Maintenace manual for wagons

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It is the maintenance manual for Wagons issued by Railway Board of Indian Railways

Transcript of Maintenace manual for wagons

  • 1. FOREWORD1. The Maintenance manual for Wagons was last compiled and issued by Ministry ofRailways in 1979.2. During the last two decades, considerable work has been done in upgrading thewagons to meet the traffic demand for higher productivity. Thus, it has becomenecessary to update the Wagon Maintenance Manual incorporating thetechnological upgradations/innovations brought out in the wagon design,maintenance strategy and operation over Indian Railways.3. The manual deals with maintenance of all systems of the wagons likesuperstructure, running gear, braking system, etc. Thus, it can act as the singlebare reference document for maintenance of wagons in workshops and open linedepots. In this manual, the attempt is not to cover the entire range of individualworking conditions, which may exist on the various zonal railways. The zonalrailways may, if considered necessary, supplement these instructions withsubsidiary procedures based on local practices with the approval of CME.4. Technological upgradation is a continuing process. Those that have beenimplemented have been covered in this manual. With IRs thrust in increasedproductivity and market orientation, emphasis on factors such as increasedthroughput in terms of higher axle load and speeds, product specific designs,enhanced reliability and availability etc. will gather momentum ushering in newerdesigns and technological upgradation of wagons more than ever before.Therefore, separate maintenance instructions will also be issued as and when thenewer designs are inducted in to the system.5. This manual has been written with the purpose of knowledge dissemination andguidance of staff dealing with repairs and maintenance of wagons. Hence full useof the same must be made to derive the intended benefits fully. However, itshould be clearly understood that practices and service wear limits mentioned inthe manual are more restrictive than wear limits based on Safety criteria, anyminor deviation from the former, though not recommended, need not beconsidered unsafe for running of wagons on line.6. Apart from detailed maintenance instructions for the different types of wagonsnow on IR, this manual also lists out various rules and provisions given in IRCAPart III as a supplement for reference purposes. It is, therefore, not the intention toreplace IRCA rules Pt. III. Statutory provisions and instructions contained in thegeneral rules and various codes are to be followed and remain unaffected by theissue of this manual.K. B. SankaranMember Mechanical, Railway BoardNew Delhi, dated March 9, 2001

2. INDIAN RAILWAYS(MECHANICAL DEPARTMENT)The previous Maintenance Manual for Wagons was published in 1979. Since only vacuumbrake system was existing on Indian Railways at that time, this manual did not contain any detailsof Air Brake System. The induction of Air Brake stock on Indian Railways transformed thecomplete scenario of operating and maintenance disciplines in Railways.Railway Board nominated a committee of officers comprising of ExecutiveDirector/CAMTECH/GWL, ED(Wagon)/RDSO/LKO, CRSE/W.Rly/Mumbai and DME(Freight)/ Railway Board vide letter No. 70/M(N)/7/16(H.T.)-Pt.I dated 4.9.98 for updation and revision ofIndian Railways Unified Maintenance Manual for Wagons. The revision and updation ofmanual has been completed taking into account latest fleet of freight stock currently running onIndian Railways.The present manual bridges this gap and covers detailed treatise of Air Brake Systemincluding its maintenance. The other salient features of the manual are as follows:! The manual has been divided into logical chapters covering various sub-assembliesand systems. The constructional details and functioning has been explained beforedescribing the detailed maintenance procedures.! The important dimensions, clearances, material specifications, drawing references etc.have been given immediately after the paragraphs where they have been referred towhile describing maintenance procedures.! Clear sketches and isometric views of the important sub-assemblies/components havebeen given in the manual.! A separate chapter titled YARD MAINTENANCE has been added covering themaintenance work to be done in yards.! A separate chapter titled SPECIAL TYPE OF WAGONS is included in the manual.For convenience of indexing of reference, the paragraphs have been numbered according to a3 /4 figure Code, in which the last two figures give the number of the paragraphs and theremaining figures the number of the chapter. Thus paragraph 101 of any code is paragraph 1 ofchapter 1 of that code and paragraph 1103, paragraph 3 of chapter 11.The page number in each chapter in this manual starts from 1. The reader can easily identifythe chapter number to which a page belongs by reading the footer of the page at the bottom wherechapter number as well as chapter title is given. This scheme of page numbering is adopted toprovide flexibility of easily revising the chapters in future, on account of design or procedurechanges or induction of new stock without disturbing the page numbers of succeeding chapters.The tables in each chapter consist of two numbers separated by a decimal point. The numberbefore decimal point indicates the chapter number whereas the number after the decimal pointindicates the running serial number of the table which start from 1 in every chapter. Theconvention adopted for numbering the figures is also identical to the numbering scheme adoptedfor the tables.The items of maintenance required to be carried out in sickline, ROH & POH have beenlisted out separately towards the end of various chapters under appropriate headings for eachsystem/subassembly covered in the manual for easy reference and guidance of maintenance units.Future addition/ deletion/ modification to this manual will be processed by RDSO and will berequire approval of the Railway Board. 3. The Committee is thankful to shri V.K. Manglik, EDME(Fr.), Railway Board, shriB.B.Modgil, DRM/BRC, shri D.K. Saraf, ADRM/Jabalpur, shri O.P.Chaube, Exec.Director,RDSO, shri Sanjay Kumar, Director, RDSO and shri S.S.Gavane, Dy.CME, N.Rly for theirvaluable contribution in finalisation of this manual. Members of the committee also express theirappreciation for the valuable assistance provided by shri A.K.Arora, AEME(Fr.), Railway Boardand shri K.K.Giri, Sr.CTA/CAMTECH.M.L.Gupta N.P.Singh K.K.Gupta Arun AroraExe. Director Sr.Exe.Director Std.(W) CRSE Dir.Mech. Engg.(Freight)CAMTECH RDSO W.Rly. Rly. Bd 4. CONTENTSFOREWORD iiJOINT NOTE iiiCONTENTS vLIST OF FIGURES xiLIST OF TABLES xivCORRECTION SLIPS ISSUED xvCHAPTER 1INTRODUCTION Page 1-12101. General 1102. Important Dimensions of Wagon 2103. Important Rule Books and References 10104. Existing Wagon Fleet 11105. Standard Infrastructure for Wagon Depot 12106. Important Wagon Modifications 12107. Page Numbering Convention in the Manual 12108. Numbering of Figures and Tables in the Manual 12CHAPTER 2WARRANTY MAINTENANCE AND CONDEMNATION Page 1-23201 Warranty Inspection of newly built wagons 1202. Examination and Maintenance Periodicity 6203. Interchanges Examination 8204. ROH of Wagon with UIC Bogie 8205. ROH of Wagon with CASNUB Bogie 9206. ROH of CRT Wagons 10207. NPOH of Goods Stock 11208. Condemnation of Wagons 12209. ROH and POH Interval 13210. Work Areas where attention is to be given 14211. Table 2.4 15-23CHAPTER 3YARD MAINTENANCE Page 1-28301 Pattern of Freight Train Examination 1302. Notification of Examination Points 1303. Frequency of Intensive Examination for different Stock 1304. Steps of Intensive Examination 3305. Details of Intensive Examination 3306. Air Brake Testing 8307. Important Parameters to be Ensured During Intensive Examination 9308. Important Parameters to be Ensured During Sick Line/ Depot Attention 10 5. 309. Common Problems in Brake System and Remedy 13310. Infrastructure & Facilities required in the yard 14311. Machinery & Plant items 15312. Tools 15313. Man Hours for various type of examinations 16314. Joint Procedure order for Goods Trains Examination 16315.CHAPTER 4WAGON BODY Page 1-15401. Introduction 1402. General Construction of Open Wagon 1403. General Construction of Covered Wagon 2404. General Construction of Flat Wagon & Well Wagon 2405. General Construction of Hopper Wagon 2406. Nature of Repairs required in Wagon body 3407. Corrosion in Wagon Body 3408. Anticorrosive Measures 4409. Rejectable Defects 4410. Repairs in Sickline and ROH Depot 4411. Repair and Maintenance in Workshops during POH and NPOH 14412. Important Precautions to be taken while taking out welding 14413. Important Dos and Donts 15414. Important Modifications 15CHAPTER 5UNDERFRAME Page 1-31501. General 1502. General Construction of BG Wagon Underframe 1503. BG Four wheeler Underframe 4504. Repair Procedure 4505. Cleaning and De-rusting of the Underframe 6506. Repairs to Head Stock 6507. Repairs to Diagonals and Cross Bars 6508. Repairs to Sole Bars 7509. Repairs to Floor Plate 8510. Underframe of Brake Van 8511. Bogie Wagon Underframe 8512. MG Fourwheeler Wagon Underframe 10513. MG Bogie Underframe 11514. List of Modifications 13515. Repair and Maintenance in Sickline and ROH Depot 30516. Repair and Maintenance in Workshop during POH/NPOH 31 6. CHAPTER 6BOGIES AND SUSPENSIONS Page 1-121601. CASNUB BogieA) General Description 1B) Constructional Details 2C) Repair and Maintenance in Sickline 11D) Repair and Maintenance during ROH and POH 12E) Nominal Clearances 13F) Reference Drawing Nos. for Components 16602. Fabricated BOX Bogie (UIC Bogie)A) General Description 17B) Constructional Details 17C) Maintenance of Sub Assemblies 28D) Repair and Maintenance in Sickline 32E) Repair and Maintenance during ROH and POH 33F) Material Specification of BOX (UIC Bogie) 34603. Cast Steel BogieA) General Description 35B) Constructional Details 35C) Maintenance of Sub-assemblies 40D) Repair and Maintenance in Sickline 43E) Repair and Maintenance during ROH/POH