SOUTH CENTRAL RAILWAY

Mechanical (Carriage & Wagon)

Question Bank

(WITH ANSWERS)

STC/SC

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Q1. Explain the pattern of Freight Train Examination as per latest JPO No. 7/2014 ?
Answer:
As per JPO No. 7/2014, there shall be only three types of examinations for freight stock.
1. Closed Circuit Rake Examination (CC rake)
2. Premium Rake examination.
3. End to End examination
1) CC rake Examination (Periodical Monitoring Examination (PME)
1. Only Off POH/ Off ROH wagons fitted with air brake system should be inducted as new
CC rakes under normal circumstances. For formation of CC rakes other than this,
CRSE’s approval is required, which should be recorded in writing.
2. CC rake shall be given 100% brake power during PME at original base depot.
3. CC rake examination is to be conducted only at nominated base depot. Code of base
depot is to be stenciled on all the wagons.
4. The BPC of the rake shall be valid for 7500 kms or 35 days whichever is earlier.
However, for BLC rakes BPC shall be valid for 6000 kms or 30 days whichever is
earlier. Within this validity rake can subjected to any no. of loading/unloading.
5. After loading, at every loading point the CC rake BPC shall be revalidated in the form of
GDR check as stipulated in Para 12.0 of the JPO.
6. CC rakes are allowed to run only in the circuit of the nominated zones.
7. Colour of BPC shall be yellow.
8. The CC rake BPC becomes invalid under the following conditions. These rakes have to
be cleared up to next examination point in the direction of movement for examination
and issuance of a fresh BPC up to PME depot. HQs Operating and C&W Control should
be appraised of all such cases so that the rakes can be brought to the PME depot within
40days from the day of issue of BPC.
i) If rake integrity disturbed by more than 4 wagons within the validity of the BPC. Only
up to 4 wagons attachment/detachment is permitted en route during the validity of the
BPC.
ii) If the rake stabled for more than 24 hours at nominated TXR examination yard / any
other station, except the loading/unloading point.
iii) If CC rakes moved to any other zone not mentioned in the circuit.
iv) If overdue CC rake is not moved in the direction of PME depot.
v) If the driver fails to log the kilometers on the BPC correctly. (BPC of such CC rakes will
deemed to be valid only for 20 days.
2) Premium End to End Rake examination:
1. Premium End – to End rakes will be formed out of Air Brake open stock (BOXN,
BOXNHA, BOXNHS), covered stock (BCN, BCNA, BCNA HS), BOBR and BOBRN.
On S. C. Railway, Premium End-to-End rakes will be intensively examined in empty
condition and certified by examination points at BPA, RDM, GY, BZA, COA, SNF and
PAU on the nominated lines, (’A’ category depots or depots should be upgraded to “A”
category depots).
2. Brake power certificate issued for such premium end-to-end rakes will be valid for 12
days from the date of issue. During this 12 day period, the rakes will be allowed multiple
loading/unloading. Loading after 12th day should be prohibited so that the rake is not
overdue.
3. After the lapse of 12 days, the rake should be offered for next intensive examination at
the first examination point in the direction of movement. To avoid examination in loaded
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 condition, a grace period of 3 days be permitted, if the rake is in loaded condition on 12th
day.
4. However, after expiry of the grace period, i.e., after a lapse of 15 days from the day of
issue of BPC, even a loaded premium rake shall be offered for examination at the first
train examination point in the direction of movement and BPC is issued in End to End
format up to the unloading point only.
5. Brake power certificate for premium end-to-end rakes to be issued with proper format in
green colour paper.
6. Minimum brake power should be 95% at originating station.
7. The movement of Premium end to end rakes will be monitored through FOIS by traffic.
3) End to End examination:
All trains which are not checked in the CC or Premium rake examination will come
under this category. This is for all stocks including mixed stock where freight wagons
are available.
1. Empty rakes shall be offered in full formation for examination and issue of BPCs.
Thereafter C&W staff will carry out no further examination after loading. After such
examination, the empty rake should be moved to the loading station as per the
requirement of traffic.
2. The validity of BPC for an empty rake will be given at the train examining point as “Up
to loading point & further up to unloading point”. But after loading the rake, the
operating staff (commercial staff if no operating staff is posted at that station) shall
ensure that the destination of the loaded train is clearly mentioned on the BPC and the
same BPC valid up to destination.
3. The empty rake must reach the loading point within 4 days of the issue of BPC
including the day of issue, for the loaded rake to move on the same BPC.
4. No driver shall move the loaded train from the loading point unless the destination is
clearly mentioned on the BPC. BPC of the loaded train without destination shall be
treated as invalid.
5. Green color BPC for Air brake stock and Pink color BPC for Vacuum Brake stock shall
be used for such rakes.
6. Minimum brake power should be 90% for Air Brake stock and 85% for Vacuum Brake
stock to be maintained at originating station after Intensive Examination.

Q2. Explain procedure of intensive examination for Freight Stock?

Answer:
The following procedure is to be followed for conducting intensive examination of freight
trains
a) Rolling-in examination including axle box feeling for detection of any defects like flat
tyre, loose parts, hanging parts and worm box.
b) Incoming BPC to be collected.
c) Inspection and repair of running gear fittings.
d) Inspection and repair of brake gear and spring gear.
e) Inspection and repair of draw and buffing gear.
f) Checking and making good the deficiency of safety fittings, safety brackets, safety loops
etc.
g) Replacement of brake blocks, correct maintenance of SAB “A” dimension and piston
stroke.
1. Minimum yard leaving Brake Block thickness – 20 mm
2. SAB “A” dimension – CASNUB bogie 70 +2/-0 mm
BOBRN, BLC 27 +2/-0 mm
3. Piston stroke –
STOCK Empty Load
BOXN, BCN, BCNA, BRN, BTGLN 85±10MM 130±1010MM
BTPN 87±10MM 117±10MM
BVZC 70±10MM
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 BOBRN/BOBYN 100±10MM 110±10MM
BOX,BOI,BCX 130MM 180MM
h) Correct fitment of washers, bulb cotters and all brake gear pins to be ensured.
i) Correct functioning of empty/load device.
j) Checking and securing of air brake components for their proper functioning and fitment.
k) Wheel profile to be checked for rejectable defects.
l) Visual examination of Bogie frame and spring for cracks/breakage.
m) Ensure correct requirement of brake power as per JPO No. 7/2014
1. CC rakes – 100%
2. Premium rakes – 95%
3. End to End rakes – 90% (for Air brake) & 85% (Vacuum brake)
n) Issue BPC in proper format as per JPO No. 7/2014.

Q3. Explain maintenance of departmental wagons in open line?

Answer:

Maintenance of departmental wagons falls under the category of End to End intensive
examination.
Types of departmental wagons:
1. Sleeper carriers
2. Rail carriers
3. Ballast wagons
4. 10RP/20RP carriers (rails of 130m/260m lengths).

BCXSC, BOXSC etc. are the wagons used as sleeper carriers as well as rail carriers.
These wagons are made out of over aged BCX, BOX wagons by removing the end walls
and side walls to enable mechanized loading and unloading at PQRS (Plaser Quick
Relaying System).

BOBYN wagons which are specially designed for carrying and lying of ballast are
categorized as ballast carriers.

Modified BRN/BRNA wagons are categorized as 10RP/20RP (Rail Panels) carriers
which are used to carry the rails from manufacturing unit to site.

• All the departmental wagons are to be based at nominated depot and code of the base
depot should be clearly stenciled on these wagons.
• Normally all the departmental wagons are to be examined intensively in empty
condition.
• In case of Sleeper carriers, Rail carriers and Ballast carriers fresh BPC will be issued
after intensive examination.
• The originating Brake Power of these trains would be 90%.
• The validity of BPC for wagons having CANUB bogies with Air Braked stock will be
for 30 days without weekly revalidation.
• The validity of BPC for wagons having UIC bogies with Air Braked stock will be for 30
days with fortnightly revalidation.
• After loading / unloading GDR check should be conducted in view of safety of the train.

Q4. Explain RPC – IV rules for coaching stock ?

Answer: Railway Board has issued guide lines for maintenance and examination of coaching
trains under Revised Policy Circular IV.

Under gear Internal External

Preventive Brake system
examination cleaning cleaning on
Sl. Category of Maint. Enroute/Terminati check prior to
and brake pass. nominated
No trains schedules ng examination start at PF at the
system amenity line with
at pit line other end
maintenance attention proper

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 at pit line and facilities
watering
Enroute: After every
250 to 350 KMs of
Mail/exp. One- run at locations to be Complete
At primary At both the At both At both the
1 way run>3500 decided by Railway air/vacuum check
end ends ends ends
KMs for each train with fresh BPC
Terminating Exam
terminating station
Mail/Exp. one
way run<3500 Complete
At primary At both the At both At both
2 KMs but round -do- air/vacuum check
end ends ends ends
trip run> 3500 with fresh BPC
KMs
Only continuity
check if stabled at
Mail/Exp. round platform,
At primary At both the At both the At primary
3(a) trip run up to -do- otherwise, brake
end ends ends ends
3500 KMs power check with
endorsement on
original BPC
At primary
Enroute: After every
To be done end and Only continuity
250 to 350 KMs of
Shuttles/Inter after 3500 each check if stabled at
At primary run at locations to be
connected KMs or 96 terminal or platform
At primary end once a decided by Railway
3(b) Mail/Exp. round hours as decided otherwise, brake
end day for for each train.
trip run up to whichever is by the CME power check with
shuttles. Terminating Exam
3500 KMs only at to ensure endorsement on
each terminating
primary end proper original BPC
station
cleanliness
Enroute: After every
To be done At every 250 to 350 KMs of Only continuity
Passenger trains
after 3500 terminal or run at locations to be check if stabled at
with toilets
KMs or 96 as decided decided by Railway platform
including At primary At primary
4 hours by the CME for each train. otherwise, brake
interconnected end end
whichever is to ensure Terminating Exam power check with
passenger trains/
earlier at proper once a day at endorsement on
shuttles
primary end cleanliness nominated original BPC
terminating station
Only continuity
To be done
check if stabled at
after 3500
Once a day at platform,
Passenger trains At primary KMs or 7 days At primary
5 Once a day primary or a otherwise, brake
without toilets end whichever is end
nominated terminal power check with
earlier at
endorsement on
primary end
original BPC.

Q5. What is rolling in and rolling out examination? What are the advantages?
Answer:
Rolling in Examination
All terminating and pass through trains are given rolling in examination, while entering a
station with C&W depot. JE/SSE(C&W) and his staff should take up position on both sides
of the line short of the normal halting place on which the train is to be received and the
following inspection should be carried out.
1. Look out for any loose or dangling components.
2. Observe whether there are any flat places on the tyre (skidded wheel).
3. Observe and listen for any worm axle box (damages in roller bearing).
4. Defective / broken springs.
5. Defective / drooping buffers.
6. Abnormal behaviour of any of the vehicles, or any other observations which may lead to
unsafe working condition.
Rolling out Examination
Similarly, while the train is leaving from the plat form / yard, rolling out examination is also
to be conducted to avoid the above mentioned defects and the last minute detentions.
Advantages of conducting Rolling in / out examination:

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 • It will reveal the defects of rolling stock which can’t be identified / checked when it is
stabled.
• This simple examination will save lot of time and avoid major disasters.

Q6. Explain various wheel defects and their effects with limits of rejections and draw
sketch of tyre defect gauge?
Answer:

Wheel defects Standard Condemning Limit

Sharp Flange 14.5mm 5 mm or Less
Thin Flange 28.5mm 16mm or Less
16mm-IRS
Less radius at root of flange 13 or Less
14mm-WWP
Hollow Tyre ----- 5 mm or above
Deep Flange 28.5mm 35mm or more
Thin Tyre ----- 28 mm or Less
50 mm or more – for Coaching
Flat Tyre -----
60 mm or more – for Goods

Effects of Wheel defects:

1. Sharp flange: when allowed in to service it leads the vehicle to two roads while negotiating
defective points/crossings.
2. Thin flange: when allowed into service worn-out flange will break due to longitudinal
reaction by track and vehicle derails.
3. Less radius root: It will lead to excessive angle of attack and lead to climbing of flange on to
rail table and leads to derailment.
4. Hallow tyre and Deep flange: Often these two will appear on wheel tread together. When
allowed into service results in rough riding with noise and damages fish plates and fish bolts
of the track disconnects the rail joints. This will cause the following train to derail.
5. Thin tyre: When solid wheels have reached to its lowest allowed wheel diameter, the load
bearing capacity of the wheel reduce drastically and will get sheared under the heavy rolling
loads causing major disaster.
6. Flat tyre: This will cause hammer blow effect on the rails and rail fittings while in run.

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Q7. What do you mean by CMI K-003? What are the defects to be observed as per CMI K-
003?
Answer:
CMI-K-003 means carriage maintenance instructions issued by RDSO in the year 2003.
As per the CMI-K-003, the wheels are to be checked visually for the following defects.

1. Shattered Rim: A fracture on the wheel tread or flange is called Shattered Rim. It is
a rejectable defect.

2. Spread Rim: If the rim widens out for a short distance on the front face, an internal
defect may be present. Spreading of rim is usually accompanied by flattening of the tread, which
may or may not have cracks or shelling on the tread. Such a wheel must be withdrawn from the
service. This condition should not be confused with a uniform curling over the outer edge of the
rim around the entire wheel, is called rim flow. Rim flow is not a rejectable defect.

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 3. Thermal cracks: Thermal cracks appear on a wheel tread due to intense heating of the
arising out of severe brake binding. Such cracks occur on the tread and generally progress across
the tread in a transverse and radial direction.

Whenever such a crack become visible on the outer face of the rim or tread crack as reached
the outer edge(non-gauge
gauge face) of the rim, the wheel should be withdrawn from the service. If a
crack becomes visible on the outer flange face, the wheel withdrawn from service. Such wheels
should be sent to workshops for examinations and subsequent rejections.
Wheels involved in service brake binding should be examined carefully during the
maintenance to rule out the possibility
possib reject able thermal cracks. Such wheels may be identified
by the presence of flats (may
may be with in acceptable limits) and severe discoloration or blue black
heating marks on the tread.

4. Heat checks: Thermal cracks are deeper and need to be distinguished

distinguis from fine
superficial cracks visible on the tread on or adjacent to the breaking surface. These are called
heat checks, which are usually denser than thermal cracks. Heat checks are caused on the tread
due to heating and cooling cycles undergone by the wheel during normal breaking. Such wheels
do not need to be withdrawn but should be carefully distinguished from the reject able thermal
cracks.

5. Shelled Tread: Shelling can be identified by pieces of metal breaking out of the tread
surface in several
eral places more or less continuously around the rim. Shelling takes place when
small pieces of metal breakout between the fine thermal cracks. These are generally associated
with small skid marks or “chain sliding”. Such wheels should be withdrawn from service
se and
sent to workshops for reprofiling.

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6.Disc crack: A crack on the disc due to material failure is called disc crack. Disc crack of any
length on disc plate is a rejectable defect.

Q8. Explain new numbering system of wagon stock from 2003?

Answer:
New wagon numbering system introduced on Indian Railways from the year 2003. According to
this system wagon number contains “11” digits.
 First 2 digits indicates type of wagon (1st & 2nd )
 Next 2 digits indicate owning railway (3rd &4th )
 Next 2 digits indicates year of manufacture (5th & 6th )
 Next 4 digits indicates individual wagon number (7th ,8th ,9th &10th )
 Last digit is a check digit (11th )
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11
Type of Year of
Owning Railway Individual wagon number Check digit
wagon manufacture
However for convenience in normal day to day work owning railway and type of wagon would
be stenciled “alphabetically” also
For example South Central Railway BCNHL wagon manufactured in the year 2009 will be
stenciled as:
SC BCNHL 33 05 09 2876 5
Procedure for finding the check digit:
Step 1--- Add all the “odd placed numbers” (ie. 1st+3rd +5th +7th +9th)
Sum1(S1) = D1+D3+D5+D7+D9 = 3+0+0+2+7 =12
Step 2--- Add even placed numbers (ie. 2nd+4th+6th+8th+10th)
Sum 2 (S2) = D2+D4+D6+D8+D10 = 3+5+9+8+6 =31
Step 3 --- Multiply S2 with 3
S3 = S2X3 = 31X3 =93
Step 4 --- Add (S1+S3)
S4= S1+S3 = 12+93 =105
STEP 5--- This S4 is to be rounded up to next multiple of 10 by adding a “single
digit number” = 105+5 = 110 (110 is a multiple of 10)
Now the number added to round up S4 is the “Check Digit” i.e. 5 (in this case)
Q9. Explain the numbering system of coaching stock?
Answer: Numbering system of coaching stock:
Eg: SC 11201/C
 Coach number is an “Alpha Numeric” code which gives the details of the coach.
 The alphabetical code represents the owning railway. It may be of two letters or more.
Eg: SC – South Central Railway
ECoR – East Coast Railway etc.
 The numerical portion consists 5 digits
 First 2 digits represents year of manufacture of the coach.
Eg: 95 – year of manufacture 1995
00 – Year of manufacture 2000 etc.
 Next 3 digits indicate the type of coach and individual number of the coach. The
codification for type of coaches is as under.
S. No. Type of Coach Range of numbers in 3
digits
1 FAC 001 to 024
2 FACCW 025 to 049
3 ACCW 050 to 099
4 ACCN 100 to 149
5 ACCZ 150 to 199
6 GSCN 200 to 399
7 GS 400 to 599
8 GSCZ 600 to 699
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 9 SLR/SLRD 700 to 799
10 All other categories like CB, VP, VPU, VPH, WLLRM,
800 to 999
Postal van, Milatry coaches etc.
Military coaches will have a suffix “M”
The last alphabet “C” indicates that the coach is fitted with “CBC”.
LHB coaches as prefix “L”
Q10. What is IRCA? How many parts are there in IRCA? Explain briefly?
Answer:
IRCA – Indian Railway Conference Association situated in New Delhi gives out the rules for
the standard and condemning sizes of various components used on a rolling stock.
They also give the guidelines for the maintenance of rolling stock in workshops and in
open lines. The rulebooks issued for the Carriage & Wagon department are:

Part III - For Wagon Stock

Part IV - For Coaching Stock
There are 4 chapters in each parts IRCA
Chapter Details
Chapter I Definitions
Chapter II Workshop repair practice
Chapter III Maintenance practice in open line
Chapter IV Rejection rules

Q11. List out rejectable items for good stock as per IRCA Part – III?
Answer:
 Wheel defects such as sharp flange, thin flange, deep flange, hollow tyre, skidded
wheel etc.
 CBC coupler body broken / cracked.
 Center pivots broken / cracked.
 Trolley frame cracked or broken.
 Hotbox.
 Sliding type brake beam broken / bent.
 Suspension bracket broken on UIC stock.
 Trolley frame broken at horn gap stiffer & Bridle bar breakage.
 CBC yoke broken.
 CBC draft gear defect.

Q12. List out rejectable items for coaching stock as per IRCA part – IV?
Answer:
Body repairs:
Door repairs, corrosion repairs of under frame near lavatory and trough floor repairs, repairs to
sole bar, repairs to head stock. Repairs to draw and buffing gear.
Under gear repairs:
Loose centre pivot bolts, crack in center pivot, center pivot bent.
Axle box defects:
Any cover broken, nonstandard, deficient sealing arrangement defective, oozing of lubricant,
any hot box.
Bogie repairs:
Cracks in sole plate of bogie, bogie transom etc. Cracks in lower spring seat of dash pot, bent
axle guide. Bogie out of square.
Breakage of any coil springs of axle box, breakage of bolster coil springs, anchor links,
equalizing stay, shock absorber, suspension links, bottom spring plank.

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Brake gear:
In effective DV, brake cylinder, leakage in isolating cock, cut-off angle cock, Defective PEASD
and PEAV. Breakage of any pipe line.
Wheel defects:
Any tyre defect as prescribed in IRCA manual including the latest RDSO – CMI – K003
technical pamphlet.
Any coach due for POH,IOH and schedules, missing of APDs provided for brake gear
suspension arrangement are considered as rejectable items under IRCA part IV.

Q13. What is maintenance? Why maintenance is required? Explain the maintenance

systems followed on Indian Railway system?
Answer:
Maintenance:
The methods of inspection, replacement or repair of components / assemblies, usage of
the quality of material / specifications of materials and keeping the tolerances / dimensions is
called maintenance.
Why maintenance is required:
Maintenance is required on any equipment to keep it in good working condition with
safety, security and reliability so that it shall not fail during the course of work.
Types of Maintenance:
I. Preventive maintenance: It is a method of carrying out inspection, repairs/
replacements of components/assemblies before the failure of equipment.
In Indian Railways the following preventive maintenance methods are followed:
Trip Schedule, “A” Schedule, “B” Schedule, “IOH/ROH” and “POH”
II. Breakdown maintenance: It is a method of carrying out inspection, repairs/
replacements of components/assemblies after the failure of equipment.
In Indian Railways the following breakdown maintenance methods are followed:

Sick line attention,

Attention of derailments and other accidents.
Both preventive and breakdown maintenances are followed on Indian Railways.

Q14. Define various maintenance practices on coaching stock?

Answer:
 Primary maintenance
 Secondary maintenance
 Terminal maintenance
 R&D

Primary maintenance:-
Primary maintenance will be done on all passenger carrying trains at primary maintenance
depots on nominated trains notified by the Chief Mechanical Engineer of the Zone.
At primary maintenance depot all the primary maintenance schedule like trip schedule
examination that is examination after every trip, schedule “A” or monthly examination, schedule
“B” or quarterly examination and IOH (Intermediate over Hauling) will be done on the coaches
in which they are running.
The attention during primary maintenance should be made more intensive with special
emphasis as the public complaints regarding the amenities and comfort in travel are directly
ascertained to primary maintenance depot. And all kinds of attentions except IOH are to be
carried out with in the stipulated time of 6 Hrs.
Secondary maintenance:-
Secondary maintenance will be done on rakes which are terminated after a run more than
3500 KM at the other ends which are nominated for this purpose.
At secondary maintenance depots on termination the rake is to brought to pit line attend all
the items of trip schedule, mandatory, like external washing, internal cleaning, watering,
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provision of missing amenity fitting etc. and fresh BPC is to be issued up to primary
maintenance depot.
Terminal maintenance:-
With in the validity of BPC whenever a train is terminated, like change in train number etc.,
the train has to bee given certain attention as per RPC IV rules. This attention is called Terminal
maintenance. All the terminating trains shall be examined at stations for safe to run examination,
internal cleaning and watering to be attended. If the train is moved to yard and stabled for more
than 1 Hr 45 Min BPC is to be endorsed with brake power check otherwise with air continuity.
R & D:-
R&D means receiving and dispatch. All the primary maintained rakes and passenger through
trains shall be conducted rolling in examination, examination on terminating /and pass through.
The R&D staff shall take up position on both sides of the line short of the platform on which
the terminating train/pass through train is to be received and watch the condition of running
gear, flat places on tyres , axle box, broken springs, defective brake gear etc.,
The R&D staff should also check, the rakes after coming to halt, gear wise and ensure that
no rejectable defects are there.
The R&D staff should also be dispatch the originating trains on platform by issuing BPC
after the levels of air pressures are ensured on the engine and brake.
Q15. Write all the preventive maintenance schedules to be attended for coaching stock
with their periodicities?
Answer:
Following are the preventive maintenance schedules to be attended on coaching stock for its
better utilisation with almost no failures.

S. Name of the Where the schedule to be

Periodicity of the Schedule
No Schedule carried out
In pit line at PM depot &
1 Trip schedule After every round trip
SM depot
2 “A” schedule 1 month ± 3 days In pit line at PM depot
3 “B” schedule 3 months ± 7 days In pit line at PM depot
12 months + 30 days for newly built In IOH depot after
coaches, midlife rehabilitated coaches detaching from the
Intermediate Over and departmental coaches
formation at PM depot
4 Hauling (IOH)
9 months +30 days for all passenger
carrying vehicles and other coaching
vehicles other than newly built
24 months for newly built coaches,
midlife rehabilitated and departmental
Periodical Over coaches
5 At workshops
Hauling (POH) 18 months for all passenger carrying
vehicles and other coaching vehicles
other than newly built

• IOH of coaches running in Rajadhani & Sathabdi express is to done at work shop.
• During IOH of express, Garibradh, Jansatabthi and OCV’s running on express bogies are to
be exchanged with overhauled bogies received from Workshops.
• “C” schedule is abolished after the POH periodicity is enhanced to 18 months from 12
months.
Departmental coaches comprise Inspection cars, Track recording cars, Coaches attached to BT
rakes and TT machines, Coaches attached to MRV/ART specials.

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Q16. What is trip schedule? What are the items to be attended during trip schedule?
Answer:
Trip Schedule: It is a preventive maintenance schedule to be attended on coaching after every
round trip in pit line at Primary maintenance depot as well as at Secondary maintenance depot.

Following items are to be attended during “Trip Schedule”:

The coaches should be washed / cleaned from outside and inside.

• Under frames, bogie frames, axle boxes, axle guards, springs etc are to checked thoroughly
from inside and outside the pit line
• All moving parts to be lubricated.
• Oil in dashpot should be checked for leakage. Add/replenish with specified grade if the oil
level is below 40 mm.
• Oil in side bearer to be checked for leakage. Add/replenish with specified grade if the oil
level is low.
• Wheel profile and thickness should be visually examined and gauged in case they appear to
be near condemning limits.
• All the air brake components are to be checked for their proper functioning with RTR.
• Alarm chain apparatus to be tested.
• Brake power to be checked and adjusted so that the piston stroke is within the specified
limit.
• Check all the amenity fittings for its proper fitment and working.

Q17. What is “A” schedule? What are the activities to be carried out during “A” schedule?
Answer:
“A” schedule: It is preventive maintenance schedule to be attended on coaching stock in pit line
at primary maintenance depot with periodicity of 1 month ± 3 days within the normal
primary maintenance time.
Following items are to be attended during “A” schedule:
 All items of trip schedule.
 Intensive cleaning of coaches.
 Intensive cleaning of lavatory pans and commode with Vim or equivalent.
 Painting of commode chutes from inside and outside with black anti-corrosive paint after
scraping and thorough cleaning.
 Thorough flushing of tanks.
 Checking of water pipes, flush pipes, flushing cocks, push cocks etc, for ease of operation
and free flow of water.
 Thorough disinfect ion of all compartments.
 Thorough cleaning of chimneys of dining cars, buffet cars, tourist cars and inspection
carriages by wire brushes.
 Examination and replacement where necessary of brake gear pins, split pins, safety
loops/brackets and their securing devices.
 Examination for wear and replacement where necessary of brake hanger pins, brake blocks
and brake heads.
 Thorough inspection and repairs of draw gear.
 Thorough inspection and repairs of buffers.

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  Checking and replenishing of oil in side bearers and dashpots.
 Thorough check and repairs of SLR doors for easy and smooth operation and correct
alignment of all wearing parts, loose screws etc.

Q18. What is “B” schedule? What are the activities to be carried out during “B” schedule?
Answer:
“B” schedule: It is preventive maintenance schedule to be attended on coaching stock in pit line
at primary maintenance depot with periodicity of 3 months ± 7 days within the normal
primary maintenance time.
Following items are to be attended during “B” schedule:
• All items of ‘A’ Schedule.
• Painting of lavatory from inside.
• Thorough inspection and repair of brake gear components.
• Examination overhauling and testing of alarm chain apparatus.
• Testing and repairs of roof, especially the one laid with over and under lays of rubberoid
sheet before monsoon begins.
• Thorough checking of trough floor, turn under etc., from underneath for corrosion.
• Touching up of painted / printed portion, if faded or soiled.
Q19. What is IOH? Explain the procedure of IOH?
Answer:
Intermediate Over Hauling (IOH): It is preventive maintenance schedule to be attended on
coaching stock at Primary maintenance depot after detaching the coach from the formation
in the IOH shed with a periodicity of 12 months for newly built coaches and departmental
coaches and 9 months for all passenger coaching vehicles and other coaching vehicles with a
grace period of 30 days.
IOH is also given on overdue POH coach before allowing in to service to ensure safety of
the coach and the coach is allowed to service for a period of 3 months only. After expiry of 3
month the coach must be sent to POH repairs at work shop.
During IOH of a coach bogies are to replaced with the over hauled bogies received from
work shop only.
Following items are to be attended during IOH:
a. Thorough repairs of running gear, brake gear and buffing gear
b. Touching up damaged paint of coaches on outside as well as inside.
c. Polishing of the polished surfaces.
d. Thorough check of SAB
e. Testing of BP and FP gauges with the master gauge.
f. Thorough checking of train pipes under pressure of 2kg/sq cm to detect thin, corroded and
punctured pipes.
g. Thorough cleaning and removal of dust, rust, dirt etc, accumulated at the pillars through the
turn under holes, with coir brush and compressed air.
h. Thorough examination and repairs of upholstery, cushions, curtains etc.
i. Thorough checking and full repairs of all window shutters, safety catches, safety latches,
staples and hasps of compartment, lavatory, body side and vestibule door step, locking
gear etc., for ease of operation and safety.
j. Thorough checking and repairs of all damages of vinyl flooring of the compartment.
k. Ultra sonic flaw detection test of axles, where facilities are available.
l. Attention to corrosion of all ICF/BEML coaches as described below:
i) C&W supervisors at PM depots should be fully familiar with the vulnerable areas of
coaches for corrosion, viz., sole bars at doorways, lavatories and adjoining areas,
Corridor sides – more so in case of SLRs’ which are used for fish, salt etc.
ii) Following schedule should be strictly followed for all ICF/BEML coaches in C&W
depots.

14
 iii) Pocket between sole bars and turn ender should be thoroughly cleaned through the
inspection opening of the sole bars and inspected with the help of torch light or
inspection lamps.
iv) 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.
v) A register should be maintained of the primary maintenance coaches on the subject.

Q20. What are the gauges used during IOH?

Answer:
The following gauges are to be used during IOH to ascertain the wear and tear and alignment of
the bogie.
• Trammeling gauge
• Dash pot distance gauge
• Knuckle profile gauge
• Knuckle nose wear and stretch limit gauge.
• Aligning wing limit gauge.
• Vertical height aligning wing pocket and gauge arm gauge (Go gage)
• Vertical height aligning wing pocket and guard arm gauge (No-Go gauge)
• Buffer height gauge
• Wheel distant gauge
• Wheel profile gauge
• Tyre defect gauge.
• Comb gauge for flange thickness gauge
The following gauge are used for checking “H” type CBC
 Knuckle nose wear and stretch limit gauge.
 Aligning wing limit gauge
 Vertical height aligning wing pocket and guard arm gauge (GO Gauge)
 Vertical height aligning wing pocket and guard arm gauge (NOGO Gauge)

Q21. What are the safety precautions to be taken at Work spot?

Answer:
1. Use dry cotton cloths as per your sizes.
2. Wear shoes.
3. Use hand gloves while grinding, lifting heavy load, holding hot bodies.
4. Protect lines both sides by providing danger boards
5. Use nose mask where the dust is available.
6. Use helmets while working under gear
7. Use ear plugs, where then noise is more
8. Keep fire extinguishers, sand, water buckets.
9. Adopt proper methods
10. Display boards for failure/defective machinery.
11. Display ambulance phone no in the work places.
12. Put separate bins for new, reuse, and scrap materials
13. Use goggles and dark glass/welding shields while working with gas
cutting & welding.

Q22. What are the items to be provided for an express fit coach to enhance its POH
periodicity from 12 months to 18 months?
Answer:

15
 To ensure proper utilisation and maximum availability of coaches for traffic utilisation to
enhance the revenue without compromising on part of safety the POH periodicity of the
coaches had been enhanced to 18 months from 12 months by providing the upgraded
materials in the coaches during POH at work shop. CAMTECH, Gwalior issued guidelines
for enhancement of POH periodicity of from 12 months to 18 months in January 2008. Vide
these guidelines following items are to be provided on coaches during POH at workshop to
the extent of 100% with new specifications issued by RDSO.

Sl. No Item Description Upgraded Specification

1. PVC Flooring RDSO/2006/CG-12

2. Seat Upholstery Fire Retardant Vinyl Coated Fabric to Spec. No.

RDSO/2006/CG-16

3. Decorative Thermosetting Fire Retardant Decorative Thermosetting resin

resin Bonded LP Sheet Bonded LP Sheet to Spec. No. C-8914

4. Cushioning Material for seats Densified Thermal Bonded Polyster Block (Recron)
and berths to Spec. No. C-K607/PU foam to spec. No. C-8914

5. Overhead water tanks Two piece Overhead water tank to ICF Drg. No.
ICF/SK-6-3-444 latest alteration

6. Brake Gear Bushes Composite brake Gear Bushes to Spec. No. C-

K605/C-K307/C-K510

7. Upper and Lower washers High capacity Hytrel washers to spec. No. C-K409
for primary suspension (Rev.1)

8. Silent block for anchor link Injection moulded silent block for anchor link to
spec. No. RDSO/2006/CG-5

Q23. Explain salient features of ICF coach?

Answer:
Salient features of ICF Coach:
1. All welded, stressed skin integral tubular construction adopted.
2. Provided with Anti telescopic body fitted with distraction tube inside the buffers with
trough flooring.
3. Lavatories are provided on either ends near doorways.
4. Self aligning spherical roller bearings are used to minimize friction resistance and easy
hauling with pendulum type axle box.
5. The bogie incorporates primary and secondary suspension arranged in series.
6. The axle boxes are guided by axle guides and wear and tear of axle boxes are eliminated
with hydraulic dashpot arrangement provided for primary suspension.
7. The secondary suspension is provided with bolster springs and double acting telescopic
shock absorbers.
8. Silent blocks are fitted in centre pivot and anchor links to reduce noise.
9. Unsprung mass is reduced by 18.5% as compared to IRS bogie by reducing wheel sizes.
10. The bogie frame is completely welded construction with flats and plates.
11. Modern welding technologies are adopted for welding due to which weight of bogie is
reduced by 25% when compared to IRS.

16
 12. Longer bolster suspension links to ensure better riding qualities. The links are inclined at
an angle of 70 away from the coach vertically.
13. In these coaches pay load is not shared by trough floor.
14. Pressed “Z” sections are used for sole bar
Q24. What is an anti telescopic coach? What features made an ICF coach “Anti
telescopic”?
Answer:
Initially railway carriages are wooden bodied. Wooden body is fixed on to the steel
under frame. During accidents these wooden bodies are prone for more damages by piercing
one coach in to another due to the weaker construction which is called telescopic nature.
This telescopic nature of wooden coaches had led to heavy causalities during accidents. In
order reduce the causalities concept of anti telescopic body was developed by using all
metal, all welded and light weight materials.
Construction features which made an ICF coach shell “anti telescopic”:
The shell of ICF coach consists of pressed steel sections welded together with sheet
covering. The skeleton shell consists of a series of hoops each consisting of floor cross
beams, body side pillars and roof carlines. The sole bar, waist rail, cant rail and roof purlines
held these hoops together. This is covered by roof sheet on top, side panels on sides and
corrugated trough floor. The corrugated trough floor offer considerable resistance to
longitudinal crushing loads. On each end specially designed head stock with
compression/destruction tubes are welded. These tubes during collision get deformed
absorbing most of the energy.
Body bolsters are welded on bottom side of trough floor. The coach ends consists 4 box
section stanchions transversely connected by “Z” section stiffeners and are welded to head
stock. During collisions impact is first absorbed largely by end stanchions. The residual
shock is absorbed by deformation of destruction/compression tubes.
The reduction in tare weight of these coaches obtained by using light weight, high
strength, and corrosion resistant CORTON steel and by use of light weight alloy fittings. The
concept of stressed skin also helps achieving light weight of coaches. 1.6 mm thick sheet
used on roof and 2 mm thick used on side wall and end wall.
The Integral Shell behaves as a hollow tube offering maximum resistance towards
telescoping in case of end wall collision. The head stock consists of main and auxiliary head
stock connected by a rigid buffer beam which transmits all the buffing forces to the under
frame.
All the above features made an ICF coach “anti telescopic”.
Q25. Describe ICF all coil bogie. And explain sequence of transmission of “tractive force,
braking force and load transmission” in ICF coach.
Answer:
Bogie: it is a general term used for the assembly of all suspension parts, which toghter
support the coach body at the two ends. It includes the structural frame, wheels, axles and
bearings, suspension links, springs etc.
ICF all coil bogie: the bogie frame is built from “I” section fabricated by welding. Axles
are located on the bogie by telescopic dashpot and axle guide assemblies with wheel base of
2896mm. helical springs are used in both primary and secondary suspension stages. The axle
guide device provides viscous damping across primary springs while hydraulic dampers are
provided across secondary suspension stage. Dampers are protected against misalignment by
resilient fittings. Isolation of vibration is effected by rubber padsin primary suspension. Weight
of coach body is transmitted to its bogie by side bearers pitched 1600mm apart. Side bearer
consists of lubricated metal slides immersed in oil bath. No vertical weight transfer is affected
through bogie pivot, and pivot acts merely as a center of rotation and serve to transmit tractive
and brake force only.
Transmission of tractive forces: The sequence of transmission of tractive force is
follows.

17
 Coupling – Head stock – under frame – Body bolster – Center pivot – Bogie bolster –
Anchor links – Bogie frame – Axle guides – Axle box – Axle – wheels.
Transmission of braking forces: Transmission of braking force is reverse of that of
tractive force.
Transmission of load: Coach body – Side bearers – Bolster – Bolster coil springs –
Lower Spring Plank – Stirrup links – Bogie side frame – Axle box Coil Springs – Axle box
Wings – Axle Box – Bearing – Axle – Wheels – Rails.
Q26. Write salient feature of LHB coach?
Answer:
The salient features of LHB coaches are
a. These coaches are longer by 2.2 meters than the ICF coaches and hence more number of
passengers can be accommodated in a given coach. As the length of the coach is longer the
number of coaches required to form a formation is reduced and hence overall cost of
maintenance becomes less.
b. These coaches are fitted with Axle Mounted Disc brakes to have an effective brake power
to stop the train within the emergency braking distance. As the brake forces are acting on
the Discs which are mounted on the Axles, the wear on the wheel tread caused due to tread
brake is eliminated and hence the life of the wheels are considerably increased.
c. These coaches are fitted with Wheel slide protection device to prevent the wheel from
getting skid. Due to various reasons it is possible for any one of the wheel to have lesser
speed when compared to the other three wheels and in such a case it releases the air from
the brake cylinder of the affected wheel automatically to prevent the wheels from getting
skidding.
d. These coaches are fitted with Brake accelerator in the Brake pipe to bring BP pressure to
zero during emergency brake application. The brake accelerator connects the Brake pipe
with exhaust during emergency application to facilitate faster releasing of air from the
brake pipe.
e. These coaches are provided with FIAT bogies, which are designed to run at a speed of 160
KMPH.
f. These coaches are fitted with Controlled discharge Toilet system designed to discharge the
human waste when the speed reaches above 30 KMPH after completion of 5 flushing. The
objective of this toilet system is to keep the station premises clean and hygienic.
g. These are fitted with tight lock AAR centre buffer coupler with anti-climbing feature to
prevent the climbing of one coach over another in case of accidents.
h. The wheelbase of Bogie is 2560 mm.
i. These coaches are fitted with earthing device to prevent damages to the Roller bearings.
j. These coaches are fitted with roof mounted AC package units.
k. The following equipments are operated by electronically operated control system
(Microprocessor)
1. Wheel slide protection device.
2. Controlled discharge toilet system.
3. Water pumping device.
4. Roof mounted AC package units
l. The riding index of LHB coach is 2.75 when compared to 3.25 in case of ICF Coaches
m. The passenger emergency alarms signal devices are provided inside passenger
compartment. This is to avoid operation of PEASD by unauthorized persons from outside.
There is no mechanical linkage like a chain and this handle directly operates the PEASD
valve for venting the brake pipe pressure.

Q27. Write salient features of Duranto express Hybrid coach?

Answer:
It is hybrid coach manufactured as per the design of ICF bogie and shell with features of
LHB shell.
a. For the first time non – AC sleeper coaches are introduced in Non – Stop trains.
b. Construction of shell is similar to that of ICF coach.

18
 c. Instead of CARTON steel, stainless steel is used for construction, which resulted in
reduction of tare weight by 2 Tonnes.
d. Length of the coach increased to accommodate more No of passenger coaches.
No of berths in 3 – tire AC (ACCN) - 72 nos.
No of berths in 3 tire Non - AC (SCN) - 78 nos.
e. All the coaches are provided with Auto closing sliding type vestibule door which will
stop spreading of the fire in case of fire accident.
f. All the coaches are provided with CDTS for comfort of passengers.
g. Bogies is similar to ICF all coil bogie excepting that in secondary suspension air springs
is provided instead of coil springs (Bolster springs) for better riding comfort which
resulted in reduction of ride index to 2.5 against 3.5 in ICF all coil bogie.
h. Extra B.P / F.P hose pipes with cut off angle cocks are provided on either ends of coach
so that in case of any defect occurred on air hose the corresponding angle cocks can be
closed and Air hose can be used, thus maintaining the punctuality.
i. In case of isolation of Air spring even on one bogie / Coach entire train has to run with a
speed not more than 60 KMPH up to destination.
j. Modification for the fitment of Air spring.
a. Bogie frame and suspension: Air spring has been installed in secondary stage
replacing steel coil springs. A fixed lower spring beam (As cradle) to accommodate
the air spring has been provided on bogie bolster. A lateral hydraulic damper and
lateral bump stop have been provided at secondary stage.
b. Bogie bolster: Provision made for air inlet to air spring. 40 Lt additional reservoirs
connected to each air spring. Duplex check valve is provided.
Due to the above modifications BSS hangers, Equalizing stays are eliminated.

Q28. What is the necessity of introduction of Air springs in Indian Railways?

Answer:
In suburban trains like DEMU, the number of passengers entraining (Super Dense
Crush Load) in to the coach cannot be controlled and hence the payload of the coach increases
from 18 tons to 34 tons. This abnormal increase of payload reduces the Riding Clearances
between the Coaches and Wayside platforms and also reduces buffer height resulting in severe
hitting of coach on the plat forms. Due to the Super Dense Crush Load the bolster springs
become solid, which in turn damages / breaks the Coil springs resulting in discomfort to the
passengers.

19
So to overcome the above problems Air Suspension (Air springs) is introduced in the secondary
suspension to maintain a constant buffer height irrespective of loaded conditions by varying the
pressure of air inside the air spring.
Due to its excellent riding index the air springs are introduced in Duronto express.

Q29. Explain working of “Air spring” with neat sketch?

Answer:
Air spring is a rubber bellow containing pressurized compressed air with an emergency rubber
spring providing various suspension characteristics to maintain a constant Buffer height
irrespective of the loaded condition.
Air spring
1. Emergency spring
2. Leveling valve
3. Adjustable screw rod
4. Duplex Valve
5. Main Air Reservoir
6. Auxiliary Reservoir
7. Isolating Cock

20
 Air suspension is a suspension where properties of air are used for cushioning effect
(springiness). Enclosed pressurized air in a pre – defined chamber called air springs, made up of
rubber bellow & emergency rubber spring, provides various suspension characteristics including
damping. Air springs are height – controlled load leveling suspension devices. With changing
loads, air springs react initially by changing the distance between air springs support and vehicle
body. The leveling valve is in turn actuated, either taking the compressed air pressure to the air
spring or releasing air pressure from it to the atmosphere. This process continuous until the
original height is restored. This mechanism ensures a constant floor height on coaches provided
with air springs, irrespective of loads.
Q30. Compare air springs with coil springs and indicate advantages and characteristics of
air springs.
Answer:
• Unlike steel springs, air springs retain their height under changing loads. The low
natural frequency of air spring suspension remains virtually constant.
• In case of coil spring, deflection is proportionate to the load, therefore, under
high payload situation, space constraint becomes critical, leading to the use of stiffer
springs resulting in unsatisfactory ride behavior and reduced speed potential.
• Air springs through their control mechanism offer a load proportionate stiffness,
constant floor height and better ride behavior with higher speed.

Advantages of Air springs:

o Capable to sustain Super Dense Crush Load of suburban traffic at high speeds.
o It maintains a Constant floor height of coach.
21
 o It facilitates excellent riding comfort with riding index of 2.5.
o Safe running due to the excellent Air Damping.
o Low design height.
o Unusual noise emitted due to hitting of coaches on the plat forms is eliminated.
o The Stirrup links, Coil springs and equalizing stays are eliminated and therefore easy
to maintenance.
Characteristics:
• Soft flexible characteristics in vertical direction achieved by compression of air.
• Excellent lateral spring characteristics achieved by variation in effective area in lateral
direction.
• Avoids excess air consumption due to instantaneous modes of oscillation / change in
pressure achieved by delayed reaction in leveling valve.

Q31. List out the parts of “Air Spring” and explain their functions briefly?
Answer:
The leveling valve is fitted with Top bolster and is designed to move up and down along with
bolster. Under normal condition, it is designed to take LAP position when the actual buffer
height is equal to the required buffer height.

The function of leveling valve is to connect the main reservoir with the air spring to admit
more pressure in to the Air spring, whenever the actual buffer height is less than the required
buffer height due to abnormal increase in the Pay load (Super Dense Crush load).

It also connects the air springs with exhaust to release the excess air from air spring, whenever
the actual buffer height is more than required buffer height due to reduction in the Pay load
after detraining of passengers from the coach

22
 .
Installation lever:
It is fitted between the leveling valve and bottom of the bogie frame. The function of
installation lever is to operate the leveling valve automatically by moving the handle of the
leveling valve up and down according to the condition of the load. The up and down
movement of handle of leveling valve admits the compressed air in to the Air spring or
releases the compressed air from the air spring through leveling valve in proportion to the pay
load of the coach.
Duplex Valve:
It is a double check valve provided between the Air springs of the same bogie .It operates
with a Pressure differential of 1.5 bar. Basically it comprises of two check valves side by side,
arranged so that air can flow in either direction whenever the air pressure differential exceeds
the pre-set value of 1.5 bar. Whenever a burst of air spring occurs on one side, this valve will
ensure that no severe tilt or twist occurs during movement of the coach.
Both the check valves of Duplex valve remains closed, if the pressure between the two springs
is within 1.5 bars.
When the differential air pressure exceeds the preset value, the air at higher pressure
overcomes the spring pressure and flows to the lower pressure via the check valve. The flow
continues till the differential reaches the preset value.
In case of burst of Air Spring, the air leaks to atmosphere. Due to high-pressure differential,
the Duplex check valve releases the air from the intact air spring through burst air spring. Thus
complete coach will gradually come down and rest on the emergency rubber springs.
Auxiliary reservoir: It is fitted with the Air spring. The capacity of this reservoir is 40
Ltrs. There is an orifice kept between air spring and additional reservoir. It acts as an Air damper
to overcome vertical and lateral oscillations so as to increase the riding comfort.
Main reservoir: The capacity of the main reservoir is 150 ltrs and it is exclusively used
for feeding the compressed air in to the Air Spring.
Emergency spring: The function of emergency spring is to support the top bolster to
prevent tilt of coaches whenever the Air spring burst.
Q32. Explain working of CDTS with neat sketch?
Answer:
The objectives of CDTS are

To keep the station premises clean and hygiene.

To release the human discrete away from the station limits.

To decrease water consumption during flushing.

To keep toilets clean, odorless and aesthetic.

To pressurize the water during flushing cycle.
Controlled discharge toilet units are fitted to avoid soiling of track in station and inhabited areas.
Waste is stored into an immediate tank, which is closed off by microprocessor-controlled slide
valves. The slide valve for waste tank outlet opens automatically at speeds above 30 kmph. The
toilet units are fitted with button operated flush valves that flush with water, which is
pressurized using compressed air. The tanks have a capacity of storage of material for 5 flushes
and must be emptied before use.

23
 The system comprises the following:
1. Control module Having a programmable logic controller (PLC) used for counting
counti the
number of cycle as well as the speed sensing.
2. Water pressuriser A pressure pump used for pumping water from overhead tank with
high pressure to clean the toilet bowl.
3. Retention tank A cylindrical tank with 40 Ltrs. capacity connected below the toilet
bowl with two sliding valves each one at top & bottom.
4. Slide valves Two numbers of electro-
electro operated by the control module during
flushing cycle and discharge.
Top valve is designed to open and close in every flushing cycle with
the cycle
c time of 15 Sec. (can be adjustable)
Bottom valve is designed to open and close after completion of 15
flushing cycles and also when the vehicle speed is above 30 KMPH.
5. Water check An electrically operated magnetic solenoid valve, used for
fo opening
valve and closing pressurised water during flushing cycle. It admits 2.5
Ltrs. For Indian water closet and 1.5 Ltrs. for European water closet
in 12 Sec.
6. Bye-pass valve A hand operated push cock which bye passes the water circuit
during emergency situation i.e. in case of electricity failure and
failure of CDTS.
7. Pressure switch A fail-safe
fail safe system, which opens the top slide valve of the retention
tank in case of failure of air supply/ electric supply to use the toilet as
an ordinary toilet.
Working: The flushing cycle is explained as follows:
1. Flush button is pressed (Soft press)
2. Water pressuriser starts working
3. Water check valve opens.
4. Pressurised water flows from the circuit to the toilet bowl and flushing takes place.
5. Top slide valve opens and
and flushed water goes to the retention tank.
6. Water pressuriser closes.
7. Water check valve closes.
8. Top sliding valve closes.

24
At the end of every 5th cycle and if the speed of the vehicle is equal to or above 30 KMPH. The
bottom discharge valve will be opened and discharges take place. The speed is sensed from the
wheel slide protection device, in which the signal from every axle is obtained by a phonic wheel
electromagnetic mechanism.

Q33. What is the procedure to be followed while attaching the coaches fitted with “H” type
CBC with locomotives fitted with “E” type CBC as per JPO?
Answer:
As per JPO dated 07-04-2009 the following procedure to be adopted while attaching the
coach fitted with “H” type CBC to Loco fitted with ”E” type CBC.
1. After berthing the CBC rake on platform and before releasing the rake by C&W staff,
the first five coaches to be in brake applied condition.
2. The loco shall be brought to the same line and to be stopped 20 m from first coach and
to move cautiously observing the hand signals.
3. The first coach CBC and Loco CBC should be aligned horizontally so that they are in
gathering range.
4. The nominated supervisors of C&W and Loco supervisor will ensure the following
“Vertical gathering between the two CBCs is to be within the allowed range. If vertical
gathering range is not within limits, the buffer heights of the Loco and Coach should be
checked (i.e. limits 1030mm to 1105mm). if buffer height of SLR is not within the
prescribed limits due to over loading, the over load contents should be unloaded from
SLR in accordance with the extent procedure with the permission obtained by Dy.SS.”
5. SC Railway will not apply any lubricant on internal coupler parts of CBC. Since the
practice of using lubricant on internal parts is in vogue in electrical and diesel
maintenance points/ loco sheds, thus in case any lubricant/ grease available will be
wiped out by C&W staff before coupling.
6. Then the following procedure to be ensured
 Remove tell tale pin (locking pin) of CBC of Coach intended to be coupled.
 Open the knuckle of the CBC of coach wide open.
 Remove locking pin of loco CBC intended to be coupled.
 Open knuckle of the BC of Loco wide open.
 Align both the CBCs in a line of gathering range.
 Guide the loco pilot through hand signals to proceed 2 to 3 KMPH for coupling.
 After coupling is made, ensure proper seating of lock of “H” type CBC by observing
the clear visibility of inverted “V” tell tale sign, yellow colour circular mark on lock
lift assembly and position of lock lifter rib is vertical and insert the telltale pin and
lock of loco CBC dropped fully.
 Ask loco pilot to notch and test proper coupling of knuckles.
 Once coupling is ensured provide tell-tale pin in slot and tie with GI wire to avoid
accidental coming out on run. Provide washers on tail piece followed split pin. The
split pin end to be opened up there after.
 The locking pin of loco to be placed in position and to be tied up by GI wire to
prevent any accidental falling out.
 Ask loco pilot notches for checking the proper coupling by pulling apart the loco.
Once it is pulled, C&W staff should insert the shims and fix the restrictor and ensure
proper coupling. The shims should be tied with GI wire by C&W staff.
 After ensuring proper coupling, the brake of 1st five coaches should be released by
C&W staff.
Then the loco pilot and guard should ensure the air continuity in presence of TXR for issue
of BPC.
Q34. What are the different amenity and safety fittings in coaches?
Answer:
The different amenity fittings in a coach are:
Main Door Door handle
Hand rails Latches to close the door
Seat Berth
Berth Chain Window
Window bars Roof ventilator
25
 Coat hook Light and fan
Alarm chain Armrest, tea/snack table
Foot steps to climb to upper berth Back rest with locking provision for the side
berths
Glass and Venetian shutters with lock Provision of securing arrangement below the seat
provision for the luggage
Luggage rack in case of general Washbasin on either ends of the coach with
compartments mirror and mirror stand
Provision of night lamp for sleeper and Vestibule with door and fall plate arrangement
upper class coaches secured with pin
Provision of reading lamp in AC and Provision of Coupe system in First class coaches
First class coaches with door
Curtains for having privacy in AC class
Provision of 3 Indian style and 1 western style toilet with the following fittings
Door with turn over latch and locking Squatting pan/Commode with commode lid and
arrangement cover
Flushing cock with FO handle, FO pipe Provision of mirror, mirror stand and wash basin
and fish tail
Windows with Frosted glass for light Provision of push cock/ Jason cocks 2 nos
and ventilation
Mugs in the upper class coaches Shower arrangement in first class coaches
Fan and Alarm chain arrangement in Air freshener in upper class coaches
Upper class coaches

The responsibility of a supervisor is to ensure that all the fittings provided for the use of
passengers are to be in correct and good condition. Else, this invites public complaints.
Q35. What are the various activities undertaken by Indian railways to improve the
condition of passenger coaching vehicles?
Answer:
Indian railways is the largest network under taking transportation of Passengers and goods. Of
late importance is given to the safety and aesthetics of coaching stock. The various
modifications and activities under taken to improve the condition of Rolling stock are.
 Provision of Air brakes and disc brakes
 Introduction of Composite brake blocks.
 Intensive cleaning of Coaches.
 Attention to Cleanliness on enroute trains.
 Steam cleaning of Pantry cars.
 Periodic Disinfection and pest control treatment.
 Attention of Zero missing of amenity fitting.
 Provision of shock absorbers in Primary suspension.
 Introduction of CDTS
 Introduction of Air springs
 Introduction of GPS boards

Q36. List out public complaints pertaining to the C&W branch and what are the remedial
measures to be taken to avoid the complaints?
Answer:

Sl. Cause Remedial measure

No
1. Non-availability of water in Ensure full watering of all coaches at originating
coaches stations and enroute at nominated watering stations.

26
 2. Non-cleaning of coach toilets, Ensure intensive cleaning of toilets during PM/SM
wash basins, coach interior. attention and proper interior cleaning of coaches.
Enroute cleaning of toilets to be done at nominated
stations.
3. Existence of cockroaches, Ensure thorough periodic disinfestations of coaches.
insects, rats, etc.
4. Improper condition of berths, Ensure through attention to berths, seats during ‘C’
seats, snack table, door closers schedule maintenance and PM/SM attention. Proper
etc. attention to be paid to the reclining mechanism of
CZAC coaches, snack tables, door closures during
PM/SM attention.
5. Dirty condition of AC Coach Ensure periodic washing of curtains of AC Coaches.
curtains.
6. Water leakage through windows Ensure proper ceiling is provided to the window
glasses of AC Coaches during the
Replacement in sick line/shops.
7. Soiled Linen Ensure proper washed Linen in sufficient quantity
available in the coach at originating stations.
Q37. Explain the classification of goods stock with suitable examples?
Answer:
Goods stock is mainly classified according to their shape of the body
1. Open wagons: These are used for transportation of Ores, Granite stones and some Steel
products etc. which are not affected with changes in atmosphere.
Example-BOX, BOXN, BXNR, BOXNHL etc.
2. Covered Wagons: These are used for transportation of food grains, sugar, cement etc. which
would spoil due to changes in atmosphere like rains etc.
Example- BCX,BCN,BCNA,BCNHL etc.
3. Flat Wagons: These are used for transportation of steel consignments
Example: BFR, BRN, BRNA etc
4. Hopper Wagons: These are used for quick and mass transportation of food grains, coal etc.
and transportation and lying of ballast for departmental use.
Example: BOBR, BOBRN & BOBYN
5. Container Wagons: These are used for transportation of containers
Example: BFKI, BLC
6. Tank Wagons: These are used for transportation of liquids and gases like petrol, k.oil, LPG
etc.
Example: BTPN, TP, TK, BTPGLN etc.
7. Well Wagons: These wagons are specially designed for carrying specific items like boilers,
parts of turbines etc.
Example: BWL
8. Brake Van: These are utilized by the guard of the train
Example: BVZC, BVZI.
Q38. List out POH & ROH periodicity of various goods stock?
Answer:

POH ROH
Sl. NO. WAGON CODE
1st Subs 1st Subs
1 BOXN,BRN 6y 4½y 1½y 1½y
BCN, BCNA,
2 6y 6y 2y 2y
BOBR, BOBRN
3 BTPN 6y 6y 1½y 1½y
4 BTPGLN 4y 4y 2y 2y
5 BOY 3y 3y 1½y 1½y
6 BTALN 4½y 4½y 1½y 1½y
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 7 BOX, BCX, BRH, BOI, BOM, BTAL 4½y 4½y 1½y 1½y
8 Brake Vans 2y 2y - -
9 Departmental stock 4y 4y - -
10 Domestic containers 1½y 1½y - -

Q39. List out different types of CASNUB bogies with salient features?
Answer:
The different types of CASNUB Bogies are: -
CASNUB 22W W – Wide jaw
CASNUB 22W (Retro) R–Retrofitted
CASNUB 22W (M) M – Modified
CASNUB 22NL N – Narrow jaw
L – Light weight
CASNUB 22NLB B – Bharat & co
CASNUB 22NLM M –Mukund & co
CASNUB 22HS HS –High Speed.
These bogies are now used in – BOXN, BCN, BCNA, BRN, BTPN, BOBR, BOBRN, BOBY,
BOBYN, BLC.
Bogie construction: - The bogie comprise of two cast steel side frames and a floating Bolster.
The bolster is supported on the side frames through two nests of springs. This also
provides a friction damping proportional to load. Fabricated mild steel spring plank
connects the side frame to maintain the bogie square. This bogie is fitted with tapered
cartridge roller bearing axles.
Salient features: -
Axle load : 20.3 t, however all bogies except CASNUB 22HS now upgraded to 22.9t
Wheel base : 2000±5 mm
Wheel diameter : New - 1000 mm & 956 mm only for CASNUB 22WR
Condemning – 906mm for all types
Type of axle bearing : Standard AAR Tapered Cartridge roller Bearing (CTRB)
Distance between journal centers – 2260 mm
Distance between side bearers – 1474 mm
Type of side bearer -- Roller type (clearance type) – Fitted on CASNUB 22W
--CCMBR Pads–Fitted on CASNUB 22WR, CASNUB 22W (M),
22NL, 22NLB, 22NLM Trolleys.
--Spring loaded – Fitted on CASNUB22 HS
-- All the above side bearers are removed and P.U (Poly Urethane ) pads
are to be fitted during POH / ROH
Type of centre pivot – IRS Type – Fitted on CASNUB 22W Trolleys.
- Spherical type – Fitted on CASNUB 22 W (M), 22NL, 22NLB, NLM
& 22 HS Bogies.
- Flat pivot provided on CASNUB 22HS fitted to BCNHL, BOXNHL,
& BLC
Type of brake beam – Unit type fabricated brake beam Fitted on CASNUB22W
supported and guided in the brake 22NL, 22NLB,22NLM &
beam pocket 22HS Bogies.
-Unit type cast steel brake beam suspended Fitted on
by hangers from side frame brackets. 22W(M)

Suspension – Long travel helical springs comprising Inner, Outer and snubber springs.

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Q40. Explain ROH procedure of BOXN wagons?
Answer:

ROH OF BOXN WAGONS: -

PERIODICITY: - 18 MONTHS FOR BOXN WAGONS
24 MONTHS FOR BCN WAGONS

ROH PROCEDURE: -
I. DISMANTLING
Collect and note down PRO particulars of BOX N/BCN wagon to be attended for ROH
1. Take initial readings such as Coupler height from Rail level and note down other
defects.
2. Disconnect bogie brake rigging to under frame and under frame brake gears.
3. Lift the body, run out the bogies and keep the body on trestles.
4. Strip the bogie components and insert assembly pins (12mm and 250 mm long) to
retain friction shoes (Snubber wedges)
5. Raise the bolster to connect top members of side frame and remove all the outer,
inner and snubber springs.
6. Remove the assembly pins and lower wedge blocks to take them out.
7. Lower the bolster to rest on the spring flank.
8. Examine bogie spring plank for cracks and check side frame alignment by
trammeling Gauge as follows: -
Wheel base – 2000 + 5 mm
Journal centre – 2260 + 5 mm
Diagonal distance of Trolley frame – 3018 + 5 mm.
9. Take out side frame keys and adopter retaining bolts.
10. Lift side frame and spring plank assembly and release the adopters and wheel sets.
11. Slide Bolster to one side to check up the column liner plates, slope liner, Land
surface, Anti rotating lugs and Bolster column with prescribed gauges and use
suitable thickness Sims.
12. Check up for wear on pedestal jaw and Adopters.
13. Check up wear on Wedge.
14. Check centre pivot for cracks and wear.

ASSEMBLING OF BOGIE COMPONENTS:

1) Replace all worn out pins and bushes.
2) Replace new brake blocks.
3) Reassemble the coil springs in nest after pairing, that is in one nest the variation of
free height of the springs not more than 3 mm. Mixing up of new and old springs
should be avoided.
4) Check the wheel profile. If required replace the wheels with ultrasonically tested
wheels.
5) Check up the side bearer rubber pads and Elastomeric rubber pads for cracks and free
height, if necessary replace with new one.
6) Lower the body on the bogie after sprinkling Graphite powder in the centre pivot.
7) Check the CBC heights if necessary keep the (CBC) Buffer height pickings in
between Adopter and Elastomeric pads.
8) Lubricate all the pins.
9) Replace all the worn out brake gear pins and use over hauled SAB and adjust A and
E dimensions and tack weld the anchor pin.
‘A ' dimension must be 70 + 2 /-0 mm.
'E ' dimension must be 555 mm to 575 mm.
10) Check the CBC operating handle for any defect and free of operation.
11) Check the Draft gear, Yoke, CBC shank, Knuckles for wear and cracks if necessary
replace by new ones.

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 12) Check hand brakes and doors for easy movement.
13) Check up Empty/Load gear arrangement and paint Yellow and Black respectively for
easy identification and set the empty tie rod check nuts correctly if required.
14) Provide side frame keys.
15) Clean the Dirt collectors and Brake cylinder strainers.
16) Change the defective Air hose assembly.
17) Examine and lubricate Cut off angle cocks and change if required.
18) Examine and attend leakages of all pipes and joints.
19) Carry out the Single wagon test for proper functioning of Air brake system.
20) Carry out the medications recommended by RDSO and other authorities
Touch up paint for sole bar and stencil station and date.
Q41. What are the modifications to be carried out on wagon stock during ROH?
Answer:
1. The striker casting wearing plate is modified and secured by means of bolts and nuts
with the striker casting to prevent working out of wearing plates on run.
2. A stopper is welded at an angle of 20º with the vertical on the air hose carrier suspension
bracket, to prevent the excessive displacement of air hose carrier on run. This
modification prevents damages to the air hoses.
3. Metallic bushes are used in the brake rigging instead of nylon bushes, to prevent frequent
replacement of bushes.
4. Bulb cotters are used instead of split cotters.
5. Worn wheel profile is adopted for the RB wheels.
6. Truss beams are strengthened near brake heads by welding three numbers of MS strips to
the length of 215 mm to prevent the truss beams from getting crack near the brake heads.
7. Bogie push rods are provided with safety straps on either ends to prevent the dropping of
truss beams on run, whenever the pins are working out. A bolt is fitted with the floating
lever to keep the bogie push rod in position, in case the pin fails.
8. Load empty horizontal lever support bracket is strengthened at the joint with the body by
welding gusset plates at the joint.
9. An anti rotation lug is welded between the sleeve nut and screw rod of empty tie rod to
prevent the tampering of empty tie rod.
10. Control rod diameter of SAB is increased from 28 mm to 32 mm, to prevent the control
rod from getting bent.
11. An additional support bracket is given for supporting the SAB pull rod to prevent
malfunctioning of SAB enroute.
12. The centre pivots are secured by means of rivets, to prevent the trolleys from getting
shifted.
13. Quick couplings are used in the brake vans, to facilitate easy fitment and removal of
pressure gauges.
14. For Casnub 22 W retrofitted bogie, the centre pivot bottom is cut by 5 mm at the top of
the projected portion, to prevent the jamming of pivots.
15. 8mm strips are to be welded on either side hand brake wheel spindle 150mm away from
sole bar to avoid accidental working out of hand brake wheel from its position when the
sleeve and its riveting is defective.

Q42. What are the modifications to be carried out to convert CASNUB – 22W to
CASNUB– 22WR?
Answer:

The following modifications are to be carried out to convert a CASNUB 22W into a 22 W
retrofitted:
1. Introduce Elastomeric pad to the thickness of 45mm between side frame and adaptor.
2. The maximum permissible wheel diameter is to be restricted to 956mm.
3. Provide modified adaptor with reduced height of 129.5mm instead of 152.5mm.
30
 4. Side frame key is to be reversed and should be fitted from bottom of jaw.
5. Provide constant contact rubber bonded side bearer instead of Roller type side bearer.
6. Cut the centre pivot bottom by 5mm at the top of the projected portion to prevent the
jamming of pivots.

Retainer bolt hole should be shifted by 25 mm below, from the position of existing hole.
Q43. How many types of couplers are available on Indian Railways? Give their limits of
Usage ?
Answer:
The different types of couplers and their usage are,
S.No Type of coupling Usage
1. Screw coupling
IRS Type 4-Wheeler wagons
Enhanced coupling All Coaching stock
2. Centre Buffer Coupler
AAR type NHT 8 Wheeler goods stock Vacuum braked stock

AAR type HT 8 Wheeler goods stock Air braked stock

Alliance II type 4 Wheeler goods stock
3. Automatic buffer Coupler MG stock
4. Schaku Coupler DEMU / EMU
5. AAR Modified LHB coaches
6. Slack free Coupler BLC Wagons

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Q44. What is the buffer height? Write the standard heights for BG stock?
Answer:
The distance between Rail to Center Line of the Buffer is called Buffer Height.
Standard Buffer heights:
Main line coaches.
Empty / Maximum: 1105 mm
Empty / Minimum: 1090 mm
Loaded / Minimum: 1030 mm
ICF/JESSOP DMU, EMU, MEMU, Motor coaches.
Empty / Maximum: 1035 mm
Empty / Minimum: 1020 mm
Loaded / Minimum: 960 mm
JESSOP EMU TRAILER COACHES
Empty / Maximum: 1041 mm
Empty / Minimum: 1026 mm
Loaded / Minimum: 966 mm
For BLC Wagons - BLCA: Max – 1105mm (On one side), 845 (Other side)

Q45. What are the design features and construction of CBC and name the part of CBC
assembly?
Answer:
Centre Buffer Coupler & Draft Gear
Indian Railway uses AAR type centre buffer couplers having E-type head and F-type shank for
freight stock on board gauge system. These couplers are generally as per requirements of AAR
specifications M-201, M-205 and M-211.
The draft capacity of the AAR coupler depends on the strength of knuckle, which is weakest
in the assembly. The yield strength of knuckle of material AAR M-201 grade ‘C’ & grade ‘E’ is
132t and 180t respectively.

ADVANTAGES OF AAR CENTRE BUFFER COUPLER

Coupler and buffing gear are both located together at the centre of the wagon.
Centre buffer coupler is identical at either end of the wagon and hence wagon direction is
immaterial.
Coupling action between wagons is automatic.
With transition arrangement, coupling with screw coupling is possible.

PARTS OF CENTRE BUFFER COUPLER ASSEMBLY

Coupler body
Knuckle
Knuckle pivot pin with washer
Lock
Knuckle thrower
Toggle
Universal lock lift lever connector
Lock lift lever hook
Lock lift rivet
Lock lift lever rivet
Top lifter lever rivet
Yoke pin
Yoke
Yoke pin support
Striker casting
32
 Sticker casting war please
Shank wear plate
Yoke support plate
Draft gear arrangement with front follower
Safety bracket gear arrangement
Uncoupling gear arrangement
Back stop
Clevis for transition type coupler only
Screw coupling for transition type coupler only
Clevis pin for transition type coupler only

Q46. What is Anti Creep Mechanism ? Explain the procedure to check Anti creep
mechanism in CBC of goods stock?
Answer:
Anti Creep Mechanism:
This is an inbuilt mechanism provided for all the CBCs’ to prevent automatic Lifting of
lock on run in order to prevent train parting.
The Anti-creep mechanism in AAR coupler is provided between the Toggle and the
coupler body. It is in the form of ledge on the toggle and in the form of lug in the coupler Body.
Whenever the lock gets lifted, it also lifts the lock lift assembly along with it. As the
toggle moves up vertically, its anti-creep ledge, which is just below the Anti-creep lug of the
coupler body hits against this anti-creep lug, thereby prevents the further lifting of lock.
The procedure for checking anti creep mechanism:
a. Close the knuckle.
b. Insert a bar between the lock and the knuckle tail shelf and lift the lock upwards and at the
same time push the lug rearward by inserting a screw driver between the coupler body and
the front of the lock hole.
c. If the lock can be raised enough to permit the opening of the knuckle, the anti-creep
mechanism is defective.
d. Replace the lock lift assembly. (Toggle, Lock lift lever and Lock lift lever hook).
e. Check again.
f. Even after replacing the above, if the lock can be raised, the Anti-creep mechanism is found
defective due to excessive wear on the lug of the coupler body.
g. In such a case, replace the coupler body.

Q47. How many types of bearings are there? Name the parts of tapered roller bearing?

Answer:
There are three types of bearings:
• CTRB (Cartridge tapered roller bearing) is used in BOXN and BCN.
• Cylindrical Roller Bearing: is used for BOXC
• Spherical Roller Bearing: is used for ICF coaches.
The parts of tapered roller bearing are:
1) Outer Race. 2) Inner Race. 3) Rollers. 4) Cage. 5) Seal. 6) spacer.
7) Backing Ring. 8) End Cap. 9) Cap Screw 10) Locking plate 11) Grease seal
12) Wear rings.

Q48. What is axle? How many types of axles are available in IR? List out parts and axle
defects?
Answer:
Axle is a shaft made out of forging with a special contour to fix wheel disc and roller
bearings on either sides. It is a very important component in safe running of train.
The different types of axles used in Indian railways are:
• 13T Axles used on BG non-AC coaches.

33
 • 16.25T Axles used on BG AC coaches.
• 20.3 T Axles used on BG DHMU/EMU motor car and BG UIC wagons.
• 16.3T BG four wheeler wagons
• 22.9T Axles used on BG CASNUB bogies.
• 25T Axles used on BG CASNUB bogies of latest wagons.
Parts of axle:
1) Journal 2) Shoulder 3) Wheel seat 4) Axle centre
Different Axle defects are:
1. Bent Axle.
2. Grooved / Notched Axle.
3. Loose Axle.
4. Dent marks on the Axle.
Q49. What is Empty/Load box? Explain the it’s working?
Answer:
It is a mechanical device, which enables to provide two different leverage ratios to the brake
rigging of the wagon for the empty and the loaded conditions

The braking force required to stop a train within the permissible stopping distance depends on
the load of the train.
• As the load increases more brake power is required, and as the load decreases less
brake power is required to stop the train.
• So the brake power should be increased or decreased according to the requirement by
changing the brake leverage ratio. To enable this, the ‘EMPTY-LOAD BOX’ device
is provided on wagons, in between the brake cylinder and the brake blocks in the
brake rigging.
• The position of the change over lever of the EL box is to be set to ensure correct
brake power according to the gross weight, as given below.
Less than 42.5 tonnes – in empty position
42.5 tonnes &above - in loaded position
Brake Rigging:-
• The LOAD-EMPTY device consists of two horizontal levers (one live and the dead)
which are connected by means of empty and load tie rods.
• When the handle is kept in empty position, the empty tie rod is connected with the
system and in turn provides low leverage ratio, thereby gives lesser brake force.
• When the handle is kept in load position, the load tie rod is connected with the
system and in turn provides high leverage ratio, there by gives higher brake force as
required.
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Q50. What is SAB? How many types of SABs available in rolling stock?
Answer:

SAB Stands for SVENSKA AKTIE BOLAGOT BROMS Regulator. This is a

mechanical device provided in the brake rigging, forms part of the pull rod, for the automatic
adjustment of the clearance between the brake blocks and wheels/ slack in the brake rigging.
This automatically operates to shorten or lengthen the length of the pull rod, to adjust the excess
or less slack in the brake rigging or brake block clearance.
This helps to maintain the clearance between the brake block and the wheels to a pre-
determined constant value always, thereby maintaining the piston stroke of the brake cylinder
constant. This, in turn, always maintains constant brake power for the wagon or coach on the
run.
There are three types of SABs
1. DRV 450 (Used on Coaching Stock)
2. DRV 600 (Used on Air Brake goods stock)
3. DRV 750 (Used on BCNHL / BOXN HL Wagons)
“D”Means “Double Acting”
“R” Means “Rapid”
“V” Means “Verificative”
450 / 600 / 750 indicate capacity to lengthen / shorten the SAB pull rod.

35
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