Vogel AG 1-8092-US
Vogel AG 1-8092-US
Vogel AG 1-8092-US
18092US
Quality Management
DIN EN ISO 9001: 2000
Environmental Management
DIN EN ISO 14001
Table of Contents
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Comparison of systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System SP8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SP84, SP82 Spray nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PF10021 Piston pump with reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SF10 Grease control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STG122 Valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STG13 Valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System SP9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SP92, SP92S7 Spray nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BF4.5 Grease reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BF6S3 Grease reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
This catalog will show you how VOGEL wheel flange VOGEL sells wheel flange lubrication systems for nearly
lubrication systems work so that you can plan, install and every kind of rail vehicle such as locomotives, multiple
properly maintain corresponding systems. train units, subways, elevated trains and streetcars as
A wheel flange lubrication system is installed either by the well as other railbound vehicles. System plans and parts
manufacturer at the factory or at a later date by trained lists are available for a large number of applications.
shop staff, our skilled personnel or by you yourself if you VOGEL's field staff will be pleased to advise you. Make
have the requisite knowledge. We provide supportive use of our experience!
technical training and assembly training courses for this
purpose.
G Wear cut by 30 to 80 %.
Longer intervals between reshaping or replacement of wheel sets and rails,
maintenance time is minimized
G Greater safety.
Less danger of derailment because
it is harder for wheel flanges to climb out of the tracks.
Introduction
Distancedependent lubrication G G G
Curvedependent lubrication G G G
Timedependent lubrication G G G
Temperature range – 25 to + 80 °C – 25 to + 80 °C – 25 to + 80 °C
Metered quantity, standard 0.03 ccm / spray 0.03 ccm / spray 0.04 ccm / spray
VOGEL Centralized Lubrication for Wheel + Rail 18092US 5
Lubricants
The quality of the lubricants has a decisive influence on the In general, NLGI grade 000 and 00 fluid grease is used in the
efficacy of the lubrication applied to the wheelrail interface. In systems made by VOGEL. The grease can contain as much as
the end, it determines the friction, wear and noise. In the last few 30 % solids. The systems can also be operated with all the wheel
years attempts have been made to achieve optimal surface flange lubricating grease approved by the Deutsche Bahn AG
smoothness and minimal wear with the help of increasingly (German Railways).
higher percentages of solids. Regardless of the fact that a certain The lubricants recommended for certain types of systems by the
amount of wheel flange wear is necessary for proper functioning manufacturers can be found in corresponding lists of approved
of the wheelrail interface, since undesirable growth in the products. After extensive testing the Deutsche Bahn AG, for
diameter of the wheel flange likewise increases the danger of instance, also assigns socalled “material numbers” to suitable
derailment, solid particles in the lubricant are only good as long lubricants and approves them for use in its vehicles.
as they do not lead to clogged systems, thereby jamming the
The lubricants approved for VOGEL's wheel flange lubrication
wheel flange lubrication installation.
systems can be found in an updated list on the Internet at
That is why the makers of lubricants and wheel flange lubrication www.vogelag.com (“Service” chapter).
systems as well as the operators of rail vehicles have all worked
together to develop a number of special biodegradable lubri
cants for wheel flange lubrication systems and separating agents
for railhead lubrication. The greases are made of substances that
are broken down into their basic ingredients by ubiquitous
microorganisms as quickly and completely as possible. They
have to be usable not only for new wheel flange lubrication sys
tems but also for the thousands of systems installed years ago.
*) rapidly biodegradable
1) Pressure has to be relieved if left to stand in SP9 systems for extended periods of time.
VOGEL Centralized Lubrication for Wheel + Rail 18092US 6
System SP8
Air line
Grease line
– Rail vehicles with a maximum of 20 m – System pressure: 100 bars Piston pump with reservoir PF10021
distance between the wheelsets to be – selectable: 2 directions of travel Spray nozzles SP84, SP82
sprayed
– separate expendables feed Grease control valve SF10
– Max. line length between pump and
– exact spraynozzle metering Actuated via valve unit STG122 or
spray nozzle: 10 m
STG13, 3/2way valve
– Low ambient temperature
VOGEL Centralized Lubrication for Wheel + Rail 18092US 7
Technical data
Order No. . . . . . . . . . . . . . . . . . . . SP84
Rated spray quantity . . . . . . . . . . . 0.03 ccm / actuation
Technical data
Order No. . . . . . . . . . . . . . . . . . . . PF10021
Reservoir capacity . . . . . . . . . . . . 5 liters
Delivery volume . . . . . . . . . . . . . . . 12 ccm/stroke
Delivery pressure . . . . . . . . . . . . . . 100 bars
Lubricant . . . . . . . . . . . . . . . . . . . .fluid grease,
NLGI grade 000, 00
Air pressure . . . . . . . . . . . . . . . . . . 6 to 10 bars
Area ratio
air side : grease side . . . . . . . . . . 10 : 1
Drive medium . . . . . . . . . . . . . . . . filtered compressed air
Ambient temperature . . . . . . . . . . . – 25 to + 80 °C
Mounting position . . . . . . . . . . . . . as shown
Filler cap
Venting line
Angle bracket
P1
P2
The grease control valve controls the flow of lubricant in the Technical data
SP8 system, e.g. for curvedependent lubrication (left/right spray
nozzles) or distancedependent lubrication (front/rear spray Order No. . . . . . . . . . . . . . . . . . . . SF10
nozzles). Air pressure . . . . . . . . . . . . . . . . . . 6 to 10 bars
Lubricant . . . . . . . . . . . . . . . . . . . . grease, NLGI grade 000, 00
Lubrication pressure . . . . . . . . . . . 100 bars
Ambient temperature . . . . . . . . . . . – 25 to +80 °C
Mounting position . . . . . . . . . . . . . as shown
The unit controls the flow of air and lubricant to the spray These valve units are used on, among others, shunting locomo
nozzles separately. tives and diesel or electric locomotives with a maximum distance
The STG122 and STG13 valve units are used for of 20 m between the wheelsets to be sprayed.
curvedependent lubrication (left/right spray nozzles)
or
distancedependent lubrication (front/rear spray nozzles).
Air nozzle 1
for tube diam. 8
Leakage grease
to reservoir
for tube diam. 6 Air port for
tube diam. 8
Grease nozzle 2
for tube diam. 10
Air pump
for tube diam. 8
Grease nozzle 1 Grease pump
for tube diam. 10 for tube
diam. 10
Air nozzle 2
for tube diam. 8
leakage
Hydraulic layout
pump
air nozzle 2
air nozzle 1
grease
pump
VOGEL Centralized Lubrication for Wheel + Rail 18092US 11
Air nozzle 1
for tube diam. 8
Leakage grease
to reservoir
Air port for
for tube diam. 6
tube diam. 8
Grease nozzle 2
for tube diam. 10
Air pump
for tube diam. 8 Grease pump
Grease nozzle 1 for tube diam. 10
for tube diam. 10
Air nozzle 2
for tube diam. 8
VOGEL Centralized Lubrication for Wheel + Rail 18092US 12
System SP9
Pressurized reservoir
Spray nozzle
Grease line
– System with a max. line length of 5 m – Simple configuration Pressure reservoir BF4.5 or BF6S3
between the grease reservoir and spray – Compact design Spray nozzles SP92, SP92S7
nozzle
– No separate grease pump Actuation via valve unit
– Separate systems on motor unit and 3/2way valve
– Separate expendables feed
end of train for the respective direction
of travel – Exact spraynozzle metering
– Independent of vehicle's length
VOGEL Centralized Lubrication for Wheel + Rail 18092US 13
Technical data
Order No. . . . . . . . . . . . . . . . . . . . SP92
Rated spray quantity . . . . . . . . . . . 0.03 ccm / actuation
Grease port
for tube diam. 8
to DIN 2353
Air port
for tube diam. 8
to DIN 2353
VOGEL Centralized Lubrication for Wheel + Rail 18092US 14
Lubricant outlet
mounting surface
Indicator
Filler socket 1)
Air port Pressure limiting valve
1) Coupling bush for filler socket
order separately,
order No. 995001500.
Technical data
Order No. . . . . . . . . . . . . . . . . . . . BF4.5
Reservoir capacity . . . . . . . . . . . . . 4.5 liters
Filling level display . . . . . . . . . . . . . analog, by indicator
Operating pressure . . . . . . . . . . . . max. 10 bars
Pressure limiting valve . . . . . . . . . . 16 – 2 bars (overfill preventer)
Air port, optional
Perm. ambient temperature . . . . . . – 25 to + 80 °C
Mounting position . . . . . . . . . . . . . preferably as shown
VOGEL Centralized Lubrication for Wheel + Rail 18092US 15
Lubricant outlet
Indicator
Filler socket 1)
Air port
1) Coupling bush for filler socket
order separately,
order No. 995001500.
Technische Daten
Order No. . . . . . . . . . . . . . . . . . . . BF6S3
Reservoir capacity . . . . . . . . . . . . . 6 liters
Filling level display . . . . . . . . . . . . . analog, by indicator
Operating pressure . . . . . . . . . . . . max. 8 bars
Pressure limiting valve . . . . . . . . . . 16 – 2 bars (overfill preventer)
Perm. ambient temperature . . . . . . – 25 to + 80 °C
Air port, optional
Mounting position . . . . . . . . . . . . . preferably as shown
VOGEL Centralized Lubrication for Wheel + Rail 18092US 16
Piston pump
Piston distributor
– Vehicles without a compressed air – Compressed air supply of its own Piston pumps with reservoir
network – Can be put to versatile use PEF98 or PEU98,
– Preferably used on urban rail vehicles Mixing block 169000205,
– Variable metered quantities of piston
Piston distributor VKSO
– Also for railhead lubrication systems distributors
Spray nozzles 169000208, 169000209
Inquiries about compressed air unit
(compressor, air vessel, etc.) must
specify model.
VOGEL Centralized Lubrication for Wheel + Rail 18092US 17
Technical data
Order No. . . . . . . . . . . . . . . . . . . . 169000208
Order No. . . . . . . . . . . . . . . . . . . . 169000209
Temperature range . . . . . . . . . . . . – 25 to +80 °C
Mounting position . . . . . . . . . . . . . any
Hose
e.g. 734700K
Nozzle 321628
Hose Nozzle
e.g. 734700K 321628
PEF98
Reservoir air compensation line
Transparent
reservoir
Filler socket 3)
PEU98
Reservoir air compensation line
Transparent
reservoir
Function
One respective mixing black is installed on the body near the
nozzles for one wheel. In each mixing block the lubricant pre
supplied by the piston distributor for a wheel flange (= two lube
points) is fed by pulses of compressed air through the hose to
the nozzles, being mixed with air in the process.
Lubricant inlet
from piston distributor
Check valve
opening pressure 2 bars
(order No. 161300099)
Hose
e.g. 734700K
max. 1000 mm
Lubricant / air
to nozzles
Lufteintritt
Air input *) 1) Ports tapped for solderless tube connection for tube diam. 4 mm
1) mit Senkung für lötlose Rohrverschraubung für Rohr ø4 *) Associated connecting pieces, see page 29.
VOGEL Centralized Lubrication for Wheel + Rail 18092US 21
The distributors meter and distribute the lubricant from the pump
to the individual lubrication points. They do so independent of
each other.
Interchangeable metering nipples make it possible to adapt the
quantity to the amount of lubricant required by the friction point.
The cycle number, i.e. the number of pump strokes per time unit VKSO4
of the lubrication system, also permits further coordination of the
lubricant quantity with the friction point and entire system.
Lubricant is only delivered under spring pressure after the end of
pump operation, i.e. after the pressure is relieved.
A collar (changeover valve) in the distributor closes the outlet to
the lubrication point during the delivery stroke, thus storing the
lubricant beneath the piston. The changeover valve opens the
outlet as soon as the pressure drops in the main line, i.e. when
the pressure relief valve of the pump opens.
Assign only one lubrication point to each distributor outlet port. Metering nipple
Connect the secondary line (connection: distributor mixing
block) to the mixing block only after bubblefree lubricant
emerges from the tubing after the pump is repeatedly actuated.
Fill long secondary lines beforehand if necessary.
VKSO2 … 2
VKSO4 … 4
1 2 3 4
If required:
VKSO4 ... 4port distributor
←
screw plug
410011 1) Quick connector connection for ø4 plastic tubing
washer 2) Ports tapped for solderless tube connection
DIN 7603A16 x 20CU
for tube diam. 10 mm
VOGEL Centralized Lubrication for Wheel + Rail 18092US 22
CS200
Standards
EN 50 153, EN 50 155, ENV 50 12132
(EMC for railway equipment));
Electromagnetic Compatibility EMC 89/336/EEC:
EN 50 0811, EN 50 0822
VOGEL Centralized Lubrication for Wheel + Rail 18092US 24
Technical data
Type of enclosure . . . . . . . . . . . . . . . IP 65
acc. to EN 60 529/10.91
Mounting position . . . . . . . . . . . . . any
Weight . . . . . . . . . . . . . . . . . . . . . . 3.5 kg
Ambient temperature
Class . . . . . . . . . . . . . . . . . . . . . . . T1
Operation . . . . . . . . . . . . . . . . . . . . – 25 to +55 °C
Storage and transport . . . . . . . . . . – 40 to +85 °C
Power input
Input L + (P at rated voltage) . . . . . . . 12 W
Input B+ (P at rated voltage) . . . . . . . 90 W
Input B+ (P max.) . . . . . . . . . . . . . . . . 180 W
Standards
EN 50 153, EN 50155, ENV 5012132
(EMC for railway equipment);
Electromagnetic Compatibility EMC 89/336/EEC:
EN 50 0811, EN 50 0822
P (supply)
A (consumption)
R (return)
electr. terminal (1) +; (4) –
VOGEL Centralized Lubrication for Wheel + Rail 18092US 27
Technical data
Order No. (2 ports, 110 V DC) ... 221296052+926
Order No. (2 ports, 72 V DC) .... 221296052+927
Order No. (3 ports, 110 V DC) ... 221296053+926
Order No. (3 ports, 72 V DC) .... 221296053+927
Rated width DN . . . . . . . . . . . . . . . 3 mm (admission and venting)
Operating pressure P . . . . . . . . . . 0 to 10 bars
Ventilsitzdichtung . . . . . . . . . . . . . . FPM
Temperature range . . . . . . . . . . . . – 25 to +80 °C
Medium . . . . . . . . . . . . . . . . . . . . . compressed air
Mounting position . . . . . . . . . . . . . any
Rated voltage . . . . . . . . . . . . . . . . 110 or 72 V DC
Voltage tolerance . . . . . . . . . . . . . . +10 % / – 30 %
Duty cycle . . . . . . . . . . . . . . . . . . . 100 % ED
Power input . . . . . . . . . . . . . . . . . . ~ 16 W
Type of enclosure . . . . . . . . . . . . . IP 65
acc. to EN 60529
2port type
P (supply)
A (consumption)
R (return)
VOGEL Centralized Lubrication for Wheel + Rail 18092US 28
Technical data
Order No. . . . . . . . . . . . . . . . . . . . 169000084
Medium . . . . . . . . . . . . . . . . . . . . . fluid grease,
NLGIKl. 000, 00, 0
Delivery rate . . . . . . . . . . . . . . . . . . 0.25 l double stroke
Temperature range . . . . . . . . . . . . 0 to + 60 °C
Grease connection for Parker fillersocket BH261…
fits reservoirs BF4.5 and BF6S3
1) Bundle size: up to 25 kg
VOGEL Centralized Lubrication for Wheel + Rail 18092US 29
8 408162 M14x1.5 29 17
10 410162 M16x1.5 31 19
1)
Straight connectors DIN 2353
Ports tapped for solderless tube connection
Banjo fittings
banjo
union Elbow bulkhead connectors DIN 2353
washer max. wall thickness
16 mm
for outer
tube diam. Order No. d1 d 2 *)
tapered sleeve
tapped port
reinforcing socket
Reinforcing (for plastic tubing)
socket Tapered
for plastic tubing sleeves Socket unions
for outer Assembly
Slide socket union and tapered sleeve onto end of the
tube diam. Order No. Order No. Order No. d1
tube.
4x0.85 404603 404611 404612MS M 8x1 In the case of plastic tubing, first insert the reinforcing
socket. Insert end of tube into tapped port up to the
8x1.25 408603 408611 408612MS M14x1.5 stop. First tighten the socket union fingertight and then
10x1.5 410603 410611 410612MS M16x1.5 turn it another 1 1/2 turns.
Material: brass
rubber profile
21381010 213870F
Shutoff valve
twin coupling
for 4 mm prong
cable gland
Design
Inner liner . . . . . . . . . . . . . . . . . synthetic rubber NBR
Reinforcement . . . . . . . . . . . . . 1 wire braiding
Outer cover . . . . . . . . . . . . . . . synthetic rubber CR
Resistant to . . . . . . . . . . . . . . . lubricants, also rapidly biodegradable
ones based on synthetic ester,
vegetable and mineral oils, compressed air
Perm. operating temperature . – 25 to + 70 °C
To fire protection standard . . . DIN 5510 “Preventive fire protection
in rail vehicles”
Flammability class . . . . . . . . . . S3
Smoke development class . . . SR1 1) Prepared in confomity with DIN 3865, light series:
with 24 ° cone and Oring for port end W to DIN 3861
Hoses
Material:
Hose: mineraloil restistant CR rubber inside; 2 layers of braided rayon;
outside rubber conditionally oilresistant, resistant to light cracks and ozone.
Tube ends: galvanized steel tubing
socket unions
double tapered sleeve
Please note!
These hoses must not be used as main lines.
Complete with socket unions and double tapered sleeves.
Material hose: oilproof internal and external rubber with braided layer of rayon.
tube ends: steel tubing, ends permanently joined to the hose.
VERZI = 25 µm galvanization yellow passivated. Length delivered 5 m. Stainless steel tubing on request.
Color: black
Tubing with other dimensions on request.
Important!
For screwed tubing joints only use unions with reinforcing sockets.
Material WVN715: PA 12 HL: polyamide 12 without plasticizer, stabilized against lightrelated and termal ageing.
Material WVN716: PA 12 PHL: polyamide 12 with plasticizer, stabilized against lightrelated and termal ageing.
VOGEL Centralized Lubrication for Wheel + Rail 18092US 33
Checklist
Company .........................................................................
Willy Vogel AG Name .........................................................................
Product Management Vehicle Dept. .........................................................................
Lubrication
Street .........................................................................
2. Industriestrasse 4
City .........................................................................
68766 Hockenheim Zip Code .........................................................................
Germany
Phone .........................................................................
Fax .........................................................................
Email .........................................................................
Fax: +49 (0) 62 0527102
Please complete the following check list. Send the check list back to the above address or fax.
Bogie: ❑ yes ❑ no
Quality Management
DIN EN ISO 9001: 2000
Environmental Management
DIN EN ISO 14001
VOGEL Centralized Lubrication for Wheel + Rail 18092US 34
...................................................................................................................................................
...................................................................................................................................................
Notes
VOGEL Centralized Lubrication for Wheel + Rail 18092US 36
Notes
Notice!
All products from VOGEL may be used only for their intended purpose.
If operating instructions are supplied together with the products, the provi
sions and information therein of specific relevance to the equipment must
be observed as well.
In particular, we call your attention to the fact that hazardous materials of
any kind, especially the materials classified as hazardous by EC Directive
67/548/EEC, Article 2, Par. 2, may only be filled into VOGEL centralized
lubrication systems and components and delivered and/or distributed with
0000 07/2005
the same after consultation with and written approval from VOGEL.
All products manufactured by VOGEL are not approved for use in con
junction with gases, liquefied gases, pressurized gases in solution and
fluids with a vapor pressure exceeding normal atmospheric pressure
(1013 mbars) by more than 0.5 bar at their maximum permissible
Subject to change without notice!
temperature.