RESTORATION OF LHB COACH - North Central Railway · PDF fileRecently LHB coach with fiat bogie...

RESTORATION OF LHB COACH

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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

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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-

MODIFIED LIFTING PAD 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.

LIFTING PAD

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.

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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.

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• LIFTING LOCATION-

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.

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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.

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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.

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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.

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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.

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.

LIFTING LOCATION

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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.

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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.

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5. Place lifting jack under articulated control arm from both side. Of bogie under defective wheel.














LIFTING LOCATION

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PROCEDURE FOR WHEEL CHANGING WITH RUNNING OUT OF BOGIE

PROCEDURE

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.

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

STEP - I

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Open four bolts of

bolster.

4. Disconnects following fittings.

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Disconnect both side foot board bracket.

Disconnect both side CDTS Intermediate tank & drainage pipes

CDTS INTERMEDIATE TANK

DRAINAGE PIPE

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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.

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SAFETY WIRE ROPE


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.

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

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.

STEP - II

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3. Place lifting jack under articulated control arm from both side of bogie under defective wheel.














LIFTING LOCATION

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LIFTING & TRAVERSING EQUIPMENT- MFD/ LUCAS & other necessary equipments

RESTORATION OF LHB COACH IN CASE OF DERAILMENT

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.

A. WITH SINGLE POINT LIFTING.

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LIFTING WITH TWO POINTS.

Under modified lifting pads

LIFTING LOCATION-


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 .

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.

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RESTORATION BY 140 T CRANE IN CASE OF DERAILMENT

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 . 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

Location – A. Lifting Pad of the coach both sides

Do’s & Don’ts

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http://www.ncr.indianrailways.gov.in/cris/uploads/files/1348829504020-LHB.zip

http://www.ncr.indianrailways.gov.in/cris/uploads/files/1350584737663-DO's and DON'Ts - NEW DESIGN 140T COWANS SHELDON CRANES_MAR_2012 - Copy.pdf

http://www.ncr.indianrailways.gov.in/cris/uploads/files/1350584737663-DO's and DON'Ts - NEW DESIGN 140T COWANS SHELDON CRANES_MAR_2012 - Copy.pdf

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.

Lower the Trolley on track with alignment. LIFTING BEAM

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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.

LOCATION – B. UNDER BOX SECTION OF SOLE BAR NEAR LIFTING PAD USING LIFTING BEAM/ WIRE ROPE

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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.

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RESTORATION OF LHB COACH - North Central Railway · PDF fileRecently LHB coach with fiat bogie...

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