(Govt.

of India)
(Ministry of Railways)

Hand Book
on
Load Sensing Device (LSD)
&
Automatic Brake Cylinder
Pressure Monitoring Device (APM)

(For official use only)

IRCAMTECH/GWl/M/14-15LSD//1.0
July, 2014

Centre
for
Advanced
Maintenance
TECHnology Excellence in Maintenance

MAHARAJPUR, GWALIOR – 474005

egkjktiqj, Xokfy;j & 474005
 HANDBOOK

ON

Load Sensing Device (LSD)

&
Automatic Brake Cylinder Pressure Monitoring
Device (APM)

FOR

WAGON MAINTENANCE STAFF

 FOREWORD

Load Sensing Device (LSD) and Automatic Brake Cylinder

Pressure Monitoring System (APM) has been introduced
for achieving 2- stage braking i.e. empty and loaded with
automatic changeover of brake power in wagons to
prevent wheel skidding on empty wagons and improving
stopping distance of loaded wagons.

This hand book contains introduction with specifications,

application & installation, function and special features of
the devices.

I am sure that the “Handbook on LSD & APM” will be very

much useful to the concerned staff, to ensure trouble free
service.

31st July, 2014 (A R Tupe)

CAMTECH, GWALIOR Executive Director
 PREFACE

Proper knowledge of Load Sensing Device & Automatic

Brake Cylinder Pressure Monitoring System in freight
stock is necessary to ensure reliability and proper
functioning of brake system in Freight stock. This
handbook on LSD & APM in freight stock has been
prepared by CAMTECH with the objective that those
involved in operation and maintenance of wagon stock,
must be aware of sufficient knowledge of LSD and APM to
avoid wheel skidding in empty wagons and to improve
stopping distance of loaded wagons.

Technological Up gradation and learning is a continuous

process. Hence feel free to write to us for any addition /
modifications or in case you have any suggestion to
improve the handbook, your contribution in this direction
shall be highly appreciated.

31st July, 2014 (K.P.Yadav)

CAMTECH GWALIOR Director/Mech
 CORRECTION SLIPS
The correction slips to be issued in future for this handbook will be
numbered as follows:

CAMTECH/GWL/M/GWL/14-15/LSD/1.0/ # XX date ---------------

Where “XX” is the serial number of the concerned correction slip
(starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. of Date of Page No. and Item no. Remarks

C.Slip issue modified
 CONTENTS
Sr. No. Description Page No.
Foreword i
Preface ii
Contents iii
Correction Slips issued iv
Sr. No. Description Page No.
1.0 Why is LSD required
2.0 Load Sensing Device (LSD) Specifications
2.1 Single Piece LSD
2.2 Two Piece LSD
3.0 Introduction of LSD
4.0 Functioning of LSD
5.0 Installation of LSD
6.0 Problems in open line
7.0 Suggestions by open lines for LSD
8.0 RDSO’s Comments & Design issues with
existing LSD
8.1 Shifted Z-Plate and LSD
8.2 Tilted LSD
8.3 LSD mounting bracket tilted
8.4 Adjusting plates of Z-plate deformed and
position shifted
8.5 Nipples broken on the LSD
9.0 Action Taken by RDSO
10.0 APM (Automatiic Pressure Modification
Device)
11.0 Design Features of APM
12.0 Fitment of APM
12.1 APM Schematic diagram
12.2 Fitment Location of APM
13.0 Advantages of APM over LSD
14.0 Suggestions by RDSO
15.0 Automatic Brake Cylinder Pressure
Modification Device (APM)
16.0 Operation of APM
16.1 Empty Position
16.2 Loaded Position
16.3 Release Position
17.0 Parts list of LSD (To be filled by RDSO)
17.1 Testing procedure of Test Rig (To be added by
RDSO)
17.2 Marking of Internal Components (To be
given by RDSO)
IRCAMTECH/GWL/M/14-15/LSD/1.0 -

1.0 Why is LSD required?

• The brake system on each bogie pushes the brake block

against the wheels and this produces braking force which
resists the wheel rotation.
• There is also friction between the wheel and the rail and
if the brake block pushes too hard, the wagon wheel will
skid.
• The lighter the wagon, the more likely it is to skid.
• To overcome this problem, Load Sensing Device (LSD)
is fitted for achieving 2-stage braking i.e. empty and
loaded with automatic change-over of brake power.
• This prevents wheel skidding on empty wagons and
provides means to improve braking distance of loaded
trains.

2.0 Load Sensing Device (LSD) Specifications

At present, there are two types of LSDs
1. Two Piece LSD 2. Single Piece LSD
As now population of two piece LSD is negligible on wagon
stock. The single piece LSDs are running in the system.
The technical data of M/s faiveley and M/s Gresham make
LSDs are given in the list.

S. Description Setting value

No.

1. Over all piston Stroke in Faiveley 75 MM

Hand Book on LSD/APM 1

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

2. Sensing Pressure in Faiveley 5.0 Kg/CM2

3. LSD Pressing Piston in Faiveley 5 mm in side

4. Filling time 5.0 Kg/CM2 in In 10 + 2 Sec.

Faiveley

5. Empty Piston Stroke in Greysham 66 mm

6. Loaded Piston stroke in Greysham 70 mm + 2 mm

7. Operating Stroke in Greysham 06 mm + 0.5 mm

8. Working Pressure in Greysham 5.0 Kg/CM2

9. Filling Time in Greysham LSD 65 +2.0 Sec

10. Draining Time in Greysham LSD 38 +2.0 Sec.

Hand Book on LSD/APM 2

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

Single Piece LSD

Two Piece LSD

Hand Book on LSD/APM 3

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

3.0 Introduction

• To effect the automatic change of a change over valve of

distributer valve depending on whether the vehicle is in
“ EMPTY” or in “LOAD” condition, a load sensing
device is employed.
• The Load Sensing Devices are Provided on
Container(CONCOR) Wagons, BOBR Wagons, Bogie
Mounted Wagons for automatic load change over.

4.0 Functioning

• When the wagon is in the empty weight range, the piston

is in its lower position. Output connection leading to the
change over valve is then exhausted through Exh. port via
upper chamber.
• When the weight reaches the “LOADED” range, piston is
pushed up. This causes the air seal to pass over output
connection, thus interrupting communication from output
connection to exhaust.
• When the wagon is in the empty weight range, the piston
is in its lower position. Output connection leading to the
change over valve is then exhausted through Exh. port via
upper chamber.
• When the weight reaches the “LOADED” range, piston is
pushed up. This causes the air seal to pass over output
connection, thus interrupting communication from output
connection to exhaust.

Hand Book on LSD/APM 4

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

• Input connection and output connection now

communicate via lower chamber, so that air from the
(AR) Auxiliary Reservoir can flow to the change over
valve.
• When weight falls to within the “EMPTY” range again,
the piston returns to its lower position and output
connection is once exhausted to Ex.port.

5.0 Installation of LSD

• LSD can be mounted from top or from side as required.

• It is mounted on bolster through mounting bracket.
• Below the LSD is a base plate mounted on spring plank.
• The LSD must be so located that its longitudinal axes is
parallel to the deflection direction of the sprung bogie
part.
• The angle formed by the longitudinal axes of the LSD
and the contact surface (base plate) must be 90°±10º.
• The inlet connection of the LSD is connected to Air
Reservoir and outlet connection is connected to change
over valve of DV.

6.0 Problems in open line:

• LSD on wagons are non functional or deficient despite

repeated special efforts for fitment during POH/ROH.
This is also pointed out by NTXRs and 174 BOBRN
wagons were turned out from KGPW (from Sept., 08 to
Feb.’09) without fitment of LSD. The necessity and
Hand Book on LSD/APM 5
IRCAMTECH/GWL/M/14-15/LSD/1.0 -

feasibility of LSD may be reviewed by RDSO while

granting exemption of fitment of LSD as rejectable item.

7.0 Suggestions by open lines:

• Fitting of LSD on BOBRN wagons should be exempted.

RDSO may review the necessity and feasibility of LSD.
• APM should be provided in place of LSDs.

8.0 RDSO’s Comments

Design issues with existing LSD

• Existing LSD has inherent tendency of fatigue failure due

to constant contact.
• LSD is in constant touch with the bracket when the
wagon is in loaded condition.
• Because of the vibrations in the wagon during run, the
mounting arrangement gets loose. Due to loosing of
bracket, K-ring gets worn-out and the piston bends.
• The breakage of LSD bodies from the neck also takes
place because of the same reason.
• Breakage/tilting of brackets of LSD and theft of LSDs
etc. have been reported from Railways.

Hand Book on LSD/APM 6

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

8.1 Shifted Z-Plate and

LSD

8.2 Tilted LSD

8.3 LSD mounting bracket

tilted

Hand Book on LSD/APM 7

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

8.4 Adjusting plates of Z-plate

found deformed and
position shifted

8.5 Nipples found broken on the

LSD

9.0 Action Taken by RDSO

• Spring buffer assembly of two piece LSD on BOBRN

wagon was getting tilted. RDSO modified the two piece
design to single piece design. The defect of tilting was
rectified.
• RDSO has developed new improved design of LSD.
This new design is known as APM- Automatic Pressure
Modification Device.

Hand Book on LSD/APM 8

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

10.0 APM (Automatic Pressure Modification Device)

• APM is a two stage automatic brake cylinder pressure
modification device.
• The APMs are supposed to sense the gap at the time of air
brake application and normally they are not in contact
with the bogie side frame.
• This will prevent fatigue failures due to vibrations
arising from constant contact.
• Extensive trials of this new LSD has been conducted on
ECOR for the last 6 years and there have been no
reported failures of the same.
• Testing facility for this APM has been created at RDSO
and APM of Knorr make(EL-60) has already been tested
and approved with BMBS.
• M/s Faiveley has also offered its Ratio- valve which is
similar to APM. It is being tested at RDSO.
• Improved design specification of this Load change-over
Device (APM) is being developed at RDSO and will be
made available very soon. Anti theft features are also
being included in this new design.

11.0 Design Features of APM

• This device does change-over of brake cylinder pressure

from empty to load.
• This valve is designed such that it does not require two
stages distributor Valve. Normal distributor valve can be
used.

Hand Book on LSD/APM 9

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

• The mounting and pipeline connecting parameters of the

design is modified according to the standard pipes and
flange used in Indian Railways, so no major change is
required in the piping arrangement. Only brake cylinder
pipeline between distributor valve and brake cylinder
needs to be modified
• A visual indicator is provided on the valve, which shows
empty load brake conditions.
• There is no physical contact of the sensor arm of LSD
with the side frame of the bogie during release & running
(both Empty & Loaded condition).
• The contact of sensing arm with side frame of the bogie
occurs during braking only.
• The sensing arm is angular type of lever; hence it does
not lead to any bending movement.

EL-60 type APM supplied by Knorr Bremse

Hand Book on LSD/APM 10

 IRCAMTECH/GWL/M/14-15/LSD/1.0 -

12.0 Fitment of APM

• APM is interposed between bogie side frame of casnub
bogie and the under frame of wagons.
• It is fitted on one of the bogies of the wagon.
• It restricts the brake cylinder pressure coming from the
Distributor valve to 2.2 kg/cm2 in empty condition of the
wagon and allows the brake cylinder pressure of 3.8
kg/cm2 in loaded condition of the wagon.
• APM is provided with a sensing arm which senses the
empty and loaded condition of the wagon during braking.
• It can be mounted on under frame of the wagon or on the
bolster of the bogie.
• The valve installed on the under frame of the wagon
senses the gap between the under frame and the side
frame of the bogie whereas on installation on the bolster
of the bogie it senses the gap between any fixed member
of bogie and bolster.
• It is also provided with the visual indicator, which shows
empty load brake condition of the wagon.
12.1 Fitment of APM

Hand Book on LSD/APM 11

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

12.2 Fitment of APM

13.0 Advantages of APM over LSD

• Installation: APM is easier to install and no shims are

required for adjustment as in LSD. Pipings and joints are
considerably reduced and no pressure reducing valve or
double check valve are required

• Maintenance: APMs are easier to maintain as one does

not have to go under the bogie (as required in LSD) and
for lifting the wagon (fitted with APM) or taking out the
bolster nothing needs to be removed as compared to LSD
fitted wagons.

Hand Book on LSD/APM 12

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

• Functional: APM systems does not require two stage

DVs as compared to LSD systems and the visual
indicator provided on the valve of the APM clearly shows
the empty/loaded condition.

14.0 Suggestion by RDSO

• RDSO has recently finalised the specification No. WD-

23-BMBS-08 of BMBS for freight stock. APM has
already been included as a part of this specification.
• To avoid the problem of breakage, missing and
malfunctioning of existing LSD, it is suggested that
APM as approved for BMBS may be used for
BOBRN wagons also

15.0 Automatic Brake Cylinder Pressure Modification Device

(APM)

Two stage APM whose functioning based on the gap between

underframe and bogie side frame of the wagon shall be as per
firm’s own design. APM should sense the gap only at the
time of air brake application. During remaining time it should
not be in contact with the bogie side frame. APM shall be a
proven design and must meet the space envelope shown in
RDSO’s drawing number WD-08096-S-01. One number of
APM shall be used per wagon. No human intervention shall
be required for operation of APM.

APM shall ensure brake cylinder pressure of 3.8 Kg/cm2

when the gap between wagon underframe and bogie side
frame is as prescribed in applicable drawings. After the gap

Hand Book on LSD/APM 13

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

between underframe and bogie side frame becomes more

than as prescribed in the applicable drawings, the brake
cylinder pressure shall be reduced to 2.2 Kg/cm2.
Performance testing of APM shall generally conform to AAR
standard S-4002 (Latest). Specific procedure and parameters
for testing shall be prescribed by the contractor/manufacturer
and will be approved by RDSO.

16.0 Operation of APM

16.1 Empty Position

As previously described in the change-over position, in the
empty position the ratio piston will move to the right as
required to open the piston check valve and satisfies the
requirements dictated by the ratio piston. When the
requirement of the ratio piston is met, the ratio piston will
move back to the left, closing the piston check valve. For
example, with a 60% ratio piston, if the control valve
p
r
e
s
s
u
r
e

w
a
s

4
.

Hand Book on LSD/APM 14

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

pressure was 4.5 kg/cm² (64psi), then the volume pressure

would be 4.5 kg/cm² (64psi) and the brake cylinder pressure
would be 2.67 kg/cm² (38psi). if an emergency occurred over
this typical full service pressure, then each pressure would
increase by 15%-20%. In release, as previously described,
pressure from the brake cylinder will flow back through the
ratio piston to the control valve (retainer) while pressure from
the volume will flow through the back flow valve to the
control valve (retainer).

16.2 Loaded Position

In load position, pressure from the control valve #3 port
flows past the open piston check valve, behind the sensor
diaphragm, and acts against the return spring to move the
sensor arm down at normally 1 kg/cm² (15psi) pressure to
contact the side frame. Pressure then flows out to the brake
c
y
l
i
n
d
e
r
.

B
r
a
k
e

cylinder pressure build-up will be unaffected by the device in

Hand Book on LSD/APM 15

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

the load position because the ratio piston will remain to the
left of the portion and the piston check valve will remain
open, permitting #3 port air to flow directly to the brake
cylinder. The air passage to the volume is cut off by the ratio
piston and the back flow valve.

16.3 Release Position

The ratio piston is held to the left of the portion by the
movement of the sensor arm against the piston check valve
and the force of the piston check valve spring against the
ratio piston. The piston check valve is fully open and the
upstream volume is connected via the back flow valve to the
control valve.

Hand Book on LSD/APM 16

IRCAMTECH/GWL/M/14-15/LSD/1.0 -

17.0 Parts list of APM to be filled by RDSO

Item Part No. Description Quantity

17.1 Testing Procedure of Test Rig (to be added by RDSO)

17.2 Marking of Internal components (To be given by RDSO)

Hand Book on LSD/APM 17

 OUR OBJECTIVE

To upgrade maintenance
technologies and methodologies and
achieve improvement in productivity
and performance of all Railway
assets and man power which inter-
alia would cover reliability,
availability, utilization and efficiency.

If you have any suggestions and any specific comments,

please write to us.

Contact person : Director (Mech.)

Postal address : Indian Railways,

Centre for Advanced
Maintenance Technology,
Maharajpur, Gwalior.
Pin code - 474 0050

Phone : 0751- 470890, 0751-470803

Fax : 0751- 470841