qrGT dri6IT - td q{tE'q t.

ioyermnent nl India-Minisrry of Railt*ays

$-l{qfi olf*rffi.*i qrffi {16" Research Designs & Standards Organisation
(n?Is -2260lI Lucknow - 226 Ol I
EPBX (0522) 24512O0 DID (0522) 245Or15
Fax (0532)24585OO orD (0522) 2465310

No. hrlCA/VNGenl Date: 01.11.2017

Principal Chief Mechanical Engineel

1. Central Railway, CSTM, Mumbai - 400 001
2. Eastern Railway, Fairly Place, Kolkata- 700 001
3. Northern Railway, Baroda House, New Delhi-110 001
4. Southern Railway, Park Town, Chennai- 600 003
5. South Central Railway, Secunderabad-S0O 071
6. South Eastern Railway, Garden Reach, Kolkata-700 043
7. North Eastern Raikay, Gorakhpur-273 001
8. North East Frontier Railway, Maligaon, Guwahati- 7U Af
9. Western Railway, Churchgate, Mumbai-400020
10. East Central Railway, Hazipur-844 101
11. East Coast Railway, Railway Complex, Bhubaneshwar-751023
12. North Central Railway, Allahabad-211 001
13. North Western Railway, Jaipur-302 006
14. South Western Railway, Hubli- 580 023
15. West Central Railway, Jabalpur- 482 001
16. South East Central Railway, Bilaspur- 495 004
17. lntegral Coach Factory, Chennai - 600 038
18. Rail Coach factory, Kapurthala- 144 602
19. B.E.M.L, Bangaloie Complex, New Thippasandra, P.B. No. 5107, Bangalore- 75.
20. Konkan Railway Corporaiion Lirit"O, iorporate Office, Belapur Bhawan, NaviMumbai-400614
21. Modern Coach factory, Lalganj, Raebareli* 229 206

Sub: CracklBreakage of solid forged wheels for FIAT lR bolies (LHB)-

Ref: (i) This office letter of even No. dated 03.{1 -z0fi-
1iitr fnis offlce letter No. MCMHTSHL dated
23.09-2009'

Presently, Solid forged wheels for LHB coaches are being procured conforming to
RCF drawing No.LW02103 (rough turned wheel) and RDSO specification No. IRS R-
1g/93 Part ll (Rev.4) with corri[endum No.1 of August 2015. There have been 14
cases of wheel breakage in LHB coaches of lndian Railways since 2005. All LHB
wheels have been failed due to fatigue at the same place i.e. rim-web transition area
at the location where web thickness is 14*3 mm. Wheel shelling/skidding marks were
also found on allthe failed wheels.

The issue of wheel shelling was discussed in 4th WMSG and it was decided that to
increase the wheel life, the turning of LHB wheels may be done as per following
limits: These shelling limits have already been advised to Railways vide this office
letter at reference (ii) aboye and the sarne are as under:

i) Depth of shelling marks has reached to 1.Smm.

ii) Length of shelling marks has reached to 4CImm.
iii) Oepifr of hollow iyre reached to 3mm. This Iimit of 3rnm is kept to study the
effect of wheel shelling and service life of wheels. The rejectable limit of
 hollow tyre will continue as more than Smm as specified in IRCA Part lV.
During investigation, it has been noticed on many wheels that the formation
of hollow tyre precedes the wheel shelling.

The turning of LHB wheels as per the above guidelines will increase the frequency of
wheel turning but loss of diameter in turning will be less. So overall wheel life will
increase. lt is seen during the study that the average diameter reduction during the
tyre turning at present is 11 mm whereas per above guidelines, diameter reduction
was expected to be 6-7mm only.

ln addition, it is also advised to carry out Dye penetration test (DPT) of all LHB
wheels running over lndian Railways at Rim-web transition area during D3
schedule to detect cracks, as all 14 nos. of LHB wheels failedlcracked due tg
fatigue at rim-web transition area at the location where web thickness is 14*3
mm.

The above instructions gre reiterated considering the recent three cases of
LHB wheel crack t"pot1^d.

Railways are advised to ensure the compliance of above instructions.

Encl.. As above
. L l/ ot.ll-17
(lndrajit Sihgh)
Executive Director Stds. Carriage

Copy to:

EDME/Coaching, Railway Board,

Rail Bhawan, New Delhi-l10 001: for kind information. -
 tor ~ Govemment of India-Ministry of Railways
~qr;{ ~
~
*
lfffif trom' -
lfAC1;
-226011
~ Research Designs & Standards Organisation
Luck.now - 226 011
EPBX (0522) 2451200 DID (0522) 2450115
Fax (0522)2458500 DID (0522) 2465310

~: 03-11-2011

1. ~~I ~I~- 400 020

2. ~ 1fCZf ~I 61~1~'<-:- 844 101
3. ~ ~I 61~~161\3*1 1 "i~~CI'C'1"i- 110 001
4. ~ ~I ~ll'!e1"icJit11 Cf>l<il¢1(11- 700 001
5. ~ ~ ~I ~ ~ ¢1~~--1\ ~<ii~Cbi~Cffil :q~~~~\!~\!ll :!q~~q( ~-751016.

~: Crack/Breakage of LHB - FIAT wheel disc.

~: (i) This office letter of even No. dated 29-4-2011.
(ii) This office letter of even No. dated 12-10-2009.
(iii) This office letter of even No. dated 23-9-2009.

There are two types of problems on LHB coach wheels facing by Indian Railways.

1. Wheel shelling.
2. Cracking/Breakage at Rim-web transition area.

Railways are facing proble_ms of wheel shelling on LHB coaches since introduction of
these coaches. There have been six cases of cracking/breakage of LHB coach wheels occurred on
Indian Railways. All failures were due to fatigue at Rim-web transition area of wheel. Wheel
shelling/skidding marks were found on all the failed wheels. To overcome the problem of wheel
shelling, RDSO has already issued the instructions to Railways vide references (i), (ii) and (iii)
above.

The issue of wheel shelling was discussed in 4th WMSG and it was decided that to
increase the wheel life, the turning of LHB wheels may be done as per following limits:

i) Depth of shelling marks has reached to 1.5mm.

ii) Length of shelling marks has r~ached to 40mm.
iii) Depth of hollow tyre reached to 3mm. This limit of 3mm is kept to study the effect of
wheel shelling and service life of wheels. The rejectable limit of hollow tyre will
continue as more than 5mm as specified in IRCA Part IV. During investigation it has
been noticed on many wheels that the formation of hollow tyre precedes the wheel
shelling.
 The turning of LHB wheels as per the above guidelines issued vide this office letter at
reference (iii), will increase the frequency of wheel turning but loss of diameter in turning will be
less. So overall wheel life will increase. It is seen during the study that the average diameter
reduction during the tyre turning at present is 11 mm whereas per above guidelines, diameter
reduction was expected to be 6-7mm only.

In view of the above, it is important that checking of LHB wheels is intensified. To

enable Railways to detect cracks and prevent failure of LHB wheels due to shelling, it is
reiterated that Railways should follow the instructions circulated vide references (ii), (iii) & (iv)
above for maintenance of LHB wheels in workshops/Coaching depots/Sick lines.

In view of the above, it requested to please confirm whether the above instructions are
being followed by Railways. Copies of the instructions issued by RDSO are enclosed for ready
reference. The status of implementation of the instructions as referred above may be advice to
this office.

In addition, all LHB wheels running over Indian Railways should be subjected to
Dye penetration test (DPT) at Rim-web transition area to detect cracks, during D3
schedule.
 \ .c::J-A •
. ~\~
~rrele : 0522-2450679 /), "'ffil " " " " - " "
~~olR'lR'O~
~
I
: 0522-2451200 (PBX)
: 0522-2450115 (DID) """""' - 226 0 II AN IS09001
~/F~X : 91-0522-2458500 Government of India -Ministry of Raihvays CERTIFIED
-=!o-' :«.' Research Designs & Standards Organisation ORGANISATION
Lucknow - 226 0 ll

~: 23-9-2009

2 5S£P
I. 1:Jfur:! ~. ~. ~ - 400 020
2. ¥ 'lU! ~- t5iu1"i9;~ - 844 101
3. ~ ~- ~ N\NT, ~ ~- 110 001-
4. ¥ t:>fcr. cf<Ne1~ ~. il>lC'i¢1\11 - 700 001
.'
·. ,,
. .'(. .'
.. ~
-

•
0
fcllm: Wheel shelling on LHB coaches.
Railways are facing the problem of wheel shelling on LHB coaches. RDSO has already
taken measures to address the problem of wheel shelling. But it is observed that wheel shelling
still continues on LHB coaches though kilometer earning has been improved. The issue was
discussed in 4'h WMSG and it was decided that to increase the wheel life, the turning of LHB
wheels may be done as per following limits:

i) Depth of shelling marks has reached to.) Smm.

ii) Length of shelling marks has reached t6.40mm.
. / - '

iii) Depth of hollow tyre reached to ,3mm,.;Jhis limit of 3mm is kept to study the effect of
wheel shelling and service life; of. wh:~els. The rejectable limit of hollow tyre will
continue as more than Smm as specified in JRCA Part IV. During investigation it has
been noticed on many wheels that the form~tion of hollow tyre precedes the wheel
.·
shell mg. "·
- _... _ / .· '

. The turning of LHB wheels as per the above guidelines will increase the frequency of
wheel turning but loss of diameter in turning will be less. So overall wheel life will increase. It is
seen during the study that the average diameter reduction during the tyre turning at present is
II mm where as per new guidelines, diameter reduction is expected to be 6-7mm only.

Railways are requested to monitor the kilometer earning and diameter reduction during
turning as per the above yard sticks to assess the enhanced wheel life. Railways are requested to
immediately implement the above instructions.

-WM
(~ IW)
~ lffiT f.'t ~~ 14> ;ffiffi ~

~~
 'lfTrt 1fT'~~F 'r'" 1fJIT"'fq Gov crnrncnt 01 Ind: ••·f\II1l"tn. 01 Rarlw a»
~ '1QT-f J'll''f'f''''l JrrT ~'l: ~-1 R" .•carch De-igns & Standards Orgaru ...atron
1 uc know - 2200 II
('PBX (0522) 2451200 010(0522)2450115
Fax (0522)2458500 010(0522)2465310

MC/CTRB/Genl. Date: 06.07.2015

The General Manager (Mech.),

1. Central Railway, Chhatrapati Shivaji Terminus, Mumbai - 400001

2. Eastern Railway, Fairlie Place, Kolkata - 700 001
3. Northern Railway, Baroda House, New Delhi - 110 001
4. Southern Railway, Park Town, Chennai - 600003
5. South Central Railway, Rail Nilayam, Secunderabad - 500 071
6. South Eastern Railway, Garden Reach, Kolkata - 700 043
7. North Eastern Railway, Gorakhpur - 273 001
8. Northeast Frontier Railway, Maligaon, Guwahati - 781 011
9. Western Railway, Churchgate, Mumbai - 400 020
10. East Central Railway, Hajipur - 844 101
11. East Coast Railway, Chandrasekharpur, Bhubaneswar - 751 016 .
12. North Central Railway, Allahabad - 211 001
13. North Western Railway, Jaipur - 302 006
14. South Western Railway, Hubli - 580 023
15. West Central Railway, Jabalpur - 482 008
16. South East Central Railway, Bilaspur - 495 004
17. Integral Coach Factory, Chennai - 600 038
18. Rail Coach Factory, Hussainpur, Kapurthala, Punjab - 144602
19. Rail Coach Factory, Lalganj, Raebareli - 229120
20. Konkan Railway Corp. Ltd. Corporate office Belapur Bhawan Nawi Mumbai - 400614

Sub: Hexagonal Head Screws/Bolt used for CTRB of FIAT bogies.

Ref: (i). ECoR's letter No. MCSW/IED/MM/M-14-1 (LHB)/1302 dated 27.05.2015.
(ii). WR's letter No. M 113/17/4 dated 20.04.2015.
(iii) This office letter no. MC/RB/Defect dated 06.06.2012.

In reference to above, RDSO have standardized the drawings of Hex. Head Screw for CTRB M20X60,
Hex. Head Bolt for Phonic wheel of CTRB M8X35 and Hex. Head Screw for Earthing device of CTRB
M8X25 by specifying tolerance on threads, property class and make. The following drawings of the
fasteners are enclosed herewith.

i. Drawing No. of Hex. Head Screw for CTRB M20X60 (LHB Shell with FIAT Bogies) : CG-15067
ii. Drawing No. of Hex. Head Bolt for Phonic wheel of CTRB M8X35 (LHB Shell with FIAT Bogies):
CG.•15071
iii. Drawing No. of Hex. Head Screw for Earthing device of CTRB M8X25 (LHB Shell with FIAT
Bogies): CG-15070

Railways are also advised to follow the procedure as below during locking/unlocking of the screws/bolt
used for CTRB of FIAT bogies:

i. The axle end holes should be checked with GO - NO GO thread plug gauge for correct size and
thread condition. If any of the tapped hole is worn out, the axle shall be detained in workshop for
thorough examination and repair as per maintenance manual for LHB Coaches.
ii. End locking plates should be replaced every time its folds are opened to unscrew Hex. Head
Screw for CTRB M20X60.
iii. The locking screws/bolt should be of high tensile steel and of reputed brands as mentioned in the
applicable drawings. The condition of their threads should be checked with GO - NO GO thread
ring gauges and worn out bolts replaced.
iv. The locking screws/bolt head should be free from any damages and should have proper spanner
grip. The length of the bolt should be less than that of tapped axle end holes. The locking
screws/bolt in service should not be reused unless they meet the above standards.
v. The locking screws/bolt while fitting should have no radial or axial play.
vi. Washers of M8X35 bolts of Phonic wheel of eTRS should be replaced in every unlocking of the
bolts.

k
DA: As above

(D~~~
DirectorlStds./Carriage
For Director General! Carriage
 , qrffi sFE{ - 1( Elmrl Covernmcnt of India-Ministry of Railways

ffi 'irgaw affm ofr{ ffi6 $16'{ Research Desigrs & Stirdards Orgasisation

ffi . Fax
ffitlF - 2260ll
EPEX (0522) 2451200
(05?2)2458ff)0
Lucknow - 2?6 0t I
DlE (0522) 2,+50115
DrD (0522) 2465310

qrio: \''fS /3Tr{fr/Bfr€ fu{i-fi : 05.0e.2014

q6rrqar6 (qik6 )
i. qe4 i-dd, u{qfr ffi effiflfl, gq_i- 4oo oo1.
2. Td iaA, +ryfr d-s, ot-d6rdr * 7oo oo1.
3. rd{ kri, e-.s}-fl 6rss, T{ ffi - 110 0o'r.
4. E|gq H, qrd ersq, ff _ 600 oo3.
5. sfuq q1a H, i-fl F-drqq, ftffi<srqK * 5oo 071.
6. EBrI Td W, qre{ tq, mtc-oror - 7oo 043.
7. Td-di ffi, .ilircgi - 213 012.
8. Td-di €qrf, i-dri, qrffi-s, XqEre - rai 011.
e. qfr-4q ffi, Td.id, Iqi - 4oo o2o.
10. gd qta W, ET-frgY - 844 101.
11. Td erAq ffi, fi€r l--d oro)_ft, ffi oFt-ffi, sEd-sigrT,f++rqr, s.Ct-sT - 7s1 016.

13. s6q qFqq ffi, srogv - 302 006.

14. EB.ur qQ-qq H, g_d$ - 5Bo 023.
15. qPqq qeq tcd, qqdg{ - 482 ooi.
16. EBri Td qrq t-d-i, onr { 3ilfu-s .nid.-ffi, f+-otsgi - 4e5 004.
17. ot-oq H orqqttcm ffi, orqfr€ 3frfu-s, +-drg{ r1aq, ffi Uq-$ - 4oo 614
18. {*l-{d *1q Sq-ft, N - 600 o3B.
1e. i-d ots ffi, gfiqgq, oT{erdr - 144 602.

frsg: Protection of CTRB during tyre turning of LHB wheelsets fitted with CTRB.

In reference to above, it is advised that during tyre turning of LHB wheelsets fitted with CTRB.
some burnt chips/coils/swarfs of the removed material of wheel tread likely to fall on the
CTRBs. These chips/coils/swarfs of the wheel material are having high temperature and sharp
edges/points and may cause damage to the grease seals of CTRB.

Hence, it is advised to provide adequate protection/covers to CTRBs during tyre turning of LHB
wheelsets f-rtted with CTRB, to prevent the damage of the grease seals of CTRB. Further, it is
also advised that unprotected tyre tumed wheels and due tyre turned LHB wheelsets fitted r.vith
CTRB shall not be parked in the vicinity of Wheel Lathe as bumt chips/coils/swarfs are often
fbund tlying in the working space.

eE T&
1

T{ATtcF: I

ffiY'ra
CSI"' I

(flVq qur<)
fr-ePTo,zqr+ozzselftp-q1

Copy to:
EDME (Coaching), Rail Bhawan, Railway Board, New Delhi- For kind information.
 'lfTrt 1fT'~~F 'r'" 1fJIT"'fq Gov crnrncnt 01 Ind: ••·f\II1l"tn. 01 Rarlw a»
~ '1QT-f J'll''f'f''''l JrrT ~'l: ~-1 R" .•carch De-igns & Standards Orgaru ...atron
1 uc know - 2200 II
('PBX (0522) 2451200 010(0522)2450115
Fax (0522)2458500 010(0522)2465310

MC/CTRB/Genl. Date: 06.07.2015

The General Manager (Mech.),

1. Central Railway, Chhatrapati Shivaji Terminus, Mumbai - 400001

2. Eastern Railway, Fairlie Place, Kolkata - 700 001
3. Northern Railway, Baroda House, New Delhi - 110 001
4. Southern Railway, Park Town, Chennai - 600003
5. South Central Railway, Rail Nilayam, Secunderabad - 500 071
6. South Eastern Railway, Garden Reach, Kolkata - 700 043
7. North Eastern Railway, Gorakhpur - 273 001
8. Northeast Frontier Railway, Maligaon, Guwahati - 781 011
9. Western Railway, Churchgate, Mumbai - 400 020
10. East Central Railway, Hajipur - 844 101
11. East Coast Railway, Chandrasekharpur, Bhubaneswar - 751 016 .
12. North Central Railway, Allahabad - 211 001
13. North Western Railway, Jaipur - 302 006
14. South Western Railway, Hubli - 580 023
15. West Central Railway, Jabalpur - 482 008
16. South East Central Railway, Bilaspur - 495 004
17. Integral Coach Factory, Chennai - 600 038
18. Rail Coach Factory, Hussainpur, Kapurthala, Punjab - 144602
19. Rail Coach Factory, Lalganj, Raebareli - 229120
20. Konkan Railway Corp. Ltd. Corporate office Belapur Bhawan Nawi Mumbai - 400614

Sub: Hexagonal Head Screws/Bolt used for CTRB of FIAT bogies.

Ref: (i). ECoR's letter No. MCSW/IED/MM/M-14-1 (LHB)/1302 dated 27.05.2015.
(ii). WR's letter No. M 113/17/4 dated 20.04.2015.
(iii) This office letter no. MC/RB/Defect dated 06.06.2012.

In reference to above, RDSO have standardized the drawings of Hex. Head Screw for CTRB M20X60,
Hex. Head Bolt for Phonic wheel of CTRB M8X35 and Hex. Head Screw for Earthing device of CTRB
M8X25 by specifying tolerance on threads, property class and make. The following drawings of the
fasteners are enclosed herewith.

i. Drawing No. of Hex. Head Screw for CTRB M20X60 (LHB Shell with FIAT Bogies) : CG-15067
ii. Drawing No. of Hex. Head Bolt for Phonic wheel of CTRB M8X35 (LHB Shell with FIAT Bogies):
CG.•15071
iii. Drawing No. of Hex. Head Screw for Earthing device of CTRB M8X25 (LHB Shell with FIAT
Bogies): CG-15070

Railways are also advised to follow the procedure as below during locking/unlocking of the screws/bolt
used for CTRB of FIAT bogies:

i. The axle end holes should be checked with GO - NO GO thread plug gauge for correct size and
thread condition. If any of the tapped hole is worn out, the axle shall be detained in workshop for
thorough examination and repair as per maintenance manual for LHB Coaches.
ii. End locking plates should be replaced every time its folds are opened to unscrew Hex. Head
Screw for CTRB M20X60.
iii. The locking screws/bolt should be of high tensile steel and of reputed brands as mentioned in the
applicable drawings. The condition of their threads should be checked with GO - NO GO thread
ring gauges and worn out bolts replaced.
iv. The locking screws/bolt head should be free from any damages and should have proper spanner
grip. The length of the bolt should be less than that of tapped axle end holes. The locking
screws/bolt in service should not be reused unless they meet the above standards.
v. The locking screws/bolt while fitting should have no radial or axial play.
vi. Washers of M8X35 bolts of Phonic wheel of eTRS should be replaced in every unlocking of the
bolts.

k
DA: As above

(D~~~
DirectorlStds./Carriage
For Director General! Carriage
 , qrffi sFE{ - 1( Elmrl Covernmcnt of India-Ministry of Railways

ffi 'irgaw affm ofr{ ffi6 $16'{ Research Desigrs & Stirdards Orgasisation

ffi . Fax
ffitlF - 2260ll
EPEX (0522) 2451200
(05?2)2458ff)0
Lucknow - 2?6 0t I
DlE (0522) 2,+50115
DrD (0522) 2465310

qrio: \''fS /3Tr{fr/Bfr€ fu{i-fi : 05.0e.2014

q6rrqar6 (qik6 )
i. qe4 i-dd, u{qfr ffi effiflfl, gq_i- 4oo oo1.
2. Td iaA, +ryfr d-s, ot-d6rdr * 7oo oo1.
3. rd{ kri, e-.s}-fl 6rss, T{ ffi - 110 0o'r.
4. E|gq H, qrd ersq, ff _ 600 oo3.
5. sfuq q1a H, i-fl F-drqq, ftffi<srqK * 5oo 071.
6. EBrI Td W, qre{ tq, mtc-oror - 7oo 043.
7. Td-di ffi, .ilircgi - 213 012.
8. Td-di €qrf, i-dri, qrffi-s, XqEre - rai 011.
e. qfr-4q ffi, Td.id, Iqi - 4oo o2o.
10. gd qta W, ET-frgY - 844 101.
11. Td erAq ffi, fi€r l--d oro)_ft, ffi oFt-ffi, sEd-sigrT,f++rqr, s.Ct-sT - 7s1 016.

13. s6q qFqq ffi, srogv - 302 006.

14. EB.ur qQ-qq H, g_d$ - 5Bo 023.
15. qPqq qeq tcd, qqdg{ - 482 ooi.
16. EBri Td qrq t-d-i, onr { 3ilfu-s .nid.-ffi, f+-otsgi - 4e5 004.
17. ot-oq H orqqttcm ffi, orqfr€ 3frfu-s, +-drg{ r1aq, ffi Uq-$ - 4oo 614
18. {*l-{d *1q Sq-ft, N - 600 o3B.
1e. i-d ots ffi, gfiqgq, oT{erdr - 144 602.

frsg: Protection of CTRB during tyre turning of LHB wheelsets fitted with CTRB.

In reference to above, it is advised that during tyre turning of LHB wheelsets fitted with CTRB.
some burnt chips/coils/swarfs of the removed material of wheel tread likely to fall on the
CTRBs. These chips/coils/swarfs of the wheel material are having high temperature and sharp
edges/points and may cause damage to the grease seals of CTRB.

Hence, it is advised to provide adequate protection/covers to CTRBs during tyre turning of LHB
wheelsets f-rtted with CTRB, to prevent the damage of the grease seals of CTRB. Further, it is
also advised that unprotected tyre tumed wheels and due tyre turned LHB wheelsets fitted r.vith
CTRB shall not be parked in the vicinity of Wheel Lathe as bumt chips/coils/swarfs are often
fbund tlying in the working space.

eE T&
1

T{ATtcF: I

ffiY'ra
CSI"' I

(flVq qur<)
fr-ePTo,zqr+ozzselftp-q1

Copy to:
EDME (Coaching), Rail Bhawan, Railway Board, New Delhi- For kind information.