Maintenance Manual for BG Coaches of ICF Design PDF

Maintenance Manual for BG coaches of ICF design Interior Fittings CHAPTER 11 INTERIOR FITTINGS 1101 GENERAL DESCRIP...

Maintenance Manual for BG coaches of ICF design Interior Fittings CHAPTER 11 INTERIOR FITTINGS 1101 GENERAL DESCRIPTION 1102 AMENITIY FITTINGS FOR COACHING STOCK Interior fittings are the fittings inside the coach consisting of panels, seats, berths, For passenger to have a comfortable train windows, lights, fans, sanitary fittings etc. journey various passenger amenities All coaching stock shall be furnished fittings have been provided in the trains. according to the standards laid down by Schedule of amenities for coaching stock the Railways/RDSO for the various types (broad gauge) is indicated in Table 11.1. and classes of vehicles in service. Table 11.1 SCHEDULE OF PASSENGER AMENITY FITTINGS FOR BG COACHES Description Air conditioned coaches Non Air conditioned coaches Day coach First class First class Chair car General Sleeper Double sleeper sleeper decker 3Tier 2Tier 1) Depth of faces of partition to the edge of: I. Seat (for seating 785 557 Long 635 680 785 560 Long 505 505 505 purpose) 665 Trans 570 Trans II. Berth (for 785 557 Long 600 Long NA 785 560 Long NA NA NA sleeping purpose) 665 Trans 635 Trans 570 Trans 2) Length I. Berth 2010 1877 1835 NA 2010 1870 NA 1676 NA 3) Hip width for 610 550 550 450 610 480 415 480 450 passenger 4) Height clearance for seat / berth I. Clear space below 265 340 305 -- 340 340 340 340 -- seats II. Height of top of 405 405 420 405 405 405 405 405 405 seat from floor III. Clear space 900 900 610 NA 900 900 NA 900 NA between top of seat and bottom of upper berth bunk 5) Corridor width 700 575 575 430 700 575 430 570 570 6) Bay width I. Four berths/ 2312 1876 1830 NA 2312 1700 1575 1575 1575 general component Chapter 11, Page 1 of 17  Maintenance Manual for BG coaches of ICF design Interior Fittings SCHEDULE OF PASSENGER AMENITY FITTINGS FOR BG COACHES Description Air conditioned coaches Non Air conditioned coaches Day coach First class First class Chair car General Sleeper Double sleeper sleeper decker 2Tier 3Tier II. Coupe single 1600 1150 - NA 1500 1050 880 880 880 row III. Pitching of NA NA - 565 NA NA NA NA NA chairs 7) Knee room I. Four berther 710 535 535 NA 710 535 535 535 535 II. Coupe 710 450 NA NA 710 450 340 340 340 8) Lavatory I. In side area in Sq. 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 metre II. Max. No. of 6 13 17 20 12 20 27 25 36 passengers per lavatory 9) Body side door I. Max. No. of 12 40 34 40 40 60 60 60 72 passengers per door a side 10) Electrical requirement A- Lighting i) Minimum lux at horizontal plane 840 mm above floor level a) Compartment 40 30 30 30 30 30 30 30 30 b) Lavatory 16 16 16 16 16 - 11 11 11 c) Corridor 16 16 16 16 16 - - - - ii) Individual Yes Yes Yes No Yes Yes No No No switches for ceiling light iii) Berth reading Yes Yes No No Yes No No No No light with switches iv) Night light Yes Yes Yes Yes Yes Yes No No No v) Individual swit ch Yes Yes Yes No Yes Yes No No No for night light vi) Toilet engage Yes Yes Yes Yes No No No No No light vii) Toilet engage No No No No No No No No No sign viii) Socket out let No No No No No No No No No 110V ix) Call bell push yes No No No No No No No No button Chapter 11, Page 2 of 17  Maintenance Manual for BG coaches of ICF design Interior Fittings SCHEDULE OF PASSENGER AMENITY FITTINGS FOR BG COACHES Description Air conditioned coaches Non Air conditioned coaches Day coach First class First class Chair car General Double sleeper sleeper sleeper decker 2Tier 3Tier B. Fannage i) No of fans a) Compartment One for One per One per One One 3 per bay 3 per 3 per 3 per two bay bay for per bay bay bay berths two berth row b) Lavatory One per One per One per One No No No No No lav. lav. lav. per lav. ii) Size/type of fan a) Compartment 400 mm 300 mm (F) 300 mm (F) 400 400 400 mm (F) 400 400 mm 400 (Swivelling = S) (S) mm mm mm (F) mm (Fixed = F) (F) (S) (F) (S) b) lavatory 200 mm 200 mm (F) 200 mm (F) 200 No No No No No (F) mm (F) c) Regulator for Yes Yes No yes Yes No No No No fans d) On/Off switch Yes Yes Yes No Yes Yes Yes Yes Yes for fans 11) Compartment and doorway fittings a) Cushioned seats Yes Yes Yes Yes Yes Yes Yes No Yes and back rests b) Cushioned Yes Yes Yes NA Yes Yes NA NA NA berths c) Longitudin al L L L S L No S S L luggage racks i) Light (L) ii) Sturdy (S) d) Folding or fixed Yes Yes Yes Yes Yes No No No No table e) Roof ventilators i) Compartment No No No No Yes Yes Yes Yes Yes ii) Doorway Yes Yes Yes Yes Yes Yes Yes Yes Yes f) T umbler holder Yes Yes Yes Yes Yes No No No No g) Ash tray i) Compartment Yes No No Yes Yes Yes Yes Yes Yes ii) Door way No Yes Yes Yes Yes Yes Yes Yes Yes h) Waste paper basket dust bin i) Compartment Yes No No No No No No No No ii) Door way Yes Yes Yes Yes No No No No No i) Foot rest No No No Yes No No No No No j) Notices Yes Yes Yes Yes Yes Yes Yes Yes Yes k) Mirror with shelf i) Compartment Yes Yes Yes No Yes No No No No ii) Doorway Yes Yes Yes Yes Yes Yes Yes Yes Yes Chapter 11, Page 3 of 17  Maintenance Manual for BG coaches of ICF design Interior Fittings SCHEDULE OF PASSENGER AMENITY FITTINGS FOR BG COACHES Description Air conditioned coaches Non Air conditioned coaches Day coach First class First class Chair car General Double sleeper sleeper sleeper decker 2Tier 3Tier l) Coat hook Yes Yes Yes Yes Yes Yes Yes Yes Yes m) Foot steps Yes Yes Yes NA Yes Yes Yes NA Yes n) Magazine pouch Yes Yes No. Yes Yes No No No No o) Wash basin i) Compartment Yes No No No No No No No No ii) Door way Yes Yes Yes Yes Yes Yes Yes Yes Yes p) Ward robe with Yes No No No No No No No No fixed hangers q) Water cooler Yes Yes No Yes No No No No No r) Drinking water Yes Yes Pouches Yes Yes Yes Yes No Yes with container s) Thali rack No. Yes Yes Yes Yes Yes Yes Yes Yes t) Linen room Yes Yes Yes No No No No No No u) Rings below No Yes Yes No Yes Yes No No No berths for securing luggage 12) Lavatory fittings a) Shower bath Yes No No No Yes No No No No b) Wash basin No Yes Yes Yes Yes Yes Yes Yes Yes c) Towel rail Yes Yes Yes Yes No No No No No d) Flushing one One One One One Nil Nil Nil Nil commode e) Flushing pan except except one Except one Exc Excep all all all all one ept t one one f) Push cock for Yes Yes Yes YesYes Yes Yes Yes Yes lotah filler g) Lotah shelf Yes Yes Yes Yes Yes Yes Yes Yes Yes h) Commode rail Yes Yes Yes Yes Yes Yes Yes Yes Yes i)Mirror shelf Yes Yes Yes Yes Yes Yes Yes Yes Yes j) Bottle opener Yes No No No No No No No No k) Coat hook 3 3 3 3 5 4 4 4 4 l) Soap dish (SD), Both SD SD SD SD SD SD SD SD Liquid soap container (LC) m) Lavatory chutes should be slanting so that ground is not visible from inside and lavatory discharge does not fall on rails and track fasteners. n) Inter communication Inter communication doors shall be provided between the two classes of accommodation in a composite coach. 13) External fittings a) Reservation Yes Yes Yes Yes Yes Yes Yes Yes No display plates b) Destination Yes Yes Yes Yes Yes Yes Yes Yes Yes board c) No. plates on Yes Yes Yes Yes Yes Yes Yes Yes yes mail & express trains only Chapter 11, Page 4 of 17  Maintenance Manual for BG coaches of ICF design Interior Fittings The schedule of safety items for passengers to be available in the interior of the coach is given in Table 11.2 Table 11.2 Safety requirements SCHEDULE OF PASSENGER AMENITY FITTINGS FOR BG COACHES Description Air conditioned coaches Non Air conditioned coaches Day coach First class First class Chair car General Double sleeper sleeper sleeper decker 2Tier 3Tier a) Alarm pull No. of - - - - - - - - - per i) Compartment 1 1 1 6 1 One One One One Tota l ii)Lavatory Alarm Alternat Alternat Alternat e e e iii) Corridor 2 2 Bay Bay Bay Bay b) Internal latches Yes Yes Yes Yes Yes Yes Yes Yes Yes at top and bottom on body side doors c) Provision of pad Yes Yes NA Yes Yes Yes NA NA NA locking arrangement from outside on one body side door d) Internal latch Yes NA NA NA Yes NA NA NA NA and shout bolts with notched stopper and outside pad locking arrangement for compartment sliding door e) Throw over latch NA Yes Yes NA Yes Yes No No No and Pad Locking arrangement for sliding of vestibule f) Shout bolts and Yes Yes Yes Yes Yes Yes Yes Yes Yes sliding door bolts for swing doors and pad locking for rolling shutters of vestibules g) Latches for Yes Yes Yes Yes Yes Yes Yes Yes Yes windows shutters of body side doors and partition walls h) Fire 2 2 2 2 No No No No No extinguishers i) Safety bars on all Yes Yes Yes Yes Yes Yes Yes Yes Yes window opening j) Windows shutters Chapter 11, Page 5 of 17  Maintenance Manual for BG coaches of ICF design Interior Fittings i) Glass shutters Yes Yes Yes Yes Yes Yes Yes Yes Yes ii) Louvre shutters No No No No No No No No No iii) Louvre cum No No No No Yes Yes Yes Yes Yes gauge shutters iv) Frosted single Yes Yes Yes Yes No No No No No glass sealed window v) Louvre cum No No No No Yes Yes Yes Yes Yes Frosted glass liftable type shutters Chapter 11, Page 6 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings 1103 FURNISHING MATERIALS ON (Polytetramethyl triethylene) and acetal are PASSENGER COACHES also available. Furnishing materials in a coach have 1103d Attention in Workshop changed considerably over the years. § The interior fittings should be Plastics, FRP and various other synthetic examined for corrosion and damage materials have been introduced which are during pre inspection of the coach. light in weight and require less All missing fittings should be made maintenance and give bette r aesthetics. good and reported, defective ones 1103a Roof Panelling Sheet removed from the coach, repaired and refitted. 2 mm thick Limpet asbestos sheet to § All distorted/ damaged panels RDSO specification No. C 8105 (Rev. 1) is should be replaced. No patch work the material used for Roof panels. 1.5 mm should be resorted to and complete thick NFTC (Natural Fibre thermoset panel piece should be fitted. While Composite) to RDSO's specification No.C- replacing the panels, care should be 9511 can be used as a permissible taken to match the colour and design alternative to 2 mm limpet asbestos sheet. to the extent possible. § While renewing ceiling panels 1103b Side Wall Panelling opportunity should be taken to examine the insulation material. Full Thermosetting synthetic resin bonded insulation should be checked when a decorative laminated plastic sheets (LP coach is internally stripped fully after sheets) of 3 mm thickness to RDSO's 5 to 7 years to attend to corrosion on specification No. C-9602 is used for side the roof sheets. Deficient/damaged wall panelling. insulation should be replaced. The LP sheets panelling provide aesthetic 1103e Anti-Pilferage Measures look to the coach interior. Being the bad conductor of heat and electricity, the LP In order to prevent theft of amenity sheets prevent the radiation of heat from fittings from coaches, workshop should atmosphere to inside coach. The L.P sheet carry out anti-pilferage measures on all provides seating to various passenger coaches during POH, as prescribed by the amenity fittings such as ash tray, tumbler Chief Mechanical Engineer or RDSO holder, coat hook, mirror and mirror shelf, especially for the following items: luggage rack and news paper pocket. i) Mirror and mirror shelf. 1103c Other Plastic Materials ii) Soap dish. iii) Ash t ray. i) Fibre Reinforced Plastic iv) Push cock. v) Wash basin. FRP has the potential of wide range of vi) Tumbler holder. application in coach interior. So far SMC vii) Hand hold. (Sheet Moulding Compound) moulded viii) Upper berth hold. window shutters, wall protectors and axle ix) Coat hook. box front covers have been developed in x) Flushing valve. FRP. xi) Window frame. xii) Folding table. ii) Plastic Push Cocks xiii) Lotah cock. xiv) Lotah shelf. Plastic push cocks made of HDPE (high xv) Shower rose. density polyethylene) to RDSO Spec. C- xvi) Wall protector. 9121 are being used in place of metallic xvii) Foothold bracket. push cocks. These push cocks are less xviii) Fans prone to the theft. xix) Lights 1103f Examination and repair practice in Better form of plastics are now readily Carriage Maintenance Depot available. Push cocks in PTMT Chapter 11, Page 7 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings i) Primary/Secondary examination and i) AC windows of ICF coaches Schedule A, B & C (Ref: ICF drawing No. WGFAC- 5- 4-001.) § Examine laminated panels & mouldings for damages /cracks. a) Windows of earlier built ICF coaches § Visually inspect passenger amenity consists of a outer glass shutter fixed fittings, replace if found damaged / on the out side of window opening deficient. of coach by studs and nuts and fully § Examine visually curtain cloth in AC sealed with rubber packing all around coaches and attend if necessary. and inner glass shutter which is top hinged on the inside and is capable § Examine ventilation grills for of swinging open to clean inside damages. surface of the glasses. § Examine luggage racks / bunks for breakage. b) In the recent built ICF coaches outer § Examine push cock, flush valve for glass is directly inserted in the fixing function. rubber glued over window opening. § Check and attend leakage in pipes, Inner glass shutter and other fittings fittings and shower ro ses in lavatory. remains same as above. § Clean drain grills and drain holes in bath room and wash basin if found ii) AC windows of RCF Coaches choke up. (Ref Drg:AE 54103) § Check and replace damage/missing mirrors/shelves/soap dishes. AC window of RCF built coaches are fitted with double glass hermetically sealed 1104 WINDOWS window units. Stainless steel supporting frame is welded in the inside of the 1104a Windows of Non AC Coaches window opening to support the window unit and also to fix specially designed The non AC coaches are provided with sealing rubber profile. FRP window glass and louver shutters made out of holding frame is screwed from inside of FRP. The Glass panel of the shutter is the coach to provide sealing of made of safety toughened glass. The conditioned air. shutters work in the grooved frame work of the window assembly. To prevent the In both types of sealed window glass shutters from dropping a balancing toughened safety glass of 5.5/6 mm mechanism comprising of spring, lever etc. thickness to IS 2553- Part II made from ‘A’ is provided. To close the window positive quality flat transparent glass to IS 2835 is force is required to be applied against the used. A reflective sun control film of spring force. In the case of louvre shutters smoke grey colour is pasted on inside instead of the balancing mechanism a surface of outer glass. spring loaded safety latch is provided to prevent the louvre shutter from drop ping. 1104c Emergency Openable Windows (for Non- AC Coaches - ICF drg No. 1104b Windows of AC Coaches DMU/DPC –5-4-002 & ICF/STD-5-4- 005) (for AC coaches - RDSO sketch SK- AC Coaches are fitted with double glass 98161 alt. I) sealed windows. Two types of sealed windows are presently in use and they are Emergency windows are provided as the as under: third window from door on either side in passenger compartment. 1104d Lavatory Windows (RDSO's Sk. 96104) FRP banjo type windows with frosted glass are fitted in lavatories. Chapter 11, Page 8 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings 1104e Lavatory Windows of AC Coaches 1104g Maintenance of Windows of Non AC (ICF drg. No. WGFAC-5-5-001) Coaches (ICF drg. no. T-5-4-701 & RDSO Sk. 96070) in workshops Sealed type windows with frosted glass are fitted in lavatories of AC coaches. Four § All window shutters should be fully protection bars are welded with outer removed from the body shell at every frame. second POH and also when they are found defective during pre 1104f Maintenance of AC windows in workshops inspection. § When windows are not removed, the § Broken, cracked, defaced or shutters should be checked for easy scratched glass should be replaced working by lifting and lowering them. and the window frame repaired as The safety catches should also be necessary. Glass should be cleaned checked to ensure that they are in with lime and detergent before working order and that, once they are refitting. The rubber or felt lining engaged, the shutter should not be between the glass and the frame unlocked and opened. Their rubber should be changed every time the channels, if deteriorated or torn, glass is removed. Chrome plated should be replaced. moulding, if provided, should be rechrome plated before fitting. § The entire window assembly should be dismantled and shutters removed. § In case of separate outer window, Presently windows are fitted with before fitting it, sealing compound glass and louvre shutters having should be applied on the joint anodised aluminum or FRP shutter surfaces of the coach as well as the frames and louvers. The anodised window to form an air-tight joint. Sun aluminum / FRP shutters and other control film should be pressed on the fittings on the newly built coaches inside of outer glass. should be cleaned with detergent § The hinges of inner window frame only at the first POH. In subsequent should be checked for easy POHs, these items should be painted operation and well oiled before with matching shades of paints, after refitting. The clamping catches painting oiling should be done on all should be attended to and tested for the safety catches. St eel components proper functioning. should be cleaned of dust and dirt. § The rubber beading between window The glass panes should be cleaned and coach body should be replaced with lime and spirit. Broken or if found set, deteriorated, or cracked glasses should be replaced damaged, to ensure air tightness. with safety toughened glass. Under no circumstances should an ordinary § The damaged FRP inner frames / glass sheet be used in shutters. holding frame should be replaced. Holes in the frames for safety The moulding on the window space catches, which have become oblong between the outer and inner should either be bushed or plugged windows should be replaced if found and re drilled. Torn, rusted or deficient or damaged; otherwise, it deteriorated wire gauze should be should be well cleaned in position. In replaced by proper galvanized wire case of steel bodied coaches, the mesh. panel should be examined for corrosion and attended to as § The shutters should be checked for required. easy working in grooves after rubber channels are replaced. Balancing § When comp onents are replaced, it is mechanism for the shutters should good practice to assemble the sealed be dismantled, cleaned and examined. window on a mock-up window All its worn out components like arrangement in the shop for correct brass/nylon rollers should be fitment and sealing. This can then be repaired/replaced as required. Pin taken as a set and fitted on the should be lightly greased. Backside coach. and other portions of window frame Chapter 11, Page 9 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings which get covered up when fitted on 1105 FLOOR the coach should be painted before the balancing mechanism is 1105a Introduction reassembled. The use of PVC flooring is used in both § Spring tension should be correctly upper and lower class coaches. RDSO adjusted such that the shutter can be vide their letter No.MC/CB/Flooring dt. easily lifted and positioned wh erever 26.04.89 have circulated the guidelines for required. using PVC flooring on main line coaches. As per RDSO ‘s letter No.MC/CB/Flooring § The wire gauge should be cleaned Dated: 08.04.96. 12mm Compreg with a wire brush and blown with floorboards shall be used whenever compressed air. floorboards of complete coach require § A coat of mastic compound should replacement. Use of PVC flooring be applied on the contact surface of improves the aesthetics of compartments, rubber channels for keeping them in besides providing for hygienic condition position. and easy maintenance. § On body side door windows of non - This arrangement is also considerably air-conditioned coaches safety bars lighter (approx.1.1t) as compared to should be provided as given in Decolite flooring. It also prevents RDSO sketch no. 84162, if not corrosion of under frames by eliminating already existing. water seapage. For this purpose, proper laying technique, sealing of joints with 1104h Examination and Repair Practice in thermo -welding process and selection of Carriage Maintenance Depot right shades are very essential. i) Primary/Secondary examination and 1105b Flooring arrangement in a Coach Schedule A, B & C The flooring in the coaches will consist of a compreg sub -floor covered with PVC sheet. § Examine window shutters of non AC The following ICF drawings give details of coaches for smooth movement in the PVC flooring arrangement over railing to prevent rattling and plywood sub -floor : disengaging of catches on run. § Window frame on non AC coaches 1. ICF/SK.4-1-135 - PVC flooring for GS should not be broken and its glass, coaches. gauze wire and venetian louver 2. ICF/SK.4-1-139 - PVC flooring for should be in proper condition. GSCN coaches. 3. GS.4-1-002 - PVC sheet covering over § Check window balancing mechanism Decolite in lavatories. on non AC coaches for proper 4. ICF/SK.4-1-136 - PVC flooring for function. AC-2Tier coaches. § Examine window safety catches for 5. ICF/SK-4-1-101- Flooring in lavatory proper engagement in their slots. for AC-2 Tier Coaches. § Check lavatory banjo shutters for 1105c Material description damage/missing. § Examine window frame and rubber § 12mm Compreg floor board to RDSO profile of sealed windows in AC Specification C-9407 (Revised) type – coaches for dama ges and attend if II shall be used for all new coaches needed. or used for coaches whenever floor boards of complete coach require § Window bars should be provided replacement. and fixed in prescribed manner and § When only part of the floor is to be replaced if damaged. replaced , repair to floor shall be § Examine sealed windows of AC carried out by using Plywood - 19 coaches, replace broken/damage mm thick plywood to IS-303-1975 glasses. Grade A fully treated for protection Chapter 11, Page 10 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings against fungi, termite, marine borers § The self tapping screw head shall and other insecticides and also be levelled by applying epoxy requirements of preservative putty. This will ensure smooth level treatment to IS:5539. for effective laying of PVC flooring § PVC Flooring - 2mm thick sheet and also avoid water seepage homogeneous Vinyl Flooring, through screw holes. preferably, in roll foam to RDSO § Scrap away excess putty, if any. specification No. C-8515 (Rev.2). If § Sweep and clean the coach floor laminated flooring is used, the top thoroughly before laying the PVC layer shall be of 1 mm hard wearing floor sheets/rolls. surface. § Adhesive - Adhesive to fix PVC ii) Laying of PVC Flooring flooring to plywood Compreg will be Neoprene based rubber adhesive of § Spread open the PVC roll/sheet on Dunlop S-758 or Fevicol SR-998 make half the width of coach (inside the or equivalent quality. coach)and leave it for some time (30 to 40 minutes approx.) to enable it to 1105d Attachment and Fixing lie flat on the floor. § Mark properly the position of the i) Laying procedure for Sub-flooring pillars, seat frames etc. on the PVC rolls/sheet and cut neatly around the § 12 mm Compreg floor board to pillars and frames. RDSO Specification C-9407 (Revised) § Fold the roll half way and spread a type –II should be laid properly in thin and even layer of adhesive with level (ensure level by suitable a notched trowel (serrator) on the packing, if required) to the cross compreg sub-floor. The members/trough floor. Before laying, recommended adhesive is Dunlop S- the joining edges of compreg sheet 758 or Fevicol SR 998 or equivalent. shall be coated with water sealing compound to specification § Also apply adhesive on the rough No.IS:7084 - 1973. This is essential to reverse side of PVC flooring thinly ensure effective sealing at the joining and evenly as above. edges to prevent any seepage of § Allow some time for solvent water. evaporation (30 minutes approx.) to § Drill holes on the compreg floor prevent solvent vapours being board and cross members/trough entrapped. As soon as the adhesive floors and fix it by self tapping becomes touch dry, both on the floor counter sunk screws as per relevant and the PVC flooring, press down the drawings. sheet in position gently and § Joints between compreg floor board gradually from one end taking care to should be minimum and if any gaps prevent air from being entrapped. exist, the same should be filled with Follow same procedure for the other epoxy putty. (see note) half of the same roll. § No welding operation is allowed Note:- 5 Kgs. of Epoxy putty is during laying of PVC, since the prepared to the following adhesive is flammable agent. combination : § After adhesive work of the 1st roll is Table 11.3 over, apply pressure on the flooring with a steel roller of 25 kgs. (approx.) French Chalk 2.1 Kg. so as to obtain perfect adhesion Resin HSK 2.1 Kg. between PVC flooring and compreg Acetone commercial 0.4 Kg. sub floor and to eliminate air being Accelerator 0.2 Kg entrapped. Catalyst 0.2 Kg Total 5.0 Kg. Chapter 11, Page 11 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings § The second roll shall be laid in position, overlapping the Ist sheet by about 5 to 10 mm (see Fig.11.1) while spreading the roll, ensure the cuts on the PVC flooring match with Figure 11.3 pillars of partition and seat frames. § "Trim in" the length by placing a straight edge along the centre of the Over-lapping edges, and with a sharp knife, cut through both thickness of Figure 11.4 PVC flooring at the sametime. Pull out the overlapping edges of top and bottom of PVC flooring and press the Note :-A deep groove cut (Figure same to the compreg floor to obtain 11.5) into the PVC flooring will result perfect butt joint. in an unsupported weld which may split in use. Figure 11.5 v) Welding Seams are thermo -welded with a hot-air gun using flexible transparent Vinyl welding cord (Figure 11.6). Details of Figure 11.1 welding equipment and PVC welding cord iii) Thermo-Welding (Hot Air welding) are given in the pare 1105f. To ensure a thermo -welded seam of maximum strength, Proper thermo-welding of PVC flooring is the gun must be held at the correct angle utmost necessary for obtaining to the flooring and used at the correct satisfactory bonding/results. Thermo- speed. The correct angle is achieved when welding of PVC flooring provides the `foot' of the welding nozzle is parallel impervious continuous floor surface. to the surface of the flooring. Start to weld the flexible cord into the PVC flooring at iv) Grooving the most even and efficient rate to ensure the correct fusion of materials. Finish off A grooving tool (hand or automatic) as near to the end of the groove as alongwith a straight edge/scale (see possible. Welding of the ends of grooves Figure 11.2) is used to groove the butting on PVC flooring can be carried out with edges of the seam to approximately two the use of hand roller. third of the thickness of the wear layer of PVC flooring. This will leave a semi- v Figure 11.2 Figure 11.6 circular groove for thermo welding (see Figure 11.3 & 11.4). Chapter 11, Page 12 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings vi) Trimming § No patchwork should be done in the lavatory flooring. When the weld has cooled to room temperature, it should be trimmed off flush 1105f Special Tools and Equipments to the surface of the material with a trimming Spatula (Figure 11.7). If trimming i) PVC Flooring is done before the welding cord has cooled, it will shrink below the surface of PVC flooring shall be to RDSO Schedule of the flooring. If at this stage, the spatula Requirement No.C-8515 (Rev.2). disturbs the weld, this indicates that a positive joint has not been achieved. The a) HOT AIR WELDING EQUIPMENT existing weld should then be removed and the seam must be re -welded. To ensure i) Hot air welding equipment - that proper bond of PVC flooring to 750 watts capacity with air compreg base floor is obtained, allow it to control device on the torch. dry for 24 hrs. in normal atmospheric ii) Roller with handle for pressing the temperature. All the edges of PVC flooring weld deposits. in the compartments should be sealed with iii) Welding Rod 2mm dia. PVC water sealing compound to avoid seepage Electrode of water. iv) Recommended procedure for welding of flexible PVC - to IS : 8002 – 1976 v) Adhesive § Dunlop adhesive S-758 § Fevicol SR - 998 vi) Water proof sealing compound - Water proof sealing compound to IS: 1580-1960. 1105g Maintenance Instructions i) All coaches, both AC and non -AC, Figure 11.7 except the luggage compartment portion of SLR coaches, are provided In the door way of GS coaches, an with compreg flooring having a PVC aluminum chequered sheet to IS:737 HS sheet pasted on it. The cracked, 20-W should be provided and properly damaged or worn out PVC flooring anchored over PVC flooring to avoid any sheets should be removed. Swollen damage to PVC flooring. or otherwise damaged floor boards should be renewed and a new PVC Water sealing compound shall be used all patch of same colour should be around the aluminum chequered sheet as pasted. The joints of PVC patch well as in the CSK scre ws to prevent should be properly thermo-welded to seepage of water. prevent seepage of water. For laying 1105e Lavatory Flooring and repair of PVC flooring over compreg, the procedure detailed in All new coaches are provided with RDSO pamphlet no. C-9001 should stainless steel inlay pasted with single be followed. piece PVC sheet to ICF drawing no. ii) The coaches undergoing corrosion ICF/STD-4-1 001 in lavatories. Coaches repair should be provided with PVC having other types of lavatory floorings flooring as per RDSO pamphlet no. should be provided with stainless steel C-9001. lavatory inlays during POH. iii) The coaches undergoing normal repairs may continue with the § The cracked, damaged or worn out flooring arrangement as existing, ie., PVC sheets should be removed and a either Decolite or PVC flooring. new single piece PVC sheet should be pasted over stainless steel inlay. Chapter 11, Page 13 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings iv) In case of Decolite flooring, the For stitching the furnishing cloth, cotton cracked, uneven or worn out flooring sewing thread no. 30 is used, thread no. 40 should be broken and patched with for curtains. Cotton padding to the same colour Decolite. At the time Specification no. G/TEX/C - 1813 is used of decoliting the floor it should be to give even shape to the cushion. ensured that dovetailed wooden battens are properly fitted and the 1106b Maintenance in workshops Decolite mixture is prepared in i) The berths and seats found defective accordance with the instructions due to opening of stitches, cracked / given in IS 657 and IS 658. The torn/ faded rexine, or sagged cushion Decolite surface should be smooth should be removed from coach and finished and given proper slope. sent to Trimming shop for repairs. Special care should also be taken at Otherwise they should be cleaned in the edges, joints and at the pedestals position with a suitable detergent or to ensure that freshly laid Decolite interior cleaning agent which does leaves not even an invisible gap to not damage/discolour and does not permit water to seep through and require water for rinsing. cause corrosion of the trough floor ii) After stripping the seats, backrests, underneath. berths, arm rests, etc., completely, 1105h Examination and repair practice in the frame should be examined for Carriage Maintenance Depot distortion/crack. These should be first got repaired in fitting section or i) Primary/Secondary examination, carpentry section as the case may be. Schedule A and B examination The wooden battens of the frame for fixing the rexine should be examined § Visually examine floor for any and replaced if damaged / broken. damages. The steel members should be painted and the wooden members varnished ii) Schedule 'C' examination after repairs before doing upholstery § Inspect and attend repair work. torn/damage/ cracked PVC iii) Following measures may be taken to flooring. improve the quality of upholstery § Examine and attend opened work: PVC joints. § Rounding of corners of berths § Examine Drain holes in trough and seats: This eliminates corner floor for accumulation of water folds where the rexine gets torn due to clogging if noticed, often for old design of berth. inspect affected area for § Use of nylon sewing thread: corrosion Nylon thread has higher strength 1106 SEATS AND BERTHS than cotton threads and hence reduces incidence of opening of 1106a Cushioned Seats and Berths stitches. § Use of straight edge rexine i) The upholstery materials used for cutting machine: This helps in seats and berths of different classes cutting rexine in a batch for of coaches is given in the following improved repair work table. productivity § Use of pneumatic staplers: Class of coach Furnishing material Cushion material Ist class AC coaches and Executive Flame retardant fabric upholstery to Foam rubber cushion to class chair car of Shatabdi Express. RDSO's STR No. C-9901. IS:1741/60 Gr. ‘B’ AC 2 tier and 3 tier, AC chair car, First Solid layer vinyl coated fabric to type Same as above class, First class chair car II of RDSO's STR No. C- 9503. Sleeper class, Second class day coach Solid layer vinyl coated fabric to type Same as above II of RDSO's STR No. C- 9503. Chapter 11, Page 14 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings Pneumatic staplers can be used § Examine and repair damaged instead of nailing. upholstery cushions and curtains. § Wooden seats and frame should be Reclining Seats of Chair Cars cleaned § The reclining chairs should be ii) Schedule A and B examination removed from the chair cars in every POH and sent to Fitting and § Examine as per (i) above. Trimming shops for overhaul. § Wooden seats and frames should be disinfected. § Strip the chairs with adjustable backrests and replace worn out gear iii) Schedule C examination wheels and other components including bottom rail. The moving § Examine as per (ii) above. parts should be oiled and the § Examine reclining mechanism on assembly checked for even sliding chair cars for proper functioning before it is refitted. The upholstery and attend if necessary. portion should be repaired as given in section 1105c. The chrome plated 1107 DOORS legs, where provided, should be examined and re -chrome plated, if 1107a Examination in Workshop necessary. After the chairs are repaired and assembled, they should i) Body side Doors be tested for easy movement and firm securing in all reclining positions. § Doors should be checked for ease of § Strip the reclining mechanism gear, working and corrosion, especially on and replace worn / defective parts. the bottom side of the panels. If The components should be painted found heavily corroded, they should all over except sliding and rotating be removed and repaired as per surfaces, which should be well RDSO Technical pamphlet C-7602 greased. After assembly the chair (Rev.1). should be tested for ease of rotation § The top and the bottom bearing and proper locking. pivots should be checked for worn § The folding table, if provided, on the ridges. If ridges are found they base of the back- rest should be should be removed and if the examined for loose or damaged condition warrants, the pivots hinges, broken of cracked moldings should be replaced. or damage to table top. Replace t able § The door handles, guard key locks if found damaged. Hinges and and safety latches on the doors locking catch should be lightly oiled should be checked for smooth and and examined and attended for easy working. The bent parts should proper operation be straightened or renewed as required. Pad locking plates on the 1106c Examination and Repair Practice in doors. Carriage Maintenance Depot § Dust excluding device in the form of i) Primary/Secondary examination a rubber tube is fitted all around on the door. This should be checked § Examine visually curtain clo th in and if perished, or torn or decayed, AC coaches attend if necessary. should be renewed. § Examine middle and upper berth § If door safety latches are found bent chains. or jammed, they should be repaired § Examine the holding / securing ensuring proper working. brackets for seat and berths and attend if necessary. ii) Sliding Doors § Examine snack table in upper class coaches for damages and rectify if necessary. Chapter 11, Page 15 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings Sliding doors of upper class n Sliding doors should be compartments removed at every POH. All corroded and damaged § Sliding doors should be panels, louvres and members removed in every POH. Top should be cut out and roller race and top guide rails replaced. should be checked for n Roller assembly should be smooth working and removed and stripped. replaced when worn more Replace rollers if found worn than 1 mm on each part. beyond 3 mm, otherwise The door stops at the top they should be reused after and bottom should be smoothening ridges or dents checked and adjusted. The formed at the rolling surface. ball bearings in the top guide Similarly, other components rollers should be checked, should be examined and greased and refitted or repaired or replaced as replaced as necessary. The required. Perished / torn ridges from the roller `V' rubber sealing shall be surfaces should be removed replaced. After assembling or, if worn too small the the components, the moving rollers should be replaced. parts of the assembly should § The automatic lock, specially be greased before fitting its lock casing, should be them in position on the door. checked for cracks at its flanges. If cracked, it should n The bottom guide, door be replaced. handle and door locking § If the door operating rod is arrangements should be broken, it should be examined and repaired or replaced. replaced to ensure smooth working in operation and § The coach door should be effective locking from inside checked for wear. If worn and outside. The inside and more than 1 mm, it should be outside locking arrangement replaced. shall be to sketch 75118 and § The pins of the lock should 75210 respectively. be cleaned, oiled and refitted. n The door assembly, after repairs should be checked, § The internal door locking preferably in a fixture, for its latches (parrot latches) and alignment of the top rollers the tower bolts should be and the bottom guide. The checked for ease of working alignment should be and replaced if required. corrected as required before § While fitting the door, it the door assembly is passed should be ensured that the for fitting on the coach. gap between the door and the panel does not exceed n Inspection door & pocket in 4.5 mm. partition for sliding door shall be provided as per ICF § Broken glass in the drawing TLR-4-2-717, SLR-4- observation windows 2-002 & WLLRM-4-2-605 in provided in sliding doors of respective coaches. AC First class coaches should be replaced. Sliding doors of luggage vans - ICF/ BEML design (TLR-5-8-001) Chapter 11, Page 16 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings iii) Vestibule doors § Thorough inspection and repair of sliding doors in SLR coaches should a) Sliding doors - These should be be undertaken. attended as per instructions § Examine door closer in AC coaches contained in section (ii) above. Semi- for proper functioning. permanent locking arrangement shall § Check lavatory hinge door for proper be as per RDSO sketch 84154. functioning. b) Flap doors - They should be § Examine lavatory door latches / tower checked for ease of working, bolts for proper function. damages to their panels, hinges, locking bolts and other parts, and 1108 VESTIBULE necessary repairs carried out. c) Rolling shutters - They should be 1108a UIC type rubber vestibule (RDSO sketch - checked for ease of working and 99056) and Foot Plate arrangement damages and necessary repairs carried out. i) Conversion to UIC type vestibule It should be ensured that the The existing stock can be provided with locking arrangements for the sliding UIC type vestibule as per RDSO SK-99056. doors / flap doors / rolling shutters are The following items/components are provided and are in working order. required for conversion. iv) Corridor inter communication doors Sr. Description of No. off Drawing No. of air conditioned coaches No. item/ component / assly. Replace all damaged or perished lining to 1 Steel frame 1 RDSO SK- ensure proper sealing. Remo ve door closer complete 99057 and test for proper functioning. Defective 2 Upper flange 1 door closer should be overhauled before RDSO SK- 3 Lateral side 2 85248 fitting. flange 1107b Examination and Repair Practice in 4 Rubber packing 2 Carriage Maintenance Depot 6x75x1900 RDSO SK- 5 Rubber packing 1 99060 i) Primary/Secondary examination, 6x75x1500 Schedule A, B and C Examination 6 Locking plate 2 § Examine body side doors for 7 Locking plate 2 RDSO SK- working/ damages. 8 Locking plate 1 99058 § Inspect door handles for damages/missing. 9 Locking plate 1 § Examine door for proper functioning. 10 Special screw 17 RDSO SK- Also check that door is properly 99059 secured with hinges and pivots and should not be grazing with floor or 11 Spring washer 53 IS:3063-65 door sill plates. M10 tab-1 type B § Examine that the door locks and 12 Hex nuts M10 70 IS:1363-92 latches are firmly secured with (D.C.) Pt.3. Tab-1 correct sized screws and are properly 13 CSK head screw 36 IS:1365-68, 4- engaging in their slot. The tongue of AM 10x25 6 Tab, 2 & 3 gravity type latch should be in proper alignment with its slot plate. 14 Snap head rivet 10 IS:2998-82, § Examine compartment sliding doors dia. 5x10 Gr.1, Tab-1 in AC first and ordinary first clas s coaches for smooth functioning. Chapter 11, Page 17 of 17 Maintenance Manual for BG coaches of ICF design Interior Fittings Sr. Description of No. off Drawing the support brackets with rubber No. item/ component / assly. No. adhesive. 15 Foot plate 1 § Clean the foot plate with wire brush arrangement to remove muck, dirt, etc. 16 Support bracket 2 RDSO SK- accumulated on the foot plate for foot plate 99057 surfaces. Examine the foot plate 17 Vestibule door 1 arrangement for wear, deformation or sill arrangement corrosion. Replace the foot plate if 18 Holding device 2 T-2-5-699 found beyond repair. Remove the for foot plate sharp corners of the foot plate. 19 Pin 2 RDSO SK- Replace the worn out or broken 99059 wearing piece. Examine the condition 20 Washer M20 2 of holding brackets and pins for 21 Split pin dia. 2 IS:549 wear, broken or welding crack. 4X36 Replace if foot plate brackets and pins are found beyond repair. Paint 22 Connecting 2 ICF/SK-2- foot plate with anti-corrosive paint. component 5-078 23 Foot plate 2 RDSO SK- § Examine the holding device for foot holding bracke t 99057 plate. Replace or repair if found 24 LP sheet 2 defective. examine the hand rail for 25 Spring plate 2 RDSO SK- breakage, etc. 99058 § Examine the bracket assembly and connecting components (if provided) 1108b Maintenance during POH for coupling the UIC vestibule with § Examine the steel frame complete for conventional vestibule. Replace the deformation, corrosion, welding deformed or missing components. crack. Repair the defective components. Straighten the § After completion of the repairs, all deformed vertical channels by components should be painted with heating and pulling inwards by one coat of red oxide zinc chromate suitable chain & screw tensioning primer. mechanism. § Examine the LP sheet on the inside of 1108c Examination and repair practice in frame. Wash and clean if found Carriage Maintenance Depot stained and dirty. Replace if found broken or cracked. For vestibules without LP sheet, painting may be i) Primary/Secondary examination, done. Schedule A, B & C examination' § Exa mine the condition of upper and lateral rubber flanges (bellows) for wear or cuts. The cracked portion up § Examine visually rolling to 300 mm on lateral side flange may shutters/sliding doors of vestibule be repaired by rubber patch and for smooth working. rubber solution. Replace if found § Inspect vestibule and its Rubber beyond repair. fittings for damages /missing § Examine the fixing screws and nuts components. Repair if necessary. for rubber flanges. Tighten if found § Visually check vestibule fall plate, loose or replace if found missing. mounting brackets, pins and lock § Examine the support brackets for foot lever for ease of operation, damages/ plate. The deformed or corroded deficiency. brackets which are beyond repair, should be replaced in position. See that the foot plate rests evenly on both the brackets. Replace the ******** perished or missing rubber sheet on Chapter 11, Page 18 of 17