LHB COACHES

Introduction of LHB Coaches on IR

• 24 imported AC chair cars arrived in India in 2000-01 under a
TOT and purchase agreement between IR and M/s ALSTOM.
• Train No. 2003/2004 New Delhi – Lucknow Shatabdi;
introduced in service on 29.5.2001.
Exterior View of LHB Coach
Interior View of LHB Coach
AC Chair Car
With Centre Table
Holding
 Premium Services Running With LHB Stock
Train No. From To No. of Rakes
Shatabdi Trains
12005/06 NDLS KLK 1
12001/02 NDLS BPL
12003/04 NDLS LKO
12011/12 NDLS KLK 6
12013/14 NDLS ASR
12017/18 NDLS DDN
Rajdhani Trains
12235/36 NDLS DBRT
3
12435/36 NDLS DBRT
12423/24 NDLS DBRT 5
12431/32 NZM TVC 3
Duronto Train
12213/14 DEE YPR 1
 Salient Features

• Speed - 160 kmph ( Fit up to180Kmph

& upgradeable to 200Kmph)

• Length over body - 23.54m

• Width of carbody - 3.24m
• Length over buffers - 24.00m
• Wheel base - 2.56m
• Minimum radius of curve - 175 m
• Car height above rail level - 4.039m
• Wheels - Monoblock
Dia : 915mm - 845mm
• Distance between center pivot - 14.90m
 LHB Coach – A Superior Alternative
Parameter ICF Design LHB Design
Cost Rs. 1.0 crore approx. Rs.1.75 Cr. approx ( Rs. 5.5 Cr. For
imported version)
Speed potential 130 Kmph 160 Kmph
Codal life 25 years 35 years
POH periodicity 18 months 36 months

Body construction Corten steel necessitating Austenitic/Ferritic Stainless steel

heavy corrosion repair(s) with almost no corrosion
Ride index 3.2 at 130 Kmph 2.5 at 160 Kmph
Coach Tare weight Approx. 43 tonnes Approx. 41 tonnes
Brake system Conventional clasp brake Disc brake
Noise and Sound Average Superior (85- 110 dB)
insulation
Aesthetics and interiors Medium size windows Large panoramic windows

LP sheet panels FRP panel

Toilet system Open discharge toilets Controlled discharge toilets

Coupling Conventional screw coupling Center Buffer Coupler
Enhanced Passenger Carrying Capacity In
LHB Coaches
Type of coach LHB ICF % Increase

I AC 24 18 33
II AC 52 46 13
III AC 72 64 12.5
Executive chair 56 46 22
car
AC chair car 78 67 16

Sleeper Class 78 72 8

General 99 90 10
SLRD 30+4 20 + 4 42
 Bogie- FIAT

• Y shaped frame with tubular cross beam, All coil spring

• Articulated Axle Guidance with control arm
• Lesser wheel base - 2560mm in ICF design 2896mm
• Anti -roll bar
• Cartridge Tapered Roller Bearing
• Disc Brakes - Disc dia 640 mm with pads on both side
 Bogie- FIAT

Primary Vertical dampers - 4 nos per bogie

( axle - bogie frame)
Secondary vertical dampers - 2 nos per bogie
(bogie frame -bolster)
Lateral shock absorber - 2 nos
( bogie frame -bolster)
Yaw dampers - 2 per coach
Secondary Damper Yaw Damper
Primary Damper
Wheel Set Earthing Equipment
 Brake calipers

Brake Pads

Axle mounted brake disc

Brake Cylinder
Brake Control Panel And Indicator Unit
Isolating cocks Test fittings Release Rod

DV

Brake control panel Brake indicator Reservoir

Brake Accelerator
Brake Indicator
 Wheel Slide Protection Equipment
• WSP unit is made up of two micro processor-driven
modules which control the state of adhesion of the axles
and of one supervisor module for diagnostic purposes.

• The operation is controlled so that the skidding wheel is

allowed to find the most favorable area for the adhesion-
skidding characteristics.

• Speed signal derived for CDTS.

WSP Electronic Unit
Speed Sensor Cable With Terminal Box

Terminal Box

Cable sensor Phonic Wheel inside the cover

 Phonic Wheel
• Part of WSP system; mounted on wheel axle with the help
of 3 HT bolts of M 8X35 size

• HT bolts of TVS, LPS and UNBRAKO make are used

• During trip schedule working of speed sensor and static

testing of dump valves is ensured.

• Checking of gap between phonic wheel and speed sensor

using feeler gauge on a drive basis
 Phonic Wheel

Speed Sensor Probe

 Water Supply & Pump Controls

Water Tanks ( 2Nos.) - 685 ltrs each ( Underslung )

Auxiliary Tank - 30 ltrs on each toilet

(Roof Mounted)

Pump Control system - To control & monitor

water circuit
Schematic Diagram of Water Supply System
 Control Discharge Toilet Systems

• Types- Euro Toilets & Oriental Toilet System

• Intermediate tank storage - speed < 30 kmph (10 - 15
flushes)
• Water pressurised flushing - 4 bar
• Manual over-ride control for discharge
CONTROL DISCHARGE TOILET
Control Panel of CDTS
 Control Discharge Toilet System

Issues in maintenance

• Jamming of slides valves – Quality of water, scales, etc.

• Ingress of undesired foreign materials i.e. paper cups,

napkins, bottles, etc.

• Lack of regular material support i.e. solenoid valves, slides,

etc.
 Center Buffer Coupler
Features & Safeguards in Operations

Double headed restrictor to prevent vertical uncoupling

of CBC knuckles in between loco and front coach
Clear Tell-tale recess which Locking arrangement for
ensures that the lock is fully manual uncoupling
dropped handle

TELL TALE LOCK

Maintenance Issues – Bogie & Under Gear
• Wheel shelling

• Breakage of brake disc

• Roller bearing failures

• Jerk during running

 Wheel Shelling
• Wheel shelling is being experienced in all the LHB coach
variants.
• About 50% unscheduled primary detachment is on account of
wheel shelling only.
• It causes impact loading on bogie components resulting in
loosening of fasteners particularly of axle box cover plates,
control arms and damage to dampers.
• It has reduced the wheel life in LHB coaches due to repeated
turning due to wheel turning (Avg. Life 4 years).
Frequent Wheel Turning Due to Wheel Shelling

A survey was conducted on population of 316 LHB coaches

and result found is as under:

No. of tyre turning after No. of coaches tyre Average time for tyre
POH/ IOH turned turning (in days)
6 times 1 57
5 times 5 98
4 times 12 114
3 times 26 139
2 times 40 156
1 times 88 238
No turning 144 211 ( After POH/IOH)

Overall average 316 200

* Taking into account approximate average running per LHB coach as 20,000KMS
Per month the approximate average KMS earning before turning comes to 1.5Lack KMS
Crack/ Breakage Of LHB Wheel Disc
 Breakage of Brake Disc
Population of brake disc

No. of coaches
FTIL KNORR
surveyed

341 173 168

BROKEN CLAMPING BRACKET

OF BRAKE DISC
 Enroute Detachment Due to Failure of
UIC-130 CTRB in LHB Coaches

No. of Average Failure in type Make of

Year
instances holding of coaches assembly

2009-10 1 214 LWSCZAC TIMKEN

1-LWSCZAC
2010-11 2 299 Both TIMKEN
1-LWACCN

2011-12 2 357 2-LWSCZAC Both TIMKEN

2012-13
( Up to 1 416 1-LWACCN SKF
July. 12)
 Jerk During Running

• Heavy jerks are being felt, particularly during sudden

acceleration & braking of the train.

• To reduce the problem, preload in draft gear of CBC has

been reduced by 50 KN to 30 KN in FTIL make. This has
resulted in a marginal improvement only.

• New design of CBC draft gear is under field trials and is

expected to control the problem considerably.
Areas Needing Regular Maintenance Attention

DOORS
• Vestibule
• Passenger Cabin Door
• Lavatory Door
• Pantry Door
• Luggage door in power car
Transition Doors
Working Out/Breakage of Holding Bracket of
Wire Rope of Vestibule Doors
Elastic Wire Grazing with Bracket Resulting
Breakage
Jamming / Rattling of Pantry Doors

Bolts getting loose

frequently
Areas Needing Regular Maintenance Attention

Seats and fittings

 Reclining gears
 Arm rest of seats
 Foot rests
 Snack table knobs
 Magazine pockets
 Upholstery getting unstitched
 Roller blind assembly failures
 Window glass assembly
Working Out of Reclining Gear Knob
Drooping of Arm Rest
Old & Torn Seat Upholstery
 Faded Seat Upholstery

New Old
Failure of Reclining Mechanism / Breakage of
Foot Rest
Working Out of Elastic Band of Magazine Bag
Breakage of Retainers of Roller Blind
Working Out of Window Glass Outer Profile
 Problem in Maintenance
AL Louvers in Compartment Sliding Door, Pantry Sliding Door
and Lavatory Door are Prone to Theft

AL. Louvers are prone to theft Window Shutters are being provided in
Coaches after the theft.
Overview Of LHB Material for DLI Division
S.N. Description Number of Items
1 Total No. of LHB Stock Items 133

2 RCF based Items 35

Year vise Vetted Demand of RCF Based 'A' Category (Imported) & 'B' category (Vital
3
Indigenous) Items
For the Year (2010-11) 25 No. (Amount Rs.97,48,806)

For the Year (2011-12) Demand not accepted by RCF

For the Year (2012-13) 18 No. (Amount Rs.2,33,09,167)

Supply For 4 (3 Raj.+ 1 Stb.) rakes
4 Free Supply Items along with new LHB Rakes
still pending with RCF

Number of LHB ITEMS procured under Non

5 56 No. (Amount Rs.80,67,197).
Stock During year 2010-11

Major constrains in procurement is limited availability of Vendors for sub assemblies

required by open line.
 Critical Stock Items Affecting LHB Coach
Maintenance
S. PL No. Feeding Material Imprest Supply
No. store depot for six ( Jan,12
month to Jun,12)

1 33501002 JUDW Primary Vertical 138 0

Damper

2 30990154 JUDW Brake Pad 35mm 2760 1687

3 33500459 JUDW Lateral Damper 28 0

4 30993076 JUDW Sealed Window Glass 360 212

(1419x819x18.4mm)

5 30993076 JUDW Sealed Window Glass 180 90

(1417x817x18mm)
 Passenger Amenity Issues – Areas Needing
Design Inputs / Improvement By RCF
• Breakage of upper berth safety rail in II AC coaches.
• Provision of polycarbonate sheets to obviate frequent
breakage of glass windows.
• Inadequate space for storing linen kits.
• Breakage of exhaust duct in toilet.
• Breakage of polycarbonate snacks table in Rajdhani coaches
• Provision of ICF type luggage door in power cars.
• Problem in fitment of amenity items on FRP panel
• Improper gap between window glass frame and FRP panel
causing ingress of dust & water in the coach
Thanks 60
 UN-SCHEDULED PRIMARY DETACHMENT OF LHB COACHES
(EQUATED TO PER COACH BASIS)

Defects 2008-09 2009-10 2010-11 2011-12

Wheel defects 1.16 1.50 1.67 1.96
Air brake system defects 0.19 0.24 0.31 0.21
Under gear defects 0.04 0.08 0.05 0.13

Axle box / roller bearing defects 0.05 0.03 0.01 0.04

Suspension defects 0.08 0.10 0.08 0.11

Draw & buffing gear defects 0.11 0.06 0.11 0.08
Body work 0.38 0.35 0.38 0.23
Modification / examination /
0.07 0.06 0.03 0.08
inspection
Others 0.01 0.01 0.01 0.01
Total 2.12 2.43 2.65 2.84

% detachment on wheel defects 55 % 62 % 63 % 69 %