SUB-DISCIPLINE: PNEUMATICS (LESSONS: 05 SESSIONS: 08)

Lesson-I: Pneumatic Symbols, Session-01: Pneumatic Symbols And Application Of Air On

Track Machines

PNEUMATIC SYSTEM:-The word pneumatic has been derived from Greek word. Which
refers to flow of air and now a days it includes flow of any gas. In a system under pressure.
The pneumatic power is used in industry, workshop and machine to perform various jobs.
Broadly speaking the pneumatic power is covered under the heading fluid power. One of which
is hydraulic which utilizes water or oil for power transmission and other is pneumatic system
that uses gas or compressed air for transmitting the force. On track machine we are concerned
with the compressed air for pneumatic system. The most common source of pneumatic is
compressor which is responsible for developing compressed air and its utilization for various
purposes on machine.

PNEUMATIC SYMBOLS:

HY-1
 Compressor

HY-2
HY-3
HY-4
HY-5
”

HY-6
HY-7
HY-8
APPLICATION OF PNEUMATIC POWER:-

1. Application of brakes.
2. Locking & unlocking of tamping unit, lifting unit, bogies.
3. Lifting and lowering of different bogies.
4. Clapper cylinder.
5. Pneumatic horn.
6. Lubricating system.
7. Application of datum.
8. Wiper.
9. Tightening of leveling chord / lining chord.
10. Filling the diesel tank.
11. Spray painting.
12. Engaging / disengage pinion to satellite gear.
13. Engaging / disengage the dog clutch
for work drive in CSM /UNIMAT.
14. Engine rpm acceleration/deceleration

HY-9
 Rear datum
Brake pipe for
cyl.
HY-10 coach
 Rear datum
cyl.

Lifting unit Satellite brake

lock/unlock cyl.
cyl.

HY-11
 SUB-DISCIPLINE: PNEUMATICS (LESSONS: 05 SESSIONS: 08)
Lesson-II: Pneumatic Components, Session-02: Working And Maintenance Of Single Stage
And Multi Stage Air Compressor, Cooling Coil, Safety Valve, Air Dryer

AIR COMPRESSOR: Compressor is a machine which converts air at atmospheric pressure

into high pressure by changing its volume. There are two types of compressor

HY-12
 Air
compressor

Air tank

1). Reciprocating Compressor.

2). Rotary compressor.

Compressor can be driven by an electric motor or by a diesel/ petrol engine, which serves as a
prime mover to the pneumatic power unit.

Reciprocating compressor:-A reciprocating compressor can be single or multiple piston

compressors. The more the number of piston in a compressor. the more powerful a compressor
is. The multi piston cylinder block of a compressor has crank shaft having same number of
crank connection has the number of piston and cylinder in it. The crank shaft is connected to
the prime mover .With each cylinder. there are two ports known as inlet and exhaust port
depending on their functions. The compressor unit is provided with a sump for storing the oil
in it for lubricating and cooling of various components of compressor assembly.

When the crank shaft of compressor rotates and the piston of air compressor takes an inward
stroke, atmospheric pressure being higher than the pressure in the compressor cylinder, the
flow of air takes place through the inlet port when the crank rotates further and piston moves
forward stroke, the inlet valve closes and exhaust port opens thus sending the compressed air
HY-13
to the system/ air container ( air tank ). The compressor reduces the volume of air thereby
increasing its pressure.

If the compressor is a multi stage, one piston sends compressed air to another cylinder and thus
to tank. The capacity of a compressor is depending upon the number of cylinder in it. The term
single or multistage depends upon the no. of stages or steps that a reciprocating compressor
uses to compress air to its final pressure. Single stage compressors are more economical for a
pressure below 100 psi but for higher operating pressure multistage compressors are more
beneficial.

The capacity of a compressor is defined as volume of air displaced per minute. In FPS ( Foot
pound system ) is denoted by CFM ( Cubic ft min ) and in M.K.S is LPM (Liter per min ).

COOLING COIL:-

As the compressed air has get its temperature risen due to compression, the temperature
has to be brought down. This is done by cooling coil which is a helical copper tube by which
the cooling coil comes in contact with atmospheric air and therefore the compressed air inside
the cooling coil cools down.

Air
Cooling coil
unloader

PRESSURE LIMITING VALVE:

The pressure limiting valves are used mainly as safety valves (pressure relief valves). They
prevent the maximum permissible pressure in a system from being exceeded. If the maximum
pressure has been reached at the valve inlet, the valve outlet is opened and the excess air
pressure exhausts to atmosphere. The valve remains open until it is closed by the built-in spring
after reaching the preset system pressure.
AIR DRYER:-
Condensate (water) enters into the air network through the air intake of the compressor.
The accumulation of condensate depends largely on the relative air humidity. The relative air
humidity is dependent on the air temperature & the weather condition.
The service life of pneumatic system is considerably reduced if excessive moisture is carried
through the air system to the components. Therefore it is important to fit the necessary air
drying equipment to reduce the moisture content to a level which suits the application & the
components used.
Drying of the compressed air is a achieved by leading the air flow from compressor through a
desiccant granulate (Means of absorption). The granules are of reticulate molecular structure,
thus achieving an active surface being large enough to absorb the moisture out of the air. The
HY-14
drying agent is a granular material (gel) consisting almost of silicon dioxide.

HY-15
 SUB-DISCIPLINE: PNEUMATICS (LESSONS: 05 SESSIONS: 08)
Lesson-II: Pneumatic Components, Session-03: Working And Maintenance Of Water
Separator, Air Oiler, DC Valve, Cylinder And Pneumatic Hoses

WATER SEPERATOR:

HY-16
 The presence of moisture results in the following types of after effects on the pneumatic
components and the system is badly affected.
1. Rusting & corrosion.
2. Formation of emulsion.
3. Reduction in lubricating property of oil.
4. Choking of small orifices, valves and system.
So it is imperative that the moisture from the air is removed to avoid crippling of the system.

The first step in process of compressed air after pressure regulation is its filtration or
removal of moisture contents which is harmful not only that it may result in rusting but also it
may form emulsion with lubricating oil which will block the pneumatic assemblies. The air
under pressure enters through inlet of a specially designed water separator having provision for
baffle and quite zone. The water droplets are thrown from air stream by virtue of their
centrifugal force when they strike the deflector with louvers at the entrance. The water collected
at the bottom of quite zone is drained out through the drain tap provided at the bottom or by
removing the transparent bowl container.

Drip cup

AIR OILER:
There are certain pneumatic tools and equipments which require lubricated air to reduce
wear and corrosion and there are certain other components which do not tolerate oil in the air
stream. The importance of lubrication can be well imagined as it not only decreases friction but
also prevent corrosion of pneumatic assemblies and simultaneously increases the efficiency.
There are two types:

HY-17
1. OIL FOG LUBRICATOR:

It has a transparent bowl which is filled with oil according to consumption. It has a
siphon tube dipping in it which open upon a needle valve. When the air under pressure passes
through the venturi section, it is atomized and causes the flow of oil in the form of oil fog (1
drop/10 cu. ft/min) which lubricates the parts through which it passes.

2. CONSTANT DENSITY LUBRICATOR:

It is very simple in construction. A transparent bowl serves as an oil container in which

dips the lower end of the siphon pipe having filter attached to its bottom. Air under pressure
enters from inlet pore to the container and keeps the oil under constant pressure (regulated by
pressure regulator).

D.C. VALVES:

Direction control valves used in pneumatic system are similar to those used in hydraulics. Their
primary function is to direct flow of air from one place to another in the system. DC valves are
devices which influence the path taken by an air stream. Normally this involves one or all of
the following:

⮚ Opening the passage of air and directing it to particular air lines.

⮚ Canceling air signals as required by blocking their passage.
⮚ Relieving the air to atmosphere via an exhaust port.

DC valve is characterized by its number of controlled connections or ways, the number of

switching positions and the method of actuation.

2-way, 2 position valve:

HY-18
3 way, 2 position valve:

4 way, 2 position valve:

4 way, 3 position valve:

HY-19
5 way, 3 position valve:

Schematic symbols for actuating D. C. Valves:

HY-20
AIR RECEIVER/CONTAINER:

Before discussing an air receiver, let us be clear in mind that unlike liquids (which are
virtually imcompressible) is readily co9mpressible. That is why a large quantity of air can be
stored in a comparatively smaller vessel or container. The more the air in a container, the
higher is the pressure and stronger should be the container to with stand that pressure.

CYLINDERS:

A pneumatic cylinder converse compressed air pressure into mechanical linear force.
When the compressed air enters on of the ports of the cylinder, it transmits movements to the
piston and its rods and becomes mechanical force to do some work. The flow rate of the
pneumatic power determines the piston speed and output in horse power.

PIPING, HOSES AND FITTINGS:

HY-21
 Piping is an important part of pneumatic system. It is not only to transmit the pneumatic
power to various components, but also to keep it clean and free from contaminants. The pipes
utilized on the machines should be flexible and strong enough to withstand the working
pressure of the system.
As a thumb rule, the testing pressure of a pipe should be double that of working pressure
and bursting pressure double that of the testing pressure.
The working pneumatic pressure on track machine varies between 6.5 – 7.0 kg/cm2.
The inside diameter of pneumatic pipe is 6.3 mm and 12.6 mm are used for general
transmission and brake system of the machine.

Fitting:

HY-22
SUB-DISCIPLINE: PNEUMATICS (LESSONS: 05 SESSIONS: 08)
Lesson-III: Pneumatic Circuits, Session-04: Pneumatic Working Circuits

Lesson-III: Pneumatic Circuits, Session-05: Pneumatic Brake Circuits

Air compressor, run by engine crankshaft, supplies compressed air to brakes and working
pneumatic system. Pneumatic pressure, in the above, is regulated by means of pressure regulator.
Due to compression of air in air compressor, temperature & pressure of air increases. The
compressed air is made to flow through cooling coil, which is helical copper tube, where air cools
down. This then passes through the drip trays for separating the moisture of the compressed air.
The excess air pressure is controlled by safety valve through which excess air is released to
atmosphere. The main stream of air flows to air dryer which dehumidifies the air by means of a
granulate. After which air flows to air-reservoirs. Upon filling up of one reservoir, pressurized air
opens the overflow valve, which is set at 3.8 bar & then the air fills up the other tank.
(a) For Braking System: From air tank, air reaches the pressure reducing valve where
pressure is reduced to approx 4 bar (brake pressure). A dual pressure gauge is provided
which shows both the pneumatic working pressure (7 bar) by white pointer & brake
pressure (4 bar) by red pointer. On operation of brake valve this pneumatic brake
pressure moves the brake cylinders, which is a spring loaded single acting cylinder for
application of brake.

(b) For Pneumatic working System: From air tank, air passes through water separator
which is provided in the outlet line of air reservoir. This removes the moisture from
the air. Now dry air passes to air oiler where lubricating oil is filled for lubrication of
air. Lubricated air then flows to solenoid operated D.C. valves & actuators for working
pneumatic system.

HY-23
 Air
dryer
Coolin
Air g Coil Pressu Safety
re Valve Air Water Air D.C. Working
Compresso
r regulat Tan Separat Oile Valve System
k or r
Air
Filter Dri
p To Pressur
Cu Atmospher e
p e reducin
g valve

Brake
valve

Brake
Cylinder

PNEUMATIC WORKING AND BRAKING SYSTEM – FLOW CHART

HY-24
Brief description and checks to be carried out :

1. Pneumatic: Check to make sure it is connected properly. The connection to the pneumatic
power may be ascertained by reading the pneumatic pressure in the pressure gauge. In case of
low pressure the lines and the brake system should be checked for leakages.
2. For new or recently overhauled circuit : It is possible in a to find components with
blockages in the flow path which should also be checked.
3. Check Connections: of all control valves for their proper connection.
4. Air Filter: Should be cleaned/replaced periodically as per schedule.
5. Air compressor: Lube oil level should be checked. Compressor fins should be cleaned by
compressed air.
6. Cooling Coil: This should be checked for leakages. Cooling coil may get punctured.It may
leak at the ferrules & joints. Repair or replace accordingly.
7. Drip Cup: This should be regularly emptied out by opening the drain valve protect the air
dryer from contamination & should be closed after completion of drain.
8.Pressure Regulator: If required pressure is not proper, check the lines & pressure regulator.
If lines are OK, then readjust the pressure regulator. If pressure is still not proper,then dismantle
the pressure regulator. Clean it, check visually the parts & replace if required.
9.Safety Valve: If pressure is not proper, check the lines &. If lines are OK, then readjust
the safety valve. If pressure is still not proper, then dismantle the safety valve. Clean it, check
visually the parts & replace if required.
10.Air Dryer: The preliminary filter to the air dryer should be checked regularly for free
passage & replaced if required. To avoid damage to the pneumatic components the air dryer
has to be checked periodically. The filter cartridges (90187-65) and the granule cartridges (432
406 9202) have to be replaced every 500hrs of operation, at the least, however once a year.
11.Air Tank: Air tanks should be drained after the days work or stoppage for a longer period
of time. These should be done by actuating the drainage valve.
12.Water Separator: Water separator should be functional. If manually operated water
separator is provided, it should be drained out regularly particularly when humidity in
atmosphere is high.
13.Air Oiler: This should be functional. Top up with lubricating oil daily/as per schedule.
14.D. C. Valve: Contamination or improper lubrication are the most common cause for valves
sticking and become inoperative. Any internal/external leakage shall be attended. This should
be checked and preventive measures taken.
15.Pressure Reducing Valve: It reduces the pressure to 4 bar approx. for application of
brakes. Since its function is based on spring loading pressure hence spring physical condition
should be checked regularly.
16.Dual Pressure Gauge: Check pressure on Dual air pressure gauge. System pressure
should be 7 bar & brake pressure should be 4 bar.
17.Brake Valve: It is most critical and costly equipment of the circuit and its function is also
critical, hence it should be checked regularly for its internal and external leakages, springs and
back pressure disc.
18.Brake Cylinder: It is the most important component of the brake circuit which converts
pneumatic energy to mechanical power for operating brake levers and shoes for ultimate
braking. It is a single acting cylinder and safety item hence its components like barrels, seal
etc. should be always in good condition. Since we have no effective checks of rubber items at
sites hence seals should always be used of reputed brand. Barrels should be free from dents,
corrosion etc. otherwise internal leakage will start. Machine working in coastal areas are
affected mostly by corrosion because presence of salty atmosphere hence cylinder should be
checked frequently and changed if needed.

HY-25
19.Pneumatic Hoses: Since Pneumatic hoses are simply synthetic yarn braided and no wire is
used hence it is prone to damage early due to mechanical damages, atmospheric effects etc.
hence it should checked regularly. Any bursting of hose will cause total failure of brake. Its
ends clamping should also be tightened well and checked regularly. Heavy handed operation
should not be done for application of brake otherwise brake hose may burst or it may slipped
off from end connection.
20.Brake shoe: Check physical condition of the brake shoe and its fixation. Gap between
wheel and brake shoe shall be maintained 3-5 mm. Any deficiencies in shoe profile if observed
it should be replaced by new one:
(i) Change worn brakes shoes at any points for minimum thickness of 13mm.
(ii)Avoid sudden and full braking otherwise chances of hose slipping/bursting which
will result total failure of braking. In case of emergency only full brake can be applied but
gradually.

Brake Test:

The driver should see the impression of brake shoe on wheel tread, whether equal or
not & whether the vehicle is pulling a side or not.
The brake system must be in absolutely reliable service condition. Before beginning
any open line travel and after a machine stand still of more than 2 hrs during a longer open line
travel, a full brake test must be carried out. During the brake test the appropriate braking
and brake releasing has to be checked. The brakes’ air tightness of the brake cylinders and
the compressed air pipes have to be observed. During the brake test the hand brake (parking
brake) must be released. If there is a risk, the machine might break away, it must be secured by
brake shoes. The brake test may be carried out, when the air pressure in the tank amounts to at
least 6 bar. The main air pipe (brake pipe) must be under a pressure of 4 bar max.

Brake Test of the Direct Acting Pneumatic Brake:

This brake acts on the machine only and not on the hauled coaches. Keep the handle of
the brake valve in release position until the brake cylinder pressure has decreased to “0”. check,
whether all brake blocks have been released. Subsequently, operate the brake valve to braking
position, pressure in the brake cylinders must increase to 3.8 bar. By hammer strokes on one
brake block of each bogie check, whether all brake blocks of the machine fit closely.

Again keep the brake valve lever in release position until the pressure in the brake
cylinders will have decreased to “0” & observe, whether all brake blocks have lifted off the
wheels.

HY-26
Hand Brake:

Action of the hand brakes of the machine has to be checked (brake blocks have to fit
closely). The hand wheels must be easy to turn.

Emergency Brake:

If emergency brake system is available on machine, it should be used in emergencies

only. After any operation of the emergency brake the hinged lid of the emergency brake
valve must be closed again.
Check of Brake Linings and Brake Block Play:

Brake Linings: Brake linings have to be changed at the latest, when their thickness of 35mm
(new) has diminished to 5mm (worn). Grooves in the brake linings are indicators of brake
lining thickness. If the grooves are no longer visible, the remaining thickness of the brake lining
is below 10mm. It will soon become necessary to change the brake linings. The thickness of
the brake linings must in no place be below 5mm.

Brake linings have to be changed at the latest

- the grooves still be fully visible

- the block is worn out on edge

- the block is worn out on one side
- the block is broken

Brake Play: During the cycle of service of a brake block its play has to be re-adjusted for at
least one time. Usually the brake play (distance between the brake block bottom and the wheel
tread) is approximately 5mm. In principle, the brake block play has to be re-adjusted, when:

1.The warning lamp indicating brake block wear lights up

2.The brake blocks are replaced
3.The wheel profile had been re-worked.

How to adjust the brake block play:

(i) Secure the machine against breaking away (skid-pans)

(ii) Release the parking brake
(iii) Release the brake cylinders (ZERO brake pressure)
(iv) When assembling new brake blocks, first shift the turnbuckles so that the brake blocks will
move backwards and make room for the new ones.
(v) Adjust the brake play by using for this purpose the turnbuckles.
(vi) Secure the turnbuckles from unintended shifting.

HY-27
 ⮚ Distributor valve: KE valve

Air Line 5 5 bar Coach brake

bar release

Air Brake System

Tan of machine
k (Air in flow)

Case I: If air pressure 5 bar is available

A. 5 bar connected with tank

B. Tank and brake system of machine are isolated.

Air Line 5 5 bar (Coach brake

bar release)

Air
Tan Tank filling
k function

Case II: If air pressure 5 bar drops.

A .5 bar disconnected from tank

B .Tank connected to machine brake system.

P<5 bar P<5 bar (Coach brake applies)

Air Brake Circuit of machine

Tan
k

HY-28
⮚ Types of Brakes
Brakes

Parking Brake M/c Brake Indirect Brakes

[When m/c is not in Direct brake applies Coach +Machine
driving mode brake to m/c only
applies to m/c.
e.g.-Waiting of signal
Problem-cant work if air
absent

A& B Inputs
A B
C Output

1. Input from A
B
A

2. Input from B

A B

C
HY-29
DC Valve –Direction Control Valve.

Air Air

X
Air Block

Normal Working : 09-CSM

CASE-1 Parking Brake (Driving Switch Off)

Driving Switch
1.ON Release
2.OFF Apply
Controlled by switch

Air
44 23

Pr. setting Direction 2.8 bar

3.8 bar at pr. control
reducing valve valve for
working Two way valve
(double check
80 valve)

KE valve

Front cab 80 80 Rear cab

60 59

Rear Brake
Front Brake
cylinder
cylinder

HY-30
 ⮚ DIRECT BRAKE VALVE :- 2 in 1

I II

A.Brake applies.

HB C HB C O

Normal Atmosphere
connection cylinder
2.8 bar to
cylinder Pressure
Regulato 44
r

B.Brake Release.

HB C O

Atmosphere
2.8 From
bar cylinder

⮚ INDIRECT BRAKE VALVE :

O HL OMV
5 bar

Atmosphere
Pressure
To KE valve 44
Regulato
+ r
coach
HY-31
A. Brake applies :

O HL OMV

Atmosphere
Air drop 5 bar
from
system

B. Brake Release :

O HL OMV

To
atmosphere 5 bar
5 bar to
the
system

⮚ Emergency Brake valve :

If once operated can be reset only after stopping of machine drops from 5 bar to 0
withour any control.

HY-32
 SUB-DISCIPLINE: PNEUMATICS (LESSONS: 05 SESSIONS: 08)

Lesson-IV: Pneumatic Circuits, Session-06: Failure Analysis and Troubleshooting of

Pneumatic Assemblies

Problem Causes Remedies

Insufficient air volume 1. System demands exceed delivery. 1. Check compressor for discharge
capacity.
2. Check the number of pneumatic
components in the system.
3. Check for leaks in the piping.
2. System leakage excessive. 1. Check all fittings and pipes.
2. Check and repair all leaking joints.
3. Check all actuators for leaks.
3. Clogged intake filters. 1. Clean the intake filters.
2.Check the compressor intake valves.
3. Check the size of intake pipe.
Low air pressure 1. System demands exceed delivery. 1. Check the compressor discharge
pressure.
2. Check the reservoir safety valve.
3. Check the system regulator valve.
4. Check the system leaks.
2. System leakage excessive. 1. Check the compressor discharge
pressure.
2. Check the reservoir safety valve.
3. Check the system regulator valve.
4. Check the system leaks.
3. Low compressor discharge 1. Check for clogged intake lines.
pressure.
2. Check for worn intake valves.
3. Check for worn discharge valves.
Oil in the system 1. Oil coming from the compressor. 1. Check the compressor piston rings.
2. Check the compressor discharge
valves.
3.Check the compressor intake valves.
2. Malfunctioning air lubricator. 1. Check the lubricator adjustment.
2. Check the oil viscosity.
Moisture in the system. 1. System demands exceed delivery. 1. Check compressor capacity.
2. Check the air consumption of the
components.
2.Moisture carryover. 1. Check the moisture separator.
2. Check the system drain i.e. drip
cup.
3. Check the location of the intake
filter.
HY-33
SUB-DISCIPLINE: PNEUMATICS (LESSONS: 05 SESSIONS: 08)

Lesson-V: Demonstration of Pneumatic Equipment Sets, Session-07: Demonstration of

Pneumatic Circuits Using FluidsimP Software & Working Exercises

Different pneumatic circuits are drawn and the circuits are made and verified through the
model components of pneumatic equipment set available in the model room.

Lesson-V: Demonstration of Pneumatic Equipment Sets, Session-08: Demonstration of

Pneumatic Circuits Using FluidsimP Software & Working Exercises

Different pneumatic circuits are drawn and the circuits are made and verified through the
model components of pneumatic equipment set available in the model room.

HY-34