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4
2
0
4
SEALNG WASHER
2 GUE
3 !ROTECT'ETUBECO!LETE
4 U!!ERRUBBERWASHER
5 TO!S!RNG SEAT
6 USTSHEL S!RNG
7 USTSHEL
8 HELCALS!RNG
9 GUERNG
0 RUBBER!ACKNG RNG
GUEBUSH
2 CRCL!
3 CO!ENSATNG RNG
4 LOWERRUBBERWASHER
5 SAFETYSTRA!
6 LOWERS!RNG SEAT
2
3
4
5
6
7
8
9
0
2
3
4
5
6
S!ECALSEREWWTH
!OWERCAR-
EXCE!T!OWERCARS
686 FORALLAC & NON-AC COACHES
XTO RALLE'EL-
X
T
O
R
A
L
L
E
'
E
L
OLLE'ELBEFORE
OLLE'EL
670 FORBOGEONLUGGAGESE
672 FORBOGEONGENERATORSE
9
2
5
4
0
OFE AXLE BOX GUE ARRANGEENT
ashpots and AxIe Guide AssembIes
ashpots and AxIe Guide AssembIes
Bolster Springs Bolster Springs
Lower Spring Beam / Seat Lower Spring Beam / Seat
rawing code of springs for ICF BG coaches
(Reference RSO Amendment sIip no. 5 of September 2001
to STR W-01-HLs- 94 (Rev.1 May 95)
Type of spring Type of spring Type of bogies Type of bogies ICF rg. No ICF rg. No rg. Code rg. Code
No. No.
Axle Axle box box All All Non Non AC AC CF CF type type FF- -0 0- - - -006 006 A0 A0
All All AC AC CF CF type type WTAC WTAC- -0 0- - - -202 202 A03 A03
!ower !ower car car WLRR WLRR2 2- -0 0- - - -202 202 A04 A04
ouble ouble decker decker - -0 0- - - -00 00 A06 A06
High High capacity capacity !ower !ower Car Car WLRR WLRR8 8- -0 0- - - -802 802 A09 A09
High High capacity capacity parcel parcel van van RSO RSO /SK /SK- -9807 9807 A0 A0
Bolster Bolster All All Non Non AC AC CF CF type type FF- -0 0- -5 5- -002 002 B0 B0
All All AC AC CF CF type type WTAC WTAC- -0 0- -5 5- -202 202 B03 B03
!ower !ower car car WLRR WLRR2 2- -0 0- -5 5- -202 202 B04 B04
ouble ouble decker decker - -0 0- -5 5- -003 003 B06 B06
Bolster Bolster
High High capacity capacity !ower !ower car car WLRR WLRR8 8- -0 0- -5 5- -802 802
B B
B3 B3
High High capacity capacity !arcel !arcel van van RSO RSO /SK /SK- -9808 9808
B5 B5
B6 B6
Load defIection testing and grouping of AxIe box spring
(B.G Main Iine coaches)
Code Code Wire Wire
dia dia
Free Free
height height
Test Test
Load Load
Acceptable Acceptable
height under height under
test load test load
Groups as per loaded spring height Groups as per loaded spring height
AA BB C C
Yellow Yellow Oxford Oxford
Blue* Blue*
Green Green
A0 A0 335 335 360 360 2000 2000 279 279- -295 295 279 279- -284 284 285 285- -289 289 290 290- -295 295
A03 A03 335 335 375 375 2800 2800 264 264- -282 282 264 264- -269 269 270 270- -275 275 276 276- -282 282
A04 A04 35 35 372 372 3000 3000 265 265- -282 282 265 265- -270 270 27 27- -276 276 277 277- -282 282
A06 A06 36 36 337 337 2400 2400 269 269- -284 284 269 269- -273 273 274 274- -279 279 280 280- -284 284
A09 A09 37 37 360 360 3000 3000 277 277- -293 293 277 277- -282 282 283 283- -288 288 289 289- -293 293
A0 A0 39 39 35 35 800 800 276 276- -289 289 276 276- -279 279 280 280- -284 284 285 285- -289 289
Load defIection testing and grouping of BoIster spring
(B.G Main Iine coaches)
Code Code Wire Wire
dia dia
Free Free
height height
Test Test
Load Load
Acceptable Acceptable
height under height under
test load test load
Groups Groups as as per per loaded loaded spring spring height height
AA BB C C
Yellow Yellow Oxford Blue Oxford Blue
# #
Green Green
BB0 0 42 42 385 385 3300 3300 30 30- -37 37 30 30- -305 305 306 306- -3 3 32 32- -37 37
BB03 03 42 42 400 400 4800 4800 29 29- -308 308 29 29- -296 296 297 297- -303 303 304 304- -308 308
BB04 04 47 47 400 400 600 600 286 286- -304 304 286 286- -29 29 292 292- -297 297 298 298- -304 304
BB06 06 36 36 46 46 4200 4200 280 280- -299 299 280 280- -286 286 287 287- -292 292 293 293- -299 299
BB 47 47
386 386 6700 6700 306 306- -322 322 306 306- -3 3 32 32- -37 37 38 38- -322 322
BB3 3 34 34
BB5 5 40 40 393 393
6000 6000 256 256- -272 272 256 256- -26 26 262 262- -267 267 268 268- -272 272
BB6 6 32 325 5 286 286
Shock absorbers
EquaIising stays
!rovided on bogies between the lower !rovided on bogies between the lower
spring plank and the bolster spring plank and the bolster
To prevent lateral thrust on the bolster To prevent lateral thrust on the bolster
springs which have not been designed to springs which have not been designed to
take the lateral forces take the lateral forces
!in connections at both ends to swivel !in connections at both ends to swivel
freely freely
EquaIising stays
Centre Pivot
Centre Pivot
Side Bearers
Consists of a machined steel wearing plate Consists of a machined steel wearing plate
immersed in an oil bath immersed in an oil bath
Floating bronze Floating bronze- -wearing piece with a wearing piece with a
spherical top surface kept in it spherical top surface kept in it
The coach body rests on the top spherical The coach body rests on the top spherical
surface of these bronze surface of these bronze- -wearing pieces wearing pieces
through the corresponding attachments on through the corresponding attachments on
the bottom of the body the bottom of the body- -bolster bolster
Side Bearer
Side Bearer Side Bearer
Wear Iimit for wearing pIate
New size New size Shop renewaI Shop renewaI
size size
Condemning size Condemning size
0 mm 0 mm 9 mm 9 mm 85 mm 85 mm
Wear Iimit for wearing piece
New size New size Shop renewaI Shop renewaI
size size
Condemning size Condemning size
45 mm 45 mm 435 mm 435 mm 42 mm 42 mm
Side Bearers
Side Bearer Side Bearer
Quantity of oil in Side bearer oil Quantity of oil in Side bearer oil- -bath (Each): bath (Each):
2 Iitres 2 Iitres
Approved brands of oils Approved brands of oils
Servoline Servoline 00 of OC 00 of OC
Yantrol Yantrol 00 of H!C 00 of H!C
Bharat univol Bharat univol 00 of B!C 00 of B!C
Anchor Links
Anchor links Anchor links
!in connection to the Bolster sides and !in connection to the Bolster sides and
the Bogie Transoms the Bogie Transoms
Can swivel universally to permit the Can swivel universally to permit the
bolster to rise and fall and sway side bolster to rise and fall and sway side
wards wards
One anchor link is provided on each side One anchor link is provided on each side
of the bolster diagonally across of the bolster diagonally across
Fitted with silent block bushes Fitted with silent block bushes
Anchor link Anchor link
To hold in position longitudinally the To hold in position longitudinally the
floating bogie bolster floating bogie bolster
To design to take the tractive and braking To design to take the tractive and braking
forces forces
ANCHOR LINK WITH SILENT BLOCK
Figure 3.5
Anchor link Anchor link
Hanger and Hanger BIocks
AxIe Box safety Strap
Hanger Pin Safety Stopper
Brake Shoe head Brake Shoe head
In order to fit the brake bIock snugIy in the brake In order to fit the brake bIock snugIy in the brake
head to avoid any movement between them. head to avoid any movement between them.
To avoid excessive wear at the ends of the brake To avoid excessive wear at the ends of the brake
head. head.
Brake shoe key
W In order to fit the brake bIock snugIy in the brake
head to avoid any movement between them.
Safety wire rope
W The oId arrangement of safety straps is reported
to be faIIing in service due to baIIast hitting.
W To improve the safety of brake beam faIIing on
the track safety wire rope introduced.
Brake bIock hanger
W To avoid brake bIock cIimbing over the wheeI in
case of fuIIy worn out wheeIs.
Standardization of equaIizing stay
W The oId equaIizing stay had a pin dia of 25 mm.
The Ionger pin is found to be bending in service
resuIting in removaI difficuIties.
W In the standardized equaIizing stay the dia of pin
has been increased to 31 mm.
Pin for brake Iever hanger
W To avoid sIipping of nyIon bush in the Iever
hanger a washer is weIded.
W CastIe nut with spIit pin introduced.
Improved brake beam
W The oId brake beam does not cater to the Ioad
requirement of air braked coaches and it aIso
bends under extra Ioads.
SingIe piece brake bIock hanger
W SingIe piece design wiII avoid misaIignment of
brake bIock with respect to wheeI tread.
Revised side buffer casing
W To avoid cracks deveIoping from the boIt hoIes in
the U/frame headstock.
W HorizontaI pitch for boIt hoIes has been increased
from 254 mm to 349 mm.
W VerticaI pitch for boIt hoIes has been increased
from 12 mm to 10 mm.
Provision of Iocking arrangement for
guide cap
W To avoid faIIing of guide cap due to breakage of
spring cIip.
Rubber stopper axIe box crown boIt
W To prevent the breakage of axIe box crown
hexagonaI boIt assembIy in service.
W The hexagonaI head boIt is prevented from hitting
directIy. Instead the rubber stopper wiII be hitting
the crown.
WeId joint of bogie side frame with
head stock
W The side frame head stock joint beIow guide in
the oId design was undesirabIe as the joint Ieads
to misaIignment of guides.
W Shifted to headstock beyond brake hanger
brackets.
SIack adjuster articuIation
W To provide freedom of rotation in horizontaI pIane
an additionaI pin joint has been provided.
W Freedom of rotation in verticaI pIane is aIso
ensured at the fIoating Iever end.
W This arrangement is expected to minimize the
incidence of sIack adjuster spring breakages.
Workshop Activities Workshop Activities
Coach lifting Coach lifting
2 2 Bogie cleaning Bogie cleaning
3 3 Bogie dismantling Bogie dismantling
4 4 Component cleaning Component cleaning
5 5 Attention to components Attention to components
6 6 Repair of components Repair of components
7 7 Bogie assembly Bogie assembly
8 8 Load testing and adjustment Load testing and adjustment
9 9 Lowering of coach Lowering of coach
0 0 Final adjustment Final adjustment
orksop Maintenance of orksop Maintenance of
ICF Bogie ICF Bogie- - Flow diagram Flow diagram
LIFTING
$OP
1
A$ING
PLANT
BOGIE
$OP
$ERVICE
$OP$
Fitting sop
&
$mit sop)
9
10
2
4
3
7
5
8
6
LS BEA
RALLE'EL
BOGEFRAE
!ART-
E
G
F
BOGEBOLSTER
A
B
C
SUS!ENSON AGRAATC ARRANGEENT
BOGEBOLSTER
RALLE'EL
FGURE 4a
BOYBOLSTER
BOGEFRAE SEBEARER
!ART-
J
N
L
2
NOTE- ! imensions E& J shall be maintained with required number of compensating rings of standard thickness of 4 mm!2 Axle box springs : WTAC
-0--202! Bolster springs : WTAC -0-5-202
H
K
2
FORSELFGENERATNG AC COACHES(CFRAWNG NO CF/SK -9-0-26)!
2
LS BEA
RALLE'EL
BOGEFRAE
!ART-
G
#
Z
F
BOGEBOLSTER
B
X
A
2896 (WHEELBASE)
SUS!ENSON AGRAATC ARRANGEENT
FOR NON AC COACHES(RCFRAWNG NO CC9009)!
NOTE- ! imensions A & Bmarked should be ensured less than dimensions C & marked respectively!2 # CRto drawing
No-CC040 to be provided!3 * CRto drawing No - CC0525 to be provided!4 'F' the variation in all the four bogie corner
heightsmust be less than or equal to 0 mm!5 rawing No SG90002, SZ90004, SE900, LB90002 are superseded by this
drawing!6 The height of Axle box spring and bolster spring in tare & gross conditionsisfor reference only!7 The requirement of CR's
as shown in the columns for primary & 30 mm in secondary suspension!8 Only blue bend springsboth in primary and secondary
stage are to be used in postal van coach
FGURE 4c
RALLE'EL
BOGEFRAE
BOYBOLSTER
BOGEBOLSTER
!ART-
SEBEARER
Y
H
Weight of each bogie = 59
t!Unsprung mass/bogie = 32 t!Bolster
weight = 04 t!CR =
Compensating ring
C
c
9
5
Type of Type of
coach coach
Tare Tare
weight of weight of
coach coach
Normal Normal
pay load pay load
Total Total
pay load pay load
Bogie frame Bogie frame
bolster bolster
clearance clearance
Body bogie Body bogie
clearance clearance
Crown clearance Crown clearance
AC AC n tonnes n tonnes n tonnes n tonnes n n
tonnes tonnes
B dimension B dimension C imension C imension A imension A imension
Tare Tare Gross Gross Tare Tare Gross Gross Tare Tare Gross Gross
ACCW ACCW
(EOG) (EOG)
448 448 368 368 368 368 40 40II5 5 50 50II5 5 70 70II3 3 60 60II3 3 28 28II3 3 20 20II3 3
ACCW ACCW
(SG) (SG)
49 49 368 368 368 368 40 40II5 5 50 50II5 5 70 70II3 3 60 60II3 3 30 30II3 3 22 22II3 3
ACCN ACCN
(EOG) (EOG)
483 483 52 52 52 52 40 40II5 5 54 54II5 5 70 70II3 3 56 56II3 3 34 34II3 3 22 22II3 3
ACCN ACCN
(SG) (SG)
5253 5253 52 52 52 52 40 40II5 5 53 53II5 5 70 70II3 3 57 57II3 3 35 35II3 3 23 23II3 3
ACCZ ACCZ
(EOG) (EOG)
43 43 536 536 536 536 40 40II5 5 54 54II5 5 70 70II3 3 56 56II3 3 32 32II3 3 20 20II3 3
Check List
Type Type
of of
coach coach
Tare Tare
weight weight
of of
coach coach
Normal Normal
pay pay
load load
Total Total
pay pay
load load
Test load per Test load per
bogie bogie
Bogie frame Bogie frame
bolster bolster
clearance clearance
Body bogie Body bogie
clearance clearance
Crown Crown
clearance clearance
AC AC n n
tonnes tonnes
n n
tonnes tonnes
n n
tonn tonn
es es
Under Under
tare tare
Under Under
Gross Gross
B dimension B dimension C imension C imension A imension A imension
n n
tonnes tonnes
n n
tonnes tonnes
Tare Tare Gross Gross Tare Tare Gross Gross Tare Tare Gross Gross
ACCZ ACCZ
(SG) (SG)
4683 4683 584 584 584 584 722 722 204 204 40 40II5 5 56 56II5 5 70 70II3 3 54 54II3 3 35 35II3 3 22 22II3 3
FACZ FACZ
(EOG) (EOG)
426 426 368 368 368 368 50 50 694 694 40 40II5 5 50 50II5 5 70 70II3 3 60 60II3 3 27 27II3 3 9 9II3 3
RA RA
(NON (NON
AC) AC)
43 43 20 20 20 20 445 445 405 405 40 40II5 5 44 44II5 5 70 70II3 3 66 66II3 3 20 20II3 3 7 7II3 3
'! '!
(HGH (HGH
CA!AC CA!AC
TY) TY)
32 32 23 23 23 23 98 98 23 23 40 40II5 5 8 8II5 5 70 70II3 3 29 29II3 3 36 36II3 3 II3 3
RQ RQ
ACCN ACCN
(SG) (SG)
43 43 52 52 52 52 945 945 220 220 40 40II5 5 54 54II5 5 70 70II3 3 56 56II3 3 35 35II3 3 23 23II3 3
RA AC RA AC 4669 4669 20 20 20 20 74 74 74 74 40 40II5 5 43 43II5 5 70 70II3 3 67 67II3 3 22 22II3 3 9 9II3 3
Check List
Type Type
of of
coach coach
Tare Tare
weigh weigh
t of t of
coach coach
Norm Norm
al pay al pay
load load
Over Over
load load
Total Total
pay pay
load load
Test load per Test load per
bogie bogie
Bogie frame Bogie frame
bolster bolster
clearance clearance
Body bogie Body bogie
clearance clearance
Crown Crown
clearance clearance
AC AC n n
tonne tonne
ss
n n
tonne tonne
ss
n n
tonne tonne
ss
n n
tonne tonne
ss
Under Under
tare tare
Under Under
Gross Gross
B dimension B dimension C imension C imension A imension A imension
n n
tonne tonne
s s
n n
tonne tonne
ss
Tare Tare Gross Gross Tare Tare Gross Gross Tare Tare Gross Gross
GS GS 3699 3699 585 585 00 00 70 70 26 26 845 845 40 40II5 5 74 74II3 3 70 70II3 3 36 36II3 3 47 47II3 3 20 20II3 3
SOC SOC 3700 3700 702 702 00 00 404 404 26 26 962 962 40 40II5 5 8 8II5 5 70 70II3 3 29 29II3 3 50 50II3 3 8 8II3 3
SCN SCN 3803 3803 576 576 - - 576 576 32 32 600 600 40 40II5 5 57 57II5 5 70 70II3 3 53 53II3 3 3 3II3 3 7 7II3 3
Check List
Type Type
of of
coach coach
Tare Tare
weight weight
of of
coach coach
Norma Norma
l pay l pay
load load
Over Over
load load
Total Total
pay pay
load load
Test load per Test load per
bogie bogie
Bogie Bogie
frame frame
bolster bolster
clearance clearance
Body bogie Body bogie
clearance clearance
Crown Crown
clearance clearance
AC AC n n
tonnes tonnes
n n
tonnes tonnes
n n
tonnes tonnes
n n
tonnes tonnes
Under Under
tare tare
Under Under
Gross Gross
B B
dimension dimension
C C
imension imension
A imension A imension
n n
tonnes tonnes
n n
tonnes tonnes
Tar Tar
e e
Gros Gros
s s
Tare Tare Gros Gros
s s
Tare Tare Gros Gros
s s
SLR SLR 370 370 060 060 26 26 320 320 265 265 925 925 40 40
II5 5
79 79II5 5 70 70II3 3 3 3II3 3 50 50II3 3 20 20II3 3
'! '! 3200 3200 800 800 - - 800 800 030 030 930 930 40 40
II5 5
77 77II5 5 70 70II3 3 33 33II3 3 39 39II3 3 II3 3
RQ RQ
SCN SCN
372 372 576 576 - - 576 576 27 27 558 558 40 40
II5 5
57 57II5 5 70 70II3 3 53 53II3 3 30 30II3 3 7 7II3 3
!ostal !ostal
'an 'an
365 365 30 30 - - 30 30 235 235 385 385 40 40
II5 5
49 49II5 5 70 70II3 3 6 6II3 3 22 22II3 3 5 5II3 3
Check List
Cause Cause -- Buffer eigt low Buffer eigt low
Wear on wheel tread Wear on wheel tread
Wear on wearing piece and wearing plate of the Wear on wearing piece and wearing plate of the
side bearers side bearers
Wear on hanger , hanger block and pin of the Wear on hanger , hanger block and pin of the
secondary suspension secondary suspension
Loss in free heights of primary and secondary Loss in free heights of primary and secondary
coil springs coil springs
Load deflection characteristics of the primary and Load deflection characteristics of the primary and
secondary springs not being within the secondary springs not being within the
prescribed limit prescribed limit