LHB Volume 1

8/6/2019 LHB Volume 1

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MAINTENANCE AND SERVICE MANUAL

ABCD Indian Railways

1.1 LEGAL REGULATIONS

1.2 SAFETY STIPULATIONS

1.3 STRUCTURE OF THE DOCUMENTATION

1.4 MAINTENANCE (PRINCIPLES AND TERMS)

1.5 RECORDING OF THE MEASURES

1.6 EDP FILES OF THE DOCUMENTATION

GENERAL HINTS AND STRUCTUREOF DOCUMENTATION

Volume 1

Issue: 04/10.03


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abcd-No. 150696 H9030Alternation: 04/10.03Printing date: 15.10.03 08:33

General hints and structure of

documentation


Indian Railways ABCD


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abcd-No. 150696 H9030Alternation: 04/10.03File name: IH_B01_A04_EPrinting date: 15.10.03 07:58

Sheet 1 of 22General hints and structure of

documentation

G

eneralhintsandstructureofdo

cumentationlog

1 GENERAL HINTS AND STRUCTURE OF

DOCUMENTATION

All information and figures present the latest state at the time of printing.

We reserve the right to technical modifications.

We reserve all rights for this technical document, also for the case of patentaward or registration of utility models. It must neither be copied, nor disclosed tothird parties nor misused in any other way without our prior written consent.

Issue: 04/10.03

Copyright 1999 - 2003 ALSTOM LHB GmbHAll rights reserved.

ALSTOM LHB GmbH

Linke-Hofmann-Busch Strae 1

D-38239 Salzgitter


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Generalhintsandstructureofdo

cumentationlog

List of Amendments

Date Issue Modification Signature

16.02.00 01/01.00 preliminary TZ 8

18.07.00 02/07.00 First revision TZ 8

21.02.03 03/02.03 Second revision CW 3

15.10.03 04/10.03 Third revision (Cap. 1.3.2.1) CW 3

Hints:

A new issue will be prepared in case that modifications become necessary.

The document concerned will be replaced completely even if individual sheets only change.

Unmodified documents will keep their issue number irrespective of what issue of theMaintenance Manual is valid at that time.

Please note that copies distributed by you may no longer be subject to our

modification service.


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Contents

1 GENERAL HINTS AND STRUCTURE OF DOCUMENTATION

1.1 LEGAL REGULATIONS___________________________________________ 51.1.1 GENERAL LEGAL REGULATIONS __________________________________ 51.1.2 LEGAL REGULATIONS RELATED TO BOGIES ________________________ 51.1.3 LEGAL REGULATIONS RELATED TO PERSONS ______________________ 6

1.2 SAFETY STIPULATIONS__________________________________________ 71.2.1 GENERAL SAFETY STIPULATIONS _________________________________ 71.2.2 SCREWED JOINTS WITH TIGHTENING TORQUES ____________________ 81.2.3 SAFETY STIPULATIONS RELATED TO THE BOGIES___________________ 91.2.4 SAFETY STIPULATIONS RELATED TO PERSONS ____________________ 10

1.3 STRUCTURE OF THE MAINTENANCE DOCUMENTATION _____________ 121.3.1 WHERE TO FIND WHAT ?________________________________________ 121.3.2 STRUCTURE OF THE MAINTENANCE DOCUMENTATION _____________ 12

1.4 MAINTENANCE (PRINCIPLES AND TERMS)_________________________ 161.4.1 GENERAL _____________________________________________________ 161.4.2 PLANNED MAINTENANCE________________________________________ 161.4.3 VISUAL INSPECTION AND SAFETY CHECKS ________________________ 171.4.4 MAINTENANANCE ______________________________________________ 181.4.5 PLANNED REPAIRS_____________________________________________ 181.4.6 REVISION (OVERHAUL) _________________________________________ 181.4.7 ELIMINATION OF FAULTS (WHOLE VEHICLE )_______________________ 181.4.8 UNPLANNED SERVICING ________________________________________ 19

1.5 RECORDING OF THE MAINTENANCE MEASURES ___________________ 20

1.6 EDP FILES OF THE DOCUMENTATION_____________________________ 211.6.1 SYSTEM REQUIREMENTS FOR ACROBAT READER __________________ 211.6.2 INSTALLING AND STARTING THE ADOBE ACROBAT READER_________ 221.6.3 STRUCTURE OF THE DOCUMENTATION CD ROM ___________________ 22


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1.1 LEGAL REGULATIONS

1.1.1 GENERAL LEGAL REGULATIONS

Use of the vehicles and their components for the purpose intended:

Any use not approved by the manufacturer shall be deemed use not for the purposeintended. No claims will be accepted by the manufacturer for damage due to improperuse.

Use for the purpose intended includes, but is not limited to, the observance of theoperating, maintenance, setting, and repair measures specified by the manufacturer.

In addition to the Maintenance Manual, please do also make use of the general legal andother binding regulations and legal stipulations as well as the instructions contributing toenvironmental protection.

1.1.2 LEGAL REGULATIONS RELATED TO BOGIES

Defects or damage at the bogies which affect the safety of transport andoperation, must be reported immediately to the central operationmanagement. These vehicles must not be taken into service.

Unauthorised alterations at the vehicle exclude any liability of the manufacturer fordamage resulting therefrom and its consequences

Without the approval of the manufacturer, no alteration, attachment or reconstructionmeasures shall be carried out at the bogie which might affect safety. This shall also beapplicable to repair work and welding of load-bearing components.

Spare parts shall meet the technical requirements stipulated by the manufacturer which isensured always in case of original spare parts.

Welding, cutting and grinding work at the bogies must not be carried out unless thewritten approval by the manufacturer has been obtained.


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1.1.3 LEGAL REGULATIONS RELATED TO PERSONS

For the activities described in this Maintenance Manual those persons arequalified which are acquainted with the relevant assembly, maintenance andrepair work. In particular they must have read all legal regulations and safetystipulations!

The personnel in charge for doing work at the vehicle must have read and understood theMaintenance Manual prior to the beginning of work. This is applicable in particular topersonnel doing work at the vehicle sometimes only.

Work at the vehicle must be carried out by reliable persons only. The legally permittedminimum age shall be observed!

Trained or instructed personnel only should be authorised. The responsibilities of thepersonnel for operation, setting, maintenance and servicing should be defined clearly.

Make sure that persons do work at the vehicle only who are authorised to do so!

Make sure that persons who are trained, informed, instructed or persons under generaltraining only do work at the vehicle only under the permanent supervision of anexperienced person.

Work at the electrical equipment of the vehicle must be carried out only by a specialisedelectrician or instructed personnel under the direction and supervision of a specialisedelectrician in accordance with the regulations of electrical engineering.

Persons only who have specific knowledge and experience in the field of hydraulicsystems shall work at the hydraulic equipment.

Persons only who have specific knowledge and experience in the field of pneumaticsystems shall work at the pneumatic equipment.

One of the persons working at the vehicle shall be instructed in First Aid measures!


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...Stipulations concerning the mechanical system (contd.)

When replacing individual parts and large sub-assemblies attach and secure the latter at

the lifting tackle to avoid danger. Use suitable and technically proper lifting tackle onlywith a sufficient load-bearing capacity. Do not stay or work below suspended loads!

Stipulations concerning cleaning

Clean connections and screwed joints from oil or preservative agents at the beginning ofmaintenance/repair! Do not use aggressive cleaning agents! Use fibre-free rags!

Remove grease deposits by means of a liquid detergent. Suitable detergents are thosewhich consist of 50 % each of turpentine substitute and methyl chloroform such astrichloro ethylene and perchloro ethylene. All other benzene solvents or kerosines whichdissolve oil and grease and do not attack the components are also suitable!

Prior to do welding, cutting, and grinding work, clean the vehicle and its surroundingsfrom dust and combustible matter and ensure sufficient ventilation (danger of explosion)!

1.2.2 SCREWED JOINTS WITH TIGHTENING TORQUES

Screwed joints which must be pre-tensioned according to the specifications, are markedin the drawing with the torque to be applied. Special attention shall be paid whenassembling these screwed joints !

The tightening torques of the screwed joints are identified by Item numbersin the drawings which are used in the assembly and demounting description.

Make sure that the quality of screw, nut, washer, etc. is in conformity with therequirements of the list of parts.

When spezified in the drawing, the screw must be provided with a molybdenum disulphidepaste (Molykote G-n PlusAbcd-LHB-ID No.: 240 754) as the lubricant.

Screw-on faces, screw head and nut supporting areas to which the tightening torque is

applied must be metallically bright in this area only or a priming coat must be providedwhich must not exceed 20 30 m. For deviating data for the screw area, such as paint-coat free or provide with insulating paste please refer to the relevant drawings.


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The design of the screw-on faces must be clearly indicated in the design drawings(individual parts, sub-assemblies!

Use a suitable torque wrench or calibrated motorised devices (e.g. screw driver) fortightening. Do not use percussion tools. Percussion tools are allowed only after havingtightened one turn of the nut at least by means of a torque wrench! The fitter mustconvince himself that the wrench has been set to the torque required.

Specific safety relevant screwed joints are identified in the drawing by a circle around theItem number. After having tightened these joints identify them using yellow paint. Prior todo so the fitter must have convinced himself that his work has been done in a correctway.

1.2.3 SAFETY STIPULATIONS RELATED TO THE BOGIES

Caution

Always secure the bogies against rolling off when doing maintenance andrepair work!

The terms given in the Maintenance Manual for recurring inspections/checks shall bekept!

Check new and overhauled components 14 days after start-up/reconnection. Checkthese components particularly for safe mounting. Check whether the marks of screws andbolts have been provided and check them for damage. If damaged, replace the screwedjoint by a new one .

Stipulations concerning the electrical system

CAUTION!

Some of the bogie components contain electrical voltage which aredangerous to life which might result in injury and damage to the vehicle

unless the safety regulations are not followed!

Prior to do maintenance and repair work, separate the main circuit from the power supplysystem. The surface of all electrical equipment parts must be dry and free from oil,grease, deposits, and corrosion. Do not place tools and working means on the conductingsurfaces of components.


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... Stipulations concerning the electrical system (contd.)

If work must be carried out at live parts always employ a second person who operated the

den Emergency OFF push-buttonor themain switchwith shunt tripping. The area ofworking must always be guarded by a red/white safety chain and a warning sign! Use

tools only which are insulated against voltage!

1.2.4 SAFETY STIPULATIONS RELATED TO PERSONS

Caution!

Reliable and safe operation of the vehicle depends on careful operating,

setting, and repair work. Non-observance of the following safety stipulationsmay result in serious injuries or the death of the maintenance staff and thosepersons staying in the vicinity !

Employ trained or instructed personnel only, clearly define the responsibilities of thepersonnel for operation, setting, maintenance, and servicing.

Make sure that persons who are trained, informed, instructed or persons under generaltraining only do work at the vehicle only under the permanent supervision of anexperienced person.

Wear the protective equipment, if necessary or required by the relevant regulations.

The personnel must not wear open hair, loose clothing, jewellery or rings. Danger ofinjury, e.g. by getting caught or drawn in.

Observe the international and national regulations of the relevant Supervision

Authority!

Stipulations concerning electrical work

Work at the electrical equipment of the vehicle must be carried out only by a specialisedelectrician or instructed personnel under the direction and supervision of a specialisedelectrician in accordance with the regulations of electrical engineering!

Keep your hands off live components, electrical contacts, housings and the work benchwhen carrying out electrical tests!


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Stipulations concerning pneumatical work

Switch the compressed line off prior to begin with assembly or maintenance work. When

demounting the components of the compressed air system it may be possible that dirtparticles and/or gaskets are torn out even if the compressed air lines are shut off. Also asudden loud noise may occur.

Caution!

Protect your eyes, ears, and skin!

Do not direct the compressed air nozzles towards other persons!

Stipulations concerning cleaning

Caution!

Cleaning agents and lubricants only must be used which have beenapproved by the manufacturer. Use of solvents as cleaning agents and theuse of lubricants may be hazardous to health and may affect labour safetyand industrial hygiene! Please contact the manufacturer prior to use suchagents and observe the safety precautions when using such agents!

Caution!

Dust particles and/or drops of cleaning agents may be in the air after havingcleaned by means of liquid cleaning agents, wire brushes and/or emerypaper! Protect your eyes!

Stipulations concerning the mechanical system

Caution!

In installed conditions, components may be subject to spring tension. In suchcases, secure the spring by means of a suitable fixture in order to avoidpersonal injury when demantling/installing!


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1.3 STRUCTURE OF THE MAINTENANCE DOCUMENTATION

1.3.1 WHERE TO FIND WHAT ?

The documentation is subdivided in the following documents:

SET OF DRAWINGS AND LISTS OF PARTS OF ALSTOM LHB,

MAINTENANCE DOCUMENTATION (MAINTENANCE MANUAL).

The principal is provided with the different documentations in form of complete volumes.Cross-references to individual chapters "Set of drawings and lists of parts" ill be used in the

maintenance documentation, if required.

1.3.2 STRUCTURE OF THE MAINTENANCE DOCUMENTATION

This Maintenance Manual is the basis of the documentation. All information related tomaintenance, operation, transport, and storage should be taken from the individual chapters.The maintenance documentation is subdivided in three volumes:

MAINTENANCE MANUAL VOLUME 1: General hints and structure ofdocumentation

SYSTEM DOCUMENTATIONVOLUME 2:

1.3.2.1 HINTS FOR USING THE MAINTENANCE MANUAL

This manual contains all data which are necessary for maintenance,operation and repair of bogies.

The information given in this manual is based on the latest state of development and theexperience gained from the operation of comparable vehicles. The manual together with thedocuments of the sub-suppliers allows to carry out the specified inspections, maintenance,setting, and repair work with maximum safety.

VOLUME 3: COMPONENTEN DOCUMENTATION


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Observe the following when doing inspection, maintenance, setting, and repair work

at the bogies:

Keep a journal for each bogie covering all works and stating the running kilometres,maintenance intervals, maintenance periods and the type and scope of work (inspection,lubrication, overhaul, ...). This will be helpful when looking for the causes of failures due tofaulty operation, maintenance, setting, or repair work. It is also possible to drawconclusions concerning the service life of individual components.

Follow all regulations and hints given in this manual and the documents of the sub-suppliers. Specific attention should be given to all safety regulations.

Reliable and safe operation of the bogies depends on careful maintenance, setting, andrepair work.

After any work done at a component, follow the relevant hints and instructions forChecks/tests and Start-up/Re-connection and carry out the steps specified there.

Caution!

Make sure to separately dispose - according to the local environmentalconditions - lubricants and parts contaminated by lubricants .


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1.3.2.2 WARNING AND SAFETY HINTS

The symbols and frames in the individual sub-chapters have the following meaning:

Caution!

Hints which might result in injuries dangerous to life or damage to the vehicleor components of vehicles when improperly followed or not at all.

Important hints in which your attention is drawn to a particular feature and/orin which a hint for operation is given.

Hints concerning the steps for demounting and assembling.

Follow the sequence of the steps!

Inspection hints and instructions which must be followed in any case in orderto ensure safe operation of the vehicle.


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1.3.2.3 ABBREVIATIONS

The following abbreviations are used in the manual:

Technical and general abbreviations

Fig. ___________________________________FigureC _____________________________degree Celsiusapprox. __________________________approximatelyDG___________________________________ bogiesIf any. _________________________If any/necessaryh _____________________________________ hourskg __________________________________ kilogram

km _________________________________ kilometrekm/h ________________________ kilometre per hourkN ________________________________KiloNewtonl ________________________________________ litrem _____________________________________ meterm ______________________________ square metermax. _______________________________ maximummin. ________________________________ minimummin _________________________________ minutesmm _______________________________ millimetresN ____________________________________NewtonOK________________________________upper edgePos._________________________________ Positions ____________________________________ seconds.o. _________________________ refer to above textSO___________________________upper edge of railDG_______________________________ trailer bogieWK _________________________________ car body


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1.4 MAINTENANCE (PRINCIPLES AND TERMS)

1.4.1 GENERAL

Maintenance is a significant factor to ensure the availability and reliability of the bogies. Thusit is of utmost importance.

Maintenance includes:

preventive measure which can beplanned, and

work which is necessary but cannot be planned.

It includes all necessary activities with the aim to maintain the desired state of all operatingmeans.

The modern concept to deal with the bogies is the planned condition-related maintenance ofcomponents and sub-assemblies which forms the balanced relation of preventive works

which can be planned to those which cannot be planned ,but are necessary. Thus thecomponents can be used in a cost-saving way up to the limits of their expected service life.

In order to ensure the proper functioning of the bogies and their components or have theright to raise guarantee claims, if any, all hints and instructions given in the data sheets andthe relevant documents of the sub-suppliers must be followed.

1.4.2 PLANNED MAINTENANCE

Planned (preventive) maintenance serves

to avoid damage

to reduce functional failures and

to ensure the availability of the vehicle.

Thus it limits costs of vehicle maintenance!


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Preventive maintenance activities include

visual checks and inspections

preventive maintenance and

planned servicing including the Revision of the sub-assemblies and of the wholevehicle

The characteristics of planned maintenance include the planned andsystematic checks, maintenance and servicing work. The intervals for theseactivities depend on the time or running capacity.

1.4.3 VISUAL INSPECTION AND SAFETY CHECKS

The visual inspections as part of the planned maintenance work are carried out primarilyto assess the technical condition of vehicles and components for use. Traditionally, thevisual inspection is carried out by the driver prior to the beginning of travel.

Primarily, the visual inspection is related to

functioning,

safety and

maintenance of value.

The results of the visual inspections are documented and evaluated as required. Correctionsare made immediately, if necessary. Comprehensive measures are planned and carried outas soon as possible, if admissible.

Safety checks shall be carried out in order to detect damage to components, if any whichresulted from external influences during operation which might be the consequence of fallingrocks, collision with objects or wilful destruction.

From the technical point of view, safety checks are not required in any case, however, arerecommended as preventive measures. Visible damage to sub-assemblies and componentswill thus be recognised early which might under certain circumstances result in seriousconsequential damage to the equipment and in a multiple of the initial maintenance cost.The relevant precautions thus limit unplanned failures and thus reduce cost.

Safety checks and visual inspections should be carried out daily.


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1.4.4 MAINTENANANCE

Preventive maintenance includes:

the checking of functions,

measuring and comparing with specified reference values,

adjustment and optimisation,

proper cleaning and

lubricating the mechanical units.

Minor repair work and replacement of wearing parts is carried out during the maintenanceactivities.

1.4.5 PLANNED REPAIRS

Planned repair work is done primarily according to the results of visual inspections oranalyses, refer to schedule of terms. Parts will be subject to preventive repair or arereplaced if functional troubles are expected prior to the next maintenance interval.

1.4.6 REVISION (OVERHAUL)

Revisions (overhauls) include basic checks and overhaul work at vehicle componentsdepending on the age, running capacity and specification of the owner.

The period of overhaul for the brake system depends on the conditions of operation of thevehicle. Thus the final overhaul intervals should be determined in time on co-ordination withthe manufacturer.

1.4.7 ELIMINATION OF FAULTS (WHOLE VEHICLE )

All faults reported by the driving and operating personnel or recorded by the vehicles failurerecorder must be processed by the maintenance staff. A decision should be made herebetween faults which affect the operation or represent a reduction in the operatingcharacteristics and must thus be eliminated immediately or those which can be eliminatedmore conveniently during the next workshop stay of the vehicle concerned and which arecan planned accordingly. Comprehensive system knowledge both in theelectrical/electronical area and in the mechanical sector is required to eliminate failures.


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1.4.8 UNPLANNED SERVICING

During planned servicing work (refer to chapter 3.4), visible defects due to wear are

eliminated by replacing or renewing components. Even if these preventive measures arecarried out with utmost care it is not possible to prevent all failures of components due towear, ageing or loading. The functional and operating failures which occur due to theseinfluences require work and repairs which are called unplanned repair works.

1.4.8.1 REPAIR OF DAMAGE

This includes repairs of damage which result from external influences such as

accidents

falling rock and

vandalism

and which are not due to malfunctioning sub-assemblies of the vehicle. Depending on thesepotential damage causes, repair work, above all, is related to the mechanical parts of thevehicle. However, they can also result in the replacement of affected electrical equipmentparts


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1.5 RECORDING OF THE MAINTENANCE MEASURES

To record the maintenance and servicing work carried out is an urgent requirement duringthe whole period of operation of the bogies.

This facilitates the processing of guarantee claims. Conclusions can be drawn about theprovision of spare and wearing parts and for the future vehicle development.

The following data must be recorded during the maintenance and servicing measure:

Date, time, if necessary

Maintenance or repair carried out by: Works, responsible person, phone No.

Vehicle number/bogie number

Hours of operation/kilometre coverage

Measures initiated: Description of activity and fault elimination

In case of fault: Type of damage/place of installation/cause of damage, if known

Material used: Material descriptionIdentification number of the new component installed.

Time expenditure, dead time of vehicle, if necessary.


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1.6 EDP FILES OF THE DOCUMENTATION

To allow printing and reading of the original files independent of conversion, all files of thedocumentation have been stored in PDF format on CD ROM.

PDF files can be read by means of the Adobe Acrobat Reader. This reader is also stored onCD ROM and has to be installed before. Adobe and Acrobat are trademarks of Adobe

Systems Incorporated, which can be registered in certain legal areas..Acrobat ReaderCopyright 1987-1999 Adobe System Incorporated.

1.6.1 SYSTEM REQUIREMENTS FOR ACROBAT READER

CD ROM drive ( 24 x speed)

1.6.1.1 IBM PC AND COMPATIBLE

Pentium PC (Pentium 150 recommended)

Microsoft Windows 95 or higher or Windows NT 4 or higher

64 MB RAM

5 MB hard disk memory and 7 MB additional temporary hard disk memory duringinstallation

24x CD-ROM Player

1.6.1.2 MACINTOSH COMPUTER

Macintosh computer with 68020 - (Macintosh II series) or better processor (including allPower Macintosh computers).

MacOS 7.0 or higher

3.5 MB RAM for 680x0 based Macintosh or Power Macintosh with activated virtualmemory ; 5 MB for Power Macintosh with deactivated virtual memory

64 MB hard disk memory, plus 4.4 MB additional temporary hard disk memory duringinstallation


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1.6.2 INSTALLING AND STARTING THE ADOBE ACROBAT

READER

Installation of the Acrobat Reader:

The CD ROM is laid out as a self-triggering system. Therefore it is not necessary to installthe program.

For starting the CD-ROM, you should activate the autorun function in the system control.

Furthermore, it is possible to start the CD ROM by double-clicking on file < Start.bat > in thefile manager or by inputting < drive letter :\start > in the input line "execute command".

Select the language preferred by you then and read the information on license regulationswhen using the Acrobat Reader.

Macintosh: Open the Adobe Acrobat folder and double click the Acrobat Reader programsymbol.

1.6.3 STRUCTURE OF THE DOCUMENTATION CD ROM

The following scheme describes the basic structure and may deviate in individual matters.

CD_INDIAN_IH:\____Programs_________ Acrobat_ReaderIII__IH_Volume_1_________*.PDFII__IH_Volume_2_________*.PDFII__ IH_Volume_3_________*.PDF

Documents

LHB Volume 1