Maintenance Manual for BG Coaches of ICF Design PDF

Maintenance Manual for BG coaches of ICF design Appendix APPENDIX- A TRANSPORTATION CODES FOR COACHES S. No. TRANSPORTATION DETAILS COD...

Maintenance Manual for BG coaches of ICF design Appendix APPENDIX- A TRANSPORTATION CODES FOR COACHES S. No. TRANSPORTATION DETAILS CODE 1 ART ACCIDENT AND TOOL VAN OR RELIEF VAN 2 CT TOURIST CAR 3 CTS TOURIST CAR FOR 2ND CLASS PASSENGERS 4 CZACEN AIR CONDITIONED CHAIR CAR WITH END ON GENERATION 5 ERR FOUR / SIX WHEELER 6 ERU FOUR / SIX WHEELER SELF PROPELLED TOWER VAN 7 FCS FIRST CLASS COUPE AND SECOND CLASS 8 FSCN FIRST CUM II CLASS 3-TIER SLEEPER 9 GS SECOND CLASS FITTED WITH SELF GENERATING EQUIPMENT 10 LR LUGGAGE WITH BRAKE VAN 11 NMG NEW MODI FIED GOODS 12 OHE OVER HEAD EQUIPEMNT INSPECTION CAR 13 PPS FULL BOGIE POSTAL VAN 14 RA INSPECTION CARRIAGE ( ADMINISTRATIVE) 15 RAAC AIR CONDITIONED INSPECTION CAR 16 RD INSPECTION CARRIAGE (SUBORDINATE) 17 RE INSTRUCTION VAN (MOBILE TRAINING CAR) 18 RH MEDICAL VAN 19 RHV AUXILIARY MEDICAL VAN 20 RK DYNAMOMETER CAR 21 RN GENERATING VAN 22 RS STORES VAN 23 RT ACCIDENT AND TOOL VAN OR RELIEF VAN 24 RZ TRACK RECORDING CAR 25 SLR SECOND CLASS LUGGAGE AND BRAKE VAN 26 SMN POWER CAR WITH MID ON G ENERATION 27 VP PARCEL VAN 28 VPC PARCEL VAN CONVERTED 29 WACCNEN VESTIBULED AC 3 -TIER WITH END-ON–GENERATION 30 WCB VESTIBULED PANTRY CAR 31 WSCZACEN VESTIBULED AC CHAIR CAR WITH END-ON -GENERATION 32 WCD VESTIBULED DINING CAR 33 WCRAC VESTIBULED AI R CONDTIONED TWIN CAR 34 WCTAC VESTIBULED AIR CONDITIONED TOURIST CAR 35 WFACEN VESTIBULED AIR CONDITIONED FIRST CLASS WITH END ON GENERATION 36 WFC VESTIBULED FIRST CLASS 37 WGACCN VESTIBULED AIR CONDITIONED THREE TIER WITH SELF GENERATING ELECTRICAL EQUIPMENT 38 WGACCW VESTIBULED AIR CONDITIONED TWO TIER WITH SELF GENERATING ELECTRICAL EQUIPMENT 39 WACCWEN VESTIBULED AIR CONDITIONED TWO TIER SLEEPER WITH END ON GENERATION 40 WGFAC VESTIBULED AIR CONDITIONED FIRST CLASS WITH SELF GENERATING ELECTRICAL EQUIPMENT 41 WGFACCW VESTIBULED FIRST CUM AC 2-TIER SLEEPER Maintenance Manual for BG coaches of ICF design Appendix S. No. TRANSPORTATION DETAILS CODE 42 WGSCN VESTIBULED SECOND CLASS THREE TIER SLEEPER WITH SELF GENERATING EQUIPMENT 43 WGSCNLR VESTIBULED SECOND CLASS THREE TIER SLEEPER WITH LUGGAGE AND BRAKE VAN 44 WGSCZ VESTIBULED SECOND CLASS CHAIR CAR WITH SELF GENERATING ELECTRICAL EQUIPENT 45 WGSCZAC VESTIBULED SELF GENERATING SECOND AC CHAIR CAR 46 WGSD VESTIBULED SECOND CLASS DOUBLE DECKER WITH SELF GENERATING ELECTRICAL EQUIPMENT 47 WLRRM POWER CAR END-ON-GENERATION 48 WSCZACEN VESTIBULED AIR CONDITIONED SECOND CLASS CHAIR CAR WITH END ON GENERATION 49 WSLRN VESTIBULED SECOND CLASS, BRAKE CUM LUGGAGE AND POWER CAR Maintenance Manual for BG coaches of ICF design Appendix APPENDIX – B ITEMS WHICH MUST BE CHANGED DURING POH OF HIGH SPEED COACHES (RDSO letter no. MC/CB/MARS dtd. 9.8.99) 1. Roller bearing grease (when opened) 2. Locking plates (T-0-2-637) (when opened) 3. Rubber sealing ring of axle box front & rear cover (T-0-2-625) (when opened) 4. Rubber packing ring (T-0-1-632) 5. Guide ring (T-0-1-635) 6. Guide bush (T-0-1-634) 7. Circlip for dash pot guide bush (if used) (ICF Sk-0-1-182, item 3) 8. Wearing piece (T-0-5-649) 9. Wearing plate (T-0-5-648) 10. Side bearer oil 11. Dashpot oil 12. Brake gear bushes (as a set) (RDSO Sk. 81039) 13. Brake shoe key (T-3-1-618) 14. Shoe adjuster assembly (T-3-1-612, T-3-1-607, T-3-1-609) & M16 nut & bolt with split pin 15. Brake beam bush collared (T-3-2-644) 16. All bulb type cotters (T-3-2-632) (when opened) 17. Sealing washer for air vent screw (T-0-1-629) 18. Rubber stopper & crown bolt (RDSO Sk.-97068) 19. Rolling ring (VB-79/M) Maintenance Manual for BG coaches of ICF design Appendix 20. Joint ring (VB-87/M) 21. Gland packing ring (VB-87/M) 22. DA valve diaphragm 23. Vacuum hose pipe – 50 mm dia (VB-504/M) 24. Vacuum brake syphon pipe – 20 mm dia (VB-510/M) 25. All rubber item of air brake equipment (if overhauled) 26. Centre pivot locking plate (T-0-6-612) 27. Bush for equalising stay (RDSO SK 88018 item 5 & 6, RDSO SK 88105 item 5) 28. Bush for 18 kw alternator (MG/T-3-2-009) 29. Bush for 4.5 kw alternator (T-0-3-659 item 5) 30. Silent block for anchor link (T-0-7-601) 31. Centre pivot bushing sleeve (T -0-6-603) 32. Dirt collector filters 33. Buffer bolts (T-2-2-503) 34. Centre pivot bolts Maintenance Manual for BG coaches of ICF design Appendix APPENDIX - C MODIFCATIONS IN BG COACHING STOCK (RDSO’s Letter No. MC/CB/MARS Dtd. 24.06.98) Sr. Description of Modifications Sketch / Drg. No. Applicability Category No. 1 Adoption of worn and intermediate RDSO SK - 92082 Railways and A profile of wheels & 91146 Production Units 2 Standardisation of 16t. Equalising Stay RDSO SK - 88105 Production Units A on all new coaches & 93236 only 3 Provision of locking arrangement for RDSO SK - 85070 Railways and A guide caps of a) Existing Bogies, alt. 3 Production Units b) New Bogies ICF / SK-0-1-182 4 Axle end locking arrangement for direct ICF Drg. No. T-0- Railways and A mounted spherical roller beari ngs 2-637 alt. a Production Units 5 Procedure for manufacture and Drg. No. C/BE- Railways and A inspection of bolster suspension hangers 4501 alt 7 Production Units 6 Schedule of technical requirement of Spec. C-9406 Railways and Spec. silent block for anchor link (Rev.1) Production Units 07 Lowering of attendant berth to approx. RCF Drg. No. Railways and A 600 mm. from floor level in AC coaches M1000517 Production Units 08 Earmarking of one seat in GS coaches RDSO SK - 96078 Railways and A for physically handicap person Production Units 09 STR No. C - 9503 for upholstery cloth Spec. No. C-9503 Railways and Spec. for coaching amendment slip 1 Production Units 10 Schedule of requirement for LP sheet Spec. C- 9602 with Railways and Spec. amend slip 1 Production Units 11 Provision of APD for foot plate of RDSO SK – 95199 Completed, may A vestibule by welding of washer with be treated as securing pin standard 12 Provision of compression spring to RDSO SK – 96006 Railways only A support canvas vestibule frame 13 Modified pin for 'Z' lever hanger to RDSO SK – 98127 Railways and A avoid working out of bushes in the Production Units brackets 14 Color coding of SAB spindles for ICF Drg. No. T-3- Railways and A different length 3-704 Production Units 15 Revised locations for fixing holes in RDSO SK – 94043 Production Units A buffer case to minimize cracking of 94044 only. Railways to head stock make new purchase as per revised drawing. 16 Provision of PVC flooring and Railways and A aluminium Production Units chequered plate in doorways and gangways 17 Use of high performance grease viz - Railways and - Servogem - RR3 and Balmerol Multi- Production Units grease in roller bearing axle boxes 18 Use of plastic axle guide bushes to RDSO SK - 84102 Railways and Spec. STR - C-8215 (Rev.II) Production Units 19 Elimination of roof filling arrangement RDSO SK - 90088 Railways only A and provision of foot step and handle in lieu of ladder 20 Interi or colour scheme RDSO SK - 90068 Railways and A Production Units Maintenance Manual for BG coaches of ICF design Appendix Sr. Description of Modifications Sketch / Drg. No. Applicability Category No. 21 Provision of FRP tissue on trough floor, ICF Drg. No. ICF Railways and A sole bar, turn under and side wall SK- 9-0-890 Production Units 22 Modification to increase linen room RDSO SK - 88103 Railways only A capacity in 2tier AC coaches Alt.2 23 Modification of suspension of under ICF Drg. No. Railways and A slung water tank provided under AC WGFAC - 6- 3-208 Production Units Coaches (col II) WGFAC3 - 6- 3- 305 alt.’d’ 24 Strengthening of bogies frame for RDSO SK – 88062 Railways and A transom mounting of 4.5 KW alternator Production Units for 110 V. dc system 25 Provision of wall type fans in the - Railways and A lavatories of AC coaches Production Units 26 Modification for pad locking of body RDSO SK –87020 Railways and A side door from inside of a coach Production Units 27 Provision of TRA type roof ventilators ICF Drg. No. Railways and A WLRRM4-7-3-402 Production Units alt. 'n' & WLRRM4-7-3-401 alt. 'g' 28 Strengthening of partition wall between ICF Drg. No. SLR - Railways and A guard’s lobby and luggage / brake van 9-0-001 Production Units 29 Provision of wire rope arrangement ICF Drg. No. Railways and A below seats for luggage securing ICF/SK -6-1-234 Production Units 30 Provision of aluminium chequered RDSO SK – 85121 Railways and A flooring in pantry portion, washing room (existing), 85120 Production Units and door ways of PCs. (new) 31 Provision of safety partition on flaps on RDSO SK – 83014 Completed, may A end berths at either end of AC Sleeper alt. 1 be treated as coaches standard 32 Provision of nylon wire net magazine - Railways and A pouches. Production Units 33 Marking of 125 mm diagonal cross in RDSO SK – 85020 Railways and A fluorescent yellow paint and fitment of Production Units acrylic reflector in addition to existing tail lamp / board 34 Provision of five additional safety bars RDSO SK – 84162 Railways and A on body side door windows Production Units 35 Modification of body pillars for RDSO SK – 76020 Railways only A corrosion repair alt. 7 36 Provision of M24 bolt and nuts for ICF Drg. No. ICF/ Railways and A fitment of bottom cover to the centre SK-1-1-135 and Production Units pivot flange with bent plate anti rotation RDSO SK- 75108 of bolts alt. 1 37 Provision of four bars on window of - Railways and A body side wall of guard's portion of Production Units brake van 38 Use of seamless pipe in air brake system Spec. No. 04 ABR Railways and Spec. – 94, amendment Production Units Slip 4 39 Modification in design of existing 13t. RDSO SK – 88018 Railways only B equalising stay & safety strap alt. 6 and SK – 97022 40 Provision of rubber stopper to maintain RDSO SK – 97068 Railways and B axle b ox crown clearance Production Units 41 Provision of FRP frame glass shutter as ICF /SK- 5-4-094 Railways only B alternative to aluminium shutter and spec. C-9403 Maintenance Manual for BG coaches of ICF design Appendix Sr. Description of Modifications Sketch / Drg. No. Applicability Category No. 42 Provision of FRP banjo shutter as ICF / SK-5-5-020 Railways only B alternative to aluminium shutter & Spec. C-9403 with amend. slip no. 1 &2 43 Provision of UHMWPE/NFTC axle box RDSO SK- 97072 Railways only B packing & STR No. C-9703 44 Standardisation of seats and berths RDSO SK- 97051, Production units B 97052, 97053, only 97054 & 97055 45 Use of single piece FRP louvre shutter RDSO SK- 97020 Railways and B & STR C - 9403 Production Units with amend slip 1 &2 46 Semi-permanent locking arrangement for RDSO SK- 84179 Railways and B unused vestibule doors & 84154 Production Units ( in vestibule with sliding doors) 47 Slack adjuster articulation arrangement RDSO SK – 96102 Railways only B in vacuum braked coaches alt. 1 48 Brake beam for air braked coaches & RDSO SK - 82010 Railways and B brake beam test procedure alt. 5 Production Units 49 Modified design of brake head and brake RDSO SK - 94026 Railways and B shoe key for snug fitting of brake block. & 94027 Production Units 50 Increased length of 30 mm of brake RDSO SK- 93286 Railways and B block hanger Production Units 51 Modification to passenger alarm system RDSO SK - 96040 Railways only B in vacuum brake system 52 Use of ventury type chute for lavatories ICF / SK-6-3-324 Railways and B Production Units 53 Modification to safety strap for axle RDSO SK - 90005 Railways and B guide arrangement and axle box lug alt. 2 Production Units 54 Provision of emergency openable ICF Drg. No. Production Units B window in non AC coaches DMU/DPC-5-4-002 55 Provision of closing piece and inspection ICF Drg. No. TLR- Railways and B door on sliding door pocket in luggage 4 -2-717, SLR - 4- Production Units compartment of SLR / WLRRM coaches 2-002, WLRRM -4- 2-604 , WLRRM-4 -2-605 56 Provis ion of complete FRP window RDSO Spec. No. C- Railways and C including window sill & guides 9502 Production Units 57 Use of 12 mm. compreg flooring in STR C- 9407 type Railways and C place of 19 mm. plywood II Production Units 58 Standardized stainless steel inlays for ICF/STD-4 -1-002 Production Units C lavatories only. Railways in corrosion repair coaches 59 Fitment of UIC vestibule on coaches Spec C-8812 rev. I Railways and C RDSO Sk-88058, Production Units alt.5 & Sk -88059, alt. 5 60 Use of Nylon 66 bushes in brake gear RDSO SK-81039, Railways and C with N5 finished Electro plated pins 82023, 84018, Production Units 84116, 84132 and 93186 alt. 2 61 Safety wire rope arrangement for brake RDSO SK- 93289, Railways and C beam 93340 & 82010 Production Units Maintenance Manual for BG coaches of ICF design Appendix Sr. Description of Modifications Sketch / Drg. No. Applicability Category No. 62 Use of high capacity buffer packs inside Spec. C- 9501 Railways and C buffers of coaches (Rev. I), SK- 96002 Production Units alt. 3 63 Fitment of enhanced screw coupling and RDSO Sk- 79061 & Railways and C draft gear Sk- 79067 Production Units 64 Fitment of Emergency window in AC RDSO-SK. 98161 Railways and C and Non AC coaches (Alt.1), ICF/STD Production Units 3 -4-005, ICF/SK. 5-4-168