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~SEAliCH reSIGNS lIND STANl>AI.1.:M ~ANlSATION,

'~1bN.AK NAGAR, LUCKNGI-226 011.

MABCH, 1980.

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1. Introduction.

REOAMBERII-G OF EMU CQlCHES. 0-8003

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Rail.ways have 1::9 en reporting about 1088 of' camber on oldi:nported EMU motor and traile:t' c.oad:1es 1ike Metro Camme11,Breda and NSSK stock and t.i~,vl 0"':0 n r.equesting ~SO for adetailed procedure order roj' .-.ecr::n;"''"1i'lring of" such coadles.The detailed method £or 6a:mbering 01" Metro Carame11 EMUcoaches was conveyed earlier by Rr.~W. v ida 'd .0 ... ' letter No"MCjCB/31!d dt. 4/5.1. '78 to CW/C ,,;:Uy, but the ma thad 'wa5 not tried out by Contral :a:,il.way. Later 1 30ard v idePara. 4.7 of' notesoi' disCU3Si on . held in Board 's of'f'is:e on12'1:0 0 79 and circulated, vide Eoardrs letter No.79!MtO)!DME( ll)/Meeting dt. 23.10.79 t ~ggested tha·t one coach eaohshould berGpaired nnd'recambered by Matunga Workshop of"Central Railway and:Mahalux~iWorkshop 'of' WQstern Railwayeach montb. Tc> startwitb, MatungaWorkshop did the workof recambering'and corrosion repairs~of Breda trailer coachNo. 7471. Assistance was also provided to Matunga Work­shop by rCF iqbvolving a pruper mothod f'or recambering of'the said coach'. Basad on the experionoe gained in repair­ing and recambering the Breda trailer- coaoh' No.7471 , the ..following method ha~ boen standa~iaed which could' bef'ollowod, by adl tho Railways Cor recam1:e ring df" th~ir EMUr.lOtoz",and',trailer coaches. :rt is Slggested that the,aval1able camber·under tare condition on the EMU coachesbGcucasured befo~G undertaking beavy eorrosion ,epairs and

- ~n'casa the negative camber at, the centre of" the coachexoeG«s 10 mm, recambering of the coach should be under­taken ~i~;l~ne(;)1:1.s1y a,lpng wi,th heavy ..; oorrosion;, rep~ir.s.

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Th~ m~th6d":iriClicated' applies eqUai1y.. t?: oth~r jlypes ofE:LU coaches as well.

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2~ • Meth?$1·o.:t ·M6a.~rom,~nt,' of' 'Cambor.:, '(.": L·'.· .'

1:t)''C~m1)t)r on a. coach canf.be'meas'I,U'l3d eitber with its.; bogie's' in posi tionor' if" bog1.es have l:a en remO' od t

thon by p~acing trestles of' equal: height belowtbe body bolstQ~s to ensure that the two trestlesbear equal weight of the coach body •

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.·il) Pl.ates of: 0qual'height having· a slot'ae shown inin Fig.1 (a) are welded vertically 0'0 the bottomof' the s'01e"bar at the locatidn of'tbe centreline of" the;bodytbolster. A piano 'wire of'req~i8ita' J.,e·ng.th with its two endseilcured to100 m~ long he~go~l bead ~crews:M 10 providedwi ~h w'ing and c,t,leck nuts alo~ with wa.shers isthon placed in. posit'ion as shown in Fig. 1 (b)

.and tho hotgnt of. the, screw is so adjusted w~th

ttla s~ring ade~uately'tightenea that the dista~ce

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between the top of the string and the bottom of thebody bolster is the same £or ,both the body bolsters~

Let this distance be 'x'. The string is then£inally tightened by rotating the w1'ag nu'ts withoutdisturbing the position of tbe string ver.tically 80

that the string is taut and straight_ The verticaldistance between the bottom o~ the sole bar to thetop o~ the string at the coach centre is thea mea­sured (let ,this distance be 'yl). ThGkamber ofthe underframe oan then be calculated as y - x asshown in Fig.1(a). rn case the bottom of the so~

bar is not at the same level as the bottom of thebody bolster (at the location where body bolster is£itted), due oognisance has to be given to thisf'act and the extent of the camber oalculated abovehas to be suitably ad justed to arrive at the pro­per figure.

Recambering Procedure, ,

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Take 'the initial oamber readings under tare comi-. I'

tion f'ollowing tho procedures indic~ted above.Run out bogies if' the se have not been ;run outal­ready and' 'support the oOach body by placing tre8-'tle8 of' equal height und~r bot~ the body boIs tors.

Support both the headstocks of' the coao~ body .by,.. placing study woode n props at the ce ntre of> the

headstock between the ground and the bottom a£the headstock.

Place channels across the track beloW' both tbe '"body bolsters am we1.d the same 'to the track~ A.pipe of 50 mm dia. bo~ or more is then placedvertioally between the top of' the channel and the.bottom of the body bolster at f'oUr locations andthe pipe is welded both: to the' body bolster and~he channel as shown in F~g.2.

Four jacks are then placed on the extremities oftho cross members On either side of' the transversecentre line of' the coach and a fifth jack isplaced a~ the centre of the un4erframe crossmember.( coinciding with the transverse'centreline of the coach) as shown in Fig. 3 • The .

reqUired positive camber is then set by liftingthe underframe simultaneouely with the qalp ofthe five ja9ks. The provision o£ 'props andclamps as indicated in Fig.2 would ensure thatthe lovel of the under£rame at the headstockportion as well as the body bolster portionremains undisturbed during this prooess. As

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v ) With a1.1. the jacks in po.itfon, beat treatment of the under­frame is to be oa~r~edou't as :follows.-

~ li£ting of the underframe alone by means of' jacks is likalyto induce ex~ra stresses in the roof portion and may resultin buokJ.ing or the pilllirs r esp~6ially at~the' portion wherethese ar8>Jzoroded J it 'WouLd be:n,:;c(lssa., to s::;.rnrt t~09

doorways and lift the roof' sinmltaheously al<;,pg "W:t.th t~lf'

underf'rame by means of' wooden beams p1aced ,aC..b-~ 88 the d JJ-r:"­

ways below which'foilr jacks supported on trestl~l!!5o£ suit­ab1e heigt.'t have been arranged. These four' jacks shoul.d besimultaneously lit'ted along with 'tbe rive jacks ,mea.nt tolift the underframe. The arrangement of supporting andlifting the roof' at the doorways is indicated in Fig.).The camber at tbti centre of' the coach ,is measured duringthe prooess of' lifting of the u~eri"rame/roo:f -ti11. a posi­t1'\"e cambel" of' about 30 mm in the' case of' ,motor coac"u andabout 20 DQ in the case of' trailer coach is ,achieved wi"thjacks in "position. Zn oase the ~nitial negative camberof' tbe eoaoh under tare is rathe~A1gh, it may be necessaryto set the c~berQn the moxor/tra!ler ooaohes to a figurehigher than )O/20:mm. , The exaot, oamqer to WAlch ~hecoach is set with jacka 10 pos~tio~ shou1d be reoorded at~arious plaoes as indiceted in Flg.4.

After the beat treatment of the sole bars iS,over,the heat treatme.nt of' tbe longitudinals' should betaken up 'starting from the ~iddle ~ongitudinal No.(J)

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Mark triangul.ar areas on th.e !lole bars as indicatedin Fig.5(a)at locations A, B~ 0, D & E. Similarlymark triangular areas on the r~ve longitudiaals asindicated in Fig.5{b) at locations A" B1, and 01.

Using, the oxy-acetylene to~ch (neutral flame), heatthe bottom :flange of' the sole bar at location Atill it becomes red hot~ Shift the £1ame' slowly tothG web of' the 801e bar and start" heating the tri­angul.a>r area stari:ill8 from the base of' the :t'r.ial1glea,nd sfow1Y' going up.- 'I'h'e .flatne'shoul.d at'intervalsbe app~ie~ ~oth6 '.flange of the 'e~le bar a't ~he

lllar~d poitlon to ,B.'Y oid :it s '. bee0lIl:1:11« oold. Wbe nthe tria~tar po~~ion oDthe'weti~~~:the'sole baram the. rectangt,tU;rpqrtio"n .e -tlie 1'1aDp of thesole bar at location '.A. .are'red bo.t, :further hea1;-ing should be stopped. Thill area, should be allowedto cool in air. lmmediate1y after "this area -~ llRae been heat-treated, heat treatment should be.-done a't locations B r 0, » &; E. It is neoessarythat both the sole bars are heat treated simu1.~a­

neously at the same location.

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at locations.l. B1 aDd 01 and then switching overto the adjacent longitudinals in turn, for example.longitudinal No.(Z). (4), (1) and (5); the heattreatment on longitudinal Nos~(2) & (4) and (1)and (5) being done simUltaneously. ' ,

Note (i) The heating zones indicated in Fig.5a.m, position of jacks indicated in Fig.2 are forBreda stock. 'Suitable heating zones andlocations of jacks may be decided for othertypes of EMU stbck ensu..ringthat heatingis do~c on' the sole bars and longitudinal.smidway betwen cross members.

,: ,(ii) The teDlperat'u.re to which the soJ.e bars a.rxl-' ~ ' ..,. ' : lon'gitud'iria.:lS; have ;t'o:~ 'belttfed":-W1.11' ::depend: 'I

'i' upon t'he1.'oss of 'caiJrbe,ri 'on1ihe' :coaeh~ Th:e~', .:, , h'igher' tll~: camber "loBS; the ;lUghv.:F will be

the tempe'ra ture ~ 'The temperatU~:"could '~;'vary betw~en du1.1 red heat ,to red heatdepend~~,'(upon.the extent of 1.098 of camber •

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(vi).J Oheck the camQer at various. 1.ooations after heat.,. . { , ·r'

. .;, treatment. This pam.b~r woul<:\ in, tn~ . nC?,r,m~ ,. '.' CQUse' bemoi:"& :,tban: t,ne camb~r to w~ioh the ..

, " '(I.oach 'b.ody was' se:t, ~arlier wi th tb~ he.l.p of. ,.. . . ' jacks' (:Para 3 (.i~,» i ., , ,. '

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(Vii)' '·L~e,~ea,se. the five Jacka.: ~uPPo,ft,i~g'" t~e" ~~derframe. simUltaneously wi:t't\' the '.:four' j'acks support:ing the, , ooach roof.· Remo"" e I the wO'ode n' prop s be lGW the

headstooks and mElasur'e ':the "camb~rs at 'V'ar10us1p!Jation8 a.~p;ng the 1~ngt.h of tha fl01e 'bar., ,. If'thil!l camber i's o:fthe broer' bf: .. ' .30 mm' f'o'r lDotarcoach and.. 20 mtn f'oi-: t'rai'le r boa:ch J no fur1ih Grheat treatlDe~t is necessary. If this camberbappe ns, t~ ~. ;L~ ss,.t')lfh~p rurt~er: ~e8:~ t.rea~me ~tat places adjacent ,t.o ,:the" pl'1ces' ~here' the" beat,: ...treatment had "e~~1iI9r be'e'n g:f"'e'o'iwould be .. " ..7'-'

reqUired a:fter the jacks are set suitably toc:,:utfp:rtn.tQ"t,b~ ep,z:liex: setting as per Para 3(vi).J. '. . "'. • ..... ", " • ':,' . ' • '

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(Viiif:" ~vlng ensll~e~ ',that the .camber with jacks• , 'removed' is rib.riiJa~, boxing of the 801.e bar should

be carried out by. welding a 10 mm plate on·Breda (mot.ot' anc;1 ·trailer), NSSK (motor and trai~­

er) and ¥~tro Camme,l1. motor coaches a:;J" show.n TnFig. 6, 7 & 8 respectiv~ly. For ~~~,r~. C~e,11trailer coa.ch~s,. tlJ.e 'st:lff'ening shall be ~on'e

by ·welding ch~n~a1s. 75:x 49, ,~t;;.~ 'kg 'alc?'n'~ ~ It :

With a lO.rom thi,*pla,te as s\1..o~:"p. ,in '~g•.9.,The propos~d st!.f;f:eni~ ·,o.! , sole':1:?cir 'Bl:Jo~ld "be " ','

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done·rrom body bo1ster to body bolster w!ta suit­able closing p1ates.

iX) Heavy corrosion repairs including repairs topillar.s and replacement of other members likecan't:Li.ever plate, crib plate, crib anglc~ etc.,shoUJ.tI the n be carried out. I..a.stly, the troughfloor and the body side panel shou1d be replacedas ~.~J ro:..1nJ.ally done in corrosion repairs.

The sequence o~ welding to be ~dopted while boxing thesole bars, weldiQg ~he pillars and other members is shownin Fig. No.10. Simultaneous welding on both sides of thecoacb' shou1d be carried out for 'this purpose.

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_I1FF~J.f.!f!.(j ..QLf?..QI.t; B/iR TO 8..lD0t:'f..M SIjO':!!':!....§F..TWc£}jJ?_OD'fBOLSTERS WIT!:f.....ClOS/NG PLA7.£!f!ON 7lte CHAN €L

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