The train during empty condition (i.e., the train having no passenger) is known as Rake and thus a series of empty coaches in the yard under maintenance is known Rake Maintenance as shown below:

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RAKE MAINTENANCE

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GROUP MEMBERS
Submitted by Submitted to
DEEWAN SINGH Mr. H K VILOTIAR
SSE ,NCR AGRA CANT.
Project Guide
Mr. PRAMOD KUMAR
SSE,NCR AGRA FORT

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ACKNOWLEDGEMENT
I would like to express my special thanks of gratitude to my teacher Mr. H K
VILOTIAR SSE, NCR, Agra Cant., who gave me the golden opportunity to
do this wonderful project on the topic Improvement in Rake Maintenance
practices at pit line to reduce Maintenance time improve quality, which also
helped me in doing a lot of research and I came know about so many new
things I am really thankful to them.
I am deeply indebted to the various sources of information and matter given
to us that helped in the making of this project.
I would like to express my special thanks of gratitude to my teacher Mr. H K
VILOTIAR SSE, NCR, Agra Cant., who gave me the golden opportunity to
do this wonderful project on the topic Improvement in Rake Maintenance
practices at pit line to reduce Maintenance time improve quality, which also
helped me in doing a lot of research and I came know about so many new
things I am really thankful to them.
Secondly I would also like to thank my parents and friends who have to me
a lot in finalizing this project within the limited time frame.

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PREFACE
The image of Indian Railways greatly depends on the perception of
travelling public. The passengers remain at railway stations for a time
ranging from 5 minutes to few hours but they remain in a coach for a time
ranging from 1 hour to 48 hours or so. While many improvements have
been done in upkeep of Railway Stations premises, much is required to be
done for ensuring upkeep of coaches. At present, every Railway is
following their own system for housekeeping of coaches and there are no
standards practices. Cleaning is no more brooms and mops. We should
use walk behind/ride on sweepers, scrubber driers, vacuum cleaners, high
pressure jet cleaners, spray extractors, multi-purpose trolleys car washing
system and windows cleaning equipment etc. This handbook has been
prepared to standardized methods of manual and mechanized cleaning of
coaches. Details of tools and equipment available for the purpose have
also been given. I am sure this handbook will provide necessary guidance
to the field staff involved in maintenance of coaches to maintain high level
cleanliness and hygiene.
RAKE MAINTENANCE
INTRODUCTION
Indian Railways run more than 7000 Passenger trains .In these trains thousands of
coaches are deployed. They earn millions of Passengers KMs every day.
To regularly run these massive operation, the rolling stocks have to remain fit and
in good fettle. These require sound Maintenance policy.
OBJECTIVE OF MAINTENANCE
The objective of Maintenance is to sustain operational efficiency of an asset over
its designed life period, so that maximum earning of revenue can be ensured. By

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timely maintenance, the availability of asset is kept high. Further reliability during
operational remains high. That avoids disruption to operation and services leading
to quick delivery, high turnover, customer satisfaction, and repeat orders and
customers loyalty. The whole systems run smoothly as planned.
MAINTENANCE SCHEDULES TO BE FOLLOWED IN
COACHING DEPOTS
To maintain coaching stock in good condition, the following preventive
maintenance schedules are prescribed to be carried out in carriage depots on
divisions where rake has been based for primary maintenance.
1. Trip schedule- After every trip by primary maintenance depot.
2. Schedule A - Monthly (1 month ±7 days)
3. Schedule B - Quarterly (3 months ± 15 days)
Primary maintenance schedules are required to be carried out by the base depots to
which coaches are allotted. In emergency, when due to any reason coaches cannot
reach their base depots and primary maintenance schedules become due, A & B
schedules should be undertaken by the carriage depots where the coaches are
available. All schedules should be carried out by primary maintenance depot.
1. TRIP SCHEDULE:-
Trip schedule is attended per trip of the rake. The trip is being attended by Primary
depots. No need to detach the coach from the rake during trip schedule. Total
distance traveled by passenger rake in a trip up and down is more than 3500 km.
Following procedure is adopted during the trip schedule:-
1. All under gear parts are thoroughly examined.
2. All moving parts are lubricated.
3. Complete examination of draw & buffing gear for its proper functioning.
Lubrication is essential.
4. Coupling should be free in its screw i.e. ensure easy movement of coupling.
5. Proper examination of primary suspension arrangement.
6. Ensure the leakage of dash pot and oil level of dash pot.
7. Proper securing of safety strap and safety loop.
8. Proper examination of secondary suspension. Ensure the working of spring,
shock absorber, safety strap & safety loop.
9. Proper examination of wear in suspension link bracket, pin & shackle stone.
10. Examine the proper function of shock absorber & securing bolt.
11. Examination of equalizing stay rod for its proper securing.
12. Examination of proper securing of bolts & cotters & silent bushes of centre
pivot.
13. Ensure the proper function of side bearer or its oil level.
14. Changing of worn brake blocks & pin & adjustment of brake power.

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15. Proper cleaning of coach from inside & outside & disinfections.
16. Spraying of pesticides elements.
17. Checking of all joints & pipe joints & other fittings & filling of water tank.
18. Proper opening & closing of vestibule doors.
19. Checking of amenity & safety items.
20. All falls plate examination of vestibule.
21. Testing of alarm signal, guard van valve & its gauge.
22. Preparation of DRS card & brake power certificate.
2. SCHEDULE `A':
Schedule `A' is required to be given every month + 7 days at the nominated
primary maintenance depot within the normal primary maintenance time on a
washing/pit line. A coach need not to be detached from the rake for Schedule `A'
examination unless it requires such repairs which cannot be attended to on the
washing line or within the prescribed maintenance time on the washing line.
Schedule maintenance:-
(i). All items of primary/secondary maintenance schedule.
(ii). Test the working of brake cylinders for proper application and release.
(iii). Thorough inspection of brake pipe, feed pipe and their connecting pipes to
brake cylinder, distributor valve, Auxiliary reservoir and hose coupling for leakage
and attention.
(iv). Carry out manual brake release test on every coach to ensure proper
functioning of release lever of distributor valve.
(v). Micro switch of ACP (Alarm Chain Pulling) should be tested by electrical staff
for proper functioning.
(vi). Clean Dirt collector filter with kerosene and refit.
(vii). Test the working of slack adjuster in under frame mounted air brake system.
Repair/Replace the defective slack adjuster.
(viii). Examine loops/ brackets and their securing devices and rectify.
(ix). Examine for wear and replace if required brake hanger pins, brake blocks and
brake heads.
The following items of work should be attended during Schedule `A'
examination, i.e., monthly examination:-
(i). All items of primary/secondary maintenance schedule.
(ii). Intensive cleaning of coaches.
(iii). Intensive cleaning of lavatory pans and commode with specified cleaning
agent.
(iv). Thorough flushing of tanks.
(v). Checking of water pipes, flush pipe, flushing cocks, push cocks, etc., for ease
of operation and free flow of water.
(vi). Thorough dis-infection of all compartments.

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(vii). Thorough inspection and repairs of draw gear.
(viii). Thorough inspection and repairs of buffers.
(ix). Oil in hydraulic dash pots should be checked to detect oil leakage from them
through defective seals or through vent screws. Add/replenish with specified grade
of oil if oil level is below 40 mm in tare condition to ensure better riding comfort.
Similarly oil in side bearer baths should be checked when the oil is below the plug
and replenished with specified grade of oil so that wear plate is fully covered by
oil.
(x). Inspection and repairs of commode chute.
(xi). Thorough check and repairs of sliding doors and vestibule doors for easy and
smooth operation and correct alignment and all wearing parts, loose screws, etc.
3. SCHEDULE `B’:
Schedule `B' is required to be given every three months + 15 days at the
nominated primary maintenance depot within the normal time allowed for primary
maintenance on a washing line in rake. Coach need not be detached from the rake
for purpose of this examination unless it requires such repairs which cannot be
attended to on the washing line or within the prescribed maintenance time on the
washing line.
Other assembly maintenance
(i). Besides brake system other items should be attended as given below:
(ii). All items of Schedule `A'
(iii). Painting of lavatories from inside.
(iv). Thorough inspection and repairs of brake gear components.
(v). Thorough checking of trough floor, turn under, etc., from underneath for
corrosion.
(vi). touching up of painted portion, if faded or soiled.
(vii). Overhauling & testing of alarm chain apparatus.
(viii). Testing of guard van valve.
(ix). Greasing of equalizing stay rod.
RAKE MAINTENANCE
The train during empty condition (i.e., the train having no passenger) is known as
Rake and thus a series of empty coaches in the yard under maintenance is known
Rake Maintenance as shown below:

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VARIOUS PROCESS INVOLVED DURIING RAKE MAINTENANCE ARE
AS FOLLOWS: -
(A). When the rake is being positioned for maintenance in the yard then place a red
color stopper in front of the coach on the track for indication.

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(B). After placing the stopper on the track the maintenance is going to start
including various checking steps and if during checking any component is being
destroyed then it will be replaced by a new one.
During maintenance the checking steps are done in following ways: -
Air brake system maintenance:
(i). Check brake cylinder for loose rocker arm plate and change on Bogie Mounted
system.
(ii). Brake cylinder should be checked for smooth functioning and prescribed
stroke. Defective brake cylinders shall be sent for repairs.
(iii). Guard’s van valve should be tested.
(iv). Test BP & FP air pressure measuring gauges with master gauge and replace if
found defective. A set of two master gauges should be kept for this purpose at
every Primary Maintenance Depot and each master gauge should be sent one after
the other to the base workshops for testing, repairs and calibration.
(v). Thoroughly clean Dirt collector filter in kerosene or replace on condition basis.
(vi). Check working of PEASD & PEAV by hearing the hissing sound of exhaust
air. After resetting with the help of key the exhaust of air should stop. Replace the
defective PEASD/PEAV.

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BRAKE CYLINDER
Brake cylinder is provided for actuating the brake rigging for the application and
release of brakes. The brake cylinder receives compressed air from auxiliary
reservoir after bring regulated by the distributor valve and develops mechanical
brake power by outward movement of its piston assembly.
DIRT COLLECTOR
Dirt collectors are provided at the junction of the main pipe and branch pipe in
both feed pipe and brake pipe. These are meant for removing dust, moisture and
scale particles from air before it enters the DV & AR. This is achieved by
centrifugal action.

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NON RETURN VALVE
A Non Return Valve or one way valve is a valve that normally allows air to flow
through it in only one direction.
ISOLATING COCK
Isolating cock is used to isolate the ACP system.

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BATTERY OPERATED NUT OPENER
Battery operated nut opener or cordless driver are more effective than manual
drivers are.
Specification:-
 Keyless Chuck for quick and easy bit changes
 Spring Loaded Slide Pack Battery System - For quick and easy battery
change and a more secure fit
 Variable speed and control with 17 position torque control for a wide
range of applications
 Reverse Switch for Added Versatility
Advantages:-
 Portability
 Safety for users
 Versatility
 Efficiency for rush jobs

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FILLING OIL IN DASHPOT
Filling must be done by the proper equipment in the dashpot. which is given below
is not a proper method. Filling must be done by the Funnel as per given figure .
Funnel saves the time and wastage of oil is negligible.
HELICAL SPRING
The helical spring can be checked by hammering on to them. After hammering is
sound is produced which conclude that the spring is fractured or not, if it so then it
can be replaced by a new one.

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DRAINING AUXILARY RESERVOIR (A.R.)
As a name indicates that the draining of pressure from 200 ltr. tank. If there
happens a problem during drainage then it can be rectified by the certain means.
The draining A.R. is shown in figure: -
SPLIT PIN
A split pin is a metal fastener with two tines that are bent during installation. A common
application of split pin is when used to secure a castellated nut.

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BRAKE BLOCK
The brake block plays a vital role during the running of a train. It would help in
result the train to be stationary position. When the brakes are applied the brake
block are rubbed with the wheels and get destroyed and in some cases it also gets
fractured. This can be inspected and get operated or it can be replaced if it gets
destroyed.
HANGER
Previously the hanger used were those which are shown in figure (a) and (c) but
there life were not so long and they gets broken from the side as shown in figure
(a).
Considering these problems we use the hanger having some clearance as shown in
fig (b) due to which their life gets extended.
Thus the maintenance time reduced to some extent.
Fig:- (a) Fig:- (b) Fig: - (c)

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INTERNAL COACH CLEANING MACHINE
This machine is departmentally designed and developed for cleaning of coaches
internally. It is operated on 220V AC as well as 110VDC supply thereby any coach
lying anywhere in the yard can be cleaned by this machine as 110V DC supply
available in a coach. Construction of this machine is sturdy and light in weight
about 6 Kg hence it is easy to handle. Due to light weight and 1.2 meter length of
machine, staff can do effective cleaning work in standing position without fatigue.
At present, this machine is specially used for toilet cleaning and intensive cleaning
of floor, berth, and side wall by using various type of brushes.
FLOOR CLEANING BERTH CLEANING
WINDOW GLASS CLEANING TOILET CLEANING

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PRESSURE WASHING PUMP
Power washing is the use the high-pressure water spray to remove dust, grime,
mud, chewing gum and dirt from surface and object such as vehicles, concrete
surface. Machine that produce pressure from (52.73-210.92 kg/cm2) (5 to 200 mpa)
or more are available.
There are many more components which are being inspected during operation and
are also being replaced if necessary.
As similar to above mentioned processes of a single coach, all the caches ( i.e. the
whole rake ) is inspected in a same way.
After inspecting all the components the pressure of the whole rake is being check
that is there any drop or leakage of pressure or not.
The pressure of the rake is tested by the pressure testing machine which is shown
as follows: -
Step 1. The B.P. and F.P. of all coaches of the rake are tightly bind up with help of
wire as shown in figure below so that during the operation it will not release.

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Step 2. After connecting the B.P. & F.P. of all the coaches these are connect to the
same of pressure testing machine respectively as shown in figure below
Step 3. There are three pipes in the pressure testing machine i.e. B.P., F.P. &
Branch pipe. After connecting B.P. & F.P. of rake of the testing machine, the
branch is connected to the pipe of charging supply which is connected to main
compressor unit from where the pressure is being supplied.
After making all this connection the pressure is being tested to a desired value.
In this process we also check the pressure drop from every coach that is it happens
or not. If it happens then it can be rectified.
SUGGESTIONS FOR PITLINE
Pit line: Pit line in line with DMRC will be suitable but both side catwalks are
required along with long span supports below catwalk.
Lighting arrangement: Light fittings of sufficient lux should be installed on
Catwalk pillars for under gear and trolley inspections. Single phase Welding
sockets and spare plug for hand lamps should also be provided on this switch
board.
Board Lifter: We can use the Board lifter to place the destination board easily.
ADVANTAGES OF MAINTENANCE PROCESS
 Increase the operational life of component
 Increase the quality of operation
 Increase the efficiency
THANK YOU