Bogie and Frieght ITP

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142655/2020/O/o PED/SW/RDSO
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For Official Use Only
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Government of India- Ministry of Railways
INSTRUCTIONS FOR INSPECTION AND MAINTENANCE OF

LCCF20 (C) BOGIE AND LWLH25 BOGIE OF FREIGHT STOCK
TECHNICAL PAMPHLET No. G-112

(Revision- First issue)
AUGUST 2020
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RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW - 226 011
5
Technical Pamphlet No. G-112
PREFACE
New designed BOXNS wagons fitted with LWLH25 bogie was introduced in
freight fleet in 2015. Whereas, LCCF 20(C) bogie fitted under BLC type Wagons
have been running since 1995. Both bogies are similar on many aspects and,
hence this technical pamphlet is applicable for both the bogies.
This technical pamphlet has been prepared for the maintenance and technical
guidelines to be followed during overhauling and inspection of LCCF 20(C) and
LWLH 25 bogie. This is based on the feedback received from Wagon Repair
Workshop, ROH depots, Bogie manufacturer and field visit of RDSO team.
Many diagrams, topics, figures and annexures have been incorporated for
better understanding.
Suggestions, enquiries or comments are welcome and should be directed to
Director General (Wagon), RDSO, Manak Nagar, Lucknow-226011, Fax 91-
522-2452494, [email protected]
(A. K. Gautam)
JDS (Wagon)/RDSO/ Lucknow
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Contents
Paragraph Description Page No.
1. Definitions and description of bogie parts 6
1.1-1.2 General Construction 9

1.3 General Arrangement 10
1.4 Salient features of LCCF20(C) and LWLH25 bogies 13
1.5 Bogie Components 14
1.6 Comparison of LCCF20(C) and LWLH25 bogie with respect to 14
dissimilar features
2. Recommended method of disassembling of Bogie 15
2.1 Recommended method of Reassembling 15
2.2 Nominal Clearances of the bogie Assembly 20
2.3 Maintenance of the Bogie 23
2.4 Repair procedure for the major bogie components 26

2.4.1-2.4.2 Bolster 26
2.4.3 Bolster land surface and rotation stop Lugs 26
2.4.4 Bolster Column Gibs 26
2.4.5 Spring Plank 27
2.4.6 Replacement of Centre pivot liners 31
2.5-2.5.1 Side Frame 31
2.5.2 Side Frame Columns friction plate 35
2.5.3 Side Frame Column sides 37
2.5.4 Side Frame Anti Rotation Lug 39
2.5.5 Pedestal Crown Roof 40
2.5.6 Pedestal Crown Sides and Sides of the Pedestal 42
2.5.6.1 Pedestal crown Sides 42
2.5.6.2 Sides of the Pedestal 42
2.5.7 Pedestal Jaw for LCCF20(C) bogie 45
2.5.8 Pedestal Jaw of LWLH25 bogie 48
3.-3.1 Wheel set with Bearings 52
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3.2 Wheel tread profile 54

3.2.1 Diameters of wheel used on LCCF20(C) & LWLH25 59
3.3 Axle 59
3.3.1 Component Parts for Cartridge Tapered Roller Bearing Assemblies 60
4. Adapter 61
4.1 Thrust shoulders 63
4.2 Adapter Bore 64
4.3 Adapter Crown Lugs 65
4.4 Adapter crown seat 67
4.5 Adapter Side Lugs 69
4.6 Adapter Sides 71
5. Elastomeric pad for LWLH25 & LCCF20(C) Bogie 73
6. Constant contact Side Bearers 74
7. Load Bearing Springs & Snubber Springs 74

7.1 Damping 74
7.2 Load Springs and Snubber springs 74
7.3 Friction Shoe Wedge Block 78
7.3.1 Vertical Surface 78
7.3.2 Slope surface 79
8.- 8.8 Brake Gear Maintenance 81
8.9 Reclamation of Brake Beam on account of Worn out Brake head 85
9. Precautions to be taken while doing welding operation on wagon or 92
bogie fitted with Cartridge Tapered Roller Bearing(CTRB)
10-10.1. Maintenance in Yard 92
11. Attention in Sick line 89

11.1-11.4 Lifting of Cars 93
11.5 Fitment and Maintenance of composition Brake Block 94
11.6 Maintenance 97
11.7 Limits of acceptable Cracks 97
12. Procurement of Spare Parts 99
13 Failure Reporting 100
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LIST OF ENCLOSURES
Enclosure Description Page No.
Enclosure-1 Welding of cast steel bogie components 100

Enclosure-2 Welding of Spring Steel liners to IS:3885 Part -1 Gr. 4 on Cast 103
Steel Surfaces
Welding of Spring Steel Liners to IS:3885 Part -1 Gr. 4 with Cast
Steel Bolster, Electrodes to be used
Welding of Manganese Steel Liner to IRS-R-65-78 on Sideframe
Column
Enclosure-3 Welding of Structural steel to IS: 2062 Fe 410 WA & Cast Steel 106
Reclamation of Friction Wedge by welding
Enclosure- 4 List of drawings & specification/STR for LCCF 22(C) Bogie 108
Enclosure-5 list of drawings & specification/STR for LWLH25 Bogie 109
Enclosure-6 (A) At a Glance 110-114
(B) Abbreviation used in the Pamphlet
(C) References
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SECTION-I
1.0 DEFINITIONS AND DESCRIPTION OF BOGIE PARTS:

(Fig.1 & 2)
Terminology Description of Bogie Parts
Axle The steel shaft on which the car wheels are mounted. The axle
holds the wheels to gauge and transmits the load from the journal
bearing to the wheels.
Axle Seat The cylindrical surface of a car wheel which comes in contact with
(wheel Bore) the axle (also called “the wheel bore”). The corresponding part of
an axle is called “the wheel seat”. Both surfaces are critical for a
proper wheel fit on the axle.
Adapter Any single component that forms a safe, reliable, and efficient
(Bearing interface between the roller bearing outer cup surface and the
adapter) Bogie.
Air Brake A combination of devices operated by compressed air arranged in

(Brake) a system and controlled manually or pneumatically by means of
which the motion of a car or locomotive is retarded or arrested.
Bogie (Truck) The complete assembly of parts including wheels, axles,

bearings, side frames, bolster, brake rigging, springs and all
associated connecting components, the function of which is to
provide support, mobility and guidance of a railroad freight car.
Bogie Bolster The main transverse member of a bogie assembly that transmits
Car body loads to the side frames through the suspension
systems. The ends of the bolster fit loosely into the openings in
the side frames and are retained by the gibs, which contact the
side frame column guides. Bogie bolster contact with the car body
is through the bogie center plate, which mates with the body
center plate and through the side bearings (side bearer).
Bogie Springs A general term used to describe any of the several types of
springs used in the suspension system of bogies to provide a
degree of vertical cushioning to the car and its load.
Bogie Side A plate or elastic unit fastened to the top surface of a truck bolster
Bearer on both sides of the center plate and functioning in conjunction
(Bearings) with the body side bearing to support the load as a moving car
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when variation in track cross level cause car body to rock

transversely on the center plates.
Bogie centers On a single freight car, the distance between the bogie center pin
as measured along the center sill from the centerline of one body
bolster to the centerline of the other.
Center Pivot The circular area at the center of a bogie bolster designed to
(Bogie Center accept the protruding center pivot and provide bearing surface of
Plate) car body support on the bogie bolster.
Cartridge Tapered roller bearings are rolling element bearings that can
Tapered Roller support axial forces as well as radial forces. The Cartridge
Bearing Tapered Roller Bearing is a self-contained, pre-assembled, pre-
adjusted, pre-lubricated, completely sealed unit and is applied to
or removed from the axle without exposing the bearing elements,
seals or lubricants to contamination or damage.
Running Gear A general term used to describe the group of parts whose
functions are related to movement of the car. Running gear
includes the wheels, axles, bearings, suspension system and
other components of the Bogie.
Side Frame A structure made of cast steel in one piece, to which the journal
boxes/Adapter or pedestals, Springs and other parts are attached,
and which forms the skeleton of a bogie.
Spring Plank A steel plate fitting under each end of the bolster on bogies to
provide a bearing surface for the spring group.
Spring Seat A cup-shaped piece of cast steel or cast wrought iron on which
(Spring plate) the bottom of a spring rest. They are further distinguished by the
name of the spring for which they serve such as bolster spring
seat, equalizer spring seat.
Suspension The resilient system through which a car body is supported on its
wheels. Suspension systems involve the use of friction elements
and helical springs etc.
Spring Group Any combination of standardized coil springs used in each bogie
side frame and selected to match car capacities and obtain
desired vertical suspension characteristics.
Spring Nest Two or more coil springs of different diameters, one fitting inside
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the other and acting in combination. Bogie springs are commonly

made up of standardized outer and inner coil, nested and
arranged in various spring groups .
Wheel Base The horizontal distance between the centers of the first and last
axles of a bogie.
Wheel Flange The tapered projection extending completely around the inner rim
of a railway wheel, the function of which, in conjunction with the
flange of a mate wheel, is to keep the wheel set on the track by
limiting lateral movement of the assembly against the inside
surface of either rail.
Wheel set The term used to describe a pair of wheels mounted on an axle.
Gauge (Track gauge)
Gauge Measured at right angles, the distance between running rails of a

(Track gauge) track at the gauge lines.
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1.1 GENERAL CONSTRUCTION
1.2 Cast steel LCCF 20(C) or LWLH25 bogies comprise of two cast steel side
frames, each resting in a longitudinal orientation, on the journals of the
wheelsets. The side frames support a cross member- the third piece- termed
a bolster. The three pieces, two side frames and a bolster are each simply
supported beams. The floating bolster is supported on the side frames
through two groups of helical springs, which also incorporate a load
proportionate friction damping. A spring plank is used to connect two side
frames to maintain the bogie squareness. These bogie designs are fit for
traffic operation up to 100 kmph. The major components of LWLH bogie is
shown in Fig. 1 and the exploded view of the bogie is shown in Fig. 2.
Fig. 1: Bogie of freight stock
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Fig. 2: Exploded View of LWLH25 bogie
1.3 The general arrangement of the Cast Steel Bogie ‘LCCF 20(C)’ and ‘LWLH25’ is
as shown in Fig. 3 & 4.
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Fig. 3: Bogie General Arrangement LCCF20(C) Bogie fitted with CTRB Class ‘E’
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Fig. 4: Bogie General Arrangement LWLH 25 Bogie fitted with CTRB Class ‘K’
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1.4 SALIENT FEATURES OF LCCF 20(C) and LWLH25 BOGIES
S. No. FEATURES LCCF 20(C) LWLH25

1. Gauge 1676 mm 1676 mm
2. Axle load 20.32t & 22t 25t
3. Wheel diameter:
New 840 mm 840 mm
Worn 780 mm 780 mm
4. Wheel Base 2000 mm 2000 mm

5. Type of Axle Standard AAR Standard AAR
bearing CTRB Class ‘E’ CTRB Class ‘K’
(6”X11”) with Wide (6 ½”X9”) with
Jaw Adapter Narrow Jaw Adapter
6. Distance between 2260 mm 2260 mm
Journal Centres
7. Side Bearer type Constant contact Constant contact
type side bearer type side bearer
(CCSB) (CCSB)
8. Distance between 1750 mm 1474 mm
side bearer
9. Centre Pivot type Flat type with Flat type with
Manganese liners Manganese liners
10. Bogie suspension Two group of helical Two group of helical
springs springs
11. Damping feature Load proportionate Load proportionate
friction damping with friction damping with
one snubber spring two snubber springs
and wedge, friction and wedge, friction
liners on Bolster and liners on Bolster and
Side-frame Side-frame
12. Anti-rotation Anti-rotation lugs Anti-rotation lugs
Features are provided on are provided on
Bolster and Bolster and
simultaneous anti simultaneous anti
rotation stopper to rotation stopper to
Side-frame Side-frame
13. Type of Brake Fabricated brake Fabricated brake
Beam beam beam
14. Load Sensing Two stage empty/ Two stage empty/
Device load brake system load brake system
fitted on Bolster and fitted on Bolster and
spring plank spring plank
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1.5 BOGIE COMPONENTS-

(See Fig. 1 & 2)
a) Side frames with friction liners and brake beam wear plate.
b) Spring plank.
c) Bolster with integral cast bottom pivot and wear liners
d) Wedge.
e) Load Bearing Suspension Springs (Outer & Inner)
f) Snubber springs
g) Bogie pivot with shackle lock, lock pin, split pin and metal cum rubber
washer.
h) Centre Pivot top (supplied along with new purchased Bogie)
i) Centre Pivot Bottom horizontal and vertical liners
j) Wheel sets with bearings, adapters and elastomeric pads.
k) Side frame key with key bolt, spring washer, nut and split pin.
l) Bogie brake gear (brake beam, equalizing levers, push rod, end pull
rod, pins bushes etc.)
m) Fit bolts, rivets, bolt & nuts etc
n) Constant contact side bearer Assemblies.
1.6 Comparison of LCCF 20(C) bogie and LWLH25 bogie with respect to
dissimilar features.
S.No. DIS-SIMILARITY LCCF-20(C) Bogie LWLH25 Bogie
1. Side frame design Cast steel design Cast steel design

suitable for Wide suitable for Narrow
jaw Adapter Class jaw Adapter Class
‘E’ (6” X 11”). ‘K’ (6 1/2” X 9”).
2. Load bearing coil 14 outer and 14/12 12 outer and 12 inner
springs inner
3. Snubber springs 2 Snubber springs 4 (2SO+2SI) Snubber
per group springs per group
4. Cartridge Tapered AAR Standard Class AAR Standard Class

Roller Bearing ‘E’ (6” X11”) ‘K’ (6 ½”X 9”)
5. Adapters Wide jaw Adapter Narrow jaw Adapter

Class ‘E’ (6” X11”) Class ‘K’ (6 ½”X 9”)
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SECTION-II
2.0 RECOMMENDED METHOD OF DISASSEMBLING OF THE BOGIES
i) Disconnect the bogie brake rigging attachments to underframe and

underframe brake gear including Rubber hosepipes and raise the
wagon body after removing split pin, lock pin and shackle lock etc.
ii) 25t whiting jacks (Jamalpur Jacks) can be used at each lifting pad
location for lifting.
iii) Run out the bogies.
iv) Lower the car body in the trestles.
v) Remove the retainer key with bolts.
vi) Remove the wheels from bogie, lifting by a crane of minimum
capacity 4t.
vi) Place on a fixture having locations for seating the pedestal tops of
side frame.
viii) Remove the brake beam push rod and other brake riggings.
ix) Insert the assembly pins dia 12 mm x 250 mm long to retain wedges.
x) Raise the bolster to contact top member of the side-frame by any
crane.
xi) Remove the outer, inner and snubber springs
xii) Remove the assembly pins and lower wedge blocks to take them
out.
xiii) Remove the side bearer from the bolster.
xiv) Remove the fit bolts, rivets.
xv) Remove the spring plank from one end.
xvi) Lower the bolster and rest on the two Packing Blocks on the
fixture so that bolster ends are free in bolster opening of side-
frame.
xvii) Take out the side frames from each end for repair.
xviii) Take out the bolster for repair.
xix) Remove adapter retainer bolt to release the adapter and
elastomeric pad.
2.1 RECOMMENDED METHOD OF REASSEMBLING

(Fig. 5)
For reassembling the bogie, procedure/step mentioned in the Fig. 5 along
with below mentioned para15, to19 shall be followed:-
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Fig. 5: Re-assembly Procedure (Continued….)
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Fig.5: Re-assembly Procedure (Continued….)
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Fig.5: Re-assembly Procedure (Continued….)
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Fig.5: Re-assembly Procedure
15.) Ream the holes of spring plank for riveting if necessary.

16.) Rivet the remaining holes of spring plank.
17.) Check diagonal and journal centres by trammel gauge. Check the
clearances and tolerances of the assembled bogies as per para
4.2 to be adhered to strictly.
18.) Apply a layer of about 1.5 mm molybdenum disulphide grease to
IS: 12203 in bottom pivot before lowering the wagon body.
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19.) After lowering the Wagon on bogies, Constant Contact Side Bearer
assembly height should be checked and maintained as per CP-
SB arrangement drawing by inserting or removing shims.
2.2 Nominal Clearances:

The nominal clearances and the tolerances of the bogie assembly are shown in
fig. 6 for LCCF20(C) and Fig. 7 for LWLH25 bogie. The main clearances (sum of
either sides) are :-
Description Type of Bogie

LCCF20(C) LWLH 25
Lateral clearance between 25 25
Sideframe and Bolster (mm)
Lateral clearance between 25 16
Sideframe and Adapter (mm)
Longitudinal clearance 10 9
between
Sideframe and Adapter (mm)
Longitudinal clearance 6 6
between
Sideframe and Bolster (mm)
Clearance between Anti-rotation 4 4
lug and Bolster (mm)
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Fig.6: Nominal Clearances LCCF20(C) bogie
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Fig.7: Nominal Clearances LWLH 25 bogie
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2.3 MAINTENANCE OF THE BOGIE
2.3.1 The bogie as designed is not expected to call for break-down maintenance.
However to obtain optimum life of the bogie, it is desirable to maintain the
various clearances within recommended limits. Due to wear of the mating
components, increase in clearance should be monitored for this purpose.
Whenever wheels are changed or bogie dismantled, the bogie clearances
and tolerances should be checked and rectified, if found necessary in
depots and during ROH of wagons.
2.3.2 Whenever the wear reaches the recommended limits in ROH or it is felt that
it will cross the recommended wear limit before next ROH, repairs should
be undertaken by either building up the wear surfaces or changing of their
liners as the case may be as per the recommended practice and facilities
available with the depot. It is suggested to replace the bogie instead of
repairing it in depots and then conduct repairs by building up worn out
surfaces in ROH depot. In case of spring plank is required to be removed,
the bogie should be sent to POH shop for repairs.
2.3.3 Fig. 8 indicates the method of checking the combined components wear in
bolster, side frame and wedge. Due to wear in bolster, side frame liners and
wedge surfaces the wedge will move upwards. If the holes in bolster pocket
wall and wedge start crossing, repair shall be undertaken. Alternatively, the
gauge shown in Fig. 9 shall be used to determine the wear limit, to decide
whether repair shall be undertaken.
2.3.4 Positioning the job for down hand welding in suitable manipulators should
be carried out for the repairs. After the repairs, the repaired surfaces should
be checked with relevant gauge for correctness. Excess material if any
should be removed by grinding. The class of electrode, gauge of electrode,
the welding procedure to be undertaken while repairing the surfaces by
welding should be followed as per Enclosure 1.
2.3.5 During POH of wagon in shops, all the wearing surfaces of the bogie shall
be brought to as new condition. The method of checking the combined
wear in bolster, side frame and wedge is as per the gauge shown in Fig. 9.
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Fig.8: Procedure for checking the combined Wear of Bolster, Side frame Liners &
Wedge
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Fig. 9: Gauge for checking the combined Wear of Bolster, Side frame
liners & Wedge
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2.4 REPAIR PROCEDURE FOR THE MAJOR BOGIE COMPONENTS
2.4.1 Bolster:
The wearing surfaces in the bolster are shown in Fig.10. Details
of reclamation procedure for each location are given in the following
paragraphs:
2.4.2 Bolster Pocket 35± 1º slope surface Nominal.
Liner Wear Limits: 5 mm
Bolster Pocket has been given with 8 mm thick silicomanganese steel liners
in the slope pocket. The liner may be permitted in service up to a thickness
of 3 mm. Chip off the welded liner to prepare the surface for welding new
liner. The procedure for welding of liner is given in the Enclosure 2.
No paint or grease should be applied on the liner.
2.4.3 Bolster Land Surface and Rotation Stop Lugs:-

(Common for LCCF20(C) bogie and LWLH25 bogie)
New Worn Wear Limit

(mm) (mm) (mm)
Dimension over Bolster land 444±1.5 438 3
surface/wear Liner
Dimension over rotation stop lug 518 512 3
Gauge: See Fig.11
Before repair is undertaken, the wear is measured by using the gauge as shown
in Fig.11. The centre line of the gauge should fall in line within the marked
centre line of the bolster as shown in the figure. With the gauge in position if a 4
mm thick shim can be inserted between the casting and the gauge at land
surfaces, rotation stop lug, then wherever the 4 mm thick shim enters that
location need to be dressed smooth to enable welding of suitable thickness of
Silico-manganese steel liner as per welding procedure given in Enclosure 2.
The width over the land surfaces and rotation stop lugs after the welding of
liners should answer the gauge.
Note: Two shims of size 4 mm are required to be used simultaneously.

Preferably liner on land surface should be welded after reclaiming inner
column gib by welding and before reclaiming outer gibs by liner.
2.4.4 Bolster Column Gibs:
New/Renewed Worn Wear Limit

(mm) (mm) (mm)
Outer Gib 241 + 2/-0 251 5
Inner Gib 136 + 3/-0 146 5
Gauge: See Fig.12
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The gauge determines the wear on outer and inner column gibs. With the gauge
in position as shown in Fig.12 if a shim of 6 mm for outer and inner gauge can be
inserted between casting and the gauge at each end at any point outer gibs are
to be reclaimed by welding silico manganese steel liners of suitable thickness as
shown in Fig.12.
Following the welding procedure as per Enclosure 2. Inner gibs are to be

reclaimed by welding procedure as per Enclosure 1. After reclaiming both the
gibs it should be ensured that width over the gibs should admit the gauge.
Note: Two 6-mm shims are required to be used simultaneously for each location.
2.4.5 SPRING PLANK:
Spring plank is a member made of mild steel (flanking quality) to IS: 5986-
2011 Grade 235 for LCCF20(C) bogie & IS-5986-2011 grade 490 for LWLH25
bogie. It joins two sideframes of LCCF/LWLH bogie by 08 number 24 dia. rivets
and four number M24 ‘fit’ bolts to keep bogie frame square.
Spring plank shall be examined for defects like loosening of

rivets/cracks/bending. Welding failure of springs spigot etc. Whenever spring
plank is renewed, the leading dimensions of the bogie as per drawing No.
CONTR-9404-S/14 for LCCF20(C) and WD-15021-S/04 for LWLH25 must be
measured on the fixture. Special care is to be taken regarding the use of ‘fit’ bolts
as well as quality of riveting. Fitment of spring plank with the siode frames should
be done on suitable fixture.
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Fig. 10: Reclamation & Locations of Worn Bolster
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Fig. 11: Bolster Land & Rotation Stop Lug Gauge
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Fig. 12: Column Jib Gauge
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2.4.6 REPLACEMENT OF CENTRE PIVOT LINERS-
Gauge for LCCF 20(C) Bogie:-

Fig.13 & 15
Gauge for LWLH25 Bogie:-
A plate gauge as shown in Fig.13 may be used for checking the wear on
the liner. A feeler gauge of 3 mm thick if goes then the liner should be
changed. The gauge should be moved around to check up for proper
fitment of C.P. liner.
Determine the amount of wear on seat and side of center bowl by using the
gauge shown in Fig. 14.
Wear limit
(mm)
Vertical side 2
Horizontal Seat 2
Wear Limit for both horizontal and vertical liners for both LCCF20(C) and
LWLH25 bogie is 2 mm. The liners required to be changed if the wear on
the liner exceeds 2 mm
The liner after replacement be welded with the bolster casting (See Fig.
15).
Fig. 13: Centre Pivot Liner Gauge
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Fig. 14: Centre Pivot Gauge
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Fig. 15: Integrated Centre Pivot Bottom Flat with Liners
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2.5 SIDE FRAME WITH FRICTION WEAR PLATES
2.5.1 Side Frame:

The wearing surfaces in the side frame are at two locations-
a) Centre opening location

b) Jaw location
The wearing surfaces in the side frame are shown in Fig. 16 (a) for LCCF
20 (C) and Fig. 16(b) for LWLH25.
Details of reclamation procedure for each location are given in the following
paragraphs:
Fig. 16 (a): Reclamation Locations of Worn Sideframe LCCF20(C) bogie
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Fig. 16 (b): Reclamation Locations of Worn Sideframe LWLH25 bogie
2.5.2 SIDE FRAME COLUMN FRICTION PLATE
Wear limit: 4 mm
Side frame columns have been provided with 10 mm thick Manganese steel
wear liners welded on to the columns. The liners may be permitted in
service upto thickness of 6 mm or whenever found cracked or broken. Use
friction liners as shown in Fig. 17.
Dress the surface of column face the new friction liner is to be held tight
against the column face during welding. Welding should be done in down
hand position. Start welding at diagonal ends of liner and weld towards
the centre. Refer Enclosure 2 for other welding details. No paint or
grease should be applied on the friction liner.
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2.5.3 SIDE FRAME COLUMN SIDES

(mm) (mm) (mm)
Column sides 216 ±1.5 206 5
Gauge: See Fig. 18
This gauge (Fig. 18) determines the amount of wear on the outside and the
inside of side-frame columns. Mark the centre line on the friction plate of
steel casting and place the gauge so that the centre line of the gauge falls
in line with the centre line of the side frame column. If a 6mm shim can be
inserted between the casting and gauge at each side at any point, the
surfaces should be welded with suitable thick liners of silicomanganese
steel as per the procedure under Enclosure 2 after dressing the area to
weld. After the repair, the gauge should answer all the relevant locations.
2.5.4 SIDE FRAME ANTI ROTATION LUG

(mm) (mm) (mm)
Anti-rotation lug 450 +2/-0 456 3
Gauge: See Fig. 19
This gauge determines the wear on the anti rotation lug. With the gauge in
position centrally placed, if a 4 mm shim can be inserted between the
casting and the gauge at each rotation stop at any point the surface should
be welded with suitable thick liners of Mn steel as per the welding
procedure.
The gauge is designed to use with friction liners of the side frame column. If
anti rotation lugs are gauged without friction liners two 10mm thick spacers
(one on each side) should be positioned within the column to simulate the
condition for using the gauge.
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Fig. 17: Friction Plate Detail & Procedure for Application to Side Frame
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Fig. 18: Column Gauge
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Fig. 19: Anti Rotation Lug Gauge
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2.5.5 PEDESTAL CROWN ROOF
Key Seat to Pedestal New/Renewed Worn Wear Limit

Crown Roof (mm) (mm) (mm)
LCCF 20(C) 318 ± 3 323 5
LWLH25 349 ± 2 354 5
Gauge: LCCF 20(C) - Fig. 20
LWLH 25 - Fig. 21
Determine the amount of wear on the side frame pedestal Crown roof by using
the relevant gauge shown in Fig. 20 & 21 as the case may be.
With the gauge in position, as shown in Fig. 20/21, if a shim of 6 mm thickness
can be inserted between the casting and the gauge at any point, the surfaces
should be repaired by welding with a suitable thick liners of Si-Mn Steel as per
procedure mentioned in Enclosure 2.
The repaired crown roof should be checked with the gauge for flatness excessive
material is to be removed by grinding.
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Fig.20: Pedestal Crown roof Gauge for LCCF20(C)
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Fig. 21: Pedestal crown Roof gauge for LWLH25 bogie
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2.5.6 PEDESTAL CROWN SIDES AND SIDES OF THE PEDESTAL:

(mm) (mm) (mm)
Crown Sides 152 144 4
LCCF 20(C)/LWLH25
Pedestal sides 105 101 2

LCCF20(C)
Pedestal sides 81 77 2
LWLH25
Gauge, LCCF 20 (C): Fig. 22
LWLH 25 : Fig. 23
Determine the amount of wear on pedestal crown sides by gauge as shown

Shown in Fig. 22 & Fig. 23 as the case may be.
2.5.6.1 PEDESTAL CROWN SIDES
With the gauge in position as shown in “A” of Fig. 22/23 if a

shim of 5 mm thickness can be inserted between the casting
and the gauge at each end at any point repair should be made
by welding, following the instructions given in Enclosure -1,
followed by grinding.
Note: Before using the gauge the centre line of the pedestal
crown sides is to be marked taking the UNWORN surface as
datum. The gauge centre line should be kept to fall in the same
line of the centre of the pedestal crown sides. Two 5 mm thick
shims are required to be used simultaneously. The should be
moved for the full length of worn surface to measure wear.
Pre heat the area to be reclaimed up to a temperature 2500 C

before undertaking the reclamation work.
After welding, the welded portion should be allowed to cool

slowly by covering it with asbestos/sand.
2.5.6.2 SIDES OF THE PEDESTAL
With the gauge in position as shown in “B” of Fig. 22/23, if a

shim of 3 mm thick can be inserted between the casting and
the gauge at each end at any point, repair should be
undertaken by welding following the instructions given in
Enclosure 1.
It is to be ensured that centre line of the unworn sides of the
Pedestal and the gauge centre line are matched and then
checked for repair. Pre heat is not necessary.
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Fig.22: Pedestal Sides & Crown Side Gauge for LCC 20(C)
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Fig: 23: Pedestal Sides & Crown Side Gauge for LWLH 25
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2.5.7 PEDESTAL JAW FOR LCCF20(C):

(mm) (mm) (mm)
Distance between 278+2/ -0 286 4
Jaws LCCF 20(C)
Gauge, Fig. 24
Determine the amount of wear on Pedestal Jaw (outer and

inner) by using the gauge shown in Fig. 24.
With the gauge in position as shown in Fig. 24, if a shim of 5
mm thickness can be inserted between the casting and the
gauge at each end at any point of Pedestal jaw face, should be
reclaimed and resorted to original contour by welding spring
steel liner as shown in Fig. 25. After reclamation, it should
answer the gauge in the jaw opening.
Sideframe key with key-bolt, spring washer nut, split pin &
retainer bolt has been provided as per RDSO’s drawing No.
CONTR-9404-S/4 (latest).
Note: Before using the gauge the centre line of the jaw
opening (i.e. distance between outer and inner jaws) is to be
marked taking the un-worn surface of the jaws as datum. The
gauge centre line should be kept to fall in the same line of the
centre line of the jaw opening. Two 5 mm thick shims are
required to be used simultaneously.
Pre-heat is not necessary.
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Fig. 24: Pedestal jaw Gauge for LCCF 20(C)
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Fig. 25: Reclamation of worn out Pedestal Jaws by Welding Spring

Steel Liners
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2.5.8 Pedestal Jaw of LWLH25 Bogie:
Pedestal Jaw (Short):

(mm) (mm) (either side)
(mm)
Distance between 203.5+2/ -1 211.5 4
Jaws
(outer and Inner)
Gauge, Fig. 26/I
Determine the amount of wear on Pedestal Jaws (outer and

Inner) by using the gauge as shown in Fig. 26/I.
With the gauge in position as shown in “A” of Fig. 26/I, if a
shim of 5 mm thickness can be inserted between the casting
and the gauge at each end at any point. Pedestal jaw face
should be dressed to enable welding of suitably thick silico
manganese steel liners as shown in Fig 25. Procedure for
welding shall be followed as per Enclosure-2. After welding of
liners, it should be ensured that gauge admits between the
jaws.
Note: Before using the gauge the centre line of the jaw
opening (i.e. distance between outer and inner jaws) is to be
marked taking the un-worn surface of the jaws as datum. The
gauge centre line should be kept to fall in the centre line of the
jaw opening for Pedestal Jaw Long and Short. Two 5 mm thick
shims are required to be used simultaneously.
Pre-heat is not necessary.
Pedestal Jaw (Long):

(mm) (mm) (either side)
(mm)
Distance between 263.5+3 271.5 4
Jaws
(outer and Inner)
Gauge, Fig. 26/II
Determine the amount of wear on Pedestal Jaws (outer and

Inner) by using the gauge shown in Fig.26/II.
With the gauge in position as shown in Fig. 26/II, if a shim of 5
mm thickness can be inserted between the casting and the
gauge at each end at any point. Pedestal jaw face should be
reclaimed and restored to original contour by welding and
grinding as per the procedure given in Enclosure-2. After
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reclaiming, it should be ensured that gauge admits in the jaw

opening.
Sideframe key with key-bolt, spring washer nut and split pin
has been provided as per RDSO’s drawing No. WD-13012-S-
04 (latest).
2.5.9 The repaired sideframe should be checked for its wheel base (distance
between centre lines of the jaw openings) and ensure whether the
correct button marking is left on the repaired sideframe. While pairing the
sideframe for a bogie, it shall be ensured that there should not be any
difference between the numbers of buttons on the two sideframes.
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Fig.26/I: Pedestal jaw (Short) Gauge for LWLH25
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Fig.26/II: Pedestal jaw (Long) Gauge for LWLH25
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SECTION-III
3. WHEEL SET WITH BEARINGS
3.1 Drawings of wheel and an axle are shown in Fig. 27 with the
various parts identified.
LCCF 20 (C) & LWLH 25 bogie are fitted with Cartridge Tapered
Roller Bearings (CTRB). LCCF 20(C) bogie fitted with wheelsets
to drawing no. CONTR-9404/S-13 (Fig.28) whereas LWLH 25
bogie fitted with wheelsets to drawing no. WD-15020/S-01 (Fig.
29).
Maintenance requirement of Cartridge Tapered Roller Bearings

have been issued under “Instruction for inspection and
maintenance of Cartridge Taper Roller Bearing fitted on Cast
Steel Bogies”, Technical Pamphlet No. G-81 by RDSO.
Fig. 27: Nomenclature of Wheel and axle
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Fig. 28: Wheel and axle assembly for LCCF 20(C) bogie
(Ref. Drg.No.CONTR-9404-S/12)
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Fig. 29 Wheel and Axle Assembly for LWLH Bogie

(Ref. Drg.No.WD-15020-S/1)
3.2 Wheel Tread Profile:
Worn wheel profile to drawing no. WD-88021 has been used in wheels of
freight stock to reduce wheel wear and increase wheel life. The tread
profile/tyre for new wheel shall be as per drawing No. WD-88021 (Fig. 30).
However, as per requirement, during POH/ROH/Maintenance of wheel
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set/wheel re-profiling, wheels-tread should be turned as per intermediate

profile having varying wheel flange thickness selecting the appropriate flange
thickness out of the nine flange thicknesses so that minimum material is
removed at the time of turning. These intermediate profiles have been
incorporated to optimize the wheel life. These are as per Drg. No. WD-
89060- S/2 (Fig. 31).
Wheel diameter for new wheel is 840 mm & Condemning wheel diameter is 780
mm.
63.5
Fig. 30: Worn wheel Profile (Ref. Drg.No.WD-88021)
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Fig. 31: Intermediate profile (Ref. Drg.No.WD-89060/S-2) Continued….
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Fig. 31: Intermediate profile (Ref. Drg.No.WD-89060/S-2) Continued….
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Fig. 31: Intermediate profile (Ref. Drg.No.WD-89060/S-2)
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3.2.1 DIAMETERS OF WHEELS USED ON LCCF20(C) & LWLH25 of BG STOCK

WITH CONDEMNING LIMITS:
Fig.32: Size of wheel for wagons (Ref. Drg.No.WD-88089/S-1).
Axle Wheel Drg. No. Nominal Dimensions

load
(t) A B C D E
20.3, CONTR-9404-S-13
22, or 840 771 730 780 793
25 WAP/W-004
3.3 AXLE
Axles have to be subjected to ultrasonic testing (UST) during ROH/POH or

whenever the wagons are sent to the shops. Wheel sets, whose axles
have under gone ultrasonic testing, shall be stamped on the wheel hub
fillet as per RDSO’s drawing no. WD-81089-S/1.
Axle end holes shall be properly cleaned and lubricated before reuse.
Thread should be checked with standard thread gauge (See Fig. 33).
Fig. 33: Axle end thread checking Gauge

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List of drawing for axle for LCCF20(C) bogie & LWLH25 bogie
S. Drawing No. of Used in Nominal wheel Condemning

No. Finished Axle Bogie seat diameter of wheel seat
axle in new diameter of
finished condition axle
(mm) (mm)
1 WD-89025-S-02 LCCF20(C) 213 207
2 WD-15020/S-02 LWLH25 214 211
3.3.1 Component parts for Cartridge Tapered Roller Bearing assemblies:
Cap Screw tightening torque value for CTRB Class ‘E’ (6” X11”) and Class
‘K’ (6 ½” X 9”) are mentioned in table below:-
S. No. Description Cap screw Size Torque*

Kg-m(ft-lb)
1. End Cap screw for End 1”-8UNC-2A 40 Kg-m
hole of axle to drawing (290 foot-
No. WD-89025S-02 pound)
2. End Cap screw for End 1 1/8”-7UNC-2A 58 Kg-m

hole of axle to drawing (420 foot-
No. WD-15020/S-02 pound)
*Torque wrenches must be accurate within ± 4%.
3.3.2 Welding on axles is not permitted and any axle showing welding or cutting
torch damage is scrap.
3.3.3 For re-disced wheels, the stamping shall be as per RDSO Drg No. WD-
87080/S-1.
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SECTION-IV
4.0 ADAPTER
LCCF 20 (C) bogie is fitted with Wide jaw adapter Class ‘E’ (6” x 11”) while
LWLH25 bogie is fitted with Narrow jaw Adapter Class ‘K’ (6 ½” x 9”).
When bogies are dismantled for any purpose, adapters must be thoroughly
inspected for soundness and excess wear. The inspection for wear shall include
the application of gauges recommended for different locations. The following
conditions shall render the adapter to be scraped and replaced.
i) Cracked or broken at any location.
ii) Warped or twisted or distorted. To check the adapter for distortion

places the adapter on the bearing outer ring. It should sit firmly on
the outer ring without rocking when hand pressure is applied on top
of the adapter. When uniform wear band is not seen at the adapter
sitting location on bearing, the adapter should be scrapped. Non
uniform wear band on the outer end indicates that the adapter does
not match with the outer cup dia.
iii) Worn to the extent that ridges or grooves prevent the proper seating
of adapter on the bearing.
iv) When the wear at the thrust shoulder, adapter bore, crown lugs,
crown seat, side lugs reaches the condemning limits indicated in this
chapter (See Fig.34 & 35).
v) Whenever visual marks of the adapter seating are found to be

confined on a limit length on circumference of the outer cup, the
bearing should be rotated so as to bring that portion of the outer cup
seating area under the adapter which does not have adapter seating
marks. This procedure will facilitate shifting of the loaded zone during
lift of the bearings and thus increase the life of the Cartridge bearing.
vi) Adapters which are worn in one side between lugs from brake
reactions but which are otherwise satisfactory for reuse should be
reversed when reused. When both sides exceed 3 mm wear do not
reuse adapter.
vii) Broken or cracked adapters must be scrapped. Repairing of adapters

by welding/brazing is not permitted.
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Fig. 34: Adapter
Fig. 35: Scrap location of Worn Adapter
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4.1 THRUST SHOULDERS:
Wear limit 0.7 mm

Gauge : Wide jaw Fig. 36
Narrow jaw
The thrust shoulder of the used adapter may have groove due to contact
with the ends of the roller bearing outer ring. The depth of such groove shall
be gauged by using the gauge at Fig. 36.
If at any point on periphery of adapter, the gauge touches i.e the groove is
greater than 0.7 mm the adapter shall be scrapped.
Fig. 36: Adapter Thrust shoulder & Bore Wear Gauge

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Fig. 37: Worn adapter showing condemnable thrust shoulder wear as gauge
Tip does not contact shoulder indicating more than 0.7 mm allowable
Wear (this wear caused by thrust loading from end of CTRB Cup).
Check both shoulders at locations where wear is maximum.
4.2 ADAPTER BORE (BEARING SEAT)
Adapter machine relief depth ≥ 0.8 mm

Gauge : Wide jaw Fig. 38
Narrow jaw
Machined relief is provided at the ends of the bearing seats at a different

level. When measured, machined relief depth shall be 0.8 mm or more.
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The gauge shown in Fig. 36 shall seat on the bearing seat without touching
the machined relief. If the gauge touches the machined relief the adapter
shall be scrapped. The adapter-bearing seat must be checked all over the
arc by this gauge (See Fig. 37).
Fig. : 38
4.3 ADAPTER CROWN LUGS:
Adapter crown lugs New Worn Wear limit

(mm) (mm) (either sides)
(mm)
Wide jaw 156 +2.75, -0.425 164 4
Narrow jaw 155.5 +2, -0.0 163.5 4
Gauge: Fig. 39
To determine the wear the gauge is positioned (Fig 39 & 40) as per figure
matching the centre lines of crown seat and gauge and if a 5 mm thick shim
can be inserted between the worn lug and the gauge on either side at any
point the adapter shall be scrapped.
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Fig. 39: Adapter Crown Lug gauge
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Fig.: 40: Adapter Crown Lug gauge application
4.4 ADAPTER CROWN SEAT
New Worn Wear Limit

(mm) (mm) (mm)
Adapter bore seat to 48.5 +1.05/ -0.1 45 3.5
Crown seat of Wide jaw
Adapter bore seat to 27.4 23.9 3.5
Crown seat of Narrow jaw
Gauge: Fig. 41
When the twin gauges are applied as shown in Fig. 41/42 and if a 4.5 mm
shim can be inserted between the gauges 1 and 2 it indicates the condemning
limit and hence the adapter should be scrapped.
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Fig. 41: Adapter Crown Seat gauge
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Fig. 42: Adapter Crown seat Gauge application
4.5 ADAPTER SIDE LUGS
New Worn Wear limit

(mm)
Adapter Side lugs wide jaw 130 +3.35 136 3
Adapter Side lugs Narrow jaw 96.82+4 /-0 106.82 3
Gauge: Fig. 43
With the gauge in position (Fig. 43/44), matching the centre lines of the
gauge and adapter side lug if a 4 mm thick shim can be inserted between
worn surface of the lug and the gauge at either sides at any point the adapter
shall be scrapped.
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Fig. 43: Adapter side lug Gauge
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Fig. 44: Adapter side Lug Gauge application
4.6 ADAPTER SIDES
New Worn Wear limit

(mm)
Adapter sides wide jaw 268+0.287/ - 2.8 262 3
Adapter sides narrow jaw 194.46+0.8/- 2.38 188.46 3
Gauge: Fig. 45
With the gauge in position as shown in Fig. 45 & 46. A matching the centre
lines of the gauge and adapter sides if a feeler gauge of 3.5mm thickness can
be inserted on each end both sides at any point of the adapter and the gauge
then the adapter should be scrapped.
It is to be noted that no rework by welding etc. is permitted on adapter and it

should be scrapped if the wear is found to be beyond limits specified above.
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Fig. 45: Adapter side Gauge
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Fig. 46: Adapter sides Gauge application
5.0 ELASTOMERIC PAD FOR BOTH LCCF 20(C) & LWLH25 BOGIES
(Drg. No. - WD-95005-S/1)
Elastomeric pads shall be condemned on the following grounds and be

replaced by new one.
i) If the top or the bottom plates show any crack in service.

ii) If any crack of more than 50 mm is developed at any surface of
rubber.
iii) If a bond failure giving way more than 40 mm in any direction
is developed in service.
iv) When in free condition, the pad has taken a permanent set of the
order given below:-
Type of Pad Nominal Dimensions Dimension after

permanent set
Elastomeric Pad 46 mm 42 mm
v) If any sign of crushing of rubber is noticed, the pad is rejected.
6.0 CONSTANT CONTACT SIDE BEARERS
The side bearer arrangement in these bogies are fitted either with spring
loaded side bearers to Drg no CONTR-9404/S-15 for LCCF 20(C) or with
RDSO approved side bearers to RDSO specification No. WD-62-Misc-17
(latest) for LWLH25 bogie (Fig. 47).
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Fitment details of side bearer is given on Centre Pivot–Side Bearer

Arrangement drawing of respective wagon.
Condemnation/replacement of side bearers shall be as per

RDSO/Approved drawing and relevant specification.
Top Housing
Bottom Housing
Inner Spring
Outer spring
Fig. 47: Constant contact Side Bearer Fig. 47/I: Exploded view of Constant
contact Side Bearer
7.0 LOAD BEARING SPRINGS AND SNUBBER SPRINGS:
The bogies are fitted with two groups of long travel helical springs nests.
The spring groups for bogie for various axle load applications are shown
in Fig. 48 & 49.
7.1 DAMPING:
The suspension is provided with load proportional friction damping
arrangement with the help of a Mn Steel cast Wedge supported on the
snubber springs. The details of the snubbing arrangement are shown in Fig.
48 & 49.
7.2 LOAD SPRINGS & SNUBBER SPRINGS
The springs per group for LCCF 20(C) bogie and LWLH25 bogie for
different axle load is mentioned in below table:-
Bogie Type Axle Load Number of Spring per Group

(t) Required
Outer Inner Snubber
LCCF20(C) 20.3 7 6 2
22 7 7 2
LWLH25 25 6 6 4 (2SO & 2SI)
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The springs are condemned on the basis of free height (Fig. 48 & 49).
Springs should not be used if minimum spring height is at or less than
shown below:
Spring type LCCF 20(C) BOGIE LWLH25 BOGIE

Free Height Condemning
Nominal Free Condemning
Nominal Height
Height (mm) Height (mm)
(mm) (mm)
Outer (O) 260 ± 2 245 264 249
Inner (I) 243 +0/- 3 228 246 231

281 (SO) 266
Snubber (S) 288 ± 3 273
289 (SI) 274
Grouping:
Matching of both load and snubber springs, is important. It is

recommended that springs having not more than 3 mm free height
variation should be assembled in the same group. Mixing of new and
old springs should be avoided. The springs are required to be
manufactured as per drawing and specification NO.WD-01-HLS-94
(latest revision).
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Fig. 48: Details of spring
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Fig. 49: Details of Bolster spring group arrangement
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Fig. : Details of spring of LWLH25 bogie
7.3 FRICTION SHOE WEDGE BLOCK

(Fig. 50 & 51)
New/renewed Worn Wear Limit

(mm) (mm) Vertical Surface
Vertical surface from 61 54 7
Centre line
Wear limit Slope surface: 3 mm
Wedge Gauge : Fig. 52
7.3.1 Vertical surface:
With gauge (Fig. 52) in position if an 8mm shim can be inserted

between the casting (vertical surface) and the gauge at any point should
be made unusable and replaced.
The worn vertical surface shall normally not be reclaimed by welding as

a lot of precaution is to be required for welding of this wedge as this is
made of IS 276 Gr. I Manganese steel. A replacement of the worn out
wedge is easier & preferable.
In case of reclamation of vertical face of wedge during POH at workshops,

clean the surface properly to remove dust, oil, cracks, scales prior to
welding. Electrode of 4 mm dia approved by RDSO under class H2 of IRS-
M-28 should be used.
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7.3.2 Slope surface:
The wear on the slope surface is measured with gauge in position as

shown in Fig. 52 and if a 4 mm shim can be inserted between the gauge
and centre point of the casting profile the wedge is required to be replaced.
No weld reclamation/rework can be done to keep the profile 940 R of the
casting.
Vertical surface
Slope surface
hjh
Fig. 50: All Cast metallic friction wedge Fig. 51: Metallic friction wedge with
composition liner
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Fig.52: Wedge gauge
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Fig. : Measurement of Vertical wear of friction Shoe wedge
8.0 BRAKE GEAR MAINTENANCE
8.1 The general arrangement of brake gear is shown in Drg. No. CONTR-9404-S/09
and bogie brake gear details are as per drawing CONTR-9404-S/10.
8.2 The brake gear consists mainly of brake beam with brake block, brake shoe key
and split pin, equalizing levers push road, end pull rod etc.
8.3 Location of pins and bushes used are as shown in Fig. drg. No. CONTR-9404-
S/09 (Fig. 53). The bushes provided are of steel to IS: 55179-C8 case hardened
and pins are made from steel to IS: 2062 Fe 410WA. The maximum permissible
wear on the pin dia and bush inside dia is limited to 1.5 mm. In service as the
tread dia of wheel decreases due to wear, pins located in end pull I rod with
underframe having equally pitched holes are to be relocated as shown in Fig.
54.
8.4 The brake beam is a fabricated one. Brake beam strut and end piece casting
are of cast steel. Brake head is integral part of end piece casting.
8.5 The non metallic brake block is shown in drg. No. CONTR-9404-S/11. The wear
of this brake block is hardly 1.5mm to 2 mm per 2000 km run.
8.6 A cracked brake block is liable for rejection and requires replacement.
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8.7 A direct hit on the brake block by hammer may be avoided. The brake blocks
gets cracked or get chipped off due to this, leading to rejection of the brake
block.
8.8 All the brake blocks may be replaced on condition basis during ROH/POH. For
maintenance in yard brake block thickness up to 10 mm is permitted. Whenever
brake block is changed it is preferable that equal thickness of brake block may be
fitted on both the ends of brake beam. More uneven wear on the brake block is
due to improper fitment of brake block on brake beam head with brake shoe key.
The key loses tension and the grip on brake block slackens causing uneven
wear. Thus this type of keys requires change and brake block worn uneven
should be changed.
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Fig.53: Brake Gear Arrangement
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Fig. 54: Manual adjustment of bogie Brake gear
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8.9 RECLAMATION OF BRAKE BEAM ON ACCOUNT OF WORN OUT BRAKE

HEAD
8.9.1 The wear on brake head is due to the following reasons.
iii) The uneven wear on the brake block.

ii) The train is allowed to run with worn out brake block or with
broken/missing brake blocks.
The proper brake shoe key with correct tension should be used to keep
brake block in parallel to the tread of wheel. Brake blocks should be
replaced when worn to 10 mm. No train should be allowed to run with
broken, cracked or missing and unevenly worn brake blocks (Refer para
8.6).
8.9.2 Reclamation: Brake head is integrally cast with end piece casting which is
welded with structural steel brake beam channel and "truss flat' at ends as
shown in Fig. 55 & 57. Depending upon the extent of wear either it is
repaired by building up the profile by welding and grinding as per enclosure,
or the worn brake heads can be replaced by new brake head as follows.
i) Removal of worn-out. Brake Head' from end piece casting Gas cut
the head as shown cross hatched in Fig. 55 & 56 and grind the gas
cut surfaces to achieve contour as shown in Fig. 55.
ii) Fabrication of new Brake Head: New Brake head shall be

manufactured as per details in Fig. 64. Alternatively, Brake Head can
be produced by modifying the standard brake head of brake beam to
SK 69596 meant for CASNUB 22 W Bogie. The modifications
required to be carried out is only the provision of opening to size 41 x
27mm.
iii) Welding of New Brake Head with this repaired brake beam be as per
Fig. 65 and Fig. 66. New brake head shall be welded with the above
repaired brake beam by keeping in a fixture so that both heads are
parallel and to the required inclination even after welding. The
welding procedure is as per Enclosure 2.
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Fig. 55: Reclamation of Brake beam end
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Fig. 58: Reclamation of Brake beam end (Brake Head)
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Fig. 59: Brake beam end (Reclaimed by new brake head)
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Fig.60: Reclamation of Brake Stamp end
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9.0 PRECAUTIONS TO BE TAKEN WHILE DOING WELDING OPERATION ON

WAGON OR BOGIE FITTED WITH CARTRIDGE TAPERED ROLLER
BEARINGS (CTRB):
Whenever wagons or bogies fitted with roller bearings require welding in

Workshops/ROH Depots/Sicklines special attentions should be paid so that
electric current may not pass through the bearings. The earthing should be
done very close to welding area and the earthing wire should be tightly secured at
both ends. One of the proposed scheme of earthing is given in Fig. 61. However,
do not forget to earth the two bogie bolster ends of two bogies of the wagon prior
to welding. If wagon is not properly earthed the current passing through the
bearings will cause arcing in between the rollers and the raceways leading
to failure.
Alternatively, the earthing can be done with aearthing wire/strip running parallel to
the track instead of earthing with the rails.
NOTE: - EARTH THE TWO ENDS OF THE TWO BOGIE BOLSTERS UNDER A
WAGON WITH THE RAIL PRIOR TO WELDING.
Fig.61
10.0 MAINTENANCE IN YARD
10.1 Generally there is no necessity for doing any major repairs at yard regarding bogie.
The following points may be noted for maintenance.
i) Missing parts if any should be replaced.
ii) Check the side bearer clearance of 8 mm between the top plate
and side bearer housing for any broken spring, for any broken
top plate, replace broken spring and top plate.
iii) Bolster springs got broken in service can be changed in yard as

per the existing procedure of lifting the bolster at end by a 10 ton
hydraulic jack. A fork type extension piece is being used to lift
the bolster by inserting one end at the end of bolster and the
other end is lifted by the jack. The bolster is lifted till it touches
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the side frame column opening top so that the springs are free.
The free springs are lifted up and pushed aside by a lever.
iv) Worn out to 10 mm, cracked, broken brake blocks require

change, equal thickness of brake block should be ensured at
both ends of the brake beam (Also refer para 8.6).
v) All the parts of bogie are checked for crack or defects and
marked sick if found on major part like side frame, bolster spring
plank etc.
vi) For wheel defects as per wheel defect gauge the car should be
marked sick for placement in sick line if arrangements for wheel
changing are not provided in yard.
vii) Roller bearing defects observed through warm axle box, found
through axle box feeling on arrival be attended in sick line
11.0 ATTENTION IN SICK LINE
i) Whenever any car is marked sick and placed in sick line the car
are required to be checked for any defect/deficiency.
ii) Apart from attending to the particular defect other areas are
also to be checked and attended to like; air brake, locks, buffing
and draw gear & underframe, apart from all bogie parts to avoid
frequent detachment of any car between ROH to ROH or POH.
iii) As lifting of wagon is required to change the wheel-sets, brake beam

etc. by run out the bogie from wagon, a systematic check for all the
cars placed in sick line for any reason may be carried out and
defects attended to avoid frequent lifting. Special attention be paid to
side bearer arrangement and the dimension to this arrangement be
checked and variation attended.
11.1 LIFTING OF CARS
11.2 Whenever cars is placed on sick line for a defect on one or more cars which
necessitates lifting, it is preferable that the adjacent cars are disconnected
by removing the yoke pin support and yoke pin. The following are the
reasons for attending to repair which necessitate lifting:
i) Wheel changing.
ii) Brake beam changing (which necessitates removal of
wheels).
iii) The failure of centre pivot top for cracks.
iv) Centre pivot bottom liner changing.
v) Repair on parts of side bearer arrangement.
94 of 114
98
11.3 The General procedure of lifting in ROH/Sick line:
i) Disconnect the bogie brake rigging with underframe brake gear SAB
pull rod and VTA hosepipe connection.
ii) Remove split pin, lock pin & shackle lock.
iii) Under frame is lifted at lifting pads on both ends by 25t
whiting jack.
iv) Run out the bogie and keep the underframe on the trestles.
v) Remove side-frame key and adapter retaining bolt.
vi) Lift the bogie by overhead crane/jib-crane.
vii) Attend to repairs like wheel changing, brake beam changing etc.
11.4 The modern procedure is to lift the car in yard and effect wheel changing
and other repairs in the yard itself.
11.5 FITMENT & MAINTENANCE OF COMPOSITION BRAKE BLOCK
11.5.1 Ideal Fitment (Fig. 62):
This illustrates an ‘ideal’ fitment of composite brake blocks on brake block

holders. The ‘gap’ at the centre shown on the drawing of approximately 0 to 3
mm is considered ideal.
Fig. 62: Ideal Fitment of Brake Block
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99
11.5.2 Poor Fitment (Fig. 63):
This illustrates the gap at the ends of the brake block and is considered a
poor fitment. Although the brake block will still function satisfactorily and
provide safe braking, cracks may develop in the block. These cracks may
develop across the face of the brake block but will not affect its
performance. In this situation it is recommended that the brake block be
replaced when 50% of the block is used. It is further recommended that the
brake block holder be replaced or modified so that fitment is as per figure.
Fig. 63: Poor Fitment of Brake Block
11.5.3 Unacceptable Fitment (See Fig. 64):
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100
This unacceptable fitment is due to an incorrect radius on the key. In this

situation the brake block is loose and can be twisted or moved relative to
the brake holder. In this case, a new key is required to ensure a tight fit.
Fig. 64: Unacceptable Fitment of Brake Block
11.5.4 Wheel Condition, there are no real concerns when using brake blocks on
new wheels other than ensuring the correct wheels are fitted with a
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101
compatible taper to the one on the block. The wheel radius will be at its
maximum however this will not be a problem if the front radius of the block
was correctly specified.
When fitting brake blocks to old wheels, the condition of the tread surface
will impact on the wear life of the block in service. A rough surface will tend
to wear the brake block more rapidly in the initial stages until a consistent
wheel surface condition is achieved. The wheel radius will have also
changed relative to a new wheel so the bedding in time required may
increase a little when new blocks are fitted. Effective braking will still be
maintained despite the initial reduction is surface area contact.
In general, composition brake blocks are normally designed with a large

factor of safety built into them so they continue to provide effective braking
performance in difficult conditions.
11.6 Maintenance
Correctly fitted composition brake blocks require little or no maintenance.

Blocks must be replaced 10 mm before friction material is left on back plate.
The life of the block depends on the service, they have a life of at least 5
times that of cast iron. As a guide, if composition brake blocks are fitted for
the first time on a new service the following inspection frequency is
recommended.
Inspection Period Comments
1 4 weeks Check 'or any loose blocks/keys and

tighten as necessary. Check for any
abnormal wear. This may indicate a
'stuck' brake or other brake rigging
problem.0
2 12 weeks Check for wear rate per 1,000 km and
estimate average life of brake blocks to
determine time of last inspection. Limits
of Acceptable Cracks.
3 90% of Replace blocks as necessary at or
average life before 10 mm condemning limit.
11.7 Limits of Acceptable Cracks (Fig. 65)
The following are limits of cracking which apply to brake blocks. Brake blocks
found with cracks in excess of these limited are to be renewed
(Also refer to para 8.6).
a) The number of radial cracks permitted in service is limited to two.

One or both cracks may be open cracks upto 5 mm deep.
b) Open cracks are permitted upto a maximum of 2 mm at the widest
point.
98 of 114
102
c) Blocks showing indications of splitting between the composite and

steel backing plate are not permitted.
d) Longitudinal cracks are not permitted.
e) Broken brake blocks are not permitted.
Fig. 65: Acceptable limit of Brake Block Cracks
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103
11.7.1 Action when Defects are found
If a brake block exceeds any of the criteria quoted above, it shall be

renewed. It is recommended that the following checks are carried out :
a) Check brake block carrier for defects, e.g. loose, missing, worn, or
damaged parts.
b) Check brake rigging for defects, e.g. loose, missing, worn, or

damaged parts.
c) Check brake cylinder pressure in accordance with the specified

limits.
d) If any component/assembly is found to be defective then appropriate

remedial action should be taken.
11.7.2 Precaution
Do not stand on composition brake block.

Do not drop/throw composition brake block.
Do not hit composition brake block.
12. PROCUREMENT OF SPARE PARTS:
Spare parts, which are considered important in the performance of bogie, are
to be procured from approved sources only. These items are also to be
compulsorily inspected by Executive Director Q.A (Mech.)/RDSO, or his
representative. List of such components is given below-
(a) Side frame and Bolster

(b) Brake beam
(c) Spring plank
(d) Springs
(e) Silico Manganese steel liners of LCCF/LWLH bogies.
(f) Adapters
(g) Elastomeric pad and side bearer pad
(h) Centre pivots To be purchased from Class ‘A’ foundries only, as
(i) Friction Wedge per vendor list issued by RDSO at every 6 months.
Marking particulars (i.e. Month & Year of manufacture, manufacturer initials,

trademarks or both etc.) shall be provided by component manufacturer on all
safety components as per component drawings/approved drawing. Any
component without these particulars Cast/embossed on them should not be
accepted and fitted on LCCF/LWLH bogies.
The vendor list of approved manufacturers is updated by QA (Mech.)

directorate of RDSO biannually. The updated vender list is issued biannual
i.e. on 1st Jan. & 1st July every year.
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13. FAILURE REPORTING:
Proper failure reporting and analysis is an important activity for ensuring proper
maintenance and quality check on components leading to improved performance.
Feedback is needed for making design improvement also.
All base depots should maintain performance statistics, which should cover defect
wise wagon detachments and repairs analysis, components life statistics & vendor
rating etc. These are general guidelines and may be modified to suit specific
requirements.
Premature failure of items in the field, inspected by R.D.S.O should be reported

directly to ED/QA (Mech.), RDSO Lucknow and copy of the same to ED/Wagon,
RDSO Lucknow.
Failure reports should have following information—
1. Wagon No.
2. Date of failure
3. Station of failure
4. Station where failed component has been kept.
5. Location of failure with a sketch.
6. Year of manufacture of the component.
7. Name of manufacturer.
8. Metallurgical investigation report. This is necessary to know the cause of
failure and fix responsibility.
Metallurgical investigation report can be sent later after conducting the

investigation.
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105
Enclosure-1
WELDING ON CAST STEEL COMPONENTS
1.0 COMPONENTS
i) Brake heads for brake beam of Cast Steel Bogies type LCCF 20(C)
/LWLH25
ii) Center Pivots.
iii) Sideframe and Bolster
2.0 ELECTRODE
Low Hydrogen Electrodes approved by RDSO under both the class C2 & 01
shall be used. Electrodes shall be preheated in a drying oven at
temperature of 150 - 200° C or as per recommendations of manufacturers'
at least one hour before use. The size of electrode shall depend upon
extent of wear.
Alternatively ROSO approved electrodes under Class C&O may be used.

These electrodes are to be dried before use as recommended by
manufactures. Short arc is to be maintained 4 or 5 mm electrodes are to be
used.
3.0 PROCEDURE
a) The worn-out area shall be cleaned preferably by grinding with

portable grinder.
b) The ground area shall be examined visually for presence of any
crack.
c) Each run of weld metal shall be de-slagged thoroughly before further
run in applied, particularly at the junction region between the weld
metal and fusion faces. Visible defects such as cracks, porosity,
voids and other deposition faults shall be removed before depositing
further weld metal
d) Each bead shall be peened with a ball pen hammer immediately
after deposition, starting from the hot end and then proceeding
backwards.
e) The welding operation, once started, shall be completed in one
stretch maintaining an interpass temperature between 250 - 300°c.
f) All welding shall be carried out preferably in down hand position with
the help of manipulator whenever required. In
case if necessary, welding can also be carried out in horizontal or
vertical - up position.
g) While using low hydrogen electrode, it shall be ensured to maintain
shortest possible arc and minimum weaving of electrodes.
h) The crater ends must be filled up by retracing back the electrodes to
about 12mm followed by withdrawal from weld pool. When a new
electrode is to be started, this shall be travel back over the crater end
and then forward again.
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i) No post weld heat - treatment is necessary.

j) The built - up area shall be finished by grinding up to the original
dimensions avoiding formations of grinding cracks.
k) The reconditioned area shall be examined visually as well as be
Magnetic Particle Test (MPT)/Dye Penetrant Test (DPT) to ensure
freedom from any defects/cracks. If any crack/defect is still
evident/persists the same should be removed and repaired and then
rechecked by MPT/DPT.
4.0 WELDERS
All welding shall be done by welders qualified as per IS : 7318 Pt. 1.

Welding Current as recommended by Electrode Manufacturers.
103 of 114
107
Enclosure – 2
A. WELDING OF SPRING STEEL LINERS TO IS:3885 PART I GR.4 on CAST
STEEL SURFACE
ELECTRODES TO BE USED:
Austenitic Stainless electrode having nominal composition of 18.8%

Chromium, 8.8% Nickel and 5.8% Manganese and approved by RDSO
against Class M1 of IRSM - 28 shall be used.
GENERAL WELDING PROCEDURE:
i) The liner shall be held in position by tack welding at mid points of the
length side.
ii) Welding shall be done in down hand position.
iii) Fillet size shall be maintained as stipulated in the drawing.
PRECAUTIONS:
Uniform bead is to be deposited. Weaving is not permitted. Each weld is to

be followed by light peening. If any crack is noticed, welding shall be
removed by cutting electrode and reweld. Check weld with dye-penetrant
Test to ensure freedom from cracks.
B. WELDING OF SPRING STEEL LINER TO IS-3885-PT-1 GR.4 WITH CAST

STEEL BOLSTER:
ELECTRODES TO BE USED:-
Same as recommended earlier for welding spring steel liners on Cast Steel
surfaces in general.
WELDING PROCEDURE FIG. 71 IS TO BE REFERRED.
i The liner shall be held in position by tack welding on either side (side
AE & MR). Tack welding shall be done at the mid point of the length
side on either side i.e. top (AE) and bottom side (MR).
ii Welding shall be done in down hand position preferably as per the
sequence given in Fig. 66.
iii The length of the spring steel liner is about 150 mm. This length shall
be divided in to four equal sizes and marked as 1, 2, 3 & 4 on one
side and 5, 6, 7 & 8 on the opposite side.
iv Start welding at D and weld up to (E). Start again at and weld up to
(D).
v Then start at (B) and weld up to (X) covering the corner (A). Start at
(D) and weld up to (Y) covering the corner (E).
vi The opposite side (Side MR) shall be welded in the manner as per
sequence given in Fig. 66.
vii The width sides (Sides AM and ER) are not accessible for welding.
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viii The fillet size shall be maintained as stipulated in the drawing.

ix Welding is to be done in two passes firstly with 3.15 mm dia.
Electrode and then with 4 and 5 mm dia.
PRECAUTIONS:
Same as mentioned for general application under same Enclosure 2.

Regarding welding sequence, refer Fig. 66.
C. WELDING OF MANGANESE STEEL LINER TO IRS- R - 65 - 78 ON THE

SIDEFRAME COLUMN.
Type of electrodes to be used, their size and precautions to be taken shall

be same as described for bolster liner application. Down hand welding shall
be used. Regarding welding sequence, refer Fig. 66.
WELDING SEQUENCE (FIG. 66)
i Start from one corner and then weld opposite corner and so on till all
four corners are completed in the same pass.
ii Sequence of welding Corner (A), (M), (L) and (N) :
iii Sequence of welding at each corner (e.g.) Corner (A).
iv Leg. (A), (C) & (8):- Start at (C) and weld outwards towards (A),
Start again at (C) and weld outwards towards (8).
v Leg. (A), (E) & (D):- Start at (E) and weld towards (A).
Start at (E) and weld towards (D).
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Fig. 66: welding Sequence of liner
106 of 114
110
Enclosure-3
A. WELDING OF STRUCTURAL STEEL TO IS: 2062 Fe 410 W & CAST STEEL TO
IS: 1030 Gr. 280 - 520 W.
Welding of New Brake Head (Structural Steel to IS : 2062 Fe 410W) with

‘End Piece Casting' (IS: 1030 Gr. 280 - 520 W).
ELECTRODES TO BE USED
Any brand of Low Hydrogen Electrodes approved by RDSO, against Class

C2 and D1 of IRSM - 28 shall be used.
WELDING PROCEDURE:
i) The 'Brake head' shall be held in position with the help of suitable
clamps and then tack welded on either side.
ii) The weld area shall be cleaned properly to make it free from heavy
scale, rust, paint, oil, grease etc. before welding.
iii) Welding shall be carried out in down hand position with the help of
suitable clamps.
iv) Each run shall be de-slugged thoroughly before depositing
subsequent run.
v) Shortest possible arc and minimum weaving shall be maintained
while using 'Low Hydrogen Electrodes'. Stray arcing should be
avoided.
vi) The crater end must be filled up properly by retracing back
slightly.
vii) Visible defects such as cracks, porosity, voids and other deposition
faults shall be removed by gouging before depositing further weld
metal.
PRECAUTION
Low Hydrogen Electrodes shall be preheated in an Electrode drying oven at

a temperature of 150º - 200 ºC or as per recommendations of Electrodes
Manufacturer for at least one hour before use.
B. RECLAMATION OF FRICTION WEDGE BY WELDING

(PREFERABLY DURING POH)
SURFACE PREPARATION
The surfaces to be welded should be cleaned properly to remove dust, oil,

cracks, scales prior to welding electrode 4 mm dia of the 1976.
CURRENT CONDITIONS
The power source as recommended by the manufacturer of the electrodes

shall be used. The lowest possible current capable of producing satisfactory
welding should be used. Over heating should be avoided.
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111
WELDING PROCEDURE
i) Short and stringent welding bead should be used

ii) Skip welding should be followed
iii) short arc should be maintained
iv) Weaving is not recommended
v) The subsequent weld runs are only after previous run gets cooled to
room temperature.
vi) The weld bead should be peened immediately after welding.
vii) The crater should be filled up by removing the electrodes
slowly after going backward.
viii) Post weld heat treatment: It should be ensured that the weld
metal is quickly cooled. (Forced air through Fan).
INSPECTION
The welded surface after cooling be grounded properly to required

dimension and then subjected to dye-penetrant test. As manganese steel
has work hardening nature, grinding should be effected in bits and enough
cooling time between runs and effective immediate cooling after each run is
to be employed.
A lot of precaution needs the repair of wedge. Hence, it is always preferable

to replace the worn out wedge with a new one instead of repairing the old.
108 of 114
112
Enclosures-4
LIST OF DRAWINGS & SPECIFICATION/STR FOR LCCF 22(C) BOGIE
S. No. Drawing Number Description
1 CONTR-9404-S/1 Index
2 CONTR-9404-S/2 Bogie General arrangement
3 CONTR-9404-S/3 Cast steel side frame
4 CONTR-9404-S/4 Bogie Details
5 CONTR-9404-S/5 Cast steel Bolster
6 CONTR-9404-S/6 Wedge
7 CONTR-9404-S/7 Spring details
8 CONTR-9404-S/8 Centre Pivot & Side bearer Assembly &
Details
9 CONTR-9404-S/9 Bogie brake gear arrangement
10 CONTR-9404-S/10 Bogie brake gear details
11 CONTR-9404-S/10 Composition brake block
12 CONTR-9404-S/11 Brake beam
13 CONTR-9404-S/12 Wheel & axle assembly
14 CONTR-9404-S/13 Wheel
or
WAP-W-004
15 CONTR-9404-S/14 Leading dimensions and tolerances
16 CONTR-9404-S/15 Spring loaded side bearer assembly & details
17 CONTR-9404-S/16 Marking scheme for Cast steel side frames &
Bolsters
18 CONTR-9404-S/17 Brake beam
19 WD-95005-S/1 Elastomeric Pad
20 SK-78527 Wide Jaw Adapter
21 CONTR-9404/S-04 Side frame key
(Item-03)
22 CONTR-9404/S-04 Key bolt nut, Spring Washer & Spring Pin.
(Item-05)
23 WD-95005-S/1 Elastomeric pad
24 CONTR-9404-S/8 Centre Pivot & Side bearer assembly details
25 WD-89006/S-1 BG, MG & NG Coil Spring Drawing Code
26 STR No. AB/RB-40- Standard AAR Class ‘E’ (6” X11”) Cartridge
2016 Tapered Roller Bearings
27 Specification No. Specification for LCCF-20(C) Cast Steel
CONTR-LCCF20(C)- Bogies
96 with friction damping arrangement for Broad
Gauge Wagons
109 of 114
113
Enclosures-5
LIST OF DRAWINGS & SPECIFICATION/STR FOR LWLH25 BOGIE
S. No Drawing Number Description
1 WD-15021-S/01 Index
2 WD-15021-S/02 Bogie General Arrangement with ‘K’ Class
bearing
3 WD-15021-S/03 Cast Steel Side Frame
(with ‘K’ Class Narrow pedestal jaw)
4 WD-13012-S/04 Bogie Details
5 WD-13012-S/05 Cast steel Bolster
(with integrated 14” center pivot bottom)
6 WD-13012-S/06 Cast Steel Wedge (for nested spring)
7 WD-98014-S/03 Outer & Inner spring details
8 CONTR-9404-S/09 Bogie brake gear arrangement
9 CONTR-9404-S/10 Bogie brake gear details
10 CONTR-9404-S/11 Composition Brake Block
11 WD-15020-S/01 Wheel & axle assembly
(For 25t axle load bogie with ‘K’ Class CTRB)
12 WD-15021-S/04 Leading dimensions and tolerances
13 WD-12008-S/01 Spring loaded side bearer assembly & details
14 WD-13012-S/09 Side bearer assembly height adjustment details
15 WD-13012-S/10 Marking scheme for Cast steel side frames &
Bolsters
16 WD-89006-S/01 BG, MG & NG Coil Spring Drawing Code
17 WD-95005-S/01 Elastomeric pad
18 WD-13012-S/11 Bogie assembly procedure
19 WD-15013-S/01 Center pivot top assembly & details
20 WD-15020-S/03 Adapter
(Narrow Jaw with lug Class ‘K’ (6 ½ ”X 9”)
21 WD-13012-S/04 Side Frame Key
(item-02)
22 WD-13012-S/04 Side frame Key bolt, nut with Spring Washer &
(item-04) Spring Pin
23 WD-16006-S/01 Brake Beam (suitable for ‘K’ type brake block)
24 Specification No. Specification for Light Weight Low Height 25t axle
WD-40-LWLH25 load Cast Steel Bogie (LWLH25) with AAR ‘K’-
Bogie (“K‟ Class)- Class CTRB for Broad Gauge Wagons
2015
25 STR no. AB/RB-41- STR Standard AAR Class ‘K’ (6 ½ ”X 9”)

2016 Cartridge Tapered Roller Bearings
110 of 114
114
Enclosures-6
(A) At a Glance:
S. Description New/ Renewed Worn Wear Relevant
No (Specified (mm) limit clause
dimension), (mm)
(mm)
Bolster
1. Bolster Liner 8 3 5
2.4.2
2. Bolster pocket 35º +1º - -
3. Bolster land surface 444 ±1.5 438 3
4. Bolster Rotation stop lug 518 512 3 2.4.3
5. Bolster column Outer 241 +2/-0 251 5

Gibs
Bolster column Inner 136 +3/-0 146 5 2.4.4
Gibs
Center Pivot
6. Wear limit vertical side - - 2 2.4.5
Horizontal Seat - - 2
Side frame
7. Side frame column sides 216±1.5 206 5 2.5.3
8. Side frame anti rotation 450+2/-0 456 3 2.5.4
lug
Pedestal crown roof
9. LCCF20(C) 318±3 323 6 2.5.5
LWLH25 349±2 354 5
10. Pedestal crown sides 152 144 4
11. Pedestal sides 2.5.6
LCCF20(C) 105 101 4
LWLH25 81 77 2
12. Pedestal Jaw
Distance between Jaws
LCCF20(C) 278+2/-0 286 4 2.5.7
Distance between Jaws 203.5+2/-1 211.5 4 2.5.8
LWLH25-
Pedestal jaw (Short) 263.5+3 271.5 4
2.5.8
Pedestal Jaw (Long)
13. Crown sides 152 144 4
Friction Shoe Wedge Block
14. Vertical surface from 61 54 7
centre line 7.1
15. Slope surface from gauge - - 3
111 of 114
115
S. Description New Worn Wear limit Relevant

No (mm) (mm) (mm) clause
Adapter
16. Thrust shoulders wear limit - - 0.7 4.1
17. Adapter bore (bearing seat) ≥ 0.8 4.2
machine relief depth
18. Crown lug
Wide jaw for LCCF20© 156+2.75/-0.425 164 4 4.3
Narrow jaw for LWLH25 155.5+2/-0 163.5 4
19. Adapter Side lugs

Wide jaw 130+3.35 136 3 4.5
Narrow jaw 96.82+4 106.82 3
20. Adapter bore seat to crown
seat
Wide jaw for LCCF20© 48.5 +1.05/-0.1 45 3.5 4.4
Narrow jaw for LWLH25 27.4 23.9 3.5
21. Adapter bore seat to crown

seat
Wide jaw for LCCF20© 268+0.287/-2.8 262 3 4.6
Narrow jaw for LWLH25 194.46 188.46 3
Note: Adapter shall not be welded at any location
ELASTOMERIC PADS & CONSTANT CONTACT SIDE BEARER
Type of pad Free height Condemning free Relevant
(mm) height (mm) clause
Elastomeric pad 46 +1 42 5
Constant contact side bearer
Spring loaded side
bearer to drg. No.
As per drawing As per drawing
CONTR-9404/S-1 for
LCCF20(C)
Side bearer shall be as 6
per Specification no. As per As per
WD-62-Misc-17 for drawing/specification drawing/specification
LWLH25
LOAD SPRINGS & SNUBBER SPRING

Bogie type Spring Free height Condemning Relevant
(mm) height (mm) clause
Outer (O) 260±2 245
LCCF20(C) Inner (I) 243+0/-3 228
Snubber(S) 288±3 273
Outer (O) 264 249 7
LWLH25 Inner (I) 246 231
Snubber(S) 281(SO) 266
289(SI) 274
112 of 114
116
B.) Abbreviation used in the Pamphlet
alt. alteration
AAR Association of American Railroads
BG Broad gauge (=1676 mm)
Fig. Figure
BPC Brake Power Certificate
º Degree
ºC Degree Centigrade
CASNUB Cast steel snubbing bogie
CCSB Constant contact side bearer
CTRB Cartridge Tapered Roller Bearing
CP Centre Pivot
Drg. Drawing
LCCF20(C) Low Container Carrier Freight Bogie.
LWLH25 Light Weight Low Height 25 t axle load bogie
Φ diameter
POH Periodic Overhauling
ROH Routine overhauling
t Tonne (=1000 Kg)
O Outer Spring
I Inner Spring
S Snubber Spring
SI Snubber Inner Spring
SO Snubber Outer Spring
IS Indian Standards
IRCA Indian Railway conference Association
IRS Indian Railway Standard
ISO International Organization for Standardization
Max. maximum
Min. minimum
mm millimeters
no. Number
OEM Original equipment manufacturer
RDSO Research Design and Standard Organisation
Ref. Reference
Rev. Revision
Spec Specification
STR Schedule of Technical Requirements
UST Ultrasonic testing
WD Wagon Design Directorate of RDSO
113 of 114
117
C.) REFERENCE MANUAL/DOCUMENTS
This Pamphlet refers to the following manual/standards (latest):
S. Reference Document Description

No.
1 RDSO’s Technical Pamphlet No. Instruction for inspection and
G-95 Maintenance of CASNUB bogie
2 RDSO’s Technical Pamphlet No. Instructions for inspection and
G-81 Maintenance of Cartridge Tapered
Roller Bearing fitted on cast steel
bogies
3 Maintenance Manual for Wagon Maintenance Manual for Wagon-
2015 or latest issued by Ministry of
Railway, CAMTECH, Gwalior
4 IRS R 19/93 Part-I Indian Railway Standard
Specification for Wheel and Axle
Assembly for carriages and
Wagons.
5 RDSO’s Specification No. Specification for Light Weight Low
WD-40-LWLH25 Bogie (“K‟ Height 25t axle load Cast Steel
Class)-2015 Bogie (LWLH25) with AAR ‘K’-
Class CTRB for Broad Gauge
Wagons
6 Specification No. Specification for LCCF-20(C) Cast

CONTR-LCCF20(C)-96 Steel Bogies with friction damping
arrangement for Broad Gauge
Wagons
7. WD-23-BMBS-2008 Specification for Bogie Mounted
Brake System for Freight stock
8 WD-62-Misc-17 Technical Specification for Constant
Contact Side Bearers For Broad
Gauge Bogie Wagons
9. CONTR-02-MISC-2007 Specification of friction wedge with
non-metallic liner
114 of 114

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INSTRUCTIONS FOR INSPECTION AND MAINTENANCE OF

TECHNICAL PAMPHLET No. G-112

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Paragraph Description Page No.

1. Definitions and description of bogie parts 6

1.1-1.2 General Construction 9

2.1 Recommended method of Reassembling 15

2.2 Nominal Clearances of the bogie Assembly 20

2.3 Maintenance of the Bogie 23

2.4 Repair procedure for the major bogie components 26

3.2 Wheel tread profile 54

6. Constant contact Side Bearers 74

7. Load Bearing Springs & Snubber Springs 74

10-10.1. Maintenance in Yard 92

11. Attention in Sick line 89

13 Failure Reporting 100

Enclosure Description Page No.

Enclosure-1 Welding of cast steel bogie components 100

Enclosure-5 list of drawings & specification/STR for LWLH25 Bogie 109

Enclosure-6 (A) At a Glance 110-114

(B) Abbreviation used in the Pamphlet

1.0 DEFINITIONS AND DESCRIPTION OF BOGIE PARTS:

Terminology Description of Bogie Parts

Air Brake A combination of devices operated by compressed air arranged in

Bogie (Truck) The complete assembly of parts including wheels, axles,

when variation in track cross level cause car body to rock

the other and acting in combination. Bogie springs are commonly

Gauge (Track gauge)

Gauge Measured at right angles, the distance between running rails of a

1.1 GENERAL CONSTRUCTION

Fig. 1: Bogie of freight stock

Fig. 2: Exploded View of LWLH25 bogie

1.4 SALIENT FEATURES OF LCCF 20(C) and LWLH25 BOGIES

S. No. FEATURES LCCF 20(C) LWLH25

4. Wheel Base 2000 mm 2000 mm

1.5 BOGIE COMPONENTS-

S.No. DIS-SIMILARITY LCCF-20(C) Bogie LWLH25 Bogie

1. Side frame design Cast steel design Cast steel design

4. Cartridge Tapered AAR Standard Class AAR Standard Class

5. Adapters Wide jaw Adapter Narrow jaw Adapter

i) Disconnect the bogie brake rigging attachments to underframe and

2.1 RECOMMENDED METHOD OF REASSEMBLING

Fig. 5: Re-assembly Procedure (Continued….)

Fig.5: Re-assembly Procedure (Continued….)

Fig.5: Re-assembly Procedure (Continued….)

Fig.5: Re-assembly Procedure

15.) Ream the holes of spring plank for riveting if necessary.

2.2 Nominal Clearances:

Description Type of Bogie

Fig.6: Nominal Clearances LCCF20(C) bogie

Fig.7: Nominal Clearances LWLH 25 bogie

2.3 MAINTENANCE OF THE BOGIE

2.4 REPAIR PROCEDURE FOR THE MAJOR BOGIE COMPONENTS

2.4.2 Bolster Pocket 35± 1º slope surface Nominal.

Liner Wear Limits: 5 mm

2.4.3 Bolster Land Surface and Rotation Stop Lugs:-

New Worn Wear Limit