Engineering Procedure

Rolling Stock

Engineering Procedure
EPR 005

MEASUREMENT OF WAGON
BRAKE BLOCK FORCES
Version 1.1

Issued October 2011

Owner: Chief Engineer Rolling Stock

Approved Stephen White Authorised Michael Uhlig

by: Technical Specialist Rolling by: Manager
Stock Performance Standards, Rolling Stock Access Integrity
Rolling Stock Access Integrity

Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.

UNCONTROLLED WHEN PRINTED Page 1 of 7

RailCorp Engineering Procedure — Rolling Stock
Measurement of wagon brake block forces EPR 005

Document control
Version Date Summary of change
(RSP 005) 1.0 May 2005
1.1 Sept 2006 RIC amended to RailCorp
1.2 Dec 2006 Position titles amended
1.3 July 2008 Document control page added
(EPR 0005) 1.0 Dec 2009 Reformatted and renumbered to EPR 0005
1.1 October 2011 Reference to report sheet added.

Summary of changes from previous version

Summary of change Section

Contents

1 Introduction .............................................................................................................................3
2 Purpose ....................................................................................................................................3
3 Scope........................................................................................................................................3
4 Application...............................................................................................................................3
5 Purpose and scope .................................................................................................................3
6 Reference Documents ............................................................................................................3
7 Definitions................................................................................................................................3
8 Test Equipment .......................................................................................................................4
9 Calibration of equipment........................................................................................................4
10 Site Safety Evaluation.............................................................................................................4
11 Procedure ................................................................................................................................4
Appendix A Sample Brake Block Force Record Sheet .............................................................6

© RailCorp Page 2 of 7
Issued October 2011 UNCONTROLLED WHEN PRINTED Version 1.1
RailCorp Engineering Procedure — Rolling Stock
Measurement of wagon brake block forces EPR 005

1 Introduction
Before any rail vehicle is permitted to operate on the RailCorp network, the vehicles must
comply with the RailCorp Minimum Operating Standards for Rolling Stock ESR 0001.

The measurement of brake block forces is one of a number of vehicle compatibility tests
that are conducted to ensure the vehicle complies with certain aspects of the Minimum
Operating Standards for Rolling Stock.

2 Purpose
The normal forces between the brake blocks and the wheels on rail vehicles are
measured to provide an indication of the efficiency of the brake rigging of a rail vehicle.

The average measured brake block force is used to calculate the brake percentage of the
brake system for a rail vehicle in accordance with the requirements of the Minimum
Operating Standards for Rolling Stock.

3 Scope
The test shall be conducted on one of every type of freight vehicle prior to operation on
the RailCorp network.

4 Application
This procedure is to be used by rolling stock manufacturers, owners, operators and
testing personnel when assessing the vehicle for compliance with the RailCorp Minimum
Operating Standards for Rolling Stock.

5 Purpose and scope

6 Reference Documents
ESR 0001 Minimum Operating Standards for Rolling Stock

ESR 0001 – 200 .24 (RSU 286) Static Brake Tests

ESR 0001 – 400.6 (RSU 441) Braking Performance

EPR 004 FM 01 Wagon Brake Block Force Record Sheet

EPR-0013 Static Test Site Safety Evaluation

7 Definitions
Brake block cast iron or non-metalic block that provides the friction force on the wheel of
a rail vehicle to decelerate it.

Brake block force the normal force measured between the brake block and the wheel,

Brake percentage calculated percentage by dividing the total brake block force (for
every brake block on a vehicle) by the tare or gross weight of the vehicle.

© RailCorp Page 3 of 7
Issued October 2011 UNCONTROLLED WHEN PRINTED Version 1.1
RailCorp Engineering Procedure — Rolling Stock
Measurement of wagon brake block forces EPR 005

8 Test Equipment
• A calibrated load cell to fit between the brake block and the wheel.
• A calibrated pressure gauge to indicate brake cylinder pressure.
• A calibrated torque wrench to apply a measured torque to the handbrake spindle.
• A one kilogram (two pound) hammer for tapping the brake rigging.
• Wedges to set the automatic load compensation valve in “loaded” position.
• Single car air tester, locomotive air supply or some means of controlling brake pipe
pressure.

9 Calibration of equipment
The equipment shall be calibrated by appropriate methods either by Rolling Stock
personnel or an external authority.

Where the calibration is carried out by Rolling Stock Access Integrity Unit personnel, an
approved procedure for the calibration shall be followed.

Where the calibration is carried out by an external authority, they shall follow standard
calibration procedures.

All records of calibration shall be kept in the Rolling Stock Access Integrity Unit
“Equipment Calibration” File.

10 Site Safety Evaluation

Conduct a safety site inspection and safety briefing in accordance with EPR-0013 Static
Test Site Safety Evaluation.

11 Procedure
a) Charge vehicle brake pipe to 500 kPa.

b) Ensure load compensation is in empty (tare) condition.

c) Apply and release the brakes a number of times to allow braking system to
equalise and settle.

d) Place load cell between brake block and wheel, or if necessary replace brake
block with test block.

e) Reduce brake pipe pressure to 350 kPa.

f) Tap brake levers to simulate dynamic (vibrating) condition.

g) Record brake block force and brake cylinder pressure on test record sheet.

h) Repeat this test three (3) times for each brake block.

i) Repeat the above procedure with the vehicle load compensation set to the
loaded condition. For automatic load compensation system, place a wedge
under the automatic load compensation spring or plunger.

j) Repeat the above procedure for the handbrake. Apply the test torque (as
detailed below) to the handbrake shaft with a tension wrench and record brake
block force.

Note: The brake rigging is not tapped during the hand brake test.

© RailCorp Page 4 of 7
Issued October 2011 UNCONTROLLED WHEN PRINTED Version 1.1
RailCorp Engineering Procedure — Rolling Stock
Measurement of wagon brake block forces EPR 005

– Measure the diameter of handwheel wheel.

– Calculate test torque:

Test torque (Nm) = diameter (metres) * 560 Newtons

2

© RailCorp Page 5 of 7
Issued October 2011 UNCONTROLLED WHEN PRINTED Version 1.1
RailCorp Engineering Procedure — Rolling Stock
Measurement of wagon brake block forces EPR 005

Appendix A Sample Brake Block Force Record Sheet

Location: __________________________ Date: __________
Vehicle Details:
Vehicle Class and Number: ______________________
Tare mass ________________ tonnes
Loaded mass ________________ tonnes

Vehicle Test Configuration:

Vehicle wheel numbers

R1 R2 R3 R4

B End
Handbrake End

L1 R2 L3 L4

Calculation of handbrake test torque:

Effective diameter of handbrake wheel____________ metres

Test torque = effective diameter m * 560 Newtons

2

= __________________ Nm

© RailCorp Page 6 of 7
Issued October 2011 UNCONTROLLED WHEN PRINTED Version 1.1
RailCorp Engineering Procedure — Rolling Stock
Measurement of wagon brake block forces EPR 005

Measured Brake Block Forces

Empty Condition Loaded Condition Park Brake

BC Pressure Brake Block BC Pressure Brake Block Brake Block
Wheel No. kPa Force Kg kPa Force Kg Force Kg

L1

Average Force Average Force Av.

R1

Average Force Average Force Av.

L2

Average Force Average Force Av.

R2

Average Force Average Force Av.

L3

Average Force Average Force Av.

R3

Average Force Average Force Av.

L4

Average Force Average Force Av.

R4

Average Force Average Force Av.

Total Force Total Force Total

© RailCorp Page 7 of 7
Issued October 2011 UNCONTROLLED WHEN PRINTED Version 1.1