1

A
Seminar Report on
Coaching, Caring and Maintenance of Railway Coaches
PRACTICAL TRAINING TAKEN AT
COACH CARE COMPLEX, JAIPUR
NORTH WESTERN RAILWAY
INDIAN RAILWAYS

submitted in partial fulfillment of the
requirements for the degree
of
B.TECH
MECHANICAL ENGINEERING
by
LOKESH SHARMA
11EVJME024
Under the guidance of
MR. SUMIT SHARMA
TRAINING SEMINAR CORDINATOR

DEPARTMENT OF MECHANICAL ENGG,
Vivekananda Institute of Technology
Jagatpura, Jaipur
2013-14
2

3


4

Vivekananda Institute of Technology
DEPARTMENT OF MECHANICAL ENGINEERING
JAIPUR (RAJASTHAN)-302022

CERTIFICATE

This is to certify that this report on Practical Training taken at Coach Care Complex of Indian
Railways is submitted by Lokesh Sharma, 11EVJME024 to the Department of Mechanical
Engineering, VIT, Jaipur, for the award of the degree in B. Tech Mechanical Engineering is a
bonafide record of work carried out by him. The contents of this Seminar report, in full or in
parts have not been submitted to any other Institute or University for the award of any degree or
diploma.


Sumit Sharma/Md. Mukhtar Alam Mr. Peeyush Vats
Incharge (Practical Training Seminar) HOD, ME

5

ACKNOWLEDGEMENT


I express my deep sense of gratitude to Mr. R.K. Sharma, Coaching Depot Officer for their
valuable guidance, keen interest and encouragement at various stages of my training period. I
acknowledge with the thanks the kind of patronage, loving inspiration and timely guidance,
which I have received from my course coordinator Mr. M.P. Singh, Sr. Section Engineer
(Incharge) and Mr. Pankaj Sharma, Sr. Section Engineer and all the staff members of Coach
Care Complex (NWR), Jaipur.
I wish to extend my sincere gratitude to respective Practical Training Seminar Coordinator, Mr.
Sumit Sharma and Md. Mukhtar Alam for their valuable guidance and regular encouragement
which has been absolutely helpful in successful completion of this training report. I am indebted
to Mr. Peeyush Vats (HOD, Department of Mechanical Engineering) for his valuable support. I
am also thankful to all the ME faculty members for their keen interest and at last my coordinal
thanks to my batch mates and friends for their cooperation.



_____________
` Lokesh Sharma
11EVJME024


6

TABLE OF CONTENT


INTRODUCTION 1

1.) ORGANSATION STRUCTURE 3
1.1) Zones of Indian Railways 4
1.2) Departments 7
2.) NORTH WESTERN RAILWAY 8
2.1) Facts and Other Statistics 9
2.2) Brief Outline of the Divisions 11
2.2.1) Jaipur Division 11
2.2.2) Bikaner Division 11
2.2.3) Jodhpur Division 11
2.2.4) Ajmer Division 12

3.) INTRODUCTION TO COACHES 13
3.1) Important Parameters of LHB Coaches 14
3.2) Various Parts of LHB Rake 16
3.2.1) Wheel and Axle Assembly 16
3.2.1.1) Wheel 16
3.2.1.2) Axle 17
3.2.1.3) Components of Wheel and Axle Assembly 18
3.2.1.4) Axle Bearings 19

4.) BOGIE 20
4.1) Bogie Frame 21
4.2)Primary Suspension 22
4.3) Secondary suspension 23
4.3.1) Cross Bar 24
4.3.2) Bolster Assembly 24
4.4) Drawing and Buffing Gear Assembly 24
4.4.1) Screw Coupling 24
4.4.2)Side Buffers 24
5.)SHELL 26
5.1)Body 27
5.1.1) Center Pivot Assembly 27
5.1.2) Body Bogie Connection 28
5.2) The Transmission of Hauling Force 28
5.2.1) Center Pivot 28
7

5.2.2) Longitudinal Bumpstop 28
5.2.3) Articulated Control Arm 28
5.3) Trolley 29
5.3.1) Trolley Frame 29
5.3.2) Center Pivot 29
5.3.3) Side Bearing 29
5.3.4) Brake Cylinders 29
5.3.5) Brake Blocks 29
5.3.6) Equilateral Sterod 30
5.3.7) Anchor Rod 30
5.3.8) Suspension System 30
5.4) The Load Distribution 32
6.) BRAKING SYSTEM 33
6.1) Air Brake System 33
6.1.1) Brake container 34
6.1.2) Connections to the Container 35
6.1.3) Brake Application 36
6.1.4) Brake Release 36
6.2) Bogie Brake Equipment 36
6.2.1) Brake Caliper Units 36
6.2.2) Brake Cylinders 38
6.2.3) Brake Discs 38
6.2.4) Brake Shoe 39
6.3) Brake Rigging System 39
6.4) Wheel Slide Protection Equipment 40
6.5) Center Buffer Coupler 42

7.) CDTS (Control Discharge Toilet system) 43
7.1) Salient Features 43
7.2) Operating Principle 43
7.3) Components of CDTS 45
7.3.1) Types 45
7.3.2) Control Panel 45
7.3.2.1) PLC 46
7.3.2.2) Solenoid Vale 46
7.3.2.3) Control Relay 46
7.3.3) Retention Tank 46
7.3.4) Lower Slide Valve 46
7.3.5) Upper Slide Valve 46
7.3.6) Flush Button 47
7.3.7) Water Pressurizer 47
8

7.3.8) Fail Safe Mode 47
7.4) Operational Description 47

8.) MAINTENANCE OF TRAINS 50
8.1) The Primary Structure 50
8.2) The Maintenance of the Trains 50
8.2.1) Primary Maintenance 51
8.2.2) Round Trip Maintenance 51
8.2.3) Secondary Maintenance 51
8.3) Maintenance Schedule and Overhauling Periods 52
8.4) Periodic Overhauling 52
8.4.1) POH Date and Return Date 53
8.4.2) Significance of Coach Number 53
Conclusion 54
Reference 55














9




LIST OF TABLES

Table No. Name of Table Page No.
Table 1.1) List of Zones of Indian Railways 5
Table 1.2) List of Departments 7
Table 3.1) Overall Dimensions of Coach 14
Table 3.2) Tare Weight of Coaches 15
Table 3.3) No. of seats in Different Coaches 16
Table 5.1) Strength of different types of Steels 26


10

LIST OF FIGURES

Figure No. Name of Figure Page No.
Fig 1.1) Zones Map 5
Fig 2.1 ) Logo of North Western Railway 8
Fig 2.2) Map of North Western Railway 10
Fig 3.1) Rail Wheels 17
Fig 3.2) Axle 18
Fig 3.3) Components of wheel and axle assembly 18
Fig 3.4) Axle Bearing 19
Fig 4.1) Bogie Frame 21
Fig 4.2) Components of Primary Suspension 22
Fig 4.3) Components of Secondary Suspension 23
Fig 4.4) Side Buffers 25
Fig 4.5) Primary Suspension Unit 25
Fig 5.1) Center Pivot Assembly 27
Fig 5.2) Trolley 31
Fig 6.1) Brake equipment for Passenger coach 34
Fig 6.2) Brake equipment panel 34
Fig 6.3) Brake equipment for Generator coaches 35
Fig 6.4) Brake Calliper Unit 37
Fig 6.5) Brake Cylinders and Callipers 38
Fig 6.6) Axle Mounted and Wheel mounted brake disc 39
Fig 6.7) Brake Rigging Pressure 40
Fig 6.8) Speed sensor and Phonic Wheel 41
Fig 6.9) Dump valve and Connector 41
Fig 6.10) Electronic connectors and Electronic Unit 41
Fig 7.1) Schematic Diagram of CDTS 45
Fig 7.2) Operational description of CDTS 47






11

INTRODUCTION



"Lifeline of the Nation"
Type : Public sector undertaking
Reporting mark : IR
Industry : Railways
Founded : April 16, 1853
Headquarters : New Delhi, India
Area served : India
Chairman : Arunendra Kumar
Services : Passenger railways
: Freight services
: Parcel carrier
: Catering and Tourism Services
: Parking lot operations
: Other related services
Track gauge : 1,676 mm (5 ft 6 in)
: 1,000 mm (3 ft 3 38 in)
: 762 mm (2 ft 6 in)
: 610 mm (2 ft)
Electrification : 23,541 kilometers (14,628 mi)
12

Length : 65,000 kilometers (40,000 mi)
Revenue : 1256.8 billion (US$21 billion)
Net income : 104.1 billion (US$1.7 billion)
Owner(s) : Government of India (100%)
Employees : 2.2 million (2012)
Parent : Ministry of Railways through Railway Board (India)
Zones : 17 Railway Zones
Website : www.indianrailways.gov.in




13

CHAPTER-1
ORGANSATION STRUCTURE

Indian Railways (reporting mark IR) is an Indian state-owned enterprise, owned and operated
by the Government of India through the Ministry of Railways. It is one of the world's largest
railway networks comprising 115,000 km (71,000 mi) of track over a route of 65,000 km (40,000
mi) and 7,500 stations. In 2011, IR carried over 8,900 million passengers annually or more than
24 million passengers daily (roughly half of which were suburban passengers) and 2.8 million
tons of freight daily. In 20112012 Indian Railways had revenues of 1119848.9 million (US$19
billion) which consists of 696759.7 million (US$12 billion) from freight and 286455.2 million
(US$4.8 billion) from passengers tickets.

Railways were first introduced to India in 1853 from Bombay to Thane. In 1951 the systems
were nationalized as one unit, the Indian Railways, becoming one of the largest networks in the
world. IR operates both long distance and suburban rail systems on a multi-gauge network of
broad, meter and narrow gauges. It also owns locomotive and coach production facilities at
several places in India and are assigned codes identifying their gauge, kind of power and type of
operation. Its operations cover twenty nine states and seven union territories and also provide
limited international services to Nepal, Bangladesh and Pakistan.

Indian Railways is the world's ninth largest commercial or utility employer, by number of
employees, with over 1.4 million employees. As for rolling stock, IR holds over 239,281 Freight
Wagons, 59,713 Passenger Coaches and 9,549 Locomotives (43 steam, 5,197 diesel and 4,309
electric locomotives).

The trains have a 5 digit numbering system as the Indian Railways runs about 10,000 trains
daily. As of 31 March 2013, 23,541 km (14,628 mi) (36%) of the total 65,000 km (40,000 mi)
route length was electrified. Since 1960, almost all electrified sections on IR use 25,000 Volt AC
traction through overhead catenary delivery.

14

On 23 April 2014, Indian Railways introduced a mobile app system to track train schedules.
The first railway on Indian sub-continent ran over a stretch of 21 miles from Bombay to Thane.
The idea of a railway to connect Bombay with Thane, Kalyan and with the Thal and Bhore Ghats
inclines first occurred to Mr. George Clark, the Chief Engineer of the Bombay Government,
during a visit to Bhandup in 1843.
Indian Railways runs around 11,000 trains everyday, of which 7,000 are passenger trains.
1.1 Zones of Indian Railways
Indian Railways is divided into several zones, which are further sub-divided into divisions. The
number of zones in Indian Railways increased from six to eight in 1951, nine in 1952 and sixteen
in 2003 and now seventeen. Each zonal railway is made up of a certain number of divisions, each
having a divisional headquarters. There are a total of sixty-nine divisions.
Each of the seventeen zones is headed by a general manager who reports directly to the Railway
Board. The zones are further divided into divisions under the control of divisional railway
managers (DRM).
15


(Fig 1.1 Zones Map)
( Table 1.1 List of Zones of Indian Railways )
Sr.
No
Zone
Name
Abbr. Date
Established
Route
length
( Km)
Headquarter Divisions
1. Central CR 5 November
1951
3905 Mumbai Mumbai, Bhusawal, Pune,
Solapur, Nagpur
16

2. East
Central
ECR 1 October 2002 3628 Hajipur Danapur, Dhanbad,
Mughalsarai, Samastipur,
Sonpur
3. East Coast ECoR 1 April 2003 2572 Bhubaneswar Khurda Road, Sambalpur,
Waltair
4. Eastern ER 14 April 1952 2414 Kolkata Howrah, Sealdah, Asansol,
Malda
5. North
Central
NCR 1 April 2003 3151 Allahabad Allahabad, Agra, Jhansi
6. North
Eastern
NER 14 April 1952 3667 Gorakhpur Izzatnagar, Lucknow, Varanasi
7. North
Western
NWR 1 October 2002 5459 Jaipur Jaipur, Ajmer, Bikaner,
Jodhpur
8. Northeast
Frontier
NFR 15 January
1958
3907 Guwahati Alipurduar, Katihar, Rangia,
Lumding, Tinsukia
9. Northern NR 14 April 1952 6968 Delhi Delhi, Ambala, Firozpur,
Lucknow, Moradabad
10. South
Central
SCR 2 October 1966 5803 Secunderabad Secunderabad, Hyderabad,
Guntakal, Guntur, Nanded,
Vijayawada
11 South East
Central
SECR 1 April 2003 2447 Bilaspur Bilaspur, Raipur, Nagpur
12. South
Eastern
SER 1955 2631 Kolkata Adra, Chakradharpur,
Kharagpur, Ranchi
13. South
Western
SWR 1 April 2003 3177 Hubli Hubli, Bangalore, Mysore
14. Southern SR 14 April 1951 5098 Chennai Chennai, Tiruchirappalli,
Madurai, Palakkad, Salem,
Thiruvananthapuram
15. West
Central
WCR 1 April 2003 2965 Jabalpur Jabalpur, Bhopal, Kota
16. Western WR 5 November
1951
6182 Mumbai Mumbai Central, Ratlam,
Ahmedabad, Rajkot, Bhavnagar,

17

1.2 Departments
A typical division has an average track length of about 1000 km and staff strength of about
15000. All the departments and services of the Indian Railways are represented in a Division.

( Table 1.2 List of Departments )
SR.NO Name of Department Role and function
1. Engineering
Department
Maintenance of all fixed assets of the Division, i.e. Track,
Bridges, Buildings, Roads, Water supply etc.
2. Mechanical
Engineering &
Power Department
Maintenance of all rolling stock of the Division , i.e.
locomotives, passenger and freight cars; and technical super
etc.
3. Electrical Engineering
Department
Maintenance of all electric locomotives, EMUs/MEMUs and
fixed electrical assets of the Division, i.e. Overhead
equipment, lighting and power for railway establishments etc.
4. Signal &
Telecommunication
Engineering Dept
Management of the Signaling and Telecommunication (S&T)
infrastructure of the division for Safe Train operations
5. Operating and Traffic
Department
Train operations
6. Commercial
Department
Passenger ticketing, ticket checking, booking of freight rakes
and collecting fares
7. Medical Department Providing medical facilities to railway employees and their
Families
8. Safety Department Ensuring safety of train operations
9. Stores Department Ensuring material for maintenance of trains (material for all
departments except the Engineering Department)
10. Accounts Department Financial management of the division
11. Personnel Department HR functions
12. Security Department Security of railway material, passenger and passenger
Belongings
18

CHAPTER -2
NORTH WESTERN RAILWAY

Serving Customer with Smile
(Fig 2.1 Logo of North Western Railway)

Reporting mark : N.W.R
Founded : October 1, 2002
Headquarters : Jaipur, Rajasthan
General Manager : R.C.Agrawal
Track gauge : 1,676 mm (5 ft. 6 in)
: 1,000 mm (3 ft. 3 38 in)
Length : 54449.29 kilometers
Stations : 578
Division : 4
Website : www.nwr.indianrailways.gov.in

The North Western Railway is one of the sixteen railway zones in India. It is headquartered at
Jaipur. It comprises four divisions: Jodhpur and reorganized Bikaner division of the erstwhile
Northern Railway and reorganized Jaipur and Ajmer divisions of the erstwhile Western Railway.
This zone came into existence on October 1, 2002. This railway comprises a total of 578 stations
covering a total of 5449.29 route km out of which 2575.03 are broad gauge and 2874.23
are meter gauge.
North Western Railway came being on 1
st
October, 2002. It was carved out of 2 divisions each
from Northern and Western Railways. The formation of this zone along with five other new
19

zones was first approved by Railway Board on 16
th
September, 1996 and foundation stone for
this zone was laid on 17
th
October 1996 by the then Prime Minister Shri H.D. Deve Gowda at
K.P. Singh Stadium, Jaipur. The impetus for formation of New Zone came with the Government
of India notification no. 97/E&R/700/1/Notification dated 14.06.2002 wherein it was decided
that North Western Railway with its jurisdiction over existing Jaipur and Ajmer divisions of
Western Railway and Jodhpur and Bikaner divisions of Northern Railway was to come into
effect from 1.10.2002.
2.1 Facts and Other Statistics
Consisting of four divisions, this railway has a total of 578 stations covering a total of 5449.29
route kms out of which 2575.03 are broad guage and 2874.23 are meter guage. The total track
kilometers of this railway, however, are 6559.546 kms. The four divisions are Ajmer, Bikaner,
Jaipur & Jodhpur. Jaipur & Ajmer divisions were originally part of Western Railway and
Bikaner & Jodhpur were part of Northern Railway. The total number of trains dealt by North
Western Railway amounts to 452 out of which BG trains total 264 and MG trains total 188.

20



(Fig 2.2 Map of North Western Railway)


21

2.2 Brief Outline of the Divisions
2.2.1 Jaipur Division
This division was formed after merging parts of BB&CI, Jaipur State Railways and Rajputana
Malwa Railway, Jaipur Division serves the states of Rajasthan, Uttar Pradesh and Haryana.
Being a predominately passenger earning division (84.92% of its earning is by way of passenger
traffic), it deals primarily with cross traffic consisting of fertilizer, cement, oil, salt, food grains,
oil seeds, lime stone and gypsum traffic. Container loading is done from here in bulk. The total
no. of stations on this division is 128 and the total no. of trains run are 146. Jaipur station alone
deals with 88 BG & 22 MG trains and 35,000 passengers in a day. In order to ensure that the
passenger does not face any hardship for reservations the division has at the moment 14
functioning Computerized Passenger Reservation System Centres. The staff strength of this
division in all categories is 12007.
2.2.2 Bikaner Division
This division was established in 1924 and it serves the states of Rajasthan, Punjab and Haryana.
This division has an equal amount of passenger and goods traffic. The main outward goods
traffic of this division is food grains, china clay and gypsum. The total no. of situations in these
divisions is 198 and the total no. of trains dealt with are 142 including the rail bus and BG and
MG mail/exp and passenger trains. Bikaner division has 12 Computerized Passenger Reservation
System functioning and one Computerized Passenger Reservation System at Ratangarh is about
to be commissioned. A proposal for opening of PRS at Mahendergarh has already been sent to
Railway Board for sanction. The staff strength of this division in all categories is 13728.
2.2.3 Jodhpur Division
This division was up in the year 1882 and it consists primarily of semiurban districts of
Rajasthan. It covers areas of Jodhpur, Pali Marwar, Nagaur Jalore, Barmer, and Jaisalmer. It also
covers certain districts of Gujarat state. This division also serves certain sensitive areas of
Rajasthan such as Jaisalmer, Barmer and Pokaran. The main commodities loaded on this division
are lime stone, salt and gypsum. This division has a total of 144 stations and deals with 92 trains
22

in the inward and outward directions. Fifteen Computerised Passenger Reservation System
Centers exist over this division and another one is on the anvil. A proposal for four more
locations has already been sent. The staff strength of this division in all categories is 10231.
2.2.4 Ajmer Division
This division is spread over the states of Rajasthan and Gujarat. It is predominantly a cement
loading division as many cement plants of Rajasthan are located within the jurisdiction of Ajmer.
Rock phosphate, soap stone powder are loaded from Udaipur area. This division is prominent on
the religious and tourist map of India as it witnesses large amount of passenger traffic to Ajmer
Sharief, Pushkar, Jain Temples Dilwara at Mount Abu and Ranakpur Temples. This division has
130 stations and the total no. of trains run over the division amounts to 36 in both the passenger
and mail/exp category. At present there are 12 Computerized Passenger Reservation System
Centres functioning over this division and one location is awaiting commissioning. Proposals for
3 more locations have already been sent. The staff strength of this division in all categories is
9046.


23

CHAPTER-3
INTRODUCTION TO COACHES

Till recently, Indian Railways have been transporting passenger traffic mainly through coaches
of ICF design. These coaches are being manufactured at ICF and RCF. A limited number of
these coaches are being manufactured at BEML/Bangalore also. These type of coaches are
having limitations in terms of
i) Speed potential;
ii) Heavy corrosion;
iii) Poor riding comfort;
iv) Wearing of parts in the under gear;
To overcome these limitations, Indian Railways entered into supply and technology transfer
contracts with M/s. ALSTOM LHB/Germany to initially supply 24 coaches consisting of 19.
AC chair cars, 2 AC Executive Class Chair cars and 3 Generator cum Brake vans. The bogies
for these coaches are manufactured by M/s. FIAT/SIG Switzerland. These coaches arrived in
India and got commissioned in the year 2001 and put in service on route. These type of coaches
are far superior w.r.t. passenger comfort, safety, speed, corrosion, maintenance and aesthetics in
appearance. These coaches are also longer as compared to ICF design resulting into more
carrying capacity. The expected benefits from these types of coaches are as under:-
1. Higher carrying capacity - These coaches are about 2 meters longer than ICF coaches.
With this extra length two additional rows of chairs in chair cars or one additional bay in
sleeper coaches can be accommodated.
2. The weight of LHB coach is lesser as compared to ICF design coaches. LHB coach
can accommodate 72 passengers as compared to 64 in conventional AC III Tier Coach.
Thus giving better pay to tier ratio.
3. Low corrosion There will be low corrosion of LHB coaches due to extensive usage of
Stainless Steel and better design and manufacturing techniques.
24

4. Low Maintenance Replacement and removal of sub-systems will be required only
after one million kilometers. There are no doors handles projecting outside the coach thus
mechanized car washing is facilitated.
5. LHB Coaches have aesthetically superior interiors with FRP panels for side wall and
roof. They can be removed easily for maintenance, resist water seepage and are wear
resistant;
6. Safety -There are no visible screws inside the passenger compartment.
7. Better passenger comfort: Ride Index of 2.5 (Not exceeding 2.75) has been specified as
compared to in conventional ICF coaches.
3.1 Important Parameters of LHB Coaches
( Table 3.1 Overall dimensions of coach )
Sr. No. Parameters Dimension(in mm)
1. Gauge 1676
2. Length over Body 23540
3. Length over Buffer 24000
4. Height over Roof 4039
5. Maximum width over body 3240
6. Maximum distance between inner wheels 12345
7. Window opening 1180 X 760
8. Distance between centre pivots 14900
9. Height of compartment floor from rail level under
tare condition
1303
25

10. Maximum buffer drop under gross load and worn
conditions
75
11.
Maximum height of centre line of side buffers
above rail level for empty vehicle
1105
12.
Maximum height of centre line of side buffers
above rail level for loaded vehicle
1030

13.
Wheels mono block 915

( Table 3.2 Tare weight of coaches )
Sr. no. Type of Coach Tare Weight (in tonnes)
1. Chair Car 39.4
2. First AC 40.5
3. Second AC 48.4
4. Third AC 50.6
5. LSLR 37.9







26

( Table 3.3 No. of Seats in Different coach )

3.2 VARIOUS PARTS OF THE LHB RAKE:

3.2.1 WHEEL AND AXLE ASSEMBLY:
It is the part of a rake which is just adjacent to the tracks. It basically consists of four main parts:
1. Wheel
2. Axle
3. Components of wheel and axle assembly
4. Axle Bearings

3.2.1.1 WHEEL:
Wheel of a rake is a specifically made cylindrical portion having an outer edge shape to fit in the
railway track. The material used is stainless steel.
Sr. no. Type of Coach No. of Seats
1. 2
nd
AC Chair Car 78
2. Exe. AC Chair car 56
3. First class sleeper (FAC) 24
4. Two tier AC sleeper (AC2T) 52
5. Three tier AC sleeper (AC3T) 72

27


(Fig 3.1 Rail Wheels)
3.2.1.2 AXLE:
Axle is the main long cylindrical bar on which wheels are fixed with the help of bearings. This is
also made of stainless steel as above. Each axle contains 2 wheels, the brake cylinders are also
attached to it and in case of LHB coaches, the braking discs are fixed on to the axle.

28



(Fig 3.2 Axle)
3.2.1.3 COMPONENTS OF WHEEL AND AXLE
ASSEMBLY



Two brake disks (4), diameter 640 mm
and width 110 mm.
In built slack adjusting brake cylinder
fitted
Two Wheel disc of tread diameter 915
(New), 845 (Worn)

Nomenclature:
1. Axle
2. Plug
3. Wheel
4. Brake disc
AXLE

(Fig 3.3 components of wheel and axle assembly)

29

3.2.1.4 Axle Bearings:
A taper roller cartridge type bearing is used and it makes up a preassembled unit. The axle
bearings on the bogie are fitted with sensors for detecting speed (whose signal is elaborated by
the ant slipping system) and a current return device.
The ends of the control arms are fitted with centering devices for the primary suspension spring
assembly. The bearing lubricating plug is fitted in the lower part.
1. Double cup
2. Sealing system
3. Backing ring

FIG. 4-10 AXLE
BEARING
(Fig 3.4 Axle Bearings)

30

CHAPTER-4
BOGIE
The FIAT Bogie is two-axle type, with a primary and a secondary suspension. The bogie
assembly is shown in fig. 4.1. The Salient features of FIAT Bogie are:
1. Solid welded Bogie Frame made up of two longitudinal components connected by two
cross beams. The bogie frame rests on the primary suspension spring units and supports
the vehicle body by means of Bolster beam. The Bolster beam is connected to the bogie
frame by secondary suspension.

2. Primary suspension consist of two steel coil springs (internal/external) laid out on the
Control Arm upper part.


3. Secondary suspension consists of two spring packs which sustain the bolster beam over
the bogie frame. Each spring pack is made up by an internal and external spring. An Anti
roll bar fitted on the bogie frame realizes a constant, reduced inclination coefficient
during running. The bogie frame is linked to the bolster beam through two vertical
dampers, a lateral damper, four safety cables and the traction rods. The bogie frame is
linked to the coach body through two yaw dampers.

4. Traction Centre - The traction Centre transmits traction and braking forces between
bogie frame and body by a traction lever on the bolster beam pin and two rods.


5. Disk Brakes The FIAT bogie is fitted with pneumatic disk brakes. The pneumatically
operated brake cylinders are fitted with automatic device for taking up the clearances.

6. Taper Roller Cartridge Bearing Fiat Bogie is fitted with 130 mm Cartridge type
roller bearings.
31

4.1 Bogie frame
The bogie frame is a solid welded frame made by steel sheets and forged or cast parts.
The frame is made up of two longitudinal components (1) connected by two cross-beams (2)
which also support the brake units. The various supports which connect the different bogie
components are welded to the frame. The bogie frame rests on the primary suspension spring
units and supports the vehicle body by means of a bolster beam. The bolster beam is connected
to the bogie frame by the secondary suspension.










(Fig 4.1 Bogie Frame)
Nomenclature:
1. Bogie frame longitudinal component
2. Cross-beam


BOGIE FRAME
32

4.2 Primary suspension
Primary suspension is implemented by two units of two steel coil springs (internal (4) and
external (5)) laid out on the control arm upper part (13) by a centering disk (8) and adjustment
shims, as shown in figure 4.2.
The suspension is also completed by the following components:
A control arm (13), fitted with twin-layer elastic joints (12), connecting the axle bearing to the
bogie frame and transmitting, not stiffly, lateral, longitudinal and part of the vertical forces;
A vertical damper (14).
Rubber elements (2) separate the primary suspension from the bogie to realize noise
reduction.

Stops and protections are mounted on the bogie frame for the lifting.
Nomenclature:
1. Bogie frame
2. Rubber disks
3. Centering disk
4. Internal spring
5. External spring
6. Bump stop
7. Shim
8. Centering disk
9. Control Arm Lower Part
10. Plate (Fig 4.2 Components of Primary Suspension)
33

11. Block
12. Rubber joint
13. Control Arm Upper Part
14. Damper
4.3 Secondary suspension
The secondary suspension enables lateral and vertical displacements and bogie rotation with
respect to body when running through curves.
It is implemented by two spring packs which sustain the bolster beam (1) over the bogie frame
(6). Each spring pack is made up by an internal (3) and an external spring (4), mounted and
positioned through the centering discs (5).
An anti-roll bar (2), fitted on the bogie frame (6), realizes a constant, reduced inclination
coefficient during running.
The bogie frame is linked to the bolster beam through two vertical dampers (7), a lateral damper
(8), four safety cables (9) and the traction rods (10).
The bogie frame is also linked to the coach body through two yaw dampers (11).

Nomenclature:
1. Bolster beam
2. Anti- roll bar
3. Internal spring
4. External spring
5. Centering disk
6. Bogie frame
7. Vertical damper (Fig 4.3 Components of Secondary Suspension)
34

8. Lateral damper
9. Safety cables
10. Traction rod
11. Yaw damper
4.3.1 Cross Bar: Cross bar is the connection between the two ends of the trolley which also
maintains the uniform distribution of the hauling force to all wheels to ensure equal velocity.
4.3.2 Bolster Assembly: Bolster assembly is the host of the secondary suspension system. In
other words it is like two interconnected housing for springs. It also connects trolley and the
body of the rake. The main function of bolster assembly is to transform the hauling force and the
raking force form body to wheel and from wheel to body respectively.
4.4 Draw and Buffing Gear Assembly: Draw and buffing gears are attached to the end of one
coach and this two gear mechanisms are made to suit two adjacent coaches into an uniform
continuous movement. They also transform the hauling force from main engine to the following
rake, draw gear is specialized for these purpose, where as the buffing gears are essential for
maintaining a vibration less motion of a coach with respect to its former one.
We have two different arrangements of draw and buffing gear assembly in ICF and LHB
coaches. They are-
4.4.1 Screw coupling and the side buffers serves the aforesaid purpose in case of the draw and
buffing gears respectively in case of ICF coaches. Screw coupling not only gives the boost but
also let two coaches to connect in the formation of a continuous rake. The two jaws of the screw
on both sides are guarded with spring and rubber to minimize the vibration the hauling force
produces. They are called the DRAFT GEARS.
4.4.2Side buffers are uniquely shaped buffers. They have a flat plate made of stainless steel and
duly lubricated in contact to each other facing each other in motion. They are also guarded with
the iron plated and spring and rubber to minimize the vibration as much as possible.

35

For LHB coaches we have a multipurpose serving coupling between the two coaches. It is called
in technical terms the Center Buffer Coupling. It has got a special locking system operated by a
handle.




(Fig 4.4 Side Buffers) (Fig 4.5 Primary Suspension Unit)


36

CHAPTER 5
SHELL
The body shell is of integral light weight construction consisting of separate assembly group for
under frame, side wall, roof and end wall. The individual assemblies are joint to each other by
welding. Three types of steel are used for manufacture of body shell.
(Table 5.1 Strengths of Different type of steels)


Shell Assemblies Steels used and their
%age compositions
UTS
N/mm
2

Yield Stress
N/mm
2

Side wall, End wall
and Roof structure
X2 Cr8 Ferritic Steel
(SS 409M)
(C< .03%, Cr 10-12%,
Si 1%, Mn 1.5%)

450-600

320
Roof sheet and
Trough floor
X5 CrNi 18 10
Austenitic Steel (SS
304)
(C< .07%, Cr 18%, Ni
10 % Si 1%, Mn 2%)


700-850


235
Under frame IRS M-41 /Carbon Steel
( C < .01%, Cr .35 -
.6%, Ni .2 - .4%
Cu .3 - .6% Si .3 - .7%,
Mn .25%)


440-480


320
37

5.1 BODY:

Body is basically the coach itself without the braking mechanisms and suspensions. It has the
following constituents. They are discussed below:
1. The Carriage is the main structure of the coach. This contains a floor which is called
Turf. There are Arch Levers which maintain the weight distribution throughout the whole
coach. And then there is the roof which is of a typical aero dynamical shape.
2. At the bottom of the carriage there are two kind of bars made of stainless steel which
transfers the weight from the carriage to the wheels.
a. The Sole Bar is throughout the whole body of the coach vertically. These are at
the bottommost position of the body.
b. The Cross Bar is the horizontally arranged bars across the body. They get their
support from the sole bar.

5.1.1 Center Pivot Assembly:

Center Pivot is welded to the upper bolster plank and passes through the supporting frame which
is rectangular in shape. This is a pivoting system used in transportation of force through a
mechanically advantageous system of pivot. At the bottom of the center pivot there is a traction
lever. A traction rod is also connected at the end of traction lever having its other end connected
with the cross bar.









(Fig 5.1 Center Pivot Assembly)
38

5.1.2 Body- Bogie connection: Especially in case of the LHB Coaches, there are a special kind
of bolts called swing bolts, which are four numbered in each trolley. These connect the body to
the bogie to the body. Each bolt is fastened with a pin which can swing in the direction of the
motion

5.2THE TRANSMISSION OF HAULING FORCE:

The transmission of hauling force is an important observation phenomenon of the running of
rakes with engines. It is done through a number of ways and each way consists of a number of
steps:

5.2.1 Center Pivot: Hauling force is first transmitted to the Screw Couplings which are
connected at the front of a coach. From there the force is transmitted to the draft gear
then to the crossbar, to the sole bar, all the way to the bolster assembly through
swing bolts. Then due to this the swing bolt moves forward and so does the traction
lever and the traction rod. So the crossbar moves forward and the wheels start rolling.


5.2.2 Longitudinal Bumpstop: There is another way of transmission of hauling force from
the center pivot which is through the longitudinal bumpstop. This is partly cubical in
shape attached at the front of pivot assembly. When pivot moves forward it also
moves covering up the little gap between the frame and the bumpstop. Through the
supporting frame it goes to the crossbar.


5.2.3 Articulated Control Arm: The articulated control arm is a direct connection
between the body and the bogie. Through this the force is directly given to the
bearings.



39


5.3 TROLLEY:

Trolley is basically the separated part containing the wheel and other similar components which
are essential to run a coach. When they are attached with the body they are called the bogie.
Here we are going to discuss about the trolley parts of the ICF coaches.


5.3.1 Trolley Frame: Trolley frame is the main construction of the trolley on which the
other components rest. This is a metallic construction just like a cage having
different gaps in between to fit the components.

5.3.2 Center Pivot: This is the centrally situated hole which will indicate the correct
position of the trolley when fitted with the body. There is a counter part of the
hole attached at the body itself to indicate the perfect position of the trolley. When
assembled they should match perfectly.

5.3.3 Side Bearing: Side bearing is the bearing space engulfed by lubes and a bearing
made of bronze which plays a good role in distributing the weight throughout the
trolley.

5.3.4 Brake Cylinder: If we see the trolley in the direction of the motion we will see
two brake cylinders one after one which have the air supply through one outlet.
These brake cylinders operate in a critical air pressure and contains a piston which
we call the slug adjuster. At that particular pressure the piston inside those
cylinders moves and the brakes hold firm onto the wheels.


5.3.5 Brake Blocks: In ICF coaches we generally use the K & L types of brake blocks.
These are used as components of shoe brakes attaches at wheels. These special
40

types of blocks are used because of their increased coefficient of friction and also
the heat absorbing capability.

5.3.6 Equilateral Sterod: This is attached to the trolley symmetrically along the trolley
frame horizontally to minimize the lateral force when in motion.

5.3.7 Anchor Rod: These are rods attached vertically to minimize the longitudinal
load. Both of them are made of stainless steel.

5.3.8 Suspension Systems: These are anti vibration attachments which are attached to
the main frame and the wheel bearing.


41



(Fig 5.2 Trolley)
42

5.4 THE LOAD DISTRIBUTION:
SIDE BEARING

UPPER SPRING BEAM

SECONDARY SUSPENSION

SUSPENSION LINK

HANGER LINK

HANGER BLOCK

PRIMARY SPRING

AXLE BOX WING

JOURNAL

BEARING

AXLE

WHEEL




43

CHAPTER 6
BRAKING SYSTEM
6.1 AIR BRAKE SYSTEM:
In Air Brake system compressed air is used for operating the brake system. The
locomotive compressor charges the feed pipe and the brake pipes throughout the length of
the train. The feed pipe is connected to the auxiliary reservoirs and the brake pipe is
connected to the brake cylinders through the distributor valve. Brake application takes
place by dropping the pressure in the brake pipe. The schematic arrangement of the brake
equipment is shown as Fig. 6.1 (For passenger coaches), Fig 6.2 (For Generator coaches)
Components of Air Brake System
1. Brake Container (Brake Equipment Panel)
2. Distributor valve
3. Pressure Tanks (125 litres, 75 litres, 6 litres)
4. Indicators
5. B.P./F.P. Couplings and Hoses
6. Emergency Brake Pull Box
7. Emergency Brake valve
8. Bogie Brake Equipment, consisting of-
Brake Discs
Brake Caliper Units (consisting of Brake Cylinder, Brake Calipers, Brake Pads)
9. Wheel Slide Control System, consisting of-
Microprocessor Control Unit
Speed Sensor/Pulse Generator


44







(Fig 6.1 Brake equipment for passenger coach)

6.1.1 Brake Container (Brake equipment panel):

The Brake Container (Brake equipment panel) consists of a Manifold on which various
devices like the Distributor Valve, Cocks, Test fittings etc. are mounted. It also consists
of the reservoirs required for the Brake system. The container is mounted under the car
body and different lines (Feed pipe, Brake pipe, etc.) are connected to it.

(Fig 6.2 Brake equipment panel)

45


(Fig 6.3 Brake equipment for Generator coach)

6.1.2 Connections to the container:
There are 4 connections to the container for Passenger Coach:
1. Feed pipe(FP)
2. Brake pipe(BP)
3. Brake cylinder pressure -- bogie
4. Auxiliary support pipe ( for toilet)

There is an additional connection for the containers of the generator coaches,
1. Support for Indicating device of handbrake
2. These connections from the container to car body are provided at the back plate
fitted with Ernesto type fittings.



46

6.1.3 Brake application:
1. The driver lowers the BP pressure by engaging the A-9 valve in the engine.
2. This loss in pressure is transmitted from one bogey to the next.
3. Since CR pressure remains same, the main diaphragm(above the CR) moves up in
response to the pressure drop in DV.
4. As a result the three pressure valve opens the AR-BC port .
5. Thus the AR pressure of 6 kg/cm2 flows into the BC through pressure limiters
which reduces BC pressure to 3.8.

6.1.4 Brake Release:
1. BP pressure is again increased to 5 kg/cm2.
2. Consequently, main diaphragm move down and the three pressure valve closes
the AR-BC port and opens the BC-atm. port.
3. BC pressure is released and the brake caliper is disengaged.

6.2 BOGIE BRAKE EQUIPMENT:
The Bogie Brake equipment consists of:
1. Brake Caliper Units
2. Brake Cylinder
3. Brake Discs
4. Brake Shoes
Each axle is equipped with two grey cast iron brake discs. The brake energy is dissipated
only at the axle mounted brake discs, so the wheel set is only stressed by the weight of
the coach. The advantage of this arrangement is that the superposition of the thermal
stresses and mechanical stresses is avoided.

6.2.1 BRAKE CALIPER UNITS
The brake caliper units are readyto-use combinations of a brake caliper and brake
cylinder, providing automatic slack adjustment for wear (abrasion) on brake pads and
47

brake discs. Consequently, the clearance required between the disc and pads for smooth
running remains practically constant while the brakes are released.
Brake Caliper units consist essentially of the brake cylinder, the brake caliper, and the
brake shoes d1 and d2 with snap lock gates. The brake caliper units are held in the
vehicle bogies by a three point-mounting arrangement.
6.2.1.1 Working principle:
Applying the service brake charges the brake cylinder and presses the brake pads against
the brake disc. Brake force is built up when the pads are applied. Venting the brake
cylinder releases the service brake. The return spring in the brake cylinder moves the
caliper levers to the release position.
The handbrake lever is moved mechanically. The piston is pushed forward, and the brake
pads are applied to the disc. When the parking brake is released, the caliper levers are
drawn to the release position by the return spring in the brake cylinder.

(Fig 6.4 Brake Caliper Unit)

48

6.2.2 BRAKE CYLINDERS:

U-series brake cylinders with automatic slack adjustment are used to operate the friction brakes
in rail vehicles. U-series brake cylinders are essentially distinguished by their integral, force
controlled slack adjustment mechanism which is designed as a single acting clearance adjuster.
The working of this mechanism is not influenced in any way by the elastic brake rigging
deflection, which varies according to the brake force. In the course of braking, the slack adjuster
quickly and automatically corrects the increasing brake pad or brake block clearance due to
wear.

(Fig 6.5 Brake Cylinder & Calipers)


6.2.3 BRAKE DISCS:
The axle mounted brake disc consists of a gray cast iron friction ring and a cast steel hub,
connected by means of radially arranged elastic resilient sleeves which are secured in the
hub by means of hexagon screws. The friction ring is manufactured as a solid component
or in a split version. In the latter case, the two halves are held together by two tight fit
screws.

49

Axle Mounted Brake Discs Wheel Mounted Brake Discs


(Fig 6.6 Axle Mounted and Wheel Mounted Brake Discs)

6.2.4 BRAKE SHOE:
The brake shoe is provided with a brake pad holder carrying replaceable pads. The brake shoe
consists of the brake pad holder, the vertical pins and the brake pad. The brake pad holder is
provided with a dovetail guide into which the pad is slipped. The pad is held in place by a
captive gate, which is pivoted at the pad holder. To lock the gate a locking spring of spring steel
has been provided which is pre-tensioned such that in one position it secures the gate in the pad
holder and in the other (released) position it holds the gate open. For each brake disc a right and
a left hand brake shoe are required.


6.3 BRAKE RIGGING SYSTEM:
1. Due to BC pressure, the piston moves forward and strikes against the brake caliper.
2. The lever arm of the brake caliper presses onto the disc brake through the brake shoe.
3. The disc brakes are mounted on the wheel axle and so rotate along with the wheels.
4. Due to application of brake shoes, the discs begin to lose their angular speed.
5. As a result the axle also begins to slow down since the two are connected.
50

6. Ultimately, the wheels stop rotating as they are mounted on the same axle.

(Fig 6.7 Diagram showing Brake Rigging Pressure)


6.4 WHEEL SLIDE PROTECTION EQUIPMENT
1. Operates as a pressure regulation device of the air pressure inside the brake cylinder and
adjusted the braking force to the wheel to rail friction conditions so as to prevent the
wheels from locking and reduce the barking distance
2. In the case of the adhesion coefficient provided by a dry rail, the device does not interact
with the pneumatic system. The device enters into action when a loss of adhesion of the
axles is detected and, moment by moment, it adjusts the braking force to the present
adhesion conditions.
3. The operation is controlled so that the skidding wheel is allowed to find the most
favorable area for the adhesion-skidding characteristics.
4. The action of the device is controlled in order to keep the skidding wheel in the most
favorable area of the adhesion-skid characteristic.
5. Speed signal derived for CDTS.
51


(Fig 6.8 Speed sensor & Phonic wheel)



(Fig 6.9 Dump Valve and Connector)



(Fig 6.10 Electronic Connectors & Electronic unit)
52

6.5 CENTER BUFFER COUPLER:
The coupler provides a means of mechanically connecting individual adjacent vehicles in order
to make a train. The coupler is located at both ends of each vehicle. When connected to a coupler
of an adjacent vehicle, it allows the vehicles to move independently to accommodate track
curvature and elevation change while remaining connected (coupled) together.
The coupler is opened manually using the coupler operating rod and is closed automatically
when the couplers on adjacent vehicles are mated. The coupler automatically locks when fully
mated.
LHB coaches have been provided with tight lock centre buffer couplers instead of screw
coupling.
Couplers are AAR-H type and have anti climbing features because of vertical interlocking.
Couplers have adequate strength for:
1. Satisfactory hauling of a train of 26 coaches at 110 kmph
2. Satisfactory hauling of a train of 18 coaches at 160 kmph
Coupling is possible under angular misalignment both horizontally and vertically. The coupler
permits coupled trains to negotiate vertical and horizontal curves and allows rotational
movements. The draw gear ensures cushioning effective in both buff and draft.


53

CHAPTER 7
CONTROL DISCHARGE TOILET SYSTEM (CDTS)

LHB coaches are fitted with controlled discharge toilet units to avoid soiling of track in station
and inhabited areas.
The toilet system is designed to operate with a pressurized water bowl wash that covers 100% of
the toilet bowl area. The waste is removed from the toilet bowl and transferred to a retention tank
with a minimal amount of water. Water consumption is only 2.5 liters per flush cycle for the
Indian style toilet bowl and 1.5 liters for the European style toilet bowl.

7.1 Salient Features of CDTS:

1. Programmable.
2. Requirement of less Air and Water.
3. P.L.C Controlled.
4. Easy to clean.
5. Hygienic.

7.2 Operating Principle of CDTS:

1. This system works on electrical & pneumatic pressure arrangement. The retention tank
stores effluent has two openings. These two openings activates by double acting
pneumatic cylinders fed by Feed pipe of air brake system with the help of
electromagnetic solenoid valves.
2. The system starts working on a single push of flush switch. As the flush switch is
pressed, water flows into the toilet bowl & the upper slide valve opens which is
connected between the toilet bowl & retention tank. All the toilet waste is transferred into
the retention tank. At the end of each flush cycle the supply of water is stopped & the
54

upper slide valve is closed. Thus, the toilet is sealed from the retention tank, preventing
odour entering from the toilet room.
3. The waste accumulated in the retention tank remains in the retention tank until two
parameters are satisfied.
4. A predetermined no. of flush counts.
5. The train is reached a predetermined speed.
6. As soon as these above two parameters are met, the lower slide valve of retention tank
opens & the toilet waste accumulated in the tank is discharged out of the tank to the rail
side, away from the station & city.
7. The lower slide valve of the retention tank remains open for only small period of time to
empty the retention tank. The lower slide valve then remains closed until the above
discharge parameter conditions is again satisfied.
55




(Fig 7.1 Schematic Diagram of CDTS)

7.3 Toilet system has following components:
7.3.1 Indian & European toilet basin with flush nozzles: These are two types of toilet
basin used in CDTS system.
7.3.2. Control panel:
56

Control panel of CDTS consists of following equipments:
7.3.2.1 Programmable logic controller (PLC):
The Programmable logic controller works on 24 V DC having 8 inputs & 4 outputs. It
records the no. of flush cycles for opening/closing of lower slide to drain out the effluent
from retention tank. PLC also controls the opening/closing of lower slide when signals
received from WSP regarding speed of vehicle through WSP System to control the
flushing & signal received from Empty WC switch.
7.3.2.2 Solenoid valve:
The solenoid valve control the entry & exit of pneumatic air in the pneumatic cylinders
fitted on the upper & lower slide valves after receipt of signal from PLC.
7.3.2.3 Control relay:
Control relay is fitted aside of PLC on the control panel. A supply of 110 V DC is present
in the control relay. This control relay operates at 24 V DC &connect 110 V DC supply.
When 24 V DC supply is received from PLC, control relay operates & the 110 VDC
supply present in control relay is passed on to the water pressurizer.
7.3.3 Retention tank:
The effluent drained from the toilet basin bowl after flushing is stored in the retention
tank. In case of extra flush (beyond the capacity of tank), overflow pipe is provided to
drain out the effluent.
7.3.4 Lower Slide valve:
Lower slide valve is designed to operate on two parameters (predetermined no. of flush
counts, & predetermined speed of vehicle). As soon as these above two parameters are
met, the retention tanks lower slide valve open. The toilet wastes accumulated in the tank
are discharged out of the tank..
7.3.5 Upper Slide valve:
Upper slide valve is opened with the operation of flush switch. It closes after effluent
enters the retention tank. The slide valves open & closes by the movement of piston of
pneumatic cylinders controlled by PLC & solenoid valves.
57

In the latest version, the flapper arrangement has been introduced instead of upper slide
valves, to overcome slide jamming problems. This flapper arrangement consists of a flap,
which is connected by means of connecting links to one pneumatic cylinder. This flapper
operates in vertical direction (open & closes). The difference between slides & flapper
arrangement is the axis of movement of opening arrangement.
7.3.6 Flush button:
This is an electrical switch. On pressing this switch the electric circuit is completed with
the PLC & flush cycle starts.

7.3.7 Water Pressurizer:
Water pressurizer is fitted in the inlet of water pipe line connection to the CDTS system.
As the flush button is operated this water pressurizer is started & pressurized water is
supplied to the toilet basin.
7.3.8 Fail Safe Mode:
A FAIL SAFE MODE of operation is been provided in both Indian and European Style
Toilet System.
In the event of a loss of air, a loss of electricity or both, to enable use of the toilet, the
FAIL SAFE MODE is provided. It is also termed as manual flush.

7.4 Operational Description:
Stand-by condition
The status of various components/devices is listed below:
Water Pressurizer Off
Water check Valve Closed
Upper Slide Valve Closed
Lower Slide Valve Closed

58

Flush Cycle
Depress momentarily Flush Button and the status of various components / devices is listed
below:
Step 1
1. Water Pressurizer & Water check valve On (for a
predetermined time)
2. Upper Slide Valve Open (for a predetermined time)

Step 2
1. Water Pressurizer & Water check valve Off
2. Upper Slide Valve Closed

Retention Tank Discharge Cycle
Condition I
If train speed is - below 30 kmph then the retention tank lower
slide valve closed

Condition II
If train speed is above 30 kmph and Flush Count is below Predetermined value, then the
Retention Tank Lower Slide Valve remain closed.
If the train is above 30 kmph and Flush Count is equal or above Predetermined value, the
Retention Tank Lower Slide Valve Opens (for a predetermined time).
End of Retention Tank Discharge Cycle
Flush Count restarts at ZERO (0)
59


(Fig 7.2 Operational description of CDTS)
60

CHAPTER 8
MAINTAINENCE OF TRAINS

8.1 THE PRIMARY STRUCTURE:
Train is the combination of various types of coach and the train engine. There are many kind of
rakes which play an important role in serving the main purpose of driving a train. Like public
transportation and carrying goods etc.
There are also varieties of train engines depending on the medium they are driven by, like
electrical and fuel based, especially diesel. Here we are going to concentrate on the trains which
are used mainly for travelling and are equipped with such facilities.








So rake can be defined as the combination of coaches attached together after detachment of the
engine from the train.
8.2 THE MAINTENANCE OF THE TRAINS:
The maintenance of the trains is an important criteria for every coaching facility and workshop.
This is very important to make the system run smoothly and to look after the passenger safety.
So knowledge about the proper maintenance is essential.

Seen from the point of view of the train itself there are three kinds of maintenance available in
Eastern railways.


Down train arriving
at platform
Drawn out of the
platform
Engine
detached
The rake stabled
at the yard or sent
for maintenance
61

8.2.1Primary Maintenance:
According to the rules of railways, every division of railways possesses the responsibility
of running some specific trains. For those trains under the consecutive divisions primary
maintenance is done before that train leaves that section of railways. In other words the
primary maintenance is done at the mother or the terminal station.
Here every aspect of pressure related systems, and aspects of public safety are checked.
The continuity, the bonding between coaches etc is also taken care of. This takes at about
5 6 and half an hour duration until it is given the fit to run certificate.
Each primary maintenance comprises a form which is known as the v-5 form. This form
has information spaces about those aspects that are secured during this maintenance. If a
train is given fit instead of any fault not so fatal, that is written in the certificate.

8.2.2 Round trip/Turn Around Maintenance:
This maintenance takes place after the train reaches its final destination from the staring
one. This is a short duration maintenance preparing the train to send it back to the
terminal station. Just the necessary maintenance is carried out.
This takes about one hour forty minutes to about two hours to complete.

8.2.3 Secondary Maintenance:
Secondary maintenance is a specific type of the primary maintenance. When the train
runs for about 3500 kilometers or about 3 days, either way, then at the destination station
the train undergoes the secondary maintenance. Here the measures taken are just similar
to the primary one. The duration is about six to seven hours.








62

8.3 THE MAINTENANCE SCHEDULES AND THE OVERHAULING PERIODS:

There are normally seven kinds of maintenance schedules depending on the condition of coaches
and wagons. They are respectively -

1. A- Schedule: after 30 days of manufacturing or of periodic overhauling, repetitive

2. B-Schedule: after 90 days of manufacturing or of periodic overhauling, repetitive

3. C-Schedule: after 180 days of manufacturing or of periodic overhauling, repetitive

4. Intermediate Overhauling: after 9 months of manufacturing or of periodic
overhauling

5. Periodic Overhauling: after the returning date given by the workshop after periodic
overhauling.

6. Non-Periodic Overhauling: This is done after 12 months or 18 months after the
manufacturing date or the periodic overhauling date depending
on the condition of the corresponding coach.

7. Inter lifting schedule: This is a special kind of maintenance done within the
maintenance facility with lifted coach and parts.

8.4 PERIODIC OVERHAULING:-
Periodic overhauling is the best available process of maintenance of coaches in India. This
generally operated after 12 or 18 months after the manufacturing or the previous periodic
overhauling done in any workshop. This undergoes a huge process of lifting the coach, isolating
the all parts, and changing or replacing the necessary or damaged parts. In other words this is the
process of renewing the coaches. Here are some varieties-

63

1. 12 month basis
2. 18 months basis
a. Mail and express trains
b. Passenger trains
3. For MLR coaches - 18 months
4. For new built coaches - 24 months


8.4.1 POH DATE AND RETURN DATE:
POH date is that date on which its POH has been done previously in an workshop. This is written
on the coach. And the return date is the date on which it is to be dropped off from the track and
to be taken for another periodic overhauling. Generally they have a 12 month or 18 month gap
between them in accordance with the definition of the POH.
Both of the dates should be given by the corresponding workshop where its POH has been done.


8.4.2SIGNIFICANCE OF COACH NUMBER:
Every coach has its own unique number attached to it which obviously carries some significant
information to us. Generally in India that is of five numbered.
The first two digits represents the year of manufacturing of the coach. And the rest three digits
represent the list of types of coaches. It represents of which type the coach is.

64

CONCLUSION

This training program is an excellent opportunity for us to get to the ground level and experience
the things that we would have never gained through going straight into a job. I am grateful to
Coach Care Complex, INDIAN RAILWAYS, Jaipur for giving me this wonderful
opportunity. The main objective of the industrial training is to provide an opportunity to
undergraduates to identify, observe and practice how engineering is applicable in the real
industry. It is not only to get experience on technical practices but also to observe management
practices and to interact with fellow workers. Also I learnt the way of work in an organization,
the importance of being punctual, the importance of maximum commitment, and the
importance of team spirit. As we all know that INDIAN RAILWAYS is the backbone of Indian
Transportation and a large population is dependent on it and as a result it give a lucrative
turnover to the Indian Government. People look up to Railways for good career opportunities as
it provides large no. of employment, also Railways are now a days taking their keen interest in
increasing the speed limit and working on the bullet train.
By attending the 6 weeks training in Coach Care Complex Jaipur division, NWR. I conclude that
this primary requirement of train transportation is to ensure safe, speedy, reliable and punctual
movement of passengers and goods to various parts of the country. The role of the Coach Care
Complex of the Indian Railways is to provide modern, efficient and reliable Coaches for speedy,
smooth and safe running of trains, as well as an effective and reliable mode of relief in
passengers. For this purpose POH (Periodic Overhauling) of coaches is done to service it time to
time for e.g. each and every bogie and coach are sent for POH in every 12 months and 18 months
respectively. This training also acquainted me to the practical applications of numerous topics
which have been covered in the university curriculum but only in theory, like I came to know
about the selection of springs for different coaches, practical work on different shops, work
sequences, etc. For this and everything else, I am eternally indebted to all the officers and staff of
Jaipur Division (N.W.R).



65

REFERENCES


1. www.indianrail.gov.in/ir_zones.pdf list of all the zones and division
2. http://www.nwr.indianrailways.gov.in/view_section.jsp?lang=0&id=0,1,285 , figure
and data related to the Jaipur division and North western zone.
3. http://en.wikipedia.org/w/index.php?title=File%3ARailway_network_schematic_map
_2009.png Railway Zonal Map .
4. http://www.nwr.indianrailways.gov.in/uploads/files/1401775686459-NWR.pdf coach
maintain manual of NWR zone.
5. http://www.nwr.indianrailways.gov.in/view_section.jsp?lang=0&id=0,1,263,602hard
ware used in japur zone in PRS.
6. http://cris.org.in/CRIS/Projects/PRS , content about the PRS.
7. https://www.google.co.in/search?q=CONCERT+Network+topology&client=firefox-
a&hs=31y&rls=org.mozilla:en-
US:official&source=lnms&tbm=isch&sa=X&ei=QhDuU4P7Ecjh8AXA5oC4Cg&ve
d=0CAgQ_AUoAQ&biw=1280&bih=857 concert network implementation.
8. Manual No.516/RRI61/A to Manual No.516/RRI61/D about bogie, coaches design
used in N.W.R Jaipur zone
9. Manual No.019/OFC09/1/23 technique and equipments used in LHB Coaches.