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Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System Chapter 6, Page 1 of 14CHAPTER 6 BOGIE MOUNTED AIRBRAKE SYSTEM 601 GENERAL I n order to overcome the problems of slack adjuster failure as well as problemsas sociated with cast iron brake blocks, adesign of brake system incorporating 8"si ze two cylinders on each bogie alongwith K type high friction compositebrake block

s has been introduced. 602DESIGN FEATURES OF THESYSTEM (refer figure 6.1) This t ype of system is exactly similar tothe standard air brake system except forthe f ollowing: a) External slack adjuster is removed/ eliminatedb) Four cylinder of 8" size is providedfor each coach in place of twocylinders of 14"in standard air brake system. These cylinders havebuilt in single acting slack adjusterfor takin g the slack created betweenwheel and brake block on account of wheel / brake blo ck wear. Mountingof cylinders is done on either side of the bogie frame in betwe en centrallongitudinal members connecting thebogie transom to the headstocks.Eac h cylinder controls the brakingon one wheel set. Each cylinder hasa piston take up stroke of 32 mmandadjustment capacity of 305 mm (Ref. Drg. RDSO Sk- 81057)c) High friction composite brake blocksof K type have been used.d) Bogie brake riggin g has beenmodified to incorporate a totalmechanical advantage of 7.644 perbogief or non-AC coaches and8.40per bogie for AC coaches.e) Curved profile pull rods ha ve beenused to interconnect leverscontrolling braking one wheel set.These pull r ods provided with oneadditional hole for the adjustment of slack between wheel a nd block afterspecified amount of wear.f) Since brake cylinders have beenmounted on the bogie frame, 15mm.bore pneumatic pipeline has beenlaid over bogie frame to interconnect the brake cylinders of onebogie. Output pipe line of distributor valve has been connected to bogiepneumatic line through flexiblehoses to provide flexibility toalround dynamic movement.603COMPOSITE BRAKE BLOCK 603aGeneral Lo w friction composite brake blockshave the following benefits: n Reduced braking distance due touniform co-efficient of friction.n Reduced weightn Reduction in the replacement of brake blocks vis a vis cast iron due tohigher wear life in t rain operation.n Reduced wear and tear of brakerigging.n Reduced noise during br aking. 603bCharacteristics of composition brakeblocks i. Composition of materia l The composition of materialconstituting the brake blocks must bechosen to give the best balancebetween : The braking characteristics The wear and service lif e of blocks Wear on the running surface of thewheels The effect on adhesion betwee n therail and wheel ii. Requirement concerning friction The average coefficient of friction is0.25. As far as possible the coefficient of friction must be indepe ndent of theinitial braking speed, the state of bedding-in of the brake block, t hespecific pressure also thetemperature and atmosphericconditions. ContentsHin di Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System Chapter 6, Page 2 of 14*STROKEINITIAL RELEASEPOSITION281117.522STROKE(MUST BEIN A STRAIGHTLINE)4-FIXINGRESETTING LATCHMAX.MAX.25RELEASE POSITION AFTERFULL 305 TAKE-UPLEVERS MUST BETHE CROSSHEAD ISARRANGED SUCH THATHELD WITH IN 1.5mmLEVERS MUST BE ARRANGEDSO THAT THE PATH OF THEMAX.MAX.21BRAKE CYLINDER WITHSKETCH-81057 B.G.203.2 mm x 95.25 mm (8"X 3 3/4")EMU STOCK & SELF GENERATINGR(C)D SO. . . .SU PERSEDED BY:SUPERSEDES:PCDT J.S.SCALEGROUP21-2/99TOLERANCE + 0/-10mm ADDED-CD/35/98 NOTE 1 ADDED & TITLE CHA NGED12/88 FLOPPY No. :-DATEDESCRIPTIONAUTHY.ALT.ITEMASSEMBLY DRAWINGSREFERENCE:SLACK ADJUSTERMAIN LINE COACHESON DIMENSION 685.CD/7/99%%UNOTE:-HOLES %%C21OF TH IS AXIS.CROSSHEAD CENTRE LIESBETWEEN THESE LINES.MAX. WORKING MOVEMENTMOVEMENT T O BE ALLOWED FOR..+ 0-10%%p0.5MAIN LINE COACHES, REFER RDSO SK-81200 AND THE1. T O MANUFACTURE BOGIE MOUNTED BRAKE CYLINDER FORBILL OF MATERIAL FOR DIFFERENT COM PONENTS.INDIAN RAILWAY STANDARDS 3 4 53-CD/21/99 NOTE 2 ADDED.12/994-CD/4/2K1.2.3.%%p0.5FIXING HOLE DIA. CHANGED TO 21mm.DIM. 117.47mm CHANGED TO 117.5 .DIMENSION 101.6mm CHANGED TO 102.5CD/8 /2K-DRAWING REVISED11/2K4/2KHAND BRAKE TRUNNION95 MAX.130127%%p0.5204204%%p0.5== POSITION B FOR EMU MOTOR COACHES==36540047473167968531POSITION A FOR MAIN LINE S ELFGENERATING AND BG EMU TRAILORCOACHESWORKING STROKE,32mm FOR SELFGENERATING MA IN LINE COACHES,60mm FOR BG EMU COACHES.*1271272 Nos.AIR INLET PIPE CONNECTION,O NE CONNECTION IS TO BE MADEDUMMY BY PLUGGING.REWINDING THE ADJUSTING TUBE.ADJUST ER IS TO BE RESET BY305 MAX. SLACK TAKE UP.95 MAX.%%p0.5SK-81200SK.SRIVASTAVAMa i n t e n a n c e Ma n ua l f o r B G I C F C o a c h e s B o g i e Mo un t e d A i r B r a k e S y s t e mC h a t e r 6 , P a e 2 o f 1 4 ABFIGURE 6.1 ContentsHindi Maintenance Manual for BG coaches of ICF design Bogie Mounted Air Brake System

Chapter 6, Page 3 of 14 Under the effect of dampness, theaverage coefficient of friction must notvary, with the other conditionremaining the same, by more than15% in relation to the value obtainedduring braking when dry. After prolonged braking followed bybraking to a stop, particularly hightemperature occur. Even in the c ase of these temperatures (maximum 4000C on the opposing friction surface) theav erage coefficient of friction must notvary with the other conditionsremaining th e same by more than 15%in relation to the value obtainedduring braking in cold and dry state. iii. Geometrical characteristics of thebrake blocks The constructiona l features of thebrake blocks must enable them to weardown to a thickness of 12 mm including the back plate, without thelatter coming into contact with therunni ng surface of the wheel. iv. Mechanical and physicalcharacteristics The various elements making up thebrake blocks must be spread uniformlyin the body of the bl ock. There mustbe no pitting, flaws or other defects.The material must not attac k theopposing friction surface or give riseto the formation of metal inclusions. Composition brake blocks mustnot bring about more serious heatdamage to the whee ls (hot spots,cracks, flaking) than would be causedby cast iron blocks used in t he sameway on the same wheels. The values of specific weight, thermalconductivity , hardness, bendingstrength and the modulus of elasticitymust be given for accep tancepurposes. No method is laid down for fixing thecomposite material part to t he back plate. The back plate must be designedto support the stresses likely to occur. The composition blocks must notaffect to an unacceptable degree theadhesio n values between wheel andrail obtained on vehicles braked withcast iron inserts . 603cNon-asbestos K type compositionbrake block Non-asbestos K type blocks shallgene rally conform to RDSO drawingNo. 98066. The use of asbestos is prohibited. The use of lead or zinc in the metalstate or in the form of compounds isnot advised. Th e same applies to allother compounds, if in the form of powder, particles or gas producedduring the used of the brake blocks,they may constitute a danger to hea lth. 603dAsbestos based K type compositionbrake Asbestos based K type blocks shallge nerally conform to RDSO drawingNo. 98146. 603eMarking Each block must bear the followingmarks:- Name of manufacturer Date of manufacturer (month andyear) Materia l code including KA forasbestos type and KNA for non-asbestos type. Type of service ML. These marks, preferably punched, cut orstamped, must be applied so that the block can be identified, even after being fullyworn in service. 603f Comparison of properties/Usage of composition brake block Vs Cast IronBrake block Type of Brake blocks in use on main linecoachesParam-eters L type CBB K typeCBBCIAppl i-cabilityAll coacheswithunderframemounted airbrake systemAll coacheswith bogiem ountedbrakesystemAllcoacheswithvacuumbrake andunderframemountedbrakesystemSpeed Upto 110KMPHupto 110KMPHUpto 140KMPHCoefficient of friction0.12 to 0.14 0.25 max . 0.12 to0.14Weight Approx. 3kg.Approx. 3kgApprox. 9kg. ContentsHindi