See00553.01 Bfc Bfcf Comp Va Maintenance Manual

Maintenance Manual Iran The SAB WABCO Block Brake Unit Type Compact BFC and BFCF with VA-details

170634 170636 170638 170640 Document: SEE00553-01 October 2003

Iran SEE00553 issue 01 Page 2 Ann Ondrejka October 2003

SAB WABCO AB Andra Tvärgatan 41, Box 515 S-261 24 Landskrona, Sweden Tel: +46 (0) 418 544 00, Fax: +46 (0) 418 106 90

Maintenance Manual Introduction The maintenance manual contains maintenance instructions for the SAB WABCO Block Brake Unit types Compact BFC and BFCF. The BFCF-unit is equipped with spring parking brake.

Issue Control Issue Prepared by

Sign

Date

Approved by

Sign

Date

00

Ann Ondrejka

Ann

011003

Rolf Lundahl

Lun

011101

01

Ann Ondrejka

Ann

031005

Michael Blohmé MB

040322

Caution! This brake unit contains springs under load. The maintenance instructions must be followed when dismantling or reassembling. Competent staff, using tool prescribed must carry out the overhaul.

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Content INTRODUCTION .......................................................................................................................................................... 2 ISSUE CONTROL .......................................................................................................................................................... 2 CONTENT........................................................................................................................................................................ 3 DRAWING BFC-UNIT .................................................................................................................................................. 4 DRAWING BFCF-UNIT................................................................................................................................................ 5 MAINTENANCE PLANNING .................................................................................................................................... 6 Maintenance Interval.................................................................................................................................................. 6 Spare Parts ................................................................................................................................................................... 7 Ordering Spare Parts in Kits...................................................................................................................................... 8 DISMANTLING ............................................................................................................................................................. 9 CLEANING AND INSPECTION .............................................................................................................................. 23 BFC-unit: .................................................................................................................................................................... 23 BFCF-unit: .................................................................................................................................................................. 24 WEAR LIMITS .............................................................................................................................................................. 24 LUBRICATION............................................................................................................................................................. 25 MOLYCOTE BR2 PLUS............................................................................................................................................ 25 BFC-unit:................................................................................................................................................................ 25 BFCF-unit: ............................................................................................................................................................. 26 DINITROL 3850 or EFCOAT 3650 .......................................................................................................................... 26 BFC-unit:................................................................................................................................................................ 26 MOBILGREASE 28.................................................................................................................................................... 27 BFC-unit:................................................................................................................................................................ 27 BFCF-unit: ............................................................................................................................................................. 27 PASTA 1000 MOLYCOTE........................................................................................................................................ 27 BFC-unit:................................................................................................................................................................ 27 BFCF-unit: ............................................................................................................................................................. 27 REASSEMBLY............................................................................................................................................................... 28 FUNCTION CONTROL .............................................................................................................................................. 44 FINAL OPERATIONS ................................................................................................................................................. 45 TOOLS............................................................................................................................................................................ 46 ORDERING TOOLS .................................................................................................................................................... 47 SIGNS ............................................................................................................................................................................. 48 EQUIPMENT STORAGE, BFC-UNITS.................................................................................................................... 49 BRAKE SHOE RENEWAL .......................................................................................................................................... 50 PARTS LISTS / DRAWINGS

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Drawing BFC-Unit

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Drawing BFCF-Unit

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Maintenance Planning The need of maintenance is always a matter of what service conditions and working environment the unit is exposed to. The most important running conditions affecting the need of maintenance are shown in the table below. Count the points together and use in the following diagrams. SERVICE CONDITION

1 point

2 points

3 points

<1

1–5

>5

< 100 000

100 000 – 300 000

> 300 000

0

1-3

>3

1 point

2 points

3 points

The units are fitted to the car body. Good rail track quality

The units are fitted to the bogie / trailer. Acceptable rail track quality.

The units are fitted completely unsprung. Bad rail track quality

Dry climate Often low humidity Seldom snow & ice

Average climate Normal humidity Snow & ice can occur

Wet climate Often high humidity or often snow & ice

Number of braking cycles per km Annual Distance (km) Number of overhaul periods carried out WORKING ENVIRONMENT Units exposed to dynamic load

Units exposed to humidity and water Units exposed to sand, dirt and dust

Quite clean environment No sand on the roadbed.

Dirty environment Extremely dirty Dirt and dust in the environment surrounding environment The roadbed consists of sand.

Maintenance Interval BFC/F- units do normally not require any special routine maintenance between scheduled overhaul. It is, however, a recommendation that during the normal and regular examination of the vehicle to check bellow 45 and breather 259. Damaged bellow or breather must be replaced. Normally the BFC require overhaul every 6 year. However, tough service conditions and working environment must be met with shorter maintenance intervals. Under extreme conditions the interval between two overhauls needs to be decreased down to 3 years. Favourable conditions allow an extended overhaul interval, up to 8 years.

Service Condition

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6

Year

5

3

Year

Year

8

6 Year

Year

<7 points

5-7 points

Year

<5 points

8

7

6

Year

Year

Year

<5 points

The diagram can be used as a guideline when setting the maintenance interval.

4

5-7 points

Use the points from the table above.

<7 points

Working Environment

Spare Parts For easy handling important spare parts are put together in kits. Depending on the running conditions, different levels of kits are available. The kits are supplied and packed separately. When overhauling a BFC-F (BFC with spring applied Parking Brake) you will need one basic overhaul kit for the service brake module and a different one for the parking brake module. The overhaul of the two different modules are preferably made and split up separate to each other. Building blocks of spare parts provides for an opportunity to satisfy most needs. Tough service conditions and working environments requires a larger extent of Extended- and Complete Overhaul Kit.

Service Condition

The diagram below can be used as guideline when estimating the need of spare parts for an overhaul program. Use to points from the table above. <7 points

0% COK 40% EOK 100% BOK

10% COK 60% EOK 100% BOK

20% COK 100% EOK 100% BOK

EOK = Extended Overhaul Kit (Parts marked “A” or “AF” in the parts list)

5-7 points

0% COK 20% EOK 100% BOK

5% COK 50% EOK 100% BOK

15% COK 70% EOK 100% BOK

BOK = Basic Overhaul Kit (Parts marked “B” or “BF” in the parts list)

<5 points

0% COK 0% EOK 100% BOK

5% COK 40% EOK 100% BOK

10% COK 60% EOK 100% BOK

<5 points

5-7 points

<7 points

Working Environment

COK= Complete Overhaul Kit (Parts marked "C" in the parts list) Use the points from the table above. The percentage tells how many of the overhauled items need a specific kit.

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Ordering Spare Parts in Kits Items which has to be renewed in an overhaul are marked A, FA, B, FB and C in the parts list. Every BFC/ BFCF has a specific kit made. For itemnumber 170634 and 170636 order kit : Kit A (Extended Overhaul Kit): FA (Extended Overhaul Kit for F-Unit): B (Basic Overhaul Kit): FB (Basic Overhaul Kit for F-Unit): C (Complete Overhaul Kit):

Kitnumber 1741 044 004 1741 044 004 170602 170347 170603

For itemnumber 170638 and 170640 order kit : Kit A (Extended Overhaul Kit): B (Basic Overhaul Kit): C (Complete Overhaul Kit):

Kitnumber 1741 044 004 170602 170603

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Dismantling Remove breathers 259 and 259F.

Remove screws 167 (6 mm A/F) and the steel balls 247.

Unscrew screw 157 about three turns from nut 307 (24 mm A/F).

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Remove: • Screws 156 (Allen key 10 mm) Screw on picture is only schematic. • Washers 152 • Seals 153 • Shaft journals 150 • Bearings 169.

Remove: • Suspension links 158 and 159 • Seals 154 • O-rings 181 • Screw 157 • Nut 307.

Cut hose clamp 134 and remove control socket protection 268 (if existing). Turn control socket 9 (50 mm A/F), anti clockwise direction, and screw spindle 916 forward. Loosen hose clamp 141.

Withdraw bellows 45 from cover 544. Remove spindle 916 from adjuster nut 3 by turning socket 9. Remove the brake shoe holder joined to the spindle. Cut hose clamp 67. Remove bellows 45 and hose clamp 141.

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Remove : • Four screws 59 ( 12 mm A/F) • Cover 544.

Separate : • Spindle 916 • Spring package 145 • Springs 146 • Cradle 147 • Bearing 143 • Brake shoe holder 91.

Connect compressed air and admit air just enough to advance push sleeve 1 and thus relive the spring force on retaining ring 71. Remove the ring. Disconnect the air supply.

Pull out socket 9 and payout unit. Remove O-ring 61 from housing 30.

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For BFC-units only. Remove four screws 69 (17 mm A/F). Caution! Care should be taken as the cover may be pushed up by the piston and the piston spring. Hand pressure is sufficient to retain it. Tap lightly on the edge of cover 232 with a soft hammer and remove the cover. For BFC-units only. Remove spring 47 and piston 31 out of the liner. Due to the airtight seal, cylinder liner 44 and O-ring 62 often stick to the cover.

For BFC-units only. Remove slide ring 37 from piston 31. Remove packing cup 74.

For BFC-units only. Remove cylinder liner 44 and O-ring 62 from cover 232.

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For BFCF-units only. Screw out screws 64F (8mm A/F) and remove the release device from intermediate housing 402F. Separate: • Wiper ring 49F • Pull rod cover 24F • Bush 100F • Seal ring 47F • O-ring 102F • Spring 35F • Ratchet pin unit 418F. The ratchet pin unit is to be considered as a complete module and should not be further dismantled. For BFCF-units only. Screw out inlet plug 27F (24 mm A/F) and remove valve cup unit 66F.

For BFCF-units only. Look out for two marks (horizontal ridges) on the corners of intermediate housing 402F. Remove only these two screws 62F (15mm A/F) at positions mentioned and remove two supports 26F. Caution! High spring load. Do not remove the other two screws at this stage.

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For BFCF-units only. 1. Put two screws M14x35 through the empty holes of cylinder 1F and clamp it down to intermediate housing 402F. 2. Remove remaining two screws 62F with their supports.

For BFCF-units only. Separate the spring brake unit from the service unit. Due to the airtight seal, cylinder liner 44 and O-ring 62 often stick to intermediate housing 402F.

For BFCF-units only. Remove piston 31 from liner 44. Remove slide ring 37 from piston 31. Remove packing cup 74.

For BFCF-units only. Remove cylinder liner 44 from intermediate housing 402F and remove O-ring 48F.

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Lever yoke 33 forward by pushing a bar between bearings 65 and 66. When the yoke is sufficiently forward, fit two rectangular bars 4-500122, which makes retaining ring 72 accessible.

Remove retaining ring 72 and position it next to its groove in push sleeve 1. If retaining ring ends are not available, turn the sleeve with the aid of control socket 9 loosely positioned into the sleeve.

Fit tool 4-300421 to the push sleeve 1 at the back of the unit, and using a soft hammer or similar, knock onto the tool until retaining ring 72 slips off from push sleeve 1. Caution! Do not knock the sleeve any further out, as spring 46 may come off. The sleeve should still be fully located in yoke 33. Remove rectangular bars 4-500122.

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Place protection (a BFC-cover or similar) over the housing 30. Caution! Spring 46 may come up. Follow instructions! Pull out the sleeve completely from the housing. Put your hand on the protection and using the shaft of a hammer or similar, lever off spring 46 from its position in the housing which will occur with a bang. Check that the spring force is released i.e. yoke 33 will lie at an angle in the housing along with the spring. Carefully remove the protection. Do not look directly into the housing until you are sure the spring is fully expanded and loose. Remove: • Yoke 33 with bearings 65 • Bevel gear wheel 36 (if existing) • Locking ring 38 • Spring 46 • Retaining ring 72.

Remove from yoke 33: • Retaining rings 73 • Slide bush 29 • Jointing ring 114 • O-rings 27 • Bearings 65 • O-rings 28 Note! Keep bearings 65 together with their original needles.

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Remove screws 59 (12 mm A/F), which secure pins 343. Screw tool 3-500128 into pins 343 and using an allen key 8 mm pull them out.

Remove: • O-rings 116 • Bearings 66 • O-rings 64. Note! Keep bearings 66 together with their original needles.

Remove bushes 48 and 49.

Place a pay-out unit onto tool 3-500125 in a press (a pedestal drilling machine may be used). Using tool 3-500126 press in bayonet washer 15 a small distance and turn spring sleeve 8 so that the ears on washer 15 line up with the slots in the sleeve.

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Release the press force.

Remove from spring sleeve 8: • Bayonet washer 15 • Ball bearing 22 • Spring 13 • Leader nut 7.

Place push sleeve 1 into a press. Using tool 4-500127 press against bush 2 and unseat retaining ring 21. Release the press force.

Remove from push sleeve 1: • Retaining ring 21 • Bush 2 • Spring 11 • Ball bearing 22 • Adjuster nut 3.

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Using tool 4-500127 press against guide bush 5. Tip clutch washer 4 at an angle from its location in the sleeve and remove the washer out from its position in the sleeve. Release the press force.

Remove form push sleeve 1: • Clutch washer 4 • Spring 12 • Brake disc 14. Pressure ring 6 may remain in the sleeve

For BFCF-units only. Place the spring brake unit on tool 2-500137 into a press and apply a light pressure. Remove the two M14x35 screws.

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For BFCF-units only. Carefully release the force and let springs 21F and 22F expand to free length.

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For BFCF-units only. Remove cylinder 1F with cylinder liner 30F and O-ring 48F. Guide sleeve unit 420F stick together with cylinder 1F. Remove guide sleeve unit 420F from cylinder 1F.

For BFCF-units only. Separate : • Spring 21F • Spring 22F • Piston unit 404F • Intermediate housing 402F

For BFCF-units only. Using tool 3-500216 to remove cylinder liner 30F and O-ring 48F from cylinder 1F.

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For BFCF-units only. Separate spindle unit 407F from piston unit 404F. Remove rib ring 60F from the spindle damping piston.

For BFCF-units only. Remove from piston 404F: • Slide ring 31F • Seal ring 45F • Slide ring 61F. Unseat retaining ring 58 from its groove in the piston.

For BFCF-units only. Remove from piston 404F: • Retaining ring 58F • Distance sleeve 115F • Damping ring 114F • Washer 116F • Needle bearing 51F • Needle race 52F • Ratchet nut unit 414F • Ball bearing 50F. For BFCF-units only. Remove from intermediate housing 402F: • O-ring 48F • Retaining ring 59F • Washer 17F • Needle race 54F • Needle bearing 53F • Ratchet wheel unit 409F • Seal ring 46F.

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Cleaning and Inspection When overhauling always renew items marked with B (FB) in the parts lists. Items marked with an A (FA) or a C should be renewed if necessary, See Maintenance Planning.

BFC-unit: 1. Clean following parts separately in degreasing fluid e.g. white spirit: • Ball bearing 22 • Yoke 33, where the ball bearing has been positioned. • Bearing 65 • Bearing 66 2. Inspect the threads of spindle 916. Brush the spindle if corrosion is evident. A rotating plastic brush with fine polish is a suggestion to obtain good result. 3. Examine cylinder liner 44 for defects i.e. score marks or undue wear. Renew liners with excessive defects, as they may lead to air leaks. 4. Degrease, clean and dry remaining components. 5. Renew worn and damaged parts. Note! The use of original spare parts only will guarantee the reputable BFC-unit’s long life and reliability. Some O-rings are made of special material. The use of standard O-rings may cause malfunction.

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BFCF-unit: 1. Clean following parts separately in degreasing fluid e.g. white spirit: • Ball bearing 50F • Needle bearing 53F • Race 54F. 2. Inspect the threads of spindle 407F. Brush the spindle if corrosion is evident. A rotating plastic brush with fine polish is a suggestion to obtain good result. 3. Check ratchet pin unit 418F and ratchet wheel unit 409F in respect of their teeth. Note! The use of original spare parts only will guarantee the reputable BFC-unit’s long life and reliability. Some O-rings are made of special material. The use of standard O-rings may cause malfunction.

Wear Limits Bush 2 Renew the bush if its inner diameter exceeds 30,45 mm.

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Lubrication When assembled in the factory the units are lubricated with: • • • •

MOLYCOTE BR2 PLUS DINITROL 3850 or EFCOAT 3650 MOBILGREASE 28 PASTE 1000 MOLYCOTE.

When lubricating before reassemble, use the same lubricants or equal.

MOLYCOTE BR2 PLUS (Extreme pressure grease) BFC-unit: • Bearings 65 and 66. Greasing of bearings 65 and 66 should be carried out in a clean environment away from general workshop conditions. When greased the bearings should immediately be mounted onto yoke 33 and pins 343. • Springs 146 and cradle 147. Bearings 65 and 66 Grease the bearing needles moderately. Fit a washer on one side of each bearing and press on a plastic cap. Place the needles into the bearing from the other side. Check that the bearing will be fitted with its original needles. Fit the other washer. Bearings 65 Fit O-rings 28 onto yoke 33 and mount the bearings. Fit O-rings 27, slide bush 29 and jointing ring 114. Secure with retaining rings 73.

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Bearings 66 Fit O-ring 116 onto bearing pin 343. Mount the bearing and another Oring 116.

BFCF-unit: • Spindle 407F. Grease the threaded part liberally. • Ratchet nut sleeve 414F. Grease liberally.

DINITROL 3850 or EFCOAT 3650 (Corrosion preventing semidrying oil) BFC-unit: • Housing 30. Grease the surfaces shown on the sketch. • Additionally, grease the visible surfaces of pins 343 and the unpainted surfaces of housing 30. Grease when the BFC-unit is assembled.

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MOBILGREASE 28 (General lubricating and corrosion protecting grease) BFC-unit: • All the unpainted inner surfaces of housing 30. • Liner 44 Note! When greasing liner 44 it is especially important to use clean grease, which has been stored under cover. For this operation always use a special brush, which is clean and have no loose bristles. • Piston 31. Grease lightly. • Packing cup 74. Grease liberally Do not grease until mounted onto piston 31. • Seats for bushes 48 and 49 in housing 30. • O-rings 61 and 62. Grease liberally before mounted onto control socket 9 and liner 44. • Nut 3 and spindle 916. • Grease all remaining parts lightly. BFCF-unit: • Liner 30F. • Packing cup 32F. • Seal rings 45F, 46F and 47F. To be filled with grease. • Thrust bearing 50F. Grease liberally. • Needle bearings 51F and 53F. Grease very lightly. • Grease all remaining parts lightly.

PASTA 1000 MOLYCOTE (Anti-friction grease) BFC-unit: Use as gap filling: • Screws 156 and 167. • Screw joints, where retaining fluid has not been used. BFCF-unit: Use as gap filling: • Screw joints, where retaining fluid has not been used.

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Reassembly Place spring sleeve 8 onto tool 3-500125 into a press (or a pedestal drilling machine). Place into the sleeve. • Leader nut 7 • Spring 13 • Ball bearing 22 (with its guiding outer diameter up) • Bayonet washer 15. Using tool 3-500126 press parts into the sleeve. Check that the bayonet washer tabs locate in the spring sleeve recesses.

Turn spring sleeve 8 until the bayonet washer tabs into the two tangential sleeve slots. Release the press force. This subassembly is referred to as the payout unit.

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Insert pressure ring 6 (if removed) into push sleeve 1. Put the payout unit into the push sleeve. Put the sleeve in press (or a pedestaldrilling machine) with the payout unit at the bottom. Mount brake disc 14 and check that its tabs fit in the leader nut slots. Mount spring 12. Release the spring force. Place into push sleeve 1: • Clutch washer 4, with its slot to the lug in the push sleeve. • Adjuster nut 3 • Ball bearing 22, with its guiding outer diameter up • Spring 11 • Guide bush 2. Place retaining ring 21 onto tool 4-500127 and press this against guide bush 2. Fit retaining ring 21 into its groove. Release the press force.

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Fit bushes 48 and 49. Check that the location tab on bush 48 fits into its groove in housing 30.

Fit O-rings 64 onto pins 343. Using a soft hammer knock the pins with bearings 66 into the housing. Secure with screws 59 (12 mm A/F).

Using tool 2-500124 compress spring 46 in a press. Place tool 2-500129 around the spring and screw the toll clamps in so that they fit over the ends of the spring.

Release the press force when you are sure the spring is fully captivated.

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Push sleeve 1 with tool 4-300421 half way into housing.

Put over tool 4-300421: • Spring 46 with tool 2-500129 • Locking ring 38 • Yoke 33 • Retaining ring 72. Note that yoke 33 should be fitted with the cast spring location boss at the top. Using tool 2-500132 gently press in sleeve 1 until retaining ring 72 slips into its groove.

Check that the internal tabs of locking ring 38 engages in the push sleeve keyways. Remove tool 4-300421.

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Partially cover the housing opening with a cloth (to protect your face from any grease that might fly up). Unscrew tool 2-500129 and lever it up to allow spring 46 to expand. Remove the cloth. Check that the flat faces of spring 46 are correctly located against housing 30 and locking ring 38. Fit O-ring 61 into housing 30. Pull out the payout unit a little and engage control socket 9. Check that the spring sleeve flanges fit in their corresponding slots in the socket. Turn socket 90° and push it fully into push sleeve 1. Note! Do not fit retaining ring 71 yet. Using tool 4-500134, mount packing cup 74 onto piston 31 in a press. Max. press force: 1,5 kN.

Mount slide ring 37 between the packing cup and the piston. Mount the ring with its split joints as indicated by the arrows.

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Push cylinder liner 44 down into housing 30. Fit O-ring 62 onto the liner body under the rolled flange.

For BFC-units only Place spring 47 onto yoke 33. Fit the piston unit and allow its wedges to slide down between bearings 65 and 66. Place cover 232 onto the piston. Check that the air connection is in correct position according to the equipment drawing. For BFC-units only Apply LOCTITE 243 in the holes for screws 69 in housing 30. Press down cover 232 evenly and carefully not to damage O-ring 62. Fasten the cover with four screws 69 (17 mm A/F). Tighten up the screws to 120 Nm. For BFCF-units only. Mount O-ring 48F around intermediate housing 402F. Fit seal rings 46F with their sealing lips directed from each other.

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For BFCF-units only. Place into intermediate housing 402F: • Ratchet wheel unit 409F • Needle bearing 53F • Needle ratchet 54F • Washer 17F. Secure with retaining ring 59F.

For BFCF-units only. Place into piston 404F: • Ball bearing 50F (with its smaller inner race diameter first) • Ratchet unit 414F • Needle race 52F • Needle bearing 51F • Washer 116F • Damping ring 114F • Distance sleeve 115F. Secure with retaining ring 58F. For BFCF-units only. Using tool 4-500134 mount packing cup 32F onto piston 404F in a press. Max force:1,5 kN.

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For BFCF-units only. Fit slide rings 31F and 61F onto piston 404F. Mount seal ring 45F with its sealing lip directed upward.

For BFCF-units only. Press spindle unit 407F into the piston.

For BFCF-units only. Place O-ring 48F onto cylinder liner 30F and insert this into cylinder 1F. Press guide sleeve 420F into cylinder 1F.

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For BFCF-units only. Place intermediate housing 402F onto guiding tool 2-500137 in a press. Check that the tool is well fixed and centred in the press in order not to damage rib ring 60F when pressing. Place into intermediate housing: • The piston unit • Spring 21F • Spring 22F. Put cylinder 1F, with guide sleeve 420F mounted, over the guide sleeve unit. Note! Position the cylinder correctly to the intermediate housing according to the assembly drawing.

For BFCF-units only. When pressing, guide the cylinder to the intermediate housing using 450 mm guiding pins inserted through the two not threaded holes.

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For BFCF-units only. Make temporary fixing by inserting two screws M14x35 through the cylinder holes and fit them into the two threaded holes of intermediate housing. Tighten up well.

For BFCF-units only. Apply LOCTITE 243 to the threads in the holes for screws 62F in housing 30.

For BFCF-units only. Using a hoist or similar, lift the spring actuator and position it above the service brake unit. Put spring 47 onto yoke 33. Place piston 31 on the spring and keep it in position with one hand. Note ! Turn the spring actuator into correct direction in relation to the service brake unit. See assembly drawing. Lower the actuator and locate it on housing 30. Be careful not to damage O-ring 62.

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For BFCF-units only. Fit two cylinder supports 26F and two screws 62F (15 mm A/F) through the intermediate housing and into housing 30. Caution! High spring load. Remove the two temporary screws and fit remaining two cylinders supports 26F and two screws 62F. For BFCF-units only. Tighten up the four screws 62F to 90 Nm.

For BFCF-units only. Apply LOCTITE 542 to the threads of inlet plug 27F and fit this into the intermediate housing 402F (24 mm A/F).

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For BFCF-units only. Place ratchet pin unit 418F and spring 35F into intermediate housing 402F. Mount O-ring 102F and seal ring 47F into bush 100F. Place bush 100F on spring 35F. Fit wiper ring 49F into pull rod cover 24F. Place the pull rod cover onto the intermediate housing and over pull rod of ratchet pin unit 418F. Apply LOCTITE 243 on the threads of screws 64F and pull them through pull rod cover 24F and tighten up with 2,5 Nm. Caution! Do not tighten too hard as cover 24F may be deformed and the pull rod axial movement may be restricted. Apply sealing compound (SILICON or PERMATEX) onto the sealing surfaces of the brake shoe holder 91.

Place cradle 147 in the holder. Fit springs 146 into the cradle grooves.

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Put spring package 145 into the spindle head and hold this against the cradle.

Fit cover 544 to brake shoe holder 91 with its inner knobs close to the spring package. Screw on four screws 59 coated with LOCTITE. Check that the spindle is correctly centred in the cover and cannot be turned in counter clockwise direction. Tighten the screws to 30 Nm (socket 12 mm). Fit bellows 45 to housing 30 and secure with hose clamp 67. Check that the bellows has entered its groove in the housing properly and check by pulling that it is well fixed.

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Fit clamp 141 over the bellows 45. By rotating holder 91, screw spindle 916 into the adjuster mechanism until the holder is close to the housing ears. Be careful, as the spindle must enter two separate nuts in the adjuster. Line up the holder vertically and turn socket 9 clockwise, thereby drawing the spindle/holder assembly back between the ears. Turn the screw device of clamp 141 upward and tighten. Mount slide bearing 143 into brake shoe holder 91.

Fit O-rings 181 and seals 154 onto the suspension links. The seal’s spongy sides must lie against the suspension link.

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Join suspension link halves 158 and 159 and brake shoe holder 91 with screw 157 coated with LOCTITE. Screw in the screw until about three turns are left.

Fit bearings 169 into the suspension links 158 and 159 and fit shaft journals 150 into the bearings. Fit seals 153. The spongy side of seal must face out towards the suspension link unit. Put washers 152 onto screws 156. Adjust suspension links 158 and 159 between the housing hangers and screw in screws 156 with washers 152 lightly. Tighten up screw 157 and nut 301 to 280 Nm (socket 24 mm) and screws 156 to 200 Nm (allen key 10 mm). Screw on picture is only schematic. Place steel balls 247 down into the threaded holes in the housing ears. Dip screws 167 into PASTE 1000 MOLYCOTE and screw them in. Tighten up screws to 24 Nm (allen key 6 mm).

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Turn socket 9 (50mm A/F) and screw spindle 916 fully into BFC-unit. Connect compressed air and admit air just enough to advance push sleeve 1. Fit retaining ring 71.

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Function Control 1. Place the BFC/ BFCF-unit into a test rig and connect compressed air to the unit. 2. Pressurise the spring brake to specified release pressure.

3. Apply the brake. Carry out repeated brake operations until correct clearance is obtained. Simultaneously check that the slack adjuster is working satisfactorily. 4. When the correct clearance is achieved, carry out repeated spring brake applications by alternatively exhausting and pressurising the spring brake unit. 5. Admit air to the service brake at a pressure of 600 kPa to the unit. Shut off the air supply and let the pressure stabilise for about one minute. Check for leakage. Max permitted pressure drop: 5 kPa/ 5min 6. For BFCF-units only. Exhaust the spring brake unit, which applies the brake. Using the pull ring 25F release the brake. Check that the brake is fully released. 7. For BFCF-units only. Pressurise and exhaust the spring brake again. Check that the brake is applied. 8. For BFCF-units only. Pressurise the spring brake unit to release the brake and admit air to the service brake at a pressure of about 80 kPa. Shut off the air supply and let the pressure stabilise for about one minute. Check for leakage. Max permitted pressure drop 3 kPa/ 5min.

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9. For BFCF-units only. Admit air to the spring brake at a pressure of 600 kPa to the unit. Shut off the air supply and let the pressure stabilise for about one minute. Check for leakage. Max permitted pressure drop: 5 kPa/ 5min

Final Operations 1. Fit a protecting plastic plug into the air inlet. 2. Fit plugs 260 and 260F in the optional holes for breather 259 and 259F. The breathers should not be fitted until the BFC-unit is mounted into the wagon.

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Tools

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Ordering tools Tools in the manual are identified by their drawing numbers, when ordering tools please state the part number, followed by the appropriate tool drawing number. Tool N C F G H J K L P S-F T-F -

Drawing number 4-300421 4-500122 2-500124 3-500125 3-500126 4-500127 3-500128 2-500129 2-500132 4-500134 4-500137 3-500216

Part number 4741 009 000 4741 002 000 4741 003 000 4741 004 000 4741 005 000 4741 006 000 4741 007 000 4741 008 000 4741 010 000 4741 012 000 4165 002 000 4741 044 000

Iran SEE00553 issue 01 Page 48

Signs

When ordering BFC/BFCF-spare parts, please state the complete type number, as well as the units' serial number shown on the nameplates.

Iran SEE00553 issue 01 Page 49

Equipment Storage, BFC-units 1)

One year storage i) Units should be stored in an upright position (storage of the units on their sides can lead to problems with the cylinder seals). ii) Undesirable environmental conditions should be avoided. Internal dry storage is recommended. iii) Due to the use of rubber components (i.e. bellows, breathers etc.) direct sunlight should be avoided. iv) Unit mounting surfaces (which are bare metal) should be coated with DINITROL 3850 or EFCOAT 3650. v) The units are supplied with dust caps fitted to all air inlet ports, these must be in place during all periods of storage. Should any become discarded or removed for any reason new caps must replace them. vi) The units must be handled with care to ensure that the rubber bellows and dust caps etc. are not disturbed. Should damage or disturbance occur it should be rectified immediately.

2)

Up to four year storage i) All the points highlighted under the one year storage section should be adhered to. ii) Periodic checking of the units (i.e. at one year or after any handling etc.) should be carried out to ensure the points of the one year storage recommendations are adhered to.

3)

Storage for longer periods than four years i) We do not recommend the storage of brake units for longer than a four year period. ii) Any units that have been stored for longer than four years will need overhauling and the grease renewed prior to entering service. This is to ensure that the functional life of the grease is not exceeded.

4)

Installation – after period of storage. After any period of storage, all units should be function tested after they have been installed on a bogie.

Iran SEE00553 issue 01 Page 50

Brake Shoe Renewal To be performed on BFC/BFCF-units installed in the vehicle. 1. When renewing brake shoes, the brakes must be released. Therefore chock the vehicle firmly in order to eliminate the possibility of moving. 2. Isolate the service brake on the vehicle to ensure that it is released and cannot be applied. 3. For BFCF-units only. Apply the parking brake. 4. For BFCF-units only. Release the parking brake. 5. Reset the slack adjuster to its shortest length by turning control socket 9 (50mm A/F) clockwise to fully wind in spindle 916. 6. Remove the brake shoe and fit a new brake shoe 7. Reset the brake unit until correct clearance between the brake shoe and the wheel is obtained. Either turn control socket 9 anticlockwise or turn control socket 9 half a turn anticlockwise (spindle 916 may be jammed) and then carry out brake applications until correct clearance is obtained.