New York Air Brake CCB Brake System BNSF CONTRACT CCB BRAKE EQUIPMENT MAINTENANCE MANUAL IP-157-C For the DASH 9 LOCOMOTIVE Operated by BURLINGTON NORTHERN SANTA FE JUNE 1999 CCB BNSF CONTRACT LOCOMOTIVE MAINTENANCE MANUAL INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES NOTE: The portion of the text effected by the changes is indicated by a vertical line in the outer margin of the page. The total number of pages in this Maintenance and Instruction Manual, is 310, consisting of: PAGE NO. CHANGE NO. ISSUE Title 1 June/99 A 1 June/99 B 1 June/99 i through vi 1 June/99 1-1 through 1-80 1 June/99 2-1 0 October/96 2-2 (Blank) 0 October/96 C.W. 135 1 January/83 C.W. 217 3 June/96 C.W. 218 1 April/94 C.W. 219 2 October/95 C.W. 220 2 October/95 C.W. 221 2 October/95 C.W. 222 2 October/95 C.W. 223 2 October/95 C.W. 224 2 June/96 C.W. 225 2 June/96 C.W. 226 3 June/96 C.W. 227 2 June/96 C.W. 228 2 June/96 C.W. 229 2 June/96 C.W. 230 2 June/96 C.W. 231 3 June/96 C.W. 232 1 April/94 C.W. 233 4 June/96 C.W. 236 2 October/95 C.W. 239 3 November/97 C.W. 243 3 June/96 C.W. 248 1 March/95 C.W. 249 1 March C.W. 250 1 June/95 C.W. 257 1 February/97 C.W. 259 1 April/97 ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED FROM: NEW YORK AIR BRAKE CORPORATION The Change No. "0" indicate the Original Issue for Manual A KNORR BRAKE COMPANY The Change No. "1" indicates the Original Issue for NYR,NYT & CW 748 STARBUCK AVENUE The Change Letter "A" indicates the Original Issue for P/L,W/D,P/D WATERTOWN, NY 13601 IP-157-C A JUNE/99 CCB BNSF CONTRACT LOCOMOTIVE MAINTENANCE MANUAL INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES NOTE: The portion of the text effected by the changes is indicated by a vertical line in the outer margin of the page. The total number of pages in this Maintenance and Instruction Manual, is 310, consisting of: PAGE NO. CHANGE NO. ISSUE 3-1 0 October/96 3-4 (Blank) 0 October/96 4-1 through 4-4 0 October/96 5-1 through 5-44 0 October/96 6-1 through 6-12 0 October/96 NYR - 380 1 October/96 7-1 through 7-1 0 October/96 7-2 (Blank) 0 October/96 P/L 1502 B April/96 P/D - 1502 B May/96 W/D - 1502 B May/96 8-1 through 8-6 0 October/96 ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED FROM: NEW YORK AIR BRAKE CORPORATION The Change No. "0" indicate the Original Issue for Manual A KNORR BRAKE COMPANY The Change No. "1" indicates the Original Issue for NYR,NYT & CW 748 STARBUCK AVENUE The Change Letter "A" indicates the Original Issue for P/L,W/D,P/D WATERTOWN, NY 13601 JUNE/99 B IP-157-C CCB BNSF CONTRACT LOCOMOTIVE MAINTENANCE MANUAL TABLE OF CONTENTS CHAPT/SECT TITLE PAGE 1.0 OPERATING PROCEDURES 1-1 1.1 AIR BRAKE EQUIPMENT 1-1 1.1.1 AIR BRAKE EQUIPMENT IN AIR BRAKE COMPARTMENT 1-1 1.1.2 BRAKE VALVE 1-6 1.1.3 LOSS OF POWER MODE 1-8 1.1.4 POWER UP PENALTY 1-8 1.2 GENERAL INFORMATION 1-8 1.2.1 CCB INTRODUCTION 1-8 1.2.2 SYSTEM DESCRIPTION 1-10 1.2.3 OPERATION 1-12 A. RELEASE POSITION 1-12 B. BRAKE CYLINDER PRESSURE CONTROL 1-17 C. SERVICE APPLICATION-AUTOMATIC 1-20 D. BRAKE CYLINDER CONTROL-AUTOMATIC 1-26 E. SUPPRESSION POSITION 1-26 F. HANDLE-OFF POSITION 1-31 G. EMERGENCY APPLICATION-EMERGENCY 1-33 H. EMERGENCY APPLICATION-FIREMANS VALVE 1-41 I. EMERGENCY APPLICATION-TRAIN SEPARATION 1-41 J. AUTOMATIC APPLICATION-BAIL OFF 1-43 K. TRAIL POSITION-AUTOMATIC BRAKE 1-51 L. TRAIL POSITION-ANY EMERGENCY APPLICATION AND RELEASE 1-51 M. TRAIL OPERATION-BAIL OFF 1-51 N. INDEPENDENT APPLICATION AND RELEASE 1-53 O. TRAILING INDEPENDENT BRAKING 1-61 P. LOSS OF POWER OR DEFAULT MODE 1-61 Q. SERVICE PENALTY DEFAULT 1-61 R. INDEPENDENT - BACK UP TRAIL OPERATION 1-65 S. AUTOMATIC SERVICE APPLICATION BAIL OFF - 1-65 BACK UP TRAIL OPERATION T. EMERGECNY APPLICATION BAIL-OFF 1-65 BACK UP TRAIL OPERATION 2.0 EQUIPMENT DESCRIPTION 2-1 2.1 COMPONENT DESCRIPTIONS 2-1 3.0 PREPARATION FOR MAINTENANCE 3-1 3.1 GENERAL INFORMATION 3-1 3.2 SAFETY PRECAUTIONS 3.3 COMPONENT ASSEMBLY PRECAUTIONS 3-3 IP-157-C i JUNE/99 CCB BNSF CONTRACT LOCOMOTIVE MAINTENANCE MANUAL TABLE OF CONTENTS (Contd.) CHAPT/SECT TITLE PAGE 4.0 SCHEDULED INSPECTION 4-1 4.1 GENERAL INFORMATION 4-1 4.2 INSPECTIONS 4-1 4.3 92 DAY INSPECTION 4-1 4.4 EQUIPMENT REPLACEMENT, REPAIR, AND OVERHAUL 4-4 5.0 CHECKOUT AND ANALYSIS 5-1 5.1 GENERAL INFORMATION 5-1 5.2 FUNCTION TESTING 5-1 5.2.1 On-Locomotive Single Car Test Procedure 5-1 (Ref. CCB Electric Brake Test Procedures SMR X-1000-12 Rev A.) 5.2.2 Code of Tests For Testing Locomotive Computer Controlled 5-14 Brake Equipment Subsystem Procedure For GE/CSX (Ref. NYT-1279-S) 5.3 TROUBLESHOOTING 5-23 5.3.1 General Information 5-23 5.3.2 Troubleshooting Chart 5-24 6.0 EQUIPMENT REPLACEMENT ** 6-1 6.1 General Information 6-1 6.2 Replacement Procedures 6-1 6.2.1 General Procedures 6-1 6.2.2 DIT Valve Replacement 6-2 6.2.3 Brake Valve Controller 6-8 6.2.4 Computer Relay Unit 6-9 6.2.5 Pneumatic Control Unit Replacement 6-12 7.0 SYSTEM EQUIPMENT 7-1 8.0 GE-BNSF FAULT CODES 8-1 JUNE/99 ii IP-157-C CCB BNSF CONTRACT LOCOMOTIVE MAINTENANCE MANUAL LIST OF ABBREVIATIONS ABCB ...........................................Air Brake Circuit Breaker AD................................................Analog to Digital AE1 ..............................................Automatic Emergency Switch NO. 1, N.C. AE2 ..............................................Automatic Emergency Switch NO. 2, N.O. AP ................................................Automatic Variable Handle Potentiometer AR................................................Automatic Release Switch, N.O. AW4-ER.......................................Analog Converter Equalizing Reservoir AW4-16........................................Analog Converter 16 Pipe (control Pipe) BAN..............................................Battery Negative BAP..............................................Battery Positive BC................................................Brake Cylinder BCCO...........................................Brake Cylinder Cut-Out Pressure Switch BCT..............................................Brake Cylinder Transducer BEA..............................................Binary Input Output BO1..............................................Bail Off Switch, Automatic BO2..............................................Bail Off Switch, Independent BP ................................................Brake Pipe BPCO...........................................Brake Pipe Cut-Off Valve BPT..............................................Brake Pipe Transducer BVJ1-BVJ2...................................Brake Valve External Connectors C1 ................................................Communicator Connector CCB .............................................Computer Controlled Brake ° C................................................Degree Centigrade COMM..........................................Communications Cont .............................................Controller COR .............................................Cut-Out Relay CP ................................................Central Processor CRU .............................................Computer Relay Unit DB1 ..............................................Magnet Valve Driver Board PCB DB2 ..............................................Relay Driver PCB dc .................................................Direct Current DCV .............................................Double Check Valve DI ................................................Diagnostic PCB ELV ..............................................Emergency Limiting Valve IP-157-C iii JUNE/99 CCB BNSF CONTRACT LOCOMOTIVE MAINTENANCE MANUAL LIST OF ABBREVIATIONS (Cont.) EMER...........................................Emergency EPA1............................................Automatic Application Analog Converter Driver PCB (AW4-ER) EPA2............................................Control Pipe Analog Converter Driver PCB (AW4-16) ER................................................Equalizing Reservoir ERT..............................................Equalizing Reservoir Transducer EXH..............................................Exhaust Magnet Valve ES ................................................Emergency Sand Fig ................................................Figure FLT...............................................Flow Transducer FOJ1 ............................................Automatic Fiber Optic External Connector FOJ2 ............................................Independent Fiber Optic External Connector FOR .............................................Fiber Optic Receiver FS ................................................Full Service ft-lbs. ............................................Foot Pounds HO................................................Handle Off IBS ...............................................Independent Brake Switch ID .................................................Inner Diameter IM.................................................Independent Maximum Applied Switch, N.O. I/O ................................................Input/Output IP..................................................Independent Variable Handle Potentiometer IR .................................................Independent Release Switch, N.O. J1-J12 ..........................................PCB Internal Connectors K1ES............................................Sanding Relay K2IBS...........................................Extended Dynamic Range Cut-Out Relay K3BCPS.......................................Dynamic Brake Cut-Out Relay (Spare) K4RLIS.........................................Rail