CnW Maintenance Manual 500-504 PDF

APPENDIX – V List of Must Change Items in freight Stock during POH & IOH Page 1 of 5 APPENDIX - V LIST OF MUST CHANGE ITEMS IN FREIGHT STOCK DURING POH AND R...

APPENDIX – V List of Must Change Items in freight Stock during POH & IOH Page 1 of 5 APPENDIX - V LIST OF MUST CHANGE ITEMS IN FREIGHT STOCK DURING POH AND ROH (Railway Board’s Letter No. 2003/M(N)/951/22 dated 16-01-2013) ITEMS TO BE REPLACED DURING ROH Sr. No. Description of item Justification for replacement A CASNUB BOGIE During dismantling of wheel from bogie, it is necessary to cut the bolt since it is tack welded with nut. A-1 SF Key nut bolt with washer Therefore the committee recommends 100% replacement of this item during ROH. The split pins of Brake Shoe key are being changed 100% in some depots as they are getting distorted A-2 Split Pin 12 x 110 mm /damaged while taking out the brake blocks. Hence 100 % replacement is recommended during ROH. The Locking plates are being changed on 100% basis. A-3 While carrying out the UST of Wheel sets, the locking CTRB Locking plate plates are to be removed and while doing so, tabs are getting damaged or broken. Hence 100 % replacement is recommended during ROH. B CBC This item is subjected to wear in service as it comes in contact with CBC Shank. Wear Plate. Some ROH depots are replacing the item to the extent of 100 %. Striker casting Wear Plate The worn out component will have serious impact on B-1 uncoupling of CBCs and it will also damage CBC shank; it will cause ovality on the top portion of Yoke Pin hole. Therefore the committee recommends 100% replacement of this item during ROH. C Air Brake System This is basically a non-metallic strainer and of a small value. At present depots are changing on condition basis and there is an apprehension that dirt collectors are not at all opened in depots during ROH. There are many cases of DV malfunctioning and subsequent C-l Dirt Collector Filter brake bindings in service and the filter is playing a major role. Therefore the committee recommends 100% replacement of this item during ROH so that it will be compulsory on the part of the depot to open the Dirt Collector. WAGON MAINTENANCE MANUAL APPENDIX – V List of Must Change Items in freight Stock during POH & IOH Page 2 of 5 C-2 Dirt Collector Washer ('O' These are the small value rubber items perishable in Ring) nature and getting damaged while opening the C-3 Rubber gaskets assemblies. Therefore the committee recommends C-4 MU washers 100% replacement of this item during ROH. C-5 AR Drain Plug leather These items are perishable in nature getting damaged washer while opening the assemblies. Therefore the committee C-6 BC Drain Plug leather recommends 100% replacement of this item during washer ROH D Tank wagons D-1 Filling Pipe Joint Ring These are the rubber items perishable in nature and (BTPN) getting damaged while opening the assemblies. D-2 Man Hole Cover Sealing Therefore the committee recommends 100% Ring. replacement of this item during ROH. ITEMS TO BE REPLACED DURING POH: Sr. No. Description of item Justification for replacement A CASNUB BOGIE A-I Side Frame These items are subjected to wear in service as they are continuously in contact with adaptor and not expected to last beyond one POH. The liners of suitable thickness are Required to be welded. Therefore the committee recommends 100% replacement of these items during POH. Committee also recommends that l. Pedestal Jaw Liners no weld metal deposit should be done on the pedestal jaw surfaces to maintain the clearances as no machining is done after welding. RDSO may explore the possibility of liners in original design. The smoothness of the surface is primarily important. During dismantling of wheel from bogie, it is necessary to cut the bolt since it is tack welded with nut. SF Key nut bolt with 2. Therefore the committee recommends 100% washer replacement of this item during POH. A-2 Bolster 1 Land surface liner These items are subjected to wear in service as they are continuously in contact with adaptor and expected to 2 Pocket slope liner last from POH to POH. The liners of suitable thickness are required to be welded. Therefore the committee recommends 100% replacement of this item during 3. Rotation stop lug liner POH. WAGON MAINTENANCE MANUAL APPENDIX – V List of Must Change Items in freight Stock during POH & IOH Page 3 of 5 A-3 Bogie Brake Gear The split pins of Brake Shoe key are being changed 100% in some depots as they are getting distorted/ 1 Split Pin 12 x 110 mm damaged while taking out the brake blocks. Hence 100 % replacement is recommended during POH. The Locking plates are being changed on 100% basis. While carrying out UST of the Wheel sets, the locking A-4 plates are to be removed and while doing so, tabs are CTRB Locking plate getting damaged or broken. Hence 100 % replacement is recommended during POH. It has been observed that many workshops are replacing this item to the extent of 100%. Being a rubber component, committee recommends 100% A-5 Elastomeric pads replacement of this item during POH. However, the serviceable EM Pads shall be given to divisions for replacement during the course of train examination. B Draw and Buffing Gear Assembly Knuckle is subjected to wear on Nose, Pulling lug area. Some workshops are changing on 100% basis and released serviceable material is given to divisions. Knuckles are playing very important role in coupling gear. In the present spurt of train parting I uncoupling cases Knuckles might be playing a vital role. Upgraded B-1 Knuckle couplers are being developed by RDSO as per WD70- BD-10. The committee therefore recommends one time replacement of indigenous knuckles with the upgraded knuckles as per WD- 70-BD-10. However, serviceable knuckles shall be given to divisions for replacement during train examination. Lock is subjected to wear on contact area corresponding to Knuckle pulling lug and curved surface. Committee has observed that majority of the uncoupling cases are on account of worn out Locks. Upgraded couplers are being developed by RDSO as per WD-70-BD-10.The B-2 CBC Lock committee therefore recommends one time replacement of indigenous CBC locks with the upgraded CBC locks as per WD- 70-BD-10. However, serviceable locks shall be given to divisions for replacement during train examination. WAGON MAINTENANCE MANUAL APPENDIX – V List of Must Change Items in freight Stock during POH & IOH Page 4 of 5 Mostly, the Anti-Creep Lug of Lock Lifter Assembly is found in worn condition. Moreover, the alignment is disturbed due to riveting became loose in service Upgraded couplers are being developed by RDSO as per B-3 Rotary Lock Lift Assembly WD-70-BD-10. The committee therefore recommends one time replacement of indigenous lock lift assembly with the upgraded lock lift assembly as per WD-70:BD- l0. However, serviceable assemblies shall be given to divisions for replacement during train examination. The committee observed that consumption of this item between workshops to workshop varies from 3% to 33%. The item is subjected to wear in service; the slot (17.5 mm x 17.5 mm) of bearing piece becomes worn out in service and not holding the Operating Handle in position. As a result the operating handle along with B-4 Bearing Piece Rotary Lock Lift Assembly gets displaced from its position thereby causing uncoupling of CBC. The item is not expected to last beyond one POH. The committee therefore recommends 100% replacement of this item. However, serviceable bearing pieces shall be given to divisions for replacement during train examination. This item is subjected to wear particularly due to interaction of Yoke Pin's vertical movement. The pin makes a dent mark on the liner which is dangerous B-5 Yoke Pin support plate liner which restricts the movement of the yoke pin resulting in the breakage of Support plate rivets. The item is not expected to last beyond one POH cycle. The committee therefore recommends 100% replacement of this item. This item is subjected to wear in service as it comes in contact with CBC Shank Wear Plate. Some workshops are replacing the item to the extent of 70%. The worn B-6 Shank Wear Plate out component will have serious impact on uncoupling of CBCs and it will also damage CBC shank. The life of the component is not expected beyond one POH cycle. Therefore the committee recommends 100% replacement of this item during POH. This item is subjected to wear in service as it comes in contact with CBC Shank. Some workshops are already B-7 replacing the item to the extent of 100%. The worn out Striker Casting Wear Plate component will have serious impact on uncoupling of CBCs. The life of the component is not expected beyond one POH cycle. Therefore the committee recommends 100% replacement of this item during POH. WAGON MAINTENANCE MANUAL APPENDIX – V List of Must Change Items in freight Stock during POH & IOH Page 5 of 5 C Air Brake System This is basically a non-metallic strainer and of a small value item. At present workshops are changing on condition basis. There are many cases of DV C-1 Dirt Collector Filter malfunctioning in service and the filter is playing a major role. The life of the component is not expected beyond one POH cycle. Therefore the committee recommends 100% replacement of this item during POH. Dirt Collector Rubber C-2 Washer ('O' Ring) These are the rubber items perishable in nature and C-3 Rubber gaskets getting damaged while opening the assemblies. The life Rubber Seals of Cut off of the items is not expected beyond one POH cycle. C-4 Angle Cocks. Therefore the committee recommends 100% C-5 MU washers replacement of this item during POH. C-6 Grip seals / Rubber washers AR Drain Plug leather These are items perishable in nature and Getting C-7 washer damaged while opening the assemblies. Therefore the BC Drain Plug leather committee recommends 100% replacement of this item C-8 washer during POH. This item is generally tested during POH for leakage and bulging at 10 Kg/cm2 pressure and about 50% rejection is there. Moreover, there are large numbers of service failures. Some workshops are changing 100%. Being a C-9 BP Air Hose Rubber item; it is not expected to last beyond one POH cycle. Therefore the committee recommends 100% replacement of this item during POH. However, serviceable hoses shall be given to divisions for replacement during train examination. D Tank wagons Filling Pipe Joint Ring These are the rubber items perishable in nature and D-I (BTPN) getting damaged while opening the assemblies. Man Hole Cover Sealing Therefore the committee recommends 100% D-2 Ring. replacement of this item during POH. Note: Zonal railways may review the consumption of items and further rationalize the AAC of the items at their ends. WAGON MAINTENANCE MANUAL