Introduction and the main parts of LHB Coaches

1. LHB COACHES
The Coach of The Future For IR

2. 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.

3. Exterior View of LHB Coach

4. Interior View of LHB Coach

5. AC Chair Car
With Centre Table

6. Holding

7. Premium Services Running With LHB Stock
Train No. From To No. of Rakes
Shatabdi Trains
12005/06 NDLS KLK 1
12001/02 NDLS BPL
6
12003/04 NDLS LKO
12011/12 NDLS KLK
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

8. 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

9. 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
heavy corrosion repair(s)
Austenitic/Ferritic Stainless steel
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
insulation
Average Superior (85- 110 dB)
Aesthetics and interiors Medium size windows
LP sheet panels
Large panoramic windows
FRP panel
Toilet system Open discharge toilets Controlled discharge toilets
Coupling Conventional screw coupling Center Buffer Coupler

10. 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
car
56 46 22
AC chair car 78 67 16
Sleeper Class 78 72 8
General 99 90 10
SLRD 30+4 20 + 4 42

11. 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

13. 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

14. Secondary Damper Yaw Damper

15. Primary Damper

16. Wheel Set Earthing Equipment

17. Axle mounted brake disc
Brake calipers
Brake Cylinder
Brake Pads

19. Brake Control Panel And Indicator Unit
Brake indicator
Brake control panel
DV
Release Rod
Reservoir
Test fittings
Isolating cocks

20. Brake Accelerator

21. Brake Indicator

22. 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.

23. WSP Electronic Unit

24. Speed Sensor Cable With Terminal Box
Cable sensor
Terminal Box
Phonic Wheel inside the cover

25. 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

26. Speed Sensor Probe
Phonic Wheel

27. 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

28. Schematic Diagram of Water Supply System

29. 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

30. CONTROL DISCHARGE TOILET

31. Control Panel of CDTS

32. 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.

33. Center Buffer Coupler
Features & Safeguards in Operations
Double headed restrictor to prevent vertical uncoupling
of CBC knuckles in between loco and front coach

34. Clear Tell-tale recess which
ensures that the lock is fully
dropped
TELL TALE LOCK
Locking arrangement for
manual uncoupling
handle

35. Maintenance Issues – Bogie & Under Gear
• Wheel shelling
• Breakage of brake disc
• Roller bearing failures
• Jerk during running

36. 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).

37. 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
POH/ IOH
No. of coaches tyre
turned
Average time for tyre
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

38. Crack/ Breakage Of LHB Wheel Disc

39. Breakage of Brake Disc
No. of coaches
surveyed
FTIL KNORR
341 173 168
Population of brake disc
BROKEN CLAMPING BRACKET
OF BRAKE DISC

40. Enroute Detachment Due to Failure of
UIC-130 CTRB in LHB Coaches
Year
No. of
instances
Average
holding
Failure in type
of coaches
Make of
assembly
2009-10 1 214 LWSCZAC TIMKEN
2010-11 2 299
1-LWSCZAC
1-LWACCN
Both TIMKEN
2011-12 2 357 2-LWSCZAC Both TIMKEN
2012-13
( Up to
July. 12)
1 416 1-LWACCN SKF

41. 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.

42. Areas Needing Regular Maintenance Attention
DOORS
• Vestibule
• Passenger Cabin Door
• Lavatory Door
• Pantry Door
• Luggage door in power car

43. Transition Doors

44. Working Out/Breakage of Holding Bracket of
Wire Rope of Vestibule Doors

45. Elastic Wire Grazing with Bracket Resulting
Breakage

46. Jamming / Rattling of Pantry Doors
Bolts getting loose
frequently

47. 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
Areas Needing Regular Maintenance Attention

48. Working Out of Reclining Gear Knob

49. Drooping of Arm Rest

50. Old & Torn Seat Upholstery

51. Faded Seat Upholstery
New Old

52. Failure of Reclining Mechanism / Breakage of
Foot Rest

53. Working Out of Elastic Band of Magazine Bag

54. Breakage of Retainers of Roller Blind

55. Working Out of Window Glass Outer Profile

56. Problem in Maintenance
AL Louvers in Compartment Sliding Door, Pantry Sliding Door
and Lavatory Door are Prone to Theft
Window Shutters are being provided in
Coaches after the theft.
AL. Louvers are prone to theft

57. S.N. Description Number of Items
1 Total No. of LHB Stock Items 133
2 RCF based Items 35
3
Year vise Vetted Demand of RCF Based 'A' Category (Imported) & 'B' category (Vital
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)
4 Free Supply Items along with new LHB Rakes
Supply For 4 (3 Raj.+ 1 Stb.) rakes
still pending with RCF
5
Number of LHB ITEMS procured under Non
Stock During year 2010-11
56 No. (Amount Rs.80,67,197).
Major constrains in procurement is limited availability of Vendors for sub assemblies
required by open line.
Overview Of LHB Material for DLI Division

58. Critical Stock Items Affecting LHB Coach
Maintenance
S.
No.
PL No. Feeding
store depot
Material Imprest
for six
month
Supply
( Jan,12
to Jun,12)
1 33501002 JUDW Primary Vertical
Damper
138 0
2 30990154 JUDW Brake Pad 35mm 2760 1687
3 33500459 JUDW Lateral Damper 28 0
4 30993076 JUDW Sealed Window Glass
(1419x819x18.4mm)
360 212
5 30993076 JUDW Sealed Window Glass
(1417x817x18mm)
180 90

59. 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

60. Thanks 60

61. 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 /
inspection
0.07 0.06 0.03 0.08
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 %