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					WAGON MAINTENANCE MANUAL                                                      Page 1 of 24




                                       CHAPTER 2


 WARRANTY, MAINTENANCE & CONDEMNATION


        This chapter gives general information about periodicity of various types of
inspections and maintenance schedules for goods stock on open line. Prescribed period at
which POH is to be carried out on various types of stock has also been given. However,
special practices to be followed for repairs during POH are indicated in the concerned
chapters later in the manual.

     At the end of this chapter, at a glance picture of the prescribed intervals for POH and
ROH of wagons are given in the tables 2.1, 2.2 & 2.3.


201. WARRANTY INSPECTION OF NEWLY BUILT WAGONS

              (Ref.- Rly. Bd.’s letter no. 64/M(WTY)/954/Policy dated 3.4.74)

       a)     All newly built wagons have a warranty period of one year or as prescribed in
              the purchase contract. In accordance with the conditions mentioned in the
              wagon manufacturing contracts, the charges for rectification of the following
              category of defects can be realised from the wagon builder :-

                   Use of inferior material
                   Poor workmanship on the part of contractor
                   Imperfect protection
                   Other faults on the part of contractor which are noticed during the
                    warranty period.

       b)     To enable the Railway Board to realise the warranty charges, a systematic
              inspection of new wagons must be undertaken by JE(C&W) to locate defects
              during the warranty period. The following procedure is laid down for this
              purpose:-
              (i)     All newly built wagons turned out must bear the warranty legend
                     stencilled on both sides of the wagons. The warranty legend will consist
                     of the following particulars:-

                           Contract Number
                           Date of Commissioning
                           Commissioned by
                           Inspection due on
                              Inspection done by ______ Depot_______ Date_______


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                          The due date of inspection falls due on completion of 11
                    months from the date of commissioning.

            (ii)    Whenever wagons due for warranty inspection pass nominated yards,
                    preferably detach them from the train and send to sick line for a
                    systematic check. This warranty inspection can also be done on the
                    train at the time of incoming or outgoing examination if the sufficient
                    time is available.

            (iii)   Examination of Defects

                            During the course of warranty inspection, it must be borne in
                    mind that only those defects, which are attributable to the manufacturer
                    due to use of inferior material, poor workmanship, improper protection
                    or any other faults, are to be reported. The following are some of the
                    defects, which fall under this category :-

                    A) Welding defects
                         All types of welding failures
                         Welding defects such as insufficient or unequal leg length of
                          fillet weld, porosity, lack of fusion, etc.

                    B) Riveting defects
                          Loose rivets
                          Badly formed rivet heads
                          Rivets with staggered heads
                          Improperly filled rivet holes

                    C) Fitting Defects
                           Improper fitting of axle guards
                           Tie rods not bent tight over the axle guards etc.

                    D) Material failures such as breakage of:
                         Bearing Springs
                         Shackle pins
                         Shackles
                         Screw coupling and drawbar
                         Underframe and body members

                    E) Improper Protection
                         Improper pairing of underframe body, roof and components
                           resulting in corrosion
                          Wagons not being water tight

                    F) Train Pipe leakage and unsatisfactory working of brake cylinders




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WAGON MAINTENANCE MANUAL                                                     Page 3 of 24




                   G) Roller Bearing Defects

                           Wagons fitted with roller bearings are normally examined only
                   in major sick lines. If any defect is noticed on opening the covers, the
                   entire wheel assembly must be sent to the workshop. After inspection
                   in the workshop, if it is felt that the defect is attributable to the
                   contractor, the workshop incharge should report the defect to the
                   concerned roller bearing manufacturer and others concerned. Since the
                   Railways normally supply wheels and axles to the builder, defects
                   noticed on the wheel and axles need not be reported to the wagon
                   builders. However, the extant instructions for reporting any defect on
                   the tyres, wheels and axles must be followed. With regard to centre
                   buffer couplers also, if the defect is attributable to the manufacturer,
                   the same procedure should be followed as in case of wheels, as this is
                   also a free supply item to the wagon builders by Railways.

                           The procedure of warranty inspection of BTPN wagons are
                   same as above with special attention to internal and external
                   examination of barrel for any failure of longitudinal/ circumferencial
                   joint, cracks in barrel, leakage by barrel fittings and examination of
                   cradles and anchoring rivets as per Technical pamphlet No. G-90.

      c)    METHOD OF REPORTING

            A.     The particulars, which are to be furnished, are as follows:-

            i.     Contract No.

                           This indicates the contract number under which the order has
                   been placed by the Railway Board on the Wagon Builders for the
                   manufacturer of wagons. This will be stencilled on the wagon in the
                   Warranty legend. The Junior Engineer (C&W) should ensure that
                   correct particulars as obtained on the wagon are fill against this item.

            ii.    Wagon number                  }   Needs no clarification. Both
            iii.   Code (Mech./Transport.)       }   Mechanical and Transportation
            iv.    Owning Railway                }   codes of the wagon must be
            v.     Name of the Manufacturer      }   recorded.

            vi. Date of Commissioning - Junior Engineer (C&W) must fill the date as
                obtained the Warranty legend stencilled on the wagon .

            vii. Date of Warranty Inspection - Junior Engineer (C&W) must fill the date
                 on which the wagon was actually inspected by him.

            viii. Defects attributable to the Manufacturer - all the defects attributable
                 to the manufacturer should be clearly indicated.


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                    The actual location of the defect should be clearly recorded. For this
            purpose, the Board has issued a Drawing SK. No.1 WTY which indicates the
            numbering of axle boxes on meter gauge four-wheelers, broad gauge four-
            wheelers, meter gauge bogie wagons and BG bogie wagons BCX and BOX.
            The Board has also issued another drawing No. WG/1/65114/S-1, which
            indicates the numbering of axle, boxes for BRH wagons. For instance, if one
            bearing spring is found broken the number of axle box on which the particular
            bearing spring is fitted should be indicated in the report.

                    In the case of material failure like top plate of laminated spring
            breakage, etc. it is essential that such items should be sent to the Chemist and
            Metallurgist of the respective Railways so as to enable him to submit the test
            reports. While sending the materials to the CMT, the particulars of the wagon
            i.e. the wagon No., owning Railway, Mechanical/Transportation codes the
            Builders‟ name, the Contract Number and the serial number of the Warranty
            Inspection Report must be mentioned in the forwarding memo. These
            particulars can be included in the Test Report submitted by the CMT. This
            will facilitate in connecting the test reports with the respective Warranty
            reports at the Railway Board‟s Office.

                    The CMT will send his analysis report direct to the Railway Board‟s
            office. In order to prefer the claims expeditiously as possible, it is desired by
            the Board that the reports of Chemist and Metallurgist should be sent to the
            Secretary(WP), Warranty, Railway Board, New Delhi, within 20 days from the
            date of warranty inspection. The report of the CMT should not be sent to the
            wagon Builders.

                    A „NIL‟ defect report should be sent if there are no defects attributable
            to the manufacturers.

            B.     Estimated cost of rectification

                    It has been found that the estimates prepared by Junior
            Engineer(C&W) differ from the estimates prepared by Board. To avoid advice
            of different estimates to wagon builders, it is decided by Railway Board that
            no estimates are to be furnished by Junior Engineer(C&W) in the warranty
            inspection reports. Against this column, simply mention “Cost will be advised
            by the Railway Board”.

                    Along with other remarks, if any, a written certificate must be given
            to the effect that the defects mentioned have arisen due to inferior material
            (i.e. material of wrong specification or cheap quality) or bad workmanship
            (poor workmanship like bad riveting, welding, fitting etc.) or imperfect
            protection of the components (vacuum cylinder rusted etc.) or any other
            defaults on the contractor’s part.




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WAGON MAINTENANCE MANUAL                                                    Page 5 of 24


C.    Numbering of the report

                    In order to enable the Board‟s office to keep a check on the
            performance of each nominated C&W Depot and also to detect the missing
            reports, all Warranty Inspection Reports must be serially numbered.

                     For uniformity it is desired that the C&W Depots should indicate the
            number of Warranty reports in three barrels by indicating the station code
            in the first barrel, Warranty in the 2nd barrel and serial number of the
            report in the last barrel. For example ASN/WTY/81 indicates that this
            warranty report was sent from Asansol Carriage Shed, ‘WTY’ refers to
            Warranty report and ‘81’ refers to the serial number of the warranty report
            i.e. serial number the wagon which has been warranty inspected from the
            commencement of the inspection.

                   Date on which the Warranty report is submitted must be indicated. The
            Junior Engineer(C&W) who signs the report should ensure that his designation
            is properly recorded by affixing his rubber stamp, which should indicate the
            designation as well as the reporting station.


      D.    Disposal of the Proforma

               In the case of wagons built by railway workshops, the report should be
                sent to the following addresses :-

                   1.   The workshop which manufactured the wagon
                   2.   CME of the manufacturing workshop
                   3.   Secretary (WP)/Railway Board/New Delhi.
                   4.   CME of the inspecting zonal railway
                   5.   D.M.E. of the inspecting division

               In the case of wagons built by private manufacturers, the report should be
                sent to the following addresses :-

                   1.   Wagon builder concerned
                   2.   Secretary (WP)/Railway Board, New Delhi.
                   3.   G..M.(Mech.) of the inspecting zonal railway
                   4.   D.M.E. of the inspecting division.

      E.    It is necessary that Junior Engineer(C&W) must send the warranty inspection
            report to the parties indicated above after inspection without any delay.

      F.    After submission of the warranty reports, the Railway Board will decide the
            finalisation of claims. Zonal railways should not enter into any correspondence
            with the wagon builders on this subject after sending the warranty report. If
            any wagon builder returns the warranty report or refuses to accept the claim,




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WAGON MAINTENANCE MANUAL                                                      Page 6 of 24


             such cases must be immediately advised to Railway Board. Only Railway
             Board will do all further correspondence and processing in this regard.

      d)     MAINTENANCE OF RECORDS

             The Train Examining Depot should maintain following files and registers:

              One file for filing all the policy instructions on warranty inspection
               received from their divisional office/CME. The Junior Engineer(C&W)
               should be conversant with the instructions issued from time to time. It is
               desired that an index sheet be maintained giving the particulars of the
               letters so as to keep a continuity of all the instructions.
              A second file for filling all the warranty inspection reports, intermediate or
               finally submitted by the Depot.
              A third file should be maintained for filing all correspondence regarding
               warranty inspection, periodical statements of inspections carried out etc.
              A register should be maintained giving the following details of the wagons
               inspected during the warranty period :-


                        a)   Date of Inspection
                        b)   Wagon No.
                        c)   Owning Railway
                        d)   Mech. Code
                        e)   Name of Builder
                        f)   Date of Commissioning
                        g)   Defects noticed
                        h)   Warranty inspection report no. and Date
                        i)   Remarks

              The above inspection procedure after 11 months of commissioning does not in
      any way preclude any Railway from reporting any defect direct to the wagon builder
      and to the parties mentioned above. In the same manner, if defects are noticed at any
      time during the warranty period. During the intermediate warranty inspection,
      stencilling of the Station Code and date of Inspection should not be done on the
      wagon. This should only be done at the time of final warranty inspection i.e. after
      completion of 11 months and before completion of 12 months from the date of
      commissioning the wagon.

202. EXAMINATION AND MAINTENANCE PERIODICITY

      a)     ROLLING IN EXAMINATION

              All terminating trains are to be given “Rolling-in-examination” while entering
      a station having a train examining depot. After Rolling in examination when the train
      stops in yard, immediately feeling of axle boxes is necessary to arrest hot/over warm
      axle box.
      b)      EXAMINATION OF TERMINATING LOAD


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              Examination of terminating loads and through goods trains, passing through
      station with a train examination depot, is to be carried out as soon as the train comes
      to a halt (unless the competent local authority of the Mechanical Department has
      waived off such examination). For the examination of terminating loads the pattern of
      train examination issued by individual Zonal Railway keeping in the view of the
      Railway Board‟s guidelines vide their letter no. 94/M(N)/951/57 dated 28.2.2000.

      c)     EXAMINATION OF TRAIN AT ORIGINATING STATION

             i.      The train examining staff must ensure that the wagons are in fit
                     condition and do not have any rejectable defects. A certificate has to be
                     given to the Station Master by JE(C&W) to this effect before despatch
                     of the train. Before issuing fit Certificate, train examining staff also
                     ensure minimum permissible percentage of brake power. For details
                     refer Chapter 3.
             ii.     The level of vacuum/air pressure on the engine & brake van alongwith
                     the percentage of effective brake cylinders must be recorded on the
                     brake certificate duly countersigned by the driver and guard.
             iii.    Wagons, which have been humped, must be specially checked for
                     damages occurring due to impacts during humping.

      d)     MAKING WAGONS FIT TO RUN BY PASSENGER TRAIN
             Goods wagon may be attached to a passenger train provided the maximum
      speed to the train does not exceed 75Kmph for BG and 50Kmph for MG. The wagons
      must satisfy the following condition:-

             i.      They are fully fitted with operative brake cylinders
             ii.     Fitted with shackle type bearing springs and not shoe ended springs
             iii.    Shackle pins with bearing springs fitted with split cotters and washers
             iv.     Brake gear should have closed type of safety brackets
             v.      Should not be overdue re-packing/oiling
             vi.     Axle Guards should have angle type bridle with two rivet holes at each
                     end
             vii.    The wagon should not be overloaded or unevenly loaded
             viii.   Wagon fitted with wheels having no star marks on journal cap to be
                     ensured by duly opening the Axle Box cover
             ix.     Wagons should not be overdue POH
             x.      Minimum wheel base should be 4724 mm (15‟-6”) for BG and 3658
                     mm (12‟-0” )for MG.

      e)     NURSING OF AXLE BOXES

             It is generally observed that plain bearing axle boxes, which have been
      attended to, have greater tendency to develop higher temperature in the first 40 to 50




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WAGON MAINTENANCE MANUAL                                                       Page 8 of 24


      km of the run after attention. If the axle boxes are felt at this stage and “nursed”, if
      required, the possibility of detachment of wagons on account of hot axle is greatly
      minimised during subsequent run. Keeping this fact in mind, “nursing stations” are
      often established at suitable stations, 40-50 km away from major marshalling yards.
      Whenever such nursing stations are set up, in addition to feeling the axle boxes and
      giving necessary attention to them, C&W staff there must also look out for any loose,
      broken or deficient wagon components.

      f)     INTENSIVE EXAMINATION

             The purpose of intensive examination of goods stock is to permit extended run
      of through trains by raising the general standard of fitness of rolling stock by
      concentrated attention at the time of despatch from originating yards. Runs can be
      extended upto 4500 Km on BG in case of air brake stock and 800 km in case of
      vacuum brake. For empty rake consisting of only BOX wagons, this can be extended
      up to 1000 km.

      Note: The details of above examinations are given in chapter 3.

203. INTERCHANGE EXAMINATION

             The procedure for train examination at interchange points has been dispensed
       with after introduction of end to end examination.

204. ROH OF WAGONS WITH UIC BOGIE

      a)   BOX Wagon and other wagons fitted with plate fabricated UIC bogies are to be
           given a routine overhaul (ROH) at C&W Depots nominated for this purpose at
           an interval of 18 months (i.e. two ROH schedules between successive POH).

      b)   Detailed instructions issued by RDSO in publication No. G-16 (Rev.II) and R7
           to be strictly followed. The important points are summarised below for ready
           reference:-

           i.      Lift the body and place it on trestles
           ii.     Run out the bogies
           iii.    Strip the brake gear fittings and examine for wear and damages. The
                   fittings should be checked with condemning gauge prescribed in G-16
                   (Rev.II) to ensure the serviceability.
           iv.     Lower vacuum brake cylinders. Overhaul and test. Station code initials
                   and date to be stencilled after overhaul.
           v.      Gauge the wheels. If necessary, carry out tyre turning
           vi.     Strip springs and springs suspension gear. Check springs for free camber
                   and defects. Replace if required. Check the suspension gear and replace
                   worn components
           vii.    Examine bogie frame for welding defects/failures; repair; modify; and
                   check alignment to ensure confirmation to RDSO pamphlet R-7



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WAGON MAINTENANCE MANUAL                                                     Page 9 of 24


            viii.  Rectification of welding defects to be done as prescribed in RDSO
                   technical pamphlet G-37.
            ix.    Examine centre pivot and side bearer for wear and cracks. Gauge the
                   centre pivots. Repair if necessary
            x.     Check horn cheeks and axle box lugs for wear. Fit liners if necessary
            xi.    Examine brake shaft bearings
            xii.   Examine brake gear levers, rods, etc. for proper functioning and wear.
                   Check adjustment of the tare tie rod, empty load device and rectify if
                   required. Manual adjustment of brake gear is done in accordance with
                   wheel diameter.
            xiii. Examine slack adjuster. Check dia „A‟ and adjust if necessary
            xiv. Examine all draft and buffing gears, CBC, locking levers and transition
                   gears. Attend the defective/worn out parts. Knuckles to be checked by
                   contour gauge, anti creep/ articulated rotary operation of CBC lock
                   assembly to be checked.
            xv.    Replace worn out brake blocks
            xvi. Thoroughly inspect axle boxes externally for any sign of defects such as
                   grease leaking out, visible sign of damage or seized bearing. Rotate axle
                   box by hand to see if it revolves freely and smoothly. If the movement is
                   abnormal or heavy, open axle box for inspection. Take further action as
                   prescribed in RDSO pamphlet No. WT-77-1.
            xvii. All the wheels are to be ultrasonically tested, Axle boxes to be topped up
                   by fresh grease. Axle bolts are to be tightened up by torque wrench with
                   proper torque. Old locking plates are not to be reused. UT and RB
                   examination to be carried out duly replacing the old grease.
            xviii. Check doors, hinges and other fittings. Lubricate.
            xix. Touch up paint and lettering, if necessary.
            xx.    Ensure that at the time of re-assembly, all specified anti-pilferage
                   measures have been taken and all safety straps, loops and other safety
                   fittings are correctly fitted.
            xxi. After completion of ROH work, each wagon has to be tested for leakage
                   for ensuring reliability of vacuum cylinder and other brake gear
                   components.

205. ROH OF AIR BRAKE WAGON WITH CASNUB BOGIE

              BOXN wagons are to be given Routine Over-Haul (ROH) after every 18
           month at the nominated sick line/wagon depot, where proper facilities are
           provided. The ROH schedule is as follows:

      a)      Lift the body, keep it on trestles and run out bogies
      b)      Strip bogie component for examination and repair as below:

               Strip spring & spring suspension arrangement including snubbing device.
                Check springs for free height and other defects. Replace where required.
               Examine Bogie frame. Check frame alignment as per instructions
                contained in RDSO Technical Pamphlet No. G-64.



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WAGON MAINTENANCE MANUAL                                                       Page 10 of 24


               Examine pivot for welding defects/cracks/abnormal depth due to wear.
                Replace where necessary and lubricate with graphite flakes to IS:495 in dry
                condition.
       c)     Strip brake gear levers and rods for examination of worn out/damaged parts.
       d)     The equipment shall be given attention in accordance with the maintenance
              manual issued by respective air brake equipment manufacturer:-
              i.      Cleaning of strainer discs (Reference 6 & 218 of the pamphlet SBA
                      795/258 of P4aG type Distributor Valve)
              ii.     Lubrication of brake cylinder/cleaning of its strainer
              iii.    Check for easy operation of isolating cock & anti-pilferage device of
                      distributor valve cut-off angle cock , manual quick release valve &
                      isolating cock of feed pipe
              iv.     Draining of Auxiliary Reservoir
              v.      Checking of hose coupling for serviceability
              vi.     Cleaning of strainer
              vii.    Dirt collector to be cleaned
              viii.   Leakage in pipes and joints to be checked
              ix.     After carrying out above items of work the wagon shall be
                      tested for proper function of air brake system with single car test device
                      in accordance with the procedure indicated below :
                       Connect the BP coupling of single car test rig to the corresponding
                        coupling of the wagon to be tested .The couplings of the other end
                        of the wagon to be closed with dummy coupling heads .Fix
                        pressure gauge on the brake cylinder.
                       The single car test device should now be coupled to the main line
                        of a compressor through a pipe.
                       Carry out the preparation and testing in accordance with the
                        procedure given in the manufacturers Maintenance Manual and
                        record the reading in the test proforma.
                       For passing the wagon, all the parameters shall be within specified
                        limits.
     e) Clean horizontal lever, hand brake & gears and lubricate
     f) Examine head stock for damage, bent/cracks
     g) Refit brake gear levers and rods, lubricate pins and other equipment and apply
        graphite to horizontal levers of empty load box
     h) Replace worn out brake blocks
     i) Check wheel profile, turn the wheels as needed. UST of Axle to be carried out &
        turning of wheel to worn wheel profile during ROH
     j) All the wheels are to be checked ultrasonically and Axle box cap bolts are to be
        tightened up by torque wrench with proper torque and in no case old locking plates
        are to be reused.
     k) CBC Knuckles are to be checked by contour gauge, anti creep/ articulated rotary
        operation of locking arrangement to be checked.
     l) Manual adjustment of brake gear to be done in accordance with wheel diameter.
     m) Modification work are to be attended as issued by RDSO from time to time.
206. ROH OF CRT WAGON

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WAGON MAINTENANCE MANUAL                                                        Page 11 of 24




       a)   ROH periodicity 21 months.
       b)   Brake gear examination of worn out/damaged parts.
       c)   Vacuum cylinders overhaul, testing, stencilling of station code, initials, dates etc.
       d)   Checking of spring and spring suspension gear, free camber, checking of shackle,
            stone, scroll iron , shackle pin, washer for worn out/damaged etc.
       e)   Examination of horn cheek, axle guard etc.
       f)   Examination of underframe.
       g)   Replacement of worn out brake blocks.
       h)   Attention to draw and buffing gear and attention to defective/ worn out parts.
       i)   Examination of alliance and CBC, uncoupling gear etc.
       j)   Checking of Doors and door opening gears and lubrication.
       k)   Attention, special modification as ordered time to time where practicable in ROH
            depots.
       l)   Attention to Roller bearing axle boxes as per instructions given in Technical
            pamphlet No. WT 77-1. Roller bearing axle boxes should be thoroughly examined
            externally for detecting sign of defects viz;

                Wear on lugs of axle box body
                Abnormal warmer axle box
                Grease leaking out of Axle box
                Tell tale marks of grease on axle box body and wheels to be looked for
                 Visible sign of damage on axle box body or front cover
                Seized roller bearing
                Axle box is also to be turned by hand to ascertain that its rotation is
                 smooth.

207.    NPOH OF GOODS STOCK

             Classification of wagon repairs has been rationalised under the following
       nomenclature :-

a)     Petty Repairs :- Repairs involving not more than 8 man - hours. Such repairs are to be
       normally carried out on nominated lines in traffic yards in less than 8 man hours.

b)     Medium Repairs :- Repairs involving more than 8 man - hours and upto 100 man -
       hours. These would normally cover repairs to underframe members viz. head stock,
       middle bars, sole bars, changing of axle guards, wheel changing heavy panel patching,
       heavy floor repairs, etc. Such repairs are to be carried out in sick lines.

c)     Special Repairs :- Repairs to heavily damaged wagons involving more than 100 man
       hours. Such repairs may be carried out either in the workshops or in major sick line.
       Recommended work areas where serious repairs should be carried out are given in the
       Table 2.4 at the end of this chapter. Repair to under frame members and other heavy
       work should be dealt in properly equipped major and medium sickline. Repair to
       under frame members viz. patching of headstock, sole bar and middle bars,
       strengthening of bulged ends, replacement of end angle, fitment of more than 5 new
       full width panel patches, replacement of axle guards to be done in sickline.


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WAGON MAINTENANCE MANUAL                                                     Page 12 of 24




      Unloadable BOX wagons will be classified as under :-

      Category ‘A’: Such unloadable BOX wagons, which can be repaired and made
                    loadable in wagon depots.

      Category ‘B’: Unloadable BOX wagons, which require attention/repairs in
                    workshops and cannot be classified as Category „A‟ or Category „C‟

      Category ‘C’: Unloadable BOX wagons in the age group of 18 to 25 years with
                    sound underframe requiring heavy repairs on body/floor. These
                    wagons to be sent for rebuilding to Dahod, Jamalpur or Charbagh
                    workshops.

              Railways to note the aforesaid and ensure that marking of unloadable BOX
      wagons to nominated workshops are carried out accordingly. JE/SE(C&W) shall do
      the classification/marking of the wagons under the above three categories in open line.

      (i)    For wagons classified under Category „B‟, the workshops undertaking
             repairs/conversion of unloadable BOX wagons should observe the following
             broad guidelines:-

                  Unloadable BOX wagons which are over aged or have less than 10
                   years residual life but having under frame in good condition should be
                   converted to container flats for carrying ISO containers to the
                   maximum possible extent.

                  Other serviceable unloadable BOX wagons should be given requisite
                   POH/NPOH attention and made as loadable.

      (ii)   BOXN wagons of (8-10) years of age and beyond, which are heavily corroded
             and due/overdue POH, should normally be selected for rehabilitation.
             However at the time of attention in workshops, wagons due for POH within
             next 12 months should be given POH. Similarly, the wagons falling due for
             ROH within next 6 months but not due for POH within next 12 months should
             be given ROH attention at the time of repairs in the workshops.

             Wagons so attended for POH/ROH should be stencilled with a fresh
      return date for POH/ROH based on laid down periodically for POH/ROH for
      BOXN wagons. All above rehabilitated wagons should be painted with golden
      yellow for easy identification.

             The repair of BOXN wagons should be carried out as per instructions
      contained in RDSO‟s G-70 /1986.




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WAGON MAINTENANCE MANUAL                                                     Page 13 of 24



208. CONDEMNATION OF WAGONS

               For condemnation of rolling stock, the powers delegated to various officers on
        zonal railways through their Schedule of Powers may be used. Certain issues have
        been clarified in Railway Board‟s letter No. 74/M(N)/951/19 dated 16.10.1974. The
        same are summarised below:-

        a)     Condemnation of overage wagons

                      Over aged wagon stock can be inspected personally by CWM/Dy.
               CME/WM-Incharge/Sr.DME and condition report prepared and personally
               signed. Condemnation can be approved by any of these officers.

        b)     Condemnation of underage wagons

                      Under aged wagon stock should be inspected personally by
               CWM/Dy.CME/WM-Incharge/Sr.DME and condition report prepared and
               personally signed. Condemnation proposals should be sent to CME/CRSE for
               approval duly concurred by associated finance i.e., WAO of the workshop
               concerned, further this proposal to expedite the whole process, following
               procedure to be adopted:-

                      BG and MG wagons should be condemned on „as is where is‟ basis
               and moved from division to the yards/stations nominated by DRMs. Each
               DRM should nominate sufficient number of yards/stations on their division for
               disposal of condemned wagons. Workshops can continue the present practice
               of sending the wagons to scrap yards.

209. POH & ROH INTERVAL
                     (Ref: i. IRCA letter M.219/Policy/W Dated 10.5.99)

                                      TABLE No. 2.1

                       POH INTERVAL OF AIR BRAKE STOCK

             Sr.             Stock                        POH (Years)
             No.                                  First        Subsequent
             1.      BOXN                           6                 4.5
             2.      BCN/BCNA                       6                  6
             3.      BRN                            6                 4.5
             4.      BOY                            3                  3
             5.      BTPH                           6                 4.5
             6.      BTPN                           6                  6
             7.      BOBR & BOBRN                   6                  6
             8.      BTPGLN                         4                  4
             9.      BTALN                         4.5                4.5
Note:


CHAPTER 2- WARRANTY, MAINTENANCE & CONDEMNATION                                    Ver.2.0
WAGON MAINTENANCE MANUAL                                                    Page 14 of 24




1.   Wagons become due POH from the last date of the month indicated in the return date
2.   Empty wagon will be marked sick for POH up to 30 days in advance of the due date
3.   Loaded wagons will be allowed up to 30 days after the due date of POH

                                            TABLE 2.2
                    POH INTERVAL OF VACUUM BRAKE STOCK

           Sr.No.               Type of Wagon                   First     Subsequent
                                                               POH in        POH
                                                                Years      in Years
           1.       All other wagons including Tank              4            3½
                    Wagons and CRT wagons except those
                    listed below
           2.       Bogie well wagons                            4             4
           3.       General service Hopper wagon                 4             4
           4.       BOBX, BOBS                                   3             3
           5.       BOX, BCX , BRH, BOI, BOM & BTAL              4½           4½
                    wagons fitted with UIC bogie
           6.       Cattle wagons                                2½           2½
           7.       Brake Van                                    2             2
           8.       TX/TCL, THA, TSA                             2             2
           9.       TAL, TPGLR, BTPGL                            4             4
           10.      Departmental Hopper wagon type BOB,          6             6
                    BOBY etc.
           11.      Departmental Stock                            4            4
           12.      Domestic Containers                          1.5          1.5

                                    TABLE 2.3
                             ROH INTERVAL OF WAGONS

            Sr.                  Stock                     ROH            ROH
            No.                                         Newly Built     After First
                                                         (Months)         POH
                                                                        (Months)
            1.      Roller Bearing Tank Wagons              24              21
            2.      4-Wheeler wagons converted              24              21
                    from 16.3 Tonnes Plain bearing
                    to Roller bearing
            3.      CRT                                     24              21
            4.      TPGLR                                   24              24
            5.      BOX,BCX,BRH fitted with UIC             18              18
                    bogie
            6.      BOXN,BCN,BCNA, BRN                      18              18
            7.      BOBR, BOBRN                             24              24
            8.      BTPN                                    18              18
            9.      BTPGL, BTPGLN                           24              24


CHAPTER 2- WARRANTY, MAINTENANCE & CONDEMNATION                                     Ver.2.0
WAGON MAINTENANCE MANUAL                                                   Page 15 of 24


          10.      BTPH                                    24              18
          11.      BTAL, BTALN                             18              18
          12.      BTCS                                    24              24
          13.      BOY                                     18              18



210. WORK AREAS WHERE ATTENTION TO BE GIVEN

              Table 2.4 summarises the nature of work to be done during various
examinations and repairs in sick line.




CHAPTER 2- WARRANTY, MAINTENANCE & CONDEMNATION                                   Ver.2.0

				
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