ESR 0545 - Overhaul of three piece bogies

Engi

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ing

Stan

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Engineering Standard Rolling Stock

ESR 0545

OVERHAUL OF THREE PIECE BOGIES

Version 1.0

Issued June 2010

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

Owner: Chief Engineer Rolling Stock Approved by:

Stephen White, Technical Specialist Rolling Stock Performance Standards, Rolling Stock Access Integrity

Authorised by:

Michael Uhlig, Manager, Rolling Stock Access Integrity

UNCONTROLLED WHEN PRINTED Page 1 of 70

RailCorp Engineering Standard — Rolling Stock Overhaul of three piece bogies ESR 0545

© Rail Corporation Page 2 of 70 Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0

Document control

Revision Date Summary of change (RSS 0042) 1.0 August 2007 Based on TRS 0159 (RSS 0545) 1.0 May 2007 Issued as a RailCorp standard and renumbered RSS 0545 (ESR 0545)1.0 June 2010 Reformatted and renumbered ESR 0545

Summary of changes from previous version

Summary of change Section NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’ to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the ‘Document control’ page carries over to a second page separate pages must be used for ‘Contents’ and ‘Document control’



Contents

1 Scope..................................................................................................................................................7 2 Preparation.........................................................................................................................................7

2.1 Disassembly..............................................................................................................................7 3 Bolsters ..............................................................................................................................................7

3.1 General overhaul requirements ................................................................................................7 3.1.1 Repair of bolsters shall be limited to the following: ......................................................7 3.1.2 Terminology..................................................................................................................8 3.1.3 Cleaning .......................................................................................................................8 3.1.4 Casting inspection ........................................................................................................8

3.1.4.1 Repair ...........................................................................................................8 3.1.5 Centre liner inspection..................................................................................................8

3.1.5.1 Repair ...........................................................................................................8 3.1.5.2 Cupped liner installation repair .....................................................................9 3.1.5.3 King pin hole repair .......................................................................................9 3.1.5.4 Shallow casting repair.................................................................................10

3.1.6 Wear plates ................................................................................................................10 3.1.6.1 Repair .........................................................................................................10

3.1.7 Gibs ............................................................................................................................11 3.1.8 Sidebearer height .......................................................................................................11

3.1.8.1 Repair .........................................................................................................11 3.1.9 Fulcrum brackets........................................................................................................11 3.1.10 Constant contact sidebearers ....................................................................................12 3.1.11 Welding ......................................................................................................................12

3.1.11.1 Grade B material.........................................................................................12 3.1.11.2 Grade C material.........................................................................................12 3.1.11.3 Heat treatment ............................................................................................13

3.2 National type ...........................................................................................................................15 3.2.1 General.......................................................................................................................15 3.2.2 Gibs ............................................................................................................................15

3.2.2.1 Repair .........................................................................................................15 3.2.3 Bolster wear plates.....................................................................................................16

3.2.3.1 Repair .........................................................................................................16 3.2.4 Rotation lands ............................................................................................................16

3.2.4.1 Repair .........................................................................................................16 3.3 Ride control type .....................................................................................................................16

3.3.1 General.......................................................................................................................16 3.3.2 Wedge pockets...........................................................................................................17

3.3.2.1 Repair .........................................................................................................17 3.3.2.2 Ride control pocket .....................................................................................18 3.3.2.3 Super service ride control pocket ...............................................................19

3.3.3 Gibs ............................................................................................................................19 3.3.3.1 Repair .........................................................................................................19

4 Friction wedges ...............................................................................................................................20



4.1 Ride control friction wedges....................................................................................................20 4.1.1 Winged and plain type wedges. – Ride control bogies ..............................................20 4.1.2 Friction wedge (in frame type) – National bogies.......................................................21

4.2 Barber friction wedges ............................................................................................................21 5 Overhaul of three piece sideframes ..............................................................................................28

5.1 General overhaul requirements ..............................................................................................28 5.1.1 Repair of sideframes shall be limited to the following ................................................28 5.1.2 Cleaning .....................................................................................................................28 5.1.3 Inspection ...................................................................................................................28 5.1.4 Friction wear liners .....................................................................................................28 5.1.5 Rotation stops ............................................................................................................29 5.1.6 Brake beam pocket ....................................................................................................29 5.1.7 Pedestal opening........................................................................................................29

5.1.7.1 Pedestal welding.........................................................................................30 5.1.7.2 Application of roof liner ...............................................................................30 5.1.7.3 Lateral frame repair.....................................................................................31

5.1.8 Wheelbase .................................................................................................................31 5.1.8.1 Pedestal opening ........................................................................................32

5.1.9 Sideframe variation ....................................................................................................32 5.1.10 Welding ......................................................................................................................33

5.1.10.1 Grade B material.........................................................................................33 5.1.10.2 Grade C material.........................................................................................33 5.1.10.3 Heat treatment ............................................................................................34

5.2 Specific requirements for ride control bBogie sideframes ......................................................36 5.2.1 Column openings .......................................................................................................36

5.2.1.1 Repair .........................................................................................................36 5.2.2 Gibs ............................................................................................................................37

5.2.2.1 Repair .........................................................................................................37 5.2.3 Rotation stops ............................................................................................................37

5.2.3.1 Repair .........................................................................................................37 5.2.4 Pedestal opening........................................................................................................37

5.2.4.1 Repair .........................................................................................................38 5.3 Specific requirements for National type bogie sideframes......................................................38

5.3.1 Friction shoe pockets .................................................................................................38 5.3.1.1 Repair .........................................................................................................38

5.3.2 Column opening .........................................................................................................39 5.3.2.1 Repair .........................................................................................................39

5.3.3 Gibs ............................................................................................................................40 5.3.3.1 Repair .........................................................................................................40

5.3.4 Pedestal opening........................................................................................................40 5.3.4.1 Repair .........................................................................................................41

5.4 Specific requirements for Barber type bogie sideframes ........................................................41 5.4.1 Column openings, gibs and rotation stops.................................................................41

5.4.1.1 Repair .........................................................................................................41 5.4.2 Pedestal .....................................................................................................................41

6 Brakegear .........................................................................................................................................44



6.1 Brake beams ...........................................................................................................................44 6.1.1 Preparation.................................................................................................................44 6.1.2 Inspection and reconditioning of parts .......................................................................44

6.1.2.1 Compression members...............................................................................44 6.1.2.2 Tension members .......................................................................................45 6.1.2.3 Brake heads................................................................................................45 6.1.2.4 Strut.............................................................................................................47 6.1.2.5 Brake beam end extensions .......................................................................47 6.1.2.6 Welding .......................................................................................................48

6.1.3 Assembly....................................................................................................................48 6.1.4 Marking.......................................................................................................................48

6.2 Connecting rods ......................................................................................................................48 6.2.1 Preparation.................................................................................................................48 6.2.2 Inspection and reconditioning of parts .......................................................................48

6.2.2.1 Damage ......................................................................................................48 6.2.2.2 Bushes and holes .......................................................................................49

6.3 Brake hangers.........................................................................................................................49 6.3.1 Terminology................................................................................................................49 6.3.2 Preparation.................................................................................................................50 6.3.3 Welding ......................................................................................................................50 6.3.4 Inspection and repair..................................................................................................50

6.3.4.1 Casting........................................................................................................50 6.3.4.2 Bushes ........................................................................................................50 6.3.4.3 Hanger foot .................................................................................................51

6.3.5 Modifications ..............................................................................................................51 6.4 Safety loops ............................................................................................................................51

6.4.1 Removal .....................................................................................................................51 6.4.2 Inspection ...................................................................................................................52 6.4.3 Installation ..................................................................................................................52

7 Springs .............................................................................................................................................53 7.1 Spring category .......................................................................................................................53 7.2 Free height ..............................................................................................................................53

7.2.1 Friction wedge spring data table ................................................................................53 8 Wheelsets.........................................................................................................................................54

8.1 Wheel turning ..........................................................................................................................54 8.2 Wheel replacement .................................................................................................................54

9 Adaptors...........................................................................................................................................54 10 Axleboxes.........................................................................................................................................54 11 Constant contact sidebearers........................................................................................................55

11.1 Stucki type...............................................................................................................................55 11.1.1 Identification of Stucki constant contact sidebearers .................................................55 11.1.2 Requalification of Stucki constant contact sidebearers..............................................56

11.1.2.1 Preparation .................................................................................................56 11.1.2.2 Blocks .........................................................................................................57

11.1.2.2.1 Separation.................................................................................57



11.1.2.2.2 Gouging ....................................................................................57 11.1.2.2.3 Top surface wear ......................................................................58 11.1.2.2.4 Over compressed block condition.............................................58 11.1.2.2.5 Free height measurement.........................................................59

11.1.2.3 Rollers.........................................................................................................60 11.1.2.4 Housings .....................................................................................................60

11.2 Miner type ...............................................................................................................................61 11.2.1 Identification of Miner constant contact sidebearers..................................................61 11.2.2 Requalification of Miner constant contact sidebearers ..............................................62

11.2.2.1 Preparation .................................................................................................62 11.2.2.2 Top caps .....................................................................................................62

11.2.2.2.1 Tecspak rubber pad..................................................................62 11.2.2.2.2 Free height................................................................................62

11.2.2.3 Housing repair and maintenance................................................................62 11.2.2.3.1 Standard housings ....................................................................63

12 Bogie assembly ...............................................................................................................................63 12.1 General....................................................................................................................................63 12.2 Wheelbase variation................................................................................................................63 12.3 Wheelsets ...............................................................................................................................63

12.3.1 Preparation.................................................................................................................64 12.3.2 Installation ..................................................................................................................64 12.3.3 Three piece bogies.....................................................................................................64 12.3.4 Inspection ...................................................................................................................64

12.4 Brakegear................................................................................................................................64 12.4.1 Identification of hand of bogies ..................................................................................65

12.4.1.1 The live brake lever.....................................................................................65 12.4.1.2 Hand of bogies............................................................................................65 12.4.1.3 Centre pick-up bogies .................................................................................65 12.4.1.4 Push and pull type brake configuration.......................................................65

12.5 Ride control friction shoes.......................................................................................................66 12.5.1 Standard metal type ...................................................................................................66 12.5.2 “Elastowedges” or wear eliminating wedge. ..............................................................67

13 Brake regulation on a freestanding bogie ....................................................................................67 13.1 General....................................................................................................................................67 13.2 Adjustment ..............................................................................................................................67

14 Identification ....................................................................................................................................68 14.1 Upon overhaul.........................................................................................................................68

15 Painting ............................................................................................................................................68 16 Reference documents.....................................................................................................................69

16.1 RailCorp standards .................................................................................................................69 16.2 RailCorp drawings...................................................................................................................69 16.3 Australian standards ...............................................................................................................70



1 Scope This standard details the overhaul requirements for three piece bogies.

2 Preparation

2.1 Disassembly Parts shall be cleaned and free of dirt, paint, rust and scale which will interfere with inspection, gauging and repair.

The bogie may not require complete dismantling depending on the rectification work to be carried out.

3 Bolsters

3.1 General overhaul requirements This section covers the general overhaul requirements for three piece bogie bolsters.

Refer to Section 3.2 for specific details of National type bogie bolsters.

Refer to Section 3.3 for specific details of Ride Control type bogie bolsters.

3.1.1 Repair of bolsters shall be limited to the following: Cleaning and inspection.

Restoration and replacement of centreplate bowl.

Restoration of friction wedge pockets.

Restoration of lateral gib guide faces.

Restoration of king pin hole

Repair, replacement or relocation of brake lever pivot lugs.

Application of sidebearer plates.

Modifications as listed.

Any bolster with any cracks outside the limits in section 3.1.11 shall be put aside and the Principal advised to inspect and subsequently approve repair or purchase of a new bolster.

Any repair areas that are not covered shall be brought to the attention of the Principal who will advise of the subsequent action.


3.1.2 Terminology

Figure 1

3.1.3 Cleaning The bolster casting shall be cleaned of dirt, paint, grease, rust and scale which will interfere with gauging, inspection and repair.

3.1.4 Casting inspection The bolster shall be visually inspected for cracks, fractures, sections broken out, worn surfaces, distortion, surface upset and service notches.

Particular attention shall be given to the centre web areas inside the bolster.

Suspect cracking shall be magnetic particle tested in accordance with ESR 0072 application code AS1171.

3.1.4.1 Repair Fractures shall be repaired in accordance with the requirements of section 3.1.11

3.1.5 Centre liner inspection Any protrusion of the centre liner above the casting surface shall be not more than 6 mm.

The internal diameter of the centre liner shall not be less than 310 for 12 inch centre castings or 360 mm for 14 inch centre castings.

Centre casting liner thickness shall not be less than 6 mm at any point.

Check for fractured welds.

Inspect the centre bearing liner for fractures. If the liner is fractured the liner shall be replaced.

Segmented liners shall be replaced and converted to cupped liners if the welds are cracked, or the liner is cracked.

Inspect the king pin hole for any signs of blockage, distortion, burring or scoring. King pins holes are considered worn if greater than 10 mm above the original size.

Check that the king pin hole is concentric to the centre bearing liner within 5 mm.

3.1.5.1 Repair Protruding liners shall be replaced.



Worn liners shall be replaced.

Fractured liners shall be replaced.

If the centre bearing liner weld beads contain fractures and there is still a full interference fit between the liner and the casting, the welds should be gouged out and repaired. If there is lack of interference with the bolster the liner shall be replaced.

3.1.5.2 Cupped liner installation repair The bolster centreplate bowl is to be machined out to provide an interference fit as shown in Figure 2.

Figure 2

Where the liner protrudes 3 mm or less a weld preparation of 3 mm shall be used around the circumference of the liner.

The bottom of the bowl shall be cleaned out to ensure correct seating. The minimum casting thickness, centre liner protrusion and sidebearer requirements all need to be considered in the machining of the centre casting.

Centre castings that cannot achieve these requirements shall be reclaimed in accordance with section 3.1.5.4.

A manganese cupped wearplate shall be fitted when required. Different base thicknesses are available and the liner shall be used that minimises repair costs.

When installing the centre liner into the bolster care shall be taken to prevent damage and bruising to the centre liner.

The wearplate shall be clamped solidly in contact with the bearing surfaces during the entire welding operation.

The centre liner shall be deemed seated when a 0.2 mm feeler gauge cannot be seated between the liner and the bolster base and the liner top surface is flat within 0.3 mm.

3.1.5.3 King pin hole repair Burring shall be removed.

King pin holes shall be reclaimed by welding up the wall of the king pin hole. Provided that the weld is neat and uniform in the hole, and the hole is 2 mm from the original size, it will not be necessary to redrill the hole, and an as welded finish will be acceptable. The hole shall be concentric with the centre liner within 5 mm.



3.1.5.4 Shallow casting repair When it is necessary to replace the centre liner it may be necessary to convert a shallow centre casting to bring the liner protrusion within the allowable limits. This shall be accomplished by fabricating a ring and welding to the centre casting as detailed in Figure 3.

Figure 3

3.1.6 Wear plates Inspect for damaged wear plates.

Inspect for broken welds.

3.1.6.1 Repair If the wear plates are cracked or broken, they shall be replaced.

If more than two welds are broken the plate shall be replaced. If one or two welds are broken they may be repaired provided the other criteria in this section are met. The broken welds shall be removed so that the correct weld preparation is provided before re-welding.

The plates shall be removed ensuring that the bolster casting and lugs are not damaged.

The surface shall be cleaned and gauged.

Any missing or excessively damaged locating lugs shall be replaced with 6 mm square bar welded on the three sides not in contact with the wear plate.

The new plates shall be clamped firmly in position during welding.

Down hand welding is recommended and preferred.

Where holes used in wear plates for welding weld around entire circumference of each hole first, then fill both recesses flush at wear plate hole edge, with remainder of recess weld flush to 1.5 mm maximum below face of plate.

Weld metal shall not protrude onto or above the friction plate sliding surface.

All wear liners are to be fitted in compliance with ESR 0414 and ESR 0312.

After welding and unclamping the wear plates shall have 85 % contact to the casting measured with a 0.2 mm feeler gauge.



3.1.7 Gibs

Figure 4

The dimensions on the gibs may be restored by building up the surface and grinding to a flat surface.

Dimensions D and E shall not differ by more than 10 mm.

The gibs shall be in line within 3 mm as shown in Figure 4.

Previous repairs may have the gibs machined and wear plates attached to restore the dimensions.

Where wearplates are already fitted the plates shall not be welded upon to restore the dimensions. If restoration is required the plates shall be removed and the gibs built up by welding.

The minimum gib thickness shall be 16mm and may require the gibs to be built up by welding on the outside of the gib.

3.1.8 Sidebearer height When the welding operation has been completed a check must be made of the height difference between the side bearer wearplate and the top wearing surface of the centre wearplate as shown in Figure 5.

3.1.8.1 Repair This difference of 18 1mm shall be maintained by either renewing side bearer wearplates or adding different thickness plates.

Figure 5

3.1.9 Fulcrum brackets The brake lever pivot lugs shall be measured and if any surface is worn more than 3, except by design, then they shall be removed and new lugs welded onto the bolster.




The case hardened bushes shall be measured and if the inside of the bush has worn more than 0.5mm then the bush shall be replaced.

Where fulcrum brackets are in the wrong position they shall be relocated to the original position.

3.1.10 Constant contact sidebearers Constant contact sidebearers should be requalified in accordance with Section 11.

3.1.11 Welding Weld procedures shall be in accordance with AS 1554

All cast surfaces showing more than 1.5 mm wear at any one point shall be puddle welded and dressed by hand grinding unless specified otherwise in this specification.

All repaired areas shall be flat with minimum 50 % contact and 0.5 mm maximum allowable surface variation.

All mating surfaces to be parallel with maximum deviation of 1 mm per 150 mm of length unless otherwise specified.

3.1.11.1 Grade B material Building up of worn surfaces in Grade B material is permitted only in cross-hatched areas provided the wear is 5 mm, or less.

Repair of cracks in Grade B material is permitted only in cross-hatched areas provided the cracks are not transverse to a load carrying member and are 25mm, or less, in length. The bolster rim may be built up if the thickness at the base is 16 mm, or greater, as measured at the level of the horizontal casting surface. If the rim thickness is less than 16 mm, the rim must be replaced by a method which will restore the original strength and contour. Heat treatment is not required.

The bolster gib may be built up if wear is 13 mm, or less. Heat treatment not required.

The side bearing attachment if originally secured by welding does not require heat treatment.

Repair of cracks in Grade B material is permitted in the lined areas provided cracks are not transverse to a load carrying member and are 25 mm, or less, in length. Stress relief per Figure 7 is required.

3.1.11.2 Grade C material Building up of worn surfaces in Grade C material is permitted only in the crosshatched areas provided the wear is 5mm, or less. The bolster rim may be built up if the thickness at the base is 16 mm, or greater, as measured at the level of the horizontal casting surface. If the rim thickness is less than 16 mm, the rim must be replaced by a method which will restore the original strength and contour. The bolster gib may be built up if wear is 13 mm, or less. Preheat is required. Post Heat Treatment is not required.

The side bearing attachment when rewelded requires a minimum of 150°C local preheat.

Repair of cracks in Grade C material is permitted in the cross-hatched or lined areas provided the cracks are not transverse to a load carrying member and are 25 mm, or less, in length. Preheat is required. Stress relief per Figure 7 is required.


No welding is permitted except in the cross-hatched or lined area shown in Figure 6.

Figure 6

3.1.11.3 Heat treatment Heat treating must not be performed after application of any wear plate, liner, or side bearing cage. Wear plates, liners or side bearing cages must be removed before heat treatment.



Figure 7



3.2 National type

3.2.1 General Bolsters shall be overhauled in conjunction with the requirements of Section 3.1.

Figure 8

3.2.2 Gibs Gib dimensions A and C shall be measured. Limits are shown in Table 1.

3.2.2.1 Repair Bolster gibs shall be repaired to the dimensions shown in Table 1.

Bolster *Dimension A mm

*Dimension B mm

*Dimension C mm

Dimension D mm

AC8011 1850 - 1858 438 - 443 208 - 213 N/A

B1213 1901 - 1909 341 - 346 151 - 156 N/A

B992 1850 - 1858 438 - 443 208 - 213 N/A

BX3270 1850 - 1858 438 - 443 208 - 213 N/A

BX3797 1850 - 1858 438 - 443 208 - 213 N/A

CS5414 Super C1

1736 - 1744 438 - 443 246 - 251 N/A

CS5838 Super C1 Wedgelock

1901 - 1909 341 - 346 151 - 156 390 - 395

CS6668 Super C1 Wedgelock

1901 - 1909 341 - 346 151 - 156 390 - 395

X2182 1850 - 1858 438 - 443 208 - 213 N/A

Table 1

*All dimensions with liners if fitted



Figure 9 Super C1 Wedgelock bolster

3.2.3 Bolster wear plates The dimension over the bolster wear plates, dimension B, shall be measured. Limits in Table 1.

3.2.3.1 Repair Worn bolster wear plates shall be replaced to comply with the dimensions shown in Table 1.

3.2.4 Rotation lands The dimension over the rotation lands on bolsters, dimension D, shall be measured. Limits in Table 1.

3.2.4.1 Repair Worn lands shall be repaired to the dimensions shown in Table 1.

3.3 Ride control type

3.3.1 General Bolsters shall be overhauled in conjunction with the requirements of section 3.1.

In addition the wedge pocket needs to be inspected and overhauled as shown in Figure 10.



Figure 10 Bolster wedge pockets

3.3.2 Wedge pockets Wedge pockets when manufactured and repaired may have the sloped surface deviating from 37.5 degrees due to manufacturing tolerances on the slope surface. The allowable deviation is +/- 1.5 degrees.

Taking into account the angular tolerance, wear will be considered to be a 4mm total gap or a 2mm abrupt step to the 37.5 degree surface when one point is contacting on the surface.

If wear plates are worn more than 3 mm they shall be replaced.

The recommended method of determining the wear of these points is with a gauge as shown in Figure 11.

Figure 11

3.3.2.1 Repair If worn outside these limits the surfaces shall be restored to the original contour shown in Figure 12.

For bolsters originally fitted with wear plates these should be removed, the casting rectified if necessary, and new wear plates fitted.



For bolsters not originally fitted with wear plates the bolsters may be modified to accept wear plates or the surfaces can be reclaimed by welding of the surfaces and grinding to the required profile. If one pocket is modified all pockets shall have the modification carried out.

Figure 12

The new dimensions for the wedge pocket area are shown in Figure 13 and Table 2.

Wedge pockets shall be built up equally and centrally to the bolster.

The distance between the control points across the wedge pocket shall be measured and shall be within the limits shown in Figure 12. The use of a gauge as shown in Figure 13 is recommended. A no go shim can be used to gauge the minimum dimension.

Figure 13

Note: All welds dags and spatter shall be removed from the wedge pocket. A new friction shoe must slide freely in and out of the repaired pocket.

The side walls of the wedge pocket shall be repaired by welding if worn more than 3 mm.

3.3.2.2 Ride control pocket Check that the ride control wedge pockets are flat across the shoe slope.

Figure 14



3.3.2.3 Super service ride control pocket Super service ride control bolsters incorporate a 3 degree taper on the slope surfaces. When slope surfaces are being repaired this taper must be restored to this original contour.

Figure 15

3.3.3 Gibs Bolster gibs shall be repaired when the measurements shown in Figure 16 and Table 1 are exceeded.

Figure 16

3.3.3.1 Repair As detailed in section 5 to limits shown in Table 2




Bolster Dimension A

mm Dimension B mm

Dimension C mm

Dimension X mm

Y mm

B1448 1733 - 1739 497 - 494 270 - 273 318.5 - 323 105

B466 1864 - 1870 510 - 513 189 - 193.5 338.5 - 343 111

B488 1826 - 1832 408 - 411 189 - 193.5 236.5 - 241* 111

B621 1864 - 1870 510 - 513 189 - 193.5 338.5 - 343 111

B665 1826 - 1832 408 - 411 198.5 - 203 222

236.5 - 241*

111

B696 1864 - 1870 510 - 513 189 - 193.5 338.5 -343 111

B703 1864- 1870 408 - 411 198.5 - 203 222

236.5 - 241*

111

B819 1826 - 1832 408 - 411 198.5 - 203 222

236.5 - 241*

111

B848 1864 - 1870 408 - 411 198.5 - 203 222

236.5 - 241*

111

B914 1826 - 1832 408 - 411 198.5 - 203 236.5 - 241* 111

B735 1864 - 1870 386 - 389 198.5 - 203 224.5 - 229* 120

Table 2

* With wear plates fitted

4 Friction wedges Friction wedges shall be replaced with new items.

4.1 Ride control friction wedges When requested, Ride Control friction wedges shall be inspected as follows. Under no circumstances shall friction wedges be reconditioned

4.1.1 Winged and plain type wedges. – Ride control bogies The friction wedges shall be inspected and the wedge shall be scrapped if the wear limit notch is less than 3 mm or either the friction or angle face wear limit has been exceeded as shown in Figure 17.

A Go/No Go gauge is recommended.


Figure 17

4.1.2 Friction wedge (in frame type) – National bogies The friction wedges shall be inspected and the wedge shall be scrapped if the wear limit notch is less than 5 mm or either the friction or angle face wear limit has been exceeded as shown Figure 18

A Go/No Go gauge is recommended.

Figure 18

4.2 Barber friction wedges When requested, Barber type friction wedges shall be inspected in accordance with Barber requirements as detailed in Figures 19 to 24.



Figure 19



Figure 20



Figure 21



Figure 22



Figure 23



Figure 24




5 Overhaul of three piece sideframes

5.1 General overhaul requirements This section covers the general overhaul requirements for three piece bogie sideframes.

Refer to section 5.2 for specific details of Ride Control bogie sideframes.

Refer to section 5.3 for specific details of Barber bogie sideframes

5.1.1 Repair of sideframes shall be limited to the following Application of side frame friction plate

Restoration of rotation stop lugs

Side frame pedestal roof repair

Side frame pedestal thrust face repair

Brake beam pocket repair

Any side frame with any cracks outside the limits in section 5.1.10 shall be put aside and the Principal advised to inspect and subsequently approve repair or purchase of a new sideframe

Any repair areas that are not covered shall be brought to the attention of the Principal who will advise of the subsequent action.

5.1.2 Cleaning The sideframe casting shall be cleaned of dirt, paint, grease, rust and scale which will interfere with gauging, inspection and repair.

5.1.3 Inspection The sideframe shall be visually inspected for cracks, fractures, sections broken out, worn surfaces, distortion, surface upset and service notches.

Suspect cracking shall be magnetic particle tested in accordance with ESR 0300 and application code AS1171.

5.1.4 Friction wear liners If the friction plates are cracked or broken, they shall be replaced.

If more than two welds are broken the plate shall be replaced. If one or two welds are broken they may be repaired provided the other criteria in this section are met. The broken welds shall be removed so that the correct weld preparation is provided before re-welding.

The plates shall be removed ensuring that the sideframe casting and lugs are not damaged.

The surface shall be cleaned and gauged.

Any missing or excessively damaged locating lugs shall be replaced with 6 mm square bar welded on the three sides not in contact with the wear plate.


The new plates shall be clamped firmly in position during welding.

Down hand welding is recommended and preferred.

Weld metal shall not protrude onto or above the friction plate sliding surface.

All wear liners are to be fitted in compliance with ESR 0322 and ESR 0414.

After welding and unclamping the wear plates shall have 85% contact to the casting measured with a 0.2 mm feeler gauge.

Any liners that are secured by fasteners shall have the fasteners installed in accordance with the recommendation of the fastener supplier. Fasteners shall not extend above the surface of the plate.

5.1.5 Rotation stops Side frame rotation stops that are worn outside the limits shall be built up by welding.

It is important that the material replaced restores this area to the original contour. i.e If only one side of the frame has worn then all weld material must be placed on this side only.

5.1.6 Brake beam pocket Sideframes have two arrangements for brake beam pockets. Some wear plates are welded to the opening and others are sprung into the cast pocket.

Welded wear plates shall be welded to the sideframe as per the original design. When wear plate metal thickness is less than 3 mm the wear plates shall be replaced.

Brake beam pocket insert wear plates shall be sprung into the cast pocket of the sideframe and located correctly by dimples pressed through the plate. When wear-plate metal thickness is 3 mm or less the pocket wear plate is to be replaced.

5.1.7 Pedestal opening

Figure 25



The sideframe roof of the pedestal opening shall be repaired if concavity exceeds 1.6 mm over 56 mm. The use of the gauge shown in Figure 25 is recommended.

The sideframe roof of the pedestal opening shall be repaired when wear in the vertical direction is 4.5 mm or more as determined from the reliefs at each end of the roof pad. These reliefs represent the wear limit allowed on the pad.

For narrow pedestals the frame opening shall be measured over the longitudinal stops dimension K shown in Figure 29.

For wide pedestals the frame width shall be measured across the sideframe dimension J, or for narrow pedestals J*, as shown in Figure 29.

Pedestals openings shall be measured perpendicular to the bottom of the outer pedestal as shown in Figure 29. The measurement should not exceed the dimension L.

If any pedestal fails to meet any of the above criteria the pedestal shall be repaired as specified below.

Figure 26

5.1.7.1 Pedestal welding The pedestal area may be repaired by welding and grinding to the original contour of the pedestal roof.

Distortion resulting from the welding operation shall be controlled and minimised. A jack placed between the pedestals to prevent excessive distortion is recommended.

Special care must be exercised that no undercutting occurs at the ends of the weld runs, these being properly terminated and swept into the existing side frame material by grinding

Alternatively if the wear is excessive a roof liner may be fitted.

5.1.7.2 Application of roof liner Grind the entire pedestal roof flat. Squareness must be within 1.6 mm checked as per Figure 31.

Weld a roof liner as shown in Figure 29 centrally located in the frame roof using plug welds in all holes. The thickness of the liner shall be 3 mm minimum to 6 mm maximum.



The weld shall be ground flush with the plate after application.

Figure 27

Figure 28

After application of the roof liner check dimension from roof liner to frame key slot as indicated in Figure 27 restored to the dimension H or H+.

5.1.7.3 Lateral frame repair The pedestal area shall be repaired by welding and grinding to the original contour of the pedestal frame as indicated in Figure 29 to dimension J.

5.1.8 Wheelbase At the completion of rectification work on the bogie the sideframe wheelbase shall be measured and the variation from the nominal dimension shown on the sideframe as detailed in Section 5.1.9.



Figure 29

5.1.8.1 Pedestal opening If the pedestal opening is outside limits specified it is an indication that the sideframe has been bent in service. Sideframes with bent pedestals shall be repaired in consultation with the Principal.

Proprietary pedestal roof liners approved by the AAR may be used when applied in accordance to the manufacturer's drawings.

5.1.9 Sideframe variation The sideframe wheel base dimension varies because of manufacturing tolerances when the sideframe are cast or repaired. Sideframes need to be identified for difference in variation so that they can be paired within limits. Excessive sideframe wheel base variation can lead to short life and poor bogie performance.

Following overhaul the wheelbase should conform to the requirements detailed below and have the number of buttons altered to reflect the true wheelbase of the sideframe.

Sideframe variation on three piece bogie sideframes is identified by the number of cast buttons remaining on the sideframe above the left hand pedestal as shown in Figure 30.

When manufactured, the sideframe is normally cast with 6 buttons and these are removed to indicate the measured sideframe variation to the nominal dimension as shown in Table 3.

Number of buttons remaining Tolerance in mm

1 - 3 to - 5

2 - 1 to - 3

3 -1 to + 1

4 +1 to + 3

5 +3 to + 5

Table 3



Figure 30

5.1.10 Welding Weld procedures shall be in accordance with AS 1554.

All cast surfaces showing more than 1.5 mm wear at any one point shall be puddle welded and dressed by hand grinding.

All repaired areas shall be flat minimum 50 % contact with 0.5 mm maximum allowable surface variation.

All mating surfaces to be parallel with maximum deviation of 1 mm per 100 mm of length unless otherwise specified.

Repair is restricted to the lined and cross-hatched areas shown in Figure 31 for side frames.

5.1.10.1 Grade B material Building up of worn surfaces in Grade B material is permitted only in the cross-hatched area provided the wear is 5mm, or less, or in the case of column guides 6 mm, or less. Specific areas are addressed elsewhere in this specification or in designers' maintenance manuals and provide wear limits which are to be followed.

Repair of cracks in Grade B material is permitted only in the cross-hatched areas provided the cracks are not transverse to a load carrying member and are 25 mm, or less, in length. Heat treatment is not required.

Repair of cracks in Grade B material is permitted in the lined areas provided the cracks are not transverse to a load carrying member and are 25 mm, or less, in length. Stress relief as per Figure 32 is required.

5.1.10.2 Grade C material Repair of cracks in Grade C material is permitted in the cross-hatched or lined areas provided the cracks are not transverse to a load carrying member and are 25 mm, or less, in length. Preheat is required. Stress relief as per Figure 32 is requires.

Building up of worn surfaces in Grade C material is permitted only in the crosshatched areas provided the wear is 4.5 mm, or less, or in the case of the column guides 6 mm, or less. Specific areas are addressed elsewhere in this standard and provide wear limits which are to be followed. Preheat is required. Post Heat Treatment is not required.

No welding is permitted except in the cross-hatched or lined area as shown in Figure 31.



5.1.10.3 Heat treatment Heat treating must not be performed after application of any wear plate or liner. Liners or wear plates must be removed before heat treatment.

Figure 31



Figure 32



5.2 Specific requirements for ride control bBogie sideframes

5.2.1 Column openings Measure the column opening dimension C shown in Figure 33 and check against the allowable dimensions shown in Table 4.

Figure 33

5.2.1.1 Repair If worn outside these limits the column wear plates shall be replaced to conform to the dimensions shown in Table 4

Figure 34

If a welded only design, the wear plates shall be attached by 4, 50 mm (minimum) welds as shown in Figure 34



5.2.2 Gibs

Figure 35

Measure the gib dimension E shown in Figure 35 and compare to the dimensions shown in Table 4.

5.2.2.1 Repair If worn outside these limits the frame shall be built up by welding to conform to the limits shown in Table 4.

5.2.3 Rotation stops Measure the dimensions over the side frame rotation stops, dimension G shown in Figure 35 and compare to the dimensions shown in Table 4.

5.2.3.1 Repair If worn outside these limits the frame shall be built up by welding to conform to the limits shown in Table 4.

Bolster Type C Column opening mm E Gibs mm G rotation stops mm

B24 349 - 352 176 - 179 N/A

B448 451 - 454 176 - 179 516 - 519

B487 349 - 352 176 - 179 414 - 418

B570 349 - 352 176 - 179 414 - 418

B575 349 - 352 176 - 179 516 - 519

B620 451 - 454 176 - 179 516 - 519

B702 349 - 352 176 - 179 414 - 418

B818 349 - 352 176 - 179 414 - 418

B849 349 - 352 176 - 179 414 - 418

B1447 443 - 448 248 - 251 500 - 505

Table 4

5.2.4 Pedestal opening Measure the pedestal opening as detailed in Section 5.1.7. Repair when outside the limits shown in Table 5.




5.2.4.1 Repair As detailed in Section 5.1 to limits shown in Table 5.

Pedestal H mm H+ mm J or J* mm K mm L mm

B24 226 - 232 63.5 - 68.3 158 - 161 218 - 221

B448 273 - 279 145 - 148 N/A 248 - 251

B487 253.- 259 145 - 148 N/A 248 - 251

B570 229 - 235 63.5 - 68.3 158 - 161 213 - 216

B575 273 - 279 145 - 148 N/A 248 - 251

B620 273 - 279 145 - 148 N/A 248 - 251

B702 248 - 254 145 - 148 248 - 251

B818 213 - 219 63.5 - 68.3 158 - 161 213 - 216

B849 213 - 219 145 - 148 158 - 161 213 - 216

B1447 92 - 96.5 234 295

Table 5

5.3 Specific requirements for National type bogie sideframes Sideframes to be overhauled in conjunction with section 5.1

5.3.1 Friction shoe pockets At overhaul periods shoe pocket wear surfaces shall be restored to 37 1/2 degrees such that the distance from casting hole centre to wear surface is 43 +2 -0 mm.

Ensure that the minimum wall thickness is greater than 9.5 mm.

5.3.1.1 Repair If no wear liners are fitted then the worn surface of the pocket shall be restored flat by pad welding and grinding.

If wear liners are fitted they shall be replaced.


43- 0+2

37.5

Figure 36

5.3.2 Column opening Measure the column opening dimension C shown in Figure 37 and compare with the dimensions given in Table 6.

5.3.2.1 Repair If worn outside these limits the frame shall be built up by welding to the limits shown in Table 6.

Figure 37



Sideframe E Gibs mm C Column opening mm

CS5409 223 - 228 448 - 453

*CS5837 235 - 240

135 - 140#

398 - 403

X2338 188 - 193 441 - 446

X2453 188 - 193 441 - 446

X2953 188 - 193 441 - 446

X3796 188 - 193 441 - 446

*Super wedgelock bogie

Table 6

5.3.3 Gibs Measure the gib dimension E shown in Figure 38 and compare to the dimensions shown in Table 6.

As the side frame can become bent in this area due to the reduction in wall thickness by wear, check that the friction wedge will fit into the sideframe pocket with a clearance of 3mm to 5 mm.

Figure 38

5.3.3.1 Repair As detailed in Section 5.1 to the limits shown in Table 6.

Restore friction wedge side clearance by welding and/or grinding.

5.3.4 Pedestal opening Measure the pedestal opening as detailed in Section 5.1. Repair when outside the limits shown in Table 7.




5.3.4.1 Repair As detailed in Section 5.1 to limits shown in Table 7

Pedestal H mm H+ mm J K L

CS5409 270 - 276 290 - 296 151 - 154 N/A 270 - 273

CS5837 248 - 254 268 - 274 145 - 148 N/A 248 - 251

X2338 273 - 279 145 - 148 N/A 248 - 251

X2453 273 - 279 145 - 148 N/A 248 - 251

X2953 303 - 309 151 - 154 N/A 270 - 273

X3796 273 - 279 145 - 148 N/A 248 - 251

Table 7

5.4 Specific requirements for Barber type bogie sideframes

5.4.1 Column openings, gibs and rotation stops Measure openings to the dimensions shown in Figures 39 or 40.

5.4.1.1 Repair If worn outside these limits the column opening wear plates and other areas are to be built up as shown in Figures 39 or 40.

5.4.2 Pedestal Pedestal openings shall be measured and reclaimed in accordance with AAR standard M214.


Figure 39



Figure 40



6 Brakegear

6.1 Brake beams This section defines the requirements for second-hand brake beams which are being inspected and/or reconditioned for fitting to bogies.

Brake beams may be of several designs:- fully welded, cast one piece or of unit construction with removable struts and brake-heads.

Brake beams shall be inspected to this specification whenever they are removed from the bogie.

Where original limits or design are noted in this specification reference shall be made to the applicable brake beam drawing.

Figure 41 – Brake beam

6.1.1 Preparation Parts shall be cleaned and free of dirt, paint, rust and scale which will interfere with inspection, gauging and repair.

Brake beams undergoing reconditioning need not be completely dismantled.

Loose rivets shall be replaced with rivets or approved two piece rivets of proper size, machine driven, provided the fastener does not extend outside the clearance outline of brake beams.

Standard bushes complying with drawing 304-697 (current issue) shall be used.

6.1.2 Inspection and reconditioning of parts

6.1.2.1 Compression members Compression members shall be scrapped when indentations or bends are greater than 20 mm when compared to a 300 mm straight edge placed against the compression members and centred as closely as possible over the indentation or bend.

Compression members shall be scrapped when discontinuities such as gouges, wear areas, etc. are deeper than 12 mm or more than 75% of the original material thickness.

Compression members suitable for repair shall be straightened to within 3 mm of the original surface when checked with a 300 mm straight edge placed against the compression member and centred as closely as possible over the bend or indentation.




Compression members may be repaired by blending any gouges, wear areas, etc. which are less than 4 mm deep. Total blend length should be 4 times the depth; no sharp corners or fillets are allowed.

Compression members may be repaired by welding to fill any gouges or wear areas, etc., which are 4 mm to 12 mm deep or 75% of the original material thickness, so that the surface is within 1 mm of original. Total blend length should be 4 times the depth; no sharp corners or fillets are allowed.

Compression members fitted with pivoting brake heads shall be inspected for wear on the shaft and lateral face of the brake beam end pivot. If worn more than 0.5 mm the pivot shall be repaired by welding and grinding to the original contour, or replaced. Where applicable, threads on shafts shall be inspected for damage and repaired if necessary.

6.1.2.2 Tension members Repair welding is prohibited on all tension members except by design in the brake head or strut area.

Round tension members shall be scrapped when diameter is reduced by wear or corrosion by more than 4 mm or when bends or indentations exceed 12 mm when checked with a 300 mm straight edge placed against the tension member and centred as closely as possible over the bend or indentation, except by design.

Solid rectangular bar tension members shall be scrapped when the long dimension is reduced by more than 4 mm or the short dimension is reduced by more than 4 mm or when bends or indentations exceed 12 mm when checked with a 300 mm straight edge placed against the tension member and centred as closely as possible over the bend or indentation, except by design.

Bends shall be straightened to within 3 mm of the original surface when checked with a 300 mm straight edge placed against the tension member and centred as closely over the bend or indentation.

Tension members may be repaired by blending any gouges, wear areas, etc. which are less than 4 mm deep. Total blend length should be 4 times the depth; no sharp corners or fillets are allowed.

Where fastener holes are worn more than 1.5 mm larger than the fastener diameter the holes shall be repaired.

6.1.2.3 Brake heads Brake heads without defects listed in this section or which can be repaired in situ, need not be removed.

Brake-heads where the thickness of any of the four brake shoe contact areas or material surrounding the lug pocket area is worn to 1.5 mm or less shall be scrapped.

Loose brake head fasteners shall be replaced with rivets, bolts or two piece rivets of proper size, machine driven.

Brake heads shall be repaired by welding to restore worn areas and ground to a 450 mm radius contour except that the gap at any two pads may be 1 mm, or there may be 3 point contact with a 2 mm gap at one pad. The deviation of these measurements across the brake head shall not vary by more than 0.5 mm.

Repair at the toes of brake-heads is not required unless wear extends more than 12 mm from the end as shown in Figure 41.


The brake shoe lug pocket shall not be more than 1.5 mm as shown in Figure 42.

The brake head toe pocket shall not be more than 1.5 mm as shown in Figure 42.

Figure 42

Figure 43

The minimum clearance from brake head lug to casting support shall be 0.5 mm as shown in Figure 43.

Brake beams supported by brake hangers shall have the hanger slot openings in the brake head checked. The openings shall not be greater than 28 mm as shown in Figure 43.



Pivoting brake heads shall have the pivot holes checked for wear. If worn by more than 0.5 mm the holes shall be bushed or the bushes replaced.

Figure 44 Figure 45

The lateral face, as shown in Figure 44, on pivoting brake heads shall be checked for wear. If the wear is greater than 0.5 mm the lateral face of the head shall be repaired by welding and grinding to the original contour.

Any worn or out of tolerance brake head can be replaced by a new or second-hand brake head meeting the requirements as described above.

Any brake heads requiring repair shall be repaired to new limits except for the head contour which may comply with the 4th paragraph above.

6.1.2.4 Strut Struts without defects listed in this section or which can be repaired in situ, need not be removed.

Struts made from ductile or malleable cast iron shall not be repaired or straightened using welding, brazing or heating except that worn pin holes may be restored to nominal dimension by oxyacetylene bronze welding process.

Struts not covered in the paragraph above shall be repaired or replaced when they are cracked, bent or twisted.

Strut pin holes or bushes shall be repaired when they are worn or elongated 0.5 mm or more. Bushes shall be to standard design but if any protrusion is evident this shall be to the outside of the strut.

The lever slot shall be repaired or strut replaced when it is worn 3 mm or more.

6.1.2.5 Brake beam end extensions Brake beam end extensions must be repaired or replaced when they are worn more than 3 mm from the original thickness.

Extension wear plates shall be replaced when they are less than 3 mm thick.




Brake beam end extensions must be replaced when they are cracked, broken, bent or twisted.

Brake beam end extensions may be repaired by building up with weld and grinding the contour to the original dimensions.

6.1.2.6 Welding Inspect all welds for signs of cracking. Repair any cracks where necessary. Welding shall not be across any tension member.

All weld repairs shall comply with AS 1554 and be to the original design.

6.1.3 Assembly The struts shall be located at the centre of the brake beam assembly, +/- 6 mm, and securely fastened to the compression member.

Brake heads applied to individual beams must have matched and proper rejection lugs, to prevent the use of incorrect brake shoes, and corresponding hanger openings if on a hanger beam.

Dimensions of brake head centres must be within the original tolerances.

The distance from centre of pin hole to centre of face of brake head must be within the original tolerances.

The deviation (rocking) of the brake head toes measured from a flat surface shall not exceed 3 mm.

6.1.4 Marking Brake beams reconditioned in accordance with this specification shall be identified by a dash of white paint between the lever slot and compression member and by marking with steel stamp the letter "R" 10 mm high followed by a two digit repair facility identification code.

6.2 Connecting rods This section details the inspection and repair requirements for bogie brake connecting rods, brake levers, fulcrums and fulcrum brackets.

6.2.1 Preparation Parts shall be cleaned free of dirt, paint rust and scale which will interfere with inspection gauging and repair.

All replacement bushes shall conform to drawing 304-697.

Bush lengths shall be the thickness of the lever minus 1 mm.

6.2.2 Inspection and reconditioning of parts

6.2.2.1 Damage Brake levers and connecting rods shall be visually inspected for fractures and fractured welds. Any items found with defects shall be scrapped.



Brake levers and connecting rods shall be straightened to within 3 mm of the original surface when checked with a 300 mm straight edge centred as closely as possible over the indentation or bend, except by design.

Brake levers and connecting rods shall be scrapped when bends are greater than 20 mm when compared to a 300 mm straight edge centred as closely as possible over the indentation or bend, except by design.

Check levers and connecting rods for signs of wear and gouging.

The maximum wear on the side of any connecting point shall be 3 mm. Brake levers and connecting rods may be repaired by welding to fill any wear areas and grinding to the original surface contour.

Brake levers and connecting rods may be repaired by blending any gouges, wear areas (except connecting points), etc. which are less than 6 mm deep. Total blend length should be 4 times the depth; no sharp corners or fillets are allowed.

Brake levers and connecting rods may be repaired by welding any gouges, wear areas (except connecting points), etc., which are 6 mm to 12 mm deep so that the surface is within a minimum of 1 mm of original.

Where fitted loose rivets shall be replaced with rivets or approved two piece rivets of proper size, machine driven.

6.2.2.2 Bushes and holes Renew bushes if worn 0.5 mm diameter at any point.

Inspect all bushes to see if they are loose. Replace all loose bushes.

Unbushed holes if worn shall be fitted with a bush. The positioning of holes shall be as per the original drawing.

When fitting bushes the hole sizes shall be as shown on 304-697.

All bushes shall be pressed into position and those bushes less than 20 mm long shall be notched in three places on both external edges after case hardening and the bush secured by tack welding.

6.3 Brake hangers This section details the requirements for the overhaul of freight bogie brake hangers as shown on SRA drawing 301-755.

6.3.1 Terminology Hanger terms are shown in Figure 46.


Figure 46

6.3.2 Preparation Prior to inspection hangers shall be cleaned to ensure that all deposits of grease and corrosion are removed that will interfere with inspection and repair.

6.3.3 Welding Welding procedures shall conform to AS 1554.

All cast wear surfaces showing more than 1.5 mm wear at any one point shall be puddle welded to give a minimum 50% flat surface contact with 0.5 mm maximum allowable surface variation.

6.3.4 Inspection and repair All repairs shall be to the dimensions shown on the original drawing unless specified otherwise.

6.3.4.1 Casting Brake hangers shall be inspected for fractures. Fractured brake hangers shall be scrapped.

Inspect the outside and sides of the hanger eyes for wear. Any casting eye worn greater than 0.5 mm shall be repaired by welding.

Inspect the hanger for any distortion, twisting or misalignment of the hanger eyes. Any hanger that can not be repaired shall be scrapped.

6.3.4.2 Bushes Inspect bushes for wear. If a bush has worn more than 0.5 mm on diameter, a new bush shall be fitted.

New bushes shall conform to drawing 304-697.



6.3.4.3 Hanger foot Inspect the hanger foot for wear. The minimum allowable dimension shall be 28 mm as shown in Figure 47.

If worn less than 28 mm restore the hanger foot to the original dimensions.

Any weld repair on the hanger foot shall be ground to the original profile.

6.3.5 Modifications Hangers made to the original drawing shall be modified by grinding to move the radius of the top of the hanger down by 6 mm as shown in Figure 47.

Figure 47

6.4 Safety loops

6.4.1 Removal If safety loops do not interfere with the inspection of the safety loop or the component they are attached too, they need not be removed. In such cases the bolts shall be tight and secure.

If necessary, bottom safety loops may be cut to facilitate removal as shown in Figure 48



Figure 48

6.4.2 Inspection Safety loops shall be scrapped if worn more than 25 % of the original material thickness.

Safety loops should be straightened or replaced if bent more than 10 mm from the original contour, as shown in Figure 49.

Any welding shall be crack free and secure. Scrap any that are defective.

Bolt holes should not be excessively worn. Scrap any that are defective.

Figure 49

6.4.3 Installation Bottom safety loops that have been cut to remove the safety loop may be installed by welding a bar across the opening as shown in Figure 50.



Figure 50

7 Springs Springs shall be inspected and requalified in accordance with ESR 0043.

7.1 Spring category The classification of the load bearing springs shall be class B. (Refer to ESR 0043)

The classification of the friction wedge springs shall be class C. (Refer to ESR 0043)

7.2 Free height The allowable free height for load bearing springs shall be as listed in ESR 0043.

The allowable free height for friction wedge springs shall be as below.

Equivalent spring types are listed in ESR 0043.

7.2.1 Friction wedge spring data table This section details the free height limits for the requalification of freight friction wedge springs.




Spring Min free height mm Colour

303-194 240 Black

303-195 164 Black

303-196 136 Black

303-197 231 Black

303-198 185 Black

303-199 173 Black

RC274 177 Black

TC300 177 Black

Table 8

8 Wheelsets

8.1 Wheel turning Wheelsets shall be reprofiled in accordance with ESR 0331.

8.2 Wheel replacement Wheelsets shall be overhauled in accordance with ESR 0331.

9 Adaptors Adaptors shall be inspected in accordance with ESR 0032.

10 Axleboxes Axleboxes shall be inspected in accordance with ESR 0032.


11 Constant contact sidebearers

11.1 Stucki type

11.1.1 Identification of Stucki constant contact sidebearers

Figure 51 Model 656CR Figure 52 Model 688BR

Figure 53 Model 690RL Figure 54 Model 656CRH

Figure 55 Model 675RL Figure 56 Model 685RM



Figure 57 Model ISB3 Figure 58 Model ISB8

Figure 59 Model ISB10 Figure 60 Model ISB12


11.1.2 Requalification of Stucki constant contact sidebearers

Figure 61 Model 656C 4”x3” roller 656C Cage

Figure 62 Model 688B 4”x3” roller 688B Cage

11.1.2.1 Preparation All Stucki constant contact sidebearers should be dissassembled for inspection of the components. For identification of components see section 11.1.1.

Housings may be left attached to bolsters.

Housing fasteners shall be correctly installed and tightly secured and replaced if required. Loose Huck bolts shall be removed and replaced


11.1.2.2 Blocks Resilient blocks should be inspected for the following conditions.

11.1.2.2.1 Separation Blocks should be inspected for separation at the Bi-layer interface.

Superficial separation as shown in Figure 62 is a typical condition found after several months in normal service. Superficial separation is if the interface can be manually opened to reveal 50% or more of the interface surface. Blocks showing superficial separation should not be replaced. Such superficial separation does not lead to partial or total separation and has no effect on block performance or normal life.

Blocks with partial separation (Figure 63) or total separation (Figure 64) should be replaced.

Figure 63 Figure 64 Figure 65

Superficial separation Partial separation Total separation

11.1.2.2.2 Gouging Blocks should be inspected for gouging by cage ends.

Moderate gouging as shown in Figure 66 is acceptable.

Severe gouging as shown in Figure 67 is not acceptable and the block should be replaced.

Gouging may be caused by missing end closures. Replace any missing end closures.

Figure 66 Figure 67

Moderate gouging OK Severe gouging



11.1.2.2.3 Top surface wear Blocks should be inspected for top surface wear.

Figure 68 Figure 69 Figure 70

Rough uneven wear Moderate fastener gouging Severe fastener gouging

Blocks with rough uneven wear as shown in Figure 68 should be replaced if rough or pitted. This damage is caused of blocks applied without break in lubricant or with unusually rough wear plate.

If rough uneven wear is found the wear plates on wagon should be inspected.

Ensure blocks are applied with break in lubrication.

Blocks with moderate fastener gouging as shown in Figure 69 should not be replaced if the wear is not over 3 mm deep. This damage is caused by loose or improperly installed side bearer fasteners.

If fastener gouging is found check the fastener application on the vehicle.

Blocks with severe fastener gouging as shown in Figure 70 should be replaced if the wear is over 3 mm deep. This damage is caused by loose or improperly installed side bearer fasteners.

If fastener gouging is found check the fastener application on the vehicle.

11.1.2.2.4 Over compressed block condition Blocks should be inspected for over compressed block condition.

Slight vertical crackling is acceptable provided that there are no more than 2 cracks each not greater than 15 mm long as shown in Figure 71. Severe cracking is shown in Figure 71. Blocks with severe cracking should be replaced. Severe vertical cracking is caused by under tolerance setup height and/or lack of break in lubricant.

If vertical cracking is found check and correct the wagon set up height.



Figure 71 Figure 72

Slight vertical cracking Severe vertical cracking

Excessive permanent bulging is shown in Figure 73. Blocks with excessive permanent bulging should be replaced. Permanent bulging is caused by under tolerance set up height.

Block with the top crushed is shown in Figure 74. Blocks with the top crushed should be replaced.

Figure 73 Figure 74

Excessive permanent bulging Top crushed

11.1.2.2.5 Free height measurement The free height of the blocks should be measured after allowing the blocks to relax at least one hour at room temperature after the removal of the bogie from the wagon.

The free height should be measured from the base to the highest point on the block and should not be below the limits as shown in Table 9.




Block type Minimum free height mm

RB-9 106

RB-11 110

RB-12 108

RB-14 108

RB-17 106

RB-24 92

RB-27 96

RB-34 95

Table 9

11.1.2.3 Rollers Rollers should be inspected and measured to the limits shown in Table 10.

Roller size Condemn diameter

4”x3” 98 mm

3” ISB model 74 mm

2” (actual 2 1/16”) 50 mm

Table 10

11.1.2.4 Housings Housings which are cracked, broken or have missing pieces shall be scrapped.

Dents, nicks, gouges and similar damage to the housing and inserts shall be ground smooth and have all sharp edges removed. There shall be no sharp edges, upset metal or other projections or damage which will prevent the correct installation and operation of any components.

The internal length of the housing between the end gibs (without the end closure inserts) shall not be more than 220 mm.


11.2 Miner type

11.2.1 Identification of Miner constant contact sidebearers

Figure 75 TCC 2600 Figure 76 TCC 4500

Figure 77 TCC 8000 Figure 78 TCC 4500RA

Figure 79 TCC 11 35 Long Travel Figure 80 TCC 111-60 Long Travel


Figure 81 TCC 111-45 RA


11.2.2 Requalification of Miner constant contact sidebearers

11.2.2.1 Preparation All Miner constant contact sidebearers should be disassembled for inspection of the components. For identification of components see section 11.21.

Housings may be left attached to bolsters.

Housing fasteners shall be correctly installed and tightly secured and replaced if required. Loose Huck bolts shall be removed and replaced

11.2.2.2 Top caps

11.2.2.2.1 Tecspak rubber pad The pad should be inspected for tears or damage. Replace any that show tears or damage.

11.2.2.2.2 Free height The free height of “Miner” top caps should be measured, as shown in Figure 82, after allowing the blocks to relax at least one hour at room temperature after the removal of the bogie from the wagon.

Scrap any top caps where the free height is less than 111 mm.

Figure 82

The use of Miner gauge 28740 can be used for this purpose.

11.2.2.3 Housing repair and maintenance Housings which are cracked, broken or have missing pieces shall be scrapped.

Dents, nicks, gouges and similar damage to the housing and inserts shall be ground smooth and have all sharp edges removed. There shall be no sharp edges, upset metal or other projections or damage which will prevent the correct installation and operation of any components.



11.2.2.3.1 Standard housings On bearings made after 1990, there are wear holes on stops inside the housing as shown in Figure 83. When wear holes cannot be seen, replace the housing.

On old housings, if the stops are worn more than 1.5 mm, replace the housing.

Figure 83

12 Bogie assembly

12.1 General The height from rail level to the centre plate bearing surface of the free standing bogie shall be within the limits show in Table 11 with the springs seated on the underside of the bolster. The figures are for bogies fitted with new wheels, and an allowance from new wheel size may be taken into account to compensate for wheel wear.

All bolts are to be correctly tightened except as detailed otherwise.

Bogie type Height mm

All three piece except as listed in this table

715 to 740

Table 11

12.2 Wheelbase variation The wheel base variation between the two sideframes of the bogie shall not be greater than 4mm, except as detailed otherwise for bogie enhancements (i.e frame bracing etc).

This can be achieved by ensuring that the number of buttons on the sideframes on a bogie are matched within one button. (See 5.1.9)

12.3 Wheelsets Wheelsets shall be installed in accordance with the following.



12.3.1 Preparation All bearings should be inspected in accordance with ESR 0040 before installation in a bogie.

Brake shoes may be removed for convenience.

12.3.2 Installation Wheels in each bogie shall have the diameters paired in accordance with ESR 0331.

Retention devices shall be installed in accordance with ESR 0040.

Following installation of the wheelset the brakes shall be regulated in accordance with section 13.

12.3.3 Three piece bogies Standard adaptors shall be inspected in accordance with ESR 0032.

Adaptors shall be matched to end caps. For identification of standard type adaptors see ESR 0041 and for identification of standard package units see ESR 0032.

12.3.4 Inspection Following installation of the wheelset the adaptors should sit squarely on the bearings.

Ensure there is at least 3 mm clearance between end caps and adaptors.

Figure 84

12.4 Brakegear The bogie shall be assembled left or right handed as required.

All brake pins other than those in the horizontal plane shall be assembled with the head uppermost.

Brakegear shall be secured in accordance with the requirements of ESR 0312.




Split pins shall be installed to the requirements of ESR 0312.

Safety loops shall be converted to swinging type as shown on SRA drawing 106-466.

Brake gear shall be free and easy to operate in the free standing state.

12.4.1 Identification of hand of bogies

12.4.1.1 The live brake lever The live lever is the bogie brake lever which connects to the vehicle brake pull-rod and freight vehicles use a combination different hand bogies (ie: right or left).

12.4.1.2 Hand of bogies Depending on the hand of the bogie the live lever will lay either to the right or the left. A bogie on which, when viewed from the live brake lever end, the brake lever leans to the right, is designated a right-hand bogie. Alternatively, if the live brake lever leans to the left, it is a left-hand bogie (refer Figure 85).

12.4.1.3 Centre pick-up bogies Bogies designated as centre pick-up bogies have their brake live lever pick-up in the centre.

12.4.1.4 Push and pull type brake configuration. Further to selecting the bogie for being left, right or centre pick-up, the vehicle brake combination may be a “push” or “pull” arrangement. That is, the bogie brake live lever is pushed towards or pulled away from the bogie bolster to affect braking.


Figure 85

12.5 Ride control friction shoes

12.5.1 Standard metal type To speed the proper break in of friction shoes the surfaces of the friction pocket shall be given a light dry film spray molydisulphide or comparable heavy duty lubricant as shown in Figure 86. Extreme caution must be exercised to prevent any of the material from getting on the front face of the block which contacts the column guide wear plate so as not to interfere with the friction snubbing.

Molydisulphate or other heavy duty lubricant permitted on there surfaces only Figure 86



12.5.2 “Elastowedges” or wear eliminating wedge. Lubricate the pocket surfaces and resilient pads with a light coating of detergent or soapy water. Lubrication as used for metal wedges shall not be used.

13 Brake regulation on a freestanding bogie

13.1 General Brake regulation on the bogie is necessary to standardise on the positioning of the brake adjustment on vehicles and to ensure the best angle of the brake levers for the most efficient operation of the brakes. It also prevents fouling of the brakegear through its full movement and life of the brake blocks.

This procedure shall be followed every time a wheelset is installed into a bogie or when otherwise specified.

13.2 Adjustment New brake shoes or brake shoe simulators, SRA drawing 207-657, shall be used when adjusting the brake regulation.

The brake rigging shall be adjusted with the brakes held on, so that the distance from the longitudinal centreline of the bolster to the centre of the live lever pickup point, is within the limits shown in Table 12.

X

Figure 86

The top and bottom pins in any adjustment holes shall be positioned so that the dead lever is in the most upright position when the brakes are pulled on.




Bogie type Regulation dimension “X” mm +/- 25 mm

All three piece 12 inch centre casting except as listed in this table

300

AVB and BVB 430

CQA CQB and CQC 485

Table 12

14 Identification All stencilled lettering shall be at least 40 mm high, white and painted clearly.

All old metal envelope tags shall be removed from the sideframes.

14.1 Upon overhaul The bogie code, serial number, overhaul date (MM/YY) and overhaul location code shall be legibly stamped on metal plates which are welded to each end of the bolster, diagonally placed such that the bolster opening on each side is only partially covered and access to the friction wedge pin retaining holes is not restricted. The stamping shall be 10mm high placed within 5 mm to the top of the plate. .e.g XLB 1234. Subsequent stamping shall be placed from 5 to 10 mm below the last stamping.

The metal plate shall be large enough to allow further information to be added at inspection periods and shall in no way limit access to either the friction wedges or their retaining holes.

The same bogie code and serial number shall be painted on each sideframe directly above the right hand inboard pedestal e.g XLB 1234. The bogie overhaul date, location code shall be painted on the right hand outboard pedestal e.g OH MM/YY PAR.

15 Painting All bogies shall be painted with one coat of enamel paint, the colour shown in Table 13.

The paint shall be a light body paint that will not prevent the detection of flaws or cracks in ordinary inspection.

The application of the paint shall be in accordance with manufacturer’s recommendations.

Painting shall be carried out in a tradesman like manner and applied coatings are free of runs, pinholes, non uniform appearance or other surface defects.

All surfaces to be painted must be clean and be free of all oil, grease, dirt, moisture, unsound paint, chalking, abrasive dust or other foreign material in accordance with AS 1627.1

All weld spatter, slag fumes and flux residue shall be removed.

Where required blast cleaning shall be in accordance with AS 1627.4 to class 2 1/2 surface quality with an approved abrasive to achieve a profile height of 30 to 45



micrometers (um). All dust, dirt, and surface contamination shall be removed by vacuum or other suitable means.

Colour coding on springs, axleboxes, package unit end caps and other items shall not be painted over.

Paint shall not be applied to the faces of wearplates, non metallic liners and sliding surfaces of bogies.

Bogie Colour AS2700

All bogies except as detailed otherwise in this table

Standard grey N64 or equivalent

Ballast wagons Viking blue B41 or equivalent

Table 13

16 Reference documents

16.1 RailCorp standards ESR 0032 Axle bearing reference manual

ESR 0040 Inspection of freight bogies

ESR 0041 Bogie DI

ESR 0043 Coil spring groups

ESR 0300 Non destructive testing

ESR 0312 Security of brakegear

ESR 0322 Welding of wear plates

ESR 0331 Wheel & axle reference manual

ESR 0414 Steel wear plates

16.2 RailCorp drawings 106-466 Three piece bogie safety loop

207-657 Dummy brake block

301-755 Brake beam hanger

304-697 Standard brake pins, bushes and cotters



16.3 Australian standards AS 1171 Non destructive testing – magnetic particle testing of ferromagnetic products,

components & structures

AS 1554 Structural steel welding code

AS 1627 Metal finishing – preparation & pretreated surfaces

AS 2700 Colour standards for general Purposes

Documents

ESR 0545 - Overhaul of three piece bogies