Maintenance Manual for BG Coaches of ICF Design PDF

Maintenance Manual for BG coaches of ICF design Painting CHAPTER 12 PAINTING 1201 GENERAL 1202c After allowing adequ...

Maintenance Manual for BG coaches of ICF design Painting CHAPTER 12 PAINTING 1201 GENERAL 1202c After allowing adequate drying time for primer, the entire coach should be 1201a After the coach body is fully repaired applied with the first coat of brushing and the flooring work completed, it filler to IS 110-83 by spray/brush to a should be swept and cleaned of all dust, DFT of 30 micron minimum. shavings, etc., before the coach is placed 1202d (i) After hard drying of filler, apply the in the Paint shop for painting and first coat of knifing stopper putty polishing. to IS:5083-88 followed by spot 1201b The condition of the paint on the inside putty application and wet rubbing. and outside surfaces should be examined (ii) After ensuring drying of water, to decide whether the old paint should apply necessary putty to get a be removed to the bare metal. Usually, uniform surface followed by wet extensive corrosion repair work rubbing. necessitates removal of old paint to bare (iii) After drying of water, apply metal and complete repainting of the second coat of filler to IS:110-83 coach. to a DFT of 30 microns minimum. 1201c If the condition of the paint so warrants or at every 5th POH of a coach, the paint 1202e The dry surface should be wet rubbed should be completely removed to the down with bone cuttle and silicon bare metal and the coach repainted as carbide water proof paper grade 120 per paint schedule `A'. If the general and 220. It should then be allowed to condition of the paint is good, follow dry. paint schedule `C'. These paint 1202f After ensuring that there is no trace of schedules cover the exterior painting of water on the surface, a coat of under- coaches with synthetic enamel paint coating to IS 8662-93 should be system. RDSO Sketch No :CSC - 1723 sprayed or applied by brush to a DFT of gives the exterior colour scheme of the 25 microns minimum. coaches (Sketch no. CSC - 1723 has 1202g The entire surface should again be been made into two parts i.e. figure rubbed down smooth with silicon 12.1a & figure 12.1b and attached at carbide water proof paper grade 320 pages 2 and 3). and after drying, a coat of enamel finishing to IS 8662-93 should be 1202 PAINT SCHEDULE `A' (Refer applied to a DFT of 20 microns Annexure 12.1) minimum. 1202h After the first coat of finish enamel has 1202a The entire surface should be applied dried completely, it should again be with a suitable paint remover and the old flattened with silicon carbide water paint scraped off. Thereafter, the coach proof paper grade 400 and apply a surface shall be swabbed with petroleum second coat of synthetic finish enamel to hydrocarbon solvent to IS:1745 to remove all traces of paint remover. IS 8662-93 to a DFT of 20 microns minimum. 1202b After the surface dries up completely, it 1202i The door handles, if not chrome plated, should be sand papered to make it should be painted with golden yellow to slightly rough and a coat of red oxide IS 8662-93. The foot steps, roof, etc., zinc chromate primer to IS 2074 -92 to a should be painted as per prescribed DFT of 25 microns minimum should colour scheme. be applied by spray/brush immediately. 1202j Standard lettering, as sp ecified, should Where facilities exist, the entire coach be done with golden yellow to IS 8662- body should be sand blasted and the 93. Similarly, all standard schedule primer coat of red oxide zinc chromate charts, signs, etc., should be should be applied by spray/brush stenciled/painted as prescribed. immediately thereafter. Chapter 12, Page 1 of 6 Maintenance Manual for BG coaches of ICF design Painting Maintenanc e Manual for BGICFc oaches Cha pter 12, Page 2 of 6 GULF RED Figure I : Vacuum Brake Trains A. Side wall - Gulf Red shade No. 473 AIRCRAFT BLUE 5 7 SATIN BLUE 75 AIRCRAFT BLUE Figure II : Air Brake Trains other than Rajdhani & Shatabdi Express A. Side wall upto 75 mm below window and from 75 mm above window - Air Craft blue shade No. 108 B. Side wall window area 75 mm above and below windows - Satin blue shade No. 177 NOTE: 1. For special rakes, instructions as per Rly. Board's letter No. 76/M (C)/137 / 31 dated 5.6.1986 shall be followed. 2. Postal portion of partial postal vans shall be painted with postal red. 3. Existing procedures for roof and end wall painting, lettering and exterior markings continue unchanged. 4. All finishing paints should be to specification No. IS:8662-93 and coloures to specification No. IS:5-94 EXTERIOR COLOUR SCHEME FOR MAIN LINE COACHES Painting RDSO Sketch No. CSC-1723. Approved vide Railway Board's letter No. 97/M (C)/ 137 / 20 dated 23.6.98 FIGURE 12.1a Chapter 12, Page 2 of 6 Maintenance Manual for BG coaches of ICF design Painting Maintenance Manua l for BG ICF coaches Cha pter 12, Pa ge 3 of 6 SIGNALRED 60 OFFWHITE SIGNAL RED BAND 7 88 60 O FFWHI TE OFFWHITE SIGNAL RED BAND OFFWHITE 11 4 SIGNALRED Figure III : Rajdhani Express A. Side walls upto 234 mm below window and from 234 mm above window - Signal Red shade No. 537 B. Band of 60 mm above and below windows at a distance of 114 mm from window - Signal Red shade No. 537. C. Side wall window area 234 mm above and below window - Off white ICI shade No. 28-1004 PALE CREAM OXFORD BLUE BAND PALE CREAM BAND 1 00 50 OXFORD BLUE Figure IV : Shatabdi Express A. Side walls upto lower window sill - Oxford Blue shade No. 105 B. Side wall above lower window sill - Pale cream shade No. 352 C. Band of 100 mm at a distance of 50 mm below lower window sill - Pale cream shade No. 352 EXTERIOR COLOUR SCHEME FOR MAIN LINE COACHES Pa inting RDSO Sketch No. CSC-1723. Approved vide Railway Board's letter No. 97/M (C)/ 137 / 20 dated 23.6.98 FIGURE 12.1b Chapter 12, Page 3 of 6 Maintenance Manual for BG coaches of ICF design Painting 1202k Finally, the window glasses, etc., should § Laminated panels should be polished be cleaned well and all paint marks with silicon paste or similar suitable removed. Any damage to the paint polish to restore luster and also to should be touched up before the coach is provide a protective coating. turned out after POH. § Coaches other than those fitted with laminated plastic panels should be 1203 PAINT SCHEDULE `C' cleaned with soap solution or suitable detergent and thereafter § The portions where paint has flaked cleaned thoroughly with wet cloth so or is damaged, should be scraped off that all head stains, oily marks, etc., of all the loose and damaged paint. are completely removed. Then a The coach should then be washed single coat or, if required, a double thoroughly with soap and water and coat of synthetic enamel to IS:133 - allowed to dry. Then a coat of red 93 should be applied by brush/spray. oxide zinc chromate primer to IS 2074-92 should be applied by brush § In case where the old paint has at the places where metal surface is become thick due to repeated visible. painting or where the paint has § After the primer dries up completely, deteriorated or cracked, the wooden it should be puttied and a coat of panel should be removed and under -coating to IS 8662-93 should replaced or reused after completely be applied at these portions. removing the old paint and § The complete coach shall thereafter repainting it. be painted in the manner described in paragraphs 1202g to 1202k above. 1205 PAINTING OF PARTS 1204 INTERIOR PAINTING § The laminated plastic seats or moulded seats of synthetic materials § Newly built coaches with laminated require no painting. They should plastic panels require painting only only be thoroughly cleaned with on the steel mouldings. The soap solution or suitable detergent. mouldings should be cleaned in § In case of seats made of wooden every POH and repainted with one battens, the battens which have been coat of synthetic enamel to IS:133- replaced should be sand papered 93 of appropriate colour. Sketch smooth and a coat of filler should be 90068 gives the interior colour applied. Then, entire surface scheme of coaches. including old painted surface should § If the condition of the paint on the be sand papered smooth and the mouldings has deteriorated or seats should be repainted with a coat become thick, the complete paint of enamel finishing of the prescribed should be removed by the paint colour to IS 133-93. remover. The moulding should then be washed thoroughly, allowed to 1206 MARKING OF COACHES dry and repainted with one coat Red- TOGETHER WITH EXTERIOR oxide zinc chromate primer to IS:2074 -92 followed by synthetic All lettering on coaches should be enamel to IS 133 -93 of appropriate according to the sizes prescribed in the colour. marking diagrams for the type of coach to which they pertain (refer RDSO drawing § Aluminum window frames should number CSC-970). Anti telescopic coach not be painted, but should be end walls should be marked with yellow thoroughly cleaned of all stains in stripes as sketch no. 77356. Each should position. If they are very dirty, they be marked with following details: should be removed and cleaned with oxalic acid. FRP windows should be i) Coach No., Owning Railway, painted with polyurethane paints to and Mechanical code if any. RDSO specification No. M&C/ PCN/100/ 96 (Chapter IV). ii) Name of base station for primary maintenance Chapter 12, Page 4 of 6 Maintenance Manual for BG coaches of ICF design Painting iii) No. of compartments and seating § Specific gravity (at full capacity as prescribed for the charge) type of coach § Corrected to temperature iv) Notices for use of alarm signal, § Cell watered on safety precautions etc. if separate § Cell examined on notice plates for these are not placed. 1207 TOOLS AND PLANTS FOR v) Transportation code applicable to PAINTING the type of coach as per appendix ‘B’ of IRCA Conference Rule 1207a Types of brushes part IV. vi) Carrying capacity of OCV’s to i) Round brushes nos. 1/0, 2/0, 3/0 & the nearest tonnes up to one 4/0. decimal place above actual capacity. ii) Flat brushes nos. 25 mm, 38 mm, vii) Tare weights as recorded at the 50 mm, 63 mm, 75 mm, 100 mm time of initial building or iii) Lettering brushes: subsequent major modifications. § Flat brushes nos. 1 to 12 viii) A woman’s fi gure head painted on illuminated panel of § Round brushes nos. 1 to 12 compartments permanently iv) Stencil brushes reserved for ladies. ix) Return date showing the month v) Cleaning brushes for LP sheets with and year in which the coach is soda ash required to be returned to the owning railway workshop for 1207b Putty knife POH. x) A block as shown below to be i) Pallet knife stenciled on the left side of end panel ii) Falling knife iii) Haking knife Table 12.1 Schedules Station Date 1207c Scrapers code Disinfected Alarm chain periodical i) Shave tukes examination done ii) Triangular Dash pot oil checked iii) Semi circular Side bearer oil level checked iv) Diagonal Over head tank flushed Intermediate lifting 1207d Abrasive papers DA valve examined i) Silicon carbide water proof paper Note: Size of letters should be grade nos. 120, 220, 320 & 400. 10 mm and the block 350x250mm. 1207e Safety apparels xi) The capacity of the dynamo and light/fan loads to be stenciled on i) Goggles the end panels. xii) The following legends should be ii) Helmet stenciled on battery box covers to iii) Gum boots enable stenciling of necessary particulars against each. 1207f Painting spray gun with air compressor § Make plant for painting. § Type Chapter 12, Page 5 of 6 Maintenance Manual for BG coaches of ICF design Painting Annexure 12.1 A SCHEDULE (NINE DAYS) 1st Day : Remove old paint 2nd Day : One coat of Red Oxide Zinc chromate primer. 3rd Day : One coat of brush filler followed by spot putty to fill up holes/dents where required. 4th Day : Filler second coat (including spot putty where necessary) 5th Day : Rub down with silicon carbide water proof paper Gr. 120 & 220 6thDay : One coat of under coat 7th Day : Flat with silicon Carbide water proof Paper Gr. 320. One coat of enamel finishing. 8th Day : Flat with silicon Carbide water proof Paper Gr. 400 and apply a second coat of synthetic enamel finishing. 9th Day : Lettering with Golden yellow and miscellaneous work (cleaning window glasses etc.) Annexure 12.2 POH PAINTING PROCEDURE "C" SCHEDULE 1st Day : Cleaning with soap solution or any other cleaning solution and wash thoroughly with water touch up damaged portion with primer recommended under A sch edule. 2nd Day : Spot putty if necessary and one coat of under coat. 3rd Day : Flat with silicon carbide water proof paper Gr. 120 & 220, and apply one coat of finishing enamel. 4th Day : Flat with silicon carbide water proof Gr. 400 and apply a second coat of synthetic enamel finishing. 5th Day : Lettering with golden yellow and miscellaneous work. ***** Chapter 12, Page 6 of 6