Esr 0511 Overhaul Of 3 Cdc Air Compressor-Books Pdf

ESR 0511 Overhaul of 3 CDC air compressor
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RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. Document control, Revision Date Summary of change, RSS 0511 1 0 August 2007 Based on TRS 1379. ESR 0511 1 0 June 2010 Reformatted and renumbered ESR 0511. Summary of changes from previous version, Summary of change Section. NOTE If the final document is small enough for the Contents and Document control. to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the Document control page carries over to a second page separate. pages must be used for Contents and Document control. Rail Corporation Page 2 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511.
2 General 4, 3 Disassembly cleaning and inspection 4. 4 Overhaul and assembly 4, 4 1 Mandatory new parts 4. 4 2 Mandatory modified parts 5, 4 3 Optional parts 5. 4 4 Minor parts supply 5, 5 Standard repairs 6, 5 1 Cylinder honing and cleaning 6. 5 1 1 Purpose 6, 5 1 2 Procedure 6, 7 Painting 6, 7 1 Surface preparation 6.
7 2 Painting 6, 8 Storage and transportation 7, 9 Identification 7. 10 Procedures and Reports 7, 11 Specifications 7, 11 1 Lube oil capacity 7. 11 2 Cylinders 7, 12 Referenced standards 7, 12 1 Paint standards 7. 12 2 Australian British standards 7, 12 3 Other standards 8. Rail Corporation Page 3 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0.
RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. The scope includes but is not limited to, Disassembly cleaning and inspection. Overhaul and assembly including parts replacement, The overhauled 3 CDC air compressors shall operate at the specified performance levels. for a period of not less than eight 8 years, This Standard Instruction sets the minimum technical requirements for the inspection. overhaul and testing of 3 CDC air compressors used in RailCorp s locomotive fleet. It is to be used in conjunction with the Manufacturer s Maintenance Instructions drawings. and technical information listed herein for this air compressor type. 3 Disassembly cleaning and inspection, The air compressor shall be disassembled cleaned inspected and guaranteed.
Major components are listed in the Manufacturer s Maintenance Instructions which shall. be used as a guide to disassemble clean and inspect the air compressor components. Inspection sheets shall be completed and supplied to the Purchaser These sheets shall. indicate components that exceed manufacturer s tolerances or cannot be reused. The Purchaser shall approve all component repair or replacement unless stated. 4 Overhaul and assembly, The Manufacturer s Maintenance Instructions Manuals shall be used as a guide to. overhaul reassemble and test the component parts of the air compressor The. Manufacturer s Maintenance Manual shall be referred to for the overhaul and reassembly. of major components, Components shall be qualified before re use and this recorded on the assembly. inspection sheets Parts replaced as mandatory require a check to ensure they have. been replaced, On completion of assembly all relevant components shall be painted to the coating. specification as detailed in Section 7, 4 1 Mandatory new parts. The following components shall be replaced, Valve springs.
Connecting rod bearing inserts, Oil pump strainer screen. Rail Corporation Page 4 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. Oil pump springs, Air filters, All gaskets, Seals and sealing rings. Cotter pins, Note All used components and sub components employed for the overhaul shall.
only be sourced from the Purchaser O E M or UTEX from O E M Overhauled. components and sub components from other rail systems are not acceptable. 4 2 Mandatory modified parts, All fixed piping from the intercooler to the air compressor shall be replaced with Duffield. D300 Series hoses, 4 3 Optional parts, The following parts shall be replaced where they exceed manufacturer s tolerances or. cannot be reused, Suction valve discs per cylinder. Discharge valve discs per cylinder, Suction valve seat. Discharge valve seat, LP cylinder, HP cylinder, Oil pump plunger.
Drain plugs, Main bearing housing, Wrist pin piston pins. Intercooler tubes, Main bearing, LP piston rings, HP piston rings. Crankcase breather filter, LP cylinder head, HP cylinder head. 4 4 Minor parts supply, The air compressors supplied by the Purchaser for overhaul may be missing minor parts. eg bolts nuts washers etc lost during operation or removal from the locomotive The. Rail Corporation Page 5 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0.
RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. Repairer shall replace all such missing or damaged minor parts with new items to ensure. that the air compressors are ready for immediate installation following acceptance of test. If the Repairer wishes to use items from a source other than the O E M written. permission shall first be obtained from the Engineer. 5 Standard repairs, 5 1 Cylinder honing and cleaning. 5 1 1 Purpose, The purpose of this repair is to return the cylinder walls to the correct surface finish. 5 1 2 Procedure, The guidelines for this procedure are outlined in the Westinghouse 3CDC Air Compressor. Operation and Maintenance Manual, The air compressor on completion of the overhaul shall be run in and tested in.
accordance with the Manufacturer s Maintenance Manual to prove correct operation. Test results shall be recorded on the sheet provided in Appendix B and supplied to the. 7 Painting, On completion of assembly and testing the air compressor is to be painted All. connections such as flange faces pipe threads gauge glass faces and name plates shall. not be painted, 7 1 Surface preparation, 1 All dirt grease and oil shall be removed using an appropriate cleaning compound in. accordance with AS 1627 1, 2 Bare steel areas shall be power tool cleaned to Class 2 standard in accordance with. AS 1627 2 All paint edges shall be feathered previously applied paintwork lightly. sanded with an appropriate grade of paper sanding debris removed and spot primed. on the same day as tool cleaning, 7 2 Painting, 1 One 1 coat of red oxide zinc phosphate alkyd primer shall be applied to all bare. steel areas to a minimum dry film thickness of 38 micrometres mm An appropriate. drying time shall be allowed, 2 One 1 coat of full gloss petrol and oil resistant enamel Alpine Green BS 4800 14C.
31 shall be applied to a minimum dry film thickness of 25 mm to the spot primed and. previously painted surface An appropriate drying time and overcoat shall be. 3 Step 2 shall be repeated allowing 24 hours drying time The primer shall be. approved under GPC C 162 and the finish shall be approved under GPC E 24. Rail Corporation Page 6 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. 8 Storage and transportation, Prior to storing the overhauled air compressor it shall be pre lubricated with an. acceptable preservative type oil such as Shell VSI 8235 or Tectyl 823 EM Clean. preservative lubricating oil shall be inserted into each low pressure intake with air filters. removed and while the air compressor is operating against atmospheric pressure at the. conclusion of the test run Immediately after the oil is inserted the air compressor must. be stopped Before the air compressor is placed in service the crankcase shall be. drained completely and then refilled to the proper level with the grade of lubricating oil. recommended for service conditions, The overhauled air compressor shall have all openings and orifices blanked off to prevent. the entry of dirt or foreign materials during storage and transportation. The air compressor shall be secured on a wooden stand for transportation purposes. The stand shall provide adequate protection for the air compressor and must prevent it. from tipping over during transportation The air compressor shall be covered to provide. protection from rain and dust, 9 Identification, The air compressor identification plate shall clearly indicate the air compressor serial.
number letter s designating repair status as indicated in the Manufacturer s. Maintenance Manual and the date of last overhaul month year. 10 Procedures and Reports, The repairer shall develop appropriate inspection report sheets and procedures for use. with this specification Sample report sheets are shown in Appendices A and B. 11 Specifications, For 3 CDC air compressor specifications see Operation and Maintenance Manual of. Westinghouse Type 3 CDC Air Compressor, 11 1 Lube oil capacity. Sump Capacity 12 5 litres, 11 2 Cylinders, No undersized cylinders will be accepted Only standard cylinder sizes are to be used. 12 Referenced standards, 12 1 Paint standards, GPC E 24 Full gloss oil and petrol resistant enamel.
12 2 Australian British standards, AS 1627 1 Cleaning using liquid solvents and alkaline solutions. AS 1627 2 Power tool cleaning, Rail Corporation Page 7 of 13. Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. AS 2625 Mechanical vibration rotating and reciprocating machinery. AS 2700 Colour standards for general purpose, BS 1571 Part 2 Simplified acceptance tests for air compressors and exhausters. BS 4800 Paint colours for building purposes, 12 3 Other standards.
Operation and Maintenance Manual of Westinghouse Type 3 CDC Air Compressor. 3 CDC Air Compressor Parts Catalogue, Rail Corporation Page 8 of 13. Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. Rail Corporation Page 9 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. Rail Corporation Page 10 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0.
RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. Rail Corporation Page 11 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511. Rail Corporation Page 12 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. RailCorp Engineering Standard Rolling Stock, Overhaul of 3CDC air compressors ESR 0511.
Rail Corporation Page 13 of 13, Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1 0. BS 1571 Part 2 Simplified acceptance tests for air compressors and exhausters BS 4800 Paint colours for building purposes 12 3 Other standards Operation and Maintenance Manual of Westinghouse Type 3 CDC Air Compressor 3 CDC Air Compressor Parts Catalogue

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