Failures of Control Arm

of LHB Coaches

Carriage Directorate, RDSO

 Control Arm of LHB coaches

■ Articulated control arm, nested

helical coil spring, rubber disc
and vertical damper.
■ Part of the load on primary
suspension absorbed by elastic
connection between control
arm and bogie frame.
■ In case of failure of
suspension, rest on bump stop
so as to avoid any possibility of
tilting during run
■ Flexible guidance
■ Control Arm is fitted with twin
layer elastic joint (Rubber Joint)
with bogie frame.
Connection of Control Arm Assembly
 Control arm position
■ FIAT Bogie (Wheel set with control arm and primary springs removed)

Primary Vertical Damper

Details of Primary Suspension in FIAT Bogie
Mounting the lower parts of Control Arm
 Role of Control Arm Assembly

S. No. Control Arm Function

Assembly

1. Upper Part Cover the CTRB and Transfer the uniform Load on
CTRB.
2. Lower Part Cover the CTRB.

3. Control Arm Wheel guiding. Transmission of tractive, braking &

Bush lateral forces and part of vertical forces,
Noise & vibration isolation.
 Working of Control Arm
■ To provide axle guidance through a resilient bush.
■ Force transmission from body to axle in following ways:

■ Vertical forces:
BODY-SECONDARY SPRINGS - BOGIE FRAME – PRIMARY SPRINGS/BALL
JOINT CONTROL ARM - AXLE.

■ Lateral forces:
BODY – SECONDARY .SPRINGS - BOGIE FRAME - BALL JOINT CONTROL
ARM- AXLES

■ Longitudinal traction effort and braking power:

BODY-TRACTION CENTRE -TRACTION RODS -TRACTION LEVER-BOGIE
FRAME-CONTROL ARM-AXLES
 RDSO Audits done at PUs/Zonal Railways
Date of Audit ZRs/PUs Place of Audit Deficiencies
Communicated on
March 2024 NFR DBRG 18.03.2024
Aug 2023 ICF ICF 01.11.2023
Aug 2023 SR PER 01.11.2023
July 2023 SER PDPK 31.07.2023
July 2023 SER SRC 31.07.2023
July 2023 SER KGPW 31.07.2023
Feb 2023 ER LLH 31.03.2023
June 2022 ECR HRT 09.06.2022
Feb 2021 CR PR 24.02.2021
Feb 2021 CR MTN 24.02.2021
Dec 2020 ER LLHM 07.01.2021
Jan 2019 NER GKP 11.02.2019
 Major Deficiencies observed during Audits
S. No Deficiency

1 Improper Storage

2 Control Arms not

procured in Pairs
 Major Deficiencies observed during Audits
S. No Deficiency
3 Control arm set
found with different
manufacturers,
which came for SS-1
schedule

4 Torque wrenches
found due for
calibration
 Major deficiencies noticed during audits
5. Poor workmanship during wheel set fitment.

• Foreign particle
sticks on molycoat
painted control
arm during fitment
of wheelset.
Foreign particle
impression on Foreign Particle • Bearing fails due
control arm
to pinching with
foreign particle
with outer ring.
 Major deficiencies noticed during audits
6. Breakage of Control Arm Lug due to poor Material or Uneven Matching of
Control Arms or Excessive Vibrational Loads due to Wheel Defects or Failure
of Primary Suspension

Breakage of Control Arm Lug

 Major deficiencies noticed during audits
7. Instruments for bore dia. measurement (inside micrometer with least count of
0.001 mm) and parallelism checking tool of control arms were not available.

8. Security plate must be bent on face of head of hexagonal bolt of control arm.
 Preventive measures issued by RDSO
Preventive instructions regarding failure of control arm in LHB coaches were issued
on 03.04.2018, reiterated on 15.01.2020 and updated instructions issued vide letter
No. SV.FIAT dated 14.03.2024. Details are as under:
Fasteners Used For Control Arms:
S. Name of Make Property Size Tighteni Photographs
N fasteners Clause ng
. Torque
1. Control TVS, TUFF, 10.9 M16x70 170 Nm
arm DFL & M16x90
housing UNBRAKO
Bolt/
Screw
2. Prevailing TVS, TUFF, 10 M16 170 Nm
type Nut DFL &
UNBRAKO
 Preventive measures issued by RDSO
■ Fasteners Used For Control Arms …..Continued….
S. Name of Make Property Size Tightening Photographs
N. fasteners Clause Torque

3. Fasteners for TVS, TUFF, 10.9 M20X100 265 Nm

control arm DFL &
silent block UNBRAKO
■ with control
arm support
bracket

4 Fasteners for TVS, TUFF, 10.9 M16X45 170 Nm

axle box front DFL &
cover UNBRAKO

Note:Thread sealant, LOCTITE 572/RITE LOKPS 65 of 3M/DARBOND 2572/MYTLOK 172R shall be applied on bolts
(screws) for control arm silent block, axle box cover, oiler ring of earthing device, phonic wheel and security disc.
 Preventive measures issued by RDSO
SN. INSTRUCTIONS RELATED PHOTOGRAPHS

5. Disc lock washers shall be provided in

upper-lower control arm fastening
systems.

6. The fasteners should be tightened to a

torque with a calibrated torque
wrench.

7. Paint mark for indication of loosening

of bolt or nut. Fasteners to be checked
for proper tightening in D3 schedule
and paint marking to be renewed. If
paint marking lost, the torque be
checked and a fresh paint marking to
be made.
 Preventive measures issued by RDSO
8. The control arm to be replaced as a set only even if same is being changed in
coaching depot/sick line.
 Preventive measures issued by RDSO
SN INSTRUCTIONS RELATED PHOTOGRAPHS

9. Damaged rubber silent bushes of control arm not

allowed.

10. Corrective action for coaches having WCM -

(OMRS)/WILD alerts from last shop schedule.

11. The orientation and grouping of inner and outer

primary springs to be ensured as per CMI no.
RDSO/2017/CG/CMI-01 issued in January 2017.

12. The dampers to be checked visually in D1/D2/D3

schedules and tested during SS1 schedule on calibrated
LHB damper testing machines.
 Preventive measures issued by RDSO
Whenever control arm is opened at Workshops or sicklines, following must be
ensured:
SN INSTRUCTIONS RELATED PHOTOGRAPHS

A Wear of control arm as per Para

4.3.2.12.1 of CAMTECH LHB
Maintenance Manual. Control arm
having diameter more than 230.312
mm must be rejected.

B Control arm bearing surface should

be coated with rust preventive
lubricants as per Para 4.3.2.12.1 &
4.6.6 of CAMTECH LHB Maintenance
Manual (issue of 2022-23).
 Preventive measures issued by RDSO
SN INSTRUCTIONS RELATED PHOTOGRAPHS

C Fitment and linkage of bogie

frame & control arm with wheel
sets should be done as per Para
4.6.6 of CAMTECH LHB
Maintenance Manual (issue of
2022-23).

D Bolts should be checked with ring

gauges. Threads of pin for fitting
control arm silent block & control
arm for fitting axle box cover to
be checked with plug gauges.
 Analysis of Control arm cases (2023-24)
 Total Cases – 75 Nos.(60 Punctuality Loss + 15 En-route Detachment)
 Punctuality Loss cases: 60 Nos

Depots having 3 or more cases Own Railways having 5 or more cases

KYQ (05 Nos.) NED (04 Nos.) NFR (15 Nos.)

APDJ (03 Nos.) HYB (03 Nos.) SCR (10 Nos.)
GHY (03 Nos.) PUNE (03 Nos.) NR (06 Nos.)
SC(03 Nos.) ER(05 Nos.)
ECR(05 Nos.)

 Total Cases of en-route detachment– 15 Nos

Depots having equal & more than 3 cases Own Railways wise analysis
GHY (03 Nos.) NFR (06 Nos.)
 Analysis of Control arm failure cases (2023-24)
En-route
Puntuality Loss Detachment Total/1000
Railway Population Cases Cases Total cases population
NFR 2182 15 6 21 9.6
SCR 1579 10 0 10 6.3
NR 3549 6 1 7 2.0
ER 2060 5 0 5 2.4
ECR 2463 5 2 7 2.8
CR 2450 4 0 4 1.6
WR 3813 4 0 4 1.0
NER 1832 3 0 3 1.6
WCR 890 2 0 2 2.2
SER 2033 2 1 3 1.5
SR 2400 1 2 3 1.3
ECOR 2165 1 1 2 0.9
SWR 2035 1 1 2 1.0
NCR 713 1 0 1 1.4
SECR 646 0 1 1 1.5
NWR 1435 0 0 0 0.0
 Analysis of Control arm failure data (2023-24)
Details of control arm failure cases having more than 09 months life:
Date of Coach Rly. Type W/sh/ PM Date IOH Life
failure No. PU Depot
26.05.23 181631 SR LWCBAC GOCW NCJ 20.01.22 - 16M 06D
07.06.23 191236 SECR LWSCN PRLW DURG 21.03.22 - 14M 17D
- 12M 11D
09.09.23 194251 NR LWSCN AMVW BE 29.08.22

08.10.23 216662 SER LS5 KGPW SRC 25.01.22 25.11.22 10M 13D
10.10.23 154135 ECR LWSCN LLHW DHN 03.03.21 28.12.22 09M 12
11.10.23 141020 ECR LWACCN LLHW DHN 30.04.21 26.12.22 09M 15D
23.12.23 171612 SWR LWACCN MYSW VSG 09.04.21 09.12.22 12M 14D
28.12.23 195640 NFR LWSCN NBQW SCL 28.10.22 - 14M
22.02.23 12M 3D
19.02.24 197993 NFR LWSCNA DBWS DBRG -

14.01.24 197676 NFR LWSCN NBQW GHY 22.11.22 - 13M23D

11.03.24 191175 NFR LWSCN1 DBSW SCL 19.10.21 01.06.23 9M10D
 Analysis of Control arm failure data (2023-24)
Details of control arm failure cases having less than 09 months life:

Date of Coach Rly. Type W/Sh/ PM Date IOH Life

failure No. PU Depot

27.04.23 204239 ECoR LWSCN MCSW VSKP 12.02.21 09.09.22 7M18D

18.05.23 215834 NFR LWSCN MCF GHY 03/21 22.10.22 6M26D

06.10.23 213073 SR LWACCW KCVL KCVL 17.12.21 20.04.23 5M16D

07.11.23 217991 NFR LWSCN NBQW GHY 22.01.22 27.10.23 11D

 Investigation of Coach No. 204239 ECoR LWSCN
Coach Built : MCF, Date of Commissioning: 12.02.2021, SS-I: 09.09.2022, Return Date:
02.2024, Date of failure: 27.04.2023.
Observations:
• L1 Wheel spread about 250 mm, 38 mm wheel shelling & 2 mm depth. Multiple
shelling in spread area. Minor grease oozing.
• R8 wheel found minor spread near about 200 mm, with minor shelling marks.
• Hitting marks visible on lower portion of lower control arm near primary damper
eye.
• The case of lower control arm failure may occur due to wheel shelling and spread
wheel. One OMRS alert with peak load of 238.05 KN was observed on 24.04.23 i.e. 4
days before failure.
• After investigation, M&C Directorate/RDSO has concluded that “Metallurgical
property of control arm does not conform to the relevant specification in terms of
lower impact strength. The failure of control arm from the sharp edges of eye hole
may be attributable to fracture initiation in a sudden crystalline manner from the
rough machining marks which acted as stress raiser during service”.
• Action taken:
• ICF has been requested for quality audit of the firm, who supplied the defective
control arm for verification of quality of product.
 Investigation of Coach No. 204239 ECoR LWSCN
Photographs of failed Control Arm of Coach No. 204239 ECoR LWSCN:
Investigation of Coach No. 204239 ECoR LWSCN
 Investigation of Coach No. 215834 NFR LWSCN

Coach Built : MCF, Date of Manufacturing: 25.03.2021, SS-I: GHY-

23.10.2022, Return Date: 07.2024, Date of failure: 18.05.2023.

Observations:
• R7 wheel found numbers of shelling and pressed marks on near about
250 mm arc area.
• TTLW Right side primary metal bump stop found broken.
• Control Arm lug was broken.
• Primary vertical damper was leaky.
• Wheel shelling was found in both wheels of same axle.
• Reason of failure found due to wheel shelling hammering effect
generated in primary suspension which results in breakage of control
arm lug and after effect of this breakage of metal top & primary inner
spring.
 Investigation of Coach No. 215834 NFR LWSCN
Photographs of failed Control Arm of Coach No. 215834 NFR LWSCN:
 Investigation of Coach No. 191236 CR LWSCN

Coach Built : MCF, Date of Manufacturing: 2019, SS-II: MTN/CR-

07.03.2022, Return Date: 04.2025, Date of failure: 08.06.2023.
Observations:
• Lower portion of control arm (L1 side) found broken and missing
and its respective damper was also found missing.
• Wheel (L1) was found with spread rim and have few wheel shelling
marks.
• Coloring of torqueing for nuts & bolts of bogie control arm were not
found in entire coach.
• Revised WSP wiring and modified junction boxes with Mil-grade
connectors were not found in the coach.
• The upper portion of failed control arm (L1 side) was found with
‘M/s PACL M1’ make while its lower portion is ‘M/s SG Kumar’
make.
 Investigation of Coach No. 191236 CR LWSCN
Photographs of failed Control Arm of Coach No. 191236 CR LWSCN:
 Investigation of Coach No. 197993 NFR LWSCNA
Coach Built : MCF, Date of Manufacturing: 22.01.2020, SS-II: DBWS-22.02.2023,
Return Date: 01.04.2026, Date of failure: 19.02.2024.
Observations:
• Axle box cover (L4 side) along-with earthing device assembly and eye piece of
oiler was deficient.
• All four bolts of axle box front cover were deficient and threads of control arm
worked out.
• Inner side lug of upper control arm found broken and lower control arm found
cracked in same location.
• Mounting hole of upper control arm lug elongated/worked out and bolt head
was embedded inside the lug.
• A clear gap of approx. 10 mm was observed in between upper and lower control
arm at front position.
• Make of upper & lower control arm was different. Upper part was PTC make &
bottom was RV Casting make.
• Wheels were checked with defect gauge and rim flow found in affected axle box
side wheel.
 Investigation of Coach No. 197993 NFR LWSCNA

• Action taken:
• The broken parts of control arm has been sent MCF/RBL for 3 D
dimensional measurement.
• The affected control arm (upper and lower) is to be sent to M&C
Directorate/RDSO for detailed metallurgical investigation and root cause
analysis..
Investigation of Coach No. 197993 NFR LWSCNA
 Investigation of Coach No. 194251 NR LWSCN
Coach Built : N/A, Date of Manufacturing: 22.01.2020, SS-II: AMV-31.08.2022,
Return Date: 10/2025, Date of failure: 09.09.2023.
Observations:
• Both wheel discs (L4 & R5) having shelling/pitted marks. On L4 side, grease
oozing also found.
• OMRS History of Coach- Data taken from CMM:
 Investigation of Coach No. 194251 NR LWSCN
• R5 Primary vertical damper found in damaged condition. L 4 primary vertical damper
visually found ok. But, replaced for load testing at AIIW. Make of damper- R5-KBIL
09/1969084, L4-SABOHEMA Automotives Pvt. Ltd. 01.09.22 62721.
• Cause of failure was due to defective speed sensor cable wheel involved in wheel
shelling/wheel pitted. Due to continuous hammering action of wheel, control arm &
other component failed.
Photographs of failed Control Arm of Coach No. 191236 NR LWSCN:
 Investigation of Coach No. 194251 NR LWSCN
• Photographs of failed Control Arm of Coach No. 191236 NR LWSCN:
 50
100
150
250

200
26-04-2023
29-04-2023
02-05-2023
05-05-2023
08-05-2023
11-05-2023
14-05-2023
17-05-2023
20-05-2023
23-05-2023
26-05-2023
29-05-2023
01-06-2023
07-06-2023
10-06-2023
13-06-2023
16-06-2023
19-06-2023
22-06-2023
25-06-2023
28-06-2023
01-07-2023
04-07-2023
07-07-2023
10-07-2023
19-07-2023
Peak Wheel Impact Force (kN)

22-07-2023
25-07-2023
28-07-2023
31-07-2023
03-08-2023
Coach No. NR 194251

06-08-2023
09-08-2023
12-08-2023
15-08-2023
18-08-2023
21-08-2023
24-08-2023
27-08-2023
30-08-2023
09.09.2023
Failure Date-

02-09-2023
05-09-2023
08-09-2023
 0.7
1.2
1.7
2.2
2.7
3.2
3.7
4.2
4.7
5.2
26-04-2023
29-04-2023
02-05-2023
05-05-2023
08-05-2023
11-05-2023
14-05-2023
17-05-2023
20-05-2023
23-05-2023
26-05-2023
29-05-2023
01-06-2023
07-06-2023
10-06-2023
13-06-2023
16-06-2023
19-06-2023
22-06-2023
25-06-2023
28-06-2023
01-07-2023
04-07-2023
07-07-2023
Wheel Impact Ratio

10-07-2023
19-07-2023
22-07-2023
25-07-2023
28-07-2023
31-07-2023
03-08-2023
Coach No. NR 194251

06-08-2023
09-08-2023
12-08-2023
15-08-2023
18-08-2023
21-08-2023
24-08-2023
27-08-2023
30-08-2023
09.09.2023
Failure Date-

02-09-2023
05-09-2023
08-09-2023
 Investigation of Coach No. 203840 SC LWS/LS-5
Coach Built : ICF, Date of Manufacturing: 2021, SS-I: NED-11.11.2022, Return Date:
04.2024, Date of failure: 12.03.2024.
Observations:
 Investigation of Coach No. 203840 SC LWS/LS-5

Load Value No’s of Peak Wheel Impact Load

Alerts
200-250 18
250-300 6
300-350 1
Total 25

■ All wheel disc of the Coach have had alerts more than 2.5 for ILF &
200 KN for peak wheel impact load.
 Action Plan to prevent failures of Control Arm
• ZRs & PUs to conduct audit and submit audit reports for compliance of RDSO
instructions issued vide letter No. SV.FIAT dated 14.03.2024.
• A special drive should be launched at depots for checking of make, property
clause, type & torqueing of fasteners of control arm, axle box front covers &
control arm silent blocks.
• Audit of control arm (with specific attention to finishing operation in pair) &
control arm silent block vendors by RCF & ICF.
• PUs to take quality control action against registered vendors of control arm
& control arm silent block having sub-standard performance record.
• Compliance of Instructions on re-profiling of wheels of LHB coaches issued
vide letter No. MC/WA/Failure dated 20.11.2023.
• Protocols for WILD & WCM of OMRS alerts reiterated vide letter No. SV.FIAT
Spring dated 07.07.2023 along with format for investigation. Compliance
with root cause identification to be ensured.
• Cause wise, make wise & age wise analysis of failures of control arm & silent
block shall be submitted by Railway as per RDSO format for further action by
RCF & RDSO.
 Action Plan to prevent failures of Control Arm
• All metallic prevailing torque type nut for control arm upper & lower
is suitable for reuse for approx. 5 times. Monitoring number of reuse
very difficult. Nyloc insert prevailing torque type locking nut as must
change item whenever unfastened may be considered.
• Disc lock washer to be critically inspected before reuse for wear &
damage of cams & serrations. Based on feedback, if damage usually
appears, it may be made must change item whenever unfastened.
• Whenever any control arm failure case is observed, history of OMRS
alert may be linked on CMM as well as Fleet1 websites. Corrective
action including wheel profiling, if required, to be taken. Coil springs,
control arms, dampers & rubber- metal parts of same axle must be
sent to workshops before reuse. Tested parts may be provided in
affected axle.
Impact & Alerts from WCM for other Coaches
involved in Control Arm Failures
 100
150
200
250
300
12-07-2023

24-07-2023

05-08-2023

11-08-2023

17-08-2023

23-08-2023

29-08-2023
Peak Wheel Impact Force (kN)

04-09-2023
Coach No. ECR 154135

17-09-2023

29-09-2023
Date-
Failure

05-10-2023
10.10.2023
 0.7
1.2
1.7
2.2
2.7
3.2
3.7
4.2
12-07-2023

24-07-2023

05-08-2023

11-08-2023

17-08-2023

23-08-2023
Wheel Impact Ratio

29-08-2023

04-09-2023
Coach No. ECR 154135

17-09-2023

29-09-2023
Date-

05-10-2023
Failure

10.10.2023
 50
100
150
200
250
30-05-2023

11-06-2023

17-06-2023

02-07-2023

05-07-2023

11-07-2023

14-07-2023

20-07-2023

26-07-2023

09-08-2023

14-08-2023
Peak Wheel Impact Force (kN)

19-08-2023

29-08-2023

03-09-2023
Coach No. SER 216662

08-09-2023

13-09-2023

18-09-2023
08.10.2023
Failure Date-

26-09-2023

01-10-2023
 0.7
1.2
1.7
2.2
2.7
3.2
3.7
4.2
4.7
5.2
30-05-2023

11-06-2023

17-06-2023

02-07-2023

05-07-2023

11-07-2023

14-07-2023

20-07-2023

26-07-2023

09-08-2023

14-08-2023
Wheel Impact Ratio

19-08-2023

29-08-2023

03-09-2023
Coach No. SER 216662

08-09-2023

13-09-2023

18-09-2023
08.10.2023
Failure Date-

26-09-2023

01-10-2023
 100
150
200
250

50
26-04-2023

02-05-2023

20-05-2023

01-06-2023

19-06-2023

25-06-2023

01-09-2023
Peak Wheel Impact Force (kN)

07-09-2023

13-09-2023
Coach No. SR 213073

19-09-2023

25-09-2023
06.10.2023
Failure Date-

01-10-2023
 0.7
1.7
2.7
4.7
5.7
6.7

3.7
26-04-2023

02-05-2023

20-05-2023

01-06-2023

19-06-2023

25-06-2023

01-09-2023
Wheel Impact Ratio

07-09-2023

13-09-2023
Coach No. SR 213073

19-09-2023
06.10.2023
Failure Date-

25-09-2023

01-10-2023
 50
100
150
200
250
300
350
21-08-2022

25-08-2022

04-09-2022

02-10-2022

06-10-2022

13-11-2022

27-11-2022

01-12-2022

12-01-2023

25-01-2023

02-02-2023
Peak Wheel Impact Force (kN)

03-03-2023
Coach No.SR 181631

15-03-2023

19-03-2023

23-03-2023

14-04-2023

30-04-2023
26.05.2023
Failure Date-

04-05-2023
 1
2
3
4
5
6
21-08-2022

25-08-2022

04-09-2022

02-10-2022

06-10-2022

13-11-2022

27-11-2022

01-12-2022

12-01-2023

25-01-2023

02-02-2023
Wheel Impact Ratio

03-03-2023
Coach No.SR 181631

15-03-2023

19-03-2023

23-03-2023

14-04-2023

30-04-2023
26.05.2023
Failure Date-

04-05-2023
 50
100
150
200
250
18-04-2023

22-04-2023

13-05-2023

20-06-2023

04-07-2023

08-07-2023

11-07-2023

25-07-2023

25-07-2023

29-07-2023

07-08-2023

26-10-2023
Peak Wheel Impact Force (kN)

31-10-2023
Coach No.SWR 171612

05-11-2023

10-11-2023

10-11-2023

15-11-2023
23.12.2023
Failure Date-

19-12-2023
 2
3
4
5

1
18-04-2023

22-04-2023

13-05-2023

20-06-2023

04-07-2023

08-07-2023

11-07-2023
Coach

25-07-2023

25-07-2023

29-07-2023
CoachNo.SWR

07-08-2023
Wheel Impact Ratio

26-10-2023
No.SR 181631

31-10-2023
171612

05-11-2023

10-11-2023

10-11-2023

15-11-2023
23.12.2023
Failure Date-

19-12-2023
 50
100
150
200
250
02-08-2023

14-08-2023

26-08-2023

01-09-2023

07-09-2023

13-09-2023
Peak Wheel Impact Force (kN)

19-09-2023
Coach No.ECR 141020

25-09-2023

01-10-2023

07-10-2023
11.10.2023
Failure Date-
 2
3
4
5
6
7

1
02-08-2023

14-08-2023

26-08-2023

01-09-2023

07-09-2023

13-09-2023
Wheel Impact Ratio

19-09-2023
Coach No.ECR 141020

25-09-2023

01-10-2023

07-10-2023
11.10.2023
Failure Date-
Thanks