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    S - POH Practices in Workshop

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    Jaikanthan Dasaratha
    The document discusses periodicity and procedures for preventive overhaul (POH) of coaches in workshops. It provides: 1) The periodicity for POH based on coach type ranging from 12-24 months. 2) The procedure for sending coaches to workshops which involves a joint check and preparation of a deficiency list. 3) An overview of repair activities during POH including bogie repairs, body repairs, painting, and testing.

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    S - POH Practices in Workshop

    Uploaded by

    Jaikanthan Dasaratha
    11 views21 pages
    The document discusses periodicity and procedures for preventive overhaul (POH) of coaches in workshops. It provides: 1) The periodicity for POH based on coach type ranging from 12-24 months. 2) The procedure for sending coaches to workshops which involves a joint check and preparation of a deficiency list. 3) An overview of repair activities during POH including bogie repairs, body repairs, painting, and testing.

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    S_POH practices in Workshop

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    The document discusses periodicity and procedures for preventive overhaul (POH) of coaches in workshops. It provides: 1) The periodicity for POH based on coach type ranging from 12-24 months. 2) The procedure for sending coaches to workshops which involves a joint check and preparation of a deficiency list. 3) An overview of repair activities during POH including bogie repairs, body repairs, painting, and testing.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    11 views21 pages

    S - POH Practices in Workshop

    Uploaded by

    Jaikanthan Dasaratha
    The document discusses periodicity and procedures for preventive overhaul (POH) of coaches in workshops. It provides: 1) The periodicity for POH based on coach type ranging from 12-24 months. 2) The procedure for sending coaches to workshops which involves a joint check and preparation of a deficiency list. 3) An overview of repair activities during POH including bogie repairs, body repairs, painting, and testing.

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    PRACTICES OF POH IN

    COACHING WORKSHOP
    Periodicity of POH of coaches in workshops

    Type Periodicity Periodicity


    IOH POH
    New coach or 12 24 months
    MLR coach
    Rajdhani/ 9 months 18 months
    Shatabdi
    coaches
    Mail/Express 9 18 months
    /Passenger
    coach

    Procedure for sending coaches

    Coaching depot shall book POH due coaches after conducting joint check
    by Mech,Elec&Security staff
    Deficiency list is prepared and sent to workshop
    On arrival in workshop, coach is to be checked jointly by Mech
    & Elec in the presence of RPF.
    Addl. Deficiencies to be noted
    Prem. Inspn is undertaken by Inspn wing and arrive at the
    extent of corrosion repairs
    Light corr < 500 man hrs
    Medium corr > 500 & upto 1000 man hrs
    Heavy corr > 1000 man hrs
    Repair activities
    Pre inspn, stripping & lifting
    Bogie repairs
    Wheel set complete attention
    Body repairs, modification/alterations
    Fitment of water tanks, plumbing work
    Repairs to interior panels
    Fitment of shutters, doors
    Painting & fitment of berths/seats
    Fitment of axle pulley, tension rod & testing of coach wiring
    Testing of branch wiring & fitment of electrical equipments
    Air brake testing and final works
    Final inspn and despatch
    Bogie repairs
    Main components of bogie:
    Axle box guide with dash pot arrgmt
    Air vent screws
    Bogie bolster suspension
    Springs, centre pivot arrgmt.
    Side bearers, anchor links, silent blocks
    Brake rigging, equalizing stay, bolster suspension
    Hangers, shock absorbers
    Sequence of activities in Bogie shop
    Coach lifting
    Bogie cleaning sand blasting
    Bogie dismantling
    Component cleaning
    Attention to components
    Repairs to components
    Bogie assembly
    Load testing and adjustment
    Lowering of coach
    Final adjustment in Outgoing shop
    Attention to Bogie frame
    Check for cracks
    Check the square ness and alignment of BSS bracket and axle
    guides with trammel gauges
    Bent or damaged suspension straps to be attended
    Replace BSS bracket bushes and pins, if bent or damaged
    Replace anchor link brackets, if bent or damaged
    Replace brake hanger brackets, if worn or damaged
    Locations where repairs carried out shall be cleaned, painted
    with 2 coats of primer followed by 1 coat of anti corrosive paint
    Attention to Bogie bolster
    Check the bolster for twist, crack or corrosion
    Check the equalizing stay bracket
    Check the anchor link bracket
    Ensure that there is no leakage of oil from side bearer
    Replace hand ground plate in the side bearer oil bath if worn
    more than 1 mm in thickness
    Replace anchor link , if worn or damaged
    Replace silent block, if rubber perished or loose
    Check lower spring beam for cracks, corrosion &
    repair/replace
    Check BSS hangers for cracks or wear , > 1mm replace
    Magna flux testing and tested with tensile load of 8 tonnes
    Replace hanger blocks if cracked, worn blocks can be built up
    Wheel shop activities
    Removal of axle boxes
    Removal of RBs and rear covers RB cleaning
    UT of axles
    Wheel set cleaning
    Wheel set Re-discing/Re-axling
    Wheel set Re-profiling
    RB inspection
    RB fitment
    Axle box assembly
    Coach body interior repairs
    Panel repairs
    PVC floor repairs
    All amenity fittings
    Water tank repairs
    Water pipeline repairs
    Lavatory fittings
    Underslung water tank attention
    Main & Lavatory door repairs
    Window shutter repairs
    CDTS & Bio-toilet attention
    Corrosion repairs
    Corrosion diagram is prepared once extent of corrosion is known
    Intensive corrosion check is done on:
    Under floor members
    Trough floor
    Head stock (both inner & outer)
    Sloe bar, body pillar and turn under at Lav area
    Sole bar, turn under and pillars above lifting pads
    Sole bars and pillars at door corners
    Tubular frame below lav
    Under frame members
    Corrosion repairs
    Side wall members
    Roof repairs & roof ventilation repairs
    Repair to door handles and door pivots
    Repairs to partition wall, seat pillar
    Repairs to draw and buffing gear support structure
    Repairs to body bolster
    Repairs to centre pivot
    Water tank support structure
    Repairs to floor channels
    During corrosion repairs
    Repairs of cracks shall be gouging and welding
    Distorted and bent parts shall be heated and straightened
    Parts used for repair shall be given proper surface treatment
    and applied with protective coating
    Thick sections such as sole bars, cross bearers etc shall be grit
    blasted, given a coat of ROZ primer paint
    Qualified and certified welders shall be employed
    Painting activities
    If condition of paint is good,
    undertake C schedule (5 days)
    Cleaning with cleaning solution and wash thoroughly
    Spot putty, Rub down Gr 120 & 220 silicon carbide water
    proof paper, apply one coat of finishing enamel
    Rub down Gr 400 silicon carbide water proof paper, apply
    one coat of synthetic enamel finishing and Lettering
    else A Schedule (9 days)
    Remove old paint, one coat of ROZ primer, coat of filler followed spot
    putty, second coat of filler, Rub down Gr 120&220 silicon carbide water
    proof paper, coat of under coat, Rub down Gr 320 silicon carbide water
    proof paper with coat of enamel finish, Rub down Gr 400 silicon carbide
    water proof paper with second coat of synthetic enamel finish, Lettering
    Trimming activities
    Repairs to cushioned seats
    Repairs to berths of all sleeper and AC coaches
    Provision of curtains in all AC coaches (new)

    Electrical /AC equipment attention & fitment

    Air brake testing and final inspection of coach


    LHB coach shop schedules

    S.No Type of Schedule Periodicity


    1 Shop Schedule I /SS-
    /SS-I 18 Months/6 Lakhs Kms earned
    whichever is earlier

    2 Shop Schedule II / SS-


    SS-II 3 Years/12 Lakhs Kms earned
    whichever is earlier

    3 Shop Schedule III /SS-


    /SS-III 6 Years/24 Lakhs Kms earned
    whichever is earlier
    Shop schedules of LHB coach 25 days
    Brief of Details of activities No. of
    Shop
    Activity days
    Pre inspection CR(AC) Stripping of partition and ceiling of pantry , 1 Day
    and stripping pantry door, etc.
    Pre inspection AC Pre inspection of deficiency, 1 Day
    and stripping (Electrical)
    Testing and analyzing of coach defects, panel 1 Day
    equipment, AC plant, water Pump,
    --do-- --do-- transformer etc.
    Stripping of all equipments. 1 Day
    Lifting and CR(Lifting) Before lifting of the coach dismantling of 1 Day
    lowering bogie components under pit under such as
    traction lever ,anti roll bar control arm etc.
    Lifting of the coach and washing of bogie 1 Day
    Repairing of bogie, control arm fitting on 1 Day
    wheel and lowering of coach.
    Repairing of Air brake components on panel, 1 Day
    fitting of silent blocks, fitting of bogie
    components under pit and air brake testing.
    CBC and WSP system repair 1 Day
    Intermediate Plumbing Cleaning of the CDTS intermediate water Tank 1 Day
    tank cleaning before lifting of coach on stripping line
    And CDTS Washing of intermediate water tank, bench testing of 1 Day
    testing CDTS panel, valves etc. in CR/L shop.
    Fitting of intermediate water Tank in the coach in 1 Day
    lifting shop.
    Body repair CR(AC) Stripping of lavatory ceiling, repair of lavatory door, 4 Day
    and furnishing repairing of vestibule door, cushion stripping ,repair of
    work reclining gear, foot rest, snack table stripping of the
    fittings Viz. Bottle holder, mirror etc.
    Fitment and AC Loading of all equipments except RMPU 2 Day
    testing of ( Electrical)
    RMPU loading, loading of pantry equipment etc. 2Day
    electrical
    equipments Complete testing, fault diagnosis and their remedy. 2 Day
    Other body CR(AC) Stripping and Fitting of window glasses, Flooring 1 Day
    repair works work etc.
    Repair and fitment of saloon sliding door, roller blinds 1 Day
    etc.
    Repair and fitment of entrance door ,electrical panel 1 Day
    door etc.
    Fitting of pantry partition, ceiling, pantry doors, 1 Day
    lavatory ceiling, other fittings etc.
    Exterior Paint Washing with suitable detergent 1 Day
    Painting
    Application of Putty 1 Day
    Rubbing Down Putty and application of Surfacer 1 Day
    Window Masking, Roof Painting, End painting and 1 Day
    painting of side Panels leaving down side area.
    Masking of upper area and down side painting 1 Day
    Removal of masks, touch up, lettering, cleaning and 1 Day
    other works.
    Interior Paint Internal painting 2 Days
    Painting
    Fitting work Fitting Body panel repair, Stripped body repair, Repair of inner 2 Day
    members like partition frames, Chair angles and seat
    supports etc.
    Trimming Trimming Stripping of curtains on stripping line 1 Day
    work
    Stripping of seats in Carriage AC shop 1 Day
    Fitting of seats and curtains in the coach 1 Day
    Cleaning of the seats and other activities 1 Day
    Water tank Plumbing Testing of under slung/over head water 1 Day
    testing tank in CR Body/CR AC section.
    Repair and testing of water tank in 1 Day
    Plumbing shop.
    Fitting of CDTS panel in coach in CR 1 Day
    Body/CR AC shop
    Final CR(AC) Final inspection and despatch 1 Day
    inspection
    Air brake CR(Lifting) Final Air brake testing 1 Day
    testing.

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