INTRODUCTION  No hair, incipient crack or through cracks permitted on

Hub/connected flange:
The Axle Mounted Disc Brake System has been provided in LHB design
Mainline Passenger Stock for Indian Railways.  Incipient cracks on Disc:
The brake system equipment provided on the LHB design coaches meet the
requirement for high-speed trains hauled by locomotives and permits the  <72.5 mm, apart by 50 mm min. permitted propagating
emergency braking for such trains to be within the stipulated limits when between two edges.
brakes are applied on a straight trac at a speed of 160 kmph with loco brakes.  <70 mm, apart by 50 mm min permitted propagating
DESIGN from the edges.
The axle mounted brake disc consists of a friction ring and a hub that  Scoring upto 1mm allowed.
are connected together and secured in place by nine screw connections.
 Concave wear up to 2 mm allowed.
FUNCTION  Residual thickness up to 14 mm of disc friction surface.
 The brake caliper closes when the brake cylinder is actuated with  Slanting wear up to 2mm allowed.
compressed air. The brake pads come into contact with the brake
 Permitted for breakage of 4 fins max. alternatively.
disc, the braking effect begins.
 The axle-mounted brake disc which rotates with the wheelset axle
is braked according to the pad Construction of the brake disc
The below two picture depicts the cross section of the brake disc for
SPECIFICATION:
better understanding.
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
.
ABOUT BRAKE DISC:
 Internally vented axle mounted brake disc
 Good heat dissipation and high braking performance
 No maintenance required
 Wear checks/limits:
Checking procedure
Safety and operational safety regulations
The axle-mounted brake disc has been built according to the state of-
the-art and recognized safety regulations. Nevertheless during its use it
may constitute a risk to the health and life of the user or third parties
and/or damage the device and other physical resources.
The axle-mounted brake disc may only be used in a technically perfect
condition and for its intended purpose, paying attention to safety, risks
and the operating manual
In addition to this instruction, you must observe and apply the binding
general statutory and other regulations on accident prevention and
environmental protection.
The personnel commissioned to work with the axle-mounted brake disc
must read the maintenance instructions and particularly chapter with
safety instructions before starting work.
Use personal safety equipment.
Ensure that brakes (Service or Parking) are off before any operation
and the vehicle is over the pit for ease of checking.

Traceability
Before taking up any checking activity, ensure that the following
traceability data are collected and noted.

1. Zonal railway
2. Coach no.
3. Coach type
4. Commissioning date
5. POH date
6. Wheel Sl.no. (if visible)
7. Axe Sl.no. (if visible)
8. Axle position no. (Starting from Non Power Pack end)
 9. Disc position - LHS (or) RHS of axle (LHS on Non Power Pack
side)
10. Disc Serial no. (if visible)
11. Photos of the Disc in case of abnormalities found
12. Caliper + Actuator assembly - FT/KB
13. Checked by
14. Any other observations

To be used Tools
Orientation of fixing numbers
Calibrated Torque wrench (20 - 100 Nm range)
Socket for M12 nut (suitable for use in torque wrench)
Torch Light for better visibility
Hand held mirror (for clear view of disc closer to wheel)
Wiping cloth
Steel brush (to be profiled suitable for better accessibility)
Cracks in Lugs of friction pair

Clean all sides of lug area (both nut and bolt head sides)
thoroughly to remove dirt particles.

Visual check for cracks / incipient cracks of lugs of the friction ring on
both sides of the disc (nut and bolt head side)

Note: If cracks are detected in any of the lug, the disc has to be taken
out of service immediately
Check for Wheel shelling (deep pit / shelling marks)
Check for Tightening torque
Visually check for any pitting marks all around the wheel tread.
In case deep pit / shelling marks are found, make a note of the same and inform to To be carried out only if there is a visible loosening of nut is observed.
Shed authorities to replace the axles. If any such cases are witnessed, the below mentioned procedure is to
be followed.

Warning: Brake disc must have cooled down. Risk of injury from
burns when touching the hot brake disc.
> If parts are missing, replace parts according to part list.
> Maximum two non — complete fixings permitted. If more
detected the disc must be replaced.
> Set torque wrench at 50Nm.
> Tighten M12 nuts using torque wrench (diagonally
opposite).
> Stop when you hear the "Click" sound. Do not over
tighten anymore.
 > Make torque marking (on each nut, washer and segment). Type Defintion Figure
Ensure that the torque mark color is different from the of
existing one. Crack
Part list fixing parts: Incipi Incipient cracks are cracks in the frictional
ent surface that begin at the inner
Part name Part no. crack or outer diameter of the friction ring and
Segment D 128332-400 s penetrate the friction ring
side locally.
Bolt D 128599-200
Lock nut D 001754-101
Spring washer D 002651-101
Surfa Surface cracks are cracks in the frictional
TYPE OF DEFECTS ce surface that do not penetrate
crack the friction ring side in an axial direction.
 Penetrating crack, one-sided s
 Penetrating crack, both sides
 Incipient cracks
 Surface cracks
 Scoring
Checking Parameters
 Hollow wear
 Splintering S No Determining the Evaluation/measures
 Hot spots actual condition
Definition of Cracks 1 Wear marks on The wear marks must be visible .Pay
friction ring. attention to hollow wear & scoring
Type of Crack Defintion Figure
Penetrating 2 Hollow wear and The permissible values for the hollow wear
Penetrating cracks are scoring in the are 1.0
cracks cracks (fractures) that frictional surfaces. mm and for the depth of scoring 1.0 mm.
reach from the inner to the
outer diameter of a 3 Splintering in the Unacceptable; replace friction ring.
frictional ring side and frictional surfaces.
penetrate this over the 4 Cracks.
entire cross-section. Cracks in the Unacceptable; replace axle-mounted brake
4.1
hub disc.
4.2 Cracks in the Unacceptable; replace axle-mounted brake Troubleshooting table
connection & disc. The most common problems are listed in the following troubleshooting
screw table. Other combinations of faults are possible.
connection areas
of hub & friction Fault Possible cause Remedy/measures
ring. Development • Preservative not • None.
of smoke removed before
4.3 Cracks in the Crack definitions during commissioning. • Check the brake disc/pads;
frictional braking determine the cause and
surfaces. (annoying • Frictional surfaces remedy
4.3.1 Penetrating Unacceptable; replace friction ring. smell). dirtied by oil or the
cracks. like.
Air slot • Friction ring loose. • Check: shake the friction
4.3.2 Incipient cracks. Unacceptable; replace friction ring. between brake ring
4.3.3 Surface cracks. a) Permissible up to a length of 50 mm, when disc • Brake caliper stuck or • Check the fastening
the inner or outer edge is reached. and brake pads defective brake elements, complete if
not parallel. cylinder
b) Permissible up to a length of half the friction necessary. Tighten all
ring width if the gap to the inner or outer edge screws to the specified
is at least 10 mm. Surface cracks may not be tightening torque.
more than of 0.5 mm width. Scoring in the • Foreign body or brake • Replace pads.
frictional disc abrasion has • Face friction rings if depth
4.4 Cracks in the Permissible on max. 2 cooling fins. Bet. surfaces gone into the brake of scoring unacceptable.
cooling fins. Cooling fins with permissible cracks there of the brake pad material. • Replace pads; check the pad
must be at least 3 undamaged cooling fins disc. • Non existence of holder lock, replace the pad
5 Foreign bodies Remove foreign bodies and clean cooling ducts brake pads. holder if necessary.
in cooling ducts. Hot spots on • Pad material • Check the pad type; fit
the frictional unacceptable specified brake pads.
6 Hot spots Permissible. surfaces of the • Unequal contact • Check hollow wear. Reduce
7 Missing or loose Unacceptable. brake disc pattern of brake pads. by overturning if necessary.
fastening, screws (overheating). • Driving with the brake
• Release the service and
and segments. on.
spring applied brake. Check
• Overloading of brake control; repair if
8 Loose friction Unacceptable; check tight fit through visual vehicle
rings. check necessary.
• (axle load to high).
and shaking the friction ring. Tighten loose • unacceptable pressure • Adjust the journey profile to
friction ring. in the permissible
• brake cylinder. specifications.
Above- • Overload on brake • Check whether the journey (For Official Use Only)
average disc. profile or design parameters
cracking. are still correct for the brake
(e.g. higher weights,
deceleration, etc..); correct if Hkkjr ljdkj GOVERNMENT OF INDIA
necessary. jsy ea=ky; MINISTRY OF RAILWAYS
• Check whether the damage
was caused by a blocking PAMPHLET
brake cylinder or if the on
vehicle was driven with the
parking brake on; remedy the Instruction for Axle Mounted Brake
cause. Disc in LHB Coach (FTIL Type)
• Overload on disc brakes by
train driver (disuse of CAMTECH/M/GWL/2014-15/Beake Disc/1.0
brakes). Sept 2014

Uneven wear • Blocking brake caliper • Check the brake caliper, repair
on the two • or defective brake if necessary.
frictional cylinder. • Check the operability of the
surfaces of a • Unequal energy input brake cylinder, replace if
brake • in brake disc. necessary.
disc. • Different grades of • Check the brake gap with the
pads. brake released.
• Check hollow wear. Before
installing new brake pads
remove any unacceptable
hollow wear.
• Fit the specified pad material.

Disclaimer:
It is clarified that this pamphlet does not supersede any existing provisions laid down
by RDSO, Railway Board or Zonal Railways. The pamphlet is for guidance only and it is not a
statutory document.
If you have any suggestion or comment, please write to:
Director (Mech), CAMTECH, Maharajpur,Gwalior (M.P.) – 474 005
Ph.0751-2470890, Fax 0751-2470841
egkjktiqj, Xokfy;j & 474 005
Maharajpur, GWALIOR - 474 005