CMI-j(OOl.Q-rl'')'iV'-'tdi~. --:- .

- "'1For Off)ctaJ U~"i

­,trolling Officer

alllrc; d~"'o",,,daa .j));,}£k -

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I Governm~t of 'IndiaMinistry of R.aiIWiiy~ .

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. MAINTENANCE MANUAL FOR-SOGIE ANDUNDERGEAR OF ac EMU, dc, EMU AND MEMU ~F,:ITTED·WITH STEEl... SPRING SUSPENSioN ARRANGEMENrr'(

Manual No. Ci\IIl-K001(April; 200J)

Research Designs & Standard;; OrganisationGov! of. India, Ministry of Railways

... Loc"ncw - 226 011.

Amendment slip No.1 of February 2007 for Maintenance Manual for Bogie and Undergear of AC EMU, DC EMU, and MEMU fitted with steel spring suspension arrangement.

Replace the existing Fig No. 32 by the revised Fig. No. 32(Rev.-I). in which a note has been added for the clearance between Bogie Frame and Body Bolstm of IVIEI\I1U Coaches, which is as under.

" Body bolster to Bogie Frame clearance 151 mm Min. Applicable for she!! Nos 1 to 87 (Manufactured during 1993 to 1995). Body Bolster clearance 131 rrm' '. ill Applicable from shell No. 88 onwards (Manufactured from 1996)".

CONTENTS

1. Brief Description Of Bogies ,:"lI'2. \\\~: Sali~nt Features Which Contribute To

Improved Riding Comforts3. Interval Of Overhaul4. Lifting The Body Off The Bogies5. Dismantling Of Motor And HCC Bogies6. Dismantling Of Trailer Bogie7. Lifting The Bogie With Jacks8. Attention To Bogie Components9. Wheel And Axle10. Roller Bearings11. Axle Box Housing12. Axle Box Springs13. Lower Spring Seat14. D.ashpots And Axle Guide Assemblies15. Bolster Springi6. Lower Spring Beams17. Hydraulic Shock Absorbers18. Rubbing Plate In MC & HCC Bogie19. Equalising Stays20. Centre Pivot (MC & HCC Coach)21. Centre Pivot (Trailer Coach)22. Side Bearers23. Anchor Links (Trailer Bogies)24. Hanger And Hanger Bloc~.s

25. Bogie Brake Gear26. A~tion To Be Taken Before Re-Assembling The Bogie27. S~quence Of Re-Assembling The Bogies28. Running Clearances29. BUffer Height Adjustment30. Brake31. BUffing & Draw Gear32. A~ention Required For Bogies In Car Sheds

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1223335611121213141415151515161618181919192021222222

1.2.3.4.5.67.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26,27:28.29.30.3132.33.34.

35.!

36.

3703839.'40.41.

LIST OF FIGURES

B09ie General Arrangement(Motor Bogie)Bogie General Arrangement(HCC Bogie)Bogie General Arrangement(Trailer Coach)Assembling & Dismantling of Bogie BolsterBogie Frame Arrangement(Motor Bogie)Bogie Frame Arrangement(HCC Bogie)Bogie Frame (Trailer Bogie)Important Dimensions in Bogie Frame(Motor & HCC Bogie)Important Dimensions in Bogie Frame(Trailer Bogie)Checking of Bogie Frame AlignmentRoller Bearing Arrangement(Motor & HCC Bogie-Direct Mounted)Roller Bearing Arrangement(Trailer Bogie-Sleeve Mounted)Roller Bearing Arrangement(Trailer Bogie-Direct Mounted)Withdrawal Tool in PositionMounting Sleeves for Roller BearingAxle Box Guide Arrangement(Motor & HCC Bogie)Axle Box Guide Arrangement(Trailer Bogie)Dip Stick(Trailer Bogie)Dip Stick(Motor & HCC Bogie)Lower Spring Beam(Motor & HCC Bogie)Lower Spring Beam(Trailer Bogie)Rubbing Plate in MC & HCC BogieEqualising Stay(Motor & HCC Bogie)Equalising Stay(Trailer Bogie)Centre Pivot Arrangement(Trailer Bogie)Centre Pivot Arrangement(Motor & HCC Bogie}Side Bearer Arrangement(Motor & HCC Coach)Side Bearer Arrangement(Trailer Coach)Hanger and Hanger Blocks(Motor & HCC Bogie)Hanger and Hanger Blocks(Trailer Bogie)Running Clearances(Motor & HCC Bogie)Running Clearances(Trailer Bogie)Split PackingBuffer Height Adjustment(Motor & HCC Coach)(EMU/MEMU stock of ICF, JESSOP, BEML)Buffer Height Adjustment(Trailer Coach)(EMUlMEMU stock of ICF, BEML)Buffer Height Adjustment(Trailer Coach)(EMU stock of JESSOP)Brake Rigging Diagram(ICF & BEML ac EMU)Brake Rigging Diagram(tCF & BEML de EMU)Brake Rigging Diagram(JESSOP ac EMU)Brake Rigging Diagram(JESSOP de EMU)Brake Rigging Diagram(MEMU)

MAINTENANCE MANUAL FOR ACmC EMU & MEMUBOGIE AND UNDERGEAR

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,I. BRIEF DESCRIPTION OF BOGIES

1.1 Bogies of motor coaches (MC), high carrying capacity coaches (HCC) and trailercoaches (TC) are of ali welded, light weight construction (Figs. 1, 2 & 3). Theaxles, with self aligning roller bearings mounted inside cast steel axle boxes, arerigidly guided by telescopic dash pot and axle box guide assemblies. Helicalsprings working in paraliel with dashpots are used for primary suspension. Coachbody is supported on two side bearers located 1700 mm (TC) and 1200 mm (MC& HCC) apart on a floating bogie bolster which in tum rests on two pairs of helicalsprings supported on a spring plank hung on swing links from bogie frame. The .helical springs at each end of bolster are damped by hydraulic shock absorbers.Side bearers consist of metal slides immersed in oil baths weli protected fromdust ingress.

1.2 No weight is transferred through the bogie pivot, which is located in the centre ofthe bolster. The pivot acts merely as a centre of.fotation and selVes· to transmitacceleration and retardation forces.

1.3 The floating bolster in TC bogie is secured in the longitudinal direction to bogieframe by means of two anchor links with silenl block bushes, located diagonallyopposite to each other and transmit draw and braking forces between bogieframe and coach body through the centre pivot. The MC & HCC bogie bolster islocated between bogie transoms and transmits draw and braking forces throughrubbing plates fixed at the bolster ends.

2. SALIENT FEATURES WHICH CONTRIBUTE TO IMPROVED RIDINGCOMFORTS

2.1 Rigidly guided axles with self aligning spherical rolier bearings, having practicaliyno play in longitudinal and lateral direction and hetical springs working in paralletwith dashpotslshock absorbers of specified characteristi~, ali contribute to ridingcomforts. It is th~refore essential to ensure that these features are wellmaintained in service in order to obtain the desired performanCe throughout thelife of these bogies.

I. INTERVAL OF OVERHAUL

3. 1 The EMU and MEMU coaches are required to be overhauled after every oneyear or two lakh kilometers, whichever is less. '

Maintenance Manual No. CMI-KOOJPage J0[24

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LIFTING THE BODY OFF THE BOGIES

Before lifting the coach body from the bogie, all eiectrical motors and earthconnections, traction motor ventilation bellows and hand brake/parking brakeconnections must be disconnected. The centre pivot cotter pin in the Te and thesecuring collar in the MC/HCC bogies must be removed. The axle box andbolster safety straps should be diseng~ged.

The coach body can be lifted off the bogies by one of the following methods: •

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4.1

4.2

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Two electric cranes each with suitably designed swings and cradles.

Four electrical/hydraulic lifting jacks simultaneously operated by onecontrol switch. Coach should not be lifted from any other point but thelifting pads.

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4.3 The cranes or jacks used for lifting shouid be operated uniformly andsimultaneously without jerks.

4.4 Before finally lifting coaoh body, steel/wooden blocks of requisite thicknessshould be inserted in the recess In between the bogie frame and bogie bolster inorder to avoid the bolster hitting the bogie frame which may strain the silent blockbushes of anchor links in trailer bogies.

4.5 Lifting of coach from one end Is striclly prohibited as the centre pivot, bogiebolster and dashpot guides are likely to suffer damage and dents may occur onbody panel near the body bolster.

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4.6 Whenever the coach body is lowered on bogies, air vent screws on the TC bogieframe and filling caps in the MC/HCC bogie frames should be unscrewedcompletely after cleaning the area around the vent hole properly. This is done torelease the air locks in the dashpots.

5. DISMANTLING OF MOTOR AND HCC BOGIES

5.1 After the bogie is run out, the traction motors,(of MC bogies) must be taken outas per Electrical Manual No. MM/DC EMU/003.

5.2 The shock absorbers should then be disconnected. The bolster may be removedfrom the bogie frame by compressing the bolster springs to relieve the load onswing links and hanger pins (Fig. 4). While the bolster springs are compressed,the pre-tension nut shOUld also be removed. The equalising stays connectingbolster to the lower spring beam should be disconnected after which the bolstercan be lifted and the springs removed.,,

5.3 The air vent caps should be ioos~ned to allow air to enter the dashpots. The. safety straps should be loosened and swung away, after which the bogie frame

may be lifted by means of crane till all the 8 guide bushes disengage the lowerspring seats and wheels are rolled out.

Maintenance ManulJ/ No_ CM/·KOO/Page 2 of24

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LIFTING THE BOGIE WITH JACKS

The bogie frame can be lifted and the wheels rolled out as explained in para 5.3.

Under no circumstances must a jack be used under a bogie frame when thecoach is under load. After running out the bogies, jacks must be applied underthe bogie side frame members and not under the bogie headstocks.

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j\DISMANTLING OF TRAILER BOGIE

.After the bogies are run out, the anchor links and shock absorbers should bedisconnected. The bolster can then be remo~ed from the bogie frame bycompressing the bolster springs to relieve the load on swing links and hangerpins (Fig.4). While the bolster springs are compressed. the safety strap boltsshould be unscrewed and the s)raps.swung away. The equalising stays shouldthen be disconnected. .-

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8. ATIENTION TO BOGIE COMPONENTS

8.1 Bogie Frame

.1 Bogie frame should be checked thoroughly after cleaning, for any cracks,particularly at places where bolster suspension brackets and the dashpotgUide flanges are welded, as indicated in Fig. 5, 6 & 7. Threads ondashpot guides should be checked for damages. Normally, squarenessand alignment of dashpot does not reqUire checking. If biased wheelflange wear or wear in the rear cover of the roller bearing axle box havebeen obselVed, the squareness and alignment of the guides should bechecked thoroughly with the help of a gauge. In the event of misalignmentof dashpot guides or damaged guides which require replacement,procedure described in paras 8.1.3 to 8.1.9 may be adopted.

.2 Alignment of axle box guides should be measured with reference to thebolster spring suspension bracket (BSS). Therefore, it is necessary toensure that BSS are in proper alignment between themselves and thecentres should form a rectangle within pennissible tolerances as shown inFig. 8 & Fig. 9 for MC/HCC and TC bogies respectively.

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.3 Centre punch mark should be made at the centre of each BSS andmeasurements taken. If they are within the tolerance, there is no need torelocate these brackets and their centres may be taken as referencepoints for further rectification.

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.4 If SSS do not lie within the toferance, the transverse centre line of bogieframe between headstock shoUld be marked and deviations on SSS fromthis line measured. Then one or more SSS should be cut out andrepositioned with correct alignment.

.5 After ensuring that BSS are in correct alignment, the location of axle boxguides from SSS are measured and checked as per dimensions shown inFig. 8 8. 9. For the purpose of checking these dimensions, gUide caps

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Maintenance Manual No, CMI·KOOJPage 3 0/24

rwith the centre hole blocked and marked with centre punch should beused as reference points. ,

.6 Where the measurement of gUides from BSS show a deviation from the .dimension given in Fig. 8 & 9, the concerned pair or guides should be cuI .and re-welded in position. The guides should always be cut in pairs as the 0" 0

adjacent guide distance o( 570,,mm (or TC bogies and 630 mm (or ."

MC/HCC bogies has to be maintained. Judicious selection of guides 10 becut will minimise rectification work. Normally, cutting and repositioning ofonly 4 out o( 8 guides should serve the purpose. These (our guides could ,be either those on one side of the frame or in two pairs diagonallyopposite 10 each other.

•.7 While cutting Ihe guides, care should be taken that only the weld metal is

cut and Ihe guide flange or bogie frame are nol damaged. Specialgouging nozzles 10 PO 18 or 19 may be used. The work calls for specialskill and the welders should practice cutting out welds on scrappedfabricated components before commencing guide cutting work on thebogie frame.

.8 The guides which are cut oul need not be scrapped but Ihe flangeperiphery should be buiil up by welding wherever damaged or pitted bygas cutting and ground to shape. Care should be taken not to damage theIhreads of the guide cap.

8.2 Welding of Dashpot Guide

.1 Locafe Ihe new guide with the help o( setting gauges with reference to theother guides. Two gauges, one providing the longitudinal and the other,diagonal location in relation to other gauges are sUfficient to locate theguide. However, a third can be used as a counter check (refer Fig. 10).

.2 Tack weld the guide to bogie frame taking care to ensure that the oil holeof the gUide is in alignment with that o( bogie (rame flange.

.3 Remove the gauge and complete welding.

.4 Allow the (rame to cool.

.5 Check the dimension of the guide in relation to the others With the help ofmaster gauges.

.6 Check the height of the guide in relation to the other guides with a straightedge.

.7 Any discrepancy in location may be rectified by suitable local heating of .~

the (rame (refer Fig. 10).

.8 Use low hydrogen supercite electrodes of approved brand for welding. "(Electrodes under IRS Class C2ID1 may be used).

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Maintenance Manual No. CM/~KOOIPage 4 0[24

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"\ I 8.3 Important dimensions to be checked after rectification are shown in Fig. 10.

8.4 Bogie frame should be thoroughly checked for any cracks, particuiarly al thebolster suspension brackets. The wear on the bush of bolster suspension bracket

.should also be checked. The bush should be replaced if the wear is more than0.5mm.

The EMU/MEMU coaches are provided with composite design of wheelsconsisting of rolled sleel wheel centres with renewable tyres. The tyres of TCbogies are faslened to the wheel disc with glut rings whereas the MC/HCCbogies have, in addition to the glut rings, 4 locking keys to ensure more positivesecuring.

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9.1

WHEEL AND AXLE;

9.2 lyre Profile

.1 The new/re·lurned tyre profile shall be as per ROSa Sketch No. 91146all. 2.

9.3 Wheel Dianieter

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The condemning limits for the flange wear, root wear, deep flange, sharpflange, hollow tread wear and nat surface on tyre shall be as per thecondemning gauge shown in plale 45 of I.R.CA Part IV.

Wheel gauge should be within the tolerance of +2/-1 mm.

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MCTCHCC

952mm952mm952 mm

Condemning

877mm857mm885mm

Last Shop Issue Size

885mm865mm873mm

9.4 Permissible Variation on Wheel Tread Diameter

.1 The permissibie varialion in tread diameter of wheels at the time of tyreturning or wheel replacement are' as follows:

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Wheels of the same axleWheels of Ihe same bogieWheels between two bogiesunder the same coach

0.5mm5.0mm

: 13.0 mm

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.2 No separate service limits are specified as the above figures have beenfixed to allow for the differential wear likely to develop betweensuccessive tyre turningslwheel changing. It is, therefore, not necessary towithdraw EMU/MEMU slack from service specifically for restoring thedifferential between wheel diameters to be within the prescribed limits.

Maintenance Manual No. CMI~KOOIPage 5 0[24

r9.5 Material Specification for Wheel and Axle

The material specification applicable to the wheels and tyres are as follows:

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.lyres

Axle

IRS Specification R-15/95.

IRS Specification R-16/95 for TC bogies.IRS Specification R-43/92 for MC & HCC bogies.

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10. ROLLER BEARINGS

10.1 MC & HCC Bogies

.1 These bogies are fitted with direct mounted, double row, seif aligningroller bearings No:22328 C/C3 as shown in Fig. 11.

10.2 TC Bogies

.1 TC bogies of EMU stock built before 1979 'have been fitted with sleevemounted, double row, self aligning roller bearing No. 22326 CKC3 asshown in Fig. 12.

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.2 TC bogies of all current EMU/MEMU stock are fitted with direct mounted,double row, self aligning roller bearing No. 22326 C/C3 as shown inFig. 13.

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10.3 Under normal service conditions, roller bearing axle boxes co not require anymaintenance. Their maintenance is, therefore. normally limited to inspection andre-Iubrication when the EMU coach comes in for POH.

10.4 List of Approved Lubricants

Application 1°C HPC BPC Balmer Lawrie

.1 Axle box Servogem BalmerolRoller bearing RR-3 multigrease

LL-3

.2 Side bearer Servoline Yantrol Bharat&dashpol -68 -68 Univol-68

.3 Shock AbsorberEscorts Servo HP-38

Friz-14

Gabriel Servo HP-38Shocarm-12/13

.4 Slack Adjuster Servogem BalmerolRR·3 multigrease

LL-3Note: The different types of greases/oils should not be mixed together.

Maintenance Manual No. CMI-KOOIPage 6 0/24

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10.5 Periods at Inspection at Roller Bearings

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All roller bearings are to be cleaned, inspected and filled with freshgrease at every POH or two years or two lakh kilometres, whichever isthe earliest.

Dismount roller bearingsftvery alternate inspection in the workshops forrenewal of the felt sealilig ring. If any defect in the roller bearing issuspected and/or the rear cover is damaged, dismount the roller bearingirrespective of the last date of dismounting.

,, .10.6 Inspection of Roller Bearings

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.1 Inspection involves removing the axle box body I cleaning differentcomponents, specially bearings, re.lubricating the bearings and re-'assembly. The bearing should not be dismounted unless there is sp~cial

reason. The inspection procedure is as fonows :

.1 Clean the outside of axle box carefully.

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Remove the front cover from the body casUng.

The condition of the bearing, to some extent, can be jUdged fromthe appearance of the old grease around it. If the grease is foundto be biackened or rust coloured, it may be taken as evidence ofwear and the bearing must be examined carefully to establish thecause.

If ~he grease is clean and does not show any discolouration andits consistency is soft and smooth, the bearing need not beremoved and may be cleaned in position. Remove the grease andwash the bearing with white spirit or kerosene with the help ofsyringes or brush.

.5 Clean the back cover and sealing components.

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Swivel the outer ring of bearing and examine the rollers, cage andouter ring track. The inner ring track can be examined if the outerring is slowly rotated. If any unusual resistance is noticed whenthis is done, the bearing should be examined more closely and ifany defect is found, the bearing should be removed.

If any defects are found as a result of examination as describedabove, check the bearing clearance with feeler gauge. Maximumbearing clearance of 0.24 mm is permissible.

If the inspection shows that the bearing is in good condition, packfresh grease between the rollers and re-grease the sealingcomponents. Finally, fann a cone of grease in front of bearing andthen mount the cover after cleaning the same and then tightenand lock the cover bolt nuts firmly.

Maintenance Manual No. CM/~KOOIPage 70/24

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,The working space for mounting and dismounting of roller bearings mustbe absolutely clean and the table on which roller bearings are cleanedmust be free from iron fillings and dust. Kerosene oil may be used forcleanings the roller bearings and journals. The cleaning bath should bechanged frequently to keep It free from dust and foreign matter. Steeltrays with lids should be used for cleaning roller bearings.

10.7 Dismounting of Direct Mounted Rollerl3earlngs

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.1 These bearings are dismounted by using oil injection method. In thismethod, oil is injected between the bearing inner ring ahd journal, forminga thin film between them. This enables the bearing to be removed quicklyand easily..

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.2 The tools shown In Fig. 14 may be used for dismounting the rollerbearing. The dismounting procedure is as follows:

.1 Push the injector adapter ring on the journal against the bearingand clamp it firmly against the bearing inner ring by means of theend washer and set screws. It is important that the screws aretightened firmly and evenly so that the adapter ring bears all roundthe face of the bearing inner ring.

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Connect the oil injection pump to the adapter ring and pump Inthick cylinder oil so that a film of oil is formed between bearing andaxle journal. The oil will remain for at least half an hour ~hen

cylinder oil is used. .

Slop pumping and remova Ihe adapler ring as soon as Ihe oil filmis formed .

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.4 Fit Ihe withdrawal 1001 shown in Fig. 14 over the bearing ring, Ihenpush the locking ring firmly so that the claws of sleeve engage theinside face of the bearing outer ring.

.5 Due to the oil film between the journal and the inner ring, thebearing can easily be dismounted by turning the withdrawal screw.

10.8 Mounting of Direct Mounted Roller Bearing & Assembly of Axle Box

.1 Mounting the back cover and felt seal

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Soak felt ring in a warm mixture of 2/3 cylinder oil and 1/3 tallow ata lemperalure of about 80 deg. C for 13 minutes and fit il in Ihegroove of the rear cover.

Clean and examine the journal and ensure that the thread holesfor locking boilS are perfect.

Clean collar and half fill it wilh grease and assemble it to the rearcover.

Maintenance Manual No. CMI-KOOIPageB of24

.5 Insert distance ring.

Mounting of Roller Beadn'g

.4 After assembling collar and ring with rear cover, insert four M22bolts in the cover and mount the assembly on the journal. Drivethe assembly on the axle with the help of mounting sleeves until ametallic sound is heard.

Clean and examine the bearing seating on the joumal, the filletand shoulder for the collar and remove any bUlTS, scratches or·bruises.

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, . .2 Check the journal profile with appropriate template.

.3 Check that the journal is cylindrical and its dimensions arc withinthe prescribed limits.

.4 After completing these checks, wipe the journal and keep it readyfor mounting of roller bearings.

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.5 The bearing is heated either in an oil bath or electrically, so thatthe bore of the inner ring expands and is slightly larger than thedlameler of the axle journal. The bearing can then be easilyplaced on its seating, where it obtains an Interference fit whencooled. When heating bearings in oil, use a container with acoarse mesh false bottom on which the bearings 'can stand so thatthey do not come into direct contact with the heated bottom. Puremineral oil must be used to which 3% melted 'Stearic Acid" shouldbe added as a rust inhibitor. The bearing should be heated at 100to 120 deg. C for a period of 20 to 40 minutes.

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.6 To mount the bearing, special tool with two sleeves as shown InFig. 15 is used. Remove the heated bearing from the oil bath bymeans of the carrying sleeve fitled with handle. Bring the bearingto the axle end and insert the guide pin of the carrying sleeve onthe centre hole of the axle. The Inside face of the sleeve is thenfitted up against the end of the joumal. Push the bearing on to itsseating and press firmly against the distance ring by means of the.mounting sleeve which is split to accept the handle of the carryingsleeve. Clean the end plate, locking washer and locking screws,smear the threads of the screws with oil and secure the lockingwasher to the end of the axle. The screws may be tightened asevenly as possible with a socket spanner.

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.7 After the bearing has cooled, swivel the outer ring and pack thebearing with grease. If the outer ring cannot be swivelledsufficiently, grease may be put in with fingers fr'lm the back of thebearing, until it is seen coming out at the front')Ensure that thespace between the bearing and rear cover is filled with grease andform a coneof greaSe at the front, from edge of end plate to the

Maintenance Manual No. CMI-KOOJPage90f24

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edge of outer ring. The axle box will have received sUitablequantity of grease when the grease can be seen coming out at theback of the bearing.

Mounting the Axle Box.." ..

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.1 Clean the axle box with kerosene oil and dry well. Smear thebearing seat with grease.1,-

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.2 Push the body over the bearing ensuring that the bolts passthrough the holes in the body. •

.3 Check that the box rotates freely.

.4 Mount the front cover and tighten and lock the cover bott nutsfirmly.

10.9 Dismounting the Sleeve Mounted Roller Bearing

.1 Screw on the HMV nut. Tighten it against the bearing inne~ ring usingtommy bar until the annular piston in the nut has been forced into ils innermost position. Ensure that the return valve of the pump is open and thepump piston pulled out so that oil Is free to fiow from the nut to thereservoir.

.2 Push a support piece into the withdrawal sleeve.

.3 Close the return valve and pump oil into the HMV nut until the withdrawalsleeve becomes loose.

.4 Open the return valve, .remove the sleeve and nut after unscrewing it.

.5 After removing the bearing. remove the rear cover and the sealing ring.>

.6 Wash and examine the bearing and other components.

10.10 Mounting of Sleeve Mounted Roller Bearing & Assembly of Axle Box

,1 Soak felt ring in.a warm mixture of 213 cylinder oil and 1/3 tallow for 30minutes and fit in the groove in the rear cover.

.2 Clean and examine journal and ensure that threaded holes in lockingbolts are perfect.

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Clean collar and half fill it with grease and assemble it to the rear cover.

After assembling collar and ring with rear cover, fix four M22 bolts in thecover and mount the assembly on the journal. Drive the assembly on theaxle with the help of mounting sleeves until a metallic sound is heard.

Maintenance Manual No. CMI-KOOIPage 100[24

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Check and note internal bearing clearance with a feeler gauge. Thegauge should have leaves in the range of 0.080 to 0.230 mm in steps ofevery 0.010 mm.

Fill spa,ce in the bearing with grease and wipe the bore of the bearing witha clean cloth free of fluff, moistened in white spirit or some similar waterfree element such as b~"nzene. Clean the withdrawal sleeve with petroland wipe the surface with clean cloth. Apply graphite powder mixed withoil on both sides of the sleeve leaving a thin film on the surface.

Position the bearing on the journal and push withdrawal sleeve on thejournal and into the bearing ensuring that the bearing is pressed againstthe ring perfectly.

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.6 Drive the sleeve in, with the help of a sledge' hammer and a dolly,carefully noting the reduclion in the internal clearance of the bearing. Thisreduction in clearance should be between 0.065 to 0.090 mm.

.9 Screw on the annular "nut and tighten well with a ring spanner. Fit thefastening piece in suitable slots and lock the assembly with retainingbolts. I

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In the later bearings, end plate locking arrangement has been providedinstead of annular nut. In this case after fixing end plate on the axle end,the bolts should be tightened and locked by bending over the corners oflocking plate against fiat of bolt heads.

Fill the space between the bearing and back cover with approved brandof grease.

.12 Liberally smear the inside of axle box with a rust preventive and fit it overthe bearing. Put front cover and tighten up bolts and lock the nuts withsplit pins,

.14 . Check that the axle box rotates freely by hand.

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.13 The date attended to shall be marked on the PR plate after sealing theaxle box cover with station code.

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11. AXLE BOX HOUSING

11.1 Double row self-aligning spherical roller bearings are housed in accuratelymachined cast steel axle boxes. The axle boxes are also provided with lightaUoy front and back covers secured by four bolts. Axle boxes and covers shouldbe thoroughly cleaned and checked for cracks particularly at the holes of thecovers which have shown pronen~~s to failures. The bolts should be examinedfor worn threads. straightness, ete]Sbefore re-use and should be well tightenedand locked by spring washers and split pins to ensure that the covers and theaxle box housing form a water tight assembly and protect bearing from dust andmoisture.

Maintenance Manual No. CMI·KOOIPage II 0/24

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12. AXLE BOX SPRINGS

12.1 Axle box springs are of helical type manufactured from centreless groundchrome vanadium, silica manganese steel. These springs are also shot-peenedto obtain higher fatigue life. It is necessary to check these springs for cracks arr:imeasure their free height to ensure that they meet the ~esign requirements.

12.2 All springs shall be grouped in thr.?e categories and used on bogies as perinstructions detailed in RDSa Technical Pamphlet No.C-8419 (Rev 1).

13. LOWER SPRING SEAT

13.1 lower spring seat on the axle box wing in which gUide bu~h of dashpot moves upand down does not normally wear in service. In the absence of inadequatequantity oil in the dashpot. the inside surface is likely to wear. If the surface isworn more than OAmm in diameter or if the surface is scored or otherwisedamaged, the lower spring seat should be reclaimed as per procedure givenbelow. All lower spring seats should be carefully checked for cracks before re-use. •

.1 Hold Ihe spring seat at the bottom portion with a three-jaw chuck on alathe.

.2 Part off the tube at a section at the following distance from the top of theflange of lower spring seat:

For Trailer Coach :48mm .•For Motor/HCC Coach :33mm •.. c-,

.3 Face the end maintaining the following distance from the top of theflange:

For Trailer Coach :45mmFor MotorlHCC Coach :30mm

.4 Bore the left over portion of the tube taking light cuts. taking care not 10damage bore (150 H7).

.5 Take a new tube as per the relevant drawing.

.6 Press the tube with spring seat machined as per para 4 above inhydraulic press of not iess than 25t capacity ensuring the squamess ofthe tube.

.7 Weld the tube end spring seat either by auto or by manual welding.

.8 Test for ieak hydraulically at a pressure of 14 kglcm2 or 200 psi. ~

.g Bore to size leaving enough material to finish by honing as per relevant ,.drawings.

.~.

" " .Maintenance Manual No. CM/~KOOI

Page /2 0124 ,

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14. DASHPOTS AND AXLE GUIDE ASSEMBLIES,

14.1 Axle box guides are accurately machined hollow forgings welded to the bogieframe to ensure that the wheel sets are rigidly guided in parallel. These gUidesare fitted with acetallbronze bush at the lewer end for close guidance of thewheel set both in lateral and longitudinal directions. The lower springs seat isfilled with oil and the assembiies sealed with rubber ring to make it oil tight. Thearrangement for topping-up oil);'n the dashpot of MC & HCC bogie is shown inFig. 16. In the trailer coach bogies, holes on the bogie side frame above eachguide are provided to top up the damping fluid when required as shown in Fig 17.

14.2 The following components which form Ihe dashpot assembly, shouid bethoroughly examined and renewed as indicated:

f

I-;; 1

.

Description of ICF Org. No. Ronew ifComponent TC Me & HCC

•• Guide T·O-3-639 EMUIM-Q·3·005 (with guide cap) Bottom threads worn,T-0-3.£10 EMUIM.£l·3-094lwilh clrclip) dam<lged or cracked CI\

the root of raelius.

2. Upper spring seat "·0-1-610 EMU/M..()-1..{)11 Oamaged, dentedor protectivEl tube or cr3cked, worn

;3. Dust shield spring T-G-1-6{)r T-G-1-Q12 DIstorted. brok~n, set

or otherwise defective,,

A. 'Oust shield T-Q-1-619 T-Q·1-619 Replace at every POH, ,'~

and Change if required.

. ,. 5. Guide ring T-Q-1-840 T-Q-1-840 Cracked, broken or"r I- worn

1 6. Rubber packing T-O-1-6J2 T-Q.1-632 Replace al every POHring

7. Guide bush T-Q.1-6J4 EMUIM-o-,-o23 Replace at every POH

6. Spring clip T-o-1-614 T-0·'-614 Replace at every POH

9. Guide cap T-Q-1-615 EMUIM-O-1-021 Threads damaged orworn holes blocked

14.3 IWhen the total diametric clearance between the guide bush and the lower springseat based on maximum bore dia and minimum bush diameter exceeds 1.6mm,,the part(s) shall be renewed. These measurements should be taken withmicrometers so that clearance can be assessed accurately.

14.4 Rubber packing ring shaii be procured as per RDSO Specification No. R47.

14.5 The holes in the guide caps should be thoroughly cleaned at every POH.

14.6 'Checking the guides by trammels is necessary.

14.7 ilf accident-involvJ!l, fuil checking is required:

-",,'. 14.8 ,Lowering must be done accurately to ensure packing rings are nol damaged.

Maintenance Manual No. CMI·KOOIPage 13 0[24

).

14.9 Axle box canting due to excess packing must be avoided.

14.10 Lower spring seat tolerances must be maintained.

14.11 The following are the'approved brands of oil for use in the dash-pot:

10C - Servoline-58HPC - Yantrol-58SPC - Sharat Univol-58

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14.12 Level of oil in dash-pot

.1 MC & HCC-Sogie

In the MC & HCC bogies. the level of oil in the dash pot from the guidecap should be 97mm when motor coach is empty. The level of oil can bechecked by unscrewing the filling r.ap and using dip stick shown inFig. 19.

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.2 Trailer bogies

Approximately 3 pints (1. 7 litres) of oil are required per dash-pol. Thelevel of the oil in the dash pot can be ascertained in service byunscrewing the bolt proVided on the bogie frame for topping oil and usinga flexible wire dip-stick shown in Fig. 18 inserted through the vent hole onthe bogie frame. The ievei of the oil when the vehicle is empty should be77mm from the guide cap inner surface and should be topped up if thelevel is less than this. It is necessary to ensure that the bolt on leatherwasher is tightened well to avoid ingress of dust through the hole whichwill lead to scoring of dashpot bronze bush. Oil split over the dashpotwhile replenishing should be wiped clean so that the subsequent leakageof oil. if any. may be detected easily.

15. BOLSTER SPRING

15.1 Bolster springs are of helical type manufactured from centreless ground chrome../" vanadium, silico manganese steel. These springs are also shot-peened to obtain

higher fatigue life. It is necessary to check these springs for cracks and measure,-./ their free height to ensure that they meet the desi9n requirements.

15.2 All springs shall be grouped in three categories and used on b09ies as perinstructions detailed in ROSO Technical Pamphlet No.C-8419 (Rev. 1).

15. LOWER SPRING BEAMS

15.1 All lower spring beams shown in Fig.20 and 21 should be carefully checked forcracks etc. before re~use.

Maintenance Manllal No. CM/-KOO IPage /40f14

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17.

17.1.

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18.1

=

. 19.

HYDRAULIC SHOCK ABSORBERS

:rha hydraulic shock absorbers are fitted to work in parallel with bolster springs.These shock absorbers normally give trouble-free service and require noattention in between POHs.

However, shock absorbers which are found either leaking or physically damagedshould be replaced. As the fesistance of these shock absorbers is likely todeteriorate in service, it is necessary to attend to them as per instructions givenin the manufacturer's maintenance manual. If the Railways have not yet got theshock absorber testing machine, the shock absorber should be got overhauledfrom the manufacturer/supplier, tested and renewed as and when required.

RUBBING PLATE IN MC & HCC BOGIE

Nylon rubbing plate (Fig. 22) has been filted to the bolster which seNes ascushion between the bolster and bogie frame. Initial clearance of 1mm on eachside has been provided between the nylon rubbing plate and steel rubbing plate.During POH,' this clearance must be maintained by fitting steel packings ofsuitable thickness. During service, this clearance should not exceed 3mm oneach side. Any higher clearance may cause excessive longitudinal oscillationsand may strain stay tubes (connecting the bolster to the spring plank) and causetheir breakage.

EQUALISING STAYS

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19.1 Equalising stays shown in Fig.23 (MC & HCC) and Fig.24 (TC) connecting thespring plank and bolster, pin jointed at both enCis. have been provided to preventlateral thrust on bolster springs. It is necessary to remove the pins at every POH,clean and oil them to ensure that they are free to rotate when re-assembled. Anyrestricted movement at these joints is likely to prevent free movement ofbolster. The free movement of pins can be ensured by greasing the assembly.

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19.2 The pins should be provided .with washers and split pins to ensure that they donot fall out in service.

20. CENTRE PIVOT (MC & HCC Coach)

20.1 The centre pivot arrangement is' shown in Fig.26. The body bolster of theunderframe is provided with a bush of inner dia 90mm in the top and 150mm diahole at the bottom and the centre pivot pin, when fitted to the body bolster,perfectly fits intq these holes as shown in Fig.26. Any wear due to bogie rotationis taken up by the upper and the lower bushes between the centre pivot pin andthe bogie bolsler. While fitting the centre pivot to body bolster, it should beensured that:

.1 The clearance between the centre pivot pin and guide bush in the bodybolster is H7-e8.

.2 ,Centre pivot pin plate has a machined surface so as to bear squarely onthe body bolster.

Maintenance Manual No. CMI-KOOJPage /5 of24

20.2 After fitting the centre pivot pin to the body bolster, there should be no clearancebetween the centre pivot pin plate and body bolster. The bol~s for securing thepivot plate to the body bolste'r do not transmit any tractive or braking forces.These are meant only for securing the centre pivot while the forces from thecentre pivot to the body bolster are transmitted through the mating surfacesbetween the pivot pin and body bolster. It is, therefore, extremely essential toensure that the designed clearances between the pivot pin and body bolsterguide bush are maintained. The lower and upper bushes in Fig.26 should bereplaced when the total diametrical wear exceeds 1mm. Before lowering thecentre pivot the bogie bolster, the pivot bearing of the bolster should be filled with3 Iitres of oil.

r

21. CENTRE PIVOT {Trailer Coachl

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21.1 The centre pivot arrangement is shown in Fig.25. It is not designed to transmitany vertical load but transmits only tractive and braking forces.

21.2 In case" the silent bloc bush requires removal it should be removed carefully bymeans of a tubular dolly registering on the outer ring to avoid damage to therubber bush. Under no circumstances, force should be used either on the rubberor on the inner bush for removing the silent bloc bush. Silent blocs which havebeen tested by ICF and received from them should be used for replacement.Tests for the silent blocs are given in para 23.5.

21.3 Rubber sealing used on centre pivot for trailer coaches should be carefullyexamined to ensure that it is not tor·n or perished to avoid foreign matter comingin contact with the silent bloc bush.

. 21.4 The type of fit between the silent bloc and sleeve is H7-u6 and the tolerance onthe pivot pin is C9. This requirement should be met.

21.5 Centre pivot of the trailer bogie is secured to underfrarne by means of four boltswith nut and spring washers, the nuts being tack-welded to the body bolster. Itshould be ensured that all bolts are correctly tightened with spring washers.

21.6 The silent bloc sleeve is secured to bogies by means of two studs with nuts andspring washers. It should be ensured that these fastenings are correctlyprovided as shown in Fig.25.

22. SIDE BEARERS

22.1 Side bearers consist of a hard wearing ground steel plate immersed in an oil bathwith a .floating bronze wearing piece, which has a self aligning spherical topsurface on Which the body rests and transmits the vertical load as shown in Figs.27 & 28 for MCfHCC and TC bogies respectively. The oil well is provided with acover to prevent ingress of dust.

22.2 The hard ground plate and the spherical bronze wearing piece are likely to wearin service.

Maintenance Manual No. CMI-KOOIPage 160/24

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22.3 The hard ground plate should be renewed when the wear exceeds 1.5mm orridges are observed on the plate. The bronze wearing piece should be renewedwhen the wear on the mating surface reaches 3mm or damages occur to the oilgrooves. Sharp edges which are known to develop at the periphery of thewearing pieces are likely to impair lubrication and should be rounded off beforere-using.

22.4 The oil well wall is welded on to bolster. Spal checks have indicated that oilleaks out of the well due to porous welding and the vehicles continue to be inservice without oiL Absence of oil apart from causing excessive wear, leads toundue constraint for bogie rotation on curves and produces screeching noise. Itis necessary that porous welds are gouged and re-welded, and the oil well isfilled with the requisite quantity of oil.

22.5 For filling up oil in side bearer without lifting the coach, oil filling nipples havebeen provided on the oil well.

22.6 Any of the following oils can be used for the side bearers and the quantityrequired per side bearer is 2.5 litres.

. -'

IOCHPCBPC

Servoline·68Yantrol-68Bharat Univol-68

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22.7 It is important to ensure that dust seal cover on the side bearer sits effectively allover without any gap on the oil well and the sleeve slides freely on the guide toprevent dust and moisture coming in contact with the oil.

22.8 If the side bearers are not properly maintained, grating noise .. is likely to causeinconvenience to passengers. It is, therefore, advised that following precautionsshould be laken during POH in shops:

22.9 The top cover should be properly fitted to the oil container, and the cover sleeveshould be able to slide freely on the guide.

22.10 The oil and the siiding surfaces should be free from dust and othercontamination..

22.11 The mating surface of the convex bronze bearing piece and the concave surfaceof the guide, and the we~ring surface of the plate should be smooth and properlybedded together.

22.12 When the oil is contaminated. it should be removed and the housing thoroughlycleaned and 2.5 litres of fresh approved brand of oil should be filled in.

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22.13 The bronze bearing piece shall be provided with 1mm relief over the peripheryand the sharp edges of the oil grooves shall be rounded off.

Maintenance Manual No. CMI-KOO/Page /70[24

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23. ANCHOR LINKS IIrailer bogies)

23.1 Anchor links should be carefully examined for cracks at the weld. The rubber inthe silent bloc should also be carefully examined for deterioration. Appearance offretting on the edges of the rubber is an indication of deterioration of rubber.Whenever a silent bloc is to be replaced, it must be from those that have beenduly tested. To avoid pre~loading of.-the anchor link while assembling on thebogie, ensure that the assembly can be d0!1€ without forcing the link intoposition. This can be dona conveniently after lowering the body on the bogies.

23.2 It shall be ensured that pins and bushes are as per revised ICF Drawing No.T-O­7-601. No coach should be permitted to run with broken anchor links as this isthe only medium to transfer the draw and braking forces from the body to thebogie and vice versa.

23.3 Care should be taken not to damage silent bloc while removing from the anchorlink.

• •

23.4

24.

Silent Blocks shoutd be procured asRequirements No. C-9406 (Rev. 1)

HANGER AND HANGER BLOCKS

per RDSO Schedule of Technical

24.1 Hanger and hanger blocks shown in Fig. 29 & 30 should be thoroughly cleanedafter dismantling and examined carefully for cracksfwear and other damages.

. The extent of permissible wear on these components is indicated below:

Trailer bogie

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24.2 The wear on the hanger cannot be made 900d by welding as it is made of Class Icase carborised steel. The wear on the hanger block can, however, be built upby welding with matching eleelrodes after preheating to 250 deg. C as it is done

Components

Hanger block

Pin

Hanger

Motor Bogie

Hanger block

Pin

Hanger

SizeNew

8

45

354

9.5

45

246

Condemning

6.5

43.5

357

8

43.5

249

1.5

1.5

3

1.5

1.5

3

ShopIssueSize

7.00

44

355.5

8.5

44

247.5•,

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Page 180[24

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for items made of Class III steel. The hanger block should be normalised andmachined to the dimensions shown on drawings.

25. BOGIE BRAKE GEAR

25.1 ~ Maximum radial clearance of 1mm between the brake gear pins and bushes isper'T'itted. It the clearance is more, the worn out part should be replaced andthe standard clearance maintair'ied.

25.2 Brake block should be replaced when they wear out to thickness 'of 16mm byremoving the looped key from the brake head.

25.3 An adjusting palm pUll rod with holes displaced at regular intervals is provided inthe brake rigging to take up slack in rigging due to tyre wear. Adjuster should bedone by relocating the pin in different holes on this palm pull rod.

26. ACTION TO BE TAKEN BEFORE RE·ASSEMBLING THE BOGIE

26.1 After attending to the various components as detailed in para 8 above, the bogiemay be re-assembled taking into constderation the following aspects:

The two wheel and axle sets selected for the bogie should not havevariation of more than 5mm on tread dia. The difference in tread diabetween two bogies shall not be more than 13mm.

The axle box springs on trailer and motor coaches selected for eachcoach should be of same groups of springs as detailed in C-841 g(Rev. 1).

Top and bottom rubber pads on the axle box spring should not be usedagain if they are not in, good condition.

The bolster springs on trailer and motor coaches selected for each bogieshould be of same group of springs as detailed in C-8419(Rev. 1).

.5 Mating surfaces of the convex wearing piece and the concave surface ofside bearer and the wearing surface of the wearing plate should besmooth and properly bedded.

27. SEQUENCE OF RE-ASSEMBLING THE BOGIES

27.1 Assemble the bogie bolster, spring plank, equalising stays, bolster springs to thebogie frame with the help of a chain and jack as shown in Fig.4 ..

27.2 Assemble rolier bearing and axle boxes as detailed in paras 10.7 to 10.10 andensure that the bearing is effectively secured .

27.3 Place axle box helical spring on the lower spring seats with rubber washers asshown in EMU-O·l-00l and EMU/M-O-1-001 and fili in the dashpot with any ofthe approved brand of oils as indicated in para 14.7.

Maintenance Manual No. CMI-KOOIPage 19 0/24

27.4

27.5

Inse~ rUb.ber washer, upper spring seat, dust shield spring,;dpsl shield, rubberpacking ring and the gUide bush on the axle box guide and lock the bush inposition as shown in Drawing Nos. EMU-O-1-001 and EMLIIM-O-1-001 andensure that the bush sits tight against the rubber packing ring and the 2 mm holein the guide is in alignment with that on the bush via the groove in the guidebush. Before lowering the bogie, the vent screw in case of trailer bqgies andfilling cap in case of motor bogies, ml)st be removed.

lower bogie frame with the bolster assembly on the wheel and axle set takingcare to ensure that all the 8 guide bushes engage the lower spring seat and thebogie frame is set ev.enly on the 4 axle boxes.

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27.6 In trailer coach bogies, connect the anchor links with pins between the bolsterand bogie frame after lowering the body on the bogies.

27.7 Touch up the paint on the bogie again with one coat of anti-corrosive black paint.

27.8 Ensure that the side bearers are resting properly.

27.9 Fill in requisite quantity of oil in dashpots and screw home the air vent screw withthe leather washers in trailer bogies and filling cap in motor bogies after thecoach is lowered on to the bogies.

27.10 In the trailer coach bogie, after inserting the cotter in the centre pivot, fit thebottom centre pivot cover housing as shown in Fig.25.

27.11 In the motor coach bogie. fit the safety collar as shown in Fig.26.

27.12 Engage the bolster strap.

27.13 Engage the axle box strap.

28. RUNNING CLEARANCES.

28.1 After assembling bogie and lowering coach body the various bogies clearancesshould be checked with the dimensions shown in Fig.31 and 32. The clearancesbetween axle box and bogie frame and between bogie and body bolster are veryimportant and these should be within the tolerance shown in Fig.31 & 32.Normally these clearance will not be less than the specified values if the springsand rubber washers are as per drawings and specification and there is no unduewear in the hanger, hanger block and hanger pins. Therefore, in case afterassembly the clearances are found to be less, the reason for the same shouldbe investigated and necessary rectification done by renewing the requiredcomponents. However, adjustment upto 6mm may be done by providingpacking below the springs. For this purpose, steel split packings shown in Fig.33may be used.

28.2 The deflection of the bolster spring of motor bogie is limited by the stops providedinside each bolster spring, It should be ensured that the requisite distancebetween the stops is maintained so as to prevent undue stressing of the springsand also to avoid body bolster striking against any of the bogie members.

Maintenance Manual No. CMI-KOOIPage 200/24

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BUFFER HEIGHT ADJUSTMENT

. The maximum centre buffer coupler height from rail level is as follows (mm):

It should be ensured that rubber snubbers on the axle boxes are properlysecured and protrude by 2mm above the axle box crown.

.,

28.3

· 29.·c ,

".~, 29.1

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,29.2

ICFJessopBEML

Motor

103510351035

HCC

106410641064

Trailer

103510411035

.1 Wear of wheel tyres.

.2

.3

.4

Wear on wearing piece and wearing plate of the side bearers.

Wear on hanger, hanger block and pins of the secondary suspension.

Loss in free heights of primary and secondary coil springs.'r .,, .5 . Load deflection characteristics of the primary and secondary springs not

being within the prescribed -limits.

Procedure for centre buffer coupter height adjustment in workshop:

.1 After POH and before assembling the b09ie; measure the wheeldiameter.

,

.2 Depending upon the wheel diameter, place wooden packing of required. thickness under the flange of lower spring sheet as indicated in table and

shown in Fi9S No. 34. 35 & 36.

-Maintenance Manual No. CMJ·KOOJPage2Jof24

Thickness of wooden packing ring (mm)

:Above 873 mm upto 885 mm(HCC)

• Based on last shop issue size (see para 9.3)

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Average wheel dia between thetwo wheels on the same bogie ...

. Above 885 mm upta 912 mm

Above 865 mm upta 885 mm(TC),

MC

20

HCC

20

28

TC

20

32

30. BRAKE

30.1 All coaches. are equipped with self lapping electro-pneumatic brakes. Thebrake system consists of electrically controlled air brakes for normal service useand ~utomatic brakes (provided as 'stand by') to be used if required. Theautomatic brake system also provides for emergency application of the brakesinitiated either by the driver or the gua~p or by a break away.

30.2 The air brake equipment is to be maintained as per the instructions given in theMaintenance Manuals supplied by the makers of the equipment

30.3 The brake rigging diagrams are shown in Figs. 37 to 41.

31. BUFFtNG & DRAW.GEAR

31.1 The EMUlMEMU coaches are provided with semi permanent/semi automaticschaku couplers. These are to be maintained as per the instructions contained inthe Maintenance Manual supplied by the manufacturers.

32. ATTENTION REQUIRED FOR BOGIES IN CAR SHEDS

32.1 Lifting the body off the bogies: Instructions contained in para 4 above should bestrictly adhered to while lilting the body off the bogies.

32.2 Dismantling of the bogies: Instructions contained in para 5 & 6 above shouldbe strictly adhered to while dismantling the bogies.

32.3 Car depots should not try to weld a damaged axle box guide or replace thesame. The bogie should be sent to workshops for welding the guide andchecking the alignment. The bogie frame should however, be checked forcracks, particularly at the bolster suspension brackets.

32.4 The wheel sets are to be machined as expla'lned in para 9.

32.5 Roller bearing should not normally be attended in car sheds. All that would benecessary in service is to feel the axle boxes for any tendency on their part togo overheated. If any axle box shows tendency to run hot, the vehicle should bedisconnected. The wheel sets which have run hot should be replaced in the CarDepot and the damaged wheel sets sent to shops for attention.

32.6 Four bolts securing 'the rear and front cover of the axle box shaH be examined toensure correct assembly with spring washer and split pins.

32.7 . Whenever a spring is to be replaced, it should be done in accordance with ROSaSpring Maintenance Manual No. C-8419 (Rev. 1).

. 32.8 For this purpose, it is necessary that Car Depots should have an imprest of axlebox and bolster springs duly tested and certified to conform to the instructionscontained in para 12 & 15.

Maintellallce Ma(lual No. CMI-KOOIPage 22 of24

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32.9 Free height of axle box and bolster springs should be within the tolerance asshown in C-8419 (Rev. 1) for used springs and as per RDSO SpecificationNo.WD-01-HLS-94 for new springs.

32.10 Whenever dashpot in the primary suspension shows signs of oil leakage throughthe sealing rings, the bogie should be lifted and the rubber sealing ring checkedand replaced if needed. In thpt event: the diametrical clearance between theguide bush and the lower spring seat should also be checked and jf more than1.6mm. the components worn out should be replaced.

32.11 Level of the oii in the dash-pot should be checked at intervals of one month withthe help of a dip stick. It is important that the oil level is checked after thevehicle has been standing for at leas"t 30 minutes as otherwise the froth in thedash-pot formed when the vehicle is running may give wrong indication. The oillevel from top surface of guide cab should not be less than 77mm for TC bogieand 97mm for MC & HCC bogie.

32.12 If hydraulic shock absorbers used on secondary suspension show any signs ofoil leakage or other damage, the same should be replace,d with a shockabsorber completely overhauled. For this purpose, the Car depots shouldmaintain an imprest for use as unit change assemblies. The leaking shockabsorbers should be sent to the workshops for overhauling. .The shockabsorbers should be checked to'ensure proper tightening of the (our securingstuds. The nylon rubbing plate in the motor coach bogies should be properlymaintained as explained in para 18.

32.13 The maximum diametrical clearance between the brake pins and bushes shouldbe limited to 2mm and the brake block should be replaced when worn out to athickness of 16mm.

32.14 Oil in the side bearer should be checked at an interval of'one month and oilreplenished through the side bearer oil filling arrangement. If it is found that theoii leaks through the weld. the weld should be gouged and re-welded properly.The bronze wearing piece and the hard-ground steel plate should be replaced,as required, i.e., when the bronze piece' has been worn out by 3mm or hasdeveloped sharp edges. The permissible wear on the steel plate is 1.5mm.

3i 15 The safety straps for the brake beams and equalising stays should be checkedfor proper securing arrangement.

32.17 Straps for the bolster and axle boxes should be checked for adequate runningclearances.

32.16 Straps for the bolster and axle boxes should be checked for proper securingarrangement.

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32.18

32.19,

Drop in buffer height due to lyre wear must be reset by prOViding packingsexplained in para 29.

It should be ensured that the screws for the vent holes are properly tightenedwith leather washers.

Maintenance Manual No. CMI-KOO/Page 23 0/24

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32.20 If a silent bloc is observed to have fretting on edges, whether on anchor link oron centre pivot, it should be removed and replaced with a new one. Thesecuring studs for the anchor link should be e)(amined for proper fastening.The four bolts securing the centre pivot to the underframe should also beexamined for proper assembly with spring washer and tack-welding of nuts.

32.21 Under no circumstances wheels wtych have reached condemning limit on thewheel rim tyres should be used. .

32.22 No coach with a broken dashpot or a broken spring should be allowed to run inservice. These coaches should be withdrawn immediately for replacement of thebroken spring and sent fOf replacing the broken dash-pot guides.

32.23 Equalising stays should be carefully examined to ensure the correct assemblywith washers and split pins. All welds and the body of the equalising staysshould also be examined for cracks. Bogies with bent, cracked or broken staysshould not be allowed in service.

32.24 The bolster assembly should be examined in position to ensure that the hangerblocks, and pins and shackles are in good condition.

32.25 Dashpots and side bearers of these bogies should be checked for a possible oilleak and in the event of signs of leakage, the oil should be replenished.

32.26 If considered necessary and provided that requisite facilities are available, any ofthe items which shouid normaliy be attended during POH may be tackled in the

o

Car Depots.

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Maintenance Manual No. CMI·KOOIPage 24 of24

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" FIG. 1

BOGIE GENERAL ARRANGEMENT. (MOTOR BOGIE) '., '-

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.; ..- ••,....-~'-- ._--- -------'----_._----.. ;,r--~-----------------;

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2696 WHEEL CENTRE

!...... ISlOE BEARER\~, ..

, SlOE IlfARER

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FIG.2

BOGIE-GENERAL ARRANGEMENT. (HCC BOGIE)

"r------------~-----'---'---,-'----'-'-'----------'--------------;

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SIDE BEARER~ ~ ,~

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BOGIE GENERAL ARRANGEME.NTTRAILER COACH. ,:'

2.886 WHEE.L e:.1'o.5E.

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I ASSEMBLING &'OISMANTLING OF BOGIE .BOLSTER

I_WOOOE NPAC.KING WOODEN PAC-KING __ .

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HAIN OR WIRE ROPE. CAPABL" OF WITHSTANDII'lG A"LOAD 'OF "3IONNES

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BOGIE FRAME ARRANGEMENTMOTOR' BOGlE

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FIG.S

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BOGIE FRAME ARRANGEMENTI

HCC',&.O~

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FIG.7

BOGIE FRAMe.(TRAILER BOGIE)

,, ­,

i,,

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DASH POT GUIDE. FL~/...--

bOLSTER SUSPE.NSION BRACKE.TS

THREADS ON DASH POT GUIDE

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FIG.8

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I 2.e9G~1

I

'lMPORTANT DIMENSIONS IN BOGIE FRAME(MOTOR-&:H'C;~enG IE-)

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NOTE.5:-I,(!"!REPRlSENTS LOCATION OF AXLE. BOX ,GUIDES.

2,0 REPRESENTS LOCATION OF BOLSTER SPRING SUSPE.N510NBRACKET.

3, TRA\'ISVER5E BOGIE 'F'RAME. CENTRE. LINE. 'zz' IS OBTAINEDBY DIVIDING TKE. DISTANCE. E!>ETWEE.N BOLSTE.R SPRINGSU9PE.W910N eRACKE:rS E.,F,G,H.

4. DIMENSION5o..b,c,d SHOULD ALL BE. EQUAL 8< 733' I,

5. WHEEL E!>ASE. AB 8< CO SHOULD BE. 2896 ~I .

6. MARK THE CENTRE LINE OF THE PIN HOLE OF THEBOLSTER SPRI"lG 'SUSPENSION' BRACKET E.,F.G 8< H ,

MARK THEIR CENTRE.S WITH A CENTRE PUNCH & CHE.CK,Ir.,;'

EF = 800:1:2 = GH

E.G ; 2140~2 = FH

F G ; 22. 8 5 t;; ; E H

-_ ..~-,, "

FIe;.9

IMPORTANT DIMENSIONS IN; BOGIE FRAME(TRAILER BOGIE)'

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'011 '/B i",\

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2.896"'1.. f-------""'-"-"-'''-'---------1

NOTES:·l.(DREPRESENTS LOCATION OF AllLE 'BOX "umFS,

2.0 REPRESENTS LOCATION OF BOLSTER SPRINGSUSPENSION BRACKET

-3. TRANSVERSE BOGIE FRAME. CENTRE LINE 27. 15OBTAINE.D B'( DIYIO'NG ,HE DISTANCE aE.TWEEN

BOLSTER SPRING SUSPENSION BRACKETS'E,F,G&H', '

•

'.

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, I

4. DIMENSiONS a, &.:c.& d SHOULD ALL BE EQUAL io493ti

5. WHEEL BASE AB ill CD SHOULD BE 2896 tl. MAR«THE CENTRE LI,NE OF THE PIN HOLE OF THE BOLSTERSPRING SUSPENSION BRACKETS E, F, Gill H.MARK THEIR CENTRES, WITH A CENTRE PUNCH &'

CHE.CK ":'.1J' ~

EF • 1340 '" 2 • GHE.G· 2159 '2 • FHEH ·2541 i?> • FG

,\,, ROLLER BEARING ARRANGEMENT

(MOTOR &Hec BOGIE-DIRECT MOUNTED),"

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7,10 •a,', '

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/""""_ .... ,

9 --"

6.~;.- ~.'.-.-- -

4

:3

ICRi>.CKS NEAR HOLE~ ON THE.COVER TO BE. CHE.CKED.

'--- BOL, THRE.ADS TO Bi;. CHECKED,

ITE.M DESCRIPTION1 AXLE BO)( HOU51NG

"- FRONT COVER

3 RE.AR COVER

4- COLLAR

5 RING

6 FE.LT RING

7 ROLLER BEARING \---

S SE,CURING CUP

9 HEX. HO' BOI-T

10 HEX. HD SCREW

\ \ 5PRINQ WASHER

12. SPRING WASHER-~- -

II,

, ,

, I

F/G.12

DESCRIPTION'

I AXLE BOX HOUSING

~ REAR COVER

,:-::

,.,;''0-- :.- ,. .~ ,

3 ,COLLAR

5 RING

S ROLLER BEARlflG

7 SLEEVE

4 FELT RING

8 JROflT COVER

9 ,BOLL

5 ' RING

6 ROUER BEARING

4 FELT RING

10 ,SPRING WASHER "11 ANNULAR NUT'

12. .LO~KING PLATE."13 HEX, HO, BOP ,..

ITEM

'.8 FRONT COVER ,,7 SLEEVE,

, , .. 9 'BOLT

10 SPRING WASHER

4ITEM DESCRIPTlOt-J

, ".lL RETNNING RING

",' 12 LOCKING PLATE,

\", '1.3 'HEX. HEAD, BOLT

"

5

2 1-'714-:Ac:-XL~E...:B.:..O<.,.:.H::..:OU:..::.Sl..:.NG=-!'--'1----- 2 REAR COVER~ f--;-+-,..,....,..,..,----l

3 COLLAR

'WJTH ANNULAR HUT \, .

6

: :WITH RETAIN\NGRING

'CRACKS NEAR HOLES ON THECOVER TO BE CHECKE.D" '

'---BOLTS THREADS TO BE CHECKED,

/

8

13

127

/II

..9,10 _,

13

10,9"

8II

ROLLER BEARING ARRANGEMENT(TRAILER BOGIE, SLEEVE MOUNTED)

BOLT THREA.])S TO BE (He-CKED

CRACKS "'EAR HOLES ON THE. 6COVER TO BE CHECKED,

3

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./27

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3

9

14

ROLLER BEARING ARRANGEMENT(TRAILER BOGlE,DIRECT MOUNTED)

FIGURE-13

12

16. "'. 17

----.

12 Ij

¢. OF AXLE,

. 10 . I I..,.. I

11,

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7,

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/TACHO GENERATOR~'

FRO\t~ COVERHiRTACHO\GE.NERATOR.--'----

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\\'",,

17 SPUT COTTER PIN15 NE.X. HD. ~1JT

15 BEARING OUTER RACE14 BEARIIlG.INHER RACE13 DISTANCE RIt\G HALF/2 SPRIHG WASHER

. II lOCKING WASHER10 B.S.w. HEX. SCREW9 HEX. HD. BOLTe AXLE CAP7 ROLLER 1lEAR\NGl5 FE.lT SEAL5 DISTAN-C-c'-RIN-G~--1

- .__....:.. .•.. -...._._---_.~.5... LA IlY__RII.ITH.It~_G._,.3 REAR COVER

~_f ,~R~N!@ER--._'::::::__1_ Al<lj:, ~r. .!:'-"..\l~'!:'.G_.

ITEI-! OE.SCRIPTION

FIG.14

CONNECTIOIl TO OIL INJECTION PUMP

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, ADOPTOR RINGEND WASHER

AXLE

..•

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CLA~S OF SLEEVE

i

\ WITHDRAWL' SCREW\\ ,

WITHDRAWAL TOOL IN POSITION

------\------"--'--

FlG.1S

MOUNTING SLEEVES FOR ROLLERI

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, 111

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----- ------- .....'------------ ....~, ,

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BEARING.

HI\NOLE.

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III,\

GUIDE PIN CARRYING SLEEVE.

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•AXLE. MOUNTING SLE.E.VE

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-~I(MOTOR Alo Hec BOGIE)

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,AX LE B0)(GUIIOE-AR-RANGE-MENT---_.-. ..

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----.--- -------------------.----- ----..---'.------- FIG.;~

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2.UPPE.R 5PRING,:SEATOR .

/1 TI~ I ~~.!s ~W r

Pf<OTECTIVE TUBE,3. DUST ~HEILD ~PRII'"

4. DUST SHE.ltD

5.GUIDE RING: 6_RU&D~R PAC.KINGIUllG

,I L!'

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f

'- 1. GUIDE BUSH- 7 :--: a.sPRING CLIP, I I 9.GUIDE. CAP

~ Oil. l VEL (Q.AXLE. SOX.14 ' .. , .. . .,.

8 . ,i U:HELlC"Al.:< SP'RINcr;'.. , , <> .... 0

l-IZ: LO,WEB.RUe.e.Ef\t= '" = .. WASHER:- , , 13 i, .'// 13 .LUWER .5PRI/'I(; SEAT

12 ---I-1---':I~1l.~tLI

.Jm§<~"-~~14COMPEN5ATlNf; i?lN~

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AX LE BOX C:;UIDEARRANGEMENT, , '(TRAILER BOGI'E)

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"DIP'STICKt,'"', '

(TRAILER BOGIE)

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. " ....l!I1.5 RIVETS-2 No.

3

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"

,',15:2062MATERIAL

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5PRING:5TEEL ,'/"

OIL lEVELRED UNE

SUITABLE MARK TOBE MADE ON THE

DIP snCKFOR PERMANENT CHECK,

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GUIDE eN' TOP UNE

"I,,

NOTE:- TO CHECK OIL L£VEJ.. THE VQIT SCRtw SHOULD BE REMOVED

J

& DIP snCK INSERTED THROUGH THE VENT HOLE TILL IT

TOUCHES THE GUIDE eft?,

.' ." .. '. . " . , . "

DIP STICK(MOTOR & HCCBOGIE)

." ". • '. ,:.• t •• _:

IFJG.-19

25

"­m

......QJ

. . ~."

SUITABLE HARKTO BE HADE ONTHE D1P STI CKFOR PERMANENTCHECK.

L

.. ".... lkTERIAL~1~5 RIVETS I512~62

I . ':3 No's:-::::::~ll-.------'l~--r~

II t~1 - ...... SPRI~GSTEEL:~ ," r- .

22 .S W G' . I='" '., ' , ; (I " .'. l ",' .. .';, I~

OIL LEVEL I~III-'--r~ . II! 1\ I'RED LINE .,@

I~I@~

~j I I 1~1~ I I II I I DIP STICK

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TOP ~INE

GO lb tA':l k- U~

NOTEI- TO CHECK OIL LEVEL. THE VENT SCREW·SHOULO. BE REMOVED

~ 0IP STI CK INSERTEO THROUG,I THE VE,iT HOLE TI LL IT

TOUCHES THE GU IDE CAP.,,,,,II

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LOWER SPRING BEAMMOTOR& HCC BOGIE

, .,.

FIG.20

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,, LOWER SPRING BEAM.., .

T~R..:..;.A..".:,;IL::.:E::,;.R..B;.O;:;.;:G::.:,IE=.: ,

FIG.21

,::.

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J

I,~e..-_'--_~__•. -'- .->._•.•.

-------'

FIG. 2.2,

I

I.-

I'" •, RUBBING PLA1'E. IN Me & HCC BOG IE."1'"\. -

,

•

L~I1I 'L.,b. _

=--2::.'"====--:. :-::=+=~:-===-=n:~::::=::-==-=;r::;;=,..II..

TRANSOMTRANSOM

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If)'III! J

~ !

.1.

I, .

'.--.-.

--'

I,

4 '14" ssw CHEESE HO: SCREW3 RUBBING PLATE.

2 RUBBiNG PLATE1 WEB BOGIE: BOLSTER

I1EM DESC.RIP'-'ON

"

o

F\G.23

. "

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..:_=-=-__._ '<:::1/f-., ---- --- --l:-- -_ - -- --=-~-=

I ----::-Jc·==-4====:::;:;:::;::;:1~ - - ~---

,'0

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0'

J

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,II

II

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ococcW-J-<ta:I--~I- '.(/)

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=-=>- - - -c.::

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o

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I,I II II II II II I

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FIG.25

CENTRE PIVOT -ARRANGEMENT­(TRAILER BOGIE)

, -

..-:-=OGIE.- BOL5TER

___-CENTRE PIVOT PIN

..__-SEALING CAP

" ·'/N' /.' .

~~;:=t:?'"-TO BE. TACK WE.LDEDAFTER ASSEMBLY

r~b::::;;:;;:;;~is'LENrBLOCK WITHf SLEEVE.

--.,....

~ ":~:"-__-BOTTPM COVER-

\'~~:ja.F=--..:. __~COMPLE.iE.SPLIi PIN

---

-.

-

I-

"!,.,I~

•

I

-.- - SL"_EVE ASSEMBLY_FLANGE -

BOTTOM COVER

-----COTTE.R

FIXING OF BOTTOM COVER

_____• .J

;.. , ,

"siDE' BEARER ARRANGEMENT'(MOTOR & HCCCOACH)

. ',

I

. '".-

, II

.. ' .

: .. ; ..

"

,.;.

0150

'",.", ,"."

"....; .>::", :', .. .;,';

": ,.'. :;.

'WEARING ,PIECE FOR' SID.. ;;t.ARtR 'p:zZm~Z21~i:22''Zt2'Z'1z,'z1--'' R t.F: DR G: N. E. M U1M- 0"5" 0 10 '"(Ie F) ,

,,' "_"'''''::::''~::::::: "c778/8 /978"C' (JESSO,o~),

o,

. -.: «)

I " '"0'I'~"'0•a. ',.' ':.

, '

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.,

,"

,"

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I,, ',

I I,

I, ,

I

"WEARING PIF.CE.

• NOT[,·

I" BRONZE WEARING PIECE. SHOULD BE R.HIE.WE.D WilEN:rHt WEAR ON 1'HF., MATI\.lG S'URFACE. RE.ACHE!'> 3"J1f17l"~"e"H!OIGfIT IS LeSS THnl 31?>1."... DR DAMAGE.SOCCURETO THE. OIL GROOVES.

2. THE. Hil.RO GRo'U"lO PLATE. !'>HOULO e,E. RE.NE.WE.O WHt.NTHE. weAR E.XCEE.OS 1'5 mm. Ce. THiCKNE.SS IS LtsSif1PoN 8'5 .".,,,,,. OR RIDGES ARE. Oe-SE.RVED ON TH"­PLA1't'...

I.I FIG.28 1

'SIDE BEARER ARRANGEMENT(TRAILER COACH)

, .

SURFACE 5HOULD&E.' SMOOTH

WEAIlING PIE.CE.

\I

,

WEARING PIECE FOR SIDE BlARlRU.t>RG.."~ ,-0-S-649'

·I .I • ,.

.. .,.

I. BRONZE. WEARING PIECe SHOULD 5E. RENEWE.D WHEN THEWE.AR ON THE MATING SURFACE REACHES 31'4111 .. i.E. HE.IGHTIS LE.5S 'THAN 42mm. OR DAMAGE.S OCCURJ;TO THE.OIL GROOVE. S.

2. 'THE. HARD <:;ROUND PLAiE. SHOULD BE. RENEWED WHENTHE. WEAR EXCE.EDS 1'5 -mm. -i..e. THICKNr:.SS IS LESS,HEN 8'5 m-m· OR RIDGES ARE OBSERVED ON ,HE PLAl'E.

'---~~-~-------. " -'-

I,i

·~I, •

\. ,FIG.26

- CENTRE PIVOT ARRANGEMENT-(M010R& HCC BOGIE)

"

BOGIE BOLSiER

LOWE.R BUSH

IUPPER E>USH

II____ BOOY BOL5iER

If Jl,l~--i-+I~__ ,

~

.-+./T'~

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\, I ' '

'$)

------==-----=-='='='"===========.--.--

"

r~"____'___ - I ! I

J

. 1

FIG.29

!I

IIi,

>,

COMPONENTS SIZE-NEW CONDEMNING Yl,EAR IN mm SHOP ISSUE SIZE~--c..=.-===--=--=--=----=.-=--=- -=::::":""-==.3---~--lW---------~----.- . -,

II:=R!'ii '. ii '/ .~~

I!

,I. II I I j' ,9,5 8 I 1.5 8.5

I!!! !! / [.--f-- HANGER BLOCK , ,

--:E1,ll-------Jj~ TOP & BOTTOM· .. "- .ibC ------- , ·

. tff\\ PIN'" ·45 43:5 " 1.5 " 441\ -'

~kJ1\ ,1/ ,- -. \

r---.~ _......·l ,HANGER -

~ 2'46 249 3 247.5. I

/ I I .~.

~~~ I-- .

--:c--: ;---- - ,---- ~,

,,

I,~-­t--,1--o

I,c--

1"------

,"

:==:~:==:==:==:==-,,'

I -

25150.:5 !

.. (..,

.;

,HANGf;R AND HANGER BLOCKS

(MOTORA-ND- HCC BOGIE) .. J

II .

..~ " I

~'.

-.

"

I " ' I,

,I.'-----_.----- --------- -----------

--_._- -- -----_._---- ---- ._-------,

FIG.30 v

,i

~.

-'~ ~-----~ COMPONENTS SIZE~NEW CONDEMNING ytEAR IN mm SHOP ISSUE SIZE. - ,I I r\i I,

I

I,

.

---r 8 6.5 1.5 7,-i '\

HANGER BLOCK ,TOP & BOn-OM

-

r K r?F\\ PIN'I/'

43.5 1.5 44• 45I --- f--[ZJ~

,

"DIp- --- c- -

, HANGER .,I

354 357 3 355.5, .I - / i,I (;~ -,I '-.:: IV,! ,-;~

I

~~al-

I IV ·I~,•I

V~ -:r •,1'/ ~

,~G7

~!I 40-.5 c

r Ii

-

..

,

"

~

:.. ",

. -

.',

..Ln

HANGER it\ND HANGER BLOCKS

___ _ --------l

f (TRAILER BOGIE)I

·_---~---------~I---------·_----·

I ... I J-~---_.--_._-_..- ----!- ----_._----------_.__.~- ---...._-- ---'

.. .RUNN'NG CLE~R~HCES(MOTOR 8, HCC BOGIE)

.'"

lr«'"3:o.Jlr>-

~'.<:~l ~ II I ,~

!I- .Jt-*.-i ,,.. 1cr0~

t'JzAI5

«CL

<!lZ0 I~

"

i . ¥-......-'4'

>0a:CL

a:'"....~

""

~1 )~I~-M\p.i."Y

·· .-; l! '" ~l-. ~.J

,-.-.-f\ f'\~'.•.....Ji,"<t. OF COUPLER

~~------- \ ~~R~L.7

, -. '-

- i

;. . /:; ~ Lr /// __ ,."" // "'" ::I . // « ',\ 1:-,. / .. \. ......~ -t, ( /,( ;=3~ I /~\: i 1\

-t .. L. ~..J ~ I .J

::='" . ~ - r$1-.. f. v../· I ' J.,

~ ..J '. '14)/ I 0 1R"f .J Y .. ~~ I /'~ I /F

. . ~,~ I~ llJb!b==ld~=~,=.J . I - / /

'i.

..

-.:.::. J _ ........- ,-ALL PIMF.NSIONS U>lD'E.R ,ARE CONDITIONS

.. MOTOR BOGIE.~

'.••

••

A B C I>S1'OCl( CROWN eL,EARANCE BOLSTER TO BOGIE! FRAME BOGIE. FRAfrtla TO BOOY BOLSTER /?L. TO <t; 010 COUPLER

C\e/ EMU/Ie", & 1!.1!1>'I'- 38"6 241:S" 95 M''''· 1035 T~!O.-- 10 ::$s "t~'

d e / EMU/ICF ~ BEMLDE. 361:' 351:5' es /11,.,NDE 45±6 Z. 91:5" 94 I\1'N. 10 55 '!.~c

MEMU/DMC 381:{; 241:5' 143 M'N. 10 3S !fs

JESSOP!> ac./EMUDE 36tb 361:':; 91 WI '~. 10:3S1~s.

NDE '3{;±b 4°1;· 91 i'1,I>/. 10 3S '!;sJESSOP!> de. EMU 291:' ~+:t5 76 ""'N. 10 '35 :!:?sHCC/IC.F &, BEMI. 62.1:' 14 ts \O~ ,..." iN. 10 b4 :icS-

I-<CC JESSOPS 48"· 25 :1:5 10 !l' MIN. 1064 !~5.

, .

~

~ ="';'--- -="=---- - - ------

I j.

I 1f"1] , 'IT""' It-" , ',I .=jj !J==',. . fij ". I.

~. I, =-"iTlT---=:'" . ,',.'r .~-~ "II. -=-- I"

I .' .. ',',,I I I'"~...l!:....~"-

'";;g:;:'-'a:~~

:lr----,~ OF COUPLER

-,

,•

RUNNI NG CLEARANCES (TRAILER BOGIE)

I----- -- ', . // ~ '--~ 'f!fltFi

. . . " ~~ . i ~"'b

j

=='iiI I IT.. ' /; 1/ / ,A '. \\ LJ[.~, , h r,;;;-, I (7 :~~<lE1~~~~i':;:iiI: "" '/ ~~ ~ . . 11\\! ,;,I;;t\.< .' • ,. . /' 7' " ",~: '~ [I ...-' ~-~[@.2 0 '\ ,. ! .

r~=!=~~. uR,L,"'7 l§--------~ ~

._"'_ e;-- -" ..-;:

I,\!;

"

"

>

,.

ALL DIMENSIONS UNDER TARE CONDITIONS

.

.' TRAILER BOGIE

t

~

,

STOCK A B C D ECROWN CLEARANCE BOLSTER, TO BOGIE FfitAME BOGIE FRAME'" TO BODY SDL.S1E~ aOL5TE~ STOP R.~.'O <t OF COUPLER

42 ct6 401'5 70 MIN. 49 MIN, I +0ICF& 8EML , 1035 -,.-

JE6S0PS 431'6 5.51'5 ~o MIN, 61 MIN. 1041 !.~

MEMU - 33 106 "Kl"'5' 151 MIN. 55' MIN.I

103S!..~..

-.

•

..,.FIG.33

SPLIT PACKING.

FOR BUHE.R HEIGHT ADJUSTMENT &. BOGlE. CLEARANCE.S.o.

I • 0

'I.1,.'"

.Io,0,I •,

o

r

,'0

, 0, ,

~.,

'"" "'[

,

0 ,

~,•

DIMENSION MOTOR TRAILERe,OGI£ e.OGIE.

.A 220 220

B0

140 140.

'0 I

, I

1

I,,\v 1.-__'------ --'- -'---'-__--'.-' .

1

,I-,

ARRANGEMENT- UNDER TARE CONDITION WITH NEW lYRE.S

•~I ,>.•~

" '""~~~~'0,",~,;;;:",,,,","""-":a..1 I'/J':./>'" I ~I :l ~H"",,"''''''WI ..

~I '""'~ \ I 1-"

.•I -

1."".II J. --f f1 ""I

- .-. r "I .-.I I

~1! I . !

~I 7 I "f ' ,;'JI • .. '\ I

~l~

II

fflf I - , "/

., .I .. •-----;--: '.I~ 0" ,,I .' ,~ . "W I

h~

I~ ""I :i :r,

J7 r;r I IIYI ( 1I

I

""'"'"8.

•ME-THaD OF PACKING FOR TYRE WEAR'TO MAINTAIN BUFFER'HEIGHT

---.,

--------'--'-------- -- - - /

FIG.34

-1 0.. ..

T(MBER PACKI ....GTo 8t:PUT $HOWN AFTER201l'lREDUCTION IN lYRETHICKNESS.

~O~ HCC. BOGIE SEC.O"'tl';~PACKIN {; OF BmMiH'CI<-roBE ADl>ED AFTER4£1,.,'" REPUCi'ON IN"lYRE l"HICKNESS

.ARRANGEMENT SHOWING PACKING WITH 20 171m. WE.AR ON TIRES

I,.I

IIi,

• I

- I.. .)

"

JII ,1

'" I,. - I,

,

" .. I• - i

, ,II

,I

I!

II,I

•

-t" ...- .1,

I,

-,. BUFFER HEIGHT ADJUSTMENT (MOTOR & HCC COACH)

(EMU/MEMU STOCK OF ICF, JESSOP, BEML)l

1\

I,,-I --_.._----'-='--='=~ ...---

, I.r-------------------------)

METHOO OF PACKING FOR iYRE WEAR TO MAINTAIN BUFFER HEIGHT, -

.-/

FIG,35

:',

I,

-_.-.J l J..,----',,-,~..-..,-- , --i ,-- '-'_.. -,. ,- --

'~

+, T! 'I~I'II ' !1 ' " , ,

, I I 11'=';:";:;;;~;;=== .' ! 79 I- I ;' "-' ',. l,Di

+1

'""'"

~'l"2! '~I I 1\113'. J, '14N~

,40-..

BUFFER HEIGHT ADJUSTMENI (1-RA\ILERCOACH)(EMUj MEMU STOCK OF ICF)~EML)

"'W.l!aER PACKlfIG' TO .-f" I .

etE., PUT. AS ~IlWtJ (...AF-TE.R 2.0=7><. ~F<UOUCl'lON IN ~

~ lY..QE T"\OHI(~ ~

~I -

. --c--_·_· .---- .._ _."_. __

o

"

o

"

lIE"",...M

I _ ,mri ;' ~ !\ niT1: .\'1\' " . . (dlri " ' ,t II 1

1,. " "

..... I: Ii I

CC;' ::::::::::: ' ~,;" R", 7·"r---- ~-

ARRANGEMENT UNDER TARE CONDITION WITH NEW TYRES ARRANGEMENT SHOWING PACKING WITH 201l1m;WEAR ON TYRfS

NOTE.:-1, FIRST PACKIl'lG OF 20mm THICK TO

BE PUT AS SHOWN AFTER '20 mmREDUCTION IN TYRETH ICKHES5.

2. SECOND PACKING OF 12·mm 10 BEADDED,AFTER 40mlYl REDUCTIONIN TYRE THICKNESS.

* 15' Mill COM PEN SATING RING FORMEMU,

;

i,II,,I

"

j..'-

,!

!,

\

,1

-l'

" i

" ,I. I

I!,I

" ,I,

-

- ..------ --'I' -- -----

METHOD OF PACKING FOR lYRE WEAR TO MAINTAIN BUFFER HEIGHT-~

FIG. 36

.•• --,

.-. -- "o

~J

",

"

I ­,,," !I; rn! ij

'- ."'"~, '

1

o 0

o "'" ..o 0~ ~

"'~.' ..'" ~.,. '"

TI..1/

m: "

u "o ...~ '"o 0-,u. u.

,

,I.

A~~~I

rARRANGEMEN.T SHOWING PACKING WITH 20''l17>l.WEAR ON TYREs- .

'""'-1.--j,,d

4r'fW,lHJt p~CKr~IGTO~'B-=.., Ii'Vl.AS SHCWl-I 1-1AFTE.R 20,..,,,., -'T\,.f<,UOUCne!'l IN~p

~ "lY.RE T\llCXII£s...#

~I

,

e

NM,

o

";l;

---lARRANGEMENT UNDER TARE CONDITION WITH NEW TYRES

..,-

. ~

• • -4

..

NOTE:-1. FIRST PACKING OF 20mm THICK TO

'. BE PUT AS SHOWN AFTER20mmREDUCTION IN ,YRE -iH ICKNESS.

2. SECOND PACKING OF 12 mm 10 BE.ADDED,AFTER 40mrn REDUC,IONIN TYRE 'THICKNESS,

BUFFER HEIGHT ADJUSTME-N'"f{TR~~ltER COACH)(EMU STOCK OF JESSOP} ,

I

,~

I,I

II, .

. ,

I ,- C ---i

•

'\.-._.__.... ---------1

CALCULATION OF PARKI~

HOLDING FORCE OF PARKING BRAkCYLlNDE.R AT 67mm STROKENO. OF PARKING BRAKE CYLINDERRIGGING RATIO

RIGGING EFFICIENCYCOEFFICIENT OF FRICTIONTOTAL PARKING BRAKE FORCE AVAil

f\10TOR COACH

om~

TRAILER COACH

Tco,'

"'-•

•

?"" A.,J.

•

"...

~ AIR BRAKEzC'~ mm 203 JrIm BRAKE CYLINDER DIAMETER

, .~ A.~ P - 650 kg. p = 520 kg LOAD eN PIS TO!,! AT PR£'SSURE DF ,

0'88 O' Btl CYU,vDER.

EFFICIENCY OF BRAKE

0·90 0·90 E.FFlClENCY, OF 8RAKE RIGGING

Wr ~ 8765 kg, Wr - 8765 k.g,

WPOCl -15375 kg. WPDCL ~ 15375kg.

Wr = 13974 kg. Wr - 1397,# kg.

WP,," -195/9 kg. WPOCL • 19519 kg.

AXLE LOADS UNDER TARE

AXLE LOADS UNDER PRACTICAL DENSE

L f.l == 2 .p)( i =Z .. ,6'0 y.5"'" 78ook.g. X6=l xp~i =2. x 6!iox6-=- 7800 Irg

l:8 x ICC ~ 7800 x 100 = 44.57.Wr 17530 •

~BxIOO= 7800XI00 -2"4'7.W,PDl:L 30750

77:1. kg.

BRAKE RIGGING DIAGRAM(Jessop- etC EMU)

LfJ 'Xpxi ~ 4)(520 ~6;1124aokg £e=:J4'APxi .. 4 >r320 X6 '="72ABO kg.

LI.\ ./00 _ 124£10 xlOO ~ 44'7""IVr 2794£1' /.

-l,:., x!E£. • 1:2.480 x100 _ ::sz. 7-WPOCL 39"38

/23Ifkg.

l£V~R":'G£ or BRAKE. RIGGINGI

TOTAL OF (DEAL BRAKE SLOCK PR£SS6

IDEAL-BR-A,KE RATIO /I./;r OF TARE.

IDEAL 8RAKE RATIO IN ":" Ole CFm..ACTUAL 8aAK£ BLOCk PRESS'...!R£ P

428 +214. y,Z ==62/4

428 +l.I4 xZ _ 6-Z/,-,3BO+190. 2 _6

190380+19°);2-=6

190•-'

I' '~,

i...~ , ,; ~

\' I)

\ ~

._.•._--_---."-_.---_..._--~ "":-.:,;.._"",~_::' ---'...---------- ._----_., ...__ U'''''__......_ ..

~i '-'---"'-'--""'~"'-="""'------'-"._' .~..- '-- ~. -,' .'--

,. I

\,

FIG.41

F~ 960 K<.

h = 4-i.- = 6·2'e = 90'/,-C ~ 0·3p"'Fxnx-c:'.x.exC

=9f,Ox4 X6·2xo·'xO.2

~6428'16K:l' I

"I -~.'...~:~";i;~- :'.,t-,:-~],

,.~

AIR BRAKE

CALCULAJJON OF PARKING BRAKE FORCE,

HOLDING FORCE OF PARKHJG BRAKECYLINDER AT 67"'m STROKENO~ OF PARKING BRAKE CYLINDERRIGGING RATIORIGGING EFFICIEHCYCOEFFICIENT OF FRICTIONTOTAL PARKING BRAKE FORCE AVAILABLE

BRAKE CYUNOER DIAMETER 1.6 kg/em2 FOR k<OTOR BOG:ELOAD ON PISTON AT PRE:SURE OF 2 k /em 2 FO,~ TRPJLER BOGIE::-:-:::ZNCY Cr BRAKE CYUNDER 9EFFICIENCY OF BRAKE RIGGING

ftXLE LOAD UNOF.R TARE

AXLE LOAD UNDER PRACTICAL DENSE CRUSH LOAD

LEVERAGE OF BRAKE RIGGING

TOTAL OF IDEAL BRAKE BLOCK PRESSURE PER BOGIE

IDEAL BRAKE RA:-l0 IN % OF TARE

IDEAL BRAKE RATIO IN % OF PRACTICAL DENSE CRUSH LOAD

ACTUAL BP~E BLOCK PRESSURE PER BRAKE BLOCK

-.'",., --,,-',

43.79%

35· 2.7.

X 0.9 ~ 1279 kg

~ 590 + 400 X 590 ~ 6 21190 190 400 .

X 520 X 6.21 ~ ·1'2917 kg

'; f-;-~/"> - ,-. -; "'"

203 mmP ~ 520 kg

0.880.90

wr ~ 14-750 kg

WDCL ~ 18345 kg

;::.'.~..,

~, -'

,,.

EB X 100lWT

m X 100 =EWPDCL

MOTOR COACH BOGIE

.-

1:8 ~4XpXI""4

~ 129:17 X 100 =29'500

129,17 X JOO =2 X 18345

D3 X 0.88 X O.g ~ 12917 X 0.888 8

203 mnlP ~ 650 <g

0.88090

¥IT ~ 9050 k3WDCL ~ 13910 kj

TRAILER COACH BOGIE

600 400 600~ 200 I 200 X400 ~ 6

EB ~ 2 X p X i ~ 2 X 650 X 6 ~ 7800 kg

"B X 100 ~ 7800 X 100 = 43.03'EWT 9050 X 2 /0

EO X 100= 7800 X 100 • 28'0370EWPDCL 2 X 139'0 0

IS X 0.88 X 0.9 = 7800 X 0.88 X 09 = 772 kgB 8

,,*,=.-

~-:-"'- . r--:.~~"_._-"-':-:< ".-'--' --.

';~J.',' ~!!:-

DIAGRAM (MEMU)- -~J

~J~1,~&n

~----,--,--

BRAKE RIGGING, .

1.1:-..' -; -, •..:,-.. -i:{( ".-'

<'tj:-.c>: ;'"-:..

..

' ..'-. ':-- ,f:

-j., .,:_:~'7"." •...,- •. ~

'._. _~~,--:!;.~ ,.. ~ __ :,;.:~ i~-/-' ~-

1

l.. r

I·,,,

<>'~71,.~') "

'J1., 'I :i',,., '". J ".; ,: !I,; ;

,-{,W,Il' :11/ \f I

\I

.'

____• _J

LOAD

I,F= 960 K'I-'" '1\'n ~ 4- '. 6 2 ., i'

f,..:a. • , (I

7. I .e.:: 90.. '. IC=O·o·' i. \ .p::oFxn'X.(..)(.ex~ I

=~bO"4 x6'2)<O'~xO-'5!

=6428,16 K:I~ ~

. ..: /:I'('. ..

l

LOAD

i i

1.6 k9!em2 FOR MOTOR BOGIE ~ r'2 kg!em 2 FOR TRALER.BOGIE ~+ I

~r4'. ,. \'

,,~ ~ ... ·Iil...

if ','r,

AIR BRAKE

..CALCULA.TION OF PARKING BRAKE FORCE, ,

TOTAL OF IDEAt BRAKE BLOCK PRESSURE PER BOGIE

IDEAL BP-AKE RATIO III % OF PRACTICAL DENSE CRUSH

ACTUAL BRAKE BLOC': PRESSURE PER BRAKE BLOCK .

LEVERAGE OF BRAKE RIGGING

IDEAL BRAKE RATIO Ii' % OF TARE

BRAKE CYUNDER DIP.METER

LOAD ON PISTON AT PRESURE OFEFFICIENCY OF BRAKE CYUNDEREFFICIENCY OF BRAKE RIGGING

AXLE LOAD UNDER T~RE

AXLE LOAD UNDER ~RAcnCAL DENSE CRUSH

HOLDING FORCE OF PARKIIJG BRAKECYLlIJDER AT 67:."m S':rROKE

NO, OF PARKmG BRAKE CYLI).JOERRIGGING RATlqR1GGIl'-tG EFFIC1Et<CYCOEFFICIENT 0,= FRICtiONTOTAL PARKII-lG eRAKE FORC~ AVAILABLE

,1

1279 kg

§

6.21 = 12917 kg

.•¥ 0.9 _~- --\L-.... fII., ~r-

.1

'i

/

./I

1\I

!I

1\

§

..~

~

_ 12917 X",- ----e~ III ;,.. I.

~B X 100'i:'NT

1:8 X 100~VlPDCL

. \

re X 0.88 X 0.98

'I

BR~KE .'. R\GG+NG~l~G~~~AM (MEM~U)-

- ~ -\ L~ffi~

r /i~1~ v H~ ~=t-:1f

.. DI'/"-""-­71 ';" N-;:. ..

MOTOR CO/,\CI-1, HO'QJI. "--

203 ", ..ormm. /P = 520 kg' ,

0,88 - '.l~--0.90 .' ~.

"I l'~ j

'Iff = 14750kg ,'"

WOCL = le3,~~ ..1 u· .----r-- ..• -"'; .........-

=. 590 ". 400.\ ',.. '0 6 -, 1190--' 190,",;, 0 ..'-

1:B = 4 X P X Ij; ~\x520 X. "

= _12917 X ,.~;"'J~4.3.7.9%29500' . '_- ............

= 12917 X.D:,",,j'35'2.7.2 X 182A~: '-'., ..

t .. ..~~-- ..-------------- ... --~"~' --~..__ --- L ; ., 7 2 ;,'-- - --",~,-

--_..- ._--."L .__ •- ---=-"---,

203 mmP = 650 kg

0.B80.90

wr = 9050 "'3WDCL = 13910 kj

TRAILER COACH BOGIE

L----

_600+400 X 600 = 6- 200 200 400

1:3 = 2 X P X j = 2 X 650 X 6 = 7800 kg

];.B X 100 = 7BOO X 100 = 43.09 'f>AI'! 9050 X 2 /0

~B X 100 = 7800 X 100 - 28-037-~VlPDCL 2 X 13910 0

re. X 0.88 X 0.9 = 7800 X 0.88 X 0.9 = 772 kg8 n

'.

.I

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,\

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'f-