Carriage Repair Shop, Tirupati

LHB Bogie overhauling as per shop schedules

and important parameters to be checked

RC - 80
 Team CRS : RC - 80
S. No. Name Designation
1 D.V. Kamalakara Rao SSE
2 Ch. Dinesh Kumar SSE
3 M. Sreedhar Naik SSE
4 B.C. Jaya Prasad SSE
5 N. Venkateswara Rao SSE
6 K. Chandra Sekhar SSE
7 D. Janardhan Naidu JE
8 R. Narasimhulu JE
9 S. Krishna JE
10 K.M. Renjith JE
 Periodicity of Maintenance Schedules

S. No. Type of Schedule Periodicity

18 Month 30 days/6 Lakhs Kms

1 Shop Schedule I (SS-I)
earned whichever is earlier

3 Years/12 Lakhs Kms earned

2 Shop Schedule II (SS-II)
whichever is earlier

6 Years/24 Lakhs Kms earned

3 Shop Schedule III (SS-III)
whichever is earlier
FIAT (Fabrica Italina de Automobil Torino) Bogie

Bolster
beam

Secondary
suspension

Vertical
damper
Brake
Primary YAW
disc Control
suspension damper
arm
 Salient features of FIAT Bogie
The FIAT Bogie is two-axle type, with a primary and a secondary suspension.
Solid welded Bogie Frame made up of two longitudinal components
connected by two cross beams.
Primary suspension consist of two steel coil springs (internal/external) laid out
on the Control Arm upper part.
Secondary suspension consists of two spring packs which sustain the bolster
beam over the bogie frame.
Traction Centre - The traction Centre transmits traction and braking forces
between bogie frame and body by a traction lever on the bolster beam pin
and two rods.
Disk Brakes The FIAT bogie is fitted with pneumatic disk brakes.
Taper Roller Cartridge Bearing Fiat Bogie is fitted with 130 mm Cartridge
type roller bearings.
Important parameters to be checked
during Shop Schedules
 Parameters to be checked
S. Dimensions in
Description
No. mm

Control Arm rubber joint half Inner >/=10

1
round Outer >/=10
Traction Lever centre bush Lateral 100 100.5
2
hole Longitudinal 100 100.5
3 Silent block of Traction rod >/=8
Length <60
4 Lateral Bump stop Depth >7
Height <30
 Parameters to be checked

Traction Lever centre bush hole

 Parameters to be checked

Silent block of Traction rod

Parameters to be checked

Lateral bump stop

 Parameters to be checked
S. Dimensions in
Description
No. mm
5 Control Arm housing Dia. 230 230.5
6 Length of Carbon rod
Laterial >/=100
7 Traction centre pin
Longitudinal >/=100
Rubber spring free height at Vertical Length >30
8
Secondary suspension crack Depth >4
Horizontal Length >40
crack Depth >5
9 Vertical rod silent block >/=10
Silent block
rubber Good/perished
condition
Parameters to be checked

Control Arm housing

Parameters to be checked

Traction centre pin

Parameters to be checked

Rubber spring free height

Parameters to be checked
Vertical rod / Anti-
roll bar link Silent
block
 Parameters to be checked
S. Dimensions in
Description
No. mm
Good/ Body
Depth of crack
Primary suspension bump damage /
10 >/=8
stop pad Rubber
Height >/=22
worn out
Good/ Body Depth of crack
damage / >/=10
11 Primary suspension pad
Rubber Height >/=30.7
worn out
Found OK /
Centering disc at secondary Body Length
12
suspension damage / </=23.5mm
crack
Parameters to be checked
Primary suspension pad
Parameters to be checked
Bump stop
Parameters to be checked
Centering disc
 Parameters to be checked

S. Dimensions in
Description
No. mm

Bump stop clearance at 5mm X Nos.

13 Shims
bolster 10mm X Nos.

Corroded /
14 Anti roll bar bracket
Good

15 Anti roll bar bearing Old / New

Parameters to be checked

Shims for adjusting bump

clearance at Bolster
 Parameters to be checked

Anti roll bar bracket

 Parameters to be checked

Anti roll bar bearing

inside of bracket
Inspection of LHB coach bogie for Shop Schedules SS-1, SS-2 & SS-3
S. Design value
Description
No. under tare
Max.915
1 Wheel diameter
Min. 845
Clearance between brake disc bottom to
2 137.5mm
Rail level
Clearance between bolster beam upper
spring seat from bottom surface to top
3 517mm
surface of bottom spring seat (Bolster
Spring Height
4 Height of Bogie frame top from Rail level 925 +0/-5mm
Height of Bogie Bolster base plate 1. 930 +2/-6mm
5
(machined surface) from Rail level 2. </= 4mm
Clearance between Secondary Vertical
6 90 95 mm
Bump stop gap
Inspection of LHB coach bogie for Shop Schedules SS-1, SS-2 & SS-3
S. Design value under
Description
No. tare
Axle box to bogie frame (Primary spring 260+0/-4mmG.car
7
height) 252+0/-4mmG.car
Clearance between safety pin & lug of Top= 45 mm
8
control arm(Top/Bottom) Bottom= 37.5 mm
Clearance between Lateral Bump Stop
9 25mm+5/-2
and Traction Centre
Clearance between Longitudinal bump
10 8mm+5/-2
stop and traction centre

Clearance between Primary Vertical

11 8mm n. Car
Bump stop Gap
 Tightening Torque for various fasteners used in FIAT bogie
S. Torque
Description Size Remark
No. value
Traction Centre Pin nut Done / Not
1 M16X70 170 Nm
tighten done
Traction Centre pin Done / Not
2
Lock plate bending done
Provided / Not
3 Wire rope spilt pin
provided
Lateral Damper Nut Done / Not
4 M12X55 70 Nm
Bolt tighten done
Bolt between Vertical Done / Not
5 M24 590 Nm
Rod and anti roll bar done
Done / Not
6 Traction Rod Nut M24X120 590 Nm
done
 Tightening Torque for various fasteners used in FIAT bogie
S. Torque
Description Size Remark
No. value
Traction Rod/Traction Done / Not
7 M24X200 590 Nm
lever link bolt done
Lateral Bump Stop Done / Not
8 M16X100 170 Nm
Nut/bolt done
Bump Stop at Bolster Done / Not
9 M8X50 21 Nm
nut/bolt done
Bolt fitted
Shims at bolster bump
10 standard Or non
stop
standard
Bolt between Anti roll Done / Not
11 M16X160 170 Nm
bar to fixing block done
 Tightening Torque for various fasteners used in FIAT bogie
S. Torque
Description Size Remark
No. value
Vertical Damper fitted at Serviceable
12 M12X100 70 Nm
Secondary Suspension /New tested
Serviceable
13 Yaw Damper nut M16X120 170 Nm
/New tested
Vertical damper fitted at Serviceable
14 M16X120 170 Nm
secondary suspension /New tested
Provided /
15 Corner Roller split pin
Not provided
Control Arm housing Nut Done / Not
16 M16X70 170 Nm
bolt done
Done / Not
17 Axle box front cover M6X45 170 Nm
done
 Tightening Torque for various fasteners used in FIAT bogie
S. Torque
Description Size Remark
No. value
Control Arm lug safety Provided /
18
pin (splitted) Not provided
Control Arm Bracket at Done / Not
19 M20X100 170 Nm
bogie bolt done
Traction Centre support
Done / Not
20 frame to Bogie cross M20X100 340 Nm
done
beam
Serviceable
21 Traction rod Silent block
/New
Serviceable
22 Lateral bump stop
/New
Serviceable
23 Traction lever Silent block
/New
 Tightening Torque for various fasteners used in FIAT bogie

S. Torque
Description Size Remark
No. value

24 Control Arm Silent block Serviceable /New

Primary Suspension
25 Serviceable /New
Upper Disc Bump stop

26 Vertical Rod Silent block Serviceable /New

27 Rubber Spring Serviceable /New

Thank you

31
 Activities to be carried out in Shop Schedules
Primary/Secondary Suspension
Examine the condition of lift stop pin and safety cables.
Check lower and upper centering discs for corrosion, wear,
damage and cracks.
Examine the condition of rubber and rubber/metal bonded
parts for damage, cracks and ageing. (Miner pads, rubber
springs etc.

Dampers
Check dampers for correct functionality, absence of
deformations and oil leakages.
Damper should be tested during Shop Sch.-I and Shop Sch.-II (or
early in case of oil leakages).
Dampers should be replaced during Shop Sch.-III (6 years).
 Activities to be carried out in Shop Schedules
Bearings
Rotate the bearing assembly to detect any abnormal condition.
Check the bearing mounted end play.
If end play is beyond permissible limit, dismount the bearing
and send for reconditioning.
 Activities to be carried out in Shop Schedules
Wheels and Axle
Perform wheel profiling and wheel balancing (for Speed >= 130
Kmph).
Perform a general overhaul of the axle, remove signs of
corrosion, renew corrosion protection and repaint the axle.
Check wear of wheels.
Perform an ultrasonic test on the wheel and axle to verify
absence of internal cracks and damages.
 Activities to be carried out in Shop Schedules
Control Arm
Remove signs of corrosion, renew corrosion protection and repaint
the components.
Check wear limit of control arm bore.
If the control arm bearing surface reaches a diameter of 230.5 mm
(i.e. wears out by more then 0.5 mm), the control arm should be
considered worn out and rejected.
The dia. is between 230.5 mm and 230.312 mm, the control arm may
be re-machined by providing a cut of 0.3 to 0.5 mm on the face of
control arm.
The diameter is less than 230.312 mm, the control arm may be
reused without re-machining.
The control arm mating surface with bearing should be coated with
Blasol 135 solution, to prevent corrosion.
Examine the rubber joint for cracks/damage and ageing.
 Activities to be carried out in Shop Schedules
Bogie Frame and Bogie Bolster
Examine the bogie frame and bolster for cracks, damages and
corrosion.
Check all the welded joints with dye penetration.
If cracks are found, hold the bogie frame in a suitable
manipulator, and rectify.
Corroded bogie frames should be attended.
Cleaning/washing of bogie frames.
Descaling/rust removal with rust converter.
Touch-up with high build epoxy primer and paint.
Small pitting holes up to a maximum depth of 3 mm may be
permitted on the frame.
 Activities to be carried out in Shop Schedules
Anti-Roll Bar Assembly
Remove signs of corrosion, renew corrosion protection and
repaint the anti-roll bar and the links.
Examine the condition of the brackets: remove signs of
corrosion, renew corrosion protection and repaint the block.
Replace fixings, rubber joints and sealings on condition basis.
Replace anti roll bar bearings, if necessary.
 Activities to be carried out in Shop Schedules

Traction Centre
Check Traction lever, Traction Rods.
Remove signs of corrosion, renew corrosion protection and
repaint the components.
Replace the rubber bush and the rubber joints, if necessary.

Rotation Limiter
Check condition of the steel roll and pin for wear /damages.
 Activities to be carried out in Shop Schedules

Rubber and Rubber/Metal Bonded Parts

Examine the Rubber and Rubber/Metal Bonded parts for ageing
/ damages/ failure of bonding.

Bogie Pins
Examine brake gear pins and other bogie pins for wear/
damages.
Replace the pins with hard chrome plated pins.
 Parameters to be checked

Lateral bump stop

Longitudinal bump stop

Parameters to be checked

Anti roll bar bearing

Parameters to be checked

Anti roll bar bearing

 Parameters to be checked

Lateral bump clearance should be 25 +/-5 mm

 Parameters to be checked

Clearance between longitudinal bu

mp stop and bump stop mounting
support frame 8mm+5/-2