BOGIES AND SUSPENSION - South Central Railway

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CHAPTER 6 – BOGIES AND SUSPENSION WAGON MAINTENANCE MANUAL Page 30 of 121 When new, the effective length of spring shackle should be 332 (+1.0/- 0.0) mm. The maximum permissible wear at this place is 2 mm. The shackle should be replaced when the diameter is reduced below 23 mm at this location. While pairing the shackle on either end of the spring, it must be ensured that variation in effective inside length does not exceed 2 mm. Excessive variation in effective length can lead to uneven loading of the two shackles and the heavily loaded shackle may fail. Inside width of the shackle is 62 (+1.0/-0.0) mm. It is necessary to ensure this dimension is less than the shackle else it will not clear the sides of the stone. The radius at the corners of the shackle has been increased from 6 mm to 10 mm to reduce undue concentration of stress at this place. The shackles manufactured with 10 mm radius should be printed yellow with two coats of paint to distinguish if from shackles having 6 mm radius. Either ends of the shackles can be used in the spring end or Bush-end of the bracket. It is important that the inside edges of the retainer is made to correct dimensions and the shackle pin hole is drilled at correct locations. d) MAINTENANCE OF HORN CHEEK & GAP STIFFENER Both the legs of the horn cheek wear in service. All the six vertical edges along the length of the horn cheek have been given a radius of 1.5 mm. The lateral play between axle box lug and horn cheek, when the both are new is 20 mm and when worn out is 25mm. The lateral clearance available between spring buckle and horn gap stiffener is 25 mm. In view of this clearance, the Horn cheek must be replaced if reduced to 13 mm in thickness, i.e. worn out by 4.5 mm or when total wear on axle box lug and horn cheek reaches 5 mm to avoid spring buckle coming in contact with horn gap stiffener. Longitudinally, a total of 12 mm clearance is provided in between the axle box and horn cheeks when new. This clearance, when axle box and horn cheeks are worn out, should not exceed 18 mm or the short leg of horn cheek should not be permitted below 12 mm in thickness. Special attention should be paid to lateral and longitudinal clearance between axle box and bogie frame, since these clearances govern the above mentioned floating characteristics of the wheel set. e) MAINTENANCE OF AXLE BOX LUGS Normally, the faces of the lugs of axle box are not expected to wear fast. However, mainly due to improper alignment of the bogie frame some times wear takes place on axle box lugs. Whenever such wear is noticed, alignment of the bogie should be done as detailed in RDSO's Technical Pamphlet No. G-16 (Rev.2).
CHAPTER 6 – BOGIES AND SUSPENSION WAGON MAINTENANCE MANUAL Page 31 of 121 Worn out axle box may be reclaimed by using manual metal arc welding of Manganese steel liner (cast or rolled) of 3 mm or 5 mm thickness to the lugs of 3mm or 5mm thickness. In case wear exceeds more than 5 mm. no reclamation should be done. Condemning size for horn cheek is based on the assumption that wear taken place on horn cheek. When Axle boxes are found to be worn, it has to be kept in mind that horn cheeks will have to be above the condemning dimensions so maximum limit of total longitudinal clearance of 18mm and lateral clearance of 24.5 mm do not exceed. Whenever wear on axle box lug is more than 1.5 mm on any side, Manganese steel liner of size 6 mm or 5 mm thickness can be welded to the lugs of these boxes. After axle box is restored to its original dimensions. The surface of the axle box lugs should be machined or ground. The mill scale on the liner should be removed either by grinding or by the wire brushing. The liners should be flat and straight. While replacing the old Manganese steel liners by new one, care should be exercised to remove all old welding by chipping or grinding to ensure a smooth surface. The surface of the axle box should be thoroughly cleaned by wire brush. The surface of the axle box lugs and liners should be totally free of oil, grits and grease etc. before the welding is undertaken. The longitudinal distance between lugs of the axle box is 265 +0 / -0.3 mm. When this distance reduces, the liners should be provided as given below. Sr. No. Longitudinal distance between lugs of the axle box 1. Between 259 mm to 262 mm 2. Between 254.7 mm 259 and Distance from the centre of axle box to any side Liner to be used between 129.5 to 131 mm 3 mm thick Between 127.35 mm to 129.5 mm 5 mm thick The lateral distance of lug from the axle box is 65± 0.0/0.4mm. When this distance reduces, the following liners are to be provided. Sr. Lateral distance between lugs of Liner to be used No. the axle box 1. Between 62 and 63.5 mm 3 mm thick 2. Between 60 mm to 62 mm 5 mm thick The condemning dimensions are as under: Longitudinal distance between lugs Below 254.7 mm Longitudinal distance between lugs Below 126.35 mm from the centre of the axle box on side Lateral distance of the lugs from the Below 60 mm centre of the axle box
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BOGIES AND SUSPENSION - South Central Railway

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