Sl.N Description Specification No Drawing No. 19. Cast Steel CASNUB bogie and its components A Casnub-22 NLB Bogie Spec. No. WD-21-Casnub-22 NLB WD-89073-S/2 Alt-10 Bogie-93 Rev. 2, with 5 Amendments: Last Amend. No. 5 issued in Sept. 2016 B Casnub-22HS-Bogie WD-17-Casnub-22HS-Bogie-92 WD-04038-S/2, WD- Rev.3, with 5 Amendments:Last 04078-S/1& WD-17013- Amend. No. 5 issued in Sept. 2016 S/2 C Casnub-22HS(Mod-I) Bogie WD-34-Casnub-22HS (Mod-I)-2004 WD-04017-S/2 with 4 Amendments: Last Amend. No. 4 issued in Sept. 2016 D Casnub-22HS(Mod-II) Bogie WD-39-Casnub-22HS (Mod-II)-2009 WD-08026-S/2 with Amendment no. 1 of Feb.’2010 & Amendment no.2 of Sept. 2016 20. Cast Steel bogies and its components for CONTR.LCCF 20 (C)-96 Rev.2 with CONTR.9404-S-2 Alt.7. CONCOR flat wagons Amend. No. 1 of Feb.’2010 & Amend. Nno.2 of Sept. 2016 21. Spring Plank A Spring plank for CASNUB NLB bogies WD-21-CASNUB-22NLB Bogie-93 SK-69594 Alt. 36- item 1 Rev. 2 of July 02 with 5 Amendments: Last Amend. No.5 issued in Sept. 2016. B Spring plank for CASNUB HS bogies WD-17-Casnub-22HS-Bogie-92 WD-92058-S/4 Alt.9 - Rev.3, with 5 Amendments:Last item 1 Amend. No. 5 issued in Sept. 2016 C Spring plank for CASNUB HS-MOD-I WD-34-Casnub-22HS(Mod-I) - 2004 WD-92058-S/4 Alt.9 - bogies with 4 Amendments: Last Amend. item 1 No. 4 issued in Sept. 2016 D Spring Plank for CASNUB HS MOD-II WD-39-Casnub-22HS(Mod-II)–2009 WD-92058-S/4 Alt.9 - bogies. with Amendment no. 1 of Feb’10 & item 1 Amendment no.2 of Sept. 2016 E Spring plank for LCCF bogie CONTR.LCCF 20 (C)-96 Rev.2 with CONTR.9404-S/04 Amend. No. 1 of Feb.’2010 & Amend. Alt.10-item1 F Spring plank for LWLH25 bogie WD-40-LWLH25Bogie (‘K”-Class)- WD-13012-S/04 2015 with Amendment no.1 of Sept. Alt.5(13.12.19)-item 1 2016 PL No. 38101579 22. Centre Pivot Washer WD-85079-S-2 Alt-26 23. Brake Beam for freight stock A CASNUB-22NLB Bogie WD-21-CASNUB-22NLB Bogie-93 WD-89033-S-1 Alt. 21 Rev. 2 July’ 02 with 5 Amendments: B Casnub-22HS-Bogie Last Amend. No.5 issued in Sept. WD-07052-S-1 Alt.01 C CASNUB-22HS(Mod-I) 2016 WD-89033-S/1 Alt.21 D CASNUB-22HS(Mod-II) WD-17-Casnub-22HS-Bogie-92 WD-07052-S-1 Alt.01 Rev.3, with 5 Amendments:Last WD-89033-S/1 Alt.21 Amend. No. 5 issued in Sept. 2016 WD-07052-S-1 Alt.01 WD-34-CASNUB-22HS(Mod-I) of WD-89033-S/1 Alt.21 2004 with 4 Amendments: Last Amend. No. 4 issued in Sept. 2016 WD-39-CASNUB-22HS(Mod-II) of 2009 with Amendment no. 1 of Feb’10 & Amendment no.2 of Sept. 2016 51
Sl.N Description Specification No Drawing No. E LCCF 20 (C) CONTR.LCCF 20 (C)-96 Rev.2 with CONTR.9404-S/17Alt.6 Amend. No. 1 of Feb.’2010 & Amend. no.2 of Sept. 2016 F LWLH25 WD-40-LWLH25Bogie (“K”-Class)- CONTR.9404-S/17Alt.6 2015 with Amendment no.1 of Sept. 2016 24. Narrow Jaw, Wide Jaw and Modified Adapter A Narrow Jaw AB/RB-39-2002 Rev. 4 of February- WD-89067-S-9 Alt.8 2018 B Wide Jaw AB/RB-39-2002 Rev. 4 of February- SK-78527 Alt.6 C Modified Adapter 2018 WD-85053-S-1 Alt.6 D Adapter class K (6 ½”X9”) - AB/RB-39-2002 Rev. 4 of February- 2018 AB/RB-41-2016 25. Side Frame Key SK-69594 Alt.35-item 6, CONTR.9404-S/04 Alt.10- item 3 & WD- 13012-S/04 Alt. 4-item 2 26. AAR approved Taper Roller Cartridge AB/RB-39-2002 Rev. 4 of February- Proprietary item Bearings class E(6”X 11”) complete for use 2018 on freight stock 27. AAR approved Cartridge Tapered Roller AB/RB-41-2016 Bearings Class ‘K’ (6 1/2” X 9”) for freight stocks fitted with light weight low height (LWLH) bogies (Narrow Jaw) for 25t axle load application. 28. Upgraded Class E CTRB AB/RB-40-2016 29. Locking Plate A Locking Plate Class E AB/RB-39-2002 Rev. 4 of February- WD-87019-S-1 Alt.2 B Locking Plate Class K 2018 WD-06085 S-2, Alt-Nil AB/RB-41-2016 30. Axle end steel high tensile cap screws A Axle end steel high tensile cap screws-1”ø AB/RB-39-2002 Rev. 4 of February- WD-18016-S-01(Alt 1, 8 UNC-2A, 2¼” thread length 2018 & IS 1367 pt.3,Cl P8.8 Item no1) B Axle end steel high tensile cap screws-1 AB/RB-41-2016 & IS 1367 pt.3,Cl WD-18016-S-01(Alt 1, 1/8”ø 7 UNC-2A, 2 ½” thread length P8.8 Item no 2) 31. Silico-Manganese & Manganese Steel WD-17-Casnub-22HS-Bogie-92 WD-97049-S/3 Alt.8 Liners & Wear Plates for Bogie and Rev.3, with 5 Amendments:Last item 3 & 4, CONTR couplers Amend. No. 5 issued in Sept. 2016, 9404-S/8-item 1; WD- WD-34-CASNUB-22HS(MOD-I) of 13012-S/04 Alt.4-item 5; 2004 with 4 Amendments (Last WD-13012-S/05 (Sheet amendment no. 4 issued in 2 of 2) Alt.1-item 2 to 4 Sept’2016), WD-39-CASNUB- & Spec. No. 48-BD-08 22HS(MOD-II) -2009 with with Amend. No.1 of 52
Sl.N Description Specification No Drawing No. Amendment no. 1 of Feb’10 & Sep. 2016, 56-BD-07 Amendment no.2 of Sept. 2016, WD- with Amend. No.1 of 21-CASNUB-22NLB Bogie-93 Rev. 2 Sep’10 & with Amend. July’ 02 with 5 Amendments (Last no. 2 of Sep 2016, 70- amendment no. 5 issued in BD-10 Sept’2016), CONTR.LCCF 20 (C)-96 Rev.2 with Amend. No. 1 of Feb.’10 & Amend. No.2 of Sept. 2016; WD- 40-LWLH25Bogie(‘K”-Class)-2015) with Amendment no.1 of Sept. 2016. 32. Cold Rolled Formed Sections for Freight WD-01-CRF-12,Rev.1 Stock 33. Brake Slack Adjuster Type IRSA-750 for 19-ABR-07 with 3 Amendments: Last WD-93061-S-01 Alt. 01 Freight Stock & Spares Amemendment no. 3 issued in Sept. 2016 34. Bogie Mounted Brake System for freight WD-23- BMBS-2008(Rev.1) with WD-08093-S-2 Alt. 3 & stock fitted with Casnub Type Bogie Amendment-1 of Sept. 2016 WD-08096-S-01 Alt. 2) 35. Body Side Wall, End Wall and Flap Door of WD-16-BOXNR-2010 Rev 01 with WD-07001-S/08 Alt. 10, BOXNR Wagons Amend. no. 02 of Dec. 2016 WD-07001-S/09 Alt.5, WD-07001-S/10 Alt.9, WD-09034-S-07 Alt.8 and WD-07064- S/01Alt.9 36. Light Weight Low height 25 T axle load WD-40-LWLH 25 Bogie( “K”-Class)- WD-15021-S/02 Alt 1 bogie (LWLH25) & its components for 25 T 2015 with Amendment no. 1 of Sept. axle load wagons 2016 37. Non-asbestos ‘L’ type Composition Brake WD-13-ABR-2019 CONTR-9404-S-11 Alt. Blocks for container flat wagons 7 38. Non-Asbestos K- type Composition Brake WD-14-ABR-2019 WD-15023-S-01 Blocks for freight stock (840mm wheel dia.) 39. Non-asbestos ‘L’ type Composition Brake WD-13-ABR-2006 Amend. No. 1 of WD-99062-S-01 Alt-03 Blocks for freight stock with 1000 mm May’07& Amendment-2 of Sept. wheel dia. 2016 40. Non-asbestos K-type Composition Brake WD-14-ABR-2007 with 3 WD-00006-S01 Alt-03 Blocks for freight stock( with 1000mm Amendments (Last:Amendment no. wheel dia) issued in 3 Sept. 2016) 41. Constant Contact PU Side Bearer Pads for WD-38-Misc.-2004 Rev. 1 of Jan’ AAL-021101 Alt. 8 HS Bogies 2008 with Amend. No. 1 of March’ 2008 & Amend. No.2 of Sept. 2016 42. Constant Contact PU Side Bearer Pads for WD-38-Misc.-2004 Rev. 1 of Jan’ AAL-021101/N Alt. 01 NLB Bogies 2008 with Amend. No. 1 of March’ 2008 & Amend. No.2 of Sept. 2016 43. Constant Contact Side Bearers for Broad WD-62-MISC-17 Rev Nil of Aug. WD-12007-S-01 Alt 2, Gauge Bogie Wagons 2018 & CONTR-01-MISC-07 Rev 1 WD-12008-S-01 Alt 2 of Sep. 2010 and WD-17025-S/01 Alt Nil, 53
Sl.N Description Specification No Drawing No. 44. Automatic Twist Lock (ATL) CONTR-01-MSG-ATL-2011 of Nov., CONTR-9405-S/21 2011 45. NM friction wedge CONTR-02-MISC-2007 WX-10046 46. Manual Metal Arc Welding Electrode As per Respective Wagons’ WPS 47. Solid MIG/MAG Welding Filler Wire As per Respective Wagons’ WPS 48. Flux cored MIG/MAG Welding Filler Wire As per Respective Wagons’ WPS with shielded gas 49. Wire for Submerged Arc Welding Class As per Respective Wagons’ WPS 50. Flux for Submerged Arc Welding Class As per Respective Wagons’ WPS 51. Paints based on epoxy and polyurethane M&C/PCN/102/2009 with RDSO’s A resin for exterior painting of wagons amendment no.1B as an Additional requirement Epoxy based Zinc Phosphate Primer (two pack) B Full gloss Red-Oxide Polyurethane Enamel M&C/PCN/109/2009 with RDSO’s (two pack) amendment no.1B as an Additional requirement. C R/M paint synthetic for the system of IS:2074/1992, second exterior painting. Ready Mixed paint, air D drying, Red Oxide, Zinc Chrome, Priming revision(Reaffirmed 2002). E 52. R/M paint synthetic for the system of IS: 8662 (2004) Enamel, Synthetic exterior painting Exterior Epoxy Cum Polyurethane Painting system (Two Pack) for the Exterior Painting (Non No.M&C/PCN/100/2018 with Specified Mother Specification) Wheel and Axle RDSO‟s amendment no. 1B as an (1000mm , 840mm) Additional requirement. IRS R-19/93 Part III WAP/SK/M-153,154 WAP-W-004 53. Huck Bolt and Collars WD-11036-S-01 & WD-11036-S-02 54. Material of Wagon Construction IS:2062 MS, IS 3502, IRS M:41& IRS M:44 SS SAIL MA 350 55. RFID Tag (V4.1) No.: 2016/ CRIS/ NDLS-ITPI/ WS-C/ POLICY/ RFID/ 0101/ PT-1 dated 05.10.2028 54
12.0 COUPLER Coupler: WD-70 BD-10 (Rev2) Indian Railways suffers a large number of train partings because of coupler and knuckle breakage which results in heavy losses. Poor quality of CBC components causes large scale premature replacements of components during maintenance in workshop, depots and yards. The manpower and material costs of such replacement is very high. Even after large scale replacement of components during maintenance in workshops depots and yards, train partings are still taking place which reflect on the poor quality of coupler components. The direct and indirect cost of train parting is huge. CBC of Indian Railways is based on the AAR specification. In 1960 few manufacturers acquired TOT of Grade B castings from North American Manufacturers. For carrying longer trains the material of CBC was first upgraded to “C‟ and then to “E‟. For indigenous development and multi sourcing RDSO issued the drawings of CBC including of gauges in 1980. However the coupler and knuckle failures continued unabated. The major problems in the manufacture of the Grade E coupler were 55
To improve the indigenous couplers RDSO constituted a Technology Development Group comprising of representatives of Wagon, QA and M &C directorates of RDSO along with representatives of Industry to improve the coupler and it‟s specifications. Three meetings of the Technology Development Group were held on 8.8.2006, 10.10.2007 and 26.06.2009. In addition these issues were also discussed in a meeting between RDSO and coupler manufacturers on 19.3.2007. The following decisions were taken in the meeting of the Technology Development Group: 56
MARKING(GR E):‐UHTE FIRM̕S NAME M&Y 57
13.0 Draft Gear : • WD‐49 BD : MK‐50 & RF‐361 • WD‐66 BD : (IMPORTED): MINER, WESTINGHOUSE, STUCKI, ASF • WD‐71 BD : Indigenous • 495 A : RITES/TP‐9405‐S/001 (Draw gear arrgt) : Draft gear : BLC WD‐49 BD : MK‐50 • Used in BOXN, BCN, BCNA, BCNAHS, BCNAHSM1, BOBRN, BFNS, BTPGLN etc • Springs inside the housing WD‐49 BD: RF‐361 • Used in BOXN, BCN, BCNA, BCNAHS, BCNAHSM1, BOBRN, BFNS, BTPGLN etc • Rubber Pad used inside 58
WD‐66 BD: ASF •Used in BOXNHL & BCNHL •Rubber Pad WD‐66 BD: WESTINGHOUSE •Used in BOXNHL, BCNHL & BOXNS •Springs used inside 59
WD‐66 BD: Stucki •Used in BOXNHL, BCNHL & BOXNS •Springs used inside WD‐66 BD: MINER •Used in BOXNHL, BCNHL & BOXNS •Rubber Pad 60
WD‐66 BD: MINER •Used in BOXNHL, BCNHL & BOXNS •Rubber Pad WD‐71 BD: MINER LICENSED TO FAS •Used in BOXNHL, BCNHL & BOXNS •Rubber Pad 61
WD‐71 BD: JUPITER •Used in BOXNHL, BCNHL & BOXNS •Springs used inside WD‐71 BD: RANEKA •Used in BOXNHL, BCNHL & BOXNS •Rubber Pads used inside 62
Draft gear : 495 A: BLC 63
14.0 Springs on Wagons It is recommended that springs having less than 3 mm free height variation should be assembled in the same group. Mixing of new and old spring must be avoided. The bogie is fitted with two groups of long helical spring nests. The spring groups per bogie for various axle load applications are as under: 64
65
14.1 Grouping of Springs: (By strip method) A. Group Band (Coloured) for in service springs (Maintenance group) 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. Coloured band should be provided for easy identification of group height as indicated in the table. All versions (except for CASNUB 22 HS) 66
B. Group Band (Coloured) of NEW Springs, Matching of both, load and Snubber springs, is important. It is recommended that springs having less than 3 mm free height variation should be assembled in the same group. 67
14.2 SPRING DATA AT A GLANCE: 68
14.3 Spring Arrangement for Various CASNUB Trolleys: 69
70
15.0 Huck / Lock Bolt 71
72
73
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16.0 Warranty/ Guaranty of Wagons Period of warranty/ guaranty of Wagons will be 30 months from the date of delivery or 24 months from the date of commissioning whichever is earlier. This clause is mentioned in Railway Board’s Purchase Orders. For individual component, their warranty should be dealt with separately for which details are given below; a) In accordance with the conditions mentioned in the wagon manufacturing contracts, the charges for rectification of the following category of defects can be realised from the wagon builder:- Use of inferiormaterial Poor workmanship on the part ofcontractor Imperfectprotection Other faults on the part of contractor which are noticed during the warranty period. b) ToenabletheRailwayBoardto realize thewarrantycharges,asystematicinspection of new (i) wagons must be undertaken by representative of C&W to locate defects during the warranty period. The following procedure is laid down for thispurpose:- All newly built wagons turned out must bear the warranty legend stencilled on both sides of the wagons. The warranty legend will consist of the following particulars:- • ContractNumber • Date ofCommissioning • Commissionedby • Inspection dueon • Inspectiondoneby Depot Date (ii) Whenever wagons due for warranty inspection pass nominated yards, preferably detach them from the train and send to sick line for a systematic check. 75
(c). Warranty claim/Inspection of components The important points which should be remembered in every warranty claim/Joint inspection are; • In respect of materials pre-inspected at the firm's premises, the consignee will issue rejection advice within 90 days from the date of receipt. ( Ref: Vide Para 417 of the Indian Railway Code for the Stores Department) • Handling of rejection of pre inspected item and warranty rejections is governed by Dy. Dir. Rly Stores (G)-I/Railway Board’s letter No. 2000/RS (G)/379/2, dt 07.08.2015 and 18.01.2018. • The procedure of testing of sample is governed by Dir. Rly Stores (G)-I/Railway Board’s letter No 2000/RS (G)/379/2, dt 28.04.2016 during joint inspection. • Joint inspection must be done with the same Inspector who inspected the material • During joint inspection, it should be carefully examined about Before start of JI, the inspector must go through above Railway Board’s guidelines. Hologram intact with the material (if applicable) Match details of material mentioned in DM/IC with the rejected material Any tampering marks on the material Marking details of manufacturer on the material Must go through the Inspection report of consumer of material based on which Rejection Advice has been issued. Must see the storage condition of rejected stores Must observe whether the parameter (s) for which the rejection has been upheld, was a part of regular Purchase Inspection Plan and mention the same in joint inspection report. Try to convince your logic with the joint signatories with the all relevant documentary evidence with very calmly. If joint signatories agree with the testing of sample, guideline mentioned in the Dir. Rly Stores (G)-I/Railway Board’s letter No 2000/RS (G)/379/2, dt 28.04.2016 is to be followed. If disagreement on any issue, dissent note is to be issued. • During joint inspection, a RDSO format no. QM-F-8.1-18, ver 1.0 w.e.f 28.08.2018 is to be filled up and get duly signature (with Name, Designation & Date) of Gazetted Official or the Controlling Officer issuing the Rejection Advice (In case of Railway Consignee) and submitted to field unit head for further action. Any action taken by the field unit must be communicated to the concerned firm or Inspector or Consignee. • All relevant papers must be accompanied with this report. ***** 76
17.0 Wagon Production Software Wagon production software has been developed by RDSO for the wagon inspection. The site is www.rdsowagon.org. The salient features of this software are; Railway/ Private purchase order registration by the wagon builders with uploading facilities of PO and Proto approval/ Waival letter and approval by Executive Director of the field units Wagon builder can raise wagon inspection against an Railway/ Private PO after filling all sub-components details Inspecting officials inspect those wagons and issue system generated Dispatch Memo (DM) and Inspection Certificate (IC) with unique numbers. SMS & e-mail alerts at each stage to the ED of the field units, wagon builders and the concerned inspecting officials On line issue of NCR One can track the wagon inspection in terms of whether the wagon is under inspection or passed or rejected. One can see the details of sub components details by searching wagon number One can see the wagon inspection details by searching DM and IC Report section has been improved such as tracking of wagon production wagon builder wise, month wise, year wise etc. 77
By entering Wagon number , we can find all important details about wagon like, Manufacturer, P.O details, Bogie Details, Chassis, Lock Bolt, CRF, Paint, Brake Equipment details, CBC/ Draft gear details, Pipes & fittings, Rlaxation, RFID etc. https://www.rdsowagon.org/Admin/View_WagonDetailslogin.aspx?wagon_no=73122014996 78
18.0 Wheel Base of CASNUB Bogie The wheel base of a CASNUB bogie is the distance between the centre lines of Jaw openings. This is 2000 ± 5 mm for all types of bogies. While casting the side frames of a CASNUB bogie in a foundry, five buttons are casted on the side frame which are called as Wheel Base buttons and indicate wheel base. After measuring the distance between the jaw openings, buttons available are removed according to wheel base and as tabulated below; Distance between centre lines of No. of buttons on bogie jaw opening frame 2004 to 2005 mm ●●●●● 2002 to 2003 mm ●●●● 2000 to 2001 mm ●●● 1998 to 1999 mm ●● 1995 to 1997 mm ● 1995 mm - In other words, it can say that if five buttons found on side frame, it means that the wheel base of that side frame is 2005 mm and if no buttons found on side frame, it means that the wheel base of that side frame is 1995 mm. While pairing the side frame for a bogie, it should be ensured that there should not be any difference between the numbers of buttons on the two-side frames (Authority : Wagon Maintenance Manual, Chapter 6, Para no. 601 B (d) page no. 6 of 43). 79
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