Indian Railways Maintenance Manual PDF

G92 SEPT.98· J MAINTENANCE MANUAL FOR IRSA-600 & IRS~~600J TYPE SLACK ADJUSTERS.. , j FREIGHT STOCKS AND JR.SA-4...

G92 SEPT.98· J MAINTENANCE MANUAL FOR IRSA-600 & IRS~~600J TYPE SLACK ADJUSTERS.. , j FREIGHT STOCKS AND JR.SA-450. SLACK ADJUSTER. USED·. ON COACIHING Sl'OCK OF... Issued By:- Research Designs & Standards Organisation - --: I\fini~t.rY.. Of.Railways. LUCKNOW-226011 0000000539  CONTENTS Sr.No. DESCRIPTION PAGE 1. INTRODUCTION 1. PRINCIPLE OF OPERATION 1. INSTALLATION 2 3.1 PREPARATION FOR ASSEMBLY ,.,.(- 3.2 JOINING PULL ROD WITH ADJUSTER SPINDLE 2 3.3 FITMENT OF IRSA-600 SLACK ADJUSTER ON 2 TO 5 ""lAGON & CHEC~:: I NG 3.4 FITMENT OF IRSA-600J SLACK ADJUSTER 5 TO 7 ON WAGON & CHECKING 3.5 FITMENT ON COACHES & CHECKING 7 TO 8 4. MAINTENANCE 8 4.1 DISMANTLING 9 4.2 CLEANING AND INSPECTION 10 4.3 LUBRICATION 10 4.4 REASSEMBLING 10 TO 12 4.5 TESTING ON TEST RACK 12 4.6 TESTING IN BRAKE RIGGING 13 4.7 PAINTING 13 5. INSPECTION OF PARTS 14 TO 16 6. WEAR LIMITS 16 TO 18 7. GENERAL 18  = I"IAINTENANCE tIANUAL EQB. !B§B. ~ &: IRSA-6OOJ SLACK ADJUSTER ~ Qt! FREIGHT STOCK AND IRSA-45Q SLACK ADJUSTERS Y§§!. ON COACHINg STOCK OF INDIAN RAILWAYS 1 INTRODUCTION Slack adjuster is a device provided in the brake rigging for automatic adjustment of slac~ between brake block and wheel. This pamphlet deals with the operation, installation and maintenance of IRSA-600 & IRSA-600J type slack adjuster used on freight stock and IRSA-4~O type Slack Adjusters used on coaching stock. 2. PRINCIPLE OF OPERATION (Fig.!) Control distance 'A' measured between control rod head 26 and barrel 22 when the brake is fully released corresponds to the correct slack. If the slack is correct~ as the brake is applied, head 26 touches barrel 22 at the moment when the brake shoes start to apply against the wheel and no adjustment will then take place. If the slack becomes too large, as the brake is applied, head 26 pushes the barrel 22 and at the moment when the brake shoes apply, the distance between barrel 22 and adjuster ear 28 is increased by an amount corresponding to the excess of slack. Clutch B is released and leader nut 35 follows the position of barrel 22~ rotating on spindle 23 to remain in contact with the left hand end of the barrel. When the brake is released, nut 35 is locked against the left hand end of barrel 22 and spring 21 causes adjuster nut 36 to rotate on spindle 23 towards nut 35. This movement of nut 36 on spindle 23 shortens the slack adjuster and thus adjusts the slack to its correct valUe. If the slack becomes too small, ~he first subsequent brake application releases clutch C and causes nut 35 and barrel 22 to rotate towards head 26 until stopped by it. The distance between nuts 36 and 35 has been shortened by an amount corresponding to the deficiency of slack> At the start of next brake application, nut 35 is locked in its new position on spindle 23 and pay-out spring 11 pushes nut 36, rotating on the spindle until normal distance between the two nuts have been restored. The slack adjuster is in this way lengthened and the slack adjusted to its correct value. 3 0000030540.. 3.. INSTALLATION 3.1 PREPARATION [F SLACK ADJUSTER Fmt ASSErIBLY The slack adjusters are some times supplied with spindle packed separately. Therefore~ before the installation, the slack adjusters are to be assembled. The following procedure shall be followed for assembling the slack adjuster:.1 Unlock the washer and screw out the adjuster ear (See Fig.2) Take out the spring dowel sleeve and screw out safety collar (See Fig.2).3 Insert the adjuster spindle through spindle sleeve, then rotate it clockwise until the spindle comes out through adjuster tube.4 Assemble the safety collar and spring dowel sleeve. Rotate the spindle anticlockwise until the spindle has come out equal to dimension 'e' (585mm) (See Fig.3). This dimension is 375 ~ 25mm for IRSA-450 Slack Adjuster 5 Slide control rod head with control rod assembly over the adjsuter tube.6 Screw in the Adjuster ear with lock washer and tighten up. Lock the adjuster tube by lock washer. 3.2 JOINING OF PULL ROD WITH ADJUSTER SPINDLE.1 Arrange for eye ended pull rod of correct length as per the installation drawing (See Fig.2).2 Join them preferably by electric flash butt welding. If this is not pOSSible, prepare both the ends by tapering to an angle of 30 degree, 25mm length of both rods and weld the prepared faces by electric arc welding. While welding the following precautions to be taken: a) Centre lines of both pull rods must lie on one common centre line. b) PI'"ovide protective cover over threaded portion of Adjuster spindle to prevent molten metal fall1ng on threads. 3.3 FITt1ENT OF IRSA-600 SLACK ADJUSTER ON WAGON " CHECKING General arrangement showing the fitment of slack adjuster provided with vacuum brake and air brake are shown in (' ODOooa0541  Fig.4 and Fig.5 respectively. For the proper working of slack adjuster~ it is essential to ensure that the brake rigging is working properly. The following check shall be made for" this. 3.3.1 CHECKING E11PTY LOAD DEVICE AND EKPTY LOAD TIE RODS.1 Put the lever arm in empty condition as shown.1n. Fig.4/Fig.5 and hear the clear click sound 2 Apply the brake. If vacuum/air pressure is not available apply hand brake fully 3 Tap empty rod pins. These should be tight, if so the adjustment is correct (See Fig.4).4 If load tie rod pins are found tight the adjustment is wrong as the sleeve nut has been tampered with. (See Fig.4) :-$.3.. 2 CHECKING SLACK ADJUSTER AND ASSOCIATEDRI6GIreG.1 Ensure the condition required in para 3.3.1.3 is satisfactory 2 Make two or three full service application and release fL\lly 3 Check 'A' dimension. This should be as follows for different wagons. a) 50 + 2 mm for BOX~ BCX, BCXC Ill, BTPaL 8( (I MBTPZ type of wagon. b) 70 + 2 mm for BOXN, BCN~ BCNA, BRN, BOY, 0 BTPGLN,BTPN BLCA 8( BLCB type of wagons. c) 6(1 + 2 mm for BFKI wagons. (I d) 27 + 2 mm for BOBRN wagon. (I 3.3.3 ADJUSTMENT OF EKPTY TIE ROD 1 Ensure brake rigging is fully released (Hand brake a1. so). 2 Ensure horizontal levers can move freely 3 Inspect tie rods and sleeve nut for mechanical damage (See Fig.4) 4 Put lever arm in loaded position as shown in Fig.6 5 00000:10542.5 Shift lock nuts and washer as far away from sleeve nut as is possible 6 Rotate sleeve nut in direction shown in fig.6. This will shorten empty tie rod fully 7 Rotate sleeve nut in direction shown in Fig.7. This will lengthen the empty tie rod.8 Stop rotating the sleeve nut when the end of the 'LIVE LEVER' starts moving. (See Fig.7).9 Then carry out test as in para 3.3.1.10 Tighten lock nuts with washers. This should be ~ done with brake still on..1.1 Bend over lock nut washer Z shape) (See Fig.7) Note: If test fails and load tie rod pins are still found tight, empty load device operating pawl (catch) shown in Fig.6 may be broken. Replace empty load device. 3.:3.4 ADJUSTING 'A" DIMENSION.1 Ensure the required movement and direction of the control rod to achieve the specified 'A' dimension.2 Take out the nut of anchor pin as shown in Fig.3 3 Turn control rod in direction shown for increasing and decreating 'A' dimension (Fig.6 & 7). One complete rotation of control rod alters 'A' dimension by 2mm.4 Put back the nut on anchor pin (Fig.3).5 Ensure you have tightened the lock nut as in Fig.3.6 'A' dimension and brake block clearance cannot be adjusted by turning the barrel. Control rod has to be shortened or lengthened. :,:, :::~. 5 RENEl:'$AL OF BRAKE BLOCKS IN SERVICE.1 Rotate the slack adjuster in the direction shown in Fig.3.2 This will ensure clearance between brake block and wheel tread (Pull rod comes out of the slack adjuster) 3 Remove old block. 00000J0543 £ '., '.  · ':.,. 4 Replace the new block.5 Apply air/vacuum brake or hand brake three or four times 6 This will automatically adjust rigging 7 Do not under any circumstances adjust 'A' dimension at the time of renewal of brake block even if it seems too large. Applying brake three or four times is the only requirement. 'A' dimension and brake block clearance will become normal after such application. 3.3.6 TEST TO ESTABLISH PROPER WORKING OF SLACK ADJUSTER.1 Ensure that the installation is correct including empty tie rod setting~'A' dimension and piston stroke 2 Rotate the slack adjuster two or three times as shown.in fig. 3.3 Clearance between brake block and wheel tread will increase 4 Apply air/vacuum brake or hand brake fully 5 Notice higher piston stroke at first application 6 Piston stroke will be normal after two or· three applications 7 Hence pay-in is satisfactory 8 Rotate the slack adjuster two or three times as shown in fig.2.9 Clearance between brake block and wheel tread will decrease. (Pull rod goes inside the slack adjuster).10 Apply air/vacuum brake or hand brake fully 11 Notice short piston stroke on first application. 12 Piston stroke will be normal after two or three applications 13 Hence pay-out is satisfactory. 3.4 FITMENT OF IRSA-600J SLACK ADJUSTER ON WAGON AND CHECKING. General arrangement showing the fitment of IRSA-600J Slack Adjuster on wagon is shown in Fig.SEc. For the proper 7 00000J0544 7 7  working of slack adjuster~ it is essential to ensure that the brake rigging is working properly. The following checks shall be made for this:- 3.4.1 ADJUSTING· A" DIMENSION.1 Ensure the req\..lired movement and direction of the control rod to achieve the specified 'A' dimension......,., Loosen the lock nuts and nuts (item Nos. 45 & 46) from the control rod..3 Move the adjuster ear (item No.26) to & fro to increase or dec.rease the 'A' dimension. 0.4 Tighten nut and lock nuts (item No.45 & 46) Not.e: It is nc.1t r"equired to remove pins or lever to adjust the 'A' dimension. 3.4.2 RE:NEtML OF BRAKE BLOCKS IN SERVICE Follow the procedure given at Para 3.3.5 above. 3.4.3 TEST TO ESTABLISH PROPER WORKING OF SLACK ADJUSTER.1 Ensure that the installation is correct including control lever stop, 'A' dimension and piston stake.2 Rotate the slack adjuster two or three times as in Fig.3.......' Clearance between brake block and wheel tread increase will.4 Apply air brake or hand brake 5 Notice higher piston stoke at first application.6 Piston stroke will be normal after two or three applications.7 Hence pay-in is satisfactory.8 Rotate the slack adjuster two or three times as in Fig.2 9 Clearance between brake block and wheel tread will decrease.(Pull rod goes inside the slack adjuster).10 Apply air or hand brake fully 11 Notice short piston stroke on first application. 12 Piston stroke will be normal aftet two or three ODODOJ0545. ":.':~'.; B J.  applications 13 Hence pay-out is satisfactory. 3.5 FITHENT ON COACHES & CHECKING General arrangement showing the fitment of slack-adjuster provided with vacuum braked and air braked coaches are shown in Fig.4A & 5A respectively. For the proper working of slack adjuster, it is essential to ensure that the brake rigging is working properly. :::;.5.1 CHECKINS SLACK-ADJUSTER AND ASSOCIATED RIBGING After the slack adjuster has been installed, carry-out the following:-.1 Make sure that the hand brake & the brakes are fully released and whole rigging is in proper order 2 Make three or four brake applications at ,correct vacuum/brake pipe pressure to ease the rigging.. 3 Once again ensure that the whole brake rigging is in the fully released position. The installation cannot be correctly adjusted or checked if the brake rigging is only partly released 4 Now check the dimension 'A'. This should be as follows:- For 13t bogies 16+2 mm -0 For 16t bogies 22+2 mm -0.5 Make a few more brake applications at correct vacuum/brake pipe pressure, this time checking the piston stroke which should be within limits specified. Also, recheck dimension 'A' again with brakes fully released and correct, if necessary. Note: 1. A long piston stroke may be caused by (I e}tcessi ve free lift in case of vacuum brake cylinder or defective or damaged brake rigging. 2. A short stroke may be caused by low vacuum/brake pipe pressure or defective cylinders or by defects/damage in the rigging. 3.5.2 ADJUSTING 'A' DIMENSION.1 Reference Fig.4A & 5A. Remove pin securing the eye end of control rod in the 'U' bracket...... '") Detach control rod, loosen locknut and rotat.e control rod in correct direction for increasing/decreasing 'A' dimension 3 One complete rotation of control rod alters 'A' dimension by 2mm 4 Rotate control rod till it suits refitting and when 'A' dimension is correct~ refit the control rod in 'U' bracket 5 Ensure tightening of lock nut etc.6 A dimension and brake block clearance cannot be adjusted by turining the barrel. Control rod has to be shortened or lengthened for this purpose. Note: 1. Measure dimension 'A' at the narrowest part of the gap. 2. Once dimension 'A' is set~ it should not be altered when the coach is in service and is only to be adjusted during POH/ROH. 3. 5.3 RENEWAL OF BLOCKS IN SERVICE Follow the procedure given in clause 3.3.5 3.5.4 TEST TO ESTABLISH PROPER WORkING OF SLACk ADJUSTER Ensure that the inst.allation of slack adjuster~ its control dimension 'A' and pistron stroke are correct. Then follow the instructions given in clause 3.3.6.2 to establish proper working of slack adjuster. 4. MAINTENANCE (re1er 1ig.8 to 19) The slack adjuster shall be overhauled at the time of POH of rolling stock. Fig.S & SA may be referred to for t.he list of components. While dismantling or assembling it. is essential to use special tools B~C,D and E shown in Fig.9 which are identical to those used for DRV2-600 and DRV2-. 450 slack adjuster. Each component of the slack adjuster shall be examined. Worn part shall be checked according to the limits given at para 6. (0 OJi"