Quality Audit report
Of
Coaching Depot
Lucknow, NE Rly
Report no. 21/2012
APRIL 2012
(Audit is done by CRSE, ECR)
Page 1 of 26 Coaching depot – LJN, NE Rly. April 2012
Quality audit Report of
Lucknow Jn. Coaching Depot, NE Railway
1.0 Introduction
As per instruction of Board vide letter No.2012/M(W)/814/5 dated 20.03.2012
and briefing by ED/QA/RDSO on 23.03.12, quality audit of LJN Coaching
Depot was done on 30th and 31st March, 2012. The team consisted of
CRSE/Chg., Dy.CME/CRW/HRK and 2 supervisors. At the outset all officers
and supervisors were briefed about the purpose of audit.
1.1 Audit team
Shri Hamid Akhtar, CRSE/Chg/ECR and Shri Janardan Prasad,
Dy.CME/CRWS/HRK,
1.2 Date of Audit 30.03.2012 and 31.03.2012
1.3 Escorting officers from depot
Shri Jairam Sandeep, Sr.DME/C&W/LJN and Shri D K Tiwary, CDO/LJN
1.4 Scope of audit
Entire coaching depot including washing Pit, Sick line, stores, wheel lathe,
Linen washing facilities, Depot records of various schedules, detachments,
DDR and Feedback.
2.0 Brief about LJN Coaching Depot
LJN Depot is at the Junction of NR and NER system. The Depot maintains 6
M/E, 1 passenger (Total 14 rakes) and 1 secondary maintenance apart from
platform return trains. It has 2 washing Pits 1 Sickline with all associated facilities
including Pit wheel lathe and 1 Linen washing facility.
3.0 STRENGTHS
3.1 The coaching depot though has only 242 coaches (bordering medium and
major depot), is spacious having 2 washing pits with 26 coach capacity,
adequate length of sick line (75x15 Mts. 4 coaches), adequate capacity service
building, 20/5 tonne capacity crane and pit wheel lathe. The surrounding area is
spacious and there is scope for capacity augmentation.
Page 2 of 26 Coaching depot – LJN, NE Rly. April 2012
3.2 Development of Training Coach: a cut model of Coach depicting all under gear,
under slung and other details like CBC, turn under, etc has been made for
training purpose.
3.3 A useful gadget has been made for PVC fitment in the toilets. Systematic
fitment, using the gadget, shall reduce water seepage.
3.4 Rolling In Hut – An all weather Rolling-in Hut has been developed and
commissioned at Lucknow Junction.
3.5 Water Tank Testing Equipment: The testing equipment has been developed to
test the Water tanks under specified water hydraulic pressure of 0.34 kg/cm2 to
check the conformity of welded joints.
4.0 Weaknesses
4.1 High pressure jet is not being used on Primary rake reportedly due to non
supply of power. This is affecting cleaning of coaches.
4.2 One supervisor is managing under gear and coach body/interior examination,
this indicates that the practice is common.
4.3 Revised maintenance pattern JPO, certificates for other end facilities etc are
not available in the Depot for references.
4.4 Brake Blocks are not being changed in set of bogie (as checked from records)
4.5 A number of passenger amenity items (60% of magazine bags, bottle tumbler,
skirt moulding, PVC floor and trimming) were found deficient/damaged in the
rake.
4.6 No record of Temperature of Rolling-In of Primary Trains is maintained.
4.7 Fire extinguishers in AC coaches are being provided and maintained by
Electrical Department. The fire extinguishers were overdue testing.
4.8 Facilities for platform return attention such as High pressure pipeline, Flood
light for Rolling-in examination, and Inspection light along the track are not
available on LJN platform.
4.9 No illumination facility is available inside washing pit for under gear
examination. The Overhead light which is available is highly inadequate to
perform work.
Page 3 of 26 Coaching depot – LJN, NE Rly. April 2012
4.10 History card is not being maintained in computer or even in register. No system
exists.
4.11 Due to non-availability of road transport for overhauled trolley for movement
from GKP workshop to LJN depot, due IOH coaches are being sent to GKP
coaching depot for changing of trolleys. This has led to practice of schedule ‘C’
attention to mail/express coaches (without using workshop overhauled trolleys).
4.12 There is no system of recording about, coaches being detached at the
secondary end or en-route. As such analysis and action is not being taken
systematically.
4.13 Availability of gauges and quality of supervisor needs improvement. Gauges for
buffer face plate, wearing piece (side bearer) were not available. Supervisors
were not aware of their importance. It would be appropriate to arrange training
in the depot for inspections.
4.14 Quality of linen washing is poor as calendaring machine has been out of order;
bleach is not being used in adequate concentration. Over-aged linen are not
being replaced as per stipulations. Supply of polyester quality of linen (for 1st
AC) is also poor. Stacking of linen is being done in shabby condition at floor.
Page 4 of 26 Coaching depot – LJN, NE Rly. April 2012
Check sheet for Quality audit of LJN/NER coaching depot
Primary maintenance attention and sick line attention
(Based on CAMTECH Maintenance Manual for BG coaches and
Railway Board / RDSO’s guidelines)
SN Item Clause Observation
1 Periodicity of periodic overhauls (POH) in
designated workshops is being followed.
103 of Chg.Manual
Table 1.1 and
correction slip 5
issued in 2008
RB letter no. 2007/M
( C)/141/1 dtd
26.09.08
Coach holding – 242
( M/E- 183, Pass-59)
Overdue POH – Nil
2 Maintenance schedules to be followed in
coaching depots
To maintain coaching stock in good
condition, the following maintenance
schedules are prescribed to be carried out in
carriage depots on divisions where rake has
been based for primary maintenance.
112(a) of Chg.
Manual and
Correction slip 5 for
coaching
maintenance manual
issued in 2008
RB letter no. 2007/M (
C)/141/1 dtd 26.09.08
3 Schedule A - Monthly (1 month ± 3
days) in rake
Overdue Sch ‘A’ –Nil
(As per register checked)
4 Schedule B -Quarterly (3 month ± 7 days) in
rake
Overdue Sch ‘B’ – Nil
(As per register checked)
5 IOH attention - detach coaches
Periodicity of IOH attention:
Coach
Category Periodicity
New coach at interval of 12
months in Depot
Rajdhani
Satabdi (Conv)
at interval of 9
months in workshop
Mail / Express at interval of 9
months in depot
Passenger at interval of 9
months in depot
Other OCVs at interval of 12
months in depot
Tolerance for IOH may be kept as + 30/-
0 days.
Maintenance activities to be carried out
during schedules should be as per Appendix-
F & G.
For IOH attention of newly built coaches,
guidelines as circulated vide RB’s letter no.
2007/M ( C)/141/1 dtd 06.08.09
Overdue IOH - Nil
(As per register checked)
None of the coaches checked
were found overdue for any
preventive schedules. However,
09 coaches out of 23 coaches
checked on rake of Train no.
12533 had ‘C’ schedule
stencilled over their end panel in
place of IOH. On query, it was
told that since there was
shortage of bogie (overhauled)
from GKPS, coaches were given
‘C’ schedule on 6 month basis at
LJN itself. Out of a load of 23
coaches, 09 coaches had been
given ‘C’ sch., 11 recent POHed,
03 MLR return
6 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. ‘C’
schedule should be done at base depot.
112(b) of Chg.Manual A & B Schedules of coaches is
being undertaken in depot as per
their arising/periodicity
IOH- is not being done at depot
as road contract for
overhauled trolley is not in
place. Coaches are being sent to
GKP depot for change of trolley.
Page 5 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
7 Examination of originating trains: 107 a of Chg. Manual
This is being ensured in
accordance to CAMTECH
manual and none of the primary
maintained train is allowed to
leave Pit with Brake power less
than 100%.
7.1 All trains must be examined by the
mechanical train examining staff before
despatch to ensure all coaches are in fit
condition without rejectable defects.
107 a (i) of Chg.
Manual
TXR staffs are examining all
coaches before dispatch to
destination.
8 Terminating Examination of Passenger
Trains – Rolling in examination.
107 b of Chg. Manual
Being done
8.1 Site shall provide unobstructed view of under
gear from both sides.
107 (b)(i)(a) of
Chg.Manual
Ok
8.2 Should have adequate space for fixing the
lighting arrangement and for staff
107 (b)(i)(d) of
Chg.Manual
Available.
8.3 As the train passes the nominated point,
C&W staff should watch out vigilantly for
loose/hanging/broken under gear parts of the
coaches, any unusual sound coming from
the coaches or any other abnormality in the
coaches.
107(b)(iv) of
Chg.Manual
Two staffs i.e. 01 from N/S & 01
from S/S carryout rolling-in-
examination and take action
accordingly in case of any
deficiency observed.
8.4 Temperature of the axle boxes should be
measured preferably with the help of the
electronic temperature measuring device.
107(b)(vi) of
Chg.Manual
No records being maintained.
Although temp being taken (as
per CDO)
9 Revised maintenance pattern for coaching
trains circulated vide Railway Board’s letter
No.95/M(C)/141/1 dt.31.01.07
Railway Board’s letter
No.95/M(C)/141/1
dt.31.01.07
JPO is not available in the
depot
9.1 While permitting introduction of round trip
primary pattern of maintenance on coaching
trains, approved mandatory condition at
primary end and other end as detailed in
Railway Board’s letter No.95/M(C)/141/1
dt.31.01.07 is followed.
Railway Board’s letter
No.95/M(C)/141/1
dt.31.01.07
6 M/E primary trains run with
Round trip certificate. As per Sr
DME LJN, certification regarding
availability of other end facilities
has been ensured.
9.1.1 Primary End
i) The brake gearing should be properly
adjusted including the slack adjuster ‘A’
dimension & the brake cylinder stroke to
ensure 100% brake power
-do- Being done wherever applicable
i.e. in UFMBC
ii) Brake blocks should be changed in bogie
sets only
-do- Not being done as per register
checked
iii) All missing passenger amenity fittings must
be replaced and the rake must be turned out
as ‘Zero-Missing-Fitting’ rake.
-do- Not being done in totality
iv) Intensive cleaning of coach toilets and
lavatory.
-do- Being done
v) Clear maintenance time of 6 hours on the pit
as per train schedule.
-do- Being followed religiously
vi) Provision of proper washing cum
maintenance pit line facility with adequate
testing equipment and high pressure jet
cleaning plant at primary end.
-do- The depot is spacious having
adequate washing pit capacity (2
* 26 coach length) of CAMTECH
design and SL capacity 3.5 8 75
meter, building, road and
surrounding space.
Page 6 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
vii) Adequate gang strength with proper
supervision
-do- No. of supervisors less (one
supervisor was managing both
upper gear and under gear of
Pushpak rake.
9.1.2 The Other End
i) Whenever the lie-over is more than 2 hours
at the platform or the rake is stabled in the
yard, the rake should be locked and positive
security should be provided.
-do- Being followed
ii) The minimum infrastructure to be provided at
the platforms from where trains are returned
without secondary maintenance should be is
available
-do- No floodlight for Rolling in
examination
No inspection light along the
side of the track
No covered drains
iii) A joint safety certificate covering each clause
of mandatory conditions will be issued by
mechanical and operating branches at
divisional level prior to changing over any
train to revised coaching maintenance
pattern.
-do- No information available
10 Rake maintenance link has provision of
maintenance time (pit attention) of 6 hrs at
primary end to enable intensive attention.
108 of Chg. Manual
and Policy circular no.
4
No information available
11 Internal cleaning, Passenger amenity
attention and watering is done at platform
line or nominated stabling line provided
stipulated facilities are available at such line
is followed
108 of Chg. Manual
Table 1.8
Yes, it is being followed
12 Washing and cleaning of coaches 109 of Chg.Manual
12.1 Use recommended solutions for cleaning as
per RDSO specification No.
M&C/PCN/101/2001 or use cleaning agents
approved by CME of the Railway
109 of Chg.Manual Cleaning agents as advised vide
contract / tender awarded are
being adhered to e.g. Johnson
Diversy, Taski etc.
12.2 It should be ensured that the rake/coach is
protected with proper board/signal for safety
of the staff working on washing/cleaning job
to prevent movement/disturbance in the
activity. Scotch blocks with locking
arrangement should protect lines and keys
should be kept with Engineer (C&W) till the
time rake is under maintenance.
109 (b)(i) of
Chg.Manual
Rake protection using stop board
during maintenance at pit is
being done. Use of scotch blocks
is being done.
12.3 External cleaning /washing:
Check that guidelines as detailed in
CAMTECH manual are being followed.
109 (b) of
Chg.Manual
High pressure jet was not
being used reportedly due to
non supply of power.
12.4 Cleaning of Toilet:
Check that guidelines as detailed in
CAMTECH manual are being followed.
109 (c) of
Chg.Manual
Toilets’ cleaning satisfactory.
Guidelines are being adhered to.
12.5 Internal cleaning of upper class AC and
sleeper coaches:
Check that guidelines as detailed in
CAMTECH manual are being followed.
109 (d) of
Chg.Manual
Being satisfactorily done.
Garbage collection followed by
dry sweeping is being done. Use
of dry vacuum cleaning not
being done.
12.6 Internal cleaning of GS, SLR:
Check that guidelines as detailed in
CAMTECH manual are being followed.
109(e) of Chg.Manual Being done
Page 7 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
12.7 Cleaning of buffers and screw couplings 109(f) of Chg.Manual Being done
(i) Buffer plungers should be scrubbed with a
scraper to remove dirt and muck. Thereafter,
they should be wiped clean with cleaning oil
and rubbed with coir rope.
109(f)(i) of
Chg.Manual
Being done
(ii) Screw coupling threads should be cleaned
with wire brush to remove all dirt and dust.
Thereafter, it should be cleaned and given a
light coat of oil. Oiling should be done on
slack adjuster also
109(f)(ii) of
Chg.Manual
Being done.
13 Conditions required for maintenance of 24
coach trains (Railway Board’s letter No.98/M
(C) / 137/19 Pt.I dt.28.7.99 & 5.5.2000
110 of Chg.Manual
13.1 Infrastructural requirements 110(a) of
Chg.Manual
(i) 24 coach length fully equipped pit line. 110(a)(i) of
Chg.Manual
Available
(ii) High pressure jet cleaning pipeline with plant
for cleaning at primary pit line. Mechanized
external cleaning is preferable
110(a)(ii) of
Chg.Manual
Available
(iii) Water hydrants for 24 coach length at en
route watering stations with 20 minutes
stoppage at nominated stations
110(a)(iii) of
Chg.Manual
Hydrants with 6” header pipe
available on CAMTECH design
(iv) Availability of the prescribed air brake
maintenance and testing equipment
110(a)(iv) of
Chg.Manual
Available
13.2 Coach Design related requirements 110(b) of Chg.Manual
(i) Air brake with twin pipe graduated release
system
110(b)(i) of
Chg.Manual
Available in all coaches
(ii) Only enhanced capacity draw gear and
screw coupling to RDSO sketch No. 79061
and 79067 are to be provided on the rake
110(b)(ii) of
Chg.Manual
75 T screw couplings available in
all coaches
13.3 Maintenance practices and system related
requirements
110(c) of Chg.Manual
i) The integrity of the rakes to be maintained. 110(c)(i) of
Chg.Manual
Being maintained
ii) Primary maintenance of the rake should be
done in one hook without splitting
110(c)(ii) of
Chg.Manual
Being done
iii) Minimum maintenance time of 6 hours on the
pit during primary maintenance
110(c)(iii) of
Chg.Manual
For train no. 15011 (LJN-
Chandigarh Exp) 6 hrs time is not
possible due to non availability of
washing pit slot as per this train
timing. For other trains
maintenance time of 6hrs is
available.
iv) It is mandatory to provide secondary
maintenance to all trains augmented to 24
coaches (RPC 4 revised and permit Round
trip attention with approval of CME)
110(c)(iv) of
Chg.Manual
Round Trip attention as per RPC
4 revised
v) Trains leakage rate to be maintained within
prescribed limits by using rake test rig.
110(c)(v) of
Chg.Manual
Being maintained strictly
vi) Provision of proportionate brake system on
the locomotive in good working order
110(c)(vi) of
Chg.Manual
Not checked
vii) Provision of audio visual alarm system on the
locomotive
110(c)(vii) of
Chg.Manual
Not checked
14 Fire extinguishers should be checked every 111(f)(i) of FEs supplied on board by C&W
Page 8 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
three months and completely refilled after
one year.
Chg.Manual was found ok. However, FEs
supplied by electrical
department’s AC wing in AC
coaches of 12533/34 were
overdue for testing.
14.1 Provision of DCP type fire extinguisher in a
rake should be in accordance with guidelines
circulated vide letter no. 95/Sec (spl)/75/1 dtd
30.05.97
Coach type Nos of FE’s
Each Break Van 2 nos found
Each AC coach 2 nos found,
overdue for tesing
Each Pantry car 4 nos found
Each Generator
van
2 nos NA
RB’s letter no. 95/Sec
(spl)/75/1 dtd
30.05.97
DCP type fire extinguishers are
in use as per this norm.
15 Similarly, other brake van equipment, which
Mechanical Train Examining staff is
responsible to supply, should be provided
according to the instructions of each Railway.
Portable control telephones, portable train
lighting equipments, portable fire
extinguisher, wooden wedges/skids and
stretcher are to be provided.
111(g)(i) of
Chg.Manual
Available in side SLR of the rake.
16 Watering and cleaning of rakes
Mechanical department of each railway will
nominate the watering and the cleaning
stations on the railway.
111(h) of Chg.Manual Nominated
17 Deficiency Rolling Stock (DRS) for Coaching
Stock
111(i) (i) of
(i) Railway should devise system for detecting
deficiencies. Reports of deficiencies/ defects
in Rolling Stock (DRS) reports in the
proforma given in Annexure 1.2, should be
prepared for each mail/express/passenger
originating train in duplicate by the Engineer
(C&W)/Electrical (TL) and should be signed
jointly with the RPF representatives.
Chg.Manual DRS is not being maintained in
proforma as given in CAMTECH
manual. However register for
upper gear is sent to platform
office & thereafter given to o/g
guard after joint signature of RPF
& C&W.
(ii) On arrival of the train at the destination
station,, the Engineer (C&W) staff and
electrical staff shall check the rakes jointly
with a representative of RPF and comparison
may be made with original report.
111(5)(b) of
Chg.Manual
Being done
18 Coach Maintenance History Card 111(k)(i) of
(i) Every coaching depot shall have computers
for maintaining the coach maintenance
history in a software programme which
should be compatible with the programme of
the coaching workshop.
Chg.Manual Coach maintenance History
card is not being maintained
(ii) The complete history book of each coach,
consisting of maintenance history cards, date
card, trial card, etc. will, however, be
maintained by the base workshops
111(k)(iii) of
Chg.Manual
Coach maintenance History
card is not being maintained
by Depot
19 Primary/Secondary maintenance
19.1 The rakes/ coaches of all trains should be
given a Primary/Secondary Maintenance
examination as prescribed by the Chief
113(a) of Chg.Manual Being followed as per latest
maintenance schedule.
Page 9 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
Mechanical Engineer of the Railway and as
per Appendix F of Chg.Manual
19.2 Coaches shall be washed and cleaned
thoroughly from outside and inside as
prescribed in clause 109.
113(b) of Chg.Manual Interior cleaning satisfactory.
High pressure jet was not
being used for external
cleaning.
19.3 Brake system maintenance
Air brake system (Bogie mounted and
underframe mounted):
Attention as detailed in para 113 ( c) is being
given during primary /secondary attention of
a rake.
113(c) of Chg.Manual Being done
19.4 In addition to above the following items of
work should be attended during the
maintenance schedule examination:
* underframes
* bogie frames
* axle boxes
* springs.
These items should be wiped with wet
waste weaves or cotton waste as necessary
so as to facilitate examination. All under gear
components should then be examined and
repaired as necessary to ensure that there is
no `S' marked rejectable defect as
mentioned in Chapter IV of IRCA Conference
Rules.
113 (d) of
Chg.Manual
Being done
19.5 The following items of undergear
components should, however, be specially
examined and attended to:-
113 (e) of
Chg.Manual
i) Oil in hydraulic dash pots of Rajdhani and
Shatabdi coaches should be checked once
in 15 days to detect oil leakage from them
through defective seals or through the vent
screw. Add/ replenish with specified grade of
oil if the oil level is below 40 mm in the tare
condition for ensuring better riding comfort.
113 (e) (i) of
Chg.Manual
No Rajdhani rake available /
maintained in depot.
D/pot oiling is ensured & oil is
replenished as & when required
during schedules.
ii) Wheel profiles should be visually examined
and gauged in case they appear to be near
condemning limits.
113(e)(ii) of
Chg.Manual
Being adhered to.
iii) The brake gear should be checked and so
adjusted that the piston stroke is within the
limits specified for different types of coaches.
(see table 1.10). 'A' and 'e' dimensions
for slack adjuster should be as per table 1.11
(as applicable for under frame mounted
brake system).
113(e)(iii) of
Chg.Manual
Coaches checked during sample
check had BMBCs.
19.6 The following coach body components and
fittings should be specially checked and
attended to
113 (f) of Chg.Manual
i) Doors should be properly secured with the
hinges/pivots and should not be grazing with
floor or door sill plates.
113(f)(i) of
Chg.Manual
Checked & found ok.
ii) Door latches and safety catches 113(f)(ii) of
Chg.Manual
Found intact.
iii) Door lock handles 113(f)(iii) of Working freely.
Page 10 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
Chg.Manual
iv) Tower bolts 113(f)(iv) of
Chg.Manual
Available
v) Window shutters should neither be tight nor
loose
113(f)(v) of
Chg.Manual
Ok.
vi) Window shutter safety catches 113(f)(vi) of
Chg.Manual
Available
vii) Window frame 113(f)(vii) of
Chg.Manual
Ok.
viii) Vestibule assemblies of all vestibule coaches
should be checked and repaired as
necessary.
113(f)(viii) of
Chg.Manual
ix) Water pipe connections, flushing valves,
cocks and shower roses should not be
leaking or choked.
113(f)(x) of
Chg.Manual
Found ok.
x) Drain grills and drain holes in the bathroom
floors and wash basin drainpipes should be
cleaned and opened where found choked.
113(f)(xi) of
Chg.Manual
Found cleaned.
xi) Any other deficiency as per Annexure 1.2
should be made good.
113(f)(xii) of
Chg.Manual
xii) A proper record should be kept by Engineer
(C&W) at washing/pit lines of schedules
carried out by them, especially of items
required to be attended at specific
periodicity.
Record to be maintained in standard DDR
(Damage deficiency register)
113(h) of Chg.Manual Being maintained.
Separate registers for ‘B’ & ‘A’
schedules are in place & are
filled in on completion of work.
20 Schedule ‘A’ Examination 114 of Chg.Manual
i. Schedule `A' is required to be given every
month + 3 days at the nominated primary
maintenance depot within the normal primary
maintenance time on a washing/pit line in a
rake.
114 (a) of Chg.
Manual
No coach of rake no.-01
12533/12534 found overdue for
‘A’ schedule when checked at
washing pit on 29/03/12.
ii. Brake system maintenance
Air brake system (bogie mounted)
A schedule maintenance as per air brake
chapter
114(b) of Chg.Manual Being done
iii. The specified items of work should be
attended during Schedule ‘A’ examination,
i.e. monthly examination:-
114(c) of Chg.Manual Found being done in accordance
to instructions laid done in
CAMTECH chg manual.
21 Schedule ‘B’ Examination 115 of Chg.Manual
i. Schedule `B' is required to be given every
three months + 7 days at the nominated
primary maintenance depot within the normal
time allowed for primary maintenance on a
washing line in rake.
115(a) of Chg.Manual Found ok.
Overdue – Nil.
ii. The specified items of work should be
attended.
115(b) of
iii. Brake system maintenance
Air brake system (Bogie mounted)
(i) Same as 'A' schedule
Chg.Manual Being done.
iv. Other assembly maintenance
Besides brake system other items should be
attended as given below:
115(b)(i) of
Chg.Manual
a. All items of Schedule`A' 115(b)(ii) of
Chg.Manual
Page 11 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
b. Painting of lavatories from inside. 115(b)(iii) of
Chg.Manual
Found done.
As per register maintained for the
purpose i.e. records c. Thorough inspection and repairs of brake
gear components.
115(b)(iv) of
Chg.Manual
d. Thorough checking of trough floor, turn
unders, etc., from underneath for corrosion.
115(b)(v) of
Chg.Manual
e. Touching up of painted portion, if faded or
soiled.
115(b)(vi) of
Chg.Manual
22 IOH attention
116 of Chg. Manual
and Correction slip 5
for coaching
maintenance manual
issued in 2008
22.1 Periodicity of IOH attention:
Coach
Category Periodicity
New coach at interval of 12
months in Depot
Rajdhani
Satabdi (Conv)
at interval of 9
months in workshop
Mail / Express at interval of 9
months in depot
Passenger at interval of 9
months in depot
Other OCVs at interval of 12
months in depot
Tolerance for IOH may be kept as + 30/-
0 days.
Maintenance activities to be carried out
during schedules should be as per Appendix-
F & G.
For IOH attention of newly built coaches,
guidelines as circulated vide RB’s letter no.
2007/M ( C)/141/1 dtd 06.08.09
117(i) of Chg. Manual
and correction slip 5
for coaching
maintenance manual
issued in 2008
Upper gear attention of IOH is
done in depot.
For Trolley change the Coach is
being sent to GKP Coaching
depot. There are some cases of
Schedule C of M/E Coaches
due to shortage of overhauled
trolleys.
Rest as per norms.
22.2 Coaches are required to be detached from
the rake and taken to the sick line or sent to
shop for IOH attention (‘C’ schedule
maintenance)
117(ii) of Chg.Manual
and Correction slip 5
for coaching
maintenance manual
issued in 2008
Being done.
22.3 Brake system : ‘C’ schedule maintenance
(IOH) as per para 426 of air brake chapter.
117(a)(i) of
Chg.Manual
No coach was under ‘C’ sch/IOH
on dates. However as explained
this is being followed.
22.4 Thoroughly clean Dirt collector filter in
kerosene or replace on condition basis.
117(a)(vii) of
Chg.Manual
Dirt collector filter was not
available in depot stores, hence it
is inferred that this is not being
done in all cases.
22.5 Other assemblies maintenance
All items of Schedule `B'
117(a)(i) of
Chg.Manual
22.6 Thorough repairs of running gear including
running out of bogies where considered
necessary. All bogies which are working on
rake links earning more than 2.5 lakhs kms.
per annum must however be run out and
thoroughly attended to as laid down in clause
111c under “Intermediate Overhaul”.
117(a)(ii) of
Chg.Manual
Being ensured as per records
Page 12 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
22.7 Touching up damaged paint of coaches on
outside as well as inside.
117(a)(iii) of
Chg.Manual
Is done as per requirement on
condition basis.
22.8 Polishing of the polished surfaces. 117(a)(iv) of
Chg.Manual
22.9 Shock absorbers should be replaced and
sent to the base workshops for repairs,
testing and return. For this purpose,
adequate spares must be maintained in the
depot.
117(a)(v) of
Chg.Manual
Are being sent to shop for repair
& return records checked &
found being done.
22.10 Thorough cleaning and removal of dust, rust,
dirt, etc., accumulated at the pillars through
the turn under holes, with coir brush and
compressed air.
117(a)(vi) of
Chg.Manual
Not in practice.
22.11 Thorough examination and repairs of
upholstery, cushions, curtains, etc.
117(a)(vii) of
Chg.Manual
Being done.
22.12 Thorough checking and full repairs of all
window shutters, safety catches, safety
latches, staples and hasps of compartment,
lavatory.
117(a)(viii) of
Chg.Manual
Is in practice.
Trimmer was seen stitching berth
rexine in 12533/34.
22.13 Thorough checking and repairs of UIC
vestibules, their rubber flanges metal frames,
doors, fall plate, locking gear, etc., for ease
of operation and safety .
117(a)(ix) of
Chg.Manual
Being done as reported
22.14 Thorough checking and repairs of all cracks
and worn out portions of flooring of the
compartments.
117(a)(x) of
Chg.Manual
Being monitored by U/gear TXR.
22.15 Engineer (C&W) of Primary Coaching
Maintenance Depots should be fully familiar
with the vulnerable areas of ICF coaches for
corrosion, viz., sole bar at doorways,
lavatories and adjoining areas, corridor sides
- more so in case of those SLRs which are
used for Fish, Salt, etc. For facilitating
inspection of sole bars even spaced
elongated holes of (215x127 mm) are
already provided in the turn unders.
117 (d) of
Chg.Manual
Standard of supervisors poor as
it was evident during interaction
22.16 Special attention should be taken for the
following:-
117(e) of Chg.Manual
i) Pocket between sole bars and turn unders
should be thoroughly cleaned through the
inspection opening of the sole bars and
inspected with the help of torch light or
inspection lamps.
117(e)(i) of
Chg.Manual
Being done during schedules.
II). Drain holes provided in the trough floors
should be kept clean and unclogged. If
during the cleaning of these drain holes any
accumulation of water is observed, the
affected area should be very carefully
inspected for possible corrosion.
117(e)(ii) of
Chg.Manual
Action being taken in accordance
to defects found during trip
schedule.
III) A register should be maintained of the
primary maintenance coaches on the
subject.
Record of Schedule A, B and IOH attention
are maintained in standard format and
records are maintained.
117(e)(iii) of
Chg.Manual
Records being maintained at
depot level.
22.17
For maintenance of coaches of Rajdhani/
Shatabdi Express Rakes, the instructions
given in RDSO Technical Pamphlet No. C-
118 (b) of
Chg.Manual
NA
Page 13 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
7807 should be followed.
22.18 The IOH of Rajdhani/Shatabdi high speed
coaches should be carried out in workshops
118(c) of Chg.Manual NA
23 Linen management
i. Complete activity of linen management
including washing, storage, supply &
distribution of linen kits in trains shall be
done by Mechanical (C&W) Dept as a single
window agency
Board’s letter
No.2009/M(C)/165/6
dt.17.12.2009.
It has been taken over from
commercial department w.e.f
01.01.2011.
ii.(a) Stock verification of linen should be carried
out on a quarterly basis
Board’s letter
No.2009/M(C)/165/6
dt.4.1.2010
It has been carried out recently
ii.(b) At least 5% of new linen should be checked
by SSE/Mechanical for:
(a) bundles being sealed and having batch
nos., manufacturer’s name, year of
manufacture, quantity, size indicated,
(b) Linen items having marking of month /
year of manufacture, Railway, etc.
(c) dimensional check, colour, feel and
workmanship, etc.
Inspection of washed linen is
being done both at supervisor
and officer level in accordance to
laid down guidelines of Railway
board.
ii.(c) Monthly report of inspections / test checks of
the linen washing contractor’s premises by
officers / supervisors, should be prepared
and payment should be made after recovery
of all penalties / dues
Suitable deductions based on
passenger complaints are been
made at CDO level.
ii.(d) Enough buffer stock of linen to last for 2 to 3
days is available
Shortage of Polyester Khadi
linen
ii.(e) Life of linen is adhered to:
Bed sheets : 12 months for khadi, 24 months
for poly vastra
Pillow cover/face towel : 9 months
Pillow : 24 months
Blanket : 48 months
Overaged stock of Dec’10
found available.
ii.(f) Committee nominated by DRM for linen
condemnation on condition basis
Committee exists for linen
condemnation on condition basis
iii. Specified frequency of washing/dry cleaning
of blankets and other linen items is adhered
to
Blankets are washed on monthly
basis. No JPO/guidelines
available.
23.1 Passenger complaint on account of linen is
analysed and corrective & preventive action
is taken
Contractor is being penalised on
account of passenger complaints
regarding poor wash quality of
linen.
23.2 Feedback on linen quality is obtained
through coach attendant as per RB’s
guidelines
Passenger feedback is being
taken.
24. Pest / Rodent Control
i. Comprehensive contract covering pest /
rodent control in coaches and rodent control
in pit lines / coaching depot yards awarded
for 3 years under two packet system
Board’s letter
No.2010(M)/C/141/7
Vol.IV dt.21.12.2010
M/S Aaditya pest specialiser has
been doing pest and rodent
control in the depot i.e. separate
contract exists.
ii. All reserved (both AC and Non-AC) covered
under contract, unreserved coaches may
also be covered as per requirement of
Railways
Pest and rodent control in all AC
and NAC coaches is being
undertaken by the firm in
accordance to periodicity as per
guidelines.
Page 14 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
iii. Minimum frequency of pest control treatment
is adhered to :
AC coaches / Pantry cars : Fortnightly,
Reserved Non-AC coaches : Fortnightly in
first 3 months, monthly thereafter,
Unreserved Non-AC coaches : Bi-monthly
Maximum tolerance +7 days, on account of
operational exigencies, disturbance of rake
links, etc.
AC and Pantry cars are treated
on fortnightly basis and other
NAC coaches on monthly basis.
iv. Chemicals to be used (with brand names),
concentration, dose specified
Solfac (20 ml per 5 litre per
coach)
v. Minimum frequency of rodent control
treatment is adhered to :
AC coaches / Pantry cars : during every
Primary maintenance,
Reserved Non-AC coaches : Weekly
Maximum tolerance +7 days, on account of
operational exigencies, disturbance of rake
links, etc.
Rodent control Box of decent
design is used inside A/c
coaches.
vi. Personnel trained by certified training
institutes deputed for pest/rodent control
Personnel carrying out
P/contract are not trained.
vii. Fumigation/mist treatment carried out
whenever coaches detached for IOH/POH.
Pest/rodent control carried out before
inducting the coach in service after IOH/POH
Not in practice as this
provision was not available in
old guidelines.
viii. In order to prevent cross infestation,
contractor may make effort to treat all AC
and all Non-AC coaches of a particular rake
together
As per available records,
coaches in rake form are being
attended for pest control
ix. Stickers indication date of pest control and
next due date provided in doorway/toilet area
Found available.
x. Railways shall make effort to detach pantry
cars from rakes once a month (within
reasonable tolerance) to facilitate complete
vacation and intensive cleaning for thorough
pest / rodent control treatment
Being done.
xi. Broad methodology for measuring the level
of infestation of cockroaches and rodents
and expected reduction over time is in place
Not available in old guidelines.
Depot relies on passenger
feedback or complaint registered
through control.
24.1 Passenger complaints on account of pest are
analysed and corrective action is taken.
Contractor is being penalised for
passenger complaints as per
records available.
25. Passenger amenities provided in various
types of coaches as specified
Board’s letter
No.2006/M(C)/141/26
dt.21.12.2006.
Rake of 12533/34 was checked
for availability of passenger
amenity fittings:
1. 60% snack table and
magazine bags found missing.
2. Push cock/gravity cocks found
available.
3. Soap dispensers found
available in AC coaches etc.
26. Infrastructure facilities – Standard
integrated modular pit line have unified
maintenance.
Appendix ‘E’ of
Coaching manual
CAMTECH report
No.CAMTECH/M/99/I
Available
Page 15 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
nfra-washing line/1.1
27 Examination and repair practice in carriage
maintenance depot for wheel sets and roller
bearing
Para 1009 of Chg
manual
27.1 Wheel and axle Para 1009 a of Chg
manual
i) Wheel profile should be checked
with Tyre defect gauge to ensure the
profile dimensions are within the
permissible limits.
Wheel profile is being checked
using tyre defect gauge wherever
suspected.
ii) Limits for flat tyres
The limits for permissible maximum flat
surfaces on tread for BG ICF coaches is 50
mm (reference Rly. Bd.'s Letter no. 83/M
(N)/960/1/Vol I dated 15/18.3.99)
Information available with
examination staffs and TXR.
iii) Guidelines for wheel inspection in
open line depots (Ref RDSO CMIK003)
In addition to normal checks exercised on
wheel condition during primary/secondary
maintenance of coaches, a detailed
inspection of wheels should be done when
the coaches are received in sickline for
attention for either schedules or out of
course attention. The wheels sets shall be
inspected for the following conditions and
action taken as indicated for each condition:
It is being done in the sick line
during schedules in the depot.
Wheel sets are visually examined
for all known defects and
thereafter confirmation is made
by using tyre defect gauge.
a) Shattered Rim (i) In 2011 (i.e. from Jan to Dec)
28 coaches had been detached
on wheel account.
(ii) in 2012 (i.e. from Jan to Mar)
08 coaches have been detached.
b) Spread Rim
c) Shelled Tread
d) Thermal Cracks
e) Heat checks
iv) The defective wheel should be sent
to workshop for repairs after entering
in the maintenance card details of the
work order and date of dispatch to
workshop.
(i) Turning is done in depot itself.
(ii) 04 new wheel sets are
available in the depot.
v) No repairs, except wheel profiling of
wheel sets is permitted to be done in
the maintenance depot.
Except wheel profiling no other
repairs on wheel sets is being
done in the depot.
27.2 Roller Bearing Axle Boxes Para 1009 b of Chg
manual
Details not available in the depot.
This should be available in
workshop.
i) A coach should invariably be detached
from service for the following defects
i) Hot axle box
ii) Damaged axle box
iii) Damaged front or rear cover
iv) Seized roller bearing
v) Coach involved in accident,
derailment, fire, flood etc.
It is in practice.
ii) Care should be taken not to keep a coach
fitted with roller bearing stationary for a long
time. Coaches grounded for a long time
should be shunted up and down at regular
intervals.
Coaches fitted with roller bearing should be
Coaches don’t remain grounded
for a long period after receipt in
the depot from POH shop.
Page 16 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
checked to ensure that :-
i) No wash basin drain hole / discharge pipe
is directly above the axle box
ii) The front and rear covers of the axle
boxes are not damaged, cracked or loose
iii) Clearance between axle box and wheel is
such that the axle box does not bind against
the wheel.
iv) Brake gear is properly adjusted to avoid
possibility of brake binding
27.2.
1
Axle box is examined for grease oozing out
from rear cover and corrective action is
taken. Concerned shop needs to be advised
for necessary corrective and preventive
action.
It is in practice.
27.3 Axle box temperature measurement by non
contact type temperature measuring
instrument during rolling in examination:
Carriage Dte/RDSO
letter no. MC /AB dtd
21.08.09
No records being maintained.
02 staffs i.e. 01 from N/S & 01
from S/S carryout temp
measurement. platform.
i) Temperature to be checked at axle box top
(crown) at front face of axle
Staffs questioned regarding
correct location for focussing
the non-contact thermometer
were found unaware of the
same.
ii) If temperature is found above 800 C, the
affected coach will be detached.
Information available.
27.4 Minimum permissible wheel diameter in ICF
design BG coaches.
RB letter no. 92/M
(C)/137/2 Vol V dtd
25.1.11
i) Shop issue size of wheel set should be 837
mm
Guidelines available.
ii) Condemning diameter of the wheel in
service, measured at a distance of 66.5 mm
from the outer face of the rim shall be 825
mm.
Guidelines available.
28 Attention brake block hangers on ICF
coaches – to avoid failures
Carriage Dte/RDSO
letter no. MC
/ICF/B/D dtd 03.07.09
28.1 The new brake block should be procured as
per revised spec C – 9808 Rev 2 and drg no.
SK – 93286 Alt 5
Being followed.
28.2 Maintenance of brake gear rigging should be
given as per guidelines circulated by
ED/Carriage /RDSO vide letter no. MC
/ICF/B/D dtd 03.07.09
Being followed.
29 Other items:
29.1 Changing of air brake hose pipe:
Air brake hose pipe to be changed in every
alternate POH attention.
Carriage Dte/RDSO
letter no. MC /APB
dtd 19.02.09
NA
29.2 Fire retardant items are provided in coaches
as per RDSO specification.
RDSO spec and STR Fitment ex shop is being done.
29.3 FAC amenities are provided as per
guidelines circulated vide DG/Carrg/RDSO’s
letter no. MC/CB/AC/BG dtd 28.04.10
29.4 Additional amenities / facilities in GSCN type
of coaches are provided as under:
Snack table in each bay.
RB letter no. 2004 / M
(C)/165/16 dtd
29.03.05
Deficiencies found in the rake no-
1 of 12533/34:
(i) Snack table-60% deficient
Page 17 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
Mirrors in each bay
Magazine holders on partition wall
Bottle and tumbler holder
(ii) Magazine bags-60% deficient
(iii) Bottle holders- 50% deficient
29.5 Maintenance of Duronto express:
i) Pattern of maintenance for Duronto train as
being followed for Rajdhani trains with pit
examination at both end should also be
follwed.
RB letter no. 2009/M
(C)/141/2 dtd
25.08.09
NA
ii) Rolling – in and rolling- out examination may
also be conducted for each of the Duronto
trains at the respective operational halts and
also at the terminals during the journey.
Such safety examinations of the Duronto
trains may be periodically super checked at
the level of officers.
RB letter no. 2009/M
(C)/141/2 dtd
25.08.09
NA
iii) Short distance Duronto with only only AC /
Non AC chair car may be permitted to run on
the extant pattern for Shatabdi trains with a
terminal attention at other end on platform /
stabling line. A minimum 2 hrs may be
planned at the non primary end to enable
thorough attention to cleanliness, hygiene
and passenger amenities at other end.
RB letter no. 2009/M
(C)/141/2 dtd
26.07.11
NA
iv) Cleaning of Vinyl wrapping on Duranto rake
coaches
Mild detergent should be used with normal
jet of water. High pressure water jet should
not be directed towards Vinyl wrapping.
RCF’s letter no. MD
22.151 dtd 09.02.10
NA
29.6 Attention of air springs ED/Carrg/RDSO’s
letter no. MC/CB/MM
dtd 09.09.2009 &
Maintenance manual
of air spring for
mainline ICF bogie
coaches
RDSO/2009/CG/CMI-
01, Sep’09
NA
Procedure for rolling – in examination:
As train passes the nominated point, C&W
staff should watch out vigilantly loose /
hanging / broken under gear parts of the
coaches special attention should be paid to
air springs in case of coaches provided with
air springs at secondary suspension stage. It
should be ensured all the air springs are in
inflated condition by noting that the levelling
valve lever is in horizontal position. In case it
is not feasible to inflate the air springs of any
particular coach, these should be isolated by
air spring isolating cock and speed of train
should be reduced to 60 Kmph or the coach
should be detached.
NA
29.7 Analysis of sick marking and en-route coach
detachment
i) Whether primary coach detachment is
analysed and corrective & preventive action
taken. Details of primary detachment for last
3 years to be collected.
Yes. Annexure 1
ii) Whether secondary detachment is being
analysed and corrective & preventive action
taken. Details of secondary detachment for
last 3 years to be collected.
No data available
iii) Whether en-route coach detachment is
investigated and corrective & preventive
action taken. Details of en-route coach
detachment for last 3 years to be collected
No data available
Page 18 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
with investigation report.
29.8 Facilities for pit line and sick line attention CAMTECH
Maintenance Manual
for BG Coaches of
ICF design,
1st correction slip–
CAMTECH/2002/M/C
/
CMM/1.0/CS-
01(07.2006)
Facilities available as per CAMTECH
guidelines as detailed in annexure – I to be
observed.
Available.
30 Passenger satisfaction
30.1 OBHS & escorting of trains
Whether depot has provision of OBHS as per
RB policy guidelines.
Only one train i.e. 12533/34
(LKO-CSTM Pushpak Express
has been provided with OBHS
facility)
ii) Nos of Mail Express train in which escorting
staff have been provided with cleaning staff
by depot.
NIL
iii) Nos of Mail / Express trains in which OBHS
have been provided.
01
iv) Nos of Mail/ Express train in which no staff
from depot and OBHS through contract have
been provided.
04
v) Average PSI for OBHS implemented rakes.
Whether systems to cross verify PSI in
OBHS provided train is existing.
Average PSI:
January’12 : 98.13
Feb’12 : 93.80
March’12 : 98.49
30.2 Whether depot has system to get feedback
of cleanliness, linen quality and pest infection
of Mail/ Express trains. Action taken by depot
on the basis of feedback from passenger.
Yes, suitable penalty wherever
applicable is being imposed on
contractors.
30.3 Whether depot has system to analyse
passenger complain and takes corrective
action. Passenger complains for last three
years with action taken to be submitted.
Available and being analysed
30.4 Whether depot has facility for mechanised
cleaning of coaches. List of equipments and
nos of rakes covered in every month to be
submitted.
Yes Mechanised Coach cleaning
is outsourced and equipment
such as high pressure jet
cleaning m/c, dry and wet
vacuum cleaner, scrubber,
buffing m/c, industrial floor
scrubber and steam cleaning
were found in adequate nos.
30.5 Whether depot has facility for upholstery and
carpet cleaning either through in-house or
through contract. Efficacy of cleaning to be
observed.
Available
30.6 Whether curtains are cleaned at prescribed
interval of 15 days as per RB guidelines
Yes
30.7 Whether blankets are cleaned at one month
interval as per RB guidelines
No
30.8 Compliance of CRB letter to GM for
sustainable image makeover of the Railways:
CRB DO no.
2011/ER/6018 dtd
28.07.11
i) Cleanliness of coaches:
Page 19 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
a) Ensure high standards of cleanliness in the
coaching maintenance depot particularly in
the washing line area.
Found satisfactory.
b) Action in respect of implementation of
systems of system for collection bagging and
disposal of leftover food from pantry cars and
coaches.
System of collection of garbage
together with bagging for OBHS
train exists
c) Sustainable garbage collection and disposal
system
Dustbins are available along the
pit for garbage collection.
d) Functional and efficient drainage to avoid
water logging and dirt collection
Available
e) Periodic fumigation of coaches and high
standards of cleanliness in washing lines
Not being done as it was not
available in the earlier
contract.
f) Monitoring the functioning of OBHS and CTS
scheme.
OBHS is being monitored
through passenger feedback
form and action is being taken
accordingly.
g) At the Zonal / Divisional level, SAG /
Selection grade officers by name and
designation may be put in –charge of
important Mail/Express trains under “Own
your train scheme (OYTS)” with responsibility
being taken by the officers for the areas for
which they have been nominated.
System of OYTS exists.
ii) Quality of linen supplied on trains:
a) Availability of clean and hygienic linen to
passenger through washing quality,
adequate quantity, replenishment with new
linen on age / condition basis, use of
washable blankets and appropriate quality of
packing.
Washed linen quality was
found poor.
Calendaring press machine
was found out of order.
Stacking of washed linen was
found being done around dirty
floors.
b) Commissioning of mechanised laundries at
critical locations dealing with large quantity of
linens
Not available. However it is
being planned.
c) System of packaging, storage and servicing
of the linen to the passenger must be
streamlined.
Plain packets being used.
31 LHB coach attention:
31.1 Periodicity of periodic overhauls (POH) in
designated workshops is being followed.
Schedule Periodicity
IOH (Shop Sch I) 18 months / 5 lakh
Km
POH (Shop Sch II) 3 yrs/ 10 lakh Km
POH (Shop Sch III) 6 yrs / 20 Lakh Km
RB’s letter no. 95 /M
(C)/ 141 (LHB) dtd
22.08.06
NA
31.2 Attention to following components are being
given as per Alsthom manual guidelines and
guidelines circulated by RDSO.
Phonic wheel / speed sensor.
Dump valve
Earthing device.
Control arm
Dampers
Primary vertical dampers.
Alsthom manual and
OEM manuals
NA
Page 20 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
Secondary vertical dampers
Yaw damper.
Secondary lateral damper
Primary and secondary springs
Disc brake attention
CDTS (Controlled discharge toilet system)
31.3 Wheel sets and CTRB attention at depot: NA
i) The wheels sets shall be inspected for the
following conditions and action taken as
indicated for each condition:
Shattered Rim
Spread Rim
Shelled Tread
Thermal Cracks
Heat checks
Para 1009 a (iii) of
chg manual
NA
ii) Wheel profile should be checked with Tyre
defect gauge to ensure the profile
dimensions are within the permissible limits.
Coaches with wheels having thickness and
profile worn below condemning limit should
not be allowed to continue in service and the
coach should be marked sick for change of
wheels in the sick lines.
Para 1009 a (i) of chg
manual
Information available.
iii) The limits for permissible maximum flat
surfaces on tread for BG ICF coaches is 50
mm (reference Rly. Bd.'s Letter no. 83/M
(N)/960/1/Vol I dated 15/18.3.99)
Para 1009 a (ii) of
chg manual
Information available.
iv) System is available for rolling – in
examination at terminating station and axle
box temperature is measured with non
contact type temperature measuring
equipment and corrective action taken for
wheel sets with high temperature.
Carriage Dte/RDSO
letter no. MC /AB dtd
21.08.09
Facility exists.
v) Last shop issue size (865 mm) and
condemnation limit for wheel sets (845 MM)
as stipulated is being followed.
Information available.
vii) Presently the refurbishing/overhauling of
LHB bearing is being done at an interval of
1.2 million km. To ensure attention of
CTRB’s as well as UST of axle, depot should
have proper identification of wheels sets. In
case wheel sets are interchanged then
traceability of wheel sets and timely attention
of wheel sets exist in the depot.
NA
viii) Depot should not permit wheel sets with
flaking in service. Adequate spare wheel sets
are available in depot.
NA
ix) Whenever coach is sent to shop for
POH/IOH or non schedule attention, details
of wheel sets with regard to CTRB attention
should be furnished to shop. Whether system
exist in depot. Similarly when loose wheel
sets are sent to shop, details of wheel sets
with regard to CTRB attention should be
furnished to shop.
NA
x) Grease oozing out is checked during
attention at depot and corrective action is
taken accordingly.
NA
Page 21 of 26 Coaching depot – LJN, NE Rly. April 2012
SN Item Clause Observation
xi) Drain holes of control arm should be
regularly cleaned to prevent its choking.
NA
xii) Checking of mounting bolts of control arm is
being done during primary maintenance.
NA
31.4 Phonic wheel/Speed censor OEM guidelines NA
i) M8 size screw to IS 1367 Pt.III class 10.9
along with spring washer to the IS 3063 type-
B should be used for securing phonic wheel.
LOCTITE 243 or equivalent glue should be
used to ensure rigid connection between
internal and external thread.
The Phonic Wheel screws should be
tightened with 21N-m torque.
NA
ii) The clearance between the phonic wheel
and speed sensor should be 0.9 to 1.4 mm in
case of KB make WSP and 1 to 2mm in case
of FTIL make WSP. This gap should be
checked in quarterly schedule or whenever
required.
NA
iii) The phonic wheel and speed sensor should
be procured through OEMs/OEMs’ approved
sources only. M/s KB and M/s FTIL are OEM
of this item.
NA
iv) Speed sensors’ cables should be properly
connected and should be without any
loose strands.
NA
31.5 Dump Valve
Proper Dump Valve connection and ensuring
that no dump valve leaks during brake
application.
OEM guidelines NA
31.6 Earthing Device OEM guidelines NA
Earthing device of most of the coaches should be functional. It consists of non ferrous components (approx 2kg weight) which are theft prone. Loose fasteners, in case of theft attempts for non-ferrous items, mounted inside of axle box housing, can damage CTRB.
NA
Most of the earthing devices with correcting
wires/cables were missing.
NA
Junction box in broken/damaged condition. NA
31.7 Disc brake attention: OEM guidelines NA
i) Brake pads are renewed on condition basis
and adequate spare is available at depot
NA
ii) Whether regular attention of brake calliper is
being ensured.
iii) whether regular attention is being given to
disc brake system through AMC or in-house
attention.
31.8 Whether guidelines circulated by RDSO for
CBC equipped coaches are being followed.
Carrg Dte/RDSO
letter no.
MC/BLB/CBC dtd
22.05.08
No CBC equipped coach is
available in the depot.
31.9 Attention of side buffer:
Length of side buffer of CBC equipped SLR
(FV & LV) is maintained to 635 mm as per
RDSO drawing no. SK - 98145
Carrg Dte/RDSO
letter no.
MC/BLB/CBC dtd
17.02.08
Attention to Side buffer of
coaching stock is being done in
accordance with laid down
procedures vide coaching
manual.
Page 22 of 26 Coaching depot – LJN, NE Rly. April 2012
Annexure - I
Standard facilities in Carriage Maintenance Depots
(Ref : CAMTECH Maintenance Manual for BG Coaches of ICF design,
1st correction slip– CAMTECH/2002/M/C/CMM/1.0/CS-01(07.2006)
Classification of depots
Classification No. of coaches based
Minor Depot Below 100
Medium Depot 100 to 250
Major Depot Above 250
Machinery and Plant
Description
Minor
Depo
t
Mediu
m
Depot
Major
Depo
t
Observation
U/floor wheel lath - - 1 Available
Whiting jacks (5 Nos.) - 1 set 1 set
Synchronising jacks
available (02 sets of 05
no. each)
EOT crane 20T - - 1 Available 20/5 T
Coach Shunter - 1 2 Available
Welding Plant 1 2 4 Available
Gas Cutting Equipment 1 2 2 01 No. available
Vacuum Exhauster 1 2 2 Not available. Not
required
Air Compressor 30 cfm 1 2 2 01 Electric- 15m3/min
01 diesel- 10m3/min
Portable Vacuum Testing Equipment - 1 1 Not available.
Portable Air Compressor - - 1 Not available.
2T Tram beam hoist 1 1 2 Not available.
Sewing machine - 1 1 Available
Truck 10T - - 1 Minitruck-01
Light Coml. Vehicle 1 1 1 Minitruck-01
Fork lift truck - - 1 02
Lister truck 1 1 2 01
Car Washer - 1 1 NIL
Portable Trolley Light 2 4 Not available
Cotton waste soaking plant 1 1 1 Not available. Not
required
Wood cutting saw machine - 1 1 NIL
Hand shearing machine - 1 1 NIL
Portable Furnace 1 1 2 NIL
Centre Lath - - 1 Available
Bogie Manipulator - - 1 Not available
Ultrasonic Testing Apparatus 1 1 1 NIL
Tool post Grinder - 1 1 NIL
Vacuum Cleaner 1 2 3 01
Pressure Jet Cleaner
1 2 4
02
Page 23 of 26 Coaching depot – LJN, NE Rly. April 2012
Description
Minor
Depo
t
Mediu
m
Depot
Major
Depo
t
Observation
Tools
Pneumatic Hand Tools
Grinder 1 1 2 Available
Drill 1 1 2 Available
Chipper / Buster - 1 2 Not available
Riveter - - 1 Not available
Electric Power Tools
Pop Riveting Gun - 1 1 Available
Drill - 1 1 Available
Bolt Tightner - - 1 Available
Hand Tools As required
Test Bench
Water Tank Test Rig - 1 1 Available
D.A. Valve Test Bench - 1 1 NA
Vac. Cyl. Test Bench - 1 1 NA
Slack Adjuster Test Bench - 1 1 Not available
DV Test Bench - 1 1 Not available
Air brake single coach test rig - 1 1 02 nos
Office Equipment
Computer system 1 1 1 04 nos.
Plain Paper Copier 1 1 2 01 no.
Telefax 1 1 01 no.
Page 24 of 26 Coaching depot – LJN, NE Rly. April 2012
Annexure - II
Emergency materials required for platform (C&W) office
SN Items Required Observation
1 Screw Coupling complete ( 75 t ) 1 no. Not available
2 Draw Hook ( ICF- Enhanced capacity) 1no. Not available
3 Draft cotter with 'U' pins 1no. NIL
4 Draft link complete 2 sets NIL
5 Equalizing Stay rod with pins ( Non-modif. & Modif.) 1 set each
(01 13 T
01 16 T) pins
deficient
6 Anchor link with securing studs 1 set NIL
7 Truss Bar Hanger with Pins & Cotters 2 sets Available
8 Bolster suspension Link (Stirrup Link) with Pins &
Stones 2 sets
01 available
9 Axle Box Face Cover (ICF) with securing nuts &
Pins 2 sets
Not available
10 'O' Ring 2 nos. NIL
11 Grease Servogen 4 kgs. NIL
12 Adaptor (BF+FP) for by-passing 2 sets Available
13 Angle cock 2 nos. NIL
14 Dummy Flange (A/B) 2 nos. NIL
15 M.U. washer 10 nos. Available
16 Teflon Tape 1 no. Available
17 Portable Air Pressure Gauge 1 no. Available
18 Pressure Gauge BP & FP 2 each Available
19 BP & FP Air hose 2 each Available
20 Guard Emergency Application Valve 2 nos. Available
21 Wooden Plug (various sizes) 10 nos. 02 nos
22 Wooden wedge 4 nos. 02 nos
23 G.I. wire Adequ. Qt. Available
24 Buffer bolts (20x120 mm.) 8 nos. 04 nos
25 Push cock 5 nos. Available
26 Spl. Jack for changing Eq/Stay rod 1no. Not available
27 Slide wrench, Pipe wrench-24'' 2 nos Available
28 Hydraulic Jacks 2 sets 01 no.
Page 25 of 26 Coaching depot – LJN, NE Rly. April 2012
Annexure - III
Depot name and division: LJN depot of Lucknow (NER) division
1. Coach Holding
Mail/Expresses coaches with conventional coupling 183
Mail/Expresses coaches with CBC coupling -
Rajdhani/Shatabdi coaches (conv) -
LHB coaches (Rajdhani/Duronto) -
Shatabdi Coaches (conv) -
Shatabdi coaches (LHB) -
Passenger coaches 59
OCV’s -
Grand Total 242
2. Maintenance attention of at depot
PM of Mail/Expresses train with secondary attention at other end Nil
PM of Mail/Expresses train with round trip attention at other end 4 pairs (M/E)
PM of passenger service with round trip attention at other end 1 pair
Total PM attention at depot: 5 pairs= 14 rakes
Total SM attention at depot: 1 weekly
Total Round trip attention at depot: 11 trains daily at station
3. Pit line attention
24 coach pit with catwalk and high pressure water jet facility/watering
facility at per CAMTECH’s guidelines Two pits with catwalk each
26 Coach capacity
Cleaning work outsourced
who as per contract, have
high pressure jet M/C, but
was not being used due to
non availability of power
24 coach pit facility with catwalk • Two pits with catwalk each 26
Coach capacity
Less than 24 coach pit facility with or without catwalk Nil
Stabling line for round trip attention and stabling of rakes:
Stabling line with 24 coach length facility
Stabling line with less than 24 coach facility
Round Trip attention is being
given at platform itself.
3 stabling lines of 24 Coach
length available
Compressed air with reservoir and ir dryer/moisture trap facility with test
rig (RTR) 2 nos. (1 electric and 1
Diesel) available with drier
Facility for welding at Yard attention Available for Pit, Sick Line and
Yard (portable)
Night maintenance facility with overhead/pit light as per CAMTECH’s
guidelines
No light in pit, overhead light
lesser than required
4. Sick line facility
Coach lifting facility with overhead crane 20/5 Tonne Crane available
Coach lifting facility with JMP jack/hydraulic jack 2 sets available
Total coach accommodation
With pit attention Without pit attention
3 with Pit, 1 without Pit
Total- 4
Facility for compressed air with test rig (SCTR) Available
Availability of hydrant water for overhead tank attention Available
Welding facility Available portable as well as
supply line
Page 26 of 26 Coaching depot – LJN, NE Rly. April 2012
5 Facility for rolling-in/rolling-out examination with adequate
lighting arrangement (for attention during night) as per
CAMTECH’s guidelines
Available but without flood light
6 Availability of staff for coaching maintenance as per Yard
stick Total as per zero based review
: 442
Sanction available- 270
Men on Roll : 250
7 Training status of supervisor and staff ( overdue training to be
observed and recorded)
Nil
8 Availability of critical/ safety stores and storage system Adequate spare available
9 Availability of coaches as per rake link with maintenance
spare
FACCW only one spare which is
being extended for POH
10 Bottlenecks / limitations of system / depot Staff shortage especially for
Linen mgt As linen
transportation is with limited
staff, while distribution in train is
by various agencies like
commercial, Electrical & even
C&W staff
Excessive theft of folding table
and other passenger safety
items
11 Safety performance record Derailment – Nil in last 3 years
Enroute detachment – Nil in
last 3 years
12 Performance of critical spare No system of communication
about Trial items Coach wise
by workshop. However this has
just started since Dec’11
Door Closure & AC 1 cabin
door locking arrangement
getting defective frequently