Trip Schedule:
Trip schedule attention is given after completion of every trip. It has to be attended both by primary and secondary depots. The coach need not be detached from the rake during trip schedule attention.
Following items are given attention during the trip schedule:
Thorough examination of all under gear parts, lubrication of all moving parts, and complete examination of buffing & draw gear is done for its proper functioning. Ensure easy operation of coupling, proper examination of primary and secondary suspension arrangement, Ensuring there is no leakage in dash pot and maintaining prescribed oil level. Ensure intactness of safety strap and safety loop. Examine the condition of springs and shock absorber. Properly examine suspension link bracket, BSS hangers, pin & hanger blocks. Examine the equalizing stay for its proper securing. Examine the proper securing of bolts & cotters & silent bushes of centre pivot. Ensure the required level of oil in side bearer. Changing of worn out brake blocks & pins and adjust the brake rigging to ensure prescribed piston stroke. Conduct Rake test as per the procedure, and ensure 100 % brake power, testing of alarm chain apparatus.
Wheel profile and thickness should be visually examined and gauged in case they appear to be near condemning limits. Ensure thorough cleaning of coach from inside & outside and disinfection of toilets after cleaning. Examination of all pipe joints & other fittings for leakages & ensure filling of water tank after attention of leakages. Examine for proper opening & closing of vestibule doors and proper fitment of fall plates. Ensure intactness 41 of all amenity & safety items. Prepare DRS card & brake power certificate.
2.5.2 Schedule – A:
Schedule `A' attention is required to be given every month with a tolerance of 3 days at the nominated primary maintenance depot within the normal primary maintenance time on a washing/pit line. A coach need not to be detached from the rake for Schedule `A' examination unless it requires such repairs which cannot be attended to on the washing line or within the prescribed maintenance time on the washing line. Following items are given attention during ‘A’ schedule:
All items of trip schedule
Thorough inspection of brake pipe, feed pipe and branch pipes connecting brake cylinder, distributor valve, Auxiliary reservoir and also hose coupling for leakage and give required attention. Carry out manual brake release test on every coach to ensure proper functioning of release lever of distributor valve. Micro switch of ACP should be tested by electrical staff for proper functioning. Clean Dirt collector filter with kerosene and refit. Test the working of slack adjuster in under frame mounted air brake system. Repair/Replace the defective slack adjuster. Examine loops/ brackets and their securing devices and rectify. Examine for wear of brake hanger pins, brake blocks and brake heads and replace if required. Thorough check and repairs of SLR doors for easy and smooth operation and correct alignment of all wearing parts, loose screws etc. Intensively clean the coaches. Ensure intensive cleaning of lavatory pans and commode with specified cleaning agent and thorough flushing of water tanks. Checking of 42 water pipes, flush pipe, flushing cocks, push cocks, etc., for ease of operation and free flow of water. Thorough dis-infection of all compartments. Thorough inspection and repairs of draw gear and buffers. Oil in hydraulic dash pots should be checked to detect oil leakage from them through defective seals or through vent screws. Add/replenish with specified grade of oil if oil level is below 40 mm in tare condition to ensure better riding comfort. Similarly oil in side bearer baths should be checked, if the oil is below the plug, replenish with specified grade of oil so that wear plate is fully covered by oil. Inspection and repairs of commode chute. Thoroughly check sliding doors and vestibule doors for easy and smooth operation and correct alignment, lubricate all moving parts. Thorough cleaning of chimneys of dining cars, buffet cars, tourist cars and inspection carriages by wire brushes.
2.5.3 Schedule – B:
Schedule `B' is required to be given once in three months with tolerance of 7 days at the nominated primary maintenance depot within the normal time allowed for primary maintenance on a washing line in rake. Coach need not be detached from the rake for purpose of this examination unless it requires such repairs which cannot be attended to on the washing line or within the prescribed maintenance time on the washing line.
The following items of work should be attended.
All items of A schedule
Painting of lavatories from inside. Thorough inspection and repairs of brake gear components. Examination overhauling and testing of alarm chain apparatus. Thorough checking of trough 43 floor, turn under, etc. from underneath for corrosion. Touching up of painted portion, if faded or soiled. Testing of guard van valve.
New Policy (Recommendations) for enhancements of POH/IOH schedules of Coaching Stock.
The revised POH periodicity from 12 to 18 months is applicable to all Mail/Express coaches also. A marking on the coach below return date shall be specified to distinguish 18 months periodicity. The general sequence of Schedule will remain as per existing coaching maintenance manual.
The items of trip schedules; ‘A’ and ‘B’ schedules will remain same. The coach will be given 2 quarterly schedules (B Schedule) before IOH.
The work specified for IOH schedule to mechanical & electrical work in appendix C & D respectively as specified by CAMTECH Pamphlet No CAMTECH 2008 coach POH/1.0 in jan2008 shall be followed.
Technical circulars/pamphlets issued by RDSO with regard to schedules on time to time shall be followed for necessary modification and replacements.
The requirement of bogies for unit exchange shall be planned as per the arising of IOH keeping two bogies spare considering the transportation time from the workshop.
The periodicity of overhauling of DV is changed from 24 months to 18 months (during every POH) Work shop to switch over to PU painting during POH in workshop as advised by RDSO.
2.5.4 Intermediate Overhauling (IOH):
IOH is required to be given every nine months + 30 days at the nominated primary depot. Coaches have to be detached from the rake and taken to Sick line for IOH attention. Coach that is detached for IOH is taken over to the washing line for cleaning, lubrication and minor maintenance.
The following items of work should be attended for newly built/passenger coaches at the depot during IOH;
All items of Schedule `B'
Thorough repairs of running gear duly running out of bogies. After lifting and running out of bogies, the bogies/under frame members and body including trough floors of integral type coaches should be thoroughly examined and all parts of running gears are repaired/ replaced as necessary.
The bogie frames should be particularly checked to detect damage, cracks or deformation and necessary repairs carried out. Where it is not possible for the maintenance depot to give attention to such heavy repairs or are prohibited to be done in the maintenance depots, the bogies should be sent to the shops for carrying out these repairs. The detailed table of maintenance activities to be carried out during IOH schedule is enclosed as appendix-G. Touching up damaged paint on coaches both outside as well as inside. Thorough cleaning and removal of dust, rust, dirt, etc., accumulated at the pillars through the turn under holes, with coir brush and compressed air. Thorough examination and repairs of upholstery, cushions, curtains, etc. Thorough examination and attention of all Doors and window shutters, for safety catches, safety latches, staples and hasps for ease of operation. Thorough 45 checking and repairs of UIC vestibules, their rubber flanges metal frames, doors, fall plate, locking gear, etc., for ease of operation and safety. Thorough checking and attention to all cracks and worn out portions of flooring in the compartments. Engineer (C&W) of Primary Coaching Maintenance Depots should be fully familiar with the vulnerable areas of ICF coaches for corrosion, viz., sole bar at doorways, lavatories and its adjoining areas, corridor portion etc. special concentration shall be given to SLRs which are more prone for corrosion as it is used in transportation of Fish, Salt, etc. For facilitating inspection of sole bars even spaced elongated holes of (215x127 mm) are already provided in the turn under.
Special attention should be given for the following:
Pocket between sole bars and turn under should be thoroughly cleaned through the inspection opening of the sole bars and inspected with the help of torch light or inspection lamps. Drain holes provided in the trough floors should be kept clean and unclogged. During the cleaning of these drain holes any accumulation of water is noticed, the affected area should be very carefully inspected for possible corrosion.
Air brake system maintenance:
Check brake cylinder for loose rocker arm plate on Bogie mounted Brake Cylinder and change if found defective. Brake cylinder should be checked for smooth functioning and prescribed stroke. Defective brake cylinders shall be sent for repairs. Guard’s van valve should be tested for operation. Test BP & FP air pressure gauges with master gauge and replace if found defective (all the gauges to be calibrated once in 6 months).A set of two master gauges should be kept for this purpose at every Primary 46 Maintenance Depot and each master gauge should be sent one after the other to the workshops for testing, repairs and calibration. Thoroughly clean filter of Dirt collector in kerosene or replace on condition basis. Check working of PEASD & PEAV by hearing the hissing sound of exhaust air. After resetting with the help of key the exhaust of air should stop. Replace the defective PEASD/PEAV. Conduct Single car test of the coach with Single car test rig and record the parameters in the prescribed pro-forma. The date of intermediate lifting should then be stencilled at the appropriate place in schedule chart on the end panel
Note: Intermediate Overhauling of Shatabdi / Rajdhani Exp. Coaches are to be attended in nominated workshops only.
Intermediate overhauling of newly built coaches are to be attended after 12 months in the depot duly replacing the wheels with repaired/UT tested wheels from work shop
Lifting of the Body from the bogie:
The coach body shall be lifted by using;
a) 4 no. of Mechanical Jacks (capacity of 25 T each) OR
b) 4 no. of Hydraulic jacks (capacity of 20 Ton each) OR
c) 2 no. of Electrical Operated Travelling Crane (capacity of 20 T/25 T each) OR
d) 4 no. of Whiting jacks (capacity of 20/25 T each)
Other Tools required:- Trestles, Complete set of Spanners, Complete set of Gas cutting & welding equipment, Different types of hammers, Wooden Wedges & Packing and Tool kit
Items to be disconnected before lifting of the body:
Remove of centre pivot cotter [If lifting is being done by E.O.T cranes or whiting jacks]. Unscrew and remove centre pivot studs [If lifting is being done be mechanical/hydraulic jacks], unscrew air vent screw of dash pot. Disconnect Dynamo belt, S.A.B pull rod, lateral shock absorber if connected, axle box safety loops etc.
Remove commode chute and dummy carrier if it is infringing, foot board if required.
Insert required thickness of wooden packing between upper portion of bolster & Bogie frame.
Following are the causes of low buffer height in ICF coaches;
Wear of wheel. Loss in stiffness of coil springs provided in primary and secondary suspension. Wear in Bronze wearing piece and wear plate of side bearer. Wear on link brackets, stone & pin provided on secondary suspension arrangement.
Procedure for buffer height adjustment in ICF coaches:
To achieve required buffer height standard size of wooden packing pieces are used which are provided below the coil springs of primary suspension as given under.
New Wheel dia :- 915 mm
Condemning: - Solid Wheel: 825 mm.
RPC-4 Revision-Jan 2007 (No. 95/M/C/141/1)
Sub: - Revised maintenance pattern of coaching train- running up to 3500 km in round trip with terminal attention at the other ends.
Note: - Internal cleaning, passenger amenity attention and watering may be done at platform line or nominated stabling line provided stipulated facilities are available at such line, in case the rake is stabled in yard for more than 6 hrs, positive safety arrangements should be made for the rake and in case the security is considered inadequate, the rake should be taken to pit line for attention to under gear as given under column (4) above.
FACILITIES REQUIRED FOR MAINTENANCE OF 24 COACH TRAINS
(Railway Bd.'s letter no. 98/M(C)/137/19 Pt. I dt. 28.7.99 & dt. 05.05.2000)
Infra structural Requirements:
24 coach length fully equipped pit line. High pressure jet cleaning pipeline with plant for cleaning in pit line at primary depot. Mechanized external cleaning is preferable. Water hydrants for 24 coach length at en-route watering stations with 20 minutes stoppage at nominated stations. Availability of the prescribed air brake maintenance and testing equipment.
Coach Design related Requirements:
Air brake with twin pipe graduated release system
Only enhanced capacity draw gear and screw coupling to RDSO sketch No. 79061 and 79067 are to be provided on the rake.
Maintenance Practices and system related requirements:
The integrity of the rakes to be maintained. Primary maintenance of the rake should be done in one hook without splitting. Minimum 6 hours’ time to be given in the pit for primary maintenance. Leakage rate in air brake system to be maintained within prescribed limits by using rake test rig. Provision of proportionate brake system on the locomotive in good working order. Provision of audio visual alarm system on the locomotive.
In case of double-headed diesel locos maximum traction motor current will be restricted to 650 Amperes and in case of double headed WAP1/WAP3 electric locos, the traction motor 54 current limit will be 750 Amperes as prescribed in RDSO 's instructions for operation of main line air brake trains - C-9408.
Operational requirements:
Communication between driver and guard should be provided through suitable means. Ensure no gap between coach buffers after tightening the coupler. No additional coach attachment beyond 24 coaches will be permissible.
Note: As per Railway Board Instruction now one occupied saloon & one parcel van can be attached with 24 coaches rake.
