of issue: Maintenance Manual No.

CM(~K40J
Ref: CGWOOOI
(Rev.-J)
.DateIMonth
October' 2004 (Rcv.-Q)
Page I of J2

INDIAN RAILWAYS
I

\
I
.J

MAINTENANCE MANUAL OF BOGlE, BRAKE, BRAKE GEAR

AND COUPLER FOR UHP DMU STOCK (1400 hpj FITIED
WITH AIR SUSPENSION
(BG -1676 mm)
(final)

S.N•. Month I Year of issue Revision / Page No. Reason for

Amendment Amendment
I. October, 2004 0 NA First Issue

ISSUED BY
RESEARCH DESIGNS AND STANDARDS ORGANISAnON
(MINISTRY OF RAlLWAYS)
MANAK NAGAR LUCKNOW - 226011
 Ref: COW {lOO1 Date/Month of issue: Mainrc1k1llCC Manual No_CMJ~K40]
(Rev.-3) October' 2004 (Re\·...()
Pa~c 2 of 32

CONTENTS

Descriptions Page No.

1. Brief Description of Bogie 3

2. Salient Features for Comfortable Riding 3
3. Interval Of periodical Overhaul 4
4. Lifting The Body Off The Bogies 4
5. Washing of Bogie 4
6. Dismantling Of DPC Bogies 5
7. Dismantling Of Trailer Bogie 5
8. Washing of bogie components 6
9. Attention To Bogie Components 6
10. Rolling Gear 9
11. Roller Bearings 11
12. Axle Box Springs 11
13. Air Spring 12
14. Air Drier 13
15. Hydraulic Shock Absorbers 13
16. Rubbing Plate In DPC Bogie 14
17. Bogie Brake Gear 14
18. Center Pivot 15
19. Side Bearers 15
20. Action To Be Taken Before Re-Assembling The Bogie 17
21. Sequence of bogie assembly 17
22. Side buffer & Center Buffer coupler Height Adjustment 19
23. Brakes 20
24. Lowering of coach body 21
25. Center Buffer Coupler 23
26. Side Buffer 23
27. Must Change Item 23

List of Appendix 24

•
"

Ref: CGW 0001 Dalc/Month of issue: Maintenance Manual NO.CMI-K401

(Rev.-]) October' 2004 (Rc\·...{I)
Pal!c 3 of 32

MAINTENANCE MANUAL OF BOGIE, BRAKE, BRAKE GEAR

AND COUPLER FOR HHP DMU STOCK (1400 hpj FITTED
WITH AIR SUSPENSION
(BG-1676 mm)

1,0 BRIEF DESCRIPTION OF BOGIES

1.1 Bogies of Driving Power Car (DPC) and Trailer Coaches (TC) to ICF drg.
No. DMU/DPC5-0-Q-501 and. DMUfTC4-0-0-401 are of all welded, light
weight construction. The axles, with self-aligning roller bearings mounted
inside cast steel axle boxes, are rigidly guided by telescopic dashpot and
axle box guide arrangement Helical springs working in parallel with
dashpots are used for primary suspension. Coach body is supported on
two side bearers located at 1600 mm (TC) and 1200 mm (DPC) apart on a
floating bogie bolster which in turn rests on two air springs supported on
lower spring beam (cradle). Vertical and lateral shock absorbers are
provided to damp the oscillation. The list of reference drawings in general
is given in Appendix' A'.

1.2 No weight is transferred through the bogie pivot, which is located in the
centre of the bolster. The pivot acts merely as a centre of rotation and
serves to transmit acceleration and retardation forces.

1.3 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.

1.4 The list of reference documents for general use is given in Appendix' B'.

2.0 SALIENT FEATURES FOR COMFORTABLE RIDING

2.1 Rigidly guided axles through telescopic dashpot with self-aligning

spherical roller bearings, having practically no play in longitudinal and
lateral direction with helical springs in primary and air spring in secondary
suspension, all contribute to riding comforts. It is therefore essential to
ensure that these features are well maintained in service in order to obtain
the desired performance throughout the life of these bogies.
 Ref CGWOOOI DateIMonth of issue: Maintenance Manual No.CMI-K4111 ]
fRev.-3) October' 20Ci-' (Rc\'.-m
Pa 'C 4 002

3.0 INTERVAL OF PERIODICAL OVERHAUL

3.1 It would be necessary in view of heavily loaded intensive service to which

DMU coaches are subjected to in our metropolitan cities to interspersE! the
POH work of the DMU once in 18 months.

3.2 It would be worthwhile lifting these DMU coaches and put I)ack
immediately after thorough checking of brake rigging and brake gears
once in 9 months.

4.0 LIFTING THE BODY OFF THE BOGIES

4.1 Before lifting the coach body from the bogie, all electrical connections,
earth connections, traction motor ventilation bellows and hand
brake/parking brake connections must be disconnected. The centre pivot
cotter pin in the TC and the securing collar in the DPC bogies rnus,t be
removed. All the pneumatic connection between bogie & under frame
should also be disconnected.

4.2 The coach body can be lifted off the bogies by one of the fOllowing
methods:

.1) Two overhead electric cranes of 40t capacity (min.) each with
suitably designed lifting tackles.

.2) Four electrical/hydraulic lifting jacks simultaneously operated by

one control switch.

4,3 The coach body should be Iiftedllowered uniformly without jerks and
should remain horizontal during the operation.

4.4 Lifting of coach from one end is strictly prohibited as the centre pivot,
bogie bolster and dashpot guides are likely to suffer damage ana dents
may OCcur on body panel near the body bolster.

4,5 The coach should not be lifted from any other point except the lifting pads
as shown in RDSO drawing No. SK-B8078 (Annexure-I).

5.0 WASHING OF BOGIE

5,1 After the bogies are run out, the traction motors must be taken out as per
Electrical Manual No, MM/DC EMU. 003 of DPC bogie,

5.2 Remove all the oil from the side bearer oil bath.
 Ref: CGW 000 I Dale/Mollth of issuc: Maintcnancc Manual No.CMI-K401
(Rev.-) October' 2004 (Re,·.-O)
Page 5 of32

5.3 Wash the bogie with high pressure hot water jet to remove all dust, mud,
scales, grease and other muck without damaging the base primer coating.

5.4 After washing and drying, roll the bogies to dismantling line.

6.0 DISMANTLING OF DRIVING POWER CAR (DPC) BOGIES

6.1 Dismantling of air spring from lower spring beam (cradle) and bogie
bolster may be as following:

.1) Remove lateral & vertical shock absorber.

.2) Remove equalizing rod connection from both ends of lower spring
beam if provided

.3) Remove connection between arm of leveling valve & installation

lever.

.4) 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.

.5) lift bolster up to bogie frame to clear the spigot of air spring.

.6) Slide air spring from lower spring seat

6.2 .The bolster may be removed from the bogie frame after removing the air
spring.

6.3 Remove the duplex check valve from bolster and maintain as per clause
19.1(0) of CMI-9802 of maintenance instruction on air suspension for
EMU/DMU coaches.

6.4 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

7.0 DISMANTLING OF TRAILER BOGIE

7.1 After the bogies are run out, the anchor links should be disconnected.

7.2 Dismantling of air spring from lower spring beam (cradle) and bogie
bolster may be as per clause No. 6.2 above.

7.3 The bolster may be removed from the bogie frame after removing the air
spring.
 Rcf: CGW 0001 Datc!Month ofisSllC: Maintcnance Manual No.CMI-K401 ]
(Rcv -3) October' 2004 (Rev.-Q)
L_· -L_ _-'P.!"a....,e"6"o,,r.=-3,,2_ _-'-- _

7.4 Remove the duplex check valve from bolster and maintain as per claus"
19.1 (0) of CMI-9802 of maintenance instruction on air suspension for
EMUIDMU coaches.

7.5 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 th"
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

8.0 WASHING OF BOGIE COMPONENTS

8.1 Collect anchor links of TC bogie, brake rigging components and axle box
springs into respective bins/pallets and send to washing for thorough
cleaning.

8.2 Send the bogie frame, bolsters and lower spring planks to washing for
thorough cleaning and drying.

9.0 ATTENTION TO BOGIE COMPONENTS

9.1 Bogie Frame

.1) Bogie frame for OPC to ICF drg. No. OMU/OPC5-0-3-501 and for
TC to ICF drg. No. OMUfTC4-0-3-401 should be check"d
thoroughly after cleaning, for any cracks, particularly at plac"s
where cradle and the dashpot guide flanges are welded. Threads
on dashpot guides should be checked for damages. TI1e
squareness and alignment of the guides should be checked
thoroughly with the help of a alignment gauge. A coordinate
measuring machine, preferably CNC type, can do the checking
accurately. In the event of misalignment of dashpot guides or
damaged guides which require replacement, procedure described
in paras 9.1.2 & 9.1.3 may be adopted.

.2) The relevant axle guides should be cut using special goug'ng
nozzles (PO 18 or 19) to prevent undercutting of bogie frame. Axle
guides found bent/cracked should also be cut out and replaced.

.3) Weld the new axle guides with the help of axle guide fixture, if the
axle guides are damaged or worn. Check the alignment of new axle
guides with respect to other axle guides using master gauges and
straight edge. Any slight discrepancy in location can be rectified by
suitable local heating of the frame.
,. Ref: CGW 000 I DalcIMonlh of issue: Maintenance Manual No.CMI-K401
(Rcl'.-3) October' 2004 (Re"...()
PaRe 7 of 32

.4) Replace the anchor link brackets if they are worn or damaged. The
M12 threaded hole should be cleaned and checked and attended
10, as required.

.5) Bent, damaged, or worn brake hanger brackets should be replaced.

If the holes are not aligned/located as per drawing, replace the
( brackets. Use single piece design of brake hanger bracket for
renewal. Replace the bushes in the brake hanger brackets at every
POH .

.6) Replace the brake lever hanger brackets if the holes are
oblong/worn or damaged.

.7) Replace all the axle box housing crown bolt and screwing piece by
rubber stoppers.

9.2 Lower Spring Beam (Cradle)

.1) Inspect all welding joints of the lower spring beam (cradle) and
repair if required.

.2) Inspect air spring fixing holes of lower spring beam for elongation, if
elongated build them to dia 13 mm.

.3) Inspect the top surface of lower spring beam for corrosion, remove
the corrosion and paint with primer and black paint.

9.3 Bogie bolster

.1) Check the bolster for twist, crack, corrosion, etc. Repair or replace
the bolster as required.

.2) Replace the anchor link bracket by holding in boister repair fixture,
if found worn or damaged.

.3) Replace the center pivot silent block.

.4) Replace the center pivot sleeve if worn, damaged, or corroded .

.5) Replace the rubber-sealing cap of center pivot silent block.

.6) 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 POHIIOH.
 Ref: CGW 0001 DateIMonth of issue: Maintenance Manual No.CMI-K401
(Rev.-3) October' 2004 (Rc\!.-O)
Pa~e 8 of32
•
.7) Piping to air spring spigot hole may be checked for leakage
(general leak Test).

.8) New rubbing plates to be provided what so ever may be the

condition of old one.

9.4 Anchor Link

.1) Anchor links to ICF drg. No. T-0-7-607 should be replaced, if worn
or corroded. Repair the anchor link, if found cracked (normally at
weld joints) under magna flux testing, by re welding after gouging.

.2) Replace the silent block. The silent block (~90+0.0501+0.025)

should be force fit in the anchor link and silent block pin (~25··
0.012/-0.052) should be slide fit in the anchor link bracket
(~25+0025/+0) .

.3) Silent Blocks should meet ROSa Schedule of TechnicCiI

Requirements No. C-9406 (Rev. II).

9.5 Axle Box Guide

.1) Axle box guides to ICF drg. No. OHMUlOPC-0-1-001 for OPC and
WTAC3-0-1-303 for 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 shoek
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

.2) Lower spring seat shall be filled with 1.75 liters of any of the
following oils: -

lac Servoline-100
HPC Yantrol-100
BPC Bharat Univol-100

.3) In open line the level of oil when the vehicle is under tare condition
should be 55 to 60 mm minimum from the guide cap inner surface
and should be topped if the level is less then this. The level of oil
,. Ref: CGW 000 I DatelMonth of issue: Maintenance Manual No.CMJ-K401
(Rev.·]) October' 2004 (Rey.-O)
Pae.e <) of 32

can be checked by unscrewing the filiing cap and using dip stick as
shown in Appendix-T of this manuaL

.4) 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.

.5) Replace the upper rubber washer, lower rubber washer, rubber
packing ring, guide ring, dust shield, guide bush, dust shield spring,
and spring clip as a kit.

.6) Replace the lower spring seat if worn, cracked, or broken.

.7) Common defects found in axle guide assembly during POH and
their reasons and remedies are given in Annexure 3.1 of Chapter 3
of Maintenance Manual of BG coaches of ICF design (2002) issued
by IRCAMTECH Gwalior.

9.6 PAINTING AFTER REPAIRS

.1) The locations where the repairs have been carried out should be
cleaned to bare metal and painted with two coats of primer to IS:
2074 to a minimum Dry Film Thickness (OFT) of 50 microns
foliowed by one coat of anti-<:orrosive Black Japan Type-B to IS-
341 to a OFT of 35 microns, after which entire bogie frame, bogie
bolster and anchor link are to be given one coat of Black Japan
Type-B to IS-341 to a minimum OFT of 35 microns. Dry film
thickness (OFT) may be checked with the help of Elcometer.

10.0 ROLLING GEAR

10.1 Wheel

.1) The OPC coaches are provided with composite design of wheels
consisting of rolied steel wheel centers with renewable tyres to IRS
Specification R-15/95. The tyres of OPC 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 to IRS specification R-19/93 pt-II (Rev.2).

.2) Tyre Profile

i) The new/re-turned tyre profile shali be as per ROSa drawing

No. SK-91146 (Annexure-II).
Ref: CGW 0001 Date/Month of issue: Maintenance Manual No.CMI-K401
(Rc\'.~3) October' 2004 (Re"·....{)
Pal!e 100f32

ii) The condemning limits for the flange wear, root wear, deep
flange, sharp flange, hollow tread wear and flat surface on
tyre shall be as per the condemning gauge shown in plate 45
of IRCA Part IV.

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

.3) Wheel Diameter

New Limitdia. Last Shop Issue Size

DPC 952mm 877 mm 885mm
TC 915 mm 813 mm 837 mm

.4) Permissible Variation on Wheel Tread Diameter

i) The permissible variation in tread diameter of wheels at th"

time of tyre turning or wheel replacement are as follows:

.1 Wheels of the same axle 0.5mm

.2 Wheels of the same bonie 5.0mm
3 Wheels between two bogies 13.0 mm
under the same coach

ii) No separate service limits are specified as the above figurE's

have been fixed to allow for the differential wear likely to
develop between successive tyre turnings / wheel changin'l
It is, therefore, not necessary to withdraw DMU stock from
service specifically for restoring the differential betwe"n
wheel diameters to be within the prescribed limits.

.5) The wheel should be inspected for rejectable defects in accordance

with RDSO's instructions No. CMI-K003.

10.2 Axles

.1) 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 a>:le.
For TC and DPC bogie, axles are to IRS Specification R-16/95 and
R-43/92 respectively.

.2) 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 as per
the code of procedure given in Annexure 10.1 of Chapter 10 of
Maintenance Manual of BG coaches of ICF design (2002) issued
 Ref: CGW 000 I Dale/Month of issue: Maintenance Manual NO.CMI·K4Ut
(Rev.-3) October' 2004 (Re\'.-o)
Pa~e II oDZ

by IRCAMTECH Gwalior. Axles found flawed, pitted or with under

size journals should be replaced.

10.3 Maintenance of Wheel and Axle

1) For maintenance of wheel and axle, clause 1002 to 1003c of

( Chapter 10 of Maintenance Manual of BG coaches of ICF design
(2002) issued by IRCAMTECH Gwalior, may be followed.

11.0 ROLLER BEARINGS

11.1 OPC Bogies
.1) These bogies are filted with direct mounted, double row, self-
aligning spherical roller bearings to ICF drg. No. EMU/M-0-2-001.
11.2 TC Bogies

.1) TC bogies of OMU stock are filted with direct mounted double row,
self-aligning spherical roller bearing to ICF drg. No. WTAC3-0-2-
304.

11.3 Maintenance of Roller Bearing

.1) For maintenance of roller bearing, clause 1005 to 1008 and 1009b
of Chapter 10 of Maintenance Manual of BG Mainline coaches of
ICF design (2002) issued by IRCAMTECH Gwalior, may be taken
as guidance.

12 AXLE BOX SPRINGS

12.1 Axle box springs are of helical type manufactured from centreless ground
chrome vanadium, silica 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
design requirements.

12.2 All springs shall be grouped in three categories and used on bogies as per
instructions detailed in ROSa Technical Pamphlet NO.C-8419 (Rev 1) At
present C-8419 is under revision.

12.3 Clean the spring thoroughly, remove any oil, grease, etc. by putting them
in a Bosch cleaning tank. After that carry out visual inspection of the
spring coil by coil. Carry out magna flux test to detect cracks. Springs
having cracks, dents or hilting marks should be rejected and scrapped.
Ref: caw 000 J Dale/Month of issue: Mainlcllancc M:mual No.CMJ~K.J.OJ
(Rev.-3) October' 2004 (Rc\'.-6)
Page 120f32

Records should be maintained of rejected springs with details of defects

noticed.

12.4 Each spring should be subjected to incremental load and load should be
maintained for a period of 2 minutes, after which the corresponding height
of spring under load is determined "

I,
12.5 Each spring may be tested for deflection/loads indicated in drawing No.
EMUIM-0-1-024 for OPC and WTAC-0-1-202 for TC and the spring
characteristics plotted. The spring should be replaced if its characteristics
are not within specified limits.

12.6 After load deflection test, the acceptabte springs shoutd be given one coat
of Red Oxide Zinc Chromate primer to 15:2074 to a minimum OFT of tiO
microns. A coat of Black Japan Type-B to 15:341 to a minimum OFT to:35
microns should follow the coat to have better abrasion resistance and
corrosion resistance. Then the springs have to be painted with 50 rnm
wide vertical stripes at three locations, equispaced on the circumference
using different colours of paints to IS: 8662 as given below:

Type Free Test Accepted Groups as per loaded spring

of height load height height'
coach (mm) (kgf) under test A B C
load (mm)
Yellow Oxford Green
Blue
OPC 284 3000 232-246 232-236 237-241 242-246
TC 375 2800 264-282 264-269 270-275 276-282

• The above data likely to change as and when C-8419 is revised.

12.7 All the springs should be grouped in three groups as shown above,
depending upon their deflection under test load. For pairing, springs
should be selected from the same group for each coach Height under test
load should be painted on all springs to enable selection of springs.

13.0 AIR SPRING

13.1 Construction details, characteristics and maintenance procedure of air

spring have been indicated in Maintenance Instruction of Air Sprin9 No.
CMI-9802 (Rev.1) issued by ROSO. The CMI-9802 should be followed for
detailed instructions on Air suspension maintenance.
 Ref: CGW 000 I DateIMonth of issue: Maintenance Manual No.CMI-K401
(Rev.-3) October' 2004 (Rev.-o)
Page 13 of32

14.0 Air Drier

14.1 Air drier shall be maintained in alternate POH as per the maintenance
instructions of the supplier including renewal of all rubber parts,
precoalescer kit and final filter kit.
r
I
14.2 Maintenance schedule for air drier shall generally be as per Appendix-'O'
of this manual.

15.0 HYDRAULIC SHOCK ABSORBERS

lS.l The hydraulic shock absorbers to ICF drg. No. OMUlOPCS-O-S-S03 in

vertical and OC/EMUM/ASR-D-S-DOS in lateral direction are fitted to damp
the oscillation. These shock absorbers normally give trouble-free service
and require no attention in between POHs.

lS.2 However shock absorbers, which are found either leaking or physically
damaged, should be replaced. As the resistance of these shock absorbers
is likely to deteriorate in service, it is necessary to attend to them as per
instructions given in the following Para.

lS.3 Periodicity of overhaul

i) Schedule overhaul: Shock absorbers should be given a schedule

overhaul as under:

a) When their capacities vary beyond ±20% of their specified

values, or
b) After 4 lakh kilometers or alternate POH, whichever is earlier.

ii) 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.

lS.4 Testing

i) The shock absorber is tested on the special purpose machine

which can measure its capacity in both tension and compression by
developing the resisting force at a velocity of 10 em/sec. The
testing machine shall generally be as per Appendix-'E' of this
manual. The length of the shock absorber and its stroke should be
within the limits specified in the table below:

"
Ref: CGW 0001 Date/Month of issue: Maintenance Manual No.CMl.K4(i~
(Rev.-J) October' 2004
Pape 14 of32
(Re,'...() --.--J
Vertical Length (mm) Nominal Variation from
and stroke nominal
Lateral Comoressed Nominal Extended (mm) Minlmm\ Maxlmm)
shock 315 365 415 100 -50 50
absorber

ii) The shock absorber must be tested at every POH and r"used if
overhauling is not due and the capacity is within ±20%. A register
should be maintained in the shock absorber section wherein the
test results of each shock absorber should be recorded before the
shock absorber is certified fit for use on coaches.
iii) After the testing and certification, the protection cover of t~,e shock
absorber should be pressed in to position on the piston rod disc
and spot welded at six points around the periphery.

Iv) The shock absorber should then be extended on the mounting

fixture and painted. When the paint dries, it should be compressed
and then removed from the fixture.

v) The date of testing, the date of overhauling and the name of the
shop where overhauled should invariably be stamped on the name
plate of the shock absorber before it is sent for fitment

15.5 Shock absorber to be maintained as per technical pamphlet No. C-7901 &
C-<l803 for maintenance and repair of Gabriel make and Esoorts make
respectively.

16.0 RUBBING PLATE IN OPC BOGIE

16.1 Nylon rubbing plate to ICF drg. No. EMU/M-0-5-017 I Manganese steel
rubbing pad complete to ICF drg. No. ICF/SK-Q-5-166 has be'en fitted to
the bolster, which serves as cushion between the bolster and bogie frame.
Initial clearance of 1mm on each side has been provided b'etween the
nylon I manganese steel rubbing plate and bogie frame liner (steel I
manganese steel). During POH, this clearance must be maintained.
During service. this clearance should not exceed 3mm on eac.h side. Any
higher clearance may cause excessive longitUdinal oscillations and there
by reduce riding comfort.

17.0 BOGIE BRAKE GEAR

17.1 Repair or replace the worn, damaged, corroded bogie brake levers.
Replace the bushes in the bogie brake levers. Nylon 66 brake gear
bushes (as a set) to RDSO drawing No.SK-81039 (Annexure-III) should
be fitted in brake gear

.,
 Rcf: CGW 000 I Date/Monlh of issuc: Maintcnance Manual No.CMI-K40t
(Rc".-3) October' 2004 (Rc\'.-O)
Papc 150f32

17.2 Repair or replace the corroded, cracked, or worn brake beams.

17.3 Repair or replace the corroded, dented, damaged brake head shoes.
Replace the bushes, adjuster, weak spring of brake head etc. in all the
serviceable brake head/shoe.

r 17.4 Replace the worn and damaged brake gear pins with new ground finished
and chromium-plated pins. 'Z' lever pin shall be to RDSO drawing No. SK-
98127 (Annexure-IV).

17.5 Replace the brake blocks if worn out to thickness of 16 mm or below.

17.6 Replacement of brake shoe key during POH is advisable.

17.7 All the brake gear components should be given one coat of red oxide
primer and one coat of anti-corrosion Black Japan Type-B to IS-341.

18,0 CENTRE PIVOT

18.1 Clean and examine the center pivot for bend, wear, cracks. Cracks shall
be detected by doing chalk testing or magnaflux dye penetrant test. If the
center pivot is found worn beyond repair or cracked, it should be replaced.
Check for loose or missing mounting bolts. Tighten and lock the bolts with
locking plate.

19,0 SIDE BEARERS

19.1 Side bearers consist of a hard wearing ground steel plate immersed in an
oil bath with a floating bronze wearing piece, which has a self aligning
spherical top surface on which the body rests and transmits the vertical
load. The oil well is provided with a cover to prevent ingress of dust.

19.2 The hard ground plate and the spherical bronze-wearing piece are likely to
wear in service.

19.3 Ensure that there is no leakage of oil from the side bearer oil-bath welding
portion. Replace the hard ground plate in side bearer, if worn more than
1.0 mm in thickness or ridges formed on the plate. Replace the bronze-
wearing piece for side bearer, if worn more than 1.5 mm in thickness.
Sharp edges on wearing piece should be rounded off before re-use.
Ensure that the dust seal cover sits effectively all round without any gap
on the oil-bath and the sleeves slide freely on the guide to ward off dust
and moisture coming in contact with the oil. Clean refilling passages and
deficient or damaged oil refilling caps and pipes should be replaced. The
oil filling plugs should be well secured by chain to prevent it from dropping.

"
Ref: CGW 000 1 DatclMonth of issue: Mainlenance Manual No.C~
(Rc\'.-J) October' 2004 (Rel·.-O) ~
Page 160f32

19.4 The oil well wall is welded on to bolster. Spot checks have indicated that
oil leaks out of the well due to porous welding and the vehicles continue to
be in service without oil. Absence of oil apart from causing excessive
wear, leads to undue constraint for bogie rotation on curves and produces
screeching noise. It is necessary that porous welds are gouged and re-
welded, and the oil well is filled with the requisite quantity of oil. -,
I
19.5 For filling up oil in side bearer without lifting the coach, oil filling nipples
have been provided on the oil well.

19.6 Any of the following oils can be used for the side bearers and the quantity
required per side bearer is 2.5 liters:

IDe Servoline-100
HPC Yantrol-100
BPC Bharat Univol-100

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

19.8 If the side bearers are not properly maintained, grating nois" is likely to
cause inconvenience to passengers. It is, therefore, advised that following
precautions should be taken during POH in shops:

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

19.10 The oil and the sliding surfaces should be free from dust and other
contamination.

19.11 The mating surface of the convex bronze bearing piece and the concave
surface of the guide, and the wearing surface of the plate should be
smooth and properly bedded together.

19.12 When the oil is contaminated, it should be removed and tl1e housing
thoroughly cleaned and 2.5 Iitres of fresh approved brand of oil should be
filled in.

19.13 The bronze bearing piece shall be provided with 1mm relief over the
periphery and the sharp edges of the oil grooves shall be rounded off.
 ,. Rer: CGW O(){> > Dale/Month of issue: Maintenancc Manual No.CMI-K401
(Rc".-3) October' 2004 (Rcv.-O)
Page 17 of32

20.0 ACTION TO BE TAKEN BEFORE RE-ASSEMBLING THE BOGIE

20.1 After attending to the various components as detailed in clause 9 above,

the bogie may be re-assembled taking into consideration the following
aspects:

.1) The axle box springs of TC and OPC coaches selected for each
." coach should be of same groups of springs as detailed in C-8419
(Rev. 1).

.2) Upper and lower rubber washers on the axle box spring should not
be re-used .

.3) Mating surfaces of the convex wearing piece and the concave
surface of side bearer and the wearing surface of the wearing plate
should be smooth and properly bedded.

21.0 SEQUENCE OF BOGIE ASSEMBLY

21.1 Bogie assembly can be systematically carried out, if it is organized under

three workstations. A sub store in the bogie shop may be necessary to
ensure supply of proper components and subassemblies for bogie
assembly.

21.2 After the inspection, repair and alignment of axle guides and the bogie
frame, place the bogie frame in the normal position on assembly stands.

21.3 Assemble the brake gear components including brake bloclks on the bogie
frame with pins, washers and split cotters. Ensure that the cotters are split
minimum 90° and not slack in the pins. Ensure that the maximum radial
clearance between the pins and bushes is 1.5 mm.

21.4 Apply some lubricating oil on outer surface of guide bush of axle guide
arrangement.

21.5 Grease the anchor link silent block pins and anchor link brackets of TC
bogies with graphite grease.

21.6 The mounting of air spring on lower spring beam (cradle) and bolster
should be done as per following instruction:

.1) '0' ring provided on air spring spigot must be changed.

.2) Mount air spring on lower spring beam and match the holes of
bottom plate of air spring and holes of lower spring beam.

'.

t,
 Ref: CGW 000 I Date/Month of issue: Maintenance Manual No.CMI-K401 ]
(Rev.-3) October' 2004 (Rc\'.-O) •
Pa2e 180[32

.3) Tighl all 6 nUl-bolts with the help of M12 Alen key and M12 spanner.

.4) Place Ihe bolsler on air spring ensuring no damage 10 spigol of air spring.

.5) Mount vertical and lateral shock absorber.

.6) Connect all flexiblelfixed pipe connections of bogie.

.7) All the Ihreaded joinls of air spring be sealed with thread sealing lape to
avoid air leakage.

.8) The filler of leveling valve must be cleaned.

21.7 Replace the rubber-sealing cap on the center pivot silent block.

21.8 Select Ihe wheel sets such thaI the maximum varialion in tread diameter betwelln the
wheels on same axle as 0.5 mm, between two wheel selS in same bogie as 5 mm
and among Ihe four wheel sets in Ihe same coach as 13 mm. Select axle box
springs in same group of springs.

21.9 Assemble Ihe lower rubber washer, lower spring seat, compensating rin,l, hard
packing ring, selecled axle box spnngs, upper spring seals, upper rubber washer,
prolective tube, etc., as per the ICF drawing No. DHMU/DPC-0-1-001 for DPC
and WTAC3-0-1-303 for TC. Pu11.71ilers dashpot oil of approved brand in lower
spring seal.

21.10 For oblaining correcI CSCI buffer height, when the coach body is lowered on the
bogies, while assembling the bogie, hard rubber, UHMWPE or NFTC packing
ring of required Ihickness, depending on Ihe wheel diameter, should be provided
under the fianges of the lower spring seats. Packing rings of thickness as given in
Ihe ICF drawing No. DHMU/DPC-D-1-D01 for DPC and WTAC3-D-1-30:lfor TC
should be used. Compensating rings of surtable thickness as perabove suspension
diagram for relevant coach should be placed over the fiange of the lower spring
seal.

21.11 Lower the bogie frame wilh Ihe bolster assembly on the wheel sets thus prepared,
laking care 10 ensure thaI the rubber packing ring for dashpot guide dOElS not get
damaged while lowering the guide bushes on to Ihe lower spring s,eat The
maximum diametrical clearance between Ihe lower spring seat and guide bush
should not exceed 1.6 mm. The bogie should sil evenly on the four axle boxes.
 .• - Ref: caw 000 I DatcJMonth of issue: Maintenance Manual No.CMI-K40t
(Rev.-}) October' 2004 (Rey,-O)
Page 19 of32

21.12 The assembled bogie should be load tested on a bogie test stand where it
is loaded up to its normal working load and the height of bolster top
surface form rail level should be measured for comparison with pre-
determined dimension corresponding to correct coach buffer height.
Adjustment for getting correct buffer height should be made, if needed. If
-" the buffer height requires further adjustment, the load on axle box spring
should be released and compensating rings should be inserted below the
axle box spring ensuring that the bogie frame height is 686 ± 5 mm for TC
and 688 ± 5 mm for DPC to ICF drg. No. DMUfTC4-0-Q-401 and
DMU/DPC-Q-3-501 respectively.

21.13 Safety straps of the axle box wing lugs and bogie bolster should be
adjusted so as to ensure a minimum ciearance of 40 mm between the lugs
and bottom of safety straps.

21. 14 Axle box rubber bump stopper should be adjusted to obtain the required
clearance between the axle box crown and the bogie frame.

21.15 After testing and making adjustments for correct buffer height, dispatch
the bogie to Lifting shop for lowering the coach body.

22.0 SIDE BUFFER & CENTRE BUFFER COUPLER HEIGHT ADJUSTMENT

22.1 The side buffers are fitted on the leading and trailing DPC of the rake. Its
height from rail level should be maintained as 1105 +0/-15 mm.

22.2 Semi permanenVsemi automatic couplers have been fitted in between the
coaches whose height from rail level under tare condition should be
maintained as 1035 +0/-15 mm.

22.3 The center buffer height should be measured under tare condition with a
suitable gauge from top of the rail level on a reasonable level tangent
track. Before taking measurement, it should be ensured that the centre
buffer couplers are not dropping.

22.4 Reasons for centre buffer coupler height being lower than the permissible
limits:

.1) Wear of wheel tyres.

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

.3) Loss in free heights of primary springs.

22.5 Procedure for centre buffer coupler height adjustment in workshop:

:
Ref: CGw 000 I DatcIMonth of issue: Maintenance Manual No CMI-K401 _1
(Rc".-3) October' 2004 (Re'·...(l) __
Pa£c 20 of 32

.1) After POH and before assembling the bogie, measure the wheel diameters.

.2) Depending upon the wheel diameter, place packing ring of required
thickness under the flange of lower spring sheet.

23.0 BRAKES

23.1 Air Brake System

1) Originally the coaches were fitted with Bogie Mounted Air Brake System.

.2) Maintain air brake system as per chapter 4 (except para 409 & 413) of
Maintenance Manual of BG coaches of ICF design (2002) issued by
IRCAMTECH, Gwalior.

.3) Maintain brake cylinder as per chapter 6 of Maintenance Manual of BG

coaches of ICF design (2002) issued by IRCAMTECH, Gwalior.

4) Piston stroke for DPC and TC should be maintained as40mrn and 32 mm

respectively as shown in ROSa drawing No. SK-81057 (Annexure-V).

5) Maintain setting of pressure limiting valve at 1.6kgfcm2 and :>afely valve

at 1.8kg/cm2

23.2 EP Brake System

.1) Newly built coaches are equipped with self-lapping electro pneumatic
brakes. The brake system consists of electrically controllecl brakes for
normal service use with automatic direct air brakes (provided as 'stand
by') to be used if required. The automatic brake system also provides for
emergency application of the brakes initiated either by the driver or the
guard or by a break away.

.2) The EP brake equipment is to be maintained as perthe instructions given

in the Maintenance Manuals supplied by the makers of the equipment.

.3) Maintain AB hose, cut-off angle cock, dirt collector, reservoirs" Guard's
emergency brake valve, check valve and isolating cock as per Chapter-4,
clause No. 407,408,411,412,421 & 422 of Maintenance Manual of BG
coaches of ICF design (2002) issued by IRCAMTECH, Gwalior.

'.
 Ref: COW 0001 DatelMonth of issue: Maintenancc Manual No.CMI-K401
(Rev..) October' 2004 (Re,,·.-Q)
Page 21 002

.4) Testing of auxiliary reservoir shall be done as per chapter 4, clause

No. 411 d of Maintenance manual of BG coaches of ICF design
(2002) issued by IRCAMTECH,Gwalior.

5) Maintain setting of pressure limiting valve at 1.6 kg/sq.cm and

safety valve at1.8 kg/sq.cm.

.6) Piston stroke for DPC and TC should be maintained as 40 mm and

32 mm respectively as shown in RDSa drawing No. SK-81 057
(Annexure-VI).

.7) Brake cylinders shall be maintained as per chapter 6, clause 608

(except clause 608 c) of Maintenance Manual of BG Mainline
coaches of ICF design (2002) issued by IRCAMTECH Gwalior.

23.3 Parking Brake System

.1) Parking brake equipments shall be maintained as per the

instructions given in the Maintenance Manuais supplied by the
makers of the equipment.

24.0 LOWERING OF COACH BODY

24.1 Whenever the coach body is lowered on bogies, air vent screws on the TC
bogie frame and filling caps in the DPC bogie frames should be
unscrewed completely after cleaning the area around the vent hole
properly. This is done to release the air locks in the dashpots.

24.2 Place the wearing plate and wearing piece in side bearer oil-bath. Fill each
side bearer oil-bath with 2.5 liters of any of three approved brands of oils
as Servoline-100 of IOC, Yantrol-100 of HPC and Bharat univol-100 of
BPC

24.3 Apply graphite grease on Center pivot pin and lower the coach body on
the side bearer wearing pieces. Care should be exercised to make sure
that the side bearers are resting properly. Place the cotter in position in
Center pivot pin and secure it with a split pin. A bottom cover should be
fitted for covering the entire assembly to prevent dust ingress. Tighten the
air vent bolt with gasket to prevent spilling of dashpot oil.

24.4 Check the oil in the dashpots with the dip stick shown in Appendix 'F' and
if necessary top up the dashpots with the approved brand of dashpot oil to
bring the level to 60 mm from inner surface of guide cap.

.
 Rcf: caw oon I DatcIMonth of issuc: Maintenance Manual No.CMI-K<OI I
(Rc".-3) October' 2004 (Re,·.-Q)
Page 22 of32

24.5 Leakage test for air spring may be carried out as follows:

.1) Connect the hose-pipes on the underframe piping with the 1'9veling valves
of the bogies.

.2) Connect pressure gauges to the drain plug locations of 150 liter reservoir.

.3) Provide packing in the gap between bolster and bogie frame.

.4) Connect the 150 liter reservoir on the underframe to the compressed air
source of pressure 6 kg/sq. em .

.5) Allow air into the air spring to a value of 6 kg/sq. em in the pressure gauge
by adjusting the horizontal lever of the leveling valve and keep it in the
same position.

.6) Close the isolating cock connecting MR pipe with 150-liter reservoir.

.7) Test all pipe joints for leakages.

.8) Check the pressure gauge readings after one hour. The pressure drop
should be within 0.2 kg/sq.cm .

.9) Drain the air completely by dropping the horizontal lever.

.10) Remove the packings.

24.6 For proper leveling of coach body, installation lever adjustment may be carried out
as follows:

.1) Keep the coach on a level track.

.2) Connect the pressure gauges to the drain plug locations of "II 20 liter
reservoirs in the bogie.

.3) Adjust the length of all installation levers to 305 mm and connecl them to
the horizontal levers.

.4) Supply the compressed airto the system and start the adjustment on one
bogie

.5) Adjust the height of air spring to approx. 255 mm by gradually increasing
the length of the installation levers.

.,
 Ref: CGW 000 [ Datc/Month of issue: Maintenance Manual No.CMI-K401
(Rc\'.-3) October" 2004- (Rc\,,-O)
Pallc 23 of32

.6) Repeat the above procedure for the other side of the air spring of
the same bogie.

7) Make minor adjustments on both sides, so that the height of air

spring and pressure of air inside the air piping on both sides of the
.
'
bogie are nearly the same.

.8) If the difference in pressure of the air in the air springs of the same
bogie is more than setting pressure of the duplex check valve i.e.
1.5 bar, then the air will continuously escape from one air spring to
other through the duplex check valve and then to atmosphere.

.9) Tighten the installation lever lock nuts with the horizontal levers, so
that the setting will not be disturbed.

.10) Repeat the above procedure for the second bogie.

.11) Disconnect the pressure gauges and replace the drain plugs.

25.0 CENTER BUFFER COUPLER

25.1 Center buffer coupler shall be maintained as per the instructions given in
the Maintenance Manuals supplied by the makers of the equipment.

26.0 SIDE BUFFER

26.1 Side buffer shall be maintained as per clause 902b of Chapter 9 of

Maintenance Manual of BG coaches of ICF design (2002) issued by
IRCAMTECH Gwalior.

27.0 MUST CHANGE ITEMS

27.1 List of 'Must change items' are given in Appendix ·C'.

:
• Ref: CGW 0001 DateIMonth of issue: Maintenance Manual No.CMI-K40t
(Rev.-3) October' 2004 (Re,,'.-O)
Pa2.c 24 of 32

LIST OF APPENDIX

Appendix 'A' - List of 'Reference Drawings'

Appendix' B' - List of 'Reference Documents'

Appendix 'C' - List of 'Must change items'

Appendix '0' - Maintenance schedule of air drier

Appendix 'E' - Diagram of shock absorber testing machine

Appendix' F' - Diagram of dip stick

Appendix' G' - List of 'Annexure'

 Ref: COW 0001 D<JlclMoJllh of issue: Mainlcnancc Manual No,CMI-KJOl
(Rcv.-3) October' 2004 (Rc\,,·II)
Pal!.c 25 of 32

-" APPENDIX 'A'

LIST OF 'REFERENCE DRAWINGS'

S,No Title Drawing No.

1 BOQie General ArranQement OPC BOQiel OMU/OPC5-D-D-501
2 Boaie General Arranaement (Trailer Coach) OMUITC4-0-0-401
3 BOQie Frame ArranQement OPC BOQie) OMU/OPC5-0-3-501
4 BOQie Frame Trailer Bogie OMUITC4-0-3-401
5 Anchor links Trailer Coach T-0-7-607
6 Axle box Quide arranQement OPC) OHMU/OPC-D-1-D01
7 Axle box auide arranaement TC) WTAC3-0-1-303
8 Roller bearinQ arranQement (OPC) EMU/M-0-2-001
9 Roller bearing arrangement (TC) WTAC3-0-2-304
10 Vertical Shock Absorber OMU/OPC5-0-5-503
11 Lateral Shock Absorber OC/EMUMlASR-D-5-D05
12 Rubbing Plate in OPC Bogie EMU/M-D-5-017
13 Manaanese Rubbina Pad in OPC Boaie ICF/SK-0-5-166
14 Axle box sprinQ for TC WTAC-0-1-202
15 Axle box sorina for OPC EMU/M-0-1-D24
16 Silent bloc for anchor link T-D-7-601
17 Bracket for anchor link T-0-3-635
18 Center pivot pin T-0-6-602
 Ref: CGW DOO I DatcIMonlh of issue: Maintenance Manual No.CMI·K401
• (Rev.-3) October' 2004 (Rc\,,-O)
Pa 'C 26 of32

-- APPENDIX -B'

LIST OF -REFERENCE DOCUMENTS'

S.No Description
1 Maintenance Manual of BG coaches of ICF design (2002) issued by
IRCAMTECH Gwalior.
2 Maintenance Instruction No.CMI-9802 issued by RDSO.
3 Maintenance Instruction No. CMI-K003 issued by ROSO.
4 STR No.C-940S issued by ROSO.
5 IRS Spec.R-15/95 issued by ROSO.
S IRS Soec.R-19/93, ot-II (Rev.2) issued by ROSO.
1 IRCA, pi-IV
8 IRS Spec. R-1 S/95 issued by ROSO.
9 IRS SDec.R-43/92 issued bv ROSO.
10 STR No. C-8419 (Rev. 1) issued by ROSO
11 STR No.C-8l03 issued by ROSO.
12 STR No.C-8914 issued bv ROSO.
"

. - Ref: CGW 000 I

(Rev,-J)
DateIMonth of issue:
Oclober' 2004
Maintenance Manual No.CMI·K401
(Rc'·...()
Pal!c 27 of 32

-- APPENDIX 'C'

LIST OF 'MUST CHANGE ITEMS'

S.No Items
1 Lockino Plates
2 Rubber sealing ring of axle box front & rear cover
3 Rubber oackino rino
4 Guide rino
5 Guide bush
6 Circlio for dash Dot ouide bush (if used
7 Brake oear bushes of nylon66 (as a sell, RDSO Sk-81 039
8 Shoe adjuster assembly & M16 nut & bolt with split pin
9 All buib tyoe callers
10 Sealing washer for air vent screw
11 Rubber stoooer & crown bolt
12 All rubber item of air brake eQuioment
13 Center pivot locking plate
14 Bush for eoualizinQ stav
15 Silent block for anchor link
16 Dirt collector filters element

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MAINTENANCE
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>
Inspect Humidity Indicators (ref: trouble sheoting guide) :
Check the condition ot Fuse (replJce ff blo~m etf) ,...._.. . .: I
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Clean 'Double Seated Auto Drain Valve :."" ..,,",.
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'. ;IT;heck the condition of Oesiccanl(replace ~ contamin:~:d).. . I. o ,~ 1::7
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,.,.., Renew all Rubber Parts
Renew Precoaktscer kit
. . '1-·:-";'
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Complete Overhaul the Air Dryer (ref Mair:·i~eria.flce m~J'fual) .::-;. . + :;"::::f'
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~ (Rev.·3) Octorer' 2004 (Rc\'.-O)
, Pae:c 30 of 32

DIP STICK APPENDIX:F'

(DPe BOGIE) SHEET-! OF2

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Ul
,.,I~ \' I \ \
~
I~
~
~
SU !TRBLE MRRK
TO BE MROE ON
OIL Lf-VEL
RED LINE
,I,I \, "I'-.
THE DIP STICK
FOR PERMANENT
Ij;
CHECK. ' II \ ', DIP STICK
\ I 'I \
--rh
o
to ~ ---
'-4111.\...1_-"1-_ III /,

',",

~",
.,I TOP LINE
GUIDE CAP.J
k- 10
,

I,

NOTE,- TO CHECK OIL LEVEL, THE VENT SCREW SHOULD BE REHOVED

&. DIP STICK INSERTED THROUGH THE VEi~T HOLE TILL IT
,
TOUCHES
, THE GUIOE CRP.
• ,
,
, \
, 'I,------+',------------------------~
,
•
 Ref: CGW ooa I Date/Month of issue: Mainlcnancc Manual No.CMI-K40J
(Rev.-3) October' 2004 (Re\'.-O)
Pa e31 of32

DIP STICK APPENDIX-'F'

(TRAILER BOGIE) SHEET-20F2
25
,
.., ';-

i,
o
N
3.

,.
MATERIAL 15:2062
,
" 1- J .' CD
... .1'
(., .' :',.:~',f ':
.
"

", , . '(------_ ... - - "

,....
......:.;......
..'.
"- ,--'
.",.: "::1.' ,
,"'-,
. '. -, .-
._ ".:_ .........._... .'. JIf:
.'"
;

, '. {':. -,>,{.;" ~. . '" '-

... , " (\
, .,i ' .. 'Y"::":',~' '.'<
,', • 'I
'>?.;,.• . ~':: ..·.,A'/, ';,-,'., ~V
, ..
• • -f '
'" .
".
, -- .' . " .',' . "
.~
',i
:
.. : .' Sij>RING 'STEEL __.·,v .. :'-:~' ,,' " .'. \. ' ~ . .
-'I
. ~. '", ',: ,: ," ''-, :.~.. '..~·",2?:;S .. ·W"G.;'~:
~; ,. ~~-:./. ','..::.:' I:···· ,.,. .,. ':,': ). ,,' ,',., .~.. :.~ ~.
l' "".' ',' . "

.l
. . '~>..

5,1
, :1. , ':, .', .., '-.. . 'if
", .
....... .::',\'" .' ,., ..... ' ..."
" ',r:
',., , '",' '. I'. 'It:

c' "
.. >:.~~
~~
'. ,.' ,'.,. ..... .'.-:', '':\
......
" "
c,.,,." ....'..
:~ ... , '" , .y__. ;~
,,~'--.".
... '..
'.' -
, ,,' ,. <' : :-' "
',C _.". ," :.,
• ,-~. . ;"
'~.'
':"'"
1:1
o "
;:!i ',.
,•
,it.

.'
,i' .' >,
,
,
,
"t ' . '.': >.' ,•. " •

- i . SUIT/iSLE MARK TO
! BE MADE ON THE OIL LE.VEl
DIP STICK RED ll~E

• I FOR PERMANENT CHECK•

I GUIDE CM' TOP UNE

-J. k 10
i
NOTE:- iTO
I CHECK
_ Oil LEVEL, THE VENT . SCREW SHOULD BE REMOVED

; & DIP STICK INSERTED'THROUGH THE vmr HOLE TILL IT

:, ITOUCHES THE GUIDE GAP,

--
(

'. Ref: CGW 0001 DatcIMonth of issue: Maintenance Manual No.CMI-K401

(Rev.-3) October' 2004 (Re".-tl)
Pae.c 32 of 32

APPENDIX 'G'

LIST OF .ANNEXURE'

S,No RDSO Drawina No.

I SK-68078
II SK-91146
III SK·81 039
IV SK-98127
V SK-81 057
.~
, ,
, ' ..

,
.---
'~

' ... I '1·-'1

~~1~
":. ~~

_ £UnING PADS
I _ --_Ll--
-,
ON BODY
.~ -I1I - -----' - - - --J
. "'-
[ iI.I l..
! /./ -- ---- i
" --
i .
I
, ,._
r ,\
.~_
.i ro I
...1. ~- ---- --_..-. -==.
( +1 " /
=
~)
2 k; j
.
,
i

\\..'R VENT SCREWS iN BOGIE SIDE FRAME

,
I
. LIniNG PAD"::'

I I
SUPERSEDED BY:
SUPERSEDES:
j
I . SCALE P \-.,:::?-,. .,
.3
C y:t~ -- POSITION OF LIFTING
\

,.,;,....
/ D
T
M
v
.S EMU/l0/0~
ROU~
PADS ICF BOGIE
1) DSC!E&S DRAWN ON CAD . , 7/04 R.D.S.a.
ALT AUTH DESCRIPTiON
..
CKD. DATE B.e. (C) I
1 I
1
SKETCH - 68078
"\
. . --~--

:-~-~..:~ .. ~:~
J - '"

.'f
" "'",

~
.. ,
• , ~~ . ",
• " '"
-~ ,if-:\ "<
I (91,32B.9) PROCEDURE OF DRAWING:-"
iB 1 DRA'N A \jERTICt-'\L liNE x~y.
2 DRAW SE~.(1I-CIRCL[ OF 145R TANCEHT\AL
TeL:h[ x~y.
.3 DPI1.W !_'~-jE 1:2.5 ~,llJ'JGENTiALLY TO :4.5R

(65 5,10J_3:'

o \
t-
;1
"~

fl.
SEM!-CIF\'CLt
DF~AW ,A, HOR1ZONTAL LINE ,b.,T 28.Sw;m
cROM THE TOP OF THE FLANGE ACJD

'J
"/ LOCATE PC 'A: AT 63.5mrn FROM THE
L1~!E X·-Y.
;;a .1;;\
0 5. ERmA Pl. ,~ LOCATE CENTRE 'B' OF ARC
OF 330R ON A VERTIC.~L LINE AT 91 mm
• i I
',~
~
~~~,,~)
i: / ".JJ ". I '0
0 FROM x- 't'.
6, DRAW fo.,RC ':JF j30R q<C\A. C::'NTRE '8'
",en
c ""
,-'
.',
I'
.,
I,
'v- I 1
"--...
0-- /
0'
\ \)
IV)
Q--
- 1 IN 20 7 LOCATE CDJTF~L ':;' Q~< "/E~Ti(~AL LiNE
0)

'" -rr~J0'4 .~~/'Y I AT A HOR.ZOf\J'"A~_ ::)!ST/·J'!C~ elF" 65.5rnm

FROM THE LiNE X-Y S.)CH lHAT ac=
, -A I, 8.
(330-100) ie 230nlM,
DRA'N I-,-RC OF 100R ",ViTH CENTRE ,AS 'c'
,(C,O) - - - - - '-------
a DRAW ARC OF RADIUS 14rT,rn :A!'~GENTI!'.,­
I
LLY TO 100R ARC AND LINE 1:2.5
,
I
1-
635 ..
I
'
10, DRAW LINE 120 TANGENTI~,LLY TO 330R
~RC
73.7
------ ------------j 11. DR.A,W A, VERTICAL L1NI.~: AT A DISTANCE
, I 1 <:n n J~' "- OF 130mm FROlv1 THE F!JNGE END.
,x ," -----

I\~OTE: - [2JPt.RSt.DED BY ~---=r ~~~I

CO-ORDiN~,TES or- POINTS B & C ISUPERSEDES ! I

ARE 8/ISED ON NOvllNAL DIMENSION SCALE
OF 28.5rT'rr'.
I m I
iC
t.1
D GVRAMAN
WORN WHEEL
~ J-~'I R[,/'so-r' . ~L'--"R~"'N 1-/ 4+----------- PRO~-ILE
L (0/.3/94. ,e.G' <Y: h .... u, r'," I -J 94 u.s.!
CD cJiS i92 I CO-ORDINATES 1 n"o
R\. u.
SIOi =]! W '-k'E~r:H
OF A;;;CS SHOWN 3/92 2l. . U

IALTJAUTH
, ,IDE'3CRIPTIO~1 i. DATE B,G. (C1 ·
2H~" I~, ,-::1 1146
-
I'
I I '

I
., ... •
, ... ~
~
_.---, . . ~'
- - • •

c-+
45~82"11--I
-~
r- -<
NOTESH
I.
....
BRAKE GEAR BUSHES SHALL BE or NYLON-56 TO THE SCHEDULE "
DI--' or
REQUIRMENlS LAID 00....111 IN C-8l07 (TENTATIVE>.
2. THESE BUSHES ARE APPLICABLE TO BOGIE BRAKE AND UNDER-
FRAME RIGGING ONLY.
, 3. PINS USED Io'ITH NYLON-66 BUSHES SHALL BE AS PER
\ , +8 ~~
J
$KETCH-93186.
4, BUSH \JIII-\ 4\.275 +: G.n, S\-\I>,LL 1l'L USED IN LEVERS ANI!
BRAKERS VHICH HAVE HOLes or SIZE Dr 41.275 H7 DlA. [N
co LEVERS 8. ~RACKETS \,IjTH HOLES SIZE OF'" 42.0 H7 D1A, BUSH
0""
r "
G
TI 0 \,lITH 42 t:8: 5
D.O. TO BE USED,

\
I, L
.\ r.--- Ir
ITEM No I 106 I. L
ITEM No. 7
-I
ITEM REFERENCE DRAWINGS No. OFF
Nos. FOR STEEL BUSH(ICF) ALT. D d L I r -< PER COACH
~~.p5!
1 T-3-3-506 , 042+ 0 ,15
+0.35
041.275+ 0 . 15 ¢32~8t 16 ~8g 3 1X4S' S' 4

+0.35/ +0.35
2 T-3-1-613/ITEM-I e 042+ 0 . 15 041.275+ 0 ,15 032 +0.2 20 ~8g 3 1X4S' 5' 100
-0.1
+0.35/ +0.35
3 T-3-2-603 n iZl42+ 0. 15 041.275+0.15 ¢32 +0.2
-0.1
32 ~8g 5 1X4S' 5' 48
+0.35
4 T-3-2-606 9 052 +0.15 ¢42+ D.2
-0.1 20 ~8g 3 1X4S' 5' 48
+0.35
5 T-3-2-608 f 052+ 0 . 15 042+ 0 . 2 32 ~gg 5 1X4S' 5' 8
-0.1
+0.35
6 T-3-3-S09 I 089+ 0 ,15 078+ 0 .2
-0.1
54 ~gg 5 1X4S' 5' 4
+0.35
7 T-3-1-603 I 070+0. 15 ¢57 +0.2 2ss~8:g 5 1X4S' 5' 32
-0.1

MATERIAL CHANGED FROM

ACETAL TO NYLDN-6E>. 4/94 SUPERSEDED BY
® CI-6/94
NOTE 8. TITLE REVISED,
SUPERSEDES:
t.1ATERIAL CHANGED FROM REFERENCE, SCALE ICF IBEML COACHES
C
NYLON 66 TO ACETAL 1'1 BRAKE GEAR BUSHES
(j) CD/14/92
AND SCHEDULE OF REQU
IREt.lENTS CfW-lGEO FROM 4/92 , S.N.SANDRIA
s.c~o FOR COACHES
C 6107 TO C-920:.'>. .S \lITH ALL COIL BOGIES
GROUP
® CD/14/90 REVISED &: REDRAWN 6/90 CHECK SHEET R.D.S.O
SKETCH 81039
ALT. AUTKY. OESCRIPTION DATI: NO. B.G [el
a .
,..
,.~~:, -= • - .
--J-.
• "- . .
~'
~ . ,

~ \ .
SUITABLE PI.AIN WASHt.K lSHALL BE PRO,,",OEO WHEN
CASTLE NUT IS USED TO AVOID SLACKNESS

5 4

1_
30'
"r- / ~
'!> \ ~t!.-?
-0
co
"N
:< / 1\/ -0
00 I-
r
4.:.- ~\-
"-

v
/ + I~ m
01
N N
v

II fA
~
0 a~ 0
., '';: o " \-\s;::, -~}

'- 1--/
-
0

--= 1~1'
~

~
I
1=1.
#
# 2RJ
5 32 11
'/
~
14
48 '8 80 48
50
194

U PIN TO BE CASE HARDENED TO A DEPTH OF 1,5mm TOTAL AND

GROUND TO 1'45 FlNI5H.
* GALVANISED TO 15:1573-86 TO SERVICE GRADE NO.2 OF TAB.2

5 SPRING WASHER FOR 1.124 1 I ~~3063- ~2 15:4072 75

Gr.3 •
4 CASTLE NUT _24 1
15:2232-67
4 TAB.,} •
3 SPUT PIN 1310~6J 1
IS:549 61
TAB,l •
2 spur PIN ¢5~56 1
15:549 61
TAB. 1 •
15:44.32 Be
1 PIN ~'94 1 Gr.13Ni13Cr3
~,'j\' WT.or
lIT_ DESCRIPTION &: DIMENSION REF.DRG. ONE(Kg) MTL.&:5PEC. REMARKS

SUPERESDED BY
SUPERSEDES
REFERENCE CALE P ICF IRCF COACHES
C
1:1 0 PIN
T
J.S FOR LEVER HANGER
CD 10/2000 fLOPPY NO.
R.D.S,a. GROUP
,
4 SID 28/KO SPECIfiCATION CORRECTED

AlT. ITEM AUTHY. DESCRIPTION DATE

sro/SKS -10
B.G (C) ki'l SKETCH-98127
• ." ~) ~, ~ .., -" t if
", ~j:
.k .. ~ ...- ~ ~r ... 7 5 - --

.,
-~ '. a..\
,~ .~'
l:
J05 "-'X. SUlCI< TN<[ UP.
ADJUSltR IS TO lIE RESET - '
1lEWIN000G rHE ADJUSTlNO rl'7ar. ..,:1.
_ 11J1~"'R;\\""'i1'
~ r------.:----.-!1!-
~ ~
en
lTDl-l 28\ I 17.s*O.s 4-AX1NQ

(SEE NO!'E-2) (WI.m 6E t •

o ..0
W
nnt-3
(SEE NOTE-2)
IN STRAI
UNt)

".~., ':i"ri::'~
L~ ~
-''--11 - ottN-,L<lll
(SEE: HO't'E-Z)

CO'C'"'
I
!~ Z----
'S: LEVERS IIIusr 8(
----- -- -------1-1--
"

I
i I-'
..,
ARRNlGED SUCH THAT
THE mosstIEAO IS

~ ~ :w""",WITH~ "~ i
~

I "'"' ""'" ""'"".

j 2 H.-AIR INLET PIPE CONNC"..........
i OtIE COMtECOON IS TO BE
OUWItl' SY PlUGQNC.
'WDE'

®
fE .- I J8S
"'"
1i0000ENT TO BE AU.OWEO FOR

,MAX. WORKING t.l0IIEN£t{f ~

;;1.

POSlTlON @ FOR ElotU WO'TO$l COA.Olo;

.
\I~ @ 2.1101-1 (womaMC STROKE-32mm) FOR SElF c:EPlER,t,llNC
MAIN UN[ COACHES
1lOl-2 (WORKfHC smOKE-6Omm) RJR ElG EWlJ COACH£S
(J) 1T'EM-3 (WORKINC STROl([-4Omm) FUR HCC EWIJ COACHES.

Ii
j~
(J) 1. TQ,.EP.I.MCE ON ~ $m(lK£ ~,

8.
II @
(/)

<ID -
- SS/11/04 NCllE-3 A llDl-3

SS/15/01 N(ITE-2 ADOED

CO/8!ll( DRAWING Rt'w'ISEll
tj 1«JlE-2 AIXIll 4/04
09/01
, 'f2 SK 81200 SUPERSEDED BY: INDIAN RAILWAY STANDARDS
I! 11'1 _ CD/4/21< '1*- 117.'_ 0W«;Gl Ttl
ASSaIBl.l' ORAWlHGS
117.500.0. 4/21< REFERENCE-
SUPERSEDES:
p
hi: STOC SE G ERA I G
MAIN UNE COACHES

a.
" \:V
Q> - CO/ll/SS t«1I! 2 Al)O(O.
QWlG(I) 10 1......
2/99
.

o ~AVA
203.2 mm x 95_25 mm (S"X 3 3/,oJ
!lRAKE CYUMDER WITH
I:
je
M\. _
\6'
CD -
to/71<><> lOURlN¢( +b!-HS""" 100m
,-g 01'1 DNENSION 6ll5.
CO/J~/9lI NOTt 1 AOOED 6: TTTL£ C!oUING£D l2/sslFlOPP'f
2/9Q
:s SlACK ADJUSTIR

.-.t B.G. R.~C~-Q """'"

No. :-

iN-r . fol AlJTMY, DESCfl/PTlON OAr:.] SKETCH-81057