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Preventive Maintenance Schedules

Preventive Maintenance Schedules. ROLE OF C&W ORGANISATION To Provide Coaches & Wagon In Good Fettle To Traffic To Keep In Good Fettle Requires Maintenance. MAINTENANCE Break Down Maintenance Fail & Fix Preventive Maintenance Periodic Maintenance Attention at Specific Interval

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Preventive Maintenance Schedules

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  1. Preventive Maintenance Schedules

  2. ROLE OF C&W ORGANISATION • To Provide • Coaches & Wagon • In Good Fettle • To Traffic • To Keep In Good Fettle Requires • Maintenance

  3. MAINTENANCE • Break Down Maintenance • Fail & Fix • Preventive Maintenance • Periodic Maintenance • Attention at Specific Interval • Based on Time / km run

  4. MAINTENANCE • With a view to Increase • Availability of Rolling Stock • Upgradation of Material • Based on Past Experience • Interval has been Increased

  5. COACHING MAINTENANCE Preventive Maintenance Schedule (ICF) Pit Examination As Per RPC-4 A Schedule 30 Days + 3 Days B Schedule 3 Months + 7 Days Intermediate Overhaul 9 Months + 30 Days Coaches incld Pantry Car & VPH For Newly Built & OCV 12 Months Periodic Overhaul 18 Months + 30 Days Coaches incld Pantry Car & VPH For Newly Built & OCV 24 Months

  6. COACHING MAINTENANCE Preventive Maintenance Schedule (LHB) Pit Examination As Per RPC-4 D1 Schedule 7 Days + 1 D2 Schedule 30 Days + 3 Days D3 Schedule 6 Months + 15 Days Shop Schedule - I 18 Months Shop Schedule - II 36 Months Shop Schedule – III 72 Months

  7. PREVENTIVE MAINTENANCE • Coaches • Rake – KM/Time Based • Coach – A B Schedule • Time Based in Rake • Coach – IOH (ICF) D3/SS-I (LHB) • Time Based in Sickline • Coach – POH (ICF) SS-II & SS-III (LHB) • Time Based in Workshop • Out of Schedule Repair • In Rake – in Pitline • Coach – in Sickline/Workshop

  8. MAINTENANCE • Coach is Allotted to Division/Depot by COM • Called Primary Maintenance Depot • In Open Line RPC-4 is Followed • Rajdhani/Duranto • PrevMaint Schedules Primary Depot • Internal Cleaning Both End • External Cleaning Both End • Undergear Examination Both End • and Brake System Maint • Complete Air Brake Testing Both End • with Issue of Fresh BPC

  9. MAINTENANCE • Shatabdi • PrevMaint Schedules Primary Depot • Internal Cleaning Both End • External Cleaning Primary End • Undergear Examination Primary End • and Brake System Maint • If stabled at PF Only Brake System Continuity • Otherwise Brake Power Check and • Endorsement on Original BPC

  10. MAINTENANCE • Mail/Express Round Trip Journey>3500 Km ICF • 4000 Km LHB • PrevMaint Schedules Primary Depot • Internal Cleaning Both End • External Cleaning Both End • Undergear Examination Both End • and Brake System Maint • Complete Air Brake Testing Both End • with Issue of Fresh BPC

  11. MAINTENANCE • Mail/Express Round Trip Journey<3500 Km ICF • 4000 Km LHB • PrevMaint Schedules Primary Depot • Internal Cleaning Both End • External Cleaning Primary End • Undergear Examination Primary End • and Brake System Maint • If stabled at PF Only Brake System Continuity • Otherwise Brake Power Check and • Endorsement on Original BPC • Min 3 Hours halt required (expt Intercity Day Train) • At Other End for Cleaning/Bk Power Check

  12. MAINTENANCE • Mail/Express R/Trip Journey<3500 Km ICF • 4000 Km LHB • or 96 Hrs • Touching Primary End more than once • PrevMaint Schedules Primary Depot • Internal Cleaning Both End • External Cleaning Primary End • Undergear Examination Primary End once • and Brake System Maint in 3500/4000 Km or 96 Hrs

  13. MAINTENANCE • Mail/Express R/Trip Journey<3500 Km ICF • 4000 Km LHB • or 96 Hrs • Touching Primary End more than once • (Contd…) • If stabled at PF Only Brake System Continuity • Otherwise Brake Power Check and • Endorsement on Original BPC • Min 3 Hours halt required • At Primary End for Intermediate Visit • At Other End for Cleaning/Bk Power Check

  14. MAINTENANCE • Mail/ExpressInterconnected <3500 Km ICF • 4000 Km LHB • PrevMaint Schedules Primary Depot • Internal Cleaning Primary End & • Each Terminal • External Cleaning Primary End • Undergear Examination Primary End Once • and Brake System Maint in 3500/4000 Km or 96 Hrs

  15. MAINTENANCE • Mail/ExpressInterconnected < 3500 Km ICF • 4000 Km LHB • (Contd…) • If stabled at PF Only Brake System Continuity • Otherwise Brake Power Check and • Endorsement on Original BPC • Min 3 Hours halt required (expt Intercity Day Train) • At Other End for Cleaning/Bk Power Check

  16. MAINTENANCE • Passengers with Toilets • PrevMaint Schedules Primary Depot • Internal Cleaning Primary End & • Each Terminal • External Cleaning Primary End • Undergear Examination Primary End within • and Brake System Maint3500 Km/96 Hrs • If stabled at PF Only Brake System Continuity • Otherwise Brake Power Check and • Endorsement on Original BPC

  17. MAINTENANCE • Passengers without Toilets • PrevMaint Schedules Primary Depot • Internal Cleaning Primary End & • Each Terminal • External Cleaning Primary End • Undergear Examination Primary End within • and Brake System Maint3500 Km/7 days • If stabled at PF Only Brake System Continuity • Otherwise Brake Power Check and • Endorsement on Original BPC

  18. MAINTENANCE • Dedicated Parcel Trains • PrevMaint Schedules Primary Depot • Undergear Examination Primary End within • and Brake System Maint in 4500 km/10 days • Complete Air Brake Testing Both End • with Issue of Fresh BPC

  19. MAINTENANCE • Military/Election Special • PrevMaint Schedules Primary Depot • Internal Cleaning Primary End & • Each Terminal • External Cleaning Primary End • Undergear Examination Primary End within • and Brake System Maint3500 Km/4000 km /96 Hrs • If stabled at PF Only Brake System Continuity • Otherwise Brake Power Check and • Endorsement on Original BPC

  20. MAINTENANCE • DEMU/EMU/MEMU • PrevMaint Schedules Primary Depot • Internal Cleaning Primary End & • Night Stabling Point • External Cleaning Primary End • Undergear Examination 7 days 700HPDEMU • and Brake System Maint 10 days for Other DEMU/EMU/MEMU • Brake System Check by Crew and Guard

  21. MAINTENANCE • Primary Maintenance • PF Activity • Pit Examination • Periodic Maintenance Schedules • A & B for ICF • D2 for LHB • 6 Hrs Maintenance Time

  22. PRIMARY MAINTENANCE • PF Attention • Rolling in Examination • At Speed Less than 30 Kmph • Unusual Sound of Flat Tyre • Rubbing Grazing Sound • Hanging Parts • Axle Box Temperature Recording • By Infrared Thermometer • Piston Release and Wheel Tapping • To Detect Brake Binding • Finally Issue Brake Power Certificate • After Maintenance Format

  23. PRIMARY MAINTENANCE • Pit Examination • Placement at Pitline • Protection of Rake • By Skid to Prevent Roll Down • By Stop Board to Prevent • Dashing by Engine During Maintenance

  24. PRIMARY MAINTENANCE • Pit Occupation Chart • Shows the Occupation of • Pitline Stabling Line of the Depot • For 24 Hrs X 7 Days • Illustration • Very Important for • Introduction of New Train • Increase in Frequency of a Train • To See Whether • Maintenance Slot Available

  25. PRIMARY MAINTENANCE • Pit Examination • Cleaning • Outside • Inside • Bogie • Lavatory • Disposal Of Garbage • Doorway • Vestibule Area

  26. PRIMARY MAINTENANCE • Pit Examination • Upper Gear Visual Examination and Repair • Piping & Plumbing • Water System • Toilet Flush • Carpentry Work • Seat & Berth • Wall & Ceiling Broken Panels • Window & Shutters • Doors & Latch • Mirror • CDTS/Bio Toilet Attention

  27. PRIMARY MAINTENANCE • Pit Examination • Under Gear Visual Examination • Wheel • Profile • Brake Gear • Draw & Buffing Gear • Bogie • Its Components • Mountings • Reservoirs • All Underslung Items

  28. PRIMARY MAINTENANCE • Pit Examination • Air Brake Testing • Leakage Check & Rectification • Piston Stroke Check & Rectification • Identify Inactive Coach & Rectify • Check Of Brake Power • Should be 100% • Identify any Late Releasing Coach • Rectify • Air Pressure Continuity Check

  29. PRIMARY MAINTENANCE • Pit Examination • Preventive Schedule • A Schedule/D2 Schedule • B Schedule/D3 Schedule • Destination Board Attention • Coach Indication Board Attention • Detachment Of • Overdue POH/IOH Coach • Sick Coach not Rectified during • Pit Attention • Linen Management • Padlocking

  30. SECONDARY MAINTENANCE • Pit Examination Done • At Other End as per RPC-4 • Activities Same As Primary Maintenance • Except • Preventive Maintenance Schedule • Linen Management • Providing Fire Extinguisher • Maintaining Coach Biodata & History • Detaching Overdue POH/IOH Coach

  31. OTHER END ATTENTION • If Not Under Pit Examination • As per RPC-4 • Time Required 3:00 Hrs Minimum • (except Intercity Day Trains) • Rolling in Examination • Dry Sweeping • Lavatory Cleaning • Watering

  32. PREVENTIVE SCHEDULES – ICF • PITLINE • A Schedule 30 Days + 3 Days • All Items of Pit Examination • Dash Pot Oiling • Cleaning of Dirt Collector • Intensive Cleaning of Coach • B Schedule 3 Months + 7 Days • All Items of A Schedule • Attention to PEASD System

  33. PREVENTIVE SCHEDULES – LHB • PITLINE • D2 Schedule 30 Days + 3 Days • All Items of Pit Examination/D1 • Gap between Brake Pad and Disc • Check Wear on Brake Pads • Washing of Bogie • Tread Dia and Wheel Profile • Lubricate Pins and Moving Parts • Intensive Cleaning of Coach • Inspection of Earthing Equipment • WSP Attention as per OEM

  34. PREVENTIVE SCHEDULES – ICF • SICKLINE • IOH 9 Months + 30 Days • Main Job • Overhauling of Bogie • Bogie Overhauling at Workshop • IOH Carried Out at Depot • Coach to be Placed at Sickline • Coach Lifting on Jacks • Bogie Run Out • Fitment of Overhauled Bogie • For Mail/Express Coach

  35. PREVENTIVE SCHEDULES – ICF • SICKLINE • IOH (Contd...) • In Addition • Thorough Inspection of • Coach Body from Under • Centre Pivot • Side Bearer • Draw & Buffing Gear In Situ Condition • Air Brake Testing by Single Coach Test Rig • Attention to Upper Gear • Adjustment of Buffer Height • All Items of B Schedule

  36. PREVENTIVE SCHEDULES – LHB • SICKLINE • D3 Schedule 6 Months + 15 Days • All Activities of D2 Schedule • Examine Bogie Frame for • Corrosion & Cracks • Paint Touch up • Check Wheel Offset • Renew Protection Treatment • On Rubber Joints of Control Arm • Replace Carbon Brush of • Earthing Equipment

  37. PREVENTIVE SCHEDULES – LHB • SICKLINE • Shop Schedule-I 18 Months + 15 Days • 6 Lakhs KM • Main Job • Overhauling of Bogie • Bogie Overhauling at Workshop • Attention to Body Floor • Attention to Couplers • Bogie Run Out • Fitment of Overhauled Bogie • For Mail/Express Coach

  38. PREVENTIVE SCHEDULES – LHB • SICKLINE • SS-I (Contd...) • In Addition • Air Brake Testing by Single Coach Test Rig • Attention to Upper Gear • Adjustment of CBC Height • All Items of D3 Schedule

  39. PREVENTIVE SCHEDULES IN SHOP • POH 18 Months + 30 Days ICF • Shop Schedule-II 36 Months + 30 Days LHB • 12 Lakhs KM • Shop Schedule-III 72 Months + 30 Days LHB • 24 Lakhs KM • MLR 12 Years ICF • MLR 12 Years LHB

  40. PREVENTIVE SCHEDULES IN SHOP • Coaches are sent to Workshop by Division • As per Calling in Program • Calling in Program is made by HQ • As per Capacity of Workshop • If Coaches could not be sent due to • Capacity Constraint of Workshop • Return Date to be Extended

  41. PREVENTIVE SCHEDULES IN SHOP • Periodic Overhaul • Carried Out at Workshop • Cycle Time 18 Days for Non AC • 20 Days for AC & LHB • Lifting Line/Stripping Line • Segregation of Coach based on • Body Repair Work • Light Medium Heavy • Coach Body to Body Shop for • Corrosion Repair • Upper Seat Floor Repair

  42. PREVENTIVE SCHEDULES IN SHOP • POH (Contd...) • Bogie Frame to Bogie Shop for Overhauling • Wheels to Wheel Shop • Wheel to Turning and Gauging • Ultrasonic Testing of Axles • Bearing Attention • Air Brake Items to Air Brake Shop • Electrical Items to Electrical Shop

  43. PREVENTIVE SCHEDULES IN SHOP • Items Specific to LHB • Disc Brake • Brake Calipers • Wheel Slide Protection • Control Arm • Centre Buffer Couplers • Dropping of CBC in SS-III • Changing of Dampers in SS-III

  44. PREVENTIVE SCHEDULES IN SHOP • POH (Contd...) • After Repair of Coach Body • Fitment of All Overhauled Items • Final Air Brake Testing • Final Finishing • Buffer Height Adjustment • NTXR Checking

  45. PREVENTIVE MAINTENANCE • Wagons • Rake – KM/Time Based • Wagon – ROH • Time Based in ROH Depot • Wagon – POH • Time Based in Workshop • Out of Schedule Repair • In Rake – in Yard • Wagon – in Sickline/Workshop

  46. WAGON MAINTENANCE • Preventive Maintenance • At Freight Examination Yard • Called Intensive Examination • End To End Examination Upto Unloading Point • Formed with Empty/Loaded Wagons • Yardstick 56 Manhours • Only One Loading and Unloading

  47. MAINTENANCE • Validity • Closed Circuit Rake 35 Days or 7500 Km A Cat • 30 Days or 6000 Km B Cat • Formed with Off POH/ROH Empty Wagons • Rake Assigned to a Depot • Yardstick 100 Manhours • Multiple Loading and Unloading Between Examination • Premium Examination 12 Days + 3 Days • Formed With Empty Wagons • No Yardstick but taken as 80 Manhours • Multiple Loading and Unloading Between Examination

  48. MAINTENANCE Routine Overhaul Periodicity

  49. MAINTENANCE Periodic Overhaul Periodicity

  50. INTENSIVE EXAMINATION • Rolling In Examination • Axle Box Bearing Temperature • Examination • Air Brake Testing • Repair of Wagons In Situ Condition • Detachment of • Overdue POH/ROH/Overage Empty Wagons • Sick Wagons not repaired during examination

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