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Questions and Answers
What modification was made to the sole bar in coaches manufactured since 1974?
What modification was made to the sole bar in coaches manufactured since 1974?
Where should special attention be paid when checking the roof of ICF coaches for corrosion?
Where should special attention be paid when checking the roof of ICF coaches for corrosion?
Which RDSO sketch numbers are associated with the strengthening of sole bars in coaches?
Which RDSO sketch numbers are associated with the strengthening of sole bars in coaches?
What should be done on coaches that have not been modified for corrosion during POH?
What should be done on coaches that have not been modified for corrosion during POH?
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According to the information, what is crucial for roof repairs of corroded ICF coaches?
According to the information, what is crucial for roof repairs of corroded ICF coaches?
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What is the primary advantage of the lightweight integral design in BG coaches?
What is the primary advantage of the lightweight integral design in BG coaches?
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Which structural feature is intended to prevent telescoping of adjacent coaches?
Which structural feature is intended to prevent telescoping of adjacent coaches?
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How is collision energy primarily absorbed during heavy collisions in BG coaches?
How is collision energy primarily absorbed during heavy collisions in BG coaches?
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Which of the following is NOT a leading dimension listed for the coaches?
Which of the following is NOT a leading dimension listed for the coaches?
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What material is primarily used for the trough floor in the construction of the coaches?
What material is primarily used for the trough floor in the construction of the coaches?
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What benefit do low alloy fittings provide in the context of BG coach construction?
What benefit do low alloy fittings provide in the context of BG coach construction?
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Which of the following has the highest height from rail level among the listed coaches?
Which of the following has the highest height from rail level among the listed coaches?
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What material thickness is used for the side walls in the tubular structure?
What material thickness is used for the side walls in the tubular structure?
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Which component is NOT part of the connected tubular framework?
Which component is NOT part of the connected tubular framework?
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What is the purpose of the corrugated trough floor?
What is the purpose of the corrugated trough floor?
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How are the vertical pillars of the end wall connected?
How are the vertical pillars of the end wall connected?
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What type of steel is used for the roof sheathing?
What type of steel is used for the roof sheathing?
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Which part is located at the bottom of the tubular structure?
Which part is located at the bottom of the tubular structure?
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What connects the end wall's pillars to the head stock?
What connects the end wall's pillars to the head stock?
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What is the primary function of light rails in the structure?
What is the primary function of light rails in the structure?
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Which component is specifically designed to take up buffing loads?
Which component is specifically designed to take up buffing loads?
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What is the maximum allowable wear of the head stock before it should be replaced?
What is the maximum allowable wear of the head stock before it should be replaced?
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Which of the following is a characteristic of corrosion-resistant steel sheet used in trough floors?
Which of the following is a characteristic of corrosion-resistant steel sheet used in trough floors?
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What should be used for the base of head stock according to specifications?
What should be used for the base of head stock according to specifications?
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What is the initial step if corrosion is detected in the trough floor?
What is the initial step if corrosion is detected in the trough floor?
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Which test can be performed to examine the buffer base of the head stock?
Which test can be performed to examine the buffer base of the head stock?
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What type of electrode is specified under IRS Class B2?
What type of electrode is specified under IRS Class B2?
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What should be done if minor corrosion has just started in certain areas?
What should be done if minor corrosion has just started in certain areas?
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What is the prescribed primer type for painting substructures?
What is the prescribed primer type for painting substructures?
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Which of the following best describes a proper buffer fixing?
Which of the following best describes a proper buffer fixing?
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What is the purpose of the spiked hammer during the examination of the trough floor?
What is the purpose of the spiked hammer during the examination of the trough floor?
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Which material should be used for flooring in lavatories and bays adjacent to lavatories in coaches over six years old?
Which material should be used for flooring in lavatories and bays adjacent to lavatories in coaches over six years old?
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What should be done to the underframe when corrosion repairs are carried out?
What should be done to the underframe when corrosion repairs are carried out?
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What is the first step in replacing the head stock of a coach?
What is the first step in replacing the head stock of a coach?
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Which parts of a coach commonly require corrosion repairs?
Which parts of a coach commonly require corrosion repairs?
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What method is recommended for examining the tubular frame for corrosion?
What method is recommended for examining the tubular frame for corrosion?
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In cases of extreme corrosion in the tubular frame, what action should be taken?
In cases of extreme corrosion in the tubular frame, what action should be taken?
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Which coatings should be applied to the underframe after repairs?
Which coatings should be applied to the underframe after repairs?
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What should be used to examine the tubes and joints of the tubular frame?
What should be used to examine the tubes and joints of the tubular frame?
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For corrosion repairs to side walls and end walls, what is the required action regarding lifting?
For corrosion repairs to side walls and end walls, what is the required action regarding lifting?
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Which sketches provide guidance for corrosion repairs to the sole bar?
Which sketches provide guidance for corrosion repairs to the sole bar?
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What structural feature of BG coaches is designed to absorb major collision energy?
What structural feature of BG coaches is designed to absorb major collision energy?
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Which of the following dimensions corresponds to the ICF/RCF coach's overall width?
Which of the following dimensions corresponds to the ICF/RCF coach's overall width?
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What material concept is employed in the construction of the coaches to achieve weight reduction?
What material concept is employed in the construction of the coaches to achieve weight reduction?
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What is the significance of corrugated sheets in the BG coach design?
What is the significance of corrugated sheets in the BG coach design?
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Which design aspect contributes to the lightweight integral design in BG coaches?
Which design aspect contributes to the lightweight integral design in BG coaches?
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What is the primary purpose of the framework forming the integral shell in the coaches?
What is the primary purpose of the framework forming the integral shell in the coaches?
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What dimension is used to measure the height from rail level for the IRS coach?
What dimension is used to measure the height from rail level for the IRS coach?
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What is the recommended method for repairing cracks on the body of BG coaches?
What is the recommended method for repairing cracks on the body of BG coaches?
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What should be ensured before performing electric welding on a coach?
What should be ensured before performing electric welding on a coach?
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Which part of the BG coach is specifically mentioned as requiring examination for damages or deficiencies?
Which part of the BG coach is specifically mentioned as requiring examination for damages or deficiencies?
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What process should be followed for distorted parts during repair?
What process should be followed for distorted parts during repair?
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What must be done to parts used for repairs on BG coaches after their installation?
What must be done to parts used for repairs on BG coaches after their installation?
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Which component is most likely to show signs of corrosion due to its location and exposure?
Which component is most likely to show signs of corrosion due to its location and exposure?
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What part of the coach is specifically mentioned as needing examination below lavatories?
What part of the coach is specifically mentioned as needing examination below lavatories?
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Which of the following members is NOT specifically listed for exam in case of corrosion?
Which of the following members is NOT specifically listed for exam in case of corrosion?
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In which section of the coach should special attention to corrosion be paid according to the manual?
In which section of the coach should special attention to corrosion be paid according to the manual?
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What should be done if signs of corrosion are found during the examination?
What should be done if signs of corrosion are found during the examination?
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What should be the initial action taken if corrosion is detected in a tubular frame?
What should be the initial action taken if corrosion is detected in a tubular frame?
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Which area above the lifting pads is specifically mentioned for corrosion concerns?
Which area above the lifting pads is specifically mentioned for corrosion concerns?
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Which component is deemed most vulnerable due to exposure and structural stress?
Which component is deemed most vulnerable due to exposure and structural stress?
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What should be checked for corrosion behind the sliding door pockets of SLRs?
What should be checked for corrosion behind the sliding door pockets of SLRs?
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What is the necessary action when corrosion is found on the bogies and underframe during inspection?
What is the necessary action when corrosion is found on the bogies and underframe during inspection?
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Which component is specifically mentioned for replacement when significant corrosion is identified?
Which component is specifically mentioned for replacement when significant corrosion is identified?
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What type of primer is specified for painting the underframe after corrosion repairs?
What type of primer is specified for painting the underframe after corrosion repairs?
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What should be visually examined to determine the incidence of corrosion in the tubular framework?
What should be visually examined to determine the incidence of corrosion in the tubular framework?
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For corrosion repairs in side walls and end walls, what lifting procedure is indicated?
For corrosion repairs in side walls and end walls, what lifting procedure is indicated?
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What is the first structural component to be stripped for head stock replacement?
What is the first structural component to be stripped for head stock replacement?
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In cases of severe corrosion on the tubular frame, what is the recommended action?
In cases of severe corrosion on the tubular frame, what is the recommended action?
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What is the purpose of the bituminous paint system applied to the underframe?
What is the purpose of the bituminous paint system applied to the underframe?
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Which option accurately describes the recommended coating for areas repaired due to corrosion?
Which option accurately describes the recommended coating for areas repaired due to corrosion?
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What is a primary focus during the visual examination of the coach's tubular frame?
What is a primary focus during the visual examination of the coach's tubular frame?
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What new structural feature was introduced to sole bars in coaches manufactured since 1974 to combat corrosion?
What new structural feature was introduced to sole bars in coaches manufactured since 1974 to combat corrosion?
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Which locations on the roof of ICF coaches require special attention during corrosion checks?
Which locations on the roof of ICF coaches require special attention during corrosion checks?
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What should be done with coaches that have not undergone modifications for corrosion during their Periodic Overhaul (POH)?
What should be done with coaches that have not undergone modifications for corrosion during their Periodic Overhaul (POH)?
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For which type of coaches are the RDSO sketch numbers 76011 & 76012 primarily relevant?
For which type of coaches are the RDSO sketch numbers 76011 & 76012 primarily relevant?
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Which components, when corroded, require repairs according to the guidelines provided in the specified RDSO technical pamphlet?
Which components, when corroded, require repairs according to the guidelines provided in the specified RDSO technical pamphlet?
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What is a critical consideration for roof repairs on corroded ICF coaches?
What is a critical consideration for roof repairs on corroded ICF coaches?
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What structural modification was specifically made to the doorways of luggage compartments?
What structural modification was specifically made to the doorways of luggage compartments?
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Which RDSO sketches detail the strengthening modifications for the sole bar?
Which RDSO sketches detail the strengthening modifications for the sole bar?
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What type of steel is generally recommended for use in the trough floor to resist corrosion?
What type of steel is generally recommended for use in the trough floor to resist corrosion?
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What action is advised when extreme corrosion is detected in the tubular frame during inspections?
What action is advised when extreme corrosion is detected in the tubular frame during inspections?
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Study Notes
Chapter 2: Shell
- The lightweight integral design concept prioritizes hollow girders' strength and material use, reducing coaches' tare weight
- Corrugated sheets form the trough floor, absorbing buffing forces
- Anti-telescopic end-walls prevent adjacent coach collisions, absorbing collision energy
- Leading dimensions for ICF, BEML, and IRS coaches are listed in a table (Figure 2.1)
Coach Shell
- The integral shell is composed of hoops (floor crossbeams, body pillars, roof carlines), regularly spaced for doors and windows
- Panels are sheathed with 2mm corten steel (IRS-M-41) on side walls, and 1.6mm corten steel on the roof
- A trough floor of 2mm corten steel is provided between sole bars, extending to cover the underframe
- In coaches with stainless steel troughs, no tubular structure is used.
Shell for ICF Coaches (Cross-Sectional View) (Figure 2.2)
- End walls consist of four vertical box-section pillars, connected by 'Z' sections, fastened to headstocks and roofs
- The head stock of BG integral coaches has outer and inner head stocks, connected by buffer stiffeners for buffing force transmission
- The underframe supports various systems (brakes, air conditioning, lighting, etc.)
Body Repairs (202)
- Body members are inspected and repaired after lifting the coach body from its bogies onto trestles
- All removed components are sent to relevant sections for maintenance
Inspection of Underframe
- Thorough inspection identifies cracked, bent, or corroded members
- Corrosion is indicated by paint flaking, metal flaking, pitting, or scale formation
- Components, like sole bars and troughs, not visible from both sides, require tapping with a spiked hammer for inspection
- Any component losing over 20% of its thickness requires repair or replacement
End Construction of Broad Gauge All Metal Light Weight Coach ICF (Figure 2.3)
- Diagrams provide dimensions and structural details of broad gauge coach ends
Particular Attention
- Sole bars, body pillars, turn under and tubular frames (i.e. trough floors) below lavatories in all coaches must be carefully examined
- Luggage compartments of all types of coaches also need extra inspection.
- Components such as sole bars, pillars, turn unders, those near coach body bolsters, door corners, and headstocks must be inspected.
Corrosion Repairs (202e)
- Corrosion repairs are carried out following RDSO technical pamphlets (no. G7602 (Rev.1)) for ICF coaches.
- Corrosion resistant steel sheets are crucial for repairs
Head Stock (202d)
- Inspect inner and outer head stocks behind the buffers and their junctions
- Examine buffer assemblies' bases, looking for corrosion
- Use chalk tests and sound tests to detect cracks or dents in the base of the buffer assembly. Minor cracks or dents are acceptable but major cracks must be repaired
- Replace head stocks if wearing exceeds 4mm (less than 4mm thickness is acceptable).
Trough Floor(202d)
- Examine trough floors (in bays adjoining lavatories and under luggage compartments) for corrosion
- Tapping with a spiked hammer augments visual inspection
- If corrosion is present, widen the inspection area to assess extent; a 300mm wide cut may be needed
- Use plywood/compreg flooring/PVC overlay flooring in lavatories & bays, from below, and do a thorough inspection for corrosion.
Tubular Frame Below Lavatories (202d)
- Visually inspect tubes and joints for corrosion
- Replace corroded tubes; replacing the entire tubular frame is necessary if extensive damage is found.
Roof Repairs (203)
- Check ICF coach roofs for corrosion, prioritizing locations where gutters and ventilators are fixed
- Repair corroded roofs according to RDSO Technical Pamphlet no. C-7602 (Rev.1).
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Description
Explore the integral design concepts of coach shells in this quiz. Learn about the materials used, structures involved, and the benefits of hollow girders in reducing tare weight. Understand the specific dimensions and components that contribute to the safety and efficiency of ICF coaches.
