DIFFERENT TESTS

in
Conv. & 3Ø LOCOS
LOCO BRAKE POWER TEST
Conv. Locos - single/multiple(freight locos)
 Keep SA 9 in application position.
(Remove wooden wedges & Release hand brake if applied)
 Ensure BC gauge reads 3.5 Kg/cm2
 Personally ensure that all BCs are applied and brake blocks are touching to
the wheels.
 Ensure nobody is standing nearby the loco or on the same line.
 Give short whistle.
 Take 2 to 3 notches gradually and observe the current rating.
 For freight locos , should not move up to 600 A
 For coaching locos, should not move up to 800 A.
 If the loco moves with in 600Amps/800Amps, it indicates that loco brake
power is poor.
 Inform to TLC.
 LOCO BRAKE POWER TEST
3 Phase loco - single/multiple (only WAG 9)

 Keep SA 9 in application position.

(Remove wooden wedges & Release hand brake/PB if applied)
 Ensure BC gauge reads 3.5 Kg/cm2 (In WAP 5 locos 5.0 Kg/cm2)
 Personally ensure that all BCs are applied and brake blocks are touching to the wheels in
WAP7 locos.
 (In case of WAG 9 locos, TBU, ensure by shaking brake blocks.)
 Ensure nobody is standing nearby the loco or on the same line.
 Set display screen in simulation mode.
 Give short whistle.
 Keep Reverser forward and move throttle gradually in TE direction.
 WAG9 and WAP7 locos should not move upto 150 KN.
 WAP 5 locos should not move upto 100 KN.
 If loco moving below 150/100 KN inform to TLC.
 ALP EMERGENCY BRAKE TEST

 ALP emergency brake(RS) to be tested by ALP whenever TOC

loco.
 This test to be conducted and ensured by ALP (To apply in case
of emergency by ALP)
 Should be ensured by LP also.
 Ensure BP pressure is 5 Kg/cm2
 ALP should inform to LP.
 ALP should open RS gradually.
 Both should ensure BP pressure is dropping.
 Normalise RS.
 PROPORTIONAL BRAKE TEST
 Ensure C3W valve isolation cock handle is in service position.
 Place A9 in release position and build up 5kg/cm² of BP pressure.
 Place A9 in application position and release SA9.
 Observe BC gauge showing max. 1.8 Kg/cm² in conventional locos.(
E 70-2.5 Kg/cm², CCB 2.0-2.5 Kg/cm²)
 Now press PVEF, brake cylinder gauge needle should come to '0'.
 Place A9 in emergency position.
 Now press PVEF, brake cylinder gauge needles should not drop.
NOTE: During RB, VEF (E) energizes through CTF 1, 2 & 3 Br I/Ls.
Hence, During RB, proportional brake is isolated.
 AFL TEST (Conventional Locos)
Preparation:
 Keep SA 9 in application position.
 Ensure BC gauge reads 3.5 Kg/cm2 & BP gauge showing 5.0 Kg/cm2
 Personally ensure that brakes are applied.
 Keep HVSI 1&2 and HVMT 1&2 on '0‘
By pressing TSAFL:
 Take 2 or 3 notches.
 Press TSAFL and observe
 Flasher light flickering
 GR coming to ‘0’ and LSGR glowing.
 Buzzer sound
 Glowing of LSAFL.
 With RS opening:
 Keep MPJ forward.
 Take few notches.
 Drop BP below 4.4 Kg/cm2 by opening RS slightly and observe
 Flashing of Flasher light.
 GR coming to ‘0’
 Buzzer sound
 Glowing of LSAFL.
 Now press SW switch.
 AFL and buzzer should stop.
 Close RS and wait till BP reaches to 5 Kg/cm2 (LSAF glows, AFI overshoots)
 Now LSAFL and LSAF also extinguishes, PR2 de-energises.
 On opening of BP angle COC /pressing ESPB also same actions will come.
 Dropping BP by A9:
 Take few notches.
 Apply A9 to min. and further to full service. Ensure
 AFL shall not glow
 LSAFL shall not glow
 Buzzer shall not sound
 GR shall not regress
 If above indications are coming means AFL circuit is
malfunctioning.
 Further bring A9 to emergency(drop BP below 2.8 Kg/cm2 ) and
observe
 GR coming to ‘0’.(LSGR glows)
 AFL test in 3Ø LOCOS
 Stand still condition AFL testing can not be done in this loco.
 On run BP pressure drops due to any reason below 4.4 kg/cm2 ACP message
of P-2 will appear on screen along with AFL.
 BPFA Glows.
 LSAF will glow.
 Buzzer will sound.
 BPFL light will flicker.
 Flasher light will start flickering.
 TE/BE reduces to ‘o’
 Keep TE/BE handle on ‘O’.
 After stopping train keep Reverser on ‘O’. Switch ON FL manually if
required.
 Acknowledge the fault by pressing BPFA. Attend the trouble.
 AIR/BP CONTINUITY TEST
OCCASSIONS:
 Before going to sign the fresh BPC.
 While clearing any stabled load from any way side station.
 After completing of power interception.
 After completion of shunting.
 After reversing the loco.
 After attaching dead loco on to the formation.
 If train parted and after recoupling the formation.
 Additional locomotive attached in rear.
 Whenever brake integrity changes on the formation.
 After completing of power changing. (i.e traction to diesel and vice – versa).
 PROCEDURE-FOR FREIGHT TRAINS
 This test is to be conducted with the cooperation of guard.
 In absence of guard YM can attend.
 Build up 9.5/10 kg/cm2 of MR pressure and 5.0 kg/cm2 of BP pressure in the
locomotive.
 Ensure 4.8 / 4.7 kg/cm2 of BP pressure in the BV/LV according to the no of
wagons.
 Apply A9 automatic brake valve and reduce BP pressure by 1.0 Kg/cm2 without
pause.(BP Gauge reading:4.0 Kg/cm2)
 Confirm from the guard for corresponding reduction of BP pressure in BV/LV.
 Physically ensure few vehicles brakes application.
 Now close A8 cock (70 COC / Mode switch in ‘Test’ in CCB2 locos and ignore
fault message).
 Now immediately guard shall open the BV emergency valve/LV BP Angle cock and
the guard shall observe the drop of BP pressure to zero in BV/LV.
 Loco pilot to ensure dropping of BP pressure completely to ‘O’ in loco. .
Now inform to guard to close emergency valve in BV/BP Angle cock of LV.
After closing BV/LV Angle cock wait for few seconds and ensure BP pressure is
not charging.
Now LP shall release A9, open A8/70 COC/Mode switch to Lead and ensure
recreation of 5.0 kg/cm2 of BP in the locomotive and 4.8 / 4.7 kg/cm2 of BP
pressure in the BV/LV.
For originating trains after turn around examination (where SSE/SE-C&W is
posted); continuity test will be done by the LP and guard in the presence of
SSE/SE-C&W who shall make endorsement on the reverse of the original BPC.
Where SSE/SE-C&W is not posted: LP and guard should conduct the continuity
test and make endorsement on the reverse of original BPC.
NEED NOT CARRIED OUT:
When locomotive other than train locomotive is detached from extreme front of
the train.
When locomotive or vehicle is detached from the extreme rear of the train.
 BRAKE CONTINUITY TEST - COACHING TRAINS
 The LP shall charge the BP to 5 Kg/cm2 and FP to 6 Kg/cm2 and confirm from the
Guard that minimum BP 4.8 Kg/cm2 and FP 5.8 Kg/cm2 in rear SLR.
 Inform to guard and drop BP pressure by A9 upto 4.0 Kg/cm2 and confirm from
guard same amount of BP dropping from his SLR or from LV. (3.8 +/-0.2 Kg/cm2
allowed in Rear SLR/LV)
 After confirming now keep A9 in release and recharge BP pressure 5 Kg/cm2 and
ensure in rear SLR/LV BP showing min.4.8 Kg/cm2.
 Now in loco close A-8 COC or E-70 COC/Mode switch in Test position in
E70/CCB2 locos (Ignore the message appeared in 3Ø locos).
 Now inform to guard to drop BP pressure from his SLR or from LV. Guard has to
drop 1.0Kg/cm2 and in engine BP pressure shall show 4.0 +/-0.2 Kg/cm2.
 Now inform to guard to close BP valve/LV Angle cock. wait for few sec and ensure
BP pressure is not recharging.
 Now open the A-8 COC/E-70 COC/ Mode switch in Lead position in CCB2 locos
and recharge the BP pressure in the loco and SLR.
 BRAKE FEEL TEST
 To be done immediately after starting the train
(Freight/coaching) at any station where crew have taken over
the charge.
 To be done before passing LSS or after clearing all points,
wherever possible.
 Train speed shall be between 12-15 kmph.
 Drop BP pressure by 0.5kg/cm2 through A9 and hold for few
seconds and release.
 Speed of train should drop to 6-8 kmph at the time of BP re-
charging.
 Crew should feel the application of brakes on train.
 BRAKE POWER TEST
 To be done in the first block section/or first opportunity in down/level gradient.
 The speed of the train should be 60 to 70 kmph in case of coaching train and 40 to 50
kmph in case of goods train.
 LP should drop the BP pressure by 1 kg/cm2 in coaching train and loaded goods train
and 0.5 kg/cm2 in case of empty goods train through A9 and release after a small
pause.(In case of BOBR rakes drop BP pressure 1.0 -1.5 Kg/cm2.)
 The speed of the train should drop 30 to 35 kmph in coaching trains & 20 to 25
kmph in goods train by the time BP pressure recharge to 5.0 kg/cm2.
 LP should judge the brake power and act accordingly.
# If brake power is less stop the train in next station and inform to TLC and act
accordingly.
Note: ALP shall keep a watch & ensure that both the tests are done by LP and will
remind him for the same, if required.
 CP EFFICIENCY TEST
 Build up MR pressure to 9.5 Kg/cm2
 Charge BP pressure 5 Kg/cm2.
 Couple 7.5mm leak hole test kit to rear BP pipe palm end.
 Press BPSW and hold.
 Open BP angle cock. Wait for 60 sec.
 BP pressure should not drop below 4.4 Kg/cm2 in BP gauge.
 Without pressing BPSW open BP angle COC.
 Wait for 60 sec. BP gauge shall show between 2.5 Kg/cm2 to 3.5
Kg/cm2
NOTE: Keep number of CPs in service according to trailing load.
Called as ‘Auto brake capacity test’ in 3Ø locos.
Charge BP pressure 5.0 Kg/cm2
Connect 7.5 mm leak hole test coupler to nonworking end BP
palm end.
Open BP angle COC.
BP pressure should not fall below 4.0 Kg/cm2 in 60 sec.
Recharge BP pressure.
Press and hold A9 for 3 sec. in ‘release’ position and open BP
angle cock.
BP pressure should not fall below 4.25 Kg/cm2 in 60 sec
 BP LEAKAGE TEST
Ensure MR pressure is 9.5 Kg/cm2
Ensure BP pressure is 5 Kg/cm2
Apply A9 to drop BP pressure to 4.0Kg/cm2
Close A8 and wait for 30 seconds to settle the gauge needle and
note down the reading.
Wait for another five minutes and note down the BP pressure
reading.
Difference of pressure should not be more than
 For loco : 0.7 Kg/cm2 within 5 minutes (0.2Kg/cm2 for one
minute)
 For formation : 1.25Kg/cm2 for 5 min (0.25Kg/cm2 for 1 minute)
 FP LEAKAGE TEST

 Ensure MR pressure is 9.5 Kg/cm2

 Ensure FP pressure is 6 Kg/cm2
 Open rear end FP angle cock slightly to drop FP pressure to 5 Kg/cm2
 Close FP feed valve COC, FP angular cock.
 Wait for one minute and note down the FP pressure reading.
 Wait for another 5 minutes, note down the reading.
 Difference of pressure should not be more than
 For loco : 0.7Kg/cm2 within 5 minutes (0.2Kg/cm2 for one
minute)
 For formation : 1.25Kg/cm2 for 5 min (0.25Kg/cm2 for one minute)
 STANDARD
PNEUMATIC SETTINGS
S.NO PARAMETER CONV.LOCO 3Ø/ E-70 3Ø/ CCB2.0
1 BP pressure 5.0 Kg/cm2 5.0+/-0.1 Kg/cm2 5.0+/-0.1 Kg/cm2
2 FP pressure 6.0 Kg/cm2 6.0+/-0.2 Kg/cm2 6.0+/-0.2 Kg/cm2
3 MR. Pr. Switch 8.0/9.5 Kg/cm2 8+/-0.2 to 10+/-0.2 8+/-0.2 to 10+/-0.2
(RGCP) Kg/cm2 (172.3) Kg/cm2 (172.3)
4 Aux. Pr. Switch … 8.0/7.0+/-0.15 8.0/7.0+/-0.15
(172.4)
5. PB Pr. switch … 5/4+/-0.1 Kg/cm2 5/4+/-0.1 Kg/cm2
(269.3)
6. FP Pr. Switch … 5.6/5+/-0.1 Kg/cm2 5.6/5+/-0.1 Kg/cm2
(269.4/2)
7. MR low pressure … Op.5.6+/-0.15 Op.5.6+/-0.15
switch (269.4) CL. 6.4+/-0.15 Cl. 6.4+/-0.15
8. BC pressure switch … CL.0.65+/-0.05 CL.0.65+/-0.05
(269.6/1 & 269.6/2) Op. 0.30+/-0.05 Op. 0.30+/-0.05
S.NO PARAMETER CONV.LOCO 3Ø/ E-70 3Ø/ CCB2.0
9. VCD Pr. switch … CL.2.0+/-0.10 CL.2.0+/-0.10
(269.5) Op. 1.5+/-0.10 Op. 1.5+/-0.10
10 Panto Pr. Switch 4.65/4.0 Kg/cm2 5.5+/-0.20 5.5+/-0.20
(130.4/1 &130.4/2 in 3Ø) (Only VCB) 4.5+/-0.20 4.5+/-0.20
(Panto & VCB) (Panto & VCB)
11 Venturi Valve Pr. Switch 4.0/3.0 Kg/cm2 5.0+/-0.15 Maintained by
(269.4/1 in E70) (RGAF) 4.0+/-0.15 CCB software

12 Brake pipe Pr. Switch 2.8/4.0 Kg/cm2 4.2+/-0.15 Maintained by

(269.1 in E70) (RGEB 2) 3.0+/-0.15 CCB software
13 CPA Safety Valve (SS 1) 8.0 Kg/cm2 8.5+/-0.25 8.5+/-0.25 Kg/cm2
Kg/cm2
14 MR Safety Valve (SS 2) 10.5 Kg/cm2 10.5 Kg/cm2 10.7+/-0.35
Kg/cm2
15 CP Safety Valve (SS) 11.0 Kg/cm2 11.5+/-0.35 11.5+/-0.35 Kg/cm2
Kg/cm2
S.NO PARAMETER CONV. LOCO 3Ø/ E-70 3Ø/ CCB2.0
16 Duplex check valve 4.9 Kg/cm2 5.0+/-0.1 Kg/cm2MROV - 5.0+/-
0.2 Kg/cm2
17 PT Raise/Lower Timings 6-10 sec 6-10 sec 6-10 sec
18 MR- pressure building 9.5 Kg/cm2/12 0-10 Kg/cm2 0-10 Kg/cm2
time (Single CP) min 1750 LPM-7 min. 1750 LPM-7 min.
1000 LPM 1450 LPM-8.5 1450 LPM-8.5
min. min.
Both CPs 1750 Both CPs 1750
LPM - 3.5 min. LPM - 3.5 min.
19 MCPA- pressure 8.0 Kg/cm2/8 min … …
building time
20 Air Flow Measuring 100 psi 100 psi 100 psi
Valve
21 SWC 1.0 Kg/cm2 CL.0.65+/-0.05 CL.0.65+/-0.05
(269.2 in 3 Ph.) Op. 0.30+/-0.05 Op. 0.30+/-0.05
S.NO PARAMETER CONV.LOCO 3Ø/ E-70 3Ø/ CCB2.0
22 P1 (AFL Ckt) 4.5/4.8Kg/cm2 … …
23 P2 (AFL Ckt) 4.4/4.7Kg/cm2 … …
25 Permitted leakage of 0.6 Kg/cm2 /5 min. 0.15 Kg/cm2 /5 ….
BP min.
26 BP reduction time … 180+/-20 sec 180+/-20 sec
from 5.5 to 5.0
Kg/cm2
27 Blending brake … RB> 90% RB> 90%
Max.2.5 Kg/cm2 Max.2.5 Kg/cm2
28 A9 RUN to FS … 6-10 sec 6-10 sec
(BP pr. drops 5.0 to
3.5 Kg/cm2 )
29 Panto air line … 0.7 Kg/cm2 in 5 ..
leakage min.
S.NO PARAMETER CONV.LOCO 3Ø/ E-70 3Ø/ CCB2.0
30 Brake Cylinder Pressure 1.8 Kg/cm2 0.4 -2.5+/-0.1 0.4 -2.5+/-0.15
with A9 Kg/cm2 Kg/cm2
Loco Brakes Application/ App. 6-9 sec in App. 8+/-2 sec
10-15/25-30 sec
WAP7
Releasing Time
18-24 in WAG9
Rel. 2.5-0.4
Kg/cm2
15-20 sec in
WAP7
45-60 sec in
WAG9
31 Brake Cylinder Pressure 3.5 Kg/cm2 0.4-3.5 Kg/cm2 Chg: 4+/-1 sec
with SA9 Max. 8 sec 17.5+/-2.5 sec
Brakes Application/ 3.5-0.4 Kg/cm2 Freight:
6-9/9-10 sec
10-15 sec 21+/-3 sec
Releasing Time
52.5+/-7.5 sec
S.NO PARAMETER CONV.LOCO 3Ø/ E-70 3Ø/ CCB2.0
32 BP leak hole (CP BP shall not drop BP shall not drop BP shall not drop
efficiency) BPSW below 4.4 Kg/cm2 below 4.0 Kg/cm2 below 4.0
pressed in 60 sec in 60 sec Kg/cm2in 60 sec
33 BPSW not pressed BP pressure shall In ‘Release’ shall In ‘Release’ shall
drop below 2.5 to not drop below not drop below
3.5 Kg/cm2 /60 sec. 4.25 Kg/cm2/60 4.25 Kg/cm2/60
sec sec
34 Brake block clearance 10 mm 5 mm each side 5 mm each side
for freight for freight
1.5 mm for 1.5 mm for
coaching coaching
35 Unloading time … Max.12 sec Max.12 sec
 A9 in CCB 2.0 brake system
A9 position BP pressure BC pressure in BC pressure in
WAG9/WAP7 WAP5
RUN 5.0+/-0.1 Kg/cm2 0 0
Initial App. 4.6+/-0.1 Kg/cm2 0.3-0.5 Kg/cm2 0.61-0.92 Kg/cm2
FS 3.35+/-0.1 Kg/cm2 2.5+/-0.15 Kg/cm2 5.15+/-0.3 Kg/cm2
Emergency Below 0.2 Kg/cm2 2.5+/-0.15 Kg/cm2 5.15+/-0.3 Kg/cm2

A9 in E70 brake system

A9 position BP pressure BC pressure in BC pressure in
WAG9/WAP7 WAP5
RUN 5.0+/-0.1 Kg/cm2 0 0
Initial App. 4.6+/-0.1 Kg/cm2 0.4+/-0.1 Kg/cm2 0.75+/-0.15Kg/cm2
FS 3.35+/-0.2 Kg/cm2 2.5+/-0.1 Kg/cm2 5.15+/-0.3 Kg/cm2
Emergency Below 0.2 Kg/cm2 2.5+/-0.1 Kg/cm2 5.15+/-0.3 Kg/cm2
THANQ Sk.SUBHANI
Sr.INSTRUCTOR/ETTC/BZA