RESTORATION OF LHB COACH

1
 Preface

Recently LHB coach with fiat bogie is introduced in Indian Railway rolling
stock which is appreciated by passengers due to better riding quality. It is also
appreciated that due to introduction of fiat Bogie, derailment cases of LHB
coaches on mechanical account is almost nil In Indian Railways however cases of
Brake disc breakage, bearing failure, bearing seizure and train parting have been
occurred. Due to change in design feature of LHB stock over ICF stock, It would
be better to make a restoration plan in advance for LHB coach to make it
convenient and effective restoration measure at the site.
RDSO/CAMTECH/Railway Board are the authority to issue guideline on this
matter. This training center is not an authority to issue any guideline for
restoration of LHB Coach. However this is an effort to give tentative training
guidelines for smooth and effective handling of LHB coaches at the site of
accident. On the basis of discussion held with restoration team of NDLS and CNB.
These guidelines are use on this matter.
Any suggestions/ Guideline on this matter are hearty welcome which will
improve in up gradation of the restoration measures.

T.S. BHATI
PRINCIPAL
STC JHS
2
Restoration of LHB coach is divided in the following cases
A. Main line clearance in case of Journal Breakage or Bearing seizure of inner
wheel (Wheel No 2 &3).
B. Main line clearance in case of journal Breakage or Bearing seizure of outer
wheel (Wheel No. 1 & 4).
C. On spot wheel changing without running out of bogie in case of wheel
disc/Axle Broken/ Bearing seizure/ Journal Breakage.
•Outer wheel No 1 & 4
•Inner wheel No 2 & 3
D. Wheel change with running out of bogie.
E. Re railing of coach by MFD/LUCUS in case of Derailment.
F. Re railing of coach by crane in case of derailment.
G. Toppling of capsized coach.
 MAIN LINE CLEARANCE IN CASE OF JOURNAL BREAKAGE/BEARING
SEIZURE
• REQUIRED EQUIPMENT- Jacks (MFD/ LUCAS), Dummy Standard Trolley/ Fabricated Wheel
Carrier & other necessary tools and equipments
• LIFTING LOCATION-
A . At sole Bar on Both Sides under modified Lifting Pads( Jacks 25/35 Ton capacity each)
In Case inner wheel (wheel no 2 & 3) journal breakage/Bearing Seizure.

1. In original Lifting Pad at earlier

location, Jacks were infringing with
trolley during lifting.
2. Location of Lifting Pad has been
modified by RCF to avoid above
problem.

LIFTING PAD MODIFIED LIFTING

PAD LOCATION

4
 STANDARD DUMMY TROLLEY/ WHEEL CARRIER

FABRICATED DUMMY TROLLEY/ WHEEL CARRIER

WHEEL ON DUMMY TROLLEY/ WHEEL CARRIER

5
PROCEDURE
1. Uncouple the coach from other coach as per following procedure :-
I. Ensure both the couplers are at centre position.
II. Provide anti skid device with the adjacent coach.
III. lightly push the coach.
IV.Unscrew the locking key of the operating rod.
V. Lift & operate the operating rod for uncoupling.
2. Provide sufficient space between coach for Safe working.
3. Ensure protection of coach to avoid rolling out by providing anti-skid device on
opposite side trolley wheels from both sides
4. Insert wooden packing of required thickness between Axle Box Lug & Safety Strap to
avoid more lifting.
5. Provide Jacks under modified lifting pad on sole bar from both sides as shown in
figure.
6. Lift the Coach Body with Bogie & ensure sufficient gap between wheel and rail to
insert Dummy Trolley /Wheel Carrier under defective Wheel.
7. Insert Dummy Trolley / Wheel Carrier under defective Wheel.
8. Lower the Jacks & ensure wheel is properly mounted on Dummy Trolley / Wheel
Carrier .
9. Remove anti skid device/ wooden wedges .
10. Remove Jacks from Shown Locations.
11. Clear the Section as single vehicle accompanied by C&W Staff with Safer Speed.
6
• LIFTING LOCATION-
B. At Sole Bar & head stock joint under sole bar both side ( Jacks 0f 25/35 Ton
each)
In Case outer wheel (wheel no 1 & 4) journal breakage/Bearing Seizure.

LIFTING LOCATION

7
PROCEDURE
1. Uncouple the coach from other coach as per following procedure :-
I. Ensure both the couplers are at centre position.
II. Provide anti skid device with the adjacent coach.
III. lightly push the coach.
IV.Unscrew the locking key of the operating rod.
V. Lift & operate the operating rod for uncoupling.
2. Provide sufficient space between coach for Safe working.
3. Ensure protection of coach to avoid rolling out by providing anti-skid device on
opposite side trolley wheels from both sides
4. Insert wooden packing of required thickness between Axle Box Lug & Safety Strap to
avoid more lifting.
5. Provide suitable wooden packing between sole bar & head stock to avoid bulging.
6. Provide jack under sole bar & head stock joint both side.
7. Lift the Coach Body with Bogie & ensure sufficient gap between wheel and rail to
insert Dummy Trolley /Wheel Carrier under defective Wheel.
8. Insert Dummy Trolley / Wheel Carrier under defective Wheel.
9. Lower the Jacks & ensure wheel is properly mounted on Dummy Trolley / Wheel
Carrier .
10. Remove anti skid device/ wooden wedges .
11. Remove Jacks from Shown Locations.
12. Clear the Section as single vehicle accompanied by C&W Staff with Safer Speed.
8
 PROCEDURE FOR WHEEL CHANGING
In case wheel disc/axle broken

1. ON SPOT WHEEL CHANGING WITHOUT RUNNING OUT THE BOGIE

A. CHANGING OF OUTER WHEEL SET ( Wheel no. 1 and 4)
REQUIRED EQUIPMENT- Jacks (MFD/ LUCAS), re-railing beam, other necessary tools & equipments

PROCEDURE
1. Uncouple the coach from other coach/rake.
Procedure is as under
I. Ensure both the couplers are at centre
position.
II. Provide anti skid device with the adjacent
coach.
III. lightly push the coach.
IV. Unscrew the locking key of the operating
rod.
V. Lift & operate the operating rod.
2. Provide sufficient space between coach for Safe
working.
3. Ensure protection of coach to avoid rolling out by
providing anti-skid device on opposite side trolley
wheels from both sides.
9
4. Disconnect following fittings
i. Four nos. axle box face plate screw
from both side of defective wheel set.
ii. Four bolts of articulated controlled arm from
both side.
iii. Speed sensor connection cable & earthling
cables.
iv. vertical shock observer bolt.

10
5. Place lifting jack under articulated control arm
from both side. Of bogie under defective wheel.
6. Lift bogie and run out defective wheel set
7. Place traverse beam between rail track and
provide jacks on suitable location.
8. Provide jack with fixture under axle.
9. Lift the jack up to required limit to lift the wheel
set.
10. Provide rope of puller with wheel for transverse
pulling.
11. Pull the wheel from the track.
12. Repeat the same procedure in reverse direction
for providing good wheel on track. LIFTING LOCATION
13. Replace defective wheel set with good wheel set
& place under bogie
14. Lower the bogie on new wheel set.
15. Lower the jack and remove from location.
16. Connect all fittings. As described in Sr. no 04
above.
17. Remove antiskid device from wheel sets.
18. Coach ready to run.

11
1. ON SPOT WHEEL CHANGING WITHOUT RUNNING OUT THE BOGIE
A. CHANGING OF INNER WHEEL SET ( Wheel no. 2 and 3)
REQUIRED EQUIPMENT- Jacks (MFD/ LUCAS), re-railing beam, other necessary tools & equipments

PROCEDURE
1. Uncouple the coach from other coach/rake.
Procedure is as under
I. Ensure both the couplers are at centre
position.
II. Provide anti skid device with the adjacent
coach.
III. lightly push the coach.
IV. Unscrew the locking key of the operating
rod.
V. Lift & operate the operating rod.
2. Provide sufficient space between coach for Safe
working.
3. Ensure protection of coach to avoid rolling out by
providing anti-skid device on opposite side trolley
wheels from both sides.
12
4. Disconnect following fittings
i. Four nos. axle box face plate screw
from both side of defective wheel set.
ii. Four bolts of articulated controlled arm from
both side.
iii. Speed sensor connection cable & earthling
cables.
iv. vertical shock observer bolt.

13
5. Place lifting jack under articulated control arm
from both side. Of bogie under defective wheel.
6. Lift bogie and run out defective wheel set
7. Place traverse beam between rail track and
provide jacks on suitable location.
8. Provide jack with fixture under axle.
9. Lift the jack up to required limit to lift the wheel
set.
10. Provide rope of puller with wheel for transverse
pulling.
11. Pull the wheel from the track.
12. Repeat the same procedure in reverse direction
for providing good wheel on track. LIFTING LOCATION
13. Replace defective wheel set with good wheel set
& place under bogie
14. Lower the bogie on new wheel set.
15. Lower the jack and remove from location.
16. Connect all fittings. As described in Sr. no 04
above.
17. Remove antiskid device from wheel sets.
18. Coach ready to run.

14
 PROCEDURE FOR WHEEL CHANGING
WITH RUNNING OUT OF BOGIE
1. WHEEL CHANGING WITH RUNNING OUT THE BOGIE
REQUIRED EQUIPMENT- Jacks (MFD/ LUCAS), re-railing beam , other tools & equipments

PROCEDURE
STEP - I
1. Uncouple the coach from other coach/rake. Procedure as under-
I. Ensure both the couplers are at centre position.
II. Provide anti skid device with the adjacent coach.
III. lightly push the coach.
IV.Unscrew the locking key of the operating rod.
V. Lift & operate the operating rod.
2. Provide sufficient space between coach for trolley run out.
3. Ensure protection of coach to avoid rolling out by providing anti-skid device on
opposite side trolley wheels from both sides.

15
4. Disconnects following fittings.

 Open four bolts of

bolster.

16
  Disconnect both side
foot board bracket.

Disconnect both side CDTS

Intermediate tank & drainage
pipes

CDTS
INTERMEDIATE TANK

DRAINAGE PIPE

17
 Disconnect electrical cable
connection.

 Disconnect flexible air hose

connection of BP & FP.
For running out of the body it is
ensured that coach should not be
lifted more than a certain height in
case of electrified section.
There are four nos. safety wire rope
in built connected with Bogie to
Bolster which will not allow to lift the
Bolster up to free height of Bolster
spring. The Bolster will lift 02 to 03
inches height only, after that these
four Nos. safety wire rope will be in
tight position & will not allow to lift
the Bolster.
SAFETY WIRE ROPE

18
It is also experienced that one
locally made C clamp is used
between bolster plank &
connecting Arm to hold
Bolster Spring in compressed
condition with the help of
Jack. This will not allow to lift
the Bolster.

Front View Side View Isometric View

 Place jack/Lucas/MFD at modified lifting pads

location as shown in figure.
 Lift the body and run out the defective bogie.
 Keep body and trestles/wooden sleepers.

MODIFIED LIFTING
PAD LOCATION
STEP - II

1. Provide anti skid/ Wooden wedge on Good wheel

set to avoid rolling out.
2. Disconnect following fittings
I. Four nos. axle box face plate screw from
both side of defective wheel set.
ii. Four bolts of articulated controlled arm
from both side.
iii. Speed sensor connection cable & earthling
cables.
iv. vertical shock observer bolt.

20
3. Place lifting jack under articulated control arm
from both side of bogie under defective wheel.
4. Lift bogie and run out defective wheel set
5. Place traverse beam between rail track and
provide jacks on suitable location.
6. Provide jack with fixture under axle.
7. Lift the jack up to required limit to lift the wheel
set.
8. Provide rope of puller with wheel for transverse
pulling.
9. Pull the wheel from the track.
10. Repeat the same procedure in reverse direction
LIFTING LOCATION
for providing good wheel on track.
11. Replace defective wheel set with good wheel set
& place under bogie
12. Lower the bogie on new wheel set.
13. Lower the jack and remove from location.
14. Connect all fittings. As described in Sr. no 02
above.
15. Remove antiskid device from wheel sets.
16. Coach ready to run.

21
RESTORATION OF LHB COACH IN CASE OF DERAILMENT
A. WITH SINGLE POINT LIFTING.
LIFTING & TRAVERSING EQUIPMENT- MFD/ LUCAS & other necessary equipments
LIFTING LOCATION-Under Yoke Support Plate
PROCEDURE-
 Uncouple the coach from other coaches
 Provide sufficient space for safe working.
 Place the Traversing Beam over the Track under Lifting Location
ensure proper packing, securing & leveling of traversing beam.
 Ensure Proper protection by using anti skid device/ wooden
wedges on opposite trolley to avoid rolling of the coach.
 Provide the Jack under yoke support plate as shown in figure
 lift the coach with Trolley as per requirement to avoid the
infringement of wheel flange with track.
 Move the Bogie in Lifting position with the help of push jack on
traverse beam towards track and aligned with the track with
wheel flange.
 After ensuring the proper alignment of the Lower the trolley on
track.
 Lower the Jack
 Remove All Re railing equipments and clear the track.

22
 LIFTING WITH TWO POINTS.
LIFTING LOCATION-
Under modified lifting pads

PROCEDURE-
 Place the Traversing Beam over the Track
under Lifting Location. Ensure proper packing,
securing & leveling of Traversing Beam.
 Provide two Jack under lifting pad at shown
location parallel to each on traversing Beam
with proper alignment .

MODIFIED LIFTING
PAD LOCATION
 Lift the coach with Trolley by operating both the jacks as per requirement to
avoid the infringement of wheel flange to track.
 Move the Bogie in Lifting position with the help of push jack on traverse beam
towards track and aligned with the track with wheel flange.
 After ensuring the proper alignment Lower the bogie on track.
 Lower the Jack.
 Remove All Re railing equipments and clear the track.
23
 RESTORATION BY 140 T CRANE IN CASE OF DERAILMENT
Location – A. Lifting Pad of the coach both sides
In case of electrified traction shut down
the supply. Do’s &
Remove/ slewing the OHE wire Don’ts
Place the crane in adjacent line/ same line
as per the condition.
Ensure proper propping of the crane.
For Crane working Please ensure
Do’s and Don’ts of 140 T Crane .
Uncouple the couplers of coaches.
Ensure Proper protection by using anti
skid device/ wooden wedges on opposite
trolley to avoid rolling of the coach.
 Lift the Jib of Crane & lower the Hook.
Provide Double Legs Chain Sling in Crane
lifting beam

24
Provide Chain Hook in the shown location in
both side of coach body for lifting from one end.
Provide Wooden Packing between Body & chain
to avoid damage on coach body. LIFTING BEAM
Lower the Trolley on track with alignment.

25
 LOCATION – B. UNDER BOX SECTION OF SOLE BAR NEAR LIFTING PAD
USING LIFTING BEAM/ WIRE ROPE
In case of electrified traction shut down the supply.
Remove/ slewing the OHE wire
Place the crane in adjacent line/ same line as per the condition.
Ensure proper propping of the crane.
For Crane working Please ensure Do’s and Don’ts of 140 T Crane .
Lift the Jib of Crane & lower the Hook .
Uncouple the couplers of coaches.
Ensure Proper protection by using anti skid device/ wooden wedges on opposite trolley to
avoid rolling of the coach.
Provide Lifting Beam/ wire rope under the coach at box section near lifting pad at suitable
location.
Proper alignment and locking of upper and lower lifting beams/ wire rope to avoid any
damage to the coach body.
Lift the trolley as per requirement to avoid infringement of wheel flange with track.
Lower the Trolley on track with alignment.

26
 TOPPLING OF CAPSIZED COACHES

In case of electrified traction shut down

the supply.
Remove/ slewing the OHE wire
Place the crane in adjacent line/ same line
as per the condition.
Ensure proper propping of the crane.
For Crane working Please ensure Do’s and
Don’ts of 140 T Crane .
 Lift the Jib of Crane & lower the Hook.
Uncouple the couplers of coaches.
Secure at suitable location at sole bar to
ensure balancing of the coach and topple
the coach on ground.

27