Description: Brake Hose Couplings 1 I N C H . . . H - 1 I N C H . .
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Description: Brake Hose Couplings 1 I N C H . . . H - 1 I N C H . . as PDF for free.
More details
- Words: 3,629
- Pages: 22
Loading documents preview...
Rail Vehicle Systems
.................... .................... B-QK80.21 Rev. 01 - 24.07.2009 - en
.................... ....................
Description
Brake hose couplings 1 inch... H-1 inch...
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
Contact address Knorr-Bremse Systeme für Schienenfahrzeuge GmbH Moosacher Str. 80 80809 München, Germany Phone: +49 (89) 3547-0 www.knorr-bremse.com
This document was originally written in German. Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 2 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
Table of contents 1
General information
5
1.1
Technical changes
5
1.2
Target group for this document
5
1.3
Notes and warning messages
6
2
Introduction
2.1 3
Related documents Basic safety information
7 7 8
3.1
Validity
8
3.2
Authorized use of the product
8
3.3
Operator's commitment to due care
8
3.3.1
Assignment of personnel
8
3.3.2
Availability of the document
8
3.3.3
Amendments to the document
9
3.3.4
Spares and wearing parts
9
4
Technical description
10
4.1
Technical features
10
4.2
Construction
10
5
Removal and installation
5.1
Installation
15 15
5.1.1
Requirements
16
5.1.2
Procedure
16
5.1.3
Leakage testing
16
5.1.4
Function testing
16
5.2
Removal
18
5.2.1
Requirements
18
5.2.2
Procedure
18
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 3 / 22
Brake hose couplings Description
6
Maintenance
6.1
Doc. no.: B-QK80.21 Revision: 01-en
19
Inspection
19
6.1.1
Interval
19
6.1.2
Special tools
19
6.1.3
Procedure
19
6.2
Servicing
19
6.3
Repair
20
6.4
Overhaul
20
6.4.1
Interval
20
Troubleshooting
21
7.1
Special tools
21
7.2
Procedure
21
7
8
Disposal
22
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 4 / 22
Brake hose couplings Description
1
Doc. no.: B-QK80.21 Revision: 01-en
General information DANGER Please read this document carefully from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment.
1.1
Technical changes
KB SfS reserves the right to change the unit or this document at any time without giving special notice.
1.2
Target group for this document
This document is intended for use by KB SfS trained service technicians who have the skill, experience, safety awareness and professional ability: •
to remove and install the unit,
•
to inspect, maintain and debug the unit,
have read and understood this document from start to finish, and are familiar with the safety codes and accident prevention regulations for these activities. NOTE This document will be useful to other target groups as well, e.g. project engineers. However, it does not claim to provide complete information for such target groups.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 5 / 22
Brake hose couplings Description
1.3
Doc. no.: B-QK80.21 Revision: 01-en
Notes and warning messages
Warning messages are subdivided into the following hazard levels in this document: DANGER Failure to comply with these instructions will lead to irreversible personal injuries which may have fatal consequences.
WARNING Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences.
CAUTION Failure to comply with these instructions may lead to personal injuries and/or to damage to the unit or the environment.
Safety notes have a specific structure which is explained here for DANGER: DANGER Source of the danger Consequence of the danger Remedial measures Notes do not contain any messages relevant to safety and are included only for the sake of completeness. NOTE Notes contain useful hints and additional information about the unit.
Warning messages in other parts of this Description draw your attention to the individual risks concerning your use of the product. Warning messages and notes generally precede the descriptions of the relevant applications.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 6 / 22
Brake hose couplings Description
2
Doc. no.: B-QK80.21 Revision: 01-en
Introduction
This Description contains particulars specific to the unit and discusses operation, installation, removal, function testing and maintenance of the unit when installed on-board.
2.1
Related documents
The related installation drawing specific to each item number must be consulted.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 7 / 22
Brake hose couplings Description
3 3.1
Doc. no.: B-QK80.21 Revision: 01-en
Basic safety information Validity WARNING Validity note (item number or type designation) ignored! The consequences may be personal injuries and damage to the unit. The validity notes in the document must always be taken into account. The item number or type designation is stated on the name plate and must agree with the validity note stated in this document.
This document is valid for units with type designations 1 inch x ...
H-1 Inch x ... NOTE Please contact a KB SfS Service Center if the unit cannot be clearly identified, e.g. because the name plate is illegible or missing.
3.2
Authorized use of the product
The unit listed in Section 3.1 shall be used only in the system that has been designed and engineered by KB SfS for the accompanying vehicle. Other applications and assignments, as well as changes, attachments and modifications may jeopardize the safety, reliability and functionality of the system. They invalidate any warranty on the part of KB SfS and transfer the liability to the operator. KB SfS must always be consulted before any other application or assignment is implemented.
3.3
Operator's commitment to due care
3.3.1 Assignment of personnel The operator shall ensure that the personnel assigned to the specified activities possesses the qualifications defined for the given target group.
3.3.2 Availability of the document The operator shall ensure that the present document is always available to the relevant personnel in a complete, up-to-date and readable form.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 8 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
3.3.3 Amendments to the document The operator shall ensure that, at the place of use, the present document is regularly amended by, or replaced with, instructions based on: statutory accident prevention regulations statutory accident protection regulations trade association regulations
3.3.4 Spares and wearing parts The operator shall ensure that none other than genuine KB SfS parts or KB approved spares or wearing parts are used. The installation of spares other than those approved may impair the safety and reliability of the given unit and overall system and invalidates any warranty on the part of KB SfS.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 9 / 22
Brake hose couplings Description
4
Doc. no.: B-QK80.21 Revision: 01-en
Technical description
The brake hose coupling connects the brake pipes or main reservoir pipes of two cars.
4.1
Technical features
The unit is distinguished by the following features: The brake hose coupling is an integral part of the pneumatic brake in rail vehicles. Type "H" is used to couple main reservoir pipes. The low-temperature flexibility of the brake hoses is identified by stars stamped on the unit: •
1 star = −45°C
•
2 stars = −60°C
The coupling heads are designed to allow brake pipes to be coupled only to brake pipes, and main reservoir pipes only to main reservoir pipes. The couplings meet the requirements of UIC Code 541-1-VE.
4.2
Construction
See Figure 1 and Figure 4 The brake hose couplings come in several models differing in the angles of their coupling heads, in their hose lengths and in the types of hose. The brake hose couplings are available in the following versions: Hose with one head at one end and one union at the other end Hose with one head at either end The heads of the brake hose couplings shown in Figure 1, Figure 2 and Figure 3 have grooved rings. Figure 4 shows the versions of the brake hose coupling heads that contain a valve.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 10 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 1
1" brake hose coupling having a coupling head with a grooved ring, and an internally threaded pipe union
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 11 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 2
H-1" brake hose coupling having a coupling head with a grooved ring, and an internally threaded pipe union
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 12 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 3
Brake hose coupling with two 1" coupling heads and a grooved ring
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
•
H-1 inch coupling heads match the representation in Figure 2.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 13 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 4
1" brake hose coupling having a coupling head with a valve, and a hose connection
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 14 / 22
Brake hose couplings Description
5
Doc. no.: B-QK80.21 Revision: 01-en
Removal and installation DANGER Beware of a moving vehicle! A vehicle allowed to move inadvertently will cause personal injury. It is vital to observe the working rules for arresting a vehicle.
5.1
Installation CAUTION Beware of contaminating the pneumatic system! Device and/or system functions will fail. Keep out dirt during installation. If necessary, blow out the pipes of the pneumatic system.
CAUTION Beware of disregarding the installation instructions! Safety will be diminished and functions restricted. Installation instructions and installation drawings must be taken into account.
CAUTION Beware of installing untested units! Safety will be diminished and functions restricted. Make sure that units are always tested before they are installed. The system must have been tested and found to be in order before the vehicle is cleared for service.
NOTE It is vital to observe the manufacturer's safety instructions and directions for the use of cleaning substances, sealants, adhesives, auxiliary products, working substances, etc.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 15 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
5.1.1 Requirements The unit can be installed with standard tools. The unit is designed for installation anywhere in the sprung part of a vehicle, provided it is protected from wet and dirt. The place of installation must be defined accordingly during engineering design of the vehicle. The notes contained in the installation drawing relating to mounting position and necessary clearances must be observed. The vehicle builder’s documents on installation – especially the data on fastening screws and tightening torques – must also be observed.
5.1.2 Procedure CAUTION Beware of installing the unit incorrectly! The unit will be damaged and/or its functionality impaired. To install the unit, hold the housing securely with a suitable tool, such as an open-end wrench. Take the covers off the onboard air pipe connection and the brake hose coupling. Thoroughly clean the ports. Attach the hose union of the brake hose coupling correctly to the onboard air pipe connection. Couple the cars correctly by the brake hose coupling. Connect the supply of compressed air.
5.1.3 Leakage testing Carry out the leakage test by applying a leakage testing substance. The test may be performed alternatively with a soap solution if no such special products are available. Test the pipe connections for leakage at the maximum acceptable working pressure. Air bubbling is unacceptable. Air leaking from the couplings is unacceptable. Leakage testing substances and all traces of soap must be removed immediately after the test.
5.1.4 Function testing The unit is an integral part of a system and must be tested for correct interaction with this system in the manner instructed by the railway administration / vehicle builder. Function testing may comprise the following points:
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 16 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
Couple up the cars several times by the brake hose coupling and test for leakage in accordance with Section 5.1.3.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 17 / 22
Brake hose couplings Description
5.2
Doc. no.: B-QK80.21 Revision: 01-en
Removal WARNING Pneumatic system is under high pressure! Particles flung outwards will, for instance, cause severe eye injuries. Observe the safety regulations for pneumatic systems. Prior to removal, release the pressure from the (sub)system.
CAUTION Beware of contaminating the pneumatic system! Device and/or system functions will fail. Keep out dirt after removal, such as by masking the ports and connections.
5.2.1 Requirements The unit can be removed with standard tools.
5.2.2 Procedure CAUTION Beware of removing the unit incorrectly! The unit will be damaged and/or its functionality impaired. To remove the unit, hold the housing securely with a suitable tool, such as an openend wrench. Turn off the supply of compressed air and vent all the reservoirs and air pipes connected to the unit. Do not allow any more compressed air to reach the brake hose coupling. Release the heads of the brake hose coupling, or release one coupling head and unscrew the hose union. Cover up the air pipe connection of the brake hose coupling. Cover up the onboard ports unless an exchange unit is going to be fitted immediately after removal.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 18 / 22
Brake hose couplings Description
6
Doc. no.: B-QK80.21 Revision: 01-en
Maintenance
In general, maintenance at KB SfS is subdivided into: Inspection Servicing Repair Overhaul The maintenance intervals required for the activities described below must be timed according to the statutory operating requirements, the service conditions under which the unit is used, and the environmental conditions in the area where the vehicles are operated. An interval stated generally for all projects will therefore be of only limited validity. KB SfS has the capacity to test the state of its units regularly during their lifetime. The aim of this service is to find together with the customer the optimal maintenance intervals for each individual project. The interval applicable to a specific project can be derived from the targets named in the table. The first target is always more significant than the successively lesser targets.
6.1
Inspection
The unit must be checked for good external condition and correct operation at regular intervals as specified by the vehicle operator.
6.1.1 Interval Activity
Interval
Inspection *
1. According to the vehicle operator's project-specific experience 2. In accordance with project-specific maintenance schedule, if any*
If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the customer and KB SfS.
6.1.2 Special tools Not required
6.1.3 Procedure See vehicle operator's instructions
6.2
Servicing
Not required
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 19 / 22
Brake hose couplings Description
6.3
Doc. no.: B-QK80.21 Revision: 01-en
Repair
If the unit develops a malfunction that cannot be corrected by the measures described in Section 7.2 please contact a KB SfS Service Center.
6.4
Overhaul
KB SfS gives top priority to safety and quality. To help fulfil this claim, KB SfS provides an overhauling service for its own units. KB SfS performs overhauls in its capacity as the original equipment manufacturer, while accounting for the safety aspects of the production processes. Both the experience and the technical equipment necessary for performing professional overhauls are present in KB SfS Service Centers.
6.4.1 Interval To judge when overhauls are required under the actual service conditions, you are urged to inspect a few randomly selected units for functionality and condition after a sufficient period of operation, and dismantle them to check for wear. Activity Overhaul *
Interval 1. According to the vehicle operator's project-specific experience 2. In accordance with project-specific maintenance schedule, if any*
If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the customer and KB SfS.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 20 / 22
Brake hose couplings Description
7
Doc. no.: B-QK80.21 Revision: 01-en
Troubleshooting
If the unit starts to malfunction, trace possible problems on board. Causes of problems can be corrected with the help of the directions proposed for debugging.
7.1
Special tools
Not required
7.2
Procedure
Problem
Cause
Remedy
See
Leaking brake hose coupling
Brake hose damaged
Remove the brake hose coupling and ship to a KB SfS Service Center for repair.
Section 5.2
Hose clamp loose Grooved ring dirty or damaged Brake hose coupling refuses to couple
Palm of the coupling head damaged
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 21 / 22
Brake hose couplings Description
8
Doc. no.: B-QK80.21 Revision: 01-en
Disposal CAUTION Improper disposal of environmentally harmful substances is dangerous! This would mean unnecessary and legally punishable harm to the environment. Observe the waste disposal regulations of the responsible authorities.
KB SfS units consist essentially of metal, rubber and plastic parts. Electronic components, auxiliary products and working substances are used as well. All materials must be separated as best possible from one another for the purposes of proper disposal. The national regulations on disposal must be observed.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 22 / 22
.................... .................... B-QK80.21 Rev. 01 - 24.07.2009 - en
.................... ....................
Description
Brake hose couplings 1 inch... H-1 inch...
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
Contact address Knorr-Bremse Systeme für Schienenfahrzeuge GmbH Moosacher Str. 80 80809 München, Germany Phone: +49 (89) 3547-0 www.knorr-bremse.com
This document was originally written in German. Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 2 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
Table of contents 1
General information
5
1.1
Technical changes
5
1.2
Target group for this document
5
1.3
Notes and warning messages
6
2
Introduction
2.1 3
Related documents Basic safety information
7 7 8
3.1
Validity
8
3.2
Authorized use of the product
8
3.3
Operator's commitment to due care
8
3.3.1
Assignment of personnel
8
3.3.2
Availability of the document
8
3.3.3
Amendments to the document
9
3.3.4
Spares and wearing parts
9
4
Technical description
10
4.1
Technical features
10
4.2
Construction
10
5
Removal and installation
5.1
Installation
15 15
5.1.1
Requirements
16
5.1.2
Procedure
16
5.1.3
Leakage testing
16
5.1.4
Function testing
16
5.2
Removal
18
5.2.1
Requirements
18
5.2.2
Procedure
18
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 3 / 22
Brake hose couplings Description
6
Maintenance
6.1
Doc. no.: B-QK80.21 Revision: 01-en
19
Inspection
19
6.1.1
Interval
19
6.1.2
Special tools
19
6.1.3
Procedure
19
6.2
Servicing
19
6.3
Repair
20
6.4
Overhaul
20
6.4.1
Interval
20
Troubleshooting
21
7.1
Special tools
21
7.2
Procedure
21
7
8
Disposal
22
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 4 / 22
Brake hose couplings Description
1
Doc. no.: B-QK80.21 Revision: 01-en
General information DANGER Please read this document carefully from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment.
1.1
Technical changes
KB SfS reserves the right to change the unit or this document at any time without giving special notice.
1.2
Target group for this document
This document is intended for use by KB SfS trained service technicians who have the skill, experience, safety awareness and professional ability: •
to remove and install the unit,
•
to inspect, maintain and debug the unit,
have read and understood this document from start to finish, and are familiar with the safety codes and accident prevention regulations for these activities. NOTE This document will be useful to other target groups as well, e.g. project engineers. However, it does not claim to provide complete information for such target groups.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 5 / 22
Brake hose couplings Description
1.3
Doc. no.: B-QK80.21 Revision: 01-en
Notes and warning messages
Warning messages are subdivided into the following hazard levels in this document: DANGER Failure to comply with these instructions will lead to irreversible personal injuries which may have fatal consequences.
WARNING Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences.
CAUTION Failure to comply with these instructions may lead to personal injuries and/or to damage to the unit or the environment.
Safety notes have a specific structure which is explained here for DANGER: DANGER Source of the danger Consequence of the danger Remedial measures Notes do not contain any messages relevant to safety and are included only for the sake of completeness. NOTE Notes contain useful hints and additional information about the unit.
Warning messages in other parts of this Description draw your attention to the individual risks concerning your use of the product. Warning messages and notes generally precede the descriptions of the relevant applications.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 6 / 22
Brake hose couplings Description
2
Doc. no.: B-QK80.21 Revision: 01-en
Introduction
This Description contains particulars specific to the unit and discusses operation, installation, removal, function testing and maintenance of the unit when installed on-board.
2.1
Related documents
The related installation drawing specific to each item number must be consulted.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 7 / 22
Brake hose couplings Description
3 3.1
Doc. no.: B-QK80.21 Revision: 01-en
Basic safety information Validity WARNING Validity note (item number or type designation) ignored! The consequences may be personal injuries and damage to the unit. The validity notes in the document must always be taken into account. The item number or type designation is stated on the name plate and must agree with the validity note stated in this document.
This document is valid for units with type designations 1 inch x ...
H-1 Inch x ... NOTE Please contact a KB SfS Service Center if the unit cannot be clearly identified, e.g. because the name plate is illegible or missing.
3.2
Authorized use of the product
The unit listed in Section 3.1 shall be used only in the system that has been designed and engineered by KB SfS for the accompanying vehicle. Other applications and assignments, as well as changes, attachments and modifications may jeopardize the safety, reliability and functionality of the system. They invalidate any warranty on the part of KB SfS and transfer the liability to the operator. KB SfS must always be consulted before any other application or assignment is implemented.
3.3
Operator's commitment to due care
3.3.1 Assignment of personnel The operator shall ensure that the personnel assigned to the specified activities possesses the qualifications defined for the given target group.
3.3.2 Availability of the document The operator shall ensure that the present document is always available to the relevant personnel in a complete, up-to-date and readable form.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 8 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
3.3.3 Amendments to the document The operator shall ensure that, at the place of use, the present document is regularly amended by, or replaced with, instructions based on: statutory accident prevention regulations statutory accident protection regulations trade association regulations
3.3.4 Spares and wearing parts The operator shall ensure that none other than genuine KB SfS parts or KB approved spares or wearing parts are used. The installation of spares other than those approved may impair the safety and reliability of the given unit and overall system and invalidates any warranty on the part of KB SfS.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 9 / 22
Brake hose couplings Description
4
Doc. no.: B-QK80.21 Revision: 01-en
Technical description
The brake hose coupling connects the brake pipes or main reservoir pipes of two cars.
4.1
Technical features
The unit is distinguished by the following features: The brake hose coupling is an integral part of the pneumatic brake in rail vehicles. Type "H" is used to couple main reservoir pipes. The low-temperature flexibility of the brake hoses is identified by stars stamped on the unit: •
1 star = −45°C
•
2 stars = −60°C
The coupling heads are designed to allow brake pipes to be coupled only to brake pipes, and main reservoir pipes only to main reservoir pipes. The couplings meet the requirements of UIC Code 541-1-VE.
4.2
Construction
See Figure 1 and Figure 4 The brake hose couplings come in several models differing in the angles of their coupling heads, in their hose lengths and in the types of hose. The brake hose couplings are available in the following versions: Hose with one head at one end and one union at the other end Hose with one head at either end The heads of the brake hose couplings shown in Figure 1, Figure 2 and Figure 3 have grooved rings. Figure 4 shows the versions of the brake hose coupling heads that contain a valve.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 10 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 1
1" brake hose coupling having a coupling head with a grooved ring, and an internally threaded pipe union
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 11 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 2
H-1" brake hose coupling having a coupling head with a grooved ring, and an internally threaded pipe union
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 12 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 3
Brake hose coupling with two 1" coupling heads and a grooved ring
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
•
H-1 inch coupling heads match the representation in Figure 2.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 13 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
1
Coupling head
3
Brake hose
1.2
Grooved ring
4
Hose union
2
Hose clamp
1)
Stars denoting low-temperature flexibility
Figure 4
1" brake hose coupling having a coupling head with a valve, and a hose connection
Remarks Coupling head (1): •
Coupling head for brake pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined downwards.
•
Coupling head for main reservoir pipes: Viewed by its opening with the union part located at the right-hand side, the coupling head is always inclined upwards.
•
The back of the coupling head for main reservoir pipes is identified by cross-shaped ribs cast onto its body.
The fire-proof hose is thicker than the hose shown here.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 14 / 22
Brake hose couplings Description
5
Doc. no.: B-QK80.21 Revision: 01-en
Removal and installation DANGER Beware of a moving vehicle! A vehicle allowed to move inadvertently will cause personal injury. It is vital to observe the working rules for arresting a vehicle.
5.1
Installation CAUTION Beware of contaminating the pneumatic system! Device and/or system functions will fail. Keep out dirt during installation. If necessary, blow out the pipes of the pneumatic system.
CAUTION Beware of disregarding the installation instructions! Safety will be diminished and functions restricted. Installation instructions and installation drawings must be taken into account.
CAUTION Beware of installing untested units! Safety will be diminished and functions restricted. Make sure that units are always tested before they are installed. The system must have been tested and found to be in order before the vehicle is cleared for service.
NOTE It is vital to observe the manufacturer's safety instructions and directions for the use of cleaning substances, sealants, adhesives, auxiliary products, working substances, etc.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 15 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
5.1.1 Requirements The unit can be installed with standard tools. The unit is designed for installation anywhere in the sprung part of a vehicle, provided it is protected from wet and dirt. The place of installation must be defined accordingly during engineering design of the vehicle. The notes contained in the installation drawing relating to mounting position and necessary clearances must be observed. The vehicle builder’s documents on installation – especially the data on fastening screws and tightening torques – must also be observed.
5.1.2 Procedure CAUTION Beware of installing the unit incorrectly! The unit will be damaged and/or its functionality impaired. To install the unit, hold the housing securely with a suitable tool, such as an open-end wrench. Take the covers off the onboard air pipe connection and the brake hose coupling. Thoroughly clean the ports. Attach the hose union of the brake hose coupling correctly to the onboard air pipe connection. Couple the cars correctly by the brake hose coupling. Connect the supply of compressed air.
5.1.3 Leakage testing Carry out the leakage test by applying a leakage testing substance. The test may be performed alternatively with a soap solution if no such special products are available. Test the pipe connections for leakage at the maximum acceptable working pressure. Air bubbling is unacceptable. Air leaking from the couplings is unacceptable. Leakage testing substances and all traces of soap must be removed immediately after the test.
5.1.4 Function testing The unit is an integral part of a system and must be tested for correct interaction with this system in the manner instructed by the railway administration / vehicle builder. Function testing may comprise the following points:
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 16 / 22
Brake hose couplings Description
Doc. no.: B-QK80.21 Revision: 01-en
Couple up the cars several times by the brake hose coupling and test for leakage in accordance with Section 5.1.3.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 17 / 22
Brake hose couplings Description
5.2
Doc. no.: B-QK80.21 Revision: 01-en
Removal WARNING Pneumatic system is under high pressure! Particles flung outwards will, for instance, cause severe eye injuries. Observe the safety regulations for pneumatic systems. Prior to removal, release the pressure from the (sub)system.
CAUTION Beware of contaminating the pneumatic system! Device and/or system functions will fail. Keep out dirt after removal, such as by masking the ports and connections.
5.2.1 Requirements The unit can be removed with standard tools.
5.2.2 Procedure CAUTION Beware of removing the unit incorrectly! The unit will be damaged and/or its functionality impaired. To remove the unit, hold the housing securely with a suitable tool, such as an openend wrench. Turn off the supply of compressed air and vent all the reservoirs and air pipes connected to the unit. Do not allow any more compressed air to reach the brake hose coupling. Release the heads of the brake hose coupling, or release one coupling head and unscrew the hose union. Cover up the air pipe connection of the brake hose coupling. Cover up the onboard ports unless an exchange unit is going to be fitted immediately after removal.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 18 / 22
Brake hose couplings Description
6
Doc. no.: B-QK80.21 Revision: 01-en
Maintenance
In general, maintenance at KB SfS is subdivided into: Inspection Servicing Repair Overhaul The maintenance intervals required for the activities described below must be timed according to the statutory operating requirements, the service conditions under which the unit is used, and the environmental conditions in the area where the vehicles are operated. An interval stated generally for all projects will therefore be of only limited validity. KB SfS has the capacity to test the state of its units regularly during their lifetime. The aim of this service is to find together with the customer the optimal maintenance intervals for each individual project. The interval applicable to a specific project can be derived from the targets named in the table. The first target is always more significant than the successively lesser targets.
6.1
Inspection
The unit must be checked for good external condition and correct operation at regular intervals as specified by the vehicle operator.
6.1.1 Interval Activity
Interval
Inspection *
1. According to the vehicle operator's project-specific experience 2. In accordance with project-specific maintenance schedule, if any*
If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the customer and KB SfS.
6.1.2 Special tools Not required
6.1.3 Procedure See vehicle operator's instructions
6.2
Servicing
Not required
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 19 / 22
Brake hose couplings Description
6.3
Doc. no.: B-QK80.21 Revision: 01-en
Repair
If the unit develops a malfunction that cannot be corrected by the measures described in Section 7.2 please contact a KB SfS Service Center.
6.4
Overhaul
KB SfS gives top priority to safety and quality. To help fulfil this claim, KB SfS provides an overhauling service for its own units. KB SfS performs overhauls in its capacity as the original equipment manufacturer, while accounting for the safety aspects of the production processes. Both the experience and the technical equipment necessary for performing professional overhauls are present in KB SfS Service Centers.
6.4.1 Interval To judge when overhauls are required under the actual service conditions, you are urged to inspect a few randomly selected units for functionality and condition after a sufficient period of operation, and dismantle them to check for wear. Activity Overhaul *
Interval 1. According to the vehicle operator's project-specific experience 2. In accordance with project-specific maintenance schedule, if any*
If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the customer and KB SfS.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 20 / 22
Brake hose couplings Description
7
Doc. no.: B-QK80.21 Revision: 01-en
Troubleshooting
If the unit starts to malfunction, trace possible problems on board. Causes of problems can be corrected with the help of the directions proposed for debugging.
7.1
Special tools
Not required
7.2
Procedure
Problem
Cause
Remedy
See
Leaking brake hose coupling
Brake hose damaged
Remove the brake hose coupling and ship to a KB SfS Service Center for repair.
Section 5.2
Hose clamp loose Grooved ring dirty or damaged Brake hose coupling refuses to couple
Palm of the coupling head damaged
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 21 / 22
Brake hose couplings Description
8
Doc. no.: B-QK80.21 Revision: 01-en
Disposal CAUTION Improper disposal of environmentally harmful substances is dangerous! This would mean unnecessary and legally punishable harm to the environment. Observe the waste disposal regulations of the responsible authorities.
KB SfS units consist essentially of metal, rubber and plastic parts. Electronic components, auxiliary products and working substances are used as well. All materials must be separated as best possible from one another for the purposes of proper disposal. The national regulations on disposal must be observed.
Copyright Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as copying and transferring. Knorr-Bremse Group
Page 22 / 22
Related Documents
E K H E M E I C H I M E I K I
January 2021 0
9 M M B S P M A C H I N E G U N
January 2021 0
E N I G M A C I P H E R
March 2021 0
E N I G M A C I P H E R
March 2021 0