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 1

Repair of LEVER

1. After stripping a sub-assembly of brake head lever and articulation, levers are sent to lever repair
bushing and de-bushing area

2. Load a lever table with inner and outer LH and RH levers.

3. Remove all Nylon bushes by using a suitable punch and hammer.

4. Check the correctness of the holes by using a GO NO-GO gauge. The levers that fail in Gauging are
rejected and sent to scrap bins.

5. The levers that passed in Gauging are inspected by inspection staff for crack, bend in the tubes and
forks, twist in the lever body, broken welding, threads of the studs, edge at safety chain hole, pitted and
scoring marks etc.

6. The defective levers like cracked, scored bent, pitted at prone area are rejected and kept in scrap bins.
Also the levers with narrow edge at safety chain hole are rejected.

7. The damaged studs of the levers are removed by gas cutter and new studs are welded with arc
welding

8. The cracks, pits, and scorings at non prone area are filled by arc welding. Also the areas where broken
welding found are also welded by arc welding

9. All the bends are removed by hammering and dressing after heating the bends and allow sufficient
time to cool

10. Fit new Nylon bushes to the levers and ensure that the gap between pin and bush is to be
maintained to 1 mm

11. Send ready levers to assembly tables or store in respective green pallet.

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

Digitally signed by ANIL

ANIL KUMAR KUMAR

Date: 2023.04.20 11:01:31
+05'30'

P45W14