB· 22W(M)

1 A 227 272 -B 272 317

. .-...... C 292 337 '-l

~ f::jOTE:

~ J . I SUBFACE MAR~EQ 'I' 6t:IQ

r "'" DIMEI::lSIDI::l UI::lQEB SCQBED 68E Ildel:!BIANT

TO If.: Bf.:CLAlbl~ ! .~.,

J!X UNf.:BS TIl SUIT MtJEBI6L

GAUGE ____ , / GAlIGf.: De IS: 1875 CL4 ,

HARQf.:I::lEQ ~ GBDUI::lQ

r--H IKlDY-IS;2D§2 Ell !lDW~

FIG. A ~ ,( ,. 160

~ .l~~ .160 PWESTAL CROWN ROOF GAUGE

11\ ntcKNESS [CAS NUB - 22W,22WCt,4) BOGIE] "I - 'TO SUIT

D£TAlL. !:IE UI::lEB FIG.27 W,ITRIAl.;IS;J1313:1 P1 l Gift'

GOOOOUUb50

• •

I ,

IJO

TO BE RECUYMED BY UNfRS TO SUIT

GAUGE

\ .. 145 .J

-~=~ "G~A DETAIL OF LINER MD.;-I5'W5 Pi! CrN

) l~ ~~ 11

j N

ii~ ~3~

~ ~

... ~ 60

2.70

C N

~ :: I: ill I')

6mm PlATE

\ \, 11\

t\I

~P.f " \ 0 N ., ~.)(' ,

&0

SURfACE lMRKED 'I' AND DIMENSION UNDER SCORED ARE IMPORTANT

MATERLAL: GAlJGE DP IS: 1875 Cl4 HARDENED AND GRdUND BODY-IS:2D62 F. 41 DWA

PEDES1AL CROWN ROOF GAUGE CASNUB- 22NL22NLB,22HS BOGIES.

FIG.28

COOJOUOG51

~- J ''\' ((Iii 'L1'1 I , J

1 ~. '--1'«""--.-.-('-""-'1' r .

+-1 t -1. '-0:.'.

5

154

5R 9R

NOTE;

MATERIAL; GAUGE DP-!S:lD75 W HARDENED AND CROUND IOPV-IS:2Q§2 Fe 410WA

--I. ______ . _._-l

PEDESTAL SIDES

FIG,..!

PEDESTAL SIDES & CROWN SIDES GAUGE [CASNUB-22W.22W(M) BOCIES]

COOOOOOG52

F\G.29

,...;:=~

(( 1! f L I CROWN SIDES

J -_. J' co::: I' -., r ~

I I I

L---1~ FlG-B

'''\ PEDESTAL SIDES

SR

o

IS -iA.

o 11'1

SCRIBE CENTRE UNE OF GAUGE ON BOTH SIDES

NOTE: SURFACE MARKED 't· AND DIMENSION UNDER SCORED ARE IMPORTANT.

MATERIAL: GAUGE TIP-IS: 1875 CL4 HARDENED AND GROUND BODY-IS:2062 Fe 410WA

-.

g -

PEDESTAL SIDES & CROWN SIDES GAUGE (CASNUB 22NL.NLB & HS BOGIES) FIG. 30

COOOOU0650

A 8

o I/'l N

20B 216 268 276 .--/

I

/

SMM Plf>.H.

MATERIAL ri.ll!GE DP IS;! 1175 CLf HARDENED t GROUNp BQoY-IS;20§2 f, 41D"'~

\ \

r

. J

( \, ~

. \j ---+--

L_~ FIG. A

PEDESTAL JAW GAUGE

[CASNUB-22W. 22W(M). BOGIES]

i COOOOOOG:),',

FIG.31

c; C) C' C...::> c..;, = C)

C:.. u: C'

SlIIE rlIN€

B -­-A

BI-

-------------------

SEcnON-AA

D A 3. I C 2 D 4 •

SEcnON-BB H7NSP6Q8 FIG. I

DIl£NS:tON CAS NUB- CASNUB-221J CASNUB-22" CRETRCFUED) 22\100

LINER SHO"'ING VELDlNG SEQUENCE

SIZE Of" LIHE'R -o 66 90 111 \{IDTH-80P'll'l,

\JELDING PROCEDURE,. HEIGHT (H)-75 OR 87 OR tOO DEPENDING UPOIi HIGHT Dr" 'WORN OUT :;l.IRF AC:S, THICKtl[SS TO SUIT,

TYPE OF ELECTRODE" AUSTENITIC STAINLESS STEEL ELECTRODE HAVING NOMINAL COMPOSITION OF 18% CHROMIUM, 8:: NICKEL AND 5% MANGANESE AND APPROVED BY R.D.S.D. AGAINST CLASS I'll OF IRS-M28 SHALL BE USED.

\. Tkf. LINER SHALL BE HELD IN PO.,ITlON BY TACK I.IELDING ON EITHER SIDE (AE AND MR) TACK I.IELDING SflALL BE DONE AT THE MID POINT OF THE LENGTH SIDE ON EITHER SIDE I.E'. TOP( AE )8. BOTTOM SIDE ( MR).

2. \oIELDING SHALL BE DONE IN DOI.IN HAND POSITION PREFERABLY AS PER SEQUENCE GIVEN IN FIG.!' 3. VIDTH OF LINER SHALL BE DIVIDED INTO FOUR' EIJUAL SIZES AND MARKED AS 1.2,3,4 ON ONE SIDE AND 5,6,7,8 [IN THE [JPPOSITE SIDE 4. START VELDING AT' (c) AND VELD UPTO (B) START AGAIN AT (c) AND I.IELD UPTO (D), . 5. THEN START AT (B) AND VELD UPTD (X) COVERING THE CORNER (A).START ATCD) AND VELD UPTO (Y) COVERING THE CORNER (D. 6. THE OPPOSITE SIDE (MR) SHALL BE ''''ELDED IN THE MANNER AS GIVEN ABOVE AND AS PER SEGlUD~CE GIVEN IN THE SKETCH. 7. THE FILLET SIZE SHALL BE MAINTAINED AS STIPULATED IN THE SKETCH. O. IJELDING IS TO BE DONE IN T\oIO PASSES nRSTL Y VITH 3.15 I'\M DIA ELECTRODE AND THEN VITH ~ DR 5 MM DlA.

PRECAUT roNSr-UNIFORI1 BEAD IS TO BE DEPOSITED. 'WEAVING IS NOT PERMITTED. EACH I.IELD IS TO BE FOLlDI.IED BY LIGHT PEENING.!F ANY CRACK IS NOTICED. 'WELDING SHELL BE REMOVED BY CUTTING ELECTODE AND RE.\oIElD.

REPURCUSSIDNS OF IMPROPER \JELDI~JG PRACTICESr-I. IF PROPER ElECTODE AND I.IELDING PROCEDURE IS NOT FOLLO\olED. IT VILl RESULT INTO CRACK IN

yiELDING AND LINER "'ILL GET SEPERATED AND FALL.

2. SETTING OF LINER ON UNEVENLY DRESSED SURFACE 'WILL RESULT INTO ITS BREAKAGE DURING SERVICE. DUE TO UNEVEN SUPPORT.

3. IF VDRN OUT SURFACE IS NOT DRESSED TRUEL v SQUARE AND LINER IS \"ElDED IT 'WILL RESULT INTO 1I1PROPER CLEARANCES AFFECTING FUNCTIONING OF BOGIE.

RECLAIMATION OF WORN OUT PEDESTAL JAWS BY WELDING

SPRING STEFL LINER

FIG.32

on I A

E; CJ D

~

"

~ .~ 5mm l I ~~B~ C~L~t& ~

.. OF GAUGEQt.iJ3OTH SIDES

~ ~""'" I AI..

J.tM G.WQ[ 5MMPLAIl::

'" V 1"'-e

~ l-e ~ I\J - •

~

~ CASNue·22NL.NLB,HS' ,

~ 30 12.8 l~ 188

I

-NOTE:- . , SURFACENARKEO e AND OIMENSION UNDER 5C~E_~

ARE I M PORTA t.f I MATERIAL GAUGsE TIP IS: 1875 CL4 -HARDENED &.. GROUND '----BODY- 15:2062 Fe 410 WA DETAIL OF LINER

AATERIf.L:-r.;:38B5 pt1 GriV I

- -

FIG:-A

"

PEDESTAl. JAWS TO BE RECLAIMED

LJ PEDESTAL JAWCSHORt CASNUB 22NL.NLB.g~ HS

BOGIES.. FIG.33

r--------------------.--~

I

STAMP 5mm L.£ITERS. ------

!

\

\

\ \

\ \

, I

NOTE: SURFACE MARKED 't' AND DIMENSION UNDER SCORED ARE IMPORTANT.

MATERIAL: GAUGE TIP-IS:1B75 CL4 HARDENED AND GROUND BODY-IS:2062 Fe 410W,A.

, ~ -, ,

I

-----------I

-----7 I ,

Jj I j LI

\.----+--

i ' :-~

FIG-A

PEDESTAL JAW(LONG) CASNUB-22NL,NLB,HS

BOGIES

C008uU06ji

GAUGE

FIG,34

o N

. SMOOTH 4r: fREt fROM FORDGN

250

._-- --. -216

,r---------- ---- - --- -.-.....~ '/ 'j}' I -- -. •

: . ___ __ _~f1!:) l; .

- 200 260

,8~46°

. -, -"'r'Jlf 1

I

21. SOIA HOl.E fOR . 20 PIA RIVETS

134

L '5

. ~J1'~ 1-1!9

,/

NOTE: TO BE CHANGED OVER TO RETROmTED DESIGN AS PER DRG.NO.WD-89094-S/1

~IDE BE.ARER DETAIL [CA~N_~!3-22W BOGIE J

FIG.35

a o o o O. c:: o 0') (J"

-.D

--.-----------------~- ---~-.--- -"--"- --

r ~t=-· =--'--t---" --=-'. '=' - .-_-~_--=:c-20~O~--~~ __ -~-- ~--~_+_.'" _",-----,~ '-r--'--- -----

I

I I

I J

_- -=- ::- _-_ ~~s::s:s::s-::s::s~

= ~ =-_ -_~-.Ls:x"~ \ --1----

I

SIDE 6[d l.£R RUBe"''' ,,-"<>

___ ._J._~.± ___ ____,~

SECTION - B B

/,2..1' eJ DIA H Ol E \'COR / 200lA RiVE r

A -~-

SIDE BEARER 0 EtAILS CtSNUB 2 2 \v(M~22NL &. NLB

If)

- BDGI( FIC.36

t

C) C) C) C) C)

c C) 0') 0": c·

-• ,

,-----------_. __ ._--------------,

WE.DGE BOLSTER

191 .1 191

POSITION OF WEDGE WHEN NEW. PROCEDURE FOR CHECKING THE COMBINED WEAR OF BOLSTER 9

SIDE FRAME LINER S AND WEDGE - -~-

CASNUB-22W. 22W(M). 22NL, 22NLB • .z2l::!~LBO-'~IES, .,

FIG.37

STAMP SM.M LE. TTERS-" COMBINED WEAR GAUGE

434

30 30

/0

CASNUB-22W. 22W(M). 22NL. 22NLB. 22HS BOGIES.

FIG-A

2 17. ___ -J

, ~1

6-

IZ DIA.X 300l.0NC

NOTE - 1. DIMENSIONS UNDER LINED &. SURFACES

MARKED THUS" ARE. It"1POBTANt

2 IF POINTS X & Y, Y START TOUCHING TH{ CASTING, REYAIR SHALL BE UNDER TAKEN

MATERIAL:-IS:1875-CL4 HARDENED &. GROUND

PROCEDURE FOR CHECKING THE COMBINED WE:AR OF BOLSTER, SIDE FRAME LINER AND WEDGE

[CASNU~·Z2'r.b22w(M~22NL,22Nl8 22HS BOGIES. FIG. 38

RECLAIM LANO SURFACES WITH LINER TO FIGAO

RECLAIM ROTATION STOP LUG WIT-H­LINER TO FIG.40//

E('LI>.IM OUTER CO\'uMN

GIe.S WITH LINER TO FIG.41

5PRING 5TE EL LI~ER / I

. RECLAIM II4NE RCOLUMN GI6S WITH WELD TO l=IT GAUGE. tOF1G:41

LOCATION TO BE RECLAIMED

I. BOLSTER POCKET SLOPE SURFACE LINER.

2. BOLSTER LAND SURFACES & ROTATION STOP lUGS/LINERS

~. BOLSTER COLUMN GIBS.

RECLAIMATION - LOCATIONS OF WORN eOLS TER

CASNUB 22W, WM,NL,NL8. & HS) BOGIES

FIG.39

0000000662

I I

AMP5MM L TTE

BOLSTE.R LANCf'ROTATION TOP LUG GAUGE CASrvB- BOGIES

I I

I I o

o N ~i " I

I

~ I ~I SCRIBE. CENTRE. LINE

ill H SIDE.S) ~--"!!~-.

'37 BOLSTE.R LAND 37 :

I ~___ ____ _~~~O~ _________ ~

ti.i-L~ ____ ....,;520ROTATION STOP LUG " ./

~J~

(:~ . I

Gy ~ '1 24

T o -:..L .1-___ -'

50 ~-- .. --

GAUG~ CENTRE liNE

\

'r1 I,

I ' I

). i iW)Rr, RCHATION STOP

I 'U~ R[~' AI"rr, ~v L I.J \ 'vL . l"ic..~ b I

TIlTt:KTHICKNE.5E' () SUIT

NOTE .suRFACE MARKED '" AND DIt.'ENSIQti UNDER SCORED ARE IMPORTANJ,

MATERIAL: PETAIL OF UNER fOR LUG GAUGE TIP-1S:1B75 Cli ~HTERiAL:IS:3885 Pi 1 Cd\' !!!Cl _________ - tiARDENFD AJW GROUN:J ---- n I C_ .. - BODY-IS 2062 Fe 410WA

o ~,~ BOLSTER LAND & ROTATION (J1 \J ~ ~ STOP LUG G_AUGE

L.J---L.

DONI OF , ~NER FOR lANO SURFACE

A!lI.:.::JS"lIWj PI 1 CrI\I

CASNUB-22W, WM,NL,NLB, HS}BOGIES

FIG.40

000000066J

· SCRIBE CENTRE LINE BOTH SIDE.

__ ._.'l

6-41 RDSO/Luck/97

i i '-.-.

I _-4~t-:l/r-WORN SURFACE RECLA-p- IMED BY WELDING ..

rSTAMP 5!Y'm LETTERS COLUMN GIB GAUGE CASNUB BOGIES

NOTE: SURFACE MARKED '" A.'iD DIMENSIDN UNDER SCORED ARE IMPORTANT. r-- MATERIAL:

GAUGE DP-IS:1875 Cli HARDENED AND GROUND BOoY-IS:2062 Fe 410WA

CASNUB BOGIES CASNUB DIMENSION EXCEPT 22 HS BOGIE

CASNUB-22HS 'X' 232 239

COLUMN GIS GAUGE CASNUB-22 W. 22 W(M), NL, NLB &

HS BOGIES. FIG,41

000000066 'f

BOL~IER WECGE. L A ~ ~

/ I I I I

~ I

~ \ ,..,.,.,., JJ">--~ I~(( ~ ~ a ~ lv'/" ....... \\ l' \7fr. J~ I"" iC: l~ '1A '/\ ~ l.! '1. l!::~'1 \~ W ~ , ~ '1 I~U~~ ;; ~ ""-~,m u~ ;; ~ ~ ..... > 1 ~Sr ___ J? <

I~~~WW ~ ~r: ~~ ~ e i ..,~ ---;;;:. ~ I~'

D \~foJR~J '{~ ~) )X.~ i»);P '-1 ~ ~ r .... "-0. ...... ~ ,~ - :;: ~I l

L 2. 2''3 t A)( LE LOAD 2.0·3t. AXLe LOAO 16·"2.t. A)(~ I..OAD SIDE-FRAME V

NO. OF SPRINGS REQUIRED

NUl ;-AXLE. LOAD

OU'fER INNER SNUBBER 1. SNUBBING ARRANGEMENT &: SNUBBER

22·9i: 7 , 2. SPRINGS ARE SAME FOR 22.9t. 20.3 t &: 16.2t AXLE LOAD. '20'3t 6 4- 2

2. DETAILS OF THE SPRINGS ARE AS PER J6·zt 4 .4 Z ORG.NO. WO-83069-S/1.

DETAIL OF SNUBBING! SPRING GROUP ARRANGEMENT CASNUB BOGIES (EXCEPT CASNUB-22 HS BOGIE)

FIG.42

B~,.e.R WEOGE.

51DE FRAME

NOTE: ,. DETAILS OF THE SPRtNG ARE AS PER

ORG.NO. WD-92058-S/5

AXLE. LO ....

20·3

a,Of' SPRINGS REQUIRED

INNER SNUBBER

7 6

DETAIL OF SNUBBING SPRING. GROUP ARRANGEMENT (CASNUB-22 HS BOGIE)

FIG.43

6MMPLATE

\

It

'v.-" 62 '. \ '. \ \ .

\\ \

NOTE

. \ \\

'y)

•

50

DIMENSIONS UNDER LINED AND 5URfACES MARKED. THUS ARE IMPORTANT

MATERIAL GAUGE TIP-fSI875 CL.4 HARDENED 6. GROUND BO DY - 15:2062 Fe 410 WA

FRICTION SHOE WEAR GAUGE CASNUB-22'w',22'w'(M),22Nl..,22NLB,22HS BOGIES.

FIG.44 0000000665

STAMPSroro LETTERS CENTER PIVOT GAUGE CASNUB-22W BOGIE

182

310. 314 382

·FIG-A

5 182

310 •

MATERIAL GAUGE TIP-IS:1875.CL-4 HARDENED & GROUND BOQY,..IS:2062Fe410WA

NOTE:-SURFACE MARKED Ie: DIMENSION UNDER SCORED ARE IMPORTANT

BOGIE BOLSTER TO SK~77578

NOTE:-GAUGE IS ALSO APPLICABLE FOR BOTTOM CENTER PIVOT TO WiSE -602

5

o

CENTRE PIVOT GAUGG CASNU8- 22W,22WCRETROFITTED)

BOGIES FtG, -45

000000066b

I/) CD I~

~ [);v

V V I g. ~ -: ~thj ! ~ >II- --V I

180

591& 5

£91& ~ /

I 1-I I

! ~66r-I i Ci-' • 0

102 ~Ox45

314

318

363

NOIE:-SURFACE MARKER 'ct' DIMENSION UNDER SCORED ARE IMPORTANT

MATERIAL GAUGE TlP-IS:1875 CL-4 HARDENED & GROUND BODY-IS:2062Fe410W/:,

180

314

STAMP 5mm LEITERS

g~QDR PIVOT GA~r B 22W(Mt22

22NLB.22HS BOGIES

~r-.~~~~+-~~ 601&

1001&

FIG-A

CENTRE PIVOT GAUGE CASNUB- 22WCM),22NL.22NLB AND 22HS BOGIES

FIG.- 46

WOL£~"H" RIYETS

_ PIVOT PIN (ITEM-6/7) RETAlNER(WO 85079-S/2-

. . 1TEM-3)

CASTlE N'uT ~ OR SHACKLE·

LOCK

'* NOTE:-MATERIAL. AAR M 201 Gr. C (CARBON-o.32" MAX.) IS USED FOR BOGIES MANUFACTURED IS PER WD-asD79-S/2 AlT. 1 e. ONWARDS

• ~.~~------------____ -L~L c. P'VOT ~N"_ ~":2ZW !OI1t

(w/lJ~. 6131

DETAIL OF C.P. PIN ITEM-7) DIM'X' BOGIE REF.DRG. 113 CASNUB-22W{M). WD-85079-S/2

22 NL ' ITEM-5 149 CASNUB-22NLB. • . .

CASNUB 22WCt.I) 22N1.22NLB.22NLM at 22HS

, 22NLM. 22HS . •

~ WO-85079-S!2 I

c.eMtt PIN CASTLE NUT ARRGT.

CASNUB-22 WeN) BoolE . .t W!>-85079-S!2 8 RETAININ(; RlNG:

7 CENTRE PIVOT PIN

6 CENTRE PIVOT PIN

5 BOGIE CENTRE PIVOT BOltOW. * 4 BOGIE CEtfTRE PIVOT TOP * CASNUB 22W 1

3 BOGIE CENTRE PIN(B,C;)

BOGI ES ~ BOGJ£ CENTRE PMJT ~(8.C) 1 BOGIE CENTRE PNOTTOP{B.G}

IT[ DESCRIPTfON REMARKS

CENTRE PIVOTS & CENTRE PIVOTS PINS F I.·G . 4 7 ()SNUB 22W,221(M),22Nl,22NlB,22NI.M A: 22HS ImES

r-:-" .. ' ---, 1"~" . ". "."~ -- .' ... '. -. --

FIG.48 000000

IQ u

~ ~ 0::: aJ

.... 0

!:l if z tt! N ~ ...... -

BRAKE KEY

\D (\J C) (\J

BRAKE BEAM

WO-89033-:

g ..,

1 •• _~ t l ~ •• ~ , ). :, 1_ • , ,

~ ~

BRAKE

58

BAA<E HE.AD

SECTlON-'AA'

BRAKE BEAM &. SHOE [CASNUB-22W,Nl, NLB & HS BOGIES]

FIG.-49.

00000006(0

· \ SIDE OPERATED HANO BRAKE AIR BRAKE. CYLINDER

?DE

A C

--~-~::-a-

\.

HOLES TO BE USED FOR BRAKE ADJUSTMENT

NOT E.:----

BETWEEN

,- E . L. BOX

'SLACK ADJUSTER

LIMITS OF WHEEL DIAMETER FOR MANUAl ADJUSTMHlT OF BRAKE GEAR.

WHEEL DIA. ON TREAD

BETWEEN BETWEEN BETWEEN 1000 & 982 981 c!c 963 962 c!c. 944 943 & 925

-A B C 0

--'-

THE ADJUSTMENT OF BRAKE GEAR PINS SHOULD BE MADE DURING THE CHANGE OF BRAKE BLOCKS & AS WHEEL WEARS.

'---' BETWEEN

924 c!c 906

E

E 0 a CA

MANUAL ADJUSTMENT OF BOGIE BRAKE GE AR ON WAGONS

CASNUB-22'W ,22'W(H),22Nl,.

22NLB,22HS BOGIES.

FIG.50

132.

II

f )

t

"

MOTE:~ I,CROSS HATCHED PORTION '5 m &: GAS CUT

2;REFER FlG. FOR SECTION BS

-I

I I

RtC.lAJMATION OF BRAKE. BE.~M END (b~G. ~O. '1011>-89033- S/I)

C"'&~UB 22 ~LI ~L~ &. \4 .50. ~O~lES

F\G.51

;-------------------_._-------------------

/

.,

SECTION 'BB"OFF\G. 51 -NQTE:-

CROSS HAiCHEO PORTION \S TO BE GAS CUl

RE. tLA1MATION OF BR~KE ~E.A.M END C~5NUB 22 Nt-, ~LB AJHS ~. 5. B()GIL

FIG. 52

'" N

<0,

"

t7~2

S 1. 31

"

...

-------

Rt.CLA. \MAT \O~ OF

BR~"t.. BE.~M END DR.<;. NO. WD89033-5/'

. (AfiE.R GAS CUTT\NG) CA~NUB 2.2NL) f\.lLB & H S. BOG1E:S

F"lG.53

·

.-L D

, , , I

HOLE J:OR. 10 P SPLIT PI'"

-±-D WnOED AS fAR

AS POSSIBLE

o 0

I ~ is!~ --'------u+-J~f._P.\#_+,_l-~~+----

NOTE:-THIS CAN BE MADE BY MODIFYING BRAKE HEAD. OF BRAKE BEAM TO SK.NO. 69596 (FOR CASNUB-22 W)

12 L.--- ~r I-r,....,..t.-*"' ---j-

SECTION-DO

BRAKE HEAD (F;OR RECLAIMING WORN OUT BRAKE HEAD) MATL:IS:2062 fe 410 WA NO. Off /BOGIE=4

RECLAIMATION .QE

BRAKE BEAM END (DRG.NO.WO-890JJ-S/1 )

CASNUB 22 NLlNLB/HS BOGIES

FIG.54

J

'.­.,..-.... '._-...

"-._J

o C) o o o c o <n ~ +:>.

131

52·

._- ==~~~II A

_-= ........ -= /1

1"11.2

J1 \ .

MOTe:- REFER fIG,

--------------'110

BRAKE BEAM END (DRG, NO. WO-89D33-S!1)

(REClAIMED BY NEW BRAKE H~)

CASNUB-22NL/NLB/HS BOGIES

FIG.55

Cl s: 9? " z I " ~ ~

: ~

:IJ 0

'" .:)

'" " , ~

«> ~

I '" 0

'" '"

0 0 0 0 0 <::)

0 0')

-.......I c...' ,

SECTION 'A 1\ O~ FIG. 55

RECLAIMATION OF

BRAKE BEAM END CASNU8-22 Ni.lNLS/HS BOGIES

FIG.56

PRIN1EI) BY T ... "iB GENERAlj ~IANAGElt, GOVT. OF INDIA PRr!SS, NASRlK~422 006 1998