ICF Coach defects and tolerances

1. IDENTIFY ICF
DEFECTS &
ITS TOLERANCES
SUBHAMOY TARAFDER
SSE/PWAY/SKP

2. ICF all coil bogie- general arrangement
1. Axle Box/ Primary Spring
2. Bolster/ Secondary Spring
3. Swing Link/ Hanger
4. Lower Spring Beam
5. Bolster
6. Side Bearer
7. Centre Pivot
8. Bogie Frame
9. Anchor Link
10.Sole Bar
11.Head Stock
12.Transom
13.Longitudinal Bar

3. Common
defects in Axle
Guide Assembly
Defects Reasons
1. Perished rubber packing ring 1.Poor quality of Rubber packing ring.
2. Axle guide found worn on one side.
3. Lower Spring Seat surface worn.
2.3.i) Misalligned fitment of axle guides to bogie
frame.
2.3.ii) Dust ingress to lower spring seat.
4. Guide ring broken.
5. Guide cap securing assembly broken.
6. Lower Spring Seat scored and dent mark on guide cap.
7. Leakage from lower spring seat.
4-7.i) Axle guide is hitting lower spring seat.
4-7.ii) Weld joint of lower spring seat and tube is
porous or cracked.
Measurement equipment / method-
Visual inspection / Dial Bore Gauge
/Trammel Gauge

4. Defects Reasons Tolerances
Dent mark on guide cap. Lower level of oil on top of guide cap/
decrease in damping.
Oil level, measured by insertion of a
fexible wire through a hole, must not
be below 40mm in tare condition.

5. Defects in Anchor Link
SL.No. Defects
1. Check the condition of the anchor link, for being worn or corroded or found cracked (normally at weld
joints)
2. Inspect the Silent block , for rubber perished (indicated by fretting) or loose in the anchor link housing,
or the sient block pin is worn thin or loose in silent block rubber.
3. No coach should be permitted to run with broken anchor links.
Mesurement Equipment /
method- Visual Inspection
Bolster Spring
Swing Link/ Hanger
Shock Absorber
Lower Spring Beam
Hanger Pin
Hanger Block

6. Defects in Swing Link
SL No. Defects Tolerances
1. Check Swing link for crack, wear on the rocking surfaces
and elongation.
Total wear is > 3mm, the swing link to be
scrapped. ( New size -387 mm, condemned size-
384 mm)
2. Hanger pin/ bush to be checked for wear or crack. Maximum permissible wear on diameter of
hanger pin is 1.5mm.
3. Check Swing link hanger box for any wear.
Defects in Shock Absorber
SL no. Defects
1. Leakage of Oil to be checked.
2. Physical damages are to be checked.
Mesurement Equipment / method- GO NO GO Gauge / Visual Inspection

7. Defects in Centre-Pivot
SL No. Defects
1. To be checked if the pivot is damaged or
bent or bracked.
2. To be checked if the bolts holding pivot to
body is secured and tight.
3. Whether cotter and cotter pin at pivot
bottom are secured
4. Verticility of pivot pin to be checked.
Mesurement Equipment / method- Visual Inspection

8. Defects in Side- Bearers
Mesurement Equipment / method- Vernier/ Height Gauge / Visual Inspection

9. SL. No. Defects Tolerances
1. Steel wearing plate should be checked for wear and
sharp corners.
Wear limit – 1.5 mm (when it reaches thickness of
8.5 mm.
ii) For high speed ICF All-Coil coaches wear limit
is 1.0 mm
2. Bronze wearing plate to be replaced when it go past the
limit
i) Bronze wearing plate to replaced when the
height reduces to 42mm (3 mm wear)
ii) For high speed ICF AA-Coil coaches wear limit
is 1.5mm
3. Leakage of oil from the side bearer oil bath welding
portion to be checked.

10. Defects in Bogie Bolster
SL No. Defects
1. Check bolster for twist or crack.
2. Check Equilizing stay bracket for bent, damage.
3. Check Anchor Link bracket for damage.
Defects in Bogie Frame
SL No Defects
1. Trolley frames are if out of squre or damaged.
2. Damages / Cracks in the bogie frame and brackets
attached with the bogie frame
3. Check the squreness and alignment of BSS
brackets and axle guides with the help of
tranverse, longitudinal, diagonal gauges and
straight edge.

11. Defects in Roller Bearing
Defects in bearing are likely to result in hot axle condition
under which the actual temperature of axle box becomes
higher than the normal operating temperature of around 70
degree celcius.
SL.
No.
Defects
1. Improper and/or excessive/inadequate grease.
2. Bearing clearance not within prescribed limits.
3. Journal finish and Diameter not as prescribed in the
drawing.
4. Excessive or inadequate lateral clearance between axle
box covers and bearings.
5. Too little or too much gap between rollers and roller ring.
Measurement equipment / method- Visual Inspection / Feeler Gauge
/ Non contact Thermometer.

12. Defects in Brake Gear
SL. No. Defects Tolerances
1. Inspect the condition of brake beam/ levers for wear or
damage.
2. Brake shoe head may be corroded, dented or damaged.
3. Check the wear, damage, etc to the brake gear pins.
4. Check the weak and damaged brake shoe if any.
5. Check the wear in composite brake block. Worn out to thickness 12mm or
below.
Measurement equipment / method- Visual Inspection

13. Defects in Buffer Height
Mode of measurement of defect – Visual Inspection / Buffer Height Gauge
SL No. Buffer measurement Value Condition
1. Maximum Buffer Height 1105mm Empty condition
2. Minimum Buffer Height 1030mm Loaded Condition
1090mm When released from POH workshop.
3. Difference of buffer height from rail level
between any two buffers of same vehicle
64mm For checking irregular loading
4. Gap between Flange of any wheel and
bottom of vehicle
25mm For checking irregular loading
5. Maximum Buffer projection limit from
head stock
635mm
6. Minimum Buffer projection limit from
head stock
584mm
7. Maximum Buffer displacement in any
direction from normal position
38mm It’s called “Displaced Buffer”

14. Defects in Wheels
Different types of wheel defects-
I. Thin Flange
II. Sharp Flange
III.Deep flange
IV. Holllow Tyre / False Flange
V. Flat Tyre
VI. Worn Root

15. Thin Flange

16. Deep Flange

17. Hollow Tyre / False Flange

18. Flat Tyre

19. Worn Out

20. Sharp Flange

21. Thin Flange
Hollow Tyre/
False Flange
Deep Flange
Sharp Flange
Flat Tyre
Worn Root

22. SL
No.
Wheel
Defects
Tolerances Repercussions
1. Thin Flange  New flange thickness- 28.5mm
 Condemn Size- 16mm
 - 22mm (Mail/Exp Train)
Thin Flange requires greater flange-way gap
which may not be available resulting in
possibility of damage to the tongue rail.
2. Sharpe Flange  At the tip of flange-
 New Radius- 14.5mm
 Condemned Radius- 5mm
Chances of bursting of point due to entering
of sharp flange between tongue rail and
stock rail.
3. Deep Flange  New Height- 28.5mm
 Condemned Height- 35mm
Shearing of fish plate bolts at rail joints.
4. Holllow Tyre
/ False Flange
 The projection of outer edge of the wheel
tread below the hollow of tyre exceeds
5mm
A False Flange may split open points while
travelling in trailing direction. It may also
mount on nose of crossing in faceing
direction.
5. Flat Tyre  For Coaching Stock- 50mm Chances of Rail Fracture.
6. Worn Root  Radius of the Flange at the Root
 New- 16R
 Condemned- 13R
Excessive lateral play result in chance of
mounting of flange of rail.

23. 1 Standard Gauge 1600 mm
2 Maximum Gauge 1602 mm
3 Minimum Gauge 1599 mm
SL. No. Wheel Gauge Value
Back surfaces of the wheels mist be clean properly before measuring the wheel Gauge.
• If the wheel Gauge is more than the permissible limit, there is a possibility of a relatively
newer wheel hitting the nose of crossing.
• If the wheel Gauge is less than the permissible limit, there exist a possibility of wheel
hitting at the back of tongue rail while passing through the switch.
Note:-
• Wheel Gauge must be checked in no load condition.
• It indicates whether any indication of shifting of wheels on the axle.
Defects in Wheel Gauge

24. Note:-
Wheel diameter is measured on the tread at a distance of 63.5 mm from the
inside face of the wheel.
5 mm 13 mm
Tolerances on difference in diameters of different wheels
Same Bogie
Same Axle Same Coach
0.5 mm
Defects on Wheel Diameter on Tread
Wheel Diameter New 915 mm
Condemn size 825 mm

25. Defects in Helical Spring
SL.
No.
Defects
1 Visual inspection of all coils for cracks, dents or hitting mark.
2 All the springs should be from same category (i.e; A, B, C) on primary and secondary suspension
separately i.e; category of primary and secondary may be different.
3 Defective / mismatched spring are likely to result in variation in vertical clearances.
Code Colour
A Yellow
B Oxford Blue
C Green

27. Defects in Vertical Clearance
Clearance Location Denoted By
Bogie Frame Bolster Clearance Between Top of Bolster and Bottom of Side Frame C
Body Bogie Clearance Between Top of Side frame and bottom of Coach body D
Crown Clearance Between Axle Box Crown and bottom of Side Frame. X

28. Defects in Coach Body
SL. No. Defects
1 Underframe members should not be cracked / bent / corroded.
2 Components which are not visible from both side like sole bar and trough floor should be examined
by tapping with a spiked hammer.
3 Particular attention to be paid to more vulnerable members like sole bar, body pillars etc
Note:
A component will require repair / replacement , if it lost more than 20%