FIAT BOGIE

S.Singh AP(C&W)

FIAT BOGIE
DESIGN FEATURES PROBLEM AREAS

DESIGN FEATURES

BOGIE FRAME
Y-FRAME -STEEL SHEETS (St52) TWO SIDE FRAMES CONNECTED BY TWO CROSS BEAMS -SUPPORT BRAKE UNITS. BOGIE FRAME ON THE PRIMARY SPRINGS AND SUPPORTS VEHICLE BODY THROUGH BOLSTER. BOLSTER-BOGIE FRAME THROUGH SECONDARY SUSPENSION.

MATERIALS USED:
STEEL CASTINGS (GS20Mn5V; DIN 17182): BRAKE SUPPORT PIN BRACKET SPRING CENTERING IN SECONDARY (1268840) BUMP STOP BRACKET LH/RH SGCI CASTINGS (IS:1865) AXLE BOX FRONT COVER CONTROL ARM TOP CONTROL ARM LOWER LEFT/RIGHT PRIMARY SPRING CENTERING LOWER AND UPPER

MATERIALS USED:
FORGINGS : TRACTION CENTER CENTER PIVOT PIN CONTROL ARM SUPPORT BKT LH/RH ANTI ROLL BAR FORK ANTI ROLL BAR BRACKET PLATE/TUBES (S355J2G3;EN10025) BOGIE FRAME BOGIE BOLSTER CROSS SECTION

IMPORTED BOGIE ITEMS:

FORGED WHEEL DISCS BRAKE SYSTEM PRIMARY SPRINGS SECONDARY SPRINGS DAMPERS RUBBER-METAL COMPONENTS (06 TYPES) MINER PAD ON PAC

Primary suspension
Four nos. each per bogie
Nested coil springs, primary vertical dampers, control arm, elastic joints-connecting the bearing on wheel-set to bogie frame.

Flexible guidance.

Primary suspension

Rubber Pad Outer Spring Spring Guide

Inner Spring Lower Spring Guide Bump Stop

WHEEL SET:

Two brake disks (4), diameter 640 mm and width 110 mm. Two wheel discs of dia 915 (New), 845 (worn).

Wheel Re-profiling and balancing:

DYNAMIC BALANCING 320 RPM LESS THAN/EQUAL TO 50 gm GLUE THE NEEDED WEIGHTS

Balancing machine

Weights

Axle bearings
CARTRIDGE TAPER ROLLER BEARING PRE-ASSEMBLED UNIT

BRAKE UNITS

AXLE MOUNTED DISC BRAKE INBUILT SLACK ADJUSTER IN BRAKE CYLINDERS CALIPER RATIO 1:2.17 FOR ALL COACHES EXCEPT POWER CAR, WHICH IS 1:2.48 35 mm BRAKE PADS
JURID 877/BECORIT984

BRAKE CALIPER UNIT

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 Bolster Lifted)

Bogie Bolster

Sec. Vertical Damper

Cross Section

Nested Secondary Spring Assembly Yaw Damper

(With Secondary Spring System Exploded) Bogie Bolster Miner Pad Spring Guide

Outer Spring

Inner Spring

Rubber Spring

(Bolster removed)
Lateral Damper Longitudinal Bump stop

Lateral Bump stop

(X-section lifted) Traction Lever Traction Center Anti Roll Assly

Curve Roll

ANTI-ROLL BAR:
A TORSION BAR WITH TWO FORKSBETWEEN BOGIE FRAME & BOLSTER, CONNECTED BY ROLL LINKS. RESISTS ROLLING MOTION OF COACH. AS PER UIC 515-1 TILTING CO-EFFICIENT <0.4.

ANTI-ROLL BAR:

Anti-roll Assly

BODY BOGIE CONNECTION

BOGIE BODY CONNECTION:

BUFFER HEIGHT ADJUSTMENT

Shims at body/bogie connection. Shims NOT added/removed in Primary and Secondary Suspension for wheel wear compensation or buffer height adjustment.

Principles of force transmission

Vertical forces: BODY-BOLSTER-MINER PAD-SEC. SUSPENSION-BOGIE FRAME-PRIMARY SPRINGS/BALL JOINT CONTROL ARM-AXLES.

Lateral forces:
BODY-BOLSTER-MINER PAD/SEC. SPRINGS/LATERAL BUMP STOP-BOGIE FRAME-BALL JOINT CONTROL ARM-AXLES.

Traction and braking forces:

BODY-TRACTION CENTRE-TRACTION LEVER/LONGITUDIN AL BUMP STOPBOGIE FRAMECONTROL ARMAXLES.

Traction Center

CURVE NEGOTIATION:
CONTROL ARM (SGCI TO IS:1865) CONNECTING AXLE BEARING AND SIDE FRAME THROUGH ELASTIC CONNECTION. FLEXIBLE GUIDANCE TO WHEEL-SET.

SUSPENSIONS OF VARIANTS
THE COMMON SUSPENSION GROUPS ARE:
GS,SCN,SLR CC,EC,CB,FAC/EOG,ACCW/EOG. ACCN/EOG,FAC/SG,ACCW/SG ACCN/SG,WLRRM SIDE 2. WLRRM SIDE 1. SLR UNDER- SLUNG.

Main Data:

CARDAN SHAFT ARRGT. FOR 25KW ALTERNATOR

CARDAN SHAFT ARRGT. FOR 25KW

CARDAN SHAFT ARRGT. FOR 25KW

SELF-GENERATING BOGIE WITH 4.5kW ALTERNATOR & V-BELT

SELF-GENERATING BOGIE WITH 4.5kW ALTERNATOR & V-BELT:

THANK YOU

PROBLEMS REPORTED IN FIAT BOGIE BY ZONAL RAILWAYS:

1. CONTROL ARM BKT WEAR

CONTROL ARM BRACKET (BOGIE) HALF ROUND MAX. RADIUS DEPTH (1267401 & ASSLY DRG NO. 1272174, 1267532) CONDEMNING SIZE TO BE SPECIFIED FOR DIA 85 AS PER DESIGN, NO MOVEMENT IS PERMITTED IN CONTROL ARM BRACKET FIXING WITH BOGIE FRAME IF PROPER TIGHTENING OF FASTENER IS ENSURED. HENCE NO WEAR LIMIT IS REQUIRED.

2 WEAR ON BOLL JOINT

CONTROL ARM 85 0.036/-0.090
CONDEMNING SIZE TO BE SPECIFIED AS PER DESIGN, NO MOVEMENT IS PERMITTED IN CONTROL ARM BRACKET FIXING WITH BOGIE FRAME IF PROPER TIGHTENING OF FASTENER IS ENSURED. HENCE NO WEAR LIMIT IS REQUIRED.

3. BOLSTER SPRING HEIGHT

517 mm SHOWN IN DRG NO. 1268801 & OTHER SEC SUSPENSION DRAWINGS. ACCEPTABLE RANGE TO BE GIVEN. FOR DIFFERENT TYPE OF COACHES DIM. TO BE MENTIONED ALONG WITH THEIR ACCEPTABLE RANGE. THIS IS FOR INFORMATION DURING MANUFACTURE AND APPLICABLE FOR ALL TYPES OF RAJDHANI COACHES. HENCE NEED NOT TO BE CHECKED DURING POH

4. HEIGHT OF BOGIE FRAME TOP FROM RAIL LEVEL:

DIMENSION 925+0/-5 SHOWN IN 1268801 WILL DECREASE WITH REDUCTION IN WHEEL DIA HEIGHT UNDER MIN. DIA OF WHEEL TO BE MENTIONED. DIMENSION IS SPECIFIED WITH NEW WHEEL DIA (MENTIONED IN CONCERNED DRAWING). DIMENSION CAN BE CALCULATED WITH ACTUAL SIZE OF WHEELS ON COACHES. CONDEMNING SIZE OF WHEEL IS *845 mm AND NEW WHEEL DIA IS *915 mm

5. HEIGHT OF PIN BRACKET MACHINED SURFACE FROM RAIL LEVEL: FROM RAIL LEVEL 930+6/-2 (1272056). HEIGHT UNDER MIN. DIA OF WHEEL TO BE MENTIONED. HEIGHT UNDER WORN WHEEL MAY BE CALCULATED AS PER ACTUAL WHEEL WEAR MEASURED.

6. CLEARANCE BETWEEN PRIMARY VERTICAL BUMP STOP GAP 13 mm FOR C. CAR & 8mm FOR GEN. CAR. DIM. NOT SPECIFIED FOR CN,CB,CW & FAC ADVISE SUITABLE MEASURING DEVICE AND PROCEDURE THIS DIMENSION IS FOR INFORMATION AND SHOWN IN CONCERNED PRIMARY SUSPENSION. DIMENSION 13MM IS APPLICABLE FOR CN, CB, CW & FAC COACHES AS SHOWN IN THEIR APPLICABLE PRIMARY SUSPENSIONS

7. CLEARANCE BETWEEN VERTICAL STOP & LUG OF CONTROL ARM

UPPER CLEARANCE = 45mm & LOWER CLEARANCE = 37.5mm. MAXIMUM AND MINIMUM LIMIT ARE NOT GIVEN THESE DIMENSIONS ARE FOR INFORMATION ONLY. HOWEVER, DURING SERVICE THESE DIMENSIONS MAY BE: 45mm MAY BE REDUCED MAXIMUM AS UNDER: FOR GEN. CAR BY 15mm & FOR OTHER COACHES BY 20mm DIMENSION 37.5mm WILL INCREASE BY SAME AMOUNT.

8. MAX. NO. OF SHIMS AT BODY BOGIE CONNECTION 55mm AS PER ALSTOM L. NO. CL 704 Dt.01.09.2001 (ANNEXURE II-b). HOW MANY SHIMS CAN BE ADDED AT ITS LAST SHOP ISSUE WE CAN ADD 5mm THICK SHIMS UPTO WHEEL WEAR OF 30mm ON RADIUS - BECAUSE WHEN WHEEL WEAR REACHES 35mm ON RADIUS, THE WHEEL WILL HAVE TO BE CONDEMNED (845mm DIA)

9. AXLE BOX TO BOGIE FRAME (PRIMARY SPRING HEIGHT)

DIMENSIONS GIVEN IN DRG NO. 1267411 & 1277142 (264+0/-4, 252+0/-4) DIM. NOT SPECIFIED FOR CN,CB,CW & FAC THESE DIMENSIONS ARE UNDER TEST LOADS OF INDIVIDUAL PRIMARY SPRINGS. NEED NOT TO BE SPECIFIED FOR DIFFERENT COACHES.

10. RAIL LEVEL TO CONTROL ARM BRACKET (VARIES DEPENDING ON WHEEL DIA.)

DIM 462.5+/-4 FOR 1272056 DIM 459+/-4 FOR 1277672 G. SIDE-1 DIM 464+/-4 FOR 1277673 G. SIDE 2 WITH REDUCTION IN WHEEL DIA, HEIGHT FROM RAIL LEVEL TO CONTROL ARM BKT. DECREASES. HEIGHT WITH MIN. WHEEL DIA TO BE MENTIONED THESE DIMENSION SHALL BE CALCULATED FOR OTHER COACHES AND SHALL BE ADVISED

11. CONDEMNING LIMIT TO BE SPECIFIED FOR CENTER PIVOT 100 :

TOLERANCE GRADE IS g8 ON 100 CENTER PIVOT PIN (-0.012/-0.066) AS PER EXISTING PRACTICE ON BG ICF BOGIES, TOLERANCE TO BE MAINTAINED ON EVERY IOH/POH. IF THE COMPONENT IS OUT OF TOLERANCE RANGE SAME TO BE REPLACED.

12. QUERY RELATED TO CHAPTER-6 PAGE 6/13 OF MAINTENANCE MANUAL:

QUERY: CONDEMNING LIMIT OF CENTRE PIVOT HOLE DIA OF 0.7 TO 1.2mm. SOLUTION: AIR GAP OF 0.7 TO 1.2mm IS SPECIFIED FOR SPEED SENSOR AND DOES NOT RELATE TO CENTER PIVOT PIN.

13. RUBBER SPRING FREE HEIGHT

CONDEMNATION LIMIT TO BE SPECIFIED 235mm FREE HEIGHT IS NOT REQUIRED TO BE CHECKED. HOWEVER, RUBBER SPRINGS SHOULD BE CHECKED FOR LOAD DEFLECTION CURVE GIVEN IN DRAWING.

14. ANTI ROLL BAR GAP BETWEEN ROLL LINK & FIXING BLOCK ANTI ROLL BAR GAP BETWEEN ROLL LINK BKT. AND FIXING BLOCK 1267422 NOT SPECIFIED. TO BE SPECIFIED. QUERY NOT CLEAR

CONTROL ARM CORROSION AND WEAR:

WEAR AND CORROSION ON MATING SURFACE WITH BEARING. TOLERANCE MAY BE ENSURED ON EVERY IOH/POH 230+ /- 210 . IF WEAR OCCURS, MAY BE REMACHINED BY GIVING A CUT OF 0.3 TO 0.5mm ON BOTTOM FACE. IF IT CAN NOT BE RECTIFIED BY ABOVE MACHINING SAME MAY BE REPLACED. M/S FIAT HAS RECOMMENDED TO USE LUBRICATING OIL BLASOL-135 DURING FITMENT TO MINIMISE WEAR ON CONTROL ARM AND AVOID CORROSION.

FAILURE OF DAMPER:

END FITTING DAMAGE, STONE HITTING, LEAKAGE RDSO HAS BEEN ASKED TO REVIEW THE SPECIFICATION OF END MOUNTING RUBBER VIDE MD23161 DTD. 08.08.07 WR HAS BEEN REQUESTED TO PROVIDE FURTHER DETAILS PERTAINING TO TYPE OF DAMAGE/FAILURE IN DAMPERS VIDE MD23161 DTD. 08.08.07