Maintenances Schedules (LHB)

MINTENANCES SCHDULE FOR LHB COACHSL N0Maintenance Schedules

ParticularsD1

Trip/WeeklyD2

MonthlyD3

H/YLY

Frequency of ExaminationEvery Trip/Weekly30 3 daysSix month 15 days

Maintenance to be done atOn rake at nominated Primary DepotOn rake at nominated Primary DepotOn rake at nominated Primary Depot

1.0Coach:

1.1Coach should be washed both from outside & inside.YESYESYES

1.2Disinfect any spray insecticide at corner and crevices of coaches after washing all the coaches

(AC Coach & Pantry Car -15 Days)---YESYES

1.3Intensive cleaning of coach panels, chequered plates and PVC floor. ---YESYES

2.0Coach Shell

2.1Visually check body panels/end walls for damages.YESYESYES

2.2Visually inspect destination boards brackets.YESYESYES

2.3Visually inspect window glass and rubber sealing for damage/missing.YESYESYES

2.4Examine body side doors for working /damages.YESYESYES

2.5Inspect door handles for damages/missing.YESYESYES

2.6Inspect vestibule and its Rubber fittings for damages/missing, repair if necessary.

YESYESYES

2.7Visually check vestibule fall plates, mounting brackets, pins and operation of sliding doors and its lock lever for ease of operation, damages/deficiency. YESYESYES

2.8Thoroughly clean and remove dust, dirt accumulated at pillars with coir brush. ------YES

2.9Examine for corrosion of sole bar and other under frame members with torch light or inspection hand lamp.------YES

2.10Touch up damaged paint both inside & outside.------YES

2.11Check roof ventilator in Non AC for damages/defects.------YES

SL N0Maintenance Schedules

ParticularsD1

Trip/WeeklyD2

MonthlyD3

H/YLY



3.0BOGIE & AIR BRAKE

Bogie Frame and Bolster Assembly

3.1Perform a visual check on longitudinal beams, cross beams & bolster for cracks, damages and for corrosionYESYESYES

3.2Perform a visual check on brake supports, damper supports, traction centre supports and anti-roll bar supports for cracks, damages and for corrosion.YESYESYES

3.3Check bogie bolster sub assembly and brackets for cracks, damages and corrosion.

YESYESYES

3.4Wash the bogie frame thoroughly with water jet, making sure that water is not directed towards pneumatic/elect. Connections and axle bearings. ---YESYES

3.5Examine the bogie frame for corrosion/damages, especially at critical locations like lower web. Yaw damper bracket etc.------YES

3.6Carry out paint touch up as per RCF specifications MDTS-166.------YES

4.0Brake Equipments

4.1Check functionality of air brake equipment and (Hand brake equipment in LWLRRM)YESYESYES

4.2Perform a visual check on Brake cylinders/brake levers and Hand brake equipment in LWLRRM or damage, cracks and corrosion.YESYESYES

4.3Perform a functional test on pneumatic brake system. Make sure that no air leaks are present.YESYESYES

4.4Perform a visual check on all air hoses.YESYESYES

4.5Visually inspect steel piping for cracks/damages/ballast hitting. Repair/replace if necessary.YESYESYES


ParticularsD1

Trip/WeeklyD2

MonthlyD3

H/YLY



4.6 Perform a Visual check on brake discs for cracks on face, fins, hub etc.---YESYES

4.7Verify that the clearance between each brake pad and disc surface is 1-15mm.---YESYES

4.8Check wear of brake pads/brake discs.YESYESYES

4.9Lubricate the brake levers, fixings and all moving parts.---YESYES

5.0Wheel Slide Protection

5.1Perform a visual check on all grounding cables & WSP equipment cables for breaks/damages.YESYESYES

5.2Visually check equipment like front axle cover & upper & lower control arms damages, cracks and corrosion marks. YESYESYES

5.3Check functioning of WSP equipments (in WSP panel & its codes).YESYESYES

5.4Inspect the Earthing equipment or wear of slip assembly /carbon bars.---YESYES

5.5Monthly/Quarterly inspection of WSP equipment to be carried out as per schedule.---YESYES

5.6Check speed sensor gap.------YES

6.0Primary & Secondary Suspension

6.1Visually check primary springs or cracks & damages.YESYESYES

6.2Visually check safety wire ropes between bogie frame and bogie bolster for damages and corrosion.YESYESYES

7.0Primary/Secondary/Yaw dampers

7.1Perform a visual check on dampers, cracks and oil leaks.YESYESYES

7.2Perform a visual check on all fixings for loosening and/or missing components.YESYESYES


ParticularsD1

Trip/WeeklyD2

MonthlyD3

H/YLY



7.3Perform a visual check on rubber elements for cracks and ageing.YESYESYES

8.0Bearings(CTRB/TBU)

8.1Carry out bearing feeling for detection of hot bearing.(During rolling in Examination) YESYESYES

9.0Wheel & Axle

9.1Perform a visual check on wheels for cracks.YESYESYES

9.2Check by while profile gauge.---YESYES

9.3Check axle for cracks and signs of corrosion.YESYESYES

9.4Check tread diameter and wear of wheel profile. If necessary, perform re-profiling.---YESYES

Check wheels offset on axle (1600+1 mm)------YES

10.0Control am

10.1Perform a visual check on all fixings for loosening and/ or missing components.YESYESYES

10.2Visually check control arm parts or damages, cracks or corrosion marks.YESYESYES

10.3Inspect the rubber joints for damages and ageing.------YES

11.0Anti Roll bar Assembly

11.1Perform a visual check on Anti roll bar, links and Brackets or cracks, damages and corrosion.YESYESYES

11.2Perform a visual check on rubber joints for cracks, damage and ageing.------YES

11.3Visually inspect for grease oozing out of anti roll bar bearings, which may result in bearing failure.YESYESYES

11.4Perform a visual check on all fixing for loosening/missing fittings. YESYESYES


ParticularsD1

Trip/WeeklyD2

MonthlyD3

H/YLY



12.0Traction Centre

12.1Perform a visual check on the traction centre lever and on the rods for cracks, damages and corrosion.YESYESYES

12.2The assembly should be free to move, and not blocked by any foreign objects.YESYESYES

12.3Perform a visual check on all fixings for loosening.YESYESYES

12.4Perform a visual check on rubber joints for cracks/damages.YESYESYES

12.5Greasing of anti roll-bar.---YESYES

13.0Rotation Limiter

13.1Perform a visual check of rotation limiter, components.YESYESYES

14.0Rubber and Rubber/Metal Bonded parts

14.1Perform a visual check on Rubber and Rubber/Metal Bonded parts for cracks, damages and ageing.---YESYES

15.0Pins and bushes

15.1Lubricate all pins and bushes.---YESYES

16.0Body works:-

16.1General inspection of Vehicle body work (print work, glazing etc).---YESYES

17.0Draw & Buffing Gears:-

(Ref: CMI No: RDSO/2006/CG/CMI/01 Rev No: Nil)

17.1Visual Inspection of Tight lock coupler head for damage. YESYESYES

17.2Visual Inspection of Knuckle for damage.---YES

17.3Checking of coupler operating mechanism or damage, loose, bolts etc.YESYESYES

17.4Greasing of slide rod of coupler operating mechanism---YESYES

17.5Checking tell tale recess for ensuring proper coupling.YESYESYES

17.6Inspection of coupler carriers/supporting device & its spring for cracks & breakage. YESYESYES


ParticularsD1

Trip/WeeklyD2

MonthlyD3

H/YLY



17.7Inspection of loose/broken/missing nuts & bolts (M-16) of coupler pin support plate & draft gear support plate.YESYESYES

18.0Corridor Connections:-

18.1Check corridor connections for external damage & foreign bodies.YESYESYES

18.2Check vestibule connections for external damage & foreign bodies.YESYESYES

19.0Air Pressure Equipment

Dry out air-filter---YESYES

Clean air-filter---YESYES

Clean airline-filter---YESYES

Drain air Reservoirs.YESYESYES

20.0Interior fitting passenger accommodation:-

20.1General visual check for damageYESYESYES

20.2Check for regulation provision in dust bins & operational fire extinguishers.YESYESYES

20.3Check hand rails, sliding doors, shutters, toilet doors, vestibule doors and their functioning.YESYESYES

20.4Check bathroom fittings visuallyYESYESYES

20.5Clean top & bottom guide rails of luggage doors of power cars & greasing of guide bearing.YESYESYES

20.6Inspect seats & check for completeness.---YESYES

20.7Inspect luggage racks & check for completeness.---YESYES

20.8Check all hand rails manually for correct fitment & fixing.---YESYES

20.9Inspect PVC floors and chequered plates for any damage.---YESYES

20.10Checks stick-on notices and directions for condition & completeness.---YESYES

20.11Check single Leaf sliding door general function & ease of movement.YESYESYES


ParticularsD1

Trip/WeeklyD2

MonthlyD3

H/YLY



20.12Check double leaf connection door general function & ease of movement.YESYESYES

21.0Passenger Doors

21.1Check General functions of passenger doors or ease of movementYESYESYES

21.2Lubricate door seals---YES

21.3Clean & lubricate door mechanisms.---YESYES

22.0Water supply system:-

21.1Check tanks pipes for leakageYESYESYES

22.2Check tank mountings brackets and fittingsYESYESYES

22.3Rinsing the pipes & water tanks---YESYES

23.0Pantry

23.1Check for damage & deficiencies in the pantry construction fittings, water supply & drainage of the pantry area.YESYESYES

24.0Sanitary Equipments

24.1Check functioning of toilet systemYESYESYES

Maintenance Manual of LHB Coaches

Air Brake System

AIR BRAKE TESTING (Single Car)

ANNEXURE - B

Coach no.TypeDate of Testing

POH DateIOHReturn Date

DV No.DV MakeBk. Equipment

WSP make

PressureBPSpecified5 0.1 kg/cm 2 Actual

FP6 0.1 kg/cm 2

Pre-Inspection : Please ensure that all the pipe fittings, brake equipments are properly fitted and in place before starting of testing.

ITEMTESTSPECIFIED VALUEACTUAL VALUEREMARKS

1.0

1.1

1.2

1.3

1.4

1.5Reservoir Charging

Charging time of AR

(0 4.8 kg/cm 2)

Charging time of CR (6.0 litre)

( 0 4.8 kg/cm 2)

BP Pressure

CR Pressure

FP Pressure 175 30 sec.(SAB)

60 to 120 sec.(KB)

16520 sec.(SAB)

160 to 210 sec.(KB)

5.00.10 kg/cm 25.00.10 kg/cm 2

6.00.10 kg/cm 2

2.0

2.1

2.2

Sealing test (Allow the system to settle for 2 min. after charging BP & FP. Observe the rate of leakage. BP (Less than 0.1 kg/cm 2 in 5 minutes) FP (Less than 0.1 kg/cm 2 in 5 minutes)

BP

Maintenances Schedules (LHB)

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