Maintenance Manual of LHB Coaches 12.
2 Schedule D1 ( Every Trip)
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 Bremse¶s 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
damages and corrosion. Control Arm y Perform a visual check on all fixings for loosening and / or missing components. it is necessary to replace the discs. damage and ageing. cracks or corrosion marks. links and brackets for cracks.3Schedule D2 (Monthly) Perform all the items of schedule D1. In addition to this perform the activities. y The assembly should be free to move. Axle Bearing Instruments y Inspect the Earthing equipment for wear of slip assembly / carbon bars. Brake Equipment y Verify that the clearance between each pad and disc surface is 1-1.Maintenance Manual of LHB Coaches
y Check by wheel profile gauge. Bogie Frame y Wash the bogie frame thoroughly with water jet in washing line. y Perform visual check on all fixings for loosening/missing fittings. Anti Roll bar Assembly y Perform a visual check on Anti roll bar. fixings and all moving parts using prescribed grease (Autol Top 2000 spray). damages and ageing. y Inspect the rubber joint until it is visible for cracks. y Perform a visual check on all fixings for loosening. Note: please refer to RDSO CMI ± K 003 (Guidelines for interpretation of wheel defects) and µ Maintenance Manual for ICF design BG coaches¶ for details.as given below. y Check axle for cracks and signs of corrosion. y Perform a visual check on rubber joints for cracks. the wheel flange thickness and profile. y Visually inspect for grease oozing out of anti roll bar bearings. if any. y Monthly / Quarterly inspection of WSP equipment to be carried out as per schedule given by OEM. y Check wear of brake pads/ brake discs. and not blocked by any foreign objects. which may result in bearing failure. making sure that water is not directed towards pneumatic / electrical connections and axle bearings.components. y Lubricate the brake levers.5 mm. y Perform a visual check on rubber joints for cracks/damages. Chapter 12 Page 2 of 17
. 12. If groove depth is reached. Traction Centre y Perform a visual check on the traction centre lever and on the rods for cracks. Rubber and Rubber/Metal Bonded Parts y Perform a visual check on rubber and rubber/metal bonded parts for cracks. damages and ageing. damages and corrosion. y Visually check control arm parts for damages. Rotation Limiter y Perform a visual check of rotation limiter.
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. Replace all worn parts. If necessary. 12. Check spring mechanism for self-regulation. 12. Replace the defective components. if necessary. Replace. Replace. Brake disc bolts should be checked for tightness. 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. y Carry out paint touch up with high built epoxy primer and paint as per RCF specifications MDTS ± 166. y Examine BP/FP couplings and hoses. 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.5 Shop Schedule-I (18 Months) The following activities shall be carried out in Shop Schedule-I. Chapter 12 Page 3 of 17
. Replace. y Examine the Brake calipers and Brake pads for wear and damages. Primary/Secondary Suspension y Attention to springs during Shop Schedules shall be as given under Para 12. Replace carbon bar and slip assembly.4 Schedule D3 (Half Yearly) Perform all the activities of schedule D2. y Check the functioning of hand brake equipment. perform reprofiling. Replace. if necessary. perform the activities. y Carry out overhauling and testing of WSP equipment as per OEM¶s instructions. if necessary. Axle Box Instruments y Overhaul the grounding equipment.Maintenance Manual of LHB Coaches
Wheel & Axle y Check tread diameter and wear of wheel profile. y Examine the brake discs to detect any thermal or fatigue cracks. if necessary. as given below Bogie Frame y Examine the bogie frame for corrosion / damages. In addition to this. especially at critical locations. Pins and Bushes y Lubricate all pins and bushes.11.
3. damage and cracks.
Page 4 of 17
. Replace. Refer to RCF specn. replace them.-I and Shop Sch. Damper Primary Vertical Damper Secondary Vertical Damper Secondary Lateral Damper Yaw Damper RCF Drg. For reconditioning of bearings.Maintenance Manual of LHB Coaches y y y Dampers y y
Examine the condition of lift stop pin and safety cables. a metal identification tag with the mounting date shall be crimped to the brake disc near the bearing. absence of deformations and oil leakages. wear. Dampers should be replaced during Shop Sch-III (6 years). If end play is beyond permissible limit or if any roughness is detected while rotating the bearing.no. read alongwith FIAT specification no. MDTS ± 168 for balancing procedure. lubricate the lathe centres with heavy grease. Check the bearing mounted end play. Replace. Replace. LW 05102 LW 05101 LW 05100 LW 05103 PL No. Bearing reconditioning is to be carried out whenever bearing is removed from axle due to wheel-shelling / bearing failure. if necessary. y Check wear of wheels. If the wheelsets are sent for reprofiling without dismounting bearings. renew corrosion protection and repaint the axle. (Miner pads. Damper should be tested during Shop Sch. 4. if necessary. dismount the bearing and send for reconditioning. remove signs of corrosion. Check dampers for correct functionality. Check lower and upper centering discs for corrosion.560. No. 2.
NOTE: 1. cracks and ageing. renew corrosion protection and repaint the components.100. If new bearing or reconditioned bearing is fitted. 00920083 00920060 00920058 00920071
Rotate the bearing assembly to detect any abnormal condition. if necessary. Control Arm y Perform a general overhaul of the control arm: remove signs of corrosion. Replace fixings/fasteners. if necessary.). Examine the condition of rubber and rubber/metal bonded parts for damage. if necessary. 17.-II (or early in case of oil leakages) as per parameters given in RCF drawings.
Wheels and Axle y Perform wheel profiling and wheel balancing (for Speed >= 130 Kmph). y Perform an ultrasonic test on the wheel and axle to verify absence of internal cracks and damages. rubber springs etc. please refer to OEM¶s instructions. y Perform a general overhaul of the axle.
MD 44121 Dt: 13. if necessary. 17. Traction Rods). hold the bogie frame in a suitable manipulator. if necessary. to prevent corrosion.5 mm and 230. Replace. MDTS 166 (Rev. Check all the welded joints with dye penetration.Maintenance Manual of LHB Coaches y
Check wear limit of control arm bore as follows. the control arm may be reused without remachining. wears out by more then 0. on condition basis.3 to 0. provided these are a) Staggered and non continuous b) Are not concentrated on the bottom bend portion of the side frame. y In case. the control arm should be considered worn out and rejected. Bogie Pins Chapter 12 Page 5 of 17
.09.5 mm).e. the diameter is less than 230. the dia. y Descaling/rust removal with rust converter to IS: 13515 y Touch-up with high build epoxy primer and paint as per RCF¶s specification no. Replace.5 mm on the face of control arm. y Corroded bogie frames should be attended as follows:y Cleaning/washing of bogie frames. if necessary. y Examine the rubber joint for cracks/damage and ageing. y Replace fixings.(Ref: RCF¶s letter no. Remove signs of corrosion. ( This machining operation should not be carried out more than once). If crakes are found. damages and corrosion.312 mm. Rotation Limiter y Check condition of the steel roll and pin for wear/damages.5 mm (i. renew corrosion protection and repaint the block. renew corrosion protection and repaint the components.08) y If the control arm bearing surface reaches a diameter of 230. NOTE: Small pitting holes upto a maximum depth of 3 mm may be permitted on the frame. Remove signs of corrosion. and rectify. is between 230. the control arm may be re-machined by providing a cut of 0. if necessary. Replace. if necessary. Bogie Frame and Bogie Bolster y Examine the bogie frame and bolster for cracks. y The control arm mating surface with bearing should be coated with ³ Blasol ± 135´ solution.09) Anti-Roll Bar Assembly y Perform a general overhaul of the anti-roll bar.08. rubber joints and sealings. y In case. y Replace anti roll bar bearings.312 mm.2) and MDTS 094. y Replace the rubber bush and the rubber joints. Rubber and Rubber/Metal Bonded Parts y Examine the Rubber and Rubber/Metal Bonded parts for ageing / damages/ failure of bonding. renew corrosion protection and repaint the anti-roll bar and the links y Examine the condition of the brackets: remove signs of corrosion.MD 44121 dt. (Ref: RCF¶s letter no. Traction Centre y Perform a general overhaul of the traction centre components (Traction lever.
for tightness y Water level Indicator . deficiency Entrance Door (Main Door) y Chapter 12 Entrance door glass for cracked. opaque y Window glasses rubber profiles y Entrance doors out side rubber gaskets y Destination board cover with locking arrangement . SV.for corrosion and damage y Inspect water tank frame.for corrosion and damage y Inspect air brake pipe lines. which may be referred by shops. Further.for corrosion and damage y Inspect water system pipe line. damage y Inspect sole bar for corrosion. damage.2006. damage y Inspect cross member for corrosion. working y Rubber hose connection -replace of all rubber hose connection y Drain cock protection cover . damage. function of lock y Entrance hand rails (body handles).damage. fixation. vide lettrer no. leakage. fixation bolt y Inspect head stock for corrosion. damage. damage
Water Supply y Water tank tightening bolts. moist.
CBC y Attend the Tight lock CBC as given in RDSO¶s CMI no.for corrosion. RDSO/2006/CG/CMI -01 Under Frame & Running Gear y Inspect trough floor.for corrosion and damage y Inspect air brake module frame.Maintenance Manual of LHB Coaches
Examine brake gear pins and other bogie pins for wear/ damages. opaque. vide letter no. condition of plating.for corrosion and damage y Inspect emergency battery box frame. y Inspect Gusset plate for corrosion.inspect for corrosion. Replace the pins with hard chrome plated pins as per RCF drawings. fixing with frame.Fiat dated 14.Coach Body y Window glasses. Page 6 of 17
NOTE: RDSO has issued a checksheet for Bogie inspection of LHB coaches during SS-I & SS-II.conduct leakage test
Exterior. moist.for tightness. availability y Water inlet cover . damage. damage.inspect for corrosion.11. cracks Ventilator. cleanliness y Foot steps ± for corrosion.2006. M442/19/4 (LHB) dated 23.03.damage. broken Roof y y y Roof sheet.provided y Water tank sensor & its bracket -damage. tightness y Ventilation grills of generator cars ± for corrosion. cracked. deficiency of louvers Roof leakage. western Railway has also issued a checklist for maintenance of LHB coaches in workshops.
universal lock. rollers. Inner & outer locking handle. deficiency Door Assembly -Proper alignment & working. for bent. for working condition y Key locking arrangement. worn out S S wire rope. rexene. tightness PVC . shabby look. stains.. for working condition. arm cylinder -Remove door flap in SS-II and fill up the gap by extending floor . broken or external damage. leveling. de-silvering Magazine pocket Bottle holder Coat hooks Berth holder Luggage racks. dust free (replace if required) Locks of ceiling panels . cleanliness Compartment mirror . Snack table. panel. lubrication Locking handles for working condition Hand safe gasket for damage. pad lock arrangement for working condition.Condition.damaged. worn out y Door Flap Elements viz. stains Upper berth fenders. Curtains (partition & window)-torn. worn out Top mechanism including pneumatic cylinder . for working condition y Rubber gasket . torn. luggage ropes Carpet (I class) .
Luggage Door Top & Bottom Sliding Mechanism including guide rail.Maintenance Manual of LHB Coaches y
y y y y y y
Locking mechanism including locking cam top & locking pin bottom. Interior. cleaned.aisle area-worn out. for damaged. damage. Door stopper (All types).working condition.cracks. holding brackets. Page 7 of 17
. smooth working Guide shaft . damaged y Locking mechanism.dusty. bearings. FRP cover.torn. shabby look. worn-out Barrel Bolt(locking arrangement) for well positioned Entrance door.fixation. lubrication Emergency window . cracked. flap complete. worn. worn out. ICV pull Box All mandatory instructions stickers .working condition. availability of handles & instruction stickers.availability in good condition
Saloon Sliding Doors y y y y Chapter 12 Nylon wire rope -damaged. etc.working condition.Passenger Area y y y y y y y y y y y y y y y y y Upholstery-condition of cushioning. damaged. louvers.lubrication by suitable lubricant.
glass. inner & outer locking handle.damaged. leakage. broken or external damage Doorway & Gangway Area Mirror (outside) .crack.stainless steel or FRP(painted) Tube light column & its fittings -crack. y Attendant berth/seat . clean as per procedure given in RCF Manual Painting of FRP panels.e. working condition CDTS Panel Door y y Locking arrangement. broken. glass gasket. condition & securing of holding brackets y Square key locks of ceiling panels .cracked. vestibule door cover. leakage Dust bin with fire extinguisher stand .loose. stoppers etc. rivets etc. Page 8 of 17
.damaged.for working condition. lubrication y Leveling of ceiling panels y Moldings. cracked Grill & grill rubber profiles Door flap elements viz.working condition. damaged. broken. torn. tear off . deficient Hopper window glass . leakage Paper roller .stainless steel or FRP painted.working condition Key locking arrangement . glass film & rubber profiles . securing brackets of fire extinguishers Electrical Panel door y y y y y Door elements like glass. damaged. availability of all fittings i. broken. locking arrangement of upper glass Dust bin .working condition.crack. y Cup boards for linen and catering items . dusty.damaged.working condition Hand safe gasket . Wash basin/ FRP embedding. alignment. lubrication
Lavatory Area y y y y y y y y y y y Chapter 12 Mirror (inside) . broken. moldings. door frame moulding. damaged.stainless steel or FRP(painted) Floor area(anti slip PVC or aluminum chequered plate) .working condition. hinges . clean Tap (gravity tap / luxury tap) . locks. cracked. .working condition. soap dish. broken.worn-out. locking pin. worn out Glass. timers (after opening ceiling panel) .bent.dusty.cleanliness. poor silver plating Wash basin . filters.condition of rubber.Maintenance Manual of LHB Coaches y y y y y y
Locking mechanism . fittings. clean as per procedure given in RCF Manual Pipes. shabby look. side & middle hinges. leakage Soap dispenser . hinges. damaged 30 litre water tank . operation of upper glass. leakage. key locking arrangements.working condition.stainless steel or FRP (painted) Tap (gravity or auto sensor) .
worn out Hand safe gasket for damaged.damaged. broken or external damage Gangway bridge (vestibule foot) plate including roller.fixation. damage. bent Barrel bolt (locking arrangement) including arrangement for toilet occupation indication. Nylon/ steel wire rope for damaged. damage. Pivot (top) for fixation. tightness Top roller for fixation.. Coat hook . damage Vestibule foot plate split pin for wear. fasteners for damaged. rivets etc. moldings. worn out Top mechanism including pneumatic cylinder for working condition. working mechanism / condition Vestibule foot plate pin for wear. broken or external damage
VestibuleSliding Door & GangBridge y y y y y y y y y y y y y 12. missing Door flap elements for bent.lubrication by suitable lubricant. and lubrication. worn out Glass & glass frame for cracked. damage.
Shop Schedule-II (36 Months)
In addition to the activities listed under Shop Schedule-I. defective Guide shaft .lubrication by suitable lubricant. missing. Locking mechanism for working condition Key locking arrangement for working condition Male & Female hand safe gasket for damaged. spring. for bent. tightness. worn out Bottom grill for damaged. locking pin. channel. inner & outer locking handle. 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
. the following activities shall be carried out in Shop Schedule-II. Vestibule Rubber for crack. opaque Door flap elements viz.Maintenance Manual of LHB Coaches
Lavatory Door (Toilet Door) y y y y y y y y y y y y Guide roller channel .6 Nylon belt for damaged. tightness. worn out . for working condition Provision of extra handles (inside) & existing handles & turn-over latches damaged. lubrication Guide roller channel . tightness Pivot (bottom) for fixation. Middle hinges gasket for damaged.
scratches y Exterior body check for corrosion. provided these are a) staggered and non continuous b) Are not concentrated on the bottom bend portion of the side frame. damage y Inspect cross member for corrosion. y Replace the rubber bush and the rubber joints . MDTS 166 ( Rev. indicators. damage Water Supply y Water tank and water supply pipe line. Anti-Roll Bar Assembly y Perform overhaul of the anti-roll bar. y Inspect Gusset plate 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. 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. Rubber and Rubber / Metal Bonded Parts y Replace all the rubber and rubber/metal bonded parts as must change item.Coach Body y Condition of exterior paint for peeling off. Bearings y Dismount the Bearings and send for inspection/reconditioning. Under Frame & Running Gear y Inspect head stock for corrosion. 1267505. y Emergency brake valve & pull box y Brake cylinders y WSP equipment y Replace brake gear pins and other bogie pins/bushes.Maintenance Manual of LHB Coaches
y Filters. sealings and anti roll bar bearings . NOTE: Small pitting holes upto a maximum depth of 3 mm may be permitted on the frame. damage y Inspect sole bar for corrosion. damage. Traction Centre y Perform a general overhaul of the traction lever.Passenger Area Chapter 12 Page 10 of 17
.2) and MDTS ± 094. with a minimum DFT of 200 microns. Interior.cleaning as per procedure given in RCF maintenance manual. y Pressure testing Exterior. y Replace Air Brake Hoses Bogie Frame and Bogie Bolster y Check the dimensional and geometrical tolerances of bogie frame as per FIAT drg. y Replace all rubber joints. test fittings. Repair/replace the defective/worn out components. Rectify/replace as necessary. No. loss of gloss.
condition.Replace FRP doors by better FRP/ LP sheet matching with interior in 1st POH . y Non upgraded PVC flooring should be replaced. Chair car. and follow repair guidelines circulated by RCF.
12. shabby look (clean by soap water) apply putty & paint the FRP panels
Furnishings y 100% replacement of Rexine. RCF guidelines) .Maintenance Manual of LHB Coaches y
FRP panels including ceiling panels for cracks.7
Shop Schedule-III (72 Months) Page 11 of 17
. damaged. shabby look. CDTS Panel Door y CDTS panel door . torn y Ladder . damaged. shabby look (clean by soap water). thereafter. condition of paint.Replace FRP doors by better design FRP / LP Sheet matching with interior in 1st POH . Lavatory Area y y FRP panels (Ref. carpet is to be provided in Aisle portion only as per extant instructions.cracks. y 100% replacement of carpets of Exec. painting. Electrical Panel door Switch board doors . condition of paint. y PVC ( inside the compartment) for worn out.
Page 12 of 17
Must Change Items During Shop Schedule ±II
List of must change items during Shop Schedule ±II is enclosed as Annexure ¶12. 12. if necessary.Passenger Area y Replacement of up graded specification PVC flooring.
Dismount the CBC from coach.8.-I and Shop Sch-II.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. and permanent set during shop schedule-I.6¶ Tool and Equipments
Tools and Equipments for maintenance of FIAT bogie are given as Annexure ¶12. cracks. Replace. the following activities shall be carried out in Shop Sch-III.Maintenance Manual of LHB Coaches
In addition to the activities listed under Shop Sch. detachment between rubber & metal.
12. disassembled and overhauled as given in RDSO¶s CMI no. Dampers y CBC y Replace all dampers during Shop Schedule-III. RDSO/2006/CG/CMI-01 Interior.7¶ and Tools and equipments for Depot maintenance and traveling TXR are given in Annexure 12.
11 Primary & Secondary Springs
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.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.Maintenance Manual of LHB Coaches 12. part document 101. version 01 for coupling and installation instructions of flexi coil secondary springs.) 1267411 1267411 1267411 1267411 1267411 1277142
Secondary Suspension Springs
Page 13 of 17
.471. 17.) 1267412 1277143 1267412 1267412 1267412 1277143
OUTER ( Drg.No.) 1269514 1268836 1269514 1269514 1269514 Side 1 1277146 Side 2 1268836
Coupling and Installation Instruction for Flexi Coil Secondary Springs Please refer to FIAT-SIG technical specification No.
This surface protection should remain undamaged. Monthly Schedule (D2) Same as Trip schedule. damages. Trip Schedule (D1) Carry out visual inspection of springs for damages. 17. y In case of corrosion ±pitting.100. if free height/deflection is beyond permissible limits. Half Yearly Schedule (D3) Same as Trip schedule Shop Schedule I. y If rust is visible. derust with the steel brush.248. 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: RCF¶s letter no. Page 14 of 17
. corrosion and breakage. Shop Schedule ± III (72 Months) In addition to activities given under Shop Schedule ±I. cracks or broken springs. corrosion. 23. resulting in spring failures. cracks or breakage.2002)
Primary Springs Inner
1267412 1277143 --LG01101
Secondary springs Inner
1269513 1268837 1277145 LG05100
1267411 1277142 --LG01100
1269514 1268836 1277146 LG05101
Paint colour to be painted on middle coil
Green Yellow Blue Black
The paint should be compatible with the paint of spring as specified in clause 8.3 of specification no. y Any damage to coating may be repaired by primer and high build epoxy paint to RCF specification. MD 23151 dt.248. Maintenance of springs Primary & secondary springs are protected against corrosion by a paint coating.11. 17. otherwise there can be local corrosion attack. replace the spring. y Inspect visually for any cracks. and repair the coating as given above.Maintenance Manual of LHB Coaches Colour Coding of Springs for Identification
For identification of springs to be used in different types of LHB Coaches.100 version 05. Replace the spring. 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. II (18 Months/36 Months) y Clean the primary/ secondary springs thoroughly (with suitable detergent water jet) in disassembled condition.
18.D.6 8.8 I.0 7.75 Height Test load under test load (mm) (KN) 28.118 + 1% 268.=317+3/-0 O.=318+3/-0 I. 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 4.5 5.4 7.226 + 1% 515 +0/-5 34.1 164.5 +0/-5 71. Not Reqd.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% 129.48 + 1% 512.3 Not Reqd.=111+3/-0 O.1 6.D.6 7.5 +0/-5
59.0 4.0 8.D.1 + 5% 556 + 5% 310 + 5% 197.D.=280+0/-2 I.9 + 5% 365.6 + 5% 317 + 5% 183 + 5% 583 + 5% 320 + 5% 337.D.25 Total no.D.=111+2/-0 I.5 Not Reqd.6 + 5% 154.=179+2/-0 I.7 7.2 +0/-5
Page 15 of 17
.336 + 1% 268.Maintenance Manual of LHB Coaches
Drawing No.3 6.9 8. Not Reqd.=179+3/-0 I. Not Reqd.2 +0/-4 14. 43.6 7.9 254. 31.7 6.3 6.D.695 + 1% 468.=321+3/-0 O.D.5 224.8 61.=280+0/-2 I.0 7.5 8.19 + 1% 471 +0/-5
26.79 + 1% 516.D.8 7. of coils 5.8 5.5 + 5% Lateral Other stiffness controlled (N/mm) for Dimension information Not Reqd.02 + 1% 47.=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.D.D.6 5.2 5.2 5.=181+3/-0 I.2 43.D.=281+0/-2 I.5 7.=315+3/-0 I.91 + 1% 17.665 + 1% 472.02 + 1% 25.5 + 5% 241.24 + 1% 47.2 +0/-4 40.1 4.5 5.=112+3/-0 O.D.32 + 1% 26.1 6.D. 284.1 6.
Damper End-Mountings. Bushes. Seals. 12. 4. If Any.
Bearing for Anti Roll Bar. 7. 5. 10. 9. Vertical Rod Silent Block. Vestibule foot plate split pin All Dampers to be Replaced During Shop Schedule-III.
2. Traction Centre Silent Block. Pins. 3. 8. Nylon/steel wire rope of GangBridge. Vestibule foot plate pin and nylon wire rope (for vestibule sliding doors). PVC of Aisle area Floor area (anti slip PVC or aluminum chequered plate).
y y y y y y y y
All Rubber and Rubber/Metal Bonded Components. Lateral/Longitudinal Bump Stops. Mirrors Nylon belts of sliding door. Split Pins. Miner Pads for Secondary Suspension. 6. Such AsControl Arm Silent Block.6
The following items must be replaced as must change items during the shop schedule-II: 1. Curtains of partitions and windows. Traction Rod Silent Block. Other Rubber and Rubber/Metal Bonded Parts.Maintenance Manual of LHB Coaches Schedules
Must change items during Shop schedule ±II
Page 16 of 17
. Fasteners. 11.
Wheel profile Lathe. Bench end-play checking fixture. Supports (Trestles) for putting bolster beam. Testing machine for Primary/Secondary/Yaw dampers. 3. Hydraulic lifters (Jacks) for lifting the coach body capacity 15 Ton . 12. 16. High pressure jet cleaning machine. Wire rope slings and trestles for rotation of bogie frame. 18. Hydraulic equipment for bearing installation & removal.) Press for removal & pressing of bolster beam. Spring testing machine for Load/Deflection Test (vertical & horizontal both) Single car testing rig for air brake system. spanners set etc.7
The followings Tools & Equipment are required for maintenance of FIAT bogie. Axle dia measurement gauge/micrometer. 21. Mounting/ dismounting tools for Anti roll bar elastic joint. 24. Wheel press (for pressing wheel on axle). 11.
Miner pad pressing Fixture
Page 17 of 17
. Lubrication fixture for bearing. Gauge for checking Bearing Mounted End Play. 17. 8. Wheel balancing equipment. 6. 7. pliers. 2. 15. Parallelism checking tool for control arm. 23. 22. Tool kit (Torque wrenches. 4.4 Nos. EOT crane (5 Ton) for lifting of bogie frame/Bolster. 9. Hydraulic press for primary suspension. 5. Mounting/ dismounting tools for Anti roll bar bearing. 20. 10. 1. 26. This list is not exhaustive and may require additional item as required. Hydraulic press (50 Ton) for removal/insertion of rubber joints. Bogie painting facilities. 13. 19. GO/NO GO threads plug gauge for axle ends. 25. Allen keys.Maintenance Manual of LHB Coaches Schedules
Tools &Equipments for FIAT Bogie
Annexure 12. Equipment for pneumatic System Functional Test. 14.