Maintenance Manual for AC-DC EMU (Siemens) PDF

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 8 BOGIE & UNDER GEARS 8.1 INTRODUCTION The bogie frame is a welded construction with two longitudinal...

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 8 BOGIE & UNDER GEARS 8.1 INTRODUCTION The bogie frame is a welded construction with two longitudinal girders and a cross bar and two frame ends. The tractive or brake force is transmitted via a bogie pin from the bogie to the body. The frame ends are used to take up the brake cylinder and the brake rigging. This vehicle features tread brakes, which have a direct effect on the wheel. Furthermore, 4 steel cables are each located between body and bogie. These are used as a lifting supports. Primary Secondary air springs suspension Lifting support For primary suspension, buffer height, brake rigging, wheel and axle, hydraulic shock absorbers of AC EMU, DC EMU, AC-DC EMU bogie refer CMI – K001 (April 2000) and amendment slip no.1(Feb. 2007) and for maintenance of air suspension refer CMI-9802 (Rev.2) , February 2008 issued by Carriage Directorate, RDSO, Lucknow. 8.2 BOGIE FRAME (Ref: CMI- K001) Bogies of motor coaches (MC), high carrying capacity coaches (HCC) and trailer coaches (TC) are of all welded, light weight construction. The axles, with self aligning roller bearings mounted inside cast steel axle boxes, are rigidly guided by telescopic dash pot and axle box guide assemblies. Helical springs working in parallel with dashpots are used for primary suspension. Coach body is supported on two side bearers located 1700 mm (TC) and 1200 mm (MC & HCC) apart on a floating bogie bolster which in turn rests on air spring supported on a spring plank hung on swing links from bogie frame. The air springs at each end of bolster are damped by hydraulic shock absorbers. Side bearers consist of metal slides immersed in oil baths well protected from dust ingress. Maintenance Manual for AC-DC EMU (Siemens) Chapter 8 2 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Refer drawing no. ICF/MRVC/M-0-0-001 (sheet 1 & 2), AC/DC EMU/D2-0-0- 201 (sheet 1 & 2) and AC/DC EMU/C2-0-0-201 (sheet 1 & 2) for bogie general arrangement of motor coach, D coach and C coach respectively given in Annexure for drawings. Refer drawing no. ICF/MRVC/M-0-3-001 (sheet 1 & 2) and ICF/MRVC/D-0-3- 001 (sheet 1 & 2) for bogie frame arrangement of motor coach and D/C coach respectively given in Annexure for drawings. No weight is transferred through the bogie (center) pivot, which is located in the centre of the bolster. The pivot acts merely as a centre of rotation and serves to transmit acceleration and retardation forces. The floating bolster in TC bogie is secured in the longitudinal direction to bogie frame by means of two anchor links with silent block bushes, located diagonally opposite to each other and transmit draw and braking forces between bogie frame and coach body through the centre pivot. The MC & HCC bogie bolster is located between bogie transoms and transmits draw and braking forces through rubbing plates fixed at the bolster ends. 8.3 WHEEL & AXLE The EMU coaches are provided with composite design of wheels consisting of rolled steel wheel centres with renewable tyres. The tyres of TC bogies are fastened to the wheel disc with glut rings whereas the MC/ HCC bogies have, in addition to the glut rings, 4 locking keys to ensure more positive securing. Refer drawing no. ICF/MRVC/M-0-2-001 for axle and wheel set given in Annexure for drawings. Chapter 8 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 3 Tyre Profile 1. The new/re-turned tyre profile shall be as per ROSO Sketch No. 91146 atl. 2. 2. The condemning limits for the flange wear, root wear, deep flange, sharp flange, hollow tread wear and flat surface on tyre shall be as per the condemning gauge shown in plate 45 of I.R.CA Part IV. 3. Wheel gauge should be within the tolerance of +2/-1 mm. Wheel Diameter Bogie New Condemning Last Shop Issue Size 1. MC 952mm 877mm 885mm 2. TC 952mm 857mm 865mm 3. HCC 952 mm 865mm 873mm Permissible Variation on Wheel Tread Diameter  The permissible variation in tread diameter of wheels at the time of tyre turning or wheel replacement are as follows: 1. Wheels of the same axle : 0.5mm 2. Wheels of the same bogie : 5.0mm 3. Wheels between two bogies under the same coach : 13.0 mm  No separate service limits are specified as the above figures have been fixed to allow for the differential wear likely to develop between successive tyre turnings/ wheel changing. It is, therefore, not necessary to withdraw EMU/MEMU stock from service specifically for restoring the differential between wheel diameters to be within the prescribed limits. Material Specification for Wheel and Axle The material specification applicable to the wheels and tyres are as follows: 1. Tyres : IRS Specification R-15/95. 2. Axle : IRS Specification R-16/95 for TC bogies IRS Specification R-43/92 for MC & HCC bogies 8.4 ROLLER BEARINGS MC & HCC Bogies are fitted with direct mounted, double row, self aligning roller bearings No. 22328 C/C3. TC Bogies are fitted with direct mounted, double row, self aligning roller bearing No. 22326 C/C3. Refer drawing no. EMU/M-0-2-016 (sheet 1 & 2) and EMU/M-0-0-001 (sheet 1 & 2) for roller bearing of motor coach, D coach/C coach respectively given in Annexure for drawings. Maintenance Manual for AC-DC EMU (Siemens) Chapter 8 4 CAMTECH/E/13-14/MM AC-DC EMU/1.0 8.5 AXLE BOX HOUSING Double row self-aligning spherical roller bearings are housed in accurately machined cast steel axle boxes. The axle boxes are also provided with light alloy front and back covers secured by four bolts. Refer drawing no. ICF/MRVC/M-0-2-002 (sheet 1 & 2) for axle roller bearing housing and gear-wheel assembly of motor coach given in Annexure for drawings. Axle boxes and covers should be thoroughly cleaned and checked for cracks particularly at the holes of the covers which have shown proneness to failures. The bolts should be examined for worn threads, straightness, etc. before re-use and should be well tightened and locked by spring washers and split pins to ensure that the covers and the axle box housing form a water tight assembly and protect bearing from dust and moisture. 8.6 AXLE BOX SPRINGS Axle box springs are of helical type manufactured from centreless ground chrome vanadium, silica manganese steel. These springs are also shot-peened to obtain higher fatigue life. It is necessary to check these springs for cracks and measure their free height to ensure that they meet the design requirements. All springs shall be grouped in three categories and used on bogies as per instructions detailed in RDSO Technical Pamphlet No.C-8419 (Rev 1). 8.7 LOWER SPRING SEAT Lower spring seat on the axle box wing in which guide bush of dashpot moves up and down does not normally wear in service. In the absence of inadequate quantity of oil in the dashpot. the inside surface is likely to wear. If the surface is worn more than 0.4 mm in diameter or if the surface is scored or otherwise damaged, the lower spring seat should be reclaimed. All lower spring seats should be carefully checked for cracks before reuse. Chapter 8 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 5 8.8 DASHPOTS AND AXLE GUIDE ASSEMBLIES Axle box guides are accurately machined hollow forgings welded to the bogie frame to ensure that the wheel sets are rigidly guided in parallel. These guides are fitted with acetal/ bronze bush at the lower end for close guidance of the wheel set both in lateral and longitudinal directions. The lower spring seat is filled with oil and the assemblies sealed with rubber ring to make it oil tight. The provision for topping-up oil in the dashpot of MC & HCC bogie are made. In the trailer coach bogies, holes on the bogie side frame above each guide are provided to top up the damping fluid when required. Refer drawing no. AC/DC EMU/M2 -0-1-201 for axle box guide given in Annexure for drawings. 8.9 BOLSTER AND BOLSTER SPRING Bolster rested on both ends on air springs as shown below. More details are given in chapter on ”Suspension”. Refer drawing no. ICF/MRVC/M-0-4-001 (sheet 1 & 2) and DMU/DPC/10-0—4- 001 (sheet 1 & 2) for bogie bolster arrangement of motor coach, D coach/C coach respectively given in Annexure for drawings. 8.10 HYDRAULIC SHOCK ABSORBERS The hydraulic shock absorbers are fitted to work in parallel with bolster springs. These shock absorbers normally give trouble-free service and require no attention in between POHs. However, shock absorbers which are found either leaking or physically damaged should be replaced. Maintenance Manual for AC-DC EMU (Siemens) Chapter 8 6 CAMTECH/E/13-14/MM AC-DC EMU/1.0 As the resistance of these shock absorbers is likely to deteriorate in service, it is necessary to attend to them as per instructions given in the manufacturer's maintenance manual. Vertical and Horizontal Shock Absorbers 8.11 RUBBING PLATE IN MC AND HCC BOGIE Nylon rubbing plate has been fitted to the bolster which serves as cushion between the bolster and bogie frame. Initial clearance of 1mm on each side has been provided between the nylon rubbing plate and steel rubbing plate. During POH,' this clearance must be maintained by fitting steel packings of suitable thickness. During service, this clearance should not exceed 3mm on each side. Any higher clearance may cause excessive longitudinal oscillations and may strain stay tubes (connecting the bolster to the spring plank) and cause their breakage. Chapter 8 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 7 8.12 EQUALISING STAYS Equalising stays connecting the spring plank and bolster, pin jointed at both ends, have been provided to prevent lateral thrust on bolster springs. It is necessary to remove the pins at every POH, clean and oil them to ensure that they are free to rotate when re- assembled. Any restricted movement at these joints is likely to prevent free movement of bolster. The free movement of pins can be ensured by greasing the assembly. The pins should be provided with washers and split pins to ensure that they do not fall out in service. Figures given for Equalising stays of MC / HCC and TC bogies: Maintenance Manual for AC-DC EMU (Siemens) Chapter 8 8 CAMTECH/E/13-14/MM AC-DC EMU/1.0 8.13 CENTRE PIVOT (MC & HCC bogie) The centre pivot arrangement is shown in Fig. given below. The body bolster of the under-frame is provided with a bush of inner dia 90mm in the top and 150mm dia hole at the bottom and the centre pivot pin, when fitted to the body bolster, perfectly fits into these holes as shown in diagram given below. Any wear due to bogie rotation is taken up by the upper and the lower bushes between the centre pivot pin and the bogie bolster. Chapter 8 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 9 8.14 CENTRE PIVOT (Trailer Coach) The centre pivot arrangement is shown below. It is not designed to transmit any vertical load but transmits only tractive and braking forces. Maintenance Manual for AC-DC EMU (Siemens) Chapter 8 10 CAMTECH/E/13-14/MM AC-DC EMU/1.0 8.15 SIDE BEARERS Side bearers consist of a hard wearing ground steel plate immersed in an oil bath with a floating bronze wearing piece, which has a self aligning spherical top surface on which the body rests and transmits the vertical load. The oil well is provided with a cover to prevent ingress of dust. The hard ground plate and the spherical bronze wearing piece are likely to wear in service. The hard ground plate should be renewed when the wear exceeds 1.5mm or ridges are observed on the plate. The bronze wearing piece should be renewed when the wear on the mating surface reaches 3 mm or damages occur to the oil grooves. Sharp edges which are known to develop at the periphery of the wearing pieces are likely to impair lubrication and should be rounded off before re-using. For filling up oil in side bearer without lifting the coach, oil filling nipples have been provided on the oil well. Any of the following oils can be used for the side bearers and the quantity required per side bearer is 2.5 litres. IOC : Servoline-68 HPC : Yantrol-68 BPC : Bharat Univol-68 Chapter 8 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 11 8.16 ANCHOR LINKS (Trailer bogies) Anchor links should be carefully examined for cracks at the weld. The rubber in the silent bloc should also be carefully examined for deterioration. Appearance of fretting on the edges of the rubber is an indication of deterioration of rubber. Whenever a silent bloc is to be replaced, it must be from those that have been duly tested. To avoid pre-loading of the anchor link while assembling on the bogie, ensure that the assembly can be done without forcing the link into position. This can be done conveniently after lowering the body on the bogies. 8.17 HANGER AND HANGER BLOCKS Hanger and hanger blocks shown in Fig. given below should be thoroughly cleaned after dismantling and examined carefully for cracks /wear and other damages. Maintenance Manual for AC-DC EMU (Siemens) Chapter 8 12 CAMTECH/E/13-14/MM AC-DC EMU/1.0 The extent of permissible wear on these components is indicated below: (Ref: CMI - K001) Trailer bogie Components Size New Condemning Wear Shop issue size Hanger block 8 6.5 1.5 7.00 Pin 45 43.5 1.5 44 Hanger 354 357 3 355.5 Motor bogie Components Size New Condemning Wear Shop issue size Hanger block 9.5 8 1.5 8.5 Pin 45 43.5 1.5 44 Hanger 246 249 3 247.5 8.18 BOGIE BRAKE GEAR Maximum radial clearance of 1 mm between the brake gear pins and bushes is permitted. If the clearance is more, the worn out part should be replaced and the standard clearance to be maintained. Brake block should be replaced when they wear out to thickness of 16 mm by removing the looped key from the brake head. An adjusting palm pull rod with holes displaced at regular intervals is provided in the brake rigging to take up slack in rigging due to tyre wear. Adjustment should be done by relocating the pin in different holes on this palm pull rod. Refer drawing no. EMU-M-3-2-064 (sheet 1 & 2) bogie brake arrangement for 20T axle bogies given in Annexure for drawings. Chapter 8 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 13 8.19 BUFFING & DRAW GEAR The EMU/MEMU coaches are provided with semi permanent/semi automatic schaku couplers. These are to be maintained as per the instructions contained in the Maintenance Manual supplied by the manufacturers. Maintenance Manual for AC-DC EMU (Siemens) Chapter 8