轉(zhuǎn)向架用戶文件匯總-拖車(chē)輪對(duì)traction

文件名稱(chēng)A2010-12-版本A編制簽名日期審核簽名日期批準(zhǔn)簽名日期?Copyright(C)CNR2010.目的／功 描述／運(yùn) 介 概 與安全有關(guān)的詞 程序注 圖紙和零件明細(xì) 使用條件／技術(shù)數(shù) 技術(shù)說(shuō) 運(yùn)行和工作監(jiān) 運(yùn) 工作監(jiān) 安裝和調(diào) ／發(fā)貨／／發(fā) 安 調(diào) 在調(diào)試之前進(jìn)行檢 調(diào) 停止使 維修保 級(jí) 維修作業(yè) 檢 大 保養(yǎng)規(guī) 排除故障、更換概念／修 排除故 拆 更換概 分 修 組 重新安 設(shè)定值和公 清潔／涂 重新啟動(dòng)／功能試 工具明細(xì) 圖解零件明細(xì)表 補(bǔ)充文 文 DP硬件文 安全數(shù)據(jù)記錄 批準(zhǔn)文 供應(yīng)商文 輪對(duì)&車(chē)輪文 軸承修理手 漆膜技術(shù)規(guī) 附 簡(jiǎn)寫(xiě) 輔助原 化學(xué) 需要使用漆膜漆層的組 潤(rùn)滑 其它的輔助材 測(cè)量和試驗(yàn)設(shè) 輪對(duì)將車(chē)輛的重量傳送到鋼軌上在運(yùn)行期間，輪對(duì)也在正常的軌道上為車(chē)輛提供方向引導(dǎo)，并將制動(dòng)力傳遞到鋼軌為了更透徹地理解，正文中包含有圖表（圖紙）和（）的相互對(duì)照。和相互對(duì) 圖和表的相互參 表錯(cuò)誤！未找到源。工 錯(cuò)誤！未找到源。輔助材 0測(cè)量&試驗(yàn)設(shè) 在各自章節(jié)之內(nèi)，只顯示對(duì)應(yīng)的章節(jié)，例如。介概執(zhí)行必要活動(dòng)的人。（關(guān)于熟練的定義，也可能參閱DINVDE0105或者IEC364的內(nèi)DINVDE0105IEC364里的說(shuō)明，不合格的人是不允許在帶電設(shè)備上工作的。只有在已經(jīng)閱讀和理解了這些文件里的指導(dǎo)和規(guī)定內(nèi)容之后，才能對(duì)轉(zhuǎn)向架進(jìn)等等）。這一規(guī)定，則不能排除隨之發(fā)生的損壞情況。 警為了避免損壞或者破壞元件，必須準(zhǔn)確地遵循工作和操作步驟指示。這也包括定期執(zhí)行的工作和負(fù)載或者異常天氣影響和工況下必需要做的工作。當(dāng)是指特別是元件的用戶必須要遵守的技術(shù)要注在沒(méi)有的情況下，或者文件，以及使用和交流文件的內(nèi)容。者會(huì)被要求賠償。特別是實(shí)用模型或者設(shè)計(jì)獲得了專(zhuān)利或者登記的情況下，所有歸作程序在拖車(chē)轉(zhuǎn)向架及動(dòng)車(chē)轉(zhuǎn)向架-0.4手冊(cè)里詳細(xì)介紹的“程序注解”包含了所只有在閱讀和理解了注解的內(nèi)容之后，才能在轉(zhuǎn)向架上進(jìn)行工作注圖在零件明細(xì)表中的描零件明細(xì)表項(xiàng)目拖車(chē)輪對(duì)項(xiàng)目：項(xiàng)目輪對(duì)軸箱，右側(cè)項(xiàng)目：項(xiàng)目輪對(duì)軸箱，在左項(xiàng)目：表2.1.51圖紙和零件明細(xì) 拖車(chē)輪對(duì) 右側(cè)軸箱 左側(cè)軸箱 圓錐滾子軸圖2.1.5-1拖車(chē)輪對(duì)部圖2.1.5-3輪對(duì)軸箱在對(duì)應(yīng)文件、圖紙和零件明細(xì)表里規(guī)定的工作條件和技術(shù)數(shù)據(jù)。（查看錯(cuò)誤！未找到源。）對(duì)于技術(shù)說(shuō)明，參見(jiàn)錯(cuò)誤！未找到源。節(jié)和文 II33410／1970（TA30484_D05/D06）制動(dòng)盤(pán)運(yùn)／發(fā)貨／除了要遵守條例規(guī)定之外，必須遵守“預(yù)備、和轉(zhuǎn)向架一般指導(dǎo)”（文件號(hào)：6Z00375073533）。此外，必須遵守供應(yīng)商文件中包含的注 也要參考錯(cuò)誤！未找 源。部分 ／發(fā) 用耐腐蝕的油對(duì)所有的金屬表面進(jìn)行處理注安4.2也要參見(jiàn)錯(cuò)誤！未找到源。部分關(guān)于在維修保養(yǎng)期間進(jìn)行重新安裝的內(nèi)容調(diào)調(diào)停止使級(jí)級(jí)80萬(wàn)公里／年的時(shí)間4,000公2101.5400.58011,201.52,4034,806表4.4.11級(jí)也要參考拖車(chē)轉(zhuǎn)向架和動(dòng)車(chē)轉(zhuǎn)向架冊(cè)維修作業(yè)數(shù)為基礎(chǔ)的技術(shù)上限。達(dá)到規(guī)定的運(yùn)轉(zhuǎn)時(shí)間或者里程就必須執(zhí)行日常維修工作。根據(jù)實(shí)際工作條件，也許要調(diào)整時(shí)間間隔。公司負(fù)責(zé)做出修改技術(shù)注 保養(yǎng)周期的決定為了立即檢出由于外界影響產(chǎn)生的可能損壞，西門(mén)子TS執(zhí)行額外的日常檢查。實(shí)施這些措施的決定是公司的職責(zé)。執(zhí)行的所有的日常維修工作必須有記錄，有案可查序組檢查工作和大運(yùn)行距使用的1傳傳構(gòu)檢查4.000公里2傳損壞和腐車(chē)輪變密封帽在潤(rùn)滑油注偏20.000公里3輪時(shí)間間隔損壞和腐蝕的外觀檢車(chē)輪直徑的檢偏斜的檢輪對(duì)內(nèi)測(cè)距檢輪對(duì)輪車(chē)輪和車(chē)軸的更換條鏇修車(chē)100.000公里4圓錐滾柱圓錐滾柱軸承的拆卸和1,200.000表4.4.21維修作業(yè) 檢按照錯(cuò)誤！未找到源。節(jié)進(jìn)行拖車(chē)輪對(duì)的維修保養(yǎng)將按照制動(dòng)盤(pán)II33410／197033410／1990N（TA30484_D05/D06）件進(jìn)行制動(dòng)盤(pán)的工作注的直徑設(shè)定值，見(jiàn)文件“RGA05CCU用戶-用戶手冊(cè)”，節(jié)。大 “輪對(duì)軸箱，左側(cè)”，參見(jiàn)圖2.1.5-3R1組校對(duì)1元件的拆除，參見(jiàn)錯(cuò)誤！未找到源。節(jié)找到2圓錐滾柱復(fù)原圓錐滾柱軸承，參見(jiàn)錯(cuò)誤！未找到源。節(jié)找到3重新安裝元件，參見(jiàn)00保養(yǎng)規(guī)排除故注拆

必須按照錯(cuò)誤！未找到源。部分進(jìn)行拖車(chē)輪對(duì)的故障排除(TA30484_D05/D06)./將按照制動(dòng)盤(pán) （TA30484_D05/D06）文件執(zhí)行制動(dòng)盤(pán)的排除故障關(guān)于圓錐滾柱軸承的排除故障的內(nèi)容，參見(jiàn)錯(cuò)誤！未找 源。節(jié)不能被損壞或者地變形。 過(guò)鎖被可靠地接地。在車(chē)輛手冊(cè)里，描述了總列車(chē)開(kāi)關(guān)。這是安全地防止觸電事故的唯一方拆卸帶有軸箱圖紙 “拖車(chē)輪對(duì)總成”，具體參見(jiàn)圖2.1.5-準(zhǔn)備工作 拆卸輪對(duì)指南（參見(jiàn)車(chē)軸導(dǎo)向裝置手冊(cè)工具和設(shè)備 壓力裝在松開(kāi)螺絲連接之前，必須可靠地放置或者頂起輪注拆卸不帶軸箱注圖紙 “拖車(chē)輪對(duì)組成”，具體參見(jiàn)圖2.1.5-“輪對(duì)軸箱，右側(cè)”，參見(jiàn)圖2.1.5-“輪對(duì)軸箱，左側(cè)”，參見(jiàn)2.1.5-3準(zhǔn)備工作 拆卸輪對(duì)軸承附件（參見(jiàn)輪對(duì)軸承手冊(cè)工具和設(shè)備 不需序組措前后參1拆卸輪對(duì)軸箱（件20）的螺絲連（A6Z00001088719／A6Z00001088721件110140）和下半部3輪下落輪對(duì)或者升起轉(zhuǎn)向架表-1拆卸不帶軸箱的輪更換概分注

關(guān)于拆開(kāi)輪對(duì)的內(nèi)容，請(qǐng)參見(jiàn)錯(cuò)誤！未找到源。 關(guān)于拆卸制動(dòng)盤(pán)的內(nèi)容，參見(jiàn)制動(dòng)盤(pán)II33410／1970（TA30484_D05/D06）文件關(guān)于拆除和拆卸圓錐滾柱軸承的內(nèi)容，參見(jiàn)錯(cuò)誤！未找 源。節(jié)修補(bǔ)。（參見(jiàn)錯(cuò)誤！未找到源。節(jié)）注組注

關(guān)于修理輪對(duì)的內(nèi)容，請(qǐng)參見(jiàn)錯(cuò)誤！未找到源。關(guān)于修理制動(dòng)盤(pán)的內(nèi)容，參見(jiàn)制動(dòng)盤(pán)II33410／1970（TA30484_D05/D06）文件關(guān)于修理圓錐滾柱軸承的內(nèi)容，請(qǐng)參見(jiàn)錯(cuò)誤！未找到源。關(guān)于組裝輪對(duì)的內(nèi)容，請(qǐng)參見(jiàn)錯(cuò)誤！未找到源。關(guān)于組裝制動(dòng)盤(pán)的內(nèi)容，參見(jiàn)制動(dòng)盤(pán)II33410／1970（TA30484_D05/D06）文件關(guān)于組裝圓錐滾柱軸承的內(nèi)容，請(qǐng)參見(jiàn)錯(cuò)誤！未找 源。重新安注

關(guān)于重新安裝輪對(duì)軸承到拖車(chē)輪對(duì)的內(nèi)容，請(qǐng)參見(jiàn)錯(cuò)誤！未找到源。重新安裝帶有軸箱的拖圖紙 “拖車(chē)輪對(duì)組成”，具體參見(jiàn)圖2.1.5-消耗材料 STABURAGNBU30PTM(H38)安裝工具和設(shè)備 壓力試驗(yàn)序組措Note/前后參1表面部分STABURAGNBU302牽引拉桿安裝牽引拉桿組成3一系懸安裝一系懸掛4輪對(duì)軸承安裝輪對(duì)軸承附件表- 重新安裝帶有軸箱的拖車(chē)輪重新安裝不帶軸箱的拖圖紙 “拖車(chē)輪對(duì)組成”，具體參見(jiàn)圖2.1.5- 序組措注前后參1軸承外2輪下降輪對(duì)或者升起轉(zhuǎn)向架3注意均勻地?cái)Q緊下部輪對(duì)軸箱部分的螺絲連4輪對(duì)軸承安裝輪對(duì)軸承附件表1-1重新安裝不帶軸箱的拖車(chē)輪設(shè)定值和參見(jiàn)錯(cuò)誤！未找到源。節(jié)，制動(dòng)盤(pán)II334101970（T30484_D05／06）錯(cuò)誤！未找到源。。注工廠尺寸運(yùn)轉(zhuǎn)的極限尺毫由操作者-byoperator/由操作者確定byoperator/由操毫由操作者由操作者/30毫表4.5.81輪徑也要參考錯(cuò)誤！未找到源。部分在參考輪對(duì)旋修或更換之后，要使用Sibias在CCU檢查/調(diào)整參輪對(duì)的車(chē)輪直徑設(shè)定值，見(jiàn)文件“RGA05CCU用戶-用戶手冊(cè)注參見(jiàn)錯(cuò)誤！未找到源。節(jié)，制動(dòng)盤(pán)II334101970注 工具將不包括在供貨范圍之內(nèi)圖解零件明細(xì)表 文DP硬件輪對(duì)&車(chē)輪文拖車(chē)輪對(duì)和保養(yǎng)手動(dòng)車(chē)輪對(duì)和保養(yǎng)手NDT軸承修理附警明細(xì)表輔助材料將不包括在供貨范圍之注化學(xué)參見(jiàn)錯(cuò)誤！未找到源。節(jié)，制動(dòng)盤(pán)II334101970注查看錯(cuò)誤！未找到源。部分或者在拖車(chē)轉(zhuǎn)向架或者動(dòng)車(chē)轉(zhuǎn)向架手冊(cè)里的相關(guān)信息潤(rùn)滑參見(jiàn)錯(cuò)誤！未找到源。節(jié)，制動(dòng)盤(pán)II334101970（TA30484_D05／D06）文件和使用的潤(rùn)滑劑內(nèi)容錯(cuò)誤！未找到源。注參其它的輔助材制造廠STABURAGNBU30裝配KlueberLubricationFAGArcanol裝配FAGKugel表7.2.41其它輔助材參見(jiàn)錯(cuò)誤！未找到源。節(jié)，制動(dòng)盤(pán)II334101970注測(cè)量&試驗(yàn)設(shè)備將不包括在供貨范圍之參見(jiàn)錯(cuò)誤！未找到源。節(jié)，制動(dòng)盤(pán)II334101970（TA30484_D05／D06）文件和使用的測(cè)量&試驗(yàn)設(shè)備內(nèi)容錯(cuò)誤！未找到注意 源。。TrailerCRH3-CRH3-TransportandmaintenancemanualSparepartslist Loverelant roductsOriginalOriginallanguage:TranslatedApprovedanditscontentsarethepropertyofLucchiniRSSpA.Thereproduction,and/oreditingofthis aswellastheutilisationofitscontentandcommunicationthereoftootherswithoutexpressauthorisationareprohibited.AnytransgressionwillbepursuedaccordingtoItalianandEUlaws,includingthepaymentofdamages. sarisingfromregistrationofmarksrantsofdesignpatentsorutilitymodelpatentsare .Theutilisationofthis representsneitheracquiescencenorabandonmentofanyrightsbyLucchiniRS.Syope?andthe“Syope?”logoaretrademarkregisteredbyLucchiniRS 262728293031323334353637383940414243444546474849X 51525354555657 Listofmodified123456789AXBXAXBGeneral Spareparts Guidelinesformanual Safety Aimand Normative Purchase Functional Wheelsets Storageand Supply Functionalreferencesoftherail-wheel Wheelsetfunctional Wheelkey Rimkey Axleskey 1stlevelpreventive Visual Wheelvisual Axlevisual ControlofintegrityoftheSyope? Control General Inspectionofrimflange Rollingplanesurfacedefects Defects FLAT(wheel IND RCF(RollingContact RCF1(RollingContactFatigue RCF2(RollingContactFatigue SPALL Suggestedcorrective Wheelsrimwidth Wheeltreadrollover Wheelsbacktobackandinnerfacesparallelism Wheelsetdefects Axleultrasonicinspectionwithboreprobe Wheelrimultrasonicinspection 1stlevelcorrective Safety Damagesfoundduring Wheelre- Dimensionafterre- Wear Syope?panelsrepairing Wheelandaxlepaintingorcorrosiondamages Notesfor Keeoftemperatureand Products Highthicknesspainting Lowthicknesspainting Painting 2ndlevelpreventive Axleboxhousingandbearingdisassembly Journalintegrityanddimensional Wheelsetultrasonic Wheels Wheelspressing Axleintegrityanddimensionalverificationonwheel Axlemagneticparticletestonwheel Wheelpressing Preliminary Finalwheelset Dynamic Otherwheelsetcomponents Axle-boxhousingandbearingassembly Wheelsetultrasonic 2ndlevelcorrective Axlere- Bearingseatcorrective Othercasesnotcoveredbythe Wheelsetsubjecttoshort Wheelsetloadedovertheallowed Operationstobecarriedoutonderailment Inspectionsin Brake Other Spareparts Foranyinformation

ViaG.Paglia4524065Lovere(BG) :GeneralInordertoguaranteeasafetyuseofthecomponents,thesafetyoftheemployedstaffandthedamageofmachinery,itisimportanttoreadthewholemanual.TechnicalLucchiniRSreservestherighttokeepmodificationstothismanualanytimeandwithoutpriornotice.It’smanagerdutytoassurethecompletedistributionofthemaintenancemanualtotheemployedstaffinthelastapplicableversion.AnymodificationorintegrationofthepresentmanualbytheoperatormustbeagreedwithLucchiniRS.SparepartsItisoperatortasktouseoriginalorauthorizedpiecesforthespareTheuseofnonoriginalornotauthorizedsparepartsimpliesthelossofLucchiniRSguarantee.GuidelinesformanualNoneoftheoperationsdescribedinthismanualisgiveninalogicalsequence;theonlypurposeistodescribethesinglemaintenanceoperations.FiguresFiguresandpartsarenotalwayscorrespondingtotheoriginalones;theironlypurposeistodescribetheoperationtobecarriedout.Figuresandpartsarenotinacorrectdimensionalscale,thereforeitisimpossibletoextrapolatedimensionsandmasses.Itis mendedtoscrupulouslyrespectallsafetyprescriptionsandtechnicalMainsafetyadvicesareunderlinedbythesymbolsasexplainedintheThissignalisplacednearbytheoperationprocedureathigherrisklevel.Death,severeinjuresandserioussystemdamagescouldresultfromfailuretofollowthesafetyrulesprescribed.Thissignalisplacednearbytheoperationswhichcouldleadtorisksfortheemployedstaff,fortheequipmentorforthevehicle.SafetySafetyindicationshereunderreportedmustbecarefully Wheelsetsarebuiltaccordingtothemostrecenttechnologiesandtheiruseissafe.Theuseormaintenanceofthematerialbyanunskilledstaffortheuseofmaterialfordifferentpurposescouldleadtodangeroussituations.Alltheusingcompanyemployeesinterestedinwheelsetsuseandmaintenancemustreadandunderstandthismanual,payingparticularattentiontothesafetyinstructions.Anymodificationorchangesarenotallowedwithouttheauthorizationoftheconstructorthatcouldaffectthesecurityofthecomponentsduringtheuse.Anydimensionalchangesorunauthorizedmodificationscanprejudicewheelsetsafety.Theworkmustbeperformedexclusivelybyaproperlytrainedandauthorizedstaff.ForwheelsetliftingtheinstructionsreportedintherelatedsectionmustbeItmustbeavoidedthatdetergentsfumesorothersfluidsusedforwheelsetmaintenancecomeintocontactwiththeskin,areswallowedorbreathed.Ifsomeoneshouldunintentionallyswallowdetergentsorothersimilarfluids,aidmustbeimmediayresortedto.Theproduct’sproducerindicationsmustbecarefullyrespected.GlovesandprotectiveglassesmustbewornduringDetergentsorotherfluidsusedformaintenancemustnotbedumpedinc sorontheAccidentspreventionprescriptionsinforceinthesitemustberespected.OnlysparepartsproducedorauthorizedbyLucchiniRSS.p.A.mustbeused.Keepworkareaclean,uncluttered,ventilatedandilluminated.LucchiniRSisnotresponsibleofthedamagestotheproductcausedbyanincorrectuseofmaintenanceinstructionsnotincompliancewithindicationcontainedinthemanual.Everyworkonthewheelsetandinthenearbypartsshouldbemadeonlybyauthorizedtrained MaintenancefrequenciesdescribedinthismanualshallbeperiodicallyEveryinspectionshallbeincludedinthegreatermultiplefrequencyEveryscrewtorquetightenedandeverysafetycriticalscrewmustbemarkedwithpaint(continuouslineonthescrewheadandonthesupportsurface).ThismarkingpermitsaquicklycheckofthescrewCorrectandfaultyscrew ScrewCorrectandfaultyscrew Screwconnection:assembling,tightening andmarkingWhetherthemarkinglineisnotcontinuousorthescrewisloose,thescrewmustbemountedagain,tightenedinthecorrectwayandmarkedagain.EveryscrewunloosedmustbeedysedinAimandThismanualshowsthepreventiveandcorrectiveactionsforthemaintenance,handlingandconservationofthetrailerwheelsetsofCRH3-350train.WeadvicetocarefullyreadthismanualbeforestartinganySpecialequipmentsindicatedinthemanual,ifnotindicatedinthepurchasecontract,arenotpartofthewheelsetsupply.NormativeThefollowing isindispensablefortheapplicationof prEN15313:2008“Railway requirements–In-serviceandoff-vehiclewheelsetmaintenance”.EN13260:2003“Railwayapplications–Wheelsetsandbogies–Wheelsets–Productsrequirements”(Englishversion).EN13261:2003“Railwayapplications–Wheelsetsandbogies–Axles–Productsrequirements”(Englishversion).EN13262:2004“Railwayapplications–Wheelsetsandbogies–Wheels–Productsrequirements”(Englishversion).doc.A6Z00001100317“WheelLucchiniRSdoc.QUAT.I.065“U.T.controlprocedureforboredaxlesandwheelsetswithamulti-channeldigitalboreprobesystemusingtransversalprobesat38°,45°and70°andat50°secantbeam”.LucchiniRSdoc.QUAT.I.113“ManualN.D.T.inspectionprocedureformotorandtraileraxlesofwheelsetsonrollingstockmaintenance”.LucchiniRSdoc.QUAT.I.078“In-servicemanualUTcontrolprocedureofsolidwheel’srimsandtyres”.LucchiniRSdoc.QUAT.I.101“In-serviceU.T.controlprocedureofsolidwheel’srimsandtyreswithanautomaticmulti-channeldigitalsystem”.LucchiniRSdoc.QUAI.T.329“ApplicationofanimpactresistantcoatingforrailwayaxlesLURSAK”.PurchaseWheelset Trailer WheelsetsforCRH3-350trainIdentificationnumbers:LucchiniRSdrw.11000000319“TrailerWheelset”ComponentsFunctionalWheelsetsaredesignedforthetrailerbogiesofCRH3-350train.Thewheelset,assubsystemofthetrainbogie,istheinterfacebetweenthebogieframeandtherailtrack.4.24.2WheelsetsWheelsetslayoutisshowninFigureFigure1-WheelsetsWheelsetsaredesignedCRH3-350trainaccordingtostandardEN13260and,accordingtostandardEN13261[3],theaxlesareclass1protectedagainstatmosphericcorrosionandmechanicalimpacts(impacts,gritting,etc.).Solidwheelsaredesignedinordertoobtainanhighreductionofacousticemission,byusingametalpanel(Syope?)gluedonthewheelweb.TheSyope?systemhasalifeequaltothewholelife-cycleofthewheel.TheapplicationoftheSyope?systemdoesn’tchangeinanycasethecharacteristicsofthewheelandallowstoperformallthemaintenanceactivitiesnecessaryduringthelife-cycleofthewheel.4.3TechnicalTrailerwheelset(drw.11000000319-Solidwheeldrawing 66L2593Solidwheelpartlist 66L2593Solidwheel ER8-EN13262 A6Z00001100317Newwheel 920Fullywornwheel Solidwheel Solidwheeldrawing(withsoundabsorbers) 66L2599Solidwheelpartlist(withsoundabsorbers) 66L2599Solidwheelmass(withsound Traileraxledrawing 66L2592Traileraxle EA4T-EN13261Traileraxle Axle-mountedbrakediscdrawing(withhubbore Numberofaxle-mountedbrakediscs(withhubbore Axle-mountedbrakediscmass(withhubbore Axle-mountedbrakediscdrawing(withhubbore Numberofaxle-mountedbrakediscs(withhubbore Axle-mountedbrakediscmass(withhubbore Trailerwheelsetdrawing TrailerwheelsetpartWheelsetbacktobackumdifferencebetweenthediametersoftwowheelsmountedonthesamewheelsetTrailerwheelsetTableI-Wheelsettechnical

1353+2/0ComponentsAllwheelsetsandrelatedcomponentsareidentifiedbythemarkingmadeonthem.FormarkingpositionandtheinformationcontainedinitthefollowingdrawingshallbereferredWheelsmarking(LucchiniRSdrw.66L25912 Axlesandwheelsetsmarking(LucchiniRSdrw.11000000224-BeforeanycommunicationtoLucchiniRSaboutthewheelsetoroneofitscomponents,therelatedidentificationdatashallbenoted.Ifthecomponentcouldnotbeidentified,e.g.ifthereadingofthereferencenumbershouldnotbepossible,LucchiniRStechnicalassistanceshallbereferredto.StorageandTakecarealsooftheprescriptionsforaxleboxesandbrakediscsnotincludedinthismanual.SupplyWheelsetsarepreparedand dcompletewithallpartspainted(whereprescribed)onwoodenpalletssuitableforhandling.Figure2-WheelsetsupplyWheelsetscanbeliftedfortransportusingatrolleywithappropriateblades(Figure3).Ifneeded,theycanbeliftedfromthepalletwithappropriatecablesasshowninFigure4(alltheexpedientsnecessarytodonotdamagethepaintedsurfacesmustbeadopted).Duetotheheavyweightofwheelset,becarefultoumallowedbyliftingequipments.Becarefultothehangingload.Donotstopunderliftedloads.Itisnotallowedthattheropeofthecranedamagesthesurfaceofthewheelset.UseofsoftcoatedslingropeismandatoryforwheelsetFigure3-WheelsetliftingwithaFigure4-WheelsetliftingwithWheelsetsmustbestoredinaclosedanddryenvironment,withfreeairWheelsetfunctionalTheessentialdimensionalreferencesforthewheelsetsaredefinedinthefollowing FigureFigure5-Interfacedimensions-wheelsetfunctionalKeye1,e2sd1,d2backtobackfronttofrontdimension(sumofe1+a1+e2)flangethicknesspositionsofwheeltreadflangeheightrimwidthflangewheelinternalfaceofthewheelriminternalzoneoftheflange(H2-s)FortherelatedvaluesthecomponentsdrawingsshallbereferredWheelkeyTheessentialreferencezonesforthewheelareshowninthefollowingFigureFigure6-WheelkeyreferenceKeyL1hubRimkeyTheessentialkeyreferencezonesfortherimareshowninthefollowingFigure7-RimkeyreferenceTheessentialdimensionalreferencesoftherimareshowninthefollowingFigure8-RimkeyreferenceKey flange flange rimFortherelativevaluesreferstothecomponentsdrawingsandFortherelativevaluesreferstothecomponentsdrawingsandfor rofilegeometry7.4AxleskeyTheessentialreferencezonesdefinedforaxlesareshowninthefollowingFigure9-AxleskeyreferenceKeywheelaxlebrakediscaxleAlltracesofoil,greaseorotherdirtthatcouldinterferewiththeinspectionorrepairingmustberemoved.Thecleaningshallbecarriedoutwithapprovedprocessesusingoneofthefollowingmethods:mechanicalscouring,provideditdoesnotchangethefatiguelimitcharacteristicsofthecomponentanddoesnotriskconcealinganycracks.AnycleaningmethodshallbedulyqualifiedbeforeitisBeforecleaningthewheelsets,referstotheothercomponentsmanualsinordertocarefullyprotectthem.Generally,waterentryintheaxleboxisnot1stlevelpreventive9.19.1MaintenanceFrequencieshereunderdonottakeintoaccounttheoperationsontreadsurfacesthatarenecessaryinthefollowinglistedcases:emergencybrakingwithadherenceanti-skidsystemanti-slipsystemsandblastingsystemflange-greasingsystemtrainrunningothergeneralproblemsforthevehicleortheThefollowingsectionsarerelatedtothewheelsandaxlesanddonotcontainanyspecificinformationrelatedtootherwheelsetcomponents,forwhichthespecificmanualsshallbeconsulted.Operation(inspectionorRollingplaneFlangePresenceofthecapinwheeloilinjectionboreWheelwearcheckedbythepresenceoftheweargrooveAxlesvisualControlofintegrityoftheSyope?systemRollingplanesurfacedefectsinspectionInspectionofrimflangeconditionsRollingdiameterinspectionRimwidthinspectionWheeltreadrolloverinspectionWheelsbacktobackandinnerfacesparallelismWheelsetdefectsAxleultrasonicinspectionwithboreprobeWheelrimultrasonicinspection TableII-PreventivemaintenanceSpecialSpecialequipmentindicatedinthismanualisnotpartofthewheelsetsupply(ifnotdifferentlyindicatedinthepurchasecontract).1Inspectionandrevisionfrequenciesreportedhereareinitialprescriptionsbutarenotgrantedbythesolidwheelsr,thereforetheycanbeimprovedonthebasisofexperiencefeedbackduringtheinitialphasesofvehicleservice.VisualBeforeBeforestartinganywork,thevehiclemustbestationaryandputoutofWheelvisualAcarefulvisualinspectionshallbeconductedwiththepurposeofcheckingtheabsenceofcracksorofotherdefectswhichcouldcausetherimorthesolidwheeltobreak.Forinformativepurposes,thezonesandthetypeofcrackswhichmayariseintherimareillustratedinFigure10.Figure10-PositionandtypeofcrackswhichcanarouseinthetyreortyreInordertoperformthefollowingoperationsitisnecessarytodescendintotheinspectionpit.Rimrollingsurfacesmustbecarefullyobserved(mainpartsareshowninFigure7):ifnecessary,cleanwitharagbeforeinspectionandrepeatthecontrolbyslightlymovingthetrainontherailsoastobeabletoinspectthewholewheelrollingsurfaces.VehicleinNoroughnessorirregularities(e.g.steps)mustbepresentonthetransitionbetweentherollingsurfaceandtheflange.Noimpressions,scratchesorwheeltreadrollovermustbepresentonthetiporontheinnersideoftheflange;theyareindexofanomalouscontactwithpoints,switchesorguardrails.Thecontactsurfaceduetotheverticalwheel-railcontact(alsonearthetyreoutersideoftherim)mustnotbeconcentratedbutuniformlyextended(asmoreaspossible)alongthetransversaltyreprofile.Thepresenceoftheweargroove(seeFigure11detail“Z”)mustbeverified;itmustbeintegerandalwaysfullyvisibleafterre-profilingandinservice,allalongitswholeextension.ThedecisioncriteriaareshowninFigure12:AnotB functionalityofanti-skidandanti-slipsystemsmustbeverified.Thewearlimitdiameterisdefinedinthewheeldesignphaseandisindicatedtherelateddrawing.Thelastre-profilingdiametershallbedefinedbytherelativetothewearlimitdiametersothatitdoesnothavealowervalueinBesidestheabovelisteddefects,nocracksareallowedonanypartofthewheelsurfaces.(seechapter9.4.4).Besidestheabovelisteddefects,nocracksareallowedonanypartofthewheelsurfaces.(seechapter9.4.4).Figure11-InspectionofoilinjectionboreandwearFigure12-WeargroovedecisionFordefectstolerabilityconditions,serviceandmaintenancenormsmustbereferredto(seechapter9.4).Inthecaseofevidentweardefectsordamagestotheflange,theusualservicetrackequipmentmustbeinspected.WheelsetswithdamagedrollingareasmustnotbekeptinserviceWheelsetswithdamagedrollingareasmustnotbekeptinservicesincethelocaldamage,becauseofvibrations,canquicklyextendtoothervehiclecomponents.Foranyfurtherinformationonvisualandinstrumentalinspectionsandforeventualacceptationlimitsseechapter9.4.AxlevisualInordertoperformtheseoperations,itisnecessarytoworkfromtheinspectionpitandtothattheaxleshavenotexternal(marks,incisions)onpaintedsurfacesInthecaseofsmallpaintingdeta ents(seeFigure13)thewheelsetcanbekeptinservicetillthefollowingplannedinspection.Figure13-ExampleoflimitedpaintingInthecaseofpaintingdamagesonwideaxlesurfacesand/orevidentcorrosion(seeFigure14)thewheelsetmustbeputoutofserviceassoonaspossibleandmustundergothenecessarymaintenanceoperations.Figure14-ExampleofwidepaintingInthecaseofdamagesimplyingscratchesorsharpcornersalsoontheaxlemetallicsurface,thewheelsetmustbeimmediayputoutofserviceandmustundergothenecessarymaintenanceoperations.thattheaxleshavenolongitudinaldefects,whi aylooklikeacrack,inthebody(seeFigure15).FigureFigure15-LongitudinaldefectsonaxlethatnocorrosionisbeginningsofthewheelpressfittingthatnocorrosionisbeginningonunprotectedzonesinIfanydamageisfound,itmustbecheckedifitislimitedtothethicknessofthepaintingorifitaffectsthemetalstructure.Ifindoubt,aUTcontrolshallberequired;inthatcaserefertochapter9.4.9.Ifacorrectiveactionisneeded,refertochapter11.ControlofintegrityoftheSyope?ThemethodandtheinspectionsappliedduringthemountingofthepanelsonthewheelsareabletoguaranteetheadhesionoftheSyope?panelduringthewholelife-cycleofthewheel.However,unexpectedimpactsortheballastcanhitthesurfacesofthepanel,causingalocaldamageand/oritspartialdetaentfromthewheelneartheedges.FortherepairingprocedurerefertochapterControlVisuallychecktheSyope?panelperimetertoidentifydetaent(ungluing)fromthewheelsurfacealongthehubsideedges(seeFigure16detail“X”)andtyregrooveside(seeFigure16detail“Y”).TableIIIdescribestheactionstobetakenifdetaentisdiscoveredofthesoundproofingpanelsfromthewheelsurface.Radialdeta developmentRepairinghub>5>20RepairingchapterContactthertyre>15>100chapter10.4ContacttherTableIII-RepairingactionsforSyope?Figure16-InnerandouterSyope?absorbers,detailsoftheWheelsetinstrumentalGeneralBeforestartinganywork,thevehiclemustbestationaryandputoutofToperformthefollowingoperationsitisnecessarytodescendintotheinspectionFordimensions,dimensionalandgeometrictolerancesofwheelandwheelsetassemblyinnewconditionsrefertothedrawingslistedatchapter4.3.Inspectionprocedureconsistsofthefollowingphases(seeTableIIforinspection-Thefollowingtre rofiledimensions(seeFigure8)mustbeverifiedwithanappropriategauge:FlangeheightFlangethicknessDimensionFordetailsrefertochapter-Rollingdiameterinspectionmustbeperformed;fordetailsrefertochapter-Rollingplanesurfacedefectsinspectionmustbeperformed.Basiclevelinspectionsdescribedatchapter9.2.1mustbeperformed;fordetailsrefertochapter9.4.4.-Wheelsriminspectionmustbeperformed;fordetailsrefertochapter-Wheeltreadrollover inspectionmustbeperformed;fordetailsrefertochapter-Wheelsbacktobackandinnerfacesparallelisminspectionmustbeperformed;fordetailsrefertochapter9.4.7.-Thepresenceandthedimension,ifany,ofwheelsetdefectsmustbechecked;fordetailsrefertochapter9.4.8.-Wheelsetultrasonicinspectionmustbeperformed;fordetailsrefertochapter-Wheelrimultrasonicinspectionis mended(notmandatory);fordetailsrefertochapter9.4.10.InspectionofrimflangeForthemeasurementofflangeheightandthicknessthegaugesalreadyownedbythedepotstaffshallbeused(wearlimitsaresetbytheuseronthebasisofexperienceandservicefeedback).Permissiblevaluesaregiveninthefollowingtable.Flangedimension(FigurePermissiblerange qR!FlangeheightFlangethicknessDimensionTableIV-PermissiblevaluesforflangeThetreadmustbere-profiledwhendimensionsareoutoftheprescribedtolerancevaluesbuttheusercansetthetoleranceonthebasisofexperienceandservicefeedback.Wheelsetswithdamagedrollingareasmustnotbekeptinservicesincethelocaldamage,becauseofvibrations,canquicklyextendtoothervehiclecomponents.Independentlyfromflangedimensions,maintenanceplantsmustalsoperformtheworksnecessarytoremoveeventualdefectsontheflangeoronitsactiveside,suchasburrsand/orsharpcorners.InFigure17aflangewhichbeginstoshowasharpcorneriscomparedwithanewone:inFigure18,Figure19andFigure20,instead,theappearanceofawornflangeisshowninthethreewheel-railcontactconditionsof:Normalcontact(FigureBeginningofdegradation(FigureVerydegraded,withevidentsharpcorner(FigureFigure17-ComparisonbetweenanewprofileandanextremelywornprofileFigure18-NormalFigure19-BeginningofFigure20-EvidentRollingdiameterRollingd