File No.

RDSO-MW0BD(CSNB)/1/2020-O/o PED/SW/RDSO-Part(1)

Hkkjr ljdkj &jsy ea=ky; Government of India - Ministry of Railways

vuqla/kku vfHkdYi vkSj ekud laxBu Research Designs & Standards Organisation
y[kuÅ & 226011 Lucknow – 226011
Fax : 91-0522-2452494 DID (0522)2450115
Tele/Fax: 0522- 2465773 DID(0522)2465310

No. MW/PLNG/CSNB/I Dated: 18.09.2024

All Bogie Manufacturers,

(As per Attached List-UVAM)

Sub: Revision of specification for CASNUB 22HS /22HS (M)/RFT Bogie No. WD-17-
CASNUB-22HS-BOGIE-92 (Rev.04)

1. The specification WD-17-CASNUB-22HS-BOGIE-92 (Revision –3) (Amendment

No.-6 of July 2020) has been revised to WD-17-CASNUB-22HS-BOGIE-92
(Revision –4) of September 2024. The final revised specification is now available
on the RDSO website and is also attached for your reference.
2. The deadline for transitioning from WD-17-CASNUB-22HS-BOGIE-92 (Revision
–3) (Amendment No.-6 of July 2020) to WD-17-CASNUB-22HS-BOGIE-92 (Rev.4)
is set for 17th December 2024. During the interim period, inspections of CASNUB
22 HS Bogies may be conducted according to either the previous or the revised
specification.
3. All bogie manufacturers are required to upgrade their infrastructure, materials,
and related aspects in accordance with the revised specification on or before
17.12.2024. Additionally, the revised Quality Assurance Plan (QAP) must be
approved by RDSO prior to regular production as per the revised specification.
4. The revised specification also includes provisions for the RAFTAAR Bogie
(CASNUB 22 RFT) and the modified CASNUB 22 HS (M) Bogie. The CASNUB 22
RFT will be governed by the same RDSO Specification WD-17-CASNUB-22HS-
BOGIE-92 (Revision –4). Notably, the CASNUB 22 RFT, CASNUB 22 HS (M), and
CASNUB 22 HS Bogies are essentially identical, with differences outlined in
Annexure-I. This shall be implemented with immediate effect. However,
CASNUB 22 RFT and CANUB 22 HS (M) can be manufactured as per existing
specification No. WD-17-CASNUB-22HS-BOGIE-92 (Rev.03) amd. till 17.12.2024
duly incorporating the design differences outlined in the revised specification.
5. The vendor status for CASNUB 22 HS will apply equally to CASNUB 22 HS (M)
and CASNUB 22 RFT for manufacturing and supply. The vendor directory has
been updated accordingly.

DA: As Above

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 File No.RDSO-MW0BD(CSNB)/1/2020-O/o PED/SW/RDSO-Part(1)

(A.K. Gautam)
Director/Wagon
for Director General/Wagon
Copy to:

(1) PED/RS, RDSO, Lucknow-for kind information please,

(2) EDME (Freight)/ Railway Board -for kind information please,
(3) Executive Directors/QA (Mech.)- for kind information and n/a please,

i) Shankar Market, Near IRCOT Building, New Delhi-110 001.

ii) 3, Koilaghat Street, Kolkata-700001.
iii) 1st floor, New Annexe Building, Western Railway Churchgate, Mumbai
400020

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 File No.RDSO-MW0BD(CSNB)/1/2020-O/o PED/SW/RDSO-Part(1)

Annexure-I

Design Differences between CASNUB 22HS BOGIE and CASNUB 22RFT Bogie

Sr. Description CASNUB 22HS Bogie CASNUB 22RFT Bogie

No.

1 Spring WD-92058-S/5 WD-22055-S/1,2,3 &4

Details Drg.
Secondary suspension details

No. of spring Outer Inner Snubbe Outer Inner Snubber Snubber

per bogie r (O)
(I)

14 14/12 4 14 14 4 4

Stiffness per 466.33 kg/mm 266 kg/mm

bogie (Tare)

Stiffness per 952 kg/mm OR 882.5 785 kg/mm

bogie kg/mm
(Gross)

2 Side Bearer As per CPSB drg. of As per CPSB drg. of wagon

wagon
(Spec. No. WD-62-MISC-17)
(Design A to RDSO
Spec. No. WD-38-MISC-
2004)

3 Bolster WD-92058-S/3 WD-22091-S/4

4 Friction Wedge SK-77579 WD-22055-S/5

(WD-17-CASNUB-
22HS-BOGIE)
(CONTR-02-Misc-2007

5 Spring Plank WD-92058-S/4 WD-22091-S/3

6 Marking CASNUB-22HS (Red CASNUB-22 RFT (Sky blue code

oxide to IS:13607) no. 101 to IS:05 2007)

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INDIAN RAILWAYS

SPECIFICATION

FOR

CASNUB 22 HS/CASNUB 22 HS (M) / CASNUB 22 RFT

CAST STEEL BOGIES
WITH FRICTION DAMPING ARRANGEMENT
FOR
BROAD GAUGE WAGONS

WD-17-CASNUB-22HS-BOGIE-92

(Revision –4)

Issued by:
Research Designs and Standards Organization
Ministry of Railways
Manak Nagar, Lucknow - 226 011.

Sept 2024 Price: Rs.-

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Contents
1.0 GENERAL .......................................................................................................................... 3
2.0 SCOPE OF SUPPLY .......................................................................................................... 4
3.0 SPECIFICATION............................................................................................................... 5
4.0 GROUPING OF COMPONENTS ................................................................................... 6
5.0 BOGIE ASSEMBLY REQUIREMENTS .......................................................................... 7
6.0 DRAWINGS ..................................................................................................................... 10
7.0 DEVIATIONS .................................................................................................................. 11
8.0 CHEMICAL COMPOSITION & MECHANICAL PROPERTIES............................. 11
9.0 INSPECTION ................................................................................................................... 11
10.0 DISPATCH ....................................................................................................................... 13
11.0 “AS MADE” DRAWINGS ............................................................................................. 13
12.0 PROCESS FOR VENDOR REGISTRATION AND PROTOTYPE TESTING.......... 14
13.0 QUALITY ASSURANCE PROGRAMME ................................................................... 15
14.0 QUALITY AUDIT ........................................................................................................... 17
15.0 OTHER REQUIREMENTS............................................................................................. 17
16.0 CLARIFICATIONS ......................................................................................................... 18
17.0 WARRANTY.................................................................................................................... 18
ANNEXURE –I ........................................................................................................................... 19
ANNEXURE –IA ........................................................................................................................ 33
ANNEXURE –II .......................................................................................................................... 35
ANNEXURE –III ........................................................................................................................ 36
ANNEXURE –III A .................................................................................................................... 37
ANNEXURE –III B ..................................................................................................................... 38
ANNEXURE –IV ........................................................................................................................ 39
ANNEXURE –V.......................................................................................................................... 40
ANNEXURE –VI ........................................................................................................................ 41
ANNEXURE –VI A .................................................................................................................... 42
ANNEXURE –VII ....................................................................................................................... 43
ANNEXURE –VIII ..................................................................................................................... 44
ANNEXURE –IX ........................................................................................................................ 45
ANNEXURE –X .......................................................................................................................... 62
ANNEXURE –XI A .................................................................................................................... 68
ANNEXURE –XI B ..................................................................................................................... 69
ANNEXURE-XII ......................................................................................................................... 70

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1.0 GENERAL

1.1 In the quest to improve the riding characteristics of freight vehicles and the
reliability of freight bogies, in 1969-70, Indian Railways decided to develop a
design for a cast steel version of the SOFT RIDE BOGIE that would perform well
on Indian Railway tracks. This effort resulted in the development of the
CASNUB bogie. The CASNUB bogie consists of two cast steel side frames
connected by a spring plank to maintain the bogie's squareness. The bolster
springs rest on this plank and support the bolster. The bogie is equipped with
two friction wedge snubbers on each side, which provide a damping force
proportional to the weight. The body weight is transferred to the bogie through
an IRS spherical center pivot and a bottom pivot integrally cast with the bolster.
Later designs featured a separate type of bottom pivot. Roller-type side bearers
are provided on each bogie bolster to control body roll and tilting on curves,
enhancing the stability and performance of the freight vehicles.
1.2 The bogie was further improved by enhancing the bolster, which was given a
fish belly profile. The depth of the bolster section was increased while the wall
thickness was reduced. For the side frame and bolster, special alloy cast steel was
used instead of IS: 1030. This superior metallurgy allowed for a reduction in the
wall thicknesses of both the side frame and the bolster, enhancing the overall
performance and durability of the bogie. The modified Bogie was called as
CASNUB 22 NLB.
1.3 In 1990, an exercise was undertaken to analyze the design parameters of the
CASNUB bogie in detail, with the goal of evolving a design suitable for an
operating speed of 100 kmph on Indian Railway tracks. The results of various
oscillation trials conducted on the BOXN wagon with CASNUB bogies were
studied and analyzed extensively. The suspension springs were redesigned to be
softer when empty and stiffer when loaded, ensuring that the inner springs
remain inactive in tare condition. The bolster gib clearance was increased from 9
mm to 12.5 mm to dissipate more energy when the bolster hits the side frame.
This effort led to the development of the CASNUB 22 HS bogie.
1.4 To increase the speed potential of all freight stocks to 100Kmph, in 2017-18,
Indian Railways had initiated a project “Project Mission Raftaar”. An extensive
exercise of envisaging suitable modification in the suspension of the freight bogie
was carried out by RDSO to upgrade the speed potential of majority of fleet to
100 Kmph on Indian Railways network.
1.5 In the first phase, the existing suspension of CASNUB 22 HS was modified to
upgrade the speed potential of Wagons. The modification includes reduction in
the number of the existing secondary springs, replacement of Side Bearer by
Newly Designed long travel Constant Contact Side Bearer (CCSB) to RDSO
specification WD-62-Misc-17 and replacement of Friction Wedge by Specified
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Coefficient of Friction Wedge to RDSO specification CONTR-02-MISC-2007. The

modified CASNUB Bogie is called as CASNUB 22 HS (M). The difference
between CASNUB 22 HS bogie and CASNUB 22 HS (M) bogie is indicated in
Annexure-XIA. The wagons fitted with this bogie are BOXNRHS, BOXNHSM2,
BOXNLWM2, BOBRNHSM2, BOBYNHSM1, BRHNEHSM1, BRN22.5M1,
BFNSM1, BTFLNM1 etc.
1.6 In the second phase, the wagons which were heavier and longer, such as covered
type wagons, tank wagons and few hopper type wagons were upgraded by a
completely new suspension system which includes newly designed Secondary
Suspension Spring to RDSO drawing WD-22055-S/1 to S/4, Side Bearer to RDSO
Specification WD-62-Misc-17 and Specified Coefficient of friction Wedge to
RDSO specification CONTR-02-MISC-2007 to upgrade the speed potential of
these wagons. The modified CASNUB Bogie is called as CASNUB 22 RFT. The
difference between CASNUB 22 HS and CASNUB 22 RFT is indicated in
Annexure-XIB. The wagons fitted with this bogie are BCNAHSM2, BCNAM2,
BCNM2, BCNHSM2, BTPNM1, BOBRNM2, FLAT COIL-3 etc.
1.7 This Specification covers the technical requirements for the manufacture and
supply of light weight CASNUB 22 HS/ CASNUB 22 HS (M)/ CASNUB 22 RFT
Cast Steel Bogies fitted with a spring plank, long travel helical springs and load
proportionate friction damping arrangement for Broad Gauge (1676 mm)
Wagons. It has been kept optional to assemble `Flat Centre Pivot` to RDSO Drg.
No. WD-97049-S/3 in place of conventional hemispherical Centre pivot to RDSO
Drg. No. WD-85079-S/2.
1.8 These bogies shall be suitable for fitment of standard wheel sets to RDSO’s
drawings No. WD-89025-S/1, Cartridge bearings to AB/RB-39-2002 (Rev. Latest)
and Elastomeric pads to Specification No. WD-20-Misc.-95 (Latest Version). The
constant contact side bearer (CCSB) assembly shall be as per CPSB arrangement
drawing of wagon where the CASNUB 22HS/ CASNUB 22 HS (M)/CASNUB 22
RFT Bogie is to be fitted and shall be manufactured as per the relevant RDSO
specification of the CCSB. RDSO Technical Pamphlet G-115 for fitment of Side
Bearer and CPSB arrangement drawings may also be referred.

2.0 SCOPE OF SUPPLY

2.1 The bogies shall be supplied complete with center pivot assembly components as
per relevant drawings, constant contact side bearer approved by RDSO and
brake rigging including brake shoes, elastomeric pads etc., but without wheel
sets, bearing, narrow jaw adapters, side frame key and side frame key bolt, nut
and washer which shall be supplied by the purchaser free of cost for fitment on
the bogies. The bogie center pivot top and other bogie components should be
properly secured with the bogie during delivery.
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2.2 The bogie manufacturer must adhere strictly to the specifications outlined in the
relevant Center pivot and Side Bearer arrangement (CPSB) drawing of the
Wagon. RDSO Technical Pamphlet G-115 may be referred for fitment of Side
Bearer and CPSB arrangement drawings. Additionally, the Firm shall approach
RDSO for latest drawings and details. The Constant Contact Side Bearer (CCSB)
must be manufactured in accordance with the drawing and specifications
provided in Annexure-IIIB.
2.3 Since, these bogies are to be used under different types of wagons with different
tare weights, to maintain designed load sharing requirement, the center pivot
and side bearer arrangement drawings pertaining to the particular wagons are
required to be referred to and the following dimensions are to be strictly
maintained under tare condition.
+𝟐
a. Bogie bolster top to top center pivot top = 120 .
−𝟎
Centre pivot top to side bearer seat on bogie bolster – as per relevant
Centre pivot and side bearer arrangement drawing of the wagon.
b. The difference between top of the Top Centre pivot to bottom of Body side
bearer (this dimension may change after shim adjustment as per relevant
drawings).
The bogie general arrangement may also be different for different type of
wagons as the heights are to be adjusted by means of packings. However, this
specification contains list of the construction drawings and load testing methods
of BOXNHS/BCNHS wagons with CASNUB 22HS/CASNUB 22 HS (M) Bogie
and CASNUB 22 RFT Bogies in Annexure – VI and Annexure-VIA respectively.

3.0 SPECIFICATION

3.1 The bogies and its components shall conform to this specification, relevant
drawings with latest alteration number, and latest relevant specifications. In case
of conflict among the STR/Drawings/Other Specifications, the drawings shall
take precedence over the STR and the Specification. The specification shall take
precedence over the STR.
3.2 The foundry should satisfy the requirements of Class “A” foundry as per IS:
12117:2023 (latest) specified for all the cast steel items and updated by the Bureau
of Indian Standards/RDSO from time to time.
3.3 For Infrastructure, manufacturing, testing and quality control requirement of cast
steel components and other components included in this specification, the
suppliers should comply the technical requirement as laid down in the following
table:

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S. Component STR No. (Latest)

No.
1 Cast steel components of CASNUB bogies QMS–09:2015
2 Metal Bonded Rubber Components-Elastomeric QMS–05:2000
pad
3 Spring steel rounds to RDSO Spec. No. WD-01- QMS–16:2000
HLS-94
4 Hot/Cold coiled helical spring for freight, QMS–17:2000
coaching & Locomotives
5 Silico manganese liners QMS–22:2009
6 Spring plank QMS–23:2009
7 Side frame key QMS–24:2009
8 Brake beam QMS–25:2009
9 Narrow jaw/wide jaw &Modified adapter QMS–26:2017
10 Metal bonded rubber components QMS–06:2000
11 Center pivots, End piece & Strut casting, wedge. QMS–20:2009

3.4 Firm shall generally follow the infrastructure, manufacturing, testing and quality
control requirement mentioned in this specification. However, the supplier can
also offer alternate process infrastructure, manufacturing, testing facilities. Firm
shall submit the detailed test report, documentary evidences, and the
justification/ evidence to establish that the same can provide consistent output to
desired level of output/ accuracy/ performance of the offered solution vis-à-vis
specified in the specification to Director General (Wagon)/RDSO, Lucknow for
obtaining approval before use.

4.0 GROUPING OF COMPONENTS

Various components, which form the bogie assembly, are grouped as given
below. Details of components in each group are detailed in relevant Annexure as
indicated below against each group.
Group Components Reference details
I Cast components Cast steel - Side frame, bolster, top & bottom
Centre pivots, brake beam strut and end pieces and
wedges (Annexure No. I and IX).
II Spring Steel Outer, inner, snubber springs (CASNUB 22 HS/
CASNUB 22 HS (M))/ Outer, inner, snubber outer
and snubber inner springs (CASNUB 22 RFT) ,
Brake Wear Plate, Brake beam liners, side
frame/bolster liners & center pivot liners
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(Annexure No.-II and IX).

III Rubber Elastomeric pads and Centre pivot washer,
Components (Annexure No. III).
IV Forged Side frame key, rivets and various types of cotter
Components & pins, lock bolts (Annexure No. IV.)
Fasteners
V Fabricated Various types of steel components, machined,
components formed, welded and pre-assembled like brake
beam, spring plank etc. (Annexure No. V).
VI Composite material Brake block L & K type (Annexure III A).
components

5.0 BOGIE ASSEMBLY REQUIREMENTS

The detailed procedure of bogie assembly is given below –

5.1 Gauging of Bolster & Side frame:
This is to be done on 100% of Bolster and Side frame. Only those castings which
are found within the specified dimensions should be taken up for assembly and
the rest rejected. Investigations should be made for the reasons of dimensional
inaccuracies; causes arrived at, remedial action introduced and defect rectified.
Bolster and Side frame should be inspected for all the important dimensions as
per the gauging scheme approved by RDSO before offering for inspection or
taking up for assembly and results recorded.

5.2 Welding of Liners:

Welding of all the liners on side frame shall be done before taking up side frames
for riveting. Welding of liners on bolster shall also be completed before taking
them up for assembly. Welding procedure to be followed as indicated in
Drawing No. WD-92058-S/3 (latest) & WD-92058-S/4 (latest) in CASNUB
22HS/CASNUB 22 HS (M) bogie and Drawing No. WD-22091-S/4 & WD-22091-
S/3 in CASNUB 22 RFT bogie respectively. Following steps have to be taken to
ensure proper quality:
i) Welds shall be visually inspected for any weld defects. Use of correct
electrodes, welding current setting, welding voltage, welding speed and
correct welding procedure has to be ensured. Welding parameters should
be standardized and its implementation ensured.
ii) Welding of liners shall be carried out on suitable fixtures so that down
hand welding can be ensured.
iii) Surface on which liners are welded shall be smooth and flat providing
proper seat. Also, Pocket for Side frame liner shall be correctly formed in

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the casting. Castings having imperfect pockets on the Side frame shall be
rejected.
iv) Welders or weld operators must be qualified in the specific welding
positions that will be used, for the materials, processes, and procedures in
accordance with AWS D15.1 or an equivalent standard. Relevant
drawings of the components must be referred to for details on welding
procedures, materials, and other requirements. The complete welding
process, material specifications, and quality parameters, including all
checks and measures, must be incorporated into the Quality Assurance
Plan (QAP).

5.3 Matching of Side frame:

Side frames which have been duly inspected, gauged and passed shall be taken
up for assembly. These shall be matched for wheel base according to RDSO’s
Drawing No. WD-89067-S/3. Crack detections (Annexure-I) and weld
reclamation (Annexure- I A) should also be completed before proceeding to next
stage. No welding is permissible after this stage on Side frame as well as on
bolster.

5.4 Riveting:
After selecting the side frames, these should be taken up for riveting with spring
plank. Before riveting it shall be ensured that pop marks are placed on the side
frames as per Drawing No. WD-89067-S/3. Stepwise procedure of assembly of
H-frame is given below :
i) Side frame holes shall be drilled using accurate jigs.
ii) The two side frames of same number button head shall only be chosen for
assembly of bogie and spring plank should be positioned on a fixture and
fastened rigidly.
iii) Four holes shown in Item No. 1 in drawing no. WD-92058-S-4 / WD-22091-
S-3 (spring plank) should be reamed along with the side frame and
secured by M-24 fit bolts as per IS: 3640. In case any mismatch between
spring plank holes and side frame holes is observed visually, detailed
check of side frame, drilling Jig and spring plank shall be made before
proceeding further. Riveting should be done as per IS:7215 Group –B.
iv) The riveted H-frame shall be gauged and dimensions recorded for
diagonals and side frame –to-side frame over pop-marks on the fixture
and again after removing from the fixture as per Para 5.
v) Regular calibration of jigs and fixtures by an authorized agency shall be
ensured. Coordinate Measuring Machine or an alternate approved system

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is necessary to maintain the accuracy of the product and gauges at

specified intervals (Prescribed by OEM or six months whichever is less).
vi) Alternatively, manufacturer can use suitable size lock bolts in lieu of
riveting with prior approval of DG(Wagon)/RDSO.

5.5 Gauging of H-Frame:

After completing the riveting, the side frame – spring plank assembly (H-Frame)
should be gauged on the fixture as per Drawing No. WD-92058-S/7 and results
recorded. It has to be ensured that all dimensions are within the specified limits
otherwise the assembly should be dismantled, re-inspected to find the causes of
any variation and then redone after eliminating those causes.
The gauging shall again be done on the assembly after removing the side frame-
spring plank assembly (H-Frame) from the fixture. This is to be done on 100% of
H-frames.

5.6 Assembly:
Assembly of bogie shall be taken up after completing the activities specified in
Para 5.5. It has to be ensured that all components have been checked as specified
in respective Annexures.

5.7 Dimensions:
The leading dimensions and tolerances of the bogies shall be in accordance with
RDSO’s Drawing No. WD-92058-S/7 (latest).

5.8 Load Testing of Bogie Assembly:

The bogies shall be tested for the loads representing tare, gross load and 50 %
overload conditions as per the details given below:
(a) For CASNUB 22 HS/CASNUB 22 HS (M)
Test load on bogie pivot in tons Tare Gross 50% overload
(7-6-2) 6.0 T 35.30 T 53.0 T
Height of center pivot from RL in 932 +3 895
+3
875
+3
−8 −8 −8
mm

(b) For CASNUB 22 RFT

Test load on bogie pivot in tons Tare Gross 50% overload
(7-7-2-2) 7.0 T 40.40 T 60.6 T
Height of center pivot from RL in 932 +3 880
+3
854
+3
−8 −8 −8
mm

Frequency of this test shall be as detailed below:

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i) 100% checking of Assembled Bogies under tare.

ii) 5% checking of Assembled Bogies under gross load and 50 % overload.

RDSO Inspector/ inspection authority shall carry out random load testing to the
extent of 5% of Assembled Bogies under tare, gross load and 50 % overload
conditions. These bogies shall be other than mandatorily tested as mentioned
above.

5.9 Bogie fitted with brake gear components of BMBS to drawing No. WD-08093-S/2
does not require the existing brake gear components to drawing No. WD-89067-
S/5 (except wear plate at S.No.-8).

5.10 Painting:
Inspected bogies shall be thoroughly cleaned to remove rust, scale dirt etc. In
case the time gap between the last shotblasting of the component and painting is
more than 24 Hours or there is a sign of surface deterioration due to rusting etc, a
final round of shot blasting shall also be carried out prior to the painting and
apply paint on each surface as per following schedules:
(a) Each bogie shall be given red oxide zinc chromate primer to Specification
IS: 2074 followed by one coat of ready mixed paint to IS:13607 color red
oxide to code no. 446 of IS: 05 2007 (For CASNUB 22 HS Bogie/CASNUB
22 HS (M)) and Blue color (sky blue) color code no. 101 to IS:05 2007 (For
CASNUB 22 RFT Bogie). The CASNUB 22 HS (M) Bogie shall further be
marked with Zebra marking on the side frame as indicated in the Wagon
Marking Diagram/ Bogie General Arrangement (GA) Drawing. Mating
faces of pivots and liners will not be painted.
(b) Bogie components shall be spray painted by use of electrostatic spray run
/ spray / normal spray. The finishing coat shall be applied when the
priming coat has dried. The dry film thickness of the primer shall not be
less than 40 microns and the complete system inclusive of finishing coat
not less than 80 microns. Record of painting process and DFT shall be
maintained.
(c) The inspecting officials shall check the quality of paints that will be used
as per relevant specifications once in two months or after painting of
every lot of 200 bogies.

6.0 DRAWINGS

CASNUB 22 HS Bogie/CASNUB 22 HS (M) shall be manufactured according to

latest RDSO’s Drawings No. WD- 04038-S/2 or WD-04078-S/1 and relevant
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drawings listed in Annexure VI. CASNUB 22 RFT Bogie shall be manufactured

according to latest RDSO’s Drawing Nos. WD-22091-S/2 and relevant drawings
listed in Annexure VIA.

7.0 DEVIATIONS

Where deviations from the original design, material specifications, dimensions

etc., are desired, specific proposals shall be submitted for prior approval of the
DG (Wagon), RDSO/Lucknow before commencement of manufacture.

8.0 CHEMICAL COMPOSITION & MECHANICAL PROPERTIES

The bogie side frame & bolster shall conform to the Material specification and
properties as laid down in Annexure-VIII. Class I tolerances to IS: 4897 shall be
followed on wall thickness wherever the tolerances are not specified.

9.0 INSPECTION

9.1 Inspecting authority shall mean RDSO or any other agency decided by the
Purchaser in accordance with the requirements of this schedule, approved
drawings and relevant IS specification. IS specifications other relevant
specification referenced are listed in Annexure VII. The list is, however, not
exhaustive.
9.2 Firm shall at his own cost supply all labour, appliances, details and gauges
necessary for the testing and inspection of the bogies. Firm will design his own
gauges for the bogie and its components wherever necessary. These gauges shall
be approved by the RDSO before commencing series production.
One complete set of gauges embossed `RDSO’ shall be kept at the Firm premise
and shall be handed over to inspecting official at the time of inspection.
9.3 The purchaser’s inspecting official, auditor or any authorized representative shall
have access to all quality related documents i.e. manufacturing process details,
quality control, procedures, records, test results, standardized proforma etc.
9.4 Quality of all the castings produced and its workmanship shall be appropriate to
the importance of these castings and any aspect considered by the inspecting
officer as detrimental to the safety and efficient performance of the components
shall be sufficient reason for rejection of the castings.
9.5 The inspection of Side Frame and Bolster shall be carried out before painting. It
shall be a part of stage inspection. The painting of the side frame and bolster shall
be completed within 24 Hours of the final shot-blasting. The bogie shall be
offered for final inspection after painting.
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9.6 Following inspections shall be done by the inspecting officer and results
recorded in addition to any other inspection which may be done by him.
9.6.1 Inspection of side frame and bolster – steel castings- shall be governed by
Annexure-I and also details given under para on “Bogie assembly requirements”
(Para 5).
a) Each cast has to be cleared by the Inspecting Officer on the basis of tests
indicated at para 1.10, 1.11, 2.0, 6.0, 8.0 of Annexure-I.
In addition to above each cast shall also be checked/tested for chemical
composition, mechanical properties and hardness test to conform the
requirements/parameters as given in Annexure –VIII.
b) Tests indicated at Para 7.0, 9.0, 10.0, 11.0 & 12.0 of Annexure-I are in the
nature of audit check and reflect on the quality of manufacturing process.

9.6.2 Gauging of H frame shall be done on 10% of the frames assembled, as per para 5
of this specification.
9.6.3 All components as per Annexure-IX are to be inspected as per details given in the
respective Annexures of the component. This is to be done by random sampling
on components received by Bogie Manufacturer. If any sample among the test
pieces drawn fails, then double the number of test pieces drawn earlier shall be
again selected and tested. If the `Double’ sample passes the tests, lot shall be
considered acceptable. Should any of the samples fail in the “Double” sampling,
the complete lot shall be rejected. No further inspection shall be carried out until
the firm has investigated and come up with satisfactory reason for the failure as
well as the remedial action to improve the quality of material and also
implemented the same. A certificate to the effect that the remedial measures
suggested by the firm have been implemented must be furnished by the
Inspecting official to the DG (Wagon), RDSO, Lucknow for approval before
undertaking inspection again.
9.6.4 In the event of rejection, the entire lot offered for inspection shall be made
unusable for Railway application in the presence of the inspecting /purchasing
authority. The methodology of making such lot unserviceable shall be part of
approved QAP.
9.6.5 The Inspecting officials shall also conduct Process/Stage inspection on monthly
basis or as decided by DG/wagon, of different Process/Stages of production as
per the approved QAP. The approved QAP/stage inspection shall cover but not
limited to following process/stage of manufacturing.
i) Incoming Raw Material
ii) Methoding and Mould-Core Preparation
iii) Melting and Pouring of Molten Metal
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iv) Knock-out
v) Fettling
vi) Shot-blasting
vii) Weld Reclamation if any as per guidelines in this specification
viii) Heat Treatment
a) Rate of Heating
b) Soaking Time
ix) Painting
x) Testing and Gauging
xi) Finished Side frames and Bolsters
xii) Drilling of Side frames and riveting with Spring Plank
xiii) Welding of liners
xiv) Matching of springs
xv) Constant contact side bearer assembly
xvi) Record keeping by the vendor at different stages of manufacture

10.0 DISPATCH

10.1 Manufacturer shall ensure that assembled bogies are handled carefully so that no
distortion of spring planks takes place. The bogie shall be loaded carefully on
the trucks/wagons and properly strapped so that no shifting can take place.
Loading scheme shall be got approved by DG (Wagon)/RDSO.
Care shall also be taken while unloading the bogies to ensure that no damage
takes place.
10.2 The items which are dispatched loose along with the bogie i.e. Elastomeric pad,
etc. shall be properly secured to ensure that no damage takes place during
transit. Bogies shall be sent in assembled condition with all components (CP top,
CP pin, CP washer, shackle lock and lock pin etc.) as per drawing to avoid
possibilities of missing/mixing of components and also ensure to avoid any
damage during transit.
10.3 Manufacturer shall ensure that Constant contact side bearer assembly is properly
secured to avoid the springs and side bearer seat falling off during transit.
10.4 Methodology of packing and securing for transport shall be part of approved
QAP.

11.0 “AS MADE” DRAWINGS

11.1 The bogie suppliers shall supply of CAD drawings of “As Made” drawings
followed in the manufacture of the bogies where deviations from the original
design, material specifications and dimensions etc. have been adopted.

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12.0 PROCESS FOR VENDOR REGISTRATION AND PROTOTYPE TESTING

All manufactures seeking approval for supply of CASNUB 22HS/CASNUB 22 HS

(M) /CASNUB 22 RFT bogie assembly covered under this specification, to Indian
Railways shall follow the procedure outlined below:

12.1 RDSO document ‘Vendor application processing’ ISO QO-D-8.1-6 (latest) shall be
followed for the registration and approval of the firm. For document scrutiny the
firm shall refer the ISO document No QO-F-8.1-1 and No QO-F-8.1-7. For
Capability assessment the firm shall refer the ISO document No ISO QO-F-8.1-8,
RDSO Document No STR (QMS-09:2015 latest), this specification and QAP.
12.2 Based on successful completion of above, prototype testing shall be undertaken.
Decision conveyed to the manufacturer regarding permission to manufacture
two nos. of prototype bogies (one set of assembled bogie and other set in loose
condition) to this specification along with provisionally approved QAP.
12.3 On receipt of permission for casting of prototypes, the manufacturer shall then
give 15 days’ notice to DG (Wagon)/RDSO for witnessing of melting, pouring
testing etc. as specified in ANNEXURE – 1 and provisionally approved QAP for
process inspection of prototypes manufacturing. Besides witness by RDSO
complete process shall be video graphed and submitted to RDSO in a hard drive
duly labeled.
12.4 The manufacturing of proto samples of bogies shall be done strictly as per
relevant drawings, specification and provisionally approved QAP. The
components fitted on proto bogies shall be duly inspected by concerned
inspecting authority. Quality conformance shall be checked with respect to the
requirements of this specification. All tests listed in Annexure-I of the
specification shall be done. Components shall be checked as per the scheme
given in their respective relevant Annexures.
12.5 During prototype testing if any sample fails/not meeting requirements, the
manufacturer has to review the process and report has to be submitted to the
approving authority (DG(Wagon)/RDSO) for consideration. Sample type testing
will be carried out as per QO-D-8.1-10 (latest) & other related documents that are
applicable.
12.6 Based on the satisfactory prototype test results and manufacturing facilities
found to be meeting the requirements in respect of infrastructure and other
requirements as covered in specification, the firm shall be considered for
approval as a RDSO vendor for Developmental Orders for the manufacture and
supply of CASNUB-22HS/CASNUB 22 HS (M) /CASNUB-22RFT bogie as per the
relevant and applicable RDSO procedure (s) for the same.
12.7 A manufacturer shall be considered from “RDSO approved vendor for
Developmental order” to “approved” for manufacture and supply of CASNUB-
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22HS/CASNUB 22 HS (M) /CASNUB-22RFT bogie after satisfactory supply for a

minimum quantity as specified in item master on UVAM of any type of
CASNUB Bogie i.e. CASNUB 22 HS or/and CASNUB 22 HS (M) or/and CASNUB
22 RFT or as specified in the relevant RDSO document, in accordance to RDSO
document no. QO-D-8.1-11 (latest).
12.8 The firm has to apply to RDSO for up gradation of their status from “RDSO
vendor for developmental order” to “approved” and the same shall be processed
as per relevant procedures applicable time to time.
12.9 All the provisions contained in RDSO’s ISO procedures laid down in document
No. QO-D-8.1-11 (Latest version) (titled “Vendor-Changes in approved status”)
and subsequent versions/amendments thereof, shall be binding and applicable
on the successful vendor/vendors in the contracts floated by Railways to
maintain quality of products supplied to Railways.
12.10 All terms and conditions for vendor registration/approval of foreign firms shall
be applicable as stipulated in RDSO ISO document QO-D-8.1-5 (latest version)
title “Application for registration of vendor”. In case of any contradiction
between the clauses of this specification and ISO document QO-D-8.1-5
regarding the vendor registration/approval of foreign firms, the clauses of ISO
document shall prevail.

13.0 QUALITY ASSURANCE PROGRAMME

The manufacturer shall prepare a quality assurance program (QAP) as per the
relevant ISO Document i.e. QO-F-8.1-7 (latest) of Annexure-A7 and submit it for
approval to the DG(Wagon)/RDSO and shall obtain his approval before commencing
the manufacture of CASNUB 22 HS/CASNUB 22 HS (M)/CASNUB-22RFT Bogie.
Besides other aspects, the following salient points shall be taken into consideration
for the preparation of QAP to be submitted to the Inspecting Authority.

13.1 In the Incoming Raw Material and In process/Final Inspection Section (Section-E),
the Firm shall clearly mention all the Test Parameters, Parameters for inspection,
testing frequency, the mode/methodology of testing, equipment/machinery involved
for testing, testing standard, acceptance criteria/limit etc. Section- (E) of the QAP
shall include but not limited to following parameters:
a) Type of raw material including scrap to be used
b) Internal specification of scraps to be used and charge-mix
c) Moulding Practice.
d) Selection of sands to be used.
e) Sand binder additives.
f) Preparation of sand and its testing.
g) Design of mould box and core boxes (Use of Wooden Core Box is prohibited)
h) Pattern and core making. (Use of Wooden pattern is prohibited)
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i) Preparation of moulds.
j) Material, size and identification of chaplets shall be specified. (Refer IS-5904)
k) Melting process.
l) Argon purging technique.
m) Stages of testing of molten metal before tapping and at the end of pouring.
n) Shot blasting.
o) Fettling i.e. knocks out and removal of risers, ingate, fins, etc.
p) Grain refining technique/ Heat treatment process.
q) Removal of protruded metal if any, with the help of air arc/gas cutting.
r) Chemical and Mechanical test, hardness test, radiographic test, solidity test,
MPI test, D.P. test etc. at the various stages of manufacture in reference to
relevant spec.
s) Maintenance of records of tests at various stages.
t) Intensity of internal inspection at different stages by Inspector/Quality Head
u) Painting.
v) Packing and dispatch.
13.2 Following details shall also be included in QAP
i) Source/Brand of Incoming Sand
a) Resin
b) Additives
c) Any other material required for preparation of moulding sand
ii) Properties of above sand
a) Clay content
b) Purity/LOI (major constituents %)
c) AFS and grain fineness number
d) Shape of grains (round, semi-angular, angular)
e) Silica Content (98% Min.)
iii) Mould wash
a) Name
b) Base
c) Consistency
d) Size of particles
iv) Properties of prepared sands (mould, core and facing)
a) System of Sand Preparation (No-Bake/High Pressure moulding)
b) Compression strength
c) Shear Strength
d) Collapsibility
e) Gas Content
v) Feeding system (to be shown on sketch/drawing)
a) Size and position of ingate
b) Size and position of runners

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c) Size and position of risers

d) Yield percentage of castings
vi) Pouring start temperature of each Mould &method of measurement
vii) Pouring end temperature of each Mould & method of measurement.
viii) Knock out time after pouring
ix) Weight of casting
All activities relating to quality assurance shall be the responsibility of Quality
Head who shall form the interface with the RDSO inspecting officer. The
relevant records for maintaining quality for each of the following items shall be
maintained and made available to the inspecting officer.

14.0 QUALITY AUDIT

The quality audit of the firm shall be carried out to ensure the adherence to its
quality assurance, and its general quality consciousness as per extant RDSO ISO
procedures and special emphasize shall be given on the process audit as per
Annexure-XII. This quality audit may also be carried out on the need basis in
case of reports of severe premature failures of the product are received from
Railways. For establishing this, the samples shall be collected from Railways and
sent to RDSO, Lucknow as and when required for carrying out the tests
mentioned in this Specification followed by fatigue testing as per AAR
guidelines/test regime at RDSO, Lucknow.

15.0 OTHER REQUIREMENTS

15.1 The accuracy of gauges shall be checked by the Inspecting Authorities before the
commencement of manufacture. Re-calibration shall subsequently be made at
the frequency stipulated in internal Quality Assurance Program. This shall also
be done during stage inspection randomly. Gauge drawings in original, shall
also be made available for checking the tolerances of these gauges. Firm shall
have sufficient sets of gauges for his own use. Firm shall install suitable
Coordinate Measuring Machine (CMM) or any other suitable system to carry out
the inspection of Gauges, Fixtures and random dimensional measurements of
Bolster and Side Frame etc. Prior approval of DG (Wagon)/RDSO shall be
obtained on use of alternate system.
15.2 In case the offer does not correspond to this specification in any respect, a
DEVIATION STATEMENT shall be submitted by the Tenderer. This statement
shall give the deviations clause wise with technical reasons for the same. Change
in drawings, if any, shall be explained and accompanied by THREE copies of
revised drawings. In case the tenderer does not require any deviation from this
specification, a NO DEVIATION CERTIFICATE shall be submitted.

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15.3 All bogie and its components should have clear and legible manufacturers name
in short code and month & year of manufacturing etc., which shall remain legible
throughout the entire service period as specified in RDSO Drawing no. WD-
86038-S/1 (latest alteration).
15.4 Any bogie components found having illegible markings at the time of fitment in
Railway Workshops, Maintenance Depot or at Wagon Builder premises, shall be
treated as rejected and shall be replace by the manufacturers free of cost. The
cost of transportation shall also be borne by manufacturer.
15.5 All manufacturer foundries, material and manufacturing process must be
approved by RDSO. The basis for such approval shall be satisfactory compliance
with all relevant provisions of Association of American Railroads (AAR)
Specifications including AAR Specifications M-201, M-202, M-203, M-210, M-
1003 and this specification.
The foundry shall satisfy the requirements for Class “A” foundries (IS:12117
latest) specified and updated by the Bureau of Indian Standards/RDSO from time
to time.
15.6 Manufacturer shall have a proper house-keeping system to ensure that
components are not damaged during storage. Critical components like springs,
center pivot, elastomeric pad, side bearers etc. must be stored under cover and be
protected against corrosion.

16.0 CLARIFICATIONS

Any further clarification required by the supplier can be obtained from the
Director General (Wagon), Research Designs and Standards Organisation,
Ministry of Railways, Manak Nagar Lucknow – 226 011 (India ).

17.0 WARRANTY

The firm shall stand warrantee for complete bogie/ components (such as side
frame, bolster, center pivots, spring plank, brake beam), unless otherwise
specified in the specification of individual component/ sub-assembly, for a
period of 72 months from the date of manufacture or 60 months from the date of
fitment/commissioning of the wagon, whichever is earlier.

In case of pre-mature failure of any component/sub-assembly, the firm will be

liable to make free replacement of failed component/sub-assembly to the depot
where failure has been reported within reasonable time. Decision of purchaser/
RDSO on warranty failure shall be final and binding on the vendor.

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ANNEXURE –I
(Sheet 1 of 14)

CAST COMPONENTS

1.0 REQUIREMENTS OF STEEL CASTINGS AND MANUFACTURING

PROCESS

i) All basic foundry processes e.g. moulding, core making, heat treatment,
fettling, shot blasting, heat treatment and weld reclamation shall be done
in house with adequate facilities and infrastructure for all steel castings.
ii) The steel shall be made by electric arc process or such other process as
approved by the DG (Wagon), RDSO, Lucknow. Keeping the limitation of
operational aspects in view, use of induction furnace for melting is not
permitted.
iii) Firms shall have NABL accreditation for their lab facilities required as per
this specification.
iv) Firm shall have a system of complete process control plan to control all the
critical activities specified in this specification. Firm must maintain records
of each process meeting the requirements of the desired values/standards.
These records shall be kept for minimum three (3) years.

1.1 Ladle analysis:

i) An analysis of test samples taken during the initial 25% of the castings
poured from each ladle must be made by the manufacturer to determine
the percentage of carbon, manganese, phosphorus, sulfur, and silicon and
of the intentional alloying elements. The result of this analysis shall be
recorded and reported to the inspecting official upon request and shall
conform to the requirements as per AAR M 201 Gr B+ material as detailed
in Annexure-VIII and/or approved QAP.

ii) Apart from the above, for each heat of steel, a sample representing the last
metal going into, or taken after the pouring of, the last acceptable casting
must be used by the manufacturer to determine the chemical composition.
The results of this analysis shall be reported to the inspecting official upon
request and shall conform to the requirements of AAR M 201 Gr B+
material as detailed in Annexure-VIII and/or approved QAP.

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ANNEXURE –I
(Sheet 2 of 14)
1.2 Raw material quality – General:

i) The foundry shall lay down the specification of all raw materials used in
the manufacture of castings and follow the same.
ii) The castings shall be manufactured from appropriate quality of raw
materials i.e. silica sand, steel scrap, foundry returns & ferro-alloys, whose
quality shall be ensured through relevant tests. Care should be taken to
ensure that the scrap selected is free from rust, grease, oil and other
prohibited contaminants.
iii) Pig iron as raw material shall be restricted below 5% and preferably
Calcined lime shall be used instead of lime stone.
iv) Quality of all additives to sand, molten metal and mould/core wash shall
be standardized, checked and only acceptable quality raw material and
additives shall be used.
v) Record of all raw materials and additives, their quality characteristics shall
be maintained which shall be made available to inspecting officer to
facilitate scrutiny and establish traceability.
vi) The Complete detail of raw material and additives used for metling shall
be incorporated in QAP.

1.3 Methoding:
i) Casting solidification software must be used to evaluate castings for
potential defects, standardize running, gating, risering system including
use of appropriate chills & chaplets and for verification of casting solidity.
It should be evaluated on the standard Software such as MAGMA and
validated through proto-type testing. In this regard the Firm is required to
submit a certificate from an authorized government
agency/IIT/CSIR/Certified third-party agency that the methoding system
meets the requirements of International/National standard and best
foundry practices for the manufacturing or to submit detailed Simulation
report along with casting proto-testing report (with same methoding) to
RDSO for approval. This analysis shall also be part of ITR submitted as
prerequisite of prototype testing.

ii) Any alteration in the methoding system shall be intimated immediately

for obtaining approval.

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ANNEXURE –I
(Sheet 3 of 14)
iii) Knock-off riser shall be used wherever possible, to eliminate damage to
the castings during finishing operation. All surface of the core coming in
contact with the molten metal and where surface finish is important to
ensure proper seating of the mating components shall be provided with
core wash.
iv) Entire methoding system shall be part of QAP of the vendor.

1.4 Moulding:
i) Moulding shall be carried out by employing either of the following
process given below:
a) High Pressure Moulding Line with Intensive Mixture for Green
sand mould with automatic Moisture Control and addition of
Binder in fixed rates. It shall be equipped with intensive mixture
with automatic dosing, water liter flow along with SCADA control
to make the moulding sand. Any deviation will require prior
approval from DG (Wagon)/RDSO.
OR
b) Articulated Mixer (continuous type) with fume extraction facility &
Compaction Table for No-Bake System. It shall be equipped with
automatic resin charge having calibration facility , compaction table
, and sand reclamation system along with SCADA control. Any
deviation will require prior approval from DG(Wagon)/RDSO.
OR
c) Any other better process as approved by DG (Wagon_, RDSO,
Lucknow.
ii) For High pressure moulding line mould hardness shall be minimum 85
and the same should be uniform at all the surfaces (within + 5% at all the
surface including vertical), and for No – Bake System scratch hardness of
mould shall be minimum 60 and same should be uniform at all the
surfaces (within + 5% at all the surface including vertical) so as to get good
dimensional accuracy in castings.

iii) Proper cleaning of moulds/cores by using T – suction pipe or any other

better process as approved by DG (Wagon)/RDSO shall be ensured before
mould closing.

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ANNEXURE –I
(Sheet 4 of 14)
iv) Suitable arrangement shall be made in the mould to obtain manufacturer’s
identity, month and year of manufacture, casting Sr. No., Drg. No. for
each side frame and bolster casting, center pivot top and brake beam end
piece & strut casting and other castings as indicated in drawings.
v) Minimum four test lugs of size 25 X 25 X 8 mm shall be provided in all
castings to facilitate micro-examination.
vi) To facilitate mechanical testing and chemical analysis, all side frames and
bolster castings shall have integrated test bars from which samples for
tests shall be prepared.
vii) On all moulds and cores, an “alcohol/water-based zircon paint” of
appropriate quality shall be applied to the entire surface that comes into
contact with molten metal. This application is crucial for ensuring a
proper surface finish and mitigating undesirable metal/mould reactions.
The process and methodology for this application, as well as the
associated quality control measures, shall be incorporated into the Quality
Assurance Plan (QAP).

1.5 Sand Preparation & Sand Lab:

i) The foundry shall lay down the characteristics of all sand mixes i.e.
moulding sand, core sand, facing sand and shall have proper arrangement
for sand drying & preparation of sand mix of consistent quality and the
characteristics of each batch shall be checked to ensure conformance to
standard arrived at by the foundry. Sand mix of unacceptable quality
shall not be processed.

ii) The foundry shall be equipped with a full-fledged sand testing lab.
Testing facilities shall comprise incoming sand tests like active clay
content, acid demand value, loss on ignition, mechanical grading (grain
fineness number) and sand mix tests like moisture content, green & dry
strength, permeability, shatter index, surface hardness, scratch hardness,
bench life, strip time, hot distortion, high temperature properties.
Outsourcing of this lab shall not be permitted.

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ANNEXURE –I
(Sheet 5 of 14)
1.6 Core-Making:
i) All cores shall be produced by No-bake process or any other better
process (with prior approval of DG/Wagon/RDSO) for which continuous
mixer with compaction table/ batch mixer shall be available in-house.
ii) Minimum number of cores, preferably single core shall be used in each
mould to achieve the desired quality of castings. Nos. of cores proposed to
be used shall be clearly specified in the QAP.

1.7 Melting:
i) Oxygen lancing process with oxygen purity level of 99% minimum shall
be used for carbon boiling.
ii) A sufficient carbon boil must be accomplished with a minimum 20 point
carbon reduction. Double slag process for proper removal of sulphur and
phosphorus shall be followed.
iii) Argon Purging shall be carried out to ensure freedom from harmful gases,
time and quantity of argon purging as per ladle size shall be specified in
QAP. Electronic display of spectrometer results near arc melting furnace
shall be installed.
iv) Ladle pre-heating at 600°C to 700°C shall be carried out. Temperature
checking in furnace and in ladle by immersion pyrometer shall be done
before pouring in Mould.

1.8 Pouring:
i) Metal should be poured by bottom pouring ladle. Mould filling time,
Pouring start and pouring end temperatures shall be recorded, ensuring
that all castings from first to last are sound & no adverse effect are noticed
due to high or low pouring temperature.
ii) Electronic display of pouring ladle weight shall be used to check amount
of metal pouring and remaining molten metal quantity.
iii) During pouring in mould, temperature checking by Laser Beam/Infrared
Type Optical Pyrometer shall be done. After pouring castings shall be
allowed to cool to a temperature below 540°C, at a rate that will not be
injurious to the castings.
iv) Moulding boxes shall be opened to remove the castings only after they
have cooled down sufficiently (100°C - 250°C). Left over metal/slag in
ladle shall be specified in QAP.

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ANNEXURE –I
(Sheet 6 of 14)
1.9 Fettling and shot blasting:
i) Risers, runners and ingates shall be removed from the castings. Use of
knock-off risers shall be preferred for improving the surface condition of
the castings. All castings shall thereafter be properly cleaned, dressed and
shot blasted to ensure freedom from surface imperfections, loosely
adherent sand, scale etc.
ii) Preferably, shot blasting shall be done in three cycles (before heat
treatment, after heat treatment and before painting).

1.10 Heat treatment:

i) All castings shall be heat treated after fettling and Shot Blasting. Shot
Blasting shall also be carried out after heat treatment process.
ii) SOTA (State of the Art) heat treatment furnaces along with SCADA
control shall be employed and must be capable of throughout even
temperature distribution within ±10°C.
The heat treatment furnace preferably shall be an electric type.
Manufacturer can use alternative furnace giving similar or better heat
treatment properties with prior approval of DG(Wagon)/RDSO. Oil fired
furnace for heat treatment shall not be deployed.
iii) All heat treatment furnaces shall be equipped with adequate number of
thermocouple’s and recorders. Facility for output chart indicating heat
number, date and time verses temperature shall be available for each
furnace.
iv) Optimum uses of heat treatment furnace (not more than 70% - 80% of total
volume) shall be ensured. Sketch depicting space, covering arrangement
and stacking procedure for bogie components shall be specified in QAP.
The stacking diagram shall be approved by RDSO. Plan for placement of
castings in the furnace shall be standardized to ensure uniformity of heat
treatment for each casting of a particular batch and the same shall be
followed without any deviation.
v) The Castings for heat treatment shall be cleaned / dressed sufficiently to
respond the heat treatment. The castings shall be normalized tempered as
detailed below to achieve properties as detailed in Annexure-VIII.
However, only normalizing can also be followed subject to condition that
it meets all the requirements of this specification with prior approval of
DG(Wagon)/RDSO.
vi) Loading temperature of bogie components in heat treatment furnace shall
not be more than 250 °C. The process of heat treatment shall be as follows.

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ANNEXURE –I
(Sheet 7 of 14)
A. Process of Normalizing castings shall be followed in following order:
a) Heat to proper uniform temperature above the transformation
range and hold for the proper time to achieve complete
austenization and to refine the grain structure. Generally, the rate
of Heating shall be at the rate of 100°C ± 20°C per hour and soaking
at 920± 10°C for minimum 4 hours. In case of any deviation, the
firm shall submit the intended process with details to RDSO for
approval of DG (Wagon)/RDSO. This shall be clearly indicated in
QAP.
b) Withdraw from the furnace and cool in still air until temperature of
entire casting reach below 370 °C.
B. Process of Normalized and tempered castings shall be followed in
following order:
a) Heat to proper uniform temperature above the transformation
range and hold for the proper time to achieve complete
austenization and to refine the grain structure. Generally, the rate
of Heating shall be at the rate of 100°C ± 20°C per hour and soaking
at 920± 10°C for minimum 4 hours.
b) Withdraw from the furnace and cool in still air until entire casting
temperature reach at least 60 °C below the tempering temperature.
c) Temper by reheating to proper uniform temperature below the
transformation range, but not less than 320 °C and hold for the
required time (Preferably for 4 Hours). Remove castings from the
furnace and allow it to cool at desired rate. In case of any deviation,
the firm shall submit the intended process with details to RDSO for
approval of DG (Wagon)/RDSO. The complete heat treatment
process shall be clearly indicated in QAP.

vii) All the stages of heat treatment with various time & temperature ranges of
processes, acceptable limits of rate of heating, shall be clearly brought out
in QAP. Inspecting Authority shall examine it with actual heat treatment
process being followed during quality audit.

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ANNEXURE –I
(Sheet 8 of 14)
1.11 Heat-Treatment Documentation:
i) The manufacturer is required to develop and document heat-treating
standards that describe the processes, process control procedures, and
record keeping requirements. These documents are to be presented and
reviewed as part of the Foundry Approval Process and are intended to
ensure that products are properly heat treated. Furnace temperatures for
heat treatment shall be controlled by thermocouples having associated
recording equipment that produce time-temperature record charts that are
identified by date and furnace number.
ii) A log sheet for each load of castings heat treated (batch) should show all
information pertinent to each heat-treat load including the following:
a) Type of casting
b) Prescribed heat treatment
c) Serial numbers and the heat numbers of the castings
d) Actual time of heat treatment.
iii) Thermocouples shall be calibrated every 6 months. Records of time-
temperature charts, furnace log sheets, and thermocouples calibrations will
be maintained for 3 years and made available to the purchaser/inspecting
authority upon request.
1.12 On completion of heat treatment, the castings shall again be shot blasted.

2.0 VISUAL EXAMINATION

i) All castings shall be examined visually and in the event of doubt by using
a magnifying glass.Final examination has to be done by magnetic particle
testing method as indicated in Para 7.2.
ii) The castings shall be free from harmful surface defects, inclusions, sand
fusion, blow holes, folds, cracks, misruns, surface imperfections, unfused
chaplets and porosity. The acceptable limit for surface defects as per
specification ASTM – A -802 SCRATA comparators is indicated below.

Surface Quality Parameters Critical Areas as Non Critical Area

Specified in the Other than specified
relevant drawing locations
Surface roughness A1 / A2 A3
Inclusions B3 B4
Gas/Porosity C2 C3
Wrinkles D2 D4

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ANNEXURE –I
(Sheet 9 of 14)

Scabs E2 E2
Chaplets F2 F4
Thermal Dressing G2 G3
Gauges (1/8 in. max. depth) H3 H4
Welds J2 J3

iii) Castings having freedom from defects shall only be processed for
machining and assembly.

3.0 WELD RECLAMATION

i) Weld Reclamation shall only be carried out prior to the heat treatment
process. Any deviation shall require prior approval of DG (Wagon)/RDSO
before use.
ii) The cracks up to a depth of 2 mm shall be ground and blended with
surrounding surfaces.
iii) In case defects are observed in the castings, a sketch showing the location,
approximate dimension and nature shall be prepared. Weld repair
possibility shall be considered after careful examination of the castings on
a case-to-case basis and specific approval of inspecting officer shall be
obtained. The defect must be removed completely and its elimination
ensured prior to weld repair. The weld reclamation shall be carried out as
per procedure outlined at Annexure-IA.
iv) All castings reclaimed by welding after heat treatment shall be subjected
to normalizing in the same manner as outlined for castings manufactured
in the first instance.
v) Welding repair on Zone-1 as indicated in Annexure-IA shall not be done.

4.0 DISPOSAL OF REJECTED CASTINGS

i) All castings which have been rejected either by the internal inspecting
officer or by purchaser’s inspecting officer shall be promptly marked with
a red paint as ‘REJECTED’.
ii) Gas cutting or other methods should be used to divide the castings into at
least two pieces to prevent mixing. These pieces must be kept stacked
separately until they are verified by the inspecting official. A record of
such castings, including their serial numbers, shall be maintained.

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ANNEXURE –I
(Sheet 10 of 14)
5.0 FEED BACK MECHANISM

i) The foundry shall have a mechanism for identifying and control of defects
through feedback obtained from inspecting and quality control personnel.
Suitable remedial action shall be introduced in the manufacturing process
with the consent of purchaser’s inspecting officer wherever the same is
necessary.
ii) Record of all improvements, modifications, and alterations shall be
maintained to assess their effect and subsequent scrutiny. A report listing
these shall be submitted to DG (Wagon)/RDSO half yearly interval.
iii) One sample per heat shall be retained for retests or cross checks of
chemical and mechanical properties. These shall be retained for period of
3 years.

6.0 TESTS FOR CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES

i) All the side frames and bolsters shall be cast with integral test bars.
ii) Chemical analysis each heat for each type of casting is to be recorded.
iii) Test shall be conducted in accordance with standard Methods and
Definition for mechanical testing of steel products, ASTM standard A 370,
latest revision/equivalent standard as approved by DG (Wagon)/RDSO.
iv) Test bars for each heat & heat treatment batch of the same grade will be
tested for mechanical properties. Test results will be recorded.
v) Re-tests will be governed by the relevant IS Specification.
vi) One sample per heat shall be retained for re-tests or cross checks of
chemical and mechanical properties when required by inspecting officer.
These shall be retained for period of 3 years.

7.0 NON-DESTRUCTIVE TESTS

The following non-destructive tests shall be carried out:

7.1 Radiographic Tests:
i) One side frame and one bolster casting in every 100 bogies or part thereof
shall be subjected to radiographic examination for the initial supply of 1500
bogies. Frequency of testing shall be reduced to 1 in 250 bogies after the
successful supply of initial 1500 bogie sets. Different contracts will be treated
as if in continuation irrespective of contract size-unless there is a gap of 3
months between execution of two consecutive contracts or there is a major
design change.

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ANNEXURE –I
(Sheet 11 of 14)
ii) The sketches showing locations for radiographic examination are enclosed
WX 24003A (for bolster) and WX 24003B (for side frame). All radiographs
shall clearly reveal the image of penetration at appropriate locations to
enable correct interpretation of radiographic classification.
Radiographically examined with sensitivity of minimum 2% and satisfy
the requirement of ASTM designation E-446 – Reference Radiographs for
Steel Casting – Level 3 in respect of blow holes, slag, sand inclusion and
shrinkage. No cracks/hot tears shall be permitted.
7.2 Magnetic particle test
i) Magnetic particle test shall be conducted on all side frame and Bolster
casting at locations indicated in sketches no. WX 24003A (for bolster) and
WX 24003B (for side frame) in accordance with IS:3703.
ii) The equipment consumables shall meet RDSO specification no.
M&C/NDT/15/91 and M&C/NDT/8/91or latest. No cracks are permitted.
The cracks up to a depth of 2 mm shall be ground and blended with
surrounding surfaces. Magnaflux test shall again be done after grinding to
ensure removal of crack. Deeper cracks shall be rectified as per Annexure
IA.
iii) Inspecting officer shall witness 10% of the bogies checked.

8.0 MICROSTRUCTURE & SURFACE ROUGHNESS

i) Microstructure of heat treated castings representing each cast shall be
conducted from the lugs provided in side frame, bolster and center pivot
castings and the grain size shall be uniform and of size ASTM 6 or better.
The microstructure shall not reveal cast dendritic structure.
ii) The surface roughness of each cast of side frame, bolster and other cast
component after shot blasting shall be ensured in accordance with the
surface roughness parameters as indicated in the relevant drawings of
respective cast components and as specified in this specification.
iii) The inspector shall check record and verify the 5% of offered lot of each
heat during the inspection.

9.0 WEIGHT
i) Castings shall be rejected if their weight is above the limits specified
below:
Side frame 430 kg +5% /-3 %
Bolster 565 kg +5% /-3 %
Brake beam 75 kg + 6.0%

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ANNEXURE –I
(Sheet 12 of 14)

ii) To ensure the weight of the bogie side frame and bolster within the limit
as specified above, inspector shall check the record of each lot and verify
the weight of 5% of bolster and side frame from a offered lot during
inspection

10.0 LOAD TESTING

i) Castings shall be selected at random for load test by the

inspector/inspecting Authority. Different contracts will be treated as if in
continuation irrespective of contract size-unless there is a gap of 3 months
between executions of two consecutive contracts or there is a major design
change. In such cases, tests will be carried out as if on a new contract.
ii) Casting will be checked by magnetic particle test and at corners and radii
with dye-penetrant test both before and after the load tests. In case of any
cracks two more castings from the same lot shall be tested. If any one of
the latter castings fails in the load test, the complete lot stands rejected. In
case of rejection, the manufacturer shall review his foundry practices and
take whatever steps necessary to satisfy the inspector of the adequacy of
the process of manufacture.
10.1 Proof load & destructive load Testing of bolster & Side frame
i) The bogie bolster and side frame shall comply with following static proof
tests as detailed in below para 10.1.1, 10.1.2 and 10.1.3.
ii) All bogie manufacturer shall have in house facilities for static proof load
testing of bogie side frame and bolster with necessary fixture and suitable
load deflection measuring device to carry out the tests as detailed below.
10.1.1 Application of test load:
i) The side frame casting shall have the test load applied in the direction of
the vertical axis at the plank seat surface of side frame and supported at
the side frame pedestal crown roof at each end.
ii) The bolster castings shall be loaded in the direction of the vertical axis at
the center pivot, the supports being at the spring seat at each end.
10.1.2 Static proof load test for bogie side frame and bolster:
This test will be conducted on side frame and bolster. The frequency of testing
and load applied shall be as below:

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ANNEXURE –I
(Sheet 13 of 14)

Item Frequency Load Maximum Permanent set

of Testing Applied Deflection max. at centre
Side frame 1 in 50 117 t -- 0.4 mm
Bolster 1 in 50 117 t -- 0.7 mm

10.1.3 Destruction Test:

i) This test will be conducted on side frame and bolster The frequency of
testing and load applied shall be as indicated at para 10.1.4:
ii) The sample castings selected for destruction test shall be subjected to
loads specified below. No fracture/cracks should take place at these loads.
The test is to be discontinued if the casting begins to fracture or show
cracks at less than the specified loads.
a) Side frame 234 t
b) Bolster 254 t
iii) Digital gauges shall be used for measurement of actual load applied and
deflection/permanent set measurement. Least count shall be 100 kg for
load application and 0.01 mm for deflection/permanent set measurement
or better.

10.1.4 Sample Size for proof and destruction load testing :

i) One side frame and one bolster casting in every 100 bogies or part thereof
shall be tested for the initial supply of 1500 bogies. Subsequent frequency
of testing shall be reduced to 1 in 300 bogies after the successful supply of
initial 1500 bogie sets. The selection of side frame/bolster for this test shall
be made at random by the inspector from the lot.
ii) For determining frequency of tests, different contracts shall be treated as if
in continuation irrespective of the size of contract unless there is a gap of 3
months between execution of two consecutive contracts or there is a major
design change. Casting used for destructive test shall not be used except
for sectioning test/scrap.

11.0 SECTIONING TEST

11.1 Castings subjected to destruction tests shall be sectioned to establish moulding

practices. Sketches showing the location for sectioning are enclosed as No.
WX24003C (for sectioning location of bolster) & WX24003D (for sectioning
location of side frame). Sample size of this test shall be same as para 10.1.4.

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ANNEXURE –I
(Sheet 14 of 14)
11.2 Following items are to be specifically checked :
a) Wall thickness
b) Internal Solidity
11.3 Permitted variation in wall thickness of the castings is as given below :

Wall thickness dimension Permissible variation

6 mm up to 11 mm (not including 11 + 3 mm to –1 mm
mm)
11 mm and above + 3 mm to –2 mm

11.4 Each sectioned face on examination, Defects such as blow holes, slag inclusions,
shrinkage, etc. are not acceptable. Porosity to a level of 2% of the cross section
may be considered acceptable. The defect shall not be clustered at any particular
location and shall be uniformly distributed throughout. Defect connected with
the outside and presence of cracks/hot tears shall be cause for rejection. Dye-
penetrant test shall be carried out on sectioned faces for detection of shrinkage
and chequered cracks. These tests shall be carried out in the physical presence of
inspecting official.
11.5 The firm should have a machine shop equipped with appropriate size Power saw
for sectioning sides frame/Bolster as per the requirement of this specification.
Outsourcing of this activity shall be prohibited.
11.6 The Firm shall maintain complete record of sectioning including measurement of
wall-thickness, internal solidity and photographs with DPT tests.

12.0 INSPECTION OF WALL THICKNESS

i) Wall thickness check shall be made at specified locations as per mentioned

in enclosed sketches of side frame and bolster nos. WX 24003C and WX
24003D on minimum 25% the castings using ultrasonic thickness gauge or
better.
ii) Any rejection will mean defect in pattern, core, mould setting or process
and appropriate investigation shall be made.

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WD-17-CASNUB-22HS-BOGIE -92 (Rev.4)

ANNEXURE –IA

WELDING REPAIR PROCEDURE FOR

CAST STEEL SIDE FRAME AND BOLSTER

1. This procedure covers the steps to be followed for weld repair of casting defects
considered repairable by the inspecting officer. The complete welding and post
welding heat treatment as per the procedure given in this specification shall only
be done in the supervision of inspecting/competent official. Complete record of
the welding reclamation and its traceability shall be maintained.
2. Before conducting weld reclamation, a sketch showing the nature, size and
location of defects shall be prepared and written permission of inspecting officer
shall be obtained on case-to-case basis.
3. While decision regarding weld reclamation shall be taken by the inspecting
officer, the following guidelines shall be followed.
3.1 Through thickness cracks shall not be considered for welding.
3.2 Misrun shall not be repaired by welding.
3.3 Defects which are located at vulnerable locations (Zone-1 as specified in enclosed
sketches nos. WX 24003E and WX 24003F) shall not be repaired and shall be
considered as rejected. Defects which are located at locations (Zone-2) as
specified in enclosed sketches nos. WX 24003E and WX 24003F shall not be
repaired if their depth exceeds 25% of the wall thickness. At other locations
defects up to 50% of the wall thickness shall be considered for weld reclamation.
3.4 The total length of the weld seam in one casting shall not exceed 100 mm and no
single weld seam length shall exceed 50 mm. If more than 2 castings reach or
exceed the stipulated defect limit, a thorough process audit as per Annexure-XII
by an RDSO inspecting official shall be necessary.
3.5 All castings repaired by welding shall be subject to same heat treatment process
as being followed for the casting (Normalized/Normalized-Tempered).
3.6 The welding shall be conducted by qualified welders with valid certificate.
3.7 The foundry must have a procedure to mark castings for repair, to ensure that
the proper repair procedure is used, and to identify castings for which repairs
have been completed.
3.8 Complete weld reclamation procedure shall be the part of QAP.
3.9 Welding repair as per this specification shall only be carried out prior to the heat
treatment of the casting. Any deviation shall require prior approval of
DG(Wagon)/RDSO before use.

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4.0 Repair procedure

4.1 The extent of crack of defect shall be judged by visual or magnetic particle
examination by qualified inspector or welder. Use of crack depth meter is also
mandatory for precise crack depth determination. The defect shall be eliminated
by pneumatic gauging, arc gauging, grinding, chipping and its elimination
ensured by MPI/dye penetrant testing.
4.2 The method of defect removal must not hide the defect.
4.3 Appropriate shaped groove shall be prepared with the help of portable pencil
grinder and entire surface cleaned properly to ensure freedom from heavy scale,
oil, grease, paint, dirt etc.
4.4 Welding electrodes AWS A5.5 –E-8015, E-8016, E-8018, E-10018 or better shall be
used for welding repair. Current, polarity and OCV shall be as per
recommendation of the electrode manufacturer. Welding shall be done in down
hand position maintaining an interpass temp of 250-300 Deg. C, de-slagging and
peening after each run.
Alternatively, GMAW welding wire consumable having class III to IRSM M
46/2020 can also be used for weld repairs. However, prior approval of DG
(Wagon)/RDSO shall be obtained before use.
4.5 Welders/weld operators must be qualified in position welding that to be
performed for the materials, processes, and procedures being used in accordance
with AWS D15.1 or equivalent.
4.6 The electrodes shall be preheated before use as recommended by electrode
manufacturer (OEM).
4.7 Preheat of base metal before putting of weld bead shall be carried out within
range of 150 – 250 ˚C. In case of multi run weld, the inter pass weld temperature
shall not be less than preheat temperature. The OEM instructions on time
duration for preheating shall also be followed.
4.8 The weldment shall be examined for presence of cracks by dye penetrant testing.
Weldments free form cracks shall be considered acceptable.
4.9 All weld must be inspected visually, MPI tested and all finished weld repairs
must meet AAR M-201, M-210. Porosity must not exceed the AWS D15.1 for class
2 welds. Weld repairs must be checked by qualified inspectors.

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WD-17-CASNUB-22HS-BOGIE -92 (Rev.4)

ANNEXURE –II

SPRING STEEL COMPONENTS

i) Material for Helical Springs: The springs to drawing No. WD-92058-S/5 shall be
manufactured out of steel conforming to RDSO’s specification No. WD-01-HLS-
94 (Latest).
ii) The helical springs shall be manufactured as per RDSO specification No. WD-01-
HLS-94 (Latest) and the relevant RDSO drawing of the helical spring.
iii) CASNUB 22RFT Bogie’s Helical springs (as relevant drg.) shall also be
manufactured out of steel conforming to RDSO’s specification No. WD-01-HLS-
94 (Latest)

******

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ANNEXURE –III

METAL BONDED RUBBER COMPONENTS

i) Elastomeric pads: The Elastomeric pads as per the RDSO specification No. WD-
20-Misc-95 (Latest) shall be provided between adapter and side frame pedestal
roof.
ii) Centre pivot washer: The washer shall be as per RDSO drawing no. WD-97049-
S/3 & WD-85079-S/2.

******

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WD-17-CASNUB-22HS-BOGIE -92 (Rev.4)

ANNEXURE –III A

COMPOSITE MATERIAL COMPONENTS

1. Brake Blocks:

i) `L’ type brake block shall be manufactured as per the RDSO Specification No.
WD-13-ABR-2006 (latest version) by manufactures approved by RDSO.
ii) ‘K’ type brake blocks shall be manufactured as per the RDSO Specification No.
WD-14-ABR-2007 (latest version) by manufactures approved by RDSO.

******

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ANNEXURE –III B

List of Constant Contact Side Bearer

A. For CASNUB 22HS Bogie

S.No. Specification Variant/Type Approved To be fitted in

No. Drawing/s
1. WD-38-Misc- Design-‘A’ AAL-021101 Alt-8 All Wagons fitted with A & B
2004 (Rev-1) or or Latest Suspension group of Bogie
Latest General Arrangement drawing.
2. WD-62-Misc- Variant-‘A’ WD-17025-S/1 Alt- Generally applicable for
17 1 or Latest wagons having empty body
(Latest) weight up to 9.4t.
Variant-‘B’ WD-12008-S/1 Alt- Generally applicable for
3 or Latest wagons having empty body
weight between 9.4t to12.7t.
Variant-‘C’ WD-12007-S/1 Alt- Generally applicable for
3 or Latest wagons having empty body
weight over 12.7t.

B. For CASNUB 22 HS (M)/CASNUB 22RFT Bogie

S.No. Specification Variant/Type Approved To be fitted in

No. Drawing/s
1. WD-62-Misc-17 Variant-‘A’ WD-17025-S/1 Alt- Generally applicable for
(Latest) 1 or Latest wagons having empty body
weight up to 9.4t.
Variant-‘B’ WD-12008-S/1 Alt- Generally applicable for
3 or Latest wagons having empty body
weight between 9.4t to12.7t.
Variant-‘C’ WD-12007-S/1 Alt- Generally applicable for
3 or Latest wagons having empty body
weight over 12.7t.
Note:-
Any deviation if required shall be mentioned in Centre pivot side bearer arrangement
drawing of that wagon.

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ANNEXURE –IV

FORGED COMPONENTS AND FASTENERS

S.No Description Drg. No. (latest) Specification(latest)

.
1. Centre Pivot Pin WD-97049-S/3 & IS: 2062
WD-85079-S/2
2. Shackle lock WD-97049-S/3 & IS: 1875
WD-85079-S/2
3. Lock pin WD-97049-S/3 & IS: 1875
WD-85079-S/2
4. Rivets – 12, 20 and 24 --- IS: 1929
dia. IS: 1148
5. Bulb cotter WD-94068-S/1 IS: 1079-73 St-42
Or IRS: M-41-74
6. Split pins --- IS: 549
7. Hexagonal Fit bolt (M- --- IS: 2232
24) with washer and IS:3640
castle nut. IS: 2016
8. Side frame key WD-92058-S/4, item –2 IS: 1875 Cl. IV
9. End piece & strut WD-89033-S/1, WD- IS: 1875 CL.III A
07052-S/1
10. Lock bolt (22.2 mm As per relevant CP-SB Medium carbon
dia) drawings of wagon. steel to SAE 15836
24 mm dia snap head IS:1929,IS:1148
rivets
Low carbon steel to
Collar BS 970 040A04 OR
SAE 1008 OR
DIN 1654 OR
Qst 34.3

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WD-17-CASNUB-22HS-BOGIE -92 (Rev.4)

ANNEXURE –V

FABRICATED COMPONENTS

S.No Description Drg. with Alt. No. Specification

.
1. Equalizing lever with SK-69597 Item 1,5,6 & 7 IS: 2062
bushes IS: 5517, 45C-8
Hardened &
tempered
2. Bogie End Pull Rod SK-69597 item 2 IS: 2062
3. Bogie Brake Push rod SK – 69597 item 3 IS: 2062
4. Pin 40 dia. with washer & SK-69597 item 14 IS: 2062, IS-5517
bulb cotter
5. Washer (OD 56, ID 31 dia. --- IS: 2062
X 5 thk )
6. Washer (OD 80, ID 43 X 6 ---- IS: 2062
thk )
7. Brake beam WD-89033-S/1 & IS: 2062
WD- 07052-S/1
8. Brake Shoe Key W/BG-6150 IS: 3885 OR
IS: 3195
9. Center pivot washer WD-97049-S/3 Item 5 & IS: 2062 & IS:
WD-85079-S/2 Item 4 5192

10. Spring Plank CASNUB- WD-92058-S/4 Item 1/ IS: 5986

22HS/CASNUB-22RFT WD-22091-S/3
Bogie
11. Side frame friction liner WD-92058-S/4 Item 3 IS: 3885
12. Bolster liner WD-92058-S/3 Item 2 IS: 3885
13. Centre pivot liner WD-97049-S/3 Item 3 & 4 IRS : R 65 – 78

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ANNEXURE –VI

LIST OF CONSTRUCTION DRAWINGS

(For BOXNHS with CASNUB 22 HS Bogie/ CASNUB 22 HS (M) Bogie )
S.No. Description Drawing No.
(Alteration latest)
1 Index WD-92058-S/1
2 General Arrangement (with spherical centre pivot & WD-04038-S/2
constant contact side bearer)
3 General Arrangement (with flat centre pivot & WD-04078-S/1
constant contact side bearer)
4 Cast steel side frame WD-89067-S/3
5 Cast steel bolster WD-92058-S/3
6 Bogie details WD-92058-S/4
7 Spring details WD-92058-S/5
8 Bogie Brake gear arrangement. WD-89067-S/5
9 Centre pivot assembly & details (spherical type) WD-85079-S/2
10 Centre pivot assembly & details ( flat type) WD-97049-S/3
11 Centre pivot & Side Bearer Arrangement (with As per relevant CP-SB
spherical pivot & constant contact side bearer) drawing of wagon.
12 Centre pivot & Side Bearer Arrangement (with flat As per relevant CP-SB
pivot & constant contact side bearer) drawing of wagon.
13 Brake beam details WD-89033-S/1
14 Brake beam (Suitable for `K’ type brake block) WD- 07052 – S/1
15 Bogie brake gear details SK-69597
16 Leading dimensions and tolerances WD-92058-S/7
17 Assembly procedure WD-85054-S/7
18 Wedge SK-77579
19 Narrow jaw adapter WD-89067-S/9
20 Modified Elastomeric pad WD-95005-S/1
21 Constant contact side bearer assembly & details Annexure-IIIB of this
specification
22 BG, MG & NG coil spring drawing codes WD-89006-S/1
23 Marking scheme for cast steel sideframe & bolster WD-86038-S/1
24 Bulb cotter WD-94068-S/1
25 Brake Gear General Arrangement for BMBS WD-08093-S/2
26 Brake shoe key W/BG-6150
27 Pin W/PN-90

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ANNEXURE –VI A
LIST OF CONSTRUCTION DRAWINGS
(For CASNUB -22RFT Bogie )

S.No. Description Drawing No.

(Alteration latest)
1 Index WD-22091-S/1
2 General Arrangement WD-22091-S/2
3 Cast steel side frame WD-89067-S/3
4 Cast steel bolster WD-22091-S/4
5 Spring plank WD-22091-S/3
6 Bogie Details (Except spring plank) WD- 92058-S/4
7 Outer Spring WD-22055-S/1
8 Inner Spring WD-22055-S/2
9 Snubber Outer Spring WD-22055-S/3
10 Snubber Inner Spring WD-22055-S/4
11 Bogie Brake gear arrangement. WD-89067-S/5
12 Brake Gear General Arrangement (For BMBS) WD-08093-S/2
13 Centre pivot assembly & details ( flat type) WD-97049-S/3
14 Brake beam details WD-89033-S/1
15 Brake beam (Suitable for `K’ type brake block) WD- 07052 – S/1
16 Bogie brake gear details SK-69597
17 Leading dimensions and tolerances WD-92058-S/7
18 Assembly procedure WD-85054-S/7
19 Friction Wedge with specified range of COF WD-22055-S/5
20 Narrow jaw adapter WD-89067-S/9
21 Modified Elastomeric pad WD-95005-S/1
22 Constant contact side bearer Annexure-IIIB of this
specification
23 BG, MG & NG coil spring drawing codes WD-89006-S/1
24 Marking scheme for cast steel side frame & WD-86038-S/1
bolster
25 Bulb cotter WD-94068-S/1
26 Brake shoe key W/BG-6150
27 Pin W/PN-90

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ANNEXURE –VII
REFERENCE SPECIFICATIONS (LATEST) FOR BOGIE MANUFACTURERS
Description Specification No.
S.No. Rules for roundoff numerical values IS:2 2022
1 Wedge/ Friction Wedge with specified range of IS:276 Gr. 1/ As per Specification
coefficient of friction No.CONTR-02-MISC-2007
2 SF friction liners, Bolster friction liners, Brake beam IS:3885 Pt. I Gr. 4
wear plate, Brake wear plate, Brake block key
3 Spring plank IS: 5986-2017
4 Push rod, pull rod & lever IS:2062
5 Rivets IS:1929 : IS:1148
6 Key bolt with 4.0 dia. Split pin IS:2585 & IS: 549
7 Primer paint IS:2074
8 Red oxide paint IS:05 ; IS:13607
9 Welding IS:9595
10 Bulb cotter IS:1079-73 St. 42/IRS-M 41-74
11 forged components IS:1875
12 Riveting IS:7215
13 Helical springs IS:3195 / IS 4454 Part 2
14 Qualification for welders IS: 7318 Pt. I
15 Deviation for untoleranced dimensions and mass of IS:4897
steel casting
16 Allowable deviations for dimensions without IS:2102
specified tolerance
17 Weight, quantity and dimensioning tolerances on IS:3469 Pt. I, II & III
forgings
18 Surface finish IS:3073
19 Hexagonal fit bolts IS:3640
20 Code of procedure for rectification of steel castings IS:5530
by metal arc welding process
21 Standard for radiographic analysis ASTM-E-446-84 or E-71
22 Top & Bottom Centre pivots, side frame , bolster AAR-M-201 Gr. B+ & C, M –
202, M - 203
23 Bushes & pins IS:5517
24 Specification of BMBS Brake System WD-23-BMBS-2008 Latest
25 Centre pivot liners IRS – R - 65 - 78
26 Standard test methods and definition for ASTM-A-370
mechanical testing of steel products
27 Standards for Chaplets IS-5904

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ANNEXURE –VIII

CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES

The material for side frame and bolster shall conform to the chemical composition and
physical properties as per AAR spec. M – 201 Gr. B+ and also detailed below:

1.1 Chemical Composition (%)

C 0.32 % (Max.)
Mn 0.90 % (Max.)
P 0.03 % (Max.)
S 0.03 % (Max.)
Si 1.50 % (Max.)

Note: Manufactures must specify range of each element and alloying elements (if any)
in chemical composition in QAP.

For each reduction of 0.01% carbon below the max. specified, an increase of 0.04%
manganese above the max. specified amount may be permitted to a max. of 1.2%.

The content of elements other than those designated above shall be selected by the
manufacturer to obtain the physical properties specified. Each manufacturer shall
establish requirements for tramp elements that can have an adverse effect on impact
properties or welding. The requirements shall account for contribution of tramp
elements to the carbon equivalency (CE) of the finished casting. For Grade B+, a CE of
0.72 max. is allowable based on the following formula given below and the max. Values
of C, Mn, and Si.
𝑀𝑛 + 𝑆𝑖 𝐶𝑟 + 𝑀𝑜 + 𝑉 𝑁𝑖 + 𝐶𝑢
𝐶𝐸 = 𝐶 + + +
6 5 15

1.2 Mechanical Properties

Ultimate Tensile strength (UTS) 551 Mpa (Min.)
Yield Strength (YS) 344.4 Mpa (Min.)
Elongation in 50 mm (%) 24 (Min.)
Reduction of Area (%) 36 (Min.)
Impact Charpy V notch (ft - lb) 15 ft-lb (20.34 joules) at 20° F/ (-
7 ° C ) Minimum
1.3 Hardness
Hardness 137 – 228 BHN

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ANNEXURE –IX
(Sheet 1 of 17)
LIST OF BOGIE COMPONENTS AND THEIR INSPECTION PROCEDURE

Various components which form the bogie assembly are grouped below. Details of
inspection requirement are shown against each group.
1. Centre pivot & its assembly Annexure –IX
(sheet 2 & 3 of 17 )
2. Manganese steel castings- wedges ADI Annexure –IX
Castings/Wedges with composite liner – (sheet 4 of 17)
Friction wedges with specified range of COF
3. Outer, inner, snubber springs Annexure –IX
(CASNUB22HS/CASNUB 22 HS (M) (sheet 5 of 17 )
/CASNUB22RFT)
4. Liners Annexure –IX
(sheet 6 & 7 of 17 )
6. Brake block key Annexure –IX
(sheet 8 of 17 )
7. Rubber components Annexure –IX
(sheet 9 of 17 )
8. Spring plank(CASNUB22HS/CASNUB 22 HS Annexure –IX
(M) /CASNUB22RFT) (sheet 10 of 17 )
9. Other forged components- Annexure –IX
Side-frame key, bulb cotter, hexagonal fit bolt, (sheet 11 of 17 )
shackle lock,
10. Brake beam Annexure –IX
(sheet 12, 13 & 14 of 17 )
11. Centre pivot retaining ring Annexure –IX
(sheet 15 of 17 )
12. Pull rod, equalizing lever, push rod, bushes, Annexure –IX
centre pivot pin & lock pin (sheet 16 & 17 of 17 )

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ANNEXURE –IX
(Sheet 2 of 17)
CENTRE PIVOT & ITS ASSEMBLY

1. Top & Bottom centre pivots are to be manufactured as per AAR spec. No. M-201
Gr. C. Center pivot castings shall be furnished normalized and tempered as per
para 1.10 (b) of Annexure-I of this specification..
2. Integral test bars, test lugs shall be cast for these castings. Specified chemical
tests and Mechanical properties shall be conducted for these castings as per AAR
specification M-201 Gr. C, representing each cast and results recorded for
clearing a cast.
3. Each centre pivot casting shall be provided with at least one test lug of size 25 X
25 X 8 mm at suitable location to judge the quality of heat-treated casting.
4. Manufacturing process and quality assurance process shall be as per the details
given in this specification.
5. Inspecting officer shall witness gauging of Centre pivot on sample basis for 1 in
every 100. In case of any rejections, Para 9.6.3 shall apply.
6. Gauging of these castings is to be done for the dimensions given below on 100%
castings by the manufacturer.

Top Pivot-Flat Top Pivot-Spherical

(Drg. No.WD-97049-S/3) (Drg. No.WD- 85079-S/2)
S.No Dimensions to be checked S.No. Dimensions to be
. checked
1. 270 + 0.5mm 1. 270 + 0.5 mm
-0.0 -0.0
2. 82 + 0.6mm (Height) 2. 20 + 0.5 mm
-0.0 -0.0
3. 20 R +1.5 3. 102 + 1 mm
-0
4. Top wall thickness 4. 20 +1.5
28 + 0.4mm
-0.0
5. 328mm (outside dia.) 5. Top wall thickness 26
mm
6 Dia. 60 mm 6. 315 mm (Outside dia)
7. R 330 + 0.5 mm

8 Dia. 60 mm

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ANNEXURE –IX
(Sheet 3 of 17)

Bottom Pivot-Flat Bottom Pivot-Spherical

(Drg. No. 97049-S/3) (Drg. No. 85079-S/2)
1. 30 + 0.4 mm 1. Height 76 mm ( 22 + 54)
-0 (wall thickness)
2. 350 mm (Inside dia) 2. 8 mm
3. 390 mm (Outside dia) 3. 325 mm Dia
4. 40 mm (height) 4. Wall thickness 30mm & 19mm
5. 76 mm (centre stem dia.) 5. R 331 + 0.5 mm
6 Dia. 60 6. 18 + 1 mm
-0
7 Dia. 60

Top & Bottom Pivot Assembly-Spherical(Drg. No. WD-85079-S/2)

S.No. Dimension to be checked
1 120 + 2 (Assembled height of centre pivots )
-0
2 Minimum area of contact 75%.

Top & Bottom Pivot Assembly-Flat (Drg. No. WD-97049-S/3)

S.No. Dimension to be checked
1 120 + 2 (Assembled height of centre pivots )
-0
2 Minimum area of contact 75%.
Note :
1. Top pivot & bottom pivot manufactured by same manufacturer should be used
on a particular wagon. Intermixing of pivots of different manufacturers is not
permitted.
2. The dimensions indicated are critical dimensions, which are to be gauged. The
other dimensions are required to be maintained as per the drawings.
3. The gauges have to be developed by the Manufacturer and approval obtained
from the RDSO, wherever necessary.
4. To achieve the hardness of CP Top as per the specification suitable Induction
hardening facility shall be installed.
5. Unspecified tolerances on casting dimensions shall be as per IS:4897 class -1 and
Unspecified tolerances on machined dimensions shall be as per IS:2102 class –
medium.

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ANNEXURE –IX
(Sheet 4 of 17)
FRICTION WEDGE

Manganese Steel /ADI Castings Wedges/ with composite liner friction wedges
Drg. No. SK-77579/WX-10046/WD-22055-S/5(for CASNUB 22 HS / CASNUB 22 HS (M)
/CASNUB 22RFT)

1. Wedges are to be manufactured as per IS: 276. Gr.1 /Specification No. CONTR-
02-MISC-2007 (Rev. Latest)
2. Wedges manufactured as per IS:276 Gr.1 shall suitably be heat treated to render
them tough. This treatment shall consist of uniform heating of the wedges to a
suitable temperature holding it at that temperature till uniformly heated
throughout and quenching in water within 60 seconds from a minimum
temperature of 1050°C. The complete heat treatment process shall be specified
in QAP.
3. Integral test bars, lugs shall be cast for these castings as specified. Chemical
analysis shall be done for each cast before clearing the same. Hardness and bend
test should be tested & recorded, as per material supply for each cast.
4. Gauging of these castings is to be done for the dimensions given below. Gauging
of all the wedges manufactured shall be done by the manufacturer.
5. It has to be ensured that the name of manufacturer, month, year of
manufacturing, drawing no. and heat number to be cast in depressed letters on
each wedge/Friction wedge on non-wearing surface.
6. Inspecting officer shall witness gauging on wedge on sample basis 1 wedge
/Friction wedge from a lot of 50 wedges. In case any rejection, Para 9.6.3 shall
apply.

S.No. Dimensions to be checked

1 69 + 0.5, 150.6 + 1
2 Perpendicularity between spring seat & vertical surface,
butting against column liner, 940 R & angle 55 degrees.
3 Wedge wing profile

Note :
1. The dimensions indicated are critical dimensions which are to be gauged. The
other dimensions are required to be maintained as per the drawings.
2. The gauges have to be developed by the manufacturer and approval obtained
from the RDSO.

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ANNEXURE –IX
(Sheet 5 of 17)
OUTER, INNER & SNUBBER SPRINGS

(Drg. No. WD-92058-S/5-For CASNUB 22HS/CASNUB 22 HS (M) )

Outer, Inner, Snubber outer & snubber inner Springs

(Drg. No. WD-22055-S/1, WD-22055-S/2, WD-22055-S/3 and WD-22055-S/4-For

CASNUB 22RFT)

1. The springs shall be manufactured as per RDSO spec. No. WD-01-HLS-94

(Latest).
2. Contractor shall purchase springs form RDSO approved sources only. All testes
as specified in specification No. WD-01-HLS-94 (Latest) and relevant drawing are
to be conducted at manufacturer’s premises.
3. Care shall be taken to ensure that springs of a particular group are only used
under a bogie.

*****

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ANNEXURE –IX
(Sheet 6 of 17)
LINERS
1. Bolster liners, side frame liners, brake wear plate & brake beam liners are to be
manufactured as per IS 3885, Pt.-1 Gr.-4, of hardness value 380-420 BHN. Centre
pivot liner liners are to be manufactured as per IRS-R: 65 -78 (Drg. No. WD-
97049-S/3)
2. Contractor shall purchase these liners from RDSO approved sources only with
proper certification. Contractor to check parameters listed in para 4 on 1 in 100
Nos. For all types of liners.
3. Manufacturers initial, month and year of manufacturing shall be marked by
metal laser engraving/dot peen in 6 mm size and 0.1 mm depth minimum. Liners
shall be fitted in such a way that marking lies on opposite to wearing surface.
4. Following tests are to be done on the liners –
a) Liners shall be visually inspected and must be free from scale, cracks, fins,
or other injurious defects
b) These shall be correctly heat treated as per established heat treatment
procedure to obtain a hardness indicated above & recorded.
c) The liners must be flat within 0.5mm. This should be checked using a
straight edge and feeler gauge.
d) Chemical and hardness tests shall be done.
e) Dimensional checks if liners is to be done as given below.
5. Inspecting officer shall check and record these parameters on a sample basis on 1
in 100. In case of any rejection, para 9.6.3 shall apply.
6. Side frame and bolster Liners
(Drg. No. WD-92058-S/3 & WD-92058-S/4) - FOR CASNUB 22HS BOGIE/
CASNUB 22 HS (M)
(Drg. No. WD-22091-S/04 & WD-92058-S/4 - FOR CASNUB 22RFT BOGIE)

S.No. Dimensions to be checked

1 Dimensions (i.e. length tolerance + 1.5 mm), (width tolerance + 1.5 mm)
and thickness tolerance as per IS: 1852 clause 8.

7. Brake Beam Pocket Liner (Brake wear plate)

(Drg. No. SK 69597)
S.No. Dimensions to be checked
1. 39 + 0.8 mm
2. 245 + 1 mm
3. 69 + 0 mm/ -2 mm
4. Thickness – tolerances as per IS: 1852 clause 8

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ANNEXURE –IX
(Sheet 7 of 17)

BRAKE BEAM END PIECE CASTING WEAR PLATE

(Drg. No. WD-89033-S/1)

1. Dimensions (i.e. length tolerance + 1.5 mm), (width tolerance + 1.5 mm) and
thickness tolerance as per IS: 1852 clause 8.

2. Horizontal wear liner

(WD-97049-S/3)

S.NO. DIMENSIONS TO BE CHECKED

1. 322 mm (Outside Dia)
2. 98 mm (Inside Dia)
3. 8 mm (Thickness)

3. Vertical wear liner

(WD-97049-S/3)

S.NO. DIMENSIONS TO BE CHECKED

1. 350 mm (Outside Dia)
2. 8 mm (Thickness)

Note:
1. The dimensions indicated are critical dimensions, which are to be gauged. The
other dimensions are required to be maintained as per the drawings.
2. The gauges have to be developed by the contractor and approval obtained from
the RDSO Engineer.

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ANNEXURE –IX
(Sheet 8 of 17)
BRAKE BLOCK KEY
( Drg. No. W/BG-6150 )

1. Key is to be manufactured a per IS:3885 Pt.1 Gr. 4 or IS:3195, Gr. 55 Si 7.

2. Contractor shall purchase these keys from RDSO approved sources only with
proper certification. Manufacturer of item to check parameters listed in Para 3.
3. Following tests are to be done –
a) Key shall be visually inspected and must be free from scale, cracks, bins or
other injurious defects.
b) These shall be correctly heat-treated as per established heat –treatment
procedure to obtain a hardness of 310 to 370 BHN. Hardness shall be
tested and recorded.
c) Dimensional check and profile of the key is to be checked.
4. Contractor to check and record these parameters on a sample basis on 1 in 100,
which shall be witnessed by Inspecting Officer. In case of any rejection, Para
9.6.3 shall apply.

S.NO. DIMENSIONS TO BE CHECKED

1. Profile is to be gauged
2. Thickness to be checked.

Note :
1. The dimensions indicated are critical dimensions which are to be gauged. The
other dimensions are required to be maintained as per the drawings.
2. The gauges have to be developed by the contractor and approval obtained from
the RDSO.

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ANNEXURE –IX
(Sheet 9 of 17)

RUBBER COMPONENTS

1. Elastomeric pad shall be manufactured as per specification No. WD-20-Misc.-95,

Rev. Latest.
2. Constant contact side bearer shall be as per Annexure- IIIB’.
3. Contractor shall source these items from RDSO approved vendors only.
4. These shall be visually inspected for cuts, cracks, or bond failure by Contractor.
Cases of rejection shall be reported to RDSO.

*****

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ANNEXURE –IX
(Sheet 10 of 17)
SPRING PLANK

( Drg. No. WD-92058-S/4)- FOR CASNUB 22HS BOGIE/CASNUB 22 HS (M)

( Drg. No. WD-22091-S/3)- FOR CASNUB 22RFT BOGIE

1. This shall be manufactured as per IS: 5986 for material.

2. Contractor shall purchase these spring planks from RDSO approved sources only
with proper certification.
a) Spring plank manufacturer to conduct bend test on raw material as per
Para 9 of IS: 5986.
3. Contractor to check and record these parameters on a sample basis on 1 in 50
which shall be witnessed by Inspecting Officer. In case of any rejection, Para
9.6.3 shall apply.
S.No. Dimensions to be checked
1. Outer profile to be gauged.
2. Thickness of 12 mm tolerances as per clause 8 of IS:1852.
3. Height 75 + 0/ -3 of spring plank
4. 2260 + 1.5
5. Arrangement, size & locations of holes for rivets and fit bolts
including orientation.
6. Size of fit bolt holes ( 25 dia + 0.020/+ 0.007)
7. Profile of top edge of flange ( 6R & finish of N10)
8. Arrangement, size & location of spring spigot.
9. Flatness to be checked with straight edge as per note of Drg. No.
WD-92058-S/4 or WD-22091-S/3 wherever applicable.
Note:
1. The dimensions indicated are critical dimensions which are to be gauged. The other
dimensions are required to be maintained as per the drawings.
2. The gauges have to be developed by the contractor and approval obtained from the
RDSO.

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ANNEXURE –IX
(Sheet 11 of 17)

OTHER FORGED COMPONENTS –SIDEFRAME KEY, BULB COTTER,

HEXAGONAL FIT BOLT, SHACKLE LOCK

1. These are important components. 1 in 50 sample check of each lot shall be

inspected and recorded at bogie contractor’s premises for dimensional check and
visual defects. In case of any rejection on inspected parts para 9.6.3 shall apply

2. Side frame Key ( WD-92058-S/4 )

S.No. Dimensions to be checked
1. 54 + 1.5
- 0.0
2. Size of hole 21 + 1/-0.0

3. Hexagonal Fit Bolt

S.No. Dimensions to be checked
1. Dia. of M-24 fit bolt & length (as per IS:3640)

4. Bulb Cotter ( Drg. No. WD-94068-S/1)

S.No. Dimensions to be checked
1. Width ( tolerance + 0.0/-0.5 mm, thickness (tolerance + 0/
-0.2 mm)

5. Shackle Lock( Drg. No. WD-85079-S/2 )

S.No. Dimensions to be checked
1. 40.5 + 0.5/ -0.0
2. 17 dia. hole
3. 35 + 0.0/-0.5

Note :
1. The dimensions indicated are critical dimensions which are to be gauged. The other
dimensions are required to be maintained as per the drawings.
2. The gauges have to be developed by the contractor and approval obtained from the
RDSO.
3. Unspecified tolerances on dimensions shall be as per IS:2102 class –medium.

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ANNEXURE –IX
(Sheet 12 of 17)
BRAKE BEAM
( Drg. No. WD-89033-S/1 & WD – 07052 – S/1)

1. Brake beam to be manufactured as per Drg. No. WD-89033-S/1 (For L –Type

brake block) OR WD – 07052 – S/1 (For K –Type brake block).
2. Contractor shall purchase these brake beams from RDSO approved sources only
with proper certification.
3. Following items to be checked on brake beam:-
a) Dimensional check
b) Visual check of welding and dye penetrate test.
c) Load test as per para –5.
d) Sectioning of brake beam as per para –6.

4. Contractor to check and record these parameters on a sample basis on 1 in 50

which shall be witnessed by Inspecting Officer. In case of any rejection, Para 9.6.3
shall apply.

5. Load Test of Brake Beam :

The brake beams shall be tested for 12 t load applied at pin centre and 3 mm
deflection is permitted under load, 0.2 mm permanent set is permitted when the
load is released. The brake beam shall be load tested 1 in 20.

6. Sectioning check of Brake Beam Welding :

Break beam selected at random shall be sectioned at plane XX and YY
respectively to check whether welding has been done as per drawings. This test
shall be as instructed in drawing.

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ANNEXURE –IX
(Sheet 13 of 17)

S.No. Brake beam assembly dimensions to be checked

1. 35 (Centre line of face of brake head at centre to centre line of hole
in strut).
2. 187
3. 1762 + 2/ - 0
4. 52 + 0.083 / + 0.053 ( OD of bush )
5. 41 + 0.2/- 0.1 (ID of bush )

6. 36 + 0.0 / - 1.0
7. Camber of 20mm
8. Dim. 35 (width of slit for lever )
End Piece and Strut Part
9. 550 +7 R

10. 260 +4.5

11. 60 +2.5
12. 30 +3
13. 26 + 0.0/ - 1.0 (thickness of ends ) – to be achieved by machining

14. 12 +2

15. 40 +3.5

16. 300 +4.5

17. Angle 64°

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ANNEXURE –IX
(Sheet 14 of 17)

MANUFACTURING OF END PIECE AND STRUT FOR BRAKE BEAM

1. End piece and strut are to be manufactured as per material AAR M – 201 Gr. B+
for castings OR IS: 1875 Class 3A or higher grade for forging. It has to be ensured
that proper heat treatment is done.
2. Integral test bars and test lugs shall be cast for castings, for forging to be taken
from finished product. Chemical tests & mechanical properties test shall be
conducted on the test bars representing each cast and results recorded for
clearing a cast.
3. Manufacturing process and quality assurance process shall be as per the details
given in this specification.
4. Inspecting officer shall witness gauging on sample basis for 1 in every 50. In case
of any rejections, Para 9.6.3 of this specification shall apply.
5. The tolerances, if not indicated, are as per IS: 4897 for castings and IS: 3469 for
forgings.

Note :

(i) Centre lines of end piece castings, brake beam strut, brake beam channel and
truss flat must be co-planer.
(ii) The dimensions indicated are critical dimensions which are to be gauged. The
other dimensions are required to be maintained as per the drawings.
(iii) The gauges have to be developed by the contractor and approval obtained from
the RDSO.
(iv) Unspecified tolerances on casting dimensions shall be as per IS:4897 class -1 and
Unspecified tolerances on machined dimensions shall be as per IS:2102 class –
medium.

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ANNEXURE –IX
(Sheet 15 of 17)

CENTRE PIVOT RETAINING RING

( Drg. No. WD-80007-S/15)

1. This shall be manufactured as per Drg. No. WD-80007-S/15.

2. This item to be sourced from any reputed manufacturers duly inspected by
suppliers and internally inspected by the bogie manufacturers.
3. Bogie manufacturer should check & recorded for following parameters during
receipt inspection of items on a sample basis for min 10 per 100 and the record
shall be produced & get it verified from the RDSO Inspecting officials. In case of
any rejection, para 9.6.3 shall apply.

S. No. Dimensions to be checked

1. 270 + 0/- 0.1 dia.

2. 20 + 0/- 0.5

Note:
1. The dimensions indicated are critical dimensions which are to be gauged. The other
dimensions are required to be maintained as per the drawings.
2. The gauges have to be developed by the contractor and approval obtained from the
RDSO.

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ANNEXURE –IX
(Sheet 16 of 17)

END PULL ROD, EQUALIZING LEVER, PUSH ROD, PINS AND

BUSHES, CENTRE PIVOT PIN & LOCK PIN
1. This item to be sourced from any reputed manufacturers duly inspected by
suppliers and internally inspected by the bogie manufacturers.
2. Bogie manufacturer should check & record for following parameters during
receipt inspection of items on a sample basis for min 1 per 100 and the record
shall be produced & get it verified from the RDSO Inspecting officials. In case of
any rejection, para 9.6.3 shall apply.
3. Following parameters are to be checked by the manufacturer –
3.1 Pull rod and push rod
a) Dimensional check
b) These shall be tested for a load of 18 t applied axially, without any
permanent set.
3.2 Equalizing lever
a) Dimensional check
3.3 Pins and Bushes
a) Dimensional check
b) Surface finish
c) Clearance not to exceed 0.75mm
d) Hardness
4. End Pull Rod ( Drg. No. SK- 69597 )
S.No. Dimensions to be checked
4. 800 mm
5. 35 mm (opening in forks )
6. Hole spacing of 57 mm
7. 29 mm dia. holes
8. Weld to be examined visually. These are critical & should
be as per drawing.

5. Push rod ( Drg. No. SK-69597 )

S.No. Dimensions to be checked
1. 1070 mm
2. 35 mm ( opening in forks )
3. 44 mm (spacing of holes )
4. 29 mm dia. hole size
5. Weld to be examined visually. These are critical & should
be as per drawing

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ANNEXURE –IX
(Sheet 17 of 17)
6. Equalising Lever ( Drg. No. SK-69597 )

S.No. Dimensions to be checked

3. 356 mm
4. 178 mm
5. Hole dia for bushes ( dia 52 + 0.046 / -0.00 & 41 + 0.039/ -0.00 )

7. Bushes ( Drg. No. SK-69597 )

S.No. Dimensions to be checked
1. Outside dia, inside dia – Surface finish to be checked visually
along with dimensional check. The hardness shall be also
check as per drawing.

8. Centre Pivot Pin (Drg. No. WD-85079-S/2 and WD – 97049 S/3)

S.No. Dimensions to be checked
1. 36 + 0.5/ +0.2
2. 36 + 0.0/ -0.5
3. 149 mm ( length of pin)
4. ø 55 ( dia of pin)

9. Load testing of Pull rod/Push rod

These components shall be tested for a load of 18 t applied in axial direction. The
components shall withstand this load without any fracture. 2 % of pull rods as
well as push rods shall be load tested as above.
Note:

1. The dimensions indicated are critical dimensions which are to be gauged. The other
dimensions are required to be maintained as per the drawings.
2. The gauges have to be developed by the contractor and approval obtained from the
Engineer.
3. Unspecified tolerances on dimensions shall be as per IS:2102 class –coarse.

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ANNEXURE –X
3183741/2024/O/o ED/SW/RDSO
(Sheet 1 of 6)
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ANNEXURE –X
(Sheet 2 of 6)

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ANNEXURE –X
(Sheet 3 of 6)

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ANNEXURE –X
(Sheet 4 of 6)

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ANNEXURE –X
(Sheet 5 of 6)

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ANNEXURE –X
(Sheet 6 of 6)

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ANNEXURE –XI A

DIFFERENCE BETWEEN CASNUB 22HS BOGIE AND CASNUB 22HS (M) BOGIE

Sr. Description CASNUB 22HS Bogie CASNUB 22HS (M) Bogie

No.
1 Second Spring Details WD-92058-S/5 WD-92058-S/5
ary Drg.
suspens No. of spring Outer Inner Snubber Outer Inner Snubber
ion per bogie 14 14/12 4 14 12 4
details Stiffness per 466.33 kg/mm 466.33 kg/mm
bogie (Tare)
Stiffness per 952 kg/mm OR 882.5 882.5 kg/mm
bogie (Gross) kg/mm
2 Side Bearer As per CPSB drg. of As per CPSB drg. of wagon
wagon (Spec. No. WD-62-MISC-17)
(Design A to RDSO Spec.
No. WD-38-MISC-2004)
3 Friction Wedge SK-77579 (WD-17- WX-10046 (CONTR-02-Misc-
CASNUB-22HS-BOGIE) 2007)
4 Marking CASNUB-22HS CASNUB-22HS(M)
(Paint-Red oxide to (Paint-Red oxide to IS:13607)
IS:13607) Note: Bogie shall further be
marked with Zebra marking on
the side frame as indicated in the
Wagon Marking Diagram
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ANNEXURE –XI B

DIFFERENCE BETWEEN CASNUB 22HS BOGIE AND CASNUB 22RFT BOGIE

Sr. Description CASNUB 22HS Bogie CASNUB 22RFT Bogie

No.
1 Secon Spring WD-92058-S/5 WD-22055-S/1,2,3 &4
dary Details
suspe Drg.
nsion No. of Outer Inner Snubber Outer Inner Snubber Snubber
details spring per (O) (I)
bogie 14 14/12 4 14 14 4 4
Stiffness 466.33 kg/mm 266 kg/mm
per bogie
(Tare)
Stiffness 952 kg/mm OR 882.5 785 kg/mm
per bogie kg/mm
(Gross)
2 Side Bearer As per CPSB drg. of As per CPSB drg. of wagon
wagon (Spec. No. WD-62-MISC-17)
(Design A to RDSO
Spec. No. WD-38-MISC-
2004)
3 Friction Wedge SK-77579 WD-22055-S/5
(WD-17-CASNUB-
22HS-BOGIE) (CONTR-02-Misc-2007
4 Bolster WD-92058-S/3 WD-22091-S/4
5 Spring Plank WD-92058-S/4 WD-22091-S/3
6 Marking CASNUB-22HS (Red CASNUB-22 RFT (Sky blue code
oxide to IS:13607) no. 101 to IS:05 2007)

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ANNEXURE-XII

CHECKLIST FOR FOUNDRY AUDIT/OUT OF TURN AUDIT OF PROSPECTIVE

BOGIE MANUFACTURER

During Quality Audit/any audit of the facility, apart from the requirements of ISO
Document No QO-F-8.1-9 Quality Audit Report, foundry shall also be audited on
the following requirements;
S.No The parameter to be checked at the time of the Foundry audit /out Status of
of turn audit firm
1.0
Critical Processes and their outputs shall be reviewed by the
auditor.
1.1
A. Pattern and Core Box
i. Pattern and core box design, dimensions, and rigging
arrangements
ii. Pattern and core box maintenance practices
1.2
B. Core Making Practices
i. Core making and finishing system
ii. Sand testing procedure
1.3
C. Molding Practices
i. Sand testing procedure
ii. Mold making and core setting process to avoid shifts and
offsets during mold movement and pouring
1.4
D. Melting Practices
i. Raw material composition & quality parameters
ii. Chemistry control including tramp elements
iii. Heat and pouring temperature control
1.5
E. Pouring Practices
i. Casting pouring time control
ii. Pouring temperature control
iii. Control of manganese reversion testing on the last casting
poured
iv. Control of chemistry
v. Chemical and physical tests on representative castings

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vi. Positive method for determining last casting

1.6
F. Cleaning/Shot blasting Process
i. Cleaning equipment must provide clean castings for proper
inspection.
ii. Observe welding operations to ensure quality workmanship
and conformance to written procedures defined in this
specification. Welding equipment must be well maintained and
show proof of periodic checking (at least annually) for correct
amperage and voltage readings. Welding rods and wire must
be properly identified and stored according to AWS standards.
Welding materials should be sourced from an approved or
authorized source.
iii. Workmanship of grinding operations should be evaluated.
iv. Facilities for performing welding according to temperature
requirements of this specifications should be available. It is
mandatory that all weld repairs be made in the green
condition prior to heat treating. Normally, there should not
be any requirements of weld repair or it should be minimal.
v. Inspection should be made of facilities and procedures for
installing wear plates and other fixtures to castings.
1.7
G. Heat-Treating Practices
i. Proper temperature control of furnace with adequate
recording capabilities must be evident.
ii. Procedures should be in place to periodically verify (as
defined in this Specification) uniform temperature
throughout furnaces.
iii. Proper records must be kept to positively identify castings
that have received heat treatment.
1.8
H. Casting Quality
i. A random sample of castings should be selected from the
inspection area and dimensionally and visually inspected.
The object of this should be to evaluate the overall quality of
the finished casting. Pattern quality, core setting, and
dimensional control should be evaluated.
ii. Availability and accuracy of gauges should be determined
and the calibration system for gauges should be evaluated.
iii. All physical test apparatus should be inspected for general
operating condition and calibrations. All equipment

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requiring calibration should have current certification.

iv. Records of internal solidity must be verified in this
specification.
v. All tests as per the requirements of prototype testing may also be
conducted if required.
2.0 Specifications, STR & Drawings
2.1 Are there adequate procedures to ensure that obsolete drawings and
documents are destroyed or isolated from use?
2..2 Are there adequate procedures for distributing new and revised drawings
to the shop in force?
2.3 System for raw materials inspected upon receipt and marked for
permanent identification?
2.4 System for all other purchased materials checked for conformance with
the purchasing document upon receipt?
2.5 Is the system for raw material test reports kept on file?
3.0 Quality Control
3.1 Does the quality control organization include a quality control supervisor
who can demonstrate an adequate knowledge of the foundry/ casting
process?
3.2 Does Quality Control have the authority to stop and responsibility to
inform operating supervision of nonconforming work?
3.3 Are there adequate procedures for correcting nonconforming material or
work in process rejected by Quality Control forces?
3.4 Are there adequate procedures for the inspection of purchased materials
and manufactured items?
4.0 Maintenance of Equipment
4.1 Is there an adequate plan for the systematic maintenance of equipment?
4.2 Are the equipment and tools periodically inspected and restored to
intended tolerance?
5.0 Engineering and Drafting
5.1 Do personnel have adequate knowledge of the applicable codes and
specifications?
5.2 Is there a current reference library of specifications, including the latest
revisions of all relevant RDSO/IS/AAR/UIC codes/manuals
5.3 Does the bogie manufacturer have access to engineering testing support
facilities? A list of major testing equipment should be provided.
6.0
Production, Inspection, and Test Planning
6.1 Check as per QAP and this specification, each inspection and test point
and its relative location in the processing cycle, including incoming
inspection, preservation of items, packaging, and site inspection and
testing.
6.2 Check inspection and test points where measurement and test records are

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maintained.
6.3 Check mandatory hold points that require witnessing or verification of
selected characteristics of an item or process and that beyond which the
work shall not proceed.
7.0
Measuring and Testing Equipment
7.1 Check whether the firm maintains documented procedures to control,
calibrate, and maintain all measuring and test equipment and devices
used to verify item quality and to monitor special processes.
7.2 Check whether the firm has a mechanism to Identify measuring and
testing equipment with a tag, sticker, or other suitable indicator to show
the calibration status.
7.3 Check whether the firm Maintains calibration records for measuring and
test equipment.
8.0
Incoming Inspection
8.1 Check whether the firm Inspect, test, and identify incoming items as
required in this specification and test plans mentioned in QAP.

8.2 Check whether the firm Holds incoming items until the required
inspection and tests are completed or the necessary inspection and test
reports are received and verified.
9.0
In-Process Inspection
9.1 Check whether the firm Holds items until the required inspections and
tests are complete or necessary reports are received and verified.
9.2 Check whether the firm Maintains documented procedures for the
verification, storage, and preservation of the supply of each component.
10.0
Final Inspection
10.1 Check whether the firm Inspect, test, and identified the final items as
required as per this specification and QAP.
10.2 Review all inspection and test records and verify that the item has been
inspected at all points shown in the inspection and test plan and that
these records are complete
10.3 Check whether the firm Retain all inspection records for Minimum three
years.
11.0 Process Control
Check whether the firm is Complying with applicable codes, standards,
11.1
specifications, documented procedures, and/ or inspection and QAP.
Ensuring that special processes (including but not limited to methoding,
11.2
melting, mould preparation, shot blasting, heat treatment, gauging,
plating, welding and non-destructive testing) are performed under
controlled conditions in accordance with this specification, standards, and

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contractual requirements by qualified personnel using qualified

equipment and procedures.
11.3 Check whether the qualification of personnel, procedures, and equipment
complies with the requirements of applicable codes, standards, and
specifications.
11.4 Check that documentation for currently qualified personnel, processes, or
equipment is maintained in accordance with the requirements of
pertinent codes, standards, and specifications.
12.0
Preservation, Packaging, and Shipping
12.1 Check whether the firm Controls packing, packaging, and marking
processes (including materials used) to the extent necessary to ensure
conformance to specified requirements.
12.2 Check the mechanism for the protection of the quality of the product after
the final inspection and test. Where contractually specified, this protection
shall be extended to include delivery to destination.
12.3 Check whether the firm has control of nonconforming conditions and
continuously improve the effectiveness of the quality program through
the use of corrective action, preventive action, and internal audit results.
12.4 Check the mechanism for segregating nonconforming items to prevent
unauthorized use, shipment, or mixing with conforming items.
12.5 Check the mechanism of Handling of customer complaints and reports of
product/service nonconformance.
12.6 Investigation of the root cause of the nonconformity relating to product,
process, and quality program and recording of the results of the
investigation. Determination of the corrective action needed to
permanently eliminate the root cause of the nonconformity.
13.0 Training
13.1 Check the procedures for identifying training needs, providing the
training, and evaluating the effectiveness of that training for all personnel
involved in activities affecting quality.
13.2 Check the Job descriptions is created and maintained. Basic job
responsibilities and qualification requirements must be defined.
13.3 Check whether the Personnel involved in special or key processes
(welding, heat treating, painting, pressure treating, product inspection,
internal quality auditing, etc.) are being imparted both function-specific
training and applicable work experience to be considered qualified.
13.4 Check whether the Training records are maintained for qualified
personnel as long as they remain qualified or as required by other
regulatory requirements.
13.5 Check the measures to ensure that personnel are aware and
knowledgeable of their specific responsibilities for quality.
14.0 Management and Line Supervision Status of the firm

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14.1 Does Bogie Manufacturer's quality assurance policy/ quality assurance

plan indicate recognition of separation of responsibility for production
and quality control supervision functions?’
14.2 Does the organizational chart clearly show the lines of plant management
authority and responsibility, which are down to principal plant
departmental supervisors?
14.3 Are assigned personnel for key positions in manufacturing qualified by
training and experience?
14.4 Are assigned personnel for key positions in manufacturing qualified by
training and experience?

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