SOUTH EASTERN RAILWAY

No:

M2/

Date: May 26,

2014
ARM/SRC
Sub: Maintenance guidelines for LHB design coaching stock
Maintenance instructions for LHB coaches have been detailed in CAMTECH
maintenance manual for LHB coaches issued in Apr13 and respective OEMs
manual. In addition, RDSO, CAMTECH and Railway Board have issued guidelines
for LHB coach maintenance. Taking into account the relevant instructions, the
following guidelines are reiterated for compliance by all concerned:
1.

Periodicity of maintenance schedules

Schedule
Trip Schedule D1
Monthly Schedule/D2
Six monthly
Schedule/D3
(Shop Schedule I) /SS-I
Shop Schedule II/SS-II
Shop Schedule III/SS-III

2.

18 Month + 30 days / 6 Lakhs Kms earned

whichever is earlier
3 years / 12 Lakhs Kms earned whichever is
earlier.
6 years/24 Lakhs Kms earned whichever is
earlier.

Material of construction: The LHB coach is of integral light weight

construction, consisting of separate assembly group for under frame, side
walls, and roof and end walls. The individual assemblies are joined to each
other by welding. Three types of steel are used for manufacture of body
shell. Only recommended electrodes (Class D2 or equivalent) should be
used for minor repair if required.
Shell Assemblies

Side wall, End

wall and Roof
structure
Roof sheet and
Trough floor
Under frame

3.

Periodicity
Every Trip/Weekly
30 days + 3 days
180 days + 15 days

Stel used and their % age

compositions
X2Cmi12 Ferritic steel (SS 409M)
(C</= 03% Cr 105-12.5%, Si 1%,
Mn0. 5-1.5%
X2C Nil 810 Austenitic steel (SS 304)
(C</= 0.07% Cr 17-19%, Si 1% max
Mn 2.0% max)

UTS
N/mm2
450600

Yield Stress
N/mm2
320

550750

235

IRS M-41/Corten steel

(C 0.01% max, Cr 0.35-0.6%, Ni 0.20.47% Cu 0.3-0.6% Si 0.28-0.72%
Mn0.25 to 0.45%

440480

320

OVERALL DIMENSIONS OF LHB COACH

Gauge

1676 mm

Length over body

23540 mm

Length over CBC

24000 mm

Wheel base

2560 mm

Maximum width over body

3240 mm

Maximum distance between inner wheels

mm

12345

Window opening

1180 x 760 mm

Distance between centre pivots

14900 mm

Height of compartment floor from rail level under tare condition 1303
mm
Maximum CBC drop under gross load and worn conditions

75 mm

Minimum height from rail level

102 mm

Maximum height of centre line of side

CBC above rail level for empty vehicle

1105 mm

Minimum height of centre line of CBC above rail level

mm
For loaded vehicle maximum tare weight
Wheels diameter (New)
Maximum axle load permissible
Number of toilets

1030

915 mm
16.25 tones
3 (for Shatabdi coaches), there
is difference In the no. of toilets
for different types of coaches.

Higher speed potential

200

160 Kmph upgradable to

Ride index of coach *

>2.75

2.5 at 160 kmph but not

EXAMINATION AND REPAIR PRACTICE

4.

Schedule D1, D2, D3 ;should be carried out in depots as per

following periodicity
D-1 (D1 Schedule, Every Trip/Weekly)
D-2 (D2 schedule, 30 days + 3 days)
Check visually the following for any damage/defects/deficiencies, it
is to be done in D1 or D2 or both:

Destination board brackets.

Body panels
End walls
Windows walls
Body side doors
Condition of head stock, sole bar and other under frame
members.

D-3 (D3 schedule, 180 days+ 15 days)

In addition to schedule D1 & D2 do the following

Examine trough floor and other under frames from underneath
for corrosion.

Attention should be given at coaching depot for different schedule

(D1, D2 and D3) as recommended by CAMTECH. Copy is enclosed
as annexure - I.
5.

Wheel sets and CTRB attention at depot:

i)
The wheels sets shall be inspected for the following conditions and
action taken as indicated for each condition:

Shattered Rim

Spread Rim

Shelled Tread

Thermal Cracks

Heat checks
(Para 1009 a (iii) of chg manual and CMI K 003)
ii) Wheel profile should be checked with Tyre defect gauge to ensure the
profile dimensions are within the permissible limits. Coaches with
wheels having thickness and profile worn below condemning limit
should not be allowed to continue in service and the coach should be
marked sick for change of wheels in the sick lines. (Para 1009 a (i) of
chg manual)
iii) The limits for permissible maximum flat surfaces on tread for BG ICF
coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I
dated 15/18.3.99) Para 1009 a (ii) of chg manual
iv) System is available for rolling in examination at terminating station
and axle box temperature is measured with non contact type
temperature measuring equipment and corrective action taken for
wheel sets with high temperature. (Carriage Dte/RDSO letter no.
MC /AB dtd 21.08.09).

Axle box temperature measurement by non contact type temperature measuring instrument
during rolling in examination.

Temperature to be checked at axle box front cover (Ref: RDSOs letter no. MC/RB/Genl
dtd. 06.01.2010)

If temperature is found above 800 C, the affected coach will be detached.

The following should be followed on the basis axle box temperature measurement:

S.N
1
2

Temperature rise
over ambient
200 C
200 C to 300 C

300 C to 400 C

Sate

Action to be taken

Normal
Bearing

Box allowed as OK
To be kept under watch by sending message to

warm

next TXR station and ascertained if temperature is

Excessively

rising.
Train to be escorted by TXR with box feeling at

warm

every station and bearing examined thoroughly at

destination. If axle box temperature is 800 C, then

v)

coach to be detached.
Last shop issue size (865 mm) and condemnation limit for wheel sets
(845 MM) as stipulated is being followed.

vi)

Presently the refurbishing/overhauling of LHB bearing is being done at

an interval of 1.2 million km. To ensure attention of CTRBs as well as
UST of axle, depot should have proper identification of wheels sets. In
case wheel sets are interchanged then traceability of wheel sets and
timely attention of wheel sets exist in the depot.
vii) Shelled wheels with length of shelling exceeding 40 mm and depth of
shelling exceeding 1.5 mm should be withdrawn from service. (Ref:
Amendment no. 1 of Dec 2011 to CMI-K003 Clause A-3.)
viii) Depot should not permit wheel sets with flaking in service. Adequate
spare wheel sets are available in depot.
ix)
Whenever coach is sent to shop for POH/IOH or non schedule
attention, details of wheel sets with regard to CTRB attention should
be furnished to shop. Similarly when loose wheel sets are sent to shop,
details of wheel sets with regard to CTRB attention should be furnished
to shop.
x) Grease oozing out is checked during attention at depot and corrective
action is taken accordingly.
6.
6.1

Air brake attention:

Changing of air brake hose pipe: Air brake hose pipe to be changed in every alternate POH attention.
(Carriage Dte/RDSO letter no. MC /APB dtd 19.02.09). Depot to ensure that hoses above 3 years of life
should be taken out from service.

6.2

The following attention should be given by depot during trip examination/IOH:

i)

100% SCTR checking should be done in all out turn coaches at Sick Line (Schedule D3 and misc
attention at sick line). SDCTR testing should be carried out as recommended by CAMTECH. A
format for SCTR testing is enclosed as Annexure II.

ii)

All new hoses to be checked under pressure under water before fitment.

iii)

Air Brake testing should be done to all coaches that will be attached to rake from yard.

iv)

Load leakage test: Full charging condition as well as service application condition.

v)

Air pressure continuity test from Guard Emergency Application Valve and rear most of the rake. BP
and FP gauges to be provided at rear end of coach to check continuity of entire rake.

vi)

Working of all Alarm Chain apparatus must be tested and ensured during trip schedule
examination.

vii)

Draining of Auxiliary Reservoir during each pit line attention\

viii)

Periodical cleaning and overhauling of Dirt Collector.

ix)

Periodical cleaning and overhauling of Guard Emergency Application Valve

x)

Angle to be secured with safety clamp to avoid its shifting during run.

xi)

No BP & FP should be coupled in twisted condition.

xii)

Spare BP /FP hose to be checked during air brake testing at fortnight interval and BP/FP
hose to be alternatively used.

xiii)

Modification of power car end BP/FP angle cock with treaded joints and isolating cock to
avoid failure during cattle run.

xiv)

Protection net to be provided below the ferrule joints of BP/FP pipe line.

xv)

Protection net to be provided over the air brake panel to avoid damage due to blast hitting
on run and subsequent damage.

xvi)

All coaches with reported brake binding en-route should be detached for thorough investigation.

xvii)

Provision of air-dryer in pneumatic line and periodic drainage of condensate from pneumatic line.
Provision of moisture trap in pneumatic line as well as in RTR.

6.3

Checking of rake through RTR:

i)

6.4

Before connecting RTR with the yard source, the source should be opened to blow out dirt and
mud.
ii)
Charge the BP of the rake to 5 kg/cm. After dropping BP pressure from 5 kg/cm by 1 kg/cm i.e.
not below 4 kg/cm to check whether all brakes cylinder piston are coming out and brake blocks
are gripping on wheel. In case there is a doubt regarding any brakes cylinder piston not coming out
to its full stroke, after dropping BP pressure 1 kg/cm , the testing should be done after re-charging
BP pressure to 5 kg/cm and dropping BP pressure by 0.5 kg/cm only and checking for piston
movement. Coaches where piston movement is found to be nil or sluggish are to be detached and
taken to sick line for checking of DV functioning. Activation of all the brake cylinder piston of the
rake must be checked by dropping BP pressure by a maximum of 1 kg/cm only and not by
dropping up to 1.5 kg/cm which may sometime give misleading response of brake cylinder piston
movement.
iii)
Load leakage to be checked at full charging condition (BP - 5 kg/cm) and Service application (BP
dropped to 4 kg/cm)
iv)
Checking for application time should be done by dropping BP pressure from 5 kg/cm by 1.5
kg/cm i.e. up to 3.5 kg/cm. Release time to be checked after re-charging the BP.
Changing of brake block: Replace brake pads if worn out to thickness of 7 mm (New 35 mm). Brake
block should be replaced in sets in a bogie. All brake block thickness in bogie should be uniform.

6.5

Attention of brake calliper: Attention of brake calliper should be given during D3 schedule. In case brake
calliper jam is observed then brake calliper to be overhauled and pins etc lubricated again.

7.

Maintenance schedules attention for CBC attention:

Interval
Trip/Weekly
schedule

D2/ Monthly
schedule

D3/Six
monthly
schedule

Maintenance
Visual inspection of coupler head for damage
Inspection of knuckle for damage
Checking of coupler operating mechanism for damage/loose bolts etc.
Greasing of glide rod of coupler operating mechanism (once in 3 months)
Checking of telltale recess, for ensuring proper coupling.
Inspection or coupler carrier/supporting device and its springs for cracks and
breakage.
Inspection of loose/broken/missing nuts and bolts (M-16) of coupler pin support
plate and draft gear support plate.
All items of D1
Visual check for external damage, condition of wear plate on shank. Replace
wear plate if necessary.
Check height 187.5 mm both sides near the bolts, Tighten the M16 nut to set
specified height.
Apply grease on wear plate
Check condition of wear plate. Replace wear plate if necessary.
Visual check for external damage, loose bolts etc.
Apply grease on the slide and slide rods.
All items of D2
Coat bare steel areas of coupler head body and knuckle with Molykote D32IR (or
equivalent) dry spray.
CAUTION: Do not spray on the knuckle locking surface and internal parts like
lock etc.
Check gap between coupler head and ;knuckle with Jaw gap gauge (NO-GO). If
wear out is not acceptable replace knuckle etc. as advised in the maintenance
manual.

8.

Check by profile gauge (GO)

Conduct anti-creep check
Examine condition of buff plate. Apply grease if necessary
Check wear on slide, slide rods and bearings. Replace if wear is excessive.

Special attention as recommended by RDSO:

Item
Phonic wheel / speed sensor

Dump valve
Earthing device

Attention to be given
i)
M8 size screw to IS 1367 Pt.III class 10.9 along with spring washer
to the IS 3063 type-B should be used for securing phonic wheel.
LOCTITE 243 or equivalent glue should be used to ensure rigid
connection between internal and external thread.
ii) The Phonic Wheel screws should be tightened with 21N-m torque.
iii) The clearance between the phonic wheel and speed sensor should
be 0.9 to 1.4 mm in case of KB make WSP and 1 to 2mm in case of
FTIL make WSP. This gap should be checked in quarterly schedule
or whenever required.
iv) The phonic wheel and speed sensor should be procured through
OEMs/OEMs approved sources only. M/s KB and M/s FTIL are
OEM of this item.
v) Speed sensors cables should be properly connected and should be
without any loose strands.
vi) Ensure WSP reading 99 on the display during each trip. In case
WSP reading 95, let the coach to run with 95 code, but ensure
required repair is done for the fault if any. Monitor the reading as its
next arrival.
Proper Dump Valve connection and ensuring that no dump valve leaks
during brake application.
i) Earthing device of most of the coaches should be functional. It
consists of non ferrous components (approx 2kg weight) which are
theft prone.
ii) Loose fasteners, in case of theft attempts for non-ferrous items,
mounted inside of axle box housing, can damage CTRB. Ensure
attention during trip scedule
iii) Most of the earthing devices with correcting wires/cables were
missing in service due to theft. Attend defect during schedule
attention
iv) Junction box may be broken or in damaged condition during service.
Attend defect during schedule attention.
Drain holes of control arm to be cleaned to prevents its chocking
Check for leakage
Check for condition of bushes.
Check for any other defects.

Control arm
Dampers
Primary vertical dampers.
Secondary vertical dampers
Yaw damper.
Secondary lateral damper
Primary and secondary Check for crack
springs
Ensure fitment as per correct pairing.
Disc brake attention
i) Brake pads are renewed on condition basis and adequate spare
quantity is available at depot. Condemning size of brake pad is 7mm
(New 35 mm).
ii) Ensure regular attention of brake calliper to avoid its jamming during
service.
iii) Ensure regular attention is being given to disc brake system through
AMC or in-house attention. (Ref: Guide lines issued by RDSO Vide
letter no. M (C)/LHB/Brake dated 20.07.2012)
CBC
Ensure guidelines circulated by RDSO for CBC equipped coaches are
being followed. (Ref: Carrg Dte/RDSO letter no. MC/BLB/CBC dtd
22.05.08)
Side buffer (Power car)
Length of side buffer of CBC equipped SLR (FV & LV) is maintained to
635 mm as per RDSO drawing no. SK - 98145 (Ref: Carrg Dte/RDSO

Item
Control arm
9.

Attention to be given
letter no. MC/BLB/CBC dtd 17.02.08)
Checking of mounting bolts of control arm is being
done during primary maintenance.

Whenever accompany staff is deputed, rake log book should be maintained

and monitored in each trip.
The above guidelines should be circulated to all officers and Supervisor for
compliance.
(MD ASAD ALAM)
Chief Rolling Stock Engineer/Chg

Copy to:
1.
CWM/M/KGPW For kind information.
2.
Sr.DME/KGP, CKP, ADA, RNC For information please.
3.
CDO/Tata, RNC, ROU For information please.