SOUTH CENTRAL RAIL WAY

Office of the CWM,

Drawing office,
Carriage Workshop,
Lallaguda.

LGDS/DRG/CARRIAGE- 2 Date: 02.12.2024

SSE/CORROSION
SSE/CARRIAGE
SSE/WHEEL
SSE/AIRBRAKE
SSE/BOGIE
SSE/PAINT
SSE/INSPECTION

Sub Mid Life Rehabilitation(MLR) of LHB coaches-reg

Ref: HQRS Lr.No. SCR-HQ0Mech(WS)/67/2019 dated : 29.11.2024

*****
Vide references above, the scope for MLR of LHB coaches submitted
by RDSO has been reviewed by Railway Board on the basis of the deliberations
held at Technical Seminar for Coaching Workshops and suggestions for
improvement from NR where MLR is already being done.

The revised GUIDELINES FOR MID LIFE REHABILITATION (MLR) OF LHB

COACHES has been forwarded herewith for information and necessary action
please.
 File No.SCR-HQ0Mech(WS)/67/2019-Oo Ch.OS WS PCME SCR

SCR-HQ0Mech(WS)/67/2019 Date : 29.11.2024

CWM / LGDS & TPTY

Sub : Mid Life Rehabilitation(MLR) of LHB coaches.

Ref : Railway Board letter No. 2023/M(C)/141/2

dated 28.11.2024.
***

On the basis of the deliberations held at Technical seminar for

coaching workshops held at RCNK/SNP and suggestion for improvement from
NR, Railway Board vide above cited letter has forwarded guidelines for the
subject issue.

Copy of the above cited Railway Board letter is sent herewith for
information and necessary action please.

Encl : As above.

DY.CME/WS/HQrs
for CWE/SCR
 भारत सरकार Government of India
रे ल मं्ቔालय Ministry of Railways
रे लवे बोर्ड Railway Board
E Office: 3434302
No. 2023/M(C)/141/2 New Delhi, Dated 28.11.2024

General Managers
All Zonal Railways

Director General
RDSO, Lucknow

Sub: Mid Life Rehabilitation (MLR) of LHB coaches.

Ref: i. Railway Board letter no. 2017/M(C)/137/14 dated 27.07.2018.

ii. RDSO letter no. MC/CB/LHB/MLR dated 10.06.2021.
iii. NR letter no. NR-HQ0Mech(CHG)/96/2021- O/oCHOS/1/C and W/HQ/NR
dated 01.07.2021.
iv. RDSO letter no. MC/ CB/LHB/MLR dated 25.04.2024.

1. In reference to the subject matter and letters under reference, the scope for MLR of LHB
coaches (as submitted by RDSO vide letter at (iv) above) has been reviewed on the basis of
the deliberations held at Technical Seminar for Coaching Workshops (organized at
RCNK/SNP) and suggestions for improvement from NR (where MLR is already being done).
2. A copy of the scope for MLR of LHB coaches, approved by the Board (MTRS) is attached
at Annexure.
3. It is further stated that some sub-assemblies which have been attended in the first MLR (12
years) may not be required to be changed in the second MLR (24 years). Accordingly, the
scope may be reviewed further on the basis of the condition of items in incoming coaches,
and feedback from MLR Workshops.
4. Further, during discussion with Zonal Railways, it was suggested that the possibility of
providing the CCTV power supply cables and telecom cable should be explored during MLR,
since the coach would be stripped down during MLR. The same may be examined by RDSO,
and report submitted to Board.

For necessary action please.

DA: Annexure.
Pranjal Digitally signed
by Pranjal Mishra
Date: 2024.11.28
Mishra 17:49:52 +05'30'
(प्ांजल िम्ቦा)
संयु्ሹ ििदे शक / यांि्ቔक इं जी. कोि ंग-II
रे लवे बोर्ड

C/- PED/ RS/ RDSO- for kind information and necessary action please.
- EDME/(PU&W)/ RB - for kind information and necessary action please.
 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

GUIDELINES FOR MID LIFE REHABILITATION (MLR) OF LHB COACHES

1.0 FOREWORD

1.1 LHB design coaches were introduced in Indian Railways in 1999 – 2000 along
with ToT agreement with M/s Alstom. The coaches introduced in the initial phase
have already completed 15-18 years of service and it is necessary to make an
assessment of rehabilitation of LHB coaches to extend the useful life and
reliability of the coaches by replacing aged & worn out components along with
essential repairs. Railway Board vide letter 2017/M(C)/137/14 dated 21.12.2017
has decided that rehabilitation shall be carried out on LHB coaches after
completion of 12 and 24 years of life. It will also include heavy corrosion repair
and complete refurbishing of coach to lease new life.

1.2 While implementation, latest versions of Standards/Instructions/Specifications

issued should be taken as references, and the scope suitably amended. It is
further stated that some sub-assemblies which have been attended in the first
MLR (12 years), may not be required to be changed in the second MLR (24
years). Accordingly, this scope document may be revised further on the basis of
the condition of items observed and feedback from MLR Workshops.

1.3 Railway Board constituted a committee of CWM/CRWS/BPL, CRSE/Chg./WR

and CRSE/Chg./CR to recommend the extent of rehabilitation work and list out
must change items for both safety as well as furnishing items. Based on the
recommendation of the committee, the extent of rehabilitation work after
completion of 12 and 24 years of life of LHB coaches has been identified in this
guideline when the coaches shall be due for Shop schedule SS-III.
Suggestions/comments received from Zonal Railways are also incorporated in
these MLR guidelines for LHB coaches.

2.0 SCOPE OF WORK

2.1 The scope of work during MLR shall include the following areas and systems of
the LHB Coaches:

i) Under frame
ii) Coach Body
iii) Flooring
iv) Interior Furnishing
v) Toilet Modules
vi) Bogie
vii) Air brake system
viii) Exterior painting of the coach
ix) Train Lighting & Other Electrical Items
x) CBC

2.2 Other work like painting, repair to other structural items like vestibule, body side
doors, compartment doors etc. along with RMPU overhauling shall be performed
as per issued guidelines of POH as well as of guidelines of refurbishment of AC
coaches after 06 years.

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 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

2.3 Detailed procedure of repairs and other activities as mandated in the CAMTECH
Maintenance Manual for POH of coaches and RDSO guidelines for refurbishment
of AC coaches in 6 years shall necessarily be performed during MLR.

3.0 LIFTING THE COACH BODY

3.1 On receipt of a coach for MLR Schedule, it must be taken on Lifting line/Stripping
line where electrical fittings should be stripped and batteries removed. All
furnishings items and other components from coach shell which are removed /
stripped off are to be sent to respective sections for maintenance.

3.2 Before lifting a coach, the following components should be removed, disengaged
or disconnected:

i) Wheel sets earthing equipment.

ii) Speed sensor cover.
iii) Yaw Dampers.
iv) Secondary Lateral Damper.
v) Roll Link from Bolster.
vi) Wire rope pin from Bolster.
vii) Hose connection from Bogie to coach.
viii) Centre pivot security plate.
ix) Bolster from coach body by means of removing nut & swing nut.
x) All air brake fittings
xi) Control arm bottom cover
xii) Centre Buffer Couplers etc.
xiii) IR-DRDO Bio Toilets
xiv) Under slung water tanks & Water Raising Apparatuses (WRA) where
provided.
xv) Battery box and electrical fittings.
xvi) AC equipment in AC coaches.

3.3 Coach body should be lifted off the bogies either by two overhead electric cranes
of min. 20 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.

3.4 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 and the sealed windows of AC coaches are also
likely to break.

3.5 After the coach body is lifted, it should be kept on trestles. The coach should be
suitably protected from movement of the other coaches as well from material
handling equipments.

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 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

4.0 UNDER FRAME REPAIR

4.1 Underframe member should be examined for corrosion. Corrosion is generally

indicated by flaking of paint, flaking of metal, pitting and scale formation. It is
essential to visually inspect underframe members of all coaches irrespective of
their age and the degree of attention given in the previous shop schedule. The
underframe should be repaired in all respects, and if not repairable, then
the same should be condemned. In cases where high corrosion in the
underframe is noticed, use of handheld spectrometer to assess the material
composition should be done. Further, to address the issue of underframe
corrosion, drainage and seepage should be attended in the coaches during MLR.

4.2 During MLR, thorough cleaning of dust, rust etc. by pneumatic jet followed by wire
brushing should be done. After cleaning, all underframe members of coach to be
examined / inspected thoroughly. If corrosion in underframe members is noticed
and loss in thickness is more than 20% of its original thickness, the member
should be replaced. Cleaning of underframe using suitable cleaning agent/
water jet followed by pneumatic jet cleaning may be done, followed by Wire
brushing and scrubbing through sandpaper wheel up to bare metal.

4.3 For Underframe corrosion repair in LHB coaches, CMI No. RDSO/2019/CG/CMI-
01 – “Guidelines for Corrosion Repairs in LHB Design Coaches” already issued to
all Zonal Railways shall be followed.

5 COACH BODY REPAIR

Body side wall and roof of LHB design coaches are made of Ferritic and
Austenitic Stainless Steel respectively which is very less prone to corrosion.
Notwithstanding the above, the coach shell should be thoroughly inspected for
damages/cracks/corrosion after complete stripping of interior panels. If sign of
damages/cracks/corrosion is noticed and is significant, then the procedure as per
Para 2.18 to 2.27 of CAMTECH LHB coach Maintenance Manual Volume-II shall
be followed for inspection and repair of coach body for components other than
underframe.

6 FLOORING
Floor covering should be removed from all areas of coach floor. The sub-floor
Floor Board is to be removed and SS trough floor is to be inspected and repaired
as required. New 16mm Floor Board along with rubber element & D coupling
arrangement to be installed with appropriate fasteners and hardware. All
mounting fasteners and floor Board are to be sealed to prevent moisture leakage.
Then flooring surface is to be levelled in preparation for the installation of the new
floor covering. Sweep and clean the coach floor thoroughly before laying anti-skit
floor covering. New anti-skid floor covering to be provided in passenger area,
door way and gang way area of the coach. CMI No. RDSO/2008/CG/CMI-04 may
be used as reference for detailed procedure for laying of PVC flooring in coaches.

7 INTERIOR FURNISHING

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 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

The following furnishing items should be changed during MLR in addition to

necessary maintenance activities and replacement as mandated in SS1, SS2 &
SS3 Schedule of CAMTECH maintenance manual and in RDSO coach
refurbishment guidelines:
7.1 FRP Panels for Side wall & roof ceiling: FRP panels get loose & damaged and
deteriorate their aesthetics due to continuous use. Sagging is also observed in
the roof ceiling over the years. FRP panels should be changed on condition basis
in Chair Car Coaches and reused to the extent possible. However, New FRP
Panels for Side wall & roof ceiling to be provided during MLR in Sleeper
Coaches.
7.2 Seats and berths: Complete seats and berths require renewal during MLR due
to loss of cushioning effects and uneven thickness, delaminated / de-bonded
condition. Upholstery also gets peeled off, cracked at corner, torn and opening of
stitches. The mounting arrangements of seats and berths should be thoroughly
examined and repaired as required, then repainted after safety inspection. Once
mounting arrangement are repaired and painted, the new seats and berths to be
installed in the coach with new hardware. The seats and berths should be
completely replaced with new ones. Further, the mounting arrangement (seat
frame etc.) should be replaced and not repaired, in case it is found damaged.
Standardization of seat assemblies like armrest, footrest, snack table, roller blind,
reclining gear etc. in chair car and magazine pocket, bottle holder and snack
table in births of sleeper type coaches should be implemented.

7.3 Snack tray: The snack tray is required to be replaced during MLR as
damage/breakage and patch repair is generally observed.
7.4 Window glass: New sealed glass window units along with new rubber or felt
lining required to be provided along with renewal of side panels and ceilings.

7.5 Passenger amenity items: The condition of Passenger amenity items in

compartment and doorway area such as mirrors, bottle holder, coat-hook, dustbin
etc. get deteriorated. All amenity fittings must be completely changed in MLR and
coach shall be provided with latest/upgraded amenities. PAPIS and CCTV
systems should be made functional during MLR, by
refurbishment/repairing/modification as suitable.

7.6 Integrated Braille display/Signage (numbers/notices) as a set:

All the numbers/notices should be displayed with Integrated Braille

display/signage (numbers/notices) as per the latest guidelines issued.

7.7 Other Structural items: Partition wall panel, Honeycomb partition structures with
SS Pillars, PU ladders, Inter-car gangway mounting(UC vestibule),Gangway
bridge mounting ,Footsteps, Plumbing items, Operating mechanism of sliding
door and Body side window should be thoroughly inspected and repaired as
required. However, if not repairable, same may be replaced on conditional basis.
For Aluminum pillars of AC coaches, 100% replacement should be one with SS
pillars where found damaged/cracked. Repairing of Aluminum pillars, honey
comb partition structures etc. should not be done.

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 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

7.8 Provision of Fire detection/suppression system and its maintenance may be done
as per instructions issued by RDSO and Railway Board from time to time for LHB
coaches.

8 TOILET MODULES

The condition of Toilet modules and RMPU tray deteriorate over the time. Toilet
modules are to be replaced completely during MLR. The existing FRP RMPU tray
shall be replaced with SS tray as per CAI No. ICF/QMS/MDM/File/F015 issued by
ICF. IR-DRDE type Bio tank fitted coaches shall be provided with Electro-
pneumatic Pressurizing Flushing System or superior system or latest instructions.
All other maintenance activities/checks for IR-DRDE Bio-Tank as mandated in
SS1, SS2 & SS3 Schedule of LHB Coaches shall be necessarily performed during
MLR as per Guidelines issued by CAMTECH/RDSO and Railway Board from time
to time for LHB coaches. Toilet upgradation work as per Railway Board guidelines
to be carried out during MLR.

9 BOGIE

Maintenance of the bogie is to be done as per Maintenance manual for BG

coaches of LHB design issued by CAMTECH, as per terms of RDSO letter No.
SV. FIAT/Corrosion repair dated 15.06.2018 (Copy enclosed as Annexure-I) &
other instructions issued from time to time for bogie maintenance.
Complete pipelines, clamps, mounting brackets and other components/ items
provided on coach underframe and bogie for pneumatic suspension to be
thoroughly checked for corrosion, damage, leakage & functionality. No leakage is
permitted in air pipe lines/joints etc. The same is to be inspected thoroughly and
replace (if required) along with connected air pipes duly carrying out necessary
swaging and proper clamping.
Existing coil springs in secondary suspension should be replaced with air
suspension, and old released coil springs should be sent to railways for use as
unit exchange spares during SS-1/SS-2/SS-3 (RDSO should issue a CAI in this
regard)
The must change items in bogie during mid life rehabilitation are as follows:
(a) All rubber & rubber-metal bonded items in FIAT bogies, including control
arm silent block, traction lever silent block and primary suspension bump
stop etc.
(b) Pins, Bushes, Seals, Split pins & Fasteners of bogie.
(c) Bearings for Anti-Roll Bar.
(d) All Dampers of bogie.
(e) New or overhauled Primary Coil spring
(f) New or overhauled Control equipment’s of air spring.
(g) New or overhauled FIBA & Indicator.
(h) New/Refurbished CTRB will be mounted on LHB wheelsets.
Serviceable items released from these bogies (within codal life) may be used in
Workshops/Coaching Depots.

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 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

10 AIR BRAKE SYSTEM

Complete Air Brakes assembly should be replaced (incl. installation of new WSP
system) and the old removed assembly should be sent to workshops/divisions for
use as unit exchange spares.

11 EXTERIOR PAINTING OF THE COACHES

Exterior painting of the coach should be done as per clause 3.3.2 for Repainting
of Coaches in Mid-Life Rehabilitation (MLR) of RDSO CMI No.
RDSO/2013/CG/CMI-01 (Procedure for Exterior PU Painting of Coaches in Indian
Railway Workshops) and as per Specification M&C/PCN/100/2018 for Epoxy cum
Polyurethane Painting System (Two Pack) for the Exterior Painting of Railway
Coaches, Diesel and Electric Locomotives and other Industrial Applications).

12 TRAIN LIGHTING & OTHER ELECTRICAL ITEMS

The following activity for train lighting & other electrical items shall be performed
during MLR after 12/24 years:

(a) All defective LED lights are to be replaced maintaining average illumination
as per stipulated standards.
(b) Electrical switches, sockets, limit switches, connectors & conduits, which
get worn out due to wear, cracks & due to repeated use, must be repaired
if under expiry of codal life and may be replaced after expiry of codal life.
(c) Mobile charging sockets shall be provided as per the latest guideline
issued.
(d) Complete RMPU, Canvass duct, Anti-vibration pads must be repaired if
under expiry of codal life, and may be replaced after expiry of codal life.
(e) Electrical Panel i.e. Switch board cabinet, DA set control panels must be
repaired if under expiry of codal life and may be replaced after expiry of
codal life.
(f) Pantry equipment must be repaired if under expiry of codal life and may be
replaced after expiry of codal life.
(g) Water raising pump must be repaired if under expiry of codal life and may
be replaced after expiry of codal life.
(h) As per Railway Board letter No.2002/ACI/2/10/Vol II dated 29.11.2019,
battery codal life is 4 years. As per clause No. 4(X) to (XII) of RDSO SMI
No. RDSO/PE/SMI/TL/0024-2004 (Rev.1), if the discharge duration of cells
is found to be more than 8 hours these can be put-back in service after
charging, if cells do not give more than 8 hours of discharge duration
before reaching and cell voltage of 1.75 Repeat this charging and
discharging cycle once more cell should not be discharged below 1.75 V.
Even then, if cells do not give more than 8 hours then the cells shall not be
put in service.
(i) Old switch board cabinet should be replaced with new switch board
cabinet, since on the basis of cost estimates from Northern Railway the

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 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

cost on overhauled SBC is almost equal to that of new SBC (which has
improved features like sealed rodent entry, MPCBs, improved layout for
wiring etc.)
(j) Replacement of on-board RBC by underslung RBC cum EBC: As per
RDSO letter no. EL/7.10.1/RBC dated 03.11.2023, if existing on-board
type RBC fails and its repair is not possible then underslung RBC cum
EBC has to be provided and draft modification sheet has been issued vide
letter no. RCF ED 2009 dated 09.05.2023. The Installation of under slung
RBC cum EBC with specification as per RDSO/PE/SPEC/AC/0183-2018
(Rev-’1’) following the mounting arrangement as per CAI No.
RCF/ED/CAI/025 dated 26.04.2023 with drawing no. 1
10113.0.03.095.001, ALT. ‘Nil’, should be done in MLR.
(k) Replacement of 1 KVA transformer by underslung 5 KVA transformer: Due
to increase in no. of mobile charging points, it is inevitable to replace 01
KVA transformer by 5 KVA underslung transformer to match the enhanced
load. All newly manufactured coaches are having this arrangement. During
MLR at RCNK, this retro fitment is done as per wiring diagram of
EI/0.6.2/LHB/EOG/AC Coaches dated 18.12.2017 of RDSO and fitment of
05 KVA transformer as per EDTS 366 Rev. 0 dated 17.11.2014 is being
followed.
(l) Replacement of E-beam cables: The replacement of existing e-beam cable
for main supply/neutral is already covered in work of through feeder
modification into high-capacity e-beam cable. In addition, as advised vide
CAI No. ED/CAI/032 dated 20.03.2024, some E-beam cables are also
planned for replacement in proposed work of segregation of positive and
negative cables.
(m) 100% replacement of mini-pantry to be done, if available in the incoming
coach, since the codal life for these equipment has been specified as 5
years.
(n) Proper tagging and routing of electrical cables should be done during MLR

In addition to the above, the following activities for electrical items are also to be
carried out during MLR:
(a) UIC coupler must be repaired if under expiry of codal life, and may be
replaced after expiry of codal life.
(b) Feeder junction boxes must be repaired if under expiry of codal life, and
may be replaced after expiry of codal life.
(c) IV coupler must be repaired if under expiry of codal life, and may be
replaced after expiry of codal life.
(d) Ensure modification in Non-AC LHB coaches which were manufactured in
RCF/KXH during 2011 & 12 according RB letter
no. 2022/Elect(G)/181/12/Part I dated 05.01.2024.
(e) Ensure provision of USB mobile charging points according RB letter
no. 2009/Elect(G)/109/14 (EONo- 3325965) dated 05.09.2024
(f) Ensure modification in LHB EOG AC 2T and 3T AC coaches for
segregation of 110 Volt DC +ve and -ve at all levels and provision of cage
clamp terminal with glass fuses according RCF/KXH letter
no. RCF/HSQ/ED/LHB/2008 dated 03.04.2024

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 Annexure to letter no. 2023/M(C)/141/2 dated 28.11.2024

During MLR of coaches, activities as mandated in the following maintenance

manual/specifications are also to be followed:
(a) Maintenance manual issued by CAMTECH/GWL for LHB Coaches.
(b) Code of practice for prevention of fire in AC coaches No. RDSO/PE/O/008-
2005 (Rev.0)
(c) The flexible poly-amide conduit for cable shall conform to RDSO
specification No.RDSO/PE/Spec./AC/0138-2009 (Rev 1) or latest.
(d) The e-beam irradiated cables shall be as per RDSO specification No.
ELRS/Spec./ELC/0019 (Rev.4) or latest.
(e) All other electrical safety aspect to be ensured.

13 CBC
The removed CBC should be replaced with new CBC as per RDSO/2011/CG-03
(Rev.-03) or latest.

14 OTHER MAINTENANCE ACTIVITY

The maintenance of other items/activities which are not covered above under the
scope of MLR and mandated in SS1, SS2 & SS3 Schedule of LHB Coaches shall
be necessarily performed during MLR as per Maintenance
Manual/Guideline/Instruction issued by CAMTECH Gwalior, RDSO and Railway
Board from time to time for LHB coaches.

***********************************************************

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ANNEXURE – I

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ANNEXURE-II(A)

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ANNEXURE-II(B)

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ANNEXURE-II(C)

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ANNEXURE-II(D)

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ANNEXURE-II(E)

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ANNEXURE-II(F)

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ANNEXURE-II(G)

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ANNEXURE-II(H)

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