In luggage van sliding doors, rollers should be replaced if found worn beyond 3 mm, otherwise they may be reused after smoothening ridges or dents.

While fitting sliding doors, it should be ensured that the gap between the door and the panel does not exceed 4.5 mm.

Lavatory doors are equipped with release lock which can be closed from inside by knob and outside by square key for privacy and access.

The shutter carries external handles of stainless steel sheet metal and internal handles in bronze along with handsafe gaskets.

Pantry door comprises of two sliding shutters operated by manual handling and have automatic return movement.

The simultaneous movement of the two shutters in end wall doors is carried by means of the serrated belt of 5mm pitch made up of polyurethane material reinforced with steel strands.

A braking cylinder acts as pneumatic brake in opposition of backward movement of the doors obtained by an elastic rope. The backward movement can be adjusted by means of unidirectional flow regulation valve.

Lower guidance of sliding doors comprises of MS 'T' section, hard chrome plated, which is fixed in the floor by means of screws.

Saloon sliding doors have hardened safety glass applied to the frame by means of EPDM rubber gasket with locking string.

Saloon sliding door comprises of sliding shutter operated by manual handling and has automatic return movement.

The steps comprise aluminum channels covered with stainless steel sheet on both sides and have a sandwich construction of thermo reactive foam placed between external and internal sheets.

The door-window is comprised of fixed type tempered glass, along with internal safety glass glued to the frame by means of sika flux.

The reclining chairs should be removed from the chair cars in every POH and sent to Fitting and Trimming shops for overhaul.

Reclining seats of chair cars are covered under Specification No. MDTS-219.

Felt padding to avoid cutting of upholstery is as per drawing to specification No. IS:1719-88 TAB-1, medium grade.

Pneumatic staplers can be used instead of nailing to improve upholstery repair work productivity.

Nylon thread (IS:4229-92 6.6 VAR.L2) has higher strength than cotton threads and hence reduces incidence of opening of stitches.

For stitching the furnishing cloth, cotton sewing thread no. 30 is used, while thread no. 40 is used for curtains.

For non-AC coaches (LGCN, LGS, & DSLR), cushion material is as per RDSO/Spec C-K607 specification.

Waterproof sealing compound to IS:1580-1960 is used for sealing edges of PVC flooring and around aluminum chequered sheets to prevent water seepage.

If at the trimming stage, the spatula disturbs the weld, this indicates that a positive joint has not been achieved. The existing weld should be removed and the seam must be re-welded.

When the weld has cooled to room temperature, it should be trimmed off flush to the surface of the material with a trimming spatula. Trimming before cooling causes shrinkage below surface.

The correct angle is achieved when the foot of the welding nozzle is parallel to the surface of the flooring for maximum weld strength.

A deep groove cut into the PVC flooring will result in an unsupported weld which may split in use, so correct grooving depth is essential.

A grooving tool is used to groove the butting edges of the seam to approximately two-third of the thickness of the wear layer of PVC flooring, leaving a semi-circular groove for thermo welding.

The second roll shall be laid in position, overlapping the 1st sheet by about 5 to 10 mm, then trimmed through both thicknesses to obtain perfect butt joint.

Spread open the PVC roll/sheet on half the width of coach and leave it for some time (30 to 40 minutes approx.) to enable it to lie flat on the floor.

Epoxy putty is prepared with French Chalk (2.1 kg), Resin HSK (2.1 kg), Acetone commercial (0.4 kg), Accelerator (0.2 kg), and Catalyst (0.2 kg) for 5 kg total.

Flooring is to be done as per RDSO specification No. RDSO/2008/CG/CMI-04 for laying PVC flooring in passenger coaches.

In the case of louvre shutters, instead of the balancing mechanism, a spring loaded safety latch is provided to prevent the louvre shutter from dropping.

To prevent the glass shutters from dropping, a balancing mechanism comprising of spring, lever etc. is provided. Positive force is required to close the window against spring force.

Hopper type windows (1 No. for each Lavatory) are provided in lavatories as per Specification No. LZ54114, Alt nil.

The sealed glass unit consists of outer 8.4 mm laminated glass and inner 4 mm tempered safety glass with 6 mm air gap filled with Krypton/Argon gas.

The document lists 19 specific items for anti-pilferage measures including mirror, soap dish, ash tray, push cock, wash basin, tumbler holder, hand hold, coat hook, fans, lights, etc.

Anti-pilferage measures are carried out during POH to prevent theft of amenity fittings like mirror, soap dish, ash tray, push cock, wash basin, etc. as prescribed by CME or RDSO.

Pre-laminated shaded compreg board to RDSO specification No. RDSO/Spec C-K513 is used for side wall paneling in LHB coaches.

Sleeper class compartments are provided with 400 mm fixed fans, while first class has 400 mm swivelling fans with regulator.

As per electrical requirements, minimum lux at horizontal plane 840 mm above floor level should be 30 lux in compartments for all types of non-AC coaches.

The schedule specifies maximum number of passengers per lavatory as 12 for first class, 20 for sleeper, 27 for day coach, and 25 for general coaches.

As per the amenity fittings schedule, the hip width for passengers in first class is 480 mm, while for sleeper and general coaches it is 415 mm.