BOGIES AND SUSPENSION - South Central Railway

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CHAPTER 6 – BOGIES AND SUSPENSION WAGON MAINTENANCE MANUAL Page 76 of 121 7. IRCA axle box ( for 4 wheeler wagons journal size 254 x 127 mm. 8. IRCA axle box (MG) for 4 wheeler wagons journal size 229 x 114. 9. IRCA axle box (MG) for 4 wheeler wagons journal size 187 x 120 mm. IRS axle boxes have been provided with key plate. IRCA Non-standard type are without key plate. Four wheeler axle boxes have two channel in which the axle guards slide. Axle box is made of cast steel class ‘A’ grade. It is normalized. An IRS BG axle box assembly for journal size 255 x 127 mm meant for four wheeler wagons has been shown in the figure below:- 8 7 1 2 3 4 5 6 238 127 DIA 82.5 CENTRE LINE OF JOURNAL 255 JOURNAL 1. AXLE BOX BODY 2. AXLE BOX BEARING 3. KEY PLATE 4. TOP COVER PLATE 5. BACK COVER PLATE 162 6. DUST SHIELD LEATHER 7. WOODEN KEEP 8. FACE PLATE 9. BACK SHROUD PLATE Fig. 6.8 AXLE BOX ASSEMBLY 255X127BG The axle box is a rectangular hollow box with openings in front and back a crown on the top. Back opening is meant for entry of the journal. Front opening has been provided for insertion/withdrawal of bearing brass, oil soaked cotton waste/FRLP, key plate, etc. Crown has been provided to keep bearing spring in position and preventing its displacement. Crown also enables insertion of packing plate between axle box and spring. After replacement of the soaked waste/FRLP, wooden key, bearing brass, key plate in position axle box is sealed in the front by riveting a faceplate to its lugs. On the backside the axle box is sealed by providing a dust shield, back cover and top plate. Axle box body is 8 mm thick at bottom and sides and 13 mm thick at the top. On the backside near the bottom, a shroud is provided for keeping soaked packing into position and not to allow the oil to find way out through and back opening. 9 154 136.5 210
CHAPTER 6 – BOGIES AND SUSPENSION WAGON MAINTENANCE MANUAL Page 77 of 121 Axle boxes having key plate have been provided with lugs in the front and back as well as on both the sides. The key plate is kept in position by these lugs. The bearing brass gets suitably locked with the key plate and thus the former is prevented from having undue movement longitudinally and transversally in relation to axle box. It is, therefore, very important that machining of the lugs should be correctly done, otherwise, there will be undue movement of the brass in relation to the axle box. The front, back and side lugs are fine-finish machined. The inner top surface of the axle box, which comes in contact with the top surface of the key plate should be fine machined. The surface on which the faceplate sits should be rough machined. The machining tolerance between the front and back lugs and side lugs is +1.0/ - o.5 mm. In addition to machine tolerance, 1 mm wear is allowed on the lugs. These dimensions should be very strictly followed at the time of manufacture as well as at the time of POH and at the times of re-packing in sick lines. It has been the experience that the initial machining at the time of manufacture is not always satisfactory and, therefore, 1 to 2% of the new axle boxes should be checked in the workshops to ensure that – The crown inner surface has not been machined out of square. The lugs are of equal depth and also at an equal distance from the centre line of the axle box and The machining of the guides is not on a taper or in other words, guide surfaces must be parallel to each other along the full length. In service, the inside crown of the axle box wears. It should be checked for wear at the time of POH and re-packing. Concave wear on the inside crown should not be permitted under any circumstances. If worn, the inside crown should be fine machined to ensure proper flatness. The thickness of the crown may be reduced to the extent of 2 mm by machining. IRCA axle boxes have not been provided with key plates. On such axle boxes instead of front & back lugs, the top inner surface have a downward projection. These axle boxes have side lugs. The bearing brass has upward projections at the 2 ends at a distance corresponding to the downward projected portion of the axle box. The projected portion rests on the top recess of the bearing brass. The raised portions of the brass do not permit its movement along the centre line of axle. The side movement is prevented by the side lugs. It is, therefore, important that the projected portions should be machined accurately. The distance between the edges should be correct. If it is more, it will infringe with the brass and if less, it will give excessive movement of the brass in relation to the axle box. a) AXLE BOX COVER PLATE (TOP AND BOTTOM) The back opening of the axle box is covered with cover plates/plate. In IRS boxes the cover plate is used in two half. It is known as ‘Cover plate top’ and ‘cover plate bottom’. In IRCA axle boxes, one complete plate is used. It is secured with axle box by welding.
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BOGIES AND SUSPENSION - South Central Railway

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