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s.
Activities
Clause
Observation
1
Lifting Shop:
Reference : Maintenance Manual of BG Coaches LHB design
Lift
- Coach Body
(On receipt of a coach for Shop Schedule-I 65-)/ Shop
Schedule-II (SS-II)/ Shop Schedule-III (SS-IIN), it must
be taken on Lifting line/ Stripping line where electrical
fittings should be stripped and batteries removed
Furnishings, especially seats and backrests should be
inspected thoroughly and only those that require
repairs or attention should be removed.
2.9.2a
Before lifting a coach, the following components should
be removed, disengaged or disconnected:-
(i) Wheel sets earthing equipment.
(il) Speed sensor cover.
(iii) Yaw dampers
(iv) Hose and pipeline connections from Bogies to
coach.
(v) Centre pivot security plate
(vi) Bolster from coach body by means of removing
nut & swing nut.
Allair brake fittings
Control arm bottom cover
Centre Buffer Couplers etc
cDTs
Under slung water tanks & Water Raising
Apparatuses (WRA), where provided.
Battery box and electrical fittings.
(xiii) AC equipment in AC coaches.
2.9.26
Coach body should be lifted off the bogies either by two
overhead electric cranes of 25 t capacity each with
suitably designed lifting tackles or by four powered
lifting jacks of 15 t capacity each operated
simultaneously by one control switch. The coach body
should be lifted uniformly without jerks and should
remain horizontal during the lifting/ lowering
operation. Coach should not be lifted from any point
other than at the lifting pads.
29.26
The coach should never be lifted from one end only. If
lifted from one end, the Centre pivots security plate are
likely to suffer damage, body panels are likely to get
dented near the body bolster.
The sealed windows of AC coaches are also likely to
break.
29.24
‘After the coach body is lifted, it should be kept on
trestles. The steel trestles of the design as mentioned in
the manual would prove useful for this purpose. Lines
should be protected by scotch blocks with locking
arrangement and key should be kept with Engineer till
the time maintenance work is carried out.
29.2
Page 1 of 50 Activities Clause Observation
6 The entire under frame should be cleaned of dust, rust | 2.9.2
etc. from underneath by pneumatic/water jet followed
by wire brushing at critical locations and check for
cracks/damage, corrosion etc. on the under frame
members.
7 After carrying out all repairs, the under frame should | 2.9.28
be painted.
8 ‘Lowering - Coach Body 294a
After all the repairs are carried out refit all repaired
sub-assemblies, which are removed for maintenance
and lower the coach body on the overhauled and tested
bogies.
All the pipelines and hose connections between coach
body and bogies to be re-connected properly. Proper
fitment, tightening and safety of the safety brackets of
bogies and under slung items to be ensured.
9 |The securing arrangement of Centre plate should be | 2946
fitted into position and secured by means of necessary
fittings.
10 | Height of CBC:
i. Height of CBC of a coach under its tare condition 295
should be as under:
Maximum height | Minimum
from rail level | heightfrom rail
level
Production [1105 mm 195mm
units
Workshops [105mm 1090 mm,
ii, CBC height of a coach should be measured under its
tare condition from the top of the rail on a level and
straight track, For this purpose, a specific portion of
the track should be earmarked in each carriage repair
workshop.
‘The height should be measured from the rail level to
center of shank.
iv.Before the height adjustment of CBCs of the coach is
taken up, it should be ensured that both the couplers
have been fitted properly.
v. The diameters of all the wheels measured before the
assembly of the bogies must be available with the
staff carrying out the height adjustment of CBCs.
TI _ |The followings Tools & Equipments are required for
maintenance. This list is not exhaustive and may
require additional items as required.
1. Hydraulic lifters (Jacks) for lifting the coach body
capacity 15 Ton - 4 Nos. or EOT cranes 251/10 T-2
Nos.
Page 2 of 50 SN.
Activities
Clause
Observation
2. Tool Kit (torque wrenches, allen keys, pliers,
spanners set etc.)
3. Rail cum Road vehicle for shunting,
4. Trestles
5._Welding equipments
12
Housekeeping, segregation of clean and dirty area,
proper stacking of materials, segregation of rejected
and serviceable materials, Proper material handling
being done in the section or not.
Availability of Personal Protective Equipments (PPEs).
rr
Display and availability of the work instructions.
Page 3 of 50
2024 - 02 - 29 Introduction of BG Open Steel Wagon BOSM - 22 - 9t Max Speed 85kmph in Empty & 75kmph in Loaded Over IR and Max Speed 85kmph in Empty & 100kmph in Loaded Over E&W DFCCIL Routes
