MAINTENANCE MANUAL FOR WAGONS - WordPress
¼ããÀ ã ÔãÀ‡ãŠãÀGOVERNMENT OF INDIAÀñÊã ½ãâ ããÊã¾ãMINISTRY OF RAILWAYS(RAILWAY BOARD)MAINTENANCE MANUALFORWAGONSMARCH 2001
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 IR’s 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.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
INDIAN RAILWAYS(MECHANICAL DEPARTMENT)The previous “Maintenance Manual for Wagons” was published in 1979. Sinceonly vacuum brake system was existing on Indian Railways at that time, this manual didnot contain any details of Air Brake System. The induction of Air Brake stock on IndianRailways transformed the complete scenario of operating and maintenance disciplines inRailways.Railway Board nominated a committee of officers comprising of ExecutiveDirector/CAMTECH/GWL, ED(Wagon)/RDSO/LKO, CRSE/W.Rly/Mumbai andDME(Freight)/Railway Board vide letter No. 70/M(N)/7/16(H.T.)-Pt.I dated 4.9.98 forupdation and revision of “Indian Railways Unified Maintenance Manual for Wagons”.The revision and updation of manual has been completed taking into account latest fleetof freight stock currently running on Indian Railways.The present manual bridges this gap and covers detailed treatise of Air BrakeSystem including its maintenance. The other salient features of the manual are as follows:The manual has been divided into logical chapters covering various subassemblies and systems. The constructional details and functioning hasbeen explained before describing the detailed maintenance procedures.The important dimensions, clearances, material specifications, drawingreferences etc. have been given immediately after the paragraphs wherethey have been referred to while describing maintenance procedures.Clear sketches and isometric views of the important subassemblies/components have been given in the manual.A separate chapter titled “YARD MAINTENANCE” has been addedcovering the maintenance work to be done in yards.A separate chapter titled “SPECIAL TYPE OF WAGONS” is included inthe manual.For 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 101 ofany code is paragraph 1 of chapter 1 of that code and paragraph 1103, paragraph 3 ofchapter 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 footer of thepage at the bottom where chapter number as well as chapter title is given. This scheme ofpage numbering is adopted to provide flexibility of easily revising the chapters in future,on account of design or procedure changes or induction of new stock without disturbingthe page numbers of succeeding chapters.
ivThe tables in each chapter consist of two numbers separated by a decimal point.The number before decimal point indicates the chapter number whereas the number afterthe decimal point indicates the running serial number of the table which start from 1 inevery chapter. The convention adopted for numbering the figures is also identical to thenumbering scheme adopted for the tables.The items of maintenance required to be carried out in sickline, ROH & POHhave been listed out separately towards the end of various chapters under appropriateheadings for each system/subassembly covered in the manual for easy reference andguidance of maintenance units.Future addition/ deletion/ modification to this manual will be processed by RDSO andwill be require approval of the Railway Board.The Committee is thankful to shri V.K. Manglik, EDME(Fr.), Railway Board, shriB.B.Modgil, DRM/BRC, shriD.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 their valuable contribution in finalisation of this manual. Members ofthe committee also express their appreciation for the valuable assistance provided by shriA.K.Arora, AEME(Fr.), Railway Board and shri K.K.Giri, Sr.CTA/CAMTECH.M.L.GuptaExe. DirectorCAMTECHN.P.SinghSr.Exe.Director Std.(W)RDSOK.K.GuptaCRSEW.Rly.Arun AroraDir.Mech. Engg.(Freight)Rly. Bd.
CONTENTSFOREWORDJOINT NOTECONTENTSLIST OF FIGURESLIST OF TABLESCORRECTION SLIPS ISSUEDCHAPTER alImportant Dimensions of WagonImportant Rule Books and ReferencesExisting Wagon FleetStandard Infrastructure for Wagon DepotImportant Wagon ModificationsPage Numbering Convention in the ManualNumbering of Figures and Tables in the ManualCHAPTER 2WARRANTY MAINTENANCE AND 0.Warranty Inspection of newly built wagonsExamination and Maintenance PeriodicityInterchanges ExaminationROH of Wagon with UIC BogieROH of Wagon with CASNUB BogieROH of CRT WagonsNPOH of Goods StockCondemnation of WagonsROH and POH IntervalWork Areas where attention is to be givenCHAPTER 3YARD 11.312.313.314.Pattern of Freight Train ExaminationNotification of Examination PointsFrequency of Intensive Examination for different StockSteps of Intensive ExaminationDetails of Intensive ExaminationAir Brake TestingImportant Parameters to be Ensured During Intensive ExaminationImportant Parameters to be Ensured During Sick Line/ Depot AttentionCommon Problems in Brake System and RemedyInfrastructure & Facilities required in the yardMachinery & Plant itemsToolsMan Hours for various type of examinationsJoint Procedure order for Goods Trains ExaminationiiiiivxixivxvPage 1-1212101112121212Page 1-24168891111131315Page 1-29111338910131515161617
viCHAPTER 4WAGON 2.413.414.IntroductionGeneral Construction of Open WagonGeneral Construction of Covered WagonGeneral Construction of Flat Wagon & Well WagonGeneral Construction of Hopper WagonNature of Repairs required in Wagon bodyCorrosion in Wagon BodyAnticorrosive MeasuresRejectable DefectsRepairs in Sickline and ROH DepotRepair and Maintenance in Workshops during POH and NPOHImportant Precautions to be taken while taking out weldingImportant Do’s and Don’tsImportant ModificationsCHAPTER .511.512.513.514.515.516.GeneralGeneral Construction of BG Wagon UnderframeBG Four wheeler UnderframeRepair ProcedureCleaning and De-rusting of the UnderframeRepairs to Head StockRepairs to Diagonals and Cross BarsRepairs to Sole BarsRepairs to Floor PlateUnderframe of Brake VanBogie Wagon UnderframeMG Fourwheeler Wagon UnderframeMG Bogie UnderframeList of ModificationsRepair and Maintenance in Sickline and ROH DepotRepair and Maintenance in Workshop during POH/NPOHCHAPTER 6BOGIES AND SUSPENSIONS601.602.CASNUB BogieA)B)C)D)E)F)General DescriptionConstructional DetailsRepair and Maintenance in SicklineRepair and Maintenance during ROH and POHNominal ClearancesReference Drawing Nos. for ComponentsFabricated BOX Bogie (UIC Bogie)A)B)C)D)E)F)General DescriptionConstructional DetailsMaintenance of Sub AssembliesRepair and Maintenance in SicklineRepair and Maintenance during ROH and POHMaterial Specification of BOX (UIC Bogie)Page 1-17112233445515161717Page 1-331145777799101112143233Page 1-1281212121417181830343536
vii603.Cast Steel BogieA)B)C)D)E)F)604.606.373742464647Diamond Frame BogieA)B)C)D)605.General DescriptionConstructional DetailsMaintenance of Sub-assembliesRepair and Maintenance in SicklineRepair and Maintenance during ROH/POHMaterial Specification for Bogie ItemsConstructional DetailsRepair and Maintenance in SicklineRepair and Maintenance during ROH and POHMaterial Specifications (Diamond Frame R)S)T)GeneralFour Wheeler SuspensionProcedure for repair & testing in WorkshopCauses for Failures of SpringsCauses of Failures to BucklesImportant Do’s and Don’ts during Repair of SpringsAxle Box Crown Packing Plate (Spring Sheet)Axle Guard Horn Cheek AssemblyClearances and Repairs of Axle Guard AssemblyRoller Bearing Axle BoxesImportant Do’s and Don’ts during POHRepair and Maintenance in SicklineRepair and Maintenance during ROH and POHAxle Box Assembly with Plain BearingPeriodicity of Repacking and OilingProcedure for Repacking and Axle BoxesAxle Box SealingImportant Do’s and Don’ts during RepackingWhite Metalling ProcedureMaintenance Instructions for 102106Wheel rs of wheels used on BG and MG withCondemning limitsWheel CentreTyre ProfileRe-axlingRetyringTyre TurningParing of WheelsWheel DefectsRepair and Maintenance in SicklineRepair and Maintenance during ROH and POHImportant dimensions related to Suspension116116117118118120122122124124125125126
viiiCHAPTER 7VACUUM BRAKE 12.713.GeneralConstructional Details“F” Type cylinderPrinciple of OperationLimitation of Vacuum BrakeModificationsMaintenance and RepairRepair and Maintenance in SicklineRepair and Maintenance during ROHRepair and Maintenance during POHStorage of Rubber FittingSpecial Tools, Jigs and FixturesBrake power calculations BOX wagonCHAPTER 8AIR BRAKE 4.825.826.827.828.Classification of Air Brake SystemPrinciple of Operation of Single Pipe Graduated Release AirBrake SystemCommon Pipe BracketIntermediate Piece (Sandwich piece)Brake Pipe HoseBrake Pipe CouplingCut Off Angle CockBrake CylinderDirt CollectorAuxiliary ReservoirGuard’s Emergency Brake ValveSlack AdjusterDistributor ValveC3W Distributor ValveTesting of Distributor ValveTesting of C3W Distributor ValveKE Distributor ValveTesting of KE Distributor ValveTest Report Proforma for C3W/KE Distributor ValveSingle Wagon TestRake TestRepair and Maintenance in SicklineRepair and Maintenance in ROHPeriodical Overhaul of Air Brake SystemDetails of Tools, Fixtures and EquipmentBrake power calculations for BOXN wagonBrake RiggingComposition brake blockCHAPTER 9DRAW AND BUFFING GEAR901.902.903.904.GeneralConventional Buffing GearBuffing Gear RepairsBuffer ProjectionPage 1-23112791013181920222223Page 2103109Page 1-461122
917.918.919.920.921.922.923.924.Buffer HeightBG Draw GearProcedure for Reclamation of BG Draw Bars in WorkshopsProcedure for Reclamation of BG Screw Coupling in WorkshopsMaintenance of Draw Gears during repacking and normal repairsin SicklineRepair and Rejection RulesCentre Buffer Couple and Draft GearParts of Centre Buffer Coupler AssemblyInspection of CBCInspection of Draft Gear(HR-40-I & MF-400-IR)Removal of Couple and Draft Gear from WagonsCoupler Reclamation PracticesDraft Gear Reclamation Practices for Cardwell Westinghouse(HR-40-1 Draft Gear)Reclamation Practices for National Rubber Type(MF 400-I-IR Draft Gear)Development of High Tensile CouplerRF-361 Draft GearMaintenance of Mark-50 Draft GearMG Buffing and Draw GearRepair and Maintenance in Sickline and ROH DepotRepair and Maintenance in Workshop During POHCHAPTER 10TANK 1020.1021.1022.1023.1024.1025.1026.Constructional DetailsPeriodicity of Overhauling of Tank WagonSteam Cleaning of Bitumen and Molasses WagonsCleaning of Tank for Corrosive LiquidsInspection of Tank BarrelsTesting of BarrelBarrel Test PressureTesting of Tanks Used for Corrosive LiquidsTest of Tank Wagons used for Petrol and Middle Distillates ofPetroleum and Vegetable OilsRepairs of Tank Barrels by WeldingRepairs of Tank Barrel Mounting FittingsFittings of Tanks for Corrosive LiquidsFittings of Tank Wagons of Petrol, other inflammable productsvegetable oils, etc.Heating Arrangement on TOH Tank WagonsTest Reports and Records of InspectionImportant ModificationsPainting and LetteringExamination and Repair of Tank WagonsPrecaution with leaky Tank WagonsPrecautions to be taken at Loading and Unloading Points(Tanks as Pressure Vessels)Loading and Unloading Corrosive LiquidsLoading and Unloading Tank WagonsPrecautions for Tanks for Petroleum and other inflammable productsPrecaution for Bitumen TanksMaintenance and Repair in SicklineMaintenance and Repair in Workshop during POH33467788101111121617192029343839Page 8
xCHAPTER 11SPECIAL TYPE OF WAGONS1101BOXNHA Wagonsa)b)c)d)Salient FeaturesWagon SuperstructureNature of Repairs in BOXNHAMaintenance and Repair Procedure1102. BOXNCR Wagonsa)b)c)d)Salient FeaturesMaintenance and RepairsPrecautions for Welding Stainless SteelSurface Preparation and Painting1103. Bogie Low Platform Container flats (BLC)Page 1-10113456788LIST OF APPENDICESAPPENDIX-IEXISTING STRENGTH OF WAGON FLEETAPPENDIX-IISTANDARDISATION OF INFRASTRUCTURAL FACILITIES INAIR BRAKE ROH DEPOTSAPPENDIX-IIILIST OF IMPORTANT MODIFICATIONS TO BECARRIED OUT ON FREIGHT STOCKAPPENDIX-IVREPAIR OF TANK WAGON PRESSURE VESSELSAPPENDIX-VWAGON MANUFACTURERS AND WORKSHOPS
LIST OF eNo.1.11.21.31.41.51.64.1 to 4.44.5 to 4.94.10 to 19.25.19.36.16.26.36.46.56.66.7ADescriptionBOXC WagonsBCXT WagonsBOXN WagonsBCN WagonsBRN WagonsCRT WagonsPanel PatchingPanel PatchingPanel PatchingDimension Checks on UnderframeTypical Four wheeler UnderframeModifications to Head Stock Diagonal andKnee Joint for Bogie Open Wagons type BOX MKCast Steel Bracket for Goods Brake Van BVGTCast Steel Knee for Four Wheeled BG Wagons BVGTCast Steel Knee for Four Wheeler wagonsPositioning of Scroll Iron, Horn Cheeks and BufferPositioning of Scroll Iron, Horn Cheek and Buffer etc.Patching of Sole BarHead Stock Straightening DeviceBG Wagon Type BCNAUnderframe for Bogie Open Wagon(type BOX)Underframe of Bogie Open Wagon (BOXN)IRS Covered Wagon Underframe (MG Four Wheeler)Underframe Bogie Wagon (Type MPTPX)IRS Eight wheeler Underframe MBTPZ Tank WagonsDetails of Stiffening of Underframe in existingMBTPX WagonsArrangement of Stiffening of Underframe in existingMBTPX Wagons.Crack in Longitudinal Channel Web at welded joint ofBottom Gusset PlateReinforcement PlatePatching of LongitudinalBogie General Arrangement CASNUB 22W BogieIsometric View of BOX type Wagon Bogie Frame (BG)Diamond Frame BogieSuspension Arrangement of Four Wheeler WagonsScroll Iron and Shackle PlateSquareness of Axle GuardRoller Bearing Axle 930313131322194853557176
9Cartridge Tapered Roller Bearing77Axle Box Assembly 255 x 127 BG81Dimensions of Roll Packing97Identification marks for wagons111Marking of face plate111Fitment of FRLP112FRLP113Tools114Tools115Wheel Profile117Worn wheel profile119Intermediate profile120Vacuum Brake Cylinder (F Type)3Schematic Arrangement of Vacuum Brake Equipment4Design of Cage7Brake power calculation of BOX wagon22Graduated Release Single Pipe Air Brake System2Charging Stage3Application Stage3Release Stage4Brake Pipe Hoses5Testing of Hose Coupling7Cut Off Angle Cock8Brake Cylinder12Test Bench For Brake Cylinder15Test Bench for Brake Angle Cock and Dirt Collector20Slack Adjuster (Figure 1-13)29, 31 & 33Test Rack36C3W Distributor Valve41Main Valve42Sectional View of Main Valve43Cut off Valve44Auxiliary Reservoir Check Valve45Quick Service Valve46Sectional view of Quick Service Valve47Limiting Device48Double Release Valve49Testing of C3W Distributor Valve59KE Distributor Valve66Three Pressure Valve67U Controller68R Charger68Choke Cover69Minimum Pressure Limiter69Maximum Pressure Limiter70
9.59.69.79.89.99.109.119.129.139.1410.111.1“A” Controller70Quick Release Valve71Test Bench for KE Distributor Valve75Single Wagon Test Rig88Rake Test Rig90Brake power calculation of BOXN wagon102Hand brake arrangement103Empty load device104Empty load device104Sliding brake beam105Hanging brake beam without additional brake beam support105Hanging brake beam with additional brake beam support 105Body underframe106Brake head107Brake head107Brake adjustment108Transition Coupler9Non-Transition CBC9Removal of Draft Gear from Wagons12Shank Length13Released Draft Gear18RF 361 Draft gear21Released Draft gear30MG Buffing and Draw Gear34Coupler45Yoke45Lock lifter45Lock piece45Knuckle45Marking of parts46Tank Wagon with Bearing Plate outside14BLC wagon9
LIST OF TABLESTable 1.3DescriptionPage No.UIC Bogie Wagon - Vacuum Brake2CASNUB Bogie Wagon - Air Brake5Open Four Wheeler Wagons5Other Standard Wagons8Tank Wagon9Brake Van9POH Interval of Air Brake Stock13POH Interval of Vacuum Brake Stock14ROH Intervals of Wagons14Work Areas where attention is to be given15Brake Pipe Pressure required in the Train8Man-Hors for Various Type of Examinations17Distribution of Intensive Staff Gang with tools & Materials 28Panel Patches of CR Wagon7Panel Patches for BOX Wagon7Panel Patches for BOXN Wagons8Thickness of Patch Plates8Ware Limits for Bogie Components15Important Dimensions of Coil Spring41Shop issued and Condemnation Sizes for CBC38Component
The previous “Maintenance Manual for Wagons” was published in 1979. Since only vacuum brake system was existing on Indian Railways at that time, this manual did not contain any details of Air Brake System. The induction of Air Brake stock on Indian Railways transformed the complete scenario of operating and maintenance disciplines in Railways.
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