Maintenance Manual for BG Coaches of ICF Design (PDF)

Maintenance Manual for BG coaches of ICF design Coach CHAPTER 1 COACH 102 CODAL LIFE OF COACHES...

Maintenance Manual for BG coaches of ICF design Coach CHAPTER 1 COACH 102 CODAL LIFE OF COACHES 101 INTRODUCTION Steel bodied coaches 25 years The first attempt at standardisation of (including dining/pantry cars) manufacture of passenger coaches on Indian Railways led to the development of IRS coaches 30 years IRS design of steel bodied coaches. An integral all metal coach design was taken Light utilisation categories of 40 from M/s Schlieren, Switzerland in 1954 coaches years for manufacture at Integral Coach Factory, Perambur. The original design had bogies with speed potential of 96 kmph only. The 103 PERIODICITY OF PERIODIC design was modified to all coil bogies OVERHAULS (POH) IN with longer suspension hangers and DESIGNATED WORKSHOPS weight transfer through side bearers, Table 1.1 thereby enabling speed potential to 105 kmph on main line standard track and i) PCVs and OCVs on Mail and Express gradually to 140 kmph for rakes Rajdhani/Shatabdi Express trains on tracks maintained to standards laid down (a) Coaches earning 12 months in RDSO report No. C&M-I, volume I. less than 2.5 lakhs kms. per Over the years changes have been made to annum use helical springs instead of laminated springs in the secondary suspension while (b) Coaches earning 12 months with IOH minor changes in the shell have been more than 2.5 after 6 months made to reduce corrosion and improve the lakhs kms. per strength of certain members. At present annum all new coaches are being manufactured with bogie mounted air brake system and ii) PCVs on other 18 months. 12 months enhanced capacity draw gear. To meet the than Mail and for AC coaches. demands of the passengers, coaches of Express rakes various layout like second class sitting accommodation, sleepers, upper class, air iii)OCVs on other 24 months conditioned chair car and sleeper, pantry than Mail and cars, generator cars, luggage-cum- Express rakes passenger cars and postal vans have been designed and manufactured. Luxury iv)Rajdhani and POH in workshops coaches mainly to boost tourism having Shatabdi after 4 lakhs kms or 18 air conditioned sleeping and sitting Express Coaches months whichever is accommodation with catering facilities earlier. have also been designed and IOH in workshops after manufactured. On date, more than a 2 lakhs kms or 9 hundred coach layouts catering to the months whichever is needs of different class of passengers are earlier on line. Transportation codes for coaches in general use are given in Appendix A. Chapter 1, Page 1 of 41 Maintenance Manual for BG coaches of ICF design Coach 104. PERIODICAL OVERHAUL (xiv) Battery box and electrical fittings. (xv) AC equipment in AC coaches. 104a The general sequence of work during POH of a coach is given in a typical 105c Coach body should be lifted off the bogies PERT chart for normal POH as shown in either by two overhead electric cranes of figure 1.1. 25 tonnes capacity each with suitably 104b List of “must change items” during POH designed lifting tackles or by four is given in Appendix B powered lifting jacks of 15 tonnes capacity each operated simultaneously by 104c Modifications in BG coaching stock is one control switch. The coach body given in Appendix C should be lifted uniformly without jerks 104d List of relevant RDSO's technical and should remain horizontal during the pamphlets/instructions/specifications is lifting/ lowering operation. Coach should given in Appendix D. not be lifted from any point other than at the lifting pads as shown in figure 1.2 105 LIFTING THE COACH BODY (sketch 68078). 105a On receipt of a coach for POH, it must be 105d The coach should never be lifted from one taken on Lifting line/ Stripping line where end only. If lifted from one end, the electrical fittings should be stripped and Centre pivots and the dash pot guides are batteries removed. Furnishings, especially likely to suffer damages, body panels are seats and backrests should be inspected likely to get dented near the body bolster. thoroughly and only those that require The sealed windows of AC coaches are repairs or attention should be removed. also likely to break. 105b Before lifting a coach, the following components should be removed, 105e After the coach body is lifted, it should be disengaged or disconnected:- kept on trestles. The revolving steel (i) Dynamo belt on the axle pulley in trestles of the design shown in Figure 1.3 case of underframe mounted (sketch 77310) would prove useful for this dynamos and disconnection of purpose Lines should be protected by electrical connection from junction scotch blocks with locking arrangement box on alternator in case of bogie and key should be kept with Engineer till mounted alternator. the time maintenance work is carried out. (ii) Lavatory chute, if situated over the 105f The entire under frame should be cleaned bogie. of dust, rust etc. from underneath by (iii) Brake pull rod from bogie brake pneumatic/water jet followed by wire rigging. brushing at critical locations and check for (iv) Centre pivot cotter. cracks/damage, corrosion etc. on the (v) Axle box safety straps. under frame members. Refer chapter 2 (Shell) for carrying out repairs on the (vi) Bolster safety straps. coach shell. (vii) Steel/ wooden blocks of requisite thickness should be inserted in 105g After carrying out all repairs, the under between the bolster and bogie frame should be painted as detailed in the frame on both sides and of both the chapter on Painting. bogies so as to keep the bolster springs compressed. 106 LOWERING THE COACH BODY (viii) Dismantle vertical shock absorbers. 106a After all the repairs are carried out refit all (ix) Air vent screws on bogie frame repaired sub-assemblies which are above dash pots should be removed for maintenance and lower the unscrewed completely after coach body on the overhauled and tested cleaning the area around the air bogies. vent holes properly. (x) Vacuum/air brake fittings 106b The Centre pivot cotter should be fitted (xi) Buffer and draw gear into position and secured by means of a (xii) Lavatory chutes split pin. A bottom cover should be fitted in position to cover the entire assembly to (xiii) Under slung water tanks & WRAS, prevent dust getting in. where provided. Chapter 1, Page 2 of 41 Maintenance Manual for BG coaches of ICF design Coach NETWORK FOR POH OF COACHES (NORMAL REPAIRS) I 6 1 F 7 3 A B C D E K L 1 2 3 4 5 10 11 12 1 1 2 3 9 1 1 G J M 3 3 8 H 1 9 2 N ACTIVITY DESCRIPTION 9 DURATION (Days) A. VERIFICATION OF DEFICIENCIES.PB. PRE-INSPECTION & LIFTINGPC. STRIPPINGPD. BODY REPAIR, MODIFICATIONS AND ALTERATIONSPE. PAINTINGPF. FITTING OF WATER TANK, PLUMBING & LEAKAGE TESTINGPG. REPAIRS TO INTERIOR 1P PANELSPH. FITMENT OF SHUTTERSPI. FITMENT OF DOORSPJ. FITMENT OF BERTHS & SEATSPK. VACUUM / AIR BRAKE 1P TESTING & FINAL WORKSPL. FINAL INSPECTION & DESPATCHPM. FITMENT OF AXLE PULLEY, TENSION ROD & TESTING OF 2P COACH WIRINGPN. TESTING OF BRANCH WIRING & FITMENT OF ELECTRICAL EQUIPMENT 3P 9P 3P 3P 2P 1P 3P 1P 1P 1P TOTAL DURATION= P18 DAYS 9 FIGURE 1.1 LIFTING PADS ON BODY LIFTING PADS AIR VENT SCREWS IN BOGIE SIDE FRAME SKETCH-68078 POSITION OF LIFTING PADS I.C.F. B.G. FIGURE 1.2 Chapter 1, Page 3 of 41 Maintenance Manual for BG coaches of ICF design Coach COACH 3250 NOTE:P1. SEE C.R.DRG. U/FRAME 2742 FOR DETAILS NO. J&TP SEE C.R.DRG. 150 DEV-99 &102 NO. J&T DEV-85P2. FOR ALTE RNATIVE DESIGNS FROM RAIL LEVEL 32 1100 1850 1200 FREE HEIGHT 25 600 275 3008 1250 1680 1250 SKETCH - 77310 REVOLVING STEEL TRESTLES 600 750 FIGURE 1.3 Chapter 1, Page 4 of 41 Maintenance Manual for BG coaches of ICF design Coach 106c Buffer height types of coaches (see suspension diagrammatic arrangement of ICF i) Buffer height of a coach under its self generating AC coaches in tare condition should be as under:- figure 1.4a and table nos. 1.3 & Table 1.2 1.4. See suspension diagrammatic arrangement of RCF AC coaches Maximum Minimum in figure 1.4b and table no. 1.5. height from height from See suspension diagrammatic rail level rail level arrangement of RCF Non AC Production 1105 mm 1095 mm coaches in figure 1.4c and table no. units 1.6). Over this, additional Workshops 1105 mm 1090 mm compensating rings can be added to a limit not exceeding 12 mm. ii) Buffer height of a coach should be iii) While lowering the bogie frame measured under its tare condition and the bolster assembly on to the from the top of the rail on a level and wheels, it should be ensured that straight track. For this purpose, a the bogie frame is set evenly on the specific portion of the track should four axle boxes. be earmarked in each carriage repair iv) The bogie assembled with packing workshop. Engineer (Permanent and compensating rings as required, Way) should get track attended and should now be loaded and the leveled once every month and then height of its bolster top surface give a certificate that nominated from rail level measured. This portion of the track has been fully should be compared with attended to and is in perfect level and predetermined dimensions to straight condition. decide on further adjustment of buffer height. iii) Before the buffer height adjustment v) If the buffer height requires further of the coach is taken up, it should be adjustment, the load on the axle ensured that all its buffers are box springs should be released and secured firmly in position. the packing rings in halves should iv) The diameters of all the wheels, be inserted below the axle box measured before the assembly of the springs. The total height of primary bogies must be available with the springs and compensating rings staff carrying out the buffer height should not exceed 295 mm. There adjustment. should be a minimum clearance of 40 mm between the axle box wing 106d Buffer height adjustment lugs and their safety straps. vi) The clearance between the axle i) To bring the buffer height to within box crown and the bogie frame the limits specified, depending on should thereafter be adjusted as per the wheel diameters, packing rings the table given below: of thickness as given in Table 3.18 of Bogie chapter should be kept Table 1.7 under the flanges of the lower spring seats as shown in Figure 3.17 Type of coach Crown (sketch 77354) in bogie chapter. clearance (mm) +0 NOTES: GS, SDC, SLR, SCN, 43 -3 VPH i) The lowest permissible wheel WCB, WFC, WFAC, 27+0 diameter for a coach turned out WSCZAC, WGSCZAC, -3 after POH shall not be less than WCBAC, WLRRM, 836 mm. WFCZAC, WGFAC, ii) According to tare weight of WACCW, WGACCW, coaches compensating ring shall be WGFACCW, WACCN, provided over lower spring seats as WGACCN shown in suspension diagrams issued by ICF and RCF for various Chapter 1, Page 5 of 41 Maintenance Manual for BG coaches of ICF design Coach PART- I BOGIE FRAME C BOGIE BOLSTER G A D E L.S. BEAM F M B RAIL LEVEL PART- II BODY BOLSTER H BOGIE FRAME SIDE BEARER K BOGIE BOLSTER J NI L RAIL LEVEL NOTE - P1. Dimensions E & J shall be maintained with required number of compensating rings of standard thickness of 4 mm.P2. Axle box springs : WTAC -0-1-202P Bolster springs : WTAC -0-5-202 2 2 SUSPENSION DIAGRAMMATIC ARRANGEMENT FOR SELF GENERATING AC COACHES (ICF DRAWING NO. ICF/SK -9-0-126)P 2 FIGURE 1.4a Chapter 1, Page 6 of 41 Maintenance Manual for BG coaches of ICF design Coach SUSPENSION DATA FOR SELF GENERATING AC COACHES (DRAWING NO. ICF/SK 2-9-0-126) Table 1.3 COACH LOAD A B C D E F G H I J K L MY Y NYY Nominal Nominal WGFAC4 Tare 38±5 40 ±5 36 ±3 275+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 299+6/-4 310 ±3 40 ±5 646 ±5 15 11 Gross 34+8/-5 44 ±5 32 +5/-2 275+6/-4 286 ±3 682 ±5 1098 +8/-5 66 ±3 295+6/-4 308 ±3 44 ±5 638 +8/-5 - - WGSCZAC Tare 38±5 40 ±5 36 ±3 276+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 300+5/-4 310 ±3 40 ±5 646 ±5 14 10 Gross 23+8/-5 54 ±5 22 +5/-2 262+6/-4 276 ±3 672 ±5 1075 +8/-5 55 ±3 285+7/-4 295 ±3 55 ±5 617 +8/-5 - - WGSCWAC Tare 38±5 40 ±5 36 ±3 274+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 298+6/-4 310 ±3 40 ±5 646 ±5 16 12 Gross 28+8/-5 49 ±5 27 +5/-2 265+6/-4 281 ±3 677 ±5 1085 +8/-5 60 ±3 288+7/-4 300 ±3 50 ±5 627 +8/-5 - - WGFSCZAC Tare 38±5 40 ±5 36 ±3 272+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 296+6/-5 310 ±3 40 ±5 646 ±5 18 14 Gross 28+8/-5 48 ±5 28 +5/-2 264+6/-4 282 ±3 678 ±5 1086 +8/-5 60 ±3 286+7/-4 300 ±3 50 ±5 628 +8/-5 - - WGFSCWAC Tare 38±5 40 ±5 36 ±3 273+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 297+6/-4 310 ±3 40 ±5 646 ±5 17 13 Gross 31+8/-5 46 ±5 30 +5/-2 267+6/-4 284 ±3 680 ±5 1091 +8/-5 63 ±3 290+7/-4 303 ±3 47 ±5 633 +8/-5 - - WGMWAC Tare 38±5 40 ±5 36 ±3 282+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 307+6/-3 310 ±3 40 ±5 648 ±5 8 3 Gross 32+8/-5 45 ±5 31 +5/-2 277+6/-4 285 ±3 681 ±5 1093 +8/-5 64 ±3 301+6/-4 304 ±3 46 ±5 635 +8/-5 - - 38±5 40±5 36±3 279+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 304+6/-4 310 ±3 40 ±5 646 ±5 DRIVING Tare 11 6 END Gross 35+8/-5 43±5 33+5/-2 276+6/-4 287 ±3 683 ±5 1098 +8/-5 67 ±3 301+6/-4 307 ±3 43 ±5 640 +8/-5 - - ARMVAC Tare 38±5 40±5 36±3 272+6/-4 290 ±3 686 ±5 1104 +0/-10 70 ±3 296+6/-4 310 ±3 40 ±5 646 ±5 18 14 DRIVING NON END Gross 33+8/-5 44±5 32+5/-2 268+6/-4 286 ±3 682 ±5 1095 +8/-5 65 ±3 291+7/-4 305 ±3 45 ±5 637 +8/-5 - - WEIGHT AND TEST LOAD (IN TONNES) FOR SELF GENERATING AC COACHES (DRAWING NO. ICF/SK2-9-0-126) Chapter 1, Page 7 of 41 Maintenance Manual for BG coaches of ICF design Coach Table 1.4 Description WGFAC4 WGSCZAC WGSCWAC WGMWAC ARMVAC Tare weight of the coach 49.75 49.30 50.00 46.50 49.30 Weight of the bogie 6.200 6.200 6.200 6.200 6.200 Weight of the bolster 0.400 0.400 0.400 0.400 0.400 Unsprung mass per 3.200 3.200 3.200 3.200 3.200 bogie Normal pay load 1.440 5.680 3.680 2.275 1.495 (18x80 kg) (71x80 kg) (46x80 kg) (34+1)x65 kg (23x65 kg) Over load Nil Nil Nil Nil Nil Total pay load 1.440 5.680 3.680 2.275 1.495 Gross weight of the 51.19 54.98 53.65 48.78 50.79 coach Test Tare 18.68 18.45 18.80 17.05 DE NDE load/Bogie 17.87 19.23 Gross 19.38 21.29 20.64 18.19 18.31 20.08 Chapter 1, Page 8 of 41 Maintenance Manual for BG coaches of ICF design Coach PART- I %% c9 15 BOGIE FRAME X BOGIE BOLSTER A Z G B L.S. BEAM F # RAIL LEVEL 2896 (WHEEL BASE) PART- II BODY BOLSTER Weight of each bogie = 6.2 tPUnsprung mass/bogie = 3.2 tPBolster weight = 0.4 tPC.R. = Compensating Ring P D BOGIE FRAME SIDE BEARER C BOGIE BOLSTER H Y RAIL LEVEL NOTE - P1. Dimensions A & B marked should be ensured less than dimensions C & D marked respectively.P2. # CR to drawing No.-CC01140 to be provided.P3. * CR to drawing No. - CC05252 to be provided.P4. 'F' the variation in all the four bogie corner heights must be less than or equal to 10 mm.P5. Drawing No. WTAC3-9-0.306 alt -e, AE90014, AE90015 are superseded by this drawing.P6. The height of axle box spring and Bolster spring in tare and gross conditions is for reference only.P7. The requirement of CR's as shown in the columns for primary & secondary suspension is for reference only.P8. The compensation by means of CR's must not exceed 20 mm in primary in all coaches except ACCN (SG) inP ACCN (SG) it is 30 mm & 30 mm in secondary suspension for all coaches. SUSPENSION DIAGRAMMATIC ARRANGEMENT FOR AC COACHES (RCF DRAWING NO. AW 90017)P FIGURE 1.4b Chapter 1, Page 8 of 41  AC of (SG) (SG) Type (EOG) (EOG) (EOG) coach ACCZ ACCN ACCN ACCW ACCW 43.1 52.53 48.3 49.1 44.8 In tonnes Tare weight of coach 5.36 5.12 5.12 3.68 3.68 In tonnes Normal pay load Chapter 1, Page 10 of 41 5.36 5.12 5.12 3.68 3.68 In tonnes pay load Total 15.35 20.07 17.95 18.35 16.2 In tare tonnes Under bogie 18.03 22.63 20.51 20.19 18.04 In Test load per tonnes Gross Under Maintenance Manual for BG coaches of ICF design 40±5 40±5 40±5 40±5 40±5 Tare C bolster Gross clearance 54±5 53±5 54±5 50±5 50±5 Bogie frame 70±3 70±3 70±3 70±3 70±3 Tare D Gross clearance 56±3 57±3 56±3 60±3 60±3 Body bogie 290 +6/-3 268+7/-4 278+6/-4 276 +5/-4 286+5/-4 Tare G 278 +6/-4 256+7/-5 266+7/-4 268 +6/-4 278+6/-4 Gross Nil 22 12 14 4 # CR Axle box spring height Table 1.5 316 +6/-3 291+7/-4 303+6/-4 301 +6/-4 312+5/-4 Tare H 302 +6/-4 278+7/-5 289+7/-4 291 +7/-4 302+7/-5 Gross height Nil 19 7 9 Nil * Bolster spring CR 32±3 35±3 34±3 30±3 28±3 Tare X Crown clearance 20±3 23±3 22±3 22±3 20±3 Gross 646±5 646±5 646±5 646±5 646±5 Tare Y height 620 +8/-5 621+8/-5 620+8/-5 628 +8/-5 628+8/-5 Gross TESTING PARAMETERS FOR AC COACHES (RCF DRAWING NO. AW90017) Bogie bolster 1104+0/-10 1104+0/-10 1104+0/-10 1104+0/-10 1104+0/-10 Tare Z height Buffer 1078+8/-5 1079+8/-5 1078+8/-5 1086+8/-5 1086+8/-5 Gross Coach  AC of VP RA AC) IRQ (SG) (SG) Type (NON FACZ CITY) (EOG) coach ACCZ ACCN CAPA (HIGH RA AC 46.69 41.3 32 41.3 42.6 46.83 In tonnes Tare weight of coach 1.20 5.12 23 1.20 3.68 5.84 In tonnes load Norm al pay Chapter 1, Page 11 of 41 1.20 5.12 23 1.20 3.68 5.84 In tonnes pay load Total 17.14 19.45 9.8 14.45 15.10 17.22 In tare tonnes Under bogie 17.14 22.01 21.3 14.05 16.94 20.14 In Test load per tonnes Gross Under Maintenance Manual for BG coaches of ICF design 40±5 40±5 40±5 40±5 40±5 40±5 Tare C bolster clearance 43±5 54±5 81±5 44±5 50±5 56±5 Gross Bogie frame 70±3 70±3 70±3 70±3 70±3 70±3 Tare D Gross clearance 67±3 56±3 29±3 66±3 60±3 54±3 Body bogie 282+5/-3 271+7/-4 287+5/-3 279+5/-3 291+5/-3 281+6/-4 Tare G 279+6/-4 259+7/-5 262+6/-4 276+6/-4 283+6/-4 268+6/-4 Gross 8 19 03 11 Nil 9 # CR Axle box spring height 307+5/-3 295+7/-4 310+5/-3 298+5/-3 318+5/-3 307+5/-4 Tare H 304+5/-4 281+7/-5 269+5/-4 294+5/-4 308+5/-4 291+7/-4 Gross height 3 15 Nil 17 Nil 3 * Bolster spring CR 22±3 35±3 36±3 20±3 27±3 35±3 Tare X Crown clearance 19±3 23±3 11±3 17±3 19±3 22±3 Gross 646±5 646±5 646±5 646±5 646±5 646±5 Tare Y height 640+8/-5 620+8/-5 580+8/-5 640+8/-5 628+8/-5 617+8/-5 Gross Bogie bolster 1104+0/-10 1104+0/-10 1104+0/-10 1104+0/-10 1104+0/-10 1104+0/-10 Tare Z height Coupler 10988/-5 1079+8/-5 10388/-5 1098+8/-5 1086+8/-5 1075+8/-5 Gross Coach Maintenance Manual for BG coaches of ICF design Coach PART- I %% c91 5 BOGIE FRAME X BOGIE BOLSTER A Z G B L.S. BEAM F # RAIL LEVEL 2896 (WHEEL BASE) PART- II Weight of each bogie = 5.9 tPUnsprung mass/bogie = 3.2 tPBolster weight = 0.4 tPC.R. = Compensating ring BODY BOLSTER D BOGIE FRAME SIDE BEARER C BOGIE BOLSTER H Y RAIL LEVEL NOTE - P1. Dimensions A & B marked should be ensured less than dimensions C & D marked respectively.P2. # CR to drawing No.-CC01140 to be provided.P3. * CR to drawing No. - CC05251 to be provided.P4. 'F' the variation in all the four bogie corner heights must be less than or equal to 10 mm.P5. Drawing No. SG90002, SZ90004, SE90011, LB90002 are superseded by this drawing.P6. The height of Axle box spring and bolster spring in tare & gross conditions is for reference only.P7. The requirement of CR's as shown in the columns for primary & 30 mm in secondary suspension.P8. Only blue bend springs both in primary and secondary stage are to be used in postal van coach. SUSPENSION DIAGRAMMATIC ARRANGEMENT FOR NON AC COACHES (RCF DRAWING NO. CC90019)P FIGURE 1.4c Chapter 1, Page 13 of 41  AC of GS Type coach SCN SOC 38.03 37.00 36.99 In tonnes of Tare coach weight 5.76 7.02 5.85 In tonnes load Norm al pay Chapter 1, Page 13 of 41 - 100% 100% In tonnes load Over 5.76 14.04 11.70 In tonnes pay load Total 13.12 12.6 12.6 In tonnes tare Under Maintenance Manual for BG coaches of ICF design bogie 16.00 19.62 18.45 In tonnes Test load per Gross Under 40±5 40±5 40±5 Tare C frame Bogie Gross bolster 57±5 81±5 74±3 clearance 70±3 70±3 70±3 Tare D Gross clearance 53±3 29±3 36±3 Body bogie 287+4/-3 289 +4/-3 289+4/-3 Tare G 273+5/-3 257 +6/-4 262+5/-4 Gross height Table 1.6 Axle box spring 3 1 1 # CR 305+5/-3 308 +5/-3 308+5/-3 Tare H 288+6/-4 267 +7/-5 274+7/-4 Gross height Bolster spring 10 7 7 * CR 31±3 50±3 47±3 Tare X Crown Gross clearance 17±3 18±3 20±3 646±5 646±5 646±5 Tare Y Bogie height bolster 616+8/-5 572 +8/-5 585+8/-5 Gross 1104+0/-10 1104+0/-10 1104+0/-10 Tare TESTING PARAMETERS FOR NON AC COACHES (RCF DRAWING NO. CC90019) Z height Buffer 1074+8/-5 1030+8/-5 1043+8/-5 Gross Coach  AC of al VP Type IRQ coach Van Post SLR SCN 36.5 37.2 32.00 37.10 In tonnes of Tare coach weight 3.0 5.76 18.00 10.60 In tonnes load Norm al pay Chapter 1, Page 13 of 41 - - - 2.6 In tonnes load Over 3.0 5.76 18.00 13.20 In tonnes pay load Total 12.35 12.7 10.30 12.65 In tonnes tare Under Maintenance Manual for BG coaches of ICF design bogie 13.85 15.58 19.30 19.25 In tonnes Test load per Gross Under 40±5 40±5 40±5 40±5 Tare C frame Bogie Gross bolster 49±5 57±5 77±5 79±5 clearance 70±3 70±3 70±3 70±3 Tare D Gross clearance 61±3 53±3 33±3 31±3 Body bogie 290+4/-3 289 +4/-3 285+4/-3 289+4/-3 Tare G 283+5/-3 275 +5/-3 257+6/-4 258+6/-4 Gross height # Axle box spring Nil 1 5 1 CR 310+5/-3 308 +5/-3 302+5/-3 308+5/-3 Tare H 301+6/-4 291 +6/-4 265+7/-5 269+7/-5 Gross height Bolster spring CR * 5 7 13 7 22±3 30±3 39±3 50±3 Tare X Crown Gross clearance 15±3 17±3 11±3 20±3 646±5 646±5 646±5 646±5 Tare Y Bogie height bolster 630+8/-5 616 +8/-5 581+8/-5 577+8/-5 Gross 1104+0/-10 1104+0/-10 1104+0/-10 1104+0/-10 Tare Z height Coupler 1088+8/-5 1074+8/-5 1039+8/-5 1035+8/-5 Gross Coach Maintenance Manual for BG coaches of ICF design Coach 107 EXAMINATION OF TRAINS b) Speed of the train shall not be more than 30 KMPH, 107a Examination of originating trains c) It should cover the entire length of i) All trains must be examined by the train, mechanical train examining staff before d) Should have adequate space for fixing dispatch to ensure that all coaches on the lighting arrangement and for staff. the train are in fit condition and without ii) For rolling in examination of train it has rejectable defects (for rejectable defects, to be ensured that proper lighting please refer to IRCA Conference Rules, arrangement is provided on both the sides Part IV). On formation of a rake and of the track at nominated spots for after its placement for Examination, examination of undergear parts during washing, cleaning and watering, the night. Focussing of lights shall be done by station master (SM) shall pass necessary keeping a coach on the line and adjusting memo to the Engineer (C&W). After the angle of light to illuminate undergear carrying out all necessary work, the and bogie. Use of fixed lights as indicated Engineer (C&W) shall communicate in figure 1.5 is preferable. fitness of the train to Station Master. Normally, Railways have standard iii) C&W staff should take position at forms for the use of Station Masters and nominated rolling in place on both the Engineers for this purpose. Railways, sides of the track before the arrival of where such forms are not used, should train. also start using these forms as uniform iv) As the train passes the nominated point, practice for the guidance of both C&W staff should watch out vigilantly for Engineer (C&W) and Station Master. loose/hanging/broken undergear parts of The Station Master shall not dispatch the coaches, any unusual sound coming the train unless the fitness certificate, in from the coaches or any other abnormality the prescribed form, is received from the in the coaches. Engineer (C&W). ii) The level of the air pressure/vacuum on v) After train comes to halt, it should be the train engine and the brake van ensured that the train is protected from gauges as well as the percentage of both the sides (with the stop board/red operative cylinders should be recorded flag during day time and red lamp during on a prescribed certificate and night time) before commencing the signatures of the driver and the guard of examination of the train. It should be the train should be obtained by the ensured that a suitable indication board is Engineer (C&W) as per the procedure placed at conspicuous location visible to laid down by each Railway. A suggested the driver indicating that C&W staff is at standard format for the certificate is work. placed at Annexure 1.1. No train should vi) Temperature of the axle boxes should be be allowed to leave with an measured preferably with the help of the inoperative/defective Brake cylinder on electronic temperature measuring device. any coach after pit attention. Trains which have been attended on pitline vii) Brake release shall be checked by should have 100% brake power. physically moving the brake beam. Trains which are attended on platform However, in case where train locomotive or where secondary examination has has to be detached, brakes of all coaches been dispensed with or enroute should shall first be manually released. For have minimum 90% brake power. checking the release of brakes the hook may be used (drawing of hook is attached 107b Enroute/Terminating Examination of as figure 1.6). Passenger Trains viii) Other undergear parts should be examined i) Sr.DME/DME incharge shall nominate visually to ensure that the train is safe to the site for carrying out rolling in/rolling run further. During night the out examination after personal inspection lamps/search light shall be used for of site. While nominating the site illumination. following should be kept in view: ix) Repairs if required should be carried out a) Site shall provide unobstructed view of promptly to avoid detention to train to the undergear from both sides. extent possible. Chapter 1, Page 13 of 41 Maintenance Manual for BG coaches of ICF design Coach 370 100 300 50 300 50 300 100 225 225 EXPANDED METAL 100 MESH FOR ADJUSTING FOCUS SWIVEL JOINT WITH NUT & BOLT 450 250 225 30 MM FLAT 100 50 550 ISMC 100 HINGES 250 W FOCUS BULB 325 CONCRETE BASE G.L. LIGHTING ARRANGEMENT FOR ROLLING IN/OUT EXAMINATION FIGURE 1.5 1200 598 c % 6 8 % R9 MATERIAL :- M.S. ROUND BAR TO IS:2062PWEIGHT :- 0.590 KG (Approx.) 21 HOOK FOR BRAKE RELEASE 286 FIGURE 1.6 Chapter 1, Page 13 of 41 Maintenance Manual for BG ICF Coaches Coach x) Lavatories of the coaches should be properly cleaned using High pressure water jet machine provided at nominated stations during halt of the train. Any complaint from passengers should be attended promptly to the satisfaction of the passenger. xi) After attending to any required repairs stop board/red flag should be removed. xii) Carriage controller (CCR) should be informed about any out of course work done. xiii) CCR shall repeat the out of course work done to the Primary Maintenance (PM) depot after corrective action. xiv) At the train examination stations where locomotives are changed on through trains, the level of air pressure/vacuum created on the locomotive and brake van gauges should be recorded on the certificate to be issued to the guard and driver on prescribed form. The inoperative/blanked cylinders, if any, should also be written in the certificate for their information. This certification should be an endorsement on the original brake power certificate; no fresh brake power certificate needs to be issued. 108. MAINTENANCE PATTERN FOR COACHING TRAINS (Railway Board letter no. 95/M(C)/141/1 dtd. 29.10.01 ) Table 1.8 Sr. Category of trains Preventive Under gear examination Internal cleaning, External Enroute/Terminating Brake system No. maintenance and brake system passenger amenity cleaning on examination check prior to schedules at pitline maintenance at pit line attention and nominated line start at platform watering with proper at the other end facilities 01 Mail/Exp. One- At primary end At both the ends At both the ends At both the ends Enroute: After every 250 Complete air/ way run>2500 to 350 kms of run at vacuum check with kms locations to be decided fresh BPC. by Railway for each train. Terminating Exam Terminating station 02 Mail/Exp. One At primary end At both the ends At both the ends At both the ends - do - Complete way run 2500 kms 3 Mail/Exp. Round At primary end At both the ends At both the ends At primary ends - do - Only continuity (a) Trip run upto check if stabled at 2500 kms platform, otherwise, brake power check with endorsement on original BPC. Chapter 1, Page 13 of 41 Maintenance Manual for BG ICF Coaches Coach Sr. Category of trains Preventive Under gear examination Internal cleaning, External Enroute/Terminating Brake system No. maintenance and brake system passenger amenity cleaning on examination check prior to schedules at pitline maintenance at pit line attention and nominated line start at platform watering with proper at the other end facilities 3 Shuttles/Intercon At primary end To be done after 2500 At primary end and At primary end Enroute: After every 250 Only continuity (b) nected Mail/Exp. kms or 4 days whichever each terminal or as Once a day for to 350 kms of run at check if stabled at round trip run is earlier only at Primary decided by the shuttles. locations to be decided platform, upto 2500 kms. end. CME to ensure by Railway for each train. otherwise, brake proper cleanliness. Terminating Exam power check with Each Terminating station endorsement on original BPC. 4. Passenger trains At primary end To be done after 2500 At every terminal At primary end. Enroute: After every 250 with toilets kms or 7 days whichever or as decided by to 350 kms of run at including is earlier at Primary end. the CME to ensure locations to be decided interconnected proper cleanliness. by Railway for each train. passenger Terminating Exam trains/Shuttles Once a day at nominated Terminating station 5. Passenger trains At primary end To be done after 2500 Once a day At primary end. Once a day at primary or Only continuity without toilets. kms or 7 days whichever a nominated terminal. check if stabled at is earlier at Primary end. platform, otherwise brake power check with endorsement on original BPC. n Internal cleaning, Passenger amenity attention and watering may be done at platform line or nominated stabling line provided stipulated facilities are available at such line. n Incase the rake stabled in yard for more than 6 hours positive safety arrangement should be made for the rake and in case the security is considered inadequate, the rakes should be taken to pit line for attention to under gear as given under column (4). Chapter 1, Page 13 of 41 Maintenance Manual for BG ICF Coaches Coach 108a Approved Mandatory conditions to be should be taken to washing lines as far as fulfilled prior to introduction of Round possible. In the event of this being not Trip Primary Pattern of Maintenance feasible, such rakes can be returned from on Coaching Trains platform/yards. However, the minimum infrastructure to be provided at the The following mandatory conditions platforms from where trains are returned should be fulfilled prior to introduction of without secondary maintenance should be round trip/kilometers base PRIMARY as under. maintenance pattern on any passenger i) One storage room for essential safety carrying train on Indian Railways: and passenger amenity item. PRIMARY END: ii) Road transportation facility for ferrying material from the main 1. The attention during primary maintenance depot to the platform. should be made more intensive with iii) Adequate number of mobile high special emphasis on the following aspects: pressure jet cleaning machines or high pressure water pipe line running i) The brake gearing should be around the platform /yard line. properly adjusted including the slack iv) Washable apron on the platform adjuster ‘A’ dimension & the brake lines with the covered drains to cylinder stroke to ensure 100% facilitate movement of maintenance brake power. staff. ii) Brake blocks should be changed in v) Walkie-Talkie/mobile telephones for bogie sets only. quick and easy communication. iii) Dash-pot oil level must be checked and maintained. vi) Standard watering hydrants. iv) All missing passenger amenity vii) Flood light at the platform ends for fittings must be replaced and the rolling-in examination at night and rake must be turned out as ‘Zero- 110 V inspection lights along the Missing-Fitting’ rake. side of the track for night v) Intensive cleaning of coach toilets