Instruction Bulletin No.

RDSO/2010/WD/WMI 03
Retro- fitment Scheme of BMBS (Bogie Mounted Brake System)
This scheme is contained with technical aspects with relevant drawings and specifications so that a self contained Instruction Bulletin is generated, which can be readily used by ROH/POH Workshops and maintenance Depots for retro-fitment of BMBS.. 1. SCOPE: This scheme covers the requirements of the retro-fitment of BMBS in BOXN, BOXNHS and BOXNR wagons. 2. GENERAL DESCRIPTION OF BMBS The equipment consists of a transversely mounted pneumatic actuator (Brake Cylinder) with a selfcontained, double acting slack adjuster, two brake beams, two bell crank levers and interconnecting push rods. The hand brake arrangement is available as a mechanical model with two flexible handbrake cables. The pneumatic actuator is 10 in diameter for application on high friction brake shoe (K type) on casnub type bogies. The system consists of a unique design with two pneumatic actuators to deliver reliable braking performance and is light in weight. It fits into any standard IR casnub bogie and uses 58mm thick brake shoes.

3. WORKING DESCRIPTION OF BMBS 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.

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 fill the gap.

4. The procurement of Bogie Mounted Brake Systems and their components should be done in accordance with RDSO letter dt. 14.09.10 (copy enclosed as annexure-VI). 5. Procedure of the retro fitment of BMBS:(A) Items should be removed as mentioned in annexure-I as per standard practice Precautions to be taken are: During removal of the items, try to minimise the oxy cutting. Ensure the proper grinding to get a smooth surface for retro fitment of BMBS. Suitable Jig and Fixtures may be used to avoid distortion due to excessive heat.

(B) New Items should be fitted as mentioned in annexure-II as per standard practice. Precautions to be taken are: 6. 7. Place the bogie frame in even surface. Alignment of all components of BMBS with respect to the fixing holes should be proper during assembly and securing arrangements to be tightened with required torque.

Drawings :- WD-10061 S-01 , WD-10061-S-02, WD-10061 S-03 & WD-10061-S-04 Testing: - After retrofitment of BMBS in BOXN, BOXNHS and BOXNR wagons following test shall be required a). Single Wagon Test Rig (SWTR ) Testing as per annexure-III b) Measurements of bogie parameters during assembly as per annexure-IV c) Brake Block force testing as per annexure-V

8.

Reference Specifications :- The following specifications should be referred for description , drawing and items related to BMBS and its associated equipments. (i) (ii) (iii) (iv) WD-23-BMBS-08: Specification for Bogie Mounted Brake System for freight stock fitted with casnub bogie. O2-ABR-02 : Specification for air brakes for freight and passenger stock of Indian Railways 04- ABR-02 : Specification for pipes & joints for air brakes for freight and passenger stock of Indian Railways WD-20-ABR-07 : Specification for Compreg clamp / packing for air brake pipes for freight stock of Indian Railway.