STANDARDISATION OF COACHING DEPOT RECORDS
59
(For official use only) CAMTECH/2002/M/CHG. RECORD/1.0 (Draft copy) January-2002 Centre for Advanced Maintenance TECHnology Excellence in Maintenance (Govt. of India) (Ministry of Railways) MAHARAJPUR, GWALIOR--474020 STANDARDISATION OF COACHING DEPOT RECORDS
Transcript of STANDARDISATION OF COACHING DEPOT RECORDS
(For official use only)
CAMTECH/2002/M/CHG. RECORD/1.0
(Draft copy)
January-2002
Centre
for
Advanced
Maintenance
TECHnology
Excellence in Maintenance
(Govt. of India)
(Ministry of Railways)
MAHARAJPUR, GWALIOR--474020
STANDARDISATION
OF
COACHING DEPOT RECORDS
CONTENTS
Contents Page No.
CHAPTER 1
General 1
Objective 1
Methodology Adopted 1
Observation And Recommendation 1
CHAPTER 2
C & W monthly statement/PCDO 2
Average detention to ineffective coaches 3
Ineffective sick coaches 4
Ineffective coaching stock 5
Defect wise break up of sick coaches 6
Sick line out-turn 7
Foreign railway coaches made sick 8
"C" schedule carried out 9
Coaches intensively cleaned 10
Coaches detached during primary maintenance 11
Coaches detached during secondary maintenance 12
Coaches detached within 3 months POH off 13
Coaches booked to workshop for POH/repair 14
Particular shop overdue POH coaches 15
Release valve and vacuum cylinders overhauled 16
Wheel transaction 17
Coach failures 18
Bearing failure 19
Train parting & accident 20 20
Disturbances of coaches 21 20 1
Amenity fittings / replacement on rakes 22 22
Contents Page No.
CHAPTER 3
Register for coaching depots 23
Sick rolling stock 24 2 25
Wheel changing record 25 2425
Dispatching defective wheels 26 27
New wheel record 27 27
Under floor wheel lathe tyre turning 28 2
Distributor valve 29 243
Defective distributor valve analysis 30 31
Vacuum brake maintenance 31 32
Vacuum cylinder maintenance 32 33
Helical spring failure 33 34
Yard position register 34 37
Placement register 35 38 , 39
Piston stroke register 36 40
Coach history sheet 37 41
Wheel history sheet 38 3442
Air brake register 39 4
Service application register 40 44
Manual release test register 41 45
Guard van valve test register 42 46
Air brake fitting securing arrangement register 43 40 47
Alarm chain pull test register 44 48
Trip schedule items 45 49
Duty- diary 46 50
"A" schedule register 48 51
"B" schedule register 49 52
"C" schedule register 50 53, 54, 55, 56
Check list 54 57, 58, 59
1
CHAPTER 1
GENERAL
1.0 OBJECTIVE
Presently the maintenance records kept by coaching depots vary considerably from
depot to depot. Hence there is a need of having standard proforma, registers of
records which are maintained in the coaching depots.
2.0 METHODLOGY ADOPTED
Field study was conducted and data collected from the following coaching depots.
Coaching depot, Secundrabad, SCR
Coaching depot, BCT, WR
Coaching depot, Kurla, CR
Coaching depot, NDLS, NR
Coaching depot, BBQ, SR
Coaching depot, Wadi Bundar, CR
A seminar was organised at CAMTECH, Gwalior on 22/11/01 and 23/11/01
and feedback was taken from the participants in the seminar from different coaching
depots.
3.0 OBSERVATION AND RECOMMENDATIONS.
After studying the formats from different coaching depots and consultations held in
seminar, Schedule forms, Maintenance registers, and Monthly statement formats have
been prepared. In chapter 2 the monthly statement (PCDO) with the relevant
annexures is given. In chapter 3 the format of registers to be maintained in the depot
is given.
2
CHAPTER 2
C & W MONTHLY STATEMENT
Depot……….
Statement of performance indices for month ………… , year …………..
Prepared on date……….
1. COACHING INEFFECTIVE
1.1 Average detention to ineffective coaches Annexure 1
1.2 Ineffective sick coaches Annexure 2
1.3 Ineffective coaching stock Annexure 3
2. DETAILS OF SICK COACHES
2.1 Defect wise breakup of sick coaches Annexure 4
2.2 Sick line outturn Annexure 5
2.3 Foreign Railway coaches made sick Annexure 6
3. "C" SCHEDULE CARRIED OUT Annexure 7
4. COACHES INTENSIVELY CLEANED Annexure 8
5. COACHING DETACHMENT
5.1 Coaches detached during primary maintenance Annexure 9
5.2 Coaches detached during secondary maintenance Annexure 10
5.3 Detachment of coaches within 3 months (POH off) Annexure 11
6. COACHES BOOKED TO WORKSHOP FOR POH/REPAIR Annexure 12
7. COACHING OVERDUE FOR POH Annexure 13
8. OVERHAULING OF VACUUM CYLINDERS Annexure 14
& RELEASE VALVES
9. WHEEL TRANSACTION DETAIL Annexure 15
10. FAILURES, TRAIN PARTING & ACCIDENTS
10.1 Coach failures Annexure 16
10.2 Bearing failures Annexure 17
10.3 Train parting and accident Annexure 18
11. DISTURBANCES OF COACHES Annexure 19
12. AMENITY FITTINGS / REPLACEMENT ON RAKES Annexure 20
Signature of CDO/CWS/Incharge
3
ANNEXURE 1
STATEMENT SHOWING AVERAGE DETENTION TO INEFFECTIVE COACHES FOR THE MONTH
OF…………………
LOCATION
NO. OF
COACHES
TRAFFIC TIME TAKEN FROM
SICK TO PLACEMENT
MAINTENANCE TINE
TAKEN TO RELEASE
WAITING FOR
MATERIAL
TIME TAKEN
Total Hrs Average
Hrs
Total Hrs Average
Hrs
Total Hrs Average
Hrs
Total
Hrs
Average
Hrs
SICK LINE
ON TRAIN
4
ANNEXURE 2
STATEMENT OF INEFFECTIVE SICK COACHES FOR THE MONTH OF………
Sr.
No
Type of Coaches Opening
Balance
Fresh
Marked
Sick
Released
during
the Month
Closing
Balance
Attended
on Train
Sent To
POH Shop
Remark
From
Depot
Arrival.
From Other
Station.
PCV
1. FAC/CZAC/FSC
ZAC
2. ACCW/ACCN
3. WGSCN
4. GS
5. FC
6. FSCN
7. SLR
TOTAL
OCV
1. WCB
2. LR
3. SP
4. VP
OTHER
TOTAL
5
ANNEXURE 3
STATEMENT SHOWING INEFFECTIVE COACHING STOCK FOR THE MONTH OF………………
Sr.
No
Coach Sick Placement Made Fit Detention of
Total Hours
Reason
for Sick
Remark
No class Rly Date Time Date Time Date Time
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
6
ANNEXURE 4
STATEMENT SHOWING DEFECTWISE BREAK-UP OF SICK COACHES FOR THE MONTH OF…
S. NO. MAJOR DEFECT PREVIOUS
BALANCE
FRESH
SICK
RELEASE CLOSING
BALANCE
1. BODY REPAIR
2. VESTIBULE REPAIR
3. REXINE REPAIR
4. FLOOR REPAIR
5. PIPE LINE REPAIR
6. BUFFING GEAR DEFECTS
7. WHEEL CHANGING
8. BOLSTER SPRING BREAKAGE
9. DASH POT SPRING BREAKAGE
10. BOGIE DEFECTS
11. DRAW GEAR DEFECTS
12. BRAKE GEAR DEFECTS
13. INTERIOR REPAIRS
14. WATER TANK REPAIRS
15. MAIN DOOR REPAIRS
16. ACP SYSTEM DEFECTS
17. UNUSUAL SOUND
18. ELECTRICAL REPAIRS
19. SHUTTER REPAIRS
20. SMOKED GLASS REPAIRS
21. MISCELLANEOUS REPAIRS
TOTAL
7
ANNEXURE 5
STATEMENT SHOWING SICK LINE OUT TURN FOR THE MONTH OF……………
S.
NO.
REASON DETACHED ON TRAIN TOTAL
SICK REPAIRS
1. WHEEL CHANGING
2. DASH POT SPRING BREAKAGE
3. BOLSTER SPRING BREAKAGE
4. BRAKE GEAR DEFECT
5. DRAW GEAR DEFECT
6. BUFFING GEAR DEFECT
7. BOGIE DEFECT
8. WATER TANK REPAIR
9. VESTIBULE REPAIR
10. REXINE REPAIR
11. FLOOR REPAIR
12. MAIN DOOR REPAIR
13. SHUTTER REPAIR
14. SMOKED GLASS REPAIRS
15. PIPE LINE REPAIR
16. ACP SYSTEM REPAIR
17. BODY REPAIR
18. UNUSUAL SOUND
19. INTERIOR REPAIR
20. MICELLANEOUS REPAIR
21. ELECTRICAL REPAIRS
SCHEDULE OUT TURN
1. " A " SCHEDULE
2. "B" SCHEDULE
3. "C" SCHEDULE
4. INTENSIVE CLEANING
8
ANNEXURE 6
STATEMENT SHOWING FOREGN RAILWAY COACHES MADE SICK DURING THE MONTH OF…………
S
No.
COACH PARTICULARS TRAIN
NO.
SICK
PARTICULARS
PLACEMENT MADE FIT NATURE OF
DEFECT
DISPOSAL
NO. CLASS Rly DATE TIME DATE TIME DATE TIME TRAIN
NO
DATE STN.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
9
ANNEXURE 7
STATEMENT SHOWING "C" SCHEDULE CARRIED OUT DURING THE MONTH OF………
SR.
NO.
COACH PARTICULARS REMARK
NO. CLASS RLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
10
ANNEXURE 8
STATEMENT SHOWING THE COACHES INTENSIVELY CLEANED FOR THE MONTH OF…………
S. NO. DATE TRAIN NO. NO.OF COACHES 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
11
ANNEXURE 9
STATEMENT SHOWING COACHES DETACHED DURING PRIMARY MAINTEINANCE DURING THE MONTH OF………..
S.
No.
PM
DEPOT
COACH PARTICULARS TRAIN
NO.
MARKED SICK MADE FIT REASON NO CLASS Rly DATE TIME DATE TIME
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
12
ANNEXURE 10
STATEMENT SHOWING COACHES DETACHED DURING SECONDARY MAINTENANCE IN THE MONTH OF…………
S.
NO.
TRAIN NO. COACH PARTICULARS MARKED SICK MADE FIT REASON
NO CLASS RLY DATE TIME DATE TIME
1.
1.
2.
2.
3.
3.
4.
5.
6.
7.
8.
9.
10.
13
ANNEXURE 11
STATEMENT SHOWING DETACHMENT OF COACHES WITHIN THREE MONTH ( POH OFF )
DURING THE MONTH OF…………
S.
NO.
DATE OF
MARKED
SICK
TRAIN
NO.
COACH PARTICULARS POH
DATE
DEFECT
NOTICED
RESPONSIBILITY REMARK NO. Class Rly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
14
ANNEXURE 12
STATEMENT SHOWING COACHES BOOKED TO WORKSHOP FOR POH/REPAIRS IN THE MONTH OF………..
S.
N0
COACHES LAST POH
PARTICULARS
BOOKED
DATE
BOOKED
SHOP
REASON FOR
BOOKING
REMARK
NO. CLASS RLY DATE SHOP RET. DATE
4.
1
5.
2
6.
3
7.
4
8.
5
9.
6
10. 7
11. 8
12. 9
10.
15
ANNEXURE 13
STATEMENT SHOWING THE PARTICULARS OF OVERDUE POH COACHES DURING THE MONTH OF……….
S. NO. COACH PARTICULARS TRAIN NO. POH PARTICULARS REMARKS
NO. CLASS Rly DATE SHOP RET. DATE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
16
ANNEXURE 14
STATEMENT SHOWING RELEASE VALVES & VACUUM CYLINDERS OVERHAULED DURING THE MONTH OF……………
S.
No.
Depot Number of
Release Valves
Overhauled
Release Valves Replaced
in Sick Line
Release Valves Replaced
in Yard
Vacuum Cylinders
Overhauled
Due Defective Due Defective Sch. O/H Non Sch. O/H
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
17
ANNEXURE 15
STATEMENT SHOWING WHEEL TRANSACTION DURING THE MONTH OF………………
S.
NO
WHEELS
TYPE WISE
IMPREST
OPENING BALANCE NEW
WHEELS
RECEIVED
OLD
WHEELS
SENT TO
SHOP
CONSUMPTION
DURING THE
MONTH
CLOSING
BALANCE
REMARK
PREVIOUS
ON HAND
PREVIOUS
DUE FROM
SHOP
ON HAND DUE
FROM
SHOP
AC
ICF
BE
ML
AC
ICF
BE
ML
AC
ICF
BE
ML
AC
ICF
BE
ML
AC
ICF
BE
ML
AC
ICF
BE
ML
AC
ICF
BE
ML
AC
ICF
BE
ML
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
18
ANNEXURE 16
STATEMENT SHOWING COACH FAILURES DURING THE MONTH OF…………
S.
No
Date Train
No.
Stn Coach
Particulars
Det.
Of
Train
Cause Of
Failure
Type
Of
Bogie
Maint. Last
Poh
Responsibility Remark
No. Class Rly Pri Sec
.
Shop Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
19
ANNEXURE 17
STATEMENT SHOWING BEARING FAILURE FOR THE MONTH OF…………
S.
NO
DATE
TRAIN
NO.
COACH
PARTICULARS
POH
PARTICULARS
TYPE OF
BEARINGS
MAKE &
MFG.
DATE
REMARKS
COACH
NO.
CLASS RLY SHOP DATE RETURN
DATE
1.
2.
3.
4.
5.
6.
7.
6.
7.
8.
9.
10.
20
ANNEXURE 18
STATEMENT SHOWING TRAIN PARTING & ACCIDENT DURING THE MONTH OF…………..
S.
No
.
Date
&
Stn.
Location Section /
Block
Div
.
Train
No.
Loco
No.
Coach
Particulars
POH
Detail
Last
Stn.
Of
Exam.
Reason Remark
No. Class Rly Date Shop Ret.
Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
21
ANNEXURE 19
STATEMENT SHOWING DISTURBANCES OF COACHES DURING THE MONTH OF…………………
LEFT TRAIN PARTICULARS ARRIVAL TRAIN PARTICULARS
SR.
NO.
DATE TRAIN
NO.
COACH
NO.
CLASS RLY ACTUAL SCH DET. AT
STATION
COACH
NO.
CLASS RLY REMARK
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
22
ANNEXURE 20
AMENITY FITTINGS / REPLACEMENT ON RAKES FOR THE MONTH OF……… TRAIN
NO.
NO OF
RAKES
MIRRORS MIRROR
SHELFS
PUSH
COCKS
SHOWER
ROSES
COMMODE
FLUSHERS
COMMODE
COVERS
GLASS
SHUTTERS
V / SHUTTERS LF
GLASSES
D R D R D R D R D R D R D R D R D R
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
23
CHAPTER 3
REGISTERS FOR COACHING DEPOTS
1. Sick Rolling Stock Annexure 1
2. Wheel Changing Record Annexure 2
3. Dispatching Defective Wheels Annexure 3
4. New Wheel Record Annexure 4
5. Under Floor Wheel Lathe Tyre Turning Annexure 5
6. Distributor Valve Annexure 6
7. Defective Distributor Valve Analysis Annexure 7
8. Vacuum Brake Maintenance Annexure 8
9. Vacuum Cylinder Maintenance Annexure 9
10. Helical Spring Failure Annexure 10
11. Yard Position Register Annexure 11
12. Placement Register Annexure 12
13. Piston Stroke Register Annexure 13
14. Coach History Sheet Annexure 14
15. Wheel History Sheet Annexure 15
16. Air Brake Register Annexure 16
17. Service Application Register Annexure 17
18. Manual Release Test Annexure 18
19. Guard Van Valve Test Register Annexure 19
20. Air Brake Fitting Securing Arrangement Register Annexure 20
21. Alarm Chain Pull Test Register Annexure 21
22. Trip Schedule Items Annexure 22
23. Duty-Diary Annexure 23
24. “ A” Schedule Form Annexure 24
25. “B” Schedule Form Annexure 25
26. “C” Schedule form Annexure 26
27. Check - List Annexure 27
24
ANNEXURE 1
REGISTER FOR SICK ROLLING STOCK
DATE……… PREVIOUS BALANCE……..
FRESH SICK………………….
ETL SICK ……………………
TOTAL……………………..
Sr.
No
.
Train
No.
Coach Particulars POH Particulars Sick Detail Placing Detail Fit Detail Reason
For Sick
Work
Executed
Remark
. No. Rly Class Date Shop Date of
Return.
Date Time Date Time Date Time
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
25
ANNEXURE 2
REGISTER FOR WHEEL CHANGING RECORD
S.
No.
Coach
Particulars
Poh
Detail
Sick
Detail
Placing Releasing Wheel
Defect
Previous
Wheel Dia.
Wheel
Dia. After Changing
No. of
Pairs
Wheel
Received From
Ultrasonic
test date for Wheel life
Remark
No. Rly Class Date Shop Date
of Ret.
Date Time Date Time Date Time
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
26
ANNEXURE 3
REGISTER FOR DISPATCHING DEFECTIVE WHEELS
Sr.
No
DATE COACH
PARTICULARS
DEFECTIVE
WHEEL PARTICULARS
WHEEL
WAGON
NO
DATE
OF
DISPATCH
REMARK
NO CLASS RLY TYPE
13 / 16 T
WHEEL
DIA.
WHEEL
DEFECT
1.
2.
3.
4.
5.
6.
7.
8.
9
10.
27
ANNEXURE 4
REGISTER FOR NEW WHEEL RECORD Sr.
NO
NEW WHEEL
RECORD
RECIEVED NEW WHEEL FITTED REMARK
WHEEL
NO.
TYPE
13 / 16 T
WHEEL
DIA.
WAGON
NO.
DATE COACH
NO
CLASS RLY LOCATION
OF WHEEL
DATE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
28
ANNEXURE 5
REGISTER FOR UNDER FLOOR WHEEL LATHE TYRE TURNING
Sr.
No.
Coach Date Wheel
defect
Placing Dt. & time Wheel dia Buffer height Remarks
No. Class Rly. POH Return IN OUT Before
turning
After
turning
Wheel
Profile
Before
turning
After
turning Date Time Date Time
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
29
ANNEXURE 6
REGISTER FOR DISTRIBUTOR VALVE
Sr.
No.
DV detail
(old)
Fault
Detecti
on
Train
No.
Coach Date
of
POH
Date
of
return
Initial
defect
Final
defect
Date
of fit
DV detail
(new)
Action
Taken
Fitter's
name
Remark &
sign of
maint. Engr. Make Sr.No No. Rly. Class Make Sr.No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
30
ANNEXURE 7
REGISTER FOR DEFECTIVE DISTRIBUTOR VALVE ANALYSIS
Sr.
No.
Dt. of
testing
Train
No.
Coach No. DV Dt. of
receipt
Reason for
removal
Final defect
after testing
Dt. of
dispatch
Remark
Make Sr.No. Tag No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
31
ANNEXURE 8
REGISTER FOR VACUUM BRAKE MAINTENANCE
Sr.
No
.
Dat
e
Coach Vacuum
in CMS
Cylinder
last exam.
Rings Diaphrag
m
Washers
Ho
se p
ipe
Cli
ps
Bra
ke
blo
ck
Pis
ton
ro
d c
utt
er
Dav
. C
on
d.
Cla
pp
et v
alv
e
Rem
ark
s &
sig
n o
f
mai
nt.
En
gr.
No
.
Rly
.
Cla
ss
On
en
gin
e
On
bra
ke
van
Stn
Dat
e
Join
t
Ro
llin
g
Nec
k
Rel
ease
val
ve
Van
val
ve
Rel
easi
ng
v
alv
e
seat
ing
Stu
ffin
g b
ox
jo
int
Pis
ton
hea
d c
ap
Van
val
ve
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
32
ANNEXURE 9
REGISTER FOR VACUUM CYLINDER MAINTENANCE
Sr.
No.
Dt. of
overhauling
Coach Last
Examination
Material used Defect
found
Cyl.
Fitted
Remarks
& Sign.
No. Type Rly. Station Date Joint
Ring
Rolling
ring
Neck
ring
Diaphragm Piston
ring
Piston
rod brass
bush
Release
valve
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
33
ANNEXURE 10
REGISTER FOR HELICAL SPRING FAILURE
Sr.
No
Date Train
No.
Coach Dt. of
POH
Dt. of
IOH
Dt. of
return
Type
of
spring
Location
of spring
Location
of
breakage
Make Stamp.
Detail
Type
detail
Type
breakage
Dt. of
dispatch
for testing
in lab
Remark
& sign
of maint.
Engr.
No. Rly Class
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
34
ANNEXURE 11
YARD POSITION
Sr.
No.
Coach Particulars Brake POH Particulars Coach Status Defect /Deficiency
No. RLY Class Type Air Brake Vac. Brake Date Shop Dt. of Ret. Sick Elec. Sick Mech. Fit
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
35
ANNEXURE 12
PLACEMENT REGISTER
Date Train No & Name Placing
Time
Washing
Line No
Schedule Actual Maint.
Time
Sign. of Maint.
Engr.
1. From To From To
2.
3.
4.
5.
6.
7.
8.
9.
10.
36
ANNEXURE 13
PISTON STROKE REGISTER
TRAIN NO. ………..
DATE ……….
Coach No.
Class & Rly
Piston Stroke
in mm
Dimension in
mm
Brake cylinder
releasing time in mm
ACP operative
or not
AIR PRESSURE CREATED
F/SLR R/SLR
BP
FP
LEAKAGE IN 3 MIN.
BP
FP
STAFF
1. ……………..
2. ……………
3. …………..
4. ……………
5. ………………
6. ………………..
7. ………………
…….
END
……..
END
…….
.END
…….
.END
………..
END
………..
END
37
ANNEXURE 14
COACH HISTORY SHEET
Date Coach No. Class Rly POH Ret. Date Built Date Base Depot C-Sch.
Draw
Gear
Exam
Buffing
Gear
Exam.
Dash
Pot
Oiling
Alarm
Chain
Pulled
Tests
Dirt Collect.
& Aux.
Reservoir
Cleaning
Commode
Chute
Painted
Pan Acid
Treatment
OHT/UST
Tank
Cleaned
Intensive
Cleaning
Pesticide
Treatment
Curtain
Changed
Naphthalene
Ball
Reason
For
Damage
Sign. Of
Maint.
Engr.
38
ANNEXURE 15
WHEEL HISTORY SHEET
S.
No
Date Coach Wheel
Diameter
Tyre Defect With Defect Gauge Buffer Height Staff
Name
Sig. of
maintenance
Engineer
No Class Rly
….E
nd
…E
nd
Sh
arp
Fla
ng
e
Dee
p
Fla
ng
e
Th
in
Fla
ng
e
Th
in
Ty
re
Ra
diu
s
Red
uce
d
Fla
t
Pla
ce
Th
in
Fla
ng
e
Trolley
No.1
Trolley No.2
End End End End
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
39
ANNEXURE 16
AIR BRAKE REGISTER
S.No. Coach
No.
Railway Class Dropping
In pressure
KG/CM2
Location
Of
Leakage
Type of
maint.
No. of parts
repaired/
replaced
Name of parts
repaired/
replaced
Sig. & remark
staff name
BP FP
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
40
ANNEXURE 1 7
SERVICE APPLICATION REGISTER
Sr.
No
Coach Piston stroke in
mm
Brake fully
applied
Yes/No.
Brake fully
released
Yes/No.
Name of
equipment
repaired/
replaced
No. of
equipment
repaired/replace
Name of staff
No. Rly. Class -- End -- End
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
41
ANNEXURE 18
MANUAL RELEASE TEST REGISTER
Sr.
No.
Coach Pressure in
kg/cm2
Exhaust air
through dist.
Valve
Proper/
improper
Return of
brake cylinder
piston
Full/partial
No. of
equipment
repair/
replaced
Name of
equipment
repair/replaced
Sig. and
Name of
staff No. Rly. Class BP FP
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
42
ANNEXURE 19
GUARD VAN VALVE TEST REGISATER
Sr.
No.
Coach Pressure
kg/cm2 in
BP gauge
in Brake
van
Dropping
pressure
kg/cm2
Leakage in
BP gauge
Working
of Brake
van valve
easy/
sagging
Exhaust of
air proper/
improper
Movement
of Brake
cylinder
piston
full/partial
Name &
Nos. of
Parts
Repair /
Replaced
Sig. And
name of
staff No. Rly Class
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
43
ANNEXURE 20
AIR BRAKE FITTING SECURING ARRANGEMENT REGISTER
Sr.
No
Coach Suspension
Module Securing
Arrangement
BP & FP Hose palm
end Securing
Arrangement
BP & FP Angle
cock Securing
Arrangement
Resetting
of
PEASED
ACP
Isolating
Cock
Checked
Under
Slung
Water tank
Checked
WRA
Module
Checked
Choke Hole
Size of PEV to
Be checked No. Rly. Class
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
44
ANNEXURE 21
ALARM CHAIN PULL TEST REGISTER
S.No Coach
Force Of
Alarm Chain
Pull
Pressure
Kg/Cm2
Wkg. of Equip. Pilot
Valve
Proper/ Improper
Movement of Brake
Cylinder Piston
No/Full/Partial
No.& Name of Defective
Parts which Repaired/
Changed No. Rly. Class FP BP
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
45
ANNEXURE 22
TRIP SCHEDULE ITEMS
1. Washing & cleaning internal & external (Lav & pan).
2. Lubricating moving / rubbing parts. (Screw coupling , Buffer Face, Pinion in
Vacuum System.)
3. Check Dash pot & side bearer bath.
4. Examine under gear safety fastenings.
5. Examine safety brackets strips & ropes.
6. Visual examination of tyre profile.
7. All axle boxes & examine front cover, bolts, & covers.
8. Examine the brake gear & adjust & brake block clearance.
9. Check lavatories fitting including taps & flushing valves for proper working.
10. Check underslung water tanks fastenings.
11. Clean & open lavatory drain holes drain pipes & commode chute .
12. Check upper berths & racks & Amenity fittings.
13. Deodorant the lavatories & compartments.
14. Air brake test system & including working of SAB & DA valve & vac.
15. Test alarm signal apparatus.
16. Check door window, including safety latches & catches & Tower bolts.
46
ANNEXURE 23
DUTY-DIARY
DATE DUTY HOURS DAY DEPOT NAME OF MAINT. ENGR
Sr.
No
Train
No.
Memo
No.
Time
Recd
Wshg.Sidg.
Pit / Line
Load Time Line
Blocked
Time Line
Released
Time Unfit
Memo Issued
Time of
Replaced
Remark
Detail of coaches marked unfit from incoming rake. ……………………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………
RAKE PARTICULARS
Sr. No.
Coach Particulars
POH Detail
IOH Detail
"B" SCH
Detail.
"A" SCH
Detail
Safety BKT.
Fastenings
SAB
No Rly Class Type Shop Date Dt.of
Ret.
Date Depot Date Depot Date Depot
47
Sr.
No
.
STAFF DISTRIBUTION
FOR UNDER GEAR WORK
STAFF NAME
T. NO.
Sr.
No
.
STAFF DISTRIBUTION
FOR INTERIOR
WORK/AMENITIES
STAFF NAME
T. NO.
1 Draw Gears, Buffers & Screw
coupling, Oiling, Lubrication
of all rubbing parts & Lugg.
Comptt. Sliding door.
1 Water pipe fittings
2. Carpentry
3 Trimming
4 Painting
2 Running gear pit
Rt. Side-
Lt. Side-
5 External Washing
6 Compartment Sweeping
3 Brake rigging / Brake power
7 Interior Dusting
4 Vac. Brake / Air brake testing 8 Glass shutters cleaning
5 Pipe Fittings 9 Washbasin cleaning
6 Carpentry 10 Commode cleaning
7 Other specific work 11 Lavatory pan cleaning
12 Watering
13 General other cleaning
14 Dis-infection of lavatory
15 Insecticide spray
16 Other specific work
Angle
cock
'A'
Dime-
nsion
DAV
/ DV
Alarm
signature
App./
V/Valve
DPO level of
leaking
D/pot,
Buffer oiling
Brake
power
piston
stroke
Wheel
tread
profile
Doors
shutters
assembly
Lavatory
fitting &
drain
Berth
&
rack
Deficiencies allowed/attended
L/G M/S V/S G/S CCR WPP
STAFF POSITION DETAIL
1 Sanctioned 4. Sick
2. Present 5. On Line
3. Leave 6. Absent
48
ANNEXURE 24
“ A” SCHEDULE FORM PERIODICITY – ONE MONTH +_ 3 DAYS
TRAIN NO……….
COACH NO…..…… RAILWAY………
TYPE…………… DATE…………… DUTY…………..
Sr.
No.
DESCRIPTION Remark Staff name & signature
Cleaning
1. Coach & lavatory pan intensively
2. Commode chute with scrapping / Painting
3. Water tank with flushing
4. Chimney of Pantry car / Buffet car
5. Centrifugal dirt collector
6. DA valve & SAB
Checking & inspection
1. DA valve & SAB
2. Sliding door of SLR
3. Alarm chain & Clappet valve
4. BP & FP (Including grip seal & union joints )
5. Brake cylinder suspension strap
6. Air hose & clips ( For leakage )
7. Palm ends ( For Cracks )
8. “B” Clearance
9. Draw bar
10. Locking pins & beam
11. Draft key locking pin
Oiling
1. Oil level in side bearer
2. Oil level in Dashpot 1. 9.
2. 10.
3. 11.
4. 12.
5. 13.
6. 14.
7. 15.
8. 16.
Note- All items of Trip maintenance to be attended.
SIGNATURE OF SSE / SE SIGNATURE OF JE I / JE II
49
ANNEXURE 25
“B” SCHEDULE FORM
PERIODICITY- THREE MONTH +- 3 DAYS
TRAIN NO………
COACH NO………… RAILWAY……….
TYPE…………… DATE…………… DUTY………………
Sr.
no.
Items Remarks Staff name &
Signature
1. Examination trough floor turn under & other
under frame member underneath for corrosion.
2. Examination and repair of roof water leakage.
3. Touch-up painted surface where found
necessary.
4. Overhauling & Testing of alarm chain & its
apparatus.
5.
Overhauling & Testing of Release valve
6. Examination of Neck rings of vacuums
cylinders.
7. Examination of Guard emergency van valve for
correct drop in pressure.
8. Examination of brake gear components for wear
and damage
Note- All items of Trip maintenance & "A" Schedule to be attended.
SIGNATURE OF SSE / SE SIGNATURE OF JE I / JE II
50
ANNEXURE 26
“C” SCHEDULE FORM
PERIODICITY: 6 MONTH +- 7 DAYS
TRAIN NO. COACH NO. TYPE RLY
DATE OF POH DATE OF RETURN PLACING TIME- RELEASING TIME
1. BODY.
Sr. No. DESCRIPTION REMARKS
1.1 Condition of Floor
1.2 Condition of roof finishing
1.3 Condition of painting inside or outside
1.4 Condition of floor and structure for corrosion
1.5 Vestibule
2. BUFFERS
Sr.
No.
Description 1 2 3 4
Before After Before After Before After Before After
2.1 Buffer height
(1090-1105 mm)
2.2 Buffer projection
(584-635 mm)
2.3 Buffer head stock
2.3 Plunger wear
3. BUFFERS PACKING AND CLEARANCES
Sr.
No.
Description 1 2 3 4 5 6 7 8 Remark
3.1 Bolster clearance or
„B‟ clearance
Before
After
3.2 Crown clearance or
„A‟ clearance
Before
After
3.3 Fiber packing rings Before
After
3.4 Compensating ring Before
After
3.5 BSS C/Rings Before
After
3.6 Wheel dia Before
After
4. DRAW GEARS AND SCREW COUPLINGS
Sr.
No.
Description Remarks
4.1 Projection of draw bar shoulder hook (max. 32 mm)
4.2 Wear of draw hook at any section (max. 10 mm)
4.3 Condition of Rubber pads worn/perished/damage
4.4 Condition of suspension hook and L bracket
4.5 Condition of screw coupling
a) Shackle Pin
b) Turnion Pin
c) Shackle hole
d) Pins hole
e) Draw hook hole
f) Lubrication
51
5. SAB (SLACK ADJUSTER BARREL)
Sr.No. Description CV End NCV End
5.1 SAB – Make/Tag No./Date
5.2 „A‟ Clearance of SAB
5.2a ICF – 20 +2/-0 mm High 22 +2/-0
6. SIDE BEARER ARRANGEMENT
Sr.No.
Description
BEFORE THICKNESS AFTER THICKNESS
CV END NCV END CV END NCV END
N S N S N S N S
6.1 Side bearer wearing piece
New - 45 mm,, Cond. – 42 mm
High Speed cond. – 43.5 mm
6.2 Side bearer wearing plate
New – 10 mm, Cond.- 8.5 mm
6.3 Securing of oil filling plug with chain
6.4 Ensure requisite oil level in both
(2 ltrs. Servoline 68)
7. DASH POT ASSEMBLY / AXLE GUIDE SPRING
Sr.No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
7.1 Dash pot spring
7.2 Tag No.
7.3 Date
7.4 Dash pot cover
7.5 Bottom seat
7.6 Sealing ring
7.7 Circlip ring
7.8 Guide cap
7.9 Oil level (Before)
7.10 Oil level (After)
8. BOLSTER ASSEMBLY
Sr. No. Description 1 2 3 4 5 6 7 8
8.1 Bolster spring
8.2 TAG No.
8.3 Date
8.4 Colour Code
8.5 Suspension Shackle Link & Stone
8.6 Magnaflux Testing of Shackle
8.7 Bolster Stay Rod
8.8 Anchor link Assembly
9. BRAKE GEAR
Sr.No. Pins & Bushes Pins &
Cotter
Bushes BK.Beam
Hanger
Brake
Shoe
Float
Lever
“Z”
Bracket
Connecting
Rod
9.1 Worn out / Defective
Max. Radial clearance
1 mm
9.2 Replace
9.3 Remark
52
10. WHEEL
Sr. No. Wheel No. &
Diameter
Stamp
No.
Flange
Thickness
Wheel Distance
Gauge
Wheel
profile
Tyre
Turning
Remark
10.1 1-
10.2 2-
10.3 3-
10.4 4-
10.5 5-
10.6 6-
10.7 7-
10.8 8-
11. AXLE
Sr.
No.
Axle Box
No. &
Tag No.
Ultrasonic Test of
Axle
Condition of axle box Roller Bearing Remarks
Done Same wheel Good Defective Tag No. Date
11.1 1-
11.2 2-
11.3 3-
11.4 4-
11.5 5-
11.6 6-
11.7 7-
11.8 8-
12. AXLE BOX GUIDE ARRANGEMENT
Sr.No. Description CV End NCV End Reason
12.1 Condition of guide bushes for
bent/damaged guides
12.2 Securing of Guide cap
12.3 Condition of jumper bolt/Roller
guide bushes pin etc.
13. IR PACKINGS AND AXLE BOX SPRINGS
Sr.No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
13.1 Condition of IR
packing
13.2 Free height in mm of
Axle springs
14. CENTRE PIVOT
Sr.No. Description CV End NCV End
14.1 Availability of locking plate
14.2 Tack welding of nut at bottom
14.3 Condition of silent block
14.4 Condition of bolts and nuts
14.5 Condition of Pivot Cotter
14.5 Condition of Pivot Cotter
53
15. BSS HANGERS AND BLOCKS
S. No. Description Yes No
15.1 Pairing of BSS Hangers & Blocks
15.2 Inner length of hangers Max 387 mm
15.3 Wear of hanger block
(max wear – 1.5 mm, Cond. size – 9 mm)
15.4 Wear of BSS pin(cond. dia 35.5mm)
Sr. No. Description Yes No
16 ICV Modified
Sr. No. Description FP BP
17 Third clamp on dirt collectors (Yes/No)
S.No. Items 1 2 3 4
18 Shock Absorber
19 Anchor Links & Bushes
Sr. No. Description Remarks
20 Filter pipe (Dirt collector/DA valve)
21 Drain Cock of AR Tank
22. Under frame pipe line condition
23. Guard for AR drain cock
24. Condition of equalizing stay assembly
25 Brake beam assembly
26 Brake shoe head
27 Single car testing/BVT
28 2 kg/cm2 train pipe testing
29 Indo-German modification carried out.
30 Safety brackets, Chain, Ropes.
Note- All items of Trip maintenance & "A" & " B " Schedule to be attended
Signature of SSE/SE Signature of JE 1 / JE II
54
ANNEXURE 27
CHECK-LIST
TRIMMER
Sr. No. Item Defect Attention Remark Staff Name &
Signature
1. Rexene
2. Curtains
3. Vestibule Canvas
4. Carpets
5. Magazine Pocket
6 Chain Cover
7 Luggage Cover
PAINTER
Sr. No. Item Defect Attention Remark Staff Name &
Signature
1. Touchup
2. Stenciling
BLACKSMITH
Sr. No. Item Defect Attention Remark Staff Name &
Signature
1. Body Panel
2. Window Bar
3. Bent Foot Board
4. Bent Fall Plate
PIPE FITTER
Sr. No. Item Defect Attention Remark Staff Name
&
Signature
1. Water tapes / Push Cock
2. Commode sheet & Lid
3. Commode chute & Cover
4. Side filling pipe
5. Water tank (OHT)
6. Under slung tank
7. Under slung pipe line
8. WRA pipe line / Mono Block Pipe Line
9. Supply pipe line
10. Wash basin
11 Wall protector
12 Flush Valve pipe
13 Fish tail
14 Squatting pan
15 Spout assembly (Upper class)
16 Pipe line securing arrangement
17 Drain pipe
18 Non return valve
19 Boiler supply (power car)
20 Boiler tray
21 Kitchen sink (power car)
22 Flush Cock
55
UNDER GEAR FITTER
Sr. No. Item Defect Attention Remark Staff Name &
Signature
1. Dashpot spring
2. Dashpot vertical lug
3. Dashpot vertical lug loop
4. Bolster spring
5. Bolster safety lug
6. Bolster safety lug loop
7. Shock absorber
8. Shackle link
9. Shackle stone
10. Brake shoe
11 Brake block
12 Brake beam (on pit).
13 Trough floor ,,
14 Trolley for welding any crack portion
15 Jumper bracket (On pit)
16. Pipe line (AB / VB)
17 Axle holding arm (BEML)
18 Eccentric pin & Bush ,,
19 Swing link bolt ,,
20 Centre pivot carrier ,,
21 Leaf spring ,,
22 Bell nut ,,
23 Main door pivot
24 Door handle
25 Hand rail
26 Drag link (BEML)
27 Buffer face
28 Buffer plunger
29 Buffer socket
30 Buffer bolt
31 Head stock patch
32 Dead Buffer / Buffer Telescopic tube
33 Draw bar hook
34 Screw coupling
34.1 Shackle
34.2 Screw rod
34.3 Turnion nut
34.4 Lever
35 Draw bar draft locking plate & key
36. Draw bar guide plate & lug
37 Suspension hook
38 Dummy carrier
39 Draw bar assembly pin
40 Draw bar spindle (on pit)
41 Fall plate
42 Fall plate securing arrangement
43 Axle link (on pit)
44 Stay rod ,,
45. Stay rod bracket (on pit )
46 Wheel ,,
47 Axle box cover
48 All isolation Cocks
49 Cut off Angle Cock
50 BP FP Air Hoses
56
51 AR Tanks
52 Non Return Valve
53 Brake Cylinder & Securing
Arrangements
54 Anti Vibration Brackets
55 Flexible Air Hoses
56 All Pins & Cotters
57 Drain Hole Cocks
58 Underslung Water Tank Securing
Arrangement
59 Condition of SAB & "A" Dimension
CARPENTER
Sr. No. Item Defect Attention Remark Staff Name
&
Signature
1. Mirror
2. Window glass
3. Window shutter
4. Window pocket
5. Body panel
6. Shelf
7. Coat hanger
8. Barrel bolt
9. Lavatory bolt
10. Any broken seat / berth
11 Safety chain
12 Holding chain (berth)
13 Wash basin
14 Ash tray
15 Door closer (upper class)
16. Sliding door ,,
17 Luggage door ,,
18 Slam door lock
19 Reclining gear (AC chair car)
20 Guard seat (In SLR )
21 Folding table
22 Parcel rack
23 Commode cover
24 Ceiling
25 Flooring
26 Foot board
27 Frosted glass
28 Foot step (upper class)
29 Vestibule door
30 Vestibule frame
31 Window frame
32 Berth holder stopper
*****
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