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Particular specification No. G-73 (Rev. – 1 of Oct., 2005 )

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

INSTRUCTIONS

FOR

OPERATION AND MAINTENANCE

OF

BOGIE OPEN BOTTOM RAPID DISCHARGE HOPPER WAGON - TYPE ‘BOBR’/ ‘BOBRN’

ISSUED BY :

RESEARCH DESIGNS & STANDARDS ORGANIZATION

LUCNOW – 226 011. OCTOBER, 2005

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C O N T E N T S

Clause Description* Preface 1. Section –I - Scope 2. Leading particulars of ‘BOBR’ wagon 3. Leading particulars of ‘BOBRN’/’BOBRNHS’ wagons 4. Special feature of ‘BOBR’ wagon 5. Special feature of ‘BOBRN’ wagon 6. Procedure for Assembly of Mechanism to wagon 7. Section –II - Operation 8. Operating instruction for Door Operating System ( Through

Spool valve) 9. Operating instruction for Door Operating System ( Manually ) 10. Section –III - Maintenance 11. Maintenance of Door Operating Mechanism 12. Routine Overhaul (ROH) 13. Periodic Overhaul (POH) 14. Out of schedule repairs

A N N E X U R E

Annexure-I Maintenance instruction for DOM of ‘BOBRN’ wagons Annexure-II A Details of various parts of the DOM of ‘BOBR’ wagon

(Ref. Drg. No. WD-86013-S-67 & 68 ) Annexure-II B Details of various parts of the DOM of ‘BOBRN’ wagon

( Single link ) Annexure-II C Details of various parts of the DOM of ‘BOBRN’ wagon

( Double link ) Fig. 1 Special features & leading particulars of ‘BOBR’ wagon Fig. 2 Special features & leading particulars of BOBRN/BOBRNHS Fig. 3 Spool valve Fig. 4 Door Operating System pneumatically / manually operated Fig. 5 Door Operating Mechanism of ‘BOBRN’ wagon ( Double link ) Fig. 6A Door Operating lever correctly adjusted Fig. 6B Door Operating lever requiring adjustment Fig. 6C Over center condition of lever and links Fig. 7 A & 7B Turn buckle adjustment Fig. 8 Secondary lock adjustment Fig. 9 Door tightness adjustment

***

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PREFACE The Kumaramanglam Committee on wagon handling systems and terminal facilities had recommended the deployment of a dedicated fleet of hopper wagons for the bulk transport of coal on account of assurance of wagon availability, achieving substantial reduction in loading and unloading time and cheaper unloading terminals as also reduction in maintenance costs. With this end in view the bogie open bottom rapid discharge hopper wagon type ‘BOBR’ has been designed by RDSO for the bulk movement of coal from the collieries to major users such as Cuper Thermal Power Stations etc. particularly for those users who are located within relatively shorter leads from the collieries. The main feature of this hopper wagon is the automatic discharge of coal with the help of manually operated. Pneumatic valve which operate the bottom doors. With the opening of doors, almost the entire bottom of the wagon opens out facilitating quick and complete discharge. The wagon is fitted with an automatic door operating system which causes opening and closing of the doors with the help of compressed air supplied by the locomotive through the door operating pipe which runs along the entire rake.

*****

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SECTION –I – GENERAL

1. SCOPE : These instructions for operation and maintenance apply only to the Bogie

Open Bottom Rapid Discharge Hopper Wagon type BOBR to RDSO’s drg. No. WD-86013-S-51 ( see Fig. 1 for diagram) & BOBRN/BOBRNHS drg. No. WD-91071-S-51 ( see fig. 2 for Diagram ) respectively.

2. LEADING PARTICULARS OF ‘BOBR’ WAGON:

2.1 Inside length 8732 mm 2.2 Inside width 3340 mm 2.3 Inside height 2461 mm 2.4 Length over coupler faces 11600 mm 2.5 Overall height from rail level 3735 mm 2.6 Slope of end plate 45 2.7 Slope of cross ridge 37 2.8 Maximum width over side stanchions 3500 mm 2.9 Cubic capacity 57.2 m3 2.10 Cubic capacity per metre length 4.93 m3/m 2.11 Pay load (gross minus tare) 55.28 t 2.12 Tare weight (estimated) 26.00 t 2.13 Maximum gross load 81.28 t 2.14 Axle load 20.32 t 2.15 Optimum commodity density 966 kg/m3 2.16 Track loading density 7.0 t/m 2.17 Pay load/metre 4.76 t/m 2.18 No. of doors 4 doors ( 8 flaps) 2.19 Doorway opening (each) 720 X 1133 mm 2.20 No. of wagons in a loop length of 585m 50 2.21 Total pay load per rake (t) 2764 2.22 Total gross load per rake (t) 4064 2.23 Distance between bogie pivot centres 7571 mm 2.24 Length over headstocks 10671 mm 2.25 Material of construction for wagon body Mild Steel, IRS:M41

& SAILMA-350-HI 2.26 Coupling arrangement Standard CBC

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3. LEADING PARTICULARS OF ‘BOBRN’/‘BOBRNHS’ WAGON:

3.1 Inside length 9327mm 3.2 Inside width 3340mm 3.3 Inside height 2466mm 3.4 Length over coupler faces 10600mm 3.5 Overall height from rail level 3735mm 3.6 Slope of end plate 42 3.7 Slope of cross ridge 43.5 3.8 Maximum width over side stanchions 3500 mm 3.9 Cubic capacity 56.78 m 3 3.10 Cubic capacity per metre length 5.35 m 3/m 3.11 Pay load (gross minus tare) 55.68 t 3.12 Tare weight (estimated) 25.6 t 3.13 Maximum gross load 81.28 t 3.14 Axle load 20.32 t 3.15 Optimum commodity density 1000 kg/m 3 3.16 Track loading density 7.67 t/m 3.17 Pay load/metre 5.25 t/m 3.18 No. of doors 4 doors ( 8 flaps) 3.19 Doorway opening (each) 700 X 1071mm 3.20 No. of wagons in a loop length of 620m

(approximate )excluding Engines 58

3.21 Total pay load per rake (t) 3229.44 3.22 Total gross load per rake (t) 4714.24 3.23 Distance between bogie pivot centres 6790 mm 3.24 Length over headstocks 9671mm 3.25 Material of construction for wagon body IS: 2062 Fe 410

CuWA IRS : M 44 & SAILMA – 350 HI

3.26 Coupling arrangement Standard CBC 4. SPECIAL FEATURES OF ‘BOBR’ WAGON :

4.1 Bottom Discharge Doors Doors are manually operated through spool valve. Door operating pipe shall be charge from the locomotive with compressed air at a pressure of 5kg/cm2 to 6 kg/cm2.

4.2 Brakes Single pipe graduated release air brake system fitted with automatic

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load sensing device to cater for the brake power requirement in empty and loaded conditions.

4.3 Bogies 2 axle cast steel bogie type CASNUB –22 NLB bogie to RDSO’s spcn. No. WD-10-CASNUB-21-CASNUB 22 NLB Bogie-93 (Rev. 2 of 2002 ) which is fitted with : (i) Spring plank (ii) Long travel helical springs (iii) Load proportionate friction

damping device. (iv) Taper roller cartridge bearings

(with narrow jaw adapters ) to RDSO’s spcn. No. STR/AB/RB-39-2002.

(v) Elastomeric pads to RDSO’s spcn. No. 20-MISC-95.

(vi) Wheels of one metre dia. On tread an 20.32 t axle load ( with 2 metre wheel base ).

4.4 Coupler and draft gear High Tensile centre buffer coupler of

knuckle type ( non –transition ) to RDSO’s spcn. No. 48-BD-2002 & 49-BD-2002 with latest amendment.

4.5 Construction All welded.

4.6 Infringement with respect of 1929 moving profile.

Wagon infringes the 1929 moving profile as shown in RDSO’s Drg. No. WD-86013-S-01.

5. SPECIAL FEATURES OF THE ‘BOBRN’ WAGON :

5.1 Bottom Discharge Doors Doors are manually operated through spool valve. Door operating pipe shall be charge from the locomotive with compressed air at a pressure of 5kg/cm2 to 6 kg/cm2.

5.2 Brakes Single pipe graduated release air brake system fitted with slack

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adjuster and automatic load sensing device to cater for the brake power requirement in empty and loaded condition.

5.3 Bogies CASNUB 22 NLB/ CASNUB 22 HS

2 axle cast steel bogie type –22NLB to RDSO’s spcn. No. WD-21- CASNUB –22NLB –BOGIE-93 Rev. 2 of 2002 which is fitted with the following spring plank, long travel helical spring, load proportionate friction damping device, taper roller cartridge bearing ( with narrow jaw adapters ) to RDSO’s spcn. No. STR/AB-39 Rev. 2 of 2002, Elastomeric pads to RDSO’s spcn. No. 20 – Misc. –95 Rev. 3 and wheels of one metre dia. On tread and 20.32 t axle load with 2 meter wheel base. If the wagon is fitted with CASNUB 22 HS bogie. Please refer RDSO specification No. WD-17-CASNUB-22HS Bogie 92 ( Rev. 3 of 2004 ).

5.4 Coupler and draft gear High tensile center buffer coupler ( Non – transition ) to RDSO’s spcn No. 48 BD – 2002 & 49-BD-2002.

5.5 Construction All welded. 5.6 Infringement with respect of

1929 moving profile The wagon infringes the max. moving dimensions of 1929 as shown in RDSO’s Drg. No. WD-91071-S-01.

6. PROCEDURE FOR ASSEMBLY OF MECHANISM TO WAGON :

6.1 Mount doors to wagon structure. 6.2 Mount bearings on center sill 6.3 Install bushing, operating shafts, adjustable levers and door operating

levers, adjustable levers must be positioned as per Fig. 3. 6.4 Install connecting rods and clevis assembly using pins provided. 6.5 Install eye bolts in door assemblies. 6.6 Install connecting rods links using pins provided. 6.7 Tighten doors using eye bolt nuts. 6.8 Install main operating lever to centre sill using two bearings fastened to

channel mounting Bkt 6.9 Install turn buckle assembly.

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6.10 Install pin connecting clevis mechanism to operating lever. 6.11 Install pre-assembled cylinder and cylinder clevis using pins provided. 6.12 Install safety hook, lock spring, spring retainer as per fig. 4. 6.13 Install air receiver tank, air filter and spool valve, taking care that during

pipe fitting the system, remove burrs and clean pipe thoroughly to present foreign matter from containing the system.

6.14 Adjust all possible members as highlighted in maintenance procedure. 6.15 Lock eye bolt nut with standard spring washer. 6.16 Tack weld clevis lock nut with cylinders rod clevis. 6.17 Use bulb cotter pins in place of split pins for DOM arrangement as per

given in drg.

SECTION –II – Operation

7. The wagons have been designed to run in fixed train formation using locomotives suitable for hauling trailing stock fitted with single pipe graduated release air brake system.

7.1 Before starting loading, it must be ensured that the door operating system is

in discharged condition and is in no way connected with the compressed air supply from the locomotive. Hoses of the door operating pipe of the first and the last wagon should be on their respective dummy couplings.

7.2 Before loading also ensure that all the door connecting links are over centre and the secondary lock hook is in locked condition ( Fig. 6C & Fig. 8 ).

7.3 For loading /unloading of these wagons, the train speed should be suitably controlled depending on the design of the loading terminal so that during the time taken for a wagon to pass under the loading bin, the amount of coal discharged into the wagon is equal to its pay load capacity. The loading terminal should also have suitable arrangement to prevent spillage of coal in the gap between the two wagons. Increase in train speed should occur only after all the wagons have been loaded.

7.4 At the unloading terminal, the train is to be brought to a hault before the unloading pit and the following sequence of operation completed.

7.5 After the last wagon has been unloaded, the train should be stopped clear of the unloading pit and the following sequence of operations ensured.

7.5.1

The doors should be visually examined to check that they are properly closed, all the door connecting links are over centre and the secondary lock hook is in locked position ( Fig. 6C & Fig. 8 ).

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7.5.2 The locomotive feed pipe is dis-connected from the door operating pipe of the first wagon.

7.5.3 Carry out checks indicated in para 11.3.4 which are specified to be carried out after each unloading/dumping.

8. OPERATING INSTRUCTIONS FOR DOOR OPERATING SYSTEM

(THROUGH SPOOL VALVE) :

The spool valve may also be operated manually for opening or closing of the doors ( Fig. 3 & 4).

8.1 DOOR OPENING : Air is first introduced to the system through auxiliary train pipe at 5kg to 6 kg/cm 2 pressure and enter into the air receiver tank. Form tank, it passes through air filter ( which provides filtered air by segregating moisture ) and pipes and enter into the ‘in’ part of pneumatic valve which is fitted air cylinder side platform of underframe using a pointed object such as a pen or pencil depress the button facing the sole bar of the wagon , the door opening is organised causing the valve slide to shift and turn allows air to flow to the door operating side of the cylinders. Thus the piston inside the cylinder moves forward by back die air pressure. Residing air in front of the piston which tends to prevent piston movement by imparting back pressure is exhausted simultaneously from the cylinder through then pipes and exhaust part of the pneumatic valve. This when the piston rod is extended it pushes the main operating lever which is connected to a series of connecting rods by clevis, turn buckle, eye bolt assembly which are located inside the wagon of center sill. Then the main operating lever is turn pulls the connecting rods towards the cylinder end of the wagon. This axial movement of the connecting rods causes the angular rotation of the adjustable lever while transmitting it to the operating shafts and in turn develop a rotational movement in the operating shafts. During opening, operating shafts are to have 96 rotation ( to have required door way opening ) in anti-clockwise direction which in turn pulls the door operating levers which are directly connected to it. Door operating levers are connected to the doors of the wagon through connecting link eye bolt assembly. So, when door operating lever is pulled by its rotation ( anti-clock wise ) with respect to shaft axis it in turn pulls the door to open.

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8.2 DOOR CLOSING : Using a pointed object such as a pen or pencil, depress the inside button of the spool valve. The valve to shift and in turn allows air to flow to the door closing side of the cylinder and thus the piston moves in reverse direction. Air causing back pressure to piston is exhausted through pipe and exhaust port of the pneumatic valve. Thus the piston rod when retracted, it pushes the connecting rod causing the axial movement of the connecting rod is reverse direction which in turn transmits the motion through adjustable lever in the operating shafts causing the shafts to rotate clockwise. Thus, door operating levers are also undergone clockwise rotation which in turn pushes the doors toward door centres causing the doors to close.

8.3 LOCKING ARRANGEMENT : When the door closes, initially after closing the doors are locked in over centre condition. The operating shafts, door operating levers and connecting links work together to provide primary over center door lock. A secondary locking arrangement is provided at the top of the air cylinder. It includes the secondary lock assembly and spring. When the piston rod of the cylinder is retracted during closing to the extreme position, it provides the secondary locking to prevent any forward movement of piston rod of the cylinder due to jerk developed during movement of wagon, secondary locking serves as a back up locking system and it locks the doors over centre.

9. OPERATING INSTRUCTIONS FOR DOOR OPERATING SYSTEM

( MANUALLY) : 9.1 The wagon fitted with pneumatic valve, if not functioning properly, the

opening and closing of the doors can be carried out by providing compressor along with one inlet and outlet air pipe with the D.O. M air cylinder to side sill side. Presently, door operating mechanism of BOBR & BOBRN wagon is carried our by compressed air. A pressure regulating valve is to be installed at each loading and unloading point so as to ensure that door opening /closing is carried out at air pressure 5 kg/cm2 and not more than 6 kg/cm2. Above instruction has already circulated to the concerned Railways vide RDSO letter No. MW/BOBRN dated 22/24.06.2004.

9.2 The door operating system can be broken down into two major areas : the pneumatic system and the door operating mechanism.

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9.2.1 The pneumatic system includes the air cylinder, 4-way air valve, reservoir, air filter, valve sub-plate piping and other miscellaneous valves. Air is introduced to the auxiliary system through the door operating pipe into the reservoir. From there it passes through the filter and into the “in” port of the four way valve. The four way valve is manually controlled through the use of a pneumatic valve actuated internal pilot air system which shifts the valve slide to one of two possible positions.

9.2.2 The door operating mechanism is powered by a double acting air cylinder which unlocks and opens when its rod is extended. It closes and locks the doors when the rod is retracted. This is accomplished through the use of a mechanical linkage system which operates as follows :

9.2.3 The air cylinder piston rod in connection to a main operating lever which connects it to a series of connecting rods located under the wagon center sill. When the cylinder piston rod extends the main operating lever in turn pulls the connecting rods toward the cylinder end of the wagon. This motion is translated to rotation at each operating shaft by the door operating shaft levers. The rotating shaft in turn rotates the door operating levers causing the connecting links to pull the doors open. When the piston retracts the motion imparted to the connecting rod is reversed which in turn closes and locks the doors over center. The operating shafts, the door operating levers and connecting work together to provide the primary over center door lock. A secondary lock is located at the air cylinder.

SECTION –III – Maintenance

10. In order to keep the wagon in good fettle the following schedules of maintenance are recommended. These are in addition to the normal trip examination at the originating & terminating stations to the wagon including its door operating system.

10.1 REPAIRS TO DOOR OPERATING MECHANISM :

To be done every year (once between successive ROHs ) as per 11.3.4 of this manual. Maintenance depots should develop suitable facilities for repair and maintenance of the door operating system.

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10.2 ROH : To be done at an interval of 2 years ( 2 ROH schedules between successive POHs). ROH will include attention to door operating system.

10.3 POH : To be done at an interval of 6 years. While 10.1 and 10.2 above can be carried out in maintenance depots, the POH shall be carried out in mechanical workshops fully equipped for this purpose.

10.4 Details maintenance instructions for ROH & POH for door operating mechanism of BOBRN wagon shall be done as per Annexure-I vide RDSO letter No. MW/BOBRN dated 18.05.2005.

11. MAINTENANCE OF THE DOOR OPERATING MECHANISM : 11.1 The various parts of the door operating mechanism can be seen at Annexure–II

and their layout can be seen at Figures 4 & 5.

11.2 SAFETY PRECAUTIONS TO BE OBSERVED FOR REPAIR/MAINTENANCE OF THE DOOR OPERATING SYSTEM: The following safety precautions must be observed whenever this ex. Wagon is operated and whenever any maintenance is performed on it.

11.2.1 All maintenance, repair or adjustments must e made on shop or repair track where the wagon will not be moved. Protective eye and ear wear should be used when doors are operated.

11.2.2 Carefully follow instructions on stencils located on the wagon. Note the stencil above doors on both sides of the wagon which reads, “CAUTION – STAND CLEAR WHILE DOORS ARE BEING OPERATED”.

11.2.3 Stand clear of the wagon when the hopper doors are being operated. The door action is simultaneous and rapid.

11.2.4 Do not operate the doors manually unless the wagon has completely stopped moving.

11.2.5 When operating the doors manually, the operator must keep well away from the air cylinder and main operating lever. The operator must also have an assistant on each side of the wagon to ensure that everyone stands clear of the wagon doors.

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11.2.6 If the wagon does not operate pneumatically /manually, refer to para 11.6 of this manual. DO NOT attempt to force the mechanism in anyway, at the doors or at the air cylinder.

11.2.7 Do not make any adjustments to the mechanism without fully releasing the air pressure in the system. To release air pressure first close door operating pipe valves to cut off air source and then slowly open reservoir drain plug.

11.3 MAINTENANCE PROCEDURE : 11.3.1 The following conditions must be checked at the recommended time intervals

specified in para 11.3.4 below and corrected if necessary.

11.3.2 No attempt at repair should be made until para 11.2 of this manual has been read and fully understood.

11.3.3 All air must be purged from the system before performing any maintenance or repair. This can be done by closing anglecocks at each end of the door operating pipe and slowly opening the reservoir drain valve.

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11.3.4 PERIODICITY OF MAINTENANCE REQUIREMENTS : PART REQUIRED MAINTENANCE TIME

INTERVAL a) Locking Levers

at Hopper Doors

Check for over center condition with door connecting links against lever stops. See adjustment procedures ( Para 11.4.2.1 ) and Fig. 6 (A &B ) and 7 (A&B).

After each dumping and before loading.

b) Secondary Lock at Air Cylinder

Check for locked condition with hook pin on inboard side of locking lug. See adjustment procedures ( Para 11.4.2.2 ) and Fig. 8. Lubricate cam surface of cylinder clevis and sliding surface of hook.

After each dumping and before loading. As required.

c) Hopper Doors Check to be sure doors are closed tightly. See adjustment procedures ( Para 11.4.2.3 ) and Fig. 9.

After each dumping and before loading.

d) Eye bolts & nuts

Inspect physically for damage, bend and loose nut & nut lock.

-do-

e) Surge Reservoir Drain condensed water by slowly opening air valve in the bottom of the reservoir till air is clear.

As required.

f) Air filter Drain water by the use of the valve at the bottom of the filter.

As required.

g) Air cylinder Inspect for physical damage. Check the correct installation. Examine all seals, barrel, piston rod, seal retaining rings for wear, rust, damage.

Once a year.

h) Four way ( spool )valve

Inspect for physical damage. Once a year.

i) Bronze bush Inspect physical damage and wear. Replace once in two years or more.

j) Cast steel bush for operating lever

-do- -do-

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k) Pins Check all the types of pins for wear, cracks. If so, it must be replaced by new one.

As required

l) Operating shafts Check the shafts for any defects, crack. If so, it must be replaced by new one.

-do-

m) Connecting rod Check each rod for wear, crack. Damaged rods must be replaced. Also, check for alignment of the rod.

Every six months.

11.4 ADJUSTMENT PROCEDURES :

11.4.1 Before attempting any adjustments read DESCRIPTION OF OPERATION ( Para 8 ) and SAFETY PRECAUTIONS ( Para 11.2).

11.4.2 The door operating mechanism has three major areas that require regular inspection to determine if adjustment or repair is required. The three areas are:

(i) The door operating levers which serve to open and close the doors and provide the primary locking means to hold the doors closed.

(ii) The secondary lock which is located at the air cylinder which serves as a backup locking system.

(iii) The doors which provide a means to retain the commodity in the wagon and prevent any leakage. A visual inspection as outlined below in Para 11.4.2.1, 11.4.2.2 & 11.4.2.3 of the three (3) areas respectively will determines the operating condition of the mechanism.

11.4.2.1 DOOR OPERATING LEVERS :

A. With doors closed and secondary lock engaged observe door operating levers. Compare to fig. 6 A and 6 B to determine if adjustment is required. Fig. 6 A shows three conditions where the adjustment is correct. On door operating levers between doors where there is no gap on one side it is permissible to have up to 5mm gap on the other side as shown. On end levers there should be no gaps. Fig. 6 B shows conditions requiring adjustment. If doors cannot be fully closed and secondary lock is not engaged, air pressure supply must be at least 5 kg/cm2. If air pressure supply is adequate, it may then be necessary to back off door eyebolts to reduce air pressure requirements. Doors can then be closed so that levers can be adjusted. Door tightness adjustment is covered in Para 11.4.2.3.

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B. Begin adjustment at lever requiring adjustment that is closest to the air cylinder. After this is completed go on in sequence to the next lever requiring adjustment until all are completed.

C. To adjust turnbuckle, first remove locking bolts. Then with doors closed note gaps at door operating levers so that an estimate can be made of, the no. of tonnes required ( one complete turn moves pin centres 8mm ) rotate the turnbuckle in the direction that increases the pin centres. When the adjustment is made, check door operating levers gap with the doors closed. Repeat this process until one or more levers have no gaps. The removing door operating levers are adjusted using the adjustable levers where gaps are present, turnbuckle locking bolts to be installed after checking secondary lock adjustment ( para 11.4.2.2 B.)

D. If adjustment cannot be made because there is no adjustment remaining in the turnbuckle, it will be necessary to check location dimension of components to determine if they are in correct positions. Correct as required.

11.4.2.2 SECONDARY LOCK :

A. Close doors using a source of air of at least 5 kg/cm2. If doors cannot be fully closed, (levers over center ) and the cylinder is not fully retracted, the doors are too tight. Door eyebolts must be backed off to allow mechanism to fully close ( see 11.4.2.3 C). If levers are over center, but cylinder is not fully retracted back off turnbuckle until cylinder is fully retracted. Go on to secondary lock adjustment after completing the above.

B. SECONDARY LOCK ADJUSTMENT :

If gap between operating lever lug and hook pin is not 6 mm to 10mm with air cylinder fully retracted under maximum 6 kg/cm2 air pressure, adjust as follows ( fig. 8 ).

1. Note gap under air ( doors closed ).

2. Release air pressure and back off clevis lock nut. This will require first removing tack weld.

3. If gap was under 6mm, turn cylinder rod so that it advances into cylinder rod clevis. If gap was over 10 mm, rotate cylinder rod so that it moves away from cylinder clevis. One turn of cylinder rod changes gap approximately 2 mm.

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4. Recheck gap with air pressure applied and repeat adjustment until within tolerance. Be sure that cylinder is fully retracted and cylinder rod clevis pin is against front stop when checking gap.

5. After adjustment is completed, securely tighten locknuts and tack weld to clevis ( not to cylinder rod ).

6. With air pressure removed, gap should be 0 to 2 mm. If it is 0, check to see that hook can be easily pried up. If hook is too tight or if gap is over 2 mm, turnbuckle must be adjusted. See fig. 7 ( A&B) for turnbuckle adjustment.

11.4.2.3 DOOR TIGHTNESS ADJUSTMENT :

The procedure for adjusting the door tightness is as follows :

A. Check each door location to determine if doors are closed tight ( see fig. 9).

This is done by sighting along the lips of doors to note if they contact one another. If they don’t, adjust appropriately eyebolt to bring door lips together as shown in Part A of fig. 9. adjustment is made by bending the nut locks away from the nut and jam nut and loosening the jam then tightening the nut until correct adjustment is obtained.

B. After the above adjustment is complete, check air pressure requirements to determine if doors are too tight or too loose. This is done by inserting a pressure gauge into the system as close to the air cylinder as possible. This can be done at the auxiliary train line at the “Y” end of the wagon or at the door operating mechanism reservoir drain. With the doors opened and the system drained slowly build up air pressure. When the pressure reaches 20 psi ( 1.4l kg/cm2) actuate air valve in the closing direction. Continue to slowly build up air pressure and no pressure where the door operating levers snap over center. This pressure should be 55 psi ( 3.87 kg/cm2 ) plus or minus 5 psi ( 0.35 kg/cm2).

C. If the pressure is higher than 55 psi ( 3.87 kg/cm2 ) or if the doors cannot be closed, back off nuts and recheck pressure using the above procedure.

D. If the pressure is too low tighten nuts and recheck. Eyebolt jamnut should be tightened the same amount. After tightness adjustment is complete tighten jam nut and bend over nut locks on nuts and jam nuts.

11.5 QUICK CHECK TO DETERMINE IF DOOR MECHANISM REQUIRES ADJUSTMENT AND WHERE TO MAKE ADJUSTMENT

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SN

Cylinder Secondary lock Door operating

levers

Remarks

1 Closed position no air pressure

Engaged ( gap – 0-2mm )

Over center as per fig. 6C

Adjustment is correct

2 Fully retracted (* under air press)

Engaged ( gap – 6-10mm )

-do- -do-

3 Closed position (*under air pressure) ( without air pressure )

Engaged - Gap 6mm-10mm - Gap 0- 2mm

All not fully overcenter.

Adjust turnbuckle followed by adjustable lever adjustment where required.

4 Closed position (* with or without air pressure )

Not engaged Not overcenter.

Adjust cylinder clevis first followed by adjustment of turnbuckle & adjustable lever.

5 Closed position (* with or without air pressure )

Not engaged Fully overcenter.

cylinder clevis needs adjustment. Check turnbuckle fine adjustment for correct gap W/o air.

6 Not fully closed ( *under air pressure )

Not engaged or engaged

Not overcenter.

Doors too tight. After adjusting doors check secondary lock & cylinder. Adjust as required.

7 Not fully closed (*with or without air pressure )

Not engaged Fully overcenter.

Adjust (Shorten) turnbuckle followed by the checking secondary lock gap. Adjust as required.

8 Not fully closed (*with or without air pressure )

Engaged Fully overcenter.

Adjust (shorten) turnbuckle followed by the checking secondary lock gap. Adjust as required.

* Note : Air pressure should be a minimum 5kg/cm2. 11.6 TROUBLE SHOOTING :

If the doors will not operate, make the following checks in the sequence listed. Do not perform any work on the wagon until the safety precautions in para 11.2 included in this manual have been read and fully understood.

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A. If the doors will not operate : If the condition persists, Pneumatically/manually proceed to

1. Check the hopper doors and mechanism for damage that could restrict operation.

( Step A-2 )

2. Make sure angle cocks are open and adequate air pressure is being supplied to the system. Inspect for and repair any leaks found in the system.

( Step A-3 )

3. Inspect the secondary lock at the air cylinder for damage or a jammed condition. Be sure to stand away from the air cylinder and lock when attempting to operate the doors.

( Step A-4 )

4.(i) Disconnect external air supply to the wagon and release the air pressure in the system. Carefully remove the hose from the rear port of the cylinder. ( toward the end of the wagon). Connect shop air through a valve directly to the rear port of the cylinder. Pressure must be atleast 5 kg/cm2 and not greater than 6 kg/cm2 .

(ii) If shop air, applied directly to the cylinder will operate the door properly:

Replace the spool valve.

(iii) If shop air, applied directly to the cylinder will not operate the door properly:

Replace the cylinder.

B. If doors operate, but mechanism : If the condition persists, will not snap over center proceed to

1. Check air pressure to cylinder should be 5

kg/cm2 minimum.

( Step B-2 )

2. Loosen door eyebolts until mechanism snaps over center.

12. ROUTINE OVERHAUL (ROH) :

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12.1 UNDERFRAME, COUPLERS & BOGIES : For ROH of underframe couplers and bogies Instructions given in Indian Railways Maintenance Manual of wagon issued by Railway Board should be followed in so far as they apply to the equipment provided on this wagon. Instructions for maintenance of bogies can also be found in Technical Pamphlet No. WD-21-CASNUB-22NLB-BOGIE-93 & WD-17-CASNUB-22HS-BOGIE-92 issued by RDSO.

12.2 BRAKES : The brake equipment shall be given the following attention :

(i) Clean the strainer discs of the distributor valve.

(ii) Lubricate the brake cylinder & clean its strainer.

(iii) Check for easy operation of isolating cock of distributor valve, cut-off angle cock, manual quick release valve and isolating cock of feed pipe.

(iv) Drain out the auxiliary reservoir.

(v) Check all hose couplings for serviceability.

(vi) Clean strainer and choke of check valve.

(vii) Clean dirt collector.

(viii) Test the brake system for proper functioning. Test shall be carried out in accordance with the procedure indicated below :

a) Connect the brake pipe (BP) to the corresponding coupling of single Car Test Device.

b) Close the coupling on other end of the wagon.

c) Fix a pressure gauge on the brake cylinder.

d) Connect the Single Car Test Device to the main line of the compressor.

e) Carry out further preparation & testing in accordance with the procedure given in the air brake manufacturer’s maintenance manual.

f) Record the readings in the test proforma and see that all the parameters are within the specified limits.

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12.3 Door operating system : To be done as per para 10.1

13. PERIODIC OVERHAUL (POH): 13.1 UNDERFRAME, COUPLERS & BOGIES :

A large number of couplers and bogies similar to the ones provided on these wagons are already being maintained by the Indian Railways workshops. POH of these assemblies shall, therefore, be carried out as per procedure laid down in the Indian Railway Maintenance Manual for wagons issued by the Railway Board and RDSO’s Technical Pamphlet No. WD-21-CASNUB-22NLB-BOGIE-93, WD-17-CASNUB-22HS-BOGIE-92 & 48 BD –2002 and 49 BD-2002 for the couplers and draft gears.

13.2 BRAKES : Maintenance of brake equipment shall be carried out as per maintenance procedure laid down in the instructions issued by the supplier of equipment.

13.3 DOOR OPERATING SYSTEM : To be done as per para 10.1

14. OUT OF SCHEDULE REPAIRS : Even after regular ROH and POH of wagons, there may arise some defects

which require out of schedule repairs. Nature of such defects shall be examined in the light of instructions contained in this manual and appropriate steps shall be taken depending upon the nature of defects.

***

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Annexure - I

Sub: Maintenance instructions for Door Operating Mechanism of BOBRN wagons. A. Door & Lever Mechanism (Must attend items)

S. No

Items to be checked/ attended

POH ROH

1.

Door hinges Replace existing door hinges by forged door hinge as per RDSO drawing no. SK-WD7-0406/S-1 alt.1 issued vide letter no. MW/BOBRN dt. 23/25.6.2004.

Visually examine door hinge for welding defects and attend the same. Stiffener plate as provided by Waltair to be ensured.

2.

Adjustable bushing Replace existing cast steel bushing by forged steel bushing as per RDSO Drg. no. WD-96038-S-04 alt. 3 (item-1)

Examine and replace defective (damaged/ bent) adjustable bushing.

3.

Securing of turn buckle

After adjustment, locking plate to be secured by bolt and spring washer and weld with turn buckle (min. 10mm length).

After adjustment, locking plate to be secured by bolt and spring washer and weld with turn buckle (min. 10mm length).

4.

Eye bolt fitment Ensure center line of eye bolt is 73 mm from bottom of center sill as given in Drg. no. WD-96038-S-01. Ensure that eye bolt is not loose and secured by bolt and spring washer (item no. 3 of Drg. no. WD-96038-S-02) and lock nut with nut lock (item no. 7 of Drg. no. WD-96038-S-02). Spring washer should be as per IS-3063. Replace bent/ damaged eyebolt.

Ensure center line of eye bolt is 73 mm from bottom of center sill as given in Drg. no. WD-96038-S-01. Ensure that eye bolt is not loose and secured by bolt and spring washer (item no. 3 of Drg. no. WD-96038-S-02) and lock nut with nut lock (item no. 7 of Drg. no. WD-96038-S-02). Spring washer should be as per IS-3063. Replace bent/ damaged eyebolt.

5

Door clip Examine door clip and replace if bent or hole is elongated due to loose eyebolt. Ensure center of hole remains 73mm below center sill.

Examine door clip and replace if bent or hole is elongated due to loose eyebolt. Ensure center of hole remains 73mm below center sill.

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6.

Pin of connecting turn buckle, clevis with main operating lever.

Replace pin & split pin arrangement by pin (same dia and material) and bulb cotter arrangement.

Replace pin & split pin arrangement by pin (same dia and material) and bulb cotter arrangement.

7.

Pin of the door operating shaft with the adjustable lever

Replace the pin and split pin Replace pin if worn out more than 1.5mm. Properly fit split pin

8

Bush bearing assembly Ensure that bush bearing is not loose fitted.

Examine for loose bush bearing and attend, if required

9

Bronze bush of the door opening square shaft

1. Replace bronze bush. 2. Ensure that both the stoppers are fitted.

1. Replace bronze bush. 2. Ensure that both the stoppers are fitted.

10.

Bush of the main operating lever

1. Examine for defects like welding with operating lever, crack etc. and replace, if defective. 2. Check for out of roundness of the bush. It should not be more than 1.0mm in dia. 3. Examine for alignment of both the bush with holes at the end of the operating lever and correct/ replace, if required.

Examine for broken bush and replace operating lever, if required.

11

Operating lever holding bearing

1. Examine for looseness in fitment. If loose refit after properly examining stud threads. 2. Check for roundness of the bearing hole. If out of round by 1mm in dia, replace.

1. Examine for looseness in fitment. If loose refit after properly examining stud threads. 2. Check for roundness of the bearing hole. If out of round by 1mm dia, replace.

12

Door lips Examine for corrosion, if heavily corroded replace door. The dimension as per drawing to be ensured during POH. Door adjustment to be ensured

Replace if door lips are heavily corroded/ damaged by new door. Door adjustment to be ensured

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correct i.e. door lips touching and evenly matched.

correct i.e. door lips touching and evenly matched.

13

Door hopper Replace if corroded. Examine for corrosion, if heavily corroded, replace, otherwise clean and paint.

B. Dimension check & surface crack check Following components of DOM should be checked for dimensional accuracy and surface cracks during POH S.No.

Components Drawing No. Dimension

1.

Side plate set Item no.3 of drawing no. WD-96038-S-04

Centre to center distance between the two holes (279 mm).

2. Lever (central) Item no.1 of drawing no. WD-92081-S-55

1. Distance from center of square hole to center of two circular holes (133mm &

201mm). 2. Off set dimension of 14mm & 3 mm of

circular holes from center line of square hole (refer drawing)

1. Thickness of stopper at both end

(dimension as 15mm).

3. Lever ‘X’ end Item no.2 of drawing no. WD-92081-S-55

1. Centre to center distance between square hole and circular hole (201mm).

2. Off set of 14mm of center of circular hole from square hole. 3. Thickness of stopper (dimension as 15mm).

4. Lever ‘Y’ end Item no.3 of drawing no. WD-92081-S-55

1. Centre to center distance between square hole and circular hole (133mm).

2. Off set of 13mm of center of circular hole from square hole.

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3. Thickness of stopper (dimension as 15mm).

5. Operating lever Item no.4 of drawing no. WD-92081-S-55

1. Centre to center distance between two holes.

2. Distance between center of bushes at

both end from center of both the holes.

6

Connecting link (small)

Item no.1 of drawing no. WD-92081-S-57

1. Centre to center distance of the holes. 2. Parallelness of forks at both ends and

distance (dimension 32mm).

7. Connecting link (large)

Item no.11 of drawing no. WD-92081-S-57

1. Centre to center distance of the holes 2. Parallelness of forks at both ends and

distance (dimension 32mm).

Note – General conditions of other items should be checked. Bent/ deformed/ damaged to be replaced. C. Maintenance of DOM cylinder during POH 1. Dismantling and cleaning a. Dismantle cylinder. a. Remove all rubber components/ gaskets etc. b. Clean all components with kerosene thoroughly. c. Dry the components and wipe with dry cloth. 2. Examination of components a. Examine all fasteners and holes with thread. Replace the components having

damaged threads. b. Piston rod having heavy scoring mark and bent piston rod to be replaced with new

piston rod.

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3. All rubber components and gaskets/ seals must be changed during POH.

(Note: Components of cylinder to be purchased from original manufacturers as RDSO has not issued drawings/ specification.)

4. During assembly of cylinder, ensure fitment of new washers/ spring washers. 5. Testing – DOM cylinder to be tested for leakage at 8 kg/cm2 pressure. POH

workshop to develop suitable test rig. D. After assembly of DOM ensure following dimensions of the system S.No.

Dimension Drawing no.

1. Vertical distance between bottom of center sill and bearing hole center (dimension 98mm) at three locations.

WD-96038-S-01

2. Vertical distance between bottom of center sill and eye bolt hole centre (dimension 73mm) at 4 locations (at all doors).

WD-96038-S-01

3. Check for over center condition with door connecting link against lever stops (procedure given below).

Check for over center condition ( Fig. 6 C) When fully locked and over center, door connecting links contact locking levers at top and bottom. If there is clearance between locking lever and door connecting link, check over center condition by placing a straight edge between the centerline of the adjustable eye bolt connecting link pin (A) and the operating shaft (B), and between the centerline of adjustable eye bolt connecting link pin (E) and the operating shaft (B). The center of the locking lever pin (C) should be below the centerline between points (A) and (B) at least 3mm. The center of the locking lever pin (D) should be above the centerline between points (E) and (B) at least 3 mm. If centerline falls less than 3 mm below or above these points, readjustment is necessary.

***

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ANNEXURE –II ( A )

DETAILS OF VARIOUS PARTS OF THE DOM OF ‘BOBR’ WAGON : ( Ref. Drg. No. WD-86013-S-67 & 68)

SN Description Quantity

Ref. Drg. No. Remarks

1 Air cylinder 1 WD-92081-S-54 2 Operating lever 1 WD-92081-S-55 Item-4 3 Clevis ( Modified ) 1 WD-92081-S-57 Item-3 4 Lever ( Clevis end ) 2 WD-92081-S-55 Item-3 5 Lever ( Opposite end ) 2 WD-92081-S-55 Item-2 6 Bearing ( near side ) 4 WD-92081-S-57 Item-8 7 Bearing ( far side ) 3 WD-92081-S-57 Item-8 8 Connecting link ( short ) 2 WD-92081-S-57 Item-1 See table at S.No. 1 9 Connecting link ( long ) 2 WD-92081-S-57 Item-1 See table at S.No. 3 10 Adjustable lever 3 WD-92081-S-59 11 Operating shaft 50.29 X

965 long 3 WD-92081-S-59 Item-6

12 Connecting rod (end) 2 WD-92081-S-53 13 Eye bolt 1 WD-92081-S-57 Item- 7 14 Turnbuckle 1 WD-92081-S-57 Item- 7 15 Jam nut 8 WD-92081-S-57 Item- 2 16 Bushing 6 WD-92081-S-57 Item- 5 17 Bracket for cylinder 1 -- 18 Door flaps 8 WD-86013-S-65 19 Eye bolt 8 WD-92081-S-57 Item 2 20 Pin with washer and cotter

pin 32 dia X 79 long 17 --

21 Pin with washer and cotter pin 32 dia X 103 long

2 WD-92081-S-53 Item 6

24 Secondary lock assembly 1 WD-92081-S-56 25 Standard nut 8 -- 26 Safety bracket 1 -- 27 Pin 32 dia X 79 long 1 WD-92081-S-57 Item 6 See table at S.No. 3 28 Pin 50 dia X 152 long 1 -- 29 Pin with two cotter pins 1 -- 30 Mechanism stops 12 X 12

X 38 24 WD-92081-S-59 Item 8

31 Lever ( centre ) 2 WD-92081-S-55 Item 1 32 Connecting link (short ) 2 WD-92081-S-57 Item 1 See table at S.No. 2 33 Connecting link ( long) 2 WD-92081-S-57 Item 1 See table at S.No. 4 34 Mounting plate for

bearing ( 320 X 100 X 12 T H )

6

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***

ANNEXURE –II (B) DETAILS OF VARIOUS PARTS OF THE DOM OF ‘BOBRN’( Single link) WAGON :

SN Component Drg. No. Quantity for two hopper four door arrangement

Remarks

1 Controlling dimension of Air cylinder

WD-92081-S-54 1

2 Controlling dimension of pneumatic valve

As per WD-92081-S-61 1

3 Controlling dimension of Air filter

As per WD-92081-S-61 1

4 Operating Lever WD-92081-S-55 Item 4 1 5 Operating Shaft

( with mech. stopper & APD.)

WD-92081-S-59 Item 8, 9 & 12

3 sets

6 Bearing ( far side ) WD-92081-S-57 Item 8 4 7 Bearing ( near side ) WD-92081-S-57 Item 8 4 8 Clevis Assembly WD-92081-S-57 Item 3 1 9 Turn Buckle ( Fitted

with 2 Nos. M-10 X 20 Hex Screw )

WD-92081-S-57 Item 9 1

10 Eye bolt 39 dia. WD-92081-S-57 Item 7 1 11 Adjustable Lever

( Assembly ) WD-92081-S-59. Item 1 to 7

3 sets

12 Bush ( Bronze ) WD-92081-S-57 Item 5 6 13 Connecting Rod WD-92081-S-53 2 14 Door Operating Lever

( Y-end) WD-92081-S-55 Item 3 2

15 Door Operating Lever ( central )

WD-92081-S-55 Item 1 2

16 Door Operating Lever ( X-end)

WD-92081-S-55 Item 2 2

17 Eye bolt 45 ¿ with nut, lock nut & spring washer

WD-92081-S-57 Item 2 4 set

18 Connecting link ( large )

WD-92081-S-57 Item 11 1

19 Connecting link ( small )

WD-92081-S-57 Item 1 1

20 Connecting link WD-92081-S-57 Item 11 1

- 29 -

( large ) 21 Connecting link (small) WD-92081-S-57 Item 1 1 22 Pin for connecting link

& connecting rod (with washer I/D 33 X O/D 70 X 4 thk 1 No. & bulb cotter pin 8 X 20 X large. 70 long

WD-92081-S-57 Item 1 of 13 9 set

23 Pin for connecting rod ( with washer I/D 33 X O/D 70 X 4 thk 1 No. & Split pin 10 ¯ X 63 long

WD-92081-S-57 Item 6 2 set

24 Pin for Clevis end ( with washer 39 I/D X 76 O/D X 4 thk 1 No. & bulb cotter pin 8 X 20 X 75 long

WD-92081-S-57 Item 2 of 13

1 set

25 Nut lock WD-92081-S-57 Item 12 4 26 Bearing pin ( with

washer 46 I/D X 89 O/D X 4 thk 2 No. & Split pin 10 ¯ X 71 long ( 2 Nos.)

WD-92081-S-52 Item 29 1 set

27 Cylinder rod Clevis assembly

WD-92081-S-56 Item 5 1

28 Cylinder rod Clevis pin ( with washer 52 I/D X 90 O/D X 4 thk 2 No. & split pin 10 ¿ X 90 long 2 Nos. )

WD-92081-S-56 Item 6 1 set

29 Safety Hook WD-92081-S-56 Item 3 1 30 Hook Pivot pin ( with

washer 39 I/D X 76 O/D X 4 thk 2 Nos. & split pin 10 ¿ X 71 long 2 Nos. )

WD-92081-S-56 Item 4 1 set Secondary lock assembly parts

31 Safety Look Spring Assly. (each set consists of 3 leaf )

WD-92081-S-56 Item 1 1 set

32 Spring retainer WD-92081-S-56 Item 2 a 1 33 Air Reservoir

( 80 liters ) WD-92081-S-60 1

***

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ANNEXURE –II ( C ) DETAILS OF VARIOUS PARTS OF THE DOM OF ‘BOBRN’( Double link) WAGON ( Fig. 5):

SN Component Ref. Drg. No. Quantity for two hopper four door arrangement

Remarks

1 Controlling dimension of Air cylinder

WD-92081-S-54 1

2 Controlling dimension of pneumatic valve

As per WD-92081-S-61 1

3 Controlling dimension of Air filter

As per WD-92081-S-61 1

4 Operating Lever WD-92081-S-55 Item 4 1 5 Operating Shaft

( with mech. stopper & APD)

WD-96038-S-04 Item 8,9 & 10

3 sets

6 Bearing ( far side ) WD-92081-S-57 Item 8 4 7 Bearing ( near side ) WD-92081-S-57 Item 8 4 8 Clevis Assembly WD-92081-S-57 Item 3 1 9 Turn Buckle ( Fitted

with 2 Nos. M-10 X 20 Hex Screw )

WD-92081-S-57 Item 9 1

10 Eye bolt 39 dia. WD-92081-S-57 Item 7 1 11 Adjustable Lever

( Assembly ) WD-96038-S-04 Item 1 to 7

3 sets

12 Bush ( Bronze ) WD-92081-S-57 Item 5 6 13 Connecting Rod WD-92081-S-53 2 14 Door Operating Lever

( Y-end) WD-92081-S-55 Item 3 2

15 Door Operating Lever ( central )

WD-92081-S-55 Item 1 2

16 Door Operating Lever ( X-end)

WD-92081-S-55 Item 2 2

17 Eye bolt 45 ¿ with nut, lock nut & spring washer

WD-92081-S-57 Item 2 8 sets

18 Connecting link ( large )

WD-92081-S-57 Item 11 2

19 Connecting link ( small )

WD-92081-S-57 Item 1 2

20 Connecting link ( large )

WD-92081-S-57 Item 11 2

21 Connecting link (small) WD-92081-S-57 Item 1 2

- 31 -

22 Pin for connecting link & connecting rod (with washer I/D 33 X O/D 70 X 4 thk 1 No. & bulb cotter pin 8 X 20 X 70 long

WD-92081-S-57 Item 1 of 13 17 sets

23 Pin for connecting rod ( with washer I/D 33 X O/D 70 X 4 thk 1 No. & Split pin 10 ¯ X 63 long

WD-92081-S-57 Item 6 2 set

24 Pin for Clevis end ( with washer 39 I/D X 76 O/D X 4 thk 1 No. & bulb cotter pin 8 X 20 X 75 long

WD-92081-S-57 Item 2 of 13

1 set

25 Nut lock WD-92081-S-57 Item 12 8 26 Bearing pin ( with

washer 46 I/D X 89 O/D X 4 thk 2 No. & Split pin 10 ¯ X 76 long ( 2 Nos.)

WD-96038-S-02 Item 26 1 set

27 Cylinder rod Clevis assembly

WD-92081-S-56 Item 5 1

28 Cylinder rod Clevis pin ( with washer 52 I/D X 90 O/D X 4 thk 2 No. & split pin 10 ¿ X 90 long 2 Nos. )

WD-92081-S-56 Item 6 1 set

29 Safety Hook WD-92081-S-56 Item 3 1 30 Hook Pivot pin ( with

washer 39 I/D X 76 O/D X 4 thk 2 Nos. & split pin 10 ¿ X 71 long 2 Nos. )

WD-92081-S-56 Item 4 1 set Secondary lock assembly parts

31 Safety Look Spring Assly. (each set consists of 3 leaf )

WD-92081-S-56 Item 1 1 set

32 Spring retainer WD-92081-S-56 Item 2 a 1 33 Air Reservoir

( 80 liters ) WD-92081-S-60 1

***