Maintenance and Warranty for Wagons
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Questions and Answers

What is the warranty period for newly built wagons?

  • 24 months (correct)
  • 36 months
  • 18 months
  • 12 months

What must newly built wagons display for warranty identification?

  • Inspection results
  • Warranty legend (correct)
  • Vendor details
  • Maintenance schedule

Who is responsible for inspecting newly built wagons during the warranty period?

  • Engineering staff
  • Vendor's quality control
  • Train Crew
  • Representative of C&W (correct)

Which category of defects can result in charges against the wagon builder during the warranty period?

<p>Use of inferior material (C)</p> Signup and view all the answers

What should be done with newly built wagons that are due for warranty inspection?

<p>Detach them from the train and send to the sick line (C)</p> Signup and view all the answers

Which of the following is NOT a fault that can be rectified at the expense of the wagon builder?

<p>Lack of regular maintenance (A)</p> Signup and view all the answers

What information is NOT included in the warranty legend stenciled on the wagons?

<p>Previous usage record (B)</p> Signup and view all the answers

Which type of defect is not attributed to improper manufacturing or fitting?

<p>Corrosion from improper painting (B)</p> Signup and view all the answers

What is a feature of roller bearing defects per the inspection guidelines?

<p>The entire wheel assembly must be sent to the workshop for inspection. (B)</p> Signup and view all the answers

Which welding defect is specifically mentioned in the inspection manual?

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

Which manufacturing or fitting defect involves the shape of rivet heads?

<p>Badly formed rivet heads (B)</p> Signup and view all the answers

What type of failure is indicated by the breakage of the DV/brake cylinder?

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

What constitutes improper protection in wagon maintenance?

<p>Corrosion due to inadequate paint application (C)</p> Signup and view all the answers

Which defect is directly related to improper assembling processes?

<p>Pin tail of lock bolt not removed (B)</p> Signup and view all the answers

Which defect is associated with train pipe leakage?

<p>Unsatisfactory working of brake cylinders (B)</p> Signup and view all the answers

What type of defect would require the workshop in-charge to report to the roller bearing manufacturer?

<p>Defects in the wheel assembly requiring inspection (A)</p> Signup and view all the answers

What is the codal life for a bogie tank wagon with air brake and CASNUB bogie?

<p>40 Years (D)</p> Signup and view all the answers

Which officer is NOT involved in the condemnation process of over-age wagons?

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

What condition must be met for the condemnation of under-age wagons?

<p>They must receive finance concurrence. (A)</p> Signup and view all the answers

What is the process for handling condemned wagons once they are approved?

<p>They can be moved 'as is where is'. (A)</p> Signup and view all the answers

What must be included when reporting defects attributable to the manufacturer?

<p>The location of the defect (B)</p> Signup and view all the answers

What is the maximum service life stipulated for open bogie wagons with air brake and CASNUB bogie?

<p>30 Years (D)</p> Signup and view all the answers

What is the primary focus during the warranty inspection of BTPN wagons?

<p>Internal and external examination of the barrel (B)</p> Signup and view all the answers

Which detail is NOT required to be reported for warranty inspections?

<p>Total weight of the wagon (A)</p> Signup and view all the answers

Where should materials be sent in case of a material failure?

<p>To the Chemist and Metallurgist of the respective Railways (C)</p> Signup and view all the answers

What kind of defects are supposed to be clearly indicated as attributable to the manufacturer?

<p>Defects resulting from manufacturing errors (C)</p> Signup and view all the answers

Which document contains guidance for examining cradles and anchoring rivets?

<p>Technical pamphlet No.G-90 (A)</p> Signup and view all the answers

What is the significance of the Contract Number during reporting?

<p>It indicates the order under which the wagon was manufactured (D)</p> Signup and view all the answers

What should be recorded in the forwarding memo when sending materials for testing?

<p>Particulars of the wagon including the wagon number (A)</p> Signup and view all the answers

Which type of failure is NOT emphasized during the warranty inspections of BTPN wagons?

<p>Failure of heating elements (A)</p> Signup and view all the answers

Which of the following is NOT a required part of warranty inspection?

<p>History of prior wagon inspections (A)</p> Signup and view all the answers

What must the train examining staff ensure before issuing a fit certificate?

<p>Percentage of brake power is satisfactory (C)</p> Signup and view all the answers

At what maximum speed can goods wagons be attached to a passenger train?

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

What must be recorded on the brake certificate prior to train departure?

<p>Level of air pressure and percentage of effective brake cylinders (A)</p> Signup and view all the answers

What must be specially checked for wagons that have been humped?

<p>Damage due to impacts during humping (B)</p> Signup and view all the answers

Which of the following is NOT a requirement for wagons attached to a passenger train?

<p>Wheels with star marks on journal cap (C)</p> Signup and view all the answers

What is the intent of conducting an intensive examination of goods stock?

<p>To raise the fitness standard of rolling stock (A)</p> Signup and view all the answers

What is required for wagons to avoid being overdue for POH/ROH?

<p>Adherence to maintenance schedules (C)</p> Signup and view all the answers

Who must countersign the brake certificate before a train departs?

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

What is included in the pattern of train examination for terminating loads?

<p>Zonal Railway guidelines and inspection protocols (C)</p> Signup and view all the answers

Before the dispatch of the train, what must be checked regarding the wagons?

<p>Defects that are not rejectable (D)</p> Signup and view all the answers

What is the axle load for the BOXNEL / BOYEL wagons?

<p>25 t (C)</p> Signup and view all the answers

Which of the following wagon types has a service life of 6 years according to the first column?

<p>BTPGLN (B), BOXNHL (D)</p> Signup and view all the answers

Identify the wagon type with the shortest service life listed in the first column.

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

What is the indicated service life for BRSTN and BWTB wagons?

<p>6 years (B)</p> Signup and view all the answers

Which wagon type is associated with a service life of 4.5 years in the subsequent use column?

<p>BOXNHA (B), BOSTHSM2 (D)</p> Signup and view all the answers

What is the primary reason for marking an empty wagon as sick for POH up to 30 days in advance?

<p>Preventive maintenance protocol (C)</p> Signup and view all the answers

Identify which of the following wagon types displays a warranty life of 4.5 years.

<p>BRN22.9 (B), BCN (D)</p> Signup and view all the answers

What is the required action for the Pedestal Crown Sides if the dimension is less than 147 mm?

<p>Renew by welding (B)</p> Signup and view all the answers

What thickness actions are required for components if the dimension exceeds 321 mm?

<p>Provide liners with suitable thickness (C)</p> Signup and view all the answers

Which component requires its vertical side to be renewed by welding if the wear exceeds 4 mm?

<p>Vertical Side 22 W (C)</p> Signup and view all the answers

When should liners be provided for the Pedestal Jaw 22 WM?

<p>If dimension is greater than 283 mm (B)</p> Signup and view all the answers

What is the action required if the slope surface wear of the wedge is measured at 3 mm?

<p>Replace the wedge (B)</p> Signup and view all the answers

What information must the representative of C&W ensure is included on the warranty report?

<p>The designation and reporting station (D)</p> Signup and view all the answers

Which addresses should a warranty report for a wagon built by a private manufacturer be sent to?

<p>Wagon builder, Railway Board, CME of inspecting zonal railway, Sr.D.M.E. (D)</p> Signup and view all the answers

What is the role of the Senior Divisional Mechanical Engineer in the warranty inspection process?

<p>To send the warranty inspection report without delay (D)</p> Signup and view all the answers

What happens if a wagon builder returns the warranty inspection report?

<p>The situation is reported to the Railway Board immediately. (D)</p> Signup and view all the answers

What types of files and registers must the Train Examining Depot maintain?

<p>All policy instructions related to warranty inspections received from various offices (B)</p> Signup and view all the answers

What must be included in the forwarding memo when sending materials for testing?

<p>Details of the wagon and reason for testing (C)</p> Signup and view all the answers

Who are the parties that receive warranty reports for wagons built by railway workshops?

<p>Workshop, CME of the manufacturing Railway, and Railway Board Secretary (A)</p> Signup and view all the answers

What is the responsibility of the representative of C&W regarding the warranty report submission date?

<p>Ensure it is recorded in the warranty report (D)</p> Signup and view all the answers

What is emphasized for the inspection of wagons built by railway workshops regarding report submission?

<p>Reports must be sent without any delay after inspection (D)</p> Signup and view all the answers

Which repair should be performed at the sick line when patching the side wall is needed?

<p>Apply top coat after cleaning the area (D)</p> Signup and view all the answers

Which of the following areas requires attention under Intensive repairs?

<p>Scraping the sole bar at doorways (D)</p> Signup and view all the answers

What type of repair is indicated for side doors according to the work areas table?

<p>Check damage, repair, and clean (A)</p> Signup and view all the answers

Which repair task is NOT included as a part of Sick line activities?

<p>Scraping the portion of the sole bar (A)</p> Signup and view all the answers

What should be checked and repaired on the side pillars during the maintenance work?

<p>Cracks at the base (B)</p> Signup and view all the answers

Which repair task applies to both ROH and POH work areas?

<p>Patching of body, roof, and floor plates (B)</p> Signup and view all the answers

Which of these actions is necessary for ensuring the water-tightness of covered wagons?

<p>Patching rusty roof plates and applying sealant (C)</p> Signup and view all the answers

For which of the following tasks is primer paint explicitly required?

<p>Applying on patched areas of the skirting (B)</p> Signup and view all the answers

What is required for intensive repair work on the underframe of a wagon?

<p>Cleaning, scraping, and applying primer paint (C)</p> Signup and view all the answers

What is the primary consideration when checking side walls for corrosion?

<p>Patch and then apply primer and top coat (B)</p> Signup and view all the answers

What must the train examining staff verify regarding the wagons before issuing a fit certificate?

<p>Wagons must be in fit condition without rejectable defects. (A)</p> Signup and view all the answers

What is the primary requirement for goods wagons to be attached to a passenger train?

<p>They should meet the maximum speed limit of 100 Kmph. (A)</p> Signup and view all the answers

When recording the air pressure on the engine and brake van, who needs to countersign the brake certificate?

<p>The driver and guard. (A)</p> Signup and view all the answers

What condition makes wagons unacceptable for service if they appear on the inspection checklist?

<p>Wagons having overdue POH/ROH. (D)</p> Signup and view all the answers

What is the main objective of performing an intensive examination of goods stock?

<p>To raise the general standard of fitness of rolling stock. (A)</p> Signup and view all the answers

What aspect should be particularly checked for wagons that have been humped?

<p>Damage occurring due to impacts during humping. (D)</p> Signup and view all the answers

What is NOT a required condition for wagons to run attached to a passenger train?

<p>Wagon must have a clear cosmetic inspection. (A)</p> Signup and view all the answers

What certification is required by the station master prior to the train's departure?

<p>A certification from Sr.SE/JE(C&amp;W) regarding wagon fitness. (A)</p> Signup and view all the answers

Which component's effectiveness must be recorded according to guidelines before the train departs?

<p>The percentage of effective brake cylinders. (C)</p> Signup and view all the answers

Flashcards

Warranty Period of New Wagons

All newly built wagons have a warranty period of 24 months, or as specified in the purchase contract.

Warranty Defects

Defects due to inferior materials, poor workmanship, imperfect protection, or other contractor faults during the warranty period, are covered by the contract.

Wagon Inspection Procedure

A systematic inspection of new wagons to identify defects within the warranty period, performed by C&W representatives to retrieve warranty charges.

Warranty Legend

A stencilled marking on new wagons containing contract number, commissioning date, commissioning authority, and inspection date.

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Wagon Inspection Location

Wagons due for warranty inspections are preferably detached from the train and sent to sick lines for systematic checking.

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Warranty Legend Details

Wagon warranty details include contract number, commissioning date, commissioning authority, and inspection schedule.

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POH and ROH Intervals

Prescribed intervals for Periodic Overhaul (POH) and Routine Overhaul (ROH) of wagons are provided in tables 2.1, 2.2 & 2.3

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Warranty Defect

A defect caused by manufacturer's fault, including materials, workmanship, or protection

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Welding Defects

Problems in welding, e.g., unequal weld lengths, porosity, or lack of fusion.

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Riveting/Bolting Defects

Issues with rivets or lock bolts, like looseness, bad heads or improper hole filling.

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Manufacturing/Fitting Defects

Problems in how parts were made or assembled.

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Material Failure

Breakage of components due to poor material quality.

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Improper Protection

Lack of proper coating or protection leading to corrosion or water damage.

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Train Pipe Leakage

Problems with the train's pipe system causing leaks.

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Roller Bearing Defect

Problems with roller bearings, often needing a complete wheel assembly replacement.

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Major Sick Lines

Wagons diagnosed to have problems that may require detailed inspection in a specialized workshop.

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Wagon Warranty Inspection

A procedure to check new wagons for defects attributable to the manufacturer during a specific time period. It focuses on internal/external examinations in certain cases.

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Defect Reporting

A systematic way to record any issue found during warranty inspection, emphasizing the location and cause of the defect. Specific materials are submitted for chemist/metallurgist analysis.

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Contract No.

The unique number assigned for a wagon building order placed by the Railway Board on the builder.

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Wagon Number

Identifying number of the wagon.

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Wagon Code

A special code to identify the type of wagon.

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Owning Railway

The railway company responsible for the wagon.

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Special Examination

Additional visual checks for internal and external barrel defects, including joints, laminations, cracks, leakage and cradle/rivets.

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Material Failure Report

If a material issue is found in a wagon part, send sample to the railway's chemist and metallurgist for analysis and report.

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Warranty Inspection Report

A document detailing all issues found during inspection of the wagon. Includes relevant identifiers like wagon number and contract number.

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Forwarding Memo

A document that accompanies the defective material(s) that are sent to the chemist and metallurgist, containing crucial information about the wagon, report, and the contract.

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Wagon Condemnation

The process to determine whether a wagon is no longer usable and should be retired.

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Over-age Wagon Condemnation

Condemning wagons that are older than their designated lifespan, as per guidelines.

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Under-age Wagon Condemnation

Condemning wagons that are not old enough, but are damaged.

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Codal Life of Wagon

The estimated lifespan of different wagon types defined by regulations.

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Premature Condemnation

Condemning wagons before their estimated lifespan due to significant damage or issues.

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Terminating Load Examination

Examination of train loads to ensure wagons meet standards before departure following Zonal Railway and Railway Board guidelines.

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Wagon Fit Condition

Wagons must be in good working order, free from defects that prevent safe operation.

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Brake Power Percentage

Ensuring a specific brake power level in wagons before dispatch.

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Humped Wagon Check

Extra scrutiny for wagons that have been humped to identify damage from the impact.

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Passenger Train Wagon Attachment

Goods wagons can be attached to passenger trains if maximum speed does not exceed 100 km/h and certain conditions are met.

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Operative Brake Cylinders

All brake cylinders must be functional on the wagon.

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Wagon Overload/Uneven Loading

Wagons must not be overloaded or loaded unevenly for safe transport.

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Wheel Journal Cap Star Marks

Ensuring wheels do not have star marks on journal caps to guarantee safe operation.

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POH/ROH Overdue Wagons

Wagons must not be past their scheduled Periodic Overhaul (POH) or Routine Overhaul (ROH) maintenance.

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Intensive Examination Purpose

Intensive examination improves the fitness of rolling stock to allow for longer runs on through trains by focusing on defects.

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BOXN wagon type

A type of wagon, likely a boxcar, with specific maintenance requirements.

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POH due date

The date by which a wagon needs a Periodic Overhaul (major repair).

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Empty wagon sick leave

An empty wagon can be marked 'sick' for repair up to 30 days before its POH due date.

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BCN wagon type

Another type of wagon, likely needing regular maintenance (POH).

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BOST wagon type

Specific type of wagon with a particular maintenance schedule.

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Wagon maintenance schedule

A set of planned maintenance intervals (POH, etc.) based on wagon type and use.

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Stainless steel wagons

A wagon body type made of stainless steel, requiring specific maintenance.

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Warranty Inspection Report

Document detailing wagon inspection issues; includes wagon number, contract number etc..

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Wagon Inspection Procedure

Step-by-step process to check wagons for defects.

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Disposal of Proforma

Process for sending warranty reports based on manufacturer, (railway workshop or private).

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Warranty Report Submission

Reporting the wagon warranty inspection result.

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C&W Representative

Individual representing the company or organization responsible for checking wagon warranty.

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Railway Board

Organization that finalizes the warranty claims and handles builder disagreements.

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Senior Divisional Mechanical Engineer

Engineer responsible for sending the warranty inspection report promptly.

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Policy Instructions on Warranty Inspection

Guidelines received from divisional office/CME pertaining to the inspection process.

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Maintenance of Records

The storing of policies and instructions on wagon inspection

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Terminating Load Examination

Checking train loads to ensure wagons meet safety standards before departure, following Zonal Railway and Railway Board guidelines.

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Wagon Fit Condition

Wagons must be in good working order without any defects that would prevent safe operation.

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Brake Power Percentage

Ensuring a specific level of brake power in wagons before dispatch.

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Humped Wagon Check

Extra examination for wagons that have been humped to identify any damage from the impact.

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Passenger Train Wagon Attachment

Goods wagons can be attached to passenger trains if the maximum train speed is below 100 km/h and specific conditions are met.

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Operative Brake Cylinders

All brake cylinders on the wagon must be functional.

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Wagon Overload/Uneven Loading

Wagons must not be overloaded or loaded unevenly for safe transport.

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Wheel Journal Cap Star Marks

Ensuring that wagons' wheels do not have star marks on their journal caps, which can affect safe operation.

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POH/ROH Overdue Wagons

Wagons must not be past their scheduled Periodic Overhaul (POH) or Routine Overhaul (ROH) maintenance.

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Intensive Examination Purpose

Intensive examination enhances the fitness of rolling stock to allow longer through train runs by scrutinizing for defects during dispatch from origin.

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Key Seat Wear Limit

The maximum amount of wear allowed on a key seat before replacement is required.

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Crown Roof Liner Requirement

If the dimension of a crown roof exceeds a certain size (276mm or 321mm), liners are necessary to meet certain standards.

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Pedestal Jaw Liners

For pedestal jaws over certain dimensions (275mm, 283mm, 195mm, 241mm), liners are required based on specified standards.

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Wedge Slope Wear Limit

A wear threshold of 3mm on the slope surface of a wedge requires replacement.

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Vertical Surface Wear Limit

The vertical surface of the spigot has a 54mm wear limitation from the center line. Repair may be by welding.

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Sickline Repairs

Activities performed on wagons in a sickline based on need, not every wagon needs these repairs.

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Body Repair Work

Repairs like patching side walls, doors, and frame parts, ensuring watertightness.

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ROH Repairs

Repairs done as part of Routine Overhaul (inspections).

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POH Repairs

Repairs performed during Periodic Overhaul (intensive inspections).

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Sole Bar Repairs

Scrap and repainting of parts of the wagon's sole bar at doorways.

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Skirting Repairs

Checking and patching corroded skirting panels on wagons.

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Door Fastening Repairs

Repair and replacement of door mechanisms like pins and bolts.

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Wagon Watertightness

Making covered wagons water resistant by various means.

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Sickline

Designated work area for wagon repairs and inspections based on need.

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Work Areas

Locations assigned for detailed wagon inspection and repair that are categorized based on type of repairs.

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Study Notes

Maintenance, Warranty, and Condemnation

  • This chapter provides general information on the frequency of various inspections and maintenance schedules for goods stock on active routes.
  • Prescribed periods for POH (Periodic Overhaul) are outlined for different types of stock. Detailed repair practices during POH are covered in separate chapters.
  • A table at the end of the chapter summarizes the prescribed intervals for POH and ROH (Routine Overhaul) of wagons.

Warranty Inspection of Newly Built Wagons

  • Warranty period for newly built wagons is 24 months, or as specified in the purchase contract.
  • Manufacturing defects, including inferior materials, poor workmanship, inadequate protection, and other constructional faults, are covered under warranty.
  • A systematic inspection process is outlined to identify warranty-related defects. Wagons must have a warranty legend attached. The legend displays the contract number, commissioning date, commissioning entity, and inspection due/completion dates and the inspecting entity.
  • Wagons flagged for warranty inspection should be temporarily removed from the train and sent to a designated sick line for thorough inspection.
  • Only defects attributable to the manufacturer (material, workmanship, protection, or other faults) are considered.

Reporting Method

  • Detailed reporting requirements are outlined for warranty inspection reports, including specific information fields (contract number, wagon number, ownership, manufacturing date, inspection dates, and type of defect).
  • All reports must include a serial number.
  • For material failures, reports should be forwarded to the appropriate chemist/metallurgist for detailed test reports.
  • Reports must be sent within 20 days of inspection to concerned authorities. A "Nil" report should be filed if no defects are found that are attributable to the manufacturer.

Estimated Cost of Rectification

  • No cost estimates for rectification should be included in warranty inspection reports.
  • Costs will be communicated by the appropriate party from the Railway Board.
  • A written certificate must be included if the defect is due to material/workmanship/protection issues by a contractor.

Maintenance and Records

  • A designated file should contain policies, instructions, and intermediate/final inspection documents. An index sheet should track all instructions.
  • A separate file should hold all inspection reports.
  • A register should maintain data of wagons inspected during the warranty period (date of inspection, wagon number, owner, wagon code, builder name, commissioning date, observed defects, warranty report number and date, and remarks).

Examination and Maintenance Periodicity

  • Rolling-in examination must be performed on all terminating trains at stations where a train examining depot exists. Axles examination should be conducted after the train stops.
  • A terminating train's load examination will occur as soon as the train stops
  • Staff must verify that wagons are fit before train departure. (brake power, level of air pressure, etc)
  • Ensure damaged wagons due to impacts during humping are reviewed.

ROH of Air Brake Wagon

  • Routine Overhaul (ROH) should be performed at designated wagon depots.
  • The procedures for the ROH depend on the type of wagon (e.g., bogie, tank).
  • Detailed steps for disassembling, inspecting, and repairing various components are listed.

Wagon Condemnation

  • Rolling stock can be condemned by authorized staff using relevant procedures.
  • There are different types of wagons with different operational ages. A schedule outlining the codes, types and time in service are provided.
  • A list of procedures and criteria is provided for under- or over-aged wagon condemnations. Specific instructions are noted, depending on the type of wagon (air brakes, bogies, tankers, etc.)

Work areas (where attention must be given)

  • A table listing various work areas (e.g., body repairs, gear repairs) and corresponding inspection requirements.
  • Specific types of work are specified, and their associated locations/frequencies (e.g., inspection of hinges, bolts, wheels, etc.).

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CnW Maintenance Manual - 70-90 PDF

Description

This quiz covers key aspects of maintenance schedules and warranty inspections for newly built wagons. It includes information on periodic overhauls and systematic inspection processes to identify manufacturing defects. Ensure you understand the importance of these protocols in maintaining the quality and safety of goods stock on active routes.

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