Bogies and Suspension Quiz
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Questions and Answers

What is the axle load of the CASNUB 22NLC bogie?

  • 25.0t (correct)
  • 20.32t
  • 22.32t
  • 23.5t

Which bogie type has a wheel diameter of 906 mm when condemned?

  • All bogie types except CASNUB 22NLC (correct)
  • LCCF 20(C)
  • CASNUB 22HS(Mod-I)
  • IRF-108HS

What is the gauge of the bogies described?

  • 1676 mm (correct)
  • 1600 mm
  • 1900 mm
  • 1800 mm

Which CASNUB bogie model can be upgraded to a load capacity of CC+8t+2t?

<p>All other bogies (C)</p> Signup and view all the answers

How does the bolster in the bogie design provide damping?

<p>With springs supporting the side frame (C)</p> Signup and view all the answers

What is the wheel base measurement for the bogies mentioned?

<p>2000 mm (B)</p> Signup and view all the answers

What characterizes the construction of a bogie, according to the description?

<p>Two cast steel frames and a floating bolster (A)</p> Signup and view all the answers

What is the maximum preheating temperature required before welding for surface reclamation?

<p>250° Celsius (D)</p> Signup and view all the answers

What is the primary purpose of the elastomeric pads in CASNUB bogies?

<p>To reduce wheel flange wear (A)</p> Signup and view all the answers

How thick of a shim indicates that repairs are necessary in a CASNUB bogie?

<p>7 mm (B)</p> Signup and view all the answers

Which component is NOT part of the brake gear assembly in CASNUB bogies?

<p>Elastomeric pad (A)</p> Signup and view all the answers

What is the maximum allowable permanent set of the elastomeric pad indicated by the respective drawing?

<p>40 mm (D)</p> Signup and view all the answers

What material is specified for the washer in the brake gear according to IS standards?

<p>IS :2062 Fe410WA (D)</p> Signup and view all the answers

What action should be taken if a crack longer than 50 mm occurs on the rubber surface of the pad?

<p>Condemn and replace the pad (C)</p> Signup and view all the answers

What is the hardness range specified for the pins and bushes in the brake gear assembly?

<p>250-280 BHN (C)</p> Signup and view all the answers

What should be done if signs of crushing of rubber are noticed on the elastomeric pads?

<p>Condemn and replace the pads (C)</p> Signup and view all the answers

What should be checked after 5 passes of screw movement?

<p>Irregularity in the movement (A)</p> Signup and view all the answers

What is a potential consequence of using wire ropes instead of prescribed lifting tackle?

<p>Damage to grease seals (B)</p> Signup and view all the answers

Which condition indicates that the adapter should be replaced?

<p>Wear bands extending to the end of the outer ring (C)</p> Signup and view all the answers

What should be ensured during welding of wagons or bogies fitted with CTRBs?

<p>Current should not pass through the bearings (D)</p> Signup and view all the answers

What action should be taken if wheels are found overdue for overhauling?

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What should be checked after repairs to the bogie surfaces?

<p>The repaired surface with the relevant gauge (D)</p> Signup and view all the answers

Which action is part of the assembly process after repairs?

<p>Reversing the procedure of disassembly (D)</p> Signup and view all the answers

What must be ensured when positioning the job for welding?

<p>That suitable manipulators are used (D)</p> Signup and view all the answers

During the disassembly process, which component must be removed first?

<p>The shackle of centre pivot pin (C)</p> Signup and view all the answers

What needs to be done to the wearing surfaces during POH?

<p>Bring them to 'As New' condition (A)</p> Signup and view all the answers

What should be done if the holes of a bolster pocket wall start crossing?

<p>Repair should be undertaken (A)</p> Signup and view all the answers

What is one method to remove excess material after surface repairs?

<p>By grinding or machining (C)</p> Signup and view all the answers

What is indicated by the 'gauge' used in the repair process?

<p>The wear of the component (B)</p> Signup and view all the answers

Which of the following steps is NOT part of the bogie disassembly process?

<p>Calibrate the electronic systems (B)</p> Signup and view all the answers

What is the purpose of using manipulators when repairing the bogie?

<p>To ensure proper positioning for welding (D)</p> Signup and view all the answers

What must be checked for defects on mounted CTRBs?

<p>Lateral play in the bearing (A), Cup spalls (C)</p> Signup and view all the answers

What is the consequence of excessive mounted lateral play in CTRBs?

<p>Higher peak roller loads (B)</p> Signup and view all the answers

Why should welding be avoided after the assembly of a wagon?

<p>It may lead to bearing failure due to electric current. (B)</p> Signup and view all the answers

What type of grounding is recommended for welding on wagons?

<p>Earthing with a wire running parallel to the track (D)</p> Signup and view all the answers

What ensures that the cup and cones of overhauled CTRBs are compatible?

<p>Maintaining similar age profiles (D)</p> Signup and view all the answers

What is the purpose of stamping the overhauling date on CTRBs?

<p>To keep a log of repair history (D)</p> Signup and view all the answers

How should wheel sets be handled during maintenance?

<p>With proper lifting tackles (A)</p> Signup and view all the answers

What is one of the repercussions of failing to ground all earthling ports properly?

<p>Current can cause arcing between rollers (D)</p> Signup and view all the answers

What should be tested on mounted CTRBs to prevent performance issues?

<p>Lateral play at mounted ends (A)</p> Signup and view all the answers

What can lead to reduced fatigue life in roller bearings?

<p>Excessive mounted lateral play (D)</p> Signup and view all the answers

What is an indication that the thrust shoulder of an adapter is worn?

<p>Presence of a shiny edge at the extreme end of the outer ring. (D)</p> Signup and view all the answers

What should be the first action if screw movement persists after 5 passes?

<p>Inspect for any irregularity. (A)</p> Signup and view all the answers

During welding of wagons or bogies fitted with CTRBs, what should be prioritized?

<p>Ensuring electric current does not pass through the bearings. (B)</p> Signup and view all the answers

What should be done if an adapter exhibits wear bands that extend to the end of the outer ring?

<p>Replace the adapter. (A)</p> Signup and view all the answers

What is an appropriate method of earthing during the welding of wagons or bogies?

<p>Running an earthing wire parallel to the track. (A)</p> Signup and view all the answers

What is the specified minimum service diameter of the wheel disc for a 25 T axle load in CASNUB 22 NLC bogies?

<p>955 mm (D)</p> Signup and view all the answers

Which of the following wheel sizes is associated with the W/WL-4750 model?

<p>1000 mm (B)</p> Signup and view all the answers

During the drawing procedure, how far should the horizontal line be drawn from the top of the flange?

<p>28.5 mm (A)</p> Signup and view all the answers

Which model features wheel sizes of 850 mm when condemned?

<p>WD-89025/S-5 (A)</p> Signup and view all the answers

What is the radius of the semi-circle to be drawn in the procedure?

<p>14.5 R (B)</p> Signup and view all the answers

What is the maximum allowable wear limit for the inner gib of the bolster column gibs?

<p>146 mm (C)</p> Signup and view all the answers

What is the condemning free height of the metal bonded rubber pad in the constant contact side bearer?

<p>109 mm (D)</p> Signup and view all the answers

What is the maximum allowed wear on the bolster land surface before it reaches the wear limit?

<p>3 mm (A)</p> Signup and view all the answers

Which dimension indicates the wear limit for the vertical side of the centre pivot?

<p>4 mm (D)</p> Signup and view all the answers

What is the new measurement for the bolster pocket at 35°/270 slope?

<p>35 cm (D)</p> Signup and view all the answers

What is the condemned free height for the PU side bearer with three rings?

<p>137 mm (C)</p> Signup and view all the answers

What is the wear limit for the outer gib in the bolster column gibs?

<p>5 mm (D)</p> Signup and view all the answers

What is the defined new dimension for the elastomeric pad in the CASNUB bogies?

<p>46 mm (A)</p> Signup and view all the answers

What is the maximum wear limit specified for the friction shoe wedge block's vertical surface from the centre line of the spigot?

<p>7 mm (D)</p> Signup and view all the answers

What is the minimum required height for a new constant contact side bearer pad?

<p>114 mm (A)</p> Signup and view all the answers

What is the maximum thickness of wear liners permitted in service for side frame columns?

<p>6 mm (B)</p> Signup and view all the answers

What must be punched on the axle end during axle renewal?

<p>Date of pressing and pressure in tonnes (C)</p> Signup and view all the answers

Which wheel sets are provided with narrow jaw adapters according to the specifications?

<p>All CASNUB types except CASNUB 22W (A)</p> Signup and view all the answers

What should be ensured before welding to the side frame during the assembly of friction plates?

<p>No grease or paint on the friction plate (C)</p> Signup and view all the answers

What is the type of bearing class used for wheel sets in CASNUB 22W bogies?

<p>Cartridge Tapered Roller Bearing Class 'E' (C)</p> Signup and view all the answers

During the reclamation process, axial defects larger than what size are not permitted according to the guidelines?

<p>5 mm (D)</p> Signup and view all the answers

What should the orientation of the welding be when attaching the friction plate to the side frame?

<p>Diagonal ends towards the center (C)</p> Signup and view all the answers

What is the recommended maximum free height variation for springs to remain assembled in the same group?

<p>3 mm (C)</p> Signup and view all the answers

Which CASNUB bogie model has the highest recommended free height for the inner spring?

<p>CASNUB 22 W(M) (A)</p> Signup and view all the answers

Which type of spring is recommended for the CASNUB 22HS bogie?

<p>All types included (D)</p> Signup and view all the answers

How does the free height of the inner spring in CASNUB 22HS(Mod-II) compare to that of CASNUB 22HS(Mod-I)?

<p>It is shorter (A)</p> Signup and view all the answers

Which CASNUB bogie model has the lowest recommended free height for the snubber spring?

<p>CASNUB 22HS(Mod-II) (B)</p> Signup and view all the answers

What aspect should be avoided when assembling springs in the bogie?

<p>Mixing new and old springs (B)</p> Signup and view all the answers

Which of the following statements is accurate regarding the snubber springs of the CASNUB 22 W(M)?

<p>The nominal free height is 294 mm. (A)</p> Signup and view all the answers

In the IRF-108HS, what is the recommended free height of the inner spring?

<p>246 mm (A)</p> Signup and view all the answers

What is the significance of the condemning height for springs in the bogie system?

<p>It indicates when a spring should be discarded. (B)</p> Signup and view all the answers

What is the maximum allowable lateral clearance between the side frame and the axle box/adopter for the 22NL bogie?

<p>16 mm (A)</p> Signup and view all the answers

Which of the following represents the worn limit for the Axle Box Crown seat (Cylindrical Roller Bearings)?

<p>33 mm (C)</p> Signup and view all the answers

What is the new limit for the lateral clearance between the side frame and bolster for the 22W model?

<p>6 mm (B)</p> Signup and view all the answers

Which of the following reflects the wear limit for the Axle Box sides (Cylindrical Roller Bearings)?

<p>262 mm (A)</p> Signup and view all the answers

What is the longitudinal clearance between the side frame and axle box/adopter for the 22W(M) model?

<p>9 mm (C)</p> Signup and view all the answers

What is the new limit for Axle Box side lugs (Cylindrical Roller Bearings)?

<p>130 mm (B)</p> Signup and view all the answers

Which of the following measures indicates the maximum lateral clearance required between the side frame and bolster for the 22HS model?

<p>25 mm (A)</p> Signup and view all the answers

What is the maximum allowable longitudinal clearance between the side frames and axle box/adopter for the 22NL model?

<p>9 mm (A)</p> Signup and view all the answers

Which limit reflects the new crown lugs limit of the Axle Box (Cylindrical Roller Bearings)?

<p>159 mm (A)</p> Signup and view all the answers

Flashcards

CASNUB Bogie Axle Load

The weight supported by a single axle of a specific CASNUB bogie type. Different CASNUB bogie models have varying axle loads.

Wheel Diameter

The size of the wheels used on different CASNUB bogies. There are new and condemned wheel sizes.

CASNUB -22HS(Mod-I), Axle Load

22.32 tonnes

Wheel Base

The distance between the centers of the two wheels on an axle, measured in millimeters.

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Gauge

The standard distance between the rails on a railway track, measured in millimeters.

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Bolster

A component in a railway bogie, supporting the load and acting as an intermediary structure between the frames.

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Spring Plank

A mild steel component that connects the side frames of a bogie.

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Reclamation Process

The process of restoring worn surfaces on a bogie to their original dimensions.

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Gauge in Position

The measuring tool positioned on a surface to verify its shape and dimensions.

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7 mm Shim

A thin plate of 7 mm thickness used to measure the depth of wear on a bogie.

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Welding Repair

Using welding to build up worn parts of the bogie bowl seat.

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Preheat Temperature

The maximum temperature (250°C) to which a surface is heated before welding.

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Side Bearers (CASNUB)

RDSO-approved side supports for CASNUB bogies, often constant contact or PU pad type.

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Elastomeric Pads

Rubber pads used in CASNUB bogies to reduce wheel flange wear.

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Condemned Pads

Elastomeric or bonded rubber pads requiring replacement due to cracks or excessive wear.

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Brake Gear Components

The brake beam, equalizing levers, push rods, end pull rods and hangers for CASNUB bogie brakes.

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Displaced Adapters

Adapters that are not in their proper position, potentially causing damage.

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Cup Spalls

Damaged areas on the inner race of a bearing, formed by impact with another moving part.

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Mounted Lateral Play

Side-to-side movement of a component (CTRB) on a mounting surface.

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Bearing Performance

The ability of a bearing to function correctly under load and movement.

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Welding on Wagons

Avoiding welding on wagons after their components are assembled, unless safety precautions are taken, especially preventing electrical issues.

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Earthing

A protective measure to prevent electrical current from affecting bearings.

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Defective CTRBs

Components that are not functioning correctly.

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Cup and Cones (Compatibility)

Using matching and appropriately aged cup and cone parts when overhauling components.

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Overhauling Date Stamping

Marking components with the date and workshop details for tracking.

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Proper Lifting Tackles

Using the correct lifting equipment for wheel sets.

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Bogie Repair

Fixing worn or damaged parts on a railway bogie (a truck/carriage support).

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ROH/POH

Routine Overhaul (ROH) and Periodic Overhaul (POH) are maintenance procedures for railway bogies.

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Dismantling (Bogie)

Taking apart a bogie for inspection and repair during maintenance.

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Welding Repairs

Using welding to fix worn or damaged components, following safety procedures.

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Gauge Checking

Using tools to verify the dimensions of a repaired surface, ensuring it meets standards.

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Excess Material Removal

Removing extra material from a repair to achieve the correct dimensions.

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Bogie Assembly

Putting together the different parts of a bogie after repair. Follow procedure for disassembly.

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Bogie Clearances

Measuring and adjusting the space between different parts of a bogie.

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Wear Determination

Checking how much a surface has worn using tools for checking wear.

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Welding Precautions

Safety measures to take during welding, including choosing of welding equipment.

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Screw Movement After 5 Passes

Persistent screw movement after five passes suggests an irregularity that needs inspection.

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Wheel Set Lifting

Use prescribed lifting tackle, not wire ropes, to handle wheel sets to avoid damage to grease seals.

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Bogie Dismantling & Adapter Inspection

When dismantling a bogie, thoroughly inspect the adapter for damage or wear; use G95 guidelines for measurements.

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Adapter Placement on CTRB

Ensure the adapter is correctly positioned on the CTRB for proper function and to prevent bearing wear.

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Warm Bearings in Incoming Trains

Check for warm bearings during the arrival of incoming trains in yards for potential issues.

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Axle Reclamation Limit

Axles can be reclaimed if notches, scratches, or nicks are less than 5mm, following RDSO guidelines (letter No. MW/WA/GENL dated 20.12.91).

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Axle Stamping

When axles are renewed, specific details (serial number, workshop code, date, pressing pressure) must be stamped on both ends in 5mm letters.

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CASNUB 22W Wide Jaw Adapter

CASNUB 22W bogies use a wide-jaw adapter (drg no. SK 78527) with Cartridge Tapered Roller Bearing (CTRB) Class ‘E’ (6” X 11”).

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Side Frame Wear Liners

Side frame columns have 10mm thick Silico Manganese Steel wear liners (IS: 3885 Pt.-I Gr.IV) welded for protection, but liners are limited to 6 mm in thickness during service.

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Friction Plate Welding

New friction plates must be held tight against the column during welding, starting at diagonal ends and working towards the center in a downhand position; avoid paint/grease on the plate.

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Bogie Wheelbase Check

Verify the wheelbase (distance between centers of jaw openings) and button markings on the side frame.

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Axle Renewal Stamping

When an axle is renewed, required details (serial number, workshop code, date, pressure) must be punched on its end in 5mm letters for documentation.

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22W Bogie Lateral Clearance (Side Frame & Bolster)

The space between the bogie's side frame and bolster is 18 mm for the 22W bogie.

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22W Bogie Lateral Clearance (Side Frame & Axle Box/Adopter)

The 22W bogie has a 25 mm lateral clearance between its side frame and axle box/adopter.

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22W Bogie Longitudinal Clearance (Side Frames & Axle Box/Adopter)

The longitudinal space between the 22W bogie's side frames and axle box/adopter is 10 mm.

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Axle Box Crown Lugs Wear Limit

The acceptable wear limit for the cylindrical roller bearings is 4 mm, measuring from a new value of 159 mm to a worn value of 167 mm.

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Axle Box Crown Seat Wear Limit

The acceptable wear limit for the cylindrical roller bearings is 3.5 mm, measuring from a new value of 36.5 mm to a worn value of 33 mm.

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Lateral Clearance (Side Frame & Bolster) - Different Bogie Types

Different bogie types (22W, 22NL, 22HS) show variations in lateral clearances between the side frame and bolster, from 18 to 25mm.

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Bogie Component Wear Limits

The wagon maintenance manual provides wear limits for bogie components, such as axle boxes and their lugs, to ensure optimal performance and safety.

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Pedestal Jaw (Short) Distance

The distance between the inner and outer pedestal jaws of a short pedestal jaw design for specific CASNUB bogies.

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Pedestal Jaw (Long) Distance

The distance between the inner and outer pedestal jaws of a long pedestal jaw design for specific CASNUB bogies.

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Bolster Pocket Wear

The acceptable range of wear in degrees on the slope surface of the bolster pocket.

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Bolster Liner Wear Limit

The maximum permissible wear (in mm) on the bolster liner, indicating when it needs replacement.

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Bolster Land Surface Wear

Maximum permissible wear (in mm) on the bolster land surface to maintain standard dimensions.

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Outer Gib Wear Limit

Maximum permissible wear (in mm) on the outer gib, a component part, of the bolster column.

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Centre Pivot Wear Limit

This is the maximum permissible wear (in mm) on the vertical side of the central pivot point.

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Friction Shoe Wear

Maximum permissible wear (in mm) on the vertical surface and slope surfaces, gauged, for friction shoe wedges.

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Elastomeric Pad Free Height

The allowable height (in mm) of the elastomeric pad.

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Constant Contact Side Bearer Height

The permissible free height (in mm) for the constant contact side bearer pad.

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Wheel Disc Minimum Diameter

The smallest acceptable diameter for a wheel disc on a specific axle load and bogie type (e.g., CASNUB 22).

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Wheel Set Lifting Method

The method for handling wheel sets during maintenance or repair to prevent damage.

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22W Bogie Lateral Clearance (Side Frame & Bolster)

The space of 18 mm between the side frame and bolster of a 22W bogie.

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Axle Reclamation Limit

The maximum acceptable depth of scratches, notches, or nicks on an axle before it's no longer usable.

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Adapter Placement on CTRB

The correct positioning of an adapter on a Cartridge Tapered Roller Bearing (CTRB) to avoid bearing wear and ensure proper function.

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Spring Free Height

The vertical distance from the bottom of the spring to the top after assembly, measured in millimeters (mm).

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Recommended Free Height

The optimal vertical distance of a spring from the bottom to the top.

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CASNUB 22W(M)

One type of bogie with specific dimensions and spring types.

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Spring Groups

Different groups in the bogie, with springs assembled for consistency in free height variation.

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Free Height Variation

The difference in spring height between individual springs, measured in millimeters (mm).

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Outer Spring

The spring that sits at the outer part of the bogie set.

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Inner Spring

The spring that sits within the bogie set.

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Snubber Spring

Spring component that absorbs shocks.

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Bogie Type

Specific design and configuration of a railway bogie.

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Mixing Springs

Avoid assembling new and old springs in the same bogie group.

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Study Notes

Bogies and Suspension

  • Bogies are fitted in box wagons and are designated CASNUB 22W
  • Modifications to the CASNUB 22W bogie include 22W (M), 22NL, and 22NLB, with and without fish belly bolster
  • High-speed versions (CASNUB 22 HS and CASNUB 22HS (Mod-I)) are designed for up to 100 km/h at 20.32t axle load
  • Older CASNUB 22W bogies were retrofitted to newer models.
  • Bogie details for 22W and retrofitted 22W versions are not included in this manual, but are found in the 2001 version of WMM
  • Various axle loads and wagon types are listed
  • Bogies are constructed from two cast steel frames and a floating bolster supported on side frames by spring nests
  • Fabricated mild steel spring plank connects side frames.
  • Bogies are fitted with Cartridge Tapered Roller Bearings (CTRB) (6"X11")
  • Axle loads, wheel diameters, and distances between journal centers and side bearers vary depending on the bogie type.
  • Various bogie types and corresponding axle loads are detailed
  • Anti-rotation lugs and type of brake beam vary
  • Suspension details include details of the types of springs used in various bogies
  • Components in CASNUB bogies include wheel sets, axle box, side frames, bolster, wear liners, spring plank, bolts, rivets, and springs
  • Wear limits for various bogie components are provided in tables.
  • Wheel sets are with Cartridge Tapered Roller bearings (CTRB) (6” X 11”) and different types of adapters (narrow or wide jaw)
  • Side frames are fitted with friction plates made of silico manganese steel
  • Bolster pockets have manganese steel liners
  • Spring plan is made of mild steel
  • Load bearing springs and snubber springs have been fitted in the bogies.
  • Detailed components are identified with drawings
  • Dampening systems utilize manganese steel cast wedges supported on snubber springs
  • Centre pivot arrangements for various bogie types are described with diagrams
  • Side bearers and elastomeric pads are used in different bogie versions
  • Brake beam assemblies are provided in bogies
  • Different bogie types have specific brake beam designs and wear plate requirements.
  • Nominal clearances and tolerances are included
  • Wear limits for axle box, adapters, side frames, and other components are presented in a table
  • Wheel defects are explained
  • Procedures for disassembling and reassembling bogies are described step-by-step
  • Procedures for axle and wheel repair and maintenance are described
  • Recommended practices for operating, inspecting, and maintaining cartridge tapered roller bearings are explained, including cleaning, inspection, and assembly
  • Procedures for tyre turning, checking wheel defects, and dealing with loose backing rings are given
  • Spring arrangement and details for each wagon type are presented in tables.
  • Various diagrams and figures illustrate features of bogies and their components

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CnW Maintenance Manual - Bogies and Suspension - PDF

Description

Test your knowledge on the different types of bogies and their specifications, including the CASNUB 22W and its modifications. This quiz covers construction details, axle loads, and bearing types used in modern wagons. Perfect for engineering students and professionals in rail transportation.

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