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 (A)</p> Signup and view all the answers

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

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

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

<p>IRSM-44 steel (B)</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 (B)</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 (A)</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. (D)</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. (D)</p> Signup and view all the answers

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

<p>IRSM-41 (C)</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 (A)</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 (D)</p> Signup and view all the answers

What is the purpose of degreasing the wagon body?

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

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

<p>61 tons (A)</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 (D)</p> Signup and view all the answers

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

<p>100 km/h (B)</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 (A)</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 (B)</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 (D)</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 (D)</p> Signup and view all the answers

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

<p>Every 3 months (C)</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) (D)</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 (C)</p> Signup and view all the answers

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

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

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

<p>Defective or damaged elastomeric pads (D)</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 (A)</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. (B)</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. (A)</p> Signup and view all the answers

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

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

What type of steel is used for constructing the wagon?

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

What is the maximum operating speed of the wagon?

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

How many wagons are designed to work in a unit?

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

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

<p>61.0 tonnes (C)</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 (A)</p> Signup and view all the answers

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

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

What specification does the bogie adhere to?

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

What component is used to secure containers during movement?

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

What type of braking system is employed in the wagon?

<p>Graduated release air brake system (D)</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. (B)</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. (B)</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. (A)</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. (A)</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. (C)</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. (D)</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 (C)</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. (A)</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. (A)</p> Signup and view all the answers

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

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

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

<p>BOST (C)</p> Signup and view all the answers

What distinguishes BOSTHSM1 from its predecessor BOSTHS?

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

What is the maximum speed allowed for BOSTHS wagons?

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

What type of adjuster is specified for the Brake Cylinder?

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

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

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

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

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

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

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

What is the auxiliary reservoir capacity specified for the wagons?

<p>75 liters (C)</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 (C)</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 (A)</p> Signup and view all the answers

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

<p>All welded construction (B)</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 (D)</p> Signup and view all the answers

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

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

What type of braking system is implemented in the wagons?

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

How many wagons are there in each flat unit configuration?

<p>Five (C)</p> Signup and view all the answers

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

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

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

<p>143 mm (D)</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 (B)</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. (A)</p> Signup and view all the answers

What is the maximum operational speed for the BCNAHS wagon?

<p>100 Kmph (D)</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. (D)</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. (D)</p> Signup and view all the answers

Which feature is NOT associated with the BCNAHSM1 modification?

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

Which spring configuration is specified for the BCNA type wagon?

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

What distinguishes the BCNA wagon from its variants?

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

Flashcards

BOXNCR Wagon

A type of open wagon similar to a BOXN wagon, but the body is made of specific steel grades (like IRS M-44).

Steel Grade IRS M-44

A specific steel type used for the body of a BOXNCR wagon.

Maintenance Schedule

A set of planned activities to keep a wagon in good operational condition.

Replacement of Corroded Panels

If panels of a BOXNCR wagon corrode, they must be replaced with matching panels of the same steel grade (IRS M-44).

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Welding Electrodes

Specific welding electrodes are required for repairing BOXNCR wagon components, determined by the steel types being joined.

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Maintenance Procedures BOXN vs BOXNCR

Maintenance schedules and repair procedures for BOXN and BOXNCR wagons are almost identical—but materials and methods MUST match the specific steel grade (for BOXNCR).

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Plasma/Shearing Cutting Methods

BOXNCR wagon metal parts MUST be cut using either a shearing machine or a plasma cutting machine, without oxy-cutting.

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Wagon Surface Prep (Underframe)

Follows standard specification G-72 with amendments for underframe wagon preparation.

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Degreasing Method

Use petroleum hydrocarbon solvent (low aromatic grade) or other degreaser to clean wagon surfaces for painting.

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Stainless Steel Primer

Apply a thin coat of etch primer (IS:5666-1970) before painting stainless steel.

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Stainless Steel Paint Coats

Two coats of IS:2074-1992 ready-mixed (red oxide zinc chrome) air-drying paint plus two coats of IS:123-1962(red oxide) semi-gloss paint for stainless steel.

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Mild/Corten Steel Prep

Remove rust, dust, and mill scale from mild/Corten steel surfaces using manual methods (scraping, chipping, wire brushing).

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Mild/Corten Steel Primer

Apply two coats of IS:102-1962 red lead priming paint to mild/Corten steel.

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Mild/Corten Steel Finish Paint

Two coats of IS:123-1962 red oxide semi-gloss paint completes the painting of mild/Corten steel.

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Bogies, Couplers, Air Brakes

Paint bogies, couplers, and air brake equipment following General Standard Specification No.G-72 (Rev.1).

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BLC Wagon Design

Designed for carrying 2896mm high ISO containers (Series I) with a 61t payload and 100km/h speed capacity.

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Coupling Type

A connection between railway cars, featuring a raised end and a slack-free drawbar.

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Brake System

A system using both air brakes and hand screws for controlling wagon movement

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Wheel Diameter

Wagon wheels are 840 mm new and 780 mm when fully worn.

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Load Distribution (Tare)

90% of a wagon's weight in an empty state (tare) is supported by side bearers.

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Hunting

Unwanted rocking or swaying motion during wagon movement.

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B Schedule Maintenance

Every 3 months, check all components, drain dirt collectors, drain cocks and test the air brake system.

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C Schedule Maintenance

Every 6 months, complete all 'B' schedule items. Also verify Load Sensing Device (VTA) distance and brakes according to manufacturer's instructions.

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VTA Load Sensing Device

A device that detects load and adjusts braking parameters for different situations.

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Air Brake System

Conforms with RDSO specifications for graduated release, single-pipe, and automatic braking control.

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Graduated Release

A braking system where the braking force is applied gradually and depend on load status.

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Bogie Tests

The contractor must ensure all tests on the bogie are performed as per the STR (Schedule of Technical Requirements).

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Elastomeric Pad Spec.

Elastomeric pads between bearing adapter and side frame crown must adhere to RDSO Specification WD-30-Misc-99 (latest revision).

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Wheel Assembly Conformity

Wheel and axle assemblies must meet requirements specified in Drg.No.CONTR-9404-S/12 and RDSO specification R-19/93 Pt I.

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Brake Shoe Type

Low friction composition brake shoes (L-type) to Drg.No.CONTR-9404-S/11 and conforming to Specification WD-13-ABR-2003 must be used for tread braking.

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Cartridge Bearing Type

Cartridge taper roller bearings of AAR 'E' type, suitable for 6"x11" journals, per RDSO STR AB-RB-39-2002 Rev.2 or latest specification, shall be used.

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Broad Gauge Bogie

A type of wagon bogie used for transporting containers on broad gauge railways.

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Steel Construction

The Broad Gauge Bogie container wagons are made completely of welded steel.

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ISO Containers

Standard containers, typically 20 or 40 feet long used for international transport.

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Maximum Axle Load

The highest weight a wagon's axle can bear without damage.

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Pay Load

The maximum weight of cargo a wagon can carry.

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Operating Speed

The maximum speed at which a wagon can safely travel.

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Minimum Curvature

The smallest radius of a turn a wagon can navigate without derailing.

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Cast Steel Bogies

Bogies made of cast steel, offering strength and durability.

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Draw Bars

Connecting parts for hitching and unhitching wagons in a train.

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Air Brake System

A braking system using compressed air to slow down or stop a wagon set.

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BOXN Wagon Capacity Increase

The carrying capacity of the BOXN wagon was increased by 6 tonnes, with nine stanchions instead of six.

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BOXNHA Axle Load

The BOXNHA wagon was designed for a maximum axle load of 23.5 tonnes/22.1 tonnes.

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BOXNLW Pay to Take Ratio

The BOXNLW wagon was designed to optimize the pay to take ratio in 1988.

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BOXNLWM1 Centre Sill Strengthening

The BOXNLWM1 wagon's centre sill was reinforced with extra plates in 2008 for enhanced capacity.

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BOXNHL Dimensions

The BOXNHL wagon is 250mm longer, 76mm higher, and 50mm wider compared to a BOXN wagon. Its maximum axle load is 22.9 tonnes.

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Wagon Speed Limits

Different wagon types (BOXNHA, BOXNLW, BOXNLWM1, BOXNHL) have various speed limits depending on the load (CC+6+2t and CC+8+2t).

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Serial Production Constraints

The BOXN design faced obstacles with other equipment (tipplers) which prevented full-scale production.

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Tare Weight Improvement

Reducing the empty weight of a wagon.

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Lock Bolts vs. Rivets

Using lock bolts for connecting wagon parts instead of rivets.

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BOST Wagon Design Year

BOST wagons were designed in 2000 for long steel products.

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BOSTHS Wagon Addition

BOSTHS wagon has additional springs for higher axle load (A/L).

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BOSTHS Modified Suspension

BOSTHS wagons were modified to operate with an increased axle load and different suspension configurations.

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Wagon Painting Color Change

Wagon painting color changed from red oxide to Phiroziblue.

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BOSTM1 Additional Springs

The BOSTM1 wagon has additional inner springs for a specific axle load (A/L).

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Wagon Speed Limits

Various wagon models have different maximum operating speeds.

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BCNM1 Modification

BCNM1 wagon has a modified suspension with additional springs to support higher axle loads.

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Wagon in Loaded Condition

When both bogies are carrying containers, the load sensing valves (VTA valves/Single piece LSDs) are activated. This activates the C3W2 or KE2CSLA Distributor valve, generating a higher brake cylinder pressure during braking.

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Wagon in Empty Condition

When a wagon is empty, the load sensing valves aren't activated, the compressed air is routed to atmosphere and the brake system is maintained in empty-load configuration.

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VTA Valve/Single-piece LSD

A load-sensing valve that detects load and sends pressure signals, in case of loaded bogies, which dictate brake pressure adjustment.

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C3W2/KE2CSLA Distributor Valve

A valve that receives signals from the load-sensing valves and adjusts the brake cylinder pressure to the appropriate level for the load condition.

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Double Check Valve

A valve that prevents air pressure from leaking/flowing through in one direction only, crucial in maintaining proper pressure levels across the system.

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BCNAM1 Wagon

A type of wagon, modified in 2006, by adding springs to the suspension of BCNA wagon, designed for operation up to CC+8+2t

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BCNAHS Wagon

A variant of BCNA wagon, featuring a Casnub 22HS bogie, designed for increased speed and Golden Yellow band.

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BCNAHSM1 Wagon

2006 modified version of BCNAHS wagon by adding additional inner springs and Golden Yellow band for operation up to CC+8+2t,.

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BCNHL Wagon

2006 wagon design for bagged commodities, reduced length, increased width and height compared BCNA with increased wagon count/rake.

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Wagon Speed Limit CC+6+2t

Specifies the speed limit for wagons carrying a CC+6+2t load.

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Wagon Speed Limit CC+8+2t

The maximum speed allowed for wagons carrying a CC+8+2t load.

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Golden Yellow Band

A distinguishing mark on specific wagon types indicating modifications and specific axle load (A/L) specification.

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Additional Springs

Extra springs added to a wagon's suspension system for improved load carrying capacity and stability.

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Casnub 22HS Bogie

A specific type of bogie used on some railway wagons, designed for increased operating speed.

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Axle Load (A/L)

The maximum weight a wagon axle can support, critical for railway maintenance and operations.

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Wagon Platform Height

The height of the wagon platform, crucial for carrying 2896 mm containers within the specified class.

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Hybrid Design (Bogies)

A combination of bogie frame and bolster design used to create a low platform height for the wagons.

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Wheel Diameter (Wagons)

The size of the wagon wheels, specifically 840 mm new, and 780 mm when worn.

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All Welded Construction

The wagon frame is entirely constructed using welding techniques, for strength.

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Cast Steel Bogies

The wagon's support structure made from cast steel, offering durability.

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5-Wagon Unit

Wagons are grouped into units of five, with end and intermediate cars.

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A & B Cars

The five-wagon unit comprises two 'A' cars at the ends and three intermediate 'B' cars.

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Centre Buffer Couplers

Couplers at the end of 'A' cars for attaching to the locomotive.

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Slackless Drawbars

Drawbars minimizing slack between cars for smoother coupling.

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Air Brake System

A mechanical brake system using compressed air for stopping wagons.

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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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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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NCR Cuisine Quiz
24 questions

NCR Cuisine Quiz

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ProsperousSagacity6799
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