Scope for Quality Audit of Wagon Depot:

1. Quality audit of wagon depot for ROH attention of freight stock (Air brake stock fitted with CASNUB
bogies and BLC wagon).
2. Quality audit of wagon depot for Yard attention (Intensive examination) and sick-line attention.
3. Quality audit of Wagon Depot with regard to maintenance of Stainless Steel Wagon (BOXNHL /
BCNHL/BRN22.9)

Page 1 of 31 Quality Audit of Wagon Depot

 Quality Assurance Directorate (Mechanical)
RDSO Lucknow

Quality audit check-sheet for ROH attention of

Freight Stock (Air brake stock fitted with CASNUB bogies and BLC wagon)

(Based on CAMTECH Maintenance Manual for Wagon and CAMTECH report on Standardisation of
Infrastructure Facilities for Freight stock maintenance)

SN Requirements Clause Observations

1 ROH ATTENTION

1.1 ROH periodicity for various types of common wagon as stipulated is Table 2.3
being followed: of wagon
manual,
SN Type of stock Periodicity of ED
ROH (Months) committee
1 Stainless steel wagon 18 month (for report and
(BOXNCR/BONLW/BOXNHL) new stock RB’s
BOXNHL – 1ST guideline
ROH - 24 for ROH of
months) BOXNHL
2 Other Open Wagon 18 (2007/
3 Covered wagon 24 M(N)/ 951 /
4 Hopper wagon 24 45)
5 BOY wagon (22.9) 18
6 BOBS wagons 18
7 BOBYN 24
8 Bogie tank wagon (BTPN) 18
9 BTPGLN 24
10 BVZI 12
11 BLC 24

1.2 ROH OF AIR BRAKE WAGON WITH CASNUB BOGIE Para 205 (Chapter 2) of CAMTECH Wagon manual.

1.2.1 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.
 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:-
 Cleaning of strainer discs (Reference 6 & 218 of the
pamphlet SBA 795/258 of P4aG type Distributor Valve)
 Lubrication of brake cylinder/cleaning of its strainer
 Check for easy operation of isolating cock & anti-
pilferage device of distributor valve cut-off angle cock ,

Page 2 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
manual quick release valve & isolating cock.
 Draining of Auxiliary Reservoir
 Checking of hose coupling for serviceability
 Cleaning of strainer
 Dirt collector to be cleaned
 Leakage in pipes and joints to be checked
 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 works are to be attended as issued by RDSO
from time to time.
1.2.2 During ROH attention, schedule Items as per table 2.4 of Table 2.4
CAMTECH manual for wagons are attended as under (Chapter 2)
a) BODY REPAIR WORK (Common for all) of
 UNDERFRAME- Sole Bar CAMTECH
 Scrap the portion of sole bar at doorways, clean and Wagon
apply primer paint followed by Top coat manual.
 SIDE WALL- Skirting
 Check and patch if corroded then apply primer and
top coat on the patch
 Side Doors- Check damage and repair clean &
lubricate hinges
 Side Pillars- Check cracks at the base & repair.
 Patching of body, roof, door or floor plates
straightening buldged ends repairs to angle irons,
stanchions and crib angles etc.
 Making wagons water-tight (Covered wagons)
 Fitting/replacement of door fastening road, door
cotter pin eye, bolt hook and eye locking pin on
empty wagons and closing of doors.

Page 3 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 Fitting/replacement of door fastening rod guide, door
hasp which requires riveting on empty wagons.
Repairs by welding to door fittings.
 Hand rail/foot board deficient/or damaged,
insecurely fastened at door way of guard’s brake
van

b) UNDER GEAR REPAIR WORK ( Common for all )

 Brake Linkage- Check free movement
 Hand Brake - Check proper working

c) BOGIE REPAIR WORKS (CASNUB BOGIE)

 BOLSTER
 Pocket slope liner Change liner if thickness less
than 5 mm
 Rotation stop lugs Provide liners (thickness to suit) if
dimensions less than 514 mm
 Inner Column Gib Provide liners (thickness to suit) if
dimension more than 142 mm
 Land surface Provide liners (thickness to suit) if
dimension less than 442 mm
 Outer Column Gib Renew by welding if dimension
more than 241 mm
 SIDE FRAME
 Column Friction Liner - Change liner if dimension
more than 455 mm
 Column sides - Provide liners (thickness to suit) if
dimension less than 209 mm
 Anti rotation lugs - Provide liners (thickness to suit) if
dimension more than 526 mm
 Key seat to pad 22 W - Provide liners (thickness to
suit) if dimension more than 276 mm
 Crown Roof 22WM - Provide liners (thickness to
suit) if dimension more than 321 mm
 Crown Roof 22NL - Provide liners (thickness to suit)
if dimension more than 326 mm
 Pedestal Crown Sides - Renew by welding if
dimension less than 147 mm
 Pedestal Jaw 22 W - Provide liners (thickness to
suit) if dimension more than 275 mm
 Pedestal Jaw 22 WM - Provide liners (thickness to
suit) if dimension more than 283 mm
 Pedestal Jaw 22 NL(Short) - Provide liners
(thickness to suit) if dimension more than 195 mm
 Pedestal Jaw 22 NL(Long) - Provide liners
(thickness to suit) if dimension more than 241 mm
 Pedestal Sides 22 W - Provide liners (thickness to
suit) if dimension less than 102 mm
 Pedestal Sides 22 WM - Provide liners (thickness to
suit) if dimension less than 102 mm
 Pedestal Side 22 NL - Provide liners (thickness to
suit) if dimension less than 78 mm - - X X
 WEDGE
 Slope Surface - Renew by welding if dimension less
than 7 mm
 Vertical Surface - If vertical surface from centre line
of spigot less than 56 mm provide liner of 6 mm
thickness

Page 4 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 CENTRE PIVOT (BOTTOM)
 Vertical Side 22 W - Renew by welding if wear more
than 4 mm
 Vertical Side 22 WM - Renew by welding if wear
more than 3 mm
 Vertical Side 22 NL - Renew by welding if wear
more than 3 mm
 Seat Side 22 W Renew by welding if wear more
than 3 mm
 Seat Side 22WM Renew by welding if wear more
than 3 mm
 Seat Side 22 NL Renew by welding if wear more
than 3 mm
 COIL SPRING
 Outer - Group and use in sets. Replace if free height
at or less than 245 mm
 Inner - Group and use in sets. Replace if free height
less than 247 mm
 Snubber - Group and use in sets. Replace if free
height less than 279 mm
 ADAPTER
 Crown Surface Replace if worn 3.5 mm or more
Side lug Replace if wear more than 3 mm on either
side
 Thrust shoulder Replace if depth exceeds 0.7 mm
 Machined relief Replace if depth less than 0.8 mm
 BOGIE BRAKE GEAR
 Pins & Bushes - Change if clearance more than
1.5 mm
d) AIR BRAKE SYSTEM
 Distributor Valve Overhauling
 Distributor Valve - Test on SWTR
 DV Isolating Cock - Examine operation
 DV Release valve - Examine operation
 DV Filter - Clean
 BRAKE CYLINDER
 Filter of Escorts & RPIL make - Clean Brake
Cylinder of Greysham & WSF make Lubricate
 CUT OFF ANGLE COCK
 Angle cock Examine and lubricate
 DIRT COLLECTOR
 Dirt Collector - Clean
 Sealing Ring - Change
 RESERVOIR
 AR & CR - Drain
 Sealing Ring - Change
 METAL PIPES & JOINTS
 Pipe Joints Examine leakage & repair
 Seals (20 mm & 32 mm)pipe - Change
 Guard’s Emergency Brake Valve - Examine
operation
 Isolating cock of BVZC Brake Van - Examine
operation
 Quick Coupling - Examine operation
 Load Sensing Device - Examine operation
e) SLACK ADJUSTER ( COMMON FOR ALL)
 Slack Adjuster - Test Functioning, repair if required
 “A” dimension - Adjust
 “e” dimension - Adjust
 M20 Anchor Pin nut - Ensure securing by welding to pin
 Air Brake System - Test on SWTR as per procedure

Page 5 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 Brake Block - Ensure Std. Key, Spilt pin & all new brake
blocks
f) CENTRE BUFFER COUPLER ( COMMON FOR ALL)
 CBC BODY
 Coupler Body - Examine & replace on condition
basis
 CBC Contour - Examine, replace if required
 Shank Wear Plate - Replace on condition
 KNUCKLE
 Nose - Replace if wear more than 9.5 mm with
HTE knuckle
 Knuckle pin - Replace on condition
 Knuckle Stretch - Examine, Replace if required
 STRIKER CASTING
 Wear Plate - Replace
 Striker casting - Replace on condition
 COUPLER MECHANISM
 Anti Creep Protection - Examine and repair.
 Lock lift assembly – Examine
 Operation Mechanism - Examine
 Lock - Examine
 DRAFT GEAR
 Slack Measure & take correction
 GENERAL
 Yoke pin support - Replace on condition
 Buffer Height Examine & Correct if required

g) WHEEL AXLE & BEARING ( COMMON FOR ALL)

 AXLE
 Ultrasonic Testing - To be carried in every ROH &
reject if fails
 Deep Notches due to gearing of pull rod - Reject if
depth is more than 5 mm
 Axle end holes - Clean and lubricate in case end
cover is opened
 WHEEL
 Tread profile - Check with tyre defect gauge
 Height of flange - Check with tyre defect gauge
 Smooth flange - If flange not completely smooth do
not use under ROH wagon
 Wheel profile - Turn to WWP if above clause are
not met for use under ROH wagon.
 Cartridge Tapered Roller Bearing
 Cup - Rotate the bearing for unusual sound check
up for Crack/chipping
 Seal - Check seal for external damage/dent
 Backing Ring - Check backing ring for looseness &
vent fitting on backing ring with vent hole ( the vent
fitting should be intact or the vent hole should be
plugged)
 Locking Plate - Use new locking plate when ever
and cover is opened
 Axle end Cap screw - Clean and lubricate in case
end cover is opened
 Load Zone Change - Change load zone area of
the cup while lowering bogie side frame

Page 6 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
1.2.3 During ROH attention of bogie Nominal & Maximum Clearances in Table 2.4
CASNUB Bogie are maintained as per table 2.4(Chapter 2) of (Chapter 2)
CAMTECH wagon manual. of
CAMTECH
Wagon
manual.
12.4 For BVZI wagon, bogies should be given IOH attention at depot. RB letter
POH after 24 month to be done at workshop no.
2003/M(N)
/ 951 / 17
dtd
30.03.11
1.3 ROH attention of BLC wagon RITES
maintenanc
e manual
for BLC
wagon
1.3.1 After placement
a) Visual checking of head stock for bent, crack as well as bogie
maintenance
b) Pre-testing of wagons: Test the wagon individually by SWTR to
ensure the condition of DV, BC, angle cock as well as pipe line for
any leakage
c) Check the DV isolating cock, manual quick release valve
d) Disconnect ‘A’ car from ‘B’ car – remove Yoke pin bolts, nuts with
split pins and yoke pin support. If yoke pin is not dropping itself a
bump through draw bar may enable the yoke pin to drop by its
weight.
1.3.2 Disassembly of Bogies
a) Disconnect the bogie brake rigging arrangement including rubber
hose pipe and raise the wagon body after removing split pin, lock
pin. Shackle lock etc. by using suitable over head cranes or 25 T
whiting jack. Remove side frame key.
b) Run out the bogies. Lower the under frame on the trestles. Remove
the bogie by lifting with 4T capacity crane from the wheel sets.
Place on fixture. Take out the bolster for repair.
1.3.3 After Lifting:
a) Strip Springs & Springs Suspension arrangement. Check Springs
for Free height and other defects. Replace when required. It is
recommended that Springs having not more than 3mm Free Height
variation should be assembled in same group.Mixing of New & Old
Springs should be avoided.
Springs should be marked as per grouping.
Spring Free Height
Nom Cond.
Outer 260 245
Inner 243 228
Snubber 288 274
b) Examine Bogie Frame, Frame Alignment by Dismantling the Bogie.
Side frame to be checked by proper gauges to inspect wear & tear
of friction liners. Worn out portion to be built up by proper welding in
down hand position. Worn out liners to be replaced.

A. BOGIE SIDE FRAME Nominal (Wear

Limit)
i) Friction Wear Plate 10 (2+2)
ii) Column Side 216 (5+5)
iii) Anti Rotation Lug 450 (3+3)

Page 7 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
B PEDESTAL CROWN Nominal (Wear
Limit)
i) Key Seat to Pedestal 318 5
ii) Pedestal Crown Side 152 4+4
iii) Pedestal Side 105 2+2
iv) Distance between Outer & 278 4+4
Inner Pedestal Jaw
v) Crown side 152 4+4

C ADAPTER Nominal (Wear

Limit)
i) Crown Lug 156 4+4
ii) Side Lug 130 3+3
iii) Adapter Side 268 3+3
D. BOGIE BOLSTER. Bolster Nomi- (Wear
pocket has 8 mm thick Si-Mg steel nal Limit)
liner in slope pocket, may be
permitted in service up to 3mm thick.
Replace worn liner. No paint or
grease should be applied on liner.

i) Bolster Land Surface 443 3+3

Linerii)T Thickness of Slope Surface Liner 8 3+3
iii) Rotation Stop Lug 518 3+3
iv) Bolster Column Jib Outer 241 5+5
v) Bolster Column Jib Inner 136 5+5

E. Center Pivot (Wear

Limit)
i). Wear Limit Vertical side 2
ii) Seat. 2

F Elastomeric Pad
i). The top or the bottom plates should not show any
cracks. If any sign of crushing of rubber is noticed
reject the pad.
ii) Permanent set in free height is allowed to 42 mm
instead of 46 mm normal size. Use up-to 44 mm in
ROH

G Side bearer Nom Cond

Side bearer springs are 123 119
condemned on the basis of height.
It is recommended springs having
variation up to 2 mm in free height
are only assembled in the same
bolster. Mixing of new and old
spring should be avoided.

H Wedge Block Wear limit

i). Wear in Vertical 7
Surface from C/L of
Spigot.
ii) Slope Surface by 3
Gauge

Page 8 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
I Bogie Dimension Nominal Tolerance
i) Cross Trammel 3018 ±4.5
ii) Journal Center 2060 ±5
Distance

1.3.4 Brake gear attention is given as under:

Brake Gear Repairs

i) SAB (set ‘A’ dimension to 72 +2, -0 mm)
ii) Control Rod – Replace on condition basis
iii) LSD (maintain gap 8 to 10 cm)
iv) Hand Brake Wheel – operate and attend
v) Hand Brake Connecting Rod – check and
replace on need basis
vi) Ext. Roller Bracket – check and replace on
need basis
vii) Pins & Cotters. – check and replace on need
basis
1.3.5 Wheel sets and CTRB’s are attended as per para 1.2.2 (g)
1.3.6 CBC and DG are attended as per para 1.2.2 (f)
1.3.7 Air brake system is attended as per para 1.2.2. (d)
1.3.8 Welding preparation:
a) The surface to be welded should be cleaned properly to
remove dust , oil, cracks, scales preferably by grinding with
portable grinder
b) All welding shall be carried out in down hand position with the
help of manipulator whenever required.
c) Low hydrogen electrodes approved by RDSO shall be used.
d) For welding of liners start from one corner and then weld
opposite corner and so on till four corners are completed in
the same pass.
e) Electrodes shall be pre heated in a drying oven at
temperature of 150-200oC at least one hour before use.
f) No post weld heat treatment is necessary.
g) Reconditioned area shall be examined visually as well as by
DTP to ensure freedom from any defect / cracks.
1.3.9 ASSEMBLY:
a) Lower the under frame on bogie provide pivot pin shackle, pin
with split pin and connect brake gear pin. Dimension-60
between CP top to side bearer top liner should be maintained.
b) Check distance of side frame top liner to side bearer keep
distance within tolerance (131 +0, -0.5) by altering.
c) Ensure all APD measure are incorporated after assembly.
d) Paint bogie, stencil station code and date of ROH.
e) Draw bar height and CBC height should not be more than 845
mm and 1105 mm respectively. No packing should be given
over axle box adapter.
f) Check proper fitment operation of twist lock for proper locking.

Page 9 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
1.3.10 After assembly and completion of finishing work, carry out air brake
testing with SWTR

Check point Specified

i). BP Pressure 5 ± 0.1kg/cm2
ii). AUX. Reservior Pressure 5 ± 0.1kg/cm2
iii) Leakage from system after charging 0.1kg/cm2 in
one minute
iv) Full service and emergency application 18 to 30 seconds
cylinder filling time
v). Maximum brake cylinder pressure Empty 2.2 ±
0.25 kg/cm2
Loaded 3.8 ± 0.1
kg/cm2
vi). Reduction in BP Pressure required for 1.3 to 1.6 kg/cm2
full service application
vii). Release after full service 45 to 60 seconds
viii). Sensitivity of brakes. Isolate brake Brake should
from mail line. Check response of brakes apply within 6
when BP Pressure is reduced to 0.6 seconds.
kg/cm2 in 6 seconds.
ix). Insensitivity of brakes. Isolate brake Brake should not
pipe from mail line. Check response of apply
brakes when BP Pressure reduced to 0.3
kg/cm2 in 60 seconds
x). Piston stroke Empty 85 ± 10
mm
Loaded 120 ± 10

Page 10 of 31 Quality Audit of Wagon Depot

 INFRASTRUCTURAL FACILITIES IN ROH DEPOTS
(Ref: Appendix –II of CAMTECH Wagon manual)
A) Depot Name: ………………………………………………..

B) Category of depot:

Category Targeted capacity for Status of Depot

ROH (Average/month) (Av ROH attention per
month in VU during last
one year)
Super Depots Above 500
Mega Depots 250 to 500
Major Depots 125 to 250
Minor Depots Upto 125

C) Covered area under cranes: The recommended cranage area for depots undertaking 250 to 500 ROHs per month is given
below:

1. For ROH depots WITH sick-line attention:

Requirements Observations
250 ROHs/month + sick line repairs with double shift. 5000 sq. m including
wheel lathe shed
300 ROHs/month + sick 5600 sq. m
350 line repairs with 6200 sq. m.
double shift.
400 6800 sq. m
450 7400 sq. m
500 8000 sq. m

2. For ROH depots WITHOUT sick-line attention:

Requirements Observations
Depots undertaking only ROH workload and no out-of-course
repairs can manage the outturn of 250 ROHs/month in about 3000
sq. m. cranage area with working in double shifts.

D) M&P requirement:

Recommended list of M&P for a unit depot i.e. handling 250 ROH per month as per CAMTECH wagon manual. For a
depot handling more than 250 ROH per month, the requirement has to be scaled up depending on depot layout and
facilities created. Requirement of M&P for each section is given below:

Page 11 of 31 Quality Audit of Wagon Depot

1. Body section

SN M&P Quantity Observations

1 EOT cranes 15t/5t 2 Nos
2 Welding machines 4 Nos
3 Portable hydraulic rivetter 1 No
4 Trestles 12 sets
5 PC terminal (common with bogie No. will depend
section if layout permits) on layout.
6 Portable Winches As per layout
7 Grit Blasting Machine 1 No.

2. Bogie section

SN M&P Quantity Observations

1 EOT crane 10t / 3t 2 Nos
2 Welding machines 6 Nos
3 Portable hydraulic rivetter 1 Nos
4 Stores bin 20 Nos
5 Portable electric griders 3 Nos.
6 Jib crane 2.5t 10 Nos.
7 Fixture for rivetting spring plank 2 Nos.
8 Work station for bogie repair 10 Nos.
9 Turn table for wheel sets As per layout
10 Road crane 10t capacity 1 No
11 Bogie manipulators 3 Nos.
12 Roller bearing diagnostic equipment 2 Nos.
13 Magnetic flaw detector 2 Nos.
14 CO2 welding machine 2 Nos.

3. Air brake equipment

SN M&P Quantity Observations

1 Elec. Stationery screw air compressors complete with 1 No.
air receiver 15 m 3/min (This is for depot only.
Additional compressors will be required for yard).
2 Portable diesel compressor 1 No.
3 Single Wagon test rig 2 Nos.
4 DV test stand 1 No
5 Hydraulic pipe bending machine 1 No.
6 Air conditioners with voltage stabilizer 2 Nos.
7 Torque wrench with various sizes of sockets less 4 set.
than 1 inch
8 Ultrasonic cleaning table for DV components 1 Nos.

4. Wheel Reconditioning Equipment

SN M&P Quantity Observations

1 Surface wheel lathe with Servo controlled voltage 1 No.
stabilizer
2 Pneumatic torque wrench with sockets 1” to 2” 4 sets
3 Pressure grease drum with guns 15t capacity. 2 Nos.
4 Ultrasonic flaw detector 2 Nos

Page 12 of 31 Quality Audit of Wagon Depot

 5 Bearing marking gadget 1 set
6 Mono-rail for handling swarf (detail plan will depend on 1 set
layout)

7 7 Bins for storing bearings As per

requirement

8 Fork lifter 2.5t 1 No.

9 P.C. Terminal 1 No.
10 Wheel diameter measuring gauge 2 Nos.

5. Machine shop & material reclamation

SN M&P Quantity Observations

1 Heavy duty shaping machine 1 No
2 Jib crane 2.5t 1 No
3 Centre lathe 12 ½” cap. 1 No.
4 Redial drilling machine 1 No.
5 Centre lathe 6” cap 1 No.
6 Bench drilling machine 1 No.
7 Heavy duty pedestal grinder double ended 1 No.
8 Shearing machine 6 mm 1 No.

6. Stores

SN M&P Quantity Observations

1 Truck 10t capacity 1 No.
2 Tractor with hydraulic lifting machine and 3 trolleys 1 No.
(trailers)
3 Fork lift 2t 2 No.
4 Platform truck 2t 2 Nos.
5 Battery charger 2 No.
6 Weighing machine 500 kg 1 No.
7 Light store vehicle 1 No.
8 Hand trolleys with rubber wheels 10 Nos.
9 Storage racks As per layout
10 Computer terminal with printer 1 No.
11 Furniture As per layout

7. Black smithy

SN M&P Qunatity Observations

1 Black smithy hearth 1 No.
2 Anvil 1 No.
3 Hand tools 5 sets
4 Motorised blower 1 No.

Page 13 of 31 Quality Audit of Wagon Depot

 8. Training equipment

SN M&P Quantity Observations

1 Cut models of DV, SAB, Angle cock. 1 No. of each
design
2 Television (large screen) projector type 1 No.
3 VCR 1 No.
4 Furniture As per layout
5 Hostel along with kitchen equipment
6 Overhead projector 1 No.
7 LCD projector 1 No

9. Canteen & staff amenities

SN M&P Quantity Observations

1 Water cooler 1 3 No.
2 Stainless steel tables & chairs As per reqt.
3 Kitchen equipment, cooking gas, utensils As per reqt.
4 Fitter’s lockers As per reqt.

10. Office Equipment

SN M&P Quantity Observations

1 PC terminal 2 No.
2 Printer 1 No.
3 Furniture As per layout
4 Air conditioner for DME’s chamber & computer room. 3 No.

5 Intercom 10 lines 1 No.

6 Fax with P&T line 1 No.
7 First aid equipment 4 set
8 Photocopier 1 No.
9 V.H.F. sets. 10 sets

11. Miscellaneous

SN M&P Quantity Observations

1 Gas cutting equipment 4 Nos.
2 Hydraulic jacks As per requt
3 SAB test bench 1 No.
4 CBC and draft gear replacement equipment 1 No.
5 DG set 350/500 KVA 1 No.
6 Lumpsum for electric and pneumatic tools
7 Lumpsum for fitter’s hand tools.
8 Lumpsum for gauges & instruments
9 Wheel flat detector system *
10 Wheel flange welding machine *

(*) To be installed in depots/yards as per instructions of Railway Board.

12. Where power failures are rampant, a Diesel Generating Set to run the wheel lathe and cranes may also be planned.

Page 14 of 31 Quality Audit of Wagon Depot

 Quality Assurance Directorate (Mechanical)
RDSO Lucknow
Quality audit check-sheet for Yard attention (Intensive examination) and
sick-line attention of air brake freight stock
(Based on CAMTECH Maintenance Manual for Wagon and CAMTECH report on
Standardisation of Infrastructure Facilities for Freight stock maintenance)
SN Requirements Clause Observations
1 Railway is following comprehensive instructions regarding RB letter no.
the pattern of freight train examination and issue of brake 94/M(N)/
power certificate issued by Railway Board. 951/57/Vol II/Pt
dtd 25.10.04
1.1 Zonal Railways should issue a detailed joint inspection RB letter no. 78
for C&W examination for freight train in terms of RB / M(W)/814/8
guidelines by Operating and Mechanical department Vol.II dtd
every year in line with changes in traffic pattern 01.10.80 and
91/
M(N)/951/31
dtd 24.03.95
2 Intensive examination of different stock: Para 303 of
a) All freight trains should be subjected to intensive CAMTECH
examination in empty condition at originating station. Wagon manual
b) In exceptional cases, the back loaded freight train
can be examined as per instruction mentioned in
para 314 item (v) of CAMTECH Wagon manual.
c) All freight trains shall be re-examined if stabled for
more than 24 hrs by JE (C&W) in yard and by Guard
and Driver in non C&W station up to next C&W point
in the direction of movement for examination.
d) Air brake stock should run on end to end pattern /
premium / CC pattern. The intensive BPC shall
remain valid provided:
 The destination is clearly mentioned on the
BPC of loaded train.
 The composition of rake is not changed by 4 or
more wagons (5 or more wagon for BLC rake.)
3 Premium examination of air brake freight train : RB letter no.
a) Premium rakes will be intensively examined in 2005/M(N)/
empty condition and certified by examination point 951/13 dtd
nominated by CME & COM. Such premium 07.04.06
examination point should be “A” category” or should
be upgraded to ‘A’ category.
b) If any of the condition i.e. examination in empty
condition or examination at nominated point is not
satisfied then rake will operate normal end to end
rake.
c) BPC issued for such premium rake will be valid for
12 days from the date of issue (Grace period of 3
days for unloading and to avoid examination in
loaded condition)
d) After each loading / unloading, the rake will be
examined by Guard and driver before
commencement of journey and recorded under the
relevant column of BPC. In case of mechanized
loading / Unloading, examination by TXR is
desirable.
e) Premium rake should be turned out with 95% Brake
Power.

Page 15 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
f) Movement of premium rake is monitored through
FIOS.
3.1 All points nominated for premium examination of trains RB letter no.
shall issue premium intensive BPC and such rakes will be 2005/M(N)/
formed by all type of air brake freight rolling stock except 951/13 / Pt dtd
BRN, BTPGLN, BLC, BFKN & departmental stock. 31.01.07
BLC rake will be examined on CC basis.
4.0 Close Circuit pattern of examination:
4.1 BOXNHL and BCNHL rakes are examined on CC RB letter no.
pattern with the following condition: 2008/M(N)/
 CC rake of BOXNHL and BCNHL will have validity 951/31 CC
of 7500 Km/ 35 days. Rakes dtd
 Rakes are examined at nominated point. During CC 11.03.10
examination, proper attention to the safety fittings
shall be given and their maintenance records shall
be maintained separately.
 CC examination will be done only at examination
lines in the yard having proper facility of material
handling, concrete pathway, welding, lighting etc.
The CC examination will be done lines on which
there is no OHE.
 CC rake is monitored through FOIS. In case CC
rake is not mad available for examination at the
base depot and offered for examination at some
other depot, it will become non CC rake and it will
follow the normal intensive examination pattern.
 After each loading/unloading, the rake will be
examined by Guard and Driver and observations
recorded on BPC.
 Detail record should be kept for the performance of
the rakes and their condition should be recorded
during every examination.
4.2 CC examination of other air brake freight stock: RB letter no.
 The air brake CC rake shall be offered for periodical 94/M(N)/
maintenance examination (PME) in empty condition 951/57/Vol II/Pt
at the CC depot that formed CC rake originally. dtd 25.10.04
 Rake integrity as listed in BPC should be and para 303 of
maintained. However, upto 4 wagons (for BLC rake CAMTECH
– 5 wagons) may be replaced by good examined Wagon manual.
wagons in the entire run between two PMEs.
 The KMs have been logged in correctly and
continuously.
 The rake is not stabled for more than 24 hrs.
 The rake is running in predefined circuit as
mentioned in BPC.
 After each loading/unloading, the rake will be
examined by Guard and Driver and observations
recorded on BPC.
 All CC freight trains will be given intensive
examination during day light hours.
 BPC of CC rake is valid for 7500 km / 35 days for ‘A’
category points (as notified) and 6000 km/30 days
for other examination point as per JPO issued by
Zonal Railways.
 POH / ROH wagons from CC rakes will be marked
and detached at base depots only.
 CC rake should be preferably formed by off ROH /
POH wagons
4.2.1 BOXN / BCN CC rakes are to be formed at nominated RB letter no.
examination points. 2008/M(N)/
951/13/CC

Page 16 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
rakes dtd
28.10.09
4.2.2 BTPN CC rakes are to be formed at nominated RB letter no.
examination points 2008/M(N)/
951/13/CC
rakes dtd
05.02.10 &
13.07.10
5.0 Attention to be given during intensive examination
(CC/ premium / end to end):
5.1 Adequate gang strength is deployed for intensive Para 313 of
examination: CAMTECH
Air brake (end to end): 56 man-hour Wagon manual
Air brake (CC): 100 man-hour
Premium rake: 66 man-hour CAMTECH
letter no.
IR/CAMTECH.
M.
GWL.Premium
Fr
Dtd 29.05.09
5.2 Rolling-in examination including axle box feeling: Para 305A of
 All terminating trains should be given rolling-in CAMTECH
examination while entering a Station / Yard with a Wagon manual.
train examination depot.
 The following inspection should be carried during
the rolling –in examination:
 In motion inspection and observation of under
gear of wagons for any loose or dangling
components and flat places on tyres / wheels
 After train has come to halt, all boxes should
be felt within 20 mts.
 Examination of any abnormal behaviour of any
of the vehicles or any other observation
which may relate to unsafe working condition.
 The rolling –in examination must be conducted
to detect any skidded wheel.
 In-coming BPC should be collected by Yard
C&W staff.
5.2 Intensive examination and repairs: Para 305 B of
Before undertaking intensive examination, the rake CAMTECH
should be protected at both the ends. The following Wagon manual
examination and repair activities should be carried out:
 Inspection and repairs of running gear fittings.
 Inspection and repairs of brake gear and spring
gears.
 Inspection and repairs of draw and buffing gear.
 Checking and making good the deficiency of safety
fittings, safety bracket, safety loop etc.
 Replacement of brake block on condition basis.
 Correct fitment of washers, bulb cotters and all
brake gear pins to be ensured.
 Correct functioning and positioning of empty load
device.
 Wagon with warm axle box to be detached and
may be taken in sick line for further action.
 Checking and proper securing doors.
 Observe CBC height, wear plate , Knuckle etc by
visual examination. In case of doubt, buffer height
should be measured.

Page 17 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 Check brake cylinders, DV, AR, CR and other pipe
joints to ensure that these are in proper working
order. Isolating cock and angle cock to be checked
for proper position. Brake cylinder should be
released and checked for piston stroke for empty
and loaded condition.
 After brakes are released, the wheel profile should
be examined visually. If any defect is noticed, it
should be checked with tyre defect gauge and
wagon to be marked sick for wheel changing.
 The bogies complete side frames and bolster to be
visually examined for cracks and missing parts,
bolster springs, snubber, spigot, centre pivot
fastening etc to be checked for defects and
attended.
 Examine brake rigging components with special
attention to brake beam deformation and wear on
integral brake shoe bracket. Check puul rod, push
rod with pins, washers, split pins and cotters.
 Hand brake must be checked for smooth and
effective operation.
 Visual examination of under-frame members, body,
door mechanism, CBC wear or deficiency of parts
to be marked and their operation to be checked.
 Brake power should be ensured. (CC – 100%,
Premium end to end – 95 % and end to end
examination – 90 %)
 Where a reject-able defect cannot be attended in
Yard, the wagon shall be damaged for attention in
sick line.
5.3 Issue of Brake Power Certificate: Para 305 C of
 All freight trains after intensive examination will be CAMTECH
given a Brake Power certificate. wagon manual.
 BPC certificate should be printed in different colour
on good quality paper:
 CC rake – Yellow clour.
 Premium rake – Green colour
 Air brake end to end – Green colour.
 BPC should be issued in standard format.
 Originating brake power for air brake rake in CC
shall be 100%
 Originating brake power for premium air brake rake
shall be minimum 95%
 The minimum brake power for air brake freight
train on end to end pattern shall be 90%.
 No fresh BPC shall be issued during re-validation.
 No safe to run BPC issued from nodal point.
 Brake pipe pressure in air brake train with
locomotive should be as follows:
Nos of wagons On On last
locomotive wagon
Upto 56 5.0 Kg/Cm2 4.8
Kg/Cm2
Beyond 56 5.0 Kg/Cm2 4.7
Kg/Cm2

5.4 Important parameters to be ensured during intensive Para 307 of

examination: CAMTECH
wagon manual

Page 18 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
5.4.1 Brake gear limit and clearances:
Description Limit
Brake block cond limit 10 mm
Yard leaving thickness of brake 20 mm
block except BOY
A dimension of air brake stock fitted 70 mm
with CASNUB bogie except BOBRN +2
-0
A dimension of BOBRN wagons 27 mm
+2
-0
5.4.2 Piston stroke:
Types of wagon Piston stroke
Empty Loaded
BOXN, BCN, 85 mm +/- 130 mm +/-
BRN, BTPGLN 10 10
BTPN 87 mm +/- 117 mm +/-
10 10
BOY 90 mm +/- 135 mm +/-
10 10
BOBRN/ 100 mm +/- 110 mm +/-
BOBR 10 10
5.4.3 Buffer Height from Rail Level:

 Maximum 1105 mm (Empty)

 Minimum 1030 mm (Loaded)
6.0 Important parameters to be ensured during Sick line / Para 308 of
Depot attention: CAMTECH
wagon manual
6.1 Nominal clearances of CASNUB bogie: Para 308 C of
CAMTECH
Description 22NLB 22 HS wagon manual
Lateral clearance between 18 mm 25 mm
side frame and bolster
Lateral clearance between 16 mm 16 mm
side frame and axle
box/adopter
Longitudinal clearance 9 mm 9 mm
between side frame and
axle box / adopter
Longitudinal clearance 6 mm 6 mm
between side frame and
bolster
Clearance between anti 4 mm 4 mm
rotation lug and bolster

Page 19 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
6.2 Wear limits Para 308 D of
Adapter thrust shoulder 0.7 mm CAMTECH
Adapter crown lugs 4.0 mm wagon manual
Adapter crown seat 3.5 mm
Adapter side lugs 3.0 mm
Adapter sides 3.0 mm
Side frame column friction plate 4.0 mm
Side frame column sides 5.0 mm
Side frame anti rotation lug 3.0 mm
Pedestal crown roof 5.0 mm
Pedestal crown sides 4.0 mm
Pedestal sides 2.0 mm
Pedestal jaw 4.0 mm
Bolster liner wear limit 5.0 mm
Bolster land surface 3.0 mm
Bolster column sides – Inner / outer 5.0 mm

6.3 Free height and condemning limit for CASNUB bogie Para 308 E of
springs (Outer, Inner and Snubber) are maintained as CAMTECH
recommended in para 308 E wagon manual
6.4 Wear limit for Friction wedge is maintained as Para 308 F of
recommended CAMTECH
wagon manual
6.5 Centre pivot dimension is checked as recommended Para 308 G of
CAMTECH
wagon manual
6.6 Wheels and axles are checked for condemning diameter Para 308 I of
CAMTECH
wagon manual
7.0 Air brake testing facility: Ch 3 of
i) Compressor of adequate capacity to carry out air CAMTECH
brake examinations of rake during intensive Manual for
examination as well as air brake testing of wagon in Wagon
sick line . Pneumatic line is provided with moisture
trap or air-dryer to ensure availability of moisture
free air for air brake testing.
ii) Availability of adequate RTR for air brake testing
during intensive examination and SWTR for air
brake testing in sick line.
8.0 Infrastructure facility for Yard maintenance Ch 3 of
i) Adequate centre to centre distance between tracks CAMTECH
(at least 7..5 mts) for conducting intensive Manual for
examination. Wagon
ii) Concrete pathway from one end to other end.
Material handling facility to ensure movement of CAMTECH
material from one end to other end. report on
iii) Proper illumination for conducting intensive Standardisation
examination. of Infrastructure
iv) Welding facility (Rectifier type) for welding during facilities for
intensive examination. freight stock
v) Adequate outlets for tapping air pressure for testing maintenance
of stock. CAMTECH /
vi) Duty room for maintenance supervisor, compressor 2003/M/NF-
room, store room, tool room, welding machine STD
room for intensive examination. Aug 2003
vii) VHF sets for close monitoring.
Infrastructure facilities for Yard attention to be verified as
per Checklist (Annexure-I) of CAMTECH guidelines for
Standardization of Infrastructure facilities for freight
stock maintenance

Page 20 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
9 Sick line facilities: Infrastructure facilities should be CAMTECH
available as per Table II of CAMTECH guidelines for report on
Standardization of Infrastructure facilities for freight stock Standardisation
maintenance of Infrastructure
facilities for
freight stock
maintenance
CAMTECH /
2003/M/NF-
STD
Aug 2003
10 Analysis of sick marking and yard attention is being -
carried out. Computer facility for such analysis is
available.
11 General housekeeping:
Level of Housekeeping
Overall ambience and working condition
Storage of Wheel sets
Storage of Air brake cylinder, BMBS, AR and other
stores.

12.0 Miscellaneous items for attention as advised by RB

12.1 Corrective and preventive measure to detect hot axle RB letter no.
box cases (potential case of train accident due hot 2005/M(N)/951/
axle breakage) 49 dtd 05.10.11
 Alertness of TXR staff on platforms, station staff,
gateman, signal maintainers etc for detecting hot
axle box case and taking necessary corrective
action.
 Safety poster depicting hot box detection and
immediate follow up should be affixed at all stations,
gate huts, cabins and maintenance depot.
 Ensure practice of box feeling immediately on arrival
of train in examination yard. Measure axle box
temperature with non contact measuring
temperature instrument.
 Care should be taken at wagon depot while handling
wheel sets to avoid any damage to grease seals.
 All cases of hot BOX must be investigated and a
detailed report must be submitted to RDSO.
12.2 Attention for non –functional hand brake: RB letter no.
 RB has advised Railway to take immediate 2012/M(Safety)/
remedial measure to make good non-functional 10/ Misc
hand brake. Inspection dtd
 Action taken by Railway for detecting non 05.10.11
functional hand brake and making good deficiency
in Workshop, ROH depot, Sick-lines and Yard.

12.3 Action taken by Railway on the basis of CRS/NE’s RB letter no.

circle final report: 2012/M(Safety)/
 Para 9.1.1 of CRS report: Railway should carry out 7/1 NCR-II dtd
a drive to check the fitment of hand brake wheel 24.05.12
and its spindle on the wagons. Riveting of spindle
with sleeves should be done wherever deficient in
accordance with RDSO drg no. WD – 09056 – S -
07.
 Para 9.1.2 of CRS report: In addition to riveting,
welding of spindle with sleeve should also be
considered as this item is said to be prone to theft.

Page 21 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Observations
12.4 Fire prevention in BTPN wagon: RB letter no.
Implementation of RDSO guidelines circulated vide letter 2005/M(N)/951/
no MW/BTPN dtd 22.06.12 for fire prevention in BTPN 41 dtd 26.06.12
wagon
12.5 Inspection of depot by Officers / Supervisors RB letter no.
 Inspection of freight depot (sick-line, Yard and ROH 2009 /
depot) is carried out as per RB guidelines: M(safety)/7/2/C
Type of inspection JA SS JS Sup hecklist –
Sick-line 1 2 2 2 inspection dtd
Yard 2 2 3 3 9.09.09
ROH depot 1 1 1 1
Super check of 1 2 4 4
goods rake
Night inspection 1 1 1 2
Office inspection 1 1 1 1
Brake Power Check
(Goods Train)
Qualities of GDR 1 1 2 4
check

 Items during freight examination as per above

schedule are checked as per guidelines laid down
vide RB letter no. 2009 / M(safety)/7/2/Checklist –
inspection dtd 9.09.09

Page 22 of 31 Quality Audit of Wagon Depot

 Annexure-I
CHECKLIST FOR FREIGHT STOCK EXAMINATION POINT
(Ref: CAMTECH guidelines for Standardization of Infrastructure facilities for freight stock maintenance)

Railway : …………. Type of stock :…………………. Type of attention :……………………..

Division:…………… Avg. no. of rakes examined :…………………………………………………..
Availability
SN Item Remarks
Yes No
1 7.5 m center to center distance between two lines
2 Concrete path way
3 Paved road for truck movement
4 Supervisors Room
5 Staff room
6 Rolling in/out huts
7 Field store + Tool room
8 Compressor Room
9 Exhauster room
10 Battery Charging room
11 Tower light
12 Street light along examination lines at two levels
13 Portable rechargeable light
14 Hand lamps
15 Welding line
16 Arc welding set (Mounted on trolley)
17 Portable DG set
18 DG set 250 KVA (for compre3ssor, light and welding)
19 Electric Compressor (500 CFM)
20 Diesel Compressor (500 CFM)
21 Exhauster
22 Gas cutting set
23 Hyd. Cold cutting set/Hand shears
24 Protective clothing with Helmet & Cloves
25 Welding apron & welding glass
26 Pneumatic pipe line (32 mm dia)
27 Rake test rig
28 Hydraulic jacks
29 Wheel barrow
30 Pick up van
31 Truck
32 Lister truck
33 Road mobile crane
34 Hand trolley
35 Portable drill machine 12 mm
36 Drill machine
37 Bending machine
38 Fitter tool box
39 Pressure gauge test stand
40 Folding type portable wheel diameter gauge
41 Rail profile gauge cum recorder in box
42 Wheel distance measuring gauge
43 Buffer height gauge
44 Tyre defect gauge
45 Electronic device/Infra red thermometer for detecting warm box
46 Electric operated hand tools, i.e., Grinder
47 Pocket jack (Hydraulic) 6 tons capacity
48 Hand tools

Page 23 of 31 Quality Audit of Wagon Depot

 Availability
SN Item Remarks
Yes No
49 Storage rack with pigeon holes
50 Rack with locker
51 Plain paper fax with P&T line
52 Walkie Talkie set/Mobile phone
53 Railway Telephone
54 BSNL Telephone
55 Computer with printer, Scanner, UPS with preloaded software & modem
56 C&W Office furniture
57 Railnet / Internet connection
58 Plain paper copier
59 First aid equipment

Page 24 of 31 Quality Audit of Wagon Depot

 Table II
Standard Infrastructural facilities
including M&P for Sick-line Maintenance of freight Stock
(Ref: CAMTECH guidelines for Standardization of Infrastructure facilities for freight stock maintenance)

Major Minor
SN Description Observations
(>250FWU per month) (up to 250 FWU per month)
A INFRASTRUCTURE
1 Covered shed 100mX75mX12m high 100mX75mX12m high Details of
Height of crane should be about Details of layout are shown layout are shown in sketch
10m so that wagon can be lifted in sketch
by EOT crane and moved over
standing wagon to place
anywhere in the bay.
2 SAB repair room 5x16m 5 x16m
3 Air brake & vacuum brake rooms 5x20m
4 Service building (electrical rooms, 5x24m 5x12m
staff room on both sides)
5 Computer room 5x8m 5x7m
6 Store room + sub store + tool 5x26m 5x15m
room
7 Machine shop 5x20m 5x8m
8 Battery room for charging 5x7m 5x3m
lister/jumbo truck
9 Compressor room+ Exhauster 5x12m 5x9m
room
10 Office & SSE/SE/JE rooms 5x16m 5x5m
11 Sections for attention to various 5x44m 5x18m
items as detailed in layout
12 Room for DG set At suitable location removed from main shed too contd. noise
interference
13 Total lines required Six lines under covered Two lines under covered shed
shed and one line each out and one linie each out of covered
of covered shed for wheels shed for wheel and turn around.
& turn around.
14 Pit line One pit 20m long (at one end only) on each line depth 960mm
from rail level with adequate drainage.

15 Distance between two lines 10 meters

16 Pathway between the lines Heavy duty concrete

B LIGHTING
1 Tower light Six tower lights per sick line Four tower lights per sick line
with adequate height with adequate height
2 Street light along examination One row per examination line covering both sides having proper
lines illumination specially covering bogies and brake gear locations.
The lights should be at two levers (lower lever for under gear and
upper lever for body)
3 Lighting in the shed and sections Refer to Annexure III on illumination
C MACHINERY & PLANT

1 EOT cranes 15T/5t 4 2

2 EOT crane 10T/3T 2 -
3 Road crane 10T capacity 1 1
4 Jib crane 2.5T 2 2
5 Electrical stationary screw air 2 1
compressor complete with air
receiver 15m3/Min (500CFM)
required for testing of air brake

Page 25 of 31 Quality Audit of Wagon Depot

 Major Minor
SN Description Observations
(>250FWU per month) (up to 250 FWU per month)
wagons.
6 Exhaust (required for testing of
vacuum brake wagons)
7 Turn table for wheel sets As per lay out
8 Trestles 12 sets 06 sets
9 Hydraulic pipe bending machine 1 -
10 Heavy duty shaping machine 1 -
11 Centre lathe 12 1/2” capacity 1 -
12 Radial drilling machine 1 1
13 Centre lathe 6” capacity 1 -
14 Bench drilling machine 1 1
15 Heavy duty pedestal grinder 1 -
double ended
16 Shearing machine 6mmx2200mm 1 1
wide (required to make patches
for body work)
17 Battery charger (required for 1 1
charging batteries of fork lifter
lister, truck and ot1h1er vehicles)
18 Weighing machine 500 kg (for 1 1
scrap disposal)
19 DG set (required to run air 1 no.(500 KVA) 1no.(350 KVA)
compressor welding machine and
for lighting in case of power
failure)
20 Gas cutting equipment 8 4
21 Work station for bogie repair 10 1
22 Fixture for riveting spring plank 2 -
23 Welding machines 10 6
24 Winches 3 1
25 Bogie manipulators 3 -
26 Pipe line for air 32 mm dia As per layout
27 CO2 welding machine 2 -
28 Rail cum road vehicle 1 -
29 Fork lifter 3T 4 1
30 Truck 10T capacity 2 1
31 Tractor with hydraulic lifting 1 -
machine & 3 trolleys (trailers)
32 Platform, truck 2T 2 1
33 Light store vehicle 1 1
34 Hand trolleys with rubber wheels 10 6
D TOOLS & EQUIPMENT
1 Portable hydraulic riveter 1 1
2 Store bin 20 15
3 Portable electric grinder 3 2
4 CBC & draft gear replacement 1 -
5 SAB test bench 1 -
6 Hydraulic jacks 15 t 8
7 Set of special spring spanners. 4sets 2sets
Box spanners. Torque spanners
8 Bottle jacks 8
9 Pneumatic/electrical hand tools As per requirement
10 Gauges & instruments As per lay out
11 single wagon test rig 1 no. per 8 wagons per day
12 DV test stand 2 1
13 Hand tools As per requirement
14 Pneumatic torque wrench with 4 sets 2sets
sockets 1” to 2”

Page 26 of 31 Quality Audit of Wagon Depot

 Major Minor
SN Description Observations
(>250FWU per month) (up to 250 FWU per month)
15 Ultrasonic leak detector for tank 1 1
wagons
16 Pressure & vacuum gauge dead 2 1
weight tester
E MISCLLEANEOUS
1 Water cooler 3 1
2 Floor cleaning machine 2 1
3 Fitter Lockers As per requirement
4 Fax with P&T line 1 -
5 Fast aid equipment 4sets 2sets
6 Photo copier 1 1
7 VHF sets mobile phone 10sets 6sets
8 Storage racks As per requirement

Page 27 of 31 Quality Audit of Wagon Depot

 Quality audit check-sheet with regard to maintenance of
Stainless Steel Wagon (BOXNHL / BCNHL/BRN22.9)

(Based on Chapter 3 of CAMTECH Maintenance Manual for Wagon

and CAMTECH Guidelines for maintenance of Stainless Steel Wagons circulated vide
CAMTECH.M/W/SS/Wagon – 1.0 Dec’09 )

SN Requirements Clause Remarks

1.0 Facilities required for maintenance of Stainless Steel Wagons: Para 2.0 of
ROH CAMTECH
Freight guidelines
Sick line (200
Yard for
SN Items (5 wagons
(3 rakes /
Wagons/day) / maintenance
day)
Month) of SS
MIG/MAG wagons
1 welding sets 02 Nos 02 Nos 03 Nos
(400 Amp)
DC Arc
Welding
2 02 Nos 02 Nos 03 Nos
Rectifier
(600 Amp)
Portable Air
Plasma
cutting
3 machine 02 Nos 02 Nos 03 Nos
(max
capacity 16
mm)
Consumables
4 for air plasma As per requirement
M/s
Welding
electrodes
5 As per requirement
(Class D &
Class M2)
Huck Bolts of
6 As per requirement
various sizes
Lock bolts
7 2 sets 2 sets 3 Sets
equipment
Portable
8 grinding 03 Nos 03 nso 05 Nos
machine)
SS wire
9 As per requirement
brush
SS (IRS M44
10 As per requirement
plates)
2.0 Equipments for Lock Bolt installation, air plasma cutting machine, DC Para 3 of
arc welding rectifier should be procured as per Specification laid down CAMTECH
in CAMTECH guidelines guidelines
for
maintenance
of SS
wagons
3.0 Welders are qualified for welding of SS to SS and SS to Mild steel -do-
4.0 Qualified personnel are available to carry out lock bolting, -do-
5.0 Sick line has facility for EOT cranes with covered area Ch 3 of
CAMTECH
Manual for

Page 28 of 31 Quality Audit of Wagon Depot

SN Requirements Clause Remarks
Wagon
6.0 Air brake testing facility: Ch 3 of
iii) Compressor of adequate capacity to carry out air brake CAMTECH
examinations of rake during intensive examination as well as air Manual for
brake testing of wagon in sick line . Pneumatic line is provided Wagon
with moisture trap or air-dryer to ensure availability of moisture
free air for air brake testing.
iv) Availability of adequate RTR for air brake testing during
intensive examination and SWTR for air brake testing in sick
line.
7.0 Infrastructure facility for Yard maintenance Ch 3 of
viii) Adequate centre to centre distance between tracks (at least 7.5 CAMTECH
mts) for conducting intensive examination. Manual for
ix) Concrete pathway from one end to other end. Material handling Wagon
facility to ensure movement of material from one end to other
end.
x) Proper illumination for conducting intensive examination.
xi) Welding facility (Rectifier type) for welding during intensive
examination.
xii) Adequate outlets for tapping air pressure for testing of stock.
xiii) Duty room for maintenance supervisor, compressor room, store
room, tool room, welding machine room for intensive
examination.
xiv) VHF sets for close monitoring.
Infrastructure facilities for Yard attention to be checked as per
Annexure – I of CAMTECH report for infrastructure facilities
8.0 Other facilities and M&P’s: Ch 3 of
i. Wheel diameter measuring gauge. CAMTECH
ii. Wheel gauge. Manual for
iii. Transportation facility for wheel sets and CTRBs. Wagon
iv. Availability of general tools for maintenance (Wrenches,
hammer, chisel, anvil etc).
v. Wheel defect gauge.
vi. Gauges for measuring ‘A” dimension & piston stroke.
vii. Electrodes heating chamber.
9.0 Analysis of sick marking and yard attention is being carried out. -
Computer facility for such analysis is available.
10.0 Supervisors and staffs are trained with regard to following: -
 Air brake testing of conventional BOXNHL / BCNHL stock as
well as BOXNHL –MBS stock
 Construction details of BOXNHL / BCNHL for yard examination
and attention as well as sick line attention.
 Huck bolting process for attention at Yard / Sick line.
 MIG / MAG welding process / MMAW welding process for SS
welding.
 Plasma cutting of SS sheets.
 Attention of BOXNHL / BCNHL door
11.0 Procurement of stores for maintenance of SS wagon
(BOXNHL/BCNHL)
i) List of stock items.
ii) List of non stock items.
iii) Storage facility with covered area for critical stores.
iv) Maintenance of ledger and consumption for last two years and
current year.
Spares to be procured as stock items include items required for
regular consumption of rolling stock.

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SN Requirements Clause Remarks
12.0 General housekeeping:
Level of Housekeeping
Overall ambience and working condition
Storage of Wheel sets
Storage of Air brake cylinder, BMBS, AR and other stores.

Page 30 of 31 Quality Audit of Wagon Depot

 Depot details
Depot name:

Division and Railway:

Activities carried out:

SN Description Observations
1 ROH outturn per month (Av of last one year in VU)
2. Nos of CC rake running in service with brake up of formation (Rake type wise)
3 Average examination per day (CC/ Premium/ end to end)
4 Average yard detachment per rake (Av of last one year)
4.1 In CC rake
4.2 In premium rake
4.3 In end to end examined rake
5. Sick line outrun per month (Av of last one in VU)
6 Training of welders for MMAW / MIG welding
7 Training of staff in Oxy cutting
8 Training of staff in Plasma cutting
9 Availability of critical and safety stores
10 Whether a dedicated store officer is nominated for urgent procurement
11 Sanctioned imprest value of depot officer
12 Whether depot is ISO 9001 certified
13 Availability and display of work instruction in ROH depot /sick-line / yard
14 Overdue refresher course of technician
15 Record keeping:
a) ROH attention - Causes of replacement/rejection of components
replaced/rejected during ROH are to be recorded in a separate register.
Assessment of monthly consumption and trend of failure can be done by
analyzing these records.
b) Record for Yard attention with regard to manpower deployment, damage
deficiency register, consumption of stores etc.
c) Record for sick-line attention stock-wise with man-hour utilization and
consumption of stores

Page 31 of 31 Quality Audit of Wagon Depot