Emu Bogies Details

EMU ICF BOGIE
EMU ICF BOGIE

SCHAKU COUPLER
3
PNEUMATIC COUPLERS (MR & BP)
4
ELECTRICAL JUMPERS COUPLERS
5
BRAKE CONTROLLER
6
MASTER CONTROLLER
7
AIR SUSPENSION
8
ADVANTAGE OF AIR SUSPENSION
Automatic control of vehicle floor height

Excellent ride comfort
Constant natural frequency from tare to full
load
Capable to sustain super dense crush load
Isolation of structure born noise
Improved reliability
9
MOTOR COACH BOGIE
10
SIDE VIEW OF MC BOGIE
11
TRAILER COACH BOGIE
12
TC BOGIE TOP VIEW
13
BOLSTER & SIDE BEARER VIEW
14
LOAD DISTRIBUTION
15
WHEELS
16
17
DASH POT
18
WHEEL MEASUREMENT
Measurement of wheel gauge: Distance between 2
wheel flanges on the same axle should be 1600mm
+2/-1 mm. This measurement should be taken at 3
locations apart.
Wheel diameter is measured by a gauge with least
count of 0.5mm.
Type of New Size Condemn
Wheel (mm) Size (mm)
MC 952 877
TC 952 857
HCC 952 865
19
MOTOR COACH
AXLE SPRING MOTOR COACH
AXLE SPRING MOTOR COACH
EMU WHEEL
BRIEF DESCRIPTION OF BOGIES
1. Bogies of motor coaches (MC), high carrying

capacity coaches (HCC) and trailer coaches (TC)
are of all welded, light weight construction (Figs.
1, 2 & 3).
2. The axles, with self aligning roller bearings
mounted inside cast steel axle boxes, are rigidly
guided by telescopic dash pot and axle box
guide assemblies.
3. Helical springs working in parallel with dashpots
are used for primary suspension.
4. Coach body is supported on two side bearers
located 1700 mm (TC) and 1200 mm (MC&HCC)
apart on a floating bogie bolster which in turn
rests on two pairs of helical springs supported
on a spring plank hung on swing links from bogie
frame.
5. The helical springs at each end of bolster are
damped by hydraulic shock absorbers Side
bearers consist of metal slides immersed in oil
baths well protected from dust ingress.
6. No weight is transferred through the bogie pivot,
which is located in the centre of the bolster.
7. The pivot acts merely as a centre of Rotation and
serves to transmit acceleration and retardation forces.
8. The floating bolster in TC bogie is secured in the
longitudinal direction to bogie frame by means of two
anchor links with silent block bushes, located
diagonally opposite to each other and transmit draw
and braking forces between bogie frame and coach
body through the centre pivot
9. The MC & HCC bogie bolster is located
between bogie transoms and transmits draw
and braking forces through rubbing plates
fixed at the bolster ends.
PARTS OF BOGIE
Bogie frame
Primary suspension
Secondary suspension
Brake Rigging
BOGIE FRAME
BOGIE FRAME TRIAILER COACH
BOGIE FRAME MOTOR COACH
733 mm
BOGIE FRAME MOTOR COACH
(g) represents location of axle. Box ,guides.
(X) represents location of bolster spring
suspension bracket.
Dimension a, b, c and d should all be equal to
7331 mm
WHEEL base AB Should be 2896 1 mm.
EF = 8002 mm=GH
EG = 21402 mm = FH
F G = 22853 mm = E H
(g) represents location of axle. Box ,guides.
(X) represents location of bolster spring
suspension bracket.
Dimension a, b, c and d should all be equal to
4931 mm
WHEEL base AB Should be 2896 1 mm.
EF = 13402 mm=GH
EG = 21592 mm = FH
F G = 25413 mm = E H
PRIMARY SUSPENSION
PRIMARY SUSPENSION
1. SPECIAL SCREW WITH SEALING WASHER
2. GUIDE
3. PROTECTIVE TUBE COMPLETE
4. UPPER RUBBER WASHER
5. TOP SPRING SEAT
6. DUST SHIELD SPRING
7. DUST SHIELD
8. HELICAL SPRING
PRIMARY SUSPENSION
9. GUIDE RING
10. RUBBER PACKING RING
11. GUIDE BUSH
12. SPRING CLIP
13. COMPENSATING RING
14. LOWER RUBBER WASHER
15. SAFETY STRAP
16. LOWER SPRING SEAT
17. GUIDE CAP
SECONDARY SUSPENSION
SIDE BEARERS
The side bearer arrangement consists of a machined
steel wearing plate immersed in an oil bath and a
floating bronze-wearing piece with a spherical top
surface kept in it, on both sides of the bogie bolster.
The coach body rests on the top spherical surface of
these bronze-wearing pieces through the
corresponding attachments on the bottom of the body-
bolster.
The whole arrangement is provided with a cover to
prevent entry of dust in the oil sump.
BOGIE BOLSTER SUSPENSION
The bolster rests on the bolster coil springs -
two at each end, located on the lower spring
beam which is suspended from the bogie side
frame by means of bolster-spring suspension
(BSS) hangers on either side.
The two anchor links diagonally positioned are
provided with silent block bushes.
The links prevent any relative movement
between the bogie frame and coach body
SPRINGS
In ICF bogie, helical springs are used in both

primary and secondary suspension.
The springs are manufactured from peeled
and centreless ground bar of chrome
vanadium/chrome molybdenum steel
conforming to STR No. WD-01-HLS- 94 (Rev.1)
CENTRE PIVOT ARRANGEMENT
The centre pivot pin joins the body with the
bogie and transmits the tractive and braking
forces on the bogies.
It does not transmit any vertical load.
It is equipped with rubber silent block bushes
which tend to centralize the bogies with
respect to the body and, to some extent,
control and damp the angular oscillations of
the bogies.
SHOCK ABSORBERS
Hydraulic shock absorbers with capacity of
600 kg at a speed of 10 cm/sec. are fitted to
work in parallel with the bolster springs to
provide damping for vertical oscillations.
BRAKE RIGGING
SALIENT FEATURES WHICH CONTRIBUTE
TO IMPROVED RIDING COMFORTS
1. Rigidly guided axles with self aligning spherical
roller bearings, having practically no play in
longitudinal and lateral direction and helical
springs working in parallel with dashpots and
shock absorbers of specified characteristic~, all
contribute to riding comforts.
2. 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.
SPRINGS
In ICF bogie, helical springs are used in both
primary and secondary suspension.
The springs are manufactured from peeled
and centreless ground bar of chrome
vanadium/chrome molybdenum steel
conforming to STR No. WD-01-HLS- 94 (Rev.1)
RUNNING CLEARANCE
RUNNING CLEARANCE FOR MOTOR COACH
STOCK AXLE BOLSTER BOGIE RAILL

CROWN TO BOGIE FRAME TO LEVEL TO
(MM) FRAME BODY CENTER
(MM) BOLSTER OF
(MM) COUPLER(
mm)
AC/EMU(ICF & 386 246 95 min 1035+0-15
BEML)
MEMU/DMC 283 245 143 min 1035+0-15
AC EMU 366 386 91 min 1035+0-15

JESSOP
air suspension
(MM) BOLSTER OF
(MM) COUPLER(
mm)
AC/EMU(ICF & 316 406 100 min 1035+0-15
BEML)
MEMU/DMC 313 406 100 min 1035+0-15
AC EMU 316 406 100min 1035+0-15

JESSOP

(MM) FRAME BODY CENTER OF
(MM) BOLSTER COUPLER(
(MM) mm)
DC EMU (ICF & 366 356 88 min 1035+0-15

BEML) 436 296 94min
DCEMU/JESSOP 296 346 76 min 1035+0-15

air suspension
(MM) FRAME BODY CENTER OF
(MM) BOLSTER COUPLER(
(MM) mm)
DC EMU (ICF & 316 406 100 min 1035+0-

BEML) 15
DCEMU/JESSOP 313 406 100 min 1035+0-
15
RUNNING CLEARANCE FOR HCC COACH

(MM) BOLSTER OF
(MM) COUPLER(
mm)
HCC(ICF & 626 146 105 min 1064+0-15

BEML)
HCC/JESSOP 486 256 105 min 1064+0-15
RUNNING CLEARANCE FOR HCC COACH
air suspension
(MM) BOLSTER OF
(MM) COUPLER(
mm)
HCC(ICF & 316 406 100 min 1035+0-15

BEML)
HCC/JESSOP 313 406 100 min 1035+0-15
RUNNING CLEARANCE FOR TAILER COACH

(MM) BOLSTER OF
(MM) COUPLER(
mm)
ICF & BEML 426 405 70 min 1035+0-15
MEMU 336 315 131 min 1035+0-15
JESSOP 436 555 50 min 1035+0-15

RUNNING CLEARANCE FOR TAILER COACH
air suspension
(MM) BOLSTER OF
(MM) COUPLER(
mm)
ICF & BEML 436 406 100 min 1035+0-15
MEMU 433 406 100 min 1035+0-15
JESSOP 436 406 100min 1035+0-15

BOGIE
The bogies being currently manufactured by
ICF/RCF which have been accepted as
standards of the Indian Railways and are of an
all welded light weight construction.
Axles are located on the bogie by telescopic
dash pot and axle guide assemblies.
Helical coil springs are used in both the
primary and the secondary stages.
BOGIE
The axle guide device provides viscous
damping across primary springs while
hydraulic dampers are provided across the
secondary stage.
Dampers are protected against misalignment
by resilient fittings.
Isolation of vibration is effected by rubber
pads in primary and secondary suspension.
BOGIE
Deflection due to the tare weight is almost
equally divided between axle and bolster
springs.
Weight of coach body is transferred to its
bogie by side
bearers pitched 1600 mm apart.
Side bearers consist of lubricated metal slides
immersed in oil baths.
BOGIE
No vertical weight transfer is effected through
bogie pivot and the pivot acts
merely as a centre of rotation and serves to
transmit tractive/braking forces only.
BOGIE ASSEMBLY
The bogie frame and components are of all-
welded light construction with a wheel base of
2.896 metre.
The wheel sets are provided with self-aligning
spherical roller bearings mounted in cast steel
axle box housings.
Helical coil springs are used in both primary
and secondary suspension.
The weight of the coach is transferred through
side bearers on the bogie bolsters.
BOGIE ASSEMBLY
The ends of the bogie bolsters rest on the
bolster helical springs placed over the lower
spring beam suspended from the bogie frame
by the inclined swing links at an angle7.
Hydraulic shock absorbers and dash pots are
provided in the secondary and primary
suspensions respectively to damp vertical
oscillations.
ANCHOR LINKS
The floating bogie bolster which supports the coach
body is held in position longitudinally by the anchor
links which are pinned to the bolster sides and the
bogie Transoms.
One anchor link is provided on each side of the bolster
diagonally across.
The links can swivel universally to permit the bolster to
rise and fall and sway side wards.
They are designed to take the tractive and braking
forces.
The anchor links are fitted with silent block bushes
SILENT BLOCK
This is a synthetic rubber bush fitted in anchor
link and center pivot of ICF bogies to transmit
force without shock and reduce noise.
EQUALISING STAYS
This device has been provided on bogies
between the lower spring plank and the
bolster to prevent lateral thrust on the bolster
springs which have not been designed to take
the lateral forces.
These links have pin connections at both ends
and, therefore, can swivel freely.
LIFTING THE BODY OF THE BOGIES
1. Before lifting the coach body from the bogie,
all electrical motors and earth connections,
traction motor ventilation bellows and hand
brake/parking brake connections must be
disconnected. The centre pivot cotter pin in
the Te and the securing collar in the MC/HCC
bogies must be removed. The axle box and
bolster safety straps should be disengaged.
2. The coach body can be lifted off the bogies
by one of the following methods:
I. Two electric cranes each with suitably
designed swings and cradles.
II. Four electrical/hydraulic lifting jacks
simultaneously operated by one control
switch. Coach should not be lifted from any
other point but the lifting pads.
3. The cranes or jacks used for lifting should be
operated uniformly and simultaneously without
jerks.
4. Before finally lifting coach body, steel/wooden
blocks of requisite thickness should be inserted
in the recess In between the bogie frame and
bogie bolster in order to avoid the bolster hitting
the bogie frame which may strain the silent
block bushes of anchor links in trailer bogies.
5. Lifting of coach from one end Is striclly
prohibited as the centre pivot, bogie bolster and
dashpot guides are likely to suffer damage and
dents may occur on body panel near the body
bolster.
6. Whenever the coach body is lowered on bogies,
air vent screws on the TC bogie frame and filling
caps in the MC/HCC 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.
DISMANTLING OF MOTOR AND HCC
BOGIES
1. After the bogie is run out, the traction
motors,(of MC bogies) must be taken out as per
Electrical Manual No. MM/DC EMU/003.
2. The shock absorbers should then be
disconnected.
3. The bolster may be removed from the bogie
frame by compressing the bolster springs to
relieve the load on swing links and hanger pins.
While the bolster springs are compressed,
4. the pre-tension nut should also be removed
DISMANTLING OF MOTOR AND HCC
BOGIES
5. The equalizing stays connecting bolster to the
lower spring beam should be disconnected after
which the bolster can be lifted and the springs
removed,
6. The air vent caps should be loosened to allow air
to enter the dashpots.
7. 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.
DISMANTLING OF TRAILER BOGIE
1. After the bogies are run out, the anchor links
and shock absorbers should be disconnected.
The bolster can then be removed from the
bogie frame by compressing the bolster
springs to relieve the load on swing links and
hanger pins. While the bolster springs are
compressed. the safety strap bolts should be
unscrewed and the straps swung away. The
equalising stays should then be
disconnected.
DISMANTLING OF TRAILER BOGIE
2. 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.
ACTION TO BE TAKEN BEFORE RE-
ASSEMBLING THE BOGIE
After attending to the various components as
detailed in para 8 above, the bogie may be re-
assembled taking into consideration the
following aspects:
1. The two wheel and axle sets selected for the
bogie should not have variation of more than
5mm on tread dia. The difference in tread dia
between two bogies shall not be more than
13mm.
2. The axle box springs on trailer and motor
coaches selected for each coach should be of
same groups of springs as detailed in C-841
g(Rev. 1).
3. Top and bottom rubber pads on the axle box
spring should not be used again if they are
not in, good condition.
4. The bolster springs on trailer and motor
coaches selected for each bogie should be of
same group of springs as detailed in C-
8419(Rev. 1).
5. 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.
SEQUENCE OF RE-ASSEMBLING THE
BOGIES
1. Assemble the bogie bolster, spring plank,
equalising stays, bolster springs to the bogie
frame with the help of a chain and jack as
shown in Fig.4..
2. Assemble roller bearing and axle boxes as
detailed in paras 10.7 to 10.10 and ensure
that the bearing is effectively secured .
BOGIES
3. Place axle box helical spring on the lower
spring seats with rubber washers as shown in
EMU-Ol-00l and EMU/M-O-1-001 and fili in
the dashpot with any of the approved brand
of oils as indicated in para 14.7.
BOGIES
4. Insert rubber washer, upper spring seat, dust
shield spring dust shield, rubber packing ring
and the guide bush on the axle box guide and
lock the bush in position as shown in Drawing
Nos. EMU-O-1-001 and EMLIIM-O-1-001 and
ensure that the bush sits tight against the
rubber packing ring and the 2 mm hole in the
guide is in alignment with that on the bush via
the groove in the guide bush. Before lowering
the bogie, the vent screw in case of trailer
bogies and filling cap in case of motor bogies,
must be removed.
BOGIES
5. lower bogie frame with the bolster assembly on
the wheel and axle set taking care to ensure that
all the 8 guide bushes engage the lower spring
seat and the bogie frame is set evenly on the 4
axle boxes.
6. In trailer coach bogies, connect the anchor links
with pins between the bolster and bogie frame
after lowering the body on the bogies.
7. Touch up the paint on the bogie again with one
coat of anti-corrosive black paint.
BOGIES
8. Ensure that the side bearers are resting properly.
9. Fill in requisite quantity of oil in dashpots and
screw home the air vent screw with the leather
washers in trailer bogies and filling cap in motor
bogies after the coach is lowered on to the
bogies.
10.In the trailer coach bogie, after inserting the
cotter in the centre pivot, fit the bottom centre
pivot cover housing as shown in Fig.25.
BOGIES
11.In the motor coach bogie. fit the safety collar
as shown in Fig.26.
12.Engage the bolster strap.
13.Engage the axle box strap.
ATTENTION REQUIRED FOR BOGIES IN
CAR SHEDS
1. Lifting the body of the bogies: Instructions
contained in para 4 above should be strictly
adhered to while lifting the body of the
bogies.
2. Dismantling of the bogies: Instructions
contained in para 5 & 6 above should be
strictly adhered to while dismantling the
bogies.
CAR SHEDS
3. Car depots should not try to weld a damaged
axle box guide or replace the same. The
bogie should be sent to workshops for
welding the guide and checking the
alignment. The bogie frame should however,
be checked for cracks, particularly at the
bolster suspension brackets.
4. The wheel sets are to be machined as
explained in para 9.
CAR SHEDS
5. Roller bearing should not normally be attended in car
sheds. All that would be necessary in service is to feel
the axle boxes for any tendency on their part to go
overheated. If any axle box shows tendency to run
hot, the vehicle should be disconnected. The wheel
sets which have run hot should be replaced in the Car
Depot and the damaged wheel sets sent to shops for
attention.
6. Four bolts securing the rear and front cover of the
axle box should be examined to ensure correct
assembly with spring washer and split pins.
CAR SHEDS
7. Whenever a spring is to be replaced, it
should be done in accordance with ROSO
Spring Maintenance Manual No. C-8419 (Rev.
1).
8. For this purpose, it is necessary that Car
Depots should have an imprest of axle box
and bolster springs duly tested and certified
to conform to the instructions contained in
para 12 & 15.
CAR SHEDS
9. Free height of axle box and bolster springs should be
within the tolerance as shown in C-8419 (Rev. 1) for
used springs and as per RDSO SpecificationNo.WD-01-
HLS-94 for new springs.
10. Whenever dashpot in the primary suspension shows
signs of oil leakage through the sealing rings, the
bogie should be lifted and the rubber sealing ring
checked and replaced if needed. In the event of the
diametrical clearance between the guide bush and
the lower spring seat should also be checked and jf
more than 1.6mm. the components worn out should
be replaced.
CAR SHEDS
11.Level of the oil in the dash-pot should be
checked at intervals of one month with the
help of a dip stick. It is important that the oil
level is checked after the vehicle has been
standing for at least 30 minutes as otherwise
the froth in the dash-pot formed when the
vehicle is running may give wrong indication.
The oil level from top surface of guide cab
should not be less than 77mm for TC bogie
and 97mm for MC & HCC bogie.
CAR SHEDS
12. If hydraulic shock absorbers used on secondary
suspension show any signs of oil leakage or other
damage, the same should be replaced with a shock
absorber completely overhauled. For this purpose,
the Car depots should maintain an imprest for use as
unit change assemblies. The leaking shock absorbers
should be sent to the workshops for overhauling. The
shock absorbers should be checked to ensure proper
tightening of the (our securing studs. The nylon
rubbing plate in the motor coach bogies should be
properly maintained as explained in para 18.
CAR SHEDS
13.The maximum diametrical clearance between
the brake pins and bushes should be limited
to 2mm and the brake block should be
replaced when worn out to a thickness of
16mm.
CAR SHEDS
14. Oil in the side bearer should be checked at an interval
of one month and oil replenished through the side
bearer oil filling arrangement. If it is found that the oil
leaks through the weld. the weld should be gouged
and re-welded properly. The bronze wearing piece
and the hard-ground steel plate should be replaced,
as required, i.e., when the bronze piece' has been
worn out by 3mm or has developed sharp edges. The
permissible wear on the steel plate is 1.5mm.
15. The safety straps for the brake beams and equalising
stays should be checked for proper securing
arrangement.
CAR SHEDS
16.Straps for the bolster and axle boxes should be
checked for proper securing Arrangement.
17.Straps for the bolster and axle boxes should be
checked for adequate running clearances. 1
18.Drop in buffer height due to lyre wear must be
reset by providing packings explained in para 29.
19.It should be ensured that the screws for the vent
holes are properly tightened with leather
washers.
CAR SHEDS
20. If a silent bloc is observed to have fretting on edges,
whether on anchor link or on centre pivot, it should
be removed and replaced with a new one. The
securing studs for the anchor link should be examined
for proper fastening. The four bolts securing the
centre pivot to the under frame should also be
examined for proper assembly with spring washer and
tack-welding of nuts.
21. Under no circumstances wheels which have reached
condemning limit on the wheel rim tyres should be
used.
CAR SHEDS
22.No coach with a broken dashpot or a broken
spring should be allowed to run in service. These
coaches should be withdrawn immediately for
replacement of the broken spring and sent for
replacing the broken dash-pot guides.
23.Equalising stays should be carefully examined to
ensure the correct assembly with washers and
split pins. All welds and the body of the
equalising stays should also be examined for
cracks. Bogies with bent, cracked or broken stays
should not be allowed in service.
CAR SHEDS
24.The bolster assembly should be examined in
position to ensure that the hanger blocks, and
pins and shackles are in good condition.
25.Dashpots and side bearers of these bogies
should be checked for a possible oil leak and in
the event of signs of leakage, the oil should be
replenished.
26.If considered necessary and provided that
requisite facilities are available, any of the items
which should normally be attended during POH
may be tackled in the Car Depots.
BRAKE POWER CALCULATION
Theoretical braking force available

on a coach
= 5.166 X 4
= 20.664Tonnes

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EMU ICF BOGIE

EMU ICF BOGIE

Automatic control of vehicle floor height

1. Bogies of motor coaches (MC), high carrying

In ICF bogie, helical springs are used in both

STOCK AXLE BOLSTER BOGIE RAILL

AC EMU 366 386 91 min 1035+0-15

AC EMU 316 406 100min 1035+0-15

STOCK AXLE BOLSTER BOGIE RAILL

DC EMU (ICF & 366 356 88 min 1035+0-15

DCEMU/JESSOP 296 346 76 min 1035+0-15

DC EMU (ICF & 316 406 100 min 1035+0-

STOCK AXLE BOLSTER BOGIE RAILL

HCC(ICF & 626 146 105 min 1064+0-15

HCC(ICF & 316 406 100 min 1035+0-15

STOCK AXLE BOLSTER BOGIE RAILL

MEMU 336 315 131 min 1035+0-15

JESSOP 436 555 50 min 1035+0-15

MEMU 433 406 100 min 1035+0-15

JESSOP 436 406 100min 1035+0-15

Theoretical braking force available

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