Hindi Contents

Maintenance Manual for BG Coaches of ICF design Bogie

CHAPTER 3

BOGIES

301 GENERAL 302b Deflection due to the tare weight is

almost equally divided between axle
The main constructional and design and bolster springs. Weight of coach
features of the ICF/RCF all-coil body is transferred to its bogie by side
bogies, used on mainline BG coaches bearers pitched 1600 mm apart. Side-
are briefly described in the following bearers consist of lubricated metal
paragraphs. Leading Parameters of slides immersed in oil baths. No
ICF bogie are as under: vertical weight transfer is effected
through bogie pivot and the pivot acts
Table 3.1 merely as a centre of rotation and
serves to transmit tractive/braking
S. Description Parameters forces only.
No.
1. Maximum Axle 16.25t, 13t
load bearing 303 BOGIE ASSEMBLY
capacity (see figure 3.1)
2. Wheel base 2896mm
3. Wheel diameter 915mm
(New)
The bogie frame and components are
4. Axle guidance Telescopic axle guide of all-welded light construction with a
with oil damping wheel base of 2.896 metre. The wheel
5. Primary Coil spring sets are provided with self-aligning
suspension spherical roller bearings mounted in
6. Secondary Coil spring cast steel axle box housings. Helical
suspension coil springs are used in both primary
7. Shock absorbers i) Vertical dashpot in and secondary suspension. The
primary suspension. weight of the coach is transferred
ii) Hydraulic double through side bearers on the bogie
acting vertical
bolsters. The ends of the bogie
shock absorber in
secondary bolsters rest on the bolster helical
suspension. springs placed over the lower spring
8. Transfer of Through bogie side beam suspended from the bogie frame
coach body bearer pitched at by the inclined swing links at an angle
weight 1600mm. 70. Hydraulic shock absorbers and
dash pots are provided in the
302 ALL-COIL ICF BOGIE secondary and primary suspensions
respectively to damp vertical
302a The bogies being currently oscillations.
manufactured by ICF/RCF which
have been accepted as standards of 304 AXLE BOX GUIDE WITH DASH
the Indian Railways and are of an all POT ARRANGEMENT
welded light weight construction. (see fig. 3.2a & 3.2b)
Axles are located on the bogie by
telescopic dash pot and axle guide Axle box guides are of cylindrical
assemblies. Helical coil springs are type welded to the bottom flanges of
used in both the primary and the the bogie side frame with close
secondary stages. The axle guide dimensional accuracy. These guides
device provides viscous damping together with lower spring seats
across primary springs while located over the axle box wings,
hydraulic dampers are provided house the axle box springs and also
across the secondary stage. Dampers serve as shock absorbers. These
are protected against misalignment by guides are fitted with guide caps
resilient fittings. Isolation of vibration having nine holes of diameter 5 mm
is effected by rubber pads in primary equidistant through which oil in
and secondary suspension. the lower spring seat passes under

Chapter 3, Page 1 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

VERTICAL SHOCK ABSORBER

SECONDARY SUSPENSION
PRIMARY SUSPENSION

SAFETY STRAP

BOLSTER SUSPENSIONPHANGER
AXLE BOX SPRING LOWER SPRING BEAM

2896 WHEEL BASE

BRAKE BEAM BRAKE BLOCK

CENTRE PIVOT

BOGIE FRAME ANCHOR LINK

2364
3950

EQUALISING STAY

WHEEL AXLE

BOGIE BOLSTER

SIDE BEARER

I.C.F. BOGIE
FIGURE 3.1

Chapter 3, Page 2 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

pressure during dynamic oscillation bogies. It does not transmit any

of coach and provide necessary vertical load. It is equipped with
damping to primary suspension to rubber silent block bushes which tend
enhance better riding quality of to centralise the bogies with respect to
coach. This type of rigid axle box the body and, to some extent, control
guide arrangement eliminates any and damp the angular oscillations of
longitudinal or transverse relative the bogies. (see figure 3.3)
movement between the axles and the
bogie frame. 309 SIDE BEARERS

Figure 3.2a & 3.2b show modified The side bearer arrangement consists
and unmodified guide arrangement of a machined steel wearing plate
respectively. The quantity of oil immersed in an oil bath and a floating
required to achieve 40 mm oil level bronze-wearing piece with a spherical
above the guide cap in modified top surface kept in it, on both sides of
arrangement is approximately 1.6 the bogie bolster. The coach body
liters and in unmodified arrangement rests on the top spherical surface of
is approximately 1.4 liters. As it is these bronze-wearing pieces through
not possible in open line to the corresponding attachments on the
distinguish between modified and bottom of the body-bolster. The
unmodified arrangements, 40 mm whole arrangement is provided with a
oil level is standardised for both. cover to prevent entry of dust in the
oil sump. (see figure 3.4 )
305 AIR VENT SCREWS
Table 3.2
On the bogie side frames, directly
above the dash-pots, tapped holes are Wear limit for wearing plate
provided for replenishing oil in the
dash pots. Special screws with New Shop renewal Condemning
copper asbestos washers are screwed size size size
on the tapped hole to make it air tight. 10 mm 9 mm 8.5 mm

306 BOGIE BOLSTER SUSPENSION Wear limit for wearing piece

The bolster rests on the bolster coil
springs - two at each end, located on New Shop renewal Condemning size
size size
the lower spring beam which is
45 mm 43.5 mm 42 mm
suspended from the bogie side frame
by means of bolster-spring-
310 ANCHOR LINKS
suspension (BSS) hangers on either
side. The two anchor links diagonally
The floating bogie bolster which
positioned are provided with silent
supports the coach body is held in
block bushes. The links prevent any
position longitudinally by the anchor
relative movement between the bogie
links which are pinned to the bolster
frame and coach body.
sides and the bogie Transoms. One
307 SPRINGS anchor link is provided on each side
of the bolster diagonally across. The
In ICF bogie, helical springs are used links can swivel universally to permit
in both primary and secondary the bolster to rise and fall and sway
suspension. The springs are side wards. They are designed to take
manufactured from peeled and the tractive and braking forces. The
centreless ground bar of chrome anchor links are fitted with silent
vanadium/chrome molybdenum steel block bushes (see figure 3.5)
conforming to STR No. WD-01-HLS-
94 (Rev.1) 311 SILENT BLOCK
308 CENTRE PIVOT This is a synthetic rubber bush fitted
ARRANGEMENT in anchor link and center pivot of ICF
The centre pivot pin joins the body bogies to transmit force without shock
with the bogie and transmits the and reduce noise.
tractive and braking forces on the

Chapter 3, Page 3 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

2
1. SPECIAL SEREW WITH
3
SEALING WASHER

4 2. GUIDE

3. PROTECTIVE TUBE COMPLETE

5
4. UPPER RUBBER WASHER
6 5. TOP SPRING SEAT

6. DUST SHIELD SPRING

7
7. DUST SHIELD

8. HELICAL SPRING
8 9. GUIDE RING
OIL LEVEL
UNDER TARE
10. RUBBER PACKING RING
9

40
11. GUIDE BUSH
OIL LEVEL BEFORE
ASSEMBLING
12. CIRCLIP
10

X TO RAIL LEVEL
13. COMPENSATING RING
142.5

14. LOWER RUBBER WASHER

92.5
104

11 15. SAFETY STRAP

16. LOWER SPRING SEAT

12

13
X TO RAIL LEVEL-

14 686 FOR ALL AC & NON-AC COACHES

EXCEPT POWER CARS

POWER CAR-

15 670 FOR BOGIE ON LUGGAGE SIDE

16 672 FOR BOGIE ON GENERATOR SIDE

MODIFIED AXLE BOX GUIDE ARRANGEMENT

Figure 3.2a

Chapter 3, Page 4 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

1
2
1. SPECIAL SEREW WITH
3
SEALING WASHER

4 2. GUIDE

3. PROTECTIVE TUBE COMPLETE

5
4. UPPER RUBBER WASHER
6 5. TOP SPRING SEAT

6. DUST SHIELD SPRING

7
7. DUST SHIELD

8. HELICAL SPRING
8 9. GUIDE RING

10. RUBBER PACKING RING

9 OIL LEVEL
11. GUIDE BUSH
UNDER TARE

OIL LEVEL BEFORE 12. SPRING CLIP

40
10 ASSEMBLING

X TO RAIL LEVEL
13. COMPENSATING RING

14. LOWER RUBBER WASHER

119.5

66.5
88

11 15. SAFETY STRAP

16. LOWER SPRING SEAT

12 17. GUIDE CAP

13
17
14 X TO RAIL LEVEL-

686 FOR ALL AC & NON-AC COACHES

EXCEPT POWER CARS

15 POWER CAR-
16
670 FOR BOGIE ON LUGGAGE SIDE

672 FOR BOGIE ON GENERATOR SIDE

AXLE BOX GUIDE ARRANGEMENT

Figure 3.2b

Chapter 3, Page 5 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

FIXING ARRGT. OF PBOTTOM

COVERPWITH BOLSTER
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

CENTRE PIVOT ARRANGEMENT

FIGURE 3.3

Chapter 3, Page 6 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

10
%
%

°
R1
c

9.5
0

45
3
WEARING PIECE FOR SIDE BEARER
5
REF. DRG. NO. T-O-5-649
5
13 %
%
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
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Maintenance Manual for BG Coaches of ICF design Bogie

ANCHOR LINK WITH SILENT BLOCK

Figure 3.5

312a Coach Under Frame Mounted

312 BRAKE RIGGING Brake Rigging

Brake rigging is provided to control The brake rigging is as per figure 3.6.
the speed of the coach by transferring In 16.25 t axle load bogie the four
the braking force from the brake lever used in bogie brake rigging are
cylinder to the wheel tread. Brake each with lever ratio of 1:1.376 and
rigging can be divided into two hence the total Mechanical advantage
groups i.e. Bogie mounted brake in a bogie is 5.504 .
rigging and coach under frame The components details of 16 t bogie
mounted brake rigging. 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
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Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.3

Sr.No. Description Ref. Drg. NO (ICF) Quantity

1 Brake Head & block complete (L.H. Assembly) T-3-1-919 8
2 Brake Head & block complete (R.H. Assembly ) T-3-1-619 8
3 Short lever WLRRM 3-2-002 12
4 Long lever WLRRM-3-2-002 8
5 Brake Block Hanger T-3-2-645 16
6 Adjusting link WT AC3-3-2-302 2
7 Lever Hanger HIG AC 3-3-2-302 16
8 Pull rod WLRRM3-2-002 4
9 Pull rod T-3-2-616 2
10 Pin T3-2-048 50
11 Washer ICF/STD 3-2-003 50
12 Split Cotter T-3-2-632 50
13 Pin T-3-2-648 8
14 Washer ICF/STD 3-2-103 24
15 Split Cotter T-3-2-632 8
16 Pin for lever Hanger ICF/SK-3-2-179 16
17 Pin for safety wire rope WT AC3/3-2-307 32
18 Plain washer M20 IS: 2016-67 T.2type A 32
19 Split cotter EMU-3-2-048 32
20 Brake beam T-3-2-804 8
21 Safety wire rope T-3-2-651 16
22 Safety straps fixing Arrangement WT AC-3-2-304 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-3-2-
601).
Table 3.4

Sr.No. Description Ref. Drg. NO (ICF) Quantity

1 Brake Head & block complete T-3-1-601 16
2 Brake Beam T-3-1-602 8
3 Long lever T-3-2-605 8
4 Short lever T-3-2-604 8
5 Pull rod T-3-2-607 4
6 Pull rod T3-2-616 2
7 Adjusting Link T-3-2-609 2
8 Lever Hanger T-3-2-611 16
9 Safety Strap T3-2-612 4
10 Safety Strap T-3-2-621 4
11 Pin T3-2-048 8
12 Pin T3-2-048 50
13 Hex head screw ½" BSWx 38 BS :3083 –64 64
14 Spring Washer M-12 IS: 3063-72 64
15 Hex. Nut ½” BSW BS:1083-65 64
16 Washer DL-0-5-034 50
17 Washer DL-0-5-034 24
18 Pin for lever Hanger ICF/SK-3-2-179 16
19 Split cotter T-3-2-632 50

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Maintenance Manual for BG Coaches of ICF design Bogie

i) CONVENTIONAL AIR BRAKE COACH POWER CAR (refer figure 3.7)

TYPE OF COACH BUILDER TARE WEIGHT IN % OF BRAKING

TONNES
POWER CAR TO ICF 53.7 118
WLRRM6-9-0-601
HIGH CAPACITY ICF 60 105.6
POWER CAR

ii) CONVENTIONAL AIR BRAKE COACH SELF GENERATING AC COACHES

(refer figure 3.8)

TYPE OF COACH BUILDER TARE WEIGHT IN TONNES % OF BRAKING

WGACCW ICF 50.0 114.8
RCF 49.1 120.9
WGACCN RCF 50.1 118.6
WGSCZAC ICF 49.3 123.7
WGFAC ICF 49.7 119.5
WGFSCZAC ICF 50.0 118.8

Levers for Power car & self generating AC coaches

Sr. No. Size Shape/Drg. Types of coaches fitted Drawing no.

1. 282 x 205 POWER CAR TO WLRRM6-9-0- SK-93373
601, HIGH CAPACITY POWER & SK-93371
CAR, WGACCW, WGACCN,
WGSCZAC, WGFAC, WGFSCZAC
2. 245 X 178 -DO- -DO-

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

Levers

Sr. No. Size Shape/Drg. Types of coaches fitted Drawing no.

1. 230 X 230 GS,FC,SLEEPER, SLR, Second SK-93372
day coach, SCNLR, PANTRY
CAR
2. 200 X 200 -DO- -DO-

TYPE OF COACH BUILDER TARE WEIGHT IN TONNES % OF BRAKING

GENERAL SECOND ICF 36 120
CLASS RCF 37.4 115.5
SECOND DAY COACH ICF 37 116.7
RCF 37.3 115.8
SLEEPER ICF 39.5 109.3
RCF 39.45 109.5
FIRST CLASS ICF 41.8 103.3
SLR ICF 40.6 106.4
RCF 40.0 108.0
SCNLR ICF 41.0 105.3
PANTRY CAR ICF 41.3 104.6

Chapter 3, Page 10 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

282
245

245
245
178

178

205
178
2,896±1

CONVENTIONAL AIR BRAKE COACH (POWER CAR)

RDSO DRAWING NO. SK-93373

FIGURE 3.7

282
245

245
245
178

178

205
178

2,896±1
CONVENTIONAL AIR BRAKE COACH SELF GENERATING AC COACHES
RDSO DRAWING NO. SK-93371
FIGURE 3.8

Chapter 3, Page 11 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

312b 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. Description Ref. Drg. No. (ICF) Quantity

1 Brake Head & block complete (LH) T-3-1-801 8
2 Brake Head & Block complete (RH) T-3-1-801 8
3 Brake beam T-3-2-650 8
4 Safety wire rope T-3-2-651 16
5 Lever WTAC4 -3-2-402 8
6 Lever WTAC4 -3-2-402 8
7 Lever Hanger WTAC4 -3-2-402 8
8 Pull rod WTAC4 -3-2-402 8
9 Brake block Hanger T3-2-645 16
10 Pin T-3-2-648 44
11 Plain Washer ICF/ISD 3-2-003 64
12 Split cotter T-3-2-632 52
13 Pin T3-2-648 4
14 Plain Washer ICF/STD 3-2-003 4
15 Pin T-3-2648 4
16 Pin for lever Hanger T-3-2-801 16
17 Pin for Safety wire rope WT AC3 –3-2-307 32
18 Pin Washer M 20 IS: W 16-67 32
19 Split cotter EMU-3-2-048 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. Description Ref. Drg. NO ICF) Quantity
1 Brake Head & block complete (L.H. Assembly) T-3-1-801 4
2 Brake Head & block complete (R.H. Assembly ) T-3-1-801 4
3 Brake beam T-3-1-804 4
4 lever T-3-1-802 4
5 lever T-3-1-802 4
6 lever Hanger T-3-1-802 4
7 Pull rod T-3-2-802 2
8 Brake block Hanger T-3-1-645 8
9 Pin T3-2-648 22
10 Plain Washer ICF/STD-3-2-103 32
11 Split Cotter T-3-2-632 26
12 Pin T-3-2-648 2
13 Plain Washer ICF/STD 3-2-103 2
14 Pin T-3-2-648 2
15 Pin for lever Hanger T-3-2-802 8
16 Pin for safety wire rope WFT AC3/3-2-307 16
17 Plain washer M20 IS: 2016-67 16
18 Split cotter EMU-3-2-048 16
19 Safety wire rope T-3-2-651 8

Chapter 3, Page 12 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

i) AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER (refer figure 3.10)

Levers

Sr. Size Shape/Drg. Types of coaches fitted Drawing no.

No.
1. 366 x 174 WGSCZAC, WGSCWAC, SK-98032
WGFAC, WGFSCZ, WSCZAC,
WSCWAC, WFAC, WCBAC
2. 311 X 148 -DO- -DO-

3. 412 -DO- -DO-

TYPE OF COACH TARE WEIGHT IN TONNES % OF BRAKING

WGSCZAC 50.95 40.56
WGSCWAC 52.10 39.66
WGFAC 49.90 41.41
WGFSCZ 50.00 41.33
WSCZAC 48.90 42.26
WSCWAC 49.40 41.83
WFAC 46.20 44.73
WCBAC 47.90 43.14

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

Levers

Sr. Size Shape/Drg. Types of coaches fitted Drawing no.

No.
1. 302 X 158 GS,SCN,SDC,WCB, SLR, WFC SK-98027

2. 256 X 134 -DO- -DO-

3. 405 -DO- -DO-

TYPE OF COACH TARE WEIGHT IN TONNES % OF BRAKING

GS 36.00 52.23
SCN 37.55 50.08
SDC 36.50 51.52
WCB 40.40 46.54
SLR 40.60 46.32
WFC 41.80 44.99

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Maintenance Manual for BG Coaches of ICF design Bogie

31 1
36 6

31 1
412

36 6
412

148
174

14 8

174
2896±1

AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER P (FITTED WITH K TYPE COMPOSITION BLOCK) RDSO DRAWING NO. SK-98032)
FIGURE 3.10

256
302

405
256

405

30 2
13 4
158

13 4

158

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

2,896±1

NON - AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER P

FIGURE 3.11

Chapter 3, Page 14 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

313 EQUALISING STAYS 316a Washing Plant

This device has been provided on i) Remove all the oil from the side
bogies between the lower spring bearer oil bath.
plank and the bolster to prevent
ii) Wash the bogie with high
lateral thrust on the bolster springs
pressure hot water jet to remove
which have not been designed to take
all dust, mud, scales, grease and
the lateral forces. These links have
other muck without damaging
pin connections at both ends and,
the base primer coating.
therefore, can swivel freely.
(see figure 3.13) After washing and drying, roll the
bogies to dismantling line.
314 BOLSTER SPRING SUSPENSION
HANGERS (BSS HANGERS) 316b Dismantling
In the secondary suspension, the i) Make sure that the vent screws
bolster is supported on helical coil are opened. Lift the bogie frame
springs which are placed on the lower along with the bolster using
spring plank. The lower spring plank overhead crane till all the eight
is suspended from the bogie side axle guides disengage from the
frame through BSS hangers on lower spring seats.
hanger blocks. (see figure 3.14) ii) Lower the bogie frame and
bolster on to the shop floor.
315 SHOCK ABSORBERS iii) Remove and collect the axle box
guide components and helical
Hydraulic shock absorbers with
springs in respective bins/ pallets
capacity of ± 600 kg at a speed of 10
and send to washing plant for
cm/sec. are fitted to work in parallel
thorough cleaning.
with the bolster springs to provide
iv) Wheel sets must be first cleaned
damping for vertical oscillations.
thoroughly in the washing plant
and then sent to wheel shop.
316 WORKSHOP MAINTENANCE-
v) Remove vertical shock absorber
BOGIE SHOP
and send to shock absorber
maintenance section.
MAINTENANCE OF BOGIES
vi) Disconnect anchor links.
(Flow Diagram)
Dismantle bolster suspension
hangers by placing a dead
LIFTING WASHING BOGIE SERVICE
PLANT SHOPS
weight on the bogie frame and
SHOP SHOP
by using a jack.
1 2 (Fitting shop
3 5 & vii) Disconnect equalising stays. Lift
9 4 Smith shop) the bolster off the bolster springs
7 8 and remove the bolster springs.
10 6
viii) Collect anchor links, equalising
stays, bolster spring suspension
1. Coach lifting
(BSS) hanger pins, BSS hanger
2. Bogie cleaning
blocks (stones), BSS hangers,
3. Bogie dismantling
pins of equalising stays, brake
4. Component cleaning
rigging components and bolster
5. Attention to components
springs into respective bins/
6. Repair of components
pallets and send to washing plant
7. Bogie assembly
for thorough cleaning.
8. Load testing and adjustment
ix) Send the bogie frame, bolsters,
9. Lowering of coach
and lower spring planks to
10. Final adjustment
washing plant for thorough
cleaning and drying.
Figure 3.12
Transport the cleaned and dried bogie
After lifting the coach body (refer
frame, bolster and spring planks to
para 105 of chapter ‘Coach’), roll out
inspection and repair stands. Place the
the bogies and send them to bogie
bogie frame on repair stands in the
washing plant in bogie shop.
inverted position.

Chapter 3, Page 15 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

Bracket on Lower Spring Beam

3 2
3 3
1

5
Bracket on Bogie Bolster
4

134 526

67

200
7

263
3
3

3
3

7 6

672
No. off per
ITEM Description & assembly
dimensions

7 RIB 120x30x5 2

EQUALISING STAY FOR LOWER SPRING BEAM 6 2

RIB 200x225x5

(16.25 t Axle Load Bogie) (RDSO Sketch 88105) 5 BUSH%%c 42/32 x32L 8

4 BODY %%c 60x134 1

3 BOSS %%c 60/40 x32L 2

2 1
TUBE %%c 50 BOREx462
FIGURE 3.13 1 TUBE %%c 50 BOREx640 1

Chapter 3, Page 16 of 36
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Maintenance Manual for BG Coaches of ICF design Bogie

COMPONENTS SIZE-NEW CONDEMNING WEAR IN mm SHOP ISSUE SIZE

9.5 8 1.5 8.50

HANGER BLOCKPTOP &

BOTTOM

PIN
37 35.5 1.5 36.00

HANGER
38.4 36.5 1.5 37.00
26
R1

9.5

-
0.25P-
HANGER AND HANGER BLOCKS
450.5

FIGURE 3.14

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Maintenance Manual for BG Coaches of ICF design Bogie

316c Attention to Bogie Frame

i) Check the bogie thoroughly for for axle guide and 0.5 mm for
any possible cracks. Check the BSS bracket bush), damaged or
BSS brackets, axle guides, area cracked, they should be
surrounding the BSS bracket and replaced.
axle guide and all the welding iii) Bent or damaged suspension
joints of bogie frame. If cracks straps should be attended to as
are detected, hold the bogie required.
frame in bogie manipulator. iv) Safety wire rope arrangement
After proper gouging, weld the and safety straps should be used
cracks and finish by grinding. for brake beams as per revised
ii) If the BSS brackets or axle RDSO instructions.
guides are worn (limits: 1 mm
Table 3.7

Suggested BSS bracket and axle 13t bogies 16.25t bogies

guide alignment gauges
Longitudinal gauge for BSS 1400±± 1.0 mm (700± ± 0.5 mm 1500±± 1.0 mm (750± ±0.5 mm
brackets from longitudinal center-line) from longitudinal center-line)
Transverse gauge for BSS brackets 2159 ±1.0 mm 2159 ± 1.0 mm
Diagonal gauge for BSS brackets 2573 ±1.0 mm 2629 ± 1.0 mm
Longitudinal gauge for axle guide ± 1.0 mm (equidistant from
570± 570 ± 1.0 mm (equidistant from
center-line of axle) center-line of axle)
Transverse gauge for axle guide 2159±± 1.0 mm 2159±± 1.0 mm
Diagonal gauge for axle guide 3612±± 1.0 mm 3612±± 1.0 mm
Distance between BSS bracket and ± 1.0 mm
463± ±1.0 mm
413±
adjacent axle guide
Longitudinal gauge for suspension ± 1.0 mm (equidistant
870± ±1.0mm (equidistant from
870±
strap from center-line of axle) center-line of the axle)

v) Check the squareness and vii) The relevant axle guides should
alignment of BSS brackets and be cut using special gouging
axle guides with the help of nozzles (PO 18 or 19) to prevent
transverse, longitudinal, undercutting of bogie frame.
diagonal gauges and straight Axle guides found bent/cracked
edge. Axle guide alignment should also be cut out and
should be checked with replaced.
reference to the BSS brackets
viii) Weld the new axle guides with
and recorded in RDSO
the help of axle guide welding
dimensional check report . A
fixture, if the axle guides are
coordinate measuring machine,
damaged or worn. Check the
preferably CNC type, can do
alignment of new axle guides
these checks accurately.
with respect to other axle guides
vi) If the BSS brackets do not lie using master gauges and straight
within the tolerances, relocate edge. Any slight discrepancy in
one or more BSS brackets with location can be rectified by
correct alignment. After suitable local heating of the
ensuring correct alignment of the frame. After complete
BSS brackets, measure the rectification, record important
location of the axle guide from dimensions in RDSO
the BSS brackets and record in dimensional check report. (See
RDSO dimensional check report. fig. 3.15 a&b, fig. 3.16 a&b)
If the measurements deviate
from the standard measurements, ix) Replace the BSS bracket bushes
relocate mis- aligned pair of axle and pins if they were damaged
guides. or worn.

Chapter 3, Page 18 of 36
 Hindi Contents
Maintenance Manual for BG Coaches of ICF design Bogie

a
DIMENSIONAL CHECK REPORT b

FOR AC & POWER CAR BOGIE FRAME

C D

35
z
+
413 - 1

F
E

876
g 1 g2 2
61 g3

K
3 g4

N
2159
T

+ 0.5

- 0.5
26
29

+
+ 1

1752
1752
-

+ 1
-

+ 1
- 1

-
35

+
M
S

J
+ 1
-

876

- 0.5
- 0.5

C.L. OF AXLE
C.L.OF AXLE

+
+

876
R

L
750 570

I
G 1500 H d
c

g 8 g 7 +
- 0.5
g 6 + 1
- g 5
2896
z
+ 1
- +
- 1
570
+ 1
-

A B

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. g TO
1 g REPRESENT
8 LOCATIONS OF BOGIE GUIDES.

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.

ICF DRG. WTAC - 0-3-301

FIGURE-3.15a 3
SHEET 1 OF 2
 Hindi Contents

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 Nominal Size Actual Size Variation Measuring Nominal Size Actual Size Variation
Point (mm) (mm) (mm) Point (mm) (mm) (mm)
E -F 1500 ± 1.0 I-J 876 ± 0.5
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
a 413 ± 1.0 R-S 876 ± 0.5
b 413 ± 1.0 S-T 876 ± 0.5
c 413 ± 1.0 I-K 1752 ± 1.0
d 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

Figure - 3.15b
SHEET 2 OF 2

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
 Hindi Contents
Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSIONAL
a CHECK REPORT b

FOR NON AC BOGIE FRAME

C D

35
z
+ 1
463 -

F
E

876
g 1 g2 12 g 3

K
36 g4

N
2159
T

- 0.5

+ 0.5
+

-
1

1752
+

1752
-

+ 1
-

- 1
25

- 1

+
35

+
73

M
S

J
+ 1
-

876

- 0.5
- 0.5
C.L. OF AXLE

C.L. OF AXLE

+
+

876
R

L
570

I
G H d
c

g 8 g 7 + 0.5
- g6 +
- 1 g 5
2896 700
z
+ 1 +
- - 1
570 1400
+
- 1

A B

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. g TO
1 g REPRESENT
8 LOCATIONS OF BOGIE GUIDES.

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

+
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.

R.D.S.O./CARR./SK93280
FIGURE-3.16a
SHEET 1 OF 2
 Hindi Contents

Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSIONAL CHECK REPORT FOR BOGIE FRAME (AC TYPE)

No. ………………….
RDSO/SK/93280

Measuring Nominal Size Actual Size Variation Measuring Nominal Size Actual Size Variation
Point (mm) (mm) (mm) Point (mm) (mm) (mm)
E -F 1400 ± 1.0 I-J 876 ± 0.5
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
a 463 ± 1.0 R-S 876 ± 0.5
b 463 ± 1.0 S-T 876 ± 0.5
c 463 ± 1.0 I-K 1752 ± 1.0
d 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

Figure - 3.16b
SHEET 2 OF 2

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
 Hindi Contents
Maintenance Manual for BG Coaches of ICF design Bogie

x) Replace the anchor link brackets if hanger bracket for renewal. Replace the bushes
they are worn or damaged. The M12 in the brake hanger brackets at every POH.
threaded hole should be cleaned and xii) Replace the brake lever hanger
checked and attended to, as required. brackets if the holes are
xi) Bent, damaged, or worn brake hanger oblong/worn or damaged.
brackets should be replaced. If the holes are xiii) Replace all the axle box housing
not aligned/located as per drawing, replace the crown bolt and screwing piece
brackets. Use single piece design of brake by rubber stoppers.

Table 3.8

WEAR LOCATIONS (Dimensions in mm)

Part name Wear location Drg. Nos.
Brake hanger bracket bush 32 H7 Hole +0.025/-0.00 T-0-3-669 &
WTAC3-0-3-316
Brake hanger bracket 35 gap T-0-3-675
Brake hanger bracket C.D.1752 +1.0 T-0-3-675
Axle guide 115g6 -0.034/+0.00 diameter T-0-3-670 alt. 2/f
Axle guide 120 diameter T-0-3-670 alt. 2/f
BSS bracket bush 38 dia. Hole T-0-3-626 alt. 9/h
Pin for BSS 37 diameter T-0-5-637 alt. m/12
Bracket for anchor link 25+0.021/-0.0 slot T-0-3-635 alt. j/16
Brake lever hanger bracket 32 dia hole T-0-3-631 &
T-0-3-632

xiv) The locations where the repairs 316d Attention to Bogie Bolster
have been carried out should be Arrangement
cleaned to bare metal and (Refer drg. no.WTAC3-0-5-301 &
painted with two coats of primer WLRRM-0-4-001 for 16.25t bogie and
to IS:2074 to a minimum Dry T-0-5-601 & T-0-4-601 for 13t bogie)
Film Thickness (DFT) of 50 i) Check the bolster for twist,
microns followed by one coat crack, corrosion, etc. Repair or
of anti-corrosive Black Japan replace the bolster as required,
Type-B to IS:341 to a DFT of and attend to the lug as required.
35 microns, after which entire ii) Repair or replace the equalising
bogie frame is to be given one stay bracket if found bent,
coat of Black Japan Type-B to damaged, or corroded.
IS:341 to a minimum DFT of 35
microns.
Table 3.9

Part name Wear location (all dimensions in mm) Drg. Nos.

Side bearer wearing plate 10 mm thick top wearing surface T-0-5-648 alt
10/L
Side bearer wearing piece 45 mm thick bottom wearing surface T-0-5-649 alt
17/h
Bolster Centre Pivot sleeve Hole 155 H7 (+0.040/-0.0) c9(-0.2/-0.3) T-0-6-606
Centre-Pivot silent block Hole 140 H7 (+0.040/-0.0) T-0-6-606
sleeve
Centre Pivot silent block Hole dia. 90 +0.15/+0.30 T-0-6-611 alt.
16/p
Centre Pivot silent block Hole dia. 75 +0.1/+0.2 -do-
Centre Pivot silent block Out side dia 140 U6 (+0.195/+0.170) -do-
Centre Pivot pin Out side dia. 90 c9(-017/-0.267) & 75 c9 T-0-6-602 alt.s
(-0.150/-0.257) (w)
 Hindi Contents
Maintenance Manual for BG Coaches of ICF design Bogie

iii) Replace the anchor link bracket xiii) The locations where the repairs
by holding in bolster repair have been carried out or found
fixture, if found worn or corroded should be cleaned to
damaged. bare metal and painted with two
iv) Replace the bushes in the stay coats of primer to IS:2074 to a
rod brackets, if found worn or minimum Dry Film Thickness
damaged. (DFT) of 50 microns followed
v) Replace the centre pivot silent by one coat of anti-corrosive
block if found worn, damaged or Black Japan Type-B to IS:341
rubber has perished. to a DFT of 35 microns, after
vi) Replace the centre pivot sleeve if which entire bogie bolster is to
worn or damaged or corroded. be given one coat of Black
vii) Replace the bolster centre pivot Japan Type-B to IS:341 to a
sleeve if worn or cracked. minimum DFT of 35 microns.
viii) Replace the rubber sealing cap 316e Anchor Link
of centre pivot silent block, if
torn or damaged or perished. (Ref: Drawing No. T – 0 – 7 – 603
ix) Replace the centre pivot pin if and T – 0 – 7 –607)
worn or cracked. Chalk test the
centre pivot pin ‘in position’ or i) Replace the anchor link, if worn
‘off position’ to detect cracks. or corroded. Repair the anchor
x) Force fit between silent block link, if found cracked (normally
and sleeve and tolerance on at weld joints) under magna flux
pivot pin, i.e., c9 (-0.18/-0.27) testing, by re welding after
should be maintained in every gouging. Refit new silent block
POH/IOH. in every POH.
xi) Ensure that there is no leakage
of oil from the side bearer oil- ii) Replace the silent block, if the
bath welding portion. Replace rubber is perished (indicated by
the hard ground plate in side fretting) or loose in the anchor
bearer, if worn more than 1.0mm link housing, or the silent block
(ref. table 3.2) in thickness or pin is worn thin or loose in
ridges formed on the plate. silent block rubber. The silent
Replace the bronze wearing block should be force fit in the
piece for side bearer, if worn anchor link and the silent block
more than 1.5 mm in thickness. pin should be slide fit in the
Sharp edges on wearing piece anchor link bracket.
should be rounded off before re-
use. Ensure that the dust seal iii) The locations where the repairs
cover sits effectively all around have been carried out should be
without any gap on the oil-bath cleaned to bare metal and
and the sleeves slide freely on painted with two coats of primer
the guide to ward off dust and to IS: 2074 to a minimum Dry
moisture coming in contact with Film Thickness (DFT) of 50
the oil. Clean refilling passages microns followed by one coat
and deficient or damaged oil of anti-corrosive Black Japan
refilling cups with caps and Type-B to IS:341 to a DFT of
pipes should be replaced. The oil 35 microns, after which entire
filling plugs should be well anchor link is to be given one
secured by chain to prevent it coat of Black Japan Type-B to
from dropping. IS:341 to a minimum DFT of 35
xii) Repair or replace the bent or microns.
damaged or broken equalising
stay rod safety loops.
Table 3.10
(all dimensions in mm)
Part name Wear location Drg. No.
Anchor link silent block pin 25 mm -0.012/-0.052, thick ends RDSO-Sketch-94101 alt.1
Anchor link silent block Outer dia. 90.5 +0.05/+0.025 RDSO-Sketch-94101 alt.1
Anchor link housing Hole dia 90.5 +0.015/ -0.03 T-0-7-605
 Hindi Contents
Maintenance Manual for BG Coaches of ICF design Bogie

316f Equalising Stay Rod and Pins iii) Replace the following parts:
(Small & Big) § bushes of BSS brackets if
(Ref: Drawing No. RDSO Sk-88105 worn beyond permissible
Alt.2 for 16.25t bogie and Sk-88018 limits
Alt.6 for 13t bogie) § equalising stay bracket
bushes
i) Hot dip galvanised equalising
§ BSS pins if worn beyond
stay of 16.25t bogie is used on
permissible limits.
all new coaches. The choice of
iv) The locations where the repairs
retro-fitment of these stays on
have been carried out or found
existing coaches is left to the
corroded should be cleaned to
Railways. For fitment of
bare metal and painted with two
equalising stays to Sk-88105
coats of primer to IS: 2074 to a
Alt.2 on 13t bogies, follow
minimum Dry Film Thickness
RDSO Sk-93236.
(DFT) of 50 microns followed
ii) Replace the corroded equalising
by one coat of anti-corrosive
stays with new hot dip
Black Japan Type-B to IS:341
galvanised stays. If any repair
to a DFT of 35 microns, after
like welding or straightening is
which entire lower spring beam
carried out, which damages the
is to be given one coat of Black
galvanising, repaint the
Japan Type-B to IS:341 to a
equalising stay with epoxy paint.
minimum DFT of 35 microns.
iii) Bushes should be replaced in
every POH and fitted with Table 3.12
washers and split pins. Replace (all dimensions in mm)
the equalising stay pins if worn Part name Wear Drg. No.
out more than 1 mm in diameter. location
BSS bracket Hole 38 H11 WLRRM-
Table 3.11 bush (+0.16/-0.00) 0-5-002
Wear Location (Dimensions in mm) Eq. Stay Hole 42 H7 WLRRM -
bracket (+0.025/-0.0) 0-4-002
Part name Wear location
Pins for 16.25t axle Dia.31 (+0.5/-0.2) 316h BSS Hanger
load bearing capacity (Ref: Drawing No. T – 0 – 5 – 639)
equalising stay
Pins For 13t axle load Dia. 24 (+0.2/-0.1) i) Check the cleaned hangers for
bearing capacity cracks and wear. Replace the
equalising stay hangers if cracked or wear
exceeds 1 mm. Magna flux
316g Lower Spring Beam crack detection equipment shall
(Ref: Drawing No.WLRRM - 0 -5 - be used for checking.
002 for 16.25t bogie and T-0 -5 - 643 ii) The horizontal wearing surface
for 13t bogie) may be built up using 2B
electrodes, filed and ground to
i) Check the lower spring beam size. Then hard powder coating
(plank) for cracks, corrosion, etc. may be applied. Hardness value
and repair or replace as required. should be 55-60 Rockwell-C
ii) The following parts of the lower iii) The vertical gap should be within
spring plank should be inspected the permissible limit i.e.,
and repaired or replaced as 384+0.0/-1.0 mm. All the hangers
required: should be tested to tensile load
§ bolster suspension straps if of 8 tonnes and replaced if any
bent or damaged permanent set is observed in the
§ stay rod brackets if worn, hangers.
bent or corroded iv) After repair and testing all the
§ shock absorber fixing bosses BSS hangers should be painted
if damaged with one coat of anti corrosive
§ spring guide rings if required black paint. Write the actual
§ lug if damaged. 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 Wear location Drg. Nos.

BSS hanger distance between horizontal wearing arms 384 T-0-5-639
BSS hanger thickness of vertical arm 25.5 -do-
BSS hanger horizontal wearing surface 42 -do-
Hanger block Thickness - 9.5 T-0-5-638
Hanger block slot 29 (+0.4/-0.2) -do-
BSS pin 29 (+0/-0.1) T-0-5-637

316i Hanger Block (Stone) iv) Whenever an axle guide is

(Ref: Drawing No.WLRRM - 0 - 5 – replaced due to damaged/
203 and T-0-5-638) misalignment, preferably
modified guide with circlip
i) Replace the hanger blocks if arrangement may be fitted.
cracked. Worn hanger blocks v) Common defects found in axle
may be built up by welding with guide assembly during POH and
2B electrodes and machined to their reasons and remedies are
size. After repair and testing all given in Annexure 3.1.
the hanger blocks should be
painted with one coat of anti- 317 COIL SPRINGS
corrosive Black Japan Type-B to i. Coil spring should be maintained
IS:341. as per C-8419 (Rev.1)
316j Axle Box Guide Assembly ii. Clean the spring thoroughly,
(Ref: Drawing No.WTAC3 - 0 - 1 – remove any oil, grease, etc. by
301 and T-0-1-636) putting them in a Bosch cleaning
tank. After that carry out visual
i. Use the modified guide cap inspection of the spring coil by
(RDSO sketch no. 85070 Alt.3) coil. Carry out magna flux test to
and its securing arrangement on detect cracks. Springs having
existing bogies. New bogies are cracks, dents or hitting marks
fitted with dash- pot guide should be rejected and scrapped.
arrangement to T-0-1-641. Records should be maintained of
rejected springs with details of
ii. Replace the upper rubber defects noticed.
washer, lower rubber washer, iii. Each spring should be subjected
packing ring, guide ring, dust to incremental load up to the
shield , guide bush, dust shield figure indicated in the table 3.16
spring, and spring clip as a kit. and 3.17 and the load should be
maintained for a period of 2
minutes, after which the
Table 3.14
corresponding height of spring
under load is determined.
Critical Dimensions
iv. Replace the upper rubber
(dimensions in mm)
washer, lower rubber washer,
Component Dimension Drg. no.
packing ring, guide ring, dust
Lower hole 140 H7 RDSO Sk- shield , guide bush, dust shield
spring seat (+0.04/-0.0) 90005 Alt.2 spring, and spring clip as a kit.
Guide bush O.D. 140 A9 RDSO SK- v. Replace the lower spring seat if
(-0.3/-0.6) 84102 Alt.5 worn, cracked, scored, etc.
Guide bush hole dia 115 -do- vi. Each spring may be tested for
(+0.15/-0) other deflections/loads indicated
Guide Ring hole 115 H7 -do- in drawing and the spring
(+0.04/-0) characteristics plotted. The
spring should be replaced if its
iii. Replace the lower spring seat if characteristics are not within
worn, cracked, scored, etc. 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 Type of bogies ICF Drg. No Drg. Code

No.
All Non AC ICF type F-0-1-006 A01
All AC ICF type WTAC-0-1-202 A03
Axle box 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
Bolster 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 B06
B11
High capacity Power car WLRRM8-0-5-802
B13
Bolster
B15
High capacity Parcel van RDSO /SK-98018
B16

Table 3.16

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

Code Wire Free Test Acceptable Groups as per loaded spring height
dia height Load height under
test load
A B C
Yellow Oxford Green
Blue*
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
A10 39 315 1800 276-289 276-279 280-284 285-289
* As per RDSO's letter no. MC/SPG dated 25.7.01
 Hindi Contents
Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.17

Load deflection testing and grouping of Bolster spring

(B.G Main line coaches)

Code Wire Free Test Acceptable Groups as per loaded spring height
dia height Load height under
test load
A B C
Yellow Oxford Green
Blue #
B01 42 385 3300 301-317 301-305 306-311 312-317
B03 42 400 4800 291-308 291-296 297-303 304-308
B04 47 400 6100 286-304 286-291 292-297 298-304
B06 36 416 4200 280-299 280-286 287-292 293-299
B11 47
*386 6700 306-322 306-311 312-317 318-322
B13 34
B15 40 393**
6000 256-272 256-261 262-267 268-272
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 318 BOGIE BRAKE GEAR

acceptable springs should be
given one coat of Red Oxide i. Repair or replace the worn,
Zinc Chromate primer to damaged, corroded bogie brake
IS:2074 to a minimum DFT of levers. Replace the bushes in the
50 microns. A coat of Black bogie brake levers. Nylon 66
Japan Type-B to IS:341 to a brake gear bushes to RDSO STR
minimum DFT to 35 microns No. C-8107 should be fitted in
should follow the primer coat to brake gear.
have better abrasion resistance
and corrosion resistance. Then ii. Repair or replace the corroded,
the springs have to be painted cracked, or worn brake beams.
with 50 mm wide vertical iii. Repair or replace the corroded,
stripes at three locations, equi- dented, damaged brake head
spaced on the circumference shoes. Replace the worn bushes,
using different colours of paints adjuster, weakened spring, etc.,
to IS:8662 as given below: in all the serviceable brake head/
shoe.
Spring group Colour code
A Yellow iv. Replace the worn, damaged, etc.
B Oxford Blue brake gear pins with new ground
C Green finished and chromium plated
pins. ‘Z’ lever pin shall be to
vi. All the springs should be RDSO Sketch 98127.
grouped in three groups as v. Replace the brake blocks if worn
shown in table above, out to thickness of 20 mm or
depending upon their deflection below.
under test load. For pairing,
springs should be selected from vi. Replace the weak and damaged
the same group. Height under brake shoe key.
test load should be painted on vii. All the brake gear components
all springs to enable selection of should be given one coat of red
springs. 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 Bogie

319 BOGIE ASSEMBLY 319c Bolster Assembly Work Station

319a General i. Grease the BSS pins, hanger

blocks, anchor link silent block
pins and anchor link brackets
Bogie assembly can be systematically with graphite grease. Ensure that
carried out, if it is organised under bolster springs with height
three workstations described (under test load) variation within
hereunder. A sub store in the bogie 2 mm are selected in the same
shop may be necessary to ensure group of springs for each bogie
supply of proper components and sub- assembly.
assemblies for bogie assembly.
ii. Assemble lower spring planks,
319b Brake Gear and Axle Guide compensating rings, bolster
Assembly Work Station spring, rubber washer and other
secondary suspension
i. After the inspection, repair and components. Compensating
alignment of BSS brackets, axle rings shall be specified in
guides and the bogie frame, relevant suspension diagram
place the bogie frame in the issued by PUs. Additional
normal position on assembly compensating ring to maintain
stands. ± 3 can be
bolster clearance of 40±
added. Lower the bogie frame
ii. Assemble the brake gear assembled with brake gear and
components including brake axle guide assembly on the
blocks on the bogie frame with bolster assembly. Connect the
pins, washers and split cotters. bogie frame and lower spring
Ensure that the cotters are split plank with BSS hanger with the
minimum 90o and not slack in help of a dead weight. Connect
the pins. Modified lever hanger the lower spring planks and
pins (RDSO sketch no. 98127) bolster with equalising stays and
should be used to prevent the pins. Secure the equalising stay
bush working out of the lever pins with washers and split pins.
hanger. Ensure that the Ensure that the split pins are
maximum dimensional clearance split to minimum 90o and not
between the pins and bushes is slack in the pins. Connect the
1.5 mm. bogie frame and bolster with
anchor links. Secure the anchor
iii. Apply some lubricating oil on links in the brackets with M12
axle guide outer surface and on hexagonal head screws and
inside surface of guide bush. spring washers.
Assemble the axle guide
components on the axle guide iii. Replace the rubber sealing cap
and secure them with guide cap on the centre pivot silent block.
(whose 9 holes should be
cleaned before securing) as per
RDSO sketch no. 85070 Alt.3. 319d Bogie Lowering Work Station
While tightening the guide cap,
it should be ensured that guide i. Select the wheel sets such that
bush sits tight against the rubber the maximum variation in tread
packing ring and the holes in the diameter between the wheels on
guide are in alignment with same axle as 0.5 mm, between
corresponding holes in the guide two wheel sets in same bogie as
bush. New coaches are fitted 5 mm and among the four wheel
with modified axle guide sets in the same coach as 13
arrangement to T-0-1-641. mm. Select axle box springs in
the same group of springs as
given in table 3.16.
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Maintenance Manual for BG Coaches of ICF design Bogie

ii. Assemble the lower rubber exceed 1.6 mm. The bogie
washer, lower spring seat, should sit evenly on the four
compensating ring, hard packing axle boxes.
ring, selected axle box springs,
upper spring seats, upper rubber v. The assembled bogie should be
washer, protective tube, etc., as load tested on a bogie test stand
per the drawing for axle box where it is loaded up to its
guide arrangement. Put dash pot normal working load and the
oil of approved brand in lower height of bolster top surface
spring seat to a level of 60 mm form rail level should be
from bottom. The approved measured for comparison with
brands of dash pot oil are the pre-determined dimension
following: corresponding to correct coach
buffer height. Adjustment for
a. Servoline - 100 of getting correct buffer height
IOC b. Yantrol - 100 should be made, if needed. If the
of HPC c. Bharat univol – buffer height requires further
100 of BPC adjustment, the load on the axle
box spring should be released
iii. For obtaining correct buffer and compensating rings should
height when the coach body is be inserted below the axle box
lowered on the bogies, while spring ensuring that the bogie
assembling the bogie hard frame height is 686 ± 5 mm.
rubber, UHMWPE or NFTC
packing of required thickness, vi. Safety straps of the axle box
depending on the wheel wing lugs and bogie bolster
diameter, should be provided should be adjusted so as to
under the flanges of the lower ensure a minimum clearance of
spring seats. Packing rings of 40 mm between the lugs and
thickness as given in table 3.18 bottom of safety straps.
and as shown in figure 3.17
(RDSO sketch 77354) should be vii. Fit the vertical shock absorber
used. Compensating rings of between the bolster and bottom
suitable thickness as per spring plank.
suspension diagram for relevant
coach should be placed over the viii. Check the oil in the dash pots
flange of the lower spring seat. with the flexible wire gauge and
if necessary, top up the dash pots
Table 3.18 with the approved brand of dash
pot oil to bring the level to 60
Average tread Thickness of mm from under surface of dash
diameter of two hard packing pot. If the flexible gauge
wheel sets of bogie ring indicates a higher level of oil,
889 to 864 mm 13 mm the guide cap may have fallen in
dash pot. This should be checked
863 to 840 mm 26 mm
and attended to.
839 to 820 mm 38 mm
819 mm 48 mm
ix. Axle box rubber bump stopper
should be adjusted to obtain the
iv. Lower the bogie frame with the
required clearance between the
bolster assembly on the wheel
axle box crown and the bogie
sets thus prepared, taking care to
frame.
ensure that the rubber packing
ring does not get damaged while
x. After testing and making
lowering the guide bushes on to
adjustments for correct buffer
the lower spring seat. The
height, dispatch the bogie to
maximum diametrical clearance
Lifting shop for lowering the
between the lower spring seat
coach body.
and guide bush should not
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Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSION `A' AS SHOWN BELOW

CROWN
TYPE OF COACH
CLEARANCE
A mm
+0
GS,SDC,SLR,SCN 43 -3

A
WCB,WCBAC,WFC,WFAC
+0
-3
WGFAC,WSCWAC,WGCWAC 27

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
FIGURE 3.17
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Maintenance Manual for BG Coaches of ICF design Bogie

LIFTING SHOP which is indicated primarily

by oil leakage or when they
319e Lowering the Coach Body in Lifting are physically damaged.
Shop
2. Testing

i. Place the wearing plate and

i) The shock absorber is tested
wearing piece in side bearer oil-
on the special purpose
bath. Fill each side bearer oil-
machine (RDSO sketch nos.
bath with 2 litres of any of the
69.2.04.00 to 69.2.04.08)
following approved brands of
which can measure its
oils.
capacity in both tension and
compression by developing
§ Servoline – 100 of IOC
the resisting force at a
§ Yantrol – 100 of HPC velocity of 10 cm/sec. The
length of the shock absorber
§ Bharat univol – 100 of BPC
and its stroke should be
within the limits specified in
ii. Apply graphite grease on Centre
the table 3.19.
pivot pin and lower the coach
body on the side bearer wearing
ii) The shock absorber must be
pieces. Care should be exercised
tested at every POH and
to make sure that the side
reused if overhauling is not
bearers are resting properly.
due and the capacity is
Place the cotter in position in
Centre pivot pin and secure it within ± 20%. A register
with a split pin. A bottom cover should be maintained in the
should be fitted for covering the shock absorber section
entire assembly to prevent dust wherein the test results of
ingress. Tighten the air vent bolt each shock absorber should
with gasket to prevent spilling of be recorded before the shock
dash pot oil. absorber is certified fit for
use on coaches.
319f Shock Absorbers
iii) After the testing and
Reference may be made to RDSO certification, the protection
specification C-8703 (Rev.1) for cover of the shock absorber
hydraulic shock absorbers for should be pressed into
coaching stock. position on the piston rod
disc and spot welded at six
1. Periodicity of overhaul points around the periphery.

i) Schedule overhaul: Shock iv) The shock absorber should

absorbers should be given a then be extended on the
schedule overhaul: mounting fixture and painted.
When the paint dries, it
a. When their capacities should be compressed and
vary beyond ± 20% of then removed from the
their specified values, fixture.
or
v) The date of testing, the date
b. After 4 lakh kilometers of overhauling and the name
or alternate POH, of the shop where overhauled
whichever is earlier. should invariably be stamped
on the name plate of the
ii) Non schedule overhaul: shock absorber before it is
Shock absorbers should also sent for fitment.
be overhauled whenever
suspected to be defective,
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Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.19

Length (mm) Nominal Variation from

Maker’s Type Stroke Nominal
Compressed Nominal Extended (mm) Min. Max.
(mm) (mm)
Vertical shock absorbers:

M/s ESCORTS
250 ± 3 320 ± 3 360 ± 3 110 -70 40
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 Ball peen hammer

Chisel Chisel
Spanner Welding transformer
Gas cutting plant
WASHING PLANT Hydraulic press
Measuring gauges
Bosch tank Center lathe
Hot water jet system Brake beam end turning m/c
Bins and pallets Electrode heater
Jib crane Hard surface plant
Fork lift BSS hanger testing m/c
Platform truck Bins and pallets
Fork lift
BOGIE SHOP Platform truck

Ball peen hammer SMITH SHOP

Chisel
Spanner set Helical spring repair tools &
Welding transformer plant
Gas cutting plant Shot peening plant
Bogie alignment gauges Heat treatment plant
Spring testing machine Smith’s tongs, hammers &
Magnaflux crack detector blocks
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
 Hindi Contents
Maintenance Manual for BG Coaches of ICF design Bogie

321 EXAMINATION AND REPAIR 321b Primary Suspension

PRACTICE IN CARRIAGE
MAINTENANCE DEPOT i) Primary/Secondary Examination
Depot maintenance staff should
ensure the following things in respect § Visually examine axle box
of proper functioning and safety of springs for breakage.
Bogie & Bogie components. § Visually examine dash pot oil
filling special screw for
321a Bogie Frame deficiency.
§ Check oil leakage in dash pot
i) Primary/Secondary through defective seals/vent
Examination, Schedule A & screws.
B Examination
§ Visually examine axle box
clearance
§ Examine visually condition of
bogie side frame, transom, ii) Schedule A & Schedule B
longitudinals and all welded
locations.
§ Examine as per (i) above.
§ Examine rubber stopper/stop
screw of axle box crown for § Add specified grade of oil in
damage/missing/loose. dash pot.
§ Inspect axle box safety § Visually examine axle box
straps/loops for clearance.
damage/broken/missing.
§ Bolster safety straps/loops for iii) Schedule C
damage/broken/missing.
§ Brake hanger brackets for § Examine as per (ii) above.
damages. § Check and attend axle guide
§ Inspect safety brackets for assembly if necessary.
brake hanger pins.
§ Check axle box clearance with
§ Check visually BSS hanger gauge
brackets.
§ Examine visually anchor link
brackets. 321c Secondary Suspension
§ Visually examine centre pivot
mounting bolts and attend if i) Primary/Secondary
needed. Examination, Schedule A, B &
C examination
§ Visually inspect centre pivot
cover.
§ Side bearer oil to be § Visually examine bolster springs
replenished in A & B breakages/damages.
schedules, if needed. § Visually examine Bolster lower
spring beam.
ii) Schedule C Examination § Visually examine BSS hangers,
hanger blocks, BSS pins.
§ Examine as per (i) above. § Check bolster clearance between
§ Examine condition of wearing top of bolster and bottom of
piece and wearing plate bogie frame.
§ Examine oil level in side § Visually examine equalising stay
bearer oil baths and replenish rods and pins (small and big).
if oil level has gone down
below the level of last thread § Visually check anchor links.
of oil filling cup.
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Maintenance Manual for BG Coaches of ICF design Bogie

§ Examine Visually anchor link § Examine and attend floating

securing bolts and attend if lever suspension brackets
needed.
§ Examine lever hanger pins.
§ Visually examine Equalising
stay rod brackets.
321e Bogie to be run out if found
§ Examine and attend safety loops necessary/During IOH following
of bolster. should be done
§ Check and attend safety loops of
Equalising stay rod.
§ Examine and replace all the
§ Examine vertical shock brake gear components found
absorbers for damages. deficient / worn out.
§ Examine and replace primary
321d Brake Rigging and secondary suspension
components as required.
i) Primary / Secondary
Examination § Examine wheel profile and
thickness and gauge in case they
appear to be near condemning
§ Check brake gear and adjust so limit
that the piston stroke is within
the limit.
322 SAFETY PRECAUTIONS
§ Examine brake beams
breakages/damages.
§ Whenever a coach is examined
§ Check and attend brake beam at maintenance depot, it should
safety wire ropes/safety straps. be ensured that the prescribed
§ Check and attend brake shoe number of safety straps, safety
head and key & replace if wire rope, axle box safety strap,
necessary. bolster safety loop, centre pivot
cap, hangers or brackets of
§ Check and replace worn brake specified dimension and sections
blocks. required for various components
§ Visually inspect and replace are fitted at specified location.
brake hangers, brake gear pins § All fasteners e.g. bolts, nuts,
and cotters/split pins if cotters etc. used in under frame
necessary. equipments, brake gear, buffing
§ Visually inspect and replace and draw gear should be
damaged/missing brake gear checked.
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.
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Maintenance Manual for BG Coaches of ICF design Bogie

Annexure - 3.1

COMMON DEFECTS FOUND IN AXLE GUIDE ASSEMBLY

S.No. Defects Reason Remedies

1. Perished rubber Poor quality of rubber 1) Replace rubber packing ring at every
packing ring packing ring examination.
2) Use only rubber packing rings
conforming to IRS specification no. R-
47-72 and the relevant drawing.
2. Axle guide found 1) Misaligned fitment 1) The alignment of axle box guide
worn on one side of axle guides to should be checked with alignment
bogie frame. gauges and corrected.
2) Dust ingress to 2) Vent hole should be sealed with
lower spring seat. gaskets. Screw to be tightened well
after oil topping.

3. Axle box spring Do Do

rubbing upper
spring seat
4. Guide bush worn Do Do
5 Lower spring Do Do
surface worn
6. Guide ring broken 1) Axle guide is 1) Guide securing bolt should not project
hitting lower out of guide cap.
spring seat 2) Use good quality upper and lower
2) Weld joint of rubber washers and correct number of
lower spring seat compensating rings in the axle guide
and tube is porous assembly.
or cracked 3) Adjust A, B and C clearances on
leveled track.
4) Strip and reweld lower spring seat
correctly.
7 Guide cap securing Do Do
assembly broken
8. Lower spring seat Do Do
scored and dent
mark on guide cap
9 Dust shield spring Do Do
broken or distorted
10 Leakage from Do Do
lower spring seat

******