Air Brake System Classification and Components
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Questions and Answers

What are the two classifications of air brake systems based on the type of release?

  • Direct and Graduated (correct)
  • Forward and Reverse
  • Single and Twin
  • Automatic and Manual

Which of the following components is NOT part of a single pipe graduated release air brake system?

  • Brake cylinder
  • Pressure gauges
  • Distributor valve
  • Speedometer (correct)

What is the role of the auxiliary reservoir in the single pipe graduated release air brake system?

  • To house the isolating cock
  • To collect dirt particles
  • To measure system pressure
  • To charge through the distributor valve (correct)

In a single pipe graduated release air brake system, which angle cocks are generally kept open?

<p>Only the front and last vehicle angle cocks (D)</p> Signup and view all the answers

Which of the following is a feature of the recently introduced Bogie mounted Brake System (BMBS)?

<p>It is detailed in Para 729 of this chapter (D)</p> Signup and view all the answers

At what pressure is the auxiliary reservoir charged through the distributor valve in a single pipe graduated release air brake system?

<p>5.0 kg/cm2 (C)</p> Signup and view all the answers

What is the purpose of the compressed payout spring in the slack adjuster mechanism?

<p>To push the adjuster nut under rotation (B)</p> Signup and view all the answers

Which tool is specifically designed for the maintenance of slack adjusters?

<p>Jacking tool (C)</p> Signup and view all the answers

What is the diameter of the brake cylinder used in the single pipe graduated release air brake system?

<p>300 mm and 355 mm (D)</p> Signup and view all the answers

At what point should the slack adjuster be overhauled?

<p>At the time of POH of rolling stock (B)</p> Signup and view all the answers

Which tool is not required for the overhauling of slack adjuster?

<p>Electric drill (B)</p> Signup and view all the answers

What should be done with worn out parts during the maintenance of the slack adjuster?

<p>Check according to specified limits (B)</p> Signup and view all the answers

What is the first step in the procedure for testing the hose coupling?

<p>Use a dummy coupling head to block the outlet port. (B)</p> Signup and view all the answers

After adjusting the pressure gauge to 10Kg/cm2, what is the next step?

<p>Open isolating cock 1(b) and check gauge 6b. (B)</p> Signup and view all the answers

What should be done if leakage is observed after changing the gasket on the coupling head?

<p>Replace the entire coupling assembly. (A)</p> Signup and view all the answers

Which safety precaution should be taken before charging the testing system to 10Kg/cm2?

<p>Cover and lock the tube with a protective cage. (B)</p> Signup and view all the answers

What must be done after testing the hose assembly?

<p>Store it in a dry and clean space. (D)</p> Signup and view all the answers

What should be checked using gauge 6b after opening isolating cock 1(b)?

<p>The pressure displayed, which should show 10Kg/cm2. (D)</p> Signup and view all the answers

If leakage occurs at the hose nipple, what step should be taken?

<p>Check and replace the clamp. (B)</p> Signup and view all the answers

Which of the following is NOT a safety precaution listed for testing the hose coupling?

<p>Always test with a protective rubber cover. (A)</p> Signup and view all the answers

What could indicate that the coupling head is unserviceable?

<p>Water leaks through the coupling head after a gasket change. (A)</p> Signup and view all the answers

What is the purpose of incorporating a push rod in the piston sub assembly?

<p>To accommodate minor variations in alignment during fitment and operation (A)</p> Signup and view all the answers

Which tool is NOT mentioned as necessary for overhauling the brake cylinder?

<p>Adjustable Wrench 10-15 mm (B)</p> Signup and view all the answers

What is the main reason for thoroughly overhauling the brake cylinder?

<p>To ensure efficient and reliable performance throughout its service life (C)</p> Signup and view all the answers

What should be done before dismantling the dome cover of the brake cylinder?

<p>Insert a rounded head pin to secure the piston trunk (A)</p> Signup and view all the answers

During the dismantling process, which component is removed first?

<p>Return spring (C)</p> Signup and view all the answers

What is the function of the special fixture during the dismantling of the brake cylinder?

<p>To clamp the dome cover securely (B)</p> Signup and view all the answers

Which part is separated from the piston rod during the unscrewing process?

<p>Piston ring packing (C)</p> Signup and view all the answers

Which of the following is a characteristic of the brake cylinder described in the content?

<p>It must conform to specific dimension tolerances (C)</p> Signup and view all the answers

What sequence occurs after the dome cover is unclamped?

<p>Allow the return spring to expand fully (C)</p> Signup and view all the answers

Which tool would be used for unscrewing the hexagonal head nut on the dome cover?

<p>Double End Spanner across face 13x14 (B)</p> Signup and view all the answers

What should be done if a ball of the valve has dents or scratch marks?

<p>It should be replaced with a new one. (A)</p> Signup and view all the answers

Which component is placed in its position in the bore of the body before inserting the ball?

<p>Seat ring (B)</p> Signup and view all the answers

What pressure is the inlet port charged with during the testing of the guard's emergency brake valve?

<p>10 Kg/cm2 (D)</p> Signup and view all the answers

What is the purpose of the slack adjuster in the brake rigging?

<p>To automatically adjust the clearance between brake blocks and wheel. (D)</p> Signup and view all the answers

What is the first step after overhauling and fixing the valve to the test bench?

<p>Put the handle of the valve in the off position. (C)</p> Signup and view all the answers

What is tested during the assembly of the quick coupling arrangement?

<p>Leak-proof integrity up to 10 kg/cm2 air pressure. (D)</p> Signup and view all the answers

Which of the following components is not mentioned in the details of part numbers for the quick coupling arrangement?

<p>Threaded plug (D)</p> Signup and view all the answers

What must be used to ensure that the gland is secured to the valve body?

<p>A spring washer and nut (B)</p> Signup and view all the answers

What happens when the handle of the guard's emergency brake valve is moved to the open position?

<p>Air escapes through the vent of the valve. (A)</p> Signup and view all the answers

What type of adjustment does the slack adjuster perform in the braking system?

<p>Automatic adjustment. (D)</p> Signup and view all the answers

What is the maximum allowable leakage in the brake system per minute?

<p>0.25 kg/cm2 (C)</p> Signup and view all the answers

In what position should the handle of the isolating cock be when it is open?

<p>Vertical down (D)</p> Signup and view all the answers

What should be ensured regarding the feed pipe hose coupling in a train?

<p>It should form a continuous passage from locomotive to last vehicle. (D)</p> Signup and view all the answers

Which of the following is prohibited regarding the angle cocks in a train?

<p>Closing them for wagon isolation under any circumstance (C)</p> Signup and view all the answers

What must be ensured about the feed pipe pressure in the locomotive and brake van before a train leaves?

<p>It must be equal to or greater than 5.8 kg/cm2 (A)</p> Signup and view all the answers

What is the consequence of allowing a feed pipe to connect to the brake pipe?

<p>It can cause failure of the brake system. (A)</p> Signup and view all the answers

Which item is specifically mentioned for the quick coupling arrangement?

<p>Air brake hose coupling (C)</p> Signup and view all the answers

What feature distinguishes the construction of the auxiliary reservoir in the air brake system?

<p>Cylindrical shape made of sheet metal with flanges for connections (A)</p> Signup and view all the answers

Which of the following steps is NOT part of the cleaning procedure for the auxiliary reservoir?

<p>Applying high-pressure steam cleaning to the interior (C)</p> Signup and view all the answers

What must be replaced if the threads of the drain plug in the auxiliary reservoir are damaged?

<p>The drain plug itself (A)</p> Signup and view all the answers

What specific task is required before the auxiliary reservoir is charged with air?

<p>Unscrewing the drain plug to remove water (B)</p> Signup and view all the answers

During maintenance, what should be done if pitting or rusting is observed on the auxiliary reservoir?

<p>Use a wire brush to clean the affected area (C)</p> Signup and view all the answers

What is the first action to be taken when testing the hose coupling?

<p>Connect the hose coupling to the flexible hose. (A)</p> Signup and view all the answers

After adjusting the pressure gauge to 10Kg/cm2, which step is taken next?

<p>Immerse the assembly in water. (D)</p> Signup and view all the answers

What should be done if there is leakage observed after changing the gasket on the coupling head?

<p>Replace the entire hose assembly. (A)</p> Signup and view all the answers

Which safety precaution must be taken before charging the testing system to 10Kg/cm2?

<p>Cover and lock the tube with a cage. (B)</p> Signup and view all the answers

If leakage occurs at the hose nipple or coupling end hose joint, what is the appropriate response?

<p>Attend to or replace the clamp. (B)</p> Signup and view all the answers

What should be included in the storage process of the hose assembly after testing?

<p>Store it in a dry and clean space. (C)</p> Signup and view all the answers

What is indicated by a failure of the coupling head to stop leakage even after a gasket replacement?

<p>The coupling head may be unserviceable. (D)</p> Signup and view all the answers

Which step directly follows the observation of leakage from the testing procedure?

<p>Close isolating cock 1(b). (B)</p> Signup and view all the answers

What must be done to the inlet and outlet ports after testing the hose assembly?

<p>Plug them with protective caps. (C)</p> Signup and view all the answers

What is the purpose of the pressure reducing valve in the brake cylinder test bench?

<p>To limit the pressure supplied to the brake cylinder. (B)</p> Signup and view all the answers

During the strength test, what pressure should be achieved in the pressure gauge after opening cock (2)?

<p>6 Kg/cm2 (C)</p> Signup and view all the answers

What is the first step required to check for air leaks over the body and joints?

<p>Use a soap solution to check for leaks (A)</p> Signup and view all the answers

Which tool is recommended for adjusting torque when working on brake cylinder components?

<p>Torque wrench (2-3 kgM) (A)</p> Signup and view all the answers

What is the significance of waiting for 2 minutes after closing cock (2) during the strength test?

<p>To ensure the pressure stabilizes and leaks can be detected. (C)</p> Signup and view all the answers

What action should be taken immediately after reducing the pressure in the main reservoir to 5 kg/cm2?

<p>Close cock (1f) (A)</p> Signup and view all the answers

What does the safety guard do during the testing of the brake cylinder?

<p>It protects operators from high-pressure failures. (B)</p> Signup and view all the answers

Which condition indicates that the filter is choked during the pressure check?

<p>No air flowing from the outlet port (D)</p> Signup and view all the answers

How is the brake cylinder stroke adjusted before conducting tests?

<p>Set at 85 + 10 mm. (B)</p> Signup and view all the answers

What should be done to prevent damage to the flange surface during maintenance?

<p>Use protective caps for inlet and outlet ports (B)</p> Signup and view all the answers

What is a recommended practice for handling small metal parts during maintenance?

<p>Keep them in a secured place (D)</p> Signup and view all the answers

What component is essential to ensure the brake cylinder operates correctly during testing?

<p>Air reservoir. (D)</p> Signup and view all the answers

During the testing process, what should be monitored for a duration of three minutes?

<p>Pressure drop in gauge 6c (C)</p> Signup and view all the answers

Which procedure is essential before dismantling the brake cylinder?

<p>Draining any residual air pressure. (C)</p> Signup and view all the answers

What is the purpose of checking the free flow of air from the outlet port?

<p>To ensure the filter is functioning properly (C)</p> Signup and view all the answers

What action should be taken if leakage is observed during the pressure tightness test?

<p>Tighten all bolts and fittings, then retest. (D)</p> Signup and view all the answers

Which component must be connected to the brake cylinder for it to function correctly on the test bench?

<p>An air supply line. (A)</p> Signup and view all the answers

What should be done if a gauge shows an unexpected pressure drop during testing?

<p>Inspect for possible leaks or blockages (A)</p> Signup and view all the answers

What is the necessary step after removing the dummy flange from the outlet port?

<p>Check the flow and quality of air (D)</p> Signup and view all the answers

What happens if the assembled dirt collector is not stored appropriately?

<p>The parts may become misaligned or damaged (C)</p> Signup and view all the answers

Flashcards

Air Brake System Classification

Air brake systems are categorized by release type (direct or graduated) and pipe configuration (single or twin pipe).

Single Pipe Graduated Release

A type of air brake system where all brake pipes are connected, and release happens gradually.

Distributor Valve

A component in the air brake system that controls the air pressure distribution to the brakes.

Auxiliary Reservoir

A reservoir that stores compressed air for the air brake system.

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Brake Pipe

A pipe that connects the air brake systems of all wagons in a train.

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Cut-off Angle Cock

A valve that controls the flow of air into or out of the brake pipes.

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Bogie Mounted Brake System (BMBS)

A type of air brake system mounted on the bogies (truck) of freight cars.

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Hose Coupling Testing Steps

A procedure for examining hose couplings to ensure they are leak-free under pressure.

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Dummy Coupling Head

A temporary fitting used to block the outlet port of a hose coupling during testing.

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10 kg/cm2 Pressure

The specific air pressure used for testing hose couplings.

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Water Immersion

Completely submerging the hose coupling assembly in water during testing.

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Leakage Observation

Checking for leaks from all parts of the hose coupling.

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Gasket Replacement

Action to take if leakage is found in the coupling head during testing.

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Hose Coupling Rejection

Rejecting the entire hose coupling assembly if leakage persists even after gasket replacement.

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Clamp Replacement

Action to repair leakages observed at the hose nipple or coupling end hose joint.

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Safety Precautions for Testing

Important steps to ensure safety while testing the hose coupling.

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Piston Sub-Assembly

Part of a brake system that includes a push rod, allowing for slight adjustments in alignment.

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Brake Cylinder Overhaul

Complete inspection and repair of the brake cylinder for improved performance over its lifetime.

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Torque Wrench (0-3 kg)

A tool to apply precise turning force up to 3 kilograms for tightening specific parts during brake cylinder overhaul.

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Double End Spanner (24x27mm)

A spanner with two wrenching ends for fastening nuts and bolts, specifically with a 24x27mm measurement.

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Dome Cover Removal

The process of disassembling the brake cylinder cover, including steps to prevent damage to piston rod from the return spring.

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Special Fixture

A specialized device for safely holding and manipulating parts of the brake cylinder.

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Brake Cylinder Plug

A plug located at the rear of the brake cylinder that needs to be unscrewed.

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Piston Rod Sub-Assembly Removal

The step of removing the piston rod sub-assembly along with associated components from the brake cylinder.

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Return Spring

A spring within the brake cylinder that helps return parts to their initial position.

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Safety Pin (12x25)

An important pin of 12x25mm length for added safety during brake cylinder disassembly to prevent the dome cover from being ejected by the cylinder return spring when opening.

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Valve Ball Replacement

If a valve ball has damage (dents/scratches), it must be replaced.

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Seat Ring Placement

Place the seat ring in the valve body bore.

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"O" Rings on Spindle

Install "O" rings onto the spindle before insertion.

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Ball Insertion

Insert the ball into the body bore, properly seated on the ring and groove.

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Gland and Second Ring

Screw the gland into the body and insert the second seat ring.

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Threaded Plug Installation

Secure the threaded plug with "O" ring and tool until the ball seat touches the ball

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Emergency Brake Valve Testing

Testing the valve involves checking for leaks and air flow.

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Quick Coupling

Quick coupling assembly components, like plug and valve are leak-proof.

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Slack Adjuster Function

Adjusts clearance automatically between brake blocks and wheels.

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Slack Adjuster Location

Fitted into the brake rigging/mechanical pull rod.

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Slack Adjuster Payout

The process where the slack adjuster spring expands, pushing the adjuster nut to adjust the slack in the train's brakes.

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Slack Adjuster Maintenance Tools

The specific tools needed for inspecting and repairing a slack adjuster, like a jacking tool, special spanners, and pliers.

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Slack Adjuster Overhaul Procedure

The step-by-step process for inspecting and repairing a slack adjuster, including examining components, replacing worn parts, and adhering to technical specifications.

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Slack Adjuster Test Bench

A specialized apparatus used for testing the functionality of a slack adjuster; often during maintenance or repair.

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POH of rolling stock

Periodic Overhaul of rolling stock, critical to maintain and repair functionalities of the wagon components.

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Brake pipe/feed pipe angle cocks

Valves controlling the flow of air in brake and feed pipes.

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Isolate wagons

To disconnect a wagon from the train's brake system.

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Feed pipe isolating cock

Valve to isolate a wagon's feed pipe from the main system.

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Feed pipe pressure

Pressure in the feed pipe, crucial for brake system function.

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Continuous feed pipe passage

Uninterrupted connection of feed pipe from locomotive to last wagon.

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Leakage limit

Maximum acceptable air loss from brake system per minute (0.25 kg/cm2).

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Single pipe coupling

A prohibited coupling method in twin pipe systems.

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Hose Coupling Testing Steps

A procedure to ensure hose couplings are leak-proof under pressure.

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Dummy Coupling Head

A temporary fitting to block the hose coupling outlet during testing.

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10 kg/cm2 Pressure

The air pressure used to test hose couplings.

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Water Immersion

Completely submerging the hose coupling in water.

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Leakage Observation

Checking for leaks from all parts of a hose coupling.

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Gasket Replacement

Replacing a gasket if a leak is found in the coupling head.

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Hose Coupling Rejection

Rejecting the entire hose coupling if leaks persist after gasket change.

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Safety Precautions for Testing

Steps to ensure safety while testing hose couplings.

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Clamp Replacement

Replacing the clamp if leaks are found at the hose nipple or coupling end.

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HD bolt torque

Using a specified amount of tightening force (torque) when attaching a high-duty (HD) bolt.

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Brake Cylinder Test Bench

Equipment used to test brake cylinders, consisting of isolating cocks, pressure gauges, and an air reservoir.

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Strength Test (Brake Cylinder)

A test to assess the brake cylinder's structural integrity by filling it with air pressure and observing for leaks.

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Pressure Tightness Test

A test to verify a brake cylinder's ability to maintain pressure, ensuring no leaks.

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Brake Cylinder Mounting Bolt Torque

Specific torque values to apply when securing a brake cylinder onto its mounting base.

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10 kg/cm2 pressure

A specific air pressure used as a reference point for testing the brake cylinder.

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Brake Cylinder Stroke

The movement of the piston within the brake cylinder, a critical value for measurement.

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Isolating cock

A valve used to temporarily stop the flow of air in a pipe.

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Pressure reducing valve

A component used to control the air pressure supplied to the system.

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Safety guard function

An essential measure for preventing harm during brake cylinder tests. The guard blocks hazards.

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Auxiliary Reservoir Function

Provides compressed air to brake cylinders for brake application.

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Auxiliary Reservoir Construction

Cylindrical sheet metal vessel with flanges for pipe connections.

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Auxiliary Reservoir Drainage

Drains condensate/moisture via a drain plug at the bottom.

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Auxiliary Reservoir Charging

Charged to 5kg/cm2 through the brake pipe and distributor valve.

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Auxiliary Reservoir Maintenance - Dismantling

Unscrew the drain plug and drain accumulated water before cleaning the reservoir.

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Leak Check

Inspecting the wagon for leaks in body and joints using soap solution; no leaks are allowed.

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Pressure Gauge 6(c)

Monitoring pressure drop for 3 minutes; pressure should be maintained.

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Main Reservoir Pressure

Reducing pressure in the main reservoir (5) to 5 kg/cm2.

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Cock (1f)

Adjust and close cock (1f) when reservoir pressure reaches 5 kg/cm2.

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Dummy Flange Removal

Removing the dummy flange from the outlet port.

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Air Flow Check

Evaluating air flow from outlet port; choked filter indicated by no flow.

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Dirt Collector Removal

Removing the dirt collector from the test stand.

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Safety Precautions

Measures to prevent damage, moisture entry, and safe handling of the assembled dirt collector.

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Pressure Regulator

The component used to control the pressure of a system.

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Outlet Port

The port where air exits the system.

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Study Notes

Air Brake System Classification

  • Air brake systems are classified based on release type as direct release or graduated release.
  • Both systems come in single pipe and twin pipe forms.

Air Brake System Components (Single Pipe Graduated Release)

  • Distributor valve
  • Common pipe bracket with control reservoir
  • Auxiliary reservoir (100 Litres or 75 Litres)
  • Three-way centrifugal dirt collector
  • Isolating cock
  • Brake cylinder (355mm or 300mm diameter)
  • Cut-off angle cock (32mm size)
  • Air brake hose coupling (32mm)
  • Brake pipe / feed pipe (32mm diameter)
  • Branch pipes from BP to brake equipment (20mm bore)
  • Guard emergency brake valve
  • Pressure gauges for BP
  • Quick Coupling

Principle of Operation of Single Pipe Graduated Release Air Brake System

  • Brake pipes of all wagons are connected.
  • All cut-off angle cocks are open except for the front and rear wagons.
  • Isolating cocks are open.
  • Auxiliary reservoir is charged to 5.0 kg/cm² through the distributor valve.

Bogie Mounted Brake System (BMBS)

  • A recently introduced system for freight stock.
  • Details are in paragraph 729 of chapter 7.

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Related Documents

CnW maintenance manual-232-382 PDF

Description

This quiz covers the classification of air brake systems based on release types, focusing on direct and graduated release systems. It also delves into the various components involved in the single pipe graduated release air brake system and its operational principles.

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