BMBS Manual _updated (1)

Bogie Mounted Brake System (BMBS)
For Freight Cars Fitted With Upgraded 11” Bra

Cylinder
Description and Maintenance Manual
This manual is divided into three different Sections as following:

 Section– A: Description and Maintenance Manual of BMBS
 Section- B: Description and Maintenance instructions for
Bogie Mounted Brake Cylinder 11”.
 Section- C: Description and Maintenance Instructions for
APM (EL - 60).
Section-A: Description and Maintenance Manual of BMBS
CONTENTS
S. No. Content Description

1 General Description
2 Working Description
3 Features
4 Air Brake System with BMBS & APM
5 Description of the Equipment
6 Critical Bogie Dimension for BMBS
7 Installation of BMBS on Bogie
8 APDs to be provided on the BMBS
9 Do’s & Don’ts
10 Procedure for changing of brake blocks
11 Typical Service / Operating procedures
12 Condemning limits of system components
13 Maintenance in Open line
14 Routine overhauling of BMBS System
15 Periodic overhauling of BMBS System
Details of special tools & gauges required during

16
maintenance 38
ke System (BMBS)
ith Upgraded 11” Brake
der
ntenance Manual
erent Sections as following:

tenance Manual of BMBS
enance instructions for
enance Instructions for
nce Manual of BMBS
Page No.
4
5
6
14
16
21
25
28
29
31
35
37
38
g
38
GENERAL DESCRIPTION
Existing 10” Brake cylinder is being upgraded to
11”. The BMBS equipment (see figure-1) consists
of a transversely mounted pneumatic actuator
(11” Brake Cylinder) with a self- contained,
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 handbrake cables. The
pneumatic actuator is 11” in diameter for
application with high friction brake shoe (K-type) on
casnub type bogies. The system consists of a unique
design with two pneumatic actuators (one per bogie)
to deliver reliable braking performance and is light in
weight. It fits into any standard IR
casnub bogie and uses 58mm thick brake shoes.
Figure 1
Secondary
Brake
Beam
Brake Beam
Pin
Brake cylinder contains an integral double acting slack
adjuster, which provides optimal braking force and
minimizes shoe & wheel wear. The design is with high
strength and minimal brake beam deflection.
Any Brake cylinder reaches end of stroke indications
(i.e. piston indicator stroke 85 mm) or brake block not
touching the wheel during brake application found during
regular checks should be mandatorily reported. A Decal /
Sticker (KB part no KP4241342) for the 11” Brake cylinder
Piston
indicator stroke would be pasted on the wagons.
Figure 1
Replaceable
Brake Head
Push Rod
Clevis Pin
Bell Crank
Lever
Primary Brake Beam

Piston Stroke
Indicator
Brake
Cylinder
Brake Beam
Pin
WORKING DESCRIPTION OF BMBS
(Refer figure 2.)
During application, the air is introduced into the
brake cylinder, which forces out the piston along the
ram assembly. The brake cylinder is floating in
nature, as result the brake cylinder extends
equally on both the sides. This extension of brake
cylinder causes the rotation of the bell crank
levers on their pivot (which is on primary brake
beam) and forces the push rod to move towards the
secondary beam. This movement causes the
secondary brake beam to move towards the
wheels and apply force on the wheels.
Simultaneously a reaction force is developed
which causes the primary brake beam (along with
levers and brake cylinder) to move towards the
wheels. The primary brake beam continues to
move until it touches the wheels and apply force
on the wheels.
Secondary Brake
Beam
Removable Brake
Head
When the brakes are released, the air from the brake
cylinder is exhausted to the atmosphere through the
Distributor valve. The return spring inside the brake
cylinder pushes the piston along with the ram assembly
back to its original position. The bell crank levers
rotate back, causing the beams to move back to their earlier
positions. The brake cylinder is equipped with a double acting
slack adjuster. If there is any wear (Brake Shoe/Wheel) or
any slackness in the structure, it will be automatically
compensated by the built-in slack adjuster which pays out to
fill the
gap.
Primary Brake
Beam
Brake
Cylinder
Figure
2
FEATURES
 The system can be easily fitted on any IR
standard Casnub bogie without making any
modifications. This is a drop in fit system and does
not require any special tools and training for
installation/assembly.
 To achieve uniform wheel loading, the loads are
applied to the ends of the brake beam instead of
center.
 The system uses IR standard 58mm thick K- type
brake blocks.
 A replaceable brake head design permits the
reuse of the beam in the event that the brake heads
gets damaged. Replacement of the brake head
is quickly accomplished by removal of only one
pin.
 The push rods are positioned under the
bolster. With this system the track clearance has
been increased, as there is nothing under the
spring plank of the bogie.
 The integral double acting slack adjuster of the
brake cylinder maintains a constant piston
stroke. The slack adjuster has a total make-up
capacity of 500mm, which will compensate for
total combination of shoe wear, wheel wear and
clearance.
 Re-screwing of slack adjuster is automatic and
can be done from the side of the wagon by a pry bar.
 All cylinders are equipped with an automatic
piston stroke indicator.
 The hand brake systems uses two steel
handbrake cables pulled through standard hand
brake rigging as a means to apply the hand brakes.
The cables provide a flexible and lightweight
interface to the hand brake actuator.
 The system also has an automatic pressure
modification (APM) device (EL-60 valve) for
two stage braking (empty / loaded). It is fitted between
wagon under frame and the bogie side frame.
 To identify visually, 2’’ wide red colour Tape / Paint strip is
pasted on the guide tube (NPH assembly) of 11” Brake
cylinder.
 A Decal / Sticker (KB part no. KP4241342) for the 11”
Brake cylinder Piston indicator stroke would be pasted on
Wagons.
Air Brake System with BMBS having APM valve
The brake system provided on the wagons with BMBS
is single / twin pipe graduated release system
with automatic two stage braking. Its operating
principle is as follows.
Schematic layout of single / twin pipe graduated
release air brake system as provided on the
wagons is shown in sketches below. Brake pipe
/ Feed pipe runs through the length of wagon.
Brake pipes / Feed pipes on consecutive wagons in a
train are coupled to one another by means of hose
coupling to form a continuous air passage from the
locomotive to the rear end of the train. Brake pipe is
charged to 5 kg/cm through the compressor of
2
the locomotive. Brake pipe is charged to 5 kg/cm 2
through the compressor of the locomotive. Feed pipe

is charged to 6 kg/cm .
2
The wagons are provided with automatic

pressure modification (APM) device EL-60 valve 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 ±
0.25 kg/cm is obtained in empty condition and 3.8 ±
2
0.1 kg/cm is obtained in the loaded condition.

2
To obtain this a changeover mechanism, APM under-

frame and side frame of the bogie. The mechanism gets
actuated at a pre-determined change overweight of the
wagon and changes the pressure going to the brake cylinder
from 2.2 ±
0.25 kg/cm to 3.8 ± 0.1 kg/cm in case of changeover
2 2
from empty to loaded and vice-versa.

For application of brake, air pressure in the brake pipe is
reduced by venting it to the atmosphere from driver’s brake
valve in the locomotive. The reduction of the brake pipe
pressure positions the distributor valve in such a way that the
auxiliary reservoir is connected to the brake cylinder
through the APM device (EL-60 valve) and
thereby applying the brake.
The distributor valve gives an output pressure of
3.8 kg/cm for the brake cylinder which is routed
2
through the APM device (EL-60 valve). Based on the

position of sensor arm of APM device (EL-60 valve), it
gives an output of 2.2 ± 0.25 kg/cm for empty
2
position braking and an output of 3.8 ± 0.1 kg/cm for

2
loaded position braking in the wagon.

During full-service brake application, a reduction of
1.3 to 1.6 kg/cm takes, a maximum brake
2
cylinder pressure of 3.8 ± 0.1 kg/cm in loaded

2
condition and 2.2 ± 0.25 kg/cm in empty 2
condition is achieved. Any further reduction of

brake pipe pressure has no effect on the brake
cylinder pressure. During emergency brake
application, the brake pipe is vented to
atmosphere very quickly as a result the distributor
valve acquires the full application position also at a
faster rate. This result in quicker built up of
brake cylinder pressure but the maximum brake
cylinder pressure will be the same as that
obtained during a full-service brake application.
For release of brakes, air pressure in the brake pipe is
increased through driver’s brake valve. The increase in the
brake pipe pressure results in exhausting the brake cylinder
pressure through the Distributor valve. The decrease in the
brake cylinder pressure corresponds to the increase in the
brake pipe pressure. When the brake pipe pressure
reaches 5 kg/cm , the brake cylinder pressure exhausts
2
completely and the brakes are

completely released.
Description of Equipment’s
Distributor Valve with Common Pipe Bracket
and Control Reservoir
The distributor valve assembly consists of
distributor valve, common pipe bracket, adapter,
control reservoir and gasket. All pipe connection to
distributor valve is through the common pipe bracket.
The distributor valve along with the adapter can
be removed from the pipe bracket without
disturbing the pipe connection for maintenance
purpose.
The control reservoir of 6 liters volume is directly
mounted to the pipe bracket. An isolating cock (R-
charger handle) is provided on the distributor valve to
isolate the distributor valve when found defective.
The handle of the R-charger will be placed in
vertical position when the distributor valve is in
open position and horizontal when the distributor
valve in closed position. A manual release
handle is provided at the bottom of the distributor
valve by which the brake in a particular wagon can be
released manually by pulling the handle.
The distributor valve used with bogie mounted
brake system has a different set of Application &
Release chokes to achieve the timings as
specified in the RDSO specification 02-ABR. The
choke sizes to be used for Distributor valve fitted on
wagons with BMBS for KE Version of
distributor valve are 1.42 mm for Application &
1.52 mm for release. The other makes of
distributor valves should be adopted with suitable
choke sizes to achieve Brake Application &
release timings as specified in 02-ABR but with a
stroke of 110mm of 14” Brake Cylinder. For
identification, the Distributor Valve is equipped
with a name plate ‘’ BMBS ‘’ on choke cover.
47 (i.e., wheel dia. reduce from 1000 mm to 906
mm).
The brake cylinders used on the bogie mounted brake
system are of two types: with hand brake cables and
without hand brake cables. The brake cylinder with
hand brake cables is used for interface with the
hand brake arrangement on the
wagons.
Brake cylinders are provided with dirt protection

caps. It should be removed only when making
connection with hose and after removing the cap,
same bolts are to be used to connect the BC Hose
with the Brake Cylinder.
Dust protection cap

Brake Cylinder with built-in Double acting Slack Adjuster
The brake cylinder receives pneumatic pressure from
auxiliary reservoir after being regulated through the
distributor valve and APM device (EL- 60 valve). Brake
cylinder develops mechanical brake power by outward
movement of its piston with ram assembly.
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
Piston thus the rigging is also brought to its original position
when brake is released.
The built-in slack adjuster compensates for the wear of
brake blocks during the brake application through equivalent
pay-out. For paying-in, a pry bar is applied between the brake
shoe and wheel and the rigging is pushed in.
The brake cylinder has got a double acting slack adjuster as a
result the actuator of brake cylinder will continue to move out
till all the slack in the system is take care off and reaction
force of the wheels is encountered.
The brake cylinder compensates for any change in gap
between brake block and wheel through the inbuilt slack
adjuster. Therefore, it maintains a constant gap between the
shoe and wheel. The slack adjuster works in both the
condition whether there is an increase or decrease in gap.
There is an indicator on the brake cylinder to show the
“APPLIED” or “RELEASED” condition of the Brake Cylinder.
Don’t hit the indicator, it may retract slowly. Hitting can
bend / damage the indicator.
The brake cylinder has slack adjustment of 500 mm which
could compensate of brake block wear
of 48 mm (From 58 to 10 mm) and wheel wear of
APM Device (EL-60 valve)
APM device is interposed between bogie side frame of
Casnub bogie and the under frame of the wagon. It is fitted
for achieving 2-stage load braking with automatic
changeover of brake power. Only one APM is required per
wagon. It restricts the brake cylinder pressure coming from
the Distributor valve to 2.2 ± 0.25 kg/cm in empty condition
2
of the wagon and allows the brake cylinder pressure of

3.8 ± 0.1 kg/cm in loaded condition of the wagon. The
2
sensor arm of the APM device comes down for sensing only
during the brake application.
The factory setting for the movement of the sensor point
is 104 mm which is consisting of loaded and empty
zone. First 79 mm of the sensor point is for the loaded
zone and the balance is for the empty zone. After 79mm
movement, changeover from loaded to empty takes
place. For each wagon, the changeover from empty to
loaded has to be aligned to this
valve.
The gap between the sensor point and the bogie is to
be measured at the point it touches the top surface of
the side frame. Also ensure that the sensor point
touches in the middle of the side frame.
It has an indicator to show the empty or loaded
position. Whenever the indication is “ON” i.e., it is
showing the orange colour, it is indicating the
empty condition with brake cylinder pressure of
2.2 ± 0.25 kg/cm . When there is no indication in the
2
indicator, it is loaded condition with 3.8 ± 0.1 kg/cm

2
going to the brake cylinder. It has a quick connect

nipple to connect the gauge to the check the
pressure through the pressure gauge.
To check the load pressure in Empty Wagon,
Kindly place a block of 25 mm thickness between the
sensor point of APM and Side frame of bogie.
A pressure gauge can be connected via two methods:
1. Quick Connect Coupling with pressure gauge
arrangement (KBI Part no. KND- 00134) directly with the
quick connect nipple provided in the EL-60 valve. Detail of
KND-00134 is given under title of Special tools & gauges
required during the maintenance at page 35.
2. We also can connect the pressure gauge with the EL-60
after removing the quick connect nipple. There is ¼”
NPTF
tapping in the housing of EL-60 valve.
Auxiliary Reservoir Dirt Collector
An auxiliary reservoir of 100 liters is provided on each Dirt collector is provided at the junction of t
wagon to store compressed air. It is charged brake pipe and branch pipe. This is meant for re
to 5 Kg/cm pressure through the distributor
2
from the air prior to entering the distributor valv
valve in case of single pipe system. However, in achieved by centrifugal action.
case of twin pipe system, it is charged to 6 Kg/cm 2
Isolating Cock
through the feed pipe. Isolating cock without vent is provided in the FP
The auxiliary reservoir is made by sheet metal. On twin pipe wagons. The isolating cock is used to is
both the ends of the reservoir, flanges are pressure to the Auxiliary reservoir. The isolatin
provided for pipe connection. One end of the are OLP type meaning that when the handle is
reservoir is kept blanked for operation with single the body, it is an open position for the cock.
pipe brake system. A drain plug is provided at the Isolating Cock with vent
bottom of the reservoir for draining the Isolating cocks with vent are provided in BC lines
condensate. isolating the mal-functioning brake cylinders o
Cut-Off Angle Cock The vent side of the isolating cock is to be maint
Cut off angle cocks are provided at the ends of brake towards the brake cylinders in order to exhaust
pipe / feed pipe on each wagon. These cocks are pressure from the brake cylinder whenever the
closed at the time of uncoupling of wagons. The The isolating cocks are OLP type meaning tha
vent provided in the cock facilitates easy uncoupling handle is parallel to the body, it is an open
of hose coupling by venting the air trapped in the the cock.
hose coupling when the cock is closed. The handle of Pipes
angle cock is spring loaded having a self-locking type ERW stainless steel pipes as per RDSO sp
of arrangement to avoid any inadvertent movement 04-ABR are used for wagons with Bogie Moun
from open to close position or vice versa. The System. Pipes of 32 & 20 mm nominal bore are
handle has to be lifted to operate the angle cock. employed. The pipes are cold bend with the
When the handle is parallel to the pipe the cock is bending equipment. The radius of the bends is to
in open position and when at right angles to the pipe the maximum possible so as to reduce re
it is in closed position. air flow.
Hose Coupling for Brake / Feed pipe Pipe fittings
The hose couplings are provided to connect brake Welded and swivel flange fittings are used f
pipeline & feed pipeline throughout the train. It joints. Fixed flanges are rigidly welded to pip
consists of rubber hose connected to coupling the Swivel flanges are used to align to the fix
head and nipple by “Band it” type of clamps. The Rubber gaskets are
nipple goes into the angle cock and the coupling used to seal the joints.
heads are coupled together. Rubber gasket is used in
the coupling head to make the
joint leak proof.
Critical Bogie Dimension for BMBS
In order to ensure trouble free fitment of the Bogie mounted brake system, it is necessary that the foll
dimension are to be checked before fitment and maintained during
maintenance. (All dimensions are in mm)
NOTE: No fouling of Push Rod assembly with any contact surface during any condition of Bogie is allowed.
Refer RDSO drg.no. WD-89067-S-03 Rev. 18.
Side pocket Gauge for checking bogie liner gap:

To ensure correct shape & size of CASNUB bogie liner gap, A special Side pocket Gauge (KBI Part no. KN00
should be move freely to the complete depth throughout the length. Image of Side pocket Gauge is shown
Important dimensions of Casnub bogie for BMBS:

r
r is provided at the junction of the main
nd branch pipe. This is meant for removing dust
prior to entering the distributor valve. This is
centrifugal action.
ck
k without vent is provided in the FP line of the
gons. The isolating cock is used to isolate the FP
he Auxiliary reservoir. The isolating cocks
e meaning that when the handle is parallel to
s an open position for the cock.
ck with vent
ks with vent are provided in BC lines for
mal-functioning brake cylinders on the wagon.
of the isolating cock is to be maintained
brake cylinders in order to exhaust the
m the brake cylinder whenever the need arise.
cocks are OLP type meaning that when the
rallel to the body, it is an open position for
ss steel pipes as per RDSO specification

used for wagons with Bogie Mounted Brake
s of 32 & 20 mm nominal bore are generally
he pipes are cold bend with the help of
pment. The radius of the bends is to be kept to
m possible so as to reduce restriction of
swivel flange fittings are used for pipe

flanges are rigidly welded to pipes; whereas
anges are used to align to the fixed locations.
ets are
the joints.
stem, it is necessary that the following Bogie
ed during
g any condition of Bogie is allowed.
de pocket Gauge (KBI Part no. KN0011151)

mage of Side pocket Gauge is shown below:
INSTALLATION OF BMBS ON BOGIE
Tools Required
Pry Bar, Pliers, hammer.
Installation Procedure
Refer figures 3, 4, & 5 for Installation of
Equipment and its adjustments.
1. To install the beams, it is necessary to split the
bogie. Lift the bolster and move the axles with wheels
outside the side frame. Slide the primary beam
assembly 3 inside the side pockets in the side
frame. Place the bell crank levers 5 & 6 in the
primary beam assembly 3. Push the Pin 9 through
the beam 3 and bell crank levers 5 & 6. Bend the bulb
cotter 14 after inserting inside the Pin 9. Slide the
secondary beam assembly 4 inside the side
pockets on the other side.
2. Install the push rods 7 between the bell
cranks and the secondary beam 4. Secure the
push rods to the secondary beam with the pin 10 and
bulb cotter 14.
3. Secure the push rod 7 with bell crank levers with
pin 8 and bulb cotter 14 on primary beam sides.
4. Attach the Brake Cylinder 1 or 2 to the bell crank
levers with two sets of pins 11, bush 19 and dowel
sleeve 20 after aligning the mounting holes in
the brake cylinder and the bell crank levers.
Note
a. Air connection flange and Ram of brake cylinder
1 or 2 to be oriented / fitted as per the Air Brake
Equipment and Under Frame Gear Arrangement
drawings. Cylinder with hand brake is to be installed
considering the location of Cable
Bracket.
Hand brake rigging
13. Handbrake system requires a set of rigging
between cable equalizer 27 and the
handbrake wheel as per requirement of
particular type of wagon.
14. Apply brakes 2-3 times from SWTR to ensure
correct piston stroke is achieved. Release air
pressure.
Warning
TO AVOID PERSONAL INJURY FROM
MOVEMENT OF THE VARIOUS PARTS WHEN
OPERATING THE SYSTEM, ALL PERSONNEL MUST BE
CLEAR OF BOGIE AND BRAKE PADS BEFORE
THE CYLINDER IS
PRESSURIZED.
Figure 3
Guide
Plate
Secondary
Figure 5 (Bogie with BMBS Arrangement)

Figure
4
List of BMBS Parts after upgraded 11” Brake cylinder

b. Brake cylinder 1 or 2 ram should be in fully
retracted position prior to installation.
5. Place the brake heads 16 on the guide plates of the
brake beams 3 & 4. Secure the brake heads to brake beams
with pin 12 and lock the same with cotter pin 13. Don’t forget
to place the washer before bending the cotter pin. After
bending the cotter pin, tack weld the same with washer.
6. Assemble the bogie by lowering the bolster with side
frame on the axle and wheel assembly.
7. Install new 58mm K-type brake shoe to beam assemblies
(3 & 4) on brake heads 16. Insert brake block keys 17 to hold
brake blocks to the removable brake heads.
8. Connect flexible air hose 20 from BC pipeline to the
flange on top of brake cylinders 1 & 2.
For Brake cylinders with Hand Brake Cables
9. Bracket for cable end support is welded to a convenient
place on the under frame of the wagon such that the bend
radius of the cables is not less than 255 mm. (Refer under
frame equipment installation drawings of the concerned
wagon).
10. Attach the cable conduits to the cable bracket (welded on
the under frame of the wagon) by placing one nut and one
washer on each side of cable bracket.
11. Tighten the lock nut to secure the cables to the bracket
properly.
12. Connect both cables on the brake cylinder to the cable
equalizer 27 using pins 28 and
cotter pins 29.
Adjustments
Adjustment is completely automatic and is
accomplished by the in-built slack adjuster. The slack
adjuster in the brake cylinder is double acting. It
automatically maintains a constant piston stroke by
taking up or letting out slack with each brake application.
The piston stroke indicator is mounted on top of the non-
pressure body of the brake cylinder (See figure 1). The
extension of the brake cylinder ram will increase as the
shoes and wheels wear. On a wagon in service, it will be
clearly visible as a shiny ring
near the ram scraper on the cylinder.
Figure 3
Side
Pocket
Guide Plate
Primary
Beam
h BMBS Arrangement)
ke cylinder
S. No. Part Description KB Part No. Qty /
Wagon
1 Cylinder Assembly without Handbrake Cables KP1796330 1
2 Cylinder Assembly with Handbrake Cables KP1802890 1
3 Primary Brake Beam with Beam stops I.3.5111 2
4 Secondary Brake Beam with Beam stops I.3.5112 2
5 Lever Assy; Right Hand I.3.5108 2
6 Lever Assy; Left Hand I.3.5109 2
7 Push Rod Assy I.3.5110 4
8 Pin; Clevis (Push Rod) C162088 4
9 Pin; Clevis (Primary Brake Beam) C162086 4
10 Pin; Clevis (Secondary Brake Beam) C162087 4
11 Pin; Clevis (Brake Cylinder) 778111 4
12 Pin; Brake Head 778112 8
13 Pin; Cotter Ø 6.3 X 90 (Brake Head) 476858 16
14 Bulb Cotter C162098 12
15 Washer; 778084 4
16 Brake Head; 778113 8
17 Brake Block Key* I.F.2172 8
18 ‘K’ – Type Brake Block* I.F.1217 8
19 Bush C140445 4
20 Dowel Sleeve C140446 4
21 Hose Assy. 1" With Flange I.4.2036 2
22 O-Ring A27763/17 2
23 Screw, Hex Head; Zinc Plated 748645 8
24 Washer, Lock; Cad Plated 735734 8
25 Washer C162060 4
26 Washer C162641 8
27 Equalizer; Cable 776622 1
28 Pin; Cable 776621 2
29 Split Pin (BMBS) I.4.2063 2
30 Pin Tie Rod I.3.2044 1
*Item is not in the KB Scope of supply.
Procedure to connect the Hand Brake Cable
with the Cable Equalizer and Tie Rod
1. Connect the outer cover of Hand Brake cables with cable bracket.
2. Ensure that the hand brake wheel and air brake are in fully release condition.
3. Pull out the cables fully from the brake cylinder in outward direction manually.
4. Connect cables with the cable equalizer.
5. Now connect the cable equalizer to the Tie rod.
6. Apply service brake to check that during the service brake application, cables should not
move/bend.
7. Apply service brake to check that during the service brake application, cables should not move/bend.
8. Secure the cable pins and tie rod pin with the APD.
ndition.
manually.
les should not
les should not move/bend.

APDs to be provided on Bogie Mounted Brake System
On Brake cylinder Pins
The pin connecting the brake cylinder with lever is to be
fitted with Bush & Dowel Sleeve.
Brake Cylinder Front End
Brake Cylinder Rear End
Exploded view of Assembly
APD for Brake cylinder
APD for Primary & Secondary Beams
APD on Primary Beams
APD on Primary Beams
APD on Secondary Beams A
APD on Secondary Beams P
D
f
o
r
C
a
b
l
e
e
q
u
a
l
i
z
e
r
A
P
D
f
o
r
P
u
s
h
R
o
d
APD on Cable Equalizer

Note: Kindly ensure that oversize APD’s should not be used at all, as it may infringing with the movem
rigging & seriously impact its functionality.
On Brake Head Pin

Split pins over the brake pin have to be Tack welded with washers as shown below.
Washer Details
OD 20 mm
ID 8 mm
Thickness 2-3 mm
APD on APM Device (EL-60 valve)

APD for APM Device (EL-60 Valve)
Lock nut on sensor arm
Additional Lock nut has to be provided on the sensor arm screw after the Gap has been adju
not be used at all, as it may infringing with the movement of Bogie
ack welded with washers as shown below.

the sensor arm screw after the Gap has been adjusted.
Do’s & Don’ts for KB Bogie Mounted
brake System
Do’s
Bogie Rigging
 Do ensure that the fitment dimensions in Bogie,
critical for fitment of BMBS are maintained within
their specified limits.
 Do ensure that the side frame pockets are of
correct dimension and free of all restriction.
 Do ensure that all the side frame pocket liners are
properly cleaned & are within the specified limits.
 Do ensure that Side pocket gauge shall move
freely throughout complete depth & the length of
Bogie pocket liner.
 Do ensure there is free sliding of Brake Beams
inside the side frame pocket liners.
 Do ensure that there is proper push rod & spring
plank clearance. If push rod clearance is less,
then check the
necessary bogie dimensions.
 Do ensure that there is proper fitment of brake
block key with Brake block and brake head.
 Do ensure that there is sufficient gap (after the
system is retracted) to change the brake blocks.
 Do ensure to use bush and dowel pin to lock the
brake cylinder pins.
 Do ensure that all split pin are in place and are
bent properly with their arms 90º
apart.
 Do ensure to check the gap between side frame &
bearing adopter in every inspection & maintained it
within
specified limit.
 Do ensure that correct shape & size of APDs are
provided on all the pins of the bogie rigging.
Brake Cylinder
 Do ensure to blow the steel pipes connecting the
brake cylinder before fitment to prevent the dirt particles
going
into the brake cylinder. This can be done by making 2-3 brake
applications before connection.
 Do ensure to regularly check the Piston stroke indicator
during every routine inspection. Take necessary action if
the
stroke is beyond the specified limit. Any over stroked (>75
mm) Brake cylinder, brake block not touching the
wheel during Brake application should be mandatorily
reported & rectified.
 Do ensure that the cables are not pulled out of the brake
cylinder on making hand brake connections.
 Do ensure that there is no rubbing of two hand brake cable
together or resting on the axle.
 Always use a suitable test bench, holding fixture for testing
the Brake cylinder
 Use hand brake cable removal tool for dis-assemble of
Hand brake cables from Brake cylinder.
 Do ensure that correct shape & size of APD’s to be
use on the Brake cylinder pins.
APM Valve (EL-60)
 Do ensure correct gap between the sensing
point of APM valve & surface of side frame. If not,
then adjust the same.
 Do ensure to put the additional check nut on the
adjusting screw to lock the same in position.
 Do ensure that changeover takes place to
loaded
position after putting 25mm
block below the sensor point on side frame.
 Do ensure that empty / load indicator of the APM
valve (EL 60) (Orange coloured) is visible during
empty condition.
 Do ensure that the reservoir for EL-60 valve is
secured properly with the underframe.
Piping layout and fitment
 Do ensure proper orientation of Check Valve &
Bogie Isolating Cocks. The vent side of the isolating
cock with vent should
be on the brake cylinder side.
 Do ensure to use the correct size of bolts, screws,
nuts and washers as specified. Use of wrong size
bolts / screw could
damage the threads on the brake cylinder /
APM valve.
 Do ensure proper clamping of APM Valve (EL 60)
hose with under frame.
 Do ensure that there is no rubbing of rubber
hoses with axle, wheel or
underframe members.
 Do not hit the indicator on the brake cylinder.
 Do not test the Brake cylinder without fixing it on Test bench.
 Do not test the Brake cylinder in open area.
 Do not carry bogies by cranes fitted with cylinder and without wheeling, by
fastened by chain wrapped in center. Use fork lifter or chain should hook in side frame holes only.
 Do not use L-type brake blocks with Bogie Mounted Brake system.
 Do not use the non-standard pin, bolts for the fitment of BMBS items.
 Do not use oversized APD’s.
 Do not use gas cutter to remove the
Brake cylinder bush dowel pin. Use Dowel pin removal tool for the same.
 Do not weld the beam stops on the Beam if
guide plate surface has dirt, rust etc.
Before welding the beam stops on the Beam guide plate, clean the surface with wire brush.
 Do not test the brake cylinder into open area.
 Do not apply the pressure into brake cylinder without proper fixing on test
bench or bogie.
Hand Brake Arrangement
 Do ensure to weld the hand brake cable bracket at its
current location. It should be welded straight and cables
should be
properly tightened to the bracket.
 Do ensure to weld the horizontal lever bracket at its
correct location.
 Do ensure that the horizontal lever is properly
supported by support brackets and have unrestricted
movement.
 Do ensure that there is proper hand brake
arrangement movement. After
applying the hand brake, there should not be any ringing
sound after striking wheels.
 Do ensure that there is no obstacle during return of
hand brake cable after releasing hand brake. Investigate
the
restriction for the cables and do the necessary
rectification.
 Do ensure to properly lubricate the hand brake screw, nut
and pivots to reduce the friction and ensure smooth
movement.
 Always use a suitable test bench, holding fixture for testing
of brake cylinder.
Don’ts
 Do not fit BMBS system if the Bogie parameters are
not within the specified
limits.
 Do not tacks weld the BMBS pins / split pins on the bogie.
 Do not hammer on beams and brake block.
ake cylinder.
hout fixing it on Test bench.
open area.
ith cylinder and without wheeling, by

e fork lifter or chain should hook in side frame holes only.
th Bogie Mounted Brake system.
s for the fitment of BMBS items.
he
e Dowel pin removal tool for the same.
am if guide plate surface has dirt, rust etc.
e Beam guide plate, clean the surface with wire brush.
en area.
ke cylinder without proper fixing on test

Wagon operating procedures b. Remove the brake block keys and replac
Procedure for changing of Brake Blocks blocks. Secure the new brake blocks with the
a. Changing the brake shoe with BMBS is easy and keys. The slack adjuster will automatically adju
fast. Ensure that the brakes are released. Slip brake shoe clearance to the proper value when t
in a pry bar between the brake block & wheel on any are applied and released. This usually
one wheel of the bogie. Force back the brake block takes from two to three brake applications.
from the wheel, thus retracting the double
acting slack adjuster and creating space for
inserting new brake blocks between the brake
head and wheel. To get more gap push the
beam
across the side pockets.
Position of Pry in order

to change the Brake Block
b. Remove the brake block keys and replace the brake
blocks. Secure the new brake blocks with the brake block
keys. The slack adjuster will automatically adjust the
brake shoe clearance to the proper value when the brakes
are applied and released. This usually
takes from two to three brake applications.
Figure 6
TYPICAL SERVICE / OPERATING PROCEDURES
Isolation of Brake Cylinder (1 & 2)
(See figure 5)
a. There are two isolating cocks with vent in BC line
for isolating each brake cylinder in the wagon.
b. To isolate any Bogie / Brake Cylinder, move the
isolating cock (OLP types) handle to closed position.
This will stop the further feeding of corresponding
brake cylinder and the air already present in the brake
cylinder will get exhausted to atmosphere, thus,
releasing the brakes in that particular bogie.
Brake Head (16) Changing
(See figure 5 & 6)
a. Ensure that the brakes are released. Slip in a pry
bar between the brake block 18 & wheel on any one
wheel of the bogie. Force back the brake block from
the wheel, thus retracting the double acting slack
adjuster (figure-6) and creating the space between the
brake block and the wheel.
b. Remove the brake block key 17 and then the brake
block 18.
c. After obtaining enough clearance between the
wheel & the brake heads 16, remove the cotter pin 13
& the brake head pin 12 consecutively to
remove the desired brake head.
d. Install a new brake head 16 and secure it with brake
head pin 12 then a cotter pin 13. Bend cotter pin legs
outwards.
e. Place brake block 18 on the new brake head
and secure the brake block with the brake block key
17 and the cotter pin 13.
a.
beam 4 & the primary beam . Force
3
brake the some
cylinder to retract to create
spac
e.
Note: However, do not retract the brake
cylinder, if the cylinder is retracted as the
ram
spring will be more compressed and will
shoot out faster if not secured
properly.
Firstly, move the lighter side i.e., ram
end
side of cylinder away from the . Please
lever
make sure that there are no one in front of
ram assembly as it may come out suddenly
and Then remove the heavier side
fast.
(cylinder body) of cylinder safely with the
help
of suitable persons for proper handling. The
ram assembly had to be pushed in /
screwed
in inside the brake cylinder as per KB
defined
metho
d.
bogie, firstly install the heavier side
cylinderofon the lever & insert the pin.
Then
install the lighter side i.e., ram side of
cylinder
on the lever & insert the to secure. Make
pin
sure that there are no one in front of
Ram
assembly Make sure that cylinder is aligned
.
f. The slack adjuster will automatically adjust the brake
shoe clearance to the proper value when the brakes are
applied and released. This usually takes from one to
three brake applications.
Brake Cylinder (1 & 2) Changing
(See figure 5 & 6)
Ensure, the brakes are released, and the brake cylinder
is completely vented. Retract the brake cylinder by using a
pry bar between wheels & brake blocks on both the
secondary
b. Disconnect the flexible air hose 21 from the cylinder
assembly flange.
c. Remove the dowel pin 20 by using dowel pin removal
tool & bush 19. Then remove the pin 11 from both sides
of the cylinder.
d. To install the new brake cylinder assembly on
in the same way as the previous cylinder,
using pin 11. Secure the brake cylinder with bush
19 & dowel pin 20.
e. Reconnect the flexible air hose 21 to the
cylinder assembly flange.
f. Apply partial brakes 2 - 3 times in order
to restore the internal slack adjuster’s position.
Note
For cylinders equipped with the hand brake
cables (see fig. 5), it is necessary to:
g. Disconnect the cable equalizer 27 from
the hand brake cables by removing the two split
pins 29 and cable pins 28.
h. Remove the two cables from the
cable bracket.
i. Use hand brake cable removal tool for
dis- assemble of Hand brake cables from Brake
cylinder.
j. Always use a suitable test bench, holding
fixture for testing the Brake cylinder.
Lever Assembly Changing RH (5) & LH (6)
(See figure 5)
This change will be required if this part has been
damaged or worn out.
a. After removing the APD, remove the bulb
cotter 14 and the pin 8 with pull rod. Now,
remove the bush 19, dowel sleeve 20 and the pin
11 with brake cylinder. Remove the bulb cotter
14 and pin 9 with the primary brake beam 3.
Pull the bell crank lever RH 5 & LH 6 from the
beam assembly 3. Install a new lever RH 5 or
LH 6 as applicable using the pin
lever 9 and the bulb cotter 14. Install pin 8
Note: Do not hit or hammered on the

cylinder
during the movement of Ram as Ram
end
assembly comes out faster & may hit
the
person
.
and bulb cotter 14 with pull rod 7. Install pin 11 with bush 19
& dowel sleeve 20. Bend cotter pin legs and provide
the required APDs.
b. The slack adjuster will automatically adjust the brake
shoe clearance to the proper value when the brakes are
applied and released. This usually takes from one to three
brake applications.
Push Rod (7) Changing
(See figure 5)
This change will be required if this part has been damaged or
worn out.
a. Remove the bulb cotter 14 and the pin 8 with bell crank
lever 5 or 6. Remove the bulb cotter 14 and the pin 10
with secondary brake beam 4. Remove the pull rod from
lever assembly RH 5 or LH 6. Remove the rod from the
secondary beam. To install a new push rod, align the rod
end hole with the mounting holes in the secondary beam 4
and then insert the pin 10 and the bulb cotter 14.
b. Do the same procedure on the other end of the pull rod by
aligning the pull rod with the lever assembly RH 5 or LH 6 with
pin 8 and bulb cotter 14. Bend the cotter pin legs and provide
the required APDs.
c. The slack adjuster will automatically adjust the brake shoe
clearance to the proper value when the brakes are applied and
released. This usually takes from 2-3 brake
applications.
Lifting of under frame from Bogie
1. Disconnect the flexible air hose 21 from the
flange of brake cylinder without hand brake cables by
unscrewing the bolts.
2. Disconnect the flexible air hose 21 from the
flange of brake cylinder with hand brake cables
by unscrewing the bolts.
3. Disconnect both the cables from the
equalizer cable 27 by removing the split pins and the
pins.
4. Detach the cables from the cable bracket by
loosening the nuts on either side of the cable bracket.
Remove the cables from the bracket after the nuts
have been loosened and enough space is created
for easy removal.
After the removal of brake cylinder hoses and the
hand brake cables from the under frame, the
wagon under frame can be lifted from the bogies.
The bogie can be dismantled or assembled with the
bogie mounted parts by following
maintenance instruction described earlier.
CONDEMNING LIMITS OF SYSTEM
COMPONENTS
Brake Head (16)
(See figure 7)
Brake Head 16 should be replaced if the following
exists.
Check brake head tip. Push brake head forward and
measure travel by pulling brake head all the way
back. Tip travel should NOT exceed 31.75
mm.
Bell Crank Lever Assembly RH (5) & LH (6)
Figure 7
Bell Crank Levers should be replaced if any one
of the following exists:
1. Excessive Wear on any surface, anything >
1.6 mm
2. Worn, Damaged or Broken Spherical Bearing
 25.4 mm Hole exceeds 26.7 mm in any direction (i.e.: oval
condition)
 32 mm Hole exceeds 33 mm in any direction (i.e.: oval
condition)
Push Rod (7)
Push Rods should be replaced if any one of the
following conditions exist:
 Any part of the push rod is Bent
 Cracked or Damaged Welds
 Excessive Wear on any surface, anything
> 1.6 mm
 Worn, Damaged or Broken Spherical
Bearing
 Worn / Enlarged Pin Holes, 25.4 mm Hole
exceeds 26.7 mm in any direction (i.e., oval
condition)
 Clevis End Gap Exceeds 27.9 mm.
Brake Beams with Beam stops (Lug)
Purpose of Beam stops weldment on Brake Beam:
Beam stops will centralize the Brake beams in the
bogie. It will prevent that one side the beam could
be barely in the guidance while the other side is
sticking too much in the pocket. In this case one
side would wear out and the other side
would show high friction and could block the slack
adjustment. (See figure below)
The whole welding process of Beam stops (Lug) on the Beam
guide plate is to be done with the help of special welding
fixture (Part no.
KN0011153) as shown below in the picture.
Welding of Beam stops (Lug) on Brake beams guide plate (both end)
S.No. WORK DESCRIPTION RESOURCES REQD
1 Place the fixture at Bottom Welding fixture (part no.

side of guide plate. Place the KN0011153)
Lug in the fixture slot as
shown in image.
2 Tight the Fixture with the -

adjustable knob provided in
Fixture
3 Do tack weld on Lug as Welding equipment

shown in image.
4 Remove the fixture & do -

welding on whole length as
shown.
Remove the spatters.
5 Repeat the Process "1-4" for -

other end of Beam guide
plate.
te (both end)
REMARKS/ PHOTOGRAPHS
Lug
Brake Beam should be replaced if the following exists. (See
figure 8)
Remove Brake Head and inspect Brake Head pin hole in
Beam. If hole exceeds 20.32 mm in length, replace
Beam. If not, replace brake head and recheck tip as
described earlier. Tip should not exceed 31.75 mm (from
FIRST check above). If tip does exceed 31.75 mm, replace
Beam and Brake Head
Figure 10
Figure 8 – Worn Condition

Gap between Bell crank lever RH 5 & LH 6 and the upper channel
of Primary brake beam 3 (See figure 9)
Measure the bell crank lever dimension with reference
to the lever being supported inside the primary brake
beam. Measure the maximum pass-through gap.
Note the locations of the measurement for the lever and
the position of the lever in regard to the primary brake
beam. (See sketch below.)
Use washers as demonstrated below to adjust the gap.
MAINTENANCE IN OPEN LINE
1. BOGIE RIGGING; BRAKE BEAMS, BELL CRANKS
LEVERS & PUSH RODS
a) Check the components for missing or any physical
damage, if found replace them.
b) Check all the pin joints for any missing parts
(pins, split pins, spring dowel, etc), if missing, provide
the same.
c) Check that the APD is provided on all the pins and on
the EL-60 valve.
d) Check that all hoses are properly tightened
and are not threatened to be damaged by axle or
wheel. If so, properly clamped them.
e) Check the thickness of Brake Block. It should be
sufficient for complete trip.
2. BRAKE CYLINDER
a) Check for any physical damage of components.
b) Check that the piston indicator is fully in.
c) In case of brake cylinder with hand brake cables, the
cables are not entangled or resting / touching the axle.
d) Check that hand brake cables should not bend
during the service brake application.
2.1 Brake Cylinder Piston Stroke Indicator General
Overview, End of Stroke Condition & Their Checking
Procedure in Wagon:
A two-coloured, integrated piston indicator pin
indicates the stroke of the piston. Under normal
conditions the piston shows only the red colour (up to 75
mm piston stroke). If the stroke of the piston is too long,
the pin shows an additional silver surface. After 85
mm piston stroke the piston reaches end of stroke. Any
end of stroke indications or brake block not touching the
wheel during brake application found during the regular
inspections should be mandatorily
reported & to rectify it as per the process.
Brake cylinders reach end of stroke during normal service
and even blocks are not touching the wheel. End of
stroke position (piston indicator) is visible from the outside of
the bogie. The end of stroke indicates an issue with the
brake which should be reported and acted upon.
The elastomeric spring between the axle box and the side
frame pedestal jaw, plays an important role. The spring can
“store” the block force even when end of stroke is reached.
Therefore, end of stroke is an indication for a problem in the
bogie, but there is still a block force available. Only when a
block doesn’t touch the wheel, there is no block force.
(KB Decal no. KP4241342 for Brake cylinder Piston indicator stroke)
2.2 Brake cylinder Piston stroke indicator & their over stroke root cause identification and related corrective act
Knorr-Bremse recommends carrying out the investigation to resolve Brake cylinder overstroke condition in
following way:
Bogie Equipment
Component Description KB Part No. Qty/
Wag
on
1 Cylinder Assy; without KP17963 1
Handbrake 30
2 Cylinder Assy; With KP18028 1
Handbrake 90
3 Valve Assy; EL-60 I.3.5114 1
4 Reservoir; EL-60 I.3.5115 1
5 Primary Beam I.3.5111 2
6 Secondary Beam I.3.5112 2
7 Lever Assy; Right Hand I.3.5108 2
8 Lever Assy; Left Hand I.3.5109 2
9 Push Rod Assy; I.3.5110 4

10 Brake Head; 778113 8
Pins, Split Pins (Bogie
Equipment)
1 Pin; Clevis C162088 4
4 Pin; Clevis 778111 4
6 Split Pin 476858 16
8 Washer C162641 8
9 Washer C162060 4
10 Washer; 778084 4
Hoses & Hardware’s (Bogie
Equipment)
1 Hose Assy. 1/2" With I.4.2037 1
Flange
2 Hose Assy. 1" With I.4.2036 2
Flange
3 O-Ring I.4.1050 2
4 O-Ring A27763/1 2
7KI
5 Spring Washer I.H.0062 2
6 Screw, Hex Head; Zinc 748645 8
Plated
7 Washer, Lock; Cad 735734 8
Plated
8 Locknut: Zinc Plated 755896 1
9 Screw, Hex Head; Zinc 734734 2
Plated
3. APM DEVICE (EL-60)
a) Check for any physical damage to the valve.
b) Check that the indicator in during the release.
c) Check the tightness of the lock nuts on sensor arm lever, if found loose, tighten them and also verify t
specified with the help of EL-60 gap adjusting gauge.
d) Check that the valve’s sensing arm is
moving freely.
4. HAND BRAKE RIGGING

a) Check all the pin joints for any missing parts (pins, split pins, spring dowel, etc), if missing, provid
b) Check the components for missing or any
physical damage, if found replace them.
Spares of M/S KNORR- BREMSE to be maintained in open lines / ROH Depots

List of items to be maintained for replacement against missing or damaged parts.
ator & their over stroke root cause identification and related corrective action:
g out the investigation to resolve Brake cylinder overstroke condition in the
ge to the valve.
uring the release.
nuts on sensor arm lever, if found loose, tighten them and also verify the Gap as
gap adjusting gauge.
ng arm is
any missing parts (pins, split pins, spring dowel, etc), if missing, provide the same.
ing or any
hem.
E to be maintained in open lines / ROH Depots

eplacement against missing or damaged parts.
ROUTINE OVERHAUL (ROH) OF BMBS
SYSTEM FOR FREIGHT CARS
In routine overhaul, first test the brake system of
BMBS using single wagon test rig. Following
action should be taken for the defects /
discrepancies identified during testing.
1.1 Brake Cylinders
Check & replace brake cylinder by tested brake
cylinder if following defects are identified:
(a) Check the brake cylinder for any physical
damage or leakage.
(b) In case of brake cylinder with hand brake
cables, check that the movement of cables is
free.
(c) Ensure that the piston indicator is fully in
released condition.
1.2 BRAKE BEAMS
Check for any physical damage, crack, etc, if found
replace them. Check for rusting & corrosion and if
found repaint them.
(a) Replace all the PINS, washer, split pins, dowel
pins from OEMs.
(b) Check the GAP at pivot pin on the
primary brake beam as shown in the condemning
limit of the system components.
(c) Check brake head for loosening or damage
as shown in the condemning limit of the system
components.
1.3 LEVERS & PUSH RODS
(a) Replace the Bell crank lever, if any of the
parameters specified in the condemning limits
is observed.
(b) Replace the push rod, if any of the
parameters specified in the condemning
limits is observed.
1.4 APM VALVE (EL-60)
(a) Clean the Indicator.
(b) Check the APM valve:
I. Any physical damage
II. Valve’s sensing arm is moving freely and is fully in.
III. Check the leakage.
IV. Tightness of the lock nuts on sensor arm lever, if found
loose, tighten them.
(c) Check the Gap between the sensor arm and the side
frame, if required readjust as specified.
1.5 HAND BRAKE RIGGING
(a) Check the pin joints / components for missing or any
physical damage, if found replace them.
(b) Replace all the PINS, washer, split pins, dowel pins,
plastic bushes.
1.6 HOSES & PIPE JOINTS
(a) Check the hoses for any cracks / damage. If so,
replace them.
(b) Check that the hoses are properly tightened and
are not threatened to be damaged by axle or wheel. If
so, properly clamped them.
(c) Check the pipe joints for leakages, if so, tighten
them properly.
1.7 Bogie pocket liner & Side fram jaw gap
a) Check the bogie pocket liner gap by using side pocket
gauge. Ensure trouble free movement of Side pocket
gauge throughout the complete length & depth
in the Bogie pocket liner.
b) Check the gap between side frame jaw & bearing BRAKE CYLINDER
adopter in every inspection & maintained it within a) Overhaul the brake cylinder as per procedur
specified limit. in the manual.
PERIODIC OVERHAUL (POH) OF BMBS b) Replace the must change items.
SYSTEM FOR FREIGHT CARS c) Check the condition base items, if found wor
BOGIE RIGGING damaged, replace them.
Replace all the must change items as listed in the list d) Test the brake cylinder as per the procedure
below on the Bogie. manual.
BRAKE BEAMS e) Always use a suitable test bench, holding
a) Check the beams for rusting & corrosion and if testing the Brake cylinder.
found repair & repaint them. APM DEVICE (EL-60 VALVE)
b) Check the GAP at pivot pin on the primary brake a) Overhaul the EL-60 valve as per pr
beam as shown in the condemning limit of the explained in the manual.
system components. b) Replace the must change items as enl
c) Check brake head for loosening or damage as manual.
shown in the condemning limits of the system c) Check the condition base items, if found wor
components. damaged, replace them.
BELL CRANKS LEVERS & PUSH RODS d) Test the EL-60 valve as per the pro
a) Replace the Bell Crank levers, if the critical in the manual.
parameters found to in condemning limits as specified. e) Check the Gap between the sensor point and
b) Replace the Push Rod, if the critical frame surface and readjust the same as specifie
parameters found to in condemning limits as specified. wagon type.
HAND BRAKE RIGGING HOSES, PIPES & PIPE JOINTS
a) Check for any physical damage of a) Check the hoses for any cracks / dam
components, if found replace them. replace them.
b) Brake rigging brackets, bolts and nuts should be b) Clean the pipes as per the procedure laid do
examined for rusting, looseness, damaged in spec. WD-04-ABR-02.
threads, etc and replaced. BOGIE POCKET LINER & SIDE FRAM JAW GAP
c) Replace all the PINS, washer, split pins, dowel a) Check the bogie pocket liner gap by usin
pins from OEMs. gauge. Ensure trouble free movement of Side
d) The plastic bushes should be changed. gauge
throughout the complete length & depth

in the Bogie pocket liner.
BRAKE CYLINDER
a) Overhaul the brake cylinder as per procedure explained
in the manual.
b) Replace the must change items.
c) Check the condition base items, if found worn or
damaged, replace them.
d) Test the brake cylinder as per the procedure given in the
manual.
e) Always use a suitable test bench, holding fixture for
testing the Brake cylinder.
APM DEVICE (EL-60 VALVE)
a) Overhaul the EL-60 valve as per procedure
explained in the manual.
b) Replace the must change items as enlisted in the
manual.
c) Check the condition base items, if found worn or
damaged, replace them.
d) Test the EL-60 valve as per the procedure given
in the manual.
e) Check the Gap between the sensor point and the side
frame surface and readjust the same as specified for the
wagon type.
HOSES, PIPES & PIPE JOINTS
a) Check the hoses for any cracks / damage. If so,
replace them.
b) Clean the pipes as per the procedure laid down by RDSO
in spec. WD-04-ABR-02.
BOGIE POCKET LINER & SIDE FRAM JAW GAP
a) Check the bogie pocket liner gap by using side pocket
gauge. Ensure trouble free movement of Side pocket
gauge
b) Check the gap between side frame jaw & bearing

adopter in every inspection &
maintained it within specified limit
Must change items during POH) For M/S
KNORR- BREMSE brake system
Items to be replaced on conditional basis
Component KB Part No. Qty/

Description Wagon
Bogie Equipment
4 Pin; Clevis 778111 4
6 Split Pin 476858 16
9 Washer C162641 8
10 Washer C162060 4
11 Washer; 778084 4
Hand Brake Equipment
1 Pin, Cable 776621 2

2 Pin, Tie Rod I.3.2044 1
3 Pin Cotter, Cable pin I.4.2063 2

Component KB Part No. Qty/
Description Wagon
1 Hose Assy. 1/2" I.4.2037 1
With Flange
2 Brake Head; 778113 8
3 Hose Assy. 1" With I.4.2036 2
Flange
4 Spring Washer I.H.0062 2
5 O-Ring I.4.1050 2
6 O-Ring A27763/17KI 2
7 Screw, Hex Head; 748645 8
Zinc
Plated
8 Washer, Lock; Cad 735734 8
Plated
Screw, Hex Head;
9 Zinc Plated 734734 2
Details of special tools and gauges
required during maintenance.
Quick connect coupling with pressure gauge.
To check the brake cylinder pressure there is a quick connect
nipple provided in the EL-60 valve.
An arrangement of quick connect coupling with pressure
gauge can be connected with this nipple to measure the BC
pressure. Knorr- Bremse part no. for quick connect coupling
with pressure gauge is KND-00134.
Quick connect coupling with pressure gauge ( KND-00134).
Tool for spring dowel sleeve EL-60 gap measuring Gauge
To remove the spring dowel sleeve from the brake
cylinder pin during the replacing/changing of brake
cylinder a special tool (Part no.KN0011152) is
required as shown in the below picture.
Tool for removal of Brake cylinder Hand Brake cable
To remove the spring dowel sleeve from the brake cylinder pin during the replacing/changing of brake cylinder a spec
no.KN0011203) is
required as shown in the below picture.
EL-60 gap measuring Gauge
To adjust the gap between the side frame of bogie and
adjuster screw of EL-60, this gauge (Part no. KN0011154) is
required. It is adjustable. Adjust it as per required gap and
place it on the side frame. Now touch the head of adjuster
screw by loosening/tightening it. Lock the position of adjuster
screw by tightened the
lock screw.
ke cylinder pin during the replacing/changing of brake cylinder a special tool (Part
Section- B:
Description & Maintenance Instructions for Bogie Mounted Brake
Cylinder 11”
CONTENTS

1 Construction & working
2 Disassembly
3 Cleaning, Inspection & Repair
4 Lubricating & Re-assembly
5 List of must change items
6 List of conditional change items
7 Brake cylinder exploded view
8 Fixtures and pressing tools
9 Testing Procedure
ctions for Bogie Mounted Brake
Page No.
42
44
46
54
56
57
58
59
61
CONSTRUCTION & WORKING
Air from the EL60 valve goes into the Brake
Cylinder through the flange in the housing of the
brake cylinder. The air pushes the piston
assembly forward against the compression
springs 2 and 3. This causes the RAM assembly to
move forward till the bearing contacts the Tube Ring
i.e. as the Brake Shoes touch and apply the brake
force on the wheels. The clutch head on the
compensator screw remains engaged with the
Front Female clutch on the piston. Thus there is no
extension of the RAM assembly on the
compensator screw. The internal construction
(springs, location of tube ring etc.) ensures that the
stroke of the brake cylinder is constant when no slack
adjustment is there.
When the Brake Shoes and the Wheel has worn out
then the slack is created. When the air from EL60
valve goes into the Brake Cylinder the piston
assembly moves forward. It moves beyond the
control distance as the slack is there (there is no
restraint to the ram extension). As the piston moves
beyond the control distance the bearing
gets in contact with the tube ring.
e.g., for a block change happens by pushing back the ram in released position with a high force (e.g.
bar).
The main feature of the slack adjuster is the toothed coupling. During normal brake applica
are three different phases of the
coupling:
During the coupling change the spindle is not locked and can rotate, therefore the gap can be adjuste
adjustment, the ram spring provides the actuating force, and it must overcome all resistances of
and mainly the resistance of the pockets.
The coupling change is visible in comparing the stroke of the piston and the ram. During coupling change
piston continues to move while the ram stands still. The difference between the piston and the ram s
the coupling
distance.
As the piston still moves forward the compression spring 1
in the clutch assembly side gets compressed thus
disengaging the compensator screw clutch head. This
allows the RAM assembly to extend due to the force
exerted by the RAM compression spring 4 till the point the
slack is taken up. Thus the Brake Shoe comes in contact with
the Wheel. After the slack has been accommodated, the
brake cylinder functions normally giving a constant stroke.
The inbuilt slack adjuster is double acting. If one wants to
retract the slack adjuster one should apply force on the
RAM side. This allows the RAM to collapse moving on
the compensator screw. This can also be achieved by
rotating the RAM on the compensator screw.
The slack adjuster defines the normal clearance between the
block and the wheel (“application stroke”) and as a
double acting slack adjuster (working in both directions)
it adjusts either a clearance which is too small or a
clearance which
is too large. The resetting of the slack adjuster
back the ram in released position with a high force (e.g., using a pry
s the toothed coupling. During normal brake application there
s not locked and can rotate, therefore the gap can be adjusted. For this
actuating force, and it must overcome all resistances of the BMBS
the stroke of the piston and the ram. During coupling change only, the
nds still. The difference between the piston and the ram stroke is
TOOLS REQUIRED
1. Socket Wrench, 9/16”
2. Socket Wrench, 3/4”
3. Impact Wrench, 1/2”
4. Socket Extension, 4”
5. Allen Wrench, 3/16”
6. Hammer
7. Pressing Tool (Fig. 2)
8. Pressing Fixture (Fig. 3)
9. Pressing Plug (Fig. 4)
10. Washer Guide (Fig. 5)
11. Pressing Tool (Fig. 6)
12. AAR SPEC. M-914 grease (Interlube)
DISASSEMBLY
(See Figure 1)
WARNING
COMPONENT SPRINGS WITHIN THIS UNIT ARE
UNDER COMPRESSIVE LOADS. EXERCISE CARE
WHEN DISASSEMBLING
NOTE
For ease of disassembly and safety, cylinder must
be in a vertical position with the ram (29) facing
up.
1. Insert a 22mm dia. rod through bushings (30) in
ram (29). Fully collapse ram (29) and spring (28)
by rotating and applying a steady downward
pressure on the 22mm dia. rod further movement
of the ram is observed.
2. Remove and discard expansion plug (31) from
ram (29).
3. With an impact wrench and 9/16” socket
wrench to remove cap screw (13) and spacer
(12) from screw (11). Discard screw (13).
THIS UNIT TO PREVENT PARTS FROM INADVERTENTLY
FLYING OUT AND CAUSING PERSONAL INJURY.
WHILE DISMANTLING, WHEN AIR PRESSURE IS REQUIRED,
USE A MAXIMUM OF 0.7Kg/cm2. EXCEEDING THIS LIMIT
COULD RESULT IN PERSONAL INJURY OR DAMAGE TO
EQUIPMENT.
WARNING
PARTS MAY BE INADVERTENTLY EXPELLED BY FORCE OF
SPRING (28).
WEAR EYE PROTECTION AND EXERCISE CARE DURING
DISASSEMBLY.
FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS CAN
LEAD TO INJURY.
4. Carefully unscrew ram (29) clockwise and remove
from screw (28). Remove spring.
WARNING
PARTS MAY BE INADVERTENTLY EXPELLED BY FORCE OF
SPRING (21).
WEAR EYE PROTECTION AND EXERCISE CARE
DURING DISASSEMBLY.
FAILURE TO OBSERVE THESE SAFETY
PRECAUTIONS CAN LEAD TO INJURY.
5. Remove four nuts (33), four lock washers
(32) and four tee head bolts (1) from non-
pressure head (25) and body (2). Remove non-
pressure head (25) from body (2).
6. Remove spring (21) and spring tube (20).
a. Remove and discard gasket (4) from body (2).
WARNING
THE USE OF AIR PRESSURE MAY BE REQUIRED
IN NEXT STEP. USE 0.7Kg/cm2 MAX.
7. While holding compensator screw (11),
carefully apply 0.7Kg/cm to the body (2) so that the
2
removal of piston assembly (7 through 19) can

be accomplished and /or may also be
removed by holding compensator screw (11)
and pulling straight up.
a. Remove and discard packing cup (5) and guide
ring (6). Then place piston assembly (7 through 19)
vertically in a press.
b. Place Pressing Fixture (see figure-3) on
compensator screw (11). When tool comes in
contact with bearing cup (16), compress slack
adjuster spring (15) and remove snap ring
(19). Carefully remove tool from compensator
screw (11).
c. Remove bearing cup (16) and slack adjuster
spring (15) from piston (9).
d. Remove retaining ring (18) and bearing (17)
from bearing cup (16).
e. Using a 3/16” Allen wrench applying a steady downward
force remove and discard four flat head socket screws (7)
that hold the front female clutch (14) to the piston (9).
f. Remove front female clutch (14) and compensator
screw (11) from piston (9).
g. Using a 3/16” Allen wrench applying a steady
force to remove and discard two flat head socket screws
(8) and remove back female clutch (10) from piston (9).
Remove piston (9) from fixture.
8. Remove and discard wiper rings (26 and 27) from non-
pressure head (25).
NOTE
The use of a press is required for disassembly of the retaining
ring (22), tube ring (23) and slack adjuster spring (24).
9. Place non-pressure head (25) in press and compress
spring (24) by pressing on ring
(23). Remove retaining ring (22). Carefully release the load
from the press, remove tube ring (23) and slack adjuster
spring (24).
10. Remove plug (35) and “O” Ring (36). Discard
“O” Ring (36).
11. Remove breather assembly (44) from non- pressure
head (25).
12. Remove piston indicator assembly (37 thru 43) from
non-pressure head (25).
a. Remove two retaining rings (37), flat washer (43),
spring (42), piston position indicator (40) and “O” Rings (39
and 41) from indicator fitting (38).
Discard “O” Rings (39 and 41).
CLEANING, INSPECTING, AND REPAIRING
WARNING
SOLVENTS AND SOLVENT FUMES CAN BE HARMFUL
TO HEALTH. WHEN USING SOLVENTS, BE SURE
TO:
 WEAR EYE, SKIN, AND RESPIRATORY
PROTECTION
 WORK IN A WELL-VENTILATED AREA
 AVOID REPEATED OR PROLONGED CONTACT
 KEEP SOLVENT CONTAINER CLOSED
 KEEP SOLVENT AWAY FROM SPARKS, FLAMES,
AND HEAT.
FAILURE TO OBSERVE THESE SAFETY
PRECAUTIONS CAN LEAD TO INJURY OR
INTOXICATION.
CLEANING USING COMPRESSED AIR CAN CAUSE
PARTICLES TO BECOME AIRBORNE, BE SURE TO:
 WEAR EYE PROTECTION
 DO NOT USE AIR PRESSURE EXCESS OF
2 Kg/cm²
1. Wash all parts in a suitable solvent that will
dissolve oil or grease and permit all the parts to be
thoroughly cleaned without abrasion (i.e. mineral
spirits). Then dry with a jet of dry, compressed air.
2. Replace all rubber parts, wiper rings. “O”
Rings, gaskets, expansion plugs and self- locking
screws.
3. In general, replace all parts that are cracked,
broken, worn, damaged, or in such a condition
as would result in unsatisfactory
operation.
4. Inspect all springs for rust pits, distortion, or
permanent set. Replace wherever necessary.
5. Replace any retaining ring or snap ring that is not
elastic enough or is stretched too much to clamp on
securely or has deformation.
6. Hand Brake Cable Assembly (for brake cylinders
with hand brake)
a. Inspect the hand brake cable. If damaged or not
usable, the cable must be replaced.
b. If repair is necessary, hand brake cable removal
tool for dis- assemble of Hand brake cables from Brake
cylinder. Always use a suitable test bench, holding
fixture for the Brake cylinder during dis-assembly &
assembly of hand brake cable.
c. Tight the mounting flange (see figure-7) using ½”-
UNC bolts. Apply air pressure up to
2Kg/cm .Remove
2
four self- locking set screw (34)
using _ wrench.
d. Pull the hand brake cables in outward direction.
e. Remove both the screw from the anti-rotation tubes
of Piston assembly (9) using socket (see figure-8) and
impact wrench.
f. Refer the hand brake cable assembly procedure in
detail on
the next page:
Hand brake cable assembly procedure
S. No. Job description Qty Tools used Parameter/
Precautions
Open inlet port of
Brake cylinder.
Ensure proper
connection of
Take 11” Brake cylinder (KB Part Brake cylinder
pressure pipeline to
1 no. KP1802890) & fix it on a 1 holding fixture,
the Brake cylinder.
suitable test bench Pins, Test bench
Ensure anti- rotation

tube should be
visible in the NPH.
Ensure trouble free
movement of RAM
Apply 0.7 – 1.0 kg/cm2 pressure Pressure line, up to 500 mm
2 -
to the Brake cylinder Test bench
Take cable assembly (KB Part

3 2 Manual -
no. C177846).
Take O-rings (KB Part no.

4 755559) and put them in the the 2 Manual -
groove of cable assembly.
Loctite activator Apply Loctite
7471 activator on the
thread.
Apply loctite activator 7471 on

5 -
the threads of cable assy.
Loctite 243 Use only enough

Loctite as not to
create excess or
carry over into bore
of anti- rotation
tubes.
Apply Loctite 243 to full thread

6 length and diameter of the cable -
assy.
Torque Wrench,
Tightening the cable assembly
Hand brake tool (KB Apply torque: 35
7 on anti-rotation tubes, and apply -
part ± 2 FT-LBS.
torque 35 LBS.
no.KN0011203)
Spanner 13 mm,
Torque Wrench
Range: 8~60 Nm),
Hand brake tool (KB
part
no.KN0011203)
Secure the cable assembly using Apply Torque: 12

8 4
set screws (747847) ± 2 FT- LBS.
Release the pressure & remove

9 - - -
Brake cylinder from test bench.
Drawings, Photographs, etc.
7. Body Assembly (2)
a. Inspect body (2). If damaged or worn, the
body (2) must be replaced.
b. Inspect the two bushings (3). If damaged or
worn, the bushings
(3) must be replaced.
c. If repair is necessary, use the proper tools to
press bushings
(3) from body (2). Press new bushings (3) into
place in body (2).
8. Inspect compensator screw (11) for
damage or surface wear. If damaged or not usable in
any way, the compensator screw must be replaced.
a. Inspect male clutch on compensator
screw for damage or surface wear. If damaged or
worn in any way, the compensator
screw must be replaced.
9. Ram assembly (29)
a. Inspect ram (29) for damage or wear. If
damaged or not usable in any way, the ram (29)
must be replaced.
b. Inspect threads of ram (29) for damage or
surface wear. If damaged or not usable in any
way, the ram must be replaced.
c. Inspect the two bushings (30). If
damaged or worn, the bushings
(30) must be replaced.
d. If repair is necessary, use the proper tools to
press the bushings (30) from the ram (29). Press new
bushings (30) into place in the ram (30).
10. Non – Pressure Head (25).
a. Inspect guide tube for damage or wear. If damaged
or not usable in any way, the tube must be replaced.
i) If repair is necessary, use Pressing Tool (see
figure-2) to press the guide tube from the non-
pressure head (25). Discard damaged guide tube.
ii) Apply LOCTITE 242 to sealant grooves (3 places) on
new guide tube, align grease fitting hole on guide tube
with indicator hole on non-pressure head (25) and,
using Pressing Tool (see figure- 6), press new guide
tube into place in the non-pressure head
(25) until guide tube shoulder seats against non-
pressure head (25).
11. Inspect piston (9) for damage or not usable.
If damaged or worn in any way, the piston must be
replaced.
12. Inspect back female clutch (10). If damaged
or not usable in any way, the clutch must be replaced.
13. Inspect front female clutch (14). If
damaged or not usable in any way, the clutch must be
replaced.
LUBRICATING AND RE-ASSEMBLY
(See Figure - 1)
NOTE
Grease to be used - AAR SPEC.M-914
(Interlube)
1. With two new screws (8), install back female
clutch (10) into its key slot on piston (9). Apply a
thin layer of grease to the face of back female
clutch (10). Tighten screws (8) to 13.5-19 Nm (10-14
ft. lbs dry torque).
a. Place compensator screw (11) onto back female
clutch (10). Apply a thin layer of grease to face
female clutch (14). Slide front female clutch
(14) onto compensator screw (11) and secure with
four new screws (7). Tighten screws (7) to 13.5-19
Nm (10-14 ft. lbs dry torque).
NOTE
Piston (9) must be in a vertical position in order to
assemble.
b. Install bearing (17) and retaining ring (18) into
bearing cup (16).
NOTE
It is not possible to stretch any retaining ring during
assembly.
c. Apply a thin layer of grease to inside cavities
of piston (9) and spring (15).
d. Place slack adjuster spring (15) and bearing
cup (16) and retaining ring (19) onto piston (9).
Place piston (9) in a spring press. Using Pressing
Fixture (see figure-3), compress slack adjuster
spring (15) and bearing cup (16). Install retaining
ring (19) into its groove on compensator screw
(11). Slowly release the press to be sure retaining ring
(19) is
securely in its groove.
NOTE
Retaining Ring (19) to be fully seated in its groove on
compensator screw (11).
e. Place a new guide ring (6) onto piston (9) and tap
lightly to seat against piston (9) shoulder.
f. Install new packing cup (5) onto piston
(9) and burp to release air trapped during installation of
packing cup (5). Lubricate the outer surface of packing
cup (5) and guide ring (6) with grease.
IMPORTANT NOTE
Do not grease dome of packing cup (5).
2. Lubricate the bore of body (2) with grease. Install
piston assembly (7 through 19) into body (2) with anti-
rotation tubes at 90 to the 1/2” flange surface on body
o
(2).
a. Apply a thin layer of grease to the threads on
compensator screw (11).
b. Apply a thin layer of grease to OD and lD of spring
tube (20) and install spring tube
(20) into the slots on bearing cup (16).
c. Apply a thin layer of grease to spring (21) and install
spring (21) onto piston (9).
NOTE
All inner surfaces to be liberally greased with grease.
3. Place non-pressure head (25) in press and liberally
lubricate the ID of non-pressure head
(25) and OD of the guide tube inside of non- pressure
head (25).
a. Apply a thin layer of grease to slack adjuster
spring (24) and install onto guide
tube inside of non-pressure head (25).
b. Place Washer Guide (see figure-5) over guide tube and
install tube ring (23).
c. Using Pressing Plug (see figure-4) apply press on tube
ring (23) so that spring (24) is compressed to allow space
to install retaining ring (22). Install retaining ring
(22) to secure tube ring (23). Slowly release the press
to make sure retaining ring (22) is securely in its
groove. Remove from press.
4. Install wiper rings (26 and 27) into their grooves on
non-pressure head (25).
5. Place a new gasket (4) onto body (2).
NOTE
Anti-rotation tubes to be greased inside and outside with
grease.
6. Place non-pressure head (25) onto body (2) with
nameplate flat in line with cylinder body flange, then place
non-pressure head (25) and body (2) into a press with
cylinder flange facing forward. Press down on non-pressure
head (25) lining up Piston anti-rotation rods into non-
pressure head and install four tee head bolts (1) and
four lock washers (32). And four nuts (33). Tighten nuts
(33) to 39- 47 Nm (29-35 ft. lbs.) dry torque.
7. Apply a thin layer of equivalent grease to spring
(28) and install spring (28) into non- pressure head (25).
CAUTION
RAM (29) IN NEXT STEP IS SUBJECT TO SPRING PRESSURE.
8. Apply grease to the internal threads on ram (29).
9. Apply a thin layer of grease to ram (29) and
place ram (29) onto spring (28), press down and screw ram
(29) onto compensator screw
(11) three turns then firmly press down on ram (29)
to get excess slack out.
10. Place spacer (12) onto compensator screw
(11). Secure spacer (12) with a new cap screw (13).
Tighten cap screw (13) to 13.5- 19 Nm (10-14 ft. lbs.) dry
torque.
NOTE
Hold ram (29) with a 22mm dia. Rod while tightening
cap screw (13).
11. Install new expansion plug (31) into end of ram
(29).
12. Seat expansion plug (31) by lightly tapping it with a
hammer.
13. Apply LOCTITE 242 to fitting of filter (44). Install
Wire mesh filter (44) into non-pressure head (25).
14. Assemble piston indicator assembly (37 thru 43).
b. Lubricate “O” Ring (39) and place into its groove
inside indicator fitting (40). Place indicator (38) into
indicator fitting (40) with red portion of indicator (38)
located at hex head end of fitting (40). Apply thin layer
of grease to spring (42). Install spring (42) and flat
washer (43) onto indicator and secure each end
with retaining rings (37).
c. Lubricant “O” Ring (41) and install on piston
indicator assembly. Install indicator assembly
into non-pressure head (25). Torque assembly to 39-
47 Nm (29-35 ft. lbs.) dry torque.
15. TESTING - At the completion of the above, the TMB-
60 Cylinder Assembly must be tested in
accordance with the test specifications.
16. Always use a suitable test bench, holding fixture
for testing the Brake cylinder.
LIST OF MUST CHANGE ITEMS:
S. No. Fig. ITEM DESCRIPTION PART NO.
Ref.
1 1 BOLT, TEE HEAD, 768330
2 3 BUSHING, 776539
3 4 GASKET, BRAKE CYLINDER,11 790685
4 5 PACKING CUP,11" 790666
5 6 GUIDE RING, BRAKE CYLINDER PISTON 790683
6 8 SCREW, FLAT HEAD; ZINC PLATED 766925

7 12 SPACER, 765823
8 - SCREW, HEX HEAD, ZINC PLATED 748645
9 15 COMPRESSION SPRING, COUPLING KP2186893
10 16 CUP, BEARING KP2345429
11 18 RETAINING RING, 764058
12 21 SPRING COMPRESSION 777776
13 22 RETAINING RING, 765847
14 24 COMPRESSION SPRING, TRIGGER KP2186892
15 26 WIPER RING, 772262
16 27 WIPER RING, 769953
17 28 COMPRESSION SPRING, RAM KP2186891
18 30 BUSHING, 776539
19 31 PLUG, EXPANSION 759488
20 32 WASHER, LOCK, ZINC PLATED 735734
21 33 NUT, HEX, ZINC PLATED 734497
22 13 SCREW, HEX HEAD, ZINC PLATED 734734
23 36 O-RING, 755559
24 - RETAINING RING, ZINC PLATED 759564
25 - O-RING, 751374
26 - O-RING, 760069
27 44 BREATHER ASSEMBLY II95097
28 - WIRE MESH FILTER A40108
29 - INDICATOR ASSEMBLY*** KP4032896
30 - SCREW, FLAT HEAD, DIN50979- 765834
Zn8/Cn/T2
31 - RETAINING RING, ZINC PLATED 752543
32 - SCREW, DRIVE, ZINC PLATED 736839
33 - SCREW, SET, 765861
34 - PIN, 756018
35 - GREASE 506621
36 - BLANKING FLANGE** C173313
37 - DOWEL SLEEVE* C140446
38 - BUSH* C140445
39 - PIN; CLEVIS* 778111
QTY / BRAKE
CYLINDER
4
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
2
1
6
4
1
2
1
1
1
1
1
1
4
1
4
2
2
0.5
1
2
2
2
Note - Old material to be discarded.
*Item no. 37, 38 & 39 provided for mounting of overhauled brake cylinder on bogie.
**Dust protection cap to be mounted on inlet flange of overhauled brake cylinder.
***Indicator assembly inclusive of items at position no. 37, 38, 39, 40, 41 & 42 as shown in Figure 1 below.
LIST OF CONDITIONAL CHANGE ITEMS:

S. Fig. Ref. ITEM DESCRIPTION PART NO. QTY / BRAKE
No. CYLINDER
a 2 BODY, CYLINDER, TMB60,11" 790675 1
b 3 BUSHING 776539 2
c 9 PISTON HEAD, BRAKE CYLINDER KP1796321 1
d 11 COMPENSATOR SCREW ASSY 778058 1
e 14 FRONT FEMALE CLUTCH 765814 1
f 10 BACK FEMALE CLUTCH 765809 1
g 25 NON-PRESSURE HEAD KP1796316 1
h 29 RAM ASSY; 778065 1
i 8 SCREW, FLAT HEAD; ZINC 766925 2

PLATED
j 7 SCREW, FLAT HEAD; ZINC 765834 4
PLATED
k 22 RETAINING RING 765847 1
l 32 LOCK WASHER 735734 4
m 33 HEX NUT 734497 4
n 19 RETAINING RING 773679 1
o 18 RETAINING RING 764058 1
p 37 RETAINING RING 759564 1
q - INDICATOR ASSY. KP4032896 1

r - CABLE ASSEMBLY C177846 2
IMPORTANT NOTE - REPLACE THE WIRE MESH FILTER (PART NO. - A40108) AT (44) DURING THE ROUTINE
OVERHOULING (ROH) OF WAGON.
BRAKE CYLINDER ASSEMBLY
e.
shown in Figure 1 below.
OVERHAUL DISPOSITION
CONDITON
Replace if bore diameter is

greater than 279.9 mm.
Replace if hole Ø25.4mm
exceeds to 26.7mm in any
direction (i.e. oval condition)
Replace if damage or
deformation observed in
threaded holes.
Replace if found damaged.
Replace if found damaged or

deformed.
deformed.
deformed.
deformed.
deformed.
deformed.
deformed.
deformed.
Replace if found jammed.
jammed.
A40108) AT (44) DURING THE ROUTINE
1. Tee Head Bolt
2. Body
3. Bushing
4. Gasket
5. Packing Cup
6. Guide Ring
7. Flat Head Socket Screw
8. Flat Head Socket Screw
9. Piston Assembly
10. Back Clutch
11. Compensator Screw Assembly
12. Spacer
13. Hex Head Cap Screw
14. Front Clutch
15. Slack Adjuster Spring
16. Bearing Cup
17. Bearing
18. Retaining Ring
19. Retaining Ring
20. Spring Tube Assembly
21. Compression Spring
22. Retaining Ring
23. Tube Ring
24. Slack Adjuster Spring
25. Non-pressure Head Assembly
26. Wiper Ring
27. Wiper Ring
28. Ram Spring
29. Ram Assembly
30. Bushing
31. Plug
32. Lock Washer
33. Hex Nut
34. Self-locking Set Screw
35. Plug
36. O-Ring
37. Retaining Ring
38. Indicator
39. O-ring
40. Piston Position Indicator Fitting
41. O-Ring
42. Spring
43. Flat Washer
44. Breather Assembly
FIXTURES / PRESSING TOOLS

Figure 1
TESTING PROCEDURE
Schematic and arrangement of test bench for
brake cylinder is shown in figure – 7.
WARNING
HIGH PRESSURE AIR IS PRESENT IN THE TEST
RACK AND ASSEMBLY BEING TESTED. PRESSURE
WILL VENT FROM COCKS AND/OR VALVE
EXHAUST PORTS WHEN TEST RACK COCKS ARE
MANIPULATED OR WHEN CONTROL DEVICES ARE
OPERATED. TO MINIMIZE THE RISK OF
PERSONAL INJURY FROM PRESSURE EXHAUSTING,
ENSURE THAT ALL PERSONS STAND CLEAR OF THE
EXHAUST PATH AND THAT HEARING PROTECTION
AND EYE PROTECTION ARE WORN AT ALL TIMES.
The following items are needed to assemble the Test
Fixture;
1. Brake Cylinder holding fixture
2. Pressure gauge
3. 4 nos. non-vented cut out cocks
4. 2.4 mm choke installed in Exhaust Cock “B”
5. 2 nos. Pressure Regulators
6. Pipes and hoses
NOTE
Shop supply pressure must be maintained at 8
Kg/cm minimum.
2
INITIAL CONDITION
Pressure regulators will be set as follows: Regulator
no.1 to 0.7 kg/cm2
Regulator no.2 to 3.8 kg/cm2

TEST NO. 1 – LOW PRESSURE LEAKAGE
Commence test with all cocks closed.
1. Open cock 1, then “A” and apply 0.7 kg/cm to the
2
cylinder.
Note that the ram extends completely out and contacts
the other end of the test setup at 0.7 kg/cm .
2
NOTE:
If the ram has not fully extended with 0.7kg/cm , it is
2
allowable to adjust regulator no.1 to upto 0.9 kg/cm , and

2
then readjust regulator no.1 back to

0.7 kg/cm for the remainder of tests.
2
2. Close cock “A”, then cock 1 and allow one

minute temperature effect.
3. Note the reading at pressure gauge. Note the
pressure drop for 10 minutes. No leakage is allowed.
4. Open cock “A” & then open exhaust cock “B” and
pressure reduces to 0 kg/cm2. Close cock “B”.
5. Open cock 1 and apply nominal 0.7 kg/cm2 to the
cylinder. Close cock 1 and open cock “B” and pressure
reduces pressure to 0 kg/cm . 2
TEST NO. 2 – HIGH PRESSURE LEAKAGE

1. Commence test with cock “A” open
2. Open cock 2 and apply a pressure of 3.8 kg/cm 2
to the brake cylinder.
3. Close cock “A”, then cock 2 and allow one
minute temperature effect.
4. Note the reading at pressure gauge. Note the
pressure drop for 10 minutes. No leakage is allowed.
5. Open Exhaust cock “B” and pressure reduces
to 0 kg/cm2.
Section- C:
Description & Maintenance Instructions for APM (EL - 60)
(Automatic Brake Cylinder Pressure Modification Device)
CONTENTS

1 General Description
2 Features
3 Description of operation
4 Installation and adjustment
5 Overhauling Instructions
6 List of must change items
7 List of conditional change item
8 EL-60 exploded view
9 Testing
tructions for APM (EL - 60)
nder Pressure Modification Device)
Page No.
63
64
66
70
72
76
s 77
78
80
GENERAL DESCRIPTION
The EL-60 valve is used to achieve 2 stages of
braking i.e. empty and loaded in a wagon. The
brake system on each bogie pushes the brake
shoes against the wheels and this shoe force
causes friction, which resists wheel rotation. There is
also a friction between the wheel and rail and if the
brake shoe pushes too hard the wheel will slide. To
overcome this EL-60 model is offered for two stages
braking i.e. empty and loaded. This prevents
wheel slides on empty wagons and provides
means to improve stopping distance of
loaded trains.
(Figure-1)
EL-60 is a contact type of load sensing device. EL- 60 is
provided with a sensing arm (figure-1), which senses the
empty and loaded condition of the wagon during
braking. It can be mounted on under frame of the wagon or
on the bolster of the bogie. The valve installed on the
under frame of the wagon senses the gap between the
under frame and the side frame of the bogie. It is also
provided with the visual indicator, which shows empty
brake
condition of the wagon.
(Figure-1)
FEATURES
 The valve is designed such that it does not
require two stages distributor Valve. Standard wagon
type distributor valve can be used.
 The device does changeover of brake cylinder
pressure from empty to load and vice-versa.
 The mounting and pipeline connecting
parameters of the device are according to the standard
pipes and flange used in Indian Railways, so no
change is required in the piping connections.
Only brake cylinder pipeline between distributor
valve and brake cylinder needs to be modified.
 A visual indicator is provided on the valve,
which shows empty brake condition.
 There is no physical contact of the sensor arm of
LSD with the side frame of the bogie during release &
running (both Empty & Loaded condition).
 The contact of sensing arm with side frame of the
bogie occurs during braking only.
 The sensing arm is angular type of lever; hence it
does not lead to any bending movement.
 Simplified piping; requires only three
connections for the EL-60.
DESCRIPTION OF OPERATION
Release Position
See Figure -2
In release position, the ratio piston (18) is held to the left of the portion by the movement of the senso
against the piston check valve (16) and the force of the piston check valve spring (14) against the ratio pist
The piston check valve
(16) is fully open and the upstream volume
(reservoir) is connected via back flow valve (6) to the distributor valve.
(Figure-2)
 The EL-60 load-sensing device is lightweight, with a
minimum no. of parts.
 Load and empty adjustment can be easily done on the
wagon.
d to the left of the portion by the movement of the sensor arm (37)
orce of the piston check valve spring (14) against the ratio piston (18).
volume
6) to the distributor valve.
(Figure-2)
Load Position
See Figure – 3
In load position, pressure from the distributor valve
port flows past the open piston check valve (16),
behind the sensor diaphragm (27), and acts
against the return spring (31) to move the sensor arm
(37) down at normally 1 kg/cm² (15psi)
pressure to contact the side frame of the bogie.
Pressure then flows out to the brake cylinder.
(Figure-3)
Brake cylinder pressure build-up will be unaffected by the
device in the load position because the ratio piston (18)
will remain to the left of the portion and the piston check
valve (16) will remain open, permitting the air from
distributor valve port air to flow directly to the brake
cylinder. The air passage to the volume is cut off by the
ratio piston (18) and
the back flow valve (6).
(Figure-3)
Changeover Position
See figure – 4
In the changeover position, pressure from the
distributor valve port flows behind the sensor
diaphragm (27) and acts against the return spring (31),
moving the sensor arm (37) down at normal 1 kg/cm²
(15psi) pressure to nominally 95mm of sensor arm
(37) travel. The piston check valve (16) within the
ratio piston (18) will close, terminating flow
between the distributor valve port and the brake
cylinder.
As pressure increases in the distributor valve port,
the ratio piston (18) will move to right to open,
(Figure-4)
when the force of the distributor valve port pressure on the
check valve (16) side of the ratio piston (18) is more
than the force of the brake cylinder pressure on the
larger right side of the ratio piston
(18). As the ratio piston (18) moves to the right, the port
to the equalizing volume is uncovered, permitting
pressure from the distributor valve to flow into the
equalizing volume. In this design, the pressure in the
control valve input and equalizing volume will be the
same and brake cylinder pressure is proportioned by
the different areas on
the ratio piston (18) and check valve (16).
(Figure-4)
Empty Position
See figure – 5
As previously described in the changeover
position, in the empty position the ratio piston (18) will
move to the right as required to open the piston check
valve (16) and satisfies the requirements dictated
by the ratio piston (18). When the requirement
of the ratio piston (18) is met, the ratio piston (18) will
move back to the left, closing the
piston check valve (16).
(Figure-5)
For example, with a 60% ratio piston (18), if the
distributor valve pressure was 3.8 kg/cm², then the volume
(reservoir) pressure would be 3.8 kg/cm² and the
brake cylinder pressure would be 2.2 kg/cm². In
release, as previously described, pressure from the
brake cylinder will flow back through the ratio piston
(18) to the distributor valve while pressure from the
volume will flow through
the back flow valve (6) to the distributor valve.
(Figure-5)
INSTALLATION AND ADJUSTMENT
The pipeline from Distributor Valve to brake
cylinder splits up in two pipes as EL-60 valve is
inserted in between the circuit to deliver the air to
two Brake Cylinders (see figure – 6).
(Figure-6)
The EL-60 valve is mounted on the bracket which is welded
on the wagon under frame. The EL-60 valve has 3 ports, 2
on the back of the bracket for connection from distributor
valve & to the brake cylinders and on the side to
connect to the
reservoir.
(Figure-6)
Installation Inspection
Before proceeding with installation / adjustment of the
Empty Load equipment the following
examination should be performed.
(See fig. 7 for Empty Load Valve)
 Ensure that the Sensor Arm is not damaged or bent.
Move the arm down manually to confirm appropriate
location on the side frame, and check for
excessive side play, beyond the effective side
frame width. Inspect the two sensor arm securing
bolts.
 Inspect the adjusting screw for damage on the
contact ball, and that both lock nuts are
present.
 Inspect the Sensor Boot damage.
 Inspect for Indicator Lens damage.
Installation Adjustments
In order to perform the adjustments, a Single
Wagon Test Rig must be connected to the wagon.
TOOLS REQUIRED:
9/16” and 3/8” open ended wrenches.
 Loosen the two 9/16” lock nuts and adjust the
screw until the contact ball just touches the side
frame when the sensor arm is manually pulled down
through it full travel.
 Apply the brakes by reducing BP to 3.6 kg/cm² by using
SWTR.
 Adjust the screw so that it makes positive contact
with the side frame (no slack in the arm assembly), hold
the screw with the 3/8” wrench and using the 9/16” wrench
tightly secure the two lock nuts.
NOTE:
1. Check that the empty load indicator is extended and is
visible. (See fig. 7).
2. Check the leakage from the vent strainers, the
indicator assembly, or the equalizing volume and piping.
 Release the brakes by using SWTR.
 Now, place a 25mm thick BLOCK on the side frame.
Apply the brakes by reducing BP to 3.6 kg/cm² by using
SWTR.
NOTE:
1. Check that the empty load indicator is not extended
and is not visible. (See fig. 7).
 If the indicator extends during this test, release the
application and re-adjust the adjusting screw downward
(decreasing set adjustment two 360 deg. turns).
(Figure-7)
The factory setting for the movement of the sensor point is 104 mm which is consisting of loaded and empt
First 79 mm of the sensor point is for the loaded zone and the balance is for the empty zone. After 79mm m
changeover from loaded to empty takes place. For each wagon, the changeover from empty to loaded mus
aligned to this valve. Accordingly, the total movement to be maintained in each
type of wagon is listed below:
OVERHAUL INSTRUCTIONS TOOLS REQUIRED

1. Wrench, Open End, 1”
2. Wrench, Open End, 7/8”
3. Wrench Open End, 9/16”
4. Wrench, Hex Key, 5/32”
5. Pliers, Retaining Ring, Internal
6. Pliers, ring Clamp
7. Pliers, Needle Nose
9. Wrench, Torque, Min. Range 13.5 Nm (10 Ft.-
Lbs).
10. Silicone grease (Dow Corning 55/55M)
DISASSEMBLING
(See figure – 8)
1. Place a 20mm block between the cover (32)
and lever (37) to assist in disassembly then
remove four hex head cap screws (33) from body
(1). Remove cover (32) from body (1)
(Figure-7)
ensor point is 104 mm which is consisting of loaded and empty zone.
ded zone and the balance is for the empty zone. After 79mm movement,
e. For each wagon, the changeover from empty to loaded must be
ovement to be maintained in each
2. Remove retaining ring (21) from body (1).

a. Remove guide sleeve (20) and ratio piston
(18) from body (1).
b. Remove and discard two “O” rings (17) and “O” ring
(19) from ratio piston (18).
c. Remove retaining ring (12), spring seat and stop
(13), spring (14), guide pin (15), and check valve (16) from
ratio piston (18). Discard check valve (16).
3. Remove tube port plug (2) and check body (5) from
body (1). Remove and discard “O” ring (3) from tube port
plug (2), umbrella valve (6) and “O” ring (4) from check
body (5).
4. Remove indicator (7) from body (1). Remove
piston (10), and spring (9) from indicator (7). Remove
and discard “O” ring (8) from indicator
(7) and “O” ring (11) from (10).
WARNING
COMPONENT SPRINGS WITHIN THIS UNIT ARE UNDER
COMPRESSIVE LOADS. EXERCISE CARE WHEN
DISASSEMBLING THIS UNIT TO PREVENT PARTS
FROM INADVERTENTLY FLYING OUT AND CAUSING
INJURIES.
5. Remove and discard “O” ring (24) from piston
follower (25).
a. Push out pin (26), remove push rod (22) and
spring (23) from piston follower (25).If spring (23) is
red discard it.
b. Place hand onto Piston Follower (25) and hold
piston follower (25) from flying out, then remove
elastic stop nut (38), shoulder screw (36) that connects
piston rod (30) to lever (37). Discard elastic stop nut
(38).
c. Remove Piston Follower with assembled piece
(25 thru 30) from valve cover (32).
d. Remove spring (31) from piston rod (30).
e. Place Piston Followers (25) in a bench vice and
remove piston rod (30). Remove washer (29),
piston (28) and diaphragm
(27) from piston follower (25). Discard diaphragm
(27). Remove piston follower
(25) from vise.
6. Remove shoulder screw (36) and elastic stop nut
(38) from cover (32). Remove lever (37) from cover
(32). Discard elastic stop nut (38).
NOTE:
Step 7 is required only if there are visible signs of wear,
damage or corrosion to quick disconnect nipple (41).
7. Remove dust cap (42) and quick disconnect nipple
(41) from body (1). Discard quick disconnect nipple
(41).
CLEANING, INSPECTING, AND REPAIRING WARNING
SOLVENTS AND SOLVENT FUMES CAN BE HARMFUL
TO HEALTH, WHILE USING SOLVENT, BE SURE TO:
 WEAR EYE, SKIN AND RESPIRATORY PROTECTION.
 WORK IN A WELL-VENTILATED AREA.
 AVOID REPEATED OR PROLONGED CONTACT.
 KEEP SOLVENT CONTAINERS CLOSED.
 KEEP SOLVENT AWAY FROM SPARKS, FLAMES AND
HEAT.
FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS
CAN LEAD TO INJURY OR INTOXICATION.
CLEANING USING COMPRESSED AIR CAN CAUSE
PARTICLES TO BECOME AIRBORNE, BE SURE TO:
 WEAR EYE PROTECTION
 DO NOT EXCEED 2 Kg/cm² (30PSI).
FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS
CAN LEAD TO INJURY.
1. Wash all parts in a suitable solvent that will
dissolve oil and grease and permit all parts to be
thoroughly cleaned without abrasion (i.e. mineral
spirits). Then blow dry with a jet of dry, compressed
air (max. at 2 kg/cm²).
2. Replace all rubber parts.
3. Examine all springs for rust pits, distortion, or
permanent set and replace where necessary.
4. Replace any other parts that are cracked,
broken, cut, worn, damaged, or in such a
condition as would result in unsatisfactory
operation.
To assist in determining if wear or damage has
occurred to the wearing parts of this assembly, the
allowable tolerances for these parts are listed in
the text that follows. If a part fails to meet a
requirement, the part should be replaced, unless
otherwise stated.
a. Piston Rod (30)
Piston rod holes to be free of scratches, nicks, or
dents and shall exhibit no elongation.
b. Shoulder Screw (36)
Shoulder screw to be free of flat spots, dirt, and
corrosion.
c. Adjusting Screw (39)
End or adjusting screw to be free of surface
wear, dents, and burrs.
5. Replace any retaining ring, which is not elastic
enough to clamp securely.
S List of Consumable Remarks

No. Items
1 Loctite 680 5 ~ 7 ml/pc
2 Loctite Primer T 7471 7 ~ 10 ml/pc
3 Isopropyl Alcohol 5 ~ 10 ml/pc

4 DOW CORNING 5 ~ 7 gms/pc
#55 Silicone grease
(M 55).
5 Loctite 271 5 ~ 7 ml/pc
REASSEMBLING & TESTING
Consumable Required
Apart from the must change items and the
replacement against the damaged items, the
following consumables are required while
assembling;
List of must change Items are listed in this manual.
REASSEMBLING
1. Rubber O-Rings must be lubricated individually with
Silicone Grease. Prior to assembly, the O- Ring shall be
coated with grease. After installing the new O-Ring in
its groove, remove only the excess grease before
inserting the assembly into the coated bushing.
2. Place lever (37) in cover (32) then insert shoulder
screw (36) and new elastic stop nut
(38) into lever (37) and cover (32). NOTE:
Install diaphragm (27) with numbers facing up so that
numbers go into the groove in the cover (32).
3. Place piston follower (25) in a vise. Install new
diaphragm (27) onto the piston (28), then install piston
(28), washer (29) and piston rod
(30) onto diaphragm follower (25). Securely tighten
piston rod (30) to diaphragm follower (25).
a. Install spring (31) onto piston rod (30)
b. Insert piston follower with assembled pieces
(25 thru 31) into cover (32).
c. Place hand on piston follower (25) and press
on piston follower (25) to compress spring (31).
Insert shoulder screw (36) through lever (37) and
piston rod (30). Attach elastic stop nut (38) to
shoulder screw (36).
d. Insert spring (23) and lightly greased push rod
(22) into diaphragm follower (25). Then insert pin (26)
into hole in piston follower
(25) and push rod (22).
e. Install new “O” ring (24) onto piston
follower (25).
4. Install new “O” ring (8) onto indicator (7) and “O”
ring (11) onto piston (10).
a. Insert spring (9) and piston (10) into
indicator body (7).
b. Insert indicator (7) into body (1) and
securely tighten.
5. Insert new umbrella valve (6) into check body (5).
a. Install new “O” ring (3) onto tube port plug (2).
b. Install new “O” ring (4) onto body check (5).
c. Insert check body (5) and tube port plug (2) into
body (1).
6. Insert new check valve (16), lightly greased
guide pin (15) stem, spring (14), spring seat and
stop (13) and retaining ring (12) into the ratio piston
(18).
a. Install two new “O” ring (17) and new “O” ring
(19) onto ratio piston (18).
b. Insert ratio piston (18) and guide sleeve
(20) into body (1).
NOTE:
Guide sleeve (20) recess should be aligned with the
hole in the body (1) to help in the ease of installing and
removing of retaining ring (21).
c. Insert retaining ring (21) into body (1).
NOTE:
Installation of retaining ring (21) should be with the plier
holes located within the cut-out in the guide sleeve (20).
7. Place a 20mm block between the cover (32) and
the lever (37) to assist in assembly then carefully align
push rod (22) into guide sleeve
(20) and install cover (32) onto body (1) and secure in
place with four hex head cap screws
(33). Tighten screws (33) to 20.3 +2 Nm
(15+1.5 Ft.-lbs).
NOTE:
Step 8 is only required if quick disconnect nipple was
discarded during disassembly.
NOTE:
Use Key-Tite pipe sealant when installing quick disconnect
Nipple (46) unless nipple has pre applied thread sealant.
8. Install quick disconnect nipple (46) into body
(1).
LIST OF MUST CHANGE ITEMS:
SN Fig. DESCRIPTION PART NO. Qty /
Ref. Valve
1 3 TUBE PORT PLUG WITH O- RING 760837 1
2 4 O-RING 738362 1
3 6 UMBRELLA VALVE 772345 1
4 8 O-RING 756728 1
5 11 O-RING 783649 1
6 17 O-RING (Old Part No. 781694) 789842- 2
047
7 19 O-RING; SPECIAL (Old Part No. 789842- 1
771637) 023
8 24 O-RING 749475 1
9 27 DIAPHRAGM 755749 1
10 34 DUST BOOT 772308 1
11 38 NUT, ELASTIC STOP 733883 2
12 44 SCREENED GASKET 772401 1
13 45 SCREENED GASKET 781215 2
14 16 CHECK VALVE 771329 1
15 7 VISOR CAP 771071 1
16 13 SPRING SEAT & STOP 770828 1
17 39 SCREW; ADJUSTING 782169 1
18 22 PUSH ROD 771224 1
19 15 GUIDE PIN, 771197 1
20 42 DUST CAP, QUICK DISCONNECT 776207 1
21 9 SPRING, COMPRESSION 771112 1

23 10 PISTON, INDICATOR 771113 1
25 40 LOCKNUT, HEX, ZINC PLATED 755896 2
26 21 RETAINING RING, ZINC PLATED 770824 1
27 26 PIN 771693 1
28 31 SPRING COMPRESSON 752173 1
29 36 SCREW, SHOULDER, ZINC PLATED 752089 2
30 41 NIPPLE, QUICK DISCONNECT 776156 1
Note - Discard old part.

LIST OF CONDITIONAL CHANGE ITEMS:
S. N. Fig. Ref. DESCRIPTION PART NO. Qty / Valve
a 46 PIPE BRACKET ASSY 770821 1
b 1 BODY ASSY 770831 1
c 32 COVER ASSY 771111 1
d 37 LEVER 772073 1
e 10 PISTON 772331 1
f 18 PISTON; 60% RATIO 770826 1
g 25 PISTON FOLLOWER 771075 1
h 30 PISTON ROD 752088 1
i 16 CHECK VALVE 771329 1
j 39 SCREW; ADJUSTING 782169 1
k 22 PUSH ROD 771224 1
l 13 SPRING SEAT & STOP 770828 1
m 7 VISOR CAP 771071 1
EL-60 Assembly (Exploded View)

Figure-8
S.No. Description Part No. Qty.(Nos)
1 Body 770831 1
2,3 Tube Port Plug with O-ring 760837 1
4 O-ring 738362 1
5 Check Body 771534 1
6 Umbrella Valve 772345 1
7 Indicator 771071 1
8 O-Ring 756728 1
9 Spring 771112 1
10 Piston 771113 1
11 O-Ring 783649 1
12 Retaining Ring 770825 1
13 Spring Seat and Stop 770828 1
14 Spring 771630 1
15 Guide Pin 771197 1
16 Check Valve 771329 1
17 O-Ring 781694 2
18 Ratio piston 770826 1
19 O-ring 771637 1
20 Guide Sleeve 771509 1
21 Retaining Ring 770824 1
22 Push Rod 771224 1
23 Spring 771629 1
24 O-Ring 749475 1
25 Piston Follower 771075 1
26 Pin 771693 1
27 Diaphragm 755749 1
28 Piston 772331 1
29 Washer 772332 1
30 Piston Rod 752088 1
31 Spring 752173 1
32 Valve Cover 771111 1
33 Hex Head Cap Screw 747053 4
34 Dust Boot 772308 1
35 Clamp 752109 1
36 Shoulder Screw 752089 2
37 Lever 772073 1
38 Elastic Stop Nut 733883 2
39 Adjusting Screw 782169 1
40 Lock Nut 755896 2
41 Quick Disconnect Nipple 776156 1
42 Dust Cap 776207 1
43 Nut 734497 2
44 Ring Gasket 772401 1
45 Ring Gasket 781215 2
46 Pipe Bracket II90520 1
TESTING
After the completion of the above, the EL-60
Empty/ Load Valve must be tested in accordance with
the test specifications.
Test Preparation
The following items are needed to assemble the
Test Fixture.
1. Load Sensing Device holding fixture
2. 2 nos. pressure gauge
3. 10liter reservoir
4. 6.6liter reservoir
5. 2 nos. - cut out cocks with vent.
6. Pressure Regulator
7. 25mm high block
8. Pipes and hoses
WARNING:
High pressure air is present in the test rack and
assembly being tested. Pressure will vent from
cocks and/or valve exhaust ports when test rack
cocks are manipulated or when control devices are
operated. To minimize the risk of personal injury
from pressure exhausting, ensure that all persons
stand clear of the exhaust path and that hearing
protection and eye protection are worn at all times.
Test Procedure
LOAD POSITION & LEAKAGE
1. Place a 25mm high block between the
adjusting screw and the stopper plate.
2. Open cock A and apply the main supply
pressure. Pressure gauge no.1 should show
3.8kg/cm pressure otherwise adjust the regulator
2
to get 3.8kg/cm .
2
3. Open cock B and apply 3.8kg/cm pressure to the

2
load-sensing device.
4. As the sensor arm comes in contact with the
block, note the reading at pressure gauge no.2. It
should be 3.8 +/- 0.1kg/cm2.
5. Check the empty load indicator. It should
remain retracted.
6. Check the leakage at all joints and ports. No
leakage is allowed.
7. Close cock A and B and reduce pressure to
0kg/cm2.
8. Remove the 25mm block from between the
sensor arm adjusting screw and the stopper plate.
Figure-09
Pneumatic schematic diagram for testing of EL-60 Valve
Test Instruction
1. Diagrammatic view and arrangement of test rack is
shown on figure – 9.
2. Shop supply pressure must be maintained at 8kg/cm2
minimum.
3. Open cock A and set the pressure regulator to
3.8kg/cm2
4. Set the sensor arm travel to 104mm from the sensor
arm adjusting screw to the stopper plate.
TEST NO. 2 – EMPTY POSITION & LEAKAGE
1. Open cock A and apply the main supply
pressure. Pressure gauge no.1 should show
3.8kg/cm pressure otherwise adjust the regulator to
2
get 3.8kg/cm . 2
2. Open cock B and apply 3.8kg/cm2 pressure to the

load-sensing device.
3. As the sensor arm stops moving further down, note
the reading at pressure gauge no.2. It should be 2.2 +/-
0.1kg/cm2.
4. Check the empty load indicator. It should be
completely extended.
5. Check the leakage at all joints and ports. No leakage is
allowed.
6. Close cock A and B and reduce pressure to
0kg/cm2 .
Figure-09
matic diagram for testing of EL-60 Valve

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Bogie Mounted Brake System (BMBS)

For Freight Cars Fitted With Upgraded 11” Bra

Description and Maintenance Manual

This manual is divided into three different Sections as following:

S. No. Content Description

4 Air Brake System with BMBS & APM

5 Description of the Equipment

6 Critical Bogie Dimension for BMBS

7 Installation of BMBS on Bogie

8 APDs to be provided on the BMBS

9 Do’s & Don’ts

10 Procedure for changing of brake blocks

11 Typical Service / Operating procedures

12 Condemning limits of system components

13 Maintenance in Open line

14 Routine overhauling of BMBS System

15 Periodic overhauling of BMBS System

Details of special tools & gauges required during

erent Sections as following:

enance Instructions for

nce Manual of BMBS

Primary Brake Beam

the locomotive. Brake pipe is charged to 5 kg/cm 2

through the compressor of the locomotive. Feed pipe

The wagons are provided with automatic

0.1 kg/cm is obtained in the loaded condition.

To obtain this a changeover mechanism, APM under-

from empty to loaded and vice-versa.

through the APM device (EL-60 valve). Based on the

position braking and an output of 3.8 ± 0.1 kg/cm for

loaded position braking in the wagon.

cylinder pressure of 3.8 ± 0.1 kg/cm in loaded

condition and 2.2 ± 0.25 kg/cm in empty 2

condition is achieved. Any further reduction of

completely and the brakes are

Brake cylinders are provided with dirt protection

Dust protection cap

of the wagon and allows the brake cylinder pressure of

indicator, it is loaded condition with 3.8 ± 0.1 kg/cm

going to the brake cylinder. It has a quick connect

Side pocket Gauge for checking bogie liner gap:

Important dimensions of Casnub bogie for BMBS:

ss steel pipes as per RDSO specification

swivel flange fittings are used for pipe

g any condition of Bogie is allowed.

de pocket Gauge (KBI Part no. KN0011151)

Figure 5 (Bogie with BMBS Arrangement)

List of BMBS Parts after upgraded 11” Brake cylinder

les should not

les should not move/bend.

APD on Cable Equalizer

On Brake Head Pin

APD on APM Device (EL-60 valve)

ack welded with washers as shown below.

hout fixing it on Test bench.

ith cylinder and without wheeling, by

s for the fitment of BMBS items.

ke cylinder without proper fixing on test

Position of Pry in order

Note: Do not hit or hammered on the