IRS 600J: Maintenance Manual
IRS 600J: Maintenance Manual
IRS 600J: Maintenance Manual
SEPT.98·
• J
MAINTENANCE MANUAL
FOR
.. , 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
1. INTRODUCTION 1.
PRINCIPLE OF OPERATION 1.
INSTALLATION 2
4. MAINTENANCE 8
4.1 DISMANTLING 9
4.3 LUBRICATION 10
4.4 REASSEMBLING 10 TO 12
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
3 0000030540
..
3.. INSTALLATION
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
5 00000:10542
.5 Shift lock nuts and washer as far away from sleeve
nut as is possible •
00000J0543
£
'., '.
· ':., .
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:-
.....,., Loosen the lock nuts and nuts (item Nos. 45 & 46)
from the control rod.
ODODOJ0545
. ":.':~'.;
B J .•
applications •
.....
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Detach control rod, loosen locknut and rotat.e
control rod in correct direction for
increasing/decreasing 'A' dimension •
(0 OJi"<,,,
UUL.'OJ0547
10
I
4.1 DISMANTLING
Fig.15 Clamp jacking tool B in a vice and place leader nut unit
as shown in figure. Compress pay-out spring 11 by turning
jacking tool handle in a clockwise direction until circlip
9 is relieved of spring pressure.
0000000548
Fig.16 Dismentle leader nut unit as shown in figure. The dog
pin 6 must not be loose. It must be press fit.
4.3 LUBRICATION
4.4 REASSEMBLING
I~
0000000549
slot of actuating sleeve 38.
Fig.13 Screw leader nut unit into place in barrel 22 and fix tab
washer 34 and lock screw 33. Inspect rubber gasket 4 on
spindle sleeve 5 and seal ring 2 in dust bushing 1. If
0000000550
they are damaged, replace them with a new rubbe~ gasket
and a new seal ring respectively. Insert spindle sleeve 5
into leader nut casing 8 and fix circlip 9 with pliers C.
Note:- The slack adjuster pays out max. 30mm per braking •
/4
0000000551
.4 After the test is finished, remove the spindle from
the slack adjuster •
4.6.1 Place an iron object e.g. a hammer between the brake block
and the wheel tread. Make two./"brake applications. After
the second application the cor~ect piston stroke should be
obtained.
4.7 PAINTING
15
0000000552
.;~l5
5. INSPECTION OF PARTS
•1 Hold the upper and lower races with the ball cage
between them and with normal hand pressure the ball
cage should not rub against either ball race at any
peripheral point •
1£
0000000553
N.B. When the actuating sleeve is rejected the
corresponding socket should also be replaced to
ensure formation of correct matching of re-dressed
lap of socket and chamfer on actuating sleeve in
assembly which is essential for the function of
Slack Adjuster •
5.9 LEADER NUT WITH DOS PIN PART Nos.35 &: 6 SEE (FI6.2~)
t7
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I}-
ADJUSTER SPINDLE PART ND.22 (SEE FIG.26)
ADJUSTER EAR WITH ADJUSTER TUBE ASSEt'IBl.Y PART Nos. 27.28 &
41
6. WEAR LIMITS
0000000555
, 6.2 ADJUSTER NUT &: LEADER NIT PART Nos.36 &: 35
0000000556
6.11 ADJUSTER EAR BUSHING PART No.29
7. GENERAL
7.1 The place of overhauling must be clean and free from
dust. Care must be taken so that no foreign
matters/particles remain inside the sub-assemblies during
re-assembly.
~p
0000000557
.8 Tab washer Part No.34
0000000558
c) Similarly adjuster-tube (item 7) and its circlip (item
4) as an assembly are fully interchangeable with
corresponding combination of these items of DRV-2-
450/IRSA-450 slack adjusters to 07-ABR-88 (Rev.).Hence
these items should be procured as a set.
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SLACK ~DJUSTER C.:J
SUPPORT BRi\CKET o
- / - BP.AJ<E CYLINDER CONTROL ROD CJ
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TO BOGIE ==-::=!=::=::--.=::-::E3~::::f=:t=:::==::-=-:!:=:::-=-=_=-_==-:_:-:=-~_:=T1111j1"----,..--l.!~
----'-
~LONG IIRM
ADJUSllNG HEAD
SLACK ADJUSTER
SUPPORT BPJ\CI<ET CONlROL ROD
'U'OR,\CKET
PULL ROD
TO BOGIE -@'.,r-=-=-' --
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FULCRUM Bft~,r.!<Ef
DIMENS!ON 'A'
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o
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....:.~ AIR BRAI(E SYSTEM OF COACHING STOCf<
FIG.-5A
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FIG.-B
SLACK ADJUSTER TYPE mSA-600 & lRSA-450
~PIIDH .DI~ NO.Of"I IIDIMICS
1101
IIE!iCIIPI'DI • *~ NO.Off RQWcj(S IJbI
1 IIUSI'~
, 2f> !IPfIIC DQIIIEL 9lll'tl Hf.ItI'( 15 II ;M 1
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,
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1 28 ~I:AII I
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4
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7 I£N'IG ~ lot. I' (Ollwun)
W«II ~ f.MiIG
1
,
,
31
12
LfAIltR NUT AMIOt
I!f..tftNG 415 TA 11 ('IITHQllr »WT NlllilEI)
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~ 'lWlllER
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t1 PM - OUT SfIIIIO 1 36 l£4iI:IEM NUT I
12 1~ Sl.UWI: I :so ~NUr I
IJ CUlf~ 1 37 TN<E-UP Sl'f11N3 I
0 14 GUIDI: II1N 1 :so ACI~ SLiDE 1
CJ
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fNCflOll IWltO
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FIG.~A 'jg
SLp.CK NJJUSTER f{PE IRSA-~OC\J
--
ITEM OESCRIP'TlON '" DIMENSIONS NO.OFF RE~if!RKS ITEM DESCRIPTION .& DIMEN~~0NS: NO.,)Ff REMPRI<5
fI OOG AN 1
-
Jl _. ",!:?"OER NUT Fl.6NGE 1
7 BEARING 45 TA 11 (COMf'I.m) 1
-32 BfARI~IG ~
Tp, 11 (WHli,OI)T Sl-W1 .....ASHER) 2
a LEADER NliT CASING
CI~UP- g~ X 4 H
1
1
33
Jf
LOCr; SCf<£.YI
rAB 'll'ASHEl'!
-- 1
1
"
lD S~NG SLEEVE 1 35 LE'lDER NIJT 1
---
11 PAY- OUT SPRNG 1 36 N))IlsID WJT 1
12 ffiACTlON SLEEVE 1 37 '''TAKE-UP SPRNG 1
13 WIDE BUSHlt.j;l 1 J6 AC1\JAliNG SLEE'lE 1
_ 1 0 BRAKE CYUNIl!.R
~UT
A' DtMlNlS~N
. SLACK ADJUSTER
ADJU~lER tAR
--- 10 SOC,IE.
CONlROL ROD
LOCK NUTS
C)
C)
c::.' FIG.8B
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a
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7
FIG.-17
FIO.-16
FXG.-19
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TOLERANCE FIELD
PRESSURE ClAUGF
SCALE
•
INDICATOR
.,
"rOUCING VALVE
,
COM.... ESSEO Alft
•
• AME CYLINO~
--~.J
f\'.) rEST RACK
WORKING PRESSURE 4KG/CMl CORRECT STROICE 125 MM
F"Xf3.-::20
+ .
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ADJUSftR ",8a ASIY. VI'lH PARY .0. 41,1",1',13
F'IG •. - 2 2
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ADJUS7BR SPINOLa p~ MO. 23
-
r:£6_-26
20
DETAIL AT 'A'
MARKING
@ MAI£RIAl-/SPECIFlCATION
GAUGE FOR ADJUSTER SPINDLE T 110W2Cr1/IS:3749
(PART NO. 23) TREAIMENJ'-HABDEND
(SEE CLAUSE 6.1) SURFACE F1NISH'-IS'3073
FIGURE:-29
4 3
2
4 GAUGE FIG.40
:3 RIVET ¢3 2
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R5 R2
~
10
~ IRSA
N ~-
30.5
70
MARKING
~ MATERIAL/SPECIFICATION
30.5 T 11OW2CR1/IS:3749
TREATMENT:- HARDENED
SURFACE FlNISH:- IS:3073
.,
.1 I. 6
MARKING
~ MAITRIAI./SPECIFlCATlON
39.0 T 110W2CR1/1S:374Q
TREAnlENT:- HARDENED
SURFACE FlNISH- 15:3073
·0000000576
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.....
•11. 6
MARKING
<S> WiTERIA!../SPEClACADQN
43.5 T 110W2CR1/1S:3749
TREATt.4ENT:- HAADENED
SURFACE ANISH:- 15:3073
R5
b IRSA
10
N ~:?H-- - -@- - - en
N
- 29,5 •
R2
12
70
MfilIRW./SP£C!f!CA1JON
T 110W2CR1/1S:37U
TREATIotENT:- HARDENED
MARKING SURfACE f1NISH:- 15:3073
®
29.5
GAUGE FOR GUIDE BUSHING
- (PART NO. 13)
(SEE ClAUSE 6.5)
fJGURE:-34
...
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R5
,
i - -I-_I~~
46.5
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.....TERIAL/SpEClElCATlON
MARKING
T 110W2CR1/IS:3749
('f) TREATWENT:- HARDENED
46.5 SURFACE E1NISH:- IS:3073
R5 .. .,,-
S![ ~---~~~------
/
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40.5
'.
10
110
.....TERIAl /SPECIElCATlON
MARKING
T 11OW2CR1/IS:3749
@ TREATWENT:- HMDENED
40.5 SURfACE FlNISH:- 1S:3073
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41
---{fr--~
125
8.5 .Y'I
R
tJL
MARKING
<D
8.5 MATERIAL!SPECIFICATION:-
T 110 W2Cr 1/IS:.:'7 49
TREATMENT:-HARDEr~D
SURFACE FINISH:-IS:3073
F!GURE" -37
8o
+.
LI";
co
os
MARKING
~)
11.5 WA!ERlt,L !SPECIElCIffiON
T 11OW2CRi/tS:3749
TREATMENT:- w.RDEND
SURFACE FlNtSH:- IS:Jon
SCALE 2: 1
HANDLE & PLUG GAUGE FOR ...ADJUSTER NUT
& LEADER NUT
(SEE FIG.30 FOR ASSEMBLY)
FIGURE-39
SECTION 8-8
. DETAIL AT -'A'
L-_______________________________________________~