Scope of quality audit for POH attention of Wagons in workshop3).pdf · Scope of quality audit for...

of 30 Quality Audit of Wagon Workshop (WS Code, Rly) June 2012

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 Pipe bracket is being done as per maintenance manual of respective manufacturer.

2.1 of G 97

1.2 Check that all the components have been replaced of POH kit irrespective of condition.

2.2 of G 97

1.3 Check that DVs have been tested for all the parameters as given in their format on a test bench.

3.1 of G 97

1.4 Check that pipe bracket is being tested for leakage with 10 kg/cm

2 air

pressure.

3.2 of G 97

1.5 DV of BOBRN/BOBR wagon shall be tested for parameters as covered in Annexure – XII

3.3 of G 97

1.6 The distributer valves not meeting any of the requirements must be attended as per procedure covered in manufacturer maintenance manual and retested for all parameters.

3.4 of G 97

1.7 Check that overhauled DVs are being stenciled as below (i) Workshop & Railway. (ii) Month & Year.

4 of G 97

1.8 Check that overhauled and tested DVs are being stored in a clean & dry place.

5 (I) of G 97

1.9 Check that all inlet points of DV & pipe bracket are covered with protective cap.

5(II) of G 97

1.10 Check that specified tools are available for DV repair.

6 of G 97

1.11 Check that overhauling is being done by trained persons.

8 of G 97

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

2.1 Brake cylinder is dismantled as specified with correct tools

2.0 of G 97

2.2 Check that all the components of brake cylinder have been thoroughly degreased and cleaned.

2.1.8 of G 97

2.3 Check that all the components have been thoroughly inspected for damage, cracks or welding, dent etc and ensure that damaged components

2.1 & 2.2 of G 97


SN Requirements Clause Remarks have been replaced.

2.4 Check that release springs have been checked for their free height (610mm min).

2.2 of G 97

2.5 Check that following components have been replaced and available in adequate nos. (i) Piston Packing (ii) Wear ring (iii) Bush

2.3 of G 97

2.6 Check those small amounts of grease have been applied before assembly. Brake cylinder is assembled as specified with correct tools.

2.4 of G 97

2.7 Check that strength test of cylinder with 10 kg/cm

2 is being carried out.

3.1 of G 97

2.8 Check that pressure tightness test is being carried out as per procedure.

3.2 of G 97

2.9 Check that brake cylinders are being painted with black enamel.

4 of G 97

2.10 Check that overhauled brake cylinders are being stored in proper way and inlet and outlet parts have been plugged with protective cap.

5.1.2 of G 97

2.11 Ensure that a test stand is available for brake cylinder testing.

6 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 damage including filter.

2.4 of G 97

3.4 Check those dirt collectors are being tested on test stand with the air pressure of 10 kg/cm

2.

3 of G 97

3.5 Check that overhauled dirt collectors are being stored in a dry & clean space and inlet & outlet parts are being plugged with protective cap.

5 of G 97

4.0 Angle Cock (Annexure-IV)

4.1 Check that all the components are being cleaned properly.

2.2 of G 97

4.2 Check that ‘O’ ring & seat are being renewed irrespective of condition.

2.3

4.3 Check that all the components have been inspected for any damage.

2.4 of G 97

4.4 Check that spring is being checked for tension and also for dimension (12mm).

2.4.5 of G 97

4.5 Check that angle cock is being tested on a test stand with air pressure of 10 kg/cm

2.

3 of G 97

4.6 Check that overhauled angle cocks are being stored in a dry and clean space.

5 of G 97

4.7 Check that inlet & outlet parts are 6


SN Requirements Clause Remarks being plugged with protective caps.

5.0 Auxiliary Reservoir (Annexure-V)

5.1 The auxiliary reservoir should be overhauled in every POH. Check that auxiliary reservoir is being cleaned from outside and inside with wire brush and dry air jet after properly draining.

2.1 of G 97

5.2 Examine for visual damages. The auxiliary reservoir having deep cuts on surfaces may be rejected.

2.2 of G 97

5.3 Check that rust preventive is being applied from inside surface of reservoir.

2.3 of G 97

5.4 Check that reservoir is being painted with black enamel from outside.

2.4 of G 97

5.5 Check that leather washer is being replaced irrespective of condition.

2.6 of G 97

5.6 Check that Teflon tape is being used over drain plug for making leak proof joints.

2.7 of G 97

5.7 Check that reservoirs are being tested with 10 kg/cm

2 Hydraulic & Air

pressure for leakage.

3 of G 97

5.8 The auxiliary reservoir should be stored in such a way to prevent the following:

a) Damage due to hitting each other.

b) The flange surface should be prevented from damages.

c) Outside paint should not be damaged.

d) Check that parts are being plugged with protective caps

5 of G 97

6.0 Hose Coupling (Annexure-VI)

6.1 Check that hose coupling is being thoroughly inspected for any damage, corroded and ensure that damaged hose are not being used.

2 of G 97

6.2 Remove the gasket and thoroughly clean the coupling head specially the internal groove for housing gasket.

2.3 of G 97

6.3 Check that hose coupling are being tested for leakage at the air pressure of 10 kg/cm

2.

3 of G 97

6.4 Check that hose coupling are being stored at dry & clean space and outlet & inlet ports are being plugged with protective caps.

5 of G 97

7.0 Isolating Cock (Annexure-VIII)

7.1 Check that isolating cocks are being overhauled and tested in accordance with manufacturer’s maintenance manual.

2&3 of G 97

7.2 Check that equipment for testing is available.

4

7.3 Check that repaired valves are protected from dust & moisture.

5


SN Requirements Clause Remarks 9.0 Pipes, Joints & Support bracket

(Annexure-X)

9.1 Check that gasket is being removed from flange joints and old one is scrapped.

2.1 of G 97

9.2 Check that pipes & joints are being cleaned from outside.

2.2 of G 97

9.3 Check that pipes & joints are being cleaned the inside by jet of dry air & all dirt and other particles are being removed.

2.3 of G 97

9.4 Check that gaskets groove of flange joints is being properly cleaned.

2.6 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 air at least 5 minutes.

2.9 of G 97

9.7 Check that ends of the pipes are being plugged with protection caps and are being only removed at the time of fitment.

2.10 of G 97

9.8 Check that testing of the pipe is being done with 10 kg/cm

2 dry air pressure

before removal and after refitment.

3 of G 97

9.9 Check that removed pipes are being kept in set and are being fitted on same wagon.

5 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 XIII/1 & 3 are stocked at depot.

G 97

10.2 POH kits of other air brake components as listed in annexure are stocked at depot.

G 97

11.0 Slack adjuster

11.1 Overhauling facility for slack adjuster is available and all Tools & equipments are available.

812 (C)(a) CAMTECH

11.2 The slack adjuster shall be overhauled at the time of POH of rolling stock. While dismantling or assembling 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.

812 (C)(b) CAMTECH

11.3 Any spring which does not conform to the requirements should not be used.

812 (C)(b)-I CAMTECH

11.4 During POH must change items as per G-92 should be replaced.

812 (C)(a)-II

CAMTECH

11.5 After cleaning and inspection, all parts of slack adjuster should be coated with semi fluid grease SERVOGEM-2 or equivalent before undertaking re-assembly.

812 (D) CAMTECH


SN Requirements Clause Remarks 11.6 The following should be ensured:

a) The place of overhauling must be clean and free from dust.

b) Ensure that no foreign matter/particle remain inside the subassemblies during re-assembly

c) All rubber gaskets, sealing ring, washers must be replaced during overhauling.

d) Specified tools and fixtures are used for disassembly and assembly operations.

812 (E) CAMTECH

11.7 After overhauling, the testing of slack adjuster is carried out in a test rack for take up (Pay in test) and Pay out test.

812 (F) CAMTECH

11.8 The slack adjuster is given a coat of anti-corrosive paint, excluding the adjuster tube 41.

812 (G) CAMTECH

11.9 A & e dimension are adjusted correctly during brake rigging setting.

812 (H) 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):

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:

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


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 OF G- 81

OBSERVATIONS

1 Removal of Bearing from Axle

1.1 Ensure that the removal of bearing is done as specified.

7.2.2 7.2.3

1.2 Check whether bearings are kept in a clean and dry place in a covered room.

7.2.4

1.3 Check that bearings are stacked properly and not thrown one over the other.

7.2.5

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 the bearing as specified.

7.3

3 Cleaning of components

3.1 Ensure proper cleaning. 7.4

3.2 Check that washing medium is filtered before use at least once in a day.

7.4

4 Inspection of Bearing Components

4.1 Ensure that the system exists to check each component carefully and measure the dimension of components as per Annexure-VI.

7.5

5 End Cap

5.1 Inspect end cap for cracks, breakage, wear and distortion of machined surface.

7.5.1

6 Cone (Inner rings with Roller Cage assemblies)

6.1 Inspect the race ways for staining corrosion, pitting, heat discoloration, false brinelling, spalling, indentation, electrical burns, and cracks and embedded contamination.

7.5.2

6.2 Inspect the inner ring with roller and cage assembly properly as fig.7.

7.5.2

7 Outer ring/Cap

7.1 Check inside dia. of counter bore, out of roundness and cup outer dia.

7.5.3.1 7.5.3.2

7.2 Check wear pattern on the outside of cup and inspect rolling surface for brinelling, sapling, smearing or peeling, fragment indentation or electric burns

7.5.3.3



OBSERVATIONS

and intensity of corrosion.

8 Rollers

8.1 Inspect Rollers for the defects such as brinelling sapling, smearing, indentation and corrosion.

7.5.4

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 parallelism of end faces.

7.5.7

12 Seal wear ring

12.1 Inspect the outer surface for cracks, nicks, scratches and also check for wear.

7.5.8

13 Vent fittings

13.1 Check that there is no vent hole in backing ring if required it should be plugged.

7.5.10

14 Backing ring

14.1 Check backing ring break out diameter and for excessive corrosion.

7.5.9

14.2 Check that distorted, cracked and heavily pitted rings are scrapped.

7.5.9

15 Cap screw and Locking plate

15.1 Check cap screws for wear on threads and for stretching or elongation.

7.5.11

15.2 Check that cap screw threads are properly cleaned and lubricated before fitment.

7.5.11

15.3 Ensure that cap screws are tightened with torque wrench.

7.5.11

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 and foreign particles.

7.7

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 within limits.

7.7.1

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



OBSERVATIONS

18.3 Ensure that specified quantity of grease is used i.e. 455 gms and verify by measuring two samples per day.

7.7.2

19 Mounting of Roller and Cage Assembly and Fitment of seals

7.7.3

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 according to clause.

7.7.5

20 Mounting of Taper Bearing on Axle 9

20.1 Check journal dia at three points as described in case of new axle.

9.1

20.2 Measure the journal dia at the two bearing seat location locations at three equidistant points around the journal in case of old axles.

9.2

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 120 degree apart around the journal.

9.2.2

21.2 Check fillet radius for proper seating of backing ring, with template.

9.3

21.3 Before mounting, coat the journal fillet and portion of axle between wheel hub and the fillet with lead free rust preventive & then coat bearing seating on the journal with heavy mineral oil.

9.4

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 dia indicator.

9.6

23 Fitment of Axle under the Bogie

23.1 Ensure that proper care has been taken while fitting axle under bogie to avoid hitting.

10.0

24 Bearing Marking

24.1 Ensure that proper marking of POH/repair particulars have been marked at the locations prescribed.

13

25 Maintenance Workshop

25.1 Ensure that working area is duly clean, dust free & dry.

14

26 Handling of Bearing Mounted Wheel Sets

15

26.1 Check that bearing mounted wheel sets are handled properly.

-do-

26.2 Ensure that all the measurement/checks properly recorded as per check list of G-81.

-do-

26.3 Ensure that all gauges have been calibrated/ checked with master gauge at least once in a month.

-do-



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 location 60º apart. 606 H

2. Check that wheel dia is being measured with the help of 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.

606 C& H

Wheel Dia New- 1000 Shop

issue size - 919 mm

3. Check that each axle is being thoroughly cleaned for 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.

Para 606 A

4. Check that wheels are being categorised into following categories after pre-inspection. (i) Normal repair wheels. (ii) Wheels requiring replacement of

Axle. (iii) Wheels requiring replacement of

Wheel dics.

Para 606

5. The wheel should be inspected for rejectable defects in accordance with CMI/K003.

CMI/ K003

6. Check that wheels are being turned to WWP & machining standard is N11 to IS:3073.

Para 606 E

7 Check that new axles are being machined as per the correct drawing dimensions.

Para 606 A and B

8 Check that dimensions of finished journals is being measured with micrometer at 3 points along length of the journal both on horizontal & vertical axis.

Para 606 A

9 Check that axles are being given ultrasonic flaw detection test.

10 Check that the bore & the wheel seats are having specified surface finish & correct

Para 606 F


SN REQUIREMENTS CLAUSE OBSERVATIONS interference fit and pressing in 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 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.

Para 606 F

12 Check that wheel press is equipped with a dial pressure gauge and pressure recording gauge with graph to record mounting pressure diagram and also is being recorded for each assembly.

Para 606 F

13 Check that mounting particulars are being punched on journal face.

Para 606 F

14 Pairing of wheels: Wheels are to be paired in wagons in accordance with clause 2.8.14.2 of IRCA Part III

Para 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:


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




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 tolerance are checked when dismantled.

4.1.3

2 Ensure that in case of excess wear the repairs are undertaken either by building up or by changing the liners.

4.1.4

3 The gauge as shown in Figure 37 & 38 of G-95 is available and is being used to check the combined wear in bolster/side frame liners and wedge.

4.1.5

4 Ensure that suitable manipulators are available and are being used regularly to carry out repair work by down hand welding.

4.1.6

5 Ensure that the repair surfaces are checked with the relevant gauge for correctness and excess material is removed by grinding machining.

4.1.7

6 Ensure that the uses of electrode and gauge welding movement and welding precautions are being taken as laid down in Annexure C-2F of G-95.

4.1.8

7 Ensure that wearing surfaces of bogie are brought to “As new condition”.

4.1.9

8 Ensure that all the load and snubber springs are inspected for proper setting after placing the wagon body on the bogies.

4.2.2

9 Ensure that centre pivot of the bogie is fitted with graphite flake to IS: 495 at the time of assembly. Ensure that centre pivot washer is used and assembled during assembly.

4.2.2

10 Ensure that the clearances are measured as per the clearances given in the G-95

4.2.3

11 Ensure that the wearing surfaces in the side frame are measured and wherever necessary, the recondition procedure as specified is followed.

5.3.1

12 Ensure that the side frame columns are provided with 10mm

5.3.2


SN ACTIVITY CLAUSE OBSERVATIONS thick silico-manganese liners.

13 Ensure that while providing the liners the 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.

5.3.2

14 Ensure that side frame col, sides are gauged to determine the amount of wear on the outside and inside frame and if necessary, the liners are welded.

5.3.3

15 Ensure that the wear on the anti-rotation lug is measured with gauge as shown in Figure 26 of G.95 and if necessary, the liners are welded.

5.3.4

16 Ensure that wear on the side frame pedestal crown 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.

5.3.5

17 Ensure that the wear on pedestal crown sides are checked by using specified gauge and is repaired by welding whenever necessary following the instructions given in Annexure ‘D’ of G-95.

5.3.5

18 Ensure that for this purpose, area to be reclaimed is heated upto

temperature of 250C. The sides of pedestal are to be gauged and whenever required welding is done.

5.3.6

19 Ensure that wear on the pedestal jaw (outer and inner) is determined by using specified gauge and wherever required, repair is made.

5.3.7

20 Ensure that the system exists to check the wheelbase of prepared side frame and pairing is done while assembling the bogie.

5.3.9

21 The bolster pocket 35+1 slope surface is maintained by using suitable liners as specified and the welding is done following the instruction in Annexure ‘F’ of G-95.

5.4.1

22 Ensure that the exact wear is measured by using specified gauge on bolster liner surfaces and rotation spot lugs and wherever required, the liners are used.

5.4.2

23 Ensure that the wear is checked on 5.4.3


SN ACTIVITY CLAUSE OBSERVATIONS outer and inner bolster col, gibs and wherever required the liners welded.

24 Ensure that the spring plank is examined for 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.

5.5.5

25 Ensure that the springs are measured for free height and are replaced if the free height is less than the specified.

5.6.2

26 Ensure that the grouping of load and snubber 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.

5.6.2

27 Ensure that wear on the friction shoe of the two wear surfaces is measured using specified gauge and reclamation by welding whenever required.

5.7

28 Ensure that the reclamation, welding inspection is done as per the procedure laid down in G-95.

5.7.3 5.7.4 5.7.5

29 System exists to determine the wear on the seat and sides of centre pivot bowl by using specified gauges and wherever required, it is reclaimed/ replaced.

5.8

30 Ensure that the surface to be reclaimed is pre-heated upto

250C and allowed to cool slowly after welding.

5.8

31 The repaired pivot is checked using gauge.

5.8

32 Ensure that the side bearer are checked and replaced if found condemned.

5.9

33 Ensure that the elastomeric pad and side bearer rubber pads (or PU pads) are replaced as recommended.

5.10.1 & RDSO

guidelines

34 Ensure that the bushes provided are IRSM4 class 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.

5.11


SN ACTIVITY CLAUSE OBSERVATIONS 35 Ensure that the pins located in end

pool rod and the pins are relocated.

5.11

36 Ensure that the bogie shoe is replaced with worn 48mm i.e. when 10mm metal is left from the base of the shoe.

5.11

37 Ensure that reclamation of brake beam is done following the procedure given in G-95.

5.11.1

38 Ensure that during welding of bogie fitted with roller bearing, the return current welding is fixed very close to the welding area.

5.13

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:


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





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 assembly are dismantled for inspection. Lock lift assembly must be inspected.

2 .3 (G80)

2 All the components detected having crack in area shown in Fig.1 of G-80 must be scrapped.

2.1 (G80)

3 Ensure that all the components are cleaned to remove dirt, paint, rust, scale etc. which may interfere with gauging & inspection.

2.4(G80)

4 All the parts are visually inspected for cracks, fracture, sections broken out, worn surfaces, distortion, and surface upset and surface notches.

2.5 (G80)

5 Ensure that all the gauges required are available.

2.6 (G80)

6 Ensure that surface upset are ground and blended to the surrounding surfaces. The ground area should be free of cracks.

3.1.5 (G80)

7 Ensure that the part or assembly classified as reconditioned is identified by single star and the code of Railway Workshop punched at the location prescribed.

3.1.7 (G80)

Coupler

8 Ensure that only those coupler bodies are used which meet the requirement of gauges listed in Table-1 of G-80 and perform all the functions.

3.2.1.1 (G80)

9 If the shank wear plate is worn out, it should be restored by application of a new wear plate.

3.2.1.2.1 (G80)

10 Ensure that the wear plate is strictly in accordance with SK-62724 item-10.

3.2.1.2.2 (G80)

11 Ensure that no heat-treatment is performed after application of shank wear plate.

3.2.1.2.2.1 (G80)

12 Ensure that coupler body is legible stamped as shown in Fig.4 of G-80.

3.2.1.3.2 (G80)


SN ACTIVITIES CLAUSE NO. OBSERVATIONS 13 The coupler shank is not out of

alignment with the head in excess of 9mm either vertically or laterally.

3.2.1.4.1 (G80)

14 Ensure that the Knuckle is checked to meet the requirements of gauges listed in Table-II of G-80.

3.2.2.1 (G80)

15 Ensure that the Lock meets the requirement of gauges listed in Table-III of G-80.

3.2.3.1 (G80)

16 The reconditioned lock is identified by single star and code of Railway workshop punched at the location prescribed.

3.2.3.2 (G80)

17 Ensure that no reconditioning is done for thrower & lock lift assembly.

3.2.4 (G80) 3.2.5 (G80)

18 After straightening and heat-treatment, knuckle pivot pin is free of cracks, fractures, sections broken out and surface notches and meets requirement of gauges listed in Table-4.

3.2.6.1 (G80) 3.2.6.2 (G80)

19 The coupler assembly meets the requirements as specified in Appendix ‘B’ of G-80.

3.2.7 (G80)

20 The coupler yoke is free of cracks, fracture, section broken out and surface notches.

3.3.1 (G80)

21 Ensure that the front of yoke pin hole to butt inside surface length as indicated: length – 786min, 787.5max.

3.3.2 (G80)

22 The yoke is legibly stamped as shown in Fig.4 of G-80.

3.3.3 (G80)

23 The draft gear follower must meet the requirement of gauges listed in Table-5 and legibly stamped.

3.4.1 (G80) 3.4.4 (G80)

24 Ensure that yoke pin is not reconditioned.

3.4..5.1 (G80)

25 Ensure that the welding is done during reconditioning using qualified welders and procedure is as specified in IS:7318 Pt.I.

4.1.1 (G80)

26 The preheating is done between 150º to 320º.

4.1.3 (G80)

27 The welding is done using low hydrogen coated electrodes or by gas shielded welding process.

4.1.4 (G80)

28 The heat-treatment required after weld repair or straightening is done as specified.

4.1.5 (G80)

29 After heat-treatment, ensure that the components are allowed to cool to a temperature below 538ºC at a rate which will not be injurious to castings.

4.2.1 (G80)


SN ACTIVITIES CLAUSE NO. OBSERVATIONS 30 Ensure that Gr. ‘C’ steel castings

are normalised and tempered and marked HT and Gr. ‘E’ steel castings are quenched & tempered and marked HTE.

4.2.2(G80)

31 Ensure that the normalising & tempering/ quenching & tempering are done as specified in Clause 4.2.3.

4.2.3 (G80)

32 Ensure that the desired hardness is achieved.

4.2.4 (G80)

33 The hardness shall be measured only at the specified locations.

4.2.4.3 (G80)

Ensure that the finish of the components is as specified.

4.3 (G80)

34 Repair procedure

35 Restoration of coupler head portion of coupler body including the application of bushings to knuckle pivot pin holes is prohibited except for top & bottom pin protector bosses.

5.1.1 (G80)

36 Restoration of shank is prohibited if wear bottom of shank exceeds 9mm depth.

5.1.2 (G80)

37 Restoration of yoke pin holes of shank is 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.

5.1.3 (G80)

38 Top & bottom pin protector with cracks or sections broken out may be weld repaired. However, if the failure exceeds beyond the permissible repair zone, the coupler body must be scrapped.

5.1.4.1 (G80)

39 The repair to the coupler head body shall be done as specified.

5.1.4 (G80)

40 The coupler body is scrapped if shank thickness is less than specified.

5.1.5 (G80)

41 Restored coupler body must be heat-treated as specified.

5.1.5.5 (G80)

42 Coupler body with shank bent in excess of 9mm in 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.

5.1.6 (G80)

43 The examination of the coupler body after straightening shall be done as specified.

5.1.6 (G80)

44 Restoration for wear of the knuckle is done only in the areas i.e. lock engagement surface,

5.2.1 (G80)


SN ACTIVITIES CLAUSE NO. OBSERVATIONS bottom hub, pulling lug top & bottom, top & bottom pin protectors.

45 Repair of cracks or sections broken out at any location is prohibited.

5.2.2 (G80)

46 Restoration for wear of the lock is done only on the knuckle engagement surface. Repair of cracks or sections broken out at any location is prohibited.

5.3.1 (G80) 5.3.2 (G80)

47 The restoration by welding is done as specified.

5.3.3 (G80)

48 The knuckle pivot pin is reconditioned as per the procedure specified.

5.4 (G80)

49 Ensure that the coupler yoke are reconditioned only when within the specified limits otherwise scrapped. The repair is done as per the specified procedure.

5.5 (G80)

50 Ensure that the high capacity draft gear are maintained and reclaimed as per the instructions circulated by M/s Bhartia for Cardwoll Mark 50 Design & by M/s Burns Standards for Miners RF-361 and as laid down in Chapter 9 of Maintenance Manual for Wagons.

As per G -80 &

Chapter 9 of Maintenance

Manual for Wagon

51 The standard draft gears are to be replaced by high capacity draft gears vide RB’s letter no. 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.

Para 919 of Maint. Manual for Wagon

52 Maintenance of RF-361 Draft gear


53 All gauges for housing, gauges for shoes, gauges for wedge and final inspection gauges as specified are available.

-do-

53.1 The RF361 draft gear will require complete 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.

-do-


SN ACTIVITIES CLAUSE NO. OBSERVATIONS 53.2 If either the shoes or wedge are

broken and the 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.

-do-

53.3 Shoes are inspected for these defects –

No concave wear on any friction surface

No cracks or spalls

No wear more than 0.8mm on any friction surface

-do-

53.4 Wedge is inspected for these defects –

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.

-do-

53.5 Housing or cylinders are examined as per laid down procedure and scrapped if found unsuitable.

-do-

53.6 For proper function, every part of the assembly must be free of oil, grease and moisture. The part should be kept properly during storage, handling and reassembling.

-do-

53.7 Wedge and shoes are to be shot peened to remove rust and dirt before assembly.

-do-

53.8 Re-assembly of draft gear is being done as per laid down procedure.

-do-

53.9 If complete reconditioning of the gear is 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.

-do-

53.10 All components such as internal followers, forged items, housing (cylinders) are inspected as per laid down procedure.

-do-

53.11 Re-assembly of reconditioned RF361 draft gear is done as

-do-


SN ACTIVITIES CLAUSE NO. OBSERVATIONS 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 specified.

-do-

53.13 Welding of rear plate after assembly is done as 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.

-do-

53.11 The assembled RF361 draft gear must be pre 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.

-do-

53.12 Maintenance of Mark – 50 Draft Gear


54 Inspection of MK 50 draft gear is done for reconditioning through a built in wear life gauge as per laid down procedure.

-do-

54.1 While removing draft gear from the wagon pocket, 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.

-do-

54.2 For removal of stuck or damaged draft gear, laid down procedures and precautions are followed.

-do-

54.3 For dismantling of MARK50 draft gear, tools and gadgets are available and procedure as specified are followed.

-do-

54.4 All gauges as per annexure are available for maintenance/reconditioning of MK50 draft gear.

-do-


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

pin

WD-84073-S-96-RC Knuckle pivot

Draft Gear

Follower

WD-84073-S-71-RC DG follower gauge


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:


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





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 frequency. Para 209 of

Maint. Manual for Wagon and

IRCA letter M.219/Policy/W Dated 10.5.99

2 Body repair work of wagon is carried out during POH as under:

Para 210 of Maint. 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


SN REQUIREMENTS CLAUSE OBSERVATIONS 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 DURING POH/NPOH 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.


for Wagon

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 be given during POH of wagon for the following 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


for Wagon


SN REQUIREMENTS CLAUSE OBSERVATIONS 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 proper painting of wagon body after surface 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.


for Wagon

6.0 ANTICORROSIVE MEASURES: While attending to miscellaneous repairs, panel 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.


for Wagon

7.0 REPAIRS TO BULGED ENDS: If there are no serious damages to wagon ends 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.

Para 410-D of Maint. Manual

for Wagon

8.0 REPAIRS TO BODY STRUCTURAL MEMBERS (STANCHIONS, CARLINES 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

Para 410-E of Maint.

Manual for Wagon


SN REQUIREMENTS CLAUSE OBSERVATIONS 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: Covered wagons must be kept watertight at all 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.

Para 410-F of Maint.

Manual for Wagon

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


SN REQUIREMENTS CLAUSE OBSERVATIONS 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: Corroded louvers have to be replaced by new 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.

Para 410-H of Maint. Manual for Wagon

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


SN REQUIREMENTS CLAUSE OBSERVATIONS 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: Lettering to be carried out as

per IRCA Part III (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.


for Wagon

14.0 IMPORTANT PRECAUTIONS TO BE TAKEN WHILE CARRYING OUT WELDING


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


SN REQUIREMENTS CLAUSE OBSERVATIONS 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:


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


8. Status of calibration of measuring instruments:

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