This document provides information on the maintenance schedules and processes for Indian Railways coaches. It discusses: 1) The different maintenance schedules for coaches including washing line (after every trip), schedule A/B/C maintenance (ranging from monthly to every 6 months), and IOH/POH (every 9 and 18 months). 2) The classification of coaching maintenance depots based on the number of coaches maintained ranging from minor (50-100 coaches) to major (above 250 coaches). 3) The various works carried out in the washing line and sick line, including inspection, cleaning, brake testing, maintenance works, and loading of provisions. 4) Additional details on wheel and axle assembly specifications

1. PERSENTATION ON COACH CARE OF
INDIAN RAILWAYS
NEW DELHI
SUBMITTED BY :
ITNESH KUMAR
B.Tech [ME-C] 4th YEAR
1403340095
RAJ KUMAR GOEL INSTITUTE OF TECHNOLOGY , GHAZIABAD
SUBMITTED TO:
UMESH JHA

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

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

4. WORKS CARRIED OUT IN WASHING LINE
 Inspection
 Cleaning & washing
 Brake testing
 Primary Maintenance
 Secondary Maintenance
 Watering
 Loading of linen
 Maintenance of AC & electrical circuits of coaches

5. Brake testing is carried by using RTR (rack test rig).
Rack testing rig is capable of testing full train (up to 24 coaches) at a
time.
 The trains for the secondary maintenance are given at least 2 hrs. on
the washing line.
 Linen and pantry car provisions
 Washing & cleaning of coaches
 Maintenance of AC of coaches
BRAKE TESTING IN WASHING LINE BRAKE
SECONDARY MAINTENANCE

6. PRIMARY MAINTENANCE
 The trains for the primary maintenance are given at least 6 hrs at the
washing line in addition to secondary maintenance
 Oil in hydraulic dash pots
 Wheel profiles are visually examined and gauged
 Pest control treatment
 Axle box is examined for grease oozing
 Brake blocks & piston stroke checked & changed

7. Sick line is the workshop for the major and periodical maintenance of the
coaches
1. Works carried out in sick line
2. Wheel and Axle Assembly
3. Bogie Maintenance
4. Buffer Maintenance
5. Air Brake System Maintenance
SICK LINE

8. 1. Width of wheel = 127 mm
2. Wheel Diameter = 915 (new), 825 (condemn)
Permissible diameter variation in wheel Coaching
a) On same axle – 0.5 mm
b) On same bogie – 5.0 mm
c) On same coach – 13.0 mm
Goods
a) On same axle – 0.5 mm
b) On same bogie – 13.0 mm
c) On same coach – 25.0 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.

10. 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.
BUFFER HEIGHT ADJUSTMENT
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. AIR BRAKE SYSTEM MAINTENANCE
Components of Air Brake System
1. Brake Container
2. Distributor Valve
3. Pressure Tanks (125 liters, 6 liters)
4. B.P. / F.P. coupling and hosts
5. Emergency Brake Pull Box
6. Emergency Brake Valve

12. Parts of Trolley
1. Trolley Frame
2. Center pivot
3. Side Bearing
4. Brake Cylinder
TROLLEY MAINTENANCE

13. Require tools and equipment's
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
LIFTING OF COACHES

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

15. 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 behavior of vehicle

16. 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

17. 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.
BRAKE POWER CERTIFICATE

18. 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.
SAFE TO RUN

19. THANK YOU