CnW Maintenance Manual PDF

CHAPTER 1- INTRODUCTION Page 1 of 51 CHAPTER 1 INTRODUCTION 101. GENERAL A comprehensive Wagon Maintenance Manual was published in 2001. A lot of de...

CHAPTER 1- INTRODUCTION Page 1 of 51 CHAPTER 1 INTRODUCTION 101. GENERAL A comprehensive Wagon Maintenance Manual was published in 2001. A lot of developments have taken place such as introduction of new stock, stainless steel wagons, permissible loading up to CC+8t+2t, introduction of premium examination, introduction of bogie mounted Air brake system, Twin pipe air brake system etc,. As a result, the maintenance pattern and requirements have changed considerably. This has necessitated revision of existing wagon maintenance manual. a) For ensuring optimum performance of wagon fleet, it is necessary that: Preventive maintenance is given timely to avoid occurrence of defects Defects are attended effectively and well in time so that the wagons remain fit for traffic use till the next schedule falls due Detention during examination and repairs is kept to minimum Frequent failures of similar nature are studied and necessary modifications/ design changes are effected to eliminate the cause of such failure. In course of time and based on experience, various procedures/ schedules for maintenance of wagons have been prepared. The schedules and procedures have been largely standardized and issued by Railway Board, RDSO, and IRCA etc. However, in many cases, instructions have been issued in piecemeal. This manual consolidates various standing instructions issued on wagon maintenance and lays down guidelines for ensuring uniformity in the practices to be followed on various railways. The important aspects of wagon maintenance have been covered and wherever necessary, the references are indicated so that the reader can refer these, if necessary, for detailed instructions and procedures not contained in this manual. b) This manual does not deal with the special stock or ODCs for which separate instructions are issued by RDSO/manufacturers. c) At the end of this chapter, the list of important instructions and references has been given. Throughout this manual, wherever IRCA Part III has been mentioned, it refers to IRCA Part-III (Latest edition). d) While proper maintenance plays a vital role in ensuring effectiveness of the rolling stock, an equally crucial role is played by proper handling and careful operation of the wagon fleet so as to minimise the incidences of damage and subsequent need for repairs. WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 2 of 51 102. IMPORTANT PARAMETERS OF WAGONS The important dimensions and sketches of main type of wagons stock used over Indian Railways are provided in this chapter. Details of following new type of wagon stock have been added. Regarding latest position of axle load, spring configuration and permissible speed, RDSO’s instructions may be referred. The speed certificates of these wagons are available on RDSO ‘s website. TABLE 1.1 OPEN WAGONS Designation Axle Bogie Springs Permissible Speed Remarks Load Loaded/Empty BOY 22.9 t Casnub 22 NLB O – 14 65/ 75 Kmph It has no doors. Designed for (modified) I – 10 heavy minerals. S–4 BOYEL 25.0 t Casnub 22 NLC O – 14 45+5/ 60+5 Kmph Min. wheel tread dia. 950 mm. I – 14 S–4 BOXN 20.32 t Casnub 22 NLB O – 12 75/ 80 Kmph Operation at CC +6 +2/ CC +8 +2 I–8 allowed as interim measure, with S–4 speed restriction 60/80 BOXN M1 22.82 t Casnub 22 NLB O – 14 70/ 80 (CC +6 +2) On specified routes the speed is (Modified) I – 10 60/ 80 (CC +8 +2) 75/80 Kmph with CC +8 +2 S–4 Kmph BOXNEL 25.0 t Casnub 22 NLC O – 14 50/ 65 Kmph Min. wheel tread dia. 950 mm I – 14 S–4 BOXNHS 20.32 t Casnub 22 HS O – 14 100/ 100 Kmph - I – 12 S–4 BOXNHS M1 22.82 t Casnub 22 HS O – 14 75/ 90 (CC +6 +2) On specified routes the speed is (Modified) I – 14 60/ 90 (CC +8 +2) 75/80 Kmph with CC +8 +2 S–4 Kmph BOXNHA 22.1 t IRF 108 HS O – 14 100/100 Kmph - I – 14 (20.32 & 22.1 t) S–4 75/100Kmph(22.82 t) BOXNLW 20.32 t Casnub 22 HS O – 14 100/ 100 Kmph Stainless steel (IRS: M44) and I – 12 Corton Steel (IRS: M41) used in S–4 body & under frame BOXNLW M1 22.82 t Casnub 22 HS O – 14 60/ 65 Kmph - (Modified) I – 14 S–4 BOXNHL 22.9 t Casnub 22 HS O – 14 75/ 100 Kmph IRS: M44 (Body), Flat centre I – 14 Pivot, K type CBB, Improved S–4 Coupler & draft gear Br. Cyl, 300 mm, IRSA 750 Slack Adj., A.R. 75 litres, PU Painting (Phirozi colour) BOST 20.32 t Casnub 22 HS O – 14 75/ 80 Kmph Operation at CC+ 6 + 2 allowed as I – 12 an interim measure with speed S–4 restriction to 50/ 80 BOSTM1 22.32 t Casnub 22 HS O – 14 60/ 65 Kmph High Axle load version of BOST (modified) I – 14 S–4 BOSTHS 20.32 t Casnub 22 HS O – 12 100/ 100 Kmph High Speed version of BOST (mod- I) I – 12 S–4 BOSTHS M1 22.32 t Modified Casnub O – 14 60/ 80 Kmph High Axle load version of BOST 22 HS (Mod- I) I – 14 HS S–4 WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 3 of 51 Designation Axle Bogie Springs Permissible Speed Remarks Load Loaded/Empty BOSTHS M2 22.32 t Modified Casnub O – 12 60/ 100 Kmph Design of suspension is different 22 HS (Mod- II) I – 12 than BOSTHS M1. S–4 BOXNHAM 22.82 t IRF 108 HS O – 14 75/ 100 Kmph - I – 14 S–4 BOXNR 22.9 t Casnub 22 NLB O – 12 75/ 80 Kmph Rehab wagon with replacement of I–8 end wall & side walls in POH S–4 BOMN 16.4 t Casnub 22 NLB O – 12 80/75 Kmph Bogie open Military wagon for I–8 defence equipments. S–4 TABLE 1.2 COVERED WAGONS Designation Axle Bogie Springs Permissible Speed Remarks Load ( in Kmph) BCN 20.32 t Casnub 22 NLB O – 12 75/ 80 Kmph Permitted with CC +6 +2 also. I–8 S–4 BCN M1 22.82 t (Modified) O – 14 75/ 80 (CC +6 +2) High axle load version of BCN Casnub 22 NLB I – 10 60/ 80 (CC +8 +2) S–4 Kmph BCNHS M1 22.82t Modified) O – 14 75/ 90 (CC +6 +2) High axle load version of BCNHS Casnub 22 HS I – 14 75/ 90 (CC +8 +2) S–4 Kmph BCNA 20.32 t Casnub 22 NLB O – 12 80/ 80 Kmph Permitted with CC +6 +2 also. I–8 S–4 BCNA M1 22.82 t (Modified) O – 14 75/ 80 (CC +6 +2) High axle load version of BCNA Casnub 22 NLB I – 10 60/ 80 (CC +8 +2) S–4 Kmph BCNAHS 20.32 t Casnub 22 HS O – 14 100/ 100 Kmph Variant of BCNA with Casnub I – 12 bogie 22 HS bogie S–4 BCNAHS M1 22.82 t (Modified) O – 14 75/ 100 (CC +6 +2) High axle load version of BCNA Casnub 22 HS I – 14 75/ 100 (CC +8 +2) HS S–4 Kmph BCNHL 22.9 t Casnub 22 HS O – 14 75/ 70 Kmph Length reduced, width and height increased I – 14 than BCNA. Under frame mounted S–4 No. of wagons/ rake = 58 Flat centre Pivot, K-type CBB, improved coupler & draft gear, Brake cylinder 300 mm, A.R. 75 liters, PU painting (Phirozi). BCNHL 22.9 t Casnub 22 HS O – 14 75/ 70 Kmph With BMBS I – 14 S–4 BCCN IRF 106 HS O – 14 100 Kmph Maruti Car Double decker End wagon A 10.425 t I – nil Middle Wagon B 10.50 t S–4 BCCW 20.32 t Casnub 22 NLB O – 12 70 Kmph Cement Wagon I–8 (Specific Route) S–4 BCCW 21.82 t Casnub 22 HS O – 14 65 Kmph Cement Wagon I – 14 S–4 BCBFG 21.82 t Casnub 22HS O – 14 75 Kmph Food Grain hopper wagon (Mod.1) I – 14 (Specific Route) S–4 WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 4 of 51 TABLE 1.3 FLAT WAGONS Designation Axle Bogie Springs Permissible speed Remarks Load Loaded/Empty BRN 20.32 t Casnub 22 NLB O – 12 75/ 80 Kmph Designed for rails and heavy steel I–8 products. S–4 BRN22.9 22.9 t Casnub 22 HS O – 14 65/ 65 Kmph Improved version of BRN I – 14 S–4 BRNA 20.32 t Casnub 22 NLB O – 12 75/ 80 Kmph Improved version of BRN, Higher I–8 pay to tare ratio. S–4 BRNAHS 20.32 t Casnub 22 HS O – 14 100/ 100 Kmph High speed variant of BRNA I – 12 S–4 BFNS 20.32 t Casnub 22 HS O – 14 100/ 100 Kmph Designed for transportation of steel I – 12 coils, plates, sheets & billets etc. S–4 BRHNEHS 20.32 t Casnub 22 HS O – 14 65/ 65 Kmph Bogie rail wagon designed for I – 12 Track Relaying trains (TRT) S–4 specially for loading RCC sleepers. BRSTN 20.32 t Casnub 22 NLB O – 12 80/ 75 Kmph Bogie rail wagon for heavy I–8 vehicles. S–4 BWTB 22.9 t Casnub 22 NLB O – 14 65/ 65 Kmph Bogie well wagon (well height I – 10 1055 mm). S–4 TABLE 1.4 HOPPER WAGONS Designation Axle Bogie Springs Permissible Speed Remarks Load BOBSN 22.9 t (modified) O – 14 75/ 75 Kmph Designed in 1994 for Casnub 22 NLB I – 10 transportation of Iron ore, side S–4 discharge. BOBSN M1 25 t O – 14 50/ 60 Kmph High axle load variant of BOBSN. Casnub 22 NLC I – 14 Casnub 22 NLC Bogie. S–4 BOB R 20.32 t O – 12 80/ 80 Kmph Designed in 1986 for coal. Bottom Casnub 22 NLB I–8 discharge. No. of wagons/ rake = S–4 53. BOBR M1 22.32 t (Modified) O – 14 70/ 75 Kmph (CC + 6 + 2) version of BOBR. Casnub 22 NLB I – 10 S–4 BOB RN 20.32 t Casnub 22 NLB O – 12 70/ 75 Kmph Designed in 1991 by reducing the I–8 length of BOBR. No. of wagons/ S–4 rake = 58. BOBRN M1 22.32 t (Modified) O – 14 70/ 80 Kmph (CC + 6 + 2) version of BOBRN. Casnub 22 NLB I – 10 S–4 BOBRNHS 20.32 t Casnub 22 HS O – 14 100/ 100 Kmph High speed BOBRN I – 12 S–4 BOBRNHS 22.32 t (Modified) O – 14 60/ 65 Kmph -- M1 Casnub 22 HS I – 14 S–4 BOBRNEL 25 t Casnub 22 NLC O – 14 45+5/ 60+5 Kmph 25 t axle load. Wheel dia 1000 I – 14 mm. POH–6 years, ROH–2 years. S–4 BOBYN 20.32 t Casnub 22 NLB O – 12 75/ 75 Kmph Air Brake version of BOBY. I–8 Designed in 1996 S–4 BOBYN22.9 22.9 t Casnub 22 HS O – 14 75/ 75 Kmph Air Brake version of BOBYHS. I – 14 S–4 BCBFG 21.82 t Casnub 22 HS O – 12 75/ 75 Kmph Bogie covered Hopper Wagon for (Mod-I) I – 12 food grains. Designed with S–4 automatic LSD. WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 5 of 51 TABLE 1.5 TANK WAGONS Designation Axle Bogie Springs Permissible Speed Remarks Load BTALN 20.32 t UIC Bogie -- 65/ 65 Kmph Bogie Ammonia Tank Wagon BTPN 20.32 t Casnub 22 NLB O – 12 80/ 75 Kmph(Loaded) Bogie POL Tank Wagon I–8 S–4 BTPGLN 19.8 t Casnub 22 NLB O – 12 75/ 80 Kmph Bogie LPG Tank Wagon. Variant I–8 of BTP GL with Air Brakes / S–4 Casnub 22 NLB bogie. BTCS 20.32 t Casnub 22 W O – 12 65/ 65 Kmph Bogie Caustic Soda Tank Wagon. I–8 Provisional speed certificate is with S–4 casnub 22W bogie. In 2007, bogie altered to NLB in the drawing. BTAP 20.32 t Casnub 22 NLB O – 12 65/ 65 Kmph Bogie Alumina Tank Wagon. I–8 S–4 BTFLN 20.32 t Casnub 22 HS O – 14 65/ 65 Kmph Bogie POL Tank Wagon I – 12 (Provisional) S–4 TABLE 1.6 CONTAINER WAGONS Designation Axle Load Bogie Springs Permissible Speed Remarks BLLA/ B 20.32 t LCCF 20 (c) O – 14 100/ 100 Kmph Bogie low platform longer I – 12 container flat wagon. S–4 BLCA/ B 20.32 t LCCF 20 (c) O – 14 100/ 100 Kmph Bogie low platform container flat I – 12 wagon S–4 BLCAM/ 22 t Modified O – 14 90/ 100 Kmph In 2007, bogie of BLC wagon was BLCBM LCCF 20 (c) I – 14 modified by providing upgraded S–4 side bearer, upgraded friction wedge, and two additional inner springs for double stack container operation. BCACM 20.32 t LCCF 20 (c) O – 14 65/ 75 Kmph For auto car industry I – 12 S–4 BCACBM A-12.715 t LCCF 20 © O – 14 100/95 Kmph For transportation of Automobile B-12.680t I – 12 cars. S–4 TABLE 1.7 BRAKE VAN Designation Axle Bogie Springs Permissible Speed Remarks Load BVZI 5.875 t ICF Bogie - 100 Kmph Designed in 2000 with ICF Bogie to achieve comfortable ride, 5 m longer than BVZC. BVZC 06.98 t 4- wheeler - 100 Kmph RDSO Drg. No. WD- 81035/S-2 103. IMPORTANT RULE BOOKS AND REFERENCES List of Technical Monographs/Instructions relevant to maintenance of Freight stock are included in the compendium of instructions/ technical monographs issued vide Railway Board‟s letter No. 2004/M(N)/951/16 Dt. 18.5.2004. The following rule books, pamphlets and monographs contain information required to supplement this manual. These may be referred to for details, if not available in this manual. WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 6 of 51 I R C A /R D S O Latest edition/ S.N Description publication correction IRCA Rules for Maintenance, Examination & Interchange of 01 Conference (Latest edition) Goods Stock of Indian Government Railways. Rules Part III Technical Pamphlet for requirements of Tippler 02 G -3 3 ( R e v. 1 ) M a y. 2 0 1 0 Installation for approval by RDSO 03 G -3 7 ( R e v. 1 ) Recommended Practice for Welded fabrication in Wagons April.1971 04 G-70 Maintenance manual for BOXN wagon Aug.1998 05 G-71 Maintenance manual for Phosphoric acid Tank Wagon Feb.1999 06 G-72 General Std. Spec. For Fabrication of Wagon 'U' frame & Oct.2001 & Bogies Corrigendum No.1 of Nov. 2002. 07 G-73 Operation and Maintenance Manual for BOBR/BOBRN Rev.I of oct.2005 08 G-76 Inspection and Maintenance of CBC for Line Staff 1987 09 G-79 Inspection and Maintenance of BTAL /BTALN April.1999 10 G-80 Inspection and Maintenance of CBC for Workshop 1989 11 G-81 Inspection and Maintenance of Cartridge Roller Bearing Feb.2000 fitted on Casnub Bogie 12 G-82 Instructions for operation and maintenance of B.G.Bogie June.1986 tank wagon for Alumina type „BTAP‟ 13 G-83 Instructions for Maintenance and Operation of Bogie Aug. 1988 Caustic Soda tank wagon type „BTCS‟ 14 G-85 Operation and maintenance Instructions for Sliding roof Apr.1989 covering on „BOXN(S)‟ 15 G-86 Maintenance Manual for Bogie Liquefied Petroleum Gas Dec.1999 Tank Wagon type BTPGL 16 G-87 Safe handling of Hazardous chemicals transported in Rail - Tankers. 17 G-90 Maintenance and Operating Instruction for Bogie July.2012 Petroleum Tank Wagon type 'BTPN' 18 G-92 Maintenance Manual for IRSA-600, IRSA-600J type slack Sept.1998 adjusters used on Freight Stock and IRSA-450 slack adjusters used on Coaching stock 19 G-95 Instructions for Inspection and Maintenance for Casnub June.2003 Bogies 20 G-97 Maintenance Manual for Air Brake System for Freight July 2001 Stock 21 G-100 Technical Pamphlet for Instructions & Maintenance of July.2010 Automatic Twist Lock (ATL) devices fitted on Container & May.2012 flat wagons. 22 G-103 Technical Pamphlet on strengthening of underframe, repair Nov.2010 of critical weld joints, repair of centre sill, Centre girders May.2011(Rev.2) and sole bar cracks 23 G-106 Bogie Covered Double Decker Wagon type „BCACBM‟ Feb, 2014 24 G-107 Procedure for re-cambering of bogie Rail wagon type BRN/BRNA/BRNHS. 25 WT-77-I Instructions for inspection and maintenance of 20.3 tonne Dec.1985 Roller Bearing axle boxes fitted on wagon. 26 WT-79-I Instructions for inspection and maintenance of 16.3 tonne 1987 Roller Bearing axle boxes fitted on wagon. WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 7 of 51 104. STANDARD INFRASTRUCTURE FOR WAGON DEPOT A separate Chapter No 11 for standard infrastructure required in wagon depots has been added. 105. IMPORTANT WAGON MODIFICATIONS The list of important modifications to be carried out on freight stock is given in Appendix-II. 106. NUMBERING CONVENTION IN THE MANUAL For convenience of indexing of reference, the paragraphs have been numbered according to a 3 /4 figure “Code”, in which the last two figures give the number of the paragraphs and the remaining figures the number of the chapter. Thus paragraph 101 of any code is paragraph 1 of chapter 1 of that code and paragraph 1103, paragraph 3 of chapter 11. The page number of each chapter in this manual starts from 1. The reader can easily identify the chapter number to which a page belongs by reading the header of the page where chapter number as well as chapter title is given. This scheme of page numbering is adopted to provide flexibility of easily revising the chapters in future, on account of design or procedure changes or induction of new stock without disturbing the page numbers of succeeding chapters. 107. NUMBERING OF TABLES AND FIGURES IN THE MANUAL The tables in each chapter consist of two numbers separated by a decimal point. The number before decimal point indicates the chapter number whereas the number after the decimal point indicates the running serial number of the table which starts from 1 in every chapter. The convention adopted for numbering the figures is also identical to the numbering scheme adopted for the tables. 108. STANDARD FEATURES OF WAGONS Important features and lay out of the wagons are given in the following appendix-A. Technical data and other important parameters are also available in this appendix for ready reference. WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 8 of 51 FIG. 1.1 BOXN WAGON (RDSO Drg. No. WD- 80007/ S-2) INTRODUCTION: - BOXN wagon has been designed for transportation of iron ores, coal etc. either fitted with Casnub-22W/ Casnub- 22W(M)/Casnub 22 NLB bogies, non-transition center buffer couplers and single-pipe graduated release air brake system. STANDARD FEATURES OF ‘BOXN’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9784 14 Cubic Capacity (Cu.M) 56.29 2 Length over couplers (mm) 10713 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 9784 16 Tare Weight (tonne) 23.2 WAGON MAINTENANCE MANUAL 4 Width inside/Width Overall (mm) 2950/3200 17 Pay load (tonne) 58.08 5 Height inside/Height (max.) from RL. 1950/3233 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 6524 19 Ratio gross load/Tare 3.5 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 2.5 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 7.59 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 APPENDIX 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.016 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.974 25 Bearing CTRB 13 Floor area (Sq.M) 28.87 26 Maximum Speed (Loaded)/ Empty 75 kmph /80 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 9 of 51 FIG. 1.2 BOXNCR WAGON (RDSO Drg. No. WD- 80007/ S-2) INTRODUCTION: - The wagon is a variant of BOXN wagon with its body in IRS M-44 steel. It‟s under frame is however made of mild steel. This has been done to provide better corrosion resistance to wagon body. All parameters of this wagon are same as that of BOXN wagon. STANDARD FEATURES OF ‘BOXNCR’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9784 14 Cubic Capacity (Cu.M) 56.29 2 Length over couplers (mm) 10713 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 9784 16 Tare Weight (tonne) 23.2 4 Width inside/Width Overall (mm) 2950/3200 17 Pay load (tonne) 58.08 5 Height inside/Height (max.) from RL. 1950/3233 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 6524 19 Ratio gross load/Tare 3.5 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 2.5 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 7.59 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.016 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.974 25 Bearing CTRB 13 Floor area (Sq.M) 28.87 26 Maximum Speed (Loaded)/ Empty 75 kmph / 80 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 10 of 51 FIG.1.3 BOXNNHA WAGON (RDSO Drg. No. WD- 98015 - S- 02) INTRODUCTION: - This wagon has been designed for transportation of coal to axle load of 22.1t. It has higher sidewalls compared to BOXN wagon. STANDARD FEATURES OF ‘BOXNHA’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9784 14 Cubic Capacity (Cu.M) 62.8 2 Length over couplers (mm) 10713 15 Maximum axle load (tonne) 22.1 3 Length inside (mm) 9784 16 Tare Weight (tonne) 23.17 4 Width inside/Width Overall (mm) 2950/3200 17 Pay load (tonne) 65.23 5 Height inside/Height(max.) from RL. 2175/3450 18 Gross load (Pay+Tare) (tonne) 88.4 6 Bogie centers (mm) 6524 19 Ratio gross load/Tare 3.82 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 2.82 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 8.25 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) - 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) - 25 Bearing CTRB 13 Floor area (Sq.M) 28.87 26 Maximum Speed (Loaded)/ Empty 75 kmph / 80 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 11 of 51 FIG. 1.4 BOXNHS WAGON (RDSO Drg. No. WD – 80007/S- 2) INTRODUCTION: - The wagon is variant of BOXN wagon with operating speed of 100 kmph in empty and 100 kmph in loaded condition. In this wagon high speed bogies have been provided. The other parameters of this wagon are same as of BOXN wagon. STANDARD FEATURES OF ‘BOXNHS’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9784 14 Cubic Capacity (Cu.M) 56.29 2 Length over couplers (mm) 10713 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 9784 16 Tare Weight (tonne) 23.2 4 Width inside/Width Overall (mm) 2950/3200 17 Pay load (tonne) 58.08 5 Height inside/Height (max.) from RL. 1950/3233 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 6524 19 Ratio gross load/Tare 3.5 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 2.5 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 7.59 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.016 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.974 25 Bearing CTRB 13 Floor area (Sq.M) 28.87 26 Maximum Speed (Loaded)/ Empty 100 kmph / 100 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 12 of 51 FIG. 1.5 BOXN (LW) WAGON (RDSO Drg. No. WD –88088- S - 02) INTRODUCTION: - To meet the requirement of higher pay to tare ratio, this bogie open wagon was designed in 1988. Cold Rolled Formed (CRF) sections and stainless steel/carton steel are used in design to reduce the tare weight of the wagon. STANDARD FEATURES OF ‘BOXN (LW)’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9784 14 Cubic Capacity (Cu.M) 61.09 2 Length over couplers (mm) 10713 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 9784 16 Tare Weight (tonne) 18.26 4 Width inside/Width Overall (mm) 3022/3250 17 Pay load (tonne) 63.02 5 Height inside/Height (max.) from RL. 2066/3341 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 6524 19 Ratio gross load/Tare 4.45 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 3.45 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 7.59 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) - 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) - 25 Bearing CTRB 13 Floor area (Sq.M) 29.57 26 Maximum Speed (Loaded)/ Empty 100 kmph / 100 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 13 of 51 FIG.1.6 BOXNHL WAGON (RDSO Drg. No. WD –05086- S - 02) INTRODUCTION: - This bogie open wagon was designed at 22.9t axle load and 250mm longer than BOXNHS wagon. The wagon is manufactured by using stainless steel and cold rolled sections. STANDARD FEATURES OF ‘BOXNHL’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 10034 14 Cubic Capacity (Cu.M) 61.05 2 Length over couplers (mm) 10963 15 Maximum axle load (tonne) 22.9 3 Length inside (mm) 10034 16 Tare Weight (tonne) 20.6 4 Width inside/Width Overall (mm) 3022/3250 17 Pay load (tonne) 71.0 5 Height inside/Height (max.) from RL. 2028/3301 18 Gross load (Pay+Tare) (tonne) 91.6 6 Bogie centers (mm) 6690 19 Ratio gross load/Tare 4.45 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 3.45 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 8.35 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) - 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) - 25 Bearing CTRB 13 Floor area (Sq.M) 30.32 26 Maximum Speed (Loaded)/ Empty 75 kmph / 100 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 14 of 51 FIG. 1.7 BOXNEL WAGON (RDSO Drg. No. WD –06083/ S - 01) INTRODUCTION: - This wagon has been designed for transportation of iron ores, coal etc. BOXNEL wagons fitted with Casnub-22NLC bogies with a maximum axle load 25 t., non-transition center buffer couplers and single-pipe graduated release air brake system. STANDARD FEATURES OF ‘BOXNEL’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9784 14 Cubic Capacity (Cu.M) 56.29 2 Length over couplers (mm) 10713 15 Maximum axle load (tonne) 25 3 Length inside (mm) 9784 16 Tare Weight (tonne) 23.1 4 Width inside/Width Overall (mm) 2950/3200 17 Pay load (tonne) 76.9 5 Height inside/Height(max.) from RL. 1950/3233 18 Gross load (Pay+Tare) (tonne) 100 6 Bogie centers (mm) 6524 19 Ratio gross load/Tare 4.33 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 3.33 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 9.33 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.016 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.737 25 Bearing CTRB 13 Floor area (Sq.M) 28.87 26 Maximum Speed (Loaded)/ Empty 45+5 kmph / 60+5 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 15 of 51 FIG. 1.8 BOXNR WAGON (RDSO Drg. No. WD –07001- S - 02) INTRODUCTION: - This wagon has been designed for transportation of iron ores, coal etc. BOXNR wagons either fitted with Casnub-22W (without Elastomeric pads) or Casnub-22W (with Elastomeric pads) bogies with a maximum axle load 22.9 t., non-transition center buffer couplers and single-pipe graduated release air brake system. STANDARD FEATURES OF ‘BOXNR’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9784 14 Cubic Capacity (Cu.M) 61.47 2 Length over couplers (mm) 10713 15 Maximum axle load (tonne) 22.9 3 Length inside (mm) 9784 16 Tare Weight (tonne) 21.2 4 Width inside/Width Overall (mm) 2954/3176 17 Pay load (tonne) 70.04 5 Height inside/Height(max.) from RL. 2127/3408 18 Gross load (Pay+Tare) (tonne) 91.6 6 Bogie centers (mm) 6524 19 Ratio gross load/Tare 4.32 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 3.32 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 8.55 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.027 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 2.033 25 Bearing CTRB 13 Floor area (Sq.M) 28.90 26 Maximum Speed (Loaded)/ Empty 60 kmph / 80 kmph WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 16 of 51 FIG. 1.9 STANDARD FEATURES OF BOXNHAM WAGON S. No. PARTICULARS Parameter S. No. PARTICULARS Parameter 1 Length over Hd. Stock 9784 mm 11 Pay load 68.18 t 2 Length over buffer/couplers 10713 mm 12 Ratio pay load /tare 2.95 3 Length inside 9784 mm 13 Gross load 91.28 t 4 Width inside/overall 2950/3200 mm 14 No. of wagons per rake 58 5 Height inside/from rail 1950/3233 mm 15 Throughput per rake 3954 t 6 Bogie centres 6524 mm 16 Loading density 8.52 t/m 7 Journal centres 2260 mm 17 Cubic capacity 56.29 m3 8 Wheel dia. On tread 1000/906 mm 18 Speed (empty/ loaded) 100/75 9 Nominal max. axle load 22.82 t 19 Type of coupler CBC 23.1 t 10 Tare 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 17 of 51 FIG. 1.10 STANDARD FEATURES OF BOXN/BOXNHS WAGON S. No. PARTICULARS Parameter S. No. PARTICULARS Parameter 1 Length over Hd. Stock 9784 mm 11 Pay load 58.18 t 2 Length over buffer/couplers 10713 mm 12 Ratio pay load /tare 2.52 3 Length inside 9784 mm 13 Gross load 81.28 t 4 Width inside/overall 2950/3200 mm 14 No. of wagons per rake 58 5 Height inside/from rail 1950/3233 mm 15 Throughput per rake 3374 t 6 Bogie centres 6524 mm 16 Loading density 7.59 t/m 7 Journal centres 2260 mm 17 Cubic capacity 56.29 m3 1000 mm 80/75 BOXN 8 Wheel dia. On tread 18 Speed (empty/ loaded) 100/100 BOXNHS 9 Nominal max. axle load 20.32 t 19 Type of coupler CBC 10 Tare 23.1 t 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 18 of 51 STANDARD FEATURES OF BOXNHL (MBS) WAGON S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 10034 mm 11 Pay load 71.08 t 2 Length over buffer/couplers 10963 mm 12 Ratio pay load /tare 3.46 3 Length inside 10034 mm 13 Gross load 91.6 t 4 Width inside/overall 3022/3250 mm 14 No. of wagons per rake 58 5 Height inside/from rail 2028/3301 mm 15 Throughput per rake 4123 t 6 Bogie centres 6690 mm 16 Loading density 8.35 t/m 7 Journal centres 2260 mm 17 Cubic capacity 61.50 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 100/75 Kmph 9 Nominal max. axle load 22.9 t 19 Type of coupler CBC 20.52 t 10 Tare 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 19 of 51 FIG. 1.11 BOST WAGON (RDSO Drg. No. WD - 00012 - S- 01) INTRODUCTION:-This bogie open wagon was designed for transportation of coal as well as steel products. The under frame has been strengthened during the design to sustain point loading of steel consignment. The payload remains the same as BOX N wagon. STANDARD FEATURES OF ‘BOST’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 12800 14 Cubic Capacity (Cu.M) 65.79 2 Length over couplers (mm) 13729 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 12800 16 Tare Weight (tonne) 25.5 4 Width inside/Width Overall (mm) 2850/3100 17 Pay load (tonne) 55.78 5 Height inside/Height (max.) from RL. 1950/3080 18 Gross load (Pay+Tare) (tonne) 81..28 6 Bogie centers (mm) 8800 19 Ratio gross load/Tare 3.19 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 2.19 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 5.92 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 45 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.036 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.792 25 Bearing CTRB 13 Floor area (Sq.M) 36.45 26 Maximum Speed (Loaded)/ Empty 75 kmph/ 80 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 20 of 51 FIG. 1.12 BOSTHS WAGON (RDSO Drg. No. WD - 00012 - S- 01) INTRODUCTION: - This wagon is variant of BOST wagon with high-speed casnub bogie. STANDARD FEATURES OF ‘BOSTHS’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 12800 14 Cubic Capacity (Cu.M) 65.79 2 Length over couplers (mm) 13729 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 12800 16 Tare Weight (tonne) 25.5 4 Width inside/Width Overall (mm) 2850/3100 17 Pay load (tonne) 55.78 5 Height inside/Height (max.) from RL. 1950/3080 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 8800 19 Ratio gross load/Tare 3.19 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 2.19 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 5.92 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 45 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.036 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.792 25 Bearing CTRB. 13 Floor area (Sq.M) 36.45 26 Maximum Speed (Loaded)/ Empty 100 kmph / 100 kmph WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 21 of 51 STANDARD FEATURES OF BOSTHSM1 WAGON (CC+6t.+2t.) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 12800 mm 11 Pay load 63.78 t. 2 Length over buffer/couplers 13729mm 12 Ratio pay load /tare 2.5 3 Length inside 12800 mm 13 Gross load 89.28 t. 4 Width inside/overall 2850/3100 mm 14 No. of wagons per rake 45 5 Height inside/from rail 1805/3080 mm 15 Throughput per rake 2870.1 t. 6 Bogie centres 8800 mm 16 Loading density 6..50 t/m 7 Journal centres 2260 mm 17 Cubic capacity 65.79 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 80/60 9 Nominal max. axle load 22.32 t. 19 Type of coupler CBC 10 Tare 25.5 t. 20 Type of bearing CTRB STANDARD FEATURES OF BOSTHSM2 WAGON (CC+6t.+2t.) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 12800 mm 11 Pay load 63.78 t. 2 Length over buffer/couplers 13729mm 12 Ratio pay load /tare 2.5 3 Length inside 12800 mm 13 Gross load 89.28 t. 4 Width inside/overall 2850/3100 mm 14 No. of wagons per rake 45 5 Height inside/from rail 1805/3078 mm 15 Throughput per rake 2870.1 t. 6 Bogie centres 8800 mm 16 Loading density 6.50 t/m 7 Journal centres 2260 mm 17 Cubic capacity 65.79 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 100/60 9 Nominal max. axle load 22.32 t. 19 Type of coupler CBC 10 Tare 25.5 t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 22 of 51 FIG. 1.13 BOYEL WAGON (RDSO Drg. No. WD –06084- S / 01) INTRODUCTION: - This wagon has been designed for transportation of iron ores, coal etc. BOYEL wagons fitted with Casnub-22NLC bogies with a maximum axle load 25 t., nontransition center buffer couplers and single-pipe graduated release air brake system. STANDARD FEATURES OF ‘BOYEL’ WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 11000 14 Cubic Capacity (Cu.M) 37.8 2 Length over couplers (mm) 11929 15 Maximum axle load (tonne) 25 3 Length inside (mm) 10990 16 Tare Weight (tonne) 20.7 4 Width inside/Width Overall (mm) 2924/3134 17 Pay load (tonne) 79.3 5 Height inside/Height(max.) from RL. 1175/2450 18 Gross load (Pay+Tare) (tonne) 100 6 Bogie centers (mm) 7330 19 Ratio gross load/Tare 4.83 7 Journal length × dia. (mm) 144x278 20 Ratio (Pay load to tare) 3.83 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 8.38 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 52 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 0.972 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.613 25 Bearing CTRB 13 Floor area (Sq.M) 32.13 26 Maximum Speed (Loaded)/ Empty 45+5 kmph / 60+5 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 23 of 51 FIG. 1.14 BCN COVERED WAGON (RDSO Drg. No. WD- 84014 – S- 1) INTRODUCTION: - This bogie covered wagon designed at 20.32t axle load in 1984.The construction of wagon was purely riveted. The wagon was designed for transportation of bag commodities. STANDARD FEATURES OF ‘BCN’ COVERD WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 14500 14 Cubic Capacity (Cu.M) 104.00 2 Length over couplers (mm) 15429 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 14494 16 Tare Weight (tonne) 27.20 4 Width inside/Width Overall (mm) 2944/3100 17 Pay load (tonne) 54.08 5 Height inside/Height (max.) from RL. 2446/3788 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 10000 19 Ratio gross load/Tare 2.99 7 Journal length × dia. (mm) RB144.5 Ø 20 Ratio (Pay load to tare) 1.99 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 5.268 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 40 10 Height of C.B.C. from R.L. (mm) 1102 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.016 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.974 25 Bearing CTRB 13 Floor area (Sq.M) 42.67 26 Maximum Speed (Loaded)/ Empty 75 kmph / 80 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 24 of 51 FIG. 1.15 BCNA COVERED WAGON (RDSO Drg. No. WD- 90030 – S- 51) INTRODUCTION: - This wagon is an improved BCN wagon having reduced length and increase height by keeping volumetric capacity same and the wagon was fully welded construction. STANDARD FEATURES OF ‘BCNA’ COVERD WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 13521 14 Cubic Capacity (Cu.M) 103.40 2 Length over couplers (mm) 14450 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 13515 16 Tare Weight (tonne) 24.55 4 Width inside/Width Overall (mm) 2944/3200 17 Pay load (tonne) 56.73 5 Height inside/Height (max.) from RL. 2677/4017 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 9500 19 Ratio gross load/Tare 3.31 7 Journal length × dia. (mm) RB144.5 Ø 20 Ratio (Pay load to tare) 2.31 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 5.625 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 43 10 Height of C.B.C. from R.L. (mm) 1104 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.2395 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.9915 25 Bearing CTRB 13 Floor area (Sq.M) - 26 Maximum Speed (Loaded)/ Empty 75 kmph / 80 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 25 of 51 FIG. 1.16 BCNAHS COVERED WAGON (RDSO Drg. No. WD- 90030 – S- 51) INTRODUCTION: - This wagon is variant of BCNA wagon with high speed bogie CASNUB-22HS-BOGIE. The other parameters of this wagon are same as of BCNA wagon. STANDARD FEATURES OF ‘BCNAHS’ COVERD WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 13521 14 Cubic Capacity (Cu.M) 103.40 2 Length over couplers (mm) 14450 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 13515 16 Tare Weight (tonne) 24.6 4 Width inside/Width Overall (mm) 2944/3200 17 Pay load (tonne) 56.68 5 Height inside/Height (max.) from RL. 2677/4017 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 9500 19 Ratio gross load/Tare 3.3 7 Journal length × dia. (mm) RB144.5 Ø 20 Ratio (Pay load to tare) 2.3 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 5.625 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 43 10 Height of C.B.C. from R.L. (mm) 1104 23 Brake System Air Brake 11 C.G. from R.L. (empty) (m) 1.2395 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 1.9915 25 Bearing CTRB 13 Floor area (Sq.M) - 26 Maximum Speed (Loaded)/ Empty 100 kmph / 100 kmph WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 26 of 51 FIG. 1.17 BCNHL COVERED WAGON (RDSO Drg. No. WD- 06076 – S- 02) INTRODUCTION: - This wagon fitted with twin pipe graduated release air brake system, high tensile non transition type CBC and cast steel bogie to STR No. WD-17 CASNUB 22 HS Bogie 92 with latest amendment. STANDARD FEATURES OF BCNHL WAGON ‐DESIGN‐D S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 10034 mm 11 Pay load 70.8t. 2 Length over buffer/couplers 10963 mm 12 Ratio pay load /tare 3.4 3 Length inside 10034 mm 13 Gross load 91.6 t. 4 Width inside/overall 3345/3450 mm 14 No. of wagons per rake 58 5 Height inside/from rail 3024/4305mm 15 Throughput per rake 4106 t. 6 Bogie centres 7153 mm 16 Loading density 8.35 t./m 7 Journal centres 2260mm 17 Cubic capacity 92.54 m³ 8 Wheel dia. On tread 1000mm 18 Speed (empty/ loaded) 100 Kmph 9 Nominal max. axle load 22.9 t. 19 Type of coupler CBC 10 Tare 20.8t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 27 of 51 STANDARD FEATURES OF BCBFG WAGON (Food Grains) Drg. No.RSD-6337-052 S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 11861mm 11 Pay load 60.84 t. 2 Length over buffer/couplers 12790 mm 12 Ratio pay load /tare 2.38 3 Length inside 11770 mm 13 Gross load 87.28 t. 4 Width inside/overall 3140/3250 mm 14 No. of wagons per rake 49 5 Max. Height from rail 4260 mm 15 Throughput per rake 2981 t. 6 Bogie centres 8661 mm 16 Loading density 6.82 t./m 7 Journal centres 2260 mm 17 Cubic capacity 81.76 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) E‐75 & L‐75 9 Nominal max. axle load 21.82 t. 19 Type of coupler CBC 10 Tare 26.44 t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 28 of 51 FIG. 1.18 STANDARD FEATURES OF BCFC WAGON S. No. PARTICULARS Fly Ash Cement S. No. PARTICULARS Fly Ash Cement 1 Length over Hd. Stock 9784mm 9784mm 11 Pay load 49 t. 67.3 t. 2 Length over buffer/couplers 10713 mm 10713 mm 12 Ratio pay load /tare 2.22 3.06 3 Length inside 10084.7 mm 10084.7 mm 13 Gross load 71 t. 89.3 t. 3128.7/3245 3128.7/3245 58 58 4 Width inside/overall 14 No. of wagons per rake mm mm 5 Height inside/from rail 4165 mm 4165 mm 15 Throughput per rake 2842 t. 3904 t. 6 Bogie centres 6684 mm 6684 mm 16 Loading density 6.62 t./m 8.335 t./m 7 Journal centres 2260 mm 2260 mm 17 Cubic capacity 72.8 m³ 72.8 m³ 8 Wheel dia. On tread 1000 mm 1000 mm 18 Speed (empty/ loaded) 65 Kmph 65 Kmph 9 Nominal max. axle load 17.75 t. 22.32 t. 19 Type of coupler CBC CBC 10 Tare 22 t. 22 t. 20 Type of bearing CTRB CTRB WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 29 of 51 FIG. 1.19 BRN FLAT WAGON (RDSO Drg. No. WD- 84013 – S- 1) INTRODUCTION: - This bogie rail wagon was designed in 1994. The design was improvement of earlier design of BRH wagon. The wagon Design is with air brake and welded construction. STANDARD FEATURES OF ‘BRN’ FLAT WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 13716 14 Maximum axle load (tonne) 20.32 2 Length over couplers (mm) 14645 15 Tare Weight (tonne) 24.393 3 Length inside (mm) 13716 16 Pay load (tonne) 56.887 4 Width inside/Width Overall (mm) 2845 17 Gross load (Pay+Tare) (tonne) 81.28 5 Height inside/Height (max.) from RL. ---/ 2544 18 Ratio gross load/Tare 3.33 6 Bogie centers (mm) 9144 19 Ratio (Pay load to tare) 2.33 7 Journal length × dia. (mm) RB144.5 Ø 20 Track Loading density (tonnes/meter) 5.55 8 Journal centers (mm) 2260 21 No. of wagons per train 42 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 Brake System Air Brake 10 Height of C.B.C. from R.L. (mm) 1105 23 Coupler C.B.C. 11 C.G. from R.L. (empty) (m) - 24 Bearing CTRB 12 C.G. from R.L. (loaded) (m) - 25 Maximum Speed (Loaded)/ Empty 75 kmph / 80 kmph 13 Floor area (Sq.M) - WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 30 of 51 FIG. 1.20 BRNA FLAT WAGON (RDSO Drg. No. WD- 92004 – S- 02) INTRODUCTION: - This bogie rail wagon was designed by improvement of BRN wagon in 1992. The design was riveted cum welded construction. It is higher pay to tare ratio as compared to BRN wagon. STANDARD FEATURES OF ‘BRNA’ FLAT WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 13716 14 Maximum axle load (tonne) 20.32 2 Length over couplers (mm) 14645 15 Tare Weight (tonne) 23.543 3 Length inside (mm) 13716 16 Pay load (tonne) 57.737 4 Width inside/Width Overall (mm) 2845 17 Gross load (Pay+Tare) (tonne) 81.28 5 Height inside/Height (max.) from RL. (mm) 2544 18 Ratio gross load/Tare 3.452 6 Bogie centers (mm) 9144 19 Ratio (Pay load to tare) 2.452 7 Journal length × dia. (mm) RB144.5 Ø 20 Track Loading density (tonnes/meter) 5.55 8 Journal centers (mm) 2260 21 No. of wagons per train 42 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 Brake System Air Brake 10 Height of C.B.C. from R.L. (mm) 1105 23 Coupler C.B.C. 11 C.G. from R.L. (empty) (m) - 24 Bearing CTRB 12 C.G. from R.L. (loaded) (m) - 25 Maximum Speed (Loaded)/ Empty 75 kmph / 80 kmph 13 Floor area (Sq.M) - WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 31 of 51 FIG. 1.21 STANDARD FEATURES OF BRSTN WAGON S. No. PARTICULARS Parameter S. No. PARTICULARS Parameter 1 Length over Hd. Stock 13716mm 11 Pay load 56.27 t. 2 Length over buffer/couplers 14998 mm 12 Ratio pay load /tare 2.25 3 Length inside 13716 mm 13 Gross load 81.28 t. 4 Width inside/overall 3200mm 14 No. of wagons per rake 41 5 Height inside/from rail 1264 mm 15 Throughput per rake -- 6 Bogie centres 9144 mm 16 Loading density 5.419 t/m. 7 Journal centres 2260 mm 17 Cubic capacity FLAT WAGON 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 80/75 Kmph 9 Nominal max. axle load 20.32 t. 19 Type of coupler CBC 10 Tare 25.01 t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 32 of 51 FIG. 1.22 STANDARD FEATURES OF BRHNEHS WAGON (WD-04 004-S-52) S. No. PARTICULARS Parameter S. No. PARTICULARS Parameter 1 Length over Hd. Stock 13716mm 11 Pay load 58.68 t. 2 Length over buffer/couplers 14986/14998 mm 12 Ratio pay load /tare 2.596 3 Length inside 12716mm 13 Gross load 81.28 t. 4 Width inside/overall 2845/3049 mm 14 No. of wagons per rake 41 5 Height inside/from rail 1264 mm/2008mm 15 Throughput per rake 2406 t. 6 Bogie centres 9144 mm 16 Loading density 5.419 t/m 7 Journal centres 2260 mm 17 Cubic capacity Flat Wagon 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 65/65 kmph 9 Nominal max. axle load 20.32 t. 19 Type of coupler Transition type CBC 10 Tare 22.6 t. 20 Type of bearing CTRB (6X11) E‐Class WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 33 of 51 STANDARD FEATURES OF BRN WAGON ‐22.9 t S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 13716mm 11 Pay load 68.292 t. 2 Length over buffer/couplers 14645 mm 12 Ratio pay load /tare 2.93 3 Length inside 13716 mm 13 Gross load 91.6 t. 4 Width inside/overall 2930 mm inside 14 No. of wagons per rake 42 5 Height inside/from rail 2555mm from R.L. 15 Throughput per rake 2868 t 6 Bogie centres 9144 mm 16 Loading density 6.25 t/m. 7 Journal centres 2260 mm 17 Cubic capacity FLAT WAGON 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 65/65 Kmph 9 Nominal max. axle load 22.9 t. 19 Type of coupler CBC 10 Tare 23.3 t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 34 of 51 FIG. 1.23 STANDARD FEATURES OF BOMN WAGON S. No. PARTICULARS Parameter S. No. PARTICULARS Parameter 1 Length over Hd. Stock 18460mm 11 Pay load 35.850 t. 2 Length over buffer/couplers 19742 mm 12 Ratio pay load /tare 1.2 3 Length inside 18460 mm 13 Gross load 65.626 t. 4 Width inside/overall 3100/3200 mm 14 No. of wagons per rake 31 5 Height inside/from rail 1275 mm 15 Throughput per rake - 6 Bogie centres 13890 mm 16 Loading density 3.324 t/m. 7 Journal centres 2260 mm 17 Cubic capacity FLAT WAGON 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 80/75 Kmph 9 Nominal max. axle load 16.4 t. 19 Type of coupler CBC 10 Tare 29.776 t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 35 of 51 FIG. 1.24 BFNS FLAT WAGON (RDSO Drg. No. WD- 98057 – S- 02) INTRODUCTION: - This bogie flat steel wagon is the one of the first wagon designed in Indian Railways to carry point load in 1998. The wagon was designed specially for transportation of hot rolled/cold rolled coils, plates, sheets and billets etc. STANDARD FEATURES OF ‘BFNS’ FLAT WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 13716 14 Maximum axle load (tonne) 20.32 2 Length over couplers (mm) 14645 15 Tare Weight (tonne) 26.71 3 Length inside (mm) 13716 16 Pay load (tonne) 54.57 4 Width inside/Width Overall (mm) 2845 17 Gross load (Pay+Tare) (tonne) 81.28 5 Height inside/Height (max.) from RL. --- 18 Ratio gross load/Tare 3.043 6 Bogie centers (mm) 9144 19 Ratio (Pay load to tare) 2.043 7 Journal length × dia. (mm) RB144.5 Ø 20 Track Loading density (tonnes/meter) 5.55 8 Journal centers (mm) 2260 21 No. of wagons per train 42 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 Brake System Air Brake 10 Height of C.B.C. from R.L. (mm) 1105 23 Coupler C.B.C. 11 C.G. from R.L. (empty) (m) - 24 Bearing CTRB 12 25 Maximum Speed (Loaded)/ Empty 100/100 kmph (75/80Kmph, in case of C.G. from R.L. (loaded) (m) - speed certificate conditions not meeting) 13 Floor area (Sq.M) - WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 36 of 51 FIG. 1.25 HOPPER TYPE “BOBR”WAGON (RDSO Drg. No. WD – 86013 – S - 51) INTRODUCTION: - This wagon is designed for transportation of coal with bottom discharge facility for faster evacuation. STANDARD FEATURES OF ‘BOBR’ HOPPER WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 10671 14 Cubic Capacity (Cu.M) 57.2 2 Length over couplers (mm) 11600 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 8732 16 Tare Weight (tonne) 26.40 4 Width inside/Width Overall (mm) 3340/3500 17 Pay load (tonne) 54.88 5 Height inside/Height (max.) from RL. 2461/3735 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 7571 19 Ratio gross load/Tare 3.08 7 Journal length × dia. (mm) RB144.5Ø 20 Ratio (Pay load to tare) 2.08 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 7.00 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 53 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air brake 11 C.G. from R.L. (empty) (m) 1.13 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 2.06 25 Bearing CTRB 13 Floor area (Sq.M) --- 26 Maximum Speed (Loaded)/ Empty 80 kmph / 80 kmph WAGON MAINTENANCE MANUAL  CHAPTER 1- INTRODUCTION Page 37 of 51 FIG. 1.26 HOPPER TYPE BOBRN WAGON (RDSO Drg. No. WD – 91071 – S - 51) INTRODUCTION: - This wagon is a variant BOBR with air brake and has two doors. STANDARD FEATURES OF ‘BOBRN’ HOPPER WAGON S.No PARTICULARS Parameter S.No PARTICULARS Parameter 1 Length over head stock (mm) 9671 14 Cubic Capacity (Cu.M) 56.78 2 Length over couplers (mm) 10600 15 Maximum axle load (tonne) 20.32 3 Length inside (mm) 9327 16 Tare Weight (tonne) 25.61 4 Width inside/Width Overall (mm) 3340/3500 17 Pay load (tonne) 55.67 5 Height inside/Height (max.) from RL. 2466/3735 18 Gross load (Pay+Tare) (tonne) 81.28 6 Bogie centers (mm) 6790 19 Ratio gross load/Tare 3.174 7 Journal length × dia. (mm) RB144.5Ø 20 Ratio (Pay load to tare) 2.174 8 Journal centers (mm) 2260 21 Track Loading density (tonnes/meter) 7.67 9 Wheel dia. on tread (New/Worn) (mm) 1000/906 22 No. of wagons per train 58 10 Height of C.B.C. from R.L. (mm) 1105 23 Brake System Air brake 11 C.G. from R.L. (empty) (m) 1.12 24 Coupler C.B.C. 12 C.G. from R.L. (loaded) (m) 2.241 25 Bearing CTRB 13 Floor area (Sq.M) --- 26 Maximum Speed (Loaded)/ Empty 70 kmph / 75 kmph WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 38 of 51 FIG. 1.27 STANDARD FEATURES OF BOBRNHS WAGON (20.32 t) WD‐91071‐S‐51(Alt-10) S.No. Particulars Parameter S. No. Particulars Parameter 1 Length over Hd. Stock 9671mm 11 Pay load 55.67 t. 2 Length over buffer/couplers 10600 mm 12 Ratio pay load /tare 2.17 3 Length inside 9327 mm 13 Gross load 81.28 t. 4 Width inside/overall 3340/3500 mm 14 No. of wagons per rake 58 5 Height inside/from rail 2466/3735 mm 15 Throughput per rake 3228.86 t. 6 Bogie centres 6790 mm 16 Loading density 7.67 t/m. 7 Journal centres 2260 mm 17 Cubic capacity 56.78 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 100/100 Kmph 9 Nominal max. axle load 20.32 t. 19 Type of coupler CBC 10 Tare 25.61 t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 39 of 51 STANDARD FEATURES OF BOBRNHSM1 WAGON(22.32 t) (CC+6t+2t) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 9671mm 11 Pay load 63.67 t. 2 Length over buffer/couplers 10600 mm 12 Ratio pay load /tare 2.48 3 Length inside 9327 mm 13 Gross load 89.28 t. 4 Width inside/overall 3340/3500 mm 14 No. of wagons per rake 58 5 Height inside/from rail 2466/3735 mm 15 Throughput per rake 3692.86 t 6 Bogie centres 6790 mm 16 Loading density 8.42 t/m 7 Journal centres 2260 mm 17 Cubic capacity 56.78 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 65/60 Kmph 9 Nominal max. axle load 22.32 t. 19 Type of coupler CBC 10 Tare 25.61 t. 20 Type of bearing CTRB STANDARD FEATURES OF BOBRNEL WAGON (25.0 t) (Iron Ore) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 9671mm 11 Pay load 74.39 t. 2 Length over buffer/couplers 10600 mm 12 Ratio pay load /tare 2.9 3 Length inside 9327 mm 13 Gross load 100.00 t. 4 Width inside/overall 3340/3500 mm 14 No. of wagons per rake 58 5 Height inside/from rail 2466/3735 mm 15 Throughput per rake 4314.62 t. 6 Bogie centres 6790 mm 16 Loading density 9.43 t/m. 2260 mm (Marking has been done for loading of 7 Journal centres 17 Cubic capacity Iron Ore upto 1725 mm. Height from top of centre sill) 1000 mm 60+5/45+5 (Provisional) Kmph 8 Wheel dia. On tread 18 Speed (empty/ loaded) 9 Nominal max. axle load 25.00 t. 19 Type of coupler -- 10 Tare 25.61 t. 20 Type of bearing -- WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 40 of 51 STANDARD FEATURES OF BOBRNM1 WAGON (22.32t) (CC+6t+2t) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 9671mm 11 Pay load 63.67 t. 2 Length over buffer/couplers 10600 mm 12 Ratio pay load /tare 2.48 3 Length inside 9327 mm 13 Gross load 89.28 t. 3340/3500 mm 58 4 Width inside/overall 14 No. of wagons per rake 5 Height inside/from rail 2466/3735 mm 15 Throughput per rake 3692.86 t 6 Bogie centres 6790 mm 16 Loading density 8.42 t/m 7 Journal centres 2260 mm 17 Cubic capacity 56.78 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 80/70 Kmph 9 Nominal max. axle load 22.32 t. 19 Type of coupler CBC 10 Tare 25.61 t. 20 Type of bearing CTRB STANDARD FEATURES OF BOBRN WAGON (22.32t) (CC+6t+2t) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 9671mm 11 Pay load 63.67 t. 2 Length over buffer/couplers 10600 mm 12 Ratio pay load /tare 2.48 3 Length inside 9327 mm 13 Gross load 89.28 t 4 Width inside/overall 3340/3500 mm 14 No. of wagons per rake 58 5 Height inside/from rail 2466/3735 mm 15 Throughput per rake 3692.86 t. 6 Bogie centres 6790 mm 16 Loading density 8.42 t/m 7 Journal centres 2260 mm 17 Cubic capacity 56.78 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) 65/60 Kmph 9 Nominal max. axle load 22.32 t. 19 Type of coupler CBC 10 Tare 25.61 t. 20 Type of bearing CTRB WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 41 of 51 RL FIG. 1.28 STANDARD FEATURES OF BOBYN/ BOBYNHS WAGON (WD-96081-S-02) (Alt-8) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 10718mm 11 Pay load 66.4 t. 2 Length over buffer/couplers 11647 mm 12 Ratio pay load /tare 2.6 3 Length inside 9000 mm 13 Gross load 91.6 t. 4 Width inside/overall 2863/3189 mm 14 No. of wagons per rake 50 (in 585 M) 5 Height inside/from rail 2018/3287 mm 15 Throughput per rake 3320 t. 6 Bogie centres 7470 mm 16 Loading density 7.86 t/m 7 Journal centres 2260 mm 17 Cubic capacity 46.1 m3 8 Wheel dia. On tread 1000 mm 18 Speed (empty/ loaded) -- 9 Nominal max. axle load 22.9 t. 19 Type of coupler NT. CBC 10 Tare 25.2 t. 20 Type of bearing CTRB (6X11) EClass WAGON MAINTENANCE MANUAL CHAPTER 1- INTRODUCTION Page 42 of 51 FIG. 1.29 STANDARD FEATURES OF ‘BOBYN 22.9’ WAGON –(22.9 WD-09090-S-02) (Design B) S.No. PARTICULARS Parameter S.No. PARTICULARS Parameter 1 Length over Hd. Stock 10718mm 11 Pay load 66.3 t. 2 Length over buffer/couplers 11647 mm 12 Ratio pay load /tare 2.6 3 Length inside