Transformation through

Engineering and Innovation

BRAKE SYSTEM
BRAKE SYSTEM
Escorts Limited was the first to commence 1. PASSENGER COACHES
manufacturing of Compressed Air Brake system in • Air brake for Conventional Coaches
India, for railway applications in 1981. • EP brake system for EMU/DMU Coaches
• Axle Mounted Disc brake System for LHB
Escorts has ultra-modern, precision manufacturing Alstom Coaches (FIAT Bogie)
• Brake Disc for LHB Alstom Coaches
facilities for Distributor Valves and is the largest
manufacturer in Asia, having supplied over
100,000 nos. to Indian Railway for various freight
and passenger car applications. 2. FREIGHT WAGONS
• Air brake for Conventional Wagons
Conversions from Vacuum Brake to Air Brake • Bogie Mounted Brake System for wagon
system has been Escorts’ forte. Over 40% of rolling fitted with CASNUB bogie
stock of Indian Railways, one of the largest
Railway systems in the world depends on Escorts
for their braking requirements.
3. LOCOMOTIVE
Some of the Air Brake Valves designed and • Microprocessor Controlled Brake System
developed by Escorts have been standardized by
Indian Railways. Over 4000 officials of Indian &
Foreign Railways have been trained at Escorts 4. BRAKE ACCESSORIES
facilities, on Air Brake systems.
• Distributor valve
• Brake Cylinders
Complete overhauling and testing facilities have • Slack Adjuster
been set up at various locations to meet customer • Automatic Drain Valve
requirements. • Passenger Emergency Brake equipment
• Load Sensing Device
• Centrifugal Dirt Collector & Air Filter
The technical expertise accumulated over three • Isolating Cocks
decades, includes ability to design and offer • Check Valves
customized brake system solutions depending • Angle Cocks
upon vehicle’s speed, load and various other • End Cocks
• Air Brake Hose coupling
parameters as per customer’s specific requirements.
• Reservoir
AXLE MOUNTED DISC BRAKE SYSTEM
FOR HIGH SPEED TRAIN
Escorts Railway Equipment Division has developed Axle Mounted Disc Brake System for high speed train services.
This brake system conforms to UIC standards and is specifically designed to meet the Indian Railways requirement
as well.

The disc brake system consist of actuators in form of brake cylinders, caliper units, integrated slack adjusting
arrangement and wheel slide protection device (WSP). The system has a panel mounted brake equipment
consisting of tri-plates, DV, manifolds, etc. The WSP is approved by UIC which protects the wheels from sliding.

SALIENT FEATURES

• Brake caliper unit along with Brake Cylinder

• Brake Caliper units with different rigging ratio for
coach application
• Wheel Slide Protection unit with latest features to
avoid wheel skidding WSP
• Brake pads from Federal Mogul, one of the best
manufacturer globally
Dump Valve

APPLICATION

• High Speed Passenger Coaches (LHB Alstom)

• Double Decker Coaches
Disc Brake
Arrangement
MAJOR COMPONENTS

• Brake control panel PMBS

• Brake Cylinder unit with calipers
• Brake Pads
• Wheel Slide Protection device as per UIC
• Dump Valve
• Toothed Wheel Brake Actuator
• Speed Sensor
ELECTRO – PNEUMATIC BRAKE SYSTEM FOR EMU
One of the largest railway network in the world with super dense crush load on their EMU and MEMU
stock running on suburban network across various cities of India run on Escorts manufactured systems
for their braking, coupling and suspensions requirements. Escorts have been manufacturing Electro-
Pneumatic Brake systems for more than three decades. These brake Systems are in use on EMUs, MEMUs
and DMUs in Indian Railways.

BRIEF DESCRIPTION

Escorts EP Brake system has two

distinct modes of operation. The
primary mode of operation is electro-
pneumatic application of the brakes
throughout the train and the second
mode of operation is the application
of back-up brakes in case of electrical
power failure in the system.

SALIENT FEATURES

• Rapid application and Release of

brakes JOYSTICK TYPE ELECTRO
• Graduated application and Release PNEUMATIC BRAKE CONTROLLER
• Auto control for fail safe operation
in Electrical failure

APPLICATION

• EMUs, MEMUs, DMU

• Any other suburban/mass rapid
transport system.

ELECTRO PNEUMATIC BRAKE CONTROLLER ALUMINIUM TRIPLATE TYPE EP UNIT

PNEUMATIC BRAKE CONTROLLER FOR
MICROPROCESSOR CONTROLLED EMU TRAINS
The MRVC/MUTP coaches are running with Escorts manufactured Pneumatic Brake Controller.
These coaches are built for Regenerative braking.

BRIEF DESCRIPTION

Escorts Pneumatic Controller is for

auto/ pneumatic graduated application
and direct release system with time
dependence on brake pipe drop (i.e.
BP shall drop continuously as long as
the handle position is kept at auto
position). Handle may be placed at
“LAP” position for lapping brakes.

SALIENT FEATURES

• Pneumatic brake is used as a

supplementary brake to stop the
vehicle
• Graduated application and direct
release is possible
• Lapping is possible by keeping
Handle in “LAP” position
• Isolation of Pneumatic Controller is
possible to avoid misuse PNEUMATIC BRAKE CONTROLLER

APPLICATION

• MRVC/MUTP/Siemens/Bombardier
coaches in MUMBAI
• Any other suburban/mass rapid
transport system similar to MRVC/
MUTP coaches.
MICROPROCESSOR CONTROLLED BRAKE SYSTEM FOR
ELECTRIC LOCO
Microprocessor Controlled Brake System (EMCBS) is a modular braking system developed for use in 3
phase Electric Locomotive suitable for application & release of train brake and locomotive brake in
accordance with graduated release twin pipe air brake system. Its electro pneumatic line replaceable
intelligent modules connected in local network function together in conjunction with loco computer
to achieve the desired brake functionality. The system has the following major parts –

• Electronic Control Unit (ECU) consisting of Brake Control

Electronics and Vigilance Control device
• Auxiliary Control Unit
• Brake Control Unit with Header for pneumatic
connections
• Cab Controller with diagnostics display
• Driver Back-up valve

SALIENT FEATURES

• Compact, modular & reliable design

• Distributed control through 8 nos. of high performance
micro Controllers
• Intelligent EP modules with redundancy
• Apply penalty brake in case driver becomes incapacitated
• Full Back up in case of Electronic brake failure
• Seamless interface with Loco propulsion system
• User friendly operation & Easy Maintenance
• User friendly GUI based Software with advanced features
and better diagnostics EMCBS Panel for Electrical Loco
• Check and configure the programmable variables, fault
data viewing and status display

SALIENT FEATURES

• Suitable for operation in WAG9, WAP7 & WAP5

locomotives

Cab Controller Drivers Back-up Valve

PC Side Diagnostic Application Software

MICROPROCESSOR CONTROLLED
BRAKE SYSTEM FOR DIESEL LOCO
The Microprocessor Controlled Brake System (MCBS) is a modular braking system developed for use in
Diesel and Electric Locomotives. The system consist of the following parts

• Brake Controllers
• Brake Control Unit
• Driver Back-Up Valve
• Various Communication Channels
• Data/Fault Logging, Diagnostics and
Display
• Programmable Variables

SALIENT FEATURES

• Compact design Cab Controller MCBS Panel for Diesel Locomotives

• Less Modules with high reliability
and redundancy
• User Friendly operation, Easy
Maintenance
• User friendly ‘state of the art’ GUI
based software with advanced
features and better diagnostics
• Check and configure the
programmable variables, fault data Lead & Trail Module BP Module
viewing and status display.

APPLICATION

Suitable for operation in WDG4, WDP4

& WDG5 locomotives
Automatic & Emergency Module Independent Module

Drivers Back-up Valve

PC Side Diagnostic Application Software

BOGIE MOUNTED BRAKE SYSTEM FOR WAGONS
Bogie Mounted Brake System
(BMBS) is a modular Braking
system developed for use in Freight
Wagons. The system is designed to
meet Indian Railways specification.
This system shall be fitted on new
wagons and can be retro fitted
on existing fleet wagons having
maximum axle load of 22.9 tons.

SALIENT FEATURES

The Bogie Mounted Brake System has

the following features compared to the
conventional brake system.

• Improved Braking Efficiency

• Reduced weight
• Less number of parts
• Uniform brake shoe and wheel wear
• Increased reliability
• Easy maintenance
• In-built automatic slack adjustment
• Easy brake shoe replacement
• Brake release and application BOGIE MOUNTED BRAKE SYSTEM
indication
• No manual intervention (until worn-
out condition)

APPLICATION

All types of Railway Freight Wagons

having maximum Axle load of 22.9 tons
such as BOBRN, BOBRNHSM1, BOXN,
BOXNHL, BCN, BCNA.
BMBS BRAKE CYLINDER WITH HAND BRAKE

SUB SYSTEMS MOUNTING BRACKET

INDICATOR

• Primary & Secondary Brake beams

• Brake Cylinder with Slack Adjuster
having two variants - with handbrake
and without handbrake
• Escort Ratio Valve which performs as a
Automatic Pressure Modulation (APM SENSING ARM
Device)
• Rigging arrangement for hand brake ESCORTS RATIO VALVE
system
• Bell Crank Levers for load transfer
• Piping arrangements

BMBS BRAKE CYLINDER WITHOUT HAND BRAKE

AIR BRAKE ACCESSORIES
Escorts manufactures air brake accessories for air brake systems for freight and passenger cars. Various
accessories manufactured by Escorts are as follows

Distributor Valve

The Distributor valve controls proper

applications and release of brakes of
different vehicles depending on the
pneumatic pressure prevailing in the BG/BGS BRAKE CYLINDER AIR RESERVOIR
brake pipe. It works automatically,
providing graduated application and
release and maintaining the pressure.

Escorts KE distributor valve complies

with the requirements of the UIC
specifications governing compressed air
brake for freight and passenger trains
in international traffic.

LOAD SENSING DEVICE DISTRIBUTOR VALVE JSL BRAKE CYLINDER

APPLICATION Brake Cylinders Isolating Cocks, Check Valves

• With slack adjusters (8” to 10”) Mounting options available are

The Escorts KE type distributor is
• Without slack adjuster (8” to 14”) threaded & flange type.
suitable for
• A wide range of different vehicles Passenger Emergency Brake Equipment Angle Cocks & End Cocks
(Passenger and Freight cars)
• Single and twin pipe brake system • Emergency Alarm Signal Device
• All sizes of brake cylinder As per AAR and UIC design, various
• Emergency Brake Valve
models available are LH-3, IRS type.
Load Sensing Device
Air Brake Hose Coupling
Modular Design • Single piece and two piece design
• Single piece design, LSD III (Side As per AAR design and UIC design.
The Escorts KE type distributor valve is mounted), LSD IV (Top Mounted)
of Modular design. The basic valve body • Two piece design model available Reservoir
can be supplemented by the connection with the operating valve B1 and
or incorporation of appropriate spring buffer F1 Various sizes of Reservoirs available
accessory components as required for ranging from 6L to 200L in MS and SS.
the purpose in view. Centrifugal Dirt Collector & Air Filter

• 3-Way suitable for main line

• 2-Way suitable for branch line

UIC ANGLE COCK ANGLE COCK

SLACK ADJUSTER
SPECIFICATIONS

• Application capacity
(300, 450, 600mm)
AAR ANGLE COCK • Available with Plain end i.e. without
coupling, H1 & H2 Spindle coupling
• Width of the adjuster ear “P” (either
30mm or 40mm)
• Inner diameter of the bushing H2 Coupling H1 Coupling Control Rod End
ISOLATING COCK WITH AND “d”(30, 37 and 40mm or as per
WITHOUT VENT customer requirement)
Example: EDRV2A-450H2P-40d-37
THE ESCORTS MAKE KE TYPE DISTRIBUTOR VALVE WITH ITS
ACCESSORY COMPONENTS

“Goods-passenger” Choke cover

change-over device (GP Change- Incorporate a complete set
over) Contains a complete set of of chokes for application and
chokes for application and release release in the pre-selected
in goods and passenger train traffic type i.e. goods or
service. passenger train service

Shut-off device with AR charging Shut-off device without AR

valve charging valve
Shown with fork lever, can be Shown with resilient handle for
changed over to ‘on’ ‘off thru’ manual operation of ‘on-off’ change-
rigging arrangement from side wall. over device.

Control chamber Bottom Cover

Shown with quick release valve SL Shown with quick release valve SL
for mounting to valve body
KR Nr Bracket with threaded end Common pipe bracket with
connections for mounting flange type connections suitable
Distributor Valve KE, adaptable to for mounting various makes
pipe sizes of 1-1/4”, 1” and 3/4 of Distributor valve by using a
intermediate adaptor.

Side Cover Relay valve KR1

When the cover is exchanged for one of the ‘Unitized action for all brake
following components the distributor valve then cylinder sizes. Neither exchange
is said to be of the ‘universal action’ type. (Basic of chokes nor adaptation are
valve with cover = Distributor type KE O) required (Basic valve with KR1
Distributor type KE 1)

Adjustable relay valve RR 1 Pressure transformer DU

Same function as KR 1, but with Same effect as KR1, but with additional
additional mechanically controlled two-stage variable load braking.
continuous load controlled braking (basic valve with DU = Distributor type
(Basic valve with RR1 = Distributor KE 2 - A, B or C, depending on the type
type KE2 AL) of ‘empty-loaded’ change-over device)
PIPING DIAGRAM OF AIR BRAKE SYSTEM FOR
PASSENGER COACHES AND FREIGHT WAGON

PNEU PULL OFF BOX

TO AUXILIARY EQUIPMENT

PRESSURE REGULATOR AIR RESERVOIR ISOLATING COCK

VALVE
EMERGENCY
BR. VALVE
ANGLE COCK
CHECK DIRT COLLECTOR
ANGLE COCK WITH VENT
DRAIN COCK VALVE
WITH VENT

HO
FEED PIPE/MAIN LINE

S
FP

EC
G

OU
N

BRAKE PIPE/TRAIN BRAKE PIPE ISOLATING COCK

LI

PL
UP

IN
CO

G
BP
SE

FP
HO
NG
HO

ANGLE COCK

S
I

ANGLE COCK
PL

EC
WITH VENT ISOLATING COCK
OU

WITH VENT

OU
EC

PL
AIR AUXILIARY
S

IN
HO

RESERVOIR CHECK

G
BP
VALVE

DISTRIBUTOR
VALVE KE-1

DRAIN COCK

BRAKE CYLINDER BRAKE CYLINDER

ISOLATING COCK ISOLATING COCK

WITH VENT WITH VENT

PASSENGER COACHES

DIRT
ANGLE COCK COLLECTOR ANGLE COCK
WITH VENT WITH VENT HO

DIRT
FP

COLLECTOR
NG

EC
LI

OU
UP

PL
CO

BP

IN
HO
E

ANGLE COCK
G
NG
S

ANGLE COCK
HO

FP
S

WITH VENT
LI

EC

WITH VENT
UP

OU
CO

PL
E

IN
S
HO

G
BP

AIR ISOLATING VALVE

RESERVOIR

DISTRIBUTOR CHECK
VALVE KE2 VALVE

BRAKE CYLINDER

LOAD SENSING DEVICE

REAR BRAKE LEVERAGE

CONNECTING ROD FRONT BRAKE LEVERAGE

BOGIE
CONTROL ROD
BOGIE
SLACK ADJUSTER

FREIGHT WAGON
TESTING EQUIPMENT & RIG
For testing, maintenance & overhauling of airbrake systems fitted on freight cars & passenger cars as
well as testing of complete rakes, Escorts manufactures various types of testing equipment like SWTR/
SCTR, RTR, DV test stand etc. Escorts has expertise in designing, developing and customizing test stands
as per customer’s requirement and specifications.

SINGLE CAR TEST RIGS (SWTR/SCTR) DISTRIBUTOR VALVE TEST STAND TEST STAN D FOR VARIOUS AIRBRAKE
ACCESSORIES
Suitable for testing air brake system for Suitable for testing KEO, KE1 & KE2 type
freight and passenger cars. of Distributor Valves or any other make Test Stands for various Air Brake
accessories like Hose Couplings,
• Test Stand with Digital pressure Centrifugal Dirt Collectors, Brake
RAKE TEST RIG (RTR) gauges interfaced with digital Cylinders, Emergency Brake Valves,
timers to record the various timings Angle Cocks, Pressure Reducing Valves,
Suitable for testing of Air Brake System • Test Stand interfaced with computer Check Valve, DV Test Bench with LSD.
for complete rake of freight/passenger so as to have the facility to record
stock. performance graphs for various tests
• Test Stand for various sub-
assemblies of DV like R- charger, GP
change-over, Relay Valve Pressure
Transformer, Control Chamber
BRAKE DISC
Brake disc is used in LHB Coaches of Indian Railways. It is mounted on the axle. When train need
to be stopped or decelerated, pressure is applied on the brake disc through brake pads. The brake
pads are on either side of the brake disc and will be operated through caliper.

SALIENT FEATURES

• It is self-ventilated so no additional requirement for

cooling of brake disc.
• It is mounted on the axle with the help of 12 bolts.
• The hub of the disc facilitates pressurized liquid assisted
assembly and disassembly.
• Velocity of 160Km/hr.
• Brake disc consists of friction ring with cooling ribs and
hub. The friction ring is casted as a single piece followed
by its machining on required surfaces
• The friction ring of brake disc has a groove around its
outside circumference to indicate the condemning limit
and when they have to be exchanged.
LOCO BRAKE UNIT (LBU)
Loco Brake Unit is a compact & modular braking system developed for use in locomotives.

Loco Brake Units are brake devices in which brake cylinder, lever transmission, slack adjusting mechanism,
parking brake and brake shoes are combined into a unit.

SALIENT FEATURES APPLICATION ADVANTAGES

• Compact in size • Locomotives • Brake shoe holder

• Inbuild automatic slack adjuster to • Metros • Brake Cylinder with Inbuilt automatic
maintain the proper gap between slack adjuster
brake block and wheel • Spring loaded Parking brake
• Provision for fitment of Double
brake shoe
• Having both service brake & parking
brake
• Easy Maintenance
• Better efficiency of braking due to
better utilisation of braking force
• No requirement of mechanical hand
brake, as spring loaded parking
brake is integral in LBU
• Easy Installation
• Light in weight

LBU- Service Brake LBU- Service with Parking Brake

Head Office & Works: Mumbai Branch: Chennai Branch: Kolkata Branch:
Plot No.114-115, Sector 24, Times Square, Unit No. A-1, M-3, “M” Block, 3rd Avenue, South Western Wing,
Faridabad - 121 005 A-Wing, 3rd floor, Anna Nagar East, 9th Floor, “AC Market”,
Haryana, India Andheri Kurla Road, Chennai - 600 102 1, Shakespeare Sarani,
Email: [email protected] Andheri East Tamil Nadu, India Kolkata - 700 071
Web: www.escortsgroup.com Sakinaka, Mumbai - 400 059 Email: [email protected] West Bengal, India
Tel.: 91-129-2516382, 6608 Maharashtra, India Tel.: +91-44-26287229 Email: [email protected]
Fax: 91-129-2232148 Email: [email protected] Fax: +91-44-26287341 Tel.: +91-33-22825191
Tel.: +91-22-24218159 Fax: +91-33-22814518
Fax: +91-22-24218153