As per Annexure 10.1, the torque value for Traction Centre support frame to Bogie cross beam bolt size M20X100 is 340 Nm.

The coach number is automatically generated by WISE (Workshop Information System) of ROAMS (Rolling Asset Management System) controlled by CRIS whenever a coach is turned-out from Production Unit or any POH Workshop.

Previous coach numbering system: AC first class (001-025), Composite 1AC + AC-2T (026-050), AC-2T (051-100), AC-3T (101-150), CC (151-200), SL (201-400), GS (401-600), 2S (601-700), SLR (701-800), Pantry car/others (801+).

CBC gauges (Set of 07 gauges) for both M/s FTIL & M/s ASF make are required as per OEM manual for proper maintenance of couplers.

Tool list for en-route troubleshooting includes: Toolkit, Laser Temperature Gun, Adaptor (BF+FP) for bypassing, Angle cock, BP/FP hoses, Ferrule joints of various sizes, M16 bolts, Inspection torches, etc.

For class B screwed assemblies according to DIN 25202, M16 has standard torque of 17.33 Kg-m (78,000 N) preload at mounting.

Fan requirements: Compartment - 400 mm (Swivelling for 1st AC, Fixed for 2nd/3rd AC), Lavatory - 200 mm fixed fan with on/off switch.

As per schedule of passenger amenity fittings for LHB coaches, minimum lux at horizontal plane 840 mm above floor level for AC coaches: Compartment - 120 lux, Lavatory - 100 lux, Corridor - 80 lux.

For uncoupling, lift the handle and turn it in clockwise direction to a horizontal position by minimum 90° and pull the loco/coaches apart.

Coupling procedure: Bring coaches near at 1m distance, unlock handle, lift and turn clockwise 90°, align, attach at 2-3 km/h, check tell-tale, lock handle by rotating clockwise, pull train slightly for reconfirmation.

For BP failure: Bring flexible coupling pipe, lay from one end to other, close BP cut off cocks, couple pipe, manually release and isolate affected coach, conduct air pressure continuity test and work train at prescribed speed.

In case of punctured/deflated air bellow, close isolation cock of air supply pipe and work the train at restricted speed of 60 km/hr up to next train examination point.

During D3 schedule, check and adjust air spring installation height to 289-294 mm as per RCF Letter to MD44121 dated 24/07/2020.

To release brake binding: Pull release lever of DV, rotate isolation cock 90° anticlockwise, if brakes released indicator changes to green. If not released, loosen hexagonal nut of brake cylinder by 27 or 46 spanner.

Classification of depots: Minor Depot - Below 100 coaches, Medium Depot - 100 to 250 coaches, Major Depot - Above 250 coaches.

For rolling in examination of passenger trains, the speed of the train shall not be more than 30 KMPH, and it should cover the entire length of train.

Rolling In Rolling Out items include: Hanging Part, Hot axle, Broken part, Wheel skidding, Air Pressure leakage, Deflated Air Spring, Brake binding, Securing arrangement of all tanks, I.V. Coupler sagging, Whistling sound from brake pad, etc.

During D2 schedule, check suppression system pressure in Nitrogen cylinder. If pressure is less than 150 kg/cm², inform to supplier/OEM for further guidance.

The gas cartridge is to be weighed during annual maintenance. Should be replaced if there is loss of weight by 10%, rusting of container, or if the container is more than 5 years old.

Fire extinguisher maintenance: Monthly maintenance (exterior cleaning, checking nozzle), Annual inspection (empty contents, examine cylinder), Hydraulic Pressure testing at 3 years interval at 25 Kg/cm² maintained for 2.5 minutes.

Provision of Dry chemical Powder type Fire Extinguishers: Each Brake Van (Front & Rear) - 2 nos., Each AC Coaches - 2 nos., Each Pantry Car - 4 nos., Each Generator Car - 4 nos.

Brake Van equipment for Coaching trains includes: Portable control telephone (2 nos.), Portable Train Lighting Equipment (1 no.), Portable Fire Extinguisher (2 nos.), Wooden wedges/Skids (2 nos.).

After brake application, the driver should wait: 40 Sec. after full application and 90 Sec. after Emergency application for twin pipe system as per TSO No. Coaching & Freight/99/1(Rev-1), Para-1.1 -- Train parting.

Primer and paint as per RDSO specification No M&C/PCN/123/2006 and MDTS-094 total DFT 265 microns (As per M&C/PCN/123/2006 - 125 micron and as per MDTS - 094 - 140 micron).

As per Annexure 10.1, the torque value for Traction Centre support frame to Bogie cross beam M20X100 is 340 Nm.

A committee has issued a check sheet for Bogie inspection of LHB coaches during SS-I & SS-II, vide letter no. IRCAMTECH/M/GWL/Check-Sheet LHB Bogies Date-25.02.2020.

The guidelines for pitting holes on bogie frame are as per RDSO No SV Bogie General dt. 14.07.2022.

Small pitting holes up to a maximum depth of 04 mm may be permitted provided these are (a) staggered and not continuous, (b) are not concentrated on the bottom bend portion of the side frame.

For corroded bogie frames, de-scaling/rust removal is done with rust converter to IS:13515 before touch-up with high build epoxy primer and paint.

In case the diameter is between 230.5 mm and 230.312 mm, the control arm may be re-machined by providing a cut of 0.3 to 0.5 mm on the face of control arm. This machining operation should not be carried out more than once.

During Shop Schedule I, perform wheel profiling and wheel balancing (for Speed >= 130 Kmph) as per RCF specification no. MDTS -- 168 for balancing procedure.

As per RDSO Letter No. MC/WA/Genl. dated 02.09.2019, Railways may use Eddy Current Array (ECA) Testing technique as an alternative method to DPT for testing of LHB wheels for detection of surface cracks.

During Schedule D3, carry out paint touch-up on bogie frame with high built epoxy primer and paint as per RCF specifications MDTS - 166.

Monthly/Quarterly inspection of WSP equipment is to be carried out as per schedule given by OEM, not on fixed calendar intervals.

During Schedule D2 function test, Brake Cylinder pressure is to be measured through test points in brake panels for ensuring desired values, and also check functioning of safety valves.

During Schedule D2, lubrication of brake panel's isolating cock is carried out as part of brake equipment maintenance, using prescribed grease.

During Schedule D1, check functioning of WSP and dump valves operation during static testing as part of the Wheel Slide Protection Device maintenance.

During Schedule D1, dismantle and thoroughly clean the air breather plug of brake cylinder/actuator followed by further assembling it on trip/weekly basis as per the condition.

Shop schedules are: Shop Schedule I: 18 months +30 days/6 lakhs Kms whichever is earlier, Shop Schedule II: 36 months/12 lakhs Kms whichever is earlier, Shop Schedule III: 72 months/24 lakhs Kms whichever is earlier.

Coaching depot schedules are: Schedule D1: Every Trip/Weekly, Schedule D2: Monthly ±3 days, Schedule D3: Half Yearly ±15 days as per the maintenance schedule document.