Box NCR Wagon Maintenance and Repair
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Questions and Answers

What is the minimum acceptable tread diameter for wheels in new condition?

  • 800 mm
  • 840 mm (correct)
  • 780 mm
  • 850 mm

    • Which type of brake shoes should be used for tread braking in the wagon?

  • Low friction type composition brake shoes (correct)
  • Non-asbestos brake shoes
  • Carbon composite brake shoes
  • Metallic segment brake shoes

    • According to the specification, how much grease is required to be applied to a single roller assembly?

  • 400 gm
  • 200 gm
  • 115 gm (correct)
  • 170 gm

    • What type of bearing is specified for the axle in the wagon?

    <p>Cartridge taper roller bearing of AAR 'E' type</p> Signup and view all the answers

    Which specification pertains to the forged wheels mentioned in the content?

    <p>R-19/93 Pt-II</p> Signup and view all the answers

    What is the primary material used for the body of the BOXNCR wagon?

    <p>IRSM-44 steel</p> Signup and view all the answers

    Which cutting method is not permitted for replacing corroded body panels on the BOXNCR wagon?

    <p>Oxy-cutting</p> Signup and view all the answers

    What type of electrodes should be used for welding IRS M-44 to IRS M-44?

    <p>IRS class M1</p> Signup and view all the answers

    How are the maintenance schedules and repair procedures for BOXNCR and BOXN wagons related?

    <p>They are exactly the same.</p> Signup and view all the answers

    What feature differentiates the BOXNCR from the BOXN wagon?

    <p>Materials used for the body and sole bar.</p> Signup and view all the answers

    Which type of steel is used for the sole bar of the BOXNCR wagon?

    <p>IRSM-41</p> Signup and view all the answers

    What is the IS code for the welding electrodes used for IRS M-44 to IRS M-41?

    <p>EB5426H3JX</p> Signup and view all the answers

    What is the minimum dry film thickness (DFT) required for the etch primer applied to stainless steel?

    <p>50 microns</p> Signup and view all the answers

    What is the purpose of degreasing the wagon body?

    <p>To facilitate better adhesion of paint</p> Signup and view all the answers

    Which standard specifies the painting of the wagon body for mild steel and corten steel?

    <p>IS:102-1962</p> Signup and view all the answers

    Which of the following processes is NOT included in the surface preparation for mild and corten steel?

    <p>Washing with water</p> Signup and view all the answers

    What is the gross payload capacity of the bogie low platform container flats (BLC)?

    <p>61 tons</p> Signup and view all the answers

    What is the prescribed action for dust and loose rust during surface preparation of the wagon body?

    <p>Removal by scrapping and wire brushing</p> Signup and view all the answers

    What is the operational speed limit for the bogie container flat wagons?

    <p>100 km/h</p> Signup and view all the answers

    Which type of paint is used for the finishing coat on the stainless steel wagon body?

    <p>Red oxide semi-gloss</p> Signup and view all the answers

    Which standard is referenced for the painting of bogies, couplers, and air brake equipment?

    <p>General Standard Specification No.G-72</p> Signup and view all the answers

    What type of couplings is used on end A of the car?

    <p>Raised end AAR E-type CBC</p> Signup and view all the answers

    What is the body weight distribution under tare condition between centre pivot and side bearers?

    <p>90% by side bearers, 10% by centre pivot</p> Signup and view all the answers

    How often should the 'B schedule' maintenance check occur?

    <p>Every 3 months</p> Signup and view all the answers

    Which component's distance must be set to 16 mm during a 'C schedule' check?

    <p>Load sensing device (VTA)</p> Signup and view all the answers

    What type of air brake system is used in the basic system?

    <p>Graduated release, single pipe air brake system</p> Signup and view all the answers

    What is one main advantage of the spring-loaded side bearers?

    <p>Ensures load distribution consistency</p> Signup and view all the answers

    What should be checked every six months under the 'C schedule'?

    <p>Defective or damaged elastomeric pads</p> Signup and view all the answers

    How is the changeover from load to empty braking condition achieved?

    <p>By the distributor valve governed by changeover valves</p> Signup and view all the answers

    Which of the following statements about wheel diameter is correct?

    <p>New wheels have a diameter of 840 mm.</p> Signup and view all the answers

    What is the primary purpose of the zero-hunting design of side bearers?

    <p>To optimize load distribution and prevent hunting.</p> Signup and view all the answers

    What is the maximum height of containers suitable for the wagon?

    <p>2896 mm</p> Signup and view all the answers

    What type of steel is used for constructing the wagon?

    <p>Micro alloyed high strength steel</p> Signup and view all the answers

    What is the maximum operating speed of the wagon?

    <p>100 kmph</p> Signup and view all the answers

    How many wagons are designed to work in a unit?

    <p>5 wagons</p> Signup and view all the answers

    What is the load capacity of the wagon in terms of payload?

    <p>61.0 tonnes</p> Signup and view all the answers

    Which type of couplers are fitted at the outer ends of the A-cars?

    <p>Non transition type center buffer couplers</p> Signup and view all the answers

    What is the minimum curvature radius that the wagon can negotiate?

    <p>175 m</p> Signup and view all the answers

    What specification does the bogie adhere to?

    <p>Drg No.CONTR-9404-S/2</p> Signup and view all the answers

    What component is used to secure containers during movement?

    <p>Automatic twist locks</p> Signup and view all the answers

    What type of braking system is employed in the wagon?

    <p>Graduated release air brake system</p> Signup and view all the answers

    What happens to the delivery ports of the VTA valves when the wagon is empty?

    <p>They are connected to the atmosphere at the exhaust ports.</p> Signup and view all the answers

    Which mechanism ensures higher brake cylinder pressure during loaded conditions?

    <p>The actuation of both VTA valves due to bogie deflection.</p> Signup and view all the answers

    What role does the Reducing valve type N1 play in the braking system?

    <p>It maintains lower pressure to one of the VTA valves.</p> Signup and view all the answers

    How does the Distributor valve behave when the wagon is in empty condition?

    <p>It maintains specified application timings based on actuation signals.</p> Signup and view all the answers

    What occurs when the VTA valves are actuated in a loaded condition?

    <p>Compressed air is delivered to interconnect at the Double check valve.</p> Signup and view all the answers

    What was a primary reason for not undertaking serial manufacturing of the BOXNH wagon?

    <p>Constraint of some tipplers for handling these wagons.</p> Signup and view all the answers

    Which of the following specifications relates to the axle load capacity of the BOXNLW wagon?

    <p>20.32t</p> Signup and view all the answers

    What key modification was made to enhance the performance of the BOXNLWM1 wagon?

    <p>Strengthened the center sill with additional plates.</p> Signup and view all the answers

    Which material combination was utilized in the construction of the BOXNLW wagon to reduce tare weight?

    <p>Corten Steel and Cold Rolled Formed sections.</p> Signup and view all the answers

    What design detail differentiates the BOXNHL from the earlier BOXN model?

    <p>A 250 mm longer chassis.</p> Signup and view all the answers

    What is the cleared speed limit for the BOXN wagons under specific loading conditions?

    <p>75/100 Kmph.</p> Signup and view all the answers

    How did the design changes for the BOXNLWM1 wagon accommodate loads up to CC+8+2 t?

    <p>Modification of suspension with additional inner springs.</p> Signup and view all the answers

    What material is primarily used in the construction of the body and under frame to reduce tare weight?

    <p>Stainless Steel</p> Signup and view all the answers

    Which model was specifically designed for long steel products in the year 2000?

    <p>BOST</p> Signup and view all the answers

    What distinguishes BOSTHSM1 from its predecessor BOSTHS?

    <p>Fitted with four additional springs</p> Signup and view all the answers

    What is the maximum speed allowed for BOSTHS wagons?

    <p>100 Kmph</p> Signup and view all the answers

    What type of adjuster is specified for the Brake Cylinder?

    <p>IRSA 750</p> Signup and view all the answers

    Which color was initially specified for painting the wagons before it was changed?

    <p>Red Oxide</p> Signup and view all the answers

    What feature allows BCN wagons to operate at CC+8+2t?

    <p>Modified suspension</p> Signup and view all the answers

    What modification was introduced in BOSTM1 compared to the original BOST design?

    <p>Additional inner springs</p> Signup and view all the answers

    What is the auxiliary reservoir capacity specified for the wagons?

    <p>75 liters</p> Signup and view all the answers

    What is the overall design feature that allows the wagons to achieve a low platform height?

    <p>Hybrid design of bogie frame and bolster</p> Signup and view all the answers

    What is the positioning of the coupler in the A car for coupling with a locomotive?

    <p>At 1105 mm from rail level</p> Signup and view all the answers

    Which construction aspect contributes to the rigidity of the wagon structure?

    <p>All welded construction</p> Signup and view all the answers

    How are the 'B' cars connected to each other and to the 'A' cars?

    <p>Using slackless drawbars</p> Signup and view all the answers

    What is the condemning size of the wheel specified for the wagon?

    <p>780 mm</p> Signup and view all the answers

    What type of braking system is implemented in the wagons?

    <p>Air brake system</p> Signup and view all the answers

    How many wagons are there in each flat unit configuration?

    <p>Five</p> Signup and view all the answers

    What is the height of containers that the wagons are designed to accommodate?

    <p>2896 mm</p> Signup and view all the answers

    What is the difference in length between the 'A' car and the 'B' car?

    <p>143 mm</p> Signup and view all the answers

    Where are the slackless drawbars located in the wagon configuration?

    <p>Between B cars and at both ends of A cars</p> Signup and view all the answers

    What modification was made to the BCNAHSM1 in 2006?

    <p>It was fitted with two additional inner springs.</p> Signup and view all the answers

    What is the maximum operational speed for the BCNAHS wagon?

    <p>100 Kmph</p> Signup and view all the answers

    How does the weight limit of the BCNA differ from that of BCNAHS?

    <p>BCNAHS is designed for a higher weight limit than BCNA.</p> Signup and view all the answers

    What differentiating feature is noted for the BCNHL wagon compared to previous types?

    <p>It has an increased width and height.</p> Signup and view all the answers

    Which feature is NOT associated with the BCNAHSM1 modification?

    <p>A higher payload capacity than BCNA.</p> Signup and view all the answers

    What is the impact of using stainless steel in the BCNHL wagon construction?

    <p>Improved quality and reduced tare weight.</p> Signup and view all the answers

    What is the unique aspect of the auxiliary reservoir in the BCNHL wagon?

    <p>It has a capacity of 75 litres.</p> Signup and view all the answers

    Which spring configuration is specified for the BCNA type wagon?

    <p>O-14, I-12, S-4</p> Signup and view all the answers

    What distinguishes the BCNA wagon from its variants?

    <p>A distinct yellow band indicating its maximum load.</p> Signup and view all the answers

    What structural change was made to the BCNA when designing the BCNHL?

    <p>Length reduced and width increased.</p> Signup and view all the answers

    Study Notes

    Box NCR Wagon

    • Similar to BOXN wagon, but body material is IRS M-44 steel instead of IS: 2062 Fe410CuWA or IRSM-41 steel.
    • Crib angles use IS: 50x50x6 IRSM-44 steel instead of IS: 2062 Fe 410 CuWA steel.
    • Sole bar is made of IRSM-41 steel instead of IS: 2062 Fe Cu WA steel.
    • Other features (dimensions, couplers, draft gear, brake gear, brake system) are the same as BOXN wagon.

    Maintenance and Repair

    • Maintenance schedule and repair procedures are similar to BOXN wagon.
    • Corroded body panels should be replaced with IRSM-44 steel panels, using either shearing or plasma cutting, not oxy-cutting. Refer to G-72 (latest version) for instructions.
    • Welding electrodes for repairs are listed in Table 10.1. (specific electrode types referenced in table)

    Electrodes for Welding

    • Table 10.1 lists material to be welded and matching electrodes/filler wires. e.g., IRS M-44 to IRS M-44 uses IRS class M1 with IS code E19. 9LR16 (by IS:2062/5986/1079).

    Precautions for Welding Stainless Steel

    • Use low welding currents with smaller gauge electrodes to minimize heat input and reduce distortion.
    • Clean surface of any dirt, oxide, oil, grease before welding.
    • Dry electrodes before use.
    • Use DC(+).
    • Lift electrode slowly and fill craters before breaking the arc.
    • Clean welds thoroughly after each bead.
    • Carry out welding in the flat position.
    • Correct electrode size, current, arc length, travel speed, and angle are required.
    • Avoid defects like cracks or blowholes.
    • Do not weld adjacent to the weld.
    • Employ correct welding sequence to reduce internal stress and distortion.
    • Weld towards the free ends of the structure.

    Surface Preparation and Painting

    • Surface preparation and painting schedule for underframes follows the standard specification G-72 (with latest amendments).
    • Degrease the wagon body using petroleum hydrocarbon solvent (IS:1745-1978 or equivalent).
    • Apply etch primer (IS:5666-1970), then two coats of ready-mixed paint (IS:2074-1992) for stainless steel. Specific DFTs are required.
    • For mild steel and corten steel use different processes and paints (See specifics in text).

    Bogie Low Platform Container Flats (BLC)

    • Design for transporting 2896 mm high ISO containers at 100 km/h.
    • Low platform height ensures the wagons fit within X-class MMD constraints.
    • Units of five wagons (2 A-cars at ends, 3 B-cars in between) with slackless drawbars for coupling. Specific dimensions (length, coupler locations) are given.
    • Employ air brakes.

    Load Distribution

    • Weight distribution is optimized to prevent hunting (oscillations) across the side bearers during operation.
    • 90% of the body weight is supported by side-bearers.
    • 10% is borne by the center pivot.

    Maintenance Schedules

    • Short duration check-ups (B-schedule) every three months. Include intensive examination, draining all collectors and cocks, and air brake system testing, per manufacturer's specs.
    • Moderate duration check-ups (C-schedule) every six months. Include all items from B-schedule along with load sensing device adjustments and air brake tests.

    Brake System

    • Conforms to RDSO specifications 02-ABR-02 with latest amendments.
    • Uses "Automatic, two-stage empty/load braking control" using a distributor valve type (C3W2/KE2CSLA) and change-over valves (VTA/Single Piece Load Sensing device).

    Automatic Twist Locks (ATL)

    • Compacting container locating and securing mechanism.
    • Meets AAR M-952 specifications. (force requirements given)
    • Employ steel springs instead of rubber bonded torsion springs for improved reliability.

    Broad Gauge Bogie Container Flat Wagon (BLLA & BLLB)

    • All-welded steel construction, suitable for 20-foot or 40-foot ISO containers.
    • Low floor height to ensure proper positioning and movement within current standards.
    • Specific dimensions, axle loads, and safety measures are detailed.
    • Incorporates pneumatic load sensing devices for precise brake function adjustments.

    Other Wagon Types

    • Numerous other wagon types (e.g., Double Decker, Covered, etc.) are described with detailed specifications, including materials, dimensions, and operating speeds.

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    Related Documents

    CnW Maintenance Manual-452-464 PDF

    Description

    This quiz covers the specifications, maintenance, and repair procedures of the Box NCR wagon, highlighting differences from the BOXN wagon. Focus is placed on the materials used for construction and repairs, as well as welding electrodes required for various applications. Ensure to refer to the relevant tables and guidelines for precise procedures.

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