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Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
CHAPTER 6
Chapter 6, Page 1 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
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
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
365
B
MAX. WORKING MOVEMENT
% % p0 . 5
M A X.
31
204
MA X.
47 . .
=
M A X.
47
M AX.
31
RESETTING LATCH
Chapter 6, Page 2 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
Chapter 6, Page 3 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
INLET PLUG
compressed air is
supplied from loco
2
3
C
4
8
7
10
6 9
b
Chapter 6, Page 4 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
Chapter 6, Page 5 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
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
29
30 19
26
18
31
52
50
51
61
47,48,49
117.5
%%p0.5
CRS
L HEAD EYE
546 TO C OF CROSS
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
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:-
+0.5
-0 204 CRS
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
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.
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
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
% %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
SECTION-`BB'
%% C2 5
IS:2062-92
.
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
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
Chapter 6, Page 12 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
3
UNION
2
BED PLATE
SCREW DOWN
COCK-2
AIR SUPPLY
1 MAIN RESERVOIR
Chapter 6, Page 13 of 14
Hindi Contents
Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System
§ 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