CnW Maintenance Manual - 70-90 PDF

CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 1 of 21 CHAPTER 2 MAINTENANCE, WARRANTY & CONDEMNATION This chapter gives general information about periodicity of various types of inspections and...

CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 1 of 21 CHAPTER 2 MAINTENANCE, WARRANTY & CONDEMNATION This chapter gives general information about periodicity of various types of inspections and maintenance schedules for goods stock on open line. Prescribed period at which POH is to be carried out on various types of stock has also been given. However, special practices to be followed for repairs during POH are indicated in the concerned chapters later in the manual. At the end of this chapter, prescribed intervals for POH and ROH of wagons at a glance are given in the tables 2.1, 2.2 & 2.3. 201. WARRANTY INSPECTION OF NEWLY BUILT WAGONS a) All newly built wagons have a warranty period of 24 months or as prescribed in the purchase contract. In accordance with the conditions mentioned in the wagon manufacturing contracts, the charges for rectification of the following category of defects can be realised from the wagon builder :-  Use of inferior material  Poor workmanship on the part of contractor  Imperfect protection  Other faults on the part of contractor which are noticed during the warranty period. b) To enable the Railway Board to realise the warranty charges, a systematic inspection of new wagons must be undertaken by representative of C&W to locate defects during the warranty period. The following procedure is laid down for this purpose:- (i) All newly built wagons turned out must bear the warranty legend stencilled on both sides of the wagons. The warranty legend will consist of the following particulars:-  Contract Number  Date of Commissioning  Commissioned by  Inspection due on  Inspection done by ______ Depot_______ Date_______ (ii) Whenever wagons due for warranty inspection pass nominated yards, preferably detach them from the train and send to sick line for a systematic check. (iii) Examination of Defects: During the course of warranty inspection, it must be borne in mind that only those defects, which are attributable to the manufacturer due to use of inferior material, poor workmanship, improper protection or any other faults, are to be WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 2 of 21 reported. The following are some of the defects, which fall under this category:- A) Welding defects  All types of welding failures  Welding defects such as insufficient or unequal leg length of fillet weld, porosity, lack of fusion, etc. B) Riveting/ Lock Bolting defects  Loose rivets/ Lock bolts  Badly formed rivet heads/ Lock bolt‟s collars  Rivets with staggered heads  Improperly filled holes  Pin tail of lock bolt not removed. C) Manufacturing /Fitting Defects  Improper manufacturing/ fitting of parts D) Material failures such as breakage of:  CBC components  Centre pivots  DV/ brake cylinder  EM pads/ PU side bearers E) Improper Protection  Improper painting of underframe body, roof and components resulting in corrosion  Wagons not being water tight F) Train Pipe leakage and unsatisfactory working of brake cylinders G) Roller Bearing Defects Wagons fitted with roller bearings are normally examined only in major sick lines. If any defect is noticed, the entire wheel assembly must be sent to the workshop. After inspection in the workshop, if it is felt that the defect is attributable to the contractor/ manufacturer, the workshop incharge should report the defect to the concerned roller bearing manufacturer and others concerned. Since the Railways normally supply wheels and axles to the builder, defects noticed on the wheel and axles need not be reported to the wagon builders. However, the extant instructions for reporting any defect on the wheels and axles must be followed. The procedure of warranty inspection of BTPN wagons is same as above with special attention to internal and external examination of barrel WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 3 of 21 for any failure of longitudinal/ circumferencial joint, lamination defects in barrel and dish end plates, cracks in barrel, leakage by barrel fittings and examination of cradles and anchoring rivets as per Technical pamphlet No. G-90. c) METHOD OF REPORTING A. The particulars, which are to be furnished, are as follows:- i. Contract No. This indicates the contract number under which the order has been placed by the Railway Board on the Wagon Builders for the manufacturer of wagons. This will be stencilled on the wagon in the Warranty legend. The representative of C&W should ensure that correct particulars as obtained from the wagon are filled. ii. Wagon number iii. Wagon Code iv. Owning Railway v. Month and Year of manufacture vi. Name of the Manufacturer vii. Date of Warranty Inspection viii. Defects attributable to the Manufacturer - All the defects attributable to the manufacturer should be clearly indicated. The actual location of the defect should be clearly recorded. In the case of material failure, it is essential that such items should be sent to the Chemist and Metallurgist of the respective Railways so as to enable him to submit the test reports. While sending the materials to the CMT, the particulars of the wagon i.e. the wagon No., owning Railway, Wagon code the Builders‟ name, the Contract Number and the serial number of the Warranty Inspection Report must be mentioned in the forwarding memo. These particulars can be included in the Test Report submitted by the CMT. This will facilitate in connecting the test reports with the respective Warranty reports at the Railway Board‟s Office. The CMT will send his analysis report direct to the Railway Board‟s office. In order to prefer the claims expeditiously as possible, it is desired by the Board that the reports of Chemist and Metallurgist should be sent to the Secretary (WP), Warranty, Railway Board, New Delhi, within 20 days from the date of warranty inspection. The report of the CMT should not be sent to the wagon Builders. A „NIL‟ defect report should be sent if there are no defects attributable to the manufacturers. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 4 of 21 B. Estimated cost of rectification No estimates are to be furnished by representative of C&W in the warranty inspection reports. Against this column, simply mention “Cost will be advised by the Railway Board”. Along with other remarks, if any, a written certificate must be given to the effect that the defects mentioned have arisen due to inferior material (i.e. material of wrong specification or cheap quality) or bad workmanship (poor workmanship like bad riveting, welding, fitting etc.) or imperfect protection of the components (Brake cylinder rusted etc.) or any other defaults on the contractor’s part. C. Numbering of the report In order to enable the Board‟s office to keep a check on the performance of each nominated C&W Depot and also to detect the missing reports, all Warranty Inspection Reports must be serially numbered. For uniformity it is desired that the C&W Depots should indicate the number of Warranty reports in three barrels by indicating the station code in the first barrel, Warranty in the 2nd barrel and serial number of the report in the last barrel. For example ASN/WTY/81 indicates that this warranty report was sent from Asansol Wagon depot, ‘WTY’ refers to Warranty report and ‘81’ refers to the serial number of the warranty report i.e. serial number the wagon which has been warranty inspected from the commencement of the inspection. Date on which the Warranty report is submitted must be indicated. The representative of C&W who signs the report should ensure that his designation is properly recorded by affixing his rubber stamp, which should indicate the designation as well as the reporting station. D. Disposal of the Proforma  In the case of wagons built by railway workshops, the report should be sent to the following addresses :- 1. The workshop which manufactured the wagon 2. CME of the manufacturing Railway. 3. Secretary (WP)/Railway Board/New Delhi. 4. CME of the inspecting zonal railway 5. Sr. D.M.E. of the inspecting division  In the case of wagons built by private manufacturers, the report should be sent to the following addresses :- 1. Wagon builder 2. Secretary (WP)/Railway Board, New Delhi. 3. G.M.(Mech.) of the inspecting zonal railway 4. CME of the inspecting zonal railway 5. Sr. D.M.E. of the inspecting division. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 5 of 21 E. It is necessary that Senior Divisional Mechanical Engineer must send the warranty inspection report to the parties indicated above after inspection without any delay. F. After submission of the warranty reports, the Railway Board will decide the finalisation of claims. If any wagon builder returns the warranty report or refuses to accept the claim, such cases must be immediately advised to Railway Board. d) MAINTENANCE OF RECORDS The Train Examining Depot should maintain following files and registers: One file for filing all the policy instructions on warranty inspection received from their divisional office/CME. The representative of C&W should be conversant with the instructions issued from time to time. It is desired that an index sheet be maintained giving the particulars of the letters so as to keep a continuity of all the instructions. A second file for filling all the warranty inspection reports, intermediate or finally submitted by the Depot. A third file should be maintained for filing all correspondence regarding warranty inspection, periodical statements of inspections carried out etc. A register should be maintained giving the following details of the wagons inspected during the warranty period :- a) Date of Inspection b) Wagon No. c) Owning Railway d) Wagon Code e) Name of Builder f) Date of Commissioning g) Defects noticed h) Warranty inspection report no. and Date i) Remarks The above inspection procedure of warranty inspection does not in any way preclude any Railway from reporting any defect direct to the wagon builder and to the parties mentioned above. In the same manner, if defects are noticed at any time during the warranty period. During the intermediate warranty inspection, stencilling of the Station Code and date of Inspection should not be done on the wagon. This should only be done at the time of final warranty inspection. 202. EXAMINATION AND MAINTENANCE PERIODICITY a) ROLLING IN EXAMINATION All terminating trains are to be given “Rolling-in-examination” while entering a station having a train examining depot. After rolling in examination when the train stops in yard, immediately feeling of axle boxes is necessary to detect hot/ warm axle box. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 6 of 21 b) EXAMINATION OF TERMINATING LOAD Examination of terminating loads is to be carried out as soon as the train comes to a halt. For the examination of terminating loads, the pattern of train examination issued by individual Zonal Railway keeping in view the Railway Board‟s guidelines issued vide their letter no. 94/M(N)/951/57 dated 28.2.2000 or latest instructions shall be followed. c) EXAMINATION OF TRAIN AT ORIGINATING STATION i. The train examining staff must ensure that the wagons are in fit condition and do not have any rejectable defects. A certificate has to be given to the Station Master by Sr. SE/JE(C&W) to this effect before despatch of the train. Before issuing fit Certificate, train examining staff to ensure requisite percentage of brake power. For details refer Chapter 3. ii. The level of air pressure on the engine & brake van alongwith the percentage of effective brake cylinders must be recorded on the brake certificate duly countersigned by the driver and guard. iii. Wagons, which have been humped, must be specially checked for damages occurring due to impacts during humping. d) MAKING WAGONS FIT TO RUN BY PASSENGER TRAIN Goods wagon may be attached to a passenger train provided the maximum speed to the train does not exceed 100 Kmph. The wagons must satisfy the following condition:- (RDSO letter No. MW/BCNA dated 30.05.2003 and MW/BOXN dated 04.07.2003.) i. They are fully fitted with operative brake cylinders ii. The wagon should not be overloaded or unevenly loaded iii. Wagon fitted with wheels having no star marks on journal cap to be ensured by duly opening the Axle Box cover iv. Wagons should not be overdue POH/ROH e) INTENSIVE EXAMINATION The purpose of intensive examination of goods stock is to permit extended run of through trains by raising the general standard of fitness of rolling stock by concentrated attention at the time of despatch from originating yards. Note: The details of above examinations are given in Chapter 3. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 7 of 21 203. ROH OF AIR BRAKE WAGON WITH CASNUB BOGIE Wagon stock should be given Routine Over-Haul (ROH) at the nominated sick line/wagon depots, where proper facilities are provided (for details, see para 206, table No. 2.2). The ROH schedule is as follows: a) Lift the body, keep it on trestles and run out bogies. b) Strip bogie component for examination and repair as below: Strip spring & spring suspension arrangement including snubbing device. Check springs for free height and other defects. Replace where required.  Examine Bogie frame. Check frame alignment as per instructions contained in RDSO Technical Pamphlet No. G-95.  Examine pivot for welding defects/cracks/abnormal depth due to wear. Replace where necessary and lubricate with graphite flakes to IS:495 in dry condition. c) Strip brake gear levers and rods for examination of worn out/damaged parts. d) The equipment shall be given attention in accordance with the maintenance manual issued by respective air brake equipment manufacturer and RDSO technical pamphlet no. G-97. i. Cleaning of strainer discs (Reference 6 & 218 of the pamphlet SBA 795/258 of P4aG type Distributor Valve) ii. Lubrication of brake cylinder/cleaning of its strainer iii. Check for easy operation of isolating cock & anti-pilferage device of distributor valve cut-off angle cock, manual quick release valve & isolating cock. iv. Draining of Auxiliary Reservoir v. Checking of hose coupling for serviceability vi. Cleaning of strainer vii. Dirt collector to be cleaned viii. Leakage in pipes and joints to be checked ix. After carrying out above items of work the wagon shall be tested for proper function of air brake system with single car test device in accordance with the procedure indicated below : Connect the BP coupling of single car test rig to the corresponding coupling of the wagon to be tested.The couplings of the other end of the wagon to be closed with dummy coupling heads.Fix pressure gauge on the brake cylinder. The single car test device should now be coupled to the main line of a compressor through a pipe. Carry out the preparation and testing in accordance with the procedure given in the manufacturers Maintenance Manual and record the reading in the test proforma. For passing the wagon, all the parameters shall be within specified limits. e. Clean horizontal lever, hand brake & gears and lubricate f. Examine head stock for damage, bent/cracks WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 8 of 21 g. Refit brake gear levers and rods, lubricate pins and other equipment and apply graphite to horizontal levers of empty load box h. Replace worn out brake blocks i. Check wheel profile, turn the wheels. UST of Axle to be carried out & turning of wheel to worn wheel profile during ROH be done. j. All the wheels are to be checked ultrasonically & ensure stamping as per Annexure IV and End Axle cap bolts are to be tightened up by torque wrench with proper torque (40 kg-m) and in no case old locking plates are to be reused. k. CBC Knuckles and coupler body are to be checked by contour gauge as per Technical Pamphlet no. G-76. Anti creep/ articulated rotary operation of locking arrangement to be checked. l. Manual adjustment of brake gear to be done in accordance with wheel diameter. Setting of Empty load device and A & E dimension of SAB shall also be done before SWTR test. m. Modification work are to be attended as issued by RDSO from time to time. n. CTRB of wheel should not be over due POH schedule. 204. CATEGORISATION OF WAGON REPAIR Classification of wagon repairs have been rationalised under the following nomenclature:- a) Petty Repairs :- Repairs involving not more than 8 man - hours. Such repairs are to be normally carried out on nominated lines in traffic yards in less than 8 man hours. b) Medium Repairs :- Repairs involving more than 8 man - hours and upto 100 man - hours. These would normally cover repairs to underframe members viz. head stock, middle bars, sole bars, changing of axle guards, wheel changing heavy panel patching, heavy floor repairs, etc. Such repairs are to be carried out in sick lines. c) Special Repairs :- Repairs to heavily damaged wagons involving more than 100 man hours. Such repairs may be carried out either in the workshops or in major sick line. Recommended work areas where serious repairs should be carried out are given in the Table 2.4 at the end of this chapter. Repair to under frame members and other heavy work should be dealt in properly equipped major and medium sickline. Repair to under frame members viz. patching of headstock, sole bar and middle bars, strengthening of bulged ends, replacement of end angle, fitment of more than 5 new full width panel patches, replacement of axle guards to be done in sickline / wagon depot. “BOXN wagon variants requiring repair are classified as under: Category A : BOXN wagons requiring petty repairs which can be attended in sick lines. Category B : unloadable BOXN wagons, which require attention/body repairs in well equipped sick lines or ROH depots. Category C: unloadable BOXN wagons requiring very heavy repair on body/floor. These may be attended in wagon depots nominated for Category C repairs or in workshops. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 9 of 21 Note : unloadable BOXN wagons in the age-group of 12-18 yrs. may be taken up for upgraded rehabilitation (BOXNR) as per RDSO‟s document No. WD-16-BOXNR-2010 of Sep. 2010. JE/SSE(C&W) shall do the classification /marking of the wagons under the above 3 categories in open line. For booking the wagon to workshop for category C repairs, prior approval of CRSE(Fr.) should be taken. In case the Category C repairs are arising on account of damages during loading/unloading, a report should be sent by the SSE(C&W) of the depot where the damages are detected to the Sr.DME(C&W) of the division as well as Sr.DME(C&W) where the damages are occurring. BOXN wagons of 8-22 yrs. of age, which are heavily corroded or have extensive body repairs, may be selected for rehabilitation. During rehabilitation, wagon should also undergo POH and return date should be marked accordingly. All such rehabilitated wagons should be painted with golden yellow for easy identification. BOXN C category wagons which are sent to workshop as NPOH with prior approval of CRSE(Fr.) , and which are not taken up for rehabilitation, should be given POH in case its POH is due within next 12 months. Similarly, such wagons which are falling due for ROH within next 6 months (but not due for POH within next 12 months) should be given ROH attention. Wagons so attended for POH/ROH should be stencilled with a fresh return date as per laid down periodicity for BOXN wagons. The repair of BOXN wagons should be carried out as per instructions contained in RDSO‟s G-70.” WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 10 of 21 205. CONDEMNATION OF WAGONS For condemnation of rolling stock, the powers delegated to various officers on zonal railways through their Schedule of Powers may be used. a) Condemnation of over-age wagons Over aged wagon stock can be inspected personally by CWM/Dy. CME/WM- Incharge/Sr.DME and condition report prepared and personally signed. Condemnation can be approved by any of these officers. Codal life of wagon stock: [ Railway Board’s letter No.2004/M(N)951/2 Dated 26.05.2006 ] SN Type of wagon stock Codal life 01 Open bogie wagon with air brake & CASNUB bogie 30 Years 02 Bogie Tank wagon with air brake & CASNUB bogie 40 Years 03 All other type of bogie wagons with air brake & 35 Years CASNUB Bogie. Certain issues have been clarified in Railway Board’s letter No. 2007/M(N)/60/7 dated 21.10.2010. The same are summarised below:- b) Condemnation of under-age wagons Under aged wagon stock should be inspected personally by CWM/Dy.CME/WM- Incharge/Sr.DME and condition report prepared and personally signed. Condemnation proposals should be sent to CME/CRSE for approval duly concurred by associated finance i.e., WAO of the workshop concerned, further this proposal to expedite the whole process, following procedure to be adopted:- BG and MG wagons should be condemned on „as is where is‟ basis and moved from division to the yards/stations nominated by DRMs. Each DRM should nominate sufficient number of yards/stations on their division for disposal of condemned wagons. Workshops can continue the present practice of sending the wagons to scrap yards. Policy for Pre-Mature Condemnation of Wagons: Board (MM & FC) have approved the following policy for pre-mature condemnation of the wagons vides Rly. Boards letter No 2007/M(N)/60/7 dated 21.10.2010. SN Category of wagons Competence for approving premature condemnation 01 All accident damaged wagons & Vacuum CMEs brake stock 02 Non Accident Air Brake Stock of CMEs with FA&CAOs concurrence morethan 25 years of age 03 Non Accident Air Brake Stock of the age Railway Board ( In this case, the of 25 Years or less proposal should be duly vetted by FA&CAO and approved by GM). Board‟s approval will normally be granted within 90 days from the date of receipt of proposal, in case the boards approval is not received within this time limit, the proposal will be deemed to have been approved and Railway may go ahead with the condemnation. The above policy does not restrict premature condemnation of any specific type of wagons permitted under specific instructions from the Railway Board. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 11 of 21 c) Use of Over-aged/ Condemnable Wagons for Departmental Purposes (Ref: Rly. Board’s letter No. 2007/M(N)/951/5 dated 11.11.2011) Overaged/ condemnable wagons which no longer remain unusable as traffic wagons, may be used for departmental purpose, with or without modifications, subject to the following provisions: i. Overaged/ condemnable wagons may be used for departmental purpose with the approval of authority competent for condemnation of such wagons. ii. In case departmental use requires modifications to be carried out on the wagons, such modifications should, invariably, have approval of RDSO except in cases where such modified wagons are pre-existing. For pre-existing modifications, approval of CME will be necessary. iii. Wagon modification work shall be carried out only at a POH workshop or at an open line wagon depot maintained by the CME. iv. Wagon selected for departmental use should provide service of minimum one POH cycle with prescribed preventive maintenance. The POH periodicity of such stock shall be same as the original wagon type. v. Departmental wagons may be used upto an age limit of 40 years on condition basis. The condition of such stock shall be reviewed in every ROH and POH to assess its suitability for continuity in service based on the extent safety norms. vi. In case it becomes necessary for any departmental stock to continue in service beyond age of 40 yrs., CME may extend the life of such stock, maximum one year (financial year) at a time upto an age limit of maximum 50 years. The annual condition reports of such wagons prepared by in-charge by base wagon depot, duly endorsed by the coordinating branch officer of Mechanical and the user department shall be put up to CME for approval prior to commencement of the financial year. Standard maintenance shall be carried out on such wagons during the period of extended life as per prescribed periodicity and all safety norms will be observed. vii. No departmental wagon shall be permitted to be in service beyond the age limit of 50 years. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 12 of 21 206. POH & ROH INTERVAL TABLE No. 2.1 POH INTERVAL OF AIR BRAKE STOCK Sr. Wagon Stock POH (Years) No. First Subsequent 01 BOXN, BOXNHS, BOXNHA, BOXNCR, 6 4.5 BOXNHL 02 BOXNR 4.5 4.5 03 BCN, BCNA, BCNAHS, BCNHL 6 6 04 BOST, BOSTHS, BOSTHSM2 6 4.5 05 BRN,BRNA, BRNAHS, BRN22.9, BFNS, 6 4.5 BRHNEHS, BLC-A, BLC-B, BLL-A, BLL-B 06 BLCAM/BLCBM 6 4.5 07 BFKN (Container) 4 3.5 08 BOY 3 3 09 BTPH 4.5 4.5 10 BTPN 6 6 11 BOBR & BOBRN, BOBYN 6 6 12 BTPGLN, BTCS 4 4 13 BTALN, BTALNM 4.5 4.5 14 BOXNLW 6 6 Stainless steel wagons 15 BOXNEL, / BOYEL 3 3 (25 t axle load) 16 BOBRNEL, BOBSNM1 3 3 17 BVZI, BVZC Brake van 2 2 18 BVCM Brake van 2 2 19 BOMN 6 4.5 20 BRSTN, BWTB 6 6 21 BCACM, BCACBM 4.5 4.5 22 BTFLN, BTOH 6 6 23 BCFC 6 4.5 24 BCCNR 6 6 25 BAFRDR 6 4.5 Note: 1. Wagons become due POH on the last date of the month indicated in the return date. 2. Empty wagon will be marked sick for POH up to 30 days in advance of the due date 3. Loaded wagons will be allowed up to 30 days after the due date of POH. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 13 of 21 TABLE 2.2 ROH INTERVAL OF WAGONS Sr. Wagon Stock ROH (Months) No. First ROH Subsequent ROH of ROH of First Subsequent POH Cycle POH Cycle 1. BOXN, BOXNHS, BOXNHA, 18 18 18 BOXNCR, BOXNR 2. BOXNHL 24 24 18 3. BOST, BOSTHS, BOSTHSM2 18 18 18 4. BLCAM/BLCBM, BLLA, BLLB, 24 18 18 BLC-A/BLC-B 5. BFKN (Container) 18 18 18 6. BCN, BCNAHS, BCNA, 24 24 24 BCNHL 7. BCCNR 24 24 24 8. BOXNLW 24 24 24 9. BRN,BRNA,BRNAHS, 18 18 18 BRN22.9, BFNS, BRHNEHS, 10. BOBR, 24 24 24 BOBRN,BOBRNEL,BOBSNM1 11. BTPN, BTPH, BTALN, BTAL, 18 18 18 BTFLN, BTOH,BTALNM 12. BTCS, BTPGLN 24 24 24 13. BOY 18 18 18 14. BOBYN 24 24 24 15. BOXNEL, BOYEL 12 12 12 16. BVZI, BVZC, BVCM Brake Van 12 12 12 17. BOMN, BRSTN, BWTB 24 24 24 18. BCACM, BCACBM 18 18 18 19. BCFC 18 18 18 20. BAFRDR 18 18 18 207. WORK AREAS WHERE ATTENTION TO BE GIVEN Table 2.3 summarises the nature of work to be done during various examinations and repairs in sickline. It is clarified that activities shown under sick line are the one‟s which can be under taken in sickline based on the need. These are not to be carried out on each and every wagon visiting sickline. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 14 of 21 WORK AREAS WHERE ATTENTION TO BE GIVEN WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 15 of 21 TABLE 2.3 WORK AREAS WHERE ATTENTION TO BE GIVEN Sr. Nature of Repairs Repairs to be under taken at X No. Intensive Sick ROH POH repairs lines 1. BODY REPAIR WORK (Common for all) UNDERFRAME- Sole Bar Scrap the portion of sole bar at door ways, clean and apply primer paint followed by Top coat - - X X SIDE WALL- Skirting 1. Check and patch if corroded then apply primer and top coat on the patch - X X X 2. Side Doors- Check damage and repair clean & lubricate hinges X X X X 3. Side Pillars- Check cracks at the base & repair - X X X 4. Patching of body, roof, door or floor plates straightening buldged ends repairs to angle irons, - X X X stanchions and crib angles etc. 5. Making wagons water-tight (Covered wagons) - X X X 6. Fitting/replacement of door fastening road, door cotter pin eye, bolt hook and eye locking X X X X pin on empty wagons and closing of doors. 7. Fitting/replacement of door fastening rod guide, door hasp which requires riveting on empty - X X X wagons. Repairs by welding to door fittings. 8. Hand rail/foot board deficient/or damaged, insecurely fastened at door way of guard‟s brake X X X X van 2. UNDER GEAR REPAIR WORK ( Common for all ) Brake Linkage- Check free movement X X X X Hand Brake - Check proper working X X X X 3. BOGIE REPAIR WORKS A. CASNUB BOGIE BOLSTER 1. Pocket slope liner Change liner if thickness less than 5 mm - - X X 2. Rotation stop lugs Provide liners (thickness to suit) if dimensions less than 514 mm - - X X 3. Inner Column Gib Provide liners (thickness to suit) if dimension more than 142 mm - - X X 4. Land surface Provide liners (thickness to suit) if dimension less than 442 mm - - X X 5. Outer Column Gib Renew by welding if dimension more than 241 mm - - X X WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 16 of 21 Sr. Nature of Repairs Repairs to be under taken at X No. Sick Intensive lines ROH POH repairs SIDE FRAME 1. Column Friction Liner Change liner if dimension more than 455 mm - - X X 2. Column sides Provide liners (thickness to suit) if dimension less than 209 mm - - X X 3. Anti rotation lugs Provide liners (thickness to suit) if dimension more than 526 mm - - X X 4. Key seat to pad 22 W Provide liners (thickness to suit) if dimension more than 276 mm - - X X 5. Crown Roof 22WM Provide liners (thickness to suit) if dimension more than 321 mm - - X X 6. Crown Roof 22NL Provide liners (thickness to suit) if dimension more than 326 mm - - X X 7. Pedestal Crown Sides Renew by welding if dimension less than 147 mm - - X X 8. Pedestal Jaw 22 W Provide liners (thickness to suit) if dimension more than 275 mm - - X X 9. Pedestal Jaw 22 WM Provide liners (thickness to suit) if dimension more than 283 mm - - X X 10. Pedestal Jaw 22 Provide liners (thickness to suit) if dimension more than 195 mm - - X X NL(Short) 11. Pedestal Jaw 22 Provide liners (thickness to suit) if dimension more than 241 mm - - X X NL(Long) 12. Pedestal Sides 22 W Provide liners (thickness to suit) if dimension less than 102 mm - - X X 13. Pedestal Sides 22 WM Provide liners (thickness to suit) if dimension less than 102 mm - - X X 14. Pedestal Side 22 NL Provide liners (thickness to suit) if dimension less than 78 mm - - X X WEDGE 1. Slope Surface Replace the Wedge if slope surface wear is 3 mm - - X X 2. Vertical Surface Vertical surface from centre line of spigot wear limit: 54 mm - X X X Reclaim the worn surface by welding. CENTRE PIVOT (BOTTOM) 1. Vertical Side 22 W Renew by welding if wear more than 4 mm - - X X 2. Vertical Side 22 WM Renew by welding if wear more than 3 mm - - X X 3. Vertical Side 22 NL Renew by welding if wear more than 3 mm - - X X 4. Seat Side 22 W Renew by welding if wear more than 3 mm - - X X 5. Seat Side 22WM Renew by welding if wear more than 3 mm - - X X 6. Seat Side 22 NL Renew by welding if wear more than 3 mm - - X X WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 17 of 21 Sr. Nature of Repairs Repairs to be under taken at X No. Intensive Sick repairs lines ROH POH COIL SPRING 1. Outer Group and use in sets. Replace if free height at or less than 245 mm - X X X 2. Inner Group and use in sets. Replace if free height less than 247 mm - X X X 3. Snubber Group and use in sets. Replace if free height less than 279 mm - X X X ADAPTER - - X X Crown Surface Replace if worn 3.5 mm or more - - X X Side lug Replace if wear more than 3 mm on either side - - X X Thrust shoulder Replace if depth exceeds 0.7 mm - - X X Machined relief Replace if depth less than 0.8 mm - - X X BOGIE BRAKE GEAR Pins & Bushes Change if clearance more than 1.5 mm X X X X 4. AIR BRAKE SYSTEM Distributor Valve Overhauling - - - X Distributor Valve Test on SWTR - X X X DV Isolating Cock Examine operation X X X X DV Release valve Examine operation X X X X DV Filter Clean - - X X BRAKE CYLINDER Filter of Escorts & RPIL make Clean - - X X Brake Cylinder of Greysham & WSF Lubricate - - X X make CUT OFF ANGLE COCK Angle cock Examine and lubricate X X X X WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 18 of 21 Sr. Repairs to be under taken at X No. Nature of Repairs Intensive Sick ROH POH repairs lines Rubber Seals Change - - X X DIRT COLLECTOR - - - - Dirt Collector Clean - X X X Sealing Ring Change - - X X RESERVOIR AR & CR Drain - X X X Sealing Ring Change - - X X METAL PIPES & JOINTS Pipe Joints Examine leakage & repair X X X X Seals (20 mm & 32 mm)pipe Change X X X X Guard‟s Emergency Brake Valve Examine operation X X X X Isolating cock of BVZC Brake Van -do- X X X X Quick Coupling -do- X X X X Load Sensing Device -do- - X X X 5. SLACK ADJUSTER ( COMMON FOR ALL) Slack Adjuster Test Functioning, repair if required X X X X “A” dimension Adjust X X X X “e” dimension Adjust - X X X M20 Anchor Pin nut Ensure securing by welding to pin - X X X Air Brake System Test on SWTR as per procedure - X X X Brake Block Ensure Std. Key, Spilt pin & all new brake blocks X X X X NB: For detailed main procedure refer RDSO manual G-97. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 19 of 21 Sr. Repairs to be under taken at X No. Nature of Repairs Intensive Sick ROH POH repairs lines 6. CENTRE BUFFER COUPLER ( COMMON FOR ALL) CBC BODY Coupler Body Examine & replace on condition basis - X X X CBC Contour Examine, replace if required - X X X Shank Wear Plate Replace on condition - X X X KNUCKLE Nose Replace if wear more than 9.5 mm with HTE knuckle X X X X Knuckle pin Replace on condition X X X X Knuckle Stretch Examine, Replace if required - - X X STRIKER CASTING Wear Plate Replace - - X X Striker casting Replace on condition - - X X COUPLER MECHANISM Anti Creep Protection Examine and repair X X X X Lock lift assembly Examine X X X X Operation Mechanism Examine X X X X Lock Examine - X X X DRAFT GEAR Slack Measure & take correction - - X X GENERAL Yoke pin support Replace on condition - X X X Buffer Height Examine & Correct if required X X X X NB: 1. For detailed maintenance Practices in open line refer RDSO‟s Manual G-76 2. For detailed maintenance Practices in Workshop refer RDSO‟s Manual G-80 3. Knuckle with nose more than 4.3 mm and less than 9.0 mm can be used in yard. WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 20 of 21 Sr. Repairs to be under taken at X No. Nature of Repairs Intensive Sick ROH POH repairs lines 7. WHEEL AXLE & BEARING ( COMMON FOR ALL) AXLE Ultrasonic Testing (If wheel is changed) To be carried in every - - X X ROH/POH & reject if fails Deep Notches due to gearing of pull rod Reject if depth is more than 5 mm X X X X Axle end holes Clean and lubricate in case end cover is opened - X X X WHEEL Tread profile Check with tyre defect gauge X X X X Height of flange If height more than 31 mm do not use under ROH wagon - - X X Smooth flange If flange not completely smooth do not use under ROH wagon - - X X Wheel profile Turn to WWP if above clauses are not met for use under ROH wagon. - X X X BEARING TAPERED CARTRIDGE Cup Rotate the bearing for unusual sound check up for Crack/chipping - - X X Seal Check seal for external damage/dent - X X X Backing Ring Check backing ring for looseness & vent fitting on backing ring with - - X X vent hole ( the vent fitting should be intact or the vent hole should be plugged) Locking Plate Use new locking plate when ever and cover is opened - - X X Axle end Cap screw Clean and lubricate in case end cover is opened - - X X Load Zone Change Change load zone area of the cup while lowering bogie side frame - - X X WAGON MAINTENANCE MANUAL CHAPTER 2 –MAINTENANCE, WARRANTY & CONDEMNATION Page 21 of 21 NOMINAL, ROH & MAXIMUM CLEARANCES IN CASNUB BOGIES S. Particular Bogie Type Measurement of Location Total Clearance in mm Nominal No. Clearance New/ ROH Worn/ New ROH Max. renewed condemned 1. Lateral clearance between Side frame& Bolster Side frame Column sides All bogies 216 210 206 Bolster column jib W(M) & NLB bogie 234 240 244 18 30 38 183 All other bogies 241 247 251 25 37 45 253 2. Lateral clearance between Side frame pedestal and Adapter a) Side frame pedestal sides W(M), LCCF Bogie 105 102 101 25 32 35 25+3/-0 Adapter sides Wide Jaw Adapter 130 134 136 b) Side frame pedestal sides All Narrow Jaw Bogies 81 78 77 16 23 26 16+6/-1.5 Adapter sides Narrow Jaw Adapter 97 101 103 3. Lateral clearance between Side frame crown and Adapter a) Side frame Crown sides W(M) Bogie 152 147 144 4 15 20 4+/-0 Adapter crown Wide Jaw Adapter 156 162 164 b) Side frame Crown sides All Narrow Jaw Bogies 152 147 144 3.5 14.5 19.5 3.5+/-0 Adapter Crown Narrow Jaw Adapter 155.5 161.5 163.5 4. Longitudinal clearance between Side frame pedestal and Adapter a) Side frame Pedestal jaw W(M), LCCF Bogie 278 283 286 10 19 24 10+5/-0 Adapter sides Wide Jaw Adapter 268 264 262 b) Side frame Pedestal jaw All Narrow Jaw Bogies 190 195 198 9 18 23 9+2/-3 Adapter sides Narrow Jaw Adapter 181 177 175 5. Longitudinal clearance between Side frame column and Bolster land surface Side frame column All bogies 450 455 458 6 14 20 6+/-0 Bolster land surface All bogies 444 441 438 6. Clearance between Side frame anti-rotation lug Bolster rotation stop lug Anti- rotation lugs All bogies 522 526 528 4 12 16 4+3/-0 Bolster rotation stop lugs All bogies 518 514 512 NOTE: Nominal clearances given above are sum of both sides. For other details please refer G-95. WAGON MAINTENANCE MANUAL