Transcript
ESR 0241 INSTALLATION AND REMOVAL OF BOGIE FROM LOCOMOTIVE Version 1.0 Issued June 2010
Owner:
Chief Engineer Rolling Stock
Approved by:
Stephen White, Technical Specialist Rolling Stock Performance Standards, Rolling Stock Access Integrity
Authorised by:
Michael Uhlig, Manager, Rolling Stock Access Integrity
Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.
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Engineering Standard
Engineering Standard Rolling Stock
RailCorp Engineering Standard — Rolling Stock Installation and removal of bogie from locomotive
ESR 0241
Document control Revision
Date
Summary of change
(RSS 0241) 1.0
August 2007
Based on TRS 1919
(ESR 0241) 1.0
June 2010
Reformatted & renumbered
Summary of changes from previous version Summary of change
Section
NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’ to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the ‘Document control’ page carries over to a second page separate pages must be used for ‘Contents’ and ‘Document control’
Contents 1 Scope..................................................................................................................................................3 2 Removal of bogie(s) from locomotive.............................................................................................3 2.1 Items to be removed/disconnected ...........................................................................................3 2.2 Inspection & requalification .......................................................................................................3 3 Fitting of bogie(s) to the locomotive ...............................................................................................4 3.1 Elephants feet: ..........................................................................................................................4 3.2 Low speed controller generator ................................................................................................4 4 Checks and tests...............................................................................................................................4 4.1 Weighing and balancing of locomotives....................................................................................5 4.2 Safety hook ...............................................................................................................................5 4.3 Sanding equipment ...................................................................................................................5 4.4 Desanding equipment ...............................................................................................................5 5 Referenced standards.......................................................................................................................5 5.1 RailCorp standards ...................................................................................................................5
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RailCorp Engineering Standard — Rolling Stock Installation and removal of bogie from locomotive
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ESR 0241
Scope This document provides the mandatory requirements for the fitting and removal of bogies from a 48 class locomotive. The objective of this instruction is to ensure that bogie changes are carried out to a consistently high standard.
2
Removal of bogie(s) from locomotive
2.1
Items to be removed/disconnected The following items must be disconnected and either removed or restrained out of the way before attempting to remove the bogies from the locomotive: • Traction motor cooling air duct bellows, discard bellows; • Traction motor leads using an appropriate disconnecting tool. Where leads are bolted the bolts, nuts and washers are to be discarded; • Hasler speedo transmitter from the axlebox; • Axle generators if fitted; • Earth leads; • Shock absorbers and/or yaw dampers, and/or lateral dampers; • Brake piping hoses, hand brake chain, sanding and desanding hoses. All hoses are to be discarded; • Any other physical connections between the locomotive body and bogies; • Low speed controller; • Safety hooks and chains.
2.2
Inspection & requalification Once all cables and leads are disconnected ensure that they are adequately secured, to prevent any damage such as crushing of the cables. Check the condition of the traction motor air ducts. Ensure that the traction motor air ducts have protective covers placed on them, once detached. Check for any modifications to be implemented to the locomotive as directed by RailCorp. Clean the load bearing surfaces of the locomotive underframe in order to facilitate visual inspection. Visually inspect the locomotive underframe for physical damage. Any defects found must be reported to RailCorp for advice. Visually inspect the centre pivot arrangement on the locomotive underframe. Report any defects to RailCorp.
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RailCorp Engineering Standard — Rolling Stock Installation and removal of bogie from locomotive
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ESR 0241
Fitting of bogie(s) to the locomotive Ensure all mating surfaces are kept clean. If the locomotive has a centre pivot and/or is fitted with “metallastic-type” bearer pads carefully guide them into position. Ensure safety hooks between the bogie and locomotive underframe are assembled. Bolt or connect the traction motor leads to their mating lead from the locomotive body using an appropriate connecting tool. New bolts, nuts and washers are to be fitted. Connect the Hasler speedo transmitter to the axlebox. Ensure that plugs are sealed with “silicone”-type sealant to overcome the ingress of dirt and water. Connect the axle generator(s) where fitted. Connect earth leads. Remove protective covers and fasten the traction motor cooling air duct bellows. Fit shock absorbers and/or yaw dampers as required. Ensure correct orientation. Connect safety hooks and chains (if fitted). Connect the air brake piping hose, hand brake chain, sanders and desanders. (See other considerations below) Adjust brakes according to ESR 0224 Adjustment of brake cylinder travel. For bogies that have not been freshly overhauled check lubricant in axleboxes as per ESR 0244 Greasing of locomotive axle bearings. Secure all traction motor lead cleats. Ensure that the traction motor leads are free from rubbing against any other items such as gear cases, air pipes and chains. Ensure that the sanding and desanding equipment function properly according to ESR 0211 Measurement of sand flow rates.
3.1
Elephants feet: Fill elephants feet loading oil pan with Caltex RPM 4000 engine oil to the level of the filling hole, and bogie centre or centre pivot to approximately 12.7 mm or 1/2” . When lowering the locomotive onto the bogie or raising the bogie to the locomotive carefully guide the top sliding plates and loading pads (elephants feet) into position. Before the locomotive underframe is completely in position, see that the loading pad cover slots are correctly positioned in relation to the retaining lugs on the bogie pan.
3.2
Low speed controller generator Ensure that the low speed controller generator is not left hanging-on cables as this can result in broken wires and hence cause failures.
4
Checks and tests Upon completion of the fitting of bogies to the locomotive, mandatory checks and tests are required as follows.
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RailCorp Engineering Standard — Rolling Stock Installation and removal of bogie from locomotive
4.1
ESR 0241
Weighing and balancing of locomotives After the fitment of bogies to the locomotive, it shall be weighed and checked for balance in accordance with Appendix C of ESR 0001-C RailCorp Minimum Operating Standards for Rolling Stock (RSUs).
4.2
Safety hook For locomotives fitted with safety hooks, inspect side safety hook and end transom safety hook for any evidence of deformation in the form of deep bruises, gouges, cracks, major bending or yielding. If a component is damaged beyond repair, a new component must be used as a replacement. If the component can be welded or bent to a serviceable condition, the repair area must be magnetic particle tested after the repair areas have cooled below 200°C. A tolerance range of ± 5mm applies to all safety hook set-up dimensions.
4.3
Sanding equipment The operation of sanding gear must be checked, in each direction, in accordance with ESR 0210 Adjustment of sandtraps.
4.4
Desanding equipment The following checks are mandatory: •
Check that tubes are delivering sufficient air to remove sand from rail;
•
Check that tubes are directed at the wheel/rail interface;
•
Check for air leaks in system.
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Referenced standards
5.1
RailCorp standards ESR 0001 RailCorp minimum operating standards for rolling stock Appendix C Vehicle weigh test ESR 0210 Adjustment of sandtraps ESR 0211 Measurement of sand flow rates ESR 0224 Adjustment of brake cylinder travel ESR 0244 Greasing of locomotive axle bearings ESR 0271 Fitting high tensile bolts to traction motor connections
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