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INDIAN RAILWAYS
MAINTENANCE INSTRUCTIONS
ON
AIR SUSPENSION
FOR
MAINLINE/RAJDHANI COACHES WITH ICF
TYPE BOGIES
RDSO/2009/CG/CMI-01
September 2009
RDSO/Lucknow
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SYNOPSIS
For Indian Railways, air suspension is a new technology and hence there is a
need to impart awareness amongst officials engaged in handling of this system,
regarding its working principle, functions and details of hardware and maintenance
practices to be followed for various items.
This booklet has been prepared with above objectives in view. Any
suggestion directed towards improvement in the quality of the booklet shall be
welcome which may be sent to Executive Director Standards/Carriage or
Director/VDG/Carriage, Research Designs & Standards Organization, Manak
Nagar, Lucknow-226011.
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INDEX
Item
DESCRIPTION
Page No.
1.
INTRODUCTION
2.
3.
4.
5.
6.
7.
8.
9.
OPERATING INSTRUCTIONS
10.
DISMANTLING OF AIR SPRING FROM LOWER SPRING BEAM
(CRADLE) AND BOGIE BOLSTER.
11.
12.
13.
14.
15.
16.
17.
19.
20.
10
21.
10
18.
22.
23.
FIGURES 1 to 9
11-19
ANNEXURES A to J
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MAINTENANCE INSTRUCTIONS
ON
AIR SUSPENSION
1.
INTRODUCTION:
Railway Board had approved fitment of air spring on AC Mainline ICF coaches for the purpose
of oscillation trials. After simulation study at RDSO, design for mainline stock with air spring at
secondary suspension has been evolved. Simulation studies have revealed a significant
improvement in the quality of ride on ICF stock fitted with air springs over those fitted with
conventional coiled springs. This is particularly significant with regard to the requirement of
better riding on high speed Rajdhani and Shatabdi trains specially in Ist AC coaches.
Oscillation trials have been conducted on ICF mainline bogie coaches successfully, with good
results. Accordingly it has been decided by Railway Board to provide air springs (pneumatic
suspension) on all stainless steel shell coaches (LHB type shell) provide with ICF bogies.
The Pneumatic suspension has been proven, on DC-EMU, AC-EMU, AC-DC EMU and HHPDMU.
2.
3.
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4.
6.
CONSTRUCTION DETAILS:
7.
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5.
Construction details of air spring are shown in (See Fig.5 page No. 15). (air spring with
outside emergency spring), & Fig. 6 at page no.16 (air spring with inside emergency
spring).
8.
8.1
Air spring has been installed at secondary stage replacing steel coil springs.
A fixed lower spring beam (as cradle) to accommodate the air spring has been provided
on bogie bolster.
A lateral hydraulic damper and lateral bump stop have been provided at secondary stage.
Primary springs have been retained as steel spring.
Details are shown in Fig.8 at page no. 18
Leveling valve provided between bogie frame and bogie bolster.
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8.2
Base plate to be used should be as per drawing No. RDSO sketch- K4018 alt 1 is
enclosed as fig.9 at page no 19.
11.
A pipeline is drawn from M.R pipe (feed pipe) for pneumatic suspension
One isolating cock, one non return valve, one 150 lit air reservoir (auxiliary reservoir) one
air filter and two separate isolating cocks to isolate each bogie have been provided
A schematic diagram is shown in fig.7 at page no 17.
OPERATING INSTRUCTIONS:
10.
BASE PLATE:
9.
Under frame:
8.4
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Bogie bolster:
8.3
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12.
Inspect all welding joints of the lower spring beam (cradle) and repair if required.
Inspect air spring fixing holes of lower spring beam for elongation, if elongated build
them to dia.17 mm or dia. 26 mm.
Inspect the corrosion on top surface of lower spring beam, Remove the corrosion paint
with primer and black paint.
The air spring piping may be checked for any leakage/damage by soap test and repair if
required.
15.
14.
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13.
Connect the hosepipes on the under frame piping with the levelling valves of the bogies.
Connect pressure gauges to the drain plug locations of 150-litre reservoir.
Provide packing in the gap between bolster & bogie frame.
Connect the 150-litre reservoir on the under frame to the compressed air source of
pressure 9.0 kgf/cm2.
Allow air into the air springs to a value of 9.0 kgf/cm2 in the pressure gauge by adjusting
the horizontal lever of the levelling valve and keep it in the same position.
Close the isolating cock connecting MR pipe with 150-litre reservoir.
Test all pipe joints for leakages.
Check the pressure gauge readings after one hour. The pressure drop should be within 1%
of the test pressure 9.0 kgf/cm2.
Release the air completely by dropping the horizontal lever.
Remove the packing.
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16.
AC SG(16 T)
NON AC (13 T)
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Than maintain the bogie corner heights as per relevant suspension diagram.
After the bogie corner height is maintained, adjust the air spring height as per relevant suspension
diagram with the help of installation lever.
After POH and before assembling the bogie, measure the wheel diameter.
Depending upon the wheel diameter, place wooden packing of required thickness under the
flange of lower spring seat as indicated in the following table:
Average wheel dia. between the Thickness of hard packing ring (mm)
two wheels on the same bogie
889 mm to 864 mm
863 mm to 840 mm
840 mm to 820 mm
819 mm
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13
26
38
48
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Connect pressure gauges to the drain plug locations of all 40-litre reservoirs in the bogie.
Place the car body on the two bogies and hook it up to the air supply (by opening the
isolating cock 1a).
First open only the isolating cock (1c0, thereby releasing the air supply for bogie 1and
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 the 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 isolating cock (1c) again, thereby interrupting the supply of air to bogie1 and
open isolating cock (1b), and thereby releasing the air supply to bogie 2.
Affix level control rod assemblies (6) to the valves (5) and set the assemblies (6) to
desired level.
Insert a suitable block (preferably hardwood) centrally between the bogie frame and the
car body and lower the car body onto block by removing the valve and assemblies (6).
Shut isolating cock (1b) again, thereby cutting off the air supply to bogie 2 and open
isolating cock (1c), and 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.
Reopen isolating cock (1b), thereby releasing air to bogie 2, and while at the same time
hanging the rod assembly (6) back in place in bogie 2.
Tighten the installation lever lock nuts with the horizontal lever, so that the setting will
not be disturbed.
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20.
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21.
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FIG. No. 2
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FIG. No. 4
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CRADLE
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ANNEXURE-A
2. VERTICAL STIFFNESS
At dz + 20 mm and constant speed of 5mm/sec, the vertical stiffness (Cz) shall be:
Load in KN (Static)
50
115
140
3. HORIZONTAL STIFFNESS
At dy +20 mm at constant speed of 5 mm/sec, the lateral stiffness (Cy) shall be:
Load in KN (Static)
50
115
140
4. Min. height of air spring under full load with no air and without spigot - 210 mm
5. Installed height without spigot - 255+0-5 mm.
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Primary /
Secondary
Schedule-A
Schedule -B
Schedule -C
AOH/POH
INSPECTION
SITE
Visual check: General conditions which includes any external damages, air leakage, infringement of any
fittings, etc.
Draining of 150-liter air reservoir of air spring
Check the position of isolating cock and drain cock, these should be on and off position respectively.
As in Primary / Secondary schedule and Draining of 40-liter reservoir.
Cleaning of leveling valve filter as per manufacturers manual. The procedure is shown at Annexure B/1.
As in Schedule -A
Checking of installation lever with inflated air spring for normal function, tightening of installation lever
nuts and protection screen nuts, tightening of bracket of all flexible hoses.
Cleaning of air filter of 150-liter reservoir.
As in Schedule -B &
Thorough checking of air spring, bulging of bellow, air leakage.
Air suspension pipe leakage check by using soap water.
Removing dust mud & oil deposit if any, on air spring and control equipment.
Thorough checking of lower spring beam for any crack and deformation.
Tightening of air spring bottom plate bolts and nuts.
Measurement of bogie clearances related to air spring.
As in Schedule - C and
Through visual check of air spring as per Annexure-C or D after dismantling as in clause 10.
Remove all valves and carry out external cleaning, overhauling and function test should be done as given
in maintenance manual supplied by respective vendors.
Checking securing arrangement of steel pipeline.
Leakage test of air springs as per clause 15.
Installation lever adjustment as per clause 18.
Lateral damper condition should be checked and replace with fresh if damaged.
Air spring bellow should not be painted.
Pit line
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Pit line
Sick line
Depot/
Work shop
ANNEXURE-B
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Pit line