The document provides details on the design features of a bogie, including its frame, materials used, imported bogie items, suspensions, wheels, brakes, and problems reported. It describes the bogie's primary and secondary suspensions, which use springs, dampers, and other components to connect the wheel set to the bogie frame and vehicle body. The document also lists specifications, dimensions, and condemning limits for various bogie parts.

1. DESIGN FEATURES

2. BOGIE FRAME
Y-FRAME -STEEL SHEETS
(St-52)
TWO
SIDE
FRAMES
CONNECTED
BY
TWO
CROSS BEAMS -SUPPORT
BRAKE UNITS.
BOGIE FRAME ON THE
PRIMARY SPRINGS AND
SUPPORTS VEHICLE BODY
THROUGH BOLSTER.
BOLSTER-BOGIE
FRAME
THROUGH
SECONDARY
SUSPENSION.

3. MATERIALS USED:
STEEL CASTINGS (GS20Mn5V; DIN 17182):
BRAKE SUPPORT
PIN BRACKET
SPRING CENTERING IN SECONDARY (1268840)
BUMP STOP BRACKET LH/RH
SGCI CASTINGS (IS:1865)
AXLE BOX FRONT COVER
CONTROL ARM TOP
CONTROL ARM LOWER LEFT/RIGHT
PRIMARY SPRING CENTERING LOWER AND
UPPER

4. MATERIALS USED:
FORGINGS :
TRACTION CENTER
CENTER PIVOT PIN
CONTROL ARM SUPPORT BKT LH/RH
ANTI ROLL BAR FORK
ANTI ROLL BAR BRACKET
PLATE/TUBES (S355J2G3;EN10025)
BOGIE FRAME
BOGIE BOLSTER
CROSS SECTION

5. IMPORTED BOGIE ITEMS:
FORGED WHEEL DISCS
BRAKE SYSTEM
PRIMARY SPRINGS
SECONDARY SPRINGS
DAMPERS
RUBBER-METAL COMPONENTS (06 TYPES)
MINER PAD ON PAC

6. Primary suspension
Four nos. each per bogie
Nested coil springs, primary vertical dampers, control arm,
elastic joints-connecting the bearing on wheel-set to bogie
frame.
Flexible guidance.

7. Primary suspension
Rubber Pad
Outer Spring
Spring Guide
Inner Spring
Lower Spring Guide
Bump Stop

8. WHEEL SET:
Two brake disks (4), diameter 640 mm and width 110
mm.
Two wheel discs of dia 915 (New), 845 (worn).

9. Wheel Re-profiling and
balancing:
DYNAMIC BALANCING
320 RPM
LESS THAN/EQUAL TO
50 gm
GLUE THE NEEDED
WEIGHTS
Balancing
machine
Weights

10. Axle bearings
CARTRIDGE TAPER
ROLLER BEARING
PRE-ASSEMBLED UNIT

11. BRAKE UNITS
AXLE MOUNTED DISC BRAKE
INBUILT SLACK ADJUSTER IN BRAKE
CYLINDERS
CALIPER RATIO 1:2.17 FOR ALL COACHES
EXCEPT POWER CAR, WHICH IS 1:2.48
35 mm BRAKE PADS
JURID 877/BECORIT984

12. BRAKE CALIPER UNIT

13. SECONDARY
SUSPENSION
NEST OF FLEXI-COIL SPRINGS INNER AND
OUTER, RUBBER SPRING AND
SECONDARY PAD
VERTICAL DAMPERS
LATERAL DAMPERS
YAW DAMPERS
ANTI-ROLL BAR
ANCHOR LINKS

14. (With Bolster Lifted)
Sec. Vertical
Damper
Bogie Bolster
Cross Section
Nested
Secondary
Spring
Assembly
Yaw Damper

15. (With Secondary Spring System Exploded)
Bogie
Bolster
Miner Pad
Spring Guide
Outer Spring
Inner Spring
Rubber Spring

16. (Bolster removed)
Lateral Damper
Lateral Bump stop
Longitudinal Bump stop

17. (X-section lifted)
Traction Lever
Traction Center
Anti Roll Assly
Curve Roll

18. ANTI-ROLL BAR:
A TORSION BAR WITH TWO FORKSBETWEEN BOGIE FRAME & BOLSTER,
CONNECTED BY ROLL LINKS.
RESISTS ROLLING MOTION OF COACH.
AS PER UIC 515-1 TILTING CO-EFFICIENT
<0.4.

19. ANTI-ROLL BAR:

20. A
Anti-roll Assly

21. BODY BOGIE CONNECTION

22. BOGIE BODY CONNECTION:

23. BUFFER HEIGHT ADJUSTMENT
Shims at body/bogie connection.
Shims NOT added/removed in Primary and
Secondary Suspension for wheel wear
compensation or buffer height adjustment.

24. Principles of force
transmission
Vertical forces:
BODY-BOLSTER-MINER PAD-SEC.
SUSPENSION-BOGIE FRAME-PRIMARY
SPRINGS/BALL JOINT CONTROL ARMAXLES.

25. Lateral forces:
BODY-BOLSTER-MINER PAD/SEC.
SPRINGS/LATERAL BUMP STOP-BOGIE
FRAME-BALL JOINT CONTROL ARMAXLES.

26. Traction and braking
forces:
BODY-TRACTION
CENTRETRACTION
LEVER/LONGITUDI
NAL BUMP STOPBOGIE FRAMECONTROL ARMAXLES.

27. A
Traction Center

28. CURVE NEGOTIATION:
CONTROL ARM (SGCI TO IS:1865)
CONNECTING AXLE BEARING AND SIDE
FRAME
THROUGH
ELASTIC
CONNECTION.
FLEXIBLE GUIDANCE TO WHEEL-SET.

29. SUSPENSIONS OF VARIANTS
THE COMMON SUSPENSION GROUPS
ARE:
GS,SCN,SLR
CC,EC,CB,FAC/EOG,ACCW/EOG.
ACCN/EOG,FAC/SG,ACCW/SG
ACCN/SG,WLRRM SIDE 2.
WLRRM SIDE 1.
SLR UNDER- SLUNG.

30. Main Data:

31. CARDAN SHAFT ARRGT. FOR
25KW ALTERNATOR

32. CARDAN SHAFT ARRGT. FOR 25KW

33. CARDAN SHAFT ARRGT. FOR 25KW

34. SELF-GENERATING BOGIE
WITH 4.5kW ALTERNATOR &
V-BELT

35. SELF-GENERATING BOGIE WITH
4.5kW ALTERNATOR & V-BELT:

37. THANKY
OU

38. PROBLEMS REPORTED IN
FIAT BOGIE BY ZONAL
RAILWAYS:

39. 1. CONTROL ARM BKT WEAR
CONTROL ARM BRACKET (BOGIE) HALF ROUND
MAX. RADIUS DEPTH
(1267401 & ASSLY DRG
NO. 1272174, 1267532)
CONDEMNING SIZE TO BE SPECIFIED FOR DIA
85
AS PER DESIGN, NO MOVEMENT IS PERMITTED
IN CONTROL ARM BRACKET FIXING WITH
BOGIE FRAME IF PROPER TIGHTENING OF
FASTENER IS ENSURED.
HENCE NO WEAR LIMIT IS REQUIRED.

40. 2 WEAR ON BOLL JOINT
CONTROL ARM ø85 –0.036/-0.090
CONDEMNING SIZE TO BE SPECIFIED
AS PER DESIGN, NO MOVEMENT IS
PERMITTED IN CONTROL ARM BRACKET
FIXING WITH BOGIE FRAME IF PROPER
TIGHTENING OF FASTENER IS ENSURED.
HENCE NO WEAR LIMIT IS REQUIRED.

41. 3. BOLSTER SPRING HEIGHT
517 mm SHOWN IN DRG NO. 1268801 & OTHER SEC
SUSPENSION DRAWINGS.
ACCEPTABLE RANGE TO BE GIVEN. FOR DIFFERENT
TYPE OF COACHES DIM. TO BE MENTIONED ALONG
WITH THEIR ACCEPTABLE RANGE.
THIS IS FOR INFORMATION DURING MANUFACTURE
AND APPLICABLE FOR ALL TYPES OF RAJDHANI
COACHES. HENCE NEED NOT TO BE CHECKED DURING
POH

42. 4. HEIGHT OF BOGIE FRAME
TOP FROM RAIL LEVEL:
DIMENSION 925+0/-5 SHOWN IN 1268801 WILL
DECREASE WITH REDUCTION IN WHEEL DIA
HEIGHT UNDER MIN. DIA OF WHEEL TO BE
MENTIONED.
DIMENSION IS SPECIFIED WITH NEW WHEEL DIA
(MENTIONED
IN
CONCERNED
DRAWING).
DIMENSION CAN BE CALCULATED WITH ACTUAL
SIZE OF WHEELS ON COACHES. CONDEMNING
SIZE OF WHEEL IS Φ845 mm AND NEW WHEEL DIA
IS Φ915 mm

43. 5. HEIGHT OF PIN BRACKET MACHINED
SURFACE FROM RAIL LEVEL:
FROM RAIL LEVEL 930+6/-2 (1272056). HEIGHT
UNDER MIN. DIA OF WHEEL TO BE MENTIONED.
HEIGHT UNDER WORN WHEEL MAY BE
CALCULATED AS PER ACTUAL WHEEL WEAR
MEASURED.

44. 6. CLEARANCE BETWEEN PRIMARY
VERTICAL BUMP STOP GAP
13 mm FOR C. CAR & 8mm FOR GEN. CAR. DIM.
NOT SPECIFIED FOR CN,CB,CW & FAC ADVISE
SUITABLE MEASURING DEVICE AND
PROCEDURE
THIS DIMENSION IS FOR INFORMATION AND
SHOWN IN CONCERNED PRIMARY
SUSPENSION. DIMENSION 13MM IS APPLICABLE
FOR CN, CB, CW & FAC COACHES AS SHOWN IN
THEIR APPLICABLE PRIMARY SUSPENSIONS

45. 7. CLEARANCE BETWEEN VERTICAL
STOP & LUG OF CONTROL ARM
UPPER CLEARANCE = 45mm & LOWER CLEARANCE =
37.5mm. MAXIMUM AND MINIMUM LIMIT ARE NOT GIVEN
THESE DIMENSIONS ARE FOR INFORMATION ONLY.
HOWEVER, DURING SERVICE THESE DIMENSIONS MAY
BE: 45mm MAY BE REDUCED MAXIMUM AS UNDER:
FOR GEN. CAR BY 15mm & FOR OTHER COACHES BY
20mm
DIMENSION 37.5mm WILL INCREASE BY SAME AMOUNT.

46. 8. MAX. NO. OF SHIMS AT BODY BOGIE
CONNECTION
55mm AS PER ALSTOM L. NO. CL 704
Dt.01.09.2001 (ANNEXURE II-b).
HOW MANY SHIMS CAN BE ADDED AT ITS LAST
SHOP ISSUE
WE CAN ADD 5mm THICK SHIMS UPTO WHEEL
WEAR OF 30mm ON RADIUS - BECAUSE WHEN
WHEEL WEAR REACHES 35mm ON RADIUS, THE
WHEEL WILL HAVE TO BE CONDEMNED (845mm
DIA)

47. 9. AXLE BOX TO BOGIE FRAME (PRIMARY
SPRING HEIGHT)
DIMENSIONS GIVEN IN DRG NO. 1267411
& 1277142 (264+0/-4, 252+0/-4)
DIM. NOT SPECIFIED FOR CN,CB,CW &
FAC
THESE DIMENSIONS ARE UNDER TEST
LOADS OF INDIVIDUAL PRIMARY
SPRINGS. NEED NOT TO BE SPECIFIED
FOR DIFFERENT COACHES.

48. 10. RAIL LEVEL TO CONTROL ARM BRACKET
(VARIES DEPENDING ON WHEEL DIA.)
DIM 462.5+/-4 FOR 1272056
DIM 459+/-4 FOR 1277672 G. SIDE-1
DIM 464+/-4 FOR 1277673 G. SIDE 2
WITH REDUCTION IN WHEEL DIA, HEIGHT FROM
RAIL LEVEL TO CONTROL ARM BKT.
DECREASES.
HEIGHT WITH MIN. WHEEL DIA TO BE
MENTIONED THESE DIMENSION SHALL BE
CALCULATED FOR OTHER COACHES AND
SHALL BE ADVISED

49. 11. CONDEMNING LIMIT TO BE SPECIFIED FOR
CENTER PIVOT Ø100 :
TOLERANCE GRADE IS g8 ON Ø100
CENTER PIVOT PIN (-0.012/-0.066)
AS PER EXISTING PRACTICE ON BG ICF
BOGIES, TOLERANCE TO BE MAINTAINED
ON EVERY IOH/POH. IF THE COMPONENT
IS OUT OF TOLERANCE RANGE SAME TO
BE REPLACED.

50. 12. QUERY RELATED TO CHAPTER-6 PAGE 6/13
OF MAINTENANCE MANUAL:
QUERY: CONDEMNING LIMIT OF CENTRE
PIVOT HOLE DIA OF 0.7 TO 1.2mm.
SOLUTION: AIR GAP OF 0.7 TO 1.2mm IS
SPECIFIED FOR SPEED SENSOR AND
DOES NOT RELATE TO CENTER PIVOT
PIN.

51. 13. RUBBER SPRING FREE HEIGHT
CONDEMNATION LIMIT TO BE SPECIFIED
235mm
FREE HEIGHT IS NOT REQUIRED TO BE
CHECKED. HOWEVER, RUBBER SPRINGS
SHOULD BE CHECKED FOR LOAD
DEFLECTION CURVE GIVEN IN DRAWING.

52. 14. ANTI ROLL BAR GAP BETWEEN ROLL
LINK & FIXING BLOCK
ANTI ROLL BAR – GAP BETWEEN ROLL LINK
BKT. AND FIXING BLOCK1267422 NOT
SPECIFIED. TO BE SPECIFIED.
QUERY NOT CLEAR

53. CONTROL ARM CORROSION AND WEAR:
WEAR AND CORROSION ON MATING SURFACE WITH
BEARING.
TOLERANCE MAY BE ENSURED ON EVERY IOH/POH
Ø230+ /- Ø210 . IF WEAR OCCURS, MAY BE
REMACHINED BY GIVING A CUT OF 0.3 TO 0.5mm ON
BOTTOM FACE.
IF IT CAN NOT BE RECTIFIED BY ABOVE MACHINING
SAME MAY BE REPLACED.
M/S FIAT HAS RECOMMENDED TO USE LUBRICATING
OIL BLASOL-135 DURING FITMENT TO MINIMISE WEAR
ON CONTROL ARM AND AVOID CORROSION.

54. FAILURE OF DAMPER:
END FITTING DAMAGE, STONE HITTING,
LEAKAGE
RDSO HAS BEEN ASKED TO REVIEW THE
SPECIFICATION OF END MOUNTING RUBBER
VIDE MD23161 DTD. 08.08.07
WR HAS BEEN REQUESTED TO PROVIDE
FURTHER DETAILS PERTAINING TO TYPE OF
DAMAGE/FAILURE IN DAMPERS VIDE MD23161
DTD. 08.08.07