BCNHL (Design-D) Check Sheet

WD-CS-01-BCNHL(DESIGN-D)-2011
INDIAN RAILWAYS
CHECK SHEETS
FOR
BOGIE COVERED WAGON (91.6 Tonnes)
TYPE BCNHL(Design-D)
(FIITTED WITH AIR BRAKE SYSTEM)
BROAD GAUGE
(1676 MM)
S.No.
Month & Year of

issue
Revision /
Amendment
Page No.
Reason for Amendment
01
October, 2011
First issue
----
----
ISSUED BY
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
LUCKNOW-226 011
October, 2011
Page 1 of 12
CONTENTS
Sr. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Description
Section A
Centre Sill
Underframe
Body End
Body Side
Roof
Door
Final Assembly
Final Wagon
Other Attributes
Page No
3
4
5
6
7
8
9
10
11-12
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 12
Centre Sill
CENTRE SILL NO:

SL.
STAGE
NO.
1.
Fitment of center Sill End
(CRF Z section) with
Centre Sill Middle (CRF
section)
1.1
Welding
1.2
2.0
2.1
2.2
2.3
3.
Dressing
Fabrication of Centre Sill
Fitment of all components
Welding
Dressing
Dimensions
LOCATION
i.
Length
ii.
Height and width of end

Centre Sill
iii.
Height and width of center

Centre Sill
iv.
Draft Gear Pocket
v.
Date:
Works Inspection
A1
Nominal
Dimensions &
Allowable
Deviation
10034, +7,-3
A2
C1
327 1.5
C2
C3
530, +1.5, -0
270 1.5
C4
X
477, +1.5, -0
625.5, +0, -1.5
327 1.5
Bow
RDSO Inspection
Remarks
As follows
Actual Dimension
Remarks
Works Inspection
RDSO Inspection
1 in 600
All dimensions are in mm
Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 3 of 12
UNDERFRAME
UNDERFRAME NO:
SL.
STAGE
NO.
1.
2.
Welding
3.
4.
i.
Dressing
Dimensions
LOCATION
Length over head stock
Date:
RDSO
Inspection
Works Inspection
Nominal Dimensions
& Allowable Deviation
A1
As follows
Actual Dimension
Works Inspection
REMARKS
Remarks
RDSO Inspection
10034, +7,-3
A2
ii.
Width over solebar
B1
33503
B2
B3
B4
B5
iii.
Distance between bolster bogie

centre
C1
iv)
Distance between side bearers

centre
E1
Diagonal difference over

headstock
D1
v)
vi)
Camber
vii)
Distance between C.L. of

centre sill to centre of first hole
of D.V. bracket.
Distance between C.L. of
centre sill to centre of Aux.
Reservoir centre.
Distance between Crossbar
centre to centre of middle hole
of brake cylinder bracket.
viii)
ix)
7153, +5, -2
C2
14742
E2
5
D2
10, +0, -3
F
1097,+0,-2
7282
701

Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 4 of 12
BODY END
BODY END NO:

SL.
STAGE
NO.
1. Fitment of all components
2. Welding
3. Dressing
4. Dimensions
LOCATION
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
Width over corner stanchion

Distance between centre line of End
stiffening centre to End stanchion (
bottom) end
Distance between Tail lamp bracket
to End stanchion( bottom) end
Distance between corner angle to
Vertical stanchion C.L
Distance between C.L of body end
to Vertical stanchion C.L
Distance between floor plate top to
center line of end stiffening centre
Distance between end coping to
center line of end stiffening centre
Distance between end coping to roof
top
Distance between corner roof car
line edge to ventilator top
Works Inspection
Nominal Dimensions &

Allowable Deviation
A
B1
Date:
RDSO Inspection
As follows
Actual Dimension
Works
Inspection
Remarks
Remarks
RDSO
Inspection
3366 3
1251 1.5
B2
C
438 1.5
D1
D2
E1
E2
F1
F2
G1
G2
H1
H2
J
1054 1.5
629 1.5
1023 1.5
1024 1.5
985 1.5
134 1.5
Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 5 of 12
BODY SIDE
BODY SIDE NO:

SL.
STAGE
NO.
1.
2.
Welding
3.
Dressing
4.
Dimensions
LOCATION
i.
ii.
Distance between floor sheet top to

top of top coping
Overall stanchion Height
iii.
Door opening horizontal
iv.
Door opening vertical
v.
vi.
Distance over corner stanchions

Diagonal difference over corners
vii.
Distance between corner stanchion

to doorway shut piller
Center to centre distance between
side stanchions
viii.
ix.
xi.
Distance between doorway shut

piller to doorway shut(end) piller
Distance between doorway stop
piller to Side stanchion center
Side sheet height
xii.
Door top track
xiii.
Distance between corner stanchion

to door center
Length of middle top coping
x.
xiv.
Date:
Works Inspection
A1
A2
B1
B2
B3
C1
C2
D1
D2
E
F1
F2
J1
J2
L1
L2
L3
L4
M1
M2
H1
H2
K1
K2
K3
N1
N2
P1
P2
B

Allowable Deviation
20473
RDSO Inspection
Remarks
As follows
Actual Dimension
Works Inspection
Remarks
RDSO Inspection
20593
1204, +0, -3
1985, +0, -3
10050, +7, -3
5
505 3
595 3
1292, 3
834 3
1905 3
2563 3
2399 1
4036 1
All dimension are in mm
Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 6 of 12
ROOF ASSEMBLY
ROOF NO:
SL.
NO.
1.
2.
3.
4.
i.
Date:
STAGE

Welding
Dressing
Dimensions
LOCATION
iii.
Distance between roof top to top

of Side top Coping
Distance between corner roof
carline
Distance between side top coping
iv.
Diagonal difference over corner
v.
Distance between centre line of

wagon to centre line of Cross
member
Cross member
Cross members
Distance between Cross member
centre line to Corner roof carline
Center Distance between
Longitude members
ii.
vi.
vii.
viii.
ix
Works Inspection
E1
E2
C1
C2
D1
D2
D3
F1
F2
J1
J2
L1
L2
H1
H2
M1
M2
K1
K2
K3

Allowable Deviation
985 3
RDSO Inspection
Remarks
As follows
Actual Dimension
Works Inspection
Remarks
RDSO Inspection
10050, +7, -3
3338 3
5
615 3
1400 3
1392 3
1618 3
1116 3
All dimension are in mm
Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 7 of 12
DOOR
DOOR NO:
SL. N0.
1.
2.
3.
4.
STAGE
Works Inspection

Welding
Dressing
Dimensions
vi.
vii.
viii.
ix.
Width of Door opening

Height of Door opening
Width of Door Flap
Height of Door
Distance between center of two
end Roller
Distance between door top
pressing end to center of end
roller
Distance of center line of door
fastener from top coping of side
wall
Distance of Door sealing
bracket from bottom edge of
door sheet
Distance of center of handle for
sliding door from bottom edge
of door sheet
Remarks
As follows
LOCATION
i.
ii.
iii.
iv.
v.
DATE:
RDSO Inspection
A
B
C
D
E

Allowable Deviation
1204, +0, -3
1985, +0, -3
1278, -0, +5
2097, -0, +5
1130 1.5
55 0.5
612 1.5
H1
H2
635 1.5
803 1.5
Actual Dimension
Works Inspection
RDSO Inspection
Rem
arks
Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 8 of 12
FINAL ASSEMBLY
SL.
NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Wagon No.:
STAGE
U/F No.:
Works Inspection
Date:
Remarks
RDSO Inspection

Huck Bolting
Welding
Operation of Doors
Operation of Couplers
Under gear Examination
Brake test i) Air brake
ii) Hand brake
Painting
Lettering
Dimensions
As follows
LOCATION
i.
Coupler height from R.L
ii.
Floor height from R.L
iii.
Length Inside
iv.
Width Inside
v.
vi.
Height Inside (Floor level to top)

Length over coupler face
vii.
viii.
Side bearer clearance

Overall Width
ix
x.
xi.
Distance between bogie centres

Overall height from R.L.
Door opening vertical
xii.
Door opening horizontal

Allowable Deviation
A1
A2
B1
B2
L1
L2
C1
C2
C3
D1
E1
E2
F1
F2
F3
G1
H1
J1
J2
K1
K2
Actual Dimension
Works Inspection
Remarks
RDSO Inspection
1105, +0, -5
1273, 3
10034, +7, -3
3345, 3
3024, 3
10963, +8, -3
Nil
3450, 3
7153, 3
4305, 3
1985, +0, -3
1204, +0, -3

Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 9 of 12
FINAL WAGON
1.
Wagon No.
2.
Date of offer
3.
Underframe No.
4.
5.
Contract/P.O. placed
by
6.
Name of the Wagon

Manufacturer:
Contract/P.O. No.
and date and D.P.
(Upto)
7.
a)
Running Gear
Bearing Make
Serial Nos.
b)
Wheel Make
Serial Nos.
c)
Axle Make
Serial Nos.
d)
Bogie Make & Sr.

Nos.
DV Make & Sr. no.
f)
h)
8.
10.
Date of air brake

testing
Coupler Make & Sr.
Nos.
Tare Weight
12.
D.M. Issue date
14.
16.
CRF Section Make

Paint Make
e)
Air Brake Make
g)
SAB Make & Sr. No.
i)
Date of *SWTR unit

calibration
Draft Gear Make & Sr.
Nos.
9.
11. Shot blasting/manually

cleaned
13. TXR fit memo issue
date
15. Lock bolt make
17. RAD availed______________________________________________________________________________
18. Defects Observed_________________________________________________________________________
* Single wagon test rake
Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 10 of 12
Other Attributes:Wagon No.:

SL
NO.
U/F No.:
ATTRIBUTES
Date:
ACCEPTANCELIMIT
1.
Check paint- for thickness & finish
2.
3.
3.1
Lettering & marking- for legibility, size,

location & punch mark.
COUPLER
Height from Rail Level
3.2
Operation of knuckle with operating handle
Full knuckle throw lock to lock
3.3
Articulation of coupler body
Free movement
4.
4.1
HAND BRAKE
Apply hand brake (by one person only and
strike all wheels with a Hammer)
Release the hand brake and apply crow bar
on one end of brake block to take up all slack
4.2
5.
5.1
EMPTY LOAD BOX.

Operate the mechanism from any end in
empty and loaded positions
6.
AIR BRAKE & SLACK ADJUSTER
6.1
Distance between the control rod head and

adjuster barrel (A)
Dimension (e) i.e. the distance between the
end of protection tube and fixed mark on the
slack adjuster pull rod
Apply air brake and then release the same.
Apply crow bar on one end of brake block to
take up all slack
Rotate the brake slack adjuster in clock-wise
direction (looking from control rod end) to
decrease the slack. Apply and release the air
brake twice.
Now, rotate the barrel in anticlockwise
direction. Apply and release the air brake
once
AIR BRAKE EQUIPMENT
Full service application
Leakage from the system
6.2
6.3
6.4
6.5
7.
7.1
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
As per Drg No.WD-10068-S-20
1105 +0, - 5
There should not be ringing sound

All brake blocks must be released. Gap
between the brake block and wheel tread
not to be less than 23.6 mm (5.9 x 4)
Empty tie rod & loaded tie rod must
engage. In loaded position the empty tie
rod pins must be loose. In empty position
the loaded tie rod pins must be loose
70 +2, - 0
560 25 mm
Gap should not be less than 23.6 mm

(5.9 x4 )
Gap between the brake block and wheel
tread as measured should be 23.6 + 1, 0
Gap between the brake block and wheel
tread as measured should be 23.6 + 1, 0
0.1 Kg/cm in 1 minute
Works Inspector
Signature:
Name:
Designation:
Date:
WORKS
INSPN.
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 11 of 12
RDSO
INSPN.
SL
NO.
ATTRIBUTES
ACCEPTANCE LIMIT
7.2
B.C filling time (pressure rise 0 to 3.6

Kg/cm )
Maximum B.C. pressure in Kg/ cm
Empty 18 to 30 sec. Loaded 18 to 30

seconds
Empty 3.8 0.1 Kg/ cm
Loaded 3.8 0.1 Kg/ cm
1.3 to 1.6 Kg/ cm
7.3
7.4
8.
8.1
9.
10.
10.1
10.2
10.3
11.
11.1
12 .
12.1
13.
13.1
13.2
14.
14.1
WORKS
INSPN.
Decrease in B.P. pressure required for full

service application
RELEASE AFTER FULL SERVICE APPLICATION
Draining time- B.C pressure to fall from a) Empty 45 to 60 seconds
3.8 to 0.4 Kg/cm
b) Loaded 45 to 60 seconds
Piston stroke in mm
a) Empty 85 10
b) Loaded 120 10
EMERGENCY APPLICATION
Emergency application- BC filling time 0 to a) Empty 18 to 30 seconds
3.6 Kg/cm
b) Loaded 18 to 30 seconds
Maximum B.C pressure in Kg/cm
a) Empty 3.8 0.1 Kg/cm
b) Loaded 3.8 0.1 Kg/cm
Leakage from B.C.
0.1 Kg/cm in 5 minute
SENSITIVITY OF BRAKES
Isolate brake pipe from main line check Brake should apply within 6 seconds
the response of brakes when brake pipe
pressure is reduced at the most equal to
0.6 Kg/cm in 6 seconds
INSENSITIVITY OF BRAKES
Isolate brake pipe from main line. Check Brake should not apply
the response of brakes when brake pipe
pressure is reduced at least equal to 0.3
Kg/cm in 60 seconds
QUICK RELEASE AND ISOLATION
After emergency brake application operate Brake cylinder and control reservoir
quick release valve
should also exhaust.
Bring isolating valve of distributor to off Auxiliary reservoir should also exhaust.
position.
APD CHECKING
Check any twenty number of APD fittings
(refer RDSO Drg. no.4020/24)
Both legs of cotter are split at 90

deg.(approx).Split pin legs are opened
at 180 degrees (approx).Tack welding of
cotter/split pin with washer/nut with bolts
is adequate.
Works Inspector
Signature:
Name:
Designation:
Date:
RDSO Inspector
Signature:
Name:
Designation:
Date:
Page 12 of 12
RDSO
INSPN.

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WD-CS-01-BCNHL(DESIGN-D)-2011

Month & Year of

Reason for Amendment

CENTRE SILL NO:

Height and width of end

Height and width of center

Draft Gear Pocket

Width over solebar

Distance between bolster bogie

Distance between side bearers

Diagonal difference over

Distance between C.L. of

All dimensions are in mm

BODY END NO:

Width over corner stanchion

Nominal Dimensions &

BODY SIDE NO:

Distance between floor sheet top to

Door opening horizontal

Door opening vertical

Distance over corner stanchions

Distance between corner stanchion

Distance between doorway shut

Door top track

Distance between corner stanchion

Nominal Dimensions &

Fitment of all components

Distance between roof top to top

Diagonal difference over corner

Distance between centre line of

Nominal Dimensions &

All dimension are in mm

Fitment of all components

Width of Door opening

Nominal Dimensions &

All dimensions are in mm

Fitment of all components

Coupler height from R.L

Floor height from R.L

Height Inside (Floor level to top)

Side bearer clearance

Distance between bogie centres

Door opening horizontal

Nominal Dimensions &

All dimensions are in mm

Name of the Wagon

Bogie Make & Sr.

Date of air brake

D.M. Issue date

CRF Section Make

Air Brake Make

SAB Make & Sr. No.

Date of *SWTR unit

11. Shot blasting/manually

17. RAD availed______________________________________________________________________________

18. Defects Observed_________________________________________________________________________

* Single wagon test rake

Other Attributes:Wagon No.: