Maintenance Manual for BG Coaches of ICF Design PDF

Maintenance Manual for BG coaches of ICF design Rolling Gear CHAPTER 10 ROLLING GEAR...

Maintenance Manual for BG coaches of ICF design Rolling Gear CHAPTER 10 ROLLING GEAR i) Wheel disc solid 1001 WHEEL AND AXLE The solid wheel disc is manufactured as 1001a Introduction per IRS Specification No. R - 19/ 93 Pt. II and drawing No. W/WL/1660 (see figure The movement of rolling stock on the 10.2). track is possible only with the help of wheels. The complete wheel set is shown ii) Axles in the figure 10.1 with the assembly components. These assembly components An axle is a component of a wheel set to are described in detail in the following hold the wheel discs in position. The axle pages. box is also mounted on the journal of the axle (See figure 10.3 for Axle) 1. DIMENSIONS MARKED THUS ARE FOR 16 TONNES AXLE FITTED 2. TO WLRRM. ALL OTHER DIMENSIONS ARE COMMON FOR BOTH 13 TONNES AND 16 TONNES AXLE +2 130 1600 - 1 130 Ø 145 Ø 172 Ø 152 Ø 178 Ø 130 Ø 145 Ø 913 Ø 915 NOTE:- 1. THE VARIATION IN THE TREAD CIRCUMFERENCE OF WHEELS ON THENOT SAME AXLE1.6 XCEED SHOULD mm (i.e.) ON DIA. 2. THE VARIATION IN WHEEL DIA BETWEEN ONE PAIR WHEELS AND THE EXCEED OTHER SHOULD 5 mm ONNOT THE SAME BOGIE. 3. THE VARIATION ON DIA UNDER THE SAME COACH SHOULD NOT EXCEED 13 mm. WHEEL AND AXLE COMPLETE Figure 10.1 Note:- Rly. Bd. vide their letter no. 1001b Components of a wheel set 98/RSF/874/1/SAIL (Pp) dt. 8/10/1998 has decided that only A wheel set is an assembly mainly of 16.25t axles would be used for two components: wheel set under 13t bogie also for new wheel sets. The existing Wheel discs(solid) on both sides of the wheel set in service may however axle continue till they are required to An axle to hold these wheel discs in be changed. position Chapter 10, Page 1 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear W/WL-1660 WHEEL PROFILE AS PER Sk.-91146 (SEE BELOW) +3 -1 IN E INCLINE 1 IN 20 30 W/WL-1660/R 2.5 INCL 14%%p2R 1 IN 45%%d 18%%p2R I.R. PART No. N11 14R 14.5R +5 22 -0 PROFILE TO GAUGE N9 70%%D%%P1%%D NOTE:- 6 47%%d-30'%%p1%%d %%P2 130 38R N9 38R 1. STAMP HOT OR COLD 10/12 mm TYPE IRS W/WL-1660, MANUFACTU- RER'S INITIAL, RAILWAY INITIAL, 6R 60%%d 3 CONTRACT No., YEAR OF MANUFAC- 5R TURE, CONSECUTIVE No., 'UT' FOR ULTRASONIC TESTING AND 'R' FOR 10%%D 25%%p1 CRS RIM QUENCHING OR 'Q' FOR ENTIRE WHEEL QUENCHING ON OUTER FACE 51R N9 OF RIM. R 10 11%%D%%P1%%D 2. * THE OUTSIDE DIA. OF THE HUB DIA. 47%%d-30' 13 TO BE MACHINED IF NECESSARY TO LIMIT +1 -0 +5 70%%d PREVENT HUB ECCENTRICITY. -0 813 29 %%C7 63%%p5 INSIDE DIA. OF RIM, ECCENTRICITY 3 MAX. DIA. OF RIM %%c660 3. COORDINATES OF CENTER POINT +3 +0 %%C918- 0 %%C165- 3 +5 22 -0 OF 330R & 100R ARCS ARE BASED +10 INSIDE -0 190.5 +10 ON NOMINAL DIMENSIONS. -5 * %%c260 %%c800%%P5 INSIDE DIA. O F RIM, ECCENTRICITY 3 MAX. +3 763 -0 63.5 ON TREAD (ECCENTRICITY 0.25 mm MAX.) 18 7 +3 655. 190 -0 +10 151 8.7 R 11%%d%%P1%%d -0 10 N9 %%c172- 0.4 +0 230R * %%c260 165R 51R 10 91 153 65.5 230 R 190 8 +3 44 -0 180 R N9 %%c 915 (91,328.9) 151 8.7 29.4 191 219 (65.5,100.3) 6R 1 IN 6R N6 2.5 N 6 151 8.7 1 IN 20 13 +1 10 0R 330R R -0 14.5 R 14 28.5 65 (0,0) 73.7 130 W/WL-1660/R FIGURE 10.2 %%p1 63.5 RIM WARP 1 MAX. +3 ROLLED SIZE -0 WHEEL PROFILE WHEEL & AXLE SOLID WA/WL-32 2 FORGED (B.G.) FOR LIGHT W/WL-1660 2/02 8 SS/4/02 RADIUS 5 INDICATED AT %%c763 AND Sd. WT. COACHING STOCK NOTE 1 DELETED WHERE USED ASSEMBLY No.. ASSLY RIM WARP 1 MAX. NOMINAL SIZE 2/94 7 CD/2/94 RADII CENTRES SPECIFIED & Sd. 28.5 SPRAG HOLES ELIMINATED 8/93 6 CD/57/93 TOLERANCE & NOTE REVISED IRS Sd. S.No.1211/1 OF GR. NO. N1 N2 N3 N4 N5 N6 MATL. ROLLED OR FORGED STEEL 4/91 5 TOLERANCES MC/WA/TENDER ADDED Sd. S.No. 1070 OF Ra m 0.025 0.05 0.1 0.2 0.4 0.8 SPEC. No. IRS R-19/93 Pt.II 3/90 4 TOLERANCESMC/WA/TENDER ADDED Sd. SYMBOL SIZE TREAT 7/85 3 DRAWING SNo. 672 OF REVISED MC/WA/TENDER Sd. W/WL-1660 ROUGHNESS VALUE TO IS:3073 SURFACE GR. No. N7 N8 N9 N10 N11 N12 FORM WEIGHT DATE AUTHY. I.R ALT No. DESCRIPTION CKR. Ra m 1.6 3.2 6.3 12.5 25 50 RLY. PATT. SCALE DO NOT SCALE W/WL-1660/R WHEEL SOLID FORGED (B.G.) SYMBOL CONCERNED RLYS. TO FILL REF. DRG. I.R. PART No. Chapter 10, Page 2 of 23  Maintenance Manual for BG coaches of ICF design Rolling Gear TOTAL LENGTH 2316 +- 0.5 0.0 85 191 1473 119 26.5 Ø 130 R40 R75 R75 In case of 16 T Bogie - φ 152 In case of 13 T Bogie - φ 145 AXLE Figure 10.3 iii) Axle boxes with roller bearings The difference in tread diameter of the The axle boxes used on ICF coaches are two wheels on the same axle should not with under mentioned spherical roller exceed 0.5 mm after tyre turning. There is bearings no 'In service' limit for this variation and rejection shall be decided by tyre defect Spherical Roller Bearings No. 22326/C3 gauge These roller bearings are with 130 mm During last shop issue the wheel is to be parallel bore on the inner ring and are turned to RDSO SK-91146. The profile is directly shrunk on the axle journals. to be turned 1 mm above the condemning 1001c Maintenance Procedure in the limit groove. The maximum diameter and Workshop last shop issue size for ICF type wheels is given below: i) Pre-inspection of wheels in the workshop Table 10.1 During pre-inspection of incoming Type of New Min. Shop wheels, the wheel-set is inspected for wheel issue assessing the condition of the ICF solid 915 836 components. Following measurements are carried out on all the wheels, received in c) Inspection of wheel disc as per shop for repairs. CMI-K003 a) Measurement of a wheel gauge The wheel should be inspected for (distance between two wheels rejectable defects in accordance with flanges on the same axle) RDSO’s instructions CMI-K003 The distance between two wheel flanges d) Inspection of Wheel Flanges on the same axle should be 1600 mm + 2/-1 mm. This measurement should be The flanges on both sides of a wheel set taken at three locations apart with the help are checked with the help of a profile of an adjustable pi gauge. If wheel gauge gauge to measure the height and thickness is not within permissible limits, then the of flanges. Accurate measurement of wheel disc (s) have to be pressed off and flange height and flange thickness is not then pressed on. possible with the profile gauge. It is, therefore, recommended to use a wheel b) Measurement of Wheel Diameter profile gauge with which accurate (Tread Diameter)/Wheel Flanges measurement of flange height and flange The wheel diameter is measured with the thickness to the extent of 0.1 mm can be help of a trammel gauge with a least count made. of 0.5 mm. on both sides. However, a After recording the diameters of wheels gauge with a least count of 0.1 mm. is and wheel flange measurements, the recommended as the measurement of a wheel set is nominated for necessary diameter would be more accurate with repairs. this gauge. Chapter 10, Page 3 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear e) Inspection of axle 1003 REPAIR PROCEDURES FOR DIFFERENT CATEGORIES OF Axle journals should be thoroughly WHEELS cleaned for inspection to detect flaws, pitting, ovality, taper, ridges etc. Each Detailed procedure for carrying out axle should be ultrasonically tested for repairs to different categories of wheel detecting internal flaws and defects as per sets is described below: the code of procedure issued by RDSO (Annexure 10.1). Axles found flawed, 1003a Normal Repair of Wheel sets pitted or with under size journals should be replaced. Normal repair wheels are of two categories. On ICF axle journal a. With roller bearings mounted § A taper should not exceed 0.015 / 0.010 mm. b. With roller bearings removed § Out of roundness (ovality) must not exceed 0.015 / 0.020 mm. The activities involved in Normal Repair Wheels are as follows: 1002 CATEGORY OF WHEELS § Pre-inspection of incoming wheels. The wheels are categorised after pre- inspection as below: § Drop axle boxes, clean and inspect axle boxes. If required, repair them. 1002a Normal repair wheels § Carry out Ultrasonic Flaw detection test of axle. If all the components are within the acceptable range of limits, these are taken § If required, dismount roller bearings directly for wheel profiling and servicing from journals. (In any case dismount of roller bearings. roller bearings in alternate POH) § If the wheels are sent for re-profiling 1002b Wheels requiring replacement of an without dismounting roller bearings axle (RA wheels) from the journals, special protective covers should be fitted on the The wheel is taken for replacement of an bearings on either side of a wheel to axle for the following : avoid entry of chips / dust or damage to the bearing during machining. § A bent axle, § Machine wheel profiles to the § Dimensional deviations on a journal prescribed dimensions. The wheel / wheel seat tread should be checked and § Axle having groove marks in the machined to the worn wheel profile middle due to rubbing of a pull rod, and machining standard N11 to IS: § Dents, corrosion, pitting marks on 3073. (see figure 10.4 for worn the surface of the axle wheel profile) § Axles found flawed in the ultrasonic § Clean roller bearing and assemble flaw detection test components in position, if not dismounted. 1002c Wheels requiring replacement of solid § Inspect roller bearing and assembly discs (RD wheels) in position. The wheel is taken for replacement of § Check radial clearance and confirm discs if found it to be within permissible limits. § Pack fresh grease § It is not possible to turn the wheel to the last shop issue size § Mount cleaned and inspected axle boxes. § There is a rejectable defect as per CMI-K003. § Fit front cover with new sealing ring. Chapter 10, Page 4 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear 127 63.5 1 IN 20 1 IN 2. R 14 28.5 5 100 R 0 10 0R 329 33 13 9R 20 33.5 FIGURE - 1 65.5 91 91 (20 MM THICK FLANGE) 1 IN 20 1 IN 2.5 R 14 100 R 0 10 0R 329 33 R 13 10 22 35.5 65.5 FIGURE - 2 (22 MM THICK FLANGE) 1 IN 20 1 IN 2.5 R 14 100 R 0 10 R 329 0 R 33.5 13 11 25 38.5 FIGURE - 3 65.5 (25 MM THICK FLANGE) DEVELOPED BY: SUPERSEDES: 1. FIG.3 SHOULD BE THE LAST PINTERMEDIATE WHEEL PROFILEPFOR THE WHEELS MEANT FOR PTHE COACHES TO RUN AT MAX.PKMPH AND ABOVE.P2. ALL THE THREE SCALE P C INTERMEDIATE INTERMEDIATE WORNPWHEEL PROFILE (FIG.1,2&3)PCAN BE USED FOR THE WHEELS FOR POTHER TYPES OF COACHES. D PAINT 9/92 WORN WHEEL 1:1 T PROFILE JS FOR COACHING STOCK B.G. RDSO[C] SKETCH-92082 FIGURE 10.4 Chapter 10, Page 5 of 23 Maintenance Manual for BG coaches of ICF design Rolling Gear 1003b RA (Replacement of Axles) Wheels § Machining of serviceable wheel disc The activities involved in replacement The serviceable wheel discs are re- of an axle are as follows: bored on the vertical boring machine. Care should be taken that the finished § Pressing off a rejected axle from a bore is straight, concentric to the tread wheel of the wheel and has a smooth surface free from ridges, scores and chatter The wheel is taken on the wheel press marks. A radius of 2.5 mm is provided for separating the rejected axle from on the hub to facilitate mounting. It the wheels. must be made after the finishing cut. § Inspection of re-bored wheel disc § Machining of new axles The rebored wheel disc should be New axles should be machined to the inspected with the help of an inside correct drawing dimensions. Journal, micrometer to ensure consistent journal fillets and shoulders should be results. Each wheel bore must be finished smooth, concentric and checked at not less than three points in without ridges, burrs or chatter marks. its length and on the different diameters at each of these points to § Inspection of machined axles ensure roundness and absence of tapers. The variation for any of these Dimensional checks measurements must not exceed 0.05 mm. A machined axle should be inspected for dimensional accuracy with the help If any taper does exist, the small of a micrometer with least count of diameter must be outside ends of the 0.01 mm. Journal diameters should be hub (a reverse taper is not allowed). measured at three points along the The surface finish of the bore should length of journals both on the vertical be within the permissible limits. and horizontal axis. The ovality and § Machining of wheel seats for taper must not exceed the limits matching of wheel disc bores prescribed in the drawing.. The wheel seat of the axle to be used Surface finish checks for re-axling is machined to suit the bore of the wheel disc keeping Surface finish of the axle on journals, interference allowance as specified. wheel seat and middle portions should be checked with the help of a surface The bore of wheel disc and wheel seat finish tester and the prescribed limits on the axle should be maintained to are as below: - the specified surface finish and diameters to achieve correct Table 10.2 interference fit and pressing in pressure Axle portions Prescribed (RA) § Pressing on Wheel Discs on Axle value for S