AD43C LOCOMOTIVE PREVENTIVE MAINTENANCE...

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Preventive maintenance plan for ALSTOM AD43C Diesel Locomotives Page 1 ABCD Transport S.A. - IRANIAN ISLAMIC REPUBLIC RAILWAYS AD43C LOCOMOTIVE PREVENTIVE MAINTENANCE PLAN Written by Agreed by Authorised by Name Antoine GERMAIN André FAGES Jean-Marc TESSIER Date Signature List of revisions REVISION PURPOSE INSERTED MODIFICATION CHAPTER / page DATE BY 1 First issue 07/2004 A.GERMAIN 2 Updated maintainability Added back of experience Modified maintenance schedule Added MAP 7094 Added MAP 7155 All chapters All chapters Maintenance schedule Locomotive step B Bogie step d 03/2005 COMIDOC

Transcript of AD43C LOCOMOTIVE PREVENTIVE MAINTENANCE...

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Preventive maintenance plan for ALSTOM AD43C Diesel Locomotives Page 1ABCD Transport S.A. - IRANIAN ISLAMIC REPUBLIC RAILWAYS

AD43C LOCOMOTIVE PREVENTIVE MAINTENANCE PLAN

Written by Agreed by Authorised by Name Antoine GERMAIN André FAGES Jean-Marc TESSIER Date

Signature

List of revisions

REVISION PURPOSE INSERTED N° MODIFICATION CHAPTER / page DATE BY

1 First issue 07/2004 A.GERMAIN 2 Updated maintainability

Added back of experience Modified maintenance schedule Added MAP 7094 Added MAP 7155

All chapters

All chaptersMaintenance

scheduleLocomotive step B

Bogie step d 03/2005 COMIDOC

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Preventive maintenance plan for ALSTOM AD43C Diesel Locomotives Page 2ABCD Transport S.A. - IRANIAN ISLAMIC REPUBLIC RAILWAYS

Summary

AD43C LOCOMOTIVE PREVENTIVE MAINTENANCE PLANAD43C LOCOMOTIVE PREVENTIVE MAINTENANCE PLANAD43C LOCOMOTIVE PREVENTIVE MAINTENANCE PLANAD43C LOCOMOTIVE PREVENTIVE MAINTENANCE PLAN ............................. 1

List of revisionsList of revisionsList of revisionsList of revisions .......................................................................................... 1 SummarySummarySummarySummary .................................................................................................. 2 General definitionsGeneral definitionsGeneral definitionsGeneral definitions .................................................................................... 2 List of consumablesList of consumablesList of consumablesList of consumables.................................................................................... 3 Bogies maintenance planBogies maintenance planBogies maintenance planBogies maintenance plan ........................................................................201 Locomotive maintenance planLocomotive maintenance planLocomotive maintenance planLocomotive maintenance plan .................................................................300

General definitions The following preventive maintenance plan is applicable on AD43C freight and passengers locomotives, type 20,5 tons per axle, without its diesel engine. This preventive maintenance plan was made according to suppliers specifications and customer’s information, however the maintenance frequencies may be adapted to the customer’s conditions of use and weather conditions. These maintenance frequencies are based on the following statistics : 25000 km per month and 190 hours per 10000 km for passengers locomotives. 12000 km per month and 520 hours per 10000 km for freight locomotives. All preventive maintenance frequencies are included in the following plan, do not refer to maintenance frequencies given in the maintenance manual This document do not deals with curative maintenance, routine cleaning, safety tests and precautions, refer to the maintenance manual for this kind of information. This maintenance plan is a synthesis of maintenance data, it doesn’t replace the maintenance manual’s instructions, specially the safety procedures. Standard tooling for maintenance workshop are not included in the “special tooling” paragraph. Maintainability data for downtime hours and manpower are given for information, it depends on structures, tools and organisation of the maintenance workshop. Maintainability data does not include diesel engine maintainability.

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List of consumables The following list is a synthesis of the principal consumables used on the locomotive, this does not include diesel engine and dismantling operations. Refer to maintenance manual and preventive maintenance plan for quantities and mixing specifications.

Consumable Function SHELL EP460 Flange lubricating device SHELL Spirax Ax-90 Gear cases MOBILITH SHC 100 traction motor bearings SHELL ALVANIA 2760B Cannon box bearings DEA mineral AG.PARAGONEP ½ cardan coupling SUMMER : DCA4 FLEETGUARD. WINTER : ES COMPLEAT EG FLEETGUARD

Cooling liquid for diesel engine cooling circuit

COOL ELF SUPRA with ethylene glycol, corrosion preventive and antifreeze for temperatures of –25°C

Cooling liquid for electrical cabinet cooling circuit

ESSO OIL 150 or SHELL CORENA P100 or TOTAL CORTUSA 100

Air compressor

SHELL ALVANIA EP2 alternator bearing R134a cooling agent Air conditioner

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Bogies maintenance plan Bogies maintenance schedule

LevelLevelLevelLevel StepStepStepStep

aaaa bbbb cccc dddd eeee ffff gggg hhhh

DailyDailyDailyDaily XXXX MonthlyMonthlyMonthlyMonthly XXXX

30’000 km30’000 km30’000 km30’000 km XXXX 60’000 km60’000 km60’000 km60’000 km XXXX XXXX 90’000 km90’000 km90’000 km90’000 km XXXX

120’000 km120’000 km120’000 km120’000 km XXXX XXXX XXXX 150’000 km150’000 km150’000 km150’000 km XXXX 180’000 km180’000 km180’000 km180’000 km XXXX XXXX 210’000 km210’000 km210’000 km210’000 km XXXX 240’000 km240’000 km240’000 km240’000 km XXXX XXXX XXXX XXXX 270’000 km270’000 km270’000 km270’000 km XXXX 300’000 km300’000 km300’000 km300’000 km XXXX XXXX 330’000 km330’000 km330’000 km330’000 km XXXX 360’000 km360’000 km360’000 km360’000 km XXXX XXXX XXXX XXXX 390’000 km390’000 km390’000 km390’000 km XXXX 420’000 km420’000 km420’000 km420’000 km XXXX XXXX 450’000 k450’000 k450’000 k450’000 kmmmm XXXX 480’000 km480’000 km480’000 km480’000 km XXXX XXXX XXXX XXXX 510’000 km510’000 km510’000 km510’000 km XXXX 540’000 km540’000 km540’000 km540’000 km XXXX XXXX 570’000 km570’000 km570’000 km570’000 km XXXX 600’000 km600’000 km600’000 km600’000 km XXXX XXXX XXXX 630’000 km630’000 km630’000 km630’000 km XXXX 660’000 km660’000 km660’000 km660’000 km XXXX XXXX 690’000 km690’000 km690’000 km690’000 km XXXX 720’000 km720’000 km720’000 km720’000 km XXXX XXXX XXXX XXXX XXXX XXXX

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Preventive maintenance plan for ALSTOM AD43C Diesel Locomotives Page 202ABCD Transport S.A. - IRANIAN ISLAMIC REPUBLIC RAILWAYS

Maintenance levels definition

Level a – daily maintenance I - Operations General inspection

Check visually for leaks, shocks or cracks, presence of screws and pins, bellows and breathers of brake blocks, electrical and pneumatical connections, hoses wear, presence of oil on carters, condition and fixations of traction motors bellows…

Check levels Gear cases, clean carefully around the plug before open in order to avoid any sand

or dust entry in the gear cases Flange lubricator tank Sand tanks

Check for leaks Cannon boxes

Gear cases Piping Dampers Flange lubricator device

Check for spots, shelling and flatness on wheels Check the brake shoes and change if necessary. Check the speed sensor fixations and the connection wire condition.

II - Maintainability

Manpower 1 Downtime hours 0,1 Total Man-hours 0,1

Special tooling None

Consumable • SHELL EP460 for flange lubricators • SHELL Spirax Ax-90 for gear case filling

III - Spares

Part number Supplier Description Qtty. Per bogie

SLO2973100007 ALSTOM Brake shoes 6 TGLS409041000 ALSTOM Speed sensor 3

IV - Links to procedures

Operation Leaflet reference Chapter

Changing brake shoes 42-51-002 Repair

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Level b – monthly maintenance I - Operations Check visually the earth braids

Change the braids which have more than 10% frayed strand Check the accumulation of dusts or scraps in the grids of the traction motors

Carry out and clean with compressed air if necessary II - Maintainability

Manpower 1 Downtime hours 0,25 Total Man-hours 0,25

Special tooling None

Consumable None III - Spares

Part number Supplier Description Qtty. Per bogie

BXX1002879180 ALSTOM Earth braids, body and bogie frame connection 2

SLO2974700000 ALSTOM Earth braids, axle boxes and bogie frame connection 6

IV - Links to procedures

Operation Leaflet reference

Chapter

Dismantling traction motor sensor 12-21-003 Dismantling Cleaning grids of traction motor 12-21-003 Cleaning

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Level c I - Operations Sanding device

Checking for cracks on the sand ejection nozzles, cleaning of the nozzles, ejectors adjustment

Flange lubricating equipment Operation tests and ejectors adjustment Control the profile and the dimensions of the wheels

Use adapted gauge, proceed to the re-profiling of the wheels if necessary II - Maintainability

Manpower 1 Downtime hours 3,1 Total Man-hours 3,1

Special tooling • Gauge P/N 0 318 3559 for wheel dimensions control

Consumable None III - Spares None

IV - Links to procedures

Operation Leaflet reference

Chapter

Sanding and lubricating ejectors adjustment 12-23-003 Gaps and tolerances Wheels dimensions control 12-23-003 Checking-Control

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Level d I - Operations Gear cases draining Check the state of gear cases

Look for cracks or leakages on the gear cases, change the half case if necessary Clean the gear case breather cap

Carry out and clean the breather part of the cap with petrol ether, clean carefully around the plug before open in order to avoid any sand or dust entry in the gear case

Check the condition of the elastomer linkings of connecting rods look for cracks or wear on primary guidance rods, motor suspension rods and

traction rods Check the condition of the secondary suspension rubber pads

look for cracks or wear Verify the height of secondary suspension pads and the distance between carbody and bogie

stops Verification of vertical and lateral stops, change if necessary Check the condition of the vertical and lateral stops, change if necessary

II - Maintainability

Manpower 1 Downtime hours 3 Total Man-hours 3

Special tooling None

Consumable • Petrol ether for breather cap cleaning • SHELL Spirax Ax-90 for gear case filling :

7 liters in PASSENGERS locomotives 5 liters in FREIGHT locomotives

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III - Spares

Part number Supplier Description Qtty. Per bogie

SLO2971901002 ALSTOM SEAL, RESILIENT FOR SECONDARY TRACTION ROD

2

SLO2971603002 ALSTOM SILENT BLOCS FOR GUIDING RODS, PRIMARY TRACTION

16

SLO2972104002 ALSTOM SILENT BLOCS FOR MOTOR SUSPENSION ROD 6 SLO2971700001 ALSTOM SPRING, RUBER-METAL, FREIGHT 4 SLO2977200001 ALSTOM SPRING, RUBER-METAL, PASSENGERS 4 SLO2971700002 ALSTOM STOP, HORIZONTAL ON BOGIE 2 SL00271900007 ALSTOM STOP, HORIZONTAL ON CARBODY 4 SLO2971700003 ALSTOM STOP, VERTICAL 2

IV - Links to procedures

Operation Leaflet reference

Chapter

Verification of heights and distances 12-23-003 p.801

Gaps and tolerances

Control condition of secondary suspension pads 12-23-003 p.502

Checking – control

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Level e I - Operations Wheels reprofiling on FREIGHT locomotives Traction motor non-drive end bearing greasing

II - Maintainability

Manpower 3 Downtime hours 8 Total Man-hours 24

Special tooling Traction motor NDE bearing :

• Lever compressor for grease cartridge – TECALEMIT P/N 100 002 363 + Flexible cable P/N 9 96 40 09 + Pull-to-lock clip P/N 9 12 22 01

Consumable Traction motor NDE bearing : • MOBILITH SHC 100 for traction motor bearing greasing (35g to 50g)

III - Spares None

IV - Links to procedures

Operation Leaflet reference

Chapter

Control wheel profile 12-23-003 p.501

Checking-control

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Level f I - Operations Carry out and dismantle one traction motor of the fleet to proceed to the checking

operations Wheels reprofiling on PASSENGERS locomotives

II - Maintainability

Manpower 3 Downtime hours 16 Total Man-hours 48

Special tooling TRACTION MOTOR TOOLING KIT:

• Tools for assembling the motor on a turning device : OKF10460-100, • Tools for assembling and dismantling the cage rotor : OKF10460-200, • Tools for dismantling the inner roller bearing ring and the deflector :

OKF10065, OKF06279, OKF10477 • Tools for dismantling the outer roller bearing ring-non drive end :

OKF10477-100 • Striking tool for inner roller bearing ring and the non drive end of the

deflector : OKF9031 • Striking tool for outer roller bearing ring non drive end : OKF10056-200• Striking wedges to make sure that the deflectors and rings drive end

are correctly seated : OKF10546 • Tool to check the radial bearing clearance-non drive end : OMF10663-

100 • Tool to check the radial bearing clearance- drive end : OMF10663-101 • Tool for blocking the rotation of the rotor (when in transport) : TRO1

095.091, TRO2 095.092, TRO0 095.090 • Tool for pinion assembling and removing : OKA2766

Consumable Traction motor maintenance : • Glycerin,5L for traction motor pinion assembling • Thinner, Dartoline SF41B, DARTOL CHIMIE for traction motor shaft cleaning • MOBILITH SHC100 grease • CURIL T sealing paste • NEVER SEEZ slushing compound • MOLYKOTE Longterm 2 plus for traction motor flanges assembling • Loctite blue N242 for traction motor

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III - Spares None

IV - Links to procedures

Operation Leaflet reference

Chapter

Carrying out the traction motor 12-23-003 Disassembling Dismantling operations on the traction motor 12-21-003 Disassembling Checking operations on the traction motor 12-21-003 Checking

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Level g I - Operations Wheels changing on FREIGHT locomotives Cannon-box bearings greasing

Fill completely the bearing II - Maintainability

Manpower 3 Downtime hours 8 Total Man-hours 24

Special tooling Gauge P/N 0 318 3559 for wheel dimensions control

Consumable Cannon-box greasing : • SHELL ALVANIA 2760B, approximately 300g per bearing

III - Spares

Part number Supplier Description Qtty. Per bogie

SLO2970201000 ALSTOM WHEEL, MACHINED 6 IV - Links to procedures

Operation Leaflet reference

Chapter

Wheels disassembling and assembling 12-23-003 Disassembling Assembling

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Level h I - Operations Bogie complete overhaul :

Brake blocks complete overhaul. Flange lubricating and sanding equipment overhaul.

Wheels changing on PASSENGERS locomotives Bearings changing : cannon-boxes and axle boxes Traction motors complete overhaul

Change both bearings II - Maintainability

Manpower 4 Downtime hours 80 Total Man-hours 320

Special tooling BRAKE BLOCK TOOLING KIT :

4-300421, 4-500122, 2-500124, 3-500125, 4-500127, 3-500128, 2-500129, 3-500134, 3-500216, 3-500126, 2-500137, 3-500212 (SAB-WABCO supply)

TRACTION MOTOR TOOLING KIT: • Tools for assembling the motor on a turning device : OKF10460-100, • Tools for assembling and dismantling the cage rotor : OKF10460-200, • Tools for dismantling the inner roller bearing ring and the deflector :

OKF10065, OKF06279, OKF10477 • Tools for dismantling the outer roller bearing ring-non drive end :

OKF10477-100 • Striking tool for inner roller bearing ring and the non drive end of the

deflector : OKF9031 • Striking tool for outer roller bearing ring non drive end : OKF10056-200• Striking wedges to make sure that the deflectors and rings drive end

are correctly seated : OKF10546 • Tool to check the radial bearing clearance-non drive end : OMF10663-

100 • Tool to check the radial bearing clearance- drive end : OMF10663-101 • Tool for blocking the rotation of the rotor (when in transport) : TRO1

095.091, TRO2 095.092, TRO0 095.090 • Tool for pinion assembling and removing : OKA2766

BOGIE ASSEMBLY TOOLING KIT : • Axle box bearings setting tooling • Gauge for the assembling of the cannon box : P/N V-267072 • Tooling for pre stress spring : SLO 2901108001 + SLO 2901108002 • Gauge for wheel profile : P/N 03183559

Consumable BRAKE BLOCKS • White spirit • LOCTITE 243 • LOCTITE 2701 • MOLYCOTE BR2 PLUS grease • MOLYCOTE 1000 paste • Silicone or Permatex sealing compound

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TRACTION MOTORS • KARCHER RM81 for windings cleaning • Glycerin,5L for pinion assembling • Thinner, Dartoline SF41B, DARTOL CHIMIE for shaft cleaning • MOBILITH SHC100 grease • CURIL T sealing paste • NEVER SEEZ slushing compound • MOLYKOTE Longterm 2 plus for flanges assembling • Loctite blue N242

BOGIE ASSEMBLY • KARCHER RM55 for metallic parts cleaning • White spirit • Pure white tallow • RHODORSIL CAF 730 • SILKRON joint paste • MOLYDAL M03

III - Spares

Part number Supplier Description Qtty. Per bogie

Kit n°170334 SAB WABCO Brake blocks SLO297300001 and SLO297300002, BOK – Basic Overhaul Kit

2

Kit n°170312 SAB WABCO Brake blocks SLO297300003 and SLO297300004, BOK – Basic Overhaul Kit

2

Kit n°170312 SAB WABCO Brake blocks SLO297300005 and SLO297300006, BOK – Basic Overhaul Kit

2

SLO2970201000 ALSTOM WHEEL, MACHINED 6 SLO2970200010 ALSTOM BEARING, CANNON BOX 6 SLO2970401005 ALSTOM BEARING, AXLE BOX 6

TRO3-526.110001 ALSTOM BEARING, DRIVE END, TRACTION MOTOR 3 TRO3-526.088001 ALSTOM BEARING, NON DRIVE END, TRACTION MOTOR 3

IV - Links to procedures

Operation Leaflet reference

Chapter

Lifting locomotive without the bogies 12-00-003 Disassembling Dismantling, checking and assembling bogie parts 12-23-003 All Dismantling, checking and assembling brake blocks 42-51-002 All Dismantling, checking, and assembling traction motors 12-21-003 All Bogies on locomotive assembling 12-00-003 Assembling Wheels disassembling and assembling 12-23-003 Disassembling Assembling

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Locomotive maintenance plan This preventive maintenance plan does not include diesel engine maintenance. Locomotive maintenance schedule

LevelLevelLevelLevel StepStepStepStep

AAAA BBBB CCCC DDDD EEEE FFFF GGGG HHHH IIII JJJJ

DailyDailyDailyDaily XXXXMonthlyMonthlyMonthlyMonthly XXXX 1250 h1250 h1250 h1250 h XXXX 2500 h2500 h2500 h2500 h XXXX XXXX 3750 h3750 h3750 h3750 h XXXX 5000 h5000 h5000 h5000 h XXXX XXXX XXXX 6250 h6250 h6250 h6250 h XXXX 7500 h7500 h7500 h7500 h XXXX XXXX 8750 h8750 h8750 h8750 h XXXX

10000 h10000 h10000 h10000 h XXXX XXXX XXXX XXXX 11250 h11250 h11250 h11250 h XXXX 12500 h12500 h12500 h12500 h XXXX XXXX 13750 h13750 h13750 h13750 h XXXX 15000 h15000 h15000 h15000 h XXXX XXXX XXXX XXXX 16250 h16250 h16250 h16250 h XXXX 17500 h17500 h17500 h17500 h XXXX XXXX 18750 h18750 h18750 h18750 h XXXX 20000 h20000 h20000 h20000 h XXXX XXXX XXXX XXXX XXXX 21250 h21250 h21250 h21250 h XXXX 22500 h22500 h22500 h22500 h XXXX XXXX 23750 h23750 h23750 h23750 h XXXX 25000 h25000 h25000 h25000 h XXXX XXXX XXXX 26250 h26250 h26250 h26250 h XXXX 27500 h27500 h27500 h27500 h XXXX XXXX 28750 h28750 h28750 h28750 h XXXX 30000 h30000 h30000 h30000 h XXXX XXXX XXXX XXXX XXXX XXXX 31250 h31250 h31250 h31250 h XXXX 32500 h32500 h32500 h32500 h XXXX XXXX 33750 h33750 h33750 h33750 h XXXX 35000 h35000 h35000 h35000 h XXXX XXXX XXXX 36250 h36250 h36250 h36250 h XXXX 37500 h37500 h37500 h37500 h XXXX XXXX 38750 h38750 h38750 h38750 h XXXX 40000 h40000 h40000 h40000 h XXXX XXXX XXXX XXXX XXXX 41250 h41250 h41250 h41250 h XXXX 42500 h42500 h42500 h42500 h XXXX XXXX 43750 h43750 h43750 h43750 h XXXX 45000 h45000 h45000 h45000 h XXXX XXXX XXXX XXXX 46250 h46250 h46250 h46250 h XXXX

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LevelLevelLevelLevel StepStepStepStep

AAAA BBBB CCCC DDDD EEEE FFFF GGGG HHHH IIII JJJJ

47500 h47500 h47500 h47500 h XXXX XXXX48750 h48750 h48750 h48750 h XXXX 50000 h50000 h50000 h50000 h XXXX XXXX XXXX XXXX 51250 h51250 h51250 h51250 h XXXX 52500 h52500 h52500 h52500 h XXXX XXXX 55553750 h3750 h3750 h3750 h XXXX 55000 h55000 h55000 h55000 h XXXX XXXX XXXX 56250 h56250 h56250 h56250 h XXXX 57500 h57500 h57500 h57500 h XXXX XXXX 58750 h58750 h58750 h58750 h XXXX 60000 h60000 h60000 h60000 h XXXX XXXX XXXX XXXX XXXX XXXX XXXX 61250 h61250 h61250 h61250 h XXXX 62500 h62500 h62500 h62500 h XXXX XXXX 63750 h63750 h63750 h63750 h XXXX 65000 h65000 h65000 h65000 h XXXX XXXX XXXX 66250 h66250 h66250 h66250 h XXXX 67500 h67500 h67500 h67500 h XXXX XXXX 68756875687568750 h0 h0 h0 h XXXX 70000 h70000 h70000 h70000 h XXXX XXXX XXXX XXXX 71250 h71250 h71250 h71250 h XXXX 72500 h72500 h72500 h72500 h XXXX XXXX 73750 h73750 h73750 h73750 h XXXX 75000 h75000 h75000 h75000 h XXXX XXXX XXXX XXXX 76250 h76250 h76250 h76250 h XXXX 77500 h77500 h77500 h77500 h XXXX XXXX 78750 h78750 h78750 h78750 h XXXX 80000 h80000 h80000 h80000 h XXXX XXXX XXXX XXXX XXXX 81250 h81250 h81250 h81250 h XXXX 82500 h82500 h82500 h82500 h XXXX XXXX 83750 h83750 h83750 h83750 h XXXX 85000 h85000 h85000 h85000 h XXXX XXXX XXXX 86250 h86250 h86250 h86250 h XXXX 87500 h87500 h87500 h87500 h XXXX XXXX 88750 h88750 h88750 h88750 h XXXX 90000 h90000 h90000 h90000 h XXXX XXXX XXXX XXXX XXXX XXXX XXXX

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Preventive maintenance plan for ALSTOM AD43C Diesel Locomotives Page 302ABCD Transport S.A. - IRANIAN ISLAMIC REPUBLIC RAILWAYS

Maintenance levels definition

Level A – daily maintenance I - Operations General inspection

Check visually for leaks, shocks or cracks, presence of screws and pins, electrical and pneumatical connexions (check inside the electrical and pneumatical blocks), high voltage cables, hoses wear (specially the air coupling and related cocks), presence of oil on sump, condition of fuel flexible pipes, dusts or scraps in air inlets (roof grids, cooling unit, filters…)

Check fluids levels Cooling liquid

Air compressor oil Fuel

Check for leaks (visual checking) Cooling circuit

Compressed air circuit Air compressor sump Fuel circuit

Check abnormal noises (blowers…) Events download Drain Rellumix filter on the driver’s brake valve

II - Maintainability

Manpower 1 Downtime hours 0.1 Total Man-hours 0.1

Special tooling • None

Consumable • Cooling liquid for diesel engine cooling circuit : SUMMER : 94% demineralized water with 6% corrosion preventive DCA4 FLEETGUARD. WINTER : 47% demineralized water with 6% corrosion preventive ES COMPLEAT EG FLEETGUARD and 47% antifreeze.

• Cooling liquid for electrical cabinet cooling circuit : COOL ELF SUPRA with ethylene glycol, corrosion preventive and antifreeze for temperatures of –25°C

• Oil for air compressor : ESSO OIL 150 or SHELL CORENA P100 or TOTAL CORTUSA 100.

III - Spares None

IV - Links to procedures None

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Preventive maintenance plan for ALSTOM AD43C Diesel Locomotives Page 303ABCD Transport S.A. - IRANIAN ISLAMIC REPUBLIC RAILWAYS

Level B – monthly maintenance I - Operations Checking operations on air conditioner

Run 10 minutes in cooling mode in order to keep the tightness of the compressor’s seal. Check air filter and change if necessary Check evaporator and condenser, clean it if necessary

Check the state of air ducts grids Clean with compressed air lateral grids, cooling unit roof, rheostatic roof, filtration

roof and diesel cover fans grids Check the state of air filters of filtering unit and of filtration roof

Check visually for scraps and dust in the inertial filters, clean with compressed air if necessary. Check the state of secondary filtration elements, change the filtering elements if necessary.

Check the state of air filters of electrical cabinet Change if necessary.

II - Maintainability

Manpower 1 Downtime hours 1,5 Total Man-hours 1,5

Special tooling None

Consumable None III - Spares

Part number Supplier Description Qtty. per locomotive

BXX0008821A01 ALSTOM CARTRIDGE, FILTER, filtering unit 4 TRK8623483000 ALSTOM FILTER, electrical cabinet 1

200543 SDEEC FILTER, AIR, air conditioner 1 IV - Links to procedures None

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Level C I - Operations First level inspection of all auxiliaries electrical motors : rheostatic roof, cooling unit roof, air

blowers, air conditioner, diesel engine room fans Check for current drained, power supplied, leakages, temperatures of windings and

bearings Follow the procedures for blowers inspection and diesel compartment cooling fans

Cleaning of motor fans : rheostatic roof, cooling unit roof, air blowers, air conditioner, diesel engine room fans

clean with compressed air Check battery electrolyte level

Check tightness and presence of grease on the connections Cardan coupling greasing

Grease until saturation Air conditioner checking operations

Check state and tension of belts Cooling circuit thickness and charge of cooling agent (proceed to leakage detection

if abnormal charge) Electrical and mechanical assembly

II - Maintainability

Manpower 2 Downtime hours 10 Total Man-hours 20

Special tooling • Battery water filling toolkit, ref : SAFT 214671

• Special toolkit for cooling agent reload : leakage detector, manifold equipped with manometer and charge piping with “schraeder”, vacuum pump.

Consumable • Distilled or demineralized water (batteries water level) • Vaseline neutral grease for batteries connections • DEA mineral AG.PARAGONEP ½ grease lubricant (cardan coupling)

III - Spares None

IV - Links to procedures

Operation Leaflet reference

Chapter

Blowers inspection 42-43-002 42-43-003 42-43-004 42-43-005

Preventive maintenance, paragraph 3A

Inspection and cleaning of diesel engine cooling fans 42-43-006 Preventive maintenance Air conditioner checking 42-45-002 Preventive maintenance

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Level D I - Operations Drain air compressor oil and change oil filter. Check suction and discharge valves on air compressor

Examine the valves seats, bumpers and discs, check the wear tolerances and the general state of the assembly. Change the springs if there are cracks, corrosion or wear.

Cleaning of inertial filters and interior of filtering unit Remove and clean with water Contactor ATP-S checking and cleaning

Clean the fixed and mobile plates of the conduction contacts, check the state of the shaft and of the contactor body, follow the procedure

Cleaning of alternator rings Check alternator rings and brushes

Check visually by the manhole Cooling unit roof’s cooler external cleaning Change the type of diesel engine cooling liquid at interseason Analyse the IGBT cooling liquid at interseason

II - Maintainability

Manpower 4 Downtime hours 8 Total Man-hours 32

Special tooling • Metallic rifle-type brush diameter 12 in steel thread 20/100 total length 500

mm. lined on 80 mm. for ATP-S contactor cleaning. • Special nozzle for aluminium cooler cleaning (BEHR supply).

Consumable • Oil for air compressor : ESSO OIL 150 or SHELL CORENA P100 or TOTAL CORTUSA 100. (40 l.)

• “AUCO-TARK” and “AUCO-ALU” grease solving agent for cooler cleaning. • Cooling liquid for diesel engine cooling circuit :

SUMMER : 94% demineralized water with 6% corrosion preventive DCA4 FLEETGUARD. WINTER : 47% demineralized water with 6% corrosion preventive ES COMPLEAT EG FLEETGUARD and 47% antifreeze.

• Cooling liquid for IGBT cooling circuit : COOL ELF SUPRA with ethylene glycol, corrosion preventive and antifreeze for temperatures of –25°C

• FLEETGUARD CC2602M, 3way test strips for coolant analysis

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III - Spares

Part number Supplier Description Qtty. per locomotive

26A43 GARDNER-DENVER FILTER, OIL, compressor 1

2007974 GARDNER-DENVER SPRING COMPRESSOR 45 78A160 GARDNER-DENVER SPRING COMPRESSOR 3 78A124 GARDNER-DENVER SPRING, COMPRESSOR 3

IV - Links to procedures

Operation Leaflet reference

Chapter

Cleaning of conduction contacts (ATP-S contactor) 42-63-008 Cleaning Checking the shaft and the contactor body(ATP-S contactor) 42-63-008 Checking-control Cleaning and checking of alternator rings 12-31-003 Cleaning, checking-control Cooling unit roof’s cooler external cleaning 42-44-006 Preventive maintenance Tests of air compressor elements See manufacturer instructions (GARDNER-

DENVER))

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Level E I - Operations Rheostatic roof cleaning

cleaning resistor elements and micaver insulator with compressed air Overhaul CLA(RT)CP and CLA(RT)RCA no-return valves

disassemble, clean, check, replace seat-seal and grease Alternator brushes changing

II - Maintainability

Manpower 1 Downtime hours 20 Total Man-hours 20

Special tooling None

Consumable • SHELL ALVANIA RL2 grease for no-return valves III - Spares

Part number Supplier Description Qtty. per locomotive

054 160 00 08 SAB-WABCO Seat seal, for CLA(RT)CP and CLA(RT)RCA 2 TRO2566061001 ALSTOM BRUSHES, ALTERNATOR 8

IV - Links to procedures

Operation Leaflet reference

Chapter

Cleaning of resistors elements 42-44-004 Cleaning Alternator bearings greasing 12-31-003 Checking-control Alternator brushes change 12-31-003 Preventive maintenance No-return valves overhaul : “CHECK VALVE 1’’ ¼” See manufacturer instructions for valve 727

046 00 08

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Level F I - Operations Main inspection of all auxiliaries electrical motors : rheostatic roof, cooling unit roof, air

blowers, air conditioner, diesel engine room fans. Follow the procedure for blower’s motors inspection.

Follow the first level inspection plus the following operations : check specially the alignment, the tightening of mechanical and electrical connections, the insulation resistance of windings, the good general conditions of working (noises, cracks, wear, leaks…)

Replace purge valve of principal air reservoir VE(PU)RP. Air conditioner overhaul

Change cooling agent R134a Change both belts

IGBT coolant checking Drain the circuit

Analyse the coolant after filtering using the appropriate filtering paper Change coolant if necessary

Change RELLUMIX filtering column of DBV air filter Change all elastomer parts of the DBV filter

II - Maintainability

Manpower 2 Downtime hours 162 Total Man-hours 324

Special tooling • Special toolkit for cooling agent reload : leakage detector, manifold equipped

with manometer and charge piping with “schraeder”, vacuum pump. Consumable • SHELL ALVANIA RL2 grease for VE(PU)RP and DBV filter assembling

• R134a cooling agent cylinder • Cooling liquid for IGBT cooling circuit :

COOL ELF SUPRA with ethylene glycol, corrosion preventive and antifreeze for temperatures of –25°C

• FLEETGUARD CC2602M, 3way test strips for coolant analysis

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III - Spares

Part number Supplier Description Qtty. per locomotive

BXX0002954001 ALSTOM VALVE, MAGNET, VE(PU)RP 1 200523 SDEEC BELT, AIR CONDITIONER 2 48784 RELLUMIX FILTERING COLUMN, DBV FILTER 1

IV - Links to procedures

Operation Leaflet reference

Chapter

Blowers main inspection 42-43-002 42-43-003 42-43-004 42-43-005

Preventive maintenance, paragraph 3A

Replacing VE(PU)RP See manufacturer instructions for drain valve 727 891 01 08

Replacing RELLUMIX filtering column See manufacturer instructions for driver’s brake valve air filter 404 461 00 08

Air conditioning overhaul 42-45-002 Preventive maintenance

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Level G I - Operations Alternator cleaning and bearing greasing

Rotor and stator cleaning and testing Bearing greasing Fuel flexible pipes checking

Check for wear or cracks, check the connections Replace if necessary

II - Maintainability

Manpower 3 Downtime hours 48 Total Man-hours 144

Special tooling • Special tools for alternator overhaul : OKF.10094, OKF.10095, OKF.10158,

OKF.10164. Consumable • KARCHER RM81 for alternator cleaning

• SHELL ALVANIA EP2 grease for alternator bearing III - Spares

Part number Supplier Description Qtty. per locomotive

BXX0007653001 ALSTOM HOSE, DIA. 60,3 4 BXX0007654001 ALSTOM HOSE, DIA. 88,9 1 BXX0007655001 ALSTOM HOSE, DIA. 38,0 1 BXX0007656001 ALSTOM HOSE, DIA. 33,7 1

IV - Links to procedures

Operation Leaflet reference

Chapter

Alternator disassembling, cleaning, checking, testing, assembling, bearing greasing

12-31-003 All

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Level H I - Operations Change bearings and seals of all auxiliaries electrical motors : cooling unit roof, rheostatic

roof, air blowers, air conditioner… Cooling unit roof overhaul :

Inside cooler cleaning, replace seals after cleaning. Carry out and overhaul one compressor of the fleet

Check the internal state of the compressor in order to define overhaul step of the fleet

II - Maintainability

Manpower 4 Downtime hours 160 Total Man-hours 640

Special tooling None

Consumable • SKF/LGHQ3 grease for traction motors blowers bearings (25g. for VTMT1, 20g. for VTMT2)

• Kluber Unisilkon L50/2 grease (15g. for VT-ALT bearings) • AUCO “ALU-B” cleaning agent for aluminium cooler cleaning • Kluber Asonic HQ72-102 grease (for cooling unit motors bearings)

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III - Spares

Part number Supplier Description Qtty. per locomotive

4000505 FLAKTWOODS BEARING, DRIVING END (VTMT1) 2 6003263 FLAKTWOODS RING, SEAL (VTMT1) 2 5003343 FLAKTWOODS BEARING, DRIVING END (VTMT2) 2 6003253 FLAKTWOODS RING, SEAL (VTMT2) 2 4002271 FLAKTWOODS BEARING, DRIVING END (VT-ALT) 1 4002270 FLAKTWOODS BEARING, NON DRIVING END (VT-ALT) 1 6003193 FLAKTWOODS RING, SEAL (VT-ALT) 1 6003173 FLAKTWOODS RING, SEAL (VT-ALT) 1

M2A100LA2, 5.10 FLAKTWOODS BEARING, DRIVING END (VT-EX) 1 M2A100LA2, 5.20 FLAKTWOODS BEARING, NON DRIVING END (VT-EX) 1 M2A100LA2, 5.22 FLAKTWOODS RING, SEAL (VT-EX) 1

MTUE 100 LH, 6206 ZZ

FLAKTWOODS BEARING, DRIVE SIDE (diesel engine room cooling fan)

2

MTUE 100 LH, 404 FLAKTWOODS BRUSH (diesel engine room cooling fan) 2 14.093.60.001 BEHR BEARING, MOTOR DRIVE END AND NON DRIVE

END(cooling unit) 6

00.759.10 BEHR SEALING, COOLERS (cooling unit) 78 IV - Links to procedures

Operation Leaflet reference

Chapter

Blower’s motors bearings changing 42-43-002 42-43-003 42-43-004 42-43-005

Preventive maintenance, paragraph 3A

Cooling unit roof overhaul 42-44-006 Preventive maintenance Change bearings and brushes of diesel engine cooling fans 42-43-006 Preventive maintenance Tests of air compressor elements See manufacturer instructions (GARDNER-

DENVER)

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Level I I - Operations Cardan shaft overhaul

Check visually the coupling element (cracks, clocks or wear) Check visually the friction disc and friction ring (cracks, clocks or wear) Check visually the U-joint crossing

Pneumatic overhaul Carry out for dismantling, checking, cleaning, greasing and replacing worn parts.

Replace systematically all elastomer parts Greasing of electrical power contacts of isolation switch ATP-S contactor overhaul Alternator overhaul

Bearing replacing and greasing Compressor overhaul

II - Maintainability

Manpower 4 Downtime hours 152 Total Man-hours 608

Special tooling • ATP-S contactor overhaul :

• 12 faces combination wrench, ref. SAM R50-7 • Single hexagonal socket 6 faces, square ¼”, ref. SAM R6 or R7 • Special tools for alternator overhaul : OKF.10094, OKF.10095, OKF.10158,

OKF.10164. • Tests bench and tools for pneumatic parts tests, refer to the manufacturer

specifications Consumable • SHELL ALVANIA RL2 (pneumatic overhaul)

• MOLYKOTE 55M (pneumatic overhaul) • MOLYKOTE BR2 (pneumatic overhaul) • MOLYDAL EI/5-846 contact grease for isolation switch power contacts • MOBIL TEMP SHC 100 for ATP-S servomotor and auxiliary contacts • SHELL ALVANIA EP2 (approximately 850g.) for alternator bearing

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III - Spares

Part number Supplier Description Qtty. per locomotive

K0550500008 VOITH KUSEL Coupling element 1 K0550550011 VOITH KUSEL Friction disc 1 K0550570010 VOITH KUSEL Friction ring 1 19092095001 VOITH KUSEL U-joint crossing 2

# SAB WABCO Pneumatic spare parts : refer to the manufacturer maintenance manual

#

TRO3526078100 ALSTOM BEARING,ALTERNATOR 1 IV - Links to procedures

Operation Leaflet reference

Chapter

Cardan coupling disassembling-assembling 12-00-003 Disassembling p.331 Assembling p.742

Pneumatic parts overhaul Refer to the manufacturer maintenance manual

ATP-S contactor overhaul 42-63-008 Preventive maintenance Isolation switch contacts greasing 42-63-009 Preventive maintenance Alternator disassembling, cleaning, checking, testing, assembling, bearing greasing

12-31-003 All

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Level J I - Operations Isolation switch auxiliary contacts replacement

II - Maintainability

Manpower 1 Downtime hours 8 Total Man-hours 8

Special tooling None

Consumable • Silicomet seal for switch reassembling III - Spares

Part number Supplier Description Qtty. per locomotive

DTR0025631276 ALSTOM AUXILIARY CONTACTS, ISOLATION SWITCH 3 IV - Links to procedures

Operation Leaflet reference

Chapter

Isolation switch auxiliary contacts replacement 42-63-009 Preventive maintenance