Podcast
Questions and Answers
What components connect the ends of a wagon with its sides?
What components connect the ends of a wagon with its sides?
- Ventilators
- Corner angles (correct)
- Top copings
- Side panels
What is the purpose of the anti bleeding device found in flap doors?
What is the purpose of the anti bleeding device found in flap doors?
- To enhance ventilation
- To facilitate manual unloading
- To prevent spillage (correct)
- To strengthen the door structure
Which components are included in the construction of the ends of the wagon?
Which components are included in the construction of the ends of the wagon?
- Swing doors and label holders
- End panels and stanchions (correct)
- Roof sheets and carlines
- Retractable anchoring locks
What type of doors are commonly used for unloading in wagons?
What type of doors are commonly used for unloading in wagons?
What type of wagons have fixed or flexible ends and no side walls?
What type of wagons have fixed or flexible ends and no side walls?
Which features do hopper wagons include in terms of their construction?
Which features do hopper wagons include in terms of their construction?
In a covered wagon, what is used to enhance the roof's integrity?
In a covered wagon, what is used to enhance the roof's integrity?
What was the purpose of the retro fitment advised by Zonal Railways?
What was the purpose of the retro fitment advised by Zonal Railways?
Which door design was determined to have performed with the least field problems in the trial?
Which door design was determined to have performed with the least field problems in the trial?
When was the bottom roller design for the sliding door developed?
When was the bottom roller design for the sliding door developed?
What document number was issued by RDSO for the retro fitment procedure in June 2010?
What document number was issued by RDSO for the retro fitment procedure in June 2010?
What is the primary method of operation for the door mechanism in most wagons?
What is the primary method of operation for the door mechanism in most wagons?
What issue led to the need for modified locking arrangements in earlier door versions?
What issue led to the need for modified locking arrangements in earlier door versions?
Which of the following is NOT a common defect that necessitates attention in wagon bodies?
Which of the following is NOT a common defect that necessitates attention in wagon bodies?
What is a likely cause of corrosion on the wagon floor and roof sheets?
What is a likely cause of corrosion on the wagon floor and roof sheets?
Which damage is specifically caused by abnormal loads in a wagon?
Which damage is specifically caused by abnormal loads in a wagon?
Which factor significantly contributes to the corrosion of wagon body components?
Which factor significantly contributes to the corrosion of wagon body components?
What is a common outcome of slackening rivets over time?
What is a common outcome of slackening rivets over time?
What condition can cause bulging of the ends of wagons?
What condition can cause bulging of the ends of wagons?
What type of wagons have a pneumatically operated door mechanism?
What type of wagons have a pneumatically operated door mechanism?
Which of the following does NOT contribute to the corrosion of wagon bodies?
Which of the following does NOT contribute to the corrosion of wagon bodies?
What is the first step in applying a riveted patch in sickliness and ROH depots?
What is the first step in applying a riveted patch in sickliness and ROH depots?
Which repair method is effective for removing bulges in wagon ends without dismantling?
Which repair method is effective for removing bulges in wagon ends without dismantling?
What should be done if structural members are bulging by more than 25mm?
What should be done if structural members are bulging by more than 25mm?
What is the correct order for securing a riveted patch?
What is the correct order for securing a riveted patch?
Why should bulging of body structural members be addressed?
Why should bulging of body structural members be addressed?
What action is recommended if stanchions develop cracks?
What action is recommended if stanchions develop cracks?
Before riveting a patch, what should be ensured regarding the riveting process?
Before riveting a patch, what should be ensured regarding the riveting process?
What might cause damages to body structural members such as stanchions and carlines?
What might cause damages to body structural members such as stanchions and carlines?
What should be the focus while straightening structural components?
What should be the focus while straightening structural components?
What type of packaging is crucial in preventing damage to structural members during transport?
What type of packaging is crucial in preventing damage to structural members during transport?
What was the primary purpose of modifying the hinge in the design?
What was the primary purpose of modifying the hinge in the design?
In Design Modification-II, what feature replaced the existing long chainless cotters?
In Design Modification-II, what feature replaced the existing long chainless cotters?
Where was the tower-bolt positioned in Design Modification-II?
Where was the tower-bolt positioned in Design Modification-II?
What was one of the main benefits of the hinge modification mentioned?
What was one of the main benefits of the hinge modification mentioned?
What did the swing bolt in the latest design help achieve?
What did the swing bolt in the latest design help achieve?
How many small chainless cotters were provided in the latest design modification?
How many small chainless cotters were provided in the latest design modification?
What issue was addressed by eliminating the gap between the door and the side wall?
What issue was addressed by eliminating the gap between the door and the side wall?
Which modification occurred in June 2010?
Which modification occurred in June 2010?
What was a key feature of the hinged door modification?
What was a key feature of the hinged door modification?
What aspect of the original design was improved regarding the door-securing mechanism?
What aspect of the original design was improved regarding the door-securing mechanism?
What is the required action if the area to be patched extends beyond 260 mm from the floor height?
What is the required action if the area to be patched extends beyond 260 mm from the floor height?
For two or more adjacent panels requiring patching, what is the coverage requirement for the special patch?
For two or more adjacent panels requiring patching, what is the coverage requirement for the special patch?
What should be the thickness of the plate for BCN/BCNA wagons for the end and sides?
What should be the thickness of the plate for BCN/BCNA wagons for the end and sides?
What should be referred to for detailed instructions on panel patching for BOXN wagons?
What should be referred to for detailed instructions on panel patching for BOXN wagons?
What is the specified thickness of the plate for the roof of BCN/BCNA wagons?
What is the specified thickness of the plate for the roof of BCN/BCNA wagons?
What is the thickness of the standard patches used for BOXN wagons?
What is the thickness of the standard patches used for BOXN wagons?
What is the minimum expected length of a special patch when repairing adjacent panels?
What is the minimum expected length of a special patch when repairing adjacent panels?
What is the material used for the side wall in BOXNR wagons compared to BOXN wagons?
What is the material used for the side wall in BOXNR wagons compared to BOXN wagons?
How many side stanchions are provided in BOXNR wagons as opposed to BOXN wagons?
How many side stanchions are provided in BOXNR wagons as opposed to BOXN wagons?
What is the thickness of the door plate in BOXNR wagons?
What is the thickness of the door plate in BOXNR wagons?
What change occurred in the inside height of the side wall when upgrading from BOXN to BOXNR?
What change occurred in the inside height of the side wall when upgrading from BOXN to BOXNR?
Which of the following features is NOT present in BOXNR wagons as described?
Which of the following features is NOT present in BOXNR wagons as described?
What is the primary reason for avoiding riveted patches in workshops?
What is the primary reason for avoiding riveted patches in workshops?
Which method is recommended for straightening bulging structural members without dismantling?
Which method is recommended for straightening bulging structural members without dismantling?
What should be checked before applying a riveted patch?
What should be checked before applying a riveted patch?
What specific condition of structural members necessitates intervention?
What specific condition of structural members necessitates intervention?
Which step is NOT part of the procedure for applying a riveted patch?
Which step is NOT part of the procedure for applying a riveted patch?
What adverse situation may lead to damages in stanchions and carlines?
What adverse situation may lead to damages in stanchions and carlines?
What is an effective method to remove bulges from wagon ends?
What is an effective method to remove bulges from wagon ends?
What is a critical requirement for riveting a patch in position?
What is a critical requirement for riveting a patch in position?
What action should be taken when stanchions develop cracks?
What action should be taken when stanchions develop cracks?
What is the first action in the repair of bulged structural members?
What is the first action in the repair of bulged structural members?
What is the minimum required number of rivets to secure a patch that is attached by riveting?
What is the minimum required number of rivets to secure a patch that is attached by riveting?
What is the maximum allowable pitch distance for rivets when securing a patch?
What is the maximum allowable pitch distance for rivets when securing a patch?
Which thickness should standard patches ideally have to match the damaged panel?
Which thickness should standard patches ideally have to match the damaged panel?
What should be done to patches before storage and application?
What should be done to patches before storage and application?
What material thickness should be used for packing if the old panel is badly corroded?
What material thickness should be used for packing if the old panel is badly corroded?
What is the purpose of retaining the 2.5 mm thick old panel sheet during repairs?
What is the purpose of retaining the 2.5 mm thick old panel sheet during repairs?
What is one requirement when welding patches?
What is one requirement when welding patches?
What is the consequence of using a patch smaller than 100 mm on any side?
What is the consequence of using a patch smaller than 100 mm on any side?
What action should be taken for a patch to be approved for stock in shops?
What action should be taken for a patch to be approved for stock in shops?
What must be done to prevent jamming of flap door hinges due to warpage?
What must be done to prevent jamming of flap door hinges due to warpage?
Which of the following actions is NOT recommended for maintaining wagon doors?
Which of the following actions is NOT recommended for maintaining wagon doors?
What is the primary purpose of introducing graphite grease in wagon doors?
What is the primary purpose of introducing graphite grease in wagon doors?
What issue did Design Modification-I in June 2009 aim to eliminate?
What issue did Design Modification-I in June 2009 aim to eliminate?
What aspect should be ensured regarding hopper wagon doors?
What aspect should be ensured regarding hopper wagon doors?
What must be checked and rectified in addition to repairing the doors?
What must be checked and rectified in addition to repairing the doors?
What modifications were made in the Design Modification-II?
What modifications were made in the Design Modification-II?
Which condition could result in inadequate overlap and sagging doors?
Which condition could result in inadequate overlap and sagging doors?
Which component's malfunction could lead to issues in operating hopper wagon doors?
Which component's malfunction could lead to issues in operating hopper wagon doors?
Which procedure is recommended for damaged or bent door stanchions?
Which procedure is recommended for damaged or bent door stanchions?
Flashcards
Wagon Body Construction
Wagon Body Construction
Wagon bodies have panels, stanchions, copings, and various fittings like doors, holders, and rain protection.
Wagon End Construction
Wagon End Construction
Wagon ends use panels, stanchions, angles, and are attached to the frame.
Covered Wagon Roof
Covered Wagon Roof
Covered wagons have thin roof sheets and supporting structures, called carlines.
Wagon Doors
Wagon Doors
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Flat/Well Wagon Ends
Flat/Well Wagon Ends
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Hopper Wagon Sides
Hopper Wagon Sides
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Hopper Wagon Doors
Hopper Wagon Doors
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Wagon Body Defects
Wagon Body Defects
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Corrosion Causes
Corrosion Causes
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Panel Puncturing
Panel Puncturing
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End Bulging
End Bulging
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Door Operating Mechanism
Door Operating Mechanism
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Pneumatic Door Operation
Pneumatic Door Operation
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Manual Door Operation
Manual Door Operation
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Wagon Structural Damage
Wagon Structural Damage
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Corrosion of panels
Corrosion of panels
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Riveted Patch Repair
Riveted Patch Repair
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Bulged Wagon Ends
Bulged Wagon Ends
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Body Structural Members
Body Structural Members
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Wagon Stanchions
Wagon Stanchions
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Carlines
Carlines
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Copings
Copings
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Repair Procedure
Repair Procedure
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25mm Bulge Limit
25mm Bulge Limit
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DREADNAUGHT Ends
DREADNAUGHT Ends
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Spot Heating/Cooling
Spot Heating/Cooling
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Pressed Door Design-Variant-II
Pressed Door Design-Variant-II
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Sliding door (Fabricated design)
Sliding door (Fabricated design)
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Top mounted rollers on guide channel
Top mounted rollers on guide channel
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RDSO Door Modifications
RDSO Door Modifications
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Door Design Standardization
Door Design Standardization
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Door Hinge Modification
Door Hinge Modification
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Chainless Cotter
Chainless Cotter
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Door Catch
Door Catch
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Design Modification-II
Design Modification-II
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Tower Bolt
Tower Bolt
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Small Chainless Cotters (2)
Small Chainless Cotters (2)
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Swing Bolt with Double Hasp
Swing Bolt with Double Hasp
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Door Locking Design
Door Locking Design
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Wagon Door Designs
Wagon Door Designs
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Door Securing
Door Securing
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Patching beyond 260mm
Patching beyond 260mm
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Adjacent panel patching
Adjacent panel patching
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BOXN wagon patches
BOXN wagon patches
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BCN/BCNA wagon thickness
BCN/BCNA wagon thickness
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Special patch width
Special patch width
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Patch plate extension
Patch plate extension
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Panel patch size
Panel patch size
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Patch Repair Procedure
Patch Repair Procedure
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Standard Patch Thickness
Standard Patch Thickness
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Minimum Patch Size
Minimum Patch Size
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Rivet Pitch Limit
Rivet Pitch Limit
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Patch Riveting Requirement
Patch Riveting Requirement
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Patch Stock Preparation
Patch Stock Preparation
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Welded Patch Procedure (Step 1)
Welded Patch Procedure (Step 1)
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Panel Cutting Heights
Panel Cutting Heights
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Packing Piece Use
Packing Piece Use
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BOXN Wagon Rehabilitation
BOXN Wagon Rehabilitation
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BOXNR Wagon Design
BOXNR Wagon Design
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Side Wall Material (BOXN)
Side Wall Material (BOXN)
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Side Stanchions (BOXNR)
Side Stanchions (BOXNR)
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Side Wall Thickness (BOXNR)
Side Wall Thickness (BOXNR)
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Riveted Patch Repair
Riveted Patch Repair
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Bulged Wagon Ends
Bulged Wagon Ends
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Body Structural Members
Body Structural Members
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25mm Bulge Limit
25mm Bulge Limit
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DREADNAUGHT Ends
DREADNAUGHT Ends
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Spot Heating/Cooling
Spot Heating/Cooling
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Repair Procedure
Repair Procedure
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Wagon End Bulging
Wagon End Bulging
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Patching Beyond 260mm
Patching Beyond 260mm
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Adjacent Panel Patching
Adjacent Panel Patching
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Wagon Door Damage
Wagon Door Damage
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Door Hinge Repair
Door Hinge Repair
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BCNHL Wagon Doors
BCNHL Wagon Doors
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Design Modification-I
Design Modification-I
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Door Alignment
Door Alignment
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Hopper Wagon Chute
Hopper Wagon Chute
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Door Securing Gear
Door Securing Gear
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Panel Corrosion
Panel Corrosion
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Wagon Door Repair
Wagon Door Repair
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RDSO Design Modifications
RDSO Design Modifications
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Study Notes
Introduction
- Wagon body is the superstructure attached to the underframe.
- It includes sides and ends, with supporting structures like stanchions, copings, roof structures, carlines, roof sheets, hoppers, tank barrels, cladding, doors, door fittings, operating handles, louvers, cleats, handles, hooks, footsteps, and hand brake wheels.
General Construction of Open Wagons
- Sides: Made of side panels and stanchions attached to the underframe by crib angles and stanchions. Includes top copings, intermediate copings (if any), doors, door fittings, hand holds, tarpaulin cleats, and label holders.
- Ends: Similar in construction to sides, consisting of end panels, stanchions, top copings, and intermediate copings. Attached to underframe by end floor angles, corner angles, and stanchions. Corner angles connect ends to sides; open wagons have reinforcing angles and corner pressings at the corner top.
- Doors: Each side has a door for manual unloading. Hinged at the bottom with locking by chainless cotter at the top. BOXN wagons have two locking bolts per door to prevent slipping of the chainless cotter during tippling.
General Construction of Covered Wagons
- Sides: Similar to open wagons with side panels, stanchions, top copings, doors, and fittings.
- Ends: Similar construction to sides, with additional intermediate copings in some cases.
- Roof: Roofs are made of thinner sheets compared to body sides and end panels.
- Doors: Each side has swing doors at the top and flap doors at the bottom, hinged at the bottom with anti-bleeding devices.
General Construction of Flat and Well Wagons
- Ends: Flat/well wagons lack side walls and roofs. The superstructure consists of either fixed or flexible ends, attached to underframe via stanchions, side attachment plates, and crib angles.
- Side Stanchions: Flexible in some cases, attached to the sole bar through brackets; support brackets are also provided in rail wagons and well wagons; container flat wagons may have retractable anchoring locks.
General Construction of Hopper Wagons
- Sides: Made of side panels and stanchions, attached to the underframe. Includes top copings, side stiffeners, doors (if side discharge), and label holders.
- Ends: Similar to other wagons, consisting of end panels, stanchions, and end top copings; corner angles connect sides and ends.
- Doors: Hopper wagons are fitted with either side or center discharge doors; operated manually by a bevel wheel and worm wheel connected to a hand wheel. Some special hopper wagons may have pneumatic operation.
Nature of Repairs Required in Wagon Body
- Wagons may need repairs due to corrosion of panels, floor plates, and roof sheets; puncturing of panels, bulging of ends (from shifting loads), tearing of panels, shearing of rivets (from severe impacts), and corrosion of floor angles. Wear, tear, weakening of welded joints (loss of weld metal), damage to door hinges and fittings, distortion or cracking of stanchions or other structural members, damages due to improper clamping on tipplers.
Corrosion in Wagon Body
- Corrosion results from water logging in crevices; contact with corrosive consignments (salt, fertilizers); spillage of corrosive fluids, or escape of corrosive vapors. Inadequate painting or surface preparation can also contribute to corrosion.
Anticorrosive Measures
- Maintains wagon cleanliness.
- Thorough surface preparation and painting for major maintenance.
- Careful attention to surfaces in repairs.
- Use of Stainless Steel for new/rehab.
Rejectable Defects
- Inspection carried out in sicklines and workshops according to IRCA Part III Rules.
Repairs in Sicklines and ROH Depot
- Panel Patching: For damaged areas, use standard patches of specific dimensions (given in table). For areas extending over 260 mm from the floor, using double patches or single large patches is recommended.
- Procedure for Welded Patches: Instructions on cutting, placing, and welding patches, with attention given to details like packing, rivets, and overlaps.
Repairs to Bulged Ends
- Bulges can often be removed without dismantling using a hydraulic jack placed between wagons.
Repairs to Body Structural Members
- Usually due to rough handling, heavy shunting, or shifting of loads.
- Often needs to be straightened without dismantling using chains.
- Possible repairs include spot heating, cooling.
- Severe damages may require welding.
Water Tightening of Wagons
- All uncovered areas must be made watertight using sealing compound, especially before the monsoon season.
Repairs to Doors and Door Fittings
- Common defects include distortion (from mishandling), jamming of hinges, inadequate overlap between door flaps, and damage to gravity cotters, hooks, or hasps.
- Addressing these involves straightening, replacing hinges, adjusting clearances, and checking and repairing anti-bleeding/rain protection devices
Repairs to Doors and Door Fittings (for BCNHL Wagons)
- Details on modified door designs for BCNHL wagons, including new roller designs for improved operation, addressing issues like rain water seepage.
Retrofitable Sliding Doors
- Two-part design supported at the bottom and pivoted for lateral movement; suitable for older BCNHL wagons; accommodates loading from the side; uses multiple rollers for easier operation.
Cleaning, Surface Preparation and Painting
- Cleaning procedures for effectively preventing rust, providing a suitable surface for adhesion.
- Prime coats, and finishing coats for complete paint job. -Cleaning procedures for effectively preventing rust, providing a suitable surface for adhesion.
- Prime coats, and finishing coats for complete paint job.
Repairs and Maintenance in Workshops During POH and NPOH
- Detailed procedures for painting.
- Specific procedures for lettering, punching of wagon particulars, preparing of PR plates, and measuring tare weights.
Important Precautions During Welding
- Precautions for safe and effective welding, including load content checks, presence of flammable materials, steam cleaning and testing before welding when possible.
Important DO's and DON'Ts
- Guidelines for properly installing and utilizing these tools for welding.
- List of what to do and what NOT to do, in terms of installing and using the tools.
New Wagon Numbering Scheme
- New numbering system for efficiency in monitoring and tracking wagons, including codes for different wagon types, owning railways, year of manufacture, and individual wagon numbers. This includes multiple detailed subsections for specific wagon types and codes.
Description of Work
- Brief description on procedures for upgrading BOXN wagons to BOXNR and maintenance, repair and operational considerations.
Lock Bolts
- Lock bolts are important for repairs and maintenance; methods for proper installation are provided. Includes details on lock bolt pin, collar, installation tools, and the benefits of lock bolts.
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Description
This quiz delves into the components and general construction of open wagons, highlighting the structural elements that comprise their body, including sides, ends, and doors. Explore the details of how these elements are assembled and function together to create the wagon's superstructure.
