(Complete Assembly)

Bogie
Frame

Wheel
& Axle
Secondary Primary
Suspension Suspension Disc Brake unit
BOGIE GENERAL ARRANGEMENT
DESIGN FEATURES:
FIAT BOGIE

SUB-SYSTEMS
BOGIE FRAME
 SOLID WELDED FRAME -STEEL SHEETS(St-52)
AND FORGED,STEEL CAST PARTS TO
MATERIAL GS20Mn5V;DIN 17182 (WELDABLE).
 TWO SIDE FRAMES CONNECTED BY TWO
CROSS BEAMS -SUPPORT BRAKE UNITS.
VARIOUS BRACKETS ON FRAME.
 THE BOGIE FRAME RESTS ON THE PRIMARY
SUSPENSION SPRING UNITS AND SUPPORTS
THE VEHICLE BODY BY MEANS OF A BOLSTER
BEAM. THE BOLSTER BEAM IS CONNECTED TO
THE BOGIE FRAME BY SECONDARY
SUSPENSION.
BOGIE FRAME 1.-SIDE FRAME
2-.CROSS BEAM
(Ø140X Ø168X2506
SEAMLESS PIPE)
 MATERIAL PROPERTIES:
S355J2G3; GS20Mn5V; SG400/18; SG400/15;
EN10025 DINl:17182 IS:1865 IS:1865
UTS IN Mpa 490-630 500 – 650 400 400
YIELD 355 360 250 250
STRENGTH
Mpa
ELONGATI 22 24 18 15
ON %AGE
IMPACT 27J AT -20 70 J -- --
0
C
CHEMICAL C 0.23, Mn C 0.17 to ---- ---
%AGE: 1.7, Si 0.6, S 0.23, Si 0.60,
&P 0.045 Mn 1.00 to
1.50, S
0.020,
P0.015, Cr 
0.30, Mo 
0.15, Ni
0.40
Primary suspension
Two coil springs, one vertical damper,
articulated control arm, elastic joints
connecting the axle bearing to the bogie
frame
 Better curve negotiation.
 (Wheel set with Primary springs removed)

Primary Damper

Control Arm
Wheel & Axle Assly

Brake Disc
 (Bogie frame lifted)

Primary Spring assly

Primary Damper
 (Primary exploded)

Rubber Pad
Outer Spring
Spring Guide

Inner Spring

Lower Spring Guide Bump Stop

Wheel and Axles
Two brake disks (4),
diameter 640 mm and
width 110 mm.
Two wheel disc of
tread dia 915 (New),
845 (worn).
 (Wheel set with Primary suspension)
Control Arm

Bearing Assly
With Anti-skid
Device
DIMENSIONS OF WHEEL SET:
Wheel Disc:
Wheel diameter

New wheel dia 915mm

worn wheel dia 845mm
Wheel Re-profiling and
balancing:
DYNAMIC BALANCING 320RPM
LESS THAT/EQUAL TO 50GM.M
GLUE THE NEEDED WEIGHTS.
DETAIL OF ADDED WEIGHTS:
Axle bearings
 TAPER ROLLER
CARTRIDGE TYPE
BEARING
 PRE-ASSEMBLED UNIT.
 MAINTENANCE FREE-
OVERHAUL 1.2 MILLION
KM.
 SENSORS FOR
DETECTING SPEED
DISC BRAKE SYSTEM

AXLE MOUNTED DISC BRAKE

TWO DISCS PER AXLE OF
DIA640
INBUILT SLACK ADJUSTER IN
BRAKE CYLINDERS
35mm BRAKE PADS
SECONDARY SUSPENSION

NEST OF FLEXI-COIL SPRINGS INNER AND

OUTER, RUBBER SPRING AND
SECONDARY PAD
VERTICAL DAMPERS
LATERAL DAMPERS
YAW DAMPERS
ANTI-ROLL BAR
ANCHOR LINKS
 (With Secondary Spring System Exploded)
Bogie
Bolster

Miner Pad

Spring Guide

Outer Spring

Inner Spring

Rubber Spring
 (Bolster removed)

Lateral Damper Longitudinal Bumpstop

Lateral Bumpstop
 (With Bolster Lifted)
Bogie Bolster

Sec. Vertical
Damper
Cross Section

Nested
Secondary
Spring
Assembly

Yaw Damper
SECONDARY SUSPENSION
ANTI-ROLL BAR:

A TORSION BAR HAVING TWO FORKS IS

PROVIDED BETWEEN BOGIE FRAME
TRANSVERS BEAM WITH THE HELP OF
TWO LINKS TO RESIST ROLLING MOTION
OF COACH.
AS PER UIC515-1 TILTING CO-EFFICIENT
<0.4
A

Anti-roll assly
ANTI-ROLL BAR:
BUFFER HEIGHT ADJUSTMENT

By adding or removing shims from

body/bogie connection as shown in
figure.
Shims will not be added/removed in
Primary and Secondary Suspension for
wheel wear compensation or buffer
height adjustment.
BOGIE BODY CONNECTION:
Principles of force
transmission

Vertical forces:
BODY-SEC.SPRINGS-BOGIE FRAME-
PRIMARY SPRINGS/BALL JOINT CONTROL
ARM-AXLES.
Lateral forces:

BODY-SEC.SPRINGS-BOGIE FRAME-
BALL JOINT CONTROL ARM-AXLES.
Longitudinal traction efforts
and braking powers:
BODY-TRACTION
CENTRE-
TRACTION RODS-
TRACTION LEVER-
BOGIE FRAME-
CONTROL ARM-
AXLES.
A

Traction Center
 (X-section lifted)

Traction Lever Traction Center

Anti Roll Assly

Curve Roll
CURVE NEGOTIATION:

AN ARTICULATED CONTROL ARM (SGCI

TO IS:1865) IS CONNECTING AXLE
BEARING AND SIDE FRAME THROUGH
ELASTIC CONNECTION, WHICH WILL
PROVIDE FLEXIBILITY BETWEEN AXLE
AND SIDE FRAME.
 FIAT BOGIE FRAME FABRICATION
(SEQUENCE OF OPERATIONS)

 STAGE-I
 FITTING OF TOP FLANGE,BOTTEM FLANGE,WEB AND 6
RIBS
 STAGE –II
 FITTING OF CONTROL ARM BRACKET,INSIDE
STIFFENER,BRAKE HEAD BRACKET,BKT. FOR
VERTICAL DAMPER.
 STGE III
 ROBOTIC WELDING OF ABOVE ITEMS.(MFR. M/S IGM
ROBOTER SYSTEM AG AUSTRIA)
 BOGIE FRAME FABRICATION
CONTD..
STAGE IV
YAW DAMPER ASSY BKT. & CURVE ROLL LINK
BKT. TACKING.
STAGE V
FULL WELDING OF BOGIE FRAME ON
MANIPULATOR
STAGE VI
FLAME STRAIGHTENING OF SIDE FRAME.
FIAT BOGIE MANUFACTURING
 BOLSTER ASSY.
 FTG. OF TOP FLANGE, BOTTOM
FLANGE,WEB AND SPRING DOME, PIN
BKT.DAMPER SUPPORT.
 FULL WELDING OF BOGIE BOLSTER ON
MANIPULATOR.
 FLAME STRAIGHTENING
 FULL WELDING
 CENTER PIVOT PIN ASSY, ANTI ROLL BAR
BKT AND SAFETY BKT.
MFG . CONTD…
 BRAKE BEAM(CROSS BEAM)
 BRAKE SUPPORT-4NOS,TRACTION BKT ASSY-2 NOS.
PNEUMATIC PIPE BKT. BOGIE LIFTING BKT.
 FULL WELDING
 BOGIE FRAME ASSY.
 JOINING OF SIDE FRAME-2NOS AND BRAKE BEAM-
2NOS ON BOGIE FRAME ASSY JIG.
 FULL WELDING.
 FLAME STRAIGHTENING AND TWIST CHECK BY Q.C.
 SHOT BLASTING AND PAINTING OF BOGIE FRAME
 MFG. CONTD..
(FINAL ASSY BOGIE)
 ANTI ROLL BAR ASSY.
 FITTING OF TRACTION CENTER ON BOGIE
FRAME.
 JOINING OF CROSS SECTION.
 ASSY OF BRAKE CALLIPER
 ASSY OF SECONDARY SUSPENSION
 CONTROL ARM ASSY. LOWERING OF PRIMARY
SUSPENSION.
 CONNECTING ANTI ROLL BAR WITH CENTER
PIVOT PIN.
 DAMPER ASSY.
Main Data:
Speed limit

Upto 160KMPH without any modification

upto 200KMPH with minor modification
RIDE INDEX

CHAIR CAR:
 VERTICAL 2.75
 LATERAL 2.5
COMPARISION OF SALIENT FEATURES OF FIAT
BOGIE AGAINST I.C.F. BOGIE
S.N I.C.F. FIAT
.
1 SPEED=140 KMPH MAX OPERATING SPEED=160
KMPH
TESTED SPEED=180
KMPH
POTENTIAL FOR OPERATION=200
KMPH
2 BOGIE FRAME I TYPE H TYPE CONSTRUCTION
3 WHEEL BASE =2896 WHEEL BASE = 2560 MM
MM
4 WHEEL DIA =915 MM 915 MM(NEW) 845 MM (WORN)
5 CLASP TYPE BRAKE AXLE MOUNTED DISC BRAKE

6 SPHERICAL ROLLER TAPERED ROLLER BEARING

 COMPARISION CONTD……
S.N I.C.F. FIAT
.
7 PRIMARY SINGLE PRIMARY NESTED SPRING =2
SPRING NOS.
8 LIMITED NOISE NOISE CONTROLLED BY USING
CONTROL FEATURES THICK RUBBER PAD
9 SECONDARY SPRING ON SECONDARY SPRING DIRECTLY
L.S. BEAM MOUNTED ON SIDE FRAME (NO
L.S. BEAM)
10 COACH LOAD IS THROUGH BOGIE BODY
TRANSFERRED CONNECTION TO SIDE FRAME VIA
THROUGH SIDE BEARER SEC. SPRINGS.
(100%)
11 CENTER PIVOT PIVOT ASSY ON TRANSVERS BEAM
TRANSFER TRACTION AND BRACKET ON DOME TAKE
AND SHOCK LOAD TRACTION/ BRACKING, SHOCK
 COMPARISION CONTD…..
S. I.C.F. FIAT
N.
12 RIDE INDEX TRANSVERSE=3.5 TRANSVERSE=2.75
VERTICAL=2.5 VERTICAL=2.5
13 NO SUCH ARRANGEMENT ANTI ROLL BAR HAS
BEEN PROVIDED TO
CURB THE TEDENCY OF
ROLL.
14 MAINTT. REQD. VERY LITTLE MAINTT. IN
1)AXLE BOX GUIDE P.O.H.
ARRANGEMENT
2)SPHERCAL ROLLER BEARING
3)CLASP BEARING
4)MORE PIN JOINTS
15 WEIGHT OF BOGIE=6.2 T WEIGHT OF BOGIE=6.3
MAINTENANCE
SCHEDULE:
SELF-GENERATING BOGIE WITH
V-BELT:
CARDAN SHAFT ARRGT. FOR
25KW ALTERNATOR
CARDAN SHAFT ARRGT. FOR 25KW
THANKY
OU