POH Procedure for Coaches

Pre Survey
• On receipt of a coach for POH, it must
be cleaned before taken on Lifting line/
Stripping line where electrical fittings
should be stripped and batteries
removed.
• Furnishings, especially seats,
backrests and Curtains should be
inspected thoroughly and only those
that require repairs need to be stripped.
• Water service section
 Lifting the coach body
• Before lifting a coach, the following
components should
be removed, disengaged or disconnected:-
– disconnection of electrical connection
from junction box on alternator in case of
bogie mounted alternator.
– Lavatory chute, if situated over the bogie.
– Bio toilets are unmounted.
– Brake pull rod from bogie brake rigging.
– Centre pivot cotter.
– Axle box safety straps.
 Corrosion repair
• Inspection
• Classification: Light, medium and heavy
corrosion repair
• Vulnerable members: Sole bar, Turn
under, body
pillar, trough floor below lavatories, lifting
pads
– Solebars, body pillars behind sliding
door pockets of
SLRs and parcel vans
– Solebars, body pillars, turn under at door
 Corrosion repair
• Corrosion repair work:
– Solebar
– Headstock
– Body pillars
– Trough floor
– Endwall
– Roof
 Bogie repair Shop
• Bogie Stripping
• Bogie frame rectification
• Bogie bolster and LS beam repair
• Bogie components
• Brake gear components
• Bogie assembly
 Bogie repair Shop
• Bogie frame
– Cleaning
– Check for cracks
– Squareness and alignment check for BSS
brackets and axle guides
– Bracket replacement if corroded
– Primer and painting
• LS Beam and Bogie Bolster
– Cleaning in Bosch tank
– Scraping
– Check for corroded part
– Replacement if corroded
– Primer
 Bogie repair Shop
• Bogie components
– Equalising stay rod and Pins
– BSS Hanger
– Anchor links
– BSS Pin
– BSS hanger block
• Equalising stay
– Cleaning and check for corrosion damages
– Shot blasting and check the welding joint
– Attend welding repair
– Replace bushes
 Bogie repair Shop
• Anchor links
• Replaced if worn or corroded
• Shot blasting and magnaflux testing
• Silent block replaced if rubber is perished
or loose in
anchor link housing
• Hanger block
• Replace hanger block if cracked
• If thickness reduced (wear limit 1.5mm)
condemn
• BSS Hanger
 Bogie repair Shop
• Brake gear components
• Brake head assembly
• Vertical lever
• Z lever
• Curved pull rod
• Brake beam
• Brake block hanger
• Brake gear components are checked for
corrosion,
replaced if damaged
• Brake gear bushes are replaced
 BOLSTER
ASSEMBLY

WHEEL AND
AXLE SETS BOGIE FRAME SPRINGS

BOGIE
 Wheel Shop
• Pre Inspection of Wheel
-Measurement of wheel gauge
-Measurement of wheel diameter
-Inspection of wheel disc
-Inspection of Axle

– Replacement of Axles (RA)

– Replacement of solid discs (RD)
 Wheel Shop
• Replacement of Axles (RA) • Replacement
of solid discs (RD)

– Pressing off rejected Axle – Pressing off

rejected discs
from wheel
– Machining & Inspection – Boring
(Machining) of new discs
of new axles
– Machining &Inspection of – Machining of
wheel seats of old
serviceable wheel disc axle for
matching Wheel disc bore
– Machining of wheel seats – Pressing on
 Roller Bearing
• Stages
– Roller bearing Dismounting
– Cleaning
– Visual Inspection for below defects
• Pitted or flaked roller tracks and rollers.
• Cracked or deformed or badly worn out
cage
• Cracked inner or outer ring
• Scored or damaged outer surface of the
outer ring
• Indentation or rings or rollers
• Scoring of roller tracks or rollers
• Rust/corrosion, damage
• Rings exhibiting deep straw or blue or
 Roller Bearing
• Zyglo testing of roller bearing
• After inspection, if bearing is found satisfactory for further
service, the
bearing may be cleaned further for reassembly and greasing
• Lubrication
• The quantity of grease filled per axle box
– SKF make bearing 2.00 kg
– Other make bearings 1.75 kg
The following components other than roller bearing should be
inspected during roller bearing
– Axle end holes
– End locking plates
– End locking bolts
– Retaining Ring
– Collar
– Felt ring
– Rear and Front Cover
 Air brake shop
• DV maintenance
– Cleaning
– testing
• Leakage test
• Charging
• BC filling time
• BC draining time
• Sensitivity test
• Insensitivity test
• Application and release steps
Must change item kit
 Air brake shop
• Different components • General
procedure
– PEASD – Disassembly,
cleaning of parts with
– PERV kerosene
– Isolating cock – Changing of rubber
items, washers,
– Cut off angle cock springs (kit)
– Centrifugal dirt collector – Assembly
– Vent cock – Check for leakage
with soap water
– Check valve – Check for proper
functioning of
components
 Draw gear and Screw coupler maintenance
• Assembly/ component is
Components cleaned of dirt, grease etc.
– Draw hook • Disassembly of screw
– Draw bar with coupler
castle nut • Visual inspection for
– Draw gear pin distortion,
– Draft key cracks and wear
– Draft key cotter • Check the parts for wear
– Bent link • Magnetic particle testing of
– Straight link draw bar
– Screw assembly • Assembly of screw coupler
– Trunion • Load testing of screw
coupler
 Buffer gear maintenance
• Components
– Buffer casing
– Buffer spindle
– Plunger
– Rubber buffer pads
– Destruction tube
– Recoil spring
– Recoil spring parting plate
– Face plate for buffer plunger
– M.24 Hex. Head bolt
 Buffer gear maintenance
• Record keeping
• Dismantling of buffer assembly
• Inspect the components for distortion, cracks,
wear, corrosion
• Check the buffer casing, plunger, face plate for
crack, wear and
deformation, if worn out more than wear limit is
discarded
• Rubber buffer pads changed at alternate PoH,
check for perishing
or permanent set to a length below 424 mm is
discarded
• Inspect the spindle for straightness, wear on
 Buffer gear maintenance
• Assembly
– Measure the free height of rubber pad
pack 448+/-2 mm
– Place washer, rubber pack, parting
plates, destruction
tube in the plunger and insert plunger
inside the buffer
casing
– Assemble washer, recoil spring, parting
plate on buffer
spindle, place M39 nut
– Press the casing in pneumatic press and
 Flow process of spring maintenance
SHIFTING OF COIL SPRINS FROM BOGIE
SECTION

LOADING IN BOSCH TANK

WASHING WITH HIGH PRESSURE

JET PUMP

SHOT BLASTING

VISUAL INSPECTION AND

RECORDING

REJECTION OF
COIL SPRINGS
C
DENT, PIT,
RUBBING MARKS
AND OVER AGE
Flow process of spring maintenance contd.

MAGNAFLUX CRACK
REJECTION - CRACKS DETECTION AND RECORDING

REJECTION – FREE HEIGHT LOAD TEST GROUPING AND

LESS, WEAK IN LOAD RECORDING

PAINTING
DS-8

DISPATCH TO BOGIE SECTION

 Coach lowering

CORROSION REPAIR BOGIE REPAIR

SHOP SHOP

COACH BODY LOWERING BOGIE ASSEMBLY

FURNISHING
SHOP
 Furnishing
• Furnishing
• Lavatory
• Doors
• Windows/shutters
• Battery box
• Internal corrosion
Furnishing
– Roof panelling- limpet asbestos
sheet 2mm
– Sidewall panelling – LP sheet
3mm
 Furnishing
• Amenity fittings
– Defectives ones removed, repaired/replaced
and refitted
• Mirror and mirror shelf.
• Soap dish
• Push cock/ Gravity cock
• Wash basin
• Tumbler holder
• Coat hook
• Flushing valve
• Folding table
• Hat rack
• Magazine pouch/ mobile pouch
 Trimming & Painting
• Defective seats - rework and replacement
• Material – Densified thermal polyester block
(DTPB)
• Criteria for fail
– Cracks
– Fading
– Uneven surface
– Loose fitting
• Painting
– A schedule -9 days
– C schedule -5 days
 NTXR examination
• Examine the safety items and undergear
examination
– Wheel diameter
– Underframe, turn under, side wall
examination of
corrosion repair quality
– Axle and bolster spring height
– Crown, bolster and bogie clearance
– Buffer height and stroke
– Air brake test
– Overall quality of repair