IRS R19/95(Part-1) GOVERNMENT OF INDIA MINISTRY OF RAILHAYS (RATLHAY BOARD) INDIAN RAILRAY STANDARD SPECIFICATION FoR WHEEL AND AXLE ASSEMBLY FOR CARRIAGES @ND WAGONS LICABLE TO ALL GAUGES) SERIAL NO.R-19/95 (PART-1) FESESSACH QESIENS % STOMIGRIS OREEMISATION LUOKNGH - Zze011.SPECIFICATIONS REFERRED IRS, R-19/93(Part=1 specification refers to the ‘latest amendments of following This i specifications:+ ae IRS R-16/93 2. IRS R-43/92 3 IRS R-19/95 (Part-1T) a. IRS R-19/93 (Part-1it) IRS R-19/93 (Part-1v) IRS R+19/93 (Part-¥) IRS R-15/64 1S:344 1812062 (Grade"A’) 19:2074 1819862 Steel axles for carriaaaes and wagons. Steel axles for Diese! and Electric Locomatives, EMU Motor, coaches anc powered axles of Rail Cars. Forged/rolled solid wheels for Carriages and Wagons except EMU stock. Cast steel solid wheels for carriages and wagons. Forged/rolled solid wheels for ENMU stock. Wheel centres tor carriages and wagons. Steel typres for locomotives, tender, carriages and wagons. Black Japan. Tyre fastening rings and locking keys. Ready mixed paint, red oxide zine chrome, priming. Ready mixed paint, brushing. uminous, lead tree, acid, alka water and neat resisting.wv ia IRS R-19/93(Part-1) INDIEN RAILWAY STENDSRAD SPECIFICATION FOR. THE SSSINELY OF WHEFLSETS FOR CARRIAGE £.WOBEN STOCK (Applicable ‘to (al LiGauges? SERIAL NO.IRS R-19/1995 (PARTI) SCOPE This specification covers the requirements for the assembly “of: wheels/wheel centres with the axle and wheel centres with the tyres for.use.on carriages and wagons. SSSEMELY CF -MNEEL © AXLE At the time of pressing on the solid wheel/tyred wheel/wheel entre shall be on the same ambient temperature as the axle. The oxles ehall be fully machined, and finished as per drawing. However, burnishing of journals wherever prescribed might either, be done before the whee! centre/uheels pressed on the axle or after that. The wheel/wheei centre bore shall be fully machine finished as per drawing to ensure its selective assembly with the axle. Theswheel/wheel centre bore and the wheel seat area of cthe axle must be cleaned carefully te remove ru grit, chips anc crease, before assembly. Surface finish of the.wheel/wheel centre bore and wheel seat area of the axle shall be as indicated in Grawings. A record of actual measuremen shall be. maintained. which can be che! verified by the Purchaser/Inspecting oF required by getting the measurements dcne in his presence. A record of actus! measurement of wheel/wheel bere. and dia. of the axl i maintained and their assembly shall be the wr ans axle numbers cting Authority if do bore mu permite Any 2 RDSO’s for cansid lubricant stated abe’ = data shel arding itways in29 2.10 IRS RO19/93(Part—1) The assemmty nt the wheelvwneei-centre wilt the axle must be carried bub geheraliyith Alnydrsndas taking all suitable precautions to prevent deformation of the components and dahage/to the ‘machined parts. especially the jaurnals. The wheel press used for the wheel/wheel centre and axle assembly shall “be equipped with a pressure indicating gauge and a graph recording facaility to show the-2 progressive development of pressure during Pressing on operation™4ncluding the’ final pressures at which the wheel centrés.or wheels: are pressed on to the ales. The fitting speed should be slow encugh to satisfy the conditions of clause 2.9(typical value 0.5 to Smm/sec.). The prising on pressure diagram shall be identified with the wheel and the axle numbers. The records “from this “gauge shall be .submitted to the Purchaser or the Inspecting? Officer, who at his discretion may verify-the records by having wheels pressed on in his presence from time to time during the progress-“f the’ contract. The” presting © on pressure diagram. shall satisfy the following conditions: +1 The’ pressure shall begin to rise before the ‘movement. of the wheel or:wheel centre on the seat haw reached 20 mm. 2 The*préssing on pressure shall increase steadily and contindusl yan relation-to the movement. -3 The. final pressing on pressure shall not be less thati Ehe Value ofthe -minimud pressing on pressure hors ekcebs - the’makimum pressing on - pressure as Specified" in -.cTdlise 2.10. However, the ‘maxinua pressing on pressure may be exceeded upto 10% if a satisfactory backpressure test is carried out as specitied’in’cladse 3: +4, A reduction of the pressing on pressure by upto 5 tonnes is permitted: in the last 25 mm movement. Some, Bf--the not acceptable-type of pressing on pressure diagram are shown in fig.i(a), 1(6) and 4(c) The’ pressing“on ‘pressure for the wheel/wheel Centre and ykle asséabiy “shall be-as follows:Ben IRS (R-19/93(Part-1) Baune Pressing on pressure in Kg. per. mm Diameter B€ axietat Wheel teat. PD Geet eeeereere Bao a 00 M.G. S00 ta, 520. N.G. 400 to 480 Location of Qut-of-balance:— In case.of wheels having been tested for. out-of-balance and. athe. extant and iposition of their residual out-of- balance being known, fitting of the wheels on the axle shall be so arranged that the residual. eyt—of—balance of. each of the two wheels of the same wheel set lies in the sane,dianetrical plane and on the same side of the centre line of the axle. The, regidual” qut-of-balance of the brake dists must lie in the same diametrical plane as .the .cut-of-balance af the “Wheels and be opposite in relation to the centre line of ‘the axle. BALK (COUNTER) PRESSURE JEST: A iback pressure?test shallibe. carried sout in the presence of the-Purchaser or theaInspecting Officer in the following cases ‘2 at Examination dof the pressing:on pressure diagram Bives risq:to doubt. +2 he dina] pressing on’pressure achieved exceeds ‘the ganimum Limit -but-notby more than 10: When the back pressure test is required, it may be carried out sbefere. finishing operations, such a5 machining of the wheel“tread: The wheel “sets should not undergo this test earlier than: 48, hours after pressing -on. However, manufacturer is free te rediice this time limit. The, back pressure, test. must be carried out on a press similar te the qne used “for pressing on Gperatzon and baquigped wifh-a pressing on pressure indication gauge The “beck.. pressure vimist be “applied ‘continously anc sinitgrmly. to, .fhe wheel set. During beck cressure test, the pressure shall reach 1.2 times the minimum pressing on pressure prescrited in clause 2.10 and the wheel must not be displaced. ASSOELY OF EMER GEUTRE an Type: Disc wheel centres may have tyres shrunk on either before or after wheel centres have beer presssc an to the “axles, but if the former order is adopted care5.8, IRS Ro39/93 (Part-I) Shall be tahen that the rim of wheel centres are turned absolutely concentric to the bores of their bosses. Tyres shell be carefully bored out to correct diameter for the wheel centres, to achieve the following shrinkage allowance. Jange Btock Shrinkage allowance Carriage & mn to 5.20 mm Wagon 3.5. etm S En (Motor: 4-20 mm fo.a.30 mm & Trailer} Ali stock C.85 mm to 0.75 mm except NL Notor coach M.G. OR EMU (toto 0.9 mm t0.1.0 mm Coach) N8- ~All stock 0-8 mh to.0.6 mm The tyres shall be heated to+the ‘temperature just sufficient ta obtain the expansion enabling the tyre to be placed in position andanbti exceeding S00 degree centigrade. Before placing in position, the bore of the tyre and the surface of the.rim shall be cleaned of al} foreign matters which--would: hinder contact between the twa components+ The retaining .ring shall.te inserted as rapidly as possible so that it is set well: into the bottom of the groove, thes:ends shali+ be: fixed ante. position immediately by: several blows with & sledge hammer applied to the retaining ring. After, tyring, wheeis or wheel sets snail be left to cool and sheltered from draughts’ and water splasnes. Tyres shell be turned on-the-tread and flange, but need not be turned on the sides if they are sufficiently accurate when finished to satisfy the Purchaser or the Inspecting. Officer. Care mst be taken when knocking down the edge.of the tyre on. to the retaining ring that thestyre is not cracked, circumferentially or .otherwise. The Knocking ‘down of the edge shall..be- done on a suitable. machine to.the satistaction of the Purchaser ar the Inspecting Officer. MARIINGs— After? assembly ef the wheel or wheel centre with the axle the fodioWine: details shavl'be stamped legibly as per-ROSG‘Sk~92114 of inner face of the wheel hub.4) 2) IRS R-19/93(Part-1) 3) Manufacturer s sWorkshop’s sode ii) Month & year ot agsemoly ii) Pressina on pressure in tonnes SGUSES (AND .TERPLATES:— The whole of the work shall be finished off in the best style of wheel work in strict accordance with the dimensions, ‘steel “gauges and templates as mentioned on drawings. ‘The gauges and templates shall be ‘submitted | to the Furchaser orlthe Inspecting Officer or .approval before the-work 1s ‘Commenced and calibrated thereafter periodically. . AXIAL AND RADIAL ‘RUN GUT:— Each pairsof.wheels and axle ‘shall be mounted on rigid centres .-to check the axial and ‘radial run out of each wheel with ‘the help“of the dial’ ‘gauge. Any wheel, not found meeting the +-following ‘requirements shali be rejected. Designation ‘Type of Rolling Tolerance in ‘stock nm» fxial of fcentre Magon stock 1.0 (run out) Sof the Coaching ‘stack 0.8 inner face of rim ofeach. wheel Radial off centre Wagon stock {run out) of the Coaching stock wheel tread at the taping line. The checks as per clause 7.1 can-be“tarried-out at thi time of reprofiling of the wheel if the same. is done after assembly of the wheel set. Manufacturer Shall maintain the records of the checks as per Clause 7.1 for all the wheels and produce the same on being asked by the Inspector er the Furchaser. The Inspector or the Purchaser may order retest for the checks as per clause 7-t on one out of every 280 wheelsets or part thereof. If a wheelzet fails ducing tris retest, the whole lot shall be rejected. The rejected lot can, however be reotfered tor inspection after necessary “rectification. subsequent rectification shall be permissible. On Feofiered lot the Inspecting authority shall carry the above tests on atleast 4 wheelset out of every wheelsets or part thereat. REPAIRS: Any repair for the purpose of hiding @ fault isto. dle IRS R-19/93(Part-1) prohibited and entails rejections of the supply. SAMPLE PAIR OF ‘WHEEL fm AXLE ASSEMBLY:: A sample pair ot wheel and axle assembly, fitted complete, shall be approved by the Furchaser or the Inspecing Officer before the-general exdcution of the order is proceeded with, and al] the wheel sets to be supplied on order must be similar to the approved sample. INSPECTION. The Inspecting Officer or the Purchaser shall have free access at all reasonable times to the-Works in which Wheel centres, wheels.and whee] and axle ecsemblies are being manufactured. He shall be at liberty.to inspect the manufacture et any stage and to reject any material or supplies that do not conform to this specification: The Inspecting Officer or the Purchaser shall have power to mark or deface in easily distinguishable manner all rejected wheel centres or wheels, but they shall not be marked or defaced in such a manner as to render them unsaleable to other parties. TESTING FACILITIES: The manufacturer shall supply the material required for testing free of charge, and shall, at his own cost, furnish and prepare the necessary’ test pieces, and supply labour and appliances tor such testing as may be carried out in his own premises in accordance with this specification. Failing facilities at his own Works for making the prescribed tests, the manufacturer shall bear the cost of carrying out the. test& elsewhere. PROTECTION:— Painting:— Journa! After inspection and approval, the journals shall be carefully protected with three coats'of ready mixed paint, brushing bitumanous black to 1S:9862 or with any other approved anti-rust, compound: capable of being removed easily’ by white spirit ‘or- kerosene oil. Sufficient drying time should bes allowed between successive coats. fle Body:— The rest of, the axle shall be painted“with a coat of Zinc, Chromate Primer to IS:2074-followed by a second coat 61. B1ScK Jaoan to'-IS:341,;- allowing sufficient crying time between the coats. Before. painting, all parts must be ‘cleaned free trom riistfand moisture.13.2 AB.2.4 IRS R-19/95(Part-1) JING Packina of the wheel sets shall be dane as follow: Roller Bearing Axles: Axle ends and the journal:— After painting as per clause 12.1.1, the axle ends and journals shall be covered with at least 5 mm thick well fitted one piece high density polyethylene to IS-7238- 74 designated as HDPE-34-MB cover which as shown in Fig.2, shall be secured by means of three PVC screw: which suit the axle end holes shown in relevant axle drawing. Axle Bedy:— Rest of the axle body atter painting as per clause 12.1.2 shall be covered with Smm thick high density polyethylene to IS-7238-74 designated as HDPE~44-Na& covering in two halves and clamped with 20am wide steel strap at three places as shown in figure 4. Plain Bearing Axles:— Axle Ends and Journal:— After painting as per clause 12.1.1 axle ends and the Journals shall be covered with at least Sam thick high density polyethylene to 1S-7238-74 designated as HDPE- 43-MB covering in two halves, clamped with 20 mm wide steel strap as shown in figure 3. Rest of the axle bedy after painting as per claus 12.1.2 shall be covered with Smm thick high density polyethylene to IS-7238-74 designated as HDPS-44-Me covering in two halves, clamped with ZOm wide strap at thres places as shown in figure 4. PSRINGs— Shipping marks and nw high density polyethylene covering of the In addition, a legend “DO NOT SLING HEF: stencilled cn both the journal covers and the legend “SLING HERE” 11 be led on the axle beady cover as indicaltec in figure 4.WHEELS Tre oF weer [POO GF SEMPRE (ONE END OF KLE ware 10% 1 WHEEL ostas WTO Be HOI/COLD STAMPED OR MARKED BY ELECTRC ETCHING IN 10 ram LETTERS ON LGUIER FACE OF DAE RM OF ROUGH TURRED OR FINISH TURNED WHEELS, 2 FOR La STAMPING SHOULD BE OONE ON OUTER FACE OF THE HE, 2 MME coRE_Detans TO 'BE COU SOUPED OR MARKED GY ELECTRIC ETCHING IN 10 onm LETTERS AT THE HATCHED LOCATIONS ON OUTER FACE OF THE HU, tam Qe fim seman a ® an te or WH eB pe TB. LE DETALS TT Be SAME CCAD Ot wAED OF LECT ETI ON BOTY EOS Wem LTRS Es arlnsoet toees or eres cae S| 2 0 BE SturtD m 10 men LETERS CASE ACES ARE SUPPLED AS FORGED CONGMION. B 4 psseu ogtans {55 TPE Co on MARDER EIOKNG W110 rm LEER OW THE OUTER | Hoc wee coche ESI . |= Rava meer SATE = ols BRANDING DETAILS Be Si See ON WHEEL & AXLE Be exter a SKETCH—92114® 2 —— 5 A 1 = S| | | loan 25mm 202 - NOT COMPLYING WITH THE PROVISIONS OF THIS SPECIFICATION DUE TO HIGH PRESSURE. 3 - COMPLYING WITH THE PROVISIONS OF THIS SPECIFICATION AFTER SATISFACTORY BACK PRESSURE TEST. 40S - COMPLYING WITH THE PROVISIONS OF THIS SPECIFICATION Refer FIG-(1a) wang >IT (REFER CLAUSE 2.9.5) RDS.c., Lkoeld® P mex Pomin 22mm NOT COMPLYING WITH THE PROVISICNS CF THIS SPECIFICATION DUE TO IR! ULSR PRESSURE INCR’ FIG-1(b} (REFER CLAUSE 2.9.5)> max |} 20mm 20 NOT COMPLYING WITH THE PROVISIONS OF THIS SPECIFICATION DUE TO IRREGULAR PRESSURE INCRERSE Fefutee ean "9 Seetion BE pang | FIG-1lc} RDS. iueamo tet (REFER CLAUSE 2.9.5)@WNYNO? HOVE NO SduwlS WALS OKL WAWINTH HLIM SNOTLYDO7 S1ULINS du SdduiS W33iS SOIM “OZ *NIW HLTA GadKHII 3G TIWHS SHIAOI BALLISLOUd *€ “@N-¥%-3dOH SY OSLUNSIS3O ¥é-BEe41S1 OL SNITAKLSAIOd ALTSN3O HOTH 3@ TIWHS Y3A03 SH1 NOs TWINSIOH “TZ 31Xd GaHSINIS SUL JO SNOISNAWOTC SNIGNOdSIYNOI GL waaay | “SNTGUY ONY HLONSTYSLSNUTO wot eu 9 “CUTe ta er Beer - ——+o ¥ €0°z0°10 ‘BINBYA TOL - SNOISN3WIG ~'43A03 NO SINBYSIOL ~1!31ON oat NDT 4 a So | 3 | SNTS30d ONG NOTISgLOud y - BeNSI4 ae BuBH SNITS ze @ - 3engI4Government of India Ministry of Railways (Railway Board) rpmo Corrigendum No. 1 of October 1997 to Indian Railway Standard Specification For wheel & A: le Assembly for Carriages & Wagons, Serial No. R-19/93 (Part-I) pce In lieu of Sketch-92114 Alt. Nil substitute Sketch- 92114 Alt.1. Government of India Ministry of Railways (Railay Board) Pe Corrigendom No.2 of September 1999 To Indian Railway standard Specification For Wheel and Axle Assembly For carriages and Wagons (applicable to All Gauges) Serial No. R-19/93 (Part-T) In Lieu of Sketch 92114 Alt.1 Substitute to Sketch-Government of India Ministry of Railways Railway Board remo Corrigendum No. 3 of June 2003 To Indian Railway Standards specification for Wheel and Axle assembly for Carriages and Wagons Serial No. IRS R-19/93 (Part I) (Applicable to all gauges) Replace Clause No. 5.1 by the following, “Marking should be done as per RDSO drawing No. Sk-92114 with latest alteration.”