File No.

RDSO-CARR0VDG(AS)/1/2020-O/o ED/CARRIAGE/RDSO

No. SV.EMU RAS Date:13.05.2021

Principal Chief Mechanical Engineer

1. Central Railway, HQ office, CSTM, Mumbai - 400 001
2. Eastern Railway, HQ office, Fairly Place, Kolkata- 700 001
3. Northern Railway, HQ office, Baroda House, New Delhi-110 001
4. Southern Railway, HQ office, Park Town, Chennai - 600 003
5. South Central Railway, HQ office, Secunderabad-500 071
6. South Eastern Railway, HQ office, Garden Reach, Kolkata-700 043
7. North Eastern Railway, Gorakhpur-273 001
8. North East Frontier Railway, HQ office, Maligaon, Guwahati- 781 011
9. Western Railway, HQ office, Churchgate, Mumbai-400020
10. East Central Railway, HQ office, Hazipur-844 101
11. East Coast Railway, Railway Complex, Bhubaneshwar- 751 023
12. North Central Railway, HQ office, Subedarganj, Prayagraj- 211015
13. North Western Railway, HQ office, Jaipur-302 006
14. South Western Railway, HQ office, Hubli- 580023
15. West Central Railway, HQ office, Jabalpur- 482 001
16. South East Central Railway, HQ office, Bilaspur- 495 004
17. Konkan Rly.Corp.Ltd., Corporate office, Belapur Bhawan, Navi Mumbai – 400614
18. Integral Coach Factory, Chennai - 600038
19. Rail Coach Factory, Kapurthala – 144 602
20. Modern Coach Factory, Rae Bareli – 229212

Sub: Maintenance of “Air Suspension System” in LHB coaches

Ref: i) RDSO letter no. SV. EMU.RAS dated 30.08.2019.
ii) RDSO letter no. SV. AS.FIBA dated 22.06.2020.
iii) RCF letter no. MD 44121 dtd 24.07.2020 for air spring height
iv) CAMTECH Maintenance Manual for LHB coaches.
v) JUDW letter no. 109-W/14/LHB dated 05.01.2020 & WR’s L.no.
S.440/2/1/Gr.33(LHB) dated 16.12.2020
vi) RCF CAI no. MD21561 dated 17.02.2021 issued vide L. No. MD44121 dtd
17.02.2021
vii) RDSO letter nos. SV.EMU.RAS dated 20.12.2019 & 15.12.2020, SV.FIAT
dated 22.01.2020.

1. 1. Instructions for maintenance of air suspension system in LHB coaches are already
included in CAMTECH Maintenance Manual for LHB coaches. Further, maintenance
instructions for Air Suspension System in LHB coaches were issued vide letters
under ref i), ii) & vi). Few references regarding maintenance instructions were
received from Zonal Railways vide letters under ref. v). It was also observed that
leakage test of Air Suspension System in LHB coaches is also not being conducted
by PUs as per instructions in CAMTECH Manual in this regard. Further, it was
observed that method for leakage test of Air Suspension System in LHB coaches
included in CAMTECH Maintenance Manual for LHB coaches also has some issues.
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Significant number of failure cases are also being reported in for “Air Suspension
System” in LHB coaches.

In view of above, maintenance instructions for “Air Suspension System” in

LHB coaches have been complied after discussions with PU, Zonal Railways &
OEMs and are enclosed herewith as Annexure-1. “Air Suspension System” in
LHB coaches is to be maintained as per these instructions in addition to
relevant clauses of CAMTECH maintenance manual for LHB coaches. In case
of any contradiction of maintenance instructions in Annexure-1 with any
instruction issued earlier in this regard, maintenance instructions in Annexure-
1 of this letter shall prevail. PUs also to ensure compliance of these
instructions, as applicable, particularly to leakage test of “Air Suspension
System” in LHB coaches before dispatching to Zonal Railways.

2. 2. Zonal Railways are reporting failures of “Air Suspension System” in LHB coaches
without details of coach type, condition of associated components, make etc, without
which failure analysis & root-cause analysis are impossible. Format for reporting
failures in “Air Suspension System” in LHB coaches has been circulated vide letters
under ref vii). Few Railways only have submitted details of failures & analysis in the
format. Google sheets for each Zonal Railway have been prepared & are being
shared with respective CRSEs & Dy. CME/Coaching for submission of details
& analysis of failures in “Air Suspension System” in LHB coaches. It is
requested for regular provision of failure details in respective Google Sheet.
Master data in format should be kept by Zonal Railway in offline mode as well, which
can be used in case of any issue with google sheet.

3. 3. In view of failures, training regarding maintenance of “Air Suspension System” in

LHB coaches has been planned in coordination with OEMs as per Annexure-2.
Respective OEMs may be approached for training programme.

This is for your kind information and necessary action please.

DA: As above.

(Shobhit Pratap Singh)

Joint Director/Carriage (VDG)
For Director General/ Carriage

Copy for kind information:

1. ED/ CAMTECH- Maharajpur, Gwalior-474020, for kind information and
incorporating the instructions in CAMTECH Maintenance manual for LHB
coaches
2. DME(Coaching), Railway Board, Rail Bhavan, New Delhi-110 001, for kind
information.
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ANNEXURE-1

Maintenance of Air Spring Assembly, Air Spring Control Equipment (ASCE)

and Air Spring Failure Indication cum Brake Application (FIBA) device in LHB
Coach

The construction of Air Spring is a robust design which sustains high static and
dynamic loads. It consists of a thick flexible rubber bellow which is sandwiched
between top plate and Emergency spring. The shape of rubber bellow is suitably
designed to provide uniform pressure on supporting surfaces, which in turn gives
vertical and lateral stiffness. Emergency spring is provided with the air cushion and
housed in series with the rubber bellows. The emergency spring comes into action
independently when the air spring gets deflated for some reason. When air spring is
installed, the top plate is connected to the bolster whereas the pedestal holds the
spring on to the bogie frame through the bracket. An additional air reservoir of 60-
liter capacity is connected to the air spring which acts as a buffer for holding the air.
Orifice of adequate size is provided between air spring and additional air reservoir
which provides self-damping characteristics. Air spring Failure Indication cum Brake
Application (FIBA) device has also been provided in air spring fitted LHB coaches to
indicate the failure of air spring (internal pressure less than 1.0 Kg/Cm 2), which apply
brake in train, gives hissing sound and red indication in affected bogie.

COACH
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1. DISMOUNTING OF AIR SPRING FROM FIAT BOGIE FRAME:

 Cut the air supply to pneumatic suspension system with the cut of angle cock
& isolating cocks provided in FP & BP pipelines. Vent internal air pressure of
air spring, 60L reservoir and 150L main reservoir with the help of horizontal
lever of levelling valve and drain cocks of reservoirs.
 Remove all body Bogie connection including duplex check valve.
 Remove secondary vertical dampers & yaw dampers.
 Remove connection between arm (horizontal lever) of levelling valve &
installation lever.
 Remove all 4 No. bolts and nut with the help of suitable spanner from bottom
plate of air spring & bogie frame.
 Lift coach body & bolster to clear the spigot of the air spring. Use chiesel /
spoon type lever made from wood or nylon to create gap between top plate of
air spring and bolster to release the spigot from air pocket.

Chisel / Spoon type lever

 Air springs not to be dropped down on ground or floor directly after

dismounting from bogie frame. Air springs should be transported in
assembled condition and air spring sub-assemblies e.g. top plate, base plate/
bottom plate & emergency springs etc. need not require dismantling during
the warranty period (except failure repair or investigation).
 Instructions of maintenance manual of respective OEMs to be referred and
followed during the maintenance of air spring assemblies.
 Use nylon strip to tighten and handling of air spring assembly. Lift air spring
assembly with the help of Nylon Strip in same position with the help of hook
or chain pulley or slide on fork lift arm at same level and transport suitably to
proper place for necessary maintenance & testing. The lifting procedure
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should be steady, slow and without swag. During the lifting and transportation
of air spring, it is to be ensured that nobody is present nearby and under the
lifted air spring to avoid any injury.

 After dismantling the air springs, ports of air spring assemblies to be covered
with suitable protection cap (rubber/PU etc) to protect from ingress of the
foreign materials.
 Air spring assemblies to be stored in dry and clean place under covered shed
and arranged properly to protect from rubbing and damages.

2. Leakage test of Air Spring at leak test bench:

Leak test of individual air springs to be carried out at leak test bench as per
following procedure: -
- Install the air spring assembly at design height (289-294 mm).
- Gradually raise the air pressure to 6 kg/cm 2 while maintaining design
height and stabilize the pressure for 1-2 minutes.
- Disconnect/ close the air supply in the test bench with the help of isolating
cock and check the leakage in air spring assembly with liquid soap
solution.
- Air spring assembly shall be checked for pressure drop after 15 minutes.
- After 15 minutes at internal pressure 6.0 kg/cm 2. No pressure drop is to
be targeted. However, pressure drop should not be more than 1% of Test
Pressure.
- During air spring leak test on bench, leakage test of pneumatic
suspension system in coach as detailed below in para 6 & load
testing of bogie, height of air spring shall be maintained as 289-294
mm. Height of air spring beyond 294 mm shall not be permitted.

3. Mounting air spring on rectangular platform provided on Y-frame of bogie

and bolster:
• Capacity of air spring &/or colour coding shall be matched for type of coach,
for which bogie is being assembled.
• New O-Rings to be fitted properly during the fitment of Air spring assembly.
Condition of O-ring, spigot and mating surface of bolster with spigot to be
checked properly for any damage, crack, cuts, sharp edge, burs etc. during
maintenance and fitment of air springs in the bogies. Condition of air spring
bellow, emergency spring and top plate also to be checked.
• Spigot cover and other packing materials used for covering and handling/
storage of air springs to be removed suitably before use/ fitment of air springs
in the bogie.
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• Air spring assembly and mating surfaces of air spring, bogie to be cleaned
properly and ports to be ensured for non-ingress of foreign material or any
blockage.
• Mount air spring on square platform provided on Y-frame of bogie and match
the holes of bottom plate of air spring and holes of square platform provided
on Y-frame of bogie.
• Tight all 4 nut-bolts-washers with the help of suitable allen key and suitable
spanner. Mounting Fasteners (M20X55) to be tightened at 340 Nm torque
value and marked with paint for tightened position. New nylock nuts as per air
spring specification are to be provided. Bolts shall be provided as per air
spring specification & checked before fitment by GO, No-GO ring gauges.

Wrong handling & fitment practices of air springs strictly to be avoided

In above images, torque wrench of having improper height for the purpose is
being used

Note: Handelling of air spring assemblies should always be proper and smooth.
Fasteners to be tightened with proper torque using proper torque wrench.

• During re-assembling of dismantled air spring due to any reason, all the sub-
assemblies e.g. top plate, emergency spring & bellow should be cleaned
properly, to be checked for any damage and non-ingress of any foreign
material, dust, dirt etc to be ensured. OEM’s instructions to be followed and
proper tools to be used for the same.
• Place all bolster beam on air spring ensuring no damage to spigot/O-rings of
air spring. Ensure that the Air Spring Assembly should not get tilted during
placing Spigot in bolster hole. After placing, check Air Spring’s Spigot and
mounting holes which should be co-centric (aligned).
• Connect levelling valve arm with installation lever.
• Mount vertical and lateral shock absorber.
• Connect all flexible/fixed pipe connections of bogie.
• All the threaded joints of air springs, FIBA & ASCEs to be sealed with thread
sealing tape or Loctite 577 and tightened at torque recommended by OEM to
avoid air leakage.
• The filter of levelling valve must be cleaned.
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4. Procedure for checking bogie clearance on AC and Non AC coaches fitted

with Air Springs:
• Place the coach at level track.
• Adjust the air spring installation height (289-294 mm) as per suspension
diagram with the help of installation lever.

5. Procedure for adjustment of installation height of Air Springs:

 Keep the coach on level track.
• Adjust the length of all installation levers as per requirement to connect them
to horizontal lever of levelling valve.
• Supply compressed air to the bogie.
• Adjust the installation height of air spring to 294 +0-5 mm by gradually increase
or decrease the length of installation lever.
• Repeat the same procedure for the other side of air springs of the same bogie.
• Re-check the installation height of all air springs of coach and make minor
adjustment if required to maintain the installation height to 294 +0-5 mm.
• Tighten the installation lever lock nuts with the horizontal lever of levelling
valve properly, so that setting will not be disturbed.
• Repeat the above procedure for the second bogie.

6. Leakage test of pneumatic suspension system on coach: (To be tested in

PUs, Workshops & Sick line after lowering of coach body on bogie & assembly)
• Release the air completely from air spring & auxiliary/ main reservoirs for
pneumatic suspension by drain cocks and dropping the horizontal lever of
levelling valve.
• Connect pressure gauges to the drain plug locations of all four 60L reservoirs.
Pressure gauge should also be connected in the port of drain cock of 150L
pneumatic suspension main reservoir.
• Tighten the Car body/bolster & bogie frame/floor with the help of lashing
chain/ suitable fixture to withstand full load of inflated air springs at 6.0 Kg/Cm 2
at installation height of air spring (289-294 mm). Till the time suitable
arrangement is not available, leak test may be done at tare pressure.
• Connect the 150-litre reservoir on the under frame to the compressed air
source of pressure 6.0 kg/cm2.
• Allow air into the air springs to a value of 6.0 kg/cm 2/ tare pressure (as
applicable) in the pressure gauge by adjusting the horizontal lever of the
levelling valve and hold it in the same position.
• Close the isolating cock connecting FP pipe with 150-litre reservoir for
pneumatic suspension.
• Test all pipe joints for leakages with soap solution.
• Check all the pressure gauge readings after 60 minutes (during SS-1, SS-2 &
SS-3) or 15 minutes (in case of lifting-lowering except shop schedules). The
pressure drop should be within 1% of the test pressure.
• Attend the leakages in entire air suspension system including air spring,
ASCE & FIBA device.
• After the leakage test, air from pneumatic system shall be drained. Drain plugs
of 60L auxiliary reservoirs in dome of bolsters & drain cock of 150 L pneumatic
suspension system main reservoir shall be fitted back & leakage from these
points shall be checked after inflating pneumatic suspension system again.
• During pneumatic suspension system leakage test, height of air spring beyond
294 mm should not be permitted.
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7. Checks for proper fitment of Air Spring assembly:

• Check air spring vertical symmetry.
• No pre twist in the air spring top plate during fitment.
• No push fitting in air spring holdings.
• Levelled top and base plate of air spring.

8. Problem and their probable reasons:

S. Nature of problem Probable reason
No.
1. Inadequate bogie • Improper installation height (Air spring height).
clearances due to • Improper functioning/ malfunctioning of levelling valve.
secondary • Non uniform/ excess wear in bogie parts.
suspension • Leakage in Air springs, pipeline arrangements, Air
suspension control equipments or FIBA devices.

2. Non- lifting of Air • Low air pressure.

Springs • Heavy air leakage in Air springs,
pipeline arrangements, Air suspension control
equipments and FIBA devices.
• Defective/ choked levelling valve.
• Blockage in air supply.

3. Delayed lifting of air • Perished rubber seat of lower diaphragm in levelling

spring valve.
• Partly choked/ malfunctioning levelling valve.
• Back lash error in levelling valve rotation or loose fitting
of horizontal lever.
• Excessive play/ wearing in ball and socket joint of
levelling valve or in any other connection/ joint.
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9. Periodical inspection of Air suspension system

SCHEDULE INSPECTION ON AIR SPRING, AIR SUSPENSION CONTROL

EQUIPMENT (150L RESERVOIR & DRAIN COCKS, DIRT
COLLECTOR, CHECK VALVE/NRV, LEVELLING VALVE,
INSTALLATION LEVER, DUPLEX CHECK VALVES, ISOLATING
COCKS, HOSES ETC.) & FIBA DEVICE with indicators:

Schedule- • Visual check: General conditions of air springs, Air Suspension

D1 control equipments, and FIBA devices including FIBA indicators,
isolating cocks, flexible hoses, duplex check valve, installation
lever, levelling valve, all air reservoirs, air reservoir drain cock, dirt
collector, check valve/NRV, mounting arrangement & fasteners.
Visually inspect all these items for proper fitment or loosening,
leakage or damages and attend suitably, if required.
• Complete pipeline arrangements of air suspension system
including joints (ferrule joints as well), isolating cocks, flexible pipes
and piping fixing arrangement for Air spring, Air Suspension
Control Equipments (ASCE) and FIBA devices also to be checked
visually for any leakage, damage or loose fittings and to be
repaired accordingly.
• Draining of 150-liter air reservoir of air spring.
• Check the position of isolating cock and drain cock, these should
be on and off position respectively.
• Visually inspect position of Isolating cocks (Open/close), FIBA
resetting knob/button/ring & indicators (Red/Green). It is to be
ensured that FIBA device, ASCE & air springs are set for its
desired function & are not in isolated condition.
• Check functioning of FIBA device as per Annexure ‘A’. (at least 01
coach in a rake during primary maintenance and the same
coach should not be repeated in next trips until all the
coaches in a rake have been attended for functional test).
Proper functioning of Indicators to be ensured at the time of
functionality test of Indicators and FIBA devices.
• Air spring installation height (Air spring height) to be ensured as
289-294 mm. Visually check condition of levelling valve, position of
horizontal lever and verify the inflated/ deflated condition of air
spring.

Schedule – • As in Schedule –D1

D2 • Checking of installation lever with inflated air spring for normal
function, tightening of installation lever nuts, checking of protection
screen nuts, tightening of bracket of all flexible hoses.
• Clean Dirt Collector filter with kerosene & refit.
• Keep the window clean for clear indication and visibility of red/ green
signal of FIBA indicator. Visually check whether the acrylic glass
pane is broken, cracked or having gap, attend accordingly, as water
will penetrate the unit and cause damage in such scenario.
• Check and adjust air spring installation height (Air spring height) to
289-294 mm. If installation height beyond 289-294 mm is observed,
cause for such disturbance to be investigated.
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Schedule – • As in Schedule –D2 &

D3 • Thorough checking of air spring, bulging of bellow, air leakage.
• Removing dust mud & oil deposit if any, on air spring, FIBA and
control equipments.
• Thorough checking of square platform provided on Y- frame of
bogie for any crack and deformation.
• Checking of air spring bottom plate bolts and nuts for loosening.
Loosened bolts to be checked with gauge and if required, new
fasteners as per spec. are to be provided. Whenever fasteners are
opened, new nylock nuts as per air spring specification are to be
provided.
• Measurement of applicable bogie clearances related to air spring.
• Check functioning of FIBA device as per Annexure ‘A’.
• In case of wrong fitment, backlash error or malfunctioning of
levelling valve, suitable action to be taken to rectify the problem.
• Checking of fasteners of FIBA device, protection screen of
installation lever, indicators, duplex check valve, levelling valve for
loosening w.r.t paint marking done by workshop/PU after
tightening. If found loosened, bolt is to be checked & new lock nut
is to be provided.
• Bottom exhaust air filter of levelling valve to be cleaned with
kerosene & refitted. For this, levelling valve is not required to be
dismounted from coach.
• Air suspension pipe leakage check by using soap water particularly
at the joints, including ferrule joints.

SS- I • As in Schedule – D3 and

• Through cleaning & visual check of air spring.
• Whenever air springs are dismounted from bogie in workshop as
per clause 1, leak test of air springs to be done on test bench as
per clause 2 mentioned above. Alternatively, similar leakage test at
6 kg/cm2 on bogie frame with suitable fixture to ensure that height
of air spring during test doesn’t go beyond 294 mm may be
conducted.
• Draining of 60-liter reservoir.
• Inspect the corrosion on top surface of square platform provided on
Y- frame of bogie. Remove the corrosion and paint with primer and
suitable paint.
• Inspect for any water collection in rubber bellow and air spring.
• Inspect air spring fixing holes of square platform provided on Y-
Frame of bogie for elongation, if elongated built them to original dia.
& PCD.
• Air spring bellow should not be painted.
• Mounting & assembly of air spring as per clause 3 of this
document.
• Isolating cocks, NRV, dirt collector, reservoir, drain cock, levelling
valve, installation lever, duplex check valve, flexible hoses fitted in
air suspension to be cleaned & tested for functioning in bogie &
coach.
• Checking & securing arrangement of steel pipeline.
• Secondary vertical & Lateral damper condition should be tested
and replaced with new/tested, if found damaged, defective or leaky.
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• Examine all flexible hoses and replace, if required.

• Thorough checking, cleaning and repair, if required, of all
reservoirs.
• Visually inspect condition of mounting bracket, mounting bolts,
fasteners & FIBA device cover.
• Installation lever adjustment as per clause 4 & 5 mentioned above.
Installation height (Air spring height) to be maintained 294 +0-5 mm.
• Air suspension pipe leakage check by using soap water particularly
at the joints, including ferrule joints. Leakage test of air springs after
mounting on bogie & coach shall be done as per instruction given
in clause 6 mentioned above.
• Perform functional test of FIBA as per Annexure ‘B’.
• All fasteners will be checked & marked for proper tightening.
• Air suspension pipe line modification, if required, shall be done as
advised by PUs/RDSO.

SS II / SS III • As in Schedule – SS I and

• Remove Isolating cocks, NRV, dirt collector, reservoir, drain cock,
levelling valve, installation lever, duplex check valve, flexible hoses
fitted in air suspension & FIBA device circuit and carry out external
cleaning, overhauling and function test as per already issued
maintenance instructions for similar Isolating cocks, NRV, dirt
collector, reservoir, & drain cock and as given in maintenance
manual supplied by respective vendors for levelling valve,
installation lever, & duplex check valve. Replace hoses after 36
months of use, otherwise check the condition of hoses, if found ok
then test at 06 kg/cm2 for strength verification and thorough checking
of leakage. If found ok, re-use the hoses upto remaining period upto
life of 36 months or upto next shop schedule, as per condition.
• Isolating cocks with ferrule type fitting are to be tested for proper
functioning & maintained as per OEM’s guidelines.
• Overhaul FIBA device & Indicators as per maintenance manual
supplied by respective vendors and perform functional test of FIBA
as per Annexure ‘B’ & indicators as follows: -
Testing of Indicator:
i) Leakage test:
Apply a pressure of 06 Kg/Cm 2. There should not be any leakage
if checked with soap water.
ii) Functionality test:
a) Apply a pressure of 0.5 to 0.6 Kg/Cm 2. Red colour should
appear in window of Indicator. Movement of piston of indicator
shall be smooth and steady.
b) Now release the pressure to 0 Kg/Cm2. Green colour should
appear in window of indicator.
c) Piston of indicator should move smoothly and piston should not
be sticky. Indicator shall be air tight and water resistant.
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