Maintenance Instruction to Upgrade BOXN, BOXNM1 Wagons to ...

WMI-001-BOXNR-UPGRADATION-2020

INDIAN RAILWAYS

Maintenance Instruction to

Upgrade BOXN, BOXNM1 Wagons to BOXNR

For Operation at 100 Kmph

S.No. Month/Year of

issue

Revision/

Amendment

Page No. Reason for

Amendment

01 June 2020 Nil First Issue

Issued By :

Wagon Directorate

Research Designs and Standards Organization

Manak Nagar, Lucknow-226011.


Page 1 of 14

Contents

Preface ..................................................................................................................................................... 2

CONVERSION OF BOXN/BOXNM1/BOXNR WAGON ............................................................ 3

1.0 Design Data for BOXNR Wagon ......................................................................................... 3

2.0 Scope of Work: ....................................................................................................................... 7

A. Change in spring group: ................................................................................................... 7

B. Change in Side bearer: ...................................................................................................... 8

C. Change in Friction wedge: ................................................................................................ 9

D. Change in Marking: ......................................................................................................... 10

3.0 Procedure: ............................................................................................................................. 11

4.0 Inspection: ............................................................................................................................. 12

(i) Check sheet for Inspection for Modification Done in BOXNR wagon .................... 12

(ii) Check sheet for Inspection of Bogie Parameters of BOXNR Wagon ...................... 13

5.0 Details of Materials Required for Modifications (Bill of Material): .............................. 14

6.0 Details of Released Materials: ............................................................................................ 14

Annexures:

1. Drawing no WD-12008-S-1

2. Drawing no WX-10046







9. Speed certificate no MW/SPD/BG/BOXNR dated 11.10.2019

10. Rly Bd letter no 2020/CEDO/SR/03 dated 30-04-2020.


Page 2 of 14

Preface

Presently, there are more than 27 variants of open type freight stocks running all over the

Indian Railways. These wide variations especially in the bogie of these wagons are mainly

due to the fact that these bogies have been evolved with time through various

modifications/improvement made from time to time. Further to meet the increasing demand

of wagon availability and throughput, a necessity was felt to enhance the speed potential and

loading capacity of all wagons.

Therefore, Wagon Directorate of RDSO has undertaken a project to enhance the speed

potential and standardize theses freight stocks.

As such, efforts have been made to develop a common suspension system including side

bearers for the operation of wide variants of wagons.

This particular WMI deals with the guidelines and procedures for the up-gradation of

wagons for operation at high speed. Based on simulation results and detailed oscillation

trials of these wagons, broadly three modifications in bogie suspension arrangement have

been finalized to upgrade the speed of the existing open type wagons:

a. Modifications in the Side Bearer arrangement.

b. Modifications in the Metallic Wedge fitted with CASNUB bogie.

c. Modification in the number of springs of different types in the secondary suspension.

With these modifications, it is now possible to standardize and upgrade the speed of different

variants of open type wagons upto 100kmph in empty and 100 kmph in loaded condition.

These modifications can be planned by POH shops and ROH depots on IR.

This particular WMI covers the detailed work instructions to modify

BOXN/BOXNM1/BOXNR, scope of bill of materials requirements, quality check and final

instructions sheet to be followed by workshops, ROH depots and NTXR during its third

party check.


Page 3 of 14

CONVERSION OF BOXN/BOXNM1/BOXNR WAGON

The BOXNM1 wagon to RDSO diagram drawing no WD-05084/S-02 is provide with

CASNUB NLB bogie and has an axle load of 22.82t & BOXNR wagon having 22.9 t axle load

to RDSO diagram drawing no WD-07001-S-02 is rehabilitated version of BOXN/BOXNM1

wagon. Only body of these wagons is rehabilitated and the bogie remains the same. These

wagons were earlier not subjected to oscillation trials.

Now, the suspension of BOXNR wagon has been modified as per BOXNM2 Wagon. The

BOXNR wagon to RDSO Diagram drawing no WD-07001-S-02 was subjected to oscillation

trials and the wagon has exhibited satisfactory riding behavior up-to a speed of 110 kmph in

empty and loaded condition at 22.9t axle load. Final speed certificate of BOXNR wagon at 100

kmph in empty condition and 60 kmph in loaded condition at 22.9t axle load has been issued

vide letter no MW/SPD/BG/BOXNR dated 11.10.2019. Railway board sanction of the wagon

has also been obtained vide Railway Board letter no 2020/CEDO/SR/03 dated 30-04-2020.

Based on the above, it has been decided to convert BOXN, BOXNM1 & suspension of BOXNR

wagons as per the scope of work given in para-02 of the WMI. Railway Board will issue a

separate RSP for the above conversion. The modification work shall be carried out during the

POH/ROH of the wagon.

1.0 Design Data for BOXNR Wagon

Major Design parameters of the BOXNR wagons are shown below.

1. CODE BOXNR Wagon

2 BOGIE CASNUB 22 NLB

3 COMMODITY TO BE LOADED Ore, Coal etc.

4 WAGON BODY DIMENSIONS (mm) :

1 Length over headstocks 9784 mm

2 Length over buffers/coupler faces 10713 mm

3 Inside width 2954 mm


Page 4 of 14

4 Inside height 2127 mm

5 Max. height form R.L. 3408 mm

6 Height of coupler from R.L. (empty with new wheels) 1105 mm

7 Distance between bogie centres 6524 mm

5 BOGIE DIMENSIONS (mm)

1 Bogie width 2780 mm

2 Wheel base 2000 mm

3 Lateral spacing (centre to centre) of elastomeric pads 2260 mm

4 Lateral spacing (centre to centre) of secondary springs 2260 mm

5 Lateral spacing (centre to centre) of side bearers 1474 mm

6 Bogie pivot diameters 325 mm (Bottom Pivot)

315 mm (Top Pivot)

6 WHEEL AXLE DETAILS

1 Axle Load (t) 22.9 t.

2 Wheel dia (mm) New 1000 mm

Condemning 906 mm

3 Distance between journal centres (mm) 2260 mm

4 Tyre Profile Worn wheel profile (WWP) to

R.D.S.O Drg.No.-WD-88021

5 Wheel & Axle Assembly WD-89025-S/1

7 WEIGHT PARTICULARS (T)

1 Tare weight 21.2t

2 Gross load 91.6t

3 Weight of the bogie 5.4 t


Page 5 of 14

8 Spring Details Primary Secondary

1 Type - Helical Spring

2 No. per bogie - 24(12 outer, 8 inner & 4 snubber)

3 No. of spring nest per bogie - 2 Nos.

4 No. of springs in each nest - 06 outer, 04 inner & 02 snubber

5 Stiffness per spring kg/mm - 45.96(outer), 20.5 (inner),

13 (snubber)

6 Stiffness per bogie (Tare) - 767.7 kg/mm

7 Stiffness per bogie (Gross) - 767.7 kg/mm

8 Helical Springs

Outer Inner Snubber

(i) Free height (mm) 260 262 294

(ii) Effective No. of coils 5.7 9.5 9.3

(iii) Mean coil dia (mm) 115 70 82

(iv) Wire dia (mm) 25 16 16

(v) Solid height (mm) 170 169.6 166.4

9 IMPORTANT CLEARANCES

(i) Between Bolster and bogie frame

a) Vertical(Tare)

(Gross)

68 mm (approx.)

114 mm (approx.)

b) Lateral 18 mm (9 mm on either side)

(ii) Between adapter and side frame

a) Lateral 16 mm (08 mm on either side)

b) Longitudinal 09 mm (4.5 mm on either side)

c) Crown clearance between axle box

and bogie frame

N.A

d) Side bearer clearances Nil


Page 6 of 14

10 DRAWINGS

1 Diagram WD-07001-S-02

2 Marking Diagram WD-07001-S-12

3 Bogie General Arrangement WD-89073-S/2

4 Side Bearer WD-12008-S/1

5 Centre pivot and side bearer arrangement WD-20024-S-2

6 Suspension Springs WD-83069-S/1

7 Friction Wedge Drg No. WX-10046

8 Leading dimensions and tolerances of

CASNUB NLB bogie

WD-90042-S-1

9 Bogie Maintenance Manual G-95

Enclosed:

1. The dimensions given in para 9 above, are shop issue dimensions and are not line

dimension.

2. Copy of drawings given in para 10 above are attached with this WMI. Latest version

of the drawings to be followed during upgradation work.

3. Speed certificate of BOXNR wagon

4. Railway Board first sanction for operation of BOXNR wagon


Page 7 of 14

2.0 Scope of Work:

The existing BOXNR wagons which are having CASNUB-NLB bogies and the BOXN &

BOXNM1 wagon which are proposed to be converted into BOXNR wagon to RDSO

specification no WD-16-BOXNR-2010 (Rev.-1) as per latest amendment, are to be modified

with these instructions. These instructions are over and above the routine maintenance

instructions i.e. yard maintenance, sick line maintenance, ROH & POH. This routine

maintenance shall not be postpone or diluted in any manner.

A. Change in spring group

B. Change in Side bearer

C. Change in friction wedge

D. Change in Marking

a. On wagon Body

b. On bogie

A. Change in spring group:

Details of spring groups being used in BOXN, BOXNM1 and proposed BOXNR are as

follows:

S.No Wagon Bogie Suspension group Remarks

outer Inner snubber

01 BOXN CASNUB-

NLB

06 04 02

02 BOXNM1

&

Existing

BOXNR

CASNUB-

NLB

07 05 02


Page 8 of 14

Shall be modified to

01 BOXNR CASNUB-

NLB

06 04 02

B. Change in Side bearer:

Details of side bearers being used in BOXN, BOXNM1 and proposed BOXNR is given in

following table:

S.No Wagon Bogie Side Bearer Remarks

Type Drawing No

01 BOXN CASNUB-

NLB

PU CCSB

OR Metal

Bonded

Rubber

pad

AAL-

021101/N

OR

WD-85076-

S/1

02 BOXNM1

& Existing

BOXNR

CASNUB-

NLB


01 BOXNR CASNUB-

NLB

Spring

Loaded to

Variant ‘B’ of

Spec. WD-62-

Misc.-17

WD-

12008-S/1

For details see Annexure-I


Page 9 of 14

C. Change in Friction wedge:

Details of friction wedge being used in BOXN, BOXNM1 and proposed BOXNR is given in

following table:

S.No Wagon Bogie Friction wedge Remarks

Type Drawing

No

01 BOXN CASNUB-

NLB

All Cast

metallic

friction wedge

SK-77579

02 BOXNM1

&

Existing

BOXNR

CASNUB-

NLB

All Cast

metallic

friction wedge

SK-77579


01 BOXNR CASNUB-

NLB

Friction wedge

with liner

(CONTR-02-MISC-

2007, Rev 1)

Drawing

no.

WX-

10046

For details see Annexure-II


Page 10 of 14

D. Change in Marking:

S.No Wagon Bogie Marking diagram Remarks

Existing Proposed

01 BOXN CASNUB-NLB WD-80007-S-21 -

02 BOXNM1

& existing

BOXNR

CASNUB-NLB WD-07040-S-01

WD-07001-S-12

-

03 BOXNR CASNUB-NLB - WD-07001-S-12 For details see

Annexure-III

a. Marking shall be done as per new marking Diagram no. WD-07001-S-12.

b. Wagon number will remain the same as on existing wagon.

c. The existing transportation code i.e. “BOXN/BOXNM1” to be replaced with new

transportation code “BOXNR”. The existing BOXNR wagons with CASNUB-NLB

bogies will remain “BOXNR”, however it should be ensured that these wagons

shall be upgraded as per this WMI and after upgradation the colour band as

detailed in marking diagram no WD-07001-S-12 shall be marked on body & bogie.

d. The existing BOXNR wagons with CASNUB-HS bogies shall be renamed as

“BOXNRHS” after the modifications. Details of modification are given in WMI-

001-BOXNRHS-UPGRADATION-2020

e. An additional Zebra strip on each side wall as indicated in marking diagram no

WD-07001-S-12 to be painted to distinguish the high speed modified wagon with

other wagons. Specification of paint to be used for Zebra marking is given in

marking diagram no. WD-07001-S-12.

f. Since, the bogies are rolled out during the ROH/POH, a special Zebra marking on

each bogie side frame to be painted to ensure fitment of modified bogie in BOXNR

wagon as per marking diagram no. WD-07001-S-12.

g. Revised colour scheme as detailed in marking diagram shall be ensured.

h. Location of RFID tag to be verified with marking drawing.


Page 11 of 14

3.0 Procedure:

a. Place the wagon on Level Track.

b. Measure the Side Bearer Set up height of all the four locations and record.

c. Disconnect brake gear, remove split pin, lock pin and shackle lock etc. of bogie

and lift the wagon body with the help of EOT Crane.

d. Run out the bogies.

e. Lower the car body on the trestles.

f. Lift the bolster and make each spring group of 6 (outer), 4 (inner) and 2 (snubber)

as shown in para 1 (A) of this WMI.

g. Free height of springs in each bogie should be as per para 5.6 of G-95.

h. Remove all old All Cast metallic friction wedge (Drg No- SK-75579) and replace

with new Metallic friction wedge with nonmetallic liner (As per envelope Drg no

WX-10046) to RDSO spec. CONTR-02-MISC-2007 (Rev-1) as shown in para 1(C) of

this WMI.

i. Remove P.U. / Metal bonded rubber type side bearer and replace it with variant

‘B’ to RDSO spec. no. WD-62-Misc-17 (drawing no. WD-12008-S-1) as shown in

para 1(B) of this WMI.

j. Remove/Insert shims of suitable size at the body bolster (underframe) at side

bearer locations to achieve proper CCSB assembled height as shown in Centre

pivot side bearer drawing no WD-20024-S-2.

k. Lower the wagon on the bogies.

l. Check CCSB assembled height at all four locations. Correct, if required, by

inserting/removing shims.

m. Provide split pin, lock pin and shackle lock etc. and fit the brake gear

n. Paint the wagon as per new painting scheme as given in marking diagram no WD-

WD-07001-S-12.


Page 12 of 14

o. Change the marking particulars and provide Zebra strips on both side walls as

well as bogie side frames of the wagon as detailed in para 1(D).

4.0 Inspection:

Wagon shall be inspected after carrying out the modification as per check sheet before

offering to NTXR/ Third party inspector (As per contract requirement

(i) Check sheet for Inspection for Modification Done in BOXNR wagon

S.NO Description Parameter Remark

01 Bogie type CASNUB 22NLB

02 Side bearer Variant ‘B’ (Drg. No.-WD-12008-S/1)

to RDSO Specification no WD-62-

MISC-17 Rev-1

03 Side bearer

setup height

As per Centre pivot side bearer

drawing no WD-20024-S-2 i.e.

128.5±1 mm

04 Friction wedge Friction wedge with Liner to RDSO

Specification no CONTR-02-MISC-

2007 (Rev-1) & space envelope

Drawing no WX-10046

05 Suspension

(Each Group)

Outer spring- 06

Inner spring-04

Snubber spring-02

06 Marking WD-07001-S-12

Wagon Code- BOXNR


Page 13 of 14

(ii) Check sheet for Inspection of Bogie Parameters of BOXNR Wagon

S.NO Description Required Value Measured

Value

01 Visual inspection of all components for

correctness

No visible defect

02 DPT of side frame and bolster at

critical locations

No crack

03 Trammeling of bogie WD-90042-S-1

04 Lateral Clearances b/w adapter and s/f

jaw

16+6

−1.5 mm (Total)

(8+3

−0.75 mm on either

side)

05 Longitudinal Clearances b/w adapter

and s/f jaw

9+2

−3 mm (Total)

(4.5+1

−1.5 mm on

either side)

06 Lateral clearance between side frame

and bolster

18 ± 3 mm (Total)

(9 ± 1.5 mm on

either side)

07 UST of Axles if required as per existing

procedures

No surface and

internal crack


Page 14 of 14

5.0 Details of Materials Required for Modifications (Bill of Material): Following material is required for the above conversion:

S.No Item

Name

Specification Drawing

No

Quantity

per Bogie

Sources

01 Side bearer RDSO Specification no

WD-62-MISC-17

WD-12008-

S/1

02 Nos Provided in

Vendor

Directory

02 Wedge RDSO Specification no

CONTR-02-MISC-

2007, Rev-1

Drg no

WX-10046

04 Nos Provided in

Vendor

Directory

6.0 Details of Released Materials:

Exiting Wagon Item ( Removed

from the existing

Wagon)

No

Per

Bogie

Drawing No Remark

BOXN

(CC-20.32t)

BOXN

(CC+6+2)

BOXN

(CC+8+2)

Outer Spring Nil WD-83069-S/1 Nil

Inner Spring Nil WD-83069-S/1 Nil

Friction

Wedge(FW)

4 SK-77579 Can be used as spare for other

Wagons

Side Bearer

(CCSB)

2 AAL-021101/N

OR

WD-85076-S/1

Can be used as spare for other

Wagons

BOXNM1

(CC+2+6)

BOXNM1

(CC+8+2)

BOXNR

(22.9)

Outer Spring 2 WD-83069-S/1 Can be used as spare for other

Wagons

Inner Spring 2 WD-83069-S/1 Can be used as spare for other

Wagons

Friction

Wedge(FW)

4 SK-77579 Can be used as spare for other

Wagons

Side Bearer

(CCSB)

2 AAL-021101/N

OR

WD-85076-S/1

Can be used as spare for other

Wagons

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Lucknolr.-l:160tlotD (05?2i ?450115DtD (052?) 24653lU

Fax No. 0522-2453916

No. MWSPD/BG/BOXNR

Tdr q-drr6 ({fr),1. qq i-dd, E-dqfr ffi dffi{vr, gqg- 4oo oo12. Td ffi, $s-.fi +fl, 6)-d-mT-dT - 200 001.

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12. v(\T{ qr4 ffi, ErfuT t-s ,{dlH-fl-E - 211 oo1.

, f,E-dmgq - 4es oo4.

subl Final speed certificate of Broad Gauge Bogie open wagon type'BOXNR' with maximum axle load of 22.9t for operation over IndianRailway B.G route.

1.0 Broad Gauge Bogie open wagon type BoXNR to RDSo drawing No. wD-07001-S-02 Alt.-11 with maximum axle load of 22.9tis BOXNR wagon fittedwith Casnub 22NLB bogies. BOXNR wagon (rehabilitated BOXN wagon)was fitted with Casnub 22HS|NLB bogies. To differentiate, the BOXNRwagons fitted with Casnub 22HS bogies are named as BOXNRHS whilethe other wagons fitted with Casnub 22NLB bogies are named as BOXNRwagons with the approval of the Railway Board vide their letter No.201 0/M(N) l9s1 t23 dated 1 0-05-201 9.

BOXNR wagons are being used for transportation of coal, ore etc. BOXNRwagons are fitted with Casnub 22NLB bogies, high tensile (non transition)centre buffer coupler, high capacity draft gear and graduated release airbrake system. The design parameters and salient fbatures of 22.gt axleload BoXNR wagon have been shown in RDSo Drg. No. wD-07001-s-02Alt.-11 & Annexure-|.

1'1 In order to assess the riding quality and stability behaviour of 'BOXNR'wagon (BOXNR fitted with Casnub 22NLB bogies) in empty and toaded

MW/SPD/BG/BOXNR Page 1of g

condition, detailed oscillation trials have been conducted over Mahoba([/BA) - Kha ) section of North Centr tts ofthe trial are O Report no. RDSO/2O ev._OAmendment 6_07_2019. Osciilation that'BOX s exhibited satisfactory riding and stability behaviour upto a of 1 10 kmph in empty and roaded condition onlocati - as per current revisions of ',Third i;p;rt ;i'standingcriteria committee" on track maintained to other than c&M_|, VoL_lStandard.

2'0 Based on the design features and details given in Annexure-l andsatisfactory test resurts as indicated RDSO neport no.RDSO/2019/TG/MT-16221F Rev.-O Amendment Nit dated 16-07-2019 andabove, it is certified that 'BOXNR'wagon having maximum axle toad of22.9tto RDSO Drg. No. wD-07001-s-Ot Att._1 1 may be permitted to run upto maximum speed of 100 kmph in empty ano so't<mpn in roadedcondition subject to the foltowing conditionsi

2.1 Track

2'1.1(i) For loaded condition- Maximum speed up to 60 kmph

The track shail be standard of 52Kg (90 UTS) rail taid onPSC sleeper with on 30Omm ballast cushion below thesleepers which ma SOmm clean and the rest in caked upcondition.

(ii) For Empty condition-

Maximum speed up to 100 kmphThe track shall be to a minimum standard of 52Kg (g0 uTS) rail laid onPSC sleeper with 1540 Nos./Km on 250mm ballast cushion betow thesleepers which may consist of 100mm clean and.the rest in caked upcondition.

Maximum speed up to 60 kmphThe track shall be to a minimum standard of 52Kg (72 uTS) rail laid onPSC sleeper with 1540 Nos./Km on 25omm baltast cushion betow thesleepers which may consist of 100mm clean and the rest in caked upcondition.

2'1'2 For track maintained to lower standard than that mentioned above, theChief ower maximum permissible speed on thebasis In this connection, Railway Abaid,s tetterNo. 6Ensin r. 1 ,, . ;? 1J::,T;ilffi,::T,H?:?,1Hr3Hldrainage; he shall suitably restrict the maximum permissible speed. depending upon the local conditions.

2'1'3 The welds shall be protected by joggled fish plates as per provisions ofPara 6.4 and para g.14 of us-FD -Manuar

,nd prr, 6.3 oi AT werdingmanual and other policy instructions of Railway Board. The maintenance of

MW/SPDiBG/BOXNRPage 2of 9

Rails and Railjoints shall be ensured as per Para250 &2S1of lRpWM. In' addition, wherever condition warrants on account of corrosion on rail/weldcollar, wear on rail, cupping of welds etc., necessary precautions shall betaken for fish plating/joggted fish ptating.

2.1.4 Zonal Railway shall insure further detailed examination of track as deemedfit, based on the age cum condition, overdue renewal and condition offormation etc. as per provisions of Chapter-lll of IRPWM-2004 regardingpermanent way renewals.

2.1.5 The maximum permissible speed on curves shall be decided on the basis ofthe existing provision of Indian Railway Permanent Way Manual Reprint-2004.

2.2 Bridges

2.2.1 The clearance refers to Bridges "standard Spans" with standard design ofgirders, slabs, pipe culverts, piers and abutments etc. issued by RDSo forBGML, RBG and MBG-I987 Standard loadings. However, the bearings ofspan 76.2m (clear) designed for BGML standard loading as per RDSO'sdrawing No. BA-11154 shall be strengthened by providing two additionalanchor bolts.

2.2.2 Superstructure & Bearings of "special Spans" (designed and constructedby Zonal Railways based on site requirements) including all arches andsubstructure of all bridges (all Standard Spans & Special Spans) are to beexamined under the directions of the Chief Bridge Engineer concerned andcertified safe with respect to current Indian Railway Standard Codes withup to-date correction slips.

2.2.3 Other specific restrictions are applicable which are indicated in relevantSpeed Certificates of hauling single/multiple locomotives issued by RDSO.

2.2.4 This clearance is subject to the following parameters of 'BOXNR' wagon.. Maximum axle load (empty). Maximum axle load (Loaded)

- 5.3 1

- 22.9 r' Maximum braking force at Rail level per axle - 10 Yo of axle load. Maximum C.G height from Rait tevet (Empty) - 1O27 mm. Maximum C.G height from Rait tevel (Loaded) - 2062 mm

2.2.4.1 For regular operation in empty condition, when bridges will be fully loadedby wagons, following restriction shall be applicable:-

(i) In empty condition, there are no speed restrictions on bridges ofBGML/RBG/MBG Loading standards for proposed speed of 1oo kmph.

2.2.4.2 For regular operation in loaded condition, when bridges will be fully loadedby wagons following restrictions shall be applicable:-

(i) All Standard spans up to 4725m (all effective) of BGML/MBG LoadingStandards shall be restricted to 75 kmph.

MW/SPO/BG/BOXNR P a g e 3of 9

(ii) Standard spans of 63.0m f . fa em (both effective) of BGML/MBGLoading Standar ls shall be restricted to 60 kmpn.

(iii) All standard spans up to 31 ,9m

(ail effective) of RBG Loading standardsshall be restricted to 75 kmph rnb rprn -ii.y's^

(effective) is restricted to70 kmph.

(iv) standard spans up to 63.0m (effective) of RBG Loading Standards shalt berestricted to 60 k rph and span 7g.8m ierectvel is restiicteo to ss kmph.(v) Track on bridges and approaches of BGML span 7g.gm (strengthened or nodified in sucn a way so as to atowrongitudinar force as per crause 2.g.3.20i tns Bridge Ruredispersion cannot be ailowed as p", .rrrr. 2.g.3.2 such as due toprovision of SEJ in bridges ,glc, lhe bridge superstructure incrudingbearings and sub-structurJshall be check.o-ior tongitudinal force withoutdispersion and certified safe by the chi;EriJge rngineer concerneo.

2'2'5 Location of bridges on which speed restrictions are imposed shall be notifiedby the Zonal Railways and incorporated in the working timetable so that alloperating staff is aware of the insiructions

2'2'6 The above clause have been arrived considering bridges are in physicallysound condition' In case the bridges are not in satisfactory physicalcondition, necessary speed restriction to be rmposed by concern chiefBridge Engineer of the Zonal Railway.

2'2.7 The directives of RDSO for operation of cc+g+2t, axre road 22.g2tcommunicated vide RDSO letter no. cBS/Golden/e/strength dated 21127-07-2009 shall also be foltowed.

2.3 Signailing

2'3'1 Provisions of GR, sR, sEM & all extant instructions issued from time totime shall be complied with.

2'3'2 while running through a station, speed of the train shall be restrictect to themaximum permissible speed as per standard of interlocking provioed at thestation.

2'3'3 on the sections where EBD of more than 1 km is to be catered for, seconddistant signal or automatic signalling shall be avaitable failing which suitablespeed restrictions is to be imposed.

2'3'4 In the normal single phase 25Kv AC electrified section where electric. locomotive is used, provision given in para 22.6,22.7,22.g,22.g &22.10 ofsEM Pt'll regarding maximum permissible length of track circuits, signalfeed' maximum permissible length for operation of point motor, use of block

MW/SPD/BGi BoxNR page 4of g

2.3.5

2.3.6

2.3.7

2.3.8

2.3.9

instruments and use of track circuits such as DC Track circuit/AFTC shallbe complied by the Railway.

All level crossing gates within station limit shall be manned and interlockedwith station signals. All manned level crossing gates outside station limitshall be interlocked depending on the classification of the level crossing.

Suitable communication shall be provided in the locomotive and guards vanfor communication between loco pilot, guard and adjacent station master.

It is necessary to provide means/arrangements to put back the home signaland last stop signal to its "oN" position immediately after passage of thetrain.

The condonation regarding infringements in schedule of dimensions, if any,shall be obtained in accordance with local conditions, before initiating theoperation.

Precaution for Automatic signalling system working:

For running through the train at a station, the last stop signal shall not betaken "OFF" at the station unless;

The sections up to the station in advance is clear, and

At the station in advance, the route of the train is clear, correcily set andlocked for reception of train.

All manned level crossing gates in a stretch of block sections referred toabove are closed to road traffic and locked.

a)

b)

c)

2.3.10 Precautions for Absolute block system working:

For running through the train at a station, the signals shall not be taken'OFF' at the station unless:

a) The section up to the station in advance is clear and the station in advancehas confirmed that it has obtained permission to approach from the nextstation.

At the station in advance, the route for the run through of the train via mainline is clear, correctly set and locked.

All manned level crossing gates in a stretch of two block sections referredto above are closed to road traffic and locked,

b)

c)

MW/SPD/BG/BOXNR P a d a qnf o

2.4 Roiling Stock

2'4'1 Before initiating the operation, pcME of the concerned ZonalRailway shallarrange to certifv the track worthiness and safety .itd;;1in itocLs. Heshat arso ensure the proper maintenan.. or in. roting stock.2'4'2

il:iff# the rake of the wagons shatt be in good working order during the

2.5 Traction Installation

2.5.1 ln 25 kV AC tractithe minimum heioin provisions of"Dimensions of 16Corrigendum Sliprunning.

2'5'2 above, the chief Erectricar Engineer of the conceany temporary speed restri6tion on the basisexperience of the Sectional OHE and th; fl;prevailing on the particular Section.

2'5'3 when the vlagon is being moved, it shall be ensured that all the protrudingparts are withdrawn and iuitabry iockeo, so tiat orring the run there is no5,ff:'fJitrr.

rt anv inrrinsement occurrine -to tni stanJirJ" movins

2.6 General

2'6'1 All the permanent and temporary speed restrictions enforced and those thatln? f,:i|i-ffi i[T,l,i: :ttr J " t' t"'r'' o'i og

"', "'.,,' rig na I ins

2'6'2 For movement of wagon on any private or assisted siding for loading orunloading the consignments, thd Oriet-rnJr..,^ of concerned ZonalRailway shalt be re eried to.

2'6'3 The profire of 'BoXNR' wagon does not infringe_ to crauses of chapter rV(A) of Indian Rairwa r scneo-ure .;bi;;;;,.rr'iy.b. revised 2004.2'6'4 The heap of roading shat not

Sxgee{ the diagram No. 1D of Indian RairwaySchedule of Dimeniions BG Revised, 2004.

2.6.5 carried out ne n thethe USFD ion thanted frequen ane continueo. q' I s per

MWiSPD/BG/BOXNRP a g e 6of g

SeF=rfi': (i) Drg. No. WD-07001-S-02 Att.-11(ii) Annexure-l -Salient Features of ,BOXNR,

(iii) Annexure-lt (List of referred documents)-in

(fi b:oll|drfr ft+pm q;qq- /ilan q|fu

sfrfrTfr:(1) qfus 1n-dfuo-a /E-S), H qt€, i-olrac,T$ ftd - 11000.1

(2) Wq ta e-{eil eil-+m, 3ryir6 qrf, as+o- 226001

(3) qd. qcrsro 1ff-dF-oa/q-fl-qrd/q-dd qs Rr-€-fl{),(i) qtq ta}, E-rqfr ffi dffi{q, gE-i- 400 00i.(ii) Td tdd, ffi d-s, o)-d-mT-dT - z0o 001.(iii) vos ffi, q-s_)-dT Ersq, C ffi - 110 001.(iv) EfS"f H, qrd ersc, # - 600 oo3.(v) qf$q qq kra, t-d F-drqq, fuo=-srfl-E - 500 0z.l

- 700 043.

. - 781 011.

(xi) Td.d-Aq fcri, 0-gr ired or-*fr, ffi o-ru-dw, "-qtqgqTTq=IetR,-zs1 016.

(xii) Bd{ qtu idd, ErfulT s}s ,{dt-6[qrE - 2j1 ooj.(xiii) s-dr qtrqq ffi, u-ogq - 302 006(xiv) qfdrT(xv) qR-dq

(xvi) qfh"T , fr-dmgq - 4es oo4.

(4) GTeseT qs qqq F-iyr-f,, otmrT l-f,} mTqfi€rc fuF-)s, qtw qrtr lo s, ialgv "ro-r,f+es -1, rtfi$ nfl:{,r-ft UE-$ - 400614

frdrmD': (i) Drg. No. WD-07001-S-02 Att.-11(ii) Annexure-l -Salient Features of 'BOXNR,(iii) Annexure-ll (List of referred documents)-in a Compact Disc enclosed.

orffi friqTo .qTnq/ildn rfu

Disc enclosed.

MW/SPD/BG/BOXNR P a g e 7of 9

Annexure-l

Principle Oimension of noltingStock ,Alt.-11). Length over Couplers/

Buffers = 10713 mm. Bogie centre distance = 6524 mm' Wheel Base = 2000 mm. Axle load (loaded) = 22.g t. AXre roacr (Empty) = 5.3 t

(Diagram drawing@

Details of Bogie anO wfreet . Casnub 22NLB AogGlo RDSO DrgWD-89073-S-02 with suspensionhaving 12 outer,0g inner and 04snubber springs.. 1000 mm diameter wheel set toDrg.no. WD-89025-S-01 and

ItqeIlqn no. R-19/93 pt-1.Details of Brake system Underframe mounte

Air Brake system to

Details of Coupler anO Outfer . ElFNT-Coupterto@No. WD-708D-10

O SpeCification1BD-15.

Periodic maintenarrceschedules and standards(safety limits) to be foilowedin respect of safety items.

. Bogie maintenance manuEl no. G€E. For wheel &axle ref . para2.g ofchapter-2 of tRCA part_|il additition-1973. Air Brake Maintenance Manual no.G-97:. Coupler Maintenance Manual no. G_76(for Workshop staffl. Coupler Maintenance Manual no.G-8O(for Line s

MW/SPD/BG/BOXNRPage 8of 9

Annexure-ll

(List of documents referred in speed certificate oI 22.9t BOXNR wagon. Thecopy of these documents available in the GD enclosed with the speed

certificate)(i) RDSO Drg WD-89073-S-02 for Bogie Generat Arrangement(ii) RDSO Drg.no.WD-07001-S-02 Wagon Diagram(iii) Wheel Spec. no. R-19i93 Pt.1(iv) Para 2.8 of chapter 2 of IRCA Part ilt | 1973(v) Air Brake Spec. No. 02-ABR-02(vi) Air Brake Maintenance Manual No. G-97(vii) E/F NT.CBC Spec. No. WD-708D-10(viii) E/F NT.CBC Spec. No. Instruction & Maintenance Manual of CBC.

(a) G-80 (For workshop staff)(b) G-76 (For line staff)

(ix) Draft Gear Spec. No. 49-BD-08/ WD-718D-1S(x) Bogie Maintenance Manual No. G-95(xi) Railway Board's letter No.65A/VDO/SR/26 dated 19t20.10.1966(xii) Indian Railways Permanent Way Manual reprint-2004(xiii) USFD manual, Revised 2012(xiv) Maximum moving profile of 1D (EDotr-2202) of tRSOD, revised 2004.(xv) RDSO Report no. RDSO/2019/TG/MT-16221F Rev.-O Amendment -Nil

dated 16-07-2019.(xvi) RDSO letter no. CBS/Golden/Q/Strength dated 21t27-07-2009(xvii) Railway Board's tetter No.201O/M(N)951t23 dated 10.05.2019

MW/SPD/BG/BOXNR Page 9of 9

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