Главная Manuals Indian Railways Wag-9 Locomotive 31000-31021. MAINTENANCE & REPAIR MANUAL

Wag-9 Locomotive 31000-31021. MAINTENANCE & REPAIR MANUAL - page 1

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Introduction
. These Maintenance & Repair Manuals of technical documentation for the Indian Railways WAG-9 locomotives are divided into Chapters; each of which contains information pertinent to a specific area of the locomotive. The Chapter numbers correspond to the Breakdown Structure of the Locomotive (GAPL), shown on the inside front cover of this binder. The same delineation of Chapters is used throughout the technical documentation for the WAG-9 locomotives.

Information in each Chapter is divided into various Sections which describe the locomotive equipment and procedures required for maintenance. See Section Description, as follows.

The Maintenance & Repair Manuals span more than one binder. For ease of identification, each Volume is labelled on its spine and front cover, indicating the Volume and binder number, and the Chapters contained within.

Section Description

Section Group Summary describes the equipment covered by the Chapter. Figures show the various components and a legend beneath identifies the items.

Section Functional Description explains the function that the equipment performs on the locomotive.

Section Technical Data contains technical information and specifications on the equipment covered in the chapter. The information varies according to the type of equipment. In some instances, specifications for equipment may be located in the appropriate chapter o1 Volume F, Suppliers Documentation.

Section Tolerances and Wear Limits List contains information regarding the allowable in service wear or tolerance specifications for the equipment covered in the chapter. In some instances the service tolerances for equipment may be located in the appropriate chapter of Volume F, Suppliers Documentation.

Section Tools & Special Tools provides information of any non-standard tools and apparatus that are required to undertake the procedures described in the chapter. Throughout this documentation it is assumed that conventional railways workshop tools and equipment are available. As such, these items are not listed.

Section Miscellaneous Materials lists the materials required for the operations describec in this chapter. Materials needed for the procedures in the chapter, such as sealants, threac locking agents, oil binding agents, solvents, cleaners and alike are listed in this section. It is assumed that normal workshop consumables and materials are available. As such, these items are not listed.

Section Before Removal Operations provides a list of procedures necessary prior to the removal of the equipment described in the chapter.

Many before removals operations require procedures described in other chapters or documents. The necessary references are given, see References.

Some before removals operations require isolation of other equipment. Details are providec as necessary, along with appropriate references. Isolation of equipment must always be car ried out in accordance with the prevailing workshop safety regulations. Any equipment that is isolated as part of the before removals operations must be reconnected after the work is completed and the associated equipment tested to ensure it functions correctly.

Section Removal describes the procedures for removal of the entire equipment assemblies from the locomotive. Some equipment can be serviced in situ:-it may not be necessary to re move the entire assembly from the locomotive. See Scope of Work.

propriate level of technical and engineering understanding before undertaking any operations on the locomotive. This manual describes the technical procedures required to service and maintain the specifics of the WAG-9 series locomotives, not general locomotive engineering practices. Workshop procedures and practices are not covered within these instructions.

Scope of Work

Due to the complex nature of locomotive engineering, every instance in which equipment can be removed or installed cannot be taken into consideration in these Volumes.

Some'equipment can be serviced in situ:-it may not be necessary to remove the entire assembly from the locomotive. For example, the valve sets can be removed from the traction converter without removing the traction converter from the locomotive. Before undertaking any work on the locomotive, the entire chapter must be read, and the user acquainted with all aspects of the procedures. The scope of work is then to be established.

General Information

Throughout this preface, the term ’equipment' refers to the components and systems that comprise the locomotive.

All figures in these volumes are graphical representations intended as general illustrations to represent the situation. They may not be dimensionally or otherwise accurate. Figures should not be used for scaling. Only the items numbered in an illustration are referenced in the associated text passages. No additional information should be inferred from the figure.

Figures, photographs and drawings may appear pictorially different from the physical situation being represented. Extraneous components may not be shown in the illustration for clarity. Others may be shown redundantly to provide a frame of reference for the situation.

References

Maintenance, removal or installation of some equipment on the locomotive can require interaction with other components described in different chapters, or volumes. In these cases, a reference is given directing the user to the appropriate documentation. For example, “refer to Chapter 3, Primary Suspension" directs the user to another chapter in Volume D where the necessary procedures are described. References, such as, “refer to Chapter 5, Oil Blowers of Volume F10, Suppliers Documentation.” direct the user to the appropriate volume and chapter of the Suppliers Documentation, Volume F. Or “refer to Section Actual value Detection, Sheet 12A, Catenary & Battery Voltage of Volume G1, Cabling Documentation" directs the user to the appropriate sheet in the locomotive schematics, Volume G.

Care should also be taken to ensure that capacitor systems on the locomotive have discharged prior to undertaking operations. The traction converters and the BUR cabinets contain capacitors. Voltage indicators on these cabinets warn of any residual voltage in the cabinet. Always ensure that indicator LEDs are flashing slower than once every 15 seconds. See Electrical Isolation of the Locomotive, Chapters 4.1, Traction Converter and 5.1, Auxiliary Three-Phase Power for more information on voltage indicators. The filter cubicle also contains capacitors, but these are automatically discharged whenever the main circuit breaker is opened.

The gases generated by a battery are highly flammable. Where a battery is found to be or suspected to be overheated, extreme caution should be taken to prevent ignition until the gases have been allowed to disperse. Keep flames, lighted cigarettes and welding operations away from batteries.

Electronics Precautions

, Do not use a buzzer, bell, megger, or flash test equipment until all circuits which include semiconductor devices have been isolated. Ensure the manufacturers directions are followed whenever testing electrical and electronic devices. Special tools and testing procedures may be required.

Whenever working with electrical equipment, it is good practice to become familiar with the related schematics. Volume G, Cabling Documentation contains the electrical schematics for the locomotive. Always ensure that any removed wiring is reconnected correctly, as incorrect wiring can cause irreparable damage to equipment and incomprehensible error messages from the control electronics.

When electrical and electronic equipment is to be removed, all wiring should first be tagged before it is disconnected. This will aid in the correct reinstallation and reconnection of the equipment.

In many chapters, references are given to the appropriate Sheet in Volume G, Cabling Documentation. Otherwise, wiring should be reconnected as tagged during removal. The wiring and terminal numbers located on equipment are referenced in the electrical schematics in Volume G.

Cabinets and Equipment Cubicles

WARNING:

Extreme care must be taken when approaching equipment which has been live, and could remain live for a short period of time because of the delayed discharge time of capacitors.

Visual Inspection
Visual inspection is usually the first form of testing or evaluation performed. Many defects, cracks and points of corrosion may be quickly discovered through a visual inspection.

Impact or stress damage, flaking, scratches and other conditions may also be apparent during a visual inspection. This type of damage is usually specific for each component. The Inspection and Repair Sections in these Maintenance and Repair volumes give more specific details of the visual inspections necessary to identify (ikely damage or faults which may occur some of components and systems covered in these volumes.

The following information discusses some forms of damage that may be apparent during a visual inspection.

Corrosion

Corrosion is common on metallic surfaces and can be readily identified through discolouration, scaling and flaking. While certainly indicators of corrosion, these symptoms may be caused by a means other than corrosion and must not be used solely as confirmation of corrosion. Overheating may appear to be similar to corrosion, both giving a brown colour and a similar texture.

Overheating

Overheating can appear similar in colour and texture to corrosion. Discolouration from heat usually appears to fade at the edges, whereas corrosion generally has defined edges of a more constant colour. Overheating may also result in a bluish colouring, quite distinct from corrosion that fades towards the edges.

Cracking

Cracks may appear in many surfaces. A crack may appear to run along the surface or to be coming out from inside the component. In either case, the source of the crack and the extent of the crack must be evaluated, possibly by use of another NDT technique, to establish the best course of action regarding the repair or rejection of the cracked component.

Magnetic Testing

When a discontinuity is present in a material, the magnetic flux within the material changes greatly as it approaches the discontinuity. This noticeable change in magnetic flux can be useful for finding and evaluating flaws and cracks in a material.

Magnetic testing equipment must always be operated by fully qualified personnel in accordance with equipment manufacturers recommendations and within the prevailing workshop regulations.

Some materials are ferromagnetic (eg. iron, steel, cobalt, nickel) and can be magnetised to provide a suitable magnetic flux for testing. Other materials, such as aluminium, copper and some stainless steels are not ferromagnetic and do not possess a magnetic flux suitable for testing. However, by inducing a current in such materials, a magnetic flux is also induced. This induced magnetic flux can be suitable for testing for discontinuities in the material.

Any item that has been magnetically tested must be demagnetised after the testing procedure, before re-use in service.

Radiographic Testing

Radiographic, or x-ray, testing involves exposing a component to a radiographic source (such as x-rays or gamma rays) and measuring the change in the source after it has passed through the material. Voids, porosity and cracks are shown as a change in radiographic distribution within the material. The distribution through a discontinuity is noticeably different than for the surrounding, continuous material.

Radiographic testing equipment must always be operated by fully qualified personnel in accordance with equipment manufacturers recommendations and strictly within the prevailing workshop regulations.

Sealant Preparation

Surfaces to be sealed and joined with Sikaflex 221, Sikalastomer710 or Sikaflex 15LM must first be prepared in accordance with the sealant manufacturers directions. If the proper preparations are not performed, the integrity of the sealant can not be guaranteed.

Some sections of this volume require that sealed joins be cut in order that some components may be removed from the loco. When reinstalling such components, a new seal must also be achieved. Any traces of the previous seal must be completely removed and the surfaces prepared accordingly so that a new seal may be achieved.

The following table shows the preparations required for particular surface types and finishes prior to the application of Sikaflex 221.

Water Test

In various chapters throughout these Maintenance and Repair Volumes, a water test is required after work has been performed. The test is to be performed to ensure the locomotive is water tight. Any water leaks on the locomotive pose an operational hazard, as the ingress of water to the locomotive can cause damage to electrical components and corrosion of metallic parts.

The locomotive must be in full operational condition for the water test. All equipment is to be installed and all sealant curing times observed. All blowers are to be running during the water test.

Do not spray water directly into breather ports on axle boxes or traction motors, or into roof vents on the cab or the mushrooms on the machine room roof hatches.

The locomotive should be positioned below a spray gantry, consisting of horizontal top rows of nozzles, each with two vertical rows of nozzles, one on each side of the locomotive. Each row of nozzles should be capable of uniformly delivering 500 litres of water per minute at 200 kPa with 90° solid cone nozzle spray patterns. With all blowers running {traction motor, oil cooler and machine room blowers, complete with scavenge blowers), the locomotive should be tested under the gantry for a period of 15 minutes. During this period, personnel within the locomotive cabs and machine room should be inspecting the locomotive for leaks. Typical areas to inspect would be seals, through bolt holes, areas where equipment passes from the outside to the inside of the locomotive, and opening with covers/doors and windows.

Tightening Torques

The tightening torques in the following tables only apply to the grade and size of bolt listed, unless otherwise specified in the procedure described in these volumes, or Volume F, Suppliers Documentation.

As a general rule, a locking compound, such as Loctite, should be used when assembling fasteners, except on the bogies. A thread sealing compound should be used on all threads opening into any compartment of the locomotive structure, and on all pipe fittings. Some compounds and coatings may alter the required tightening torque. Use the compound manufacturer’s recommendations for modification of the tightening torques to avoid mechanical failure.

Steel Hexagon Head Bolts and Screws

Steel Socket Head Cap Screws

IR WAG9 Volume D1

Loco Body

1.01 Structure
1.02 Exterior Finish

1.03 Doors & Steps
1.04 Draftgear & Couplers
1.05 Windows
1.06 Horns/Lights
1.07 Washers/Wipers
1.08 Buffers
1.09 Cable Conduct

1 Loco Body
For complementary information see following Chapters in Volume D1 Structure 1.01

Exterior Finish 1.02

Doors and Steps 1.03

Draftgear and Couplers 1.04

Windows 1.05

Horns and Lights 1.06

Wipers and Washers 1.07

Buffers 1.08

Cable Duct 1.09

1.1 Structure
General Notes on Hazards in the Work Area
WARNING:

HIGH VOLTAGE! DANGER OF ELECTROCUTION. Some of the components are live when the locomotive is connected to an active overhead. NEVER WORK ON THE ROOF AREA WHILE THE LOCOMOTIVE

UNDER A LIVE OVERHEAD.

Functional Description
0.1140

The converter and pantograph roof hatches are sealed around the entire perimeter. The roof beam can be removed for ease of access during maintenance. Lugs are provided on the roof hatches for attaching lifting equipment.

Technical Data

0.11(0

Welding Equipment
ES4S Welding Wire Mechanical Properties

- Type	ES4S, Copper Coated
- С (carbon)	0.10%
- P (phosphorous)	0.015%
- Si (silicon)	0.75%
- Mn (magnesium)	1.3%
- Yield Strength	390 MPa
- Tensile Strength	500 MPa
- Elongation	32%
Argoshield 51 Welding Gas Properties
- CO² (carbon dioxide)	16% ± 0.2%
- H (hydrogen)	2.5% ± 0
- Ar (argon)	81.5% approximately, remainder

Tolerances and Wear Limits List

в.1170

[Not required]

Tools and Special Tools

e.itao

These maintenance procedures in this Chapter require conventional workshop equipment.

Miscellaneous Materials

0.1200

[Not required]

Before-Removal Operations

0.1220

[Not required]

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