210: Escalator-Specific: Step Installation and Maintenance



Rail Vehicle Doors Troubleshooting and ReplacementCourse 309Participant GuideMarch 2018Rail Car Training ConsortiumREVISION INDEXAny additions, deletions, or revisions are to be listed below.Revision No.DateSectionDescription of ChangeRevision AuthorDISCLAIMER: This course is intended to educate employees of public transportation systems that have agreed to voluntarily participate in the Rail Car Training Consortium. It is intended only as informal guidance on the matters addressed, and should not be relied upon as the only method or manner for performing the tasks or work outlined in the materials. Anyone using this document or information provided in the associated training program should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of care in any given circumstances. These materials are based on compendiums of knowledge from transit employees, manufacturers and outside consultants, each of whom may approach a repair, update, or maintenance in their own unique way. Always follow the safety and maintenance procedures from your own agency, union, relevant OEM(s) and/or regulatory organizations. In addition, the course materials include examples from member agencies, nomenclature, procedures, and configurations which can vary from one transit location to another. The document that you are now referencing may have been modified by the Consortium member. For the original versions, please go to or contact the Transportation Learning Center.The Rail Car Training Consortium, its participating agencies and labor unions, as well as the Transportation Learning Center, make no guaranty or warranty as to the accuracy or completeness of any information provided herein. The Rail Car Training Consortium, its participating agencies and labor unions, as well as the Transportation Learning Center, disclaim liability for any injury or other damages of any nature whatsoever, directly or indirectly, resulting from the use of or reliance on this document or the associated training program.NOTE: All images contained within this document were contributed by Rail Car Training Consortium members unless otherwise noted.How to Use the Participant Guide Purpose of the CourseCourse 309: Troubleshooting of Rail Vehicle Doors provides participants with the essential steps to approach troubleshooting and replacement of door assembly components on U.S. transit light and heavy rail vehicles.Approach of the BookEach course Module begins with an outline, a statement of purpose, objectives, and a list of key terms. The outline will discuss the main topics to be addressed in the Module. A list of key terms identifies important terminology that will be introduced in this Module. Learning objectives define the basic skills, knowledge, and abilities course participants should be able to demonstrate to show that they have learned the material presented in the Module. Exercises are built in throughout the course materials to assist the participants in learning and reviewing key information.Table of Contents TOC \o "1-3" \h \z \u How to Use the Participant Guide PAGEREF _Toc508705653 \h 3MODULE 1 DOOR CONTROLS PAGEREF _Toc508705655 \h 61-1Overview PAGEREF _Toc508705656 \h 81-2Manual Mechanical Operation of Door PAGEREF _Toc508705657 \h 91-3Electrical and Electronics of Door Operation PAGEREF _Toc508705658 \h 111-4Passenger Indication System PAGEREF _Toc508705659 \h 121-5Relays and Solenoids PAGEREF _Toc508705660 \h 131-6Door Motors and Drive Mechanisms PAGEREF _Toc508705661 \h 141-7Switches PAGEREF _Toc508705662 \h 161-8Obstruction Detection Devices PAGEREF _Toc508705663 \h 181-9 Emergency Release Mechanism PAGEREF _Toc508705664 \h 211-10 Door Control Unit (DCU) PAGEREF _Toc508705665 \h 221-11 PTU Software for Door Adjustments PAGEREF _Toc508705666 \h 231-12Summary PAGEREF _Toc508705667 \h 24MODULE 2 DOOR PANEL AND TRACK PAGEREF _Toc508705669 \h 252-1 Overview PAGEREF _Toc508705670 \h 262-2 Door Leaf and Panel PAGEREF _Toc508705671 \h 272-3 Roller Hanger Assembly PAGEREF _Toc508705672 \h 292-4 Door Interlock System PAGEREF _Toc508705673 \h 302-5 Door Guide PAGEREF _Toc508705674 \h 312-6 Cab Door Hinge and Mounting PAGEREF _Toc508705675 \h 322-7 Other Door Panel and Track Components PAGEREF _Toc508705676 \h 332-8 Summary PAGEREF _Toc508705677 \h 35MODULE 3 REPLACEMENT OF DOOR COMPONENTS PAGEREF _Toc508705679 \h 363-1 Overview PAGEREF _Toc508705680 \h 373-2 Door Controls Components PAGEREF _Toc508705681 \h 383-3 Door Panel and Track Components PAGEREF _Toc508705683 \h 483-4 Summary PAGEREF _Toc508705684 \h 54List of Figures TOC \t "Caption" \c Figure 1.1 Door Mechanisms, Courtesy of MTA PAGEREF _Toc508706017 \h 10Figure 1.2 Relays, Courtesy of MTA PAGEREF _Toc508706018 \h 14Figure 1.3 Door Operator Mechanisms, Courtesy of MTA PAGEREF _Toc508706019 \h 20Figure 2.1 Door Guide, Courtesy of MTA PAGEREF _Toc508706020 \h 31Figure 3.1 Door Control Unit (DCU), Courtesy of VTA PAGEREF _Toc508706021 \h 39Figure 3.2 Out of Service Indicator, Courtesy of LA Metro PAGEREF _Toc508706022 \h 40Figure 3.3Transfer Tubing, Courtesy of MTA PAGEREF _Toc508706023 \h 41Figure 3.4 Emergency Release Cables, Courtesy of MTA PAGEREF _Toc508706024 \h 42Figure 3.5 Door Closed Switch Replacement, Courtesy of VTA PAGEREF _Toc508706025 \h 45Figure 3.6 LV Locker Relays, Courtesy of LA Metro PAGEREF _Toc508706026 \h 47Figure 3.7 Sensitive Edge Cable, Courtesy of SFMTA PAGEREF _Toc508706027 \h 48Figure 3.8 Disconnected Door Panel, Courtesy of SFMTA PAGEREF _Toc508706028 \h 49Figure 3.9 Cab Door, Courtesy of RTD PAGEREF _Toc508706029 \h 52Figure 3.10 Window Frame and Seal, Courtesy of LA Metro PAGEREF _Toc508706030 \h 53Module 1TROUBLESHOOTING DOOR CONTROLS COMPONENTSOutlineOverviewManual Mechanical Operation of DoorElectrical and Electronics of Door OperationPassenger Indication System Relays/SolenoidsDoor Motors and Drive MechanismsSwitches Obstruction Detection DevicesEmergency Release MechanismDoor Control Unit (DCU)Portable Test Unit (PTU) Software for Door AdjustmentsSummaryPurpose and ObjectivesThe purpose of this Module is to provide participants with an overview to troubleshooting rail vehicle door controls components within the context of general troubleshooting and best practices.Following the completion of this module, the participant should be able to complete the objectives with an accuracy of 75% or greater:The participant will be able to demonstrate the ability to troubleshoot:Manual mechanical operation of doorElectrical and electronics of door operationPassenger indication system Relays/solenoidsDoor motors and drive mechanismsDoor switchesObstruction detection devicesEmergency release mechanismDemonstrate the ability to download and make door adjustments using Portable Test Unit (PTU) softwareKey TermsPassenger Indication SystemSensitive EdgeDoor Control Unit (DCU)Emergency ReleaseDoor MotorManual mechanical operationElectrical operation1-1overviewIn Course 300, Troubleshooting Principles, the participant was provided with an overview of the troubleshooting process along with related general strategies, tips and pitfalls. This course, Course 309, builds on the earlier troubleshooting course and focuses on commonly reported problems with the door systems on the rail car.Troubleshooting is a systematic approach to find the source of a problem in an effort to restore a component, operation or process. Because there are so many variances in rail car types and systems, this course cannot be a one-size-fits-all course on troubleshooting rail vehicle doors. The goal of this course is to identify common troubleshooting scenarios that the rail car technician can analyze and apply to similar situations in their role at their transportation agency. This Module will focus on Door Controls components, which make up the rail vehicle door assembly. Warning: Safety Precautions!Before deciding which system in a car is malfunctioning, check that all switches and the circuity breakers are properly set and that there is 37.5 VDC supplied to the system.When performing any troubleshooting procedures, be alert for unexpected door operation. Follow proper safety procedures to protect yourself and others.This module jumps right into troubleshooting Door Controls components. For each component discussed in this module, a troubleshooting table is presented with three columns:SymptomProbable CauseCorrective ActionThe tables presented are useful however, further agency specific information may be needed. Therefore, participants are encouraged to add their notes and observations to these tables during training.1-2Manual mechanical operation of doorAs part of the troubleshooting process, the rail car technician will operate the doors manually, and visually inspect components to determine the cause of problems. Manual operation of the doors helps to isolate issues by eliminating electronic feeds to the door equipment. As part of this process, the rail car technician will check that the doors are able to retract in and out of the door pocket without binding. The following table outlines common examples of mechanical faults that may arise when troubleshooting doors manually. Manual Mechanical Operation TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONDoor is binding when opening/closing.Bearings are loose.Tighten loose bearings.Trash on the track.Clear debris off track.The door linkage is not adjusted correctly.Adjust the linkage to the correct settings.Binding of the air cylinder.Check the condition of the air cylinder. Lubricate or replace, if necessary. Check air pressures and adjust, if necessary.The driving fork is detached.Remount and adjust the driving fork.Coupling rubber sleeve damaged.Change the coupling rubber sleeve.Agency Specific:Agency Specific:Figure 1.1 shows an illustration of the interior of the Door Operator at Maryland Transit Administration (MTA). The component identified in Figure 1.1 as “switch to disengage door”, can be used to mechanically disengage the door so there are no electrical parts to it. Once the door is disengaged, technicians can manually test the opening and closing of the vehicle doors. Door assemblies vary, always refer to their transportation system for specific procedures.29612493270738Switch to disengage door00Switch to disengage doorFigure 1.1 Door Mechanisms. Courtesy of MTA.1-3electrical and electronics of door operationThe table below outlines common electrical and electronic door opening troubleshooting scenarios. Prior to determining which troubleshooting measures are the correct, ensure there is power to the door system and Door Control Unit (DCU). Individual electrical components, such as limit switches and proximity sensors, are all tested separately, and are based on the results of a functional door test, which was discussed in Course 209. Space is provided at the bottom of the table for agency specific information.Electrical and Electronics of Door Operation TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONNo “closing” signal.The pushbutton is damaged or is not connected.Check train lines.Issues with “opening” signal.DCU is not working.Check that power supply is ok. Replace the DCU.The pushbutton is damaged or is not connected.Make a continuity test using a multimeter. Repair or replace as necessary.No “enable” signal.The pushbutton is damaged or is not connected.Check the train lines.Door position is not being read.Limit/Proximity Switches.Check for voltages going to switches.Check for broken switches.Check for ground.Agency Specific:Agency Specific:1-4Passenger indication systemThe table below lists common troubleshooting symptoms for the passenger indication system. Space is provided at the bottom of the table for the participant to list troubleshooting specific to their agency.Passenger Indication System TroubleshootingCOMPONENTSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONDoor Open Indication LightDoors are open. The inside and/or outside door open indication lights fail to light.The panel sensing switch for each respective door panel fails to close in the door open position.Readjust or replace PSS1 switches.Burned out bulbs in the lights.Replace the burned-out bulbs.The inside or outside “door open” indication signal lights fail to light when the emergency brake is applied.Emergency brake switch is failing to make contact.Replace the emergency brake switch.Burned out bulbs in the lights.Replace the burned out bulbs.Out of Service LightThe out of Service Light fails to illuminate.Power is not ON.Check for power. Turn power ON.Burned out bulbs in the lights.Replace the bulbs.Agency Specific:Agency Specific:In addition to the inside and outside door indication lights, the technician may also have to troubleshoot the ADA warning chime. When troubleshooting the ADA Warning chime, the rail car technician shall visually inspect to ensure that the terminal strip and carbody wiring are tight and corrosion free. When the doors close, the warning chime should be audible. If power is removed and then applied, and the chime does not sound, the unit should be removed and replaced. If power is not being applied, the carbody should be checked.1-5relays and solenoidsThe table below outlines common relays and solenoids troubleshooting scenarios.Relays/Solenoids TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONThe relay/solenoid is not energized.No voltage to the relay/solenoid.Check the battery voltage.Check for an open in the circuit upstream from relay/solenoid.No ground for the relay/solenoid.Check for the ground connection. Repair the connection, if necessary.Check for an open in the circuit downstream from relay/solenoid.Open the coil.Use ohmmeter to measure coil resistance. Replace the coil or the relay, if applicable.Relay contacts are not carrying current.The contacts are burned.Replace the contacts, if applicable, or the replace relay.The contacts are corroded.Replace the contacts, if applicable, or the replace relay.The contacts are looseTighten the contacts, if applicable, or replace the relay.Agency Specific:Agency Specific:Figure 1.2 is an example of Latching Relays and Crew Switch Relays, as provided by MTA.Figure 1.2 Relays. Courtesy of MTA.1-6door motors and drive mechanismsIssues with the door motors and drive mechanisms can be a mechanical and/or an electrical issue. The first step to troubleshooting the door motors and the drive mechanisms is to see if the motor is getting power. Then, the rail car technician must determine if the issue is electrical or if it is mechanical. For example, on pneumatic doors, the rail car technician should check for air pressure on the mon troubleshooting scenarios for Door Motors and Drive Mechanisms include:Door Motor and Drive Mechanisms TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONThe door cannot be open or closed and the motor is not energized.The motor wiring is cut or unplugged.Check the motor wiring.The drive mechanism is damaged.Repair or replace.The DCU is damaged.Replace the DCU.Motor will not turn.Motor mounting hardware is loose causing binding or drive mechanism.Tighten hardware. Run the motor and observe the motor visually.Internal failure of the motor (example: bearing failure).Replace the motor.Thermal protection switch is triggered. Temperature issues: motor is hot.Binding drive mechanisms. Faulty limit switch is not removing power from the motor at the proper time, causing the motor to stall.Rest the thermal protection switch. Ensure that the door panel(s) moves freely and that the drive mechanisms are not binding. Check the door limit switches and replace if found to be faulty.Agency Specific:Agency Specific:1-7switchesSwitches play an important role in train operations; switches control a signal to the DCU that all doors are closed, and allows the train to move. For example, on one car at Maryland Transit Administration (MTA), 36 different switches need to work correctly in order for the car to receive operational clearance to begin movement. The table below outlines common symptoms when troubleshooting switches. As door assemblies vary by agency, make and model, a technician must always refer to a technician agency for specific procedures when troubleshooting switches. Space is provided at the bottom of the table to supplement with agency specific information. Rail Vehicle Switches TroubleshootingTYPE OF SWITCHSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONCut-Out Switch (electric)Cut-out switch is not functioning.Power, ground and voltages are not ok.Fix the power, ground and voltages.Power, ground and voltages are OK. Check the signal aspect of door.Ensure that a passenger switch is sending a signal (checked with multimeter).If the continuity is ok and the signals are being sent, it is a motor or controller issue. From the controller, check output voltage. If output is good, there is a motor fault.Crew SwitchCar does not receive a door clear. The car cannot move.The crew switch sticking.Reset the switch.PushbuttonsPushbuttons are sticking.Coffee spill, gum, etc.Clean and check the operation. Replace the switch.Rail Vehicles Switches Troubleshooting, ContinuedTYPE OF SWITCHSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONPushbuttonsThe operator cannot open/close door.The contacts in the pushbutton are bad.Replace the switch.Limit/Proximity SwitchFaulty switch that does not detecting position of door.No power, ground, continuity in wires.Investigate further. Repair the issue.Misaligned the switch.Realign the switch.No continuity when the door closes.Defective switch.Replace the switch.Agency Specific:Agency Specific:1-8obstruction detection devicesAs you will recall from Course 109, obstruction detection devices help to avoid obstructions, such as, a passenger’s purse strap or a child’s arm from getting caught in between closing doors. The obstruction detection devices that will be discussed in this section include:Sensitive EdgesSensorsLight BarrierOvercurrentThe table below identifies some common scenarios to be aware of when troubleshooting obstruction detection devices. Space is provided below the table for agency specific information.Obstruction Detection Devices TroubleshootingOBSTRUCTION DETECTION DEVICESYMPTOMPROBABLE CAUSECORRECTIVE ACTIONSensitive EdgeTorn or cut bladder.Wear and tear.Replace the Sensitive Edge.Faulty tubing.Loose connection.Reconnect tubing.Tubing is worn through due to wear and tear.Replace the tubing.Pressure switch is not sensing the air pressure when it is squeezed.Worn switch.Adjust or replace the switch.Faulty tape switch.Wear and tear.Replace the switch.Sensitive pressure switch.Hot day coming out of a cooler tunnel. Pressure change in tunnel, for example when it is a hot day and then the vehicle moves into cooler tunnel, the door will oscillate because of the air pressure change.Adjust the switch.Obstruction Detection Devices Troubleshooting, ContinuedOBSTRUCTION DETECTION DEVICESYMPTOMPROBABLE CAUSECORRECTIVE ACTIONSensorThe sensor is not detecting obstructions.No power or ground.Determine the cause for no power or ground.The sensor may need to be cleaned or checked for scratches.Clean sensor as determined by OEM/Agency guidelines.Faulty touch handle sensor.Bad connection, broken wire.Repair or replace.Light BarrierMisalignments, obstructionsWear and tear.Realign or clear obstructions.The light barrier is not detecting obstructionsNo power or ground.Determine the cause for no power or ground.OvercurrentA door closing issue; the door is dragging.Obstruction in the trackClear the obstruction.Bad motor.Identify the problem with the PTU deviceAgency Specific:Agency Specific:An example on the operation of sensitive edges is explained in Figure 1.2, which shows the Door Operator mechanisms on a Heavy Rail vehicle at MTA. Although not shown, there is tubing that meanders from the top of the image all the way down to the pressure wave switch (1). The pressure wave switch (1) signals to the sensitive edge relay (2) and the motor control relay (3) if an obstruction is detected. The doors will attempt to recycle, at the point of obstruction. When the door retracts into the door pocket, it then opens again (oscillates) after the motor control relay recycles. This process will continue until the obstruction is removed. When testing or troubleshooting sensitive edges, a three-point inspection is typically performed on the top, middle and bottom of the door through the use of the sensitive edge tools (as explained in detail in Course 109). The obstruction has to be at least 2 inches to be caught by the sensitive edge.Figure 1.3 Door Operator Mechanisms. Courtesy of MTA.1-9 emergency release mechanismIt is important to note that the location of the emergency release device will vary by agency. For example, at SEPTA, the emergency release is located underneath the train, and passengers do not have access to it. The emergency release device is shaped like a ball and has two mechanical arms that attach to the arms, which move the door panels back and forth. The arms pull down and move the arm levers, so they are not locked in the close position and then manually open the rest of the way. Refer to your agency for the specific location of the emergency release mechanism.The following table lists some common checks to perform when troubleshooting interior and exterior emergency release devices. Space is provided at the bottom of the table for agency specific information to be included.Interior & Exterior Emergency Device Does Not Open Doors TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONEmergency device does not open the doors.The spiral cable brokenReplace the cable and adjustThe fixed cable clamp broken off at emergency egress deviceReplace the cable and adjustThe clamp fitting is loose at lever bracketAdjust the cable and tighten the clampThe cable length is incorrectAdjustThe lever bracket at the brake is broken or attaching screws looseReplace bracket or tighten screwsLifting gap of released gap: Gap 0.5mm minimumAdjustThe emergency egress device is brokenReplace the emergency egress deviceAgency specific:Agency specific: 1-10 Door control unit (DCU)The following table provides some troubleshooting scenarios for the Door Control Unit or “DCU”. Space is provided at the end of the table for agency specific information.Door Control Unit TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONThe door open/close signal is not being received.CouplersReplace the couplers. Doors do not operate.DCU unplugged/turned off.Plug in/turn on and test doors.Agency Specific:Agency Specific:1-11 PTU software for door adjustments This portion of the course is specific to the participant’s agency. The instructor will facilitate and guide the participant through the Portable Test Unit (PTU) software used at their agency either through a simulation or hands-on learning lesson. Listed below are questions that the participant should be able to answer at the end of the lesson.What is the name of PTU software?What are the steps to download Door subsystem related software to the PTU? How are history records or events accessed?How do you reprogram the door controller using a PTU?What are the steps for checking door faults?How do you resolve and analyze the fault logs?What are some common fault codes?What are the steps for setting the door opening/closing times using a PTU?As your progress through the simulation or hands-on activities, use the space provided below to take notes. 1-12 summaryTroubleshooting is an important part of the rail car technician’s job. This Module presented common troubleshooting scenarios for Door Controls components on rail vehicle doors. Space was provided at the end of each section for supplemental agency specific materials and resources to be provided to the participant. Module 2TROUBLESHOOTING DOOR PANEL AND TRACK COMPONENTSOutlineOverviewDoor Leaf and PanelRoller Hanger AssemblyDoor Interlock SystemDoor GuideCab Door Hinge and MountingOther Door Panel and Track Components SummaryPurpose and ObjectivesThe purpose of this Module is to provide participants with an overview to troubleshooting rail vehicle door panel and track components within the context of general troubleshooting and best practices.Following the completion of this Module, the participant should be able to complete the objectives with an accuracy of 75% or greater:The participant will be able to demonstrate the ability to troubleshoot:Door leaf and panelRoller Hanger AssemblyDoor interlock systemDoor guideCab door hinge and mountingWindow and FrameGaskets and SealsKey TermsOscillate2-1 OverviewIn Course 300, Troubleshooting Principles, the participant was provided with an overview of the troubleshooting process along with related general strategies, tips and pitfalls. This course, Course 309, builds on the earlier troubleshooting course and focuses on commonly reported problems with the door systems on the rail car.Troubleshooting is a systematic approach to find the source of a problem in an effort to restore a component, operation or process. Because there are so many variances in rail car types and systems, this course cannot be a one-size-fits-all course on troubleshooting rail vehicle doors. The goal of this course is to identify common troubleshooting scenarios that the rail car technician can analyze and apply to similar situations in their role at their transportation agency. Space is provided at the bottom of each table for agency specific information to be included. Warning: Safety Precautions!Before deciding that a particular system in a car is malfunctioning, first check that all switches and circuity breakers are properly set and that there is 37.5 VDC supplied to the system.When performing any troubleshooting procedures, be alert for unexpected door operation. Follow proper safety procedures to protect yourself and others.This module jumps right into troubleshooting Door Panel and Track components. For each component discussed in this module, a troubleshooting table is presented with three columns:SymptomProbable CauseCorrective ActionThe tables presented are useful however, further agency specific information may be needed. Therefore, participants are encouraged to add their notes and observations to these tables during training.2-2 Door Leaf and panelDoor Leaf and Panel troubleshooting will vary depending on door type, example door types are: pneumatic, electric, plug, swinging, and folding. The following table provides some common troubleshooting scenarios. Space is provided at the bottom for agency specific notes.Door Leaf and Panel TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONOne and/or both door panels fail to close.An obstacle is keeping the doors from closing.Remove the obstacle.Height adjustment of the roller hanger assemblies. Rollers press too hard on pressure plates of door leaf.Adjust the heights.Sensitive edge rubbers do not meet correctly or the door leaf assemblies are not parallelAdjust the door leaf assemblies.Guide rails are binding.Adjust the guide rails as needed.Check the motor thermal cutout.Reset if open.One and/or both door panels they fail to open.Linkage.Adjust as needed.Check the motor thermal cutout.Reset if open.Doors on one side fail to open. Doors on the other side open.Check the circuit breaker for power.Reset the circuit breaker.Perform a voltage check of the motor power circuit.Replace defective wiring, circuit breaker.All doors, on both sides of car, fail to open.Check for power.Turn power On.Doors on one side of the car fail to close.Check the motor power circuit breaker.Reset the circuit breaker.Check motor power circuit for voltage.Replace defective wiring, circuit breaker.Agency Specific:Agency Specific:2-3 Roller hanger assemblyThe following table outlines common roller hanger assembly troubleshooting scenarios. Roller Hanger Assembly TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONBall bearings are bindingBall bearings are not greased.Remove and replace bearings.The arm that pushes door out is “balling” up. Door binding.Ball bearings are not greasedRemove and replace bearings.Agency Specific:Agency Specific:2-4 door interlock systemThe following table identifies common reported faults of the door interlock system. As always, refer to your individual agency for specific symptoms, causes and corrective actions related to your specific rail vehicles. Space is provided at the bottom of the table for agency specific information to be added.Door Interlock System TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONDoor cannot lock mechanicallyLoss of mechanical adjustment of the lock position.Re-adjust the locking cam.Locking spring is damaged.Replace the locking spring.The operator’s cab door lock is sticking.Wear and tear.Remove and replace.The front door locks (to move from car to car)*It is Rare for problems to arise with front door locks.*If there are problems, remove and replace.Agency Specific:Agency Specific:2-5 door guideDepending on the vehicle, the door guide may be located at the top or bottom of the track. An example provided from Maryland Transit Administration (MTA) describes the doors on their vehicles getting “hung up” due to debris or other objects getting stuck in the door guide. The door guide on the trains at MTA are located at the bottom of the track and have issues with batteries, or other objects getting wedged in the door. The limit switches then prevent the door from closing all the way, thus requiring the operator to take the door out of service. The fix is often easy; a pocket knife, or other pocket tool, is easily able to remove the object from the guide. Operators, however, often do not have the necessary tool at their disposal and therefore, have to cut-out the door and bring the vehicle to the maintenance shop for the technician to address. Other common troubleshooting scenarios are provided in the following table. Figure 2.1 Door Guide. Courtesy of MTA.Door Guide TroubleshootingSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONThe door will not close.Door Guide binding. Adjust as needed.Debris or object are caught in the guideRemove the debris or object.Agency Specific:Agency Specific:2-6 cab door hinge and mountingThe table below outlines common troubleshooting scenarios for the cab door hinge and mounting. As always, door assemblies will vary by agency. Be sure to check with your agency for specific procedures.Cab Door Hinge and Mounting TroubleshootingSYMPTOM PROBABLE CAUSECORRECTIVE ACTIONThe hinge and the mounting are misaligned.Wear and tear.Remove and replace the worn parts.Adjust parts as necessary.Agency Specific:Agency Specific:2-7 Other door panel and track ComponentsCommon troubleshooting scenarios for the window, window frame, and gaskets and seals are presented in the following table. Other Door Panel and Track Components TroubleshootingCOMPONENTSYMPTOMPROBABLE CAUSECORRECTIVE ACTIONWindow Broken window.Wear and tear, vandalism.Replace.Window FrameGlazing chipped or cut out.Wear and tear.Replace.Gaskets and SealsChipped or torn.Wear and tear.Replace.Agency Specific:Agency Specific:-55880-45085000Learning Application 2.1 – Troubleshooting FlowchartIn small groups, draft a flow chart for troubleshooting a common failure. The instructor will provide a component and symptom discussed in Module 1 or 2 of this course. An agency specific Troubleshooting Matrix may be available for use. Once complete, examine your flow chart with the other groups and discuss:Similarities and difference between the flow charts.If any troubleshooting steps are missing?Component: ___________________________144145285750To begin, write the component’s symptom in the circle.2-8 SummaryTroubleshooting is an important part of the rail car technician’s job. This Module presented common troubleshooting scenarios for Door Panel and Track components on rail vehicle doors. Space was provided at the end of each section for supplemental agency specific materials and resources to be provided to the participant.Module 3REPLACEMENT OF DOOR COMPONENTSOutline3-1Overview3-2Door Controls Components3-3Door Panel and Track Components3-4SummaryPurpose and ObjectivesThe purpose of this Module is to provide participants with an overview of replacing rail vehicle door assembly components.Following the completion of this Module, the participant should be able to complete the objectives with an accuracy of 75% or greater:Demonstrate the ability to replace:DCUDoor Lights and Warning ChimesRelays and SolenoidsSwitches Obstruction Detection Devices Emergency Release MechanismRoller Hanger AssemblyDoor GuideDoor Interlock System Window and FrameCab Doors3-1 overviewWhen troubleshooting does not work, a rail car technician may need to replace a door assembly component. Depending on the agency and component, this may or may not be within the scope of the rail car technician’s job. Because there are so many variances in rail car door components, this Module cannot be a one-size-fits-all on replacement. The goal of this Module is to provide the participant with the proper steps to replace door components. For each section within this Module, the specific steps taken to replace a component will be explained using procedures from the various rail agencies which participate in the consortium. Space will be provided at the end of each section for the participant and instructor to supplement with agency specific materials and resources, such as job-cards and standard operating procedures.3-2 Door controls componentsCase studies explaining the procedure for replacing the following components will be discussed in this section:Door Control Unit (DCU)Passenger Indication SystemObstruction Detection DevicesEmergency Release MechanismSwitchesRelays & SolenoidsDoor Control Unit (DCU)The following case study on replacing the DCU is provided by Santa Clara Valley Transportation Authority (VTA). The DCU should only be replaced when troubleshooting indicates the DCU cannot be repaired. Case Study 3.1: Replacing Door Control Unit – Santa Clara Valley Transportation Authority (VTA)Replacement:Tag and disconnect wiring at connectors.Remove all hardware.Remove DCU.Install new DCU on console.Install attaching hardware.Tighten hardware.Connect wiring per tags at connectors.Agency Specific:WasherConnectorDCUConsoleWasherConnectorDCUConsoleFigure 3.1 Door Control Unit. Courtesy of VTA.Passenger Indication SystemThe following case study on replacing Door Out of Service Indicator is provided by LA Metro. As always, refer to your agency for specific procedures on changing the various rail vehicle lights and warning chimes.Case Study 3.2: Replacing Door Out of Service Indicator – Los Angeles County Metropolitan Transportation Authority (LA Metro)Replacement:Follow safety proceduresOpen the cover on top of each doorwayDisconnect the door out of service indicator connector plugRemove indicator fixing hardwareRemove the door out of service indicatorInstall a new door out of service indicatorFix the indicator with the relevant fixing hardwareRe-connect the door out of service indicator connector plugClose the cover on top of each doorway53445880010Fixing HardwareFixing Hardware00Fixing HardwareFixing Hardware650240166370Figure 3.2 Out of Service Indicator. Courtesy of LA Metro.Figure 3.2 Out of Service Indicator. Courtesy of LA Metro.Agency Specific:Obstruction Detection DevicesThe following case study, provided by MTA presents the participant with the appropriate steps to replace sensitive edges. As explained in prior courses, there are different types of obstruction detection devices. The case study below represents the procedure for one type. Always refer to your agency for specific procedures.Case Study 3.3: Replacing Sensitive Edge – Maryland Transit Administration (MTA) Light Rail VehiclesReplacement:Cutout the door and manually push the door panels to the open position.Remove screws securing the locking plate to the door panel.The sensitive edge assembly can be removed from the door panel-retaining channel starting at the top or bottom. Be sure to pull the transfer tubing from the sensitive edge connector before completely removing the assembly.The transfer tubing edge connector should be oriented toward the top.Transfer TubingMounting GroovesSensitive EdgeTransfer TubingMounting GroovesSensitive Edge Figure 3.3Transfer Tubing. Courtesy of MTA.Apply lubricant to the mounting grooves of the sensitive edge assembly for ease of mounting into the door panel channel. The sensitive edge should be flush with the bottom of the door panel; an excess length may be trimmed off at the top.The sensitive edge should be installed in the door channel working from bottom to top.Connect the transfer tubing to the sensitive edge connector and loop the excess tubing inside the door panel.Secure the sensitive edge assembly to the door panel with the locking plate and screws removed previously.NOTE: Verify that the sensitive edge is flush and even with the door panel.Agency Specific:Emergency Release MechanismThe case study below, provided by Maryland Transit Administration (MTA), presents the participant with the steps to replace the emergency release cable.Case Study 3.4: Replacing Emergency Release Mechanism (Cable) – Maryland Transit Administration (MTA)Removal:At either door operator where cable assembly terminates, remove wire and pin holding cable at the clevis.Unscrew screws at support clamps holding cable at car body.At the cable assembly near emergency handle where cable assembly attaches to bracket, loosen nut to remove bolt at clevis.Remove nut and bolt at clevis attached to lever. Emergency cable assembly is now free to be removed from car.Remove support clamps from cable. Right Hand Inside Emergency Cable Assembly: At the right-hand operator, which operates center door, locate bracket that supports two cable assemblies. Remove right hand inside cable assembly by removing cotter pin, washer, disengage black oxide spring from clevis, and remove retaining pin.Remove cable assembly from car.Installation:Place cable clamps on cable assembly for attaching to car body in its former position.Place cable assembly into position for installation, and reinstall support clamps at car body.Connect clevis to emergency handle by aligning clevis with connecting point and placing bolt thru clevis and screw nut on bolt until finger tight.Slip cable thru cable bracket slot making sure that nuts and washers are in their appropriate position for fastening cable assembly to cable bracket. Move threaded portion of casing thru cable bracket and then slip washers over threaded portion and fasten finger tight in position with top and bottom nuts.At the door operator, the emergency handle must be in the actuated (down) position before connecting cable assembly. Assemble hardware.Inside Emergency CableOutside Emergency CableDoor OperatorInside Emergency CableOutside Emergency CableDoor OperatorFigure 3.4 Emergency Release Cables. Courtesy of MTA.Agency Specific:SwitchesRegardless of the switch, generally, the procedure for replacing switches will be the same. As always, refer to your agency for specific procedures. The following case study presents the steps for replacing a Door Closed Switch.Case Study 3.5: Replacing Door Closed Switch – Santa Clara Valley Transportation Authority (VTA)Replacement:Remove power.Tag and disconnect wiring at switch.Remove clips.Remove door closed switch from pins of bracket.Install switch on pins.Install new clips on pins.Connect wiring per tags.Turn on power.Use pushbutton to open and close the doors. The doors should operate normally.Agency Specific:73660046164503175004648200A0A39052501181100A0A127000698500Pin00Pin3244850184150Clips00Clips127000184150Switch00SwitchFigure 3.5 Door Closed Switch Replacement. Courtesy of VTA.Relays & SolenoidsThe following case study on replacing Relays is provided by LA Metro.Case Study 3.6: Replacing Relays – Los Angeles County Metropolitan Transportation Authority (LA Metro)Removal:Follow safety proceduresGain access to the Relays Rack by opening the relevant locker door using a maintenance keyLocate the relay to be replacedLoosen and remove the self-locking nuts and washers fixing the relay to the rack. Keep for later use.Slide out the relay in order to gain access to the relevant wiring and terminals connectionsTake not of wiring color codes and relevant positions on relay terminalsDisconnect the wiring cable from relay terminalsRemove and discard the relayInstallation:Clean the relay seat using recommended cleaner and lint-free ragsCheck the relay plate for installation, missing or loose hardwareTorqueCheck wires and wire terminals for signs of overheatingConnect the wiring to the relay terminals according to their position and color codes previously notedTorque the wires screw terminals Install the relay in its positionInstall the relay attaching washers and self-locking nuts. Close and lock the locker door using maintenance keyRestore electrical powerFigure 3.6 LV Locker Relays. Courtesy of LA Metro.Agency Specific:3-3 Door panel and track componentsCase studies explaining the procedure for replacing the following components will be discussed in this section:Roller Hanger AssemblyDoor GuideDoor Interlock SystemCab DoorsWindow and SealsRoller Hanger AssemblyThe following case study on replacing the Roller Hanger Assembly is provided from San Francisco Municipal Transportation Agency (SFMTA).Case Study 3.7: Replacing Roller Hanger Assembly – San Francisco Municipal Transportation Agency (SFMTA)Identify the defect in the bracket.Remove the spindle nut carrier.Remove the sensitive edge cable.344170118745000 Figure 3.7 Sensitive Edge Cable. Courtesy of SFMTA.Remove the bearing.Mount the lower door support bracket. Adjust as necessary to secure the lower doors.Remove the Allen bolts from support bracket.Remove all telescoping bracket door mount bolts except for one on each door panel.Secure the upper door panels with enough slack to allow them to lean out slightly.Use track iron for leverage and remove final bolt on each door panel. Disconnected door panels can now tilt out supported by ropes. Figure 3.8 Disconnected Door Panel. Courtesy of SFMTA.Adjust door panel as necessary to provide a gap between door and body.Remove Allen bolts holding telescoping bracket to body.Installation of new bracket:Line up replacement bracket with defective bracket and adjust set screws to match.Apply small amount of Loctite to countersunk Allen mount bolts.Position bracket on top of doors and install Allen mounting bolts.Measure the distance from the edge of center spindle to inner edge of u-guide block.Install the outer spindle support bracket mount bolts.Install the sensitive edge electrical connection and install the Allen bolts to mount the u-guide block.Perform the door function test and sensitive edge test.Agency Specific:Door GuideThe following case study provided by Dallas Area Rapid Transit (DART), which provides the steps for replacing the Door Guide.Case Study 3.8: Replacing Door Guide – Dallas Area Rapid Transit (DART)Replacement:Unscrew the hardware from the door guide.Replace the door guide.Screw the hardware back into the door guide.Agency Specific:Door Interlock SystemThe following case study on replacing the mechanical lock assembly, is provided by Maryland Transit Administration (MTA). The procedure discussed below is used on their heavy rail vehicles.Case Study 3.9: Replacing Mechanical Lock Assembly – Maryland Transit Administration (MTA)Replacement:Disconnect incoming wires at the terminal strip.Remove all hardware at bracket assembly where assembly fastens to the car structure.Bolt replacing bracket assembly of the mechanical lock assembly to assigned position of the car structure that is using the hardware designated.Connect the incoming wires to a terminal strip.Agency Specific: Cab DoorsThe following case study outlines the process for replacing the cab door on the rail vehicle. Be sure to follow your agency’s specific procedures for replacing cab doors.Case Study 3.10: Replacing Cab Doors – Denver Regional Transportation District (RTD)Removal:Unlock and open cab door.Support the bottom of the door in a fully-open position.Remove screws that attach hinges to car structure.Remove cab door with attached parts from the doorway.Remove parts as needed for use on new cab door which may include: Self-tapping screws, molding, hinges, cab door lock assembly, handle, grille.Installation:As needed, install cab door parts on new cab door.Position cab door for mounting, and support it from the bottom.Install the screws used to attach cab door assembly to car structure.Remove any blocking or supports used.Test the cab door operation.Self-Tapping ScrewMoldingCab Door Lock AssemblyHandleGrilleHingesSelf-Tapping ScrewMoldingCab Door Lock AssemblyHandleGrilleHingesFigure 3.9 Cab Door. Courtesy of RTD.Agency Specific:Window Frame and SealThe following procedure describes the steps to replace the rail vehicle window frame and seal, as provide by LA Metro. Depending on the transportation agency, technicians may or may not replace rail vehicle windows. As always, refer to your agency for specific guidelines and procedures.Case Study 3.11: Replace Window Frame and Seal – Los Angeles Country Metropolitan Transportation AuthorityReplacement:Remove the Door Leaf.Strip off the Filler Strip starting from one end.Pop out the glazing by pressing on one of the corners from inside and remove the window seal.Install the new window seal on door leaf with the filler groove on external side.Spread the mounting paste on the window seal groove.Use a rope to insert the glazing. The marking on glazing should be readable from inside at bottom.Install the filler strip with the help of a tapestry roller starting at bottom middle.Cut the filler strip with the help of a tapestry roller starting at bottom middle.Check that the window seal is watertight.Install the Door Leaf.Restore the power supply to the relevant door by switching to ON the relevant protection circuit breaker.48831501079500Filler Strip00Filler Strip13779501079500Glazing Seal00Glazing Seal31051501079500Glazing00Glazing Figure 3.10 Window Frame and Seal. Courtesy of LA Metro.Agency Specific: 3-4 SummaryThe Module presented the participant with rail car consortium agency examples for replacing specific door component. As previously addressed, due the variances between rail vehicles, this Module is not be a one-size-fits all. Space was provided at the end of each section for agency specific materials to supplement general troubleshooting practices outlined by the Module. ................
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