Faiveley Transport Confidential

Air Brake System of LHB Coaches

AXLE MOUNTED DISC BRAKE

EQUIPMENT FOR
ALSTOM-LHB DESIGN
COACHES BUILT BY RCF

A PRESENTATION
BY
Faiveley Transport India Ltd

LHB-Disc Brake
Faiveley Transport Confidential

Features of Air Brake System

• COMPACT PANEL MOUNTED BRAKE CONTROL EQUIPMENT

• AXLE MOUNTED DISCS
• BRAKE CALLIPERS WITH BRAKE PADS
• BRAKE ACTUATOR WITH INTEGRATED SLACK ADJUSTER
• WHEEL SLIDE PROTECTION DEVICE

COMPLIANCE WITH RCF TECHNICAL SPECIFICATION FOR

AXLE MOUNTED DISC BRAKE SYSTEM FOR ALSTOM-LHB
DESIGN COACHES – MDTS077 REV-2

LHB-Disc Brake
Faiveley Transport Confidential

Brake control system

SPECIFICATION:
Type - Twin pipe graduated release
Performance - RCF Spec. no. MDTS077
RDSO Spec. no. 02-ABR-94
Dimension - Brake Frame 1505 x 1350 x 720 mm
Weight - 350 kg (Brake Frame with equipment)

LHB-Disc Brake
 Faiveley Transport Confidential

Brake control equipment

• COMPACT PANEL MOUNTED BRAKE EQUIPMENT
• BRAKE CONTROL PANEL ON A BRAKE FRAME FOR MOUNTING ON
THE UNDERFRAME.
• DISTRIBUTOR VALVE Type C3W-lP AND OTHER CRITICAL
VALVES ACCOMODATED ON BRAKE CONTROL PANEL AS
REQUIRED BY MDTS077.
• AIR RESERVOIRS ARE ACCOMODATED IN THE BRAKE CONTAINER.

LHB-Disc Brake
 Faiveley Transport Confidential

Brake control equipment

• DISTRIBUTOR VALVE MOUNTED ON INTERMEDIATE PIECE

FOR INTERCHANGEABILITY OF DISTRIBUTOR VALVE WITH
ANOTHER TYPE.
• RELAY VALVE PROVIDED WITH DISTRIBUTOR VALVE TO
ENSURE CONSISTENT BRAKE APPLICATION AND BRAKE
RELEASE TIMINGS.

LHB-Disc Brake
 Faiveley Transport Confidential

Brake control equipment

• STAINLESS STEEL PIPE WITH THREADLESS JOINTS USING
BITING TYPE FERRULES USED IN PIPE WORK ON BRAKE
CONTAINER.
• ALL PIPE CONNECTIONS ARE LOCATED ON TOP OF BRAKE
CONTAINER.
• BRAKE PANEL IS A TRIPLATE CONSTRUCTION USING O-RING
SEALING TECHNIQUES.

LHB-Disc Brake
Faiveley Transport Confidential

Brake Control Schematic

LHB-Disc Brake
Faiveley Transport Confidential

Passenger Emergency Brake

PULLING THE HANDLE OF
PASSENGER EMGERGENCY
ALARM VALVES EXHAUSTS THE
BP PRESSURE RESULTING IN
BRAKE APPLICATION.

BP ACCELERATOR VALVE
EXHAUSTS THE BP PRESSURE
IMMEDIATELY TO BELOW 3 bar.

• THEREAFTER EMERGENCY EXHAUST

VALVE EXHAUSTS THE BP PRESSURE.

LHB-Disc Brake
Faiveley Transport Confidential

Brake Indication and Brake Isolation

• UIC PATTERN BRAKE INDICATORS ARE PROVIDED TO REFLECT

WORKING CONDITION OF BRAKES ON EACH BOGIE.
• ISOLATING COCKS FOR THE BOGIES ARE FITTED ON BRAKE
PANEL FOR ISOLATION OF BRAKES WHEN NECESSARY.
Bogie Isolating cocks

LHB-Disc Brake
Faiveley Transport Confidential

Brake disc
SPECIFICATION:
Dimension - 640 mm x 110 mm; Brake Radius 247 mm
Type - Axle shaft mounted, concentrically split,
Material - Grey cast iron
Friction ring
wear (allowed) -7 mm max.
Weight - 126 kg

LHB-Disc Brake
Faiveley Transport Confidential

Brake caliper & Brake pad

• SPECIFICATION:
Dimension - Conforms to RCF drawings / spec. no. MDTS077
Pad holder suitable for UIC type 200 x 2 brake pads
Caliper suitable to receive Ø 10” Brake actuator
Caliper ratio - 2.17 (2.48 for special coaches)
Brake radius - 247 mm
Weight - 67 kg (with brake pad)
Brake Pad - BBA Becorit 984,
35 mm (thick)
Synthetic rubbers with
metal and mineral fibres
-asbestos free.
Friction co-eff.- 0.35
Conforms to requirements
in UIC 541-3.

LHB-Disc Brake
Faiveley Transport Confidential

Brake actuator
SPECIFICATION:
Type - PBAC 254 - 130
Diameter - 254 mm
Piston stroke - 15 mm
Slack adjusting
capacity - 130 mm
Max. pressure - 6 kg/cm²
Air connection – G ½” port
Weight - 24 kg

LHB-Disc Brake
Faiveley Transport Confidential

Brake actuator (Parking brake)

• SPECIFICATION:
Type - PBACM 254 - 130
Diameter - 254 mm
Piston stroke - 15 mm
Slack adjusting
capacity - 130 mm
Max. pressure - 6 kg/cm²
Air connection – G ½” port
Hand brake
lever ratio - 6.2
Pull force on
handle lever - 10 kN (max.)
Weight - 30 kg

LHB-Disc Brake
Faiveley Transport Confidential

Wheel Slide Protection Equipment

• SPECIFICATION:
Type - SWKP AS20 R

LHB-Disc Brake
Faiveley Transport Confidential

Wheel Slide Protection Equipment

• Main components and their installation

Speed sensor &

Phonic wheel

Dump valve & connector

LHB-Disc Brake
Faiveley Transport Confidential

Wheel Slide Protection Equipment

Main components and their installation

Electronic connectors

Electronic unit

LHB-Disc Brake
Faiveley Transport Confidential

Maintenance–Brake control system

LHB-Disc Brake
Faiveley Transport Confidential

Maintenance–Brake control system

LHB-Disc Brake
Faiveley Transport Confidential

Maintenance–Brake disc
Functional check with brake caliper.
Weekly
Visual check for external damage.
Repeat above checks.
Check disc for cracks.
Monthly
Check cooling ducts for foreign bodies.

Repeat above checks.

Bi-annually
Check friction ring wear (scoring/splintering).
Repeat above checks.
Annually
Check for loose friction ring and loose bolts.
Repeat above checks.
5 – 6 years Clean and check friction ring for damage and
impermissible wear. Replace if necessary.

LHB-Disc Brake
Faiveley Transport Confidential

Maintenance–Brake actuator
Functional check done with caliper and disc.
Weekly

Repeat above checks.

Monthly

Repeat above checks.

Bi-annually

Repeat above checks.

Annually

General servicing after removal of actuator.

Disassemble, replace “mandatory to replace
Every 5 years
parts” cleaning and verification of parts.
Replace worn parts during reassembly.

LHB-Disc Brake
Faiveley Transport Confidential

Maintenance–Brake caliper & Br. pad

Functional check with brake disc.
Weekly Visual check for external damage.

Repeat above checks.

Monthly Check condition of brake pads (external damage,
pad wear, cracks, inclusions, crumbling).
Repeat above checks.
Check longitudinal play, damage to the back of
Bi-annually
pad and free movement on installation.
Check clearance of pad with brake disc.
Repeat above checks.
Annually Check caliper mounting on bogie & easy
movement, pneumatic hoses and brake actuators.
Repeat above checks.
5 – 6 years Remove and dismantle brake caliper.

LHB-Disc Brake
Faiveley Transport Confidential

Maintenance–WSP device
Electronic unit
Replace internal battery of CPU-board after 8 years to keep
function of storing process data.
Do not unnecessarily separate and restore electrical
connections.
Conduct self test during car inspection.

Visual check for external damages regularly.

At interval of 4 years remove valve from car clean filter and
Dump valve replace parts on condition.
Function test the valve and mount on car.

Visual check for external damage to sensor head and

protection hose.
Speed sensor Check gap between sensor and phonic wheel.
Check LED on sensor head for modulation.
Self test on car.

Check teeth during bogie overhaul.

Phonic wheel

LHB-Disc Brake