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

WMI-001-BOXNM2-UPGRADATION-2020

INDIAN RAILWAYS

Maintenance Instruction to

Upgrade BOXN/BOXNM1 Wagons to BOXNM2

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 WAGON ............................................................................ 3

1.0 Design Data for BOXNM2 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 BOXNM2 wagon ................. 12

(ii) Check sheet for Inspection of Bogie Parameters of BOXNM2 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/BOXNM2 dated 11.10.2019

10. Rly Bd letter no 2020/CEDO/SR/04 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 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, 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 WAGON

The BOXN wagon to RDSO diagram drawing no WD-80007-S-02 is provided with CASNUB

NLB bogie and has an axle load of 20.32t. The BOXNM1 wagon having 22.82 t axle loads to

RDSO diagram drawing no WD-05084-S-02 is same as BOXN wagon except the axle load and

change in suspension system i.e. One number additional springs in Inner and outer group

each. These wagons are presently operating at 80/75 kmph (L/E).

Now, the suspension of BOXN and BOXNM1 has been modified and a new transportation

code “BOXNM2” has been allocated. The BOXNM2 wagon to RDSO Diagram drawing no

WD-05084-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 22.82t axle load.

Final speed certificate of BOXNM2 wagon at 100 kmph in empty condition and 60kmph in

loaded condition at 22.82t axle load has been issued vide RDSO letter no

MW/SPD/BG/BOXNM2 dated 11.10.2019. Railway board sanction of the wagon has also been

obtained vide Railway Board letter no 2020/CEDO/SR/04 dated 30-04-2020.

Based on the above, it has been decided to convert all types of BOXN and BOXNM1 wagons

(approximately 40,400 in numbers for the conversion) into BOXNM2 wagons. Railway Board

will issue a separate RSP for the above conversion.

1.0 Design Data for BOXNM2 Wagon

Major Design parameters of the BOXNM2 wagons are shown below.

1. CODE BOXNM2 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 2950 mm


Page 4 of 14

4 Inside height 1950 mm

5 Max. height form R.L. 3233 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) 22.82 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 22.53t

2 Gross load 91.28t

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-05084-S-02

2 Marking Diagram WD-20017-S-01

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 BOXNM2 wagon

4. Railway Board first sanction for operation of BOXNM2 wagon


Page 7 of 14

2.0 Scope of Work:

Only those BOXN & BOXNM1 wagon to be modified with these instructions, which are not

proposed to be converted into BOXNR/BOXNRHS to RDSO specification no WD-16-BOXNR-

2010 (Rev.-1). These instructions are over and above the routine maintenance instructions i.e.

yard maintenance, sick line maintenance, ROH & POH. These 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 BOXNM2 are as

follows:

S.No Wagon Bogie Suspension group Remarks

outer Inner snubber

01 BOXN CASNUB-

NLB

06 04 02

02 BOXNM1 CASNUB-

NLB

07 05 02


Page 8 of 14

Shall be modified to

01 BOXNM2 CASNUB-

NLB

06 04 02

B. Change in Side bearer:

Details of side bearers being used in BOXN, BOXNM1 and proposed BOXNM2 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 CASNUB-

NLB


01 BOXNM2 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 BOXNM2 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 CASNUB-

NLB

All Cast

metallic

friction wedge

SK-77579


01 BOXNM2 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 CASNUB-

NLB

WD-07040-S-01 -

03 BOXNM2 CASNUB-

NLB

- WD-20017-S-01 For details see

Annexure-III

a. Marking shall be done as per new marking diagram no. WD-20017-S-01.

b. Wagon no will remain the same as on existing wagon.

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

New transportation code “BOXNM2”.

d. An additional Zebra strip on each side wall as indicated in marking diagram 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-20017-S-01.

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

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

BOXNM2 wagon. Details and location of marking on bogie are given in

marking diagram no. WD-20017-S-01.

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

g. 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 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-

20017-S-01.


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 BOXNM2 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

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) & Drg no WX-10046

05 Suspension

(Each Group)

Outer spring- 06

Inner spring-04

Snubber spring-02

06 Marking WD-20017-S-01

Wagon Code- BOXNM2


Page 13 of 14

(ii) Check sheet for Inspection of Bogie Parameters of BOXNM2 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)

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

Annexure-ll

{List of documents referred in speed certificate of BOXNM2 wagon. The copy of thesedocuments available lh ttre CD enclosed with the speed certificate)

i) lR specification no. R-19/93 Part-lii) Specification no. 02-ABR-02iii) G-97 of May 1996 with amendment no. 2 of July 2002.iv) G-80 with Revision 1 of March 1997v) G-95 with Revision 1 of March 1997vi) IRPWM-2004vii) Railway Board's letter no. 65-WDO-SR-26 dated 19120-10-1966.viii) Manual for ultrasonic testing of Rails and Welds (Revised 2012)ix) Drawing no. BA-11154x) Misc. Report MP-1461 of March 1993xi) G-76 of September 1987xii) IRCA Part-lllxiii) RDSO Drg. No. WD-05084/S-02 Alt.-s.xiv) Oscillation trial report No. MT-1646/Fxv) Railway Board letter no. 201O/m/(N)1951123 dated 13.09.2019

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