Work Instructions for Testing of
Primary Vertical Dampers
(RCF Drawing No.LW 05102)
1. Receive the Primary Vertical Dampers from Bogie Repair Shop.
2. Check the damper whether it belongs to Shop Sch.I, Shop
Sch.II or Shop Sch.III. Dampers should be replaced during
Shop Sch-III(6 years). Damper should be tested during Shop
Sch.I and Shop Sch.II (Or early in case of oil leakages) as
as per parameters given in RCF drawings, read along with FIAT
specification no.17.560.100 – version 03,
3. Clean the Dampers completely and offer them for visual
Inspection.
4. Conduct visual inspection as per LHB Maintenance manual
(Chapter 4 of Page 33, 34 and 35) as follows,
5. Passed Dampers after visual inspection are taken to Hydraulic
Shock Absorber testing machine for load testing and shock
absorbers must be tested in real position.
6. Check the machine for any oil leakage, loose cable
connections etc..,
7. Switch ON the computer system.
8. Switch ON the machine; wait till line pressure builds up to 95
to 105 Kg/cm² and check whether the oil temperature is
below 50 degree Celsius.
9. Switch ON the Interface unit as soon as computer system
gets ON.
10. Check the machine arm’s up and down movement and tilting
movement without mounting shock absorber. Then keep the
arm’s position in such a way that the fixtures and shock
absorber can be mounted.
11. Lock the machine and mount the fixture for primary
vertical Dampers on top and bottom of the machine arm.
12. Mount the Primary Vertical Damper with the fixture on
lower arm of the machine.
13. Close the door, unlock the machine and slowly move the
lower arm of the machine to mount the top part of Primary Vertical
Damper safely.
14. Lock the machine. Open the door and mount the top of
Primary Vertical Damper to upper arm of the machine and ensure
that the Top and Bottom of Primary Vertical Damper is properly
tightened and mounted on the machine.
15. Close the door.
16. Select Primary Vertical Damper Testing Profile on the
Computer Desktop (Template readily available in the desktop which is
425kg at 0.3m/s Velocity)
17. Now select “Connect” Button on desktop.
18. Select ‘Null load’ on Load Profile and start testing Dampers
with null load initially.
19. Now select ‘Load Profile’ and start load testing of dampers
for one cycle. Watch the Result on Desktop.
20. Repeat the test for 10 cycles.
21. Accept the Damper if it passes in all the cycles.
22. Open the door and safely dismount the
damper from the machine using proper tools.
Safety Precautions:
a.
b.
All the employees involved in the above activity should use the
personal protective equipments like safety shoes, helmets, safety
spectacles & hand gloves.
Always keep work place clean and dry.
********
Work Instructions for Testing of
Yaw Dampers
(RCF Drawing No.LW 05103)
1. Receive the Yaw Dampers from Bogie Repair Shop.
2. Check the damper whether it belongs to Shop Sch.I, Shop
Sch.II or Shop Sch.III. Dampers should be replaced during
Shop Sch-III(6 years). Damper should be tested during Shop
Sch.I and Shop Sch.II (Or early in case of oil leakages) as
as per parameters given in RCF drawings, read along with FIAT
specification no.17.560.100 – version 03,
3. Clean the Dampers completely and offer them for visual
Inspection.
4. Conduct visual inspection as per LHB Maintenance manual
(Chapter 4 of Page 33, 34 and 35) as follows,
5. Passed Dampers after visual inspection are taken to Hydraulic
Shock Absorber testing machine for load testing and shock
absorbers must be tested in real position.
6. Check the machine for any oil leakage, loose cable
connections etc..,
7. Switch ON the computer system.
8. Switch ON the machine; wait till line pressure builds up to 95
to 105 Kg/cm² and check whether the oil temperature is
below 50 degree Celsius.
9. Switch ON the Interface unit as soon as computer system
gets ON.
10. Check the machine arm’s up and down movement and tilting
movement without mounting shock absorber. Then keep the
arm’s position in such a way that the fixtures and shock
absorber can be mounted.
11. Lock the machine and mount the fixture for yaw
Dampers on top and bottom of the machine arm.
12. Mount the yaw Damper with the fixture on
lower arm of the machine.
13. Close the door, unlock the machine and slowly move the
lower arm of the machine to mount the top part of yaw Damper
safely.
14. Lock the machine. Open the door and mount the top of
yaw Damper to upper arm of the machine and ensure that the Top
and Bottom of yaw Damper is properly tightened and mounted on the
machine.
15. Close the door.
16. Select Yaw Dampers Testing Profile on the Computer Desktop
(Template readily available in the desktop which is 1100kg at
0.1m/s Velocity)
17. Now select “Connect” Button on desktop.
18. Select ‘Null load’ on Load Profile and start testing Dampers
with null load initially.
19. Now select ‘Load Profile’ and start load testing of dampers
for one cycle. Watch the Result on Desktop
20. Then tilt the arm of the testing machine, select ‘Load Profile’
and start load testing of dampers for one cycle. Watch the Result on
Desktop.
21. Repeat the test for 10 cycles for both vertical and tilted
positions.
22. Accept the Damper if it passes in all the cycles.
23. Lock the machine, open the door and safely dismount the
Damper from the machine using proper tools.
Safety Precautions:
a.
b.
All the employees involved in the above activity should use the
personal protective equipments like safety shoes, helmets, safety
spectacles & hand gloves.
Always keep work place clean and dry.
*******
Work Instructions for Testing of
Secondary Vertical Dampers
(RCF Drawing No.LW 05101)
1. Receive the Secondary vertical Dampers from Bogie Repair Shop.
2. Check the damper whether it belongs to Shop Sch.I, Shop
Sch.II or Shop Sch.III. Dampers should be replaced during
Shop Sch-III(6 years). Damper should be tested during Shop
Sch.I and Shop Sch.II (Or early in case of oil leakages) as
as per parameters given in RCF drawings, read along with FIAT
specification no.17.560.100 – version 03,
3. Clean the Dampers completely and offer them for visual
Inspection.
4. Conduct visual inspection as per LHB Maintenance manual
(Chapter 4 of Page 33, 34 and 35) as follows,
5. Passed Dampers after visual inspection are taken to Hydraulic
Shock Absorber testing machine for load testing.
6. Check the machine for any oil leakage, loose cable
connections etc..,
7. Switch ON the computer system.
8. Switch ON the machine; wait till line pressure builds up to 95
to 105 Kg/cm² and check whether the oil temperature is
below 50 degree Celsius.
9. Switch ON the Interface unit as soon as computer system
gets ON.
10. Check the machine arm’s up and down movement and tilting
movement without mounting shock absorber. Then keep the
arm’s position in such a way that the fixtures and shock
absorber can be mounted.
11. Lock the machine and mount the fixture for Secondary
Vertical Dampers on top and bottom of the machine arm.
12. Mount the Secondary Vertical Damper with the fixture on
lower arm of the machine.
13. Close the door, unlock the machine and slowly move the
lower arm of the machine to mount top part of Secondary Vertical
Damper safely.
14. Lock the machine. Open the door and mount the top of
Secondary Vertical Damper to upper arm of the machine and ensure
that the Top and Bottom of Secondary Vertical Damper is properly
tightened and mounted on the machine.
15. Close the door.
16. Select Secondary Vertical Dampers Testing Profile on the
Computer Desktop (Template readily available in the desktop
which is 350kg at 0.2m/s Velocity)
17. Now select “Connect” Button on desktop.
18. Select ‘Null load’ on load Profile and start testing Dampers
with null load initially.
19. Now select ‘Load Profile’ and start load testing of dampers
for one cycle. Watch the Result on Desktop
20. Repeat the test for 10 cycles.
21. Accept the Damper if it passes in all the cycles.
22. Lock the machine, open the door and safely dismount the
Damper from the machine using proper tools.
Safety Precautions:
a.
b.
All the employees involved in the above activity should use the
personal protective equipments like safety shoes, helmets, safety
spectacles & hand gloves.
Always keep work place clean and dry.
*******
Work Instructions for Testing of
Secondary Lateral Dampers
(RCF Drawing No.LW 05100)
1. Receive the Secondary lateral Dampers from Bogie Repair Shop.
2. Check the damper whether it belongs to Shop Sch.I, Shop
Sch.II or Shop Sch.III. Dampers should be replaced during
Shop Sch-III(6 years). Damper should be tested during Shop
Sch.I and Shop Sch.II (Or early in case of oil leakages) as
as per parameters given in RCF drawings, read along with FIAT
specification no.17.560.100 – version 03,
3. Clean the Dampers completely and offer them for visual
Inspection.
4. Conduct visual inspection as per LHB Maintenance manual
(Chapter 4 of Page 33, 34 and 35) as follows,
4. Passed Dampers after visual inspection are taken to Hydraulic
Shock Absorber testing machine for load testing.
5. Check the machine for any oil leakage, loose cable
connections etc..,
6. Switch ON the computer system.
7. Switch ON the machine; wait till line pressure builds up to 95
to 105 Kg/cm² and check whether the oil temperature is
below 50 degree Celsius.
8. Switch ON the Interface unit as soon as computer system
gets ON.
9. Check the machine arm’s up and down movement and tilting
movement without mounting shock absorber. Then keep the
arm’s position in such a way that the fixtures and shock
absorber can be mounted.
10. Lock the machine and mount the fixture for secondary
lateral Dampers on top and bottom of the machine arm.
11. Mount the Secondary lateral Damper with the fixture on
lower arm of the machine.
12. Close the door, unlock the machine and slowly move the
lower arm of the machine to mount top part of Secondary lateral
Damper safely.
13. Lock the machine. Open the door and mount the top of
Secondary lateral Damper to upper arm of the machine and ensure
that the Top and Bottom of Secondary lateral Damper is properly
tightened and mounted on the machine.
14. Close the door.
15. Select Secondary lateral Dampers Testing Profile on the
Computer Desktop (Template readily available in the desktop
which is 800kg at 0.3m/s Velocity)
16. Now select “Connect” Button on desktop.
17. Select ‘Null load’ on load Profile and start testing Dampers
with null load initially.
18. Now select ‘Load Profile’ and start load testing of dampers
for one cycle. Watch the Result on Desktop
19. Then tilt the arm of the testing machine, select ‘Load Profile’ and start
load testing of dampers for one cycle. Watch the Result on Desktop
20. Repeat the test for 10 cycles including both vertical and tilted
positions.
21. Accept the Damper if it passes in all the cycles.
22. Lock the machine, open the door and safely dismount the
Damper from the machine using proper tools.
Safety Precautions:
a.
b.
All the employees involved in the above activity should use the
personal protective equipments like safety shoes, helmets, safety
spectacles & hand gloves.
Always keep work place clean and dry.
*******