Bogie & Under Gears Overview
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Questions and Answers

What is the function of the bogie pin in the bogie frame?

  • To transmit tractive or brake force (correct)
  • To support the weight of the coach body
  • To reduce friction between axles
  • To stabilize the vehicle during turns

    • What type of brakes are mentioned as part of the bogie system?

  • Disc brakes
  • Tread brakes (correct)
  • Drum brakes
  • Hydraulic brakes

    • What is used for primary suspension in the bogie system?

  • Air bags
  • Hydraulic cylinders
  • Helical springs (correct)
  • Solid rubber mounts

    • Which components are responsible for damping the air springs at the ends of the bolster?

    <p>Shock absorbers</p> Signup and view all the answers

    What construction method is used for the bogies of motor coaches and trailer coaches?

    <p>All welded, light weight construction</p> Signup and view all the answers

    How far apart are the side bearers located in the trailer coaches?

    <p>1700 mm</p> Signup and view all the answers

    What provides support for the coach body in the bogie system?

    <p>Side bearers</p> Signup and view all the answers

    What is the primary function of hydraulic shock absorbers in the bogie bolster arrangement?

    <p>To work in parallel with bolster springs and absorb shock</p> Signup and view all the answers

    What should be done if the clearance between the nylon rubbing plate and the steel rubbing plate exceeds 3mm during service?

    <p>Address it to prevent excessive longitudinal oscillations</p> Signup and view all the answers

    What maintenance is required for equalising stays during a periodic overhaul?

    <p>The pins should be removed, cleaned, and oiled</p> Signup and view all the answers

    What is the consequence of using a damaged hydraulic shock absorber?

    <p>It may lead to increased wear on the bolster springs</p> Signup and view all the answers

    What is the significance of providing washers and split pins on the assembly of equalising stays?

    <p>To ensure that the pins do not fall out during service</p> Signup and view all the answers

    What function does the center pivot of the bogie serve?

    <p>Acts as a center of rotation</p> Signup and view all the answers

    How are the floating bolsters secured in the TC bogie?

    <p>By means of two anchor links</p> Signup and view all the answers

    What type of design is used for the wheels of the EMU coaches?

    <p>Composite design with rolled steel wheel centers</p> Signup and view all the answers

    Which sketch provides the new/re-turned tyre profile requirements?

    <p>ROSO Sketch No. 91146 atl. 2</p> Signup and view all the answers

    What is the condemning limit for the wheel diameter of the MC bogie?

    <p>877mm</p> Signup and view all the answers

    What additional feature secures the tyres on MC/HCC bogies compared to TC bogies?

    <p>Additional locking keys</p> Signup and view all the answers

    Which of the following statements about wheel gauge is true?

    <p>Wheel gauge should be within +2/-1 mm tolerance.</p> Signup and view all the answers

    Which measure is NOT accounted for in the tyre condemning limits?

    <p>New tyre installation</p> Signup and view all the answers

    Which of the following best describes the function of rubbing plates in MC & HCC bogies?

    <p>Transfer braking forces</p> Signup and view all the answers

    What should be checked when examining bolts for re-use?

    <p>Worn threads and straightness</p> Signup and view all the answers

    What material is used to manufacture axle box springs?

    <p>Centrefless ground chrome vanadium steel</p> Signup and view all the answers

    What is necessary to check for in axle box springs to ensure they are suitable for use?

    <p>Cracks and free height</p> Signup and view all the answers

    What happens if the lower spring seat is scored or damaged?

    <p>It should be reclaimed if worn more than 0.4 mm</p> Signup and view all the answers

    What component is used for close guidance of the wheel set in the axle box assembly?

    <p>Acetal/bronze bush</p> Signup and view all the answers

    What is the primary function of the rubber ring in the axle guide assemblies?

    <p>To seal the assembly and make it oil tight</p> Signup and view all the answers

    What happens to the lower spring seat if the oil quantity in the dashpot is inadequate?

    <p>It is likely to wear</p> Signup and view all the answers

    How are the axle box guides described in terms of construction?

    <p>Accurately machined hollow forgings welded to the bogie frame</p> Signup and view all the answers

    What is the role of the bolster in the suspension system?

    <p>It rests on air springs to support load</p> Signup and view all the answers

    What is one method of maintaining the damping fluid level in the dashpot?

    <p>Having holes on the bogie side frame for topping up</p> Signup and view all the answers

    What is the permissible variation in tread diameter for wheels of the same axle?

    <p>0.5mm</p> Signup and view all the answers

    What is the permissible diameter variation between two bogies under the same coach?

    <p>13.0mm</p> Signup and view all the answers

    What material specification is applicable for tyres?

    <p>IRS Specification R-15/95</p> Signup and view all the answers

    What type of bearings are fitted in MC & HCC bogies?

    <p>Double row, self-aligning roller bearings No. 22328 C/C3</p> Signup and view all the answers

    What maintenance procedure should be performed on axle boxes?

    <p>Thoroughly clean and check for cracks, particularly at cover holes.</p> Signup and view all the answers

    Which specification is applicable to axles for TC bogies?

    <p>IRS Specification R-16/95</p> Signup and view all the answers

    What is the main purpose of specifying permissible variations in wheel tread diameter?

    <p>To allow for differential wear between tyre turnings/wheel changes.</p> Signup and view all the answers

    What additional feature do axle boxes have for maintenance?

    <p>Light alloy front and back covers secured by four bolts.</p> Signup and view all the answers

    Which specification applies to axles for MC & HCC bogies?

    <p>IRS Specification R-43/92</p> Signup and view all the answers

    What type of roller bearings are found in TC bogies?

    <p>Self-aligning spherical roller bearings No. 22326 C/C3</p> Signup and view all the answers

    What is the method of construction used for the bogies of motor coaches, high carrying capacity coaches, and trailer coaches?

    <p>Welded construction</p> Signup and view all the answers

    Which component is responsible for providing primary suspension in the bogie system?

    <p>Helical springs</p> Signup and view all the answers

    How are the side bearers described in terms of their protection from the environment?

    <p>Immersed in oil baths</p> Signup and view all the answers

    What spacing is maintained between the side bearers in motor coaches and high carrying capacity coaches?

    <p>1200 mm</p> Signup and view all the answers

    What type of shock absorbers are used for damping the air springs in the bogie system?

    <p>Hydraulic shock absorbers</p> Signup and view all the answers

    What is the distance maintained between the side bearers in trailer coaches?

    <p>1700 mm</p> Signup and view all the answers

    What type of bearings are mounted inside the axle boxes of the bogies?

    <p>Self-aligning roller bearings</p> Signup and view all the answers

    What is the primary function of the side bearers in the bogie system?

    <p>To absorb vertical loads and provide lateral stability</p> Signup and view all the answers

    At what wear measurement should the hard ground plate of the side bearers be renewed?

    <p>1.5 mm</p> Signup and view all the answers

    Which of the following oils can be used for the side bearers?

    <p>Any appropriate oil</p> Signup and view all the answers

    What problem is likely to occur if sharp edges develop at the periphery of the bronze wearing pieces in side bearers?

    <p>Impairment of lubrication</p> Signup and view all the answers

    How is the centre pivot of the trailer coach designed in terms of load transmission?

    <p>It transmits only tractive and braking forces</p> Signup and view all the answers

    What is the main purpose of the nylon rubbing plate in the bogie system?

    <p>To provide cushioning between bolster and bogie frame</p> Signup and view all the answers

    What should be done when the vertical and horizontal shock absorbers begin to leak?

    <p>Replace the shock absorbers</p> Signup and view all the answers

    What is the consequence of not maintaining the initial clearance of 1mm on each side of the nylon rubbing plate during maintenance?

    <p>Increased risk of excessive longitudinal oscillations</p> Signup and view all the answers

    What is necessary to ensure the free movement of equalising stay pins during maintenance?

    <p>Grease the assembly after pin removal</p> Signup and view all the answers

    When should the maintenance of hydraulic shock absorbers be performed according to the provided guidelines?

    <p>As per the manufacturer's maintenance manual</p> Signup and view all the answers

    What is the function of equalising stays in the bogie system?

    <p>To prevent lateral thrust on bolster springs</p> Signup and view all the answers

    What aspect of hydraulic shock absorbers is likely to deteriorate over time?

    <p>The resistance of the shock absorber</p> Signup and view all the answers

    What should not exceed 3mm during service as per maintenance guidelines?

    <p>The clearance on each side of the nylon rubbing plate</p> Signup and view all the answers

    What component should be included with the equalising stays to prevent pin loss during service?

    <p>Washers and split pins</p> Signup and view all the answers

    Which statement is true regarding the maintenance of the nylon rubbing plate?

    <p>Steel packings of suitable thickness must be fitted during POH</p> Signup and view all the answers

    What is the maximum allowable wheel diameter for the MC bogie?

    <p>885mm</p> Signup and view all the answers

    Which component is responsible for transmitting draw and braking forces in the TC bogie’s floating bolster?

    <p>Anchor links</p> Signup and view all the answers

    What design feature is utilized to secure tyres in MC and HCC bogies that is not present in TC bogies?

    <p>Locking keys</p> Signup and view all the answers

    Beyond the bogie pivot’s function as a center of rotation, what specific role does it play in the system?

    <p>It transmits acceleration and retardation forces.</p> Signup and view all the answers

    What is the permissible tolerance for wheel gauge adjustment?

    <p>+2/-1 mm</p> Signup and view all the answers

    What specific tyre profile requirements should be followed for new or re-turned tyres?

    <p>As per standard sketch 91146 at all times.</p> Signup and view all the answers

    Which wear condition is NOT included in the condemning limits for wheels?

    <p>Surface roughness wear</p> Signup and view all the answers

    What is the minimum condemning limit for flange wear on MC bogies?

    <p>877mm</p> Signup and view all the answers

    Which axle design is specified for TC bogies?

    <p>Composite axle</p> Signup and view all the answers

    What is the permissible variation in tread diameter for wheels between two bogies under the same coach?

    <p>13.0 mm</p> Signup and view all the answers

    What material specification corresponds to the axles used in TC bogies?

    <p>IRS Specification R-16/95</p> Signup and view all the answers

    Which type of roller bearings are used in TC bogies?

    <p>Double row, self-aligning spherical bearings No. 22326 C/C3</p> Signup and view all the answers

    What is a key maintenance practice required for axle boxes?

    <p>Thoroughly clean and check for cracks</p> Signup and view all the answers

    For which bogie type is IRS Specification R-43/92 applicable?

    <p>HCC bogies</p> Signup and view all the answers

    What is the primary function of the roller bearings installed in MC & HCC bogies?

    <p>To allow rotating parts to operate smoothly</p> Signup and view all the answers

    How much variation in diameter is permissible for the wheels of the same axle?

    <p>0.5 mm</p> Signup and view all the answers

    Which part of the axle box housing is specifically mentioned for special attention during maintenance?

    <p>Holes of the covers</p> Signup and view all the answers

    What kind of bearings are designed as 'self-aligning' in the described bogies?

    <p>Double row roller bearings</p> Signup and view all the answers

    What is the maximum permissible variation in wheel tread diameter when changing tyres according to the guidelines?

    <p>5.0 mm for the same bogie</p> Signup and view all the answers

    Study Notes

    Bogie & Under Gears

    • Bogie Frame: A welded construction with two longitudinal girders, a crossbar, and two frame ends.
    • Tractive/Brake Force Transmission: Transmitted via a bogie pin from the bogie to the body.
    • Frame Ends: Used to house brake cylinders and brake rigging.
    • Tread Brakes: Directly affect vehicle wheels.
    • Lifting Supports: Four steel cables located between the body and bogie.
    • Primary Suspension: Uses helical springs working in parallel with dashpots.
    • Secondary Air Suspension: Provides buffer height, brake rigging, wheel axle, and hydraulic shock absorbers. Refer to CMI-K001 (2000), Amendment Slip No. 1 (2007), and CMI-9802 (2008) for details.
    • Lifting Support: Hydraulic shock absorbers are used for support function.

    Bogie Frame Assembly

    • Bogies (MC, HCC, TC): Motor coaches, high-carrying capacity coaches, and trailer coaches have all-welded, lightweight construction.
    • Axles: Feature self-aligning roller bearings, mounted inside cast steel axle boxes, with rigid guidance from telescopic dashpot and axle box guide assemblies.
    • Bolster (MC, HCC): Located between bogie transoms, transmits draw and braking forces through rubbing plates.
    • Bolster (TC): Floating bolster secured in longitudinal direction to bogie frame with two anchor links and silent block bushes.
    • Suspension: Uses helical springs and dashpots for primary suspension; air springs supported on a spring plank via swing links for support.
    • Weight Transfer: No weight is transferred through the bogie pivot; it acts as a center of rotation, transmitting acceleration and deceleration forces.

    Wheel and Axle

    • Wheel Design: EMU coaches have composite wheels with rolled steel centers and renewable tires.
    • Fastening: Different designs: TC bogies use glut rings, while MC/HCC bogies use glut rings and four locking keys for secure fastening.

    Tyre Profile

    • Profile Standard: Follows ROSO Sketch No. 91146.
    • Condemnation Limits: Defined for flange wear, root wear, deep flange, sharp flange, and hollow/flat tread wear (refer I.R.CA Part IV, plate 45).
    • Wheel Gauge: Must be within the tolerance of +2/-1 mm.
    • Wheel Dimensions: Provides specific dimensions for MC, TC, and HCC bogies (New, Condemning, and Last Shop Issue).

    Permissible Variation

    • Wheel Tread Diameter: Variations are allowed during wheel replacement, based on axle and bogie.

    Material Specifications

    • Tyres: Conform to IRS Specification R-15/95.
    • Axles: Follow IRS Specification R-16/95 (TC bogies) and R-43/92 (MC & HCC bogies).

    Roller Bearings

    • Types: MC and HCC bogies use No. 22328 C/C3 self-aligning roller bearings; TC bogies use No. 22326 C/C3 self-aligning roller bearings.

    Axle Box Housing

    • Material: Cast steel.
    • Covers: Light alloy front and back covers secured by bolts.
    • Maintenance: Regular cleaning and examination of cracks, worn threads, etc., for bolts and covers are required.

    Axle Box Springs

    • Type: Helical.
    • Material: Chrome vanadium, silica manganese steel.
    • Treatment: Shot-peened to improve fatigue life.
    • Maintenance: Checking for cracks and measuring free height is crucial.
    • Grouping: Springs are grouped into three categories based on RDSO Technical Pamphlet No. C-8419 (Rev 1).

    Lower Spring Seat

    • Wear: Minimal wear during service.
    • Repair: Repair/replacement if wear exceeds 0.4 mm or damage is present.

    Dashpots and Axle Guide Assemblies

    • Axle box guides: Machined hollow forgings welded to the bogie frame to ensure rigid guidance of the wheel sets.
    • Sealed: Sealed with rubber rings ensuring oil tightness.
    • Topping-up: Provides provision for topping-up oil (MC & HCC); holes are provided in trailer coaches for topping up.

    Bolster and Bolster Spring

    • Bolster Location: Rested on both ends of air springs.

    Hydraulic Shock Absorbers

    • Function: Work in parallel with bolster springs for smooth operation.
    • Maintenance: Regular checks and replacement if leaked or physically damaged.

    Rubbing Plate

    • Material: Nylon.
    • Function: Cushions between bolster and bogie frame.
    • Clearance: Maintenance of 1 mm clearance (each side) is required during POH (Periodic Overhaul).
    • Wear Limit: Wear shouldn't exceed 3 mm (each side) during service, else repair and fitting of steel packings are required.

    Equalising Stays

    • Function: Prevents lateral thrust on bolster springs.
    • Maintenance: Pins need regular cleaning and oiling to ensure smooth rotation.

    Centre Pivot

    • Mechanism: Used to transfer forces between the vehicle's body and bogie.
    • Wear: Bogie rotation results in wear on upper and lower bushes.
    • Types: Arrangements exist for MC & HCC bogie and Trailer bogies.
    • Cracks: Check for cracks at the weld points and rubber conditions on silent blocks.
    • Testing: Silent blocks must be duly tested.
    • Assembly: Ensure no forcing during assembly to avoid pre-loading condition.

    Hanger and Hanger Blocks

    • Cleaning: Thorough cleaning is necessary after dismantling.
    • Inspection: Examine for cracks and wear.

    Bogie Brake Gear

    • Clearance: Maximum permissible clearance between brake gear pins and bushes is 1 mm; any more indicates repair or replacement is necessary.
    • Brake Block Thickness: Brake blocks must be replaced when thinning down to 16 mm.
    • Maintenance: Regular maintenance to adjust slack in rigging, with adjusting palm pull rod featuring holes displaced to account for wear.

    Buffing & Draw Gear

    • Couplers: Semi-permanent/semi-automatic Schaku couplers used.
    • Maintenance: Adherence to manufacturer-supplied maintenance manuals.

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    Description

    Explore the intricacies of bogie and under gear systems in this quiz. Learn about various components, such as bogie frames, tractive forces, and suspension types. This knowledge is essential for understanding vehicle stability and performance.

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