Professional Documents
Culture Documents
LHB Monogram
LHB Monogram
MONOGRAPH
ON
FIAT BOGIE
(LHB COACHES)
November 2016
i
ii
FOREWORD
Pune, N. C. Sharda
Nov. 2016 Director
IRICEN, PUNE
iii
iv
PREFACE
With the view to educate field officials and increase their awareness,
it is proposed to issue series of Monographs for Rolling stock commonly
used in Coaching, Freight and Loco operations.
Pune S. K. Agarwal
Nov. 2016 Professor (Works)
v
MONOGRAPHS PUBLISHED
FORTHCOMING MONOGRAPHS
vi
CONTENTS
1 General Description 1
2 FIAT – Bogie 1
2.1 Main Technical Data of FIAT Bogie 3
2.2 Load Transmission 3
3 Bogie Frame 3
4 Body-Bogie Connection 4
5 Primary Suspension System 5
5.1 Control Arm 7
5.2 Primary Springs 8
5.3 Primary Dampers 9
6 Secondary Suspension System 9
6.1 Bolster Beam 11
6.2 Secondary Spring 12
6.3 Secondary Dampers 13
6.4 Anti Roll Bar 14
6.5 Traction Assembly 15
7. Axle Bearing 16
8. Wheel & Axle 18
8.1 Tyre Defects 19
8.2 Thermal Wheel Defects 24
8.3 Wheel Gauge 26
8.4 Bent Axle 26
8.5 Wheel Diameter on Tread 26
9. Bogie Brake Equipment 27
10. Coupler & Buffing Gears 29
11. Coach Under Frame 33
12 Checklist of Important Items for Derailment Investigation 34
vii
viii
1 General Description
LHB (Linke Hoffman Bush, Germany) coaches with FIAT (Fabric Italina de
Automobil Torino, Switzerland) bogies (Fig.1) are imported along with technology
transfer from M/s. ALSTOM, Germany during 2001. These coaches are superior
w.r.t. passenger comfort, safety, speed, corrosion, maintenance and aesthetics.
These coaches are slightly longer as compared to ICF design resulting into more
carrying capacity. Fiat Bogies are used in LHB coaches.
2 FIAT – Bogie
The FIAT bogie is two-axle type and two stage suspension bogie. The FIAT Bogie
frame if solid welded frame. The bogie assembly is shown in Fig. 2. Bogie is
designed for maximum operating speed of 160 km/h and has potential for operation
up to 200 km/h. Bogie is capable to permit the coach body to negotiate curve of
175 m radius at minimum speed potential of 40 km/h and 1 in 81/2 turn out in either
direction at 30 kmph.
The car body directly rests on the secondary stage helical springs, which rests on
Y shaped side beam. The bogie frame rests on primary stage helical spring which
is resting above the axle box crown. Axle guidance is provided by an articulated
control arm through a resilient bush. The tracking and braking force from axle to
bogie frame is transferred through articulated control arm system of primary
suspension.
1
2
Fig. 2 : FIAT bogie assembly
The bogie is provided with disc brake system, tapered roller bearing and permanent
earth connector to avoid passage of current through roller bearings. It is also
provided with wheel slip protection arrangements.
3 Bogie Frame
The bogie frame is a solid welded frame made by steel sheets and forged or cast
parts. The bogie frame consists of two side members of ‘Y’ shaped longitudinal
beam connected by two tubular cross steel beams members which also support
the brake units. The ‘Y’ shaped side members consist of structural steel and welding
is done to form box sections. The various supports which connect the different
bogie components are welded to the 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 the secondary suspension.
The bolster beam and the bogie frame are linked by four Safety cables with the
help of pins and washers.
3
3.1 Items to be checked
To be How to
Item Repercussion
checked for check
Bogie frame
Longitudinal beams, Cross
beams Cracks,
Brake supports, damper Damages Loss of
supports, traction centre at critical integrity and
Visually,
supports and anti roll bar locations functionality of
DTP
supports and for affected
loose component
Bogie bolster and its connections
subassembly and brackets
Safety cables
4 Body-Bogie Connection
A special type of body-bogie connection has been provided between coach body
and bolster (Fig. 3). This connection consists of disc spring, hemispherical ball,
swinging link pin, link pin, etc. This connection is capable to cater for the acceleration
value upto 0.25g in lateral and longitudinal direction. Beyond that value, a bracket
comes into action between bogie bolster and coach body.
5
1. Bogie frame 2. Rubber disk 3. Centering disk 4. Internal spring
5. External spring 6. Bump stop 7. Shim 8. Centering disk
9. Control arm lower part 10. Plate 11. Block 12. Rubber joint
13. Control arm 14. Damper.
7
5.1.1 Items to be Checked:
To be How to
Item Repercussion
checked for check
All fixings Loose, Missing Visually
Damages, Cracks, Slake connection will
Control arm parts Visually
Corrosion marks cause excessive play.
Ineffective in load
By calipers/
Diameter transmission.
Control arm bore Go No-go
( 230.5 mm)
gauge
Control arm silent Cracks ( 10 mm ), Worn out and rejected
block, rubber element Damages, Ageing, By calipers (RCF’s letter no. MD
in ball joint Detachments 44121, Dt: 13.08.08)
Visually, If two
or more axle Unserviceable
Looseness, missing- end bolts of
Bottom strap of screws, screws The wheel set must not
different pairs remain in service and to
control arm holding top are found be removed from the
loose or truck.
missing
Displaced, cracked, Excessively heated
Control arm Visually
heat/ burn marks bearing
Table contd...
12
Table contd from previous page
14
6.5 Traction Assembly
The traction assembly consists of traction frame and traction centre. The traction
centre transmits traction and braking forces between bogie frame and car body
located at the center of the bogie approximately in the plane of axle. The car body
is connected to the traction centre through bolster beam pin; while traction centre
is connected to cross beam. The longitudinal and lateral displacements of the
bolster beam are limited by four bump stops (two longitudinal and two laterals)
fitted on the traction frame.
6.5.1 Items to be Checked:
To be How to
Item Repercussion
checked for check
Cracks, damages Ineffective transmission
Visually, DPT
and corrosion. of longitudinal force.
Traction centre
lever and rods Free to move, not
blocked by any Visually Resistance on curve.
foreign objects
Excess play, Ineffective
All fixings- Rubber
Visually transmission of
bush, Elastic joint
Loose, Missing, longitudinal force.
Traction lever cracks, damages Play and vertical lift
Visually
bush and plates un-checked
Loose, Missing, Visually, calipers
Play and Lateral and
Bump Stops cracks, damages, Projected length
longitudinal jerks
Crushed 30 mm
15
6.6 Curve Rolls
At the two outer corners of the frame a roll is mounted which prevents excessive
rotation of the bogie. The roll is fixed by a pin, a washer and a safety split pin.
7. Axle Bearing
The axle bearing are self contained, preassembled, pre-lubricated taper roller
cartridge type bearings. The axle bearings on the bogie are fitted with sensors for
detecting speed (whose signal is elaborated by the anti slipping system) and a
current return device. The overhaul cycle is 1.2 million km.
16
Fig.14: Taper roller bearing, WSP system, earthing equipment.
If any roughness is
Any abnormal Rotate the bearing detected while rotating,
condition assembly the bearing is not fit to
be in service.
Table contd...
17
Table contd from previous page
Metal
identification tag Crimped to the brake disc Detail of bearing will not
with the mounting near the bearing be known.
date
Front cover of The wheel set must not
Loose/ missing Visually. If two or more axle
bearing and remain in service and to
screws, screws end bolts of different pairs
bottom strap be removed from the
holding top are found loose or missing
of control arm truck.
Displaced, Excessively heated
Control arm cracked, Visually bearing. Coach shall be
heatburn marks detached.
Breaks,
damages,
Visually
dislodged
All grounding /open / missing
cables, wheel Verify that the signal arrives
slip protection functioning of Bearing will behave
correctly to the diagnostic abnormally.
(WSP) WSP
equipment.
equipments,
Speed sensor Earthing ,
equipment for
wear spring WSP will behave
Visually
mechanism for abnormally.
self-regulation
To be
Item How to check Repercussion
checked for
Measured at a depth of Chances of bursting of point
Inspection of Thickness
13 mm from the tip of due to entering of flange
Thin Flange 22 mm the flange as shown in between Tongue rail and Stock
above figure rail.
20
Item To be
How to check Repercussion
checked for
Due to sharp flange the wheel
set can take two roads at
Radius of the tip
slightly gaping points.
of the flange
Checked at the tip of Chances of bursting the points
Inspection of reduced from
the flange as shown in due to entering of sharp flange
Thin Flange 14.5 mm (New)
the figure with a Tyre between tongue rail and stock
to less than
defect gauge. rail. Wheel flange bites the rail
5 mm
causing high frictional force
(Condemn)
and mounting of flange on the
rail.
21
8.1.4 Inspection of Hollow Tyre/False Flange
To be
Item How to check Repercussion
checked for
A false flange may split open
The projection
points while travelling in trailing
of the outer
direction as the flange may tend
Inspection of edge of the Place the tyre defect
to get wedged in between the
Hollow Tyre/ wheel tread guage as shown in the
tongue and the stock rail.
False Flange below the figure above.
Wheel with the false flange also
hollow tyre
may mount on nose crossing in
exeeds 5mm
facing direction.
22
To be
Item How to check Repercussion
checked for
Flatness of the
wheel should
not be more Chances of rail fracture due to
Place the tyre defect hammering of wheel on rail.
Inspection of than 50 mm on
guage as shown in the
Flat Tyre the May also cause thermal
figure above.
circumference cracks on wheel tyre.
of the wheel
tread.
Item To be
How to check Repercussion
checked for
Contact face of wheel flange
Radius of the
almost become vertical
flange at root
Place the tyre defect resulting in reduction of
Inspection of shall not be less
guage as shown in the effective flange depth.
Worn Root than 13 mm in
figure above. Excessive lateral play result in
service.
chances of mounting of flange
(New 16 mm)
over rail.
23
8.2 Thermal Wheel Defects
The following defects due to heating of wheel tyre, highly loaded plastic deformation
of tyre surface. The visual inspection of wheels shall be more focused to catch
these flaws. The following wheel conditions should be paid special attention during
the visual inspections of the wheel.
Shattered Rim
A wheel with a fracture on the tread or flange
must be withdrawn from service. This does not
include wheels with localized pitting or flaking
without presence of any other rejectable
condition.
Shattered rim
Spread Rim
If the rim widens out for a short instance on
the front face, an internal defect may be
present. Spreading of the rim is usually
accompanied by a flattening of the tread, which
may or may not have cracks or shelling on the
tread. Such wheels must be withdrawn from
service.
Shelled Tread
Shelling can be identified by pieces of metal
breaking out of the tread surface in several
places more or less continuously around the
rim. Shelling takes place when small pieces of
metal break out between the fine thermal
checks. These are generally associated with
small skid marks or "chain sliding." Such
wheels should be withdrawn from service and
sent to workshops for re- profiling. Railways
Shelled tread
24
are facing the problem of wheel shelling on LHB coaches. A shelled wheel requires
re-profiling to ensure that unsafe situations do not arise. For this purpose, following
shelling limits need to be followed.
Depth of shelling marks has reached to 1.5 mm.
Length of shelling marks has reached to 40 mm
Thermal Cracks
Thermal cracks appear on a wheel due to intense
heating of the wheel arising out of sever brake
binding. Such cracks occur on the tread and
generally progress across the tread in a
transverse & radial direction. Whenever such a
crack becomes visible on the outer face of the
rim or a tread crack has reached the outer edge
(non-gauge face) of the rim; the wheel should
be withdrawn from service. If a crack becomes Thermal cracks
visible on the outer flange face the wheel should
be withdrawn from service.
Heat checks
Thermal cracks are deeper and need to be
distinguished from fine superficial cracks visible
on the tread on or adjacent to the braking surface.
These are called heat checks, which are usually
denser than the thermal cracks. Heat checks are
caused on the tread due to heating and cooling
cycles undergone by the wheel during normal
braking. Such wheels do not need to be
withdrawn but should be carefully distinguished
from the reject able thermal cracks. Heat checks
Heat check
25
8.3 Wheel Gauge
There should be no variation in the values of wheel gauge -measured at four
points 90 degrees apart on a wheel set. However the actual value of the wheel
gauge can vary as per tolerances given in Table (IRCA Part III Para. 2.8.7)
Wheel gauge
Standard 1600 mm
Maximum 1602 mm
Minimum 1599 mm
If the wheel gauge is more than permissible limit, there exists a possibility of
a relatively newer wheel hitting the nose of crossing.
If the wheel gauge is less than minimum value, there is a possibility of wheel
hitting at the back of a tongue rail while passing through the switch and thus
damaging the tongue rail.
27
9.1. Items to be Checked
28
Fig 19: Axle mounted brake disc with caliper unit.
29
Main components of the coupler system are:
WEAR PLATE
COUPLER SHANK
30
Figure 21: Coupler assembly.
Item How to
To be checked for Repercussion
check
Integrity of CBC is
Loose / broken / compromised.
All bolt connections Visually
missing nuts and bolts Excessive play and
movement.
Free movement in Capacity to negotiate
horizontal and vertical Manually, vertical and horizontal
direction. curve is restricted.
Coupler head
Integrity of CBC is
Damage Visually
compromised
Measure Excessive slack – Not
Coupler assembly Free slack ½ in
manually fit to remain in service.
Table contd...
31
Table contd from previous page
Excessive wear on
Excessive distortion and
Vertical Height the interlocking
vertical height of
Condemning Limit Aligning Gauge surface of the wing
aligning wing and/or
Wing Pocket and Guard must pass pocket and/or guard
guard arm of the coupler
Arm Gauge arm– Not fit to remain
head
in service.
32
11. Coach Under Frame
The front part of under frame is made by joining head stock and body bolster. Two
side sills of sole bar are made of W section. Cross members of the frame are
made of folded channel sections. Floor is made of corrugated sheets. Corrugated
trough floor is plug welded from top with the cross members.
33
12 Checklist of Important Items for Derailment Investigation
Measurement
Item of
SN Equipment/ Permitted Range/Condition
Inspection
Method
• Should not have cracks or damages at
critical locations.
Bogie frame
and • Should not have loose connections.
1 connected Visually, DTP. • Height of the bogie frame top from rail
parts of level 925+0/-5 mm
bogie. • Maximum No of shims at bogie-body
connection 11.Nos. 1 metal shim=05 mm
Measurement
Item of
SN Equipment/ Permitted Range/Condition
Inspection
Method
• Ageing, Crack, Damage, Detachments
Rubber Visually, • Horizontal length of crack 30 mm
9
spring Calipers • Vertical length of crack 10 mm
• Crack depth 4 mm
All Rubber
and Rubber/
Metal Bonded
Components, • Loose, Missing, Cracks, damages,
12 Visually ageing, Detachments
Joints,
Bushes,
Seals,
Fasteners.
Measurement
Item of
SN Equipment/ Permitted Range/Condition
Inspection
Method
Corner rolls • Should not be missing, cracked or
14 Visually
and fittings damaged.
• Check temperature ( 80° C) and
compare with mate bearing on same axle
and bearings on same coach.
• Look for sign of grease leakage.
• Rotate the bearing assembly and feel for
Using non- any rough condition. Note down details
contact type of bearing from metal identification tag
infra-red with the mounting date crimped to the
thermometers. brake disc near the bearing. Examine
15 Bearing Visual front cover of bearing and bottom strap
With a dial of control arm for Loose/ missing screws,
indicator screws holding top. Two or more axle end
mounted on a bolts of different pairs is not allowed to
magnetic base. be loose or missing.
• Bearing mounted end play shall be within
the limit.
• Bench End Play (0.58 - 0.64 mm).
• Mounted End Play at installation (0.096
- 0.330 mm).
• Examine all cables for breakages,
Grounding damages, dislodged /open /missing
cables • Ensure functioning of WSP by verifying
(b)wheel slip the correct signal arrival to the diagnostic
protection equipment.
16 Visual
(WSP)
• Examine the earthing , equipment for
equipments
wear
(c) Speed
sensor • Examine the spring mechanism for self-
regulation
Measurement
Item of
SN Equipment/ Permitted Range/Condition
Inspection
Method
Measurement
Item of
SN Equipment/ Permitted Range/Condition
Inspection
Method
Table contd...
39
Table contd from previous page
Measurement
Item of
SN Equipment/ Permitted Range/Condition
Inspection
Method
Maximum-1602 mm
20 Wheel gauge Wheel gauge
Minimum- 1599 mm
Wheel Maximum-915 mm
Wheel tread
21 diameter
diameter Minimum-845 mm
gauge
Under frame, head stock, sole bar, gusset
plate, cross member, welds, and body
pillars.
Visually,
22 Coach body Loose and hanging parts and for fresh
DPT
damage, bent parts.
Damages, cracks in welds connecting yaw
damper bracket with sole bar
40
Check List of Important Items for Derailment Investigation Addition in
Monograph as per Railway board letter No.2018/Safety (A&R)/1/8
Dated 25.01.2018
Permitted
Measurement
S.N Item of Inspection Range/conditions to
Instrument/method
be observed.
Any indication of bent axle or
23 visual -
wheel having shifted on axle
Wheel and axle face
24 particulars in case of visual -
breakage of wheel/axle.
Axle face particulars. In case
of breakage of any
25(a) visual
axle/wheel. 1L-1R,2L-2R,3L-
3R, 4L-4R
Ultrasonic particulars on the
hub of the disc in case of
25(b) visual
breakage of any axle/wheel
1L-1R,2L-2R,3L-3R, 4L-4R
Stamping particulars on
wheel disc regarding
manufacture RA/RD in case
26 visual -
of breakage of any
axle/wheel. 1L-1R,2L-2R,3L-
3R, 4L-4R
Roller bearing (to be
recorded in case of any
27 visual -
abnormalities observed in
roller bearings /Axle box.
Condition of axle box, rear
27(a) visual -
and front covers/ End cap.
27(b) Condition of face cover plate. Visual -
Condition of bearing seal&
27(c) studs/ locking plate and visual -
bolts.
Condition of roller bearings
27(d) Visual -
and its components
28 Spring and spring gear
Condition of Air spring
28(a) Visual
including leakage in piping.
Deflected height of coil
Measuring tape/
28(b) spring after re-railing on level -
steel rule
un- canted track
41
Permitted
Measurement
S.N Item of Inspection Range/conditions to
Instrument/method
be observed.
Height of bogie bolster base
29 Measuring tape 930+6/-2mm
plate from Rail level
Details of broken parts giving
locations w.r.t point of mount
30 and derailment and whether visual
breakage considered due to
accident.
Any other defect in the
vehicle which may have
contributed to or caused the
31 visual
derailment such as condition
of the the coupler, draft gear
pocket, shearing plate etc.
List of damages to the coach
32 -
due to accident
Other observations
33 considered relevant -
derailment.
General informations
Permitted
Measurement
S.N Item of Inspection Range/conditions to
Instrument/method
be observed.
34 Date of incident & time As per actuals
Details of BPC along with the
name of the station, where
35 -
issued and Engineer C&W
who issued it
36 Vehicle No -
37 Type
38 Tare in tones -
39 Carrying capacity in tones -
40 POH Details -
Station
41 -
(from-to)
42 Position from the engine.
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42