EMU Workshop, Mahalaxmi, Western Railway, Mumbai

Work Instruction
Chapter Title: WORK INSTRUCTIONS FOR MAINTENANCE OF BRAKE RIGGING
ISO 9001:2015 Issue No: 02 Rev. No: 00 Doc No WI/BR/01
Date: 20.04.2023 Rev. date: Nil Page 1 of 2

Repair of brake beams (inner/outer)

* After washing keep brake beams near the brake beam repair area

* Clean beams by using the wire brush thoroughly to remove any dirt or dust or unwanted matter on the
pin of the brake beam.

A. Outer brake beam:

1. Inspect the outer brake beam for the defects like bend, dent, crack, scoring marks or abrasion on
brake beam pin, pitted, and welding of the brackets as well as bend in the brackets etc.

2. The cracked, heavily pitted beams and beams with heavy dent marks and scorings are rejected and
sent to scrap bins.

3. The repairable bends are removed by hammering it with a die. The bends at pins of the brake beam
are removed by hammering and dressing.

4. Weld the bracket by arc welding if the bracket welding is broken and straighten the brackets if it is
found bend.

5. Keep the repaired beams on the outer brake beam stand or supply the repaired beams on assembly
work bench.

Approved By - Dy.CEE Stamp of controlled/uncontrolled copy Issued By- PE

Digitally signed by ANIL

ANIL KUMAR KUMAR

Date: 2023.04.20
11:01:06 +05'30'

P45W14
 EMU Workshop, Mahalaxmi, Western Railway, Mumbai
Work Instruction
Chapter Title: WORK INSTRUCTIONS FOR MAINTENANCE OF BRAKE RIGGING
ISO 9001:2015 Issue No: 02 Rev. No: 00 Doc No WI/BR/01
Date: 20.04.2023 Rev. date: Nil Page 2 of 2

B. Inner brake beam:

1. Inspect the inner brake beam for the defects like bend, dent mark, crack, scoring marks or abrasion on
brake beam pin, pitted, squareness and welding of the brackets as well as bend in the brackets etc.

2. The cracked, heavily pitted beams and beams with heavy dent mark and scorings are rejected and
sent to scrap bins.

3. The repairable bends are removed by hammering it with a die. The bends at pins of the brake beam
are removed by hammering and dressing.

4. The squareness of the inner beams is examined and repaired by using in-house developed brake
beam repair arrangement which consists of a fixture table, clamps supporters and a distance gauge of
1678mm length

5. Fix the inner beam in the fixture table. Match the block position with marking on the fixture table. If it
is not matching then insert a support below the brake beam, clamp brake beam end with the clamping
equipment and apply a force with the pipe so that the block position is getting matched. Use distance
gauge to maintain outer distance of the block to 1678 mm.

6. Weld the bracket by arc welding if the bracket welding is broken and straighten the brackets by
hammering if it is found bent.

7. Keep the repaired beams on the inner brake beam stand or supply the repaired beams on the
assembly work bench.

Approved By - Dy.CEE Stamp of controlled/uncontrolled copy Issued By- PE

Digitally signed by ANIL

ANIL KUMAR KUMAR

Date: 2023.04.20 11:24:13
+05'30'

P45W14