IRSA Slack Adjusters Maintenance Manual
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Questions and Answers

What is the first step in checking the slack adjuster?

  • Apply the air brake fully
  • Ensure the control lever stop is in place (correct)
  • Confirm that the hand brake is fully released
  • Rotate the slack adjuster several times

    • What indicates that the slack adjuster is functioning normally after initial use?

  • Normal piston stroke after two or three applications (correct)
  • Decreased clearance after multiple applications
  • Consistent clearance between brake block and wheel tread
  • Increased piston stroke after the first application

    • What should be done to ease the brake rigging after installing the slack adjuster?

  • Rotate the slack adjuster multiple times
  • Ensure the brake pressure is correct and make several applications (correct)
  • Release the hand brake and brake completely
  • Make two or three applications at high pressure

    • What should be observed in the piston stroke after applying the air or hand brake fully for the first time?

    <p>It should be short</p> Signup and view all the answers

    Which statement is true regarding the clearance between the brake block and wheel tread during operation?

    <p>It increases after initial brake application</p> Signup and view all the answers

    What is the first step in assembling the slack adjuster?

    <p>Unlock the washer and screw out the adjuster ear</p> Signup and view all the answers

    What is the specified dimension for the adjuster spindle to extend from the slack adjuster?

    <p>585 mm</p> Signup and view all the answers

    What is the preferred method for joining the pull rod with the adjuster spindle?

    <p>Electric flash butt welding</p> Signup and view all the answers

    What should be done if electric flash butt welding is not possible?

    <p>Prepare both ends by tapering to an angle of 30 degrees</p> Signup and view all the answers

    Which of the following is a precaution to take while welding the pull rod?

    <p>Ensure the centre lines of both rods lie on one common centre line</p> Signup and view all the answers

    What should be provided over the threaded portion of the adjuster spindle during welding?

    <p>A protective cover</p> Signup and view all the answers

    What is the purpose of checking the brake rigging when fitting the IRSA-600 slack adjuster?

    <p>To ensure proper brake performance</p> Signup and view all the answers

    What should be done if vacuum/air pressure is not available?

    <p>Apply the hand brake fully.</p> Signup and view all the answers

    What does it indicate if load tie rod pins are found to be tight?

    <p>The adjustment is wrong.</p> Signup and view all the answers

    What is the recommended 'A' dimension for BOXN, BCN, and BRN type wagons?

    <p>70 + 2 mm</p> Signup and view all the answers

    Which step should be taken to adjust the empty tie rod after ensuring the brake rigging is fully released?

    <p>Rotate the sleeve nut to shorten the empty tie rod.</p> Signup and view all the answers

    What should be done after rotating the sleeve nut in the direction shown in Fig.6?

    <p>Carry out a test as outlined in para 3.3.1.</p> Signup and view all the answers

    What action is required after adjusting the empty tie rod according to the specified procedures?

    <p>Tighten lock nuts with washers.</p> Signup and view all the answers

    Which dimension should be checked for BFKI wagons?

    <p>60 + 2 mm</p> Signup and view all the answers

    What is the purpose of checking the slack adjuster during inspections?

    <p>To confirm the adjustment is within accepted ranges.</p> Signup and view all the answers

    In what scenario should the horizontal levers be inspected for mechanical damage?

    <p>After the brake rigging is fully released.</p> Signup and view all the answers

    What is the proper action to take if the test fails but the load tie rod pins are still tight?

    <p>Replace the empty load device operating pawl</p> Signup and view all the answers

    How much does one complete rotation of the control rod alter the 'A' dimension?

    <p>2 mm</p> Signup and view all the answers

    Which step must NOT be done when renewing brake blocks?

    <p>Adjust the 'A' dimension</p> Signup and view all the answers

    What should be done to ensure clearance between the brake block and the wheel tread?

    <p>Rotate the slack adjuster</p> Signup and view all the answers

    What is the first step to adjust the 'A' dimension?

    <p>Take out the nut of the anchor pin</p> Signup and view all the answers

    What is indicated by applying the brake three or four times after renewing brake blocks?

    <p>Automatic adjustment of rigging</p> Signup and view all the answers

    Which statement is true regarding the adjustment of the 'A' dimension?

    <p>It requires shortening or lengthening of the control rod</p> Signup and view all the answers

    What action should be taken if the control rod needs to increase the 'A' dimension?

    <p>Turn the control rod clockwise</p> Signup and view all the answers

    If the load device operating pawl is broken, what is the immediate corrective action?

    <p>Replace the empty load device</p> Signup and view all the answers

    After changing brake blocks, what may happen if the brake is not applied three or four times?

    <p>Adjustment of the 'A' dimension may not occur</p> Signup and view all the answers

    What should be observed after applying the brake fully for the first time?

    <p>Notice higher piston stroke after the first application</p> Signup and view all the answers

    After adjusting the slack adjuster, how can one tell if the pay-in is satisfactory?

    <p>The clearance increases after multiple applications</p> Signup and view all the answers

    What indicates a satisfactory pay-out during the testing of the slack adjuster?

    <p>Decreased clearance between brake block and wheel tread</p> Signup and view all the answers

    Which step is not necessary for adjusting the 'A' dimension of the slack adjuster?

    <p>Remove pins or lever attached to the slack adjuster</p> Signup and view all the answers

    How many times should the slack adjuster be rotated to observe a change in clearance during testing?

    <p>Two to three times</p> Signup and view all the answers

    What is the correct method to adjust the 'A' dimension of the slack adjuster?

    <p>Loosen the lock nuts and move the adjuster ear to desired position</p> Signup and view all the answers

    What is indicated if there is a short piston stroke after the first application?

    <p>The slack adjuster is functioning as expected</p> Signup and view all the answers

    What is the primary purpose of ensuring correct brake rigging before slack adjuster fitment?

    <p>To establish proper movement and function of slack adjuster</p> Signup and view all the answers

    What occurs to the clearance between the brake block and wheel tread after rotating the slack adjuster two or three times?

    <p>It gradually increases</p> Signup and view all the answers

    What action is required if the load device operating pawl is determined to be broken?

    <p>Replace the empty load device</p> Signup and view all the answers

    What should be ensured after installing new brake blocks and applying the brake several times?

    <p>That the brake block clearance returns to normal</p> Signup and view all the answers

    What should NOT be done when renewing brake blocks according to the procedures described?

    <p>Adjust the slack adjuster</p> Signup and view all the answers

    Which of the following is essential for achieving the specified 'A' dimension?

    <p>Lengthening or shortening the control rod appropriately</p> Signup and view all the answers

    What is the primary function of a slack adjuster in brake rigging?

    <p>To enable automatic adjustment of slack between the brake block and the wheel.</p> Signup and view all the answers

    Which of the following steps is part of the maintenance process for a slack adjuster?

    <p>Performing cleaning and inspection of the slack adjuster.</p> Signup and view all the answers

    Which aspect of the slack adjuster should be checked to ensure it is functioning correctly?

    <p>The wear limits of its components.</p> Signup and view all the answers

    During maintenance, what is the correct procedure following the dismantling of the slack adjuster?

    <p>Conduct cleaning and inspection of parts.</p> Signup and view all the answers

    What action should be taken if excessive wear is found on the slack adjuster during inspection?

    <p>Schedule immediate replacement of the adjuster.</p> Signup and view all the answers

    In the context of slack adjuster assembly, what is necessary when joining the pull rod to the adjuster spindle?

    <p>Employing electric flash butt welding if necessary.</p> Signup and view all the answers

    What is the significance of observing the 'A' dimension in the context of slack adjuster operation?

    <p>It indicates the efficiency of brake application.</p> Signup and view all the answers

    What happens when the slack becomes too large during brake application?

    <p>The head pushes the barrel, increasing the distance from the adjuster.</p> Signup and view all the answers

    During the brake application, which component locks against the left-hand end of the barrel?

    <p>Nut 35.</p> Signup and view all the answers

    What occurs immediately after the brake is released if slack is too small?

    <p>Nut 35 and barrel rotate towards the head until contact.</p> Signup and view all the answers

    Which operational issue arises if the slack adjuster does not function correctly after initial use?

    <p>Nut 36 will remain static, failing to adjust the slack.</p> Signup and view all the answers

    What would be the effect of the control rod head touching the barrel at the correct slack position?

    <p>No adjustments will occur until the next brake application.</p> Signup and view all the answers

    What role does the spring 21 play when the brake is released?

    <p>It initiates the lengthening of the slack adjuster.</p> Signup and view all the answers

    In what condition is the slack adjuster assembled before installation?

    <p>With all components individually unpacked.</p> Signup and view all the answers

    What is the purpose of clutch B in the slack adjuster operation?

    <p>To facilitate the rotation of nut 36 on the spindle.</p> Signup and view all the answers

    What adjustment occurs if the control rod needs to decrease the separation known as 'A' dimension?

    <p>The control rod is pulled to shorten its reach.</p> Signup and view all the answers

    What should be done to the adjuster spindle before inserting it through the spindle sleeve?

    <p>Screw out the safety collar</p> Signup and view all the answers

    What is the correct angle for tapering the ends of pull rods if electric flash butt welding is not an option?

    <p>30 degrees</p> Signup and view all the answers

    During the assembly process of the slack adjuster, what is the correct dimension 'e' that the spindle must extend to?

    <p>585mm</p> Signup and view all the answers

    Which of the following precautions should be taken while welding the pull rod?

    <p>Align the centre lines of both pull rods</p> Signup and view all the answers

    What should be ensured regarding the brake rigging before fitting the IRSA-600 slack adjuster?

    <p>It must be inspected for operational safety</p> Signup and view all the answers

    What is the purpose of providing a protective cover over the threaded portion of the adjuster spindle during welding?

    <p>To prevent molten metal from damaging threads</p> Signup and view all the answers

    What is the maximum allowable dimension for the adjuster spindle extension for IRSA-450 slack adjuster?

    <p>375mm</p> Signup and view all the answers

    What adjustment must be made after assembling the safety collar and spring dowel sleeve on the adjuster spindle?

    <p>Rotate the spindle anticlockwise to dimension 'e'</p> Signup and view all the answers

    What is the main reason for checking the empty load device when fitting the slack adjuster?

    <p>To confirm that the brake rigging operates correctly</p> Signup and view all the answers

    After completing the assembly of the slack adjuster, which step must be repeated multiple times for optimal performance?

    <p>Apply the brake fully</p> Signup and view all the answers

    What dimension should 'A' be for BOX~ BCX, BCXC Ill, and BTPaL wagons?

    <p>50 + 2 mm</p> Signup and view all the answers

    Which of the following indicates that the adjustment of load tie rod pins is incorrect?

    <p>If rod pins are tight</p> Signup and view all the answers

    Which procedure should be followed immediately after ensuring the brake rigging is fully released?

    <p>Inspect the condition of the tie rods</p> Signup and view all the answers

    What should be observed regarding the horizontal levers during the inspection process?

    <p>They should move freely without obstruction</p> Signup and view all the answers

    What is the effect of rotating the sleeve nut as indicated in Fig.6?

    <p>It shortens the empty tie rod</p> Signup and view all the answers

    After adjusting the slack adjuster, what is the next critical step to confirm proper functioning?

    <p>Carry out a test as defined in the manual</p> Signup and view all the answers

    What should be avoided during the adjustment process if electrical welding is not an option?

    <p>Mechanical fastening of parts</p> Signup and view all the answers

    What action should be taken if the sleeve nut is tampered with?

    <p>Conduct a complete system inspection</p> Signup and view all the answers

    Which of the following is true about the adjustment of the sleeve nut in relation to the 'LIVE LEVER'?

    <p>The nut should stop rotating before the lever starts moving</p> Signup and view all the answers

    If adjustments result in a short piston stroke after initial application, what could this indicate?

    <p>The brake is over-adjusted</p> Signup and view all the answers

    What should be done first when checking the slack adjuster?

    <p>Ensure the brake rigging is fully released</p> Signup and view all the answers

    If load tie rod pins are found to be tight, what does it suggest?

    <p>The adjustment is incorrect due to tampering</p> Signup and view all the answers

    What is the 'A' dimension specified for BOXN type wagons?

    <p>70 + 2 mm</p> Signup and view all the answers

    What action must be taken before rotating the sleeve nut to adjust the empty tie rod?

    <p>Ensure horizontal levers can move freely</p> Signup and view all the answers

    What indicates the need to stop rotating the sleeve nut while adjusting the tie rod?

    <p>When the end of the 'LIVE LEVER' starts moving</p> Signup and view all the answers

    What is a common consequence of not applying brakes several times after changing brake blocks?

    <p>Insufficient clearance between the brake block and wheel tread</p> Signup and view all the answers

    Which component’s condition must be checked alongside the slack adjuster during maintenance?

    <p>Tie rods and sleeve nut</p> Signup and view all the answers

    Which measurement is relevant when checking the tie rod during adjustments?

    <p>'A' dimension for various wagon types</p> Signup and view all the answers

    What should be done with lock nuts after adjusting the empty tie rod?

    <p>Tighten lock nuts with washers</p> Signup and view all the answers

    What should be the orientation of the spindle when inserting it through the spindle sleeve?

    <p>Clockwise until it comes out through the adjuster tube</p> Signup and view all the answers

    What dimension should the spindle extend to after rotating it anticlockwise?

    <p>375 ~ 25mm</p> Signup and view all the answers

    What is the recommended method for joining the pull rod to the adjuster spindle?

    <p>Using electric flash butt welding</p> Signup and view all the answers

    What is essential to ensure for proper functioning of the slack adjuster?

    <p>Brake rigging is operational and correctly aligned</p> Signup and view all the answers

    Which precaution should be taken during the welding of pull rods?

    <p>Provide a protective cover over the threaded portion of the adjuster spindle</p> Signup and view all the answers

    What is the purpose of applying the air brake or hand brake after the installation of the slack adjuster?

    <p>To establish the normal piston stroke after initial application</p> Signup and view all the answers

    What should the pull rod's end look like for welding, according to the alternative method?

    <p>Tapered to an angle of 30 degrees</p> Signup and view all the answers

    How does the clearance between the brake block and wheel tread change after rotating the slack adjuster two or three times?

    <p>It decreases as the slack adjuster is rotated</p> Signup and view all the answers

    Why is checking the brake rigging important when fitting the IRSA-600 slack adjuster?

    <p>To guarantee that brakes function properly</p> Signup and view all the answers

    What should be observed about the piston stroke after the first application when the hand brake is fully applied?

    <p>It will exhibit a short stroke initially</p> Signup and view all the answers

    What must be ensured before performing brake applications to ease the rigging after slack adjuster installation?

    <p>The whole rigging must be in a fully released position</p> Signup and view all the answers

    What is indicated if the slack adjuster's pay-out is not satisfactory after testing?

    <p>The installation of the slack adjuster is incorrect</p> Signup and view all the answers

    What should be done after adjusting the control rod to change the 'A' dimension?

    <p>Tighten the lock nut on the anchor pin.</p> Signup and view all the answers

    What action must NOT be taken during the renewal of brake blocks?

    <p>Adjust the 'A' dimension at the time of renewal.</p> Signup and view all the answers

    How is the required movement of the control rod achieved?

    <p>By turning the control rod in the specified direction.</p> Signup and view all the answers

    What is the impact of one complete rotation of the control rod on the 'A' dimension?

    <p>It alters the 'A' dimension by 2mm.</p> Signup and view all the answers

    What must be done if load device operating pawl is found to be broken?

    <p>Replace the load device.</p> Signup and view all the answers

    What procedure is necessary after installing new brake blocks?

    <p>Apply the brake three or four times.</p> Signup and view all the answers

    What happens if the control rod needs to be shortened?

    <p>The control rod itself must be physically shortened.</p> Signup and view all the answers

    What should be ensured regarding the lock nut after adjusting the control rod?

    <p>It must be tightened after adjustment.</p> Signup and view all the answers

    What indicates the load tie rod pins are still found tight after a test failure?

    <p>The empty load device operating pawl may be broken.</p> Signup and view all the answers

    What is the effect of pulling the control rod too far?

    <p>It might increase the 'A' dimension excessively.</p> Signup and view all the answers

    What observation should be made after applying the brake or vacuum brake fully for the second time?

    <p>Piston stroke will be normal</p> Signup and view all the answers

    Which step should be taken to adjust the 'A' dimension of the slack adjuster?

    <p>Move the adjuster ear to increase or decrease the dimension</p> Signup and view all the answers

    What will happen to the clearance between the brake block and wheel tread after rotating the slack adjuster two or three times?

    <p>Clearance will decrease</p> Signup and view all the answers

    What is a key indicator that indicates satisfactory pay-in during testing?

    <p>High piston stroke followed by stabilization</p> Signup and view all the answers

    How should the slack adjuster be tested after the installation is complete?

    <p>By applying the brake fully multiple times</p> Signup and view all the answers

    What does a short piston stroke after the first application suggest?

    <p>It indicates improper movement of the slack adjuster</p> Signup and view all the answers

    What is the main purpose of ensuring the brake rigging is working properly before installing the slack adjuster?

    <p>To ensure accurate adjustments can be made</p> Signup and view all the answers

    What is the correct action to take if the slack adjuster needs to be adjusted?

    <p>Use a wrench to loosen the lock nuts before adjustment</p> Signup and view all the answers

    What indicates if the load tie rod pins are functioning properly during inspection?

    <p>They should be tight and not move</p> Signup and view all the answers

    What additional step is required after adjusting the slack adjuster successfully?

    <p>Tighten all nuts and lock nuts again</p> Signup and view all the answers

    Study Notes

    Maintenance Manual

    • This document is a maintenance manual for IRSA-600 and IRSA-600J type slack adjusters used on freight stocks, and IRSA-450 slack adjusters used on coaching stock of Indian Railways.
    • Issued by Research Designs & Standards Organisation, Ministry of Railways, Lucknow-226011.
    • Document date is September 1998.

    Contents

    • The manual outlines various sections: introduction, principle of operation, installation, maintenance, inspection of parts and wear limits.
    • Each section contains a list of subtopics and corresponding page numbers.
    • These subtopics detail procedures for assembling and maintaining slack adjusters. Includes numerous diagrams and figures.

    Introduction

    • The manual explains slack adjusters as devices in brake rigging used for automatic slack adjustment between brake blocks and wheels.
    • This specific manual handles IRSA-600, IRSA-600J, and IRSA-450 types.

    Principle of Operation

    • Control distance "A" between control rod head 26 and barrel 22 indicates correct slack.
    • If slack is correct, head 26 contacts barrel 22 when brake is applied.
    • Increased slack results in head 26 pushing the barrel, adjusting the slack.
    • When brakes are released, the adjuster is re-adjusted to correct slack. This adjustment is facilitated by a clutch and spring mechanism.

    Installation

    • The manual details procedures for assembling slack adjusters. These include:
      • Disconnecting and removing parts,
      • Assembling parts,
      • Connecting parts,
    • Additional step-by-step instructions, figures and diagrams to aid in assembly and installation. Includes specific figures for different types of slack adjusters.
    • Various procedures are detailed, including tasks for assembling components, using tools & techniques for specific slack adjuster types

    Maintenance

    • The maintenance section details procedures like dismantling, cleaning, inspection, lubrication, reassembling, and testing.
    • Procedures include checking various components and specific measurements, including 'A' dimension.
    • Tests for empty/loaded conditions on wagons and coaches are detailed.

    Diagrams and Figures

    • Numerous figures and diagrams illustrate essential components, procedures, and measurements throughout the manual.
    • These diagrams are crucial for understanding and implementing maintenance tasks.
    • Includes figures for specific slack adjuster types, component assembly & detailed illustrations and figures for various testing setups.
    • Figures showing different parts and procedures are included

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    Indian Railways Maintenance Manual PDF

    Description

    This quiz covers the maintenance manual for IRSA-600, IRSA-600J, and IRSA-450 slack adjusters used in Indian Railways. It includes sections on operational principles, installation, maintenance procedures, and inspection criteria. Test your knowledge on the specific maintenance procedures required for these vital components in railway systems.

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