INDIAN RAILWAYS

G-33 (Rev. 2)

TECHNICAL PAMPHLET

FOR

REQUIREMENTS OF TIPPLER INSTALLATION

FOR APPROVAL BY RDSO

Month/Year of Revision /
S.No. Page No. Reason for Amendment
issue Amendment
1. May, 2010 Revision 1 - First issue
2. Revision 2 - Second issue

ISSUED BY

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS
LUCKNOW-226 011

………, 2022 Rs.-……./=

Page 1 of 17
 CONTENTS

Clause No. Description Page No

1.0 Scope
2.0 General
3.0 Particular requirements/Design stipulations
3.1 Design parameters
3.2 Technical requirements
3.3 Safety requirements
3.4 Positioning system for wagon
3.5 Train & wagon holding devices
3.6 Eligibility criteria/Requirements for RDSO’s approval
for tippler installation
3.7 Acceptance/approval process
4.0 Testing
5.0 Inspection/ Check sheet for joint inspection

ANNEXURES
Annexure 1 Format of approval certificate

Annexure 2 Schematic diagram for tippler (G-33-2008)

Annexure 3 Schematic diagram for BOY wagon

Annexure 4 Schematic diagram for BOXC wagon

Annexure 5 Schematic diagram for BOXN/BOXNHS wagon

Annexure 6 Schematic diagram for BOXNLW wagon

Annexure 7 Schematic diagram for BOXNHL wagon

Annexure 8 Schematic diagram for BOYEL wagon

Annexure 9 Schematic diagram for BOXNEL wagon

Annexure 10 Schematic diagram for BOXNS wagon

Annexure 11 Schematic diagram for BOXNHA wagon

Annexure 12 Schematic diagram for BOST /BOSTHS wagon

Annexure 13 Schematic diagram for BOXNR/BOXNRHS wagon

Annexure 14 Conceptual diagram for 25t axle load Iron ore wagon for DFC

Annexure 15 Conceptual diagram for 25t axle load Coal wagon for DFC

Annexure 16 Conceptual diagram for 32.5t axle load Iron ore wagon for DFC

Annexure 17 Conceptual diagram for 32.5t axle load Coal wagon for DFC

Annexure 18 Proposed “Maximum Moving Dimension” of Diesel locomotive

for DFC

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1.0 Scope

1.1 This document provides guidelines for selection of tipplers for BG open
Railway wagons of
a. Current design
b. Wagon designs, of 25t axle load, for existing routes
c. Proposed wagon designs, of 32.5t & 25t axle load, for DFC &
Feeder routes
d. Proposed wagon design with rotary coupler

1.2 This document also gives the basic requirements to be met for obtaining
RDSO’s approval for installation.

1.3 Codal life of wagon tippler shall be 20 years from the date of commissioning.

2.0 General

2.1 The existing population of open wagons in the Indian Railways consist of
BOY, BOYEL, BOX, BOXN, BOXNHA, BOXNLW, BOXNHL, BOXNEL
and BOXNS wagons, of which BOXN wagons form the bulk.

2.2 New designs for open wagons for coal and iron ore for DFC & Feeder routes
are also under consideration & conceptual diagrams have been developed.

2.4 Conceptual Diagrams and other details of these wagons (both 25t & 32.5t axle
load) are covered in the annexure.

2.5 These wagons are suitable for transporting coal, ore, lime stone etc., hence
while planning for mechanised unloading, the parameters of these types of
wagons should be taken into consideration.

2.6 For handling of any other special type of wagons, the purchaser should take
into consideration the size & gross weight of the wagons or intimate the same
to RDSO.

2.7 Introduction of new type of freight wagons is a continuous process. Hence,

limiting boundary dimensions should be taken into consideration while
planning a tippler. The limiting boundary dimensions are indicated in the item
3.6.4 (g).

3.0 Particulars requirements/Design stipulations

3.1 Design parameters

3.1.1 These guidelines shall be applicable for both Side discharge and Rotary type
wagon Tipplers.

3.1.2 Single wagon tippler shall be designed for handling a gross load of 140t,
taking into consideration a 4-axle bogie wagon with an axle load of 32.5t plus
the overloading caused due to variable density of the bulk material and heap
loading of the wagon. For tippling two or more wagons at a time, the capacity
parameters will increase proportionately.

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3.1.3 Wagon tippler shall be designed/ capable for handling of wagons with existing
coupler OR wagons with rotary coupler and existing coupler both as per the
purchaser requirement.

3.1.4 The tippler shall be capable of handling either one or more open wagons of
BOXNHL length i.e. 10.963 m over couplers. The minimum length of the
tippler table should 10.963 m or in multiples thereof, depending on the nos. of
wagons to be tippled. When two or more wagons are tipped simultaneously,
the wagons should be in coupled position.

3.1.5 However, wherever, older BOXC/BOST/BOSTHS wagons have to be tippled

(user shall have to consult the concerned zonal railway for this confirmation),
the minimum length of the tippler table shall be at least 13.729m.

3.1.6 Additional extension piece may be utilized for tippling of iron ore wagons (i.e.
BOY wagon variants), to compensate for their less height of the wagon, as in
the existing tipplers.

3.1.7 Where a locomotive is required to pass over or stand on the tippler, the tippler
shall be able to bear the load of the locomotive without sustaining any
permanent deformation. The clearance diagrams for the diesel loco is indicated
vide Annexure -18. For electric loco, a bypass track to be provided parallel to
the wagon tipplers

3.2 Technical requirements

3.2.1 The design and construction of components of tipplers and auxiliary handling
equipment coming into contact with any part of wagon shall be such that no
damage whatsoever is caused to the wagon equipment or its paint.

3.2.2 The top clamping pressure shall be such as will hold the wagons firmly in
position on rails and keep the running gear from getting dislodged without
causing any deformation to the wagon structure.

3.2.3 Adequate compensating measures shall be taken in top clamps and side
support beam to compensate for manufacturing imperfections, within the
permissible limits, in the top copings and side stanchions of the wagon, so that
clamping pressure on the contacting area on the side and top of the wagon is
uniformly distributed.

3.2.4 The side supports for tipplers shall meet the following requirements:

a) The side support shall consist of a longitudinal beam, which shall be as

long as the longest wagon to be tippled. This beam shall be
continuous.

b) The side support shall be articulated so that it can take the tapered as
well as parallel stanchions on the body of the wagons. Alternatively,
the cradle shall be articulated on trunion to achieve this.

c) Full-face contact between the side support beam and the side
stanchions shall be ensured. The side supports shall extend from a
height of 1000 mm up to 2950mm, from rail level, i.e. contact the side
of the wagon over a width of not less than 1950mm. [For wagons of
height less than 2950mm, typically iron ore wagons, (user shall have to

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 consult the concerned zonal railway for this confirmation) suitable
slots shall be provided in the side support beam, to permit the top
clamping of the wagons] There shall be metal to metal contact
between the side support beam and the side stanchions of the
wagon i.e. no rubber pad or any other alternative, shall be provided on
the contact face of the side support beam

d) The side support beam shall be moveable type, the movement being
done by hydraulic arrangement. (No external or moveable counter
weights should be used with the side support beam) Facility of
forward/ backward movement should exist, such that it should be able
to move & touch the wagon without applying any pressure on the
wagon side-wall. At this position it should get locked and the tilting
operation can begin. At the end of the tippling cycle, the side support
should return to its home position, so that the next wagon can be
positioned on the tippler
Movement of the side support should be controlled & the speed should
be crawling just before making contact with the wagon sidewall.

e) Pressure gauge/s should be mounted, at easily accessible location, for

reading the hydraulic pressure of the side support hydraulic
arrangement.

3.2.5 The top clamping arrangement shall conform to the following requirements.

a. The top clamping of the wagon shall be done through hydraulically

locked top clamps. No external or moveable counter weights should be
used with the hydraulic clamps.

b. Top clamps should engage when the wagon tilts by more than 15
degree. Top clamp locks should include a wagon bogie spring relief
mechanism for permitting release of bogie springs. Top clamps
should exert the bare minimum pressure on the top coping of the
wagon, so as to just keep it in position. The pressure exerted by the top
clamps at the tilt angle of 160 degrees should be just enough to bear
the weight of the empty wagon, which should be achieved through the
bogie spring relief mechanism, incorporated in the tipplers design.

c. Pressure gauge/s should be mounted, at easily accessible location, for

reading the hydraulic pressure of the top clamping hydraulic
arrangement.

d. The top clamping arrangement shall be of longitudinal/ transverse type

and provided with self-aligning feature, whereby the load is borne on
the top at each of the wagons.
i. The transverse type top clamping shall have 6 nos. transverse
top clamping beams i.e. the bearing face of the beam shall
contact the top of the wagon at 12 locations (six on each side).
Each of the six top hydraulic clamps shall be individually
articulated, to ensure firm clamping of wagon at every gripping
point. The location of the clamping pads shall be as under:

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 ii. The longitudinal type top clamping shall be such that the
clamping pads cover the full length of wagon top coping.
Each top hydraulic clamp shall be individually articulated, to
ensure firm clamping of wagon at every gripping point.

f. The beam shall be so arranged that the discharge of the contents of the
wagon is not impeded to any appreciable extent.

g. Each bearing face shall contact the top of the wagon over a width of
not less than 250 mm and shall be provided with rubber pads or
suitable alternative not less than 50 mm thick. The shore hardness of
the rubber pad should not be less than 70A.

h. The total force between the wagon tops and supporting beam shall be
not more than is necessary to ensure retention of the wagon and
engagement of wagon wheels with the rails of the tippler throughout
the tippling cycle.

i. The design of the appliance shall take account of the nature of the
material to be discharged, bearing in mind the maximum lump size,
moisture content, possible climatic conditions and other influencing
factors.

3.2.6 Devices shall be built-in for spotting of wagons on the tippler table, so as to
discharge the material in hoppers.

3.2.7 Size and gauge of rails on the wagon tippler platform shall be as per railway
specifications taking into considerations the maximum duty condition that the
wagon tippler has to undergo in field operation.

3.2.8 If so specified by the purchaser, integrated weigh bridges, load cell type or
mechanical type, conforming to relevant Indian Standard shall be provided on
the tippler to weigh the gross and tare weight of wagons which are being
handled. There may also be a provision to record gross load, tare load, date
and number of wagons.

3.2.9 Marking - All tipplers shall be marked permanently and legibly at a clearly
visible place with the name of the manufacturer, serial number, the year of
manufacture, type and capacity of tippler and RDSO allotted Serial No.

3.3 Safety requirements – Notwithstanding anything contained in various

statutory regulations, safety requirements for tipplers, divided into the
following three stages, shall be followed:

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3.3.1 Construction stage

a. The design of the tippler shall avoid, as far as possible, any spillage of
the material handled by the wagons.
b. Devices shall be built-in to prevent any over run of the wagons in
either direction.
c. The tippler shall be designed so that the wagon is securely held in all
operating positions.
d. Automatic devices shall be provided to hold the tipplers securely in
any position in the event of failure of the drive unit.
e. All tipplers shall have means to limit the angle of tippling.
f. Arrangement shall be made on tipplers to prevent feet being trapped
between the platform and the base of the tippler.
g. Whenever possible mechanical or electrical devices shall be built-in to
ensure that all the conditions allowing wagon tipping are coordinated.
h. Additionally, a device shall be provided to prevent an empty wagon
from being released until the tippler is back in original position.
i. A device shall be provided to prevent the entry of a non-scheduled
wagon into a tippler.
j. Sharp edges and corners in all working spaces shall be avoided.
k. The parts projecting into working spaces shall be as small as possible.
l. All the frequently used lubrication points shall be accessible without it
being necessary to remove the guards.
m. It is recommended that equipment shall be so designed that
maintenance and cleaning is facilitated.
n. Fully integrated controls should be provided for wagon positioning
system, wagon holding devices and wagon tippler. The controls should
be interlocked so that there is no chance of accident due to error in
sequence of operation.

3.3.2 Installation stage

a. All tippler installations shall be marked permanently and legibly in a

clearly visible place, with the following information:

i) Maximum capacity of the wagons & the type of wagons to be

tippled.
ii) If locomotives are required to run over the tippler, the maximum
permissible mass, maximum permissible axle loading and speed.
iii) Maximum speed of the wagon passing through the tippler and
iv) An instruction forbidding the tippler to be operated as long as the
wagon is not held on the platform in its tippling position. This
instruction shall also state that the tippler shall be held in
appropriate position before an attempt is made to remove the empty
wagon.

b. The emergency stop controls shall be provided adjacent to the wagon

tipplers in the readily accessible positions.

c. Frequently used lubrication points shall be accessible without being

necessary to remove guards and shall be painted to standard pattern.

d. All starting and stopping devices shall be clearly indicated and easily
accessible and shall be painted or printed as a standard pattern.

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 e. Gangways, handrails, staircases, ladders, guards, etc. wherever
provided shall be erected before installation is put into service.

f. The outhaul side track should satisfy the following conditions:

 The gradient of the outhaul track should not exceed “1 in 1200”
 The length of the outhaul track, with the specified gradient, is
not less than 650 m for full rake tippling.
 For partial rake tippling (not less than the half rake),
proportionate track length (equal to the half the rake length or
more) with track gradient not exceeding “1 in 1200” will be
permitted.
 In case of limitation of adequate track length on the outhaul
side, as specified above, the user can consider use of transfer
platform for shifting the empty wagons, on a parallel track.
This parallel track shall satisfy the same conditions of gradient
as listed out above.
 It should be certified that the length & the gradient of the
outhaul track is within the limits, as per above, by the
competent railway authority, under whose jurisdiction the
tippler location lies. The same certificate should be submitted
to this office, along with other documents, at the time of
approval by the firm/user.

3.3.3 Utilization stage

a. The inspection, adjustment, maintenance and cleaning of moving

components and of cleaning devices shall be carried out regularly
according to the manufacturer’s instructions.
b. No person, other than a qualified and competent person so authorized
shall operate the tippler.
c. Normal and emergency stopping devices shall be made known to all
personnel and be easily accessible. All areas giving access to them
shall be kept clear of obstacles.
d. All restarting operations on tipplers which have been in operative
because of an emergency of accidental stoppage shall be preceded by
an inspection aiming at:
i) Determining the cause of the emergency or accidental stoppage
ii) Repairing the fault
e. If so specified by the purchaser, a dust collection system shall be
installed at the tippler.
f. IP based CCTV system shall be installed in such a way that total area
of unloading is clearly visible. This system shall also be accessible by
railway authorities for monitoring purpose.
g. ROH/POH/Overhauling of wagon tippler shall be done preferably by
OEM or by its nominated representative or by any mutually (OEM &
End user) agreed mechanism for proper upkeep of Tippler.

3.4 Positioning system for wagon

Wagon tipplers shall be provided with side arm charger for positioning of
wagons on the tipplers OR any suitable arrangement to position the wagon in
case of wagon tippler being capable of handling both type of wagons i.e.
wagon with existing coupler and wagon with rotary coupler, such that

Page 8 of 17
 a. Side arm charger should be of sufficient capacity, depending on
whether complete train or some wagons are to be moved / positioned.
There should be some positive system for centering of wagon on
the tippler table.

b. Drive unit for the side arm charger should be of positive type e.g. rack
& pinion, so that sudden jerks/slippages are avoided. Suitable
technology should be used, so that the wagon can be moved at slow
speeds for placement on tippler table e.g. Low speed hydraulic motors,
Variable frequency AC motors or thyrister controlled DC motors
(through epicyclical reduction gearing), etc.

c. Charger should be able to slow down to creeping speed just before the
final positioning

3.5 Wagon & Train holding devices

3.5.1 Wheel grippers

a. These are mandatory & should be located on the tippler table, to

prevent inadvertent motion of the wagons during tippling operation.

b. These should be so designed that balanced pressure is applied on both

sides of the wheel rim. It should have a floating arrangement so as to
ensure that force on each gripper is same and should have some lateral
float so that it can take a new position in case of variation in wheel
gauge. Wheel grippers should be free from serrations or any such
provision on its holding face. Wheel grippers should be made of soft
material.

3.5.2 Retractable wheel chocks

a. These are mandatory & should be fitted at the in-haul & out –haul
tracks, to prevent accidental rolling of the wagons on the tippler table.
b. They should be so designed that flange of the wheel is not contacted
while blocking tread of the wheel. Shape of the chock should take into
account the wheel incline, so that a line contact is made with the
wheel.

3.6 Eligibility Criteria/Requirements for RDSO’s approval for tippler

installation

3.6.1 The wagon tippler manufacturer shall be required to keep in mind all design
requirements when they will planned to design the wagon tippler.
3.6.2 Manufacturers shall be required to submit all required documents for further
approval.

3.6.3 List of documents to be supplied to RDSO

a. Name of the manufacturer.

b. Name of the user & site of installation.
c. Number of tipplers to be supplied / installed & their model no., if any.
d. Capability of tippler-Capable with Wagon with existing coupler OR
Capable with Wagon with Rotary coupler & Existing coupler both.
e. Nearest railhead.

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 f. Commodity to be handled.
g. Site layout drawings (duly approved by the railways)
h. General arrangement drawings of tippler, clearly showing side support
beam and top clamp with dimensions.
i. Certificate, that the length & the gradient of the outhaul track is within
the limits [as per clause 3.3.2(f)], by the competent railway authority,
under whose jurisdiction the tippler location lies. The same certificate
should be submitted to this office, along with the other documents.
j. The maximum dimensions of the wagons that can be handled on the
tippler should also be indicated.
k. The clamping forces per pad achieved and the clamping angle for
different types of wagons. Calculations of the clamping force shall be
furnished separately for the all the type of open wagons, which will be
tippled. (User shall have to consult the concerned zonal railway for this
confirmation and submit a copy of the same to RDSO.)
l. Suitability of tippler for accepting locomotives weighing up to
140t, at a speed of 8 kmph
m. Capacity of the tipplers.
i. Maximum height of the wagon that can be handled.
ii. Number of tips per hour.
n. Sketch showing location of clamps with respect to centre-line of the
tippler.
o. Details of side arm charger to be used for placement of wagons on the
tippler.
p. Complete maintenance instructions manual should be supplied along
with trouble shooting, preventive maintenance and periodical
inspection for different components of the tippler for its proper
functioning.
q. Force, pressure and moment calculations at 90 degree and 150 degree
of rotation for the wagons to be tipped, as mentioned above.
r. Pressure calculations on top coping and side stiffener at various angles
of rotation as given above. Moment on side stiffener and wheel flange
with respect to centreline of bogie pivots.
s. Checklist of items as shown in a indicative sketch No. G-33-2000 and
their details & type, namely
i. Side arm Charger
ii. Top clamps, hydraulically operated
iii. Movable side support beam, hydraulically operated
iv. Wagon holding device.
t. Filled GST invoice form for consultancy charges and payment to be
made through online on RDSO web page.

3.6.4 List of conditions for tipplers

a. Minimum 50 mm thick rubber lining on top clamp pads shall be

provided. The shore hardness of the rubber pads shall be at least 70A.
b. Max. Angle of rotation should not exceed 160 degree for side
discharge tippler.
c. The tippler shall have the capacity to tip at least 25 wagons per
hour i.e. 25 tips per hour (For tippling two or more wagons at a time,
the capacity parameters will increase proportionately), with suitable
provisions so that the wagon is not damaged in the tippling
process. If the client desires lesser numbers of tips, concurrence of
the concerned railway shall be obtained.

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d. The forces exerted by the top clamps of the tipplers on wagon copings
shall not exceed 1.5t per clamp pad. This shall be ensured by
providing some positive arrangement, other than provision of
rubber pads, for absorbing the clamping forces (permitting release
of bogie springs). The rubber pads on the clamps are to be provided
to take care of constructional undulations of wagon copings.
e. The length & the gradient of the outhaul track are within the limits as
per clause 3.3.2(f).
f. The location of the top clamp pads on the tippler should be as indicated
below:

g. The tipplers shall be capable of handling wagons with the following

overall measurements without heavily impacting the wagons during the
course of tippling.
i. Width : 3130 mm to 3660 mm
ii. Height* : 3160mm to 4000 mm
iii. Length over # : min. 10963 mm (or in multiples thereof for
coupler faces simultaneous tipping of two or more wagons)

Note: ‘*’ – This range is true for coal wagons. However, the height
requirement for iron ore wagons is lesser, range being
2393mm to 2650mm.
‘#’ – For tipping of older BOXC/BOST/BOSTHS wagons, the
minimum rail table length will be 13.729m
h. The tippler shall be capable of handling a single wagon of up to 140t
(gross). For tippling two or more wagons at a time, the capacity will
increase proportionately.
i. No tippler/handling equipment component should protrude more than
100 mm from the rail level within the rails.
j. The tippler shall have such parking/arrangement as would facilitate
placement of wagon centrally on the tippler table.
k. After installation and commissioning of the tippler, Sr.DME of the
concerned Division, Railway shall certify it safe for the operation.
l. Operation of the tippler shall be suspended on request of the Sr.DME
of the concerned Division in case of its causing damage to the wagons
and not meeting any of the above conditions and requiring
maintenance.
m. Sr. DME of the concerned Railway Division or his representative may
inspect the Tippler and its operation, whenever such a need is felt, or
may depute Railway staff permanently for inspection of wagons after
each tipping. The entire cost of inspection and attention to the wagons
shall be borne by the owner of the tippler.
n. It shall entirely be the responsibility of the owner for ensuring that no
damage whatsoever is caused to the wagons during handling on the
tippler. The owner shall guarantee to pay to the Railway the
rectification charges in case of any damage to the wagons.

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 o. The approval for operation of tippler is subject to withdrawal at any
time in event of owner’s failure to ensure handling of wagons without
damage.
p. Owner/User or his representative shall submit a certificate to Sr. DME
of the concerned Rly/Division in the prescribed format that the tippler
is in good working condition, once in every six months.

3.7 Acceptance/approval process

3.7.1 For Indian Manufactures

3.7.1.1 Any Indian manufacturers shall apply to RDSO for model/type approval of
wagon tippler on the basis of actual installation of the new tippler and the
design shall be approved compliant to safety requirements as laid out in this
specification in real terms on site.
3.7.1.2 On receipt of application and documents submitted by the manufacturer
shall be scrutinized by RDSO. If the information submitted by the firm
found to be inadequate firm shall be intimated for necessary compliance.
After compliance of the design and safety requirements, design and
working verification shall be conducted in real terms on site. On the basis
of successful trial, tippler operation shall be permitted provisionally under
close watch of concerned Railways.
3.7.1.3 After six months, an approval in the proforma of annexure-1 of this
specification shall be issued as a type/model approval for the firm’s
conceptual model design of wagon tippler.
3.7.1.4 All subsequent installations of identical design will be covered by the
type/model approval, subject to location specific approvals by the
concerned Zonal Railway and RDSO need not be approached for case-by-
case tippler design approvals for identical tipplers.
3.7.1.5 The approval extends only to items covered therein and certificate is not
valid for equipment, the design, ratings or operating parameters of which
have been varied from the specimen tested.
3.7.1.6 The manufacturer should notify RDSO of any modification or changes to
the equipment in order to obtain a valid certificate.

3.7.2 For other than Indian Manufactures

3.7.2.1 All other manufacturers shall apply to RDSO for specific one time approval
of wagon tippler on the basis of actual installation of the new tippler and
the design shall be approved compliant to safety requirements as laid out in
this specification in real terms on site.
3.7.2.2 On receipt of application and documents submitted by the manufacturer
shall be scrutinized by RDSO. If the information submitted by the firm
found to be inadequate firm shall be intimated for necessary compliance.
After compliance of the design and safety requirements, design and
working verification shall be conducted in real terms on site. On the basis
of successful trial, an approval in the proforma of annexure-1 of this
specification shall be issued as a provisional approval for the firm’s specific
design of wagon tippler.

4.0 Testing

4.1 Design and working verification shall be conducted compliant to safety

requirements as laid out in this specification in real terms on site.

Page 12 of 17
5.0 Check sheet for joint inspection

Check sheet for joint inspections of the tipplers (frequency of such joint
inspection should not be more than six months) to conduct by DME/Sr.
DME (C&W) of the concerned division or his authorised representative
and representative of the siding owner, as per Railway Board letter
no.98/M (N)/951/12 dated 27.11.02, is as follows:

SN Item Check Remark

1 End frame (i) Steel work to be examined for
platform side damage or defects
(ii)
beam Check & record the gap between
the side beam and the wagon side
stanchion, during tipping operation.
2 Drive gear (i) Check proper matching of rack and
pinion tooth & tooth wear
(ii)
Check whether coupling gives jerk
during rotation. The tippling
operation should be smooth &
without any jerks
3 Top hydraulic (i) Check the level of clamp pad.
clamp Whether sitting properly or not.
(ii)
Check the condition & thickness of
clamp pad (thickness should not be
(iii) less than 50 mm)
Check the smoothness of clamp
(iv) movement
Check for provision of indicators
on the tippler table for all types of
wagon stock, which are likely to be
tippled on the tippler. This is to
ensure that wagons are placed on
the tippler table in such a manner
that the top clamping pads position
(v)
is near the side stanchions.
Force exerted by the top clamps
(vi) should not exceed 1.5t per clamp
pad. Check & record the value.
Check for provision of a wagon
bogie spring relief mechanism in
the top clamp locks for permitting
release of bogie springs.
4 Rail table of (i) Check the level and alignment of
wagon tippler rail. The level of track on tippler
table and that of approach rails
should be the same so that the
wagons do not experience any jerk
during in-haul and out-haul
5 Limit switches (i) Check for proper function
6 In haul & out (i) Check satisfactory working of stop
haul stop movement
(ii)
linkage Check the gradient on the outhaul
side
7 Side arm (i) Check damage / defects of steel
charger* work
Page 13 of 17
 Check proper matching of drive
(ii) pinion & rack & tooth wear
(iii)
Check the smooth movement and
final position of arm hoist
(iv) Check the proper tightening of
fastener & condition of track
(v) Check for proper functioning of
limit switches & proximity
switches
8 Damages to (i) Damages during tippling & post
wagons tippling damages:
 Dents/nick on the side
stanchions, top copings,
wagon body, etc
 Displacement of bogie
pivot or suspension springs
 Damages to air brake pipes
 Axle box adopter shifting
 Coupler damages
 Any other

*Note: (1) There should not be any loose shunting of the wagons. In-haul and
out-haul arrangements consisting of side arm charger should be used
for placement and removal of wagon on tippler table. The practice of
shunting empty wagon after tippling by rake of loaded wagons, is not
acceptable as it results into large scale damages to CBC and bogies

Representative of the Sr. DME (C&W) /DME

Siding owner or
Authorised representative

Page 14 of 17
 Annexure-1
Format of type/model approval certificate

Hkkjr ljdkj &jsy ea=ky;

vuqla/kku vfHkdYi vkSj ekud laxBu
y[kuÅ & 226011
QSDl@Fax : 91-0522-2452494 Government of India - Ministry of Railways
VsyhQksu@Tele: 0522- 2465774 Research Designs & Standards Organisation
Lucknow – 226011
No. Date:
TYPE/MODEL APPROVAL CERTIFICATE FOR TIPPLER INSTALLATION
1. Certificate No. and date
2. Manufacturer
3. Test site
4. Tippler Model no
5. Drg. reference
6. Type of Tippler
7. Capacity (Wt. & Height of wagon)
8. Max rotation angle
9. Tipping Cycle time
10. Top clamping
11. Side support
12. Wheel gripper on tippler table
13. Side arm charger
14. RDSO no allotted
15. Approval
16. Validity

This is to certify that the Model no. - ………… Wagon tippler installed and
commissioned successfully as per RDSO specification G-33 Rev-2.
Remarks: The above approval is subject to following conditions:
1. RDSO allotted no. may be indicated on the wagon tippler & control panel of
the wagon tippler.
2. The attached drawings, its supplementary type approvals terms and conditions
and annexure-A form part of this certificate. Other list of conditions is given
overleaf.

Director/Wagon
For Director General /Wagon
Copy to: -
1. GM/ Mechanical, All Indian Railways.
2. Tippler supplying firm.

Page 15 of 17
List of type approvals terms and conditions
1. Type approval will be valid for particular tippler model no. – ……….. Wagon
Tippler. In case any change in design model firm should have to apply a
fresh for type approval.
2. All subsequent installations of identical design will be covered by this type
approval, subject to location specific approvals by the concerned Zonal
Railway and RDSO need not be approached for case-by-case tippler design
approvals for identical tipplers.
3. This approval extends only to items covered therein. This certificate is not
valid for equipment, the design, ratings or operating parameters of which have
been varied from the specimen tested. The manufacturer should notify RDSO
of any modification or changes to the equipment in order to obtain a valid
certificate.
4. The outhaul side track should satisfy the conditions as per clause no. 3.3.2
(f) of RDSO specification G-33 R-2 for subsequent identical tippler
installations.
5. No tippler/handling equipment component should protrude more than 100 mm
from the rail level within the rails.
6. On receipt of higher load wagon or 32.5 t axle wagon in future, the test trial
run will be required by Owner/ manufacture and Zonal Railway for its safe
operation. As the Tippler has been designed for handling a gross load of 140 t.
7. Tippler should be installed and commissioned by manufacturer to the
satisfaction of owner. Commissioning report should be jointly certified by
manufacturer and owner of the tippler and a copy of the same should be
handed over to Sr. DME concerned for its operation.
8. After installation and commissioning of the tippler, Sr. DME of the concerned
Division, Railway shall certify it safe for the operation.
9. The commissioning certificate should be jointly signed by manufacturer,
owner of the tippler and Railway representative and a copy should be sent to
RDSO for information.
10. Operation of the tippler shall be suspended on request of the Sr. DME of the
concerned Division in case of its causing damage to the wagons and not
meeting any of the above conditions and requiring maintenance.
11. Sr. DME of the concerned Railway Division or his representative may inspect
the Tippler and its operation, whenever such a need is felt, or may depute
Railway staff permanently for inspection of wagons after each tipping. The
entire cost of inspection and attention to the wagons shall be borne by the
owner of the tippler.
12. It shall entirely be the responsibility of the owner for ensuring that no damage
whatsoever is caused to the wagons during handling on the tippler. The owner
shall guarantee to pay to the Railway the rectification charges in case of any
damage to the wagons.
13. The approval for operation of tippler is subject to withdrawal at any time in
event of owner’s failure to ensure handling of wagons without damage.
14. Owner/User or his representative shall submit a certificate to Sr. DME of the
concerned Rly/Division in the prescribed format that the tippler is in good
working condition, once in every six months.
*******************

Page 16 of 17
 Annexure-A
COMMISSIONING CERTIFICATE
(The following information shall be sent to RDSO for each and every subsequent
identical wagon tippler installation/commissioning against the type/model approval :)

1. Purchase Order no
2. Manufacturer
3. Contractor/Consultant
4. User/Consignee
5. Installation Site
6. Nearest Railway station
with their Division &
Zone
7. Type of Tippler & their
model no.
8. Total Installed Units
9. Year of commissioning
10. Material handled
11. List of wagons to be
handled
12. Suitability for locomotive
13. Capacity of wagon tippler
14. Max rotation angle
15. Tipping Cycle time
16. Available length &
gradient of post tippling (Ref. Rly. HQ. Approved Track Layout Drg.
line No.-…………………)
17. Top clamping force and
pressure
18. Side clamping force and
pressure

This is to certify that the tippler model no. …………..has been successfully
commissioned as per RDSO specification no. G-33 Rev.-2.

Signature of manufacturer Signature of User Signature of Railway

representative

Copy to:
1. Exe. Director/Wagon, Research Designs & Standards Organisation,
Manaknagar, Lucknow – 226011.
2. GM/Mechanical of concerned Zonal Railways.

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