READY RECKONER & TECHNICAL INFORMATION FOR BUS APPLICATION

Transcription

1 READY RECKONER & TECHNICAL INFORMATION FOR BUS APPLICATION BI / HCV/ 02 Aug 2015 Padi, Chennai Telephone : (044) Fax : (044) Visit our website at : 1

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3 Contents Description Page No. 1 POINTS FOR YOUR Bus ATTENTION LIST OF ABBREVIATIONS S CAM BRAKE EXPLODED VIEWS... 8 AL BUS APPLICATION 4 BRAKE PRODUCT MATRIX BSIII & BSIV HLT BRAKES COMPARISON TVS-GIRLING BRAKE IDENTIFICATION BRAKE PRODUCT MATRIX BSII BSII BRAKES COMPARISON FLANGE, TUBE & BRACKET DETAILS CAM SHAFT DETAILS HLT & NON HLT SHOE COMPARISON LINING THICKNESS & RIVET DETAILS REGULAR VS VA/VE COMPARISON SPRING & ROLLER DETAILS INTERCHANGEABILITY CHART

4 Contents Description Page No. 16 JNNURM BUS DETAILS CLUTCH CYLINDER DETAILS TML BUS APPLICATION 18 PRODUCT MATRIX PRIOR TO JUNE NON VA/VE VS VA/VE COMPARISON INTERCHANGEABILITY CHART CURRENT PRODUCT MATRIX CAM SHAFT DETAILS LINING PART NOS LINED SHOE COMPARISON CLUTCH CYLINDER DETAILS VECV (EML) BUS APPLICATION 26 PRODUCT MATRIX NON VA/VE VS VA/VE COMPARISON CLUTCH CYLINDER DETAILS

5 Points For Your Attention Dear Customer, We are pleased to release the TVS-Girling Technical information & Ready Reckoner for AL, TML & VECV Bus Application. While every effort has been made to make the Ready Reckoner clear and concise, suggestions for improvement are welcome. The data in this Ready Reckoner is subject to change from time to time and we reserve the right to effect changes regarding serviceability of parts, as and when necessary. Thanking you and assuring you of our best service at all times. Divisional Manager Technical Service - Marketing Brakes India Limited Chennai

6 List of Abbreviations ABS A/F Alu AS Assy CI CMC CSC CV Dia Eng FLH FRH HLT LH mm MTC NA No O/S RESLF RH Anti Lock Braking System Across Flat Aluminium American Standard Assembly Cast Iron Clutch Master Cylinder Clutch Slave Cylinder Centre Valve Diameter Engine Front Left Hand Front Right Hand Higher Lining Thickness Left Hand Millimetre Metropolitan Transport Corporation (Chennai) Not Available Number Over Size Rear Engine Semi Low Floor Right Hand 6

7 List of Abbreviations RLH Rr RRH Std STU VA/VE W/O Rear Left Hand Rear Rear Right Hand Standard State Transport Undertaking Value Added & Value Engineering Without Various State Transport Undertakings APSRTC Andhra Pradesh State Road Transport Corporation AMTS Ahmedabad Municipal Transport Service BMTC Bangalore Metropolitan Transport Corporation DIMTS Delhi Integrated Multi-Modal Transit System GSRTC Gujarat State Road Transport Corporation HRTC Himachal Road Transport Corporation HSRTC Haryana State Road Transport Corporation KDMT Kalyan Dombivli Municipal Transport KSRTC Karnataka State Road Transport Corporation MSRTC Maharashtra State Road Transport Corporation PMPML Pune Mahanagar Parivahan Mahamandal Limited RSRTC Rajasthan State Road Transport Corporation UPSRTC Uttar Pradesh State Road Transport Corporation 7

8 1. Torque Plate 2. Lined Shoe 3. Roller 4. Fulcrum Pin 5. Bush-Fulcrum End 6. Spring-Abument End 7. Cam Shaft 8. O Ring 9. Bush 10. Tube, Flange & Bracket 11. Bush 12. Oil Seal 13. Sleeve Derin 14,15,16,17 Washer & Shim 18. Circlip 19. Dust Cover 20. Grommet 21. Washer 22. Bolt 23. Washer 24. Bolt 25. Spring-Cam End Typical Front S Cam Brake Exploded view

9 1. Torque Plate 2. Lined Shoe 3. Roller 4. Bush-Fulcrum End 5. Fulcrum Pin 6. Cam Shaft 7. O Ring 8. Bush 9. Oil Seal 10. Cam Shaft Bracket 11. Sleeve 12,13,14,15. Washer & Shim 16. Circlip 17. Spring-Cam End 18. Spring-Abument End 19. Dust Cover 20. Grommet 21. Bolt 22. Washer Typical Rear S Cam Brake Exploded view

10 AL Bus Application Note : All our parts catalogues are posted in Brakes India website under Parts & Service Page Visit our website at : 10

11 Product Matrix BSIII & BSIV Vehicle Model Front Brake Rear Brake Viking / Cheetah / / 96 6 HLT 7 HLT Viking / Cheetah / / 98 7 HLT 8 HLT 12 M BSIII (4/170) / / 19 Jan Bus 7 HLT 8 HLT RESLF E+1 BSIII, / / 19 Tarmac 7 HLT 8 HLT Lynx - FA90 Front Axle / / 60 5 Non HLT 7 Non HLT Lynx - 5T Front Axle / / 60 (Not in OE) 5 Non HLT 7 Non HLT Note : Currently all brakes are converted to VA/VE brakes. Refer Page No. 20 & 21 to differentiate theva/ve & Non VA/VE brakes. ABS models front & Rear Brake are Non BIL Supply. 11

12 HLT Brakes Comparison Brakes Brake Assembly Part No (LH / RH) 6" Front HLT / 43 7" Front HLT / 70 - Cast Bracket & 288 mm Cam shaft length 7" Front HLT / 93 - Fabricated Bracket & 250 mm cam shaft length. To suit 38mm offset Auto Slack Adjuster 7" Rear HLT / 49 8" Rear HLT / 51 - Cast Bracket & 426 mm cam shaft length 8" Rear HLT / 19 - Fabricated Bracket & 446 mm cam shaft length. To suit 28.5mm offset Auto Slack Adjuster 12

13 Brake Assembly Identification TVS - Girling Brake Identification Grommet hole & Grommet shape 13

14 Product Matrix BSII Vehicle Model Front Brake Rear Brake 12 M Bus / / 83 6 Non HLT 7 Non HLT Viking / Cheetah / / 01 Front 6 Brakes 6 Non HLT 7 Non HLT Viking / Cheetah / 35 Front 5 Brakes FA90 Front Axle Serrated Bolt / 25 5T Front Axle / 01 Stud Version / 32 6T Front Axle Stud Version 222 Viking Best / / 01 SLF Bus 6 Non HLT 7 Non HLT MTC Chennai / / 01 5 Non HLT 7 Non HLT 14

15 BSII Brakes Comparison Front Brake Comparison Brake Part No Width Cam Shaft Mounting Bracket Length Details Type / 25 5" 268 Stud Version Cast / 02 6" 268 Stud Version Fabricated / 30 5" 268 No stud / Fabricated No bolt / 32 5" 288 Stud Version Fabricated / 26 6" 288 Stud Version Fabricated / 35 5" 288 Serrated Bolt Cast / 71 6" 288 Serrated Bolt Cast Note To improve the brake performance, front brake chamber size changed the from type 16 to type 20 effective sep In order to accommodate the type 20 chamber, the length of "S" cam shaft & front flange, tube & Bracket increased from 268 mm to 288 mm. Except for the cam shaft & flange, tube & bracket, all the child parts are interchangeable 15

16 Flange, Tube & Bracket Details Flange, Tube & Hand Bracket Casting Mounting Bracket Assy No. part No hole size RLH mm RLH mm RRH mm RRH mm FLH mm FRH mm FLH mm FLH mm FRH mm FRH mm FLH Fabricated type 14.6 mm FRH Fabricated type 14.6 mm FLH Fabricated type 14.6 mm FRH Fabricated type 14.6 mm FLH Fabricated type 14.6 mm FRH Fabricated type 14.6 mm FLH Fabricated type 12.6 mm FRH Fabricated type 12.6 mm 16

17 Cam Shaft Details Part Number Length Profile Remarks / mm 2 Front - HLT / mm 1 Front - Non HLT / mm 1 Front - Non HLT / mm 2 Front - HLT / mm 2 Front - HLT / mm 1 Front - Non HLT / mm 2 Rear - HLT / mm 1 Rear - Non HLT / mm 2 Rear - HLT Profile 1 BI TVS Profile 2 BI TVS LH LH Cam Shaft Length Groove to identify the HLT Cam Shaft 17

18 Lined Shoe Details HLT Vs Non HLT Lined Shoe Identification Non HLT Lined shoe HLT Lined shoe Type 1 Type 2 Rim Miter cutting is high than HLT Rim not extended up to web Rim chamfer is less than Non HLT Lined Shoe Width No of Rivets Type Part No per Lining CA 7" 10 Non HLT CA 5" 10 Non HLT " 10 HLT " 10 HLT " 12 HLT 18

19 Lining Thickness & Rivet Details A Dimension A is Useful Lining Thickness at centre Linings Non HLT (A) HLT (A) Standard 11.6 mm 14.8 mm 1 st Over Size 12.4 mm 15.6 mm 2nd Over Size 13.2 mm 16.4 mm Rivet Non HLT 13 mm Rivet HLT 14 mm 10 mm 10 mm Rim Rim Rim thickness = 4 mm Rim thickness = 5 mm 19

20 Regular Vs VA/VE Brake Comparison VA/VE Brake Introduction : Apr 2012 Mounting Bolt of Tube, Flange & Bracket (shown in arrow mark) size is Regular - M14 VA/VE - M12 To identify the above thread size, check the Mounting Bolt of Tube, Flange & Bracket size is Bolt Head A/F Size in Regular-22 mm Bolt Head A/F Size in VA/VE-18 mm Mounting Bolt of Dust Cover (shown in arrow mark) size is Regular - M10 VA/VE - M8 To identify the above thread size, Check the Mounting Bolt of Dust Cover size is Bolt Head A/F Size in Regular - 16 mm Bolt Head A/F Size in VA/VE - 13 mm 20

21 Regular Vs VA/VE Brake Comparison Non VA/VE Brake VA/VE Brake CA CA Note : Non VA/VE Brake assembly part No. & Corresponding VA/VE Brake assembly part No. are one to one interchangeable. (As Brake Assy only) 21

22 Shoe Return Spring Details Single Piece Spring ( Red Colour) Three Piece Spring (HLT Rear) ( Black Colour) Note : Front Brakes (Both HLT & Non HLT brakes fitted with single coil spring) Roller (All Models) Roller Details 54 mm 38 mm 22

23 Interchangeability Chart Description Part No Alternate Part No BRAKE ASSY FLH BRAKE ASSY FRH BRAKE ASSY FLH BRAKE ASSY FRH BRAKE ASSY RLH BRAKE ASSY RRH BRAKE ASSY RLH BRAKE ASSY RRH BRAKE ASSY RLH BRAKE ASSY RRH BRAKE ASSY FLH BRAKE ASSY FRH BRAKE ASSY FLH BRAKE ASSY FRH BRAKE ASSY FLH BRAKE ASSY FRH BRAKE ASSY RLH BRAKE ASSY RRH C M C ASSY TORQUE PLATE FLH TORQUE PLATE FRH

24 Interchangeability Chart Description Part No Alternate Part No BRACKET ASSY FLH BRACKET ASSY FRH BRACKET ASSY FLH BRACKET ASSY FRH LINED SHOE ASSY LINED SHOE ASSY TORQUE PLATE FLH TORQUE PLATE FRH KIT LINING SET-STD KIT LINING SET-1 O/S KIT LINING SET-2 O/S KIT LINING SET-STD KIT LINING SET-1 O/S KIT LINING SET-2 O/S BRAKE ASSY RLH CA BRAKE ASSY RRH CA BRAKE ASSY RLH FJ BRAKE ASSY RRH FJ BRAKE ASSY FLH FJ BRAKE ASSY FRH FJ

25 JnNURM Bus Details Front Brake Size 6" 7" Lined Shoe Kit Lining Set - Std Kit Lining Set - 1 O/S Kit Lining Set - 2 O/S Spring-Cam End Spring-Abutment End Bush-Cam End Bush-Bracket End Bush-Fulcrum Roller Rear Brake Size 6" 7" Lined Shoe Kit Lining Set - Std Kit Lining Set - 1 O/S Kit Lining Set - 2 O/S Spring-Cam End Spring-Abutment End Bush-Cam End Bush-Bracket End Bush-Fulcrum Roller

26 Clutch Cylinder Details Vehicle Model Part No Size, Type & Details Description 12M (4 /106), (4/107), AS Yellow Finish - Last 4 Digit Casting No is (4/169), (4/170), Lynx CMC 3640 Seal No is & M (4 / 86), Lynx CNG AS White Finish - Last 4 Digit Casting No is CMC 3640 Seal No is & Luxura CV White Finish - Last 4 Digit Casting No is CMC 1682 Seal No is M (4 /106), (4/107), White Finish - Last 4 Digit Casting No is (4/169), (4/170) CSC Seal No is & Lynx White Finish - Last 4 Digit Casting No is CSC Seal No is M (4 / 86), Lynx CNG Yellow Finish - Last 4 Digit Casting CSC No is Seal No is

27 Clutch Cylinder Details & Description BI Part No BI Part No BI Part No CMC Assembly CMC Major Kit CMC Minor Kit

28 Clutch Cylinder Details Description BI Part No BI Part No BI Part No CSC Assembly CSC Major Kit CSC Minor Kit

29 TML Bus Application Note : All our parts catalogues are posted in Brakes India website under Parts & Service Page Visit our website at : 29

30 Product Matrix Prior to June-2006 The following parts are different between Non VA/VE & VA/VE. Application : TML 1312 Axle Front Description NON VA/VE VA/VE Brake Assy-LH FJ FJ Brake Assy-RH FJ FJ Torque Plate-LH Torque Plate-RH Flange, Tube & Bracket-LH Flange, Tube & Bracket-RH Cam Shaft-LH Cam Shaft-RH Lined Shoe Assy FJ FJ Roller Application : TML 1312 Axle Rear Description NON VA/VE VA/VE Brake Assy-LH FJ FJ Brake Assy-RH FJ FJ Torque Plate Cam Shaft-LH Cam Shaft-RH Lined Shoe Assy FJ FJ Roller

31 Product Matrix Prior to June-2006 Application : TML KULBEER SINGH Axle Rear Description NON VA/VE VA/VE Brake Assy-LH FJ FJ Brake Assy-RH FJ FJ Torque Plate Cam Shaft-LH Cam Shaft-RH Lined Shoe Assy FJ FJ Roller Application : TML 1210 Axle Rear Description NON VA/VE VA/VE Brake Assy-LH FJ FJ Brake Assy-RH FJ FJ Torque Plate Cam Shaft-LH Cam Shaft-RH Lined Shoe Assy FJ FJ Roller

32 Non VA/VE Vs VA/VE Comparison Tube, Flange & Bracket 4 Holes Torque plate 4 Holes Mounting Bolt of Flange, Tube & Bracket Non VA / VE - M14 VA / VE - M12 Identification : 1 Check the Mounting Bolt of Flange, Tube & Bracket size is Bolt Head A / F Size in Non VA / VE - 22 mm Bolt Head A / F Size in VA / VE - 18 Identification : 2 Check the Last 4 digit casting part number. Non VA / VE VA / VE Last 4 digit casting No. cast here

33 Non VA/VE Vs VA/VE Comparison Non VA/VE BI TVS VA/VE BI TVS Cam Head width : 35mm Cam Head width : 29mm Non VA/VE Roller VA/VE Roller 51.5 mm 38 mm 33

34 Non VA/VE Vs VA/VE Comparison Non VA/VE Lined Shoe VA/VE Lined Shoe Lesser dia to accommodate VA/VE Roller Hole is eliminated to iden fy the VA/VE Shoes Assembly Possibilities in field Existing Rollers assembled with VA/VE Cam Shaft VA/VE Rollers assembled with existing Cam Shaft Effects of wrong assemblies Brake set diameter increases. Drum will not enter Effective braking is available only for 50 % of lining thickness 34

35 Interchangeability Chart Delrin Bush Version Brake Vs Metal Bush Version Brake Delrin Bush Metal Bush Equivalent MASU Brake Part No. Brake Part No Lining part No / / / / / / / / / / / / / / / 86 Note : Delrin Bush brake assembly part No., Metal Bush brake assembly part No. & Corresponding MASU Lining Brake assembly part No. are one to one interchangeable 35

36 Current Product Matrix TML 1312 Axle Front & Rear Front Brake : / 98 Rear Brake : / 70 LPO 1510/ 55 BS-II&BS-III LP 1512 C BS-III LPO 1512TC/ 55 BS-III (2012 EDITION) LP 1512/ 52 (497 TCIC) BS-III LP 1512TC/ 52 BS-III LP/ LPO 1510 TCIC RHD BS-II LP/ LPO 1512C BS-II LP/ LPO 1613 SUPER MILO LP 1512TC/ 52 BS-III (RSRTC), (KERALA), (MSRTC), (TNSTC) LPO 1512TC/ 53 BS-III (KSRTC) LPO 1512TC/ 55 BS-III (APSRTC), (GSRTC), (HSRTC) LPO 1512C/ 55 BS-III (BMTC) LPO 1512C/ 55 BS-II (UTTARAKHAND) Front Brake : / 02 Rear Brake : / 86 LPO 1613 / CNG BS-III (AMTS) LPO 1512TC / 55 BS-III (KDMT) 36

37 Current Product Matrix TML 1312 Axle Front & Rear KULBEER SINGH Axle Front Brake : / 98 Rear Brake : / 86 LP / LPO 1615 TCIC BS-III LP / LPO 1613 SUPER MILO (APSRTC) LPO 1512 TC / 53 BS-III (UPSRTC), (HRTC), (TNSTC) LPO 1512 TC / 53 BS-III (KSRTC EDITION) TML 1312 Axle Front & Rear 1210 Axle Front Brake : / 98 Rear Brake : / 02 LPO 1612TC / 62 BS II (MSRTC) LPO 1612TC / 62 BS-III LPO 1610C-59 RE BUS RHD BS-II LPO 1612C / 62 BS-II LPO 1612C-59RE BUS RHD BS-II & BS-III LPO 1616C RHD BS II 37

38 Current Product Matrix Front Brake : / 50 Rear Brake : / 70 LP 1613 / 52 (697 ENG) BS-IV LPO 1612TC / 62 BS-3( 2013 EDN.) LPO 1613 / 55 CNG BS-IV (DIMTS) LPO 1618 TC / 62 BSIII (KSRTC) LPO 1613 / 55 (697 ENG) BSIV LPO 1613 CNG BSIV LPO 1512TC / 55 BS-III (TAMILNADU) LPO 1616TC / 62 BS-IV (BMTC) LPO 1618C / 62 BSIII (BMTC) LPO 1618C / 62 BSIII (APSRTC) LPO 1613, 55 WB, 697 CNG BS-IV (PMPL) LPO 1618 RE LE BS-III(BHOPAL) * LPO 1624 RELE BS-III (2012 EDN) * LPO 1628 HIDECK BUS * Note : * models are with front disc brakes (Non BIL supply) 38

39 Cam Shaft Details Brake Assy Cam Shaft Length Profile Part No Part No / / mm / / mm / / mm / / mm / / mm / / mm / / mm 3 Wear Sensor compatible / / mm / / mm / / mm / / mm / / mm 2 39

40 Cam Shaft Details Profile 1 BI TVS Profile 2 BI TVS Profile 3 BI TVS Cam Shaft Length 40

41 Lining Part Nos Specification No of Rivets / Lined Shoe Std 1 O/S 2 O/S Lining Lining Lining Lining 160 Width - (TVS Grade) Width - (Masu Grade) Width - (Rane Grade) Width - (TVS Grade) Width - (Masu Grade) Width - (Rane Grade) Width - WTP Brake Width - WTP Brake

42 Lined Shoe Comparison Lined Shoe 160 & 180 width Lined Shoe 200 & 220 width width ROLLER WEB PLATE SPLIT PIN 42

43 Clutch Cylinder Details Standout , , ,

44 Clutch Cylinder Details BIL Part No Description Type & Size Push Rod Casting No Seal Standout Part No CMC - CI 25.4 AS w/o Push Rod CMC - CI CV 126 mm CMC - CI CV 150 mm CMC - Alu CV 150 mm CMC - Alu CV 126 mm CSC - CI mm CSC - CI 38.1 w/o Push Rod

45 Clutch Cylinder Details Cylinder Assy No Major Kit Minor Kit

46 VECV Bus Application Note : All our parts catalogues are posted in Brakes India website under Parts & Service Page Visit our website at : 46

47 Product Matrix Vehicle Models : 15.16, 20.15, & RESLF Note : From July 2011 onwards, all brakes are converted to VA/VE brakes. Refer Page No. 49 to differentiate the VA/VE & Non VA/VE brakes. The following parts are difference between Non VA/VE & VA/VE. Front Brake Description NON VA/VE VA/VE Brake Assy-LH FJ Brake Assy-RH FJ Torque Plate-LH Torque Plate-RH Flange, Tube & Bracket-LH Flange, Tube & Bracket-RH Cam Shaft-LH Cam Shaft-RH Lined Shoe Assy FJ Kit Lining Set-Std FJ Kit Lining Set-1 O/S FJ Kit Lining Set-2 O/S FJ Roller Bush

48 Product Matrix Rear Brake Description NON VA/VE VA/VE Brake Assy-LH FJ Brake Assy-RH FJ Torque Plate Cam Shaft-LH Cam Shaft-RH Cam Shaft Bracket Lined Shoe Assy FJ Kit Lining Set-Std FJ Kit Lining Set-1 O/S FJ Kit Lining Set-2 O/S FJ Roller Bush Lining Grade Supply Reference TVS AF 235 July-2011 to Oct 2011 RAF 7 Nov-2011 to Oct 2013 TVS AF 5429 B Nov-2013 onwards 48

49 Non VA/VE Vs VA/VE Comparison Tube, Flange & Bracket 4 Holes Torque plate 4 Holes Last 4 digit casting No. cast here Mounting Bolt of Flange, Tube & Bracket Non VA / VE - M14 VA / VE - M12 Identification : 1 Check the Mounting Bolt of Flange, Tube & Bracket size is Bolt Head A / F Size in Non VA / VE - 22 mm Bolt Head A / F Size in VA / VE - 18 Identification : 2 Check the Last 4 digit casting part number. Non VA / VE VA / VE

50 Non VA/VE Vs VA/VE Comparison Non VA/VE BI TVS VA/VE BI TVS Cam Head width : 35mm Cam Head width : 29mm Non VA/VE Roller VA/VE Roller 51.5 mm 38 mm 50

51 Non VA/VE Vs VA/VE Comparison Non VA/VE Lined Shoe VA/VE Lined Shoe Lesser dia to accommodate VA/VE Roller Hole is eliminated to iden fy the VA/VE Shoes Assembly Possibilities in field Existing Rollers assembled with VA/VE Cam Shaft VA/VE Rollers assembled with existing Cam Shaft Effects of wrong assemblies Brake set diameter increases. Drum will not enter Effective braking is available only for 50 % of lining thickness 51

52 Clutch Cylinder Details CMC : CMC Assembly Dia mm CMC Major Kit CV CMC Minor Kit Alu Body CMC : CMC Assembly Dia mm CMC Major Kit CV CMC Minor Kit CI Body CMC : 20.15, CMC Assembly Dia 25.4 mm CMC Major Kit AS CMC Minor Kit CI Body CMC : 20.15, CMC Assembly Dia 25.4 mm CMC Major Kit AS CMC Minor Kit Alu Body CSC 15.16,20.15,20.16 CSC Assembly Dia 38.1 mm CSC Major Kit CI Body CSC Minor Kit

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60 Please send your suggestions to Marketing - Service Padi,Chennai Phone : (044) Fax : (044) E - mail : bi-marketing@brakesindia.co.in 60