rdso.ggn.rcil.gov.in · annexure-iii performance test for door operating me chanism (dom)....

Ref:WDW/0002 (Rev – 3) of 21 Date of issue: March, 2009 WD-12-BOBRN-2009

(Sup:WD-11-BOBRN-1999

Page 1 of 21

INDIAN RAILWAYS

PARTICULAR SPECIFICATION WITH LIST OF DRAWINGS

FOR

BOGIE OPEN RAPID DISCHARGE HOPPER WAGON

TYPE `BOBRNM1’/`BOBRNHSM1’

BROAD GAUGE-1676 mm

(B.G. 5’ 6’’)

S.No. Month/Year of

issue Revision / Amendment

Page No. Reason for Amendment

1. March, 2009 --- --- First Issue

2. September.2009 1 12 Drgs.Altered

3. October.2009 2 12 & 15 Drgs.Altered

Issued By: Wagon Directorate

Research Designs and Standards Organization Manak Nagar, Lucknow -206011.

March,2009 Price:Rs. 0/-



Page 2 of 21

AMENDMENT NO. 1 OF SEPTEMBER 2009 APPLICABLE TO PARTICULAR

SPECIFICATION NO. WD-12-BOBRN-2009 OF MARCH 2009

FOR BOBRNM1/BOBRNHSM1

A) Annexure-I (A) of the subject specification, last alteration No. of following drawings shall be read as follow :- S.No. Drawing No. Description Last Alt. No. 1. WD-91071-S-50 Index 9 2 WD-91071-S-58 Body structure assembly 5

3 WD-91071-S-66 Door details 9 4 WD-96038-S-03 Door Assembly (Double

liner) 4

5 WD-96038-S-04 Adjustable lever fro DOM assembly & details

7

6 WD-92081-S-57 Details of DOM 10



Page 3 of 21

AMENDMENT NO. 2 OF OCTOBER 2009 APPLICABLE TO PARTICULAR

SPECIFICATION NO. WD-12-BOBRN-2009 OF MARCH 2009

FOR BOBRNM1/BOBRNHSM1

A) Annexure-I (A) of the subject specification, last alteration No. of following drawings shall be read as follow :- S.No. Drawing No. Description Last Alt. No. 1. WD-91071-S-74 Air brake and Equipment

pipe layout 6

2 WD-91071-S-75 Air brake pipe details (sheet 1of 2)

3

3 WD-91071-S-75 Air brake pipe details (sheet 2of 2)

3

B) Annexure-II shall be read as follow:-

METHOD OF DETERMINING THE TARE WEIGHT OF WAGONS. All contractors (Whether equipped with weigh bridges or not in their works) will

arrange to weight each wagon of identical design and mark individual tare weight on them by actual weighment. The tare weight so arrived shall be deducted from the gross load to arrive at the correct carrying capacity that shall be marked on the wagons.

Tare weight of the wagon shall also be intimated to the Engineers duly certified by the Inspecting Officer.



Page 4 of 21

C O N T E N T S

Clause Description

1. Scope

2. Definitions

3. Welding

4. Testing

5. Standard Specification

6. Use of Alternatives

7. Particular Requirements

8. Spare Parts of Door Operating Mechanism (RDSO Design).

9. Training of Railway Supervisor/ Skilled Staff on Door Operating

Mechanism.

10. Inspection

11. Drawings

12. `As Made' Drawings, Photographs and Models.

A N N E X U R E

Annexure-I (A) List of Construction Drawings

Annexure-I (B) List of Part Drawings

Annexure-II Method of Determining the Tare Weight of Wagons.

Annexure-III Performance Test for Door Operating Mechanism (DOM).

Annexure-IV Proforma for Single Wagon Air Brake Test.

Annexure-V Nylon Brake Gear Bushes in the Brake Gear on Under frame.

Annexure-VI List of Spare Parts of Door Operating Mechanism (RDSO Design).

Annexure-VII Diagram of Wagon to RDSO Drg. No. WD-91071-S-51.



Page 5 of 21

INDIAN RAILWAYS

PARTICULAR SPECIFICATION

FOR

BROAD GAUGE BOGIE OPEN RAPID DISCHARGE

HOPPER WAGONS

TYPE ‘BOBRNM1’ / ‘BOBRNHSM1’ ...

1. SCOPE

This Specification covers the particular requirements for the manufacture and supply of

Broad Gauge Bogie Open Rapid Discharge Hopper Wagons Type ‘BOBRNM1’ /

‘BOBRNHSM1’ strictly to Drg. No. WD-91071-S-51 and other relevant drawings as

provided hereinafter in this Specification and General Standard Specification No. G-72 Rev.

3 (with latest amendment) issued by RDSO (Wagon), Manak Nagar, Lucknow-226011.

These wagons shall be supplied complete in all respect.

1.2 Cast steel CASNUB-22 NLB bogie (modified for 22.9t axle load) or Cast Steel CASNUB-

22HS bogie (modified for 22.9t axle load) complete together with bogie brake rigging,

wheels and axle sets with cartridge roller bearing narrow jaw adapters along with

elastomeric pads thereon, top & bottom centre pivots, C.P. pins and constant contact side

bearers referred to in clause 7.3, high tensile straight centre buffer coupler (non

transition) together with high capacity draft gears, striker castings, yokes, yoke pins,

yoke pin support plates as referred to in clause 7.4 and complete air brake equipment

along with pipes and pipe joints as referred to in clause 7.5 shall be fitted with these

wagons.

1.3 The Contractor shall prepare his own working drawings based on the aforesaid key design

drawings and submit them to the Èngineers' for approval before undertaking construction.

The Contractor shall ensure that working drawings submitted for approval of the Èngineers'

are fully in accordance with key design drawings and deviations, if any, are specially pointed

out. Approval of the Èngineers' will only pertain to the design features, important controlling

dimensions and the deviations from the design drawings specially pointed out by the

Contractor. Other details in drawings will not be checked by the Èngineers' and the

responsibility for the same will be that of the Contractor.

2. DEFINITIONS

2.1 Purchaser'means the President of the Republic of India.

2.2 Engineer' means Research Designs and Standards Organization, Ministry of Railways,

Manak Nagar, Lucknow- 226011 and will be represented by Ex. Director Standard Wagon,

RDSO.

2.3 Inspection Officer' means the person, firm or department nominated by the purchaser to

inspect the work on his behalf and the deputies of the Inspecting Officer so nominated.



Page 6 of 21

2.4 Contractor' means the person, firm or company with whom the order for the supply is

placed and shall be deemed to include the contract's successors(approved by the Purchaser),

representatives, heirs, executors and administrators as the case may be unless excluded by

the terms of contract.

2.5 Sub-Contractor' means the person, firm or company from whom the contractor may obtain

any material or fittings to be used in the manufacture of the above parts.

3. WELDING

3.1 General requirements and comprehensive guidance with regard to edge preparation, fit up

for welding, welding procedure and inspection of welded joints are contained in Clause 8

of General Standard Specification No. G-72 Rev. 3 ( with latest amendment ) which can

be had from Director General, RDSO, Manak Nagar, Lucknow – 226 011.This should be

strictly followed.

3.2 Wherever welding is specified or adopted in the manufacture of the wagons or in the

fabrication of sub-assemblies and components, the manufacturer shall submit his proposed

welding procedure and sequence to the Inspecting Officer and obtain his approval for the

same. This, however, will not in any way reduce the Contractor's responsibility for

satisfactory execution of the contract in all respects as stipulated in Clause 4 of General

Standard Specification No.G-72 Rev. 3. (with latest amendment)

3.3 The Contractor shall furnish three copies of the "Welding Procedure and sequence of

assembly of the Wagon" which is finally approved by the Inspecting Officer, to the

Purchaser/Engineers, before commencement of regular production.

4. TESTING

4.1 Before taking series production of wagon, a pattern wagon shall be manufactured and got

approved by the Engineers.

4.2 The `Pattern Wagon' shall be tested as detailed in Clause 12 of General Standard

Specification No. G-72 Rev. 3 (with latest amendment). Clearance found between various

members of underframe and bogie shall be measured under tare, fully loaded, overloaded and

unloaded condition and submitted to the Engineers through the Inspecting Officer. In case of

Contractors who would take up the manufacture of this type of wagon for the first time, the

tests to be conducted on the ‘Pattern Wagon' shall be decided in consultation with the

Engineers. The pattern wagon will have to be cleared by the Engineers before taking up of

series manufacture.

4.3 The performance of Air Brake Equipment of each wagon shall be tested with single wagon

test as per proforma given in Annexure-IV.

4.4 As a result of prototype load tests if some modification to the wagon is called for the same

shall be executed by the manufacturer.



Page 7 of 21

4.5 Testing of Door Operating Mechanism shall be done as per Annexure-III.

5. STANDARD SPECIFICATIONS

All materials required for the manufacture of the wagons shall conform to the latest issue of

relevant specifications as adopted by RDSO for Railway's use unless otherwise specified

herein.

6. USE OF ALTERNATIVES

In Clause 7 of this Specification, as also in some of the drawings listed at Annexure-I,

certain alternatives showing different methods of manufacture or use of alternative materials,

which are technically permissible, have been indicated. Wherever such alternative use has

been permitted, the tenderer must quote separately for the alternatives.

7. PARTICULAR REQUIREMENTS

7.1 Leading Particulars

7.1.1 The key details of the wagons are as per RDSO Drg. No. WD-91071-S-51, at Annexure VII.

7.1.2 Cast steel CASNUB-22 NLB bogie (modified for 22.9t axle load) or Cast Steel CASNUB-

22HS bogie(modified for 22.9t axle load)

7.1.3 Provided with cartridge taper roller bearing (with narrow jaw adapters).

7.1.4 Provided with high tensile centre buffer coupler (Non-transition).

7.1.5 Provided with bottom discharge doors having Double Link Mechanism operated by

pneumatic systems with compressed air supply from loco & external compressed air supply

(input through quick coupling & double check valve)

7.1.6 Provided with gradual release air brake system with single pipe.

7.1.7 Provided with Automatic Load Sensing Device.

7.1.8 Provided with Slack Adjuster Type IRSA-600J.

7.2 Material of Construction

(i) Under-frame members like center-sill, side-

sills, end sills, side stanchions, side coping,

hopper frame etc.

Structural Steel to IS:2062 E250A/

IS:5986 Fe 360 Cu

(ii) Side wall, end slope plate, vertical support

plate, pressings etc.

Steel to IS: 2062 E250A/ IRSM-44



Page 8 of 21

(iii) Longitudinal ridge with ribs, cross ridge,

connecting plate, end-ridge, cross-brace, door

holds, door clips & door stiffener, etc.

High tensile steel to SAILMA 350

HI / IRSM-44

(iv) Door flap, hopper plates & end slope plate

(upper portion)

IRSM-44

(v) Door hinge IRS: 1875 Cl-IV

(vi) Other Items As specified in the drawing

7.3 Bogie & Wheel

7.3.1 The BOBRNM1 wagon shall be equipped with Cast Steel Bogie type Cast steel CASNUB-

22 NLB bogie (modified for 22.9t axle load) to Specification No. WD-21-Casnub 22 NLB

Bogie-93 (Rev.2) of July 2002 with latest Amendment & Drg. No. WD-89073-S/2.This

bogie will be fitted with springs and load propionate friction damping arrangement for

Broad Gauge (1676 mm) wagons.

7.3.2 The BOBRNHSM1wagon shall be equipped with cast steel bogie type Cast Steel

CASNUB-22HS bogie(modified for 22.9t axle load)to Drg. No. WD-04038-S/2 (with

spherical center pivot) and Drg. No. WD-04078-S/1 (with flat center pivot) and STR No.

WD-17-Casnub 22 HS Bogie-92 (Rev.3) of September 2004 with latest amendment. The

bogie is equipped with constant contact side bearers

7.3.3 These bogies complete in all respect including wheel sets, cartridge bearings and elastomeric

pads shall be fitted with these wagons.

7.4 Coupler & Draft Gears

7.4.1 Wagon shall be equipped with: -

i. High tensile centre buffer coupler AAR “E/F” type to RDSO STR No. 48-BD-08

with latest amendment

ii. High capacity draft gear to RDSO STR No. 49-BD-08 with latest amendment.

7.4.2 The fitment of coupler, high capacity draft gear, striker casting, yoke pin support, and yoke

etc. shall conform to RDSO Drg. No. WD-81010-S-03 (with latest amendment).

7.4.3 The Centre Buffer Couplers shall be as shown in Drg. No.WD-81010-S-03 with latest

alteration and the uncoupling gear for the centre buffer couplers shall be to Drg. No.

WD-89007-S-78 ( with latest alteration) and shall be procured by the contractor.

7.5 Air Brake

7.5.1 The wagon shall be equipped with single pipe graduated release air brakes equipped in

accordance with RDSO Specification No. 02-ABR-2002 with latest amendment.



Page 9 of 21

7.5.2 The brake equipment and pipe layout of the wagon shall be to RDSO Drg. No.

WD-91071-S-74.

7.5.3 Air brake equipment consisting of distributor valve (suitable for automatic empty load device

of two stage type), pipe bracket, brake cylinder, auxiliary reservoir, cut off angle cocks,

single piece load sensing device, flexible hoses and hose couplings for BP as specified in

specification No. 02-ABR-2002 (with latest amendment) shall be fitted with these wagons.

7.5.4 The pipes and joints consisting of brake pipe, branch pipes and pipe joints as specified

in RDSO specification no. 04-ABR-2002 (with latest amendment ) shall be fitted with these

wagons.

7.5.5 The complete air brake equipment including the pipes and joints shall be fitted on pattern

wagon as per RDSO's Drg. No. WD-91071-S-74 and offered to the `Engineers' for approval.

The Contractor shall be obliged to carry out any modification on the layout of the air brake

equipment, if found necessary by the `Engineers'.

7.5.6 Contractor shall proceed with the bulk production of the wagon only after the final approval

of the layout of complete air brake equipment, on the pattern wagon.

7.5.7 During the bulk production of wagons, Contractor shall ensure that the complete air brake

equipment is fitted on the wagon correctly as per the dimensions shown in the layout

drawing. Special care must be taken with regard to the clamping of pipes.

7.5.8 The wagon shall be fitted with brake gear arrangement to RDSO's Drg. No.

WD-89007-S-70.

7.5.9 The wagon shall be fitted with side operated screw type hand brake as indicated in RDSO's

Drg. No. WD-91071-S-73 and hand brake wheel to Drg.No. W/BG-1343 & W/BG-1344

(with latest alteration).

7.5.10 The wagon shall be fitted with Automatic Empty Load Device of Two Stage Type as shown

in RDSO Drg. No. WD- 91071-S-74 to provide 2.2 kg/cm2 and 3.8 kg/cm2 cylinder pressure

under empty and fully loaded conditions respectively, as shown in RDSO Drg. No. WD-

91071-S-69.The system shall meet all the provisions relating to the characteristics and tests

of brake equipment stipulated in "UIC Code No. 541".

7.5.11 The wagon shall be fitted with Slack Adjuster IRSA-600J to Drg. No. WD-90002-S-01 -RC.

The control lever and fulcrun bracket, shall be in accordance with item 4 and 7 Drg. No.

WD-89007-S-71.

7.6 Bottom Discharge Doors

7.6.1 The wagon shall be equipped with R.D.S.O. design, Double Link Mechanism pneumatically

operated Bottom Discharge Doors, generally to RDSO Drg. No. WD-96038-S-01 & 02 and

shall be supplied by the Contractor. Prototype wagon shall be given Performance Test as per

Annexure-III.



Page 10 of 21

7.6.2 Detail of Door Flaps and Hinges shall be as per Drg. No. WD-96038-S-03 and linkages,

equipments etc. as per drawing in listed Index WD-96038-S-01A.Door operating air pipe

layout shall be as per Drg. No. WD-91071-S-79.

7.6.3 The doors are to be operated through a Manual Pneumatic Valve (M.P.V). The valve can be

operated through two push buttons provided one at each end of the valve. The operation of

one push button facing the side sill will allow the actuation of air drive system for opening

the door, while the actuation of other button will close the door as shown in RDSO Drawing

No. WD-91071-S-79.The air connection of the reservoir for door-operating cylinder is given

to the hose coupling (Item No.11) for air pipe system shown in the above mentioned

drawing. The air pressure required for door operation is 5kg/cm² to 6kg/cm².

7.6.4 In case the DOM Air Reservoir does not have compressed air supply from the loco, the

compressed air may be supplied through Quick coupling & double check valve, fitted on

wagon for operation of DOM through Manual Pneumatic Valve (M.P.V), as explained in

para 7.6.3

7.6.5 Air Cylinder

The overall dimensions of air cylinder shall be as per RDSO Drg. No. WD-92081-S-54.The

cylinder should be of fibre-glass of suitable quality having inside diameter 305mm and stroke

559 mm. The piston shall be of Aluminum Casting of suitable quality. The testing pressure of

the cylinder should be 10 Kg./cm². The cylinder should be capable of working for six years

trouble free service in actual field operation for which a guarantee from the manufacturer

shall be obtained.

7.6.6 Filter

The overall dimensions of the filter shall be as per RDSO Drg. No. WD-92081-S-61.The

filter should be provided with 10 Micron elements and tested for a pressure of 10 Kg/cm².

The filter should be provided with automatic/manual water drainage system. The filter,

except the element, should be guaranteed by the manufacturer for six years trouble free

service in actual operating condition.

7.6.7 Control Valve

The overall dimensions of the control valve shall be as per RDSO Drg. No.

WD-92081-S-61.The valve shall be tested against test pressure of 10 kg/cm2 and should be

guaranteed by the manufacturer for six years trouble free service under actual operating

conditions.

7.6.8 Anti Pilferage

Anti-pilferage measures for Door Operating Mechanism parts outlined in RDSO Drg. No.

WD-94002-S-01 and 02 shall be provided.



Page 11 of 21

7.7 Painting & Marking

7.7.1 The surface preparation of the wagon shall be as indicated in Clause No.11 of General

Standard Specification No. G-72 Rev.3 (with latest amendment)

7.7.2 Wagon Superstructure shall be painted with paint system as specified in Clause No. 11.2.6 of

G-72 rev. 3 (with latest amendment).

7.7.3 Other sub-assemblies like Bogie, Couplers, Airbrake shall be painted as per G-72 Rev. 3 (with

latest amendment).

7.7.4 Wheel and axle assemblies for wagon shall be painted as specified in IRS:R-19/93 (Part 1

with latest revision)

7.7.5 Zebra strips shall be painted on the outside corners of the wagon with paint of Red Colour

No. 537 to IS:5-1978 and Ready Mixed White Paint to IS:127 as indicated in RDSO Drg.

No. WD-91071-81.

7.7.6 The marking on the wagon shall be as indicated in Drg. No. WD-91071-S-81.

7.7.7 The tare weight of the wagons shall be marked in tonnes upto one decimal plate, as

determined by the method detailed in Annexure-II.

7.7.8 The operating direction (On and Off) of side operated hand brake wheel shall be marked as

indicated in Drg. No. WD-91071-S-81.

7.7.9 Standard Plates shall be attached on the underframe sole bars at diagonally opposite corners

as shown in Drg. No. WD-91071-S-81.One plate on each underframe shall be in Hindi to

Drg. No. W/ML-14 & W/ML-7 Mild Steel drop stamped standard plate is acceptable as an

alternative.

7.7.10 Railway's initials to be marked will be intimated later. The mechanical code BOBRNM1or

BOBRNHSM1 [for Cast steel CASNUB-22 NLB bogie (modified for 22.9t axle load) or

Cast Steel CASNUB-22HS bogie(modified for 22.9t axle load) respectively] to be stenciled

and stamped at locations as shown in Drg. No. WD-91071-S-81.

8. SPARE PARTS OF DOOR OPERATING MECHANISM (RDSO DESIGN)

8.1 Mandatory spare parts for DOM as per Annexure-VI shall be supplied by the manufacturer of

the wagon along with order of `BOBRN' wagons.

9. TRAINING OF RAILWAY SUPERVISOR/SKILLED STAFF ON DOOR

OPERATING MECHANISM

9.1 The Contractor shall arrange to train sufficient number (10 No. per 100 No. wagon or part

thereof) Railway Personals free of cost on following aspects of Door Operating Mechanism

to be covered in five working days:-



Page 12 of 21

- Salient features of Door Operating Mechanism.

- Adjustment procedure during mounting of Door Operating

Mechanism on Wagon.

- Testing Procedure.

- Tools used for mounting of Door Operating Mechanism

- Trouble Shooting.

9.2 The Contractor shall provide free accommodation to Railway Personnel during training.

10. INSPECTION

The inspection of the wagon with all its fittings is to be carried out by RDSO Wagon

Inspection Directorate. The Wagon Manufacturer will provide all the facilities to the

Inspecting Officer during various stages of manufacture of wagons.

11. DRAWINGS

Wagons shall be manufactured strictly to RDSO Drg. No. WD-91071-S-51 and other

relevant drawings listed in the Annexure-I. The alteration numbers indicated against each

drawing in the Annexure to this Particular Specification are, however, subject to

advancement in course of construction of these amendments in manufacturing of

components. Copies of such amended drawings will be supplied to the Contractor free of

cost. The drawings listed are complete in all respects and any detailing, if necessary, will be

done by the Contractor.

12. AS MADE' DRAWINGS, PHOTOGRAPHS AND MODELS

12.1 Drawings

12.1.1 The Contractor shall supply two sets of `As Made' Polyster Film Tracings(50 Micron thick

matte) of drawings followed in the manufacture of the wagons for the record of Purchaser

and Engineers. These tracings shall conform to the requirement as detailed in Clause 21 of

General Standard Specification No. G-72 Rev.3 (with latest amendment)The Contractor shall

incorporate in the above set of tracings, any deviations, modification and relaxations granted

in the course of manufacture.

12.1.2 The `As Made' drawings detailed above shall contain full details of each

component/assembly/sub- assembly, inclusive of the material specification, actual average

weight and reference drawings. The general order of the drawings, title block etc. shall be

strictly as indicated in SK.67521 with space for IRS drawings number left blank. The size of

the sheet shall be A1(841 mm x 594 m)and the Code of Practice for drawings shall conform

to IS Specification No. 696.

12.1.3 The hard wood strips for binding the tracings shall conform to SK.67520 along with 6 mm

size brass set screws to SK.67522.



Page 13 of 21

12.2 Photographs

The Contractor shall furnish to the Engineers free of cost suitably mounted colour photos 600

mm x 450 mm bringing out the Salient Features as called for in Clause 21 of General

Standard Specification No. G-72 Rev.3 (with latest amendment).

12.3 Models

The Contractor shall furnish to the Engineers, if and when required, free of cost, a 1/16

scale model made out of steel or acrylic transparent sheet as called for in Clause 21 of

General Standard Specification No. G-72 Rev.3 (with latest amendment).

***



Page 14 of 21

ANNEXURE-I

ANNEXURE TO PARTICULAR SPECIFICATION NO. WD-11-BOBRN-99 FOR

BOBRN TYPE WAGON

(A) List of construction drawings :

Drg. No. Description Last Alt. No.

SK-63720 PRO/PR Stencil 1

SK-66511 Railway Initials in Hindi NIL

SK-73552 Hose Coupling Support 5

WD-81010-S-03 Arrngt. of HTCBC (Non-trnasition) 8

WD-87056-S-01 Striker Casting Wear Plate 4

WD-88036-S-02 Fitment of Load Sensing Device CASNUB

Bogie (Escorts Equipment)

4

WD-91101-S-05 Quick coupling arrangement & details 5

WD-89073-S-02 CASNUB 22 NLB Bogie General Arrngt. 9

WD-91071-S-50 Index 8

WD-91071-S-51 Diagram 10

WD-91071-S-52 General Arrangement 6

WD-91071-S-53 Underframe Arrangement 4

WD-91071-S-54 Centre Sill & End Sill Details 8

WD-91071-S-55 Cross Ridge Assembly & Details 5

WD-91071-S-56

OR

WD-05016-S-56

Center Pivot & Side Bearer Arrgt.

Center Pivot & Side Bearer Arrgt.

(Fitted with Casnub 22HS Bogie )

5

2

WD-91071-S-57 Bolster Details 5

WD-91071-S-58 Body Structure Assembly 4

WD-91071-S-59 Side-Wall Assembly & Details 6

WD-91071-S-60 End-Wall (X-End)Assembly & Details 5

WD-91071-S-61 End-Wall (Y-End)Assembly & Details 5

WD-91071-S-62 End Frame Construction & Details 2

WD-91071-S-63 Hopper Arrangement 5

WD-91071-S-64 Hopper Details 4

WD-91071-S-66 Door Details 7

WD-91071-S-69 Brake Diagram 7

WD-89007-S-70 Brake Gear Arrangement 7

WD-89007-S-71 Brake Details (Sheet-I) 6

WD-89007-S-72 Brake Details (Sheet-II) 7

WD-91071-S-73 Hand Brake Arrangement & Details 6

WD-91071-S-74 Air Brake & Equipment Pipe Layout 5

WD-91071-S-75 Air Brake Pipe Details(Sheet 1of2) 2

WD-91071-S-75 Air Brake Pipe Details(Sheet 2of2) 2

WD-91071-S-76 Air Brake Details 4

WD-89007-S-78 Uncoupling Gear Arrgt.& Details 4

WD-91071-S-79 Door operating Air Pipe Layout 3



Page 15 of 21

WD-91071-S-80 Door operating Air Pipe Details 4

WD-91071-S-81 Marking Diagram 11

WD-89007-S-83 Centre Filler Arrgt.& Details 4

WD-92081-S-53 Connecting Rod & Bushes for DOM 3

WD-92081-S-54 Controlling Dimensions of Air Cylinder 1

WD-92081-S-55 Levers 3

WD-92081-S-56 Secondary Lock Assembly & Details 5

WD-92081-S-57 Details of DOM 8

WD-92081-S-60 Air Receiver Tank ( 80 LTS) 2

WD-92081-S-61 Controlling Dimensions of Air Filter and

Pneumatic Valve

1

WD-94002-S-01 Anti Pilferage Device for DOM Components NIL

WD-94002-S-02 Anti Pilferage Device for DOM NIL

WD-96038-S-01A Index for DOM (Double Link) NIL

WD-96038-S-01 Door Mechanism Arrgt. (Sheet I) 2

WD-96038-S-02 Door Mechanism Arrgt. (Sheet II) 3

WD-96038-S-03 Door Assembly 2

WD-96038-S-04 Adjustable Lever for DOM ( Assembly &

Details )

5

(B) LIST OF PART DRAWINGS

IRS Part Drg. No. Last Alt. No.

C/BF-1113 NIL

L/BU-526/M 4

L/BU-527/M 4

L/BU-528/M 4

L/BU-529/M 4

L/PN-631/M 6

W/BG-1102 3

W/BG-1131 3

W/BG-1133 1

W/BG-1134 1

W/BG-1343 1

W/BG-1344 1

W/BG-6310 3

W/BG-6311 2

W/BG-6313 1

W/ML-11 2

W/ML-14 6

W/ML-7 7

WA/BD-4460 6

WA/BD-4462 3

WA/BG-6313 1



Page 16 of 21

NOTE:-

1. Part Drawings for the components used in CASNUB 22NLB Modified bogie are indicated in

the Bogie Specification No. WD-21 CASNUB-22 NLB-Bogie-93 (Rev.2 of 2002) with latest

amendments.

OR

Part drawings for the components used in CASNUB 22HS bogie Modified are indicated in the

bogie specification No. WD-17- CASNUB -22HS Bogie 92 (Rev3 of 2004) with latest

amendments.

2. Part drawings for components used in Coupler Assembly are given in the specification

No. 48-BD-08 & 49-BD-08 for Coupler & Draft Gear respectively (with latest amendment).

3. Part drawings for air brake equipment are given in the RDSO Specification No. 02-ABR-2002

(with Latest Amendment) and 04- ABR-2002 (with Latest Amendment).

***



Page 17 of 21

ANNEXURE-II

METHOD OF DETERMINING THE TARE WEIGHT OF WAGONS

All Contractors will arrange to weigh each wagon.

Tare weight of the wagon shall also be intimated to the ‘Engineers’ duly certified by the Inspecting

Officer.

Pay-load of the wagon would be fixed as given on its ‘Diagram/Drawing’.

***



Page 18 of 21

ANNEXURE-III

PERFORMANCE TEST FOR DOOR OPERATING MECHANISM (DOM)

1. The Wagon Manufacturer should install a Test Rig/use the pattern wagon along with a

suitable pit below it to test the complete DOM to simulate the working condition of DOM.

2. For each order, the DOM shall be actuated 2000 times, 1000 times door opening and 1000

times door closing on the test rig/pattern wagon. For 1000 door opening and 1000 door

closing, the failure of the DOM shall not exceed 0.3%.

3. The DOM shall be checked for five times with full payload on prototype wagon by unloading

the payload over the pit. It shall be ensured that the moving parts under the centre sill do not

infringe during movement. The unloading Test is however, not mandatory for those Wagon

Builders who has already executed an order earlier of BOBRNM1 /BOBRNHSM1 Wagon

with Double Link Door Mechanism of RDSO Design and have no adverse report from

Railways on functioning of Door Mechanism. Loaded prototype wagon in this case should be

moved and checked inside the Builder’s Yard for a distance of 5 Kms at a speed not less than

6 Kmph.

4. During the Unloading Test, the wagon unloading time shall be checked and recorded. The

unloading time should be 15 seconds or less.

5. Leakage Test

(i) Charge the system to maximum operating pressure and cut-off the supply of air to the

system.

(ii) Observe the reservoir pressure for one minute and record the drop of pressure, if any. It

should not exceed 0.1 kg/cm2 in one minute.

6. Self Operation

Operate the DOM with air from reservoir only with main supply to reservoir cut-off. Record

the number of cycle, which can be done, and pressure drop for each cycle.



Page 19 of 21

ANNEXURE-IV

PROFORMA FOR SINGLE WAGON AIR BRAKE TEST

S. NO. Check Specified Actual

1 Pressure in BP 5 ± 0.1 kg/sq.cm

2 Pressure in AR 5 ± 0.1 kg/sq.cm

3 Leakage from the system 0.1 kg/sq.cm. in one minute.

4 Full service application after charging

4.1 Brake cylinder filling time

(Pressure rise from 0 to 3.6 kg/sq.cm.)

a) Empty 18 to 30 sec.

b) Loaded 18 to 30 sec.

4.2

Maximum brake cylinder pressure

a) Empty 2.2+0.25 kg/sq.cm.

b) Loaded 3.8 + 0.1 kg/sq.cm.

4.3 Reduction in BP pressure required for full service

application.

1.3 to 1.6 kg/sq.cm.

5 Release after full service application.

5.1 Draining time (Brake cylinder pressure to fall from 3.8 +0.1

kg/sq.cm. to 0.4 kg/sq.cm.)

45 to 60 sec.

6. Sensitivity of brakes Isolate brake pipe from mainline.

Check the response of brakes when brake pipe pressure is

reduced at the most equal to 0.6 kg/sq.cm. in 6 sec.

Brake should apply within 6

sec.

7. Insensitivity of brakes isolate brake pipe from mainline.

Check the pressure of brakes when brake pipe pressure is

reduced atleast equal to 0.3 kg/sq.cm. in 60 sec.

Brake should not apply

8. Emergency application:

8.1 Brake cylinder filling time

(Pressure to rise from 0 to 3.6 kg/sq.cm.)

a) Empty 18 to 30 sec.

b) Loaded 18 to 30 sec.

8.2 Maximum brake cylinder pressure

a) Empty 2.2 +/- 0.25 kg/sq.cm.

b) Loaded 3.8 +/- 0.1 kg/sq.cm.

9. Piston stroke

a) Empty 100 +/- 10 mm

b) Loaded 110 +/- 10 mm

10. Leakage from brake cylinder after emergency application. 0.1 kg/sq.cm. Within 5

minutes

11. Automatic exhausting of brake cylinder and control

chamber.

11.1 Apply emergency brakes (i.e. BP = 0 kg/sq.cm.). Check

the brake cylinder pressure after giving a brief pull to release

hook.

Brake cylinder and control

reservoirs should exhaust

automatically.

Date Signature & name of

Testing Authority.



Page 20 of 21

ANNEXURE-V

NYLON BRAKE GEAR BUSHES IN THE BRAKE GEAR

(ON UNDER FRAME)

1. Brake gear bushes of Nylon-66 shall be procured as per Schedule of Technical Requirements

(STR) NO.WD-04-Nylon Brushes-2002.

2. Nominal dimensions of Nylon-66 bushes to be used will be same as of steel bushes, inclusive of

step sizes, outside diameter. However, the tolerances and the chamfering should be as per

Fig.1 of the STR.

3. Universal holes should be drilled initially in the form type support brackets or fork end of

pull/push rods. These holes should be drilled together to the required size only after the assembly

but before the Nylon bushes are fitted therein. This will ensure that the two holes are concentric

and, therefore, the pins passing through the bushes fitted therein will not tilt.

4. Steel pins used with the Nylon-66 bushes shall be with fine finish machined on all contact

surfaces with the bush.

***



Page 21 of 21

ANNEXURE-VI

LIST OF SPARES FOR DOOR OPERATING MECHANISM

(RDSO DESIGN)

S.No. Description Drg. No. No. of Spares per

100 Nos. wagons or

thereof.

1. Operating Shaft WD-96038-S-04

(Item-9)

10

2. Bush ( Bronze ) WD-92081-S-57

(Item-5)

20

3. Safety Lock Spring

Assembly

WD-92081-S-56

(Item-1)

3

4. Pin with Washer &

Bulb Cotter32 Dia x

94 Long

WD-92081-S-57

(Item-13/1)

25

5. Pin with Washer & Split

Pin, 32 Dia x 103 Long

WD-92081-S-57

(Item-6)

6

6. Pin with Washer &

Bulb Cotter 37Dia x 93

Long.

WD-92081-S-57

(Item-13/2)

3

7. Clevis Pin with

Washer & Split Pin

WD-92081-S-56

(Item-6)

3

8. Pin with Washers &

Split Pins

WD-92081-S-52

(Item-29)

3

9. Hook Pivot Pin

with Washers &

Split Pins.

WD-92081-S-56

(Item-4)

3

***

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