'l1T«f ~ - ~ lj-~fw:r Government of Ind ia-Ministry of Railways

-3l:rBtll'f aT~ ~ l1R'f; Wro.r Research Designs & Standards Organisation

~ -226011 Lucknow - 226 011
EPBX (0522) 2451200 DID (0522) 2450115
Fax (0522)2458500 DID (0522) 2465310

No. MC/LHB/Brake Date: 07 .12.2020

Principal Chief Mechanical Engineers,

1. Central Railway, Chhatrapati Shivaji Terminus, Mumbai -
400001
3. Eastern Railway, Fairlie Place, Kolkata - 700 001
5. Northern Railway, Baroda House, New Delhi - 110 001
7. Southern Railway, Park Town , Chennai - 600 003 . 8. West Central Railway, Jabalpur - 482 008
9. South Central Railway, Rail Nilayam, Secunderabad - 500
071
11. South Eastern Railway, Garden Reach , Kolkata - 700 043
13. North Eastern Railway, Gorakhpur - 273 001
15. Western Railway, Churchgate, Mumbai - 400 020
17. Northeast Frontier Railway, Maligaon, Guwahati - 781 011
19. East Central Railway, Hajipur - 844 101
2. East Coast Railway, Chandrasekharpu r, Bhubaneswar -
751016
4. North Central Railway, Allahabad - 211 001
6. North Western Railway, Jaipur - 302 006
10 . .South Western Railway, Hubli - 580 023
12. South East Central Railway, Bilaspur - 495 004
14. Integral Coach Factory, Chennai - 600 038
16. Rail Coach Factory, Hussainpur, Kapurthala,
Punjab - 144 602
18. Modern Coach Factory, Raebareli, Lalganj - 229206
20. Konkan Railway Corp. Ltd. Corporate office, Belapur
Bhawan, Nawi, Mumbai-400 614

Sub: Modification in air brake pipeline & associated fittings in LHB Coaches.

Ref: i) This office letter of even no. dated 24.06.2019, 23.08.2019 & 04.08.2020.
ii) ICF letter no. MD/DSS/Brakes/1 03B dated 23.1 1.2020.

1. Vide letters at reference (i) above, instructions for the modification in air brake pipeline &
associated fittings in LHB coaches were issued by this office for mitigating wheel shelling . These
instructions consist of respective annexures which illustrate the procedure for modification to be
carried out in new & existing LHB coaches with single ferrule air brake fittings.

2. ICF vide ref (ii) above has submitted the details of regarding modification in air brake pipeline &
associated fittings in LHB coaches with double ferrule fittings. The same is being forwarded
herewith and ZRs & brake system OEMs (for AMC coaches) are requested for early
implementation of subject modification in LHB coaches with double ferrule fitting s for mitigating
wheel shelling. ryO-yO
DA: Ref (ii). 1" \')...-
t)

(Sudhir Singh)
Jt. Director/E&S and Brake
for Director General/Carriage
Copy to: For information,
i. MIs Knorr-Bremse India Pvt. Ltd., Palwal-121102, Haryana
ii. MIs Faiveley Transport Rail Technologies India Pvt. Ltd. , Plot No. 3A, Apparel Park cum Industrial
Area, Katha, Bhatoli, Baddi, Solan (H.P)
iii. MIs Escorts Limited, Plot No.114-115, Sector-24, Faridabad-121 005 (Haryana)
.-, \'1

~ ~ <fIlHgHI ~ 600038/
INTEGRAL COACH FACTORY,CHENNAI- 600 038.
Telefax No. (044) 26261872 Rly.:46809
E-mail~smebdlcf@gmail.com

~ >r./c:IT.(3l~~') CfiT eWMI4

0/0. General Manager/Mech. Design

~ /NO. :MD/DSS/Brakes/103B ~.1Dt.;23.11 . 2020

Jt. Director / E&S and Brake

RDSO, Manak Nagar,
Lucknow - 226 011

Sub: Modification in air brake pipeline & associated fittings in LHB

coaches.

Ref: 1. RDSO Ltr No. MC/LHB/Brake Dtd 24.06.2019, 23.08.2019

& 04.08.2020.
2. RDSO Ltr No. MC/LHB/Brake Dtd 04.11.2020.

Vide Ref (1) letters, RDSO has issued instructions to ICF to follow the standard
brake piping layout with respective annexures in all LHB coaches.

2. Vide Ref (2) letter, ICF was requested to provide the details regarding modification in air
brake pipeline & associated fittings in LHB coaches for mitigating wheel shelling.

3. ICF has been following the standard piping layout issued by RDSO vide ref.(1). The
modification in a'ir brake pipeline, connecting flexible hoses & associated double ferrule
fittings has been implemented in all the LHB coaches as per drg. nos. 874-3-5-001 alt
"nil" and 455,.3-2..004 alt "a". The details of modification in air brake pipe line with
double ferrule fittings are as follows:

i) PIPING ARRANGEMENT BEFORE MODIFICATION:

Refer ANNEXURE-A

ii) PIPING ARRANGEMENT AFTER MODIFICATION:

Refer ANNEXURE-B

4. Work Instructions for modification in the pipeline:

i. Remove item-5 (Male Elbow connector %" ODx1l2" BSPT) from coach body
side of Flexible Hose connection and replace it with item-10 (Male Elbow
connector 3/4" OD x M26 x 1.5(M) with 24°conical seating to drg. no.
ICF/STD-3-5-137, item-1)

Contd ...
 P-2

ii. Remove the item-6 (hose connection R1/2" x 600mm with BSPT threads on
both sides) and replace it with item-11 (hose connection R 1/2" x 650mm with
M26 x1.5 threads & with 240 conical seating on both sides to ROSa drg.no.
CG-19036 )
iii. Remove the items-2,7,8 & 9 (Male connectors %"00 x W' BSPT, Pipes %"
00 with double ferrule fittings & Bulk head straight union %" 00) from the
bogie side of the flexible hose connection and replace them with item-12
(Bulk head male connector 3/4" 00 x M26 x 1.5(M) with 24 conical seating
0

to drg. no. 455-3-2-005/item-1)

Enc!. : ICF drg. Nos. 783-3-5-001, alt.nil

455-3-2-004, alt.nil
874-3-5-001, alt.nil
455-3-2-004, alt.'a'

(3lR. d"C1-r;j~'1)/(R.RAVI HANORAN)

0Ift.7:IT.~./t)-1 ISME/O-I
~ ~ ~./~.( awrcfi~)/for GMlMech. Design

Ct-
COE/Mech :for kind information

tI.\
-UO. .

~
 ANNEXURE-A
(PIPING ARRGT. BEFORE MODIFICATION)

1 2 3 5
---I 1--------------
.-~~~~~~--_+----~~ i I

~1 I
1
I

81 1
CD I I
CLAMP ON BOGIE

l5« 1
I
1
I
9
81 1 I I

(REFER 783-3-5-001 alt.NiI

FOR COACH BODY SIDE
PIPING MODIFICATION)
I I

1 I
I I

1 1
I I

1
I
I
I
~
<3
! !g (REFER 455 ... 3 .... 2- 004 alt . .

--- ~ L --- ------------

FOR BOGIE SIDE
PIPING MODIFICATION) v

SI.No. Description Drg.No. Qty.

Mis Knorr Bremse
1. Dump valve or Anti skid valve Drg.No. C131766 2
leF/STD-3-o-016
2. Maie connector 3/4" 00 x i /2" Eisr'l' ITEM-2 4

3. Pipe 3/4" 00 with Double ferrule fittings 1

4. Pipe 3/4" 00 with Double ferrule fittings 1

rCF/STD-3-5-023
~. Male Elbow connector 3/4"ODx1/2" BSPT rr;M-~ ~
Hose Connection R 1(2" x 600mm Mis Knorr Bremse
6. (BSPT threads on both sides) Drg.No. 1.3.3503/3 2
7. Pipe 3/4" 00 with Double ferrule fittings 1

8. Pipe 3/4" 00 with Double ferrule fittings 1

leF/STO ...3...5... 123
9. Bulk head straight union 3/4" 00 ITEM-l 2

~"lloifA.\
~
" r-~------------------------------------------------------------~--------------~

ANNEXURE-8
(PIPING ARRGT. AFTER MODIFICATION)

1 2 3 10
---~ 1--------------
r-~~~~~~--_+----~~~ 9 I I

~I I
o I I

~~ I II I
CLAMP ON BOGIE

81 I I

I I

(REFER 874-3-5-001 alt.Nil

FOR COACH BODY SIDE
PIPING MODIFICATION)
I

1
I

I
I
w
Cl
Vi
w
I
I
(3
oCD
I
I I (~Errn 455-3-2-004 alt."a"
FOR BOGIE SIDE
---~ L PIPING MODIFICATION)
--------------
1
SI.No. Deseri ption Drg.No. Qty.
Mis Knorr Bremse
1. Dump valve or Anti skid valve Drg.No. C131766 2
leF/STD-3-5-016
2. Male connector 3/4" 00 x 1/2" BSPT ITEM-2 2

3. Pipe 3/4" 00 with Double ferrule fittings 1

4. Pipe 3/4" 00 with Double ferrule fittings 1

ICF-,tSID 3 5 ()23
5. "'(11, Elbow C;OIIlIlC;tCIi 3/4" ee x t/2" aSPT IliM 2 2
_,
M's Kilo, r Ela ell1se
6. " " 2

7. ~ipe 3/4" ee with Elouble fell ule fiUilui/& 1

I

8. j;!ipe 3/4" eEl wit~ Bouble fe~r:tIle fittillgs 1

ICF/SID 3 5-123
9. Stille I,ead stlQigl,t Ullioll 3/4" at) IliM 1 2
~/~e Elbow connector )}~~h conical seating) ICF/STQ:-3-5-137
10. 3 4" 00 x M26 x 1.5 M ITEM-1 2
Hose Connection R1/2" x 650mm ROSO
11. (M26x1.5 threads &: conical seating on both sides) Drg.No. CG-19036 2
8,~~ "Head Male connec~Orl) (with conical seating) 455-3-2-005
12. 3 4 00 x M26 x 1.5 M ITEM-1 2
 \l ROUGH MACHINED ® ROUGH CLEANED AlTERATIONS
ICF/STD-3-5-1371 W FINISH MACHINED ® CHAMFERED
\lW FINE FINISH MACHINED E> BURRS REMOVED

Ax

A~f-'ll ~
F
, r
A/f
NOTE ..-
:-::;=
•
I -- 1. THIS FITTING SHALL CONFIRM TO ICF/MO/SPEC.-166 (LATEST REVISION/AMENDMENT)
I- ~ - - 1-
2. GENERAL TOLERANCE ON DIMENSIONS : (0) BELOW 25mm : ~8·5
--= I
(b) ABOVE25mm: +1.0 EXCEPT "P '" Pl"
-0
:£ 3. REMOVE ALL BURRS AND SHARP CORNERS.
I D I L
~H
4. ISO 7/1 &: ISO 228/1 FOR TAPER AND PARALLEL THREADS

5. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.

~~~GlC2
P
6. Q1Y. SHALL BE AS PER RELEVANT ASSEMBLY DRAWINGS.
7. ITEMS SHALL BE PROCURED FROM APPROVED SOURCES ONLY.

l 24' ~

ITEM T P Ax B ¢ C1 ¢C2 D Dx ¢E ¢Ex F G Hx Hy

No. TUBE METRIC
MAlE A/F A/F
00
1 ~" M26x1.5 40.2 14.0 18.0 20.3 24.4 7.5 15.8 15.0 27 32 30.0 30.0

_ MAlE ELBOW CONN~OR 3/4" 00 X M26X1.5

. (WITH CONICAL SEATING
l 1J 1Cf/IiD/SPEC.-166
LATEST AIIENIJIIENT
No. Off DESCRIPTION '" DIMENSIONS IITIEM I REf. DRG MAT. SPEC. WEIGHT/UNIT I REMARKS
N III II I GROUP: 3-5, BRAKE PIPING SUPERSEDED BY
SUPERSEDES:
SCA~E SSE/D I ,..-
MALE ELBOW CONNECTOR CHD
If)
V
o
T

8·.
NTS A~T
(WITH CONICAL SEATING) DRN JUl. V.Kumar
AlT. I I 1
ASSEMBLY DRAWINGS CAD FILE: C:\t.1D-CAD\ 140\3-5\ 137---00.DWG
INTEGRAl COACH FACTORY

27-11-2019 /?- DATA

CODE No. INDIAN RAILWAY
STANDARDS
SHEET
1 OF 1
ICF/STD-3-5-137
CHENNAI - 600 038

I I AlT. DAlE OF LA1£SI ALTN. DATE OF FlRST ISSUE SME/D 140

FORIA IR A3 420 x 300
 'l ROUGH t.lAC!-ilNEIl @) ROUGH CLEANED
45532004 V'V fiNISH IoIACIiINED @ CHAMFERED
\7'VY'FlNE FINISH MACHINED @l BURRS REMOVEO

r!
~II~~~~~
L
SECTION-AA

1 STIFFENER- 23 ~ -126882.6-
1 HEX: HEAD scREW,: ~10x22 22 fiM'i ZlNCELECTROP[)JE(l
4 SPRING 'WASHER 810 " '21 ' '063 GALVANIZED
4 ALL METAL f'RS\'A1UNG TORQUE
TYPE HEX NUT M10 - 10 o 01N6925 ZINC ELECTROPlATED
"" HEX. HEAD SCREW ~ t OxJO ZlNC ELECTROPL4lED

I, ,171-40..,.3-5-116 rmH
rrBH
15 1272160
1 PIPE 3/fOD ~ ,14.24, ' 14"='"
'1 PIPE 13
, 1 PIPE I ' 12 lW36180

" PIPE'
, 1Q {WJ6107

t UNION TEE 3/4"00 ; ~ 7i WI-3':5-<l18 " ITEM-2

1. THE HEX. HEAD SCREWS SHALL rroH

""'-'
rTElH
2 BULK HEAD STiWGHT UNJON 3/4"00 ; 2. 140-;5-5-123
2 MALE CONNECYoR 3/-4'00 x 1/21lSPT(M) 1 1.w-l-S-Q16
DESCRIPTION & DIMENSIONS fTEl,f W!'lGHT/UNIT
fI III I I GROUP; BOGlE FR.IME AARGT.(O_J) SUPERSEDEDEJY
SUPERSEtlES:

~
S~E ssEjo
BRAKE PIPING ARRGT. 1:10

WITH DOUBLE FERRULE FITTINGS

, ",,:,"t,""N INDIAN, RAILWAY

ALT, o.o.TErA'lAtEST'ALT[/A1E{)fARSTISSUE STANDARDS
 --------------- ---------- -- -- ------ -- ----------------------------------- - - ,
LWSCWAC-3-2-004 '11 ROVQH ~ftIED {l ~ ClDIHfD='--1I:::---"":::"":::-~-_;
fcw=-=="""=o""''''c=c+.@
'V'V\lf1NE FINISH w.cHlNED
~'''' ...=FERED
@l i!l.JFIRS RE!'I(M[)
@09/2019
ITEM-24 ADDED.
~~,2& _8DELETED

~~

17,18,19,20

t·~:I~
SECTION - AA

I
,

.-------+- I

I
I

L-A ITOH

1 PIPE
, P1PE - - - - - - +.~~=,_t---_t_--- -t_---

1 PIPE
, P1PE

1 PIPE

NOTE: 7 140-J-5-018 flDo4-2

1. THE HEX. HEAD SCR£WS SHAll BE OF t.AAKE - 1VS OR UN8RA1<O OR LPS ONLY.
~~~~~~~~~~~,~~;~:~.,-:~:~:~~'----t----+--=:~:~:-~
18,21,22,23/
H -f--R,f"BW<=.:-\£\Il="""'=:':'=/'=o. o== -I~+;:-::::~ :~:

~ BRAKE PIPING ARRGT.

_ 455-0-0-00' ffi~" WITH DOUBLE FERRULE FITTINGS
1 s/J/I'J 2001-21)19 y • ''''' ,. INDIAN RAILWAY
L-____________________________________________________-LL!~~~~~~~~~~~-J-LJ-~--L------------L--~F:M:"-:'R~A'~.:~;:,:~:-~
455 STANDARDS "'" '" ""'"'' "'" '" ""'.... ...;0-'
____ _____
 'V ROUGH WCHINED ® ROUGH ClEANED ALTERATIONS
LWSCWAC-3-2-005 'V'V FINISH WCHINED @ CHAMFERED
'V'V'V FINE FINISH MACHINED @ BURRS REMOVED

Hx

NOTE:
1. THIS FlTIING SHALL CONFIRM TO ICF/MD/SPEC.-166 (LATEST REVISION/AMENDMENT)
2. GENERAL TOLERANCE ON DIMENSIONS : (0) BELOW 25mm : :8.5
(b) ABOVE 25mm : :6.0 EXCEPT T&P
3. REMOVE ALL BURRS AND SHARP CORNERS.
4. ISO 7/1 & ISO 228/1 FOR TAPER AND PARALLEL THREADS RESPECTIVELY.
5. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.
6. QTY SHALL BE AS PER RELEVANT ASSEMBLY DRAWINGS.
7. ITEMS SHALL BE PROCURED FROM APPROVED SOURCES ONLY.

Ax
A

ITEM T P A Ax B o F Fx G H Hx
No. lUBE 0.0 A/F A/F A/F
1 3/4" M26Xl.5 75.6 47 19.1 24.4 15.8 32 36 32 66 37.4

- ~,LK HE"AIl IIAI..E ~~qoR (Wmi CONICAl. SEATING)

3/4"00 X 1126 x 1.51111
11 1 ICF/IID/SPEC
-
16~
'u

No. OFF DESCRIPTION & DIMENSIONS IITE~REF. DRG MAT. SPEC. WEIGHT/UNIT REMARKS
IV III II I GROUP: 3-2. BRAKE PIPING SUPERSEDED BY:
SUPERSEDES:

BULK HEAD MALE CONNECTOR SCALE SSE/D

CHD
~. tt~VV\..

(WITH CONICAL SEAnNG) NTS ALT

(DOUBLE FERRULE COMPRESSION TUBE Fl11lNGS) ~~__D__ . ....,Mu_rc_lidc-rr---I
RNi-'--r-R
I I I

c::::r '*"' I
ALT.
ASSEMBLY DRAWINGS
DATA c::l INTEGRAL COACH FACTORY
~ CHENNAI - 600 038
COlE No. SHEET
INDIAN RAILWAY
I I ALT ~TE Of LATEST AlT. ~TE OF FIRST ISSUE SME/D-I
455 STANDARDS
1 OF 1
LWSCWAC-3-2-005
lSCN/EOGjASR-3-5- 001

~133134135
4113 / ' 120132 ill;11
}<U'''''=--,=OO'

122 / 0
394447 394447
13 944126/ / ,1139 ~,!y /'8394447
43444712 7 \ 11 31 61
~!! ! ,3944.47,125 !' ~ ,
"'\
!~ .- '. - ' ~=L~ ~- - ' ...

~
97,1 60
~
97,160

I '
/f~·4 ;47
.·'t
3944 4044147148 1 ·- /-
I -
~~
r'"p
-~ ' -r .! '-
- -L "'---- ~t
1- '-

'\ 71015
404447 \404447
152,153,1 54
SECTION -E E
SECTION-KK
ILSCN/EOG/ASR- '-S-001I

140
75,136, 137,138
166
\~,
79,81,82
~" !~1I" -~'- "-\
i ,- • I " \

. ~ ~ ~ . ...J!

70 58 85 / 1'87
DETAI L AT-P

404447153,154165
11 39 44 47 125 \
9 \
~ .- - _ .",
L._..~ . - ~--- ~

SECTION - DO
'<;ON,
tillIE:
1. .o.u. SCREW CONNECTIONS 'll'lTM NUTS or ST~Nl.[SS STEEL HAIlE TO GRUSED WlTfl
1oI00YKOTE!t.tOLYlIDENUIoIOiSVLPHIDE P!!IORTO BE SC('jjEO IN.
2. FASTEI<IERSSH.<.l.LBEOFWlKEGI<WORTVSOR UNBRAKOORLPS ONLY

hsc "i"~Iio';" ,,,,, '1,"0.0 ,ruo-" ' 1,:g:;",:;:!'."i::'~'OO' " l'''~,

"" "" -"
h4C"i~'('';'' ""-,
."0:;':;"'';;'"
' ~m'. """",

J~jfO:~~,"
~-~
,~,e~f"
, '"''
,""m '-M,.-;';' , V,,;;'
""'" ",.~'
"""~ :t.'Mr.;r,,'W{" "" -10 :.i;;";';'

I
.1."
,""rr,-"
-" I ~' "' 1""-"" ~.~i~ ;";0'
"" :~\o
""
"",ro"""" '· O.O'I'''''' "" -,
oou".~"

"''''"",''',,m .• "">I= -"~ '-

". , ~""
. ,w, ~ , ..,
~.-
,, - ~

I - ~, ... =.-~ "~(;" "~'g!,I"

""''''.'~'''''''''''- "" -, I ~ ~oo-,,- ~-~ ~ - :1:;"',;;'
I ~·" '· =~~m"'" ':,.' "" ""-~ I"'" = ~

i
.
I"" , 00 ""-" ~, '1"0.0 "',-" ,,~""" :~> :.';;""
I"" 1/" 0.0 ",,-n "" 1/"0.0 "'-" _IT :::l'''''= ~ ' , ~, :'(;";0'
I"" 'I" 0.0 ,ruo-n :'~i"»"m ~ .~. =. 1 1S: 1 ~_ I!f'MI '~'~emc
~ "","u~.~m.
:':!'l;
I"...."""''''
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:\,"~'''m_".

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"'i1: "''lie;";;, "" '"0.0 ,rr,-"" ""H I"" ~-,

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, "" 'I" . ~-" I"'" ' I" 0.' ~ -,

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