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Hindi Contents

Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

CHAPTER 6

BOGIE MOUNTED AIR


BRAKE SYSTEM
601 GENERAL bore pneumatic pipeline has been
laid over bogie frame to inter
In order to overcome the problems of connect the brake cylinders of one
slack adjuster failure as well as problems bogie. Output pipe line of distributor
associated with cast iron brake blocks, a valve has been connected to bogie
design of brake system incorporating 8" pneumatic line through flexible
size two cylinders on each bogie along hoses to provide flexibility to
with ‘K’ type high friction composite alround dynamic movement.
brake blocks has been introduced.
603 COMPOSITE BRAKE BLOCK
602 DESIGN FEATURES OF THE 603a General
SYSTEM (refer figure 6.1)
Low friction composite brake blocks
This type of system is exactly similar to have the following benefits:
the standard air brake system except for
n Reduced braking distance due to
the following:
uniform co-efficient of friction.
n Reduced weight
a) External slack adjuster is removed/ n Reduction in the replacement of
eliminated brake blocks vis a vis cast iron due to
b) Four cylinder of 8" size is provided higher wear life in train operation.
for each coach in place of two n Reduced wear and tear of brake
cylinders of 14" in standard air rigging.
brake system. These cylinders have n Reduced noise during braking.
built in single acting slack adjuster
for taking the slack created between 603b Characteristics of composition brake
wheel and brake block on account of blocks
wheel / brake block wear. Mounting i. Composition of material
of cylinders is done on either side of
the bogie frame in between central The composition of material
longitudinal members connecting the constituting the brake blocks must be
bogie transom to the headstocks. chosen to give the best balance
Each cylinder controls the braking between :
on one wheel set. Each cylinder has
a piston take up stroke of 32 mm and § The braking characteristics
adjustment capacity of 305 mm § The wear and service life of blocks
(Ref. Drg. RDSO Sk- 81057) § Wear on the running surface of the
wheels
c) High friction composite brake blocks
§ The effect on adhesion between the
of ‘K’ type have been used.
rail and wheel
d) Bogie brake rigging has been
modified to incorporate a total ii. Requirement concerning friction
mechanical advantage of 7.644 per § The average coefficient of friction is
bogie for non-AC coaches and 8.40 0.25.
per bogie for AC coaches.
§ As far as possible the coefficient of
e) Curved profile pull rods have been friction must be independent of the
used to interconnect levers initial braking speed, the state of
controlling braking one wheel set. bedding-in of the brake block, the
These pull rods provided with one specific pressure also the
additional hole for the adjustment of temperature and atmospheric
slack between wheel and block after conditions.
specified amount of wear.
f) Since brake cylinders have been
mounted on the bogie frame, 15mm.

Chapter 6, Page 1 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

M aintena nce M anua l for BG ICF C oaches


C hapter 6, Page 2 of 14
+0
685 -10

305 MAX. SLACK TAKE UP. 679


ADJUSTER IS TO BE RESET BY
%%p0.5 4-FIXING
REWINDING THE ADJUSTING TUBE. 95 MAX.
HOLES %%C21

1 27
STROKE

95 MAX. (MUST BE
IN A STRAIGHT
STROKE
WORKING STROKE,32mm FOR SELF LINE)
*

% % p 0 .5
GENERATING MAIN LINE COACHES, 117.5
281 22
A
60mm FOR BG EMU COACHES.
*

127
130
= =

%%p0.5
204

12 7
LEVERS MUST BE
ARRANGED SUCH THAT
POSITION A FOR MAIN LINE SELF

R EL EA SE PO SITION AF TE R
THE CROSSHEAD IS

25
HAND BRAKE TRUNNION

F ULL 305 TAK E- UP


GENERATING AND BG EMU TRAILOR HELD WITH IN 1.5mm
COACHES OF THIS AXIS.

PO SITIO N
IN ITIA L R E LE ASE
2 Nos.AIR INLET PIPE CONNECTION,
ONE CONNECTION IS TO BE MADE
DUMMY BY PLUGGING.

400

MOVEMENT TO BE ALLOWED FOR

365
B
MAX. WORKING MOVEMENT
% % p0 . 5

M A X.
31
204

MA X.
47 . .
=

M A X.
47

M AX.
31
RESETTING LATCH

B og ie M ounted Air Brake System


LEVERS MUST BE ARRANGED
SO THAT THE PATH OF THE
POSITION B FOR EMU MOTOR COACHES CROSSHEAD CENTRE LIES
BETWEEN THESE LINES. %%UNOTE:-
1. TO MANUFACTURE BOGIE MOUNTED BRAKE CYLINDER FOR
MAIN LINE COACHES, REFER RDSO SK-81200 AND THE
BILL OF MATERIAL FOR DIFFERENT COMPONENTS.
FIGURE 6.1

SUPERSEDED BY: INDIAN RAILWAY STANDARDS


SK-81200
5 - CD/8/2K DRAWING REVISED 11/2K

1. DIMENSION 101.6mm CHANGED TO 102.


ASSEMBLY DRAWINGS SUPERSEDES: EMU STOCK & SELF GENERATING
4 - CD/4/2K 2. DIM. 117.47mm CHANGED TO 117.5 . %%p0.5
4/2K REFERENCE:- SCALE P MAIN LINE COACHES
3. FIXING HOLE DIA. CHANGED TO 21mm.
C 203.2 mm x 95.25 mm (8"X 3 3/4")
3 - CD/21/99 NOTE 2 ADDED. 12/99
D SK.SRIVASTAVA
BRAKE CYLINDER WITH
-
TOLERANCE +0/-10mm ADDED T
2 CD/7/99 2/99
ON DIMENSION 685.
J.S. SLACK ADJUSTER
1 - CD/35/98 NOTE 1 ADDED & TITLE CHANGED 12/88 FLOPPY No. :-
R . D . S . O.
GROUP 1 2

ALT. ITEM AUTHY. DESCRIPTION DATE B.G. (C)


3 4 5
SKETCH-81057

Chapter 6, Page 2 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

§ Under the effect of dampness, the § The use of asbestos is prohibited.


average coefficient of friction must not § The use of lead or zinc in the metal
vary, with the other condition state or in the form of compounds is
remaining the same, by more than not advised. The same applies to all
±15% in relation to the value obtained other compounds, if in the form of
during braking when dry. powder, particles or gas produced
§ After prolonged braking followed by during the used of the brake blocks,
braking to a stop, particularly high they may constitute a danger to health.
temperature occur. Even in the case of 603d Asbestos based ‘K’ type composition
these temperatures (maximum 400 0C brake
on the opposing friction surface) the
average coefficient of friction must not § Asbestos based ‘K’ type blocks shall
vary with the other conditions generally conform to RDSO drawing
remaining the same – by more than No. 98146.
±15% in relation to the value obtained
during braking in cold and dry state. 603e Marking
iii. Geometrical characteristics of the
Each block must bear the following
brake blocks
marks:-
§ The constructional features of the
brake blocks must enable them to wear § Name of manufacturer
down to a thickness of 12 mm § Date of manufacturer (month and
including the back plate, without the year)
latter coming into contact with the § Material code including ‘KA’ for
running surface of the wheel. asbestos type and ‘KNA’ for non-
iv. Mechanical and physical asbestos type.
characteristics § Type of service ML.
§ The various elements making up the
These marks, preferably punched, cut or
brake blocks must be spread uniformly
stamped, must be applied so that the block
in the body of the block. There must
can be identified, even after being fully
be no pitting, flaws or other defects.
worn in service.
The material must not attack the
opposing friction surface or give rise
603f Comparison of properties/Usage of
to the formation of metal inclusions.
composition brake block Vs Cast Iron
Composition brake blocks must
Brake block
not bring about more serious heat
damage to the wheels (hot spots,
Param- Type of Brake blocks in use on main line
cracks, flaking) than would be caused
eters coaches
by cast iron blocks used in the same
'L' type CBB 'K' type CI
way on the same wheels.
CBB
§ The values of specific weight, thermal
conductivity, hardness, bending Appli- All coaches All coaches All
strength and the modulus of elasticity cability with with bogie coaches
must be given for acceptance underframe mounted with
purposes. mounted air brake vacuum
§ No method is laid down for fixing the brake system system brake and
composite material part to the back under
plate. The back plate must be designed frame
to support the stresses likely to occur. mounted
§ The composition blocks must not brake
affect to an unacceptable degree the system
adhesion values between wheel and Speed Upto 110 upto 110 Upto 140
rail obtained on vehicles braked with KMPH KMPH KMPH
cast iron inserts. Coeffic 0.12 to 0.14 0.25 max. 0.12 to
ient of 0.14
603c Non-asbestos ‘K’ type composition friction
brake block Weight Approx. 3 Approx. 3 Approx. 9
§ Non-asbestos ‘K’ type blocks shall kg. kg kg.
generally conform to RDSO drawing
No. 98066.

Chapter 6, Page 3 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

604 WORKING PRINCIPLE cylinder pressure developed is 3.8 +/ - 0.1


kg/cm2 as in the case of standard air
There is no change in the overall brake brake.
system in bogie-mounted arrangement up
to the action of distributor valve. Here the 604b Release
system will respond to action on A-9 For release of the brakes, driver moves
valve in similar fashion as in the case of handle of A-9 valve to release position.
standard air brake system. Working of By this movement, the brake pipe is
bogie mounted brake system beyond charged to the required pressure of 5
distributor valve is explained below. kg/cm2. This actuates the distributor valve
and brake cylinder is cut off from the
604a Application (see fig. 6.2 ) auxiliary reservoir. The air from brake
cylinder is exhausted to atmosphere and
brakes are released.
For application of brakes, driver moves
the handle of A-9 valve in the application 604c Slack up Action
position. By this movement the brake pipe Cylinders of bogie mounted brake system
pressure is reduced which is sensed by are provided with automatic slack take up
distributor valve to operate brake cylinder features. As soon as the piston stroke
(1). Pneumatic pressure in the brake exceeds a pre determined value (on
cylinder causes piston assembly (2) to account of either brake block or wheel or
move outward thereby causing lever (3) to both) a ratchet with adjusting screw fitted
rotate about its fulcrum (a) thus bringing inside the cylinder turns thereby
brake block (4) to come in contact with increasing the length of the piston rod
the wheel (5) through the brake beam (6). automatically. During return stroke, the
Since lever (3) is hung on the bogie frame adjusting movement takes place. A red
through lever hangers, it will start moving paint mark on the adjusting tube assembly
forward about fulcrum (b) after brake indicates that piston unit has extended
block (4) has contacted wheel (5). This over its full range and requires resetting of
forward motion of the lever (3) about pull rod (7).
fulcrum (b) will cause pull rod (7) to
move forward thereby causing lever (8) to 605 COMPARISION OF IMPORTANT
swing about fulcrum (c) and hence PARAMETERS
resulting in contact of brake block (9)
against wheel (5) through brake beam In the underframe mounted brake gear
(10). arrangement, it is seen that there are 51
pin joints per bogie in the system. To
Extent of brake cylinder pressure reduce the number of pin joints, levers,
developed in the brake cylinder will pull rods and push rods, bogie mounted
depend upon the extent of reduction in brake system for mainline coaches have
brake pipe pressure. Maximum brake become a viable alternative. Comparison

INLET PLUG
compressed air is
supplied from loco
2

3
C
4
8

7
10
6 9
b

SCHEMATIC BOGIE BRAKE GEAR


ARRANGEMENT FOR BOGIE MOUNTEDFIGURE 6.2
BRAKE SYSTEM

Chapter 6, Page 4 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

of bogie brake system with conventional WTAC4-3-2-402 which is designed


air brake system for various parameters is for 16T bogies.
as follows:- iv) While fitting curved profile/pull rods
Table 6.1 as per Para (iii) above, it shall be
ensured that they are fitted as shown
Item Convent- Bogie in the bogie brake arrangement
ional Air Mounted drawings and not reversed under any
Brake Brake circumstances.
System System v) Curved profile/pull rods as per Para
Weight reduction - 492 kg. (iii) have been provided with a single
(as compared to hole at one end and two holes at
conventional air other end, for initial fitment, when
brake system) wheel as well as brake blocks are
Braking distance 905 m 800 m new, connection of levers through
at 110 kmph pull rod will have to be made using
(18 coaches) extreme holes/strictly. When wheel
No. of pins and 102 84 diameter reduces to 839 mm. and 38
bushes packing is provided at axle box to
Brake block wear 3 cc/kwh 1.325 compensate for the wheel wear,
rate cc/kwh connection of pull rod must be
shifted to adjacent hole.
606 MAINTENANCE INSTRUCTIONS vi) Under new condition of wheel
(dia. 915 mm) and brake block,
As explained above, bogie mounted brake gap between brake block and
system from maintenance point of view is wheel (with brake block in released
exactly same as the standard air brake condition) be maintained at about 5
system except for brake cylinder, which mm. This will ensure that piston
are different than the existing system. stroke (without utilizing the slack
Therefore, to maintain the system, take up capacity) of brake cylinder
instructions contained in the Air Brake remained within the value of 32
System (chapter 4) will have to be mm.
followed in addition to those which are vii) Design of brake rigging has been
indicated in the maintenance manual for done in such a way that up to
brake cylinders supplied by wheel diameter of 839 mm. and
manufacturers. brake block in full worn condition,
607 SPECIAL PRECAUTIONS TO BE red paint mark on the adjusting
TAKEN DURING MAINTENANCE tube sub assembly will not appear
(indicating condition that piston
The maintenance of underframe unit has extended fully and
equipments and fittings should be done as requires resetting). However, if due
per underframe mounted air brake system. to some reasons, this mark appears,
Following special precautions must be worn brake blocks must be
taken to ensure proper working of the replaced by new ones. Failures to
bogie mounted brake system. observe this condition will result in
increased gap between wheel and
i) It shall be ensured that only high brake blocks. Procedure for
friction composition brake blocks
resetting is explained in the
‘K’ type are used with this maintenance manual of brake
arrangement. cylinder supplied by the
ii) It shall be ensured that levers of non- manufacturers.
AC coaches (13T bogies) are not
viii) Once the brake block has worn to
mixed with those on AC coaches
condemning limit (shown by the
(16T bogies) under any
mark on the block) it must be
circumstances.
replaced by a new one.
iii) It is very important to ensure that
curved profile pull rods (item ‘6’ of ix) The rocker from position of Brake
ICF Drg. No. T-3-2-802 which is Cylinder should be kept in
meant to be used for 13T bogies is horizontal axis of cylinder before
not intermixed or replaced with pull fitment.
rod (item 4) of ICF Drg. No.

Chapter 6, Page 5 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

x) Adequate size of pins and bushes 608f Dismantling


as indicated in the drawing of the
system must be used in the rigging i) Unscrew cross head and
to get effective working of the adjusting tube sub-assembly.
system.
ii) Loose jubilee clips and remove
xi) All flexible hose pipes should be dust excluder and bush.
tested in every POH.
iii) Admit compressed air in brake
cylinder, unscrew grub screw.
608 DESCRIPTION AND
Vent compressed air and
MAINTENANCE OF BOGIE
unscrew collar by using C-
MOUNTED BRAKE CYLINDERS
spanner. remove hand brake
(REFER RDSO SKETCH- 81200 &
trunion.
81204)
iv) Unscrew hex nuts M12 slowly.
608a Figure 6.3a & figure 6.3b (RDSO sketch. Please note that release spring
81200) gives the details of brake compressed with force of 60 kg.
cylinders and the part number list is Note: The release spring exerts
indicated in the table 6.2. severe force while dismantling
the unit, the front cover should
608b Detail of 203 mm Air Brake Cylinder be removed very carefully. The
(with slack adjuster) is given in figure 6.4 dismantling can not be done by a
(RDSO sketch-81204) single person. Atleast two
persons are necessary.
608c Hand Brake Attachment v) Remove front cover, release
On the Piston trunk of brake cylinder spring, piston trunk sub-
hand brake trunions are fitted whenever it assembly with trunion body and
is required. During the service application ratchet with adjusting screw.
the hand brake trunion does not move. vi) Remove split pin, pin and rocker
The maximum hand brake stroke required arm.
at the trunion corresponds to maximum vii) Remove allen bolts and piston
brake cylinder stroke. and piston trunk sub-assembly.
Please not that piston and piston
608d Re-Setting trunk sub-assembly are matched
A red paint mark on the Adjusting tube pair and are not interchangeable.
sub-assembly indicates that the piston unit Always put some identification
has extended over its full range and mark.
requires re-setting. The design of brake viii) Remove circlip, collar , ratchet
rigging unit is done in such a way that with adjusting screw, pawl, pawl
range of slack adjuster covers the life of spring, Plunger, turnion body,
brake blocks so that resetting and thrust washer.
replacing the brake blocks will be done at
ix) Remove Piston packing from
the same time. While keeping the
piston.
adjusting screw stationary, by turning the
adjusting tube sub-assembly in clock wise 608g Cleaning and Inspection
direction the distance between piston to
cross head is reduced to minimum level. Wash all the parts in suitable cleaning
The resetting of unit takes place at fluid and wipe them carefully. Inspect
position. pawls, Pawl housing ring, ratchet, tooth
rollers, roller plate, thrust washer for wear
608e Procedure for Re-setting and damage. Inspect threads of ratchet
with adjusting screw and adjusting tube
Hold the latch out of engagement with the for the possible damage. Replace packing.
resetting plate. The adjusting tube should Check all the springs for possible
be turned in clockwise direction by means corrosion and distortion. It is advisable to
of the lugs until it reaches the inner end. change the springs on every POH. Give
Then reengage the latch. all other parts a thorough visual inspection
to detect apparent defects. Replace worn
or damaged parts.

Chapter 6, Page 6 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

Chapter 6, Page 7 of 14

Maintenance Manual for BG ICF Coaches


A 9,10,11
3 6 7 8
2 4 5 12
14 15
1
13 18 19
16
32 21
20
24
28 17 23
22 25

29

30 19
26

18
31

52

50

51
61

47,48,49

Bogie Mounted Air Brake System


45,46
33 35 42
36,37,38 43,44
34
A 39 40,41,38

117.5
%%p0.5
CRS
L HEAD EYE
546 TO C OF CROSS

(CROSSECTION SHOWN IN HORIZONTAL PLANE TO SHOW

THE LOCATION OF ROCKER ARM AND BUSH/FILTER ON


THE SIDE OF CYLINDER.)

VIEW OF BRAKE CYLINDER SUPERSEDED BY:


INDIAN RAILWAY STANDARDS
FIGURE 6.3a
CORRECTED,ALTERNATIVE
4 - CD/8/2000 SIZE FOR ITEM 9 GIVEN 11/2000 ASSEMBLY DRAWINGS SUPERSEDES:
E.M.U. STOCK AND SELF GENERATING
AND DIMENSION 130
CHANGED TO 130%%P0.5mm
REFERENCE:- SCALE P MAIN LINE COACHES.

TOLERANCES ADDED ON
C
3 - CD/3/99 8/99 1:1
DIMENSION 204 CRS %%P 0.5 D SK SRIVASTAVA 203mm AIR BRAKE CYLINDER
T
2 - CD/35/98 TITEL CHANGED. 12/98 (WITH SLACK ADJUSTER)
J.S.
1 1,16 CD/24/98 VIEW CORRECTED. 8/98 FLOPY No. :-
R . D . S . O.
GROUP 1 2

ALT. ITEM AUTHY. DESCRIPTION DATE B.G. (C)


3 4 SKETCH-81200

Chapter 6, Page 7 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

58,37,38

57

56,11

%%p0.5
60

27
55
130

59
54

53 %%uNOTE:-

1. ITEM-17 WITH WASHER AND SPLIT PIN TO BE USED WHEN


HAND BRAKE IS NEEDED.

2. BRAKE CYLINDER SHOULD BE LEAK PROOF WITH TESTING


AIR PRESSURE 7 kg/sq.cm.

3. REFER RDSO SK-81057 FOR OTHER WORKING PARAMETERS.

+0.5
-0 204 CRS

%%USECTION A-A (FULL CROSSECTION OF CYLINDER SHOWN)

VIEW OF BRAKE CYLINDER SUPERSEDED BY:


CORRECTED,ALTERNATIVE INDIAN RAILWAY STANDARDS
4 - CD/8/2000 SIZE FOR ITEM 9 GIVEN 11/2000 ASSEMBLY DRAWINGS SUPERSEDES:
AND DIMENSION 130 E.M.U. STOCK AND SELF GENERATING
REFERENCE:- SCALE P MAIN LINE COACHES.

FIGURE 6.3b
CHANGED TO 130%%P0.5mm

TOLERANCES ADDED ON
C
3 - CD/3/99 8/99 1:1
DIMENSION 204 CRS %%P 0.5 D SK SRIVASTAVA 203mm AIR BRAKE CYLINDER
T
2 - CD/35/98 TITEL CHANGED. 12/98 (WITH SLACK ADJUSTER)
J.S.
1 1,16 CD/24/98 VIEW CORRECTED. 8/98 FLOPY No. :-
R . D . S . O.
GROUP 1 2

ALT. ITEM AUTHY. DESCRIPTION DATE B.G. (C)


3 4 SKETCH-81200

Chapter 6, Page 8 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

TABLE 6.2

Item Description & dimensions No. off Ref. Drg. Mtl. & Remarks
spec.
1 Cylinder Body 1 SK-81201 Item 1, 3,4 & 5
2 Piston 1 SK-81203 Item - 1
3 Piston packing 1 SK-81204 Item -10
4 Plunger 1 SK-81206 Item - 2
5 Circlip Light B22 1 - IS:3075 Galv.
6 Special Washer 1 SK-81206 Item-14
7 Plunger Spring 1 SK-81206 Item-18
8 Piston Trunk 1 SK-81204 Item-1 & 2
9 Tee bolt M12x35 4 - Galv.
Alternatively M12x45
10 Hex. head nut M12 4 - IS:1363 Galv.
11 Spring washer M12 type A 8 - IS:3063 Galv.
12 Dome cover 1 SK-81202 Item-1
13 Ratchet with adjusting screw 1 SK-81204 Item-9
14 Adjusting tube 1 SK-81204 Item-6, 7 & 8
15 Release Spring 1 SK-81206 Item-20
16 Guide bush 1 SK-81202 Item-2
17 Hand brake trunion 1 SK-81205 Item-12
18 Split pin φ5 x 40 3 - IS:549 Galv.
19 Washer M22 type -C 3 - IS:2016 Galv.
20 Slotted head grub screw 'C' 2 - IS:2388 Galv.
M6x6
21 Jubilee clip size-5 1 - Galv.
22 Dust excluder 1 SK-81204 Item-11
23 Latch 1 SK-81206 Item-3
24 Latch spring 1 SK-81206 Item-21
25 Ring 1 SK-81206 Item-23
26 Slotted Nut 7/8" B.S.W. 1 - Galv.
(20 mm high)
27 Shims for plunger As SK-81206 Item-16
required
28 Special washer 1 SK-81206 Item-12
29 Trunion Body 1 SK-81205 Item-1
30 Coller 1 SK-81206 Item-4
31 Circlip light A32 1 - IS:3075 Galv.

Contd… on next page

Chapter 6, Page 9 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

Item Description & dimensions No. off Ref. Drg. Mtl. & Remarks
spec.
32 Plug ½" B.S.P. 1 - Galv.
33 Solid Taper pin φ 2 x14 1 - IS:2393 Galv.
34 Plunger pin 1 SK-81206 Item-11
35 Rocker arm 1 SK-81206 Item-1
36 Rocker arm pivot pin 1 SK-81206 Item-10
37 Special washer 2 SK-81206 Item-9
38 Split pin φ 3.2x18 3 - IS:549 Galv.
39 Roller 2 SK-81206 Item-5
40 Rocker arm roller pin 1 SK-81206 Item-9
41 Washer 1 SK-81206 Item-5
42 Roller Plate 1 SK-81201 Item-2
43 Bush 1 SK-81202 Item-3
44 Filter 1 SK-81202 Item-4
45 Guide bar 1 SK-81204 Item-3
46 Snap Head rivet φ 2.5x8 2 - IS:2155 Galv.
47 Hex. head bolt M6x25 8 - IS:2155 Galv.
48 Hex. nut M6 8 - IS:1363 Galv.
49 Spring washer M6 type A 8 - IS:3063 Galv.
50 Bush 1 SK-81206 Item-17
51 Jubilee clip size 2 1 - Galv.
52 Cross head 1 SK-81203 Item-2
53 Circlip light B16 2 - IS:3075 Galv.
54 Special washer 2 SK-81206 Item-15
55 Pawl spring 2 SK-81206 Item-19
56 Alen screw ½" BSFx 2"x7/8" 4 - Galv
TD. length
57 Pawl housing ring 1 SK-81206 Item-6
58 Pivot pin 1 SK-81205 Item-3
59 Pawl 2 SK-81206 Item-8
60 Plunger 1 SK-81206 Item-7
61 Retaining nut 1 SK-81206 Item-24

Chapter 6, Page 10 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

63

Chapter 6, Page11of 14

Maintenance Manual for BG ICF Coaches


11 DRILL
A
3
%%C13 DRILL

5
+0
+0.5
- -0.1
3
69.9
%%C21

6
%%C20 = =
60%%d
2 3 4
5 %%c14 +0.5
-0

1x45 %% D
2 +0.1
-0.5
%%c82
5

=
%%c80

73
%%C52

+0.2

+0.2
-0. 5
2 3R

.5
3 R %%C47

% %c8 9 16 TP I (BSP)

+0
-

98 .5
1 02

1 08

13 4
+0. 5

+0.0
3 0.5

%% C89 .5-0.5
+
-

-
3R

7
C8
48 .5

%%
%% c95
04 3R
2 %
C1

-0.1
-0. 2

+0
%

+0

=
L)
MA
OR
306 0(N +0
c8 .5
%%
3R
59R
%%C14

1x45 % %D
+0.1
-

=
=
3
25 20 %%C13 DRILL +0.1
-0

10
16 SECTION-`AA' 13R

19
3
+0
120 52 = = -0.1
+0.5
- 333
13 73.1
A
9

18

%%c168
3R L
4 9 4 24 2.5
THIS MACHINING TO BE
52

25

% %C1 8
DONE AFTER BOLTING
4R 4R
PISTON(SK-81203,ITEM-1)
10
IN POSITION.
18

+0. 0
-0.1
X 74%%d

1 0.2 5

% %C4 0

%% C3 1 .5

% %C2 0

16
+0.05

%% C36 .5
+0.05 %%C171.45 -0
-0
+0.5

50
-0.0

+0.0
%%c35-0.02 3R %%C186.5
76

1X45%%D 1X45%%D DETAIL AT-`X'


+0.1
%%c44.5-
(ENLARGED)

% %C45
16

3X45%%D

16R
2 18
1 10

13
TEETH OF RATCHET ONLY TO
9

9.5
BE HEAT TREATED.

24
18 TEETH EQUI-SPACED
+0

35
(1) QUENCHING IN OIL FOR CORE
B 4 -0.1
130

46
REFINING (850%%DC BEFORE QUENCHING)
3 (2) HARDENING (760%%DC BEFORE
" , 2 START, 1/4" LEAD, 1/8" PITCH,
%%C1 1.5 1.5x45%%D 391

64
8 9 QUENCHING IN OIL)
WHIT. FORM THREAD. 0.4R HARDNESS HRC-50, CASE DEPTH 0.5mm. 463

%%
C4

3 %% d
4. 5 +0

. .
+0

X
R-48-88 GRADE-`C' OF CL.5.2.4.1

.
.
-0. -0.02
05 +0 0.8
-0. 01 3.2
R %% C5 HARDNESS: 70+5 SHORE `A'
-
%% C44
+0.0
% % C25. 31 -0. 05

3R
%%c95
1R

1.6 %%C98
49.2 34
% %C19. 05 - 0.13
+0

%%c103

ANNEXURE-'A'
10 PISTON PACKING 1 of Spec.C-K013
492

%%UNOTE:- 9 RATCHET WITH ADJUSTING SCREW 1 EN 353


%% C30

SECTION-`BB'
%% C2 5

IS:2062-92

Bogie Mounted Air Brake System


1. ALLOWABLE DEVIATION FOR DIMENSIONS WITHOUT SPECIFIED 8 ADJUSTING TUBE SECREWED END 1
(ENLARGED) TOLERANCES- `FINE' IS :2102.
Fe-410WA
B IS:2062-92
2. ITEM-9 SHOULD TRAVEL FREELY IN ITEM-6 7 RESETTING PLATE 1
501 Fe-410WA
3. STAMP `I.R.' OF SUITABLE SIZE ON EACH COMPONENT. ST.GR.CDS-6 OR
CDS-13,
86 SQ. 6 ADJUSTING TUBE 1
62 430 7 THE STAMPING SHOULD NOT INTERFERE IN THE WORKING BS-980-1955

6 REDUCE O/D OF TUBE BY 0.25 mm. OF THE COMPONENT.

.
5 DUST EXCLUDER 1

X.
.
.
21 WHERE MARKED THUS, & 4. ALTERNATIVELY PISTON FOLLOWER MAY BE CAST IN SINGLE PIECE,
3 MATERIAL SHALL CONFORM TO GRADE SG 400/18 OF IS:1865-91 4 SNAP HD. RIVET %%C2.5X8 2 GALV.
TO BE PAINTED RED. IS:2155
13 533
7
IS:2062-92
3 GUIDE BAR 1
Fe-410WA
STEEL
15
2 PISTON TRUNK 1 HEAVY
+0.0
6
DESCRIPTION DIMENSION `L' IS:1239-90 PART-1
%% C36 .5 +0.1

-
SEE NOTE
%% C8

+0.1

IS:2062-92
-
%% c7 /8" 9T PI

-0.5

1 PISTON FOLLOWER 1
+0

WITH HAND BRAKE Fe-410WA No.4


-

102
%%c208 No. WT. OF
50 ITEM DESCRIPTION & DIMENSIONS REF. DRG. &
MTL. SPEC. REMARKS
WITHOUT HAND BRAKE OFF ONE kg.
%%c172
RDSO/SK-81200
SUPERSEDED BY: INDIAN RAILWAY STANDARDS
%%c168
ASSEMBLY DRAWINGS SUPERSEDES: EMU STOCK SELF GENARATING
1

%%C5
3"
DIA 2 START;1 1/4" LEAD, REFERENCE:- SCALE P MAIN LINE COACHES
19

8
4.5 6
C
2
1/8" PITCH WHITWORTH THREADS 3 1 CD/8/2000 NOTE 4 ADDED. PISTON,PACKING
PROFILE MODIFIED.
11/2000 1:1 DETAILS OF 203 mm. AIR
D SK.SRIVASTAVA
8 8
2 - CD/35/98 TITLE CHANGED 12/98
2:1
T
BRAKE CYLINDER
4 Nos-%%C12 HOLES
(WITH SLACK ADJUSTER)
FIGURE 6.4
4-%%c15 mm. DRILL
EQUISPACED FOR 1. MATERIAL SPEC. CHANGED J.S.
PLUG WELDING %%c171.45 1 10 CD/24/98 2. DIMENSION 182 CHANGED TO 8/98
FLOPY No. :- GROUP 1 2
186.5, TOLERANCE CORRECTED R . D . S . O.
%%C186.5
ALT. ITEM AUTHY. DESCRIPTION DATE B.G. (C)
3
SKETCH-81204
%%c191

%%c203.2

Chapter 6, Page 11 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

insert rocker arm pivot pin and


608h Assembly
washer and lock it with split pin.
After cleaning and inspection of all the
parts and before re-assembly apply ix) Tighten roller plate with front
uniform layer of grease Esso Becon 2 on cover with 8 Nos. hex. bolts
all the moving parts. Grease cylinder body spring washers and hex. nuts .
and piston packing liberally with Esso
Becon 2. x) After applying grease Esso
Becon 2 on all the moving parts,
i) Put washer and insert ratchet with
piston packing, cylinder body,
adjusting screw in turnion body.
insert the above sub-assembly
Put two collars in the groove of
(consisting of piston trunk sub-
ratchet with adjusting screw and
assembly, piston in cylinder
lock it with circlip.
body.
ii) Insert spring retaining cup plunger
xi) Place release spring on piston
spring, washer and internal circlip
trunk sub-assembly.
with circlip plier in the longer side
of trunion body.
xii) Place front cover in required
position A,B,C on the release
iii) Insert pawl (ensure proper
spring and compress the spring
position) pawl spring in the square
with a force of 60 kg
hole of the trunion body and lock it
approximately. Tighten front
with strip. Bend the ends of the
cover with body with 4 Nos. hex.
strip.
head bolts, spring washer and
hex. nut with a tightening torque
iv) Place pawl housing ring on
of 200 kg cm.
trunion body so that it pivots on
the pivot pin of turnion body.
xiii) Place hand brake trunion sub-
Check that tooth of pawl housing
assembly on piston trunk sub-
ring matches with teeth of ratchet
assembly. Screw collar on piston
with adjusting screw. If required,
trunk sub-assembly and screw in
tooth of pawl housing ring may
grub screw. Put latch spring and
be filed.
latch in cross head. Insert ring in
the latch.
v) Insert plunger pin with required
No. of shims. Insert this sub-
xiv) Put cross head sub-assembly on
assembly in the shorter side of
adjusting tube sub-assembly
trunion body.
consisting of adjusting tube,
adjusting tube screwed and
vi) Place the above sub-assembly
resetting plate). Lock cross head
(consisting of all the above parts)
with adjusting tube sub-assembly
on piston (ensure proper position
by washer, hex. slotted nut and
as indicated in the assembl y
split pin.
drawing. Place piston trunk sub-
assembly on it and lock it with
xv) Clamp dust excluder on bush
piston by 4 Nos. allen screw and
with jubilee clip and insert
spring washer with a tightening
adjusting tube sub-assembly in
torque of 200 kg.cm. Insert
bush. Screw adjusting tube sub-
packing on piston.
assembly in bush. Screw
adjusting tube sub-assembly on
vii) Insert rocker arm roller pin in
ratchet with adjusting screw till it
roller and then insert it in rocker
reaches its dead end.
arm. Insert roller and washer on
the roller side of roller pin and
xvi) Clamp dust excluder on collar
lock it with split pin.
with jubilee clip.
viii) Place rocker arm sub-assembly
xvii) Screw 1/2” plug with O-ring in
within two shackles of piston
body.
trunk ring sub-assembly and

Chapter 6, Page 12 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

608i Testing Procedure TEST NO. 2 - OPERATION:


The testing procedure of brake cylinder is A. Full Stroke
given below
§ Close cock 3 and open cock 2.
PREPARATION FOR TEST § Observe the full stroke of the piston.
§ This must be within ± 1.0 mm of the
The test layout is shown in the attached maximum stroke value.
figure 6.5 (RDSO's Sk 98108). A special
pin will be required to locate the cross B. Take-up Stroke
head between the angle iron slots.
§ Close cock 2 and open cock 3 to
During testing cock 2 must be opened
exhaust the cylinder pressure to zero.
slowly whenever the cock is used to
admit air under pressure to the cylinder. § Close cock 3.
Connect the air supply to the cylinder § Open cock 2 and allow the piston to
body. Commence with all cocks closed move out slowly until the operating
pawl is heard to “click over” then
TEST NO. 1 Leakage: close cock 2.
§ Measure the take up stroke .
Open Cock 1 to charge the MR to 7 § This must be 32 mm for main line self
kg/cm2 pressure generating coaches of 95 mm stroke.
Open Cock 2 to charge the cylinder 0.7 § Close cock 2 and open cock 3.
kg/cm2 pressure
§ As the cylinder returns to release the
locking pawl must be heard to click into
The piston stroke must be limited to
position
32mm, wait for one minute for
settlement and there must be no drop in Note:
pressure shown in the leakage volume
gauge for a further minute. Also observe 1. Operate the piston at full stroke at
that leakage does not exceed 0.1 kg/cm2 least 18 times to test all ratchet teeth.
in 10 minutes. 2. Observe that the adjuster operates at
each release and the adjusting tube
Repeat this test with the cylinder charged and cross head being ‘inched’ out
to 3.8 kg/cm2 pressure and with cock 3 along the stroke.
closed limiting the maximum piston
stroke to 95 mm. Observe that the 3. The movement of the Piston must be
leakage does not exceed 0.1 kg/cm2 in 10 smooth without any
minutes. tendency to stick at any part of the
stroke.
Open Cock 3 to exhaust the cylinder
pressure to zero.
LEAKAGE VALUME GAUGE
SLOTTED ANGLE SCALE 0.5 MM

3
UNION

2
BED PLATE
SCREW DOWN
COCK-2
AIR SUPPLY
1 MAIN RESERVOIR

TEST LAYOUT FOR BRAKE CYLINDER


WITH BUILT IN SLACK ADJUSTER
FIGURE 6.5

Chapter 6, Page 13 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

C. Take-up Length (without Quick Resetting requirement, in the plunger pin so


Gear) that spring Dowel pin Ö2X14 easily
locks the plunger and plunger pin by
§ Close cock 2 and open cock 3. inserting the dowel pin in the holes.

§ Remove the pin from the cross head and iii) At the time of re-assembly check
unscrew the adjusting tube until the red that the tooth of pawl housing ring
resetting mark on the adjusting Tube is matches with the teeth of Ratchet
visible. with adjusting screw. The pawl
housing ring must go smoothly
§ Disengage resetting latch and screw in inside the teeth of Ratchet. If it is not
the Adjusting Tube. matching then the notch portion of
§ Re-engage resetting latch. the tooth of pawl housing ring
should be filed till it matches with
§ Check that the Dust Excluder Collar is the teeth of Ratchet screw.
free and does not twist when the
Adjusting Tube is being rotated. iv) Before final assembly of piston and
piston trunk sub-assembly ensures
§ Close cock 1 and open cock 2. that the threads of adjusting tube
§ Close all cocks when the system is at (turns in clock wise direction)
atmospheric pressure. smoothly matches with the threads
of Ratchet screw.
D. Take-up Length (With Quick Resetting Gear)
v) Before fixing the front cover in the
§ Close cock 2 and open cock 3. cylinder body check visually the red
§ Remove the pin from the cross head and paint mark appears in the Adjusting
turn the resetting screw until the red tube. If it is not visible then repaint.
resetting mark on Adjusting tube is 608k Special Tools
visible.
Table 6.3
§ Screw in the Adjusting Tube with the
resetting screw.
§ Check that the Dust Excluder Collar is Description No. off
free and does not twist when the
Adjusting tube is rotated . Close cock 1 Ball peen hammer 1/2 kg 1
and open cock 2.
Screw driver big 1
§ Close all cocks when the system is at
atmospheric pressure Screw driver small 1
608j Important Instructions for Double end spanner to 1
Reassembling the Brake Cylinder at the tighten/loosen M6 nut
Workshops
Press machine to apply 60 kg force 1
for assembling front cover with
i) While fixing the Roller plate with body
front cover 4 pairs of hex. Bolts
M 6x25 along with spring washer A6 Scriber to remove Split pin 1
and hex nut M6 are required. Before
fixing the roller plate, the inner 5 mm Allen key 1
surface of front cover should be
checked for perfect plane. At the Torque wrench with 200 kg cm 1
time of fixing the roller plate with
front cover 2 Nos. of spring washers
*****
are kept inside in between them (one
each side) in first two bolts, so that
the rollers can move smoothly in the
cover plate in angular position.
ii) While matching the holes of plunger
and plunger pin number of shims are
added (say 2 or 3) as per the

Chapter 6, Page 14 of 14

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