The document discusses various components of ICF coaches including bogies, rolling gear, brake systems, and underframes. It provides detailed descriptions and specifications for sub-components of the dust bin, bogie frames, suspension systems, wheel assemblies, air brakes, headstocks, and buffing gear. It emphasizes the importance of understanding the products being procured and their individual parts in order to effectively manage materials.

1. ICF Coach ComponentsICF Coach Components
Jogendra Yadvendu
Dy.CMM-MTN, CR
yadvendu@gmail. com

2. Virtual WareHouse !
The dilemma

Materials Management or a stores Cader ?

Materials Management sounds
impressive !

Do we know the product we buy day in
and day out ?

Have we seen the product ?

Well, this is not really a part of my job


3. 
How many times we call for the
drawing, study it and only then float a
tender ?

How many times the T.C. has the
knowledge of the product it is
deliberating about ?

A stores guy has an idea about the
product. A materials manager knows
the product.

4. The Dust Bin !The Dust Bin !

We all have an idea about the dustbin used in
coaches

Do we know the dust Bin ?

Purchased as per ICF Drg No WGSCWAC-6-
4-005 ALT. l/4

There are total 49 sub components in it. Yes 49
!

Majority of the components are of IS: 2062
steel

5. 
Some components such as Pedal Lever &
pedal end piece is of IRS M41

Which fabricator will obtain IRS M41
steel for the few components ?

Result: Either a vigilance case or
harassment to the vendor

Why not change the material spec for
the Dust Bin.

Well, that’s not my Job !
The DustBin

6. Virtual WarehouseVirtual Warehouse

The writing is on the wall !

No awards for guessing !

There is limited or no attempt to know the
product before tendering or at the time of
placement of order !

Common refrain: Time nahi hai !

Locomotive sheds/ Workshops are not far away.

Will is lacking to know the product.

It is not considered important

7. Virtual WarehouseVirtual Warehouse

Busy officers not able to go to the
shed /Workshop to see the product.

An attempt has been made to bring the
product to the confines of Air
Conditioned environs .

8. Why know the components ?Why know the components ?
Most purchase officers are trained engineers.
However, most officers cannot identify the item
they are buying.
Totally dependent on decision of user
department for very basic issues.
No role in vendor development.
No role in inspection of stores at depot level
Hence , the non technical Tag.
No professional satisfaction.

9. Materials Management or Stores ?Materials Management or Stores ?
 Stores ? Warehouse Manager ? Clerical ?
 Materials Manager: Knows about Material
 Types of steels , Rubber & Why to use a particular one.
 What is the component ?
 Where is it used ?
 Why does it need replacement ?
 How Can the frequency of replacement be reduced ?
Is there a better material available ?
 Best time to learn is when there is a crisis.

10. How does one start ?How does one start ?
Go to the basics.
Macro to micro.
Assemblies to Sub Assemblies.
Sub Assemblies to components.
25 KV to movement of a wheel
Load transfer in rolling stock
Transfer of Buffing Gear forces in a rolling stock
No one is too old to learn.

11.  What is the minimum web thickness of the ICF Wheel ?
 A. 50 mm
 B. 150 mm
 C. 250 mm
 D. 350mm
 E. > 350 mm
 What about LHB Wheel ?

12. Wheel ProfileWheel Profile

13. Minimum Web Thickness ofMinimum Web Thickness of
WheelWheel
ICF : 19 mm
LHB: 13 mm

14. What is the difference ?What is the difference ?
Lower Spring Seat
Top Spring Seat

16. ICF BogieICF Bogie

17. Main Assemblies in ICF BogieMain Assemblies in ICF Bogie
 Bogie Frame
 Bogie Bolster
 Primary Suspension
 Secondary Suspension
 Axle Box Housing
 Lower Spring Beam
 Center Pivot Arrangement
 Anchor Link Assembly
 Wheel Set arrangement
 Brake Beam Assembly
 Axle Pulley & Alternator arrangement

18. Bogie FrameBogie Frame

19. Bogie FrameBogie Frame
 Fabricated structure made up Mild steel channels
and angles welded to form the main frame of the
bogie.
 Divided into seven sections. The central section
has Bogie Bolster at the bottom & connects the
Body Bolster of the coach through the center Pivot
 Various types of brackets are welded to the frame
for supporting bogie components.
Mechanical code silent about bogie
condemnation.
Bogie POH periodicity reduced to 9 months.

20. Bogie Bolster

21. Bogie BolsterBogie Bolster
Bogie Bolster
Side Bearer Housing
Bronze wearing Piece
Wearing Plate
Brackets for Anchor Link-Design Issue.
Silent Block for center Pivot-History
Center Pivot Sleeve-

22. Primary Suspension

23. Primary SuspensionPrimary Suspension
 Axle Box Housing-Design Changes
 Washers- Hytrel or Rubber-Case Study-Delrin ?
 Lower Spring Seat- Honning
 Axle Box Spring- Three categories
 Dashpot Cover- Shop Practice
 Axle Box Guide- Two Holes,cap
 Guide Bush- Development
 Guide Ring
 Circlip-
 Rubber Packing Ring
 Air Vent Screw

24. Axle Box Guide ArrangementAxle Box Guide Arrangement

25. Secondary SuspensionSecondary Suspension

26. Secondary SuspensionSecondary Suspension
 Bogie Bolster
 Lower Spring Beam-Plank-AC & NAC
 Rubber Washers- Upper & Lower-
Hytrel
 Secondary spring
 Shock Absorber: 600 & 900 Kg. ?
 Flange for Shock Absorber
 Equalizing Stay Rod- 13 T & 16 T
 Anchor Link- Shop Practice
 Silent Block for Anchor Link- History

27. Axle Box Arrangement

28. Axle Box HousingAxle Box Housing
 Collar for DM Roller Bearing
 Rear cover for Axle Box- V Groove
 Labyrinth Ring
 Nitrile O Ring
 Woolen felt- Density Issue
 Bearing
 End cap
 Locking Plate
 Locking Bolt
 Front Cover- History & Practise
 Front cover Bolts

29. Front & Rear Cover Assembly

30. Lower Spring Beam

31. Lower Spring Beam AssemblyLower Spring Beam Assembly
Trapezoidal Section
Fabricated Member
Connected to Bogie Frame with BSS Hanger
Connected to Bogie Bolster with Anchor Link
Receives vertical load of coach through bogie
Bolster & secondary springs
Transfers load to Bogie Frame through BSS
Hanger.

32. Center Pivot AssemblyCenter Pivot Assembly

33. Center Pivot AssemblyCenter Pivot Assembly
No vertical load transfer.
Acts as a center of rotation
Transmits tractive/Braking
forces only
Center Pivot
Silent Block for center Pivot
Center Pivot Sleeve

34. Anchor Link Arrangement

35. Anchor Link arrangementAnchor Link arrangement
Consists of Anchor Link & Silent Block
Seamless tube welded with Cylindrical
housing
Anchor link Bracket for Bogie Bolster &
Bogie Frame.
Holds the Bogie Bolster to the Bogie
Frame
Two anchor link per Bogie
Permits Bogie Bolster to rise , fall & sway.

36. Wheel Set assemblyWheel Set assembly
Wheel
Axle
Pulley Rubber Pad- Historical Data
V Grove Pulley: 4 & 6 Groove
Pulley Bolts- Karnavati Accident
V Belt

37. Brake Beam AssemblyBrake Beam Assembly

38. Brake Beam AssemblyBrake Beam Assembly
Brake Beam: 13 T & 16 T-- Myth
Brake Head- Types
Brake Block- Types
Bushes: Nylon & Phenolic ( Issues )
Brackets
Safety wire rope (Rajdhani ?)
Block Hanger

39. Draw Gear ArrangementDraw Gear Arrangement

40. Draw Gear ArrangementDraw Gear Arrangement
Draw Hook
Draw Bar with castle Nut
Draft Key
Screw Coupling
Draw Bar Springs
Yoke
Yoke Housing

41. Draw GearDraw Gear
Screw Coupling- Spares
Draw Hook – 60 to 75 Ton
Draft Yoke
Draft Key
Draw Bar & Castle Nut
Rubber Buffer Spring
Manufactured from IS:5517-93 Grade 35
Mn6Mo3.
Proof Load 75 Ton
Breaking Load 130 Ton

42. Contd.Contd.
Specially heat treated to obtain the desired
strength. Not to be heated above 550 deg.
No tempering allowed.
Only yoke can be reclaimed.
 No reclamation of any draw gear
components permitted.
Load application gradual, hold for 2
minutes. No permanent set .
No creep motion permitted. In pins and
oblongity in holes.

43. Buffer HeightBuffer Height
Maximum height from rail level(Loaded)
MAX- 1105 mm
MIN - 1090 mm
Reason for different Buffer Heights ?
A. Wheel tread wear .
B. Different Types of Springs (Green, Blue,
Red)
Adjustment- How ?
Use compensating Ring & Packing Ring.

44. Buffer Height AdjustmentBuffer Height Adjustment
 Use Packing Ring under the flange of Lower Spring
Seat.
 Lowest wheel diameter permissible is 836 mm.
 Compensating ring to be used based on the tare weight.
 Check for height of bolster top level from the rail level.
 Provide packing ring below the axle spring if Buffer
height requires further adjustment.
 Total height of Axle spring and compensating ring <
295 mm.
 Minimum clearance of 40 mm between the Axle box
wing lug & Safety strap

45. Rolling GearRolling Gear
Wheel. Drawing No. W/WL/1660. Spec.
IRS R-19/93 Part II
Axle
Roller Bearing 22326 / C3 130 mm bore

46. Rolling Gear ComponentsRolling Gear Components
End Locking Plate
End Locking Bolt
Felt Ring- Why Important ?
Retaining Ring
Collar
Rear & Front Cover- Historical Data
Axle Box Housing- Case of Hytrel Washer

47. Roller BearingRoller Bearing
Outer Race, Barrel Rollers, Inner Race
Self Aligning properties.
Can take care of radial, axle, complex loads.
Suitable for Vibrations & Shocks.
130 mm bore dia.
Dismount every POH or 2 Lakh Km.

48. Air Brake SystemAir Brake System
6
6
5
5

49. Air Brake ComponentsAir Brake Components
 Feed Pipe
 Brake Pipe
 Common Pipe Bracket
 Intermediate Piece
 Cut off Angle Cock
 Three way dirt Collector
 Brake Cylinder- BMBC & N-BMBC
 Auxiliary Reservoir
 Distributor Valve
 Isolating Cock
 PEASD
 PEAV
 Check Valve

50. Principle of Air BrakePrinciple of Air Brake
FP Pressure 6 Kg./Cm Sq.
Auxiliary Reservoir 6 Kg./Cm Sq.
BP Pressure 5 Kg./Cm Sq.
Control Reservoir 5 Kg./Cm Sq.
Braking by dropping air Pressure in B.P.

51. Brake ApplicationBrake Application
How.
Control Reservoir Disconnected from B.P.
D.V. connects the Auxiliary Reservoir to Brake
Cylinder & Brake cylinder piston moves out.
Auxiliary Reservoir is continuously charged with
6 Kg pressure from F.P.

52. Brake ReleaseBrake Release
Recharge B.P with 5 Kg pressure through
drivers brake Valve
D.V. isolates brake cylinder from Auxiliary
reservoir
Brake cylinder Piston moves inwards.

53. Common Pipe Bracket & Intermediate PieceCommon Pipe Bracket & Intermediate Piece
Common Pipe Bracket: Mounted on under
frame & suitable for all types of D.V.
Intermediate Piece: Mounted on CPB to fit
D.V on CPB.. Blanks all holes on CPB other
than required for a particular D.V. IP is
specific for each D.V.

54. Air Brake HosesAir Brake Hoses
F.P Hose: Maintains connectivity along the
train.
F.P. : White
B.P. Green.
Testing at 10 Kg./ Cm2

55. BMBCBMBC
8 “ instead of 14” Brake Cylinder
Four BC per coach instead of 2 earlier.
External Slack adjuster removed
K type Brake Blocks used.
Cylinder has built in slack adjuster.
M.A. of 7.644 & 8.40 for NAC & AC
Coach.
15 mm pneumatic pipe.

56. Brake BlocksBrake Blocks
Low friction composite Brake Blocks.
Uniform coefficient of friction. 0.25 for k Type &
0.15 for L type.
Reduced wear. Max 12 mm
Less noise.
Less weight

57. Brake Head with Brake Block & Brake Shoe KeyBrake Head with Brake Block & Brake Shoe Key

58. Brake HeadBrake Head
•Brake Head holds the Brake Block
•Brake Shoe Key is used for
mechanical interlocking
•Two types of Break Head based on
the Brake Block.
•L type Brake Blocks use ICF Brake
Head
•K Type Brake Blocks use IGP Brake
Head

59. Brake Block ComparisonBrake Block Comparison
Parameters Type of Brake Blocks
L K CI
Applicability Under frame
B.C.
BMBC V.B. & Under
Frame B.C.
Speed 110 KMPH 110 KMPH 140 KMPH
Coefficient of
friction
0.13 0.25 0.13
Weight 3 Kg. 3 Kg. 9 Kg.
Braking
Distance(110
KMPH, 18 C)
905 800 905
Weight reduction 492 Kg.
No of Pins 102 843 Kg. 102

60. Inner & Outer Head Stock

61. Draw Gear ArrangementDraw Gear Arrangement

62. Head stockHead stock
Head stock : Two Types. Inner & Outer
connected by Center Buffer Stiffener- Hole ?
Under frame supports various equipments
End section has four vertical pillars of box
section
They are connected transversely by Z section
members

63. Draw Bar with Draft KeyDraw Bar with Draft Key

64. Floor DetailsFloor Details

65. Shell Components-UnderShell Components-Under
FrameFrame
Sole Bar- Negative Camber
Outer & Inner Head Stock
Turn Under (Why Oblong Holes)
Body Pillar – RH & LH
Tubular Frame
Trough Floor – MS to SS

66. Body Pillar, Sole Bar & Turn UnderBody Pillar, Sole Bar & Turn Under

67. Buffing GearBuffing Gear

68. Buffing GearBuffing Gear
•Buffers of 1030 Kg-m Capacity used to IRS-M 10 Spec.
•Buffer Assembly
•Buffer Casing- Cracks on line
•Buffer Plunger: Repair Practice
•Rubber Buffer Pads- Single pad to G4
•Buffer Spindle
•Destruction Tube
•Recoil Spring
•Recoil Spring Parting Plate
•Recoil Spring Washer
•Buffing Spring Parting Plate
•Face Plate- Hardfacing & Hytrel
•M24 Hex Head Bolt.

69. ShellShell
 Made of a framework of hoops, x beams, BSP,
roof Car lines, .
 Longitudinally by sole Bar, Waist Rail, CAR Rail.
 2mm CR sheet makes the skin.
 1.6 mm CR sheets makes the roof.
 2mm CR corrugated trough floor is used.
 Tubular structure provided in place of trough floor
at the lavatory area.

70. Shell Components- SuperShell Components- Super
StructureStructure
TRA Ventilator ?
Door Handles
Door Pivot- 100 day sick marking
Body Bolster- Repair
Center Pivot
Water Tank- 2 piece
Floor Channel- MS to SS

71. PaintingPainting
 Paint Schedule “A”
 Paint remover-Strip to bare metal every 5th
POH
 Use petroleum solvent to remove paint remover IS: 1745
 Sand paper
 Red oxide zinc chromate IS: 2074-92 DFT 25 micron.
 1st
coat of brushing filler IS:110-83 , DFT 30 micron
 Apply knifing stopper putty IS 5083: 88, sport application & wet
rubbing
 Second filler coat IS:110-83 DFT 30 micron
 Wet rub with Bone Cuttle & emery paper SiC 120 & 220 No.
 Under coat IS: 8662-93 DFT 25 micron
 Rub with 320 paper & enamel IS: 8662-93
 Rub 400 No paper , Second coat IS:8662:93 DFT 20 micron

72. Train LighteningTrain Lightening
BG Coach
EOG SG MOG
SU
Under slung
RMPU AC NAC
SU
Under slung
RMPU with
25 KV Alternator

73. Battery
Box
Fabricated from MS Sheets & Angles with
FRP Trays
BCT Battery Charging Terminal provided on Both
end of the Coach for external Charging
RJB Rotary Junction Box in the coach for control &
power supply to various equipments
EFT Emergency Feed Terminal at both end of the
coach to feed additional supply to adjacent
coach in case of emergency
TL Lamp 25 W& 40 W lamps.
20 W , 110 V DC Tubelight

74. Axle & Alternator Pulley with V Belt & Alternator

75. Air-conditioning EquipmentAir-conditioning Equipment
 Axle Pulley- Two Halfs
 V Belt
 Alternators 4.5 & 25 kw
 Battery & Battery Box 120, 800, 1100 AH,
 Compressor & Condenser Motor
 Evaporator Motor
 Compressor – Maneurope & Scroll
 Condenser
 Dehydrator & Liquid Receiver
 Filters-
 Thermostats- RMPU
 Panel Board
 Pre Cooling Unit

76. AlternatorsAlternators
Type of Coach Alternator Type
Non AC Coach 4.5 KW, 37.5 A, 120 V DC
SG AC Coach 18 KW, 138.5 A, 130 V DC X
SG AC Coach 22.75/ 25 KW, 175/195 A, 130
V DC

77. TL Components
RRU Rectify 3 P AC output of Alternator through
DC Full Wave Bride Rectifier & regulate
output current
Battery 6V, 120AH-Non AC BG SG Coach
2V, 120 AH, VRLA on NAC BG SG
2V, 1100 AH, 56 Cell, VRLA , 110 V on
coaches with RMPU
2V, 800 AH, Flooded Type on Under Slung
Split AC
120 AH, 24 V on EOG AC

78. Shop Manufactured ItemsShop Manufactured Items
•32 mm Plate
•Anchor Link Bracket for Bogie Frame
•Anchor Link Bracket for Bogie Bolster
•Pull Rod
•Thickener for Alternator Bracket

79. 25 mm Plate
Bottom Pivot for BEML Coach
Yoke Bracket for trimmer Bar
•20 mm Plate
•Lever Hanger Short
•Lever Hanger Long
•Vertical Lever
•Hinge for Flap Door
•Milk Tanker Center Pivot Base Plate
•Face Plate for Buffer Plunger
•Center Pivot Cotter

80. 16 mm Plate16 mm Plate
Bogie Alternator Bracket Support Plate
Holding Device for Vestibule Foot Plate
Packing Plate for Draft Link
Horizontal Levr for Power Car
 12 mm Plate
 Plate for Destruction Piece
 Hinge for NMG
 Closing Palte for AB Guide
 Lever for Hand Brake Pull Rod
 Support plate for Vestibule Foot Plate

81. Compensating Ring
Brake Cylinder Bracket
Buffer Head Stock patch
IGP Brake Head Stopper Piece
Packing Plate for AB Housing
Inner Head Stock
Base Plate
Trimmer Bar
Modified Brake Head Piece
Fulcrum Bracket
10 mm Plate

82.  Equaling Stay Rod Bracket Side Plate
 Head Stock
 Buffer Head Stock Patch
 Eye Piece for UIC Vestibule
 Compensating Ring
 Buffer Bolt Stiffner
 Battery Box Knee
 Side Berth Pivot
 Plian washer for rubber Bump Stopper
 Bend Plate for side bearer
 Packing Plate for AB Housing
8 mm Plate

83.  Water Tank Support Bracket
 Lug for Brake Beam Safety Strap
 Comensating Ring
 Wire Rope Bracket
 Common Pipe Bracket
 Stiffner Angle for Sole Bar
 Formed Channel
 C Channel
6 mm Plate

84. 5 mm Plate
Sole Bar
Equalizing Stay Rod Bracket
Head Stock Inner
 C & U Channel
Rib of Brake Cylinder Bracket
Common Pipe Bracket Plate
Hinges for Seat Berth
Angle for Vestibule Foot Plate
Brake Beam Plate
Collar of Protective Tube
Clip for Anchor Link Bracket

85. Water Tank for BEML
Vacuum Reservoir for Double Decker
Center Pivot Top Plate
Foot Step for ICF
 C & U Tube
Center Pivot Cap
3.15 mm Sheet

86. 2 mm Sheet
 Trough Floor
 Body Side Lower Panel
 U Tube
 Z Type Car Line Moulding
 UIC Vestibule Bracket
 Z Pillar
 Body Pillar , Right & Left
 Turn Under

87. 1.6 mm Sheet
 Z Molding
 Half Round Roof Carline Patch
 Waist Rail
 Side & Stiffener Angle for Battery Box
 Battery Box
 Moldings of various sizes.
 Wall Protector
 Wheel Tag
 Locking Plate for Anchor Link

88. ?