WD-CS-01-BOXNS-2015-Rev.
-02Amendment-01
INDIAN RAILWAYS
CHECK SHEETS
FOR
BOGIE OPEN WAGON (100 Tonnes)
TYPE – BOXNS
S.No. Month & Year of Revision / Page No. Reason for Revision /
issue Amendment Amendment
1. October, 2015 First issue - -
2. JUN, 2016 Revision - 01 - Side wall design revised
Width & Depth of Bolster pocket-1
3. September, 2016 Amendment -01 4&7 and End Wall overall height
3, 4 & Bogie tolerances revised &
4. February, 2017 Revision - 02
6 to 10 RFID data added
Changed acceptance limit of Check
5. April, 2017 Amendment -01 11 paint for thickness & finish
ISSUED BY
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
LUCKNOW-226 011
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
Amendment no. 1 to check sheets of WD-CS-01-BOXNS-2015-REV-02
Check sheet of WD-CS-01-BOXNS-REV.-02 to be read with following amendments.
1. Page no.11 of 13 to be read as:
Other Attributes:-
Wagon No.: U/F No.: Date:
SL ATTRIBUTES ACCEPTANCELIMIT WORKS RDSO
NO. INSPN. INSPN.
1. Check paint- for thickness & finish One coat of etch primer of DFT 10
microns on IRSM:44 materials.
Two coat of primer to minimum DFT 140
microns and two coat of finish paint to
minimum DFT 70 microns. Paint surface
to be free from blistering & peeling
2. Lettering & marking- for legibility, size, As per Drg.WD-14014-S-18
location & punch mark.
3. COUPLER
3.1 Height from Rail Level 1105 +0, - 5
3.2 Operation of knuckle with operating handle Full knuckle throw lock to lock
3.3 Articulation of coupler body Free movement
4. HAND BRAKE
4.1 Apply hand brake (by one person only and There should not be ringing sound
strike all wheels with a Hammer)
4.2 Release the hand brake and apply crow bar All brake blocks must be released. Gap
on one end of brake block to take up all slack between the brake block and wheel tread
not to be less than 23.6 mm (5.9 x 4)
5. EMPTY LOAD BOX.
5.1 Operate the mechanism from any end in Empty tie rod & loaded tie rod must
empty and loaded positions engage. In loaded position the empty tie
rod pins must be loose. In empty position
the loaded tie rod pins must be loose
6. AIR BRAKE & SLACK ADJUSTER
6.1 Distance between the control rod head and 70 +2, - 0
adjuster barrel (A)
6.2 Dimension (e) i.e. the distance between the 560 ± 25 mm
end of protection tube and fixed mark on the
slack adjuster pull rod
6.3 Apply air brake and then release the same. Gap should not be less than 23.6 mm
Apply crow bar on one end of brake block to (5.9 x4 )
take up all slack
6.4 Rotate the brake slack adjuster in clock-wise Gap between the brake block and wheel
direction (looking from control rod end) to tread as measured should be 23.6 + 1, -
decrease the slack. Apply and release the air 0
brake twice.
6.5 Now, rotate the barrel in anticlockwise Gap between the brake block and wheel
direction. Apply and release the air brake tread as measured should be 23.6 + 1, -
once 0
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
CONTENTS
Sr. No. Description Page No
Check sheets page
1. Centre Sill 3
2. Underframe (without sole bar) 4-5
3. Underframe (with sole bar) 6
4. Body End 7
5. Body Side 8
6. Final Assembly 9
7. Final Wagon 10
8. Other attributes 11
9. Performance for Single wagon air brake test 12-13
Note:
These check sheets do not detail all the dimensions or technical
requirements of respective wagon assemblies/components.
These check sheets are issued only for General Guidance & assistance of
inspecting officials. Notwithstanding the above, the inspecting officials are
advised to refer to relevant drawings and/or relevant specifications to confirm
conformity to the specified dimensions and technical details.
Page 2 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
Centre Sill
CENTRE SILL NO: Date:
SL. STAGE Works Inspection RDSO Inspection Remarks
NO.
1. Centre Sill `Hat’ section.
1.1 Fitment of all components
1.2 Welding
1.3 Dressing
1.4 Lock Bolting
2. Dimensions As follows
LOCATION Nominal Actual Dimension Remarks
Dimensions & Works Inspection RDSO Inspection
Allowable
Deviation
i. Length A1 9784, +4,-2
A2
ii. Height C1 327, ±1.5
C2 .
iii. Width D1 674, ±3
D2
iv. Draft Gear Pocket Y 327, +3, -0
All dimensions are in mm
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 3 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
UNDERFRAME(without sole bar)
UNDERFRAME NO: Date:
SL. STAGE Works Inspection RDSO Inspection REMARKS
NO.
1. Fitment of all
components
2. Welding
3. Dressing
4. Dimensions As follows
LOCATION Nominal Actual Dimension Remarks
Dimensions & Works Inspection RDSO Inspection
Allowable
Deviation
i. Distance between A1 1530, ±1
pockets for side A2
stanchions
B1 1412 ±1
B2
C1 1412 ±1
C2
E1 1530 ±1
E2
ii. Width & Depth of Bolster W 160 ±1
pocket -1 D1 102 ±1
D2 110 ±1
Continue ……….
All dimensions are in mm
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 4 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
Continue
UNDERFRAME NO: Date:
4. Dimensions As follows
LOCATION Nominal Actual Dimension Remarks
Dimensions & Works Inspection RDSO Inspection
Allowable
Deviation
iii. Width & Depth of Bolster W 160 ±1
pocket -2 D1 102 ±1
D2 110 ±1
iv. Width & Depth of Bolster W 160 ±1
pocket -3 D1 102 ±1
D2 110 ±1
v. Width & Depth of Bolster W 160 ±1
pocket -4 D1 102 ±1
D2 110 ±1
vi. Width & Depth of W 160 ±1
crossbar pocket -1 D1 102 ±1
vii. Width & Depth of W 160 ±1
crossbar pocket -2 D1 102 ±1
viii. Width & Depth of W 160 ±1
crossbar pocket -3 D1 102 ±1
ix. Width & Depth of W 160 ±1
crossbar pocket -4 D1 102 ±1
x. Width & Depth of W 160 ±1
crossbar pocket -5 D1 102 ±1
xi. Width & Depth of W 160 ±1
crossbar pocket -6 D1 102 ±1
All dimensions are in mm
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 5 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
UNDERFRAME
UNDERFRAME NO: Date:
SL. STAGE Works Inspection RDSO Inspection REMARKS
NO.
1. Fitment of all
components
2. Welding
3. Dressing
4. Dimensions As follows
LOCATION Nominal Actual Dimension Remarks
Dimensions & Works Inspection RDSO Inspection
Allowable
Deviation
i. Length over corner A1 9808, +7,-3
stanchions A2
ii. Width over solebar B1 3135 ±3
B2
B3
B4
B5
iii. Distance between C1 6524, +5,-2
bolster bogie centre C2
iv) Distance between side E1 1474±2
bearers centre E2
v) Diagonal difference over D1 ≤5
headstock D2
vi) Camber *6 ±2
vii) Difference between side 50.5,+0.5,-0
bearer top liner and
center pivot top
All dimensions are in mm
*to be measured in final assembly
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 6 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
BODY END
BODY END NO: Date:
SL. STAGE Works Inspection RDSO Inspection Remarks
NO.
1. Fitment of all components
2. Welding
3. Dressing
4. Dimensions As follows
LOCATION Nominal Actual Dimension Remarks
Dimensions & Works Inspection RDSO Inspection
Allowable
Deviation
i. Width over corner A1 3035 +3 -0
stanchions A2
ii. Diagonal dimensions B1 ≤5
B2
iii. End Wall overall height C1 2560 ± 3
C2
iv. Distance between corner D1 462.5 ± 1.5
sheet to outer stanchion D2
V. Distance between inner to E1 380 ± 1.5
outer stanchion E2
Vi. Distance between inner to F 550 ± 1.5
inner stanchion
Vii. Length of end top coping G 2915 ± 1.5
All dimensions are in mm
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 7 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
Body Side
BODY SIDE NO:
Date:
SL. STAGE Works Inspection RDSO Inspection Remarks
NO.
1. Fitment of all
components
2. Welding
3. Dressing
4. Dimensions As follows
LOCATION Nominal Dimensions Actual Dimension Remarks
& Allowable Deviation Works Inspection RDSO Inspection
i. Length over side A 10090 ±3
top coping
Side Wall Overall B1 2549 ±3
ii. Height B2
iii. Length over corner C1 9808 +0,-3
stanchions C2
iv. Height between D 1140.5 ±1.5
middle copings
v. Distance between E 1148.5 ±1.5
ST cop. to M cop.
vi Diagonal difference F1 ≤5
over corner F2
vii. Distance between G1 1407 ± 1.5
stanchions G2 1440 ± 1.5
G3 1322 ± 1.5
G4 1322 ± 1.5
G5 1440 ± 1.5
G6 1407 ± 1.5
All dimensions are in mm
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 8 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
FINAL ASSEMBLY
Wagon No.: U/F No.: Date:
SL. STAGE Works Inspection RDSO Inspection Remarks
NO.
1. Fitment of all components
2. Lock Bolting
3. Welding
4. Operation of Couplers
5. Under gear Examination
6. Brake test i) Air brake
ii) Hand brake
7. Painting
8. Lettering
9. RFID (Fitment/Location/Data
Entry)
10. Dimensions As follows
LOCATION Nominal Dimensions & Actual Dimension Remarks
Allowable Deviation
Works Inspection RDSO Inspection
i. Coupler height from R.L A1 1105, +0, -5
A2
ii. Length Inside L1 9784, +7, -3
L2
iii. Width Inside C1 3111, ± 3
C2
C3
iv. Height Inside D1 2300, ± 3
D2
D3
v. Width over ends E1 3135, ± 3
E2
vi. Centre pivot assembled height B1 78, +0.8, -0.3
B2
vii. Side bearer set up height from H1 128.5, ± 1
bolster seat H2
viii. Overall Width F1 3135, ± 3
F2
F3
F4
All dimensions are in mm
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 9 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
FINAL WAGON
1. Wagon No. 2. Date of offer
3. Underframe No. 4. Name of the Wagon
Manufacturer:
5. Contract/P.O. placed 6. Contract/P.O. No.
by and date and D.P.
(Upto)
7. Running Gear
a) Bearing Make Serial Nos.
b) Wheel Make Serial Nos.
c) Axle Make Serial Nos.
d) Bogie Make & Sr. e) Air Brake Make
Nos.
f) DV Make & Sr. no. g) Date of air brake
testing
h) Date of SWTR i) Coupler Make & Sr.
calibration Nos.
j) Auxiliary Reservoir k) P.U. Pad Make
Make
8. Draft Gear Make, 9. Tare Weight
Model & Sr. Nos.
10. CRF section make 11. Lock Bolt Make
12. Paint Make 13. D.M. Issue date
14. TXR fit memo issue 15. CBB make & Sr. Nos.
date
16. Brake Cylinder Make & 17. Shot Blasting
Sr. Nos.
18. RFID Tag
19. RAD availed______________________________________________________________________________
20. Defects Observed_________________________________________________________________________
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 10 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
Other Attributes:-
Wagon No.: U/F No.: Date:
SL ATTRIBUTES ACCEPTANCELIMIT WORKS RDSO
NO. INSPN. INSPN.
1. Check paint- for thickness & finish Two coat of primer to minimum DFT 120
microns and two coat of finish paint to
minimum DFT 80 microns. Paint surface
to be free from blistering & peeling
2. Lettering & marking- for legibility, size, As per Drg.WD-14014-S-18
location & punch mark.
3. COUPLER
3.1 Height from Rail Level 1105 +0, - 5
3.2 Operation of knuckle with operating handle Full knuckle throw lock to lock
3.3 Articulation of coupler body Free movement
4. HAND BRAKE
4.1 Apply hand brake (by one person only and There should not be ringing sound
strike all wheels with a Hammer)
4.2 Release the hand brake and apply crow bar All brake blocks must be released. Gap
on one end of brake block to take up all slack between the brake block and wheel tread
not to be less than 23.6 mm (5.9 x 4)
5. EMPTY LOAD BOX.
5.1 Operate the mechanism from any end in Empty tie rod & loaded tie rod must
empty and loaded positions engage. In loaded position the empty tie
rod pins must be loose. In empty position
the loaded tie rod pins must be loose
6. AIR BRAKE & SLACK ADJUSTER
6.1 Distance between the control rod head and 70 +2, - 0
adjuster barrel (A)
6.2 Dimension (e) i.e. the distance between the 560 ± 25 mm
end of protection tube and fixed mark on the
slack adjuster pull rod
6.3 Apply air brake and then release the same. Gap should not be less than 23.6 mm
Apply crow bar on one end of brake block to (5.9 x4 )
take up all slack
6.4 Rotate the brake slack adjuster in clock-wise Gap between the brake block and wheel
direction (looking from control rod end) to tread as measured should be 23.6 + 1, -
decrease the slack. Apply and release the air 0
brake twice.
6.5 Now, rotate the barrel in anticlockwise Gap between the brake block and wheel
direction. Apply and release the air brake tread as measured should be 23.6 + 1, -
once 0
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 11 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
SINGLE WAGON TEST RIG (SWTR)
PROFORMA FOR SINGLE WAGON AIR BRAKE TEST FOR SINGLE PIPE/ TWIN PIPE
Wagon No…………………. Bogie Make……………………….DV Make…………….
S.No. Check Specified Actual
1 Pressure in BP 5 ± 0.1 kg/sq.cm.
2 Pressure in FP 6 ± 0.1 kg/sq.cm. ( twin pipe)
3 Pressure in AR 5 ± 0.1 kg/sq.cm.(for single pipe)
6 ± 0.1 kg/sq.cm. (for twin pipe)
4 Leakage from the system in one minute. 0.1 kg/sq. cm.(max.)
5 FULL SERVICE APPLICATION
5.1 Brake cylinder filling time
a) Empty (Pressure rise from 0 to 3.6 kg/sq.cm.) 18 to 30 sec
b) Loaded (Pressure rise from 0 to 3.6 18 to 30 sec.
kg/sq.cm.)
5.2 Maximum brake cylinder pressure
a) Empty 3.8 ± 0.1 kg/sq.cm.
b) Loaded 3.8 ± 0.1 kg/sq.cm.
5.3 Reduction in BP pressure required for full service 1.3 to 1.6 kg/sq.cm.
application.
6 RELEASE AFTER FULL SERVICE APPLICATION.
6.1 Draining time (Brake cylinder pressure to fall from
3.8 ± 0.1 kg/sq.cm. to 0.4k g/sq.cm.
a) Empty 45 to 60 sec
b) Loaded 45 to 60 sec.
7 SENSITIVITY OF BRAKES
7.1 Isolate brake pipes from mainline. Check the Brake should apply within 6 sec.
response of brakes when brake pipe pressure is
reduced at the most equal to 0.6 kg/sq.cm. in 6 sec.
8 INSENSITIVITY OF BRAKES
8.1 Isolate brake pipe from mainline. Check the Brake should not apply
pressure of brakes when brake pipe pressure is
reduced at least equal to 0.3 kg/sq.cm. in 60 sec.
9 EMERGENCY APPLICATION:
9.1 Brake cylinder filling time
a) Empty (Pressure rise from 0 to 3.6 kg/sq.cm.) 18 to 30 sec.
b) Loaded (Pressure rise from 0 to 3.6 kg/sq.cm.) 18 to 30 sec.
9.2 Maximum brake cylinder pressure
a) Empty 3.8 ± 0.1 kg/sq.cm.
b) Loaded 3.8 ± 0.1 kg/sq.cm.
Continue ..
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 12 of 13
WD-CS-01-BOXNS-2015-Rev.-02Amendment-01
Continue ..
S.No. Check Specified Actual
10 Piston stroke
Empty Condition 85 +10
Loaded Condition 120 +10
11 Leakage from brake cylinder after emergency 0.1 kg/sq.cm. (max.)
application. within 5 minutes
12 Automatic exhausting of brake cylinder and control
chamber.
12.1 Apply emergency brakes (i.e. BP=0kg/sq.cm). Brake cylinder and control
Check the brake cylinder pressure after giving a reservoirs should exhaust
brief pull to release hook. automatically.
13 Hand Brake
13.1 Apply hand brakes(by one person only and strike There should not be ringing
all wheels with hammer) sound
S.No. 14 and 15 to be checked at the time of prototype Wagon only
14. AR Charging time (Pressure rise from 0 to 5.0 175 + 30 Sec for C3W D.V
kg/sq.cm.)
60 to 120 Sec for KEO D.V.
15 CR Charging time (Pressure rise from 0 to 4.8 165 + 20 Sec for C3W D.V
kg/sq.cm.)
160 to 210 Sec for KEO D.V
Works Inspector RDSO Inspector
Signature: Signature:
Name: Name:
Designation: Designation:
Date: Date:
Page 13 of 13
