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
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SAB WABCO AB Page 2
Andra Tvärgatan 41, Box 515 Ann Ondrejka
S-261 24 Landskrona, Sweden October 2003
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
Number of braking <1 1–5 >5
cycles per km
Annual Distance (km) < 100 000 100 000 – 300 000 > 300 000
Number of overhaul 0 1-3 >3
periods carried out

WORKING 1 point 2 points 3 points

ENVIRONMENT
Units exposed to The units are fitted to The units are fitted to the The units are fitted
dynamic load the car body. bogie / trailer. completely unsprung.
Good rail track quality Acceptable rail track Bad rail track quality
quality.
Units exposed to Dry climate Average climate Wet climate
humidity and water Often low humidity Normal humidity Often high humidity or
Seldom snow & ice Snow & ice can occur often snow & ice
Units exposed to sand, Quite clean Dirty environment Extremely dirty
dirt and dust environment Dirt and dust in the environment
No sand on the surrounding environment The roadbed consists of
roadbed. 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.
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6 5 3
The diagram can be used as a guide-
<7
Service Condition

points Year Year Year line when setting the maintenance

interval.
5-7 8 6 4
points Year Year Year Use the points from the table above.

<5 8 7 6
points Year Year Year

<5 5-7 <7

points points 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.

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.

EOK = Extended Overhaul Kit

0% COK 10% COK 20% COK
<7 (Parts marked “A” or “AF” in the
Service Condition

40% EOK 60% EOK 100% EOK

points
100% BOK 100% BOK 100% BOK parts list)

0% COK 5% COK 15% COK

BOK = Basic Overhaul Kit
5-7
points
20% EOK 50% EOK 70% EOK (Parts marked “B” or “BF” in the
100% BOK 100% BOK 100% BOK
parts list)

<5
0% COK 5% COK 10% COK COK= Complete Overhaul Kit
0% EOK 40% EOK 60% EOK
points
100% BOK 100% BOK 100% BOK
(Parts marked "C" in the parts list)
Use the points from the table above.
<5
points
5-7
points
<7
points
The percentage tells how many of the
overhauled items need a specific kit.
Working Environment
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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 Kitnumber
A (Extended Overhaul Kit): 1741 044 004
FA (Extended Overhaul Kit for F-Unit): 1741 044 004
B (Basic Overhaul Kit): 170602
FB (Basic Overhaul Kit for F-Unit): 170347
C (Complete Overhaul Kit): 170603

For itemnumber 170638 and 170640 order kit :

Kit Kitnumber
A (Extended Overhaul Kit): 1741 044 004
B (Basic Overhaul Kit): 170602
C (Complete Overhaul Kit): 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 O-
ring 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 pedestal-
drilling 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 inter-
mediate 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 Drawing number Part number

N 4-300421 4741 009 000
C 4-500122 4741 002 000
F 2-500124 4741 003 000
G 3-500125 4741 004 000
H 3-500126 4741 005 000
J 4-500127 4741 006 000
K 3-500128 4741 007 000
L 2-500129 4741 008 000
P 2-500132 4741 010 000
S-F 4-500134 4741 012 000
T-F 4-500137 4165 002 000
- 3-500216 4741 044 000
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Signs

When ordering BFC/BFCF-spare parts, please state the complete type

number, as well as the units' serial number shown on the nameplates.
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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.
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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.