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 iv)Rajdhani and designed and manufactured. Luxury POH in workshops Shatabdi coaches mainly to boost tourism having 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 H 8 9 1 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 N O S T E E E :

P C 1 . . R U/FRAME 2742 F . D O R R G

D .

E N T O A I . L

S J & S T E P E

C

D . 0 R E 5 . D V 1 - R 9 G 9 .

& N 1 O 0 . 2

J & T

F D R O E V

2 M

- 3

8 R 5 A 0 I P L

2 0 L E . 1

V F 1 E O L R

A

L T 0 E T 5

H R 8 N G 1 I A E T H I V E E E

D R F E

S 0 I G 0 2 N 1 S 5 2

0 0 6 275 3008

1250 1680 1250 S K E T C H

-

7 7 3 1 0

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 VPH -3 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

BOGIE BOLSTER C G A D E

L.S. BEAM F M B

RAIL LEVEL

PART- II

BODY BOLSTER H

BOGIE FRAME SIDE BEARER K

BOGIE BOLSTER I J N 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/SK2-9-0-126)

Table 1.3

COACH LOAD A B C D E F G H I J K L MY NY Nominal Nominal ±5 ±5 ±3 +6/-4 ±3 ±5 +0/-10 ±3 +6/-4 ±3 ±5 ±5 WGFAC4 Tare 38 40 36 275 290 686 1104 70 299 310 40 646 15 11 +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +6/-4 ±3 ±5 +8/-5 Gross 34 44 32 275 286 682 1098 66 295 308 44 638 - - ±5 ±5 ±3 +6/-4 ±3 ±5 +0/-10 ±3 +5/-4 ±3 ±5 ±5 WGSCZAC Tare 38 40 36 276 290 686 1104 70 300 310 40 646 14 10 +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +7/-4 ±3 ±5 +8/-5 Gross 23 54 22 262 276 672 1075 55 285 295 55 617 - - ±5 ±5 ±3 +6/-4 ±3 ±5 +0/-10 ±3 +6/-4 ±3 ±5 ±5 WGSCWAC Tare 38 40 36 274 290 686 1104 70 298 310 40 646 16 12 +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +7/-4 ±3 ±5 +8/-5 Gross 28 49 27 265 281 677 1085 60 288 300 50 627 - - ±5 ±5 ±3 +6/-4 ±3 ±5 +0/-10 ±3 +6/-5 ±3 ±5 ±5 WGFSCZAC Tare 38 40 36 272 290 686 1104 70 296 310 40 646 18 14 +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +7/-4 ±3 ±5 +8/-5 Gross 28 48 28 264 282 678 1086 60 286 300 50 628 - - ±5 ±5 ±3 +6/-4 ±3 ±5 +0/-10 ±3 +6/-4 ±3 ±5 ±5 WGFSCWAC Tare 38 40 36 273 290 686 1104 70 297 310 40 646 17 13 +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +7/-4 ±3 ±5 +8/-5 Gross 31 46 30 267 284 680 1091 63 290 303 47 633 - - ±5 ±5 ±3 +6/-4 ±3 ±5 +0/-10 ±3 +6/-3 ±3 ±5 ±5 WGMWAC Tare 38 40 36 282 290 686 1104 70 307 310 40 648 8 3 +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +6/-4 ±3 ±5 +8/-5 Gross 32 45 31 277 285 681 1093 64 301 304 46 635 - -

±5 ±5 ±3 +6/-4 ±3 ±5 +0/-10 ±3 +6/-4 ±3 ±5 ±5

Tare 38 40 36 279 290 686 1104 70 304 310 40 646 11 6

END +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +6/-4 ±3 ±5 +8/-5 Gross 35 43 33 276 287 683 1098 67 301 307 43 640 - - DRIVING

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

ARMVAC +8/-5 ±5 +5/-2 +6/-4 ±3 ±5 +8/-5 ±3 +7/-4 ±3 ±5 +8/-5 END NON Gross 33 44 32 268 286 682 1095 65 291 305 45 637 - - DRIVING 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 % % c 9 1 5

BOGIE FRAME X

BOGIE BOLSTER A Z B G

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. =

D Compensating Ring P

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

Maintenance Manual for BG coaches of ICF design Coach

TESTING PARAMETERS FOR AC COACHES (RCF DRAWING NO. AW90017)

Table 1.5

Type Tare Normal Total Test load per Bogie frame Body bogie Axle box spring height Bolster spring Crown Bogie bolster Buffer of weight pay load pay bogie bolster clearance height clearance height height coach of coach load clearance Under Under C D G CR H CR X Y Z

tare Gross

AC

# * In In In tonnes In tonnes In tonnes Tare Tare Tare Tare Tare Tare Tare Gross Gross Gross Gross Gross Gross Gross tonnes tonnes

5

10 -

4 4 4 5 5

ACCW ------

5

5 5 3 3 3 3 +8/

± +0/

(EOG) +5/ +6/ +5/ +7/ +8/ ± ± ± ± ± ± 4 Nil 44.8 3.68 3.68 16.2 40 50 70 60 28 20 18.04 646 286 278 312 302 628 1086 1104

5

10 -

4 4 4 4 5

ACCW ------

5 5 5 3 3 3 3

+8/

± +0/

(SG) +5/ +6/ +6/ +7/ +8/ ± ± ± ± ± ± 9 14 49.1 3.68 3.68 40 50 70 60 30 22 18.35 20.19 646 276 268 301 291 628 1086 1104

5

10 - 4 4 4 4 5

ACCN ------

5 5 5 3 3 3 3

+8/

± +0/

(EOG) +6/ +7/ +6/ +7/ +8/ ± ± ± ± ± ± 7 12 48.3 5.12 5.12 40 54 70 56 34 22 17.95 20.51 646 278 266 303 289 620 1078 1104

5

10 -

4 5 4 5 5

ACCN ------

5 / 5 5 3 3 3 3

+8/ ± +0/

(SG) +7 +7/ +7/ +7/ +8/ ± ± ± ± ± ± 22 19 5.12 5.12 40 53 70 57 35 23 52.53 20.07 22.63 646 268 256 291 278 621 1079 1104

5

10 -

3 4 3 4 5

ACCZ ------

5

5 5 3 3 3 3 +8/ ± +0/

(EOG) +6/ +6/ +6/ +6/ +8/ ± ± ± ± ± ± Nil Nil 43.1 5.36 5.36 40 54 70 56 32 20 15.35 18.03 646 290 278 316 302 620 1078 1104

Chapter 1, Page 10 of 41

Maintenance Manual for BG coaches of ICF design Coach

Type Tare Norm Total Test load per Bogie frame Body bogie Axle box spring height Bolster spring Crown Bogie bolster Coupler of weight al pay pay bogie bolster clearance height clearance height height coach of coach load load clearance Under Under C D G CR H CR X Y Z

tare Gross

AC

# * In In In tonnes In tonnes In tonnes Tare Tare Tare Tare Tare Tare Tare Gross Gross Gross Gross Gross Gross Gross tonnes tonnes

5

10 -

4 4 4 4 5

ACCZ ------

5 5 5 3 3 3 3 +8/

± (SG) +0/ +6/ +6/ +5/ +7/ +8/ ± ± ± ± ± ± 9 3 5.84 5.84 40 56 70 54 35 22 46.83 17.22 20.14 646 281 268 307 291 617 1075 1104

5

10 -

3 4 3 4 5

FACZ ------

5

5 5 3 3 3 3 +8/ ± (EOG) +0/ +5/ +6/ +5/ +5/ +8/ ± ± ± ± ± ± Nil Nil 42.6 3.68 3.68 40 50 70 60 27 19 15.10 16.94 646 291 283 318 308 628 1086 1104

5

10 -

3 4 3 4 5

RA ------

5 5 5 3 3 3 3

+8/ ± +0/

(NON +5/ +6/ +5/ +5/ +8/ ± ± ± ± ± ± 6 AC) 11 17 41.3 1.20 1.20 40 44 70 66 20 17 14.45 14.05 646 279 27 298 294 640 1098 1104

10 5 3 4 3 4 5

VP ------

5

5 5 3 3 3 3 8/ ± +0/ +5/ +6/ +5/ +5/ +8/ ± ± ± ± ± ±

(HIGH 32 23 23 03 9.8 Nil 21.3 40 81 70 29 36 11 646

CAPA 287 262 310 269 580 1038 CITY) 1104

5

10 -

4 5 4 5 5

IRQ ------

5 5 5 3 3 3 3

+8/ ± +0/

ACCN +7/ +7/ +7/ +7/ +8/ ± ± ± ± ± ± .45

(SG) 19 15 41.3 5.12 5.12 40 54 70 56 35 23 19 22.01 646 271 259 295 281 620 1079 1104

10 5

3 4 3 4 5

RA AC ------

5 5 5 3 3 3 3 8/

± +0/ +5/ +6/ +5/ +5/ +8/ ± ± ± ± ± ± 8 3 1.20 1.20 40 43 70 67 22 19 46.69 17.14 17.14 646 282 279 307 304 640 1098 1104

Chapter 1, Page 11 of 41

Maintenance Manual for BG coaches of ICF design Coach

PART- I

% % c 9 1 5 BOGIE FRAME X

BOGIE BOLSTER A Z B G

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

Maintenance Manual for BG coaches of ICF design Coach

TESTING PARAMETERS FOR NON AC COACHES (RCF DRAWING NO. CC90019)

Table 1.6

Type Tare Norm Over Total Test load per Bogie Body bogie Axle box spring Bolster spring Crown Bogie Buffer of weight al pay load pay bogie frame clearance height height clearance bolster height coach of load load bolster height coach clearance Under Under C D G CR H CR X Y Z tare Gross

AC

In tonnes In tonnes In tonnes In tonnes

e

# * Tare Tare Tar Tare Tare Tare Tare Gross Gross Gross Gross Gross Gross Gross In tonnes In tonnes

5

10 - 3 4 3 4 5

------

5 5 3 3 3 3 3 +8/

GS ± +0/ +4/ +5/ +5/ +7/ +8/ ± ± ± ± ± ± 1 7 5.85 12.6 40 74 70 36 47 20 36.99 11.70 18.45 100% 646 289 262 308 274 585 1043 1104

5

10 -

3 4 3 5 5

------

5 5 5 3 3 3 3

SOC +8/

± +0/ +4/ +6/ +5/ +7/ +8/ ± ± ± ± ± ± 1 7 7.02 12.6 40 81 70 29 50 18 37.00 14.04 19.62 100% 646 289 257 308 267 572 1030 1104

5

10 -

3 3 3 4 5 ------

5 5 5 3 3 3 3

SCN +8/

± +0/ +4/ +5/ +5/ +6/ +8/ ± ± ± ± ± ± - 3 10 5.76 5.76 40 57 70 53 31 17 38.03 13.12 16.00 646 287 273 305 288 616 1074 1104

Chapter 1, Page 13 of 41

Maintenance Manual for BG coaches of ICF design Coach

Type Tare Norm Over Total Test load per Bogie Body bogie Axle box spring Bolster spring Crown Bogie Coupler of weight al pay load pay bogie frame clearance height height clearance bolster height coach of load load bolster height coach clearance Under Under C D G # H * X Y Z tare Gross

AC tonnes

In tonnes In tonnes In tonnes In CR CR Tare Tare Tare Tare Tare Tare Tare Gross Gross Gross Gross Gross Gross Gross In tonnes In tonnes

5

10 -

3 4 3 5 5

------5

5 5 3 3 3 3 7/ +8/

SLR ± +0/ +4/ +6/ +5/ + +8/ ± ± ± ± ± ± 1 7 2.6 40 79 70 31 50 20 37.10 10.60 13.20 12.65 19.25 646 289 258 308 269 577 1035 1104

5

10 -

3 4 3 5 5

------5 5 5 3 3 3 3

+8/

VP ± +0/ +4/ +6/ +5/ +7/ +8/ ± ± ± ± ± ± - 5 13 40 77 70 33 39 11 32.00 18.00 18.00 10.30 19.30 646 285 257 302 265 581 1039 1104

5

10 -

3 3 3 4 5

------5 5 5 3 3 3 3

IRQ +8/

± +0/ +4/ +5/ +5/ +6/ +8/ ± ± ± ± ± ± - 1 7 37.2 5.76 5.76 12.7 40 57 70 53 30 17

SCN 15.58 646 289 275 308 291 616 1074 1104

5

10 -

3 3 3 4 5

------

5

5 5 3 3 3 3

Post +8/

± +0/ +4/ +5/ +5/ +6/ +8/ ± ± ± ± ± ± - 5 3.0 3.0 Nil 36.5 al 40 49 70 61 22 15 12.35 13.85 646 290 283 310 301 630 1088 Van 1104

Chapter 1, Page 13 of 41

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.

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Maintenance Manual for BG coaches of ICF design

Coach

370

100 300 50 300 50 300 100 25 2 225

EXPANDED METAL 0

0 MESH

1 FOR ADJUSTING FOCUS SWIVEL JOINT WITH NUT & BOLT 0 0 5 5 4 2 5 2 T 2 A L F

0 M 0 M 1

0 3 0 0 5 5 5 ISMC 100 HINGES 250 W FOCUS BULB 5 2 3

CONCRETE BASE

G.L.

LIGHTING ARRANGEMENT FOR ROLLING IN/OUT EXAMINATION

FIGURE 1.5

1200 8 9 5

c % 6 9 % R 8 MATERIAL :- M.S. ROUND BAR TO IS:2062PWEIGHT :- 0.590 KG (Approx.)

21

HOOK FOR BRAKE RELEASE

286 FIGURE 1.6

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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 air/vacuum check kms but round with fresh BPC. trip 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).

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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 examination of the under gear. and lavatory. 7. The decision, whether such trains may be vi) No coach should run overdue shunted for working on pit line or schedule. attended at platform itself, has to be taken carefully after weighing these factors by 2. Clear maintenance time of 6 hours on the the mechanical and Traffic HODs on the pit as per train schedule. Any exception to zonal Railway on case to case basis. be jointly decided by COM/CME of the Railways. 8. The status of implementation of revised pattern of coaching trains should be 3. Provision of proper washing cum reviewed every year in the month of June maintenance pit line facility with adequate by Mechanical and Operating branches at testing equipment and high pressure water Divisional level and any discrepancy cleaning arrangement. should be removed. 4. Adequate gang strength with proper supervision. 109 WASHING AND CLEANING OF COACHES THE OTHER END:

Use recommended solutions for cleaning 5. Whenever the lie-over is more than 2 as per RDSO specification No. hours at the platform or the rake is stabled M&C/PCN/101/2001 or use cleaning in the yard, the rake should be locked and agents approved by CME of the Railway. positive security should be provided. 6. Amenity and cleaning attention is carried 109a Platform cleaning and washing out best on the washing lines where complete infrastructure by way of men, i) Wherever washable aprons are available material and machines are available. on the platforms, the time available before Watering and drainage facilities are also the terminating trains are pulled out into available on these washing lines. Ideally, the yard, should be utilised for inside for cleaning and watering, the rakes sweeping and toilet cleaning. Chapter 1, Page 13 of 41

Maintenance Manual for BG ICF Coaches Coach

109b External Cleaning / Washing v) The flooring should be rubbed with nylon bristles/sponge brush and cleaned with i) Place the rake/coaches on the washing pit recommended cleaning agent. The drain provided with equipments required for holes should be cleaned thoroughly for washing and cleaning. It should be easy discharge of water. ensured that the rake/coach is protected vi) The mirrors in toilet should be cleaned with proper board/signal for safety of the with light wet cloth. Recommended staff working on washing/cleaning job to solution should be used for cleaning the prevent movement/disturbance in the dirty portion of glasses. activity. Scotch blocks with locking vii) After all the washing and cleaning in the arrangement should protect lines and keys toilets mentioned above, the toilets should should be kept with Engineer (C&W) till be thoroughly cleaned with water jets and the time rake is under maintenance. water should be flushed out. All fittings ii) Before starting washing and cleaning of and floor should be wiped dry with a cloth. side wall, ensure that the glass shutters viii) After cleaning, spray deodorant in the and louver shutters of that side are toilet to remove the bad odour. lowered. Remove dirt/dust accumulated on shutters by compressed air or duster. 109d Internal cleaning of upper class AC and sleeper coaches iii) Remove old reservation charts/labels on the body panels. Splash water on old i) Collect the cigarette ends from all Ash charts so that they are wet for easy trays, news paper from magazine bag and separation. Care should be taken to avoid waste from dust bin. Sweep the whole any damage to the paint. coach with broom in sleeper coaches. iv) The cleaning solution should be Clean the floor of AC coaches with spread/rubbed with nylon brush or sponge vacuum cleaner. brushes and then rubbed thoroughly to ii) Remove dust from floor, berths/seat, clean the panels. Extra attention should be magazine nylon wire mesh bag fitted on given to oily and badly stained surfaces. panels and fan guards with duster. Use of v) Destination boards may be removed and vacuum cleaner is excellent in such areas. cleaned with brush/duster. iii) Also remove dust/dirt from under the vi) Clean the external surface by high berths, window sill, sliding door, railing pressure jet where facilities are available. corner and all corner & crevices of coach interior with vacuum cleaner if provided. vii) All exterior panels including end panels iv) Ceiling panels, wall panels, cushion should be hosed with water and brushed berths, fittings, table top, etc. should be with diluted soft soap (detergent solution) cleaned with duster and stain marks on The strength of the solution may be these should be removed by use of increased or decreased according to recommended soft detergent. RDSO specification M&C/PCN/101/ v) Aluminum frames, strips, and other metal 2001. fittings, etc. should be cleaned with 109c Cleaning of Toilet recommended cleaning agent. vi) FRP window frames, louvers, etc. should i) Before starting cleaning of toilets ensure be cleaned with recommended solution that all repairs in the toilets have been and rubbed out by nylon brush or sponge carried out and after cleaning no /duster to remove stain marks. employee should enter in the toilet. vii) Alarm chain handle and its holding ii) Doors and walls should be cleaned with bracket should be washed and cleaned. water sprayed by high pressure jet up to viii) The coach flooring should be rubbed with waist level. Apply specified solution and hard coir brush and PVC flooring should rub thoroughly with sponge be rubbed with nylon bristles/sponge brush/duster/nylon bristle brush. brush and cleaned with recommended iii) Indian style lavatory pans have to be cleaning agent. cleaned by thorough rubbing with ix) In AC coaches, the amenity fittings and concentrated solution of recommended toilet fittings such as coat hanger, stools, cleaning agent. arm rest, foot rest, towel hanger, etc. iv) Western style commode shall be cleaned should be cleaned with duster. Stains on as (iii) however due care should be taken these items should be removed with that recommended solution should not fall recommended detergent solution. on commode lid which may damage/spoil x) The compartment carpet should be it. cleaned with vacuum cleaner. Every Chapter 1, Page 13 of 41

Maintenance Manual for BG ICF Coaches Coach

month, the carpet should be cleaned (Railway Bd.'s letter no. 98/M( C)/137/19 thoroughly by taking it out from Pt. I dt. 28.7.99 & dt. 05.05.2000) compartment and if necessary they should 110a Infra structural Requirements be dry cleaned in every three to four months. Before re-laying the carpet, the (i) 24 coach length fully equipped pit compartment floor should be thoroughly line. cleaned. (ii) High pressure jet cleaning pipeline xi) Spray recommended air freshener in the with plant for cleaning at primary coach. No employee should be allow to pit line. Mechanised external enter the coach for any purpose/work after cleaning is preferable. complete cleaning (iii) Water hydrants for 24 coach length at en route watering stations with 20 xii) Curtains in the AC Coaches and Tourist minutes stoppage at nominated Cars should be removed for periodical stations washing and cleaning. Faded and (iv) Availability of the prescribed air damaged curtains should be replaced on brake maintenance and testing condition basis. equipment. xiii) Precaution should be taken to prevent nuisance of cockroaches in AC coaches 110b Coach Design related Requirements

and pantry cars by periodical spray of (i) Air brake with twin pipe graduated recommended insecticides release system xiv) No repair works on Electrical train (ii) Only enhanced capacity draw gear light/fan/AC) or Mechanical account and screw coupling to RDSO sketch should be left to be carried out after No. 79061 and 79067 are to be washing and cleaning of the coach.. provided on the rake

110c Maintenance Practices and system 109e Internal Cleaning of GS, SLR related requirements

(i) The integrity of the rakes to be i) Cleaning of GS, guard and passenger maintained. compartments of SLR should be done as (ii) Primary maintenance of the rake mentioned under para 109d above should be done in one hook without wherever applicable. splitting (iii) Minimum maintenance time of 6 ii) If necessary clean the wooden seat and hours on the pit during primary their frames with recommended detergent maintenance solution and water. (iv) It is mandatory to provide secondary iii) Interior surfaces of parcel and luggage maintenance to all trains augmented vans should be cleaned with to 24 coaches . recommended detergent and water. (v) Trains leakage rate to be maintained within prescribed limits by using rake test rig. 109f Cleaning of buffers and screw couplings (vi) Provision of proportionate brake system on the locomotive in good i) Buffer plungers should be scrubbed with a working order scraper to remove dirt and muck. (vii) Provision of audio visual alarm Thereafter, they should be wiped clean system on the locomotive with cleaning oil and rubbed with coir (viii)In case of double-headed diesel locos rope. maximum traction motor current will be restricted to 650 amperes and in ii) Screw coupling threads should be cleaned case of double headed WAP1/WAP3 with wire brush to remove all dirt and electric locos, the traction motor dust. Thereafter, it should be cleaned and current limit will be 750 amperes as given a light coat of oil. Oiling should be prescribed in RDSO 's instructions done on slack adjuster also. for operation of main line air brake trains - C-9408. 110 CONDITIONS REQUIRED FOR MAINTENANCE OF 24 COACH 110d Operational requirements TRAINS

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Maintenance Manual for BG ICF Coaches Coach

i) Communication between driver and guard the permission of the Chief Mechanical should be provided through suitable Engineer and according to the calling in means. program of the workshop. iii) For requesting permission for non-POH ii) Special care to ensure no gap between repairs, the supervisor incharge of the coach buffers after tightening the coupler. depot should prepare a complete list of iii) No additional coach attachment beyond damages and deficiencies and forward it 24 coaches will be permissible. to Divisional Mechanical Engineer for

getting permission of the Chief 111 MAINTENANCE PRACTICES IN Mechanical Engineer to book the coach to OPEN LINE DEPOTS the shop for non-POH repairs. A copy of the list of damages and deficiencies 111a Nomination of a Depot should simultaneously be sent to the workshop concerned for planning it in i) All passenger coaching vehicles (PCVs), their calling-in programme. other coaching vehicles (OCVs), owned by individual railways should be allotted a 111c Intermediate Overhaul base depot for primary maintenance and a base workshops for periodical overhaul i) All bogies of such ICF coaches shall be and special repairs by the Chief given IOH after six months ± 15 days of Mechanical Engineer/Chief Operation the date of last POH as per table 1.1. All Manager of the Railway. the newly built coaches shall be given ii) The base depot to which the coaches are IOH after one year of service. allotted will be responsible for their ii) During this lifting schedule, maintenance. It will also be responsible bogies/underframe members and body for the secondary maintenance of the including trough floors of integral type coaches as prescribed by the Railway. coaches should be thoroughly examined iii) If a coaching stock allotted to a particular and all parts of running gears are repaired/ depot, finds its way to another depot, it replaced as necessary. The bogie frames should be despatched to the allotted depot should be particularly checked to detect for proper service. damage, cracks or deformation and necessary repairs carried out. Where it is iv) Due to exigencies of service a coach of not possible for the maintenance depot to another depot can be retained with the do these repairs or are prohibited to be sanction of the Chief Mechanical done in the maintenance depots, the Engineer (CME). It should, however, be bogies should be sent to the shops for subjected to necessary examination and carrying out these repairs. repairs including maintenance schedules iii) The detailed table of maintenance in the manner as it belonged to the depot. activities to be carried out during IOH v) No overdue periodical overhaul (POH) schedule is enclosed as appendix-G. coaches of other railway should be iv) The date of intermediate lifting should allowed in service but should be booked then be stencilled at the appropriate place to the owning railway for POH. in schedule chart on the end panel. vi) If home railway stock is retained in service beyond return date for any reason, 111d Formation of Block Rakes IRCA rule 2.2.4 should be followed. i) For the purpose of maintaining the vii) Standard integrated modular pit line coaches and the rakes in good condition should be provided as given in Appendix and to avoid public complaints, the Chief E. Mechanical Engineer, in consultation with the Chief Operations Manager of the 111b Special Repairs Railway, shall form Block Rakes for each i) The special repairs (Non-POH repairs) by of the long distance trains and the inter- workshops are those repairs, which can railway trains; and also nominate spare not be done in the sickline with their block rake coaches of adequate number existing facilities or are specifically for these block rakes to replace sick block prohibited to be carried out on the rake coaches. divisions. ii) Special repair coaches should be sent to ii) The station staff shall ensure that no non- the base workshops only after obtaining block coach is attached in any Block Rake Chapter 1, Page 13 of 41

Maintenance Manual for BG ICF Coaches Coach

except with the express permission of the tanks of the train at each of the nominated Divisional Mechanical Engineer, who will watering stations of the railway. If grant such permission only in emergency necessary, where halts are small, boosters and that too for a specified trip only. of adequate capacity should be provided to increase the water pressure and 111e Destination Boards accelerate water filling. iv) After completing watering, the staff, in i) Coaches on originating trains should be case of overhead watering arrangement, provided with destination boards of must ensure that water hosepipes are approved types as prescribed by each coiled and secured properly with the Railway. overhead hydrants and that the hydrants 111f Fire Extinguishers are fully closed. All leaky hydrants should be reported to the Engineer i) Fire Extinguishers should be provided on (C&W)/Engineer(Civil), as the case may all originating trains according to the be, who will arrange to get them attended. number prescribed by the Railways for In case of ground level side filling air-conditioned coaches, brake vans, watering arrangements, it should be postal vans, dining cars, etc. These fire ensured that water hose pipes are not extinguishers should be checked every dragged or left over on the platform three months and completely refilled after aprons, but are hung properly on the poles one year. These extinguishers should not to prevent contamination of water. be overdue testing / refilling. In case they v) Adequate staff and time should be are used or damaged en route, the report provided to clean the compartment and of the same should be obtained from the the bathrooms/ lavatories as prescribed at guard, head sorter, etc., as the case may be, nominated cleaning stations of the railway. and replaced. Portable pressure jet cleaning equipment

111g Brake Van Equipment should be used for efficient cleaning of toilets. i) Similarly, other brake van equipment, vi) Deployment of C&W staff on which Mechanical Train Examining staff Rajdhani/Shatabdi Express/Rajdhani type is responsible to supply, should be nominated trains/Other superfast and provided according to the instructions of Mail/Express trains should be as per each Railway. As per RDSO's letter no. Railway Board's letter no. 99/TG.V//12/2 MC/CB/28 dtd. 19.5.2000, racks have to dated 13.9.99. The `Safaiwalas' should be provided in the SLRS for provision of wear identification armbands while on duty. portable control telephones, portable train A suitable cleaning kit consisting of lighting equipments, portable fire requisite cleaning agents, brushes, mops, extinguisher, wooden wedges/skids and etc. should be standardised by the Railway stretcher. Railways can modified existing and provided to them. emergency equipments rooms in the guard's compartment to provide racks for 111i Deficiency Rolling Stock (DRS) for keeping the above mentioned items except Coaching Stock fire extinguisher as shown in the figure 1.7 (RDSO's sketch K 0014) i) Railway should devise system for detecting deficiencies. Reports of 111h Watering and cleaning of rakes. deficiencies/ defects in Rolling Stock (DRS) reports in the proforma given in i) Mechanical department of each railway Annexure 1.2, should be prepared for will nominate the watering and the each mail/express/passenger originating cleaning stations on the railway. train in duplicate by the Engineer (C&W)/Electrical (TL) and should be ii) All water tanks should be filled on a signed jointly with the RPF washing line so that no watering is representatives. Reports for mechanical necessary on a platform at the originating deficiencies should be prepared on station. Arrangements should, however, Performa I (the fittings mentioned in these be available at each of the platforms for Performa are selective and not exhaustive filling the tanks in emergencies. iii) Adequate staff and time should be provided at intermediate stations to enable complete replenishment of all the water

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Maintenance Manual for BG ICF Coaches Coach

0

4 115 EXISTING FUNNEL 150 FIRE EXTINGUISHERS BELOW RACK 50 195 50 0 5

22, TO BE 5 2 0

DOG BOX 4 FITTED INSIDE EXISTING OBSERVATION 19 CEILING WINDOW WHERE PROVIDED EXISTING WATER PIPES 25

RACK FOR PORTABLE CONTROL TELEPHONE

1,2 L

8 L 0

C A 22, TO BE 4 W

E 10 0 FITTED OUTSIDE 0 D I 8 24 S 40 200 40 200 15 16 7 150 RACK FOR PORTABLE TRAIN

LIGHTING EQUIPMENT 0 3.15 20 6 0 1,2 23 3 EXISTING WATER 9 1

STRETCHER 0 PIPES WHERE LAV. 5 PROVIDED 254 1 , ANGLE FOR SLIDING FEED BOX 25 17 178 0 0 0

FLOOR LEVEL 1 0

2 B 11,12,13 18 Y 9 EXISTING DOG BOX 0

%%uDETAIL AT -A 0

3,4,5 4 4 5 1 2 RACKS CAN BE LOCATED ON OPPOSITE SIDE,IF REQUIRED Y DOUBLE FLAP M5 CSK HD. TO AVOID INFRINGEMENT WITH SIDE FILLING PIPE. DOOR SCREW STOPER FOR FEED BOX SPACE FOR WOODEN NOTE:- 0 0

8 WEDGES/SKIDS ETC. 1. THE THREADED PORTION OF THE EYE (ITEM-2) TO BE CUT

AND SHOULD BE WELDED TO THE BRACKET AS SHOWN. X X 26

0 2. SUITABLE STEEL BACK PIECE SHOULD BE PROVIDED IN 0

3 21 300 THE PARTITION FRAME FOR FIXING THE RACKS. 14 M6 CSK HD. SCREW 0 3. THE WATER FILLING FUNNEL PRESENTLY LOCATED INSIDE THE 4 0 2

40 1 6 EMERGENCY EQUIPMENT ROOM,SHALL BE RELOCATED ABOVE 0 0 3 2 4 5 800 4 DOG BOX RETAINING EXISTING PIPE LINE AND WATER TRAY. 5 2 4. THE EXISTING SWING TYPE FEED TRAY WILL BE REPLACED TO BE 0

0 22, FLOOR LEVEL 8 5 1

FLOOR LEVEL 0 5 BY NEW FEED BOX OF SLIDING TYPE.SUITABLE OPENING FITTED INSIDE 7 0 SHALL BE MADE IN DOG BOX AS SHOWN. 5 1

340%%uVIEW FROM C (WITH DOOR) %%uVIEW FROM C (WITHOUT DOOR)

0 HOOK FOR FIRE EXTINGUISHER IS:2062-99 3.15 0 26 4 10 9 5 5x20x190 Fe 410 WC

4 25 GUARD'S LOCK 1 CA/DW-920 EXPANDED METAL SHEET 18, ANGLE %%C6.5 HOLES ICF DRG.No. IS:2062-99 6 3.15 WELDED TO ANGLE 20 24 HANDLE 2 (50x25x3.15) T-5-6-020 Fe 410 WC 100 IS:281-73 5 23 DOOR BOLT 200 mm 1 2 FIG.-2 IS:204-91 4 5 22 TOWER BOLT 125 mm 3 = 610 PART-1 0 18 80 50 100 3

0 IS:1341-81 = 6 5 21 HINGE SIZE-100 mm TABLE-3 0 200 200 200 5

%%uSECTION - YY 1

0 IS:1079

5 20 SHEET 3.15x195x200 2 GRADE-DD 0 0

45 8 IS:1079 200 %%uSECTION - XX 19 ANGLE 3.15x70x295 4 5 GRADE-DD 5 110 4 %%C5.5 HOLES FOR RIVETS IS:1079 C 18 ANGLE 3.15x70x1900 4 % CSK HOLE FOR M5 %%C6.5 % 3 GRADE-DD CSK HD. SCREW IS:808-76 R3.15 2 17 ANGLE ISA 5050x3 2 2 (PART V) R %%c10 IS:737-74 16 FEED BOX 1

0 31000 H2 5 BEML DRG.No. 2 15 WATER CONTAINER 1 2 3.15 20 412-29100

9 1 0 0 CAP. 5 Kg 1 0 14 FIRE EXTINGUISHER 2 IS:2171-85 1 30 30 6 EACH

0 IS:3063 0 20 3 13 SPRING WASHER M6

0 26 5 TAB.1,TYPE-B 5 2R 0 4 3 2 0 IS:1364 CSK HOLE FOR M6 0 HEX.HD.NUT M6 20 5 1 12 5

7 PART-3 40 CSK HD. SCREW IS:1364

5 20

0 11 HEX.HD.BOLT M6x40 2 0 1 PART-1

11 2 238 11 5 1 100 5 7 IS:2907-64 IS:740-77 10 CSK.HD.RIVET %%c5x14 28 0 0 5 TAB-3,FIG-3 64430 WP 8 3 4 2 1 7 100 200 200 200 100 9 COMPREG 6x297x800 2 STR C-9407 TYPE-2 2 800 EXPANDED METAL SHEET IS:412-75 8 4 REF.-34

5 25 245x850 TAB-1 7 IS:1079 18 7 BRACKET 3.15x147x280 1 GRADE-DD 0

2 IS:1079 5mm THICK BACK PIECE 6 PLATE 3.15x40x220 4 GRADE-DD WITH CUT A WAY IS:1079 5 BRACKET 3.15x185x335 2 GRADE-DD DOG BOX BELOW IS:1079 AND TABLE WITH 4 ANGLE 3.15x75x800 2 FIRE EXTINGUISHERS GRADE-DD PEGION HOLES ABOVE LAV. IS:1079 3 ANGLE 3.15x80x1060 2 FIRE EXTINGUISHERS CSK.HD. BOLT M5X15 GRADE-DD LAV. A 20 WITH WASHER & NUT IS:207-64 2 HOOK & EYE SIZE 250mm 1 IS:1812-61 A TYPE-1 IS:1079 %%uDETAIL AT -B 1 BRACKET 2x30x462 1 GRADE-DD LUGGAGE COMPT. . T

P SUITABLE CUT A WAY TO BE MADE IN THE No. WT. OF ITEM DESCRIPTION & DIMENSION REF. DRG. MAT. & SPEC. REMARKS M ONE Kg O OFF DOOR ANGLE FOR LOCK AND TOUNG. C FIRE EXTINGUISHERS E G A A G

G z U L EMERGENCY EQUIPMENT SLR & WLRRM COACHES LAV. vuqeki ih ROOM lh EMERGENCY EQUIPMENT 1:10 EMERGENCY EQUIPMENT DOG BOX BELOW & TABLE Mh ROOM 1:5 PROVISION OF RACKS IN EMERGENCY ROOM WITH PEGION HOLES ABOVE %%uGUARD'S COMPARTMENT(WLRRM COACH) 1:2 Vslzz 1:1 ts,l STD-08/K0 EQUIPMENT ROOM IN GUARD'S COMPARTMENT %%uGUARD'S COMPARTMENT(BEML COACH) %%uGUARD'S COMPARTMENT(ICF COACH) FIGURE 1.7 1 STD-26/K0 12/2000 1 LK-8/K0014A1 SKETCH - K0014

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and may be altered by each Railway on the general inspection should be recorded the basis of the items most prone to theft on DRS Cards as done at originating on their system). This should be done stations. New DRS Cards showing soon after the maintenance of the rake is deficiencies/ defects of each vehicle will complete in the sick/ washing lines. In be prepared and sent to originating case the train starts from the platform station along with the rake. In case itself, these reports should be prepared by vandalism is suspected, suitable remarks the train duty Engineer (C&W)/Electrical should also be given. The Engineer (TL). The originating station must keep (C&W) staff, Electrical staff and RPF copy of the report. It should be preferable staff should sign the report. On receipt of if one booklet is maintained for each the report by the originating station, a service so that the carbon copy is sent comparison will be made and statement with train guard, retaining the original for prepared of deficiencies that occurred record. enroute. ii) After the coaches have been jointly vi) The Supervisors at the destination station, checked, and DRS reports have been viz., Engineer (C&W)/Engineer (TL) shall made, the coaches should be padlocked/ report the thefts on the form already key locked and the key and report should prescribed by RPF, to the RPF/GRP as be sent to the platform Engineer (C&W). quickly after arrival of the train as possible and not later than 24 hours after iii) Coaches with attendants the arrival of each rake. If the GRP For the coaches, which have nominated refuses to accept such reports at the arrival attendants, the DRS card will be given to station of train from the Mech. /Elec. him. Deficiencies will be noted down by Supervisors, it shall be incumbent on the the attendant and advised to Engineer RPF in-charge at the arrival station of the (C&W) and Engineer (Electrical) at the train to get cases registered with GRP and coaching depot after end of the journey. take further action as deemed fit to get the So he will have to keep a register noting thefts traced/ reduced. If such reports are down the deficiencies and the date of to be made to any other RPF post, this advice and the date of recoupment. shall also be done by the RPF in-charge of the train arriving station. iv) Trains which are escorted by Engineer vii) The Supervisors of the originating station (C&W) & Engineer (Elect.) should compare these DRS Reports with

For trains where an escorting C&W staff the original DRS Reports and prepare a is provided on the train, he shall carry summary of the deficiencies/ thefts DRS card for coaches other than para iii) occurring in the up and down trips above and get them filled up at the separately. secondary maintenance depot by the viii) A train wise summary of the deficiencies/ Mechanical/Electrical staff and get the defects shall be prepared and forwarded to rake examined by RPF personnel in case the DME/DEE with a copy to Security of any deficiency. Commissioner, RPF, of the division. The cost of the fittings should also be shown v) Trains/Coaches not covered in para iii) in the summary, price being taken from & iv) IRCA Rules Part IV. For items not covered in these, stores cost should be a) For other trains/coaches not covered in given. para iii) & iv), the DRS Reports should be ix) In the first week of every month, handed over to the train guard and his Supervisors in charge of Mechanical, signature obtained on the office copy. The Electrical and Officer- in charge of RPF guard will be responsible for safe carriage Posts/Outposts should hold a joint of the Report up to the destination. At the meeting to identify the areas where the destination station, the outgoing guard deficiencies/ thefts are occurring and must ensure that the reports are handed analyse the items more prone to over to the Mechanical/Electrical staff breakage/losses/thefts. The officials immediately on arrival of the train. should take remedial measures as possible b) On arrival of the train at the destination at their level. A monthly statement of station, the Engineer (C&W) staff and thefts, giving their cost and analysis electrical staff shall check the rakes should be prepared by RPF but jointly jointly with a representative of RPF and signed by Engineer(C&W), Engineer (TL) comparison may be made with original report. If original report is not received, Chapter 1, Page 13 of 41

Maintenance Manual for BG ICF Coaches Coach

with the copy each sent to DME, DEE and important fittings and furniture in case of Security Commissioner, RPF. Air Conditioned coaches, dining cars, etc., x) The Divisional Officers, viz. Sr. DME, Sr. defects and deficiencies of the fittings, if DEE & SC must meet every three months any, to the base depot when a coach is to carry out similar analysis and decide turned out of workshops after POH or upon preventive steps to be taken in each special repairs. Any special instructions area. They should submit similar joint regarding the coach for its base depot report to their Headquarters Officers should also be maintained in the card. If concerned, viz., CME, CEE and CSC. modifications are carried out, they should xii) The CME, CEE and CSC should furnish be indicated in the card under its every six months a report to the Director/ appropriate column. Similarly, if trial Mechanical Engineering, the Director/ fittings/ components are fitted or materials Electrical Engineering and DG/RPF in the are on trial on the coach, the details of the Railway Board, indicating the extent of fittings/ components or the materials, the theft of C&W and electrical fittings on authority for conducting such a trial, the their system and the remedial measures purpose of the trial, the nature and the taken by them bringing out any help in frequency of the observations to be made, any area required from the Ministry of the type of interim/final reports required Railways. to be submitted, the name and the address of the authority to whom it is to be 111j Reporting of thefts submitted and any other instruction in i) All damages/deficiencies which may detail should be maintained in a "Trial apparently be due to mischief or theft Card" which should be sent by the during service should be reported to the workshops to the base depot for RPF/GRP and the Divisional Mechanical compliance of the instructions. The base Engineer according to the procedure laid depot, on receipt of the coach from the down in Railway Board's letter No.73M(c) shop, will check the fittings/ articles in the /165/4 dt.4.7.77 circulated to General coach with the list sent by the workshops Managers, all Indian Railways. and note all the instructions for compliance. It will also make 111k Coach Maintenance History Card examinations and observations as i) Every coaching depot shall have prescribed in respect of trial fittings, computers for maintaining the coach components or materials and submit the maintenance history in a software trial reports to the appropriate authority as programme which should be compatible prescribed in the Trial Card received with with the programme of the coaching the coach. workshop. vii) The base workshops will also carry out a ii) The "Coach Maintenance History Card" detailed examination when a new coach is (MHC) for each of its coaches. The card received, register the coach, open its will contain records of maintenance history book, make a list of all defects and schedules including POH and special deficiencies and then, in consultation with repairs in shops. It will also show the the CME's office, will allot a rake number history of the coach from the time the and its base depot, stencil the same on the coach is placed in service till its coach and, if it is fit in all respects, it will condemnation and will give details of all then send the coach to the base depot for major repairs like wheel changing, bogie service. Also, it will prepare a warranty changing, etc. card as per Performa given in Annexure iii) The complete history book of each coach, 1.3 and will forward it to the base depot consisting of maintenance history cards, with detailed instructions for preferring date card, trial card, etc. will, however, be claims from the manufacturers through Divisional Mechanical Engineer. maintained by the base workshops. When a coach is sent for POH or special repairs, 111 Warranty claim for defective/failed a copy of its maintenance history card items should be sent by its base depot to the workshops for record in its complete There are some items for which it is history book. mandatory for the manufacturers to give warranty claim if the item fails or iv) The workshops should send a new becomes defective during the warranty maintenance history card (MHC) giving period as specified in the the condition of the coach, the list of specification/drawings /purchase order. Chapter 1, Page 13 of 41

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Warranty period for few items is given in carriage depots on divisions where rake below as an illustration: has been based for primary maintenance.

Table 1.9 i) Schedule A - Monthly (1 month ± 3 days) in S. Description Warranty period rake No of item ii) Schedule B - Quarterly (3 month ± 7 days) in 1. Distributor 36 months from the date rake valve of delivery or 24 months iii) Schedule C - for date of fitment 6 months 15 days whichever is earlier After ( ± ) detach coaches 2 Air brake -do- cylinder A detailed table of maintenance activities 3 BP/FP hose -do- to be carried out during schedules is enclosed as Appendix-F 4 Slack adjuster -do- 5 Shock 15 months form the date 112b Primary maintenance schedules are absorber of delivery or 12 months required to be carried out by the base from date of fitment depots to which coaches are allotted. In whichever is earlier. emergency, when due to any reason 6 Direct 36 months from the date coaches cannot reach their base depots mounted of delivery or 4 lakhs km and primary maintenance schedules spherical from the date of become due, A & B schedules should be Roller bearing commissioning undertaken by the carriage depots where whichever is later the coaches are available. ‘C’ schedule should be done at base depot. 7 Upholstery for One and half year from st 1 AC coaches the date of delivery 112c Open Line Maintenance of Parcel Vans and executive (as per Rly. Bd's Lr. No. 95/M class chair car (C)/141/1Pt. dated 19.12.2001) of shatabdi express For piecemeal operation of ordinary parcel vans or VHP, the responsibility to 8 Composition 18 months from the carry out openline schedules including 'C' brake blocks month of supply or duty schedule (irrespective of the owning life cycle i.e. time taken railway) will be under : in reaching the wear limit of the brake block, 1. In case of parcel vans which from a whichever is earlier regular part of the rake as per 9 UIC type 36 months from the date authorised composition: elastomer of delivery or fitment The primary depot of the train. flange for UIC whichever is later. vestibule 2. In case independent movement of parcel vans: 10 Rubber spring 2 years from the date of The coaching depot where it becomes of 1000 kg.m mounted in coaching due prior to next movement. side buffers stock. In case facilities are not available Format of warranty claim is given in at any destination, the van shall be Annexure 1.5 (for workshop use) and moved a coaching depot for schedule Annexure 1.6 (for Division/depot use). within the stipulated period as per BG coaching Maintenance Manual. 112 MAINTENANCE SCHEDULES TO No VPUs will be permitted to be BE FOLLOWED IN COACHING attached to a train from a coaching depots DEPOTS without attending to prescribed preventive

schedules as laid down above. As regards 112a To maintain coaching stock in good POH, the instructions contained in condition, the following maintenance Board's above referred letter will be schedules are prescribed to be carried out applicable.

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112d Maintenance Pattern for NMG rakes 113b Coaches shall be washed and cleaned (as per Rly. Bd's Letter No. 91/M thoroughly from outside and inside as (C)/650/1 dated 29.5.2000) prescribed in clause 109.

In order to optimize utilization of NMG 113c Brake system maintenance rakes it has been decided to introduce the following maintenance pattern : Air brake system (Bogie mounted and underframe mounted ) i) NMG rakes may be run on goods pattern with intensive examination at i) Visually check all the air brake both the ends, following other equipments (DV, PEASD, PEAV, conditions for enroute detention in etc.) including their mounting case at stabling at road side stations. brackets and anti pilferage devices In case of close circuit runs upto for any damage on coach of the rake 2500 km, the rake may be run on as per the check list given in clause round trip basis. 423. ii) Close circuit rake must be clearly ii) Check the operation of brake identified and should have a cylinder while conducting brake tests. nominated base depot where If the red paint on the piston rod is adequate trained staff and spares visible, replace the brake blocks and should be available. Also each NMG make necessary resetting of coach should be marked with the Adjusting tube sub-assembly before nominated POH workshop and the coaches are put into service runs. return date. iii) Perform leakage test for brake pipe iii) The maintenance schedules of the and feed pipe and its connecting NMG coaches will continue to be on pipes as described in annexure 4.5 the coaching pattern to be carried out para 3 (Rake test). by the base depot. iv) Performs service application and iv) NMG coaches are fit for only 75 release tests as described in annexure kmph. Also the revised maximum 4.5 para 3 (Rake test). payload of NMG coaches is fixed at v) Carry out alarm chain pull test & 9.2 tonnes. Therefore, using these check the working of PEASD and coaches as parcel vans for running Passenger emergency valve as per on piecemeal basis on passenger annexure 4.4 para 4.6 (Rake test).. carrying trains is strictly prohibited. vi) Drain the dirt collectors for removal of water/moisture. The instruction regarding POH and vii) Perform manual release test and life of converted coaches continue to check the movement of brake remain same which are as per Board's cylinder piston. Brakes should be in letter no. 91/M(C)/650/1 dtd. 10.9.96. fully release condition.

112e Each coach should be stencilled at a Vacuum brake system suitable place on its end panel, the code name of the base depot and a schedule i) Entire vacuum brake system chart. The date and station code of the including slack adjusters and direct depot where a particular schedule is admission valves should be tested for carried out should be stencilled at the leakage and proper functioning as appropriate place in the schedule chart described in vacuum brake system immediately when the schedule is chapter at para no. 509b (Balance completed. vacuum test and normal vacuum test). Balance vacuum test to be done as 113 PRIMARY/ SECONDARY per schedule when vacuum cylinder MAINTENANCE is replaced. ii) Test alarm chain apparatus under full 113a The rakes/ coaches of all trains should be vacuum. and check clappet for given a Primary/Secondary Maintenance leakage. examination as prescribed by the Chief Mechanical Engineer of the Railway. 113d In addition to above the following items of work should be attended during the maintenance schedule examination:

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* underframes * bogie frames (i) Doors should be properly secured * axle boxes with the hinges/pivots and should * springs. not be grazing with floor or door sill plates. These items should be wiped with wet (ii) Door latches and safety catches waste weaves or cotton waste as should be firmly secured with screw necessary so as to facilitate examination. of correct sizes and engaging All under gear components should then be properly and smoothly in their slots. examined and repaired as necessary to The tongue of a gravity type latch ensure that there is no `S' marked should be in proper alignment with rejectable defect as mentioned in Chapter its slot plate. IV of IRCA Conference Rules. (iii) Door lock handles should neither

113e The following items of undergear be stiff nor too loose and should be components should, however, be specially properly engaging on the striking examined and attended to:- plate. (iv) Tower bolts should be complete i) Oil in hydraulic dash pots of and should operate easily and be in Rajdhani and Shatabdi coaches alignment with the clamp. Tower should be checked once in 15 days to bolts should be fitted on a sound detect oil leakage from them base with proper screws, at an through defective seals or through angle of 15o to the horizontal to the vent screw. Add/ replenish with avoid locking by its self. specified grade of oil if the oil level is below 40 mm in the tare condition (v) Window shutters should neither be for ensuring better riding comfort. tight nor loose in railings to allow ii) Wheel profiles should be visually rattling and disengaging of catches examined and gauged in case they on run. appear to be near condemning limits. (vi) Window shutter safety catches iii) The brake gear should be checked should properly engage in their and so adjusted that the piston stroke slots. is within the limits specified for (vii) Window frame should not be different types of coaches. (see table broken and its glass, gauze wire or 1.10). 'A' and 'e' dimensions for venetian louvers should be in slack adjuster should be as per table proper condition. 1.11. (viii) Vestibule assemblies of all

vestibule coaches should be Table – 1.10 checked and repaired as necessary. Brake cylinder piston stroke No coach with vestibule ends

should be allowed to work without Type Minimum Maxi provision of proper fall plates and mum end doors to make the vestibules Bogie mounted air 32 95 functional. brake cylinder (ix) Any defective vestibule should be Under frame mounted 75 95 checked with permanent locking. air brake cylinder Vacuum brake 125 135 (x) Water pipe connections, flushing cylinder valves, cocks and shower roses should not be leaking or choked. Table – 1.11 (xi) Drain grills and drain holes in the bathroom floors and wash basin 'A' & 'e' dimension for slack adjuster drainpipes should be cleaned and Type of 'A' 'e' dimension opened where found choked. bogie dimension 13 tonne 16 ±2 mm 375 ± 25 mm (xii) Any other deficiency as per bogie Annexure 1.2 should be made 16.25 tonne 22 ± 2 mm 375 ± 25 mm good. bogie 113f The following coach body components 113g After coaches are attended to in and fittings should be specially checked washing/pit lines, they should be and attended to : disinfected and insecticide sprayed Chapter 1, Page 13 of 41

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especially at crevices and corners before i) Thorough inspection of train pipe, they are released for use. hose pipes including their cages, vacuum cylinders, siphon pipes and 113h A proper record should be kept by vacuum system. Engineer (C&W) at washing/pit lines of schedules carried out by them, especially ii) Testing of cylinders and train pipe 51 cms of items required to be attended at specific joints with exhauster under periodicity. of vacuum. (iii) Cleaning, greasing and testing of 114 SCHEDULE `A' EXAMINATION alarm chain apparatus under full vacuum with a spring balance and 114a Schedule `A' is required to be given every cleaning and checking of clappet month + 3 days at the nominated primary valve for leakage. maintenance depot within the normal primary maintenance time on a (iv) Cleaning of DA valve filters as mentioned under in vacuum brake washing/pit line in a rake. A coach need chapter para no. 506b for Escort / not be detached from the rake for Schedule `A' examination unless it Greysham D.A valve.

requires such repairs which cannot be 114c The following items of work should be attended to on the washing line or within attended during Schedule `A' examination, the prescribed maintenance time on the i.e., monthly examination:- washing line. (i) All items of primary/secondary 114b Brake system maintenance maintenance schedule. (ii) Intensive cleaning of coaches. Air brake system (Bogie mounted) (iii) Intensive cleaning of lavatory pans and commode with specified ‘A’ schedule maintenance as per air brake cleaning agent. chapter. (iv) Thorough flushing of tanks. (i) All items of primary/secondary (v) Checking of water pipes, flush pipe, maintenance schedule. flushing cocks, push cocks, etc., for (ii) Test the working of brake cylinders ease of operation and free flow of for proper application and release. water. (iii) Thorough inspection of brake pipe, (vi) Thorough dis-infection of all feed pipe and their connecting compartments. pipes to brake cylinder, distributor valve, Auxiliary reservoir and hose (vii) Thorough inspection and repairs of coupling for leakage and attention. draw gear as per item 6.0 of (iv) Carry out manual brake release test appendix F. on every coach to ensure proper (viii) Thorough inspection and repairs of functioning of release lever of buffers as per item 7.0 of appendix distributor valve. F. (v) Micro switch of ACP should be (ix) Oil in hydraulic dash pots should tested by electrical staff for proper be checked to detect oil leakage functioning. from them through defective seals (vi) Clean Dirt collector filter with or through vent screws. kerosene and refit. Add/replenish with specified grade (vii) Test the working of slack adjuster of oil if oil level is below 40 mm in in under frame mounted air brake tare condition to ensure better system as per annexure 4.4 para riding comfort. Similarly oil in side 4.8 in Air brake chapter. bearer baths should be checked Repair/Replace the defective slack when the oil is below the plug and adjuster. replenished with specified grade of (viii) Examine loops/ brackets and their oil so that wear plate is fully securing devices and rectify. covered by oil. (ix) Examine for wear and replace if (x) Inspection and repairs of commode required brake hanger pins, brake chute. blocks and brake heads. (x) Thorough check and repairs of Vacuum brake sliding doors and vestibule doors for easy and smooth operation and Chapter 1, Page 13 of 41

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correct alignment and all wearing ii) For maintenance of major break–down/ parts, loose screws, etc. mal-functioning of any subassembly etc. 115 SCHEDULE `B' EXAMINATION the decision whether the coach is to be detached from the formation for attending 115a Schedule `B' is required to be given every to maintenance/replacement of major three months + 7 days at the nominated subassembly is dependent on maintenance primary maintenance depot within the requirements, operational convenience, normal time allowed for primary time availability etc. The decision is taken maintenance on a washing line in rake. by the Engineer (C&W). Coach failure Coach need not be detached from the rake report as per Annexure 1.4 should be for purpose of this examination unless it made. For failure components/assemblies requires such repairs which cannot be during warranty, action to be taken as per attended to on the washing line or within para 111 . the prescribed maintenance time on the iii) At depot, the coach that is detached for washing line. schedule ‘C’ maintenance is taken over to the washing line for cleaning, lubrication 115b The following items of work should be and minor maintenance. The coach that attended. are detached due to a major defect in the distributor valve, brake cylinder, Brake system maintenance Auxiliary reservoir etc, is taken to the pit Air brake system (Bogie mounted) line for the replacement of such sub- assemblies, on unit exchange basis. The (i) Same as 'A' schedule detachment of coach is carried out so as to make the maintenance or testing activities Vacuum Brake system convenient and faster so that the coach is made ready for use without delay. (i) Examination, overhauling and testing of alarm chain apparatus as 116b PROCEDURE

prescribed in vacuum brake chapter. The activities performed to detach a coach (ii) Overhauling of release valve, with Air Brake system are as follows: replacement of its diaphragm and sealing washers, if necessary. i) Safety precautions shall be taken to (iii) Examination of neck rings and their prevent injury while detaching/attaching a replacement, if necessary. coach. ii) Remove the clamps on the cut-off angle Other assembly maintenance cocks. Close the cut-off angle cock of both feed pipe and brake pipe on both (i) Besides brake system other items sides of the coach that has to be detached. should be attended as given below: iii) Close the cut-off angle cocks of the feed (ii) All items of Schedule`A' and brake pipe of adjacent coaches. This (iii) Painting of lavatories from inside. is to ensure that the air pressure locked up (iv) Thorough inspection and repairs of in the air hose coupling gets vented to brake gear components. atmosphere through the vent hole of the (v) Thorough checking of trough floor, cut-off angle cock. turn unders, etc., from underneath iv) Observe above mentioned safety for corrosion. measures to close all the four cut-off (vi) Touching up of painted portion, if angle cocks on either side of the coach to faded or soiled. be detached so that while opening air hose coupling, it may not cause injury due to 116 DETACHMENT A COACH air pressure inside. v) Release the brake of the coach to be A coach is detached from the rake due to detached by pulling the manual release several reasons such as: lever of the distributor valve. vi) Open the Feed Pipe and Brake Pipe hose 116a For IOH and schedule ‘C’ coupling from both sides of the coach. maintenance. vii) If the air pressure of brake cylinder does not vent by pulling the manual release i) Coaches required for detachment for valve of distributor valve, open the brake maintenance under schedule 'C' and IOH cylinder vent plug to drain the air pressure. maintenance. Chapter 1, Page 13 of 41

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viii) Uncouple Screw coupling and detach the (iii) Testing of vacuum gauges with coach. the master gauge, and ix) Observe all other safety measures as replacement of defective or prescribed. inaccurate gauge. A set of two master gauges should be kept for 117 SCHEDULE `C' EXAMINATION this purpose at every Primary Maintenance Depot and each Brake system Maintenance master gauge should be sent one after the other to the base Air brake maintenance: workshops for testing, repairs (i) Schedule `C' is required to be given every and calibration. six months + 15 days at the nominated (iv) Thorough checking of train pipes primary depot. under pressure of 2 kg/cm2 to (ii) Coaches are required to be detached from detect thin, corroded and the rake and taken to the sick line for punctured pipes. A high pressure schedule `C' examination and repairs. pump must be provided at each Primary Maintenance Depot for 117a The following items of work should be this purpose. attended during schedule `C' examination. Other assemblies maintenance Air brake system maintenance (i) All items of Schedule `B' (i) ‘C’ schedule maintenance as per para (ii) Thorough repairs of running gear 426 of air brake chapter. including running out of bogies (ii) Check brake cylinder for loose where considered necessary. All rocker arm plate and change on bogies which are working on Bogie Mounted system. rake links earning more than 2.5 (iii) Check proper functioning of slack lakhs kms. per annum must adjuster mechanism. however be run out and (iv) Brake cylinder should be checked for thoroughly smooth functioning and prescribed attended to as laid down in stroke. Defective brake cylinders clause 111c under “Intermediate shall be sent for repairs. Overhaul”. (v) Guard’s van valve should be tested as per para 412d of air brake chapter. (iii) Touching up damaged paint of (vi) Test BP & FP air pressure measuring coaches on outside as well as gauges with master gauge and inside. replace if found defective. A set of (iv) Polishing of the polished two master gauges should be kept for surfaces. this purpose at every Primary Maintenance Depot and each master (v) Shock absorbers should be gauge should be sent one after the replaced and sent to the base other to the base workshops for workshops for repairs, testing and return. For this purpose, testing, repairs and calibration. adequate spares must be (vii) Thoroughly clean Dirt collector filter in kerosene or replace on condition maintained in the depot. basis. (vi) Thorough cleaning and removal (viii) Check working of PEASD & PEAV of dust, rust, dirt, etc., by hearing the hissing sound of accumulated at the pillars exhaust air. After resetting with the through the turn under holes, help of key the exhaust of air should with coir brush and compressed stop. Replace the defective air. PEASD/PEAV. (vii) Thorough examination and

Vacuum brake system repairs of upholstery, cushions, curtains, etc. (i) All items of ‘B’ schedule (viii) Thorough checking and full (ii) Overhauling of vacuum cylinders, if repairs of all window shutters, due. safety catches, safety latches, staples and hasps of compartment, lavatory, body side Chapter 1, Page 13 of 41

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and vestibule doors for ease of 119. PROCEDURE FOR SENDING THE operation. COACHES TO SHOPS FOR POH (ix) Thorough checking and repairs of UIC vestibules, their rubber The following procedure may be followed flanges metal frames, doors, fall in regard to movement of coaching stock plate, locking gear, etc., for ease for repair to shops - of operation and safety . (a) Security Department shall arrange to escort all coaches booked to shops when (x) Thorough checking and repairs booked by coaching specials or in lots of of all cracks and worn out 3 coaches or more on receipt of memo portions of flooring of the from Engineer (C&W) of the booking compartments. station.

(b) All coaches booked to shops for POH will 117d Engineer (C&W) of Primary Coaching be booked by passenger/parcel/Coaching Maintenance Depots should be fully special. familiar with the vulnerable areas of ICF coaches for corrosion, viz., sole bar at c) Before any carriage is allowed to proceed doorways, lavatories and adjoining areas, to workshops a joint check should be corridor sides - more so in case of those carried out by the representatives of the SLRs which are used for Fish, Salt, etc. Mechanical, Electrical and Security For facilitating inspection of sole bars Branches on the basis of which a even spaced elongated holes of (215x127 deficiency list will be prepared at the mm) are already provided in the turn rake/coach maintaining station under joint unders. signature of the three representatives in five legible copies with proper reference, 117e Special attention should be taken for the number and date out of which one copy following:- should be pasted in side the compartment on one of the end wall. Two copies of the i) Pocket between sole bars and deficiency list will remain in the personal turn unders should be thoroughly custody of the RPF sainik accompanying cleaned through the inspection the rolling stock to the workshop (In case opening of the sole bars and of unescorted coach, deficiency list will inspected with the help of torch be sent by post to CWM concerned and light or inspection lamps. one copy will be sent to OC/RPF).the ii) Drain holes provided in the remaining two copies will be retained by trough floors should be kept the Engineer (C&W) /Electrical clean and unclogged. If during Supervisor of the base station. Upper class the cleaning of these drain holes coaches must be pad locked/locked with any accumulation of water is carriage key and also sealed after the joint observed, the affected area check at the starting station by the should be very carefully booking Engineer (C&W). inspected for possible corrosion. d) Once a Joint check has been carried out iii) A register should be maintained and the deficiency list drawn out no of the primary maintenance removal of fitting from the stock at the coaches on the subject. starting depot should be entertained. e) Coaches escorted by the RPF staff will 118 SPECIAL SCHEDULE continue to be under watch of the Security Force (RPF) until coaches are taken over 118a For high speed trains and some special by the shops. On arrival of carriage at the coaches like Power Vans, etc., special Workshops, a careful check be made out maintenance schedules by the individual jointly by the representatives of the railways may be followed. Mechanical & Electrical Departments in 118b For maintenance of coaches of Rajdhani/ presence of RPF staff in four copies. In Shatabdi Express Rakes, the instructions case of any additional deficiency being given in RDSO Technical Pamphlet No. noticed, a list of such additional C-7807 should be followed. deficiencies be made out in four copies jointly by all the three staff. 118c The IOH of Rajdhani/Shatabdi high speed

coaches should be carried out in (f) One copy each of the deficiency list workshops. prepared by the representatives of

workshop duly signed by RPF be sent to Chapter 1, Page 13 of 41

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the Engineer (C&W) /Elec. Supervisor of base station and one copy be given to RPF for submission of the same to the OC/RPF of the base station and one copy is to be kept on shop record. On receipt of the additional deficiency list, OC/RPF of the base station will arrange to fix responsibility for the additional deficiencies and take suitable action including sending a copy of his report to Engineer (C&W) /Elec. Supervisor concerned. On receipt of the report from OC/RPF, Engineer (C&W) /Elec. Supervisor will submit a report to the controlling Divisional Officer enclosing copies of the original as well as the additional deficiencies to enable the Divisional Officer to initiate action for the write-off of the cost of such materials. While granting write off or forwarding the case to Headquarters for arranging the write off due remarks should be given for the reasons of the deficiencies and the action taken. A certified true copy of the joint check mentioned above should accompany the losses due to theft and pilferage.

A copy of the write-off memo should be submitted to Budget section of the divisional Headquarters office for exhibition in Appropriation Accounts.

(g) Generally coaches should be sent in lots of three duly escorted. In exceptional cases coaching stock coming to Workshop by passenger/parcel trains unescorted by RPF sainik, the deficiency list prepared jointly at the originating station should again be checked at the workshop in presence of RPF representative and the difference of the two checking should be taken as theft. On receipt of unescorted coach in the Shop, the deficiency list in five copies in presence of representatives of RPF, Mechanical and Electrical Dept. will be prepared jointly. One copy of the deficiency list will be retained as office copy, 2 copies will be given to OC/RPF of the shop station and one copy each will be sent to Engineer (C&W) /Electrical Supervisor of base station. Out of two copies of deficiency list received by the RPF representative at the workshop, one copy be sent to OC/RPF base station for necessary action by the security Department.

(h) The workshop should have a proper organisation to check these coaches immediately on arrival.

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Annexure 1.1 Indian Railways Hkkjrh; jsy czsd ikoj izek.k Ik= BRAKE POWER CERTIFICATE

1. Date 2. Station/Railways fnukWad LVs’ku@ jsYos

3. Train No. 4. Load Vªsu ua- yksM

5. Engine No. 6. Attached at batu ua- xkMh ij yxus dk le;

7. Vac./Air 8. Vac/Air Pr. on Air Pressure Vac. cms of Hg Pr.ready Departure (kg/cm2) oSD;we@ ,;j izS’kj oSD;we@ ,;j izS’kj rS;kj gksus dk le; pyrs le; FP BP In engine 9. Pressure of Brake Power batu esa lqpfyr czsd ikoj dk izs’kj In Brake Van czsdoku esa Air Brake Train 100% ,;j czsd Vªsu Vacuum Brake Train oSD;we czsd xkMh

9. A.i) Total No. of brake/Vac/Cylinders czsd@oSD;we@flysaMjksa dh dqy la- No. of operative Brake Vac. Cylinders vkWijsfVo czsd oSD;we flysaMj dh la-

10. Individual numbers of two coaches next to the Engine and at rear in case of Vacuum trains and of 4 middle coaches also in case of Air Brake Trains oSD;we Vªsukas esa batu@ czsdoku esa yxs nks nks dksp ds ua- ,;j izS’kjzS’kj VªSuVªSu esaesa budsbuds vfrfjDrvfrfjDr chpchp dsds pkjpkj dsUnzdsUnz dsds dkspksadkspksa dsds uu- Hkh vafdr djsaA

Engine end Rear end batu ls fiNyk fljk

Middle e/;

THIS CERTIFICATE IS VALID UPTO DESTINATION PROVIDED THE RAKE INTEGRITY IS NOT BROKEN OR CHANGED BY MORE THAN TWO VEHICLE UNITS OR THE TRAIN ENGINE IS NOT CHANGED IF RAKE INTEGRITY IS BROKEN BY MORE THAN TWO VEHICLE UNITS, A FRESH CERTIFICATE IS REQUIRED. IF THE TRAIN ENGINE IS CHANGED. THE CERTIFICATE SHOULD BE VALIDATED BY ENGINEER (C&W) THROUGH ENDORSEMENT IN THE COLUMN ON THE REVERSE. ;g izek.k Ik= iwjs jSd ds xarO; LFkku rd ;fn [kafMr u gqbZ gks tkjh fd;k tk;sxk ;k nks dksp ls vf/kd bdkbZ esa ifjofrZr gqbZ gks ;k Vªsu batu dks u cnyk x;k gksA ;fn jSd dh v[kaMrk nks dksp ls vf/kd bdkbZ esa ifjofrZr gqbZ gks rks izek.k Ik= dh vko’;drk gksrh gSA izek.k Ik= dh oS/krk vfHk;ark ¼dS ,oa oS-½ }kjk fiNyh rjQ fy[ks dkWye }kjk fd;k tk;sxkA

Driver’s name & signature Guard’s name & signature Engineer (C&W) Mªkboj dk uke o gLrk{kj xkMZ dk uke o gLrk{kj vfHk;ark ¼dS ,oa oS-½

(Space for enroute endorsement & Driver’s remarks on the reverse) Mªkboj dh f’kdk;rsa ihNs iUus ij

Chapter 1, Page 35 of 41

Maintenance Manual for BG ICF coaches Coach

II. Driver remarks & enroute endorsements by Engineer (C&W) Mªkbojks }kjk dh x;h fVIi.kh ds vuqlkj vfHk;ark ¼dS ,oa oS-½ }kjk jkLrs esa dh x;h izo`f"V

Station/Rly. Engine No. of vehicles without brake power Percentage of Signature of where No. DV S.A.B Brake brake power Engineer examined batu ua- Mh Ogh ,l , ch rigging czsd ikoj dk izfr’kr xkM+h ijh{kd ds LVs’ku @ jsyos vkblksysV [kjkc [kjkc czsd gLrk{kj tgkW ijh{k.k fd;k fjfxax x;k gks

IMPORTANT

1. The incoming Driver shall handover the certificate to relieving driver. If he is leaving the train without relief, it shall be deposited with the authority nominated to receive it, who will give it to the outgoing Driver. bu dfeax Mªkboj dks pkfg, fd og vius izek.k Ik= vkmV xksbax Mªkboj dks lkSai ns vkSj ;fn og fcuk fjyhoj ds Vªsu NksM+ jgk gS rks og vius izek.k Ik= ml vf/kd`r O;fDr ds ikl tek djsa tks fjyhfoax Mªkboj dks lkSaisaA

2. The outgoing Driver & Guard will satisfy themselves from the coach nos. given in item 10 that the certificate pertains to their train. tkus okys Mªkboj rFkk xkMZ] vkbVe dzekad 10 esa fn;s x;s dksp la[;kvksa ls vius vki dks larq"V djsxsa tks mldh xkM+h ls lEcfU/kr izek.k i= gksrs gSaA

3. It is responsibility of the Driver of train to satisfy himself that the brake power certificate is proper and valid, before working the train shall handover the certificate to relieving driver. If he is leaving the train without relief, it shall be deposited with the authority nominated to receive it, who will give it to the outgoing Driver. ;g Vªsu Mªkboj dh ftEesnkjh gS fd og vius vki dks larq"V djsa fd czsd ikoj dk izek.k i= mfpr ,oa oS/k gSA xkM+h ds dk;Z djus ls igys og ;g izek.k i= fjyhfoax Mªkboj dks gLrkUrfjr djsxkA ;fn og xkM+h dks fcuk fjyhoj vk;s NksM+rk gS rks og ukekafdr ,oa ftEesnkj O;fDr dks gLrkUrfjr djsxk tks ckgj tkus okys pkyd dks gLrkUrfjr djsxkA

Chapter 1, Page 36 of 41

Maintenance Manual for BG ICF coaches Coach

Annexure 1.2

CENTRAL RAILWAY DRS CARD IN THE TRAIN SHOWING CONDITION OF MECHANICAL EQUIPMENTS

Rake No. …… Train No. ………………. Date: ………. Card No. ………………

Coach NO. Remarks Check

Type & enroute

Owning Rly.

Coat hook Ash tray Mirrors Push Cocks Shower roses & valves Towel Rail Window Shutter Folding Table Tumbler holder Mirror shelves Ladder or foot steps 1 2 3 4 5 6 7 8 9 10 11 12 13 14

At Departure On Arrival

Signature of inspecting staff Engineer (C&W) Engineer (C&W)

RPF RPF

Guard Checking official will enter date, time and place after signature.

Chapter 1, Page 37 of 41

Maintenance Manual for BG ICF coaches Coach

Annexure 1.3

WARRANTY CARD

PROFORMA FOR REPORTING DEFECTS ON THE NEWLY BUILT COACHES DURING THE WARRANTY PERIOD

1. Coach No.

2. Code transportation ………….Mechanical code

3. Owning Railways

4. Name of manufacturer

5. Date of manufacture

6. Date of commission

7. Due date of warranty inspection

8. Date of inspection(by the depot)

9. Defects attributable to the manufacturers

Remark ……. (cost will be advised by the Railway board)

Report No. ………

Engineer (C&W) (Rubber stamp of the depot)

Chapter 1, Page 38 of 41

Maintenance Manual for BG ICF coaches Coach

Annexure 1.4

------Railway Carriage Depot ………….. (station)

COACH FAILURE REPORT

Train Details: Date Train No. Station Division Originating Stn. Last Exam. Stn Prim. Maint. Depot Sec. Maint. Depot. Coach Details: Coach Number Owning Railway & Base Depot Coach type code Coach Make: IRS/ICF/BEML/RCF Last POH Date & Shop Return Date

Failure Particulars: Cause of Failure (Detachment)

Defect found (on examination) Defect code

Remarks:

File No. DRM(M)'s Office, ---- Railway ---- (Station) Date:------

Copy forwarded to: CME, (owning) Railway CME, (reporting) Railway Sr. DME, (C&W), Division Railway (of primary maint. depot) Sr. DME, (C&W), Division Railway (of Secondary maint. depot) CWM, Railway and Workshop (of last POH)

(Signature) (Name and Designation)

Chapter 1, Page 39 of 41

Maintenance Manual for BG ICF coaches Coach

Annexure - 1.5 File No. CWM's Office Carriage Workshop ______Railway Tele/Fax. no. e.mail no. Date: To, M/s ------

Sub: Warranty claim for failed /defective item (name) ______

1 Reporting workshop & Railway a) Coach no. & type 2 b) POH date c) Return date a) Manufacturer's name 3 b) Date of Manufacture c) No. given by Manufacturer 4 Date of supply to workshop a) P.O. No. 5 b) Name of Inspecting agency a) Date of first fitment 6 b) Date of failure Type of service to which coach is 7 generally attached 8 Defects found/ cause of failures i) ii) 9 Other observations and remarks iii) iv) v)

Inspecting Officer For CWM Copy to:- 1. CME/ Rly. for kind information 2. COS/ Rly. for kind information 3. ED/Carriage/ RDSO Manak nagar Lucknow - 226011 4. CME/ ICF Perambur, Chennai/ RCF Kapurthala & BEML Bangalore 5. COS/ ICF Perambur, Chennai/ RCF Kapurthala & BEML Bangalore 6. Dy COS/Workshop for proper storage, delivery and receipt 7. Inspecting agency

Chapter 1, Page 40 of 41

Maintenance Manual for BG ICF coaches Coach

Annexure - 1.6 File No. CDO's/ DRM's Office ______Division ______Railway Tele/Fax. no. e.mail Date: To, M/s ------

Sub: Warranty claim for failed /defective item (name of item)

1 Reporting Division/Depot & Railway a) Coach no. & type 2 b) POH date c) Return date a) Manufacturer's name 3 b) Date of Manufacture c) No. given by Manufacturer 4 Date of supply to workshop a) P.O. No. (if available) 5 b) Name of Inspecting agency (if available) a) Date of first fitment 6 b) Date of failure Type of service to which coach is generally 7 attached 8 Defects found/ cause of failures i) ii) 9 Other observations and remarks iii) iv) v)

Depot Officer/DME For DRM(M) Copy to:- 1. CME/ Rly. for kind information 2. COS/ Rly. for kind information 3. ED/Carriage/ RDSO Manak nagar Lucknow - 226011 4. CME/ ICF Perambur, Chennai/ RCF Kapurthala & BEML Bangalore 5. COS/ ICF Perambur, Chennai/ RCF Kapurthala & BEML Bangalore 6. CWM/Workshop 7. Dy COS/Workshop for proper storage, delivery and receipt 8. Inspecting agency

Chapter 1, Page 41 of 41

Maintenance Manual for BG Coaches of ICF design Bogie

CHAPTER 3

BOGIES

301 GENERAL 302b Deflection due to the tare weight is almost equally divided between axle The main constructional and design and bolster springs. Weight of coach features of the ICF/RCF all-coil body is transferred to its bogie by side bogies, used on mainline BG coaches bearers pitched 1600 mm apart. Side- are briefly described in the following bearers consist of lubricated metal paragraphs. Leading Parameters of slides immersed in oil baths. No ICF bogie are as under: vertical weight transfer is effected through bogie pivot and the pivot acts Table 3.1 merely as a centre of rotation and serves to transmit tractive/braking S. Description Parameters forces only. No. 1. Maximum Axle 16.25t, 13t load bearing 303 BOGIE ASSEMBLY capacity (see figure 3.1) 2. Wheel base 2896mm 3. Wheel diameter 915mm (New) The bogie frame and components are 4. Axle guidance Telescopic axle guide of all-welded light construction with a with oil damping wheel base of 2.896 metre. The wheel 5. Primary Coil spring sets are provided with self-aligning suspension spherical roller bearings mounted in 6. Secondary Coil spring cast steel axle box housings. Helical suspension coil springs are used in both primary 7. Shock absorbers i) Vertical dashpot in and secondary suspension. The primary suspension. weight of the coach is transferred ii) Hydraulic double through side bearers on the bogie acting vertical bolsters. The ends of the bogie shock absorber in secondary bolsters rest on the bolster helical suspension. springs placed over the lower spring 8. Transfer of Through bogie side beam suspended from the bogie frame coach body bearer pitched at by the inclined swing links at an angle weight 1600mm. 70. Hydraulic shock absorbers and dash pots are provided in the 302 ALL-COIL ICF BOGIE secondary and primary suspensions respectively to damp vertical 302a The bogies being currently oscillations. manufactured by ICF/RCF which have been accepted as standards of 304 AXLE BOX GUIDE WITH DASH the Indian Railways and are of an all POT ARRANGEMENT welded light weight construction. (see fig. 3.2a & 3.2b) Axles are located on the bogie by telescopic dash pot and axle guide Axle box guides are of cylindrical assemblies. Helical coil springs are type welded to the bottom flanges of used in both the primary and the the bogie side frame with close secondary stages. The axle guide dimensional accuracy. These guides device provides viscous damping together with lower spring seats across primary springs while located over the axle box wings, hydraulic dampers are provided house the axle box springs and also across the secondary stage. Dampers serve as shock absorbers. These are protected against misalignment by guides are fitted with guide caps resilient fittings. Isolation of vibration having nine holes of diameter 5 mm is effected by rubber pads in primary equidistant through which oil in and secondary suspension. the lower spring seat passes under

Chapter 3, Page 1 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

VERTICAL SHOCK ABSORBER SECONDARY SUSPENSION PRIMARY SUSPENSION

SAFETY STRAP

BOLSTER SUSPENSIONPHANGER AXLE BOX SPRING LOWER SPRING BEAM

2896 WHEEL BASE

BRAKE BLOCK BRAKE BEAM CENTRE PIVOT

BOGIE FRAME ANCHOR LINK

4 6 3 2

3950

EQUALISING STAY

WHEEL AXLE

BOGIE BOLSTER

SIDE BEARER I.C.F. BOGIE

FIGURE 3.1

Chapter 3, Page 2 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

pressure during dynamic oscillation bogies. It does not transmit any of coach and provide necessary vertical load. It is equipped with damping to primary suspension to rubber silent block bushes which tend enhance better riding quality of to centralise the bogies with respect to coach. This type of rigid axle box the body and, to some extent, control guide arrangement eliminates any and damp the angular oscillations of longitudinal or transverse relative the bogies. (see figure 3.3) movement between the axles and the bogie frame. 309 SIDE BEARERS

Figure 3.2a & 3.2b show modified The side bearer arrangement consists and unmodified guide arrangement of a machined steel wearing plate respectively. The quantity of oil immersed in an oil bath and a floating required to achieve 40 mm oil level bronze-wearing piece with a spherical above the guide cap in modified top surface kept in it, on both sides of arrangement is approximately 1.6 the bogie bolster. The coach body liters and in unmodified arrangement rests on the top spherical surface of is approximately 1.4 liters. As it is these bronze-wearing pieces through not possible in open line to the corresponding attachments on the distinguish between modified and bottom of the body-bolster. The unmodified arrangements, 40 mm whole arrangement is provided with a oil level is standardised for both. cover to prevent entry of dust in the oil sump. (see figure 3.4 ) 305 AIR VENT SCREWS Table 3.2 On the bogie side frames, directly above the dash-pots, tapped holes are Wear limit for wearing plate provided for replenishing oil in the dash pots. Special screws with New Shop renewal Condemning copper asbestos washers are screwed size size size on the tapped hole to make it air tight. 10 mm 9 mm 8.5 mm

306 BOGIE BOLSTER SUSPENSION Wear limit for wearing piece

The bolster rests on the bolster coil springs - two at each end, located on New Shop renewal Condemning size size size the lower spring beam which is 45 mm 43.5 mm 42 mm suspended from the bogie side frame

by means of bolster-spring- 310 ANCHOR LINKS suspension (BSS) hangers on either

side. The two anchor links diagonally The floating bogie bolster which positioned are provided with silent supports the coach body is held in block bushes. The links prevent any position longitudinally by the anchor relative movement between the bogie links which are pinned to the bolster frame and coach body. sides and the bogie Transoms. One 307 SPRINGS anchor link is provided on each side of the bolster diagonally across. The In ICF bogie, helical springs are used links can swivel universally to permit in both primary and secondary the bolster to rise and fall and sway suspension. The springs are side wards. They are designed to take manufactured from peeled and the tractive and braking forces. The centreless ground bar of chrome anchor links are fitted with silent vanadium/chrome molybdenum steel block bushes (see figure 3.5) conforming to STR No. WD-01-HLS- 94 (Rev.1) 311 SILENT BLOCK

308 CENTRE PIVOT This is a synthetic rubber bush fitted ARRANGEMENT in anchor link and center pivot of ICF

The centre pivot pin joins the body bogies to transmit force without shock with the bogie and transmits the and reduce noise. tractive and braking forces on the

Chapter 3, Page 3 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

1

2

1. SPECIAL SEREW WITH 3 SEALING WASHER

4 2. GUIDE

3. PROTECTIVE TUBE COMPLETE 5 4. UPPER RUBBER WASHER

6 5. TOP SPRING SEAT

6. DUST SHIELD SPRING 7 7. DUST SHIELD

8. HELICAL SPRING

8 9. GUIDE RING OIL LEVEL UNDER TARE 10. RUBBER PACKING RING 0 9 4 11. GUIDE BUSH OIL LEVEL BEFORE ASSEMBLING 12. CIRCLIP L E

10 V

E 13. COMPENSATING RING L 5

. L 2 I 4 5 4 . A 1 0 2

R 14. LOWER RUBBER WASHER

1 9 O T 11 X 15. SAFETY STRAP

16. LOWER SPRING SEAT 12

13 X TO RAIL LEVEL-

14 686 FOR ALL AC & NON-AC COACHES EXCEPT POWER CARS

POWER CAR- 15 670 FOR BOGIE ON LUGGAGE SIDE 16 672 FOR BOGIE ON GENERATOR SIDE

MODIFIED AXLE BOX GUIDE ARRANGEMENT

Figure 3.2a

Chapter 3, Page 4 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

1 2

1. SPECIAL SEREW WITH 3 SEALING WASHER

4 2. GUIDE

3. PROTECTIVE TUBE COMPLETE 5 4. UPPER RUBBER WASHER

6 5. TOP SPRING SEAT

6. DUST SHIELD SPRING 7 7. DUST SHIELD

8. HELICAL SPRING 8 9. GUIDE RING

10. RUBBER PACKING RING 9 OIL LEVEL UNDER TARE 11. GUIDE BUSH

OIL LEVEL BEFORE 12. SPRING CLIP 0 4

ASSEMBLING L E

10 V

E 13. COMPENSATING RING L

L I 5 A .

5 R 14. LOWER RUBBER WASHER 9 .

1 8 6 1 O 8 6 T 11 X 15. SAFETY STRAP

16. LOWER SPRING SEAT

12 17. GUIDE CAP

13 17 14 X TO RAIL LEVEL- 686 FOR ALL AC & NON-AC COACHES EXCEPT POWER CARS

15 POWER CAR- 16 670 FOR BOGIE ON LUGGAGE SIDE

672 FOR BOGIE ON GENERATOR SIDE AXLE BOX GUIDE ARRANGEMENT

Figure 3.2b

Chapter 3, Page 5 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

FIXING ARRGT. OF PBOTTOM COVERPWITH BOLSTER SECTION A-A

TO BE TACK WELDEDPAFTER ASSEMBLY

CENTRE PIVOT PIN

SEALING CAP

A

BOGIE BOLSTER

SILENT BLOCK

SLEEVE HEX. HEAD SCREWP& SPRING WASHER

BOTTOM COVER PCOMPLETE

COTTER

SPLIT PIN A

CENTRE PIVOT ARRANGEMENT

FIGURE 3.3

Chapter 3, Page 6 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

10 % R %

5 5 10 c . 4 9

3 °

WEARING PIECE FOR SIDE BEARER 5 REF. DRG. NO. T-O-5-649 5 13 % % c

6

SURFACE SHOULD BE SMOOTH

FELT

OIL LEVEL CHECK FOR POROUS WELDING

WEARING PIECE

Note:-P1. Bronze Wearing Piece should be renewed when the wear on the mating surface reaches 3mm that is, height is less than 42 mm or damages occur to the oil grooves.P2. The hard ground plate should be renewed when the wear exceeds 1.5mm that is, thickness is less than 8.5 mm or ridges are observed on the plate.

SIDE BEARER ARRANGEMENT

FIGURE 3.4

Chapter 3, Page 7 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

ANCHOR LINK WITH SILENT BLOCK Figure 3.5

312a Coach Under Frame Mounted 312 BRAKE RIGGING Brake Rigging

Brake rigging is provided to control The brake rigging is as per figure 3.6. the speed of the coach by transferring In 16.25 t axle load bogie the four the braking force from the brake lever used in bogie brake rigging are cylinder to the wheel tread. Brake each with lever ratio of 1:1.376 and rigging can be divided into two hence the total Mechanical advantage groups i.e. Bogie mounted brake in a bogie is 5.504 .

rigging and coach under frame The components details of 16 t bogie mounted brake rigging. are given in table 3.3 (Refer ICF

drawing No. WTAC3-3-2-305).

COACH UNDERFRAME BRAKE RIGGING Figure 3.6

Chapter 3, Page 8 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.3

Sr.No. Description Ref. Drg. NO (ICF) Quantity 1 Brake Head & block complete (L.H. Assembly) T-3-1-919 8 2 Brake Head & block complete (R.H. Assembly ) T-3-1-619 8 3 Short lever WLRRM 3-2-002 12 4 Long lever WLRRM-3-2-002 8 5 Brake Block Hanger T-3-2-645 16 6 Adjusting link WT AC3-3-2-302 2 7 Lever Hanger HIG AC 3-3-2-302 16 8 Pull rod WLRRM3-2-002 4 9 Pull rod T-3-2-616 2 10 Pin T3-2-048 50 11 Washer ICF/STD 3-2-003 50 12 Split Cotter T-3-2-632 50 13 Pin T-3-2-648 8 14 Washer ICF/STD 3-2-103 24 15 Split Cotter T-3-2-632 8 16 Pin for lever Hanger ICF/SK-3-2-179 16 17 Pin for safety wire rope WT AC3/3-2-307 32 18 Plain washer M20 IS: 2016-67 T.2type A 32 19 Split cotter EMU-3-2-048 32 20 Brake beam T-3-2-804 8 21 Safety wire rope T-3-2-651 16 22 Safety straps fixing Arrangement WT AC-3-2-304 8

In 13 t axle load bogie the four lever used in bogie brake rigging are each with lever ratio of 1:1 and hence the total Mechanical advantage in a bogie is 4.

The components details of 13 t bogie are given in table 3.4 (Refer ICF drawing No. T-3-2- 601). Table 3.4

Sr.No. Description Ref. Drg. NO (ICF) Quantity 1 Brake Head & block complete T-3-1-601 16 2 Brake Beam T-3-1-602 8 3 Long lever T-3-2-605 8 4 Short lever T-3-2-604 8 5 Pull rod T-3-2-607 4 6 Pull rod T3-2-616 2 7 Adjusting Link T-3-2-609 2 8 Lever Hanger T-3-2-611 16 9 Safety Strap T3-2-612 4 10 Safety Strap T-3-2-621 4 11 Pin T3-2-048 8 12 Pin T3-2-048 50 13 Hex head screw ½" BSWx 38 BS :3083 –64 64 14 Spring Washer M-12 IS: 3063-72 64 15 Hex. Nut ½” BSW BS:1083-65 64 16 Washer DL-0-5-034 50 17 Washer DL-0-5-034 24 18 Pin for lever Hanger ICF/SK-3-2-179 16 19 Split cotter T-3-2-632 50

Chapter 3, Page 9 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

i) CONVENTIONAL AIR BRAKE COACH POWER CAR (refer figure 3.7)

TYPE OF COACH BUILDER TARE WEIGHT IN % OF BRAKING TONNES POWER CAR TO ICF 53.7 118 WLRRM6-9-0-601 HIGH CAPACITY ICF 60 105.6 POWER CAR

ii) CONVENTIONAL AIR BRAKE COACH SELF GENERATING AC COACHES (refer figure 3.8)

TYPE OF COACH BUILDER TARE WEIGHT IN TONNES % OF BRAKING WGACCW ICF 50.0 114.8 RCF 49.1 120.9 WGACCN RCF 50.1 118.6 WGSCZAC ICF 49.3 123.7 WGFAC ICF 49.7 119.5 WGFSCZAC ICF 50.0 118.8

Levers for Power car & self generating AC coaches

Sr. No. Size Shape/Drg. Types of coaches fitted Drawing no. 1. 282 x 205 POWER CAR TO WLRRM6-9-0- SK-93373 601, HIGH CAPACITY POWER & SK-93371 CAR, WGACCW, WGACCN, WGSCZAC, WGFAC, WGFSCZAC 2. 245 X 178 -DO- -DO-

iii) CONVENTIONAL AIR BRAKE COACH NON AC COACHES (refer figure 3.9)

Levers

Sr. No. Size Shape/Drg. Types of coaches fitted Drawing no. 1. 230 X 230 GS,FC,SLEEPER, SLR, Second SK-93372 day coach, SCNLR, PANTRY CAR 2. 200 X 200 -DO- -DO-

TYPE OF COACH BUILDER TARE WEIGHT IN TONNES % OF BRAKING GENERAL SECOND ICF 36 120 CLASS RCF 37.4 115.5 SECOND DAY COACH ICF 37 116.7 RCF 37.3 115.8 SLEEPER ICF 39.5 109.3 RCF 39.45 109.5 FIRST CLASS ICF 41.8 103.3 SLR ICF 40.6 106.4 RCF 40.0 108.0 SCNLR ICF 41.0 105.3 PANTRY CAR ICF 41.3 104.6

Chapter 3, Page 10 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

2 8 5 5 2 2 4 4 4 2 2 5

2 8 1 8 0 7 7 7 1 5 8 1

2,896±1 CONVENTIONAL AIR BRAKE COACH (POWER CAR)

RDSO DRAWING NO. SK-93373 FIGURE 3.7

2 8 5 5 2 2 4 4 4 2 2 5

8 2 1 8 7 7 0 7 1 1 5 8

2,896±1 CONVENTIONAL AIR BRAKE COACH SELF GENERATING AC COACHES

RDSO DRAWING NO. SK-93371 FIGURE 3.8

Chapter 3, Page 11 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

312b Bogie Mounted Brake Rigging

Bogie brake rigging has been modified to incorporate a total mechanical advantage of 7.644 per bogie for non-ac coaches and 8.40 per bogie for ac coaches.

The components of bogie mounted air brake (16 t bogie) to ICF drawing no. WTAC4-3-3-401 is given in table 3.5.

Table 3.5

Sr.No. Description Ref. Drg. No. (ICF) Quantity 1 Brake Head & block complete (LH) T-3-1-801 8 2 Brake Head & Block complete (RH) T-3-1-801 8 3 Brake beam T-3-2-650 8 4 Safety wire rope T-3-2-651 16 5 Lever WTAC4 -3-2-402 8 6 Lever WTAC4 -3-2-402 8 7 Lever Hanger WTAC4 -3-2-402 8 8 Pull rod WTAC4 -3-2-402 8 9 Brake block Hanger T3-2-645 16 10 Pin T-3-2-648 44 11 Plain Washer ICF/ISD 3-2-003 64 12 Split cotter T-3-2-632 52 13 Pin T3-2-648 4 14 Plain Washer ICF/STD 3-2-003 4 15 Pin T-3-2648 4 16 Pin for lever Hanger T-3-2-801 16 17 Pin for Safety wire rope WT AC3 –3-2-307 32 18 Pin Washer M 20 IS: W 16-67 32 19 Split cotter EMU-3-2-048 32

The components of bogie mounted air brake (13 t bogie) to ICF drawing no. T-3-2-801 is given in table 3.6 Table 3.6

Sr. No. Description Ref. Drg. NO ICF) Quantity 1 Brake Head & block complete (L.H. Assembly) T-3-1-801 4 2 Brake Head & block complete (R.H. Assembly ) T-3-1-801 4 3 Brake beam T-3-1-804 4 4 lever T-3-1-802 4 5 lever T-3-1-802 4 6 lever Hanger T-3-1-802 4 7 Pull rod T-3-2-802 2 8 Brake block Hanger T-3-1-645 8 9 Pin T3-2-648 22 10 Plain Washer ICF/STD-3-2-103 32 11 Split Cotter T-3-2-632 26 12 Pin T-3-2-648 2 13 Plain Washer ICF/STD 3-2-103 2 14 Pin T-3-2-648 2 15 Pin for lever Hanger T-3-2-802 8 16 Pin for safety wire rope WFT AC3/3-2-307 16 17 Plain washer M20 IS: 2016-67 16 18 Split cotter EMU-3-2-048 16 19 Safety wire rope T-3-2-651 8

Chapter 3, Page 12 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

i) AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER (refer figure 3.10)

Levers

Sr. Size Shape/Drg. Types of coaches fitted Drawing no. No. 1. 366 x 174 WGSCZAC, WGSCWAC, SK-98032 WGFAC, WGFSCZ, WSCZAC, WSCWAC, WFAC, WCBAC 2. 311 X 148 -DO- -DO-

3. 412 -DO- -DO-

TYPE OF COACH TARE WEIGHT IN TONNES % OF BRAKING WGSCZAC 50.95 40.56 WGSCWAC 52.10 39.66 WGFAC 49.90 41.41 WGFSCZ 50.00 41.33 WSCZAC 48.90 42.26 WSCWAC 49.40 41.83 WFAC 46.20 44.73 WCBAC 47.90 43.14 ii) NON - AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER (refer figure 3.11)

Levers

Sr. Size Shape/Drg. Types of coaches fitted Drawing no. No. 1. 302 X 158 GS,SCN,SDC,WCB, SLR, WFC SK-98027

2. 256 X 134 -DO- -DO-

3. 405 -DO- -DO-

TYPE OF COACH TARE WEIGHT IN TONNES % OF BRAKING GS 36.00 52.23 SCN 37.55 50.08 SDC 36.50 51.52 WCB 40.40 46.54 SLR 40.60 46.32 WFC 41.80 44.99

Chapter 3, Page 13 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

6 1 6 1 3 3 3 3 1 6 412 1 412 6

8 4 4 1 1 7 4 1 8 1 7 4

2896±1

AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER P(FITTED WITH K TYPE COMPOSITION BLOCK) RDSO DRAWING NO. SK-98032)

FIGURE 3.10

2 6 0 5 2 2 3 3 405 5 0 6 405 2

4 3 8 1 1 5 3 1 4 1 5 8

2,896±1 NON - AC COACHES WITH BOGIE MOUNTED AIR BRAKE CYLINDER P (FITTED WITH K TYPE COMPOSITION BLOCK) RDSO DRAWING NO. SK-98027

FIGURE 3.11

Chapter 3, Page 14 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

313 EQUALISING STAYS 316a Washing Plant

This device has been provided on i) Remove all the oil from the side bogies between the lower spring bearer oil bath. plank and the bolster to prevent ii) Wash the bogie with high lateral thrust on the bolster springs pressure hot water jet to remove which have not been designed to take all dust, mud, scales, grease and the lateral forces. These links have other muck without damaging pin connections at both ends and, the base primer coating. therefore, can swivel freely. (see figure 3.13) After washing and drying, roll the bogies to dismantling line. 314 BOLSTER SPRING SUSPENSION 316b Dismantling HANGERS (BSS HANGERS) In the secondary suspension, the i) Make sure that the vent screws bolster is supported on helical coil are opened. Lift the bogie frame springs which are placed on the lower along with the bolster using spring plank. The lower spring plank overhead crane till all the eight is suspended from the bogie side axle guides disengage from the frame through BSS hangers on lower spring seats. hanger blocks. (see figure 3.14) ii) Lower the bogie frame and bolster on to the shop floor. 315 SHOCK ABSORBERS iii) Remove and collect the axle box guide components and helical Hydraulic shock absorbers with springs in respective bins/ pallets capacity of ± 600 kg at a speed of 10 and send to washing plant for cm/sec. are fitted to work in parallel thorough cleaning. with the bolster springs to provide iv) Wheel sets must be first cleaned damping for vertical oscillations. thoroughly in the washing plant

and then sent to wheel shop. 316 WORKSHOP MAINTENANCE- v) Remove vertical shock absorber BOGIE SHOP and send to shock absorber

maintenance section. MAINTENANCE OF BOGIES vi) Disconnect anchor links. (Flow Diagram) Dismantle bolster suspension

hangers by placing a dead

LIFTING WASHING BOGIE SERVICE weight on the bogie frame and SHOP PLANT SHOPS SHOP by using a jack. (Fitting shop 1 2 vii) Disconnect equalising stays. Lift 3 5 & the bolster off the bolster springs 9 4 Smith shop) 7 8 and remove the bolster springs. 10 6 viii) Collect anchor links, equalising

stays, bolster spring suspension 1. Coach lifting (BSS) hanger pins, BSS hanger 2. Bogie cleaning blocks (stones), BSS hangers, 3. Bogie dismantling pins of equalising stays, brake 4. Component cleaning rigging components and bolster 5. Attention to components springs into respective bins/ 6. Repair of components pallets and send to washing plant 7. Bogie assembly for thorough cleaning. 8. Load testing and adjustment ix) Send the bogie frame, bolsters, 9. Lowering of coach and lower spring planks to 10. Final adjustment washing plant for thorough

cleaning and drying. Figure 3.12

Transport the cleaned and dried bogie After lifting the coach body (refer frame, bolster and spring planks to para 105 of chapter ‘Coach’), roll out inspection and repair stands. Place the the bogies and send them to bogie bogie frame on repair stands in the washing plant in bogie shop. inverted position.

Chapter 3, Page 15 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

Bracket on Lower Spring Beam

3

6

3 2 3 3 1

5 Bracket on Bogie Bolster 4

3 134 526

67

200 7

263 3 3

3 3

5

7 6

5

672

No. off per ITEM Description & assembly dimensions

7 RIB 120x30x5 2

EQUALISING STAY FOR LOWER SPRING BEAM 6 2 RIB 200x225x5

(16.25 t Axle Load Bogie) (RDSO Sketch 88105) 5 BUSH%%c 42/32 x32L 8

4 BODY %%c 60x134 1

3 BOSS %%c 60/40 x32L 2

2 TUBE %%c 50 BOREx462 1

FIGURE 3.13 1 TUBE %%c 50 BOREx640 1

)

Chapter 3, Page 16 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

COMPONENTS SIZE-NEW CONDEMNING WEAR IN mm SHOP ISSUE SIZE

9.5 8 1.5 8.50

HANGER BLOCKPTOP & BOTTOM

PIN 37 35.5 1.5 36.00

HANGER 38.4 36.5 1.5 37.00 6 2

1

R 5 . 9

- 0.25P- HANGER AND HANGER BLOCKS 45 0.5

FIGURE 3.14

Chapter 3, Page 17 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

316c Attention to Bogie Frame

i) Check the bogie thoroughly for for axle guide and 0.5 mm for any possible cracks. Check the BSS bracket bush), damaged or BSS brackets, axle guides, area cracked, they should be surrounding the BSS bracket and replaced. axle guide and all the welding iii) Bent or damaged suspension joints of bogie frame. If cracks straps should be attended to as are detected, hold the bogie required. frame in bogie manipulator. iv) Safety wire rope arrangement After proper gouging, weld the and safety straps should be used cracks and finish by grinding. for brake beams as per revised ii) If the BSS brackets or axle RDSO instructions. guides are worn (limits: 1 mm Table 3.7

Suggested BSS bracket and axle 13t bogies 16.25t bogies guide alignment gauges Longitudinal gauge for BSS 1400±1.0 mm (700±0.5 mm 1500±1.0 mm (750±0.5 mm brackets from longitudinal center-line) from longitudinal center-line) Transverse gauge for BSS brackets 2159 ±1.0 mm 2159 ± 1.0 mm Diagonal gauge for BSS brackets 2573 ±1.0 mm 2629 ± 1.0 mm Longitudinal gauge for axle guide 570±1.0 mm (equidistant from 570 ± 1.0 mm (equidistant from center-line of axle) center-line of axle) Transverse gauge for axle guide 2159±1.0 mm 2159±1.0 mm Diagonal gauge for axle guide 3612±1.0 mm 3612±1.0 mm Distance between BSS bracket and 463±1.0 mm 413±1.0 mm adjacent axle guide Longitudinal gauge for suspension 870±1.0 mm (equidistant 870±1.0mm (equidistant from strap from center-line of axle) center-line of the axle)

v) Check the squareness and vii) The relevant axle guides should alignment of BSS brackets and be cut using special gouging axle guides with the help of nozzles (PO 18 or 19) to prevent transverse, longitudinal, undercutting of bogie frame. diagonal gauges and straight Axle guides found bent/cracked edge. Axle guide alignment should also be cut out and should be checked with replaced. reference to the BSS brackets viii) Weld the new axle guides with and recorded in RDSO the help of axle guide welding dimensional check report . A fixture, if the axle guides are coordinate measuring machine, damaged or worn. Check the preferably CNC type, can do alignment of new axle guides these checks accurately. with respect to other axle guides vi) If the BSS brackets do not lie using master gauges and straight within the tolerances, relocate edge. Any slight discrepancy in one or more BSS brackets with location can be rectified by correct alignment. After suitable local heating of the ensuring correct alignment of the frame. After complete BSS brackets, measure the rectification, record important location of the axle guide from dimensions in RDSO the BSS brackets and record in dimensional check report. (See RDSO dimensional check report. fig. 3.15 a&b, fig. 3.16 a&b) If the measurements deviate from the standard measurements, ix) Replace the BSS bracket bushes relocate mis- aligned pair of axle and pins if they were damaged guides. or worn.

Chapter 3, Page 18 of 36

Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSIONALa CHECK REPORT b FOR AC & POWER CAR BOGIE FRAME

C D 5

3 z + 1 413 -

F

E 6 g g 2 7 1 2 1 8 K 6 g 3 g 4 3 N 9

5 2 T 5 Q 5

1 6 . 2 . 2 0 9 0 + - + 1 - + 2

1 - 2 5 5 7 + - 7 1 1 1 1 + - + - 5 P 3 M S +

- J 1 6 7 8 5 . 5 0 . E E 0 L + - L X + - X A A 6

7 F F 8 O O R O

. . L L L .

750 . 570 C I C

G H c 1500 d

g g + 0.5 g + 1 8 7 - 6 - g 5 2896 z + 1 - + - 1 570

+ 1 -

A B

1. BOGIE SIDE FRAME & HEAD STOCK CENTRES ON EITHER SIDE OF THE BOGIE FRAME AS SHOWN THUS WILL BE PERMANENTLY PUNCH MARKED IN CONSPICUOUS MANNER.TO ENSURE THIS 2mmTHICK X 25mmWIDE STRIP SHOULD BE WELDED AT THE LONGITUDINAL AND TRANSVERSE CENTRES OF THE BOGIE FRAME.PUNCH MARK SHOULD BE PUNCHED ON THIS STRIP ACCORDINGLY.

2. g TO1 g REPRESENT8 LOCATIONS OF BOGIE GUIDES.

3. E,F,G & H REPRESENT LOCATIONS OF SUSPENSION BRACKETS FOR BOLSTER SUSPENSION ARRGT.

4. BOLSTER SUSPENSION BRACKET PIN HOLES E,F,G,H SHALL BE LOCATED AT

+ 750 0.5mm- FROM THE TRANSVERSE CENTRE LINE PUNCH MARKS ON BOGIE SIDE FRAME & CHECK IT AS PER FIG.-3.15b.

5. WELDING JOINT SHALL NOT COME UNDER THE BOGIE GUIDE.

6. NO INACCURACY IN LOCATION OF HANGER BRACKET AND THE ALIGNMENT

OF HOLES IN THE BRACKETS WILL BE PERMITTED.

ICF DRG. WTAC - 0-3-301 FIGURE-3.15a 3 SHEET 1 OF 2

Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSIONAL CHECK REPORT FOR BOGIE FRAME (AC TYPE)

No. ………………….

ICF DRG. NO. WTAC3 0 Measuring Nominal Size Actual Size Variation Measuring Nominal Size Actual Size Variation Point (mm) (mm) (mm) Point (mm) (mm) (mm) E - F 1500 ± 1.0 I - J 876 ± 0.5 G - H 1500 ± 1.0 J - K 876 ± 0.5 E - G 2159 ± 1.0 L - M 876 ± 0.5 F - H 2159 ± 1.0 M - N 876 ± 0.5 E - H 2629 ± 1.0 O - P 876 ± 0.5 - 3

- F - G 2629 ± 1.0 P- Q 876 ± 0.5 301

a 413 ± 1.0 R - S 876 ± 0.5 b 413 ± 1.0 S - T 876 ± 0.5 c 413 ± 1.0 I - K 1752 ± 1.0 d 413 ± 1.0 L - N 1752 ± 1.0 g1 - g2 570 ± 1.0 O - Q 1752 ± 1.0 Figure SHEET 2 OF g3 - g4 570 ± 1.0 R - T 1752 ± 1.0 g5 - g6 570 ± 1.0 g1 - g6 3612 ± 1.0 -

g7 - g8 570 ± 1.0 g2 - g5 3612 ± 1.0 3.15b z - F 750 ± 0.5 g3 - g8 3612 ± 1.0

z - H 750 ± 0.5 g4 - g7 3612 ± 1.0

Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSIONALa CHECK REPORT b FOR NON AC BOGIE FRAME

C D 5

3 z + 1 463 -

F

E 6 g g 2 7 2 1 8 K 1 6 g 3 g 4 3 N 9 5 T 5 Q 5 1 . . 2 0 0 + 1 - + - + 2 1 2

- 5 5 7 + - 7 1 1

2 1 1 + 5 - 7 + - 5 P 3 3 M S +

- J 1 6 7 8 5 . 5 0 E . E 0 L L + - X X + - A A 6

7 F F 8 O O R O

. . L L L

. . 570 I C C

G H c d

g + 0.5 g + 1 8 g 7 - 6 - g 5 2896 700 z + 1 + - - 1 570 1400

+ 1 -

A B

1. BOGIE SIDE FRAME & HEAD STOCK CENTRES ON EITHER SIDE OF THE BOGIE FRAME AS SHOWN THUS WILL BE PERMANENTLY PUNCH MARKED IN CONSPICUOUS MANNER.TO ENSURE THIS 2mmTHICK X 25mmWIDE STRIP SHOULD BE WELDED AT THE LONGITUDINAL AND TRANSVERSE CENTRES OF THE BOGIE FRAME.PUNCH MARK SHOULD BE PUNCHED ON THIS STRIP ACCORDINGLY.

2. g TO1 g REPRESENT8 LOCATIONS OF BOGIE GUIDES.

3. E,F,G & H REPRESENT LOCATIONS OF SUSPENSION BRACKETS FOR BOLSTER SUSPENSION ARRGT.

4. BOLSTER SUSPENSION BRACKET PIN HOLES E,F,G,H SHALL BE LOCATED AT

+ 700 0.5mm- FROM THE TRANSVERSE CENTRE LINE PUNCH MARKS ON BOGIE SIDE FRAME & CHECK IT AS PER FIG.-3.16b.

5. WELDING JOINT SHALL NOT COME UNDER THE BOGIE GUIDE.

6. NO INACCURACY IN LOCATION OF HANGER BRACKET AND THE ALIGNMENT

OF HOLES IN THE BRACKETS WILL BE PERMITTED.

R.D.S.O./CARR./SK93280 FIGURE-3.16a SHEET 1 OF 2

Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSIONAL CHECK REPORT FOR BOGIE FRAME (AC TYPE)

No. ………………….

RDSO/SK/9 Measuring Nominal Size Actual Size Variation Measuring Nominal Size Actual Size Variation Point (mm) (mm) (mm) Point (mm) (mm) (mm) E - F 1400 ± 1.0 I - J 876 ± 0.5

3280 G - H 1400 ± 1.0 J - K 876 ± 0.5

E - G 2159 ± 1.0 L - M 876 ± 0.5 F - H 2159 ± 1.0 M - N 876 ± 0.5 E - H 2573 ± 1.0 O - P 876 ± 0.5 F - G 2573 ± 1.0 P- Q 876 ± 0.5 a 463 ± 1.0 R - S 876 ± 0.5 b 463 ± 1.0 S - T 876 ± 0.5 c 463 ± 1.0 I - K 1752 ± 1.0 d 463 ± 1.0 L - N 1752 ± 1..0 g1 - g2 570 ± 1.0 O - Q 1752 ± 1.0 Figure SHEET 2 OF g3 - g4 570 ± 1.0 R - T 1752 ± 1.0 g5 - g6 570 ± 1.0 g1 - g6 3612 ± 1.0 -

g7 - g8 570 ± 1.0 g2 - g5 3612 ± 1.0 3.16b z - F 700 ± 0.5 g3 - g8 3612 ± 1.0

z - H 700 ± 0.5 g4 - g7 3612 ± 1.0

Maintenance Manual for BG Coaches of ICF design Bogie x) Replace the anchor link brackets if hanger bracket for renewal. Replace the bushes they are worn or damaged. The M12 in the brake hanger brackets at every POH. threaded hole should be cleaned and xii) Replace the brake lever hanger checked and attended to, as required. brackets if the holes are xi) Bent, damaged, or worn brake hanger oblong/worn or damaged. brackets should be replaced. If the holes are xiii) Replace all the axle box housing not aligned/located as per drawing, replace the crown bolt and screwing piece brackets. Use single piece design of brake by rubber stoppers.

Table 3.8

WEAR LOCATIONS (Dimensions in mm) Part name Wear location Drg. Nos. +0.025 Brake hanger bracket bush 32 H7 Hole /-0.00 T-0-3-669 & WTAC3-0-3-316 Brake hanger bracket 35 gap T-0-3-675 Brake hanger bracket C.D.1752 +1.0 T-0-3-675 -0.034 Axle guide 115g6 /+0.00 diameter T-0-3-670 alt. 2/f Axle guide 120 diameter T-0-3-670 alt. 2/f BSS bracket bush 38 dia. Hole T-0-3-626 alt. 9/h Pin for BSS 37 diameter T-0-5-637 alt. m/12 +0.021 Bracket for anchor link 25 /-0.0 slot T-0-3-635 alt. j/16 Brake lever hanger bracket 32 dia hole T-0-3-631 & T-0-3-632

xiv) The locations where the repairs 316d Attention to Bogie Bolster have been carried out should be Arrangement cleaned to bare metal and (Refer drg. no.WTAC3-0-5-301 & painted with two coats of primer WLRRM-0-4-001 for 16.25t bogie and to IS:2074 to a minimum Dry T-0-5-601 & T-0-4-601 for 13t bogie) 50 Film Thickness (DFT) of i) Check the bolster for twist, microns followed by one coat crack, corrosion, etc. Repair or of anti-corrosive Black Japan replace the bolster as required, Type-B to IS:341 to a DFT of and attend to the lug as required. 35 microns, after which entire ii) Repair or replace the equalising bogie frame is to be given one stay bracket if found bent, coat of Black Japan Type-B to damaged, or corroded. IS:341 to a minimum DFT of 35 microns.

Table 3.9

Part name Wear location (all dimensions in mm) Drg. Nos. Side bearer wearing plate 10 mm thick top wearing surface T-0-5-648 alt 10/L Side bearer wearing piece 45 mm thick bottom wearing surface T-0-5-649 alt 17/h +0.040 -0.2 Bolster Centre Pivot sleeve Hole 155 H7 ( /-0.0) c9( /-0.3) T-0-6-606 +0.040 Centre-Pivot silent block Hole 140 H7 ( /-0.0) T-0-6-606 sleeve +0.15 Centre Pivot silent block Hole dia. 90 /+0.30 T-0-6-611 alt. 16/p +0.1 Centre Pivot silent block Hole dia. 75 /+0.2 -do- +0.195 Centre Pivot silent block Out side dia 140 U6 ( /+0.170) -do- -017 Centre Pivot pin Out side dia. 90 c9( /-0.267) & 75 c9 T -0-6-602 alt.s -0.150 ( /-0.257) (w)

Maintenance Manual for BG Coaches of ICF design Bogie

iii) Replace the anchor link bracket xiii) The locations where the repairs by holding in bolster repair have been carried out or found fixture, if found worn or corroded should be cleaned to damaged. bare metal and painted with two iv) Replace the bushes in the stay coats of primer to IS:2074 to a rod brackets, if found worn or minimum Dry Film Thickness damaged. (DFT) of 50 microns followed v) Replace the centre pivot silent by one coat of anti-corrosive block if found worn, damaged or Black Japan Type-B to IS:341 rubber has perished. to a DFT of 35 microns, after vi) Replace the centre pivot sleeve if which entire bogie bolster is to worn or damaged or corroded. be given one coat of Black vii) Replace the bolster centre pivot Japan Type-B to IS:341 to a sleeve if worn or cracked. minimum DFT of 35 microns.

viii) Replace the rubber sealing cap 316e Anchor Link of centre pivot silent block, if torn or damaged or perished. (Ref: Drawing No. T – 0 – 7 – 603 ix) Replace the centre pivot pin if and T – 0 – 7 –607) worn or cracked. Chalk test the centre pivot pin ‘in position’ or i) Replace the anchor link, if worn ‘off position’ to detect cracks. or corroded. Repair the anchor x) Force fit between silent block link, if found cracked (normally and sleeve and tolerance on at weld joints) under magna flux -0.18 pivot pin, i.e., c9 ( /-0.27) testing, by re welding after should be maintained in every gouging. Refit new silent block POH/IOH. in every POH. xi) Ensure that there is no leakage of oil from the side bearer oil- ii) Replace the silent block, if the bath welding portion. Replace rubber is perished (indicated by the hard ground plate in side fretting) or loose in the anchor bearer, if worn more than 1.0mm link housing, or the silent block (ref. table 3.2) in thickness or pin is worn thin or loose in ridges formed on the plate. silent block rubber. The silent Replace the bronze wearing block should be force fit in the piece for side bearer, if worn anchor link and the silent block more than 1.5 mm in thickness. pin should be slide fit in the Sharp edges on wearing piece anchor link bracket. should be rounded off before re- use. Ensure that the dust seal iii) The locations where the repairs cover sits effectively all around have been carried out should be without any gap on the oil-bath cleaned to bare metal and and the sleeves slide freely on painted with two coats of primer the guide to ward off dust and to IS: 2074 to a minimum Dry moisture coming in contact with Film Thickness (DFT) of 50 the oil. Clean refilling passages microns followed by one coat and deficient or damaged oil of anti-corrosive Black Japan refilling cups with caps and Type-B to IS:341 to a DFT of pipes should be replaced. The oil 35 microns, after which entire filling plugs should be well anchor link is to be given one secured by chain to prevent it coat of Black Japan Type-B to from dropping. IS:341 to a minimum DFT of 35 xii) Repair or replace the bent or microns. damaged or broken equalising stay rod safety loops. Table 3.10 (all dimensions in mm) Part name Wear location Drg. No. -0.012 Anchor link silent block pin 25 mm /-0.052, thick ends RDSO-Sketch-94101 alt.1 +0.05 Anchor link silent block Outer dia. 90.5 /+0.025 RDSO-Sketch-94101 alt.1 +0.015 Anchor link housing Hole dia 90.5 / -0.03 T-0-7-605

Maintenance Manual for BG Coaches of ICF design Bogie

316f Equalising Stay Rod and Pins iii) Replace the following parts: (Small & Big) § bushes of BSS brackets if (Ref: Drawing No. RDSO Sk-88105 worn beyond permissible Alt.2 for 16.25t bogie and Sk-88018 limits Alt.6 for 13t bogie) § equalising stay bracket bushes i) Hot dip galvanised equalising § BSS pins if worn beyond stay of 16.25t bogie is used on permissible limits. all new coaches. The choice of iv) The locations where the repairs retro-fitment of these stays on have been carried out or found existing coaches is left to the corroded should be cleaned to Railways. For fitment of bare metal and painted with two equalising stays to Sk-88105 coats of primer to IS: 2074 to a Alt.2 on 13t bogies, follow minimum Dry Film Thickness RDSO Sk-93236. (DFT) of 50 microns followed ii) Replace the corroded equalising by one coat of anti-corrosive stays with new hot dip Black Japan Type-B to IS:341 galvanised stays. If any repair to a DFT of 35 microns, after like welding or straightening is which entire lower spring beam carried out, which damages the is to be given one coat of Black galvanising, repaint the Japan Type-B to IS:341 to a equalising stay with epoxy paint. minimum DFT of 35 microns. iii) Bushes should be replaced in every POH and fitted with Table 3.12 washers and split pins. Replace (all dimensions in mm) the equalising stay pins if worn Part name Wear Drg. No. out more than 1 mm in diameter. location BSS bracket Hole 38 H11 WLRRM- Table 3.11 bush (+0.16/ ) 0-5-002 -0.00 Eq. Stay Hole 42 H7 WLRRM - Wear Location (Dimensions in mm) +0.025 bracket ( /-0.0) 0-4-002 Part name Wear location +0.5 Pins for 16.25t axle Dia.31 ( /-0.2) 316h BSS Hanger load bearing capacity (Ref: Drawing No. T – 0 – 5 – 639) equalising stay +0.2 i) Check the cleaned hangers for Pins For 13t axle load Dia. 24 ( /-0.1) bearing capacity cracks and wear. Replace the equalising stay hangers if cracked or wear exceeds 1 mm. Magna flux 316g Lower Spring Beam crack detection equipment shall (Ref: Drawing No.WLRRM - 0 -5 - be used for checking. 002 for 16.25t bogie and T-0 -5 - 643 ii) The horizontal wearing surface for 13t bogie) may be built up using 2B electrodes, filed and ground to i) Check the lower spring beam size. Then hard powder coating (plank) for cracks, corrosion, etc. may be applied. Hardness value and repair or replace as required. should be 55-60 Rockwell-C ii) The following parts of the lower iii) The vertical gap should be within the permissible limit i.e., spring plank should be inspected +0.0 and repaired or replaced as 384 /-1.0 mm. All the hangers required: should be tested to tensile load § bolster suspension straps if of 8 tonnes and replaced if any bent or damaged permanent set is observed in the § stay rod brackets if worn, hangers. bent or corroded iv) After repair and testing all the § shock absorber fixing bosses BSS hangers should be painted if damaged with one coat of anti corrosive § spring guide rings if required black paint. Write the actual § lug if damaged. length between the wearing arms on the BSS hanger with paint.

Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.13 (all dimensions in mm)

Part name Wear location Drg. Nos. BSS hanger distance between horizontal wearing arms 384 T-0-5-639 BSS hanger thickness of vertical arm 25.5 -do- BSS hanger horizontal wearing surface 42 -do- Hanger block Thickness - 9.5 T-0-5-638 +0.4 Hanger block slot 29 ( /-0.2) -do- +0 BSS pin 29 ( /-0.1) T-0-5-637

316i Hanger Block (Stone) iv) Whenever an axle guide is (Ref: Drawing No.WLRRM - 0 - 5 – replaced due to damaged/ 203 and T-0-5-638) misalignment, preferably modified guide with circlip i) Replace the hanger blocks if arrangement may be fitted. cracked. Worn hanger blocks v) Common defects found in axle may be built up by welding with guide assembly during POH and 2B electrodes and machined to their reasons and remedies are size. After repair and testing all given in Annexure 3.1. the hanger blocks should be painted with one coat of anti- 317 COIL SPRINGS

corrosive Black Japan Type-B to i. Coil spring should be maintained IS:341. as per C-8419 (Rev.1) 316j Axle Box Guide Assembly ii. Clean the spring thoroughly, (Ref: Drawing No.WTAC3 - 0 - 1 – remove any oil, grease, etc. by 301 and T-0-1-636) putting them in a Bosch cleaning tank. After that carry out visual i. Use the modified guide cap inspection of the spring coil by (RDSO sketch no. 85070 Alt.3) coil. Carry out magna flux test to and its securing arrangement on detect cracks. Springs having existing bogies. New bogies are cracks, dents or hitting marks fitted with dash- pot guide should be rejected and scrapped. arrangement to T-0-1-641. Records should be maintained of rejected springs with details of ii. Replace the upper rubber defects noticed. washer, lower rubber washer, iii. Each spring should be subjected packing ring, guide ring, dust to incremental load up to the shield , guide bush, dust shield figure indicated in the table 3.16 spring, and spring clip as a kit. and 3.17 and the load should be maintained for a period of 2

minutes, after which the Table 3.14 corresponding height of spring

under load is determined. Critical Dimensions iv. Replace the upper rubber (dimensions in mm) washer, lower rubber washer, Component Dimension Drg. no. packing ring, guide ring, dust Lower hole 140 H7 RDSO Sk- +0.04 shield , guide bush, dust shield spring seat ( /-0.0) 90005 Alt.2 spring, and spring clip as a kit. Guide bush O.D. 140 A9 RDSO SK- -0.3 v. Replace the lower spring seat if ( /-0.6) 84102 Alt.5 worn, cracked, scored, etc. Guide bush hole dia 115 -do- +0.15 vi. Each spring may be tested for ( /-0) other deflections/loads indicated Guide Ring hole 115 H7 -do- in drawing and the spring +0.04 ( /-0) characteristics plotted. The spring should be replaced if its iii. Replace the lower spring seat if characteristics are not within worn, cracked, scored, etc. specified limits.

Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.15

Drawing code of springs for ICF BG coaches

(Reference RDSO Amendment slip no. 5 of September 2001 to STR WD-01-HLs- 94 (Rev.1 May 95)

Type of spring Type of bogies ICF Drg. No Drg. Code No. All Non AC ICF type F-0-1-006 A01 All AC ICF type WTAC-0-1-202 A03 Axle box Power car WLRRM2-0-1-202 A04 Double decker DD-0-1-001 A06 High capacity Power Car WLRRM8-0-1-802 A09 High capacity parcel van RDSO /SK-98017 A10 Bolster All Non AC ICF type F-0-5-002 B01 All AC ICF type WTAC-0-5-202 B03 Power car WLRRM2-0-5-202 B04 Double decker DD-0-5-003 B06 B11 High capacity Power car WLRRM8-0-5-802 B13 Bolster B15 High capacity Parcel van RDSO /SK-98018 B16

Table 3.16

Load deflection testing and grouping of Axle box spring (B.G Main line coaches)

Code Wire Free Test Acceptable Groups as per loaded spring height dia height Load height under test load A B C Yellow Oxford Green Blue* A01 33.5 360 2000 279-295 279-284 285-289 290-295 A03 33.5 375 2800 264-282 264-269 270-275 276-282 A04 35 372 3000 265-282 265-270 271-276 277-282 A06 36 337 2400 269-284 269-273 274-279 280-284 A09 37 360 3000 277-293 277-282 283-288 289-293 A10 39 315 1800 276-289 276-279 280-284 285-289 * As per RDSO's letter no. MC/SPG dated 25.7.01

Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.17

Load deflection testing and grouping of Bolster spring (B.G Main line coaches)

Code Wire Free Test Acceptable Groups as per loaded spring height dia height Load height under test load A B C Yellow Oxford Green Blue # B01 42 385 3300 301-317 301-305 306-311 312-317 B03 42 400 4800 291-308 291-296 297-303 304-308 B04 47 400 6100 286-304 286-291 292-297 298-304 B06 36 416 4200 280-299 280-286 287-292 293-299 B11 47 *386 6700 306-322 306-311 312-317 318-322 B13 34 B15 40 393** 6000 256-272 256-261 262-267 268-272 B16 32.5 286 ** * Combined load deflection test is done ** As per RDSO's letter no. MC/MV dtd. 21.11.01 # As per RDSO's letter no. MC/SPG dtd. 25.7.01

v. After load deflection test, the 318 BOGIE BRAKE GEAR acceptable springs should be given one coat of Red Oxide i. Repair or replace the worn, Zinc Chromate primer to damaged, corroded bogie brake IS:2074 to a minimum DFT of levers. Replace the bushes in the 50 microns. A coat of Black bogie brake levers. Nylon 66 Japan Type-B to IS:341 to a brake gear bushes to RDSO STR minimum DFT to 35 microns No. C-8107 should be fitted in should follow the primer coat to brake gear. have better abrasion resistance and corrosion resistance. Then ii. Repair or replace the corroded, the springs have to be painted cracked, or worn brake beams. with 50 mm wide vertical iii. Repair or replace the corroded, stripes at three locations, equi- dented, damaged brake head spaced on the circumference shoes. Replace the worn bushes, using different colours of paints adjuster, weakened spring, etc., to IS:8662 as given below: in all the serviceable brake head/ shoe. Spring group Colour code A Yellow iv. Replace the worn, damaged, etc. B Oxford Blue brake gear pins with new ground C Green finished and chromium plated pins. ‘Z’ lever pin shall be to vi. All the springs should be RDSO Sketch 98127. grouped in three groups as v. Replace the brake blocks if worn shown in table above, out to thickness of 20 mm or depending upon their deflection below. under test load. For pairing, springs should be selected from vi. Replace the weak and damaged the same group. Height under brake shoe key. test load should be painted on vii. All the brake gear components all springs to enable selection of should be given one coat of red springs. oxide primer and one coat of anti-corrosion Black Japan Type-B to IS: 341.

Maintenance Manual for BG Coaches of ICF design Bogie

319 BOGIE ASSEMBLY 319c Bolster Assembly Work Station

319a General i. Grease the BSS pins, hanger blocks, anchor link silent block pins and anchor link brackets Bogie assembly can be systematically with graphite grease. Ensure that carried out, if it is organised under bolster springs with height three workstations described (under test load) variation within hereunder. A sub store in the bogie 2 mm are selected in the same shop may be necessary to ensure group of springs for each bogie supply of proper components and sub- assembly. assemblies for bogie assembly. ii. Assemble lower spring planks, 319b Brake Gear and Axle Guide compensating rings, bolster Assembly Work Station spring, rubber washer and other

secondary suspension i. After the inspection, repair and components. Compensating alignment of BSS brackets, axle rings shall be specified in guides and the bogie frame, relevant suspension diagram place the bogie frame in the issued by PUs. Additional normal position on assembly compensating ring to maintain stands. bolster clearance of 40±3 can be added. Lower the bogie frame ii. Assemble the brake gear assembled with brake gear and components including brake axle guide assembly on the blocks on the bogie frame with bolster assembly. Connect the pins, washers and split cotters. bogie frame and lower spring Ensure that the cotters are split plank with BSS hanger with the minimum 90o and not slack in help of a dead weight. Connect the pins. Modified lever hanger the lower spring planks and pins (RDSO sketch no. 98127) bolster with equalising stays and should be used to prevent the pins. Secure the equalising stay bush working out of the lever pins with washers and split pins. hanger. Ensure that the Ensure that the split pins are maximum dimensional clearance split to minimum 90o and not between the pins and bushes is slack in the pins. Connect the 1.5 mm. bogie frame and bolster with anchor links. Secure the anchor iii. Apply some lubricating oil on links in the brackets with M12 axle guide outer surface and on hexagonal head screws and inside surface of guide bush. spring washers. Assemble the axle guide components on the axle guide iii. Replace the rubber sealing cap and secure them with guide cap on the centre pivot silent block. (whose 9 holes should be cleaned before securing) as per RDSO sketch no. 85070 Alt.3. 319d Bogie Lowering Work Station While tightening the guide cap, it should be ensured that guide i. Select the wheel sets such that bush sits tight against the rubber the maximum variation in tread packing ring and the holes in the diameter between the wheels on guide are in alignment with same axle as 0.5 mm, between corresponding holes in the guide two wheel sets in same bogie as bush. New coaches are fitted 5 mm and among the four wheel with modified axle guide sets in the same coach as 13 arrangement to T-0-1-641. mm. Select axle box springs in the same group of springs as given in table 3.16.

Maintenance Manual for BG Coaches of ICF design Bogie

ii. Assemble the lower rubber exceed 1.6 mm. The bogie washer, lower spring seat, should sit evenly on the four compensating ring, hard packing axle boxes. ring, selected axle box springs, upper spring seats, upper rubber v. The assembled bogie should be washer, protective tube, etc., as load tested on a bogie test stand per the drawing for axle box where it is loaded up to its guide arrangement. Put dash pot normal working load and the oil of approved brand in lower height of bolster top surface spring seat to a level of 60 mm form rail level should be from bottom. The approved measured for comparison with brands of dash pot oil are the pre-determined dimension following: corresponding to correct coach buffer height. Adjustment for a. Servoline - 100 of getting correct buffer height IOC b. Yantrol - 100 should be made, if needed. If the of HPC c. Bharat univol – buffer height requires further 100 of BPC adjustment, the load on the axle box spring should be released iii. For obtaining correct buffer and compensating rings should height when the coach body is be inserted below the axle box lowered on the bogies, while spring ensuring that the bogie assembling the bogie hard frame height is 686 ± 5 mm. rubber, UHMWPE or NFTC packing of required thickness, vi. Safety straps of the axle box depending on the wheel wing lugs and bogie bolster diameter, should be provided should be adjusted so as to under the flanges of the lower ensure a minimum clearance of spring seats. Packing rings of 40 mm between the lugs and thickness as given in table 3.18 bottom of safety straps. and as shown in figure 3.17 (RDSO sketch 77354) should be vii. Fit the vertical shock absorber used. Compensating rings of between the bolster and bottom suitable thickness as per spring plank. suspension diagram for relevant coach should be placed over the viii. Check the oil in the dash pots flange of the lower spring seat. with the flexible wire gauge and if necessary, top up the dash pots Table 3.18 with the approved brand of dash pot oil to bring the level to 60 Average tread Thickness of mm from under surface of dash diameter of two hard packing pot. If the flexible gauge wheel sets of bogie ring indicates a higher level of oil, 889 to 864 mm 13 mm the guide cap may have fallen in dash pot. This should be checked 863 to 840 mm 26 mm and attended to. 839 to 820 mm 38 mm 819 mm 48 mm ix. Axle box rubber bump stopper

should be adjusted to obtain the iv. Lower the bogie frame with the required clearance between the bolster assembly on the wheel axle box crown and the bogie sets thus prepared, taking care to frame. ensure that the rubber packing ring does not get damaged while x. After testing and making lowering the guide bushes on to adjustments for correct buffer the lower spring seat. The height, dispatch the bogie to maximum diametrical clearance Lifting shop for lowering the between the lower spring seat coach body. and guide bush should not

Maintenance Manual for BG Coaches of ICF design Bogie

DIMENSION `A' AS SHOWN BELOW

CROWN TYPE OF COACH CLEARANCE A mm

+0 GS,SDC,SLR,SCN 43 -3

A WCB,WCBAC,WFC,WFAC +0 -3 WGFAC,WSCWAC,WGCWAC 27

WGACCN,WACCN,WSCZAC

WGSCZAC,WFCZAC,WLRRM

1. INSERT 13 mm PACKING FOR 13 mm TREAD WEAR.

2. INSERT 26 mm PACKING FOR 26 mm TREAD WEAR.

3. INSERT 38 mm PACKING FOR 38 mm TREAD WEAR.

4. INSERT 48 mm PACKING FOR 819 DIA. TREAD.

BUFFER HEIGHT ADJUSTMENT (ICF COACH)

SKETCH-77354 FIGURE 3.17

Maintenance Manual for BG Coaches of ICF design Bogie

LIFTING SHOP which is indicated primarily by oil leakage or when they 319e Lowering the Coach Body in Lifting are physically damaged. Shop 2. Testing

i. Place the wearing plate and i) The shock absorber is tested wearing piece in side bearer oil- on the special purpose bath. Fill each side bearer oil- machine (RDSO sketch nos. bath with 2 litres of any of the 69.2.04.00 to 69.2.04.08) following approved brands of which can measure its oils. capacity in both tension and

compression by developing § Servoline – 100 of IOC the resisting force at a § Yantrol – 100 of HPC velocity of 10 cm/sec. The length of the shock absorber § Bharat univol – 100 of BPC and its stroke should be

within the limits specified in ii. Apply graphite grease on Centre the table 3.19. pivot pin and lower the coach body on the side bearer wearing ii) The shock absorber must be pieces. Care should be exercised tested at every POH and to make sure that the side reused if overhauling is not bearers are resting properly. due and the capacity is Place the cotter in position in Centre pivot pin and secure it within ± 20%. A register with a split pin. A bottom cover should be maintained in the should be fitted for covering the shock absorber section entire assembly to prevent dust wherein the test results of ingress. Tighten the air vent bolt each shock absorber should with gasket to prevent spilling of be recorded before the shock dash pot oil. absorber is certified fit for use on coaches. 319f Shock Absorbers iii) After the testing and Reference may be made to RDSO certification, the protection specification C-8703 (Rev.1) for cover of the shock absorber hydraulic shock absorbers for should be pressed into coaching stock. position on the piston rod disc and spot welded at six 1. Periodicity of overhaul points around the periphery.

i) Schedule overhaul: Shock iv) The shock absorber should absorbers should be given a then be extended on the schedule overhaul: mounting fixture and painted. When the paint dries, it a. When their capacities should be compressed and vary beyond ±20% of then removed from the their specified values, fixture. or v) The date of testing, the date b. After 4 lakh kilometers of overhauling and the name or alternate POH, of the shop where overhauled whichever is earlier. should invariably be stamped on the name plate of the ii) Non schedule overhaul: shock absorber before it is Shock absorbers should also sent for fitment. be overhauled whenever suspected to be defective,

Maintenance Manual for BG Coaches of ICF design Bogie

Table 3.19

Length (mm) Nominal Variation from Maker’s Type Stroke Nominal Compressed Nominal Extended (mm) Min. Max. (mm) (mm) Vertical shock absorbers:

M/s ESCORTS 250 ± 3 320 ± 3 360 ± 3 110 -70 40 M/s KNORR BREMSE

M/s GABRIEL ICF/SK-0-5-015

320 LIST OF TOOLS AND PLANT

LIFTING SHOP FITTING SHOP

Ball peen hammer Ball peen hammer Chisel Chisel Spanner Welding transformer Gas cutting plant WASHING PLANT Hydraulic press Measuring gauges Bosch tank Center lathe Hot water jet system Brake beam end turning m/c Bins and pallets Electrode heater Jib crane Hard surface plant Fork lift BSS hanger testing m/c Platform truck Bins and pallets Fork lift BOGIE SHOP Platform truck

Ball peen hammer SMITH SHOP Chisel Spanner set Helical spring repair tools & Welding transformer plant Gas cutting plant Shot peening plant Bogie alignment gauges Heat treatment plant Spring testing machine Smith’s tongs, hammers & Magnaflux crack detector blocks Paint brushes Floor scraper Bogie frame repair fixture Bolster repair fixture Bogie test rig Working stands Overhead crane Bins and pallets Fork lift Platform truck

Maintenance Manual for BG Coaches of ICF design Bogie

321 EXAMINATION AND REPAIR 321b Primary Suspension

PRACTICE IN CARRIAGE MAINTENANCE DEPOT i) Primary/Secondary Examination

Depot maintenance staff should ensure the following things in respect § Visually examine axle box of proper functioning and safety of springs for breakage. Bogie & Bogie components. § Visually examine dash pot oil filling special screw for 321a Bogie Frame deficiency. § Check oil leakage in dash pot i) Primary/Secondary through defective seals/vent Examination, Schedule A & screws. B Examination § Visually examine axle box clearance § Examine visually condition of bogie side frame, transom, ii) Schedule A & Schedule B

longitudinals and all welded locations. § Examine as per (i) above. § Examine rubber stopper/stop screw of axle box crown for § Add specified grade of oil in damage/missing/loose. dash pot. § Inspect axle box safety § Visually examine axle box straps/loops for clearance. damage/broken/missing. § Bolster safety straps/loops for iii) Schedule C damage/broken/missing. § Brake hanger brackets for § Examine as per (ii) above. damages. § Check and attend axle guide § Inspect safety brackets for assembly if necessary. brake hanger pins. § Check axle box clearance with § Check visually BSS hanger gauge brackets.

§ Examine visually anchor link brackets. 321c Secondary Suspension § Visually examine centre pivot mounting bolts and attend if i) Primary/Secondary needed. Examination, Schedule A, B & C examination § Visually inspect centre pivot cover. § § Side bearer oil to be Visually examine bolster springs replenished in A & B breakages/damages. schedules, if needed. § Visually examine Bolster lower spring beam. ii) Schedule C Examination § Visually examine BSS hangers, hanger blocks, BSS pins. § Examine as per (i) above. § Check bolster clearance between § Examine condition of wearing top of bolster and bottom of piece and wearing plate bogie frame. § Examine oil level in side § Visually examine equalising stay bearer oil baths and replenish rods and pins (small and big). if oil level has gone down below the level of last thread § Visually check anchor links. of oil filling cup.

Maintenance Manual for BG Coaches of ICF design Bogie

§ Examine Visually anchor link § Examine and attend floating securing bolts and attend if lever suspension brackets needed. § Examine lever hanger pins. § Visually examine Equalising

stay rod brackets. 321e Bogie to be run out if found § Examine and attend safety loops necessary/During IOH following of bolster. should be done § Check and attend safety loops of Equalising stay rod. § Examine and replace all the § Examine vertical shock brake gear components found absorbers for damages. deficient / worn out. § Examine and replace primary 321d Brake Rigging and secondary suspension components as required. i) Primary / Secondary Examination § Examine wheel profile and thickness and gauge in case they appear to be near condemning § Check brake gear and adjust so limit that the piston stroke is within the limit. 322 SAFETY PRECAUTIONS § Examine brake beams breakages/damages. § Whenever a coach is examined § Check and attend brake beam at maintenance depot, it should safety wire ropes/safety straps. be ensured that the prescribed § Check and attend brake shoe number of safety straps, safety head and key & replace if wire rope, axle box safety strap, necessary. bolster safety loop, centre pivot cap, hangers or brackets of § Check and replace worn brake specified dimension and sections blocks. required for various components § Visually inspect and replace are fitted at specified location. brake hangers, brake gear pins § All fasteners e.g. bolts, nuts, and cotters/split pins if cotters etc. used in under frame necessary. equipments, brake gear, buffing § Visually inspect and replace and draw gear should be damaged/missing brake gear checked. bushes if necessary.

ii) Schedule A, B & C Examination

§ Examine as per (i) above.

§ Check and attend brake block adjuster. § Examine and attend brake levers.

Maintenance Manual for BG Coaches of ICF design Bogie

Annexure - 3.1

COMMON DEFECTS FOUND IN AXLE GUIDE ASSEMBLY

S.No. Defects Reason Remedies

1. Perished rubber Poor quality of rubber 1) Replace rubber packing ring at every packing ring packing ring examination. 2) Use only rubber packing rings conforming to IRS specification no. R- 47-72 and the relevant drawing. 2. Axle guide found 1) Misaligned fitment 1) The alignment of axle box guide worn on one side of axle guides to should be checked with alignment bogie frame. gauges and corrected. 2) Dust ingress to 2) Vent hole should be sealed with lower spring seat. gaskets. Screw to be tightened well after oil topping.

3. Axle box spring Do Do rubbing upper spring seat 4. Guide bush worn Do Do 5 Lower spring Do Do surface worn 6. Guide ring broken 1) Axle guide is 1) Guide securing bolt should not project hitting lower out of guide cap. spring seat 2) Use good quality upper and lower 2) Weld joint of rubber washers and correct number of lower spring seat compensating rings in the axle guide and tube is porous assembly. or cracked 3) Adjust A, B and C clearances on leveled track. 4) Strip and reweld lower spring seat correctly. 7 Guide cap securing Do Do assembly broken 8. Lower spring seat Do Do scored and dent mark on guide cap 9 Dust shield spring Do Do broken or distorted 10 Leakage from Do Do lower spring seat

******

Maintenance Manual for BG coaches of ICF design Air Brake System

CHAPTER 4

AIR BRAKE SYSTEM

401 INTRODUCTION 403a Charging the brake system

In Air Brake system compressed air is § Brake pipe throughout the length of used for operating the brake system. The train is charged with compressed air locomotive compressor charges the feed at 5 Kg/cm2. pipe and the brake pipes throughout the § Feed pipe throughout the length of length of the train. The feed pipe is train is charged with compressed air connected to the auxiliary reservoir and at 6 Kg/cm2. the brake pipe is connected to the brake § Control reservoir is charged to cylinder through the distributor valve. 5 Kg/cm2. Brake application takes place by § Auxiliary reservoir is charged to 6 dropping the pressure in the brake pipe. Kg/cm2.

402 CLASSIFICATION OF AIR BRAKE 403b Brake application stage SYSTEM § For brake application the brake pipe The schematic layout shown in figure 4.1 pressure is dropped by venting air illustrates the underframe mounted twin from the driver’s brake valve. pipe graduated release air brake system on Subsequently the following actions main line coaches. The components and take place their relative location is indicated in the schematic layout. § The control reservoir is

403 PRINCIPLE OF OPERATION OF disconnected from the brake TWIN PIPE GRADUATED RELEASE pipe. AIR BRAKE SYSTEM (See figure 4.1)

vent type vent type Figure 4.1 SCHEMATIC LAYOUT OF TWIN PIPE GRADUATED RELEASE AIR BRAKE SYSTEM Note: Pressure gauges are installed only in guard’s brake van.

Chapter 4, Page 1 of 50

Maintenance Manual for BG coaches of ICF design Air Brake System

§ The distributor valve connects The brief details of the air brake the auxiliary reservoir to the components and it’s maintenance and test brake cylinder and the brake procedure is described below:

cylinder piston is pushed outwards for application of 405 COMMON PIPE BRACKET brakes. § The auxiliary reservoir is Common pipe bracket is mounted on the however continuously charged coach under frame and is suitable for use from feed pipe at 6 Kg/cm2. with all type of distributor valves presently in use on main line coaches. Table 4.1 406 INTERMEDIATE PIECE Description Reduction in B. P. (SANDWICH PIECE) Pressure Minimum Brake 0.5 to 0.8Kg/cm2 An intermediate piece is mounted on the Application common pipe bracket to fit the distributor Service Brake 0.8 to 1.0Kg/cm2 valve on the common pipe bracket. The intermediate piece serves the purpose of Application blanking all the other ports on the Full Service Brake 1.0 to 1.5Kg/cm2 common pipe bracket other than required Application for a particular make of distributor valve. Emergency Brake Brake pipe is fully Each type of distributor valve is mounted Application exhausted and its on the common pipe bracket with its own pressure reduces to intermediate piece. almost zero. 407 AIR BRAKE HOSES 403c Brake release stage: 407a Brake Pipe & Feed Pipe Hoses § Brakes are released by recharging (see figure 4.2) brake pipe to 5 Kg/cm2 pressure

through the driver’s brake valve. To maintain continuity through out the § The distributor valve isolates the length of train, the brake pipe (BP) and brake cylinder from the auxiliary feed pipe (FP) are fitted with flexible reservoirs. hoses. Each hose is provided with palm § The brake cylinder pressure is vented end coupling. For easy identification, to atmosphere through DV and the coupling heads are painted with green Brake cylinder piston moves colour for B.P and white colour for F.P.

inwards. Also raised letters 'BP' and 'FP' are

404 AIR BRAKE SUB ASSEMBLIES embossed on coupling heads representing Brake Pipe and Feed Pipe respectively. The various Air Brake sub-assemblies and Hose couplings must be checked for components are: leakage of air as per the test procedure given below:: i) Common pipe bracket ii) Intermediate piece iii) Brake pipe and feed pipe iv) Brake pipe coupling v) Cut-off angle cock vi) Brake cylinder vii) Dirt collector viii) Auxiliary reservoir ix) Slack adjuster x) Distributor valve xi) isolating cock xii) PEASD xiii) PEAV xiv) Check valve

Figure 4.2 - AIR BRAKE HOSES

Chapter 4, Page 2 of 50

Maintenance Manual for BG coaches of ICF design Air Brake System

407b Test Procedure (see figure 4.3) § Observe leakage, if any from all parts of the hose coupling. For testing the hose coupling the steps § Close the isolating cock 1(b). given below should be followed: § Disconnect the hose coupling from

§ Use a dummy coupling head to test bed. block the outlet port of the hose § If the leakage is observed through coupling. the coupling head, replace the § Connect to hose coupling under gasket and test again. test to the end of flexible hose. § If leakage persist even after change of gasket the coupling head is § Open isolating cock 1(a) § Adjust pressure regulator (2) so unserviceable and complete that pressure gauge (6a) shows assembly shall be rejected. 2 However if leakage occurs at the 10Kg./cm air pressure. hose nipple or coupling end hose § Immerse the hose coupling assembly completely in the tub of joint the clamp should be attended/replaced to make the water. assembly leak proof. § Open isolating cock (1b) and see that (6b) shows 10 Kg/cm2 pressure.

Kg Cm 6a MR 6b Kg Cm CHARGING PRESSURE GAUGE 11/4” BSP SOCKET TO MAIN RESERVOIR ISOLATING COCK COUPLE HOSE PRESSURE REDUCER ISOLATING COCK COUPLING NIPPLE END

6 1a 1b 2 4 1c FLEXIBLE HOSE HIGH PRESSURE EXHAUST COCK (10 KG/CM2 CAL) figure 4.3 – TEST BENCH FOR HOSE COUPLING

408 CUT OFF ANGLE COCK on either end of each coach to facilitate (see figure 4.4) coupling and uncoupling of air hoses. When (Ref: Drg. No. WD-88123-S-01 the handle of the cut off angle cock is and WD-88123-S-01) placed in closed position it cuts off the passage of compressed air, there by Cut off angle cocks are provided facilitating coupling and uncoupling action. both on brake pipe & feed pipe

Figure 4.4 - CUT OFF ANGLE COCK

Chapter 4, Page 3 of 50

Maintenance Manual for BG coaches of ICF design Air Brake System

The cut off angle cock consists of two (b) Screw driver 12”/300 mm long. parts viz. cap and body which are secured (c) Vice. together by bolts. The cap and the body (d) Light hammer. together hold firmly the steel ball inside it, which seated is on nitrile rubber seat. 408c Procedure The ball has a special profile with the provision of a groove at the bottom i) Dismantling portion for venting the air to the atmosphere. § Hold the cut – off angle cock in a vice. On the top surface of the body a bore is § Unscrew the lock nut from the stem. provided for placing the stem, to which a § Take out the handle assembly (The self locking type handle is fixed. When handle assembly need not be the handle is placed parallel to the cut off dismantled further unless it is angle cock the inlet port of the cut off necessary to change the plate spring angle cock body is connected to the outlet i.e. if it is found, heavily rusted, port, through the hole provided in steel pitting crack or the spring is ball. Thus air can easily pass through the permanent set). cock. This position of the handle is known § Unscrew the four hexagonal bolts as open position. When the handle is and spring washers. placed perpendicular to the cock body the § Detach cap from the body. steel ball gets rotated and the spherical § Remove ‘O’ ring and ball seat from and groove portion of the ball presses the cap. against the sealing ring at inlet and outlet § Turn the stem in such a way that the port, there by closing the passage of inlet ball can be pulled from the stem. air and venting the outlet air through the § Slightly hammer the stem at its top vent hole. This position of the handle is and take out the stem through the known as closed position. bore of the body. With the stem one leaf spring is provided § Remove the ball seat from the body. which presses the operating handle downwards. By virtue of this, handle gets ii) Cleaning of Parts seated in deep grooves at ON / OFF position resulting in a mechanical lock. § Clean out side portion of the body and cap with wire brush. Under normal working conditions, the § Direct a jet of air to remove the dust. handle of all cut off angle cocks of BP are § Clean all metallic parts with kept open except the rear end angle cocks kerosene oil and wipe dry. (BP). This facilitates in charging the complete air brake system with iii) Replacement of Parts compressed air supplied by the compressor housed in the locomotive. Cut § Replace all rubber parts. off angle cock fitted on the brake pipe is § Replace spring-washer, nut & bolts painted green. in case they are excessively corroded or defective. 408a Overhauling of Cut Off Angle Cock § Replace handle spring if it is found heavily rusted, is having pitting The cut-off angle cock is to be completely crack or is permanently set dismantled and overhauled in every POH or when there is some specific trouble. (Dismantle the handle assembly, and fit a new spring along with a snap During overhauling, it is dismantled for head rivet). cleaning, replacement of parts and checking for effective functioning. The § Replace stainless steel ball if found with scratch marks on the outer POH kit should be as per annexure 4.3. surface or dented. 408b Tools & Equipment iv) Assembly The following tools and fixtures are required for overhauling § Insert the two ‘O’ rings in their

(a) Single end spanner. respective grooves on the stem. 1) A/F 17 for M10 nut pivot screw. 2) A/F 10 for M6 nut.

Chapter 4, Page 4 of 50

Maintenance Manual for BG coaches of ICF design Air Brake System

§ Keeping the threaded end of the § Check pressure drop in gauge (6b) stem first, insert the stem into the there should not be any leakage from body through the bore of the body. flange joints, vent and outlet port of § Place one ball seat in its groove the angle cock. inside the body. § Close cock (1c) and tighten the § Position the ball after correctly dummy plug and seal the outlet of aligning its venting slot in the bore the angle cock. of the body. § Move the handle to the open § Place the second ball seat and ‘O’ position. Open cock 1c. ring in their respective positions on § Check for leakage from body and the cap. cap joint, vent and all over the stem § Secure the body and cap by Hex. periphery using soap water. No Hd. Bolt (M6) and spring washer leakage is permissible. (for M6). § Move the handle to closed position § Place the handle assembly on the and notice a short blast of air through stem and secure it with Hex. Hd. the vent. Nut (M10). § Close cock 1c then Open cock (1d) § During assembly apply a light coat and exhaust the pressure to zero. of shell MP2 or equivalent grease on § Remove the angle cock. the external surface of the threads § Report results of the test. and the ball. iii) Safety Precautions 408d Testing of Cut Off Angle Cock § Specified tools and fixtures should be used for assembly and i) Tools and Equipment disassembly operations.

§ The small metal parts like leaf § Test Bench spring, nut, bolts, washers, screws § Compressor to build pressure upto etc should be kept in a safe place 10 kg/cm2 . and replaced in case found § Single ended spanner as per IS 2027 defective. a) Across face 17 (for M10 lock § Inlet and outlet port of the tested nut) 1No. angle cock should be plugged with b) Across Face 13 (for M8 studs) 2 protection cap to prevent entry of No. dust and moisture inside the cut off § Screw Driver –300mm,1 No. angle cock. § 1 ¼ “ BSP dummy Plug with seal. § Dummy plug for angle cock. 409 BRAKE CYLINDER (see figure 4.5) (Refer Drg. RDSO SK-97015) ii) Test Procedure (refer figure 4.9) On every coach fitted with air brake Following test procedure sh ould be system two brake cylinders are provided adopted for performing the leakage test. for actuating the brake rigging for the application and release of brakes. During § Mount the angle cock on the base of application of brakes the brake cylinder the test bench (Part No. 7 of the develops mechanical brake power by figure 4.9 of the test bench). outward movement of its piston assembly § Move the handle to the closed after receiving air pressure from Auxiliary position. reservoir through the distributor valve. § See that cock (1e) and (1c) are in This is transmitted to the brake shoes closed position. through a combination of levers. During § Now open cock 1(a) and 1(b) till release action of brakes the compression MR indicates a pressure of 10 spring provided in the brake cylinder 2 Kg/Cm . brings back the rigging to its original § If necessary, adjust pressure position. The cylinder body is made out of regulator (2) to maintain the sheet metal or cast iron and carries the 2 pressure at 10 kg/Cm . mounting bracket, air inlet connection, § Open cock (1c) and check the ribs and flange. To the cylinder body, a leakage with soap solution. There dome cover is fitted with the help of bolts should not be any leakage. and nuts. The dome cover encloses the spring and the passage for the piston

Chapter 4, Page 5 of 50

Maintenance Manual for BG coaches of ICF design Air Brake System

Figure 4.5 – BRAKE CYLINDER

trunk, which is connected to the piston by Sr. Description screws. The piston is of cast iron having No. a groove in which piston packing is 4. Socket Wrench 19 mm (For seated. Piston packing is of oil and M12) abrasion resistant rubber material and is 5. Screw Driver 12" (300 mm) snap fit to the piston head. The packing 6. Special fixture (Screw press/ has self lubricating characteristic which Pneumatic) ensures adequate lubrication over a long 7. Gauge for examining bore of the service period and extends seal life cylinder considerably 409c Dismantling of Brake Cylinder The piston packing also seals the air- flow from the pressure side to the other side Before dismantling the dome cover insert and is guided by the wear ring. The wear a bolt f 12x25 long and secure one of the ring prevents the friction between cylinder hole in the piston trunk for the purpose of body and the piston head. The piston sub safety to prevent dome cover working out assembly incorporates a push rod, which of the piston rod due to the cylinder return can articulate and take minor var iations in spring force. alignment during fitment/operation. For preventing knocking during running, a § Unscrew the Hex. HD nut and take rubber anti rattler ring is also provided. out the spring washer on the dome cover. 409a Overhauling of Brake Cylinder § Turn the handle of the fixture to

Brake cylinder has to be thoroughly release the clamp and withdraw the overhauled for efficient and reliable holding clamp of the fixture till the trouble free performance during its return spring inside the cylinder is prolonged service life. The complete fully expanded and free. overhauling of the brake cylinder is to be § Remove the dome cover and take carried out every POH of the coach. out the return spring. § Remove the piston rod sub- 409b Tools & Equipments assembly, piston ring packing, wear ring and slide out the anti Sr. Description rattler ring from the piston rod. No. § Unscrew the CSK , head screw and 1. Torque Wrench 0-3 Kg m range separate the piston, pin, and piston 2. Double End Spanner 24x27 mm trunk & piston rod assembly. across face (For M16) § Unscrew the brake cylinder plug at 3. Double End Spanner across face the rear end. 13x14 (For M12)

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Maintenance Manual for BG coaches of ICF design Air Brake System

409d Cleaning of Parts § Smear the piston head & inside the cylinder body with MP 2 grease or § Blow a jet of air to clean the dust equivalent. on the external surface. § Ease the packing into the cylinder § Clean the metallic parts using wire with a wooden spatula with a brush and kerosene oil. round nose and round edge to § Clean the internal parts with nylon avoid damage to the piston bristle brush. packing. Clean piston packing, wear ring § § Push the piston assembly and rubber parts with soap water approximately to the central solution. position of the cylinder. 409e Replacement of Parts § With the help of special fixture, bring down the dome cover on to § Replace return spring in case of the cylinder body and fasten the 8 crack, kinks or permanent set. Hex. HD bolt, nut and spring § Replace the brake cylinder body if washer with required torque. found with deep marks, heavily § Take out the f 12x25 long pin corroded, or the bor e is worn from the piston trunk hole. uneven or having ovality. § Fit back the plug at the rear of the § Replace all rubber parts. cylinder. § If piston trunk is worn excessively it should be replaced. 409i Testing of Brake Cylinder (see

409f Inspection and Repairs of the Parts figure 4.6)

§ Examine visually that the internal i) Brake Cylinder Test Bench surface is free from scratches, rust. § Brake cylinder bore to be checked Test bench consists of the following for ovality with gauge. main parts § Check the characteristics of the a) 5 nos. of isolating cocks (1a, 1b, return spring. 1c, 1d, 1e and 1f). § Piston trunk to be checked for wear b) Pressure reducing valves as and tear. below § Pin, piston rod should be checked c) 2a - to be set on 10 Kg/cm2. for wear. d) 2b - to be set on 6 Kg/cm2. § Dome cover shall be checked for e) 2c - to be set on 0.8 Kg/cm2. excessive wear and if worn build 2 up with welding and thereafter re- f) 2d - to be set on 3.8 Kg/cm . bore to the required size. g) Pressure gauges § Gauge, bush bore of the piston rod, h) 6a - to measure supply pressure. replace it if worn. i) 6b- to measure brake cylinder

409g Testing of Brake Cylinder Body for pressure. Leakage j) Pipe line filter – Item no 3 k) Brake cylinder pressure Before assembly, put dummy plate on the mounting base with fixture –Item dome side and subject the brake cylinder no 4 for hydraulic pressur e of 10 kg/cm2 for 5 minutes. No leakage is permitted. l) Air reservoir – Item no.5

ii) Tools required during Testing 409h Assembly of Brake Cylinder

§ Assemble piston rod, pin, and piston a) Torque wrench range (2-3 kgm trunk on piston, tighten CSK screws capacity) – One number. to piston trunk and piston. b) Double ended spanner (M16) § Slide anti-rattler ring from the piston across face 24x27 – One number. front side. c) Socket wrench (M12) across face § Assemble piston return spring on the 19 – One Number. piston head and insert the dome d) Double ended spanner (M8) cover over the piston trunk. across face 13x14 – One number. e) Screw Driver – 300mm – One § Insert f 12 x 25 mm long head pin into the hole provided in the number. extended portion of the trunk.

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Maintenance Manual for BG coaches of ICF design Air Brake System

Ref. No. of Description No. of Ref. No. of Description No. of Isolating cock Pressure Reducing valve 1a Supply angle cock 1 2a Set on 10 kg/cm 2 1 1b Angle cock 1 2b Set on 6 kg/cm2 1 1c Angle cock 1 2c Set on 0.8 kg/cm 2 1 1d Angle cock 1 2d Set on 3.8 kg/cm 2 1 1e Exhaust cock 1 3 Pipe line filter 1 1f Angle cock 1 4 Brake Cylinder pressure 1 mounting base 5 Air reservoir 1 Pressure Gauge 6a Supply Pressure 1 6b Brake Cylinder Pressure 1

Figure 4.6 – TEST BENCH FOR BRAKE CYLINDER

After the overhauling of the brake § Check the brake cylinder piston cylinder, it is mounted on the test bench stroke at 0-5 kg/Cm2 pressure and tested. It should be operated a few for its jerk free smooth times on the test bench to ease the piston. movement. Each brake cylinder after its maintenance § Close the safety guar d. and overhaul shall be subjected to the § Close the cock (1b), (1c) and following tests on the test bench. (1d).

§ Open cock (1a) and (1f) and let a) Strength test b) Pressure Tightness Test. the reservoir pressure increase. § Set pressure regulator (2a) at 2 iii) Strength Test 10Kg/cm . § Monitor the pressure in the For strength test, procedure reservoir with the help of the MR described below should be follow: Gauge (6a). § Let the pressure reach upto 10 § Place the repaired/overhauled kg/cm2. brake cylinder body on mount ing § Open cock (1b) so that air base of the test stand. This collected in the reservoir is mounting base (4) is provided transferred to the brake cylinder. with a safety guard. § Adjust the pressure in the brake § Connect the air pressure line to cylinder with the help of the the brake cylinder. pressure regulator (2b).

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Maintenance Manual for BG coaches of ICF design Air Brake System

§ Monitor the pressure in the brake This will discharge the brake cylinder with the help of the cylinder. pressure gauge (6b). § Remove the brake cylinder from § Close the cock 1(b) as soon as the test stand. 2 pressure reaches 6 kg/cm . § If operation is not correct or § Wait for 2 minutes. leakage rate is higher, dismantle § Brake cylinder should withstand the brake cylinder and examine this pressure. the piston packing wear ring for § Open cock (1e), this will proper fitment, examine the discharge the air pressure from fitment of the plug for leakage, the brake cylinder and the piston reassemble the components and assembly will come back. retest.

v) Precautions during Testing iv) Pressure Tightness Test

§ Safety Guard should be used Brake cylinder when fully assembled during the strength test. must be tested for leakage. For § Assembled or dismantled brake pressure tightness test, procedure cylinder should be stored in such described below should be followed. a way to prevent the following:

§ Mount the brake cylinder on the i. Flange surface should be test stand and tighten the prevented from damage. mounting bolts and nuts. ii. Inlet port should be plugged § Set the brake cylinder, piston with a protective cap to stroke at 85+ 10 mm and the prevent the entry of dust and pressure regulator (2c) at 0.8 moisture inside the brake 2 Kg/cm . cylinder. § Open cock (1c) and let the air be transferred to the brake cylinder § Avoid damage to piston packing till the air pressure reaches upto by dull or sharp edged thin 0.8 kg/cm2. Monitor this bladed tool. pressure with the help of the § Fit 12 dia, 25 mm long round pressure gauge (6b). headed pin on the hole provided § Close cock (1c) as soon as the in the extended portion of trunk pressure reaches upto 0.8 surface before loosening the kg/cm2. cover bolts. § Excessive lubrication of the § Wait for 1 minute till the cylinder must be avoided. pressure stabilizes in the gauge § Specified tools and fixtures (6b). Measure the final pressure should be used for handling, in the gauge (6b). mounting and removing the § Check for the pressure drop, brake cylinder from the test which should not be more than bench. 2 0.1 kg/cm in 10 minutes. § The small metal parts like § Open cock (1e). springs, washer, screws, nuts, bolts, washers should be kept in § Close cock (1c) and open cock (1d). a safe place and replaced in case found defective. § Repeat the test by setting the piston stroke at 130+10 mm. 410 DIRT COLLECTOR (See figure 4.7 & This time the air pressure is to be 4.8 ) (Ref. Drg. RDSO. SK-97005) maintained in the cylinder at 3.8 2 kg/cm with the help of the 410a Salient features of Dirt Collector pressure regulator (2d ) at 3.8 Kg/cm2. As above, the leakage 2 Dirt Collector is placed in the brake pipe should not exceed 0.1 kg/cm in line and feed pipe line at a point from 10 minutes. where a branch is taken off to the § After the test is over, close the distributor valve and the auxiliary cock (1d) and the open cock (1e). reservoir . The air entering into the dirt

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Maintenance Manual for BG coaches of ICF design Air Brake System

410b Tools and Fixtures for overhauling

The following tools and fixtures are required for overhauling:

a) Spanner 19 x 22mm b) Vice. c) Screw Driver

410c Procedure for Overhauling

i) Disassembly

Figure 4.7 - COMPONENTS OF DIRT § Hold the dirt collector in vice. § Loosen drain plug and remove it COLLECTOR completely from housing. collector from the brake pipe and feed § Remove top cover and seal by pipe is guided through suitably shaped loosening four hexagonal nuts and passages in the dirt collector body to removing hexagonal bolts. produce centrifugal flow. The air is then § Remove filter from body. filtered through additional filter assembly before it is passed to outlet on branch pipe ii) Cleaning of Parts side to provide dust proof air to the distributor valve /auxiliary reservoir after § Clean all metallic parts using brush arresting fine dust particles. The dirt and kerosene oil. contained in the air descends down and § Clean filter with soap water. gets deposited in the dirt chamber. § Check all parts for any damage. However, fine particles are also arrested in the filter assembly. The dust particles iii) Replacement of Parts

accumulated in the dirt chamber are removed by opening the drain plug. § Replace sealing ring and gasket. Rubber gasket is provided between the § Replace filter if found punctured cover and housing to prevent leakage. or damaged. Similarly leather washer is provided between the housing and the drain plug to Check spring washer and replace in prevent leakage. case defective or excessively corroded. The dirt collector is to be completely dismantled and overhauled in every POH.

Fig. 4.8 - SECTIONAL VIEW OF DIRT COLLECTOR

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Maintenance Manual for BG coaches of ICF design Air Brake System

iv) Assembly § Keep cocks ( 1f), (1c) and 1(e) § Assemble body after smearing closed. grease. § Open cock (1a) and (1b). Locate filter in position and § § Charge the reservoir (5) to 10 assemble top cover with new kg/cm2. gasket. § Close two openings on the dirt § Fix hexagonal bolts/nuts along collector using dummy flanges. with the spring washer. § Open cock (1e), check the § Fix new sealing ring to the pressure at (6c). it should be bottom and assemble drain plug. equal to 10 kg/sq. cm.

§ If not develop pressure up to 10 410d Testing of Dirt Collector 2 kg/cm by adjusting pressure Testing of dirt collector is needed after its regulator (2). overhauling. § Close cock ( 1e) § Check for leak over the body and i) Tools and Equipment joints with the help of soap

§ Test Bench solution, no leak is permitted. § Compressor, capable of building § Also check for pressure drop in air pressure up to 10 kg/sq. cm. gauge 6 (c)- for 3 minutes § Double ended spanner (Across § Pressure in the gauge 6c should Face 19x22) – One No. be maintained. § Dummy flange for dirt collector § Reduce the pressure in the main 2 – 2 nos. reservoir (5) to 5 kg/cm by opening cock (1f) and adjusting ii) Test Procedure (refer figure 4.9) the pressure regulator (2).

§ Close cock (1f) as soon as § Mount the dirt collector on base pressure reaches upto 5 kg/cm2. of the test bench.

Fig. 4.9 - TEST BENCH FOR ANGLE COCK, ISOLATING COCK, DIRT COLLECTOR, CHECK VALVE AND GUARD'S EMERGENCY VAN VALVE

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Maintenance Manual for BG coaches of ICF design Air Brake System

§ Remove the dummy flange from 411c Procedure for Overhauling the outlet port (which feeds to the distributor valve). i) Dismantling § Check for free flow of air from the outlet port. (If air is not § Unscrew the drain plug and drain flowing freely it means that the cock. filter is choked). § Drain the water accumulated ni the § The pressure will soon exhaust tank. through the outlet port. ii) Cleaning of Parts § Remove the dirt collector from

the test stand. § Examine the outer surface for any

pitting, scales or rusting. 411 AUXILIARY RESERVOIR § Clean the exterior of the auxiliary (refer figure 4.10) reservoir with a wire brush.

411a SALIENT FEATURES § Pour kerosene oil in to the auxiliary reservoir and roll few times and

drain the oil. The auxiliary reservoir is a cylindrical vessel made of sheet metal. On both the § Dry the interior of the reservoir with a jet of air. ends of the reservoir, flanges are provided § Rinse the reservoir with RUSTO- for pipe connections. One end of the LINE and then with ESSO-RUST auxiliary reservoir is connected to the 392 or equivalent. brake pipe through the distributor valve. § Clean the drain plug with a wire Auxiliary reservoir is charged through the brush. feed pipe to a pressure of 6kg/sq cm. At § Auxiliary reservoir shall be painted the bottom of the auxiliary reservoir, a on the exterior with two coats of zinc drain cock is provided for draining out the chromium primer and two coats of condensate /moisture. The auxiliary black enamel. reservoir should be overhauled in every POH. iii) Replacement of Parts Note: The dimension & tolerances of the auxiliary reservoir shall be as § Replace the plug washer. indicated in latest revision of RDSO § Replace the plug if threads are rusted drawing number SK-96081. or damaged.

411b Tools and Equipment for overhauling iv) Assembly

Spanner A/F 19x22. Assemble the drain plug with washer by Light hammer screwing it back into its position

Figure 4.10 – AUXILIARY RESERVOIR

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Maintenance Manual for BG coaches of ICF design Air Brake System

411d Testing of Auxiliary Reservoir 412a Salient Features

i) Air Pressure Test The guard’s emergency brake valve § Block one side passage of the consists of a housing in which a ball is auxiliary reservoir with dummy housed. The ball has a through hole flange. similar to the isolating cock. To the ball a § Admit air pressure from the other handle is fixed at the top. By operating the side passage at 10 Kg/cm2. handle the ball can be rotated along the § Check the leakage at the weld seams, vertical axis. When the hole in the ball with soap water solution. gets aligned with the inlet and the exhaust § No leakage is permitted. port the compressed air can pass through the valve. However, for restricting the ii) Hydraulic Test flow of air a choke of 5mm is fitted in the exhaust port for controlling the rate of BP § With a hydraulic pump, apply a exhaust. The inlet port of the valve is pressure of 16 Kg/cm2 from one connected to the brake pipe. In case of an flange end after blocking the emergency, the guard moves the handle of opposite end. the guard’s emergency brake valve so that § Hold the pressure for 5 minutes. it is placed parallel to the inlet pipe. This § Check for the leakage on the external action causes the air from the brake pipe surface of the reservoir by gently to be exhausted to the atmospher e through tapping on the weld seams with a a choke of 5 mm. The drop in pressure in light hammer. the brake pipe can also be observed in the § No leakage or bulging is permitted. air flow meter provided in the locomotive § Drain out the water completely and cabin and the driver applies the brakes for allow the reservoir to dry, by stopping the train. The handle of the directing a jet of air. guard’s emergency brake valve has to be reset manually to normal position before 411e SAFETY PRECAUTIONS the brake pipe pressure is recharged.

§ Specified tools and fixtures should Note: The general design and controlling be used for assembly and dimension of guard’s emergency dismantling operations. valve shall conform to the latest § Rubber / leather components should revision of RDSO drawing no SK- be stored in a safe place away from 73549. heat, alcohol & acids. All metal parts like washers should be kept in a safe The guard's emergency brake valve place. should be completely dismantled and overhauled in every POH. 412 GUARD'S EMERGENCY BRAKE VALVE (refer figure 4.11)

Figure 4.11 – GUARD’S EMERGENCY BRAKE VALVE

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Maintenance Manual for BG coaches of ICF design Air Brake System

412b Tools and Fixtures for overhauling iv) Assembly

The following tools and fixtures are § Place seat ring in its position in the required for overhauling bore of the body on one side. § Apply grease lightly on the ball. § Test rig/stand § Fit ‘O’ rings on the spindle. § Spanner A/F 19/22. § Insert the ball in the bore of the body § Special spanner for removing thread in such a way that the ball sits on the plug. seat ring and the groove seat for § Sp anner for removing gland. spindle is in top position. § Light hammer § Insert the spindle with ‘O’ rings such § Vice. that the sp indle enters in to the groove. 412c Procedure for Overhauling § Screw the gland in to the body. § Insert the second seat ring through i) Dismantling the bore of the housing. § Fit ‘O’ ring on the threaded plug. § Hold the valve in the vice. With a special tool screw the § Unscrew the nut on the stem and threaded plug. remove the nut and the spring § Screw the threaded plug along with washer. the ‘O’ ring into the housing till the § Remove the handle. ball seat touches the ball. § Unscrew the gland and pull out the § The handle shall be put on the stem from the body. spindle and tightened with spring § Remove the two -gland packing on washer and nut. the stems. § Unscrew the threaded plug from the 412d Testing of Guard’s Emergency Brake body using a special spanner. Valve § Remove the ‘O’ ring and the ball seat from the body. § After overhauling, fix the valve to § Remove the ball and the second ball the test bench. (refer figure 4.9 & seat from the body. 4.11) § Put the handle of the valve in off ii) Cleaning of Parts position (close position). § Charge the inlet port with a pressure § Direct a jet of air on the valve body of 10 Kg./cm2. to remove the dust & dirt. § Check for leakage on the spindle § Clean the external parts of the valve portion and on the exhaust port with with wire brush. soap water solution. § All metal parts shall be washed with § No leakage is permitted. kerosene oil and wiped dry. § Operate guard’s emergency brake § Rubber parts shall be washed with valve, by putting the handle in open soap water solution. position. Air should escape through § Steel ball shall be handled carefully the vent of the valve. to avoid scratch marks or dent. 412e Safety Precautions iii) Replacement of Parts § Specified tools and fixtures should § Replace all the rubber parts such as be used for assembly and gland packing and ‘O’ ring. dismantling operations. § If spindle thread is corroded or § Rubber components should be stored damaged, the spindle shall be in a safe place away from heat, replaced with a new one. alcohol & acids. § If threads on the threaded plug are § All metal parts like nuts, washers damaged or corroded badly, the plug should be kept in a safe place. shall be replaced with a new one. § If ball of the valve has dent or scratch marks it should be replaced with a new one.

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Maintenance Manual for BG coaches of ICF design Air Brake System

413 SLACK ADJUSTER (see figure 4.12) adjuster does not pay out slack immediately, but indexes the amount of 413a Salient Features slack to be paid out. If the slack really is

Slack adjuster (also known as brake too small, the slack adjuster will pay out regulator) is a device provided in the this indexed slack at the next brake brake rigging for automatic adjustment of application. Thus false payout will not occur. clearance/slack between brake blocks and wheel. It is fitted into the brake rigging as True Slack Adjuster i.e. The slack a part of mechanical pull rod. The slack adjuster adjusts incorrect slack only, thus adjuster is double acting and rapid giving the brake its best possible pre- working i.e. it quickly adjusts too large or adjusted limit of piston strokes, ensuring a too small clearance to a predetermined smooth and efficient braking force at all value known as `A’ dimension. The slack times. adjuster maintains this `A’ dimension throughout its operation. The slack Shock Resistant i.e. Train shocks will not adjuster, type IRSA-450 is used in cause false take-up or payout of slack. passenger coaches, It is composed of the When brakes are released, the moving following parts parts of the slack adjuster are securely

§ Adjuster spindle with screw thread of locked. quick pitches (non self-locking). § Traction unit containing adjuster nut, 413b Overhauling of Slack Adjuster

adjuster tube and adjuster ear etc. i) Tools & Equipment § Leader nut unit containing leader nut

and barrel etc. The following tools and fixture are § Control rod with head. required for overhauling of slack adjuster; The out standing features of slack adjuster IRSA-450 are: (i) Jacking tool – for mass repair / Fully Automatic i.e. once initially set, no overhauling of Slack Adjuster manual adjustment is further necessary at pneumatically operated fixture is any time during its operation. used.

Double-Acting i.e. The brake shoe (ii) Special Spanner clearance is adjusted to its correct value (iii) Straight Nose pliers (external) both ways, either when it has become too (spring type)18 mm to 25 mm- large (owing to wear of the brake shoes external and wheels) or when it has become too (iv) Bend nose pliers (internal) 25 -30 small (e.g. owing to renewal of `worn out mm –internal brake blocks’). (v) Screw driver

Rapid working i.e. correct brake shoe (vi) Pipe vice & simple 6” vice clearance is automatically restored after (vii) Open end spanner 11-13 mm. one or two applications of the brake. (viii) Hand punches

Verification i.e. If resistance occurs early (ix) Kerosene oil bath in the brake application, caused by heavy (x) Air jet gun brake rigging, e.g. an ice coating on the (xi) SAB test bench brake shoes, etc., in such cases the slack

A1

A

Note: The Slack Adjuster takes up100 mm per braking. Dimension A1 will be 98 + 1/-4 mm (refer G-92) Figure 4.12 – SLACK ADJUSTER

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Maintenance Manual for BG coaches of ICF design Air Brake System

413c Procedure for Overhauling 413e Safety Precautions

The slack adjuster shall be overhauled at The following safety precautions should the time of POH of rolling stock. While be observed during overhauling of slack dimantaling or assembling it is essential to adjuster. use special tools. Each component of § The place of overhauling must be slack adjuster shall be examined. Worn clean and free from dust. out part shall be checked according to the § Ensure that no foreign limits. For details, refer RDSO Technical matter/particle remain inside the sub - pamphlet No. G-92(October-91). assemblies during re-assembly. § All rubber gasket, seal ring, washers The minimum desired characteristic of must be replaced during overhaul. each spring should be taken as under [Ref: § Specified tools and fixtures are used RDSO Technical pamphlet No. G-92 for disassembly and assembly (October -91)]: operations.

Table 4.3 413f Testing of Slack Adjuster (refer figure 4.13) Sr. Description Part Spring Minimum No of spring No. length permiss- After overhauling, testing of slack compre- ible force adjuster in carried out in a test rack for :- ssion 1. Barrel spring 21 330 mm 140 kg i) Take up test & ii) Pay out test

2. Pay out 11 100 mm 58 Kg. a) Attach the adjuster ear to the free spring end of the cylinder lever of the test rack 3. Take out 37 21.5 mm 22 Kg. b) Screw the test rack spindle into the spring Slack Adjuster until the entire length of thread is covered by spindle 4. Clutch 39 38 mm 300 Kg. sleeve and attach the free end of the spring spindle to the test rack.

i) Pay-in test Any spring, which does not conform, to the above characteristic should not be § Let down the control rod, so that the used. In addition any of the springs is fork of the rod clasps the adjuster badly rusted or having compressed coil tube of the Slack Adjuster turns should not be used. § Apply and release the brake a few times letting the slack Adjuster take The following parts must be replaced up until the correct piston stroke is during POH of the slack adjuster[Ref: obtained (until the indicator is within RDSO Technical pamphlet No. G-92 + 5 mm tolerance field of the scale). (October -91)]; ii) Pay-out test § Spring dowel sleeve part No. (18) § Lock washer part No. (27) § Turn up control rod and make two § Seal ring part No. (2) brake applications letting the slack § Seal ring part No. (43) adjuster pay out. § Rubber gasket part No. (4) § Repeat the above pay in and pay-out § Spring dowel sleeve part No. (25) tests a couple of times. § Dog pin part No. (6) § satisfactorily, dismantle it and check § Tab washer part No. (34) that the parts are placed correctly. § The slack adjuster must then be 413d Lubrication tested once more in the test rack in accordance with the above After cleaning and inspection all parts of instruction. slack adjuster should be coated with semi- § After the test is finished, remove the fluid grease SERVOGEM -RR3 or spindle from the slack adjuster. MALMEROL MULTIGREASE LL3 § Remove the slack adjuster from the (refer G-92) before undertaking re- test rack and unscrew adjuster ear. assembly.

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Maintenance Manual for BG coaches of ICF design Air Brake System

Figure 4.13 – TEST RACK FOR SLACK ADJUSTER

Give adjuster spindle a final thorough installed in the brake rigging and the correct piston stroke is obtained as inspection making sure that the threads follows:- are liberally greased, and screw it into the Slack Adjuster unt il its end protrudes § Place an iron object e.g. a hammer from Adjuster tube. Put the safety collar between the brake block and the and secure it with the spring dowel sleeve. Make sure that the spring dowel sleeve wheel tread. Make two brake applications after the second pin fits tightly and that its ends do not application the correct piston stroke protrude above the surface of the collar. should be obtained. Should there be any burrs on the collar,

smooth off with a fine file and wipe clean. § Remove the iron object. Make two Then screw the adjuster spindle back into brake applications. After the first the Slack Adjuster enough to make room application the piston stroke is too for the adjuster ear. long, but after the second application Slide control rod head with control rod the correct piston stroke is recorded on to adjuster tube. Place lock washer on by the slack adjuster. thr eaded portion of adjuster ear and screw ear into threaded end of adjuster 413g Painting tube. The slack adjuster is given a coat of Note : Hold adjuster tube firmly with a anticorrosive paint, excluding the adjuster pipe wrench. Secure lock washer. Install tube. the Slack Adjuster in the brake rigging.

iii) Testing of slack adjuster in brake Note : The unthreaded portion of the rigging with hand brake adjuster spindle should not have a thick coating. In case a test rack is not available in the work shop, a test of function of the slack adjuster ought to be carried out after the slack adjuster is

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Maintenance Manual for BG coaches of ICF design Air Brake System

413h Procedure for Brake Rigging setting such cases the `e' dimension can and measurement of “A” and “e” be restored by adjusting link dimensions:- provided on the bogie frame head stock. The procedure to be adopted for operating brake rigging setting and measuring ‘A’ (ii) Measure ‘e’ dimension i.e. and ‘e’ dimension is listed below:- distance between protection tube end and mark on adjuster spindle For ‘A’ dimension (16 +2/-0 mm for 13 using measuring stick after two t bogie and 22 +2/-0 mm for 16.25 t or three brake application. It bogie) (refer G-92) should be set to nearly to its maximum limit i.e. 375±25mm. (i) Ensure the air brake is in fully released condition and all the 413i Safety Precautions brake rigging gears are in proper condition. § Always use wedge between wheel and rail before application and (ii) Apply brake three to four times release operations for setting and to ease the rigging, by dropping measuring A and e dimension to and re-charging the air pressure prevent rolling of coach. in the brake pipe (iii) Ensure once again that brake § Ensure no part of the worker’s body rigging is in fully released is in touch with moving brake condition. rigging gears during application and releasing of brakes.

If ‘A’ dimension is not correct § Do not touch or hold slack adjuster barrel while it is in motion. 1. Remove pin securing the control rod in U bracket. § Before setting any dimension ensure wear of brake shoe does not exceed 2. Detach control rod and rotate it to its minimum permissible worn to adjust the gap between barrel limit (i.e. thickness of the shoe end face & control rod head as 20 mm specified in note above. Secure should not be less then ). the control rod in U bracket. § There won't be any slack take up 3. Apply brakes two to three times. provision in the slack adjuster and slack adjuster will only act as 4. Check the ‘A’ dimension using strut/pull rod. This is because of the gauge. brake shoes and wheel wear reaching 5. Recheck dimension ‘A’ with their condemning limit/near brakes fully released after every condemning imit.l In such cases the brake release. `e' dimension can be restored by adjusting link provided on the bogie 6. Lock the control rod head firmly frame head stock. with check nut and tooth lock washer. § Measure ‘e’ dimension i.e. distance between protection tube end and 7. Secure pin with split pin. mark on adjuster spindle using

measuring stick after two or three For ‘e’ dimension brake application. It should be set to

nearly to its maximum limit i.e. (i) If slack is in excess beyond the 375±25 mm. capacity of slack adjuster (`e' dimension 375+25mm) there won't be any slack take up provision in the slack adjuster and slack adjuster will only act as strut/pull rod. This is because of brake shoes and wheel wear reaching their condemning limit/near condemning limit. In

Chapter 4, Page 18 of 50

Maintenance Manual for BG coaches of ICF design Vacuum Brake System

CHAPTER 5

VACUUM BRAKE SYSTEM

501 GENERAL DESCRIPTION respective repair/ maintenance sections for thorough cleaning in the washing plant and 501a Vacuum brake system has been improved overhaul. gradually over the years by increasing the brake rigging ratio, effecting modifications Slack adjuster to the vacuum brake cylinders, hose pipe D.A.Valve cages and adopting direct admission valves Vacuum cylinder with release valve and slack adjusters (See figure 5.1 ). Vacuum reservoir Alarm chain apparatus 502 MAINTENANCE AT WORKSHOP Guard van valve

502a During POH all components of the brake 503b Train pipe gear system shall be examined, repaired and replaced as necessary. The pins and bushes i) Check the train pipe with compressed 2 shall be examined for wear and replaced if air of 2 kg/cm for leakage specially at the radial clearance exceeds 0.75 mm. threaded joints, bends and portions where clamps are fitted, tee joints, 502b Following items should receive particular swan neck, etc. with one end dummy. attention during POH: ii) Check and replace corroded, dented, bent more than 10 mm, or thin walled portions of the train pipes. Spiked i) Safety brackets provided for brake gear hammer should be used to check thin components should be in accordance wall, corrosion, etc. While renewing with the approved drawings and shall the pipe, it should be ensured that be examined for proper condition and bending do not decrease the cross secured according to the prescribed sectional area of pipe passage at the method. bends. New brake pipe should be given a coat of anti-corrosive paint before ii) Vacuum cylinders and their trunnion fitting. brackets, vacuum reservoirs and train pipes, rubber hose & syphon pipes, iii) Renew the damaged/ missing brackets alarm chain apparatus including the or clamps used for clamping the train chain, disc and locking arrangement, pipe. brake beams, hangers, and brake iv) All the pipe threads must be cleaned blocks shall be secured as prescribed. and applied with white lead before All brake gear pins (should be couplings are fitted. Clean the grooves chromium plated) shall be secured on swan neck. with washers and split cotters. v) After attending to all the repairs, test iii) Vacuum gauges shall be properly the train pipe for sound joints and tested and adjusted using master bends with compressed air at 2 kg/cm2 gauges before being fitted. pressure. There should not be any leakage of air over the entire length of

the train pipe. 503 LIFTING SHOP vi) After repairs and testing, the train pipe 503a After lifting the coach body and placing it should be given a coat of anti- on trestles, dismantle the following parts of corrosive paint. the vacuum brake system and send to the

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

BRAKE CYLINDER 24" TYPE F

D.A. VALVE HOSE PIPE

RAIL LEVEL

D.A. VALVE

SLACK ADJUSTER VACUUM RESERVOIR TRAIN PIPE SLACK ADJUSTER

LINE DIAGRAM OF VACUUM BRAKE

FIGURE 5.1

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

503c Rubber hose pipe and syphon pipe surfaces and cages fitted before the couplings are inserted into the hoses. i) Renew the hose pipe and syphon pipes They should be clipped firmly. if they had cracked or lost the bond between the various layers/ 503d Vacuum Reservoir Straps components. ii) Reusable hose/ syphon pipes should be Vacuum reservoir straps should be tested for vacuum retention. For this examined for slackness, corrosion and test, the hose should be connected by thinning, and damaged or worn out threads means of a cylindrical nozzle of size at their ends. and entire straps or threaded corresponding to the vacuum/ syphon ends, as required, should be replaced. If the hose bore to a chamber of 1640 cu. securing holes in the under frame are worn cm. volume and the free end of hose more than 3 mm, build up by welding and closed with a cylindrical plug. 510 mm redrill the holes. The reservoir straps should Hg of vacuum should be created in the be double secured with spring washer and chamber and hose system. On isolation check nuts. After all repairs, the reservoir from the source of vacuum, the drop of straps should be given a coat of anti- vacuum should not be more than 75 corrosive paint. FRP tissue should be placed mm Hg in one hour on the chamber in between reservoir and safety straps. APD gauge. The pipe should not be clipped should be done.

or otherwise bound to the chamber 503e Vacuum cylinder trunnion bracket nozzle or plug for this test. The hose should also be bent around a mandrel Where bushes are provided in the brackets, of 228 mm diameter till the ends of the they should be renewed and a light coat of hose are parallel. This should not result graphite grease applied before fitting a in any displacement or distortion of cylinder. Trunnions of the cylinder must wire. neither be too loose nor too tight in their iii) Cracks, porosity, tears, etc., of the hose brackets. Lateral clearances on the trunnions should be detected by giving it a (on each side) should not exceed 3 mm. It stretch test. For this purpose, hose pipe should be adjusted by renewing the bushes. should be secured to a special jig and If there are no bushes, the trunnions should should be stretched to 20% over its be bored and bushes of correct size fitted to original length and released 100 times. get the required clearance. Thereafter, in the stretched position, its surface should be examined to detect 503f Brake shaft the defects, if any. Cracked, torn, porous, or collapsed hose pipes or hose Brake shaft should be examined for pipes with coiled wire loose or straightness, bending and wear on its missing, or length reduced below 50 bearing surfaces. The shaft bearing worn cms . should be rejected. beyond 3 mm should be built up by welding and machined to its original size. Before the iv) Serviceable hose pipe should be shaft is fitted into its brackets its bearing secured on swan neck (after applying surfaces should be smeared lightly with rubber solution on swan neck) with grease. The fork arm should also be clip and tighten with spanner. examined for bending, distortion and wear v) Renew the corroded or damaged hose on its forked ends and restored to its original pipe clips. shape and size as required. The brake shaft vi) Broken, damaged, or distorted cages mounted in its brackets under a coach should be replaced with modified should be parallel to the trunnions on which cages to drg.No.VB 409/M. the cylinder swings to avoid setting up of side or crosses stresses and hence damage to vii) Universal coupling should be the arm. The brake shaft should not have a examined for broken, cracked and side play in its bracket bushes in excess of 2 distorted lugs and renewed on mm after POH. condition basis. Rubber solution should be applied on the mating

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

503g Brake shaft brackets the vertical pipe should be blown clear with compressed air and the pipe Brake shaft bracket bolts and nuts should be threads should be checked before the examined for rusting, looseness, thinning assembly is connected to train pipe. and worn out or damaged threads and v) All moving parts including spring replaced, if required. Good bolts and nuts should be greased and checked for should otherwise be reused after greasing proper movement. their threads. The brackets should be checked for cracks, corrosion and thinning vi) The clappet operating chain and the or damage and repaired/ replaced as pipe through which the chain passes required. The brake shaft bracket bushes should be dismantled, examined and should invariably be changed. renewed with standard chain or 6 mm wire. If in normal position of the 503h Slack adjuster support bracket on coach clappet valve, the chain hangs loose in any of the compartment openings, its The support brackets should be stripped and length should be adjusted by cutting it examined for missing or worn out rollers out to the extent necessary. Wooden and bent, defective or missing springs. The handles provided in the compartment defective or missing roller and springs openings for pulling the chain should should be replaced. Defective spring should also be checked and replaced where be repaired by restoring them to their found broken or cracked. original shape and size and hardened and tempered to give correct tension. The vii) After the clappet valve assembly is securing brackets and nuts as well as pins overhauled and refitted, its chains, etc., should also be checked and replaced or are checked and replaced, the alarm repaired as required. chain apparatus should be tested at the outgoing pit for its operation in 503i Alarm chain apparatus accordance with the following procedure. i) During POH, alarm chain apparatus should be opened, cleaned and 503j Alarm chain apparatus test overhauled. i) Create 460 mm to 510 mm of vacuum, ii) The chain must be of the prescribed pull the chain, using a spring balance, specification and each link must be at both sides of the coach from the end physically examined for crack/ wear/ where the chain is anchored, ie., from elongation. Proper fitment/ anchoring the end which is farthest away from of all the components should be the clappet valve. checked and ensured to avoid their ii) The alarm chain should not operate the failure/ non-operation/ mal-functioning clappet valve if the pull applied during service. vertically down wards is less than 6.4 iii) The clappet valve should be removed kgs. It should also not require a pull of from the coach for overhauling. more than 10 kgs. for its operation. Replace the rubber washer. The iii) When the chain is pulled, the brakes clappet valve cover should be checked should apply on the coach and the drop and repaired or replaced as necessary. of vacuum in the train pipe should be The clappet valve operating rods, between 180 mm and 200 mm if one levers, indicating discs and other coach is being tested, or between 130 moving parts should be cleaned and mm and 180 mm when a rake as a checked and straightened if bent, or whole is being tested. If the drop in replaced if broken or deficient. The vacuum is less than 130 mm and still pins if worn should be renewed, if not the brakes are applied, it shows an they should be cleaned before reuse. obstruction in the vertical pipe, in iv) The vertical pipe connecting the which case it is necessary to locate and clappet valve with train pipe should be clear the obstruction in vacuum examined to ensure that it is neither vertical pipe. leaking nor blocked. The air passage in

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

iv) On resetting the clappet valve, it 504b Guard Van Valve should automatically come to lap position. After restoration of 460 mm i) During overhaul of guard van valve, its to 510 mm of vacuum, the exhauster rubber diaphragm and rubber washer should be isolated and the drop in should be invariably changed. Passage vacuum noted. The drop in vacuum through the valve connecting its train should not be more than 25 mm in one pipe side to its chamber should be minute. This check should be carried cleaned. If the passage hole diameter out twice. exceeds 6 mm, the valve should be replaced. 504 OVERHAUL OF COMPONENTS ii) The chamber space of the guard van 504a Vacuum reservoir valve should be checked for leakage, cracks and damage and repaired or i) The vacuum reservoir should be replaced as necessary. The valve itself examined for corrosion, damages, should be checked for easy and correct distortion, cracks, etc. If the extent of lift. The valve cover holes should be corrosion, etc., are only about 5% of cleaned, blocked holes opened and total area, it should be cut off and bent/deficient lever replaced. The replaced with another plate by vacuum gauge nipple provided on the welding. Otherwise the whole barrel guard van valve chamber should be should be replaced. Open the drain checked for damaged or worn out plug and blow compressed air into the threads. The loose nipple should be reservoir to remove dusts, dirt and secured firmly on the chamber. water particles, accumulated inside the reservoir. iii) All studs and nuts with worn or damaged threads should be placed. The ii) After thorough cleaning, refit the drain threads in the body of the chamber plug smeared with small quantity of should also be good enough to ensure graphite grease on the threads and no leakage past them. The guard van tighten it firmly. Clean the pipe threads valve body threads on which train pipe with a brass wire brush in both the dish is secured should also be checked for ends to fit the syphon nipples. Replace damage and wear and the body the missing or damaged syphon in the replaced if the threads are bad. dish ends of the reservoir. iii) After attending the defects and before iv) After overhaul, the entire guard van painting the reservoir, a pneumatic valve assembly should be tested for pressure of 2.0 kg/cm2 by gauge satisfactory functioning, as given should be applied in it for the purpose below: of ensuring sound fabrication and finish. With the pressure applied, the ¨ Vacuum retaining capacity test: welded seams all over the body should Guard van valve connected to a be thoroughly checked for leakage chamber of 1640 cu. cm. volume with soap and water solution. throughout the assembly, should not, on isolation from the source of iv) Vacuum reservoir should be tested for vacuum, record a drop of more than vacuum retaining capacity with 510 25 mm in 1 minute on the chamber mm of vacuum throughout the gauge. assembly. It should not, on isolation from the source of vacuum, record a ¨ Operation test drop of more than 13 mm in 30 minutes on test gauge. 1) On release of operating handle, v) Aft er all repairs and tests, the reservoir the valve should, with should be given a coat of anti- atmospheric pressure corrosive paint and FRP tissue pasted throughout the assembly, re-set at the areas where suspension straps itself by its own weight. are located.

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

2) With 460 to 510 mm of vacuum 504f Gland box (Stuffing box) throughout the assembly, and the source of vacuum isolated, Table 5.1 gradual admission of air to the train pipe should show a Guide Bush corresponding drop in vacuum Inside diameter 44.52 +0/-0.03 mm on the van valve gauge. Outside diameter 54 +0/-0.1 mm

3) With vacuum throughout the Renew all the rubber items like the neck assembly, the guard van valve ring and gland box joint washer invariably. should automatically lift on a Renew the worn/ loose guide bush. Replace rapid destruction in the train the worn, damaged, or broken studs. Secure pipe of approximately 225 mm the gland box on the cylinder cover with of vacuum, and on the operating spring washers and nuts. handle of the test apparatus being placed in the "running" 504g Piston rod position, the guard van valve Dismantle the piston rod from the piston. should re-set itself within 3 to Renew the bent, damaged, dented, worn, 5 seconds. corroded, or pitted piston rods. If the threads of the piston rod are damaged, the rod Note:- Above tests 2 & 3 apply only to should be replaced. automatic type of guard van valves having a diaphragm and dome above 504h Piston the atmospheric valve. The cracked piston should be replaced. The 504c Vacuum gauge piston skirt serrations should be cleaned free of dust, rust and sediments. Visually check Vacuum gauge which is permanently fitted the piston for worn or cracks. Replace the in guard's van should be removed and piston if found damaged beyond salvage. calibrated with master gauge before Measure the out side diameter with refitting. If defective, it should be repaired micrometer of range 575-600 mm & record and again calibrated with master gauge and the dimensions. While assembling the refitted. The vacuum gauge guard must be Piston and Vacuum cylinder the diametrical invariably provided to protect the gauge difference between the two should be 20.3 from damage or theft. mm. The blind holes for the piston rod cover bolts should be tapped and eased. 504d Vacuum brake cylinder 504i Ball valve cage Strip the vacuum cylinder completely. Thoroughly clean and dry the components The ball valve should be opened, thoroughly and check for defects like cracks, damages cleaned free of dust, dirt and sediments and and wear. lightly lapped. Four holes in the cage which should be of 6 mm diameter should be 504e Pan (Cylinder cover) cleaned thoroughly. The ball valve cage cover should be checked for good threads. Replace the cracked/ broken cover or if the The ball should be replaced even when welded lugs are more than 50% of the total slightly worn. Ball valve should be changed lugs. Broken/ cracked lugs should be when its seating is worn out or pitted and replaced with new lugs by welding and the surface is not smooth to provide good grinding. After attending to the defects, the seating for the ball. the ball and the ball seat pan should be painted with one coat of anti- should otherwise be cleaned with emery corrosive paint. paper and lapped together before assembly. The cage cover should be replaced if its threads are damaged.

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

504j Piston assembly and horizontal, when the ring is in its piston groove. Select the serviceable/ new piston assembly ii) In order to test the ring for twist, it components and assemble the piston should be hung on a stretched finger assembly as per drawing No.VBA - 16 / M. and examined. A good ring should The piston should then be painted all over hang straight and should not make a except over the working surface ie., serrated figure of 8 and show a twist. The portion. The date of overhauling and the rolling ring should also be stretched by code of the shop of overhauling should then hand and examined. If any cracks be stenciled on the cover end of the piston appear, it should be considered as disc. perished and replaced. 504k Barrel (Cylinder body) iii) New rolling rings should be tested for compression and stretching. A 50-mm Cracked barrel including the one with long test piece cut from the ring should cracked trunnions should be replaced. Lugs be compressed to half of its sectional cracked or broken should be replaced with diameter and kept in the compressed new lugs by welding and grinding. The condition for 3 hours. On release, if its barrel should be replaced if the number of diameter does not come back within original lugs (ie., those which have not been 2% of its original diameter within an repaired at all) goes down below 50%. hour, it should be rejected as defective. Thoroughly clean the serrations and check Similarly, the ring should be stretched for wear. Measure the inside diameter with to 300% of its original length and kept micrometer of range 600-625 mm. Replace in the stretched condition for 3 hours. the barrel if serrations are found worn or If on release, the ring does not come damaged. Dry the barrel with hot air after back to within 5% of its original wiping out all the traces of water particles. length within an hour, it should be Clean the release valve seat and the holes rejected as defective. for proper seating and free passage of air

respectively. After attending to the defects and cleaning, inside of the barrel should be 504n Release valve

painted with one coat of anti-corrosive paint i) Open the release valve and renew all except the serrated surface, which should be left unpainted. the rubber items like diaphragm, seating washer, etc., invariably during 504 Joint rings overhaul. Dry the release valve after wiping out all the traces of water. Every time a vacuum cylinder is opened, the Check the release valve operating lever joint ring should invariably be replaced. and renew if found cracked. The After fitting the joint ring in the correct release valve studs should be cleaned position between flange of cylinder and and replaced if found damaged or cover, it can be retained in the correct worn. While assembling the valve, alignment while fitting the cylinder cover to nuts should be smeared with graphite the cylinder by suitably designed clips. grease. It should also be ensured that all the sharp edges on the seat of the 504m Rolling ring spindle washer are rounded off. After i) Twisted, cut, worn out or perished assembly, the release valve should be rolling rings should be replaced. While tested as given below:

fitting a rolling ring on a piston A) Vacuum retaining capacity test surface, it should be ensured that it is of the correct size, i.e. diameter is ¨ Release valve, connected either 13.1mm or 13.5 mm depending through the cylinder port to upon the wear on the serrated surfaces chamber of 1640 cu. cm. of the piston and the cylinder and, that volume with 510 mm of the ring does not get twisted. The seam vacuum throughout the line of the rolling ring should be even assembly, shall not, on isolation from the source of

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

vacuum, record a drop of more vacuum exhauster and train pipe. This than 20 mm in one minute on valve will automatically control the the chamber gauge. vacuum to a maximum of 460 mm ¨ Release valve, connected with lever in horizontal position and a through the chamber port to a minimum of 356 mm with the lever in chamber of 1640 cu. cm. vertical position with, exhauster volume with 510 mm of working. vacuum throughout the ii) Create 460 mm of vacuum (lever of assembly, shall not, on control valve horizontal). destruction of the vacuum, iii) Destroy the vacuum. record a drop of more than 20 iv) 20 minutes after destruction, create the mm in 1 minute on the balancing vacuum of 356 mm (lever of chamber gauge. control valve vertical). The piston of B) Operation test: cylinder in good condition should partly descend but not completely. ¨ Release valve, connected That which completely descends is through the chamber port to a faulty and should be dismantled and reservoir with vacuum repaired again. throughout the assembly shall, v) Increase vacuum to 460 mm (lever of when the vacuum is destroyed control valve in horizontal) when in the train pipe by pulling on piston should completely descend. the operating lever wire thus That which does not descend operating the valve, remain in completely is faulty and should be the open position till there is dismantled and repaired again. pull on the lever wire. It After successful BVT testing, supply the should re-set immediately on brake cylinder to lifting shop for fitting on removal of the pull. coach. ¨ On re-creation of not more than 205 mm of vacuum, the 506 D.A.VALVE (ESCORT- KNORR D.A. valve shall re-set itself. VALVE)

505 ASSEMBLING AND TESTING OF 506a Open the two halves of DA valve by VACUUM CYLINDER removing the four M8 hexagonal nuts. Clean all the components and sub 505a After attending to the defects of vacuum assemblies like lower locking screw cylinder parts, assemble the Parts as per subassembly of the lower housing, housing IRS drawing No.VBA - 16 / M. alt 6. Care upper subassembly, diaphragm sub should be taken to invariably replace all assembly, valve seat subassembly, etc. All the rubber items like rolling ring, joint the rubber items should be replaced ring, release valve joint washer, piston cap invariably and other parts should be washer, etc. While assembling the Piston changed on condition basis. and Vacuum cylinder the diametrical difference between the two should be 20.3 List of Rubber Items which should be mm. After complete assembly, the changed

vacuum cylinder should be tested on the Table 5.2 test bed and stencil the date of overhaul, the date of testing and shop code on the Part Name Drawing Number vacuum cylinder body. Diaphragm 4A 38266 Seal 48174 505b Testing of Brake cylinder (Balanced Nylon guide bush KB 408 Vacuum Test ) Sealing ring A 35 x 41 Dln 7603 i) Attach the overhauled brake cylinder Sealing ring A 30 x 36 Dln 7603 to test stand train pipe and test K Ring N 891 / 20.2 reservoir. The balanced vacuum Joint ring KB 115 control valve is connected in between

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

506b The filter element of (Escort-Knorr 506d Testing of DA valve: After the DA valve is D.A.Valve) should be thoroughly washed in overhauled and assembled, it should be kerosen and blow with compressed air to tested on the test bench as indictated in remove the entire collected dirt. Before figure 5.2 for its functional performance fitting back, the filter element should be and leakage. immersed in light machine oil and the oil allowed to be drained. i) Retention test : Mount the DA valve on the test stand and create vacuum till The filter element of (Greysham 530 mm Hg is indicated on both D.A.Valve) should be thoroughly washed in gauges A and B of the test stand. Close parafin to remove the entire collected dirt. stop cock "Y" and then stop cock "X". Record the drop of vacuum in both the List of Items to be Changed in Escort gauges A & B, which should not be type DA valve on Condition Basis more than 12.5 mm in 10 minutes.

ii) Operation test : The stop cock "X" is Table 5.3 opened till the gauges A & B again record 530 mm of vacuum. Then stop Part Name Drawing Number cock "X" is closed and "Y" is opened. Pin and screw assembly 4KB 613 Record the drop in gauge B (brake cylinder) from 530 mm to 25 mm Diaphragm seat 4A 50314 which should be within 3 seconds. Valve seat 4A 50807 iii) Proportionality test : Open stop cock Locking screw 4A 55757 "X". Vary vacuum in gauge A by Valve seat 4A 54952 opening and closing cock "Y". It will be observed the gauge B follows gauge Locking screw 4A 69805 A very closely both during creation of Hex. nut M8, DIN 934 vacuum and brake application. Spring washer B8, DIN 127 Hexagonal bolt M8x35 DIN 931 507 SLACK ADJUSTER (SAB DRV2-450) Self tapping screw 4x5/16" Refer to write-up on Slack adjuster in para 413 of Air Brake Chapter. Filter assembly KB 137

Cup plate KB 409 507a End piece for slack adjuster pull rod Hex. nut M10 x 1.5 DIN 439 Prepare end piece for pull rod as per the Washer DIN 433 RDSO SK - 96102 alt. 3 to be used in Compression spring 4A 30485 / 8 modified vacuum brake system to provide horizontal movement to slack adjuster:

506c The DA valves should be closely examined Type of coaches Length of end and seats ground lightly to avoid leaks. piece While assembling care should be taken for fitting the diaphragm on to the lower WFSCN, SL, SCNLR 265 mm housing groove properly. The end corners must be pressed inside the groove. Free All other vacuum 155 mm movement of the diaphragm subassembly braked coaches should be checked by hand. During the final assembly of upper and lower housing, tightening of hexagonal nuts should start from the O-ring end and the 4 nuts must be tightened evenly.

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

GAUGE ‘B’ GAUGE ‘A’ (BRAKE CYLINDER) (TRAIN PIPE)

COCK - X

FILTER 1/2” 1/2" TP TO VACUUM PUMP DA VALVE UNDER LC TEST RESERVOIR 3/4" 34 LITER 1.2 Cu. ft. COCK - Y

RESERVOIR 1/2" 34 LITER 1.2 Cu. ft.

TESTING OF DA VALVE Figure 5.2

508 ASSEMBLING BRAKE SYSTEM ON should be tested with 255 mm vacuum COACH to detect and attend porous or leaky hose pipe and or joints. After receiving the overhauled brake system ii) The balanced vacuum control valve is components, these should be fitted on the connected in between vacuum coach in proper order and in their respective exhauster and train pipe. This valve locations. Then lower the coach on will automatically control the vacuum overhauled bogies and connect the pull rod to a maximum of 460 mm with lever end of slack adjuster to vertical levers of the in horizontal position and a minimum bogie brake rigging. of 356 mm with the lever in vertical position with exhauster working. 509 ADJUSTMENT OF BRAKES Although the vacuum reading at the valve applies to the front of the coach, 509a A vacuum cylinder as fitted shall have a it will control the necessary drop of minimum clearance of 13 mm between the 102 mm for balancing throughout the piston cotter and fork end arm of the brake train during test. shaft when both are in their lowest positions. iii) After the vacuum is created up to the The brake gear adjustment should be such end of the coach completely destroy that the piston stroke is within limits the vacuum. specified for different types of stock. With iv) 20 minutes after destroying, create the the piston in fully lifted up position, there balancing vacuum of 356 mm (lever of must be a minimum clearance of 25 mm control valve vertical). The pistons of between the top of the fork end arm and the cylinders in good condition should cylinder stuffing box. partly descend but not completely. That which completely descends is 509b Testing of vacuum brake system (Balance faulty and should be replaced and vacuum test) checked again. v) Increase vacuum to 460 mm (lever of i) Adjust brake gear to ensure that the control valve in horizontal) when piston stroke is within prescribed piston should completely descend. limits i.e,. 203 –3 mm (This is That which does not descend important as the balancing vacuum is completely is faulty and should be based on the correct piston stroke). replaced and checked again. While this is being done, the train pipe

Chapter 5, Page 10 of 14

Maintenance Manual for BG coaches of ICF design Vacuum Brake System

510 ADJUSTMENTS OF SLACK dimension `A' again with brake fully ADJUSTER released and correct if necessary. vi) Lock the control rod head firmly with 510a Control dimension `A' Slack adjuster: After nut and tooth lock washer. Secure pin the Brake Regulator has been installed or with split pin. when checking an existing installation, carry out the following: 510b Dimension `e'

i) Make sure that the hand brake and the The dimension `e' which is 375 ± 25 mm vacuum brake are fully released and represents the capacity available for the whole rigging is in proper order. adjustment and will decrease as wear takes ii) Make three or four brake applications place at brake shoes, wheel and pin joints. at correct vacuum to ease the rigging. iii) Once again ensure that the whole brake The maximum value of dimension `e' rigging is in the fully release position. should be within the permissible limits for The installation can not be correctly each value when: adjusted or checked if the brake rigging is only partly released. i) All brake shoes are new. iv) Now set the dimension `A' between the ii) All pin joints have new pins and control rod head and the barrel head bushes. which is 16 +4/-0 mm and 22 +4/-0 iii) All wheels are new. mm for ICF coaches with 13t and 16.25t bogies respectively and rotate to If it is not within permissible limits, after suit refitting control rod and pin when ensuring that all other relevant parts in the the dimension `A' is correct. rigging are correct to the drawing, the v. Make a few more brake applications at length of one of the pull rods may be the correct vacuum, this time checking adjusted and the piston stroke checked piston strokes which should be within again. the limits specified. Also recheck

511 LIST OF TOOLS AND PLANT

Table 5.4

Lifting shop Vacuum brake shop Slack adjuster shop

Ball peen hammer Ball peen hammer Ball peen hammer Chisel Chisel Chisel Spanner set Spanner set Steel measuring type Gas cutting plant Single girder electric hoist Pipe vice Welding plant Box spanner set Spanner set Jack for brake cylinder fitting Vacuum exhauster Jacking tool BVT test equipment BVT valve Screw driver Pallets D.A. Valve test rig soaking tank Platform truck Compressed air supply Inspection guages Guard van valve test rig Box spanner set Clapet valve test rig Spring testing rig Vacuum gauge test bench Gas cutting plant Train pipe test rig Welding plant Vacuum test rig D.A. Filter cleaning plant Fork lift Plat form truck Cleaning plant Hot water jet system Waste water treatment plant

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

512 TROUBLE SHOOTING ON VACUUM BRAKE

Table 5.5

Sr. Defects Probable cause Method of Testing Remedies No. i) Coaches not provided with Slack Adjuster Brake Power Weak a) Brake Blocks slack & Check the piston Adjust brake gear. If even not braking wheels travel. Brake shaft then the brake power is arm will be touching weak, change the brake the cylinder when blocks. brakes are applied. b) Brake blocks slack Check whether the Adjust the brake gear or but braking wheels piston travel is more change the brake blocks. without requisite than 125 mm or not. force. c) Brake gear bushes Shake brake hangers Adjust the brake gear or worn out. with hand to see Change all bushes and pins whether bushes come as necessary. out along with the hangers or pins rattle in bushes. d) Brake rigginng stiff Brake shaft arm Ease the brake shaft & and brake release remains up even after replace the strong release spring too strong. release of brake, spring with that having though the piston proper tension. comes down. ii) Coaches provided with Slack Adjuster Brake Power weak e) Excessive free lift Measure free lift. Adjust free lift to 14 mm. (f) Defective cylinder See whether the Repair or replace vacuum piston goes up cylinder. when vacuum is destroyed. (g) Excess 'A' dimension Measure 'A' Adjust as specified for the dimension type of coach.

h) Defective brake Check that all brake Change brake gear compo- rigging rigging components nents, pins and bushes as are as per drawing necessary. and the clearance between brake gear pins & bushes are within the permissible limit.

(i) Manual adjustment Measure wheel Adjust 'e' dimension in in respect of wear of diameter and respect of wear of wheels wheel has not been check "e" dimension. made

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Maintenance Manual for BG coaches of ICF design Vacuum Brake System

Sr. Defects Probable cause Method of Testing Remedies No. j) SAB Slack Adjuster On application & Replace slack adjuster. pin defective. release of brake see whether the Slack adjuster barrel rotates.

2) Brake on a coach (a) Brake rigging pin & Move or shake by Ease the jammed compo- do not release. brake shaft jammed. hand and feet. nents.

(b) External leak in the Test by a flame Rectify the leak or change train space of vac. which will be drawn the neck ring or the piston cylinder commonly in at places of rod as required. due to worn out neck leakage or close the ring or scored piston valve connecting the rod source of vacuum, after creation of vacuum and check the train needle in the vacuum gauge which will come down.

(c) Engine not creating Visual examination Release train vacuum the same amount of cylinders. vacuum as was prior to an application of brakes 3) Fall in vacuum on (a) Clappet valve spring a) Drop of vacuum by Adjust the clappet valve or run by 125 to 175 defective. 125 to 175 mm. blank it. If can not be mm reported by (b) Syphon pipe getting b) Drop of vacuum adjusted, adjust and secure Driver. disconnected. by 125 to 175 mm. the syphon pipe.

4) Vacuum cannot be a) Leakage at joints of Starting with the last coach, created on the train. train pipe, train pipe check all joints and rectify nipple, hose pipe, all leaks with a sealing Syphon pipe. compound, or/and replace (b)Rubber washers defective hose pipe clips in hose pipe joints Check vacuum in the and rubber washer, as missing or brake van and the necessary. after checking all twisted. engine. Listen for coaches upto the engine and hissing sound to rectifying defects as noticed, (c)Rearmost hose detect leaks. if vacuum still cannot be pipe of the train created, then devide the train not secured into two equal parts and test on its dummy. each part separately. Again (d)Leakage in vacuum subdivide the part found chamber. defective and test each sub- (e)Guard' s van part. This is continued till valve leakage. the defective vehicle is located.

(f) D.A. Valve Check for leakage. Replace or by -pass D.A. leaking. Valve.

Chapter 5, Page 13 of 14

Maintenance Manual for BG coaches of ICF design Vacuum Brake System

Sr. Defects Probable cause Method of Testing Remedies No. 5. Abnormal variation a) Partial obstruction of Create the vacuum 460 to in the amount of hose pipes of the train 510 mm and destroy it. Now vacuum between pipe observe closely the extent of engine gauge and piston travels of all coaches. brake van gauge. The travel of the piston would be greater on coaches between the locked portion and the engine, than that of the coaches in the portion beyond the blockage i.e. between the blocked coach and the rear brake van. In case there is a complete blockage, the piston travel would indicate where the vacuum brake has not functioned, at all. b) Vacuum gauge of Replace the defective Guard Van valve vacuum gauge. defective. 6) Piston applies a) Leak at neck. Destroy vacuum and Change the neck ring or brakes when the see if the piston blank off the vacuum vacuum is created comes down. cylinder and advise the next train examining station to change the neck-ring.

b) Wrong connection of Ditto Correct the syphon pipe syphon pipe on the triple connection. way release valve

*****

Chapter 5, Page 14 of 14

Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

CHAPTER 6

BOGIE MOUNTED AIR BRAKE SYSTEM 601 GENERAL bore pneumatic pipeline has been laid over bogie frame to inter In order to overcome the problems of connect the brake cylinders of one slack adjuster failure as well as problems bogie. Output pipe line of distributor associated with cast iron brake blocks, a valve has been connected to bogie design of brake system incorporating 8" pneumatic line through flexible size two cylinders on each bogie along hoses to provide flexibility to with ‘K’ type high friction composite alround dynamic movement. brake blocks has been introduced. 603 COMPOSITE BRAKE BLOCK

602 DESIGN FEATURES OF THE 603a General SYSTEM (refer figure 6.1) Low friction composite brake blocks This type of system is exactly similar to have the following benefits: the standard air brake system except for n Reduced braking distance due to the following: uniform co-efficient of friction.

n Reduced weight a) External slack adjuster is removed/ n Reduction in the replacement of eliminated brake blocks vis a vis cast iron due to b) Four cylinder of 8" size is provided higher wear life in train operation. for each coach in place of two n Reduced wear and tear of brake cylinders of 14" in standard air rigging. brake system. These cylinders have n Reduced noise during braking. built in single acting slack adjuster for taking the slack created between 603b Characteristics of composition brake blocks wheel and brake block on account of wheel / brake block wear. Mounting i. Composition of material of cylinders is done on either side of the bogie frame in between central The composition of material longitudinal members connecting the constituting the brake blocks must be bogie transom to the headstocks. chosen to give the best balance Each cylinder controls the braking between : on one wheel set. Each cylinder has a piston take up stroke of 32 mm and § The braking characteristics adjustment capacity of 305 mm § The wear and service life of blocks (Ref. Drg. RDSO Sk- 81057) § Wear on the running surface of the wheels c) High friction composite brake blocks § The effect on adhesion between the of ‘K’ type have been used. rail and wheel d) Bogie brake rigging has been modified to incorporate a total ii. Requirement concerning friction

mechanical advantage of 7.644 per § The average coefficient of friction is bogie 8.40 for non-AC coaches and 0.25. per bogie for AC coaches. § As far as possible the coefficient of e) Curved profile pull rods have been friction must be independent of the used to interconnect levers initial braking speed, the state of controlling braking one wheel set. bedding-in of the brake block, the These pull rods provided with one specific pressure also the additional hole for the adjustment of temperature and atmospheric slack between wheel and block after conditions. specified amount of wear. f) Since brake cylinders have been mounted on the bogie frame, 15mm.

Chapter 6, Page 1 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

M C a h +0 i a 685 -10 n p t e t e n a r

305 MAX. SLACK TAKE UP. 679 6 n , ADJUSTER IS TO BE RESET BY c

P %%p0.5 4-FIXING e

a REWINDING THE ADJUSTING TUBE.

95 MAX. M 7 g HOLES %%C21 2 e 1 STROKE a

n 2 u (MUST BE o

95 MAX. a f l

IN A STRAIGHT 1 STROKE f o 4 5 . LINE)

WORKING STROKE,32mm FOR SELF r 0

p B % * GENERATING MAIN LINE COACHES, G % 281 22 117.5

60mm FOR BG EMU COACHES. 7 I

A 0 * 2 C 3 1 1 F

C o a

c

= = h e s %%p0.5 204 7 2 LEVERS MUST BE 1 ARRANGED SUCH THAT R 5

POSITION A FOR MAIN LINE SELF E

2 THE CROSSHEAD IS T P F

U HAND BRAKE TRUNNION A -

GENERATING AND BG EMU TRAILOR E HELD WITH IN 1.5mm N K A O COACHES I T OF THIS AXIS.

T I 5 S 0 N E O 3 S

P O I A L T L I E E L S S U 2 Nos.AIR INLET PIPE CONNECTION, E F A O R E P

L ONE CONNECTION IS TO BE MADE L E A I R T

I DUMMY BY PLUGGING. N I

400

MOVEMENT TO BE ALLOWED FOR

365 B

5 MAX. WORKING MOVEMENT . 0 p = . 1 X % 3 A % 4 M 0 2 . X 7 A 4 M . . . = X 7 A 4 M . X 1 A 3 M

RESETTING LATCH B o g i e

LEVERS MUST BE ARRANGED M SO THAT THE PATH OF THE o

POSITION B FOR EMU MOTOR COACHES CROSSHEAD CENTRE LIES u n

BETWEEN THESE LINES. %%UNOTE:- t e d

1. TO MANUFACTURE BOGIE MOUNTED BRAKE CYLINDER FOR A i

MAIN LINE COACHES, REFER RDSO SK-81200 AND THE r

B

BILL OF MATERIAL FOR DIFFERENT COMPONENTS. r a

FIGURE 6.1 k e

S y s t e

SUPERSEDED BY: INDIAN RAILWAY STANDARDS m 5 - CD/8/2K DRAWING REVISED 11/2K SK-81200 ASSEMBLY DRAWINGS SUPERSEDES: 1. DIMENSION 101.6mm CHANGED TO 102. EMU STOCK & SELF GENERATING %%p0.5 4 - CD/4/2K 2. DIM. 117.47mm CHANGED TO 117.5 . 4/2K REFERENCE:- SCALE P MAIN LINE COACHES 3. FIXING HOLE DIA. CHANGED TO 21mm. C 203.2 mm x 95.25 mm (8"X 3 3/4") - CD/21/99 NOTE 2 ADDED. 12/99 3 D SK.SRIVASTAVA BRAKE CYLINDER WITH TOLERANCE +0/-10mm ADDED T - CD/7/99 2/99 2 ON DIMENSION 685. J.S. SLACK ADJUSTER - 1 CD/35/98 NOTE 1 ADDED & TITLE CHANGED 12/88 FLOPPY No. :- R . D . S .O. GROUP 1 2 3 4 5 ALT. ITEM AUTHY. DATE B.G. SKETCH-81057 DESCRIPTION (C)

Chapter 6, Page 2 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

§ Under the effect of dampness, the § The use of asbestos is prohibited. average coefficient of friction must not § The use of lead or zinc in the metal vary, with the other condition state or in the form of compounds is remaining the same, by more than not advised. The same applies to all ±15% in relation to the value obtained other compounds, if in the form of during braking when dry. powder, particles or gas produced § After prolonged braking followed by during the used of the brake blocks, braking to a stop, particularly high they may constitute a danger to health.

temperature occur. Even in the case of 0 603d Asbestos based ‘K’ type composition these temperatures (maximum 400 C brake on the opposing friction surface) the average coefficient of friction must not § Asbestos based ‘K’ type blocks shall vary with the other conditions generally conform to RDSO drawing remaining the same – by more than No. 98146. ±15% in relation to the value obtained during braking in cold and dry state. 603e Marking

iii. Geometrical characteristics of the Each block must bear the following brake blocks marks:- § The constructional features of the brake blocks must enable them to wear § Name of manufacturer down to a thickness of 12 mm § Date of manufacturer (month and including the back plate, without the year) latter coming into contact with the § Material code including ‘KA’ for running surface of the wheel. asbestos type and ‘KNA’ for non-

iv. Mechanical and physical asbestos type. characteristics § Type of service ML.

§ The various elements making up the These marks, preferably punched, cut or brake blocks must be spread uniformly stamped, must be applied so that the block in the body of the block. There must can be identified, even after being fully be no pitting, flaws or other defects. worn in service. The material must not attack the

opposing friction surface or give rise 603f Comparison of properties/Usage of to the formation of metal inclusions. composition brake block Vs Cast Iron Composition brake blocks must Brake block not bring about more serious heat

damage to the wheels (hot spots, Param- Type of Brake blocks in use on main line cracks, flaking) than would be caused eters coaches by cast iron blocks used in the same 'L' type CBB 'K' type CI way on the same wheels. CBB § The values of specific weight, thermal conductivity, hardness, bending Appli- All coaches All coaches All strength and the modulus of elasticity cability with with bogie coaches must be given for acceptance underframe mounted with purposes. mounted air brake vacuum § No method is laid down for fixing the brake system system brake and composite material part to the back under plate. The back plate must be designed frame to support the stresses likely to occur. mounted § The composition blocks must not brake affect to an unacceptable degree the system adhesion values between wheel and Speed Upto 110 upto 110 Upto 140 rail obtained on vehicles braked with KMPH KMPH KMPH cast iron inserts. Coeffic 0.12 to 0.14 0.25 max. 0.12 to ient of 0.14 603c Non-asbestos ‘K’ type composition friction brake block Weight Approx. 3 Approx. 3 Approx. 9 § Non-asbestos ‘K’ type blocks shall kg. kg kg. generally conform to RDSO drawing No. 98066.

Chapter 6, Page 3 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

604 WORKING PRINCIPLE cylinder pressure developed is 3.8 +/ - 0.1 kg/cm2 as in the case of standard air There is no change in the overall brake brake. system in bogie-mounted arrangement up 604b Release to the action of distributor valve. Here the system will respond to action on A-9 For release of the brakes, driver moves valve in similar fashion as in the case of handle of A-9 valve to release position. standard air brake system. Working of By this movement, the brake pipe is bogie mounted brake system beyond charged to the required pressure of 5 distributor valve is explained below. kg/cm2. This actuates the distributor valve and brake cylinder is cut off from the 604a Application (see fig. 6.2 ) auxiliary reservoir. The air from brake cylinder is exhausted to atmosphere and brakes are released. For application of brakes, driver moves the handle of A-9 valve in the application 604c Slack up Action

position. By this movement the brake pipe Cylinders of bogie mounted brake system pressure is reduced which is sensed by are provided with automatic slack take up distributor valve to operate brake cylinder features. As soon as the piston stroke (1). Pneumatic pressure in the brake exceeds a pre determined value (on cylinder causes piston assembly (2) to account of either brake block or wheel or move outward thereby causing lever (3) to both) a ratchet with adjusting screw fitted rotate about its fulcrum (a) thus bringing inside the cylinder turns thereby brake block (4) to come in contact with increasing the length of the piston rod the wheel (5) through the brake beam (6). automatically. During return stroke, the Since lever (3) is hung on the bogie frame adjusting movement takes place. A red through lever hangers, it will start moving paint mark on the adjusting tube assembly forward about fulcrum (b) after brake indicates that piston unit has extended block (4) has contacted wheel (5). This over its full range and requires resetting of forward motion of the lever (3) about pull rod (7). fulcrum (b) will cause pull rod (7) to move forward thereby causing lever (8) to 605 COMPARISION OF IMPORTANT swing about fulcrum (c) and hence PARAMETERS resulting in contact of brake block (9) against wheel (5) through brake beam In the underframe mounted brake gear (10). arrangement, it is seen that there are 51 pin joints per bogie in the system. To Extent of brake cylinder pressure reduce the number of pin joints, levers, developed in the brake cylinder will pull rods and push rods, bogie mounted depend upon the extent of reduction in brake system for mainline coaches have brake pipe pressure. Maximum brake become a viable alternative. Comparison

INLET PLUG compressed air is supplied from loco 2

1 3 C 4 8

7 10 6 9 b

5

SCHEMATIC BOGIE BRAKE GEAR ARRANGEMENT FOR BOGIE MOUNTEDFIGURE 6.2 BRAKE SYSTEM

Chapter 6, Page 4 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

of bogie brake system with conventional WTAC4-3-2-402 which is designed air brake system for various parameters is for 16T bogies. as follows:- iv) While fitting curved profile/pull rods

Table 6.1 as per Para (iii) above, it shall be ensured that they are fitted as shown Item Convent- Bogie in the bogie brake arrangement ional Air Mounted drawings and not reversed under any Brake Brake circumstances. System System v) Curved profile/pull rods as per Para Weight reduction - 492 kg. (iii) have been provided with a single (as compared to hole at one end and two holes at conventional air other end, for initial fitment, when brake system) wheel as well as brake blocks are Braking distance 905 m 800 m new, connection of levers through at 110 kmph pull rod will have to be made using (18 coaches) extreme holes/strictly. When wheel No. of pins and 102 84 diameter reduces to 839 mm. and 38 bushes packing is provided at axle box to Brake block wear 3 cc/kwh 1.325 compensate for the wheel wear, rate cc/kwh connection of pull rod must be shifted to adjacent hole. 606 MAINTENANCE INSTRUCTIONS vi) Under new condition of wheel (dia. 915 mm) and brake block, As explained above, bogie mounted brake gap between brake block and system from maintenance point of view is wheel (with brake block in released exactly same as the standard air brake condition) be maintained at about 5 system except for brake cylinder, which mm. This will ensure that piston are different than the existing system. stroke (without utilizing the slack Therefore, to maintain the system, take up capacity) of brake cylinder instructions contained in the Air Brake remained within the value of 32 System (chapter 4) will have to be mm. followed in addition to those which are vii) Design of brake rigging has been indicated in the maintenance manual for done in such a way that up to brake cylinders supplied by wheel diameter of 839 mm. and manufacturers. brake block in full worn condition,

607 SPECIAL PRECAUTIONS TO BE red paint mark on the adjusting TAKEN DURING MAINTENANCE tube sub assembly will not appear (indicating condition that piston The maintenance of underframe unit has extended fully and equipments and fittings should be done as requires resetting). However, if due per underframe mounted air brake system. to some reasons, this mark appears, Following special precautions must be worn brake blocks must be taken to ensure proper working of the replaced by new ones. Failures to bogie mounted brake system. observe this condition will result in increased gap between wheel and i) It shall be ensured that only high brake blocks. Procedure for friction composition brake blocks resetting is explained in the ‘K’ type are used with this maintenance manual of brake arrangement. cylinder supplied by the ii) It shall be ensured that levers of non- manufacturers. AC coaches (13T bogies) are not viii) Once the brake block has worn to mixed with those on AC coaches condemning limit (shown by the (16T bogies) under any mark on the block) it must be circumstances. replaced by a new one. iii) It is very important to ensure that curved profile pull rods (item ‘6’ of ix) The rocker from position of Brake ICF Drg. No. T-3-2-802 which is Cylinder should be kept in meant to be used for 13T bogies is horizontal axis of cylinder before not intermixed or replaced with pull fitment. rod (item 4) of ICF Drg. No.

Chapter 6, Page 5 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

x) Adequate size of pins and bushes 608f Dismantling as indicated in the drawing of the

system must be used in the rigging i) Unscrew cross head and to get effective working of the adjusting tube sub-assembly. system. ii) Loose jubilee clips and remove xi) All flexible hose pipes should be dust excluder and bush. tested in every POH. iii) Admit compressed air in brake

cylinder, unscrew grub screw. 608 DESCRIPTION AND Vent compressed air and MAINTENANCE OF BOGIE unscrew collar by using C- MOUNTED BRAKE CYLINDERS spanner. remove hand brake (REFER RDSO SKETCH- 81200 & trunion. 81204) iv) Unscrew hex nuts M12 slowly. 608a Figure 6.3a & figure 6.3b (RDSO sketch. Please note that release spring 81200) gives the details of brake compressed with force of 60 kg. cylinders and the part number list is Note: The release spring exerts indicated in the table 6.2. severe force while dismantling the unit, the front cover should 608b Detail of 203 mm Air Brake Cylinder be removed very carefully. The (with slack adjuster) is given in figure 6.4 dismantling can not be done by a (RDSO sketch-81204) single person. Atleast two persons are necessary. 608c Hand Brake Attachment v) Remove front cover, release On the Piston trunk of brake cylinder spring, piston trunk sub- hand brake trunions are fitted whenever it assembly with trunion body and is required. During the service application ratchet with adjusting screw. the hand brake trunion does not move. vi) Remove split pin, pin and rocker The maximum hand brake stroke required arm. at the trunion corresponds to maximum vii) Remove allen bolts and piston brake cylinder stroke. and piston trunk sub-assembly. Please not that piston and piston 608d Re-Setting trunk sub-assembly are matched A red paint mark on the Adjusting tube pair and are not interchangeable. sub-assembly indicates that the piston unit Always put some identification has extended over its full range and mark. requires re-setting. The design of brake viii) Remove circlip, collar , ratchet rigging unit is done in such a way that with adjusting screw, pawl, pawl range of slack adjuster covers the life of spring, Plunger, turnion body, brake blocks so that resetting and thrust washer. replacing the brake blocks will be done at ix) Remove Piston packing from the same time. While keeping the piston. adjusting screw stationary, by turning the adjusting tube sub-assembly in clock wise 608g Cleaning and Inspection direction the distance between piston to cross head is reduced to minimum level. Wash all the parts in suitable cleaning The resetting of unit takes place at fluid and wipe them carefully. Inspect position. pawls, Pawl housing ring, ratchet, tooth rollers, roller plate, thrust washer for wear 608e Procedure for Re-setting and damage. Inspect threads of ratchet with adjusting screw and adjusting tube Hold the latch out of engagement with the for the possible damage. Replace packing. resetting plate. The adjusting tube should Check all the springs for possible be turned in clockwise direction by means corrosion and distortion. It is advisable to of the lugs until it reaches the inner end. change the springs on every POH. Give Then reengage the latch. all other parts a thorough visual inspection to detect apparent defects. Replace worn or damaged parts.

Chapter 6, Page 6 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

C M h a a i n p

A t t 9,10,11 e e

6 8 n r 3 7 5 a 6 2 4 12 n ,

c P 14 15

a 1 e

g 13 18 19 M e

16 a

7 32 21 n

u o

20 a f

l 1

24 f 4 28 17 23 o r

22 B

25 G

I C

29 F

C o a

19 c

30 h

26 e s

18 31

52

50

51 61

47,48,49 B o g

45,46 i e

35 42 33 M 36,37,38 43,44 o

34 40,41,38 u

39 n

A t e

%%p0.5 546 TO C OF CROSSL HEAD EYE d 117.5 CRS A i r

B r a (CROSSECTION SHOWN IN HORIZONTAL PLANE TO SHOW k

THE LOCATION OF ROCKER ARM AND BUSH/FILTER ON e

S

THE SIDE OF CYLINDER.) y s t e m

VIEW OF BRAKE CYLINDER SUPERSEDED BY: CORRECTED,ALTERNATIVE INDIAN RAILWAY STANDARDS 4 - CD/8/2000 SIZE FOR ITEM 9 GIVEN 11/2000 ASSEMBLY DRAWINGS SUPERSEDES: E.M.U. STOCK AND SELF GENERATING FIGURE 6.3a AND DIMENSION 130 REFERENCE:- SCALE P CHANGED TO 130%%P0.5mm MAIN LINE COACHES. C TOLERANCES ADDED ON CD/3/99 3 - DIMENSION 204 CRS %%P 0.5 8/99 1:1 D SK SRIVASTAVA 203mm AIR BRAKE CYLINDER T 2 - CD/35/98 TITEL CHANGED. 12/98 (WITH SLACK ADJUSTER) J.S. 1 1,16 CD/24/98 VIEW CORRECTED. 8/98 FLOPY No. :- R . D . S .O. GROUP 1 2 3 4 ALT. ITEM AUTHY. DESCRIPTION DATE B.G. (C) SKETCH-81200

Chapter 6, Page 7 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

58,37,38

57

56,11

60 5 . 0 p %

% 27

0 55 3 1 59 54

53 %%uNOTE:-

1. ITEM-17 WITH WASHER AND SPLIT PIN TO BE USED WHEN HAND BRAKE IS NEEDED.

2. BRAKE CYLINDER SHOULD BE LEAK PROOF WITH TESTING AIR PRESSURE 7 kg/sq.cm.

3. REFER RDSO SK-81057 FOR OTHER WORKING PARAMETERS.

+0.5 -0 204 CRS

%%USECTION A-A (FULL CROSSECTION OF CYLINDER SHOWN)

VIEW OF BRAKE CYLINDER SUPERSEDED BY: CORRECTED,ALTERNATIVE INDIAN RAILWAY STANDARDS 4 - CD/8/2000 SIZE FOR ITEM 9 GIVEN 11/2000 ASSEMBLY DRAWINGS SUPERSEDES: E.M.U. STOCK AND SELF GENERATING AND DIMENSION 130 REFERENCE:- SCALE P CHANGED TO 130%%P0.5mm MAIN LINE COACHES. C FIGURE 6.3b TOLERANCES ADDED ON 3 - CD/3/99 8/99 DIMENSION 204 CRS %%P 0.5 1:1 D SK SRIVASTAVA 203mm AIR BRAKE CYLINDER T 2 - CD/35/98 TITEL CHANGED. 12/98 (WITH SLACK ADJUSTER) J.S. 1 1,16 CD/24/98 VIEW CORRECTED. 8/98 FLOPY No. :- R . D . S .O. GROUP 1 2 3 4 ALT. ITEM AUTHY. DESCRIPTION DATE B.G. (C) SKETCH-81200

Chapter 6, Page 8 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

TABLE 6.2

Item Description & dimensions No. off Ref. Drg. Mtl. & Remarks spec. 1 Cylinder Body 1 SK-81201 Item 1, 3,4 & 5 2 Piston 1 SK-81203 Item - 1 3 Piston packing 1 SK-81204 Item -10 4 Plunger 1 SK-81206 Item - 2 5 Circlip Light B22 1 - IS:3075 Galv. 6 Special Washer 1 SK-81206 Item-14 7 Plunger Spring 1 SK-81206 Item-18 8 Piston Trunk 1 SK-81204 Item-1 & 2 9 Tee bolt M12x35 4 - Galv. Alternatively M12x45 10 Hex. head nut M12 4 - IS:1363 Galv. 11 Spring washer M12 type A 8 - IS:3063 Galv. 12 Dome cover 1 SK-81202 Item-1 13 Ratchet with adjusting screw 1 SK-81204 Item-9 14 Adjusting tube 1 SK-81204 Item-6, 7 & 8 15 Release Spring 1 SK-81206 Item-20 16 Guide bush 1 SK-81202 Item-2 17 Hand brake trunion 1 SK-81205 Item-12 18 Split pin f5 x 40 3 - IS:549 Galv. 19 Washer M22 type -C 3 - IS:2016 Galv. 20 Slotted head grub screw 'C' 2 - IS:2388 Galv. M6x6 21 Jubilee clip size-5 1 - Galv. 22 Dust excluder 1 SK-81204 Item-11 23 Latch 1 SK-81206 Item-3 24 Latch spring 1 SK-81206 Item-21 25 Ring 1 SK-81206 Item-23 26 Slotted Nut 7/8" B.S.W. 1 - Galv. (20 mm high) 27 Shims for plunger As SK-81206 Item-16 required 28 Special washer 1 SK-81206 Item-12 29 Trunion Body 1 SK-81205 Item-1 30 Coller 1 SK-81206 Item-4 31 Circlip light A32 1 - IS:3075 Galv.

Contd… on next page

Chapter 6, Page 9 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

Item Description & dimensions No. off Ref. Drg. Mtl. & Remarks spec. 32 Plug ½" B.S.P. 1 - Galv. 33 Solid Taper pin f 2 x14 1 - IS:2393 Galv. 34 Plunger pin 1 SK-81206 Item-11 35 Rocker arm 1 SK-81206 Item-1 36 Rocker arm pivot pin 1 SK-81206 Item-10 37 Special washer 2 SK-81206 Item-9 38 Split pin f 3.2x18 3 - IS:549 Galv. 39 Roller 2 SK-81206 Item-5 40 Rocker arm roller pin 1 SK-81206 Item-9 41 Washer 1 SK-81206 Item-5 42 Roller Plate 1 SK-81201 Item-2 43 Bush 1 SK-81202 Item-3 44 Filter 1 SK-81202 Item-4 45 Guide bar 1 SK-81204 Item-3 46 Snap Head rivet f 2.5x8 2 - IS:2155 Galv. 47 Hex. head bolt M6x25 8 - IS:2155 Galv. 48 Hex. nut M6 8 - IS:1363 Galv. 49 Spring washer M6 type A 8 - IS:3063 Galv. 50 Bush 1 SK-81206 Item-17 51 Jubilee clip size 2 1 - Galv. 52 Cross head 1 SK-81203 Item-2 53 Circlip light B16 2 - IS:3075 Galv. 54 Special washer 2 SK-81206 Item-15 55 Pawl spring 2 SK-81206 Item-19 56 Alen screw ½" BSFx 2"x7/8" 4 - Galv TD. length 57 Pawl housing ring 1 SK-81206 Item-6 58 Pivot pin 1 SK-81205 Item-3 59 Pawl 2 SK-81206 Item-8 60 Plunger 1 SK-81206 Item-7 61 Retaining nut 1 SK-81206 Item-24

Chapter 6, Page 10 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

C 63 M h 11 DRILL A a a i n

p 3 5 %%C13 DRILL t e

t +0

e +0.5

- n 3 -0.1 r a 69.9 6 6

%%C21 n , c P %%C20 = = e a 60%%d

2 3 4 g M e

5 +0.5 a

1 %%c14

-0 n 1 D u o 2 % +0.1 a % f

5 -0.5

l 4

1

x %%c82 f 1 o 4 = 5 r

B

3 %%c80 7 G

2 . I

2 %%C52 . 0 5 C 0 . + - 0 + - 2 5 3R ) . F 0 P 3R

S + - %%C47 B ( 5 C 2 8 4 5 0 .

. I .5 . 0 0

5 0 3 0 . 8 0 P

1 3 + 1 1 0 T 9 o + -

+ - - 5 6

. 7 1 a

8 3R 9 5

. 9 C 8 = =

8 8 % c C 4

c % 5 4 0 9 % h

% 1 C 3R 2 c % 1

2 % 0 . % e 0 .

% 0 % 0 + - + - s %

L) = MA OR 0(N 306 c8 +0 %% .5 3R 59R %%C14 D %

% +0.1

= 5 - = 4

x 3

25 20 %%C13 DRILL 1 +0.1 -0 10 16 SECTION-`AA' 13R

19 3

+0 120 52 +0.5 = = -0.1 - 333 13 73.1 9 A 8 1 %%c168 3R L 4 9 4 24 2.5

THIS MACHINING TO BE 2

5 25 8

DONE AFTER BOLTING 1

C 4R 4R

PISTON(SK-81203,ITEM-1) %

10 %

IN POSITION. 8 1 0 . 1 . 0 0 + - X 74%%d 5 0 5 0 . 2 4 2 1 . 6 0 C 3 C 1 5 1 C

% % . +0.05 6

% +0.05

% % %%C171.45 3 -0 5 . % -0 0 C 0 . 50 0 + - +0.0 % % %%c35-0.02 3R %%C186.5

76

1X45%%D 1X45%%D DETAIL AT-`X' +0.1 -

%%c44.5 5 4 6 (ENLARGED) C 1 3X45%%D % %

16R 2 18 3 9 10

TEETH OF RATCHET ONLY TO 1 1 9.5

BE HEAT TREATED. 4 2 18 TEETH EQUI-SPACED +0 5

(1) QUENCHING IN OIL FOR CORE 3 B 4 -0.1 130 6 REFINING (850%%DC BEFORE QUENCHING) 4 3

(2) HARDENING (760%%DC BEFORE 4 %%C1 " 1.5 1.5x45%%D 391 , 2 START, 1/4" LEAD, 1/8" PITCH, 6 8 9 QUENCHING IN OIL) WHIT. FORM THREAD. 0.4R HARDNESS HRC-50, CASE DEPTH 0.5mm. 463

% % C 4 d . 4 + . . 0 X . 0 + . 5 % R-48-88 GRADE-`C' OF CL.5.2.4.1 -0 .02 -0 % . 05 +0 5 0.8

3 C .2R %%

4 . 01 3 HARDNESS: 70+5 SHORE `A'

0 5 -0 .

0 4 - 0 . 0 C + -

3R 1 % 3 . % 5

2 %%c95

1R C % % %%C98 49.2 1.6 34 3 1 0 . 0 + - %%c103 5 0 . 9 1 C

% ANNEXURE-'A' % 10 PISTON PACKING 1 492 of Spec.C-K013 %%UNOTE:-

0 EN 353

5 9 RATCHET WITH ADJUSTING SCREW 1 3 2 C C SECTION-`BB' B % % IS:2062-92 % o % 1. ALLOWABLE DEVIATION FOR DIMENSIONS WITHOUT SPECIFIED 8 ADJUSTING TUBE SECREWED END 1 Fe-410WA (ENLARGED) TOLERANCES- `FINE' IS :2102. g i

B IS:2062-92 e 2. ITEM-9 SHOULD TRAVEL FREELY IN ITEM-6 7 RESETTING PLATE 1 Fe-410WA 501 M 3. STAMP `I.R.' OF SUITABLE SIZE ON EACH COMPONENT. ST.GR.CDS-6 OR 86 SQ. 6 ADJUSTING TUBE 1 CDS-13, o 62 430 7 THE STAMPING SHOULD NOT INTERFERE IN THE WORKING BS-980-1955 u n . t

REDUCE O/D OF TUBE BY 0.25 mm. OF THE COMPONENT. . .

5 DUST EXCLUDER 1 X e

6 .

21 WHERE MARKED THUS, & 4. ALTERNATIVELY PISTON FOLLOWER MAY BE CAST IN SINGLE PIECE, d

3 TO BE PAINTED RED. MATERIAL SHALL CONFORM TO GRADE SG 400/18 OF IS:1865-91 4 SNAP HD. RIVET %%C2.5X8 2 IS:2155 GALV. A

13 i 7 533 r

IS:2062-92 B

3 GUIDE BAR 1 r

Fe-410WA a k STEEL 15 e 2 PISTON TRUNK 1 HEAVY .06 IS:1239-90 PART-1

1 0 . + DIMENSION `L' S 0 - DESCRIPTION y I 8 1 + - .

P SEE NOTE

0 5 5 IS:2062-92 C . s T . 0

+ - 0 PISTON FOLLOWER

9 1 1 t 6 + - % No.4 " 3 WITH HAND BRAKE 102 Fe-410WA e 8 % / C m 7 %%c208

% No. WT. OF c & REMARKS % ITEM DESCRIPTION & DIMENSIONS REF. DRG. MTL. SPEC. % WITHOUT HAND BRAKE 50 OFF ONE kg. % %%c172 SUPERSEDED BY: RDSO/SK-81200 INDIAN RAILWAY STANDARDS %%c168 1 6 ASSEMBLY DRAWINGS %%C5 SUPERSEDES: EMU STOCK SELF GENARATING 3 " MAIN LINE COACHES DIA 2 START;1 1/4" LEAD, 9 REFERENCE:- SCALE P 8 1 4.5 6 NOTE 4 ADDED. PISTON,PACKING C 1/8" PITCH WHITWORTH THREADS 3 1 CD/8/2000 11/2000 1:1 DETAILS OF 203 mm. AIR 2 PROFILE MODIFIED. D SK.SRIVASTAVA 8 2:1 8 2 - CD/35/98 TITLE CHANGED 12/98 BRAKE CYLINDER 4 Nos-%%C12 HOLES T 4-%%c15 mm. DRILL EQUISPACED FOR 1. MATERIAL SPEC. CHANGED J.S. (WITH SLACK ADJUSTER) 10 CD/24/98 2. DIMENSION 182 CHANGED TO 8/98 PLUG WELDING %%c171.45 FIGURE 6.4 1 FLOPY No. :- GROUP 1 2 186.5, TOLERANCE CORRECTED R . D . S .O. 3 %%C186.5 ALT. ITEM AUTHY. DESCRIPTION DATE B.G. (C) SKETCH-81204

%%c191

%%c203.2

Chapter 6, Page 11 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

insert rocker arm pivot pin and 608h Assembly washer and lock it with split pin. After cleaning and inspection of all the parts and before re-assembly apply ix) Tighten roller plate with front uniform layer of grease Esso Becon 2 on cover with 8 Nos. hex. bolts all the moving parts. Grease cylinder body spring washers and hex. nuts . and piston packing liberally with Esso Becon 2. x) After applying grease Esso Becon 2 on all the moving parts, i) Put washer and insert ratchet with piston packing, cylinder body, adjusting screw in turnion body. insert the above sub-assembly Put two collars in the groove of (consisting of piston trunk sub- ratchet with adjusting screw and assembly, piston in cylinder lock it with circlip. body. ii) Insert spring retaining cup plunger xi) Place release spring on piston spring, washer and internal circlip trunk sub-assembly. with circlip plier in the longer side of trunion body. xii) Place front cover in required position A,B,C on the release iii) Insert pawl (ensure proper spring and compress the spring position) pawl spring in the square with a force of 60 kg hole of the trunion body and lock it approximately. Tighten front with strip. Bend the ends of the cover with body with 4 Nos. hex. strip. head bolts, spring washer and hex. nut with a tightening torque iv) Place pawl housing ring on of 200 kg cm. trunion body so that it pivots on the pivot pin of turnion body. xiii) Place hand brake trunion sub- Check that tooth of pawl housing assembly on piston trunk sub- ring matches with teeth of ratchet assembly. Screw collar on piston with adjusting screw. If required, trunk sub-assembly and screw in tooth of pawl housing ring may grub screw. Put latch spring and be filed. latch in cross head. Insert ring in the latch. v) Insert plunger pin with required No. of shims. Insert this sub- xiv) Put cross head sub-assembly on assembly in the shorter side of adjusting tube sub-assembly trunion body. consisting of adjusting tube, adjusting tube screwed and vi) Place the above sub-assembly resetting plate). Lock cross head (consisting of all the above parts) with adjusting tube sub-assembly on piston (ensure proper position by washer, hex. slotted nut and as indicated in the assembly split pin. drawing. Place piston trunk sub- assembly on it and lock it with xv) Clamp dust excluder on bush piston by 4 Nos. allen screw and with jubilee clip and insert spring washer with a tightening adjusting tube sub-assembly in torque of 200 kg.cm. Insert bush. Screw adjusting tube sub- packing on piston. assembly in bush. Screw adjusting tube sub-assembly on vii) Insert rocker arm roller pin in ratchet with adjusting screw till it roller and then insert it in rocker reaches its dead end. arm. Insert roller and washer on the roller side of roller pin and xvi) Clamp dust excluder on collar lock it with split pin. with jubilee clip. viii) Place rocker arm sub-assembly xvii) Screw 1/2” plug with O-ring in within two shackles of piston body. trunk ring sub-assembly and

Chapter 6, Page 12 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

608i Testing Procedure TEST NO. 2 - OPERATION:

The testing procedure of brake cylinder is A. Full Stroke given below § Close cock 3 and open cock 2. PREPARATION FOR TEST § Observe the full stroke of the piston. § This must be within ± 1.0 mm of the The test layout is shown in the attached maximum stroke value. figure 6.5 (RDSO's Sk 98108). A special pin will be required to locate the cross B. Take-up Stroke head between the angle iron slots. § Close cock 2 and open cock 3 to During testing cock 2 must be opened exhaust the cylinder pressure to zero. slowly whenever the cock is used to admit air under pressure to the cylinder. § Close cock 3. Connect the air supply to the cylinder § Open cock 2 and allow the piston to body. Commence with all cocks closed move out slowly until the operating pawl is heard to “click over” then TEST NO. 1 Leakage: close cock 2. § Measure the take up stroke . Open Cock 1 to charge the MR to 7 § This must be 32 mm for main line self kg/cm2 pressure generating coaches of 95 mm stroke. Open Cock 2 to charge the cylinder 0.7 § Close cock 2 and open cock 3. kg/cm2 pressure § As the cylinder returns to release the

locking pawl must be heard to click into The piston stroke must be limited to position 32mm, wait for one minute for settlement and there must be no drop in Note: pressure shown in the leakage volume gauge for a further minute. Also observe 1. Operate the piston at full stroke at that leakage does not exceed 0.1 kg/cm2 least 18 times to test all ratchet teeth. in 10 minutes. 2. Observe that the adjuster operates at each release and the adjusting tube Repeat this test with the cylinder charged and cross head being ‘inched’ out 3.8 kg/cm2 to pressure and with cock 3 along the stroke. closed limiting the maximum piston stroke to 95 mm. Observe that the 3. The movement of the Piston must be leakage does not exceed 0.1 kg/cm2 in 10 smooth without any minutes. tendency to stick at any part of the stroke. Open Cock 3 to exhaust the cylinder pressure to zero.

LEAKAGE VALUME GAUGE SLOTTED ANGLE SCALE 0.5 MM

3 UNION

2 BED PLATE SCREW DOWN COCK-2 AIR SUPPLY 1 MAIN RESERVOIR

TEST LAYOUT FOR BRAKE CYLINDER WITH BUILT IN SLACK ADJUSTER FIGURE 6.5

Chapter 6, Page 13 of 14 Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

C. Take-up Length (without Quick Resetting requirement, in the plunger pin so Gear) that spring Dowel pin Ö2X14 easily locks the plunger and plunger pin by § Close cock 2 and open cock 3. inserting the dowel pin in the holes. § Remove the pin from the cross head and iii) At the time of re-assembly check unscrew the adjusting tube until the red that the tooth of pawl housing ring resetting mark on the adjusting Tube is matches with the teeth of Ratchet visible. with adjusting screw. The pawl housing ring must go smoothly § Disengage resetting latch and screw in inside the teeth of Ratchet. If it is not the Adjusting Tube. matching then the notch portion of § Re-engage resetting latch. the tooth of pawl housing ring should be filed till it matches with § Check that the Dust Excluder Collar is the teeth of Ratchet screw. free and does not twist when the Adjusting Tube is being rotated. iv) Before final assembly of piston and piston trunk sub-assembly ensures § Close cock 1 and open cock 2. that the threads of adjusting tube § Close all cocks when the system is at (turns in clock wise direction) atmospheric pressure. smoothly matches with the threads of Ratchet screw. D. Take-up Length (With Quick Resetting Gear) v) Before fixing the front cover in the § Close cock 2 and open cock 3. cylinder body check visually the red § Remove the pin from the cross head and paint mark appears in the Adjusting turn the resetting screw until the red tube. If it is not visible then repaint. resetting mark on Adjusting tube is 608k Special Tools visible. Table 6.3 § Screw in the Adjusting Tube with the resetting screw. § Check that the Dust Excluder Collar is Description No. off free and does not twist when the Adjusting tube is rotated . Close cock 1 Ball peen hammer 1/2 kg 1 and open cock 2. Screw driver big 1 § Close all cocks when the system is at atmospheric pressure Screw driver small 1

608j Important Instructions for Double end spanner to 1 Reassembling the Brake Cylinder at the tighten/loosen M6 nut Workshops Press machine to apply 60 kg force 1 for assembling front cover with i) While fixing the Roller plate with body front cover 4 pairs of hex. Bolts M 6x25 along with spring washer A6 Scriber to remove Split pin 1 and hex nut M6 are required. Before fixing the roller plate, the inner 5 mm Allen key 1 surface of front cover should be checked for perfect plane. At the Torque wrench with 200 kg cm 1 time of fixing the roller plate with front cover 2 Nos. of spring washers ***** are kept inside in between them (one each side) in first two bolts, so that the rollers can move smoothly in the cover plate in angular position. ii) While matching the holes of plunger and plunger pin number of shims are added (say 2 or 3) as per the

Chapter 6, Page 14 of 14 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC coaches)

CHAPTER 7

TRAIN LIGHTING AND MAINTENANCE SCHEDULES OF NON AC COACHES

701 INTRODUCTION Depending upon the train lighting The following systems of Train Lighting systems, the coaches are of following are in use on Indian Railways BG types. coaching stock: In this chapter the train lighting system 1. End On Generation (EOG) of Non AC and AC SG coaches will be discussed. 2. Self Generation (SG)

3. Mid On Generation (MOG)

BG COACHES

Self Generating Mid On Generation End On Generation (SG) Coaches (MOG) Coaches (EOG) AC Coaches

Split type Roof Mounted AC Non- AC Under Package Unit Coaches Coaches slung (RMPU)

Split type RMPU with 25 Under Slung KVA inv erter

Chapter 7, Page 1 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

702 GENERAL DESCRIPTION OF during journey from minimum speed MAJOR EQUIPMENT for full output (MFO) to maximum speed. The alternator is used for: 702a BRUSH LESS ALTERNATORS i. Charging the coach batteries. Brushless alternators are axle driven, with ‘V’ belt drive, mounted on the ii. To meet electrical load i.e. fans, lights, bogies of the AC & TL coaches. These air conditioning, water-raising alternators are of various ratings and apparatus (WRA) etc. in the coach. make as per requirement for different type of coaches. They are being 4.5 kW brush-less alternator procured as per following RDSO’s are driven by 4 Nos. of C122 matched specifications: - sets of ‘V’belt coupled between the axle and the alternator pulley. The axle Specification No. Ratings pulley is of 572.6 mm PCD (pitch circle dia.) and alternator pulley is of EL/TL/47 Rev 'C' 4.5 kW, 37.5A, 120 V 200 mm PCD. Belts are kept under with amdt no.1,2,3 DC tension by a spring-loaded belt- used on non AC tensioning device. coaches. EL/TL/54 Rev 'A' 18 kW, 138.5A, 130 V 18kW/ 22.75kW/ 25kW DC alternators are fitted with 12 Nos. of with amdt no.1,2,3 deep V-grooved pulleys of 200 mm used on SG AC PCD with six grooves on each side of coaches. the shaft, which is driven by V-belt in (Split type underslung) conjunction with an axle pulley. ELPS/SPEC/TL/01, Optimized 22.75 Dec. 1993 kW/25kW, 702b RECTIFIER-CUM-REGULATOR UNIT (RRU) with amdt no. 1 & 2 175A/ 193A, 130V DC, used on AC The rectifier cum regulator unit has coaches of SG type mainly following functions:

4.5 kW Brush less alternators are used i To rectify the 3 phase AC output of on Non AC BG Coaches. It consists of the alternator through DC full a three-phase hetropolar inductor type wave bridge rectifier. Alternator and a static Rectifier-Cum- ii Regulating the voltage generated by Regulator Unit (RRU). the alternator at the set value.

Earlier AC coaches provided iii Regulating the output current. with under slung split type AC units were fitted with two nos. of 18 kW Recently electronic rectifier cum brush less alternators. After the regulator (ERRU) confirming to development of roof mounted AC units RDSO specification (RMPU) and 25 KVA inverters, 22.75 No.RDSO/PE/SPEC/D/AC/0013 kW (Optimized) brush less alternator (Rev.0), developed, which has was developed within the same frame been fitted on a very few coaches size of 18 kW alternator. Subsequently on trial. 25 KW alternator with new design was developed for 2 tier and 3 tier AC 702c BATTERIES sleeper coaches with RMPU and 25 kVA inverters and for AC 1st class one The following types of batteries are 25 kW alternator with 25 kVA inverter provided on under-frame of AC & non provided. AC Self Generating type and End On Generation type coaches. The brushless Alternator with the help of static rectifier cum regulator i. 6V/120 Ah flooded type (Mono unit is capable of developing voltage at block cells) on Non AC BG SG the set value to meet the coach load coaches. Chapter 7, Page 2 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

ii. 2V/120 Ah , VRLA cells on Non battery box is painted with anti- AC BG SG (Self Generating) corrosive paint. coaches. iii. 2V,1100 Ah 56 cells VRLA 110 V While mounting the battery SG AC coaches fitted with RMPUs box in underframe of the coaches, and 25 kVA Inverter special care is taken to provide locking nuts and split pins to avoid iv. 2 V, 800 Ah flooded type cells on any accidental falling of batteries under -slung mounted split type AC while running. equipment . v. 90/120 Ah, 24V on EOG (End- Recently both the Production On -Generation) type AC coaches Units have been instructed to provide (Emergency batteries for lighting ) battery boxes as per RDSO drg. No. RDSO/SK/K/0037, which is suitable The 2V,120 Ah TL batteries are for both makes of VRLA batteries i.e. used in conjunction with brushless M/S Exide and M/S Amar Raja. The alternator with suitable Rectifier-cum battery box is having improved safety Regulator of 4.5 kW capacity for train factor coup led with flexibility to lighting system of TL BG SG type accommodate both makes of VRLA coaches. The 2V, 56 cells 800 Ah / 2V, batteries. 56 cells 1100 Ah VRLA batteries are used in conjunction with brushless 702e BCT (Battery Charging Terminals) alternator with Rectifier -cum Regulator unit of 18/22.75/25 kW capacity for AC BCT is provided at the both coaches. 1100 Ah batteries are used on sides of the coaches for external AC coaches equipped with the Roof charging of the batteries at stations of Mounted Package type AC plants. 1100 maintenance lines . Ah capacity battary are of the valve regulated lead acid (VRLA) type which 702f RJB (Rotary Junction Box) has its inherent advantages like : Rotary Junction Box is provided inside the coach. It is used to · Topping up with water is not arrange and control the power supply to required. various circuit of the coach (e.g. light, · Periodical checking of specific fan) with the help of rotary switches gravity is not required. and HRC fuses. · Regular maintenance to avoid sulphation of terminals and 702g EFT (Emergency Feed Terminals) connections not required. It is provided at the both ends

of the coach to feed the additional The VRLA batteries are also known as supply to the adjacent coach in case of Sealed Maintenance Free (SMF) emergency. Supply from the healthy batteries. coach may be extended to him/dark

coach by connecting supply to the 702d BATTERY BOX positive and negative terminals of the

EFT. ICF type design battery box

for AC coaches is a fabricated 702h TL Lamps framework made of mild steel

confirming to drg. No. WGFAC-7-1- 25 and 40 Watt lamps are 026. Whereas RCF design is of closed type confirming to drg. No. CC71448 provided in the non AC coaches. The (PP side) & CC71451 (NPP side), It is power supply is at 110 Volt DC. 25 suspended on coach in the under Watt lamps are used in corridor, light frame and is provided with front lamp, wash-basin, toilet. 40 W lamps opening doors for paying attention to are used for lights in the coach. batteries. FRP trays are provided to prevent corrosion. The interior of the

Chapter 7, Page 3 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

702i FTL (Fluorescent Tube Light) as per platform report. Proceed as follows:- It is a 2 feet long, 20 watt fluorescent tube light provided in the n Check field fuse, replace if found coach for the light. It works at 110 V blown, with approved makes i.e., DC supply. It gives better illumination S&S or English Electric make. and is being provided in the coaches in place of TL lamps. n Check the continuity of field and phase winding with the help of test 702j Carriage Fans lamp/ multi-meter to ensure that windings are not open circuited. On non AC BG coaches 400 mm sweep carriage fans are used where n Check for loss of residual system voltage is 110 DC. These fans magnetism with the help of are fixed type and confirm to IS : 6680- voltmeter across the field 92 with latest annexure 'H' for deviation terminals. In case of loss of to IS 6680-92. magnetism, give 12 V DC flashing to the field terminals for few 703 TRIP SCHEDULE seconds to regain lost residual (PRIMARY & SECONDARY magnetism. MAINTENANCE) n Check that the regulator feedback 703a ATTENTION ON MAINTENANCE loop is O.K. LINES n Check connections for tightness in As soon as the rake is berthed alternator and rectifier regulator. If in the maintenance lines and before this is all right, remove belt from commencing the work, a caution board alternator. shall be clamped to the rail on either side of the rake by TXR or his n Use testing machine for testing representative. Rail locks shall be used alternator in situation. Couple the on either side of the rake for the safety portable motor drive with of maintenance staff attending under Alternator. gear equipment. TXR should ensure clearance from electrical n Check the DC output voltage at the Chargemen/staff incharge for the rectifier and regulator terminals. maintenance of rack before removing Identify the defects if any and the caution board and rail locks. rectify them. The battery should be isolated while doing this test. To avoid any malfunctioning of the above system, print ed forms for n Provide new split pin for pulley permit to work on pit lines issued by castle nut after completion of work. the traffic department and after completion of the work, completed / n Check up the condition of safety men withdrawn form can be used. chain and availability of split pins in safety chain bolts. Check the plate-form attention report and concentrate first on n Check up alternator suspension attending the defects in these coaches bracket and tension gear for any by adapting systematic trouble shooting damage and replace, if necessary. procedures. Proceed as follows in respect of other equipment. n Check up and tighten loose bolts in terminals box covers. 703b ALTERNATOR n Check availability of split pin for First attend alternators in alternator castle nut. coaches for generation, which have arrived "cold" and coach dark condition n Check the belt tension after every round trip of the coach.

Chapter 7, Page 4 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n For new V-belt fitted, the belt meter as per recommendations of should be re-tightened after V belt manufacturers. completing the first trip. n Check that all the sets of belts n Check the tension indicator pin at provided should be of same make suspension point after every round & grade. trip for flat belt drive alternator. 703e RECTIFIER CUM REGULATOR n Never energize field from battery in case of failure of field circuit n Clean regulator externally. Open diode in regulator. Apart from non regulator terminal cover and check regulation, this may cause for signs of overheating in all the permanent damage to field terminals/bus bars/etc. Check up windings. for loose connections and tighten the same. If the terminal board is n If there is no generation, ensure found affected due to heat, replace that there is no breakage in the terminal board with new one. cable termination. n Check for any damage to the phase and field wires /cables inter 703c AXLE PULLEY connecting regulator and alternator and its anchoring arrangement. n Examine the indicating white mark n Check and secure properly the on the pulley axle and ensure that terminal cover and regulator cover. the pulley has not slipped. If pulley has slipped, take necessary n If the generator is normal, check corrective action. the cable termination of the regulator visually for any n Tap the pulley with hammer and abnormality. judge the tightness or crack by n sound. If it gives clean metallic If the alternator arrived without sound the pulley is tight. Dull generation, open the regulator and sound indicates that it is loose. Bolt check for any abnormality and should be tightened with torque ensure the fuses are intact. wrench to 30 kgm. n Check the cable for any abnormality from the alternator to n Check the lock nuts and split pins the regulator by using test lamp, if for availability and tightness. found open/short attend the same.

703d BELTS n Ensure the residual magnetism is available in the alternator. n Check condition of belt for fraying n If needed change the regulator and of edges, etc., ensure the generator by running the alternator with a portable motor. n Check the belts for overturn and correct it, if necessary. NOTE : Components : Components of RRU such as MA, ET, CT, OVR etc., and n Check the number of belts which electronic components such as power should be 4 nos. for 4.5 kW diode, field diodes, zener diodes, alternator. auxiliary diaode etc., shall be procured only from OEM. n Tension should be felt by hand by striking it slightly. Belt in correct Maintenance of alternator/RRU has tension will respond `alive' and to be done in line with SMIs issued `spring-back'. If required by RDSO as well as Manufacturer's retensioning, the same shall be recommendations. retensioned to the recommended values as applicable. This can also be checked using a suitable tension

Chapter 7, Page 5 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

703f BATTERIES/BATTERY BOX n Coaches with discharged batteries which shows less than 100 V on i. Conventional Lead Acid load should be put on charge at Batteries double the normal rate of charge and the charging reduced to half n To know the condition of cells the rate of charge as soon as the during `Trip Examination' some gassing starts and continued till cells in a battery are treated as the specific gravity rises to the `pilot' cells. On arrival of train in fully charged value which should the maintenance line, disconnect be between 1210 and 1220. Use all inter vehicle connections. the battery charging terminals Record the specific gravity of provided in coaches for charging `pilot' cells in each battery. purpose. Check up correct polarity Different cells should be identified and connect the charging cables. as pilot cells every month. The idea Use a clip on D.C. ammeter of 0- of identifying different cells as 25 A range to check up the battery pilot cells every month is to ensure charging current. Note down the that true condition of the battery is rate of charging and the number of reflected. hours of charge.

In case of conventional coaches n Check specific gravity of pilot cells working on 110 V D.C. system and the total voltage of battery on there are two crates with 9 mono load at the end of charge and block batteries in each battery box. record. Marking of these cells to indicate pilot cells shall be done as follows. n Keep micro porous vent plug tight. Ensure that washer is available in Table 7.1 micro porous vent plugs.

1 2 3 4 5 6 7 8 9 n Check all the battery box members 10 11 12 13 14 15 16 17 18 for any cracks in the fabricated battery box/cradle and take Table 7.2 corrective action.

Month Pilot Cells n Check for proper fit ment of mono 1st Month 1, 12, 13 block in the battery box ensuring 2nd Month 2, 11, 14 wooden packing pieces. 3rd Month 3, 10, 15 4th Month 4, 9, 16 n The person in charge of battery 5th Month 5, 8, 17 maintenance should record all the 6th Month 6, 7, 18 readings mentioned above in his diary and this information should Repeat cycle further. be transferred to the register maintained for various trains. Check the floats of each cell and check for correct electrolyte level n Check anti-theft rods and provision as indicated in the float stem. Replace of nuts both inside and outside the missing/defective floats. In case of battery box on either side. Provide low level, replenish with distill water. If if found missing. Secure battery any cell needs too much water for box cover finally after all works replenishing, watch for crack in the are completed. cells and also check the voltage on load n Ensure that the fitment of the which should not be less than 1.80 V. battery box is in order with all the In case of any defect, remove the cell bolts, nuts, lock nuts, split pins etc. and replace by a spare one preferably are in order. of the same make and lug date or a lug date as close to the one already in the n Ensure the weldings are proper coach. and the bottom plate of the box is well secured. Chapter 7, Page 6 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n Ensure the cells are properly 703h FANS cleaned. Following scheme is prescribed for all n Ensure the water level in all the trains during primary or secondary cells/mono block is upto the mark maintenance at a depot:- and top up the cells with distilled

water wherever required. n Switch on each fan individually. n Ensure all micro porous vent plugs Check starting of fan when and sealed floats guide are properly switched on. In upper class closed. coaches, check fan for starting in the lowest position of regulator and n Check the sp. Gravity of the cells if also for variation of speed in the it is less than 1200, the battery other regulator positions. If the fan shall be connected on charge. does not start, short the switch n Measure the load voltage of the terminals with a small piece of cells/mono block if it less than 100 wire temporarily. If the fan starts V, identify the low voltage cell and this will indicate that the replace if needed. controlling tumbler switch/regulator is defective. n Check the terminations in the fuse Replace defective switch/regulator. and the condition of the fuse. n Check the termination of cable in n If the fan does not start when the the under frame link box, for toggle switch terminals are proper condition and attend if shorted, proceed as follows: needed. ¨ Test for supply at the 2-way ii. VRLA Batteries : connector terminals near the fan with the tumbler switch SMI no.RDSO/PE/TL/SMI/0001- on. If there is no supply, the 98 (Rev.0) dt. 01.06.98 to be wiring is defective and has to followed. be attended.

703g EARTH CHECKING ¨ Open dome cover in case of swiveling fans and remove fan Before checking the earth in body fixing screws in case of the coach, it should ensure that coach is fixed fans. not connected to the adjacent coach

through EFT (Emergency Feed Terminal). After isolating the coach the ¨ Remove carbon brushes. earth shall be tested by using a double Check brushes for condemning test lamp as explained in the RDSO size, proper bedding, correct code of practice of 110 V coaches. If spring tension and correct any earth is noticed the required grade of brush.

corrective measures should be taken to remove the earth before inducting the ¨ Check for free movement of coach in the service. No coach shall be brush in the brush holder. allowed for service with +ve earth. Replace defective brushes/ However incase of –ve earth this can be springs. allowed for maximum one trip that too with properly marking as –ve earthed. ¨ If the commutator is dirty, clean the surface with sand Record all the attention given paper of 0/0 size. in the under frame and roof, the Specific Gravity, the condition of ¨ If the commutator surface is generation, lamps, fans and fuses, grooved or the segments are availability of belts etc. with coach and found pitted in one or more other details. locations, replace the fan by an overhauled fan. The defective fan can thereafter be rectified by replacing the defective Chapter 7, Page 7 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

armature by a good one. If repeated large scale deficiencies of spare armature is not available foreign Railway's coaches. The send defective fan to shop for Depot/Railway entrusted with attention. primary maintenance shall be advised by message whenever the ¨ If the fan is noisy, check for deficiency is made good or when loose blades/fan guards and large scale deficiencies are noted tighten them. If the noise is on arrival.

due to bearings, replace the 703i LIGHTING fan and send defective fan to shop for replacing. n Switch on each lamp/tube light. If the lamp/tube light does not glow, n Check the fuse for fans and ensure check lamp/tube light and that it is of correct size (35 SWG) replace, if fused. If the lamp is all tinned copper. right, check control fuse and replace, if found blown. n Clean fan body and its guard. n If the fuse is all right, check control n In swiveling and bracket fans switch and replace, if necessary. ensure that the fan dust cover is If the switch is all right, check up promptly replaced after attention lamp holder for stuck up plunger and also that the nylon cord or loose connection and rectify provided to prevent loss of fan defect. If there is no defect in the dust cover, is available in position. lamp holder, check up for supply at the holder terminals and if the n The MCB/fuse controlling the fan wiring is found defective, mark the circuit shall be checked for correct coach "Sick" and arrange for rating (16A for non AC SG attention in maintenance lines. coaches and 6 A for SG AC coaches and proper functioning and n Note down the coach number, total replace if found defective. number of lights in each coach and the number of defective/missing n Note down the total number of fans lights on arrival. in each coach and the number of fans found defective. Defective n Provide switch covers and fuse fans shall include fans, which covers promptly, if they are required push start. The aim is to missing. achieve cent percent working of fans. The records mentioned above n If any dome cover is open or not will help in working out the extent secured properly, rectify defect, if of the problem in any particular any and secure. service to take quick remedial action. n Replace broken glass domes/acrylic covers of tubelights. n The fans shall be available as per lay out for the coaches. In case it is n In case of berth lights in first class necessary to remove any fan for and AC coaches, check up for free attending to major defects and no movement of shutters. Replace, if spare fan is available a ‘Deficiency found defective. Label’ shall be affixed near the fan point. In case no deficiency Label n Clean side lamp glasses and red is available. Theft Memo shall be shield inside the lamp in SLRs. issued to the security branch. Check up for free movement of operating handle and drop same n Deficiency of fans shall be lubricating oil, if necessary. Clean promptly made good when noted tail lamp glass and the reflecting by any depot irrespective of surface inside. whether the train is primarily maintained or not except in case of Chapter 7, Page 8 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n In case of fluorescent light check n The chipping of insulation is a holders, switches, electronic ballast dangerous practice this leaves and wiring and rectify permanent scratch on the cable. defect/replace component. The taped conductor will not be quite satisfactory and so chipping n Check MCBs/fuses for light should never be done. Testing circuits in junction box for proper shall be done only at cable operation and replace defective terminations. MCBs. Watch for loose connections between MCB and bus n Poor chipping of cable, poor bars and rectify. Ensure that crimping of cable lugs and loose MCBs/fuses are intact for connections in terminals will protection of each circuits. result in excessive heating and discoloration of lugs, tapes and n Check tightness of terminal cables. Watch for this during connections of HRC fuse for inspection and take prompt action negative circuit in junction box and to locate and rectify the defects. rectify defect, if any. Replace overheated tape and re- tape the overheated portion of n Use fuses/fuse wires of cable insulation at terminals using recommended sizes in junction PVC tape after ensuring proper box as a stop gap measure in place cable connection and cause of of MCBs and HRC fuses. Ensure overheating. that fuse wire provided in junction box as a temporary measures n Replace blown fuses, incorrect size enroute should be rep laced with fuses and discolored fuses by MCBs & HRC fuses of the correct fuses of proper rating. Replace sizes at the primary maintenance blown or incorrect size of HRC depot. fuses by correct rating. Check all fuses and ensure that they are n Remember that fuses & MCBs are secured tightly to their terminals. safety switch gears provided for Replace defective MCBs/fuses in isolating the supply in case of junction box by MCBs/fuses of faults. Never by-pass or use correct rating. incorrect fuses as this may result in serious failures . n Never replace a blown fuse by a higher gauge fuse. Remember that 703j WIRING AND ACCESSORIES fuses are provided for protecting circuits in case of faults. Try to n Earthing of wiring in the coach find out the cause of fault. shall be checked both on the positive and negative wire n Loose and exposed/hanging wires separately in each coach by the should be secured and properly earth testing device. A coach with covered. In case wiring is found negative earth fault in case of 110 mechanically damaged or tampered V DC system, which could not be with or needs replacement , the attended in time, can be given in coach should be marked service in case of emergency. The electrically sick. If the work is of coach shall be taken for attention a minor nature, this may be done in by the primary maintenance maintenance lines. station during the next trip. n If the repairs are heavy the coach n Cable insulation on coaches get may be booked to Shops for damaged in various ways resulting attention. Coaches which are in earthing. Damaged insulation suspected to have wiring defect whenever noticed shall be either in the underframe or roof promptly taped with PVC tape. shall be subjected to insulation test with 500 V megger.

Chapter 7, Page 9 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

704 FORTNIGHTLY SCHEDULE n Check the "make of cells and the lug date. Different "makes" of cells 704a BATTERY mono block if found mixed together should be replaced by a In addition to the instructions single "make " of cells. If it is not contained under "Trip examination" the possible to do this during one following works shall be carried out. Fortnightly Examination this should be noted down and attempts n Clean the interior of battery box. made to replace the same during the next Fortnightly Examination. n Clean the cell tops and deposit of sulphate, if any, in inter cell and n Check whether cell/ mono block end cell connections. packing is tight and provide additional packing, if necessary. n Remove sulphated inter cell Use only hard wood coated with connections, clean the connecting acid resistant paint for cell surface with a piece of cloth. Use packing. Never use untreated wood fresh fasteners. Sulphated internal or plywood for packing of cells/ connections and fasteners should mono block. If any cell/ mono be soaked in kerosene oil, cleaned block is found cracked, replace it with warm water and kept ready promptly. for use. Inter cell connections should be provided with both small n Check for provision of anti-theft and large strips and four fasteners rods and provision of nuts, both each with one hexagonal nut, one inside and outside the battery box spring washer to IS:3063 and two on either side. Replace deficient steel punched washers to IS:2016. rod and nuts.

n Remove end cell connectors, clean n Apply petroleum jelly on inter cell the connecting surface both in cell connection and end cell and connector thoroughly and connections. Do not use grease. provide back. Check for proper crimping of terminal. In case n Check battery fuses and replace strands of connecting cable are overheated/incorrect size fuses by found cut at the crimping end, cut correct size. wire at the crimping end and re- crimp with a new inter cell n Check battery box fixing nuts for connector. End cell connector tightness. confirming to IS:6848 should only be provided. Tinned copper n VRLA Batteries : SMI.No. crimping sockets with a single RDSO/PE/TL/SMI/0001-98 IRev hole, if any, provided as a stop 0) dtd. 01.06.98 to be followed. gap measure should be replaced by standard end cell connector. 705 MONTHLY SCHEDULE Provide end cell connectors with both the fasteners each with one In addition to the works mentioned in spring washer to IS: 3063 and one Trip & Fortnightly Examination, carry punched steel washer to IS:2016. out the following:

n Tap sealed float guides and check for free movement. Look for elongated holes in sealed float guides and replace such guides. Replace deficient floats promptly.

n Check whether vent plugs are of the anti-splash type and replace if required.

Chapter 7, Page 10 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

705a ALTERNATORS, RECTIFIER AND case pilot cells show no REGULATORS appreciable improvement, check specific gravity of adjacent cells. If i) Check for tightness of terminal the specific gravity does not connections of alternators and improve in spite of charging, rectifier regulators. replace the battery by another set and send the defective battery to ii) Thoroughly clean externally the Depot/Shop for treatment at the alternator and regulator. earliest. Cells should be handled with due care while unloading and iii) Open inspection cover of regulator. in transit to avoid breakage. Blow dust with a portable blower. Adequate facilities should be Secure covers tightly after created in Depot for treatment of inspection. cells which do not pick up charge. Sulphation will be the main cause iv) Check locking of current setting of for this and Sulphated cells regulator, if disturbed it should be should be treated for their recovery reset/locked as prescribed. as specified.

v) Check the alternator pulley for n On completion of charging, record proper fixture and the availability the specific gravity of individual of castle nut and split pin. cells. If there is any wide variation in the specific gravity/ voltage of 705b AXLE PULLEY cells, disconnect and replace those cells showing low specific n Watch for shifting of axle pulley gravity/voltage by spare ones. In by observing the white band on case there are more than 1/3 of either side of pulley. Reset the total cells with low specific correct position of pulley, if found gravit y, the entire set should be shifted and tighten the loose nuts replaced. Cells showing reverse with torque wrench with voltage, zero volts should be recommended torque.. withdrawn and replaced by charged cells immediately. n Check tightness of nuts and also availability of chuck nuts and split n Record individual voltage of cells pins in all fixing bolts. and the total voltage on full load of the coach. 705c BATTERIES n Change the marking of the pilot i. Conventional Lead Acid Batteries cell as given in table 7.2.

n Record specific gravity of ii. VRLA Batteries individual cells/mono block. "Switch on" full load of the coach SMI no. IRCAMTECH/PE /TL/ SMI/ and record individual voltage of 0001-98- (Rev.0) dtd. 01.06.98 & cells and total voltage. "Switch RDSO/PE/TL/SMI/ 0002-98 (Rev.0) dt. off" load. If the specific gravity is 09.12.98 less than that painted on the battery box, charge the cells as 705d JUNCTION BOX specified under "Trip Examination" after topping up with n Open front door. Check all DM water, if required. connections in MCB-cum-fuse panel for tightness any for heating n Use battery charging terminals sign, fuses etc. Check availability provided on coaches for charging of terminal lugs for all cables in purposes. Charging should be junction box and replace if continued till the specific gravity necessary by terminal lugs of rises to the value of mentioned in correct size. battery box, on "Pilot" cells. In

Chapter 7, Page 11 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n Check Rotary Switch / MCBs n Studs used for fixing the fan to provided for lights, fans circuits for coach body, shall be checked and correct condition and Rotary tightened, wherever necessary. Switch and EFTs for proper Availability of all the three fixing operation. Replace/ repair studs should be ensured. defective MCBs. If MCBs are not n All the switches controlling the readily available provide fans shall be checked for its rewirable fuses of appropriate smooth operation and correct ratings, purely as a stop gap working and replaced, where measure. Check up negative fuse necessary. and replace if necessary by different ratings of HRC fuse for n Fan regulators in Upper class AC and non AC coaches. If rotary coaches shall be checked for switches are provided instead of smooth operation from one MCBs, Check for proper operation. position to the other. In case the Check up HRC fuses provided with regulators are not regulating the rotary switches for correct rating fan speed, the resistance box shall and replace, if necessary. be checked and replaced, where n Close front door and secure necessary. properly by the locking key. If n found defective, the same may be Fan blades shall be replaced if attended/replaced. found bent, or if there is no proper air discharge. 705e WIRING AND ACCESSORIES

In addition to the items listed under trip 705g CARRIAGE LIGHTING

inspection, the following items shall be inspected: In addition to the items listed out under "Trip Examination" proceed as follows. Superstructure wiring and underframe wiring shall be tested separately for n Open each fitting with the dome which the main negative fuse in shall be key and remove the dust of the opened and controlling MCBs for all fitting both from inside and circuits kept off. All other fuses shall outside. Ensure free operation of remain in circuit. Insulation resistance locking mechanism and eplacer shall be measured with all fittings and defective fitting. Clean glass equipment connected both on domes first with wet cloth and then underframe and superstructure. The with a clean dry cloth. underframe wiring shall be tested with battery fuse open. The IR value n Replace rusted fittings and fittings should be minimum 2 Mega-Ohm in with damaged surface. fair weather condition and min. 1 Mega-Ohm under adverse weather n Check up wattage of lamps and condition. Availability of inspection replace with that of correct cover of DFBs should ensured. wattage.

705f FANS n Check up whether toggle switches In addition to the items listed under " are marked to indicate lighting trip examination ", the following control "L", night light control works shall be carried out : `NL', side lamps in guards compartment as `SL', tail lamps as n The fan body, guards and blade `TL-Rear', `TL-Front', luggage shall be thoroughly cleaned with room as `LRL'. If not, stencil cloth. legends with fluorescent paint.

n All fans shall be opened and n Check up all lighting circuit fuses condition of commutator, brushes in each coach for correct sizes and and brush gear shall be thoroughly replace if necessary. Stencil the checked. Action should be taken size of fuses near the locations, if where necessary as given under not already done. "Trip Attention". Chapter 7, Page 12 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n Terminate charging when 3 n Mark inspection covers of successive readings are constant. Distribution fuse boards as `DFB' Record specific gravity and no if not done already. load voltage of each cell 10 minutes after terminating charge. n Thoroughly clean metal guards for Specific gravity should be between roof light fittings in luggage rooms 1.210 and 1.220 for cells upto 120 and paint, if necessary. Ah capacity. The voltage should not be less than 2.1 V. 705h TUMBLER / TOGGLE SWITCHES n If there is a wide variation in the Check each toggle switch of lights specific gravity and voltage and fans for proper fixing and readings, such cells should be operation. Replace defective toggle replaced and sent to shops for switches. Toggle switches should treatment. be provided in the locations intended for them and provided n Check the cell voltage on full load. with covers with their knobs Cells showing reverse and low exposed for operation by voltage are to be replaced with passengers. hwalthy cells of the same make/type. 705i DISTRIBUTION FUSE BOARDS AND FUSE CUT OUTS ii. VRLA Batteries :

Check distribution fuse boards and SMI no.RDSO/PE/TL/SMI-0001- fuse cut outs of light and fan circuits, 98 (Rev.0) dt.01.06.98 & for tightness of connections and RDSO/PE/TL/SMI/0002-98 provisions of correct size of fuses in (Rev.0) dt. 09.12.98 to be the fuse terminals. Replace missing followed. distribution fuse board covers. 707 HALF YEARLY SCHEDULE 705j EMERGENCY FEED TERMINALS (EFTs) Measure insulation values as follows:

n Check up supply and marking of 707a SUPER STRUCTURE polarity of EFTs. Short all the outgoing positive n Replace missing EFTs and those terminals from MCB cum fuse panel. without wiring nuts. Measure and record the following 706 QUARTERLY SCHEDULES insulation values:

706a BATTERIES n Between the bunched outgoing terminals and earth. In addition to the instructions contained under "Monthly n Between the bunched outgoing Examination" following activities positive terminal and main should be done: negative outgoing terminal.

i. Conventional Lead Acid n Between the main negative Batteries outgoing terminals and earth.

n `Switch off’ load. Charge the cells 707b UNDERFRAME at 50% of normal rate of charge, i.e., at 1/10th of the rated capacity Short the incoming terminals PM and of cells. Record hourly cell L+ in MCB cum fuse panel. Measure voltage and specific gravity and record the following insulation reading of every cell. values:

Chapter 7, Page 13 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n Between the bunched terminals PM n Check voltage drop between & L+ and earth. battery and the farthest light or fan point with full coach load “on”. n Between the bunched terminals PM The voltage drop should not & L+ and main negative exceed 3.0 V. incoming terminal.

n Between the main incoming n Provide deficient switch and fuse negative terminal and earth. covers promptly.

Note: Insulation resistance under fair n Coach wiring should be terminated weather conditions shall be minimum 2 in two way connectors which mega ohm. However under adverse shall be of tough non-ignitable (highly humid/wet) weather conditions, moulding materials of rigid PVC the minimum insulation resistance upto from which connection to the 1 M.ohm will be acceptable. fitting shall be provided by In case the insulation resistance is flexible single core cables for the found less than the values mentioned following : above, individual sub-circuits at junction box for super structure wiring · Fans and different feeders for underframe · Reading light fittings wiring shall be meggered separately. · Side light fittings The sub-circuit having an insulation · Tail light fittings value lower than that prescribed above · Step light fittings. shall be taken up for rewiring. If the nature of repairs is heavy, the coach n Provide missing connectors. shall be booked to shops for attention. Do not resort to patchwork in wiring n All cable ends shall be properly with temporary joints. socketed. Provide crimping type sockets wherever this is not in Proceed further as follows: existence. Use sockets of appropriate size. Corrosion n Strands of alluminium wire cannot inhibiting conducting grease shall serve as tinned copper fuses to be applied to the conductor as well protect circuits. Never resort to as inside the socket before this habit. crimping. Soldered joints should ordinarily be avoided, where this is n Use crimped socket of appropriate absolutely necessary, only size in all cable ends to avoid approved grade of solder and flux loose connections and shall be used. consequent overheating. n Electrical connections provided n Use corrosion inhibiting with bolts and nuts shall be conducting grease while crimping checked and provided with a set cables or while connecting wires of mild steel plain washer and to prevent oxidation. spring washers, protected against corrosion by Zinc or Cadmium n Stencil the correct size of fuses plating and passivation. Use near the locations, if not already correct tools for tightening cable done. connections.

n Check all fuses and MCBs for n Surface of aluminum sockets and correct rating and MCBs for proper bus bars, whenever removed for functioning. Replace if necessary. attention shall be cleaned to remove the oxide film from the n Provide spare fuse wires of correct jointing surface before making a rating for use in branch circuits on bolted joint and shall be coated the bobbins located on distribution with corrosion inhibiting fuse boards. conducting grease to prevent re- formation of oxide film. Chapter 7, Page 14 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

· Field terminals and stator n V-Belt : The existing V-Belts shall terminals be replaced with the new V-belt. 4 nos. having same make/grade. The (Note : Minimum insulation resistance old V-belts removed from service should not be less than 1 Mega ohms to be destroyed. for 4.5 kW under worst weather conditions and 20 mega ohm for 708 POH SCHEDULE 18/22.75 kW respectively)

708a BRUSHLESS iii. OVERHAULING ALTERNATOR n The machine received for The procedure to be followed shall be overhauling should be externally as per guide lines given below. cleaned with wire brush and wiped before dismantling. i. VISUAL INSPECTION n Clean and re-grease the bearing Carry out visual inspection of the after removing the bearing from machine and record the following:- the bearing housing. Only Servo Gem (RR-3) grease shall be used. n Serial number and name plate particulars of the machine. n Clean the mating surface of the end shield. n Check that rotor rotates freely. n Check the suspension bushes. n While removing and placing the rotor, care should be taken that the n Check insulation resistance rotor does not rub over the field n Check continuity of the field coils. and stator n If any grease has crept into the n Check alternator tension rod stator surface, clean it before n Check the bearing noise with assembling. shockpulse meter n If stator and rotor parts are found

rusty, clean. Apply the insulating ii. ELECTRICAL CHECKS varnish (air drying) of

recommended grade. Impregnation Carry out the following electrical of the varnish shall be done in an checks and record the following: - air circulated oven.

n Open the cover of the terminal box n Change the alternator suspension and check whether the internal nylon bushes 100% and change the termination and terminal board are suspension pin on condition basis. intact. n Tighten all the connections on the n Apply the insulating varnish (air terminal board. drying) of recommended grade. n Using a multimeter, check Impregnation of the varnish shall continuity between be done in an air circulated oven. · Field terminal F+&F- · Stator terminals U&V, V to W n After complete fitment and and W to U greasing, the bearing noise shall be recorded using shock pulse meter. n Check the insulation resistance by 500 V megger between n Only bearing of SKF/FAG shall be

provided as per recommendation of · Stator terminals and frame of RDSO. machine

· Field terminals and frame

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iv. TESTING OF ALTERNATORS speed from 600 rpm to 2400 rpm. Setting shall be done at INSULATION RESISTANCE TEST 1500 rpm and half load 19A before starting the test. Check the insulation resistance · Alternator The voltage should not exceed ± 5 % of the set Place of Check Required Value for voltage at a speed from 600 Conventional Coaches rpm to 2400 rpm. The set voltage can be 120 V, 122 V, Between stator. Above 1 M W 124 V at 19 Amp. 1500 rpm. winding and earth Check the MFO (minimum speed for full output) i.e. 37.5 Amp. for 4.5 kW alternator, it Between field Above 1 M W winding and earth. should not be more than 600 rpm.

Between field Above 1 M W vii. TEMPERATURE RISE TEST winding and stator.

For 4.5 kW Alternator · Regulator Run the alternator at 600 rpm Place of Check Required Value and apply the load. The alternator Conventional Coaches should be capable of giving 37.5 Amps at 120 Volts. Run the Short all terminal alternator at 2500 rpm with full (live parts) together Above 1 M W load for five hours with a fan and check the insulation cooling the body. Check the resistance between the temperature at different part of the live parts and earth. alternator and should be as follows:- Note: The insulation resistance of all the above should be measured a) Power diode - Should not exceed by 500 V megger. 100 0C at ambient of 500 C. v. NO LOAD TEST b) Alternator terminal - Should Connect the alternator not exceed 100 0C and regulator with a at ambient of 500 C. resistance/battery load. Run the Alternator at base load (1 c) Bearing temperature - Should not A) at various speed from 357 exceed 85 0C at rpm to 2500 rpm. ambient of 500 C.

This voltage should d) Stator and Field - Should not 0 not exceed ± 5% of set the exceed 90 C at voltage. The cut in speed win ding load of should also be checked. It 37.5 Amps. should not be more than 357 rpm at 108 volts at zero load. 708b RECTIFIER REGULATOR UNIT

vi. LOAD TEST The procedure to be followed shall be as per guidelines given below. Connect the alternator and regulator with n Check the terminals and inside resistance/battery load. Run wires for heating signs and the alternator at half load i.e. looseness. Blow out the dust. 19 Amp. and full load 37.5 Amp. respectively at various Chapter 7, Page 16 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n Replace the damaged n Record voltage and specific gravity wiring/terminals. The wiring of the of each cell. regulator shall be done n Clean exterior of the cell/ mono systematically, block thoroughly. Wash top of the

battery with a 10% solution of soda n Check the PCB circuit with PCB and a wire brush. During such testing kit or multimeter to identify cleaning, it is necessary to ensure defective components. Replace the that the micro porous vent plugs defective components. are mounted on the cells so that the

water does not enter into the cells. n Check field transformer for correct voltage. Replace, if found n Battery boxes shall be defective. cleaned/repaired and repainted with anti corrosive epoxy based paint 708c V- BELTS/ TENSIONING GEAR after removing the bat tery. Check the opening of welds and cracks n The existing V belts shall be thoroughly specially on load replaced with the new V belts 4 bearing members, vicinity of Nos. having same grade/make. The mounting bolts etc. Detection of old V belts removed from service minor hair line crack shall be done to be destroyed. with ultrasonic testers.

n Top up cells wherever necessary n Tensioning gear shall be removed and its spring shall be checked for with distilled water. The level proper functioning. If required should be corrected as indicated on moving parts of tensioning device the float. including spring shall be replaced. n If there is corrosion/sulphation on the inter-cell- connectors etc., clean 708d ‘V’ GROOVED AXLE PULLEY them thoroughly and protect from further corrosion by applying The procedure to be followed shall petroleum jelly or Vaseline. Cell be as per guidelines given below: connectors and fasteners should be changed on condition basis. n Check the axle pulley for slippage, tightness and physical damage to n Replace defective sealed float grooves. Ensure availability of guide and micro porous vent plugs, locking nuts and split pins in if any. position. Check the alignment of n Clean micro porous vent plugs and axle pulley with the alternator sealed float guides and ensure that pulley and adjust. Change the vent holes are in order. rubber packing. n Record lug date to determine the n Replace the pulley if any groove is life of the battery. damaged/broken/worn-out . n Charge the battery fully till 3 constant half hourly readings of n The pulley shall be replaced after voltage and specific gravity are four years period or earlier on obtained. This will indicate that condition basis. battery is fully charged.

708e BATTERY AND BATTERY BOX n Discharge the battery at 10 hrs discharge rate. While discharging, The procedure to be followed shall be record the voltage and specific as per guidelines given below. gravity. n Record the capacity of the battery n Remove the cells from the battery during discharge. It should not be boxes on arrival of the coach in less than 80% of the rated capacity. workshop and bring them in the battery shops for maintenance.

Chapter 7, Page 17 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n In case while discharging, any of ii. Cable termination joint the cells fall below 1.8 volts, disconnect the cell from the circuit n All cable joints shall be for treatment with one or two checked for its loosness or cycles of slow charge and heating signs. Loose joints and discharge. cables having damaged insulation shall be n After two cycles of charge and replaced/repaired. All cable discharge, recharge the cells fully. ends shall be properly socketed with crimping type n Battery box vertical/horizontal sockets. member shall be checked for any n Surface of crimping sockets minor/hair line cracks, its and bus-bars shall be cleaned mounting arrangement ensuring to remove the oxide film from proper securing through nut the jointing surface before bolts/washers etc. making a bolted joint and shall be coated with corrosion n In case of VRLA Batteries, SMI resistant conducting grease of no.RDSO/PE/TL/SMI/0001 -98 approved make to prevent (Rev.0) dt. 01.06.98 and reformation of oxide film. RDSO/PE/TL/SMI/0002-98 (Rev.0) dt. to be followed. n Fire retarding PVC grommets to IS:1767 or grade 6 of 708f WIRING (After 2 years for new coaches IS:5831 shall be provided at and 1 year for old coaches) all cable entry points in metallic members. The wiring shall be completely n The under -frame wiring if inspected for damage by opening side running loose shall be panels, end wall near EFT's and also provided in flexible steel near fittings after stripping. The re- conduit. wiring shall be done on condition basis or planned on the basis of life of 20 n All inspection covers shall be years for cables. opened to check the distribution boards and The cables used for re-wiring condition of wiring. shall be as per IS:694-1990 (Third Revision) The cables taken up for re- iii. General Precautions wiring shall be done through PVC conduits in super structure conforming n Do not peel insulation for to IS:2509. Bushes/Grommets used testing. If wires are found shall be of Hard PVC as per BS:1767 - with peeled insulation replace 1951 or to grade 6 of IS-5831 latest. them with fresh wires. If Flexible conduits used, if any, under peeling is of short length water tank shall be as per IS:6946. apply proper PVC adhesive tape.

i. Coach insulation n Do not use twisted joints of Insulation resistance of the coach aluminum cables to avoid shall be measured with 500 V oxidation and improper megger. IR value should be contacts and over minimum 2 Mega ohms but it heating/earth fault due to should not be less than 1 Mega loose strands. ohm under highly humid/wet weather. n Remove earth fault by isolation method instead of hit and trials and short cir cuiting of opposite polarity of earth.

Chapter 7, Page 18 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n Use proper rating of fuses both in branch circuits, rotary 708h FANS panels and regulator boxes for field and main fuse. n Dismantle the lower guard, upper guard, blade and fan motor. n Use HRC fuse to the extent possible except for branch n Check the guard assembly, which may be done with re- repair/replace if necessary. wirable tinned copper fuse. In the absence of HRC fuse use n Check the blade angle with a correct size equivalent re- measuring gauge. Correct the wirable fuse. Do not use same, if necessary. under rated or over rated rewirable fuse to avoid faulty n Check the insulation resistance of tripping of defective circuits. the fan motor. The IR value should not be less than 2 Mega ohms as n Use connectors for lights & specified in IS: 6680-1992. fans. n Check the fan leads and change it n Ensure extra length of cables if necessary. near termination’s for future maintenance and replacement, n Check the armature winding and if found inadequate at the field coil, repair/replace, if earliest opportunity. necessary.

n Check for earth fault on every n Check the commutator for maintenance and rectify those grooving, pitting marks, ovality, detected. blackness etc. Polish the commutator if required. n Do not tamper with regulator potentiometer setting unless n Check the carbon brush and brush tested in a proper alternator spring. Replace by correct grade of drive having variable speeds. carbon brush as recommended by RDSO. The fan spring should 708g SWITCHES, LIGHT FITTINGS, meet the requirements given in ETC. IS:6680. Replace the same if necessary. i. Light fittings n Apply air drying insulating varnish The light fittings, reflectors, clear if IR value of the armature and acrylic sheet cover, glass globe, field coils is low, give holders, etc., shall be checked and impregnation treatment in an air cleaned. Any defective part shall be circulated oven. replaced. Ant i- theft arrangement for fluorescent light fittings shall be n Clean the ball bearing, check for checked as per ICF Drg. No. noise, replace if necessary or ICF/SK-7-6-079. grease it with recommended grade grease. ii. Rotary Switch Cum Junction Box Testing Strip the housing from the coach and clean thoroughly and remove i) Check the load current at oxidation from terminal points and rated voltage. The wattage check the function of rotary of the fan should not exceed switches. Fit back the same and do the value specified in IS: the connections using corrosion 6680. inhibiting compound for better conductivity and to avoid oxidation of all contacts.

Chapter 7, Page 19 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

ii) Check the air delivery of one or two fans from a batch n Do keep the terminal box to ascertain the correctness tightly closed. of the blade angle. The value of the air delivery n Do open the terminal box shall not be less than that once in a week and clean the specified in IS:6680. accumulated dust, if any.

NOTE : n Do check tightness of the connection regularly, at least n SKF/FAG (imported) make once in a week. bearings for alternator procured directly from manufacturers as n Do use the cable grommets specified in the RDSO or cable gland of correct size specification shall be used. Use of for reducing the vibration of other makes of bearing is not terminal connections. It is permitted. preferable to anchor the cables externally to avoid n Shock pulse meter shall be shocks and vibrations on the procured by Railways and terminals. workshops to monitor condition of the bearing regularly during ii. DON’TS maintenance service and after replacement of defective bearings. n Don’t use improper tools to handle the alternator, it may n Induction heater/oil bath shall be damage parts of the used for heating the bearing to the alternator. required recommended temperature. n Don’t re-grease the bearing frequently. Re-greasing should be done after n The pulley condition such as wear thoroughly cleaning the on V group, pulley key way, shaft bearing with white spirit. It way, groove angle etc. shall be is preferable to re-grease the monitored during POH. Proper bearing only during POH. gauges shall be used for checking

"V" groove of the pulley. n Don’t over-grease the

bearing. 709 DO’S AND DON’TS FOR MAJOR

EQUIPMENT n Don’t keep the belts in over

tension as this may reduce 709a ALTERNATOR life of the belt.

i. DO’S 709b REGULATOR

n Do ensure the correct i. DO’S polarity of field winding i.e. positive connected to F + n Do check the regulator while measuring the terminal box once in a continuity of the field month for loose connections winding, otherwise the and for cleaning the dust. alternator will not self

excite. n Do short all seven terminals

of the terminal box before n Do check the proper measuring the insulation compression force on the resistance. tensioning spring with indicator plate by tightening the special nut.

Chapter 7, Page 20 of 21 Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches

n Do ensure that DC ‘+’ and upto the split pin for the 18 DC ‘-’ are connected to kW, 22.75 kW, 25 kW battery positive and battery Alternators and 55 mm for negative respectively. 4.5 kW alternators. Wrong connection will damage main diodes. n Maintain proper alignment between axle pulley and ii. DON’TS alternator pulley. n Don’t disturb the settings of the regulator shunt and n Replace pulley with burn potentiometer. out grooves i.e. 0.8 mm depression on sides and n In any circumstances the bottom of grooves with burden resistance setting uniformly shining surface. should not be disturbed.

n Form grades of the belts n Don’t open the regulator box unless there is a defect. received from the stores/suppliers after n Don’t use a megger to test checking on belt the components . Use measurement gadgets. The multimeter. grading of belts should be between 48 and 52 only of n Don’t reverse the field matched sets. terminals on regulator and alternator. ii. DON’TS n Never use a fuse wire for field fuse. Always use HRC n Do not allow loose belts. fuse of specified value. n Do not disturb the nut and 709c `V’ BELTS check-nut on free end of tension rod if proper gap is i. DO’S available between

n Use belt of the same length supporting plate and fixing for a set. nut i.e. 75 mm for AC coach alternators and 55 mm for n Belts should be stocked in TL alternator. lots as per date of receipt and use in the principle of n Do not use repaired pulleys. first in first out basis. The belts shall be stored in a n Do not use old and new well ventilated room free mixed belts in sets. from direct sunlight and moisture. n Belt should not have any oil or grease traces ,if persist n Ensure correct belt tension clean it by soap and water. i.e. 330 Kg for 18 kW, 22.75 kW and 25 kW alternators n The matched set should and 105 kg for 4,5 kW have belts of one alternators. The tolerance of manufacturer only. Do not tension shall be ± 5 kg in use belt of same grade of both cases. different manufacturer in a set. n Re-tension newly fitted belts after first trip. 709d VRLA Batteries : Do's and Don'ts from SMI no. RDSO/PE/TL/ SMI/ n Maintain a gap of approx. 0001 - 98 (Rev.0) dt. 01.06.98 to be 75 mm between supporting followed. plate and fixing nut on the free end of tension rod or

Chapter 7, Page 21 of 21 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

CHAPTER 8

AIR CONDITIONED COACHES

801 INTRODUCTION

Types of AC coaches on Railways can be classified broadly as under :

AC COACHES

End –On –Generation Self – Generating coaches coaches

Under Slung Roof Mounted Under Slung Roof Mounted Package Unit Package Unit

801a Power Supply System: As far as power 801b MAJOR EQUIPMENTS USED IN AC supply system is concerned, the coaches UNIT ARE : are of the following two types : 1. Compressor (open type for under (i) End-On-Generation (EOG) : In this slung, sealed type for Roof Mounted system two types of Power cars are used Package Unit (RMPU)

2. Condenser including liquid receiver a. Coaches mounted with 50 KVA, 750 V/415V, 3 f and dehydrator. transformer. 3. Expansion Valve b. Coaches with out stepdown 4. Evaporator with heater element. transformer suitable only for old low capacity power cars. 5. Motors for compressor, condenser,

(ii) Self Generating (SG) : Based on evaporator . AC equipment, there are two types 6. Other protective devices and control of Self Generating coaches. panels. a. 110 V DC with under slung type AC equipment working 7. Thermostat, Filters etc. from 110 V DC. 802 MAINTENANCE SCHEDULES FOR b. 110 V DC with Roof SELF GENERATING AIR Mounted AC Package Units CONDITIONED COACHES FITTED working from 415 V, 3 f, WITH UNDER SLUNG EQUIPMENT: obtained with the help of 25 (Ref: RDSO’s maintenance KVA inverters mounted on schedule No EL/TL- underslung as well as AC/Maint.Sched./Rev.1) onboard.

Chapter 8 – Page 1 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

802a TRIP SCHEDULE (PRIMARY AND iii. Alternators SECONDARY MAINTENANCE) n Check the condition of i Axle Pulley outgoing cables and its cleating arrangement. n Examine the indicating Replace the grommet, if white mark on the pulley necessary. Ensure that axle and ensure that the flexible pipe carrying the pulley has not shifted . If cables is connected properly pulley has shifted , pulley to to the grommet to prevent be removed and re- damage to insulation. tightened after replacing n Check the suspension pin, rubber pads. Indicating bush and securing nuts and white marks to be provided. bolts. Also check distance between wheel axle and axle pulley n Check the pulley fixing, with gauge. concentrating on lock nut and locking collar pin. If n Tap wit h hammer and lock nut is damaged, replace judge the tightness by it. sound. n Carry out visual inspection of terminal box for signs of n Check the lock nuts and overheating and presence of split pins for availability fumes. Blow off dust if and tightness. required.

n Check the terminal box for n Check profile of ‘V’ presence of water and drain groove for worn out out if necessary. pulleys, replace pulley if worn out. n Check the connections for looseness or cracks, if ii Belts required re-crimping/ tightening should be done. n Check condition of belt for n Check main suspension lugs fraying of edges and replace of alternators for signs of it on condition basis. crack.

n Clean the regulator box externally and remove all the n Check the belts for overturn and correct it, if necessary. dust particularly from heat sinks.

n Check the number of belts. n Check safety chains and The belts should be 12 (6 on chain fixing nuts, bolts and either side) for each split pins. alternator in primary depot n Check tension rod fixing pin and 10 (5 on either side) in of alternator with washer secondary depot. and split pin.

n Check the log book for n Tension should be felt by hand by striking it slightly. abnormal /unequal load Belt in correct tension will sharing . Corrective action respond `alive' . Pull the belt should be taken to ensure and check the spring action. that the difference is within the range of 30 %.

Chapter 8 – Page 2 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

iv. Battery & Battery Box n Ensure that spare batteries, particularly VRLA cells are n Check the level of properly kept at places not electrolyte in all the cells exposed to direct sunlight, and top up with distilled rain, dust etc. The batteries water, if necessary. should be stored indoor preferably between 20 to n Check the specific gravity 35°C in clean and dry and voltage of 4 pilot cells. location. n Check inter-cell connection for looseness. Check for n VRLA Batteries : SMI crack in containers leading no.RDSO/PE/TI/SMI/0001- to leakage. If needed replace 98 (Rev.0) dt. 01.06.98 to be the defective cell with followed. healthy cell of similar capacity and lug date. v. Compressor and Condenser Motor n Check for heating signs on the positive and negative n In case of compressor motor, terminals and discolouring examine the tyre coupling of the cells container/top lid. for any indication of looseness or slip and rectify n If required, individual cells in the battery bank or defects. complete battery bank may be subject to charging so that n Open insp ection cover and the Specific Gravity (SPG) examine the condition of may rises to min. 1240. commutator. Clean with sand paper or pumice stone, n Check the top of cells and if necessary. Do not remove keep it clean and dry. Plugs the dark tan film should be tight. unnecessarily. Clean all n In case of Valve Regulated carbon dust with dry Lead Acid (VRLA) compressed air. batteries, check for abnormal bulging of cell lids, cracks n Check condition of carbon on positive and negative brushes. If worn out, replace terminals. Replace defective with carbon brushes of cells.. approved grade.

n In case of sulphation of n Check condition of pigtails. terminals remove the connectors, clean, put back If necessary, replace as per and apply petroleum jelly. the manufacturer's recommendation. n Check suspension/cradle of battery box for availability n Check the starting resistance of all suspension bolts, signs connectors for tightness. of any crack, corrosion, rusting and take corrective n Check suspension of action, if necessary. compressor motor unit for n Check for proper fitment of any signs of crack, corrosion battery cells in battery box and rusting. Take remedial or module fitment in case of action if required. VRLA batteries, if required proper packing may be n Carry out visual inspection provided. for signs of overheating and presence of fumes. Blow off dust if required.

Chapter 8 – Page 3 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

n Examine flexible type n Check the direction of coupling and replace, if rotation for correctness if the found defective. same has been attended. n Clean the compressor n Check the fan blades for externally with compressed tightness in case of air. condenser motor. n Check for signs of leakage vi. Evaporator Motor at joints & shaft seal and take remedial measure n Open the inspection cover wherever necessary. and examine the condition of commutator. Clean with 0-0 n Examine the fixing sand paper or pumice stone, arrangement, check the if necessary. Do not remove condition of the anti the dark tan film vibration mountings for unnecessarily. Clean all tightness of the fixing bolt. carbon dust with dry compressed air. viii. Condenser

n Check condition of carbon n Check and ensure that the brushes and pigtails. Replace protection plates and grills if necessary as per the are provided on the three manufacturer's sides of the frame. recommendation. n Examine the fins for external n Check the bearing for noise. damage due to flying ballast and take corrective action if n Check the blower fixing for necessary. tightness. n Check suspension of the n Carry out visual inspection condenser for signs of for signs of overheating and cracks, corrosion or rusting presence of fumes. Blow off and take remedial action. dust if required. Tighten bolts, etc., if necessary. vii. Compressor ix. Dehydrator And Liquid Receiver n Check the proper lubrication of compressor n Check the sight glass for level of oil when operating leakage, rectify if necessary. should be upto half of the bull eye glass. n After 10 minutes of starting the compressor, check the n Lubricate the compressor as level of liquid refrigerant per RDSO SMI No. should be at the bottom of RDSO/AC/SMI/6 the lower glass of the liquid receiver. n Examine the reading of HP, LP and OP gauges recorded n After 15 minutes of starting during the journey for the plant, feel the outlet and abnormality and take inlet to dehydrator by hand necessary action. for temperature difference. The outlet should not be colder than inlet.

Chapter 8 – Page 4 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

xiii. Lights And Fan Wiring x Filters n Check for earth leakage in n Remove fresh air and return the wiring with a double test air filters and replace it by lamp. Rectify if any defect spare clean units. noticed.

n Check and ensure that fresh n Check for any loose air dampers are in proper connection & tighten if order. necessary.

xi Thermostats xiv. Lights And Fans

n If the report of the attendant n Check all the lights and fans indicates that thermostate for proper working. Rectify do not work, examine the or replace if necessary. thermostats for break in mercury, break in stem, etc. n Clean the fan and light Replace the thermostats, if fitting externally. necessary. Follow RDSO SMI No RDSO/SMI/AC/15. n Check all switches, fan regulators, call bells and n Clean thermostat bulb with push buttons for proper cotton. working. Replace if necessary. n Ensure working of plants in auto mode for all xv. Pre-Cooling Unit temperature setting. n Clean rectifier unit xii. Panel Board externally with dry compressed air. n Clean the panel and remove dust. n Check the presence of water in terminal box, drain out if n Check the working of necessary. indication lamps, replace it if necessary. n Load the pre-cooling unit to its maximum capacity and n Check the availability of check for any overheating. spare fuses in the place provided for the same and n Check suspension of battery provide if necessary. charger for sign of any crack, corrosion or rusting n Check the availability of arc and take action if required. chute and provide if necessary. n Check the pre-cooling socket n Check and clean the contacts pins and its fixing of contactors 12, 13 and arrangements. 13A. xvi. General n Check the operation of cooling pilot relay (by short n Check log- sheet of last trip circuiting terminals C.T.). and attend all the faults Remove short after the recorded in the log sheet. completion of check.

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n Run the plant for half an iii. Rectifier Cum Regulator Box hour. Check system operation, specially the n Clean all dust with dry following: compressed air externally. 1. Suction pressure gauge n Open the cover and check reading should be 2-3 sealing rubber gasket for signs Kg/cm2 . of fraying. Drain out water if 2. Delivery pressure gauge any. reading should be 10 – 2 14 Kg/cm . n Clean all dust with dry 3. Oil pressure should be 2 compressed air. preferably a minimum 3kg/cm above hand blower from inside to suction pressure. remove all dust particularly 4. Suction should be cold from heat sink of electronic and sweaty. Delivery components and terminal should be very hot and board. liquid line should be warm. n Check that the voltage and 5. Feel the expansion valve current setting. Ensure that by hand. It should be they have not been disturbed cold. and are in locked position.

n Note the battery voltage on n Check the field fuses and LOAD and NO LOAD. phase fuse and ensure that only specific HRC fuses have been 802b MONTHLY SCHEDULE used.

In addition to the trip schedule n Check all the electrical items, following are also to be attended. connections for tightness.

i. Axle Pulley iv. Alternators

n Ensure that the gap between n Lubricate the threads of the the two halves of the pulley is tension rod and adjusting nut. 3 mm. Check tightness of the axle pulley bolts by 30 kg-m n Check the profile of ‘V’ torque wrench. grooves and replace worn-out pulleys. n Check distance between wheel hub and axle pulley with v. Battery Chargers gauge plate. n Ensure that the coarse ii. Belts and fine control switch is in position No.1. n Check tension of belts. For the n Check and clean all exact measurement of static connections and contacts. tension, apply force `P' with a Spring balance at the Centre of vi. Battery span in direction perpendicular to the span until Conventional Lead Acid the belt is deflected from the Batteries normal to the extent of 16 mm per metre of span. The force n Check specific gravity `P' should be between 31.4 to and voltage of all cells. 47.0 kg. If the belts are loose. replace them.

Chapter 8 – Page 6 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

viii. Condenser & Condenser Motor n Remove inter-cell connection, take out the cells, clean thoroughly n Clean the condenser fins the cells, intercell and end thoroughly with high cell connectors and fit pressure water jet so that air back in the coach. Use passes through the fins petroleum jelly. uniformly .

n Examine condition of n Clean fins with liquid battery boxes. Paint if solution and high force necessary. water jet.

n Check vent plugs. Tighten n Ensure minimum air flow of if necessary. Replace if 4 meters per second through missing. condenser.

n Check the condition of n Check the incoming leads cells by cell tester. for proper connection and Replace defective cells. tightness. Ensure that the grommet is in position and VRLA Batteries the flexible hose- pipe is connected properly at both SMI no.RDSO /PE/ TL /SMI /0001-98 ends. (Rev.0) dt. 01.06.98 and n Check the spring tension as RDSO/PE/TL/SMI/0002-98 (Rev.0) recommended by the dt. 09.12.98 to be followed. manufacturers.

vii. Compressor Motor n Check the carbon brushes; replace with approved grade n Check tightness of the of carbon brushes if coupling and mounting bolts necessary. by 30 kg-m torque wrench and tighten, if necessary. ix. Evaporator Motor

n Check the terminal n Check the blower drum connections in the terminal for looseness. box and tighten, if necessary. n Check the spring tension n Examine the incoming leads as recommended by the manufacturers. for proper connections and tightness. Check the flexible n Flush the drip tray. Check conduit for proper anchoring drain pipe of drip tray for at both ends. clogging by passing n Measure the spring tension water through the drip of brush holder. If less than tray and clean, if found clogged. the value recommended by manufacturer, replace the spring. x. Compressor

n Check the carbon brushes; if necessary, replace with n Check tightness of bolts approved grade of carbon of anti-vibration mounting brushes. with 30 kg- m torque and tighten if necessary. n Check the alignment of the compressor and motor.

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n Do not remove dark tan film n Check the tightness of unnecessarily. If necessary, nuts and bolts of replace the carbon brushes compressor head and its with carbon brushes of cover. approved grade. n Check oil and liquid n Remove the cover of tube levels and note any signs light, night light and clean the of leakage which will be bulb, tube and cover from indicated by presence of inside. the oil at the point of leakage. 802c QUARTERLY SCHEDULE n Clean the oil strainer with petrol or CTC (Carbon In addition to Trip and Monthly Schedule Tetrachloride). items, following are also to be attended.

xi. Evaporator & Drip Water Drain i. Axle Pulley

n Clean evaporator coil. n Check grooves for wear and n Replace return and fresh take necessary action. air filters. ii. Alternator n Pour water on evaporator

coil and ensure the water n Disconnect the regulator and drains out easily.. measure the insulation by 500 V megger; if less than 2 xii. Panel Board Meg ohm, remove winding of alternator and heat in the n Clean contactor tips of all oven at 80 degrees C for 1 contactors; replace where hour. necessary. n Check all the electrical iii. Compressor, Condensor And connections for tightness Evaporator Motors and tighten if necessary. n n Check the relays and Disconnect the motors, contactors for their proper measure the insulation by functioning. 500 V megger; if less than 2 Meg ohms, remove and n Check the PCB in the heat in air oven at 80° C thermostat circuits. for 1 hour. n Check the diodes provided n Check for the positive on the panel board. locking of rockers. n Check the rotary switch for n Lubricate the bearings of fluorescent lights. The all motors with polarity change connections recommended grease.

should be in order. iv. Condenser

xiii. Light and Fan n Clean the compressor fins

and copper tubes as per n Open the inspection-cover of RDSO SMI No. each coach fan and examine RDSO/SMI/AC/16 the condition of commutator. Clean with 0-0 sand paper. if n Check the condition of necessary. body frame and replace the condenser, if necessary.

Chapter 8 – Page 8 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

with pre-cleaned/new-filter v. Dehydrator and Liquid and close access doors Receiver properly. n Clean the strainer in the v. Check the log sheet maintained dehydrator-cum-filter for each AC coach and attend unit. the defects noticed during run as reported by escorting staff. vi. Evaporator And Expansion Valve vi. Check for working of Roof Mounted Package Unit n Clean the strainer used (RMPU) and Control panel as before expansion valve. following:.

n Clean the assembly of n Switch `ON’ RSW-I and evaporator coil and check that all the three surroundings with pilot indication lamps vacuum cleaner. (Red, yellow and blue) for R.Y.B. phases and power n Clean the drip tray and `ON’ indication LED drain-pipe thoroughly and (Green) are glowing. check for water leakages. n Put RSW-2 in ``ON’ vii. General position and keep RSW-3 in `VENT’ position and n Adjust the air distribution check that: by measuring the temperature of each q Indication LED (green compartment. colour) for Blower `ON’ is glowing and 803 MAINTENANCE SCHEDULE q Blower fan is working FOR ROOF MOUNTED AC PACKAGE UNITS AND ITS CONTROL PANEL n Check for satisfactory operation of vane relay by 803a TRIP SCHEDULE (PRIMARY moving the flap by hand AND SECONDARY gently. MAINTENANCE) n Check for satisfactory i. Clean all dust from panel by operation of the package dry compressor air from the unit by moving RSW-3, in panel. AUTO, MANUAL HEATING & MANUAL ii. Check that all the safety and COOLING modes. This protection devices are in can also be verified from working condition and not in indication LEDs (green the by passed condition. colour).

iii. Replace defective/by passed n Check that cooling system components including is working even if only indication LEDs and lamps, if one condenser fan out of any. the two is working. This iv. Remove fresh air and return air can be done by simply filters by opening the access switching off MCB 2 or doors provided under the MCB 3/taking out fuses of bottom of unit. Clean these condenser motor 1 or filters with pressurised air and condenser motor 2. jet of water and place them in their place or replace them

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n Check that cooling and heating 803b MONTHLY SCHEDULE thermostats works properly, i.e. A/C system “cut-off” and “cut-in’ In addition to trip schedule following in auto-mode. items should also to be attended to:-

n Check that compressor by pass i. Run the plant for half an hour and switch RSW-5 works satisfactorily check the current drawn by various n HP1 & HP2 Cut-outs equipment with the help of clamp tester. Switch ‘ON’ the compressor with condenser fan ‘OFF’. Take out Normal currents for various equipment fuses /switch-off MCB-1 and and mode of operation shall be as MCB-3 of the condenser fan under:- motors and keep the package in manual cooling mode. n Package in cooling mode Compressor should trip within 10 : 20-23 Amp. minutes. HP cut outs should be n Package in heating mode reset after each tripping. : 11-13 Amp.

n LP-1 & LP-2 Cut outs n Compressor motors : 7-10 Amp. Switch `ON’ the compressor with n Condenser motors condenser. Take out fuses/switch- : 1.5-2 Amp. off MCB-1 provided in the power circuit of blower motor and short n Blower Motor terminals of vane relay. Keep the : 1.5-2.5 Amp. package in manual cooling mode. n Check working of both Roof Compressor should trip with 10 Mounted Package Unit (RMPUs) minutes. with either of the inverter on the Self Generating (SG) AC coaches n OHP1 and OHP2 provided with two package units.

Switch ‘ON’ the heaters with ii. Check and tighten all terminals in the blower off, take out blower motor control panel. fuses or put off MCB-I and short the terminals of contactors AC-I iii. Check and clean contacts of contactors or vane Relay. In old control and replace pitted contacts if required. panels where AC-I is not iv. Check visually condenser fan blades provided, keep the package in and ensure there is no crack on the manual heating mode. The blades or the hubs. heaters should trip with 10 v. Check and tighten mountings of minutes. blower and condenser motors and

ensure that these are in good n CONTROL PCB conditions.

Keep the AC package unit in vi. Check that all legend plates inside the Auto Mode. Run the blower short control are intact. terminals of cooling thermostat vii. Check all connections on switch gears, on PCB. The compressor LED terminal blocks are tight. indication should come ‘ON’. viii. Check that glass cover over indication Open the terminals of heating PCB is intact. thermostat on PCB Heater LED should come `ON’. ix. Check for proper tightening of cover provided over evaporators compartments.

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x. Create single phasing in compressor n Terminal Connections/Fixing : circuits by taking out one

fuse/removing one phase wire from n Electrical - Normally loose incoming terminals of MCB-4/MCB-5. connections leading to wire Compressors should trip and CP1/CP2 burning/sparking are observed at over load trip indication should come connection terminals. ``ON’. n Usage of spring washer mostly xi. Check for proper operation of time avoids this problem. delay relays provided in compressor circuit. As soon as power supply is n Gently shake the wire (especially switched `ON’ first compressor should power cables) near the joints and come in circuit immediately and the on observation of loose joints, second one after 2.5 minutes. tighten the same and also observe cable insulation for any xii. Inverter deformation/brittleness. If so Caution: Inverter must be switched off replace them with same size of preferably at power panel itself before the cable only. attempting to do any maintenance n Mechanical - Inverter should be operation. fixed at the bottom as well as top, tighten the bolts and nuts used for § Cleaning of cubuicle : Dust deposit fixing the inverter and ensure that inside the converter should be it does not vibrate in run. Also carefully removed at regular basis. tighten the sub-assemblies if Unit should be cleaned with brush found loosened. In case of under- and vacuum cleaner or with dry slung inverter these shall also be compressor (Max. 1bar) – regularly checked and tightened. inaccessible parts. n Protection circuit/ Induction § Cleaning of PCBs : Using a soft circuit : brush, remove the dust collected on

PCBs gentle. n Check the indication/ protection circuits ensure 803c QUARTERLY SCHEDULE that all the protection and indication are working In addition to trip and monthly schedules properly. following items should also be attended. n Uses of fuse of power i. Inverter rating in the inverter, don,t use wire fuses. Caution: inverter must be switched n Remove both inverter and off preferably at power panel itself battery fuses in power before attempting to do any panel before attempting maintenance operation. some fitting or wiring in the inverter. n Cleaning of cubicle : Dust deposit inside the converter n Capacitor - On observing should be carefully removed at leakage of any capacitor regular basis. Unit should be inside the inverter remove cleaned with brush and vacuum the respective capacitor cleaner or with dry compressor and replace with new one (Max. 1 bar) – inaccessible parts. of the same value and make. n Cleaning of PCBs : Using a soft brush, remove the dust collected on PCBs gently.

Chapter 8 – Page 11 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

n Cooling Fan – Check the cooling n Check anti-vibration mountings of fan for operation. If damaged/burnt compressor, condenser and blower replace with new one of the same motors and replace if necessary. rating. Life of fan is about 3 years, n Charge refrigerant (R-22) if less replace, if due. cooling is noticed.(refer RDSO

SMI No. RDSO/AC/SMI/7 n Instrument cooling fans- Check if the instrument fan provided n Check that locking arrangement of between inverter and chopper control panel works properly. modules is working when the inverter is “ON”. If not working n Check insulation resistance of all the motor by 1000 V megger. replace the fan, by taking out Attend motors with poor insulated chopper and inverter modules. (in on-board type inverter). less than 2 Mega-ohm. iv. NOTE : n PCB Terminal – Gently tap the wires at PCB terminals and check n SKF/FAG (imported) make for any loose connection. Tighten bearings for alternator procured the screw or solder the terminals if directly from manufacturers as found blackened, informed the specified in the RDSO specification inverter supplier. shall be used. Use of other makes of bearing is not permitted. n Colour change in PCBs – Check for any colour change in PCBs. n Shock pulse meter shall be Replace the PCB, if found procured by Railways and blackened and inform the inverter workshops to monitor condition of supplier. the bearing regularly during maintenance service and after n MCCB – When MCCB is switched replacement of defective bearings. “ON” MCCB is tripping and fuse is blowing instantaneously, it is due n Induction heater/oil bath shall be to IGBT problems. They have to be used for heating the bearing to the checked and replaced, if they are required recommended found defective. temperature. ii. Drip Tray n The pulley condition such as wear on V group, pulley key way, shaft key way, groove angle etc. shall be n Check the normal flow of water in monitored during POH. Proper drip tray by running the AC plant gauges shall be used for checking continuously for 2 to 3 hours. “V” groove of the pulley.

n Pour water into drip tray and 804 SIX MONTHLY SCHEDULE ensure that the poured water is drained through the outlet pipe. 804a V-belts:

n Some sort of cleaning agent should The existing “V” belts shall be replaced be used for cleaning the sludge with the new “V” belt (6+6) nos., having inside the pipe walls. same grade/make. The old “V” belts removed from service to be destroyed.

iii. Others 805 POH SCHEDULES OF UNDER

SLUNG Self Generating (SG) TYPE n Check all the motors for abnormal AIR CONDITIONED COACHES sound use shock pulse meter and (Ref : RDSO doc. No. EL/AC/POH replace the bearing of condenser Schedule/002, Nov.,93) and blower motor, if necessary.

Chapter 8 – Page 12 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

805a. SEQUENCE OF WORK TO BE DONE iii. Dusting DURING POH With the help of compressed air On arrival into shop place the coach on pit remove the dust of air ducts. line and inspect electrical and A/C equipment. Note down the defects and iv. Cleaning and overhauling deficiencies. Disengage the `V' belt tensioning gear on both the bogies. Before overhauling, measure the Disconnect the alternator connection, and insulation resistance of all the remove the belt-tensioning device. electrical equipment such as alternator, motor and wiring to know i. Lifting the condition of equipment. Check and clean all the under frame Remove the alternator cables and suspension arrangements, lugs and carry out visual inspection on conduit terminals. After POH, test the wiring and refrigeration pipes. Remove the for insulation and fit the pre-cooling alternators from bogies. Replace plugs. alternator, regulator and tensioning gears with over hauled alternator, v. Simulation testing regulator and tensioning gear. During this activity carry out repairs, if Check the alternator output on required, to equipment suspension different load conditions. Check arrangement on under carriage. Send both the alternators for load sharing the alternators and regulators to shop with the help of variable speed for overhauling. motors.

ii. Stripping vi. Equipping

During this activity, the following air- In this activity fit all the conditioning and electrical equipment refrigeration and electrical will be removed: equipment to their respective n Fresh air and return air filter positions. Connect all the wiring and flanges in the refrigeration system n Compressors and their motors wherever necessary. Charge the gas n Condenser including liquid into the system. receiver cum dehydrator and condenser motors vii. Static testing n Evaporator unit and its motor Run the plant through pre-cooling n Water raising apparatus terminal and check for proper n Battery and battery box for functioning of electrical and AC repairs. equipment. n Battery charger-cum-pre-cooling transformer viii. Alternator Connection and Tensioning n Thermostats

n Control p anel Join the connections of alternators n Expansion valve and fit the belt-tensioning device. Provide the new 6+6 `V' belts for n Gauges and cutouts alternators. n Carriage fans n Berth light fittings

n Ammeters and voltmeters of power panel

Chapter 8 – Page 13 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

805b OVERHAULING ACTIVITIES OF n In case of carrier 5F 30 MAJOR AC EQUIPMENTS DURING compressor match the colour POH to ensure proper matching between tapered shaft and i. Compressors corresponding flexible n The given activities are only for coupling. under slung type AC system n In case of ACCEL installed with open type compressor check the end compressors. Remove driving play of crank shaft and flange and provide `V' groove replace the thrust plate, if pulley. Test the compressor to necessary. ascertain its condition. Record n Check the anti vibration the oil pressure during run. For mounting and replace, if Carrier and ACCEL necessary on condition basis. compressors, oil pressure developed should be 3.2 to 3.9 n Use suitable grade of oil for Kg/Sq. cm and 4.2 to 4.9 Lubricating the compressor Kg/Sq.cm respectively. as per RDSO SMI No.RDSO/AC/SMI/6. n Dismantle the compressor completely. ii. Tests on Overhauled Compressor n Inspect and check the dimensions of the wearing Following tests should be components. Replace the worn conducted on overhauled out components. compressor n Replace following components n Temperature rise test 100% irrespective of their condition. n Volumetric efficiency test

n Piston rings n Leak back test n Scrapper ring n Vacuum test n Suction and discharge valve n Sub merge test

n Shaft seal assembly/O Temperature rise test rings n Gasket packing This test shall be conducted with compressor running in free air with n Half section bearing both suction and discharge valve n Self locking nuts open. Run the compressor till the n Lubricating oil of correct temperature gets stabilized. The grade. temperature will be recorded on the casing cover. Maximum n Replace other components temperature rise at shaft seal shall on condition basis. The not be more than 45° C. sealed control valve shall be

replaced after ascertaining Volumetric efficiency test its performance.

n Assemble the compressor The compressor shall be run with with replaced components air at nominal speed of 1500 and charge it with rev/min and time taken to attain a lubricating oil. Change the pressure of 7 Kg./Sq.cm shall be lube oil and refrigerant recorded when the discharge line is suction strainers. connected to a reservoir of 100 litters capacity.

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The time taken to attain a pressure of 7 n Immerse the heat exchanger in Kg./sq cm in the reservoir should not be water tank for 24 hours. Wash more than 53 seconds for ACCEL the coils and fins thoroughly compressor and 73 seconds for Carrier, with compressed water jet at KPC, Elgi and Alfa Laval compressors. 12 Kg/sq.cm pressure. Remove Time to attain above specified pressures all the suspended material from in the reservoir shall vary according to the fins. Clean the water- working speed of the compressor and spraying pipe and open the atmospheric pressure also. holes.

n The cleaning process shall be Leak back test supplemented by scrubbing

with brush and use of This test is in continuation of volumetric compressed water jet. efficiency test. In this test immediately after attaining pressure of 7 Kg/sq.cm. in n After cleaning the cooling coil the reservoir, the compressor shall be pressurize with air at 300 psi stopped and pressure drop due to leakage (21kg./sq.cm.) and immerse in shall be noted. Pressure shall be recorded water tank duly connecting a at the end of 5 minutes and the drop in pressure gauge for 24 hours to pressure shall not exceed 1.25 Kg/sq.cm. detect any leakage by air bubble method. Also see if the Vacuum test pressure drops. Leaks in pipe shall be detected and brazed. The compressor shall be run with suction n After cleaning check the air valve closed and delivery valve open to atmosphere till a vacuum of 100 mm of flow of unit with anemometer. Hg. below atmospheric pressure is n Deflange the liquid receiver by created. The drop in vacuum level shall be removing the outer cover and recorded, after switching off the gasket packing. Clean compressor. thoroughly the inner walls of receiver to remove any Sub-merge test oil/impurity. Clean the sight glass. Assemble the cleaned The compressor shall be charged with dry liquid receiver parts by air at 21 Kg/sq.cm pressure and providing suitable gasket and submerged in water. Then check shall be flanging the outer cover. conducted for any leakage; the same shall be attended and test repeated. No leakage n Pressurize the liquid receiver through casing shall be permitted. at 300 psi (21 kg./sq.cm) and test it for leakage by iii. Condenser Unit (Including liquid immersing in water tank and receiver cum dehydrator) notice for any air bubble in case of leakage. n Dismantle the MS Frame, n Replace the filter and drier condenser coil, liquid receiver- after leak testing of the liquid cum-dehydrator. Cover the inlet receiver. Clean the condenser and outlet flanges of cooling coil housing thoroughly and paint it with a strip of cover plate and before assembly of other gasket so that water may not enter equipment. in to cooling coil. Clean thoroughly n Change the dehydrator-cum- the condenser coil, MS frame by filter element. Also clean the dry air to remove the loose conical filter thoroughly. suspended particles in and around cooling fins.

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iv. Evaporator Unit v. Motors for Condenser, Compressor & Evaporator n Dis-mantle the housing assembly and take out the cooling coil. n Dismantle the motor. Attend the heating element in n Test the insulation resistance position by conducting continuity of armature with 500 V test. Also check the insulation megger. It should be more value between the positive than 1 mega ohm. terminal and negative terminals shorted and the earth. If the value n Check armature winding by a is less than 2 meg ohms, replace voltage drop test method for the complete unit. IR value shall open circuit & short circuit be measured with 500 V megger. fault.

n Clean the cooling coil by blowing n If the armature is burnt, over compressed air. Cover the inlet heated or short circuited, and outlet flanges of cooling coil rewind it as per with strip of cover plate and manufacturer's instructions. gasket so that water may not n If armature is in good enter into cooling coil. Immerse in water tank for 24 hours and condition apply a coat of air drying varnish on the wash with compressed water jet winding. at 12kg./cm. sq. pressure. Remove all suspended material n Check the commutator on fins and clean the cooling coil. surface. If the surface is found (as per RDSO SMI No. improper, skim the RDSO/AC/SMI/8 commutator surface.

n The cleaning process shall be n Check the under cut between supplemented by scrubbing with segments. If it is found brush and use of compressed shallow under cut the mica to water jet. the required depth. Chamfer the edges of the segments. n After cleaning the cooling coil pressurize with compressed air at n Check the bearing with the 300 psi (21kg./sq.cm) and help of shock pulse meter. In immerse in water tank duly case of compressor and connecting a pressure gauge to condenser motors, replace by detect any leakage by air bubble new ones on condition basis, method. Also see if the pressure otherwise after cleaning and drops. Leaks in pipe shall be greasing re-use it. In case of detected and brazed. evaporator motor 100%, bearings shall be changed. n Clean the Evaporator housing and paint it. Assemble the cleaned n Check the field winding by unit. resistance measurement method for open circuit and n Take out main and auxiliary drip trays from the bottom of the short circuit. evaporator unit, disconnecting the n Check the insulation of field drain pipe connection. Check for coil with the help of 500 Volt free flow of water through drip megger. It shall be more than drainpipe by admitting water on 1 mega ohm. Replace the the drip tray. Replace the hose field coil, if defective. If field pipes and hose clips by new ones. winding is in good condition apply a coat of air drying varnish on the windings.

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n Check the brush boxes and vi. Control Panel studs for rigidity, clean the n Completely isolate the panel rocker assembly. from the power supply and n Replace the carbon brushes its loads, Contacts of the and clean the brushes using contactors (12, 13, 13A, 29 sand paper of size 400 grade and 17) shall be removed and or by using brush seating cleaned by means of clean rag stone until the faces of socked in petrol. Any brushes make perfect contact contacts, which are burnt, on commutator surface. Blow should be replaced, after out the carbon dust using dry which they should be lightly air jet. covered with vaseline. n After assembly conduct the n Similarly, dismantle the load test and insulation test. contacts of the relays and Current taken by motor clean them by means of clean should not be more than the rag socked in petrol. Any rated current. Conduct contacts which are burnt insulation test with 500v should be replaced. megger. It should be more than 1 meg ohm. n Check the flexible braided connections. If found n After the compressor/ damaged, replace the same. condenser motor is n The pin holding the pull off completely assembled spring on the armature frame- connect a milli-voltmeter work of the contactor should across brushes of opposite polarity. Connect the shunt be pulled out of its slot and the armature hinge pin field to 110V mains through a removed. This should be switch. Switch on the mains and note the kick in the examined for wear and if necessary, replaced by a new voltmeter. Rock the brush pin lightly covered with gear to the left or right and vaseline. repeat the test as before. Clamp the rocker arm in a n Measure the insulation particular position at which resistance of each relay and the kick is zero or minimum. contactor. If the insulation Before this test, care should value is less then 2 mega be taken to make sure that the ohms, replace the coil of the brushes are bedded properly. respective unit. If brushes are at neutral axis, n Check whether all the speed in both the connections are tight. If found directions of rotation will be loose, tighten the same. same. n Replace all the fuse links. n After the evaporator is

completely assembled the vii. Gauge and Cut outs neutral axis can be selected

by running the motor in both n Clean the contacts with the directions on no load at CTC/Petrol and test for approximately 25% of the correct operation of settings. rated voltage and measure the Calibrate with the standard speed in both the directions. gauge. If brushes are at neutral axis, n Check the performance of the the speed in both the gauges. Calibrate with the directions of rotation will be standard gauge. Replace same. defective gauges.

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viii. Refrigerator Piping n Check IR value of the transformer with 500V n Whenever the AC equipment megger. It shall be minimum are removed from the one mega ohms. refrigeration system for the n Check the gasket for sealing purpose of overhauling the the front cover provided for pipe outlets should be closed proofing. immediately to prevent entry of any foreign material into n Check the diodes and the piping system. adhesion with heat sink. Clean the base and heat sink n After reconnecting all the AC and tightened diode as per equipment, pressure test and manufacturers guide line. vacuum test shall be performed before charging x. Fans the refrigerant. n Dismantle the lower guard, ix. Pre-Cooling Transformer & upper guard, blade and fan Rectifier Unit motor.

n Check the guard assembly, n Open the cover and clean repair/replace if necessary. externally with compressed air. n Check the blade angle with a measuring gauge. Correct the n Dismantle the unit as per same, if necessary. manufacturer's instructions. n Check the insulation resistance of the fan motor. n Remove and clean the The IR value should not be contacts by means of a clean less than 2 mega ohms as rag soaked in petrol. specified in IS: 6680-1992. Contacts, which are burnt shall be replaced and covered n Check the fan leads and change it if necessary. with petroleum jelly. n Check the armature winding n Clean the transformer, and field coil, repair/replace, rectifier and rotary switch if necessary. (RSW). Check for operation n Check the commutator for and, if defective, change it. grooving, pitting marks, Checking shall be done as per ovulity, blackness etc. Skim following activities: or polish the commutator as n Check proper functioning required. of indication lamp. n Check the carbon brush and n Check all protective brush spring. Replace by circuit and fuses etc. correct grade of carbon brush n Ensure that earthing of as recommended by RDSO. housing is intact at two The fan spring should meet points. the requirements given in IS:6680. Replace the same if n Check for any crack/aging necessary. in PVC cable. Replace if required. n Apply air drying insulating varnish if IR value of the n Check the voltage armature and field coils is generation at RSW low, give impregnation position 1-1 and 4-4. treatment in an air circulating oven.

Chapter 8 – Page 18 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

n Clean the ball bearing, check q Surface of copper sockets for noise, replace if necessary and bus bars shall be or grease it with cleaned to remove the oxide recommended grade. film from the jointing surface before making a n Testing bolted joint and shall be coated with corrosion q Check the load current resistant conducting grease at rated voltage. The of approved make to wattage of the fan prevent reformation of should not exceed the oxide film. value specified in IS- n Fire retardant PVC grommets to 6680. BS-1767 or grade 6 of IS-5831 shall be provided at all cable entry q Check the air delivery points in metallic members. of one or two fans from a batch to ascertain the n The under frame wiring if running correctness of the blade loose shall be provided in rigid angle. The value of the steel conduit. air delivery shall not be n All inspection covers shall be less than that specified opened to check the distribution in IS- 6680. boards and condition of wiring. xi. Wiring xii. Air Filter n Light fittings

n For cleaning the ferrule type fresh The light fittings, reflectors, clear air and return air filters remove acrylic sheet cover, glass globe, them from frames and after holders, etc., shall be checked brushing or shaking off all loose and cleaned. Any defective part dirt immerse them in a solution of shall be replaced. Anti- theft hot water and soda (sodium arrangement for fluorescent light carbonate) approximately 6 grams fittings shall be checked as per to one litre of water. When ICF Drg. No. ICF/STD 7-6-001. thoroughly cleaned, the filter units should be rinsed in clean hot water n Coach insulation and allowed to dry. When properly dry, they should be completely Insulation resistance of the coach kept immersed in the oil shall be measured with 500 V (compressor lubricating oil) until megger. IR value will be air bubbles cease to rise. Then minimum 2 mega ohms but it remove and allow to drain for at should not be less than 1 mega least 8 hrs. before being placed in ohm under highly humid/wet service again. weather. n Replace the filter with new one in case of synthetic type filters. n Cable termination joint xiii. Cooling Tests q All cable joints shall be checked. Loose joints and n Cooling capacity test should be cables having damaged carried out by providing electrical insulation shall be compensating loads for worst replaced/repaired. All cable ambient conditions and full ends shall be properly occupancy of the coach. The screwed with crimping type duration for pre cooling of the copper sockets. coach should be between 3 to 4 hrs.

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After the stabilization of the n Check earth leakage by two temperature of each berth (20 mm lamp method. from window and back rest and n Check refrigration system 100 mm above the berth) should be for any leakage before recorded. The variation in charging the gas. temperature on different berths n Conduct vacuum test. (For should not exceed 1 deg. C. 12 hrs.) n Conduct pressure test ( by n The cycling duty of the plant shall charging Freon 12 or CO2 be determined by recording ON gas ) and OFF time of the compressor. It n Vacuum test for 15 minutes should be between 10 to 15 cycles for dehydration of per hour. refrigeration system. n Check control panel and xiv. Additional Items for End-On- ensure that proper fuses are Generation (EOG) Coaches provided. n Check contactors, relay and n Overhaul the DG set as per switches for correct the manufacturer's sequential operation. instructions. n Ensure that time delay in operation of contactor No. n Inter-vehicle coupler, 12, 13, 13A is 2.5 sec. ratchet assembly, junction n Check heaters for correct box and connections: operation. inspect, clean and check for n Check hooter for proper over heating, solder run out, operation. replace if defective. Tighten n Start the plant and check connections as needed. condenser motor, n Measure insulation compressor motor, blower resistance value of the motor for any abnormality. circuit with 500 V megger. It n Check leakage air from should not be less than 2 doors. mega ohms. n Check oil level in compressor, the level when n Check the proper operating should be 1/2 functioning of WRA. bull's eye. n Check the proper working of xv. Final Testing of AC Coach, after capacity control solenoid POH valve. n Run the plant for four hours. n Visual inspection of each An equivalent heat load equipment for their proper (convector heater) should be fitment. kept for performance test of plant. n Ensure that refrigerant pipes are properly clamped. n If new expansion valve is provided during POH, it n Ensure all the modifications should be set properly. are complied with. n Ensure that batteries are in n Check safety chain and fully charged condition. tension rod of alternator for n Run the plants with proper fitness. dynodrive motors for 8 hrs. at different speeds. n Under frame cables leading n Ensure that both the to alternator should be alternators are sharing load properly cleaned. equally during run. If not set both the alternator panels.

Chapter 8 – Page 20 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

xvi. General Checks ii. Lifting

n Suction pressure gauge reading Remove the alternator cable and should be 37-40 PSI (2.6-2.8 carry out visual inspection on Kg/sq.cm.) conduit. Remove the alternator from bogies, replace alternator, n Delivery pressure gauge reading regulator and tensioning gear with should be 150-170 PSI (10.6-12 overhauled alternator, regulator and Kg/sq.cm.) tensioning gear. Suspension n Oil pressure should be minimum arrangement on under carriage 3 Kg/sq. cm. above suction frame. Send the alternators pressure. regulators to shop for overhauling.

n Feel temperature. Suction should Lift the roof-mounted unit with the be cold and sweaty. Delivery help of 1 ton lifting arrangement as should be very hot and liquid line per procedure given below and should be warm. place it on the wheeled trolley to n The coach shall be jointly take it to the shop for overhauling.

inspected with division’s staff iii. Precaution / Procedure for and the performance of electrical Removal of AC Package Unit and refrigeration equipment shall from the Roof be recorded. Any attention to the given equipment shall be given n Remove lock to access the before dispatch of the coach from evaporator unit from bottom, workshop. in the doorway ceiling.

n Disconnect condensed 806 POH SCHEDULE FOR SELF drainpipe connection. GENERATING (SG) TYPE AC COACHES FITTED WITH ROOF n Disconnect all electrical connections to package unit. MOUNTED AC PACKAGE UNIT (Ref. : RDSO maintenance schedule No. ELPS/SCH/AC/01 ) n Dismantle the first piece of main duct. Disconnect the

806a SEQUENCE OF WORK TO BE supply duct and return air duct bellows. TACKLED DURING POH n Remove Top cover provided i. Pre-Inspection above the package unit. Remove rubber package also On arrival to shop, place the coach provided to prevent water on the pit line and inspect the leakage. electrical and air-conditioning n Unscrew the 8 Nos. of equipment. Conduct the cooling test. If the cooling time is less than mounting bolts of AC package unit. the specified values, any further attention to refrigeration circuit is n Do not use forklift. not necessary, except cleaning. Check operation of all protections n Lift the package unit carefully using suitable and note down the defects and deficiencies. In case of self- crane of 1 ton capacity. generating type of coaches, Arrangement as per RCF drawing No.XZ003801 for disconnect the cable connection lifting ring may be used. from alternator terminals and remove belt tensioning device. n Do not drop the package unit on the ground while handling.

Chapter 8 – Page 21 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

iv. Stripping ii. Check for corrosion of welded joints of AC package unit During this activity, the following structure air-conditioning and electrical equipment will be removed: The welded joints of AC package unit structure should be examined n Fresh and return air filters. carefully for presence of corrosion n Water raising apparatus and such corroded members shall be replaced/rectified. n Battery and battery box

n Battery charger iii. Check for accumulation of water in condensed drain pipe and n A/C Control panel & power trough outlet panel n Inverter units Clean the condensed drain pipe and trough outlet pipe with help of n Carriage fans compressed air. It is also desirable to blow compressed air into the v. Dusting pipe from below, every two months With the help of compressed air, to avoid any choking of pipe due to remove the dust of the conditioned accumulation of dust, etc. air duct. iv. Deterioration of rubber lining vi. Cleaning and Overhauling If there is any deterioration or Before overhauling, measure the cracks in rubber lining provided on insulation resistance of all the AC package unit, it should be electrical equipment such as replaced. alternator, motor and wiring to know the condition of equipment. 806c PROCEDURE FOR LOWERING AC Check and clean all the under PACKAGE UNIT frame suspension arrangements, lugs and terminals. After POH, test n Before lowering package unit, the wiring for insulation and fit the check roof opening and stainless pre cooling plugs. steel trough for corrosion. Jig to drawing No.XD000201 may be vii. Equipping used for ensuring the squareness of In this activity fit all the the opening. refrigeration and electrical equipment to its respective n Package unit is mounted on positions. Connect all the wiring strengthening frame with the help and flanges in the refrigeration of 8 Nos. of mounting pads system wherever necessary. (Resistoflex, STB-0069 Type-70). Mounting pad should preferably be 806b SPECIAL ITEMS TO BE INSPECTED replaced. DURING POH n While lowering the package unit, i. Check for corrosion in trough care should be taken that it does not It is necessary to check steel touch/interfere with the coach at trough, which is provided below any place. The unit should sit AC package unit during every POH properly on mounting pads. of AC coach. If any corrosion is observed, then it should be patched n Lower the AC unit on the coach up with 2 mm. thick sheet of and secure it with 8 nos. of bolts as stainless steel. per drg. No.CC44162.

Chapter 8 – Page 22 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

n Provide rubber sheet seal on the 806d OVERHAULING ACTIVITIES OF strengthening frame as shown in MAJOR AC EQUIPMENTS the drg. No.CC44162. i. Compressor

n Connect transition duct and There is no need to open the return air duct bellows with the refrigeration system of the ac unit with D-panel. package units, since it is completely sealed at factory. n Make electrical connection as per Conduct the cooling test. If the circuit diagram issued for a time required to cool the coach is particular type of coach and more than the recommended value package unit. and it does not decrease even after cleaning of condenser and n Connect condense drain pipe of evaporator, the compressor will package unit with the gradient of have to be changed. drain pipe to avoid filling of ii. Procedure for replacement of condense tray. compressor

n Place roof top cover above the n Braze a 1/4" (6mm) OD unit, after the unit is sealed by copper tube fitted with shut means of rubber sheet in off valve at one of the ends. evaporator area. Connect the shut off valve

through a charging line to an n Test the unit for water leakage. empty refrigerant cylinder For stopping any leakage, and keep in a cold iced water suitable sized of rubber sheet container until all gas is may be used. extracted. Weigh the

cylinder before and after. i. Static Testing Ensure that weight gain is

minimum 2600 grams. A gas Run the plant through pre- compressor can also be used cooling terminals and check to extract the gas and forcing for proper functioning of it into the empty cylinder. electrical and air conditioning equipment, n De-solder the suction and including all the protections. discharge lines and disconnect the electrical ii. Simulating Testing wiring from the compressor.

n Remove the compressor and For self-generating type of clean the system using coaches, check the carbon tetrachloride (CTC) alternator and inverter with the help of circulating output on different load pump. It is advised that CTC conditions. Check both the flushing should not be done alternators for load sharing. with compressor of AC

coach in circuit but a iii. Alternator Connection separate compressor should and Tensioning be used.

In this activity join the n Install a new compressor, connection of alternator and and re-solder the suction and fit the belt -tensioning discharge lines. Make the device. Provide 6+6 ‘V’ electrical connections. Use belts for alternator. high quality silver based copper solder with minimum 40% silver.

Chapter 8 – Page 23 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

n Test for leakage under 30 n Clean the motor by blowing Kg/sq.cm. pressure using compressed air.

nitrogen/carbon dioxide gas n Lubricate the motor bearing by cylinder fitted with a two approved lubricant use stage pressure regulator. lubricating gun for greasing.

n Create a vacuum of 50 n Check the alignment and re-align micron for 15 minutes with the driving and driven shafts. the help of two stage rotary vacuum pump to extract the n Check the coupling for looseness moisture from the and tighten if necessary.

refrigeration system. n Check the duct for crack and for n Charge the required loose/missing fixing bolts.

quantity of refrigerant gas n Measure the insulation resistance (R22) as per of winding with a 500 V megger. recommendation of the If the insulation resistance is less manufacturer. Charging than 10 M ohm, run the motor for stub-tube on the compressor half an hour for drying. If should be 1/4" OD and of insulation level does not improve heavy gauge. Pinch off re-varnish the armature. charging tube nearest to the compressor body so that it n To avoid brinelling, the armature remains as short as possible. must be rotated periodically by Longer stub tube can break quarter to half of the revolution.

due to vibrations. Place n It has been observed that bearing slight amount of solder at the greases deteriorate when in the pinch point for use and ceases to be effective as a strengthening. lubricant with the lapse of time. The deterioration might show in iii. Condenser and Evaporator the form of dry cakes/ flakes in sodium base grease while in the Clean the condenser coil and lithium base grease starts cooling coil with steam of 10 thinning and its oil content kg/sq.cm. to clean thoroughly and separates out of the rest of the to remove all dirt and mud grease. Deteriorated grease throughly. This can be done should be changed. without removing the coils from their places. v. A/C Control Panel And Power Panel

iv. Motor for Condenser and n Completely isolate the panel Evaporator from the power supply and its

loads. Contacts of the n Check for abnormal noise, contactors shall be removed and vibrations, burning smell. cleaned by means of clean rag n Check foundation bolts for socked in petrol. Contacts, looseness and tight, if which are burnt, should be necessary. replaced, after which they n Check the terminals after should be lightly covered with opening terminal box cover and silican gel/petroleum jelly. see for tightness. n Similarly, dismantle the n Check the condition of terminal contacts of the relays and clean lugs. them by means of clean rag n Check the earth connection of soaked in petrol. Contacts the motor body. which are burnt should be replaced.

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n Check the flexible braided n Check for cracks/edging, connections. If found damaged, deterioration of wiring. HV test replace the same. shall be performed with 2.5 KV for 1 minute. IR shall be min. 10 n The pin holding the pull off M ohm. spring on the armature frame- work of the contactor should be n Check that all mounting screws pulled out of its slot and the are intact and tight. armature hinge pin removed. n Check all terminals, terminal This should be examined for marking and ensure that legend wear and if necessary, replaced plates are intact. it with a new pin lightly n Check all indicating LEDs are covered with silican functioning. gel/petroleum jelly. vi. Cut Outs

n Measure the insulation n Clean the cover with CTC/Petrol resistance of each relay and and test for correct operation of contactor. If the insulation settings. value is less than 2 mega ohms, replace the coil having n Calibrate with the standard Insulation Resistance less than gauges. 2 mega ohm, also check the vii. Pre-Cooling Transformer Rectifier following: Unit · Leakage may be through tracking/dust accumulation. n Open the cover and clean externally with compressed air. · Clearance and creapage distance may be checked. n Dismantle the unit as per manufacturer's instructions. · Cracks in the housing of n Remove and clean the contacts switch gear may be by means of a clean rag soaked in checked. petrol. Contacts, which are burnt, n Check whether all connections should be replaced and covered are tight. If found loose, tighten with Vaseline. the same. n Clean the transformer, rectifier n Replace all the fuse links. and rotary switch. Check for operation; if defective, change it. n Check rotary switch for proper working by ensuring following: viii. Inverter Unit · Ensure that all the poles are functioning. n Open the front panel door and · Check that knob shaft is not clean with compressed dry air. In having any play. case the compressed air pressure n Check, clean and tighten all is too high, cover the nozzle with connections. thin cloth to reduce the pressure. n Check for defective ammeters n Clean the semi-conductor and voltmeters, and replace the device's heat sink with defective ones. compressed air. In case the dust is not removed completely from n Check for operation of fins use hard hairbrush and again heating/cooling relay and PCB blow with compressed air for for ensuring automatic cleaning the heat sink. functioning of AC units. n Check for continuity and n Check that all connections to sequence list of AC equipment. PCB are tight and no insulation

Chapter 8 – Page 25 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

on cables, boards and insulator is n Check the load current at damaged. rated voltage. The wattage of n Check for normal routine the fan should not exceed the performance test as per value specified in IS: 6680. manufacturer's instructions. n Check the air delivery of one or two fans from a batch to ix. Fans and Lights ascertain the correctness of the blade angle. The value of n Dismantle the lower guard, the air delivery shall not be upper guard, blade and fan less than that specified in IS: 6680. motor.

n Check the guard assembly, xi. Wiring

repair/ replace if necessary. n Light Fittings n Check the blade angle with a measuring gauge. Correct The light fittings, reflectors, clear the same if necessary. acrylic sheet cover, glass globe, n Check the insulation holders, etc., shall be checked and resistance of the fan motor. cleaned. All defective parts shall be The IR value should not be replaced. Anti-theft arrangement less than 2 mega ohms as for fluorescent light fittings shall specified in IS: 6680-1992. be checked as per ICF Drg. n Check the fan leads and No.ICF/SK-7-6-079. change it if necessary. n Check the armature winding n Coach Insulation and field coils, repair/ replace, if necessary. Insulation resistance of the coach n Check the commutator for shall be measured with 500 V grooving, pitting marks, megger. The same should be ovule, blackness etc. Skim minimum 2 mega ohms in fair or polish the commutator weather conditions but it should as required. not be less than 1 mega ohm under n Check the carbon brush and highly humid/wet weather. brush spring. Replace by correct grade of carbon n Cable Joints brush as recommended by RDSO. The fan spring · It shall be checked. Loose should meet the joints and cables having requirements given in damaged insulation shall be IS:6680. Replace the same if replaced/repaired. All cable necessary. ends shall be properly n Apply air drying insulating socketed with crimping type varnish if IR value of the copper sockets. armature and field coils is low, give impregnation · Surface of copper sockets and treatment in an air bus bars shall be cleaned to circulating oven. remove the oxide film from the jointing surface before n Clean the ball bearing, check for noise, replace if making a bolted joint and necessary or grease it with shall be coated with corrosion recommended grade. resistant conducting grease of n Check the rubber packing at approved make to prevent fan base. Replace if found reformation of oxide film. cut/damaged. n Fire retardant PVC grommet s

x. Testing to BS:1767 or grade 6 of IS:5831 shall be provided at

Chapter 8 – Page 26 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

all cable entry points in no reason it should be not more metallic members. than fresh air.

n The under frame wiring if Condition for airflow tests are- running loose shall be provided in rigid steel · Voltage set at 130 volts ± 1 conduct. volts.

n All inspection covers shall be · Both side blower motors are opened to check the working. distribution boards and · Compartment fans are `OFF'. condition of wiring. xii. Air Filter · Readings are taken after half an hour stabilization. n Replace the filter with new · Coach inside the shop. one in case of synthetic type filters. · Return air filter should be n In case of wire mess type suitably regulated to achieve filters, wash the filter in hot the fresh air flow nearer to the water first, then with non- required quantity. subzing detergent and again · Compartment door exhaust air with hot and cold water. Dry grill blocked partially to make the filter and replace them in the exhaust air equal to fresh the unit. air or 10 % less. n The manufacturer's instructions for any other · Fresh air dampers regulator specified type of filter, shall permanently locked, with paint be followed. mark after setting the required fresh air on both sides. xiii. Testing

n Cooling test n Air delivery test Cooling test should be carried out After checking the air leakage, air by providing electrical delivery test is conducted. The total compensating heat loads for air delivery for any coach is worst ambient conditions and full calculated from the fundamental occupancy of the coach. After the requirement of the `FRESH AIR stabilization, the temperature of REQUIRED PER PERSON' each berth (20 mm from window depending upon the type of the and back rest panel and 100 mm coach (i.e. smoking allowed in I above the berth) should be class AC and no smoking allowed recorded. The variation in in II class AC coach). Minimum temperature on different berths fresh air required per person for should not exceed 10 C. smoking coach is 0.7 m3/min. for non-smoking coach is 0.35 m3/min. xiv. Additional Item for End-On- respectively. Fresh, return and Generation (EOG) Coaches: exhaust air velocities are measured with the help of anemometer using suitable hoods (for fresh air only) n Check Inter vehicle coupler, to avoid turbulence of air. The ratchet assembly, junction box and electrical volume of air is computed by multiplying the velocity with face connections. area. For ideal condition, the exhaust air should be equal to fresh n Inspect cleat for over air or it can be less by 10 % but for heating, solder run out and replace if defective.

Chapter 8 – Page 27 of 28 Maintenance Manual for BG coaches of ICF design Air Conditioned Coaches

Tighten connections as compressor, blower motor needed. for any abnormality.

n Measure insulation n Check leakage air from resistance value of the doors. circuit with 500 V megger. It should not be less than 2 n Check that batteries are in mega ohms. fully charged condition.

n Overhaul the DG set as per n Run the plants with manufacturer’s instructions. dynodrive motor for 8 hrs. at different speeds. n Check the proper functioning of WRA. n Ensure that both the

alternators are sharing load xv. Final Testing of AC Coach after equally during run. If not set POH both the alternator panels.

n Visual inspection of coach xvi. Final Inspection for proper fitment of equipment. n The coach shall be jointly inspected with division staff n Ensure that refrigerant pipes and the performance of are properly clamped. electrical and refrigeration equipment shall be recorded. n Suction pipe for proper A list of equipment changed lagging. with their serial nos. will also be handed over along n Check safety chain and with the coach. Any tension rod of alternators for attention, if required to the proper fitness. equipment shall be given before dispatch of the coach n Under frame cables leading from workshop to division to alternator are properly

cleated.

n Check earth leakage by two ***** lamp method.

n Check control panel and ensure that proper MCB/fuses are provided.

n Check contactors, relay and switches for correct sequential operation.

n Check heaters for correct operation.

n Check hooter for proper operation.

n Start the plant and check condenser motor,

Chapter 8 – Page 28 of 28

Maintenance Manual for BG coaches of ICF design Rolling Gear

CHAPTER 10

ROLLING GEAR

i) Wheel disc solid 1001 WHEEL AND AXLE The solid wheel disc is manufactured as 1001a Introduction per IRS Specification No. R - 19/ 93 Pt. II and drawing No. W/WL/1660 (see figure The movement of rolling stock on the 10.2). track is possible only with the help of wheels. The complete wheel set is shown ii) Axles in the figure 10.1 with the assembly components. These assembly components An axle is a component of a wheel set to are described in detail in the following hold the wheel discs in position. The axle pages. box is also mounted on the journal of the axle (See figure 10.3 for Axle)

1. DIMENSIONS MARKED THUS ARE FOR 16 TONNES AXLE 2.FITTED ALL OTHER TO WLRRM. DIMENSIONS ARE COMMON FOR BOTH 13 TONNES AND 16 TONNES AXLE

+ 2 130 1600 - 1 130

145 172 152 178 130 145 913

915

Ø Ø Ø Ø Ø Ø Ø

Ø

NOTE:- 1. THE VARIATION IN THE TREAD CIRCUMFERENCE OF WHEELS ON THE NOT SAME XCEED AXLE 1.6 SHOULD mm (i.e.) ON DIA. 2. THE VARIATION IN WHEEL DIA BETWEEN ONE PAIR WHEELS AND THE EXCEEDOTHER SHOULD 5 mm ON NOT THE SAME BOGIE. 3. THE VARIATION ON DIA UNDER THE SAME COACH SHOULD NOT EXCEED 13 mm. WHEEL AND AXLE COMPLETE Figure 10.1

Note:- Rly. Bd. vide their letter no. 1001b Components of a wheel set 98/RSF/874/1/SAIL (Pp) dt. 8/10/1998 has decided that only A wheel set is an assembly mainly of 16.25t axles would be used for two components: wheel set under 13t bogie also for new wheel sets. The existing · Wheel discs(solid) on both sides of the wheel set in service may however axle continue till they are required to · An axle to hold these wheel discs in be changed. position

Chapter 10, Page 1 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

3 1 W/WL-1660 WHEEL PROFILE AS PER Sk.-91146 (SEE BELOW) + - E N I 0 L 5 INCLINE 1 IN 20 . 3 C 2

N W/WL-1660/R 14%%p2R I N I 45%%d 1

18%%p2R I.R. PART No.

14R 14.5R N11 +5 22 -0 PROFILE TO GAUGE

6 N9 70%%D%%P1%%D 47%%d-30'%%p1%%d NOTE:- %%P2 130 38R N9 38R 1. STAMP HOT OR COLD 10/12 mm TYPE IRS W/WL-1660, MANUFACTU- RER'S INITIAL, RAILWAY INITIAL, 6R 60%%d 3 CONTRACT No., YEAR OF MANUFAC- 5R TURE, CONSECUTIVE No., 'UT' FOR ULTRASONIC TESTING AND 'R' FOR 10%%D 25%%p1 CRS RIM QUENCHING OR 'Q' FOR ENTIRE WHEEL QUENCHING ON OUTER FACE 51R

R OF RIM. N9 0 1 11%%D%%P1%%D . A I 47%%d-30' 2. * THE OUTSIDE DIA. OF THE HUB D

T I 13 1 TO BE MACHINED IF NECESSARY TO 0 M I + - L

+5

70%%d PREVENT HUB ECCENTRICITY.

3 -0 .

1 29 X 8 M I A R

M 0 F 6 3 3 O 0 6 0 3 . +5 + - Y 3. COORDINATES OF CENTER POINT + - c 8 T A I 5 I 1

22 -0 6 % C D 9 0 I 1 1

% OF 330R & 100R ARCS ARE BASED R E C 0 T C + - 0

D 190.5 1 I % N % + 5 S E - %

% ON NOMINAL DIMENSIONS. N C I 0 .

6 C X

2 E A

+3 3 c , M 6

M -0 % 7 I 3

R %

Y

F T *

63.5 I O C ) I . . R X A 7 I T A 8 D N

1 E M E C D I m C

65.5 S

+3 E m N I ,

190 5 -0 5 M I 2 . p R 0

0 111.5887

1 % R 11%%d%%P1%%d F

Y 0 0 1 + - T % O I

3 N9 . C I 6 A I 4 R 0 . 7 T 0 D +

- 2 0 C 30 N R E 2 6 E % 7 D 2 I C 1 0 S c % 165 51R C c 1

R N I E %

( %

5 %

D P

% 91

A * % E R

153 % T 0 0 N 8 O 65.5 230 R c 190 % % 8 3 0

+ - 44 180 R 5

1 (91,328.9) 111.5887 9 N9 29.4 191 c %

% 219 1 (65.5,100.3) 6R

NI

2 6R . N6 5 N6 111.5887

1 IN 20 1 3 R 0 R R + - 1 5 0 . 0 0 4 3 1 1 3

5 R . 4 8 1 65 2 W/WL-1660/R (0,0) 130 FIGURE 10.2 73.7 %%p1

63.5 RIM WARP 1 MAX. +3 ROLLED SIZE -0

WHEEL PROFILE

WHEEL & AXLE SOLID WA/WL-32 2 FORGED (B.G.) FOR LIGHT RADIUS 5 INDICATED AT %%c763 AND WT. COACHING STOCK W/WL-1660 2/02 8 SS/4/02 NOTE 1 DELETED Sd. . WHERE USED ASSEMBLY No LY. ASS RADII CENTRES SPECIFIED & 2/94 7 CD/2/94

5 NOMINAL SIZE Sd. . RIM WARP 1 MAX. SPRAG HOLES ELIMINATED 8 2 I R S 8/93 6 CD/57/93 TOLERANCE & NOTE REVISED Sd. S.No.1211/1 OF MATL. ROLLED OR FORGED STEEL GR. NO. N1 N2 N3 N4 N5 N6 4/91 5 TOLERANCES MC/WA/TENDERADDED Sd. S.No. 1070 OF Ra m 0.025 0.05 0.1 0.2 0.4 0.8 SPEC. No. IRS R-19/93 Pt.II 3/90 4 TOLERANCES ADDED Sd. MC/WA/TENDER SNo. 672 OF SYMBOL SIZE TREAT 7/85 3 DRAWING REVISED Sd. W/WL-1660

E MC/WA/TENDER E U 3 L 7 C A 0 I.R ALT No. A GR. No. N7 N8 N9 N10 N11 N12 FORM WEIGHT DATE AUTHY. DESCRIPTION CKR. V 3 F : R S S I S U E S

O Ra m 1.6 3.2 6.3 12.5 25 50 N SCALE DO NOT SCALE

T RLY. PATT. W/WL-1660/R H G

U WHEEL SOLID FORGED (B.G.)

O SYMBOL CONCERNED RLYS. TO FILL REF. DRG.

R I.R. PART No.

Chapter 10, Page 2 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

+ 0.5 TOTAL LENGTH 2316 - 0.0

85 191 1473 119 26.5

Ø 130

R40 R75 R75

In case of 16 T Bogie - f 152 In case of 13 T Bogie - f 145 AXLE Figure 10.3

iii) Axle boxes with roller bearings The difference in tread diameter of the The axle boxes used on ICF coaches are two wheels on the same axle should not with under mentioned spherical roller exceed 0.5 mm after tyre turning. There is bearings no 'In service' limit for this variation and rejection shall be decided by tyre defect Spherical Roller Bearings No. 22326/C3 gauge These roller bearings are with 130 mm During last shop issue the wheel is to be parallel bore on the inner ring and are turned to RDSO SK-91146. The profile is directly shrunk on the axle journals. to be turned 1 mm above the condemning 1001c Maintenance Procedure in the limit groove. The maximum diameter and Workshop last shop issue size for ICF type wheels is given below: i) Pre-inspection of wheels in the workshop Table 10.1

During pre-inspection of incoming Type of New Min. Shop wheels, the wheel-set is inspected for wheel issue assessing the condition of the ICF solid 915 836 components. Following measurements are carried out on all the wheels, received in c) Inspection of wheel disc as per shop for repairs. CMI-K003

a) Measurement of a wheel gauge The wheel should be inspected for (distance between two wheels rejectable defects in accordance with flanges on the same axle) RDSO’s instructions CMI-K003

The distance between two wheel flanges d) Inspection of Wheel Flanges on the same axle should be 1600 mm + 2/-1 mm. This measurement should be The flanges on both sides of a wheel set taken at three locations apart with the help are checked with the help of a profile of an adjustable pi gauge. If wheel gauge gauge to measure the height and thickness is not within permissible limits, then the of flanges. Accurate measurement of wheel disc (s) have to be pressed off and flange height and flange thickness is not then pressed on. possible with the profile gauge. It is, therefore, recommended to use a wheel b) Measurement of Wheel Diameter profile gauge with which accurate (Tread Diameter)/Wheel Flanges measurement of flange height and flange

The wheel diameter is measured with the thickness to the extent of 0.1 mm can be made. help of a trammel gauge with a least count of 0.5 mm. on both sides. However, a After recording the diameters of wheels gauge with a least count of 0.1 mm. is and wheel flange measurements, the recommended as the measurement of a wheel set is nominated for necessary diameter would be more accurate with repairs. this gauge.

Chapter 10, Page 3 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

e) Inspection of axle 1003 REPAIR PROCEDURES FOR DIFFERENT CATEGORIES OF Axle journals should be thoroughly WHEELS cleaned for inspection to detect flaws, pitting, ovality, taper, ridges etc. Each Detailed procedure for carrying out axle should be ultrasonically tested for repairs to different categories of wheel detecting internal flaws and defects as per sets is described below: the code of procedure issued by RDSO (Annexure 10.1). Axles found flawed, 1003a Normal Repair of Wheel sets pitted or with under size journals should be replaced. Normal repair wheels are of two categories. On ICF axle journal a. With roller bearings mounted § A taper should not exceed 0.015 / 0.010 mm. b. With roller bearings removed § Out of roundness (ovality) must not exceed 0.015 / 0.020 mm. The activities involved in Normal Repair Wheels are as follows: 1002 CATEGORY OF WHEELS § Pre-inspection of incoming wheels. The wheels are categorised after pre- inspection as below: § Drop axle boxes, clean and inspect axle boxes. If required, repair them. 1002a Normal repair wheels § Carry out Ultrasonic Flaw detection test of axle. If all the components are within the acceptable range of limits, these are taken § If required, dismount roller bearings directly for wheel profiling and servicing from journals. (In any case dismount of roller bearings. roller bearings in alternate POH) § If the wheels are sent for re-profiling 1002b Wheels requiring replacement of an without dismounting roller bearings axle (RA wheels) from the journals, special protective covers should be fitted on the The wheel is taken for replacement of an bearings on either side of a wheel to axle for the following : avoid entry of chips / dust or damage to the bearing during machining. § A bent axle, § Machine wheel profiles to the § Dimensional deviations on a journal prescribed dimensions. The wheel / wheel seat tread should be checked and § Axle having groove marks in the machined to the worn wheel profile middle due to rubbing of a pull rod, and machining standard N11 to IS: § Dents, corrosion, pitting marks on 3073. (see figure 10.4 for worn the surface of the axle wheel profile) § Axles found flawed in the ultrasonic § Clean roller bearing and assemble flaw detection test components in position, if not dismounted. 1002c Wheels requiring replacement of solid § Inspect roller bearing and assembly discs (RD wheels) in position.

The wheel is taken for replacement of § Check radial clearance and confirm discs if found it to be within permissible limits. § Pack fresh grease § It is not possible to turn the wheel to the last shop issue size § Mount cleaned and inspected axle boxes. § There is a rejectable defect as per CMI-K003. § Fit front cover with new sealing ring.

Chapter 10, Page 4 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

127

63.5

1 IN 20 1

I N

R 4 2

1 . 5 5 . 8 0 R 2 0 0

1 0 R 1

9 0 3 2 3 3 3 R 1 9

20

33.5 FIGURE - 1 65.5 91

(20 MM THICK FLANGE)

1 IN 20 1

I N

R 4 2 1 . 5

0 R 0 0

1 0 R 1

9 0 3 2 R 3 3 3 0 1 1

22

35.5 FIGURE - 2 65.5

(22 MM THICK FLANGE)

1 IN 20 1

I N

R 4 2 1 . 5

0 R 0 0

1 0 R 1

9 0 R

2 3 5 3 . 3 3 1

1 1

25

38.5 FIGURE - 3 65.5

(25 MM THICK FLANGE)

DEVELOPED BY: 1. FIG.3 SHOULD BE THE LAST PINTERMEDIATE WHEEL SUPERSEDES: PROFILEPFOR THE WHEELS MEANT FOR PTHE COACHES TO SCALE P INTERMEDIATE RUN AT MAX.PKMPH AND ABOVE.P2. ALL THE THREE C INTERMEDIATE WORNPWHEEL PROFILE (FIG.1,2&3)PCAN BE WORN WHEEL USED FOR THE WHEELS FOR POTHER TYPES OF COACHES. D PAINT 9/92 PROFILE 1:1 T

JS FOR COACHING STOCK

B.G. RDSO[C] SKETCH-92082

FIGURE 10.4

Chapter 10, Page 5 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

1003b RA (Replacement of Axles) Wheels § Machining of serviceable wheel disc

The activities involved in replacement The serviceable wheel discs are re- of an axle are as follows: bored on the vertical boring machine. Care should be taken that the finished § Pressing off a rejected axle from a bore is straight, concentric to the tread wheel of the wheel and has a smooth surface free from ridges, scores and chatter The wheel is taken on the wheel press marks. A radius of 2.5 mm is provided for separating the rejected axle from on the hub to facilitate mounting. It the wheels. must be made after the finishing cut.

§ Inspection of re-bored wheel disc § Machining of new axles The rebored wheel disc should be New axles should be machined to the inspected with the help of an inside correct drawing dimensions. Journal, micrometer to ensure consistent journal fillets and shoulders should be results. Each wheel bore must be finished smooth, concentric and checked at not less than three points in without ridges, burrs or chatter marks. its length and on the different diameters at each of these points to § Inspection of machined axles ensure roundness and absence of tapers. The variation for any of these Dimensional checks measurements must not exceed 0.05 mm. A machined axle should be inspected for dimensional accuracy with the help If any taper does exist, the small of a micrometer with least count of diameter must be outside ends of the 0.01 mm. Journal diameters should be hub (a reverse taper is not allowed). measured at three points along the The surface finish of the bore should length of journals both on the vertical be within the permissible limits. and horizontal axis. The ovality and § Machining of wheel seats for taper must not exceed the limits matching of wheel disc bores prescribed in the drawing.. The wheel seat of the axle to be used Surface finish checks for re-axling is machined to suit the bore of the wheel disc keeping Surface finish of the axle on journals, interference allowance as specified. wheel seat and middle portions should be checked with the help of a surface The bore of wheel disc and wheel seat finish tester and the prescribed limits on the axle should be maintained to are as below: - the specified surface finish and diameters to achieve correct Table 10.2 interference fit and pressing in pressure

Axle portions Prescribed (RA) § Pressing on Wheel Discs on Axle value for Surface finish in microns § Before pressing on operation, wheel seats on the axle and bore of Journal portion 0.8 the wheel centres should be carefully cleaned to remove rust, grit, swarf, dirt etc. Wheel seat 1.6 portion § The wheel seat should be lubricated with a mixture of basic Middle portion 3.2 carbonate white lead and boiled linseed oil, in the proportion of 1.2 kg. of white lead paste to 1 litre of Ultrasonic flaw detection checks boiled linseed oil. The wheel and axle should be properly aligned on Ultrasonic flaw detection test is the wheel press. carried out as per annexure 10.1.

Chapter 10, Page 6 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

§ The wheel press should be § Boring (Machining) of new discs

equipped with a dial pressure New discs are bored on the vertical gauge and pressure recording boring machine. Care should be taken gauge with graphs to record to ensure the finished bore is mounting pressure diagrams for concentric to the tread of the wheel each assembly. and has a smooth surface free from § Wheels should be mounted within ridges, scores and chatter marks. The the prescribed pressure limits. radius of 2.5 mm, which is provided § Wheels should be mounted on the wheel bore to facilitate (pressed in) carefully on the axle mounting, should be made after the such that the wheel gauge distance finishing cut. An inside micrometer is maintained. should be used for measuring wheel bores to ensure consistent results. § The axle end should be stamped Each wheel bore must be checked at with the shop code, date of not less than three points in its length mounting, pressing in pressure, and on the different diameters at each axle no., cast no., cons. no. to of these points to ensure roundness enable identification of wheels. and absence of tapers. The variation Care should be taken to ensure that among any of these measurements wheel disc number is preserved must not exceed 0.05 mm. If any taper (see figure 10.5) does exist, the small diameter must be § The wheel gauge should be at an outside end of the hub bore checked by gauging at three or (reverse taper is not allowed) more equi-angular points around the circumference. § Machining of wheel seats on an old axle for matching of wheel disc

bores 1003c RD (Replacement of solid discs) Wheels The wheel seats on the old axle During pre-inspection, if it is found that (released from RD wheels) are tread diameters of the solid disc wheels machined to suit the bore of the wheel cannot be issued at the last shop issue, the discs keeping interference allowance wheel is taken for replacement of discs. as prescribed.

The activities involved in replacement The bore and the wheel seat should be of discs: machined to the specified surface finish to achieve correct interference § Dismounting of Axle boxes & Roller fit and pressing in pressure. Bearings § Pressing on Wheel on Axle

Axle boxes are dropped from the RD § Before pressing on operation, Wheel. The wheel is then taken for wheel seats on the axle and bore of dismounting of roller bearings from the wheel should be carefully journals. cleaned to remove rust, grit, swarf, dirt etc. § Inspection of Axle journals/ § The wheel seat should be Ultrasonic testing of the axle lubricated with a mixture of basic carbonate white lead and boiled Journal diameters should be measured linseed oil, in the proportion of 1.2 with an outside diameter to confirm to kg. of white lead paste to 1 litre of be within the permissible limits. The boiled linseed oil. The wheel and axle should be ultrasonically tested for axle should be properly aligned on flaw detection and should be flawless. the wheel press. § The wheel press should be § Pressing off rejected discs from a equipped with a dial pressure wheel gauge and pressure recording gauge with graphs to record The wheel is taken on the wheel press mounting pressure diagrams for for separating the rejected discs from each assembly. the wheels.

Chapter 10, Page 7 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

§ Wheels should be mounted within raceway within which operate, two rows the prescribed pressure limits. of barrel shaped rollers, which in turn are Pressing pressure should be 400 to guided by an inner ring with two 600 kg/mm of diameter of wheel raceways separated by a centre rib. The seat. For ICF 16t axle with wheel spherical roller bearings have self- seat diameter from 176mm to aligning properties and therefore can 178mm, the pressing pressure automatically adjust to any deviation in should be 71t to 108t. the centre line of the axle.

§ Wheels should be mounted Spherical roller bearings have a large (pressed in) carefully on the axle capacity for radial loads, axle loads in such that the wheel gauge distance either direction, and complex loads. They is maintained. are suited for the applications such as § The axle end should be stamped railway rolling stocks where vibrations with the shop code, date of and shock loads are encountered. mounting, pressing in pressure, axle no., cast no., cons. no. to Roller Bearings are named according to enable identification of wheels. the shape of rollers. Roller Bearings with (see figure 10.5) spherical rollers are called as Spherical § The wheel gauge should be Roller Bearings. (see figure 10.7 for roller checked by gauging at three or bearing arrangement)

more equi-angular points around Spherical Roller bearing no. 22326/C3 the circumference. (see figure with 130 mm parallel bore on the inner 10.6) ring are being used on ICF type coaches. List of Tools and Plant They are directly shrunk fit on the axle 1. EOT crane 5 tonnes journals.

2. Wheel profiling lathe These roller bearings need to be inspected 3. Axle journal turning and periodically at a pre-defined schedule in burnishing lathe the workshop in a Roller Bearing 4. Axle journal grinding machine Maintenance Shop well equipped with all for assembled wheel set. the facilities and proper lay out. The 5. Hydraulic wheel press with period of maintenance specified is as facility for mounting pressure follows: diagram 6. Axle turning lathe Periodicity of Inspection of Roller 7. Vertical turning lathe Bearing 8. Axle centering machine 9. Axle end drilling machine § All roller bearings should be cleaned, 10. Axle grinder inspected and filled with fresh grease at every POH. 1004 AXLE BOX ASSEMBLY § All bearings should be dismounted every alternate POH or 2 lakh km In passenger coaches of Indian Railway whichever is earlier in the workshop system, only single bearing type axle box for renewal of felt sealing ring and arrangement is used. The inner ring of the overhaul of the roller bearings. bearing is provided with either a cylindrical bore (Direct Mounted type) or 1005b Roller Bearing Maintenance in Shop with a taper bore and withdrawal sleeve (Sleeve Mounted type). All new Roller Bearing Maintenance Shop should passenger coaches built by Indian be well equipped with all the tools, Railways, use only direct mounted type equipment and facilities for careful spherical roller bearings. Therefore, bearing handling. It should have proper practices related to the sleeve mounted workflow for easy maintenance of roller bearings, have not been covered in this bearings. Clean surroundings and dust manual. free atmosphere should be maintained in the shop. It should have adequate 1005 ROLLER BEARINGS equipment and facilities for cleaning,

1005a Construction feature of Roller Bearings handling, dismounting, dismounting, inspection, repair and storage of roller Spherical roller bearing consist of an bearings. outer ring having a continuous spherical

Chapter 10, Page 8 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

O 8 T. W 0 N 32 O O N T N A C 0 E 6 S M 5 . 1 O 1

R . I 4 V

.

P 24

C 5 0 C A 3 0 S 3 4 O 0 4 0 N T N 2 S N O

DATE & INITIALS OF WORK SHOP WHERE THE RELAXING IS DONE

L 5 W 3 I 0 W A O N N . T S 0 E M 6 S

. . 4

R O V

6

. . I 8 P

6 E O. N 6. C

NOTE : ALL MARKINGS TO BE DONE P ON BOTH JOURNAL FACES

STAMPING SHOP INITIALS ON AXLE

FIGURE 10.5

Newly assembled wheel set should be checked for the distance between inner face of wheel i.e. 1600 +2/-1 mm using Wheel Distance Gauge.

The wheels to be gauged on a level track after taking off from coaching vehicle.

Under loaded conditions the limits are not applicable. Wheel Distance Gauge Scale (Line Gauge)

Moving End Fixed end Locking knob

SPRIT LEVEL INDICATOR

WHEEL DISTANCE GAUGE

FIGURE 10.6

Chapter 10, Page 9 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

DIRECT MOUNED ROLLER BEARING ARRANGEMENT Figure 10.7

1005c List of Tool and Plants for Roller Bearing maintenance

Following are the tools and plants required for a Roller Bearing Maintenance Shop.

Table 10.3

Sr. Nature of Work Equipment/Facility required

1 Cleaning of Roller Bearing Automatic roller bearing cleaning equipment with 3 stage cleaning of pre-wash, wash and water rinsing. 2 Cleaning of Axle Boxes Axle box cleaning plant with Bosch tank and spray jet cleaning in a close chamber 3 Axle Box extraction Axle Box extractor 4 Dismounting of Spherical Roller Bearings - Hydraulic dismounting taper bore Equipment – Withdrawal Nut 5 Dismounting of Spherical Roller Bearings - Hydraulic straight bore Dismounting equipment 6 Mounting of Roller Bearings Induction heater with de-magnetising device 7 Securing of end locking bolts Torque wrench and torque wrench tester

Chapter 10, Page 10 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

Sr. Nature of Work Equipment/Facility required

8 Visual inspection of dismounted roller Magnifying glass with light bearings 9 Measuring/checking of radial clearance Long feeler gauge set with number of leaves with different thickness 10 Measurement of journal/ shoulder diameter Outside micrometers 11 Inspection of axle end tapped holes Thread plug gauges for different sizes of tapped holes 12 Inspection of locking bolts Thread ring gauges for different sizes of Locking bolts 13 Exact quantity of grease to be filled Volumetric containers with different Sizes for different quantity of grease 14 Identification of bearings, inspection details Engraving / Etching machine

§ Indentation or rings or rollers 1005d Inspection of Roller Bearings in § Scoring of roller tracks or rollers Mounted Position § Rust/corrosion, damage or Following procedure should be adopted excessive fretting corrosion for carrying out inspection of roller § Brinelling or false brinelling bearings in mounted position. § Rings exhibiting deep straw or blue or purple colour indicating § Clean the exterior of axle box, front heat effect cover, axle box housing. § Excessive or less radial § Remove axle box with the help of clearance. mechanical screw type puller, by taking care to protect axle centre with § Radial clearance should be measured the use of pad not allowing the screw in a mounted position with a long to rest on the axle centre. The end feeler gauge simultaneously over locking plate should be removed. both the rows of roller (see figure § Examine the grease for consistency, 10.8). The blades of the feeler gauge colour, contamination with water, should be inserted between the outer foreign particles, etc. ring and the unloaded rollers. While § If the grease is in good condition, the measuring the radial clearance, the bearing should not be dismounted, rollers should not be allowed to roll provided its felt sealing ring and rear over the blade. The acceptable range cover do not require renewal. of radial clearance for bearing in § Remove old grease. Roller bearing and mounted position on journal for its components should be thoroughly different makes of roller bearings is washed and cleaned with kerosene and given in table 10.4. then petrol/white spirit. § All components viz., rollers, cage, outer and inner rings (races), roller track of outer ring should be examined after swiveling the outer ring.

§ Bearing should be rejected for the following defects: -

§ Pitted or flaked roller tracks and rollers. § Cracked or deformed or badly worn out cage Checking Bearing radial clearance § Cracked inner or outer ring in mounted condition § Scored or damaged outer surface Figure 10.8 of the outer ring

Chapter 10, Page 11 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

Table 10.4 § A truncated cone of grease should be (Reference Letter no. MC/ RB/ Genl formed to in from of the bearing. The dtd. 10.7.98) ‘V’ grooves in the rear cover should also be filled with fresh grease after Bearing make Radial clearance in mm thorough cleaning. SKF 0.105 to 0.296 mm § The axle box housing, front cover and FAG/NORMA 0.080 to 0.185 mm ‘V’ grooves on their faces should be NEI/NBC 0.080 to 0.190 mm thoroughly cleaned and checked for damages, distortion and trueness of n After inspection, if bearing is found dimensions. After filling the fresh satisfactory for further service, the grease in the grooves, the axle box bearing may be cleaned further for re- housing should be carefully pushed on assembly and greasing. Care should be the bearing and the front cover taken that outer ring is aligned or tightened in position. The nuts of the turned back to it's original position axle box should be secured with the slowly. Jerky movement of outer ring split pin. Month, year and workshop can cause damage to rollers. code should be stenciled on the front n Carry out detailed inspection of all cover and the axle box sealed. The free other parts for wear, mechanical rotation of the axle box should be damage and any other defect, the checked by hand. locking plate should be fitted in 1005f Lubrication position, the end locking bolts tightened with a torque wrench to a § The quantity of grease filled per axle correct torque value as given below: box

2.00 kg 11 to 12 m kg. For M16 bolts. SKF make bearing Other make bearings 1.75 kg 15 to 16 m kg. For M20 bolts. § Only lithium base grease of § Torque wrenches should be approved brands should be used periodically checked for accuracy with torque wrench tester. n Guidelines for storage of Grease § Bend all tabs of locking plate against 1. Grease drums should be stored in the sides of the bolt using adjustable vertical position in a covered room. rib joint plier. 2. Take all precautions to prevent § The date, the month, and the year of contaimination of grease due to attention and workshop code should be dirt, moisture, dust foreign punched on the locking plate in case of particals etc. retaining ring and on the annular nut in 3. Always store grease in container case of annular nut type arrangement with cover. (see figure 10.9) 4. Never mix different types of grease. 5. Use only clean tools and container when handling the grease.

1005g Inspection of other Roller Bearing Components

§ The following components other than roller bearing should be

inspected during roller bearing Figure 10.9 maintenance in the workshop.

§ Fresh grease should be packed § Axle end holes between the rollers and the space § End locking plates between rear cover and the roller § End locking bolts bearing. Correct quantity of grease is § Retaining Ring filled in each axle box for which § Collar volumetric containers having unique § Felt ring shape and size are used to eliminate § Rear and Front Cover mistake by staff. § Axle box housing

Chapter 10, Page 12 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

i) Axle end hole unless it is damaged or the interference fit with the axle is lost. Once dismounted, it The axle end holes should be checked should be invariably replaced. with GO–NO GO thread plug gauge for correct size and thread condition. If any of vi) Felt ring the tapped hole is worn out, a helical thread insert could be fitted in that hole Whenever the rear cover is removed from for using the same size of bolt. The the roller bearing axle box, the felt ring practice of blocking of worn out holes and should be replaced. New felt ring should o be soaked in warm cylinder oil to IS- drilling a new hole 60 away from old o o ones reduces the probing are on axle face 1589-60 type I Gr. 3 heated to 40 to 50 for ultrasonic testing. C for 30 minutes and smeared with the same grease as used in the axle box before ii) End locking plate fitting in the rear cover.

End locking plates should be replaced vii) Rear and front cover every time its folds are opened to unscrew bolt. These covers should be cleaned and inspected for any crack, correct iii) End locking bolt dimensions and concentricity of bolt holes. The height should be 61+/- 0.1 mm § The end locking bolts should be of in the as cast condition and may be high tensile steel of reputed brand/ checked with the help of a gauge. In case RDSO approved manufacturers. The the cover is worn out, it should be condition of their threads should be replaced. However the height of the checked with GO-NO GO thread shoulder from the face of both front cover ring gauges and worn out bolts and rear cover should be 60 ± 0.1 mm replaced. (refer RDSO's letter no. MC/RB/General § The bolt head should be free from dtd. 24/27-3-2000). any damages and should have proper spanner grip. The length of the bolt viii) Axle box housing should be less than that of tapped axle end holes. Bolts in service The axle boxes should be thoroughly should not be reused unless they cleaned in the axle box cleaning plant and meet the above standards. inspected. Check for any mechanical § Bolt while fitting should have no damage or distortion. The housing should radial or axial play. be free from score marks, excessive corrosion and any wear. The dimensions iv) Retaining ring of the bore and width should be within

The retaining ring should be cleaned and specified tolerance limits. The axle box inspected for flatness and correct should be checked for distortion, dimensions. The mating surfaces must be particularly at the spring seat. Use free from burr, sharp edge, rust or any cylindrical gauge fitted with dial indicator other type of defect that will prevent to check housing bore diameter at bearing proper seating with mating part. seat (see figure10.10 & 10.11). Check the

bore at several places and it must be v) Collar within specified tolerances. Housings not conforming to the limits or otherwise The collar should not be dismounted found unsatisfactory must be rejected.

Figure 10.10 Chapter 10, Page 13 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear

Axle box faces should be even. The width of the box should be 216+/- 0.1 mm between faces.

Figure 10.11

1006 MAINTENANCE WHEN BEARING § All bearing components such as IS DISMOUNTED. inner ring, outer ring, rollers, cage are examined for cracks, damage and 1006a Dismounting of bearing breakage. Roller (track of outer ring) is examined by swiveling the outer § For dismounting roller bearings, a ring. Roller track of inner ring is special hydraulic dismounting examined by mechanically pulling equipment is used (see figure 10.12). out a few rollers from the cage. Following is the procedure for § Inspection of roller bearings should dismounting of roller bearing - Oil is be carried out under sufficient light, injected between the journal and using magnifying glass. If the bore of the inner ring with high bearing is found free from all the pressure, which expands inner ring defects mentioned above, the radial resulting in breaking of interference. clearance is measured with proper The bearing becomes loose on the feeler gauge and compared with the journal and slides over it. The permissible limits prescribed by bearing is then removed from the RDSO in the maintenance manual journal and sent to the cleaning for different makes of roller plant. Bearing after cleaning is bearings. If any of the components is thoroughly inspected for defects. found to be defective or radial

clearance is not within prescribed

limits, the bearing is rejected and discarded from service.

Figure 10.12 Chapter 10, Page 14 of 23