INDIAN RAILWAY AIR

BRAKE SYSTEM
By
Syed Khaja Hussain B.Tech., M.B.A.

Instructor/Running

DTTC/GTL/SCR

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 Brake System

28 LV1 KNORR 28LAV IRAB CCB

1

Types of Brake System

Loco Formation Loco Formation Loco Formation Loco Formation
Brake Brake Brake Brake Brake Brake Brake Brake

AIR Vacuum AIR Vacuum AIR Both AIR AIR

Air &

Vacuu
m
Syed Khaja Hussain (Dual)
Instructor/Rng/DTTC/GTL
 Brake System

28 LV1 KNORR 28LA IRAB CCB

V1

TypesWDS4B
YDM4 of Brake System
WDM2A
NON
in
WDG4
MODIFIE

LocomotivesWDP1 WDG3A
MODIFIE WDP4 D
WDS6 ZDM3 D

28 VB C3W
PROPOTIONAL DISTRIBUT WDM3A
VALVE ER VALVE
WDM3D
SA9 FOOT
QUICK REALASE PEDAL
Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
 VALVES USED & THEIR FUNCTION
SL DESCRIPTION PURPOSE
1A9. Automatic Valve
Brake application for Loco as well as formations

2SA 9 Ind. Brake Valve

Brake Application for Loco alone
3 MU –2B M.U. Operation.
4 F 1–Selector M. U. Operation
5 AddlC2Valve Feeding B. P. Pressure to formation
624 A. Double Check will
Thisallow only one Valve operation
at a time.

7 C3.WDistributor
Valve Proportionate
Brake application
during
A9 application.

8 CRelay
2. Valve For
Locomotive
Brake

9 Pressure Switch Locowill bebroughtto idleduringA9emergency

application

10
D1. Emergency Valve For
Emergency
brake
application
Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
 VALVES USED & THEIR FUNCTION

SL DESCRIPTION PURPOSE
11D1. Pilot air valve To release Loco brake

12
Pressure Limiting Valve
Pilot air to C2. is Limiting to 1.8 kg / 2Cm
Relay

13
M. R. Safety Valve
When M. R. Pressure goes beyond 10.5 kg This
(Main Reservoir)Valve will function

14
Duplex Check Valve It
Setwill not allow MR
equalising
pipe Air to return back
at 5 kg / Cm
2 to MR

Feed Valve
15 F2/C2N To maintain Feed pipe Pr at 6 kg / Cm
2

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
SA-9 Ind brake valve C2 RELAY VALVE
A9-Automatic Brake Valve

F-1 Selector Valve 24 A. Double Check

MU-2B valve
Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
C2 RELAY VALVE D-1 Emergency Brake Valve-

LOCO BRAKE CYLINDER

C3W DISTRIBUTOR VALVE

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 BP (GREEN) PIPE
FP (WHITE) PIPE

AIR FLOW INDICATOR

WHITE NEEDLE (REFERENCE)
RED NEEDLE (REGESTER)

AIR FLOW MEASURING

VALVE
Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
SA9 CUT OUTCOCK IN CONTROL STAND
A9 CUT OUT COCK IN CONTROL STAND
PRESSURE SWITCH

MR SAFETY VALVE Syed Khaja Hussain F2 FEED VALVE

Instructor/Rng/DTTC/GTL
 SA-9
(Working BySA-9 Release
Loco Brake Application (Non-Working Control
Control
Stand) Application
SA-9 by SA-9 Stand)

MR 3 2
2 3
2 0 0
0 0 BRAKE
SA9 8 to 10 SA9
COC SYSTEM KG/CM2 COC
COC(MR-2
COC)
DCV
3.5 KG/CM2 TRA
MU2 IL
B 2 3.5 KG/CM2
LEA
2 D
0 From C3W
DCV DV

C-2 RELAY BC Gauge

VALVE

1 2
MR-2

3
APPLY-SA9
3.5 KG/CM2

Bogie Isolation Bogie Isolation

Brake COC-2 COC-1 Brake
Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL Cylinder
 SA-9
(Working SA-9 (Non-Working
Control
Stand)
Releasing SA-9 Control Stand)

MR 3 2
2 3
2 0 0
0 0
Exh BRAKE SA9
SA9 SYSTEM COC
-Port COC
COC (MR-2 COC)
DCV
0 KG/CM2 TRAI
MU2 L 0 KG/CM2
B 2 LEA
D
From C3W
20 DCV
DV

BC Gauge
C-2

2
MR-2 1

3
0 KG/CM2
Exhaust Port

Brake Bogie Isolation Bogie Isolation Brake

Cylinder COC-2 COC-1 Cylinder
Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL
 Brake Pipe Charging A-9 Release (Non-
A-9 (Working
Control Stand)
Ex in
Working Control Ex
Stand)
1 IRAB
A-9 kept in Release
1

MR 3 5
5 3
2 0
A9
0 BRAKE A9
SYSTEM
8 to 10 COC
COC KG/CM2
COC(MR-2
Open Close
COC)

5 KG/CM2 Closes below 4.5

TRA
Kg/cm 2 VCD COC
IL OPEN 5 KG/CM2
Opens above 4.8 3
Kg/cm2 P 1 1
Airflow LEA Exhaut Port

Indicat 3 D VCD
or Magnet
MU2 Valve
R6 Addl. C-2 B BP Gauge
RELAY
VALVE 2
MR2 Drops out 2.8
Choke 5.5 MM
1 Kg/cm2
Picks up at 4.0
3 P2 P C2 S
Kg/cm
Run/Rel. 5
Air Flow Magnet
Measuring Valve KG/CMCloses
2
below 4.4
3/4 “ OR PCS
Valve E Kg/cm 2

X 1” BP Opens above 4.7 COC

19.5 COC Kg/cm2 Ope
MM n
Open
BP PIPE Developed By Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
When SP1/SP2 Pressed
LINE --- Quick Charging of BP
 Exhaust Port GRADUATED APPLICATIONA-9 (Non-Working
Control Stand) Ex
in IRAB
1
A-9 kept in APPLICATION
A-9 (Working
1

MR 3 5
5 3Control Stand) 2 0
0 BRAKE 8 to 10 A9 COC
A9 SYSTEM KG/CM2 Close
COC COC(MR-2
Open COC)

Closes below 4.5 MU2

Airflow Kg/cm2 TRA VCD COC
Indicat Opens above B IL OPEN 5 KG/CM2
4.8 3 EX
or Kg/cm2 P 1 1 LEA VCD
3 D Magnet
Valve

R6 BP
Addl. C-2
RELAY Gaug
VALVE 2 e
MR2
Choke 5.5 MM Drops out 2.8
1 Kg/cm2
3 Picks up at 4.0
Run/Rel. P2 Kg/cm2
Airflow Magnet
PCS
Measuring Valve Closes below 4.4
3/4 “ OR
Valve E Kg/cm2 PCS
X 1” BP Opens above 4.7 COC
19.5 COC Kg/cm2 Ope
MM Open n

BP PIPE LINE
Developed By Syed Khaja Hussain
Instructor/Rng/DTTC/GTL
 Conjunction Loco Brakes Application
MR -2 BP Pipe Line BP Foot Pedal Not
Destroy Pressed MR-2
C-3 Connection BKI
MR-2
W DV V
Limiting Valve

Isolati BC 4 16
on 1.8 Kg/CM2 EX F-1
MR-2
Handle H Selector
Isolati
on DCV
QR From C3W
Cock V From
Open
DV
SA-9
C-2

2
MR-2 1 1.8 KG/CM2
3
1.8 KG/CM2

Bogie Isolation Coc- Bogie Isolation

2 Coc-1
Brake
Cylinder

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
Prop by BP drop
asing of Conjunction loco brakes( By BP charg
MR -2 BP 5 Kg / cm2 BKIV Foot Pedal Not
Pressed MR-2
C-3W
BP Pipe Line
DV
Connection
BC 1.8 4 16
MR-2 Kg/Cm2
Isolating EXH Limitin
handle Port g Valve MR-2 EX F-1
Isolati H Selector
on QRV DCV
Cock From
Open SA-9
C2 Relay
Valve
2
MR-2
MR- 1 0
KG/CM2 0 KG/CM2
3
EXH
Port

Bogie Isolation Coc- Bogie

2 IsolationCoc-1
Brake Brake
Cylinder Cylinder

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
Prop. release by BP
easing of Conjunction Loco Brakes( by Foot Pe
MR -2 BKIV When Foot Pedal
BP Pipe Line MR-2
Pressed
C-3W Connection
MR-2
DV
Limiti
BC ng
Isolating Valve EX
handle H F-1
Isolati Selector
MR-2
on Release DCV
r
Cock From SA-9
Open C-2 Relay Valve

2
MR-2
MR 1
0 KG/CM2 0 KG/CM2
3
EXH
Port

Bogie Isolation Bogie Isolation

Brake Coc-2 Coc-1 Brake
Cylinder Cylinder

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
By PVEF
Releasing of Conjunction loco brakes( By QRV
MR -2 BKIV Foot Pedal Not
Pressed MR-2
C-3W BP Pipe Line
DV Connection
BC 1.8 4 16
MR-2 Kg/Cm2
Isolating EXH Limitin
handle Port g Valve MR-2 EX F-1
Isolati H Selector
on DCV
Cock QRV From
Open SA-9
C2 Relay
Valve
2
MR-2
MR- 1 0
KG/CM2 0 KG/CM2
3
EXH
Port

Bogie Isolation Coc- Bogie

2 IsolationCoc-1
Brake Brake
Cylinder Cylinder

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
Prop. release by BP
oco Brake application in MU/Idle/Dead
MR2 MR EQ Pipe & BC EQ Pipe are coupled
When

MU2B From C3W MU2B(Tra

2 (Lead) From C3W il)
SA-9 DV SA-9
DV
2 DC DC
0 V V X
4 4

16 16 C-2
C-2 20 2
2
MR 14 14 MR
1 1
2 2
EX 30 30 EX
H BC 3 H
3
F-1 EQ F-1
DTT (Lead) (Trail) DTT
wC wC
GTL GTL

MRE
Q
MR MR MR MR
To 2 1 Syed Khaja Hussain 1 2 To
Brake LEADING LOCO Instructor/Rng/DTTC/GTL TRAILING Brake
rake application in MU/Idle/Dead thro
MR2 MR EQ Pipe & BC EQ Pipe are coupled
When
MU2B B MU2B(Tra
(Lead) P il)
SA-9 2 MR MR SA-9
From C3W From C3W 2
DC 2 DC
2 DV DV
V V X
0
4 4

16 16 C-2
C-2 20 2
2
MR 14
1
14 1 MR
2 2
EX 30 30 EX
H BC 3 H
3
F-1 EQ F-1
DTT (Lead) (Trail) DTT
wC wC
GTL GTL

MRE
Q
MR MR MR MR
To 2 1 Syed Khaja Hussain 1 2 To
Brake LEADING LOCO Instructor/Rng/DTTC/GTL TRAILING Brake
Loco Brake Application In Dead Loco
n MR EQ & BC EQ Pipes are not coupled only B.P conne

BP ( Live BP ( Dead Loco )

Isolation COC
loco)
F1 (Auto Lead)BKIV LV MR Gauge
From SA9 DCV 16 4
1.8 Kg/CM2
C3W DV

5
Kg/CM2
MU2B (Lead)

Kg/CM2
MR-
2

2
5
C2 1 MR2
Relay
NRV
Valve EX
3 H

MR-
1
BC

6.4.
1.
So,
7.
5.3.
The
And
As When
pilot
2.
Then
BP
Further
MR2
such air
pressure
BP
from
MR pressure
pressure
pressure
this
MR2 pressure
ofAir
pressure from
Live
waiting
reduces
(Pressure
5 loco
MR2goes
at
Kg/Cm2)is
, C3W
goes
port
charged
goes
toisMR-2through
D.V.
No.
to
toport
port
1of
to
enters
availabledead
no.
dead
No.1
at2C3W
loco
in
loco,
of
ofbrake
C-2 C-2
C2
get
the
relay
Relay
Syed Khaja Hussain
valve
unbalanced
cylinder
same(1.8BP
to
Kgapply
and
pressure
/ Cm2)
connect
Loco
asgoes
distributor
per
brakes
ValveMR2
relay
the
to dead
of pressure
C3W
in
valve.
setting
dead
valve
DV loco.
of
loco.
Instructor/Rng/DTTC/GTL
Through
via
Limiting
C3W
( MaxIsolation
to1.8Kg/Cm2)
Valve.
F1 Selector
Where
COC
Dead
 FEED PIPE CHARGING
MR Safety valve

J Filter
Main Reservoir
Main Reservoir 11

Control reservoir, auxiliaries etc.

Brake system COC

Main Reservoir 2

Check valve Duplex check valve

5 Kg/cm2
To MR Equalizing pipe
J Filter
To Brake system Feed
D24B
valve
Feed Valve 6 Kg/cm2
COC
FEED PIPE ( 6 Kg/cm2)
Developed By Syed Khaja Hussain Instructor/Rng/DTTC/GTL
 WORKING PRINCIPLE
OF TWIN PIPE AIR BRAKE
SYSTEM

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 PARTS OF TWIN PIPE SYSTEM
Feed Pipe

BrakePip
e

Isolation COC Isolation COC

FP BP
Control
Dust Collector Res. Dust
FP Collector BP
Distributor
NRV
Aux. Valve
Res. EX
Brake QRV Brake
Cylinder Cylinder

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 CHARGING FP

B
P
BC is
BP ConnectedTo
& CR Exhaust
Charged to BC 2in
5kg/cm 2
IC FP &Released
AR Charged to 6kg/cm
Condition IC

CR
DC
DC

NRV DV
Aux.Res.
6 kg/cm2
EX
QRV BC
BC

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 RECHARGE FP
APPLICATION
B
P
BPconnected
BC
AR isCR
is Reduced
Connected inBC
is connected
To
to Steps
exaustBCto
to&BP &BCApply
AR Brake &
is disconnected
pressure
Pressure comes
Reaches CR
tois 2
3.8kg/cm
IC BP Recharged
zero &&Brakes to
Disconnected
From BC 5kg/cm
areApplied
Brakes are released
2
IC

CR
DC
DC

NRV DV
AR
EX
QRV BC
BC

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
 MANUAL RELEASE
FP

B
P

BCisconnected
Qrv pulled & CRtopressureComes
exaust BC pressure
to zero
IC IC
comes to zero & brakes are released
CR
DC DC

NRV DV
AR
EX
QRV
BC BC

Developed By Syed Khaja Hussain

Instructor/Rng/DTTC/GTL
Thank You

Syed Khaja Hussain

Instructor/Rng/DTTC/GTL