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 44F) Material Specification for Bogie Items 44604. Diamond Frame BogieA) Constructional Details 45B) Repair and Maintenance in Sickline 48C) Repair and Maintenance during ROH and POH 48D) Material Specifications (Diamond Frame Bogie) 49605. SuspensionA) General 49B) Four Wheeler Suspension 50C) Procedure for repair & testing in Workshop 57D) Causes for Failures of Springs 59E) Causes of Failures to Buckles 60F) Important Dos and Donts during Repair of Springs 61G) Axle Box Crown Packing Plate (Spring Sheet) 61H) Axle Guard Horn Cheek Assembly 62I) Clearances and Repairs of Axle Guard Assembly 65J) Roller Bearing Axle Boxes 71K) Important Dos and Donts during POH 73L) Repair and Maintenance in Sickline 74 7. M) Repair and Maintenance during ROH and POH 75N) Axle Box Assembly with Plain Bearing 75O) Periodicity of Repacking and Oiling 92P) Procedure for Repacking and Axle Boxes 93Q) Axle Box Sealing 95R) Important Dos and Donts during Repacking 95S) White Metalling Procedure 96T) Maintenance Instructions for FRLP 99606. Wheel AssemblyA) Axle 109B) Wheel 109C) Diameters of wheels used on BG and MG with 110Condemning limitsD) Wheel Centre 111E) Tyre Profile 111F) Re-axling 114G) Retyring 115H) Tyre Turning 115I) Paring of Wheels 116J) Wheel Defects 117K) Repair and Maintenance in Sickline 118L) Repair and Maintenance during ROH and POH 118607 Important dimensions related to Suspension 119CHAPTER 7VACUUM BRAKE SYSTEM Page 1-20701. General 1702. Constructional Details 1703. F Type cylinder 2704. Principle of Operation 6705. Limitation of Vacuum Brake 7706 Modifications 9707. Maintenance and Repair 11708. Repair and Maintenance in Sickline 15709. Repair and Maintenance during ROH 16710. Repair and Maintenance during POH 17711. Storage of Rubber Fitting 18712. Special Tools, Jigs and Fixtures 19713. Brake power calculations BOX wagon 19CHAPTER 8AIR BRAKE SYSTEM Page 1-109801. Classification of Air Brake System 1802. Principle of Operation of Single Pipe Graduated Release Air 1Brake System 8. 803. Common Pipe Bracket 4804. Intermediate Piece (Sandwich piece) 5805. Brake Pipe Hose 5806. Brake Pipe Coupling 5807. Cut Off Angle Cock 8808. Brake Cylinder 12809. Dirt Collector 17810. Auxiliary Reservoir 21811. Guards Emergency Brake Valve 22812. Slack Adjuster 25813. Distributor Valve 39814. C3W Distributor Valve 39815. Testing of Distributor Valve 54816. Testing of C3W Distributor Valve 58817. KE Distributor Valve 64818. Testing of KE Distributor Valve 73819. Test Report Proforma for C3W/KE Distributor Valve 81820. Single Wagon Test 84821. Rake Test 88822. Repair and Maintenance in Sickline 90823. Repair and Maintenance in ROH 92824. Periodical Overhaul of Air Brake System 95825. Details of Tools, Fixtures and Equipment 98826. Brake power calculations for BOXN wagon 101827. Brake Rigging 102828. Composition brake block 108CHAPTER 9DRAW AND BUFFING GEAR Page 1-46901. General 1902. Conventional Buffing Gear 1903. Buffing Gear Repairs 2904. Buffer Projection 2905. Buffer Height 3906. BG Draw Gear 3907. Procedure for Reclamation of BG Draw Bars in Workshops 4908. Procedure for Reclamation of BG Screw Coupling in Workshops 6909. Maintenance of Draw Gears during repacking and normal repairs in Sickline 7910. Repair and Rejection Rules 7911. Centre Buffer Couple and Draft Gear 8912. Parts of Centre Buffer Coupler Assembly 8913. Inspection of CBC 10914. Inspection of Draft Gear(HR-40-I& MF-400-IR) 11915. Removal of Couple and Draft Gear from Wagons 11916. Coupler Reclamation Practices 12917. Draft Gear Reclamation Practices for Cardwell Westinghouse 16(HR-40-1 Draft Gear) 9. 918. Reclamation Practices for National Rubber Type (MF 400-I-IR Draft Gear) 17919. Development of High Tensile Coupler 19920. RF-361 Draft Gear 20921. Maintenance of Mark-50 Draft Gear 29922. MG Buffing and Draw Gear 34923. Repair and Maintenance in Sickline and ROH Depot 38924. Repair and Maintenance in Workshop During POH 39CHAPTER 10TANK WAGON Page 1-271001. Constructional Details 11002. Periodicity of Overhauling of Tank Wagon 61003. Steam Cleaning of Bitumen and Molasses Wagons 81004. Cleaning of Tank for Corrosive Liquids 81005. Inspection of Tank Barrels 91006. Testing of Barrel 91007. Barrel Test Pressure 101008. Testing of Tanks Used for Corrosive Liquids 101009. Test of Tank Wagons used for Petrol and Middle Distillates of 11Petroleum and Vegetable Oils1010. Repairs of Tank Barrels byWelding 111011. Repairs of Tank Barrel Mounting Fittings 141012. Fittings of Tanks for Corrosive Liquids 151013. Fittings of Tank Wagons of Petrol, other inflammable products vegetable oils, etc. 151014. Heating Arrangement on TOH Tank Wagons 161015. Test Reports and Records of Inspection 161016. Important Modifications 161017. Painting and Lettering 161018. Examination and Repair of Tank Wagons 171019. Precaution with leaky Tank Wagons 181020. Precautions to be taken at Loading and Unloading Points 20(Tanks as Pressure Vessels)1021. Loading and Unloading Corrosive Liquids 211022. Loading and Unloading Tank Wagons 221023. Precautions for Tanks for Petroleum and other inflammable products 231024. Precaution for Bitumen Tanks 241025. Maintenance and Repair in Sickline 251026. Maintenance and Repair in Workshop during POH 26CHAPTER 11 SPECIAL TYPE OF WAGONS Page 1-91101 BOXNHA Wagonsa) Salient Features 1b) Wagon Superstructure 1c) Nature of Repairs in BOXNHA 3d) Maintenance and Repair Procedure 3 10. 1102. BOXNCR Wagonsa) Salient Features 5b) Maintenance and Repairs 5c) Precautions for Welding Stainless Steel 6d) Surface Preparation and Painting 61103. BOGIE LOW PLATFORM CONTAINER FLATS (BLC) 7LIST OF APPENDICESAPPENDIX-I EXISTING STRENGTH OF WAGON FLEET 1 to 4APPENDIX-II STANDARDISATION OF INFRASTRUCTURAL 1 to 7FACILITIES IN AIR BRAKE ROH DEPOTSAPPENDIX-III LIST OF IMPORTANT MODIFICATIONS TO BE 1 to 3CARRIED OUT ON FREIGHT STOCKAPPENDIX-IV REPAIR OF TANK WAGON PRESSURE VESSELS 1 to 3APPENDIX-V WAGON MANUFACTURERS AND WORKSHOPS 1 to 3APPENDIX-VI BRANDING DETAILS ON WHEEL AND AXLE 11. LIST OF FIGURESSr. Figure Description Page No.No. No.CHAPTER 11. 1.1 BOXC Wagons 32. 1.2 BCXT Wagons 43. 1.3 BOXN Wagons 64. 1.4 BCN Wagons 75. 1.5 BRN Wagons 86. 1.6 CRT Wagons 10CHAPTER 47. 4.1 to 4.4 Panel Patching 511. 4.5 to 4.9 Panel Patching 915. 4.10 to 4.13 Panel Patching 10CHAPTER 519. 5.1 Dimension Checks on Underframe 1320. 5.2 Typical Four wheeler Underframe 1421. 5.3 Modifications to Head Stock Diagonal and 14Knee Joint for Bogie Open Wagons type BOX MK22. 5.4 Cast Steel Bracket for Goods Brake Van BVGT 1523. 5.5 Cast Steel Knee for Four Wheeled BG Wagons BVGT 1624. 5.6 Cast Steel Knee for Four Wheeler wagons 1725. 5.7 Positioning of Scroll Iron, Horn Cheeks and Buffer 1826. 5.8 Positioning of Scroll Iron, Horn Cheek and Buffer etc. 1927. 5.9 Patching of Sole Bar 2028. 5.10 Head Stock Straightening Device 2029. 5.11 BG Wagon Type BCNA 2130. 5.12 Underframe for Bogie Open Wagon(type BOX) 2231. 5.13 Underframe of Bogie Open Wagon (BOXN) 2332. 5.14 IRS Covered Wagon Underframe (MG Four Wheeler) 2433. 5.15 Underframe Bogie Wagon (Type MPTPX) 2534. 5.16 IRS Eight wheeler Underframe MBTPZ Tank Wagons 2635. 5.17 Details of Stiffening of Underframe in existing MBTPXWagons 2736. 5.18 Arrangement of Stiffening of Underframe in existing 28MBTPX Wagons.37. 5.19.1 Crack in Longitudinal Channel Web at welded joint of 29Bottom Gusset Plate38. 5.19.2 Reinforcement Plate 2939. 5.19.3 Patching of Longitudinal 30CHAPTER 640. 6.1 Bogie General Arrangement CASNUB 22W Bogie 241. 6.2 Isometric View of BOX type Wagon Bogie Frame (BG) 1842. 6.3 Diamond Frame Bogie 45 12. 43. 6.4 Suspension Arrangement of Four Wheeler Wagons 5044. 6.5 Scroll Iron and Shackle Plate 5245. 6.6 Squareness of Axle Guard 6746. 6.7A Roller Bearing Axle Box 7247. 6.7B Cartridge Tapered Roller Bearing 7348. 6.8 Axle Box Assembly 255 x 127 BG 7649. 6.9 Dimensions of Roll Packing 9050 6.10 Identification marks for wagons 10351. 6.11 Marking of face plate 10452. 6.12 Fitment of FRLP 10553 6.13 FRLP 10654. 6.14 Tools 10755. 6.15 Tools 10856. 6.16 Wheel Profile 11057. 6.17 Worn wheel profile 11258. 6.18 Intermediate profile 113CHAPTER 759. 7.1 Vacuum Brake Cylinder (F Type) 760. 7.2 Schematic Arrangement of Vacuum Brake Equipment 761. 7.3 Design of Cage 1062. 7.4 Brake power calculation of BOX wagon 19CHAPTER 863. 8.1 Graduated Release Single Pipe Air Brake System 264. 8.2 Charging Stage 365. 8.3 Application Stage 366. 8.4 Release Stage 467. 8.5 Brake Pipe Hoses 568. 8.6 Testing of Hose Coupling 769. 8.7 Cut Off Angle Cock 870. 8.8 Brake Cylinder 1271. 8.9 Test Bench For Brake Cylinder 1572. 8.10 Test Bench for Brake Angle Cock and Dirt Collector 2073. 8.11 Slack Adjuster (Figure 1-13) 29, 31 & 3374. 8.12 Test Rack 3675. 8.13 C3W Distributor Valve 4176. 8.14 Main Valve 4277. 8.15 Sectional View of Main Valve 4378. 8.16 Cut off Valve 4479. 8.17 Auxiliary Reservoir Check Valve 4580. 8.18 Quick Service Valve 4681. 8.19 Sectional view of Quick Service Valve 4782. 8.20 Limiting Device 4883. 8.21 Double Release Valve 4984. 8.22 Testing of C3W Distributor Valve 58 13. 85. 8.23 KE Distributor Valve 6486. 8.24 Three Pressure Valve 6587. 8.25 U Controller 6688. 8.26 R Charger 6689. 8.27 Choke Cover 6790. 8.28 Minimum Pressure Limiter 6791. 8.29 Maximum Pressure Limiter 6892. 8.30 A Controller 6993. 8.31 Quick Release Valve 7094. 8.32 Test Bench for KE Distributor Valve 7595. 8.33 Single Wagon Test Rig 8796. 8.34 Rake Test Rig 8997. 8.35 Brake power calculation of BOXN wagon 10198. 8.36 Hand brake arrangement 10299. 8.37 Empty load device 103100. 8.38 Empty load device 103101. 8.39 Sliding brake beam 104102. 8.40 Hanging brake beam without additional brake beam 104support103. 8.41 Hanging brake beam with additional brake beam support 105104. 8.42 Body underframe 105105. 8.43 Brake head 106106. 8.44 Brake head 106107. 8.45 Brake adjustment 107CHAPTER 9108. 9.1 Transition Coupler 9109. 9.2 Non-Transition CBC 9110. 9.3 Removal of Draft Gear from Wagons 12111. 9.4 Shank Length 13112. 9.5 Released Draft Gear 18113. 9.6 RF 361 Draft gear 21114. 9.7 Released Draft gear 30115. 9.8 MG Buffing and Draw Gear 34116. 9.9 Coupler 45117. 9.10 Yoke 45118. 9.11 Lock lifter 45119. 9.12 Lock piece 45120. 9.13 Knuckle 45121. 9.14 Marking of parts 46CHAPTER 10122. 10.1 Tank Wagon with Bearing Plate outside 13CHAPTER 11123. 11.1 BLC wagon 8APPENDIX-VI BRANDING DETAILS ON WHEEL AND AXLE 1 14. LIST OF TABLESTable No. Description Page No.CHAPTER 11.1 UIC Bogie Wagon - Vacuum Brake 21.2 CASNUB Bogie Wagon - Air Brake 51.3 Open Four Wheeler Wagons 51.4 Other Standard Wagons 81.5 Tank Wagon 91.6 Brake Van 9CHAPTER 22.1 POH Interval of Air Brake Stock 132.2 POH Interval of Vacuum Brake Stock 142.3 ROH Intervals of Wagons 142.4 Work Areas where attention is to be given 15CHAPTER 33.1 Brake Pipe Pressure required in the Train 83.2 Man-Hors for Various Type of Examinations 163.3 Distribution of Intensive Staff Gang with tools & Materials 27CHAPTER 44.1 Panel Patches of CR Wagon 64.2 Panel Patches for BOX Wagon 64.3 Panel Patches for BOXN Wagons 74.4 Thickness of Patch Plates 7CHAPTER 66.1 Ware Limits for Bogie Components 146.2 Important Dimensions of Coil Spring 39CHAPTER 99.1 Shop issued and Condemnation Sizes for CBC Components 38CHAPTER 1010.1 Material Specification 210.2 Details of Safety Fittings 310.3 Periodicity of Overhauling 610.4 List of Important modifications to be carried out in Tank Wagons 1710.5 Tank wagons 2610.6 Modification on BTPN type wagon 2710.7 List of RDSO Maintenance Publications for Tank wagon 27CHAPTER 1111.1 Details of Super Structure 211.2 Electrodes for Welding 511.3 New Wagons 8 15. CORRECTION SLIPS ISSUEDC.S. No. & Date Reference Item No. & Chapter No. Remarks 16. CHAPTER 1- INTRODUCTION Page 1 of 12WAGON MAINTENANCE MANUALCHAPTER 1INTRODUCTION101. GENERALa) For ensuring optimum performance of wagon fleet, it is necessary that:! Preventive maintenance is given timely to avoid occurrence of defects! Defects are attended effectively and well in time so that the wagonsremain fit for traffic use till the next schedule falls due! Detention during examination and repairs is kept to minimum! Frequent failures of similar nature are studied and necessarymodifications/ design changes are effected to eliminate the cause ofsuch failure.In course of time and based on experience, various procedures/schedules for maintenance of wagons have been prepared. The schedules andprocedures have been largely standardized and issued by Railway Board,RDSO, IRCA etc. However, in many cases, instructions have been issuedpiecemeal. This manual consolidates various standing instructions issued onwagon maintenance and lays down guidelines for ensuring uniformity in thepractices to be followed on various railways. The important aspects of wagonmaintenance have been covered and wherever necessary, the references areindicated so that the reader can refer these, if necessary, for detailedinstructions and procedures not contained in this manual. In addition, theWorkshop Orders, Carriage and Wagon circulars, important letters andTechnical Standing Orders issued by Zonal Railways; taking into account theparticular requirements and conditions existing on the railways; must be readin conjunction with this manual.b) This manual does not deal with the special stock or ODCs for which separateinstructions are issued by RDSO/manufacturers. It also doesnt cover non-pooledstock, used only on one or two zonal Railways.c) At the end of this chapter, the list of important instructions and referenceshave been given. Throughout this manual, wherever IRCA Part III has beenmentioned, it refers to IRCA Part-III, 2000 edition.d) While proper maintenance plays a vital role in ensuring effectiveness of therolling stock, an equally crucial role is played by proper handling and carefuloperation of the wagon fleet so as to minimise the incidences of damage andsubsequent need for repairs. Care must be taken to avoid bumping of wagonshaving CBC Knuckles in closed position. Proper release of brakes must beensured. Cleaning of wagon interiors after unloading of corrosive, hygroscopic 17. CHAPTER 1- INTRODUCTION Page 2 of 12or other harmful consignments is necessary by unloading party and to beensured by the commercial staff. Place free end of hose pipes on dummycarriers and couplings on suspension hooks.102. IMPORTANT DIMENSIONS OF WAGONSThe important dimensions and sketches of main type of wagons have been givenbelow.TABLE 1.1 UIC BOGIE WAGONS VACUUM BRAKEType of wagons BOXT BOXC BCXTLength over Head stock (mm) 12800 12800 14500Length over Buffers (mm) 14070 N.A. 15770Length over Couplers (mm) 14082 13729 15782Length inside/ Length of wall (mm) 12792 12790 14494Width inside (mm) 2852 2852 2944Inside height/ Height of wall (mm) 1880 1880 2446Wheel Base (mm) 2000 2000 2000Bogie Centre (mm) 8800 8800 10,000Journal Size (mm) RB 130 RB 130 RB 130Journal Centre (mm) 2240 2240 2240Wheel dia on tread (mm) 1000 1000 1000Max. Axle load (t) 20.32 20.32 20.32Tare (t) 26.23 25.0 28.5Pay load (t) 55.05 56.28 52.8Gross load (Pay + Tare) (t) 81.28 81.28 81.3Ratio Gross Load/Tare 3.1 3.24 2.85Loading density (t/m) 5.77 5.92 5.16Floor Area (Sq. m) 36.5 36.5 42.7Cubic Capacity (Cu. m) 68.58 68.58 104Total Brake power- Empty (Kg) 19339 19339 18618Total Brake power Loaded (Kg) 34913 34913 34192WAGON MAINTENANCE MANUAL 18. CHAPTER 1- INTRODUCTION Page 3 of 12WAGON MAINTENANCE MANUAL8800 CRS. OF BOGIES12800 OVER HEAD STOCKS13729 OVER COUPLING FACES (NON TRANSITION TYPE)Fig. 1.1 BOX WAGON (Ref. R.D.S.O. SK.101-62601)HEIGHT INSIDERL12790 LENGTH INSIDECL 19. CHAPTER 1- INTRODUCTION Page 4 of 12WAGON MAINTENANCE MANUAL14494 LENGTH INSIDE1278 TOP OF FLOOR(AT CENTRE PIVOTS)RAIL LEVEL2250 10000 BOGIE CENTRES225014500 OVER HEADSTOCKS15770 OVER BUFFERS15782 OVER COUPLER FACES (TRANSITION TYPE)Fig. 1.2 BCX WAGON (Ref. R.D.S.O. SK. 701-63901)MAXIMUM MOVING DIMENSIONS OF STD 'X' CLASS ENGINE2944 WIDTHINSIDE 20. CHAPTER 1- INTRODUCTION Page 5 of 12TABLE 1.2 CASNUB BOGIE WAGONS AIR BRAKEType of wagons BOXN BCN BRNLength over Head stock (mm) 9784 14500 13716Length over Buffers (mm) - - 14986Length over Couplers (mm) 10713 15429 14645Length inside/ Length of wall (mm) 9784 14494 13716Width/Dia inside (mm) 2950 2944 2845Inside height/ Height of wall (mm) 1950 2446Wheel Base (mm) 2000 2000 2000Bogie Centre (mm) 6524 10,000 9144Journal Size (mm) CTRB 144.5 144.5 144.5Journal Centre (mm) 2260 2260 2240Wheel dia on tread (mm) 1000 1000 1000Max. Axle load (t) 20.32 20.32 20.32Tare (t) 22.47 27.20 24.4Pay load (t) 58.81 54.08 56.9Gross load (Pay + Tare) (t) 81.28 81.28 81.3Ratio Gross Load/Tare 3.62 2.99 3.33Loading density (t/m) 7.59 5.27 5.55Floor Area (Sq. m) 28.86 42.67 39Cubic Capacity (Cu. m) 56.28 104.37Total Brake power- Empty (Kg) 18900 18900 18900Total Brake power Loaded (Kg) 33642 33642 33642TABLE 1.3 OPEN FOUR WHEELER WAGONSParticulars Broad gauge Metre gaugeMechanical code O OM MO MOX MOMDescription Open generalWAGON MAINTENANCE MANUALpurposeOpen military Open OpenheavyOpenmilitaryTare (t) 10.31 10.62 5.69 5.84 5.5Pay load (t) 22.29 21.98 18.71 18.56 18.9Axle load(t) 16.30 16.30 12.2 12.2 12.2Length over buffers/couplers(mm)7214 9652 7786 7786 7786Floor area (Sq.m) 16.91 23.85 14.98 14.97 14.98Cubic capacity (Cu.m) 27.00 15.07 17.5 21.28 9.5Journal centre (mm) 2235 2235 1475 1475 1475Journal size (mm) 255x127 255x127 230x115 230x115 230x115Wheel dia on tread (mm) 1090 1090 725 725 725Wheel base (mm) 3504 4877 3657 3657 3657Type of coupler ScrewcouplingScrewcouplingABC ABC ABCType of bearing Plain Plain Plain Plain PlainType of brakes Vacuum Vacuum Vacuum Vacuum Vacuum 21. CHAPTER 1- INTRODUCTION Page 6 of 12WAGON MAINTENANCE MANUALs9784 LENGTH INSIDE6524 BOGIES CENTRES9784 OVER HEAD STOCKS10713 LENGTH OVER COUPLER FACES (NON TRANSITION)Fig. 1.3 BOXN WAGON (Ref. R.D.S.O. WD - 80007/S-2)1105 (L.V.)1275 FLOOR HT (L.V.) 1950 HEIGHT INSIDE322 5 HEIGHT OVERALL2260 JOURNAL CENTRES 22. CHAPTER 1- INTRODUCTION Page 7 of 12WAGON MAINTENANCE MANUALRAIL LEVEL10000 BOGIES CENTRES14500 OVER HEAD STOCKS15429 OVER COUPLING FACES (NON TRANSITION TYPE)Fig. 1.4 BCN WAGON (Ref. R.D.S.O. WD 84014-S-1)MAXIMUM MOVING DIMENSIONS OF STD 'X' CLASS ENGINE2446 HT IN SDIE 23. CHAPTER 1- INTRODUCTION Page 8 of 121000 DIA . WHEEL ON TREADFig. 1.5 BRN WAGON (Ref. RDSO WD 84013-S-1)TABLE 1.4 OTHER STANDARD WAGONSParticulars Broad gauge Metre gauge NarrowWAGON MAINTENANCE MANUALgaugeMechanical code TP CRT BOI BOY MBO MBOC NOLDescription TankPetrolCoveredwagonOpengondolaOpengondolaBogieopenOpencoalBogieopenTare (t) 12.2 13.1 22.80 19.9 10.82 13.98 8.48Pay load (t) 20.4 27.54 58.48 71.7 37.98 35.82 24.03Axle load(t) 16.3 20.32 20.32 22.9 12.2 12.2 8.1Length over buffers/couplers (mm)8280 8822 11629 11929 12511 14340 11430Floor area (Sq.m) 23.2 30.47 32.13 25.78 29.96 22.76Cubic capacity(Cu.m)25.5 61.9 32.0 37.75 16.32 35.0 29.02Journal centre (mm) 2235 2240 2240 2260 1475 1475 1220Journal size (mm) 255 x127RB 130 130 144.5 230x115 230x115 180x95Wheel dia on tread(mm)1090 1000 1000 1000 725 725 585Wheel base (mm) 4572 4900 6700 7330 7620 9449 7925Type of coupler DrawbarTran.CBCCBC CBC ABC ABC ABCType of bearing Plain/RBRB RB RB Plain Plain PlainType of brakes Vac Vac Vac/Air AirbrakeVac Vac Vac9144 CRS OF BOGIES13716 OVER HEAD STOCKS14645 OVER COUPLING FACES (NON TRANSITION TYPE)CENTER LINE OF CBC 24. CHAPTER 1- INTRODUCTION Page 9 of 12TABLE 1.5 TANK WAGONParticulars Broad gaugeMechanical code TBT TR TM TPGL TPGLRDescription BitumentankWAGON MAINTENANCE MANUALCoal TartankMolassestankLiquidpetroleumgas tankLiquidpetroleum gastankTare (t) 13.00 10.8 10.75 20.66 17.1Pay load (t) 19.5 21.7 21.76 11.84 15.4Axle load(t) 16.3 16.3 16.3 16.3 16.3Length over buffers/couplers (mm)7215 7215 7215 9652 9652Dia inside barrel (mm) 2362 2143 2143 2000 2300Cubic capacity (Cu.m) 23.5 19.4 19.4 24.1 33.1Journal centre (mm) 2235 2235 2235 2235 2235Journal size (mm) RB120diaRB120diaRB120diaRB120 dia RB120 diaWheel dia on tread(mm)1090 1090 1090 1090 1090Wheel base (mm) 3505 3505 3505 4877 4878Type of coupler ScrewcouplingScrewcouplingScrewcouplingScrewcouplingScrew couplingType of bearing RB RB RB RB RBType of brakes Vacuum Vacuum Vacuum Vacuum VacuumTABLE 1.6 BRAKE VANParticulars Broad GaugeMechanical code BVG BVMDescription Brake van goods Brake van match truckTare (t) 10.77 12.7Pay load (t)Axle load(t) 16.3 16.3Length over buffers/ couplers7213 7213(mm)Journal centre (mm) 2235 2235Journal size (mm) 225 x 127 225 x 127Wheel dia on tread (mm) 1090 1090Wheel base (mm) 3505 3505Type of coupler Screw coupling CBCType of bearing Plain PlainType of brakes Vacuum Vacuum 25. CHAPTER 1- INTRODUCTION Page 10 of 12MAXIMUM MOVING DIMENSIONS OF STD 'X' CLASS ENGINE2446 WIDTH IN SIDE1676 GAUGE1000 o WHEEL ON TREAD1495 14954900 WHEEL BASE7890 OVER HEADSTOCKS6 6Fig. 1.6 CRT WAGON (Ref. R.D.S.O. SK. 71605)103. IMPORTANT RULE BOOKS AND REFERENCESList of technical monograms/instructions relevant to maintenance of freight stock areincluded in the compendium of instructions/ technical monograms issued videRailway Boards letter No. 99/EAR/3400/21 dt. 4.5.99. The following rule books,pamphlets and monograms contain information required to supplement this manual.These may be referred to for details not available in this manual.i. IRCA Conference Rules Part III (2000) - Rules for Maintenance, Examinationand Interchange of Goods Stock (BG & MG System) of Indian GovernmentRailwaysii. Prevention of Hot Boxes - A Guide (Published by Railway Board)iii. RDSOs Technical Pamphlet G-16 - Instructions for Maintenance andOperation of Box Wagonsiv. RDSOs Technical Pamphlet G-37 - Recommended practice for weldedfabrication in wagonsv. RDSOs Technical Pamphlet G-38 - Instructions for Maintenance andOperation of TCL Tank wagonvi. RDSOs Technical Pamphlet G-40 - Manual of Instructions for AnhydrousAmmonia Tank.vii. RDSOs tech. Pamphlet No. G-44H/Jan 78 Instructions for operating staffhump shunting and marshalling of BOX wagonviii. RDSOs tech. Pamphlet No. G-45H Instructions for fitting trapaulingequipment on BOX wagon.ix. RDSOs tech. Pamphlet No. G-55H/Aug.76 Instructions for maintenance andoperation of hydrochloric acid tank wagon type THA.x. RDSOs tech. Pamphlet No. G-62/June.77 Maintenance manual of alliance IIcouplerWAGON MAINTENANCE MANUAL2240 CRS. OF JOURNALSMAXIMUMMOVINGDIMENSIONSOF 1929(3081 WIDTH OVER STANCHIONS OVER ALL)1956 CRS. OFBUFFERSRevised movingGauge ForCoaching StockSketch SK. 660233977 OVERAALL HEIGHT8810 OVER BUFFERS20.3 (Roller Bearing)8822 OVER COUPLER FACES512307890 LENGTH INSIDE2675 HEIGHTINSIDEAXLE BOX 130 mm o 26. CHAPTER 1- INTRODUCTION Page 11 of 12xi. Indian Railways Code for the Mechanical Department (Workshops)xii. RDSOs Technical Pamphlet G-65 Instructions for inspection andmaintenance of TPGLRxiii. RDSOs tech. Pamphlet No. G-66/1983 Maintenance manual for TSA.xiv. RDSOs Technical Pamphlet G-70 Instructions for inspection andmaintenance of BOXN wagons fitted with CASNUB Bogies and twin pipe airbrake system.xv. RDSOs tech. Pamphlet No. G-71 Maintenance manual for phosphoric acidtank wagon.xvi. RDSOs tech. Pamphlet No. G-72 General standard specification forfabrication of wagon U frame and bogies.xvii. RDSOs Technical Pamphlet G-73 Instructions for inspection andmaintenance of BOBRxviii. RDSOs Technical Pamphlet No.G-76 (Supersedes old pamphlet No.G-46)xix. RDSOs tech. Pamphlet No. G-79 Instructions for operation and maintenancefor BTAL/BTALNxx. RDSOs Technical Pamphlet No. G-80(Supersedes old pamphlet No. G-47)xxi. RDSOs Technical Pamphlet G-81 Instructions for inspection andmaintenance of CTRBxxii. RDSOs tech. Pamphlet No. G-82 Instructions for operation and maintenanceBG bogie tank wagon for alumina type BTAL.xxiii. RDSOs tech. Pamphlet No. G-83 Instructions for operation for maintenanceof BTCS wagonxxiv. RDSOs Technical Pamphlet G-86 Instructions for inspection andmaintenance of BTPGL/BTPGLNxxv. RDSOs tech. Pamphlet No. G-87 Safe handling of hazardous chemicalstransported in rail tankers.xxvi. RDSOs Technical Pamphlet G-90 Instructions for inspection andmaintenance of BTPNxxvii. RDSOs Technical Pamphlet G-92 Instructions for inspection andmaintenance of Slack Adjuster type IRSA 450 & 600xxviii. RDSOs Technical Pamphlet G-95 Instructions for inspection andmaintenance of CASNUB Bogiesxxix. RDSOs Technical Pamphlet G-97 Instructions for inspection andmaintenance of Air Brakesxxx. RDSOs Technical Pamphlet No. WT-77-1 & WT-79-1 for inspection andmaintenance of 20.3 Tonnes Roller Bearing and 16.3 Tonnes Roller Bearingaxle boxes fitted wagons.104. EXISTING WAGON FLEETThe strength of present wagon fleet on Indian Railways is given at the end of thismanual in Appendix-I.WAGON MAINTENANCE MANUAL 27. CHAPTER 1- INTRODUCTION Page 12 of 12105. STANDARD INFRASTRUCTURE FOR WAGON DEPOTThe standard infrastructure required in wagon depot is given in Appendix-II.106. IMPORTANT WAGON MODIFICATIONSThe list of important modifications to be carried out on freight stock is given inAppendix-III.107. NUMBERING CONVENTION IN THE MANUALFor convenience of indexing of reference, the paragraphs have been numberedaccording to a 3 /4 figure Code, in which the last two figures give the number of theparagraphs and the remaining figures the number of the chapter. Thus paragraph 101of any code is paragraph 1 of chapter 1 of that code and paragraph 1103, paragraph 3of chapter 11.The page number in each chapter in this manual starts from 1. The reader caneasily identify the chapter number to which a page belongs by reading the header ofthe page where chapter number as well as chapter title is given. This scheme of pagenumbering is adopted to provide flexibility of easily revising the chapters in future, onaccount of design or procedure changes or induction of new stock without disturbingthe page numbers of succeeding chapters.108. NUMBERING OF TABLES AND FIGURES IN THE MANUALThe tables in each chapter consist of two numbers separated by a decimal point. Thenumber before decimal point indicates the chapter number whereas the number afterthe decimal point indicates the running serial number of the table which start from 1in every chapter. The convention adopted for numbering the figures is also identical tothe numbering scheme adopted for the tables.WAGON MAINTENANCE MANUAL!!!!! 28. CHAPTER 2 WARRANTY,MAINTENANCE & CONDEMNATION Page 1 of 23WAGON MAINTENANCE MANUALCHAPTER 2WARRANTY, MAINTENANCE & CONDEMNATIONThis chapter gives general information about periodicity of various types ofinspections and maintenance schedules for goods stock on open line. Prescribed period atwhich POH is to be carried out on various types of stock has also been given. However,special practices to be followed for repairs during POH are indicated in the concernedchapters later in the manual.At the end of this chapter, at a glance picture of the prescribed intervals for POH andROH of wagons are given in the tables 2.1, 2.2 & 2.3.201. WARRANTY INSPECTION OF NEWLY BUILT WAGONS(Ref.- Rly. Bd.s letter no. 64/M(WTY)/954/Policy dated 3.4.74)a) All newly built wagons have a warranty period of one year or as prescribed inthe purchase contract. In accordance with the conditions mentioned in thewagon manufacturing contracts, the charges for rectification of the followingcategory of defects can be realised from the wagon builder :- Use of inferior material Poor workmanship on the part of contractor Imperfect protection Other faults on the part of contractor which are noticed during thewarranty period.b) To enable the Railway Board to realise the warranty charges, a systematicinspection of new wagons must be undertaken by JE(CW) to locate defectsduring the warranty period. The following procedure is laid down for thispurpose:-(i) All newly built wagons turned out must bear the warranty legendstencilled on both sides of the wagons. The warranty legend will consistof the following particulars:- Contract Number Date of Commissioning Commissioned by Inspection due on Inspection done by ______ Depot_______ Date_______The due date of inspection falls due on completion of 11 months fromthe date of commissioning. 29. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 2 of 23(ii) Whenever wagons due for warranty inspection pass nominated yards,preferably detach them from the train and send to sick line for asystematic check. This warranty inspection can also be done on the trainat the time of incoming or outgoing examination if the sufficient time isavailable.(iii) Examination of DefectsDuring the course of warranty inspection, it must be borne in mind thatonly those defects, which are attributable to the manufacturer due to useof inferior material, poor workmanship, improper protection or any otherfaults, are to be reported. The following are some of the defects, whichfall under this category :-A) Welding defects All types of welding failures Welding defects such as insufficient or unequal leg length ofWAGON MAINTENANCE MANUALfillet weld, porosity, lack of fusion, etc.B) Riveting defects Loose rivets Badly formed rivet heads Rivets with staggered heads Improperly filled rivet holesC) Fitting Defects Improper fitting of axle guards Tie rods not bent tight over the axle guards etc.D) Material failures such as breakage of: Bearing Springs Shackle pins Shackles Screw coupling and drawbar Underframe and body membersE) Improper Protection Improper pairing of underframe body, roof and componentsresulting in corrosion Wagons not being water tightF) Train Pipe leakage and unsatisfactory working of brake cylinders 30. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 3 of 23G) Roller Bearing DefectsWagons fitted with roller bearings are normally examined only inmajor sick lines. If any defect is noticed on opening the covers, theentire wheel assembly must be sent to the workshop. After inspectionin the workshop, if it is felt that the defect is attributable to thecontractor, the workshop incharge should report the defect to theconcerned roller bearing manufacturer and others concerned. Sincethe Railways normally supply wheels and axles to the builder, defectsnoticed on the wheel and axles need not be reported to the wagonbuilders. However, the extant instructions for reporting any defect onthe tyres, wheels and axles must be followed. With regard to centrebuffer couplers also, if the defect is attributable to the manufacturer,the same procedure should be followed as in case of wheels, as thisis also a free supply item to the wagon builders by Railways.The procedure of warranty inspection of BTPN wagons aresame as above with special attention to internal and externalexamination of barrel for any failure of longitudinal/ circumferencialjoint, cracks in barrel, leakage by barrel fittings and examination ofcradles and anchoring rivets as per Technical pamphlet No. G-90.c) METHOD OF REPORTINGA. The particulars, which are to be furnished, are as follows:-i. Contract No.This indicates the contract number under which the order has beenplaced by the Railway Board on the Wagon Builders for themanufacturer of wagons. This will be stencilled on the wagon in theWarranty legend. The Junior Engineer (CW) should ensure thatcorrect particulars as obtained on the wagon are fill against this item.ii. Wagon number } Needs no clarification. Bothiii. Code (Mech./Transport.) } Mechanical and Transportationiv. Owning Railway } codes of the wagon must bev. Name of the Manufacturer } recorded.vi. Date of Commissioning - Junior Engineer (CW) must fill the date asobtained the Warranty legend stencilled on the wagon .vii. Date of Warranty Inspection - Junior Engineer (CW) must fill thedate on which the wagon was actually inspected by him.viii. Defects attributable to the Manufacturer - all the defects attributableto the manufacturer should be clearly indicated.WAGON MAINTENANCE MANUAL 31. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 4 of 23The actual location of the defect should be clearly recorded. For thispurpose, the Board has issued a Drawing SK. No.1 WTY which indicatesthe numbering of axle boxes on meter gauge four-wheelers, broad gaugefour-wheelers, meter gauge bogie wagons and BG bogie wagons BCXand BOX. The Board has also issued another drawing No.WG/1/65114/S-1, which indicates the numbering of axle, boxes for BRHwagons. For instance, if one bearing spring is found broken the numberof axle box on which the particular bearing spring is fitted should beindicated in the report.In the case of material failure like top plate of laminated springbreakage, etc. it is essential that such items should be sent to theChemist and Metallurgist of the respective Railways so as to enable himto submit the test reports. While sending the materials to the CMT, theparticulars of the wagon i.e. the wagon No., owning Railway,Mechanical/Transportation codes the Builders name, the ContractNumber and the serial number of the Warranty Inspection Report mustbe mentioned in the forwarding memo. These particulars can be includedin the Test Report submitted by the CMT. This will facilitate inconnecting the test reports with the respective Warranty reports at theRailway Boards Office.The CMT will send his analysis report direct to the Railway Boardsoffice. In order to prefer the claims expeditiously as possible, it isdesired by the Board that the reports of Chemist and Metallurgist shouldbe sent to the Secretary(WP), Warranty, Railway Board, New Delhi,within 20 days from the date of warranty inspection. The report of theCMT should not be sent to the wagon Builders.A NIL defect report should be sent if there are no defectsattributable to the manufacturers.B. Estimated cost of rectificationIt has been found that the estimates prepared by Junior Engineer(CW)differ from the estimates prepared by Board. To avoid advice of differentestimates to wagon builders, it is decided by Railway Board that noestimates are to be furnished by Junior Engineer(CW) in the warrantyinspection reports. Against this column, simply mention Cost will beadvised by the Railway Board.Along with other remarks, if any, a written certificate must be givento the effect that the defects mentioned have arisen due to inferiormaterial (i.e. material of wrong specification or cheap quality) or badworkmanship (poor workmanship like bad riveting, welding, fittingetc.) or imperfect protection of the components (vacuum cylinderrusted etc.) or any other defaults on the contractors part.WAGON MAINTENANCE MANUAL 32. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 5 of 23C. Numbering of the reportIn order to enable the Boards office to keep a check on the performanceof each nominated CW Depot and also to detect the missing reports, allWarranty Inspection Reports must be serially numbered.For uniformity it is desired that the CW Depots should indicatethe number of Warranty reports in three barrels by indicating thestation code in the first barrel, Warranty in the 2nd barrel and serialnumber of the report in the last barrel. For example ASN/WTY/81indicates that this warranty report was sent from Asansol CarriageShed, WTY refers to Warranty report and 81 refers to the serialnumber of the warranty report i.e. serial number the wagon which hasbeen warranty inspected from the commencement of the inspection.Date on which the Warranty report is submitted must be indicated.The Junior Engineer(CW) who signs the report should ensure that hisdesignation is properly recorded by affixing his rubber stamp, whichshould indicate the designation as well as the reporting station.D. Disposal of the Proforma! In the case of wagons built by railway workshops, the report shouldbe sent to the following addresses :-1. The workshop which manufactured the wagon2. CME of the manufacturing workshop3. Secretary (WP)/Railway Board/New Delhi.4. CME of the inspecting zonal railway5. D.M.E. of the inspecting division! In the case of wagons built by private manufacturers, the reportshould be sent to the following addresses :-1. Wagon builder concerned2. Secretary (WP)/Railway Board, New Delhi.3. G..M.(Mech.) of the inspecting zonal railway4. D.M.E. of the inspecting division.E. It is necessary that Junior Engineer(CW) must send the warrantyinspection report to the parties indicated above after inspection withoutany delay.F. After submission of the warranty reports, the Railway Board will decidethe finalisation of claims. Zonal railways should not enter into anycorrespondence with the wagon builders on this subject after sending thewarranty report. If any wagon builder returns the warranty report orrefuses to accept the claim, such cases must be immediately advised toRailway Board. Only Railway Board will do all further correspondenceand processing in this regard.WAGON MAINTENANCE MANUAL 33. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 6 of 23d) MAINTENANCE OF RECORDSThe Train Examining Depot should maintain following files and registers: One file for filing all the policy instructions on warranty inspectionreceived from their divisional office/CME. The Junior Engineer(CW)should be conversant with the instructions issued from time to time. It isdesired that an index sheet be maintained giving the particulars of theletters so as to keep a continuity of all the instructions. A second file for filling all the warranty inspection reports, intermediate orfinally submitted by the Depot. A third file should be maintained for filing all correspondence regardingwarranty inspection, periodical statements of inspections carried out etc. A register should be maintained giving the following details of the wagonsinspected during the warranty period :-a) Date of Inspectionb) Wagon No.c) Owning Railwayd) Mech. Codee) Name of Builderf) Date of Commissioningg) Defects noticedh) Warranty inspection report no. and Datei) RemarksThe above inspection procedure after 11 months of commissioning doesnot in any way preclude any Railway from reporting any defect direct to thewagon builder and to the parties mentioned above. In the same manner, ifdefects are noticed at any time during the warranty period. During theintermediate warranty inspection, stencilling of the Station Code and date ofInspection should not be done on the wagon. This should only be done at thetime of final warranty inspection i.e. after completion of 11 months and beforecompletion of 12 months from the date of commissioning the wagon.202. EXAMINATION AND MAINTENANCE PERIODICITYa) ROLLING IN EXAMINATIONAll terminating trains are to be given Rolling-in-examination while entering astation having a train examining depot. After Rolling in examination when thetrain stops in yard, immediately feeling of axle boxes is necessary to arresthot/over warm axle box.b) EXAMINATION OF TERMINATING LOADExamination of terminating loads and through goods trains, passing throughstation with a train examination depot, is to be carried out as soon as the traincomes to a halt (unless the competent local authority of the MechanicalDepartment has waived off such examination). For the examination ofWAGON MAINTENANCE MANUAL 34. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 7 of 23terminating loads the pattern of train examination issued by individual ZonalRailway keeping in the view of the Railway Boards guidelines vide their letterno. 94/M(N)/951/57 dated 28.2.2000.c) EXAMINATION OF TRAIN AT ORIGINATING STATIONi. The train examining staff must ensure that the wagons are in fit conditionand do not have any rejectable defects. A certificate has to be given to theStation Master by JE(CW) to this effect before despatch of the train.Before issuing fit Certificate, train examining staff also ensure minimumpermissible percentage of brake power. For details refer Chapter 3.ii. The level of vacuum/air pressure on the enginebrake van alongwith thepercentage of effective brake cylinders must be recorded on the brakecertificate duly countersigned by the driver and guard.iii. Wagons, which have been humped, must be specially checked for damagesoccurring due to impacts during humping.d) MAKING WAGONS FIT TO RUN BY PASSENGER TRAINGoods wagon may be attached to a passenger train provided the maximum speedto the train does not exceed 75Kmph for BG and 50Kmph for MG. The wagonsmust satisfy the following condition:-i. They are fully fitted with operative brake cylindersii. Fitted with shackle type bearing springs and not shoe ended springsiii. Shackle pins with bearing springs fitted with split cotters and washersiv. Brake gear should have closed type of safety bracketsv. Should not be overdue re-packing/oilingvi. Axle Guards should have angle type bridle with two rivet holes at eachendvii. The wagon should not be overloaded or unevenly loadedviii. Wagon fitted with wheels having no star marks on journal cap to beensured by duly opening the Axle Box coverix. Wagons should not be overdue POHx. Minimum wheel base should be 4724 mm (15-6) for BG and 3658mm (12-0 )for MG.e) NURSING OF AXLE BOXESIt is generally observed that plain bearing axle boxes, which have beenattended to, have greater tendency to develop higher temperature in the first 40 to 50km of the run after attention. If the axle boxes are felt at this stage and nursed, ifrequired, the possibility of detachment of wagons on account of hot axle is greatlyminimised during subsequent run. Keeping this fact in mind, nursing stations areoften established at suitable stations, 40-50 km away from major marshalling yards.Whenever such nursing stations are set up, in addition to feeling the axle boxes andgiving necessary attention to them, CW staff there must also look out for any loose,broken or deficient wagon components.WAGON MAINTENANCE MANUAL 35. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 8 of 23f) INTENSIVE EXAMINATIONThe purpose of intensive examination of goods stock is to permit extended runof through trains by raising the general standard of fitness of rolling stock byconcentrated attention at the time of despatch from originating yards. Runs canbe extended upto 4500 Km on BG in case of air brake stock and 800 km in caseof vacuum brake. For empty rake consisting of only BOX wagons, this can beextended up to 1000 km.Note: The details of above examinations are given in chapter 3.203. INTERCHANGE EXAMINATIONThe procedure for train examination at interchange points has been dispensed withafter introduction of end to end examination.204. ROH OF WAGONS WITH UIC BOGIEa) BOX Wagon and other wagons fitted with plate fabricated UIC bogies are to begiven a routine overhaul (ROH) at CW Depots nominated for this purpose atan interval of 18 months (i.e. two ROH schedules between successive POH).b) Detailed instructions issued by RDSO in publication No. G-16 (Rev.II) and R7to be strictly followed. The important points are summarised below for readyreference:-i. Lift the body and place it on trestlesii. Run out the bogiesiii. Strip the brake gear fittings and examine for wear and damages. Thefittings should be checked with condemning gauge prescribed in G-16(Rev.II) to ensure the serviceability.iv. Lower vacuum brake cylinders. Overhaul and test. Station code initials anddate to be stencilled after overhaul.v. Gauge the wheels. If necessary, carry out tyre turningvi. Strip springs and springs suspension gear. Check springs for free camberand defects. Replace if required. Check the suspension gear and replaceworn componentsvii. Examine bogie frame for welding defects/failures; repair; modify; andcheck alignment to ensure confirmation to RDSO pamphlet R-7viii. Rectification of welding defects to be done as prescribed in RDSOtechnical pamphlet G-37.ix. Examine centre pivot and side bearer for wear and cracks. Gauge thecentre pivots. Repair if necessaryx. Check horn cheeks and axle box lugs for wear. Fit liners if necessaryxi. Examine brake shaft bearingsxii. Examine brake gear levers, rods, etc. for proper functioning and wear.Check adjustment of the tare tie rod, empty load device and rectify ifrequired. Manual adjustment of brake gear is done in accordance withwheel diameter.xiii. Examine slack adjuster. Check dia A and adjust if necessaryWAGON MAINTENANCE MANUAL 36. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 9 of 23xiv. Examine all draft and buffing gears, CBC, locking levers and transitiongears. Attend the defective/worn out parts. Knuckles to be checked bycontour gauge, anti creep/ articulated rotary operation of CBC lockassembly to be checked.xv. Replace worn out brake blocksxvi. Thoroughly inspect axle boxes externally for any sign of defects such asgrease leaking out, visible sign of damage or seized bearing. Rotate axlebox by hand to see if it revolves freely and smoothly. If the movement isabnormal or heavy, open axle box for inspection. Take further action asprescribed in RDSO pamphlet No. WT-77-1.xvii. All the wheels are to be ultrasonically tested, Axle boxes to be topped upby fresh grease. Axle bolts are to be tightened up by torque wrench withproper torque. Old locking plates are not to be reused. UT and RBexamination to be carried out duly replacing the old grease.xviii. Check doors, hinges and other fittings. Lubricate.xix. Touch up paint and lettering, if necessary.xx. Ensure that at the time of re-assembly, all specified anti-pilferage measureshave been taken and all safety straps, loops and other safety fittings arecorrectly fitted.xxi. After completion of ROH work, each wagon has to be tested for leakagefor ensuring reliability of vacuum cylinder and other brake gearcomponents.205. ROH OF AIR BRAKE WAGON WITH CASNUB BOGIEBOXN wagons are to be given Routine Over-Haul (ROH) after every 18 month at thenominated sick line/wagon depot, where proper facilities are provided. The ROHschedule is as follows:a) Lift the body, keep it on trestles and run out bogiesb) Strip bogie component for examination and repair as below: Strip springspring suspension arrangement including snubbing device.Check springs for free height and other defects. Replace where required. Examine Bogie frame. Check frame alignment as per instructionscontained in RDSO Technical Pamphlet No. G-64. Examine pivot for welding defects/cracks/abnormal depth due to wear.Replace where necessary and lubricate with graphite flakes to IS:495 in drycondition.c) Strip brake gear levers and rods for examination of worn out/damaged parts.d) The equipment shall be given attention in accordance with the maintenancemanual issued by respective air brake equipment manufacturer:-i. Cleaning of strainer discs (Reference 6218 of the pamphlet SBA795/258 of P4aG type Distributor Valve)ii. Lubrication of brake cylinder/cleaning of its straineriii. Check for easy operation of isolating cockanti-pilferage device ofdistributor valve cut-off angle cock , manual quick release valve isolating cock.WAGON MAINTENANCE MANUAL 37. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 10 of 23iv. Draining of Auxiliary Reservoirv. Checking of hose coupling for serviceabilityvi. Cleaning of strainervii. Dirt collector to be cleanedviii. Leakage in pipes and joints to be checkedix. After carrying out above items of work the wagon shall be tested forproper function of air brake system with single car test device inaccordance with the procedure indicated below : Connect the BP coupling of single car test rig to the correspondingcoupling of the wagon to be tested .The couplings of the other endof the wagon to be closed with dummy coupling heads .Fixpressure gauge on the brake cylinder. The single car test device should now be coupled to the main lineof a compressor through a pipe. Carry out the preparation and testing in accordance with theprocedure given in the manufacturers Maintenance Manual andrecord the reading in the test proforma. For passing the wagon, all the parameters shall be within specifiedlimits.e) Clean horizontal lever, hand brakegears and lubricatef) Examine head stock for damage, bent/cracksg) Refit brake gear levers and rods, lubricate pins and other equipment and applygraphite to horizontal levers of empty load boxh) Replace worn out brake blocksi) Check wheel profile, turn the wheels as needed. UST of Axle to be carried out turning of wheel to worn wheel profile during ROHj) All the wheels are to be checked ultrasonically and Axle box cap bolts are to betightened up by torque wrench with proper torque and in no case old lockingplates are to be reused.k) CBC Knuckles are to be checked by contour gauge, anti creep/ articulated rotaryoperation of locking arrangement to be checked.l) Manual adjustment of brake gear to be done in accordance with wheel diameter.m) Modification work are to be attended as issued by RDSO from time to time.206. ROH OF CRT WAGONa) ROH periodicity 21 months.b) Brake gear examination of worn out/damaged parts.c) Vacuum cylinders overhaul, testing, stencilling of station code, initials, datesetc.d) Checking of spring and spring suspension gear, free camber, checking ofshackle, stone, scroll iron , shackle pin, washer for worn out/damaged etc.e) Examination of horn cheek, axle guard etc.f) Examination of underframe.g) Replacement of worn out brake blocks.h) Attention to draw and buffing gear and attention to defective/ worn out parts.i) Examination of alliance and CBC, uncoupling gear etc.WAGON MAINTENANCE MANUAL 38. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 11 of 23j) Checking of Doors and door opening gears and lubrication.k) Attention, special modification as ordered time to time where practicable inROH depots.l) Attention to Roller bearing axle boxes as per instructions given in Technicalpamphlet No. WT 77-1. Roller bearing axle boxes should be thoroughlyexamined externally for detecting sign of defects viz; Wear on lugs of axle box body Abnormal warmer axle box Grease leaking out of Axle box Tell tale marks of grease on axle box body and wheels to be looked forVisible sign of damage on axle box body or front cover Seized roller bearing Axle box is also to be turned by hand to ascertain that its rotation issmooth.207. NPOH OF GOODS STOCKClassification of wagon repairs has been rationalised under the followingnomenclature:-a) Petty Repairs :- Repairs involving not more than 8 man - hours. Such repairsare to be normally carried out on nominated lines in traffic yards in less than 8man hours.b) Medium Repairs :- Repairs involving more than 8 man - hours and upto 100man - hours. These would normally cover repairs to underframe members viz.head stock, middle bars, sole bars, changing of axle guards, wheel changingheavy panel patching, heavy floor repairs, etc. Such repairs are to be carried outin sick lines.c) Special Repairs :- Repairs to heavily damaged wagons involving more than 100man hours. Such repairs may be carried out either in the workshops or in majorsick line. Recommended work areas where serious repairs should be carried outare given in the Table 2.4 at the end of this chapter. Repair to under framemembers and other heavy work should be dealt in properly equipped major andmedium sickline. Repair to under frame members viz. patching of headstock,sole bar and middle bars, strengthening of bulged ends, replacement of endangle, fitment of more than 5 new full width panel patches, replacement of axleguards to be done in sickline.Unloadable BOX wagons will be classified as under :-Category A: Such unloadable BOX wagons, which can be repaired and madeloadable in wagon depots.Category B: Unloadable BOX wagons, which require attention/repairs inworkshops and cannot be classified as Category A or Category CCategory C: Unloadable BOX wagons in the age group of 18 to 25 years withsound underframe requiring heavy repairs on body/floor. These wagonsto be sent for rebuilding to Dahod, Jamalpur or Charbagh workshops.WAGON MAINTENANCE MANUAL 39. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 12 of 23Railways to note the aforesaid and ensure that marking of unloadable BOXwagons to nominated workshops are carried out accordingly. JE/SE(CW) shall dothe classification/marking of the wagons under the above three categories in open line.(i) For wagons classified under Category B, the workshops undertakingrepairs/conversion of unloadable BOX wagons should observe the followingbroad guidelines:- Unloadable BOX wagons which are over aged or have less than 10 yearsresidual life but having under frame in good condition should be convertedto container flats for carrying ISO containers to the maximum possibleextent. Other serviceable unloadable BOX wagons should be given requisitePOH/NPOH attention and made as loadable.(ii) BOXN wagons of (8-10) years of age and beyond, which are heavily corrodedand due/overdue POH, should normally be selected for rehabilitation. Howeverat the time of attention in workshops, wagons due for POH within next 12months should be given POH. Similarly, the wagons falling due for ROH withinnext 6 months but not due for POH within next 12 months should be given ROHattention at the time of repairs in the workshops.Wagons so attended for POH/ROH should be stencilled with a freshreturn date for POH/ROH based on laid down periodically for POH/ROH forBOXN wagons. All above rehabilitated wagons should be painted with goldenyellow for easy identification.The repair of BOXN wagons should be carried out as per instructionscontained in RDSOs G-70 /1986.208. CONDEMNATION OF WAGONSFor condemnation of rolling stock, the powers delegated to various officers on zonalrailways through their Schedule of Powers may be used. Certain issues have beenclarified in Railway Boards letter No. 74/M(N)/951/19 dated 16.10.1974. The sameare summarised below:-a) Condemnation of overage wagonsOver aged wagon stock can be inspected personally by CWM/Dy. CME/WM-Incharge/Sr.DME and condition report prepared and personally signed.Condemnation can be approved by any of these officers.b) Condemnation of underage wagonsUnder aged wagon stock should be inspected personally byCWM/Dy.CME/WM-Incharge/Sr.DME and condition report prepared andpersonally signed. Condemnation proposals should be sent to CME/CRSE forapproval duly concurred by associated finance i.e., WAO of the workshopWAGON MAINTENANCE MANUAL 40. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 13 of 23concerned, further this proposal to expedite the whole process, followingprocedure to be adopted:-BG and MG wagons should be condemned on as is where is basisand moved from division to the yards/stations nominated by DRMs. EachDRM should nominate sufficient number of yards/stations on their division fordisposal of condemned wagons. Workshops can continue the present practiceof sending the wagons to scrap yards.209. POHROH INTERVAL(Ref: i. IRCA letter M.219/Policy/W Dated 10.5.99)WAGON MAINTENANCE MANUALTABLE No. 2.1POH INTERVAL OF AIR BRAKE STOCKSr.No.Stock POH (Years)First Subsequent1. BOXN 6 4.52. BCN/BCNA 6 63. BRN 6 4.54. BOY 3 35. BTPH 6 4.56. BTPN 6 67. BOBRBOBRN 6 68. BTPGLN 4 49. BTALN 4.5 4.5Note:1. Wagons become due POH from the last date of the month indicated in the returndate2. Empty wagon will be marked sick for POH up to 30 days in advance of the duedate3. Loaded wagons will be allowed up to 30 days after the due date of POH 41. CHAPTER 2- WARRANTY, MAINTENANCECONDEMNATION Page 14 of 23WAGON MAINTENANCE MANUALTABLE 2.2POH INTERVAL OF VACUUM BRAKE STOCKSr.No.Type of Wagon First POHin YearsSubsequent POHin Years1. All other wagons including Tank Wagons andCRT wagons except those listed below4 3.52. Bogie well wagons 4 43. General service Hopper wagon 4 44. BOBX, BOBS 3 35. BOX, BCX , BRH, BOI, BOMBTALwagons fitted with UIC bogie4.5 4.56. Cattle wagons 2.5 2.57. Brake Van 2 28. TX/TCL, THA, TSA 2 29. TAL, TPGLR, BTPGL 4 410. Departmental Hopper wagon type BOB,BOBY etc.6 611. Departmental Stock 4 412. Domestic Containers 1.5 1.5TABLE 2.3ROH INTERVAL OF WAGONSSr.No.Stock ROHNewlyBuilt(Months)ROHAfter First POH (Months)1. Roller Bearing Tank Wagons 24 212. 4-Wheeler wagons convertedfrom 16.3 Tonnes Plain bearing toRoller bearing24 213. CRT 24 214. TPGLR 24 245. BOX,BCX,BRH fitted with UICbogie18 186. BOXN,BCN,BCNA, BRN 18 187. BOBR, BOBRN 24 248. BTPN 18 189. BTPGL, BTPGLN 24 2410. BTPH 24 1811. BTAL, BTALN 18 1812. BTCS 24 2413. BOY 18 18210. WORK AREAS WHERE ATTENTION TO BE GIVENTable 2.4 summarises the nature of work to be done during various examinations andrepairs in sick line. 42. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL15TABLE 2.4WORK AREAS WHERE ATTENTION TO BE GIVENSr. Nature of RepairsRepairs to be under taken at XNo.IntensiverepairsSicklines ROH POH1. BODY REPAIR WORK (Common for all)UNDERFRAME- Sole BarScrap the portion of sole bar at door ways, clean and apply primer paint followed by Top coat - - X XSIDE WALL- Skirting1. Check and patch if corroded then apply primer and top coat on the patch - X X X2. Side Doors- Check damage and repair cleanlubricate hinges X X X X3. Side Pillars- Check cracks at the baserepair - X X X4. Patching of body, roof, door or floor plates straightening buldged ends repairs to angle irons,stanchions and crib angles etc.- X X X5. Making wagons water-tight (Covered wagons) - X X X6. Fitting/replacement of door fastening road, door cotter pin eye, bolt hook and eye lockingpin on empty wagons and closing of doors.X X X X7. Fitting/replacement of door fastening rod guide, door hasp which requires riveting on emptywagons. Repairs by welding to door fittings.- X X X8. Hand rail/foot board deficient/or damaged, insecurely fastened at door way of guards brakevanX X X X2. UNDER GEAR REPAIR WORK ( Common for all )1. Brake Linkage- Check free movement X X X X2. Hand Brake - Check proper working X X X X3. BOGIE REPAIR WORKSA. CASNUB BOGIEBOLSTER1. Pocket slope liner Change liner if thickness less than 5 mm - - X X2. Rotation stop lugs Provide liners (thickness to suit) if dimensions less than 514 mm - - X X3. Inner Column Gib Provide liners (thickness to suit) if dimension more than 142 mm - - X X4. Land surface Provide liners (thickness to suit) if dimension less than 442 mm - - X X5. Outer Column Gib Renew by welding if dimension more than 241 mm - - X X 43. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL16Sr. Nature of RepairsRepairs to be under taken at XNo.IntensiverepairsSicklines ROH POHSIDE FRAME1. Column Friction Liner Change liner if dimension more than 455 mm - - X X2. Column sides Provide liners (thickness to suit) if dimension less than 209 mm - - X X3. Anti rotation lugs Provide liners (thickness to suit) if dimension more than 526 mm - - X X4. Key seat to pad 22 W Provide liners (thickness to suit) if dimension more than 276 mm - - X X5. Crown Roof 22WM Provide liners (thickness to suit) if dimension more than 321 mm - - X X6. Crown Roof 22NL Provide liners (thickness to suit) if dimension more than 326 mm - - X X7. Pedestal Crown Sides Renew by welding if dimension less than 147 mm - - X X8. Pedestal Jaw 22 W Provide liners (thickness to suit) if dimension more than 275 mm - - X X9. Pedestal Jaw 22 WM Provide liners (thickness to suit) if dimension more than 283 mm - - X X10. Pedestal Jaw 22NL(Short)Provide liners (thickness to suit) if dimension more than 195 mm - - X X11. Pedestal Jaw 22NL(Long)Provide liners (thickness to suit) if dimension more than 241 mm - - X X12. Pedestal Sides 22 W Provide liners (thickness to suit) if dimension less than 102 mm - - X X13. Pedestal Sides 22 WM Provide liners (thickness to suit) if dimension less than 102 mm - - X X14. Pedestal Side 22 NL Provide liners (thickness to suit) if dimension less than 78 mm - - X XWEDGE1. Slope Surface Renew by welding if dimension less than 7 mm - - X X2. Vertical Surface If vertical surface from centre line of spigot less than 56 mmprovide liner of 6 mm thickness- X X XCENTRE PIVOT (BOTTOM)1. Vertical Side 22 W Renew by welding if wear more than 4 mm - - X X2. Vertical Side 22 WM Renew by welding if wear more than 3 mm - - X X3. Vertical Side 22 NL Renew by welding if wear more than 3 mm - - X X4. Seat Side 22 W Renew by welding if wear more than 3 mm - - X X5. Seat Side 22WM Renew by welding if wear more than 3 mm - - X X6. Seat Side 22 NL Renew by welding if wear more than 3 mm - - X X 44. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL17Sr. Nature of RepairsRepairs to be under taken at XNo.IntensiverepairsSicklines ROH POHCOIL SPRING1. Outer Group and use in sets. Replace if free height at or less than 245 mm - X X X2. Inner Group and use in sets. Replace if free height less than 247 mm - X X X3. Snubber Group and use in sets. Replace if free height less than 279 mm - X X XADAPTER - - X X1. Crown Surface Replace if worn 3.5 mm or more - - X X2. Side lug Replace if wear more than 3 mm on either side - - X X3. Thrust shoulder Replace if depth exceeds 0.7 mm - - X X4. Machined relief Replace if depth less than 0.8 mm - - X XBOGIE BRAKE GEARPinsBushes Change if clearance more than 1.5 mm X X X XB. UIC BOGIEAXLE BOX (UIC BOGIE)1. Welding of worn out axle box grooves, wearing of axle box liners - X X X2. Fitting of bent/grooved liners in the axle box grooves - X X X3. Repairs by welding to cracked or broken axle boxes - X X X4. Fitting of axle box back plates and/or dust shield - X X X5. Fitting of axle box back cover top plates - X X X6. All repairs by welding to back plates, back collars - X X X7. Attention to hot boxes - X - -8. Changing of axle boxes and wheels - X X X9. Re-packing of axle boxes X X X X10. Attention/Examination of roller Bearings X X X X11. Attention to warm boxes, ranging faceplates, etc. X X X X 45. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL18Sr.No.Nature of RepairsRepairs to be under taken at XIntensiverepairsSicklinesROH POHAXLE GUARDS (UIC BOGIE)1. Repairs to expanded axle guard legs. - X X X2. Repairs to worn axle guards and/or horn cheeks by welding, changing of horn cheeks,and/or rivets- X X X3. Repairs to bent axle guards - X X X4. Repairs to pressed steel axle guards cracked up to 25 mm - X X X5. Attention to hanging axle guard bridles X X X X6. Changing of axle guards. - X X XSPRING GEAR ( UIC BOGIE)1. Replacement of laminated bearing spring X X X X2. Replacement of bolster spring - X X X3. Setting of displaced plates of laminated bearing spring X X - -4. Replacement/fitting of scroll iron or rivet of correcting alignment of scrolling - X X X5. Repairs to scroll iron by welding (As this repair involves normalising after welding, onlyWorkshops should undertake the repair where proper facilities are available)- - - X6. Replacement/fitting of bearing spring shackle, shackle pin, hanger bolt, nut and cotter etc. X X X X4. AIR BRAKE SYSTEMDistributor Valve Overhauling - - - XDistributor Valve Test on SWTR - X X XDV Isolating Cock Examine operation X X X XDV Release valve Examine operation X X X XDV Filter Clean - - X XBRAKE CYLINDERFilter of EscortsRPIL make Clean - - X XBrake Cylinder of GreyshamWSFLubricate - - X XmakeCUT OFF ANGLE COCKAngle cock Examine and lubricate X X X X 46. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL19Sr. Repairs to be under taken at XNo. Nature of Repairs IntensiverepairsSicklinesROH POHRubber Seals Change - - X XDIRT COLLECTOR - - - -Dirt Collector Clean - X X XSealing Ring Change - - X XRESERVOIRARCR Drain - X X XSealing Ring Change - - X XMETAL PIPESJOINTSPipe Joints Examine leakagerepair X X X XSeals (20 mm32 mm)pipe Change X X X XGuards Emergency Brake Valve Examine operation X X X XIsolating cock of BVZC Brake Van -do- X X X XQuick Coupling -do- X X X XLoad Sensing Device -do- - X X X5. VACUUM BRAKE SYSTEM1. Attention to cracked or perforated train pipe/replacement of knee or piece - X X X2. Periodical overhauling and testing of vacuum cylinders - X X X3. Replacement fitting release valves, levers diaphragms and seating washers, replacement ofpacking ring and stuffing box.X X X X4. Replacing deficient and defective vacuum cylinders - X X X5. Attention to vacuum cylinder after lowering - X X X6. Fitting of brake blocks/adjustment of brake/fittings or replacement or replacement of pinsand cottersX X X X7. Fitting of brake beam hanger bolt/nut/pin cotters X X X X8. Adjustment of hand brakes X X X X9. Fitting of hand brake lever collars/rivets X X X X10. Fitting/replacement of safety hangers to pull rod and brake beam and push rod, which arerequired to be secured by, rivets.- X X X11. Repairs to broken safety brackets/hangers by welding X X X X12. Riveting of brake beam hanger brackets to the underframe - X X X13. Changing of brake beams - X X X 47. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL20Sr. Repairs to be under taken at XNo. Nature of Repairs IntensiverepairsSicklinesROH POH6. SLACK ADJUSTER ( COMMON FOR ALL)Slack Adjuster Test Functioning, repair if required X X X XA dimension Adjust X X X Xe dimension Adjust - X X XM20 Anchor Pin nut Ensure securing by welding to pin - X X XAir Brake System Test on SWTR as per procedure - X X XBrake Block Ensure Std. Key, Spilt pinall new brake blocks X X X XNB: For detailed main procedure refer RDSO manual G-97.7. CENTRE BUFFER COUPLER ( COMMON FOR ALL)CBC BODYCoupler Body Examinereplace on condition basis - X X XCBC Contour Examine, replace if required - X X XShank Wear Plate Replace on condition - X X XKNUCKLENose Replace if wear more than 9.5 mm with HTE knuckle X X X XKnuckle pin Replace on condition X X X XKnuckle Stretch Examine, Replace if required - - X XSTRIKER CASTINGWear Plate Replace - - X XStriker casting Replace on condition - - X XCOUPLER MECHANISMAnti Creep Protection Examine and repair X X X XLock lift assembly Examine X X X XOperation Mechanism Examine X X X XLock Examine - X X X 48. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL21Sr. Repairs to be under taken at XNo. Nature of Repairs IntensiverepairsSicklinesROH POHDRAFT GEARSlack Measuretake correction - - X XGENERALYoke pin support Replace on condition - X X XBuffer Height ExamineCorrect if required X X X XNB: 1. For detailed maintenance Practices in open line refer RDSOs Manual G-762. For detailed maintenance Practices in Workshop refer RDSOs Manual G-803. Knuckle with nose more than 4.3 mm and less than 9.0 mm can be used in yard.8. WHEEL AXLEBEARING ( COMMON FOR ALL)AXLE1. Ultrasonic Testing To be carried in every ROHreject if fails - X X X2. Deep Notches due to gearing of pull rod Reject if depth is more than 5 mm X X X X3. Axle end holes Clean and lubricate in case end cover is opened - X X XWHEEL1. Tread profile Check with tyre defect gauge X X X X2. Height of flange If height more than 31 mm do not use under ROH wagon - - X X3. Smooth flange If flange not completely smooth do not use under ROH wagon - - X X4. Wheel profile Turn to WWP if above clause are not met for use under ROH wagon. - X X XBEARING TAPERED CARTRIDGE1. Cup Rotate the bearing for unusual sound check up for Crack/chipping - - X X2. Seal Check seal for external damage/dent - X X X3. Backing Ring Check backing ring for loosenessvent fitting on backing ring with venthole ( the vent fitting should be intact or the vent hole should be plugged)- - X X4. Locking Plate Use new locking plate when ever and cover is opened - - X X5. Axle end Cap screw Clean and lubricate in case end cover is opened - - X X6. Load Zone Change Change load zone area of the cup while lowering bogie side frame - - X X 49. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL22Sr. Repairs to be under taken at XNo. Nature of Repairs IntensiverepairsSicklinesROH POH9. DRAW GEAR ( COMMON FOR B.G.M.G.)1. Replacement/fitting draw links shanks and other components X X X X2. Replacement of draw bar springs, washers or rubber pads. X X X X3. Repairs to draw bar cradle yoke support plate, race plate or wearing plates. - X X X4. Replacement/fitting screw coupling shackles, links, pin, suspension hook or shackle pin rivets. X X X X5. Replacing draw bar nuts/check nuts cotter, etc. X X X X6. Building up of draw bar shank or link, worn more than (13 mm) As this requires normalisingafter building up- - X X7. Provision of anti-turning device on MG draw bar - X X X10. BUFFING GEAR (B.G.)1. Repairs by welding to buffer socket, plunger, replacement of buffer spindle/springs and washer,replacement of buffer socket or plunger- X X X2. Attention to dead buffer requiring releasing of springs - X X X3. Attention to dead buffers involving changing the broken/perished spring/pads - X X X4. Replacement of deficient or wrong buffer spindle nut - X X X5. Attention to drooping buffers, replacement to deficient bolts. X X X XBUFFING GEAR (M.G.)1. Replacement of any of the components of buffing or coupling assembly not involving removal ofdraw barX X X X2. Replacement of buffer springs, washers involving removal of draw bar X X X X3. Fitting of bolsters, stanchions, lashing chain and coupling on bogie rail trucks - X X X4. Securing of lashing chain against trailing X X X X5. Any fitting or part of a wagon or load infringing standard dimensions secured or preventing freemovement of the wagonX X - -6. Inspection of wagons overdue warranty inspection or stencilling of details on newly built wagonsor warranty inspection.- X - - 50. CHAPTER 2 WARRANTY, MAINTENANCECONDEMNATIONWAGON MAINTENANCE MANUAL23NOMINALMAXIMUM CLEARANCES IN CASNUB BOGIEMeasurement of location Total Clearance in NominalClearanceS.No.Particular TypeNew At ROH Cond. New ROH Max1. Lateral clearance betweenS.F. Column sides All 216 209 206 18 32 38 183Bolster column jib All 234 241 2442. Lateral clearance betweena. S.F. Pedestal sides 22W,22W(M) I/II 105 102 101 25 34 35 25+3/-0b. S.F. Pedestal sides Adapter (wide jaw) I/II 130 136 1363. Lateral clearance betweena. S.F. Crown sides I/II 152 147 144 4 17 20 4+/-0Adapter crown (wide jaw) I/II 156 164 164b. S.F. Crown sides NL 152 147 144 3.5 16.5 19.5 3.5+/-0Adapter Crown NL 155.5 163.5 163.54. Long clearance betweena. S.F. Pedestal jaw I 270 275 278 2 13 16 2+/-0Adapter I 268 262 262b. S.F. Pedestal jaw II 278 283 286 10 21 24 10+5/-0Adapter II 268 262 262c. S.F. Pedestal jaw NL 190 195 198 9 20 23 9+2/-3Adapter NL 181 175 1755. Long clearance betweenSide frame column All 450 455 458 6 13 20 6+/-0Bolster land surface All 444 442 4386. Clearance betweenAnti rotation lug All 522 526 528 4 12 16 4+3/-0Bolster rotation stop lug All 518 514 512Ref: RDSO manual G-95 and Review of ROH issued by RDSO L.No. MW/BOXN/Maint. 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