AIRBRAKE SYSTEM

INDIAN RAILWAYS
Created by A.srinivas,
junior engineer,
Wagon workshop,
rayanapadu,vijayawada.
 SAFE WORKER IS THE
BESTWORKER
 TOPICS
Introduction & Types Of Air Brake System

Principal Operation Of Single & Twin Pipe System

Advantages Of Twin Pipe System

Types Of DV & Operations Of EKDV

Modification Of The Air Brake System (LSD,EL-60)

BMBS Working System & Advantages - Disadvantages

SWTR & Rake Testing

AIR BRAKE
SYSTEM
AIR BRAKE SYSTEM
INTRODUCTION:-
In the air brake system, a lot of
developments have taken
place such as bogie mounted Air
brake system, Twin pipe
air brake system, Automatic load
sensing device etc,.
As a result, the maintenance and
requirements have changed
considerably.
AIR BRAKE SYSTEM
CLASSIFICATION OF AIR BRAKE SYSTEM:-
On the basis of type of release,
air brake system is classified as:
1. Direct release air brake system.
2. Graduated release air brake system.

Both Direct and Graduated release are

further available in two forms viz.
1. Single pipe and
2. Twin pipe

On the basis of type of fitment,

air brake system is classified as:
1.Under frame mounted air brake system.
2.Boige mounted air brake system.
AIR BRAKE SYSTEM
The graduated release air brake system
consists of following components:-

1. Distributor valve.
2. Common pipe bracket with control reservoir.
3. Auxiliary reservoir-100 Litres & 75 Litres.
4. Brake cylinder 355mm dia. , 300 mm dia.,BMBS & BMBC.
5. Isolating cock.
6. Three way centrifugal dirt collector.
7. Cut off angle cock (32mm size on either ends of brake pipe &
feed pipe).
8. Air brake hose coupling (32mm for brake pipe / 32 mm from
feed pipe).
9. Brake pipe/feed pipe (32mm dia).
10. Branch pipes from BP/FP to brake equipment (20mm bore).
11. Guard emergency brake valve.
12. Pressure gauges for BP/FP.
13. Quick Coupling.
AIR BRAKE SYSTEM
The processes involved in working of
graduated release air brake system are:-

1. CHARGING STAGE.

2. APPLICATION STAGE.

3. RELEASE STAGE.
 CHARGING STAGE
5 charging time BC
kg/cm2 3 - 4 min.
5kg/cm2 DC

Created BP
by A.srinivas
JE/AB/WWS/GTPL/SCR
DV CPB
Driver AR C
brake
valve 5kg/cm2 R Created by
5kg/cm 2
srinivas

During this stage, brake pipe is charged to

5kg/cm2 pressure which in turn charges control
reservoir and auxiliary reservoir to
5 kg/cm2 pressure via distributor valve. At this stage,
brake cylinder gets vented to atmosphere through
 APPLICATION
3.8kg/cm2
1.5 STAGE
5 Application time BC
DROP
kg/cm 2 18 - 30 sec.
5kg/cm2 2
3.5kg/cm DC

Created BP
by A.srinivas
JE/AB/WWS/GTPL/SCR
DV CPB
Driver AR C
brake
valve 45kg/cm
kg/cm22
R Created by
5kg/cm2 srinivas

For application of brakes, the pressure in brake pipe has to be dropped. This
is done by venting air from driver's brake valve. Reduction in brake pipe
pressure positions the distributor valve in such a way that the control reservoir
gets disconnected from brake pipe and auxiliary reservoir gets connected to
brake cylinder. This results in increase in air pressure in brake cylinder resulting
in application of brakes. The magnitude of braking force is proportional to
reduction in brake pipe pressure.
NOTE:- 1. Brake Application takes places when Brake pipe pressure is
RELEASE STAGE
3.8kg/cm2
1.5
5 release time BC
DROP2
kg/cm 45 - 60 sec.
5kg/cm2 2
3.5kg/cm DC

Created BP
by A.srinivas
JE/AB/WWS/GTPL/SCR
DV CPB
Driver AR C
brake
valve 4
5 kg/cm
kg/cm22 EXHAUST R Created by
5kg/cm 2
srinivas

For releasing brakes, the brake pipe is again

charged to 5kg/cm2 pressure by compressor through
drivers brake valve. This action positions distributor valve
in such a away that auxiliary reservoir gets isolated from
brake cylinder and brake cylinder is vented to atmosphere
 CHARGING BC
NEED
6kg/cmFOR
2

APPLICATION
FP
5kg/cm2 DC

CreatedBPby A.srinivas
JE/AB/WWS/GTPL/SCR
NRV
DV CPB
AR C
6kg/cm2 R Created by
5kg/cm 2
srinivas

TWIN PIPE SYSTEM:-

In addition to the brake pipe, there is one more pipe
called feed pipe Running from loco to the brake van to charge
the auxiliary reservoir to 6kg/cm2.Up to 5kg/cm2 it is charged by
both BP & FP. Beyond 5kg/cm2 & up to 6kg/cm2 it is exclusively
 READY TO
CHARGING
APPLICATION BC
6kg/cm2
FP
5kg/cm2 DC

CreatedBPby A.srinivas
JE/AB/WWS/GTPL/SCR
NRV
DV CPB
AR C
6kg/cm2 R Created by
5kg/cm 2
srinivas

TWIN PIPE SYSTEM:-

In addition to the brake pipe, there is one more pipe
called feed pipe Running from loco to the brake van to charge
the auxiliary reservoir to 6kg/cm2.Up to 5kg/cm2 it is charged by
both BP & FP. Beyond 5kg/cm2 & up to 6kg/cm2 it is exclusively
ADVANTAGES OF TWIN PIPE
RDSO, which is the highest technical body on Indian Railways and
functions as the Technical Advisor to the Railway Board had conveyed to
them vide their letter No.MW/APB/TP/M dated 27.02.2003, as under
Railway Board has also taken a decision to procure all freight wagons
suitable for 100 kmph operation.
It is proposed that all newly built wagons suitable for 100 kmph
operation shall be fitted with twin pipe brake system.
The advantages of providing twin pipe brake system are as under: -
(i) Provision of twin pipe will result into improved application and
release of brakes.
(ii) Due to improved release timings of twin pipe, it would be easier for
driver to control the train.
(iii) Due to improved release and application timings, drag on the train
will be reduced resulting into better fuel economy/reduced drag would
also mean reduced shuttling action and in turn reduced longitudinal
forces on coupler and draft gear system.
 ENROUTE BP FAILURE
BC
6kg/cm2
5kg/cm
FP
0kg/cm2
5kg/cm
CreatedBPby A.srinivas
DC

ISOLATING

JE/AB/WWS/GTPL/SCR
COAC
DV CPB

AR CR

Created by
srinivas

BYPASS TWIN PIPE SYSTEM:-

In case due to any reason brake pipe of a coach or any
wagon gets damaged orgoes defective, it can be bypassed
in twin pipe system and the detachment of the coach
orwagon would not be essential as in the case of single pipe
 HEART OF
DISTRIBUTOR
THE
VALVE
AIRBRAKE
 DISTRIBUTOR VALVE
Distributor valve is the most important
functional component of the air brake
system and is also sometimes referred to
as the heart of the air brake system.
The function of the distributor valve is
to distribute compressed air received from
brake pipe to auxiliary reservoir and control
reservoir. In addition to this it also senses
drop and rise in brake pipe pressure for
brake application and release respectively.

It is connected to brake pipe through branch

pipe. Various other components connected to the
distributor valve are auxiliary reservoir, brake cylinders
and control reservoir.
The distributor valve is removed for overhaul,
maintenance & replace without disturbing the pipe
 DISTRIBUTOR VALVE
Two designs of distributor valves are in
use on wagons. These are:

1) KE Type distributor valve.

2) C3W Type distributor

valve.

The KE type distributor valve consists of

the following
main subassemblies:-
1. Three pressure valve 5.
 KE DV / R-CHARGER
ASSEMBLING
In dv assembling
R-CHARGER
48 no.s must change items,
64 no.s spare parts,
20 no.s bolts & nuts,
total near about 140 items
are used.
around 60 Tools are used in
assembling.
FUNCTIONS
The function of R-
charger are
To charge the auxiliary
reservoir from BP to 5
kg/cm2 in single pipe
system during
charging.
It prevents back flow
of air from AR to BP
during brake
application.
To isolate the DV in
 KE DV / A-CONTROLLER
ASSEMBLING FUNCTIONS
The functions of A-
controller are
It charges control reservoir
to
5 kg/cm2 from BP during
charging.
It isolates the CR from BP,
when the brake pipe
pressure is reduced at the
faster rate, during
sensitivity range.
It connects CR with
BP,when the brake pipe
pressure is reduced at the
slower rate, during
KE DV / U-CONTROLLER
ASSEMBLING FUNCTIONS
The function of U-
controller is
to reduce the brake
pipe pressure further
by 0.4 kg/cm2, in
addition to brake pipe
pressure reduced by
the driver from the
loco, to accelerate the
brake application.
As soon as BC gets
a pressure of 0.4
kg/cm2,The U-controller
KE DV / 3 PRESSURE VALVE
ASSEMBLING FUNCTIONS
It connects AR with BC
during brake
application.
It connects BC with
Exhaust during brake
release.
It admits BC pressure
in steps, when the
brake pipe pressure is
reduced in steps, to
facilitate graduated
application.
It releases air from BC
KE DV / MIN.PR.LIMITER
ASSEMBLING FUNCTIONS
The function of MIN.pressure
limiter is to admit a pressure
of 0.8kg/cm2
immediately into the BC
during brake application to
overcome the resistance
offered by the brake rigging.
It is a non restricted passage
between AR & BC.
Initially during brake
application the air from AR is
sent into BC through two
passeges.one with
restrictions and another
without restrictions. as soon
as BC gets a pressure of 0.8
kg/cm2 the min.limiter closes
KE DV / MAX.PR.LIMITER
ASSEMBLING FUNCTIONS
The function of
MAX.pressure limiter is
to admit a max.pressure
of 3.8 kg/cm2 even
emergency application.
It is a restricted passage
between AR & BC.
When the BC gets a
pressure of 3.8 kg/cm2
max. limiter closes the
restricted passage. and
this passage is closed,
the AR completely
disconnected from
KE DV / QUICK RELEASE VALVE
ASSEMBLING FUNCTIONS
The function of quick
release valve is to
release the air from CR
manually to facilitate
manual
release.
NOTE:- In case of C3W
DV,
it is a double release
valve and it is to release
the air from CR as well
as from AR manually.
1. When the release valve
is pulled only
 KE DV / CHOKE COVER
ASSEMBLING FUNCTIONS
The choke cover has
application & release
chokes inside it. The
application and release
chokes help in regulating
the application and release
times of brake.
The following are the
different hole sizes used in
our workshop.
1. BOXN,BCN,BTPN,BOBYN,BC
NHL & etc.
application/release choke
hole size - 1.7/1.7 mm
 3-PR.VALVE
0 kg/cm2
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH
AR
Created by A.srinivas 5 kg/cm2

JE/AB/WWS/GTPL/SCR
EXH

R-CHARGER

5
kg/cm2
CR
QRV

BP PRESSURE
CR PRESSURE 5 kg/cm2
AR PRESSURE
OFF
BC PRESSURE CHARGING ON
NO PRESSURE Created by srinivas
 3-PR.VALVE
0 kg/cm2
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH
AR
Created by A.srinivas 5 kg/cm2

JE/AB/WWS/GTPL/SCR
EXH

R-CHARGER

5
kg/cm2
CR
QRV

BP PRESSURE
CR PRESSURE 5 kg/cm2
AR PRESSURE
BC PRESSURE CHARGING Created by
ON
NO PRESSURE
 3-PR.VALVE
0.6
3.7 3.6
3.9
0 kg/cm
kg/cm22
U-CTLR A-CTLR MAX.LR MIN.LR
B
0.4 0.2 3.8 0.8 C
EXH
AR
Created by A.srinivas 54.7-4.2
kg/cm
4.1- 4 2
kg/cm2

JE/AB/WWS/GTPL/SCR
EXH

R-CHARGER

5
5 kg/cm2
CR
QRV

4.8-3.7
3.6-3.4
BP PRESSURE
CR PRESSURE 51.4
0.2 - 1.6
1.3
kg/cm2
AR PRESSURE DROP
BC PRESSURE
NO PRESSURE APPLICATION Created by
 3-PR.VALVE TAKE LAP POSITION
3.7
1.25 -3.9
3 kg/cm2
0 kg/cm2
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
GRADUATED GRADUATED
EXH APPLICATION
Decrease BP pressure
RELEASE
AR
Increase BP pressure
Created by A.srinivas
BP {kg/cm2} BC {kg/cm2} BP {kg/cm2} BC {kg/cm2}
54.7-4.2
kg/cm2
4.1- 4
4.8 0.6 3.6 kg/cm2
kg/cm
3.8 2
JE/AB/WWS/GTPL/SCR
EXH

4.6 1.2 3.8

R-CHARGER 3.6
4.4 5 1.8 4.0 3.0

5
kg/cm2
4.2 2.4 4.2 2.4

QRV 4.0 CR 3.0 4.4 1.8

3.8 3.6-3.4 3.6 4.6 1.2
BP PRESSURE
3.6 1.4 1.2 3.8
0.5 - 1.6 4.8 0.6
CR PRESSURE 5 kg/cm2
DROP
AR PRESSURE
BC PRESSURE
NO PRESSURE APPLICATION Created by
 3-PR.VALVE
3.7 3.9
0 kg/cm
kg/cm22
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH
AR
Created by A.srinivas 54kg/cm
- 4.1 2
kg/cm2

JE/AB/WWS/GTPL/SCR
0
EXH

R-CHARGER

5
5 kg/cm2
CR
QRV

0
BP PRESSURE
CR PRESSURE
AR PRESSURE
5
5 kg/cm
DROP
2

BC PRESSURE
NO PRESSURE EMERGENCY Created by
 3-PR.VALVE
3.7 3.9
0 kg/cm
kg/cm22
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH

AR
Created by A.srinivas 54kg/cm
- 4.1 2
kg/cm2

JE/AB/WWS/GTPL/SCR
0
5
EXH

R-CHARGER

5
5 kg/cm2
CR
QRV

5
0
BP PRESSURE
CR PRESSURE
AR PRESSURE
5
5 kg/cm
DROP 2

BC PRESSURE
NO PRESSURE RELEASE Created by
 3-PR.VALVE
0 kg/cm2
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH
AR
Created by A.srinivas 5 kg/cm
4.9 2
4.8
4.7

JE/AB/WWS/GTPL/SCR
EXH kg/cm2

4.9
4.8
4.7 R-CHARGER

5
4.9
4.8
4.7
5 kg/cm2
CR
QRV

BP PRESSURE 0.3 kg/cm2

CR PRESSURE 5 60
in kg/cm 2
sec.
AR PRESSURE
BC PRESSURE
NO PRESSURE INSENSITIVITY Created by
 3-PR.VALVE
1.5
0 kg/cm
kg/cm2
B
2

U-CTLR A-CTLR MAX.LR MIN.LR

0.4 0.2 0.8 C

EXH
AR
Created by A.srinivas 5 kg/cm
4.6 kg/cm22

JE/AB/WWS/GTPL/SCR
EXH

R-CHARGER

5
5 kg/cm2
CR
QRV

4.4
BP PRESSURE
0.6 kg/cm2 2
CR PRESSURE 5 kg/cm
in 6 sec.
AR PRESSURE
BC PRESSURE
NO PRESSURE SENSITIVITY Created by
 3-PR.VALVE
EMPTY
LOAD
U-CTLR A-CTLR MAX.LR MIN.LR

P
EXH T
Created by A.srinivas
A
JE/AB/WWS/GTPL/SCR
EXH
R R-CHARGER
B
5 C
5 kg/cm2
CR
0.4-2.2
0.6-3.8
0

QRV

AR LSD
4.8-0
BP PRESSURE
CR PRESSURE 0.2-55kg
kg/cm2
DROP
AR PRESSURE SPRING
BC PRESSURE EK PT Created by PLANK
NO PRESSURE
 LOAD
SENSING
DEVICE
 BOBR/BTAP/BCCW &
LOAD SENSING DEVICE
BLC wagons are provided
with' automatic two stage
empty load device to cater for
higher brake power in loaded
condition instead of the
conventional manual empty
load' device. With the
provision of this, brake
cylinder pressure of 2.2 kglcm2
is obtained in empty condition
So as to obtain this3.8
and a change
kglcm2over mechanism
is obtained in
called "Load Sensing Device"
loaded (LSD) is interposed
condition.
between the bogie bolster and spring plank. The
mechanism gets actuated at a pre determined
change over weight and the distributor valve
 LOAD SENSING DEVICE
LSD AR
Created by A.srinivas 5 kg/cm2

PT

JE/AB/WWS/GTPL/SCR DV CPB
C
R
5 kg/cm2
BP
5
SPRING kg/cm2
PLANK
3.8
2.2
Created by
BC srinivas

In loaded
Load
Another condition
Sensing
flexible the
Device
hose operating valve lets
(LSD) consisting
is connected between the
ofELoperating
port of
compressed
distributor air signal
valve and spring
valve buffer
pipe tomounted
EL port
bracket andof
ondistributor
the bogie
operating valve pipe
and pipe
valve. The bracket
with
operating
and
valvethe
flexible transformer
hoses
remains gets
Compressed
closed theairpneumatic
in empty command
from auxiliary
condition. andenters
Thusreservoir the brake
no pneumatic into
signal
 BLC-DOUBLE CHECK
VALVE
Created byCONTAINER
A.srinivas
JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2
N1
LSD

LSD
AR AR

SPRING PT DV CPB 3.8

2.2 SPRING
PLANK C PLANK

R BC Created by
srinivas
 BLC-DOUBLE CHECK
VALVE
Created by CONTAINER
CONTAINER A.srinivas
JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2 4 kg/cm2 5 kg/cm2
N1
LSD

LSD
AR AR

SPRING PT DV CPB 3.8

2.2 SPRING
PLANK C PLANK

R BC Created by
srinivas
 BLC-DOUBLE CHECK
VALVE
Created by A.srinivas
CONTAINER
JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2 4 kg/cm2
N1
LSD

LSD
AR AR

SPRING PT DV CPB 3.8

2.2 SPRING
PLANK C PLANK

R BC Created by
srinivas
 AUTOMATIC
PRESSURE
MODIFICATION
{EL-60 VALVE}
 EMPTY APM
RESERVIOR

BC BC
1 2

DV CPB
3.8
APM
2.2
Created
104mm by A.srinivas SENSOR ARM

JE/AB/WWS/GTPL/SCR Created by
srinivas

AUTOMATIC PRESSURE MODIFICATION:-

1.APM device is interposed between bogie side

frame of Casnub bogie and the under frame of
wagons.
2.APM should sense the gap only at the time of air
 LOAD APM
RESERVIOR

BC BC
1 2

DV CPB
3.8
APM
3.8
Created by A.srinivas
JE/AB/WWS/GTPL/SCR Created by
srinivas

AUTOMATIC PRESSURE MODIFICATION:-

It restricts the brake cylinder pressure coming from
the Distributor valve to 2.2 0.25 Kg/cm 2 in empty condition
of the wagon and allows the brake cylinder pressure of 3.8
0.1 Kg/cm2 in loaded condition of the wagon.
The factory setting for the movement of the sensor point
is 104mm which is consisting of loaded & empty zone. First
 BOGIE
MOUNTED
BRAKE
SYSTEM
BOGIE MOUNTED BRAKE SYSTEM
BP HOSE
COAC DC COAC
6kg/cm2

Created by A.srinivas
FP FP
FP
HOSE ISOLATING HOSE
COCK DC
5kg/cm2
3.5kg/cm
COAC COAC

JE/AB/WWS/GTPL/SCR
BP
BP

BP CPB BP
HOSE 6 HOSE
kg/cm2 APM
NRV
3.8 T
DV FLANGE
AR APM RESERVIOR
100 LTRs (WITH OUT PT)

ISO.COCK
WITH VENT
FLEXIBLE
HOSE
PIPE

Created by 10 BC FOR
EMPTY LOAD 10 BC FOR
BOGIE 1 (WITH
srinivas BOGIE 2 2.2 3.8 HANDBRAKE
CABLES)
 BMBS-BRAKE CYLINDER
GASKET

Created by A.srinivas
PISTON
INDICATOR
ASSLY. BC PIN
COMPR.SPRING 3

JE/AB/WWS/GTPL/SCR
CLUTCH LOCKING STUD

COMPENSATOR
SAB SPRING RAM ASSEMBLY
COMPR.SPRING 1
COMPR.SPRING 2
Created by srinivas

The brake cylinder receives pneumatic pressure from auxiliary reservoir after
being regulated through the distributor valve and APM device. Brake cylinder
develops mechanical brake power by outward movement of its piston with ram
assembly.
 BMBS-BRAKE CYLINDER
BC PRESSURE

Created byPISTON
A.srinivas
STROKE
54+/-10mm
JE/AB/WWS/GTPL/SCR

Created by srinivas

The piston rod assembly is connected to the brake shoes through a system of rigging
arrangement to amplify and transmit the brake power. The compression spring provided
in the brake cylinder brings back the ram thus the rigging is also brought to its original
position when brake is released.
 BMBS-BRAKE CYLINDER
BC PRESSURE

Created by A.srinivas
JE/AB/WWS/GTPL/SCR

Created by srinivas

The
This
The built-in
brake
ensures slack
cylinder
that adjuster
every
has time compensates
got aevery
double
time
acting for the
the brake
slack wear ofasbrake
application
adjuster takes blocks
a result the during
place,sufficient
the brake
actuator
brake ofapplication
force is
brake
delivered through
cylinder
on the equivalent
willwheels.
continue pay-out.
Thetobrake For
tillpaying-in,
movecylinder
out compensates a pry
all the slack inforbar
theanyis
applied
system in
change between
is gap the
takebetween
care offbrake
and
brake shoe and
reaction
block andwheel
force ofand
wheel the the
throughrigging
wheels is pushed
theisinbuilt
encountered. in.
slack adjuster.
BOGIE MOUNTED BRAKE SYSTEM
BK.BLOCK
BELL CRANK
LEVER

SECONDARY BEAM
Created by A.srinivas

PRIMARY BEAM
P
BMBS W U
DOUBLE
JE/AB/WWS/GTPL/SCR
BOGIE
TOP
H
EE
L
ACTING
S
H
R
SE O
VIEW T D
s
BC PIN
EYE PIN
CLEVIS PIN

Created by srinivas
BOGIE MOUNTED BRAKE SYSTEM

BMBS
Created by A.srinivas
JE/AB/WWS/GTPL/SCR
BOGIE
TOP
VIEW

Created by srinivas
BOGIE MOUNTED BRAKE SYSTEM
NEED FOR ADOPTION OF BMBS
IN FREIGHT STOCK:

In order to overcome the problem faced in conventional

bogie breakage, missing components and malfunctioning of
SAB. In BMBS fitted wagons, BC is equipped with in
built SAB.
In conventional BOXN/BCN wagons due to frequent theft of control
rod, main pull Rod, End pull rod & Brake Rigging parts in
tripling operation of wagons causing poor brake power in
Rakes, resulting Detentions of wagons. In BMBS, wagons
these Items are eliminated.
In order to Improve Mechanical efficiency of
brake power.
In a Normal Rake of BOXN wagon Fitted with conventional type
brake system there was around 18% Brake fading after a trial run of
BOGIE MOUNTED BRAKE SYSTEM
NEED FOR ADOPTION OF BMBS
IN FREIGHT STOCK:
Braking distance of conventional Rake of 58 +1 wagons of
BOXN is 1350 m.
However in BMBS wagons it is 880 m (approx).

In conventional wagons setting of A Dimension was a

major problem. If any change made in sleeve nuts of E/L
device that may create to heavy loss of wagon creating brake
binding / wheel skidding. In order to overcome this, BMBS
fitted wagons came into field which contains in built slack
adjuster.

In case of BMBS system Automatic Load sensing

Device is used which Gives 2.2Kg/cm2 Pressure to
brake cylinder during empty condition 3.8 Kg/cm2
pressure during loaded for avoiding the above
Problems.
BOGIE MOUNTED BRAKE SYSTEM
SILENT FEATURES
Use of two nos. of 10 dia brake cylinders with automatic load
sensing device & vent isolating cocks.
Use of 58 mm thick K type non asbestos composite brake block.

A constant 56 mm piston stroke is required to maintain uniform and

efficient braking performance.

Application of loads is at the ends the brake beam instead of centre

resulted no chances of bending of brake beams.

Cylinder is with double acting slack adjustment feature with constant

piston stroke resulting in uniform brake performances even as the brake
shoes and wheels wears.
Total slack adjusting capacity is 500 mm including brake block wear,
wheel wear and all clearances.
BOGIE MOUNTED BRAKE SYSTEM
SILENT FEATURES
All cylinders are equipped with an automatic piston
stroke indicator.
Replacement of the brake head is quickly and easy by
removal by only one pin.
Provision of mechanical hand brake system with the use of
two nos stainless hand brake cables pulled through
standard hand brake rigging.
Easy fitment of bogie mounted cylinder on any standard
bogies without making any modifications.
Cylinder is mounted parallel to the brake beam and
transfers forces through the bell cranks.
Improves the efficiency and alignments of the braking
forces with the wheels which reduced the wear of shoes
and wheels.
Use of pressure regulated load sensing device, installed
between body and bogie under frame act on 15 psi to
maintain normal sensor arm travel of 95 mm.
BOGIE MOUNTED BRAKE SYSTEM
DISADVANTAGES
The system requires special parts for working
such as push rod, bell crank lever, hand brake
cable,BC indicators & etc, which are not easily
available and very costly.
Bk. Cylinder fails working even if there is a very
small defect noticed in distributor valve / if DV
releasing time slightly more / if APM failed.

This type of wagon can not be mixed with a

normal rake of conventional type.
More wear & tear is noticed near eye hole in
push rod.
High skilled worker are required for maintenance
of these wagons.
SINGLE
WAGON
TEST
RIG
BMBS-SINGLE WAGON TEST RIG
Couple up all Brake Gear
Fittings properly.

Move SWTR near to the

Wagon and connect Brake
Pipe of the Wagon to
SWTR.
Dummy the other ends of
the Brake Pipe & feed pipe
at Palm ends of the Hose
Pipe.
Fit a BC Pressure Gauge on
APM Device.
Connect SWTR to the main source of Air
Compressor with 8 - 10 kg/cm2 capacity. Set the
Pressure Regulator to 5kg/cm2 & 6kg/cm2 for BP
& FP respectively.
Open the Cut off Angle Cocks on both ends
 BMBS-SINGLE WAGON TEST RIG
Keep Brake Valve in charging position and
charge the Wagon at Brake Pipe Pressure of 5
0.1 kg/cm2. If there is drop in pressure, locate
the leakage with Soap Water and arrest it by
changing the "O" Ring.
To check the leakage in Brake Pipe close the
cocks for 1 minute and then open them. Allow
leakage of 0.1 kg/cm2 for 1 minute.
Bring Brake Valve in position for full
service application. Brake should apply with a
pressure drop in BP by 1.3 to 1.6 kg/cm2 in 18 to
30 secs.

Record time for filling air to the maximum

pressure in Brake Cylinder of 3.8 0.1kg/cm2.
 BMBS-SINGLE WAGON TEST RIG
Record piston stroke for BMBS cylinder. It
should be 50 + 6 mm for Empty and 62 + 6 mm
in loaded condition. BUT latest modification
(sp.no:WD-23-BMBS-08) ONLY TESTED IN EMPTY-
54+/- 10mm(i.e. BC PRESSURE-2.2kg/cm2)
During the normal condition (without lifting
the sensor arm) the brake cylinder pressure
should be 2.2 + 0.1 Kg/cm2.
During the loaded condition,lift the sensor
arm of APM device by using 25mm packing
piece. the brake cylinder pressure should be 3.8
+/- 0.1 Kg/cm2.
Bring Brake Valve position to Release
position. The brake release time should be within
45 to 60 secs.
Ensure if the Brakes are completely released
and Piston regained to its original position.
 BMBS-SINGLE WAGON TEST RIG
Check leakage in B.C. for 5 minutes.
Keep Brake Valve in charging position and
charge the Wagon at Brake Pipe Pressure of 5
0.1 kg/cm2,.
For Sensitivity Test, operate the Brake Valve for
a BP pressure drop of 0.6 kg/cm2 in 6secs. and
check for the application of Brakes. It should
apply within 6 secs
For In Sensitivity Test, operate the Brake Valve
for a BP pressure drop of 0.3 kg/cm2 in 60secs.
and watch for the application of Brakes. It
should not apply even for 60 secs.

Ensure if the Brakes are completely released and

Piston regained to its original position.
RAKE
TEST
RIG
 RAKE TEST RIG
Rake Test can be performed
by using a portable device called
RAKE TEST RIG. The test rig
provides all facilities like a
locomotive to conduct the test.
The rake test rig has air supply
and mobile test rig. The mobile test
rig is having a cubical structure
and is mounted on wheels. It can
be taken to the yard.

A rake consisting of 60 wagons can be tested with this rig. This

rig may be used for testing the train in yard before attaching
the engine.
 RAKE TEST RIG
The procedure is as follows:
A. Prepare set up (Rig) for Rake Test.
B. Carry out Visual Examination.
C. Conduct Leakage, Service Application and
Release Test.
A.Prepare set up (Rig) for Rake Test:-
Place a board DANGER - MEN AT WORK on
either side
of the formation for safety.
Connect RTR to the main source of Air
Compressor
with 8 - 10 kg/cm2 capacity.
Set the Pressure Regulator to 5 kg/cm2 & 6
kg/cm2
For BP & FP respectively.
Couple the BP & FP to the first wagon of the rake.
B. Carry out Visual Examination:-
Visually inspect by coupling the BPs &
RAKE TEST RIG
Ensure that hand brakes of all
wagons are fully released
(i.e. OFF position).

Ensure that operating handle of

empty load box is in correct
position (i.e. EMPTY position).

Ensure that the isolating cock on

DVs of all wagons are in open
position (i.e. vertical position).
RAKE TEST RIG
Ensure that the isolating cock of
feed pipe of all wagons are in open
position (i.e. horizontal position).

Ensure that the non return

valve(check valve) of feed pipe of
all wagons are in right direction.

Inspect loose suspension brackets and

anti-pilferage devices of all air brake
subassemblies. In case of BOBRs inspect
the primary & secondary locks.
RAKE TEST RIG
Visually inspect for any
problem/damage in the brake pipe,
hose pipe, coupling , COACs & etc.

Ensure that BP & FP hose couplings are

connected to form a continues air
passage from the test rig to the last
vehicle. for proper identification BP &
FP coupling heads are marked with
BP- FP and painted in green & white
respectively. in no case ,a FP should be
connected to the BP any where in the
train or vice versa.
RAKE TEST RIG
Ensure that cut-off angle cocks of
brake pipe and feed pipe at the
rear end of train are kept closed.

Provide the pressure gauges for BP & FP

are in the brake van. Ensure that quick
couplings are attachable & detachable.

The drop in brake pipe pressure

gauge shall not be more than
0.25 kg/cm2 per minute.
 RAKE TEST RIG
C. Conduct Leakage, Service Application and
Release Test.
Examine for leaky components, malfunctioning of
distributor valves, brake cylinders, control and auxiliary
reservoirs, angle cocks, BP hoses. In case of BOBR,BCCW,BLC
& BTAPs Examine the LSDs. Rectify or replace the problematic
part/subassembly.
If the leakage rate is more then the value indicated
(0.25 kg/cm2 per minute) check for excessive leakage on
individual wagon as indicated below:
A hissing sound would be audible at points where
leakage is heavy.. Once the hissing sound is heard from a
particular area, pin point the location of leakage by applying
soap water solution.
Use of permitted material viz. Teflon tape for arresting the
leakage at threaded joints.
 RAKE TEST RIG
Service Application:-

1.Bring Brake Valve position for

service application.
Brake should apply with a pressure drop in BP
by 0.9 kg/cm2 in 18 to 30 secs.
2.Observe the BC piston rollings for 1 hour.
3.if rollings are found, check leakage from the
CR O rings/CR dummy/BC front cover/BC dummy/
BC branch pipe for arresting leakage.
4.use Teflon tape for arresting the leakage at
CR & BC dummy nuts.
 RAKE TEST RIG
Full Service Application {1.5kg/cm2}:-
Record the Piston Stroke of Brake Cylinders.
It should be a following lengths.

(BVZI- 45 mm+/- 10)

/BOBYN
 RAKE TEST RIG
Full Service Application {1.5kg/cm2}:-
1.In case of BMBS cylinder. It should be
50 + 6mm for Empty and 62 + 6mm in loaded condition.
but latest modification (sp.no:WD-23BMBS08)
ONLY TESTED IN EMPTY i.e. 54+/-10mm.

2. Ensure that piston stroke under empty & loaded

conditions are within the specified limits.

3. Ensure that the brake shoes of each wagon are

mating the wheels when brakes are applied.
 RAKE TEST RIG
Release Test:-

1.Bring Brake Valve position to Release position.

2. The brake release time should be within
45 to 60 secs.
3. Ensure if the Brakes are completely released
and Pistons are regained to its original position.
4.The drop in brake pipe pressure gauge shall not
more than 0.25 kg/cm2 per
minute at the Brake van.
5. Manually release the quick release valves of all
wagons for Attaching the engine.
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