SERVICE MANUAL FOR RAILWAY
Contents
1. 2 3 PRESETTING TO ACHIEVE AN IDENTICAL FREE GAP While it is not absolutely necessary that the air spring system be preset by means of SHIMS USING THEM ENSURE THAT FOR ALL FOUR AIR SPRING SYSTEMS HAVE EXACTLY THE SAME FREE GAP AT TARE Because of the manufacturing tolerances in the bogie and in the auxiliary spring a car body would never be exactly level in an emergency but would exert forces of varying strength on the auxiliary springs In addition non uniform load distribution in the car body can give rise to differences in stress and thus to compression of the auxiliary spring in emergencies All of this leads ultimately to a torsional distortion of the car body and to eventual force variations between the air spring system and the car body and between the wheel and the rail THIS 15 WHY THE MANUFACTURE OF MODERN RAIL VEHICLES MEASURING UP IN PARTICULAR TO THE HIGH DERAILMENT PREVENTION STANDARDS THE LEVEL OF ALL AIR SPRING SYSTEMS IS EQUALIZED DURING MOUNTING BY THE INSERTION OF SO CALLED SHIMS ON THE BOGIE THIS HAS THE EFFECT THAT AN IDENTICAL LEVEL IS ATTAINED FOR ALL AIR SPRING SYSTEM IN EMERGENCIES The following course of action is to be adhered to when presetting the bogies If need be level equalization by means of adapter plates in the primary suspension to offset the manufacturing tolerances in these springs gt uniform height and parallel bogie frames Placement of the air spring systems on the bogie fram2. Miscellaneous Solvents fuels lubricating agents chemicals acids disinfectants etc may not be stored in the store room STORAGE AND HANDLING General Care should be taken to ensure that the rubber products are stored in an unstressed condition i e without tension pressure or other deformation since stressing not only promotes permanent deformation but also crack formation O ring seals for instance are not to be stored hanging on hooks Certain metals particularly copper and manganese have a harmful effect on rubber products For this reason such products should not be stored in contact with these metals but should be protected by wrapping or sealing with a layer of suitable material e g antistatic sheeting or bags made of paper polyethylene or polyamides nylon The material used for storage containers wrapping and covering purposes may not contain any components which are harmful to the products e g copper or copper containing plasticizers must not be used for wrapping If rubber products are dusted the dusting powder should be free from components harmful to the products Suitable materials for dusting are talcum whiting finely ground mica powder and rice starch Contact between rubber products of different composition should be avoided This particularly applies to rubber products of different colours Rubber products should remain in store for as short a time as possible In the event of long term storage c
3. Place upper plate on this side It is recommended to fix these j EX portions together by welding or It is recommended to 2 bolting fix the piece firmly by A Length approx 1200 welding 30 1947 RESISTOFLEX ontinenfal in collaboration with 39 EXTUS AIR SPRINGS amp RUBBER PRODUCTS REQUIREMENTS FOR STORAGE CLEANING AND MAINTENANCE S No _ Topic _ Page Nos 1 Scope 40 2 General 40 3 Store Room 40 42 4 Storage and Handling 42 5 Cleaning and Maintenance 43 RESISTOFLEX ww collaboration with 1 2 3 1 40 RASR SM 07 Handling and storage 1 SCOPE 1 1 These directions apply to products of rubber in the pure form of combined with other materials namely to elastomers of natural rubber and or synthetic rubber as well as to unvulcanized rubber compounds adhesives and solutions with rubber The directions in Sections 3 amp 4 apply principally as requirements for long term storage in general more than 6 months For short term storage less than 6 months for example in production or supplier s stores where stocks are continually being drawn upon the provisions of this Standard apart from the general requirements in relation to the storage rooms in Sections 3 and 3 1 apply as appropriate provided the appearance and performance of the products do not thereby suffer any detrimental alteration see however Section 4 2 1 b GENE
4. the second major inspection should continue to be carried out after a maximum of 6 years The details listed under 2 1 to 2 3 above are based on statements issued by the German Federal Railways or from the international governing body Union Internationale des Chemins de Fers It should also be noted that according to the experience gained by the German Federal Railways there is no need to replace Continental Air oprings prematurely ontinen fal in collaboration with CHAPTER 5 TROUBLESHOOTING S No _ Topic Page Nos 1 General Aspects 20 21 2 Top and Bottom Sealing Surface Area 22 3 Cracks Above or Below The Direct Belt Area 23 4 Surface Damage In The Top Shoulder Area 24 5 Chafing or Damage By Cutting 25 6 Foreign Bodies Chafing Or Damage By Cuts 25 26 7 Peeling Of The Outer Rubber Outer Cover Layer 26 1947 RESISTOFLEX in collaboration with ontinenfal 20 RASR SM 07 Troubleshooting JUDGMENT CRITERIA FOR A POSSIBLE DEFECT PATTERN ON AIR SPRINGS FOR RAIL VEHICLES ARISING THROUGH EXTERNAL EFFECT Mos 1 AIR SPRING PLATE Se A SSS EN 3 2 RIM 3 BOTTOM RIM RUNS NE NA 4 SPRING E Li pe Urb 8 CONICAL EMERGENCY AP SPRING 1 GENERAL ASPECTS During their period of utilization in the vehicle Air Springs are subject to varyingly high external mechanical 12 and internal natural loads 1 1 lf these lead to failures of t
5. car body and the bogie frame or if necessary between the bogie and the upper edge of the rail on the basis of which the distance during the adjustment operation can be easily controlled Usually these points are determined individually for each vehicle or each bogie following manufacturing and appropriately marked on the bogie or vehicle ATTENTION IN THE EVENT NO MARKINGS CAN BE FOUND ON THE CAR BODY AND OR BOGIE FRAME PLANE PARALLEL SURFACES CAN ALSO BE USED EVERY IRREGULARITY AND ANY MANUFACTURING TOLERANCES WOULD IMPEDE OR EVEN DISTORT THE SETTINGS HOWEVER THE FOLLOWING AIDS OR PERSONNEL ARE REQUIRED TO SET LEVELLING VALVES ON A RAIL VEHICLE 1 1 2pcs block of wood if need be block of metal capable of supporting 2 3 of the weight of the car body without major deformation or even destruction The block must be so dimensioned that the length of at least one edge corresponds to the center distance between the car body and the bogie when the air spring is ready for operation 1 2 2 pcs tape measure or measuring device for determining the height of the car body above the bogie frame or upper edge of the rail 1 3 2 wrench to lock the nuts on the adjusting rods 1 4 2 workers to adjust the valve 1 5 What s more the whole rail vehicle must be hooked up to a permanent pressure supply system with at least 6 bars of pressure ontinenfal gt in collaboration with RASR SM 07 Installation Instructions 2 1 2 2
6. the air supply by opening the stop cock 1a First open only the stop cock 1 0 thereby releasing the air supply for bogie 1 and affix the level control rod assembly to the valves On the rod assemblies 6 set the general level 5mm that the car body is ultimately to have above the bogie frame and the upper edge of the bogie Insert a suitable block ca 10 mm under the nominal height and preferably of hardwood centrally between the bogie frame and the car body and lower the car body onto the block by removing the valve rod assembly 6 Shut the stop cock 1c again thereby interrupting the supply of air to bogie 1 and open stop cock 1b thereby releasing the air supply to bogie 2 Affix level control rod assemblies 6 to the valves 5 and set the assemblies 6 to the desired level NOTE IN THE EVENT THAT THE TARGET HEIGHT IS ALREADY EXCEEDED EFFECTING THE SETTINGS ROD ASSEMBLIES ARE FIRST TO BE REMOVED AGAIN BECAUSE OF THE VALVE S DEADBAND AND THEN SCREWED BACK WITH NO IMPACT ON THE VALVES OF THE ROD ASSEMBLY 6 ONCE THE AIR SPRING SYSTEMS ARE BLED AND THE CAR BODY HAS SETTLED ON THE AUXILIARY SPRINGS THE ROD ASSEMBLIES 6 ARE TO BE HUNG BACK INTO PLACE AND THE HEIGHT READJUSTED Insert a suitable block preferably hardwood centrally between the bogie frame and the car body and lower the car body onto the block by removing the valve and assemblies 6 ontinenfal gt in co
7. 47 31 RASR SM 07 Instructions for removal SS 2 SSSSSSSSS NS SSSSSSSSSSSSSSSSSSSSWAZO 1 ASSSSSSSSSSSSSSSSSSSSSSS SSSSSSSNS RSS errat 74 hee ma 172 7 2 6 Air spring partially comes off flange seating and can then easily be removed completely from the air spring plate RESISTOFLEX o Qnfinental in collaboration with 42 ETATEM INSTRUCTIONS FOR INSTALLING AIR SPRINGS 7 BELTED AIR SPRINGS WITH HOLDING LIP ON THE UPPER AIR SPRING PLATE S No Topic Page Nos A Tools and Components 33 B Installation 34 38 RESISTOFLEX ww collaboration with 33 RASR SM 07 Instructions for installation The following instructions for installing Conti Belted Air Springs are mainly confined to explaining the assembly of AIR SPRING and MOUNTING HARDWARE lt may be necessary to change the order of assembly procedure in certain cases as different types of piston are used in terms of both seating the Air Spring and fixing the air spring plate to the rail car body A TOOLS AND COMPONENTS Air Spring Plate Upper Rim Air Spring am Lower Rim Plate BEST Piston PME Water or soap suds and cloth Giger Piece of wood approx 40 x 20 x 400 mm I onec odi Hammer i ip WI p RESISTOFLEX ontinenfal RESIS TUFLEA in collaboration with 1947 _ 34 RASR SM 07 Instr
8. ARS THIS IS EQUIVALENT TO HALF THE SERVICE LIFE OF THE BOGIE 32 YEARS Major inspections have to be carried out at certain intervals on rolling stock for example WAGONS OPERATING ON SUBURBAN ROUTES SHOULD BE INSPECTED VERY 4 YEARS but this inspection may be delayed by one year on two consecutive years if the general state of the wagon would suggest that an inspection is not absolutely necessary after 4 years this case the longest interval between major inspections could be extended to a maximum of 6 years In view of their annual mileage 550 000 700 000 Km WAGONS OPERATING ON INTERCITY ROUTES MUST BE INSPECTED more frequently namely approx EVERY 1 5 YEARS During the major inspections Point 2 1 the Air Springs are subjected to a visual check ageing and ozone cracking damage caused by external influences If necessary they may be removed for closer examination but this is not the normal procedure AIR SPRINGS ARE TO BE REMOVED FOR THE 2 INSPECTION TO UNDERGO A VISUAL CHECK BUT SPRING PROPERTIES ARE NOT TESTED According to the latest edition of the German Railway construction and Operating Regulations the first scheduled inspection of wagons used as passenger trains but not in intercity service is due after 6 years although this may be delayed by one year on two consecutive year We would like to point out that in principle the above intervals of time can elapse between inspections of Continental Air Springs However
9. R RESERVOIR FOR LHB 3 E RASR AIR SPRING ASSEMBLY RESISTOFLEX _incotiaboration with SINCE 1947 ontinenfal gt 7 INSTALLATION INSTRUCTIONS FOR LEVELLING VALVE 3 SYSTEM AIR SPRUNG VEHICLES S No Topic Page Nos 1 Prerequisites and Preconditions 8 2 Presetting to achieve an identical free gap 9 10 3 Installation Procedure 4 Point Suspension System 11 4 Procedure for setting 12 13 5 Important Instructions 14 6 Air Spring Installation Height Record 15 1947 RESISTOFLEX in collaboration with ontinenfal RASR SM 07 Installation Instructions 1 PREREQUISITES AND PRECONDITIONS The air supply system in the rail vehicle should be designed in such a way that the air feed for each bogie can be adjusted individually by means of a stop cock What s more in designing the rail vehicle and the car body care is to be taken that the installation lever of the leveling valves is easily accessible from outside When the settings are adjusted the car body has to be supported intermittently in the center by means of a strong block of wood on the bogie likewise in the center It is necessary therefore that the bogie design also briefly allow at tare for imposition of a load in the center In the event that the design does not allow the car body to be supported centrally on the bogie Precise level adjustment requires in any case that there are fixed points between the
10. RAL Under unfavourable storage conditions or with inappropriate handling most rubber products change their physical properties This can cause a reduction in service life and they may for example become unserviceable due to excessive hardening softening permanent deformation or as a result of flaking cracking or other surface damage ouch changes may for example result from the effects of oxygen ozone heat light humidity solvents or from storage under stress Properly stored and handled rubber products will retain their properties virtually unchanged over long periods some years This however does not apply to unvulcanized rubber compounds STORE ROOM The store room should be cool dry free from dust and moderately ventilated Outdoor storage with protection against weathering is not permitted Temperature The storage temperature for products made of rubber depends on the goods in question and the elastomers used ontinen fal in collaboration with RASR SM 07 Handling and storage 3 2 3 3 3 4 3 5 Rubber products should not be stored at temperature below 106 and above 156 whereby the upper limit may be exceeded up to 25 Any temperatures above this are only permissible for a short period Deviations to this rule can be rubber products made of certain types of rubber e g chloroprene rubber where the required storage temperature may not be lower than 12C Heating Rubber products stored i
11. RASR SM 07 SERVICE MANUAL RASR SM 07 FOR BELTED AIRSPRING ASSEMBLIES Air D rin gs for ERE CARON CODED Coaches 2050 STR C K 406 150 kN Code RASR 747 N 100 P 10 RDSO STR No C K 106 MAIN LINE 140 kN Code RASR 747 N2 100 P 11 RDSO STR No C K 106 LHB Fiat 120 kN Code RASR 747 N3 100 P 16 RDSO STR No C K 508 EMU DEMU 180 kN MEMU 150 kN MAIN LINE 140 kN LHB FIAT 120 From In collaboration with ntinental amp SINCE 1947 CONTITECH Mktg B 103 SECTOR 5 NOIDA 201 301 Email sales resistoflex in Tel 0120 242 0321 322 315 Mob 9818200361 365 Fax 0120 242 1417 INSTRUCTION MANUAL FOR BELTED AIR SPRING ASSEMBLIES RESISTOFLEX ntinental RESIS TUFLEA in collaboration with Chapter Particulars Preamble The Technology Air Suspension Installation Instructions Inspection Requirements Troubleshooting Instructions for Removal of Air Spring Instructions for Reassembly of Air Spring Handling and Storage of Air Spring R D S O approved Air Springs RESISTOFLEX in conavoration with SINCE 1947 Page Nos 3 4 6 T 15 16 18 19 26 25e 32 38 39 43 44 ontinenftal CHAPTER 1 PREAMBLE In 1956 the first German rail bus was fitted with Conti air spring Since then air springs have made unstoppable progress in the world of transport Everywhere in Europe the
12. STOP COCKS 1B AND 1C SHUT TO INTERRUPT THE AIR SUPPLY TO BOTH BOGIES AND ALL SYSTEMS BLED ONE MUST THEN PROCEED AGAIN AS INDICATED UNDER POINT ontinen fal in collaboration with 14 RASR SM 07 Installation Instructions 5 1 5 2 5 3 5 4 5 5 IMPORTANT INSTRUCTIONS Following points must be taken care of Name plate affixed to the top plate of the Air Spring Assembly must be visible from outside Please ensure that only one type of Air Spring make is used in one coach There should not be any mix up of two different types of Air spring Assembly in one coach as they will have different characteristics Installation height of Air Spring must be as under Air Spring Assembly Application Installation Height 5 3 a RASR 747 100 P10 EMU 255 260 mm MEMU DEMU CCF 5 3 b RASR 845N 100 P02 EMU DEMU 5 3 C RASR 747N2 100 P11 MLC 5 4 d RASR747N3 100 P16 LHB 292 294 mm After installation please fill up the RDPL F2 format and return to Hesistoflex for our reference and further use 8050 has recommended spare Air Spring Bellows for maintenance of Air Suspension vide letter No SV EMU RAS dated 21 01 2003 to all GM Mech amp GM Elect of Zonal Railways Limited Nos may be kept for use in event of failures Air Bellows fitment by shed workshop is not feasible without special tools When required we may offer refurbishment facility at our works against payment of cost of Air Bellow T
13. United States Canada South America Far East and Australia trains running on urban suburban and intercity networks provide a comfortable ride thanks to air spring technology The pinnacle to date of this trend is high speed train traffic for the French high speed train TGV holding the world speed record for trains reaching 515Km h on the Paris Tours run Today Air Springs are in widespread use in Trams Metros Suburban EMUs DMUs and Mainline Coaches because of the various advantages they offer over conventional suspension systems Since 1997 Indian Railways have successfully employed Air Suspension Systems in EMUs DMUs and Freight Cars Without having to repeat the basic research and development work this latest technology will benefit Mass Transit and Intercity Coaches Likewise Hydro Springs which combines a conical rubber adjustable spring and a hydraulic damper in the primary suspension will eliminate maintenance provide additional comfort drastically reduce transmission of hum frequencies and jounce and serve as wheel set guidance in modern bogies ontinenfal in collaboration with CHAPTER THE TECHNOLOGY OF AIR 2 SUSPENSION Generally the entire load of the vehicle is shared by the various springs present in the bogie These springs provide the required cushioning for the vehicle When loading on the vehicle varies which invariably happens the Ride Height of that vehicle varies accordingly It manifests in the
14. are should be taken to ensure that newly delivered products are stored separately from those already in store ontinen fal in collaboration with 43 RASR SM 07 Handling and storage 5 CLEANING AND MAINTENANCE Rubber products can be cleaned with soap and warm water The cleaned articles should be dried at room temperature After a fairly long period of storage 6 to 8 months the products can be cleaned with a 1 5 sodium bicarbonate solution Remaining traces of the cleaning fluid should be rinsed off with water The manufacturer will recommend effective and particularly harmless cleaning agents Solvents such as trichloroethylene carbon tetrachloride as well as hydrocarbons must not be used for cleaning purposes Moreover sharp edged objects wire brushes emery paper etc should not be used Rubber metal bondings are to be cleaned using a glycerine spirit mixture 1 10 1947 RESISTOFLEX in collaboration with ontinenfal A
15. area through undue mechanical also external stress nonetheless during the inspections traces are found of surface damage then this may beDUE TO the following reason a IMPROPER FITMENT b IMPROPER DISMANTLING C IMPROPER OR BAD STORAGE BEFORE PUTTING INTO SERVICE OR BETWEEN INSPECTIONS QOOQQQOQOR OSG Tri tenter OO OQ Sa ORG DD OK ICI E OLOR OO RCM OP ORR Sato redo L7 09 OR a Re ut gut at toda Torn n Put tst nt a a sat see n rat a ut a a i natn Lo 1206060056 OO tutu term Ps toT tote 4 4 4 4 G a a te es wees Qi ee shearing detachment of rubber 1947 RESISTOFLEX ntinental 5 23 RASR SM 07 Troubleshooting Detachment of rubber by mechanical effect or foreign bodies may lead to leaks Air Springs of this kind may not be fitted anymore since there is no longer any uniform radial sealing surface and there is a point of connection between the inner space and the ambient environment Uneven partial shearing may have been caused by prior dismantling of the Air springs This can in general be tolerated When assessing such a pattern it is however necessary to observe that the edges of the bead be partl
16. bogie is serviced Coatings of dirt on the surfaces of fitting elements which are in contact with the airbag wall should be removed either mechanically or with water ensuring that there is no damage to the airbag wall or metal surfaces Should any corrosion scars or roughness on the surfaces of the fitting elements which are in contact with the airbag wall be evident they should be smoothed down small localized items of damage on the outer cover such as small cracks or chafing marks providing the top cord ply has not been damaged are acceptable in the short term without impairing the functional performance DAMAGE TO THE CORD PLY for instance fraying of the fibres by chafing or severed threads NECESSITATES THE IMMEDIATE REPLACEMENT OF THE AIR SPRING CONTI AIR SPRINGS WITH 6 FABRIC PLIES ARE BURST PROOF IF ACCIDENTALLY PENETRATED THE LOSS OF PRESSURE WILL BE SLOW AND STEADY THUS AVOIDING A SUDDEN RELEASE OF LOAD TO THE PRIMARY SUSPENSION DERAILING SECURITY If an Air Spring is selected appropriate to the effective service conditions and the rolling stock runs trouble free there will not be any limitation of service life of the Air Spring by necessary wear and tear of loss of strength during the life of the vehicle ontinenfal gt in collaboration with RASR SM 07 Inspection requirements 2 1 2 2 2 3 2 4 INTERVALS BETWEEN INSPECTIONS OF AIR SPRINGS AIR SPRINGS ARE EXPECTED TO HAVE A SERVICE LIFE OF 16 YE
17. e On a corresponding pressure testing facility hydrocylinders are used to subject the air springs or just the auxiliary springs as the case may be to a force exactly equal to the force that would result at this point in the car body at tare gt Because of the manufacturing tolerances there will be differences in the distance between the level of upper edge of the rail and the upper edge of the air spring system or the laminated rubber metal spring support 2 4 The air spring systems or the auxiliary spring are lifted off the bogie frame again ontinenfal gt in collaboration with RASR SM 07 Installation Instructions 25 THE LEVEL DIFFERENCES ARE DETERMINED AND SUFFICIENT SHIMS STAINLESS STEEL PLATES FOR EXAMPLE INSERTED UNDER THE AIR SPRING SYSTEM OR THE AUXILIARY SPRING TO OFFSET THE DIFFERENCES AND ATTAIN A UNIFORM LEVEL 2 6 PLACE THE AIR SPRING SYSTEMS AND THE AUXILIARY SPRING ON THE SHIMS ON THE BOGIE FRAME AND MOUNT SECURELY PLEASE NOTE DEVELOPING AND DESIGNING THE BOGIE AND THE CAR BODY CARE IS TO BE TAKEN THAT SUFFICIENT OVERALL HEIGHT IS AVAILABLE FOR THE INSERTION OF SHIMS UNDER THE AIR SPRING SYSTEMS 1947 RESISTOFLEX in collaboration with ontinenfal RASR SM 07 Installation Instructions 3 INSTALLATION PROCEDURE 4 POINT SUSPENSION SYSTEM The 4 point system is a statically defined system that can effect various forces between car body and bogie and thus between wheel and rai
18. ese must be removed IF FABRIC IS ALREADY EXPOSED OR DAMAGED see point 4 THIS AIR SPRING MUST BE CHANGED The same effect may also be produced by what are called pieces of pigment which may occur when the surface protection is applied Unevennesses of this kind on the Air Spring plate or indeed on any other points of contact between the bellows wall and the metal part must be removed at once 7 PEELING OF THE OUTER RUBBER OUTER COVER LAYER During the time of utilization if any unevenness of the surface occurs in the form of a partial raising this is to be ATTRIBUTED IN MOST CASES TO INCORRECT STORAGE INTERIM STORAGE TOGETHER WITH LONG TERM CONTACT WITH OIL CHANGING IS NECESSARY 1947 RESISTOFLEX in collaboration with ontinen fal sars CHAPTER INSTRUCTIONS FOR REMOVALS 6 OF AIR SPRING Instructions for removing Air Springs with a clamping projection on the table top In certain circumstances the clamping projection which facilitates the exact fixing of the bead may hinder the removing process FLANGE SEATING z AIR SPRING PLATE EE gt Ter s k EIE i M OP DNI M Sa S EM i Or m EA no 22 gt 2 ti pu E ontinenftal in collaboration with 28 RASR SM 07 Instructions for removal To obviate damage to or even the destruct
19. form of variation in Coupling Height of a train formation The Ride Height of the vehicle is important to maintain parity with the way side Platform level and vehicle floor level To maintain Passenger Comfort in rolling and pitching the ride height of the vehicle and the coupling height between vehicles in a formation an extra cushioning is provided in form of air Suspension The air Suspension comprises mainly of two parts 1 Air Spring Assembly 2 Pneumatic Control System to maintain constant height independent of load The air suspension is preferred where there is frequent and sudden changes in the loading pattern and also Passenger Comfort is called for on EMUs DMUs Rail Bus Intercity trains etc The required load proportional braking effort can be given to the vehicle depending upon the particular load present at that instant by introducing an additional valve called averaging relay valve which uses the airflow from the relief valve as a signal Air suspension are installed as shown in the enclosed sketch with a 4 point system which as the name suggests have four leveling valves Four point systems tend to be the accepted norm for high speed operation allowing individual control of each air spring and hence optimum riding control The two air springs at one end of the vehicle are provided with a relief valve which will prevent excessive pressure difference occurring between the air springs onti
20. he reinforcement structure or damage in the sealing surface area it may lead to functional deterioration or the functional failure of the Air Springs In order to give the user the possibility of being able to recognize and assess damage himself and where necessary introduce countermeasures the main possible causes and effects are described hereinafter It should be mentioned that this description is based on long experience and intensive collaboration with manufacturers and operators of rail vehicles It is recommended that in instances of doubt you should check back with the manufacturer 1 1 Internal Natural Loads of and Air Spring Air Springs are highly stressed spring elements which are designed with regard to service life and bursting pressure protection are designed in such a way that they satisfy the demands of the Technical Delivery Conditions Z BTL 91843 of the German Railways of different operators with rail vehicles So in general it may be assumed that Air Springs under normal operating conditions with regard to service life fulfill the condition La 16 years that is to say half the service life of the bogie However the prerequisite is that before being put into service or in the event of possible changing of the Air Springs the storage specifications be observed and during operation undue stresses be avoided See Appendices 2 and 3 RESISTOFLEX in collaboration with ontinenfal 1947 RASR SM 07 Troubleshooti
21. ion of the bead when removing the top plate the following procedure is recommended s ur Lr ae eden pa ony pale an _ irate 1 Increase the top plate distance A as much as possible while air spring is in the uniflated state allai AIR S2RINIGS PLATE gt COCOS Tt BE 5 SS 2 4 oe SN 2 S 2 Fix top plate in this extreme position so that it does not exert any pressure on the Air Spring ntinental RESISTOFLEX in collaboration with SINCE 1947 uU RASR SM 07 Instructions for removal Force in assembly lever until it touches the metal cone whereby the lever 5 concave side should be against the air spring s wall lt is important to ensure that the lever is pushed between top plate air spring s wall until it touches the flange lf assembly lever is not in contact with the cone there is a danger of the spring being destroyed of it may prove impossible to unseat it ontinenftal RESISTOFLEX _incotiaboration with j SINCE 1947 30 RASR SM 07 Instructions for removal 4 Force spring bead from flange seat by movement of the lever and using the air spring s supporting edge as pivot 5 If necessary shift lever by spoon s width along flange circumference and repeat action Pos 2 RESISTOFLEX in collaboration with ontinenfal A 19
22. ith 37 RASR SM 07 Instructions for installation sl gt a 7 ni 52 7 WY z 2 4 1 Ifthe Air Spring is to be mounted directly onto the bogie the bolster or transom can now be applied If the rail car body is to be fitted afterwards or if technical approval of the bogie under load is to be conducted the bead area of the Air Spring is brought into position 4c to guarantee a tight seal The sealing area 4a and 4b must however be cleaned beforehand 4ab 4 2 f you intending to fit the whole Air Spring System as a unit later into the bogie this can be done by means of a suitable device The type of device used is illustrated on page 5 After cleaning and moistening the sealing area 4a b the Air Spring can be inflated at a spring internal pressure of p 6 bar ntinental RESISTOFLEX in collaboration with SINCE 1947 RASR SM 07 Instructions for installation pm EH S z Ld a Se ts a Em eus LA i tal 3 Air Spring is now fully installed Note All Conti Air Springs undergo a 100 airtightness test However for early detection of any errors or irregularities during installation which may lead to leakages we recommend conducting an airtightness test once installation has been completed Airtightness Testing Device Illustration of the principle Channel 150 X 75 5 zt a L3 Bolt M30 ON
23. l as well A4 point system guarantees protection from derailing only by respectively equipping each bogie with a double check overflow valve 7 that depending on its characteristics allows for certain pressure or force differentials The following drawing shows the basic structure of a 4 point system 5 7 ate 3 2 1 5 KD gt a H 5 v 5 6 S No PART NO DESCRIPTION 3 RARiSUL 1S0LAIR RESERVOIR WITHDRAINCOCK 1 _ 4 RCV CHECK VALVE NON RETURN VALVE 1 5 Riv LEVELLING VALVE WITHAIRRESTRICTION 4 pw UIN EXCCENNI C5 EMU DEMU MEMU MAINLINE LHB EXCINN E a COACHING CONTAINER roman MR NN EMU MEMU DMU HLC 40L AIR RESERVOIR WITH DRAIN COCK FOR ume meer _ RASR AIR SPRING ASSEMBLY ntinental RESISTOFLEX in coliavoration with j SINCE 1947 RASR SM 07 Installation Instructions 4 PROCEDURE FOR SETTING Within the possible pressure differences the car body can nonetheless be distorted or via the respective diagonal the air springs subjected to higher and then to lower pressure when the car body settings are improperly effected To minimize the pressure difference the following course of action 15 to be adhered to in adjusting the settings 4 1 4 2 4 3 4 4 4 5 4 6 4 7 Place the car body on the two bogies and hook it up to
24. llaboration with RASR SM 07 Installation Instructions 4 8 4 9 4 10 4 11 4 12 4 13 Shut stop cock 1b again thereby cutting off the air supply to bogie 2 and open stop cock 1c thereby releasing the air supply to bogie 1 Attach level control rod assemblies 6 to the valves 5 and after aeration carefully adjust settings on both rod assemblies 6 simultaneously proceeding from below until the desired car body height has been attained NOTE THE EVENT THAT THE TARGET LEVEL IS ALREADY EXCEEDED WHEN THE SETTINGS ARE EFFECTED THE ROD ASSEMBLIES 6 ARE FIRST TO BE REMOVED AGAIN BECAUSE OF THE DEAD CENTER OF THE VALVES AND SCREWED BACK WITHOUT IMPACT ON THE VALVES ONCE THE AIR SPRING SYSTEMS HAVE BEEN BLED AND THE CAR BODY HAS SETTLED ONTO THE AUXILIARY SPRINGS THE ROD ASSEMBLIES 6 ARE TO BE HUNG BACK IN PLACE AND THE HEIGHT CORRECTED Remove the block from bogie 1 Reopen stop cock 1b thereby releasing air to bogie 2 while at the same time hanging the rod assembly 6 back in place in bogie 2 Remove the block from bogie 2 Recheck the height at all measuring points NOTE IF NO CONSTANT HEIGHT IS ESTABLISHED ALL FOUR ROD ASSEMBLIES 6 ARE BE REMOVED SIMULTANEOUSLY HUNG BACK IN PLACE AFTER THE SYSTEMS HAVE BEEN BLED IN THE EVENT THAT THE LEVEL STILL ISN T CONSTANT THE BLOCK IS TO BE INSERTED CENTRALLY UNDER BOGIE 1 AGAIN
25. n heated store rooms must be shielded from the source of heat The distance between the source of heat and the stored goods must be at least 1 m A greater distance is required in the case of rooms heated by blast heating apparatus Humidity Storage of rubber products in damp store rooms should be avoided Care must be taken to ensure that no condensation occurs The relative humidity should preferably be below 65 Lighting The goods should be protected from light in particular from direct sunlight and strong artificial light with high ultra violet content For this reason the windows of store rooms are to be covered with a red or orange never blue protective coating Room lighting with ordinary incandescent bulbs is preferable Oxygen and ozone Rubber products should be protected from air changes above all from draughts by wrapping by storing in airtight containers or by other means This applies in particular to articles with a large surface to volume ratio e g rubberized fabrics or cellular rubber articles As ozone Is particularly harmful store rooms should not contain any equipment generating ozone such as electric motors or other equipment which may produce sparks or other electrical discharges Combustion gases and vapours which may produce ozone via photo chemical processes should be removed from the store room ontinenfal gt in collaboration with 42 RASR SM 07 Handling and storage 3 6 4 1
26. nenfal gt in collaboration with RASR SM 07 The technology Air Suspension The nominal height and level of the vehicle is set in the tare condition Depending upon the evenness of the load spread on the vehicle each suspension spring will have a slightly different air pressure to maintain this level Any subsequent increase or decrease in load over any air spring will cause a linear deflection to occur at that point The leveling valve s SI Nos 5 6 amp 7 of the enclosed schematic will register this movement and increase or decrease the pressure in the air spring S as appropriate to bring the vehicle body back to the correct level When a vehicle body has two leveling valves the air springs of a bogie need to be connected together so that if an air spring burst occurs on one side it does not cause a severe tilt or twist However if a direct connection was made then the pressures in each air spring would try to equalise and side to side leveling would not be possible Also in trying to level itself the more lightly loaded side would be exhausting air to try and bring itself to the correct height whilst the more heavily loaded side would be re feeding the air into the air springs To prevent this happening they are separated by a Relief Valve SI No 7 of the enclosed schematic on that bogie which only allows air to pass between the air springs when a set differential is attained This allows the leveling system to perform i
27. ng That is to say that WITH DISTURBANCE FREE OPERATION THE SERVICE LIFE IS NOT LIMITED BY WEAR AND TEAR OR ANY REDUCTION IN STRENGTH POSSIBLE SLIGHT SHORT OZONE OR AGEING CRACKS EXPOSE THE FABRIC STRUCTURE MAY BE ACCEPTED AT ONCE BUT SHALL BE OBSERVED IN SUBSEQUENT INSPECTIONS 1 2 External loads 1 2 1 BASIC STRUCTURE OF AN AIR SPRING Reinforcement Belt Internal protective coat 1 2 2 Functional description of the structural elements Attachment wire core Steel wire guarantees stable seating of the sealing bead on the rim and sealing of the Air Spring plate or piston External Protective Coat 100 highly flexible neoprene protection against the effects of the weather faces and extensively against oil Reinforcement Polyamide fabric guarantees operation bursting pressure protection and service life Belt Specific functional element Internal cover coat 100 highly flexible neoprene guarantees sealing of the internal space of the Air Spring against atmosphere 1947 RESISTOFLEX in collaboration with ontinenfal EU us RASR SM 07 Troubleshooting 1 2 3 Description and judgment of possible damage zones 2 TOP AND BOTTOM SEALING SURFACE AREA This area is extremely important for the operation of the Air Spring and is amongst other things checked by the works in the form of a 10096 leak test If the Air Spring is fitted properly then there is no possibility of damaging this
28. o amp fro freight charges will be to your account ontinenfal in collaboration with Installation Instructions RASR SM 07 AIR SPRING INSTALLATION HEIGHT RECORD 6 X3 1SOLSISAY dois dois 13M5 v88 ay eJnsselg juBieH paesu 391 peljeisul 1 2807 dasr TN ontinenfal c 9 2 S CHAPTER A INSPECTION REQUIREMENTS S No Topic Page Nos 1 Maintenance of Air Springs 17 2 Intervals between Inspections of Air Springs 18 ontinenfal RESISTOFLEX in conavoration with 5 SINCE 1947 RASR SM 07 Inspection requirements MAINTENANCE OF AIR SPRINGS Continental AIR SPRINGS are in principle MAINTENANCE FREE The OUTER COVERING consists of a thin age resistant flexible chloroprene rubber cover whichlS RESISTANT amongst other things to the influence of WEATHER AND SEWERAGE and to a large extent to OIL ABRASION through contact WITH OTHER BOGIE ELEMENTS extending into the confines of the Air Spring through thrown RAVEL AND SAND and any damage of the airbag wall by FOREIGN BODIES AND THE TRAPPING OF THESE BETWEEN THE BELLOWS WALL AND THE FITTING ELEMENTS MUST DEFINITELY BE AVOIDED Heavier coatings of DIRT OR MUD on the airbags wall should be washed off using only water whenever the
29. s during inspection intervals or afterwards Air Springs changed and released from the top Air Spring plate If this is not done properly it could lead to surface damage through the use of the necessary tool which could even penetrate as far as the reinforcement Due to the structure there is not immediate safety reducing damage only if several threads of the individual layers 4 6 are pierced may there under certain circumstances be an immediate functional failure IMMEDIATE CHANGING IS HOWEVER NECESSARY 1947 WRESISTOFLEX nfi nenifal gt 2 in collaboration with I RASR SM 07 Troubleshooting 5 CHAFING DAMAGE BY CUTTING chafing Points of chafing or DAMAGE BY CUTS caused by design attachment elements hose connections or BALLAST ACCELERATED with an unusually high intensity may by experience occur in this area or also in the area 5 ABRASION OR SHORT CRACKS ON THE TOP COVER LAYER MAY BE TOLERATED IF HOWEVER THE REINFORCING MATERIALS ARE EXPOSED PIERCED AND UNRAVELED A THEN THIS AIR SPRING MUST BE CHANGED AT ONCE 6 FOREIGN BODIES CHAFING OR DAMAGE BY CUTS For this area the same procedure applies to chafing and damage by cuts as in area 4 foreign bodies piece of pigment ntinental in collaboration with D6 RASR SM 07 Troubleshooting If foreign bodies have got between Air Spring plate and bellows wall and have ended up jammed th
30. ts function and prevent excess air consumption whilst allowing both air springs to be deflated to a level where they would rest on their emergency spring should one air spring burst The pressure differential on the Relief Valve offered is dependent on the coach requirement This pressure differential is linked to the maximum difference in air pressure that can be seen between the air bags in dynamic conditions plus the collapse pressure of the air bags Notes a The mechanical Pneumatic Control System is generally not in our scope of supply b An Electronic Control System cum Emergency Warning System based on electronic sensor electronic valve and a tailored control function has been developed This allows automatic and close tolerance setting of Air opring dispensing with any manual setting and associated problems ontinenfal gt in collaboration with RASR SM 07 The technology Air Suspension 9 7 9 Je s n a T 2 8 5 5 8 6 1 3 2 1 HD 2 i L ats Uu 9 6 S No PART NO DESCRIPTION ISOLATING COCK TYPE AIR FILTER TWO WAY 1501 AIR RESERVOIR WITH DRAIN COCK CHECK VALVE NON RETURN VALVE LEVELLING VALVE WITH AIR RESTRICTION Pete R IL 315 INSTALLATION LEVER WITH BALL amp SOCKET 4 S e EMU DEMU MAINLINE LHB en naan anon ___ NO AI
31. uctions for installation B INSTALLATION 1 Clean the upper bead a and upper rim b using a cloth The upper air spring plate is already in the illustrated reversed position 2 Locate and point of the Air Spring upper bead on the rim and press the bead behind underneath the upper lip Fig 2a RESISTOFLEX in collaboration with 1947 RASR SM 07 Instructions for installation d Plate a suitably sized piece of wood 3a on the surface of the bead and using a hammer tap the wire bead into position 3b Note Working away from the starting point radially tap evenly at increasing distances to the left and right until the bead has slipped under the holding lip around its entire circumference The Air Spring is now properly connected to its air spring plate 1947 RESISTOFLEX ontinenfal in collaboration with 26 RASR SM 07 Instructions for installation ty A 2 4 The final step is to now fit the Air Spring to the lower rim 4 To do so it is sufficient to place the Air Spring on the rim so that the bead area is positioned parallel to the rim A SSS AAN 2 Clean both the bead area of the Air Spring 4a the sealing areas of the rim 4b beforehand It is recommended that this area is moistened with water or soap suds to make installation easier in collaboration w
32. y chamfered by the works depends on manufacture 3 CRACKS ABOVE OR BELOW THE DIRECT BELT AREA Fault pattern external protection layer internal rubber layer reinforcement belt casing belt ontinenfal RESISTOFLEX in conaboration with SINCE 1947 _ 24 RASR SM 07 Troubleshooting IF CRACKS OCCUR RADIALLY DURING OPERATION IN THIS AREA THEN AIR SPRINGS OF THIS KIND SHOULD BE CHANGED ON THE NEXT INSPECTION This surface damage has no functional effect on the Air Springs or any effect which might prejudice their safety Due to the structure there can be neither damage to the reinforcement nor peeling of the belt nor any reduction in bursting pressure Cracks of this kind may after the time at which they occur grow radially with respect to the depth however they simply move to the middle of the belt and not in the direction of the reinforcement This defect pattern may be triggered by different causes for example extreme horizontal bellows wall deformations damage by cutting due to external effects ballast Possibly where there is doubt it may be necessary to bring in the manufacturer to obtain an assessment 4 SURFACE DAMAGE IN THE TOP SHOULDER AREA Plan view ca 20 30 mm t ia i trs um MEE uvm f sate Sree ee MF In many case
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