Air Brake System Maintenance Manual for LHB Coaches

AIR BRAKE TESTING (Single Car) ANNEXURE - B

Coach no. Type Date of Testing

POH Date IOH Return Date
DV No. DV Make Bk. Equipment
WSP make

BP 5 ± 0.1 kg/cm2
Pressure FP Specified 6 ± 0.1 kg/cm2 Actual

Pre-Inspection: Please ensure that all the pipe fittings, brake equipments are
properly fitted and in place before starting of testing.

ITEM TEST SPECIFIED VALUE ACTUAL REMA

VALUE RKS
1.0 Reservoir Charging
1.1 Charging time of AR 175± 30 sec.(SAB)
(0 – 4.8 kg/cm2) 60 to 120 sec.(KB)
1.2 Charging time of CR (6.0 litre) 165±20 sec.(SAB)
( 0 – 4.8 kg/cm2) 160 to 210 sec.(KB)
1.3 BP Pressure 5.0±0.10 kg/cm2
1.4 CR Pressure 5.0±0.10 kg/cm2
1.5 FP Pressure 6.0±0.10 kg/cm2
2.0 Sealing test
(Allow the system to settle for 2 min.
after charging BP & FP. Observe the
rate of leakage.
2.1 BP (Less than 0.1 kg/cm2 in 5 minutes) BP<0.2 kg/cm2/minute
2.2 FP (Less than 0.1 kg/cm2 in 5 minutes) FP <0.2 kg/cm2/minute

3.0 Full Brake Application

3.1 Reduce BP from 5.0 to 3.4 kg/cm2 3 – 5 Sec.
3.2 Brake Accelerator should not respond Should not respond
3.3 Maximum BC pressure 3.0 ±0.1 kg/cm2
3.4 Leakage in BC Pressure within 5 <0.1 kg/cm2
3.5 minutes Applied
3.6 All brake cylinder are applied Red
Both side Brake indicators should show
Red
4.0 Release full Brake Application
4.1 Charge BP ( up to 5.0 kg/cm2) 5.0±0.1 kg/cm2
4.2 All brake cylinders are released Released
4.3 Both side Brake indicators should show Green
Green
5.0 Over Charge Protection
Check the overcharging of CR it should Less than
not be overcharged more than 0.1 0.1 kg/cm2 in 10 sec.
kg/cm2 in 10 second.
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 Maintenance Manual of LHB Air Brake

ITEM TEST SPECIFIED VALUE ACTUAL REMARKS

VALUE
6.0 Emergency Application
6.1 Reduce BP to 0 kg/cm2 0 kg/cm2
6.2 Brake accelerator should respond blast of air
6.3 Charging time of brake cylinder (0 – 3 – 5 Sec.
3.6 kg/cm2 )
6.4 Max. brake cylinder pressure 3.0 ± 0.1 kg/cm2
6.5 All Brake Cylinders applied Applied
6.6 Both side Brake indicator window Red
should show red
7.0 Release emergency Brake
application
7.1 BC release time (Maximum to 0.4 15 -20 Sec.
kg/cm2)
7.2 All Brake Cylinder released Released
7.3 Both side Brake indicator window Green
should show Green
8.0 Graduated brake application and
Release Brake should apply and
Graduated brake application and release corresponding
Release to decrease and
(Minimum 7 steps) increase of BP Pressure
9.0 Test for Pressure switch for Anti
skid device
9.1 Charge the Feed pipe/Brake Ok
9.2 pipe* pressure Ok
Anti skid device get power supply at
9.3 1.8±0.2 kg/cm2 Ok
Anti skid device get power supply off
at 1.3±0.2 kg/cm2

* For SAB - FP & For KB - BP.

10.0 Isolation Test
10.1 Close the isolating cocks for Bogie –1 Brake should
&2 not applied
10.2 Reduce BP pressure to full brake Green
application ( Brake should not apply) Brake apply
10.3 Both side Brake indicators shows
Green
10.4 Open both isolating cock (Brake should Red
apply corresponding to opening of Brake will Release
isolating cock for bogies)
10.5 Both side Brake indicators shows Red Green
10.6 Again close the Isolating cock of bogie
1&2 one by one.
10.7 Both side Brake indicators of bogie
1&2 shows Green one by one.

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ITEM TEST SPECIFIED VALUE ACTUAL REMARKS

VALUE
11.0 Sensitivity Test
11.1 Reduce the BP pressure at the rate of Brake should applied
0.6kg/cm2 in 6 second. within 6 second
12.0 Insensitivity Test Brake should not
12.1 Exhaust BP pressure at the rate of 0.3 applied
kg/cm2 Per minute
13.0 Passenger Emergency Pull Box
13.1 testing
Pull the emergency pull box handle & BP pressure should
check remain 2.0±0.2 kg/cm2
13.2 Brake accelerator does respond. should respond
13.3 BP Pressure exhaust from emergency Yes
Brake valve
13.4 Indicator Lamp on out side coach Yes
13.5 glowing Red
13.6 Both side Brake indicators shows Red Should stop
After resetting, exhaust from
13.7 emergency Brake valve is stopped Green
Both side Brake indicators shows
Green
14.0 Hand Brake test (Power car only)
14.1 Apply hand brake by means of wheel OK
14.2 Both side Hand Brake indicators shows Red
Red
14.3 Brake Cylinders provided with hand Applied
brake lever are applied
14.4 Movement of flex ball cable is proper Yes
14.5 Release hand brake by means of wheel Ok
14.6 Brake should release Releases
14.7 Both side Hand Brake indicators shows Green
Green
15.0 Emergency brake by guard van
valve (Power car only)
15.1 Drop BP Pressure by means of guard Brake Apply
valve (Brake Should apply)
15.2 Brake accelerator should respond Blast of air
15.3 Both side Brake indicators shows Red OK
& Hand Brake indicators shows Green
15.4 Reset guard van valve Releases
( Brake should release)
16.0 Manual release test
Apply full brake application and pull CR Drops to zero,
manual release wire of DV, it should Brake releases
be released in one brief pull of Manual
release valve.
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 Maintenance Manual of LHB Air Brake

ITEM TEST SPECIFIED VALUE ACTUAL REMARKS

VALUE
17.0 WSP test
17.1 Check all Speed sensor air gap between 0.9 to 1.4 mm
sensor and Phonic wheel by means of
filler gauge.
17.2 Charge the BP/FP Pressure at full 1.8±0.2 kg/cm2
specified value.
Check the WSP Micro Processor
17.3 Activated
activated
17.4 OK
Check the WSP Micro Processor
showing code 99.
17.5 Check the Dump Valve venting by test Venting one by one in
mode proper sequence

18.0 Clearance between brake disc & 1.5 mm

brake pad

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