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¼vkbZ,lvks 9001-2015 izekf.kr laLFkku½ Excellence in Maintenance
CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY
Ministry of Railways
Maharajpur, Gwalior – 474005
(An ISO: 9001-2015 Certified Organisation)
Qksu/Phone: 0751- 2470890 (P&T), QSDl/ 91-0751-2470841
E-mail: - [email protected]

No.: M.CAMTECH/M/GWL/MR/ICF/Corr. slips Date: 14.08.2023

PCMEs
All Zonal Railways

Sub: Corrigendum on BG ICF Maintenance Manual (Corrections Slips).

Ref: E- office no. 2007823/2023/O/o PR.ED/CAMTECH/GWALIOR.

IRCAMTECH Gwalior has prepared a Corrigendum on BG ICF Maintenance Manual

(Corrections Slips). This is being issued with the approval of competent authority.

This is for your kind information and necessary action please.

DA: Correction slips No. 11, 12, 13 & 14.

Digitally signed by BRIJ

BRIJ MOHAN MOHAN

Date: 2023.08.14 15:41:12
+05'30'

(बृज मोहन / Brij Mohan)

संयुक्त निदे शक (य ंनिक) / Jt. Director (Mechanical)
ईरकेमटे क, ग्व नियर / IRCAMTECH, Gwalior
 भारत सरकार
रे ल मंत्रालय
(Govt. of India)
(Ministry of Railways)

Corrigendum
on BG ICF
Maintenance Manual
No.: CAMTECH/M/GWL/ICF/Correction slip

May-2023
(For official use only)

MAHARAJPUR GWALIOR- 474005

 mPp vuqj{k.k izkS|ksfxdh dsUæ
jsy ea=ky;
egkjktiqj] Xokfy;j & 474005
¼vkbZ,lvks 9001-2015 izekf.kr laLFkku½ Excellence in Maintenance
CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY
Ministry of Railways
Maharajpur, Gwalior – 474005
(An ISO: 9001-2015 Certified Organisation)
Qksu/Phone: 0751- 2470890 (P&T), QSDl/ 91-0751-2470841
E-mail: - [email protected]

Sub: 11th Correction Slip of Maintenance Manual for BC coaches of ICF Design.
Ref: Coach Maintenance Manual no. CAMTECH/July 2002.

The 11th correction slip to the coach maintenance manual is enclosed.

SN CAMTECH Manual Topic Existing Modified/corrected

Reference instruction instruction
1 Chapter 1 Para 103, Periodicity of Table no 1.1 Notified by RB vide
page 1 of 41, table Periodic letter No. 2007/M(C)/
1.1 (iii) Overhauls 141/1 (IOH/POH)
(POH) in dated-20.04.2021)
Designated Annexure- A-I
Workshops
2 Chapter 1 Para Intermediate All Bogies of such Notified by RB vide
111c, page 22 of 41 Overhauls ICF coaches shell letter No. 2007/M(C)/
(IOH) be given IOH after 141/1 (IOH/POH)
six month +/- 15 dated-20.04.2021)
days of the date of Annexure- A-I
last POH as per
table 1.1.
3 Chapter 1 Para Warranty Added Added S. No. 11 to 19
111(L), table 1.9 claim for in table 1.9
page 26 & 27 of 41 defective / Details enclosed in
failed items Annexure- A-II
4 Chapter 1 Maintenance (As per Rly. Bd's (As per Railway
Para 112(d) of page pattern for Letter No. 91/M Board letter No:
no 28 of 41 NMG rakes (C)/650/1 dated 2010/M(C)/650/2
29.5.2000) NMG Dated-
26.05.2022 &
02.12.2022 & Letter
No 2020/M(C) /650/2
dated 15.09.2022 &
06.07.23) enclosed in
Annexure- A-III
5 Chapter 3 Para 313 Equalizing Equalizing stay for Equalizing stay CG-
page 16 of 36, figure stay for lower lower spring beam 11060 alt.3 (forged
3.13 spring beam (16.25 t axle load type) LS of beam
bogie) RDSO 16.25 t & 13 t bogie.
sketch 88105 Letter attached
Annexure -A-IV
6 Chapter 3 in para Silent Block Replace the centre Silent Block for Centre
316 d (v) at page no. for Centre pivot silent block if Pivot” must be
24 of 36, Pivot found worn, replaced during 3rd
damaged or
POH assuming POH
rubber has
perished. periodicity of 18
months (Vide this
office letter no.
MC/Bogie/BG/SB for
CP dated
05.03.2014). attached
Annexure- A-V
6 Chapter 3 In table Anchor link Drawing No. Drawing No. RDSO
no. 3.10 at page no. Silent block RDSO-Sketch- Sketch-94101 alt-2.
24 of 36, In 3rd 94101 alt.-1.
column
7 Chapter 4 Overcharge 06 Kg/cm2 for 25 06 Kg/cm2 for 10
Para 415(d) of page protection test seconds seconds
no 24
8 Chapter 4 Overcharge 0.1 Kg/cm2 in 25 0.1 Kg/cm2 in 10
Para 417 (test protection test seconds seconds
report) page no 29
9 Chapter 6 Para Design Each cylinder has The brake cylinder
602(b) Page no 1 & features of a piston take-up has a piston stroke of
2 the stroke of 32 mm 32 mm ( 40 mm in
system and adjustment GS & SLR) and an
capacity of 305 adjustment capacity
mm of 305 mm
(Ref. Drg. RDSO (Ref. Drg. RDSO Sk-
Sk- 81057) 81057 Alt.10)
10 Ch 11, Para 1105c, Material 12mm Compreg 12mm Wood based
Page 09 of 17 Description Floor Board to impregnated
RDSO compressed laminates
specification no.C-to RDSO specification
9407 (Revised)no. C-9407 (Rev.3)
Type-II Amnd.-4
11 Ch 11, Para1105c, PVC Flooring- RDSO Flexible poly vinyl
Page-10 of 17 specification no. C-
chloride (PVC)
8515 (Rev.2) flooring to RDSO
spec. No.
RDSO/2006/CG-12
(Rev.1) Amnd.-4
12 Ch 11, Para 1105f (i) PVC Flooring- RDSO schedule of Flexible poly vinyl
, Page-12 of 17 requirement no. C- chloride (PVC)
8515 (Rev.2) flooring to RDSO
spec. No.
RDSO/2006/CG-12
(Rev.1) Amnd.-4
13 Ch 11, Para 1105(g) Maintenance Procedure for Procedure for laying
(i) & (ii), page-12 of instruction laying PVC flooring Flexible poly vinyl
17 in passenger chloride (PVC)
coaches. RDSO flooring in passenger
pamphlet no.C- coaches. RDSO spec.
9001 No. RDSO/2006/CG-
12 (Rev.1) Amnd.-4

14 Ch 11, para 1106a Cushioned Flame retardant Fire retardant

(i), In 1st row of 2nd seats and fabric upholstery to upholstery to RDSO
column, page-13 of berths RDSO's STR No. spec. no.
17 C-99901. C-9901 (Rev.2),
Amnd.-6
15 Ch 11, para 1106a Cushioned Vinyl coated fabric Vinyl coated
(i), in 2nd row of 2nd seats and to type II of upholstery Fabric
column & in 3rd row berths RDSO's STR No. (artificial leather) to
of 2nd column, page- C- 9503. RDSO spec. No.
13 of 17 RDSO/2008/CG-7
Amnd.-5
16 Annexure “D” of 1st Injection RDSO's STR No. RDSO spec. No.
correction slip dated Moulded C-K102 RDSO/2006/CG-6
7.8.2006 at Page Silent Block (Rev.1)
no. 45 of 47 for Centre
Pivot of BG
coaches
17 Appendix C Modification in Appendix C Revised Details are
BG coaching attached in
stock Annexure-B-I
18 Appendix D List of RDSO Appendix D Revised Details are
technical attached in
Pamphlets Annexure-B-II
19 Chapter 10 of Check list for Added Check list attached in
Rolling gear minimize the Annexure-B-III
axle box (RB letter No.
Canting/Whee MC/GS/Rubber dated
l grazing on 17.04.2017
ICF type BG
Coaches

Encl: Annexure- A-I to A-V & B-I to B-III

 Annexure-A-I

Revised IOH/POH periodicity of ICF coaches

(Railway Board letter no. 2007/M(C)/141/1(IOH/POH) dated 20.04.2021)

Periodicity in
Coach Category (Months)
IOH POH
MAIL/EXPRESS, GARIB RATH, JAN SHATABDI Coaches &
OCVs FORMING PART OF STANDARD RAKE 9 18
COMPOSITION OF MAIL/EXPRESS TRAINS
PASSENGER Coaches and OCVs working in these trains. 9 18
Other OCVs
CAMPING COACH ATTACHED TO TRACK MACHINE 24 48
SLR/GS COACHES, ATTACHED AS WIRE DECK IN RE
24 48
PROJECTS
INSPECTION CARRIAGES, TRAINING & OBSERVATION
12 48
CARS
ART/ARME/ARMV COACHES 12 48
i) IOH of all types of vehicle to be conducted in open line depot only using workshop
overhauled Bogie.
ii) All mandatory regular examination like pit line examination and BPC issuance
/validation/Re-validation should be carried out as per extant guidelines prescribed
by Board/RDSO/CAMTECH.
iii) For RA/CT/Observation Cars and ART/ARME vehicles that shall henceforth go for
POH only in 48 months, a coat of paint and touch up for lettering may be restored to
in IOH.
 Annexure-A-II

Warranty claim for defective/failed items (Chapter-1 On Page no. 27 of 41)

In Table -1.9, Following item details to be added

SN Description of Item Warranty Period/Conditions

1. Flexible Poly Vinyl Chloride Minimum 6 years from date of supply or 5
as per spec. No. RDSO/ years from date of fitments which ever earlier.
2006/ CG-12 (Rev.1)
Amend.-4
2 Vinyl Coated Upholstery as 54 months from date of supply or 48 months
per spec. No. from date of fitment whichever earlier.
RDSO/2008/CG-7 Amend-5
Hytrel Washer as per Spec. Warranty of the manufacturer against defective
3 No. C-K409 (Rev.2) materials/workmanship and performance for a
Amendment-4 August, 2016 min. period of 30 months from the date of
supply or 24 months from the date of fitment,
whichever is earlier. In case, washer cracks,
bulges, deforms or height becomes less than
32mm due to permanent set within the
warranty period, it shall be replaced by new
one within one month.
4 Injection Moulded Silent
Block for Centre Pivot of BG Within 60 months after their delivery or date of
coaches as per spec. No. fitments which ever later.
RDSO/ 2007/ CG-6 (Rev-1)
Amend-3 of Aug-15
5 Fibre Glass Reinforced
Plastics (FRP) Window for The warranty period will be 30 months from
B.G. M/Line and EMU the date of supply or 24 months from the date
Coach” as per spec. no. of fitment.
RDSO/ 2007/ CG-02
(Rev.1) Amend.3 .
6 FRP Window Guides, The warranty period will be 30 months from
Window Sills and Cross the date of supply or 24 months from the date
Members for Main line and of fitment of the window guides, sills & cross
EMU Coaches as per spec. members.
no. RDSO/ 2007/CG-03
(Rev.1) Amend.-3.
UIC type Elastomer Flange The manufacturer shall replace the stores
7 Connections for Inter- failing /proving unsatisfactory in service within
communication between a period of 60 months after their delivery or
Passenger coaches as per fitment date whichever is later, for failure
spec. no. RDSO/2007/CG- attributed to faulty design/defective material or
05 (Rev.1) of November poor workmanship. For the replacement of the
2018, stores, the period of 60 months would
commence when the replaced equipment is
commissioned in service.
8 Silicon Foam as Cushioning The manufacturer shall replace the stores
Material for Indian Railwayagainst defective materials/workmanship and
passenger coaches as per performance for period of 10.5 Years from the
spec. no. RDSO/2013/CG- date of supply or 10 years of fitment of
13 (Amend-2) of May 2018, seats/berths whichever is earlier. The products
shall be warranted against permanent set of
the material during service. The
sagging/reduction in thickness of seats and
berths shall be less than 5% of
Original thickness.
9 Flexible load bearing 6 years from date of dispatch of the coach.
polyurethane foam for seat
and berth of LWFAC
coaches as per spec. no.
MMDTS – 19020 (Rev-3)
Amend-1.
 Annexure-A-III
(Railway Board letter No: 2010/M(C)/650/2NMG dated-26.05.2022 & 02.12.2022
& Letter No 2020/M(C) /650/2 dated 15.09.2022 & 06.07.2023 or latest)

Guidelines for Operation and Maintenance of ICF design NMG/NMGH/NMGHS

1. 31 Coaching depots are nominated as base depot for

NMG/NMGH/NMGHS automobile Cars/rakes examination point vide
above Railway Board letters. For the latest & revised list of base
depots, latest Railway Board letter may be followed.
2. Zonal Railways to make exclusive rakes of NMG/NMGH/NMGHS
cars to the extent possible.
3. While formation of rakes, it should be ensured that NMG coaches
are not intermixed with NMGH/NMGHS Coaches.
4. NMG/NMGH/NMGHS rakes will normally be examined only in the 22
Coaching depots, as nominated above.
5. The examination of NMG/NMGH/NMGHS rakes in yard and on non-
Pit lines is not permitted.
6. All nominated depots may issue BPC with validity of 6000 KMs or 15
days whichever is earlier (12 Days+03 days as grace period for last
loading) after pit line examination for NMG/NMGH/NMGHS rakes.
7. Deleted.
8. In exceptional circumstances only, Pit line Examination of
NMG/NMGH/NMGHS may also be done at any other coaching
depots/any other pit line examination points, other than the above
nominated depots.
9. However, from any other depot other than the above 22 depots, BPC
will be issued for NMG/NMGH/NMGHS with validity for only one next
loading and unloading cycle within 3500 KMs or 07 days, whichever
is earlier (05 Days+02 days as grace period of last loading) after pit
line examination.
10. NMG/NMGH/NMGHS Automobile Cars becoming POH/IOH due
within 7 days will never be permitted from any of the above 22
nominated examination points and accordingly such cars shall be
detached at these nominated examination points only.
11. Whereas, from examination points other than the above 22
nominated points, POH/IOH Overdue/Due NMG/NMGH/NMGHS
automobile cars may be permitted up to one month from due date of
IOH/POH. This is basically to avoid higher in-effective due to
scattered detachments of NMG/NMGH/NMGHS.
12. Full composition of NMG/NMGH/NMGHS rake shall be ensured at all
of these above examination points.
13. NMG/NMGH/NMGHS Automobile Cars whenever becomes defective
and detached in adjoining Railways, should be sent to the nearest
nominated depot in nominated Zonal Railways only.
14. BPC for all NMG/NMGH/NMGHS rakes in operation must be issued
through CMMS without fail.
15. All workshops should to convert eligible NMG coaches necessarily
into NMGH/NMGHS as per the directives issued by Board vide letter
no. 2020/M(C)/650/2 dated 03.01.2022.
16. All data related to conversion into NMG/NMGH/NMGHS from ICF
coaches, and subsequent attentions in ION/POH/A-schedule/B-
 schedule, pit line examinations Etc. should scrupulously be uploaded
on CMMS, including Corrosion diagram. GM/CRIS and
PCMEs/Zonal Railways to ensure this.
17. Adequate material and infrastructure including provision of
additional pit line in the above nominated depots and in the
workshops of nominated Railways should be planned on priority to
ensure proper maintenance of NMG/NMGH/NMGHS. IOH of
NMG/NMGH/NMGHS shall be carried out in any of the 22
Nominated depots as mentioned above only, as per total target of
the Zonal Railways. ICF Trolley for IOH schedules should be
provided by the workshop as nominated above.
18. POH of NMG/NMGH/NMGHS shall be carried out in any of the 08
workshops as mentioned above only, as per total target of the Zonal
Railways.
19. Oiling of dashpot and side bearer should be checked and topped up
if required without fail during Pit line examination and records should
be maintained.
20. Only SLR/SLRD will be used as last vehicle for the
NMG/NMGH/NMGHS rakes.
21. The maintenance of NMG/NMGH/NMGHS will be done as per the
maintenance schedule mentioned in Appendix F of maintenance
manual for BG coaches of ICF design.
22. At Non TXR points, Driver and Guard will ensure pressure continuity
before starting. Guard and driver will ensure that there are no loose
or missing fitting in the under gear (such as brake blocks, safety
brackets, brake gear pins etc.) which may endanger the safe running
of the train. Driver and guard will then prepare the memo jointly on
the plain paper in triplicate and both Guard and Driver will sign it.
The Driver and Guard will retain one copy and handover the third
copy to Station Master/Yard Master.
23. After each loading/unloading the rake will be examined by Guard
and Driver before commencement of journey and observations will
be recorded under the relevant columns of the brake power
certificate. In case of mechanized loading/unloading examination of
rake to be done by (SSE/JE/C&W).
24. Premium NMG coach will run in rake form only at a maximum speed
of 75 KMPH and NMGH/NMGHS may run up to 110 KMPH.
25. All the cases of violation of this limit shall be analyzed by the
concerned Division /Zone where such rake gets detected, either on
run or during subsequent examination, for adequate corrective and/
or preventive action (if necessary).
26. In case Km / Days limit is breached due to lack of monitoring or
otherwise, and the rake is in empty condition, it shall be pushed for
examination point for Pit line examination.
27. GDR Check: GDR check is an important check for ensuring safety in
trains operations. Instructions issued from time to time on GDR
check are summarized below:
a. Kilometers earned are logged properly on the backside of BPC
without fail by crew & Guard after each run. In case distance is not
recorded, BPC will be deemed valid for only 7 days from the date of
issue.
b. GDR check should be done post loading/back loading of rake.
 c. If a rake is stabled at non-C&W point for more than 24 hours or BPC
has become invalid, GDR check should be done before clearance
of stabled load.
d. In case of attachment/detachment of the NMG/NMGH/NMGHS or
reversal of power at non C&W point, continuity of the brake pipe
pressure should be ensured by Guard and Driver.
e In case of a premium end to end rake the observation by Guard and
Loco Pilot will be recorded under the relevant Para of the Brake
Power Certificate. In partial modification to Railway Board’s earlier
letter no.2005/M(N)/951/13 dated 08.02.2006, GDR check sheet is
modified with respect to NMG/NMGH/NMGHS and items to be
checked during Guard and Driver checks are as under:

1. All couplings and Air hoses pipes are properly coupled and
locked.
2. All the angles cock are in open position.
3. The last angle cock is in closed position.
There is no loose fittings/hanging parts like Brake Beam,
4. Safety brackets, Brake Blocks etc. which may endanger
safe running of the train.
5. Hand brakes are released.
6. All the doors of NMG/NMGH coaches should be locked.
7. There should not be any fall plate missing/Damaged.
8. Check the springs should be intact and there should be no
broken spring.
9. Lock and latches of doors are closely secured.
10. The brake blocks should be in good condition.
11. Check the continuity of air pressure before starting.

f. It is primary responsibility of the Guard (Being in-charge of the train)

as well as of Loco Pilot & Station Staff for not allowing train running
on invalid BPC in violation of the existing instructions.
g. If any unusual situation arises, the train will be started after GDR
check and will run to the next C&W examination point in the direction
of movement.
h. SS/Dy.SS/Loco pilot/Guard will hand over the Last trip BPC to the
C&W staff after completing the trip. In case of Non C&W point it is
the responsibility of SS/Dy.SS to collect the BPC with all relevant
document and hand over the BPC to the coaching depot before the
next examination.
i. These instructions do not amend any provisions contained in IRCA,
ICF coaching manual and GR&SR and the same may be brought to
the notice of Railway Board.
j. The BPC should be linked with Rake id of NMG/NMGH/NMGHS.
BPC generated only through CMM and it should have rake id
mentioned over it.
I. Workshops converting ICF coaches into NMG/NMGH/NMGHS
should make entries in WISE/CMM before rolling out of coach.
28. The above maintenance regime to be followed scrupulously without
any kind of compromise.
Annexure-A-IV
Annexure-A-V
 Annexure-B-I

Following revision may be included in Appendix-C

i) S. No. 06: STR no. C-9406 (Rev.1) at Column ‘Sketch / Drg. No.’ to be updated
as ‘Spec. C-9406 (Rev.2) Amendment-2 of silent block for anchor link.
ii) S. No.-09: STR no. C-9503 modified as RDSO /2008 /CG-07 Amendment 5 title
as schedule for technical requirements for vinyl coated upholstery (artificial
leather) for coaching stock.
iii) S. No. 18: STR. no. C-8215 to be modified as C-8215 {Rev.-2}, Amendment 2,
for Schedule of Requirements for Plastic Axle Guide Bush for Axle Box Guide
Arrangement of ICF BG & MG Bogies.
iv) S. No. 41, 42 & 45: STR. no. C-9403 to be modified as RDSO/2007/CG-
02(Rev.1) Amend.3.
v) S. No. 56: STR. no. C-9502 to be modified as RDSO/2007/CG-03(Rev.1)
Amend.3.
vi) S. No. 57: STR no. C-9407 type-II modified as C-9407(Rev.3) Amnd.4 title as
schedule for technical requirements for wood –based impregnated compressed
laminates for use in railway coaches.
vii) S. No. 59: STR no. to be modified as RDSO/2007/CG-05 (Rev.1) November
2018.
 Annexure-B-II
Following revision may be included in Appendix-D

i) S. No. 24: STR No. C-8215 to be modified as C-8215 {Rev.ll}, Amendment-2, for
Schedule of Technical Requirements for Plastic Axle Box Guide Bush for Axle
Box Guide Arrangement of ICF BG & MG Bogies.
ii) S. No. 29: STR no. C-8409 to be modified as RDSO/2007/CG-01, Amendment-3
and title as “Schedule of Technical Requirements for Sheet Moulding Compound
(SMC) to be used For Manufacture of F.R. P. Products.
iii) S. No. 33: STR no. C-8515 (Rev.2) modified as RDSO/2006/CG-12 (Rev.1)
Amndment-4 schedule for technical requirements for flexible poly vinyl chloride
(PVC) flooring) for use in coaching stock.
iv) S. No. 48: STR no. to be modified as RDSO/2007/CG-05 (Rev.1) November
2018, FOR UIC TYPE ELASTOMER FLANGE CONNECTIONS FOR
INTERCOMMUNICATION BETWEEN PASSENGER COACHES (Page No 301 of
429).
v) S. No. 76: STR no. C-9406 (Rev.1) at Column ‘Sketch / Drg. No.’ to be updated
as ‘Spec. C-9406 (Rev.2) Amendment-2. of silent block for anchor link.
vi) S. No. 79: STR no. C-9403 to be modified as RDSO/2007/CG-02 (Rev.)
Amendment-3 and title as “Schedule of Technical Requirements for Fibre Glass
Reinforced Plastics (FRP) Window for B.G. Main Line and EMU Coaches”
vii) S. No. 81: STR no. C-9407 modified as C-9407 (Rev.3) Amnd.4 schedule for
technical requirements for wood –based impregnated compressed laminates for
use in Railway coaches.
viii) S. No. 84: STR no. C-9502 to be modified as RDSO/2007/CG-03(Rev.1)
Amendment-3 and title as “Schedule of Technical Requirements for Fibre Glass
Reinforced Plastics (FRP) Window Guides, Window Sills and Cross Members for
Main line and EMU Coaches”.
ix) S. No. 85: STR no. C-9503 modified as RDSO/2008/CG-07 Amndment-5 title as
schedule for technical requirements for vinyl coated upholstery (artificial leather)
for coaching stock.
x) S. No. 102:.STR no. C-9901 modified as C-9901 (Rev.2) Amndment-6 title as
schedule for technical requirements for fire retardant upholstery.
xi) S. No.119: STR no. R-64/98 (Revised) to be modified as R-64/98 (Rev.2) Indian
Railway Standard Specification for Rubber Washers used in the Primary &
Secondary Suspension of Main Line and EMU Coaches

Following specifications may be added in Appendix-“D”

1. Spec No. RDSO/2007/CG-07, (Rev. 1) Amendment 1, for Schedule of Technical

requirements for Injection Moulded Thermoplastic Polymer Elastomer (Hytrel)
Axle Box Front Cover for M.G & B.G. Mainline and EMU Coaches.
2. Spec No. C-K409 (Rev.-2) Amendment 4, for Schedule of Technical requirements
for High Capacity Thermoplastic Polyester Elastomer (Hytrel) Upper & lower
Washers used in the primary suspension for B.G. mainline coaches.
3. Spec No. RDSO/2009/CG-03 Amendment 2, for Schedule of Technical
requirements for Injection Moulded Poly acetal Protective Tube for ICF type B.G.
Main Line & EMU Trailer Coaches.

APPENDIX-D of 1st correction slip dated 07.08.2006: STR to be modified as

RDSO/2007/CG-05 (Rev.1) November 2018, for UIC type elastomer flange
connections for intercommunication between passenger coaches (Page No 390 of
429).
 Annexure-B-III

Check list for minimize the axle box Canting/Wheel grazing on ICF type BG Coaches:

Specified values/attribute / Action found non

S.N. Activities
observations confirming
It is to be ensured that the As per item 6 of Appendix – Must change.
guide bush to be replaced II of Maintenance Manual
1
100% during POH for BG coaches of ICF
Design.
Internal diameter of the The ID of the lower spring I.S. seat to be replaced, if
lower spring seat should be seat should be between ID worn out beyond the
measured during 140.00 to 140.04, if wear ispermissible limit i.e.
2
IOH/POH. more than 0.4 mm or 140.00or surface scored
surface scored. (As per Para A-II-2.14 of
IRCA Part IV).
The diametrical clearance It should be less than 1.6 Guide bush for I.S. Seat
between the guide bush mm. to be replaced if
and lower spring seat. diametrical clearance is
3
beyond permissible limit
(As specified in Para 10
of A-II-3 of IRCA Part IV).
The trammeling of bogie As per table 3.7 of chapter Alignment should be
should be done on the 3 of Maintenance Manual made properly.
level surface during POH for BG coaches of ICF
4 following the procedure Design.
given in the Maintenance
Manual for BG coaches of
ICF Design.
The axle box housing bore If bore size is more than Axle box housing to be
should be checked during 280 + 0.080 mm if excess replaced if bore size is
IOH/POH or when bearing ovality is found. beyond the permissible
5
is attended and the axle limit (as per RDSO letter
box with excess ovality and no. MC/RB/Genl. dated
excess bore. 26.6.1991).
AAC of guide bush, I.S. Planned to be replaced in
seat. Hytrel Washer and a time bound manner.
Axle box Housing should
6 be reviewed by Railways -
depending upon the
condition of in-service
items.
Bogie featuring in axle box If rear cover is worn- Rear cover and axle box
canting/grazing. The roller out/dented/damaged. If housing to be replaced.
bearings of wheel sets bore size is more than 280+
should be pulled out and 0.080 mm.
7
the condition of the rear
cover and bore dia of
housing should be
thoroughly checked.
If repeated sick coach If repeated sick due to The dimension of guide
found in between single canting/wheel grazing is location to be checked by
8 POH/IOH. observed. trammeling method and
pairing of spring should
be redone after testing.
 In year 2005, flange dia of Flange dia. of axle guide Railways may get the
axle guide was reduced should be ensured 250 mm face of guide flange
from 260 to 250 mm as per in place of 260 mm. ground/cut to have
9
ICF drawing. sufficient clearance
between flange of axle
guide and the wheel.
The bottom derlin liner of Bottom derlin liner of lower Condition based
lower Hytrel wash Hytrel washer assembly replacement in IOH and
10 assembly is to be replaced should be replaced, if Must change in POH.
during every POH due to indentation observed on it.
indentation observed on it.
Measure the thickness of Minimum thickness is 32 Change the hytrel lower
11 Hytrel lower washer mm. washer assembly if
assembly. beyond permissible limit.
 mPp vuqj{k.k izkS|ksfxdh dsUæ
jsy ea=ky;
egkjktiqj] Xokfy;j & 474005
¼vkbZ,lvks 9001-2015 izekf.kr laLFkku½ Excellence in Maintenance
CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY
Ministry of Railways
Maharajpur, Gwalior – 474005
(An ISO: 9001-2015 Certified Organisation)
Qksu/Phone: 0751- 2470890 (P&T), QSDl/ 91-0751-2470841
E-mail: - [email protected]

Sub: 12th Correction Slip of Maintenance Manual for BC coaches of ICF Design.
Ref: Coach Maintenance Manual no. CAMTECH/July 2002.

The 12th correction slip to the coach maintenance manual is enclosed. The
correction was done in Appendix -A of the Transportation codes for coaches.
SN CAMTECH Topic Existing Modified/Corrected/Adde
Manual instruction d/ instruction
Reference
1. Appendix -A Transportation codes RB/L.No. 87/ M(C)/202/10
for BG main line ---- Vol.II dt-18.09.2007. To
coaches include as Appendix-A-3
Transportation codes RB/L.No. 87/ M(C)/202/10
for coaches of Palace ---- Vol.II dt 28.08.2008. To
on Wheels-II include as Appendix-A-3
Transportation codes RB/L.No. 87/ M(C)/202/10
for coaches to IRCTC Vol.II dt 23.02.2010. To
----
Luxury Train- include as Appendix-A-3
Maharajas' Express
Transportation codes RB/L.No. 87/ M(C)/202/10
of CAMPs coaches ---- Vol.II dt 15.12.2010. To
include as Appendix-A-3
Transportation code for RB/L.No. 87/ MC/202/10
Deccan Odyssey Vol (iv) pt (vi) New Delhi,
luxury tourist train ---- dated 23.05.2018. To
running on Central include as Appendix-A-3
Railway
Transportation codes RB/L.No.2010/M
for BG Coaches (ICF (C)/650/2NMG dt-
----
type) 24.11.2020. To include as
Appendix-A-3
Conversion of ICF RB.No. 2010/M(C)/650/2
design Non AC NMG dt- 25.08.2021. To
coaches into include as Appendix-A-3
---
automobile carrier
coaches with side entry
provision

Encl:- Appendix -A-3

 Appendix -A-3

Transportation
SN Description
Code
1 Enhanced capacity I AC (SG) coach (passenger capacity 22) WGFAC 1
2 Enhanced capacity AC 2T (SG) coach (passenger capacity 48) WGACCW 1
3 Enhanced capacity AC 3T (EOG) coach for Garib Rath (with mini WACCNH 1
pantry, linen room & passenger capacity of 78))
4 Enhanced capacity 3 Tier sleeper coach (passenger capacity 84) WGSCN 2
5 Enhanced capacity AC 2T cum AC 3T (SG) coach (capacity 24 in WGCWNAC 1
AC 2T & 39 in AC 3T)
6 I AC cum AC 3T (SG) coach (capacity 10 in I AC & 33 in AC 3T) WGFCNAC
Palace on Wheels-II
8 Super Deluxe WPCTFAC
9 Deluxe-I WPCTAC1
10 Deluxe-II WPCTAC2
11 Restro Lounge-I WPCRAC1
12 Restro Lounge-II WPCRAC2
13 Spa Car WPCGAC
14 Kitchen Car WPCB
15 Staff Car WPSAC
16 Staff cum Store Car WPSLAC
17 Power car WPSRRMAC
Maharaja Express
18 Presidential suite car WMCTAC1
19 Suite car WMCTAC2
20 Super deluxe WMCTAC3
21 Deluxe car WMCTAC4
22 Restaurant car WMCRAC1
23 Bar car WMCRAC1
24 Observatory car with Bar WMCRAC1
25 Staff car WMSAC
26 Generator car WMSRRMAC
27 Kitchen car WMCBAC
28 Camp coach RCC
Odyssey Luxury Tourist Train
29 Cabin Car1 for Deccan Odyssey WDCTAC-A
30 Cabin Car2 for Deccan Odyssey WDCTAC-A
31 Gym/Yoga/Health club coach for Deccan Odyssey WDCGNAC-A
32 Conference Car for Deccan Odyssey WDCCAC-A
33 Restaurant Car1 for Deccan Odyssey WDCRAC-A
34 Restaurant Car2 for Deccan Odyssey WDCRAC-A
35 Bar Car for Deccan Odyssey WDCBAC-A
36 AC Staff Car for Restaurant Car1 for Deccan Odyssey WDSAC-A
37 Suit Car for Deccan Odyssey WDCTAC-A
38 Brake, Luggage & Generator with high capacity DG set with WLRRM-A
RMPU (Power car) for Deccan Odyssey
39 Automobile carrying vehicle (75 KMPH) NMG
40 Automobile carrying vehicle (110 KMPH) NMGH
40 Automobile carrier coach with side entry NMGHS
 mPp vuqj{k.k izkS|ksfxdh dsUæ
jsy ea=ky;
egkjktiqj] Xokfy;j & 474005
¼vkbZ,lvks 9001-2015 izekf.kr laLFkku½ Excellence in Maintenance
CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY
Ministry of Railways
Maharajpur, Gwalior – 474005
(An ISO: 9001-2015 Certified Organisation)
Qksu/Phone: 0751- 2470890 (P&T), QSDl/ 91-0751-2470841
E-mail: - [email protected]

Sub: 13th Correction Slip of Maintenance Manual for BC coaches of ICF Design.
Ref: i) Coach Maintenance Manual no. CAMTECH/July 2002.
ii) RDSO L/No. MC/CB/MM dated 25.06.2020.

The 13th correction slip to the coach maintenance manual is enclosed. The following
Modifications in BG coaching stock is added as Appendix C-I.
Appendix C-I
SN Description of modifications Reference Document
1. Retro fitment of battery boxes on AC coaches. MC/CB/AC/3-Tier dated
22.04.2004
2. Procedure for repair and condemnation of 13t RDSO/2008/CG/CMI-03,
bogies of mainline coaches. Amend-01
http://10.100.2.19/carriage/cmis/
rdso_cmis/2008-CG-CMI-03.pdf
3. Repair procedure of body bolster of hybrid LHB MC/LC/LHB, dated 04.08.2011
coaches.
4. Instruction for corrosion repairs ICF/RCF built RDSO/2011/CG/CMI-01,
coaches. Amend-01
http://10.100.2.19/carriage/cmis/
rdso_cmis/rdso-2011-cg-cmi-
01.pdf
5. Procedure for repair of 16.25t bogie frame RDSO/2012/CG/CMI-02,
(BMBS) of ICF RCF built mainline coaches. Amend-01.
6. Procedure for reclamation of bogie bolster MC/CRN/REH, dated
assembly of ICF design AC and Non-AC 15.11.2012
coaches.
7. Guidelines for repairs of oriental type and TRA RDSO/2012/CG/CMI-03, Rev.-
type roof ventilators and redesigning of TRA 01
type roof ventilator of ICF/RCF built BG
mainline Non-AC coaches.
8. Procedure for exterior PU painting of coaches RDSO/2013/CG/CMI-01
in Indian Railways workshop.
9. Maintenance instructions for repairs of pin for MC/ICF/B/D, dated 04.01.2013
bolster spring suspension in IOH/POH of BG (Annexure-C).
coaches of ICF design.
10 Provision of SS Dust Bin in lavatories of MC/CB/LF dated 12.09.2013
coaches fitted with Bio-Toilet.
11 Maintenance Instructions for Brake Gear Pins MC/Bogie/BG/STD dated
of Bogies of BG Coaches of ICF design. 15.10.2013.
12. Breakage of Brake Block Hanger review design MC/ICF/B/D dated 12.06.2014
13. Procedure for repair of cracks of 13t RDSO/2014/CG/CMI-02
crashworthy bogie frame of RCF built BG
mainline coaches of ICF design.
14. Procedure for corrosion repair of headstock RDSO/2014/CG/CMI-04
assembly of BG mainline passenger coaches
of ICF design.
15. RCF built BG mainline crashworthy GS MC/Crashworthy/Cons/Proj,
coaches of ICF design fitted with 13t dated 05.06.2014
crashworthy bogie.
16. Retro-fitment of headstock, center buffer A Report by: The Committee
coupler(CBC) and modular toilets in coaches of Nominated By Railway Board
ICF design in service- Draft work instructions Revision-01 Jan’ 2017.
and drawings.
17. Issue of improper fitting of water tap at wash MC/CB/36 dated 30.10.2017.
basin in ICF design coaches .
18. Adoption of alternate design of equalizing stay MC/Bogie/BG/E/Stay dated
to drawing no. CG-11060, alt-2 (Forged Type) 19.05.2017
for LS Beam of 16.25t and 13t bogie.
19. Alteration in drawing No. CG-11060, alt-2 MC/Bogie/BG/E/Stay dated
(Forged Type) for LS Beam of 16.25t and 13t 01.03.2019
bogie.
20. Painting Scheme of ICF design Coaches of MC/PNT dated 25.04.2019
project under "UTKRISHT".
21 RDSO issued modification in Battery box frame RDSO letter No. MC/CB/AC/3-
arrangement in drg. No. Sketch-K0037, alt. 4 & tier dated 27.09.2013 or latest
Sketch-K1015, alt 1 (RDSO letter No. (Annexure-D)
MC/CB/AC/3-tier dated 27.09.2013).
22 Revised compendium on IR-DRDO Bio- toilet IRCAMTECH/MECH/GWL/Com
for IR Sept-2018 and latest. pendium on IR-DRDO Bio-
Toilet/1.0/Rev-I
September – 2018 or latest
23 SS dustbin in lavatories of coaches fitted with RDSO L/No.MC/CB/LF dated
bio toilets. 12/09/2013 & latest (Annexure-
E)
24 PU Painting. RDSO/2013/CG/CMI-1, July-
2014 & latest
25 Marking of “Trespassers shall be prosecuted” RDSO L/No. MC/MK/3 dated
in portion of train/rake specified for Divyangjan. 27.12.2019
(Annexure-F)
26 Magazine pouch/Bag . D- listing of Magazine pouch
from AC/NAC sleeper coaches
vide RB letter no 2018/M(C)
/141/1dt 20.04.2018.
27 Snack Table. D- listing of Snack Table from
NAC sleeper coaches vide RB
letter no 2018/M(C) /141/1dt
20.04.2018.
Annexure-C
Annexure-D
Annexure-E
Annexure-F
 mPp vuqj{k.k izkS|ksfxdh dsUæ
jsy ea=ky;
egkjktiqj] Xokfy;j & 474005
¼vkbZ,lvks 9001-2015 izekf.kr laLFkku½ Excellence in Maintenance
CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY
Ministry of Railways
Maharajpur, Gwalior – 474005
(An ISO: 9001-2015 Certified Organisation)
Qksu/Phone: 0751- 2470890 (P&T), QSDl/ 91-0751-2470841
E-mail: - [email protected]

No. M.CAMTECH/M/GWL/ICF/Corr. slips Date: 19.06.2023

Sub: 14th Correction Slip of Maintenance Manual for BC coaches of ICF Design.
Ref: RDSO letter no. MC/ BLB/CBC dated 12.06.2023.

The 14th correction slip to the coach maintenance manual is enclosed. The CBC
maintenance schedule being added to Maintenance Manual for BC coaches of ICF
Design July 2002.
In reference to above, it is to inform that all schedules of H -Type couplers with BDG
fitted in ICF coaches shall be carried out as described below:

Recommendations for H -Type coupler in ICF

SN ICF
coaches
1 Primary /  Visual inspection of coupler head for damage.
Secondary  Visual inspection of coupler operating mechanism &
Maintenance tertiary locking pin arrangement in proper position and
any loose bolts etc.
 Greasing of glide/operating rod of coupler operating
mechanism (once in 3 months)
 Checking of tell-tale recess clear for ensuring proper
coupling.
 Inspection of coupler supporting device and its springs
for cracks / breakage etc.
 Inspection of loose/broken/missing nuts and bolts etc.
2 1 month ± 3 Days  All items of SN 1.
(Schedule A) On  Apply grease on wear plate of coupler / supporting
rake at nominated device.
primary depot
3 3 months ±7 Days  All items as mentioned at SN 2.
(Schedule B) On
rake at nominated
primary depot
4 6 months ± 15  All items as mentioned at SN 2.
Days (Schedule C)  Coat bare steel areas of coupler head body and knuckle
Sick line at with Molykote D321R (or equivalent) dry spray.
nominated Primary (CAUTION: Do not spray on the knuckle locking surface
depot and internal parts like lock etc).
 Check wear on slide rods of manual uncoupling device.
Take corrective action, if wear is excessive.
5 IOH (9 Months) In  All items as mentioned at SN 4.
workshop
6 1st POH Inspection of coupler assembly by gauges:
(18 Months) In a) Checking of knuckle contour by contour maintenance
workshop gauge.
b) Checking of contour by contour condemning limit
gauge.
c) Checking of distortion of aligning wing pocket and guard
arm by aligning wing limit gauge and guard arm
distortion gauge.
d) Checking of vertical height of aligning wing pocket and
guard arm by vertical height aligning wing pocket and
guard arm gauge.
e) Wear of aligning wing pocket and guard arm to be
checked by vertical height condemning limit aligning
wing pocket and guard arm gauge.
f) Checking of knuckle nose wear and stretch limit by
knuckle nose wear and stretch limit gauge.
 Visual inspection of tilting of coupler assembly, take
corrective action and adjust height of Supporting device
which should be kept at 187± 2 mm.
 Checking of double rotary lock lift assembly gap (37
mm), if found excess, take corrective action.
 Visual inspection of gap between front fork and front
carrier plate.
 Visual inspection of rusting on front carrier plate. Take
corrective action, if rust is observed.
 Inspection of anti-creep protection.
 Measurement of coupler height 1105 mm from rail level-
Reference point – Vertical centre of knuckle or centre of
shank.
 Cleaning of coupler head and its sub-assemblies for
any rust and dust for its smooth functioning.
 Checking of functional operation of coupler.
 Checking of coupler operating mechanism.
 MPI of Knuckle & coupler head (as per RDSO letter No.
MC/BLB/CBC dt. 03.06.2021 & 18.08.2021).
nd
7 2 POH  All item of 1st POH as mentioned at SN-6.
(36 months) In  Inspection of spherolastic bearing (silent block) to be
workshop done for any damage, if required, to be replaced.
th
8 4 POH  All item of 1st POH as mentioned at SN-6.
(72 months) In  All parts of CBC and allied accessories to be dismantled
workshop and overhauled as per OEM’s manual.
 Visual inspection & MPI/NDT to be carried out for
cracks, damages, distortions etc.
 Checking of wear of coupler shank wear plate.
 Checking for wear of lock, knuckle, knuckle pivot pin
and knuckle support pin.
 Condition of draft gear rubber pads, crack and
looseness and all allied components of BDG, replace as
per latest OEM recommendation.
This is for your kind information and necessary action please.