Discipline

Rolling Stock Engineering Standard

Category
Maintenance

Title
Overhaul of 3-piece Bogies

Reference Number
RSS 0042

Version
1.0
Date of Issue
January 2004
Status
Approved

Copy No:
(Controlled copies are numbered in red)
Rolling Stock Engineering Standard RSS 0042
Maintenance
Overhaul of Three Piece of Bogies

DISCLAIMER

Rail Infrastructure Corporation has used its best endeavours to ensure that the
content, layout and text of this document is accurate, complete and suitable for its
stated purpose. It makes no warranties, express or implied, that compliance with the
contents of this document shall be sufficient to ensure safe systems of work or
operation. Rail Infrastructure Corporation will not be liable to pay compensation in
respect of the content or subsequent use of this document for any other purpose than
its stated purpose or for any purpose other than that for which it was prepared except
where it can be shown to have acted in bad faith or there has been wilful default.

DOCUMENT APPROVAL

The technical content of this document has been approved by the relevant RIC
engineering authority and has also been endorsed by the RIC Configuration
Management Committee directly or as delegated through the conditions of the
Configuration Management Policy.

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It is the document user’s sole responsibility to ensure that copies are checked for
currency against the Primary Version prior to its use.

Controlled hardcopy versions of this document will be issued by the Principal Engineer
Rolling stock & Mechanical Assurance.

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COPYRIGHT

The information in this document is Copyright protected. Apart from the reproduction
without alteration of this document for personal use, non-profit purposes or for any fair
dealing as permitted under the Copyright Act 1968, no part of this document may be
reproduced, altered, stored or transmitted by any person without the prior written
consent of RIC.

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About This Standard

This standard is based on the following TRS Standards:

TRS 0159 Bogie Three Piece Overhaul

TRS 1079 Qualification for Helical Coil Springs for Reuse in Locomotives and
Rolling Stock
TRS 1613 Brakebeam Inspection & Repair for Freight Bogies
TRS 1614 Brake Regulation for Freight Bogies
TRS 1615 Bogie Assembly for Three Piece Freight Bogies
TRS 1617 Friction Wedge Requalification fort Freight Bogies
TRS 1621 Brake Connecting Rod & Brake Lever Inspection & Repair for Freight
Bogies
TRS 1624 Bogie Disassembly for Freight Bogies
TRS 1637 Wagon Maintenance Policy for Freight Vehicles
TRS 1638 Brake Gear Brake Hanger Requalification for Three Piece Freight Bogies
TRS 1639 Bolster National Type Overhaul
TRS 1641 Spring Friction Wedge Data Table for Freight Bogies
TRS 1642 Sideframe Three Piece Ride Control Overhaul
TRS 1643 Sideframe Overhaul for National Type
TRS 1741 Hand of Bogies – Selecting Centre Pick-up, Left & Right Handed Freight
Bogies
TRS 1763 Sideframe Wheel Base for Three Piece Bogies
TRS 1768 Bogie Painting for freight Bogies
TRS 1769 Bolster General Overhaul Requirements
TRS 1796 Sideframe Three Piece General Overhaul Requirement
TRS 1803 Wheelset Removal & Installation in Freight Bogies
TRS 1895 Sidebearer Constant Contact Identification for Stuki Type
TRS 1896 Sidebearer Constant Contact Identification for Miner Type
TRS 1897 Sidebearer Constant Contact Requalification for Miner Type
TRS 1899 Sidebearer Constant Contact Requalification for Stuki Type
TRS 1984 Bolster Ride Control Overhaul
TRS 2022 Friction Wedge Barber Requalification
TRS 2024 Sideframe Barber Overhaul

Version History
Version 1.0

January 2004

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Table of Contents
About This Standard 3
Version History 3

1 Scope 9

2 Preparation 9
2.1 Disassembly 9

3 Bolsters 9
3.1 General Overhaul Requirements 9
3.1.1 Repair of bolsters shall be limited to the following: 9
3.1.2 Terminology 10
3.1.3 Cleaning 10
3.1.4 Casting Inspection 10
3.1.5 centre liner Inspection 10
3.1.6 Wear plates 13
3.1.7 Gibs 13
3.1.8 Sidebearer Height 14
3.1.9 Fulcrum Brackets 15
3.1.10 Constant contact sidebearers 15
3.1.11 Welding 15

3.2 National Type 18

3.2.1 General 18
3.2.2 Gibs 18
3.2.3 Bolster wear plates 19
3.2.4 Rotation lands 19

3.3 Ride Control Type 20

3.3.1 General 20
3.3.2 Wedge Pockets 20
3.3.3 Gibs 23

4 Friction Wedges 24
4.1 Ride Control Friction Wedges 24
4.1.1 Winged and plain type wedges. 24
4.1.2 Friction wedge (in frame type) 24

4.2 Barber Friction Wedges 25

5 Overhaul of Three Piece Sideframes 32

5.1 General overhaul requirements 32
5.1.1 Repair of sideframes shall be limited to the following 32
5.1.2 Cleaning 32
5.1.3 Inspection 32
5.1.4 Friction Wear Liners 33
5.1.5 Rotation stops 33
5.1.6 Brake Beam Pocket 33
5.1.7 Pedestal Opening 34
5.1.8 Wheelbase 36

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5.1.9 Sideframe Variation 37

5.1.10 Welding 38

5.2 Specific Requirements for Ride Control Bogie Sideframes 42

5.2.1 Column Openings 42
5.2.2 Gibs 43
5.2.3 Rotation stops 43
5.2.4 Pedestal opening 44

5.3 National Type 44

5.3.1 Friction Shoe Pockets 44
5.3.2 Column opening 45
5.3.3 Gibs 46
5.3.4 Pedestal opening 46

5.4 Barber Type 47

5.4.1 Column Openings, Gibs and Rotation Stops 47
5.4.2 Pedestal 47

6 Brakegear 50
6.1 Brakebeams 50
6.1.1 Preparation 50
6.1.2 Inspection and Reconditioning of Parts 51
6.1.3 Assembly 55
6.1.4 Marking 55

6.2 Connecting rods 55

6.2.1 Preparation 55
6.2.2 Inspection and reconditioning of parts 56

6.3 Brake hangers 57

6.3.1 Terminology 57
6.3.2 Preparation 57
6.3.3 Welding 57
6.3.4 Inspection and repair 58
6.3.5 Modifications 58

6.4 Safety loops 59

6.4.1 Removal 59
6.4.2 Inspection 60
6.4.3 Installation 60

7 Springs 61
7.1 Spring Category 61

7.2 Free height 61

7.2.1 Friction Wedge Spring Data Table 61

8 Wheelsets 62
8.1 Wheel turning 62

8.2 Wheel replacement 62

9 Adaptors 62

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10 Axleboxes 62

11 Constant Contact Sidebearers 62

11.1 Stuki Type 62
11.1.1 Identification of Stuki Constant Contact Sidebearers 62
11.1.2 Requalification of Stuki Constant Contact Sidebearers 64

11.2 Miner Type 69

11.2.1 Identification of Miner Constant Contact Sidebearers 69
11.2.2 Requalification of Miner Constant Contact Sidebearers 70

12 Bogie assembly 72
12.1 General 72

12.2 Wheelbase Variation 72

12.3 Wheelsets 72
12.3.1 Preparation 72
12.3.2 Installation 72
12.3.3 Three Piece Bogies 73
12.3.4 Inspection 73

12.4 Brakegear 73
12.4.1 Identification of hand of bogies 74

12.5 Ride Control Friction Shoes 75

12.5.1 Standard metal type 75
12.5.2 “Elastowedges” or wear eliminating wedge. 75

13 Brake Regulation on a Freestanding Bogie 75

13.1 General 75

13.2 Adjustment 76

14 Identification 77
14.1 Upon Overhaul 77

15 Painting 77

16 Reference Documents 78
16.1 RIC Standards 78

16.2 RIC Drawings 78

16.3 Australian Standards 79

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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.

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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 RSS 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.

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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.

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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

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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 been 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 RSS 0096 and RSS 0052.
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

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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

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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 permitted only in cross-hatched

areas provided the wear is 5 mm, or less.
Repair of cracks in Grade B material permitted only in cross-hatched areas
provided the cracks are not transverse to a load carrying member and are 25mm,
or less, in length.. Bolster rim may be built up if thickness at 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.
Bolster gib may be built up if wear is 13 mm, or less. Heat treatment not required.
Side bearing attachment if originally secured by welding does not require heat
treatment.

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Repair of cracks in Grade B material permitted in 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. Bolster rim may be built
up if thickness at 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.
Bolster gib may be built up if wear is 13 mm, or less. Preheat is required. Post
Heat Treatment is not required.
Side bearing attachment when rewelded requires minimum of 150°C local
preheat.
Repair of cracks in Grade C material permitted in 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.

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Figure 7

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National Type
3.1.12 General

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

Figure 8

3.1.13 Gibs

Gib dimensions A and C shall be measured. Limits in Table 1.

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

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Bolster *Dimension *Dimension B *Dimension C Dimension D

A mm mm mm 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 1736 - 1744 438 - 443 246 - 251 N/A
Super C1
CS5838 1901 - 1909 341 - 346 151 - 156 390 - 395
Super C1
Wedgelock
CS6668 1901 - 1909 341 - 346 151 - 156 390 - 395
Super C1
Wedgelock
X2182 1850 - 1858 438 - 443 208 - 213 N/A
Table 1
*All dimensions with liners if fitted

Figure 9 Super C1 Wedgelock bolster

3.1.14 Bolster wear plates

Bolster wear plates, dimension B, shall be measured. Limits in Table 1.

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

3.1.15 Rotation lands

Rotation lands on bolsters, dimension D, shall be measured. Limits in Table 1.

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

3.2 Ride Control Type

3.2.1 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

3.2.2 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.

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Figure 11

3.2.2.1 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.

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Figure 13

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

3.2.2.2 Ride control pocket

Ride control wedge pockets are flat across the shoe slope.

Figure 14

3.2.2.3 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

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3.2.3 Gibs

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

Figure 16

3.2.3.1 Repair
As detailed in Section 5 to limits shown in Table 2

Bolster Dimension Dimension Dimension Dimension X Y

A mm B mm C mm mm 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 - 203 222 111
236.5 - 241*
B696 1864 - 1870 510 - 513 189 - 193.5 338.5 -343 111
B703 1864- 1870 408 - 411 198.5 - 203 222 111
236.5 - 241*
B819 1826 - 1832 408 - 411 198.5 - 203 222 111
236.5 - 241*
B848 1864 - 1870 408 - 411 198.5 - 203 222 111
236.5 - 241*
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

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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.

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)

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.

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Figure 18

4.2 Barber Friction Wedges

When requested, Ride Control friction wedges shall be inspected in accordance

with Barber requirements as detailed in Figures 19 to 24.

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Figure 19

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Figure 20

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Figure 21

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Figure 22

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Figure 23

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Figure 24

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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 RSS 0072
and application code AS1171.

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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 been 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 RSS 0052 and RSS 0097.
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

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wear-plate metal thickness is 3 mm or less the pocket wear plate is to be

replaced.

5.1.7 Pedestal Opening

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.

Figure 25

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 shall be measured over the longitudinal stops
dimension K shown in Figure 29.
For wide pedestals the frame 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 of the pedestal fails to meet any of the above criteria the pedestal shall be
repaired as specified below.

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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.

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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.

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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 tolerance

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 top 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.

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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 permitted only in 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.

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

5.1.10.2 Grade C material

Repair of cracks in Grade C material permitted in 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 32.
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 and
provide wear limits which are to be followed. Preheat per 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.

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Figure 31

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Figure 32

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5.2 Specific Requirements for Ride Control Bogie Sideframes

5.2.1 Column Openings

Measure the column opening dimension C shown in Figure 33 the dimensions

shown in Table 3

Figure 33

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

Figure 34

If welded only design, the wear plates shall be attached by 4, 50 mm (minimum)

welds as shown in Figure 34

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5.2.2 Gibs

Measure the gib dimension E shown in Figure 35 to the dimensions shown in

Table 3.

Figure 35

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

5.2.3 Rotation stops

Side frame rotation stops dimension G shown in Figure 35 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 the limits
shown in Table 4.

Bolster Type C Column opening E Gibs mm G rotation stops

mm 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

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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 4

5.3 National Type

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 DBA 45 +2-0 mm.A
Ensure that the minimum wall thickness is greater than 9.5 mm.

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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.

37.5

43-+20

Figure 36

5.3.2 Column opening

Measure the column opening dimension C shown in Figure 37.

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

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Sideframe E Gibs mm C Column opening

mm
CS5409 223 - 228 448 - 453
*CS5837 235 - 240 398 - 403
135 - 140#
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 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.

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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 Barber Type

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 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.

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Figure 39

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Figure 40

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6 Brakegear

6.1 Brakebeams

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 - Brakebeam

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 fastener does not extend outside clearance
outline of brake beams.
Standard bushes complying with drawing 304-697 (current issue) shall be used.

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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 discontinuity’s 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 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.

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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.
Brake shoe lug pocket shall not be more than 1.5 mm as shown in Figure 42.
Brake head toe pocket shall not be more than 1.5 mm as shown in Figure 42.

Figure 42

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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

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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 0 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.

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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.

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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.

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6.3 Brake hangers

The standard 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 45

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.

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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 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. Minimum measurement shall be 28 mm as
shown in Figure 47.
If worn less than 28 mm restore hanger foot to 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.

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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

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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.
Bolts 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 49

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7 Springs

Springs shall be inspected and requalified in accordance with RSS 0043.

7.1 Spring Category

The classification of the load bearing springs shall be class B. (Refer to RSS
0043)
The classification of the snubber springs shall be class C. (Refer to RSS 0043)

7.2 Free height

The free height for load bearing springs shall be as listed in RSS 0043.
The free height for snubber springs shall be as below.
Equivalent spring types are listed in RSS 0043.

7.2.1 Friction Wedge Spring Data Table

This specification 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

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8 Wheelsets

8.1 Wheel turning

Wheelsets shall be reprofiled in accordance with RSS 0031.

8.2 Wheel replacement

Wheelsets shall be overhauled in accordance with RSS 0031.

9 Adaptors

Adaptors shall be inspected in accordance with RSS 0032.

10 Axleboxes

Axleboxes shall be inspected in accordance with RSS 0032.

11 Constant Contact Sidebearers

11.1 Stuki Type

11.1.1 Identification of Stuki Constant Contact Sidebearers

Figure 50 Model 656CR Figure 50 Model 688BR

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Figure 52 Model 690RL Figure 53 Model 656CRH

Figure 54 Model 675RL Figure 55 Model 685RM

Figure 56 Model ISB3 Figure 57 Model ISB8

Figure 58 Model ISB10 Figure 59 Model ISB12

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Figure 60 Model 656C Figure 61 Model 688B

4”x3” roller 4”x3” roller
656C Cage 688B Cage

11.1.2 Requalification of Stuki Constant Contact Sidebearers

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.

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Figure 62 Figure 63 Figure 64

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 65 is acceptable.
Severe gouging as shown in Figure 66 is not acceptable and the block should be
replaced.
Gouging may be caused by missing end closures. Replace any missing end
closures.

Figure 65 Figure 66
Moderate Gouging OK Severe gouging

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11.1.2.2.3 Top surface wear

Blocks should be inspected for top surface wear.

Figure 67 Figure 68 Figure 69

Rough uneven wear Moderate fastener gouging Severe fastener gouging

Blocks with rough uneven wear as shown in Figure 67 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 68 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 69 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 Overcompressed block condition

Blocks should be inspected for overcompressed 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 70. 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.

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Figure 70 Figure 71
Slight vertical cracking Severe vertical cracking

Excessive permanent bulging is shown in Figure 72. 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 73. Blocks with the top crushed
should be replaced.

Figure 72 Figure 73
Excessive permanent bulging Top crushed

11.1.2.2.5 Free height measurement

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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.

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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 74 TCC 2600 Figure 75 TCC 4500

Figure 76 TCC 8000 Figure 77 TCC 4500RA

Figure 78 TCC 11 35 Long Travel Figure 79 TCC 111-60 Long Travel

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Figure 80 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 dissassembled 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 81,
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 81

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

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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 82. 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 82

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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 715 to 740

this table
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).

12.3 Wheelsets

Wheelsets shall be installed in accordance with the following.

12.3.1 Preparation

All bearings should be inspected in accordance with RSS 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 RSS
0031.
Retention devices shall be installed in accordance with RSS 0040.

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Following installation of the wheelset the brakes shall be regulated in accordance

with Section 12.

12.3.3 Three Piece Bogies

Standard adaptors shall be inspected in accordance with RSS 0032.

Adaptors shall be matched to end caps. For identification of standard type
adaptors see RSS 0041 and for identification of standard package units see RSS
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 83

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 secured in accordance with the requirements of RSS 0063.
Split pins shall be installed to the requirements of RSS 0063.

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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 84).

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.

Figure 84

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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.

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 85. 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.

Figure 85

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

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levers for the most efficient operation of the brakes. It also prevent 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 9.

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 300
casting except as listed in this
table
AVB and BVB 430
CQA CQB and CQC 485
Table 12

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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 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 manufacturers
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.

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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 Standard grey N64 or equivalent
otherwise in this table
Ballast wagons Viking blue B41 or equivalent
Table 13

16 Reference Documents

16.1 RIC Standards

RSS 0031 Wheel & Axle Reference Manual

RSS 0032 Axle Bearing Reference Manual
RSS 0040 Inspection of Freight Bogies
RSS 0041 Bogie DI
RSS 0043 Coil Spring Groups
RSS 0052 Welding of Wear Plates
RSS 0063 Security of Brakegear
RSS 0072 Non Destructive Testing
RSS 0097 Steel Wear Plates

16.2 RIC 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

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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

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