1
DISCLAIMER
This Booklet is solely for reference and to be taken as a guide only for
Railway Staff dealing with Wagon manufacturing, inspection and
maintenance. Specifications, drawings and other relevant documents are
to be referred for authentic information.
In case of doubt, provisions of relevant codes and the latest Railway
Board/RDSO circulars/Letters on the concerned subject should be
referred to. Feedback and suggestions may be sent to
dirqamndls@gmail.com
2
3
4
5
Indian Railways Wagons
Sl.No
Description
Page no.
1.
Nomenclature of Wagon
7
2.
Wagon Holding on IR
8
3.
Important Parameters and Development of Wagons
9
3.1
Open Wagons
9-11
3.2
Covered Wagons
12-13
3.3
Flat Wagons
14-15
3.4
Hopper Wagons
16-17
3.5
Tank Wagons
18-19
3.6
Container Wagons
20-21
3.7
Auto Car Wagons
22-23
3.8
Brake Van
4.0
Revised Painting Scheme
25-26
5.0
Wagon Numbering System
27-29
6.0
Catridge Roller Bearing
30-32
7.0
RFID Tags on Wagons
33
8.0
Types of Bogies
9.0
Air Brake System
-44
10.0
Wheel Tyre Assembly (WTA)
45-48
11.0
List of Important Components of Wagons
49-54
12.0
Centre Buffer Coupler
55-57
13.0
Draft Gear
58-63
14.0
Springs on wagons
64-6
14.1
Grouping of springs
66-67
14.2
Spring data at a glance
14.3
Spring arrangement for CASNUB trolleys
69-70
15.0
Huck / Lock Bolt
71-74
16.0
Warranty/ Guarantee of wagons and components
75-76
17.0
Wagon Production Software www.rdsowagon.org
77-78
18.0
Wheel Base of CASNUB Bogie
24
34-
68
79
6
1.0
Nomenclature of Wagon:
B : (prefix) Bogie wagon (sometimes omitted)
BV : Brake van
O : Open wagon (gondola)
C : Covered wagon (boxcar)
F : Flat car
FK : Flat car for container transport
FU : Well wagon
LA : Low flat car with standard buffer height
LB : Low flat car with low buffer height
R : Rail-carrying wagon
T : Tanker (additional letters indicate material carried)
C : Centre discharge
R : Rapid (forced) discharge, bottom discharge
LW: Light Weight
HL: Higher Axle load/Heavy load
HS: High Speed
N: Pneumatic Brake
CR: Corrosion Resistant
AP: Alumina Powder
7
2.0
Wagon Holding on IR(As on 01.04.2020)
2.1
Indian Railway wagons are manufactured in Railway Workshops (ASR/NR,
GOC/SR, JMP/ER, SPJ/ECR& UBL/SWR), PSUs (Braithwaite & Company
Limited, SAIL-RITES Bengal Wagon Industry Private Limited) and Private
Wagon Builders (Texmaco Rail, Modern Industries, HEI, Besco(WD),
Titagarh Wagons, Jupiter Wagons, Cimmco, Besco(FD), Jindal Rail, Amzen,
SRBWIPL, Oriental, CEBBCO).
2.2
Final Inspection of Wagons at PSUs and Private Wagon Builders is done by
Quality Assurance (Mech.), RDSO, while in Railway Workshops inspection is
done by Neutral Control Organisation (NCO).
8
3.0
Important Parameters and Development of Wagons
The important dimensions and sketches of main type of wagons stock used
over Indian Railways are provided in this portion. 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 websitehttp://10.100.2.19/wagon/index.html(on Railnet)
3.1
OPEN WAGONS
9
Type
Bogie
Permissible Speed
Loaded/Empty
65/ 75 Kmph
Remarks
BOY
Axle
Load
22.9 t
BOYEL
25.0 t
Casnub 22 NLB
(modified)
Casnub 22 NLC
BOXN
20.32 t
Casnub 22 NLB
75/ 80 Kmph
BOXNR
22.9t
Casnub 22 NLB
75/ 80 Kmph
BOXN M1
22.82 t
Casnub 22 NLB
(Modified)
70/ 80 (CC +6+2)
60/ 80 (CC +8+2)
Kmph
BOXNEL
25.0 t
Casnub 22 NLC
50/ 65 Kmph
BOXNHS
20.32 t
Casnub 22 HS
100/ 100 Kmph
‐
BOXNHS
M1
22.82 t
Casnub 22
HS
(Modified)
75/ 90 (CC +6+2)
60/ 90 (CC +8+2)
Kmph
On specified routes the speed is 75/80
Kmph with CC +8 +2
45+5/ 60+5 Kmph
10
It has no doors. Designed for heavy
minerals.
Min. wheel tread dia. 950 mm.
IS‐2062
Operation at CC +6 +2/ CC +8 +2
allowed as interim measure, with speed
restriction 60/80
Corrosion, SW, EW bulging, F/P damage &
CC+8 +2 operation
Rehabilitation with CRF Stainless steel
IRS:M44 & CRF sections
Top coping redesigned
On specified routes the speed is 75/80
Kmph with CC +8 +2
CTRB Grease changed – AAR Approved
grease
Min. wheel tread dia. 950 mm
Type
Bogie
BOXNHA
Axle
Load
22.1 t
IRF 108 HS
BOXNS
25.0t
LWLH Bogie
Permissible Speed
Loaded/Empty
100/100 Kmph
(20.32 & 22.1 t)
75/100Kmph(22.82)
100/ 100 Kmph
BOXNLW
20.32 t
Casnub 22 HS
100/ 100 Kmph
BOXNLW
M1
22.82 t
60/ 65 Kmph
BOXNHL
22.9 t
Casnub 22
HS
(Modified)
Casnub 22 HS
75/ 100 Kmph
BOST
20.32 t
Casnub 22 HS
75/ 80 Kmph
BOSTM1
22.32 t
60/ 65 Kmph
BOSTHS
20.32 t
BOSTHS
M1
22.32 t
Casnub 22 HS
(modified)
Casnub 22
HS (mod‐ I)
Modified
Casnub 22 HS
(Mod‐ I)
100/ 100 Kmph
60/ 80 Kmph
11
Remarks
‐
Conventional Brake System
SB: Constant Contact Spring loaded
K type CTRB
Stainless steel (IRS: M44) and Corton Steel
(IRS: M41) used in
body & under frame
‐
IRS: M44 (Body), Flat centre Pivot, K type
CBB, Improved Coupler & draft gear Br.
Cyl,300 mm, BMBS, A.R. 75 litres, PU
Painting (Phirozicolour), Huck Bolt, Top
coping redeveloped.
Operation at CC+ 6 + 2 allowed as an
interim measure with speed
restriction to 50/ 80
High Axle load version of BOST
High Speed version of BOST
High Axle load version of BOST HS
3.2
COVERED WAGONS
Type
BCN
Axle
Load
20.32 t
BCN M1
22.82 t
BCNHS M1
22.82t
BCNA
20.32 t
BCNA M1
22.82 t
BCNAHS
20.32 t
Bogie
Casnub 22 NLB
(Modified)
Casnub 22
NLB
Modified)
Casnub 22
HS
Casnub 22 NLB
(Modified)
Casnub 22
NLB
Casnub 22 HS
Permissible Speed
( in Kmph)
75/ 80 Kmph
Remarks
Permitted with CC +6 +2 also.
75/ 80 (CC +6+2)
60/ 80 (CC +8+2)
Kmph
High axle load version of BCN
75/ 90 (CC +6+2)
75/ 90 (CC +8+2)
Kmph
High axle load version of BCNHS
80/ 80 Kmph
Permitted with CC +6 +2 also.
75/ 80 (CC +6+2)
60/ 80 (CC +8+2)
Kmph
High axle load version of BCNA
100/ 100 Kmph
Variant of BCNA with Casnub bogie 22
HS bogie
12
Type
Bogie
BCNAHS M1
BCNHL
22.9 t
(Modified)
Casnub 22
HS
Casnub 22 HS
BCNHL
22.9 t
Casnub 22 HS
75/ 70 Kmph
IRF 106 HS
100 Kmph
20.32 t
Casnub 22 NLB
Cement Wagon
BCCW
21.82 t
Casnub 22 HS
70 Kmph
(Specific Route)
65 Kmph
BCBFG
21.82 t
Casnub
22HS
(Mod.1)
75 Kmph
(Specific Route)
Food Grain hopper wagon
BCCN
End
wagon A
Middle
Wagon B
BCCW
Permissible Speed
( in Kmph)
75/ 100 (CC +6+2)
75/ 100 (CC +8+2)
Kmph
Remarks
Axle
Load
22.82 t
75/ 70 Kmph
High axle load version of BCNA HS
Length reduced, width and height
increased than BCNA.
IRSM44 , CRF, Conventional Brake Sys.
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).
With BMBS
Maruti Car Double decker
10.425 t
10.50 t
13
Cement Wagon
3.3
FLATWAGONS
14
Designation
BRN
Axle
Load
20.32 t
BRN22.9
Bogie
Casnub 22 NLB
Permissible speed
Loaded/Empty
75/ 80 Kmph
Designed for rails and heavy steel products.
22.9 t
Casnub 22 HS
65/ 65 Kmph
Improved version of BRN
BRNA
20.32 t
Casnub 22 NLB
75/ 80 Kmph
Improved version of BRN, Higher pay to tare ratio.
BRNAHS
20.32 t
Casnub 22 HS
100/ 100 Kmph
High speed variant of BRNA
BFNS/
BFNSM1
20.32 t
Casnub 22 HS
100/ 100 Kmph
Designed for transportation of steel coils, plates,
sheets & billets etc.
BRHNEHS
20.32 t
Casnub 22 HS
65/ 65 Kmph
BRSTN
20.32 t
Casnub 22 NLB
80/ 75 Kmph
Bogie rail wagon designed for Track
Relaying
trains
(TRT)
specially for loading RCCsleepers.
Bogie rail wagon for heavy vehicles.
BWTB
22.9 t
Casnub 22 NLB
65/ 65 Kmph
Bogie well wagon (well height 1055 mm).
15
Remarks
3.4
HOPP
PER WAGO
ONS
16
Designation
BOBSN
Axle
Load
22.9 t
BOBSN M1
Bogie
Permissible Speed
75/ 75 Kmph
25 t
(modified)
Casnub 22 NLB
Casnub 22 NLC
50/ 60 Kmph
BOB R
20.32 t
Casnub 22 NLB
80/ 80 Kmph
BOBR M1
22.32 t
70/ 75 Kmph
BOB RN
20.32 t
(Modified)
Casnub 22 NLB
Casnub 22 NLB
BOBRN M1
22.32 t
BOBRNHS
20.32 t
BOBRNHS
M1
BOBRNEL
22.9 t
Remarks
Designed
in
1994
for
transportation of Iron ore, side discharge.
High axle load variant of BOBSN. Casnub 22 NLC
Bogie.
Designed in 1986 for coal. Bottom
discharge. No. of wagons/ rake = 53.
(CC + 6 + 2) version of BOBR.
70/ 75 Kmph
(Modified) Casnub 70/ 80 Kmph
22 NLB
Casnub 22 HS
100/ 100 Kmph
Designed in 1991 by reducing the length of BOBR.
No. of wagons/rake = 58.
(CC + 6 + 2) version of BOBRN.
High speed BOBRN
60/ 65 Kmph
25 t
(Modified)
Casnub 22 HS
Casnub 22 NLC
BOBYN
20.32 t
Casnub 22 NLB
75/ 75 Kmph
Air Brake version of BOBY. Designed in 1996
BOBYN22.9
BCBFG
22.9 t
21.82 t
Casnub 22 HS
Casnub 22 HS
(Mod-I)
75/ 75 Kmph
75/ 75 Kmph
Air Brake version of BOBYHS.
Bogie covered Hopper Wagon for
food grains. Designed with automatic LSD.
45+5/ 60+5 Kmph
17
Modified DOM, BMBS, Revised painting and
marking scheme
25 t axle load. Wheel dia 1000 mm. POH–6 years,
ROH–2 years.
3.5
TANK WAGONS
18
Designation
Bogie
Permissible Speed
Remarks
BTALN
BTPN
Axle
Load
20.32 t
20.32 t
UIC Bogie
Casnub 22 NLB
65/ 65 Kmph
80/ 75 Kmph(Loaded)
Bogie Ammonia Tank Wagon
Bogie POL Tank Wagon
BTPGLN
19.8 t
Casnub 22 NLB
75/ 80 Kmph
Mild Steel
Bogie LPG Tank Wagon. Variant
of BTP GL with Air Brakes / Casnub 22 NLB
bogie.
BTCS
20.32 t
Casnub 22 W
65/ 65 Kmph
Bogie Caustic Soda Tank Wagon. Provisional speed
certificate is with casnub 22W bogie. In 2007, bogie
altered to NLB in the drawing.
BTAP
20.32 t
Casnub 22 NLB
65/ 65 Kmph
Bogie Alumina Tank Wagon.
BTFLN
20.32 t
Casnub 22 HS
65/ 65 Kmph
(Provisional)
Frameless design
Tractive & buffing forces are taken up by the barrel
itself, thus optimizing the use of wagon mass
Bogie POL Tank Wagon
19
3.6
CONTAINER WAGONS
20
Designation
BLLA/ B
Axle
Load
20.32 t
Bogie
Permissible Speed
LCCF 20 (c)
100/ 100 Kmph
Bogie low
wagon.
BLCA/ B
20.32 t
LCCF 20 (c)
100/ 100 Kmph
Bogie low platform container flat wagon
BLCAM/
BLCBM
22 t
Modified
LCCF 20 (c)
90/ 100 Kmph
In 2007, bogie of BLC wagon was modified by
providing upgraded side bearer, upgraded friction
wedge, and two additional inner springs for double
stack container operation.
BCACM
20.32 t
LCCF 20 (c)
65/ 75 Kmph
For auto car industry
BCACBM
LCCF 20 ©
100/95 Kmph
For transportation of Automobile cars.
BLCM
A-12.715
t B12.680t
22.3t
LCCF 20 (C) bogie 100 kmph
modified : Spring
nest change
IS:2062
Twin pipe
BLCS
25t
LWLH Bogie
IS:2062
K Type CTRB
Twin Pipe
100 kmph
21
Remarks
platform
longer container flat
3.7
AUTO CAR WAGONS
22
Designation
BCACBM
Axle
Load
Bogie
LCCF bogie
(Dia-840mm)
Permissible Speed
65 kmph
23
Remarks
Movable Middle Deck permitting freedom to load
all types of cars
Use of M.S(IS:2062) to minimizecost
CBC used
Constant Contact Side Bearer
Special amenability for Loading is required
3.8
8
BRAKE VAN
Designation
Bogie
Permisssible Speed
BVZI
Axle
Load
5.875 t
ICF Bogie
1000 Kmph
Designed inn 2000 with IC
CF Bogie to achhieve
comfortablee ride, 5 m longger than BVZC
C.
BVZC
06.98 t
4- wheeler
1000 Kmph
RDSO Drg.. No. WD- 810035/S-2
Casnub
C
22 HS
1000 kmph
IS 2062 E2550 AU
BVCM
24
Rem
marks
4.0
Revised Painting Scheme : Railway Board’s L/No. 94/M(N)/951/27 Pt, dt
17.10.2018
S.No
Criteria
Types of wagon
Painting Scheme
1
Railway Wagons
BCNAHSM1 etc
Gentian Blue (RAL 5010)
2
Privately owned
wagons
BLCM etc
Signal Red
25
3
Privately owned
wagons for
GPWIS
BOXNHL etc
4
No Change in colour for BTAL, BTPGLN, BTAP, BCACBM, BTPN &
BTFLN and Brake Vans etc.
26
Black Grey (RAL 7021)
5.0
NEW NUMBERING SYSTEM OF WAGONS
Monitoring and liquidating overage arrears of rolling stock is a focus area in the
interest of safety of train operations. However, some of the Railways have reported
difficulty in ascertaining the age of wagons where the manufacturer’s plate is
missing. Also computerization of wagon data is becoming cumbersome with
development of various versions in a category e.g. BG bogie open wagons BOXN,
BOXNHS, BOXNAHA, BOXNCR, BOXNHL, BOXNR and BOXNLW are being
clubbed together by the computer cell and shown as BOXN in the holding. To
overcome the above-mentioned problems and to facilitate computerization of the
wagon data base, a new wagon numbering system was introduced by Railway
Board as per Letter No. 2000/M(N)/60/2/wagon census. Dated 4th July, 2003 In the
new scheme, the wagon number shall consist of 11 digits as follows:
It can also be remembered as TOYS i.e T: Type of Wagon (Two digits), O: Owning
Railway (Two digits), Y: Year of Manufacture (Two digits), S: Serial number of wagon
(Four digits)
The codification for various types of wagons, owning railways, year of manufacture and
individual wagon no. are as follows:
27
BVCM
28
87
5.1
YEAR OF MANUFACTURE CODE (C5, C6):
This will consist of last two digits of the year of manufacture. For example wagon
manufacture in 2016 will have code 16.
5.2
INDIVIDUAL WAGON No. (C7, C8, C9, C10):
This will be running serial number from 0001 to 9999. Numbers 0001 to 0999 will be
departmental stock and 1000 to 9999 will be other (traffic) stock. This will be running
number irrespective of year. For departmental, after 0999, the number will begin from
0001. For others, after 9999, the number will begin from 1000. The series will not change
with type of wagon. For example on ECR if 1001 is BOXNHS next wagon which may be
BCNHS will be 1002.
5.3
CHECK DIGIT – Method of calculation
The CHECK DIGIT for each wagon is calculated using a six-step algorithm based on ten
digit wagon number arrived at as indicated below.
29
6.0
Cartridge Tapered Roller Bearing (CTRB)
The Cartridge Type Taper Roller Bearing (CTRB) has two inner races (cones) along with
rollers and cage, separated by a spacer, a single case-hardened outer race (cup), a grease
seal and a seal-wear ring at each end, a backing ring at the rear, axle end cap, 3 capscrews, and locking plate. The cup also acts as the bearing housing and is fitted in the
bogie side frame with a suitable adapter (See General Arrangement of CTRB Drg. No.WD92089-S-01 for Narrow Jaw adapter & WD- 13042-S-01 for Wide Jaw adapter. The weight
of Class 'E' 6 X 11 CTRB is around 34.3 kg, weight of Narrow Jaw Adapter is around 12.0
kg and wide jaw Adapter is around 23 kg.
a) There are basically two types of CTRB i.e Class E (6’’X 11’’) and Class K (6 1/2’’X9”).
Class E type CTRB is used in all air brake freight stock and govered by RDSO spec no.
AB/RB-39/2002 whereas class K CTRB is used in 25 t Wagons only which is governed by
AB/RB-41/2016.
b) Recently, Railway Board has directed to use upgraded CTRB class E in all freight stock
other than 25 t wagons vide L/No. 2017/M(N)/951/14, dt 18.09.2019 which is governed by
RDSO spec no. AB/RB-40/2016 in which polymide cage and low torque grease seal will be
used.
c) RDSO approved suppliers of Class E CTRB are M/s NEI, Jaipur, M/s Timken, Jamshedpur
and M/s SKF, Ahmedabad
d) RDSO approved supplier of Class K CTRB is now M/s NEI, Jaipur. However, as RDSO
vendor directory (Validity 01.01.2020 to 30.06.2020), till such time vendors are approved
for this specification (RDSO STR NO. AB/RB-41-2016), Orders are to be placed on
vendors who are approved by AAR. Following 03 (three) sources have AAR approved
design and manufacturing facilities for K Class bearing – 1. M/s National Engineering
Industries Limited. 2. M/s SKF India Limited. 3. M/s Timken India Limited.
Class E CTRB
30
C
Class
K CTRB
31
Exploded view of CTRB
32
7.0
RFID Tags on Wagons (Radio Frequency IdentificationTags)
a) The purpose of providing RFID tags on freight stock is to result in
Automatic Wagon Identification using Radio Frequency Identification.
b) Fitted at DV & Non DV Side of wagons. Information like Year of Mfg,
Owning Rly, Wagon Type, Wagon Serial No., Date of entry of data, Mfg
code, Station Code are entered in the tag.
c
)
.
Specification No. 2016/CRIS/NDLS-HQ/CC/PROJECT/RFID/0225/Pt.1
dated 05.10.2018 under which RFID tags (V4.1) are procured.
d). Data reading of RFID is illustrated below;
33
8.0
Types of Bogies
34
8.1
1
BOGIE TYPES
S- CASNU
UB BOGIE
E
35
8.2
CASNUB→ CAST STEEL + SNUBBER SPRING
This Bogie is tested in India in 1972 with BOI Wagon.After this it is tested in BOXN
Wagon with 90 kmph speed.CTRB used in CASNUB bogie. 22.9 ton Axle load.
Wheel size
Condemning wheel size
– 1000 mm
- 905 mm
Wheel Base
- 2000 mm
Wheel Gauge
- 1600 mm
Distance between journal centre
-2260 mm
Distance between side bearers
-1474 mm
Three types of Centre pivot used in Casnub Bogie:a. IRS type
b. Hemi spherical
c. Flat type centre pivot
8.3
Development of CASNUB Bogie
CASNUB-22W:
Wide jaw category without EM Pad.
No locking at centre pivot & bolster pin.
Brake beam is pocket type or sliding
type.
Maximum speed 75 kmp. Side bearer
roller type.
 The disadvantage of this bogie are:a. Higher wheel wear
b. Replacement of brake beam requires
removalof wheel set.
c. Low stability as vertical load not
shared byside bearer.
36
CASNUB 22W(M)
Major difference in the side frame as compared to 22W is provision of Negative
camber(sag at the middle of the side frame)to maintaining same buffer height while
using EM pad.
EM pad has been introduced along with adapter to reduce higher wheel wear as
experienced with 22W version.
Spherical type centre pivot fitted with bolster.
Metal bonded side bearer used in this version for improving the stability of Wagon
as compared 22W version.
Hanger type brake beam used with separate brake head through spring loaded
brake shoe adjuster.
Main disadvantage of this bogie is dropping of brake beam and grazing of brake
components.
CASNUB-22W(Retrofitted)
The main difference with 22W are:
Use of Elastomeric pad with adapter
Use of constant contact metal bonded elastomeric pad in side bearer housing.
To accommodate elastomeric pad& to maintain buffer height the height of the
adapter has been reduced because it is not possible to use higher diameter wheel
set to maintain the buffer height.
Wheel below dia. of 956 mm is to be used in this version.
37
CASNUB 22 NL
Narrow jawcategory.
The side bearer, centre pivot,
bolster
are
similar
to
22W(M)version.
Centre pivot pin is locked by
shackle lock as compared to
castle
nut
used
in
22W(M)version.
The adapter used with this
version is of smaller size to
suit to narrow jaw opening of
the side frame.
CASNUB -22NLB
This is similar to 22NL version
except for bolster.
The shape of bolster is ‘fish
belly’ at the centre to reduce the
weight of bogie.
Narrow Jaw Category
Brake beam moves in pocket
38
CASNUB -22NLM
The only difference is change in
material of the side frame and
bolster.
The equivalent carbon % of
side frame and bolster in
NL/NLB is 0.85%.This has
reduced the weight of bogie.
The weight of the NLM version
bogie is 5.125 ton where as the
weight of NL version is 5.5 ton.
CASNUB-22HS
The CASNUB-22HS bogie has
been developed for high
speed operation up to 100
Kmph.
The side frame, elastomeric
pad, centre pivot, centre pivot
lock,adapter are similar to NLB
version.
The spring loaded constant
contact type PU side bearer
used in this bogie.
Initially Spring loaded side
bearer is used, now PU type
side bearer is used
Springs
are
interchangeable.
not
39
LCCF 20 (C )
Used in BLC Wagon
Wheel dia -840 /780 mm
End pull rod - 02 Nos
Integral flat type centre pivot
40
9.0
0
Air Bra
ake Syste
em
9.1
1
Graduated releaase compre
essed air brake
b
equipment forr freight sto
ock
(a) Disstributor Valve
V
(b) Auxiliary Reservoirs
e Cock wiith Vent
(c) Cut off Angle
or assemb
bly
(d) Dirrt Collecto
(e) Airr Brake Ho
ose coupling
(f) Gua
ard Emerg
gency Bra
ake Valve
(g) Iso
olating Cock
(h) Check Valve
e assembly
es & Jointts for Air Brakes
B
(i) Pipe
(j) Pressure gau
uge for airr brake Syystem
9.2
2
Speciial Compo
onent forr Two Sta
age DV (L
LSD Type
e Brake System)
a) DV with pres
ssure tran
nsformer
ad Sensing
g Device
b) Loa
c) Pressure Reg
gulating Valve
V
(prv)
uble Chec
ck Valve (d
dcv)
d) Dou
e) Brake Cylinder 14”
f) Slacck Adjuste
er (irsa 60
00)
g) Brake Rigging
41
9.3
3 SPECIAL COMPONE
ENT FOR SINGLE
S
ST
TAGE DV(B
BMBS TYP
PE BRAKE SYSTEM)
a) Distribu
utor Valve (single stag
ge)
b) Automa
atic pressure modifier (apm/el60))
c) BMBS arrangeme
ent & brake rigging
9.4
4
SCHEM
MATIC LIN
NE DIAGRA
AM OF BMB
BS AIR BR
RAKE SYST
TEM
9.5
5
Distrib
butor Valv
ve (DV)
Firmw
wise types of Distrib
butor Valvves
S.NO
O.
FIRM’S NAME
DV TYP
PE
1
KBIL
KEO
Yes
Yes
2
FTRTIIL
C3W
Yes
Yes
3
ESCO
ORTS
KEO
Yes
Yes
4
GIPL
C3W
Yes
Yes
5
STONE INDIA
C3W
Yes
Yes
6
S D TE
ECH
P4A
(WESTIN
NG
HOUSE)
No
No
42
G
Goods
Goods
s
(Two
o Stage) ((Single Sta
age)
9.5.1 Distributor Valve (DV)
43
44
10.0 Wheel Tyre Assembly (WTA)
10.1 Classification of Wheels
S.No
Parameters
Particulars
1
2
3
4
Wheel Diameter (mm)
Manufacturing process
Running speed
Source
5
Utilisation
1000, 952, 915, 840
Casted, forged
>120 kmph, <120 kmph
Railway production, Outsource(DSP),
Imported
wagon, carriage(ICF,LHB,MEMU/TC),
Locomotive
10.2 Types of Wheels and their Application
Rolling
Stock
SIZE
(mm)
Mfg
process
Specification
Drawing no.
source
Wagon
1000,840
Casted
IRS R-19/93 Part III
WAP/SK/M-153,154
WAP-W-004
RWF &
RWP
Description
Wheel dia used on BOXN/CASNUB bogie)
Wheel dia used on BLC/ BLL
New
1000 mm
840 mm
Limits
Condemn.
906 mm
780 mm
10.3 Prsently Wheel Manufactured by by Rail Wheel Factory, Bengalauru
and Rail Wheel Plant, Bela are used on IR.
45
10.4 LIST OF DRGS. FOR WHEELS OF DIFFERENT WAGONS
S.No
TYPE OF WAGONS
DRAWING NO.
AXLE
LOAD(t)
1.
BOXN, BCN, BRN, BOBR, BTPN,
BOY (FITTED WITH CASNUB
BOGIES)
W/WL-4764 SK-68512
WD-97037-S-01
OR
WAP/SK/M 153
22.9
2.
BLC WAGONS
*
22.0
CONTR-9404-S/13 OR WAP/W-004
3.
4.
5.
BOBS MK-II, BOZ
SK-69601
BWT/A, BWL
W/WL-4771
BOX, BOX MK-1, BOX MKWD-89025-S-05
II,BVZC
(*Cast Wheel Disc to RWF Drg. Drg. No. WAP/W‐004 is also being used BLC wagons.)
46
22.9
22.9
20.3
47
48
11.0 List of Important Wagon Components: This list is prepared with reference to
latest Vendor Directory – QM-M-8.1-1 (Validity – 01.01.2020 to 30.06.2020).
However, all users are requested to confirm with latest issue of Vendor
Directory.
Sl.N
1.
Description
Specification No
Graduated release compressed air brake
equipment for freight stock
No.- 02-ABR-02 with 4 Amendments
Drawing No.
(Last Amendment-4 of Sept. 2016;)
(a).Distributor Valve
02-ABR-02 with Amend. No. 4and
Appendix–A1& A2
Proprietary item
(b).Common pipe bracket with control
reservoir
02-ABR-02 with Amend. No. 2 and
Appendix-A1
WD9-7951-S-10 Alt.3
(c). Brake Cylinder (355 mm)
02-ABR-02 with Appendix–B
WD-92051-S-06 Alt. 5
WD-92051-S-11 Alt. 3
(d) Auxiliary Reservoirs 100 Lit.
02-ABR-02 with Appendix-C
WD-92051-S-01 Alt. 3
Auxiliary Reservoirs 75 Lit.
02-ABR-02 with Appendix-C
WD-92051-S-02 Alt. 2
(e) Cut off Angle Cock with Vent
02-ABR-02 with Appendix-D
WD-88123-S-01 Alt.2
(f) Dirt Collector assembly
02-ABR-02 with Appendix-E
WD-92051-S-03 Alt.4
(g) Air Brake Hose coupling
02-ABR-02 with Appendix-F
QMS No.
SK-73547 Alt.13 ,
WD-81027-S-01Alt.13
(h) Guard Emergency Brake Valve
(i) Isolating Cock
(j) Check Valve assembly
02-ABR-02 with Appendix-G
02-ABR-02 with Appendix-I
02-ABR-02 with Appendix-I
(k) Pipes & Joints for Air Brakes
04-ABR-2019 (Rev. 02 of Dec-2019)
(l) Pressure gauge for air brake System
02-ABR-02 with Amend. no. 4 of
Sept’16 & Appendix-O & Appendix-H
(m) Load Sensing Device
02-ABR-02 with Appendix-P
SK-73549 Alt. 5
WD-83062-S-04 Alt.02
WD-83062-S-03 Alt.3
& SK-98112 Alt. Nil
WD-83062-S-6 Alt. 4
&WD-83062-S-7, Alt.6
WD-94056-S-1 Alt.1
WD-92047-S-01
Alt.
04, WD-92047-S-02,
WD-83062-S-05 Alt. 3,
WD-91101-S-05 Alt. 5
& SK-73553 Alt. 04
WD-01065-S-01
Alt.
Nil (or) Alternative
design approved by
RDSO
WD-92051-S-06 Alt. 5
WD-92051-S-11 Alt. 3
WD-82064-S-01-RC Alt.
12 & WD-90002-S-01RC Alt. 02)
Brake Cylinder (300mm)
2.
Brake Cylinder Assembly
02-ABR-02 with Appendix–B
3.
Brake Slack Adjuster and Spares for
Freight Stock
07-ABR-1992 with 5 Amendments –
Last Amendment No. 5 of Sept. 2016
4.
Empty Load device -IR-ELD-10
Drg. No.WD-84074-S-01
RC Alt. 3, WD-84074-S02 RC Alt. 1, WD84074-S-03 RC Alt. 3
49
Sl.N
Description
Specification No
5.
Hot Coiled Helical springs to material Gr.
60 Si7 and Gr. 52Cr4Mo2V for Freight
stock
WD-01-HLS-1994 Rev. 3 with
Amendment no. 3 of August ’2019 &
Material –IS: 3195, T-31-1992 with
Corrigendum-II
6.
Hot Coiled Helical springs to material
Gr.60Si7 and Gr.52Cr4 Mo2V for freight
stock
WD-01-HLS-1994 Rev. 3 with
Amendment no. 3 of August ’2019;
Material – IS: 3195
7.
Rubber Buffer Spring for Freight stock
R-36-88
W/BD-2267 Alt. 6
8.
Metal Bonded Rubber Pads for Side Bearer
03- Misc. 86 Rev.4 of Aug’09 with
Amendment no. 1 of Sept’2016
Drg.No. WD-85076-S/1
9.
Rubber Spring of High Capacity Draft Gear
for Centre Buffer Coupler of BG Bogie
Wagons
55-BD-90 with 4 Amendments: Last
Amend. No.4 of Sep’2016
WD-90076-S-01Alt 01
10.
Elastomeric Pads
20-Misc.-95 Rev. 3 of March’ 2003
with 6 Amendments (Last
amendment no. 2 issued in
Sept’2016
WD-95005-S/1 Alt 07 of
May’06
11.
Nylon-66 brake gear bushes
WD–04–nylon bush–02
SK-81039 Alt -11
12.
High tensile centre buffer coupler & its
components for Freight stock
48-BD-2008 with Amendment-1 of
Sep 2016
WD-81010-S-03 Alt.11,
SK-62724 Alt. 28,
WA/BD-4462 Alt.6,
WA/BD-4460 Alt.9
13.
Upgraded High Tensile Centre Buffer
Coupler for freight stock
WD-70-BD-10 (Rev.2)
14.
Coupler components (Lock, Knuckle
thrower, toggle, Lock Lift Lever Hook &
Universal Lock Lift Lever Connector for
upgraded CBC
High Capacity Draft Gear
WD-70-BD-10 (Rev.2)
SK-62724 Alt.28
49-BD-08 with Amendment-1 of Sep
2016
WD-81010-S-03 Alt.11
16.
Upgraded High Capacity Draft Gear for
BOXNHL/BCNHL wagons
WD-71-BD-15 (Rev. 01)
17.
Slackless Draw Bar (SDB)
CONTR-02-MSG-SDB-2012 of May,
2012
RITES/TP-9405-S/001
18.
Draft Gears for Slackless Draw Bar
WD-72-BD(SDB)-19
RITES/TP-9405-S/001
15.
50
Drawing No.
WD-87056-S-01 Alt.4
WD-81010-S-03, Alt. 11
SK-62724 Alt.28
WA/BD-4462 Alt. 6
WA/BD-4460 Alt.9
WD-87056-S-01 Alt. 4
W/BD-699 Alt. 3
Sl.N
19.
Description
A
Cast Steel CASNUB
components
Casnub-22 NLB Bogie
bogie
B
Casnub-22HS-Bogie
C
Casnub-22HS(Mod-I) Bogie
D
Casnub-22HS(Mod-II) Bogie
and
Cast Steel bogies and its components for
CONCOR flat wagons
21.
Spring Plank
A
Spring plank for CASNUB NLB bogies
B
Spring plank for CASNUB HS bogies
C
Spring plank
bogies
D
Spring Plank for CASNUB HS MOD-II
bogies.
E
Spring plank for LCCF bogie
F
Spring plank for LWLH25 bogie
CASNUB
22.
Centre Pivot Washer
23.
Brake Beam for freight stock
A
CASNUB-22NLB Bogie
B
Casnub-22HS-Bogie
C
CASNUB-22HS(Mod-I)
D
CASNUB-22HS(Mod-II)
Drawing No.
Spec. No. WD-21-Casnub-22 NLB
Bogie-93 Rev. 2, with 5
Amendments: Last Amend. No. 5
issued in Sept. 2016
WD-17-Casnub-22HS-Bogie-92
Rev.3, with 5 Amendments:Last
Amend. No. 5 issued in Sept. 2016
WD-34-Casnub-22HS (Mod-I)-2004
with 4 Amendments: Last Amend.
No. 4 issued in Sept. 2016
WD-39-Casnub-22HS (Mod-II)-2009
with Amendment no. 1 of Feb.’2010
& Amendment no.2 of Sept. 2016
CONTR.LCCF 20 (C)-96 Rev.2 with
Amend. No. 1 of Feb.’2010 & Amend.
Nno.2 of Sept. 2016
WD-89073-S/2 Alt-10
WD-21-CASNUB-22NLB Bogie-93
Rev. 2 of July 02 with 5
Amendments: Last Amend. No.5
issued in Sept. 2016.
WD-17-Casnub-22HS-Bogie-92
Rev.3, with 5 Amendments:Last
Amend. No. 5 issued in Sept. 2016
WD-34-Casnub-22HS(Mod-I) - 2004
with 4 Amendments: Last Amend.
No. 4 issued in Sept. 2016
WD-39-Casnub-22HS(Mod-II)–2009
with Amendment no. 1 of Feb’10 &
Amendment no.2 of Sept. 2016
CONTR.LCCF 20 (C)-96 Rev.2 with
Amend. No. 1 of Feb.’2010 & Amend.
WD-40-LWLH25Bogie (‘K”-Class)2015 with Amendment no.1 of Sept.
2016
SK-69594 Alt. 36- item 1
its
20.
for
Specification No
HS-MOD-I
WD-21-CASNUB-22NLB Bogie-93
Rev. 2 July’ 02 with 5 Amendments:
Last Amend. No.5 issued in Sept.
2016
WD-17-Casnub-22HS-Bogie-92
Rev.3, with 5 Amendments:Last
Amend. No. 5 issued in Sept. 2016
WD-34-CASNUB-22HS(Mod-I) of
2004 with 4 Amendments: Last
Amend. No. 4 issued in Sept. 2016
WD-39-CASNUB-22HS(Mod-II) of
2009 with Amendment no. 1 of
Feb’10 & Amendment no.2 of Sept.
2016
51
WD-04038-S/2, WD04078-S/1& WD-17013S/2
WD-04017-S/2
WD-08026-S/2
CONTR.9404-S-2 Alt.7.
WD-92058-S/4 Alt.9 item 1
WD-92058-S/4 Alt.9 item 1
WD-92058-S/4 Alt.9 item 1
CONTR.9404-S/04
Alt.10-item1
WD-13012-S/04
Alt.5(13.12.19)-item 1
PL No. 38101579
WD-85079-S-2 Alt-26
WD-89033-S-1 Alt. 21
WD-07052-S-1 Alt.01
WD-89033-S/1 Alt.21
WD-07052-S-1 Alt.01
WD-89033-S/1 Alt.21
WD-07052-S-1 Alt.01
WD-89033-S/1 Alt.21
Sl.N
Description
Specification No
Drawing No.
E
LCCF 20 (C)
CONTR.9404-S/17Alt.6
F
LWLH25
CONTR.LCCF 20 (C)-96 Rev.2 with
Amend. No. 1 of Feb.’2010 & Amend.
no.2 of Sept. 2016
WD-40-LWLH25Bogie (“K”-Class)2015 with Amendment no.1 of Sept.
2016
24.
A
Narrow Jaw, Wide Jaw and Modified
Adapter
Narrow Jaw
B
Wide Jaw
C
Modified Adapter
D
Adapter class K (6 ½”X9”)
25.
Side Frame Key
26.
28.
AAR approved Taper Roller Cartridge
Bearings class E(6”X 11”) complete for use
on freight stock
AAR approved Cartridge Tapered Roller
Bearings Class ‘K’ (6 1/2” X 9”) for freight
stocks fitted with light weight low height
(LWLH) bogies (Narrow Jaw) for 25t axle
load application.
Upgraded Class E CTRB
29.
Locking Plate
27.
A
Locking Plate Class E
B
Locking Plate Class K
30.
A
B
31.
CONTR.9404-S/17Alt.6
AB/RB-39-2002 Rev. 4 of February2018
WD-89067-S-9 Alt.8
AB/RB-39-2002 Rev. 4 of February2018
AB/RB-39-2002 Rev. 4 of February2018
AB/RB-41-2016
SK-78527 Alt.6
WD-85053-S-1 Alt.6
SK-69594 Alt.35-item 6,
CONTR.9404-S/04
Alt.10- item 3 & WD13012-S/04 Alt. 4-item 2
AB/RB-39-2002 Rev. 4 of February2018
Proprietary item
AB/RB-41-2016
AB/RB-40-2016
AB/RB-39-2002 Rev. 4 of February2018
AB/RB-41-2016
WD-87019-S-1 Alt.2
WD-06085 S-2, Alt-Nil
Axle end steel high tensile cap screws-1”ø
8 UNC-2A, 2¼” thread length
Axle end steel high tensile cap screws-1
1/8”ø 7 UNC-2A, 2 ½” thread length
AB/RB-39-2002 Rev. 4 of February2018 & IS 1367 pt.3,Cl P8.8
AB/RB-41-2016 & IS 1367 pt.3,Cl
P8.8
WD-18016-S-01(Alt 1,
Item no1)
WD-18016-S-01(Alt 1,
Item no 2)
Silico-Manganese & Manganese Steel
Liners & Wear Plates for Bogie and
couplers
WD-17-Casnub-22HS-Bogie-92
Rev.3, with 5 Amendments:Last
Amend. No. 5 issued in Sept. 2016,
WD-34-CASNUB-22HS(MOD-I)
of
2004 with 4 Amendments (Last
amendment no. 4 issued in
Sept’2016),
WD-39-CASNUB22HS(MOD-II)
-2009
with
WD-97049-S/3
Alt.8
item 3 & 4, CONTR
9404-S/8-item 1; WD13012-S/04 Alt.4-item 5;
WD-13012-S/05 (Sheet
2 of 2) Alt.1-item 2 to 4
& Spec. No. 48-BD-08
with Amend. No.1 of
Axle end steel high tensile cap screws
52
Sl.N
32.
Description
Specification No
Drawing No.
Amendment no. 1 of Feb’10 &
Amendment no.2 of Sept. 2016, WD21-CASNUB-22NLB Bogie-93 Rev. 2
July’ 02 with 5 Amendments (Last
amendment no. 5 issued in
Sept’2016), CONTR.LCCF 20 (C)-96
Rev.2 with Amend. No. 1 of Feb.’10
& Amend. No.2 of Sept. 2016; WD40-LWLH25Bogie(‘K”-Class)-2015)
with Amendment no.1 of Sept. 2016.
Sep. 2016, 56-BD-07
with Amend. No.1 of
Sep’10 & with Amend.
no. 2 of Sep 2016, 70BD-10
Cold Rolled Formed Sections for Freight
Stock
Brake Slack Adjuster Type IRSA-750 for
Freight Stock & Spares
WD-01-CRF-12,Rev.1
19-ABR-07 with 3 Amendments: Last
Amemendment no. 3 issued in Sept.
2016
WD-93061-S-01 Alt. 01
34.
Bogie Mounted Brake System for freight
stock fitted with Casnub Type Bogie
WD-23- BMBS-2008(Rev.1)
Amendment-1 of Sept. 2016
WD-08093-S-2 Alt. 3 &
WD-08096-S-01 Alt. 2)
35.
Body Side Wall, End Wall and Flap Door of
BOXNR Wagons
WD-16-BOXNR-2010 Rev 01 with
Amend. no. 02 of Dec. 2016
WD-07001-S/08 Alt. 10,
WD-07001-S/09 Alt.5,
WD-07001-S/10 Alt.9,
WD-09034-S-07 Alt.8
and WD-07064S/01Alt.9
36.
Light Weight Low height 25 T axle load
bogie (LWLH25) & its components for 25 T
axle load wagons
WD-40-LWLH 25 Bogie( “K”-Class)2015 with Amendment no. 1 of Sept.
2016
WD-15021-S/02 Alt 1
37.
Non-asbestos ‘L’ type Composition Brake
Blocks for container flat wagons
WD-13-ABR-2019
CONTR-9404-S-11 Alt.
7
38.
Non-Asbestos K- type Composition Brake
Blocks for freight stock (840mm wheel dia.)
WD-14-ABR-2019
WD-15023-S-01
39.
Non-asbestos ‘L’ type Composition Brake
Blocks for freight stock with 1000 mm
wheel dia.
WD-13-ABR-2006 Amend. No. 1 of
May’07& Amendment-2 of Sept.
2016
WD-99062-S-01 Alt-03
40.
Non-asbestos K-type Composition Brake
Blocks for freight stock( with 1000mm
wheel dia)
WD-14-ABR-2007 with 3
Amendments (Last:Amendment no.
issued in 3 Sept. 2016)
WD-00006-S01 Alt-03
41.
Constant Contact PU Side Bearer Pads for
HS Bogies
WD-38-Misc.-2004 Rev. 1 of Jan’
2008 with Amend. No. 1 of March’
2008 & Amend. No.2 of Sept. 2016
AAL-021101 Alt. 8
42.
Constant Contact PU Side Bearer Pads for
NLB Bogies
WD-38-Misc.-2004 Rev. 1 of Jan’
2008 with Amend. No. 1 of March’
2008 & Amend. No.2 of Sept. 2016
AAL-021101/N Alt. 01
43.
Constant Contact Side Bearers for Broad
Gauge Bogie Wagons
WD-62-MISC-17 Rev Nil of Aug.
2018 & CONTR-01-MISC-07 Rev 1
of Sep. 2010
WD-12007-S-01 Alt 2,
WD-12008-S-01 Alt 2
and WD-17025-S/01 Alt
Nil,
33.
53
with
Sl.N
Description
Specification No
Drawing No.
44.
Automatic Twist Lock (ATL)
CONTR-01-MSG-ATL-2011 of Nov.,
2011
CONTR-9405-S/21
45.
NM friction wedge
CONTR-02-MISC-2007
WX-10046
46.
Manual Metal Arc Welding Electrode
As per Respective Wagons’ WPS
47.
Solid MIG/MAG Welding Filler Wire
As per Respective Wagons’ WPS
48.
As per Respective Wagons’ WPS
49.
Flux cored MIG/MAG Welding Filler Wire
with shielded gas
Wire for Submerged Arc Welding Class
50.
Flux for Submerged Arc Welding Class
As per Respective Wagons’ WPS
51.
Paints based on epoxy and polyurethane
resin for exterior painting of wagons
Epoxy based Zinc Phosphate Primer (two
pack)
A
M&C/PCN/102/2009 with RDSO’s
amendment no.1B as an Additional
requirement
B
Full gloss Red-Oxide Polyurethane Enamel
(two pack)
M&C/PCN/109/2009 with RDSO’s
amendment no.1B as an Additional
requirement.
C
R/M paint synthetic for the system of
exterior painting. Ready Mixed paint, air
drying, Red Oxide, Zinc Chrome, Priming
R/M paint synthetic for the system of
exterior painting
Epoxy Cum Polyurethane Painting system
(Two Pack) for the Exterior Painting (Non
Specified Mother Specification)
Wheel and Axle
(1000mm , 840mm)
IS:2074/1992,
revision(Reaffirmed 2002).
D
E
52.
As per Respective Wagons’ WPS
second
IS: 8662 (2004) Enamel, Synthetic
Exterior
No.M&C/PCN/100/2018
with
RDSO‟s amendment no. 1B as an
Additional requirement.
IRS R-19/93 Part III
WAP/SK/M-153,154
WAP-W-004
53.
Huck Bolt and Collars
WD-11036-S-01 &
WD-11036-S-02
54.
Material of Wagon Construction
IS:2062 MS, IS 3502, IRS M:41& IRS
M:44 SS
SAIL MA 350
55.
RFID Tag (V4.1)
No.: 2016/ CRIS/ NDLS-ITPI/ WS-C/
POLICY/ RFID/ 0101/ PT-1 dated
05.10.2028
54
12.0
COUPLER
Coupler: WD-70 BD-10 (Rev2)
Indian Railways suffers a large number of train partings because of coupler and knuckle
breakage which results in heavy losses. Poor quality of CBC components causes large scale
premature replacements of components during maintenance in workshop, depots and yards. The
manpower and material costs of such replacement is very high. Even after large scale
replacement of components during maintenance in workshops depots and yards, train partings
are still taking place which reflect on the poor quality of coupler components. The direct and
indirect cost of train parting is huge.
CBC of Indian Railways is based on the AAR specification. In 1960 few manufacturers acquired
TOT of Grade B castings from North American Manufacturers. For carrying longer trains the
material of CBC was first upgraded to “C‟ and then to “E‟. For indigenous development and multi
sourcing RDSO issued the drawings of CBC including of gauges in 1980. However the coupler
and knuckle failures continued unabated.
The major problems in the manufacture of the Grade E coupler were
55
To improve the indigenous couplers RDSO constituted a Technology Development Group
comprising of representatives of Wagon, QA and M &C directorates of RDSO along with
representatives of Industry to improve the coupler and it‟s specifications. Three meetings
of the Technology Development Group were held on 8.8.2006, 10.10.2007 and
26.06.2009. In addition these issues were also discussed in a meeting between RDSO
and coupler manufacturers on 19.3.2007. The following decisions were taken in the
meeting of the Technology Development Group:
56
MARKING(GR E):‐UHTE
FIRM̕S NAME
M&Y
57
13.0 Draft Gear :
•
•
•
•
WD‐49 BD : MK‐50 & RF‐361
WD‐66 BD : (IMPORTED): MINER, WESTINGHOUSE, STUCKI, ASF
WD‐71 BD : Indigenous
495 A : RITES/TP‐9405‐S/001 (Draw gear arrgt) : Draft gear : BLC
WD‐49 BD : MK‐50
• Used in BOXN, BCN, BCNA, BCNAHS, BCNAHSM1, BOBRN, BFNS, BTPGLN etc
• Springs inside the housing
WD‐49 BD: RF‐361
• Used in BOXN, BCN, BCNA, BCNAHS, BCNAHSM1, BOBRN, BFNS, BTPGLN etc
• Rubber Pad used inside
58
WD‐66 BD: ASF
•Used in BOXNHL & BCNHL
•Rubber Pad
WD‐66 BD: WESTINGHOUSE
•Used in BOXNHL, BCNHL & BOXNS
•Springs used inside
59
WD‐66 BD: Stucki
•Used in BOXNHL, BCNHL & BOXNS
•Springs used inside
WD‐66 BD: MINER
•Used in BOXNHL, BCNHL & BOXNS
•Rubber Pad
60
WD‐66 BD: MINER
•Used in BOXNHL, BCNHL & BOXNS
•Rubber Pad
WD‐71 BD: MINER LICENSED TO FAS
•Used in BOXNHL, BCNHL & BOXNS
•Rubber Pad
61
WD‐71 BD: JUPITER
•Used in BOXNHL, BCNHL & BOXNS
•Springs used inside
WD‐71 BD: RANEKA
•Used in BOXNHL, BCNHL & BOXNS
•Rubber Pads used inside
62
Draft gear : 495 A: BLC
63
14.0 Springs on Wagons
It is recommended that springs having less than 3 mm free height variation should be assembled in the
same group. Mixing of new and old spring must be avoided. The bogie is fitted with two groups of long
helical spring nests. The spring groups per bogie for various axle load applications are as under:
64
65
14.1 Grouping of Springs: (By strip method)
A. Group Band (Coloured) for in service springs (Maintenance group)
Matching of both, load and snubber springs, is important. It is recommended that springs
having not more than 3 mm free height variation should be assembled in the same group.
Coloured band should be provided for easy identification of group height as indicated in the
table.
All versions (except for CASNUB 22 HS)
66
B. Group Band (Coloured) of NEW Springs,
Matching of both, load and Snubber springs, is important. It is recommended that
springs having less than 3 mm free height variation should be assembled in the
same group.
67
14.2 SPRING DATA AT A GLANCE:
68
14.3 Spring Arrangement for Various CASNUB Trolleys:
69
70
15.0 Huck / Lock Bolt
71
72
73
74
16.0 Warranty/ Guaranty of Wagons
Period of warranty/ guaranty of Wagons will be 30 months from the date of delivery or 24 months
from the date of commissioning whichever is earlier. This clause is mentioned in Railway Board’s
Purchase Orders. For individual component, their warranty should be dealt with separately for
which details are given below;
a)
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:-




b)
Use of inferiormaterial
Poor workmanship on the part ofcontractor
Imperfectprotection
Other faults on the part of contractor which are noticed during the warranty period.
ToenabletheRailwayBoardto realize thewarrantycharges,asystematicinspection 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 thispurpose:(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:• ContractNumber
• Date ofCommissioning
• Commissionedby
• Inspection dueon
• Inspectiondoneby 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.
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(c). Warranty claim/Inspection of components
The important points which should be remembered in every warranty claim/Joint inspection
are;
• In respect of materials pre-inspected at the firm's premises, the consignee will issue
rejection advice within 90 days from the date of receipt. ( Ref: Vide Para 417 of the Indian
Railway Code for the Stores Department)
• Handling of rejection of pre inspected item and warranty rejections is governed by Dy.
Dir. Rly Stores (G)-I/Railway Board’s letter No. 2000/RS (G)/379/2, dt 07.08.2015 and
18.01.2018.
• The procedure of testing of sample is governed by Dir. Rly Stores (G)-I/Railway Board’s
letter No 2000/RS (G)/379/2, dt 28.04.2016 during joint inspection.
• Joint inspection must be done with the same Inspector who inspected the material
• During joint inspection, it should be carefully examined about
 Before start of JI, the inspector must go through above Railway Board’s guidelines.
 Hologram intact with the material (if applicable)
 Match details of material mentioned in DM/IC with the rejected material
 Any tampering marks on the material
 Marking details of manufacturer on the material
 Must go through the Inspection report of consumer of material based on which
Rejection Advice has been issued.
 Must see the storage condition of rejected stores
 Must observe whether the parameter (s) for which the rejection has been upheld,
was a part of regular Purchase Inspection Plan and mention the same in joint
inspection report.
 Try to convince your logic with the joint signatories with the all relevant
documentary evidence with very calmly.
 If joint signatories agree with the testing of sample, guideline mentioned in the Dir.
Rly Stores (G)-I/Railway Board’s letter No 2000/RS (G)/379/2, dt 28.04.2016 is to
be followed.
 If disagreement on any issue, dissent note is to be issued.
•
•
During joint inspection, a RDSO format no. QM-F-8.1-18, ver 1.0 w.e.f 28.08.2018 is to
be filled up and get duly signature (with Name, Designation & Date) of Gazetted Official
or the Controlling Officer issuing the Rejection Advice (In case of Railway Consignee)
and submitted to field unit head for further action. Any action taken by the field unit must
be communicated to the concerned firm or Inspector or Consignee.
All relevant papers must be accompanied with this report.
*****
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17.0 Wagon Production Software
Wagon production software has been developed by RDSO for the wagon
inspection. The site is www.rdsowagon.org. The salient features of this software
are;
 Railway/ Private purchase order registration by the wagon builders with
uploading facilities of PO and Proto approval/ Waival letter and approval by
Executive Director of the field units
 Wagon builder can raise wagon inspection against an Railway/ Private PO
after filling all sub-components details
 Inspecting officials inspect those wagons and issue system generated
Dispatch Memo (DM) and Inspection Certificate (IC) with unique numbers.
 SMS & e-mail alerts at each stage to the ED of the field units, wagon builders
and the concerned inspecting officials
 On line issue of NCR
 One can track the wagon inspection in terms of whether the wagon is under
inspection or passed or rejected.
 One can see the details of sub components details by searching wagon
number
 One can see the wagon inspection details by searching DM and IC
 Report section has been improved such as tracking of wagon production
wagon builder wise, month wise, year wise etc.
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By entering Wagon number , we can find all important details about wagon like, Manufacturer,
P.O details, Bogie Details, Chassis, Lock Bolt, CRF, Paint, Brake Equipment details, CBC/ Draft
gear details, Pipes & fittings, Rlaxation, RFID etc.
https://www.rdsowagon.org/Admin/View_WagonDetailslogin.aspx?wagon_no=73122014996
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18.0 Wheel Base of CASNUB Bogie
The wheel base of a CASNUB bogie is the distance between the centre lines of Jaw openings.
This is 2000 ± 5 mm for all types of bogies. While casting the side frames of a CASNUB bogie in
a foundry, five buttons are casted on the side frame which are called as Wheel Base buttons and
indicate wheel base. After measuring the distance between the jaw openings, buttons available
are removed according to wheel base and as tabulated below;
Distance between centre lines of No. of buttons on bogie
jaw opening
2004 to 2005 mm
frame
●●●●●
●●●●
●●●
●●
●
-
2002 to 2003 mm
2000 to 2001 mm
1998 to 1999 mm
1995 to 1997 mm
1995 mm
In other words, it can say that if five buttons found on side frame, it means that the wheel base of
that side frame is 2005 mm and if no buttons found on side frame, it means that the wheel base
of that side frame is 1995 mm. While pairing the side frame for a bogie, it should be ensured
that there should not be any difference between the numbers of buttons on the two-side
frames (Authority : Wagon Maintenance Manual, Chapter 6, Para no. 601 B (d) page no. 6
of 43).
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