‘bast /Fax: 91-0522-2452494 arereROR RerraTeTT ar aI TAG aggrarraiferonateerrerdTot Telegram : ‘RAILMANAK'Lucknow seas 226011 echheir / Tele: 2465773 (DOT) Government of India - Ministry of Railways 032-42921(Rly) weoherat Research Designs & Standards Organization Email: [email protected] eee No. MWIBVZI December 31, 2013 Chief Mechanical Engineer, Zonal Railways. Sub: Reported Field failures of Bolts of Center pivots in BVZI wagons. Ref: CRSEICR letter No. M.79.C&W.Policy dated 05.12.2013 & 23.12.2013 Reference above, the relevant drgs of BVZI wagons have been cross- checked & the following may kindly be taken note of: (i) RDSO Drg WD-00039-S-08 & WD-11065-S-01 of BVZI wagons, detail the center pivot bolt mounting arrangement. These drgs, only conceptually show the bolt mounting arrangement & include reference to ICF Drg No. T-0-6-601 for details of the bolts/ mounting arrangement. It is hence expected that, ICF Drg No. T-0-6-601, be referred for details on the mounting arrangement. (ii) ICF Drg No. T-0-6-601 (Copy enclosed) apart from detailing the mounting bolts also detail the securing of the mounting bolts using a split pin & lock plate. (ii) CRSE/CR letters (Ref above) indicate that the above securing arrangements of the bolts are not being physically observed in BVZI wagons, in field. It is hence feared that the applicable drgs are not being followed during repair! examination/ even new manufacture. It is hence requested, that the above be kindly looked into & kind instructions be issued to Repair W'shops & examining depots to ensure correct locking of mounting bolts to avoid on-line field failures. For ready reference, a copy of above referred ICF Drg is enclosed ol} D.A- As above, Voges (Rupesh Kohli) DirectorWagon For Director GeneralWagon Copy for Kind Info: * CRSEICR: In Ref to your letter ref above. Your kind feedback is thankfully acknowledged + EDME/Frt/ Rly Bd: For kind info, please.RL 1269 1 AS PER ICF BODY BOLTER DRG No.:T-1-1-731 (ONLY DIMENSION MODIFIED) 4= Nos 7/8” Lock BOLTs TO_BE TACK WELDED] ‘AFTER ASSEMBLY 100 45.5] M=24 HT BOLTS&NUTS 842 FROM R.L 480 362 530 235 CRS 20 Bo ZA [976.2 5°61 40PCD 310 350 H1j0 ll “zys_ IF t 4|= fa LP 120.5 120.5 384 bh (FOR OTHER DETAILS REFER DRG. NO. T-1-1-741) 175 I I TENTATIVE PROCEDURE FOR REPAIR OF CP TOP BRACKET OF BVZI WAGON 530. 438 438 235 CRS 265 102 326 102 530. oN (22 HT_BOLTs @ * Ris S51. IN ITEM-1,12MM THICK U-PRESSING TO BE D.P. TESTED TO ENSURE CRACK FREE. == 2. ALTERNATIVE OPTION IN PROCEDURE Sr. No.4 FOR INSERTION OF BOLTS CAN BE AVOIDED IF SMALLER LENGTH BOLTS ARE USED FOR FASTENING CP TOP PIN WITH BRACKET ATTACHEMENT. ALREADY AVAILABLE HOLES(235 mm CRS) ON CENTER SILL WITH TOP PLATE (ITEM—3) OF THE BRACKET. WELD FILLER PLATE ITEM—4 WITH CENTER SILL ALL—ROUND. FINALLY NUT BOLT THE ATTACHEMENT WITH CP TOP PIN (ITEM—2) AS PER DRAWING. ALL MATING SURFACES OF THE BRACKET TO BE MACHINED/GRIND TO SMOOTH FOR CLOSE MATING OF THE PLATE 10. ALL WELDING WORK TO BE DONE WITH DOWN HAND EXCEPT FILLER PLATE WITH CENTER SILL. REMOVE EXISTING CP TOP BRACKET AND BOLSTER BOTTOM GUSSET COMPLETELY AND GRIND IT TO MAKE SMOOTH SURFACE. MARK CENTRE LINE OF BOLSTER AND DRILL 4—HOLES OF $23.5 mm ON CENTERSILL WITH 438 mm CRS AT CP TOP LOCATION. 3. MANUFACTURE PIVOT BRACKET AS PER ITEM—1 OF THIS DRAWING. INSERT 4-NOS. OF M-24 HT BOLTS IN U-PRESSING ( ITEM-1) OF THIS DRAWING AND WELD U-PRESSING COMPLETELY WITH PIVOT BRACKET TOP PLATE (ITEM—3). 5. FILLER PLATE ITEM-4 IS TO BE WELDED ON ITEM —3 (BRACKET TOP PLATE). 6. NOW FULL ASSEMBLY TO BE LOCK BOLTED (7/8” LOCK BOLT WITH 40 mm GRIP i.e. GRIP No.24) WITH PREVIOUSLY DRILLED $23.5 mm HOLES ON CENTER SILL KEEPING FILLER PLATE TO BE LATERALLY INSERTED IN CENTER SILL AT CP TOP LOCATION AND THE ASSEMBLY ALSO TO BE BOLTED WITH 4—NOS. OF M—22 HT BOLTS ON 327 4 | FILLER PLATE STIFFENERS 2 — ce Pi iOe? an 3 | BRACKET TOP PLATE (530x530x20)| 2 - ce Bo caw 2 | CENTRE PIVOT COMPLETE 2 | T-0-6-601 - (Se) DRG 1 | PIVOT BRACKET 2 - Re ast MODIFIED ITEM) =~ DESCRIPTION Oe REF. ORG.| or} MTL | remarks ONLY FOR PROTOTYPE PRELIMINARY SKETCH APPLICATION UNDER GUIDAN CE OF R.D.S.O. (WAGON)| ALT. ITEM AUTHY. DESCRIPTION DATE ASSLY. DRGS. —— =az{BOGIE BRAKE VAN TYPE ‘BVZI’ vs el} CENTRE PIVOT TOP BRACKET coset ——— [REPAIR PROCEDURE OF OLD DESIGN BRACKET) B.G. | Reso. [orour T WD-11065-S-01Y 7 | A 3 | | | | 1 N AS PER ICF BODY BOLTER N DRG No.T-1~1-731 S | _ (ONLY DIMENSION MODIFIED) x -i — ' ===E==8 —— 8 J Y So wD TO BE TACK WELDED gs} > at = \rrhZ Sst | | | | SSSESSI | | 2 peers | | w M24 HT BOLTS&NUTS I i é 4 | == | | al S= iL 8/3 =e 7 2) & g SS “S a3 x T S| I & I i. + | | 3 | 2} | 5 vo “ S| z = oO fe ~ BOGIE BOLSTER aS Se 2 2 Xt = 1600 CRS OF SIDE BEARERS 186 8 t 8 3 aL (FOR OTHER DETAILS REFER DRG. NO. T-1-1-741) a @ WD-00039-S—05 _ 2 5 | FILLER PLATE STIFFENERS = 00058- s 3g 3g @)| 4 | FILER PLATE (400x327x20) - re tio WA 2 3 | SIDE BEARER By) T-1-1-741 - (Se) DRO NOTE n 2 | CENTRE PIVOT COMPLETE T-0-6-601 - (Se) DRG * 5 y ICF DRG. 1. THE LENGTH OF SIDEBEARER HAS BEEN INCREASED FROM 273 mm. TO 319 mm. AS SHOWN IN THE DRG. PIVOT BRACKET = t=1=1-751__|_MODIFED . Wh) MTL & 2. IF REQUIRED SUITABLE PACKING MAY BE GIVEN BELOW AXLE BOX SPRINGS AND BOLSTER SPRINGS TO DESCRIPTION REF. ORG.| oF | spec __ | REMARKS © ~ waivtaiy COUPLER HEIGHT. ONLY FOR PROTOTYPE APPLICATION or IN ITEM-1 , 12MM THICK U-PRESSING TO BE D.P. TESTED TO ENSURE CRACK FREE. PRELIMINARY SKETC UNDER GUIDANCE OF R.0.S.0. (WAGON) ISUPERSEDED BY e > SUPERSEDES OME BOGIE BRAKE VAN TYPE ‘BVZI ISCALE|PASSED |A N MEHTA |9/2009) ™ CHECKED|J.AHMAD _ [9/2009] 1S [DRAWN |p x Tiwari|9/2009] CENTRE PIVO I AND TRACED ama! _| SIDE BEARER ARRGT. 1 PIVOT BRACKET CHANGED AND DRG. = REVISED & REDRAWN, NOTE MODIFIED. B GC R.D.S.O. GROUP WD 00039 _ S- 06 ITEM DESCRIPTION ASSLY. DRGS. «> [W7 B _ 3/2002“ [B__12/2000 —~[@ 4/2000 5/98 So ve |O Bees |O 2/0 [Ou77|® a7 © 575 |® v7 @ sn Osea s/s DESCRIPTION OF wie 7 TOOL [7 ROUGH wacHNeD [@) ROUGH CLEANED ALTERATIONS T—O-6—-60 GN. FoR wesczAc/s | GTY. FOR WGSCZACS 4GTY. FOR ARMY ADDED] GTY FAR DMUZsed ac | Gry. FOR ARMVAC| GTY. FOR LR | ORAWNG | DRAWING e_fary. FoR oD apoen | Gry. FOR ary. FoR WLARMA Gry. FOR WARM wy scan @ o 70786 WGSCZ/J&SR/J ADDED| WGSCZAC6 ADDED IN | IN COL.IL wus Te pe ADDED IN COLI. | DELETED IN RETRACED. | RETRACED. | SLR ADDED | IN COL.II WITH ASSY. | WGFSCZAC | ADDED IN COL.IL ADDED IN COL.| WITH FINISH MACHINED GHMFERED IN coLa cout e oui Ado=D| WWCALIE | BRGNe.DO-O-S=002,| ADDED IN | ASSY.OAG NowwiLRM | Ce ‘ASSY.ORG No. LRRD ao > DRAWING RETRACED AND ofr. tact oes 0-55 ‘ADOE IN COLI COLI. —0-5-401 ADDED. ct -0-5-201, FINE FINSH MACHINED _|@) BURRS REMOVED REVISED TO SUIT 1_RM. SIZE ,WDCBAG, WOCRAC a2 sse:s4.2.5.02Swe/80 | ssr/asd, suc/ansd|sse/asd sMe/apsdlasé/e: sweep | sp: sa. D: Sd, pa_sa, |epa: sa, Los .Lopa: sa, DASd,.26/5| CDA: _$4.03.12,74 DA:_$4,20.08.69 BP ERNGED ORO, Saf a BND WOoeAE ADDED IN COLL @ 6/2000 IO 5769 115/28 To. e10nB088-1578 DRAWING REORAWN IN CAD. | aTy. FOR BG/S WITH corTEN | TAB:1 TO IS:549-61 ‘SSE/D Sd/-28.6.02 SME/BD MAT.SPEC. FOR ITEMS—5,8,11 | STEEL BOGIE ADDED IN COLII| CDA: Sd. —_ 13, UPDATED. aTy. FOR WLRRNG| WITH ASSY. DRG. NosT=O-5— To oa ‘ADDED IN COLL 701. ITEMS—24,25,26&27 © f ‘ADDED. COLI WITH ITEMS—14 TO 18 A So S&_08.0589 __) ATE ADDED, BWENGION. FOR 1205 120.5 SSE/S: Set SuE/80: le 9/90 TEM~5.ALTERED FROM #10e : lO 10/2000 80 TO 010x100. SIZE OF a 28 Gry. FOR WGSCWAC ADDED IN | SPRING WASHERS OF TEM-8,1) 3 TIGHTENING TORQUE SHALL BE 66 Kgf-m LocaTING OM. OF rem=28 | COLL. IS:2075~62C.20 DELETED) ani METRICISED g FROM SECN. OF tTews~i6art?.| 2 se so BE TACK WELDED 7 THE FOLLOWING. MAT-&SPECN 2PTeR ASSEMBLY 1] | 14 ARMIN 7 WNT, 5 ALTERED, © 9/73 V + Ta x, oe : ee ne ALTERED. FAOM MEX. Hb, 16 l 4 nf | 7 Yis1363-87 ]sy384297] Sotr‘\ipanzx95 TO. HEX. HD. + “s Y Mo ANAC >} - RTS - 8 TAB.3) SCREW M24x2x100 AND SPEC, GE A Zi Wz gags Mi .yxy BSSSSS pee or a wasrHCMO] centre Pivot PIN 1 |t-0-6-602 © owustes, omu/ores SPFAG 0-500 No. OFF DESCRIPTION & BWENSIONS [mew | EFORS [WAIL SPEC REMARS —wraes 65 —36e— | * [Dou] wi] w]v [wm] [1 [onour: centre pwor areancewenT SUPERSEDED BY SECTION—AA aaMa_6-5 26) SUPERSEDES 1-06-8601 AR P/AA WeRRNO—5— 00 55/8 T SOE [59 18/2 CENTRE PIVO ow —0-5662— 6-560 ae ARRANGEMENT cee eee eléle mW | Ravan — 8 8 ale |e ane I ASSEMBLY DRAWINGS CHD FUE: 6 WO CHD\000\0-B\6OT_SST7_OWE WiEGwL concn FacvoR® DATA CODE Chena —600 038 omlalalogg INDIAN RAILWAY | ser tors —0-6_— a cake | 870 il STANDARDS J—0—6—601 FORM IR At 840 x 600