Title Page
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Vehicle No;
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Vehicle owned by;
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Vehicle tested at;
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Prepared by
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Date test completed
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Location
Intro
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A locomotive is to be given this code test prior to "pass out" of workshops, when called for in the servicing schedule or when any doubt exists as to the correct functioning of the brake equipment.
ALL TESTING SHALL BE CARRIED OUT USING CERTIFIED TEST GAUGES. -
This has been copied from NZR brake code of October 1974.
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List serial number/s of test gauge/s used in these tests.
Test 1 CHARGING
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Ensure the main reservoir/s have been drained.
Ensure the oil level is correct in compressors.
Ensure Brake Valve Isolating cock is open and brake valve is in Running position.
Start the compressor and note pressure rises steadily.
Note compressor operates without undue noise of vibration. -
Did the loco pass this test
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List the issue then repair before retesting.
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Did the loco pass the retest
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List the issue before rectifying then retesting
Test 2 PRESSURE GAUGES
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Check main reservoir, brake pipe and brake cylinder gauges against test gauge.
Loco gauges must register within 20 kpa of test gauge -
List issue before rectifying then retesting
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List the issue before rectifying then retesting
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List the issue before rectifying then retesting
Test 3 MAIN RESERVOIR LEAKAGE
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Stop compressor
Isolate brake valve
Adjust main reservoir pressure to 550 kpa.
Leakage must not exceed 20 kpa.
Leakage must be reduced to this figure before continuing these tests. -
List the issue before rectifying then retesting
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Did the loco pass the retest
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List the issue before rectifying then retesting
Test 4 BRAKE PIPE LEAKAGE
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(If more than one automatic brake valve is fitted, this test must be repeated for each brake valve)
Recharge main reservoir and brake pipe.
Make a 75 kpa brake pipe reduction.
Close brake valve isolating cock.
Brake pipe leakage must not exceed 15 kpa per minute.
Leakage must be reduced to this figure before continuing these tests. -
List the issue before rectifying then retesting
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Did the loco pass the retest
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List the issue before rectifying then retesting
Test 5 COMPRESSOR GOVERNOR
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The governor must load or restart the compressor when the main reservoir pressure has fallen to the stipulated minimum pressure and unload or stop the compressor when the pressure has risen at least 75 kpa, but no more than 120 kpa.
DE, DSC, electric and diesel mechanical locos, except TR.
Cut in 650 kpa, cut out on governors with adjustable differential 725 kpa.
Governors with fixed differential should cut out at pressure not exceeding 750 kpa.
TR cut in 575 kpa
cut out 700 kpa -
Governor cut out pressure
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Governor cut in pressure
Test 6 AIR COMPRESSOR
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Air compressors may be tested by orifice test or by time taken to charge the main reservoir from 0 to 550 kpa.
After a compressor change, the replacement must be orifice tested. TR class must be orifice tested on all occasions.
Where orifice tests are made each compressor must be tested separately.
On diesel mechanical locos the charging time shown is for both compressors where two are fitted.
If this time is not obtained, each compressor must be separately orifice tested. -
ORIFICE TESTING
a) Screw the appropriate orifice and pressure gauge into the main reservoir cock. Close the brake valve isolating cock.
b) Ensure engine idle speed is as specified.
c) With main reservoir pressure adjusted to the test pressure, open orifice cock fully.
d) The compressor must maintain, or increase, the test pressure for a period of two minutes. -
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Charging Time/Orifice test;
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Has the loco passed this test
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List the issue before rectifying then retesting
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List the issue before rectifying then retesting
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The brake valve handle must operate freely and must not be slack on the spindle.
Test for leakage at the direct exhaust port in release, running and lap positions. Only a slow bubble is allowed.
With handle in release position, test for leakage at cap nuts, chamber caps and equalising reservoir connection and piping. No leakage is allowed.
With handle in running position, test for leakage at secondary exhaust port. A slow bubble is allowed.
Rotary valve spindle lift must not exceed 3 mm.
During these tests the brake valve handle latch must engage firmly at each position.
Test 7 DRIVERS AUTOMATIC BRAKE VALVE No. 4
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List the issue before rectifying then retesting
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List the issue before rectifying then retesting
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List the issue before rectifying then retesting
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With brake valve in RUNNING position, open isolating cock.<br>Brakes must release and brake pipe rise and settle at correct pressure.
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List the issue before rectifying then retesting
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Place handle in RELEASE position.<br>Brake pipe must rise to main reservoir pressure.
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List the issue before rectifying then retesting
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Place handle in EMERGENCY position.<br>Brake pipe must rapidly drop to zero.
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List the issue before rectifying then retesting
Test 8 STRAIGHT AIR BRAKE - TYPE W SELF LAPPING
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Operate handle two or three times from RELEASE to FULL SERVICE, before returning to RELEASE position.
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Move handle from RELEASE to FULL SERVICE, noting 50 kpa increments are obtainable.<br>Full pressure should be 350 kpa except of DSC and Mitsubishi DSA<br>DSC with 2 cylinders per bogie and Mitsubishi DSA set to 275 kpa.<br>DSC with 4 cylinders er bogie set to 375 kpa.
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List the issue before rectifying then retesting
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Move handle from FULL SERVICE to RELEASE, noting 50 kpa increments are obtainable.
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List the issue before rectifying then retesting
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Move handle to EMERGENCY position.<br>Brake Cylinder pressure must rise to reducing valve setting.<br>Failure to do this indicates the stop screw is incorrectly set.
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List the issue before rectifying then retesting Loco must not enter service if stop screw has not been set correctly.
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Did the loco pass the restest.
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List the issue before rectifying then retesting
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DOUBLE CHECK VALVE TEST<br>Charge automatic brake, then make a 150 kpa brake pipe reduction.<br>Note loco brakes apply.<br>Move independent brake valve handle to approximately mid way position.<br>Release automatic brake.<br>Note cylinder pressure should reduce to between 150 and 200 kpa
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List the issue before rectifying then retesting
Test 9 BRAKE CYLINDER LEAKAGE
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Remove nipple from the brake cylinder exhaust port at the triple valve or retaining valve.
Connect to the exhaust port a test gauge and release valve..
With the air brake system charged, make a full service application.
Release the independent brake.
The pressure on the brake cylinder gauge should rise to 350 kpa or slightly more.
Allow one minute for pressure adjustment.
If the pressure registered is in excess of 350 kpa, reduce to 350 kpa
If less than 350 kpa, lightly reapply and release the brakes. -
On some locos it is very difficult to access the triple valve exhaust.
These may be tested by fitting the test gauge to the brake cylinder.
To test leakage by this method, make a full service reduction on brake pipe pressure.
Leave the brake valve in LAP position during the leakage test. -
List the issue before rectifying then retesting
Test 10 SAFETY VALVES
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Safety valves must be adjusted and set to correct pressures.
Main Reservoir safety valves must be set to 775 kpa.
Brake Cylinder Safety Valves
All classes except DSC and Mitsubishi DSA, set to 425 kpa.
DSC with two brake cylinders per bogie and Mitsubishi DSA, set to 375 kpa.
DSC with four brake cylinders per bogie, set to 450 kpa. -
Pressure safety valves set at:
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Did the loco pass this test
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List the issue before rectifying then retesting
Test 11 BREAK IN TWO
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With brake valves in running psoition, open each headstock brake pipe cock.<br>The loco brakes must apply then release when cock is closed.<br>Repeat for each headstock brake pipe cock.
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List the issue before rectifying then retesting
GENERAL
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Examine brake rigging, piping and hoses, adjust cylinder travel if required.
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List the issue before rectifying then retesting
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Check operation of slack adjusters
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List the issue before rectifying then retesting
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Check handbrake operates freely
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List the issue before rectifying then retesting
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Check operation of sanding equipment
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List the issue before rectifying then retesting
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Check operation of air horn and wipers.
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List the issue before rectifying then retesting
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Check operation of vigilance device
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List the issue before rectifying then retesting
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Check operation of deadmans device
