INFRASTRUCTURE

Classical Definition
Basic
Physical
Facilities
needed for the operation
MAINTENANCE IN INDIAN RAILWAYS

Preventive Maintenance

Periodic Maintenance

Attention at Specific Interval

Based on Time / km run
LHB INFRASTRUCTURE
Maintenance Activities require
Man
Machine
Tools & Plant
Material
Infrastructure
Technical Know-How
LHB COACH
Supplied by M/s. ALSTOM LHB/Germany
With Technology Transfer
for Manufacturing in India

Bogies Manufactured
by M/s FIAT/SIG Switzerland

Currently being Manufactured

at ICF RCF MCF
LHB COACH
Preventive Maintenance Schedule (LHB)

Pit Examination As Per RPC-4

D1 Schedule 7 Days + 1
D2 Schedule 30 Days + 3 Days
D3 Schedule 6 Months + 15 Days
Shop Schedule - I 18 Months
Shop Schedule - II 36 Months
Shop Schedule – III 72 Months
LHB COACH
Scheduled Attention
Rake – KM/Time Based
Coach – D2 Schedule
Time Based in Rake
Coach –D3/SS-I (LHB)
Time Based in Sickline
Coach –SS-II & SS-III (LHB)
Time Based in Workshop
Out of Schedule Repair
In Rake – in Pitline
Coach – in Sickline/Workshop
LHB COACH
Population Railway wise (As on 31-03-2017)
Railway AC NAC Total
CR 155 107 262
ER 268 114 382
ECR 123 233 356
ECoR 91 68 159
NR 798 187 985
NCR 40 28 68
NER 82 57 139
NFR 106 32 138
NWR 36 32 68
LHB COACH
Population Railway wise (As on 31-03-2017)
Railway AC NAC Total
SR 116 109 225
SCR 110 21 131
SER 180 25 205
SECR 25 48 73
SWR 141 33 174
WR 338 100 438
WCR 0 0 0
OCV 190 535 725
Total 2799 1729 4528
LHB COACH
Workshops dealing with LHB Coach
Workshop AC NAC SS2/SS3 SS1
Matunga/CR 33 157 -- --
Liluah/ER 38 131 17.8 43.6
Mancheshwar/ECoR 20 90 6.4 8.5
AMV/NR 36 105 -- --
Jagadhari/NR 15 74 32.8 24.8
Gorakhpur/NER 25 145 -- 3.3
Dibrugarh/NFR 9 53 2 4.1
New 11 54 -- --
Bongaingaon/NFR
LHB COACH
Workshops dealing with LHB Coach
Workshop AC NAC SS2/SS3 SS1
AII/C - NWR 24 84 3.9 7.2
JU/NWR 17 70 -- --
PWP ( C )/ SR 37 150 4.8 15.6
Goldenrock/SR 17 75 -- --
Lallaguda/SCR 24 84 1.8 --
Titupathy/SCR 9 74 -- --
Kharagpur/SER 26 121 -- --
MYSS/SWR 8 66 6.7 2.5
Hubli/SWR 22 74 -- --
LHB COACH
Workshops dealing with LHB Coach
Workshop AC NAC SS2/SS3 SS1
Lower Parel/WR 29 100 11.2 28.3
Kanchrapara/ER -- 45 -- --
HRT/ECR -- 45 -- --
IZN/NER -- 40 -- --
PWP (L)/SR -- 45 -- --
MIB/SECR -- 5 -- --
BVP/WR -- 63 -- --
TOTAL 400 1950 87.3 146.1
LHB COACH MAINTENANCE
Schedules at Pitline – Primary/Secondary
Pit Examination
Features of Rakes coming from Pitline
100% Brake Power
Zero Missing Fitting Rake
Cleaned Washed Watered
Fire Extinguisher
Brake Van Equipment
LHB COACH MAINTENANCE
Activities during Pit Examination
Protection of rake
Cleaning and Washing of Rake
Watering of Rake
Fixing of Passenger Amenity Fittings
Air Brake Testing
Vacuum Cleaning of Carpets if any
LHB COACH MAINTENANCE
Activities during Pit Examination
Visual Check of
Bogie Frame and Bolster Assembly
Brake Equipment
Axle Bearing Instruments
Primary & Secondary Suspension
Primary/Secondary/Yaw dampers
Bearings
Wheel & Axle
Control Arm
PITLINE – PRIMARY/SECONDARY
Activities during Pit Examination (Contd…)
Visual Check of
Anti Roll bar Assembly
Traction Centre
Rotation Limiter
Rubber and Rubber/Metal Bonded Parts
Provision of
Fire Extinguisher Brake Van Equipment
Battery Charging if Self Generating Coach
LHB COACH MAINTENANCE
Schedules at Pitline – D2 Schedule
Activities during D2 Schedule
Washing of Bogie Frame
Brake Equipment
Gap between Pad and Disc
Wear of Pad/Disc
Lubrication of Brake Levers
Axle Bearing Instrument
Earthing Equipment
WSP Attention as per OEM
LHB COACH MAINTENANCE
Activities during D2 Schedule
Wheel & Axle
Measurement of Tread Diameter
Wheel Profile
Pins & Bushes
Lubrication of Pins & Bushes
PITLINE
Requirement of Infrastructure
Provision of Washing cum Maintenance Pitline
With or Without Catwalk
Broad and Obstacle Free Pathways
Under Pit Pathway below the Rake/Track
Pitline on Metallic (Steel) Pillars
Ramp at both the sides
Provision of Stairs to go from Ground Level
PITLINE
Requirement of Infrastructure
Provision of Washing cum Maintenance Pitline
Provision of Mobile Lifting Platform for
without Catwalk
Provision of Compressed Air Pipe Line
Provision of Overhead Light
Provision of Under Pit Light
Provision of Cables and Sockets
48V, 110V, 230V ,440V
PITLINE
Requirement of M&P
Adequate Air Brake Testing Facility
Air Compressor RTR
Automatic Coach Washing Plant
High Pressure Water Jet Cleaning Arrangement
Watering Facility
Water Storage Hydrant
Wheel Diagnostic System
PITLINE
Requirement of Tools
Tool Kit (Allen Keys, Pliers, Spanners Set etc.)
Torque Wrenches
Inspection Torches
Spiked Hammers
Ball Peen Hammers
Measuring Tape
Measuring Scale
Feeler Gauge
Pitline without catwalk with Twin Depth Pit
Pitline with One side catwalk with Twin Depth Pit
LAYOUT OF COACHING DEPOT
LHB COACH MAINTENANCE
Maintenance at Other End – No Secondary
Examination at Platform
Activities during Other End Examination
Rolling in Examination
Protection of rake
Dry Sweeping of Rake
Watering of Rake
Wet Cleaning of Lavatory
OTHER END MAINTENANCE AT PF
Maintenance at Other End – No Secondary
Examination at Platform
Infrastructure required
Storage Room for Safety and Passenger
Amenity Items
Road Transportation Facility for Man and
Material from Depot
Mobile Water Jet Machine or HP Jet Pipeline
around PF
Standard Watering Hydrant
OTHER END MAINTENANCE AT PF
Examination at Platform
Infrastructure required
Washable Apron on PF with Covered Drains
For Movement of Staffs
Walkie Talkie Communication
Flood Light at PF End for Rolling in
Examination
Inspection Light alongside for
Night Examination of Undergear
LHB COACH MAINTENANCE
Schedules at Sickline – D3 Schedule
Activities during D3 Schedule
Bogie Frame
Examine for Corrosion/Damage
At Critical Location
Carry Out Paint Touch up
Wheel Axle
Check Wheel Offset on Axle – Double Decker
DPT of Wheel Disc
Control Arm
Renew Protection Treatment on Rubber
LHB COACH MAINTENANCE
Activities during D3 Schedule
Axle Bearing Instrument
Replacement of Carbon Brush
Couplers
Check by Gauge – Gap Coupler Knuckle
Application of Dry Lubricants
Attention to Phonic Wheel
Gap
LHB COACH MAINTENANCE
Schedules at Sickline – SS-I Schedule
Activities during SS-I Schedule
Brake Equipment
Function Test of Air Brake Equipment
By SCTR
Examine BP/FP Hose
Function Test of Hand Brake
CBC
LHB COACH MAINTENANCE
Activities during SS-I Schedule
Lifting of Coach Body
Removal of Bogie Body Connection
Lifting
Bogie Run Out
Fitment of Overhauled Bogie
Body Bogie Connection
CBC Height Adjustment
LHB COACH MAINTENANCE
Activities during SS-I Schedule
Checking and repair of
Underframe & Running Gear
Water Supply System
Roof
Exterior Coach Body
Interior
Panel Doors
Lavatory
Doorway & Gangway
Vestibule
SICKLINE
Requirement of Infrastructure
Covered Shed
Length – 200 m Width – 19.5 m
Lines – 2
Shed for Wheel Lathe
SICKLINE
Requirement of Infrastructure
Provision of Service Rooms
Store
Vehicle Parking Space
Provision of Wheel Parking under Shed
Provisions of Electrical Fitting, Light, Fan etc
Electric Supply to all Fixed and Portable
Machines and Equipment
 SICKLINE
Requirement of M&P
For SS-I
EOT crane 20/10T
Synchronized Lifting Jacks
Press for Removal and Pressing of Bolster
Press for Primary Suspension
Coach Lifting Jacks
Hydraulic Material Carrying and
Lifting System (for CBC etc)
 SICKLINE
Requirement of M&P
Air Brake System
Air Compressor-350 cfm with Air Dryer
Test Bench for Brake Control Panel
WSP Test Facilities
Single Car Test Rig
Pipe Bending Machine
 SICKLINE
Requirement of M&P
Material Handling
Material Carrier
Fork Lifter
Hoist
Bogie Turn Table
 SICKLINE
Requirement of M&P
Welding
AC/DC TIG Welding Machine
Air Plasma Cutting Machine
Welding Plant (Portable) Single phase 230 V
Welding Plant (Stationary) 3 Ph. 440 V
 SICKLINE
Requirement of M&P
Other Machines
Pillar Drilling Machine
Pedestal Grinder
Winching Machine for Movement of Coach
Wheel Profile Lathe
 SICKLINE
Requirement of Tools
Tool Kit (Allen Keys, Pliers, Spanners Set etc.)
Square drive torque wrench 1”
for fastening of Nuts and bolts of Bogie
Hydraulic torque wrench
For Nuts and bolts of Bogie frame
Torque Wrench (ratchet) torque 38 Kg-m sq.
Torque Wrench (ratchet) torque 3-14 Kg-m sq.
Torque Wrench (ratchet) torque 7-35 Kg-m sq.
Gauge for checking Bearing Mounted End Play
 SICKLINE
Requirement of Tools
Vernier Callipers
Vernier Height Gauge
Digital Micrometers
Inside Micrometers
Impact Spanner
Pallet Trolley
Feeler Gauge
Trestle for stabling coach body
 SICKLINE
Requirement of Tools
Allen key set as per list
Stainless Steel Scale
Measuring Tapes
Heavy duty rechargeable torch
Axle Dia Measurement Gauge/Micrometer
Go/No Go Threads Plug Gauge for Axle Ends
Parallelism Checking Tool for Control Arm
Mounting/ Dismounting Tools for Anti Roll Bar
Bearing
 SICKLINE
Requirement of Tools
Mounting/ Dismounting Tools for Anti Roll Bar
Elastic Joint
Miner Pad Pressing Fixture
Inspection Torches
Spiked Hammers
Ball Peen Hammers
Gas Cutting Plants
Electrical Angle Grinders
Pneumatic Hand Grinders
LHB COACH MAINTENANCE
Schedules at Workshop – SS-I Schedule
Activities during SS-I Schedule at Workshop
During Overhauling of Bogie
Brake Equipment
Check of Brake Gear Pin and Bogie Pin
for Wear and Re-greasing
Examine Brake Caliper and Pad for
Wear and Damage
Examine Brake Disc for Cracks
Check Tightness of Brake Disc Bolts
LHB COACH MAINTENANCE
Schedules at Workshop – SS-I Schedule
Axle Box Instruments
Overhaul Grounding Equipment
Overhaul WSP as per OEM
Dampers
Checking and Testing
Primary/Secondary Suspension
Check of Springs Centering Discs
Rubber and Metal Bonded Parts
LHB COACH MAINTENANCE
Schedules at Workshop – SS-I Schedule
Bearing
Rotate Bearings to check abnormalities
Check of End Play
Wheel & Axle
Re-profiling and Wheel Balancing
Ultrasonic Testing
Control Arm
Check of Bore
Bogie Frame & Bolster
Cleaning and Painting
LHB COACH MAINTENANCE
Schedules at Workshop – SS-I Schedule
Anti Roll bar
Traction Center
Rotation Limiter
Rubber & Metal Bonded Parts
Bogie Pins
Springs
Cleaning Inspection for Cracks
Painting if required
LHB COACH MAINTENANCE
Schedules at Workshop – SS-II Schedule
Activities during SS-II Schedule
Brake Equipment
Complete Overhaul of Items
Replacement of Pins Bushes Hoses
Bogie Frame and Bolster
Check for Dimensional Tolerances
Full Painting
Bearing
Dismounting and Inspection/Reconditioning
LHB COACH MAINTENANCE
Activities during SS-II Schedule
Anti Roll Bar & Traction Center
Overhaul and Replacement of Rubber Parts
Replacement of
all Rubber and Metal Bonded Rubber Parts
Underframe and Running Gear
Inspect and Repair
Water Supply
Water Tank Testing
Pipeline Cleaning
LHB COACH MAINTENANCE
Activities during SS-II Schedule
Springs
Test for Free Height and under Load
Exterior
Interior – Passenger Area
Panel doors
Lavatory
Furnishing
Replacement of Rexine
LHB COACH MAINTENANCE
Schedules at Workshop –
SS-III Schedule
Activities during SS-III Schedule
Replacement of Dampers
Dismounting of CBC
Interior
Replacement of PVC Flooring
LHB COACH MAINTENANCE
PERT Chart of Shop Schedules
Critical Path
Pre-inspection & Stripping - 3 days
Lifting & Lowering - 5 days
Body Repair & Furnishing - 4 days
Fitment and Testing Electrical - 6 days
Exterior Painting - 6 days
Final Inspection - 1 day
Total 25 days
LHB COACH MAINTENANCE
PERT Chart of Shop Schedules
Non-Critical Activities
Pre-inspection Elect - 1 days
Toilet Tank Attention - 3 days
Other Body Repair - 4 days
Interior Painting - 2 days
Fitting Work - 2 days
Trimming - 4 days
Water Tank Attention - 4 days
Air Brake Testing - 1 day
WORKSHOP
Requirement of Infrastructure
Each Section
Shed Area –
Outturn X Cycle Time of Activity
WORKSHOP
Requirement of Infrastructure
Provision of Service Rooms
Store
Vehicle Parking Space
Provision of Wheel Parking under Shed
Provisions of Electrical Fitting, Light, Fan etc
Electric Supply to all Fixed and Portable
Machines and Equipment
WORKSHOP
Requirement of M&P
Painting
Oven for Forced Curing of Paint
Grit Blasting Booth
Painting Booth of One Coach Length
Airless Spray Painting Unit
Full Fledged ETP
Dedicated Compressor
Winches for Coach Movement
WORKSHOP
Requirement of M&P
Bogie Section
Press for Removal and pressing of Bolster
Press for Primary Suspension
Hydraulic Press for Removal/Insertion of
Rubber Joints
Bogie Load Testing Machine
Coil Spring Scragging and Load Deflection
Testing Machine for Primary Spring
Coil Spring Scragging and Load Deflection
Testing Machine for Secondary Spring
Damper Testing Machine
WORKSHOP
Requirement of M&P
Air Brake Section
Air Compressor with Air Dryer
Single Car Test Rig
Test Bench for DV
Test Bench for Brake Control Panel
WSP Test Facilities
Single Car Test Rig
Pipe Bending Machine SS
WORKSHOP
Requirement of M&P
Material Handling
Material Handling Trolleys and Ladles
Pick & Carry Mobile Crane
Material Carrier
Fork Lifter
Hoist
WORKSHOP
Requirement of M&P
Welding
Air Plasma Cutting Machine
AC/DC TIG Welding Machine
Synergic Pulse Tag Welding Plants
Portable Profile Cutting Machine
Welding Rectifier
WORKSHOP
Requirement of M&P
Body Section/Main Bay
Synchronized Lifting Jacks 15 T Set of 5
EOT Crane – 25/10 T
Hydraulic Material Carry & Lifting System for
CBC
Bogie Turn Table
WORKSHOP
Requirement of M&P
Wheel Section
Surface Wheel Lathe
Wheel Press
Wheel Boring Machine
Axle Turning Machine
Bearing Mounting and Dismounting Machine
Ultrasonic Testing Machine
Dynamic Balancing Machine for Wheel Sets
WORKSHOP
Requirement of M&P
Other Machines
Pillar Drilling Machine
Pedestal Grinder
Static Weighbridge for Coach Weighment
Fire Fighting Equipment
Milling Machine
Horizontal Tensile Testing Machine for CBC
Rail cum Road Vehicle for Shunting
 WORKSHOP
Requirement of Tools
Tool Kit (Allen Keys, Pliers, Spanners Set etc.)
Square drive torque wrench 1”
for fastening of Nuts and bolts of Bogie
Hydraulic torque wrench
For Nuts and bolts of Bogie frame
Torque Wrench (ratchet) torque 38 Kg-m sq.
Torque Wrench (ratchet) torque 3-14 Kg-m sq.
Torque Wrench (ratchet) torque 7-35 Kg-m sq.
Gauge for checking Bearing Mounted End Play
 WORKSHOP
Requirement of Tools
Vernier Callipers
Vernier Height Gauge
Digital Micrometers
Inside Micrometers
Impact Spanner
Pallet Trolley
Feeler Gauge
Trestle for stabling coach body
 WORKSHOP
Requirement of Tools
Allen key set as per list
Stainless Steel Scale
Measuring Tapes
Heavy duty rechargeable torch
Axle Dia Measurement Gauge/Micrometer
Go/No Go Threads Plug Gauge for Axle Ends
Parallelism Checking Tool for Control Arm
Mounting/ Dismounting Tools for Anti Roll Bar
Bearing
 WORKSHOP
Requirement of Tools
Mounting/ Dismounting Tools for Anti Roll Bar
Elastic Joint
Miner Pad Pressing Fixture
Inspection Torches
Spiked Hammers
Ball Peen Hammers
Gas Cutting Plants
Electrical Angle Grinders
Pneumatic Hand Grinders
REFERENCE
Maintenance Manual for
BG Coaches Of LHB Design

Report of CAMTECH on
Infrastructural Facility for
Maintenance of LHB Coaches