MECHANICAL ENGINEERING COCH CARE COMPLEX

1. Submitted by:-
Amit Verma
1203340026

2. Serial No. Depot No. of based Coaches
1 Minor 50 – 100
2 Medium 100 – 250
3 Major Above 250
CLASSIFICATION OF COACHING
MAINTENANCE DEPOTS

3. • ICF- Integral Coach Factory(Chennai)
• RCF- Rail Coach Factory( Kapurthala , Punjab)
• LHB- Link Holfmann Bushh (Fiat Bogies)
• HYBRID- LHB body on modified ICF bogies
COACHES

4. ICF/RCF LHB/HYBRID
Length over buffer 22296(mm) 24000(mm)
Length over head
stock
21336(mm) 23540(mm)
Width 3245(mm) 3030(mm)
Codal life 25 years 30 years
DIMENSIONS OF COACH SHELL

5. Washing Line
1. Trip Schedule : After every trip by primary maintenance depot.
 Sick Line
1. Schedule A : Monthly (1 month + 7 days)
2. Schedule B : Quarterly (3 months + 15 days)
3. Schedule C : After 180 days or 6 Months
4. IOH : Every 9 months
5. POH : Every 18 months
MAINTENANCE SCHEDULE AND
CATEGORY

6. SICK LINE
• Sick line is the workshop for the major and periodical
maintenance of the coaches.
• It consists of modern facilities like pit for working
under frame And crane for separation of coach &
bogie for repair of all type of defects.

7. 1. Wheel and Axle Assembly
2. Bogie Maintenance
3. Buffer Maintenance
4. Air Brake System Maintenance
5. Trolley Maintenance
6. Lifting of Coaches
7. Riding Index
WORKS CARRIED OUT IN SICK LINE

8. 1. Width of wheel = 127 mm
2. Wheel Diameter = 915 (new), 825 (condemn)
Permissible diameter variation in wheel
Coaching
• On same axle – 0.5 mm
• On same bogie – 5.0 mm
• On same coach – 13.0 mm
Goods
• On same axle – 0.5 mm
• On same bogie – 13.0 mm
• On same coach – 25.0 mm
Fig. 1 Wheel profile (all length dimension are in mm)
Wheel and Axle Assembly

9. Wheels are fixed on the axle with the help of bearings.
Like wheel, it is also made up of steel.
Brake cylinder are attached to axle.
Braking discs are fixed on the axle
Fig. 2 Axle

10. Buffer height adjustment
Causes of low buffer height in ICF coaching stock :
a) excessive wear of wheel
b) Due to loss of proper stiffness of coil spring
c) Due to excessive wear on side bearer’s metal & bronze piece.
Maximum buffer height = 1105 mm [In empty condition]
Minimum buffer height = 1030 mm [In loaded condition]
To achieve buffer height a standard size of wooden packing pieces are used
which are kept below the Dash Pot Flange on axle Box wings of primary
suspension.
Serial N0. Wheel Diameter (mm) Thickness of Wooden Packing (mm)
1. Below 889 up to 863 13
2. Below 863 up to 839 26
3. Below 839 up to 819 38
4. 819 & below 48

11. In Air Brake system compressed air is used for operating the
brake system. The locomotive compressor charges the feed
pipe and the brake pipes throughout the length of the train.
The feed pipe is connected to the auxiliary reservoirs and the
brake pipe is connected to the brake cylinders through the
distributor valve. Brake application takes place by dropping the
pressure in the brake pipe.
TYPES:
1. Direct Release System- brakes are released immediately,
as soon as releasing of brakes is initiated.
2. Gradguate Release System - brake cylinder pressure can
be reduced gradually in steps in proportion to the increase in
brake pipe pressure.
AIR BRAKE SYSTEM

12. • Single Pipe Air Brake System:- There is only one
pipe called brake pipe running from loco to the
brake van in order to get continuity of air for the
application & release of brakes.
• Twin Pipe Air Brake System :- In addition to brake
pipe, there is one more pipe called feed pipe ,
running loco to the brake van to charge the
auxiliary reservoir continuously to 6 kg/cm2
Types of Gradguate Release System

13. Trolley Maintenance
Parts of Trolley
1. Trolley Frame
2. Center pivot
3. Side Bearing
4. Brake Cylinder
Fig. 3 Trolley

14. Lifting of coaches
Require tools and equipments
1. With the use of Mechanical Jacks
2. With the use of Hydraulic Jacks
3. With the use of Electrical operated Travelling Crane
4. With the use of Whiting Jacks

15. PLATFORM TRAIN DUTY
 Rolling In
Rolling out
Axle box feeling
Brake Power Certificate
Safe to Run

16. ROLLING IN/ROLLING OUT
When train enters in station Examiner staff take up positions on
both sides inspect the train enters at the speed of 8 Km/hr
Whistling sound of hot axle boxes.
 Any hanging part or loose fitting of vehicle.
Any component or spring suspension bracket loose/broken.
 Abnormal behaviour of vehicle.

17. Axle box feeling
After the train come to halt, all axle boxes are felt within 20
minutes. The temp. of axle is checked by touching with hand
Temp. is found high then it is checked by the temp. gun which
gives exact temp.
If this temp. is found more than 30 degree than atm. temp.
then the cause is inspected and coach is sent to workshop

18. BRAKE POWER Certificate
 This certificate is jointly signed by Guard , Driver, and C&W
supervisor.
 The incoming driver shall handover the brake power
certificate to Reliving driver or Deposit it the nominated
authority, who will give it to the outgoing Driver.
 The outgoing driver and guard will satisfy themselves from
the listed coach numbers that the Brake Power Certificate
pertains to their train.

19. Safe to run
If all of above factors like no hanging parts brakes are
working correctly the temp of axle box is with in range
and the train is in good and safe condition of running
then the train is announced as safe to run.

20. Riding is a quality of comfort experienced by passenger,
depends not only upon acceleration, rate of change of
acceleration & vibration but also some other factors as like
noise, moisture temperature etc.
Ride Index = 0.896
10 𝑏3
𝑓
𝐹(𝑓)
b : Amplitude of acceleration
f : Frequency of acceleration
F(f) : a correction factor dependent on the frequency
Ride index for ICF: <3.5
for LHB<2.75
RIDING INDEX

21. THANK YOU ALL FOR YOUR KIND ATTENTION