Ref: CGW 0001 Page 1 of 12 Date of issue: Spec. No.

CK-013
(Rev.–3) ______, 2011 Rev. 01

INDIAN RAILWAYS

SPECIFICATION

For

BOGIE MOUNTED BRAKE CYLINDER

For

BG MAINLINE AND EMU COACHES

Month/Year of Revision / Reason for Amendment
SN Page No.
issue Amendment

1 November, 2000 - - First issue

1. Reformatted.
2. Para 5.1.1.2.f added.
2 3. Test no. 3 in Annexure B
_______, 2011 1 All
for Endurance testing of
BMBC added.

Issued By:

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

MANAK NAGAR, LUCKNOW- 226011.

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 2 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

SECTION-A
Specification for Bogie Mounted Brake Cylinder with Built in Slack Adjuster for
EMU and Main Line Passenger Coaches
1. Scope
1.1 This specification covers the technical requirements related to material,
dimensions, inspection and testing of brake cylinder used on bogie mounted
air brake system and does not include other necessary provisions of the
contract.
2. Particular Requirements

2.1 Air brake manufacturers should seek approval from RDSO for manufacture of
brake cylinder with built in slack adjuster clearly bringing out the input given at
their works or sub-contractors, if any.

2.2 The manufacturer shall have adequate facilities for the manufacture, testing and
Quality control requirement of brake cylinder conforming to as per annexure „B‟
of this specification.

2.3 Rubber items shall be procured from RDSO approved sources only. However,
the manufacturers shall be fully responsible for satisfactory performance of the
rubber items.

3. Material

3.1 The material of brake cylinder with built in slack adjuster shall conform to the
latest revision of RDSO drawing nos. RDSO/SK-81200, 81201, 81202, 81203,
81204, 81205, and 81206.
3.2 All the components shall be manufactured / procured to the material
specification indicated against each component in the drawings.
3.3 The castings shall be sound, clean and sharp without defects or blemishes of any
kind and conform to the requirement of the specification.
3.4 The rubber item shall be smooth, free from pin holes, blisters, porosities and
other visual flaws.
3.5 The fabrication and welding of fabricated cylinder body shall conform to the
requirements of Section II of IS: 2825 (code for unfired pressure vessel).
3.6 Testing of other items shall be carried out in accordance with the procedure laid
down in RDSO pamphlet no. G-72 (Rev. I).
3.7 The piston packing shall conform to the requirements laid down in Annexure-A.

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 3 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

4. DIMENSIONS AND TOLERANCES

4.1 The dimensions and tolerances of brake cylinder shall be as indicated in the
latest revision of RDSO drawing indicated at para 3.1 above.

4.2 All dimensions identified in the drawing shall be gauged. The manufacturers
shall have the necessary gauge available with them. Gauge drawings shall be
got approved from RDSO prior to the manufacture.

4.3 Discrepancies in dimensions, if noticed shall be brought to the notice of RDSO at

the developmental stage and sorted out.

5. DEVELOPMENTAL INSPECTION

5.1 Developmental inspection shall be carried out at the manufacturer‟s premises

at the time of Fresh registration of the firm with RDSO and at the time of
Renewal of registration.

The following procedure shall be followed for the developmental inspection:-

5.1.1 The inspecting authority shall verify and ensure that the manufacturer is
having and strictly following a well-documented system of the „Internal
Quality Assurance Plan‟. After having done the same, the following procedure
shall be followed:-

5.1.1.1 The manufacturer shall offer five brake cylinders complete in all
respects and two brake cylinder bodies with test plates in accordance
with the layout corresponding to fig. 8.2 of IS:2825 Section III.

5.1.1.2 The inspecting authority shall carryout the following test/check on the five
complete brake cylinders as per details given below:-
a) Checking of dimensions and tolerances interchange-ability of components and
general workmanship.
b) Pressure test as per details given at para 7.1
c) Leakage test with 7 Kg/cm2 hydraulic pressure as per details given at para 7.2.
d) Two numbers piston packing shall be tested for conformity as per Annexure-A.
e) Two nos. dust excluders as per requirements of spec. R-48/88 mentioned in the
drawing shall be tested for conformity.
f) Endurance test on one Brake cylinder as per details given in Annexure B.

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 4 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

5.2 In case samples offered fail in any of the test/check indicated at para 5.1.1.2 the
complete lot of develop-mental order placed on the firm shall be rejected.

6. PURCHASE INSPECTION

6.1 Purchase inspection shall be carried out at the premises of manufacturer who
are cleared for the regular manufacture of brake cylinder. The following
procedure shall be followed for the purchase inspection:-

6.1.1 The inspecting authority shall make audit checks of the manufacturing
procedure/internal quality assurance system to ensure that the brake cylinder
offered for inspection is manufactured strictly as per internal quality
assurance system and the manufacturer has carried out all tests/inspection
during manufacturing stage to ensure that brake cylinder offered are strictly
to the specification. During such audit checks, the inspecting authority shall
also see from the records of internal quality assurance that the raw material
u s e d for the manufacture of brake cylinder is as per specification laid down.

6.1.2 Inspecting authority shall conduct following checks from a lot of not more than
100 nos.

6.1.2.1 Two percent brake cylinder picked up at random shall be checked for
dimensions with respect to RDSO assembly drawings.

6.1.2.2 One percent brake cylinder shall be dismantled and dimensions and
general work man ships of each component checked as per RDSO drawings.

6.1.2.3 Ten percent brake cylinder picked up at random shall be subjected to tests
as given at para 7.1 and 7.2 of this specification.

6.1.2.4 Two piston packing rings every contract shall be t e s t e d for conformity as
per Annexure-A.

6.1.2.5 Two Nos. dust excluder per every contract shall be tested for conformity as
per R-48/88 mentioned in the drawing.

6.2 In case the samples picked up fail in any of the tests/checks indicated in para
6.1.2.1 to 6.1.2.5, the reasons for such failure shall be identified. The
inspecting authority shall verify the reasons by conducting audit check on
internal Quality Assurance System. If it is found that such failures are due to
non- implementation of internal Quality Assurance System, the entire lot of
brake cylinders shall be rejected. In c a s e the failures are on account o f
r e a s o n s other than non- implementation of internal Quality Assurance
Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 5 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

System, the manufacturers may re-offer the lot after rectifying the defects.
However, in such cas es , double the quantity of the samples shall be picked
up and tests/checks conducted as per para 6.1.2.1 to 6.1.2.5. In case the samples
again fail in any of the tests/checks, the entire lot shall be rejected.

7. TESTS
7.1 Leakage & Function Test for Brake Cylinder Complete
The leakage and function test of the brake cylinders should be conducted in
accordance with Annexure-B.
7.2 Hydraulic Test
These tests shall be conducted on cylinder body. The cylinder body shall be
subjected to hydraulic pressure of 7 Kg/cm2 for 5 minutes and there should
be no leak-age.
8. PAINTING
The exterior of the brake cylinder shall be painted with black enamel paint.
9. PACKING
9.1 The manufacturer shall ensure that all external ports of brake cylinders are
suitably covered with protection caps to prevent ingress of foreign matter
during handling and storage.
9.2 The manufacturer shall also ensure that brake cylinders in assembled condition
are adequately packed before dispatch to prevent damage in handling and
storage.

___________________

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 6 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

ANNEXURE-A
PISTON PACKING FOR 203.2mm BOGIE MOUNTED BRAKE CYLINDER
1.0 SCOPE
1.1 This specification covers the requirements for piston packings used in
bogie mounted brake cylinders of main line and EMU coaches.
1.2 Type
1.2.1 The piston packing shall conform to item 10 of RDSO SK-81204 with latest
alteration.
1.3 Requirements
1.3.1 Material:
1.3.1.1 The rubber used in the manufacture of piston packings shall be
Butadiene Acrylonitrite without insertion.
1.3.2 Construction, Workmanship and Finish:
1.3.2.1 The piston packing shall be smooth, free from pin holes, blisters,
porosity and other visual defects. The dimensions and tolerances of
the piston packings shall be as indicated in the drawing mentioned in
clause 1.2.1.
1.3.3 Physical Properties of Rubber
The rubber used in the manufacture of piston packing shall conform to
the following requirements:
SN Property Requirements
1. Hardness 80+5 shore A
2. Tensile strength kg/cm2(min.) 105.5
3. Elongation at break %age (min.) 100
4. Compression set (%), max. at 100+1oC for 24
70
+0/-2 hours.
5. Swelling hy-volume (%) max. in grease at +10/-0 %
100+1oC for 72 +0/-2 hours.
Brand of grease SERVOGEM-RR-3
o
Accelerated ageing: After ageing at 100+1 C in an air oven for 168 hours, the
hardness, tensile strength, elongation at break shall not vary by more than the
following from the values obtained with un-aged specimens.
a. Hardness (shore A) +5/-0
b. Tensile strength +5 %
c. Elongation at break 50%
o
6. Tension set at 20+2 C for 10 minutes. 2% (Max.)

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 7 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

ANNEXURE-B

TESTING PROCEDURE OF AIR BRAKE CYLINDER WITH BUILT IN

SLACK ADJUSTER
1.0 PREPARATION FOR TEST:
The test layout is shown in the attached SK-98108. A special pin will be required
to locate the crosshead between the angle iron slots. During Testing Cock 2
must be opened slowly whenever the cock is used to admit air under pressure to
the cylinder.
 Connect the air supply to the cylinder body.
 Commence with all cocks closed.
2.0 TESTING PROCEDURE
TEST NO. 1 - Leakage test:
 Open Cock 1 to charge the MR to 7 kg/cm2 pressure
 Open Cock 2 to charge the cylinder 0.7 kg/cm2 pressure
 The piston stroke must be limited to 32mm, wait for one minute for
settlement and there must be no drop in pressure shown in the leakage
volume gauge for a further minute. Also observe that leakage does not
exceed 0.1 kg/cm2 in 10 minutes.
 Repeat this test with the cylinder charged to 3.8 Kg/cm2 pressure and
with cock 3 closed limiting the maximum piston stroke to 95mm. Observe
that the leakage does not exceed 0.1 kg/cm2 in 10 minutes.
 Open Cock 3 to exhaust the cylinder pressure to zero.

TEST NO. 2 – Operation Test:

A. Full Stroke
 Close Cock 3 and Open Cock 2.
 Observe the full stroke of the piston. This must be within + 1.0 mm of the
max. Stroke value.
B. Take-up Stroke
 Close Cock 2 and Open Cock 3 to exhaust the cylinder pressure to zero.
 Close Cock 3.
 Open Cock 2 and allow the piston to move out slowly until the operating
pawl is heard to “click over” then close Cock 2.
 Measure the take up stroke. This must be 32 mm for main line self-
generating coaches and between 54mm to 60mm for EMU coaches for
cylinders of 95 mm stroke

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 8 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

 Close Cock 2 and open Cock 3.

 As the cylinder returns to release the locking pawl must be heard to
click into position.
NOTE:
1. Operate the piston at full stroke at least 18 times to test all ratchet teeth.
2. Observe that the Adjuster operates at each Release and the Adjusting
tube and crosshead being „Inched‟ out along the stroke.
3. The movement of the Piston must be smooth without any tendency to stick
at any part of the stroke.
C. Take-up Length (Without Quick Resetting Gear)
 Close Cock 2 and Open Cock 3.
 Remove the pin from the crosshead and unscrew the Adjusting tube until
the red resetting mark on the Adjusting Tube is visible.
 Disengage resetting latch and screw in the Adjusting Tube.
 Re-engage resetting latch.
 Check that the Dust Excluder Collar is free and does not twist when the
Adjusting Tube is being rotated.
 Close Cock 1 and open Cock 2.
 Close all cocks when the system is at atmospheric pressure.

D. Take-up Length (With Quick Resetting Gear)

 Close Cock 2 and open Cock 3.
 Remove the pin from the crosshead and turn the resetting screw until
the red resetting mark on Adjusting tube is visible.
 Screw in the Adjusting Tube with the resetting screw. Check that the
Dust Excluder Collar is free and does not twist when the Adjusting tube
is rotated.
 Close Cock 1 and open Cock 2.
 Close all cocks when the system is at atmospheric pressure.

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 9 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

TEST NO. 3 – Endurance Test:

1. Carry out leakage test as per para Test no. 1.

2. Charge the brake cylinder with air @ 3.8 Kg/cm2.

3. With 32 mm piston stroke, measure the force on load cell.

4. Carry out endurance test for 2,00,000 cycles at frequency 7

cycle/minute with 32mm piston stroke.

5. After completion of endurance test measure the force on load cell at

32mm piston stroke.

6. Force on load cell at 32mm piston stroke should not be differ by ±2% of
force measured at begining of endurance test.

7. Repeat the leakage test as per para Test no. 1. Brake cylinder should
pass the Test no. 1.

8. Conduct the operation test as described in Test no. 2. Brake cylinder

should pass the Test no. 2.

__________________________

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 10 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

SECTION-B
INFRASTRUCTURE - MANUFACTURING AND TESTING FACILITIES
1.0 SCOPE
The schedule of technical requirements covers the norms for manufacturing of
Air Brake cylinder 203mm with built in slack adjuster for coaching stock.
2.0 REQUIREMENTS
The vendors seeking approval shall comply with all the below mentioned
requirements.
GENERAL & MANUFACTURING FACILITIES:
2.1 Covered area with adequate space for machine shop, Assembly Sections,
performance test benches, welding section, standard room laboratory,
storage of raw material and finished product should be available.
2.2 The vendor should have adequate machining facilities such as turning,
facing, boring, milling, drilling, tapping, grinding, honing and threading for
carrying out the required machining operations on the components. The
operations involved for each component should be specified machine wise in
the process flow chart with accuracy of the machine.
2.3 The firm should have a honing machine for honing of cylinder body.
2.4 The firm should have adequate supply of compressed air at 8 kg/cm2 minimum
on the shop floor for performance testing of the equipment.
2.5 It is to be ensured that all the hardware items are of reputed make and adhere
to the required specifications.
2.6 There should be a painting booth for painting the components.
3.0 TESTING FACILITIES
3.1 The firm should have facilities of testing the Brake cylinders to meet the
requirements mentioned in Section-A of this specification.
3.2 The firm should have a test stand for conducting endurance testing of brake
cylinders.
3.3 A hydraulic pressure testing arrangement of capacity 15 kg/cm2 to conduct
hydraulic test of brake cylinder should be available.
3.4 Firm should have a shadow graph for checking profile of the rubber packing
ring.
3.5 Firm should have a surface finish tester for measuring the surface finish of
cylinder bore.
3.6 Spring load testing machine for testing stiffness of
i) Plunger spring.
ii) Pawl spring.
iii) Latch spring.
Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 11 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

iv) Release spring.

3.7 Hardness testing machine for measuring hardness of
i) Rocker arm tip.
ii) Plunger.
iii) Pawl.
iv) Latch.
3.8 Shore hardness tester for checking hardness of rubber items.
3.9 In addition to above machine the standard room should also have the
following instruments:
a) Surface plate.
b) Three point bore gauge of 250mm.
c) Vernier depth gauge of 300mm.
d) Bevel protector for measuring angle.
e) Minimum one Vernier height gauge of 300mm.
f) Minimum two sets of outside micrometer up to 75mm.
g) Plug, Go - No-Go and thread gauges as per requirement of the
components.
4.0 QUALITY CONTROL REQUIREMENTS
4.1 It is to be ensured that head of the Quality control is a graduate engineer with 5
years‟ experience or a diploma holder in relevant field with 10 years‟
experience. He should have full knowledge of the product and should be
involved in day to day activities of quality control, stage inspection and also
compliance of QAP.
4.2 The firm should have acquired ISO-9000 series certification and the product for
which the approval is sought should be broadly covered in the scope of the
certification for manufacturing and supply.
4.3 The quality manual of the firm should clearly indicate control over
manufacturing process, system of measuring and testing.
4.4 The firm should have Quality Assurance Plan as per RDSO guidelines available
on RDSO website.
4.5 There should be a methodical approach for calibration and record keeping of
Gauges, Instruments, Jig and Fixtures.
4.6 There should be an established and working system for assessing the quality of
the sublet vendors.
4.7 Rubber packing ring should be procured from RDSO approved sources only.
4.8 Despite obtaining test certificates from sublet vendors for non-ferrous and
malleable casting items, a system should exist to get samples tested
periodically and records should be maintained.
**************************

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage
 Ref: CGW 0001 Page 12 of 12 Date of issue: Spec. No. CK-013
(Rev.–3) ______, 2011 Rev. 01

Signature
Name & Prepd. By:- Santosh Kumar Singh Checked By:- Praveen Kumar Approved By- Rajesh Awasthi
Designation JE/EMU & Brake/Carriage ADE/ EMU & Brake/Carriage Director/ EMU & Brake/Carriage