BRAKE BINDING

Brake binding is a
phenomenon of binding of
wheels by brake blocks
when the loco pilots brake
valve is in release position.

SIGNS & SYMPTOMS

Train running heavy with push back
tendency.
Train does not move during starting
on prescribed notch/current.
Rise in temperature and emission of
smoke from affected wheels.
Unusual sound due to binding of
wheels by brake blocks.
Skidding of wheels on rail.

MAIN CAUSES
Defective DV/mal functioning of DV.
Air leakage from DV, AR, Dirt
collector, angle COC and branch
pipes.
Jamming of brake cylinder piston.
Jamming of brake gear levers, pins,
brake beam hangers etc.
Hand brake is in applied condition.

SCHEMATIC DIAGRAM FOR AIR BRAKE

1)
2)
3)
4)
5)
6)
7)
8)

BRAKE PIPE
FEED PIPE
BRAKE CYLINDER
AUXILARY RESERVIOR
ISOLATION COCK WITH FILTER
DISTRIBUTOR VALVE
CONTROL RESERVIOR
ISOLATING COCK

9) CHECK VALVE WITH COCK & ISOLATING COCK

10) CUT OFF ANGLE COCK
11) HOSE COUPLING FOR BRAKE PIPE
12) HOSE COUPLING FOR FEED PIPE
13) EMERGENCY BRAKE VALVE
14) MANUAL RELEASE
15) PASS.EMERGENCY ALARAM VALVE ASSEMBLY
16) PRESSURE GAUGE

BRAKE BINDING
ON ONE TROLLY

ON BOTH TROLLEYS

ONLY ONE TROLLY AFFECTED

Binding with BK.Cyl in
release condition

Rotate SAB

SAB rotating

SAB stuck up

Release BK
rigging by
rotating
SAB

Release BK
rigging by
removing palm
end pin

Dummy BK cyl. Work

train upto destination

Binding with BK.Cyl in

operative condition

Binding with BK.Cyl in operative condition

Operate QRV of DV
If BK cyl. Does not release

If BK cyl. released

Isolate FP & AR isolating cock,

Isolate the DV and pull QRV
QRV
Isolate BK cyl.
isolating cock

If piston
releases

If piston does not

release

Leave DV in isolate
condition

ROTATE TO
ISOLATE DV

Isolate BK cyl. And pull

drain plug of BK cyl

BOTH TROLEYS AFFECTED

Operate QRV of DV
If piston released

Isolate BK
cyl. & DV

If piston does not

release
QRV Isolate FP & AR isolating

cock, isolate DV & Pull

QRV again

If piston
released

If piston does not

release

ROTATE TO
ISOLATE DV

Leave DV in
isolating
condition

Open AR drain
cock & if piston
does not release
Isolate both cyl.&
open drain plug
of BK cyl.

BMBS TROLLEYS AFFECTED

SCHEMATIC DIAGRAM OF
BMBS AIR BRAKE SYSTEM
BRAKE PIPE
PRESSURE GAUGE

FP
ANGLE COCK

ALARAM PULL CHAIN

GDS
EVB

FEED PIPE
PRESSURE GAUGE

PEAV

FEED PIPE

BP
ANGLE COCK

PEAV
ISOLATING COCK

BRAKE PIPE
BP
ISOLATING COCK
CR

AR
ISOLATING
COCK

DV

AR

QRV

DRAIN COCK

ISOLATING HANDLE

BC ISOLATING COCK
BC

BC

STEPS TO RELEASE
BRAKE BINDING
BP
STEP-1

STEP-2

Close isolating cock of

BP & FP branch pipe line

Isolate DV by moving the

handle from vertical to
horizontal position & secure

FP

STEP-3

STEP-4

Release DV by pulling QRV

till all the air escaped
Through DV

Close both bogie brake

Isolating cocks

STEP-5

Pull out the clutch &

rotate spindle rod
clock wise to
release the piston

FOR SLR
COACHES

Check hand brake and

ensure gap between
wheel and brake block.

IF ACP ON
COACHES

Reset the PEAV & if not

success isolate the
PEAV isolating cock

AIR BARKE SYSTEM ON LHB COACHES

(Axle Mounted Disc Brake)

Brake
calipers
Brake Pads

Axle mounted
brake disc

Brake
Cylinder

AIR BRAKE SYSTEM ON LHB COACHES

Principle characteristics of brake system:
Application time:
Release time:

3-5 SEC
15-20 SEC

BRAKE INDICATORS
BRAKE APPLIED

BRAKE RELEASED

Pull QRV handle to release control

reservoir pressure. If brakes released
brake indicator will turn red to green.
QRV
HANDLE

DV
QRV

CDTS
ISOLATING
COCK

FEED PIPE
ISOLATING
COCK

BOGIE-1
ISOLATING
COCK

BOGIE-2
ISOLATING
COCK

SAB WABCO BRAKE CONTROL PANEL

KNORR BREMSE BRAKE CONTROL PANEL

FEED PIPE
ISOLATING
COCK

BOGIE-1
ISOLATING
COCK

CDTS
ISOLATING
COCK

BOGIE-2
ISOLATING
COCK

KNORR BREMSE BRAKE CONTROL PANEL

FEED PIPE
ISOLATING
COCK

Turn the FP cock horizontal to

vertical to Isolate feed pipe supply
to aux. reservoir.

SAB WABCO BRAKE CONTROL PANEL

Open the drain cock of Aux. reservoir to

discharge the full pressure then close it.
The brake indicator will turn to green if
brake binding is due to pneumatic failure.

125 lt. AR for

brake system

AR
Drain cock

75 lt. AR
For CDTS

Isolate bogies by isolating both bogie cut out

cock, put FP in service and work the train.
The affected coach will run as piped vehicle.

BOGIE-1
ISOLATING
COCK

BOGIE-2
ISOLATING
COCK

FEED PIPE
ISOLATING
COCK

SAB WABCO BRAKE CONTROL PANEL

RESETING OF ACP

ACP RESETING PROCEDURE

SALIENT FEATURES &

WORKING PRINCIPLE OF
BMBS WAGON

GENERAL DESCRIPTION OF BMBS

The equipment consists of a transversely mounted
pneumatic actuator (Brake Cylinder) with a selfcontained, double acting slack adjuster, two brake
beams, two bell crank levers and interconnecting push
rods. The hand brake arrangement is available as a
mechanical model with two flexible hand brake cables.
The pneumatic actuator is 10 in diameter for application
on high friction brake shoe (K type) on casnub type
bogies. The system consists of a unique design with two
pneumatic actuators to deliver reliable braking
performance and is light in weight. It fits into any
standard IR casnub bogie and uses 58mm thick brake
shoes.

SALIENT FEATURES :1- Use of Two nos of 10 Dia brake cylinders with automatic
load sensing device.

2- Use of 58 mm thick K type non asbestos composite

brake block.
3- Piston stroke of 56(+6,-0) mm in empty condition and 62
(+6,-0) mm in loaded condition is required to maintain.
4- Application of loads is at the ends the brake beam
instead of centre resulted no chances of bending of brake
beams.
5- Cylinder is with double acting slack adjustment feature
with constant piston stroke resulting is uniform brake
performances even as the brake shoes and wheels wears.

6- Total slack adjusting capacity is 500 mm including

brake block wear, wheel wear and all clearances.
7- All cylinders are equipped with an automatic piston
stroke indicator.

8- Replacement of the brake head is quickly and easy

by removal by only one pin.
9- Provision of mechanical hand brake system with the
use of two nos stainless hand brake cables pulled
through standard hand brake rigging.
10- Easy fitment of bogie mounted cylinder on any
standard bogies without making any modifications.

ADVANTAGES OF BMBS OVER CONVENTIONAL

BRAKE SYSTEM
1-SAB is eliminated providing in built slack adjuster to
take up slack automatically.
2- Brake Rigging completely eliminated.
3- Wt of BK system Reduced approx: 300 Kg resulting
more carrying capacity.

4- E/L system Modified to Automatic Load sensing hence

there is no L/E handle.
5- Mechanical efficiency ( Brake percentage) Increased
to 47.6% ( was 43.8% in case of BOXN)
6- Push Rod of conventional type eliminated BK rigging
eliminated so there was a low chance of hanging
parts in Train.

7- Braking Distance decreased.

8- Wheel wear is Reduced due to use of K-Type 58 mm
thick composite BK Block.
9- Speed of Train Increased due to better control.

10- Reliability of BK system is increased.

11- Low Maintenance Cost.
12- No need of Detachment of wagons in en route when
BK pipe Damage.
13- Cylinder is mounted parallel to the brake beam and
transfer forces through the bell cranks.

14- Improves the efficiency and alignments of the

braking forces with the wheels which reduced the
wear of shoes and wheels.
15- 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.
16- Use of single stage distributor valve (conventional
type).
17- Use of Two bell crank levers and two Inter
connecting Push rods, to transmit braking force from
bk cyl. to wheel through primary and secondary brake
beams.

Brake cylinder with double acting

slack adjustment feature.

DV in service

When BP reduced, piston moves outward

and the indicator comes out from the BC.

Piston stroke
indicator

DV in isolated condition and manually

Released

Piston moves inside

and the indicator also moves inside.

Automatically changes the BC pressure, 3.8kg/cm2 /

2.2kg/cm2 depending upon loaded / empty
condition. Installed between Distributor Valve and
Brake Cylinder. Physical contact of lever with side
frame only during braking.
Mounted on under frame, takes Deflection
of Bolster taken against side frame.

APM (EL-60 Valve)

Individual bogie can be isolated by isolating the

corresponding bogie COC.

Normal position
of bogie COC

Individual bogie can be isolated by isolating the

corresponding bogie COC.

Isolated position
of bogie COC

During single pipe operation the FP can be

isolated by FP COC.

Isolated position
of FP COC

Provision of mechanical hand brake

system with the use of two numbers
stainless hand brake cables pulled
through standard hand brake rigging in
one trolley only.

DV

Mechanical arrangement for

Hand brake.

To apply hand brake rotate the wheel

towards DV. (on either side)

DV

As an indication the piston stroke

indicator will comes out.

To release hand brake rotate the wheel

opposite to DV. (on either side)

DV

As an indication the piston stroke

indicator will go inside.

To ensure the hand brake application

check the brake blocks are griping on
the wheel of corresponding trolley .