monthly with daily basis

bogie items
water drainage holes in control arm
cleaning of bearing grease drain hole
lift stop J braket(tightness)
brake calliper, nut-bolts, pads, brake shoe,lever, locking arrangement, flexible pipes

Air spring
installation lever,its tightness, oiling
50 lit air tank(leakage/tightness)
75 lit air tank(leakage/tightness)
its pipe line
air bellow leakage test with soap solution

brake items
brake panel ,protction cover, additional protection cover/tightness
200 lit air tank, its braket, nut-bolt/tightness
75 lit AR tank/tightness
its pipe line & its brakets/tightness
angle cock, palm end,hose pipe, its brakets/leakage /tightness
leakage test with soap solution
gap between disc& brake pad,

water tank
its braket & nut-bolt/tightness

bio tank
its safty brakets & nut-bolts/tightness

cattle guard
brakets,nut-bolts

nose cone
brakets , nut-bolts

Foot board
nut-bolts/tightness

Wheel & axle

wheel dia
wheel profile
axle/crack/damage
brake disc/crack/damage/heat crack/limit

cleaning
brake disc
coil spring
trolley & Its parts
air bellow
brake panel protection cover
gangway

torque req.
yaw damper/leakage/tightness
primery damper/leakage/tightness
secondry damper/leakage/tightness
lateral damper/leakage/tightness

control arm outer & inner stud(tightness)

control arm closing plate & its stud(tightness)
control rubber bush

axle box frant cover stud

axle box rear cover stud

centre pivot & its nut-bolts

centre pivot closing plate, its studs
traction rod(tightness/rubber bush)

lateral bump stop(tightness),diamension,its gap & its stud

stabiliser assemblly(tightness),nut-bolts , its link(measurment590-640/tightness/rubber bush),grease nipple

Bellow upper bolt(tightness)

bellow lower bolt(tightness)

semi permanet coupler/ its socket & nut-bolt/supporting plate , its nut-bolt

check list for knorr representative

Air spring
levling valve & its function(tightness)
duplex check valve & its function(tightness)
air bellow isolation cock
air spring height (300-305mm)

brake items
brake panel dusting
auto drain valve & its fuctional test
fuctional test of all isolation cock(MR,B01,B02,trolley isolation cock)
fuctional test of magnetic valves
parking push button test(B01) & manual release by its lever
harting connector/tightness
BC vent hole
speed sensor fittings,gap,connecting joints
antiskid valve fittings, function, its connection
antiskid valve test by IST tool/weekly
all brake skid sensor connection

plug door
functional test
defect attention

EBCU
tcms defect code attention
 items SIZE
Traction Rod – Traction Center side M22x110
Traction Rod – Bogie Frame side M22x140
Center pivot closing plate side M16x80
( apply torque in 3 steps 116/174/232)

Center pivot carbody side M24x120

Lateral Bump stop (Side Bumper) M16
Lateral Damper – Traction center side M12x55
Lateral Damper frame side M12x50
Control arm Upper - Lower M16x120
Control arm closing plate M16x80
(Apply Torque in 3 STEPS 124/186/248)

Lift Stop M16x80

Primary Damper bottom M16
Primary damper top M12x50
Bump stop M12
Air spring top side M16x70
Air Spring Bottom side M12X100
Stabilizer Link assembly – Bogie frame M20x65
Stabilizer Link top M14x60
Stabilizer Link bottom M14x80
Stabilizer link assembly cover M8x20
Secondary Vertical damper top M12x55
Secondary Vertical damper bottom M12x55
Yaw damper bogie frame side M16x60
Yaw damper Coach side M16x130
Steps M16x120
Axle Bearing end pad without Phonic wheel M20x65
Axle Bearing end pad with Phonic wheel M20x80
Axle Bearing Rear cover M16x45
Axle Bearing End cover M16x50
semi permanent coupler m16
cbc m16
brake calliper m20

WITHOUT torque

bio tank brackets m16

water tank brackets m16
50 lit dom tank with lb panel m16
75 lit AR tank m16
 200lit MAIN reservior m16
brake disc m12
EBCU brackets m16
cab foot board m12
25 lit air tank m12
nose cone m12
installation lever m10
ferrule joint in pnumatic pipe
bc flexible pipe m20
flexible pipe in console
angle cock
horn m12
cattle guard m16

REMARKS
TORQUE WRENCH AVAILABILITY
RANGE 1 12-70 Nm
RANGE 2 80-400 Nm
RANGE 3 250-850 Nm
PRE-ASSEMBLY INSTRUCTIONS Lubricate the threaded portion of
 SCHEDULES

Nord Lock
Plain Washer + FS no. of bolt per
BOLT GRADE Washer + DAILY WEEKLY Monthly
Lock Nut (Nm) rake
Nut(Nm)
10.9 717 744 64 V V T
10.9 717 744 64 V V T
10.9 232 32 V V T
V V T
10.9 900 128 V V T
8 188 190 32 V V T
8.8 79 77 64 V V T
8.8 79 77 64 V V T
10.9 273 279 128 V V T
10.9 248 256 V V T
V V T
8.8 188 190 128 V V T
100 (NUT) 64 V V T
8.8 79 77 128 V V T
8 40 40 64 V V T
8.8 170 168 128 V V T
8.8 64 60 128 V V T
10.9 530 546 128 V V T
10.9 181 180 64 V V T
10.9 181 180 64 V V T
8.8 23 128 V V T
8.8 79 77 64 V V T
8.8 79 77 64 V V T
8.8 188 190 64 V V T
8.8 188 190 64 V V T
10.9 97 102 128 V V T
10.9 157 (WITHOUT WASHER) 96
10.9 157 (WITHOUT WASHER) 96
10.9 320 V V T
10.9 320 V V T
252 V V T
20 V V T
508 256 V V T

j bracket-84 Safety V V T
bracket-168
128 V V T
192 V V T
96 V V T
 12 V V T
768 V V T
32 V V T
8 V V T
32 V V T
28 V V T
224 V V T
….. V V T
48 V V T
12 V V T
32 V V T
16 V V T
16 V V T

250-850 Nm
Lubricate the threaded portion of all hardware with Molykote-1000 Anti Seize paste
SCHEDULES

nine
quaterly
monthly
T T
T T
T T
T T
T T
T T
T T V - Visual Inspection
T T T- Tightness check
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
V
V
T T
T T
T T
T T
T T

T T

T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
bio tank j6 s12
water tank 32
50 lit 12
75 lit 12
200lit 6
wheel disc 24 m12
caliper 4
stabilizer ass 8 allen 6
ebcu 4
foot board 4
cab foot board 2
20 lit
nose cone 14
cbc 10
semi permanet 36
installation lever 7
ferrule joint 108
bc flexible pipe 6
dtc 6
angle cock
horn 16
monthly with daily basis
bogie items
water drainage holes in control arm
cleaning of bearing grease drain hole
lift stop J braket(tightness)
brake calliper, nut-bolts, pads, brake shoe,lever, locking arrangement, flexible pipes

Air spring
installation lever,its tightness, oiling
50 lit air tank(leakage/tightness)
75 lit air tank(leakage/tightness)
its pipe line
air bellow leakage test with soap solution

brake items
brake panel ,protction cover, additional protection cover/tightness
200 lit air tank, its braket, nut-bolt/tightness
75 lit AR tank/tightness
its pipe line & its brakets/tightness
angle cock, palm end,hose pipe, its brakets/leakage /tightness
leakage test with soap solution
gap between disc& brake pad,

water tank
its braket & nut-bolt/tightness

bio tank
its safty brakets & nut-bolts/tightness

cattle guard
brakets,nut-bolts

nose cone
brakets , nut-bolts

Foot board
nut-bolts/tightness

Wheel & axle

wheel dia
wheel profile
axle/crack/damage
brake disc/crack/damage/heat crack/limit

cleaning
brake disc
coil spring
trolley & Its parts
air bellow
brake panel protection cover
gangway

torque req.
yaw damper/leakage/tightness
primery damper/leakage/tightness
secondry damper/leakage/tightness
lateral damper/leakage/tightness

control arm outer & inner stud(tightness)

control arm closing plate & its stud(tightness)
control rubber bush

axle box frant cover stud

axle box rear cover stud

centre pivot & its nut-bolts

centre pivot closing plate, its studs
traction rod(tightness/rubber bush)

lateral bump stop(tightness),diamension,its gap & its stud

stabiliser assemblly(tightness),nut-bolts , its link(measurment590-640/tightness/rubber bush),grease nipple

Bellow upper bolt(tightness)

bellow lower bolt(tightness)

semi permanet coupler/ its socket & nut-bolt/supporting plate , its nut-bolt

check list for knorr representative

Air spring
levling valve & its function(tightness)
duplex check valve & its function(tightness)
air bellow isolation cock
air spring height (300-305mm)

brake items
brake panel dusting
auto drain valve & its fuctional test
fuctional test of all isolation cock(MR,B01,B02,trolley isolation cock)
fuctional test of magnetic valves
parking push button test(B01) & manual release by its lever
harting connector/tightness
BC vent hole
speed sensor fittings,gap,connecting joints
antiskid valve fittings, function, its connection
antiskid valve test by IST tool/weekly
all brake skid sensor connection

plug door
functional test
defect attention

EBCU
tcms defect code attention
 items SIZE
Pantograph - M22x110
VCB- M22x140
25 Transmission line at roof M16x80
driver desk
Traction transformer M24x120
Brake Chopper M16
Line and traction converter with DC earthing link M12x55
switch
Traction motor M12x50
Baby Compressor M16x120
Main air compressor M16x80
Cab Rear wall Panel
IVC socket other than AC and lightning M16x80
TCAS M16
Tail Lamp M12x50
Flasher Lamp M12
Head Coad Display M16x70
Head Lamp M12X100
Marker Light Red M20x65
Marker Light White
ERCU M14x80
Wiper system M8x20
ECC panel M12x55
Gear drive M12x55
M16x60
M16x130
M16x120
M20x65
M20x80
M16x45
M16x50
m16
m16
m20

WITHOUT torque

Main air compressor-Check mounting tightness.

Main air compressor-Check the Earthing Cable tightness
Auxiliary Compressor-Check earthing cable tightness
Check all fasteners for under-slung equipment for tightness, check for any loose hanging parts.
Check for coupler mounting properly and presence of
corrosion.

Check Jumper cables are not hanging with one end

free, secure them if necessary.

Check power couplers for the intactness.

REMARKS
TORQUE WRENCH AVAILABILITY
RANGE 1 12-70 Nm
RANGE 2 80-400 Nm
RANGE 3 250-850 Nm
PRE-ASSEMBLY INSTRUCTIONS Lubricate the threaded portion of
 SCHEDULES

Nord Lock
Plain Washer + FS no. of bolt per
BOLT GRADE Washer + DAILY WEEKLY Monthly
Lock Nut (Nm) rake
Nut(Nm)
10.9 717 744 64 V V T
10.9 717 744 64 V V T
10.9 232 32 V V T
V V T
10.9 900 128 V V T
8 188 190 32 V V T
8.8 79 77
64 V V T
8.8 79 77 64 V V T
10.9 273 279 128 V V T
10.9 248 256 V V T
V V T
8.8 188 190 128 V V T
100 (NUT) 64 V V T
8.8 79 77 128 V V T
8 40 40 64 V V T
8.8 170 168 128 V V T
8.8 64 60 128 V V T
10.9 530 546 128 V V T
10.9 181 180 64 V V T
10.9 181 180 64 V V T
8.8 23 128 V V T
8.8 79 77 64 V V T
8.8 79 77 64 V V T
8.8 188 190 64 V V T
8.8 188 190 64 V V T
10.9 97 102 128 V V T
10.9 157 (WITHOUT WASHER) 96
10.9 157 (WITHOUT WASHER) 96
10.9 320 V V T
10.9 320 V V T
252 V V T
20 V V T
508 256 V V T

V V T

V V T
V T T
ose hanging parts. V V T

V V T

V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T

250-850 Nm
Lubricate the threaded portion of all hardware with Molykote-1000 Anti Seize paste
SCHEDULES

nine
quaterly
monthly
T T
T T
T T
T T
T T
T T

V - Visual Inspection
T T T- Tightness check
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
V
V
T T
T T
T T
T T
T T

T T

T T
T T
T T

T T

T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
 items SIZE
Isolation Transformer
RMPU
RMPU Control Panel
mono block pump
pump controller
coach lightning
PAC Lamp side lamp outside
cell phone sockets in coaches
sub pantry equipments
cab AC
Aux Converter
IVC Sockets for AC & Lightning
Battery management system and battery charging
system BMS & BCS
Battery set
Lavatory Electrical equipments like shaver socket, hand
dryer etc
power coupler and their receptacles

WITHOUT torque
 REMARKS
TORQUE WRENCH AVAILABILITY
RANGE 1 12-70 Nm
RANGE 2 80-400 Nm
RANGE 3 250-850 Nm
PRE-ASSEMBLY INSTRUCTIONS Lubricate the threaded portion of
 SCHEDULES

Nord Lock
Plain Washer + FS no. of bolt per
BOLT GRADE Washer + DAILY WEEKLY Monthly
Lock Nut (Nm) rake
Nut(Nm)
10.9 717 744 64 V V T
10.9 717 744 64 V V T
10.9 232 32 V V T
V V T
10.9 900 128 V V T
8 188 190 32 V V T
8.8 79 77 64 V V T
8.8 79 77 64 V V T
10.9 273 279 128 V V T
10.9 248 256 V V T
V V T
8.8 188 190 128 V V T
100 (NUT)
64 V V T
8.8 79 77 128 V V T
8 40 40
64 V V T
8.8 170 168 128 V V T
8.8 64 60 128 V V T
10.9 530 546 128 V V T
10.9 181 180 64 V V T
10.9 181 180 64 V V T
8.8 23 128 V V T
8.8 79 77 64 V V T
8.8 79 77 64 V V T
8.8 188 190 64 V V T
8.8 188 190 64 V V T
10.9 97 102 128 V V T
10.9 157 (WITHOUT WASHER) 96
10.9 157 (WITHOUT WASHER) 96
10.9 320 V V T
10.9 320 V V T
252 V V T
20 V V T
508 256 V V T

V V T

V V T
 V T T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T
V V T

250-850 Nm
Lubricate the threaded portion of all hardware with Molykote-1000 Anti Seize paste
SCHEDULES

nine
quaterly
monthly
T T
T T
T T
T T
T T
T T
T T V - Visual Inspection
T T T- Tightness check
T T
T T
T T
T T

T T
T T

T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
V
V
T T
T T
T T
T T
T T

T T

T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T
T T