MINTENANCES SCHDULE FOR LHB COACH

SL N0
Particulars
Frequency of Examination
Maintenance to be done at
1.0
1.1
1.2
1.3
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11

Coach:
Coach should be washed both from outside & inside.
Disinfect any spray insecticide at corner and crevices of coaches
after washing all the coaches
(AC Coach & Pantry Car -15 Days)
Intensive cleaning of coach panels, chequered plates and PVC
floor.
Coach Shell
Visually check body panels/end walls for damages.
Visually inspect destination boards brackets.
Visually inspect window glass and rubber sealing for
damage/missing.
Examine body side doors for working /damages.
Inspect door handles for damages/missing.
Inspect vestibule and its Rubber fittings for damages/missing, repair
if necessary.
Visually check vestibule fall plates, mounting brackets, pins and
operation of sliding doors and its lock lever for ease of operation,
damages/deficiency.
Thoroughly clean and remove dust, dirt accumulated at pillars with
coir brush.
Examine for corrosion of sole bar and other under frame members
with torch light or inspection hand lamp.
Touch up damaged paint both inside & outside.
Check roof ventilator in Non AC for damages/defects.

Maintenance Schedules
D1
D2
D3
Trip/Weekly
Monthly
H/YLY
Every
30 3 days
Six month 15
Trip/Weekly
days
On rake at
On rake at
On rake at
nominated
nominated
nominated
Primary Depot
Primary Depot
Primary Depot
YES
---

YES
YES

YES
YES

---

YES

YES

YES
YES
YES

YES
YES
YES

YES
YES
YES

YES
YES
YES

YES
YES
YES

YES
YES
YES

YES

YES

YES

---

---

YES

---

---

YES

-----

-----

YES
YES

SL N0

Maintenance Schedules
Particulars
Frequency of Examination
Maintenance to be done at

3.0
3.1
3.2
3.3

3.4
3.5
3.6
4.0
4.1
4.2
4.3
4.4
4.5

BOGIE & AIR BRAKE

Bogie Frame and Bolster Assembly
Perform a visual check on longitudinal beams, cross beams &
bolster for cracks, damages and for corrosion
Perform a visual check on brake supports, damper supports,
traction centre supports and anti-roll bar supports for cracks,
damages and for corrosion.
Check bogie bolster sub assembly and brackets for cracks,
damages and corrosion.
Wash the bogie frame thoroughly with water jet, making sure that
water is not directed towards pneumatic/elect. Connections and axle
bearings.
Examine the bogie frame for corrosion/damages, especially at
critical locations like lower web. Yaw damper bracket etc.
Carry out paint touch up as per RCF specifications MDTS-166.
Brake Equipments
Check functionality of air brake equipment and (Hand brake
equipment in LWLRRM)
Perform a visual check on Brake cylinders/brake levers and Hand
brake equipment in LWLRRM or damage, cracks and corrosion.
Perform a functional test on pneumatic brake system. Make sure
that no air leaks are present.
Perform a visual check on all air hoses.
Visually inspect steel piping for cracks/damages/ballast hitting.
Repair/replace if necessary.

D1
Trip/Weekly
Every Trip/Weekly

D2
Monthly
30 3 days

D3
H/YLY
Six month 15
days
On rake at
nominated
Primary Depot

On rake at
nominated Primary
Depot

On rake at
nominated
Primary
Depot

YES

YES

YES

YES

YES

YES

YES

YES

YES

---

YES

YES

---

---

YES

---

---

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES
YES

YES
YES

YES
YES

SL N0

Maintenance Schedules
Particulars

D1
Trip/Weekly
Every Trip/Weekly

D2
Monthly
30 3 days

Maintenance to be done at

On rake at
nominated Primary
Depot

On rake at
nominated
Primary
Depot

Perform a Visual check on brake discs for cracks on face, fins, hub
etc.
Verify that the clearance between each brake pad and disc surface
is 1-15mm.
Check wear of brake pads/brake discs.
Lubricate the brake levers, fixings and all moving parts.
Wheel Slide Protection
Perform a visual check on all grounding cables & WSP equipment
cables for breaks/damages.
Visually check equipment like front axle cover & upper & lower
control arms damages, cracks and corrosion marks.
Check functioning of WSP equipments (in WSP panel & its codes).
Inspect the Earthing equipment or wear of slip assembly /carbon
bars.
Monthly/Quarterly inspection of WSP equipment to be carried out as
per schedule.
Check speed sensor gap.
Primary & Secondary Suspension
Visually check primary springs or cracks & damages.
Visually check safety wire ropes between bogie frame and bogie
bolster for damages and corrosion.
Primary/Secondary/Yaw dampers
Perform a visual check on dampers, cracks and oil leaks.
Perform a visual check on all fixings for loosening and/or missing
components.

---

YES

YES

---

YES

YES

YES
---

YES
YES

YES
YES

YES

YES

YES

YES

YES

YES

YES
---

YES
YES

YES
YES

---

YES

YES

---

---

YES

YES
YES

YES
YES

YES
YES

YES
YES

YES
YES

YES
YES

Frequency of Examination

4.6
4.7
4.8
4.9
5.0
5.1
5.2
5.3
5.4
5.5
5.6
6.0
6.1
6.2
7.0
7.1
7.2

D3
H/YLY
Six month 15
days
On rake at
nominated
Primary Depot

SL N0

Maintenance Schedules
Particulars
Frequency of Examination
Maintenance to be done at

7.3
8.0
8.1
9.0
9.1
9.2
9.3
9.4
10.0
10.1
10.2
10.3
11.0
11.1
11.2
11.3
11.4

Perform a visual check on rubber elements for cracks and ageing.

Bearings(CTRB/TBU)
Carry out bearing feeling for detection of hot bearing.(During rolling
in Examination)
Wheel & Axle
Perform a visual check on wheels for cracks.
Check by while profile gauge.
Check axle for cracks and signs of corrosion.
Check tread diameter and wear of wheel profile. If necessary,
perform re-profiling.
Check wheels offset on axle (1600+1 mm)
Control am
Perform a visual check on all fixings for loosening and/ or missing
components.
Visually check control arm parts or damages, cracks or corrosion
marks.
Inspect the rubber joints for damages and ageing.
Anti Roll bar Assembly
Perform a visual check on Anti roll bar, links and Brackets or cracks,
damages and corrosion.
Perform a visual check on rubber joints for cracks, damage and
ageing.
Visually inspect for grease oozing out of anti roll bar bearings, which
may result in bearing failure.
Perform a visual check on all fixing for loosening/missing fittings.

D1
Trip/Weekly
Every Trip/Weekly

D2
Monthly
30 3 days

On rake at
nominated Primary
Depot
YES

On rake at
nominated
Primary Depot
YES

D3
H/YLY
Six month 15
days
On rake at
nominated
Primary Depot
YES

YES

YES

YES

YES
--YES
---

YES
YES
YES
YES

YES
YES
YES
YES

---

---

YES

YES

YES

YES

YES

YES

YES

---

---

YES

YES

YES

YES

---

---

YES

YES

YES

YES

YES

YES

YES

SL N0

Maintenance Schedules
Particulars
Frequency of Examination
Maintenance to be done at

12.0
12.1
12.2
12.3
12.4
12.5
13.0
13.1
14.0
14.1
15.0
15.1
16.0
16.1
17.0
17.1
17.2
17.3
17.4
17.5
17.6

Traction Centre
Perform a visual check on the traction centre lever and on the rods
for cracks, damages and corrosion.
The assembly should be free to move, and not blocked by any
foreign objects.
Perform a visual check on all fixings for loosening.
Perform a visual check on rubber joints for cracks/damages.
Greasing of anti roll-bar.
Rotation Limiter
Perform a visual check of rotation limiter, components.
Rubber and Rubber/Metal Bonded parts
Perform a visual check on Rubber and Rubber/Metal Bonded parts
for cracks, damages and ageing.
Pins and bushes
Lubricate all pins and bushes.
Body works:General inspection of Vehicle body work (print work, glazing etc).
Draw & Buffing Gears:(Ref: CMI No: RDSO/2006/CG/CMI/01 Rev No: Nil)
Visual Inspection of Tight lock coupler head for damage.
Visual Inspection of Knuckle for damage.
Checking of coupler operating mechanism or damage, loose, bolts
etc.
Greasing of slide rod of coupler operating mechanism
Checking tell tale recess for ensuring proper coupling.
Inspection of coupler carriers/supporting device & its spring for
cracks & breakage.

D1
Trip/Weekly
Every Trip/Weekly

D2
Monthly
30 3 days

On rake at
nominated Primary
Depot

On rake at
nominated
Primary Depot

D3
H/YLY
Six month 15
days
On rake at
nominated
Primary Depot

YES

YES

YES

YES

YES

YES

YES
YES
---

YES
YES
YES

YES
YES
YES

YES

YES

YES

---

YES

YES

---

YES

YES

---

YES

YES

YES
--YES

YES
YES

YES
YES
YES

--YES
YES

YES
YES
YES

YES
YES
YES

Maintenance Schedules
Particulars
SL N0

Frequency of Examination
Maintenance to be done at

17.7
18.0
18.1
18.2
19.0

20.0
20.1
20.2
20.3
20.4
20.5
20.6
20.7
20.8
20.9
20.10
20.11

Inspection of loose/broken/missing nuts & bolts (M-16) of coupler

pin support plate & draft gear support plate.
Corridor Connections:Check corridor connections for external damage & foreign bodies.
Check vestibule connections for external damage & foreign bodies.
Air Pressure Equipment
Dry out air-filter
Clean air-filter
Clean airline-filter
Drain air Reservoirs.
Interior fitting passenger accommodation:General visual check for damage
Check for regulation provision in dust bins & operational fire
extinguishers.
Check hand rails, sliding doors, shutters, toilet doors, vestibule
doors and their functioning.
Check bathroom fittings visually
Clean top & bottom guide rails of luggage doors of power cars &
greasing of guide bearing.
Inspect seats & check for completeness.
Inspect luggage racks & check for completeness.
Check all hand rails manually for correct fitment & fixing.
Inspect PVC floors and chequered plates for any damage.
Checks stick-on notices and directions for condition &
completeness.
Check single Leaf sliding door general function & ease of
movement.

D1
Trip/Weekly
Every Trip/Weekly

D2
Monthly
30 3 days

On rake at
nominated Primary
Depot
YES

On rake at
nominated
Primary Depot
YES

D3
H/YLY
Six month 15
days
On rake at
nominated
Primary Depot
YES

YES
YES

YES
YES

YES
YES

------YES

YES
YES
YES
YES

YES
YES
YES
YES

YES
YES

YES
YES

YES
YES

YES

YES

YES

YES
YES

YES
YES

YES
YES

-----------

YES
YES
YES
YES
YES

YES
YES
YES
YES
YES

YES

YES

YES

Maintenance Schedules
Particulars
SL N0

Frequency of Examination
Maintenance to be done at

20.12
21.0
21.1
21.2
21.3
22.0
21.1
22.2
22.3
23.0
23.1
24.0
24.1

Check double leaf connection door general function & ease of

movement.
Passenger Doors
Check General functions of passenger doors or ease of movement
Lubricate door seals
Clean & lubricate door mechanisms.
Water supply system:Check tanks pipes for leakage
Check tank mountings brackets and fittings
Rinsing the pipes & water tanks
Pantry
Check for damage & deficiencies in the pantry construction fittings,
water supply & drainage of the pantry area.
Sanitary Equipments
Check functioning of toilet system

D1
Trip/Weekly
Every Trip/Weekly

D2
Monthly
30 3 days

D3
H/YLY
Six month 15
days
On rake at
nominated
Primary Depot
YES

On rake at
nominated Primary
Depot
YES

On rake at
nominated
Primary Depot
YES

YES
-----

YES
YES

YES
YES
YES

YES
YES
---

YES
YES
YES

YES
YES
YES

YES

YES

YES

YES

YES

YES

Maintenance Manual of LHB Coaches

Air Brake System

AIR BRAKE TESTING (Single Car)

ANNEXURE - B

Coach no.
POH Date
DV No.
WSP make

Type
IOH
DV Make

Date of Testing
Return Date
Bk. Equipment
BP
FP

Pressure

Specified

5 0.1 kg/cm 2
6 0.1 kg/cm 2

Actual

Pre-Inspection : Please ensure that all the pipe fittings, brake equipments are properly fitted and in place before starting of testing.
ITEM
1.0
1.1

2.1
2.2

TEST
Reservoir Charging
Charging time of AR
(0 4.8 kg/cm 2)
Charging time of CR (6.0 litre)
( 0 4.8 kg/cm 2)
BP Pressure
CR Pressure
FP Pressure
Sealing test
(Allow the system to settle for 2 min. after
charging BP & FP. Observe the rate of leakage.
BP (Less than 0.1 kg/cm 2 in 5 minutes)
FP (Less than 0.1 kg/cm 2 in 5 minutes)

3.0
3.1
3.2
3.3
3.4
3.5
3.6

Full Brake Application

Reduce BP from 5.0 to 3.4 kg/cm 2
Brake Accelerator should not respond
Maximum BC pressure
Leakage in BC Pressure within 5 minutes
All brake cylinder are applied
Both side Brake indicators should show Red

3 5 Sec.
Should not respond
3.0 0.1 kg/cm 2
<0.1 kg/cm 2
Applied
Red

4.0
4.1
4.2
4.3

Release full Brake Application

Charge BP ( up to 5.0 kg/cm 2)
All brake cylinders are released
Both side Brake indicators should show Green

5.00.1 kg/cm 2
Released
Green

1.2
1.3
1.4
1.5
2.0

SPECIFIED VALUE
175 30 sec.(SAB)
60 to 120 sec.(KB)
16520 sec.(SAB)
160 to 210 sec.(KB)
5.00.10 kg/cm 2
5.00.10 kg/cm 2
6.00.10 kg/cm 2

BP<0.2 kg/cm 2/minute

FP <0.2 kg/cm 2/minute

ACTUAL VALUE

REMARKS

5.0

6.0
6.1
6.2
6.3
6.4
6.5
6.6
7.0
7.1
7.2
7.3
8.0

9.0
9.1
9.2
9.3

10.0
10.1
10.2
10.3
10.4
10.5
10.6

Over Charge Protection

Check the overcharging of CR it should not be
overcharged more than 0.1 kg/cm 2 in 10
second.
Emergency Application
Reduce BP to 0 kg/cm 2
Brake accelerator should respond
Charging time of brake cylinder (0 3.6 kg/cm 2 )
Max. brake cylinder pressure
All Brake Cylinders applied
Both side Brake indicator window should show
red
Release emergency Brake application
BC release time (Maximum to 0.4 kg/cm 2)
All Brake Cylinder released
Both side Brake indicator window should show
Green
Graduated brake application and Release
Graduated brake application and Release
(Minimum 7 steps)
Test for Pressure switch for Anti skid device
Charge the Feed pipe/Brake pipe* pressure
Anti skid device get power supply at 1.80.2
kg/cm 2
Anti skid device get power supply off at 1.30.2
kg/cm 2
* For SAB - FP & For KB - BP.
Isolation Test
Close the isolating cocks for Bogie 1 & 2
Reduce BP pressure to full brake
application ( Brake should not apply)
Both side Brake indicators shows Green
Open both isolating cock (Brake should
apply corresponding to opening of
isolating cock for bogies)
Both side Brake indicators shows Red

Less than
0.1 kg/cm 2 in
0.2 10 sec.
0 kg/cm 2
blast of air
3 5 Sec.
3.0 0.1 kg/cm 2
Applied
Red

15 -20 Sec. Released

Green
Brake should apply and release
corresponding to decrease and
increase of BP Pressure
Ok
Ok
Ok

Brake should
not applied
Green Brake apply
Red
Brake will Release

10.7

Again close the Isolating cock of bogie 1&2 one

by one. Both side Brake indicators of bogie 1&2
shows Green one by one.

11.0
11.1

Sensitivity Test
Reduce the BP pressure at the rate of
0.6kg/cm2 in 6 second.
Insensitivity Test
Exhaust BP pressure at the rate of 0.3 kg/cm 2
Per minute
Passenger Emergency Pull Box testing
Pull the emergency pull box handle & check

12.0
12.1
13.0
13.1
13.2
13.3
13.4
13.5
13.6
13.7

14.0
14.1
14.2
14.3
14.4
14.5
14.6
14.7
15.0
15.1
15.2
15.3
15.4

Brake accelerator does respond.

BP Pressure exhaust from emergency
Brake valve
Indicator Lamp on outside coach glowing
Both side Brake indicators shows Red
After resetting, exhaust from emergency Brake
valve is stopped
Both side Brake indicators shows Green
Hand Brake test (Power car only)
Apply hand brake by means of wheel
Both side Hand Brake indicators shows Red
Brake Cylinders provided with hand brake lever
are applied
Movement of flex ball cable is proper
Release hand brake by means of wheel
Brake should release
Both side Hand Brake indicators shows Green
Emergency brake by guard van valve
(Power car only )
Drop BP Pressure by means of guard valve
(Brake Should apply)
Brake accelerator should respond
Both side Brake indicators shows Red & Hand
Brake indicators shows Green
Reset guard van valve ( Brake should release)

Green

Brake should applied

within 6 second
Brake should not
applied
BP pressure should
remain 2.00.2 kg/cm 2
should respond
Yes
Yes
Red
Should stop
Green

OK
Red
Applied
Yes
Ok
Releases
Green

Brake Apply
Blast of air
OK
Releases

16.0

17.0
17.1

Manual release test

Apply full brake application and pull manual
release wire of DV, it should be released in one
brief pull of Manual release valve.

17.5

WSP test
Check all Speed sensor air gap between sensor
and Phonic wheel by means of filler gauge.
Charge the BP/FP Pressure at full specified
value.
Check the WSP Micro Processor activated
Check the WSP Micro Processor
showing code 99.
Check the Dump Valve venting by test mode

18.0

Clearance between brake disc & brake pad

17.2
17.3
17.4

CR Drops to zero,
Brake releases

0.9 to 1.4 mm
1.80.2 kg/cm 2
Activated
OK
Venting one by one in
proper sequence
1.5 mm