Indian Railway



Scope of quality audit for POH attention of Wagons in workshop

1. QUALITY AUDIT FOR ATTENTION OF AIR BRAKE SYSTEM (FREIGHT STOCK).

2. QUALITY AUDIT FOR ATTENTION OF CARTRIDGE TAPER ROLLER BEARING & WHEEL SETS (FREIGHT STOCK).

3. QUALITY AUDIT FOR CASNUB – BOGIE REPAIR.

4. QUALITY AUDIT FOR ATTENTION OF CBC COUPLER & DRAFT GEAR.

5. QUALITY AUDIT FOR ATTENTION OF WAGON BODY & UNDER-FRAME.

CHECK SHEET FOR

QUALITY AUDIT OF AIR BRAKE SYSTEM (FREIGHT STOCK)

(Based on Maintenance Manual G-97 of Air Brake System for Freight Stock as well as Chapter 8 of CAMTECH Maintenance Manual for Wagon)

During the audit, activities should be checked with regard to as specified in the maintenance manual G-97 and Chapter 8 of CAMTECH Maintenance Manual for Wagon. Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.

|SN |Requirements |Clause |Remarks |

|1.0 |Distributor Valve (Annexure-I of G-97). | | |

|1.1 |Check that dismantling/assembly of DV assembly and |2.1 | |

| |Pipe bracket is being done as per maintenance manual |of G 97 | |

| |of respective manufacturer. | | |

|1.2 |Check that all the components have been replaced of |2.2 | |

| |POH kit irrespective of condition. |of G 97 | |

|1.3 |Check that DVs have been tested for all the parameters|3.1 | |

| |as given in their format on a test bench. |of G 97 | |

|1.4 |Check that pipe bracket is being tested for leakage |3.2 | |

| |with 10 kg/cm2 air pressure. |of G 97 | |

|1.5 |DV of BOBRN/BOBR wagon shall be tested for parameters |3.3 | |

| |as covered in Annexure – XII |of G 97 | |

|1.6 |The distributer valves not meeting any of the |3.4 | |

| |requirements must be attended as per procedure covered|of G 97 | |

| |in manufacturer maintenance manual and retested for | | |

| |all parameters. | | |

|1.7 |Check that overhauled DVs are being stenciled as below|4 | |

| | |of G 97 | |

| |Workshop & Railway. | | |

| |Month & Year. | | |

|1.8 |Check that overhauled and tested DVs are being stored |5 (I) | |

| |in a clean & dry place. |of G 97 | |

|1.9 |Check that all inlet points of DV & pipe bracket are |5(II) | |

| |covered with protective cap. |of G 97 | |

|1.10 |Check that specified tools are available for DV |6 | |

| |repair. |of G 97 | |

|1.11 |Check that overhauling is being done by trained |8 | |

| |persons. |of G 97 | |

|2.0 |Brake Cylinder (Annexure-II of G-97) | | |

|2.1 |Brake cylinder is dismantled as specified with correct|2.0 | |

| |tools |of G 97 | |

|2.2 |Check that all the components of brake cylinder have |2.1.8 | |

| |been thoroughly degreased and cleaned. |of G 97 | |

|2.3 |Check that all the components have been thoroughly |2.1 & 2.2 | |

| |inspected for damage, cracks or welding, dent etc and |of G 97 | |

| |ensure that damaged components have been replaced. | | |

|2.4 |Check that release springs have been checked for their|2.2 | |

| |free height (610mm min). |of G 97 | |

|2.5 |Check that following components have been replaced and|2.3 | |

| |available in adequate nos. |of G 97 | |

| |Piston Packing | | |

| |Wear ring | | |

| |Bush | | |

|2.6 |Check those small amounts of grease have been applied |2.4 | |

| |before assembly. Brake cylinder is assembled as |of G 97 | |

| |specified with correct tools. | | |

|2.7 |Check that strength test of cylinder with 10 kg/cm2 is|3.1 | |

| |being carried out. |of G 97 | |

|2.8 |Check that pressure tightness test is being carried |3.2 | |

| |out as per procedure. |of G 97 | |

|2.9 |Check that brake cylinders are being painted with |4 | |

| |black enamel. |of G 97 | |

|2.10 |Check that overhauled brake cylinders are being stored|5.1.2 | |

| |in proper way and inlet and outlet parts have been |of G 97 | |

| |plugged with protective cap. | | |

|2.11 |Ensure that a test stand is available for brake |6 | |

| |cylinder testing. |of G 97 | |

|2,12 |Avoid damage to piston packing by dull edge thin | | |

| |bladed tool. | | |

|3.0 |Dirt-collector (Annexure-III) | | |

|3.1 |Check that all parts are being cleaned properly. |2.2 | |

| | |of G 97 | |

|3.2 |Check that Gasket & Leather washer is being renewed. |2.3 | |

| | |of G 97 | |

|3.3 |Check that all the parts are being inspected for |2.4 | |

| |damage including filter. |of G 97 | |

|3.4 |Check those dirt collectors are being tested on test |3 | |

| |stand with the air pressure of 10 kg/cm2. |of G 97 | |

|3.5 |Check that overhauled dirt collectors are being stored|5 | |

| |in a dry & clean space and inlet & outlet parts are |of G 97 | |

| |being plugged with protective cap. | | |

|4.0 |Angle Cock (Annexure-IV) | | |

|4.1 |Check that all the components are being cleaned |2.2 | |

| |properly. |of G 97 | |

|4.2 |Check that ‘O’ ring & seat are being renewed |2.3 | |

| |irrespective of condition. | | |

|4.3 |Check that all the components have been inspected for |2.4 | |

| |any damage. |of G 97 | |

|4.4 |Check that spring is being checked for tension and |2.4.5 | |

| |also for dimension (12mm). |of G 97 | |

|4.5 |Check that angle cock is being tested on a test stand |3 | |

| |with air pressure of 10 kg/cm2. |of G 97 | |

|4.6 |Check that overhauled angle cocks are being stored in |5 | |

| |a dry and clean space. |of G 97 | |

|4.7 |Check that inlet & outlet parts are being plugged with|6 | |

| |protective caps. | | |

|5.0 |Auxiliary Reservoir (Annexure-V) | | |

|5.1 |The auxiliary reservoir should be overhauled in every |2.1 | |

| |POH. Check that auxiliary reservoir is being cleaned |of G 97 | |

| |from outside and inside with wire brush and dry air | | |

| |jet after properly draining. | | |

|5.2 |Examine for visual damages. The auxiliary reservoir |2.2 | |

| |having deep cuts on surfaces may be rejected. |of G 97 | |

|5.3 |Check that rust preventive is being applied from |2.3 | |

| |inside surface of reservoir. |of G 97 | |

|5.4 |Check that reservoir is being painted with black |2.4 | |

| |enamel from outside. |of G 97 | |

|5.5 |Check that leather washer is being replaced |2.6 | |

| |irrespective of condition. |of G 97 | |

|5.6 |Check that Teflon tape is being used over drain plug |2.7 | |

| |for making leak proof joints. |of G 97 | |

|5.7 |Check that reservoirs are being tested with 10 kg/cm2 |3 | |

| |Hydraulic & Air pressure for leakage. |of G 97 | |

|5.8 |The auxiliary reservoir should be stored in such a way|5 | |

| |to prevent the following: |of G 97 | |

| |Damage due to hitting each other. | | |

| |The flange surface should be prevented from damages. | | |

| |Outside paint should not be damaged. | | |

| |Check that parts are being plugged with protective | | |

| |caps | | |

|6.0 |Hose Coupling (Annexure-VI) | | |

|6.1 |Check that hose coupling is being thoroughly inspected|2 | |

| |for any damage, corroded and ensure that damaged hose |of G 97 | |

| |are not being used. | | |

|6.2 |Remove the gasket and thoroughly clean the coupling |2.3 | |

| |head specially the internal groove for housing gasket.|of G 97 | |

|6.3 |Check that hose coupling are being tested for leakage |3 | |

| |at the air pressure of 10 kg/cm2. |of G 97 | |

|6.4 |Check that hose coupling are being stored at dry & |5 | |

| |clean space and outlet & inlet ports are being plugged|of G 97 | |

| |with protective caps. | | |

|7.0 |Isolating Cock (Annexure-VIII) | | |

|7.1 |Check that isolating cocks are being overhauled and |2&3 | |

| |tested in accordance with manufacturer’s maintenance |of G 97 | |

| |manual. | | |

|7.2 |Check that equipment for testing is available. |4 | |

|7.3 |Check that repaired valves are protected from dust & |5 | |

| |moisture. | | |

|9.0 |Pipes, Joints & Support bracket (Annexure-X) | | |

|9.1 |Check that gasket is being removed from flange joints |2.1 | |

| |and old one is scrapped. |of G 97 | |

|9.2 |Check that pipes & joints are being cleaned from |2.2 | |

| |outside. |of G 97 | |

|9.3 |Check that pipes & joints are being cleaned the inside|2.3 | |

| |by jet of dry air & all dirt and other particles are |of G 97 | |

| |being removed. | | |

|9.4 |Check that gaskets groove of flange joints is being |2.6 | |

| |properly cleaned. |of G 97 | |

|9.5 |Check that pipe is painted from outside. | 2.8 | |

| | |of G 97 | |

|9.6 |Check that pipes & joints are being re-cleaned by dry |2.9 | |

| |air at least 5 minutes. |of G 97 | |

|9.7 |Check that ends of the pipes are being plugged with |2.10 | |

| |protection caps and are being only removed at the time|of G 97 | |

| |of fitment. | | |

|9.8 |Check that testing of the pipe is being done with 10 |3 | |

| |kg/cm2 dry air pressure before removal and after |of G 97 | |

| |refitment. | | |

|9.9 |Check that removed pipes are being kept in set and are|5 | |

| |being fitted on same wagon. |of G 97 | |

|9.10 |Check that all gaskets are being renewed. |6 | |

| | |of G 97 | |

|10.0 |Others: | | |

|10.1 |POH kit for C3W and KE design DV as listed in annexure|G 97 | |

| |XIII/1 & 3 are stocked at depot. | | |

|10.2 |POH kits of other air brake components as listed in |G 97 | |

| |annexure are stocked at depot. | | |

|11.0 |Slack adjuster | | |

|11.1 |Overhauling facility for slack adjuster is available |812 (C)(a) | |

| |and all Tools & equipments are available. |CAMTECH | |

|11.2 |The slack adjuster shall be overhauled at the time of |812 (C)(b) | |

| |POH of rolling stock. While dismantling or assembling |CAMTECH | |

| |it is essential to use special tools. Each component | | |

| |of slack adjuster shall be examined. Worn out parts | | |

| |shall be checked according to the limits. | | |

|11.3 |Any spring which does not conform to the requirements | 812 (C)(b)-I | |

| |should not be used. |CAMTECH | |

|11.4 |During POH must change items as per G-92 should be |812 (C)(a)-II | |

| |replaced. |CAMTECH | |

|11.5 |After cleaning and inspection, all parts of slack |812 (D) | |

| |adjuster should be coated with semi fluid grease |CAMTECH | |

| |SERVOGEM-2 or equivalent before undertaking | | |

| |re-assembly. | | |

|11.6 |The following should be ensured: |812 (E) | |

| |The place of overhauling must be clean and free from |CAMTECH | |

| |dust. | | |

| |Ensure that no foreign matter/particle remain inside | | |

| |the subassemblies during re-assembly | | |

| |All rubber gaskets, sealing ring, washers must be | | |

| |replaced during overhauling. | | |

| |Specified tools and fixtures are used for disassembly | | |

| |and assembly operations. | | |

|11.7 |After overhauling, the testing of slack adjuster is |812 (F) | |

| |carried out in a test rack for take up (Pay in test) |CAMTECH | |

| |and Pay out test. | | |

|11.8 |The slack adjuster is given a coat of anti-corrosive |812 (G) | |

| |paint, excluding the adjuster tube 41. |CAMTECH | |

|11.9 |A & e dimension are adjusted correctly during brake |812 (H) | |

| |rigging setting. |CAMTECH | |

Annexure for quality audit check sheet of air brake system

1. Consumption of vital spares (Check availability of spares and shortcomings to be highlighted):

|SN |Description |Total Per month (Av of last six |

| | |month) |

|1 |Total No of Air Brake Wagon overhauled | |

|2 |Total DV kits received from store | |

|3 |Total DV overhauled | |

|4 |Total air hose received from store | |

|5 |Total air hose rejected | |

|6 |Total Angle cock received from store | |

|7 |Total Kit for Angle cock received from stores | |

|8 |Total new DV received from store | |

|9 |Total DV rejected | |

2. Availability of CAMTECH manual for wagon and G -97 manual and OEM’s manual for DV attention:

3. Display of work instruction on shop floor:

4. Training status of staff and supervisor for DV overhauling and air brake attention:

5. Status of record keeping:

6. Status of calibration of gauges and measuring instruments:

CHECK SHEET FOR QUALITY AUDIT OF

CARTRIDGE TAPER ROLLER BEARING

AND WHEEL SETS (FREIGHT STOCK)

(Based on Maintenance Manual G -81 and

Chapter 6 of CAMTECH Manual for Wagon)

During the audit, activities should be checked with regard to as specified in the maintenance manual G-81 Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.

|SN |Activities |Clause No |Observations |

| | |of G- 81 | |

|1 |Removal of Bearing from Axle | | |

|1.1 |Ensure that the removal of bearing is done as |7.2.2 | |

| |specified. |7.2.3 | |

|1.2 |Check whether bearings are kept in a clean and dry |7.2.4 | |

| |place in a covered room. | | |

|1.3 |Check that bearings are stacked properly and not |7.2.5 | |

| |thrown one over the other. | | |

|2 |Dismantling of bearing | | |

|2.1 |Check that dismantling is done properly. |7.3 | |

|2.2 |Ensure that the tools are available for dismantling of|7.3 | |

| |the bearing as specified. | | |

|3 |Cleaning of components | | |

|3.1 |Ensure proper cleaning. |7.4 | |

|3.2 |Check that washing medium is filtered before use at |7.4 | |

| |least once in a day. | | |

|4 |Inspection of Bearing Components | | |

|4.1 |Ensure that the system exists to check each component |7.5 | |

| |carefully and measure the dimension of components as | | |

| |per Annexure-VI. | | |

|5 |End Cap | | |

|5.1 |Inspect end cap for cracks, breakage, wear and |7.5.1 | |

| |distortion of machined surface. | | |

|6 |Cone (Inner rings with Roller Cage assemblies) | | |

|6.1 |Inspect the race ways for staining corrosion, pitting,|7.5.2 | |

| |heat discoloration, false brinelling, spalling, | | |

| |indentation, electrical burns, and cracks and embedded| | |

| |contamination. | | |

|6.2 |Inspect the inner ring with roller and cage assembly |7.5.2 | |

| |properly as fig.7. | | |

|7 |Outer ring/Cap | | |

|7.1 |Check inside dia. of counter bore, out of roundness |7.5.3.1 | |

| |and cup outer dia. |7.5.3.2 | |

|7.2 |Check wear pattern on the outside of cup and inspect |7.5.3.3 | |

| |rolling surface for brinelling, sapling, smearing or | | |

| |peeling, fragment indentation or electric burns and | | |

| |intensity of corrosion. | | |

|8 |Rollers | | |

|8.1 |Inspect Rollers for the defects such as brinelling |7.5.4 | |

| |sapling, smearing, indentation and corrosion. | | |

|9 |Cage | | |

|9.1 |Check cage pocket clearance and cracks. |7.5.5 | |

|9.2 |Cage once taken out should not be reused. |7.5.5 | |

|10 |Seals | | |

|10.1 |Ensure that seals are not reused. |7.5.6 | |

|11 |Spacer | | |

|11.1 |Check spacer for cracks nicks and burns and also check|7.5.7 | |

| |parallelism of end faces. | | |

|12 |Seal wear ring | | |

|12.1 |Inspect the outer surface for cracks, nicks, scratches|7.5.8 | |

| |and also check for wear. | | |

|13 |Vent fittings | | |

|13.1 |Check that there is no vent hole in backing ring if |7.5.10 | |

| |required it should be plugged. | | |

|14 |Backing ring | | |

|14.1 |Check backing ring break out diameter and for |7.5.9 | |

| |excessive corrosion. | | |

|14.2 |Check that distorted, cracked and heavily pitted rings|7.5.9 | |

| |are scrapped. | | |

|15 |Cap screw and Locking plate | | |

|15.1 |Check cap screws for wear on threads and for |7.5.11 | |

| |stretching or elongation. | | |

|15.2 |Check that cap screw threads are properly cleaned and |7.5.11 | |

| |lubricated before fitment. | | |

|15.3 |Ensure that cap screws are tightened with torque |7.5.11 | |

| |wrench. | | |

|15.4 |Ensure that locking plates are not reused. |7.5.12 | |

|16 |Assembly of Bearing | | |

|16.1 |Check that all the inspected parts are free from dust |7.7 | |

| |and foreign particles. | | |

|16.2 |Ensure that all the parts, tools and workbenches are | | |

| |thoroughly cleaned. | | |

|16.3 |Ensure that all the inspected parts are covered with | | |

| |polythene sheet whenever reassembly work is | | |

| |discontinued for delayed. | | |

|17 |Bench lateral play | | |

|17.1 |Check bench lateral play and ensure that this is |7.7.1 | |

| |within limits. | | |

|18 |Lubrication | | |

|18.1 |Ensure that grease container is always kept closed. |7.7.2 | |

|18.2 |Ensure that approved brand of grease is used. |7.7.2 | |

|18.3 |Ensure that specified quantity of grease is used i.e. |7.7.2 | |

| |455 gms and verify by measuring two samples per day. | | |

|19 |Mounting of Roller and Cage Assembly and Fitment of |7.7.3 | |

| |seals | | |

|19.1 |Ensure that all the components are properly mounted | | |

| |with due care. | | |

|19.2 |Check the fitment of seal wear ring & backing ring. |7.7.4 | |

|19.3 |Ensure that seal wear ring and backing ring are fitted|7.7.5 | |

| |according to clause. | | |

|20 |Mounting of Taper Bearing on Axle |9 | |

|20.1 |Check journal dia at three points as described in case|9.1 | |

| |of new axle. | | |

|20.2 |Measure the journal dia at the two bearing seat |9.2 | |

| |location locations at three equidistant points around | | |

| |the journal in case of old axles. | | |

|20.3 |Check the grooves on axle. |9.2.1 | |

|21 |Measuring for Upset Journal Ends | | |

|21.1 |Measure the journal dia at end. Take three readings at|9.2.2 | |

| |120 degree apart around the journal. | | |

|21.2 |Check fillet radius for proper seating of backing |9.3 | |

| |ring, with template. | | |

|21.3 |Before mounting, coat the journal fillet and portion |9.4 | |

| |of axle between wheel hub and the fillet with lead | | |

| |free rust preventive & then coat bearing seating on | | |

| |the journal with heavy mineral oil. | | |

|21.4 |Ensure the final mounting pressure i.e. 50+-5 tons. |9.5 | |

|22 |Mounted lateral play | | |

|22.1 |Check the mounted lateral play with a magnetic base |9.6 | |

| |dia indicator. | | |

|23 |Fitment of Axle under the Bogie | | |

|23.1 |Ensure that proper care has been taken while fitting |10.0 | |

| |axle under bogie to avoid hitting. | | |

|24 |Bearing Marking | | |

|24.1 |Ensure that proper marking of POH/repair particulars |13 | |

| |have been marked at the locations prescribed. | | |

|25 |Maintenance Workshop | | |

|25.1 |Ensure that working area is duly clean, dust free & |14 | |

| |dry. | | |

|26 |Handling of Bearing Mounted Wheel Sets |15 | |

|26.1 |Check that bearing mounted wheel sets are handled |-do- | |

| |properly. | | |

|26.2 |Ensure that all the measurement/checks properly |-do- | |

| |recorded as per check list of G-81. | | |

|26.3 |Ensure that all gauges have been calibrated/ checked |-do- | |

| |with master gauge at least once in a month. | | |

CHECK SHEET FOR QUALITY AUDIT OF

WHEEL SETS (FREIGHT STOCK)

Ref: Chapter 6 of CAMTECH Manual for Wagon

|SN |Requirements |Clause |Observations |

|1. |Check that wheel gauge (1600+2/-1) is being measured at 3 |606 H | |

| |location 60º apart. | | |

|2. |Check that wheel dia is being measured with the help of |606 C& H | |

| |trammel gauge with least count of 0.5mm or wheel dia | | |

| |measuring gauge of least count of 0.1mm. Check that wheel | | |

| |flanges are being checked with the help of wheel profile | | |

| |gauge and thickness and height of flanges is being measured.| | |

| |The difference in tread dia of the two wheels on the same | | |

| |axle permitted is 0.5mm max and this is being measured. | | |

| |Check that wheels turned out from wheel shop are according | | |

| |to shop issue sizes. | | |

| | | | | | |

| |Wheel Dia |New- 1000 |Shop issue | | |

| | | |size - | | |

| | | |919 mm | | |

|3. |Check that each axle is being thoroughly cleaned for |Para 606 A | |

| |inspection & inspected for pitting, ovality, taper, ridges &| | |

| |ultrasonically as per RDSO procedure. | | |

| |Taper must not exceed – 0.015/0.01mm. | | |

| |Out of roundness must not exceed-0.015/0.02mm. | | |

|4. |Check that wheels are being categorised into following |Para 606 | |

| |categories after pre-inspection. | | |

| |Normal repair wheels. | | |

| |Wheels requiring replacement of Axle. | | |

| |Wheels requiring replacement of Wheel dics. | | |

|5. |The wheel should be inspected for rejectable defects in |CMI/ | |

| |accordance with CMI/K003. |K003 | |

|6. |Check that wheels are being turned to WWP & machining |Para | |

| |standard is N11 to IS:3073. |606 E | |

|7 |Check that new axles are being machined as per the correct |Para 606 A and B | |

| |drawing dimensions. | | |

|8 |Check that dimensions of finished journals is being measured|Para | |

| |with micrometer at 3 points along length of the journal both|606 A | |

| |on horizontal & vertical axis. | | |

|9 |Check that axles are being given ultrasonic flaw detection | | |

| |test. | | |

|10 |Check that the bore & the wheel seats are having specified |Para | |

| |surface finish & correct interference fit and pressing in |606 F | |

| |pressure interference allowed – 0.001 mm/ mm dia of the | | |

| |wheel seat | | |

| |Surface finish – 1.6 microns | | |

| |Pressing in pressure – 400 to 600 kg/mm dia of wheel seat. | | |

|11 |Check that cleaned wheel seat and bore on wheel is being |Para 606 F | |

| |lubricated with a mixture of basic carbonate white lead and | | |

| |boiled linseed oil in the proportion of 1.2 kg of white lead| | |

| |to 1 lt. of boiled linseed oil. | | |

|12 |Check that wheel press is equipped with a dial pressure |Para | |

| |gauge and pressure recording gauge with graph to record |606 F | |

| |mounting pressure diagram and also is being recorded for | | |

| |each assembly. | | |

|13 |Check that mounting particulars are being punched on journal|Para | |

| |face. |606 F | |

|14 |Pairing of wheels: Wheels are to be paired in wagons in |Para | |

| |accordance with clause 2.8.14.2 of IRCA Part III |606 I | |

Annexure for quality audit of CTRB & wheel sets (Freight stock)

1. CTRB overhauled per month (Average of last six months):

2. Consumption of vital spares (Check availability of spares and shortcomings to be highlighted):

|SN |Items |MC |Av consumption per month (during last six |

| | | |month) |

|1 |Cup – Brenco make | | |

|2 |Cup – TIMKEN | | |

|3 |Cone – Brenco | | |

|4 |Cone – TIMKEN | | |

|5 |New CTRB | | |

|6 |Locking washer | | |

|7 |Seal wear ring | | |

|8 |Backing ring | | |

|9 |End cap screw | | |

|10 |Grease ALVINIA EPD | | |

|11 |Grease seal | | |

3. Availability of CAMTECH manual for wagon and G -81 manual:

4. Display of CMI – K003 of CAMTECH for assessing rejectable wheel defect:

5. Display of work instruction on shop floor:

6. Training status of staff and supervisor for CTRB and wheel sets attention:

7. Status of record keeping:

8. Status of calibration of gauges and measuring instruments:

CHECK SHEET FOR QUALITY AUDIT OF

CASNUB – BOGIE REPAIR

(Based on Maintenance Manual – G-95)

During the audit, activities should be checked with regard to as specified in the maintenance manual G-95 Wherever the activities are not performed correctly, the method adopted should be indicated or the nature of non-compliance should be recorded.

|SN |Activity |Clause |Observations |

|1 |Ensure that the bogie clearance and other |4.1.3 | |

| |tolerance are checked when dismantled. | | |

|2 |Ensure that in case of excess wear the repairs |4.1.4 | |

| |are undertaken either by building up or by | | |

| |changing the liners. | | |

|3 |The gauge as shown in Figure 37 & 38 of G-95 is |4.1.5 | |

| |available and is being used to check the combined| | |

| |wear in bolster/side frame liners and wedge. | | |

|4 |Ensure that suitable manipulators are available |4.1.6 | |

| |and are being used regularly to carry out repair | | |

| |work by down hand welding. | | |

|5 |Ensure that the repair surfaces are checked with |4.1.7 | |

| |the relevant gauge for correctness and excess | | |

| |material is removed by grinding machining. | | |

|6 |Ensure that the uses of electrode and gauge |4.1.8 | |

| |welding movement and welding precautions are | | |

| |being taken as laid down in Annexure C-2F of | | |

| |G-95. | | |

|7 |Ensure that wearing surfaces of bogie are brought|4.1.9 | |

| |to “As new condition”. | | |

|8 |Ensure that all the load and snubber springs are |4.2.2 | |

| |inspected for proper setting after placing the | | |

| |wagon body on the bogies. | | |

|9 |Ensure that centre pivot of the bogie is fitted |4.2.2 | |

| |with graphite flake to IS: 495 at the time of | | |

| |assembly. | | |

| |Ensure that centre pivot washer is used and | | |

| |assembled during assembly. | | |

|10 |Ensure that the clearances are measured as per |4.2.3 | |

| |the clearances given in the G-95 | | |

|11 |Ensure that the wearing surfaces in the side |5.3.1 | |

| |frame are measured and wherever necessary, the | | |

| |recondition procedure as specified is followed. | | |

|12 |Ensure that the side frame columns are provided |5.3.2 | |

| |with 10mm thick silico-manganese liners. | | |

|13 |Ensure that while providing the liners the |5.3.2 | |

| |surfaces of the side frame column face is dressed| | |

| |and friction plate is held tight against the | | |

| |column face during welding and the welding is | | |

| |done in down hand position. | | |

|14 |Ensure that side frame col, sides are gauged to |5.3.3 | |

| |determine the amount of wear on the outside and | | |

| |inside frame and if necessary, the liners are | | |

| |welded. | | |

|15 |Ensure that the wear on the anti-rotation lug is |5.3.4 | |

| |measured with gauge as shown in Figure 26 of G.95| | |

| |and if necessary, the liners are welded. | | |

|16 |Ensure that wear on the side frame pedestal crown|5.3.5 | |

| |roof is measured using gauge as shown in Figure | | |

| |27 and 28 of G-95 and if necessary, the liners | | |

| |are welded. Also after repair, the crown roof is | | |

| |checked with the gauge for flatness and excessive| | |

| |material is removed by grinding. | | |

|17 |Ensure that the wear on pedestal crown sides are |5.3.5 | |

| |checked by using specified gauge and is repaired | | |

| |by welding whenever necessary following the | | |

| |instructions given in Annexure ‘D’ of G-95. | | |

|18 |Ensure that for this purpose, area to be |5.3.6 | |

| |reclaimed is heated upto temperature of 250(C. | | |

| |The sides of pedestal are to be gauged and | | |

| |whenever required welding is done. | | |

|19 |Ensure that wear on the pedestal jaw (outer and |5.3.7 | |

| |inner) is determined by using specified gauge and| | |

| |wherever required, repair is made. | | |

|20 |Ensure that the system exists to check the |5.3.9 | |

| |wheelbase of prepared side frame and pairing is | | |

| |done while assembling the bogie. | | |

|21 |The bolster pocket 35+1 slope surface is |5.4.1 | |

| |maintained by using suitable liners as specified | | |

| |and the welding is done following the instruction| | |

| |in Annexure ‘F’ of G-95. | | |

|22 |Ensure that the exact wear is measured by using |5.4.2 | |

| |specified gauge on bolster liner surfaces and | | |

| |rotation spot lugs and wherever required, the | | |

| |liners are used. | | |

|23 |Ensure that the wear is checked on outer and |5.4.3 | |

| |inner bolster col, gibs and wherever required the| | |

| |liners welded. | | |

|24 |Ensure that the spring plank is examined for |5.5.5 | |

| |defects line loosening of rivet/crack/welding, | | |

| |welding failure of spring spigots and whenever | | |

| |the spring plank is renewed welding diameter of | | |

| |the bogie are measured on the fixture. | | |

|25 |Ensure that the springs are measured for free |5.6.2 | |

| |height and are replaced if the free height is | | |

| |less than the specified. | | |

|26 |Ensure that the grouping of load and snubber |5.6.2 | |

| |spring is done in such a way that the springs | | |

| |having more than 3mm free height dimension are | | |

| |not assembled in the same group. Also, the mixing| | |

| |of new and old spring is avoided. | | |

|27 |Ensure that wear on the friction shoe of the two |5.7 | |

| |wear surfaces is measured using specified gauge | | |

| |and reclamation by welding whenever required. | | |

|28 |Ensure that the reclamation, welding inspection |5.7.3 | |

| |is done as per the procedure laid down in G-95. |5.7.4 | |

| | |5.7.5 | |

|29 |System exists to determine the wear on the seat |5.8 | |

| |and sides of centre pivot bowl by using specified| | |

| |gauges and wherever required, it is reclaimed/ | | |

| |replaced. | | |

|30 |Ensure that the surface to be reclaimed is |5.8 | |

| |pre-heated upto 250(C and allowed to cool slowly | | |

| |after welding. | | |

|31 |The repaired pivot is checked using gauge. |5.8 | |

|32 |Ensure that the side bearer are checked and |5.9 | |

| |replaced if found condemned. | | |

|33 |Ensure that the elastomeric pad and side bearer |5.10.1 | |

| |rubber pads (or PU pads) are replaced as |& RDSO guidelines | |

| |recommended. | | |

|34 |Ensure that the bushes provided are IRSM4 class |5.11 | |

| |IV or class I case hardened and pins are made | | |

| |from steel to IS: 226 Fe 410WA /IS 2062. | | |

| |Fe 410WA. The system exists to measure the | | |

| |measured wear on the Pins diameter and bush | | |

| |inside the diameter and these are replaced if the| | |

| |wear is more than 1.5mm. | | |

|35 |Ensure that the pins located in end pool rod and |5.11 | |

| |the pins are relocated. | | |

|36 |Ensure that the bogie shoe is replaced with worn |5.11 | |

| |48mm i.e. when 10mm metal is left from the base | | |

| |of the shoe. | | |

|37 |Ensure that reclamation of brake beam is done |5.11.1 | |

| |following the procedure given in G-95. | | |

|38 |Ensure that during welding of bogie fitted with |5.13 | |

| |roller bearing, the return current welding is | | |

| |fixed very close to the welding area. | | |

|39 |Ensure that RDSO modifications as detailed in | | |

| |Annexure ‘G’ of G-95 are carried out. | | |

Annexure for quality audit check sheet of CASNUB Bogie overhaul

1. Av Bogie overhauled per month (during last six month)

2. Consumption of vital spares:

|SN |Items |MC |Av consumption per month (during last six month) |

|1 |Brake Block | | |

|2 |PU pad | | |

|3 |C.C. Pad | | |

|4 |EM Pad | | |

|5 |Mn. Steel Liner Kit | | |

|6 |Spring (outer) | | |

|7 |Spring (inner) | | |

|8 |Spring (Snubber) | | |

3. Welders training and certification by CMT as per IS 7310 Pt-I:

4. Availability of CAMTECH manual, G – 95 manual at Shop:

5. Display of work instruction on shop floor:

6. Training of staff and supervisor for maintenance of CASNUB bogie :

7. Status of record keeping:

8. Status of calibration of gauges and measuring instruments:

CHECK SHEET FOR QUALITY AUDIT OF

CBC COUPLER & DRAFT GEAR

(Based on Maintenance Manual – G-80 and

Chapter 9 of CAMTECH Maintenance Manual for Wagon)

While doing the audit, activities are checked with regard to as specified in the maintenance manual G-80 and Chapter 9 of CAMTECH Maintenance Manual for Wagon. Wherever the activities are not performed correctly, the method adopted is indicated or the nature of non-compliance is recorded.

|SN |Activities |Clause No. |Observations |

|1 |Ensure that all parts except coupler lock lift |2 .3 (G80) | |

| |assembly are dismantled for inspection. Lock | | |

| |lift assembly must be inspected. | | |

|2 |All the components detected having crack in area|2.1 (G80) | |

| |shown in Fig.1 of G-80 must be scrapped. | | |

|3 |Ensure that all the components are cleaned to |2.4(G80) | |

| |remove dirt, paint, rust, scale etc. which may | | |

| |interfere with gauging & inspection. | | |

|4 |All the parts are visually inspected for cracks,|2.5 (G80) | |

| |fracture, sections broken out, worn surfaces, | | |

| |distortion, and surface upset and surface | | |

| |notches. | | |

|5 |Ensure that all the gauges required are |2.6 (G80) | |

| |available. | | |

|6 |Ensure that surface upset are ground and blended|3.1.5 (G80) | |

| |to the surrounding surfaces. The ground area | | |

| |should be free of cracks. | | |

|7 |Ensure that the part or assembly classified as |3.1.7 (G80) | |

| |reconditioned is identified by single star and | | |

| |the code of Railway Workshop punched at the | | |

| |location prescribed. | | |

| |Coupler | | |

|8 |Ensure that only those coupler bodies are used |3.2.1.1 (G80) | |

| |which meet the requirement of gauges listed in | | |

| |Table-1 of G-80 and perform all the functions. | | |

|9 |If the shank wear plate is worn out, it should |3.2.1.2.1 (G80) | |

| |be restored by application of a new wear plate. | | |

|10 |Ensure that the wear plate is strictly in |3.2.1.2.2 (G80) | |

| |accordance with SK-62724 item-10. | | |

|11 |Ensure that no heat-treatment is performed after|3.2.1.2.2.1 (G80) | |

| |application of shank wear plate. | | |

|12 |Ensure that coupler body is legible stamped as |3.2.1.3.2 (G80) | |

| |shown in Fig.4 of G-80. | | |

|13 |The coupler shank is not out of alignment with |3.2.1.4.1 (G80) | |

| |the head in excess of 9mm either vertically or | | |

| |laterally. | | |

|14 |Ensure that the Knuckle is checked to meet the |3.2.2.1 (G80) | |

| |requirements of gauges listed in Table-II of | | |

| |G-80. | | |

|15 |Ensure that the Lock meets the requirement of |3.2.3.1 (G80) | |

| |gauges listed in Table-III of G-80. | | |

|16 |The reconditioned lock is identified by single |3.2.3.2 (G80) | |

| |star and code of Railway workshop punched at the| | |

| |location prescribed. | | |

|17 |Ensure that no reconditioning is done for |3.2.4 (G80) | |

| |thrower & lock lift assembly. |3.2.5 (G80) | |

|18 |After straightening and heat-treatment, knuckle |3.2.6.1 (G80) | |

| |pivot pin is free of cracks, fractures, sections|3.2.6.2 (G80) | |

| |broken out and surface notches and meets | | |

| |requirement of gauges listed in Table-4. | | |

|19 |The coupler assembly meets the requirements as |3.2.7 (G80) | |

| |specified in Appendix ‘B’ of G-80. | | |

|20 |The coupler yoke is free of cracks, fracture, |3.3.1 (G80) | |

| |section broken out and surface notches. | | |

|21 |Ensure that the front of yoke pin hole to butt |3.3.2 (G80) | |

| |inside surface length as indicated: length – | | |

| |786min, 787.5max. | | |

|22 |The yoke is legibly stamped as shown in Fig.4 of|3.3.3 (G80) | |

| |G-80. | | |

|23 |The draft gear follower must meet the |3.4.1 (G80) | |

| |requirement of gauges listed in Table-5 and |3.4.4 (G80) | |

| |legibly stamped. | | |

|24 |Ensure that yoke pin is not reconditioned. |3.4..5.1 (G80) | |

|25 |Ensure that the welding is done during |4.1.1 (G80) | |

| |reconditioning using qualified welders and | | |

| |procedure is as specified in IS:7318 Pt.I. | | |

|26 |The preheating is done between 150º to 320º. |4.1.3 (G80) | |

|27 |The welding is done using low hydrogen coated |4.1.4 (G80) | |

| |electrodes or by gas shielded welding process. | | |

|28 |The heat-treatment required after weld repair or|4.1.5 (G80) | |

| |straightening is done as specified. | | |

|29 |After heat-treatment, ensure that the components|4.2.1 (G80) | |

| |are allowed to cool to a temperature below 538ºC| | |

| |at a rate which will not be injurious to | | |

| |castings. | | |

|30 |Ensure that Gr. ‘C’ steel castings are |4.2.2(G80) | |

| |normalised and tempered and marked HT and Gr. | | |

| |‘E’ steel castings are quenched & tempered and | | |

| |marked HTE. | | |

|31 |Ensure that the normalising & tempering/ |4.2.3 (G80) | |

| |quenching & tempering are done as specified in | | |

| |Clause 4.2.3. | | |

|32 |Ensure that the desired hardness is achieved. |4.2.4 (G80) | |

|33 |The hardness shall be measured only at the |4.2.4.3 (G80) | |

| |specified locations. | | |

| |Ensure that the finish of the components is as |4.3 (G80) | |

| |specified. | | |

|34 |Repair procedure | | |

|35 |Restoration of coupler head portion of coupler |5.1.1 (G80) | |

| |body including the application of bushings to | | |

| |knuckle pivot pin holes is prohibited except for| | |

| |top & bottom pin protector bosses. | | |

|36 |Restoration of shank is prohibited if wear |5.1.2 (G80) | |

| |bottom of shank exceeds 9mm depth. | | |

|37 |Restoration of yoke pin holes of shank is |5.1.3 (G80) | |

| |prohibited if crack exceeds 35mm in length in | | |

| |the shaded area of shank pin hole as shown in | | |

| |Fig. 7, wear on bottom of shank exceeds 9mm, any| | |

| |buckling in shank valves. | | |

|38 |Top & bottom pin protector with cracks or |5.1.4.1 (G80) | |

| |sections broken out may be weld repaired. | | |

| |However, if the failure exceeds beyond the | | |

| |permissible repair zone, the coupler body must | | |

| |be scrapped. | | |

|39 |The repair to the coupler head body shall be |5.1.4 (G80) | |

| |done as specified. | | |

|40 |The coupler body is scrapped if shank thickness |5.1.5 (G80) | |

| |is less than specified. | | |

|41 |Restored coupler body must be heat-treated as |5.1.5.5 (G80) | |

| |specified. | | |

|42 |Coupler body with shank bent in excess of 9mm in|5.1.6 (G80) | |

| |any direction and out of alignment with the | | |

| |coupler head must be reclaimed by heating to a | | |

| |temperature of 816 to 817ºC and straightened | | |

| |under a press. | | |

|43 |The examination of the coupler body after |5.1.6 (G80) | |

| |straightening shall be done as specified. | | |

|44 |Restoration for wear of the knuckle is done only|5.2.1 (G80) | |

| |in the areas i.e. lock engagement surface, | | |

| |bottom hub, pulling lug top & bottom, top & | | |

| |bottom pin protectors. | | |

|45 |Repair of cracks or sections broken out at any |5.2.2 (G80) | |

| |location is prohibited. | | |

|46 |Restoration for wear of the lock is done only on|5.3.1 (G80) | |

| |the knuckle engagement surface. Repair of cracks|5.3.2 (G80) | |

| |or sections broken out at any location is | | |

| |prohibited. | | |

|47 |The restoration by welding is done as specified.|5.3.3 (G80) | |

|48 |The knuckle pivot pin is reconditioned as per |5.4 (G80) | |

| |the procedure specified. | | |

|49 |Ensure that the coupler yoke are reconditioned |5.5 (G80) | |

| |only when within the specified limits otherwise | | |

| |scrapped. The repair is done as per the | | |

| |specified procedure. | | |

|50 |Ensure that the high capacity draft gear are |As per G -80 | |

| |maintained and reclaimed as per the instructions|& | |

| |circulated by M/s Bhartia for Cardwoll Mark 50 |Chapter 9 of Maintenance | |

| |Design & by M/s Burns Standards for Miners |Manual for Wagon | |

| |RF-361 and as laid down in Chapter 9 of | | |

| |Maintenance Manual for Wagons. | | |

|51 |The standard draft gears are to be replaced by |Para 919 of Maint. Manual | |

| |high capacity draft gears vide RB’s letter no. |for Wagon | |

| |84/M(N)/172/3 dtd 5.7.90 and new freight stocks | | |

| |would be fitted with high capacity draft gear | | |

| |i.e RF-361 & MK-50. | | |

|52 |Maintenance of RF-361 Draft gear |Para 920 of Maint. Manual | |

| | |for Wagon | |

|53 |All gauges for housing, gauges for shoes, gauges|-do- | |

| |for wedge and final inspection gauges as | | |

| |specified are available. | | |

|53.1 |The RF361 draft gear will require complete |-do- | |

| |reconditioning i.e., removal and replacement of | | |

| |the rear wall plate only if the gear has loosed | | |

| |clutch components (shoe & wedge), a broken | | |

| |housing or cracked weld at the rear wall. If | | |

| |loose clutch, broken housing or a cracked weld | | |

| |are not present then only removal and | | |

| |replacement of clutch component is necessary. | | |

| |Normally, clutch disassembly and replacement is | | |

| |the only reconditioning needed in the RF 361 | | |

| |draft gear. | | |

|53.2 |If either the shoes or wedge are broken and the |-do- | |

| |clutch is not loose, RF361 draft gear is | | |

| |dismantled as per laid down procedure in para | | |

| |920C(b) and necessary equipments are available | | |

| |for this purpose. | | |

|53.3 |Shoes are inspected for these defects – |-do- | |

| |No concave wear on any friction surface | | |

| |No cracks or spalls | | |

| |No wear more than 0.8mm on any friction surface | | |

|53.4 |Wedge is inspected for these defects – |-do- | |

| | | | |

| |No crack or spall of the carborized case on the| | |

| |friction face or the top of the wedge | | |

| |No wear more than 0.8mm or 1/32” on the friction| | |

| |surface. | | |

| |No indication of broken or any cracks on any of | | |

| |the locking lugs. | | |

|53.5 |Housing or cylinders are examined as per laid |-do- | |

| |down procedure and scrapped if found unsuitable.| | |

|53.6 |For proper function, every part of the assembly |-do- | |

| |must be free of oil, grease and moisture. The | | |

| |part should be kept properly during storage, | | |

| |handling and reassembling. | | |

|53.7 |Wedge and shoes are to be shot peened to remove |-do- | |

| |rust and dirt before assembly. | | |

|53.8 |Re-assembly of draft gear is being done as per |-do- | |

| |laid down procedure. | | |

|53.9 |If complete reconditioning of the gear is |-do- | |

| |required either because of a loose clutch or a | | |

| |broken weld, then procedure as laid down in para| | |

| |290(D) are followed. Rubber pads are inspected | | |

| |as per laid down procedure and static test is | | |

| |performed. | | |

|53.10 |All components such as internal followers, |-do- | |

| |forged items, housing (cylinders) are inspected | | |

| |as per laid down procedure. | | |

|53.11 |Re-assembly of reconditioned RF361 draft gear is|-do- | |

| |done as specified and tools such as 50T vertical| | |

| |press and draft gear assembly ring support | | |

| |fixture are available for assembly purpose. | | |

|53.12 |Reconditioned draft gear RF361 is inspected as |-do- | |

| |specified. | | |

|53.13 |Welding of rear plate after assembly is done as |-do- | |

| |specified in the manual. MIG welding (with 100% | | |

| |CO2 shielding gas) is used for filler pass | | |

| |welding and MIG welding (with 75% Argon and 25% | | |

| |CO2) is used for root run welding. | | |

|53.11 |The assembled RF361 draft gear must be pre |-do- | |

| |shortened to facilitate installations into the | | |

| |yoke and draft pocket. After pre shortening the | | |

| |external surface of the draft gear is to be | | |

| |painted with black or blue paint. | | |

|53.12 |Maintenance of Mark – 50 Draft Gear |Para 921 of Maint. Manual | |

| | |for Wagon | |

|54 |Inspection of MK 50 draft gear is done for |-do- | |

| |reconditioning through a built in wear life | | |

| |gauge as per laid down procedure. | | |

|54.1 |While removing draft gear from the wagon pocket,|-do- | |

| |it is necessary to compress the draft gear | | |

| |approximately (1/4”). Suitable lifting/lowering | | |

| |jack is available for removal of draft gear from| | |

| |wagon pocket. | | |

|54.2 |For removal of stuck or damaged draft gear, laid|-do- | |

| |down procedures and precautions are followed. | | |

|54.3 |For dismantling of MARK50 draft gear, tools and |-do- | |

| |gadgets are available and procedure as specified| | |

| |are followed. | | |

|54.4 |All gauges as per annexure are available for |-do- | |

| |maintenance/reconditioning of MK50 draft gear. | | |

Annexure for quality audit check sheet of CBC and DG

1. Availability of gauges at LLH shop vis-à-vis gauges required as per G -80

|Component |Gauge no. |Description |Status |

|Head |WD-84073-S-1-RC |10 Contour gauge | |

| |WD-84073-S-3-RC |Bottom anti creep horizontal location | |

| |WD-84073-S-5-RC |Pivot lug | |

| |WD-84073-S-6-RC |Pin protector | |

| |WD-84073-S-8- RC |Pivot pin | |

| |Gauge no. 1 |Coupler contour | |

| | |Checking gauge | |

|Shank |WD-84073-S-17-RC |Shank butt width | |

| |WD-84073-S-21-RC |Shank height with wear plate | |

| |WD-84073-S-22-RC |Shank length (Non transition) | |

| |WD-84073-S-23-RC |Shank butt and end contour | |

| |WD-84073-S-24-RC |Spherical butt and pin hole | |

| |WD-84073-S-25-RC |Shank butt height | |

|Knuckle |Gauge No. 10,11&12 |Checking of Knuckle | |

| |Gauge No.3 |Checking of profile | |

| |Gauge No.9 |Checking of Knuckle lock engagement | |

| | |Surface | |

| |WD-84073-S-47-RC |Knuckle pin hole gauge | |

|Lock |WD-84073-S-59-RC |Lock parallel and thickness gauge | |

|Knuckle pivot |WD-84073-S-96-RC |Knuckle pivot | |

|pin | | | |

|Draft Gear |WD-84073-S-71-RC |DG follower gauge | |

|Follower | | | |

2. Check status of repairing carried out for Knuckle, Coupler body, lock and yoke assembly (whether shop has prescribed process for such repair).

|Items |Reclamation/repair done |

| |or not done |

|Coupler | |

|Knuckle | |

|Lock | |

|Knuckle pivot pin | |

|Coupler yoke | |

|Thrower & lock lift assembly | |

|Yoke pin | |

3. Availability of CAMTECH manual for wagon and G -80 manual:

4. Display of work instruction on shop floor:

5. Training status of staff and supervisor for CBC and draft gear attention:

6. Status of record keeping:

7. Status of calibration of gauges and measuring instruments:

CHECK SHEET FOR QUALITY AUDIT OF

Wagon Body & Under-frame attention during POH

(Based on CAMTECH Manual for Wagon)

While doing the audit, activities are checked with regard to as specified in CAMTECH Maintenance Manual for Wagon. Wherever the activities are not performed correctly, the method adopted is indicated or the nature of non-compliance is recorded.

|SN |Requirements |Clause |Observations |

|1. |Wagons are given POH attention as per prescribed|Para 209 of Maint. | |

| |frequency. |Manual for Wagon and| |

| | |IRCA letter | |

| | |M.219/Policy/W Dated| |

| | |10.5.99 | |

|2 |Body repair work of wagon is carried out during |Para 210 of Maint. | |

| |POH as under: |Manual for Wagon | |

|2.1 |UNDERFRAME- Sole Bar - Scrap the portion of sole| | |

| |bar at doorways, clean and apply primer paint | | |

| |followed by Top coat. | | |

|2.2 |SIDE WALL- Skirting | | |

| |Check and patch if corroded then apply primer | | |

| |and top coat on the patch. | | |

| |Side Doors- Check damage and repair clean & | | |

| |lubricate hinges. | | |

| |Side Pillars- Check cracks at the base & repair.| | |

| |Patching of body, roof, door or floor plates | | |

| |straightening bulged ends repairs to angle | | |

| |irons, stanchions and crib angles etc. | | |

| |Making wagons water-tight (Covered wagons). | | |

| |Fitting/replacement of door fastening road, door| | |

| |cotter pin eye, bolt hook and eye locking pin on| | |

| |empty wagons and closing of doors. | | |

| |Fitting/replacement of door fastening rod guide,| | |

| |door hasp which requires riveting on empty | | |

| |wagons. Repairs by welding to door fittings. | | |

| |Hand rail/foot board deficient/or damaged, | | |

| |insecurely fastened at door way of guard’s brake| | |

| |van. | | |

|2.3 |UNDER GEAR REPAIR WORK (Common for all ) | | |

| |Brake Linkage- Check free movement. | | |

| |Hand Brake - Check proper working. | | |

|3.0 |REPAIR & MAINTENANCE OF UNDER-FRAME IN WORKSHOP|Para 516 of Maint. | |

| |DURING POH/NPOH |Manual for Wagon | |

| |Thorough inspection of under-frame is to be | | |

| |carried out. Major repairs as well as all | | |

| |defects and deficiencies that come to the notice| | |

| |must be given meticulous and thorough attention.| | |

|3.1 |In addition to the work indicated in Para 515, | | |

| |the following work is to be carried out in | | |

| |workshops during POH/NPOH :- Inspection of | | |

| |under-frame, as given in para 504, to be done | | |

| |for | | |

| |i. Rivets | | |

| |ii. Cracks | | |

| |iii. Alignment | | |

|3.2 |The diagonal distance between the axle guard | | |

| |centres is checked for finding out if the | | |

| |under-frame has retained its overall alignment | | |

| |or has become skew. | | |

|3.3 |The cleaning and de-rusting of the under-frame | | |

| |and its fittings. | | |

|3.4 |Repairs to floor plate as given in para 509. | | |

|3.5 |Under-frame of brake van as given in para 510. | | |

|3.6 |Under-frame of Bogie wagon as given in para 511.| | |

|3.7 |Paint under-frame as per Spec. G-72 (Rev.1) read| | |

| |with latest amendment. | | |

|4.0 |REPAIRS REQUIRED IN WAGON BODY: Attention should|Para 406 of Maint. | |

| |be given during POH of wagon for the following |Manual for Wagon | |

| |areas: | | |

| |Corrosion of panels, floor plates and roof | | |

| |sheets. | | |

| |Puncturing of panels. | | |

| |Bulging of ends. | | |

| |Tearing of panels, fracture of stanchions and | | |

| |shearing of rivets. | | |

| |Corrosion of end floor angles and crib angles. | | |

| |Bulging of side wall. | | |

| |Slackening of rivets. | | |

| |Weakening of welded joints due to loss of weld | | |

| |metal by corrosion, wear and tear. | | |

| |Wearing out of door hinges. | | |

| |Damage to door fittings. | | |

| |Distortion of doors. | | |

| |Failure of welded joints. | | |

| |Distortion or cracking of stanchions and other | | |

| |structural members. | | |

| |Wear and tear or breakage of miscellaneous | | |

| |fittings, such as ladders, cleats, label holders| | |

| |etc. | | |

|5.0 |CORROSION IN WAGON BODY: Action is taken for |Para 407 of Maint. | |

| |proper painting of wagon body after surface |Manual for Wagon | |

| |preparation and interior paint up to a height of| | |

| |230 mm from floor, rivet seams and in the case | | |

| |of covered wagons, the swing and flap doors and | | |

| |the roof. | | |

|6.0 |ANTICORROSIVE MEASURES: |Para 408 of Maint. | |

| |While attending to miscellaneous repairs, panel |Manual for Wagon | |

| |patching or welding; it is important to ensure | | |

| |that surfaces in contact are well fitted to | | |

| |avoid water pockets. Due care is to be taken to | | |

| |clean and paint the affected surfaces to prevent| | |

| |corrosion by electrochemical action. | | |

|7.0 |REPAIRS TO BULGED ENDS: |Para 410-D of Maint.| |

| |If there are no serious damages to wagon ends |Manual for Wagon | |

| |other than bulging, the bulges can be | | |

| |effectively removed without dismantling. If two | | |

| |wagons with bulged ends are coupled together and| | |

| |a hydraulic jack is applied between them at the | | |

| |bulges, suitable packing being interposed | | |

| |between the jack and the wagon body. This method| | |

| |is particularly effective in dealing with | | |

| |dread-naught ends. | | |

|8.0 |REPAIRS TO BODY STRUCTURAL MEMBERS (STANCHIONS, |Para 410-E of Maint.| |

| |CARLINES |Manual for Wagon | |

| |AND COPINGS): | | |

| |Bulging of wagon side walls by more than 25mm | | |

| |should be rectified. These components should be | | |

| |straightened without dismantling by pulling into| | |

| |correct position with the help of a chain and | | |

| |screw coupling or stripped and straightened | | |

| |either cold or by heating, as required and then | | |

| |riveted in position. Spot heating and cooling to| | |

| |straighten the stanchions can rectify bulging of| | |

| |all welded ends. | | |

| | | | |

| |In certain cases, these components may have | | |

| |developed cracks, or may have broken in pieces. | | |

| |Such of these components should be repaired by | | |

| |welding both the pieces and applying a stiffener| | |

| |angle prepared by bending a 6mm plate in the | | |

| |shape of an angle with its outer faces sitting | | |

| |flush in the inner profile of the member to be | | |

| |patched and welding it all round to the member. | | |

| |Elongated holes in these components should be | | |

| |filled up by welding and refilled. | | |

|9.0 |WATER TIGHTENING OF WAGON: |Para 410-F of Maint.| |

| |Covered wagons must be kept watertight at all |Manual for Wagon | |

| |times. Covered wagons must be tested for water | | |

| |tightness at the time of leaving the workshop | | |

| |after POH or other repairs. | | |

| |After a wagon has been made watertight, it | | |

| |should be marked “WT” with station code and date| | |

| |on the left-hand bottom corner of both sides. | | |

|10. |REPAIRS TO DOORS AND DOOR FITTINGS |Para 410-G of Maint.| |

| | |Manual for Wagon | |

|10.1 |Damaged doors of covered wagons are responsible | | |

| |for a very large proportion of claims due to | | |

| |wetting or pilferage of consignments. Warpage of| | |

| |flap doors is often responsible for jamming of | | |

| |flap door hinges. Special care must therefore, | | |

| |be taken in attending to doors. | | |

|10.2 |Distorted or bulged doors must be taken down and| | |

| |straightened to ensure proper fit. Worn out | | |

| |hinges are responsible for sagging or gaping | | |

| |doors and inadequate overlap. Such hinges must | | |

| |be replaced with new or reconditioned ones. | | |

|10.3 |Bent door stanchions and depressed crib angles | | |

| |must be straightened to ensure free functioning | | |

| |of doors and prevent gaping. Corroded crib | | |

| |angles must be cut out and replaced. Graphite | | |

| |grease should be introduced in all hinges, | | |

| |sliding cotters and other working parts. | | |

|10.4 |After repairs, doors must sit flush against | | |

| |striking plates with adequate overlap between | | |

| |leaves and without gaping at the stanchions or | | |

| |crib angles. Anti-bleeding devices and rain | | |

| |protection angles should also be checked and | | |

| |rectified where necessary. | | |

|10.5 |In the case of hopper wagons, it should be | | |

| |ensured that when the doors are closed, no gap | | |

| |is left between the chute plate and frame, and | | |

| |that the operating gear works freely and is in | | |

| |good condition. | | |

|11 |LOUVERS: |Para 410-H of Maint.| |

| |Corroded louvers have to be replaced by new |Manual for Wagon | |

| |ones. Special care must be taken to ensure that | | |

| |the louvers are given good surface preparation | | |

| |and painting, and those overlapping joints are | | |

| |properly cleaned and painted to obtain the | | |

| |maximum possible life. | | |

|12.0 |CLEANING, SURFACE PREPARATION AND PAINTING | | |

|12.1 |The purpose of cleaning is to remove dirt, oil, | | |

| |grease, rust and other contaminants, which would| | |

| |prevent the paint film from adhering to the | | |

| |metal or would provide a nucleus for | | |

| |commencement of corrosion. | | |

| |Cleaning by hammering, chiseling or scraping is | | |

| |unsatisfactory and should not be resorted to. | | |

| |The surface cleaning may be done by vigorously | | |

| |scrubbing with a stiff brush. All welded parts | | |

| |and adjacent surfaces should be thoroughly | | |

| |cleaned to remove residual alkaline flux and | | |

| |washed with hot water. | | |

|12.2 |A coat of priming paint should be applied | | |

| |immediately after the surface has been cleaned | | |

| |and dried. A delay of more than 4 hours may | | |

| |result in development of fresh rust on the | | |

| |surface. A second coat of primer must be given | | |

| |when the first coat is dry. Painting must be | | |

| |done under cover in a shed or shop. The painted | | |

| |surfaces must remain under cover until the paint| | |

| |is dry. | | |

|12.3 |Panel patches and riveting strips must be | | |

| |cleaned, as prescribed above, and given two | | |

| |coats of primer before storage or fitment. | | |

|12.4 |After completion of all repairs a final coat of | | |

| |finishing paint should be given to all painted | | |

| |surfaces. | | |

|12.5 |When the paint film is only partially damaged, | | |

| |it should be touched up with one coat of primer | | |

| |and then given the finishing coat. | | |

|12.6 |Surfaces, which will become inaccessible after | | |

| |assembly must be given complete painting before | | |

| |assembly. | | |

|13.0 |Lettering: |Para 411 of Maint. | |

| |Lettering to be carried out as per IRCA Part III|Manual for Wagon | |

| |(2000) Rule 2.4 by stenciling the relevant | | |

| |figures. | | |

| |Punching of wagon particulars. | | |

| |PRIO plate. | | |

| |Tare weight to be measured after POH and it | | |

| |should be marked up to one decimal. | | |

|14.0 |IMPORTANT PRECAUTIONS TO BE TAKEN WHILE CARRYING|Para 412 of Maint. | |

| |OUT WELDING |Manual for Wagon | |

|14.1 |It should first be ensured that no portion of an| | |

| |inflammable consignment packing material or | | |

| |dunage is present in the area to be welded. | | |

| |Empty tank wagons should be given welding | | |

| |repairs and only after thorough steam cleaning | | |

| |and testing to ensure that there are no | | |

| |inflammable/explosive vapours left. | | |

|14.2 |Wagons fitted with roller bearing | | |

| |No welding should be attempted without | | |

| |effectively earthing the member or component to | | |

| |be welded. Neglect in taking this precaution | | |

| |will result in passage of the return current | | |

| |through the roller bearing, which may suffer | | |

| |severe damage leading to premature failure. | | |

|15.0. |Other items for attention: |Para 413 of Maint. | |

| | |Manual for Wagon | |

|15.1 |Ensure that proper tools required for the job | | |

| |are available. | | |

|15.2 |Ensure that tools and equipment are in good | | |

| |condition. | | |

|15.3 |See that rivet heads are properly formed with | | |

| |correctly profiled snaps. | | |

|15.4 |While fitting patches to structural members, | | |

| |ensure that the pitch of rivets conforms to the | | |

| |original pitch in the structural members. | | |

|15.5 |See that doors are provided with all required | | |

| |fittings so as to ensure proper securing and | | |

| |prevent unauthorised opening. | | |

|15.6 |Ensure that door hooks are intact and so placed | | |

| |that they will engage with the door eye in open | | |

| |position. | | |

|15.7 |Ensure that all chains links and other | | |

| |attachments are in position and in working | | |

| |order. | | |

|15.8 |Do not use patches of less thickness than the | | |

| |original panel. | | |

|15.9 |Do not patch existing patches. | | |

|15.10 |Do not build up perforations in panel due to | | |

| |corrosion. Cut out and fit a new patch. | | |

Annexure for quality audit check sheet of Wagon body

and under-frame attention

1. Av POH outturn per month (during last six month):

2. Consumption of vital spares:

3. Welders training and certification by CMT as per IS 7310 Pt-I:

4. Availability of CAMTECH manual at Shop:

5. Display of work instruction on shop floor:

6. Training of staff and supervisor for wagon body and under-frame attention :

7. Status of record keeping:

8. Status of calibration of measuring instruments:

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