Maintenance Manual of LHB Coaches 12.

2 Schedule D1 ( Every Trip)

Maintenance Schedules

The following items shall be attended during schedule D1. Bogie Frame and Bolster Assembly y Perform a visual check on longitudinal beams, cross beams & bolster for cracks, damages and corrosion. y Perform a visual check on brake supports, damper supports, traction centre supports and anti roll bar supports for cracks, damages and corrosion. y Check bogie bolster sub-assembly and brackets for cracks, damages andcorrosion. Brake Equipments y Check functionality of Air Brake equipment and Hand brake equipment. Check flex ball cable arrangement for proper working. y Perform a visual check on Brake cylinders/ brake levers and Hand brake equipment for damage, cracks and corrosion. y Perform a functional test on pneumatic brake system. Make sure that no leaks are present. y Check operation of passenger emergency valve & pull box. y Perform a visual check on hoses for cracks/damages. y Visually inspect steel piping for cracks/ damages/ ballast hitting and leakages, Repair/ replace as necessary. y Perform a visual check on brake discs for damage/wear/broken ribs. Verify absence of axial movement along the axle. Note: For attending Brake Discs with broken ribs, please refer to M/S Knorr Bremses letter no. kbi/m&s/lhb/ser. Dt. 31.08.2007. Axle Bearing Instruments y Perform a visual check on all grounding cables & WSP equipment cables for breaks/ damages. y Visually check equipment for absence of damages, cracks, and corrosion marks. y Check functioning of WSP equipment. Verify that the signal arrives correctly to the diagnostic equipment. Primary & Secondary Suspension y Visually check springs for cracks, damages, corrosion or foreign objects presence. y Check miner pads for cracks, damages and ageing. y Visually check safety cables for damages, cracks and corrosion. Primary/Secondary/Yaw dampers y Perform a visual check on dampers for damage, cracks and oil leaks. y Perform a visual check on all fixings for loosening and/or missing components. y Perform a visual check on rubber elements for cracks and ageing. Bearings y Carry out bearing feeling for detection of hot bearing. y Check bearings for grease leakage. Wheel & Axle y Perform a visual check on wheels for cracks, damages and tyre defects. Chapter 12 Page 1 of 17

Maintenance Manual of LHB Coaches

Maintenance Schedules

y Check by wheel profile gauge, the wheel flange thickness and profile. y Check axle for cracks and signs of corrosion, if any. Note: please refer to RDSO CMI K 003 (Guidelines for interpretation of wheel defects) and Maintenance Manual for ICF design BG coaches for details. Control Arm y Perform a visual check on all fixings for loosening and / or missing components. y Visually check control arm parts for damages, cracks or corrosion marks. y Inspect the rubber joint until it is visible for cracks, damages and ageing. Anti Roll bar Assembly y Perform a visual check on Anti roll bar, links and brackets for cracks, damages and corrosion. y Perform a visual check on rubber joints for cracks, damage and ageing. y Visually inspect for grease oozing out of anti roll bar bearings, which may result in bearing failure. y Perform visual check on all fixings for loosening/missing fittings. Traction Centre y Perform a visual check on the traction centre lever and on the rods for cracks, damages and corrosion. y The assembly should be free to move, and not blocked by any foreign objects. y Perform a visual check on all fixings for loosening. y Perform a visual check on rubber joints for cracks/damages. Rotation Limiter y Perform a visual check of rotation limiter- components. Rubber and Rubber/Metal Bonded Parts y Perform a visual check on rubber and rubber/metal bonded parts for cracks, damages and ageing. 12.3Schedule D2 (Monthly) Perform all the items of schedule D1. In addition to this perform the activities- as given below. Bogie Frame y Wash the bogie frame thoroughly with water jet in washing line, making sure that water is not directed towards pneumatic / electrical connections and axle bearings. Brake Equipment y Verify that the clearance between each pad and disc surface is 1-1.5 mm. y Check wear of brake pads/ brake discs. If groove depth is reached, it is necessary to replace the discs. y Lubricate the brake levers, fixings and all moving parts using prescribed grease (Autol Top 2000 spray). Axle Bearing Instruments y Inspect the Earthing equipment for wear of slip assembly / carbon bars. y Monthly / Quarterly inspection of WSP equipment to be carried out as per schedule given by OEM. Chapter 12 Page 2 of 17

Maintenance Manual of LHB Coaches

Maintenance Schedules

Wheel & Axle y Check tread diameter and wear of wheel profile. If necessary, perform reprofiling. Pins and Bushes y Lubricate all pins and bushes. 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 y Examine the bogie frame for corrosion / damages, especially at critical locations. y Carry out paint touch up with high built epoxy primer and paint as per RCF specifications MDTS 166. Wheel & Axle y Check wheels offset on axle (1600 mm 1 mm) Control Arm y Renew protection treatment with Tectyl / Cortec VC 1368 on the rubber joint on visible areas. 12.5 Shop Schedule-I (18 Months) The following activities shall be carried out in Shop Schedule-I. Brake Equipment y Perform function test of the Air Brake system components: y Distributor valve y Check valve y Isolating cocks/angle cocks y Filters, indicators, test fittings. y Emergency brake valve & pull box y Brake cylinders y WSP Equipment y Brake gear pins and other bogie pins must be examined for wear and re-greasing. Replace, if necessary. y Examine BP/FP couplings and hoses. Replace, if necessary. y Examine the Brake calipers and Brake pads for wear and damages. Replace, if necessary. y Check the functioning of hand brake equipment. Replace the defective components. y 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 y Overhaul the grounding equipment. Check spring mechanism for self-regulation. Replace carbon bar and slip assembly. Replace all worn parts. y Carry out overhauling and testing of WSP equipment as per OEMs instructions. Primary/Secondary Suspension y Attention to springs during Shop Schedules shall be as given under Para 12.11. Chapter 12 Page 3 of 17

Maintenance Manual of LHB Coaches y y y Dampers y y

Maintenance Schedules

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. 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 Primary Vertical Damper Secondary Vertical Damper Secondary Lateral Damper Yaw Damper RCF Drg. No. LW 05102 LW 05101 LW 05100 LW 05103 PL No. 00920083 00920060 00920058 00920071

Bearings y

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. Bearing reconditioning is to be carried out whenever bearing is removed from axle due to wheel-shelling / bearing failure. 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. If the wheelsets are sent for reprofiling without dismounting bearings, lubricate the lathe centres with heavy grease. For reconditioning of bearings, please refer to OEMs instructions.

NOTE: 1. 2. 3. 4.

Wheels and Axle y Perform wheel profiling and wheel balancing (for Speed >= 130 Kmph). Refer to RCF specn.no. MDTS 168 for balancing procedure. y Perform a general overhaul of the axle, remove signs of corrosion, renew corrosion protection and repaint the axle. y Check wear of wheels, if necessary, replace them. y Perform an ultrasonic test on the wheel and axle to verify absence of internal cracks and damages. Control Arm y Perform a general overhaul of the control arm: remove signs of corrosion, renew corrosion protection and repaint the components.

Chapter 12

Page 4 of 17

Maintenance Manual of LHB Coaches y

Maintenance Schedules

Check wear limit of control arm bore as follows; (Ref: RCFs letter no. MD 44121 Dt: 13.08.08) y 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. y 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). y In case, the diameter is less than 230.312 mm, the control arm may be reused without remachining. y The control arm mating surface with bearing should be coated with Blasol 135 solution, to prevent corrosion. y Examine the rubber joint for cracks/damage and ageing. Replace, if necessary. Bogie Frame and Bogie Bolster y 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. y Corroded bogie frames should be attended as follows:y Cleaning/washing of bogie frames. y Descaling/rust removal with rust converter to IS: 13515 y Touch-up with high build epoxy primer and paint as per RCFs 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: RCFs letter no.MD 44121 dt. 17.09.09) Anti-Roll Bar Assembly y 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 y Examine the condition of the brackets: remove signs of corrosion, renew corrosion protection and repaint the block. y Replace fixings, rubber joints and sealings, on condition basis. y Replace anti roll bar bearings, if necessary. Traction Centre y Perform a general overhaul of the traction centre components (Traction lever, Traction Rods). Remove signs of corrosion, renew corrosion protection and repaint the components. y Replace the rubber bush and the rubber joints, if necessary. Rotation Limiter y Check condition of the steel roll and pin for wear/damages. Replace, if necessary. Rubber and Rubber/Metal Bonded Parts y Examine the Rubber and Rubber/Metal Bonded parts for ageing / damages/ failure of bonding. Replace, if necessary. Bogie Pins Chapter 12 Page 5 of 17

Maintenance Manual of LHB Coaches

Maintenance Schedules

y y

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 checksheet for Bogie inspection of LHB coaches during SS-I & SS-II, vide lettrer 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.
CBC y Attend the Tight lock CBC as given in RDSOs CMI no. RDSO/2006/CG/CMI -01 Under Frame & Running Gear y Inspect trough floor- for corrosion and damage y Inspect water tank frame- for corrosion and damage y Inspect air brake module frame- for corrosion and damage y Inspect air brake pipe lines- for corrosion and damage y Inspect water system pipe line- for corrosion and damage y Inspect emergency battery box frame- for corrosion, fixation bolt y Inspect head stock for corrosion, damage y Inspect sole bar for corrosion, damage. y Inspect Gusset plate for corrosion, damage y Inspect cross member for corrosion, damage

Water Supply y Water tank tightening bolts- for tightness y Water level Indicator - damage, leakage, working y Rubber hose connection -replace of all rubber hose connection y Drain cock protection cover - damage, availability y Water inlet cover - provided y Water tank sensor & its bracket -damage, broken Roof y y y Roof sheet- inspect for corrosion, damage, cracks Ventilator- inspect for corrosion, damage, deficiency of louvers Roof leakage- conduct leakage test

Exterior- Coach Body y Window glasses, cracked, moist, opaque y Window glasses rubber profiles y Entrance doors out side rubber gaskets y Destination board cover with locking arrangement , function of lock y Entrance hand rails (body handles)- for tightness, condition of plating, cleanliness y Foot steps for corrosion, damage, fixation, tightness y Ventilation grills of generator cars for corrosion, damage, deficiency Entrance Door (Main Door) y Chapter 12 Entrance door glass for cracked, moist, opaque, fixing with frame. Page 6 of 17

Maintenance Manual of LHB Coaches y

Maintenance Schedules

y y y y y y

Locking mechanism including locking cam top & locking pin bottom, universal lock, pad lock arrangement for working condition, damage, worn out, lubrication Locking handles for working condition Hand safe gasket for damage, worn-out Barrel Bolt(locking arrangement) for well positioned Entrance door, flap complete, panel, FRP cover, arm cylinder -Remove door flap in SS-II and fill up the gap by extending floor . Door stopper (All types)- Condition, deficiency Door Assembly -Proper alignment & working.

Luggage Door Top & Bottom Sliding Mechanism including guide rail, rollers, bearings, holding brackets, for working condition, worn, damaged y Locking mechanism, for working condition y Key locking arrangement, for working condition y Rubber gasket , for damaged, worn out y Door Flap Elements viz. Inner & outer locking handle, louvers, etc., for bent, broken or external damage. Interior- Passenger Area y y y y y y y y y y y y y y y y y Upholstery-condition of cushioning, rexene, leveling. Curtains (partition & window)-torn, stains Upper berth fenders- fixation, tightness PVC - aisle area-worn out, shabby look, torn. Snack table- cracks, damaged, shabby look, cleanliness Compartment mirror - dusty, cracked, de-silvering Magazine pocket Bottle holder Coat hooks Berth holder Luggage racks, luggage ropes Carpet (I class) - torn, stains, cleaned, dust free (replace if required) Locks of ceiling panels - working condition, lubrication Emergency window - working condition, availability of handles & instruction stickers. ICV pull Box All mandatory instructions stickers - availability in good condition

Saloon Sliding Doors y y y y Chapter 12 Nylon wire rope -damaged, worn out S S wire rope- damaged, worn out Top mechanism including pneumatic cylinder - working condition, smooth working Guide shaft - lubrication by suitable lubricant. Page 7 of 17

Maintenance Manual of LHB Coaches y y y y y y

Maintenance Schedules

Locking mechanism - working condition Key locking arrangement - working condition Hand safe gasket - damaged, worn out Glass, glass film & rubber profiles - cleanliness, dusty, cracked Grill & grill rubber profiles Door flap elements viz. inner & outer locking handle, locking pin, moldings, rivets etc. - bent, broken or external damage Doorway & Gangway Area Mirror (outside) - dusty, cracked. Wash basin/ FRP embedding- stainless steel or FRP (painted) Tap (gravity or auto sensor) - for working condition, leakage Dust bin with fire extinguisher stand - stainless steel or FRP(painted) Floor area(anti slip PVC or aluminum chequered plate) - worn-out, shabby look, tear off . y Cup boards for linen and catering items - working condition, broken, damaged, availability of all fittings i.e. hinges, locks, stoppers etc. y Attendant berth/seat - damaged, torn, broken, condition & securing of holding brackets y Square key locks of ceiling panels - working condition, lubrication y Leveling of ceiling panels y Moldings, vestibule door cover, soap dish, securing brackets of fire extinguishers Electrical Panel door y y y y y Door elements like glass, glass gasket, door frame moulding, side & middle hinges, key locking arrangements- damaged, alignment, working condition CDTS Panel Door y y Locking arrangement, hinges - working condition, lubrication

Lavatory Area y y y y y y y y y y y Chapter 12 Mirror (inside) - cracked, poor silver plating Wash basin - stainless steel or FRP painted, clean Tap (gravity tap / luxury tap) - working condition, leakage Soap dispenser - working condition, leakage Paper roller - loose, deficient Hopper window glass - condition of rubber, glass, operation of upper glass, locking arrangement of upper glass Dust bin - stainless steel or FRP(painted) Tube light column & its fittings -crack, broken, damaged 30 litre water tank - crack, broken, damaged, leakage, clean as per procedure given in RCF Manual Pipes, fittings, filters, timers (after opening ceiling panel) - crack, broken, damaged, leakage, clean as per procedure given in RCF Manual Painting of FRP panels. Page 8 of 17

Maintenance Manual of LHB Coaches

Maintenance Schedules

Lavatory Door (Toilet Door) y y y y y y y y y y y y Guide roller channel - fixation, tightness, lubrication Guide roller channel - lubrication by suitable lubricant. Pivot (top) for fixation, tightness Pivot (bottom) for fixation, tightness Top roller for fixation, tightness, and lubrication. Middle hinges gasket for damaged, worn out Hand safe gasket for damaged, worn out Bottom grill for damaged, bent Barrel bolt (locking arrangement) including arrangement for toilet occupation indication., for working condition Provision of extra handles (inside) & existing handles & turn-over latches damaged, missing. Coat hook - damaged, missing Door flap elements for bent, broken or external damage

VestibuleSliding Door & GangBridge y y y y y y y y y y y y y 12.6 Nylon belt for damaged, worn out . Nylon/ steel wire rope for damaged, worn out Top mechanism including pneumatic cylinder for working condition, damage, defective Guide shaft - lubrication by suitable lubricant. Locking mechanism for working condition Key locking arrangement for working condition Male & Female hand safe gasket for damaged, worn out Glass & glass frame for cracked, opaque Door flap elements viz. inner & outer locking handle, locking pin, moldings, rivets etc. for bent, broken or external damage Gangway bridge (vestibule foot) plate including roller, channel, spring, fasteners for damaged, working mechanism / condition Vestibule foot plate pin for wear, damage Vestibule foot plate split pin for wear, damage. Vestibule Rubber for crack, damage.

Shop Schedule-II (36 Months)

In addition to the activities listed under Shop Schedule-I, the following activities shall be carried out in Shop Schedule-II. Brake Equipment y Perform overhauling and function test of the brake system components: y Distributor valve y Check valve y Isolating cocks/angle cocks Chapter 12 Page 9 of 17

Maintenance Manual of LHB Coaches

Maintenance Schedules

y Filters, indicators, test fittings. y Emergency brake valve & pull box y Brake cylinders y WSP equipment y Replace brake gear pins and other bogie pins/bushes. y Replace Air Brake Hoses Bogie Frame and Bogie Bolster y Check the dimensional and geometrical tolerances of bogie frame as per FIAT drg. No. 1267505. Rectify/replace as necessary. y The complete bogie frame should be cleaned (with scrapping/shot blasting) and painted with high built epoxy primer and paint as per RCF specification no. MDTS 166 ( Rev.2) and MDTS 094, with a minimum DFT of 200 microns. 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. Bearings y Dismount the Bearings and send for inspection/reconditioning. Anti-Roll Bar Assembly y Perform overhaul of the anti-roll bar. Repair/replace the defective/worn out components. y Replace all rubber joints, sealings and anti roll bar bearings . Traction Centre y Perform a general overhaul of the traction lever. y Replace the rubber bush and the rubber joints . Rubber and Rubber / Metal Bonded Parts y Replace all the rubber and rubber/metal bonded parts as must change item. Under Frame & Running Gear y Inspect head stock for corrosion, damage y Inspect sole bar for corrosion, damage. y Inspect Gusset plate for corrosion, damage y Inspect cross member for corrosion, damage Water Supply y Water tank and water supply pipe line- cleaning as per procedure given in RCF maintenance manual. y Pressure testing Exterior- Coach Body y Condition of exterior paint for peeling off, loss of gloss, scratches y Exterior body check for corrosion, damage Entrance Door (Main Door) y Pivot (top) for working condition y Pivot (bottom) for working condition Complete overhauling of main doors/Vestibules doors/sliding doors and Lavatory doors. Interior- Passenger Area Chapter 12 Page 10 of 17

Maintenance Manual of LHB Coaches y

Maintenance Schedules

FRP panels including ceiling panels for cracks, damaged, condition of paint, shabby look (clean by soap water), and follow repair guidelines circulated by RCF. y PVC ( inside the compartment) for worn out, shabby look, torn y Ladder - condition, painting. y Non upgraded PVC flooring should be replaced. Electrical Panel door Switch board doors - Replace FRP doors by better FRP/ LP sheet matching with interior in 1st POH . CDTS Panel Door y CDTS panel door - Replace FRP doors by better design FRP / LP Sheet matching with interior in 1st POH . Lavatory Area y y FRP panels (Ref. RCF guidelines) - cracks, damaged, condition of paint, shabby look (clean by soap water) apply putty & paint the FRP panels

Furnishings y 100% replacement of Rexine. y 100% replacement of carpets of Exec. Chair car, thereafter, carpet is to be provided in Aisle portion only as per extant instructions.

12.7

Shop Schedule-III (72 Months) Page 11 of 17

Chapter 12

Maintenance Manual of LHB Coaches

Maintenance Schedules

In addition to the activities listed under Shop Sch.-I and Shop Sch-II, the following activities shall be carried out in Shop Sch-III. Dampers y CBC y Replace all dampers during Shop Schedule-III.

Dismount the CBC from coach, disassembled and overhauled as given in RDSOs CMI no. RDSO/2006/CG/CMI-01 Interior- Passenger Area y Replacement of up graded specification PVC flooring.

12.8
12.9

Must Change Items During Shop Schedule II

List of must change items during Shop Schedule II is enclosed as Annexure 12.6 Tool and Equipments

Tools and Equipments for maintenance of FIAT bogie are given as Annexure 12.7 and Tools and equipments for Depot maintenance and traveling TXR are given in Annexure 12.8. 12.10 Rubber and Wear Parts The major rubber and wear parts of FIAT bogie are: y Rubber bush for traction centre y Rubber joint for control arm y Elastic joint for traction rods y Joints for anti roll bar y Longitudinal bump stops y Lateral bump stops y Rubber disc and bump stop for primary suspension y Rubber ring and rubber spring for secondary suspension Examine all rubber and wear parts for external condition, cracks, detachment between rubber & metal, and permanent set during shop schedule-I. Replace, if necessary.

Chapter 12

Page 12 of 17

Maintenance Manual of LHB Coaches 12.11 Primary & Secondary Springs

Maintenance Schedules

The primary & secondary suspension springs used in various LHB coaches are given as follows:Primary Suspension Springs

Coach type AC-Chair car Ist& 2nd ACCN/EOG ACCW/EOG FAC/EOG Hot buffet car

INNER ( Drg.No.) 1267412 1277143 1267412 1267412 1267412 1277143

OUTER ( Drg.No.) 1267411 1267411 1267411 1267411 1267411 1277142

Power Car
Secondary Suspension Springs

INNER(Drg.No.) AC-Chair car Ist& 2nd ACCN/EOG ACCW/EOG FAC/EOG Hot buffet car 1269513 1269513 1269513 1269513 1269513 Side 1 Side 2 1268837

OUTER(Drg.No.) 1269514 1268836 1269514 1269514 1269514 Side 1 1277146 Side 2 1268836

Power Car

1277145

Coupling and Installation Instruction for Flexi Coil Secondary Springs Please refer to FIAT-SIG technical specification No. 17.471, part document 101, version 01 for coupling and installation instructions of flexi coil secondary springs.

Chapter 12

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Maintenance Manual of LHB Coaches Colour Coding of Springs for Identification

Maintenance Schedules

For identification of springs to be used in different types of LHB Coaches, middle coil of the primary & secondary springs to be painted with compatible paint of springs in different colours indicated against each group as shown below: (Ref: RCFs letter no. MD 23151 dt. 23.11.2002)

Primary Springs Inner

Secondary springs Inner

Outer
1267411 1277142 --LG01100

Outer
1269514 1268836 1277146 LG05101

Paint colour to be painted on middle coil

The paint should be compatible with the paint of spring as specified in clause 8.3 of specification no. 17.248.100 version 05. Maintenance of springs Primary & secondary springs are protected against corrosion by a paint coating. This surface protection should remain undamaged, otherwise there can be local corrosion attack, resulting in spring failures. Trip Schedule (D1) Carry out visual inspection of springs for damages, corrosion, cracks or broken springs. Monthly Schedule (D2) Same as Trip schedule. Half Yearly Schedule (D3) Same as Trip schedule Shop Schedule I, II (18 Months/36 Months) y Clean the primary/ secondary springs thoroughly (with suitable detergent water jet) in disassembled condition. y Inspect visually for any cracks, damages, corrosion and breakage. y Any damage to coating may be repaired by primer and high build epoxy paint to RCF specification. y If rust is visible, derust with the steel brush, and repair the coating as given above. y In case of corrosion pitting, cracks or breakage, replace the spring. Shop Schedule III (72 Months) In addition to activities given under Shop Schedule I, carry out the followingy y y Chapter 12 Testing of springs for free height (permanent set) Testing of spring for load/deflection characteristics as given in drawings and specification no. 17.248.100. Replace the spring, if free height/deflection is beyond permissible limits. Page 14 of 17

Maintenance Manual of LHB Coaches

Maintenance Schedules

SPRING PARAMETERS
Drawing No. Bar Mean No of dia Coil dia active (mm) (mm) coils 38 26 34 50 40 27 38 57 55 37 40 27 55 36 219 138 246 368 219 138 243 372 372 243 219 138 376 245 4.1 6.1 6.8 5.1 4.3 6.4 7.2 5.5 5.5 7.0 4.1 6.2 5.0 7.25 Total no. of coils 5.6 7.6 8.3 6.6 5.8 7.9 8.7 7.0 7.0 8.5 5.6 7.7 6.5 8.75 Height Test load under test load (mm) (KN) 28.91 + 1% 17.02 + 1% 25.24 + 1% 47.02 + 1% 47.32 + 1% 26.38 + 1% 264 +0/-4 264 +0/-4 468 +0/-5 512 +0/-5 252 +0/-4 252 +0/-4 Vertical stiffness (N/mm) 475 + 5% 280 + 5% 129.5 + 5% 241.1 + 5% 556 + 5% 310 + 5% 197.9 + 5% 365.6 + 5% 317 + 5% 183 + 5% 583 + 5% 320 + 5% 337.6 + 5% 154.5 + 5% Lateral Other stiffness controlled (N/mm) for Dimension information Not Reqd. Not Reqd. 31.1 164.5 Not Reqd. Not Reqd. 43.9 254.5 224.2 43.3 Not Reqd. Not Reqd. 284.8 61.8 I.D.=181+3/-0 I.D.=112+3/-0 O.D.=280+0/-2 I.D.=318+3/-0 I.D.=179+3/-0 I.D.=111+3/-0 O.D.=281+0/-2 I.D.=315+3/-0 I.D.=317+3/-0 O.D.=280+0/-2 I.D.=179+2/-0 I.D.=111+2/-0 I.D.=321+3/-0 O.D.=281+0/-2 Direction of coiling

1267411 1267412 1269513 1269514 1277142 1277143 1277145 1277146 1268836 1268837 LG01100 LG01101 LG05101 LG05100 Chapter 12

Right hand Left hand Left hand Right hand Right hand Left hand Left hand Right hand Right hand Left hand Right hand Left hand Right hand Left hand

38.695 + 1% 468.5 +0/-5 71.48 + 1% 512.5 +0/-5

59.226 + 1% 515 +0/-5 34.19 + 1% 471 +0/-5

26.118 + 1% 268.2 +0/-4 14.336 + 1% 268.2 +0/-4 40.79 + 1% 516.2 +0/-5

18.665 + 1% 472.2 +0/-5

Page 15 of 17

Maintenance Manual of LHB Coaches Schedules

Maintenance

Must change items during Shop schedule II

Annexure 12.6

The following items must be replaced as must change items during the shop schedule-II: 1.
y y y y y y y y

All Rubber and Rubber/Metal Bonded Components, Such AsControl Arm Silent Block. Traction Centre Silent Block. Traction Rod Silent Block. Vertical Rod Silent Block. Lateral/Longitudinal Bump Stops. Damper End-Mountings. Miner Pads for Secondary Suspension. Other Rubber and Rubber/Metal Bonded Parts, If Any.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Bearing for Anti Roll Bar. Pins, Bushes, Seals, Split Pins, Fasteners. Curtains of partitions and windows. PVC of Aisle area Floor area (anti slip PVC or aluminum chequered plate). Mirrors Nylon belts of sliding door. Nylon/steel wire rope of GangBridge. Vestibule foot plate split pin All Dampers to be Replaced During Shop Schedule-III. 12. Vestibule foot plate pin and nylon wire rope (for vestibule sliding doors).

Chapter 12

Page 16 of 17

Maintenance Manual of LHB Coaches Schedules

Maintenance

Tools &Equipments for FIAT Bogie

Annexure 12.7

The followings Tools & Equipment are required for maintenance of FIAT bogie. This list is not exhaustive and may require additional item as required. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Hydraulic lifters (Jacks) for lifting the coach body capacity 15 Ton - 4 Nos. Tool kit (Torque wrenches, Allen keys, pliers, spanners set etc.) Press for removal & pressing of bolster beam. EOT crane (5 Ton) for lifting of bogie frame/Bolster. Supports (Trestles) for putting bolster beam. Wire rope slings and trestles for rotation of bogie frame. High pressure jet cleaning machine. Bogie painting facilities. Hydraulic press for primary suspension. Hydraulic equipment for bearing installation & removal. Hydraulic press (50 Ton) for removal/insertion of rubber joints. Wheel profile Lathe. Wheel balancing equipment. Wheel press (for pressing wheel on axle). Axle dia measurement gauge/micrometer. GO/NO GO threads plug gauge for axle ends. Gauge for checking Bearing Mounted End Play. Bench end-play checking fixture. Lubrication fixture for bearing. Parallelism checking tool for control arm. Equipment for pneumatic System Functional Test. Spring testing machine for Load/Deflection Test (vertical & horizontal both) Single car testing rig for air brake system. Testing machine for Primary/Secondary/Yaw dampers. Mounting/ dismounting tools for Anti roll bar bearing. Mounting/ dismounting tools for Anti roll bar elastic joint.

Miner pad pressing Fixture

Chapter 12

Page 17 of 17