SOUTH EASTERN RAILWAYDated, 26th May’2014 No. Sr.DME/KGP, CKP, ADA, RNC ARM/SRC CDO/Tata, Hatia, ROU Sub: Maintenance guideline for BG coaches of ICF design – safety related instruction Maintenance instructions for BG coaches of ICF design have been detailed in CAMTECH maintenance manual for BG coaches of ICF design. In addition RDSO, CAMTECH and Railway Board have issued guidelines with regard to safety related maintenance. Taking into account the relevant instructions, the following guidelines are reiterated for compliance by all concerned: 1. Maintenance schedules to be followed: 1.1 To maintain coaching stock in good condition, the following maintenance schedules are prescribed to be carried out in carriage depots on divisions where rake has been based for primary maintenance. Schedule A - Monthly (1 month ± 3 days) in rake Schedule B - Quarterly (3 month ± 7 days) in rake Record of schedule attention should be kept in a schedule form for Sch ‘A’ and Sch ‘B’. Items are to be attended as detailed in Appendix ‘F’ of CAMTECH maintenance manual for BG design ICF coaches. (Ref: 112(a) of CAMTECH Chg. Manual) 1.2 IOH and POH attention: i) Periodicities of IOH/POH attention of conventional ICF coaches are as under: Coach Category New coach / MLR coaches Rajdhani Satabdi (Conv) Mail / Express Passenger Other OCVs IOH Periodicity At interval of 12 months in Depot At interval of 9 months in workshop At interval of 9 months in depot At interval of 9 months in depot At interval of 12 months in depot POH Periodicity At interval of 24 months in workshop At interval of 18 months in workshop At interval of 18 months in workshop At interval of 18 months in workshop At interval of 24 months in workshop (Ref: Para 103 of Chg. Manual Table 1.1 and correction slip 5 issued in 2008 & RB letter no. 2007/M ( C)/141/1 dtd 26.09.08) Tolerance for IOH may be kept as + 30/-0 days. ii) IOH attention at depot: Coaches are required to be detached from the rake and taken to the sick line for IOH attention (‘C’ schedule maintenance). For passenger and other OCVs, bogies should be rolled out and wheel sets to be retained and overhauled bogies to be provided in same coaches. Wheel sets to be changed on condition basis. For Mail/Express coaches, overhaul bogies from workshop should be fitted. For new coach / MLR coaches, bogies are to be rolled out and attended at depot. Wheel sets to be replaced with overhauled wheel sets. Bogies from new coaches/MLR coaches should not be sent to shop for attention during IOH. iii) Extension of POH date: Stock retained in service beyond return date for any reason shall be given another schedule C (IOH) within one month of expiry of return date, after which the return date may be extended for three month from the date of such schedule C (IOH). A vehicle, whose return date has been extended once, must be booked to shop for POH as per the extended return date. (Ref: IRCA Pt IV – 2003, Para 2.3.4). For extension of POH date, bogies should be rolled out and attended at depot. Wheel sets to be replaced with overhaul wheel sets. (Ref: Correction slip no. 5 for CAMTECH manual for coaching stock). cracked or loose. a detailed inspection of wheels should be done when the coaches are received in sick-line for attention for either schedules or out of course attention.5 3. a post service life of 10 years after conversion or a total life of 35 yrs whichever is less shall be applied uniformly to all such OCVs converted from PCV’s. In addition to normal checks exercised on wheel condition during primary/secondary maintenance of coaches. Sealing of front cover should be ensured in depot and resealing to be done if seal is found broken after ensuring that front cover has not been tempered. vii) Temperature to be checked at axle box top (crown) at front face of axle. Coaches fitted with roller bearing should be checked to ensure that :i) No wash basin drain hole / discharge pipe is directly above the axle box. iii) Clearance between axle box and wheel is such that the axle box does not bind against the wheel. vi) Derailment. 2010/M (C)/660/2 dtd 20.7 Codal life of coaching stock: The following guidelines should be followed for codal life of coaching stock Type of coaching stock Steel body coaches including DMUs and restaurant car Full stainless steel body coaches including DMU’s and restaurant car Light utilisation category of coaches like inspection carriages etc (As manufactured) Codal life 25 years 30 years 40 years For OCVs (such as ART coaches. Care should be taken not to keep a coach fitted with roller bearing stationary for a long time. the affected coach will be detached. Concerned shop needs to be advised for necessary corrective and preventive action. Wheel profiles should be visually examined and gauged with tyre defect gauge in case they appear to be near condemning limits. Tyre defect gauge as per plate 38 of IRCA Part IV should be used and regularly calibrated.6 3. floods etc. 3. The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition (Ref RDSO CMI K003 and Para 1009 of CAMTECH Chg manual): Shattered Rim Spread Rim Shelled Tread Thermal Cracks Heat checks The defective wheel should be sent to workshop for repairs after entering in the maintenance card details of the work order and date of dispatch to workshop. (Ref: RB letter no. fire. iv) Brake gear is properly adjusted to avoid possibility of brake binding v) Axle box is examined for grease oozing out from rear cover and corrective action is taken.1 3.12. No repairs. Coaches grounded for a long time should be shunted up and down at regular intervals.2.4 3.3 3. 3. vi) Axle box temperature measurement by non contact type temperature measuring instrument during rolling in examination. viii) If temperature is found above 800 C.2 3. except wheel profiling of wheel sets are permitted to be done in the maintenance depot. Axle box front cover should not be opened in depot for attention of roller bearing. Roller Bearing Axle Boxes: A coach should invariably be detached from service for the following defects i) Hot axle box ii) Damaged axle box iii) Damaged front or rear cover iv) Seized roller bearing v) Coach involved in accident. ix) The following should be followed on the basis axle box temperature measurement: .10) Guidelines for Roller bearing and wheel inspection in open line depots: During rake examination. Tyre defect gauge should be used as illustrated in plate 41 to plate 44 of IRCA part IV. RA’s and material van etc) converted from PCVs. ii) The front and rear covers of the axle boxes are not damaged. Coach with defective wheel sets to be detached from rake for sick-line attention. 5 mm from the outer face of the rim shall be 825 mm. 3. inspected and re-lubricated with fresh grease during each attention to the wheel sets/bearing in workshop. i) Shop issue size of wheel set should be 837 mm ii) Condemning diameter of the wheel in service. 24) 3.S. June2033.” ii) During each attention at shop. For passenger service and OCVs.9 Minimum permissible wheel diameter in ICH design BG coaches. depot will despatch wheel sets after 9 month of service to shop for attention.12 Wheel gauge: i) Wheel to be gauged on a level track after taking off from the coaching vehicle. (Ref: IRCA Part IV . these limits are not applicable. 3.N 1 2 Temperature rise over ambient 200 C 200 C to 300 C 3 300 C to 400 C Sate Normal Bearing warm Excessively warm Action to be taken Box allowed as OK To be kept under watch by sending message to next TXR station and ascertained if temperature is rising. This is permissible for speed of 100 Kmph and above. necessary be dismounted in case of any warranted out of course attention in the workshop. wheel sets to be retained in service till 18 months if no defects observed. rear cover and renewal of felt seal ring. ii) The distance between the wheel flange on the same axle should be within the range of 1599 mm to 1602 mm iii) Under loaded condition.5 mm 5 mm 13 mm 3. axle should be given UST.5 > 35 Hollow tyre >5 Radius at root flange (WWP) 14 < 13 Thin flange < 22 Flat place 50 Wheel diameter 915 825 i) ii) . iii) Shop should restrict to supply of loose wheel sets to depot up-to 831 mm 3.5 mm 5 mm 13 mm Self propelled vehicle 0. If axle box temperature is 800 C. Depot will not carry out UST at their end. Train to be escorted by TXR with box feeling at every station and bearing examined thoroughly at destination.4 mm to RDSO sketch 91146. 92002). 3. The roller bearing must be dismounted from the wheel sets during alternate POH attention in the workshop for thorough inspection of the components. iii) Depending on service. Wheel to be turned to WWP with flange thickness of 25 mm (fig 3 of RDSO Sketch no.07 has stipulated the following for roller bearing attention: “All roller bearing must be cleaned. then coach to be detached.8 Roller bearing attention: i) RB vide letter no2004/m(C)/137/8 dtd 29. measured at a distance of 66.11.10 Pairing of wheel sets: Pairing of wheel sets should be ensured as under: On the same On the same On the same axle bogie coach Four wheeled bogie (ICF/BEML) 0. The bearing must however.11 Wheel profile: New wheel should be turned to WWP with flange thickness 29. plate no.13 Rejection limit of wheel profile: All dimension in MM Defects New Cond limit Sharp flange 14.5 <5 Deep flange 28. 4 Dash pot oil level: Dash pot oil level to be measured during Sch A and Sch B and oil to be added as required.09.5 4.25 T axle load with tolerance of +043 to . During IOH.7 . Brake block should be replaced in sets in a bogie.07. RDSO/2009/CG – 17 Non Critical location: 100% HPPA type to Spec No. RDSO/2009/CG.3 Wear limit for wearing piece: This should be measured during IOH and the following parameter to be maintained: New size Shop renewal size Condemning size 45 mm 43. 4.11) iii) Ensure that minimum dimensional clearance between the pins and bushes is within 1. Bogie brake gear: i) Replacement of brake block: Replace composite brake blocks if worn out to thickness of 12 mm including the back plate.025 mm. B and 14 RA (NAC) 20 ± 3 40 ± 5 70 ± 3 IOH.5 mm 4. This should be ensured during CRB fitment at shop.N Type of coach Remarks clearance bolster clearance clearance (A clearance) (B clearance) (C clearance) 1 GS 45 ± 3 40 ± 5 70 ± 3 Visually examined 2 GSCN 45 ± 3 40 ± 5 70 ± 3 axle box 3 SLR 48 ± 3 40 ± 5 70 ± 3 clearance during 4 VPU 39 ± 3 40 ± 5 70 ± 3 pit examination.6 4.6 litters.068 mm and bearing has a bore of 130 mm with tolerance of 0 mm to . C – K – 605 and 50% HPPA type to spec no. Interference limit permissible is 0. 8 ACCN(EOG) 34 ± 3 40 ± 5 70 ± 3 9 ACCN (SG) 35 ± 3 40 ± 5 70 ± 3 10 ACCZ(EOG) 32 ± 3 40 ± 5 70 ± 3 Check Bolster 11 ACCZ(SG) 35 ± 3 40 ± 5 70 ± 3 clearance (B 12 FACZ (EOG) 27± 3 40 ± 5 70 ± 3 dimension) during 13 FAC 25± 3 40 ± 5 70 ± 3 Sch A. Oil level of 40 mm should be maintained above the modified cap. For Rajdhani/Shatabdi service with conventional coaches. 5 VPH 36 ± 3 40 ± 5 70 ± 3 Crown clearance 6 ACCW (EOG) 28 ± 3 40 ± 5 70 ± 3 with gauge during 7 ACCW(SG) 30 ± 3 40 ± 5 70 ± 3 IOH. The quantity of oil required to achieve 40 mm of oil level above the guide cap in modified arrangement is approximately 1. SK – 93286 Alt 5.3. Maintenance of brake gear rigging should be given as per guidelines circulated by ED/Carriage /RDSO vide letter no.2 Wear limit for wearing plate: This should be measured during IOH and the following parameter to be maintained: New size Shop renewal size Condemning size 10 mm 9 mm 8.5 mm Attention brake block hangers on ICF coaches – The new brake block should be procured as per revised spec C – 9808 Rev 2 and drg no. ii) Brake gear bushes: Critical location: 50% self lubricated polyester resin type to RDSO spec no. (Ref Carr Dte RDSO Letter no.14 4. fill with 2 litres of approved brands of oil (Servoline 100/ Yantrol 100/ Bharat univol 100). oil to be checked and replenished at 15 days interval. 4.043 mm to . MC /ICF/B/D dtd 03.. brake block should be renewed and serviceable brake block may be used for trip attention.1 Rolling bearing journal: Journal diameter is 130 mm for 16.1 It must however be ensured that only one type of bushes is fitted in all critical location in a particular coach. 15 RA (NAC) 22 ± 3 40 ± 5 70 ± 3 4. 093 mm. MC/Bogie/BG dtd 20. Bogie frame bolster clearance. Side bearer oil bath: During IOH attention. All brake block thickness in bogie should be uniform.5 mm 42 mm 4. Attention of bogies: Bogie clearances: Bogie parameters such crown clearance (A clearance).04. body to Bogy clearances to be measured as stipulated: Clearances to be measured Crown Bogie frame Body bogie S. 6.8 Shock absorber: Shock absorber should be given a schedule overhaul when their capacities vary beyond ± 20 % of their specified values or after 4 Lacs Km or alternate POH whichever is earlier. MU washer to be replaced during IOH. Buffer & screw coupling attention: 5. Air brake schedule attention must be done during IOH attention at sick line. v) Air pressure continuity test from Guard Emergency Application Valve and rear most of the rake. v) Difference of Buffer height between adjacent coaches should not be more than 37. BP and FP gauges to be provided at rear end of coach to check continuity of entire rake. Depot to ensure that hoses above 3 years of life should be taken out from service. The buffer height should never be taken from the centre of the buffer face because it will not give correct value. shackle /link holes and draw hook holes should not exceed 3 mm.09).(Ref: Para 4. 5. The measurement should be taken from the centre of the buffer socket to the top of the rail head.3 Buffer height: i) Buffer height of coach under tare condition should be within the following limit: Maximum height from rail Minimum height from rail level level Production unit 1105 mm 1095 mm Workshop 1105 mm 1090 mm ii) In open line minimum buffer height in loaded condition is 1030 mm (Ref IRCA Part IV – June’03 Rules 2. Thereafter. vii) Ensure that wear on any section of draw hook should not exceed 13 mm (during IOH 10 mm). vii) Draining of Auxiliary Reservoir during each pit line attention\ viii) Periodical cleaning and overhauling of Dirt Collector during A & B schedule and IOH attention.6. it should be cleaned and given a light coat of oil.14.2 Maintenance in depot: i) Buffer plunger should be scrubbed with scrapper to remove dirt and muck.2 of IRCA Pt IV ) vi) Ensure that wear on screw coupling shackle pin. . iv) Buffer projection should not be less than 600 mm and not more than 635 mm v) Shoulder of draw bar hook projection should not be more than 32 mm beyond Head Stock. iii) Air Brake testing should be done to all coaches that will be attached to rake from yard.1). iv) Load leakage test: Full charging condition as well as service application condition.4. Thereafter. drooping of buffers and slackness of buffer plunger to ensure destruction tubes are nor damaged. vi) Working of all Alarm Chain apparatus must be tested and ensured during trip schedule examination. Apply graphite grease on faceplate after checking for cracks and wear. Apr’98.1 Coach is provided double dumb bell symbol in which enhanced screw coupling of 70 T to material specification IS 5517 – 93 Grade 35 Mn 6 Mo3 is provided. Air brake system: 6.(Carriage Dte/RDSO letter no. they should be wiped clean with cleaning oil and rubbed with wire rope. 5. ii) Screw coupling threads to be cleaned with wire brush to remove all dirt and dust. Old hoses to be removed during IOH and to be checked under pressure and under water. 6. iii) Check for tightness of buffer fixing bolts.2 The following attention should be given by depot during trip examination/IOH: i) 100% SCTR checking should be done in all out turn coaches at Sick Line (IOH and misc attention at sick line).11. ii) All new hoses to be checked under pressure under water before fitment.5 mm in tare.2). MC /APB dtd 19. (Ref: A Technical guide on derailment – CAMTECH/M/3. trunion pin.02. 5. para 3. page 47. iii) Buffer height should be adjusted by adding hard packing ring: Average tread diameter of two wheel sets of bogie Thickness of hard packing ring 889 – 864 mm 13 mm 863 to 840 mm 26 mm 839 to 829 mm 38 mm iv) Buffer height of SLR fitted with CBC coach should be maintained above 1090 mm to avoid uncoupling of coach CBC with loco CBC.1 Changing of air brake hose pipe: Air brake hose pipe to be changed in every alternate POH attention. 8.5 kg/cm². All coaches with reported brake binding en-route should be detached for thorough investigation.ix) x) xi) xii) xiii) 6. C&W staff should watch out vigilantly for loose/hanging/broken under gear parts of the coaches. the source should be opened to blow out dirt and mud. Manual) Fire extinguishers: i) Fire extinguishers should be checked every three months and completely refilled after one year. Coaches where piston movement is found to be ‘nil’ or sluggish are to be detached and taken to sick line for checking of DV functioning. Activation of all the brake cylinder piston of the rake must be checked by dropping BP pressure by a maximum of 1 kg/cm² only and not by dropping up to 1. Checking of rake through RTR: Before connecting RTR with the yard source.5 6.5 kg/cm² only and checking for piston movement.05. iv) Temperature of the axle boxes should be measured preferably with the help of the electronic temperature measuring device.5 kg/cm²) and Service application (BP dropped to 4 kg/cm²) iv) Checking for application time should be done by dropping BP pressure from 5 kg/cm² by 1. After dropping BP pressure from 5 kg/cm² by 1 kg/cm² i. In all cases. Release time to be checked after re-charging the BP. Adjustment of piston stroke: Piston stroke should be adjusted to 36 mm in BMBC coaches at the time of brake block changing. Provision of moisture trap in pneumatic line as well as in RTR. Piston travel in BMBC coaches should not be kept less than 32mm and this should not be more than 36 mm. Availability of bypass coupler to be mentioned in BPC.4 6. ii) Site should have adequate space for fixing the lighting arrangement and for staff hut. All brake block thickness in bogie should be uniform. iii) As the train passes the nominated point. up to 3.5 kg/cm² i. During IOH. Brake block should be replaced in sets in a bogie.6 7. Coach type Each Break Van Each AC coach Each Pantry car Each Generator van Nos of FE’s 2 nos 2 nos 4 nos 2 nos .e. No BP & FP should be coupled in twisted condition. iii) Load leakage to be checked at full charging condition (BP . Provision of air-dryer in pneumatic line and periodic drainage of condensate from pneumatic line. any unusual sound coming from the coaches or any other abnormality in the coaches. not below 4 kg/cm² to check whether all brake cylinder pistons are coming out and brake blocks are gripping on wheel.3 Periodical cleaning and overhauling of Guard Emergency Application Valve Securing of BP & FP hose coupling by ‘T’ lock. 95/Sec (spl)/75/1 dtd 30. All outgoing trains to be provided with BP & FP bypass coupler in guard’s compartment. brake block should be renewed and serviceable brake block may be used for trip attention. the testing should be done after re-charging BP pressure to 5 kg/cm² and dropping BP pressure by 0. In case there is a doubt regarding any brake cylinder piston not coming out to its full stroke. The coaches in the rake having sign of brake binding should be checked thoroughly to identify the cause of brake binding and rectification of the same accordingly. Rolling –in examination: i) Site shall provide unobstructed view of under gear from both sides. ii) Provision of DCP type fire extinguisher in a rake should be in accordance with guidelines circulated vide letter no. (Ref :107(b)(vi) of CAMTECH Chg.e. clearance of brake block with wheel tread should not be less than 5 mm. Changing of brake block: Replace composite brake blocks if worn out to thickness of 12 mm including the back plate.97 i) ii) 6. after dropping BP pressure 1 kg/cm² .5 kg/cm² which may sometime give misleading response of brake cylinder piston movement. Clearance of brake block with wheel tread should not be less than 5 mm. Charge the BP of the rake to 5 kg/cm². A minimum 2 hrs may be planned at the non primary end to enable thorough attention to cleanliness. iii) En-route coach detachment is investigated and corrective & preventive action taken. these should be isolated by air spring isolating cock and speed of train should be reduced to 60 Kmph or the coach should be detached. Record should be kept. Record to be maintained in standard DDR (Damage deficiency register). shop representative should be associated for investigation. . Record of schedule attention given (Schedule A. For defect related to shop activity. GRC Copy to: CWM/M/KGPW – For kind information and necessary action please. iii) Short distance Duronto with only only AC / Non AC chair car may be permitted to run on the extant pattern for Shatabdi trains with a terminal attention at other end on platform / stabling line.08. 11.1 11. ii) Secondary detachment should be analysed and corrective & preventive action should be taken. 11.9.09) Attention of air springs: i) Procedure for rolling – in examination: As train passes the nominated point.out examination may also be conducted for each of the Duronto trains at the respective operational halts and also at the terminals during the journey.3 11. Manual). Record should be kept.2 11. ii) Rolling – in and rolling. For Coach roller bearing failure. Such safety examinations of the Duronto trains may be periodically super checked at the level of officers. bearing manufacturer should also be called for joint investigation. hygiene and passenger amenities at other end. In case it is not feasible to inflate the air springs of any particular coach. 2009/M (C)/141/2 dtd 25. ( RB letter no. The above guidelines should be circulated to all officers and Supervisor for compliance.4 Maintenance of Duronto train: i) Pattern of maintenance for Duronto train as being followed for Rajdhani trains with pit examination at both end should also be followed. Analysis of sick marking and en-route coach detachment i) Primary coach detachment should be analysed and corrective & preventive action should be taken. especially of items required to be attended at specific periodicity. Coach history and coach maintenance records: Every coaching depot shall have computers for maintaining the coach maintenance history in a software programme which should be compatible with the programme of the coaching workshop. Schedule B and IOH) should be kept in standard format and records are maintained (As per item mentioned in Appendix F of CAMTECH manual) (Ref: 117(e)(iii) of Chg. 10. Record of trip schedule attention: A proper record should be kept by Engineer (C&W) at washing/pit lines of schedules carried out by them. C&W staff should watch out vigilantly loose / hanging / broken under gear parts of the coaches special attention should be paid to air springs in case of coaches provided with air springs at secondary suspension stage. (MD ASAD ALAM) Chief Rolling Stock Engineer/Chg South Eastern Railway. ii) It should be ensured all the air springs are in inflated condition by noting that the levelling valve lever is in horizontal position.
Report "Maintenance Guidelines for Depot- ICF Stock"