Railway Coach Maintenance Procedures

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Questions and Answers

What is the purpose of using scotch blocks with a locking arrangement on the dynamo belt?

To secure the dynamo in place during operation.

To facilitate faster maintenance work.

To protect electrical connections during maintenance. (correct)

To enhance the dynamo's efficiency.

Which maintenance task should be performed to check the underframe of the coach?

Use a pneumatic/water jet for cleaning. (correct)

Intermediate shock absorbers should be tested.

Inspect the bogie for paint deterioration.

Air vent screws must be unscrewed.

What should be done with the bolster springs during maintenance?

Leave them compressed during the entire process.

Wrap them in plastic to prevent rust.

Insert blocks to keep them compressed. (correct)

Remove them completely from the underside.

After completing repairs, what must be done before lowering the coach body?

Refit all repaired sub-assemblies. Signup and view all the answers

What is the function of the centre pivot cotter in maintenance?

It secures the centre pivot in position. Signup and view all the answers

What type of maintenance is required for the lavatory chute?

Requires unscrewing air vent screws above dash pots. Signup and view all the answers

Which task is related to ensuring the effectiveness of vacuum/air brake fittings?

They must be tightly secured in place after inspection. Signup and view all the answers

What is the main focus of the body repair process described?

Painting and interior panel repairs Signup and view all the answers

How many total days are allocated for the entire repair process?

18 days Signup and view all the answers

What type of fitment is NOT mentioned in the outlined procedures?

Windshield fitment Signup and view all the answers

Which item requires a testing procedure after its fitment?

Electrical equipment Signup and view all the answers

What is one of the last steps in the body repairing process?

Final inspection and despatch Signup and view all the answers

Which of the following is a part of the repair process related to plumbing?

Fitting of water tank Signup and view all the answers

Which process involves the use of a vacuum or air brake?

Testing and final works Signup and view all the answers

How many types of fitments are included in the body repair modifications?

Seven Signup and view all the answers

For which component is leakage testing required?

Water tank Signup and view all the answers

What action must be ensured for proper examination of a train at night?

Both sides of the track must have proper lighting. Signup and view all the answers

What should the C&W staff do before the arrival of a train?

Position themselves at the nominated rolling in place. Signup and view all the answers

What is required from the Engineer (C&W) before the train is dispatched?

A fitness certificate must be received. Signup and view all the answers

What is the role of the Station Master regarding train dispatch?

To receive and verify the fitness certificate. Signup and view all the answers

What should C&W staff monitor as the train passes the nominated point?

Loose or broken undergear parts. Signup and view all the answers

What is the maximum height from the rail level for RCF AC coaches?

1105 mm Signup and view all the answers

What is the minimum height requirement from the rail level for RCF Non AC coaches?

1090 mm Signup and view all the answers

What is the maximum additional height that can be added using compensating rings?

12 mm Signup and view all the answers

Which aspect must be ensured while lowering the bogie frame onto the wheels?

The bogie frame is set evenly on the four axle boxes Signup and view all the answers

What must be measured after loading the bogie with packing and compensating rings?

Height of the bolster top surface from rail level Signup and view all the answers

What condition should the track be in before measuring the height of the bolster?

In perfect level and straight condition Signup and view all the answers

How often should the nominated portion of the track be attended and leveled?

Once every month Signup and view all the answers

Who is responsible for ensuring the nominated portion of the track is leveled?

Track engineer Signup and view all the answers

What action is required if the height of the bolster top surface does not match predetermined dimensions?

Further adjustment of buffer height should be decided Signup and view all the answers

What is the tare condition of a coach primarily measured against?

Under its tare condition Signup and view all the answers

What should be ensured before the buffer height adjustment of the coach is taken up?

All the buffers are secured firmly in position. Signup and view all the answers

What must be done if the buffer height requires further adjustment?

Release the load on the axle box springs. Signup and view all the answers

What is the maximum height for the total of primary springs and compensating rings?

295 mm Signup and view all the answers

What is the minimum clearance required between the axle box wing lugs and safety straps?

40 mm Signup and view all the answers

How should packing rings be positioned during buffer height adjustment?

Under the flanges of the lower spring seats. Signup and view all the answers

Which aspect of the wheels is important before performing the buffer height adjustment?

Their diameters. Signup and view all the answers

What should be done to adjust the clearance between the axle box crown and the bogie frame?

Refer to a designated table for adjustments. Signup and view all the answers

What is the purpose of the packing rings during buffer height adjustment?

To maintain the desired height. Signup and view all the answers

What should follow the release of the load on the axle box springs?

Insert packing rings below the axle box springs. Signup and view all the answers

Why is it necessary to measure the wheel diameters before buffer height adjustment?

To ensure the buffer height is within specified limits. Signup and view all the answers

What is the buffer height of a coach expected to be in its tare condition?

As specified in Table 1.2 Signup and view all the answers

In relation to the maintenance of ICF design coaches, what is a significant factor to consider regarding buffer height?

The tare weight of the coach Signup and view all the answers

What does the term 'tare condition' refer to in the context of coach maintenance?

The specification of the coach under no load Signup and view all the answers

What percentage of brake power must a train have if it is attended on the platform without secondary examination?

90% Signup and view all the answers

Which of the following documents provides detailed information regarding the underframe dimensions for ICF coaches?

C.R.DRG U/FRAME 2742 Signup and view all the answers

Which method is recommended for measuring the temperature of axle boxes?

Electronic temperature measuring device Signup and view all the answers

What is one of the specific details mentioned for the buffer height adjustment procedure?

Adjustment must be made in a stationary condition Signup and view all the answers

What should be ensured before starting the examination of a train that has come to a halt?

The train is protected with appropriate signaling Signup and view all the answers

Which component is indirectly related to the maintenance of coaches to ensure that buffer height remains within specifications?

Compensating rings used in the suspension system Signup and view all the answers

Why is it important to maintain the specified buffer height in coaches?

To ensure safe coupling with other coaches Signup and view all the answers

What action is required to check the brake release on a train?

Physically move the brake beam Signup and view all the answers

Who is responsible for obtaining signatures on the operational cylinder records?

Engineer (C&W) Signup and view all the answers

What is the minimum permissible wheel diameter for a coach after POH?

836 mm Signup and view all the answers

Where should compensating rings be provided according to tare weight considerations?

Over lower spring seats Signup and view all the answers

Which of the following components are NOT mentioned in relation to the acceptable wheel diameter?

WGFACCW Signup and view all the answers

Which agency issues the suspension diagrams for the coaches?

ICF and RCF Signup and view all the answers

What should not be less than 836 mm according to the maintenance manual?

Wheel diameter of coaches Signup and view all the answers

Which is true regarding the arrangement of components in suspension diagrams?

Specific layouts are assigned for each coach type Signup and view all the answers

What is the consequence of a wheel diameter being less than the permissible limit?

Potential structural failures or instability Signup and view all the answers

Which component is described as being affected by the tare weight of coaches?

Compensating ring Signup and view all the answers

Which term refers to the system used to depict the arrangement of springs in a coach?

Suspension diagrams Signup and view all the answers

What is the maximum allowable variation in all four bogie corner heights?

10 mm Signup and view all the answers

What is the unsprung mass per bogie stated in the content?

3.2 tP Signup and view all the answers

What is the maximum compensation allowed by means of compensating rings in primary suspension for all coaches except ACCN (SG)?

20 mm Signup and view all the answers

Which drawing numbers are superseded by the drawing mentioned in the content?

WTAC3-9-0.306, AE90014, and AE90015 Signup and view all the answers

What should be ensured regarding dimensions A & B marked in the context?

They should be less than dimensions C & D. Signup and view all the answers

What is the tare and gross condition reference for the height of axle box spring and bolster spring?

They are for reference only. Signup and view all the answers

In the context, what weight is mentioned for each bogie?

6.2 tP Signup and view all the answers

What is the maximum height stated for the total of primary springs and compensating rings?

120 mm Signup and view all the answers

What is one of the specific requirements for the compensating rings in ACCN (SG) mentioned in the content?

Must be 30 mm in primary suspension Signup and view all the answers

What must be done with compensating rings in controlling primary and secondary suspension?

Avoid exceeding specific limits Signup and view all the answers

What is the maximum tare weight of the coach specified?

19.45 tonnes Signup and view all the answers

Which value indicates the tare height of the bogie bolster?

1104+0/-10 Signup and view all the answers

What is the gross bogie frame clearance specified for the coach?

43±5 Signup and view all the answers

Which of the following values represents the tare weight of the driving axle load?

5.12 tonnes Signup and view all the answers

What is the minimum allowable height for the bolster spring in CR?

3 Signup and view all the answers

Identify the gross height of the bogie bolster defined in the data.

640+8/-5 Signup and view all the answers

Which specified variation refers to the normal payload of the underbogie?

9.8 tonnes Signup and view all the answers

What is the tare bolster clearance measurement according to the standards?

40±5 Signup and view all the answers

What is the gross clearance requirement for the BODY BOGIE?

67±3 Signup and view all the answers

What do the numbers 282+5/-3 represent in this context?

Tare bogie bolster height Signup and view all the answers

Study Notes

Coach Maintenance

Introduction: The first attempt at standardizing passenger coach manufacturing on Indian Railways led to the development of the IRS steel-bodied coach design. An all-metal coach design was adopted from Switzerland in 1954.
Coach Design Evolution: Bogies were initially designed for 96 kmph, later modified for 105 kmph standard track and 140 kmph for Rajdhani/Shatabdi Express trains. Helical springs replaced laminated springs in secondary suspension.
Coach Types: Various coach layouts exist, including second-class sitting, sleeper, upper-class, air-conditioned chair car, sleeper, pantry cars, generator/luggage cars, passenger cars, postal vans and luxury coaches.
Coach Life: The lifespan of coaches, including dining cars, is 25 years. IRS coaches have a lifespan of 30 years, and light utilization coaches last 40 years.
Periodic Overhauls (POH): Coaches undergo POH at designated workshops based on usage.
- Mail and Express Coaches (PCVs and OCVs):
 - Annual mileage < 2.5 Lakhs km: 18 months
 - Annual mileage > 2.5 Lakhs km: 12 months
- Coaches other than Mail and Express:
 - Other than Mail/Express: 24 months
 - AC coaches: 12 months
- Rajdhani and Shatabdi Express Coaches: 18 months or 2 Lakhs km, whichever is earlier.
- Other coaches: 24 months or 4 Lakhs km, whichever is earlier.

Lifting the Coach Body

Procedure: Coaches are lifted off bogies using either overhead cranes or powered lifting jacks.
Safety: Lifting should be uniform and avoid jerks. Lifting from one end should be avoided, as it can damage the coach body.
Components Removed: Removal of components like dynamo belts, electrical connections, and other related items, is mandatory before lifting.
Trests: Coaches are placed on trestles to facilitate repairs. Protection of the underframe is crucial during lifting.

POH Work and Procedures

General Sequence: The overall POH (Periodical Overhaul) process is outlined in a PERT chart, showing the steps involved, and estimated time for each.
Essential Procedures: The tasks include stripping, body repair, modifications, painting, plumbing repairs, electrical work, interior panel repairs, door replacement, berth/seat replacement, brake testing, and final inspection. These activities are carried out in a defined order and timeline.

Other Important Information

Buffer Height: The buffer height of a coach is measured under tare condition and should be within specified limits (see Table 1.2). The bogie assembly and adjustments are crucial to ensure safe and proper running.
Coach Dimensions: Standard dimensions of coaches and their relevant parameters are included in several tables.
Testing Parameters: Standards for testing various aspects of coaches are detailed in several tables (Tables 1.3, 1.4, 1.5, and 1.6). These tables include specific figures for various coach types and loads.
Maintenance Schedules: Different maintenance schedules (A, B, and C) are detailed. The purpose, frequency, and applicable coaches of each schedule are outlined, with specific details about examination frequency and timings.
Examination of Trains: Essential procedures for examining trains at different stages—originating, enroute, and terminating. Safety, location, and timing factors are vital. This includes inspection of brake systems, undercarriage, and all other aspects in a timely manner to ensure safe running.
Open-Line Maintenance of Parcel Vans: Procedures for ensuring proper maintenance of parcel components, frequency of assessment, and inspection measures, are outlined to support the need for timely evaluation and proactive maintenance.
Maintenance Patterns: Procedures for NMG (Non-Motorised Goods) rakes are specific, outlining necessary considerations for their operational needs.
Special Practices: Practices for high-speed trains and special coaches like power vans are emphasized. Other special operational provisions, like those for Intermediate Overhaul (IOH) and schedule 'C' maintenance, are described in more detail.
Coach Repair and Maintenance Procedure: The text outlines procedures for sending coaches for repair to workshops. Aspects like security, documentation, and depot procedures are detailed.

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Description

Test your knowledge on the essential maintenance procedures for railway coaches, including tasks related to the underframe, springs, and braking systems. This quiz covers various aspects of coach repairs and outlines the specific steps required during maintenance operations. Assess your understanding of the repair processes and their significance in ensuring operational safety.