Hindi

Maintenance Manual for BG Coaches of ICF design

Contents
Bogie

CHAPTER 3

BOGIES
301

GENERAL

302b

Deflection due to the tare weight is

almost equally divided between axle
and bolster springs. Weight of coach
body is transferred to its bogie by side
bearers pitched 1600 mm apart. Sidebearers consist of lubricated metal
slides immersed in oil baths. No
vertical weight transfer is effected
through bogie pivot and the pivot acts
merely as a centre of rotation and
serves to transmit tractive/braking
forces only.

303

BOGIE ASSEMBLY
(see figure 3.1)

The main constructional and design

features of the ICF/RCF all-coil
bogies, used on mainline BG coaches
are briefly described in the following
paragraphs. Leading Parameters of
ICF bogie are as under:
Table 3.1
S.
No.
1.

2.
3.
4.
5.
6.
7.

8.

Description

Parameters

Maximum Axle
load bearing
capacity
Wheel base
Wheel diameter
(New)
Axle guidance

16.25t, 13t

Primary
suspension
Secondary
suspension
Shock absorbers

Transfer of
coach body
weight

2896mm
915mm
Telescopic axle guide
with oil damping
Coil spring
Coil spring
i)

Vertical dashpot in
primary suspension.
ii) Hydraulic double
acting vertical
shock absorber in
secondary
suspension.
Through bogie side
bearer pitched at
1600mm.

302

ALL-COIL ICF BOGIE

302a

The
bogies
being
currently
manufactured by ICF/RCF which
have been accepted as standards of
the Indian Railways and are of an all
welded light weight construction.
Axles are located on the bogie by
telescopic dash pot and axle guide
assemblies. Helical coil springs are
used in both the primary and the
secondary stages. The axle guide
device provides viscous damping
across
primary
springs
while
hydraulic dampers are provided
across the secondary stage. Dampers
are protected against misalignment by
resilient fittings. Isolation of vibration
is effected by rubber pads in primary
and secondary suspension.

Chapter 3, Page 1 of 36

The bogie frame and components are

of all-welded light construction with a
wheel base of 2.896 metre. The wheel
sets are provided with self-aligning
spherical roller bearings mounted in
cast steel axle box housings. Helical
coil springs are used in both primary
and secondary suspension. The
weight of the coach is transferred
through side bearers on the bogie
bolsters. The ends of the bogie
bolsters rest on the bolster helical
springs placed over the lower spring
beam suspended from the bogie frame
by the inclined swing links at an angle
70. Hydraulic shock absorbers and
dash pots are provided in the
secondary and primary suspensions
respectively
to
damp
vertical
oscillations.
304

AXLE BOX GUIDE WITH DASH

POT ARRANGEMENT
(see fig. 3.2a & 3.2b)
Axle box guides are of cylindrical
type welded to the bottom flanges of
the bogie side frame with close
dimensional accuracy. These guides
together with lower spring seats
located over the axle box wings,
house the axle box springs and also
serve as shock absorbers. These
guides are fitted with guide caps
having nine holes of diameter 5 mm
equidistant through which oil in
the lower spring seat passes under

Hindi

Maintenance Manual for BG Coaches of ICF design

VERTICAL SHOCK ABSORBER

PRIMARY SUSPENSION

Contents
Bogie

SECONDARY SUSPENSION
SAFETY STRAP

BOLSTER SUSPENSIONPHANGER
LOWER SPRING BEAM

AXLE BOX SPRING

2896 WHEEL BASE

BRAKE BLOCK

BRAKE BEAM

CENTRE PIVOT
ANCHOR LINK

2364

BOGIE FRAME

3950
EQUALISING STAY
WHEEL AXLE
BOGIE BOLSTER
SIDE BEARER

I.C.F. BOGIE
FIGURE 3.1

Chapter 3, Page 2 of 36

Hindi

Maintenance Manual for BG Coaches of ICF design

pressure during dynamic oscillation

of coach and provide necessary
damping to primary suspension to
enhance better riding quality of
coach. This type of rigid axle box
guide arrangement eliminates any
longitudinal or transverse relative
movement between the axles and the
bogie frame.

309

AIR VENT SCREWS

Table 3.2

New
size
10 mm

CENTRE PIVOT
ARRANGEMENT
The centre pivot pin joins the body
with the bogie and transmits the
tractive and braking forces on the

Chapter 3, Page 3 of 36

Shop renewal
size
9 mm

Condemning
size
8.5 mm

Wear limit for wearing piece

New
size
45 mm

310

Shop renewal
size
43.5 mm

Condemning size
42 mm

ANCHOR LINKS
The floating bogie bolster which
supports the coach body is held in
position longitudinally by the anchor
links which are pinned to the bolster
sides and the bogie Transoms. One
anchor link is provided on each side
of the bolster diagonally across. The
links can swivel universally to permit
the bolster to rise and fall and sway
side wards. They are designed to take
the tractive and braking forces. The
anchor links are fitted with silent
block bushes (see figure 3.5)

SPRINGS
In ICF bogie, helical springs are used
in both primary and secondary
suspension.
The springs are
manufactured from peeled and
centreless ground bar of chrome
vanadium/chrome molybdenum steel
conforming to STR No. WD-01-HLS94 (Rev.1)

308

Wear limit for wearing plate

BOGIE BOLSTER SUSPENSION

The bolster rests on the bolster coil
springs - two at each end, located on
the lower spring beam which is
suspended from the bogie side frame
by
means
of
bolster-springsuspension (BSS) hangers on either
side. The two anchor links diagonally
positioned are provided with silent
block bushes. The links prevent any
relative movement between the bogie
frame and coach body.

307

SIDE BEARERS
The side bearer arrangement consists
of a machined steel wearing plate
immersed in an oil bath and a floating
bronze-wearing piece with a spherical
top surface kept in it, on both sides of
the bogie bolster. The coach body
rests on the top spherical surface of
these bronze-wearing pieces through
the corresponding attachments on the
bottom of the body-bolster. The
whole arrangement is provided with a
cover to prevent entry of dust in the
oil sump. (see figure 3.4 )

On the bogie side frames, directly

above the dash-pots, tapped holes are
provided for replenishing oil in the
dash pots.
Special screws with
copper asbestos washers are screwed
on the tapped hole to make it air tight.
306

Bogie

bogies. It does not transmit any

vertical load. It is equipped with
rubber silent block bushes which tend
to centralise the bogies with respect to
the body and, to some extent, control
and damp the angular oscillations of
the bogies. (see figure 3.3)

Figure 3.2a & 3.2b show modified

and unmodified guide arrangement
respectively. The quantity of oil
required to achieve 40 mm oil level
above the guide cap in modified
arrangement is approximately 1.6
liters and in unmodified arrangement
is approximately 1.4 liters. As it is
not possible in open line to
distinguish between modified and
unmodified arrangements,
40 mm
oil level is standardised for both.
305

Contents

311

SILENT BLOCK
This is a synthetic rubber bush fitted
in anchor link and center pivot of ICF
bogies to transmit force without shock
and reduce noise.

Hindi

Maintenance Manual for BG Coaches of ICF design

1
2
1. SPECIAL SEREW WITH

SEALING WASHER

2. GUIDE
3. PROTECTIVE TUBE COMPLETE

4. UPPER RUBBER WASHER

5. TOP SPRING SEAT

6. DUST SHIELD SPRING

7. DUST SHIELD
8. HELICAL SPRING

9. GUIDE RING

OIL LEVEL

10. RUBBER PACKING RING

UNDER TARE

40

11. GUIDE BUSH

OIL LEVEL BEFORE

ASSEMBLING

12. CIRCLIP
X TO RAIL LEVEL

92.5

142.5

11

104

10

13. COMPENSATING RING

14. LOWER RUBBER WASHER
15. SAFETY STRAP
16. LOWER SPRING SEAT

12
13
X TO RAIL LEVEL-

14

686 FOR ALL AC & NON-AC COACHES

15

670 FOR BOGIE ON LUGGAGE SIDE

EXCEPT POWER CARS

POWER CAR-

16

672 FOR BOGIE ON GENERATOR SIDE

MODIFIED AXLE BOX GUIDE ARRANGEMENT

Figure 3.2a

Chapter 3, Page 4 of 36

Contents
Bogie

Hindi

Maintenance Manual for BG Coaches of ICF design

1
2
1. SPECIAL SEREW WITH

SEALING WASHER

2. GUIDE
3. PROTECTIVE TUBE COMPLETE

4. UPPER RUBBER WASHER

5. TOP SPRING SEAT

6. DUST SHIELD SPRING

7. DUST SHIELD
8. HELICAL SPRING

9. GUIDE RING
10. RUBBER PACKING RING

OIL LEVEL

11. GUIDE BUSH

UNDER TARE

12. SPRING CLIP

66.5

119.5

88

11

ASSEMBLING

X TO RAIL LEVEL

10

40

OIL LEVEL BEFORE

13. COMPENSATING RING

14. LOWER RUBBER WASHER
15. SAFETY STRAP
16. LOWER SPRING SEAT

12

17. GUIDE CAP

13
17
14

X TO RAIL LEVEL686 FOR ALL AC & NON-AC COACHES

EXCEPT POWER CARS

15

16

POWER CAR670 FOR BOGIE ON LUGGAGE SIDE

672 FOR BOGIE ON GENERATOR SIDE

AXLE BOX GUIDE ARRANGEMENT

Figure 3.2b

Chapter 3, Page 5 of 36

Contents
Bogie

Contents

Hindi

Maintenance Manual for BG Coaches of ICF design

FIXING ARRGT. OF PBOTTOM

COVERPWITH BOLSTER

Bogie

SECTION A-A

TO BE TACK WELDEDPAFTER
ASSEMBLY
CENTRE PIVOT

PIN

SEALING CAP

BOGIE BOLSTER
SILENT BLOCK
SLEEVE
HEX. HEAD SCREWP& SPRING
WASHER
BOTTOM COVER
PCOMPLETE
COTTER

SPLIT PIN

A
CENTRE PIVOT ARRANGEMENT
FIGURE 3.3

Chapter 3, Page 6 of 36

Hindi

%
%
c

Contents

45

10

R1

9.5

Maintenance Manual for BG Coaches of ICF design

WEARING PIECE FOR SIDE BEARER

5
13 %

REF. DRG. NO. T-O-5-649

%
c

SURFACE SHOULD BE SMOOTH

FELT
OIL LEVEL
CHECK FOR POROUS WELDING

WEARING PIECE

Note:-P1. Bronze Wearing Piece should be renewed when the wear on the mating surface reaches
3mm that is, height is less than 42 mm or damages occur to the oil grooves.P2. The hard ground
plate should be renewed when the wear exceeds 1.5mm that is, thickness is less than 8.5 mm or
ridges are observed on the plate.

SIDE BEARER ARRANGEMENT

FIGURE 3.4

Chapter 3, Page 7 of 36

Bogie

Hindi

Maintenance Manual for BG Coaches of ICF design

Contents
Bogie

ANCHOR LINK WITH SILENT BLOCK

Figure 3.5

312a
312

BRAKE RIGGING
Brake rigging is provided to control
the speed of the coach by transferring
the braking force from the brake
cylinder to the wheel tread. Brake
rigging can be divided into two
groups i.e. Bogie mounted brake
rigging and coach under frame
mounted brake rigging.

Coach Under
Brake Rigging

Mounted

The brake rigging is as per figure 3.6.

In 16.25 t axle load bogie the four
lever used in bogie brake rigging are
each with lever ratio of 1:1.376 and
hence the total Mechanical advantage
in a bogie is 5.504 .
The components details of 16 t bogie
are given in table 3.3 (Refer ICF
drawing No. WTAC3-3-2-305).

COACH UNDERFRAME BRAKE RIGGING

Figure 3.6

Chapter 3, Page 8 of 36

Frame

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

Bogie

Table 3.3
Sr.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Description
Brake Head & block complete (L.H. Assembly)
Brake Head & block complete (R.H. Assembly )
Short lever
Long lever
Brake Block Hanger
Adjusting link
Lever Hanger
Pull rod
Pull rod
Pin
Washer
Split Cotter
Pin
Washer
Split Cotter
Pin for lever Hanger
Pin for safety wire rope
Plain washer M20
Split cotter
Brake beam
Safety wire rope
Safety straps fixing Arrangement

Ref. Drg. NO (ICF)

T-3-1-919
T-3-1-619
WLRRM 3-2-002
WLRRM-3-2-002
T-3-2-645
WT AC3-3-2-302
HIG AC 3-3-2-302
WLRRM3-2-002
T-3-2-616
T3-2-048
ICF/STD 3-2-003
T-3-2-632
T-3-2-648
ICF/STD 3-2-103
T-3-2-632
ICF/SK-3-2-179
WT AC3/3-2-307
IS: 2016-67 T.2type A
EMU-3-2-048
T-3-2-804
T-3-2-651
WT AC-3-2-304

Quantity
8
8
12
8
16
2
16
4
2
50
50
50
8
24
8
16
32
32
32
8
16
8

In 13 t axle load bogie the four lever used in bogie brake rigging are each with lever ratio of
1:1 and hence the total Mechanical advantage in a bogie is 4.
The components details of 13 t bogie are given in table 3.4 (Refer ICF drawing No. T-3-2601).
Table 3.4
Sr.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Description
Brake Head & block complete
Brake Beam
Long lever
Short lever
Pull rod
Pull rod
Adjusting Link
Lever Hanger
Safety Strap
Safety Strap
Pin
Pin
Hex head screw " BSWx 38
Spring Washer M-12
Hex. Nut BSW
Washer
Washer
Pin for lever Hanger
Split cotter

Chapter 3, Page 9 of 36

Ref. Drg. NO (ICF)

T-3-1-601
T-3-1-602
T-3-2-605
T-3-2-604
T-3-2-607
T3-2-616
T-3-2-609
T-3-2-611
T3-2-612
T-3-2-621
T3-2-048
T3-2-048
BS :3083 64
IS: 3063-72
BS:1083-65
DL-0-5-034
DL-0-5-034
ICF/SK-3-2-179
T-3-2-632

Quantity
16
8
8
8
4
2
2
16
4
4
8
50
64
64
64
50
24
16
50

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

i)

CONVENTIONAL AIR BRAKE COACH POWER CAR (refer figure 3.7)

TYPE OF COACH

BUILDER

POWER CAR TO
WLRRM6-9-0-601
HIGH CAPACITY
POWER CAR
ii)

Bogie

% OF BRAKING

ICF

TARE WEIGHT IN
TONNES
53.7

ICF

60

105.6

118

CONVENTIONAL AIR BRAKE COACH SELF GENERATING AC COACHES

(refer figure 3.8)

TYPE OF COACH
WGACCW
WGACCN
WGSCZAC
WGFAC
WGFSCZAC

BUILDER
ICF
RCF
RCF
ICF
ICF
ICF

TARE WEIGHT IN TONNES

50.0
49.1
50.1
49.3
49.7
50.0

% OF BRAKING
114.8
120.9
118.6
123.7
119.5
118.8

Levers for Power car & self generating AC coaches

Sr. No.
1.

Size
282 x 205

2.

245 X 178

iii)

Shape/Drg.

Types of coaches fitted

POWER CAR TO WLRRM6-9-0601, HIGH CAPACITY POWER
CAR, WGACCW, WGACCN,
WGSCZAC, WGFAC, WGFSCZAC
-DO-

Drawing no.
SK-93373
& SK-93371

-DO-

CONVENTIONAL AIR BRAKE COACH NON AC COACHES (refer figure 3.9)

Levers

Sr. No.
1.

Size
230 X 230

2.

200 X 200

TYPE OF COACH
GENERAL SECOND
CLASS
SECOND DAY COACH
SLEEPER
FIRST CLASS
SLR
SCNLR
PANTRY CAR
Chapter 3, Page 10 of 36

Shape/Drg.

BUILDER
ICF
RCF
ICF
RCF
ICF
RCF
ICF
ICF
RCF
ICF
ICF

Types of coaches fitted

GS,FC,SLEEPER, SLR, Second
day coach, SCNLR, PANTRY
CAR

Drawing no.
SK-93372

-DO-

-DO-

TARE WEIGHT IN TONNES

36
37.4
37
37.3
39.5
39.45
41.8
40.6
40.0
41.0
41.3

% OF BRAKING
120
115.5
116.7
115.8
109.3
109.5
103.3
106.4
108.0
105.3
104.6

Hindi

178

205

178

178

282

245

Bogie

245

245

Maintenance Manual for BG Coaches of ICF design

2,8961

CONVENTIONAL AIR BRAKE COACH (POWER CAR)

RDSO DRAWING NO. SK-93373

245
178

178

FIGURE 3.8

Chapter 3, Page 11 of 36

205

178
2,8961

RDSO DRAWING NO. SK-93371

282

245

245

FIGURE 3.7

CONVENTIONAL AIR BRAKE COACH SELF GENERATING AC COACHES

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

312b

Contents
Bogie

Bogie Mounted Brake Rigging

Bogie brake rigging has been modified to incorporate a total mechanical advantage of 7.644
per bogie for non-ac coaches and 8.40 per bogie for ac coaches.
The components of bogie mounted air brake (16 t bogie) to ICF drawing no. WTAC4-3-3-401
is given in table 3.5.
Table 3.5
Sr.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Description
Brake Head & block complete (LH)
Brake Head & Block complete (RH)
Brake beam
Safety wire rope
Lever
Lever
Lever Hanger
Pull rod
Brake block Hanger
Pin
Plain Washer
Split cotter
Pin
Plain Washer
Pin
Pin for lever Hanger
Pin for Safety wire rope
Pin Washer M 20
Split cotter

Ref. Drg. No. (ICF)

T-3-1-801
T-3-1-801
T-3-2-650
T-3-2-651
WTAC4 -3-2-402
WTAC4 -3-2-402
WTAC4 -3-2-402
WTAC4 -3-2-402
T3-2-645
T-3-2-648
ICF/ISD 3-2-003
T-3-2-632
T3-2-648
ICF/STD 3-2-003
T-3-2648
T-3-2-801
WT AC3 3-2-307
IS: W 16-67
EMU-3-2-048

Quantity
8
8
8
16
8
8
8
8
16
44
64
52
4
4
4
16
32
32
32

The components of bogie mounted air brake (13 t bogie) to ICF drawing no. T-3-2-801 is
given in table 3.6
Table 3.6
Sr. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Description
Brake Head & block complete (L.H. Assembly)
Brake Head & block complete (R.H. Assembly )
Brake beam
lever
lever
lever Hanger
Pull rod
Brake block Hanger
Pin
Plain Washer
Split Cotter
Pin
Plain Washer
Pin
Pin for lever Hanger
Pin for safety wire rope
Plain washer M20
Split cotter
Safety wire rope

Chapter 3, Page 12 of 36

Ref. Drg. NO ICF)

T-3-1-801
T-3-1-801
T-3-1-804
T-3-1-802
T-3-1-802
T-3-1-802
T-3-2-802
T-3-1-645
T3-2-648
ICF/STD-3-2-103
T-3-2-632
T-3-2-648
ICF/STD 3-2-103
T-3-2-648
T-3-2-802
WFT AC3/3-2-307
IS: 2016-67
EMU-3-2-048
T-3-2-651

Quantity
4
4
4
4
4
4
2
8
22
32
26
2
2
2
8
16
16
16
8

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

i)

Bogie

AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER (refer figure 3.10)
Levers
Sr.
No.
1.

Size
366 x 174

2.

3.

Shape/Drg.

Types of coaches fitted

Drawing no.
SK-98032

311 X 148

WGSCZAC, WGSCWAC,
WGFAC, WGFSCZ, WSCZAC,
WSCWAC, WFAC, WCBAC
-DO-

412

-DO-

-DO-

TYPE OF COACH
WGSCZAC
WGSCWAC
WGFAC
WGFSCZ
WSCZAC
WSCWAC
WFAC
WCBAC

TARE WEIGHT IN TONNES

50.95
52.10
49.90
50.00
48.90
49.40
46.20
47.90

-DO-

% OF BRAKING
40.56
39.66
41.41
41.33
42.26
41.83
44.73
43.14

ii) NON - AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER (refer figure 3.11)

Levers
Sr.
No.
1.

Size

Shape/Drg.

302 X 158

GS,SCN,SDC,WCB, SLR, WFC

SK-98027

2.

256 X 134

-DO-

-DO-

3.

405

-DO-

-DO-

TYPE OF COACH
GS
SCN
SDC
WCB
SLR
WFC

Chapter 3, Page 13 of 36

Types of coaches fitted

TARE WEIGHT IN TONNES

36.00
37.55
36.50
40.40
40.60
41.80

Drawing no.

% OF BRAKING
52.23
50.08
51.52
46.54
46.32
44.99

Hindi

31 1
148

412

174

14 8

174

Bogie

36 6

412

31 1

36 6

Maintenance Manual for BG Coaches of ICF design

Contents

28961

(FITTED WITH K TYPE COMPOSITION BLOCK) RDSO DRAWING NO. SK-98032)

AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER P

256
13 4

158

13 4

158

405

30 2

405

256

302

FIGURE 3.10

2,8961

NON - AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER P

FIGURE 3.11

Chapter 3, Page 14 of 36

(FITTED WITH K TYPE COMPOSITION BLOCK) RDSO DRAWING NO. SK-98027

Hindi
Maintenance Manual for BG Coaches of ICF design

313

Bogie

316a

EQUALISING STAYS
This device has been provided on
bogies between the lower spring
plank and the bolster to prevent
lateral thrust on the bolster springs
which have not been designed to take
the lateral forces. These links have
pin connections at both ends and,
therefore,
can
swivel
freely.
(see figure 3.13)

314

316b

Hydraulic
shock absorbers with
capacity of 600 kg at a speed of 10
cm/sec. are fitted to work in parallel
with the bolster springs to provide
damping for vertical oscillations.
WORKSHOP
BOGIE SHOP

MAINTENANCE-

MAINTENANCE OF BOGIES
(Flow Diagram)
LIFTING
SHOP

WASHING
PLANT

BOGIE
SHOP

SERVICE
SHOPS

(Fitting shop
&
Smith shop)

10

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Coach lifting
Bogie cleaning
Bogie dismantling
Component cleaning
Attention to components
Repair of components
Bogie assembly
Load testing and adjustment
Lowering of coach
Final adjustment
Figure 3.12

After lifting the coach body (refer

para 105 of chapter Coach), roll out
the bogies and send them to bogie
washing plant in bogie shop.

Chapter 3, Page 15 of 36

i)

Remove all the oil from the side

bearer oil bath.

ii)

Wash the bogie with high

pressure hot water jet to remove
all dust, mud, scales, grease and
other muck without damaging
the base primer coating.

Dismantling
i)

SHOCK ABSORBERS

316

Washing Plant

After washing and drying, roll the

bogies to dismantling line.

BOLSTER SPRING SUSPENSION

HANGERS (BSS HANGERS)
In the secondary suspension, the
bolster is supported on helical coil
springs which are placed on the lower
spring plank. The lower spring plank
is suspended from the bogie side
frame through BSS hangers on
hanger blocks. (see figure 3.14)

315

Contents

Make sure that the vent screws

are opened. Lift the bogie frame
along with the bolster using
overhead crane till all the eight
axle guides disengage from the
lower spring seats.
ii) Lower the bogie frame and
bolster on to the shop floor.
iii) Remove and collect the axle box
guide components and helical
springs in respective bins/ pallets
and send to washing plant for
thorough cleaning.
iv) Wheel sets must be first cleaned
thoroughly in the washing plant
and then sent to wheel shop.
v) Remove vertical shock absorber
and send to shock absorber
maintenance section.
vi) Disconnect
anchor
links.
Dismantle bolster suspension
hangers by placing a dead
weight on the bogie frame and
by using a jack.
vii) Disconnect equalising stays. Lift
the bolster off the bolster springs
and remove the bolster springs.
viii) Collect anchor links, equalising
stays, bolster spring suspension
(BSS) hanger pins, BSS hanger
blocks (stones), BSS hangers,
pins of equalising stays, brake
rigging components and bolster
springs into respective bins/
pallets and send to washing plant
for thorough cleaning.
ix) Send the bogie frame, bolsters,
and lower spring planks to
washing plant for thorough
cleaning and drying.
Transport the cleaned and dried bogie
frame, bolster and spring planks to
inspection and repair stands. Place the
bogie frame on repair stands in the
inverted position.

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

Bracket on Lower Spring Beam

6
2

3
3

1
5

Bracket on Bogie Bolster

4

134

526
67
200

263
3
3
3
3

672
ITEM

EQUALISING STAY FOR LOWER SPRING BEAM

(16.25 t Axle Load Bogie)

(RDSO Sketch 88105)

Chapter 3, Page 16 of 36

3.13

RIB 120x30x5
RIB 200x225x5

No. off per

assembly

2
2

BUSH%%c 42/32 x32L

BODY %%c 60x134

BOSS %%c 60/40 x32L

FIGURE

Description &
dimensions

TUBE %%c 50 BOREx462

TUBE %%c 50 BOREx640

1
1

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

COMPONENTS

SIZE-NEW

CONDEMNING

9.5

WEAR IN mm

1.5

SHOP ISSUE SIZE

8.50

HANGER BLOCKPTOP &

BOTTOM

PIN
37

35.5

38.4

36.5

1.5

36.00

9.5

R1

26

HANGER

0.25P-

HANGER AND HANGER BLOCKS

450.5

FIGURE

Chapter 3, Page 17 of 36

3.14

1.5

37.00

Hindi
Maintenance Manual for BG Coaches of ICF design

316c

Contents
Bogie

Attention to Bogie Frame

i)

ii)

for axle guide and 0.5 mm for

BSS bracket bush), damaged or
cracked,
they
should
be
replaced.
iii) Bent or damaged suspension
straps should be attended to as
required.
iv) Safety wire rope arrangement
and safety straps should be used
for brake beams as per revised
RDSO instructions.

Check the bogie thoroughly for

any possible cracks. Check the
BSS brackets, axle guides, area
surrounding the BSS bracket and
axle guide and all the welding
joints of bogie frame. If cracks
are detected, hold the bogie
frame in bogie manipulator.
After proper gouging, weld the
cracks and finish by grinding.
If the BSS brackets or axle
guides are worn (limits: 1 mm
Table 3.7

Suggested BSS bracket and axle

guide alignment gauges
Longitudinal gauge for BSS
brackets
Transverse gauge for BSS brackets
Diagonal gauge for BSS brackets
Longitudinal gauge for axle guide
Transverse gauge for axle guide
Diagonal gauge for axle guide
Distance between BSS bracket and
adjacent axle guide
Longitudinal gauge for suspension
strap

v)

vi)

13t bogies

16.25t bogies

1400
1.0 mm (700
0.5 mm
from longitudinal center-line)
2159 1.0 mm
2573 1.0 mm
570
1.0 mm (equidistant from
center-line of axle)
2159
1.0 mm
3612
1.0 mm
463
1.0 mm

1500
1.0 mm (750
0.5 mm
from longitudinal center-line)
2159 1.0 mm
2629 1.0 mm
570 1.0 mm (equidistant from
center-line of axle)
2159
1.0 mm
3612
1.0 mm
413
1.0 mm

870
1.0 mm (equidistant
from center-line of axle)

870
1.0mm (equidistant from
center-line of the axle)

Check the squareness and

alignment of BSS brackets and
axle guides with the help of
transverse,
longitudinal,
diagonal gauges and straight
edge. Axle guide alignment
should
be
checked
with
reference to the BSS brackets
and
recorded
in
RDSO
dimensional check report . A
coordinate measuring machine,
preferably CNC type, can do
these checks accurately.
If the BSS brackets do not lie
within the tolerances, relocate
one or more BSS brackets with
correct
alignment.
After
ensuring correct alignment of the
BSS brackets, measure the
location of the axle guide from
the BSS brackets and record in
RDSO dimensional check report.
If the measurements deviate
from the standard measurements,
relocate mis- aligned pair of axle
guides.

Chapter 3, Page 18 of 36

vii) The relevant axle guides should

be cut using special gouging
nozzles (PO 18 or 19) to prevent
undercutting of bogie frame.
Axle guides found bent/cracked
should also be cut out and
replaced.
viii) Weld the new axle guides with
the help of axle guide welding
fixture, if the axle guides are
damaged or worn. Check the
alignment of new axle guides
with respect to other axle guides
using master gauges and straight
edge. Any slight discrepancy in
location can be rectified by
suitable local heating of the
frame.
After
complete
rectification, record important
dimensions
in
RDSO
dimensional check report. (See
fig. 3.15 a&b, fig. 3.16 a&b)
ix)

Replace the BSS bracket bushes

and pins if they were damaged
or worn.

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

a
DIMENSIONAL
CHECK REPORT

FOR AC & POWER CAR BOGIE FRAME

C
35

D
z
413

+
- 1

+
- 1

+ 1
-

1752

1752

+
- 0.5

g4

c
g 8

1500

g 7

2896

+
- 0.5

570

750

876

C.L. OF AXLE

C.L.OF AXLE

+
- 0.5

876

+ 1
-

35

g3
+ 0.5
-

+ 1
-

+ 1
-

2159

2
61

29
26

g2

876

F
E
g 1

d
g 6

+
- 0.5

+ 1
-

g 5

z
+ 1
-

+
- 1

570

+ 1
-

A
1.

BOGIE SIDE FRAME & HEAD STOCK CENTRES ON EITHER SIDE OF THE BOGIE
FRAME AS SHOWN

THUS WILL BE PERMANENTLY PUNCH MARKED IN

CONSPICUOUS MANNER.TO ENSURE THIS 2mmTHICK X 25mmWIDE STRIP SHOULD

BE WELDED AT THE LONGITUDINAL AND TRANSVERSE CENTRES OF THE BOGIE
FRAME.PUNCH MARK SHOULD BE PUNCHED ON THIS STRIP ACCORDINGLY.
2.

TO
1 g

REPRESENT
LOCATIONS OF BOGIE GUIDES.
8

3.

E,F,G & H REPRESENT LOCATIONS OF SUSPENSION BRACKETS FOR BOLSTER

SUSPENSION ARRGT.
4.

BOLSTER SUSPENSION BRACKET PIN HOLES E,F,G,H SHALL BE LOCATED AT

750

+
0.5mm
FROM THE TRANSVERSE CENTRE LINE PUNCH MARKS ON BOGIE
-

SIDE FRAME & CHECK IT AS PER FIG.-3.15b.

5.

WELDING JOINT SHALL NOT COME UNDER THE BOGIE GUIDE.

6.

NO INACCURACY IN LOCATION OF HANGER BRACKET AND THE ALIGNMENT

OF HOLES IN THE BRACKETS WILL BE PERMITTED.

FIGURE-3.15a

ICF DRG. WTAC - 0-3-301

3
SHEET 1 OF 2

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

DIMENSIONAL CHECK REPORT FOR BOGIE FRAME (AC TYPE)

No. .
ICF DRG. NO. WTAC3 0-3-301

Measuring
Point
E -F

Nominal Size
(mm)

Actual Size
(mm)

Variation
(mm)

G -H

1500 1.0

J-K

876 0.5

E -G

2159 1.0

L-M

876 0.5

F -H

2159 1.0

M-N

876 0.5

E -H

2629 1.0

O-P

876 0.5

F -G

2629 1.0

P- Q

876 0.5

413 1.0

R-S

876 0.5

413 1.0

S-T

876 0.5

413 1.0

I-K

1752 1.0

413 1.0

L-N

1752 1.0

g1 - g2

570 1.0

O-Q

1752 1.0

g3 - g4

570 1.0

R-T

1752 1.0

g5 - g6

570 1.0

g1 - g6

3612 1.0

g7 - g8

570 1.0

g2 - g5

3612 1.0

z -F

750 0.5

g3 - g8

3612 1.0

z -H

750 0.5

g4 - g7

3612 1.0

Actual Size
(mm)

Variation
(mm)

876 0.5

Figure - 3.15b

SHEET 2 OF 2

Nominal Size
(mm)

1500 1.0

Measuring
Point
I-J

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

a
DIMENSIONAL
CHECK REPORT
FOR NON AC

BOGIE FRAME

C
35

D
z
463

+ 1
-

K
1752

+ 0.5
-

+
- 0.5

g4

+
- 1

+
- 1

c
g 8

g 7

2896

700

+ 0.5
-

1400

+
- 1

BOGIE SIDE FRAME & HEAD STOCK CENTRES ON EITHER SIDE OF THE BOGIE
FRAME AS SHOWN

THUS WILL BE PERMANENTLY PUNCH MARKED IN

CONSPICUOUS MANNER.TO ENSURE THIS 2mmTHICK X 25mmWIDE STRIP SHOULD

BE WELDED AT THE LONGITUDINAL AND TRANSVERSE CENTRES OF THE BOGIE
FRAME.PUNCH MARK SHOULD BE PUNCHED ON THIS STRIP ACCORDINGLY.
2.

TO
1 g

3.

E,F,G & H REPRESENT LOCATIONS OF SUSPENSION BRACKETS FOR BOLSTER

REPRESENT
LOCATIONS OF BOGIE GUIDES.
8

SUSPENSION ARRGT.
4.

BOLSTER SUSPENSION BRACKET PIN HOLES E,F,G,H SHALL BE LOCATED AT

700

+
0.5mm
FROM THE TRANSVERSE CENTRE LINE PUNCH MARKS ON BOGIE
-

SIDE FRAME & CHECK IT AS PER FIG.-3.16b.

5.

WELDING JOINT SHALL NOT COME UNDER THE BOGIE GUIDE.

6.

NO INACCURACY IN LOCATION OF HANGER BRACKET AND THE ALIGNMENT

OF HOLES IN THE BRACKETS WILL BE PERMITTED.

FIGURE-3.16a

+
- 0.5
+
- 1

+
- 1

1.

570

d
g6

z
+ 1
-

570

876

C.L. OF AXLE

C.L. OF AXLE

+
- 0.5

876

+ 1
-

35

73
25

g 3

1752

+
-

+ 1
-

2159

g2

g 1

12
36

876

F
E

R.D.S.O./CARR./SK93280
SHEET 1 OF 2

g 5

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

DIMENSIONAL CHECK REPORT FOR BOGIE FRAME (AC TYPE)

No. .
RDSO/SK/93280

Measuring
Point
E -F

Nominal Size
(mm)

Actual Size
(mm)

Variation
(mm)

G -H

1400 1.0

J-K

876 0.5

E -G

2159 1.0

L-M

876 0.5

F -H

2159 1.0

M-N

876 0.5

E -H

2573 1.0

O-P

876 0.5

F -G

2573 1.0

P- Q

876 0.5

463 1.0

R-S

876 0.5

463 1.0

S-T

876 0.5

463 1.0

I-K

1752 1.0

463 1.0

L-N

1752 1..0

g1 - g2

570 1.0

O-Q

1752 1.0

g3 - g4

570 1.0

R-T

1752 1.0

g5 - g6

570 1.0

g1 - g6

3612 1.0

g7 - g8

570 1.0

g2 - g5

3612 1.0

z -F

700 0.5

g3 - g8

3612 1.0

z -H

700 0.5

g4 - g7

3612 1.0

Actual Size
(mm)

Variation
(mm)

876 0.5

Figure - 3.16b

SHEET 2 OF 2

Nominal Size
(mm)

1400 1.0

Measuring
Point
I-J

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

x)

Replace the anchor link brackets if

they are worn or damaged. The M12
threaded hole should be cleaned and
checked and attended to, as required.
xi)
Bent, damaged, or worn brake hanger
brackets should be replaced. If the holes are
not aligned/located as per drawing, replace the
brackets. Use single piece design of brake

Bogie

hanger bracket for renewal. Replace the bushes

in the brake hanger brackets at every POH.
xii) Replace the brake lever hanger
brackets if the holes are
oblong/worn or damaged.
xiii) Replace all the axle box housing
crown bolt and screwing piece
by rubber stoppers.

Table 3.8
WEAR LOCATIONS (Dimensions in mm)
Part name
Wear location
Brake hanger bracket bush
32 H7 Hole +0.025/-0.00
Brake hanger bracket
Brake hanger bracket
Axle guide
Axle guide
BSS bracket bush
Pin for BSS
Bracket for anchor link
Brake lever hanger bracket

35 gap
C.D.1752 +1.0
115g6 -0.034/+0.00 diameter
120 diameter
38 dia. Hole
37 diameter
25+0.021/-0.0 slot
32 dia hole

xiv) The locations where the repairs

have been carried out should be
cleaned to bare metal and
painted with two coats of primer
to IS:2074 to a minimum Dry
Film Thickness (DFT) of 50
microns followed by one coat
of anti-corrosive Black Japan
Type-B to IS:341 to a DFT of
35 microns, after which entire
bogie frame is to be given one
coat of Black Japan Type-B to
IS:341 to a minimum DFT of 35
microns.

316d

Drg. Nos.
T-0-3-669 &
WTAC3-0-3-316
T-0-3-675
T-0-3-675
T-0-3-670 alt. 2/f
T-0-3-670 alt. 2/f
T-0-3-626 alt. 9/h
T-0-5-637 alt. m/12
T-0-3-635 alt. j/16
T-0-3-631 &
T-0-3-632

Attention
to
Bogie
Bolster
Arrangement
(Refer drg. no.WTAC3-0-5-301 &
WLRRM-0-4-001 for 16.25t bogie and
T-0-5-601 & T-0-4-601 for 13t bogie)
i) Check the bolster for twist,
crack, corrosion, etc. Repair or
replace the bolster as required,
and attend to the lug as required.
ii) Repair or replace the equalising
stay bracket if found bent,
damaged, or corroded.

Table 3.9
Part name
Side bearer wearing plate

Wear location (all dimensions in mm)

10 mm thick top wearing surface

Side bearer wearing piece

45 mm thick bottom wearing surface

Bolster Centre Pivot sleeve

Centre-Pivot silent block
sleeve
Centre Pivot silent block

Hole 155 H7 (+0.040/-0.0) c9(-0.2/-0.3)

Hole 140 H7 (+0.040/-0.0)

Centre Pivot silent block

Centre Pivot silent block
Centre Pivot pin

Hole dia. 75 +0.1/+0.2

Out side dia 140 U6 (+0.195/+0.170)
Out side dia. 90 c9(-017/-0.267) & 75 c9
(-0.150/-0.257)

Hole dia. 90 +0.15/+0.30

Drg. Nos.
T-0-5-648
10/L
T-0-5-649
17/h
T-0-6-606
T-0-6-606
T-0-6-611
16/p
-do-doT-0-6-602
(w)

alt
alt

alt.

alt.s

Hindi
Maintenance Manual for BG Coaches of ICF design

iii) Replace the anchor link bracket

by holding in bolster repair
fixture, if found worn or
damaged.
iv) Replace the bushes in the stay
rod brackets, if found worn or
damaged.
v) Replace the centre pivot silent
block if found worn, damaged or
rubber has perished.
vi) Replace the centre pivot sleeve if
worn or damaged or corroded.
vii) Replace the bolster centre pivot
sleeve if worn or cracked.
viii) Replace the rubber sealing cap
of centre pivot silent block, if
torn or damaged or perished.
ix) Replace the centre pivot pin if
worn or cracked. Chalk test the
centre pivot pin in position or
off position to detect cracks.
x) Force fit between silent block
and sleeve and tolerance on
pivot pin, i.e., c9 (-0.18/-0.27)
should be maintained in every
POH/IOH.
xi) Ensure that there is no leakage
of oil from the side bearer oilbath welding portion. Replace
the hard ground plate in side
bearer, if worn more than 1.0mm
(ref. table 3.2) in thickness or
ridges formed on the plate.
Replace the bronze wearing
piece for side bearer, if worn
more than 1.5 mm in thickness.
Sharp edges on wearing piece
should be rounded off before reuse. Ensure that the dust seal
cover sits effectively all around
without any gap on the oil-bath
and the sleeves slide freely on
the guide to ward off dust and
moisture coming in contact with
the oil. Clean refilling passages
and deficient or damaged oil
refilling cups with caps and
pipes should be replaced. The oil
filling plugs should be well
secured by chain to prevent it
from dropping.
xii) Repair or replace the bent or
damaged or broken equalising
stay rod safety loops.

Part name
Anchor link silent block pin
Anchor link silent block
Anchor link housing

Contents
Bogie

xiii) The locations where the repairs

have been carried out or found
corroded should be cleaned to
bare metal and painted with two
coats of primer to IS:2074 to a
minimum Dry Film Thickness
(DFT) of 50 microns followed
by one coat of anti-corrosive
Black Japan Type-B to IS:341
to a DFT of 35 microns, after
which entire bogie bolster is to
be given one coat of Black
Japan Type-B to IS:341 to a
minimum DFT of 35 microns.
316e

Anchor Link
(Ref: Drawing No. T 0 7 603
and T 0 7 607)
i)

Replace the anchor link, if worn

or corroded. Repair the anchor
link, if found cracked (normally
at weld joints) under magna flux
testing, by re welding after
gouging. Refit new silent block
in every POH.

ii)

Replace the silent block, if the

rubber is perished (indicated by
fretting) or loose in the anchor
link housing, or the silent block
pin is worn thin or loose in
silent block rubber. The silent
block should be force fit in the
anchor link and the silent block
pin should be slide fit in the
anchor link bracket.

iii) The locations where the repairs

have been carried out should be
cleaned to bare metal and
painted with two coats of primer
to IS: 2074 to a minimum Dry
Film Thickness (DFT) of 50
microns followed by one coat
of anti-corrosive Black Japan
Type-B to IS:341 to a DFT of
35 microns, after which entire
anchor link is to be given one
coat of Black Japan Type-B to
IS:341 to a minimum DFT of 35
microns.

Table 3.10
(all dimensions in mm)
Wear location
25 mm -0.012/-0.052, thick ends
Outer dia. 90.5 +0.05/+0.025
Hole dia 90.5 +0.015/ -0.03

Drg. No.
RDSO-Sketch-94101 alt.1
RDSO-Sketch-94101 alt.1
T-0-7-605

Hindi
Maintenance Manual for BG Coaches of ICF design

316f

Bogie

Equalising Stay Rod and Pins

(Small & Big)
(Ref: Drawing No. RDSO Sk-88105
Alt.2 for 16.25t bogie and Sk-88018
Alt.6 for 13t bogie)
Hot dip galvanised equalising
stay of 16.25t bogie is used on
all new coaches. The choice of
retro-fitment of these stays on
existing coaches is left to the
Railways. For fitment of
equalising stays to Sk-88105
Alt.2 on 13t bogies, follow
RDSO Sk-93236.
ii) Replace the corroded equalising
stays with new hot dip
galvanised stays. If any repair
like welding or straightening is
carried out, which damages the
galvanising,
repaint
the
equalising stay with epoxy paint.
iii) Bushes should be replaced in
every POH and fitted with
washers and split pins. Replace
the equalising stay pins if worn
out more than 1 mm in diameter.

iii) Replace the following parts:

bushes of BSS brackets if
worn beyond permissible
limits
equalising
stay
bracket
bushes
BSS pins if worn beyond
permissible limits.
iv) The locations where the repairs
have been carried out or found
corroded should be cleaned to
bare metal and painted with two
coats of primer to IS: 2074 to a
minimum Dry Film Thickness
(DFT) of 50 microns followed
by one coat of anti-corrosive
Black Japan Type-B to IS:341
to a DFT of 35 microns, after
which entire lower spring beam
is to be given one coat of Black
Japan Type-B to IS:341 to a
minimum DFT of 35 microns.

i)

Table 3.11
Wear Location (Dimensions in mm)
Part name
Wear location
Pins for 16.25t axle
Dia.31 (+0.5/-0.2)
load bearing capacity
equalising stay
Pins For 13t axle load
Dia. 24 (+0.2/-0.1)
bearing capacity
equalising stay
316g

Lower Spring Beam

(Ref: Drawing No.WLRRM - 0 -5 002 for 16.25t bogie and T-0 -5 - 643
for 13t bogie)
i)

ii)

Check the lower spring beam

(plank) for cracks, corrosion, etc.
and repair or replace as required.
The following parts of the lower
spring plank should be inspected
and repaired or replaced as
required:
bolster suspension straps if
bent or damaged
stay rod brackets if worn,
bent or corroded
shock absorber fixing bosses
if damaged
spring guide rings if required
lug if damaged.

Contents

Table 3.12
(all dimensions in mm)
Part name
Wear
Drg. No.
location
BSS bracket Hole 38 H11 WLRRM(+0.16/-0.00)
0-5-002
bush
Eq.
Stay Hole 42 H7 WLRRM bracket
(+0.025/-0.0)
0-4-002
316h

BSS Hanger
(Ref: Drawing No. T 0 5 639)
i)

Check the cleaned hangers for

cracks and wear. Replace the
hangers if cracked or wear
exceeds 1 mm. Magna flux
crack detection equipment shall
be used for checking.
ii) The horizontal wearing surface
may be built up using 2B
electrodes, filed and ground to
size. Then hard powder coating
may be applied. Hardness value
should be 55-60 Rockwell-C
iii) The vertical gap should be within
the permissible limit i.e.,
384+0.0/-1.0 mm. All the hangers
should be tested to tensile load
of 8 tonnes and replaced if any
permanent set is observed in the
hangers.
iv) After repair and testing all the
BSS hangers should be painted
with one coat of anti corrosive
black paint. Write the actual
length between the wearing
arms on the BSS hanger with
paint.

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

Bogie

Table 3.13
(all dimensions in mm)
Part name
BSS hanger
BSS hanger
BSS hanger
Hanger block
Hanger block
BSS pin
316i

Hanger Block (Stone)

(Ref: Drawing No.WLRRM - 0 - 5
203 and T-0-5-638)
i)

316j

Wear location
distance between horizontal wearing arms 384
thickness of vertical arm 25.5
horizontal wearing surface 42
Thickness - 9.5
slot 29 (+0.4/-0.2)
29 (+0/-0.1)

Replace the hanger blocks if

cracked. Worn hanger blocks
may be built up by welding with
2B electrodes and machined to
size. After repair and testing all
the hanger blocks should be
painted with one coat of anticorrosive Black Japan Type-B to
IS:341.

Axle Box Guide Assembly

(Ref: Drawing No.WTAC3 - 0 - 1
301 and T-0-1-636)
i.

Use the modified guide cap

(RDSO sketch no. 85070 Alt.3)
and its securing arrangement on
existing bogies. New bogies are
fitted with dash- pot guide
arrangement to T-0-1-641.

ii.

Replace the upper rubber

washer, lower rubber washer,
packing ring, guide ring, dust
shield , guide bush, dust shield
spring, and spring clip as a kit.
Table 3.14

Critical Dimensions
(dimensions in mm)
Component
Dimension
Drg. no.
Lower
hole 140 H7 RDSO Skspring seat
(+0.04/-0.0)
90005 Alt.2
Guide bush
O.D. 140 A9 RDSO SK(-0.3/-0.6)
84102 Alt.5
Guide bush
hole dia 115 -do(+0.15/-0)
Guide Ring
hole 115 H7 -do(+0.04/-0)
iii. Replace the lower spring seat if
worn, cracked, scored, etc.

Drg. Nos.
T-0-5-639
-do-doT-0-5-638
-doT-0-5-637

iv) Whenever an axle guide is

replaced due to damaged/
misalignment,
preferably
modified guide with circlip
arrangement may be fitted.
v) Common defects found in axle
guide assembly during POH and
their reasons and remedies are
given in Annexure 3.1.
317

COIL SPRINGS
i.

Coil spring should be maintained

as per C-8419 (Rev.1)
ii. Clean the spring thoroughly,
remove any oil, grease, etc. by
putting them in a Bosch cleaning
tank. After that carry out visual
inspection of the spring coil by
coil. Carry out magna flux test to
detect cracks. Springs having
cracks, dents or hitting marks
should be rejected and scrapped.
Records should be maintained of
rejected springs with details of
defects noticed.
iii. Each spring should be subjected
to incremental load up to the
figure indicated in the table 3.16
and 3.17 and the load should be
maintained for a period of 2
minutes, after which the
corresponding height of spring
under load is determined.
iv. Replace the upper rubber
washer, lower rubber washer,
packing ring, guide ring, dust
shield , guide bush, dust shield
spring, and spring clip as a kit.
v. Replace the lower spring seat if
worn, cracked, scored, etc.
vi. Each spring may be tested for
other deflections/loads indicated
in drawing and the spring
characteristics
plotted.
The
spring should be replaced if its
characteristics are not within
specified limits.

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

Bogie

Table 3.15
Drawing code of springs for ICF BG coaches
(Reference RDSO Amendment slip no. 5 of September 2001 to STR WD-01-HLs- 94
(Rev.1 May 95)
Type of spring

Axle box

Bolster

Type of bogies

ICF Drg. No

Drg. Code
No.
A01

All Non AC ICF type

F-0-1-006

All AC ICF type

WTAC-0-1-202

A03

Power car

WLRRM2-0-1-202

A04

Double decker

DD-0-1-001

A06

High capacity Power Car

WLRRM8-0-1-802

A09

High capacity parcel van

RDSO /SK-98017

A10

All Non AC ICF type

F-0-5-002

B01

All AC ICF type

WTAC-0-5-202

B03

Power car

WLRRM2-0-5-202

B04

Double decker

DD-0-5-003

High capacity Power car

WLRRM8-0-5-802

High capacity Parcel van

RDSO /SK-98018

B06
B11
B13
B15
B16

Bolster

Table 3.16
Load deflection testing and grouping of Axle box spring (B.G Main line coaches)

Code

Wire
dia

Free
height

Test
Load

Acceptable
height under
test load

Groups as per loaded spring height

Yellow

Oxford
Blue*

Green

A01

33.5

360

2000

279-295

279-284

285-289

290-295

A03

33.5

375

2800

264-282

264-269

270-275

276-282

A04

35

372

3000

265-282

265-270

271-276

277-282

A06

36

337

2400

269-284

269-273

274-279

280-284

A09

37

360

3000

277-293

277-282

283-288

289-293

276-279

280-284

285-289

A10
39
315
1800
276-289
* As per RDSO's letter no. MC/SPG dated 25.7.01

Hindi
Maintenance Manual for BG Coaches of ICF design

Contents
Bogie

Table 3.17
Load deflection testing and grouping of Bolster spring
(B.G Main line coaches)
Code

Wire
dia

Free
height

Test
Load

Acceptable
height under
test load

Groups as per loaded spring height

A
Yellow
B01
42
385
3300
301-317
B03
42
400
4800
291-308
B04
47
400
6100
286-304
B06
36
416
4200
280-299
B11
47
*386
6700
306-322
B13
34
B15
40
393**
6000
256-272
B16
32.5
286 **
* Combined load deflection test is done
** As per RDSO's letter no. MC/MV dtd. 21.11.01
# As per RDSO's letter no. MC/SPG dtd. 25.7.01
v.

After load deflection test, the

acceptable springs should be
given one coat of Red Oxide
Zinc Chromate primer to
IS:2074 to a minimum DFT of
50 microns. A coat of Black
Japan Type-B to IS:341 to a
minimum DFT to 35 microns
should follow the primer coat to
have better abrasion resistance
and corrosion resistance. Then
the springs have to be painted
with 50 mm wide vertical
stripes at three locations, equispaced on the circumference
using different colours of paints
to IS:8662 as given below:
Spring group
A
B
C

vi.

Colour code
Yellow
Oxford Blue
Green

All the springs should be

grouped in three groups as
shown
in
table
above,
depending upon their deflection
under test load. For pairing,
springs should be selected from
the same group. Height under
test load should be painted on
all springs to enable selection of
springs.

318

301-305
291-296
286-291
280-286

B
Oxford
Blue #
306-311
297-303
292-297
287-292

C
Green
312-317
304-308
298-304
293-299

306-311

312-317

318-322

256-261

262-267

268-272

BOGIE BRAKE GEAR

i.

Repair or replace the worn,

damaged, corroded bogie brake
levers. Replace the bushes in the
bogie brake levers. Nylon 66
brake gear bushes to RDSO STR
No. C-8107 should be fitted in
brake gear.

ii.

Repair or replace the corroded,

cracked, or worn brake beams.

iii. Repair or replace the corroded,

dented, damaged brake head
shoes. Replace the worn bushes,
adjuster, weakened spring, etc.,
in all the serviceable brake head/
shoe.
iv.

Replace the worn, damaged, etc.

brake gear pins with new ground
finished and chromium plated
pins. Z lever pin shall be to
RDSO Sketch 98127.

v.

Replace the brake blocks if worn

out to thickness of 20 mm or
below.

vi.

Replace the weak and damaged

brake shoe key.

vii. All the brake gear components

should be given one coat of red
oxide primer and one coat of
anti-corrosion
Black
Japan
Type-B to IS: 341.

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

319

BOGIE ASSEMBLY

319a

General

Bogie

319c

Bolster Assembly Work Station

i.

Grease the BSS pins, hanger

blocks, anchor link silent block
pins and anchor link brackets
with graphite grease. Ensure that
bolster springs with height
(under test load) variation within
2 mm are selected in the same
group of springs for each bogie
assembly.

ii.

Assemble lower spring planks,

compensating rings, bolster
spring, rubber washer and other
secondary
suspension
components.
Compensating
rings shall be specified in
relevant suspension diagram
issued by PUs. Additional
compensating ring to maintain
bolster clearance of 40
3 can be
added. Lower the bogie frame
assembled with brake gear and
axle guide assembly on the
bolster assembly. Connect the
bogie frame and lower spring
plank with BSS hanger with the
help of a dead weight. Connect
the lower spring planks and
bolster with equalising stays and
pins. Secure the equalising stay
pins with washers and split pins.
Ensure that the split pins are
split to minimum 90o and not
slack in the pins. Connect the
bogie frame and bolster with
anchor links. Secure the anchor
links in the brackets with M12
hexagonal head screws and
spring washers.

Bogie assembly can be systematically

carried out, if it is organised under
three
workstations
described
hereunder. A sub store in the bogie
shop may be necessary to ensure
supply of proper components and subassemblies for bogie assembly.
319b

Brake Gear and Axle

Assembly Work Station

Guide

i.

After the inspection, repair and

alignment of BSS brackets, axle
guides and the bogie frame,
place the bogie frame in the
normal position on assembly
stands.

ii.

Assemble the brake gear

components including brake
blocks on the bogie frame with
pins, washers and split cotters.
Ensure that the cotters are split
minimum 90o and not slack in
the pins. Modified lever hanger
pins (RDSO sketch no. 98127)
should be used to prevent the
bush working out of the lever
hanger.
Ensure
that
the
maximum dimensional clearance
between the pins and bushes is
1.5 mm.

iii. Apply some lubricating oil on

axle guide outer surface and on
inside surface of guide bush.
Assemble the axle guide
components on the axle guide
and secure them with guide cap
(whose 9 holes should be
cleaned before securing) as per
RDSO sketch no. 85070 Alt.3.
While tightening the guide cap,
it should be ensured that guide
bush sits tight against the rubber
packing ring and the holes in the
guide are in alignment with
corresponding holes in the guide
bush. New coaches are fitted
with modified axle guide
arrangement to T-0-1-641.

iii. Replace the rubber sealing cap

on the centre pivot silent block.
319d

Bogie Lowering Work Station

i.

Select the wheel sets such that

the maximum variation in tread
diameter between the wheels on
same axle as 0.5 mm, between
two wheel sets in same bogie as
5 mm and among the four wheel
sets in the same coach as 13
mm. Select axle box springs in
the same group of springs as
given in table 3.16.

Hindi
Maintenance Manual for BG Coaches of ICF design

ii.

Assemble the lower rubber

washer, lower spring seat,
compensating ring, hard packing
ring, selected axle box springs,
upper spring seats, upper rubber
washer, protective tube, etc., as
per the drawing for axle box
guide arrangement. Put dash pot
oil of approved brand in lower
spring seat to a level of 60 mm
from bottom. The approved
brands of dash pot oil are the
following:

Bogie

exceed 1.6 mm. The bogie

should sit evenly on the four
axle boxes.
v.

The assembled bogie should be

load tested on a bogie test stand
where it is loaded up to its
normal working load and the
height of bolster top surface
form rail level should be
measured for comparison with
pre-determined
dimension
corresponding to correct coach
buffer height. Adjustment for
getting correct buffer height
should be made, if needed. If the
buffer height requires further
adjustment, the load on the axle
box spring should be released
and compensating rings should
be inserted below the axle box
spring ensuring that the bogie
frame height is 686 5 mm.

vi.

Safety straps of the axle box

wing lugs and bogie bolster
should be adjusted so as to
ensure a minimum clearance of
40 mm between the lugs and
bottom of safety straps.

a. Servoline
- 100 of
IOC b. Yantrol
- 100
of HPC c. Bharat univol
100 of BPC
iii. For obtaining correct buffer
height when the coach body is
lowered on the bogies, while
assembling the bogie hard
rubber, UHMWPE or NFTC
packing of required thickness,
depending
on
the
wheel
diameter, should be provided
under the flanges of the lower
spring seats. Packing rings of
thickness as given in table 3.18
and as shown in figure 3.17
(RDSO sketch 77354) should be
used. Compensating rings of
suitable thickness as per
suspension diagram for relevant
coach should be placed over the
flange of the lower spring seat.
Table 3.18
Average tread
diameter of two
wheel sets of bogie
889 to 864 mm
863 to 840 mm
839 to 820 mm
819 mm
iv.

Thickness of
hard packing
ring
13 mm
26 mm
38 mm
48 mm

Lower the bogie frame with the

bolster assembly on the wheel
sets thus prepared, taking care to
ensure that the rubber packing
ring does not get damaged while
lowering the guide bushes on to
the lower spring seat. The
maximum diametrical clearance
between the lower spring seat
and guide bush should not

Contents

vii. Fit the vertical shock absorber

between the bolster and bottom
spring plank.
viii. Check the oil in the dash pots
with the flexible wire gauge and
if necessary, top up the dash pots
with the approved brand of dash
pot oil to bring the level to 60
mm from under surface of dash
pot. If the flexible gauge
indicates a higher level of oil,
the guide cap may have fallen in
dash pot. This should be checked
and attended to.
ix.

Axle box rubber bump stopper

should be adjusted to obtain the
required clearance between the
axle box crown and the bogie
frame.

x.

After testing and making

adjustments for correct buffer
height, dispatch the bogie to
Lifting shop for lowering the
coach body.

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

Bogie

DIMENSION `A'

AS SHOWN BELOW

TYPE OF COACH

GS,SDC,SLR,SCN

+0

43

-3

WCB,WCBAC,WFC,WFAC
WGFAC,WSCWAC,WGCWAC
WGACCN,WACCN,WSCZAC
WGSCZAC,WFCZAC,WLRRM

1. INSERT 13 mm PACKING FOR

13 mm TREAD WEAR.
2. INSERT 26 mm PACKING FOR
26 mm TREAD WEAR.
3. INSERT 38 mm PACKING FOR
38 mm TREAD WEAR.
4. INSERT 48 mm PACKING FOR
819 DIA. TREAD.

BUFFER HEIGHT ADJUSTMENT

(ICF COACH)
SKETCH-77354

CROWN
CLEARANCE
A
mm

FIGURE 3.17

27

+0
-3

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

which is indicated primarily

by oil leakage or when they
are physically damaged.

LIFTING SHOP
319e

Lowering the Coach Body in Lifting

Shop
2.
i.

Place the wearing plate and

wearing piece in side bearer oilbath. Fill each side bearer oilbath with 2 litres of any of the
following approved brands of
oils.
Servoline

100 of IOC

Yantrol

100 of HPC

Bharat univol 100 of BPC

ii.

319f

Apply graphite grease on Centre

pivot pin and lower the coach
body on the side bearer wearing
pieces. Care should be exercised
to make sure that the side
bearers are resting properly.
Place the cotter in position in
Centre pivot pin and secure it
with a split pin. A bottom cover
should be fitted for covering the
entire assembly to prevent dust
ingress. Tighten the air vent bolt
with gasket to prevent spilling of
dash pot oil.

Shock Absorbers
Reference may be made to RDSO
specification C-8703 (Rev.1) for
hydraulic shock absorbers for
coaching stock.
1. Periodicity of overhaul
i) Schedule overhaul: Shock
absorbers should be given a
schedule overhaul:
a.

b.

When their capacities

vary beyond 20% of
their specified values,
or
After 4 lakh kilometers
or
alternate
POH,
whichever is earlier.

ii) Non schedule overhaul:

Shock absorbers should also
be overhauled whenever
suspected to be defective,

Contents

Testing
i) The shock absorber is tested
on the special purpose
machine (RDSO sketch nos.
69.2.04.00 to 69.2.04.08)
which can measure its
capacity in both tension and
compression by developing
the resisting force at a
velocity of 10 cm/sec. The
length of the shock absorber
and its stroke should be
within the limits specified in
the table 3.19.
ii) The shock absorber must be
tested at every POH and
reused if overhauling is not
due and the capacity is
within 20%. A register
should be maintained in the
shock
absorber
section
wherein the test results of
each shock absorber should
be recorded before the shock
absorber is certified fit for
use on coaches.
iii) After the testing and
certification, the protection
cover of the shock absorber
should be pressed into
position on the piston rod
disc and spot welded at six
points around the periphery.
iv) The shock absorber should
then be extended on the
mounting fixture and painted.
When the paint dries, it
should be compressed and
then removed from the
fixture.
v) The date of testing, the date
of overhauling and the name
of the shop where overhauled
should invariably be stamped
on the name plate of the
shock absorber before it is
sent for fitment.

Contents

Hindi
Maintenance Manual for BG Coaches of ICF design

Bogie

Table 3.19

Compressed

Nominal

Extended

Nominal
Stroke
(mm)

250 3

320 3

360 3

110

Length (mm)
Makers Type

Variation from
Nominal
Min.
Max.
(mm)
(mm)

Vertical shock absorbers:

M/s ESCORTS
M/s KNORR BREMSE
M/s GABRIEL
ICF/SK-0-5-015

320

LIST OF TOOLS AND PLANT

LIFTING SHOP

FITTING SHOP

Ball peen hammer

Chisel
Spanner

Ball peen hammer

Chisel
Welding transformer
Gas cutting plant
Hydraulic press
Measuring gauges
Center lathe
Brake beam end turning m/c
Electrode heater
Hard surface plant
BSS hanger testing m/c
Bins and pallets
Fork lift
Platform truck

WASHING PLANT
Bosch tank
Hot water jet system
Bins and pallets
Jib crane
Fork lift
Platform truck
BOGIE SHOP
Ball peen hammer
Chisel
Spanner set
Welding transformer
Gas cutting plant
Bogie alignment gauges
Spring testing machine
Magnaflux crack detector
Paint brushes
Floor scraper
Bogie frame repair fixture
Bolster repair fixture
Bogie test rig
Working stands
Overhead crane
Bins and pallets
Fork lift
Platform truck

SMITH SHOP
Helical spring repair tools &
plant
Shot peening plant
Heat treatment plant
Smiths tongs, hammers &
blocks

-70

40

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

321

EXAMINATION AND REPAIR

PRACTICE
IN
CARRIAGE
MAINTENANCE DEPOT

Bogie

321b

Primary Suspension
i) Primary/Secondary Examination

Depot maintenance staff should

ensure the following things in respect
of proper functioning and safety of
Bogie & Bogie components.
321a

Visually examine axle box

springs for breakage.

Visually examine dash pot oil

filling special screw for
deficiency.

Check oil leakage in dash pot

through defective seals/vent
screws.

Bogie Frame
i)

Primary/Secondary
Examination, Schedule A &
B Examination

Visually examine
clearance

axle

box

Examine visually condition of

bogie side frame, transom,
longitudinals and all welded
locations.

ii)

Examine rubber stopper/stop

screw of axle box crown for
damage/missing/loose.

Examine as per (i) above.

Add specified grade of oil in

dash pot.

Inspect axle box safety

straps/loops
for
damage/broken/missing.

Visually examine axle box

clearance.

Bolster safety straps/loops for

damage/broken/missing.

Brake hanger
damages.

Inspect safety brackets for

brake hanger pins.

Check visually BSS hanger

brackets.

Examine visually anchor link

brackets.

brackets

iii)

for

Visually examine centre pivot

mounting bolts and attend if
needed.

Visually inspect centre pivot

cover.

Side bearer oil to be

replenished in A & B
schedules, if needed.

321c

Schedule A & Schedule B

Schedule C

Examine as per (ii) above.

Check and attend axle guide

assembly if necessary.

Check axle box clearance with

gauge

Secondary Suspension
i)

Primary/Secondary
Examination, Schedule A, B &
C examination

Visually examine bolster springs

breakages/damages.

Visually examine Bolster lower

spring beam.

ii)

Schedule C Examination

Visually examine BSS hangers,

hanger blocks, BSS pins.

Examine as per (i) above.

Examine condition of wearing

piece and wearing plate

Check bolster clearance between

top of bolster and bottom of
bogie frame.

Examine oil level in side

bearer oil baths and replenish
if oil level has gone down
below the level of last thread
of oil filling cup.

Visually examine equalising stay

rods and pins (small and big).

Visually check anchor links.

Hindi

Contents

Maintenance Manual for BG Coaches of ICF design

321d

Examine Visually anchor link

securing bolts and attend if
needed.

Visually examine
stay rod brackets.

Examine and attend safety loops

of bolster.

Check and attend safety loops of

Equalising stay rod.

Examine
vertical
absorbers for damages.

Bogie

Examine and attend floating

lever suspension brackets

Examine lever hanger pins.

Equalising
321e

shock

Bogie to be run out if found

necessary/During IOH following
should be done

Examine and replace all the

brake gear components found
deficient / worn out.

Examine and replace primary

and
secondary
suspension
components as required.

Examine wheel profile and

thickness and gauge in case they
appear to be near condemning
limit

Brake Rigging
i)

Primary / Secondary
Examination

Check brake gear and adjust so

that the piston stroke is within
the limit.

Examine
brake
breakages/damages.

Check and attend brake beam

safety wire ropes/safety straps.

Check and attend brake shoe

head and key & replace if
necessary.

Check and replace worn brake

blocks.

Visually inspect and replace

brake hangers, brake gear pins
and
cotters/split
pins
if
necessary.

beams

Visually inspect and replace

damaged/missing brake gear
bushes if necessary.

ii)

Schedule A, B & C
Examination

Examine as per (i) above.

Check and attend brake block

adjuster.

Examine and attend brake levers.

322

SAFETY PRECAUTIONS

Whenever a coach is examined

at maintenance depot, it should
be ensured that the prescribed
number of safety straps, safety
wire rope, axle box safety strap,
bolster safety loop, centre pivot
cap, hangers or brackets of
specified dimension and sections
required for various components
are fitted at specified location.

All fasteners e.g. bolts, nuts,

cotters etc. used in under frame
equipments, brake gear, buffing
and draw gear should be
checked.

Hindi
Maintenance Manual for BG Coaches of ICF design

Contents
Bogie

Annexure - 3.1
COMMON DEFECTS FOUND IN AXLE GUIDE ASSEMBLY

S.No.

Defects

Reason

1.

Perished
rubber
packing ring

Poor quality of rubber

packing ring

2.

Axle guide found

worn on one side

1)

Misaligned fitment
of axle guides to
bogie frame.
2) Dust ingress to
lower spring seat.

3.

Axle box spring

rubbing
upper
spring seat
Guide bush worn
Lower spring
surface worn
Guide ring broken

Do

Do

Do
Do

Do
Do

4.
5
6.

1)

2)

7
8.

9
10

Guide cap securing

assembly broken
Lower spring seat
scored and dent
mark on guide cap
Dust shield spring
broken or distorted
Leakage from
lower spring seat

Axle guide is
hitting
lower
spring seat
Weld joint of
lower spring seat
and tube is porous
or cracked

Remedies
1)

Replace rubber packing ring at every

examination.
2) Use only rubber packing rings
conforming to IRS specification no. R47-72 and the relevant drawing.
1) The alignment of axle box guide
should be checked with alignment
gauges and corrected.
2) Vent hole should be sealed with
gaskets. Screw to be tightened well
after oil topping.

Do

1) Guide securing bolt should not project

out of guide cap.
2) Use good quality upper and lower
rubber washers and correct number of
compensating rings in the axle guide
assembly.
3) Adjust A, B and C clearances on
leveled track.
4) Strip and reweld lower spring seat
correctly.
Do

Do

Do

Do

Do

Do

Do

******