It is an independent unit used under a long

vehicle.
It is usually mounted on two pairs of
wheels.
In exceptional cases, such as special
purpose
stocks or high capacity vehicles of well
Wagons or crocodile trucks, inspection
carriages etc the bogie may be mounted on
 Normally two bogies are used under a
Vehicle.
 Each bogie carries half the load of the
vehicle body and it’s loading.
 Each bogie is provided with a pivot on its
central transom or bolster for
engagement with its male counterpart
provided underneath the vehicle under
frame.
 IRS Bogie
 SCHLIEREN Bogie (ICF Laminated
Bogie)
 MAN-HAL Bogie (BEML Bogie)
 ICF All Coiled Bogie
 Fiat Bogie
Bogies of Driving Power Car (DPC) and Trailer
Coaches (TC) are of all welded, light weight
construction of ICF type.
The axles, with self-aligning roller bearings
Helical springs working in parallel with dashpots are
used for primary suspension
Coach body is supported on two side bearers
Vertical and lateral shock absorbers are provided to
damp the oscillation
No weight is transferred through the bogie pivot,
which is located in the centre of the bolster.
The centre pivot acts merely as a centre of rotation
and serves to transmit acceleration and retardation
forces.
The floating bolster in TC bogie is secured in the
longitudinal direction with the bogie frame by means
of two anchor links with silent block bushes, located
diagonally opposite to each other
The DPC bogie bolster is located between bogie
transoms through rubbing plates fixed at the bolster
ends.
 POH work of the DEMU is done in
every18 months
 It would be worthwhile lifting these DMU
coaches and put back immediately after
thorough checking of brake rigging and
brake gears once in 9 months during IOH.
 Bogie Bolster Suspension:
 The bolster rests on the Air spring – one at each end,
located on the lower spring beam which is suspended
from the bogie side frame by means of fixed beam on
either side.
The centre pivot pin joints the body with the
bogie & transmit the tractive & braking
forces on the bogie.
It does not bear any vertical load of the
coach body.
Function: Serves the purpose of a
movable joint between coach body &
trolley.
ANCHOR LINK
 The Anchor Link connected to the bogie bolster to
bogie frame diagonally. This is fitted with silent
block bushes which act like silencers.
 Function: The anchor links transmit the tractive
and braking forces between the coach body and the
bogie.
 Keep the trolley in alignment with the track all
condition.
It consist of a machined steel wearing plate immersed in oil bath
& floating bronze wearing piece with a spherical top surface
kept in it. The whole arrangement provide with a cover to
prevent entry of dust in the oil sump.

Wear limit of wearing plate: 10mm (New) 8.5mm

Function :
 To checking the coach body from tilting & jolting . Helps in
keeping the coach body straight
 Transmit the downward shock of body on the bolster spring .
 Hydraulic shock absorber with capacity
of +/- 600 Kg at a speed of 10 cm/sec.
are fitted vertical and lateral direction to
provide damping for oscillations.
 Air Spring is a rubber bellow containing pressurized
compressed air with an emergency rubber spring
providing various suspension characteristics to
maintain a constant Buffer height irrespective of the
loaded condition.
 Air suspension system as secondary suspension in
coaching stock is far superior to conventional
secondary suspension & provides –
o Better riding comfort
o Improved reliability and reduced maintenance
o Capacity to sustain super dense crush load
Axle box guides for DPC and TC are of cylindrical
type welded to the bottom flanges of the bogie side
frame with close dimensional accuracy.
These guides together with lower spring seats located
over the axle box wings, house the axle box springs
and also serve as a shock absorbers.
These guides are fitted with guide caps having nine
holes of diameter 5 mm equidistant through which oil
in the lower spring seat passes under pressure during
dynamic oscillation of coach and provide necessary
damping to primary suspension to enhance better
riding quality of coach.
This type of rigid axle box guide arrangement
eliminates any longitudinal or transverse relative
movement between the axle and the bogie frame.
 Air vent screws provided on the bogie side frames,
directly above the dashpots.
 Tapped holes are provided for replenishing oil in the
dashpots.
 Special screws with copper asbestos washers are
screwed on the tapped hole to make it airtight
 Oil Level: Under tare condition above inner surface
of guide Cap
- BG: 80mm;
- Above Guide Cap – 40 mm
Oil consumption : 1.6 lits ( modified ) BG,
 Approved brand of oil for dash pot - Servoline-100,
Yantrol-100, Bharat Univol-100
 Wheel
The DPC coaches are provided with composite design of
wheels consisting of rolled steel wheel centers with
renewable tyres to IRS Specification R-15/95.
The tyres of DPC wheels to IRS R-19/93 Part-V are
secured with glut ring and 4 locking keys.
The wheel of trailer coaches is solid wheel same as being
used in BG main line stock.
Wheel Diameter
 New Limit dia. Last Shop Issue Size
DPC 952 mm 877 mm 885 mm
TC 915 mm 813 mm 837 mm
An axle is a component of a wheel set to hold the
wheel discs in position.
The axle box is also mounted on the journal of the
axle.
For TC and DPC bogie, axles are to IRS
Specification R-16/95 and R-43/92 respectively.
Axle journals should be thoroughly cleaned for
inspection to detect flaws, pitting, ovality, taper,
ridges etc.
Each axle should be ultrasonically tested for
detecting internal flaws and defects.
 DPC Bogies
 These bogies are fitted with direct mounted, double
row, self-aligning spherical Roller Bearings similar to
ICF
TC Bogies
 TC bogies of DMU stock are fitted with direct
mounted double row, self-aligning spherical roller
bearing similar to ICF
Primary suspension springs are of helical type
manufactured from centreless ground chrome
vanadium, silico manganese steel.
Air Spring used in Indian Railway as a secondary
suspension to provide comfort to the passenger by
absorbing shocks and vibrations.
Air spring is working on totally control by air
(pneumatic system ).
In Indian Railway, working of air spring is based on 4-
point suspension system.
 Nylon rubbing plate of Manganese steel rubbing pad complete
has been fitted to the bolster, which serves as cushion between the
bolster and bogie frame.
 Initial clearance of 1mm on each side has been provided between
the nylon / manganese steel rubbing plate and bogie frame liner
(steel / manganese
 During POH, this clearance must be maintained. During service,
this clearance should not exceed 3mm on each side. Any higher
clearance may cause excessive longitudinal oscillations and there
by reduce riding comfort.
 LIFTING THE BODY OFF THE BOGIES
Before lifting the coach body from the bogie, strip the
following
All electrical connections,
Earth connections,
Traction motor ventilation bellows
Hand brake/parking brake connections
The centre pivot cotter pin in the TC
Securing collar in the DPC bogies must be removed.
All the pneumatic connection between bogie & under
frame should also be disconnected.
The coach body can be lifted off the bogies by Two
overhead electric cranes of 40t capacity (min.) each
with suitably designed lifting tackles.
 Lifting the body off the bogies
 Washing of bogie
 Dismantling of bogie.
 Washing Of Bogie Components
 Attention to Bogie components
 Repair to components
 Bogie assembly
 Load testing and adjustment
 Lowering of Coach
 Must Change Items
 Final Adjustment
 Before lifting electrical fittings/ furnishing items should
be stripped and batteries removed
 Before lifting a coach, the following components should
be removed, disengaged or disconnected:
 Dynamo belt /disconnection of electrical connection
 Broke pull rod from bogie Brake rigging.
 Centre pivot cotter.
 Axle box safety straps.
 Dismantle vertical shock absorbers.
 Air vent screws on bogie frame
 Air brake fittings
 Lavatory chutes
 Under slung water tanks & WRAS,
where provided.
 AC equipment in AC coaches.
 After the bogies are run out, the traction
motors must be taken out
 Remove all the oil from the side bearer oil
bath.
 Wash the bogie with high pressure hot water
jet to remove all dust, mud, scales, grease
and other muck
 After washing and drying, roll the bogies to
dismantling line.
 Dismantling of air spring from lower spring beam (cradle) and
bogie bolster may be as following:
 Remove lateral & vertical shock absorber.
 Remove equalizing rod connection from both ends of lower
spring beam if provided.
 Remove connection between arm of leveling valve &
installation lever.
 Remove all 6 No. bolts and nut with the help of M12 Alen key
and M12 spanner from bottom plate of air spring & lower
spring beam.
 Lift bolster up to bogie frame to clear the spigot of air spring.
 Slide air spring from lower spring seat.
 The bolster may be removed from the bogie frame after
removing the air spring.
 Remove the duplex check valve from bolster
 The air vent caps should be loosened 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 lower
spring seats and wheels are rolled out.
 After the bogies are run out, the anchor links should be
disconnected.
 Dismantling of air spring from lower spring beam
(cradle) and bogie bolster.
 The bolster may be removed from the bogie frame after
removing the air spring.
 Remove the duplex check valve from bolster and
maintain
 The air vent caps should be loosened 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 lower
spring seats and wheels are rolled out.
 Collect anchor links of TC bogie, brake rigging
components and axle box springs into respective
bins/pallets and send to washing for thorough cleaning.
 Send the bogie frame, bolsters and lower spring planks
to washing for thorough cleaning and drying.
Bogie Frame
 Bogie frame for DPC and for TC should be checked thoroughly after cleaning,
for any cracks, particularly at places where cradle and the dashpot guide flanges
are welded
 If cracks are detected, the frame should be placed on a manipulator and after
proper gauging they should be repainted by welding.
 The squareness and alignment of the guides should be checked thoroughly with
the help of a alignment gauge
 Axle guides found bent/cracked should also be cut out and replaced.
 Weld the new axle guides with the help of axle guide fixture, if the axle guides
are damaged or worn.
 Replace the anchor link brackets if they are worn or damaged
 All bushes must be renewed at every POH.
 Bent, damaged, or worn brake hanger brackets should be replaced.
 The axle box safety brackets should be straightened or renewed if found bent or
damaged.
 Check the bolster for twist, crack, corrosion, etc. Repair or replace
the bolster as required.
 Replace the anchor link bracket by holding in bolster repair fixture,
if found worn or damaged.
 Replace the center pivot silent block.
 Replace the center pivot sleeve if worn, damaged, or corroded.
 Replace the rubber-sealing cap of center pivot silent block.
 Force fit between silent block and sleeve and diameter of pivot pin,
i.e. 75 –0.150/-0.257 and 90-0.170/-0.267 should be maintained in
every POH/IOH.
 Piping to air spring spigot hole may be checked for leakage
 New rubbing plates to be provided what so ever may be the
condition of old one.
 Inspect all welding joints of the lower spring beam
(cradle) and repair if required.
 Inspect air spring fixing holes of lower spring beam for
elongation, if elongated build them to dia 13 mm.
 Inspect the top surface of lower spring beam for
corrosion, remove the corrosion and paint with primer
and black paint.
 After the coach body is Lifted and kept on trestles duly
leveled the alignment of its top centre pivot fitted under
the coach body should be checked. It should be removed
if found bent or out of alignment for straightening /
replacement as required.
 All pivots should be chalk tested either in position of
when they are dropped and the pivots found cracked
should be replaced.
 The silent block bushes provided in all-coil’ bogies
should be examined for perished rubber and loose
rubber bonding.
 Replace the anchor link, if worn or corroded
 Repair the anchor link, if found cracked (normally at weld
joints) under magna flux testing, by re-welding after
gauging.
 Refit new Silent block in every POH.
 Replace the silent block, if the rubber is perished or loose
in the Anchor link housing, or the silent block pin is worn
thin
 Shock absorbers should be given a schedule overhaul
when their capacities vary beyond ± 20% of their
specified values, or after 4 lacs kilometres or alternate
POH, which ever is earlier.
 Non schedule overhaul: Shock absorbers should also be
overhauled whenever suspected to be defective, which
is indicated primarily by oil leakage or when they are
physically damaged.
41
STC / NBQ