Coach Maintenance Manual of LHB Coaches

channel sections 140x50x4

 Floor is made of corrugated sheets of 1.25 mm thickness
 Corrugated trough floor is plug welded
from top with the cross members.

Water tank mounting

brackets are welded
on the under frame

YAW DAMPER (connected

between under frame and
bogie frame) brackets are
welded on the under frame

CROSS BEARER 4 MM
SOLE BAR 6 MM
IRS:M-41-97
IRS:M-41-97

Figure: 2.3 Diagram Showing Various Sections of Shell

Page 4 of 40 Chapter 2

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 Coach Maintenance Manual of LHB Coaches

(x) All air brake fittings

(xi) Control arm bottom cover
(xii) Centre Buffer Couplers etc.
(xiii) CDTS
(xiv) Under slung water tanks & Water Raising Apparatuses (WRA), where
provided.
(xv) Battery box and electrical fittings.
(xvi) AC equipment in AC coaches.
c) Coach body should be lifted off the bogies either by two overhead electric cranes of
25 tonnes capacity each with suitably designed lifting tackles or by four powered
lifting jacks of 15 tonnes capacity each operated simultaneously by one control
switch. The coach body should be lifted uniformly without jerks and should remain
horizontal during the lifting/ lowering operation. Coach should not be lifted from
any point other than at the lifting pads as shown in figure 2.5.
d) The coach should never be lifted from one end only. If lifted from one end, the
Centre pivots security plate is likely to suffer damages, body panels are likely to get
dented near the body bolster. The sealed windows of AC coaches are also likely to
break.
e) After the coach body is lifted, it should be kept on trestles. The steel trestles of the
design shown in Figure 2.4 would prove useful for this purpose Lines should be
protected by scotch blocks with locking arrangement and key should be kept with
Engineer till the time maintenance work is carried out.
f) The entire under frame should be cleaned of dust, rust etc. from underneath by
pneumatic/water jet followed by wire brushing at critical locations and check for
cracks/damage, corrosion etc. on the under frame members.
g) After carrying out all repairs, the under frame should be painted.

2.9.3 Maintenance during Shop Schedule-I

i) All bogies of LHB coaches shall be given SS-I after 18 months  15 days from the
date of last Shop Schedule as per table 1.
ii) During this schedule, bogies/under frame members and body including trough
floors should be thoroughly examined and all parts of running gears are repaired/
replaced as necessary.
iii) The detailed of maintenance activities to be carried out during SS-I schedule, please
refer Chapter 12 of this manual.
iv) The date of this schedule should then be stenciled at the appropriate place in
schedule chart on the end panel.
2.9.4 Lowering the Coach Body
a) After all the repairs are carried out refit all repaired sub-assemblies which are
removed for maintenance and lower the coach body on the overhauled and tested
bogies.
b) The securing arrangement of Centre plate should be fitted into position and secured
by means of necessary fittings.
Page 6 of 40 Chapter 2

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 Maintenance Manual of LHB Coaches Coach

2.9.8 Repairs to Door Handles

Examine the door handle for breakage, damages. If the fixing bolts are loose or missing,
tighten the bolts. Replace the door handles which are found beyond repairs.

2.9.9 Repairs to Door Pivots

Examine the door pivots for corrosion, breakage or wear by cutting the bottom portion of
outer panel. Cut the corroded portion of the door pillar (Z molding) and weld new piece
joining the door pivot pin. If the female socket is worn or damaged beyond repairs then
replace it. Replace the bush provided in the socket.

2.9.10 Repairs to CBC Support Structure

Examine the CBC support structure for corrosion, breakage, etc. If the corrosion is light,
scrap off the rust to bare metal, clean well and re-paint. If the corrosion is heavy, replace
the corroded angle or gusset plate with new support angle.
Similarly examine the CBC support structure for corrosion, breakage, etc. If the corrosion
is light, scrap off the rust to bare metal, clean well and re-paint. If the corrosion is heavy,
replace the corroded angle or stiffeners.

2.9.11 Water Tank Support Structure

Examine the water tank support structure for corrosion, breakage, wear, etc. If the
corrosion is light, scrap off the rust to bare metal, clean well and re-paint. If the
corrosion, breakages are beyond repair, replace the corroded angle with new angle of
suitable size as per the requirement. Replace the rubber/wooden packing if perished or
damaged.

2.9.12 Repairs to Floor Channel

Examine the floor channel for corrosion, breakage, wear, etc. by cutting opening the PVC
and plywood flooring where the corrosion suspected. If the corrosion is light, scrap off
the rust to bare metal, clean well and re-paint. If the corrosion, breakages are beyond
repair, replace the corroded channels with new channel of suitable size as per the
requirement.

2.9.13 P.U. Surfacer Application

P.U. surfacer/touch up on shell to be carried out as per instruction issued by

RCF/Kapurthala vide document No. PLW 905 dated 09.06.2004 and M&C/PCN-
100/2006.

2.10 GENERAL PRACTICE FOR WELDING

 All repairs of cracks should be carried out by gouging and welding by suitable
electrodes.
 CAUTION: No electric welding on the coach should be carried out without proper
earthing from near the portion being welded such that the return current has a
distinct path (earth) which should not be allowed through the bogies and rails. In
the absence of such earthing, the return current passes through axle roller bearings
causing pitting of rollers and bearing failure in service.
Chapter 2 Page 11 of 40

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 Maintenance Manual of LHB Coaches Coach

Removal of masks, touch up, 1 Day Direct Act.

lettering, cleaning and other
works.
J Interior Paint Internal painting 2 Days Parallel to
Painting act.I
K Fitting work Fitting Body panel repair, Stripped body 2 Day Parallel
repair, Repair of inner members to Act.F
like partition frames, Chair angles
and seat supports etc.
L-1 Trimming Trimming Stripping of curtains on stripping 1 Day Parallel to
work line Act.A
L-2 Stripping of seats in Carriage AC 1 Day Parallel to
shop Act.F
L-3 Fitting of seats and curtains in the 1 Day Parallel to
coach Act.G
L-4 Cleaning of the seats and other 1 Day Parallel to
activities Act.N
M Water tank Plumbing Testing of under slung/over head 1 Day Parallel
testing water tank in CR Body/CR AC to Act.G
section.
Repair and testing of water tank 1 Day
in Plumbing shop.
Fitting of water tank in the coach. 1 Day
Fitting of CDTS panel in coach in 1 Day
CR Body/CR AC shop
N Final CR(AC) Final inspection and despatch 1 Day Direct.
inspection Act.
O Air brake R(Lifting) Final Air brake testing 1 Day Parallel
testing. to Act.N

Total days of Direct Activities 25 Days

Chapter 2 Page 31 of 40

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 Maintenance Schedules (Mechanical) Maintenance Manual for LHB Coaches

12.4 SCHEDULE D3 (HALF YEARLY)

Perform all the activities of schedule D2. In addition to this, perform the activities, as
given below

Bogie Frame

 Examine the bogie frame for corrosion / damages, especially at critical locations.

 Carry out paint touch up with high built epoxy primer and paint as per RCF
specifications MDTS – 166.

Wheel & Axle

 Check wheels offset on axle (1600 mm± 1 mm)

Control Arm

 Renew protection treatment with Tectyl / Cortec VC 1368 on the rubber joint on
visible areas.

Axle Bearing Instruments

 Replace all carbon brushes on earthing devices.

12.5 SHOP SCHEDULE-I (18 MONTHS)

The following activities shall be carried out in Shop Schedule-I.

Brake Equipment

 Perform function test of the Air Brake system components:

 Distributor valve

 Check valve

 Isolating cocks/angle cocks

 Filters, indicators, test fittings.

 Emergency brake valve & pull box

 Brake cylinders

 8WSP Equipment

 Brake gear pins and other bogie pins must be examined for wear and re-greasing.
Replace, if necessary.

 Examine BP/FP couplings and hoses. Replace, if necessary.

 Examine the Brake calipers and Brake pads for wear and damages. Replace, if
necessary.

 Check the functioning of hand brake equipment. Replace the defective components.

Page 4 of 19 Chapter 12

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 Maintenance Manual for LHB Coaches Maintenance Schedules (Mechanical)

 Examine the brake discs to detect any thermal or fatigue cracks. Replace, if
necessary. Brake disc bolts should be checked for tightness.

Axle Box Instruments

 Overhaul the grounding equipment. Check spring mechanism for self-regulation.

Replace carbon bar and slip assembly. Replace all worn parts.

 Carry out overhauling and testing of WSP equipment as per OEM‟s instructions.

Primary/Secondary Suspension

 Attention to springs during Shop Schedules shall be as given under Para 12.11.

 Examine the condition of lift stop pin and safety cables. Replace, if necessary.

 Check lower and upper centering discs for corrosion, wear, damage and cracks.
Replace, if necessary.

 Examine the condition of rubber and rubber/metal bonded parts for damage, cracks
and ageing. (Miner pads, rubber springs etc.). Replace, if necessary.

Dampers

 Check dampers for correct functionality, absence of deformations and oil leakages.
Replace fixings/fasteners, if necessary.

 Damper should be tested during Shop Sch.-I and Shop Sch.-II (or early in case of
oil leakages) as per parameters given in RCF drawings, read alongwith FIAT
specification no. 17.560.100. Dampers should be replaced during Shop Sch-III (6
years).

Damper RCF Drg. No. PL No.

Primary Vertical Damper LW 05102 00920083

Secondary Vertical Damper LW 05101 00920060

Secondary Lateral Damper LW 05100 00920058

Yaw Damper LW 05103 00920071

Bearings

 Rotate the bearing assembly to detect any abnormal condition. Check the bearing
mounted end play. If end play is beyond permissible limit or if any roughness is
detected while rotating the bearing, dismount the bearing and send for
reconditioning.

NOTE:
1. Bearing reconditioning is to be carried out whenever bearing is removed
from axle due to wheel-shelling / bearing failure.

Chapter 12 Page 5 of 19

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 Maintenance Schedules (Mechanical) Maintenance Manual for LHB Coaches

2. If new bearing or reconditioned bearing is fitted, a metal identification tag

with the mounting date shall be crimped to the brake disc near the bearing.
3. If the wheelsets are sent for re-profiling without dismounting bearings,
lubricate the lathe centres with heavy grease.
4. For reconditioning of bearings, please refer to OEM’s instructions.

Wheels and Axle

 Perform wheel profiling and wheel balancing (for Speed >= 130 Kmph). Refer to
RCF specn.no. MDTS – 168 for balancing procedure.

 Perform a general overhaul of the axle, remove signs of corrosion, renew corrosion
protection and repaint the axle.

 Check wear of wheels, if necessary, replace them.

 Perform an ultrasonic test on the wheel and axle to verify absence of internal cracks
and damages.

Control Arm
 Perform a general overhaul of the control arm: remove signs of corrosion, renew
corrosion protection and repaint the components.
 Check wear limit of control arm bore as follows; (Ref: RCF‟s letter no. MD 44121
Dt: 13.08.08)
 If the control arm bearing surface reaches a diameter of 230.5 mm (i.e. wears
out by more then 0.5 mm), the control arm should be considered worn out and
rejected.
 In case, the dia. is between 230.5 mm and 230.312 mm, the control arm may be
re-machined by providing a cut of 0.3 to 0.5 mm on the face of control arm.
(This machining operation should not be carried out more than once).
 In case, the diameter is less than 230.312 mm, the control arm may be reused
without remachining.
 The control arm mating surface with bearing should be coated with “ Blasol –
135” solution, to prevent corrosion.
 Examine the rubber joint for cracks/damage and ageing. Replace, if necessary.

Bogie Frame and Bogie Bolster

 Examine the bogie frame and bolster for cracks, damages and corrosion. Check all
the welded joints with dye penetration. If crakes are found, hold the bogie frame in
a suitable manipulator, and rectify.

 Corroded bogie frames should be attended as follows:-

 Cleaning/washing of bogie frames.

 De-scaling/rust removal with rust converter to IS: 13515

Page 6 of 19 Chapter 12

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 Maintenance Manual for LHB Coaches Maintenance Schedules (Mechanical)

 Touch-up with high build epoxy primer and paint as per RCF‟s specification no.
MDTS 166 (Rev.2) and MDTS 094.

NOTE: Small pitting holes upto a maximum depth of 3 mm may be permitted

on the frame, provided these are a) Staggered and non continuous b)
Are not concentrated on the bottom bend portion of the side
frame.(Ref: RCF’s letter no.MD 44121 dt. 17.09.09)

Anti-Roll Bar Assembly

 Perform a general overhaul of the anti-roll bar. Remove signs of corrosion, renew
corrosion protection and repaint the anti-roll bar and the links

 Examine the condition of the brackets: remove signs of corrosion, renew corrosion
protection and repaint the block.

 Replace fixings, rubber joints and sealings, on condition basis.

 Replace anti roll bar bearings, if necessary.

Traction Centre

 Perform a general overhaul of the traction centre components (Traction lever,

Traction Rods). Remove signs of corrosion, renew corrosion protection and repaint
the components.

 Replace the rubber bush and the rubber joints, if necessary.

Rotation Limiter

 Check condition of the steel roll and pin for wear/damages. Replace, if necessary.

Rubber and Rubber/Metal Bonded Parts

 Examine the Rubber and Rubber/Metal Bonded parts for ageing / damages/ failure
of bonding. Replace, if necessary.

Bogie Pins

 Examine brake gear pins and other bogie pins for wear/ damages.

 Replace the pins with hard chrome plated pins as per RCF drawings.

NOTE: RDSO has issued a check sheet for Bogie inspection of LHB coaches during SS-I
& SS-II, vide letter no. SV.Fiat dated 14.03.2006.

Further, western Railway has also issued a checklist for maintenance of LHB
coaches in workshops, vide letter no. M442/19/4 (LHB) dated 23.11.2006,
which may be referred by shops.

Chapter 12 Page 7 of 19

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 Maintenance Schedules (Mechanical) Maintenance Manual for LHB Coaches

CBC

 Attend the Tight lock CBC as given in RDSO‟s CMI no. RDSO/2006/CG/CMI -01

Under Frame & Running Gear

 Inspect trough floor- for corrosion and damage

 Inspect water tank frame- for corrosion and damage

 Inspect air brake module frame- for corrosion and damage

 Inspect air brake pipe lines- for corrosion and damage

 Inspect water system pipe line- for corrosion and damage

 Inspect emergency battery box frame- for corrosion, fixation bolt

 Inspect head stock for corrosion, damage

 Inspect sole bar for corrosion, damage.

 Inspect Gusset plate for corrosion, damage

 Inspect cross member for corrosion, damage

Water Supply
 Water tank tightening bolts- for tightness
 Water level Indicator - damage, leakage, working
 Rubber hose connection -replace of all rubber hose connection
 Drain cock protection cover - damage, availability
 Water inlet cover - provided
 Water tank sensor & its bracket -damage, broken

Roof
 Roof sheet- inspect for corrosion, damage, cracks
 Ventilator- inspect for corrosion, damage, deficiency of louvers
 Roof leakage- conduct leakage test

Exterior- Coach Body

 Window glasses, cracked, moist, opaque

 Window glasses rubber profiles

 Entrance doors out side rubber gaskets

 Destination board cover with locking arrangement , function of lock

Page 8 of 19 Chapter 12

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Maintenance Manual for LHB Coaches
Maintenance Schedule (Mechanical) Annexures

PERIODICIT
CRITERIA TO BE Y
S. NO WORK TO BE INSPECTED
CHECKED & ATTENDED
SS-I SS-II
Ladder Painting - M
Torn, stains, cleaned, dust
Carpet (I Class) - C
free (Replace if required)
3 SALOON SLIDING DOORS
Nylon Wire rope Damaged, worn out C C
S S Wire rope Damaged, worn out C C
Working condition, smooth
Top Mechanism C C
working
Locking mechanism Working condition C C
Glass & Rubber profiles Cleanliness, dusty, cracked C C
Grill & Grill rubber profiles Condition C C
4 UNDER FRAME
Head Stock Corrosion, Damage - C
Sole Bar Corrosion, Damage - C
Guset Plate Corrosion, Damage - C
Cross Members Corrosion, Damage - C
Corrosion, Damage, tight nut
Water Tank Frame C C
bolt
Corrosion, Damage, tight nut
Air brake Module frame C C
bolt
Corrosion, Damage, clamp
Air brake pipe lines C C
tightening
Corrosion, Damage, clamp
Water system pipe line C C
tightening
Emergency Battery Box Frame Corrosion, Fixation Bolt C C
5 WATER TANK
Pressure testing At 4.5 Kg/cm2 / (9 POUND) - M
Water tank tighting bolts Tightness - M
Water level Indicator Damage, Leakage - C
Replace of all Rubber hose
Rubber hose connection - M
connection
Drain Cock Deficient, repair & refit - M
Drain Cock Protection Cover New provided C C
Water inlet Cover Provided - C

Chapter 12 Page 1
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