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    Modification For Fitment: With Steel Spring With Air Spring

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    iso9002
    This document provides information on air spring suspension modifications and components. It discusses: 1) Modifications including using a fixed lower spring beam and making primary springs stiffer. 2) Key components of the air spring system including the air spring, leveling valve, installation lever, and duplex check valve. 3) The working principles of the leveling valve which monitors pressure changes to maintain vehicle height as loads change by supplying air to or releasing it from the bellow.

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    Modification For Fitment: With Steel Spring With Air Spring

    Uploaded by

    iso9002
    51 views33 pages
    This document provides information on air spring suspension modifications and components. It discusses: 1) Modifications including using a fixed lower spring beam and making primary springs stiffer. 2) Key components of the air spring system including the air spring, leveling valve, installation lever, and duplex check valve. 3) The working principles of the leveling valve which monitors pressure changes to maintain vehicle height as loads change by supplying air to or releasing it from the bellow.

    Original Description:

    MTNS 2

    Original Title

    MTNS 2

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    This document provides information on air spring suspension modifications and components. It discusses: 1) Modifications including using a fixed lower spring beam and making primary springs stiffer. 2) Key components of the air spring system including the air spring, leveling valve, installation lever, and duplex check valve. 3) The working principles of the leveling valve which monitors pressure changes to maintain vehicle height as loads change by supplying air to or releasing it from the bellow.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    51 views33 pages

    Modification For Fitment: With Steel Spring With Air Spring

    Uploaded by

    iso9002
    This document provides information on air spring suspension modifications and components. It discusses: 1) Modifications including using a fixed lower spring beam and making primary springs stiffer. 2) Key components of the air spring system including the air spring, leveling valve, installation lever, and duplex check valve. 3) The working principles of the leveling valve which monitors pressure changes to maintain vehicle height as loads change by supplying air to or releasing it from the bellow.

    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    of 33

    Modification for Fitment

    With steel spring

    With air spring

    Modification for Fitment

    Installed at
    Secondary Stage.
    A FIXED lower
    spring beam used
    in place of
    standard bolster
    suspension
    arrangement.
    Primary springs
    made stiffer.

    Working Principles

    The height monitoring valve (called


    leveling valve) actuates as per changing
    loads on vehicle,

    Either getting the compressed air pressure to


    the rubber bellow or
    Releasing air pressure from bellow to
    atmosphere.
    The process continues until the original height
    is restored.

    Working Principles

    Normal Condition
    No flow of air

    Working Principles

    Loaded Condition
    From Reservoir to bellow

    Empty Condition
    From bellow to atmosphere

    Main Equipments of the System

    Air Spring

    Leveling Valve

    Installation Lever

    Duplex Check Valve

    Air Spring

    Contitech make

    Firestone make

    Air Spring

    Codal life expected : 16 Yrs.

    Manufacturers

    M/s Contitech/Germany

    M/s Firestone

    SIL, Kolkata

    Asika Commercial Pvt. Ltd, Kolkata.

    Main Parts of Air Spring (Fig. of


    Firestone Make)
    TOP PLATE

    BID SKIRT

    RUBBER BELLOW

    EMERGENCY SPRING
    BID RING

    PADESTAL
    ASSEMBLY
    BASE PLATE

    Main Parts of Air Spring

    Spigot

    Emergency Spring

    Part of top plate which connects the air path


    for bellow from bolster. Two o rings are
    provided on this spigot.
    Made by layers of metal and rubber. The
    coach rests on this spring when there is no
    air, i.e. deflated condition.

    Bellow

    Main Parts of Air Spring


    (FirestoneFittedMake)
    on pedestal assembly by

    Emergency spring:

    rubber with metallic plate at both


    Holes for fixing
    ends
    pedestal assembly

    4 M10 bolts with 40 kgm torque.

    Rubber

    Metal Plate

    Main Parts of Air Spring


    (Firestone Make)

    Emergency Spring

    This spring is capable of safety carrying the


    affected vehicle (either fully or partially
    loaded) for minimum 1000km at speed of at
    least 60KMPH under normal operating
    conditions without suffering any self damage
    or any further damage to the air spring which
    will make them unfit for the further use.
    This situation may arise occasionally in the
    service of the air springs.

    Cleaning & maintenance of Air


    Spring

    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.

    Cleaning & maintenance of Air


    Spring

    Solvents such as trichloroethylene, carbon


    tetrachloride as well as hydrocarbons
    must not be used for cleaning purposes.
    Sharp-edged objects, wire brushes, emery
    paper etc. should not be used.
    Rubber- metal bondings are to be cleaned
    using a glycerin-spirit mixture (1:10).

    Tools and components for Air


    Spring

    Screws,

    Lever,

    Hammer,

    Torque spanner,

    Plastic stick,

    Loctite 243.

    Cloth.

    Levelling Valve

    Levelling Valve

    Mounted on
    bolster.
    Heart of the
    system.
    Its link is
    connected with
    installation lever.
    It has three

    Dead Band Zone

    Levelling Valve

    Charging mode

    Discharging mode

    From Reservoir

    From
    bellow
    To bellow

    To atmosphere

    DETAILS WORKING OF
    LEVELING VALVE
    FROM 150 LTRS.
    EXTERNAL LOAD

    RESERVOIR

    BOLSTER

    INCREASED
    DECREASAED

    AIR SPRING BELLOW


    BOGIE FRAME

    Installation Lever

    Fitted between link


    of Leveling valve
    and bogie frame.
    The ball and
    socket joint at both
    ends are provided
    to give flexibility.
    Left and Right
    hand threads are
    there at its either

    Duplex Check Valve

    Descriptions:

    Fitted between two


    air springs of the
    same bogie.
    Pressure
    differential on DC
    valve is set at
    1.5+0.15 bar.
    Allows air to flow in
    either direction
    when pressure

    Duplex Check Valve Detail operation

    AIR SPRING

    P2

    P1
    DUPLEX CHECK VALVE
    (P 1 P2) (1.5 0.15) kg/cm2

    Duplex Check Valve Detail operation

    AIR SPRING

    P2

    P1
    DUPLEX CHECK VALVE

    (P 2 P1) (1.5 0.15)


    kg/cm2

    Duplex Check Valve

    Maintenance

    No schedule maintenance required between POH.

    During POH functional testing to be done.

    OVH after 03 yrs

    Infrastructure for Mtc

    Open line/ POH

    Tools

    Test eqpt

    Gauges

    Testing+Rejectable parameters

    failure during run

    Spares

    Warranty claims

    Available Guidelines from


    RDSO

    CMI- 9802 (rev.1) May 2001 and CMI- 9802 (re


    Feb 2008 on Maintenance Instructions on
    Air Suspension for DC, Ac & AC-DC
    EMU/HHP DMU Coaches.
    CMI- RDSO/2009/CG/CMI-01 Sep.2009
    on Maintenance Instructions on Air
    Suspension for Mainline Rajdhani
    Coaches with ICF Bogie
    C-K509 (rev.0) Aug 2005, C-K509 (rev.1)
    Jan 2008 and C-K509 (rev.2) Sep 2008 on

    Operating Instruction

    Maintain 7 bar pressure in compressor.


    In case of heavy leakage of air from air
    spring system,

    isolate the affected bogie and observe speed


    restriction

    at 50 kmph for DC, AC &AC-DC EMU/HHP DMU


    COACHES (CMI-9802-rev.2) and

    at 60 kmph for Mainline Rajdhani Coaches with


    ICF Bogie (CMI- RDSO/2009/CG/CMI-01) up to
    the terminal point for maintenance.

    Dismantling of AS from LS
    Beam & Bogie Bolster

    Remove All Body, Bogie connections.

    Remove duplex check valve from bolster.

    Remove lateral & vertical shock absorber.

    Remove equalizing rod connection from


    both ends of lower spring beam if
    provided.
    Remove connection of levelling valve &
    installation lever.
    Remove all 6 or 4 No. Bolts and nut with

    Measurement and readings


    for hybrid coaches

    Inspection & Maintenance

    Air spring

    Inspect for any water collection in rubber


    bellow of air spring
    Inspect the air spring for any damage or
    leakage.
    Inspect air spring seat and top plates for
    corrosion, if corrosion noticed is paint with
    primer & black paint

    LS beam

    Maintenance Instructions

    Tightened the lock nut of installation lever


    after adjustment spring height/clearances.
    Provide a safety plate for leveling valve to
    avoid stone hitting etc.
    Ensure that all the fasteners are properly
    tightened.
    Check the leakage of all air joints and
    rectify if required.
    Ensure that installation lever is in position

    Leakage Testing

    Connect hosepipes on under frame piping


    with levelling valves.
    Connect pressure gauges to 150-litre
    reservoir.
    Provide packing in the gap between
    bolster & bogie frame.
    Connect the 150-litre reservoir to the
    source of pressure.
    Allow air in air springs to 9.0 kgf/cm2 by

    THANK YOU

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