quality assurance directorate (mechanical) rdso...

of 27 Quality Audit of Coaching Depots (Depot Code, Rly) Month &Year

Quality Assurance Directorate (Mechanical) RDSO Lucknow

Check sheet for Quality audit of coaching depot Primary maintenance attention and sick line attention

(Based on CAMTECH Maintenance Manual for BG coaches and Railway Board / RDSO’s guidelines)

SN Item Clause Observation

1. Periodicity of periodic overhauls (POH) in designated workshops is being followed.

103 of Chg. Manual

Table 1.1 and correction slip 5 issued in 2008

RB letter no. 2007/M(C)/141/1 dtd 26.09.08

2. Maintenance schedules to be followed in coaching depots

To maintain coaching stock in good condition, the following maintenance schedules are prescribed to be carried out in carriage depots on divisions where rake has been based for primary maintenance.

112(a) of Chg. Manual and Correction slip 5 for coaching maintenance manual issued in 2008

RB letter no. 2007/M(C)/141/1 dtd 26.09.08

3. Schedule A - Monthly (1 month ± 3 days) in rake

4. Schedule B -Quarterly (3 month ± 7 days) in rake

5. IOH attention - detach coaches

Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Shatabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9 months in depot

Passenger at interval of 9 months in depot

Other OCVs at interval of 12 months in depot

Tolerance for IOH may be kept as + 30/-0 days.

Maintenance activities to be carried out during schedules should be as per Appendix-F & G.

For IOH attention of newly built coaches,


guidelines as circulated vide RB’s letter no. 2007/M (C)/141/1 dtd 06.08.09

6. Primary maintenance schedules are required to be carried out by the base depots to which coaches are allotted. In emergency, when due to any reason coaches cannot reach their base depots and primary maintenance schedules become due, A & B schedules should be undertaken by the carriage depots where the coaches are available. ‘C’ schedule should be done at base depot.

112(b) of Chg.Manual

7. Examination of originating trains: 107 a of Chg. Manual

7.1 All trains must be examined by the mechanical train examining staff before dispatch to ensure all coaches are in fit condition without rejectable defects.

107 a (i) of Chg. Manual

8. Terminating Examination of Passenger Trains – Rolling in examination.

107 b of Chg. Manual

8.1 Site shall provide unobstructed view of under gear from both sides.

107 (b)(i)(a) of Chg. Manual

8.2 Should have adequate space for fixing the lighting arrangement and for staff

107 (b)(i)(d) of Chg. Manual

8.3 As the train passes the nominated point, C&W staff should watch out vigilantly for loose/hanging/broken under gear parts of the coaches, any unusual sound coming from the coaches or any other abnormality in the coaches.

107(b)(iv) of Chg. Manual

8.4 Temperature of the axle boxes should be measured preferably with the help of the electronic temperature measuring device.

107(b)(vi) of Chg. Manual

9. Revised maintenance pattern for coaching trains circulated vide Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

9.1 While permitting introduction of round trip primary pattern of maintenance on coaching trains, approved mandatory condition at primary end and other end as detailed in Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 is followed.

Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

9.1.1 Primary End


i) The brake gearing should be properly adjusted including the slack adjuster ‘A’ dimension & the brake cylinder stroke to ensure 100% brake power

-do-

ii) Brake blocks should be changed in bogie sets only

-do-

iii) All missing passenger amenity fittings must be replaced and the rake must be turned out as ‘Zero-Missing-Fitting’ rake.

-do-

iv) Intensive cleaning of coach toilets and lavatory.

-do-

v) Clear maintenance time of 6 hours on the pit as per train schedule.

-do-

vi) Provision of proper washing cum maintenance pit line facility with adequate testing equipment and high pressure jet cleaning plant at primary end.

-do-

vii) Adequate gang strength with proper supervision

-do-

9.1.2 The Other End

i) Whenever the lie-over is more than 2 hours at the platform or the rake is stabled in the yard, the rake should be locked and positive security should be provided

-do-

ii) The minimum infrastructure to be provided at the platforms from where trains are returned without secondary maintenance should be is available

-do-

iii) A joint safety certificate covering each clause of mandatory conditions will be issued by mechanical and operating branches at divisional level prior to changing over any train to revised coaching maintenance pattern.

-do-

10. Rake maintenance link has provision of maintenance time (pit attention) of 6 hrs at primary end to enable intensive attention.

108 of Chg. Manual and Policy circular no. 4

11. Internal cleaning, Passenger amenity attention and watering is done at platform line or nominated stabling line provided

108 of Chg. Manual Table 1.8


stipulated facilities are available at such line is followed

12. Washing and cleaning of coaches 109 of Chg. Manual

12.1 Use recommended solutions for cleaning as per RDSO specification No. M&C/PCN/101/2001 or use cleaning agents approved by CME of the Railway

109 of Chg. Manual

12.2 It should be ensured that the rake/coach is protected with proper board/signal for safety of the staff working on washing/cleaning job to prevent movement/disturbance in the activity. Scotch blocks with locking arrangement should protect lines and keys should be kept with Engineer (C&W) till the time rake is under maintenance

109 (b)(i) of Chg. Manual

12.3 External cleaning /washing:

Check that guidelines as detailed in CAMTECH manual are being followed.

109 (b) of Chg. Manual

12.4 Cleaning of Toilet:


109 (c) of Chg. Manual

12.5 Internal cleaning of upper class AC and sleeper coaches:


109 (d) of Chg. Manual

12.6 Internal cleaning of GS, SLR:


109(e) of Chg. Manual

12.7 Cleaning of buffers and screw couplings 109(f) of Chg. Manual

(i) Buffer plungers should be scrubbed with a scraper to remove dirt and muck. Thereafter, they should be wiped clean with cleaning oil and rubbed with coir rope.

109(f)(i) of Chg. Manual

(ii) Screw coupling threads should be cleaned with wire brush to remove all dirt and dust. Thereafter, it should be cleaned and given a light coat of oil. Oiling should be done on slack adjuster also

109(f)(ii) of Chg. Manual

13. Conditions required for maintenance of 24 coach trains (Railway Board’s letter No.98/M(C)/137/19 Pt. I dt.28.7.99 & 5.5.2000

110 of Chg. Manual

13.1 Infrastructural requirements 110(a) of Chg. Manual

(i) 24 coach length fully equipped pit line. 110(a)(i) of Chg. Manual


(ii) High pressure jet cleaning pipeline with plant for cleaning at primary pit line. Mechanized external cleaning is preferable

110(a)(ii) of Chg. Manual

(iii) Water hydrants for 24 coach length at en route watering stations with 20 minutes stoppage at nominated stations

110(a)(iii) of Chg. Manual

(iv) Availability of the prescribed air brake maintenance and testing equipment

110(a)(iv) of Chg. Manual

13.2 Coach Design related requirements 110(b) of Chg. Manual

(i) Air brake with twin pipe graduated release system

110(b)(i) of Chg. Manual

(ii) Only enhanced capacity draw gear and screw coupling to RDSO sketch No. 79061 and 79067 are to be provided on the rake

110(b)(ii) of Chg. Manual

13.3 Maintenance practices and system related requirements

110(c) of Chg. Manual

i) The integrity of the rakes to be maintained. 110(c)(i) of Chg. Manual

ii) Primary maintenance of the rake should be done in one hook without splitting

110(c)(ii) of Chg. Manual

iii) Minimum maintenance time of 6 hours on the pit during primary maintenance

110(c)(iii) of Chg. Manual

iv) It is mandatory to provide secondary maintenance to all trains augmented to 24 coaches (RPC 4 revised and permit Round trip attention with approval of CME)

110(c)(iv) of Chg. Manual

v) Trains leakage rate to be maintained within prescribed limits by using rake test rig.

110(c)(v) of Chg. Manual

vi) Provision of proportionate brake system on the locomotive in good working order

110(c)(vi) of Chg. Manual

vii) Provision of audio visual alarm system on the locomotive

110(c)(vii) of Chg. Manual

14. Fire extinguishers should be checked every three months and completely refilled after one year.


14.1 Provision of DCP type fire extinguisher in a rake should be in accordance with guidelines circulated vide letter no. 95/Sec (spl)/75/1 dtd 30.05.97

Coach type Nos of FE’s

Each Break Van 2 nos

Each AC coach 2 nos

RB’s letter no. 95/Sec (spl)/75/1 dtd 30.05.97


Each Pantry car 4 nos

Each Generator van

2 nos

15. Similarly, other brake van equipment, which Mechanical Train Examining staff is responsible to supply, should be provided according to the instructions of each Railway. Portable control telephones, portable train lighting equipments, portable fire extinguisher, wooden wedges/skids and stretcher are to be provided.

111(g)(i) of Chg. Manual

16. Watering and cleaning of rakes

Mechanical department of each railway will nominate the watering and the cleaning stations on the railway.

111(h) of Chg. Manual

17. Deficiency Rolling Stock (DRS) for Coaching Stock

111(i) (i) of

(i) Railway should devise system for detecting deficiencies. Reports of deficiencies/ defects in Rolling Stock (DRS) reports in the Performa given in Annexure 1.2, should be prepared for each mail/express/passenger originating train in duplicate by the Engineer (C&W)/Electrical (TL) and should be signed jointly with the RPF representatives.

Chg. Manual

(ii) On arrival of the train at the destination station, the Engineer (C&W) staff and electrical staff shall check the rakes jointly with a representative of RPF and comparison may be made with original report.

111(5)(b) of Chg. Manual

18. Coach Maintenance History Card 111(k)(i) of

(i) Every coaching depot shall have computers for maintaining the coach maintenance history in a software programme which should be compatible with the programme of the coaching workshop.

Chg. Manual

(ii) The complete history book of each coach, consisting of maintenance history cards, date card, trial card, etc. will, however, be maintained by the base workshops

111(k)(iii) of Chg. Manual

19. Primary/Secondary maintenance

19.1 The rakes/ coaches of all trains should be given a Primary/Secondary Maintenance examination as prescribed by the Chief Mechanical Engineer of the Railway and as per Appendix F of Chg .Manual

113(a) of Chg. Manual

19.2 Coaches shall be washed and cleaned thoroughly from outside and inside as

113(b) of Chg. Manual


prescribed in clause 109.

19.3 Brake system maintenance

Air brake system (Bogie mounted and under frame mounted):

Attention as detailed in Para 113 ( c) is being given during primary /secondary attention of a rake.

113(c) of Chg. Manual

19.4 In addition to above the following items of work should be attended during the maintenance schedule examination:

* under frames

* bogie frames

* axle boxes

* springs

These items should be wiped with wet waste weaves or cotton waste as necessary so as to facilitate examination. All under gear components should then be examined and repaired as necessary to ensure that there is no `S' marked reject able defect as mentioned in Chapter IV of IRCA Conference Rules.

113 (d) of Chg. Manual

19.5 The following items of under gear components should, however, be specially examined and attended to:-

113 (e) of Chg. Manual

i) Oil in hydraulic dash pots of Rajdhani and Shatabdi coaches should be checked once in 15 days to detect oil leakage from them through defective seals or through the vent screw. Add/ replenish with specified grade of oil if the oil level is below 40 mm in the tare condition for ensuring better riding comfort.

113 (e) (i) of Chg. Manual

ii) Wheel profiles should be visually examined and gauged in case they appear to be near condemning limits.

113(e)(ii) of Chg. Manual

iii) The brake gear should be checked and so adjusted that the piston stroke is within the limits specified for different types of coaches. (See table 1.10). 'A' and 'e' dimensions for slack adjuster should be as per table 1.11 (as applicable for under frame mounted brake system)

113(e)(iii) of Chg. Manual

19.6 The following coach body components and fittings should be specially checked and attended to

113(f) of Chg. Manual


i) Doors should be properly secured with the hinges/pivots and should not be grazing with floor or door sill plates.


ii) Door latches and safety catches 113(f)(ii) of Chg. Manual

iii) Door lock handles 113(f)(iii) of Chg. Manual

iv) Tower bolts 113(f)(iv) of Chg. Manual

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg. Manual

vi) Window shutter safety catches 113(f)(vi) of Chg. Manual

vii) Window frame 113(f)(vii) of Chg. Manual

viii) Vestibule assemblies of all vestibule coaches should be checked and repaired as necessary.

113(f)(viii) of Chg. Manual

ix) Water pipe connections, flushing valves, cocks and shower roses should not be leaking or choked.

113(f)(x) of Chg. Manual

x) Drain grills and drain holes in the bathroom floors and wash basin drainpipes should be cleaned and opened where found choked.

113(f)(xi) of Chg. Manual

xi) Any other deficiency as per Annexure 1.2 should be made good.

113(f)(xii) of Chg. Manual

xii) A proper record should be kept by Engineer (C&W) at washing/pit lines of schedules carried out by them, especially of items required to be attended at specific periodicity.

Record to be maintained in standard DDR (Damage deficiency register)

113(h) of Chg. Manual

20. Schedule ‘A’ Examination 114 of Chg. Manual

i. Schedule `A' is required to be given every month + 3 days at the nominated primary maintenance depot within the normal primary maintenance time on a washing/pit line in a rake.

114 (a) of Chg. Manual

ii. Brake system maintenance

Air brake system (bogie mounted)

A schedule maintenance as per air brake chapter

114(b) of Chg. Manual

iii. The specified items of work should be attended during Schedule ‘A’ examination,

114(c) of


i.e. monthly examination, Chg.Manual

21. Schedule ‘B’ Examination 115 of Chg.Manual

i. Schedule `B' is required to be given every three months + 7 days at the nominated primary maintenance depot within the normal time allowed for primary maintenance on a washing line in rake.

115(a) of Chg.Manual

ii. The specified items of work should be attended

115(b) of

iii. Brake system maintenance

Air brake system (Bogie mounted)

Same as 'A' schedule

Chg.Manual

iv. Other assembly maintenance

Besides brake system other items should be attended as given below:

115(b)(i) of Chg.Manual

a. All items of Schedule -`A' 115(b)(ii) of Chg.Manual

b. Painting of lavatories from inside. 115(b)(iii) of Chg.Manual

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual

d. Thorough checking of trough floor, turn unders, etc., from underneath for corrosion.

115(b)(v) of Chg.Manual

e. Touching up of painted portion, if faded or soiled.

115(b)(vi) of Chg.Manual

22. IOH attention

116 of Chg. Manual

and Correction slip 5 for coaching maintenance manual issued in 2008

22.1 Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9 months in depot

Passenger at interval of 9 months in depot

Other OCVs at interval of 12

117(i) of Chg. Manual

and correction slip 5 for coaching maintenance manual issued in 2008


months in depot

Tolerance for IOH may be kept as + 30/-0 days.

Maintenance activities to be carried out during schedules should be as per Appendix-F & G.

For IOH attention of newly built coaches, guidelines as circulated vide RB’s letter no. 2007/M ( C)/141/1 dtd 06.08.09

22.2 Coaches are required to be detached from the rake and taken to the sick line or sent to shop for IOH attention (‘C’ schedule maintenance)

117(ii) of Chg.Manual

and Correction slip 5 for coaching maintenance manual issued in 2008

22.3 Brake system: ‘C’ schedule maintenance (IOH) as per para 426 of air brake chapter.

117(a)(i) of Chg.Manual

22.4 Thoroughly clean Dirt collector filter in kerosene or replace on condition basis.

117(a)(vii) of Chg.Manual

22.5 Other assemblies maintenance

All items of Schedule `B'

117(a)(i) of Chg.Manual

22.6 Thorough repairs of running gear including running out of bogies where considered necessary. All bogies which are working on rake links earning more than 2.5 lakhs kms. per annum must however be run out and thoroughly attended to as laid down in clause 111c under “Intermediate Overhaul”.

117(a)(ii) of Chg.Manual

22.7 Touching up damaged paint of coaches on outside as well as inside.

117(a)(iii) of Chg.Manual

22.8 Polishing of the polished surfaces. 117(a)(iv) of Chg.Manual

22.9 Shock absorbers should be replaced and sent to the base workshops for repairs, testing and return. For this purpose, adequate spares must be maintained in the depot.

117(a)(v) of Chg.Manual

22.10 Thorough cleaning and removal of dust, rust, dirt, etc., accumulated at the pillars through the turn under holes, with coir brush and compressed air.

117(a)(vi) of Chg.Manual

22.11 Thorough examination and repairs of upholstery, cushions, curtains, etc.

117(a)(vii) of Chg.Manual


22.12 Thorough checking and full repairs of all window shutters, safety catches, safety latches, staples and hasps of compartment, lavatory,

117(a)(viii) of Chg.Manual

22.13 Thorough checking and repairs of UIC vestibules, their rubber flanges metal frames, doors, fall plate, locking gear, etc., for ease of operation and safety.

117(a)(ix) of Chg.Manual

22.14 Thorough checking and repairs of all cracks and worn out portions of flooring of the compartments.

117(a)(x) of Chg.Manual

22.15 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 adjoining areas, corridor sides - more so in case of those SLRs which are used for Fish, Salt, etc. For facilitating inspection of sole bars even spaced elongated holes of (215x127 mm) are already provided in the turn unders.

117 (d) of Chg.Manual

22.16 Special attention should be taken for the following:-

117(e) of Chg.Manual

i) Pocket between sole bars and turn unders should be thoroughly cleaned through the inspection opening of the sole bars and inspected with the help of torch light or inspection lamps.

117(e)(i) of Chg.Manual

II). Drain holes provided in the trough floors should be kept clean and unclogged. If during the cleaning of these drain holes any accumulation of water is observed, the affected area should be very carefully inspected for possible corrosion.

117(e)(ii) of Chg.Manual

III) A register should be maintained of the primary maintenance coaches on the subject.

Record of Schedule A, B and IOH attention are maintained in standard format and records are maintained.

117(e)(iii) of Chg.Manual

22.17

For maintenance of coaches of Rajdhani/ Shatabdi Express Rakes, the instructions given in RDSO Technical Pamphlet No. C-7807 should be followed.

118 (b) of Chg.Manual

22.18 The IOH of Rajdhani/Shatabdi high speed coaches should be carried out in workshops

118(c) of Chg.Manual

23 Linen management

i. Complete activity of linen management including washing, storage, supply & distribution of linen kits in trains shall be done by Mechanical (C&W) Dept as a single window agency

Board’s letter No.2009/M(C)/165/6 dt.17.12.2009.


ii.(a) Stock verification of linen should be carried out on a quarterly basis

Board’s letter No.2009/M(C)/165/6 dt.4.1.2010

ii.(b) At least 5% of new linen should be checked by SSE/Mechanical for:

(a) bundles being sealed and having batch nos., manufacturer’s name, year of manufacture, quantity, size indicated,

(b) Linen items having marking of month / year of manufacture, Railway, etc.

(c) dimensional check, colour, feel and workmanship, etc.

ii.(c) Monthly report of inspections / test checks of the linen washing contractor’s premises by officers / supervisors, should be prepared and payment should be made after recovery of all penalties / dues

ii.(d) Enough buffer stock of linen to last for 2 to 3 days is available

ii.(e) Life of linen is adhered to:

Bed sheets : 12 months for khadi, 24 months for poly vastra

Pillow cover/face towel : 9 months

Pillow : 24 months

Blanket : 48 months

ii.(f) Committee nominated by DRM for linen condemnation on condition basis

iii. Specified frequency of washing/dry cleaning of blankets and other linen items is adhered to

23.1 Passenger complaint on account of linen is analysed and corrective & preventive action is taken

23.2 Feedback on linen quality is obtained through coach attendant as per RB’s guidelines

24. Pest / Rodent Control

i. Comprehensive contract covering pest / rodent control in coaches and rodent control in pit lines / coaching depot yards awarded for 3 years under two packet system

Board’s letter No.2010(M)/C/141/7 Vol.IV dt.21.12.2010

ii. All reserved (both AC and Non-AC) covered under contract, unreserved coaches may also be covered as per requirement of Railways

iii. Minimum frequency of pest control treatment is adhered to :

AC coaches / Pantry cars : Fortnightly,


Reserved Non-AC coaches : Fortnightly in first 3 months, monthly thereafter, Unreserved Non-AC coaches : Bi-monthly

Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc.

iv. Chemicals to be used (with brand names), concentration, dose specified

v. Minimum frequency of rodent control treatment is adhered to :

AC coaches / Pantry cars : during every Primary maintenance,

Reserved Non-AC coaches : Weekly Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc.

vi. Personnel trained by certified training institutes deputed for pest/rodent control

vii. Fumigation/mist treatment carried out whenever coaches detached for IOH/POH. Pest/rodent control carried out before inducting the coach in service after IOH/POH

viii. In order to prevent cross infestation, contractor may make effort to treat all AC and all Non-AC coaches of a particular rake together

ix. Stickers indication date of pest control and next due date provided in doorway/toilet area

x. Railways shall make effort to detach pantry cars from rakes once a month (within reasonable tolerance) to facilitate complete vacation and intensive cleaning for thorough pest / rodent control treatment

xi. Broad methodology for measuring the level of infestation of cockroaches and rodents and expected reduction over time is in place

24.1 Passenger complaints on account of pest are analyzed and corrective action is taken.

25. Passenger amenities provided in various types of coaches as specified

Board’s letter No.2006/M(C)/141/26 dt.21.12.2006.

26. Infrastructure facilities – Standard integrated modular pit line have unified maintenance.

Appendix ‘E’ of Coaching manual

CAMTECH report No.CAMTECH/M/99/Infra-washing line/1.1


27 Examination and repair practice in carriage maintenance depot for wheel sets and roller bearing

Para 1009 of Chg manual

27.1 Wheel and axle Para 1009 a of Chg manual

i) Wheel profile should be checked

with Tyre defect gauge to ensure the

profile dimensions are within the

permissible limits.

ii) Limits for flat tyres

The limits for permissible maximum flat surfaces on tread for BG ICF coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99)

iii) Guidelines for wheel inspection in

open line depots (Ref RDSO CMIK003)

In addition to normal checks exercised on wheel condition during primary/secondary maintenance of coaches, a detailed inspection of wheels should be done when the coaches are received in sickline for attention for either schedules or out of course attention. The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition:

a) Shattered Rim

b) Spread Rim

c) Shelled Tread

d) Thermal Cracks

e) Heat checks

iv) The defective wheel should be sent

to workshop for repairs after entering

in the maintenance card details of the

work order and date of dispatch to

workshop.

v) No repairs, except wheel profiling of

wheel sets is permitted to be done in

the maintenance depot.

27.2 Roller Bearing Axle Boxes Para 1009 b of Chg manual

i) A coach should invariably be detached


from service for the following defects

i) Hot axle box

ii) Damaged axle box

iii) Damaged front or rear cover

iv) Seized roller bearing

v) Coach involved in accident,

derailment, fire, flood etc.

ii) Care should be taken not to keep a coach fitted with roller bearing stationary for a long time. Coaches grounded for a long time should be shunted up and down at regular intervals.

Coaches fitted with roller bearing should be checked to ensure that :-

i) No wash basin drain hole / discharge pipe is directly above the axle box

ii) The front and rear covers of the axle boxes are not damaged, cracked or loose

iii) Clearance between axle box and wheel is such that the axle box does not bind against the wheel.

iv) Brake gear is properly adjusted to avoid possibility of brake binding

27.2.1 Axle box is examined for grease oozing out from rear cover and corrective action is taken. Concerned shop needs to be advised for necessary corrective and preventive action.

27.3 Axle box temperature measurement by non contact type temperature measuring instrument during rolling in examination:

Carriage Dte/RDSO letter no. MC /AB dtd 21.08.09

i) Temperature to be checked at axle box top (crown) at front face of axle

ii) If temperature is found above 800 C, the

affected coach will be detached.

27.4 Minimum permissible wheel diameter in ICF design BG coaches.

RB letter no. 92/M (C)/137/2 Vol V dtd 25.1.11

i) Shop issue size of wheel set should be 837 mm

ii) Condemning diameter of the wheel in service, measured at a distance of 66.5 mm from the outer face of the rim shall be 825 mm.

28 Attention brake block hangers on ICF coaches – to avoid failures

Carriage Dte/RDSO letter no. MC /ICF/B/D dtd 03.07.09

28.1 The new brake block should be procured


as per revised spec C – 9808 Rev 2 and drg no. SK – 93286 Alt 5

28.2 Maintenance of brake gear rigging should be given as per guidelines circulated by ED/Carriage /RDSO vide letter no. MC /ICF/B/D dtd 03.07.09

29 Other items:

29.1 Changing of air brake hose pipe:

Air brake hose pipe to be changed in every alternate POH attention.

Carriage Dte/RDSO letter no. MC /APB dtd 19.02.09

29.2 Fire retardant items are provided in coaches as per RDSO specification.

RDSO spec and STR

29.3 FAC amenities are provided as per guidelines circulated vide DG/Carrg/RDSO’s letter no. MC/CB/AC/BG dtd 28.04.10

29.4 Additional amenities / facilities in GSCN type of coaches are provided as under:

Snack table in each bay.

Mirrors in each bay

Magazine holders on partition wall

Bottle and tumbler holder

RB letter no. 2004 / M (C)/165/16 dtd 29.03.05

29.5 Maintenance of Duronto express:

i) Pattern of maintenance for Duronto train as being followed for Rajdhani trains with pit examination at both end should also be followed.

RB letter no. 2009/M (C)/141/2 dtd 25.08.09

ii) Rolling – in and rolling- out examination may also be conducted for each of the Duronto trains at the respective operational halts and also at the terminals during the journey. Such safety examinations of the Duronto trains may be periodically super checked at the level of officers.


iii) Short distance Duronto with only AC / Non AC chair car may be permitted to run on the extant pattern for Shatabdi trains with a terminal attention at other end on platform / stabling line. A minimum 2 hrs may be planned at the non primary end to enable thorough attention to cleanliness, hygiene and passenger amenities at other end.


iv) Cleaning of Vinyl wrapping on Duranto rake coaches

Mild detergent should be used with normal jet of water. High pressure water jet should not be directed towards Vinyl wrapping.

RCF’s letter no. MD 22.151 dtd 09.02.10

29.6 Attention of air springs ED/Carrg/RDSO’s


Procedure for rolling – in examination:

As train passes the nominated point, C&W staff should watch out vigilantly loose / hanging / broken under gear parts of the coaches special attention should be paid to air springs in case of coaches provided with air springs at secondary suspension stage. It should be ensured all the air springs are in inflated condition by noting that the levelling valve lever is in horizontal position. In case it is not feasible to inflate the air springs of any particular coach, these should be isolated by air spring isolating cock and speed of train should be reduced to 60 Kmph or the coach should be detached.

letter no. MC/CB/MM dtd 09.09.2009 & Maintenance manual of air spring for mainline ICF bogie coaches RDSO/2009/CG/CMI-01, Sep’09

29.7 Analysis of sick marking and en-route coach detachment

i) Whether primary coach detachment is analyzed and corrective & preventive action taken. Details of primary detachment for last 3 years to be collected.

ii) Whether secondary detachment is

Being analyzed and corrective & preventive action taken. Details of secondary detachment for last 3 years to be collected.

iii) Whether en-route coach detachment is investigated and corrective & preventive action taken. Details of en-route coach detachment for last 3 years to be collected with investigation report.

29.8 Facilities for pit line and sick line attention CAMTECH Maintenance Manual for BG Coaches of ICF design,

1st correction slip–

CAMTECH/2002/M/C/

CMM/1.0/CS-01(07.2006)

i) Facilities available as per CAMTECH guidelines as detailed in annexure – I to be observed.

30 Passenger satisfaction

30.1 OBHS & escorting of trains

i) Whether depot has provision of OBHS as per RB policy guidelines.

ii) Nos of Mail Express train in which escorting staff have been provided with cleaning staff by depot.


iii) Nos of Mail / Express trains in which OBHS have been provided.

iv) Nos of Mail/ Express train in which no staff from depot and OBHS through contract have been provided.

v) Average PSI for OBHS implemented rakes. Whether systems to cross verify PSI in OBHS provided train is existing.

30.2 Whether depot has system to get feedback of cleanliness, linen quality and pest infection of Mail/ Express trains. Action taken by depot on the basis of feedback from passenger.

30.3 Whether depot has system to analyse passenger complain and takes corrective action. Passenger complains for last three years with action taken to be submitted.

30.4 Whether depot has facility for mechanised cleaning of coaches. List of equipments and nos of rakes covered in every month to be submitted.

30.5 Whether depot has facility for upholstery and carpet cleaning either through in-house or through contract. Efficacy of cleaning to be observed.

30.6 Whether curtains are cleaned at prescribed interval of 15 days as per RB guidelines

30.7 Whether blankets are cleaned at one month interval as per RB guidelines

30.8 Compliance of CRB letter to GM for sustainable image makeover of the Railways:

CRB DO no. 2011/ER/6018 dtd 28.07.11

i) Cleanliness of coaches:

a) Ensure high standards of cleanliness in the coaching maintenance depot particularly in the washing line area.

b) Action in respect of implementation of systems of system for collection bagging and disposal of leftover food from pantry cars and coaches.

c) Sustainable garbage collection and disposal system

d) Functional and efficient drainage to avoid water logging and dirt collection

e) Periodic fumigation of coaches and high standards of cleanliness in washing lines

f) Monitoring the functioning of OBHS and


CTS scheme.

g) At the Zonal / Divisional level, SAG / Selection grade officers by name and designation may be put in–charge of important Mail/Express trains under “Own your train scheme (OYTS)” with responsibility being taken by the officers for the areas for which they have been nominated.

ii) Quality of linen supplied on trains:

a) Availability of clean and hygienic linen to passenger through washing quality, adequate quantity, replenishment with new linen on age / condition basis, use of washable blankets and appropriate quality of packing.

b) Commissioning of mechanized laundries at critical locations dealing with large quantity of linens

c) System of packaging, storage and servicing of the linen to the passenger must be streamlined.

31 LHB coach attention:

31.1 Periodicity of periodic overhauls (POH) in designated workshops is being followed.

Schedule Periodicity

IOH (Shop Sch I) 18 months / 5 lakh Km

POH (Shop Sch II)

3 yrs/ 10 lakh Km

POH (Shop Sch III)

6 yrs / 20 Lakh Km

RB’s letter no. 95 /M (C)/ 141 (LHB) dtd 22.08.06

31.2 Attention to following components are being given as per ALSTOM manual guidelines and guidelines circulated by RDSO.

Phonic wheel / speed sensor.

Dump valve

Earthing device.

Control arm

Dampers

Primary vertical dampers.

Secondary vertical dampers

Yaw damper.

Secondary lateral damper

Primary and secondary springs

ALSTOM manual and OEM manuals


Disc brake attention

CDTS (Controlled discharge toilet system)

31.3 Wheel sets and CTRB attention at depot:

i) The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition:

Shattered Rim

Spread Rim

Shelled Tread

Thermal Cracks

Heat checks

Para 1009 a (iii) of chg manual

ii) Wheel profile should be checked with Tyre defect gauge to ensure the profile dimensions are within the permissible limits. Coaches with wheels having thickness and profile worn below condemning limit should not be allowed to continue in service and the coach should be marked sick for change of wheels in the sick lines.

Para 1009 a (i) of chg manual

iii) The limits for permissible maximum flat surfaces on tread for BG ICF coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99)

Para 1009 a (ii) of chg manual

iv) System is available for rolling – in examination at terminating station and axle box temperature is measured with non contact type temperature measuring equipment and corrective action taken for wheel sets with high temperature.

Carriage Dte/RDSO letter no. MC /AB dtd 21.08.09

v) Last shop issue size (865 mm) and condemnation limit for wheel sets (845 mm) as stipulated is being followed.

vii) Presently the refurbishing/overhauling of LHB bearing is being done at an interval of 1.2 million km. To ensure attention of CTRB’s as well as UST of axle, depot should have proper identification of wheels sets. In case wheel sets are interchanged then traceability of wheel sets and timely attention of wheel sets exist in the depot.

viii) Depot should not permit wheel sets with flaking in service. Adequate spare wheel sets are available in depot.

ix) Whenever coach is sent to shop for POH/IOH or non schedule attention, details of wheel sets with regard to CTRB attention should be furnished to shop. Whether system exist in depot. Similarly when loose wheel sets are sent to shop, details of wheel sets with regard to CTRB attention should be furnished to shop.


x) Grease oozing out is checked during attention at depot and corrective action is taken accordingly.

xi) Drain holes of control arm should be regularly cleaned to prevent its choking.

xii) Checking of mounting bolts of control arm is being done during primary maintenance.

31.4 Phonic wheel/Speed censor OEM guidelines

i) M8 size screw to IS 1367 Pt.III class 10.9 along with spring washer to the IS 3063 type-B should be used for securing phonic wheel. LOCTITE 243 or equivalent glue should be used to ensure rigid connection between internal and external thread.

The Phonic Wheel screws should be tightened with 21N-m torque.

ii) The clearance between the phonic wheel and speed sensor should be 0.9 to 1.4 mm in case of KB make WSP and 1 to 2mm in case of FTIL make WSP. This gap should be checked in quarterly schedule or whenever required.

iii) The phonic wheel and speed sensor should be procured through OEMs/OEMs’ approved sources only. M/s KB and M/s FTIL are OEM of this item.

iv) Speed sensors’ cables should be properly connected and should be without any

loose strands.

31.5 Dump Valve

Proper Dump Valve connection and ensuring that no dump valve leaks during brake application.

OEM guidelines

31.6 Earthing Device OEM guidelines

Earthing device of most of the coaches should be functional. It consists of non ferrous components (approx 2kg weight) which are theft prone. Loose fasteners, in case of theft attempts for non-ferrous items, mounted inside of axle box housing, can damage CTRB.

Most of the earthing devices with correcting wires/cables were missing.

Junction box in broken/damaged condition.

31.7 Disc brake attention: OEM guidelines

i) Brake pads are renewed on condition basis and adequate spare is available at depot


ii) Whether regular attention of brake calliper is being ensured.

iii) whether regular attention is being given to disc brake system through AMC or in-house attention.

31.8 Whether guidelines circulated by RDSO for CBC equipped coaches are being followed.

Carrg Dte/RDSO letter no. MC/BLB/CBC dtd 22.05.08

31.9 Attention of side buffer:

Length of side buffer of CBC equipped SLR (FV & LV) is maintained to 635 mm as per RDSO drawing no. SK - 98145

Carrg Dte/RDSO letter no. MC/BLB/CBC dtd 17.02.08


Annexure - I

Standard facilities in Carriage Maintenance Depots

(Ref: CAMTECH Maintenance Manual for BG Coaches of ICF design,

1st correction slip– CAMTECH/2002/M/C/CMM/1.0/CS-01 (07.2006)

Classification of depots

Classification No. of coaches based

Minor Depot Below 100

Medium Depot 100 to 250

Major Depot Above 250

Machinery and Plant

Description Minor

Depot

Medium

Depot

Major

Depot

Observation

U/floor wheel lath - - 1

Whiting jacks (5 Nos.) - 1 set 1 set

EOT crane 20T - - 1

Coach Shunter - 1 2

Welding Plant 1 2 4

Gas Cutting Equipment 1 2 2

Vacuum Exhauster 1 2 2

Air Compressor 30 cfm 1 2 2

Portable Vacuum Testing Equipment - 1 1

Portable Air Compressor - - 1

2T Tram beam hoist 1 1 2

Sewing machine - 1 1

Truck 10T - - 1

Light Coml. Vehicle 1 1 1

Fork lift truck - - 1

Lister truck 1 1 2

Car Washer - 1 1 Nil

Portable Trolley Light 2 4

Cotton waste soaking plant 1 1 1


Description Minor

Depot

Medium

Depot

Major

Depot

Observation

Wood cutting saw machine - 1 1

Hand shearing machine - 1 1

Portable Furnace 1 1 2

Centre Lath - - 1

Bogie Manipulator - - 1

Ultrasonic Testing Apparatus 1 1 1

Tool post Grinder - 1 1

Vacuum Cleaner 1 2 3

Pressure Jet Cleaner 1 2 4

Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2

ii. Drill 1 1 2

iii. Chipper / Buster - 1 2

iv. Riveter - - 1

b. Electric Power Tools

i. Pop Riveting Gun - 1 1

ii. Drill - 1 1

iii. Bolt Tightner - - 1

c. Hand Tools As required

d. Test Bench

i. Water Tank Test Rig - 1 1

ii. D.A. Valve Test Bench - 1 1

iii. Vac. Cyl. Test Bench - 1 1

iv. Slack Adjuster Test Bench - 1 1

v. DV Test Bench - 1 1

vi. Air brake single coach test rig - 1 1

e. Office Equipment

i. Computer system 1 1 1

ii. Plain Paper Copier 1 1 2

iii. Telefax 1 1


Annexure - II

Emergency materials required for platform (C&W) office

Sl. Items Required Observation

1 Screw Coupling complete ( 75 t ) 1 no.

2 Draw Hook ( ICF- Enhanced capacity) 1no.

3 Draft cotter with 'U' pins 1no.

4 Draft link complete 2 sets

5 Equalizing Stay rod with pins ( Non-modif. &

Modif.) 1 set each

6 Anchor link with securing studs 1 set

7 Truss Bar Hanger with Pins & Cotters 2 sets

8 Bolster suspension Link (Stirrup Link) with Pins &

Stones 2 sets

9 Axle Box Face Cover (ICF) with securing nuts &

Pins 2 sets

10 'O' Ring 2 nos.

11 Grease Servogen 4 kgs.

12 Adaptor (BF+FP) for by-passing 2 sets

13 Angle cock 2 nos.

14 Dummy Flange (A/B) 2 nos.

15 M.U. washer 10 nos.

16 Teflon Tape 1 no.

17 Portable Air Pressure Gauge 1 no.

18 Pressure Gauge BP & FP 2 each

19 BP & FP Air hose 2 each

20 Guard Emergency Application Valve 2 nos.

21 Wooden Plug (various sizes) 10 nos.

22 Wooden wedge 4 nos.

23 G.I. wire Adequ. Qt.

24 Buffer bolts (20x120 mm.) 8 nos.

25 Push cock 5 nos.

26 Spl. Jack for changing Eq/Stay rod 1no.

27 Slide wrench, Pipe wrench-24'' 2 nos

28 Hydraulic Jacks 2 sets


Annexure – III

Details regarding coaching depot

Depot name and division: Darbhanga/SPJ

1. Coach Holding

Mail/Expresses coaches with conventional coupling

Mail/Expresses coaches with CBC coupling

Rajdhani/Shatabdi coaches (conv)

LHB coaches (Rajdhani/Duronto)

Shatabdi Coaches (conv)

Shatabdi coaches (LHB)

Passenger coaches

OCV’s

Grand Total

2. Maintenance attention of at depot

PM of Mail/Expresses train with secondary attention at other end

PM of Mail/Expresses train with round trip attention at other end

PM of passenger service with round trip attention at other end

Total PM attention at depot:

Total SM attention at depot:

Total Round trip attention at depot:

3. Pit line attention

24 coach pit with catwalk and high pressure water jet

facility/watering facility at per CAMTECH’s guidelines

24 coach pit facility with catwalk

Less than 24 coach pit facility with or without catwalk (details to

be collected)

Stabling line for round trip attention and stabling of rakes:

Stabling line with 24 coach length facility

Stabling line with less than 24 coach facility

Compressed air with reservoir and ir dryer/moisture trap facility

with test rig (RTR)

Facility for welding at Yard attention

Night maintenance facility with overhead/pit light as per

CAMTECH’s guidelines

4. Sick line facility

Coach lifting facility with overhead crane

Coach lifting facility with JMP jack/hydraulic jack

Total coach accommodation

With pit attention Without pit attention

Facility for compressed air with test rig (SCTR)

Availability of hydrant water for overhead tank attention

Welding facility


5. Facility for rolling-in/rolling-out examination with adequate lighting arrangement (for attention during night) as per

CAMTECH’s guidelines.- Available at SPJ End of DBGPF, Not as per CAMTECH guide line

6. Availability of staff for coaching maintenance as per Yard stick.

There is acute shortage of staff As- Req. as per Rly Bd bench mark -

As per sanctioned BOS -

Actual on Roll -

7. Training status of supervisor and staff – overdue training to be observed and recorded

Supervisor/Staff - Overdue as there is acute shortage

8. Availability of critical/ safety stores and storage system.-

Sl

no. PL no. Description EAC Supply

Present stock

on hand

1. 30010548 Compensating ring of Axle Box.

2. 30051149 Bronze Wearing piece

3. 30310337 Self lubricating polyester resin

bush item no.2

4. 30377237 Self lubricating polyester resin

bush item no.3

5. 30320392 Brake beam complete for 16 T

bogie

9. Availability of coaches as per rake link with maintenance spare. –

Coach with CBC Coach with

screw coupling

Bare

Traffic spare

Maint. spare

Total required

Available

10. Bottlenecks / limitations of system / depot.

- Acute shortage of staff.

- In adequate sick line facility.

- No proper storage & other basic infrastructure facility.

- No any Truck to transport stores & condemned materials.

11. Safety performance record.

Accident -

Enroute detachment- Secondary detachment-

quality assurance directorate (mechanical) rdso...

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